Graco 309457G User Manual
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
EN
• 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.
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
21
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
2 309457G
Warnings
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.
309457G 3
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.
4 309457G
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.
309457G 5
Introduction
Introduction
How the Electrostatic Air Spray Gun Works
The automatic electrostatic air spray gun operates very
similar to a traditional air spray gun. The atomization
and fan air are emitted from the air cap. The atomization
air breaks up the fluid stream and controls the droplet
size. The fan air controls the shape and width of the
spray pattern. The fan and atomization air can be
adjusted independently.
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.
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
Introduction
F
KV1
TA
FO
CYL
KV2
A1
P1
TI1557A
A2
P2
E
EXH
A
CD
B
H
TI1790A
Manifold Back
TI1780A
G
J
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
Installation
Installation
Install the System
WARNING
Fire, Explosion, and Electric Shock Hazard
Installing and servicing this equipment
requires access to parts which may cause
electric shock or other serious injury if work
is not performed properly.
•Do not install or service this equipment
unless you are trained and qualified.
•Be sure your installation complies with 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
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
X
fitting if not used)
kV Switch Air Hose, 5/32 in. (4 mm) OD (optional; plug KV2
Y
fitting if not used)
10 309457G
Installation
NOTE:
L
above
See *
W
* The turbine air supply (TA) must be electrically interlocked with the spray booth ventilation fans to prevent
the power supply from operating without ventilating fans on.
A
K
K
Y
X
BCD
TA
KV1
KV2
K
L
A2A1
L
CYL
K
N
E
M
G
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
P
T
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.
P1
F
J
TI1801A
Manifold Back
H
KV
mA
V**
Q
85.0 KV
TI1797A
S
Fig. 3. Optional Fiber Optic Connection to Voltage Display Module
309457G 11
Installation
e
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
NN
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
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
TA
CYL
A1
P1
KV1
FO
A2
P2
2. Check the electrical grounding of the gun as
instructed on page 19.
EXH
TI1790A
Fig. 5. Manifold Connections
309457G 13
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)
A
B
T
F
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
Installation
P1
9
F
R
N*M*
C
M*
N*
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
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).
E
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).
2
3
T
Fig. 8. Hose Connection at Isolated Fluid Supply
C
J
TI1805A
16 309457G
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.
5
BB
AA
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.
5
120
Fig. 9. Fiber Optic Fitting
TI1794A
309457G 17
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
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