DeVilbiss Compact-I Operation Manual

Service Bulletin

SB-2-586-E

Replaces SB-2-586-D

OPERATION MANUAL

COMPACT-I — AUTOMATIC SPRAY GUN

CONVENTIONAL, TRANS-TECH & HVLP

Air Cap Selection Determines Spray Technology

English: Pages 1-14

Español: Páginas 15-28

Replacement Parts Ordering Information SEE PAGE 4

Explanation of Conventional, Trans-Tech and HVLP SEE PAGE 9

Complete Spray Gun Assembly Ordering Information SEE PAGE 10

Installation Details SEE PAGES 11, 12, 13, 14

Page 2 SB-2-586-E

Operation Manual

Compact-I Automatic Spraygun

Important

Read and follow all instructions and Safety Precautions before using

this equipment

CHARACTERISTICS

This automatic spray gun complies to ATEX regulations
94/9/EC, protection level II 2 G X, suitable to use in Zones
1 & 2.

This Compact-I is a production spray gun suitable for
use with automatic and semi-automatic machine in
conventional, HVLP or Trans-Tech application. (See page
9 for application details.)

To handle a wide range of coating materials the material
passages are manufactured from high grade stainless

steel. Several needles are available with plastic tips.

Fluid tips and needles are available in high grade stainless
steel.

Pressure feed material supply can be re-circulating or
direct.

The needle adjustment knob has 18 ratchet positions
(per one revolution of the knob) which allows fine and
accurate fluid flow control.

SPECIFICATIONS & MATERIALS OF CONSTRUCTION

Thread Pressure
Fluid inlet & recirculation “P” & "R"
Air inlet (Atom & Fan) “A” & “F”
Cylinder/trigger “Cyl”
Maximum temperature in use
Spray gun weight
Gun body
Tip / Needle / Spray head

EC Declaration of Conformity
We, ITW Finishing UK, Ringwood Rd, Bournemouth, Dorset, BH11 9LH, UK, as the manufacturer of the

Spray gun model Compact-I, declare, under our sole responsibility that the equipment to which this

document relates is in conformity with the following standards or other normative documents:
BS EN 292-1 PARTS 1 & 2: 1991, BS EN 1953: 1999; and thereby conform to the protection requirements

of Council Directive 98/37/EEC relating to Machinery Safety Directive, and; EN 13463-1:2001, council
Directive 94/9/EC relating to Equipment and Protective Systems intended for use in Potentially
Explosive Atmospheres protection level II 2 G X.

1/4" BSPP(F) Max 7 Bars (100 psi)

1/4" BSPP(F) Max 7 Bars (100 psi)

1/8" BSPP(F) 4 to 7 Bars (60-100 psi)

40° C (104° F)

656 gms (1.44 lbs)

Aluminium hard anodized

Stainless steel 303

CA PROP

65

PROP 65 WARNING

WARNING: This product

contains chemicals known

to the State of California
to cause cancer and birth

defects or other

reproductive harm.

ITW Industrial Finishing reserves the right to modify equipment specification without prior notice.

B. Holt, General Manager

24th April 2007

Page 3SB-2-586-E

SAFETY WARNINGS

FIRE AND EXPLOSION
Solvents and coating materials can be highly flammable or combustible when sprayed. ALWAYS refer

to the coating material supplier's instructions and MSDS sheets before using this equipment.

Users must comply with all local and national codes of practice and insurance company requirements
governing ventilation, fire precautions, operation and house-keeping of working areas.

This equipment, as supplied, is NOT suitable for use with Halogenated Hydrocarbons.

Static Electricity can be generated by fluid and/or air passing through hoses, by the spraying process
and by cleaning non- conductive parts with cloths. To prevent ignition sources from static discharges,
earth continuity must be maintained to the spray gun and other metallic equipment used. It is essential
to use conductive air and/or fluid hoses.

PERSONAL PROTECTIVE EQUIPMENT
Toxic vapors – When sprayed, certain materials may be poisonous, create irritation or be otherwise

harmful to health. Always read all labels, safety data sheets and follow any recommendations for the
material before spraying. If In doubt, contact your material supplier.

The use of respiratory protective equipment is recommended at all times. The type of equipment must
be compatible with the material being sprayed.

Always wear eye protection when spraying or cleaning the spray gun

Gloves must be worn when spraying or cleaning the equipment.

TRAINING

Personnel should be given adequate training in the safe use of spraying equipment.

MISUSE

Never aim a spray gun at any part of the body.

Never exceed the max. recommended safe working pressure for the equipment.

The fitting of non-recommended or non-original spares may create hazards.

Before cleaning or maintenance, all pressure must be relieved from the equipment.

The product's metal parts can be cleaned using a gun-washing machine. However, this equipment
should not be left inside gun-washing machines for prolonged periods of time. Certain selas and
o-rings may not be solvent compatible.

NOISE LEVELS

The A-weighted sound level of spray guns may exceed 85 dB (A) depending on the set-up being used.
Details of actual noise levels are available on request. It is recommended that ear protection is worn at
all times when spraying.

OPERATING

Spray equipment using high pressures may be subject to recoil forces. Under certain circumstances,
such forces could result in repetitive strain injury to the operator.

Page 4 SB-2-586-E

PARTS LIST

For the arrangement of the parts, refer to the exploded view on page 5.

Item Description

Order

Part Number

1 Air cap and its retaining ring with seals. See chart on page 6. SP-100-xxx-K 1

Tip with air separator seal

2

Ø 0.85 / 1.0 / 1.4 / 1.8 / 2.2 mm
Ø 0.5 for air cap 590

Air cap 591

SP-200S-xx-K

SP-259S-xx-K
4 Locator ring for indexed air cap SPA-112 1
5 Air separator ring (kit of 5 rings) SPA-27-K5* 1
6 Screw M4 x 25 (kit of 4 Torx 20 screws) S-14192-K4* 4
8 Spray head for Compact-I SPA-40 1



9 Packing seal (kit includes items 9

, 10, 11, 16a) SPK-115* 1

10 Sealing washer (kit includes items 9, 10, 11, 16a) SPK-115* 1

11

O-ring gasket (kit includes items 9, 10, 11

, 16a)

n

SPK-115* 2
12 Gun body for Compact-I SPA-1-CMAI-S 1
13 Air valve (fan and atomizing air) AGG-403 2
14 O-ring (kit includes items 14, 15a, 16) SPK-104* 1
15 Piston + o-ring (kit includes items 14, 15a, 15b, 16) SPA-6X-K* 1

15a O-ring (kit includes items 14, 15a, 16) SPK-104* 1
15b Piston REF. 1

16 O-ring (kit includes items 14, 15a, 16) SPK-104* 1

16a O-ring (kit includes items 9, 10, 11, 16a) SPK-115* 1

17 Piston Spring (kit includes items 17, 22, 23, 24) SPK-105* 1

Stainless steel needle 0.5 / 0.85 / 1.0 / 1.4 / 1.8 / 2.2 mm

18

Plastic tip needle 0.85 / 1.4 mm

SPA-310-xx

SPA-310P-xx
19 Housing SPA-3 1
20 Kit of ring and ball for ratchet (kit includes items 20, 21, 25) SPK-106* 1
21 Ring (kit includes items 20, 21, 25) SPK-106* 1
22 Needle spring (kit includes items 17, 22, 23, 24) SPK-105* 1
23 Spring cap (kit includes items 17, 22, 23, 24) SPK-105* 1
24 Spring washer (kit includes items 17, 22, 23, 24) SPK-105* 1
25 Adjusting knob (kit includes items 20, 21, 25) SPK-106* 1
27 Kit for air connection of remote control (includes "A" and "F" fittings) SPA-22-K2* 1
28 Gun mounting bar (kit includes items 28, 29, 31) SPK-110* 1
29 Gun mounting bar nut (kit includes items 28, 29, 31) SPK-110* 1
30 Plug ¼" BSPP for spray gun without fluid recirculation REF. 1
31 M5 hexagon socket head cap screw, length 8 (kit includes items 28, 29, 31) SPK-110* 2
32 Fluid insert plug REF. 1
33 Kit of retaining ring with gasket (kit includes air cap ring and gaskets) SPK-102-K* 1

Spare parts must be ordered as part of replacement kits listed above.

*



Item 9: Fluid packings only (10 pack) SPA-86-K10.

n Item 11: Air gaskets only (10 pack) SPA-53-K10.

See page 10 for additional adapter/fitting kits for air and fluid hoses.

Qty

1

1

Compact-I AUTOMATIC SPRAY GUN

Page 5SB-2-586-E

COMPACT-I AUTOMATIC GUN
EXAMPLE OF PART NUMBERING SYSTEM

CMAI-85P

CMAI 85 P

Compact-I
Automatic
Spray Gun

NOTE: SPN-8 Torx wrench for item 6 shipped with gun.

85 = .85 mm Fluid Nozzle and Needle
00 = No Fluid Nozzle, No Needle

P = Plastic Needle
– or no letter = Stainless Steel Needle

Page 6 SB-2-586-E

Compact-I AUTOMATIC GUN — AVAILABLE AIR CAPS

Air cap Type

Air Flow

Pressure

at Inlet

Fluid Flow

Pattern size

@ 8" distance

SCFM l/min psi bar oz/min ml/min in mm

SP-100-430-K Conventional 12 340 50.7 3.5 6.7 - 9.5 200 - 280 7.9 200
SP-100-443-K Conventional 12.2 345 43.5 3.0 6.7 - 10.1 200 - 300 11.8 300
SP-100-497-K Conventional 18 510 50.7 3.5 6.7 - 20.2 200 - 600 15.0 380

SP-100-500R-K Round Spray 6.8 200 16.0 1.1 .6 - 5.0 20-150 1.6 40

SP-100-506-K H V L P 10.6 300 19 1.3 4.4 - 6.5 130 – 190 12 310
SP-100-507-K H V L P 19 385 40 1.4 4.4 - 6.5 130 – 190 10.6 270
SP-100-508-K H V L P 11 311 14 1.0 4.4 - 6.5 130 – 190 10 250
SP-100-510-K Trans-Tech 10 283 29 2.0 5.4 - 7.5 160 - 220 10.6 270
SP-100-513-K Trans-Tech 18.8 531 43.5 3.0 6.7 - 20.2 200 - 600 13.8 350
SP-100-522-K Trans-Tech 14.5 410 29 2.0 6.7 - 20.2 200 - 600 13.8 350
SP-100-590-K Trans-Tech 7.7 218 29 2.0 1.6 - 5.0 50 -150 6.0 150
SP-100-591-K Trans-Tech 12.3 350 29 2.0 1.7 - 5.1 50 -150 4.5 115

KK-5090-507 HVLP Test Kit – includes cap, gauge & tube

Other test kits available: KK-5090-430, KK-5090-443, KK-5090-497, KK-5090-506, KK-5090-507, KK-5090-508, KK-5090-510, KK-5090-513,
KK-5090-522, KK-5009-590

Compact-I AUTOMATIC GUN — AIR CAP COMBINATIONS

TYPE

CONVENTIONAL HVLP TRANS-TECH

AIR CAP MODEL NO. 430 443 497 500R 506 507 508 510 513 522 590 591

.020" (0.5 mm) X X
.033" (0.85 mm) X X X X X X
.039" (1.0 mm) X X X X X X X X X X
.055" (1.4 mm) X X X X X X X X X X
.070" (1.8 mm) X X X X X X X X X

FLUID TIP SIZES

.086" (2.2 mm) X X X X X X

ATOM ADJUSTMENT

G

D

C

B

P

E

FAN ADJUSTMENT

FAN &

ATOM AIR

SUPPLY

CYL AIR

Needle travel adjusting knob –

A

18 positions per 1 turn

B Gun head – stainless steel

A

C Air cap ring

D Air cap

E Air valve (fan / atom)

Spray gun body – anodized

F

aluminum

P Fluid inlet – stainless steel

G Fluid tip – stainless steel

F

INSTALLATION

Important: To ensure that this equipment reaches you in first class condition,
protective coatings have been used. Flush the equipment through with appropriate
solvent before use. Mount the spray gun using mounting stem ref.28 and secure it
with nut ref.29.

AIR AND FLUID HOSES

See pages 11, 12, 13 and 14 for installation details.

Page 7SB-2-586-E

Use separate filtered regulated air supplies for
atomizing and cylinder air. Connect the cylinder air
‘CYL AIR’ on top of the body via a control valve.
For fast cylinder operation the control valve should
be fitted as close to the gun as possible or an addi­tional quick exhaust valve installed in the line.
Attach atomizing air hose to the inlet threaded
hole ‘FAN & ATOM AIR’ under the gun body.

Connect material hose(s) ‘P’ to the spray head. If
material re-circulation is required, remove plugs
(30) & (32). Fit standard connector (¼” BSPP) to
the spray head.

Important: The Spray gun must be grounded to dissipate any electrostatic charges
which may be created by fluid or air flows. This can be achieved through the Spray
gun mounting, or conductive air/fluid hoses. Electrical bond from the spray gun to
earth should be checked with an ohmmeter. A resistance of less than 106 Ohms is
recommended.

SETTING

1. The ATOM ‘A’ air valve controls the atomizing air
pressure FAN ‘F’ valve reduces the spray pattern
size. To increase the pressure turn clockwise, to
reduce turn counter-clockwise.

2. Fluid flow can be adjusted with the rear ratchet
knob, fluid flow is increased when you turn the
knob counter-clockwise.

3. For the arrangement of the parts, refer to the
exploded view on page 5.

Recommended hose size up to 34 ft. (10 m) long:
Atomization Air = 0.315 in. (8 mm)
Cylinder Air = 0.236 in. (6 mm)
Material = 0.315 in. (8 mm)

STARTING UP

1. Turn the needle adjusting knob (25) clockwise
until the needle is fully closed.

2. Turn the FAN ‘F’ and ATOM ‘A’ air valves (13)
counter-clockwise to be full open.

3. Use the air cap chart above to set the air pressure
at the air regulator to achieve recommended
pressures above.

4. Turn the adjusting knob (25) counter clockwise to
obtain the desired fluid flow.

5. Test spray. If the finish is too dry or fine, reduce
the airflow by reducing the air inlet pressure or
by screwing the valve ATOM ‘A’ (13) in clockwise,
or increase the fluid flow using ratchet knob,
rotating counter clockwise.

Page 8 SB-2-586-E

INSTALLATION (CONTINUED)

START UP (continued)

6. If the finish is too wet, turn the ratchet knob (25)
in clockwise to reduce the fluid flow, or reduce
the fluid pressure. If the atomization is too coarse,
increase inlet air pressure, or reduce fluid flow.

7. The pattern size can be controlled by turning
adjusting valve FAN ‘F’ (13) clockwise.

8. The spray pattern will give the best results when
perpendicular to the target.

MAINTENANCE

PREVENTIVE MAINTENANCE

Turn off air and coating supply and
relieve pressure in the supply lines, or
disconnect from airline and fluid line.

1. Remove air cap (1) and clean. If any of the holes
in the cap are blocked with coating material use
a toothpick to clean. Never use metal wire which
could damage the cap and produce distorted
spray patterns

2. Ensure the nozzle of the fluid tip (2) is clean and
free from damage. Any build up of dried paint
can distort the spray pattern.

9. The recommended spray distance is 6’’ to 8’’
(150-220 mm).

10. Spray edges first. Overlap each spray stroke a

minimum of 50%. Move gun at a constant
speed.

11. Always turn off air and fluid supply and relieve

pressure and clean down when gun is not in
us.

Unscrew the adjusting needle knob (25) fully in
counter-clockwise rotation, push the needle from
the front of the spay gun, carefully so to avoid
damage the needle end, then pull out the needle
(18) from the back.

If necessary, replace the needle and the tip, first
screw the tip with its air separator ring
(recommended torque between 9.5 to 12 Nm).

Use gun lube to lubricate all the surface of the
needle which will be in contact with the packing
and o ring. Slide the needle into the spray gun from
the back.

Fit the needle springs with its plastic pad (22,23,24)
and replace the needle adjusting knob (25).

REPLACEMENT OF PARTS

Turn off air and coating supply and
relieve pressure in the supply lines,
before any maintenance operation.

TIP (2) & NEEDLE (18)

Remove the air cap (1) by unscrewing its retaining
ring counter- clockwise, remove the index ring if it
remains on the gun head (if fitted and used).

Remove the tip (2) and its air separator ring (3) by
unscrewing counter- clockwise with 10mm
hexagonal spanner.

PACKING SEAL (9)

Unscrew the air cap (1), tip (2) and its air separator
ring (3).

Unscrew the 4 screws (6) to disassemble the gun
head (8).

Push back the two packing seals (9) using a 5.5 mm
diameter rod from the front of the gun head. Clean
the packing location hole carefully with water or
solvent compatible with material being sprayed.

Fit new packing seals (9) with "U" face towards the
fluid passage.

REPLACEMENT OF PARTS (CONTINUED)

FAN & ATOM AIR VALVE (13)

Before assembling, check the air valve
is in fully open position by unscrewing
it counter-clockwise.

Page 9SB-2-586-E

PISTON (15), O RING (16) & (14)

Unscrew the rear housing (19) at the back of the
gun body counter clockwise, pull out the needle
(18).

Use bent nose pliers so to pull out the piston which
has a 12 mm internal groove for this purpose.

It is recommended to replace the o-ring (14) into the
gun body as soon you disassemble the Piston.

If necessary, when replacing the piston, slightly
lubricate the piston lip with petroleum jelly before
fitting into the gun body.

DEVILBISS SPRAY GUN TECHNOLOGY—APPLICATION DETAILS

HVLP

TRANS-TECH

Piston Assembly
(ref.)

Bent Nose Pliers
(ref.)

CONVENTIONAL

Maintains Regulatory
Compliance

The DeVilbiss "HVLP" Compact
gun allows you to maintain EPA
compliance and produce a superb
finish.

Built to provide outstanding
coating atomization, the "HVLP"
Compact can handle all types of
solvent and waterborne
materials.

High performance is coupled
with a gun body light in weight
and designed for operator
comfort to increase productivity.

Maximum Efficiency with
Environmental Responsibility

The DeVilbiss "Trans-Tech"
Compact gun utilizes the very
latest advances in computational
fluid dynamics. This results in
superior atomization with the
new DeVilbiss TRANSFER­TECHNOLOGY.

Exceptionally efficient material
transfer for optimum coverage
and paint usage is achieved with
reduced air consumption,
lowering your electrical needs
and energy costs.

Exceed your production
requirements with the highest
atomization levels at an
accelerated application rate of up
to 600cc/min.

Outperforms the Competition

The DeVilbiss "Conventional"
Compact is our Advanced
Conventional gun and has a
unique high capacity airflow with
outstanding atomization to
produce a superior result.

Compact's Advanced Conven­tional Air Caps make this gun the
ideal performer in both small
operations or high volume
facilities, with the added bonus
of instantly improved finishing
productivity.