Ecco Xtatic HP6000 User manual

ECCO FINISHING AB, Box 93, S-532 22 SKARA, Sweden 9836 4057 01
Tel: [phone], Fax: [phone]-07
E-mail: [e-mail] • www.eccofinishing.com
EIB12/15-02
0518 II 2 G EEx 0.24 mJ
Operation and Maintenance Manual
ECCOXtatic
HP6000
This manual contains important information on warnings and cautions. Read the
manual thoroughly before starting to operate this equipment, and follow the
instructions. Always keep the manual handy until such time as the equipment is no
longer being used. If your manual is lost or worn badly, do not hesitate to contact
our agency which is closest to you, or the ECCO Finishing AB, directly, and ask us to
send you a new one.
Air Wrap Airless Electrostatic Spray Gun

1
Contents
1
2
3
4
5
6
7
8
9
Thank you for buying our product, Air Wrap Airless Electrostatic Spray Gun,
ECCO Xtatic HP6000.
Before you use the equipment, carefully read this manual and get to know how to use
it safely, efficiently and effectively. Especially, fully understand the operating
conditions described in the specifications, as well as warnings, cautions, notes and
“do’s and don’ts”in the manual. Following these instructions, get the most out of the
equipment for many years to come.
The painting equipment in this manual is for professional use only, calling for a
qualified person to operate. Use of the equipment should, therefore, be limited to
those who have acquired operation and application skills through an authorized
training course.
Should you have any questions about the manual, please get in touch with us at the
addresses, phone and fax numbers as shown on the back of this manual. In order
for us to give you an answer that’s relevant to your particular needs, don’t forget to
give us the “model”and “serial number”of your equipment at that time.
Introduction
For Your Safety·······················································1
Specifications ·························································9
Installation ·····························································10
Precautions Before Operation ····································15
Operation Procedure················································16
Maintenance ··························································18
Nozzle Selection and Precautionary Notes····················20
Troubleshooting ······················································21
Parts Replacement Procedure and Adjustments·············24
Exploded Diagram and Names of Parts························28
Maintenance Log·····················································32
Warranty ·······························································33
10
11
「
」
12

1
Please read and follow all the technical and safety instructions in this manual.
Failure to do so may result in personal injury and/or property damage.
While all the safety precautions in the manual are very important, you should not consider them to be as
cure-all. They are nothing but minimum requirements. You may need some other types of safety
precautions: in fact, you may come across with other types of hazards not shown in the manual down the road.
And, of course, there are regulatory and voluntary safety requirements set forth by the governments and
businesses.
So, shown below and in the pages that follow are the basic minimum safety precautions in connection with
use of our product.
●Safety precautions are classified into three categories based on the severity of hazards involved.
WARNING
Alerts a hazardous situation which may result in personal injury, along with
hazard avoidance measures.
CAUTION
Alerts a hazardous situation which may result in equipment damage or
breakage, along with hazard avoidance measures.
NOTE
Indicates important methods and practical information.
※Safety precautions classified into the CAUTION category could cause personal injury if not properly
followed. To ensure safety and prevent equipment failure, always observe the safety precautions and
follow the hazard avoidance measures.
1
For Your Safety

2
For correct use of the product
Never use acids, corrosive materials and halogenated hydrocarbon-based solvents for the product
covered by this manual.
If you have any doubt about the intended use or materials of the product, please consult us.
The use of the product under conditions other than specified above is always considered as misuse
and may lead to an accident unless our special approval has been obtained.
Danger of the pressurized fluid
<<General safety notes>>
The coating machine uses a high pressure that may cause serious injury.
The paint is supplied under high pressure to the air wrap airless electrostatic spray gun. If the
paint sprayed or leaked under high pressure or a broken piece of a part directly shots your body at
point-blank, it injures your skin and a large amount of toxic substances intrudes into your body.
If you fail to immediately receive adequate treatment, the toxic substances destroy your nerve
system, possibly resulting in a serious situation, e.g. lifetime functional disorders or amputation of
the injured part of your body. Even a splash of the paint may lead to serious injuries if it enters your
eyes or sticks to your skin.
<<Necessity of treatment>>
If you are shot by the paint spray under high pressure, do not undergo home treatment but
immediately see a medical specialist such as orthopedist. It is necessary to notify him or her of
the correct type of the paint used.
Never direct the tip of the air wrap airless electrostatic spray gun toward your body or another
person or get closer to the way in which the paint is to be shot.
Never hold the nozzle of the gun with your finger, palm or another part of your body.
Do not use the coating machine until you fully understand the procedures for operating it.
WARNING

3
<<Safety devices for the air wrap airless electrostatic spray gun>>
The air wrap airless electrostatic spray gun is equipped with safety devices.
Correctly use them.
Whenever using the gun, check that all of the safety devices correctly function.
□Trigger lock
The gun trigger can be locked by raising the switch button at the backside of the trigger.
When not spraying, always lock the trigger so that it will not move. If you fail to do so, the gun
may be accidentally triggered.
<<For the safety of the nozzle>>
Do not hold the nozzle with your finger, palm or any object in your hand.
Take special care when cleaning or replacing the nozzle.
If the nozzle is clogged during a spraying operation, immediately lock the trigger, reduce the paint
pressure according to the “pressure releasing procedure”and remove to clean the nozzle.
It is dangerous to wipe the deposited paint off the nozzle and its surrounding parts with the paint
pressure incompletely released or the trigger unlocked.
Release the pressure with the following procedure.
<<Pressure releasing procedure>>
To reduce the possibility of injury from the paint spray or splashes into your eyes or skin,
always release the paint pressure with the following procedure before inspecting the pump or
gun, mounting, removing, cleaning or replacing the nozzle or stopping the spraying operation.
①Lock the trigger of the air wrap airless electrostatic spray gun.
②Stop the compressed air supply into the pump.
When a power pump has been used, turn it off.
③Stop the compressed air supply into the gun.
④Slowly open the drain valve of the pump to reduce the paint pressure in the hose
and gun.
Then, unlock the trigger and slowly pull the trigger to release the paint. After
checking that the paint pressure has been sufficiently reduced, lock the trigger
again.
⑤Keep the drain valve open until restarting the spraying operation.
If the nozzle or hose is completely clogged or it seems that the pressure cannot be sufficiently
reduced with the aforementioned procedure, slowly loosen the chip guard mounting nut or hose
terminal connector to reduce the pressure until it is completely loosened. Then, check the nozzle
or hose.
WARNING

4
Danger of the misuse
<<General safety notes>>
An excessive pressure, modifications to the parts, the misuse of the paint or solvent or the use of a
worn or broken part may lead to damage to the pump, injury from the paint spray or splashes into
your eyes or skin and/or serious disasters such as fire and explosion.
Never replace or modify any part of the air wrap airless electrostatic spray gun or coating machine
without permit as doing so may lead to a malfunction or injury.
Periodically inspect the whole machine and repair it or replace defective parts as necessary.
Contaminants on the barrel of the gun may generate electrostatic sparks, possibly resulting in fire.
Periodically clean the barrel and keep it free from paint and deposited matters.
Electrostatic sparks may catch fire during the treatment of the machine.
When cleaning the gun or nozzle with a solvent or removing a part, always turn off the controller
and, five seconds after that, bring the corona pin at the tip of the gun into contact with the
grounding wire, or any grounded metallic object for 10 seconds or longer.
When servicing the product, do not remove any part other than specified.
If a problem such as a crack in the barrel or another insulating parts or a flaw on the connecting
cable is found during the inspection, withdraw the product from service and immediately contact
the distributor or us for replacement of the defective part.
When stopping or finishing the spraying operation, turn the controller off.
Some substances contained in the paint or solvent do harm if inhaled or contacted to your skin.
Observe the instructions in the Material Safety Data Sheets provided by the paint and solvent
manufacturers.
Install an adequate ventilation system to prevent accumulation of hazardous substances.
When performing a spraying operation, always wear the safety goggles, working clothes and mask
recommended by the paint and solvent manufacturers. Special protective devices may be
required depending on the paint type or ventilation. Please consult the paint and solvent
manufacturers.
<<Machine internal pressure>>
The maximum operating paint pressure in the air wrap airless electrostatic spray gun is 21MPa.
Never apply the pressure above this level. Take care when setting the pressure of the paint
pressure-feed pump. For the nozzle, use a high-pressure type with a protrusion on the seat at the
backside of the chip. Check that all components of the machine and its accessories such as hose,
connectors and swivel withstand the maximum operating pressure specified above.
If the withstanding pressure of a component or accessory of the machine is lower than the
maximum operating pressure of the pump, take care not to exceed the maximum operating
pressure specified for that component or accessory.
Before using the machine, fasten all connections.
WARNING

5
<<Compatibility of the paint, solvent and compressed air>>
This system cannot be used for electrostatic coating with a conductive paint such as water-soluble
one.
Check that the paint and solvent to be used are compatible with the “materials of part of the pump
that is in contact with the fluid.”Before using a paint or solvent with the air wrap airless electrostatic
spray gun, fully check its specifications provided by the material manufacturer.
Acids, corrosive materials and halogenated hydrocarbon-based solvents cannot be used.
If the moisture is included in the compressed air, it may result in poor coating or activation of the
warning buzzer and safety circuit. Take enough care not to include the moisture.
<<For safety of the hose>>
The pressurized paint in the hose has a higher possibility of danger. If the hose is leaking,
cracked, damaged, worn or incorrectly used, the paint may spout out and cause injury or damage
to the equipment
Handle the hose with care. Do not move the pump by pulling the hose or use an inappropriate paint
or solvent for the outside and inside surfaces of the pump.
If the hose is bent or pressurized by something at a point, the paint pressure is centered at that
point, possibly resulting in paint leakage.
Do not expose the hose to a temperature higher than 80°C or lower than -40°C.
Fasten the hose connector and joint before use.
Never use a damaged hose. Check the hose over its entire length for cuts, paint leakage, wear,
blisters, flaws and loose fittings.
If any of those problems is found, immediately withdraw the hose from service and replace with a
new one.
Never hold the leaking point with your hand nor temporarily close it with an item, such as a tape as
doing so may rather increase the possibility of danger.
Do not repair the leaking point with a repair joint.
If a paint leakage is found, always replace the hose with a new one.
Use a standard hose that meets our specifications.
In order to ground the whole coating machine, it is essential to ground the paint hose. The hose
can be completely grounded by correctly grounding the pump body and tightening the connector.
The paint hose to be used shall have an electric resistance not greater than 100Ω, which is
equivalent to that provided by class D grounding.
If the maximum electric resistance is not indicated on the paint hose, consult the distributor from
which the paint hose was purchased or the hose manufacturer. Connect an ohmmeter to a proper
part of the paint hose and measure the resistance. If the resistance exceeds the permissible limit,
immediately replace the hose with a new one.
<<Danger of moving parts>>
When inspecting or servicing the coating machine or its components, reduce the paint pressure
according to the pressure releasing procedure (on page 3) so that the pump will not accidentally be
actuated.
Do not leave the coating machine while it is running. When stopping or finishing a spraying
operation, reduce the pressure according to the pressure releasing procedure (page 3).
Do not allow children and those who do not fully understand the coating machine to get into the
working area, especially around the air wrap airless electrostatic spray gun or paint pump.
WARNING

6
Possibility of fire or explosion
<<Sources of ignition>>
Static electricity is generated when the paint runs through the pump or hose.
If parts of the coating machine are not appropriately grounded, electrostatic sparks may be
generated to ignite the volatile component of a solvent, sprayed paint mist, suspending debris or
other combustible substance, possibly resulting in serious injury or damage to the machine.
Check that the coating machine and all peripheral metallic objects and the products to be coated
are grounded. If not, electrostatic sparks may be generated to cause fire or explosion.
Fully ventilate the area where a spraying operation is performed.
Do not bring the high-voltage electrode at the tip of the gun or its surrounding parts into contact
with the product to be coated or ground during an electrostatic coating operation. Unknowingly
using a defective gun may generate big sparks and damage the nozzle and electrode.
Do not insert or remove the power plug into or from the power outlet on the coating machine or
electric equipment within a 7m to 8m radius of the spraying operation area.
Do not perform a spraying operation in the vicinity of an open flame, pilot lamp or other source of
ignition.
Never smoke in the area where a spraying operation is performed.
If you feel electric shock, even slightly, when handling the coating machine, immediately stop the
spraying operation and check the grounded condition of each part.
Do not restart the spraying operation until the cause is located and countermeasure is completed.
If the power cable or connecting cable is damaged, it may generate sparks to cause fire or
explosion. Protect the cables from damage.
An extinguisher with a sufficient capacity must be provided at the area where a spraying operation
is performed.
<<Grounding (earthing)>>
To prevent hazards from static electricity, completely ground the paint pump, coating machine, all
surrounding metallic objects and the products to be coated. If there is no proper grounding object,
ground them according to the methods specified by the technical standards for electric equipment
(class D grounding or equivalent).
The methods for grounding the coating machine are as described below.
□Grounding of the working floor
The working floor shall be made of a conductive material and grounded.
Immediately wipe the spilt paint and dirt off the floor and keep the floor clean.
□Grounding of the paint pump
Connect the crimped round terminal at one end of the attached grounding cable to the grounding
terminal on the paint pump body and connect the clip at the other end to a class D grounded
object.
WARNING

7
□Grounding of the paint hose
Use a securely grounded paint hose. When using an extension paint hose, check that it has been
securely grounded. See the section “For safety of the hose”(on page 5).
□Grounding of the air wrap airless electrostatic spray gun
The air wrap airless electrostatic spray gun firmly connected with the correctly grounded hose
and paint pump is considered to be sufficiently grounded.
□Always ground the controller.
□Grounding of the product to be coated
The resistance between the product to be coated and the grounded conveyor shall not exceed
10kΩ. Keep the hangers and earth clips clean in order to maintain the grounded condition.
□Grounding of the human bodies
All operators entering the area where a spraying operation is performed shall wear antistatic
clothes with grounding wires and antistatic shoes with clean soles (conductive shoes with a
resistance about 10MΩ) so that they will not be charged with static electricity.
When performing an electrostatic coating operation, hold the gun with bare hand. If you inevitably
need to wear gloves, make a hole at the palm of each glove so that part of your hand is kept in
direct contact with the gun grip or use conductive gloves.
□Grounding of the paint container
No container other than lidded metallic ones can be used. The container shall be provided with an
exclusive opening for paint and put on a grounded floor or table so that it will be completely
grounded. If no floor or table is used for grounding, connect an exclusive grounding wire to the
paint container to completely ground it.
The container shall be kept closed with the lid during a spraying operation.
For detail, follow the instructions from the fire station with jurisdiction over your region.
□Grounding of cans of solvent used for cleaning
Dripping or spouting cleaning solvent generates static electricity. If the container collecting the
cleaning solvent is made of a metal and not sufficiently grounded, a large amount of static
electricity is accumulated to impose a possibility of danger. Use a metallic container and put it on a
grounded floor or table, or otherwise completely ground it. Never put the container on a
non-conductive sheet such as a corrugated cardboard.
If no floor or table is used for grounding, connect an exclusive grounding wire to the solvent
container to completely ground it. When cleaning the paint pump or reducing the paint pressure,
the hose cap at the bottom of the gun extension shall be supported at the edge of the grounded
solvent container before pulling the trigger.
<<For safe cleaning>>
Before cleaning, check that the whole coating machine and cleaning solvent can have been correctly
grounded. (See the section “Grounding cans of solvent used for cleaning.”)
When cleaning the system, remove the nozzle according to “For safety of the nozzle”(on page 3)
and reduce the pressure as far as possible (to the lowest pressure required to run the cleaning
fluid).
To prevent generation of electrostatic sparks, bring the tip of the spray gun into contact with a
grounded can (metallic) before pulling the trigger to clean.
WARNING

8
<<Solvents>>
The solvent used for cleaning shall have a flash point not lower than 38°C and equivalent to or
higher than that of the paint to be used.
Ahalogenated hydrocarbon-based solvent may explode if it is brought into contact with an aluminum
or plated part in a pressure vessel (e.g. pump, heater, filter, valve or gun), possibly resulting in fatal
injury.
Never use halogenated hydrocarbon-based solvents.
●Typical halogenated hydrocarbon solvents.
Chlorines
Trichloroethylene, Tetrachloroethylene, Ethylene chloride
Bromines
n-Propyl Bromide
Carbon-fluorines
HCFC-225, HFC-43-10mee, HFE-449s1(HFE-7100)
(Shown above are typical examples and there are, of course, other kinds of halogenated
hydrocarbon solvents in the marketplace. Please check with your paint vendors or manufactures
for further details.)
The paint mist or sprayed atmosphere may cause dyspnea or organic solvent
poisoning.
Do not use the product in a room, tunnel, tank or other poorly ventilated place.
Take enough care of not only yourself but also the surrounding people and domestic animals.
The cemented carbide nozzle is a precision machined product. Pricking the
nozzle with a hard metallic needle or the like damages the nozzle hole and
makes the nozzle unusable. To remove clogging matter, clean the nozzle from
the tip to the inside with a soft toothpick or the like and then blow off the
clogging matter.
NOTE
WARNING
WARNING

9
Air wrap airless electrostatic spray gun
Model
HP6000
Maximum voltage to be charged
DC -60kV
Shorting current
80μA
Fluid pressure
Normal
2 to 16MPa
Max.
21MPa
Wrap air
pressure
Normal
0.2 to 0.5MPa
Max.
0.6MPa
Air consumption
Max. 150L/min (normal)
Outside dimensions
L208 × W55 × H219 (mm)
Weight
560g
Connecting cable length
10m (extendable up to 30m in increments of 10m)
Standard
Machinery Directive 2006/42/EC
Low-Voltage Directive 2006/95/EC
EMC Directive 2004/108/EC
ATEX Directive 94/9/EC
EN 50050:2001
Certification
Sira 10ATEX5053X
Sira Test & Certification Ltd.
Rake Lane, Eccleston
Chester, CH4 9JN, England
※The cable length can be extended up to 30m by combining the extension and connecting cables.
2
Specifications

10
[Connecting the controller and paint pump]
See the example of system construction on page 29.
Before starting operation, be sure to read thoroughly the Operation and Maintenance Manuals for controller
and paint pump.
①Connecting to the connecting cable
Correctly connect the air wrap airless electrostatic spray gun to the attached connecting cable.
There is a possibility of injury or electric shock.
When installing the air wrap airless electrostatic spray gun, raise the trigger
lock of the gun to apply the lock.
②Connecting to the grounding cable
Fasten the crimped round terminal at one end of the attached grounding cable to the grounding terminal
on the controller. The crimped terminal at the other end shall be grounded together with the product to
be coated, by connecting to a class Agrounded booth or steel pillar using M6 screws and accessory
screws.
The paint pump shall be completely grounded by means of the accessory grounding wire in the same
manner.
Firmly connect a grounding wire to the controller. This operation requires a cross-ended screwdriver.
The control unit grounding wire shall be 3.5mm2or thicker and firmly connected
to a class A grounded object (with a grounding resistance not higher than 10Ω)
so that it will not come off.
There is a possibility of fire or explosion.
Completely ground the gun and the product to be coated. The electrostatic
coating process uses the high-voltage electrostatic phenomenon and positively
generates static electricity. If not properly grounded, they may discharge static
electricity or generate sparks and fire or explosion may result.
3
Installation
WARNING
CAUTION
WARNING

11
Firmly connect the cable to the gun with hand. After connecting, lock it using stopper. If the cable is not in
right position, do not connect it forcibly but unscrew the nut so as to bring its hexagonal flat into close
contact with the stopper for proper connection.
Forcible tightening using a tool may damage the cable connector. Do not use an
excessive force. Be sure to lock the connector with stopper.
Secure the connecting cable and air hose at a point 70cm to 80cm away from the gun using insulation
locks. At this time, leave a slack in the connecting cable so as not to apply a load to the connector where it
is connected.
When bundling the cable and air and paint hoses with a tape or the like, leave a
slight slack in the cable so as not to apply a tensile force to the cable. Using
the cable as tensed may cut wires in the cable.
For detail, see 6 “Caution in bundling and handling the connecting cable.”
Connect the other end of the connecting cable to the top of the controller as shown below.
③Connecting to the air supply.
Connect the air supply to the air hose joint (screw size G 1/4) on the paint pump unit.
Never raise the paint pressure in the paint pump over 21MPa.
Doing so damages the gun or paint may spout out, possibly resulting in injury
or other accidents.
CAUTION
CAUTION
WARNING

12
④Connecting to the paint hose
In order to connect the paint hose, connect the hose joint on the electrostatic spray gun and that at the
paint outlet of the paint pump. (Connect 3, 5m long and 6, 5m long hoses using an intermediate joint
into a 10m long hose.)
Be sure to check the paint hose for loose connections. The spouting paint
may lead to injury or other accidents.
Apply a wrench on the black part of the gun stay and the hose nipple and firmly
tighten the hose nipple with the gun stay fixed.
Failure to fix the black part of the gun stay may loosen the gun stay, possibly
resulting in a paint leakage.
When fastening the air or paint hose to the gun, always use two wrenches and
do not apply an excessive force to the gun.
When installing or removing the hose, take care not to bring the wrenches into
contact with the cable connector.
⑤Connection of the air hose
Connect the air hose joint on the electrostatic spray gun to the hose joint at the wrap air outlet of the
paint pump (see “Example of system construction”on page 29).
Be sure to check the air hose for loose connections.
The spouting compressed air may lead to injury or another accident.
Fully drain the air transformer, air compressor, etc.
If the moisture is included the compressed air, it may result in poor coating
and conduct static electricity to activate the safety circuit and warning
buzzer.
WARNING
CAUTION
CAUTION
WARNING
CAUTION

13
⑥Caution in bundling and handling the connecting cable
(1)When bundling the electrostatic spray gun connecting cable and hoses, follow the instructions below, in
order not to impair the strength and service life of the connecting cable.
①Do not bundle the connecting cable and hoses at points within about 70cm from the electrostatic
spray gun.
②When bundling, leave a slack in the connecting cable relative to the air and paint hoses so that the
connecting cable will not be bent at an acute angle or tensed when the electrostatic gun is directed
to the top, bottom, right or left.
③Bundle the cable and hoses at intervals of 5cm, starting at the point 70cm apart from the grip of the
electrostatic spray gun, using resin bands (insulation locks) or plastic tapes with some slack left in
the cable. Do not continuously wind a plastic tape or wider spiral tube around them. The wound part
of them become rigid like a stick and both ends of this part may be bent to cut or damage the
connecting cable and/or hoses.
(2) During a spraying operation, do not operate the electrostatic spray gun or bundle the connecting cable
and hoses in such a manner that bends at an acute angle or excessively tenses the connecting cable
and air and paint hoses. Doing so reduces their strength and may cut them.
(3) Take enough care not to step on the connecting cable. Stepping on it over a metallic drain board may
cut wires in it by the board.
(4) Do not continuously wind a plastic tape or the like around the connecting cable alone (especially around
the electrostatic spray gun connector) to reinforce the cable or prevent contamination. Doing this rather
reduces its strength and may cut wires in it.
(5) Do not immerse the connecting cable in a solvent or paint for a long time.
Doing so significantly impairs its strength and service life.
(6) After cleaning the connecting cable, be sure to wipe off the solvent deposited to its surface or blow it off.
(7) Do not use metallic bands. The static electricity may be accumulated in them to give you a smarting
pain.
CAUTION
Paint hose
Air hose (black)
Connecting cable
When bundling, leave more slack in the
connecting cable than in air and paint hoses so
that the connecting cable will not be severely
tensed when the gun is directed upward or
downward.
Bundle at intervals of 50cm or more after the
point 70cm apart from the gun.
Approx. 70 cm

14
[Installing and removing the air wrap airless electrostatic spray nozzle]
When installing the air wrap airless electrostatic spray nozzle, engage it with the air cap with the notch on
the nozzle aligned with the locating pin on the air cap and firmly tighten it to the gun barrel with a retaining
nut.
When installing or removing the air wrap airless electrostatic spray nozzle, always firmly hold the gun barrel
by hand.
Installing or removing the nozzle while holding the grip, not the barrel, applies a
torsional force to the gun, possibly resulting in damage or paint leak.
If the nozzle is engaged without aligning the notch on it with the pin on the air
cap, the paint may spout out from the nozzle when the gun is triggered.
If the gun is used with the pin on the air cap broken or collapsed, the nozzle may
get out of position and disturb the spray pattern, possibly resulting in poor
coating.
If the locating pin on the air cap is broken or collapsed, the air cap cannot be
used any longer and must be replaced with a new one.
Check the packing condition on the mating face of the air wrap airless
electrostatic spray nozzle. If the packing is missing or damaged, the pressurized
paint intrudes into the air circuit, possibly resulting in poor coating or disorder.
WARNING
CAUTION
WARNING
CAUTION

15
There is a possibility of fire or explosion.
Check that the devices, equipment and floor in the coating workshop and the
parts of hangers that are in contact with the product to be coated are free from
deposited paint.
Especially, remove the paint completely from the parts of hangers in contact
with the product to be coated.
Do not bring any articles other than specified into the coating workshop.
Articles brought into the workshop must be grounded.
Be sure to check the power cord connector for insulation.
Do not smoke in the area where a spraying operation is performed.
A fire extinguisher with a sufficient capacity must be provided at the area where
a spraying operation is performed.
The paint thinner brought into the coating workshop must be the minimum and
stored in a metallic container closed with a lid.
There is a possibility of electric shock or injury.
The operators must wear cotton socks and conductive shoes and must not wear
gloves.
If you need to wear gloves, make a hole at the palm of each glove so that part of
your hand is kept in direct contact with the gun grip, or use conductive gloves.
If a trouble, inconvenience or other sign of failure is found, check within the
specified scope of maintenance according to the subsequent section
“Troubleshooting”(on page 21 and subsequent).
If the problem persists, stop checking and immediately contact us for proper and
complete repair.
Precautions Before Operation
4
WARNING
CAUTION

16
①Preparation of paint
This system can be used for electrostatic coating with almost all types of synthetic resin paints except
some types of paints. It is not necessary to specially prepare a paint by mixing.
However, some paints require adjustment using a solvent to improve the electrostatic coating effect.
Also note that a sufficient electrostatic coating effect cannot be expected from some paints with an
extremely low electric resistance. Check the electric resistance of the paint with a paint ohmmeter.
A high electrostatic coating effect can be obtained with a paint resistance between 10 and 60MΩ-cm.
To determine the acceptability of the electrostatic coating effect, ground a 20 to
30 steel pipe and coat it from the front surface. If it is coated to the rear end, the
electrostatic coating effect is considered to be sufficient.
Note that very little electrostatic coating effect can be expected from a metallic
paint or other conductive paints with an extremely low electric resistance.
There is a possibility of dyspnea or organic solvent poisoning.
Some substances contained in the paint or solvent do harm if inhaled or
contacted to your skin.
Follow the instructions in the Material Safety Data Sheets provided by the paint
and solvent manufacturers.
Work in a well ventilated place so as to prevent accumulation of hazardous
substances.
②Operating procedures
For the paint pump and controller, thoroughly read the operation and maintenance manuals for them.
(1) Before starting operation, check that the paint and air hoses and connecting cable have been correctly
installed and that the paint pump and controller completely grounded.
There is a possibility of fire or explosion.
Completely ground the gun and the product to be coated. The electrostatic
coating process uses the high-voltage electrostatic phenomenon and positively
generates static electricity. If not properly grounded, they may discharge
static electricity or generate sparks to cause fire or explosion.
(2) Immerse the suction pipe of the paint pump into a mixed paint so as to suck it in and set the pressure to
a low level between 2MPa and 3MPa.
(3) Check that the power switch on the controller has been set to off. First, spray a small amount of paint
into an empty can or the like with no nozzle mounted on the gun and the gun trigger unlocked. Thus
the foreign matter and air from the paint circuit are discharged.
Operation Procedure
5
NOTE
WARNING
WARNING

17
(4) Check the coating machine and hose joints for paint leakage. Set the operating pressure to between
2MPa and 16MPa.
The maximum operating paint pressure for this gun is 21MPa. Never use it with a
paint pressure exceeding 21MPa. Doing so may damage the gun or lead to injury
or other accidents from the ejected paint.
(5) Lock the trigger again and install the air wrap airless electrostatic spray nozzle.
There is a possibility of injury.
When spraying is not performed, always raise the slider at the trigger to lock
the trigger.
(6) Set the wrap air pressure regulator to between 0.1MPa and 0.5MPa.
Air comes out of the nozzle as the gun is triggered. In order to adjust the spray pattern, rotate the air
flow control knob counterclockwise to increase the air flow and decrease the spray pattern width or
rotate it fully clockwise to decrease the air flow to zero and increase the spray pattern width.
Note that the spray pattern width cannot be varied enough at a higher paint pressure.
(7) Turn on the power switch on the controller and check that the green lamp is on.
(8) Incline the slider inside the trigger downward and trigger the gun. If the red lamp on the controller lights,
this means that a high voltage has been applied to the tip of the gun. The output voltage can be
adjusted.
(9) Start coating operation.
Discharges from the air wrap airless electrostatic spray gun may cause electric
shock or fire. In steps 3 to 9, always hold the gun grip with the one hand and
operate the machine with the other hand.
③Termination of operation
(1) If you want to interrupt operation or restart within 24 hours:
1. Be sure to turn off the power switch on the controller.
2. Reduce the operating pressure of the paint pump to 0MPa.
(Rotate the air pressure regulator counterclockwise to zero.)
3. Trigger the gun to remove the paint in the pressurized paint circuit to reduce the pressure to zero.
4. Thoroughly wipe off the paint mist and other contaminants deposited to the nozzle and barrel by
means of a cloth soaked with solvent. Remove the nozzle and remove the paint deposited to the gun
and nozzle seats.
5. Reduce the wrap air pressure and slightly trigger the gun to release the wrap air only and remove the
solvent that has intruded into the air circuit.
6. Reduce the wrap air pressure to 0MPa again.
7. Lock the trigger to terminate operation.
WARNING
WARNING
WARNING

18
(2) If you want to suspend the work longer than 24 hours:
When using a two-component paint or other paint that cures by chemical action
or paint that settles easily, clean the gun with the following procedure after each
use.
1. Be sure to turn off the power switch on the controller.
2. Remove the suction pipe from the paint container.
3. Reduce the operating pressure of the paint pump to a low level and run the pump to discharge the
paint from the return side.
4. Trigger the gun to discharge the paint remaining in the hose and gun from the tip of the gun.
5. Suck the solvent through the suction pipe and discharge it from the return side. Repeat those steps
until the inside of the pump becomes clean.
6. Trigger the gun to discharge the solvent from the tip of the gun. Repeat those steps until the hose
and the inside of the gun become clean.
7. Reduce the operating pressure to 0MPa and stop the paint pump to release the pressure in the paint
circuit from the tip of the gun.
8. Thoroughly wipe off the paint mist and other contaminants deposited to the nozzle and barrel by means
of a cloth soaked with solvent. Detach the nozzle and remove the paint deposited to the gun and nozzle
seats.
9. Raise the wrap air pressure and slightly trigger the gun to release the wrap air only and remove the
solvent that has intruded into the air circuit.
10. Reduce the wrap air pressure to 0MPa again.
11. Lock the trigger to terminate operation.
There is a possibility of injury.
When suspending or finishing operation be sure to raise the slider at the trigger to
lock the trigger. If you fail to do so, the gun maybe accidentallytriggered.
①Air wrap airless electrostatic spray gun
(1) Keep the air wrap airless electrostatic spray gun clean. When cleaning the gun, do not immerse it into a
solvent but carefully wipe out using a bristle brush or cloth soaked with a small amount of solvent while
holding the gun with hand.
There is a possibility of injury, electric shock or fire.
Before cleaning, be sure to check that the power switch on the controller has
been turned off for 10 seconds or longer. Then, reduce the pressure according to
the pressure releasing procedure (on page 3).
Never immerse the air wrap airless electrostatic spray gun in paint thinner.
Doing so will significantly reduce the service life of the gun.
(2) Do not disassemble the gun parts other than specified. If the gun gets out or order, please contact us.
(3) When not using the gun, hang it on a dedicated gun hook.
CAUTION
WARNING
Maintenance
6
WARNING
CAUTION