Graco Inc. 216-119 Paint Sprayer User Manual
Contents
1. INSTRUCTIONS PARTS LIST 74 Rev A This manual contains IMPORTANT GRACO WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE AUTOMATIC 100 KV ELECTROSTATIC AIR SPRAY GUN 100 psi 7 bar MAXIMUM WORKING PRESSURE Model 216 119 With 0 047 in 1 2 mm fluid tip and standard air cap GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 COPYRIGHT 1980 GRACO INC WARNING Before cleaning the gun nozzle or attempting to service the gun or other components always turn off the high voltage first then shut down paint pump and trigger gun to relieve fluid pressure Grounding All components of the system except the gun and paint hoses must be electrically grounded Be sure the elec tric power circuit is properly grounded LE E FORMAE Be sure your gun is not grounded Use urigr unded paint hoses to gun only and be sure your supply pump and the object you are painting are grounded All conductive objects within 10 ft 3 m of the gun must be electrically grounded The object being coated must be grounded How The Electrostatic Automatic Air Spray Gun Works A transformer supplies high voltage current through the cable to the gun s ionizing electrode where the elec trostatic field is developed The pump supplies paint INSTALLATION Be sure your installation complies with Federal State and local codes for the installation of electrical apparatus in a Class 1 Divisions 1 and 2 Hazardous Location2. The particular type and size system for your operation will have to be custom designed for your needs For a correctly sized system contact the Graco Finishing System Division Franklin Park Illinois Mount the gun on an insulated stationary support or reciprocator arm The spray gun has a mounting hole to fit a 0 5 in 13 mm diameter rod Use a mounting fixture which allows adjustment of the spray pattern direction and distance from the work WARNING Mount the gun at least 12 305 mm from the work To prevent arcing the gun head must be at least 12 305 mm from any ground Follow OSHA 29 CFR 1910 107 h 6 Install a normally closed 3 way air solenoid valve in the cylinder air supply line BEFORE CONNECTING AIR LINES BLOW THEM OUT TO REMOVE METAL CHIPS AND OTHER FOREIGN PARTICLES Connect an air OPERATION Adjust the system s control device so the gun starts spraying just before the spray meets the workpiece and stops as soon as it is past The gun requires a minimum of 30 psi 2 bar air pressure to the cylinder Fluid Control Adjust the fluid flow to the proper rate using a fluid 2 307434 Be sure your installation complies with all applicable local codes ALWAYS use the lowest pressure possible when flushing and use a grounded metal waste container When flushing avoid conductive solvents if possible Be sure to turn off H V Power Supply before flushing and to remove all solvent from gu
3. along with ad justing screw 31 locknut 19 and air cap 7 For ad justment see Replacing Fluid Needle Extension 4 307434 Replacing Needle Guide Needle guide 47 is pressed into rear of fluid housing 5 Remove fluid housing and press out needle guide When replacing be sure internal chamfered end faces rear of fluid housing Replacing Fluid Needle Extension Remove needle see Replacing Fluid Needle When replacing extension 46 locknut 29 and needle ad justing nut 30 must be readjusted on needle extension Push needle 41 needle extension 46 and piston 38 fully forward and turn the adjusting nut 30 all the way into the piston Remove needle assembly from piston turn adjusting nut two turns counterclockwise and tighten locknut 29 This adjustment provides atom izing air just before the fluid needle is engaged and after seating Replacing Fluid Packing The fluid packing 23 is replaced when the needle 41 is removed Remove the packing nut 22 then pick out the packing and replace Replace the packing nut In sert the fluid needle tighten the packing nut and apply pressure on the packing to a firm seating Do not over tighten The fluid needle should move without binding When the gun is completely assembled and fluid pressure applied the packing nut may be tightened to correct a slight leak Removing Gun Barrel It is seldom necessary to remove the gun barrel 42 from the gun body 37 When
4. 5 making sure that the wire goes through center hole of air cap then tighten ring nut 8 onto barrel 42 allowing air cap to be drawn up evenly on the fluid tip Check alignment of ionizing wire in the fluid stream Removing Fluid Tip Housing If the housing 5 is removed the o rings 2 should be replaced and the housing firmly seated The housing must be torqued no more than 15 20 ft lb 20 N m or plastic threads may become stripped Lubricate with petroleum jelly new o rings on housing before replacing in gun barrel NOTE Fluid tip 6 must be removed from housing before replacing to avoid damage to ionizing wire Replacing Fluid Needle Turn off the atomizing air and fluid trigger the gun to release needle pressure on the tip Remove ring nut 8 and air cap 7 Remove fluid tip 6 with a 7 16 in wrench Remove nut 19 and screw 31 from the rear of the gun With a long nose pliers pull out needle ex tension 46 nut 29 nut 30 spring 33 and needle 41 Unscrew needle 41 from extension 46 Pliers maybe necessary as Loctite is used on threads Install new needle 41 applying Locrite no 290 or equivalent to threads to prevent needle from coming loose during operation Reassemble needle into back of gun using extreme care lonizing wire must remain straight as it passes through rear actuator packings 18 After needle is assembled in the gun replace fluid tip 6 and rear spring 33 and spring 34
5. NOTE When increasing to a wide flat pattern increase supply of fluid to gun to maintain same coverage over larger area Direction of spray pattern horizontal or vertical is changed by loosening lock ring and turning air cap to the desired position TIGHTEN LOCK RING HAND TIGHT DO NOT OVERTIGHTEN Normal Spray Pattern Proper adjustment will give a spray pattern shaped ike this Improper Spray Patterns Heavy on top or bottom right or left Caused by paint buildup on air cap or fluid tip partially plug ged air holes or fluid tip To remedy clean the cap or tip Heavy in the center Caused by too much or too thick material To remedy reduce flow by re ducing fluid pressure or thinning the paint Split pattern Caused by insufficient paint or too much air pressure To remedy increase fluid pressure or reduce air pressure WARNING Make sure the K V power supply electricity is ofif befor connecting or disconnecting the high voltage leads at guns or jumction arm SERVICE TROUBLESHOOTING CHART WHAT S WRONG Fluid needle packing nut leakage Air leakage from front of gun Fluid leakage from front of gun Spitting or fluttering spray Defective spray pattern Orange Peel finish Streaks in finish Runs or sags in finish Excessive spray fog Fluid won t cornie from spray gun Connect high voltage cable to the high voltage adapter 44 When all adjustments are
6. necessary this is ac complished by unscrewing the gun coupling 8 and carefully lifting away from the gun body Inspect o rings 1 and 4 and replace if necessary To line up guide pin in barrel with hole actuator assembly keep indicator de tent intop of barrel lined up with top of actuator Replacing Cylinder Adapter The cylinder adapter 43 should not be removed unless damaged Replacing Electrode Stem of Fluid Needle If electrode stem 48 of fluid needle 41 needs replace ment first unscrew electrode stem from fluid needle ex tension 46 Unscrew setscrew and remove old elec trode stem Insert new electrode stem and replace setscrew Reassemble fluid needle 41 to fluid needle extension NOTE 5 5 5 10200 ELECTROSTATIC AUTOMATIC AIR SPRAY GUN Model 216 119 2 47 8 y7 CHAMFERED END 5 TOWARD NEEDLE 6 e 9 d 7 6 43 1 T N 20 N m 2 Torque to 41 20 25 in ib H N p 38 Ref No 10 Automatic Air Valve Assy includes items eer ya rque tU d 40 45 ft ib 4141 54 61 lt gt 13 Torque to None 15 20 ft Ib Ref No 39 Air Adjusting Screw Assy includes items 26 26 36 ye 25 ft lb er 0734 N m R 20 40 15 18 fib l 20 25 N ml 46 29 Included in Repair Kit 215697 See back page REF PART DESCRIPTION QTY REF PART DESCRIPTION QTY NO NO NO NO 1 103649 PACKING o ring viton 1 31 170 244 SCREW nee
7. 1 4 npsm 2 26 176 773 HOUSING spring 1 Recommended tool box spare parts Keep on hand to reduce 27 105 456 WASHER 1 down time 28 168 1 10 O RING polyurethane 1 29 170 242 lock needle 1 Order parts by name and number Always give the model number and 30 170 243 NUT needle adjusting 1 series letter of the assembly for which you are ordering 307 43 5 AIR CAP CONSUMPTION AND FLUID TIP FLOW RATE CHART Approximate Pattern Length Air Cap Part Number 254 mm 10 in from gun 381 432 mm 15 17 in 330 381 mm 13 15 in 381 432 m m 15 17 in 279 330 m m 11 13 in 356 406 14 16 Standard Model 216 119 The Equivalence Chart is designed to update old style guns with Fluid Tip and Air Cap part numbers no longer available to current Fluid Tip and Air Cap part numbers The left side of the chart identifies old style guns with the Fluid Tip and Air Cap part numbers which are no longer available The right side of the chart gives the equivalent current Fluid Tip and Air Cap part number that should be ordered when replacing parts 6 307 434 Air Consumption m3 min 2 06 bar CFM 30 PSI vro grad voe Pari 177 532 355 710 591 1182 1035 1479 FLow Rate 3550 ml min 1 2 mm 1 5 mm 1 8 mm min 0 040 in 0 047 in 0 060 in 0070 in Fluid Tip Size Description Round end pattern excellent atomization for automatic an
8. L E deccm ee BENZENE 2 NITRO PROPANE 02 pp ae as a I NN BEE xv TURPENTINE SOLVESSO 100 DEPTINE METHYL CELLO nem KNEE 08 MEG ee 06 S o EE 4 CVCLO SC 150 semow 0 01 et DOWANOL DPM OPHORN ee oT 15 ED 1 ROO DE TIIE OEE p ETE ee eS rr Is cp c tb cep RESISTANCE MEASURED W TH GRACO PROBE AND METER LOW RESISTANCE SHAOED AREAS SHOW HIGH RESISTANCE N BUTYL ACETATE AMYLACETATE a TAG CLOSED CUP OR POLAR SOLVENTS MEASURE NORMALLY kss THAN 1 MEG HIGH RESISTANCE OR NONPOLAR SOLVENTS MEASURE INFINITY TUE MINERAL SPIRITS ODORLESS MIN ERAL SPIRITS HNE OIL s DIMENSIONAL DRAWING TS an 0 5 13 mm DIA MOUNTING ROD HOLE 15 75 400 mm 19 5 500 mm ACCESSORIES TECHNICAL DATA Must be purchased separately STRAINER AIR OR PAINT 202 271 Uses the following filter screen Maximum operating voltage 100 000 volts 157 332 40 mesh Maximum air amp fluid working pressure 100 psi 7 bar 156 967 60 mesh Minimum air cylinder operating pressure 30 psi 2 bar 156 939 100 mesh Fluid inlet 3 8 npsm m Atomizing air inlet 1 4 npt m Cylinder air inlet 1 4 npt m Weight 3 Ib 2 oz 1 4 kg H V CABLE
9. S 724 410 For stationary mounting 2 ft 610 mm lg 721 997 For reciprocator mounting 15 in 381 mm lg THE GRACH WARRANTY Graco Inc warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship under REPAIR KIT 215 697 must be purchased separately normal use and service This warranty extends to the original Consists of purchaser for a period of 12 months from the date of purchase and Ref No Qty applies only when the equipment is installed and operated in 2 accordance with written factory recommendations This warranty does not cover damage or wear which in the reasonable judgment of 4 1 Graco arises from misuse abrasion corrosion negligence accident 11 l substitution of non Grace parts faulty installation or tampering 13 14 1 This warranty is conditioned upon the prepaid return of the equipment 15 1 claimed to be defective for examination by Graco to verify the claimed defect If the claimed defect is verified Graco will repair or replace 16 2 free of charge any defective parts The equipment will be returned to 18 2 the original purchaser transportation prepaid If inspection of the 23 1 equipment does not disclose any defect in workmanship or material 28 1 repairs will be made at reasonable charge and return transportation will be charged 38 THIS LIMITED WARRANTY IS EXCLUSIVE AND IS IN LIEU OF x ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING Conde
10. d hand gun high produc tion Medium viscosity materials 19 30 sec No 2 Zahn cup metallics lacquers and enamels Round end pattern very good atomization for medium automatic hand gun produc tion Medium viscosity materials 19 30 sec No 2 Zahn cup primers lacquers enamels sealers Tapered end pattern excellent atomization for heavy and high solid material High viscosity materials over 28 sec No 4 Zahn cup high solid lacquers enamels epoxies and urethanes Round end pattern good atomization for low production Low viscosity materials 1522 sec No 2 Zahn cup stains primers sealers and lacquers Tapered end pattern very good atomiza tion for heavy viscosity material over 28 No 4 Zahn cup Water Base and Frit materials acrylics alkyds vinyl enamels and lacquers EQUIVALENCE CHART OLD GUN NEW GUN Part Fluid Orifice Air Part Orifice Air Number Nozzle Size Cap Number Size Cap 172 834 172 835 177 033 17494 177 037 177 037 177 033 177 034 172 842 172 318 171 630 SOLVENT CHART EVAP FLASH RATE POINT PARAFFINS MIN ESTERS GLYCOL ETHERS ALIPHATIC AROMATIC CHLORINATEO HYDROCARBONS _HYDROCARBONS SOLVENTS pcm EH CHLORIDE METHYL ACETATE ACETONE 5 MEG 0 6 15 TEXTILE SPIRITS TRICHLOR ETHYLENE ETHYL ACETATE 0 46 MEG METHYL ALCOHOL 9 RES SC 1 OLVESSO 50 TOLUOL PROPANE ETHYL ALCOHO
11. dle adjusting 1 2 103 823 PACKING o ring nitrile rubber 2 32 170 249 CYLINDER air piston 1 3 722 615 ELBOW 1 4 npt m x 724 391 SPRING compression 1 1 4 npsm f swivel 2 34 170 253 SPRING compression 1 4 155 685 PACKING o ring nitrile rubber 1 35 171 722 HOUSING valve 1 5 172 191 HOUSING fluid tip 1 217 198 SCREW air adjusting 1 6 177 062 FLUID TIP See chart for optional tips 37 21 0 743 HOUSING valve 1 7 177 033 AIR CAP See chart for optional air caps 38 208 718 PISTON air 1 8 176 387 RETAINING RING 2 39 217 199 AIR ADJUSTING SCREW ASSY 9 176 388 RETAINING RING 1 includes items 10 217 013 AUTOMATIC AIR VALVE ASSY part of ref no 1 Series B includes items 1 1 40 and 52 1 40 171 052 10BASKET PTFE 11 e 103338 PACKING o ring viton 1 part of ref no 10 1 13 103 523 GASKET copper 1 41 215 695 NEEDLE fluid 1 14 103 524 GASKET copper 1 42 214 919 BARREL 1 15 103 610 PACKING o ring viton 1 43 724306 ADAPTER cylinder 1 16 103649 PACKING o rina viton 1 44 728 136 ADAPTER 3 8 16 x 5 8 NPT 1 18 160 240 PACKING v block leather 2 46 176 390 NEEDLE ext fluid 1 19 162 782 LOCKNUT 1 47 176 513 GUIDE needle 1 20 174 099 STUD coupler 1 48 215696 STEM electrode replacement kit of 25 1 21 171 333 NUT packing 1 49 177 122 STEM coupling 1 22 171332 NUT packing 1 50 177 121 STEM fluid 1 23 106 901 x PACKING needle PTFE 1 53 177 142 WRENCH 1 24 169 870 ADAPTER air inlet
12. made trigger air atomizing air fluid pressure and fan pattern you can turn on the high voltage and begin operation Care of Gun Good housekeeping is important Clean the gun and work area daily A buildup of conductive residue on either exterior or interior surfaces of gun may interfere with proper operation Flush out the gun with an approved solvent at the end of the work day Wipe the outside of the gun with an approved gun cleaner Remove the air cap and clean it If ionizing wire of needle 41 is bent after cleaning straighten wire so that it is centered in fluid stream For an approved solvent or gun cleaner see your local sup plier or Graco Branch Also refer to OSHA 29 CFR 1910 107 g 5 Cleaning After each spraying operation turn off the high voltage power supply and solvent flush until all remaining paint is removed from hose and gun If air cap needs cleaning remove and soak in clean compatible solvent not over 15 minutes and scrub with a fine bristled brush To clean out holes in air cap use a toothpick or other soft implement CAUTION Never use metal instruments to clean holes in air cap or fluid tip Never immerse entire gun in solvent WARNING During cleaning or repair the H V Power Supply must be turned off Before removing air cap or spray tip shut down paint pump and trigger gun to relieve fluid pressure WHY WHAT DO Loose needle packing nut or worn packing Air valve
13. n before turning on high voltage Operating Never use or store solvents in the spray area NEVER IMMERSE THE SPRAY GUN IN SOLVENT OR OTHER LIQUID Keep work hangers and conveyor equipment clean so work pieces are well grounded through the hose and gun where it is electrostatically charged as it passes the ionizing electrode The charged paint is attracted to the grounded work piece wrapping around it and coating surfaces indirectly hose from the solenoid valve to the gun s 1 4 npt m cylinder air inlet Connect an air supply line to the 1 4 npt m atomizing air inlet BEFORE CONNECTING FLUID LINES BLOW THEM OUT WITH AIR AND FLUSH WITH SOLVENT BE SURE THAT THE SOLVENT YOU USE IS COMPATI BLE WITH THE MATERIAL TO BE SPRAYED Connect a fluid hose to the paint supply pump s outlet and to the gun s 3 8 npsm fluid inlet Install fluid tip in gun Be sure fluid pressure is relieved and high voltage turned off before installing tip Recommended Hose Sizes General Purpose 0 10 ft 0 3 1 4 ID 10 35 ft 3 11 m 3 8 ID 35 100 ft 11 30 m 1 2 ID 100 200 ft 30 61m 3 4 ID 0 50 ft 0 15 m 1 4 ID 50 100 ft 15 30 m 5 16 ID 100 200 ft 30 61 3 4 IDI regulator installed in paint line It is best to adjust flow rate with a fluid regulator Spray Pattern Control Turn air adjusting screw 36 counterclockwise for a wide flat spray pattern or clockwise to decrease to a round pattern
14. not seating properly Fluid needle not seating properly Tighten or replace Clean lubricate service Loosen packing nut Clean or replace Fluid low Loose fluid tip or damaged seat Loose air cap dirty or damaged fluid nozzle or air cap Needle worn or damaged Too much air pressure Insufficient air pressure Poorly mixed and or strained fluid Fluid thinned out too much Improper thinner Check fluid supply Tighten clean replace Tighten clean clear replace Replace Use least necessary Increase air pressure Properly mix and strain Properly thin fluid Use proper thinner 307434 3 SERVICE continued CAUTION When assembling metal and plastic extreme care should be taken when starting threads Applied common sense and good housekeeping will pro vide you with years of durability and efficiency which is built into this equipment These working parts require periodic replacement 1 Air cap 7 2 Fluid tip 6 3 Needle fluid 41 Removing Fluid Tip To remove fluid tip 6 for cleaning or replacement remove the ring nut 8 and air cap 7 turn off the atomizing air trigger the gun to release needle pressure on the tip Remove the tip with a wrench Replace with the needle triggered to the rear When replacing air cap 7 on the gun be sure the wire electrode coming from the needle 41 is centered in the air cap center hole The best method is to slide the air cap onto fluid housing
15. s o OE IRE E trod WARRANTY OF MERCHANTABILITY OR WARRANTY OF 25 177 ectrode FITNESS FOR A PARTICULAR PURPOSE AND OF ANY NON CONTRACTUAL LIABILITIES INCLUDING PRODUCT LIABILITIES KIT REPAIR GUN eee DET SEE COR eau OF FAN VALVE 215 PECIAL R NSEQUENTIAL 215 506 DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED Ref No Qty EQUIPMENT NOT COVERED BY GRACO WARRANTY Accessories 27 1 or components of equipment sold by Graco that are not manufactured 28 1 by Graco such as electric motors switches hose etc are subject to 26 1 the warranty if any of their manufacturer Graco will provide 36 1 purchaser with reasonable assistance in making such claims Factory Branches Atlanta Dallas Detroit Southfield Los Angeles West Caldwell N J Subsidiary and Affiliate Companies Canada England Switzerland France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 PRINTED IN U S A 307434 8 80
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