Graco 309457G User Manual

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Page 1

Instructions/Parts List

ELECTROSTATIC, FOR WATERBORNE COATINGS

™

PRO

Auto Xs

Air Spray Gun

Part No. 244591, Series A

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

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

For use when electrostatically spraying conductive, waterborne fluids that meet at least one of the following conditions for non-flammability:

309457G

• The fluid has a flash point above 140°F (60°C)

and a maximum organic solvent concentration of 20%, by weight, per ASTM Standard D93.

• The fluid does not sustain burning when tested per

ASTM Standard D4206 Sustained Burn Test.

NOTE: Fluid hose must be ordered separately.

For patent information, see www.graco.com/patents

Important Safety Instructions

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

TI1557A

See page 2 for Table of Contents.

Page 2

Table of Contents

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

Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 3

Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

How the Electrostatic Air Spray Gun Works . . . . 6

Spraying Waterborne Fluids Electrostatically . . . 6

Gun Features and Options . . . . . . . . . . . . . . . . . 6

Operating the Spray Function . . . . . . . . . . . . . . . 7

Operating the Electrostatics . . . . . . . . . . . . . . . . 7

Changing the kV Setting . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 9

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . 10

Install the Air Line Accessories . . . . . . . . . . . . . 12

Install the Gun and Mounting Bracket . . . . . . . . 12

Connect the Air Line . . . . . . . . . . . . . . . . . . . . . 13

Manifold Connections . . . . . . . . . . . . . . . . . . . . 13

Connect the Waterborne Fluid Hose . . . . . . . . . 14

Optional Fiber Optic Cable Connection . . . . . . . 17

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Check Electrical Grounding . . . . . . . . . . . . . . . . 19

Install the Fabric Cover . . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fluid Voltage Discharge and Grounding Procedure

Pressure Relief Procedure . . . . . . . . . . . . . . . . 21

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 22

Select a Fluid Nozzle and Air Cap . . . . . . . . . . 22

Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 23

Adjust the Electrostatics . . . . . . . . . . . . . . . . . . 25

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Triggering the Fluid Alone . . . . . . . . . . . . . . . . . 25

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 26

Clean the Air Cap and Fluid Nozzle . . . . . . . . . 28

Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 29

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 30

Test Power Supply Resistance . . . . . . . . . . . . . 31

Test Electrode Resistance . . . . . . . . . . . . . . . . . 32

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Voltage Loss Troubleshooting . . . . . . . . . . . . . . 33

Spray Pattern Troubleshooting . . . . . . . . . . . . . 36

Gun Operation Troubleshooting . . . . . . . . . . . . . 37

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 38

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Prepare the Gun for Service . . . . . . . . . . . . . . . 39

Remove the Gun from the Manifold . . . . . . . . . . 40

Install the Gun on the Manifold . . . . . . . . . . . . . 40

Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 41

Electrode Replacement . . . . . . . . . . . . . . . . . . . 42

Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 43

Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 44

Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . 46

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 47

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 48

Power Supply Removal and Replacement . . . . 49

Turbine Alternator Removal and Replacement . 50

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 56

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 56

Miscellaneous Accessories . . . . . . . . . . . . . . . . 57

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 58

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 60

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 60

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Page 3

Warnings

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

WARNING

Electric Shock Hazard

Improper grounding, setup, or usage of an isolated waterborne system can cause a hazardous condition and result in electric shock or other serious injury.

• Ground the equipment, all personnel in or close to the spray area, the object being sprayed, and all conductive objects in the spray area. See Grounding, page 18.

• The gun must be connected to a voltage isolation system that will discharge the system voltage when the gun is not in use.

• All components of the isolation system that are charged to high voltage must be contained within an enclosure that prohibits personnel from making contact with the high voltage components before the system voltage is discharged.

Caution Symbol

CAUTION

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

• The gun turbine air supply must be interlocked with the isolation system to shut off the turbine air supply anytime the isolation system enclosure is opened.

• The voltage isolation system must be interlocked with the spray area entrance to automatically discharge the voltage and ground the fluid whenever someone enters the spray area.

• The areas of the waterborne hose that are accessible to personnel must be covered by the conductive hose layer. The area of the hose that is not covered by the conductive hose layer must be inside the voltage isolation system enclosure.

• Only use the red-colored Graco grounded turbine air hose with this gun. Do not use the black or grey-colored air hoses.

• Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the spray gun. Do not splice hoses together.

• Follow the Fluid Voltage Discharge and Grounding Procedure on page 21 when instructed to discharge the voltage; before cleaning, flushing, or servicing the system; before approaching the front of the gun; and before opening the enclosure for the isolated fluid supply.

• Do not enter a high voltage or hazardous area until all high voltage equipment has been discharged.

• Do not come within 2 ft (0.61 m) of the gun nozzle during gun operation or until you follow the Fluid Voltage Discharge and Grounding Procedure.

• Follow the warnings and instructions in the voltage system isolation system manual.

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Page 4

Warnings

WARNING

Fire and Explosion Hazard

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire or explosion.

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

requirements in this manual.

• Ground the equipment, all personnel in or close to the spray area, the object being sprayed, and all other electrically conductive objects in the spray area. See Grounding, page 18.

• Provide fresh air ventilation to avoid buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Interlock the gun air supply to prevent operation of the power supply unless ventilating fans are on. See Ventilate the Spray Booth on page 10.

• Do not flush with the gun electrostatics turned on.

• If there is any static sparking while using the equipment, stop spraying immediately. Identify

and correct the problem.

• Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.

• Check gun resistance daily. See Test Gun Resistance on page 30.

• Only use this equipment to spray non-flammable, waterborne fluids, as defined on the front

cover of this manual.

• Only flush, purge, or clean the electrostatic waterborne spray system with non-flammable fluids, as defined on the front cover of this manual.

• Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the spray area.

• Use only non-sparking tools to clean residue from the booth and hangers.

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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Page 5

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.

• Do not operate the power supply above 60 kV. Use only Graco Part No. 244542 Power Supply

with this gun.

• 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).

• 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, page 21, 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.

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Page 6

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.

Spraying Waterborne Fluids Electrostatically

CAUTION

The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.

This electrostatic air spray gun is designed to spray only waterborne fluids with a flash point above 140°F (60°C) and a maximum organic solvent concentration of 20%, by weight, per ASTM Standard D93. Also, the fluid must not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.

Precautions must be taken when using electrostatic waterborne equipment to avoid potential shock hazards. When the spray gun charges the isolated fluid to high voltage, it is similar to charging a capacitor or a battery. The system will store some of the energy while spraying and retain some of that energy after the spray gun is shut off. It is not safe to touch the front end of the gun until the stored energy is discharged. The amount of time it takes to discharge the energy depends on the system design. Follow the Fluid Voltage Discharge and Grounding Procedure on page 21 before approaching the front of the gun.

A safe, well designed voltage isolation system should have the following features:

• All components of the isolation system that are

charged to high voltage must be contained within an enclosure that prohibits persons from making contact with the high voltage components before the system voltage is discharged.

• The voltage isolation system must be interlocked

with the spray area entrance to automatically discharge the voltage and ground the fluid whenever someone opens the enclosure or enters the spray area.

• A bleed resistor to drain off the system voltage when

the spray gun is not in use.

When connected to a voltage isolation system, all of the fluid in the spray gun, fluid hose, and isolated fluid supply is charged to high voltage, which means that the system has more electrical energy than a solvent-based system. Therefore, only non-flammable fluids (as defined on the front cover of this manual) can be sprayed with the system or be used to clean, flush, or purge the system.

6 309457G

• The system should not have any severe arcing

occurring when the isolation mechanism opens and closes. Severe arcing will shorten the life of the system components.

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.

• Gun functions are activated from a separate control-

ler that sends the appropriate signal to the actuating solenoids.

Page 7

Introduction

• 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.

WARNING

Electric Shock Hazard

To reduce the risk of electric shock, do not use the Graco ES Display Module readings

to determine if your system is discharged. The display modules will only display the system voltage while the gun’s power supply is operating. Follow the Fluid Voltage Discharge and Grounding Pro- cedure on page 21 to ensure the system is discharged.

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.

Changing the kV Setting

The gun’s full voltage setting is 60 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.

NOTE: 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: Low Voltage Adjustment

12kV

ON ON 35 ON OFF 40 OFF ON 50 OFF OFF 60

309457G 7

Page 8

Introduction

KV1

CYL

KV2

TI1557A

EXH

TI1790A

Manifold Back

TI1780A

Fig. 1. Gun Overview Key

Manifold Markings

A Air Cap B Fluid Nozzle C Retaining Ring D Shroud E Mounting Bracket F Manifold G Turbine H Power Supply JElectrode

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 P2 Not Used TA Turbine Air Inlet Fitting

8 309457G

Page 9

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 all

National, State and Local safety and fire codes, NFPA 33, NEC 504 and 516, and OSHA standard 1910.107.

FIG. 2. shows a typical electrostatic air 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.

Basic Guidelines

When spraying waterborne fluids electrostatically:

• The gun must be connected to a voltage isolation

system, which isolates the fluid supply from ground and allows voltage to be maintained at the tip of the gun.

• The gun must be connected to a voltage isolation

system that will discharge the system voltage when the gun is not in use.

• All components of the isolation system that are

charged to high voltage must be contained within a fence or enclosure that prohibits persons from making contact with the high voltage components before the system voltage is discharged.

• The gun turbine air supply must be interlocked with

the isolation system to shut off the turbine air supply anytime the isolation system enclosure or safety fence is opened.

• The voltage isolation system must be interlocked

with the spray area entrance to automatically discharge the voltage and ground the fluid whenever someone enters the spray area.

• The system should not have any severe arcing

occurring when the isolation mechanism opens and closes. Severe arcing will shorten the life of the system components.

Graco Waterborne Fluid Hose

Use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun fluid inlet. See Accessories on page 56 for available hoses. The hose consists of an inner PTFE tube, a conductive layer covering the PTFE tube, and an outer cover.

If a hose failure occurs where high voltage arcs through the inner tube, voltage will be discharged to ground through the conductive hose layer. When properly installed, the conductive hose layer is grounded through its connection to the grounded enclosure.

309457G 9

Page 10

Installation

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

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 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.

NOTE: 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 (A1) D Fan Air Hose, 3/8 in. (10 mm) OD (A2) E Cylinder Air Hose, 5/32 in. (4 mm) OD (CYL) F Graco Waterborne Fluid Hose (P1) G To Isolated Fluid Supply System 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

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

fitting if not used)

10 309457G

Page 11

Installation

NOTE:

above

See *

* 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.

BCD

KV1

KV2

A2A1

CYL

Non-Hazardous 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 57.

Non-Hazardous Hazardous Area

U**R

Do not use the Display Module readings to determine if your system is discharged. The display modules only display the system voltage while the gun’s power supply is operating. Follow the Fluid Voltage Discharge and Grounding Procedure on page 21 to ensure the system is discharged.

TI1801A

Manifold Back

V**

85.0 KV

TI1797A

Fig. 3. Optional Fiber Optic Connection to Voltage Display Module

309457G 11

Page 12

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

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 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.

NOTE: 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

03460

Fig. 4. Mounting Bracket

102 103

IG. 4.

9.22 in (234.2

TI1570A

IG. 4.

2.88 in (73.2

To nozzl

12 309457G

Page 13

Installation

Connect the Air Line

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

IG. 5. shows the manifold connections. Connect the air

lines as instructed.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of a fire, explosion, or electric shock, the gun turbine air supply must be interlocked with:

•The isolation system to shut off the turbine

air supply anytime the enclosure or safety fence is opened.

•The ventilators to prevent operation of the

power supply unless the ventilating fans are on.

WARNING

Electric Shock Hazard

To reduce the risk of electric shock or other serious injury, you must use the red-colored

Graco grounded air hose for the turbine air supply hose, and you must connect the hose ground wire to a true earth ground. Do not use the black or grey-colored Graco air hoses.

1. Connect the red-colored 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 56 for further information about the hose.

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.

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 17).

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

Connect a Graco waterborne fluid hose.

P2 Not used. TA Turbine Air Inlet Fitting

Connect the red-colored Graco Grounded 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 19.

EXH

TI1790A

Fig. 5. Manifold Connections

309457G 13

Page 14

Installation

Connect the Waterborne Fluid Hose

CAUTION

The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.

• Always use a Graco waterborne fluid hose between

the voltage isolation system fluid outlet and the gun fluid inlet. See page 56 for available Graco waterborne hoses.

• Before connecting the waterborne fluid hose to the

gun, blow it out with air and flush with water to remove contaminants.

WARNING

Electric Shock Hazard

To reduce the risk of electric shock, install only one continuous Graco waterborne hose between the isolated fluid supply and the gun. Do not splice hoses together.

1. Remove the air cap (3) and shroud (2). See page

41.

Key to F

Fig. 6. Waterborne Hose Dimensions

3. Inspect the o-ring (R) on the barrel fitting (F) of the

4. Lubricate the o-ring (R) on the barrel fitting (F) with

5. Unscrew the strain relief nut (N) from the hose fer-

IG. 6.

A 9.75 in. (248 mm) B 1.5 in. (38 mm)

hose. Replace if worn or damaged. See F

dielectric grease. Screw the fitting into the fluid inlet of the gun barrel (9) and tighten.

rule (M) and slide the nut up the hose.

TI1806A

IG. 7..

2. For the fluid hose to seal properly, it must be stripped and assembled to the dimensions shown in F

IG. 6.. Push the inner tube (T) into the barrel fitting

(F) until the tube bottoms. A new Graco waterborne fluid hose comes fully assembled to these dimensions.

CAUTION

Be careful not to cut into the inner tube (T) of the hose when stripping the hose. Nicks or cuts in the PTFE tube will cause premature hose failure.

14 309457G

Page 15

Installation

N*M*

TI1793A

*Ferrule (M) and nut (N) are part of the waterborne hose assembly (purchase separately).

TI1802A

Fig. 7. Connect the Waterborne Fluid Hose

309457G 15

Page 16

Installation

6. Slide the inner tube (T) of the hose through the slot and into the fluid inlet port (P1) of the manifold. Screw the hose ferrule (M) into the port.

WARNING

Electric Shock Hazard

To maintain grounding continuity, the conductive hose layer (C) must be engaged in the ferrule (M) when the nut (N) is tightened. Failure to properly install the hose in the fitting could result in an electric shock.

7. Screw the strain relief nut (N) onto the hose ferrule (M). Tighten to about 55 in-lb (6.2 N•m). Pull back on the hose to make sure it is secure.

8. Reinstall the shroud (2) and air cap (3).

9. Check the gun’s electrical grounding (see page 19).

10. Connect the other end of the hose to the fluid outlet of the isolated fluid supply. See F

IG. 8..

WARNING

Electric Shock Hazard

To reduce the risk of electric shock, the areas of the waterborne fluid hose that are accessible to personnel during normal operation must be covered by the outer

hose jacket (J). The portion of the inner hose layer (T) not covered by the outer jacket must be inside the voltage isolation system enclosure (E).

The conductive hose layer (C) must be grounded through its connection to the isolation system’s grounded enclosure (E).

Fig. 8. Hose Connection at Isolated Fluid Supply

TI1805A

16 309457G

Page 17

Installation

Optional Fiber Optic Cable Connection

WARNING

Electric Shock Hazard

To reduce the risk of electric shock, do not use the Graco ES Display Module readings to determine if your system is discharged. The display module will only display the

system voltage while the gun’s power supply is operating. Follow the Fluid Voltage Discharge and Grounding Procedure on page 21 to ensure that the system is discharged.

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 11, 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. 9..

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. 10..

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

TI1795A

Fig. 10. Fiber Optic Cable NOTE: 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.

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

120

Fig. 9. Fiber Optic Fitting

TI1794A

309457G 17

Page 18

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 waterborne 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.

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

necting the red-colored 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 19.

• 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.

• Graco Waterborne Fluid Hose: the hose is grounded

through the conductive layer. Install the hose as instructed on page 14.

• Voltage Isolation System: electrically connect to a

true earth ground.

• 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.

18 309457G

Page 19

Check Electrical Grounding

Installation

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see F

IG. 11.) 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;

•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.

Fig. 11. Check Gun Grounding

TI1798A

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

2. Make sure the red-colored 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.

4. Measure the resistance between the turbine air inlet fitting (TA) and a true earth ground (N), using an ohmmeter. The resistance should not exceed 100 ohms.

5. If the resistance is greater than 100 ohms, 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.

309457G 19

Page 20

Installation

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

Fig. 12. Fabric Cover

IG. 12..

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 29. Strap down the exhaust tube to prevent it from moving around.

ti1787A

TI1792A

20 309457G

Page 21

Operation

Fluid Voltage Discharge and Grounding Procedure

WARNING

Electric Shock Hazard

The high voltage fluid supply is charged with high voltage until the voltage is discharged. Contact with the charged components of the isolation system or spray gun

electrode will cause an electric shock. To avoid an electric shock, follow the Fluid Voltage Discharge

and Grounding Procedure:

• when instructed to discharge the voltage

• before cleaning, flushing, or servicing the system

equipment

• before approaching the front of the gun

• or before opening the safety fence or enclosure

for the isolated fluid supply.

NOTE: An accessory grounding rod, part No. 210084, is available to discharge any voltage remaining on a system component. Contact your Graco distributor to order.

1. Turn off the turbine air to all spray guns connected to the isolated fluid supply.

2. Discharge the voltage at the voltage isolation system by following the procedure specified in the voltage isolation system instruction manual.

3. Touch the electrode of the gun with a grounded rod to make sure the voltage has been discharged. If you see an arc, verify that the electrostatics are turned off or see Electrical Troubleshooting on page 38 or the voltage isolation system manual for other possible problems. Resolve the problem before proceeding.

Pressure Relief Procedure

WARNING

Pressurized Equipment Hazard

The system pressure must be manually relieved to prevent the system from starting

or spraying accidentally. To reduce the risk of an injury from electric shock, accidental spray from the gun, splashing fluid, or moving parts, follow the

Pressure Relief Procedure whenever you:

• are instructed to relieve the pressure

• stop spraying

• check or service any of the system equipment

• or install or clean the fluid nozzle.

1. Follow the Fluid Voltage Discharge and Grounding Procedure, on page 21.

2. Relieve fluid pressure in the fluid supply and voltage isolation system as instructed in their instruction manuals.

3. 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, air pressure is also needed at the regulator air inlet.

NOTE: The air shut-off device must bleed the air out of the system.

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

5. Turn off all remaining air supplies to the gun.

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.

309457G 21

Page 22

Operation

Operating Checklist

Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.

All operators are properly trained to safely operate an automatic electrostatic waterborne air spray system as instructed in this manual.

All operators are trained in the Fluid Voltage Discharge and Grounding Procedure on page 21.

All operators are trained in the Pressure

Relief Procedure.

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 is thoroughly grounded and the operator and all persons entering the spray area are properly grounded. See Grounding on page 18.

The condition of the gun’s electrical components has been checked as instructed in Elec- trical Tests on page 30.

All fluid hose connections are tight.

Ventilation fans are operating properly.

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 21 before removing or installing a fluid nozzle and/or air cap.

The gun is supplied with Part No. 197266 Nozzle and 24A276 Air Cap. If you require a different size, refer to Table 2 and Table 3 , and instruction manual 309419, or consult with your Graco distributor. See Air Cap/Nozzle Replacement on page 41.

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 2: Fluid Nozzles

Part No.

197263 0.75 (.030) 197266 1.5 (.055) 197264 1.0 (.042) 197267 1.8 (.070) 197265 1.2 (.047) 197268 2.0 (.080)

Size, mm (in.)

Part No.

Size, mm (in.)

Workpiece hangers are clean and grounded.

Table 3: Air Caps

Pattern Shape

Part No.

All debris, including flammable fluids and rags, is removed from the spray area.

24A438

All conductive objects in the spray area are electrically grounded and the floor of the spray

24A279

area is electrically conductive and grounded. The manifold exhaust tubes have been

24A376*

checked for the presence of any fluid as instructed in Check for Fluid Leakage on page 29.

22 309457G

24A274

24A439

*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)

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.

Page 23

Adjust the Spray Pattern

Follow the steps below to establish the correct fluid flow and air flow. Do not turn on the turbine air (TA) yet.

WARNING

Fire and Explosion Hazard

To reduce the risk of fire and explosion, only use this equipment with fluids that meet at least one of the following conditions for non-flammability:.

• The fluid has a flash point above 140°F (60°C)

and a maximum organic solvent concentration of 20%, by weight, per ASTM Standard D93.

• The fluid does not sustain burning when tested

per ASTM Standard D4206 Sustained Burn Test.

Operation

WARNING

Component Rupture Hazard

To reduce the risk of component rupture, which can cause serious injury, do not

exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi (0.7 MPa, 7 bar) maximum working air and fluid pressure.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 21

whenever you are instructed to relieve the

pressure.

WARNING

Electric Shock Hazard

Contact with the charged components of the spray gun will cause an electric shock. Do not touch the gun nozzle or electrode or come within 2 ft (0.61 m) of the front of the

gun during operation or until performing the Fluid Voltage Discharge and Grounding Procedure on page 21.

Follow the Fluid Voltage Discharge and Grounding Procedure on page 21 when you stop spraying and whenever you are instructed to discharge the voltage.

1. Discharge the system voltage (page 21).

2. Relieve the pressure (page 21).

3. Loosen the air cap retaining ring, and rotate the air cap for a vertical or horizontal spray pattern. See F

IG. 13.. 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.

Vertical Pat-

Horizontal Pat-

Fig. 13. Air Cap Positions

4. Adjust the fluid flow with the fluid pressure regulator. Refer to instruction manual 309419 to set the fluid pressure for various fluid flows, according to the size of the fluid nozzle being used.

309457G 23

Page 24

Operation

5. Use the air pressure regulator on the atomization air supply line (A1) to adjust the degree of atomization. See F

IG. 14.. For example, for a fluid flow rate of 10

ounces per minute (0.3 liters per minute), a typical atomization pressure would be 20-30 psi (1.4-2.1 bar, 0.14-0.21 MPa) at the gun manifold.

KV2

CYL

KV1

6. Use the air pressure regulator on the fan air supply line (A2) to adjust the pattern size.

• For the most efficiency, always use the lowest

air pressure possible.

• When increasing to a wide, flat pattern, it may

be necessary to increase the supply of fluid to the gun to maintain the same amount of coverage over a large area.

• See Spray Pattern Troubleshooting on page

36 to correct spray pattern problems.

Fig. 14. Manifold Air Connections

TI1790A

24 309457G

Page 25

Operation

Adjust the Electrostatics

1. Shut off the fluid supply.

2. Prepare the isolation system for high voltage operation.

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

IG. 14..

4. Refer to Table 4 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.

Table 4: Turbine Air Pressures

Turbine A ir

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)

5. Check the voltage output of the gun using a high voltage probe and meter or by reading the ES (kV) Display Module.

NOTE: The gun’s normal high voltage reading is 45-55 kV.

See Electrical Troubleshooting on page 38 to correct voltage problems.

Air pressure at turbine air hose

inlet for full voltage

psi (bar, MPa)

Spraying

WARNING

Electric Shock Hazard

To reduce the risk of electric shock, do not touch the gun electrode or come within 2 ft (6.1 m) 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 (A1), fan air (A2), and fluid (P1). See F

2. Turn the gun functions on and off 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. 14..

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 29.

Triggering the Fluid Alone

1. Shut off and relieve the air pressure to the atomization (A1) and fan (A2) air lines, using the bleed-type air shutoff valves.

2. Apply 50 psi (3.5 bar, 0.35 MPa) air pressure to the cylinder air fitting (CYL) to trigger the fluid.

Shutdown

1. Discharge the system voltage (page 21).

2. Flush and clean the equipment. See Maintenance on page 26.

3. Relieve the pressure (page 21).

309457G 25

Page 26

Maintenance

Daily Care and Cleaning

CAUTION

• Clean all parts with a non-conductive, compatible

Do not immerse the gun in fluid.

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.

TI1788A

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

rated; wring out the excess fluid.

02027A

TI1789A

26 309457G

Page 27

Maintenance

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the Pressure Relief Procedure on page 21 before doing any maintenance on the gun or system.

• 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 and fluid nozzle daily, minimum.

Some applications require more frequent cleaning. Replace the fluid nozzle and air cap if they are damaged. See Clean the Air Cap and Fluid Nozzle, page 28.

• Check the electrode and replace if broken or damaged. See Electrode Replacement on page 42.

• Check for fluid leakage from the gun and fluid hoses. See Check for Fluid Leakage on page 29. Tighten fittings or replace equipment as needed.

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.

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

309457G 27

Page 28

Maintenance

Clean the Air Cap and Fluid Nozzle

Equipment Needed

• soft bristle brush

• compatible solvent

Procedure

1. Discharge the system voltage, page 21.

2. Relieve the pressure, page 21.

3. Remove the air cap assembly (1, 3) and shroud (2). See F

IG. 15..

4. Wipe the fluid nozzle (4), shroud (2), and exterior of the gun clean with a cloth dampened in non-flammable solvent. Avoid getting any solvent into the air passages. Whenever possible, point the gun down when cleaning it.

9. 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.

10. Test gun resistance, page 30.

TI1779A

5. If it appears that there is fluid inside the fluid nozzle (4) air passages, remove the gun from the line for servicing.

6. Clean the air cap (3) with the soft bristle brush and solvent or submerge the air cap in suitable solvent and wipe it clean.

CAUTION

Do not use metal tools to clean the air cap or fluid nozzle holes as this could scratch them, and make sure the electrode is not damaged. Scratches in the air cap or nozzle or a damaged electrode can distort the spray pattern.

7. Slide the shroud (2) onto the gun.

8. Carefully install the air cap (3). Be sure to insert the electrode (7) through the center hole of the air cap. Rotate the air cap to the desired position.

Fig. 15. Clean Air Cap and Fluid Nozzle

28 309457G

Page 29

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.

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

IG. 16.. Fluid in these

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. Discharge the voltage (page 21), relieve the pressure (page 21), and then remove the gun for repair.

ti1787A

TI1792A

Fig. 16. Check for Fluid Leakage

309457G 29

Page 30

Electrical Tests

Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (12) and electrode (7), and electrical continuity between components.

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. 17.) 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;

•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).

Test Gun Resistance

1. Flush and dry the fluid passage.

2. Measure resistance between the electrode needle tip (7) and the turbine air inlet fitting (TA); it should be 117-137 megohms. If outside this range, remove the gun for service (page 39) and go to the next test. If in range, refer to Electrical Troubleshooting on page 38 for other possible causes of poor performance.

TI1790A

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

TI1799A

Fig. 17. Test Gun Resistance

30 309457G

Page 31

Electrical Tests

Test Power Supply Resistance

1. Remove the power supply (12), page 49.

2. Remove the turbine alternator (13) from the power supply, page 50.

3. Measure resistance from the power supply's ground strips (EE) to the spring (12b). See F

4. The resistance should be 95-105 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 38 for other possible causes of poor performance, or contact your Graco distributor.

IG. 18..

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

12b

ti1599a

Fig. 18. Test Power Supply Resistance

309457G 31

Page 32

Electrical Tests

Test Electrode 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 electrode (7). The resistance should be 20-30 megohms. See F

IG. 19..

3. If in range, refer to Electrical Troubleshooting on page 38 for other possible causes of poor performance, or contact your Graco distributor.

4. Remove the electrode (7), page 42. Measure the resistance between the contact (E) and the electrode wire (F). The resistance should be 20-30 megohms. If out of range, replace the electrode. See F

IG. 20..

5. Make sure the metal contact (C) in the barrel, the nozzle contact ring (4a, F

IG. 21.), and the electrode

contacts (E) are clean and undamaged.

ti1499a

F7E

Fig. 20. Electrode

ti1513a

Fig. 21. Nozzle Conductive O-Ring

ti1548a

Fig. 19. Test Electrode Resistance

32 309457G

Page 33

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.

Troubleshooting

Voltage Loss Troubleshooting

Normal spraying voltage for a system using the waterborne gun is 45-55 kV. The system voltage is lower due to spraying current demands and voltage isolation system losses.

A loss of spraying voltage can be caused by a problem with the spray gun, fluid hose, or voltage isolation system, since all of the system components are electrically connected through the conductive, waterborne fluid.

Follow the Fluid Voltage Discharge and Grounding Procedure on page 21 before checking or servicing the system and whenever you are instructed to discharge the voltage.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 21

before checking or servicing any part of the

system and whenever you are instructed to

relieve the pressure.

Before troubleshooting or servicing the voltage isolation system itself, you need to determine which component in the system is most likely causing a problem. Possible causes include the following:

Spray Gun

• Fluid leakage

• Dielectric breakdown at the fluid hose connection or

fluid packings

• Not enough air pressure for the turbine

• Faulty power supply

• Excessive overspray on gun surfaces

• Fluid in the air passages

Waterborne Fluid Hose

• Dielectric failure of hose (pin-hole leak through

PTFE layer)

• Air gap in the fluid column between the gun and iso-

lated fluid supply, causing a low voltage reading on the isolation system voltage meter.

Voltage Isolation System

• Fluid leakage

• Dielectric breakdown of hoses, seals, or connec-

tions

• Isolators not functioning properly

309457G 33

Page 34

Troubleshooting

Visual Check

First, check the system for any visible faults or errors to help isolate whether the spray gun, fluid hose or voltage isolation system has failed. A voltage probe and meter, part no. 236003, is helpful for diagnosing voltage problems and is required for some of the troubleshooting tests that follow.

1. Check that all of the air and fluid tubes and hoses are properly connected.

2. Check that the voltage isolation system valves and controls are properly set for operation.

3. Check that the spray gun and voltage isolation system have sufficient air pressure.

4. Check that the gun turbine air (TA) is turned on and the pressure is set correctly.

5. Check that the voltage isolation system's enclosure door is closed and that any safety interlocks are engaged and working properly.

6. Make sure the voltage isolation system is in the “isolate” mode, where it is isolating the fluid voltage from ground.

Tests

If you still have no voltage, separate the spray gun and hose from the voltage isolation system and check whether the gun and hose alone will hold voltage with the following test.

1. Flush the system with water and leave the lines filled with water.

2. Discharge the system voltage (page 21).

3. Relieve the pressure (page 21).

4. Disconnect the fluid hose from the voltage isolation system.

Avoid allowing any water to leak out of the fluid hose as that could cause a significant air gap in the fluid column up to the gun electrode, which can break the conductivity path and conceal a potential failure area.

5. Position the end of the hose as far as possible away from any grounded surface. The end of the hose must be at least 1 ft. (0.3 m) from any ground. Make sure that no one is within 3 ft. (0.9 m) of the end of the hose.

7. To eliminate air gaps in the fluid column, spray enough fluid to purge the air out between the voltage isolation system and the spray gun. An air gap in the fluid hose can break the electrical continuity between the spray gun and the isolated fluid supply and cause a low voltage reading on a voltage meter connected to the isolated fluid supply.

8. Check the spray gun cover and barrel for accumulated overspray. Excessive overspray can create a conductive path back to the grounded gun. Install a new gun cover and clean the exterior of the gun.

9. Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found. Pay special attention to the following areas:

• Packing area of the spray gun

• Fluid hose: check for leakage or any bulges in

the outer cover, which may indicate an internal leak

• Internal voltage isolation system components

6. Turn the turbine air to the gun on. Measure the voltage at the gun electrode with a voltage probe and meter.

7. Discharge the system voltage by waiting 30 seconds and then touching the gun electrode with a grounded rod.

8. If the meter reading is 45 to 55 kV, the gun and fluid hose are okay, and the problem is in the voltage isolation system.

If the reading is below 45 kV, the problem is in the gun or fluid hose.

9. Flush the fluid hose and gun with enough air to dry out the fluid passages.

10. Turn the turbine air to the gun on. Measure the voltage at the gun electrode with a voltage probe and meter.

34 309457G

Page 35

Troubleshooting

11. If the meter reading is 55-60 kV, the gun power supply is okay, and there is probably a dielectric breakdown somewhere in the fluid hose or gun. Continue with step 12.

If the reading is below 55 kV, do the electrical tests on page 30 to check the gun and power supply resistance. If those tests show the gun and power supply are okay, continue with step 12.

12. A dielectric breakdown is most likely in one of the following three areas. Repair or replace the component that is failing.

• Fluid hose

Check for leakage or any bulges in the outer cover, which may indicate a pin-hole leak through the PTFE layer. Disconnect the fluid hose from the gun, and look for signs of fluid contamination on the outside of the PTFE portion of the fluid tube.

Inspect the end of the hose connected to the voltage isolation system. Look for cuts or nicks.

Make sure the hose is properly stripped. Restrip or replace the hose.

13. Before reassembling the gun, clean and dry the gun fluid inlet tube. Repack the inner spacer of the fluid packing rod with dielectric grease and reassemble the gun.

14. Reconnect the fluid hose.

15. Check the gun voltage with the voltage probe and meter before filling the gun with fluid.

• Fluid packings

Remove the packing assembly from the gun as instructed on page 43, and look for signs of fluid leakage or any blackened areas, which would indicate arcing is occurring along the packing rod.

• Fluid hose connection joint to the spray gun

A breakdown at the fluid hose connection joint would be caused by fluid leaking past the o-ring seals on the end of the hose. Remove the hose at the gun connection and look for signs of fluid leakage along the PTFE tube.

309457G 35

Page 36

Troubleshooting

Spray Pattern Troubleshooting

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

NOTE: 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.

Loose, dirty, damaged nozzle/seat. Clean or replace nozzle, page 41.

Air in fluid supply. Check fluid source. Refill.

Improper spray pattern. Damaged nozzle or air cap. Replace, page 41.

Fluid buildup on air cap or nozzle. Clean. See page 28.

Fan air pressure too high. Decrease.

Fluid too thin. Increase viscosity. Fluid pressure too low. Increase. Fan air pressure too low. Increase.

Fluid too thick. Reduce viscosity. Too much fluid. Decrease flow.

Streaks. Did not apply 50% overlap. Overlap strokes 50%.

Dirty or damaged air cap. Clean or replace, page 41.

36 309457G

Page 37

Troubleshooting

Gun Operation Troubleshooting

Problem Cause Solution

Excessive spray fog. Atomizing air pressure too high. Decrease air pressure as low as pos-

sible.

Fluid too thin. Increase viscosity.

“Orange Peel” finish. Atomizing air pressure too low. Increase air pressure; use lowest air

pressure necessary. 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 45. Fluid leakage from the front of the

gun

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

Dirty air cap Misaligned air cap (3) and fluid noz-

Air leaks from manifold Manifold is not tight. Tighten manifold screws (106). Fluid leaks at the quick-disconnect. Manifold is not tight. Tighten manifold screws (106).

Worn packings or rod. Replace packings or rod; see pages

43 or 44.

Worn or damaged packing rod (8). Replace; see page 43

Worn fluid seat. Replace fluid nozzle (4) and/or elec-

trode needle (7); see pages 41 to 42. Loose fluid nozzle (4). Tighten; see page 41. Damaged nozzle o-ring (4b). Replace; see page 41.

Damaged air cap (3). Replace; see page 41. Dirty or clogged fluid nozzle (4). Clean; see page 41. Damaged fluid nozzle (4). Replace; see page 41. Piston (34) not actuating. Check cylinder air. Check piston

u-cup (34d); see page 45. Actuator arm (29) is out of position. Check actuator arm and nuts. See

page 46.

Clean fluid buildup off air cap and zle (4).

Damaged nozzle orifice. Replace nozzle (4); see page 41. Fluid is coming on before the air. Check actuator arm and nuts. See

Fluid hose o-rings are worn or missing.

Hose not seated properly. Make sure the hose was stripped and

fluid nozzle seat; see page 28.

page 46.

Inspect or replace o-rings.

installed correctly. See page 14.

309457G 37

Page 38

Troubleshooting

Electrical Troubleshooting

Problem Cause Solution

Voltage still present at gun after following the Fluid Voltage Discharge

and Grounding Procedure

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

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

Turbine air is not turned off. Turn off.

Did not wait long enough for voltage to discharge.

Air pocket in fluid line leaves fluid near gun isolated.

Voltage isolation system failed. Service voltage isolation system.

Booth exhaust velocity is too high. Reduce velocity to within code limits. Atomizing 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

Faulty gun resistance. See Test Gun Resistance on page

Low fluid resistivity. Check fluid resistivity, page 20. 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 49. Damaged fiber optic cable or connec-

tion. 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

Wait longer before touching electrode with grounded rod. Check for bleed resistor failure.

Determine cause and correct. Purge air from fluid line.

less. Clean workpiece hangers.

30.

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

44.

back of the turbine alternator housing. Remove and test the turbine alternator. See page 50.

needed.

Check; replace damaged parts.

Wrap, above. See Grounding on page 18.

page 19 and Test Gun Resistance on page 30.

less. Clean workpiece hangers.

38 309457G

Page 39

Repair

Prepare the Gun for Service

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of a fire, explosion, or electric shock:

•Follow the Fluid Voltage Discharge and Grounding Procedure on page 21

before flushing, checking, or servicing the system and whenever you are instructed to discharge the voltage.

• Clean all the parts with a non-flammable solvent

as defined on the front cover of this manual.

• Do not service this equipment unless you are

trained and qualified.

• Do not come within 2 ft (0.6 m) of the gun nozzle

during gun operation or until after following the

Fluid Voltage Discharge and Grounding Procedure.

1. Discharge the system voltage, page 21.

2. Flush and clean the gun, page 26.

3. Relieve the pressure, page 21.

4. Remove the gun from the manifold, page 40.

5. Remove the gun from the worksite. Repair area must be clean.

WARNING

Pressurized Equipment Hazard

To reduce the risk of injury, follow the Pressure Relief Procedure on page 21 before

checking or servicing any part of the system and whenever you are instructed to relieve the pressure.

• Check all possible remedies in Troubleshooting

before disassembling the gun.

• Use a vise with padded jaws to prevent damage to

plastic parts.

• Lubricate the power supply o-ring (12a), some pack-

ing rod 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.

309457G 39

Page 40

Repair

Remove the Gun from the Manifold

1. Discharge the system voltage, page 21.

112

105

2. Flush and clean the gun, page 26.

3. Relieve the pressure, page 21.

4. Remove the air cap (3) and shroud (2), page 41.

5. Disconnect the fluid hose fitting (F) from the gun barrel (9).

6. 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.

TI1778A

102

Fig. 22. Remove Gun from Manifold

Install the Gun on the Manifold

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

7. Holding the gun firmly in hand, loosen the three screws (106) from the back of the manifold.

8. Remove the gun from the manifold and take it to the service area.

40 309457G

4. Make sure the fittings and barrel are clean and dry, then reconnect the waterborne fluid hose, page 14.

5. Reinstall the gun shroud (2) and air cap (3), page

41.

Page 41

Air Cap/Nozzle Replacement

Repair

WARNING

CAUTION

Hold the front end of the gun up and trigger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from entering the air passages.

1. Prepare gun for service, page 39.

2. Remove the retaining ring (1) and air cap (3). See

IG. 23..

3. Point gun up while removing the fluid nozzle (4) assembly with the multi-tool (40).

1, 3

Fire, Explosion, and Electric Shock Hazard

The nozzle contact ring (4a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the nozzle contact ring (4a) 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.

NOTE: Use non-silicone grease, Part No. 111265, on the small o-ring (4b). Do not over-lubricate. Do not lubricate the contact ring (4a).

4. Lightly lubricate the o-ring (4b). Install it and the contact ring (4a) on the nozzle (4).

NOTE: Make sure the electrode needle (7) is fingertight (page 42).

5. Install the fluid nozzle (4) with the multi-tool (40). Tighten until the fluid nozzle seats in the gun barrel (1/8 to 1/4 turn past hand-tight).

TI1572A

Fig. 23. Air Cap/Nozzle Replacement

6. Carefully install the air cap (3). Be sure to insert the electrode (7) through the center hole of the air cap. Rotate the air cap to the desired position.

7. 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.

8. Test gun resistance, page 30.

9. Install the gun onto the manifold and bracket. See page 40.

309457G 41

Page 42

Repair

Electrode Replacement

1. Prepare the gun for service, page 39.

2. Remove the air cap and nozzle, page 41. Remove the gun shroud (2).

3. Unscrew the electrode (7) with the multi-tool (40). Hold the packing rod end (8h) to prevent it from turning, F

IG. 24..

CAUTION

To avoid damaging the plastic threads, be very careful when installing the electrode.

4. Apply low-strength (purple) Loctite® or equivalent thread sealant to the electrode and packing rod threads. Install the electrode finger-tight. Do not overtighten.

5. Install the fluid nozzle, page 41.

6. Test gun resistance, page 30.

7. Install the gun shroud (2) and air cap, page 41.

8. Install the gun onto the manifold and bracket. See page 40.

TI1782A

Fig. 24. Electrode Replacement

42 309457G

Page 43

Fluid Packing Removal

NOTE: You may replace the packing rod as an assem-

bly, as described below, or as individual parts (see page

44). The assembly is pre-adjusted at the factory.

1. Prepare the gun for service, page 39.

2. Remove the air cap, page 41. Remove the gun shroud (2).

3. Remove the jam nut (28) and actuator arm (29). See page 45.

Repair

NOTE: The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.

4. Remove the fluid nozzle (4) and electrode (7). See pages 41 and 42.

5. Remove the packing rod (8), using the multi-tool (40).

CAUTION

Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause the gun to malfunction.

6. Check all parts for wear or damage and replace if necessary.

NOTE: Before installing the packing rod, clean the internal surface of the barrel (9) with a soft cloth or brush. Check for marks from high voltage arcing. If marks are present, replace the barrel.

TI1783A

Fig. 25. Fluid Packing Removal

309457G 43

Page 44

Repair

Packing Rod Repair

NOTE: You may replace the packing rod as individual

parts, as described below, or as an assembly (see page

43). The assembly is pre-adjusted at the factory.

NOTE: Before installing the fluid packing rod into the gun barrel, make sure the internal surfaces of the barrel are clean. Remove any residue with a soft brush or cloth. Check the inside of the barrel for marks from high voltage arcing. If marks are present, replace the barrel.

To assemble the individual parts:

1. Place the packing nut (8e) and seal (8b) on the fluid rod (8h). Flats on the packing nut must face the back of the fluid rod. The seal o-ring must face away from the packing nut. See F

2. Fill the inner cavity of the spacer (8g) with dielectric grease. Place the spacer on the fluid rod (8h) in the direction shown. Generously apply dielectric grease to the outside of the spacer.

3. Place the rod packing (8d), packing spreader (8c), and housing (8f) on the packing rod (8h).

IG. 26..

4. Lightly tighten the packing nut (8e). The packing nut is properly tightened when there is 3 lb (13.3 N) of drag force when sliding the packing housing (8f) assembly along the rod. Tighten or loosen the packing nut as needed.

5. Install the o-ring (8a) on the outside of housing (8f). Lubricate the o-ring with non-silicone grease, Part No. 111265. Do not over-lubricate.

6. Install the spring (25) against the nut (E) as shown.

7. Install the packing rod assembly (8) into the gun barrel. Using the multi-tool (40), tighten the assembly until just snug.

8. Install the electrode, page 42 and nozzle, page 41.

9. Install and adjust the actuator arm (29) and jam nut (28). See page 46.

10. Test gun resistance, page 30.

11. Install the gun shroud (2) and air cap, page 41.

12. Install the gun onto the manifold and bracket. See page 40.

Fig. 26. Packing Rod

TI1489A

44 309457G

Page 45

Repair

Piston Repair

1. Prepare the gun for service, page 39.

2. Remove the air cap, page 41. Remove the gun shroud (2).

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

NOTE: The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.

Fig. 27. Actuator Arm

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

IG. 27..

28 29 30 34b

TI1800A

Table 5: Piston O-Rings

Front O-Ring

(34e)

Back O-Ring

(34f)

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

34e

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

Separates cylinder air from fan and atomizing air.

at back of manifold when gun is triggered.

34a

34d

34c

34f

TI1575A

34b

34d

34g

34f

34e

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

IG. 28..

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

111265. Do not over-lubricate.

Fan Air Side

Atomizing Air Side

34g

TI1576A

7. Align the two stems (34c) with the holes in the gun body and press the piston assembly into the back of the gun until it bottoms.

Fig. 28. Piston O-Rings

8. Install and adjust the actuator arm, page 46.

Table 5: Piston O-Rings

Description Function

Shaft O-Ring

(34g)

309457G 45

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

Page 46

Repair

Adjust the Actuator Arm

NOTE: The fluid nozzle (4) must be in place when

removing or installing the jam nut and 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

27. on page 45.

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 (E), which allows the atomizing air to actuate before the fluid. See F

IG. 29..

3. Tighten the adjustment nut (30) against the actuator arm (29). Check that the 0.125 in. (3 mm) gap has been maintained. In addition, there should be 3-4 mm of electrode needle travel when the gun is triggered. Adjust the jam nut position to obtain these dimensions.

4. Test gun resistance, page 30.

IG.

0.125 in. (3 mm) gap

30 34b

Fig. 29. Actuator Arm Adjustment

TI1567A

5. Install the gun shroud (2) and air cap (3), page 41.

6. Install the gun onto the manifold and bracket. See page 40.

46 309457G

Page 47

Repair

Barrel Removal

1. Prepare the gun for service, page 39.

2. Remove the air cap, page 41. Remove the gun shroud (2).

3. Carefully loosen the fluid fitting nut (20). Pull the tube (19) out of the fitting (23). Make sure both ferrules (21, 22) and the nut stay with the tube.

4. Remove the jam nut (28) and actuator arm (29). See page 45.

5. Loosen the three screws (10, 33). See F

IG. 30..

CAUTION

To avoid damaging the power supply (12), pull the gun barrel (9) 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 (9) straight off the body. See F

Fig. 30. Barrel Removal

IG. 30..

TI1781A

Fig. 31. Disconnect Fluid Tube

TI1800A

309457G 47

Page 48

Repair

Barrel Installation

1. Be sure the gasket (11) and grounding spring (51) are in place. Make sure the air holes are aligned properly. Replace if damaged. See F

2. Place the barrel (9) 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. 32..

CAUTION

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

4. Assemble the fluid tube (19) into the fluid fitting (23). Ensure that the ferrules (21, 22) are in place. Tighten the nut (20).

5. Install and adjust the actuator arm (29) and jam nut (28). See page 46.

6. Test gun resistance, page 30.

7. Install the gun shroud (2) and air cap, page 41.

8. Install the gun onto the manifold and bracket. See page 40.

Fig. 32. Barrel Installation

TI1785A

48 309457G

Page 49

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 39.

2. Remove the barrel (9), page 47.

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 (39) from the socket at the top of the body (32). See F

IG. 33., page 50.

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 (39) 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 (9), page 48.

12. Test gun resistance, page 30.

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 (39) from the power supply.

5. Check the power supply resistance, page 31. 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 (39) 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.

309457G 49

Page 50

Repair

Fig. 33. Power Supply

12a

12b

13a

13e

Turbine Alternator Removal and Replacement

TI1784A

7. Install the power supply/alternator assembly, page

49.

NOTE: Replace turbine alternator bearings after 2000 hours of operation. Order Part No. 223688 Bearing Kit.

1. Prepare gun for service, page 39.

2. Remove the power supply/alternator assembly, page 49.

3. Disconnect the alternator from the power supply, page 49.

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 49.

50 309457G

Page 51

Repair

309457G 51

Page 52

Parts

Part No. 244591 PRO Auto Xs Electrostatic Gun, Series A, for waterborne coatings

13a

12a

12b

Ref. No. 13: Alternator Detail

13b

13a

13e

13b

TI1481a

34d

34a

13d

13c

13e

34c

34f

34e

TI1777A

34b

ti1601a

34g

Ref. No. 8: Packing Rod De-

52 309457G

Page 53

Part No. 244591 PRO Auto Xs Electrostatic Gun, Series A, for waterborne coatings

Parts

Ref. No.

1 244950 RING, retaining, air cap; includes 1a1

1a*† 198307 . U-CUP 1

2 245325 SHROUD 1

3 24A276 AIR CAP 1

4 197266 NOZZLE; 1.5 mm orifice; includes

4a 111261 . O-RING, conductive 1

4b 111507 . O-RING; fluoroelastomer 1

5 198486 CONNECTOR, tube, fiber optic;

7 276867 NEEDLE, electrode, WB 1

8 244521 ROD, packing; includes 8a-8h 1

8a* 111316 . O-RING; fluoroelastomer 1

8b* 116905 . SEAL 1

8c* 178409 . SPREADER, packing; uhmwpe 1

8d* 178763 . PACKING, rod; acetal 1

8e 197641 . NUT, packing 1

8f 185495 . HOUSING, packing 1

8g* 186069 . SPACER, packing; acetal 1

8h 244696 . ROD, packing 1

Part No. Description Qty

4a and 4b

see page 55 (unassembled)

Ref. No.

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

15 107460 TOOL, wrench, ball end

16 179791 TAG, warning (not shown);

17 186118 SIGN, warning (not shown);

19 197624 SPRING, grounding 1

25 185111 SPRING, compression 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; 1/4-20 x 3/4

Part No. Description Qty

13a-13e

and rear bearings and fan

(not shown)

replacement available at no cost

in. (19 mm)

9 244394 BARREL, gun 1

10 197518 SCREW; socket-hd; 10-24 x 3/4

in. (19 mm)

11*† 197517 GASKET, barrel 1

12 244542 POWER SUPPLY, 60 kV; includes

12a-12b

12a*† 103337 . O-RING; fluoroelastomer 1

12b 197624 . SPRING, compression 1

309457G 53

32 198363 BODY, gun, auto, WB 1

33 116575 SCREW, cap, socket-hd; 10-24; 3

in. (76 mm)

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

Page 54

Parts

Ref. No.

35 244938 MANIFOLD; see separate parts

37 245265 CIRCUIT, flexible 1

39 276741 MULTI-TOOL 1

40 189888 COVER, gun; box of 10 (not

42 116553 TUBE, grease, lubricant 1

48 290171 SIGN, warning (not shown);

56 24A431 KIT, wide pattern 1

Part No. Description Qty

list on page 55

shown)

replacement available at no cost

* Recommended spare parts. Keep on hand to reduce downtime.

† Included in repair kit 15D592.

NOTE: Replacement Warning labels, signs, tags, and cards are available at no cost.

54 309457G

Page 55

Part No. 244938 Manifold, Series A

101 (Ref)

Parts

5 (see pages 53 or 55)

106 (Ref)

112

116

116a

102

104

103

TI1796A

Ref. No.

113

105

Part No. Description Qty

101 198362 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

117

120

109

119

114

115

108

106

107

Ref. No.

Part No. Description Qty

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.

101

TI1791A

110

108 186845 FITTING, turbine 1

109 110078 FITTING, tube, fluid 2

110 112646 PLUG 1

112† 197925 GASKET, manifold 1

113 108290 SCREW, machine 2

114 189365 CAP, kV, HI/LO 2

309457G 55

Page 56

Accessories

Air Line Accessories

Grounded Air Hose (Red Cover)

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; red cover with stainless steel braid ground path.

235068 6 ft (1.8 m) 235069 15 ft (4.6 m) 235070 25 ft (7.6 m) 235071 36 ft (11 m) 235072 50 ft (15 m) 235073 75 ft (23 m) 235074 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

Fluid Line Accessories

Shielded Waterborne Fluid Hose

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

PTFE; 1/4 in. (6 mm) ID

245327 25 ft (7.6 m) 245328 36 ft (11 m)

Unshielded Waterborne Fluid Hose

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

PTFE; 1/4 in. (6 mm) ID. See manual 308688 for installation requirements.

245329 25 ft (7.6 m) 245330 36 ft (11 m)

Fluid Shutoff/Drain Valve

500 psi (35 bar, 3.5 MPa) Maximum Working Pressure

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

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.

208630 1/2 npt(m) x 3/8 npt(f); carbon steel and

PTFE; for non-corrosive fluids

Drain Valve

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

236853 Mounts directly to gun manifold for faster

flushing and color changes. Must be used with 233676 Fluid Recirculation Kit.

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Accessories

Miscellaneous Accessories

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.

Grounding Rod 210084 Use to discharge voltage from voltage isola-

tion system enclosure.

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.

Power Supply 235301 Supplies low voltage DC power to 224117

Display Module. See 308265.

Fiber Optic Y Cables

See item T in F 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)

Remote Voltage Display 189762 Battery-operated meter displays actual

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)

Fiber Optic Cables

See item V in F and remote voltage display, bulkhead connector and remote display, or bulkhead connector and gun manifold. See 308265.

224672 25 ft (7.6 m) 224674 50 ft (15 m) 224676 100 ft (30.5 m)

IG. 3. on page 11. For use with 224117

spraying voltage. remote mount outside hazardous area. Connects to gun via fiber optic cable. See 308265.

IG. 3. on page 11. Connect gun manifold

Bulkhead Connector 189870 For connecting two fiber optic cables.

309457G 57

Page 58

Accessories

Gun Accessories

Round Pattern Kits

Consists of fluid tip, diffuser and air cap.

245217 4-6 in. (102-152 mm) diameter 245219 8-10 in. (203-254 mm) diameter

Dielectric Grease 116553 1 oz (28 g) tube of dielectric grease for the

power supply o-ring (12a), some packing rod parts (8), and certain fluid fittings.

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.

58 309457G

Page 59

Technical Data

Category Data

Maximum Working Fluid Pressure 100 psi (0.7 MPa, 7 bar) Maximum Working Air Pressure 100 psi (0.7 MPa, 7 bar) Minimum Air Pressure at Gun Inlet 40 psi (0.28 MPa, 2.8 bar) Maximum Fluid Operating Temperature 120°F (48°C) Short Circuit Current Output 125 microamperes Voltage Output 30-60 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 Fan 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 custom 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.

309457G 59

Page 60

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

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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

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

Original instructions. This manual contains English. MM 309457

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised April 2012

Graco 309457G User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Warnings

Warning Symbol

Caution Symbol

Introduction

How the Electrostatic Air Spray Gun Works

Spraying Waterborne Fluids Electrostatically

Gun Features and Options

Operating the Spray Function

Operating the Electrostatics

Changing the kV Setting

Installation

Install the System

Warning Signs

Ventilate the Spray Booth

Install the Air Line Accessories

Install the Gun and Mounting Bracket

Connect the Air Line

Manifold Connections

Connect the Waterborne Fluid Hose

Optional Fiber Optic Cable Connection

Grounding

Check Electrical Grounding

Install the Fabric Cover

Operation

Fluid Voltage Discharge and Grounding Procedure

Pressure Relief Procedure

Operating Checklist

Select a Fluid Nozzle and Air Cap

Adjust the Spray Pattern

Adjust the Electrostatics

Spraying

Triggering the Fluid Alone

Shutdown

Maintenance

Daily Care and Cleaning

Clean the Air Cap and Fluid Nozzle

Check for Fluid Leakage

Electrical Tests

Test Gun Resistance

Test Power Supply Resistance

Test Electrode Resistance

Troubleshooting

Voltage Loss 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

Air Cap/Nozzle Replacement

Electrode Replacement

Fluid Packing Removal

Packing Rod Repair

Piston Repair

Adjust the Actuator Arm

Barrel Removal

Barrel Installation

Power Supply Removal and Replacement

Turbine Alternator Removal and Replacement

Parts

Accessories

Air Line Accessories

Fluid Line Accessories

Miscellaneous Accessories

Gun Accessories

Technical Data

Graco Standard Warranty

Graco Information