Graco 244399, 309291P User Manual

Instructions - Parts List

MANUAL ELECTROSTATIC

PRO™ Xs2 Air Spray Gun

For use in Class I, Div. I hazardous locations using Group D spray materials.

#53

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

II 2 G EEx 0.24 mJ

For Professional Use ONLY.

309291P

ENG

Important Safety Instructions:

Read all warnings and instructions in this manual. Save these instructions.

See page for 2 Table of Conte nts and List of Models.

Part No. 244399, Series C

See page 2 for Model 244399 information.

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

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

US Patents 6758424 and 7,226,004

U.S. Patents 6758424 and 7,226,004

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Table of Contents

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

How the Electrostatic Spray Gun Works . . . . . . . 5

Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 6

Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Connect the Air Line . . . . . . . . . . . . . . . . . . . . . . 8

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

Select a Fluid Nozzle and Air Cap . . . . . . . . . . . 9

Connect the Fluid Line . . . . . . . . . . . . . . . . . . . 10

Filter the Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Check Electrical Grounding . . . . . . . . . . . . . . . . 12

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 13

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 13

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 17

Test Power Supply Resistance . . . . . . . . . . . . . 18

Test Electrode Resistance . . . . . . . . . . . . . . . . . 19

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Spray Pattern Troubleshooting . . . . . . . . . . . . . 20

Gun Operation Troubleshooting . . . . . . . . . . . . 21

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 22

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Pressure Relief Procedure . . . . . . . . . . . . . . . . 23

Prepare the Gun for Service . . . . . . . . . . . . . . . 24

Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 25

Electrode Replacement . . . . . . . . . . . . . . . . . . . 26

Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 27

Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 28

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 29

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 29

Power Supply Removal and Replacement . . . . 30

Turbine Alternator Removal and Replacement . 31

Fan Air Adjustment Valve Repair . . . . . . . . . . . . 32

Fluid Adjustment Valve Repair . . . . . . . . . . . . . 33

Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . 33

Atomizing Air Restrictor Valve Removal and

Replacement . . . . . . . . . . . . . . . . . . . . . . . . 34

ES ON/OFF Valve Repair . . . . . . . . . . . . . . . . . 35

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 39

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 39

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 39

Miscellaneous Accessories . . . . . . . . . . . . . . . . 40

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

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 42

Model Information

Type of Coatings

Part No. Model

Standard High Conductivity

244399 PRO Xs2

2 309291P

Operation Manual

309294/3W9294/3Z9294

Warnings

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.

• 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.

Caution Symbol

CAUTION

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

Toxic Fluid Hazard

Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin, swallowed, or inhaled.

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

• Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all

local, state, and national guidelines.

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

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Warnings

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-

tor.

• 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-

mum working air and fluid pressure of this equipment is 100 psi (0.7 MPa, 7.0 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).

• Do not kink or overbend hoses or use hoses to pull equipment.

• Wear hearing protection when operating this equipment.

• Comply with all applicable local, state, and national fire, electrical, and other safety regula-

tions.

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 at 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 23 when you stop spraying and before clean-

ing, checking, or repairing equipment.

• Check hoses and couplings daily. Replace worn, damaged, or loose parts immediately.

• Tighten all fluid connections before each use.

4 309291P

Introduction

How the Electrostatic Spray Gun Works

The air hose supplies air to the spray gun. Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed. The turbine generates power, which is converted by the power cartridge to supply high voltage current to the gun’s electrode.

The pump supplies fluid to the hose and gun, where the fluid is electrostatically charged as it passes the electrode. The charged fluid is attracted to the grounded workpiece, wrapping around and evenly coating all surfaces.

Gun Overview

The electrostatic gun includes the following controls (see F

IG. 1).

• FLUID adjustment valve. Adjusts fluid rod travel.

Use only in low flow conditions, to reduce wear.

• Atomizing air RESTRICTOR valve. Restricts

atomizing air flow. Replace with plug (included) if desired.

• ES ON/OFF valve. Turns electrostatics ON (I) or

OFF (0).

• ES INDICATOR. Green when ES is ON (I).

ES INDICATOR

ES ON/OFF

I O

RESTRICTOR

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AIR

FLUID

• Fan AIR adjustment valve. Adjusts fan size and

shape.

Fig. 1 Gun Overview

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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 spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.

Warning Sign

Mount warning signs in the spray area where they can easily be seen and read by all operators. An English Warning Sign is provided with the gun.

Ventilate the Spray Booth

WARNING

Flammable or Toxic Vapor Hazard

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

Electrically interlock the gun 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. Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufficient.

6 309291P

Installation

ES ON/OFF valve: I is ON, 0 is OFF

C*D

I O

The air supply to the gun must be electrically interlocked with the ventilators to pre-

vent the power supply from operating without

ventilating fans on.

Non-Hazardous Hazardous Area

Fig. 2. Typical Installation Key

A Main Air Supply Line B* Ventilation Fan Interlock Solenoid Valve C* Main Air Supply Shutoff Valve (bleed-type) D Pump Air Line Filter/Water Separator E* Pump Air Supply Shutoff Valve (bleed-type) F Air Line Lubricator G Air Pressure Regulator HPump J* Pump Ground Wire K Fluid Filter L Fluid Supply Line Shutoff Valve M Fluid Pressure Regulator

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N Fluid Supply Line O Gun Air Line Filter/Water Separator P Gun Air Supply Line Shutoff Valve Q* Air Hose Ground Wire R* Graco Grounded Air Hose S Electrostatic Air Spray Gun T Air Line Drain Valve U* Fluid Drain Valve VGun Air Inlet W Gun Fluid Inlet * Required for safe operation. Must be purchased

separately. NOTE: Solenoid valve (B) is not offered as a Graco accessory.

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Installation

Connect the Air Line

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 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 (Q) to a true earth ground.

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

4. Install a bleed-type air valve (E) on the pump air line to shut off air to the pump. Install an additional bleed-type air valve (C) on the main air line (A) to isolate the accessories for servicing.

WARNING

Pressurized Equipment Hazard

The bleed-type air valve (E) is required in your system to relieve air trapped between the valve and the pump after the air regulator is shut off. Trapped air can cause the pump to cycle unexpectedly, which can result in serious injury, including splashing fluid in the eyes or on the skin.

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

Connect the Exhaust Tube

Press the exhaust tube (38) onto the barbed adapter on the bottom of the gun handle. Secure the tube with the clamp (39).

8 309291P

Installation

Select a Fluid Nozzle and Air Cap

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the Pressure Relief Procedure on page 23 before removing or installing a fluid nozzle and/or air cap.

The gun is supplied with Part No. 197266 Nozzle and 24A376 Air Cap. If you require a different size, refer to Table 1 and Table 2 , and instruction manual 309419, or consult with your Graco distributor. See Air Cap/Nozzle Replacement on page 25.

A wide pattern kit (P/N 24A431) is included with the gun and if installed, will provide more fan air for wider spray patterns. (If pattern becomes split, use the fan air valve to reduce the amount of fan air.)

Table 1: Fluid Nozzles

Part No. Orifice Size

197263 0.75 mm (.030 in.) 197264 1.0 mm (.042 in.) 197265 1.2 mm (.047 in.) 197266 1.5 mm (.055 in.) 197267 1.8 mm (.070 in.) 197268† 2.0 mm (.080 in.) 249920* 0.75 mm (.030 in.) 249921* 1.0 mm (.042 in.) 249922* 1.2 mm (.047 in.) 249923* 1.5 mm (.055 in.) 249924* 1.8 mm (.070 in.) 249925*† 2.0 mm (.080 in.)

Table 2: Air Caps

Pattern Shape

Part No.

24A438

24A279

24A376*

24A274

24A439

24A275

*Also available in the following colors:

24A276 - blue 24A277 - red 24A278 - green

and Length in. (mm)

Round end; 15-17 (381-432)

Round end; 14-16 (356-406)

Tapered end; 17-19 (432-483)

Tapered end; 12-14 (305-356)

Round end; 11-13 (279-330)

Tapered end; 14-16 (356-406)

Recommended Fluids and Production Rates

Light to medium viscosity. Up to 15 oz/min (450 cc/min)

Medium to high viscosity and high solids. Up to 15 oz/min (450 cc/min)

Light to medium viscosity. Up to 15 oz/min (450 cc/min)

Medium to high viscosity and high solids. Up to 15 oz/min (450 cc/min) For use with 2.0 mm nozzle.

Light to medium viscosity and high solids. Aerospace coatings. Up to 25 oz/min (750 cc/min).

* Glass-reinforced acetal construction.

† Air cap 24A439 must be used with a 2.0 mm (0.80 in.) nozzle.

309291P 9

Installation

Connect the Fluid Line

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 npsm gun fluid inlet (W).

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

Filter the Fluid

Install a fluid filter (K) to remove particles and sediment which could clog the spray nozzle.

10 309291P

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.

• 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. If gloves are necessary, wear the conductive gloves that are supplied with the gun. If non-Graco gloves are worn, cut off fingers or palm area of glove, to ensure your hand contacts the grounded gun handle.

• 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.

• Electrostatic Air Spray Gun: ground the gun by con-

necting the Graco Grounded Air Hose and connecting the air hose ground wire to a true earth ground. See Check Electrical Grounding, page 12.

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• Air compressors: ground the equipment according

to the manufacturer's recommendations.

• All air and fluid lines must be properly grounded.

Use only grounded hoses with a maximum of 100 feet (30.5 m) combined hose length to ensure 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.

309291P 11

Installation

Check Electrical Grounding

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see F

IG. 3.) 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).

Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.

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

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5. Measure the resistance between the gun handle (BB) and a true earth ground (CC). Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 1 megohm. See F

IG. 3..

6. If the resistance is greater than 1 megohm, 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.

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

2. Turn the ES ON/OFF valve OFF.

I O

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

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Fig. 3. Check Gun Grounding

12 309291P

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.

309291P 13

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