Graco 309297L User Manual
Instructions/Parts List
AUTOMATIC ELECTROSTATIC AIR SPRAY GUN
™
PRO
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 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.
For Professional Use ONLY.
U.S. Patent 7,226,004
Auto Xs
II 2 G EEx 0.24 mJ
309297L
EN
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents and page 3 for
List of Models.
TI1557A
Table of Contents
List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 3
Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
How the Electrostatic Air Spray Gun Works . . . . 6
Operating the Spray Function . . . . . . . . . . . . . . . 6
Operating the Electrostatics . . . . . . . . . . . . . . . . 6
Gun Features and Options . . . . . . . . . . . . . . . . . 6
Changing the kV Setting . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install the System . . . . . . . . . . . . . . . . . . . . . . . . 8
Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 8
Install the Air Line Accessories . . . . . . . . . . . . . 10
Install the Fluid Line Accessories . . . . . . . . . . . 10
Install the Gun and Mounting Bracket . . . . . . . . 10
Connect the Air and Fluid Lines . . . . . . . . . . . . 11
Manifold Connections . . . . . . . . . . . . . . . . . . . . 11
Optional Fiber Optic Cable Connection . . . . . . 12
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Check Electrical Grounding . . . . . . . . . . . . . . . 14
Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 15
Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 15
Install the Fabric Cover . . . . . . . . . . . . . . . . . . . 15
245324 HC Conversion Kit . . . . . . . . . . . . . . . . 16
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Relief Procedure . . . . . . . . . . . . . . . . 17
Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 18
Select a Fluid Nozzle and Air Cap . . . . . . . . . . 18
Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 19
Adjust the Electrostatics . . . . . . . . . . . . . . . . . . 20
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Triggering the Fluid Alone . . . . . . . . . . . . . . . . . 21
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 22
Clean the Air Cap and Fluid Nozzle . . . . . . . . . 24
Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 25
Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 26
Test Power Supply Resistance . . . . . . . . . . . . . 27
Test Electrode Resistance . . . . . . . . . . . . . . . . . 28
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Spray Pattern Troubleshooting . . . . . . . . . . . . . 29
Gun Operation Troubleshooting . . . . . . . . . . . . 30
Electrical Troubleshooting . . . . . . . . . . . . . . . . . 31
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Prepare the Gun for Service . . . . . . . . . . . . . . . 32
Remove the Gun from the Manifold . . . . . . . . . . 33
Install the Gun on the Manifold . . . . . . . . . . . . . 33
Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 34
Electrode Replacement . . . . . . . . . . . . . . . . . . . 35
Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 36
Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 37
Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . . 39
Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 40
Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 41
Power Supply Removal and Replacement . . . . 42
Turbine Alternator Removal and Replacement . 43
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 52
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . . 52
Miscellaneous Accessories . . . . . . . . . . . . . . . . 53
Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 54
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56
2 309297L
List of Models
Part No. Model Voltage
List of Models
Type of Coatings
Standard High Conductivity
244589 PRO Auto Xs 40-85 kV
244590 PRO Auto Xs 40-85 kV
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
X
X
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the instructions.
309297L 3
Warning
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.
To comply with EN50050 requirements, cleaning solvents must have a flash point at least 5°C
above ambient temperature.
• 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.
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 309297L
Warning
WARNING
Equipment Misuse Hazard
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in a serious injury.
• This equipment is for professional use only.
• Read all manuals, tags, and labels before operating the equipment.
• Use the equipment only for its intended purpose. If you are uncertain, call your Graco 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 Technical 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.
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 steps under Prepare the Gun for Service, page 32, when you stop spraying and
before cleaning, checking, or repairing equipment.
• Check hoses and couplings daily. Replace worn, damaged, or loose parts immediately.
• Tighten all fluid connections before each use.
309297L 5
Introduction
Introduction
How the Electrostatic Air Spray Gun Works
The automatic electrostatic air spray gun operates very
similar to a traditional air spray gun. The atomization
and fan air are emitted from the air cap. The atomization
air breaks up the fluid stream and controls the droplet
size. The fan air controls the shape and width of the
spray pattern. The fan and atomization air can be
adjusted independently.
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.
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 fluid and air lines
to the gun.
• Gun functions are activated from a separate controller that sends the appropriate signal to the actuating
solenoids.
• The optional fiber optic readout system can be
installed to monitor the gun’s spraying voltage. A
fiber optic cable connected to the gun manifold carries the signal from the gun to a remote display
module. Part No. 224117 Display Module displays
the gun’s spraying voltage and current. Battery-operated Display Module 189762 displays the
gun’s spraying voltage only.
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.
Changing the kV Setting
The gun’s full voltage setting is 85 kV. Three lower voltage settings are possible by actuating the KV1 and KV2
switches. Supply 50 psi (0.35 MPa, 3.5 bar) air pressure
to the KV1 and KV2 ports. Turn the air on or off as
shown in Table 1 to set the desired voltage.
The solenoid valves used to activate the KV1 and KV2
switches must bleed the air out of the lines for the
switches to draw back to the higher voltage setting.
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
6 309297L
Introduction
F
KV1
TA
FO
CYL
KV2
A1
P1
TI1557A
A2
P2
E
EXH
A
CD
H
TI1577A
Manifold Back View
TI1561A
B
G
J
Fig. 1: Gun Overview
Key
AAir Cap
B Fluid Nozzle
C Retaining Ring
D Shroud
E Mounting Bracket
FManifold
G Turbine
H Power Supply
J Electrode
A1 Atomization Air Inlet Fitting
A2 Fan Air Inlet Fitting
CYL Cylinder Air Inlet Fitting
EXH Shroud Exhaust Outlet Fitting
FO Fiber Optic Fitting (shipped unassembled)
KV1 kV Switch 1 Air Inlet
KV2 kV Switch 2 Air Inlet
P1 Fluid Supply Inlet Fitting
Manifold Markings
P2 Fluid Return Inlet Fitting (optional)
TA Turbine Air Inlet Fitting
309297L 7
Installation
Installation
Install the System
WARNING
Fire, Explosion, and Electric Shock Hazard
Installing and servicing this equipment
requires access to parts which may cause
electric shock or other serious injury if work
is not performed properly.
•Do not install or service this equipment
unless you are trained and qualified.
•Be sure your installation complies with
National, State and Local codes for the
installation of electrical apparatus in a Class
I, Div. I, Group D or a Group II,
Category 2G Hazardous Location.
• Comply with all applicable local, state, and
national fire, electrical, and other safety regulations.
F
IGURE
2 shows a typical electrostatic air spray system,
and F
IGURE
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 (B) 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
IGURE
2 and F
A Air Hose Ground Wire
B Graco Grounded Turbine Air Hose (TA)
C Atomizing Air Hose, 3/8 in. (10 mm) OD (A1)
D Fan 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 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
kV Switch Air Hose, 5/32 in. (4 mm) OD (optional; plug KV1
X
fitting if not used)
kV Switch Air Hose, 5/32 in. (4 mm) OD (optional; plug KV2
Y
fitting if not used)
IGURE
3
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.
8 309297L
Installation
NOTE:
L
above
See *
W
* 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.
A
L
L
M
Non-Hazardous Area Hazardous Area
Fig. 2: Typical Installation
NOTE:
K
K
Y
X
BCD
TA
KV1
KV2
K
A2A1
CYL
K
N
E
F
G
P1
J
Manifold Back View
TI1712A
** 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 53.
Non-Hazardous Area Hazardous Area
P
T
KV
μA
U**R
V**
Q
85.0 KV
S
Fig. 3: Optional Fiber Optic Connection to Voltage Display Module
H
TI1583A
309297L 9
Installation
Install the Air Line Accessories
1. Install a bleed-type 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, D, 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.
WARNING
Pressurized Equipment Hazard
WARNING
Pressurized Equipment 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
splashing in the eyes or on the skin.
2. Install a fluid regulator on the fluid line to control
fluid pressure to the gun.
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
IGURE
4.
Trapped air can cause the gun to spray
unexpectedly, which can result in serious
injury, including splashing fluid in the eyes
or on 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.
Install the Fluid Line Accessories
1. Install a fluid filter and drain valve at the pump outlet.
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
102
103
9.22 in
(234.2 mm)
NN
03460
Fig. 4: Mounting Bracket
IGURE
TI1570A
4.
2.88 in
(73.2 mm)
To nozzle tip
10 309297L
Installation
Connect the Air and Fluid Lines
F
IGURE
3 shows a schematic of air and fluid line connec-
tions, and F
IGURE
5 shows the manifold connections.
Connect the air and fluid lines as instructed.
WARNING
Electric Shock Hazard
To reduce the risk of electric shock or other
serious injury, the turbine 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 (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 left-hand threads 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 11).
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 Fluid Return Inlet Fitting (optional)
Order Part No. 233676 Fluid Recirculation Kit.
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
TA
CYL
KV1
FO
2. Check the electrical grounding of the gun as
instructed on page 14.
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 Atomization Air Inlet Fitting
Connect a 3/8 in. (10 mm) OD tube between this fitting and
the air supply.
A2 Fan 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.
A1
P1
Fig. 5: Manifold Connections
A2
P2
EXH
TI1577A
309297L 11
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
URE
3, page 9, for a schematic of the fiber optic connec-
tions.
1. Remove the plug (120) from the fiber optic port, and
install the fiber optic fitting (5, shipped loose with the
gun). See F
IGURE
6.
5
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
IGURE
7.
3. Push the cable (BB) into the fitting (5) until it bottoms out. Tighten the nut (AA) to secure the cable.
5
BB
AA
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.
TI1581A
Fig. 6: Fiber Optic Fitting
TI1580A
4. See manual 308265 to install a Graco ES Display
Module.
12 309297L
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:
wire and clamp as described in your separate pump
instruction manual.
•
Electrostatic Air Spray Gun:
necting 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 Ground-
ing, page 14.
ground the pump by connecting a ground
ground the gun by con-
•
Air compressors and hydraulic power supplies:
ground the equipment according to the manufacturer's recommendations.
•
All air and fluid lines
•
All electrical cables
•
All persons entering the spray area:
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:
clean and grounded at all times. Resistance must
not exceed 1 megohm.
•
The floor of the spray area:
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:
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:
cans, must be properly grounded.
including fluid containers and wash
must be properly grounded.
must be properly grounded.
shoes must
keep the workpiece hangers
must be electrically con-
must be kept in
Installation
309297L 13
Installation
A
Check Electrical Grounding
WARNING
Fire, Explosion, and Electric Shock Hazard
Megohmmeter Part No. 241079 (AA-see
F
IGURE
8) is not approved for use in a hazardous area. To reduce the risk of sparking,
do not use the megohmmeter to check
electrical grounding unless:
• The gun has been removed from the
hazardous area;
• Or all spraying devices in the hazardous
area are turned off, ventilation fans in the
hazardous area are operating, and there
are no flammable vapors in the area
(such as open solvent containers or
fumes from spraying).
4. Measure the resistance between the turbine air inlet
fitting (TA) and a true earth ground (N).
a.
If using a black or grey turbine air hose,
use a
megohmmeter to measure the resistance. Use
an applied voltage of 500 minimum to 1000
volts maximum. The resistance should not
exceed 1 megohm.
b.
If using a red turbine air hose,
use an ohmmeter
to measure the resistance. The resistance
should not exceed 100 ohms.
3. If the resistance is greater than the maximum reading specified above for your hose, check the tightness of the ground connections and be sure the
turbine air hose ground wire is connected to a true
earth ground. If the resistance is still too high,
replace the turbine air hose.
N
AA
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. The fluid
hose must not have any fluid in it.
TA
B
TI1584
Fig. 8. Check Gun Grounding
14 309297L
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
YY
Fig. 9. Fabric Cover
XX
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
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 25. Strap down the exhaust
tube to prevent it from moving around.
YY
ti1571a
TI1579A
IGURE
9.
309297L 15
Installation
245324 HC Conversion Kit
Part No. 245324 Conversion Kit is available to convert
PRO Auto Xs standard coating guns (Part No. 244589)
to high conductivity guns (244590).
The kit is for use with fluids with low resistivity values.
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 17
before installing this kit.
1. Turn the turbine air (TA) off.
2. Flush the gun.
3. Relieve the pressure.
4. Remove the retaining ring (1), air cap (3), and
shroud (2).
5. Refer to the parts drawing for Model 244589 on
page 45. Loosen the two nuts (20) and remove the
fluid tube (19) and ferrules (21, 22). Remove the
other parts (14, 15, 16, 17, 18) at the gun barrel
inlet.
6. Slide the loops of the hc tube (19) onto the gun barrel (9).
7. Make sure the barrel threads are clean and dry.
Apply Graco Part No. 116553 dielectric grease to
the fluid fitting (19d) threads and o-rings. Thread
the fitting into the barrel inlet. See F
8. Slide the nut (20) and ferrules (21, 22) onto the
coiled tube (19). Insert the end of the tube into the
fitting (23). Make sure the ferrules seat in the fitting.
Tighten the nut (20).
9
19
19d
Fig. 10. HC Conversion Kit
21
IGURE
22
20
10.
23
TI1731A
16 309297L
Operation
Operation
Pressure Relief Procedure
WARNING
Pressurized Equipment Hazard
The system pressure must be manually
relieved to prevent the system from starting
or spraying accidentally. To reduce the risk
of an injury from electric shock, accidental spray from
the gun, splashing fluid, or moving parts, follow the
Pressure Relief Procedure whenever you:
• are instructed to relieve the pressure
• stop spraying
• check or service any of the system equipment
• or install or clean the fluid nozzle.
2. Turn off the fluid supply to the gun.
3. Trigger the gun into a grounded metal waste container to relieve the fluid pressure.
4. If an air pilot fluid regulator is used, turn off the air
pressure at the regulator air inlet.
5. Relieve fluid pressure in the fluid supply equipment
as instructed in its instruction manual.
6. Turn off the main air supply by closing the
bleed-type master air valve on the main air supply
line. Leave the valve closed until you are ready to
spray again.
1. Turn off all the air to the spray gun except the cylinder air, which triggers the gun. If an air pilot fluid
regulator is used in the system, the air pressure is
needed at the regulator air inlet.
309297L 17
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