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INSTRUCTIONS–PARTS LIST 307–638
Rev. AE
This manual contains IMPORTANT Supersedes AD
WARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
Model PRO4000
MANUAL MID–RANGE ELECTROSTATIC
AIR SPRAY GUN
7 bar (100 psi) MAXIMUM WORKING AIR and FLUID PRESSURE
Part Number 218–026, Series E
With 1.2 mm (0.047 in.) fluid nozzle, part no. 218–996
U.S. Patent No. 4,290,091; 4,219,865; 4,462,061; 4,497,447; 4,660,774
U.K. Patent No. 2,140,327B; 2,142,559B; 2,147,158; 2,191,423
Patented 1986, 1987 Canada
B
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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 Any misuse of the spray equipment or accessories,
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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. The operator must not All parts of the electrostatic system are properly grounded. wear gloves which insulate the hand from spray gun. The gloves must be conductive or mod
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TYPICAL INSTALLATION M A T N S O BC D E H G W G P J X R K Q F WARNING L SIGN U V NON–HAZARDOUS AREA HAZARDOUS AREA Power Supply Must Be Interlocked With Spray Booth Exhaust Fan. KEY J Pump Ground Wire Q Spray Gun Ground Wire A Main Air Supply Line K Fluid Filter R Grounded Air Supply Hose B Ventilation Fan Interlock Solenoid Valve L Fluid Supply Line Shutoff Valve S Electrostatic Spray Gun C Main Air Supply Shutoff Valve (bleed–type) M Fluid Pressure Regulator T ES On–Off Valve Lever D Air & Wa
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INSTALLATION 4. Install a bleed–type air shutoff valve (C, E, P) on the Ventilate the Spray Booth main air line, the pump line, and each gun air supply line to shut off air to the pump and/or gun(s). Install WARNING To prevent hazardous concentrations of toxic an additional bleed–type valve on each pump air and/or flammable vapors, spray only in a properly supply line to relieve air trapped between this valve ventilated spray booth. Never operate the spray and the pump after the air regulator is
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INSTALLATION Check the Electrical Grounding (See Fig 1) KEY WARNING Y Gun Handle Proper electrical grounding of every part of your Z True Earth Ground system is essential. For your safety, read the AA Ohmmeter warning section, FIRE OR EXPLOSION BB Grounded Air Hose HAZARD, on page 5. Ground the system as explained there. Then check your system as Z explained below. AA 1. Turn the ES On–Off valve to OFF. See Fig 2 for the location of the valve lever. 2. Turn off the air and fluid supply to the gu
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OPERATION WARNING Operating Checklist Pressure Relief Procedure Check the following list daily, before starting to operate To reduce the risk of serious bodily injury, including the system, to help ensure you of safe, efficient splashing in the eyes or on the skin, injury from operation. moving parts or electric shock, always follow this procedure when shutting off the system, when 1. Be sure all operators are properly trained to checking or servicing any part of the spray system, safely operate
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OPERATION NOTE: A minimum of 2.8 bar (40 psi) air supply at the Install the Fluid Nozzle and Air Cap gun is required to ensure full voltage from the WARNING power supply. The gun may be operated at a To reduce the risk of serious bodily injury, including lower air pressure/voltage if required, but may splashing in the eyes or on the skin or electric lose some electrostatic wrap. shock, always follow the Pressure Relief Proce- dure on page 9 before installing, or removing the 6. First, complete a
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MAINTENANCE Procedure: Daily Care and Cleaning 1. Follow the Pressure Relief Procedure Warning on WARNING page 9. To reduce the risk of serious bodily injury, including splashing in the eyes or on the skin or electric 2. Remove the air cap assembly (14). See Fig 6. shock, always follow the Pressure Relief Proce- dure Warning on page 9 when shutting off the sys- 3. Turn the locking pin (84) to the unlocked position. tem, when you stop spraying and before checking, servicing, installing, cleaning
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MAINTENANCE Flush the Spray Gun 4. Flush the gun with solvent until it is clean. WARNING To reduce the risk of fire or explosion and serious 5. Follow the Pressure Relief Procedure Warning, bodily injury, the ES ON–OFF lever must be OFF then disconnect the solvent supply. before flushing. 6. Reconnect the fluid supply line. 1. Follow the Pressure Relief Procedure Warning on page 9. 7. Turn on the fluid and air supplies. 2. Disconnect and plug the fluid line. 8. Trigger the gun until it is clea
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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 Worn needle packing. Replace packing assembly. See page 21. Leakage from fluid pack- ing nut. Air valve not seating properly. Clean, service. See page 24. Air leakage from front of gun. Air stem packing too tight. Loosen packing. See page 24. Electrode worn or damaged. Replace electrode. See page 18. Fluid leakage from 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 *ES ON–OFF lever in OFF position. Turn lever to ON. Poor wrap–around. 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 high. Reduce fluid pressure. Fluid viscosity. Check supplier for
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