Graco 307896A User Manual
INSTRUCTIONS-PARTS LIST OJ
OIlACO
This manual contains IMPORTANT
WARNINGS
READ
and INSTRUCTIONS
AND
RETAIN
FOR
REFERENCE
307-896
Rev.
A
AUTOMATIC
AIR
7 bar (100 psi)
Part Number 907-292
Spray Gun & 75 ft. High Voltage Cable
Part
Number
Spray Gun & 50 Ft. High Voltage Cable
Part Number 956-610
Spray Gun with 25 Ft. High Voltage Cable
HIGH-RANGE ELECTROSTATIC
SPRAY
MAXIMUM
956-112
GUN
WORKING PRESSURE
GRACO
INC.
P.O.
Box
1441
©COPYRIGHT
u.s.
PATENT
and 4,501,394
MINNEAPOLIS,
1988
GRACO INC.
NO.
4,241,880; 4,335,861;
MN
55440-1444
H003
WARNINGS
HOW THE ELECTROSTATIC AIR SPRAY GUN WORKS
INSTALLATION
Typlc.1
V.ntll.te
Conn.ct
Connect
Ch.ck
Mount
Connect
Connect
Conn.ct
OPERATION
Op.r.tlng
Fllt.r
Adju.t
CI
••
CI
•• n the
Flu.hlng
SERVICE
Spray
Gun
EI.ctrlc.1
Gun
EI.ctrod. R ••
fluid N ••
......................................................................
In.t.lI.tlon
the
the
the
the
Electrical Grounding
the
Spr.y
the
the
the
Ch.ckllat
the
fluid
the
Spr.y
nlng
........................................................................
Air
.................•.......................••.............................
Patt.rn
Op.r.tlon
Troubl
DI
•••••
dl.
.........................................................
Spr.y
Booth
High
Voltage
High
Volt.ge
Gun
Air
Une
High
Volt.ge
fluid
Une
................................................................
P.tt.rn
C.p
and
Troubl
Troubl
••
mbly
..........................................................
I.tor
R.mov.1
................................................
Power
Supply
Ca
...........................................
......................................................
........................................................
.....................................................
........................................................
fluid
••
hootlng
••
hootlng
R.pl.c.m.nt
....................................................
........................................
Control
.................................................
Tip
.........................................
Ch.rt
hootlng
Ch.rt
Ch.rt
.....................................
.....................................
...........................
....................................
................................
..............................
TABLE OF CONTENTS
..........
10
11
11
12
2
4
4
4
4
15
15
15
15
8
8
1
1
8
7
7
7
8
9
fluid
B.rr"
fluid
B.rrel R .....
R
..
lator
R
..
lator
Servicing
F.n
Air
AIR CAP CONSUMPTION
Air
Cape
Air
Cap A
PARTS DRAWING
PARTS LIST
HOW TO ORDER REPLACEMENT PARTS
ACCESSORIES
TECHNICAL
The
words Warning, Caution, and
tion within this manual.
WARNING: Alerts user
personal injury.
CAUTION: Alerts user
damage
NOTE:
WARNING
Needle Replacement
Remov"
Pecking
Valve Replacement
to or destruction
Identifies essential procedures or extra information.
.............................................................
Repl.cement
mbly
Tubel R ..
Tube Reg
the
.......................................................................
...
lator
......
Actuator
mbll
..........................................................
...........................................................
....................................................................
................................................................
DATA
.............................................
to
..............................................
.••••••••.•••••••••••••••••••••••••••••••••.••••.•.••••.•
to
............................................
Repl.cement
ng
......... ~ ....................................
.................................................... 14
............................................
.nd
FLUID
avoid or correct conditions that could
avoid or correct conditions that could
of
equipment.
..............................
np
FLOW RATE CHART
...........................
Not.
are
used
B.ck
to
classify informa-
12
12
12
13
13
13
14
11
11
11
11
17
17
18
Cover
cause
cause
SERIOUS
SHOCK
BODILY
CAN
INJURY,
OCCUR IF THE
FOLLOWED.
•
READ
TAGS,
AND
AND
UNDERSTAND
WARNING
MENT.
c!J
Instruction.
EQUIPMENT MISUSE
General
Any misuse
overpressurizing, modifying parts, using incompatible
chemicals
cause them to rupture and
explosion or property damage.
NEVER
body.
ALWAYS follow the Pre
right,
system equipment.
NEVER
NEVER
could cause
CHECK
worn or damaged parts immediately.
This gun
Never exceed the maximum working pressure
any other component or accessory used in the system.
point the spray gun at anyone or at any part
NEVER
befo~e
try
alter or modify any part
all
ELECTROSTATIC
PERSONNEL
QUIREMENTS
EQUIPMENT
WHO
SHALL
STATED
WITHIN
HAZARD
Safety
of
the spray equipment or acc8880ries, such
and fluids, or using worn
put hand or fingers over the spray tip.
cleaning or removing the fluid tip or servicing any
to
stop or deflect
it
to
malfunction.
spray equipment regularly and repair or replace
has
a maximum working pressure
result in serious bodily injury, fire,
..
ure
leaks
or
damaged parts, can
Relief
of
Procedure,
with your hand or body.
this equipment; doing
of
7 bar
(100
of
the gun or
to
BE FULLY
88
of
the
the
so
psi).
EXPLOSION, FIRE, OR ELECTRIC
PRECAUTIONS
ALL
INSTRUCTION
LABELS BEFORE
SHALL
ONLY
BE
CONVERSANT
THIS
INSTRUCTION
Pressure Relief
To reduce the risk
in the eyes, injury from moving parts or electric shock, always
this procedure when shutting
follow
checking or servicing any part
stalling, cleaning or changing fluid tips, and whenever you
stop spraying.
1.
Turn
2.
3.
4.
5.
off
Turn
off
Trigger the gun into a grounded metal waste container
relieve fluid pressure.
Open the pump drain valve, having a grounded metal waste
container ready
Leave
spray again.
Procedure
of
the high voltage power supply.
the air and fluid supply
the pump drain valve open until you are ready
BELOW
ARE
NOT
MANUALS,
OPERATING
USED BY
WITH
EQUIP-
TRAINED
THE RE-
MANUAL.
serious bodily injury, including splashing
off
of
the spray system, when in-
to
catch the drainage.
the system, when
to
the gun.
to
to
2
307-896
Bleed· Type
Valve
These
reduce the risk
the
repairing the pump.
The bleed-type air
this
Required
two
eyes and injury from moving parts
valve and the pump after the air regulator
AIr
Shutoff
accessories are required in your system
of
serious bodily injury, including splashing in
shutoff
Valve and
valve relieves air trapped between
fluid
if
you are adjusting or
is
shut
to
off.
Drain
Trap-
help
pad
air can cause the pump
valve within easy reach
The fluid drain valve assists in
displacement pump, hose and gun; triggering the gun to
relieve pressure may not be sufficient.
to
cycle unexpectedly. Locate the
of
the pump.
relieving fluid pressure in the
All parts
grounded
Static electricity
through the pump and hose and the spray gun's
power
charged and sparking may occur. Sparks can ignite fumes
from
flammable substances, which can cause a fire
and
If you experience any sparking or feel even a slight shock,
STOP SPRA
ing
lem before starting
The minimum spraying distance from the gun tip
workpiece is
workpiece will cause sparking.
Grounding
The following are minimum requirements for grounding a
basic
equipment
check your local electrical code
tions.
ground.
1.
2.
3.
4.
5.
6.
7.
of
the electrostatic spray system must be properly
to
reduce the risk
is
created by the high velocity
supply. Ungrounded objects can become electrically
solvents, fluid being sprayed, dust particles and other
result in serious bodily injury and property damage.
YING
of
the entire system.
electrostatic system. Your system may include other
Be
sure your system is connected
Pump: ground by using a ground wire and clamp
described
Air
compressors: ground according
recommendations.
High voltage
located outside the spray
and
the manufacturer's recommendations.
High voltage cable: obtain grounding through connection
of
an
undamaged cable
supply.
All
electric cables going
perly grounded.
Spray gun: obtain grounding through connection
perly grounded high voltage cable.
Object being sprayed: keep the workpiece hangers clean
and grounded at all times. Contact points must be sharp
points or knife
IMMEDIA
to
spray again.
100
mm (4 in.). Holding the gun any closer
or
objects which must also be grounded. Always
in
your separate pump instruction manual.
power
edges.
of
static electricity discharge.
TEL
Y.
Be
sure you have corrected the prob-
supplies: must be properly grounded
Check
for
detailed grounding instruc-
to
area.
Ground according
to
a properly grounded power
to
the power supply must be pro-
flow
of
fluid
or
explosion
for
proper ground-
to
the
to
the
to
a true earth
the manufacturer's
to
pro-
as
to
8.
All
electrically conductive objects
area,
including paint containers and wash cans, must
properly grounded.
9.
All
persons entering the spray area: shoes must have con-
ductive
straps must be worn. Rubber or
ductive.
10.
The
and grounded. Do not cover the floor
any non-conductive
grounding continuity.
11.
Flammable liquids in the spray
approved, grounded containers. Do not store more than
the quantity needed for one shift.
12.
All
conductive. Do not place the pail on any non-conductive
surface, such
rupt grounding continuity.
flushing
To reduce the risk
follow
remove the
pressure and use a grounded metal waste container.
Be
sure the high voltage power supply is
NEVER
(700F)
point
AL WAYS remove
tivating the spray gun.
Use
only non-sparking tools
and hangers.
Ventilate
To prevent hazardous concentrations
mable
The
High Voltage Power Supply
ed with the ventilators
ply unless ventilating
NEVER
operating.
soles, such
floor
of
the spray area must
solvent pails: use only grounded metal pails, which
and
Cleaning
the Pre
use
to clean the gun. NEVER
of
vapors, spray only in a properly ventilated spray booth.
operate the spray gun unless the ventilating fans
••
fluid tip before flushing.
solvents having a flash point
less
than 38°C
the
Spray
as
leather, or personal grounding
material which would interrupt
as
cardboard or paper, which would inter-
Safety
of
static sparking or splashing, always
ure
Renef
(1000F)
all
solvent from the system before reac-
to
Booth
to
prevent operation
fans
are
or
devices, in the spray
plastic soles
be
electrically conductive
area
Procedure
Use
OFF
use
solvents having a flash
to
clean the spray system.
clean residue from the booth
of
must
be electrically interlock-
operating.
are
with
cardboard or
must
be
on page 2, and
the lowest possible
during flushing.
of
less
than 21°C
toxic
and/or
of
the Power Sup-
not
con-
kept in
flam-
be
are
are
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
stallation, operation and maintenance
of
electrostatic spray painting equipment.
be
consulted in connection with the in-
307-896
3
How
the
Electrostatic
Air
Spray
Gun
Works
A transformer supplies high voltage current through the
cable
to
trostatic field
through the hose and gun, where
the gun's ionizing electrode, where the elec-
is
developed. The pump supplies fluid
it
is
electrostatically
INSTALLATION
TYPICAL
INSTALLATION
p
G
charged
as
it
passes
fluid is attracted
around
it
and coating all surfaces.
the ionizing electrode. The charged
to
the grounded workpiece, wrapping
NON-HAZARDOUS AREA
KEY
A Air
B Air Line Filter
C Air Line Lubricator
D Pump
EON-OFF
F Electric Power Line
G Air
The Typical Installation shown above
H High
Supply Line
(D.P.-D.T.) Switch
Supply Shutoff Valve (Bleed-type)
Voltage Power Supply
J Air Regulator
K Air Filter
L Atomizing Air Line
M High Voltage Cable
N Fluid Line
o Remote Switch & Lights Wiring
P Normally Closed, 3-way Air Solenoid
Valve or 3-way Manual Valve
is
only a guide
(40
micron)
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 ac-
cess
to
other serious
this equipment
Be
parts which may cause electric shock or
bodily injury. Do not install or service
unless you
sure your installation complies
are
qualified.
with
national,
state and local codes for the installation
trical
apparatus in a
Class
1,
Group
0;
Divisions 1
of
......
elec-
and 2 Hazardous Location.
WARNING
SIGN
H
HAZARDOUS AREA
Q Electrostatic Automatic Gun
R Fluid Regulator
S Remote Switch & Lights
T Relay
U Connection Between
V Cylinder
W Electrical Signal Required
EE
FF
Ventilate
the
Spray
..------WARNING
To prevent hazardous concentrations
and/or
ventilated spray booth. The High Voltage Power
Supply must be electrically interlocked with the
ventilators
ly unless the ventilation fans
OPERATE THE SPRAY GUN UNLESS VENTILATION FANS ARE OPERATING.
Check and follow
Local codes regarding air exhaust velocity
requirements.
Check and
OSHA standard 1910-107(b)(5)(i).
flammable vapors, spray only in a properly
to
prevent operation
follow all local safety and fire codes and
for
(CYU Air Line
Fluid Filter
Drain Valve
Booth
all
of
Electrical Signal
Relay
& Power Supply
to
Actuate Air
-------.
of
of
the power supp-
are
operating.
the National, State and
NEVER
toxic
Warning
Signs
Mount warning signs in the spray
easily
be
seen
and
read
cessories section on page
by all operators.
18.
4 307-896
area
where they can
See
the Ac-
NOTE: High velocity air exhaust will decrease the
operating efficiency
system. Air exhaust velocity
meters/minute (100-150
sufficient.
of
the electrostatic
of
31-46 linear
ft/min)
should
be
Connect
The electrical connections
must
dance with
the
High
Voltage
be
performed by a qualified electrician, in accor-
all applicable local, state and national codes.
Power
to
Supply
the Power Supply (H)
z--~=-
Connect
Grease
Regreasing on page
Route the High Voltage Cable (M) from the gun
Power
Connect the High Voltage
To avoid permanent indentations
failures due to unnecessary stress
these steps:
1.
2.
3.
Check
...------WARNING
Proper electrical grounding
system
ing section,
page
Then check your system
1.
2. Shut
the
High
the resistor tube
Supply. Lubricate o-rings with petroleum jelly.
Support the cable overhead
walking
DO
Avoid sharp kinks and bends in the cable.
on
NOT clamp the cable too tightly at supports.
the
Electrical
Voltage
13.
it and vehicles driving over it.
Cable
as
described
Cable
to
Grounding
in
Resistor
the Power Supply.
of
the cable and cable
to
the cable, follow
to
keep
people from
(See
Fig
1)
Tube
to
the
-------.
of
is
essential. For your safety,
FIRE OR EXPLOSION
3.
Ground the system
Make sure the High Voltage Power Supply is properly grounded and located outside the spray area.
The
Power
can
grounded.
voltage circuit and
nected
precaution, attach a separate ground wire
case
to
the gun.
Supply
become
of
off
The
to a true
the High Voltage Power Supply.
the Power Supply and the air and fluid lines
case
charged
ground
must,
earth
every part
as
as
explained there.
explained below.
and
spray
if
the
case is
wire
is
without
ground.
of
read
the warn-
HAZARD,
gun
actuator
of
fail,
As
not
the high
be
an
part
your
on
well
con-
added
to
the
3. Have a qualified electrician check the electrical
grounding continuity
meter
(X)
to
tuator
of
The resistance should
measure resistance between the ac-
the gun
of
the spray gun.
(Y)
and a true earth ground
be
less
than
20
Use
an
ohms.
ohm-
(Z).
KEY
M High Voltage Cable
X Ohmmeter
Y Gun
Z Grounded Object
Fig 1
________________
Connect
Installation Drawing)
1.
2. Install
3.
4. Install
5.
the
Air
Lines (Refer
Install
an
supply
ruin the appearance
cause
(D)
Install a normally closed, 3-way air solenoid (P), or
hand valve in the air supply
supply
gun.
Install a bleed-type air shutoff valve
air line and each gun air supply line
the pump
type valve on each pump air supply line to relieve air
trapped between this valve and the pump after the
air regulator
Shutoff
warnings section, page
air line filter (B) to ensure a clean, dry air
to
the gun. Dirt and moisture in the line can
malfunction
an
air line lubricator
as
possible.
an
air regulator
lines
and/
Valve
of
to
control air pressure
or gun(s). Install
is
shut off.
and
to
the Typical
of
your finished piece, and
the Power Supply.
(C)
as
close
to
line (A).
(E)
on the pump and gun air
Fluid
See
Drain
3.
to
(G)
on the main
to
shut
an
additional bleed-
Bleed-Type
Valve
the pump
pump and
off
air
Required,
6. Connect the atomizing air line (U from the air line
the gun's 114 npt(f) atomizing air inlet. Refer
Typical
Installation drawing .
to
_
to
Air
to
the
...------WARNING
If the resistance is over
property grounded, and the
dous.
Check again that you have properly ground-
ed
your system components;
PLOSION
grounded through connection
properly grounded, high voltage cable (which
grounded through connection
grounded power supply), check for a grounding
problem with the cable and power supply first.
SURE you have corrected the problem before using the system.
Mount
Mount the gun
reciprocating arm. The mounting rod must
grounded.
Mount the gun head 254
the workpiece.
the
HAZARD,
Spray
Gun
(Q)
20
on page 3. Since the gun
on a stationary support or on a
to
-------,
ohms, the gun
system may be hazar-
see
FIRE OR EX-
to
an
undamaged,
to
a properly
be
300
mm
(10
to
12
is
not
is
is
BE
properly
in.) from
7. Connect the cylinder air line (V) from the solenoid
valve
to
the gun's
Adjust
If the gun is mounted
plug (11), adjust the air bleed valve
more atomizing air through the front
replace the plug
ping from the front
the
Air
1/4
npt(f) cylinder air inlet.
Bleed
Valve
above
(11), This helps prevent fluid from drip-
of
the gun onto the workpiece.
(See
Fig
the workpiece, remove the
2)
(43)
to
of
the gun, then
allow slightly
11~'~
43
·~.~~1··~\/~
Fig 2
________________
~"""'
\UI)
:::
.......
,,~/
__
~'7
)
V
_
307-896 5
Connect
An electrical signal
closed, 3-way air solenoid valve (P). The air solenoid
valve opens the cylinder air
the fluid needle, allowing the fluid
signal
relay (T). A set
to
Voltage
the
(W)
the 120
to
High
Voltage
is
required
that actuates the air solenoid valve actuates a
of
contacts from this relay
KV
Power Supply. This allows the High
be
turned on and
Control
to
actuate the normally
to
the actuator, which opens
to
spray. The same
is
connected
off
automatically.
KEY
13
88
Plug
O-Ring
Connect
Before connecting the fluid line
and flush
compatible with the fluid
Connect
the
and
assists
pump,
and
a
flUid
pressure
Color
Remove the plug
the gun barrel, and install a
cessories Section) in the gun barrel inlet.
the
Fluid Line
it
with
solvent.
the
fluid
line
1 /8
~ube
Fitting
and
(FF)
gun.
(R)
gun.
inlet
between
(13)
drain
valve
in
relieving fluid pressure
hose
~Iuid
Drain Valve Required,
regulator
to
the
Change/Circulating
(N),
blow
Be
sure the solvent you use is
to
be sprayed.
(PTFE)
at
from
the
of
the
gun.
Warnings
pump
System
1/4
Install a fluid
outlet.
and
(66)
npt(f) elbow
the
pump
See
Bleed-Type Air Shutoff Valve
and o-ring
it
outlet
of
The
in
the
displacement
Section.
gun
to
Option
from one side
out
the
drain
control
OPERATION
...------WARNING
For Your Safety, always follow the Pressure
Relief
the system, when you stop spraying, and before
checking, servicing, installing, cleaning or changing any part in the system.
Operating
Check the following list daily, before starting
the system,
operation.
_
_
_
_
_
_
_
Procedure
Checklist
to
1.
Be
sure
operate
2.
Be
and completely relieve system pressure.
3.
Be
FIRE OR EXPLOSION
Check
4.
Be
spray
5.
Be
6.
Be
grounded. Contact points must be sharp points
or knife edges.
7.
Be
all
an
sure all operators
sure the system
the
sure the operator and
area
sure ventilation fans
sure the workpiece hangers
sure
all
on page 2 when shutting
help assure you
operators
electrostatic air spray system.
is
Electrical
are
properly grounded.
refuse
is
-------.
of
safe, efficient
are
properly trained
are
trained
thoroughly grounded.
HAZARD
Grounding
all
are
removed from spray booth.
how
to
on page
on
persons entering the
operating properly.
are
with
air,
pump
to
filter
(EE)
valve
Install
fluid
(see
Ac-
off
to
operate
to
safely
properly
See
3,
page
and
5.
clean and
of
Fig 3
_______________
...------WARNING
Do not
fittings
plosion and cause serious bodily injury.
For color change, connect a fluid line
Remove the fluid tube assembly and install a flushing
valve
let. Connect the fluid flushing
Connect
For a circulating system, connect the fluid return line
the elbow.
Filter
Filter the fluid
which could clog the spray tip.
Adjust
This gun
viscosities and at various
to
establish the correct fluid
1.
2.
3.
4.
5.
6.
use
metal fittings at the gun head. Metal
can
cause sparking and result in fire or ex-
(see
Accessories Section) in the gun barrel fluid in-
an
air line
the
Fluid
the
Spray
can
Set the atomizing air pressure at 2 bar
fluid pressure at
Choose the correct fluid tip and air cap combination
for
your application. (See the Air
and Fluid Tip Flow Rate Chart), page
rate and viscosity must
(0.047 in.) fluid tip
Turn on the High Voltage Power Supply.
Adjust the fluid
regulator
Section).
For fine adjustment,
(39)
located at the rear
the knob
being sprayed, and
the amount being sprayed.
Use
an
for the desired degree
the lowest air pressure possible
air pressure regulator
to
actuate the flushing valve.
to
remove coarse particles and sediment
Pattern
atomize many fluids with different
installed in the fluid line. (See Accessories
clockwise to reduce the amount
flow
0.25 bar
is
furnished with the gun.
flow
use
counterclockwise to increase
-------.
to
the elbow.
line
to
the flushing valve.
rates. Follow these steps
flow
and air flow:
(3
to
4 psi).
be
considered. A 1.2 mm
by using the fluid pressure
the fluid adjusting screw
of
the gun.
to
of
atomization. Always
for
(30
Cap
Consumption
15.
See
Fig
adjust the pressure
most efficiency.
psi) and
Both
4.
of
_
flow
Turn
fluid
use
to
8.
Be
_
_
9.
sure all flammable liquids in the spray booth
are
in approved, grounded containers.
Be
sure all conductive objects within 6 m
of
the
gun-
of
the spray
grounded.
6 307-896
are
electrically grounded and the floor
area
is
electrically conductive and
(20
ft)
7.
Use
the fan valve
spray pattern.
counterclockwise
for
a solid, round pattern.
(57)
See
to
Fig
for
a wide pattern
change the shape
4.
Turn fan valve knob
and
clockwise
of
the
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