Graco Inc 218-745 User Manual

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INSTRUCTIONS±PARTS LIST

307±712

 

Rev P

This manual contains IMPORTANT

Supersedes N

WARNINGS AND INSTRUCTIONS

 

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Model PRO 5000

AUTOMATIC MID-RANGEELECTROSTATIC

AIR SPRAY GUN

7 bar (100 psi) MAXIMUM WORKING AIR PRESSURE

Part Number 218±745, Series B

With 1.2 mm (0.047 in.) spray nozzle and part no. 218±996 air cap assembly

U.S. Patent No. 4,290,091; 4,219,865; 4,462,061; 4,497,447; 4,660,774; 4,554,622

U.K. Patent No. 2,140,327B; 2,142,559B; 2,147,158; 2,191,423

Patented 1986, 1987 Canada

Brevete 1986, 1987

French Patent No. 84 07942; 84 10234

Italian Patent No. 1,111,380

Japanese Patent No. 86. 07416

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440±1441

COPYRIGHT 1985, GRACO INC.

TABLE OF CONTENTS

Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 3

Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 4, 5

How The Electrostatic Air Spray Gun Works

. . . . 5

Installation

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . . . . 6

Mount the Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Connect the Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Connect the Fluid Line . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Check the Electrical Grounding . . . . . . . . . . . . . . . . . . 8

Installing Optional Remote Fan Air Adapter . . . . . . . . 8

Operation

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Filter the Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Spraying Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Selecting a Fluid Nozzle and Air Cap . . . . . . . . . . . . . 9

Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . 10

Maintenance

Daily Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . 11 Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 To Clean or Change Air Cap and Fluid Nozzle . . . . 12

Spray Pattern Troubleshooting Chart . . . . . . . . . . 13

Gun Operation Troubleshooting Chart . . . . . . . . . 14

Electrical Troubleshooting Chart . . . . . . . . . . . . . . 15

Electrical Tests

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Test Power Supply Resistance . . . . . . . . . . . . . . . . . . 16

Test Resistor Stud Resistance . . . . . . . . . . . . . . . . . . 17

Service

Gun Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Electrode Replacement . . . . . . . . . . . . . . . . . . . . . . . . 18

Resistor Stud Replacement . . . . . . . . . . . . . . . . . . . . . 19

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fluid Needle Packing Replacement . . . . . . . . . . . . . . 20

Power Cartridge Replacement . . . . . . . . . . . . . . . . . . 22

Turbine Alternator Removal . . . . . . . . . . . . . . . . . . . . . 23

Fan Air Valve Replacement . . . . . . . . . . . . . . . . . . . . . 23

Piston Removal and Repair . . . . . . . . . . . . . . . . . . . . . 24

Disc Regulator O-RingReplacement . . . . . . . . . . . . . 25

Muffler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . 27

Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . 28

Technical Data . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . 29

How To Order Replacement Parts . . . . . . . .

. . . . . . . 29

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 30, 31

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Back Cover

TERMS

WARNING: Alerts user to avoid or correct conditions that could cause bodily harm.

CAUTION: Alerts user to avoid or correct conditions that could cause damage to or destruction of equipment.

NOTE: Identifies essential procedures or helpful information.

PRESSURE RELIEF PROCEDURE: A safety procedure for relieving air and fluid pressure in the system.

FOR YOUR SAFETY: Alerts user to read the additional safety warnings on the page indicated.

SAFETY WARNINGS

SERIOUS BODILY INJURY, EXPLOSION, FIRE, OR ELECTRIC SHOCK CAN OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED.

READ AND UNDERSTAND ALL INSTRUCTION MANUALS, TAGS, AND WARNING LABELS BEFORE OPERATING EQUIPMENT.

ELECTROSTATIC EQUIPMENT SHALL ONLY BE USED BY TRAINED, QUALIFIED PERSONNEL WHO SHALL BE FULLY CONVERSANT WITH THE REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL.

EQUIPMENT MISUSE HAZARD

General Safety

Any misuse of the spray equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in serious bodily injury, fire, explosion or property damage.

NEVER point the spray gun at anyone or at any part of the body. NEVER put hand or fingers over the fluid nozzle.

ALWAYS follow the Pressure Relief Procedure, at right, before cleaning or removing the fluid nozzle or servicing any system equipment.

NEVER try to stop or deflect leaks with your hand or body.

NEVER alter or modify any part of this equipment; doing so could cause it to malfunction.

CHECK all spray equipment regularly and repair or replace worn or damaged parts immediately.

System Pressure

This gun has a maximum working air and fluid pressure of 7 bar (100 psi).

Never exceed the maximum working pressure of the gun or any other component or accessory used in the system.

Fluid Compatibility

BE SURE all fluids and solvents used are chemically compatible with the

ªWettedPartsº shown in the TECHNICAL DATA. Always read the fluid and solvent manufacturer's literature before using the fluid or solvent in this gun.

Pressure Relief Procedure

To reduce the risk of serious bodily injury, including splashing in the eyes or on the skin, injury from moving parts or electric shock, always follow this procedure when shutting off the system, when checking or servicing any part of the spray system, when installing, cleaning or changing fluid nozzles, and whenever you stop spraying.

1.Turn off all the air to the gun except the cylinder (actuating) air.

2.Turn off the fluid supply to the gun.

3.Actuate the gun into a grounded metal waste container to relieve fluid pressure.

4.Open the pump drain valve, having a waste container ready to catch the drainage.

5.Leave the pump drain valve open until you are ready to spray again.

HAZARDOUS FLUID HAZARD

Improper handling of hazardous fluids or inhaling vapors can cause extremely serious bodily injury, even death, due to splashing in the eyes, ingestion, inhalation, or bodily contamination.

Be sure you know what fluid you are pumping and its specific hazards. Observe all precautions when handling known or potentially hazardous fluids, including, but not limited to, the following.

1.Store hazardous fluids in approved containers.

2.Dispose of any waste fluid according to all Local, State and Federal regulations pertaining to the disposal of hazardous wastes.

3.Read and follow the fluid and solvent manufacturer's literature regarding the use of protective clothing and equipment such as eye protection, respiratory protection, and gloves.

4.Provide for the safe piping and disposal of all exhaust air.

5.Provide proper ventilation in accordance with accepted industry standards and governmental regulations. Refer to Ventilate the Spray Booth, on page 6.

HOSE SAFETY

TIGHTEN all fluid connections securely before each use.

NEVER use a damaged hose. Before each use, check the entire hose for cuts, leaks, abrasion, bulging cover, or damage or movement of the hose couplings. If any of these conditions exist, replace the hose immediately.

HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on hoses to move equipment. Do not use fluids or solvents which are not compatible with the inner tube and cover of the hose.

47 7

FIRE OR EXPLOSION HAZARD

To reduce the risk of fire, explosion, or electric shock, which may result from electrical discharge, it is essential that:

SAll parts of the electrostatic system are properly grounded.

SAll personnel in or close to the spray area are properly grounded.

SAll electrically conductive objects or devices in the spray area, including paint containers, wash cans and tools, are properly grounded.

When operating the electrostatic device, any ungrounded objects in the spray area (such as people, containers, tools, etc.) can become electrically charged. Arcing may occur if these objects then come in contact or close to ground. Arcing of sufficient energy levels can ignite the fluid being sprayed, fumes from solvents, dust particles, and other flammable substances. This can cause a fire or explosion and result in serious bodily injury and property damage.

Static electricity can also be generated by the flow of fluid through the pump, hose, gun, and nozzle, but it is dissipated through proper grounding as described in Grounding below.

If you experience any arcing or feel even a slight shock, STOP SPRAYING IMMEDIATELY. Check for proper grounding of the entire system. Be sure you have corrected the problem before starting to spray again.

Grounding

The following are minimum requirements for grounding a basic electrostatic system. Your system may include other equipment or objects which must also be grounded. Always check your local electrical code for detailed grounding instructions. Be sure your system is connected to a true earth ground.

1.Pump: ground by using a ground wire and clamp as described in your separate pump instruction manual.

2.Air compressors and hydraulic power supplies: ground according to the manufacturer's recommendations.

3.Electrostatic Spray Gun: obtain grounding through connection to a properly grounded air supply hose. Use only the Graco Electrically

Conductive Air Supply Hose; see ACCESSORIES section to order. Connect the air hose ground wire to a true earth ground.

4.Object being sprayed: keep the work piece hangers clean and grounded at all times. Contact points must be sharp points or knife edges.

5.All electrically conductive objects or devices in the spray area, including paint containers and wash cans, must be properly grounded.

6.All persons entering the spray area: shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Rubber or plastic soles are not conductive.

7.The floor of the spray area must be electrically conductive and grounded. Do not cover the floor with cardboard or anynon-conductivematerial which would interrupt grounding continuity.

8.Flammable liquids in the spray area must be kept in approved, grounded containers. Do not store more than the quantity needed for one shift.

9.All solvent pails: use only grounded metal pails, which are conductive. Do not place the pail on anynon-conductivesurface, such as cardboard or paper, which would interrupt grounding continuity.

10.All air and fluid lines and electric cables must be properly grounded.

Flushing and Cleaning Safety

To reduce the risk of static sparking or splashing, always follow the Pressure Relief Procedure on page 4.

Be sure the turbine air (electrostatics) is OFF before flushing or cleaning any part of the spray system.

Use the lowest possible pressure to flush. Trigger the gun into a grounded metal waste container.

To flush or purge equipment, ALWAYS use solvents with a flash point equal to or greater than that of the fluid being sprayed.

To clean the exterior of the equipment, ALWAYS use solvents with a flash point of higher than 38_ C (100_ F).

ALWAYS remove all solvent from the system before reactivating the spray gun.

Use only non-sparkingtools to clean residue from the booth and hangers.

Ventilate the Spray Booth

To prevent hazardous concentrations of toxic and/or flammable vapors, spray only in a properly ventilated spray booth.

NEVER operate the spray gun unless the ventilating fans are operating.

Check and follow all National, State and Local codes regarding air exhaust velocity requirements. Check and follow all local safety and fire codes and OSHA standard 1910±107(b)(5)(i).

IMPORTANT

United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards±±particularly the General Standards, Part 1910.107 and any other appropriate regulations±±should be consulted in connection with the installation, operation, and maintenance of electrostatic spray painting equipment.

HOW THE ELECTROSTATIC AIR SPRAY GUN WORKS

The air hose supplies air to the spray gun. Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed. The turbine generates power, which is converted by the power cartridge, to supply high voltage current to the gun's ionizing electrode.

The pump supplies fluid to the hose and gun, where the fluid is electrostatically charged as it passes the electrode. The charged fluid is attracted to the grounded workpiece, wrapping around and evenly coating all surfaces.

7 7 5

TYPICAL INSTALLATION

A

B

Power Supply Must Be Interlocked

K

 

 

With Spray Booth Exhaust Fan.

 

 

 

Main Air Line

 

Fluid Line

A

F

Air

WARNING

 

 

SIGN

Fan

 

 

 

E

RemoteOpt.

 

J

 

 

C

D

L

G J

H

NON±HAZARDOUS AREA

KEY

A

Air Supply Shut-offValve(bleed-type)

F

Pump

B

Air & Water Separator

G

Fluid Filter

C

Ball Valve

H

Drain Valve

D

Air Line Lubricator

J

Pump Ground Wire

E

Air Regulator

K

Air Filter (40 micron)

Electric Box

P

E

A

Turbine Air

Atom. Air

Cyl. Air

J

Q N

HAZARDOUS AREA

L Fluid Regulator

N ES Automatic Gun

PNormally Closed, 3-WayAir Solenoid Valve or3-WayManual Valve

QExhaust Hose

The Typical Installation shown above is only a guide for selecting and installing electrostatic air spray systems. It is not an actual system design. The particular type and size system for your operation must be custom designed for your needs. For assistance in designing a system, contact your Graco representative.

WARNING

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily injury if work is not performed properly.

Do not install or service this equipment unless you are trained and qualified.

Be sure your installation complies with National, State and Local codes for the installation of electrical apparatus in a Class 1, Group D, Divisions 1 and 2 Hazardous Location.

Warning Signs

A warning sign in English and one in Spanish is supplied with the gun. Mount warning signs in the spray area where they can easily be seen and read by all operators. This sign is also available in French and German. See the ACCESSORIES section to order.

Ventilate the Spray Booth

WARNING

To prevent hazardous concentrations of toxic and/ or flammable vapors, spray only in a properly ventilated spray booth. Never operate the spray gun unless ventilation fans are operating. The air supply to the gun must be electrically interlocked with the ventilators to prevent operation of the power supply unless ventilating fans are running.

Check and follow all of the National, State and Local codes regarding air exhaust velocity requirements.

Check and follow all local safety and fire codes and OSHA standard 1910±107(b)(5)(i).

NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 19 linear meters/minute (60 ft/min).

6307-712

INSTALLATION

Mount the Gun

Mount the gun on a stationary support or on a reciprocating arm. The mounting rod must be properly grounded.

Mount the gun so the front of the gun is 254 to 300 mm (10 to 12 in.) from the work piece.

Connect the Air Line (Refer to the Typical Installation Drawing)

WARNING

To reduce the risk of electric shock or other serious bodily injury, the air supply hose must be electrically connected to a true earth ground. Use Only Graco Electrically Conductive Air Supply Hose. This hose, and the gun, have special threads which prevent using any other type of hose with the gun. See theACCESSORIES section to order the hose.

1.Install an air line filter (K) and an air and water separator (B) on the main air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

2.Install an air line lubricator (D) close to the pump air inlet.

3.Install a normally closed, 3-wayair solenoid (P) or manual valve on the turbine, cylinder and remote fan air supply lines.(The remote fan line is optional.)

4.Install a bleed-typeair regulator (E) on the pump, turbine, atomizing, cylinder, and remote fan(optional) air supply lines to control air pressure to the pump and gun.

5.Install a bleed-typeair shutoff valve (A) on the main air line, the pump line, and each gun air supply line to shut off air to the pump and gun.

WARNING

The bleed±type air shutoff valve(A) is required in your system to relieve air trapped between this valve and the pump after the air regulator is closed. Trapped air can cause the pump to cycle unexpectedly, which could result in serious bodily injury, including splashing in the eyes or on the skin and injury from moving parts.

6.Connect the cylinder air line to the gun's cylinder air inlet (marked CYL).

7.Connect the atomizing air line to the gun's atomizing air inlet (marked ATOM).

8.Connect the turbine air supply line to the gun's air inlet (marked ES).The gun air inlet fitting has a left hand thread. Connect the air supply hose ground wire to a true earth ground.

9.A remote fan air adapter is available to control the fan air at the control booth. See Installing the Optional Remote Fan Air Adapter, on page 8.

Connect the Fluid Line (Refer to the Typical Installation Drawing)

1.Before connecting the fluid line, blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.

2.Install a fluid regulator (L) on the fluid line to control fluid pressure to the gun.

3.Install a fluid filter (G) and drain valve (H) at the pump outlet.

WARNING

The fluid drain valve (H) is required in your system to assist in relieving fluid pressure in the displacement pump, hose and gun; triggering the gun to relieve pressure may not be sufficient. Install a drain valve close to pump's fluid outlet. The drain valve reduces the risk of property damage or serious bodily injury, including splashing in the eyes or on skin and contamination from hazardous fluids.

4. Connect the fluid line to the gun fluid inlet.

CAUTION

Do not use metal fittings at the gun barrel. For circulation systems, use plastic fittings.

INSTALLATION

Check the Electrical Grounding

WARNING

Proper electrical grounding of every part of your system is essential. For your safety, read the warning section, FIRE OR EXPLOSION HAZARD, on page 5. Ground the system as explained there. Then check your system as explained below.

1.Shut off all air lines to the gun.

2.Shut off the fluid supply to the gun.

3.Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose.

a.With the electrically conductive air hose (BB) connected and properly grounded, use a megohmmeter (AA) (shown in ACCESSORIES section) to measure the resistance between the gun body (Y) and a true earth ground (Z). Use an applied voltage of 500 voltsminimum to 1000 voltsmaximum. See Fig 1.

b.If the resistance is greater than 2 megohms, check the tightness of the ground connections, and be sure the air supply hose ground wire is connected to a true earth ground. If the resistance is still greater than 2 megohms, replace the air supply hose.

Installing Optional Remote Fan Air Adapter

NOTE: SeeACCESSORIES to order the Remote Fan Air Adapter 181±053 and 90_ Elbow 108±234.

1.Place a wrench on the flats of the valve housing (55) and remove the fan air valve assembly from the gun body (1). See Fig 20, page 23.

KEY

YTurbine Air Inlet

ZTrue Earth Ground

AAOhmmeter

BBGrounded Air Hose

AA

Z

BB

Y

Fig 1

2.Apply PTFE tape to the threads of the remote fan air adapter (part no. 181±053) and install it in the gun body (1). Torque the adapter to 1.1±1.4 NSm (10±12 in-lb).

3.Install the 90_ elbow (part no. 108±234) in the adapter.

4.Install the remote fan air line, solenoid valve, air regulator and shut-offvalve as instructed inConnect the Air Lines, on page 7.

OPERATION

WARNING

Pressure Relief Procedure

To reduce the risk of serious bodily injury, including splashing in the eyes or on the skin, injury from moving parts or electric shock, always follow this procedure when shutting off the system, when checking or servicing any part of the spray system, when installing, cleaning or changing fluid nozzles, and whenever you stop spraying.

1.Turn off all the air to the gun except the cylinder (actuating) air.

2.Turn off the fluid supply to the gun.

3.Trigger the gun into a grounded metal waste container to relieve fluid pressure.

4.Engage the gun safety latch.

5.Open the pump drain valve, having a waste container ready to catch the drainage.

6.Leave the pump drain valve open until you are ready to spray again.

Operating Checklist

Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.

1.Be sure all operators are properly trained to safely operate an automatic air spray system.

2.Be sure all operators are trained how to properly and completely relieve system pressure.

3.Be sure the system is thoroughly grounded. See FIRE OR EXPLOSION HAZARD, page 5, andCheck the Electrical Grounding, page 8.

4.Be sure the operator and all persons entering the spray area are properly grounded by wearing shoes with conductive soles or personal grounding straps.

5.Be sure ventilation fans are operating properly.

6.Be sure the work piece hangers are clean and grounded. Contact points must be sharp points or knife edges.

7.Be sure all refuse is removed from the spray booth.

8.Be sure all flammable liquids in the spray booth are in approved, grounded containers.

9.Be sure all conductive objects within 6 m (20 ft) of the gun are electrically grounded and the floor of the spray area is electrically conductive and grounded.

Filter the Fluid

Filter the fluid to remove coarse particles and sediment which could clog the spray nozzle.

Spraying Operation

This gun has a built-inlead and lag operation. The gun begins emitting air before the fluid is discharged. When you release the trigger, the fluid stops before the air flow stops. This helps prevent fluidbuild-upon the air cap.

Adjust the system's control device, if it is automatic, so the gun starts spraying just before meeting the work piece, and stops as soon as the work piece has passed.

When spraying, the ES indicator lights (BB) should glow, indicating the electrostatic charge. See Fig 4.

Selecting a Fluid Nozzle and Air Cap

WARNING

To reduce the risk of serious bodily injury, including splashing in the eyes or on the skin or electric shock, always follow the Pressure Relief Procedure, above, before installing, or removing the fluid nozzle/air cap assembly.

This gun is supplied with fluid nozzle 181±299 and air cap 180±739. See Instruction Manual 307±803 for air cap consumption and fluid nozzle flow rate information.

The fluid output and pattern shape depends on the fluid nozzle size, fluid viscosity, and fluid pressure. If your application requires a different nozzle and air cap combination, use manual 307±803 to select the appropriate fluid nozzle and air cap.

To install a different fluid nozzle and air cap, see To Clean or Change Air Cap and Fluid Nozzle, page 12.

9

OPERATION

Adjust the Spray Pattern

Follow the steps below to establish the correct fluid flow and air flow. DO NOT turn the turbine air on yet.

1.Adjust the fluid flow for the appropriate flow rate by using the fluid pressure regulator installed in the fluid line. Check the fluid nozzle chart in manual 307±803 for the appropriate flow rate for the air cap. Start with the lowest rate shown and increase it until you get the desired flow rate.

2.For fine adjustment of how much fluid is sprayed, tighten or loosen the trigger adjusting nut (24). See Fig 4. Turn the nut out to reduce the amount of fluid sprayed or turn itin to increase the amount.

3.Close the fan adjusting knob (56) by turning it fully clockwise.

4.Use an air pressure regulator to adjust the degree of atomization. Always use the lowest air pressure possible for the most efficiency.

5.Use the fan adjusting knob to change the shape of the spray pattern. Turn the knobcounterclockwise for a wide pattern andclockwise for a solid, round pattern. When increasing to a wide, flat pattern, it may be necessary to increase the supply of fluid to the gun to maintain the same amount of coverage over a large area.

6.First, complete all the checks under the Operating Checklist on page 9. Then turn the turbine air on. When spraying, theES indicator light (51) should glow, indicating the electrostatic charge.

NOTE: Provide a 3.1 bar (45 psi) clean, dry, regulated air supply to the gun to ensure full voltage from the power supply. The gun may be operated at lower turbine air pressure, but may lose some electrostatic effect. Do not operate the turbine at an air pressure greater than 3.1 bar (45 psi) as there is no benefit and turbine life will be reduced.

NOTE: A remote fan air adapter is available to control the fan air at the control booth. See

ACCESSORIES.

See the Spray Pattern Troubleshooting Charton page 13 to correct spray pattern problems.

KEY

24 Trigger Adjusting Nut

51 ES Indicator Light

56 Fan Adjusting Knob

56

51

Fig 2

24

Fig 3

Fig 4