Sealey HVLP2002 User manual

INSTRUCTIONS FOR:
HVLP SPRAY GUN SYSTEM
MODEL : HVLP2002
Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions and
properly maintained, give you years of trouble free performance.
HVLP2002 - 2 - 160502
1. SAFETY INSTRUCTIONS
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND
CAUTIONS. USE THIS PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY
CAUSE DAMAGE OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
1.2. GENERAL SAFETY.
3Familiarise yourself with the application, limitations and potential hazards peculiar to the spray gun.
pWARNING! Disconnect the spray gun from the air hose before changing accessories, servicing or performing any maintenance.
3Maintain the spray gun in good condition (use an authorised service agent).
3Replace or repair damaged parts. Use recommended parts only. Unauthorised parts may be dangerous and will invalidate the warranty.
3Keep the spray gun clean for best and safest performance.
3Wear approved safety respiratory protection and safety goggles.
3Remove ill fitting clothing. Remove ties, watches, rings, and other loose jewellery, and tie back long hair.
3Locate the spray gun in the desired working area, keep area clean and tidy and free from unrelated materials and ensure that there is
adequate ventilation and lighting.
3Keep children and unauthorised persons away from the working area.
3Avoid unintentional operation.
7DO NOT point spray gun at yourself, other persons or animals.
7DO NOT carry the spray gun by the hose, or yank the hose from the air outlet.
7DO NOT use the spray gun for any purpose other than for which it is designed.
7DO NOT allow untrained persons to operate the spray gun.
7DO NOT get the spray gun wet and DO NOT use outside or in damp or wet locations or areas where there is condensation.
7DO NOT operate the spray gun if any parts are missing or damaged as this may cause failure and/or possible personal injury.
7DO NOT direct air from the air hose at yourself or at others.
3When not in use switch the unit off and disconnect from the mains.
7DO NOT use the machine in the presence of flammable liquids or gases.
7DO NOT use the machine on premises where explosive substances are stored.
7DO NOT open the main unit or loosen or remove any of its retaining screws.
7DO NOT wipe plastic parts with any solvents such as petrol, thinners, carbon tetrachloride, alcohol or ammonia.
1.1. ELECTRICAL SAFETY. p
p
p
WARNING! It is the users responsibility to read, understand and comply with the following:
You must check all electrical equipment and appliances to ensure they are safe before using. You must inspect power supply leads, plugs and
all electrical connections for wear and damage. You must ensure the risk of electric shock is minimised by the installation of appropriate safety
devices. An RCCB (Residual Current Circuit Breaker) should be incorporated in the main distribution board. We also recommend that an RCD
(Residual Current Device) is used with all electrical products. It is particularly important to use an RCD with portable products that are plugged
into an electrical supply not protected by an RCCB. If in doubt consult a qualified electrician. You may obtain a Residual Current Device by
contacting your Sealey dealer. You must also read and understand the following instructions concerning electrical safety.
1.1.1. The Electricity At Work Act 1989 requires all portable electrical appliances, if used on business premises, to be tested by
a qualified electrician, using a Portable Appliance Tester (PAT), at least once a year.
1.1.2. The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of the appliance
and the safety of the appliance operator. If in any doubt about electrical safety, contact a qualified electrician.
1.1.3. Ensure the insulation on all cables and the product itself is safe before connecting to the mains power
supply. See 1.1.1. & 1.1.2. above and use a Portable Appliance Tester (PAT).
1.1.4. Ensure that cables are always protected against short circuit and overload.
1.1.5. Regularly inspect power supply, leads, plugs for wear and damage and all electrical connections
to ensure that none is loose.
1.1.6. Important: Ensure the voltage marked on the product is the same as the electrical power supply
to be used and check that plugs are fitted with the correct capacity fuse. A 13 amp plug may require
a fuse smaller than 13 amps for certain products,see fuse rating at right.
1.1.7. DO NOT pull or carry the powered appliance by its power supply lead.
1.1.8. DO NOT pull power plugs from sockets by the power cable.
1.1.9. DO NOT use worn or damaged leads, plugs or connections. Immediately replace or have repaired by
a qualified electrician. A U.K. 3 pin plug with ASTA/BS approval is fitted. In case of damage, cut off
and fit a new plug according to the following instructions (discard old plug safely).
(UK only - see diagram at right). Ensure the unit is correctly earthed via a three-pin plug.
a) Connect the GREEN/YELLOW earth wire to the earth terminal E.
b) Connect the BROWN live wire to live terminal L.
c) Connect the BLUE neutral wire to the neutral terminal N.
After wiring, check there are no bare wires, that all wires have been correctly connected, that cable outer insulation
extends beyond the cable restraint and that the restraint is tight.
Double insulated products are often fitted with live (BROWN) and neutral (BLUE) wires only. Double insulated products are always marked with
this symbol . To re-wire, connect the brown & blue wires as indicated above. DO NOT connect the brown or blue to the earth terminal.
1.1.10. Some products require more than a 13 amp electrical supply. In such a case, NO plug will be fitted. You must contact a qualified electrician
to ensure a 30 amp fused supply is available. We recommend you discuss the installation of a industrial round pin plug and socket with your electrician.
1.1.11. Cable extension reels. When a cable extension reel is used it should be fully unwound before connection. A cable reel with an RCD
fitted is recommended since any product which is plugged into the cable reel will be protected. The section of the cores of the cable
is important. We suggest 1.5mm2section as a minimum but to be absolutely sure that the capacity of the cable reel is
suitable for this product and for others that may be used in the other output sockets, we recommend the use of 2.5mm2section cable.
Blue
Neutral
Wire
Yellow & Green
Earth Wire
Cable
Restraint
FUSE RATING
THIS PRODUCT MUST BE FITTED
WITH A
13 AMP FUSE
Brown
Live
Wire

2. DESCRIPTION & SPECIFICATION
2.1. Specification
Model HVLP2002 Suction Feed
Standard set-up 1.8mm
Max operating pressure 4psi
Voltage 230 volts AC, 50Hz
Power consumption 1000W
Air Hose length 4.5m
Weight 5.2Kgs
Overall dimensions excluding hose.
Length 470mm
Width 225mm
Height 320mm
3. PAINT PREPARATION
The HVLP2002 spray gun set is a high volume, low pressure system intended primarily for the spraying of paints used for interior decorating
including water based paints, oil based paints, laquers and stains. It is not suitable for spraying solvent based paints such as those used in the
car refinishing trade. The all-in-one unit consists of a base station which houses the integral air supply unit and provides convenient stowage
for the spray gun plus a storage pocket. The spray gun has a plastic body, which resists corrosion and has a low affinity for paint making the unit
easy to clean. It also has an adjustable spray pattern and air flow control.
fig. 1
3.1. Checking paint viscosity.
As most paints are made for brush or roller action it will normally be necessary to thin the paint to achieve proper atomization and
good coverage. Use the viscosity cup provided to check the viscosity of the paint prior to thinning (see fig.2). Dip the cup into the
paint to completely fill it and then time how long it takes for the paint to flow out again. If the paint is the correct viscosity the flow time
will be between 8 and 20 seconds. If the flow time is more than 20 seconds the paint is too thick. Thin the paint slightly and retest until
the flow time is within the limits stated. If the flow time is less than eight seconds the paint is too thin.
3.2. Paint condition.
Any debris in the paint will clog the gun which will require a complete strip down and clean before the gun will function again properly.
This is particularly important when using paint that has previously been opened. The paint should be thoroughly mixed and free from skin
and lumps. If necessary strain the paint through a 60 mesh paint strainer, or a piece of cheesecloth or an old nylon stocking to ensure a
smooth finish. The paint should be strained into a clean container and if any paint is left over it should be stored in a clean container.
7DO NOT mix or thin paint in an area where there may be functioning appliances producing a naked flame or electrical sparking. This
includes equipment that is electric motor powered.
7DO NOT switch on the HVLP2002 when paint is being mixed or thinned.
3Ensure that any vapours have dispersed before switching on the HVLP2002.
3Tightly recap all containers immediately after thinning or mixing paint and store away from the spraying area.
7DO NOT spray where there are any sources of ignition such as an open fire, cigarettes, cigars or pipes, sparks, glowing wires or hot
surfaces or naked lighting.
3Ensure that the air hose is firmly connected to the unit and the gun to avoid the possibility of any spilt material being drawn into the unit.
fig. 2
HVLP2002 - 2 - 160502
4. ASSEMBLY / PREPARATION
fig. 3 fig. 4
4.1. Remove the unit from the packaging and uncoil the power cable from the storage flange at the back
of the unit. Do not plug the unit in yet.
4.2. Remove the spray gun from the unit and set the air cap to give the required spray pattern. Do this
by loosening the air cap locking ring as indicated in fig.4 and rotating the air cap to give the
required spray pattern as shown in fig.5. Retighten the locking ring.
4.3. Unscrew the paint container. Fill container with paint (see Section 3 regarding paint preparation).
Refit the paint container to the gun and tighten. Place the gun back in the main unit.
4.4. Lay out the air hose and connect one end to the back of the unit using a push and twist action
(see fig.3). Connect the other end of the hose to the gun as shown in fig.4.
4.5. Plug the unit into the mains and switch on. You are now ready to spray. fig. 5

5. OPERATING INSTRUCTIONS
5.1. To adjust the width of the spray pattern turn the fluid control knob as indicated
in fig.4. To reduce the amount of material sprayed screw the knob in. To
increase the amount of material sprayed screw the knob out.
5.2. Control the air flow using the trigger.
5.3. If necessary re-adjust the spray pattern.
5.4. Good results will be obtained using a combination of the above adjustments.
If you have no previous experience of spraying we suggest that you
experiment on a non-essential area first before performing the final spraying
operation
5.5. For best results, handle the gun correctly. It should be held perpendicular to
the surface being sprayed and moved parallel to it. Start the stroke before
squeezing the trigger and release the trigger before finishing the stroke. This
will give accurate control of the gun and material (fig.6).
5.6. Spray from a distance of about 6 to 10 inches. The material deposited should
always be even and wet. Each stroke must overlap the preceding stroke to
obtain a uniform finish.
6. CLEANING
7. MAINTENANCE
fig. 6
HVLP2002 - 2 - 160502
6.1. The gun must be cleaned immediately after you have finished using it. On no account must any paint be allowed to even partially
dry as this may make your gun unusable. Empty the paint container immediately and flush it out. If using water based paint refill with
clean water and operate the gun until it is spraying clean water only. If using an oil based paint, stain, or laquer clean the paint
container with the appropriate thinning medium then refill the container with the medium and operate the gun until all paint residue has
been flushed out.
6.2. Clean the outside of the gun and the main unit with a soft cloth soaked in warm soapy water.
7.1. Switch off the unit and disconnect from the mains before performing any maintenance or cleaning. Disconnect the air hose from the
unit and from the spraygun. When reassembling after maintenance, be sure to take care when screwing parts together. At first screw
parts hand tight to avoid cross-threading. If a part cannot easily be turned by hand, check that you have the correct part, unscrew,
realign and try again. DO NOT use excessive force when reassembling.
7.2. Cleaning the spray gun. To maintain the spray gun in peak operational condition the main parts as shown in fig.7 should be regularly
inspected and cleaned. Metal parts should be soaked in a suitable paint thinning medium. This will normally be the thinning agent
used for the paint that was last in the gun. Plastic parts can only be immersed in hot soapy water and brushed clean. Never soak
plastic parts in any solvents as this may cause the parts to disintegrate.
7.3. To disassemble the gun for routine maintenance withdraw the fluid needle (D) first. To do this unscrew and remove the fluid adjusting
screw (E) and the spring behind it. Now withdraw the fluid needle. It may be necessary to squeeze the trigger slightly to dislodge the needle.
7.4. Unscrew the air cap locking ring (A) and remove the air cap (B).
7.5. Using a suitable spanner unscrew and remove the fluid cap (C).
7.6. The fluid tube (F) is a push fit into the main body of the gun. To remove for cleaning simply pull it out of its seating.
7.7. Clean metal and plastic parts as previously directed and then carefully reassemble the gun in the reverse order.
7.8. Should any deterioration in the performance of your gun occur refer first to the trouble shooting guide below or return the gun to your
Sealey service agent.
fig. 7
7.9. Cleaning the air filter.
The air filter should be cleaned on a regular basis. Remove the filter cover by pulling it off as shown in fig.8 and remove the foam filter.
If using water based paints clean the filter in mild soapy water and remove excess water by pressing in a soft cloth. Allow to dry flat
before reinstalling.
Where a build-up of non-water soluble paint has occurred the filter cannot be cleaned and will have to be replaced. Place the new
filter into the back of the filter cover and insert the tabs on the bottom edge of the cover into the slots in the main unit. Swing the cover
upwards until it snaps into place.
To prolong filter life place the main unit as far away as possible from the spraying area.
fig.8

PROBLEM CAUSE SOLUTION
Fluid flow is too high for the quantity
of air flow.
Paint is too thin.
Air entering the paint supply
One of the horn holes blocked (A).
In order to check, turn the air cap
180O, if the faulty pattern is now
reversed the hole must be cleaned.
Possible paint build-up between fluid
nozzle and air cap (A).
1. Reduce paint flow by screwing in the fluid control knob.
2. Paint could be too thick, in which case dilute it.
1. Increase proportion of paint to thinning medium
1. Tighten the connection between the gun and the cup.
2. Tighten fluid nozzle with gun spanner.
3. Check whether paint pot is empty.
1. Place the air cap in cleaning solution.
2. Clean hole with compressed air or with a soft probe.
DO NOT use a metal probe which will damage the hole.
1. Clean the air cap and the fluid nozzle, check also that they
match correctly.
2. Check needle for damage.
8. TROUBLESHOOTING
9. DECLARATION OF CONFORMITY
Poor atomization, heavy centre pattern
Heavy atomization, poor centre pattern
Heavy right or left side pattern
Top heavy or bottom heavy pattern
Intermittent spray pattern
HVLP2002 - 2 - 160502
01284 757500 E-mail: [e-mail]
01284 703534
Sole UK Distributor,
Sealey Group,
Bury St. Edmunds, Suffolk.
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts
without prior notice.
IMPORTANT: No responsibility is accepted for incorrect use of this product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your name and address, including post code.
Signed by Mark Sweetman
For Jack Sealey Ltd. Sole importer into the UK of Sealey Power Products.
Declaration of Conformity We, the sole importer into the UK, declare that the product listed here is in conformity with the following
standards and directives.
The construction file for this product is held by the
manufacturer and may be inspected, by a national authority,
upon request to Jack Sealey Ltd.
Spray Gun System
Model HVLP2002
73/23/EEC Low Voltage Directive
89/336/EEC EMC Directive
93/68/EEC CE Marking Directive
14th January 2002