Graco Inc. 244592 Paint Sprayer User Manual
Contents
1. KV A mA Q 85 0 KV S Fig 3 Optional Fiber Optic Connection 10 E aia E TI1715A 3092985 Install the Air Line Accessories Ah WARNING Component Rupture Hazard To reduce the risk of serious injury due to ca component rupture The pump pressure must be limited by the pump air regulator Do not rely on the gun fluid regulator to limit the fluid pressure to the gun The fluid supply pump must be prevented from pro ducing a fluid pressure greater than the 3000 psi 21 MPa 210 bar Maximum Working Fluid Pressure of the gun For example the air supply pressure to a 30 1 ratio pump must not exceed 100 psi 0 7 MPa 7 bar Be sure that all spray equipment and accessories added to the spray system are properly rated to with stand the maximum working pressure of your system 1 Install a bleed type master air valve L on the main air line W to shut off all air to the gun H 2 Install an air line filter water separator on the gun air line to ensure a dry clean air supply to the gun Dirt and moisture can ruin the appearance of your fin ished workpiece and can cause the gun to malfunc tion 3 Install a bleed type air regulator M on each of the air supply lines B C E X Y to control air pressure to the gun 4 Install a solenoid valve K on the cylinder air line E2. 102 Y 113 yk 103 TI1740A 107 110 iy PartNo Description Qty Ref PartNo Descripti Qt Mo ener SBSSerpn n y 1124 197925 GASKET manifold 1 101 198220 MANIFOLD 1 113 108290 SCREW machine 2 102 189581 BRACKET reciprocator 1 114 189365 CAP kV HI LO 2 103 110465 SCREW set gt 115 198764 RESTRICTOR 1 104 112689 SCREW button hd 2 116 244772 PISTON includes 116a 2 105 112640 SPRING compression 1 116at 112085 O RING 1 106 197518 SCREW socket hd 10 24 x 3 4 3 117 114263 FITTING connector 3 in 19 mm 119 116621 SPRING compression 2 107 111157 FITTING tube 1 120 112645 PLUG 4 108 186845 FITTING turbine 1 T Included in repair kit 15D592 109 110078 FITTING tube 2 110 112646 PLUG 1 50 309298J Spray Tip Selection Chart Spray Tip Selection Chart Part No GG3217 Fan Width at 10 in 250 mm in mm 4 6 100 150 Orifice Size in mm 0 017 0 432 GG3317 6 8 150 200 GG3417 8 10 200 250 GG3517 10 12 250 300 GG3617 GG3319 12 14 300 350 6 8 150 200 0 019 0 483 GG3419 8 10 200 250 GG3519 GG3619 10 12 250 300 12 14 300 350 GG3719 GG3421 14 16 350 400 8 10 200 250 0 021 0 533 GG3521 10 12 250 300 GG3621 12 14 300 350 GG3721 14 16 350 400 GG3821 GG3423 16 18 400 450 8 10 200 250 0 023 0 584 GG3523 10
3. Measure resistance between the electrode needle tip 40a and the turbine air inlet fitting TA it should be 156 180 megohms If outside this range relieve pressure and remove the air cap page 37 Inspect the electrode 40a and the barrel conductive ring 6a for damage and proper position to ensure that the electrode makes contact with the conductive ring Reinstall the air cap and repeat the measure ment If it is still outside this range remove the gun for service AA toa Coe ral Te T11733B Fig 19 Test Gun Resistance 29 Electrical Tests Test Power Supply Resistance 1 Remove the power supply 12 page 46 2 Remove the turbine alternator 13 from the power supply page 47 3 Measure resistance from the power supply s ground strips EE to the spring 12b See FiG 20 4 The resistance should be 135 150 megohms If out side this range replace the power supply If in range proceed to the next test 5 If you still have problems refer to Electrical Trou bleshooting on page 34 for other possible causes of poor performance or contact your Graco distribu tor 30 6 Be sure the spring 12b is in place before reinstall ing the power supply an inj gt _ i a m Fig 20 Test Power Supply Resistance ti1599a 3092985 Electrical Tests Test Barrel Re
4. 8 Make sure the fluid filter 20 is in place Tighten the bottom nut C onto the fitting 22 and torque to 20 30 in lb 2 3 3 4 Nem Make sure the top nut remains tight 9 Reinstall the shroud and air cap assembly page 37 10 Test gun resistance page 29 40 Fig 26 Fluid Tube Replacement Fluid Filter Removal 1 Prepare the gun for service page 35 2 Remove the air cap assembly page 37 Remove the shroud 2 3 Disconnect the bottom fluid tube nut C 4 Remove the fluid filter 20 Clean or replace the fil ter as needed Replacement filters are available in 100 mesh stan dard or 60 mesh sizes See page 52 5 Install the fluid filter Tighten the bottom nut C onto the fitting 22 and torque to 20 30 in lb 2 3 3 4 Nem Make sure the top nut D remains tight CAUTION Be sure the fluid tube 19 is not twisted after tighten ing the bottom nut C 6 Reinstall the shroud and air cap assembly page 37 7 Test gun resistance page 29 3092985 Fluid Needle Replacement Prepare the gun for service page 35 Remove the air cap assembly and seat housing page 37 Remove the barrel 6 page 44 Remove the spring cap 45 and the spring 8a from the barrel See FIG 27 Be sure the seat housing 5 is removed Place the 2 mm ball end wrench 44 in the back of the fluid needle assembly Push the tool in and turn it coun terclockwise about 12 full turns
5. Installation Check Fluid Viscosity To check fluid viscosity you will need e a viscosity cup e a stopwatch 1 Completely submerge the viscosity cup in the fluid Lift the cup out quickly starting the stopwatch as soon as the cup is completely removed 2 Watch the stream of fluid coming from the bottom of the cup As soon as there is a break in the stream shut off the stopwatch 3 Record the fluid type elapsed time and size of the viscosity cup 4 If the viscosity is too high or too low contact the material supplier Adjust as necessary Install the Fabric Cover 1 Install a fabric cover XX over the front of the gun and slide it back to cover the exposed tubing and hoses at the back of the manifold See FIG 9 2 Route the exhaust tube YY outside the cover This enables you to monitor the exhaust tube for the presence of any paint or solvent See Check for Fluid Leakage on page 28 Strap down the exhaust tube to prevent it from moving around F TH736A TII716A 17 Operation Operation Pressure Relief Procedure WARNING Skin Injection Hazard The system pressure must be manually Yo relieved to prevent the system from starting or spraying accidentally Fluid under high pressure can be injected through the skin and cause serious injury To reduce the risk of an injury from fluid injection splashing fluid or electric shock follow the Pressure Relief Procedure whenever you e are inst
6. always follow the Pressure Relief Proce dure on page 18 when you stop spraying and whenever you are instructed to relieve the pressure 1 Relieve the pressure Ah WARNING Fire Explosion and Electric Shock Hazard To reduce the risk of fire explosion or elec y tric shock turn off the turbine air TA before flushing the gun or any part of the system y 2 Be sure the turbine air TA is turned off 3092985 Maintenance Remove the retaining ring 1 tip guard 3 air cap 40 spray tip 4 and gun shroud 2 See FIG 14 Clean these parts and set them aside Turn on the solvent supply Use the lowest possible fluid pressure when flushing Turn on the cylinder air CYL to trigger the gun Flush the gun spraying into a grounded metal con tainer until clean solvent comes from the gun Turn off the solvent supply Relieve the pressure Install the spray tip 4 and air cap 40 tip guard 3 shroud 2 and retaining ring 1 onto the gun Tighten the retaining ring firmly TI1723A Fig 14 Remove Spray Tip Before Flushing 25 Maintenance Clean the Spray Gun Equipment Needed e soft bristle brush e compatible solvent Procedure WARNING Skin Injection Hazard To reduce the risk of a fluid injection injury y E always follow the Pressure Relief Proce dure on page 18 when you stop spraying and whenever you are instructed to relieve the pre
7. ball end 4 mm TAG warning not shown replacement available at no cost SIGN warning not shown replacement available at no cost COVER gun box of 10 not shown TUBE fluid gt oo ce a ce ae ee A E Cre Cae 2 a Nana Ref No 20 22 23 25 26 27 28 29 30 31 32 33 34 34a 34b 34c 34dt 34et 34ft 34gt 35 37 39 40 40a 44 45 Part No 205264 189366 245265 197624 189367 185122 101324 197919 102025 112689 245662 116575 244702 197920 189754 189355 189752 111504 112319 111508 244843 276741 198486 245276 244917 112080 198516 Description FILTER fluid inline FITTING fluid CIRCUIT flexible SPRING grounding CAP exhaust MUFFLER NUT jam hex ARM actuator NUT hex SCREW button hd BODY gun SCREW cap socket hd PISTON includes 34a 34g PISTON ROD piston STEM piston PACKING u cup O RING O RING O RING MANIFOLD see separate parts list on page 50 MULTI TOOL CONNECTOR tube AIR CAP includes 40a ELECTRODE kit of 5 TOOL needle 2 mm CAP spring Parts Qty gt a N Na Naa HN dd dd FS SF ss M oo k i b l Recommended spare parts Keep on hand to reduce downtime Replacement Warning labels signs tags and cards are available at no cost T Included in repair kit 15D592 49 Parts Part No 244843 Manifold Series A for standard and high conductivity coatings 5 see page 49 101 Ref 106 Ref
8. to actuate the gun The solenoid valve must have a quick exhaust port 5 Install a bleed type master air valve L on each pump air line to shut off all air to the pump H 309298J Installation Ah WARNING Skin Injection Hazard Trapped air can cause the gun to spray J unexpectedly which can result in serious injury including injecting fluid through the skin The solenoid valves K must have a quick exhaust port so trapped air will be relieved between the valve and gun when the solenoids are shut off The bleed type master air valve L is required on the pump air line so trapped air will be relieved between the valve and the pump after the valves or regulator are closed Install the Fluid Line Accessories 1 Install a fluid filter and drain valve at the pump out let Filtering the fluid will help remove coarse parti cles and sediment that could clog the spray tip The gun includes an inline fluid filter 20 for addi tional filtration Ah WARNING Skin Injection Hazard The fluid drain valve is required in your sys UU tem to assist in relieving fluid pressure in the displacement pump hose and gun Trig gering the gun to relieve pressure may not be suffi cient Install a drain valve close to the pump s fluid outlet The drain valve reduces the risk of serious injury including fluid injection and splashing in the eyes or on the skin 2 Install a fluid regulator on the fluid line
9. Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years o
10. TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free 612 623 6921 612 378 3505 Fax 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 309298 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2002 Graco Inc is registered to ISO 9001 www graco com Revised 10 2009
11. Test gun resistance page 29 309298J Repair 5 Install the gun shroud 2 and air cap page 37 6 Install the gun onto the manifold and bracket See page 36 gt ea 0 125 in 3 mm gap Fig 32 Actuator Arm Adjustment 43 Repair 6 Hold the gun body 32 with one hand and pull the Barrel Removal barrel 6 straight off the body See FIG 33 1 Prepare the gun for service page 35 2 Remove the air cap page 37 Remove the gun shroud 2 3 Disconnect the fluid tube nut C 4 Remove the jam nut 28 and actuator arm 29 See page 42 5 Loosen the three screws 10 33 See FiG 33 ZA CAUTION To avoid damaging the power supply 12 pull the gun barrel 6 straight away from the gun body 32 If necessary gently move the gun barrel from side to side to free it from the gun body TH728A Fig 33 Barrel Removal 32 IN e 7 EEES 29 ly qa E A se 30 fai Sd T11732A C Fig 34 Disconnect Fluid Tube 44 309298J Repair I 4 Make sure the fluid filter 20 is in place Tighten the Barrel Installation bottom nut C onto the fitting 22 and torque to 20 30 in Ib 2 3 3 4 Nem Make sure the top nut D 1 Be sure the gasket 1
12. always follow the Pressure Relief Proce lt i dure on page 18 when you stop spraying 3 To change to a lower voltage setting activate the and whenever you are instructed to relieve solenoids controlling the KV1 and KV2 ports See the pressure Changing the kV Setting on page 7 1 Relieve the pressure 2 Flush and clean the equipment See Maintenance Ah WARNING on page 23 Fire and Explosion Hazard If any fluid leakage from the gun is y detected stop spraying immediately Fluid leakage into the gun shroud could cause W fire or explosion and result in serious injury and property damage See Check for Fluid Leakage on page 28 22 309298J Maintenance Maintenance Daily Care and Cleaning Z N CAUTION e Clean all parts with a non conductive compatible Do not immerse the gun in fluid solvent Conductive solvents can cause the gun to malfunction Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components e Fluid in the air passages could cause the gun to malfunction and could draw current and reduce the electrostatic effect Fluid in the power supply cavity can reduce the alternator life Whenever possible point the gun down when cleaning it Do not use any cleaning method which could allow fluid into the gun air passages Do not point the gun up while cleaning it Do not wipe the gun with a cloth that is heavily satura
13. are turned off ventilation fans in the hazardous area are operating and there are no flammable vapors in the area such as open solvent containers or fumes from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage 1 Have a qualified electrician check the electrical grounding continuity of the spray gun and turbine air hose 2 Make sure the turbine air hose B is connected and the hose ground wire is connected to a true earth ground TI1735A Fig 8 Check Gun Grounding 3 Turn off the air and fluid supply to the gun 16 309298J Check Fluid Resistivity Ah WARNING Fire Explosion and Electric Shock Hazard Check the fluid resistivity in a non hazard ous area only Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area Failure to follow this warning could cause fire explosion or electric shock and result in serious injury and property damage SER Graco Part No 722886 Resistance Meter and 722860 Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the require ments of an electrostatic air spray system Follow the instructions included with the meter and probe Readings of 25 megohms cm and above provide the best electrostatic results En O y a wd A y A AA XX Fig 9 Fabric Cover 309298J
14. connections or fluid packing leakage If fluid is seen in these areas stop spraying immediately Relieve the pressure then remove the gun for repair T1736A TI1716A 309298J Electrical Tests Electrical components inside the gun affect performance and safety The following procedures test the condition of the power supply 12 and barrel 6 and electrical continuity between components N CAUTION The barrel resistor cartridge is part of the barrel and is not replaceable To avoid destroying the gun barrel do not attempt to remove the barrel resistor Use megohmmeter Part No 241079 AA and an applied voltage of 500 V Connect the leads as shown Ah WARNING Fire Explosion and Electric Shock Hazard Megohmmeter Part No 241079 AA see FIG 19 is not approved for use in a haz ardous area To reduce the risk of sparking do not use the megohmmeter to check elec trical grounding unless xke eThe gun has been removed from the haz ardous area eOr all spraying devices in the hazardous area are turned off ventilation fans in the hazardous area are operating and there are no flammable vapors in the area such as open solvent containers or fumes from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage 3092985 Electrical Tests Test Gun Resistance Flush and dry the fluid passage
15. fiber optic cable See 308265 Fiber Optic Cables Connect gun manifold and remote display bulkhead connector and remote display or gun manifold and bulk head connector See 308265 224672 25 ft 7 6m 224674 50 ft 15 m 224676 100 ft 30 5 m Remote Voltage Display Kits Include 189762 Remote Voltage Display and fiber optic cable 236917 25 ft 7 6 m 236919 50ft 15m 236921 100 ft 30 5 m Bulkhead Connector 189870 For connecting two fiber optic cables 53 Accessories Ni 54 309298J Technical Data Category Maximum Working Fluid Pressure Maximum Working Air Pressure Maximum Fluid Operating Temperature Paint Resistivity Range Short Circuit Current Output Voltage Output Sound Power measured per ISO Standard 9216 Sound Pressure measured 1 m from gun Turbine air inlet fitting left hand thread Atomizing air inlet fitting Cylinder air inlet fitting Hi Lo voltage selector air inlet fittings Fluid inlet fitting Gun Weight Gun Length Wetted Parts Technical Data Data 3000 psi 21 MPa 210 bar 100 psi 0 7 MPa 7 bar 120 F 48 C 3 megohm cm to infinity 125 microamperes 40 85 kV at 40 psi 0 28 MPa 2 8 bar 90 4 dB A at 100 psi 0 7 MPa 7 bar 105 4 dB A at 40 psi 0 28 MPa 2 8 bar 87 dB A at 100 psi 0 7 MPa 7 bar 99 dB A 1 4 npsm m 3 8 in OD nylon tube 5 32 in OD
16. instruc tions 4h WARNING Fire Explosion and Electric Shock Hazard 4 4 Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion e Electrostatic equipment must be used only by trained qualified personnel who understand the requirements of this manual e Ground equipment personnel object being sprayed and conductive objects in work area See Grounding instructions ul e Only use grounded Graco conductive air supply hoses Y e Check gun and hose resistance and electrical grounding daily e Use and clean equipment only in well ventilated area e Interlock the gun air supply to prevent operation unless ventilating fans are on e Use cleaning solvents with highest possible flash point when flushing or cleaning equipment e Always turn the electrostatics off when flushing cleaning or servicing equipment e If there is static sparking or you feel a shock stop operation immediately Do not use equip ment until you identify and correct the problem e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plas tic drop cloths potential static arc e Do not plug or unplug power cords or turn lights on or off when flammable fumes are present e Keep work area free of debris including solvent rags and gasoline e Keep a working fire extinguisher in the work area 309298J 3 Warning A warna Skin
17. nylon tube 5 32 in OD nylon tube 1 4 18 npsm m 3 52 Ib 1 6 kg 12 25 in 31 1 cm Stainless Steel Nylon Acetal Ultra High Molecular Weight Polyethylene Fluoroelastomer PEEK Tungsten Wire Polyethylene Loctite is a registered trademark of the Loctite Corporation 309298J 55 Graco Standard Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months or two thousand hours of operation from the date of sale repair or replace any part of the equipment determined by Graco to be defective However any deficiency in the gun barrel gun body manifold mounting bracket internal power supply and alternator excluding turbine bearings will be repaired or replaced for thirty six months or six thousand hours of operation from the date of sale This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall
18. shock never operate the gun with a missing or damaged electrode y 4 Make sure the electrode 40a is not damaged or missing See page 39 to install the electrode 37 Repair 5 Install the seat housing 5 with the tool 14 pro vided Tighten until snug then 1 4 turn more do not overtighten See FIG 24 A CAUTION To avoid damaging the seat housing and gun barrel never overtighten the seat housing Overtightening may affect the fluid shutoff 6 Place the spray tip 4 in the air cap 40 Align the tab of the tip with the groove in the air cap Be care ful not to damage the electrode 40a 38 7 8 Slide the shroud 2 onto the gun Install the spray tip 4 and air cap 40 tip guard 3 shroud 2 and retaining ring 1 onto the gun Make sure the u cup 1a is in place on the retaining ring 1 The lips must face forward Tighten the retaining ring until the air cap is held firmly in place you should not be able to rotate the air cap horns by hand Test gun resistance page 29 Install the gun onto the manifold and bracket See page 36 3092985 Electrode Replacement Ah WARNING Electric Shock Hazard tric shock do not operate the spray gun W To reduce the risk of fire explosion or elec without the electrode installed in the air cap 1 Prepare the gun for service page 35 2 Remove the air cap assembly page 37 3 Pull the elect
19. to control fluid pressure to the gun 11 Installation Install the Gun and Mounting Bracket 1 Loosen the mounting bracket s two set screws 103 and slide the bracket 102 onto a 1 2 in 13 mm mounting rod See FIG 4 2 Position the gun and tighten the two set screws For added positioning reliability insert a 1 8 in 3 mm locating pin into the slot NN in the bracket and through a hole in the rod See the detail in FIG 4 12 WEE ig a Sl 103 9 24 in TIi1738A NOZZle 234 7 mm Tip Fig 4 Mounting Bracket 309298J Connect the Air and Fluid Lines FIG 3 shows a schematic of air and fluid line connec tions and FIG 5 shows the manifold connections Con nect the air and fluid lines as instructed Ah WARNING Electric Shock Hazard serious injury the air supply hose must be electrically connected to a true earth ground Use only Graco Grounded Air Supply Hose W To reduce the risk of electric shock or other e Installation EXH Shroud Exhaust Outlet Fitting Connect a 1 4 in 6 mm OD x 4 ft 1 22 m long tube to this fitting FO Fiber Optic Fitting Optional Connect the Graco Fiber Optic cable see page 14 KV1 kV Switch 1 Air Inlet Fitting Connect a 5 32 in 4 mm OD tube between this fitting and the solenoid KV2 kV Switch 2 Air Inlet Fitting Connect a 5 32 in 4 mm OD tube between this fitting a
20. 1 and grounding spring 25 remains tight are in place Make sure the air holes are aligned properly Replace if damaged See FIG 35 5 Install and adjust the actuator arm 29 and jam nut 28 See page 43 2 Place the barrel 6 over the power supply 12 and onto the gun body 32 6 Test gun resistance page 29 3 Tighten the three screws 10 33 oppositely and 7 Install the gun shroud 2 and air cap page 37 evenly about a half turn past snug 8 Install the gun onto the manifold and bracket See page 36 CAUTION Do not over tighten the screws 10 33 9 a e 4 dl 5 gt S I P f o 99 29 eS y L 25 A Z 28 TI1729A 20 D 19 c Fig 35 Barrel Installation 309298J 45 Repair Power Supply Removal and Replacement Inspect the gun body power supply cavity for dirt or moisture Clean with a clean dry rag Do not expose gasket 11 to solvents Prepare gun for service page 35 Remove the barrel 9 page 44 ZA CAUTION Be careful when handling the power supply 12 to avoid damaging it 3 46 Grasp the power supply 12 with your hand With a gentle side to side motion free the power sup ply alternator assembly from the gun body 32 then carefully pull it straight out Disconnect the flex ible circuit 23 from the socket at the top of the body 32 See FIG 36 Disconnect the 3 wire connector GG from the power supply Slide the
21. 12 250 300 GG3623 12 14 300 350 GG3723 14 16 350 400 Fan widths Orifice Size Part No 10 in 250 mm in mm in mm GG3107 2 4 50 100 0 007 0 178 GG3207 4 6 100 150 GG3307 6 8 150 200 GG3209 4 6 100 150 0 009 0 229 GG3309 6 8 150 200 GG3409 8 10 200 250 GG3211 4 6 100 150 0 011 0 279 GG3311 6 8 150 200 GG3411 8 10 200 250 GG3511 10 12 250 300 GG3611 12 14 300 350 GG3213 4 6 100 150 0 013 0 330 GG3313 6 8 150 200 GG3413 8 10 200 250 GG3513 10 12 250 300 GG3613 12 14 300 350 GG3215 4 6 100 150 0 015 0 381 GG3315 6 8 150 200 GG3415 8 10 200 250 GG3515 10 12 250 300 GG3615 12 14 300 350 3092985 GG3823 GG3425 16 18 400 450 8 10 200 250 0 025 0 635 GG3525 10 12 250 300 GG3625 12 14 300 350 GG3725 14 16 350 400 GG3825 16 18 400 450 51 Accessories Accessories Gun Accessories Electrode Replacement Kit 244917 Includes five electrodes Inline Fluid Filters 238561 100 mesh filter Set of three 238563 60 mesh filter Set of three Round Pattern Kit Provides higher level of performance to electrostatic spraying 245298 Gun Valve Lubricant 111265 4 oz 113 g tube of sanitary non silicone lubricant for fluid seals and wear areas Includes tip of choice Alternator Bearing Kit 223688 To repair the tu
22. 12 Connect the Air and Fluid Lines 13 Manifold Connections o o 13 Optional Fiber Optic Cable Connection 14 GPOUNGING tesis Sohn eee aa 15 Check Electrical Grounding 16 Check Fluid Resistivity 17 Check Fluid Viscosity 17 Install the Fabric Cover o 17 Operation iia idad das 18 Pressure Relief Procedure 18 Operating Checklist 18 Selecta Spray Tip ooooccooccococoo co 19 Install the Spray Tip 0 0000 19 Set the Atomization Fluid Pressure 20 Adjust the Electrostatics 21 Spraying Mica ads pees 22 Triggering the Fluid Alone 22 Shutdown go cd ead vga abel ad 22 Maintenance 0 000 eee eee eee eee 23 Daily Care and Cleaning 23 Daily Care and Cleaning continued 24 Flush the Spray Gun 0005 25 Clean the Spray GUN 0 0005 26 Check for Fluid Leakage 28 Electrical Tests oooooooocooommmmo 29 Test Gun Resistance 000000 29 Test Power Supply Resistance 30 Test Barrel Resistance 31 Troubleshooting o 0ooooomommmm 32 Spray Pattern Troubleshooting 32 Gun Operation Troubleshooting 33 Electrical Troubleshooting 34 A te cere a ee w
23. 7 1 2 npt m fluoroelastomer seals 210658 3 8 npt m fluoroelastomer seals 210659 3 8 npt x 1 4 npt m fluoroelastomer seals 214037 1 4 npt m PTFE seals Miscellaneous Accessories Ground Wire and Clamp 222011 For grounding pump and other components and equipment in the spray area 12 gauge 25 ft 7 6 m Megohmmeter 241079 500 Volt output 0 01 2000 megohms Not for use in hazardous areas Paint Resistance Meter 722886 Use with 722860 Paint Probe to measure resistance of paint Not for use in hazardous areas 3092985 Paint Probe 722860 Use with 722886 Paint Resistance Meter to measure resistance of paint Not for use in hazardous areas Safety Warning Signs 180060 English Warning Sign FM Approved Avail able at no charge from Graco ES Display Module 224117 Receives fiber optic transmission from the PRO Auto Xs gun and displays the gun s output voltage and current Mounts in a standard 19 in DIN rack See 308265 Fiber Optic Y Cables For use with 224117 Display Module only Connect gun manifold and display module or bulkhead connector and display module See 308265 224682 25 ft 7 6 m 224684 50 ft 15 m 224686 100 ft 30 5 m Power Supply 235301 Supplies low voltage DC power to 224117 Display Module See 308265 309298J Accessories Remote Voltage Display 189762 Battery operated meter displays actual spraying voltage remote mount outside hazardous area Connects to gun via
24. Dirty air cap Clean see page 37 Manifold is not tight Tighten manifold screws 106 Worn or missing o rings Replace o rings See page 43 Fluid doesn t shut off properly Seat housing 5 too tight Replace see page 37 Fluid buildup on fluid needle 8 Replace needle see page 41 Piston sticking Clean or replace o rings See page 43 309298J 33 Troubleshooting Electrical Troubleshooting Problem Cause Solution Poor wrap Turbine air is not turned on Turn on Booth exhaust velocity is too high Reduce velocity to within code limits Atomization air pressure too high Decrease Fluid pressure too high Decrease Incorrect distance from gun to part Should be 8 12 in 200 300 mm Poorly grounded parts Resistance must be 1 megohm or less Clean workpiece hangers Faulty gun resistance See Test Gun Resistance on page 29 Low fluid resistivity Check fluid resistivity page 17 Fluid leaks from the packing 8d and causes a short Clean the packing rod cavity Replace the packing rod See page 41 Faulty turbine alternator Be sure the plug is in place on the back of the turbine alternator hous ing Remove and test the turbine alternator See page 47 The KV switch is stuck on low Check the switch actuation replace if needed No power Replace power suppl
25. Injection Hazard Spray from the gun hose leaks or ruptured components can inject fluid into your body and cause Wi an extremely serious injury including the need for amputation Splashing fluid in the eyes or on the skin can also cause serious injury e Fluid injected into the skin might look like just a cut but is a serious injury Get immediate surgical treatment Do not point the gun at anyone or at any part of the body Do not put your hand or fingers over the spray tip Do not stop or deflect fluid leaks with your hand body glove or rag e Never spray without the tip guard in place e Follow the steps under Prepare the Gun for Service page 35 when you stop spraying and before cleaning checking or repairing equipment e Check the hoses and couplings daily Replace worn damaged or loose parts immediately Permanently coupled hoses cannot be repaired replace the entire hose e Tighten all fluid connections before each use Toxic Fluid Hazard Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin swallowed or inhaled e Know the specific hazards of the fluid you are using Read the fluid manufacturer s warnings e Store hazardous fluid in an approved container Dispose of the hazardous fluid according to all local state and national guidelines e Wear appropriate protective clothing gloves eyewear and respirator 4 3092985 Warning A
26. Instructions Parts List O GRACO AUTOMATIC ELECTROSTATIC AIR ASSISTED SPRAY GUN PRO Auto Xs AA dai Part No 244592 Series A 100 psi 0 7 MPa 7 bar Maximum Air Inlet Pressure 3000 psi 21 MPa 210 bar Maximum Working Fluid Pressure For use in Class I Div hazardous locations using Group D spray materials M APPROVED For use in Group ll Zone 1 areas using Group IIA spray materials C Ed 2 G EEx 0 24MJ For Professional Use ONLY Important Safety Instructions PNA Read all warnings and instructions in this manual a Save these instructions See page 2 for Table of Contents a U S Patent 7 226 004 TI1713A HOO3 PROVEN QUALITY LEADING TECHNOLOGY Table of Contents SYMDO S eiii a cae oink ee 3 Warning Symbol o ooooccccccccoo 3 Caution SyMbOl ooooocoooooo ooo 3 Warning ia aa a ia 3 Introduction 00 cece o 6 How the Electrostatic AA Spray Gun Works 6 Operating the Spray Function 6 Operating the Electrostatics 6 Gun Features and Options 6 Changing the kV Setting 7 Installation ooooooooommommmmommm o 9 Install the System ooocccccccco ee eee 9 Warning Signs 00 0c eee 9 Ventilate the Spray Booth 9 Install the Air Line Accessories 11 Install the Fluid Line Accessories 11 Install the Gun and Mounting Bracket
27. Pressure Relief Procedure at left NM The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators The system the operator and all persons entering the spray area are properly grounded See Grounding on page 15 The condition of the gun s electrical compo nents has been checked as instructed in Elec trical Tests on page 29 Ventilation fans are operating properly Workpiece hangers are clean and grounded All debris including flammable fluids and rags is removed from the spray area O All flammable fluids in the spray booth are in approved grounded containers All conductive objects in the spray area are electrically grounded The floor of the spray area is electrically conductive and grounded The manifold exhaust tubes have been checked for the presence of any fluid See Check for Fluid Leakage on page 28 309298J Select a Spray Tip The fluid output and pattern width depend on the size of the spray tip the fluid viscosity and the fluid pressure Use the Spray Tip Selection Chart page 51 as a guide for selecting the appropriate spray tip for your application Install the Spray Tip Ah WARNING Skin Injection Hazard To reduce the risk of a fluid injection injury Wc always follow the Pressure Relief Proce 7 dure on page 18 before removing or installing the spray ti
28. alternator up and off the power supply Inspect the power supply and alterna tor for damage Disconnect the 6 pin flexible circuit 23 from the power supply 5 Check the power supply resistance page 30 Replace if necessary Before installing the power supply make sure the o rings 12a 13a spring 12b and pads 13e are in place 6 Connect the 6 pin flexible circuit 23 to the power supply Connect the 3 wire connector GG Slide the alter nator 13 down onto the power supply 12 Lubricate the alternator o ring 13a with non sili cone grease Part No 111265 Do not over lubri cate Lubricate the power supply o ring 12a with dielec tric grease Insert the power supply alternator assembly in the gun body 32 Make sure the ground strips make contact with the body Connect the flexible circuit 23 to the socket at the top of the body Push the 6 pin connector into the socket to ensure it is prop erly connected Install the barrel 6 page 45 Test gun resistance page 29 3092985 Fig 36 Power Supply Turbine Alternator Removal and Replacement Replace turbine alternator bearings after 2000 hours of operation Order Part No 223688 Bearing Kit 1 2 Prepare gun for service page 35 Remove the power supply alternator assembly page 46 Disconnect the alternator from the power supply page 46 gt Measure resistance between the two outer termi nals of th
29. d wannine Rs 309298J Equipment Misuse Hazard Equipment misuse can cause the equipment to rupture malfunction or start unexpectedly and result in a serious injury e This equipment is for professional use only e Read all manuals tags and labels before operating the equipment e Use the equipment only for its intended purpose If you are uncertain call your Graco distribu tor e Do not alter or modify equipment Use only genuine Graco parts and accessories e Check the equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system component Maxi mum working fluid pressure of this equipment is 3000 psi 21 MPa 210 bar e Use fluids and solvents that are compatible with the equipment wetted parts See the Techni cal Data section of all equipment manuals Read the fluid and solvent manufacturer s warn ings e Route the hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 40 F 40 C e Wear hearing protection when operating this equipment e Comply with all applicable local state and national fire electrical and other safety regula tions Introduction Introduction How the Electrostatic AA Spray Gun Works WARNING Skin Injection Hazard Remember this is not an air spray gun For your safety read and
30. e electrical and other safety regula tions FIG 2 shows a typical electrostatic air assisted spray system and FIG 3 shows possible system options It is not an actual system design For assistance in design ing a system to suit your particular needs contact your Graco distributor Warning Signs Mount warning signs in the spray area where they can easily be seen and read by all operators An English Warning Sign is provided with the gun Ventilate the Spray Booth Ah WARNING Flammable or Toxic Vapor Hazard Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying flushing or cleaning the gun Do not operate the gun unless ven tilation fans are operating 309298J Installation Electrically interlock the gun turbine air supply with the ventilators to prevent gun operation without ventilating fans operating Check and follow all National State and Local codes regarding air exhaust velocity require ments High velocity air exhaust will decrease the operating effi ciency of the electrostatic system The minimum allow able air exhaust velocity is 60 ft minute 19 linear meters minute Key to FIG 2 and FIG 3 Air Hose Ground Wire Graco Grounded Turbine Air Hose TA Atomizing Air Hose 3 8 in 10 mm OD A2 Cylinder Air Hose 5 32 in 4 mm OD CYL Fluid Hose 1 4 18 npsm gun fluid inlet P1 To Fluid Supply Auto PRO Xs Air Assisted Spray Gu
31. e 3 wire connector GG it should be 2 5 3 5 ohms If outside this range replace the alternator coil Follow the bearing replacement procedure in the bearing kit manual 308034 Install the alternator on the power supply page 46 Install the power supply alternator assembly page 46 Parts Parts Part No 244592 PRO Auto Xs AA Electrostatic Gun Series A y we WDA SS AN oxy v y DN ti1722 13d 13c 48 309298J Part No 244592 PRO Auto Xs AA Electrostatic Gun Series A Ref 11 12 12a t 12b 13 13a t 13b 13c 13d 13e 14 15 16 17 19 Part No 244950 198307 197916 276767 GG3XXX 183459 245280 244531 197486 244714 112691 197518 197517 244541 103337 197624 244555 110073 223688 244577 111745 198821 107460 179791 180060 239945 244713 3092983 Description RING retaining air cap includes la U CUP SHROUD TIP GUARD SPRAY TIP customer s choice includes item 4a SEAL spray tip HOUSING seat BARREL gun includes item 6a O RING conductive NEEDLE fluid includes item 8a SPRING compression SCREW socket hd 10 24 x 3 4 in 19 mm GASKET barrel POWER SUPPLY 85 kV includes 12a 12b O RING fluoroelastomer SPRING compression TURBINE alternator includes 13a 13e O RING fluoroelastomer BEARING KIT includes front and rear bearings and fan COIL RING retaining PAD pressure WRENCH
32. ectric Shock Hazard qualified Skin Injection Hazard W Installing and servicing this equipment To reduce the risk of a fluid injection injury g Cuires access to parts which may cause ll y always follow the Pressure Relief Proce an electric shock or other serious injury if 7 dure on page 18 before doing any mainte the work is not performed properly Do not install or nance or service on this gun or system repair this equipment unless you are trained and Check all possible remedies in the Troubleshooting Chart before disassembling the gun Spray Pattern Troubleshooting Some spray pattern problems are caused by the improper balance between air and fluid Problem Cause Solution Fluttering or spitting spray No fluid Refill supply Air in fluid supply Check fluid source Refill Irregular pattern Fluid buildup partially plugged tip Clean See page 26 Worn damaged tip or air cap holes Clean or replace Pattern pushed to one side air cap Air cap holes plugged Clean See page 26 gets dirty Tails in pattern Atomization air pressure too low Increase atomization air pressure Fluid pressure too low Increase Fluid buildup on air cap tip guard Atomization air pressure too high Decrease Fluid pressure too low Increase 32 3092985 Gun Operation Troubleshooting Troubleshooting Problem Cause Solution Excessive spray fog Atom
33. f the date of sale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Information For the latest information about Graco products visit www graco com
34. follow all Warn ings in this manual The air assisted spray gun combines airless and air spraying concepts The spray tip shapes the fluid into a fan pattern as does a conventional airless spray tip Air from the air cap further atomizes the fluid and completes the atomization of the fluid tails to produce a uniform pattern The high working fluid pressure of this gun provides the power needed to atomize higher solids materials Operating the Spray Function Applying a minimum of 50 psi 0 35 MPa 3 5 bar air pressure to the gun manifold s cylinder air fitting CYL will retract the gun piston which opens the air valves and a short time later opens the fluid needle This pro vides the proper air lead and lag when triggering the gun A spring returns the piston when the cylinder air is shut off Operating the Electrostatics To operate the electrostatics apply air pressure to the gun manifold s turbine air fitting TA through a Graco grounded air hose The air enters the manifold and is directed to the inlet of the power supply turbine The air spins the turbine which then provides electrical power to the internal high voltage power supply The fluid is charged by the spray gun electrode The charged fluid is attracted to the nearest grounded object wrapping around and evenly coating all surfaces The turbine air is exhausted into the shroud and out the back of the manifold through the exhaust fitting EXH The exha
35. he o rings 34e 34f 34g and u cup packing 34d with non silicone grease Part No 111265 Do not over lubricate 7 Align the two stems 34c with the holes in the gun body and press the piston assembly into the back of the gun until it bottoms 8 Install and adjust the actuator arm page 43 42 Table 3 Piston O Rings Description Function Shaft O Ring Seals cylinder air along the piston rod 34g 34b Replace if air leaks along rod Front O Ring Air shutoff seal Replace if air leaks from 34e air cap when gun is de triggered Back O Ring Separates cylinder air from atomizing air 34f U Cup 34d Replace if air leaks from small vent hole at back of manifold when gun is trig gered 34d 34c 34f E 34e N SE E A D a TIH575A gt y y C y 34g TI1576A Fig 31 Piston O Rings 309298J Adjust the Actuator Arm 1 Install the adjustment nut 30 actuator arm 29 and jam nut 28 onto the piston rod 34b Note that the jam nut 28 has a slightly larger hex and a thin ner profile than the adjustment nut 30 See FIG 30 on page 42 2 Position the parts so there is a 0 125 in 3 mm gap between the actuator arm 29 and the fluid packing rod nut U which allows the atomizing air to actuate before the fluid See FIG 32 3 Tighten the adjustment nut 30 against the actuator arm 29 Check that the 0 125 in 8 mm gap has been maintained See FIG 32 4
36. ine te eee oe 35 Prepare the Gun for Service 35 Remove the Gun from the Manifold 36 Install the Gun on the Manifold 36 Tip Guard Air Cap Spray Tip or Seat Housing Replacement o oococcccco 37 Electrode Replacement 39 Fluid Tube Replacement 40 Fluid Filter Removal 0 40 Fluid Needle Replacement 41 Piston Repair 0 0 0 0 eee ee eee 42 Adjust the Actuator Arm 43 Barrel Removal 000002 ee eee 44 Barrel Installation o o 45 Power Supply Removal and Replacement 46 Turbine Alternator Removal and Replacement 47 Parts 22 eee ie Se ee He Ee ES oie a edt 48 Spray Tip Selection Chart 51 Accessories 22s fe eee eee Ree ets 52 Gun Accessories 0 00 eee eee 52 Air Line Accessories 000 0 52 Fluid Line Accessories 4 52 Miscellaneous Accessories 52 Technical Data 0000 cess eee eee 55 Graco Standard Warranty oo oooo 56 Graco Information 0 0002008 56 309298J Symbols Symbols Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious injury This symbol alerts you to the possibility of damage to or or death if you do not follow the instructions destruction of equipment if you do not follow the
37. ion and Electric Shock Hazard e All persons entering the spray area shoes must have conductive soles such as leather or personal grounding straps must be worn Do not wear shoes with non conductive soles such as rubber or plastic When operating the electrostatic gun any pA ungrounded objects in the spray area peo ple containers tools etc can become W electrically charged Improper grounding can result in static sparking which can Wy cause a fire explosion or electric shock Follow the grounding instructions below e Object being sprayed keep the workpiece hangers clean and grounded at all times Resistance must not exceed 1 megohm e The floor of the spray area must be electrically con The following are minimum grounding requirements for ductive and grounded Do not cover the floor with a basic electrostatic system Your system may include cardboard or any non conductive material which other equipment or objects which must be grounded would interrupt grounding continuity Check your local electrical code for detailed grounding instructions Your system must be connected to a true e Flammable liquids in the spray area must be kept in earth ground approved grounded containers Do not use plastic containers Do not store more than the quantity e Pump ground the pump by connecting a ground needed for one shift wire and clamp as described in your separate pump instruction manual e All electrically conducti
38. ization air pressure too high Decrease air pressure as low as pos sible Fluid too thin Increase viscosity Orange Peel finish Atomization air pressure too low Increase air pressure use lowest pressure necessary Spray tip 4 too large Use smaller tip see page 51 Poorly mixed or filtered fluid Remix or refilter fluid Fluid too thick Reduce viscosity Fluid leaks from the fluid packing area Worn fluid needle packings or shaft Replace fluid needle assembly 8 see page 41 Air leaks from the air cap Worn piston stem o rings 34e 34f Replace see page 42 Fluid leakage from the front of the gun Worn or damaged fluid needle 8 Replace see page 41 Worn fluid seat housing 5 Replace see page 37 Loose spray tip 4 Tighten retaining ring 1 see page 37 Damaged tip seal 4a Replace see page 37 Gun does not spray Low fluid supply Add fluid if necessary Dirty or clogged spray tip 4 Clean see page 37 Damaged spray tip 4 Replace see page 37 Damaged fluid needle 8 Replace see page 41 Piston 34 not actuating Check cylinder air Check piston u cup 34d see page 48 Actuator arm 29 is out of position Check actuator arm and nuts See page 43 Paint buildup on air cap Air leaks from manifold Atomization air pressure too high Reduce
39. n Mounting Bracket for 1 2 in 13 mm rod Solenoid Valve requires quick exhaust port Bleed Type Master Air Valve Air Pressure Regulator True Earth Ground 24 Volt Power Supply 4 20 microampere Outputs Full Feature ES Display Module kV Only ES Display Module battery operated Fiber Optic Y Cable Bulkhead Fiber Optic Cable Main Air Line kV Switch Air Hose 5 32 in 4 mm OD optional plug KV1 fitting if not used kV Switch Air Hose 5 32 in 4 mm OD optional plug KV2 fitting if not used s lt C100UZZFACIoqmmo uy gt x lt lt Installation NOTE The turbine air supply TA must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on KV1 L ow Ser i i j PE a a W k Da OA A Te E E s Non Hazardous Area Fig 2 Typical Installation NOTE E Pd G J TH741A Hazardous Area A n Manifold Back View A maximum of two splices with a total of 108 ft 33 m of cable can be used For the strongest light signals use a minimum number of bulkhead splices See Accessories on page 52 Non Hazardous Area Hazardous Area U
40. nd the solenoid P1 Fluid Supply Inlet Fitting Connect a 1 4 npsm swivel fitting between this fitting and the fluid supply P2 Not Used TA Turbine Air Inlet Fitting Connect the Graco Electrically Conductive Air Hose between this fitting left hand thread and the solenoid Connect the air hose ground wire to a true earth ground 1 Connect the Graco Grounded Turbine Air Supply Hose B to the gun s turbine air inlet TA and con nect the hose ground wire A to a true earth ground N The gun turbine air inlet fitting has a left hand thread to prevent connecting another type of air hose to the turbine air inlet See Accessories on page 52 for further information about the hose 2 Check the electrical grounding of the gun as instructed on page 16 3 Before connecting the fluid line P1 blow it out with air and flush it with solvent Use solvent which is compatible with the fluid to be sprayed Manifold Connections A1 Not Used A2 Atomization Air Inlet Fitting Connect a 3 8 in 10 mm OD tube between this fitting and the air supply CYL Cylinder Air Inlet Fitting Connect a 5 32 in 4 mm OD tube between this fitting and the solenoid For quicker response use the shortest hose length possible 309298J KV2 TA ra CYL O A2 S EN NA 4 O O Y PD A PO O 9 O SS lt EXH TI1739A Fig 5 Manifold C
41. ng 12a some fluid needle parts 8 and certain fluid fittings with Part No 116553 Dielectric Grease as specified in the text Lightly lubricate o rings and seals with non silicone grease Order Part No 111265 Lubricant Do not over lubricate Only use genuine Graco parts Do not mix or use parts from other PRO Gun models Flush and clean the gun page 23 Relieve the pressure page 18 Remove the gun from the manifold page 36 Remove the gun from the worksite Repair area must be clean 35 Repair Remove the Gun from the Manifold 1 Remove the fluid supply hose from the fluid fitting 22 2 Loosen the bottom gun screw 31 until the gun sits loosely in the mounting bracket slot A See FIG 22 CAUTION The piston return spring 105 is compressed between the manifold and the gun body when they are assembled To avoid sudden movement of the gun loosen the bottom gun screw 31 before loosen ing the three manifold screws 106 This allows the gun to move forward gradually as the manifold screws are loosened Hold the gun firmly in hand while loosening the manifold screws 3 Holding the gun firmly in hand loosen the three screws 106 from the back of the manifold 4 Remove the gun from the manifold and take it to the service area 36 Fig 22 Remove Gun from Manifold Install the Gun on the Manifold 1 Make sure the gasket 112 and spring 105 are in place on the ma
42. nifold See FIG 22 Inspect the parts for damage and replace them as needed 2 Secure the gun to the manifold by tightening the three screws 106 3 Secure the gun to the mounting bracket 102 by tightening the bottom screw 31 3092985 Tip Guard Air Cap Spray Tip or Seat Housing Replacement 1 Prepare gun for service page 35 2 Remove the retaining ring 1 tip guard 3 air cap 40 spray tip 4 and shroud 2 You may have to turn the air cap with the tip guard to remove it See FIG 23 3 Remove the seat housing 5 with the tool 37 pro vided See FIG 24 TI1723A Fig 23 Tip Guard Air Cap and Spray Tip Replace ment ZA CAUTION The barrel resistor cartridge B is part of the barrel and is not replaceable To avoid destroying the gun barrel do not attempt to remove the barrel resistor 309298J Repair Ah WARNING Fire Explosion and Electric Shock Hazard The barrel contact ring 6a is a conductive contact ring not a sealing o ring To reduce the risk of sparking or electric shock do not remove the barrel contact ring 6a except to replace it and never operate the gun with out the contact ring in place Do not replace the contact ring with anything but a genuine Graco part ske Fig 24 Seat Housing Replacement Ah WARNING Fire Explosion and Electric Shock Hazard To reduce the risk of fire explosion or elec y tric
43. onnections 13 Installation I I I 2 Remove the nut AA from the fiber optic fitting 5 Optional Fiber Optic Cable and slide the nut over the end of the fiber optic cable Connection BB See Fic 7 3 Push the cable BB into the fitting 5 until it bot An optional fiber optic fitting is shipped unassembled toms out Tighten the nut AA to secure the cable with the gun If an ES kV display module is used install the fitting in the FO port of the manifold See FIG 3 page 10 for a schematic of the fiber optic connec 5 tions ae 7 1 Remove the plug 120 from the fiber optic port and a install the fiber optic fitting 5 shipped loose with the BB EH AA gun See FIG 6 Ea Fig 7 Fiber Optic Cable Most of the fiber optic light transmission loss occurs at the bulkhead splices For the strongest light signals use a minimum number of bulkhead splices A maximum of two splices with a total of 108 ft 33 m of cable is rec ommended 4 See manual 308265 to install a Graco ES Display Module Fig 6 Fiber Optic Fitting 14 309298J Installation 7 e Air compressors and hydraulic power supplies G rou nd In g ground the equipment according to the manufac turer s recommendations e Allair and fluid lines must be properly grounded A WARN ING e All electrical cables must be properly grounded Fire Explos
44. p air cap or tip guard Operation 3 Install the spray tip and air cap tip guard 3 shroud 2 and retaining ring 1 onto the gun Be sure the electrode 40a is in place Tighten the retaining ring firmly Ah WARNING Fire Explosion and Electric Shock Hazard To reduce the risk of fire explosion or elec y tric shock never operate the gun with a damaged electrode y 1 Relieve the pressure 2 Place the spray tip 4 in the air cap 40 aligning the tab on the tip with the groove in the air cap Be careful not to damage the electrode 40a A eS 2 ue 40 Fig 10 Install Spray Tip 3092985 TI1717A Fig 11 Install Air Cap Assembly 19 Operation Set the Atomization Fluid Pressure Atomization fluid pressure will vary based on the viscos ity of the fluid flow rate desired and other system char acteristics 1 Turn off the turbine air TA and atomization air A2 2 Start the pump Set the fluid regulator to 400 psi 2 8 MPa 28 bar 3 With the turbine air TA and atomization air A2 turned off spray a test pattern holding the gun 12 in 305 mm from the surface Examine the particle size Do not be concerned about the presence of tails they will be removed in step 6 4 Increase the fluid pressure in small increments Spray another pattern and compare the particle size Smaller particle size indicates improved atomi
45. rbine alternator Cleaning Brush 105749 For cleaning air cap and fluid nozzle Air Line Accessories AirFlex Flexible Grounded Air Hose 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 244963 s 6 ft 1 8 m 244964 15 ft 4 6 m 244965 25 ft 7 6 m 244966 36ft 11 m 244967 50ft 15m 244968 75 ft 23 m 244969 100 ft 30 5 m Standard Grounded Air Hose Grey 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 223068 6 ft 1 8 m 223069 15 ft 4 6 m 223070 25 ft 7 6 m 223071 36 ft 11 m 223072 50 ft 15 m 223073 75 ft 23 m 52 223074 100 ft 30 5 m Bleed Type Master Air Valve 300 psi 21 bar 2 1 MPa Maximum Working Pressure Relieves air trapped in the air line between this valve and the pump air motor when closed 107141 3 4 npt Air Line Shutoff Valve 150 psi 10 bar 1 0 MPa Maximum Working Pressure For turning air to gun on or off 224754 1 4 npsm m x 1 4 npsm f left hand thread Fluid Line Accessories Nylon Fluid Hose 3000 psi 210 bar 21 MPa Maximum Working Pressure 223540 1 4 in 6 mm ID x 25 ft 7 6 m 1 4 npsm 223541 1 4 in 6 mm ID x 50 ft 15 2 m 1 4 npsm Fluid Shutoff Drain Valve 5000 psi 350 bar 35 MPa Maximum Working Pressure For turning fluid on or off to the gun and for relieving fluid line pressure at the pump 21065
46. res as there is no added bene fit and turbine life could be reduced oo 3919 970 59 50 15 3 57 4 0 0 40 75 22 9 59 4 1 0 41 100 30 5 61 4 3 0 43 3 Check the voltage output of the gun using a high voltage probe and meter or by reading the ES kV Display Module The gun s normal high voltage reading is 60 70 kV If a ball end high voltage measurement probe is used the gun voltage will rise to about 85 kV This will happen with all resistive electrostatic guns See Electrical Troubleshooting on page 34 to correct voltage problems 309298J 21 Operation Spraying Triggering the Fluid Alone 1 Shut off and relieve the air pressure to the atomiza tion A2 air line using the bleed type air shutoff valve WARNING 2 Apply 50 psi 3 5 bar 0 35 MPa air pressure to the cylinder air fitting CYL to trigger the fluid Electric Shock Hazard touch the gun electrode or come within 4 in Shutd own W To reduce the risk of electric shock do not Y 10 cm of the nozzle during gun operation 1 Apply a minimum of 50 psi 3 5 bar 0 35 MPa air pressure to the cylinder air fitting CYL to activate the on off sequence of atomization air A2 and fluid A WARN NG P1 See FIG 12 Skin Injection Hazard 2 Turn the gun functions off and on by using the air solenoid valves on the cylinder CYL and turbine To reduce the risk of a fluid injection injury TA air supply lines A
47. rode 40a out of the back of the air cap using a needle nose pliers 3092985 Repair 4 Push the new electrode through the air cap hole Make sure the short end BB of the electrode engages the hole CC in the back of the air cap Press the electrode in place firmly with your fingers See FIG 25 5 Install the air cap assembly page 37 6 Test gun resistance page 29 40a AE Fig 25 Electrode Replacement 39 Repair Fluid Tube Replacement There are no replaceable parts in the fluid tube assem bly Only remove when necessary 1 Prepare the gun for service page 35 2 Remove the air cap assembly page 37 Remove the shroud 2 3 Disconnect the bottom fluid tube nut C See FIG 26 4 Carefully unscrew the top fluid tube nut D CAUTION Be careful not to damage the fluid tube assembly 19 when cleaning or installing it especially the sealing surface E If the sealing surface is damaged the entire fluid tube assembly must be replaced 5 Apply Part No 116553 dielectric grease to the entire length of the plastic extension on the end of the fluid tube 19 6 Apply low strength thread sealant to the fluid tube nut threads 7 Install the fluid tube into the gun barrel and tighten the top nut D hand tight then 1 4 to 1 2 turn witha wrench There will be a gap between the nut and barrel Do not overtighten the nut
48. ructed to relieve the pressure e stop spraying e check or service any of the system equipment e or install or clean the spray tip 1 Turn off all the air to the spray gun except the cylin der air which triggers the gun 2 Turn off the fluid supply to the gun 3 Trigger the gun into a grounded metal waste con tainer to relieve the fluid pressure 4 Open the pump drain valve and all other drain valves in the system having a waste container ready to catch the drainage Triggering the gun to relieve pressure may not be sufficient Leave the drain valve open until you are ready to spray again 5 Relieve fluid pressure in the fluid supply equipment as instructed in its instruction manual 6 Close the bleed type master air valve on the main air supply line to shut off the air Leave the valve closed until you are ready to spray again 18 7 If you suspect that the spray tip or hose is still clogged or that pressure is not fully relieved after fol lowing the steps above very slowly loosen the hose end coupling and relieve pressure gradually then loosen completely Now clear the tip or hose obstruction Operating Checklist Check the following list daily before operating the sys tem to help ensure you of safe efficient operation E All operators are properly trained to safely operate an automatic electrostatic air assisted spray system as instructed in this manual All operators are trained in the
49. sistance 1 Inserta 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 A e 2 Measure the resistance between the conductive rod B and the barrel contact ring 6a See FIG 21 The resistance should be 19 29 megohms If the resistance is incorrect make sure the metal contact C in the barrel and the barrel contact ring 6a are clean and undamaged 3 If the resistance is still outside the range remove the barrel contact ring 6a and measure the resis tance between the conductive rod B and the wire lead at the bottom of the contact ring groove ti1515b 4 Ifthe resistance is in range replace the contact ring Fig 21 Test Barrel Resistance 6a with a new one Press the contact ring firmly into the groove on the front of the barrel Ah WARNING Fire Explosion and Electric Shock Hazard The barrel contact ring 6a is a conductive contact ring not a sealing o ring To reduce the risk of sparking or electric shock do not remove the barrel contact ring 6a except to replace it and never operate the gun with out the contact ring in place Do not replace the contact ring with anything but a genuine Graco part xke 5 If the resistance is still outside the range replace the barrel 309298J 31 Troubleshooting Troubleshooting WARNING Ah WARNING El
50. soft brush daily mini f mum Replace any damaged parts Be careful not to 10 Check the electrode 40a Replace if damaged damage the electrode 40a 11 Install the spray tip page 19 12 Install the spray tip and air cap tip guard shroud and retaining ring page 19 Be sure the electrode CAUTION ia 13 Test gun resistance page 29 Do not use metal tools to clean the air cap or spray tip holes as this could scratch them and make sure the electrode is not damaged Scratches in the air cap or spray tip or a damaged electrode can distort the spray pattern 309298J 27 Maintenance Check for Fluid Leakage WARNING Fire and Explosion Hazard If any fluid leakage from the gun is y detected stop spraying immediately Fluid leakage into the gun shroud could cause W fire or explosion and result in serious injury and property damage YY Fig 18 Check for Fluid Leakage 28 WARNING Skin Injection Hazard To reduce the risk of a fluid injection injury always follow the Pressure Relief Proce dure on page 18 when you stop spraying and whenever you are instructed to relieve the pressure Way During operation periodically check the manifold exhaust tube YY and both ends of the gun shroud ZZ for the presence of fluid See Fic 18 Fluid in these areas indicates leakage into the shroud which could be caused by leaks at the fluid tube
51. ssure 1 Relieve the pressure 2 Be sure the turbine air TA is turned off 3 Remove the retaining ring 1 tip guard 3 air cap 40 spray tip 4 and gun shroud 2 See page 19 4 Dip the end of a soft bristle brush into compatible solvent clean the front of the gun with the brush Avoid getting any solvent into the air passages Whenever possible point the gun down when clean ing it See Fia 15 If it appears that there is paint inside the air passages remove the gun from the line for servicing 26 TI1719A Fig 15 Clean Front of Gun 5 Dampen a soft cloth with solvent and wring out the excess Wipe the exterior of the gun and shroud clean See FIG 16 TI1720A Fig 16 Clean Gun Body 6 Remove the bottom fluid tube fitting P and fluid fil ter 20 See Fic 17 Clean the filter in compatible solvent 7 Reinstall the filter 20 and fitting P Do not over tighten the fitting and make sure the top fitting Q remains tight 309298J Maintenance 9 Wipe off the parts with a dry cloth Be careful not to damage the electrode Ah WARNING Fire Explosion and Electric Shock Hazard J 1117254 To reduce the risk of fire explosion or elec y tric shock never operate the gun with a 20 damaged electrode Fig 17 Clean the Inline Fluid Filter W w 8 Clean the retaining ring 1 tip guard 3 air cap 40 and spray tip 4 with a
52. ted wring out the excess fluid 02027A TI734A 3092985 23 Maintenance Daily Care and Cleaning continued WARNING Skin Injection Hazard To reduce the risk of a fluid injection injury Wc always follow the Pressure Relief Proce dure on page 18 when you stop spraying and whenever you are instructed to relieve the pressure e Clean the fluid and air line filters daily e Clean the outside of the gun daily with a soft cloth dampened in a compatible solvent e Clean the air cap spray tip and tip guard daily min imum Some applications require more frequent cleaning Replace the parts if they are damaged See Clean the Spray Gun page 26 24 Check the electrode and replace if broken or dam aged See Electrode Replacement on page 39 Check for fluid leakage from the gun and fluid hoses See Check for Fluid Leakage on page 28 Tighten fittings or replace equipment as needed Check all work hangers for fluid buildup clean if necessary Flush the gun before changing colors and whenever you are done operating the gun Ah WARNING Fire Explosion and Electric Shock Hazard To reduce the risk of fire explosion or elec amp tric shock turn off the turbine air TA before flushing the gun or any part of the system y 309298J Flush the Spray Gun Ah WARNING Skin Injection Hazard To reduce the risk of a fluid injection injury Wc
53. to unthread the nee dle 6 Using the multi tool 37 pull back on the packing nut N to remove the fluid needle assembly See FIG 28 Push in on the needle with the 2 mm ball end wrench 44 and tighten See FIG 29 8 Install the spring 8a ing spring 25 is in place Tighten until snug Do not overtighten 10 Install the barrel 6 page 45 Install the fluid needle assembly in the gun barrel Install the spring cap 45 making sure the ground ZA CAUTION To avoid damaging the seat housing and gun barrel never overtighten the seat housing Overtightening may result in improper fluid shutoff 11 Install the seat housing and air cap page 37 12 Test gun resistance page 29 3092985 Repair Fig 28 Fluid Needle Removal Fig 29 Fluid Needle Replacement 41 Repair Piston Repair 1 Prepare the gun for service page 35 2 Remove the air cap page 37 Remove the gun shroud 2 3 Remove the jam nut 28 actuator arm 29 and adjustment nut 30 See FIG 30 L I e L q E a T F 5 TI1732A 28 99 30 34b Fig 30 Actuator Arm 4 Push on the piston rod 34b to push the piston out the back of the gun 5 Inspect the o rings 34e 34f 34g and u cup pack ing 34d for damage See Table 3 and FIG 31 6 Lubricate t
54. ust air helps keep contaminants out and helps keep the gun clean Gun Features and Options e The gun is designed for use with a reciprocator and can be mounted directly on a 1 2 in 13 mm rod With additional brackets the gun can be mounted for robotic applications e The gun s quick disconnect design enables its removal without disconnecting the air lines to the gun e Gun functions are activated from a separate control ler that sends the appropriate signal to the actuating solenoids e The optional fiber optic readout system can be installed to monitor the gun s spraying voltage A fiber optic cable connected to the gun manifold car ries the signal from the gun to a remote display module Part No 224117 Display Module displays the gun s spraying voltage and current Bat tery operated Display Module 189762 displays the gun s spraying voltage only 309298J Changing the kV Setting The gun s full voltage setting is 85 kV Three lower volt age settings are possible by actuating the KV1 and KV2 switches Supply 50 psi 0 35 MPa 3 5 bar air pressure to the KV1 and KV2 ports Turn the air on or off as shown in Table 1 to set the desired voltage The solenoid valves used to activate the KV1 and KV2 switches must bleed the air out of the lines for the switches to draw back to the higher voltage setting 3092983 Introduction Table 1 KV1 and KV2 Switch Settings KV1 Air KV2 Air Outp
55. ut Voltage kV OFF OFF 85 OFF ON 70 ON OFF 60 ON ON 45 7 Introduction No WN Fig 1 Gun Overview Key TI1713A Air Cap Spray Tip Tip Guard Retaining Ring Shroud Mounting Bracket Manifold Turbine Power Supply ALS I oo TM olol o gt Electrode SS A e oS 6 A 7 AL A X i AS ZAS i zA CY E TI1739A DA TI1714A Manifold Back View P1 Sl SS ce N A S Manifold Markings KV1 EXH A1 not used A2 Atomization Air Inlet Fitting CYL Cylinder Air Inlet Fitting EXH Shroud Exhaust Outlet Fitting FO Fiber Optic Fitting KV1 kV Switch 1 Air Inlet KV2 kV Switch 2 Air Inlet P1 Fluid Supply Inlet Fitting P2 not used TA Turbine Air Inlet Fitting 309298J Installation Install the System Ah WARNING Fire Explosion and Electric Shock Hazard Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly Do not install or service this equipment unless you are trained and qualified xke Be sure your installation complies with National State and Local codes for the installation of electrical apparatus in a Class Div Group D or a Group Il Category 2G Hazardous Location e Comply with all applicable local state and national fir
56. ve objects or devices in the spray area including fluid containers and wash e Electrostatic Air Assisted Spray Gun ground the cans must be properly grounded gun by connecting the Graco Grounded Air Hose to the turbine air inlet and connecting the air hose ground wire to a true earth ground See Check Electrical Grounding page 16 3092985 15 Installation I 7 4 Measure the resistance between the turbine air inlet Check Electrical Grounding fitting TA and a true earth ground N a Ifusing a black or grey turbine air hose use a megohmmeter to measure the resistance Use an applied voltage of 500 minimum to 1000 volts maximum The resistance should not exceed 1 megohm WARNING Fire Explosion and Electric Shock Hazard Megohmmeter Part No 241079 AA see b Ifusing a red turbine air hose use an ohmmeter k FIG 8 is not approved for use in a hazard to measure the resistance The resistance ous area To reduce the risk of sparking do should not exceed 100 ohms W not use the megohmmeter to check electri cal grounding unless 3 Ifthe resistance is greater than the maximum read W ing specified above for your hose check the tight The gun has been removed from the ness of the ground connections and be sure the hazardous area turbine air hose ground wire is connected to a true earth ground If the resistance is still too high e Or all spraying devices in the hazardous replace the turbine air hose area
57. y See page 46 No voltage or low voltage reading on the gun ES display module Damaged fiber optic cable or connec tion Check replace damaged parts Turbine air is not turned on Turn on Poor wrap See causes and solutions under Poor Wrap above Operator gets mild shock Operator not grounded or is near ungrounded object See Grounding on page 15 Gun not grounded See Check Electrical Grounding on page 16 and Test Gun Resistance on page 29 Operator gets shock from workpiece Workpiece not grounded Resistance must be 1 megohm or less Clean workpiece hangers 34 3092985 Repair Prepare the Gun for Service Ah WARNING Electric Shock Hazard requires access to parts that may cause electric shock or other serious injury if the work is not performed properly Do not install or ser vice this equipment unless you are trained and quali fied W Installing and repairing this equipment w Ah WARNING Skin Injection Hazard To reduce the risk of a fluid injection injury Wc sj always follow the Pressure Relief Proce dure on page 18 when you stop spraying before servicing the gun and whenever you are instructed to relieve the pressure 3092985 Repair 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 ri
58. zation Ah WARNING Pressurized Equipment Hazard To reduce the risk of an injury never exceed the maximum working pressure of the low est rated system component Maximum working fluid pressure of this equipment is tien 3000 psi 21 MPa 210 bar 5 Continue to increase the fluid pressure and spray test patterns Do not exceed 3000 psi 21 MPa 210 bar fluid pressure When the particle size remains constant the fluid is being atomized at the lowest possible fluid pressure For improved atomization at lower fluid flow rates change to a smaller tip orifice size 20 6 Turnon the atomization air A2 and adjust the air pressure until the tails disappear See Spray Pattern Troubleshooting on page 32 to cor rect spray pattern problems KV2 SS KV1 TA sal ay CYL ay A2 ES T11739A Fig 12 Manifold Air Connections No Air Too Little Correct Air Amount of Air Fig 13 Eliminating Tails 309298J Operation Adjust the Electrostatics Table 2 Dynamic Turbine Air Pressures 1 Shut off the fluid supply Turbine Air Air pressure at turbine air hose 1 Trigger the gun then turn on the turbine air TA Hose Length inlet for full voltage See FIG 12 ft m psi bar MPa 15 4 6 54 3 8 0 38 2 Refer to Table 2 to set the proper pressure at the turbine air hose inlet when air is flowing Do not 25 7 6 55 3 85 0 38 exceed these pressu
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