Graco Inc UNICARB 308936 User Manual

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INSTRUCTIONS-PARTSLIST

308936

This manual contains important

Rev. B

Supersedes Rev. A

warnings and information.

READ AND KEEP FOR REFERENCE.

First choice when

quality counts.t

 

INSTRUCTIONS

 

85 KV ELECTROSTATIC

Model PRO AA4500t/UNICARBr

Air-AssistedSpray Gun

100 psi (7 bar, 0.7 MPa) Maximum Working Air Pressure

3000 psi (207 bar, 20.7 MPa) Maximum Working Fluid Pressure

For use with Class I, Group D paint spray materials

Part No. 965722, Series B

Spray Gun with basic power supply, 2-fingertrigger

01944A

NOTE: Any modification of genuine Graco parts or replacement of parts withnon-Gracoparts will void agency approvals.

U.S. Patent No. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774; 5,063,350; 5,080,289; 5,289,977

Patented 1986, 1987 Canada

Brevete 1986, 1987

U.K. Patent No. 2,147,158; 2,142,559B; 2,140,327–B

Other U.S. and Foreign Patents Pending

UNICARB IS A REGISTERED TRADEMARK OF UNION CARBIDE, DANBURY CT.

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

ECOPYRIGHT 1999, GRACO INC.

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

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire, explosion, or electric shock.

DElectrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction manual.

DGround the equipment, personnel in or close to the spray area, the object being sprayed, and all

other electrically conductive objects in the spray area. See Ground the System on page 8.

DCheck the spray gun resistance daily. See Test Gun Resistance, page 25.

DIf there is any static sparking while using the equipment, stop spraying immediately. Identify and correct the problem.

DProvide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Interlock the gun turbine air supply to prevent operation of the power supply unless the ventilating fans are on. See

Ventilate the Spray Booth on page 6.

DWhen cleaning, flushing, or purging electrostatic equipment, use solvents that comply with your local regulations. For countries following the U.S. National Fire Protection Association (NFPA) 33

requirements, use solvents with a flash point higher than 100_ F (38_ C) or a solvent normally used in spray operations.For European Countries complying with EN 50053, use solvents with a flash point as high as possible and higher than the ambient temperatures.

DUse only non-sparkingtools to clean residue from the booth and hangers.

DDo not flush the system with the gun electrostatics turned on.

DDo not turn on the gun electrostatics until all solvent is removed from the system.

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

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

DDo not store any flammable fluids in the spray area.

DDo not turn on or off any light switch in the spray area while operating or if fumes are present.

DDo not smoke in the spray area.

DDo not operate a gasoline engine in the spray area.

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.

DKnow the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.

DStore hazardous fluid in an approved container. Dispose of the hazardous fluid according to all local, state, and national guidelines.

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

2308936

WARNING

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 a serious injury.

DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medical attention.

DDo not point the spray gun at anyone or any part of the body.

DDo not put hand or fingers over the spray tip.

DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.

DDo not “blow back” fluid; this is not an air spray system.

DAlways have the tip guard on the spray gun when spraying.

DCheck the gun diffuser operation weekly.

DBe sure the gun trigger safety operates before spraying.

DLock the gun trigger safety when you stop spraying.

DFollow the Pressure Relief Procedure on page 10 whenever you: are instructed to relieve pressure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.

DTighten all the fluid connections before operating the equipment.

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

EQUIPMENT MISUSE HAZARD

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

in a serious injury.

INSTRUCTIONS

D This equipment is for professional use only.

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

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

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

DCheck the equipment daily. Repair or replace worn or damaged parts immediately.

DDo not exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi (7 bar, 0.7 MPa) maximum working air pressure and 3000 psi (207 bar, 20.7 MPa) maximum working fluid pressure.

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

DRoute 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).

DDo not use the hoses to pull equipment.

DWear hearing protection when operating this equipment.

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

308936 3

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installing the System . . . . . . . . . . . . . . . . . . . . . . . . 6

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . 6

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . . . . 6

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . . . . . 7

Ground the System . . . . . . . . . . . . . . . . . . . . . . . . . 8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 10

Gun Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Daily Gun Care, Flushing, and Cleaning . . . . . . . 17

Spray Pattern Troubleshooting . . . . . . . . . . . . . . . . 22

Gun Operation Troubleshooting . . . . . . . . . . . . . . . 23

Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . 24

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . . . 25

Test Power Supply Resistance . . . . . . . . . . . . . . . 26

Test Barrel Resistance . . . . . . . . . . . . . . . . . . . . . . 27

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Prepare the Gun for Service . . . . . . . . . . . . . . . . . 28

Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Pre-Orifice,Tip Guard, Air Cap, Spray Tip,

or Seat Housing Replacement . . . . . . . . . . . . . . 29

Electrode Replacement . . . . . . . . . . . . . . . . . . . . . 30

Fluid Tube Removal & Replacement . . . . . . . . . . 31

Fluid Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . 31

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Fluid Packing Adjustment . . . . . . . . . . . . . . . . . . . 33

Fluid Needle Assembly Removal . . . . . . . . . . . . . 34

Power Supply Removal and Replacement . . . . . 35

Power Supply Adjustment . . . . . . . . . . . . . . . . . . . 35

Turbine Alternator Removal and Replacement . 36

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 36

ES ON-OFFValve Repair . . . . . . . . . . . . . . . . . . . 37

Air Control Valve Repair . . . . . . . . . . . . . . . . . . . . 38

Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . . . 47

Pre-orifice Selection Chart . . . . . . . . . . . . . . . . . . . . 47

The Graco Warranty and Disclaimers . . . . . . . . . . 48

Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . 48

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 corresponding instructions.

4308936

Introduction

How the PRO AA4500/UNICARB

Electrostatic Air-AssistedSpray Gun

Operates

WARNING

Remember, this is not an air spray gun; for your safety be sure to read and follow the Warnings on pages 2 to 3 and throughout the text of this instruction manual.

The spray tip shapes the fluid into a fan pattern.

As the gun is triggered, the regulated air is directed to the power cartridge turbine.

The air control valve does not control pattern width. To change pattern width, a new tip size must be used.

The ability of the PRO AA4500/UNICARB Electrostatic Spray Gun to spray at higher fluid pressures, combined with the addition of CO2 from the UNICARB process, provides the additional power needed to atomize higher solids materials.

The gun’s internal power cartridge provides high voltage current. The fluid is electrostatically charged as it passes the gun’s electrode. The charged fluid is attracted to the grounded object, wrapping around and evenly coating all surfaces.

NOTE: The gun’s air control valve must be completely turned off to haveairless atomization. Closing the air control valve does not effect the operation of the turbine.

Power Supply’s Adjustable Lower Voltage Setting

The gun’s lower voltage setting (LO) is adjustable. The LO setting can be adjusted from 45 to 80 kV; it is preset by the factory at 60 kV. See page 35 to change the setting. NOTE: The gun’s full (HI) voltage setting is 85 kV.

 

 

 

 

 

ES Indicator

 

 

 

 

 

 

Light

Air Control

Tip Guard

 

 

 

 

 

 

 

 

Valve

(orange)

 

 

 

 

 

 

 

 

 

Air

Spray

Retaining

 

ES ON-OFF

 

ES HI-LO

Cap

Tip

Nut

Trigger Safety

 

(black)

(orange)

 

Latch

Lever

 

Lever

 

 

 

 

 

 

 

01944A

 

Back View of Gun

01947

308936 5

Installation

Installing the System

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.

DDo not install or service this equipment unless you are trained and qualified.

DBe sure your installation complies with National, State and Local codes for the installation of electrical apparatus in a Class I, Group D Hazardous Location.

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

Fig. 1 shows a typical electrostatic UNICARB spray system. It is not an actual system design. The particular type and size system for your operation must be custom designed for your needs. For assistance in designing a system, 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. Additional English, French, German, and Spanish signs are available at no charge. See Accessories to order them.

Ventilate the Spray Booth

WARNING

FLAMMABLE OR TOXIC VAPOR HAZARD

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Do not operate the gun unless ventilation fans are operating.

Electrically interlock the gun 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 requirements.

NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufficient.

Air Line Accessories (Refer to Fig. 1)

1.Install an air shut-offvalve ( P) on each gun air supply line (Q) to shut off air to the gun(s).

2.Install an air regulator (N) on the gun air supply line to control air pressure to the gun.

3.Install an air line filter (B) on the air supply line to ensure a dry, clean air supply to the gun. Dirt and moisture can cause the gun to malfunction.

WARNING

COMPONENT RUPTURE HAZARD

To reduce the risk of serious injury due to component rupture, supply pressure must be limited.

The fluid supply system must be prevented from producing a fluid pressure greater than the 3000 psi (207 bar, 20.7 MPa) Maximum Working Pressure of the spray gun.

6308936

Installation

A

B

H

K

L

R

S

R

Y

KEY

A*

Bleed-typeAir Shutoff Valve

N

Gun Air Regulator

B

Air Line Filter

P

Gun Air Shut-offValve

H

Fluid Shutoff Valve

Q*

Graco Electrically Conductive

K

Pressure Gauge

 

Air Supply Hose

L*

Grounded Braid Type Fluid Hose

 

(1/4 npsm x 1/4 npsm LH)

 

with spring guards

R*

Fluid Drain Valve

M

Gun Fluid Inlet (1/4 npsm)

S

Fluid Filter

N W

P

Q

X M

WARNING

SIGN

01945B

WPRO AA4500/UNICARB Spray Gun

XGun Air Inlet (1/4 npsm LH)

YShrouded/Vented Waste Container

*Equipment required for safe operation of system. Must be purchased separately. See ACCESSORIES.

Fig. 1

Fluid Line Accessories (Refer to Fig. 1)

1.Install a fluid filter (S) and drain valve (R) at the pump outlet. Filtering the fluid will help remove coarse particles and sediment that could clog the spray tip.

2.Install a fluid regulator (J) on the fluid line to control fluid pressure to the gun.

WARNING

INJECTION HAZARD

The fluid drain valve (R) is required in your system to assist in relieving fluid pressure in the supply system, hose and

gun; triggering the gun to relieve pressure may not be sufficient. 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.

308936 7

Installation

Ground the System

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

When operating the electrostatic device, any ungrounded objects in the spray area (such as people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock. Follow the grounding instructions below.

The following are minimum requirements for grounding a basic electrostatic system. Your system may include other equipment or objects which must be grounded.

Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground.

1.Pump: ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual.

2.Air compressors and hydraulic power supplies: ground the equipment according to the manufacturer’s recommendations.

3.Electrostatic Spray Gun: ground the gun by connecting the Graco Electrically Conductive Air Hose and connecting the air hose ground wire to a true earth ground. Check the electrical grounding of the gun as instructed on page 12.

4.All air and fluid lines must be properly grounded. Use only grounded hoses with a maximum of 500 feet (150 m) combined hose length to ensure grounding continuity.

5.All electric cables must be properly grounded.

6.All persons entering the spray area: their shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Rubber or plastic soles are not conductive. The operator must not wear gloves that insulate the hand from the spray gun. The gloves must be conductive or modified as shown in Fig. 2, page 9.

7.Object being sprayed: keep the workpiece hangers clean and grounded at all times. Contact points must be sharp points or like knife edges.

8.The floor of the spray area: must be electrically conductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.

9.Flammable liquids in the spray area: must be kept in approved, grounded containers. Do not store more than the quantity needed for one shift.

10.All electrically conductive objects or devices in the spray area: including fluid containers and wash cans, must be properly grounded.

8308936

Operation

Operating Checklist

Check the following list daily, before starting to operate the system, to help ensure safe, efficient operation.

____ 1. All the operators are properly trained to safely operate an electrostatic air-assistedairless spray system as instructed in this manual.

____ 2. All the operators are trained how to properly relieve pressure, using the Pressure Relief Procedure on page 10.

____ 3. The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded. See Ground the System, page 8.

____ 4. The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators.

____ 5. The operator and all persons entering the spray area are properly grounded by wearing shoes with conductive soles or personal grounding straps.

____ 6. The operator is not wearing gloves which insulate the hand from the spray gun. If worn, gloves must be conductive or modified as shown in Fig. 2 so as not to interfere with the operator grounding through the gun.

____ 7. The condition of the electrical components of the spray gun has been checked as instructed in Electrical Tests, page 25.

____ 8. The ventilation fans are operating properly.

____ 9. The workpiece hangers are clean and grounded. Contact points must be sharp points or like knife edges.

____ 10. All the debris, including flammable liquids and rags, is removed from the spray area.

____ 11. All flammable liquids in the spray booth are in approved, grounded containers.

____ 12. All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded.

WARNING

INJECTION HAZARD

Be sure the wallet sized warning card 179960, provided with the gun, is available and easily accessible, at all times,

for anyone operating or servicing this equipment. The card contains important information on what to do if an injection injury occurs. Additional cards are available at no charge from Graco.

3 in. (76 mm) square cut out and finger of glove cut off

NOTE: If gloves are worn, they must be conductive or modified as shown so they do not interfere with operator grounding through the gun.

06445

Fig. 2

308936 9

Operation

Pressure Relief Procedure

WARNING

INJECTION HAZARD

The system pressure must be manually 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 injection, splashing fluid or electric shock, follow the Pressure Relief Procedure whenever you:

Dare instructed to relieve the pressure,

Dstop spraying,

Dcheck or service any of the system equipment,

Dor install or clean the spray tip.

1.Lock the spray gun trigger safety latch. See Fig. 3.

2.Turn the ES ON-OFFlever to OFF.

3.Turn off the fluid supply to the gun.

4.Close the bleed-typemaster air valve (required in system).

5.Close the air valve for the gun air supply line.

6. Unlock the gun trigger safety latch.

Fig. 3

7.Trigger the gun into a grounded, shrouded and vented metal waste container to relieve fluid and air pressure. This may take several minutes.

8.Lock the gun trigger safety latch again.

9.Open the fluid drain valve (required in system) to help relieve fluid pressure. In addition, open the drain valve connected to the fluid pressure gauge (in a system with fluid regulation) to help relieve fluid pressure in the hose and gun. Triggering the gun to relieve pressure may not be sufficient. Have a container ready to catch the drainage.

10.Leave the drain valve(s) open until you are ready to spray again.

11.If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully relieved after following the steps above, very slowly loosen the hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose obstruction.

Trigger Safety

Latch Unlocked

Trigger Safety

Latch Locked

01988A

10 308936