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Graco 015.050-DP User Information

Reciprocating pumps
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USER INFORMATION
KEEP FOR FUTURE USE
GRACO N.V.
Industrieterrein "Oude Bunders"
Loc. 2206 - Slakweidestraat 31
3630 Maasmechelen - Belgium
Tel.: 32 89 770 700 Fax: 32 89 770 777
015.050-DP
020.035-DP
025.008-DP
030.020-DP
030.050-DP
040.035-DP
060.020-DP
6000305E
Reciprocating pumps MERKUR 2000
Rev. B
B.6.20.44
®

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Summary of Contents for Graco 015.050-DP

  • Page 1 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 GRACO N.V. ® Industrieterrein “Oude Bunders” Loc. 2206 - Slakweidestraat 31 3630 Maasmechelen - Belgium Tel.: 32 89 770 700 Fax: 32 89 770 777...
  • Page 2 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 person The operator must ensure that the test results are properly recorded in writing for every liquid spray equipment...
  • Page 3 R E C I P R O C A T I N G P U M P S M E R K U R 2 0 0 0 The original manufacturer’s designation can be found on the reciprocating pump. Read and understand the operator manual and the safety instructions before taking the pump into operation Please compare all specifications and complete, if necessary.

  • Page 4: Table Of Contents

    CONTENTS – CONT’D Page TECHNICAL DESCRIPTION OF PRODUCT DESCRIPTION OF THE RECIPROCATING PUMP SUITABILITY, MATERIAL TECHNICAL DATA Key to designation, the module DATA Sound emission Construction materials of wetted parts Dimensions, connection threads, nominal diameters, attachment position LIST OF REPAIR PARTS REPAIR –...
  • Page 5 FUNCTIONAL DIAGRAM Compressor RECIPROCATING PUMP Air pressure container Fluid container Suction line AIR PRESSURE SUPPLY Pipeline or hose (Suction tube) EXHAUST AIR SOUND High-pressure Pressure control valve SUPPRESSION screen FLUID SUCTION SYSTEM Ball valve Pressure line FLUID PRESSURE SYSTEM Ball valve Spray gun APPLIANCE SUPPORT Safety valve...
  • Page 6 DESCRIPTION OF FUNCTIONS The air pressure is supplied to the reciprocating pump from the pressure tank via a tube or hose line and a pressure control valve The air supply from the pressure tank to the reciprocating pump can be interrupted by the ball valve The ball valve is used for manually releasing condensation (an automatic steam trap would be preferable here).
  • Page 7 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°...
  • Page 8 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 The air pressure must be free from any substances that may interfere with paint spraying, like silicone or oil.
  • Page 9 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 The connection units are used for connecting the suction system, the suction line and the suction cup.
  • Page 10 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.
  • Page 11 The agitator is pneumatically driven: maximum permissible air inlet pressure: 6 bar. Speed can be set on the built-in flow control valve. The ideal agitator speed for a particular fluid must be determined by the user. – The propeller of the agitator is enclosed within a protection ring. –...
  • Page 12 FLUID PRESSURE SYSTEM The fluid pressure system usually consists of a high-pressure screen, a hose line and a spray gun or atomizer. In most reciprocating pumps, the screen PN 500 is fitted at the factory and tested together with the reciprocating pump (final testing of the pump).
  • Page 13 The characteristics of the hoseline: Operating temperature -40° to +90°C or higher. Connection thread generally G 1/4 or G 3/8. Operating pressure > max. permissible operating excess pressure of the reciprocating pump (about 400bar). 1/m (tested to ISO 8031). Electrically conductive, max. permissible resistance 3 x 10 The sealing head nipples of the hose fittings are made from austenitic stainless steel or galvanised and yellow chromatised steel.
  • Page 14 Profiled sheet metal (wall support), stand, container cover, pump trolleys, mechanical elevating trucks, pneumatic elevating trucks, pneumatic elevating equipment. Most reciprocating pumps are fixed to the wall of a building or machine by means of the profiled sheet metal. If plugs are used for fixing, the drilling hole and screw Profile sheet length must comply with the manufacturer’s specifications.
  • Page 15 The pump trolleys are two-wheeled transport units. In their function, they correspond to a bag truck While in idle position, the load holder is located in front of the Form I wheels, in running position directly behind The pump trolley Form I can only have one MERKUR 2000 reciprocating pump mounted on it without any add-on equipment.
  • Page 16 Fast lowering (dropping) can be prevented by manual force. Lifting height 400 Carrying capacity ca. 40 kg As for the pneumatic lifting trolley (Form IV), the lifting, maintaining the load in an elevated position and lowering to starting position is effected by means of a pneumatic hand lever valve.
  • Page 17 When a reciprocating pump with container cover and agitator is affixed to the lifting apparatus, the Directive on Flammable Liquids (VbF) prohibits the use of this assembly for highly flammable liquids Class AI and AII (agitator design not approved). The directive does not apply if at the place of work (in the container) AI or AII liquid is only kept in such quantity as is sufficient to continue work.
  • Page 18 The reciprocating pumps must not be installed in Zone 0 (containers). GROUNDING In hazardous locations, the appliances must be earthed. In accordance with the directive on "Static Electricity" ZH 1/200, the following applies: The grounding connection must be mechanically resistant and corrosion-proof to withstand all conditions to which it may be subjected during operation.
  • Page 19 COMPRESSED AIR LINE If an air pressure line must be laid it must have a gradient of 3 to 5 mm per m down to the air pressure tank or the water trap. If a branch line has to be made from an existing air pressure Main line line, this should be carried out above the level of the pipe axis.
  • Page 20 When attaching the suction assembly to the connection , pay attention to the following: Insert the tube end of the suction assembly into the connector and press it against the stop in the internal taper. When the end of the tube does not touch the stop, the installation is incorrect. Continue until clear resistance is felt –...
  • Page 21 GENERAL ASSEMBLY INSTRUCTIONS Always use recommended torques. Grease thread lightly. Do not use PTFE tape or hemp. Components not supplied by us must have dimensions that correspond to the given dimensions of the reciprocating pump. - Follow the manufacturer’s instructions Observe manufacturer's assembly instructions when using cutting rings or double conical rings.
  • Page 22 Screw off the union nut and remove the screen housing. Introduce the screen insert into the housing via the support spring and fasten the housing again. FLUSH THE RECIPROCATING PUMP As every reciprocating pump is tested in the works after assembly using an anti-corrosion liquid it is necessary to thoroughly flush out the rest of this liquid (and any other contaminants which have entered during installation) with detergent (flushing agent).
  • Page 23 LOW LOCAL TEMPERATURE If start up or operation is carried out at a local temperature around 10 °C the air pressure should be supplied with anti-freezer from a dosing apparatus (AIR lubricator). We recommend ethylene glycol, diluted, with high-pressure additives, 1000 ml, Item ID 75682 114002). IMPORTANT INFORMATION CONCERNING START UP AND OPERATION Do not operate the reciprocating pump without a liquid primer (detergent in the coupling...
  • Page 24 OPERATION The reciprocating pumps run automatically, i.e. during operational shutdown (no fluid drawn from fluid pressure system) no fluid is pumped. If there is a slight leakage, however, pumping will start. It is therefore recommended that the pump be disconnected from the air supply overnight or at the weekend and, if possible, material pressure be reduced by withdrawal (after the air is disconnected.) This can be achieved by using a spray device for example.
  • Page 25 If there is no automatic water drainage in the air pressure supply to the pressure regulation valve, then drain the condensed water every day from the pressure container, filter or filter regulator. When using anti-freeze (when operating at around 10 °C), replenish it after use. Regularly check the dirt trap on the suction side.
  • Page 26 If during daily inspection, a rise in pressure pulsation or irregular travel of the piston rod is observed, wear at the decant valve (valve in the piston) is usually the reason. If the operating pressure falls with the fluid pressure system closed (gun shut and sealed), the probable cause is a leaky suction valve.
  • Page 27 REPAIR OF WEARING PARTS IN THE AIR MOTOR Loosen the cheese head screws and remove Remove the connection piece Replace the flat slide and slide plate The flat slide and the slide plate should always be removed together. If on replacing the flat slide, it is found that between the drive pin and the new flat slide, the gap "S"...
  • Page 28 REPAIR OF THE VALVE SEATS The valve seats are made in such a Decant way that if one side is worn, they can be valve turned over and replaced. If the profile sealing rings underneath the seats are worn (clear deformation) they should be replaced.
  • Page 29 REPLACING THE SUCTION UNIT When the suction unit must be replaced, the union nut must be replaced along with – Union nut with sealing ring, Part No. 75089 100002. Union nut Suction If the sealing ring is defective, it can be pulled off the free tube end after loosening the union nut.
  • Page 30 TORQUE MOMENTS Reciprocating pump Pos. Thread Material Torque Moment - 28 - B.6.20.44-B F22.060.02, issued on 01.98...
  • Page 31 SHUTDOWN If the pressure is removed from the air to the air motor while the fluid pressure system is still under pressure, the fluid pressure can rise depending on the system. Therefore remove the pressure from the reciprocating pump (on the air and fluid side) by removing fluid with the air pressure supply shut off.
  • Page 32 - 30 - B.6.20.44-B F22.060.02, issued on 01.98...
  • Page 33 TROUBLESHOOTING Component group Nature of defect Defect symptoms Possible cause Countermeasure Air pressure supply Heavy leakage Defective fitting Replace defective fitting Fluid pressure drops Hose line pinched, dirty Check lines, Narrowing of diameter fittings Clean fittings Air motor, control Irregular operation, Air too humid, stroke Remove ice, change Stroke frequency drops,...
  • Page 34 NOTES PULSATION REDUCING MEASURES - Important for demanding painting operations For viscosities of 10-750 mm²/s at an operating temperature In general it should be ensured that the air pressure is available in sufficient quantity and without large pressure fluctuations. Use of a sound absorber with large flow volumes Part No.
  • Page 35 Self-check If the MERKUR 2000 reciprocating pumps/appliances are operated without monitoring, dangerous situations should be avoided by using automatic self-regulation. A stop valve is particularly suitable for this purpose as it cuts off the air pressure supply to the reciprocating pump if the set limit is exceeded (e.g. due to excessive stroke frequency in case of a line breakage).

  • Page 36: Description Of The Reciprocating Pump

    R E C I P R O C A T I N G P U M P S M E R K U R 2 0 0 0 Air pressure driven double action reciprocating pumps are recommended for coating and process materials.

  • Page 37: Suitability, Material

    When the pressure system is closed, there is an equilibrium of forces [air pressure (p ) x area of ring piston (A ) = fluid pressure (p ) x area of the thinner part of the step piston (A )] and the pump is stationary.

  • Page 38: Technical Data

    Action: double-action oscillating OF THE MODULES DISPLACEMENT PUMP RECIPROCATING PUMPS PRODUCT RANGE Reciprocating pump 015.050-DP Detailed information about basic versions, Reciprocating pump 020.035-DP basic devices, complete devices and article numbers can Reciprocating pump 025.008-DP Reciprocating pump 030.020-DP be found in sales catalogue 01.2044 Reciprocating pump 030.050-DP...

  • Page 39: Data

    DATA Theoretical Material Stroke frequency in DH/min transmission Stroke Max. Volume Max. ratio volume permissible Reciprocating pump permissible operating inlet overpressure overpressure (Nominal pressure) Fluid- max. flow Volume (pump delivery) V= 0.4 m/s Max. V= 0.7 m/s V= 1.5m/s Flow Volume Reciprocating pump DIN 24374 T1 Stroke...

  • Page 40: Sound Emission

    As the working place cannot be anticipated and every place is different, the highest sound level is shown. MEASUREMENT SPACING Sound source Air inlet overpressure in bar Measuring Reciprocating device 8 (7)* pump 015.050-DP 020.035-DP 025.008-DP 030.020-DP 030.050-DP 040.035-DP 060.020-DP SOUND PRESSURE A danger warning sign is attached to the reciprocating pump. > 70dB(A)

  • Page 41: Dimensions, Connection Threads, Nominal Diameters, Attachment Position

    DIMENSIONS, SCREW CONNECTION THREADS, RATED DIAMETER OF CONNECTIONS, MOUNTING POSITION Safety valve Earthing ring Fluid outlet connection Reciprocating pump ≥ Air pressure air line Elastic connections: ≥ Fluid pressure line Reciprocating pump –air pressure system, Fluid suction line ≥ Reciprocating pump – fluid container / line Suction line ≥...
  • Page 42 R E C I P R O C A T I N G P U M P S M E R K U R 2 0 0 0 Air motor Displacement pump Thread piece Parallel pin Pos. 10 Pos. 20 Pos. 30 Pos. 40 Reciprocating pump 000.050-DO 015.050-DP 78003 014002 D110 S70 M14 x 1 78015 004003 76742 016001 000.035-DO 020.035-DP 78003 015002 D60 S70 000.008-DO M8 x 1 025.008-DP...
  • Page 43 AIR MOTOR D60 AIR MOTOR D110 S70 AIR MOTOR D160 S70 - 2 - B.6.20.44.-EO F22.060.02, issued on.01.98...
  • Page 44 AIR MOTOR D60 S70 List of repair parts, Air motor control Part No. 79978 904103 Pos 180 2 off Flat packing 80 x 25 x 0.75 Pos 210 4 off O-ring 30 x 2 B Pos 220 1 off Drive pin Pos 250 1 off Flat slide...
  • Page 45 AIR MOTOR D160 S70 List of repair parts, Air motor control Part No. 79978 904103 Pos 180 2 off Flat packing 80 x 25 x 0.75 Pos 210 4 off O-ring 30 x 2 B Pos 220 1 off Drive pin Pos 250 1 off Flat slide...
  • Page 46 DISPLACEMENT PUMP 000.008-DO DISPLACEMENT PUMP 000.020-DO DISPLACEMENT PUMP 000.035-DO DISPLACEMENT PUMP 000.050-DO - 5 - B.6.20.44.-EO F22.060.03, issued on 01.98...
  • Page 47 DISPLACEMENT PUMP 000.008-DO List of repair parts, seals Part No. 79978 906053 Pos 90 1 off Stuffing complete 11.9 x 26.1 x 18.3 Pos 120 1 off Flat packing D53.5 x T1 Pos 170 1 off Stuffing complete 16.7 x 28.7 x 16.0 Pos 210 1 off Seal washer...
  • Page 48 DISPLACEMENT PUMP 000.035-DO List of repair parts, seals Part No. 79978 906153 Pos 90 1 off Stuffing complete. 24.5 x 42.7 x 19.2 Pos 120 1 off Flat packing D73.5 x T1 Pos 170 1 off Stuffing complete 34.4 x 49.2 x 16.7 Pos 210 1 off Seal washer...
  • Page 49 REPAIR RECIPROCATING PUMPS REPAIR ACCESSORIES (Sales catalogue 01.2044 extract) The reciprocating pumps in their basic version Reciprocating pump Pos. Type Weight (kg) Item ID 015.050-DP 11.3 79042 062002 020.035-DP 10.9 79042 068002 025.008-DP 79042 074002 - without safety valve 030.020-DP 10.2...
  • Page 50 COMPRESSED AIR CONNECTION GROUNDING Necessary in hazardous locations ! SUCTION CONNECTION For non-return valve (back pressure control valve) see separate catalogue. PRESSURE CONNECTION Can only be assembled with extension ! For non-return valve (admission pressure control valve) see separate catalogue. B.6.20.44-A - 2 -...
  • Page 51 For fluid screen see page 1 Hose connection G 1/4 Hose connection G 3/8 Hose connection either G 1/4 or G 3/8 Order Example Please lay out each order as follows: Description Pos. No. Part No. Reciprocating pump 015.050-DP 79042 062002 B.6.20.44-A...
  • Page 52 With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco´s written recommendations.
  • Page 53 GRACO N.V. Industrieterrein “Oude Bunders” Loc. 2206 – Slakweidestraat 31 ® 3630 Maasmechelen – Belgium Telephone: 32 89 770 700 Telefax: 32 89 770 777 eserve the right to make amendments B.6.20.44 / 10.99 / 79990 001001 / D...

This manual is also suitable for:

020.035-dp025.008-dp030.020-dp030.050-dp040.035-dp060.020-dp