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INSTRUCTIONS–PARTS LIST 307–712
Rev P
Supersedes N
This manual contains IMPORTANT
WARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
Model PRO 5000
AUTOMATIC MID-RANGE ELECTROSTATIC
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
Patent
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TABLE OF CONTENTS Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical Tests Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5 Test Power Supply Resistance . . . . . . . . . . . . . . . . . . 16 Test Resistor Stud Resistance . . . . . . . . . . . . . . . . . . 17 How The Electrostatic Air Spray Gun Works . . . . 5 Service Installation Gun Disassem
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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 Fluid Compatibility BE SURE all fluids and solvents used are chemicall
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FIRE OR EXPLOSION HAZARD To reduce the risk of fire, explosion, or electric shock, which may result 6. All persons entering the spray area: shoes must have conductive from electrical discharge, it is essential that: 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 All parts of the electrostatic system are properly grounded. grounded. Do not cover the floor with cardb
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TYPICAL INSTALLATION
! Power Supply Must Be Interlocked A B K With Spray Booth Exhaust Fan. Main Air Line P E F A A WARNING SIGN E J J C D L G J N Q H NON–HAZARDOUS AREA HAZARDOUS AREA KEY A Air Supply Shut-off Valve (bleed-type) F Pump L Fluid Regulator B Air & Water Separator G Fluid Filter N ES Automatic Gun C Ball Valve H Drain Valve P Normally Closed, 3-Way Air Solenoid D Air Line Lubricator J Pump Ground Wire Valve or 3-Way Manual Valve E Air Regulator K Air Filter
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INSTALLATION 6. Connect the cylinder air line to the gun’s cylinder air Mount the Gun inlet (marked CYL). Mount the gun on a stationary support or on a reciprocat- ing arm. The mounting rod must be properly grounded. 7. Connect the atomizing air line to the gun’s atomizing air inlet (marked ATOM). Mount the gun so the front of the gun is 254 to 300 mm (10 to 12 in.) from the work piece. 8. Connect the turbine air supply line to the gun’s air in- let (marked ES). The gun air inlet fitting has a
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INSTALLATION KEY Check the Electrical Grounding Y Turbine Air Inlet WARNING Z True Earth Ground Proper electrical grounding of every part of your AA Ohmmeter system is essential. For your safety, read the warn- BB Grounded Air Hose ing section, FIRE OR EXPLOSION HAZARD, on AA page 5. Ground the system as explained there. Z 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
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OPERATION WARNING Pressure Relief Procedure 2. Turn off the fluid supply to the gun. To reduce the risk of serious bodily injury, including 3. Trigger the gun into a grounded metal waste con- splashing in the eyes or on the skin, injury from moving tainer to relieve fluid pressure. parts or electric shock, always follow this procedure when shutting off the system, when checking or serv- 4. Engage the gun safety latch. icing any part of the spray system, when installing, 5. Open the pump drain va
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OPERATION NOTE: Provide a 3.1 bar (45 psi) clean, dry, regulated air Adjust the Spray Pattern supply to the gun to ensure full voltage from the Follow the steps below to establish the correct fluid flow power supply. The gun may be operated at lower and air flow. DO NOT turn the turbine air on yet. turbine air pressure, but may lose some electro- static effect. Do not operate the turbine at an air 1. Adjust the fluid flow for the appropriate flow rate by pressure greater than 3.1 bar (45 psi) as
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MAINTENANCE 5. Flush the spray gun before changing fluids or colors Daily Care and Cleaning and whenever you are done operating the gun. See CAUTION Flush the Spray Gun. Clean all parts with a non–conductive solvent, compatible with the fluid being sprayed. Conduc- 6. Check the electrode wire. Straighten if bent, and re- tive solvents can cause the gun to malfunction. place if broken or damaged. See Electrode Replacement. Do not use any cleaning method which may al- low solvent into the gun air
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MAINTENANCE KEY To Clean or Change Air Cap and Fluid Nozzle 15 Fluid Nozzle BB CAUTION BB Air Cap Assembly Do not use metal tools to clean the air cap holes as 81 Locking Pin this may scratch them, and make sure the elec- trode wire is not damaged. Scratches in the air cap holes or a damaged electrode wire can distort the DETAIL DETAIL spray pattern. Equipment needed: Soft bristle brush (supplied). Fluid nozzle wrench (supplied). 15 Solvent compatible with fluid being sprayed. Unlocked Locked P
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SPRAY PATTERN TROUBLESHOOTING CHART WARNING Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified. To reduce the risk of serious bodily injury, including splashing fluid or solvent in the eyes or on the skin, always follow the Pressure Relief Procedure Warning on page 9 before checking, adjusting, cleaning o
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GUN OPERATION TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Leakage from fluid pack- Worn needle packing. Replace packing assembly. See page 20. ing nut. Air leakage from front Air valve not seating properly. Clean, service. See page 24. of gun. Air stem packing too tight. Loosen packing. See page 24. Fluid leakage from Electrode worn or damaged. Replace electrode. See page 18. front of gun. Worn fluid seat. Replace fluid nozzle and/or electrode. See page 18. Fluid packing too tight. Adjust pac
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ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Poor wrap–around. *Turbine alternator not operating. Check air supply to turbine. Check for dirt or moisture in turbine. See page 23. Improper distance between gun Adjust spraying distance to and workpiece. 203–305 mm (8–12 in.). Parts poorly grounded. Clean hangers, check for proper ground on conveyer or track. High booth exhaust velocity. Reduce within code limits. Atomizing air pressure too high. Reduce air pressure. Fluid pressure too
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ELECTRICAL TESTS The performance of the spray gun is directly affected by KEY A Megohmmeter the condition of the electrical components contained 1 Gun Body inside the gun. The electrical tests below can be used to A 14 Electrode determine the condition of the power supply (5) and the 86 Air Inlet Adapter resistor stud (17) as well as the continuity of the electrical path between the components. Use megohmmeter 218–979 (see ACCESSORIES) and an applied voltage of 500 volts to complete these electr
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ELECTRICAL TESTS KEY Test Resistor Stud Resistance A Megohmmeter Insert a conductive rod (FF) into the gun barrel (removed FF Conductive Rod for the power supply test) and against the metal contact GG Metal Contact A (GG) in the front of the barrel. See Fig 9. 14 Electrode 20 Gun Barrel Measure the resistance between the conductive rod (FF) and the gun electrode (14). The resistance should be 20 to 30 megohms. If the resistance is correct, refer to the Electrical Troubleshooting Chart for other
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SERVICE 2. Unscrew and remove the electrode (14) with the Gun Disassembly wrench (66c) supplied. See Fig 10. If the needle shaft WARNING assembly (9) turns while trying to loosen the elec- Installing and servicing this equipment requires trode, hold the needle shaft assembly nut with a access to parts which may cause electric shock or small wrench. other serious bodily injury if the work is not per- formed properly. Do not install or service this 3. Install the new electrode (14) with the wrench
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SERVICE 3. Using the wrench supplied, install the resistor stud in Resistor Stud Replacement the front of the gun barrel. Tighten until snug. WARNING Old/New Style Resistor Stud and Electrode 4. Install the electrode as described in Electrode Re- To reduce the risk of sparking, which could cause placement. fire or explosion, BE SURE the electrode and stud you install are black. The old style electrode and 5. Install the fluid nozzle and air cap assembly as stud in the Series A Guns were white. D
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SERVICE KEY Barrel Removal 31 Fluid Tube 1. Unscrew the nut (34) at the gun’s fluid inlet adapter 52 Cap Screw (35). See the PARTS DRAWING. 66f Wrench 2. Pull the fluid tube (31) out of the fluid adapter (35). 3. Remove the trigger by removing the screws and spacers from the gun. 66f 4. Remove the ES indicator lights from the socket head 31 52 cap screws (52). 5. Using the wrench (66f) supplied, loosen and remove the two socket head cap screws (52) from the gun. See Fig 12. 6. Hold the gun body
