Graco 015.050-DP Operation manual

USER INFORMATION 6000305E
KEEP FOR FUTURE USE Rev. B
B.6.20.44
015.050-DP
020.035-DP
025.008-DP
030.020-DP
030.050-DP
040.035-DP
060.020-DP
Reciprocating pumps MERKUR 2000
*5$&2
®
GRACO N.V.
Industrieterrein “Oude Bunders”
Loc. 2206 - Slakweidestraat 31
3630 Maasmechelen - Belgium
Tel.: [phone] Fax: [phone]

REGULAR TESTING OF THE APPLIANCES
Person responsible
Test certificate No. Test date Company Name
Liquid spray equipment is intended in particular for surfacing (e.g. airless paint spraying equipment,
two-component coating equipment).
The operator must ensure that liquid spray equipment is tested for proper operation after an
operating pause of more than 6 months, but at least every 12 months by a competent person1).
The operator must ensure that the test results are properly recorded in writing for every liquid spray
equipment2) and kept until the next test.
The operator must ensure that the test certificate is available at the place of use 3) of the liquid spray
equipment.
 A competent person is somebody who on the basis of their professional training and
experience has sufficient knowledge in the field of liquid spray equipment and is sufficiently
conversant with the relevant national health and safety regulations, accident prevention
regulations, recommendations and generally accepted rules and industrial norms that they are
in the position to evaluate liquid spray equipment.
 Written records (test results) can, for example, be in the form of test certificates.
 At the place of use, a copy of the test certificate or a test stamp on the appliance is considered
as compliance with the requirement.
-Extract from: Working with liquid spraying equipment (VBG 87)
Issued on: 10th October 1993
§ 23 (1), (3) and (4)
Implementation instructions VBG 87
to § 1 Para. 1 and to §23 Para. 1, Para. 3, Para. 4

Page 1 of 33
10.99
RECIPROCATING PUMPS MERKUR 2000
USER INFORMATION
- OPERATING INSTRUCTIONS - Issued
B.6.20.44-B
Subject to change
Note the protection mark in accordance with DIN 34
Approved 19.10.99 Kuhn
Proc. 15.10.99 Hilse
F22.060.01, issued on 01.98
*5$&2
The original manufacturer’s designation can be found on the
reciprocating pump.
Please compare all specifications and complete, if necessary.
All important sections in this Operator Manual have been marked
with the following symbols:
Directions involving your safety
Important operational directions
Ensure that all other users know and understand all safety directions.
CONTENTS OF USER INFORMATION
Page
OPERATING INSTRUCTIONS
CORRECT USE 2
FUNCTIONAL DIAGRAM 3
DESCRIPTION OF FUNCTIONS 4
EQUIPMENT COMPONENTS – IMPORTANT INFORMATION 4
LIST OF TOOLS 15
INSTALLATION 15
START UP 19
IMPORTANT INFORMATION REGARDING START UP AND OPERATION 21
OPERATION 22
MAINTENANCE AND INSPECTION, REPAIRS 22
THREADED CONNECTIONS 27
SHUTTING DOWN 29
SOLVING BREAKDOWNS 29
NOTES 32
Pulsation reducing measures 32
Self-check 33
Guidelines, directives and regulations 33
User information 33
Read and understand the operator manual and the safety
instructions before taking the pump into operation
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- 2 - B.6.20.44-B
F22.060.02, issued on 01.98
CONTENTS – CONT’D
Page
TECHNICAL DESCRIPTION OF PRODUCT
DESCRIPTION OF THE RECIPROCATING PUMP 01
SUITABILITY, MATERIAL 02
TECHNICAL DATA 03
Key to designation, the module 03
DATA 04
Sound emission 05
Construction materials of wetted parts 05
Dimensions, connection threads, nominal diameters, attachment position 06
LIST OF REPAIR PARTS
REPAIR – RECIPROCATING PUMPS, REPAIR – ACCESSORIES (Sales catalogue extract)
Includes:
TEST CERTIFICATE (final inspection)
EC DECLARATION OF CONFORMITY
BRIEF USER INSTRUCTIONS (can be adhered to pump)
BRIEF OPERATING INSTRUCTIONS, WARNING SIGNS
CORRECT USE
The MERKUR 2000 reciprocating pumps are exclusively manufactured for the usual applications in
surfacing technology (to convey coatings or auxiliary agents or for spraying) or similar work.
Any other purpose above and beyond this is considered inappropriate use. We shall not be liable for
any damage or injury resulting from this; the user shall bear sole responsibility in such cases.
Correct use includes observing the operating, maintenance and inspection conditions and
regulations laid down by us.
The MERKUR 2000 reciprocating pumps should only be operated, maintained and serviced by
personnel familiar with, and trained to recognise its inherent dangers.
The relevant accident prevention regulations as well as safety and medical rules must be observed.
In case of unauthorised modifications of the appliance we cannot be held responsible for any
damages or injury resulting from such modifications.
The user is responsible for the correct installation of the equipment.

-
3 - B.6.20.44-B
F22.060.03, issued on 01.98
FUNCTIONAL DIAGRAM
RECIPROCATING PUMP 1Air pressure container 9Fluid container
AIR PRESSURE SUPPLY 2Pipeline or hose bl Suction line
(Suction tube)
EXHAUST AIR SOUND
SUPPRESSION 3Pressure control valve bm High-pressure screen
FLUID SUCTION SYSTEM 4Ball valve bn Pressure line
FLUID PRESSURE SYSTEM 5Ball valve bo Spray gun
APPLIANCE SUPPORT 6Safety valve bp Screen
7Safety valve bq Liquid model
8Sound absorber br Filter regulator
Compressor

- 4 - B.6.20.44-B
F22.060.02, issued on 01.98
DESCRIPTION OF FUNCTIONS
The air pressure is supplied to the reciprocating pump from the pressure tank 1via a tube or
hose line 2and a pressure control valve 3.
The air supply from the pressure tank to the reciprocating pump can be interrupted by the ball valve
4.
The ball valve 5is used for manually releasing condensation (an automatic steam trap would be
preferable here).
The safety valve 6protects the pressure tank against inadmissible rises in air pressure (e.g. in the
event of heating).
Since as a rule the air pressure supply is not installed for the reciprocating pump and because it
is obligatory, the reciprocating pump is also provided with a safety valve 7.
During operation of the drive (air motor) of the reciprocating pump, the air pressure escapes into the
atmosphere via the silencer 8.This releases its pressure.
The fluid (coating or auxiliary agent) is sucked into the reciprocating pump from a container 9via
the suction line bl and supplied under pressure to the spray gun bo via the high-pressure screen
bm and pressure line (hose or pipe) bn.
A sieve (dirt trap) bp protects the reciprocating pump against foreign bodies which have accidentally
entered the fluid.
A liquid unit (detergent unit) bq is essential in reciprocating pumps of this design. The operating
position (attachment position) of the reciprocating pump will depend on it.
Since the appliances also use AIRLESS PLUS for spraying (air-boosted high-pressure spraying
equipment), it is recommended to attach a filter regulator br at the air pressure branch.
EQUIPMENT COMPONENTS – IMPORTANT INFORMATION
The following components are required in an operational system:
THE RECIPROCATING PUMP
Functional description of the reciprocating pump; following part "Technical Description of
Product B.6.20.44-P".
AIR PRESSURE SUPPLY
The air pressure supply consists of the compressor, the pressure tank with steam trap,
possibly an air pressure drier and pipeline.
The air pressure supply is generally already available to the user.
- When air pressure supply needs to be installed, the relevant accident prevention
regulations, safety rules and user information must be observed, in particular the
information supplied by the manufacturer of the compressor.

-
5 - B.6.20.44-B
F22.060.03, issued on 01.98
There must be a flexible connection between the reciprocating pump and the air pressure line
(avoids fractures caused by vibrations). A hose line is most suitable
- Nominal diameter 9 or larger
- Operational pressure = max. mains pressure, preferably ( 16 bar
- air and ambient temperatures -20° to +50 °C
- free from any substances that may interfere with paint spraying, such as silicone
In areas with a danger of explosion the air pressure line and the hose line must be electrically
conductive (to avoid electrostatic charging).
-Discharge resistance < 106Ωrelative to earth.
The pressure control valve is in most cases directly fitted to the reciprocating pump.
- Efficient flow rate
at 6 bar and 25m/s > 50 m3/h
- Air inlet pressure 16 bar
- Air and ambient temperatures 0° C to 50° C
It goes without saying that the pressure control valve can be situated between the hose line
and the air pressure line.
The manometer – 3.1 in functional diagram – enables accurate adjustment and monitoring of
the necessary air pressure.
- Display range 0 to 16 bar
- Air and ambient temperatures 0° to 50 °C
- Damped construction
A shut-off mechanism (e.g. a ball retaining valve) should always be fitted between the
pressure control valve and the hose line, or between the hose line and the air pressure line.
This enables quick and safe switch-off of the reciprocating pump for operational breaks,
maintenance work and in cases of breakdown.
- Do not change the values set on the pressure control valve
- Rated pressure ≥15 bar
- Material CuZn, nickel-plated
The rule for ball retaining valves: wings transverse to flow direction = line is closed off
Do not use PTFE tape or hemp to seal connections
(- malfunctioning of pressure control valve - as a result of residue in air pressure supply).

- 6 - B.6.20.44-B
F22.060.02, issued on 01.98
There are no special requirements as regards the quality of the air pressure supplied to the
reciprocating pump.
- Condensation and residue oil from the compressor are trapped
(pressure tank, air filter)
- Lubrication of compressed air not necessary
- Temperature of compressed air 10° C to 50° C
When compressed air is used for fluid atomising, a filter regulator, branched off from the main
compressed air supply – 16 in functional diagram – must be installed upstream.
- Efficient flow rate
at 6 bar and 25m/s > 32 m3/h
- Air inlet pressure 16 bar
- Air and ambient temperatures 0° to 50°C
EXHAUST AIR SILENCER
Without a silencer the sound emission of a reciprocating pump operated by air pressure is
high [ > 100 dB(A) ] and causes damage to hearing. Since there is a relationship between
sound absorption and icing of the reciprocating pump control system, it is not possible to lower
the sound pressure level as much as desired (not 70 dB(A)].
All MERKUR 2000 reciprocating pumps are therefore equipped with appropriately
dimensioned silencers.
The reciprocating pumps may not be operated without the silencer.
The silencer must not be screwed off during operation.
- The decision to wear ear protection depends on the operating pressure and the
resulting sound level.
The air pressure must be free from any substances that may interfere with
paint spraying, like silicone or oil.
- This also applies to component parts of the air pressure supply.
See "Technical Description of Product B.6.20.44-P", page 05
for more detailed information on the sound level.

-
7 - B.6.20.44-B
F22.060.03, issued on 01.98
FLUID SUCTION SYSTEM
The suction connection of MERKUR 2000 reciprocating pumps is constructed in such a way
that both a swivel unit (angular or T-shaped) and a connector or suction pipe can be screwed
in.
The connection units 1and 2are used for connecting the suction system, the suction line
and the suction cup. The connector 3is only used for retrofitting. The end of the thread is 4
situated at the suction pipes.
Most of the reciprocating pumps are equipped with the
connection unit 1and a suction system (suction hose,
tube and suction sieve).
The swivel connector enhances the flexibility of the
suction hose so an almost empty fluid container will not
be turned over by the recoil force of the suction hose.
The diameter of the suction line is dimensioned in such a way that fluids with a kinematic
viscosity of up to 750 mm2/s (cSt) can be sucked without difficulty by the reciprocating pump.
A higher viscosity rating can result in a reduction of suction performance, or even result in
interrupted suction, which can be identified by an increasing pressure drop during the change
of direction (pulsating pressure).
- Measures for improvement are:
keeping the suction line as short as possible or a short suction hose with a larger cross
diameter.
Specifications of suction assembly:
Electrically conductive, maximum permissible resistance 3 x 104Ω/m (tested to ISO 8031)
and leakage resistance to earth < 106Ω.
(Suitable for use in hazardous locations.)
Suction
Connector 1

- 8 - B.6.20.44-B
F22.060.02, issued on 01.98
The individual parts of the suction system are designed to withstand an excess pressure of
12 bar (- Suitable for suction heights of up to 8.5 m).
The suction hose and the suction sieve are resistant to the usual solvents in the surface
coating and are silicone-free.
Minimum rated diameter 19
Fluid temperature 10 °C to 85 °C
Mesh size of screen 1.8
In case of a fixed installation the connection between
reciprocating pump and fluid container must be flexible
(to avoid rupture caused by vibration).
The ratings for this connecting suction line must
correspond with those of the suction equipment.
The admission pressure (pressure in a supply system, e.g. in a circuit) acting on the
reciprocating pump and the suction line, must not exceed 10 bar.
When a threaded tube is used in the suction assembly, the manufacturer’s directions for
installation of the screwed connection apply.
The viscosity of thixotropic fluids is reduced by stirring;
this improves e.g. the suction behaviour of the
reciprocating pump.
The agitator is clamped to the suction equipment. The
clamp (holder) must be fastened to the rim of the fluid
container. This ensures correct positioning of the
propeller of the agitator relative to the wall and base of
the container as well as to the suction tube, and prevents
the parts from touching.
All metal parts in contact with the suction area material are made of austenitic
stainless steel. (suitable for use with water lacquer).
All immersed parts of the agitator (spindle and propeller) are made from austenitic
stainless steel (suitable for water-based paints).
Connector 1
Suction pipe
Suction
Agitator