Graco Inc 224400, 308131, 224200 User Manual

INSTRUCTIONS-PARTS LIST

308131

This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.

INSTRUCTIONS

Model PRO 4500sc
Electrostatic Air Spray Gun

85 kV, MANUAL GUN

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

For use with Class I, Group D paint spray materials

Part No. 224200, Series B
Air Spray Gun with two-finger trigger

With 0.059 in. (1.5 mm) spray nozzle

Part No. 224400, Series B
Air Spray Gun with four-finger trigger

With 0.059 in. (1.5 mm) spray nozzle

Rev. R

Part No. 224200 shown

NOTE: Any modification of genuine Graco parts or replacement of parts with non-Graco parts 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; D350,387
Patented 1986, 1987 Canada
Brevete 1986, 1987
U.K. PATENT NO. 2,147,158; 2,142,559B; 2,140,327B; 2,245,197B
Other U.S. and Foreign Patents Pending

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

COPYRIGHT 1991, GRACO INC.

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

0365

2 308131

Table of Contents

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

Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Installing the System 7. . . . . . . . . . . . . . . . . . . . . . . .

Warning Signs 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilate the Spray Booth 7. . . . . . . . . . . . . . . . . . . .

Connect the Air Line 7. . . . . . . . . . . . . . . . . . . . . . . .

Connect the Exhaust Tube 8. . . . . . . . . . . . . . . . . . .

Connect the Fluid Line 8. . . . . . . . . . . . . . . . . . . . . . .

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

Check the Electrical Grounding 9. . . . . . . . . . . . . . .

Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Relief Procedure 11. . . . . . . . . . . . . . . . . .

Filter the Fluid 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Checklist 11. . . . . . . . . . . . . . . . . . . . . . . .

Selecting a Fluid Nozzle and Air Cap 12. . . . . . . . .

Operating the Spray Gun 12. . . . . . . . . . . . . . . . . . .

Shutdown 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Care and Cleaning 14. . . . . . . . . . . . . . . . . . . .

Clean the Air Cap and Fluid Nozzle 15. . . . . . . . . .

Flush the Spray Gun 15. . . . . . . . . . . . . . . . . . . . . . .

Electrode Needle Replacement 23. . . . . . . . . . . . . .

Barrel Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Packing Removal 25. . . . . . . . . . . . . . . . . . . . .

Fluid Packing Rod Repair 26. . . . . . . . . . . . . . . . . . .

Power Supply Removal and Replacement 27. . . . .

Power Supply Adjustment 27. . . . . . . . . . . . . . . . . . .

Turbine Alternator Removal and Replacement 28.

Barrel Installation 28. . . . . . . . . . . . . . . . . . . . . . . . . .

Fan Air Adjustment Valve Repair 29. . . . . . . . . . . . .

Fluid Adjustment Assembly Repair 30. . . . . . . . . . .

Air Trigger Valve Repair 31. . . . . . . . . . . . . . . . . . . .

Atomizing Air Valve Removal and Replacement 31

ES ON-OFF Valve Repair 32. . . . . . . . . . . . . . . . . . .

Parts 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Graco Warranty and Disclaimers 40. . . . . . . . . .

Graco Phone Number 40. . . . . . . . . . . . . . . . . . . . . . . .

Symbols

Troubleshooting 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spray Pattern Troubleshooting 16. . . . . . . . . . . . . . .

Gun Operation Troubleshooting 17. . . . . . . . . . . . . .

Electrical Troubleshooting 18. . . . . . . . . . . . . . . . . . .

Electrical Troubleshooting with SVR 19. . . . . . . . . .

Electrical Tests 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Gun Resistance 20. . . . . . . . . . . . . . . . . . . . . . .

Test Power Supply Resistance 21. . . . . . . . . . . . . . .

Test Resistor Stud Resistance 21. . . . . . . . . . . . . . .

Service 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Gun for Service 22. . . . . . . . . . . . . . . . .

Air Cap/Nozzle/Resistor Stud Replacement 22. . .

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.

308131 3

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.

 Electrostatic equipment must be used only by trained, qualified personnel who understand the

requirements stated in this instruction manual.

 Ground 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.

 Check the spray gun resistance daily. See Test Gun Resistance, page 20.
 If there is any static sparking while using the equipment, stop spraying immediately. Identify and

correct the problem.

 Provide 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 7.

 When flushing or purging electrostatic equipment, use solvents with a flash point equal to or

greater than that of the fluid being sprayed.

 To clean the exterior of the electrostatic equipment, use solvents with a flash point higher than

100F (38C).

 Use only non-sparking tools to clean residue from the booth and hangers.
 Do not flush the system with the gun electrostatics turned on.
 Do not turn on the gun electrostatics until all solvent is removed from the system.
 Extinguish all open flames or pilot lights in the spray area.
 Keep the spray area free of debris, including solvent, rags, and gasoline.
 Do not store any flammable fluids in the spray area.
 Do not turn on or off any light switch in the spray area while operating or if fumes are present.
 Do not smoke in the spray area.
 Do not operate a gasoline engine in the spray area.

TOXIC FLUID HAZARD

Hazardous fluids or toxic fumes can cause 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 308131

INSTRUCTIONS

WARNING

PRESSURIZED EQUIPMENT HAZARD

Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin
and cause serious injury.

 Do not point the spray gun at anyone or any part of the body.
 Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
 Follow the Pressure Relief Procedure on page 11 whenever you: are instructed to relieve the

pressure; stop spraying; clean, check, or service the equipment; and install or clean the fluid
nozzle.

 Tighten all the fluid connections before operating the equipment.
 Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.

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

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 the instruction manuals, tags, and labels before operating the equipment.
 Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco

distributor.

 Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
 Check the equipment daily. Repair or replace worn or damaged parts immediately.
 Do not exceed the maximum working pressure of the lowest rated system component. This equip-

ment has a 100 psi (7 bar, 0.7 MPa) maximum working air and fluid pressure.

 Use 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.

 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).

 Do not use the hoses to pull equipment.
 Wear hearing protection when operating this equipment.
 Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

308131 5

Installation

B* C*

O

A

M

ES ON-OFF Lever
1 is ON 0 is OFF

N

H

S

D

*E

GF

J*

V

G

L

K

P

R*

X

W

U*

WARNING

SIGN

Non-Hazardous Area Hazardous Area

The air supply to the gun must be electrically interlocked with the ventilators to
prevent the power supply from operating without ventilating fans on.

KEY

A Main Air Supply Line
B* Ventilation Fan Interlock Solenoid Valve
C* Main Air Supply Shutoff Valve (bleed-type)
D Air & Water Separator
E* Pump Air Supply Shutoff Valve

(bleed-type)

F Air Line Lubricator
G Air Pressure Regulator
H Pump
J* Pump Ground Wire

Fig. 1

K Fluid Filter
L Fluid Supply Line Shutoff V alve
M Fluid Pressure Regulator
N Fluid Supply Line
O Air Filter (20 micron)
P Air Supply Line

Shutoff Valve

Q* Air Hose Ground Wire
R* Graco Electrically Conductive Air Hose
S Electrostatic Spray Gun

Q*

T

0389

T Air Line Drain Valve
U* Fluid Drain Valve
V Gun Air Inlet
W Gun Fluid Inlet
X Gun Exhaust Tube

* Required for safe operation. Must pur-

chase separately. See Accessories.
NOTE: Solenoid Valve (B) is not offered
as a Graco accessory.

6 308131

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.

 Do not install or service this equip-

ment 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, Group D
Hazardous Location.

 Comply with all applicable local, state, and

national fire, electrical, and other safety regula­tions.

Fig. 1 shows a typical electrostatic air 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

NOTE: High velocity air exhaust will decrease the op-

erating efficiency of the electrostatic system. Air ex­haust velocity of 100 ft/min (31 linear meters/minute)
should be sufficient.

Connect the Air Line (Refer to Fig. 1)

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 Electrically Con-

ductive Air Supply Hose.

1. Connect the Graco Electrically Conductive Air
Supply Hose (R) between the air supply line and
the gun’s air inlet (V). The gun air inlet fitting has a
left hand thread. Connect the air supply hose
ground wire to a true earth ground.

2. Install an air line filter (O) and an air and water
separator (D) on the 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-type air regulator (G) on the pump
and gun air supply lines to control air pressure to
the pump and gun.

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.

4. Install a bleed-type air shutoff valve on the main air
line (C) and the pump air line (E) to shut off air to
the pump. Install an additional bleed-type valve on
each pump air supply line to relieve air trapped
between this valve and the pump after the air
regulator is shut off.

WARNING

PRESSURIZED EQUIPMENT HAZARD

The bleed-type air shutoff valve is required in your
system to relieve air trapped between this valve
and the pump after the air regulator is closed.
Trapped air can cause the pump to cycle unexpect­edly, which could result in serious injury, including
splashing in the eyes or on the skin.

5. Install an air line lubricator (F) as close to the
pump (H) as possible.

6. Install an air shutoff valve ( P) on each gun air
supply line to shut off air to the gun(s).

308131 7

Installation

Connect the Exhaust Tube

Press the exhaust tube (provided) onto the barbed
adapter on the bottom of the gun handle. Secure the
tube with the clamp provided. Refer to page 34.

Connect the Fluid Line (Refer to Fig. 1, page 6)

1. Before connecting the fluid line (N), blow it out with
air and flush it with solvent. Use solvent which is
compatible with the fluid to be sprayed.

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

3. Install a fluid filter (K) and drain valve (U) at the
pump outlet.

WARNING

PRESSURIZED EQUIPMENT HAZARD

The fluid drain valve (U) 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 splashing in the eyes or on the skin.

4. Connect the fluid line to the 3/8–18.6(m) gun fluid
inlet (W).

5. Before running any paint through the spray gun,
flush it out with a compatible solvent.

Ground the System

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.

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 Air 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 9.

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. 3, page 11.

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

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.

8 308131

WARNING

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.

Installation

Check the Electrical Grounding (See Fig. 2)

WARNING

FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD

Megohmmeter P/N 241079 (AA-see Fig.

2) 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, electric shock and result in serious injury
and property damage.

a. If using a black or grey air hose, use a me-

gohmmeter (AA) to measure the resistance.
Use an applied voltage of 500 minimum to
1000 volts maximum. The resistance should
not exceed 2 megohms.

b. If using a red turbine air hose, use an ohmme-

ter to measure the resistance. Resistance
should not exceed 100 ohms.

6. 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 air hose ground wire is connected to a true
earth ground. If the resistance is still too high,
replace the air hose.

R

BB

1. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.

2. Turn the ES ON-OFF Lever to OFF. See Fig. 4,
page 12, for the location of the lever.

3. Turn off the air and fluid supply to the gun. The
fluid hose must not have any fluid in it.

4. Make sure the air hose (R) is connected and the
hose ground wire is connected to a true earth
ground.

5. Measure the resistance between the gun handle
(BB) and a true earth ground (CC).

AA

CC

0368B

Fig. 2

308131 9

Notes

10 308131

Operation

Pressure Relief Procedure

WARNING

PRESSURIZED EQUIPMENT HAZARD

The system pressure must be manually relieved to
prevent the system from starting or spraying acci­dentally. To reduce the risk of an injury from electric
shock, accidental spray from the gun, splashing
fluid, or moving parts, 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 fluid nozzle.

1. Turn the ES ON–OFF Lever to OFF.

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

3. Trigger the gun into a grounded metal waste
container to relieve fluid pressure.

4. Open the pump drain valve, having a waste con­tainer ready to catch the drainage.

5. Leave the pump drain valve open until you are
ready to spray again.

Filter the Fluid

Filter the fluid to remove coarse particles and sediment
which could clog the spray nozzle.

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 spray
system as instructed in this manual.

____ 2. All the operators are trained how to properly

relieve pressure as instructed at left.

____ 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 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. 3 so as not to interfere with
the operator grounding through the gun.

____ 5. The condition of the electrical components of

the spray gun has been checked as
instructed in Electrical Tests, page 20.



 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.

Fig. 3

06445

____ 6. The ventilation fans are operating properly.

____ 7. The workpiece hangers are clean and

grounded. Contact points must be sharp
points or like knife edges.

____ 8. All the debris, including flammable liquids

and rags, is removed from the spray area.

____ 9. All flammable liquids in the spray booth are

in approved, grounded containers.

____ 10. All conductive objects in the spray area are

electrically grounded and the floor of the
spray area is electrically conductive and
grounded.

308131 11

Operation

26

0365

45

43c

DD

43g

31

1

20

Fig. 4

Selecting a Fluid Nozzle and Air Cap

WARNING

PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury, follow the Pressure
Relief Procedure on page 11 before removing or

installing a fluid nozzle and/or air cap.

The gun is supplied with a 0.059 in. (1.5 mm) fluid
nozzle, P/N 185158, and air cap, P/N 193033. If your
application requires a different nozzle and air cap
combination, use instruction manual 307803 or consult
your authorized Graco distributor to select the ap­propriate fluid nozzle and air cap. Install the air cap
and fluid nozzle into the gun barrel as instructed in Air
Cap/Nozzle/Resistor Stud Replacement, page 22.

0369A

Operating the Spray Gun

WARNING

PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury, follow the Pressure
Relief Procedure on page 11 whenever you stop

spraying and whenever you are instructed to
relieve pressure.

WARNING

COMPONENT RUPTURE HAZARD

To reduce the risk of component rupture,
which can cause serious injury, do 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 and fluid pressure.

12 308131

Follow the steps on page 13 to establish the correct
fluid flow and air flow. Do not turn the ES ON-OFF
lever to ON yet.