DeVilbiss SB-2-545-L Operation Manual

SERVICE MANUAL

OPERATION MANUAL

HVLP PRESSURE / SIPHON FEED SPRAYGUN

EN

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EN

4-3197R-1

Product Description/Object of Declaration:

Zone 1 / Zone 2

Suitable for use in hazardous area:

This Product is designed for use with:

Compact Series Spray Guns

The object of the declaration described above is in conformity with the relevant Union harmonisation

This Declaration of Conformity

Finishing Brands UK Ltd,

Protection Level:

II 2 G X

Notified body details and role:

Element Materials Technology. WN8 9PN UK

Lodging of Technical file

11-May-16

Signed for and on behalf of

Machinery Directive 2006/42/EC

Providing all conditions of safe use / installation stated within the product manuals have been complied with and also installed

(General Manager)

Solvent and Water based Materials

/incorporation is issued under the sole
responsiblility of the manufacturer:

legislation:

ATEX Directive 2014/34/EU
by complying with the following statutory documents and harmonized standards:
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN 13463-1:2009 Non electrical equipment for use in potentially explosive atmospheres - Basic methods and requirements
The object of the declaration described above is in conformity with the relevant Union harmonisation legislation: Directive 94/9/EC
(until April 19th, 2016) and Directive 2014/34/EU (from April 20th, 2016)

Ringwood Road,
Bournemouth, BH11 9LH. UK

EU Declaration of Conformity

in accordance with any applicable local codes of practice.

Dave Smith

Finishing Brands UK Ltd:

Bournemouth,BH11 9LH,UK

SB-2-545-L (5/2016)2 / 12

IMPORTANT: Read and follow all
instructions and SAFETY PRECAUTIONS
before using this equipment.

DESCRIPTION

The Compact Pressure feed Spraygun Kit
complies to ATEX regulations 94/9/EC,
protection level; II 2 G X, Suitable for use

in Zones 1 and 2.

IMPORTANT: These Sprayguns are suitable

for use with both waterbased and solvent
based coating materials. The design uses
HVLP atomising technology to reduce
overspray and improve coating efficiency.
If there is any doubt regarding the
suitability of a specific material contact
your local Distributor or DeVilbiss direct.

DeVilbiss reserves the right to modify
equipment specification without prior
notice.

EN

SAFETY WARNINGS

FIRE AND EXPLOSION

Solvents and coating materials can be highly flammable or
combustible when sprayed. ALWAYS refer to the coating material

suppliers 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 spraygun and other metallic
equipment used.

PERSONAL PROTECTIVE EQUIPMENT

Toxic vapors – When sprayed, certain materials may be poisonous,

create irritation or be otherwise harmful to health. Always read all
labels and safety data sheets for the material before spraying and
follow any recommendations. If In Doubt, Contact Your Material
Supplier.

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.

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 spraygun

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 spraygun 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 isolated and
relieved from the equipment.

The product should be cleaned using a gun washing machine.
However, this equipment should not be left inside gun washing
machines for prolonged periods of time.

NOISE LEVELS

The A-weighted sound level of sprayguns 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.

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EN

Patent No. 2372465 (GB)

MODEL PART NUMBER

Example: COM-PS506B-14-00

Stainless Steel
Fluid Passage

Aircap

Blue anodized

Fluid nozzle size
(14 = 1.4 mm)

00 = No cup
01 = Siphon cup

PARTS LIST

Ref.
No. Description Part Number Qty. Options

1 Air Cap/Retaining ring SP-100-***-K 1 506, 507, 508 e.g *** = 506

COM-506, COM-507, or COM-508
2 Nozzle SP-200S-**-K 1
+3 Separator (Pack of 5) SP-623-K5 1
+4 Packing (Pack of 2) GTI-445-K2 1
5 Spreader Valve SP-401-K 1
6 Stud and Screw 1
7 Needle Adjusting Screw SP-614-K 1
+8 Spring (Pack of 5) SP-622-K5 1
9 Needle SP-300S-**-K 1
10 Airvalve housing & seal SP-612-K 1

•11 Spindle 1
12 Trigger, Stud and Screw SP-617-CR-K 1
13 Connector SP-611-K 1
14 Plug JGA-132 1
15 Fluid Inlet Connector and seal SP-636-K 1
17 Retaining Ring and Seals SPK-102-K 1
+18 Clip, Seal and Pin Kit (Pack of 5) GTI-428-K5 1

• 20 Air Valve Assembly Tool 1
21 Spanner SPN-5 1

Spraygun Service Kit includes SPK-402-K 1
1 each of parts marked +

16 Air Valve Service Kit includes SPK-101-K 1
1 each of parts marked •

085, 10, 12, 14, 16, 18, 22 e.g ** =14 =1.4 mm

085, 10, 12, 14, 16, 18, 22 e.g ** =14 =1.4 mm

*T-20 six point star wrench required.

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EN

SPECIFICATION
Air supply connection:

Universal 1/4" BSP and NPS

Fluid supply connection:

Universal 3/8" BSP and NPS

Maximum static Air inlet pressure:

P1 = 12 bar (175 psi)

Maximum static Fluid inlet pressure:

P2 = 15 bar (218 psi)

Nominal gun Air inlet pressure
with gun triggered:

1.5 bar (22 psi) 507 HVLP Air Cap

1.1 bar (16 psi) 506 HVLP Air Cap

Maximum Service temperature:

40°C / 104°F

Gun Weight: 412 g / 14.5 oz.

MATERIALS OF CONSTRUCTION

Gun body: Anodized Aluminum

Nozzle: Stainless Steel

Needle: Stainless Steel

Fluid Inlet / Fluid Passages:

Stainless Steel / PTFE

Trigger: Nickel Plated Steel

AIR CAP SPECIFICATIONS

SP-100-506-K (Pressure Feed)

12.2 CFM @ 16 psi inlet
Fan Pattern Max: 11.8"

SP-100-507-K (Pressure/Siphon)

17.3 CFM @ 22 psi inlet
Fan Pattern Max: 15.7"

SP-100-508-K (Pressure Feed)

11.0 CFM @ 14 psi inlet
Fan Pattern Max: 10"

INSTALLATION

Important: To ensure that this
equipment reaches you in first
class condition, protective
coatings have been used. Flush
the equipment through with a
suitable solvent before use.

1. Attach air hose to connector (13).
Recommended hose size 8 mm
bore. The hose must be conductive
and electrical bond from the
spraygun to earth should be checked
with an ohmeter. A resistance of less
than 106 Ohms is recommended.

2. Attach fluid supply hose to Fluid
Inlet (15).

OPERATION

1. Mix coating material to
manufacturers instructions

2. Turn needle adjusting screw (7)
clockwise to prevent movement.

3. Turn spreader valve (5) counter­clockwise to fully open.

4. Adjust inlet air pressure (For
recommended figures see
Specifications) at the gun inlet with
the gun triggered. (pressure gauge
attachment shown under
Accessories is recommended for
this).

5. Turn needle adjusting screw counter
clockwise until first thread shows.

6. Test spray. If the finish is too dry
reduce airflow by reducing air inlet
pressure or by the Airflow Valve (14).
Screw the Adjusting Knob (14) in to
reduce pressure.

7. If finish is too wet reduce fluid flow
by turning needle screw (7) clockwise
or reducing the fluid pressure. If
atomization is too coarse, increase
inlet air pressure. If too fine reduce
inlet pressure.

8. The pattern size can be reduced by
turning spreader valve (5) clockwise.

9. Hold gun perpendicular to surface
being sprayed. Arcing or tilting may
result in uneven coating.

10. The recommended spray distance is
150-200 mm (6"-8").

11. Spray edges first. Overlap each
stroke a minimum of 50%. Move gun
at a constant speed.

12. Always turn off air and fluid supply
and relieve pressure when gun is
not in use.

PREVENTATIVE MAINTENANCE

1. Turn off air and coating supply and
relieve pressure in the supply lines,
or if using QD system, disconnect
from airline and fluid line.

2. 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

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

4. Lubrication – stud/screw (6), packing
(4) and air valve (11) should be oiled
each day.

REPLACEMENT OF PARTS
Nozzle (2) and Needle (9) – Remove parts

in the following order: 7, 8, 9, 1 and 2.
Replace any worn or damaged parts and
re-assemble in reverse order.
Recommended tightening torque for
nozzle (2) 9.5-12 Nm (80-100 lbf in).

Packing – Remove parts 7, 8, 9. Unscrew
cartridge (4). Fit new cartridge finger
tight. Re-assemble parts 9, 8, and 7 and
tighten cartridge (4) with spanner
sufficient to seal but to allow free
movement of needle. Lubricate with gun
oil.

Air Valve Seal Kit (16) – (Refer to photos
1 to 28 and fig 2)

Spreader valve (5) – Caution: always
ensure that the valve is in the fully open
position by turning screw fully counter­clockwise before fitting to body.

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EN

1. Remove Adjusting Knob (7),
Spring (8), and Needle (9).

4. Remove Spindle (11). 5. Using Service Tool SPN-7,

2. Loosen Housing (10). 3. Remove Housing (10) and

engage groove behind the
Valve Seat.

Airvalve Spring.

6. Remove Valve Seat.

7. Push out the Front Airvalve
Seal with a finger.

10. Fit new Seal to gunbody and
press firmly to ensure Seal is
engaged.

8. Turn the Gun upside down
and let the Seal fall out.

11. Fit New Valve Seat to Service
Tool. Groove must face
outwards.

9. Fit New Front Seal to Service
Tool.

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EN

12. Fit Valve Seat to Gunbody. 13. Remove Rear Airvalve Seal
from housing (10) with a
hooked instrument.

15. Fit Seal to Housing (10). 16. Replace Spindle (11). 17. Replace Valve Spring and

14. Fit new Seal to Service Tool.

attach Housing (10).

18. Tighten Housing. 19. Fit Needle (9). 20. Fit Spring (8) and Knob (7).

21. Adjust Needle Packing (4)
with Spanner sufficient to
seal but to allow free
movement of needle.
Lubricate with gun oil.

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EN

TROUBLESHOOTING

CONDITION CAUSE CORRECTION

Heavy top or Horn holes plugged. Clean. Ream with non-metallic point.
bottom pattern Obstruction on top or bottom of fluid tip. Clean.
Cap and/or tip seat dirty. Clean.

Heavy right or left side pattern Left or right side horn holes plugged. Clean. Ream with non-metallic point.
Dirt on left or right side of fluid tip. Clean.

Remedies for the top-heavy, bottom-heavy, right-heavy and left-heavy patterns:

1) Determine if the obstruction is on the air cap or the fluid tip. Do this by making a test spray
pattern. Then, rotate the cap one-half turn and spray another pattern. If the defect is inverted,
obstruction is on the air cap. Clean the air cap as previously instructed.

2) If the defect is not inverted, it is on the fluid tip. Check for a fine burr on the edge of the fluid tip.
Remove with #600 wet or dry sand paper.

3) Check for dried paint just inside the opening. Remove paint by washing with solvent.

Heavy center pattern Fluid pressure too high for atomization Balance air and fluid pressure.
air (pressure feed). Increase spray pattern width with
spreader adjustment valve.
Material flow exceeds air cap's capacity. Thin or lower fluid flow.
Spreader adjustment valve set too low. Adjust.
Atomizing pressure too low. Increase pressure.
Material too thick. Thin to proper consistency.

Split spray pattern Atomization air pressure too high. Reduce at transformer or gun.
Fluid pressure too low (pressure feed only). Increase fluid pressure (increases gun
handling speed).
Spreader adjusting valve set too high. Adjust.

Jerky or fluttering spray *Loose or damaged fluid tip/seat. Tighten or replace.
Material level too low. Refill.
Container tipped too far. Hold more upright.
Obstruction in fluid passage. Backflush with solvent.
Loose or broken fluid tube or fluid inlet nipple. Tighten or replace.
Dry or loose fluid needle packing nut. Lubricate or tighten.

Unable to get round spray Spreader adjustment screw not seating properly. Clean or replace.
Air cap retaining ring loose. Tighten.

Will not spray No air pressure at gun. Check air supply and air lines.
Internal mix or pressure feed air cap and tip Change to proper suction feed air cap and tip.
used with suction feed.
Fluid pressure too low with internal mix cap and Increase fluid pressure at tank.
pressure tank.
Fluid needle adjusting screw not open enough. Open fluid needle adjusting screw.
Fluid too heavy for suction feed. Thin material or change to pressure feed.

Excessive overspray Too much atomization air pressure Reduce pressure.
Gun too far from work surface. Adjust to proper distance.
Improper stroking (arcing, gun motion too fast). Move at moderate pace, parallel towork surface.

Excessive fog Too much, or too fast-drying thinner. Remix properly.
Too much atomization air pressure. Reduce pressure.

Dry Spray Air pressure too high. Reduce air pressure.
Gun tip too far from work surface. Adjust to proper distance.
Gun motion too fast. Slow down.
Gun out of adjustment Adjust.

Fluid leaking from packing nut Packing nut loose. Tighten, do not bind needle.
Packing worn or dry Replace or lubricate.

Fluid leaking or dripping from Packing nut too tight. Adjust.
front of pressure feed gun Dry packing. Lubricate.
Fluid tip or needle worn or damaged. Replace tip & needle with lapped sets.
Foreign matter in tip. Clean.
Fluid needle spring broken. Replace.
Wrong size needle or tip. Replace.

Runs and sags Too much material flow. Adjust gun or reduce fluid pressure.
Material too thin. Mix properly or apply light coats.
Gun tilted on an angle, or gun motion too slow. Hold gun at right angle to work and adapt to
proper gun technique

Thin, sandy coarse finish Gun too far from surface. Check distance. Normally approx. 8".
drying before it flows out
Too much air pressure. Reduce air pressure and check spray pattern.
Improper thinner being used. Follow paint manufacturer's mixing instructions.

*Most common problem.

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