Graco Inc 244592, 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

2

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.

309298J

3

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.

4

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.

309298J

5

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 follow all Warnings in this manual.

The air-assistedspray 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 provides 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 exhaust air helps keep contaminants out and helps keep the gun clean.

Gun Features and Options

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.

The gun’s quick-disconnectdesign enables its removal without disconnecting the air lines to the gun.

Gun functions are activated from a separate controller that sends the appropriate signal to the actuating solenoids.

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 carries 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-operatedDisplay Module 189762 displays the gun’s spraying voltage only.

6

309298J

Changing the kV Setting

The gun’s full voltage setting is 85 kV. Three lower voltage 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.

Introduction

Table 1: KV1 and KV2 Switch Settings

KV1 Air

KV2 Air

Output Voltage (kV)

 

 

 

OFF

OFF

85

 

 

 

OFF

ON

70

 

 

 

ON

OFF

60

 

 

 

ON

ON

45

 

 

 

309298J

7

Introduction

 

G

KV1

 

 

 

TA

 

A

CYL

FO

 

C

 

KV2

 

 

 

 

A2

 

P1

 

 

TI1713A

 

F

H

 

B

 

EXH

E

 

 

J

 

TI1739A

 

 

 

 

TI1714A Manifold Back View

D

K

Fig. 1. Gun Overview

Key

AAir Cap

BSpray Tip

CTip Guard

DRetaining Ring

EShroud

FMounting Bracket

GManifold

HTurbine

JPower Supply

KElectrode

 

Manifold Markings

 

 

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

 

 

8

309298J

Installation

Installation

Install 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.

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

Be sure your installation complies with National, State and Local codes for the installation of electrical apparatus in a Class I, Div. I, Group D or a Group II,

Category 2G Hazardous Location.

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

FIG. 2. shows a typical electrostaticair-assistedspray system, andFIG. 3. shows possible system options. It is not an actual system design. For assistance in designing 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

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 ventilation fans are operating.

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 requirements.

High velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 60 ft/minute (19 linear meters/minute).

Key to FIG. 2. andFIG. 3.

AAir Hose Ground Wire

BGraco Grounded Turbine Air Hose (TA)

CAtomizing Air Hose, 3/8 in. (10 mm) OD (A2)

ECylinder Air Hose, 5/32 in. (4 mm) OD (CYL)

FFluid Hose, 1/4-18npsm gun fluid inlet (P1)

GTo Fluid Supply

HAuto PRO Xs Air-AssistedSpray Gun

JMounting Bracket for 1/2 in. (13 mm) rod

KSolenoid Valve, requires quick exhaust port

LBleed-TypeMaster Air Valve

MAir Pressure Regulator

NTrue Earth Ground

P24 Volt Power Supply

Q4-20microampere Outputs

RFull Feature ES Display Module

SkV Only ES Display Module (battery operated)

TFiber Optic Y Cable

UBulkhead

VFiber Optic Cable

WMain Air Line

X

kV Switch Air Hose, 5/32 in. (4 mm) OD (optional; plug KV1 fitting if not used)

Y

kV Switch Air Hose, 5/32 in. (4 mm) OD (optional; plug KV2 fitting if not used)

309298J

9

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.

 

L

W

See *

 

 

 

 

 

 

above

 

X

Y

B

C

 

 

 

 

 

 

 

 

A

 

 

 

TA

 

 

 

 

K

 

 

 

KV1

 

 

 

 

 

 

 

 

 

 

 

K

 

 

 

 

KV2

 

 

 

 

 

 

 

 

 

 

 

K

 

 

 

CYL

A2

 

 

L

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K

 

 

 

 

 

 

 

 

 

 

 

 

P1

 

 

 

 

 

N

 

 

F

 

 

 

 

 

E

 

 

 

 

 

 

 

 

 

 

 

 

 

M

 

G

 

 

J

 

 

 

 

 

 

 

TI1741A

 

 

Non-HazardousArea

Hazardous Area

 

 

 

 

 

 

 

 

 

Manifold Back View

Fig. 2. Typical Installation

NOTE:

** 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 page52.

Non-HazardousArea

Hazardous Area

P

 

 

R

T

U**

 

 

H

KV

 

 

mA

 

 

Q

 

V**

 

 

85.0 KV

 

 

 

 

TI1715A

S

Fig. 3. Optional Fiber Optic Connection

10

309298J

Install the Air Line

Accessories

WARNING

Component Rupture Hazard

To reduce the risk of serious injury due to 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 producing 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 withstand the maximum working pressure of your system.

1.Install a bleed-typemaster 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 finished workpiece and can cause the gun to malfunction.

3.Install a bleed-typeair 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 (E) to actuate the gun. The solenoid valve must have a quick exhaust port.

5.Install a bleed-typemaster air valve (L) on each pump air line to shut off all air to the pump (H).

Installation

WARNING

Skin Injection Hazard

Trapped air can cause the gun to spray 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-typemaster 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 outlet. Filtering the fluid will help remove coarse particles and sediment that could clog the spray tip.

The gun includes an inline fluid filter (20) for additional filtration.

WARNING

Skin Injection Hazard

The fluid drain valve is required in your system to assist in relieving fluid pressure in

the displacement pump, 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.

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

309298J

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..

 

 

2.88 in

102

NN

(73.2 mm)

 

 

103

 

To

9.24 in

 

TI1738ANozzle

(234.7 mm)

 

Tip

Fig. 4. Mounting Bracket

12

309298J

Connect the Air and Fluid

Lines

FIG. 3. shows a schematic of air and fluid line connections, andFIG. 5. shows the manifold connections. Connect the air and fluid lines as instructed.

WARNING

Electric Shock Hazard

To reduce the risk of electric shock or other serious injury, the air supply hose must be electrically connected to a true earth ground. Use only Graco Grounded Air

Supply Hose.

1.Connect the Graco Grounded Turbine Air Supply Hose (B) to the gun's turbine air inlet (TA) and connect the hose ground wire (A) to a true earth ground

(N). The gun turbine air inlet fitting has a left-handthread to prevent connecting another type of air hose to the turbine air inlet. SeeAccessories on page52 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.

 

 

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 and

 

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-handthread) and the solenoid.

 

Connect the air hose ground wire to a true earth ground.

 

 

KV2

KV1

 

TA

FO

CYL

 

 

A2

P1

 

EXH

TI1739A

Fig. 5. Manifold Connections

309298J

13

Installation

Optional Fiber Optic Cable

Connection

An optional fiber optic fitting is shipped unassembled with the gun. If an ES (kV) display module is used, install the fitting in the FO port of the manifold. See FIG. 3., page10, for a schematic of the fiber optic connections.

1.Remove the plug (120) from the fiber optic port, and install the fiber optic fitting (5, shipped loose with the gun). See FIG. 6..

5

120

TI1737A

Fig. 6. Fiber Optic Fitting

2.Remove the nut (AA) from the fiber optic fitting (5) and slide the nut over the end of the fiber optic cable (BB). See FIG. 7..

3.Push the cable (BB) into the fitting (5) until it bottoms out. Tighten the nut (AA) to secure the cable.

5

BB

AA

TI1581A

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 recommended.

4.See manual 308265 to install a Graco ES Display Module.

14

309298J

Grounding

WARNING

Fire, Explosion, and Electric Shock Hazard

When operating the electrostatic gun, any ungrounded objects in the spray area (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 grounding requirements for 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.

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

Electrostatic Air-AssistedSpray Gun:ground the 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.

Installation

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

All air and fluid lines must be properly grounded.

All electrical cables must be properly grounded.

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.

Object being sprayed: keep the workpiece hangers clean and grounded at all times. Resistance must not exceed 1 megohm.

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.

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

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

309298J

15

Installation

Check Electrical Grounding

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-seeFIG. 8.) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

The gun has been removed from the hazardous area;

Or 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.

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.

3.Turn off the air and fluid supply to the gun.

4.Measure the resistance between the turbine air inlet fitting (TA) and a true earth ground (N).

a.If using 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.

b.If using a red turbine air hose, use an ohmmeter to measure the resistance. The resistance should not exceed 100 ohms.

3.If the resistance is greater than the maximum reading specified above for your hose, check the tightness of the ground connections and be sure the turbine air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the turbine air hose.

N

AA

TA

B

TI1735A

Fig. 8. Check Gun Grounding

16

309298J

Check Fluid Resistivity

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.

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 requirements of an electrostatic air spray system.

Follow the instructions included with the meter and probe. Readings of 25 megohms-cmand above provide the best electrostatic results.

YY

XX

Fig. 9. Fabric Cover

Installation

Check Fluid Viscosity

To check fluid viscosity you will need:

a viscosity cup

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 page28. Strap down the exhaust tube to prevent it from moving around.

YY

TI1736A

TI1716A

309298J

17

Operation

Operation

Pressure Relief Procedure

WARNING

Skin 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 fluid injection, splashing fluid, or electric shock, follow the Pressure Relief Procedure whenever you:

are instructed to relieve the pressure

stop spraying

check or service any of the system equipment

or install or clean the spray tip.

1.Turn off all the air to the spray gun except the cylinder air, which triggers the gun.

2.Turn off the fluid supply to the gun.

3.Trigger the gun into a grounded metal waste container 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-typemaster air valve on the main air supply line to shut off the air. Leave the valve closed until you are ready to spray again.

7.If you suspect that the spray tip or hose is still clogged or that pressure is not 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.

Operating Checklist

Check the following list daily, before operating the system, to help ensure you of safe, efficient operation.

All operators are properly trained to safely operate an automatic electrostatic air-assistedspray system as instructed in this manual.

All operators are trained in the Pressure

Relief Procedure at left.

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 page15.

The condition of the gun’s electrical components has been checked as instructed in Electrical Tests on page29.

Ventilation fans are operating properly.

Workpiece hangers are clean and grounded.

All debris, including flammable fluids and rags, is removed from the spray area.

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.

18

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, page51, as a guide for selecting the appropriate spray tip for your application.

Install the Spray Tip

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Procedure on page18, before removing or installing the spray tip, air cap, or tip guard.

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).

40

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.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, never operate the gun with a damaged electrode.

2

40

3

1a

1

TI1717A

Fig. 11. Install Air Cap Assembly

01995

40a

4

Fig. 10. Install Spray Tip

309298J

19

Operation

Set the Atomization Fluid

Pressure

Atomization fluid pressure will vary based on the viscosity of the fluid, flow rate desired, and other system characteristics.

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 atomization.

6.Turn on the atomization air (A2) and adjust the air pressure until the tails disappear.

See Spray Pattern Troubleshooting on page 32 to correct spray pattern problems.

KV2

KV1

TA

CYL

A2

TI1739A

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, never 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).

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.

Fig. 12. Manifold Air Connections

No Air

Too Little

Correct

 

Air

Amount of Air

Fig. 13. Eliminating Tails

20

309298J

Adjust the Electrostatics

1. Shut off the fluid supply.

1.Trigger the gun, then turn on the turbine air (TA). See FIG. 12..

2.Refer to Table 2 to set the proper pressure at the turbine air hose inletwhen air is flowing. Do not exceed these pressures as there is no added benefit and turbine life could be reduced.

Operation

Table 2: Dynamic Turbine Air Pressures

Turbine Air

Air pressure at turbine air hose

Hose Length

inlet for full voltage

ft (m)

psi (bar, MPa)

 

 

 

15

(4.6)

54 (3.8, 0.38)

 

 

 

25

(7.6)

55 (3.85, 0.38)

 

 

36 (11)

56 (3.9, 0.39)

 

 

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 60-70kV. 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

WARNING

Electric Shock Hazard

To reduce the risk of electric shock, do not touch the gun electrode or come within 4 in. (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 (P1). See FIG. 12..

2.Turn the gun functions off and on by using the air solenoid valves on the cylinder (CYL) and turbine (TA) air supply lines.

3.To change to a lower voltage setting, activate the solenoids controlling the KV1 and KV2 ports. See

Changing the kV Setting on page 7.

WARNING

Fire and Explosion Hazard

If any fluid leakage from the gun is detected, stop spraying immediately. Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage. See Check for Fluid Leakage on page28.

Triggering the Fluid Alone

1.Shut off and relieve the air pressure to the atomization (A2) air line, using the bleed-typeair shutoff valve.

2.Apply 50 psi (3.5 bar, 0.35 MPa) air pressure to the cylinder air fitting (CYL) to trigger the fluid.

Shutdown

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Procedure on page18 when you stop spraying and whenever you are instructed to relieve the pressure.

1.Relieve the pressure.

2.Flush and clean the equipment. See Maintenance on page23.

22

309298J

Maintenance

Maintenance

Daily Care and Cleaning

CAUTION

Clean all parts with anon-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.

 

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

TI1742A

the gun air passages.

 

Do not point the gun up while cleaning it.

Do not wipe the gun with a cloth that is heavily

 

saturated; wring out the excess fluid.

02027A

TI1734A

309298J

23

Maintenance

Daily Care and Cleaning, continued

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Procedure on page18 when you stop spraying and whenever you are instructed to relieve the pressure.

Clean the fluid and air line filters daily.

Clean the outside of the gun daily with a soft cloth dampened in a compatible solvent.

Clean the air cap, spray tip, and tip guard daily, minimum. Some applications require more frequent cleaning. Replace the parts if they are damaged. See Clean the Spray Gun, page26.

Check the electrode and replace if broken or damaged. See Electrode Replacement on page39.

Check for fluid leakage from the gun and fluid hoses. See Check for Fluid Leakage on page28. 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.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, turn off the turbine air (TA) before flushing the gun or any part of the system.

24

309298J

Flush the Spray Gun

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Procedure on page18 when you stop spraying and whenever you are instructed to relieve the pressure.

1. Relieve the pressure.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, turn off the turbine air (TA) before flushing the gun or any part of the system.

2. Be sure the turbine air (TA) is turned off.

Maintenance

3.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.

4.Turn on the solvent supply. Use the lowest possible fluid pressure when flushing.

5.Turn on the cylinder air (CYL) to trigger the gun.

6.Flush the gun, spraying into a grounded metal container until clean solvent comes from the gun.

7.Turn off the solvent supply.

8.Relieve the pressure.

9.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.

2

4a

4

40

TI1723A

3

1a

1

Fig. 14. Remove Spray Tip Before Flushing

309298J

25

Maintenance

Clean the Spray Gun

Equipment Needed

soft bristle brush

compatible solvent

Procedure

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Procedure on page18 when you stop spraying and whenever you are instructed to relieve the pressure.

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 FIG. 15..

If it appears that there is paint inside the air passages, remove the gun from the line for servicing.

TI1719A

02007

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 filter (20). See FIG. 17.. Clean the filter in compatible solvent.

7.Reinstall the filter (20) and fitting (P). Do not overtighten the fitting, and make sure the top fitting (Q) remains tight.

26

309298J

TI1725A

Q

P 20

Fig. 17. Clean the Inline Fluid Filter

8.Clean the retaining ring (1), tip guard (3), air cap (40), and spray tip (4) with a soft brush daily, minimum. Replace any damaged parts. Be careful not to damage the electrode (40a).

CAUTION

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.

Maintenance

9.Wipe off the parts with a dry cloth. Be careful not to damage the electrode.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, never operate the gun with a damaged electrode.

10.Check the electrode (40a). Replace if damaged.

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 (40a) is in place.

13.Test gun resistance, page 29.

309298J

27

Maintenance

Check for Fluid Leakage

WARNING

Fire and Explosion Hazard

If any fluid leakage from the gun is detected, stop spraying immediately. Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage.

YY

ZZ

ZZ

Fig. 18. Check for Fluid Leakage

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Procedure on page18 when you stop spraying and whenever you are instructed to relieve the pressure.

During operation, periodically check the manifold exhaust tube (YY) and both ends of the gun shroud (ZZ) for the presence of fluid. See FIG. 18.. Fluid in these areas indicates leakage into the shroud, which could be caused by leaks at the fluid tube connections or fluid packing leakage.

If fluid is seen in these areas, stop spraying immediately. Relieve the pressure, then remove the gun for repair.

YY

TI1736A

TI1716A

28

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.

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.

Electrical Tests

Test Gun Resistance

1.Flush and dry the fluid passage.

2.Measure resistance between the electrode needle tip (40a) and the turbine air inlet fitting (TA); it should be 156-180megohms. If outside this range, relieve pressure and remove the air cap (page37). 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 measurement. If it is still outside this range, remove the gun for service.

TA

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-seeFIG. 19.) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

The gun has been removed from the hazardous area;

Or 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.

AA

TI1739A

40a

TA

TI1733B

Fig. 19. Test Gun Resistance

309298J

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 135-150megohms. If outside this range, replace the power supply. If in range, proceed to the next test.

5.If you still have problems, refer to Electrical Troubleshooting on page34 for other possible causes of poor performance, or contact your Graco distributor.

6.Be sure the spring (12b) is in place before reinstalling the power supply.

EE

12b

ti1599a

Fig. 20. Test Power Supply Resistance

30

309298J

Test Barrel Resistance

1.Insert a 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.

2.Measure the resistance between the conductive rod

(B)and the barrel contact ring (6a). See FIG. 21.. The resistance should be19-29megohms. 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 resistance between the conductive rod (B) and the wire lead at the bottom of the contact ring groove.

4.If the resistance is in range, replace the contact ring (6a) with a new one. Press the contact ring firmly into the groove on the front of the barrel.

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 without the contact ring in place. Do not replace the contact ring with anything but a genuine Graco part.

5.If the resistance is still outside the range, replace the barrel.

Electrical Tests

C

6a

B

ti1515b

Fig. 21. Test Barrel Resistance

309298J

31

Troubleshooting

Troubleshooting

WARNING

Electric Shock Hazard

Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if

the work is not performed properly. Do not install or repair this equipment unless you are trained and qualified.

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Procedure on page18 before doing any maintenance or service on this gun or system.

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

309298J

Troubleshooting

Gun Operation Troubleshooting

Problem

Cause

Solution

 

 

 

Excessive spray fog.

Atomization 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

Worn fluid needle packings or shaft.

Replace fluid needle assembly (8);

area

 

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

Worn or damaged fluid needle (8).

Replace; see page 41

gun

 

 

 

 

 

 

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 page48.

 

 

 

 

Actuator arm (29) is out of position.

Check actuator arm and nuts. See

 

 

page 43.

 

 

 

Paint buildup on air cap

Atomization air pressure too high.

Reduce.

 

 

 

 

Dirty air cap.

Clean; see page 37.

 

 

 

Air leaks from manifold

Manifold is not tight.

Tighten manifold screws (106).

 

 

 

 

Worn or missing o-rings.

Replace o-rings.See page43.

 

 

 

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 8-12in.(200-300mm).

 

 

 

 

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

Clean the packing rod cavity.

 

causes a short.

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 supply. See page 46.

 

 

 

No voltage or low voltage reading on

Damaged fiber optic cable or connec-

Check; replace damaged parts.

the gun ES display module

tion.

 

 

 

 

 

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

See Grounding on page15.

 

ungrounded object.

 

 

 

 

 

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

309298J

Repair

Prepare the Gun for Service

WARNING

Electric Shock Hazard

Installing and repairing this equipment requires access to parts that may cause electric shock or other serious injury if the

work is not performed properly. Do not install or service this equipment unless you are trained and qualified.

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Procedure on page18 when you stop spraying, before servicing the gun, and whenever you are instructed to relieve the pressure.

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-ring(12a), some fluid needle parts (8), and certain fluid fittings with Part No. 116553 Dielectric Grease, as specified in the text.

Lightly lubricate o-ringsand seals withnon-siliconegrease. Order Part No. 111265 Lubricant. Do notover-lubricate.

Only use genuine Graco parts. Do not mix or use parts from other PRO Gun models.

1.Flush and clean the gun, page 23.

2.Relieve the pressure, page 18.

3.Remove the gun from the manifold, page 36.

4.Remove the gun from the worksite. Repair area must be clean.

309298J

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 loosening 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.

106

112

105

A

TI1721A

102

22

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 manifold. 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).

36

309298J

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) provided. See FIG. 24..

Repair

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 without the contact ring in place. Do not replace the contact ring with anything but a genuine Graco part.

2

4a

4

40

TI1723A

3

1a

1

B

Fig. 23. Tip Guard, Air Cap, and Spray Tip Replacement

37

Fig. 24. Seat Housing Replacement

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.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, never operate the gun with a missing or damaged electrode.

4.Make sure the electrode (40a) is not damaged or missing. See page 39 to install the electrode.

309298J

37

Repair

5.Install the seat housing (5) with the tool (14) provided. Tighten until snug, then 1/4 turn more; do not overtighten. See FIG. 24..

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 careful not to damage the electrode (40a).

7.Slide the shroud (2) onto the gun.

8.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.

9.Test gun resistance, page 29.

10.Install the gun onto the manifold and bracket. See page 36.

38

309298J

Electrode Replacement

WARNING

Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, do not operate the spray gun 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 electrode (40a) out of the back of the air cap, using a needle-nosepliers.

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

CC

BB

02013

Fig. 25. Electrode Replacement

309298J

39

Repair

Fluid Tube Replacement

There are no replaceable parts in the fluid tube assembly. 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).

C

20

E

D

ti1524a

Fig. 26. Fluid Tube Replacement

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 with a wrench. There will be a gap between the nut and barrel. Do not overtighten the nut.

8.Make sure the fluid filter (20) is in place. Tighten the bottom nut (C) onto the fitting (22) and torque to 20-30in-lb(2.3-3.4N•m). Make sure the top nut remains tight.

9.Reinstall the shroud and air cap assembly, page 37.

10.Test gun resistance, page 29.

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 filter, as needed.

Replacement filters are available in 100 mesh (standard) or 60 mesh sizes. See page 52.

5.Install the fluid filter. Tighten the bottom nut (C) onto the fitting (22) and torque to 20-30in-lb(2.3-3.4N•m). Make sure the top nut (D) remains tight.

CAUTION

Be sure the fluid tube (19) is not twisted after tightening the bottom nut (C).

6.Reinstall the shroud and air cap assembly, page 37.

7.Test gun resistance, page 29.

40

309298J

Repair

Fluid Needle Replacement

1. Prepare the gun for service, page 35.

2. Remove the air cap assembly and seat housing,

 

page 37.

8a

 

3.Remove the barrel (6), page 44.

4.Remove the spring cap (45) and the spring (8a) from the barrel. See FIG. 27..

5.

Be sure the seat housing (5) is removed. Place the

Fig. 27. Spring Cap and Springs

 

 

2 mm ball end wrench (44) in the back of the fluid

N

 

needle assembly. Push the tool in and turn it coun-

 

terclockwise about 12 full turns 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..

 

7.

Install the fluid needle assembly in the gun barrel.

37

 

Push in on the needle with the 2 mm ball end

 

 

 

wrench (44) and tighten. See FIG. 29..

 

8.

Install the spring (8a).

 

9.

Install the spring cap (45), making sure the ground-

Fig. 28. Fluid Needle Removal

 

 

ing spring (25) is in place. Tighten until snug. Do

 

 

not overtighten.

 

10.

Install the barrel (6), page 45.

 

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.

Fig. 29. Fluid Needle Replacement

12. Test gun resistance, page 29.

25

45

309298J

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..

TI1732A

28 29 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) andu-cuppacking (34d) for damage. SeeTable 3 andFIG. 31..

6.Lubricate the o-rings(34e, 34f, 34g) andu-cuppacking (34d) withnon-siliconegrease, Part No. 111265. Do notover-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.

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.

 

 

34a

34d

34c

34f

34e

TI1575A

34b

34d 34g

34f

34e

34g

TI1576A

Fig. 31. Piston O-Rings

42

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 thinner profile than the adjustment nut (30). See FIG. 30. on page42.

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. (3 mm) gap has been maintained. See FIG. 32..

4.Test gun resistance, page 29.

Repair

5.Install the gun shroud (2) and air cap, page 37.

6.Install the gun onto the manifold and bracket. See page 36.

0.125 in. (3 mm) gap

U

29

TI1567A

28 30 34b

Fig. 32. Actuator Arm Adjustment

309298J

43

Repair

Barrel Removal

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..

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.

6

6.Hold the gun body (32) with one hand and pull the barrel (6) straight off the body. See FIG. 33..

 

6

 

10

C

32

 

33

TI1728A

Fig. 33. Barrel Removal

32

29

28 30

19 TI1732A

C

Fig. 34. Disconnect Fluid Tube

44

309298J

Repair

Barrel Installation

1.Be sure the gasket (11) and grounding spring (25) are in place. Make sure the air holes are aligned properly. Replace if damaged. See FIG. 35..

2.Place the barrel (6) over the power supply (12) and onto the gun body (32).

3.Tighten the three screws (10, 33) oppositely and evenly (about a half turn past snug).

CAUTION

Do not over-tightenthe screws (10, 33).

11

10

9

25

4.Make sure the fluid filter (20) is in place. Tighten the bottom nut (C) onto the fitting (22) and torque to 20-30in-lb(2.3-3.4N•m). Make sure the top nut (D) remains tight.

5.Install and adjust the actuator arm (29) and jam nut (28). See page 43.

6.Test gun resistance, page 29.

7.Install the gun shroud (2) and air cap, page 37.

8.Install the gun onto the manifold and bracket. See page 36.

32

12

22

29

28

TI1729A

20

D

C

19

 

Fig. 35. Barrel Installation

309298J

45

Repair

Power Supply Removal and

Replacement

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.

Inspect the gun body power supply cavity for dirt or moisture. Clean with a clean, dry rag.

Do not expose gasket (11) to solvents.

1.Prepare gun for service, page 35.

2.Remove the barrel (9), page 44.

CAUTION

Be careful when handling the power supply (12) to avoid damaging it.

3.Grasp the power supply (12) with your hand. With a gentle side to side motion, free the power supply/alternator assembly from the gun body (32), then carefully pull it straight out. Disconnect the flexible circuit (23) from the socket at the top of the body

(32). SeeFIG. 36..

4.Disconnect the 3-wireconnector (GG) from the power supply. Slide the alternator up and off the power supply. Inspect the power supply and alternator for damage. Disconnect the6-pinflexible circuit

(23)from the power supply.

6.Connect the 6-pinflexible circuit (23) to the power supply.

7.Connect the 3-wireconnector (GG). Slide the alternator (13) down onto the power supply (12).

8.Lubricate the alternator o-ring(13a) withnon-sili-cone grease, Part No. 111265. Do notover-lubri-cate.

9.Lubricate the power supply o-ring(12a) with dielectric grease.

10.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-pinconnector into the socket to ensure it is properly connected.

11.Install the barrel (6), page 45.

12.Test gun resistance, page 29.

46

309298J

23

12

 

12a

12b

32

11

 

 

 

 

13a

13

13e

GG

TI1730A

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.Prepare gun for service, page 35.

2.Remove the power supply/alternator assembly, page 46.

3.Disconnect the alternator from the power supply, page 46.

4.Measure resistance between the two outer terminals of the 3-wireconnector (GG); it should be2.5-3.5ohms. If outside this range, replace the alternator coil.

5.Follow the bearing replacement procedure in the bearing kit manual 308034.

6.Install the alternator on the power supply, page 46.

7.Install the power supply/alternator assembly, page 46.

Parts

Parts

Part No. 244592 PRO Auto Xs AA Electrostatic Gun, Series A

 

 

 

 

10

 

 

 

 

 

6

 

 

 

 

5

 

6a

 

 

 

 

 

 

 

 

 

 

4a

 

 

19

 

 

2

 

 

 

 

 

4

 

 

 

 

 

40

 

 

 

 

 

 

3

 

 

 

 

 

 

1a

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

40a

 

 

 

 

 

 

13a

 

 

 

23

13e

13

 

34a

 

 

 

 

 

 

12

 

 

 

 

 

 

12b

 

 

 

34d

 

 

 

 

 

34c

 

 

 

 

 

 

 

 

12a

 

 

 

34f

 

 

 

 

34e

 

 

 

 

 

 

 

 

 

 

11

 

 

 

35

 

 

25

 

 

 

 

27

 

 

 

34b

 

 

26

 

 

 

 

 

 

29

 

 

 

Ref. No. 13: Alternator Detail

13a*

 

 

 

33

 

 

 

 

 

 

 

8

 

45

 

34g

13b

 

 

 

 

 

 

8a

 

 

32

 

 

 

30

 

 

 

 

 

 

 

13b

 

 

 

 

 

 

 

 

 

 

 

22

31

 

TI1481a

 

 

 

 

 

 

28

 

20

 

14

 

 

 

 

 

 

 

 

 

 

37

 

 

 

19 (Ref)

 

 

13e

 

 

 

 

44

 

ti1722

 

 

 

 

 

 

 

 

 

 

13d

13c

 

48

309298J

Parts

Part No. 244592 PRO Auto Xs AA Electrostatic Gun, Series A

Ref.

Part No.

Description

Qty

No.

 

 

 

1

244950

RING, retaining, air cap; includes

1

 

 

1a

 

1a*†

198307

. U-CUP

1

2

197916

SHROUD

1

3

276767

TIP GUARD

1

4

GG3XXX

SPRAY TIP (customer’s choice);

1

 

 

includes item 4a

 

4a

183459

. SEAL, spray tip

1

5

245280

HOUSING, seat

1

6

244531

BARREL, gun; includes item 6a

1

6a

197486

. O-RING;conductive

1

8

244714

NEEDLE, fluid; includes item 8a

1

8a

112691

. SPRING, compression

1

10

197518

SCREW; socket-hd;10-24x 3/4

1

 

 

in. (19 mm)

 

11*†

197517

GASKET, barrel

1

12

244541

POWER SUPPLY, 85 kV; includes

1

 

 

12a-12b

 

12a*†

103337

. O-RING;fluoroelastomer

1

12b

197624

. SPRING, compression

1

13

244555

TURBINE, alternator; includes

1

 

 

13a-13e

 

13a*†

110073

. O-RING;fluoroelastomer

1

13b

223688

. BEARING KIT; includes front

1

 

 

and rear bearings and fan

 

13c

244577

. COIL

1

13d

111745

. RING, retaining

1

13e

198821

. PAD, pressure

2

14

107460

WRENCH, ball end; 4 mm

1

15

179791

TAG, warning (not shown);

1

 

 

replacement available at no cost

 

16

180060

SIGN, warning (not shown);

1

 

 

replacement available at no cost

 

17

239945

COVER, gun; box of 10 (not

1

 

 

shown)

 

19

244713

TUBE, fluid

1

Ref.

Part No.

Description

Qty

No.

 

 

 

20

205264

FILTER, fluid, inline

1

22

189366

FITTING, fluid

1

23

245265

CIRCUIT, flexible

1

25

197624

SPRING, grounding

1

26

189367

CAP, exhaust

1

27

185122

MUFFLER

1

28

101324

NUT, jam, hex

1

29

197919

ARM, actuator

1

30

102025

NUT, hex

1

31

112689

SCREW, button-hd

1

32

245662

BODY, gun

1

33

116575

SCREW, cap, socket-hd

2

34

244702

PISTON; includes 34a-34g

1

34a

197920

. PISTON

1

34b

189754

. ROD, piston

1

34c

189355

. STEM, piston

2

34d†

189752

. PACKING, u-cup

1

34e†

111504

. O-RING

2

34f†

112319

. O-RING

2

34g†

111508

. O-RING

1

35

244843

MANIFOLD; see separate parts

1

 

 

list on page 50

 

37

276741

MULTI-TOOL

1

39

198486

CONNECTOR, tube

1

40

245276

AIR CAP; includes 40a

1

40a

244917

. ELECTRODE (kit of 5)

1

44

112080

TOOL, needle; 2 mm

1

45

198516

CAP, spring

 

* Recommended spare parts. Keep on hand to reduce downtime.

Replacement Warning labels, signs, tags, and cards are available at no cost.

† Included in repair kit 15D592.

309298J

49

Parts

Part No. 244843 Manifold, Series A, for standard and high conductivity coatings

5 (see page 49)

101 (Ref)

106 (Ref)

112

 

 

 

 

 

 

101

 

116

117

120

 

 

 

 

116a

 

 

 

119

 

 

 

114

 

 

 

110

115

 

 

 

 

102

 

 

 

104

108

 

 

 

 

113

103

106

 

105

 

TI1740A

 

 

 

 

TI1582A

 

 

107

110

Ref.

Part No.

Description

Qty

No.

 

 

 

101

198220

MANIFOLD

1

102

189581

BRACKET, reciprocator

1

103

110465

SCREW, set

2

104

112689

SCREW, button-hd

2

105

112640

SPRING, compression

1

106

197518

SCREW; socket-hd;10-24x 3/4

3

 

 

in. (19 mm)

 

107

111157

FITTING, tube

1

108

186845

FITTING, turbine

1

109

110078

FITTING, tube

2

110

112646

PLUG

1

Ref.

Part No.

Description

Qty

No.

 

 

 

112†

197925

GASKET, manifold

1

113

108290

SCREW, machine

2

114

189365

CAP, kV, HI/LO

2

115

198764

RESTRICTOR

1

116

244772

PISTON; includes 116a

2

116a†

112085

. O-RING

1

117

114263

FITTING, connector

3

119

116621

SPRING, compression

2

120

112645

PLUG

1

† Included in repair kit 15D592.

50

309298J

Spray Tip Selection Chart

Spray Tip Selection Chart

 

Fan Width at

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)

 

 

 

 

 

Fan Width at

Orifice Size

Part No.

10 in. (250 mm)

in. (mm)

 

in. (mm)

 

 

 

 

 

GG3217

4-6(100-150)

0.017 (0.432)

 

 

 

GG3317

6-8(150-200)

 

 

 

 

GG3417

8-10(200-250)

 

 

 

 

GG3517

10-12(250-300)

 

 

 

 

GG3617

12-14(300-350)

 

 

 

 

GG3319

6-8(150-200)

0.019 (0.483)

 

 

 

GG3419

8-10(200-250)

 

 

 

 

GG3519

10-12(250-300)

 

 

 

 

GG3619

12-14(300-350)

 

 

 

 

GG3719

14-16(350-400)

 

 

 

 

GG3421

8-10(200-250)

0.021 (0.533)

 

 

 

GG3521

10-12(250-300)

 

 

 

 

GG3621

12-14(300-350)

 

 

 

 

GG3721

14-16(350-400)

 

 

 

 

GG3821

16-18(400-450)

 

 

 

 

GG3423

8-10(200-250)

0.023 (0.584)

 

 

 

GG3523

10-12(250-300)

 

 

 

 

GG3623

12-14(300-350)

 

 

 

 

GG3723

14-16(350-400)

 

 

 

 

GG3823

16-18(400-450)

 

 

 

 

GG3425

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)

 

 

 

 

309298J

51

Includes tip of choice.

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.

Alternator Bearing Kit

223688 To repair the turbine alternator.

Cleaning Brush

105749 For cleaning air cap and fluid nozzle.

Air Line Accessories

AirFlexFlexible 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-handthread

244963

6 ft (1.8 m)

244964

15 ft (4.6 m)

244965

25 ft (7.6 m)

244966

36 ft (11 m)

244967

50 ft (15 m)

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-handthread

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)

223074 100 ft (30.5 m)

Bleed-TypeMaster 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-handthread.

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 npsm223541 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.

210657 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;0.01-2000megohms.

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.

52

309298J

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. Available 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.

Accessories

Remote Voltage Display

189762 Battery-operatedmeter displays actual spraying voltage. remote mount outside hazardous area. Connects to gun via fiber optic cable. See 308265.

Fiber Optic Cables

Connect gun manifold and remote display, bulkhead connector and remote display, or gun manifold and bulkhead connector. See 308265.

224672

25 ft (7.6 m)

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

50 ft (15 m)

236921

100 ft (30.5 m)

Bulkhead Connector

189870 For connecting two fiber optic cables.

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53

Accessories

54

309298J

Technical Data

Technical Data

Category

Data

Maximum Working Fluid Pressure

3000 psi (21 MPa, 210 bar)

Maximum Working Air Pressure

100 psi (0.7 MPa, 7 bar)

Maximum Fluid Operating Temperature

120°F (48°C)

Paint Resistivity Range

3 megohm/cm to infinity

Short Circuit Current Output

125 microamperes

Voltage Output

40-85kV

Sound Power (measured per ISO Standard 9216)

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)

Sound Pressure (measured 1 m from gun)

at 40 psi (0.28 MPa, 2.8 bar): 87 dB(A)

 

at 100 psi (0.7 MPa, 7 bar): 99 dB(A)

Turbine air inlet fitting, left-handthread

1/4 npsm(m)

Atomizing air inlet fitting

3/8 in. OD nylon tube

Cylinder air inlet fitting

5/32 in. OD nylon tube

Hi/Lo voltage selector air inlet fittings

5/32 in. OD nylon tube

Fluid inlet fitting

1/4-18npsm(m)

Gun Weight

3.52 lb (1.6 kg)

Gun Length

12.25 in. (31.1 cm)

Wetted Parts

Stainless Steel; Nylon, Acetal, Ultra-HighMolecular

 

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-sixmonths 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-Gracocomponent parts. Nor shall 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 of 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 rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:

1-800-328-0211Toll Free

612-623-6921

612-378-3505Fax

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