HP TI1681A - Manual

Warning 309293J 5 WARNING Fire and Explosion Hazard Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire or explosion. • Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements in this ...

Warning 6 309293J WARNING Equipment Misuse Hazard Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in a serious injury. • This equipment is for professional use only. • Read all manuals, tags, and labels before operating the equipment. • Use the equi...

Introduction 309293J 7 Introduction How the Electrostatic Air Spray Gun Works The air hose supplies air to the spray gun. Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed. The turbine generates power, which is converted by the power cartridge to supply hi...

Introduction 8 309293J Gun Overview The electrostatic gun includes the following controls (see F IG . 1.). • FLUID adjustment valve. Adjusts fluid rod travel. Use only in low flow conditions, to reduce wear. • Fan AIR adjustment valve. Adjusts fan size and shape. • Atomizing air RESTRICTOR valve. Re...

Installation 309293J 9 Installation System Requirements A safe, well designed voltage isolation system should have the following features: • All components of the isolation system that are charged to high voltage must be contained within an enclosure that prohibits persons from making con-tact with ...

Installation 309293J 11 Ventilate the Spray Booth Check and follow all National, State, and Local codes regarding air exhaust velocity requirements. High velocity air exhaust will decrease the operating effi-ciency of the electrostatic system. The minimum allow-able air exhaust velocity is 60 linear...

Installation 16 309293J Select a Fluid Nozzle and Air Cap The gun is supplied with Part No. 197266 Nozzle and 197477 Air Cap. If you require a different size, refer to Table 1 and Table 2 , and instruction manual 309419, or consult with your Graco distributor. See Air Cap/Nozzle Replacement on page ...

Installation 309293J 17 Grounding The following are minimum grounding requirements for a basic electrostatic waterborne system. Your system may include other equipment or objects which must be grounded. Check your local electrical code for detailed grounding instructions. Your system must be connect...

Installation 18 309293J Check Electrical Grounding 1. Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose. 2. Turn the ES ON/OFF valve OFF. 3. Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it. 4. Make sure the...

Operation 309293J 19 Operation Operating Checklist Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation. All operators are properly trained to safely operate an electrostatic waterborne air spray system as instructed in this manual. A...

Operation 20 309293J Fluid Voltage Discharge and Grounding Procedure 1. Turn the ES ON/OFF valve OFF and wait 30 sec-onds. 2. Remove the door T-handle locking screw. This will shut off the air to the gun and trigger the grounding cylinder to discharge any remaining electrical charge. 3. Use the grou...

Operation 309293J 21 Fill the Fluid Supply 1. Discharge the system voltage (page 20). 2. Relieve the pressure (page 20). 3. Open the isolated enclosure door. 4. Remove the pail cover from the pail, holding a rag over the suction tube strainer to prevent any fluid from dripping into the isolated encl...

Operation 309293J 23 8. Adjust the pump air regulator to start the fluid supply unit. Adjust the fluid flow with the air pressure regu-lator until the stream from the gun travels 8-12 in. (200-300 mm) before falling off. Typically, if fluid pressure is below 5 psi (.04 MPa, 0.4 bar) or above 20 psi ...

Operation 309293J 25 Shutdown 1. Discharge the system voltage (page 20). 2. Flush the spray gun. See page 26. 3. Relieve the pressure (page 20). 4. Hang the gun from its hook or place it in the acces-sory holster, with the nozzle pointing down. Be sure to keep the gun from grounding out. Low Voltage...

Maintenance 26 309293J Maintenance Flush the Spray Gun Flush the gun before changing colors, at the end of the day, before storing, and before repairing the gun. 1. Turn the ES ON/OFF valve OFF and wait 30 sec-onds for the voltage to bleed off. 2. Discharge the system voltage (page 20). 3. Relieve t...

Maintenance 309293J 27 Daily Care and Cleaning CAUTION • Clean the outside of the gun daily with a soft cloth dampened with a non-flammable solvent, as defined on page 26. • Check for fluid leaks. Tighten all fittings. • Clean the air cap and fluid nozzle daily, minimum. See page 29. Some applicatio...

Maintenance 309293J 29 Clean the Air Cap and Fluid Nozzle Equipment Needed • soft bristle brush • non-flammable solvent Procedure 1. Turn the ES ON/OFF valve OFF. Wait 30 seconds. 2. Discharge the system voltage (page 20). 3. Relieve the pressure (page 20). 4. Remove the retaining ring (27) and air ...

Electrical Tests 30 309293J Electrical Tests Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (18) and electrode (29), and electri-cal continuity between components. Use megohmmeter Par t No. 241079 (AA) and an applie...

Electrical Tests 309293J 31 Test Power Supply Resistance 1. Prepare the gun for service as instructed on page 41. 2. Remove the power supply (18), page 46. 3. Remove the turbine alternator (19) from the power supply, page 47. 4. Measure resistance from the power supply's ground strips (EE) to the sp...

Electrical Tests 32 309293J Test Electrode Resistance 1. Prepare the gun for service as instructed on page 41. 2. Insert a conductive rod (B) into the gun barrel (removed for the power supply test) and against the metal contact (C) in the front of the barrel. 3. Measure the resistance between the co...

Electrical Tests 309293J 33 Test Ground Strip Resistance See F IG . 22.. Using an ohmmeter, measure the resis- tance between the latch housing (206) and the ground lug (214). The ground strip is grounded through the cart back to the ground lug. Resistance must be less than 100 ohms. If greater than ...

Troubleshooting 34 309293J Troubleshooting Voltage Loss Troubleshooting Normal spraying voltage for a system using the water-borne gun is 45-55 kV. The system voltage is lower due to spraying current demands and voltage isolation sys-tem losses. A loss of spraying voltage can be caused by a problem ...

Troubleshooting 309293J 35 Visual Check First, check the system for any visible faults or errors to help isolate whether the spray gun, fluid hose or voltage isolation system has failed. A voltage probe and meter, part no. 236003, is helpful for diagnosing voltage prob-lems and is required for some ...

Troubleshooting 309293J 37 Spray Pattern Troubleshooting Check all possible remedies in the Troubleshooting Chart before disassembling the gun. Some spray pattern problems are caused by the improper balance between air and fluid. Problem Cause Solution Fluttering or spitting spray. No fluid. Refill ...

Troubleshooting 38 309293J Gun Operation Troubleshooting Problem Cause Solution Excessive spray fog. Atomizing air pressure too high. Close restrictor valve some, or decrease air pressure as low as pos-sible; minimum 40 psi (0.28 MPa, 2.8 bar) needed at gun for full voltage. Fluid too thin. Increase...

Troubleshooting 309293J 39 Electrical Troubleshooting Problem Cause Solution Voltage still present at gun after fol-lowing the Fluid Voltage Discharge and Grounding Procedure ES ON/OFF valve is not turned OFF. Turn OFF. Did not wait long enough for voltage to discharge. Wait longer before touching e...

Repair 309293J 41 Repair Prepare the Gun for Service • Check all possible remedies in Troubleshooting before disassembling the gun. • Use a vise with padded jaws to prevent damage to plastic parts. • Lubricate the power supply o-ring (18a), some pack-ing rod parts (26), and certain fluid fittings wi...

Repair 42 309293J Air Cap/Nozzle Replacement 1. Prepare gun for service, page 41. 2. Remove the retaining ring (27) and air cap (9). See F IG . 24.. 3. Point gun up and squeeze trigger while removing the fluid nozzle (7) assembly with the multi-tool (37). Fig. 24. Air Cap/Nozzle Replacement Use non-...

Repair 309293J 43 Electrode Replacement 1. Prepare the gun for service, page 41. 2. Remove the air cap and nozzle, page 42. 3. Unscrew the electrode (29) with the multi-tool (37). Hold the packing rod end (26h) to prevent it from turning, F IG . 25.. 4. Apply low-strength (purple) Loctite ® or equiv...

Repair 44 309293J Fluid Packing Removal 1. Prepare the gun for service, page 41. 2. Remove the air cap and fluid nozzle, page 42. 3. Remove the electrode, page 43. 4. Loosen the trigger screws (8) and trigger (30). See F IG . 26.. 5. Remove the packing rod (26), using the multi-tool (37). 6. Check a...

Repair 309293J 45 Packing Rod Repair You may replace the packing rod as individual parts or as an assembly. The assembly is pre-adjusted at the factory. Before installing the fluid packing rod into the gun barrel, make sure the internal surfaces of the barrel are clean. Remove any residue with a sof...

Repair 46 309293J Barrel Removal 1. Prepare the gun for service, page 41. 2. Remove the air inlet fitting (35) and take the bracket (104) off the gun handle (17). 3. Loosen the three screws (11). 4. Hold the gun handle (17) with one hand and pull the barrel (16) straight off the handle. See F IG . 2...

Repair 309293J 49 Fan Air Adjustment Valve Repair 1. Prepare the gun for service, page 41. 2. Place a wrench on the flats of the valve assembly (20) and unscrew it from the handle (17). You may replace the valve as an assembly (go to step 9) or as individual parts (steps 3-9). 3. Remove the retainin...

Repair 50 309293J Fluid Adjustment Valve Repair 1. Prepare the gun for service, page 41. 2. Remove the fluid adjustment valve (25). It can only be replaced as a complete assembly. See F IG . 32.. 3. Screw the valve (25) into the gun handle. Torque to 15-25 in-lb (1.7-2.8 N•m). Fig. 32. Fluid Adjustm...

Repair 309293J 51 Atomizing Air Restrictor Valve Removal and Replacement 1. Prepare the gun for service, page 41. 2. Remove the atomizing air restrictor valve (23). Inspect the o-ring (23c*). Replace if necessary. See F IG . 34.. 3. Install a new atomizing air restrictor valve (23), or disassemble a...

Parts 52 309293J Parts Part No. 244581 60 kV Electrostatic Gun, Series B (items 4-55) Part No. 245301 60 kV Electrostatic Gun with Shielded waterborne fluid hose, Series A (items 4-55, 101-108) TI1679A 27 9 7 26 16 11 18 19 *10 17 28 20 22 25 15 21 23b 35*** 24 38 8 *6 ti1266a I O ES 7a 7b 11 *18a 1...

Parts 309293J 63 Tubing and Wiring Chart Use the diagrams on page 64 to find the connection points for the tubing and wiring listed below. Code Ref. No. Lengthin. (mm) Description A1 248 20 (508) 1/4 OD tube, regulator to pump A2 248 9 (229) 1/4 OD tube, regulator (216) to mani-fold B2 249 17 (432) ...

Parts 64 309293J Tubing and Wiring Diagrams C1 Detail of Control Box Detail of Door Interlock Switch C9 A1 A2 B4 C2, C9 E1 B2 A2 B5 B3 C3, C4, C5 C1 C6 B3 A1 C8 C6, C7, C8 B5 B2 C2 TI2145A TI2144A TI2143A C3

Accessories 309293J 65 Accessories Air Line Accessories Grounded Air Hose (Red Cover) 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread; red cover with stainless steel braid ground path. 235068 6 ft (1.8 m) 235069 15 ft (4.6 m) 235070 2...

Accessories 66 309293J Gun Accessories Gun Repair Kits 244781 Air Seal Repair Kit 244911 Fluid Seal Repair Kit Round Pattern Kits Consists of fluid tip, diffuser and air cap. 245217 4-6 in. (102-152 mm) diameter 245219 8-10 in. (203-254 mm) diameter Push/Pull Fan Air Valve 244912 For quick change of...

Technical Data 309293J 69 Technical Data Loctite® is a registered trademark of the Loctite Corporation. Category Data Maximum Working Fluid Pressure 100 psi (0.7 MPa, 7 bar) Maximum Working Air Pressure 100 psi (0.7 MPa, 7 bar) Minimum Air Pressure at Gun Inlet 40 psi (0.28 MPa, 2.8 bar) Maximum Flu...

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. This manual contains English. MM 309293 Graco Headquarters: Minneapolis International Offices: Bel...