Graco 3A2495C User Manual
Instructions - Parts
Pro Xp™ Electro
Air-Assisted
For use in Class I, Div. I Hazardous Locations using Group D spray materials.
For use in Group II, Zone 1 Explosive Atmosphere Locations using Group IIA spray materials. For
professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these
instructions.
3000 psi (
Fluid Wor
100 psi (
Air Work
21 MPa, 210 bar) Maximum
king Pressure
0.7 MPa, 7 bar) Maximum
ing Pressure
Spray Gun
static
3A2495C
EN
See pag
and app
e 3 for model part numbers
roval information.
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Models............................................................... 3
Warnings ........................................................... 4
Gun Overview .................................................... 7
How the Electrostatic AA Spray Gun
Works ............................................ 7
Controls, Indicators, and Components ........... 8
Smart Guns ................................................. 9
Installation.......................................................... 15
Warning Sign............................................... 15
Ventilate the Spray Booth............................. 15
Air Supply Line ............................................ 16
Fluid Supply Line ......................................... 16
Gun Setup.......................................................... 18
Gun Setup Checklist .................................... 18
Grounding ................................................... 21
Check Gun Electrical Grounding ................... 25
Check Fluid Resistivity ................................. 26
Check Fluid Viscosity ................................... 26
Flush Before Using Equipment...................... 26
Operation........................................................... 27
Pressure Relief Procedure............................ 27
Startup ........................................................ 27
Shutdown.................................................... 27
Maintenance ...................................................... 28
Flushing ...................................................... 28
Clean the Gun Daily..................................... 29
Daily System Care ....................................... 31
Electrical Tests................................................... 32
Test Gun Resistance.................................... 32
Test Power Supply Resistance ..................... 33
Test Gun Barrel Resistance .......................... 34
Troubleshooting.................................................. 35
Spray Pattern Troubleshooting...................... 35
Gun Operation Troubleshooting .................... 36
Electrical Troubleshooting ............................ 37
air................................................................ 39
Rep
pare the Gun for Service ......................... 39
Pre
Cap, Spray Tip, and Fluid Seat Housing
Air
placement.................................. 40
Re
ectrode Replacement ................................ 41
El
Fluid Tube Rem
Fluid Filter R
Gun Barrel Rem
Gun Barrel In
Fluid Needle
Power Supply
Alternator
Fan Air Adju
Atomizing A
ES On-Off V
Air Valve R
Smart Modu
Air Swivel
Parts.................................................................. 54
Standard Air-Assisted Spray Gun
Smart Air-Assisted Spray Gun
Alternator Assembly ..................................... 58
ES On-Off Valve Assembly........................... 59
Fan Air Valve Assembly ............................... 60
Air Cap Assembly ........................................ 61
Smart Module Assembly............................... 61
Spray Tip Selection Chart....................................62
AEM Fine Finish Spray Tips.......................... 62
AEF Fine Finish Pre-Orifice Spray
r Kits, Related Manuals, and
Repai
Acces
Gun Ac
Syste
Test E
Hose
Oper
Dimensions ........................................................ 66
Technical Data ...................................................67
co Pro Xp Warranty....................................... 68
Gra
cessories.......................................... 64
m Accessories..................................... 64
quipment ........................................... 64
s ......................................................... 65
ator Accessories................................... 65
oval and Replacement........... 42
eplacement............................... 42
oval..................................... 43
stallation.................................. 43
Replacement............................ 44
Removal and
Replacement
Removal and Replacement ........... 46
stment Valve Repair .................. 48
ir Adjustment Valve
Repair............................................ 49
alve Repair ............................... 50
epair........................................... 51
le Replacement.......................... 52
and Exhaust Valve
Replaceme
Assembly....................................... 54
Assembly....................................... 56
Tips ............................................... 63
sories .......................................... 64
.................................. 45
nt.................................. 53
2
3A2495C
Models
Models
Part No. kV
H60T10 60
H60M10 60
H85T10 85
H85M10 85
Smart Display Standard Display
✔
✔
✔
✔
II 2 G
EEx 0.24 mJ T6
FM12ATEX0068
EN 50050
Ta 0°C – 50°C
3A2495C 3
Warnings
Warnings
The following
exclamation p
risks. When th
Warnings. Pr
the body of th
warnings are for the setup, use, grounding, maintenance and repair of this equipment. The
oint symbol alerts you to a general warning and the hazard symbol refers to procedure-specific
ese symbols appear in the body of this manual or on warning labels, refer backtothese
oduct-specific hazard symbols and warnings not covered in this section may appear throughout
is manual where applicable.
WARNING
FIRE, EXPL
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire, explosion, and electric shock:
• Electrostatic equipment must be used only by trained, qualified personnel who understand
the requirements of this manual.
• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to
spray area. Resistance must not exceed 1 megohm. See Grounding instructions.
•Onlyuseg
• Do not use pail liners unless they are conductive and grounded.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use
equipment until you identify and correct the problem.
• Check gu
• Use and clean equipment only in well ventilated area.
• Interlock the gun air supply to prevent operation unless ventilating fansareon.
• Use cle
• To clean the exterior of the equipment, cleaning solvents must have a flash point at least
5°C above ambient temperature.
• Always turn the electrostatics off when flushing, cleaning or servicing equipment.
• Elimi
plast
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep spray area free of debris, including solvent, rags and gasoline.
•Keep
OSION, AND ELECTRIC SHOCK HAZARD
rounded Graco conductive air supply hoses.
n resistance, hose resistance, and electrical grounding daily.
aning solvents with highest possible flash point when flushing or cleaning equipment.
nate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
ic drop cloths (potential static arc).
a working fire extinguisher in the work area.
4
3A2495C
Warnings
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not spray w
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
•Donotputyo
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking,
or servicing equipment.
• Tighten al
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing
parts.
•SeeTechnical Data in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
TOXIC F
Toxic fl
inhale
• Read MSDSs to know the specific hazards of the fluids you are using.
•Store
LUID OR FUMES
uids or fumes can cause serious injury or death if splashed in the eyes or on skin,
d, or swallowed.
hazardous fluid in approved containers, and dispose of it according to applicable
lines.
guide
ithout tip guard and trigger guard installed.
ur hand over the spray tip.
l fluid connections before operating the equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
ective eyewear, and hearing protection.
•Prot
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
3A2495C 5
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operat
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alte
and create
• Make sure all equipment is rated and approved for the environment in which youareusingit.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hos
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
•Complyw
e the unit when fatigued or under the influence of drugs or alcohol.
the work area while equipment is energized or under pressure.
r or modify equipment. Alterations or modifications may void agency approvals
safety hazards.
es and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
ith all applicable safety regulations.
6 3A2495C
Gun Overview
Gun Overview
How the Electr
ostatic AA Spray Gun
Works
This is not an air spray gun. To help prevent
serious injury from pressurized fluid, such as skin
injection, and splashing fluid, read and follow the
Skin Injection Hazard Warnings on page 5.
The air-assisted spray gun combines airless and
air spraying concepts. The spray tip atomizes
and shapes the fluid into a fan pattern, as does
a conventional airless spray tip. Air from the air
cap further atomizes the fluid and completes the
atomization of the fluid tails to produce a uniform
pattern.
As the gun is triggered, part of the regulated air
operates the alternator turbine and the rest of the
air helps atomize the fluid being sprayed. The
alternator ge
the power car
gun’s electr
The fluid is electrostatically charged as it passes
the electrode. The charged fluid is attracted to the
grounded workpiece, wrapping around and evenly
coating all surfaces.
The regulated air that is directed to the air cap can
be further controlled using the gun’s atomizing air
adjustment valve. This valve can be used to restrict
air flow to the air cap while maintaining sufficient air
flow to the alternator. The atomizing air adjustment
valve does not control pattern width. To change
patternwidth,useanewtipsize,orusethefan
adjustment to narrow the pattern width.
Thehighw
the power
NOTE: For airless atomization, if desired, turn the
gun’s atomizing air adjustment valve completely off.
Closing this valve does not affect alternator operation.
nerates power, which is converted by
tridge to supply high voltage to the
ode.
orking fluid pressure of this gun provides
needed to atomize higher solids materials.
3A2495C
7
Gun Overview
Controls, Ind
The electrostatic gun includes the following
controls, indicators, and components (see Fig.
1). For information on Smart guns, also see
Smart Guns, page 9 .
Item Description Purpose
A
B Fluid Inlet
C
D
EElectrode
FFanAir
Air Swivel
Inlet
Turbine Air
Exhaust
Air Cap/Tip
Guard and
Spray Tip
Adjustment
Valve
icators, and Components
1/4 npsm(m) left-hand
thread, for Graco grounded
air supply hose.
1/4 npsm(m
supply hos
Barbed fitting, for supplied
exhaust tube.
See Spray Tip Selection
Chart, page 62, for avail-
able sizes.
Supplie
charge
Adjusts fan size and shape.
Canbeusedtodecrease
pattern width.
), for fluid
e.
s electrostatic
to the fluid.
Item Description Purpose
G
H
J
K
L Inline F
Atomizing Air
Adjustment
Valve
Trigger Safety
Lock
ES On-Off
Valve
ES Indicator (standard
gun only; for
Smart gun indicator, see
Operating
Mode, page
9 )
luid
Filter
Adjusts atomi
Locks trigge
gun from spra
Turns elect
or OFF (O).
Lit when ES is ON (I).
Color indicates alternator
frequency. See the LED
indicator table in the Gun
Setup Checklist, page 18.
Provides final filtration of
fluid. Located inside fluid
tube fitting.
zing air flow.
rtoprevent
ying.
rostatics ON (I)
Figure 1 Gun Overview
8 3A2495C
Smart Guns
Gun Overview
The Smart Gun module displays spraying voltage,
current, alternator speed, and the voltage setting (low
or high). It also allows the user to change to a lower
spraying voltage. The module has two modes:
• Operating Mo
• Diagnostic M
Operating M
de
ode
ode
Bar Graph
See Fig. 2,
Mode displ
display u
kiloVolt
(uA). The
value.
If the uA bar graph LEDs are blue, the gun is ready
to spray. If the LEDs are yellow or red, the current is
too high. The fluid may be too conductive, or see
Electrical Troubleshooting, page 37 for other possible
causes.
and Table 1 on page 11. The Operating
ays gun data during normal spraying. The
ses a bar graph to show the voltage level in
s (kV) and the current level in microAmperes
bar graph range is from 0 to 100% for each
Voltage Adjustment Switch
The voltage adjustment switch (VA) allows the
operator to change from low to high voltage.
• The high volt
maximum volt
•Thelowvolt
when the swi
voltage set
Adjusting t
NOTE: If the Error display appears, the Smart module
has lost communication with the power supply. See
Error Display, page 10, for further information.
age setting is determined by the
age of the gun and is not adjustable.
age indicator (LO) lights
tch is set to LO. The low
ting is user adjustable. See
he Low Voltage Setting, page 10.
Hz Indicator
The Hz indicator functions the same as the ES
indicator on standard guns. The indicator lights to
show the alternator speed status, and has three
colors:
• Green indicates the alternator speed is correct.
• If the indicator changes to amber after 1 second,
increase the air pressure.
• If the indicator changes to red after 1 second,
reduce the air pressure.
Figure2 SmartGunModuleinOperatingMode
3A2495C 9
Gun Overview
Error Display
If the Smart module loses communication with
the power supply, the Error display appears, the
Hz indicator turns red, and the Smart module is
disabled. See Fig. 3, and Table 1 on page 11.
This can occur in Operating Mode or Diagnostic
Mode. See Electrical Troubleshooting, page 37.
Communication must be restored to make the Smart
module functional.
NOTE: It takes 8 seconds for the Error display to
appear. If the gun has been disassembled, wait 8
seconds before spraying to ensure that an Error
condition has not occurred.
NOTE: If there is no power to the gun, the Error
display will not appear.
for your gun. Continue pressing the button until you
reach the desired setting.
NOTE: After 2 s
return to the O
NOTE: The low voltage setting may be locked. See
Lock Symbol, page 10.
Figure 4 Low Voltage Setting Screen (Unlocked)
econds of inactivity the display will
perating Screen.
Lock Symbol
Figure 3 Error Display
Adjusting the Low Voltage Setting
The low voltage setting is user adjustable. To access
the low voltage setting screen when in Operating
Mode, press the LO SET button (LS) momentarily.
The screen will display the current low voltage
setting. SeeFig. 4,andTable1onpage11. The
possible ranges are:
• 85 kV guns: 40–85 kV
• 60 kV guns: 30–60 kV
t the Voltage Adjustment switch (VA) to LO. Press
Se
e LO SET button repeatedly to increase the setting
th
n increments of 5. When the display reaches the
i
aximum setting it will return to the minimum setting
m
The low voltage setting may be locked. When locked,
an image (LK) appears on the screen. See Fig. 5,
and Table 1 on page 11.
• When in HI mode, the low voltage setting is always
locked. The lock symbol will appear when the LO
SET button is pressed.
• In LO mode, the lock symbol will only
appear if the lock is enabled. See
Low Voltage Lock Screen, page 14,tolock
or unlock the low voltage setting.
gure 5 Low Voltage Setting Screen (Locked)
Fi
10 3A2495C
Table 1 . Key for Figs. 2–9.
Item Description Purpose
Gun Overview
VA
LO
kV
uA
LS LO SET bu
Voltage Adjustment Switch
Low Voltage Mode Indicator
Voltage (kV) Display
Current (uA) Display
tton
Two-position
gun voltage to
high setting (
functional i
in Diagnosti
Lights (blue) when the smart gun
is set to Low Voltage.
Displays ac
of the gun, i
Mode, disp
In Diagnos
displayed
Displays actual spraying current
of the gun, in uA. In Operating
Mode, display is a bar graph.
In Diagnostic Mode, current is
displayed as a number.
Press momentarily to enter the
Low Voltage Setting screen.
Press an
seconds
Mode.
switch sets smart
low setting (LO) or
HI). This switch is
n Operating Mode and
c Mode.
tual spraying voltage
n kV. In Operating
lay is a bar graph.
tic Mode, voltage is
as a number.
d hold for approximately 5
to enter or exit Diagnostic
LV Low V
LK Low Voltage Locked
oltage Display
While in Diagnostic Mode, press
momentarily to advance through
screens.
While on the Low Voltage Lock
Screen (in Diagnostic Mode),
press and hold to turn the lock on
or off.
lays the low voltage setting
Disp
umber. The setting can be
as a n
ged. See Fig. 4.
chan
Appears if the low voltage setting
is locked. See Fig. 5 and Fig. 9.
3A2495C
11
Gun Overview
Item Description Purpose
LD Lo Display Appears on the Low Voltage Lock
Screen. See Fig. 9.
ER Error Display
VI Voltage Indicator In Diagnostic Mode, the two top
CI Current Ind
AS Alternator Speed Display
Hz
Alternator Speed Indicator In Operating Mode, indicator color
icator
Appears if the
communicatio
supply. See F
right LEDs of the screen light,
indicating that the value displayed
is in kV. See Fig. 6.
In Diagnostic Mode, the two
bottom right LEDs of the screen
light, indicating that the value
displayedisinuA.SeeFig. 7.
In Diagnos
displaye
8.
varies to show the alternator
speed status:
• green in
speed is
•Ifthei
after 1
speed i
Smart module loses
nwiththepower
ig. 3.
tic Mode, Hz level is
d as a number. See Fig.
dicates the alternator
at the correct level.
ndicator changes to amber
second, the alternator
stoolow.
•Ifthei
In Diagnostic Mode, the indicator
is green when in the Alternator
Speed (Hertz) screen.
ndicator changes to red
1 second, the alternator
after
is too high. The indicator
speed
lsoturnrediftheError
will a
ay appears.
displ
2
1
3A2495C
Diagnostic Mode
Diagnostic Mode includes four screens which display
gun data:
Gun Overview
• Voltage (kilo
• Current (mic
• Alternator S
• Low Voltage L
NOTE: You must be in Operating Mode to adjust the
low voltage setting; the setting is not adjustable in
Diagnostic Mode. However, the voltage adjustment
switch (VA) can be set to HI or LO in Operating Mode
and in Diagnostic Mode.
To enter Diagnostic Mode, press and hold the LO SET
(LS) button for approximately 5 seconds. The display
will go to the Voltage (kiloVolts) Screen, page 13.
To advanc
button ag
To exit Diagnostic Mode, press and hold the LO SET
button for approximately 5 seconds. The screen will
return to Operating Mode.
NOTE: If the gun is detriggered while in Diagnostic
Mode,thelastscreenviewedwillbedisplayedwhen
the gun is retriggered.
NOTE: D
from th
Low Vol
Volta
e Low Voltage Lock Screen. See
ge (kiloVolts) Screen
Volts) Screen
roAmperes) Screen
peed (Hertz) Screen
ock Screen
e to the next screen, press the LO SET
ain.
iagnostic Mode cannot be exited
tage Lock Screen, page 14 for details.
Figure 6 Voltage (kiloVolts) Screen
Current (microAmperes) Screen
The Current (microAmperes) Screen is the second
screen in the Diagnostic Mode. See Fig. 7, and Table
1 on page 11. To enter this screen, press the LO
SET button while in the Voltage (kiloVolts) Screen.
This screen displays the spraying current of the gun
as a number (uA), rounded to the nearest 5 uA. The
two bottom right LEDs (CI) of the display panel light,
indicating that the Current (microAmperes) Screen
is displayed. The display is a readout and cannot
be changed.
Press the LO SET button to advance to the
Alternator Speed (Hertz) Screen, page 14.Press
and hold for approximately 5 seconds to return to
Operating Mode.
The Vo
appea
and T
and h
seco
This screen displays the spraying voltage of the
gun as a number (kV), rounded to the nearest 5 kV.
The two top right LEDs (VI) of the display panel
light, indicating that the Voltage (kiloVolts) Screen
is displayed. The display is a readout and cannot
be changed.
Press the LO SET button to advance to the
Current (microAmperes) Screen, page 13.Press
and hold for approximately 5 seconds to return to
Operating Mode.
ltage (kiloVolts) Screen is the first screen to
r after entering Diagnostic Mode. See Fig. 6,
able 1 on page 11. To enter this screen, press
old the LO SET button for approximately 5
nds while in the Operating Mode.
Figure 7 Current (microAmperes) Screen
3A2495C 13
Gun Overview
Alternator Speed (Hertz) Screen
The Alternator Speed (Hertz) Screen is the third
screen in the Diagnostic Mode. See Fig. 8, and Table
1 on page 11. To enter this screen, press the LO SET
button while in the Current (microAmperes) Screen.
This screen d
number (AS),
display is a r
alternator s
will show 99
The Hz indicator lights green to show that you are
viewing the Alternator Speed (Hertz) Screen.
Press the LO SET button to advance to the
Low Voltage Lock Screen, page 14. Press and hold
for approximately 5 seconds to return to Operating
Mode.
isplays the alternator speed as a 3 digit
rounded to the nearest 10 Hz. The
eadout and cannot be changed. If the
peed is greater than 999 Hz, the display
9.
Low Voltage Lock Screen
The Low Voltage Lock Screen is the fourth screen in
the Diagnostic Mode. See Fig. 9, and Table 1 on
page 11. To enter this screen, press the LO SET
button while in the Alternator Speed (Hertz) Screen.
This screen d
Lock. If the s
appears to th
is unlocked,
To change the lock status, press and hold the
LO SET button until the lock image appears or
disappears. If the lock is set, the image will also
appear on the Low Voltage Setting Screen when in
low voltage mode (see Fig. 4).
NOTE: Diagnostic Mode cannot be exited from this
screen, because pressing and holding the LO SET
button is used to turn the lock on or off. To exit,
press LO SET momentarily to return to the Voltage
(kiloVolts) Screen, then exit Diagnostic Mode from
there.
isplays the status of the Low Voltage
etting is locked, the lock image (LK)
e left of the Lo display (LD). If the setting
the lock image does not appear.
Figure 8 Alternator Speed (Hertz) Screen
4
1
Figure 9 Low Voltage Lock Screen
3A2495C
Installation
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 local,
state, and national codes for the installation
of electrical apparatus in a Class I, Div. I
Hazardous Location or a Group II, Zone I
Explosive Atmosphere Location.
• Comply with all applicable local, state, and
national fire, electrical, and other safety
regulations.
Fig. 10 shows a typical electrostatic air-assisted
spray system. It is not an actual system design.
For assistance in designing a system to suit your
particular needs, contact your Graco distributor.
Installation
Warning Sign
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
Provide fresh air ventilation to reduce the risk of fire
or explosion caused by 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 air supply with the
ventilators to prevent gun operation without
ventilating fans operating. Check and follow all local,
state, and national codes regarding air exhaust
velocity requirements.
High velocity air exhaust will decrease the operating
efficiency of the electrostatic system. Air exhaust
velocity of 100 ft/min (31 linear meters/minute) should
be sufficient.
3A2495C 15
Installation
Air Supply Lin
To reduce the risk of electric shock, the air supply
hose must be electrically connected to a true earth
ground. Use only Graco Grounded Air Supply
Hose.
1. See Fig. 10. Use the Graco Grounded Air Supply
Hose (AH) to supply air to the gun. The gun air
inlet fitting has a left-hand thread. The air supply
hose ground wire (AG) must be connected to a
true earth ground. Do not connect the air supply
hose to the gun air inlet yet.
2. Install an air line filter/water separator (AF) on the
gunairlinetoensureadry,cleanairsupplytothe
gun. Dirt and moisture can ruin the appearance
of your finished workpiece and can cause the
gun to malfunction.
e
4. Install a blee
air supply lin
required in yo
and relieve a
the pump afte
an additiona
line(MA)toi
5. Install an a
supply line
air trapped
the air reg
d-type air valve (BV) on the pump
e. The bleed-type air valve (BV) is
ur system to shut off air to the pump
ir trapped between the valve and
r the air regulator is shut off. Install
l bleed-type air valve on the main air
solate the accessories for servicing.
ir bleed valve (BV) on each gun air
to shut off air to the gun(s) and relieve
between the valve and the gun after
ulator is shut off.
Fluid Supply Line
1. Blow out t
with solv
with the fl
fluid supp
2. Install
linetoc
he fluid line (FL) with air and flush it
ent. Use solvent which is compatible
uid to be sprayed. Do not connect the
lylinetothegunfluidinletyet.
a fluid pressure regulator (FR) on the fluid
ontrol fluid pressure to the gun.
To reduce the risk of serious injury due to
component rupture, including skin injection,
pump pressure must be limited by the pump air
regulator. Do not rely on the gun fluid regulator
tolimitthefluidpressuretothegun.
The flu
produ
3000 p
Fluid
supp
exce
3. Install bleed-type air regulators (PR, GR) on
the pump and gun air supply lines to control air
pressure to the pump and gun.
Trapped air can cause the pump to cycle
unexpectedly, which can result in serious
injury, including skin injection and splashing
fluid in the eyes or on the skin. Do not operate
the equipment without the bleed-type air valve
(BV) installed.
id supply pump must be prevented from
cing a fluid pressure greater than the
si (21 MPa, 210 bar)
Pressure
ly pressure to a 30:1 ratio pump must not
ed 100 psi (0.7 MPa, 7 bar).
of the gun. For example, the air
Maximum Working
3. Install
4. Thefluiddrainvalve(FD)isrequiredinyour
a fluid filter (FF) near the pump outlet, to
remove
the spr
NOTE: T
additi
To reduce the risk of serious injury, including
skin injection and splashing fluid in the eyes or
on the skin, do not operate equipment without
the fluid drain valve (FD) installed.
system to assist in relieving fluid pressure in the
displacement pump, hose, and gun. Triggering
the gun to relieve pressure may not be sufficient.
Install a drain valve close to the pump's fluid
outlet.
particles and sediment which could clog
ay nozzle.
he gun includes an inline fluid filter for
onal filtration.
16 3A2495C
NON-HAZARDOUS AREA HAZARDOUS AREA
Installation
Figure 10 Typical Installation
Typical Installation Key
Item Description
AF
AG* Gun Air Hose Ground Wire
AH* Graco Grounded Air Hose (left-hand
AL Pump Air Line Lubricator
BV* Pump Bleed-Type Air Shutoff Valve
EG Electrostatic Air Spray Gun
FD*
FF Fluid Filter
FG Fluid Pressure Gauge
FL
FR Fluid Pressure Regulator
Air Filter/Water Separator
threads)
Fluid Drain Valve
Fluid Supply Line
Item Description
FV
GR Gun Air Pressure Regulator
MA
PG* Pump Ground Wire
PR Pump Air Pressure Regulator
RV Pump Runaway Valve
SP Supply Pump
SV* Ventilation Fan Interlock Solenoid Valve
* These items are required for safe operation. They
must be purchased separately.
Fluid Shutoff Valve
Main Air Supply Line
NOTE: The solenoid valve is not offered as
a Graco accessory.
3A2495C
17
Gun Setup
Gun Setup
Gun Setup Chec
See Fig. 11 to locate the electrostatic gun controls.
Figure 11 Electrostatic Gun Controls
1. Turn OFF (O) the ES On-Off switch (J).
klist
4. Connect the Graco grounded air hose to the gun
air inlet. The gun air inlet fitting has left-hand
threads.
5. Follow all steps under Grounding, page 21.
6. Follow all steps under
Check Gun Electrical Grounding, page 25.
Readingmustbelessthan1megohm.
7. Verify that the material resistivity meets
requirements for electrostatic spray. See
Check Fluid Resistivity, page 26.
8. Connect the exhaust tube and secure with the
clamp provided.
2. Shut off the air bleed valve to the gun.
3. Check gun resistance. See
Test Gun Resistance, page 32.
9. Connect the fluid hose to the gun fluid inlet.
10. Flush if needed. See Flushing, page 28.
18 3A2495C
To reduce the risk of a skin injection injury, always follow the
Pressure Relief Procedure, page 27,
before removing or installing the spray tip, air
cap, or tip guard.
11. The fluid output and pattern width depend
on the size of the spray tip, the fluid
viscosity, and the fluid pressure. Use the
Spray Tip Selection Chart, page 62, as a guide
for selecting the appropriate spray tip for your
application.
12. Align the spray tip tab with the groove in the air
cap. Install the tip.
Gun Setup
15. Check that the ES On-Off switch is OFF (O).
16. Start the pum
(2.8 MPa, 28
17. Spray a test
the center o
in step 21)
increment
particle s
the partic
3000 psi (2
p. Set the fluid regulator to 400 psi
bar).
pattern. Examine the particle size in
f the pattern (tails will be removed
. Increase the pressure in small
s. Spray another pattern. Compare
ize. Continue increasing pressure until
le size remains constant. Do not exceed
1 MPa, 210 bar).
13. Install the air cap and retaining ring. Orientate
the air cap and tighten the retaining ring securely.
14. Close the atomizing air adjustment valve (G) and
the fan air adjustment valve (F).
18. Turn ON (I) the ES On-Off switch.
3A2495C 19
Gun Setup
19. Check that the ES indicator (K) [Hz indicator on
Smart guns] is lit. See the following table.
Table 2 . LED Indicator Colors
Indicator
Color
Green
Amber
Red
20. Set the gun air regulator to deliver a minimum
of 45 psi (0.32 MPa, 3.2 bar) at the gun when
triggered, to ensure full spraying voltage. See
the table below.
When spraying, the indicator
should remain green, indicating
sufficient air pressure to the
alternator turbine.
If the indicator changes to amber
after 1 second, the air pressure
is too low. Increase air pressure
until the indicator is green.
If the indi
after 1 se
too high.
until the
Description
cator changes to red
cond, the air pressure is
Decrease air pressure
indicator is green.
21. Turn the atomizing air adjustment valve
counterclockwise until any tails disappear.
22. If desired atomization is not achieved, change
the tip size. The smaller the tip orifice, the finer
the atomization.
23. Spray a test piece. Examine the edges
for coverage. If wrap is poor, see
Troubleshooting, page 35.
Table 3 . Pressure Drop
Air Hose
Length in ft (m)
(using 5/16 in. [8
mm] diameter hose)
15 (4.6) 52 (0.36, 3.6)
25 (7.6) 57 (0.40, 4.0)
50 (15.3) 68 (0.47, 4.7)
75 (22.9) 80 (0.56, 5.6)
100 (30.5) 90 (0.63, 6.3)
Air Regulator Setting
in psi (MPa, bar)
[with gun triggered]
NOTE: If a narrower pattern is needed occasionally,
open the fan air adjustment valve slightly. (Excessive
fan air flow can cause paint buildup on the air cap.)
20 3A2495C
Grounding
Gun Setup
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. Ground all equipment, personnel,
object being sprayed, and conductive objects
in or close to the spray area. Resistance must
not exceed 1 megohm. Follow the grounding
instructions below.
The following are minimum grounding requirements
for a basic electrostatic system (see Figs. 12–15).
Your system may include other equipment or objects
which must be grounded. Check your local electrical
code for detailed grounding instructions. Your system
must be connected to a true earth ground.
•
Pump/fluid source:
by connecting its ground wire to a true earth
ground.
ground the pump/fluid source
•
Object being s
clean and grou
•
All electrically conductive objects or devices in the
spray area:
•
Fluid and waste containers:
waste containers in the spray area. Do not use pail
liners unless they are conductive and grounded.
When flushing the spray gun, the container used
to catch the excess fluid must be electrically
conductive and grounded.
prayed:
nded at all times.
must be properly grounded.
keep the workpiece hangers
ground all fluid and
•
Electrostatic Air-Assisted Spray Gun:
the gun by connecting the Graco Grounded
Air Hose to the gun, and connecting the air
hose ground wire to a true earth ground. See
Check Gun Electrical Grounding, page 25.
ground
•
Air compressors:
to the manufacturer's recommendations.
•
All air and fluid lines
Use only grounded hoses with a maximum of 100
feet (30.5 m) combined hose length to ensure
grounding continuity
ground the equipment according
must be properly grounded.
3A2495C
21
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