Graco 309298K User Manual
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
309298K
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
2 309
298K
Symbols
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.
• 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.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the instructions.
309298K 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 309298K
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-
• Use fluids and solvents that are compatible with the equipment wetted parts. See the Techni-
• Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
• Wear hearing protection when operating this equipment.
• Comply with all applicable local, state, and national fire, electrical, and other safety regula-
Warning
tor.
mum working fluid pressure of this equipment is 3000 psi (21 MPa, 210 bar).
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
expose Graco hoses to temperatures above 180°F (82°C) or below -40°F (-40°C).
tions.
309298K 5
Introduction
Introduction
How the Electrostatic AA Spray Gun Works
WARNING
Skin Injection Hazard
Remember, this is not an air spray gun.
For your safety, read and follow all Warnings in this manual.
The air-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 309298K
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
309298K 7
Introduction
G
KV1
TA
A
CYL
C
FO
KV2
A2
P1
TI1713A
F
B
H
EXH
E
J
TI1714A
Manifold Back View
TI1739A
D
K
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 309298K
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 reg-
ulations.
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
IG. 2. and FIG. 3.
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
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)
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.
309298K 9
Installation
L
W
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.
X
BC
Y
A
TA
KV1
K
K
K
L
K
N
E
M
G
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.
P
Non-Hazardous Area Hazardous Area
KV2
CYL
P1
A2
F
J
TI1741A
Manifold Back View
T
U**R
H
KV
mA
V**
Q
85.0 KV
TI1715A
S
Fig. 3. Optional Fiber Optic Connection
10 309298K
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.
309298K 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..
IG. 4..
103
9.24 in
(234.7 mm)
Fig. 4. Mounting Bracket
102
NN
2.88 in
(73.2 mm)
To
TI1738A
Nozzle
Tip
12 309298K
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
TA
CYL
KV1
FO
A2
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.
P1
EXH
TI1739A
Fig. 5. Manifold Connections
309298K 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..
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
IG. 7..
3. Push the cable (BB) into the fitting (5) until it bottoms out. Tighten the nut (AA) to secure the cable.
5
BB
AA
TI1581A
Fig. 7. Fiber Optic Cable
Most of the fiber optic light transmission loss occurs at
the bulkhead splices. For the strongest light signals, use
a minimum number of bulkhead splices. A maximum of
two splices, with a total of 108 ft (33 m) of cable, is recommended.
Fig. 6. Fiber Optic Fitting
TI1737A
4. See manual 308265 to install a Graco ES Display
Module.
14 309298K
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.
309298K 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.
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.
TA
B
TI1735A
Fig. 8. Check Gun Grounding
16 309298K
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..
YY
Fig. 9. Fabric Cover
XX
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.
YY
TI1736A
TI1716A
309298K 17
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