Campbell Hausfeld HV2100, HV2105 User Manual

HVLP Paint Sprayers

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Operating Instructions and Parts Manual

IN422300AV 11/02

Thank you for purchasing a Campbell Hausfeld product. If you have any technical questions about this product, please call 1-800-626-4401.

For Parts and Accessories: 1-800-626-4401

NOTE: If you purchased Model HV2105, please refer to page 8 for additional

instructions on the setup and operation of your product.

HV2100, HV2105

For parts, product & service information

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REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

BUILT TO LAST

Operating Instructions and Parts Manual

Description

This product is a High Volume Low Pressure (HVLP) Paint Sprayer, a durable, self-contained painting system suited for painting cabinets, furniture, machinery, equipment, walls, trim, and many other surfaces. HVLP systems operate differently than those used with air compressors because HVLP systems do not require an air tank to hold compressed air. HVLP turbines are portable, can be plugged into standard outlets and sound similar to shop-vacs.

Safety Guidelines

This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

Danger indicates

an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

Warning indicates

a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

Caution indicates a

potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.

Notice indicates

important information, that if not followed, MAY cause damage to equipment.

Unpacking

After unpacking the unit, inspect carefully for any damage that may have occurred during transit. Make sure to tighten fittings, bolts, etc., before putting unit into service.

Do not operate

unit if damaged during shipping, handling or use. Damage may result in bursting and cause injury or property damage.

General Safety Information

Read all instructions and safety precautions before operating the unit.

• Risk of fire or explosion! Solvent and paint fumes can explode or ignite, causing severe injury and property damage.

• Paints and solvents containing HALOGENATED HYDROCARBONS can react explosively with aluminum. DO NOT USE HALOGENATED HYDROCARBONS WITH THIS EQUIPMENT. Consult the paint or solvent product label or Material Safety Data Sheets (MSDS) to help determine if it contains halogenated hydrocarbons.

• Make sure the room is wellventilated.

• Avoid all ignition sources, such as static electricity sparks, open flames, hot objects, sparks from connecting and disconnecting power cords, and working light switches.

• Follow the material and solvent manufacturers’ safety precautions and warnings. Do not use liquids with flash points less than 100 degrees Fahrenheit (38 degrees Celsius).

• Unit is not intended for spraying flammable materials other than lacquer. See Special Note on Lacquers and Other Oil (Solvent) Based Coatings.

• Do not carry TURBINE while spraying.

• Keep the turbine at the maximum distance from the spraying area.

• Static electricity can be produced by HVLP spraying. Make sure any electrically conductive object being sprayed is grounded to prevent static sparking. The sprayer is grounded through the electric cord. If an extension cord is necessary, the cord must be a grounded, 120 volt, three wire type cord.

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HV2100, HV2105

Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

General Safety Information . . . . . . . . . . . . . . . . . . . . . . .2

Grounding Instructions . . . . . . . . . . . . . . . . . . . . . . . .3

How Your HVLP System Works . . . . . . . . . . . . . . . . . . . . .4

How Your HVLP Spray Gun Works . . . . . . . . . . . . . . . . . .4

Pre-Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Preparing to Use System . . . . . . . . . . . . . . . . . . . . . . .4

Familiarizing Yourself With Spray Gun . . . . . . . . . . . .4

Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Preparing to Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Spray Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Using Your Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . .7

Spraying Technique . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Running Multiple Spray Guns with Turbine . . . . . . . .7

Using Pressure Pots with Turbine Systems . . . . . . . . .8

Using Optional Accessories with Spray Gun . . . . . . . .8

Additional Instructions for

Model HV2105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Attaching Turbine Unit to Cart . . . . . . . . . . . . . . . . . .8

Converting Spray Gun from Cup Gun to

Production Fluid Feed . . . . . . . . . . . . . . . . . . . . . . . . .8

Attaching Air Hose and Fluid Hose . . . . . . . . . . . . . . .9

Preparing to Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Setting Pot Pressure and Priming Spray Gun . . . . . . .9

Cleaning the System . . . . . . . . . . . . . . . . . . . . . . . . . .10

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Turbine Maintenace . . . . . . . . . . . . . . . . . . . . . . . . . .10

Cleaning Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . .10

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . .12

Turbine Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Parts Diagrams and Parts Lists . . . . . . . . . . . . . . . . . . . .14

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

DANGER

WARNING

CAUTION

NOTICE

WARNING

MANUAL

HVLP Paint Sprayers

Operating Instructions and Parts Manual

General Safety Information

(Cont.)

• Hazardous vapors: Paints, solvents, insecticides, and other materials may be harmful if inhaled, causing severe nausea, fainting, or poisoning.

• Always wear a mask or respirator and eye protection when painting. Be certain mask or respirator will provide necessary protection against inhalation of harmful vapors.

• NEVER point the spray gun at any part of the body, or at anyone else.

• Tipping the gun may cause the gun to clog. Dried spray material clogs the pressure delivery tube and fittings. The spray gun does not function when clogging occurs.

• When not in use, be sure to disconnect the hose and place the gun on a solid, level surface or in the turbine gun storage area to avoid tipping.

GROUNDING INSTRUCTIONS

This product must be properly grounded. In the event of an electrical short circuit, grounding reduces the risk of electrical shock by providing an alternate path for the electrical current.

This product is equipped with a cord that has a ground wire and an appropriate ground plug. Plug the unit into an outlet that is properly installed and grounded in accordance with local codes and ordinances.

Improper installation of the ground plug can result in the risk of electrical shock. If repair or replacement of the plug or cord is necessary, consult an authorized service provider.

1. For any questions regarding proper installation of the ground plug, consult a qualified (licensed or certified) electrician.

2. Do not modify the plug provided. If the plug does not fit the outlet, have the proper outlet installed by a qualified electrician.

3. This product is for use on a nominal 120-volt circuit and has a grounding plug that looks like the plug in Figure 1. Make sure that the product is connected to an outlet having the same configuration as the plug. No adapters should be used with this product.

4. If an extension cord is required, use only a three wire extension cord that has the same configuration as the unit cord, including the (round) ground terminal. Make sure that the extension cord is plugged into a properly grounded receptacle.

5. When using an extension cord, be sure it is in good condition and heavy enough to meet the specifications in the chart below. If an extension cord is needed, the following wire sizes must be used (See Table 1).

Length of Cord Gauge

25’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

25-50’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

50-100’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

100-150’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Table 1 - Appropriate Extension Cord Lengths

Extension Cord Requirements

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SPECIAL NOTE ON LACQUERS AND OTHER OIL (SOLVENT) BASED COATINGS

When mixing or thinning:

1. Eliminate potential sources of fire

• Turn off the HVLP sprayer, all other electrical appliances, spark or flame sources

• Follow lacquer (or other coating) and thinner (solvent) manufacturer directions very carefully

2. Minimize vapors in the spray area.

Eliminate all potential for spilling lacquer or thinner in the spray area

• Tightly recap all containers immediately after mixing or thinning and store away from the spray areas.

• Do not operate the HVLP turbine in the presence of open containers or spillage.

• Make sure all vapors have dispersed prior to turning the HVLP sprayer on.

Grounded Outlet

Box

Grounding Pin

Figure 1 - Grounding

HV2100, HV2105

WARNING

RESET

TEST

DANGER

CAUTION

Operating Instructions and Parts Manual

HVLP Paint Sprayers

How Your HVLP System Works

Your turbine system has three components: the turbine unit, an air hose and a spray gun. The turbine unit, when connected to the correct electrical power supply and powered on, provides a continuous source of clean, warm, dry, High Volume Low Pressure air. The air hose connects the turbine unit to the spray gun. Air flows through the hose to the nozzle of the specially designed spray gun. Atomization of the coating is achieved when the air mixes with the stream of fluid passing through the tip/nozzle. This low pressure atomization principle achieves minimum misting (overspray) to the spray environment.

The turbine blower has one air hose outlet on the side of the unit and is designed to run one spray gun. The 4stage model has the capability to run two spray guns at the same time with an optional “Y” connector. When using only one spray gun, always be sure that one outlet is capped.

How Your HVLP Spray Gun Works

Turbine Spray Guns are bleeder type spray guns. When the turbine is turned on, air will constantly flow through the air cap. This helps makes the equipment more durable. Air also flows through the air feed tube in order to pressurize the cup, and deliver fluid to the tip/nozzle. When the paint flow screw is opened and the trigger pulled back, fluid flows through the tip/nozzle, mixing with the air flow delivered from the air cap. The spray gun projects a fine atomized mist on your work piece.

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Pre-Operation

PREPARING TO USE YOUR HVLP TURBINE SYSTEM

1. Connect the air hose to the turbine. Pull back the spring loaded quick disconnect coupler and insert the male connector on the air hose into the turbine connector. Release the ring. Your air hose will be locked into place. To disconnect, pull back on the connector to release the air hose.

If you have just

finished spraying, the metal coupler at the turbine end may be hot.

2. Plug the electric cord into a

correctly grounded electrical outlet. Be sure the electric current is the correct voltage. If you need to use an extension cord, be sure it is at least 12 gauge wire and has a correctly grounded outlet.

3. Select a safe, well ventilated area

where you will spray your work piece. Locate your turbine unit away from the area where you will be directly spraying. Do not cover or enclose the turbine. It is important to draw cool/ambient air through the unit for optimum performance. Avoid placing the

turbine in a warm environment or in direct sunlight.

FAMILIARIZING YOURSELF WITH YOUR SPRAY GUN

HVLP Spray Gun:

1. Slide the lever to one side, releasing the cup from the holding pins on the cup. Reverse the procedure to install the cup onto the gun body. Make sure the cup is secure. Be sure the cup is centered on the gasket under the top of the cup.

2. Familiarize yourself with the controls on the spray gun. There are three main controls: rotating air cap, material flow knob and air cap locking ring. Click the rotating air cap into each position: horizontal, vertical and 45°. When the air cap is in the 45° position the pattern is round. This is useful for spraying small, narrow pieces of work. Paint flow will increase when using the diagonal position. It is usually necessary to reduce the paint flow by adjusting the flow knob. (See Figure 2)

3. Turn the material flow knob counterclockwise to open or release more fluid, clockwise to reduce or close material flow.

HV2100, HV2105

Figure 2 - Material flow knob positions and spray patterns

1. Use this position when spraying across from side to side.

2. Use this position when spraying from top to bottom.

3. Use this position for spotting small objects, corners and sharp angles.

CAUTION

Operating Instructions and Parts Manual

Pre-Operation (Cont.)

4. Loosen the air cap locking ring one or two turns. This will feather the top and bottom of the fan pattern and slightly reduce the fan pattern size.

COATINGS

COATING PROPERTIES:

Coatings are a blend of resins and additives to create a product that will provide a protective and beautifying surface to your work piece. Different resins have different properties. It is important to use the correct coating to achieve a desired result. Manufacturers of coatings can control the resin solids content, production viscosity, sheen, color, flowout enhancement and other properties. Some products offer ways to adjust the coating properties such as speeding up or slowing down the drying time, adding catalysts to strengthen the molecular bond or adding flattening agents to lower the sheen. Manufacturers will often give some guidelines on how to thin their product for spray application.

There are many different types of spray equipment in use. Coating manufacturers cannot address all of them. Make sure you know about your spray equipment. Make sure to use the correct fluid viscosity to produce the best possible results.

YOUR CHOICE OF COATINGS AND VISCOSITY: Extremely thin, watery or light bodied fluids such as inks, aniline dyes and oil stains can generally be used straight from the can. Most water based finishing products are also formulated to be used straight from the can without thinning with a 3 stage or larger turbine. Most other coating products will need to be thinned anywhere from 10% to 50% depending on the available air pressure of the turbine model and the

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HVLP Paint Sprayers

HV2100, HV2105

properties of the coating selected (see Table 4).

HVLP TURBINE PROPERTIES: Each turbine unit offers the finisher a maximum operating pressure. This pressure is determined by the size and output of the unit you have selected. The maximum available pressure will have a direct bearing upon the viscosity of the fluid that you choose to spray. Atomizing pressure and fluid viscosity directly relate to the efficiency of the equipment operation and the quality of the results that you will achieve.

The available air volume and pressure at the air cap will meet the delivery of fluid coming out of the nozzle to create a fine mist called atomization. This mist travels directly to your work piece where it blends together to form

a connected wet film. Achieving a smooth, level surface will depend on the proper relationship between available atomizing pressure, the viscosity of the coating being applied and the properties of the coating.

USING LATEX PAINT:

Although your turbine spray system is best suited to spray Class A Finish coatings such as lacquers, enamels, urethanes, varnishes, waterbornes etc., you can spray latex house paint if you follow a few simple rules:

1. It is necessary to thin some latex

paints. This will vary from as little as 5% to no more than 20%. This will depend on the model turbine you are using and the quality of the paint used.

2. It is necessary to use a larger nozzle

and needle set in the spray gun (2.0 mm or 2.5 mm).

3. It is recommended that a latex

conditioner, Floetrol, be added to aid flow-out. If unable to find this product, locate one that is labeled “latex enamel” or “HVLP compatible.” These products are available at local paint stores.

Turbine Size . . . . . . . . . . . . . . 4 stage

Unrestricted Pressure . . . . . . .7.0 psi

Coating Types Light-Heavy

Viscosity Materials

Turbine Performance

Table 2

Tip/Needle Size Application Air Cap

.75 mm (.0295) Inks, dyes, stains, extremely thin viscosity HV104505AV HV104520SV fluids, water based finishes

1.0 mm (.039) All purpose, thin lacquers, thin enamels, HV104505AV HV104521SV water based finishes, automotive, marine,

airplane finish

1.5 mm (.059) Catalyzed lacquers, conversion varnish, HV104505AV, HV104522SV primers, automotive, marine, airplane, finish A.5297

varnish, high viscosity industrial coatings, urethanes, enamel

2.0 mm (.079) Thinned latex paint, multi-spec, heavy A.5297 A.5220-2 primers, butyrate, nitrate dope, high visosity

industrial coatings

2.5 mm (.098) Thinned latex paint, multi-spec, solvent A.5297 A.5221 adhesives, wax based paint strippers

Table 3 - Needle, Nozzle, and Air Cap Combinations

Nozzle, Needle, and Air Caps

Pre-Operation (Cont.)

PREPARING TO SPRAY

After some practice, you should be ready to spray your coating of choice on your work piece. (See the Operation section for more information on spray patterns, spray gun use, and other usage procedures). Good quality results with your HVLP system are a combination of:

- Careful preparation of your project

- A proper spraying environment

- A basic knowledge of the coatings you will be using and how these coatings work with your spray equipment

- Close adherence to safety precautions

Operation

SPRAY PATTERNS

Your spray gun offers you many options. You can adjust (click) the air cap to three positions. One will produce a horizontal pattern for spraying across, another will produce a

Operating Instructions and Parts Manual

HVLP Paint Sprayers

vertical pattern for spraying up and down, and the third will produce a round pattern to spray small or narrow pieces. (See Figure 2.)

USING YOUR SPRAY GUN

Your spray gun is certified High Volume Low Pressure. This means your spray gun only uses from 3 psi to 10 psi (depending on your turbine unit) of air pressure measured at the air cap. All passages and air ports are much larger than on a conventional spray gun. If one of these air passages becomes blocked, or buildup of material starts to occur, your spray pattern will become distorted. Therefore, always keep your spray gun clean.

Your spray gun comes fitted with a 1mm tip/nozzle and needle inscribed with the number “2”. This will cover about 85% of all the materials/coatings that you will spray. Using this size tip/nozzle and needle, you can achieve a 1/4" line up to a 10" fan pattern just by rotating the air cap to the desired fan type (see Spray Gun Diagrams), opening the material flow knob counterclockwise and moving the

spray gun closer or further away from your work piece. A little practice will enable you to master this technique.

PRACTICE:

Practice using your spray

gun by following these steps:

1. Remove the cup from your spray gun. Fill it halfway with some water.

2. Attach the cup to the body of the spray gun.

3. Attach the spray gun to the air hose.

4. Turn the turbine unit on.

5. You will notice air is now flowing through the air cap. This is normal and correct.

6. Position the air cap in the horizontal position (see Figure 2) and turn the material flow knob counter clockwise approximately 1 to 1-1/2 turns.

7. Point the spray gun away from yourself (and anyone else) and pull the trigger all the way back. You should see a “V” shaped mist (or triangle) called a fan pattern.

8. Now, with the trigger depressed, slowly begin to turn the material flow knob clockwise (closing). Notice that the fan pattern is beginning to get smaller.

9. Turn the material flow knob counterclockwise and notice the pattern get larger.

10. Take a large piece of cardboard and direct the pattern at the surface. Turn the material flow knob 2 full turns and hold the spray gun approximately 6" from the surface.

11. Pull the trigger. Observe the outline and size of the pattern.

12. Turn the material flow knob clockwise (closing). Move the spray gun 1-2” closer to the surface.

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HV2100, HV2105

Type of Coating Amount to Thin/Reduce (Typical)

Lacquers 25-50%

Sanding Sealer 20-30%

Enamels 20-40%

Stains Use from can

Acrylic Enamel 50-60%

Catalyzed Polyurethane 10-30%

Polyurethanes, Varnishes 20-30%

Waterborne Coatings 0-10%

Latex Paint, Emulsion Paint 10-40%

NOTE: The amount of thinning needed will depend on the model turbine used, flow out properties of the coating, and the desired appearance of the finished work piece. It is best to test spraying results prior to thinning.

Table 4 - Types of Coatings, Recommended Amount of Thinning

Viscosity

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