INSTRUCTIONS-PARTS LIST
308496
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
AUTOMATIC, 60 kV, ELECTROST ATIC,
Model PRO 5500wb
Air Spray Gun
100 psi (0.7 MPa, 7 bar) Maximum Working
Pressure
For use when electrostatically spraying conductive,
waterborne fluids that meet at least one of the following conditions for non-flammability:
1. The fluid has a flash point above 140F (60C)
and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.
Part No. 237603
Rev. F
04299
2. The fluid does not sustain burning when tested per
ASTM Standard D4206 Sustained Burn Test.
Part No. 237603*, Series A
Includes the spray gun, shroud, manifold, and
mounting bracket.
Part No. 236824, Series A
Includes the spray gun and shroud only.
Part No. 238091, Series A
Includes the spray gun, shroud, manifold, regulator,
and mounting bracket.
NOTE: The fluid hose must be ordered separately.
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 U.S. and Foreign Patents Pending
NOTE: The PRO 5500wb spray gun is Factory Mutual approved for use with Graco isolation systems. The spray gun is also
approved for use with other Factory Mutual approved voltage isolations systems provided that the fluid hose is assembled as
shown in Fig. 15, page 17. Any modification of genuine Graco parts or replacement of parts with non-Graco parts will void agency
approvals.
Part No. 238091
05928
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 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
Installing the System 9. . . . . . . . . . . . . . . . . . . . . . . . .
Warning Signs 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilate the Spray Booth 9. . . . . . . . . . . . . . . . . . . . .
Install the Air Line Accessories 11. . . . . . . . . . . . . . . .
Install the Gun and Mounting Bracket 11. . . . . . . . . .
Connect the Air Lines 12. . . . . . . . . . . . . . . . . . . . . . . .
Optional Fiber Optic Cable Connection 13. . . . . . . . .
Optional Fiber Optic Lens Kit Installation 14. . . . . . .
Install the Fluid Hose 15. . . . . . . . . . . . . . . . . . . . . . . .
Ground the System 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Check the Electrical Grounding 18. . . . . . . . . . . . . . .
Install the Fabric Cover 18. . . . . . . . . . . . . . . . . . . . . .
Operation
Fluid Voltage Discharge & Grounding Procedure 19
Pressure Relief Procedure 19. . . . . . . . . . . . . . . . . . . .
Operating Checklist 20. . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a Fluid Nozzle and Air Cap 20. . . . . . . . . . .
Operating the Spray Gun 20. . . . . . . . . . . . . . . . . . . . .
Maintenance
Daily Care and Cleaning 23. . . . . . . . . . . . . . . . . . . . .
Clean the Air Cap and Fluid Nozzle 24. . . . . . . . . . . .
Check for Fluid Leakage 25. . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Voltage Loss Troubleshooting 26. . . . . . . . . . . . . . . . .
Poor Electrostatic Wrap Troubleshooting 28. . . . . . .
Electrical Troubleshooting 29. . . . . . . . . . . . . . . . . . . .
Gun Operation Troubleshooting 30. . . . . . . . . . . . . . .
Spray Pattern Troubleshooting 32. . . . . . . . . . . . . . . .
Service
Tools Included with the Gun 35. . . . . . . . . . . . . . . . . .
Prepare the Gun for Service 35. . . . . . . . . . . . . . . . . .
Air Cap/Nozzle/Resistor Stud Replacement 36. . . . .
Electrode Needle Replacement 37. . . . . . . . . . . . . . .
Fluid Packing Rod Removal and Repair 38. . . . . . . .
Piston Repair 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Barrel Removal 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Removal and Replacement 42. . . . . .
Turbine Alternator Removal and Replacement 43. . .
Barrel Installation 44. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install the Gun onto the Manifold 44. . . . . . . . . . . . . .
Part No. 238039 Fluid Regulator Repair 46. . . . . . . .
Part No. 238147 Fluid Regulator Conversion
Kit Installation 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Waterborne Fluid Hose Repair 48. . . . . . . . . .
Spray Gun Parts
Part No. 237603 and 236824 50. . . . . . . . . . . . . . . . .
Part No. 237091 52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Parts 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 60. . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 60. . . . . . . . . . . . . . . . . . . . . . . .
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
Electrical Tests
Test Gun Resistance 33. . . . . . . . . . . . . . . . . . . . . . . .
Test Power Supply Resistance 34. . . . . . . . . . . . . . . .
Test Resistor Stud Resistance 34. . . . . . . . . . . . . . . .
2 308496
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the corresponding instructions.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding or an improper setup and usage of an isolated waterborne system can cause a
hazardous condition and result in an electric shock or other serious injury.
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 17.
The gun must be connected to a voltage isolation system that will discharge the system voltage
when the gun is not in use.
All components of the isolation system that are charged to high voltage must be contained within a
fence or enclosure that prohibits personnel from making contact with the high voltage components
before the system voltage is discharged.
The gun turbine air supply must be interlocked with the isolation system to shut off the turbine air
supply anytime the isolation system enclosure or safety fence is opened.
The voltage isolation system must be interlocked with the spray area entrance to automatically
discharge the voltage and ground the fluid whenever someone enters the spray area.
The areas of the waterborne fluid hose that are accessible to the personnel must be covered by
the conductive hose layer. The area on the hose that is not covered by the conductive hose layer
must be inside the voltage isolation system enclosure. Refer to Fig. 15, page 17.
Only use the red-colored Graco electrically conductive gun air hose with this gun. Do not use the
black or grey-colored Graco air hoses.
Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the
spray gun. Do not splice hoses together.
Follow the Fluid Voltage Discharge and Grounding Procedure on page 19 when instructed to
discharge the voltage; before cleaning, flushing, or servicing the system; before approaching the
front of the gun or the gun-mounted fluid regulator; and before opening the safety fence or the
enclosure for the isolated fluid supply.
Do not use the Graco ES Display Module readings to determine if your system is discharged. The
display modules will only display the system voltage while the gun power supply is operating.
Follow the Fluid Voltage Discharge and Grounding Procedure to ensure the system is dis-
charged.
Do not enter a high voltage or hazardous area until all high voltage equipment has been
discharged.
Do not come within 2 ft. (610 mm) of the gun nozzle or gun-mounted fluid regulator during gun
operation or until after following the Fluid Voltage Discharge and Grounding Procedure.
If there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.
Follow the warnings and instructions in the voltage isolation system manual.
308496 3
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion.
Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements 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 17.
Test the gun electrical resistance daily as instructed on page 33.
Provide fresh air ventilation to avoid the buildup of 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.
Only use this equipment to spray non-flammable, waterborne fluids, as defined on the front cover
of this manual.
Only flush, purge, or clean the electrostatic, waterborne spray system with non-flammable fluids,
as defined on the front cover of this manual.
Do not flush the system with the gun electrostatics turned on.
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 19 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 each use.
Check the hoses, tubes and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
4 308496
Warnings are continued on the next page.
WARNING
EQUIPMENT MISUSE HAZARD
INSTRUCTIONS
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 usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Do not operate the gun power supply above 60 kV. Use only the Graco power supply, part no.
237250, with this spray gun.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 100 psi (0.7 MPa, 7 bar) 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.
308496 5
Introduction
Spraying Waterborne Fluids
Electrostatically
The PRO 5500wb spray gun is a 60 kV electrostatic
spray gun that is designed to spray conductive, waterborne, non-flammable fluids. When spraying waterborne fluids electrostatically, the gun must be connected to a voltage isolation system, which isolates the
fluid supply from ground and allows voltage to be
maintained at the tip of the gun. For information on the
Graco H2O PRO Voltage Block System, contact your
Graco distributor.
A safe, well designed voltage isolation system should
have the following features:
All components of the isolation system that are
charged to high voltage must be contained within a
fence or enclosure that prohibits personnel from
making contact with the high voltage components
before the system voltage is discharged.
A means for automatically discharging the system
voltage if someone opens the fence or enclosure or
enters the spray area.
Precautions must be taken when using electrostatic
waterborne equipment to avoid potential shock hazards. When the spray gun charges the isolated fluid to
high voltage, it is similar to charging a capacitor or
battery. The system will store some of the energy while
spraying and retain some of that energy after the spray
gun is shut off. It is not safe to touch the front end of
the gun until the stored energy is discharged. The
amount of time it takes to discharge the energy depends on the system design. Follow the Fluid Voltage
Discharge and Grounding Procedure, page 19,
before approaching the front of the gun.
Operating the Spray Function
Applying a minimum of 50 psi (345 kPa, 3.5 bar) 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.
A bleed resistor to drain off the system voltage
when the spray gun is not in use.
The system should not have any severe arcing
occurring when the isolation mechanism opens and
closes. Severe arcing will shorten the life of the
system components.
CAUTION
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
When connected to a voltage isolation system, all of
the fluid in the spray gun, fluid hose, and isolated fluid
supply are charged to high voltage, which means that
the system has more electrical energy than a solventbased system. Therefore, only non-flammable fluids
(defined on the front cover of this manual) can be
sprayed with the system or be used to clean, flush, or
purge the system.
Operating the Electrostatics
(Refer to page 7)
To operate the electrostatics, air pressure is applied to
the gun manifold’s turbine air fitting (which is marked
“TA”) 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”, unless you are using part no. 238091 spray
gun, then the air is exhausted out of the slot in the
bottom of the shroud. The exhaust air helps keep
contaminants out and helps keep the gun clean.
6 308496
Introduction
F
F.O.
TA
CYL
ACDE
04299
H
A1
P1
A2
EXH
(PA)
Manifold Back View
04302
KEY
A Air Cap
B Fluid Nozzle
C Retaining Nut
D Shroud
E Mounting Bracket
F Manifold
G Turbine
H Power Supply
J Electrode
B
J
Manifold Markings
A1 Atomization Air Inlet Fitting
A2 Fan Air Inlet Fitting
CYL Cylinder Air Inlet Fitting
EXH (PA) Shroud Exhaust Outlet or Pilot Air Inlet Fitting
F.O. Fiber Optic Fitting
P1 Fluid Supply Inlet Fitting
TA T urbine Air Inlet Fitting
KV not used
P2 not used
G
04482
308496 7
Introduction
Gun Features and Options
(Refer to page 7)
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. Refer to Fig. 2, page 10.
An optional fiber optic readout system can be
installed to monitor the gun’s spraying voltage. A
fiber optic cable connected to the gun manifold
carries the signal from the gun to a remote ES
(electrostatic) display module. An ES Display
Module, part no. 224117, is available and will
display the gun’s spraying voltage and current. A
battery operated ES Display Module, part no.
189762, is also available; it displays the gun’s
spraying voltage only. Refer to Fig. 3, page 10.
Part no. 238091 spray gun has a fluid regulator
located at the gun barrel inlet. The fluid regulator
provides precise fluid control.
This fluid hose consists of three layers (see Fig. 1):
Inner Hose Layer (EE): is a PTFEtube.
Conductive Hose Layer (DD): covers the PTFE
tube.
Outer Hose Jacket (FF): is a protective polyethyl-
ene hose cover.
If a hose failure occurs, where the high voltage arcs
through the inner hose layer (EE), the voltage will be
discharged to ground through the conductive hose
layer (DD). When properly installed, the conductive
hose layer is grounded through its connection to the
grounded safety fence or enclosure (CC). All areas of
the fluid hose that are accessible to personnel must be
covered by the outer hose jacket (FF) to avoid electric
shock.
KEY-Fig. 1
DD Conductive Hose Layer
EE Inner Hose Layer
FF Outer Hose Jacket
CC Grounded Enclosure
The portion of the inner hose layer (EE-PTFE tube) that is not
covered by the conductive hose layer (DD), must be inside the
safety fence or enclosure (CC).
The areas of the waterborne fluid hose that are accessible to per-
sonnel during normal operation must be covered by the outer
hose jacket (FF).
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock,
do not use the Graco ES Display Module
readings to determine if your system is
discharged. The display modules will only display
the system voltage while the guns power supply
is operating. Follow the Fluid Voltage Discharge
and Grounding Procedure, page 19, to ensure
the system is discharged.
Graco Waterborne Fluid Hose (purchased
separately)
A Graco waterborne fluid hose must be used between
the voltage isolation system fluid outlet and the spray
gun fluid inlet.
CC
H2O PRO Voltage Block connection shown
Fig. 1
DDEE
FF
05179
8 308496
Installation
Installing the System
WARNING
ELECTRIC SHOCK HAZARD
Installing and servicing this equipment
requires access to parts which could
cause an electric shock or other serious
injury if the work is not performed properly.
Do not install or service this equipment unless
you are trained and qualified.
Comply with all local, state, and national 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.
Fig. 2, page 10, shows a typical Model PRO 5500wb
waterborne system. Fig. 3 shows the optional ES
Display Modules. The particular type and size system
for your operation must be custom designed for your
needs. For assistance in designing a system, contact
your Graco representative.
All components of the isolation system that are
charged to high voltage must be contained within a
fence or enclosure that prohibits personnel from
making contact with the high voltage components
before the system voltage is discharged.
The gun turbine air supply must be interlocked with
the isolation system to shut off the turbine air
supply anytime the isolation system enclosure or
safety fence is opened.
The voltage isolation system must be interlocked
with the spray area entrance to automatically
discharge the voltage and ground the fluid whenever someone enters the spray area.
The system should not have any severe arcing
occurring when the isolation mechanism opens and
closes. Severe arcing will shorten the life of the
system components.
Warning Signs
Mount the warning signs, part no. 186118 and 290171,
at the entrance to the spray booth, where it can easily
be seen and read by all operators. Additional warning
signs are available at no charge.
Ventilate the Spray Booth
WARNING
Accessories are available from your Graco representative. Refer to the Product Data Sheet for the gun,
Form No. 305678.
Basic Guidelines
When spraying waterborne fluids electrostatically:
The gun must be connected to a voltage isolation
system, which isolates the fluid supply from ground
and allows voltage to be maintained at the tip of the
gun.
The gun must be connected to a voltage isolation
system that will discharge the system voltage when
the gun is not in use.
TOXIC FLUID HAZARD
Provide fresh air ventilation to avoid the
buildup of toxic vapors. Do not operate
the gun unless the ventilating fans are
on.
Electrically interlock the gun turbine air supply with the
ventilators to prevent operation of the electrostatic
power supply unless the 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 linear feet/minute
(18.3 linear meters/minute).
308496 9
Installation
BASIC SYSTEM
QP
Non-Hazardous Area Hazardous Area
Fig. 2
W
A
K
L
C
D
E
K
B
*
A1
*
A2
*
CYL
*
EXH (PA)
*
P1
*
S
MN
M R
Non-Hazardous Area Hazardous Area
ZT
U
H
TA
F
J
G
05929
SYSTEM OPTION
ES Display Module
Y
kV
mA
X
kV
V
AA
Fig. 3
KEY
A Ground Wire on Graco Electrically Conductive Air Hose
B Graco Electrically Conductive Air Hose (Turbine Air Hose),
P/N 235068 to 235074, color coded red
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 Graco Waterborne Fluid Hose, see page 56 for parts
G Graco H2O PRO Voltage Block Isolation System
H PRO 5500wb Spray Gun
J Mounting Bracket for 1/2 inch (127 mm) rod, P/N 189581
K Solenoid Valve-requires quick-exhaust port
L Bleed-type Air Shut-off Valve
M Air Pressure Regulator for fluid regulator pilot
N True Earth Ground
P Main Air Line
Q Bleed-type Master Air Valve
R Shroud Exhaust Port for Gun P/N 237603 or Pilot Air Line for Gun
P/N 238091; 1/4 inch (6.4 mm) O.D.
F.O.
*
S Check Valve
T Fiber Optic Cable, P/N 224680 to 224686
U Bulkhead, P/N 189870
V Fiber Optic Cable, P/N 224670 to 224676
W 24 Volt Power Supply, P/N 235301
X4–20 mA Outputs
Y PRO 5500wb Spray Gun
Z Full Feature ES Display Module, P/N 224117
AA kV Only ES Display Module (battery operated), P/N 189762
The turbine air supply must be interlocked with the spray booth
ventilation fans and the voltage isolation system.
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 12 for a description of the manifold connections.
04300
10 308496
Install the Air Line Accessories
Installation
1. Install an air line filter and an air and water separator on the main air supply line to ensure a dry,
clean air supply to the gun. Dirt and moisture can
ruin the appearance of your finished workpiece
and can cause the gun to malfunction.
2. Install a bleed-type air shutoff valve (Q) on the
main air supply line to shut off all the air to the gun.
3. Install a bleed-type air regulator (M) on each of the
gun air supply lines to control the air pressure to
the gun. See Fig. 2, page 10.
4. Install a bleed-type air shutoff valve (L) on the fan
(C) and atomization (D) air lines to shut off the fan
and atomization air to the gun.
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 bleed-type air shutoff
valve is required on the fan and atomization air
lines so trapped air will be relieved between the
valve and the gun after the valves are closed.
5. Install a check valve (S) in the pilot air line (R) to
prevent fluid from backing up into the air controls.
B
A
= 2 in. (51 mm)
B
= 4 in. (102 mm)
A
A
A
05937
Fig. 4
1. Loosen the two square head bolts (103), and slide
the mounting bracket onto a 0.50 inch (12.7 mm)
mounting rod. See Fig. 5.
2. Position the gun, and tighten the two bolts (103)
securely.
2.775 in .
(70.5 mm)
103
0.50 in.
(12.7 mm)
rod
9.32 in.
(236.7 mm)
103
Fig. 5
04301
NOTE: For added positioning reliability, the mounting
bracket (DD) has an 1/8 inch (3.2 mm) slot where a
locating pin (BB–not included) can be inserted through
the mounting rod (CC). See Fig. 6.
Install the Gun and Mounting Bracket
CAUTION
To avoid electrical breakdown damage to the fluid
regulator and other gun components, do not have
any grounded objects within the minimum clearance
zone shown in Fig. 4 during gun operation.
Fig. 6
CC
BB
DD
03460
308496 11
Installation
Connect the Air Lines
See Fig. 2, page 10, for a schematic of air line connections. Connect the air lines to the gun manifold as
instructed at right.
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of a fire, explosion, or
electric shock, the gun turbine air supply
must be interlocked with:
The isolation system to shut off the
turbine air supply anytime the enclosure or safety fence is opened.
The ventilators to prevent operation
of the power supply unless the ventilating fans are on.
Graco Electrically Conductive Air Hose
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock or
other serious injury, you must use the
red-colored Graco Electrically Conductive Air Hose for the turbine air hose, and you must
connect the hose ground wire to a true earth
ground. Do not use the black or grey-colored Graco
air hoses.
Manifold Connections (See Fig. 7)
A1 Atomization Air Inlet Fitting
Connect a 3/8 inch (9.5 mm) O.D. tube between the
fitting and the air supply.
A2 Fan Air Inlet Fitting
Connect a 3/8 inch (9.5 mm) O.D. tube between the
fitting and the air supply.
CYL Cylinder Air Inlet Fitting
Connect a 1/4 inch (6.4 mm) O.D. tube between this
fitting and the solenoid. For quicker trigger response, use the shortest hose length possible.
EXH Shroud Exhaust Outlet or Pilot Air Inlet Fitting
(PA) If using part no. 238091 spray gun, which includes a
fluid regulator, connect a 1/4 inch (6.4 mm) O.D.
pilot line to the fitting to control the fluid outlet pressure. If using part no. 237603 or 236824 spray gun,
connect a 1/4 inch O.D. (6.4 mm) x 4 foot (1.22 m)
long exhaust tube to the fitting.
F.O. Fiber Optic Fitting (Optional)
Connect the Graco Fiber Optic Cable as instructed
on page 13.
P1 Fluid Supply Inlet Fitting
Connect a Graco waterborne fluid supply hose as
instructed on page 15.
TA Turbine Air Inlet Fitting
Connect the red 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.
F.O.
TA
CYL
A2
A1
Connect the red-colored Graco Electrically Conductive
Air Hose (B) to the gun turbine air inlet and connect
the hose ground wire (A) to a true earth ground (N).
Refer to Fig. 2, page 10. Check the electrical grounding of the gun as instructed on page 18. See page 57
to order the air hose.
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.
12 308496
P1
Fig. 7
EXH
(PA)
Manifold Back View
04302
Installation
Optional Fiber Optic Cable Connection
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock,
do not use the Graco ES Display Module
readings to determine if your system is
discharged. The display modules will only display
the system voltage while the guns power supply
is operating. Follow the Fluid Voltage Discharge
and Grounding Procedure, page 19, to ensure
the system is discharged.
An optional fiber optic fitting (124) is shipped unassembled with the gun. If an ES (kV) display module is
used, install the fitting in the manifold. See Fig. 3, page
10, 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 (124). See Fig. 8.
124
115
2. Remove the nut (EE) from the fiber optic fitting
(124), and slide the nut over the end of the fiber
optic cable (FF). See Fig. 9.
3. Insert the cable (FF) into the fitting (124), and push
the cable in until it bottoms out. Tighten the nut
(EE) to secure the cable.
EE
FF
Fig. 9
4. If you have two bulkhead splices in your system, it
is recommended that you install the fiber optic lens
kit, as described on page 14.
124
04306
Fig. 8
04305
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.
308496 13
Installation
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 35.
2. Make sure the lens (HH) is clean. Push the lens
into the counterbore (KK) in the manifold fiber optic
port (GG). See Fig. 10 and 11.
3. Press the lens retainer (JJ) into the manifold fiber
optic port (GG) until it is flush with the manifold
surface.
4. Assemble the gun to the manifold as instructed on
page 44.
GG
HH
JJ
Fig. 11
HH
JJ
KKGG
04485
Fig. 10
04484
14 308496
Installation
Install the Fluid Hose
NOTE:
A Graco waterborne fluid hose must be used
between the voltage isolation system fluid outlet
and the spray gun fluid inlet. See page 56 to order
the Graco waterborne fluid hoses and the hose
replacement parts.
Before connecting the fluid supply line to the gun,
blow it out with air, and flush it with water to remove
contaminants.
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock,
install only one continuous Graco water-
borne fluid hose between the isolated
fluid supply and the spray gun. Do not splice hoses
together.
1. For the fluid hose to seal properly, the hose must
be stripped and assembled to the dimensions
shown in Fig. 12. A new Graco waterborne fluid
hose comes fully assembled to the proper dimensions.
3. Unscrew the strain relief nut (L) from the fluid inlet
fitting (P1), and slide the nut onto the hose (H).
See Fig. 13.
4. Apply a light coat of dielectric grease (supplied
with the gun) to the entire length of the exposed
inner hose layer (K). See Fig. 12.
Apply a light coat of dielectric grease to the o-rings (G) and the
entire length of the inner hose layer (K)
G
Spray Gun
Hose End
04303
HJ K
Fig. 12
Minimum:
6.85 in.
(174 mm)
5.1 + 0.10 in.
(130 + 2.5 mm)
CAUTION
Be careful not to cut into the inner hose layer (K)
when stripping the hose. Nicks or cuts in the tube will
cause premature hose failure.
2. Inspect the condition of the o-rings (G) on the hose
barbed-fitting. Replace the o-rings if they are worn
or damaged.
Fig. 13
L
H
P1
04304
308496 15
Installation
Install the Fluid Hose (continued)
5. Insert the hose into the fluid inlet fitting (P1). See
Fig. 14.
6. Push the hose into the fitting until the o-rings (G)
on the hose barbed-fitting are seated and the hose
bottoms out.
WARNING
ELECTRIC SHOCK HAZARD
To maintain grounding continuity, the
conductive hose layer (J) must be
engaged in the fitting (P1) when the nut
(L) is tightened. See Fig.14. Failure to properly
install the hose into the fitting could result in an
electric shock.
P1GL
7. Tighten the nut (L) firmly with a wrench to about 55
in-lb (6.2 Nm). Pull back on the hose to make
sure it is secure.
CAUTION
If the hose comes loose from the fitting, fluid leakage
will occur. Make sure the nut (L) is tight and that
nothing will pull or catch on the hose during operation.
8. Check the gun’s electrical grounding as instructed
on page 18.
9. Connect the other end of the hose as instructed in
the voltage isolation system manual. See Fig. 15.
WARNING
Fig. 14
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock,
the areas of the waterborne fluid hose
that are accessible to personnel during
normal operation must be covered by the outer
hose jacket (H). See Fig. 15.
CAUTION
The Graco warranty is void if the spray gun is con-
J LP1
05927
nected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
16 308496
Install the Fluid Hose (continued)
K H
Installation
DETAIL
HK
Fig. 15
R
R
J
H2O PRO Voltage Block
connection shown
Ground the System
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
When operating the electrostatic device,
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, waterborne
system. Your system may include other equipment or
objects which must be grounded. Check your local
electrical code for detailed grounding instructions. Your
system must be connected to a true earth ground.
1. Fluid Supply: Ground the fluid supply by connecting a ground wire and clamp between the fluid
supply and a true earth ground. See your fluid
supply instruction manual for grounding instructions.
The areas of the waterborne fluid hose that are accessi-
ble to personnel during normal operation must be covered by the outer hose jacket (H).
The portion of the inner hose layer (K) that is not cov-
ered by the outer hose jacket (H) must be inside the voltage isolation system enclosure (R).
The conductive hose layer (J) must be grounded through
its connection to the isolation system’s grounded safety
fence or enclosure (R).
04574
2. PRO 5500wb Electrostatic Air Spray Gun:
Install the red-colored Graco electrically conductive air hose between the gun and air supply line
and connect the air hose ground wire to a true
earth ground. Check the electrical grounding of the
gun as instructed on page 18.
3. Graco Waterborne Fluid Hose: The conductive
layer of the hose must be properly grounded by
correct installation as instructed on pages 15 to 17.
4. Voltage Isolation System: Ground the system
according to the manufacturer’s instructions.
5. 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.
6. Object being sprayed: Keep the workpiece
hangers clean and grounded at all times. Contact
points must be sharp points or knife edges.
7. The floor of the spray area: The floor must be
electrically conductive and grounded. Do not cover
the floor with cardboard or any non-conductive
material which would interrupt grounding continuity.
8. All electrically conductive objects or devices
in the spray area: They must be properly
grounded.
308496 17
Installation
Check the Electrical Grounding
1. Have a qualified electrician check the electrical
grounding continuity of the gun and turbine air
hose (M). See Fig. 16.
2. Make sure the turbine air hose (M) [the red Graco
electrically conductive air hose] 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 (N) and a true earth ground (P) with an
ohmmeter (Q). Resistance should not exceed 100
ohms.
5. If the resistance is greater than 100 ohms, check
the tightness of the ground connections, and be
sure the turbine air hose ground wire is connected
to a true earth ground. If the resistance is still too
high, replace the turbine air hose.
Install the Fabric Cover
(Part No. 237603 and 236824 Guns Only)
1. Install a fabric cover (AA) over the front of the gun,
and slide it back to cover the exposed tubing and
hoses at the back of the manifold. See Fig. 17.
2. Route the exhaust tube (BB) outside the cover.
This enables you to monitor the exhaust tube for
the presence of any paint or solvent. See Check
for Fluid Leakage on page 25. Strap down the
exhaust tube to prevent it from moving around.
Fig. 16
N
Q
M
P
04307B
Fig. 17
BB
Manifold Back View
AA
04308
BB
04309
18 308496
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