Graco 236685, PRO 5500hc, 237300 Instructions And Parts List
INSTRUCTIONS-PARTS LIST
308442
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
Rev. G
AUTOMATIC ELECTROSTATIC, HIGH CONDUCTIVITY
Model PRO 5500hcAir Spray Gun
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
The PRO 5500hc spray gun offers increased electrostatic performance when spraying metallic
paints and highly conductive fluids. The gun is for use with Class I, Group D paint spray
materials.
U.S. PATENT NO. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774;
5,063,350; 5,073,709; 5,080,289; 5,093,625; 5,289,977
Patented 1986, 1987 Canada
Brevete 1986, 1987
U.K. PATENT NO. 2,147,158; 2,142,559B; 2,140,327–B
Other Foreign Patents Pending
Part No. 236685, Series A
Complete PRO 5500hc Spray Gun: includes spray
gun, shroud, manifold, and mounting bracket
Part No. 237300
PRO 5500hc Conversion Kit: to convert the PRO
5500sc spray gun to the PRO 5500hc spray gun
03209
NOTE: Any modification of genuine Graco parts or replacement of parts with non-Graco parts will void agency approvals.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1994, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comparison of a PRO 5500sc to a PRO 5500hc
Spray Gun 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Characteristics and Gun Performance 6. . . . . . . .
Operating the Spray Function 6. . . . . . . . . . . . . . . . . . . .
Operating the Electrostatics 6. . . . . . . . . . . . . . . . . . . . . .
Switching to the Higher or Lower kV Setting 6. . . . . . . .
Gun Features and Options 6. . . . . . . . . . . . . . . . . . . . . . .
Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the System 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Signs 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilate the Spray Booth 9. . . . . . . . . . . . . . . . . . . . . . . .
Install the Air Line Accessories 10. . . . . . . . . . . . . . . . . .
Install the Fluid Line Accessories 10. . . . . . . . . . . . . . . .
Install the Gun and Mounting Bracket 10. . . . . . . . . . . .
Connect the Air and Fluid Lines 11. . . . . . . . . . . . . . . . .
Optional Fiber Optic Cable Connection 12. . . . . . . . . . .
Optional Fiber Optic Lens Kit Installation 12. . . . . . . . .
Ground the System 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the Electrical Grounding 14. . . . . . . . . . . . . . . . . .
Install the Fabric Cover 15. . . . . . . . . . . . . . . . . . . . . . . . .
Service 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools Included with the Gun 28. . . . . . . . . . . . . . . . . . . . .
Prepare the Gun for Service 28. . . . . . . . . . . . . . . . . . . .
Air Cap/Nozzle/Resistor Stud Replacement 29. . . . . . .
Electrode Needle Replacement 30. . . . . . . . . . . . . . . . . .
Fluid Packing Rod Removal and Repair 31. . . . . . . . . .
Piston Repair 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Barrel Removal 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Removal and Replacement 35. . . . . . . .
Power Supply Adjustment 35. . . . . . . . . . . . . . . . . . . . . .
Turbine Alternator Removal and Replacement 36. . . . .
Barrel Installation 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install the Gun onto the Manifold 37. . . . . . . . . . . . . . . .
Standard Spray Gun Parts 38. . . . . . . . . . . . . . . . . . . .
Manifold Parts 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit Parts and Installation 42. . . . . . . . . . . . . . . . . . . . .
Installing the PRO 5500hc Conversion Kit 42. . . . . . . .
Technical Data 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Graco Warranty and Disclaimers 46. . . . . . . . . .
Operation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 16. . . . . . . . . . . . . . . . . . . . . .
Operating Checklist 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a Fluid Nozzle and Air Cap 16. . . . . . . . . . . . .
Adjusting the Spray Pattern 17. . . . . . . . . . . . . . . . . . . . .
Activating and Adjusting the Electrostatics 18. . . . . . . .
Activating the kV Switch 18. . . . . . . . . . . . . . . . . . . . . . . .
Spraying 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Triggering the Fluid Alone 18. . . . . . . . . . . . . . . . . . . . . .
Shutdown 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily Care and Cleaning 19. . . . . . . . . . . . . . . . . . . . . . . .
Clean the Air Cap and Fluid Nozzle 21. . . . . . . . . . . . . .
Check for Fluid Leakage 22. . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Pattern Troubleshooting 23. . . . . . . . . . . . . . . . . .
Gun Operation Troubleshooting 24. . . . . . . . . . . . . . . . .
Electrical Troubleshooting 25. . . . . . . . . . . . . . . . . . . . . .
Electrical Tests 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Gun Resistance 26. . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Power Supply Resistance 27. . . . . . . . . . . . . . . . . .
Test Resistor Stud Resistance 27. . . . . . . . . . . . . . . . . .
Graco Phone Number 46. . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.
2 308442
WARNING
FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire, explosion, or electric shock.
Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements stated in this instruction manual.
Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all
other electrically conductive objects in the spray area. See Ground the System on page 13.
Check the spray gun resistance daily. See Test Gun Resistance, page 26.
If there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Interlock the gun
turbine air supply to prevent operation of the power supply unless the ventilating fans are on. See
Ventilate the Spray Booth on page 9.
When flushing or purging electrostatic equipment, use solvents with a flash point equal to or
greater than that of the fluid being sprayed.
To clean the exterior of the electrostatic equipment, use solvents with a flash point higher than
100F (38C).
Do not flush the system with the gun electrostatics turned on.
Do not turn on the gun electrostatics until all solvent is removed from the system.
Use only non-sparking tools to clean residue from the booth and hangers.
Extinguish all open flames or pilot lights in the spray area.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Do not store any flammable fluids in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not smoke in the spray area.
Do not operate a gasoline engine in the spray area.
PRESSURIZED EQUIPMENT HAZARD
Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin
and cause a serious injury.
Do not point the spray gun at anyone or any part of the body.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure on page 16 whenever you: are instructed to relieve the
pressure; stop spraying; clean, check, or servicing the equipment; and install or clean the fluid
nozzles.
Tighten all the fluid connections before operating the equipment.
Check the hoses, tubes and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
Warnings are continued on the next page.
308442 3
INSTRUCTIONS
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 the instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about the usage, call your
Graco distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 100 psi (7 bar, 0.7 MPa) maximum working air and fluid pressure.
Use fluids that are compatible with the equipment wetted parts. See the Technical Data section of
all the equipment manuals. Read the fluid manufacturer’s warnings.
Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180F (82C) or below –40F (–40C).
Do not use the hoses to pull equipment.
Wear hearing protection when operating this equipment.
Comply with all applicable local, state, and national fire, electrical, and other safety regulations.
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 308442
Introduction
03221 03904A
PRO 5500sc Spray Gun
8 in. (203.2 mm) fluid path
Comparison of a PRO 5500sc to a PRO
5500hc Spray Gun
The PRO 5500hc spray gun offers increased electrostatic performance when spraying highly conductive
fluids and metallic paints.
In an electrostatic spray gun, the fluid in the fluid tube
becomes a path to ground when the high voltage is
turned on. The amount of current drawn through the
fluid tube depends on the fluid resistivity and the length
of the fluid path to ground.
PRO 5500hc Spray Gun
20 in. (711.2 mm) fluid path
The PRO 5500sc and PRO 5500hc guns will perform
equally well when spraying fluids with high resistivity,
as shown in the graph below. Even with the shorter
fluid tube of the PRO 5500sc gun, very little current
travels through the fluid, due to its high resistivity, and
the spraying voltage is minimally affected. However,
when the fluid resistivity decreases to low levels, more
current is drawn through the fluid and the spraying
voltage of the PRO 5500sc gun is reduced.
The PRO 5500hc gun can support high voltages when
spraying conductive fluids because the longer fluid
tube increases the total resistance of the fluid column
and reduces the current draw through the fluid.
Full Spraying Voltage
kV
Low Resistivity
(high conductivity)
PRO 5500hc
PRO 5500sc
NOTE: Fluid resistance
value is approximate.
Actual resistance will
vary depending on the
type of resistance meter
and the fluid being used.
200
High Resistivity
(low conductivity)
Fluid Resistivity MEG CM
308442 5
Introduction
Fluid Characteristics and Gun Performance
For some fluids (especially metallic paints), measuring
the fluid resistivity is not always a reliable indicator of
paint performance in a spray gun. The voltage applied
by the resistivity meter is very low compared to the
voltage applied by the spray gun. Some conductive
components and additives in the fluid may exhibit
reduced resistivity when high voltage is applied by the
spray gun.
When testing a fluid to see if it will be suitable for
electrostatic spraying, it is important to measure the
spraying voltage when the fluid is flowing. The turbulence created when the fluid is flowing helps to retard
the negative effects of the conductive components and
additives in the fluid.
The PRO 5500hc guns offer the capability of monitoring the actual spraying voltage with the optional fiber
optic spraying voltage readouts. Either the kV only
readout or the kV and current readout can be very
helpful in monitoring the voltage characteristics when
spraying conductive fluids. Refer to Fig. 2, page 8.
To provide a smoother transition to the high voltage
and prevent some very conductive fluids from shorting
out, it may be necessary to operate the gun with the
voltage first turned to the lower kV setting, then switch
to the higher kV setting.
Operating the Spray Function
Applying a minimum of 50 psi (3.5 bar, 0.35 MPa) air
pressure to the gun manifold’s cylinder air fitting (which
is marked “CYL”, see page 7) 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, air pressure is applied to
the gun manifold’s turbine air fitting (which is marked
“TA”, see page 7) through a Graco electrically conductive air hose. The air enters the manifold and is
directed to the inlet of the power supply turbine (G).
The air spins the turbine, which then provides electrical
power to the internal high voltage power supply (H).
The fluid is charged by the spray gun electrode (J).
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 (D) and
out the back of the manifold through the fitting marked
“EXH”. The exhaust air helps keep contaminants out
and helps keep the gun clean.
Switching to the Higher or Lower
kV Setting
The gun’s full high voltage setting is 85 kilovolts. The
gun’s spraying voltage can be reduced by switching to
the low voltage setting for spraying in areas where too
much electrostatic wrap is not desirable. Applying a
minimum of 50 psi (3.5 bar, 0.35 MPa) air pressure to
the kV switch air inlet (which is marked “KV”, see page
7) will activate it and switch to the lower voltage setting. The lower voltage is factory set to 60 kilovolts at
zero microamperes. This setting can be adjusted from
45 to 80 kilovolts, as instructed on page 35. The solenoid valve used to activate the kV switch must bleed
the air out of the line for the switch to draw back to the
higher voltage setting.
Gun Features and Options
The gun is designed for use with a reciprocator,
and it can be directly mounted to a one-half inch
rod. With additional brackets, the gun can be
mounted for robotic applications.
The gun is designed for quick-disconnect, which
enables the operator to quickly remove the spray
gun without disconnecting the fluid and air lines to
the gun.
The gun functions are activated from a separate
controller that sends the appropriate signal to the
actuating solenoids (K). See Fig. 1, page 8.
An optional fiber optic readout system can be
installed to monitor the gun’s spraying voltage. A
fiber optic cable (V) connected to the gun manifold
carries the signal from the gun to a remote ES
(electrostatic) display module. See Fig. 2, page 8.
An ES Display Module (R), P/N 224117, is available
and will display the gun’s spraying voltage and
current. A battery operated ES Display Module (S),
P/N 189762, is also available; it displays the gun’s
spraying voltage only.
6 308442
Introduction
F
AB C D E
TA
CYL
A1
P1
KV
F.O.
A2
EXH
P2
Manifold Back View
0321303209
KEY
A Air Cap
B Fluid Nozzle
C Retaining Nut
D Shroud
E Mounting Bracket
F Manifold
G Turbine
H Power Supply
J Electrode
H
J
G
04803
Manifold Markings
A1 Atomization Air Inlet Fitting
A2 Fan Air Inlet Fitting
CYL Cylinder Air Inlet Fitting
EXH Shroud Exhaust Outlet Fitting
F.O. Fiber Optic Fitting
KV kV Switch Air Inlet
P1 Fluid Supply Inlet Fitting
P2 Fluid Return Inlet Fitting
TA Turbine Air Inlet Fitting
308442 7
Fig. 1
Installation
BASIC SYSTEM
Non-Hazardous Area Hazardous Area
XW
A
H
B
TA
*
KV
*
A1
*
A2
*
CYL
*
P1
*
F
J
M
K
K
K
K
Y
C
D
E
K
N
G
P
Q
S
Fig. 2
Non-Hazardous Area Hazardous Area
RT
kV
mA
kV
U
*
V
SYSTEM OPTIONS
Spraying Voltage
Display Module
H
F.O.
04801
8 308442
Installation
KEY-Fig. 1 and 2
A Ground Wire on Graco Electrically Conductive Air Hose
B Graco Electrically Conductive Air Hose (Turbine Air Hose),
See page 11 for part numbers
C Atomizing Air Hose, 3/8 inch (9.5 mm) O.D.
D Fan Air Hose, 3/8 inch (9.5 mm) O.D.
E Cylinder Air Hose, 1/4 inch (6.4 mm) O.D.
F Fluid Hose, 1/4–18.6 npsm gun fluid inlet
G To Fluid Supply
H PRO 5500hc Spray Gun, P/N 236685
J Mounting Bracket for 1/2 inch (127 mm) rod, P/N 189581
K Solenoid Valve, requires quick-exhaust port
M Air Pressure Regulator
N True Earth Ground
P 24 Volt Power Supply, P/N 235301
Q4–20 mA Outputs
R Full Feature ES Display Module, P/N 224117
S kV Only ES Display Module (battery operated), P/N 189762
T Fiber Optic Cable, P/N 224680 to 224686
U Bulkhead, P/N 189870
V Fiber Optic Cable, P/N 224670 to 224676
W Main Air Line
X Bleed-type Master Air Valve
Y kV Switch Air Hose, 1/4 inch (6.4 mm) O.D., plug the gun fitting if
it is not used
Z Air Pilot Fluid Regulator, P/N 236854
The turbine air supply must be interlocked with the spray booth
ventilation fans.
A maximum of two splices with a total of 108 feet (32.94 m) of
cable can be used. For the strongest light signals, use a minimum
number of bulkhead splices.
* See page 11 for a description of the manifold connections.
Installing the System
Fig. 1, page 8, shows a typical Model PRO 5500hc
system. Fig. 2 shows some possible system options.
Accessories are available from your Graco representative. Refer to the Product Data Sheet for the gun,
Form No. 305660.
For assistance in designing a system that is customized for your application, contact your Graco distributor.
Warning Signs
Mount the 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. Additional signs are available at no charge. See below.
Part No. Description
180060 Warning Sign (English)
Ventilate the Spray Booth
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 equip-
ment unless you are trained and
qualified.
Be sure your installation complies with National,
State and Local codes for the installation of
electrical apparatus in a Class I, Group D
Hazardous Location.
Comply with all applicable local, state, and
national fire, electrical, and other safety regulations.
WARNING
FLAMMABLE OR TOXIC
VAPOR HAZARD
Provide fresh air ventilation to avoid the
buildup of flammable or toxic vapors. Do
not operate the gun unless ventilation
fans are operating.
Electrically interlock the gun turbine air supply line with
the ventilators to prevent operation of the electrostatic
power supply unless ventilating fans are on.
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. The minimum
allowable air exhaust velocity is 60 feet/minute (19
linear meters/minute).
308442 9
Installation
Install the Air Line Accessories
1. Install a bleed-type master air valve (X) on the
main air supply line (W) to shut off all the air to the
gun. See Fig. 1, page 8.
2. To ensure a dry, clean air supply to the gun, install
an air line filter and an air and water separator on
the air lines. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the
gun to malfunction.
3. Install an air regulator (M) on each of the air supply
lines (B, C, D, E, Y) to control the air pressure to
the gun.
4. Install a solenoid valve (K) on the fan and atomization air lines (C, D) to actuate the gun and shut off
the fan and atomization air to the gun. The solenoid valves must have a quick exhaust port.
WARNING
PRESSURIZED EQUIPMENT HAZARD
Trapped air can cause the gun to spray
unexpectedly, which could result in a
serious injury, including splashing 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 the gun when the
solenoids are shut off.
Install the Fluid Line Accessories
1. Install a fluid filter and drain valve at the pump
outlet. See Fig. 1, page 8.
WARNING
2. Install a fluid regulator on the fluid line to control
fluid pressure to the gun.
Install the Gun and Mounting Bracket
1. Loosen the mounting bracket’s two square head
bolts (103) and slide the mounting bracket onto a
0.50 in. (12.7 mm) mounting rod. See Fig. 3.
2. Position the gun and tighten the two bolts (103)
securely.
2.775 in .
(70.5 mm)
PRO 5500 Gun
103
0.50 in.
(12.7 mm)
rod
103
Fig. 3
NOTE: For added positioning reliability, the mounting
bracket (MM) has an 1/8 in. (3.2 mm) slot where a
locating pin (NN-not included) can be inserted through
the mounting rod (PP). See Fig. 4.
9.32 in.
(236.7 mm)
03444
NN
MM
PRESSURIZED EQUIPMENT HAZARD
The fluid drain valve is required in your system to
assist in relieving fluid pressure in the displacement
pump, hose and gun; triggering the gun to relieve
pressure may not be sufficient. Install a drain valve
close to the pump’s fluid outlet. The drain valve
reduces the risk of serious injury, including splashing in the eyes or on the skin.
10 308442
Fig. 4
PP
03460
Installation
Connect the Air and Fluid Lines
See Fig. 1 and 2, page 8, for a schematic of air and
fluid connections. Connect the air and fluid lines to the
gun manifold as instructed at right.
Graco Electrically Conductive Air Hose
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of electric shock or
other serious injury, the air supply hose
must be electrically connected to a true
earth ground. Use Only Graco Electrically Con-
ductive Air Supply Hose.
Connect the Graco electrically conductive air hose (B)
to the gun turbine air inlet and connect the hose
ground wire (A) to a true earth ground. See Fig. 1,
page 8. Check the electrical grounding of the gun as
instructed on page 14.
NOTE: The hose and the gun have special left-hand
threads to prevent connecting another type of air hose
to the gun turbine air inlet.
Graco Electrically Conductive Air Hose
Required for gun operation.
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand
Manifold Connections (See Fig. 5)
A1 Atomization Air Inlet Fitting
Connect a 3/8 inch O.D. tube between the fitting and
the air supply.
A2 Fan Air Inlet Fitting
Connect a 3/8 inch O.D. tube between the fitting and
the air supply.
CYL Cylinder Air Inlet Fitting
Connect a 1/4 inch O.D. tube between this fitting and
the solenoid. For quicker trigger response, use the
shortest hose length possible.
EXH Shroud Exhaust Outlet Fitting
Connect a 1/4 inch O.D. x 4 foot (1.22 m) long tube to
the fitting.
F.O. Fiber Optic Fitting (Optional)
Connect the Graco Fiber Optic Cable as instructed on
page 12.
KV kV Switch Air Inlet Fitting
Connect a 1/4 inch O.D. tube between the fitting and
the air solenoid.
P1 Fluid Supply Inlet Fitting
Connect a 1/4 inch npsm swivel fitting between the
fitting and the fluid supply.
P2 Fluid Return Inlet Fitting (Optional)
Connect 1/4 inch O.D. tube between the fitting and the
dump valve for recirculation.
TA Turbine Air Inlet Fitting
Connect the Graco Electrically Conductive Air Hose
between this fitting (left-hand thread) and the solenoid.
Connect the air hose ground wire to a true earth
ground.
Part No.
Length Black Hose Grey Hose Red Hose
6 ft. (1.8 m)
15 ft. (4.6 m)
25 ft. (7.6 m)
36 ft. (11.0 m)
50 ft. (15.2 m)
75 ft. (23.0 m)
100 ft. (30. 5 m)
Black Hose: standard hose, semi-conductive nylon core,
urethane outer
Grey Hose: more flexible (less durable) than black hose,
modified semi-conductive polyamide core, urethane cover
Red Hose: conductive SST wire braid for grounding, polyurethane tube and cover
220444
218100
218101
218102
218103
220119
220120
223068
223069
223070
223071
223072
223073
223074
235068
235069
235070
235071
235072
235073
235074
Fluid Line
Before connecting the fluid line, blow it out with air and
flush it with solvent. Use solvent that is compatible with
the fluid being sprayed.
TA
CYL
A1
P1
Fig. 5
KV
F.O.
A2
EXH
P2
Manifold Back View
03213
308442 11
Installation
Optional Fiber Optic Cable Connection
An optional fiber optic fitting (37) is shipped unassembled with the gun. If an ES (kV) display module is
used, install the fitting in the manifold. See Fig. 2, page
8, for a schematic of the fiber optic connections.
1. Remove the 1/8 npt plug (115) from the manifold’s
fiber optic port, and install the black fiber optic
fitting (37). See Fig. 6.
37
115
Fig. 6
03508
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 feet (32.94
m) of cable, is recommended.
5. See manual 308265 to install a Graco ES Display
Module.
Optional Fiber Optic Lens Kit Installation
NOTE: The fiber optic lens kit is not included with the
gun. Order it separately; the part number is 236852.
1. Remove the gun from the manifold as instructed
on page 28.
2. Make sure the lens (TT) is clean. Push the lens
into the counterbore (VV) in the manifold fiber optic
port (SS). See Fig. 8 and 9.
3. Press the lens retainer (UU) into the manifold fiber
optic port (SS) until it is flush with the manifold
surface.
4. Assemble the gun to the manifold as instructed on
page 37.
2. Remove the nut (QQ) from the fiber optic fitting
(37), and slide the nut over the end of the fiber
optic cable (RR). See Fig. 7.
3. Insert the cable (RR) into the fitting (37), and push
the cable in until it bottoms out. Tighten the nut
(QQ) to secure the cable.
37
QQ
RR
Fig. 7
4. If you have two bulkhead splices in your system, it
is recommended that you install the fiber optic lens
kit, as described at right.
03509A
UU
Fig. 8
Fig. 9
TT
SS
UU
TT
VVSS
04798
04485
12 308442
Installation
Ground the System
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
When operating the electrostatic gun,
any ungrounded objects in the spray
area (such as 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 grounding instructions are minimum
requirements for a basic electrostatic system. Your
system may include other equipment or objects which
must be grounded. Check your local electrical code for
detailed grounding instructions. Your system must be
connected to a true earth ground.
1. Pump: ground the pump by connecting a ground
wire and clamp as described in your separate
pump instruction manual.
3. Electrostatic Air Spray Gun: ground the gun by
connecting the Graco Electrically Conductive Air
Hose to the turbine air inlet and connecting the air
hose ground wire to a true earth ground. Check
the electrical grounding of the gun as instructed on
page 14.
4. All air and fluid lines must be properly grounded.
5. All electric cables must be properly grounded.
6. All persons entering the spray area: their shoes
must have conductive soles, such as leather, or
personal grounding straps must be worn. Rubber
or plastic soles are not conductive.
7. Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Contact points
must be sharp points or knife edges.
8. The floor of the spray area: must be electrically
conductive and grounded. Do not cover the floor
with cardboard or any non-conductive material
which would interrupt grounding continuity.
9. Flammable liquids in the spray area: must be kept
in approved, grounded containers. Do not store
more than the quantity needed for one shift.
2. Air compressors and hydraulic power supplies:
ground the equipment according to the manufacturer’s recommendations.
10. All electrically conductive objects or devices in the
spray area: including fluid containers and wash
cans, must be properly grounded.
308442 13
Installation
Check the Electrical Grounding (See Fig. 10)
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
Megohmmeter P/N 241079 (WW) is not
approved for use in a hazardous area.
To reduce the risk of sparking, do not
use the megohmmeter to check electrical grounding unless:
The gun has been removed from the
hazardous area;
Or all spraying devices in the hazardous area
are turned off, ventilation fans in the hazardous
area are operating, and there are no flammable
vapors in the area (such as open solvent containers or fumes from spraying).
Failure to follow this warning could cause fire,
explosion, electric shock and result in serious injury
and property damage.
a. If using a black or grey turbine air hose, use a
megohmmeter (WW) to measure the
resistance. Use an applied voltage of 500
minimum to 1000 volts maximum. Resistance
should not exceed 2 megohms.
b. If you are using a red turbine air hose, use an
ohmmeter to measure the resistance.
Resistance should not exceed 100 ohms.
5. If the resistance is greater than the maximum
reading specified above for your hose, check the
tightness of the ground connections and be sure
the turbine air hose ground wire is connected to a
true earth ground. If the resistance is still too high,
replace the turbine air hose.
N
WW
1. Have a qualified electrician check the electrical
grounding continuity of the spray gun and turbine
air hose.
2. Make sure the turbine air hose (B) is connected
and the hose ground wire is connected to a true
earth ground.
3. The air and fluid supplies to the gun must be
turned off, and the fluid hose must not have any
fluid in it when checking the continuity.
4. Measure the resistance between the turbine air
inlet fitting (TA) and a true earth ground (N).
TA
B
TI0376
Fig. 10
14 308442
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