Graco Optimiser 2K 02748 User manual

308–341

Rev. G

Supersedes F

First

choice when

quality counts.



02748

INSTRUCTIONS-PARTS

LIST

INSTRUCTIONS

This

manual contains important

warnings and information.

READ AND KEEP FOR REFERENCE.

Optimiser



HVLP T

wo Component

Adhesive Spray Gun

100 psi (7 bar) Maximum Working Fluid and Air Pressure

This gun is for use with water-based contact adhesives only

Part

No. 949–239, Series C

U.S.

Patent Pending

GRACO INC. P.O. BOX 1441

MINNEAPOLIS, MN

55440–1441

COPYRIGHT

1993, GRACO INC.

Graco

Inc. is registered to I.S. EN ISO 9001



Table

of Contents

Warnings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selection

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air

Flow and Atomizing Pressure

. . . . . . . . . . . . . . . .

Installation 6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup

and Shutdown

. . . . . . . . . . . . . . . . . . . . . . . . . .

Ratio

Check

13.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily

Gun Care, Flushing, and Cleaning

14.

. . . . . . . . .

Troubleshooting 17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service 18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical

Data

26.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco

Phone Number

Back Cover

. . . . . . . . . . . . . . . . .

Warranty Back

Cover

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols

Warning Symbol

WARNING

This

symbol alerts you to the possibility of serious

injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This

symbol alerts you to the possibility of damage to

or destruction of equipment if you do not follow the

instructions.

WARNING

INSTRUCTIONS

EQUIPMENT MISUSE HAZARD

Equipment

misuse can cause the equipment to rupture, malfunction or start unexpectedly and result in

serious injury



This equipment is for professional use only



Read all instruction manuals, tags, and labels before operating the equipment.



Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco

distributor.



Do not alter or modify this equipment. Use only genuine Graco parts and accessories.



Check equipment daily

. Repair or replace worn or damaged parts immediately



Use this equipment only in low pressure, air spray systems.



Do not exceed the maximum working pressure of the lowest rated system component. This equip

ment has a

100 psi (7 bar) maximum working fluid and air pressure



Do not lift pressurized equipment.



Use fluids or solvents that are compatible with equipment wetted parts. See the

echnical Data

section of all equipment manuals. Read the fluid and solvent manufacturer

’

s warnings.



Comply with all applicable local, state and national fire, electrical and other safety regulations.



WARNING

PRESSURIZED EQUIPMENT HAZARD

Spray

from the gun, hose leaks or ruptured components can splash fluid in the eyes or on the skin and

cause serious injury



Do not stop or deflect fluid leaks with your hand, body

, glove or rag.



Follow the

Pressure Relief Procedure

on page 7 when: you are instructed to relieve pressure;

stop spraying; clean, check or servicing the equipment; and install or clean fluid nozzles.



Never point the spray gun at anyone or at any part of the body



Never put hand or fingers over the spray nozzle.

T

ighten all fluid connections before operating the equipment.



Check the hoses, tubes and couplings daily

. Replace worn, damaged or loose parts immediately

Permanently coupled hoses cannot be repaired; replace the entire hose.



Route hoses away from traf

fic areas, sharp edges, moving parts and hot surfaces.



Do not use the hoses to pull equipment.

FIRE AND EXPLOSION HAZARD

Poor

air ventilation, open flames or sparks can cause a hazardous condition and result in fire or explo

sion and serious injury



Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being

sprayed.



Extinguish all open flames or pilot lights in the spray area.



Electrically disconnect all equipment in the spray area.



Keep the spray area free of debris, including solvent, rags and gasoline.



Do not turn on or of

f any light switch in the spray area while operating or if fumes are present.



Do not smoke in the spray area.



Do not operate a gasoline engine in the spray area.

TOXIC FLUID HAZARD

Hazardous

fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the

skin, inhaled, or swallowed.



Know the specific hazards of the fluid you are using. Read the fluid manufacturer

’

s warnings.



Store hazardous fluid in an approved container

. Dispose of hazardous fluid according to all local,

state and national guidelines.



Dress appropriately for your application. W

ear protective eyewear

, noise protection for the ears, a

personal respirator

, gloves and clothing.



Selection

Chart

Includes:

Needle/

Nozzle/Air

Cap

Kit

P/N

Needle

Assembly

P/N

Air Cap

P/N Nozzle

P/N

Replacement

Needle T

P/N

Orifice Size

949–276 238–703 185–794 185–756 191–564 0.020” (0.508 mm)

949–277 238–703 185–794 185–757 191–564 0.026” (0.660 mm)

949–278 238–703 185–794 185–700 191–564 0.030” (0.762 mm)

949–279 238–217 185–794 185–701 191–016 0.042” (1.067 mm)

949–280 238–218 185–794 185–702 191–017 0.055” (1.397 mm)

949–281 238–219 185–795 185–703 191–018 0.070” (1.778 mm)

949–282 238–220 185–796 185–704 191–019 0.086” (2.184 mm)

Selecting a Needle/Nozzle/Air Cap Kit

The

kits range in size to provide different fluid flow

rates.



Use the fluid nozzle that will give the required flow

with the fluid adjustment knob opened four full turns

counterclockwise and an adhesive pressure of

approximately 5 to 20 psi (0.35 to 1.4 bar).



For low flow rates or light viscosity fluid, select the

smaller nozzle sizes.



For high flow rates or high viscosity fluid, select the

larger nozzle sizes.



Using an air cap size that is smaller than the

nozzle/needle size

is not recommended.

T

o help select the proper needle/nozzle size, a fluid

pressure gauge may be connected temporarily to

the gun fluid inlet to determine the fluid pressure.



See

Service

to install the parts.

Selection Problems and Solutions

PROBLEM POSSIBLE

CAUSE SOLUTION

Fluid pressure

required to achieve

flow rate is too high

Using set with

too small of an

orifice

Use needle/

nozzle/air cap

set with larger

orifice

Using a low pres

sure setting, the

fluid flow

is too high,

making it necessary

to restrict needle

travel to reduce fluid

flow

Using set with

too large of an

orifice

Use needle/

nozzle/air cap

set with small

er orifice

Fluid system will not

operate at low

enough fluid pres

sure

Fluid regulator is

not installed or

air regulator is

not sensitive

enough

Add low pres

sure fluid regu

lator or add

more sensitive

air regulator on

pressure pot

308-3415

Air

Flow and Atomizing Pressure

NOTE:

All tests completed with the fan air fully open.

Air Flow

15 25 35 45 55 65 75 85 95

AIR FLOW (scfm)

GUN

AIR INLET PRESSURE (psi)

Atomizing Pressure Versus

Activator Inlet Pressure

Air

flowing through the gun creates back pressure,

which the activator must overcome before beginning to

flow

. The chart below shows the minimum activator

pressure required to overcome the atomizing air

pressure. Higher pressures may be necessary to

maintain the mix ratio.

GUN

AIR INLET PRESSURE (psi)

15 25 35 45 55 65 75 85 95

MINIMUM

ACTIVAT

OR INLET PRESSURE (psi)

Atomizing Air Pressure

(inlet pressure vs. atomizing pressure)

GUN

AIR INLET PRESSURE (psi)

15 25 35 45 55 65 75 85 95

NOMINAL

OMIZING PRESSURE (psi)

Gun

Inlet Pressure

Nominal Atomizing Pressure

15 psi (1.05 bar)

1.5 psi (0.1

1 bar)

25 psi (1.75 bar)

3.0 psi (0.22 bar)

35 psi (2.45 bar)

4.5 psi (0.33 bar)

45 psi (3.15 bar)

6.0 psi (0.42 bar)

55 psi (3.85 bar)

8.5 psi (0.62 bar)

65 psi (4.55 bar)*

10.0 psi (0.70 bar)

75 psi (5.25 bar)

13.0 psi (0.95 bar)

85 psi (5.95 bar)

15.5 psi (1.14 bar)

95 psi (6.97 bar)

18.0 psi (1.32 bar)

For compliant operation, operate at 65 psi (4.55 bar) or less

6308-341

Installation

KEY

A Optimiser

2K Spray Gun

Air Inlet; 1/4 npsm

Air Hose

Recommend

5/16” (7.9 mm) ID hose;

Optional

3/8” (9.5 mm) ID hose

Gun Air Shut-of

f V

alve

Gun Air Regulator

Air Filter

Air Supply Line

Pressure Pot Air Shut-of

f V

alve

Pressure Pot Air Regulator

Activator Pressure Pot

Activator Fluid Shut-of

f V

alve

Activator Fluid Hose

Activator Inlet 1/8–27 npt(f)

Adhesive Pressure Pot

Adhesive Fluid Shut-of

f V

alve

Adhesive Fluid Hose

Adhesive Inlet; 3/8 npsm (R3/8–19)

NDEF

02750

HJKL

Fig.

Fluid Compatibility of Accessories

When

selecting system components to supply the

adhesive and activator

, consider the following:



Adhesives and activators are water-based and

corrosive. A

void carbon steel, unplated brass,

copper

, and aluminum. Stainless steel, nickel-

plated brass and most plastics are usually accept

able.



Piston pumps are not recommended for use with

adhesives as they are often shear sensitive and will

coagulate in your equipment. Stainless steel

pressure pots function well in place of a pump and

fluid pressure regulator. On drum or tote tank

supplied systems, plastic diaphragm pumps are

often used.



Some adhesives will coagulate in fluid pressure

regulators due to shear

. Consult with the fluid

supplier for regulator recommendations.



Refer to Fig. 1 and see Form No. 305–591 for the

accessories recommended to install the system.

Consult with the fluid supplier or Graco for specific

recommendations.

Ventilate the Spray Booth

WARNING

FLAMMABLE/TOXIC

FLUID HAZARD

o avoid hazardous concentrations of

flammable or toxic fumes, spray only in

a properly ventilated spray booth.

Comply with all applicable local, state

and national fire and safety regulations.

308-3417

Installation

Air Line Accessories

The

gun air line must have an air regulator (E) to

control air pressure to the gun. See Fig. 1.



If the gun air source does not have a filter

install a

filter (F) on the gun air line to ensure a dry

, clean

air supply

T

o eliminate the need to shut of

f the air pressure at

the air supply

, install a quick-disconnect at the gun

air inlet fitting.

Fluid Line Accessories

If

you are using diaphragm pumps to supply adhe

sive or activator to the gun(s), install a fluid regula

tor (T) on each gun fluid supply line to control fluid

pressure to the gun(s). See Fig. 9, page 9.



Install a fluid filter in the gun fluid supply lines to

avoid clogging the fluid nozzle. A 100 mesh filter is

recommended for the activator supply line to avoid

clogging the activator needle and orifice.



Use 5/32 or 1/4 inch I.D. tubing for the activator

supply line.

Setup

and Shutdown

Pressure Relief Procedure

WARNING

PRESSURIZED

EQUIPMENT HAZARD

The equipment stays pressurized until pressure is

manually relieved. To reduce the risk of serious

injury from pressurized fluid, accidental spray from

the gun or splashing fluid, follow this procedure

whenever you:



Are instructed to relieve pressure



Stop spraying



Check, clean or service any system equipment



Install or clean fluid nozzles

Close the adhesive and activator shut-of

f valves

(Q and L). See Fig. 2.

2. T

rigger the gun into the spray booth* to relieve the

fluid pressures and clear excess activator from the

gun. See Fig. 3.

*If

the gun has been flushed with solvent, be sure to spray

the solvent into a grounded metal waste container

3. Close

the atomizing air shut-of

f valve (D). See

Fig. 4.

Fig. 2

02059

Fig. 3 02753

Fig. 4

02780



Setup

and Shutdown

Removing and Installing the Fluid Nozzle

this procedure whenever you remove and install

a fluid nozzle. See page 4 to select a nozzle or

needle/nozzle/air cap kit.

Follow the

Pressure Relief Procedure

page 7.

Remove the air cap ring (12), air cap (19), and air

cap seal (47). See Fig. 5.

3. T

rigger the gun while you remove the fluid nozzle

(20) with the gun wrench (35).

Fig. 5 02757A

35 20

12, 19

Lightly

lubricate baf

fle o-ring (17)

Apply

PTFE

adhesive to nozzle (20) threads. T

rigger gun and

tighten

to 125–150 in-lbs (14–17 N

Sm)

CAUTION

Trigger

the gun whenever you tighten or remove the

fluid nozzle (20) to pull the needle away from the

nozzle seating surface and avoid scratching it.

Apply PTFE

adhesive to the threads of the fluid

nozzle (20) you are installing.

Lubricate the baf

fle o-ring (17).

CAUTION

Lubricate the baf

fle o-ring (17) before installing the

fluid nozzle (20). A dry o-ring will prevent the nozzle

from tightening properly and adhesive may leak

inside the gun.

6. T

rigger the gun while you install the fluid nozzle

(20) with the gun wrench (35). T

ighten it to 125 to

150 in-lbs (14 to 17 N

Sm).

CAUTION

When tightening the fluid nozzle (20), do not

exceed

150 in-lbs (17 N

m) torque. Over-tightening can

damage the nozzle, af

fect the spray pattern, and is

unnecessary to guarantee a seal.

Install the air cap seal (47), air cap ring (12), and

air cap (19).

308-3419

Setup

and Shutdown

WARNING

EQUIPMENT

MISUSE HAZARD

This gun is for use with water-based contact adhe-

sives only. Any other use of the gun could cause

unsafe

operating conditions or damage to the gun.

1. Connect the air line.

A. Connect

the air hose (C) to the gun air inlet

(B). See Fig. 6.

02751

Fig. 6

11/4

npsm

B. Connect

the other end of the air hose (C) to a

regulated air supply line (G).

See Fig. 7.

NOTE:

Fig. 7 shows the air supply line filter (F), air

regulator (E), and air shut-of

f valve (D).

01990

Fig. 7

2. Flush the adhesive and activator fluid

lines with water and blow them out

with air before connecting them to the

gun.

3. Connect the adhesive fluid hose.

A. Connect

the fluid hose (R) to the gun adhesive

inlet (S). See Fig. 8.

02752

Fig. 8

13/8–18

npsm [R 3/8–19]

compound thread

B. Connect

the other end of the fluid hose (R) to

a regulated fluid supply line (U–see Fig. 9) or a

pressure tank (P–see Fig. 1, page 6).

NOTE:

Fig. 9 shows the fluid supply line regulator

(T) and fluid shut-of

f valves (Q).

02777

Fig. 9



Setup

and Shutdown

4. Connect the activator tube.

A. Connect

the fitting (V) and tube (M) to the gun

activator inlet. See Fig. 10.

Connect the other end of the fluid tube (M) to a

regulated fluid supply line or a pressure tank.

Fig. 10 02784

5. Position the Air Cap for a vertical or

horizontal spray pattern. See Fig. 11.

Vertical Pattern

Horizontal Pattern

Fig.

102020

6. Adjust the spray pattern.

WARNING

COMPONENT

RUPTURE HAZARD

Do not exceed the

100 psi (7 bar)

maximum fluid and air pressure

of this gun.

Higher pressures can cause parts to rupture and

result in serious injury

NOTE:

Refer to the

Atomizing Pressure V

ersus

Activator Inlet Pressure

chart on page 5 to help set

air and activator pressures.

Close the fluid adjustment valve by turning the

knob (8) fully clockwise. Then turn the knob

counterclockwise four full turns to open it. See

Fig. 12.

02784

Fig. 12

Open

Open the adhesive fluid shut-of

f valve (Q). Ad

just the fluid flow with the fluid regulator (T)

installed in the gun fluid line (see Fig. 13) or

the air regulator on the adhesive tank (see Fig.

1). T

ypical industrial flow rates will vary with

regulator pressures from 5 to 20 psi (0.35 to

1.4 bar).

Fig. 13

02778

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