Graco Inc 309298J User Manual
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Instructions/Parts List

AUTOMATIC ELECTROSTATIC AIR-ASSISTEDSPRAY GUN

PROAuto Xs AA

309298J

ENG

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. I hazardous locations using Group D spray materials.

#53

For use in Group II, Zone 1 areas using Group IIA spray materials.

II 2 G EEx 0.24MJ

For Professional Use ONLY.

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

See page 2 for Table of Contents.

TI1713A

U.S. Patent 7,226,004

Table of Contents

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . .

3

Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 9

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 9

Install the Air Line Accessories . . . . . . . . . . . . . 11

Install the Fluid Line Accessories . . . . . . . . . . . 11

Install the Gun and Mounting Bracket . . . . . . . . 12

Connect the Air and Fluid Lines . . . . . . . . . . . . 13

Manifold Connections . . . . . . . . . . . . . . . . . . . . 13

Optional Fiber Optic Cable Connection . . . . . . . 14

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Check Electrical Grounding . . . . . . . . . . . . . . . . 16

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 17

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 17

Install the Fabric Cover . . . . . . . . . . . . . . . . . . . 17

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pressure Relief Procedure . . . . . . . . . . . . . . . . 18

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 18

Select a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . 19

Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . 19

Set the Atomization Fluid Pressure . . . . . . . . . . 20

Adjust the Electrostatics . . . . . . . . . . . . . . . . . . 21

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Triggering the Fluid Alone . . . . . . . . . . . . . . . . . 22

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 23 Daily Care and Cleaning, continued . . . . . . . . . 24 Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . 25 Clean the Spray Gun . . . . . . . . . . . . . . . . . . . . . 26 Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 28

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 29 Test Power Supply Resistance . . . . . . . . . . . . . 30 Test Barrel Resistance . . . . . . . . . . . . . . . . . . . . 31

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Spray Pattern Troubleshooting . . . . . . . . . . . . . 32 Gun Operation Troubleshooting . . . . . . . . . . . . . 33 Electrical Troubleshooting . . . . . . . . . . . . . . . . . 34

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . 37 Electrode Replacement . . . . . . . . . . . . . . . . . . . 39 Fluid Tube Replacement . . . . . . . . . . . . . . . . . . 40 Fluid Filter Removal . . . . . . . . . . . . . . . . . . . . . . 40 Fluid Needle Replacement . . . . . . . . . . . . . . . . 41 Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . 43 Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 44 Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 45 Power Supply Removal and Replacement . . . . 46 Turbine Alternator Removal and Replacement . 47

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . 51 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 52 Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 52 Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 52 Miscellaneous Accessories . . . . . . . . . . . . . . . . 52

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 56

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309298J

Symbols

Symbols

Warning Symbol

Caution Symbol

WARNING

CAUTION

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

WARNING

Fire, Explosion, and Electric Shock Hazard

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements of this manual.

Ground equipment, personnel, object being sprayed, and conductive objects in work area. See Grounding instructions.

Only use grounded Graco conductive air supply hoses.

Check gun and hose resistance and electrical grounding daily.

Use and clean equipment only in well ventilated area.

Interlock the gun air supply to prevent operation unless ventilating fans are on.

Use cleaning solvents with highest possible flash point when flushing or cleaning equipment.

Always turn the electrostatics off when flushing, cleaning or servicing equipment.

If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

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

Keep a working fire extinguisher in the work area.

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Warning

WARNING

Skin Injection Hazard

Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause serious injury.

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.

Never spray without the tip guard in place.

Follow the steps under Prepare the Gun for Service, page35, when you stop spraying and before cleaning, checking, or repairing equipment.

Check the hoses and couplings daily. Replace worn, damaged, or loose parts immediately. Permanently coupled hoses cannot be repaired; replace the entire hose.

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.

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 the hazardous fluid according to all local, state, and national guidelines.

Wear appropriate protective clothing, gloves, eyewear, and respirator.

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309298J

Warning

WARNING

Equipment Misuse Hazard

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in a serious injury.

This equipment is for professional use only.

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

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

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

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. Maximum working fluid pressure of this equipment is 3000 psi (21 MPa, 210 bar).

Use fluids and solvents that are compatible with the equipment wetted parts. See the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

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).

Wear hearing protection when operating this equipment.

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

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