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Graco 237-426 Operation manual

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INSTRUCTIONS–P
ARTS LIST
308–465
Rev.
B
Supersedes A
30:1 PRESIDENT, CARBON STEEL, CART MOUNTED
Heated
Air-Assisted Airless
Electrostatic
Package
See the Data Sheet, 305–669, for application information
3000 psi (210 bar) Maximum System Working Pressure
100 psi (6.9 bar) Maximum Air Inlet Pressure
Model 237–426, Series A
This
complete package includes a pump,
an electrostatic air-assisted airless–spray gun with size a 41
1 spray tip,
a portable cart, 25 ft. (7.6 m) air and fluid hoses,
air and fluid controls, and a fluid feed.
IMPORTANT
This manual provides the basic safety
, installation and
operation information for the spray system. For your
safety
, also read the component manuals supplied with
this system before operating it.
GRACO INC. P.O. BOX 1441
MINNEAPOLIS, MN
55440–1441
COPYRIGHT
1994, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
04133

Table
of Contents
Symbols 2.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System
Component Information
8.
. . . . . . . . . . . . . . . . .
Operation 10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical
Data
20.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco
Phone Numbers
20.
. . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This
symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution SymbolCAUTION
This
symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.
WARNINGWARNING
FIRE, EXPLOSION AND ELECTROSTATIC SHOCK HAZARD
Improper
grounding, poor air ventilation, open flames or sparks can cause a hazardous condition
and result in a fire, explosion or electrostatic shock and other serious injury
.
D
Electrostatic equipment must be used only by trained, qualified personnel who shall be under
-
stand with the requirements stated in this instruction manual and the electrostatic gun manual.
D
Ground the equipment, the object being sprayed and all other electrically conductive objects in
the spray area. Proper grounding dissipates static electricity generated in the equipment. See
Ground the system
on 7.
D
If there is any static sparking while using the equipment,
stop spraying immediately
. Identify
and correct the problem.
D
When flushing or purging electrostatic equipment, use solvents with a flash point equal to or
greater than that of the fluid being sprayed.
DT
o clean the exterior of the electrostatic equipment
,
use solvents with a flash point higher than
100_F (38_C).
DRemove
all solvent from the system before reactivating the electrostatic spray gun.
D
Use only non-sparking tools to clean residue from the booth and hangers.
D
Spray only in a ventilated spray booth. Electrically interlock the gun air supply with the ventilators
to prevent operation of the electrostatic power supply unless ventilating fans are running.
D
Do not smoke in the spray area.
D
Extinguish all open flames or pilot lights in the spray area.
D
Do not turn on or of
f any light switch in the spray area.
D
Electrically disconnect all equipment in the spray area.
D
Keep the spray area free of debris, including solvent, rags and gasoline.
D
Do not operate a gasoline engine in the spray area.


WARNINGWARNING
FLUID INJECTION HAZARD
Spray
from the gun, hose leaks or ruptured components can inject fluid into your body and cause
extremely serious injury
, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause can also cause serious injury
.
D
If a fluid injection occurs, get emergency medical care at once. Do not treat as a simple cut. T
ell
the doctor exactly what fluid was injected.
D
Give the doctor this information: Injection into the skin is a traumatic injury
. T
reat the injury surgi
-
cally as soon as possible. Do not delay treatment to research toxicity
. T
oxicity is a concern with
some exotic coatings injected directly into the blood stream. Consultation with a plastic surgeon
or reconstructive hand surgeon may be advisable.
D
Do not point the spray gun at anyone or any part of the body
.
D
Do not put hand or fingers over the spray tip.
D
Do not stop or deflect fluid leaks with your hand, body
, glove or rag.
D
Do not “blow back” fluid, this is not an air spray system.
D
Always have the tip guard and the trigger guard on the spray gun when spraying.
D
Check the gun dif
fuser operation weekly
. Refer to the gun manual.
D
Be sure the gun trigger safety operates before spraying the gun.
D
Lock the gun trigger safety when you stop spraying.
D
Follow the
Pressure relief procedure
on page 10 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
DT
ighten all fluid connections before each use.
D
Check the hoses, tubes and couplings daily
. Replace worn or damaged parts immediately
. Per
-
manently coupled hoses cannot be repaired.
D
Handle and route hoses and tubes carefully. Keep hoses and tubes away from moving parts and
hot surfaces. Do not use the hoses to pull equipment. Do not expose Graco hoses to tempera
-
tures above 180
_F (82_
C) or below –40
_F (–40_C).
MOVING
P
ARTS HAZARD
Moving
parts, such as the air motor piston, which can pinch or amputate fingers.
D
Never operate the equipment with the air motor plates removed.
D
Keep clear of any moving parts when starting or operating the equipment.

EQUIPMENT MISUSE HAZARD
Equipment
misuse can cause the equipment to rupture, malfunction or start unexpectedly and result
in serious injury
.
D
This equipment is for professional use only
.
D
Read all instruction manuals, tags, and labels before operating the equipment.
D
Use the equipment only for its intended purpose. If you are in doubt about this, call Graco T
echni-
cal Assistance at 1–800–543–0339.
D
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D
Check equipment daily
. Repair or replace worn or damaged parts immediately
.
D
Do not exceed
3000 psi (210 bar) maximum working pressure at 100 psi (6.9 bar) maximum
incoming air pressure
at the pump, or the maximum working pressure of any accessory used
with it.
D
Do not move or lift pressurized equipment.
DUse
fluids or solvents which are compatible with equipment
wetted parts. Refer to the
T
echnical Data
section
of all equipment manuals. Read the fluid and solvent manufacturer
’
s warnings.
D
Fluid hoses must have spring guards on both ends to protect it from rupture caused by kinks or
bends at or close to the couplings.
D
Comply with all applicable local, state and national fire, electrical and other safety regulations.
TOXIC FLUID HAZARD
Improper
handling of hazardous fluids or inhaling toxic fumes can cause extremely serious injury
,
even death, due to splashing in the eyes, ingestion, or bodily contamination.
D
Know the specific hazards of the fluid you are using.
D
Store hazardous fluid in an approved container
. Dispose hazardous fluid according to all local,
state and national guidelines.
DW
ear appropriate clothing, gloves, eyewear and respirator
.
FLUID HEATER HAZARD
Follow
these precautions to reduce the risk of a serious injury from burns or a fire.
D
The heater is equipped with an ordinary power cord and should not be operated in hazardous
locations as defined in NFP
A 33 or your local fire code.
D
Do not touch the heater during operation; it is very hot.
WARNINGWARNING


Setup
I. Prepare the operator.
All
persons who operate the system should be trained
in the safe, efficient operation of all system compo
-
nents as well as the proper handling of the chemical
coating. At a minimum, all operators should
thoroughly read the safety
, installation and operation
sections of this manual and the component manuals.
II. Prepare the site.
1. Use
a minimum recommended 7 HP (5.8 kW) air
compressor for ef
ficient operation.
2.
Clear obstacles and debris that could hinder the
operator’
s movement.
3.
Bring an air line from your compressed air supply
to the pump location. Be sure the air is dry and
filtered. Install a bleed–type master air valve (A)
upstream from the pump. Another master air valve
(32) is supplied with the package. When the
bleed–type master air valve is closed and the
pump air regulator (31a) is opened, the valve
relieves all air pressure to the system.
4.
Have a grounded waste pail available to use when
draining the fluid filter
.
5. V
entilate the spray booth.
To prevent hazardous concentrations of
toxic and/or flammable vapors, spray
only
in a properly ventilated spray booth.
Never operate the spray gun unless
ventilation
fans
are operating.
The air supply to the
gun must be electrically interlocked with the ventila-
tors
to prevent operation of the power supply unless
ventilating
fans are running.
Check and follow all of the national, state and local
codes
regarding air exhaust velocity requirements.
WARNING
KEY
Components
you must supply:
A
Bleed-type master air valve
Required for pump, order
part no. 107–142, 1/4” npt(f)
B
Air filter
. Order part no.
106–149, 1/2 npt(f)
C
Air supply line
D
Grounded 5 gallon metal pail
E
Air line moisture trap
Components supplied with package:
1
30:1 President pump
2
Fluid heater
3
Back pressure regulator
28
Fluid filter (not visible)
29
Filter drain valve
(not visible)
31a
Pump air regulator
31b
Gun air regulator
32
Bleed–type air valve
54
Gun air hose
55 Electrostatic
Air-assisted
airless spray gun
64
Gun fluid hose
66
Pump ground wire
71
Whip hose
A
Fig.
1
B
E

C
D
3
71
54
64
1
66
31b
31a
32
2
8
28
29
55

Setup
III. Unpack the system.
1. In
addition to the assembled unit, these compo
-
nents are packed separately: suction assembly
,
hose set, gun. In Fig. 1
items identified with a
number are supplied with the system. Items identi
-
fied with a letter are supplied by you.
2.
These are the manuals you should receive:
306–981
30:1 President pump
308–294
Electrostatic air-assisted
airless spray gun
307–273
Fluid filter
307–805
Fluid heater
306–860
Back pressure regulator
308–167
Air regulator
306–861
Ball valve
308–136 Cart
IV. Connect the hose set and gun to the
system. See
Fig. 1 and 2
.
Fig. 2


To
gun air regulator (31b) outlet
T
o fluid filter (28) outlet
T
o back pressure regulator (3) outlet


Ref
54
19
64
64
54
55
1.
Connect the special electrostatic
air hose (54) be
-
tween the gun air regulator (31b) and the air inlet
of the spray gun (55). The gun inlet and air hose
have left hand threads.
2.
Connect one blue fluid hose (64) to the fluid filter
(28) outlet. Connect the other blue fluid hose to the
back pressure regulator (3) outlet. These are
1/4–18 swivel fittings.
3.
Connect the whip hose (19) to the fluid inlet of
the spray gun (55). These are 1/4–18 swivel fit
-
tings.
4.
Press the exhaust tube (F) onto the barbed
adapter on the bottom of the gun handle. Secure
the tube with the clamp provided. See Fig. 3.
Fig. 3 01992A
F
5. V
erify that all fittings throughout the system are
tightened securely
.
6.
Use a tie strap to secure the insulated hose to the
leg of the cart. This provides strain relief so that
tugs on the heavy hoses don’t damage the hose
connections.
7
308-465
Setup
V. Ground the system.
WARNING
To
reduce the risk of static sparking, ground the
pump and all other equipment used or located in
the spray area. Check your local electrical code for
detailed grounding instructions for your area and
type of equipment.
Ground all of this equipment.
Also read
FIRE, EXPLOSION OR ELECTROS
-
TA
TIC SHOCK HAZARD
on page 2
.
1.
Pump
: one end of the ground wire (66) is already
connected to the air motor grounding lug. Connect
the clamp end of the ground wire to a true earth
ground. Connect the clamp end of the ground wire
to a true earth ground.
2.
Air and fluid hoses
: use only grounded hoses with
a maximum of 500 ft. (150 m) combined hose
length to ensure grounding continuity
.
3.
Heater:
by plugging into a properly grounded elec
-
trical outlet. If you use an extension cord, be sure
it is a 3-wire grounded cord which is properly sized
for the heater
.
4.
Air compressor
: according to manufacturer
’
s
recommendations.
5.
Electrostatic spray gun:
grounding is obtained
through connection to a properly grounded air
supply hose. Use only Graco electrically conduc
-
tive air supply hose (34) as supplied with this
system. Loosen the grounding lug locknut (W) and
washer (X). Insert the bare end of the air hose
ground wire into the slot in the lug and tighten the
locknut securely
. Connect the air hose ground wire
to the air motor grounding lug. See Fig. 4.
Fig. 4
2Connect
air hose ground wire to
pump grounding lug
1
W
X
30
0864
1
Pump ground wire.
Connect to a true earth ground
2
6.
Spray
gun:
grounding is obtained through connec
-
tion to properly grounded air and fluid hoses and
pump.
7.
Object being sprayed:
keep the work piece
hangers clean and grounded at all times. Contact
points must be sharp points or knife edges. Use a
megohmeter or a circuit tester buzzer or light to
verify that the parts are properly grounded.
8.
All electrically conductive objects or devices in the
spray area,
including paint containers, wash cans.
9.
All persons entering the spray area:
shoes must
have conductive soles, such as leather
, or
personal grounding straps must be worn. Rubber
of plastic soles are not conductive. The operator
must not wear gloves which insulate the hand from
the spray gun. The gloves must be conductive or
modified as shown in Fig. 5. Use the gun cover
,
supplied, to help protect your hand and the gun
from overspray
.
Fig. 5
3
in. (76 mm) square
cut out and finger
of glove cut of
f
10.
The
floor of the spray area
must be electrically
conductive and grounded. Do not cover the floor
with cardboard or any non–conductive material
which would interrupt grounding continuity
.
11.
Flammable liquids
in the spray area must be kept
in approved, grounded containers. Do not store
more than the quantity needed for one shift.
12.
Fluid supply container:
according to local code.
13.
All solvent pails used when flushing
, according to
local code. Use only metal pails, which are con
-
ductive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which inter
-
rupts the grounding continuity
.

System Component Information
I. How to use the air-assisted airless
electrostatic spray gun.
The
air hose supplies air to the spray gun. Part of the
air operates the turbine and the rest of the air assists
in the atomization of the fluid being sprayed. The
turbine generates power which is converted by the
power cartridge to supply high voltage current to the
gun’
s ionizing electrode.
The pump supplies fluid to the hose and gun, where
the fluid is electrostatically charged as it passes the
electrode. The charged fluid is attracted to the
grounded work piece, wrapping around and evenly
coating all surfaces.
The air control valve (C) controls all of the air to the
gun air cap.
See Fig. 7 for how to operate the trigger safety latch.
See the gun instruction manual, 308–294, for detailed
information, including troubleshooting, cleaning and
repair.
Always hang the gun in its bracket (F) with its
nozzle pointing down to prevent solvent from
running into the gun air passages. See Fig. 8.
Solvent in the gun air passages can cause poor
atomization and excessive current demands and
damage the gun.
CAUTION
Fig. 6
KEY
AES
indicator light
B
ES On–Of
f lever
I is ON and 0 is OFF
C
Air control valve
D Electrode
E
Air cap
BC
DE
01947
A
Fig.
7


UNLOCKED
trigger
safety latch
LOCKED
trigger
safety
latch


Fig.
8
02010A
F
II. Fluid heater.
See
Fig. 9.
The heater (3) used in this system is a high mass
heater
. Always circulate the fluid when the heater is
operating to prevent overheating and damaging the
fluid. Do not use catalyzed material in this heater
.
9
308-465
System Component Information
III. How to use the 3–way valve.
See
Fig. 9.
Heated systems require that the fluid circulate
constantly when the heater is turned on. The 3-way
valve (7) supplied with this system allows you to drain
or circulate the fluid. The words
Drain
and
Circulate
are marked on the valve.
1.
In the
Drain
position and with the gun untriggered,
the fluid returns from the gun, to the back pressure
regulator (3), to the hose (19) and to the 3–way
valve (7) which directs the fluid out the drain hose
(8). This position is used when flushing the system
and when relieving system pressure.
2.
In the
Circulate
position, with the gun untriggered,
fluid returns from the gun, to the back pressure
regulator (3), to the hose (19) and to the 3–way
valve (7) which directs the fluid back into the pump
intake. This position is used during normal opera
-
tion and it helps keeps the fluid at a constant
temperature.
Fig. 9
32
19
7
8
IV. How to adjust the air and
back pressure regulators. See
Fig. 10.
This system has two air regulators. As you look at the
system, the regulator (31a) on the left of the pump
regulates air to the gun and the regulator (31b) on the
right regulates air to the pump.
1.
Always open air regulators slowly to prevent surg
-
ing during startup.
2. T
o open the regulator
, which allows air to flow
, turn
the T–handle IN (clockwise). T
urn the T–handle
OUT (counterclockwise) to close off the air flow
.
Be sure the jam nut under the T–handle does not
interfere with your adjustments. T
ighten the jam
nut to lock in the setting, if desired.
3.
The back pressure regulator (3), located on the
fluid return side of the circulating system, acts as a
flow control. Use it to balance the pressure of the
circulating fluid so that the pump sucks in a suf
fi-
cient volume of fluid without running too fast or too
slow. T
urn the regulator IN (clockwise) to restrict
fluid and slow down the pump. T
urn the regulator
OUT (counterclockwise) to allow more flow which
speeds up the pump. See Fig. 10.
4. T
o open the back pressure regulator
, which allows
fluid to flow
, turn the knob IN (clockwise).
5.
Adjust the back pressure regulator only when the
gun is triggered and fluid is flowing through the
regulator for an accurate setting.
Fig. 10
CW
CCW
31b
31a
3

10 308-465
Operation
I. Pressure relief procedure
WARNING
To
reduce the risk of serious injury
, including
splashing fluid or solvent in the eyes or on the skin,
always follow the
procedure below when you stop
spraying or shut of
f the pump, check or service any
part of the system, or install, clean or change spray
tips.
1.
Engage the gun trigger safety
.
2. T
urn the ES On/Of
f valve lever to OFF
.
3. T
urn off the heater (turn to
0).
4. T
urn the 3-way valve (7) to
Drain.
5.
Close the bleed-type master air valve (A,14).
6.
Close the air regulators (31a,31b).
7.
Disengage the gun trigger safety
.
8.
Hold the gun firmly to a grounded metal pail.
T
rigger the gun to relieve pressure.
9.
Engage the gun trigger safety
.
10.
Open the drain valve (29), having a container
ready to catch the drainage.
If you suspect that the spray tip or hose is completely
clogged or that pressure has not been fully relieved,
very slow loosen the tip guard retaining nut or hose
end coupling and relieve pressure gradually
. Clean the
tip or hose obstruction.
II. Flush the pump before the first use.
Flush
with a solvent compatible to your fluid. Consult
the fluid manufacturer
’
s literature for recommenda
-
tions. See
Flushing
on page 14.
III. Prime the system.
See
Fig. 1
1.
1.
Remove the air cap and spray tip from the gun.
2.
Close the filter drain valve (29).
3.
Put the suction tube into the fluid supply container
.
4.
Hook the drain hose (8) on the waste pail.
5. T
urn the 3-way valve (7) to the
Drain
position.
6. T
urn the back pressure regulator (3) all the way
out (counterclockwise)
7.
Make sure the air regulators (31a,31b) are closed.
8.
Open the master air valves (A,32).
KEY
Components
you must supply:
A
Bleed-type master air valve
C
Air supply line
2
Fluid heater
3
Back pressure regulator
28
Fluid filter (not visible)
29
Filter drain valve
(not visible)
31a
Pump air regulator
31b
Gun air regulator
32
Bleed–type air valve
A
Fig.
1
1
C
331b
31a
32
2
8
28
29