Graco Inc 244592, 309298J User Manual

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Instructions/Parts List

AUTOMATIC ELECTROSTATIC AIR-ASSISTED SPRAY GUN

™

PRO

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.

Auto Xs AA

II 2 G EEx 0.24MJ

309298J

ENG

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.

U.S. Patent 7,226,004

TI1713A

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

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death 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.

Caution Symbol

CAUTION

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

ment 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, page 35, 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

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 distribu-

• 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. Maxi-

Warning

tor.

mum 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 Techni- cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warn-

ings.

• 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 regula-

tions.

309298J 5

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-assisted spray gun combines airless and air spraying concepts. The spray tip shapes the fluid into a fan pattern, as does a conventional airless spray tip. Air from the air cap further atomizes the fluid and completes the atomization of the fluid tails to produce a uniform pattern.

The high working fluid pressure of this gun provides the power needed to atomize higher solids materials.

Operating the Spray Function

Applying a minimum of 50 psi (0.35 MPa, 3.5 bar) air pressure to the gun manifold’s cylinder air fitting (CYL) will retract the gun piston, which opens the air valves and a short time later opens the fluid needle. This 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-disconnect design enables its

removal without disconnecting the air lines to the gun.

• Gun functions are activated from a separate control-

ler 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. Battery-operated Display Module 189762 displays the gun’s spraying voltage only.

6 309298J

Changing the kV Setting

Introduction

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.

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

KV1

CYL

KV2

TI1713A

EXH

TI1714A

Manifold Back View

TI1739A

Fig. 1. Gun Overview Key

A Air Cap BSpray Tip C Tip Guard D Retaining Ring E Shroud F Mounting Bracket G Manifold H Turbine J Power 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

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 electrostatic air-assisted spray system, and F

IG. 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

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 F

A Air Hose Ground Wire B Graco Grounded Turbine Air Hose (TA) C Atomizing Air Hose, 3/8 in. (10 mm) OD (A2) E Cylinder Air Hose, 5/32 in. (4 mm) OD (CYL) F Fluid Hose, 1/4-18 npsm gun fluid inlet (P1) G To Fluid Supply H Auto PRO Xs Air-Assisted Spray Gun J Mounting Bracket for 1/2 in. (13 mm) rod K Solenoid Valve, requires quick exhaust port L Bleed-Type Master Air Valve M Air Pressure Regulator N True Earth Ground P 24 Volt Power Supply Q 4-20 microampere Outputs R Full Feature ES Display Module S kV Only ES Display Module (battery operated) T Fiber Optic Y Cable U Bulkhead V Fiber Optic Cable W Main Air Line

IG. 2. and FIG. 3.

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

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

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.

309298J 9

Installation

See * above

NOTE:

* The turbine air supply (TA) must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on.

KV1

Non-Hazardous Area Hazardous Area

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 page 52.

Non-Hazardous Area Hazardous Area

KV2

CYL

TI1741A

Manifold Back View

U**R

V**

85.0 KV

TI1715A

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.

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-type master air valve (L) is required on the pump air line so trapped air will be relieved between the valve and the pump after the valves or regulator are closed.

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-type master air valve (L) on the main air line (W) to shut off all air to the gun (H).

2. Install an air line filter/water separator on the gun air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

3. Install a bleed-type air regulator (M) on each of the air supply lines (B, C, E, X, Y) to control air pressure to the gun.

4. Install a solenoid valve (K) on the cylinder air line (E) to actuate the gun. The solenoid valve must have a quick exhaust port.

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

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 F

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 F

IG. 4..

103

9.24 in (234.7 mm)

Fig. 4. Mounting Bracket

102

2.88 in (73.2 mm)

TI1738A

Nozzle Tip

12 309298J

Installation

Connect the Air and Fluid Lines

FIG. 3. shows a schematic of air and fluid line connections, and F

IG. 5. shows the manifold connections. Con-

nect 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-hand thread to prevent connecting another type of air hose to the turbine air inlet. See Accessories on page 52 for further information about the hose.

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-hand thread) and the solenoid. Connect the air hose ground wire to a true earth ground.

KV2

CYL

KV1

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.

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 F

3., page 10, 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 F

IG. 6..

120

IG.

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 F

IG. 7..

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

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.

Fig. 6. Fiber Optic Fitting

TI1737A

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

14 309298J

Installation

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-Assisted Spray 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.

• 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 con-

ductive 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-see F

IG. 8.) is not approved for use in a hazard-

ous 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).

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.

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.

TI1735A

Fig. 8. Check Gun Grounding

16 309298J

Installation

Check Fluid Resistivity

WARNING

Fire, Explosion, and Electric Shock Hazard

Check the fluid resistivity in a non-hazardous 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-cm and above provide the best electrostatic results.

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 F

IG. 9..

Fig. 9. Fabric Cover

2. Route the exhaust tube (YY) outside the cover. This enables you to monitor the exhaust tube for the presence of any paint or solvent. See Check for Fluid Leakage on page 28. Strap down the exhaust tube to prevent it from moving around.

TI1736A

TI1716A

309298J 17

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.

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-assisted spray 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 page 15.

The condition of the gun’s electrical components has been checked as instructed in Elec- trical Tests on page 29.

Ventilation fans are operating properly.

Workpiece hangers are clean and grounded.

4. Open the pump drain valve and all other drain valves in the system, having a waste container ready to catch the drainage. Triggering the gun to relieve pressure may not be sufficient. Leave the drain valve open until you are ready to spray again

5. Relieve fluid pressure in the fluid supply equipment as instructed in its instruction manual.

6. Close the bleed-type master air valve on the main air supply line to shut off the air. Leave the valve closed until you are ready to spray again.

18 309298J

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.

Operation

Select a Spray Tip

The fluid output and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pressure. Use the Spray Tip Selection Chart, page 51, as a guide for selecting the appropriate spray tip for your application.

Install the Spray Tip

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Proce- dure on page 18, before removing or installing the spray tip, air cap, or tip guard.

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.

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).

01995

40a

Fig. 10. Install Spray Tip

Fig. 11. Install Air Cap Assembly

TI1717A

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 cor- rect spray pattern problems.

KV2

CYL

KV1

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

Air

Fig. 13. Eliminating Tails

TI1739A

Correct

Amount of Air

20 309298J

Adjust the Electrostatics

1. Shut off the fluid supply.

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

IG. 12..

2. Refer to Table 2 to set the proper pressure at the turbine air hose inlet when 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

Hose Length

ft (m)

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 60-70 kV. If a ball end high voltage measurement probe is used, the gun voltage will rise to about 85 kV. This will happen with all resistive electrostatic guns.

Air pressure at turbine air hose

inlet for full voltage

psi (bar, MPa)

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 F

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.

IG. 12..

Triggering the Fluid Alone

1. Shut off and relieve the air pressure to the atomization (A2) air line, using the bleed-type air 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 Proce- dure on page 18 when you stop spraying and whenever you are instructed to relieve the pressure.

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 page 28.

1. Relieve the pressure.

2. Flush and clean the equipment. See Maintenance on page 23.

22 309298J

Maintenance

Daily Care and Cleaning

Maintenance

CAUTION

• Clean all parts with a non-conductive, compatible

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 the gun air passages.

Do not point the gun up while cleaning it. Do not wipe the gun with a cloth that is heavily

Do not immerse the gun in fluid.

TI1742A

saturated; wring out the excess fluid.

TI1734A

309298J 23

02027A

Maintenance

Daily Care and Cleaning, continued

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Proce- dure on page 18 when you stop spraying and whenever you are instructed to relieve the pressure.

• 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, min-

imum. Some applications require more frequent cleaning. Replace the parts if they are damaged. See Clean the Spray Gun, page 26.

• Check the electrode and replace if broken or damaged. See Electrode Replacement on page 39.

• Check for fluid leakage from the gun and fluid hoses. See Check for Fluid Leakage on page 28. Tighten fittings or replace equipment as needed.

• Check all work hangers for fluid buildup; clean if necessary.

• Flush the gun before changing colors and whenever you are done operating the gun.

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

Maintenance

Flush the Spray Gun

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Proce- dure on page 18 when you stop spraying and whenever you are instructed to relieve the pressure.

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.

3. Remove the retaining ring (1), tip guard (3), air cap (40), spray tip (4), and gun shroud (2). See F 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.

IG. 14..

TI1723A

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

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 Proce- dure on page 18 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 cleaning it. See F

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

IG. 15..

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 F

IG. 16..

TI1720A

Fig. 16. Clean Gun Body

6. Remove the bottom fluid tube fitting (P) and fluid filter (20). See F

IG. 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

Maintenance

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

WARNING

Fire, Explosion, and Electric Shock Hazard

TI1725A

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.

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.

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Proce- dure on page 18 when you stop spraying and whenever you are instructed to relieve the pressure.

During operation, periodically check the manifold exhaust tube (YY) and both ends of the gun shroud (ZZ) for the presence of fluid. See F 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.

IG. 18.. Fluid in these

Fig. 18. Check for Fluid Leakage

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.

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see F

IG. 19.) is not approved for use in a haz-

ardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

•The gun has been removed from the haz-

ardous area;

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 156-180 megohms. If outside this range, relieve pressure and remove the air cap (page 37). Inspect the electrode (40a) and the barrel conductive ring (6a) for damage and proper position, to ensure that the electrode makes contact with the conductive ring. Reinstall the air cap and repeat the measurement. If it is still outside this range, remove the gun for service.

40a

TI1739A

•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.

309298J 29

Fig. 19. Test Gun Resistance

TI1733B

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 F

4. The resistance should be 135-150 megohms. 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 Trou- bleshooting on page 34 for other possible causes of poor performance, or contact your Graco distributor.

IG. 20..

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

12b

Fig. 20. Test Power Supply Resistance

ti1599a

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 F The resistance should be 19-29 megohms. If the resistance is incorrect, make sure the metal contact (C) in the barrel and the barrel contact ring (6a) are clean and undamaged.

3. If the resistance is still outside the range, remove the barrel contact ring (6a) and measure the resistance between the conductive rod (B) and the wire lead at the bottom of the contact ring groove.

IG. 21..

Electrical Tests

ti1515b

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.

Fig. 21. Test Barrel Resistance

309298J 31

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.

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Proce- dure on page 18 before doing any maintenance or service on this gun or system.

Check all possible remedies in the Troubleshooting Chart before disassembling the gun.

WARNING

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 gets dirty.

Tails in pattern. Atomization air pressure too low. Increase atomization air pressure.

Fluid buildup on air cap/tip guard. Atomization air pressure too high. Decrease.

Air cap holes plugged. Clean. See page 26.

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 area

Air leaks from the air cap Worn piston stem o-rings (34e, 34f). Replace; see page 42. Fluid leakage from the front of the

gun

Gun does not spray Low fluid supply. Add fluid if necessary.

Paint buildup on air cap Atomization air pressure too high. Reduce.

Air leaks from manifold Manifold is not tight. Tighten manifold screws (106).

Fluid doesn’t shut off properly. Seat housing (5) too tight. Replace; see page 37.

Worn fluid needle packings or shaft. Replace fluid needle assembly (8);

see page 41.

Worn or damaged fluid needle (8). Replace; see page 41

Worn fluid seat housing (5). Replace; see page 37. Loose spray tip (4). Tighten retaining ring (1); see page

37.

Damaged tip seal (4a). Replace; see page 37.

Dirty or clogged spray tip (4). Clean; see page 37. Damaged spray tip (4). Replace; see page 37. Damaged fluid needle (8). Replace; see page 41. Piston (34) not actuating. Check cylinder air. Check piston

u-cup (34d); see page 48. Actuator arm (29) is out of position. Check actuator arm and nuts. See

page 43.

Dirty air cap. Clean; see page 37.

Worn or missing o-rings. Replace o-rings. See page 43.

Fluid buildup on fluid needle (8). Replace needle; see page 41. Piston sticking. Clean or replace o-rings. See page

43.

309298J 33

Troubleshooting

Electrical Troubleshooting

Problem Cause Solution

Poor wrap. Turbine air is not turned on. Turn on.

Booth exhaust velocity is too high. Reduce velocity to within code limits. Atomization air pressure too high. Decrease. Fluid pressure too high. Decrease. Incorrect distance from gun to part. Should be 8-12 in. (200-300 mm). Poorly grounded parts. Resistance must be 1 megohm or

less. Clean workpiece hangers.

Faulty gun resistance. See Test Gun Resistance on page

29. Low fluid resistivity. Check fluid resistivity, page 17. Fluid leaks from the packing (8d) and

causes a short.

Faulty turbine alternator. Be sure the plug is in place on the

The KV switch is stuck on low. Check the switch actuation; replace if

No power. Replace power supply. See page 46.

No voltage or low voltage reading on the gun ES display module

Operator gets mild shock. Operator not grounded or is near

Operator gets shock from workpiece. Workpiece not grounded. Resistance must be 1 megohm or

Damaged fiber optic cable or connection.

Turbine air is not turned on. Turn on. Poor wrap. See causes and solutions under Poor

ungrounded object. Gun not grounded. See Check Electrical Grounding on

Clean the packing rod cavity. Replace the packing rod. See page

41.

back of the turbine alternator housing. Remove and test the turbine alternator. See page 47.

needed.

Check; replace damaged parts.

Wrap, above. See Grounding on page 15.

page 16 and Test Gun Resistance on page 29.

less. Clean workpiece hangers.

34 309298J

Repair

Prepare the Gun for Service

Repair

• Check all possible remedies in Troubleshooting

before disassembling the gun.

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 Proce-

dure on page 18 when you stop spraying,

before servicing the gun, and whenever you

are instructed to relieve the pressure.

• 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-rings and seals with non-silicone

grease. Order Part No. 111265 Lubricant. Do not over-lubricate.

• Only use genuine Graco parts. Do not mix or use

parts from other PRO Gun models.

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 F

22..

IG.

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.

106

112

105

TI1721A

102

Fig. 22. Remove Gun from Manifold

Install the Gun on the Manifold

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.

1. Make sure the gasket (112) and spring (105) are in place on the manifold. See F 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).

IG. 22.. Inspect the

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 F

IG. 23..

3. Remove the seat housing (5) with the tool (37) provided. See F

IG. 24..

TI1723A

Repair

WARNING

Fire, Explosion, and Electric Shock Hazard

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

Fig. 24. Seat Housing Replacement

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 F

IG. 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

Repair

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-nose pliers.

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 F

IG. 25..

5. Install the air cap assembly, page 37.

6. Test gun resistance, page 29.

40a

Fig. 25. Electrode Replacement

02013

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 F

26..

4. Carefully unscrew the top fluid tube nut (D).

IG.

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.

ti1524a

Fig. 26. Fluid Tube Replacement

Fluid Filter Removal

1. Prepare the gun for service, page 35.

2. Remove the air cap assembly, page 37. Remove the shroud (2).

3. Disconnect the bottom fluid tube nut (C).

4. Remove the fluid filter (20). Clean or replace the 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 20-30 in-lb (2.3-3.4 N•m). Make sure the top nut (D) remains tight.

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.

CAUTION

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

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

10. Test gun resistance, page 29.

40 309298J

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.

Fluid Needle Replacement

1. Prepare the gun for service, page 35.

Repair

2. Remove the air cap assembly and seat housing, page 37.

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

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

5. Be sure the seat housing (5) is removed. Place the 2 mm ball end wrench (44) in the back of the fluid needle assembly. Push the tool in and turn it counterclockwise about 12 full turns to unthread the needle.

6. Using the multi-tool (37), pull back on the packing nut (N) to remove the fluid needle assembly. See F

IG. 28..

7. Install the fluid needle assembly in the gun barrel. Push in on the needle with the 2 mm ball end wrench (44) and tighten. See F

8. Install the spring (8a).

IG. 27..

IG. 29..

Fig. 27. Spring Cap and Springs

9. Install the spring cap (45), making sure the grounding 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.

12. Test gun resistance, page 29.

Fig. 28. Fluid Needle Removal

Fig. 29. Fluid Needle Replacement

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).

Table 3: Piston O-Rings

Description Function

Shaft O-Ring

(34g)

Seals cylinder air along the piston rod (34b). Replace if air leaks along rod.

3. Remove the jam nut (28), actuator arm (29), and adjustment nut (30). See F

IG. 30..

34b

TI1732A

Fig. 30. Actuator Arm

4. Push on the piston rod (34b) to push the piston out the back of the gun.

5. Inspect the o-rings (34e, 34f, 34g) and u-cup packing (34d) for damage. See Table 3 and F

IG. 31..

6. Lubricate the o-rings (34e, 34f, 34g) and u-cup packing (34d) with non-silicone grease, Part No.

111265. Do not over-lubricate.

Front O-Ring

(34e)

Back O-Ring

(34f)

U-Cup (34d) Replace if air leaks from small vent hole

Air shutoff seal. Replace if air leaks from air cap when gun is de-triggered.

Separates cylinder air from atomizing air.

at back of manifold when gun is triggered.

34a

34d

34c

34f

34e

TI1575A

34b

34d

34g

34f

7. Align the two stems (34c) with the holes in the gun

34e

body and press the piston assembly into the back of the gun until it bottoms.

8. Install and adjust the actuator arm, page 43.

34g

TI1576A

Fig. 31. Piston O-Rings

42 309298J

Repair

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 F

30. on page 42.

2. Position the parts so there is a 0.125 in. (3 mm) gap between the actuator arm (29) and the fluid packing rod nut (U), which allows the atomizing air to actuate before the fluid. See F

IG. 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 F

IG. 32..

4. Test gun resistance, page 29.

IG.

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

TI1567A

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 F

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

Fig. 33. Barrel Removal

IG. 33..

TI1728A

Fig. 34. Disconnect Fluid Tube

TI1732A

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 F

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).

IG. 35..

CAUTION

Do not over-tighten the screws (10, 33).

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

Fig. 35. Barrel Installation

TI1729A

309298J 45

Repair

Power Supply Removal and Replacement

• Inspect the gun body power supply cavity for dirt or

moisture. Clean with a clean, dry rag.

• Do not expose gasket (11) to solvents.

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). See F

IG. 36..

5. Check the power supply resistance, page 30. Replace if necessary.

Before installing the power supply, make sure the o-rings (12a, 13a), spring (12b), and pads (13e) are in place.

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

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

8. Lubricate the alternator o-ring (13a) with non-silicone grease, Part No. 111265. Do not over-lubricate.

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-pin connector into the socket to ensure it is properly connected.

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

12. Test gun resistance, page 29.

4. Disconnect the 3-wire connector (GG) from the power supply. Slide the alternator up and off the power supply. Inspect the power supply and alternator for damage. Disconnect the 6-pin flexible circuit (23) from the power supply.

46 309298J

Fig. 36. Power Supply

12a

12b

13a

13e

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.

TI1730A

4. Measure resistance between the two outer terminals of the 3-wire connector (GG); it should be

2.5-3.5 ohms. 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

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

12a

12b

13e

13a

40a

34e

34f

34a

34d

34c

34b

19 (Ref)

ti1722

48 309298J

34g

Ref. No. 13: Alternator Detail

13b

13e

13d

13c

13a*

TI1481a

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

Parts

Ref. No.

1 244950 RING, retaining, air cap; includes

1a*† 198307 . U-CUP 1 2 197916 SHROUD 1 3 276767 TIP GUARD 1 4 GG3XXX SPRAY TIP (customer’s choice);

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; 10-24 x 3/4

11*† 197517 GASKET, barrel 1 12 244541 POWER SUPPLY, 85 kV; includes

12a*† 103337 . O-RING; fluoroelastomer 1 12b 197624 . SPRING, compression 1 13 244555 TURBINE, alternator; includes

13a*† 110073 . O-RING; fluoroelastomer 1 13b 223688 . BEARING KIT; includes front

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);

16 180060 SIGN, warning (not shown);

17 239945 COVER, gun; box of 10 (not

19 244713 TUBE, fluid 1

Part No. Description Qty

includes item 4a

in. (19 mm)

12a-12b

13a-13e

and rear bearings and fan

replacement available at no cost

shown)

Ref. 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

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

Part No. Description Qty

list on page 50

* 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

101 (Ref)

112

106 (Ref)

116

102

116a

119

114

110

117

120

5 (see page 49)

101

115

104

103

TI1582A

Ref. No.

113

105

Part No. Description Qty

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; 10-24 x 3/4

in. (19 mm)

107 111157 FITTING, tube 1

108 186845 FITTING, turbine 1

109 110078 FITTING, tube 2

108

106

Ref. No.

107

Part No. Description Qty

110

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.

TI1740A

110 112646 PLUG 1

50 309298J

Spray Tip Selection Chart

Fan Width at

Part No.

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)

10 in. (250 mm)

in. (mm)

Orifice Size

in. (mm)

Fan Width at

Part No.

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)

10 in. (250 mm)

in. (mm)

Orifice Size

in. (mm)

GG3625 12-14 (300-350)

GG3725 14-16 (350-400)

GG3825 16-18 (400-450)

309298J 51

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 Includes tip of choice. 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

AirFlex™ Flexible Grounded Air Hose

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

244963 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)

223074 100 ft (30.5 m)

Bleed-Type Master Air Valve

300 psi (21 bar, 2.1 MPa) Maximum Working Pressure

Relieves air trapped in the air line between this valve and the pump air motor when closed.

107141 3/4 npt

Air Line Shutoff Valve

150 psi (10 bar, 1.0 MPa) Maximum Working Pressure

For turning air to gun on or off.

224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.

Fluid Line Accessories

Nylon Fluid Hose

3000 psi (210 bar, 21 MPa) Maximum Working Pressure

223540 1/4 in. (6 mm) ID x 25 ft (7.6 m), 1/4 npsm 223541 1/4 in. (6 mm) ID x 50 ft (15.2 m), 1/4 npsm

Fluid Shutoff/Drain Valve

5000 psi (350 bar, 35 MPa) Maximum Working Pressure

For turning fluid on or off to the gun and for relieving fluid line pressure at the pump.

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

Standard Grounded Air Hose (Grey)

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

223068 6 ft (1.8 m) 223069 15 ft (4.6 m) 223070 25 ft (7.6 m) 223071 36 ft (11 m) 223072 50 ft (15 m) 223073 75 ft (23 m)

52 309298J

Ground Wire and Clamp 222011 For grounding pump and other components

and equipment in the spray area. 12 gauge, 25 ft (7.6 m).

Megohmmeter 241079 500 Volt output; 0.01-2000 megohms.

Not for use in hazardous areas.

Paint Resistance Meter 722886 Use with 722860 Paint Probe to measure

resistance of paint.

Not for use in hazardous areas.

Accessories

Paint Probe 722860 Use with 722886 Paint Resistance Meter to

measure resistance of paint.

Not for use in hazardous areas.

Safety Warning Signs 180060 English Warning Sign. FM Approved. Avail-

able at no charge from Graco.

ES Display Module 224117 Receives fiber optic transmission from the

PRO Auto Xs gun and displays the gun’s output voltage and current. Mounts in a standard 19 in. DIN rack. See 308265.

Fiber Optic Y Cables

For use with 224117 Display Module only. Connect gun manifold and display module, or bulkhead connector and display module. See 308265.

224682 25 ft (7.6 m) 224684 50 ft (15 m) 224686 100 ft (30.5 m)

Power Supply 235301 Supplies low voltage DC power to 224117

Display Module. See 308265.

Remote Voltage Display 189762 Battery-operated meter 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.

309298J 53

Accessories

54 309298J

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 40-85 kV 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-hand thread 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 1/4-18 npsm(m) Gun Weight 3.52 lb (1.6 kg) Gun Length 12.25 in. (31.1 cm) Wetted Parts Stainless Steel; Nylon, Acetal, Ultra-High Molecular

Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten

Wire, Polyethylene

Loctite® is a registered trademark of the Loctite Corporation.

309298J 55

Graco Standard Warranty

Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months or two thousand hours of operation from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deficiency in the gun barrel, gun body, manifold, mounting bracket, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months or six thousand hours of operation from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco's written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall 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:

1-800-328-0211 Toll Free

612-623-6921

612-378-3505 Fax

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

This manual contains English. MM 309298

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

www.graco.com

Revised 10/2009

Graco Inc 244592, 309298J User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Symbols

Warning Symbol

WARNING

Caution Symbol

Introduction

How the Electrostatic AA Spray Gun Works

Operating the Spray Function

Operating the Electrostatics

Gun Features and Options

Changing the kV Setting

Installation

Install the System

Warning Signs

Ventilate the Spray Booth

Install the Air Line Accessories

Install the Fluid Line Accessories

Install the Gun and Mounting Bracket

Connect the Air and Fluid Lines

Manifold Connections

Optional Fiber Optic Cable Connection

Grounding

Check Electrical Grounding

Check Fluid Resistivity

Check Fluid Viscosity

Install the Fabric Cover

Operation

Pressure Relief Procedure

Operating Checklist

Select a Spray Tip

Install the Spray Tip

Set the Atomization Fluid Pressure

Adjust the Electrostatics

Spraying

Triggering the Fluid Alone

Shutdown

Maintenance

Daily Care and Cleaning

Daily Care and Cleaning, continued

Flush the Spray Gun

Clean the Spray Gun

Check for Fluid Leakage

Electrical Tests

Test Gun Resistance

Test Power Supply Resistance

Test Barrel Resistance

Troubleshooting

Spray Pattern Troubleshooting

Gun Operation Troubleshooting

Electrical Troubleshooting

Repair

Prepare the Gun for Service

Remove the Gun from the Manifold

Install the Gun on the Manifold

Tip Guard, Air Cap, Spray Tip, or Seat Housing Replacement

Electrode Replacement

Fluid Tube Replacement

Fluid Filter Removal

Fluid Needle Replacement

Piston Repair

Adjust the Actuator Arm

Barrel Removal

Barrel Installation

Power Supply Removal and Replacement

Turbine Alternator Removal and Replacement

Parts

Spray Tip Selection Chart

Accessories

Gun Accessories

Air Line Accessories

Fluid Line Accessories

Miscellaneous Accessories

Technical Data

Graco Standard Warranty

Graco Information