Graco 3A2494D User Manual

Instructions-Parts

Pro

Pro Pro

Gun

Gun Gun

For

For For For

For For professional

professional professional

100 psi (0.7 MPa, 7.0 bar) Maximum Fluid Working Pressure 100 psi (0.7 MPa, 7.0 bar) Maximum Air Working Pressure

See

See See numbers

numbers numbers information.

information. information.

Xp™

Xp™ Xp™

use

use use use

use use

Class

in ininClass Class

Group

in in

Group Group

use

use use

Important

Important Important Readallwarningsandinstructionsinthismanual. Save

these

Save Save

these these

page

page page

for

3 33for for

and

and and

Electrostatic

Electrostatic Electrostatic

Div.

I, I,I,Div. Div.

II,

II, II,

only.

only. only.

Safety

Safety Safety

instructions.

instructions. instructions.

model

model model

approval

approval approval

Hazardous

I IIHazardous Hazardous

Zone

Zone Zone

Explosive

1 11Explosive Explosive

Instructions

Instructions Instructions

part

part part

Air

Air Air

Spray

Spray Spray

3A2494D

Locations

Locations Locations

Atmosphere

Atmosphere Atmosphere

using

Group

using using

Group Group

Locations

Locations Locations

spray

D DDspray spray

materials.

materials. materials.

using

Group

using using

Group Group

IIA

spray

IIA IIA

spray spray

materials.

materials. materials.

For

For For

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents

Contents Contents

Models...............................................................3

Warnings...........................................................4

GunOverview....................................................7

HowtheElectrostaticSprayGun

Works............................................7

Controls,Indicators,andComponents...........8

SmartGuns.................................................9

Installation..........................................................15

WarningSign...............................................15

VentilatetheSprayBooth.............................15

AirSupplyLine............................................16

FluidSupplyLine.........................................16

GunSetup..........................................................18

GunSetupChecklist....................................18

Grounding...................................................21

CheckGunElectricalGrounding...................25

CheckFluidResistivity.................................26

CheckFluidViscosity...................................26

FlushBeforeUsingEquipment......................26

GuidelinesforAbrasiveMaterials..................26

Operation...........................................................27

PressureReliefProcedure............................27

Startup........................................................27

Shutdown....................................................27

Maintenance......................................................28

Flushing......................................................28

CleantheGunDaily.....................................29

DailySystemCare.......................................30

ElectricalTests...................................................31

TestGunResistance....................................31

TestPowerSupplyResistance.....................32

TestElectrodeResistance............................32

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

SprayPatternTroubleshooting......................33

GunOperationTroubleshooting....................34

ElectricalTroubleshooting............................35

Repair................................................................37

PreparetheGunforService.........................37

AirCapandNozzleReplacement..................38

ElectrodeReplacement................................39

FluidPackingRodRemoval..........................40

PackingRodRepair.....................................40

BarrelRemoval............................................42

BarrelInstallation.........................................42

PowerSupplyRemovaland

Replacement..................................43

AlternatorRemovalandReplacement...........44

FluidTubeRemovalandReplacement...........46

FanAirAdjustmentValveRepair..................47

AtomizingAirRestrictorValveRepair............48

ESOn-OffandFluidAdjustmentValve

Repair............................................49

AirValveRepair...........................................50

SmartModuleReplacement..........................51

AirSwivelandExhaustValve

Replacement..................................52

Parts..................................................................53

StandardAirSprayGunAssembly................53

RoundSprayAssembly................................55

StandardHighConductivityAirSprayGun

Assembly.......................................56

SmartHighConductivityAirSprayGun

Assembly.......................................58

SmartAirSprayGunAssembly.....................60

PackingRodAssembly.................................62

AlternatorAssembly.....................................63

ESOn-OffandFluidAdjustmentValve...........64

FanAirAdjustmentValveAssembly..............65

AtomizingAirRestrictorValve

Assembly.......................................65

SmartModuleAssembly...............................66

HighConductivityFluidTube

Assembly.......................................67

AirCapsandFluidNozzles.................................68

FluidNozzleSelectionChart.........................68

FluidNozzlePerformanceCharts..................68

AirCapSelectionChart................................70

AirConsumptionCharts...............................71

RepairKits,RelatedManuals,and

Accessories..........................................73

GunAccessories..........................................73

OperatorAccessories...................................74

SystemAccessories.....................................74

TestEquipment...........................................74

Hoses.........................................................75

Dimensions........................................................76

TechnicalData...................................................77

GracoProXpWarranty.......................................78

3A2494D

Models

Models Models

Part

No.

Part Part

No. No.

L40T1040

L40T1440

L40T1540

L40T1640

L60T1060

L60T1160

L60T1260

L60T1660

L60M1060

L60M1260

L60M1660

L85T1085

L85T1685

L85M1085

kV kV

1.5

1.5 1.5 mm

mm mm

Nozzle

Nozzle Nozzle

Round

1.2

Round Round

1.2 1.2 Spray

Spray Spray

mm mm

✔✔✔

✔✔✔✔

✔✔✔

Standard

Standard Standard Display

Display Display

Smart

Smart Smart Display

Display Display

Standard

Standard Standard Coatings

Coatings Coatings

High

High High Conductivity/

Conductivity/ Conductivity/ High

Wear

High High

Wear Wear

Increased

Increased Increased Transfer

Transfer Transfer Ef󰘰ciency

Ef󰘰ciency Ef󰘰ciency

L85M1685

✔✔✔

II IIII2 22G G

EEx0.24mJT6

FM12ATEX0068

EN50050

Ta0°C–50°C

3A2494D 3

Warnings

Warnings Warnings

Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout thebodyofthismanualwhereapplicable.

WARNING

WARNING WARNING

FIRE,

EXPLOSION,

FIRE, FIRE,

EXPLOSION, EXPLOSION,

Flammablefumes,suchassolventandpaintfumes,inwork work prevent󰘰re,explosion,andelectricshock:

•Electrostaticequipmentmustbeusedonlybytrained,quali󰘰edpersonnelwhounderstand therequirementsofthismanual.

•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorcloseto sprayarea.Resistancemustnotexceed1megohm.SeeGrounding Grounding

•OnlyusegroundedGracoconductiveairsupplyhoses.

•Donotusepaillinersunlesstheyareconductiveandgrounded. Stop

•Stop Stop

•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.

•Useandcleanequipmentonlyinwellventilatedarea.

•Interlockthegunairsupplytopreventoperationunlessventilatingfansareon.

•Usecleaningsolventswithhighestpossible󰘱ashpointwhen󰘱ushingorcleaningequipment.

•Tocleantheexterioroftheequipment,cleaningsolventsmusthavea󰘱ashpointatleast

•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and

•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.

•Keepsprayareafreeofdebris,includingsolvent,ragsandgasoline.

•Keepaworking󰘰reextinguisherintheworkarea.

operation

operation operation

equipmentuntilyouidentifyandcorrecttheproblem.

5°Caboveambienttemperature.

plasticdropcloths(potentialstaticarc).

AND

ELECTRIC

AND AND

ELECTRIC ELECTRIC

immediately

immediately immediately

ifstaticsparkingoccursoryoufeelashock.Donotuse

SHOCK

SHOCK SHOCK

HAZARD

HAZARD HAZARD

work

area

area area

canigniteorexplode.Tohelp

Grounding

instructions.

3A2494D

WARNING

WARNING WARNING

PRESSURIZED

PRESSURIZED PRESSURIZED Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin andcauseseriousinjury.

EQUIPMENT

EQUIPMENT EQUIPMENT

HAZARD

HAZARD HAZARD

Warnings

•FollowthePressure Pressure cleaning,checking,orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

PLASTIC

PLASTIC PLASTIC Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious injuryorpropertydamage.

•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing parts.

•SeeTechnical Technical solventmanufacturer’sMSDSsandrecommendations.

TOXIC

TOXIC TOXIC Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin, inhaled,orswallowed.

•ReadMSDS’stoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable guidelines.

PERSONAL

PERSONAL PERSONAL Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury, includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective equipmentincludesbutisnotlimitedto:

Pressure

PARTS

PARTS PARTS

Technical

FLUID

FLUID FLUID

OR OR

PROTECTIVE

PROTECTIVE PROTECTIVE

Relief

Procedure

Relief Relief

Procedure Procedure

CLEANING

CLEANING CLEANING

Data

Data Data

inthisandallotherequipmentinstructionmanuals.Read󰘱uidand

FUMES

FUMES FUMES

SOLVENT

SOLVENT SOLVENT

EQUIPMENT

EQUIPMENT EQUIPMENT

whenyoustopspraying/dispensingandbefore

HAZARD

HAZARD HAZARD

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent manufacturer.

3A2494D 5

Warnings

WARNING

WARNING WARNING

EQUIPMENT

EQUIPMENT EQUIPMENT Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated systemcomponent.SeeTechnical Technical

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete informationaboutyourmaterial,requestMSDSfromdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

MISUSE

MISUSE MISUSE

HAZARD

HAZARD HAZARD

Technical

Data

Data Data

Pressure

inallequipmentmanuals.

Relief

Relief Relief

Technical

Procedure

Procedure Procedure

whenequipmentisnotinuse.

Data

Data Data

6 3A2494D

GunOverview

Gun

Gun Gun

How

How How

Theairhosesuppliesairtothespraygun.Partof theairoperatesthealternatorturbineandtherest oftheairatomizesthe󰘱uidbeingsprayed.The alternatorgeneratespower,whichisconvertedby thepowercartridgetosupplyhighvoltagetothe gun’selectrode.

Overview

Overview Overview

the

Electrostatic

the the

Electrostatic Electrostatic

Spray

Spray Spray

Gun

Gun Gun

Works

Works Works

Thepumpsupplies󰘱uidtothe󰘱uidhoseandgun, wherethe󰘱uidiselectrostaticallychargedasit passestheelectrode.Thecharged󰘱uidisattracted tothegroundedworkpiece,wrappingaroundand evenlycoatingallsurfaces.

3A2494D

GunOverview

Controls,

Controls, Controls,

Theelectrostaticgunincludesthefollowing controls,indicators,andcomponents(seeFig.

1).ForinformationonSmartguns,alsosee

SmartGuns,page9.

Figure1GunOverview

Item

Item Item

Indicators,

Indicators, Indicators,

Descrip-

Descrip- Description

tion tion

Purpose

Purpose Purpose

and

Components

and and

Components Components

Item

Item Item

Descrip-

Descrip- Description

tion tion

Purpose

Purpose Purpose

BFluidInlet

EElectrode

FFanAir

AirSwivel Inlet

TurbineAir Exhaust

AirCap and Nozzle

Needle

Adjustment Valve

Atomizing Air Restrictor Valve

1/4npsm(m)left-handthread, forGracogroundedairsupply hose.

3/8npsm(m),for󰘱uidsupply hose.

Barbed󰘰tting,forsupplied exhausttube.

SeeAirCapsandFluid

Nozzles,page68,foravail-

ablesizes.

Supplieselectrostaticcharge tothe󰘱uid.

Adjustsfansizeandshape. Canbeusedtodecrease patternwidth.

Restrictsaircapair󰘱ow. Replacewithplug(included) ifdesired.

HFluidAd-

justment Knob

ESOn-Off Valve

ESIndicator(standardgun only;for Smartgun indicator,see

Operating Mode, page9)

Adjusts󰘱uid󰘱owbylimiting 󰘱uidneedletravel.Useonly inlow󰘱owconditions,to reducewear.

TurnselectrostaticsON(I)or OFF(O).

LitwhenESisON(I).Colorindicatesalternatorfrequency. SeetheLEDindicatortable intheGunSetupChecklist,

page18.

8 3A2494D

GunOverview

Smart

Smart Smart

TheSmartGunmoduledisplayssprayingvoltage, current,alternatorspeed,andthevoltagesetting(low orhigh).Italsoallowstheusertochangetoalower sprayingvoltage.Themodulehastwomodes:

•OperatingMode

•DiagnosticMode

Operating

Operating Operating

Bar

Bar Bar

SeeFig.2,andTable1onpage10.TheOperating Modedisplaysgundataduringnormalspraying.The displayusesabargraphtoshowthevoltagelevelin kiloVolts(kV)andthecurrentlevelinmicroAmperes (uA).Thebargraphrangeisfrom0to100%foreach value.

IfthebargraphLEDsareblue,thegunisreadyto spray.IftheLEDsareyelloworred,thecurrentis toohigh.The󰘱uidmaybetooconductive,orsee

ElectricalTroubleshooting,page35forotherpossible

causes.

Guns

Guns Guns

Mode

Mode Mode

Graph

Graph Graph

Voltage

Voltage Voltage

Thevoltageadjustmentswitch(VA)allowsthe operatortochangefromlowtohighvoltage.

•Thehighvoltagesettingisdeterminedbythe maximumvoltageofthegunandisnotadjustable.

•Thelowvoltageindicator(LO)lights whentheswitchissettoLO.Thelow voltagesettingisuseradjustable.See

AdjustingtheLowVoltageSetting,page10.

NOTE:

NOTE: NOTE: haslostcommunicationwiththepowersupply.See

ErrorDisplay,page10,forfurtherinformation.

Adjustment

Adjustment Adjustment

IftheErrordisplayappears,theSmartmodule

Switch

Switch Switch

Indicator

Hz Hz

Indicator Indicator

TheHzindicatorfunctionsthesameastheES indicatoronstandardguns.Theindicatorlightsto showthealternatorspeedstatus,andhasthree colors:

•Greenindicatesthealternatorspeediscorrect.

•Iftheindicatorchangestoamberafter1second, increasetheairpressure.

•Iftheindicatorchangestoredafter1second, reducetheairpressure.

Figure2SmartGunModuleinOperatingMode

3A2494D 9

GunOverview

Error

Error Error

IftheSmartmodulelosescommunicationwith thepowersupply,theErrordisplayappears,the Hzindicatorturnsred,andtheSmartmoduleis disabled.SeeFig.3,andTable1onpage10. ThiscanoccurinOperatingModeorDiagnostic Mode.SeeElectricalTroubleshooting,page35. CommunicationmustberestoredtomaketheSmart modulefunctional.

NOTE:

NOTE: NOTE: appear.Ifthegunhasbeendisassembled,wait8 secondsbeforesprayingtoensurethatanError conditionhasnotoccurred.

NOTE:

NOTE: NOTE: displaywillnotappear.

Display

Display Display

Ittakes8secondsfortheErrordisplayto

Ifthereisnopowertothegun,theError

foryourgun.Continuepressingthebuttonuntilyou reachthedesiredsetting.

NOTE:

NOTE: NOTE: returntotheOperatingScreen.

NOTE:

NOTE: NOTE:

LockSymbol,page10.

Figure4LowVoltageSettingScreen(Unlocked)

Lock

Lock Lock

After2secondsofinactivitythedisplaywill

Thelowvoltagesettingmaybelocked.See

Symbol

Symbol Symbol

Figure3ErrorDisplay

Adjusting

Adjusting Adjusting

Thelowvoltagesettingisuseradjustable.Toaccess thelowvoltagesettingscreenwheninOperating Mode,presstheLOSETbutton(LS)momentarily. Thescreenwilldisplaythecurrentlowvoltage setting.SeeFig.4,andTable1onpage10.The possiblerangesare:

•85kVguns:40–85kV

•60kVguns:30–60kV

SettheVoltageAdjustmentswitch(VA)toLO.Press theLOSETbuttonrepeatedlytoincreasethesetting inincrementsof5.Whenthedisplayreachesthe maximumsettingitwillreturntotheminimumsetting

the

Low

the the

Voltage

Low Low

Voltage Voltage

Setting

Setting Setting

Thelowvoltagesettingmaybelocked.Whenlocked, animage(LK)appearsonthescreen.SeeFig.5, andTable1onpage10.

•WheninHImode,thelowvoltagesettingisalways always locked.ThelocksymbolwillappearwhentheLO SETbuttonispressed.

•WheninLOmode,thelocksymbolwill only

only only

appearifthelockisenabled.See

LowVoltageLockScreen,page14,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

always

10 3A2494D

GunOverview

Table

Table Table

Item

Item Item

LSLOSETbutton

Key

for

Figs.

1 11. ..Key Key

for for

2–9.

Figs. Figs.

2–9. 2–9.

Description

Description Description

VoltageAdjustmentSwitch

LowVoltageModeIndicator

Voltage(kV)Display

Current(uA)Display

Purpose

Purpose Purpose

Two-positionswitchsetssmart gunvoltagetolowsetting(LO)or highsetting(HI).Thisswitchis functionalinOperatingModeand inDiagnosticMode.

Lights(blue)whenthesmartgun issettoLowVoltage.

Displaysactualsprayingvoltage ofthegun,inkV.InOperating Mode,displayisabargraph. InDiagnosticMode,voltageis displayedasanumber.

Displaysactualsprayingcurrent ofthegun,inuA.InOperating Mode,displayisabargraph. InDiagnosticMode,currentis displayedasanumber.

Pressmomentarilytoenterthe LowVoltageSettingscreen.

Pressandholdforapproximately5 secondstoenterorexitDiagnostic Mode.

WhileinDiagnosticMode,press momentarilytoadvancethrough screens.

WhileontheLowVoltageLock Screen(inDiagnosticMode), pressandholdtoturnthelockon oroff.

LVLowVoltageDisplayDisplaysthelowvoltagesetting

asanumber.Thesettingcanbe changed.SeeFig.4.

LKLowVoltageLocked

Appearsifthelowvoltagesetting islocked.SeeFig.5andFig.9.

3A2494D

GunOverview

Item

Item Item

ERErrorDisplay

VIVoltageIndicatorInDiagnosticMode,thetwotop

CICurrentIndicator

ASAlternatorSpeedDisplay

Description

Description Description

LODisplay

AlternatorSpeedIndicatorInOperatingMode,indicatorcolor

Purpose

Purpose Purpose

AppearsontheLowVoltageLock Screen.SeeFig.9.

AppearsiftheSmartmoduleloses communicationwiththepower supply.SeeFig.3.

rightLEDsofthescreenlight, indicatingthatthevaluedisplayed isinkV.SeeFig.6.

InDiagnosticMode,thetwo bottomrightLEDsofthescreen light,indicatingthatthevalue displayedisinuA.SeeFig.7.

InDiagnosticMode,Hzlevelis displayedasanumber.SeeFig.

variestoshowthealternator speedstatus:

•greenindicatesthealternator speedisatthecorrectlevel.

•Iftheindicatorchangestoamber after1second,thealternator speedistoolow.

•Iftheindicatorchangestored after1second,thealternator speedistoohigh.Theindicator willalsoturnrediftheError displayappears.

InDiagnosticMode,theindicator isgreenwhenintheAlternator Speed(Hertz)screen.

3A2494D

GunOverview

Diagnostic

Diagnostic Diagnostic

DiagnosticModeincludesfourscreenswhichdisplay gundata:

•Voltage(kiloVolts)Screen

•Current(microAmperes)Screen

•AlternatorSpeed(Hertz)Screen

•LowVoltageLockScreen

NOTE:

NOTE: NOTE: lowvoltagesetting;thesettingisnotadjustablein DiagnosticMode.However,thevoltageadjustment switch(VA)canbesettoHIorLOinOperatingMode andinDiagnosticMode.

ToenterDiagnosticMode,pressandholdtheLOSET (LS)buttonforapproximately5seconds.Thedisplay willgototheVoltage(kiloVolts)Screen,page13.

Toadvancetothenextscreen,presstheLOSET buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET buttonforapproximately5seconds.Thescreenwill returntoOperatingMode.

NOTE:

NOTE: NOTE: Mode,thelastscreenviewedwillbedisplayedwhen thegunisretriggered.

NOTE:

NOTE: NOTE: fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page14fordetails.

Voltage

Voltage Voltage

Mode

Mode Mode

YoumustbeinOperatingModetoadjustthe

IfthegunisdetriggeredwhileinDiagnostic

DiagnosticModecannotbeexited

(kiloVolts)

(kiloVolts) (kiloVolts)

Screen

Screen Screen

Figure6Voltage(kiloVolts)Screen

Current

Current Current

TheCurrent(microAmperes)Screenisthesecond screenintheDiagnosticMode.SeeFig.7,andTable 1onpage10.Toenterthisscreen,presstheLO SETbuttonwhileintheVoltage(kiloVolts)Screen.

Thisscreendisplaysthesprayingcurrentofthegun asanumber(uA),roundedtothenearest5uA.The twobottomrightLEDs(CI)ofthedisplaypanellight, indicatingthattheCurrent(microAmperes)Screen isdisplayed.Thedisplayisareadoutandcannot bechanged.

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page14.Press

andholdforapproximately5secondstoreturnto OperatingMode.

(microAmperes)

(microAmperes) (microAmperes)

Screen

Screen Screen

TheVoltage(kiloVolts)Screenisthe󰘰rstscreento appearafterenteringDiagnosticMode.SeeFig.6, andTable1onpage10.Toenterthisscreen,press andholdtheLOSETbuttonforapproximately5 secondswhileintheOperatingMode.

Thisscreendisplaysthesprayingvoltageofthe gunasanumber(kV),roundedtothenearest5kV. ThetwotoprightLEDs(VI)ofthedisplaypanel light,indicatingthattheVoltage(kiloVolts)Screen isdisplayed.Thedisplayisareadoutandcannot bechanged.

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page13.Press

andholdforapproximately5secondstoreturnto OperatingMode.

Figure7Current(microAmperes)Screen

3A2494D 13

GunOverview

Alternator

Alternator Alternator

TheAlternatorSpeed(Hertz)Screenisthethird screenintheDiagnosticMode.SeeFig.8,andTable 1onpage10.Toenterthisscreen,presstheLOSET buttonwhileintheCurrent(microAmperes)Screen.

Thisscreendisplaysthealternatorspeedasa3digit number(AS),roundedtothenearest10Hz.The displayisareadoutandcannotbechanged.Ifthe alternatorspeedisgreaterthan999Hz,thedisplay willshow999.

TheHzindicatorlightsgreentoshowthatyouare viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page14.Pressandhold

forapproximately5secondstoreturntoOperating Mode.

Speed

Speed Speed

(Hertz)

(Hertz) (Hertz)

Screen

Screen Screen

Low

Voltage

Low Low

Voltage Voltage

TheLowVoltageLockScreenisthefourthscreenin theDiagnosticMode.SeeFig.9,andTable1on page10.Toenterthisscreen,presstheLOSET buttonwhileintheAlternatorSpeed(Hertz)Screen.

ThisscreendisplaysthestatusoftheLowVoltage Lock.Ifthesettingislocked,thelockimage(LK) appearstotheleftoftheLodisplay(LD).Ifthesetting isunlocked,thelockimagedoesnotappear.

Tochangethelockstatus,pressandholdthe LOSETbuttonuntilthelockimageappearsor disappears.Ifthelockisset,theimagewillalso appearontheLowVoltageSettingScreenwhenin lowvoltagemode(seeFig.4).

NOTE:

NOTE: NOTE: screen,becausepressingandholdingtheLOSET buttonisusedtoturnthelockonoroff.Toexit, pressLOSETmomentarilytoreturntotheVoltage (kiloVolts)Screen,thenexitDiagnosticModefrom there.

DiagnosticModecannotbeexitedfromthis

Lock

Screen

Lock Lock

Screen Screen

Figure8AlternatorSpeed(Hertz)Screen

Figure9LowVoltageLockScreen

3A2494D

Installation

Installation Installation

Installingandservicingthisequipmentrequires accesstopartswhichmaycauseelectricshock orotherseriousinjuryifworkisnotperformed properly.

•Donotinstallorservicethisequipmentunless youaretrainedandquali󰘰ed.

•Besureyourinstallationcomplieswithlocal, state,andnationalcodesfortheinstallation ofelectricalapparatusinaClassI,Div.I, HazardousLocationoraGroupII,ZoneI ExplosiveAtmosphereLocation.

•Complywithallapplicablelocal,state,and national󰘰re,electrical,andothersafety regulations.

Fig.10showsatypicalelectrostaticairspraysystem. Itisnotanactualsystemdesign.Forassistance indesigningasystemtosuityourparticularneeds, contactyourGracodistributor.

Warning

Warning Warning

Mountwarningsignsinthesprayareawherethey caneasilybeseenandreadbyalloperators.An EnglishWarningSignisprovidedwiththegun.

Ventilate

Ventilate Ventilate

Providefreshairventilationtoreducetheriskof󰘰re orexplosioncausedbythebuildupof󰘱ammableor toxicvaporswhenspraying,󰘱ushing,orcleaning thegun.Donotoperatethegununlessventilation fansareoperating.

Electricallyinterlockthegunairsupplywiththe ventilatorstopreventgunoperationwithout ventilatingfansoperating.Checkandfollowalllocal, state,andnationalcodesregardingairexhaust velocityrequirements.

Highvelocityairexhaustwilldecreasetheoperating ef󰘰ciencyoftheelectrostaticsystem.Airexhaust velocityof100ft/min(31linearmeters/minute)should besuf󰘰cient.

Sign

Sign Sign

the

Spray

the the

Spray Spray

Booth

Booth Booth

3A2494D 15

Installation

Air

Supply

Air Air

Supply Supply

Toreducetheriskofelectricshock,theairsupply hosemustbeelectricallyconnectedtoatrueearth ground.Use Use Hose.

Hose. Hose.

1.SeeFig.10.UsetheGracoGroundedAirSupply Hose(AH)tosupplyairtothegun.Thegunair inlet󰘰ttinghasaleft-handthread.Theairsupply hosegroundwire(AG)mustbeconnectedtoa trueearthground.Donotconnecttheairsupply hosetothegunairinletyet.

Line

Line Line

Use

only

Graco

only only

Graco Graco

Grounded

Grounded Grounded

Air

Air Air

Fluid

Fluid Fluid

1.Blowoutthe󰘱uidline(FL)withairand󰘱ushit

Supply

Supply Supply

2.Installa󰘱uidregulator(FR)onthe󰘱uidlineto

3.Installa󰘱uid󰘰lter(FF)nearthepumpoutlet,to

Supply

Supply Supply

withsolvent.Usesolventwhichiscompatible withthe󰘱uidtobesprayed.Donotconnectthe 󰘱uidsupplylinetothegun󰘱uidinletyet.

control󰘱uidpressuretothegun.

removeparticlesandsedimentwhichcouldclog thespraynozzle.

Line

Line Line

2.Installanairline󰘰lter/waterseparator(AF)onthe gunairlinetoensureadry,cleanairsupplytothe gun.Dirtandmoisturecanruintheappearance ofyour󰘰nishedworkpieceandcancausethe guntomalfunction.

3.Installbleed-typeairregulators(PR,GR)on thepumpandgunairsupplylinestocontrolair pressuretothepumpandgun.

Trappedaircancausethepumptocycle unexpectedly,whichcanresultinserious injury,includingsplashing󰘱uidintheeyesor ontheskin.Donotoperatetheequipment withoutthebleed-typeairvalve(BV)installed.

4.Installableed-typeairvalve(BV)onthepump airsupplyline.Thebleed-typeairvalve(BV)is requiredinyoursystemtoshutoffairtothepump andrelieveairtrappedbetweenthevalveand thepumpaftertheairregulatorisshutoff.Install anadditionalbleed-typeairvalveonthemainair line(MA)toisolatetheaccessoriesforservicing.

Toreducetheriskofseriousinjury,including splashing󰘱uidintheeyesorontheskin,do notoperateequipmentwithoutthe󰘱uiddrain valve(FD)installed.

4.The󰘱uiddrainvalve(FD)isrequiredinyour systemtoassistinrelieving󰘱uidpressureinthe displacementpump,hose,andgun.Triggering theguntorelievepressuremaynotbesuf󰘰cient. Installadrainvalveclosetothepump's󰘱uid outlet.

5.Installanairbleedvalve(BV)oneachgunair supplylinetoshutoffairtothegun(s)andrelieve airtrappedbetweenthevalveandthegunafter theairregulatorisshutoff.

16 3A2494D

Installation

NON

HAZARDOUS

NON NON

- --HAZARDOUS HAZARDOUS

AREA

AREA AREA

HAZARDOUS

HAZARDOUS HAZARDOUS

AREA

AREA AREA

Figure10TypicalInstallation

Typical

Typical Typical

Installation

Installation Installation

Item

Item Item

ADAirLineDrainValve

AG*GunAirHoseGroundWire

AH*GracoGroundedAirHose(left-hand

ALPumpAirLineLubricator

BV*PumpBleed-TypeAirShutoffValve

EGElectrostaticAirSprayGun

FD*

FFFluidFilter

FRFluidPressureRegulator

Description

Description Description

AirFilter/WaterSeparator

threads)

FluidDrainValve

FluidSupplyLine

Key

Key Key

Item

Item Item

GRGunAirPressureRegulator

PG*PumpGroundWire

PRPumpAirPressureRegulator

SPSupplyPump

SV*VentilationFanInterlockSolenoidValve.

*Theseitemsarerequiredforsafeoperation.They mustbepurchasedseparately.

Description

Description Description

FluidShutoffValve

MainAirSupplyLine

NOTE:

NOTE: NOTE: asaGracoaccessory.

Thesolenoidvalveisnotoffered

3A2494D

GunSetup

Gun

Gun Gun

Gun

Gun Gun

SeeFig.11tolocatetheelectrostaticguncontrols.

Figure11ElectrostaticGunControls

1.Thegunisshippedwiththe󰘱uidnozzleandair

2.TurnOFF(O)theESOn-Offswitch(J).

Setup

Setup Setup

Setup

Setup Setup

capinstalled.Checkthattheretainingringis tight.

NOTE:

NOTE: NOTE: size󰘱uidnozzleoraircap,see

FluidNozzleSelectionChart,page68and AirCapSelectionChart,page70.To

installthenozzleandaircap,see

AirCapandNozzleReplacement,page38.

Toselectadifferent

Checklist

Checklist Checklist

5.ConnecttheGracogroundedairhosetothegun airinlet.Thegunairinlet󰘰ttinghasleft-hand threads.

6.FollowallstepsunderGrounding,page21.

7.Followallstepsunder

CheckGunElectricalGrounding,page25.

Readingmustbelessthan1megohm.

8.Verifythatthematerialresistivitymeets requirementsforelectrostaticspray.See

CheckFluidResistivity,page26.

9.Connecttheexhausttubeandsecurewiththe clampprovided.

10.Connectthe󰘱uidhosetothegun󰘱uidinlet.

3.Shutofftheairbleedvalvetothegun.

11.Flushifneeded,seeFlushing,page28.

12.Positiontheaircapasdesired.

4.Checkgunresistance.See

TestGunResistance,page31.

18 3A2494D

GunSetup

13.Fullyopenthefanairadjustmentvalve(F)

counterclockwise.

14.Fullyopenthe󰘱uidadjustmentvalve(H)

counterclockwise.

15.Fullyopentheatomizingairrestrictorvalve(G)

clockwise.

17.Setthegunairregulatortodeliveraminimum 45psi(0.32MPa,3.2bar)atthegunwhen triggered,toensurefullsprayingvoltage.See thetablebelow.

Table

Table Table

mm]

mm] mm]

18.CheckthattheESindicator(K)[Hzindicatoron Smartguns]islit.Seethefollowingtable.

Table

Table Table

Pressure

2 22. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

(using

(using (using

in ininft ftft(m) (m)

5/16

5/16 5/16

diameter

diameter diameter

15(4.6)55(0.38,3.8)

25(7.6)65(0.45,4.5)

50(15.3)80(0.56,5.6)

LED

3 33. ..LED LED

Drop

Drop Drop

(m)

in.

in. in.

[8 [8

hose)

hose) hose)

Indicator

Indicator Indicator

Colors

Colors Colors

Air

Regulator

Air Air

Regulator Regulator

psi

in ininpsi psi

[with

gun

[with [with

gun gun

Setting

Setting Setting

(MPa,

(MPa, (MPa,

triggered]

triggered] triggered]

bar)

bar) bar)

16.TurnON(I)theESOn-Offswitch(J).

Indicator

Indicator Indicator

Color

Color Color

Green

Amber

Red

Whenspraying,theindicator shouldremaingreen,indicating suf󰘰cientairpressuretothe alternatorturbine.

Iftheindicatorchangestoamber after1second,theairpressure istoolow.Increaseairpressure untiltheindicatorisgreen.

Iftheindicatorchangestored after1second,theairpressureis toohigh.Decreaseairpressure untiltheindicatorisgreen.

Description

Description Description

3A2494D 19

GunSetup

19.Shutofftheairtothegun.TurnOFF(O)theES On-Offswitch(J).

20.Startthepump.Adjustthe󰘱uidregulatoruntilthe streamfromtheguntravels8-12in.(200-300 mm)beforefallingoff.Typically,if󰘱uidpressure isbelow5psi(.04MPa,0.4bar)orabove30psi (0.21MPa,2.1bar),achangeofnozzlesizeis recommended.

22.Sprayatestpattern.Checktheatomization.If over-atomizationoccursatminimumpressure, adjusttherestrictorvalve.Ifatomizationis inadequate,increaseairpressureordecrease 󰘱uid󰘱ow.

23.Adjustthefanairadjustmentvalve:clockwisefor anarrowerpattern,counterclockwiseforawider pattern.

21.Turnontheairtothegun.TurnON(I)theES On-Offswitch(J).

24.Sprayatestpiece.Examinetheedges forcoverage.Ifwrapispoor,see

Troubleshooting,page33.

20 3A2494D

GunSetup

Grounding

Grounding Grounding

Whenoperatingtheelectrostaticgun,any ungroundedobjectsinthesprayarea(people, containers,tools,etc.)canbecomeelectrically charged.Impropergroundingcanresultinstatic sparking,whichcancausea󰘰re,explosion,or electricshock.Groundallequipment,personnel, objectbeingsprayed,andconductiveobjects inorclosetothesprayarea.Resistancemust notexceed1megohm.Followthegrounding instructionsbelow.

Thefollowingareminimumgroundingrequirements forabasicelectrostaticsystem(seeFigs.12–15). Yoursystemmayincludeotherequipmentorobjects whichmustbegrounded.Checkyourlocalelectrical codefordetailedgroundinginstructions.Yoursystem mustbeconnectedtoatrueearthground.

•

Pump/󰘱uid source:

byconnectingitsgroundwiretoatrueearth ground.

groundthepump/󰘱uidsource

•

Object being sprayed:

cleanandgroundedatalltimes.

•

All electrically conductive objects or devices in the spray area:

•

Fluid and waste containers:

wastecontainersinthesprayarea.Donotusepail linersunlesstheyareconductiveandgrounded. When󰘱ushingthespraygun,thecontainerused tocatchtheexcess󰘱uidmustbeelectrically conductiveandgrounded.

Air compressors:

•

tothemanufacturer'srecommendations.

mustbeproperlygrounded.

keeptheworkpiecehangers

groundall󰘱uidand

groundtheequipmentaccording

•

Electrostatic Air Spray Gun:

byconnectingtheGracoGroundedAirHose (AH)tothegun,andconnectingtheairhose groundwiretoatrueearthground.See

CheckGunElectricalGrounding,page25.

groundthegun

•

All air and 󰘱uid lines

Useonlygroundedhoseswithamaximumof100 feet(30.5m)combinedhoselengthtoensure groundingcontinuity.

mustbeproperlygrounded.

3A2494D

GunSetup

•

The 󰘱oor of the spray area:

conductiveandgrounded.Donotcoverthe󰘱oor withcardboardoranynon-conductivematerial whichwouldinterruptgroundingcontinuity.

mustbeelectrically

•

All persons entering the spray area:

shoeshavingconductivesolessuchasleather, orwearpersonalgroundingstraps.Donot wearshoeswithnon-conductivesolessuchas rubberorplastic.Ifglovesarenecessary,wear theconductiveglovessuppliedwiththegun.If non-Gracoglovesareworn,cutoff󰘰ngersorpalm areaofglovestoensureyourhandcontactsthe groundedgunhandle.

mustwear

•

Flammable liquids in the spray area:

inapproved,groundedcontainers.Donotuse plasticcontainers.Donotstoremorethanthe quantityneededforoneshift.

mustbekept

Key

Key Key

Fig.12

Fig.13

Fig.14

Fig.15Fluidsupplylineandsourcemust

Figs.

to totoFigs. Figs.

12–15

12–15 12–15

Operatorisgroundedthrough bareskincontactwiththegun handleandconductiveshoes.A conductiveglovecanalsobeused.

Objectbeingsprayedisgrounded throughcontactwiththehanger andconveyorsystem.

Gunisgroundedthroughthe conductiveairhose.

begrounded.

3A2494D

Figure12GroundtheOperator

GunSetup

Figure13GroundtheObjectBeingSprayed

3A2494D 23

GunSetup

Figure14GroundtheGun

Figure15GroundtheFluidSupply

3A2494D

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