Graco Pro Xp Instruction Manual

Instructions-Parts

Pro

Pro Pro
Air

Air Air

For

For For
For

For For
use

use use

100psi(0.7MPa,7.0bar)Maximum
FluidWorkingPressure
100psi(0.7MPa,7.0bar)MaximumAir
WorkingPressure

Seepage3formodelpartnumbersand
approvalinformation.

Xp™

Xp™ Xp™

Spray

Spray Spray

use

use use
use

use use

only.

only. only.

Class

in ininClass Class

Group

in ininGroup Group

Important

Important Important
Thisequipmentcouldpresenthazardsifnotoperatedaccordingto
theinformationinthismanual.Readallwarningsandinstructionsin
thismanualbeforeusingtheequipment.Save Save

Electrostatic

Electrostatic Electrostatic

Gun

Gun Gun

Div.

I, I,I,Div. Div.

II,

II, II,

Safety

Safety Safety

Hazardous

I IIHazardous Hazardous

Zone

Zone Zone

Explosive

1 11Explosive Explosive

Instructions

Instructions Instructions

3A2494P

EN

Locations

Locations Locations

Atmosphere

Atmosphere Atmosphere

using

Group

using using

Group Group

Locations

Locations Locations

Save

these

instructions.

these these

instructions. instructions.

materials.

D DDmaterials. materials.

using

Group

using using

Group Group

IIA

materials.

IIA IIA

materials. materials.

For

professional

For For

professional professional

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents

Contents Contents

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

Approvals...........................................................7

RelatedManuals................................................7

Warnings...........................................................8

GunOverview....................................................11

HowtheElectrostaticSprayGun

Works............................................11

Controls,Indicators,andComponents...........12

SmartGuns.................................................13

Installation..........................................................18

WarningSign...............................................18

VentilatetheSprayBooth.............................18

AirSupplyLine............................................19

FluidSupplyLine.........................................19

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

GunSetup..........................................................25

GunSetupProcedure...................................25

SoftSprayGunSetupProcedure..................28

HVLPGunSetupProcedure.........................29

RoundSprayGunSetupProcedure..............31

AbrasiveMaterialGunSetup

Procedure......................................33

CheckGunElectricalGrounding...................34

CheckFluidResistivity.................................35

CheckFluidViscosity...................................35

FlushBeforeUsingEquipment......................35

Operation...........................................................36

PressureReliefProcedure............................36

Startup........................................................37

Shutdown....................................................37

Maintenance......................................................38

DailyCareandCleaningChecklist................38

Flushing......................................................38

CleantheGunDaily.....................................40

DailySystemCare.......................................41

ElectricalTests...................................................42

TestGunResistance....................................42

TestPowerSupplyResistance.....................43

TestElectrodeResistance............................43

Troubleshooting..................................................44

SprayPatternTroubleshooting......................44

GunOperationTroubleshooting....................45

ElectricalTroubleshooting............................46

Repair................................................................47

PreparetheGunforService.........................47

AirCapandNozzleReplacement..................48

ElectrodeReplacement................................49

FluidPackingRodRemoval..........................50

PackingRodRepair.....................................50

BarrelRemoval............................................52

BarrelInstallation.........................................52

PowerSupplyRemovaland

Replacement..................................53

AlternatorRemovalandReplacement...........54

FluidTubeRemovalandReplacement...........56

FanAirAdjustmentValveRepair..................57

AtomizingAirRestrictorValveRepair............58

ESOn-OffandFluidAdjustmentValve

Repair............................................59

AirValveRepair...........................................60

SmartModuleReplacement..........................61

AirSwivelandExhaustValve

Replacement..................................62

Parts..................................................................63

GunModelswithStandardDisplay................63

GunModelswithSmartDisplay....................66

PackingRodAssembly.................................69

AlternatorAssembly.....................................70

ESOn-OffandFluidAdjustmentValve...........71

FanAirAdjustmentValveAssembly..............72

QuickAdjustFanValveAssembly.................72

AtomizingAirRestrictorValve

Assembly.......................................73

SmartModuleAssembly...............................74

RoundSprayAssembly................................75

HighConductivityFluidTubeAssembly:40

kV..................................................77

HighConductivityFluidTubeAssembly:60

kVand85kV..................................78

FluidNozzles.....................................................79

FluidNozzleSelectionChart.........................79

FluidNozzlePerformanceCharts..................80

AirCaps.............................................................82

AirCapSelectionGuide...............................82

AirConsumptionCharts...............................87

ElectrodeSelectionChart....................................88

RepairKitsandAccessories................................89

GunAccessories..........................................89

InlineFluidFilterKitAccessories...................90

OperatorAccessories...................................90

SystemAccessories.....................................90

Signs..........................................................91

TestEquipment...........................................91

Hoses.........................................................92

Dimensions........................................................93

TechnicalSpeci󰘰cations......................................94

CaliforniaProposition65.....................................94

2

3A2494P

Models

Models

Models Models

General

General General

Equippedwithstandardelectrode,nozzle,aircapand󰘱uidtube.ForapplyingaClassA󰘰nishwithstandard
andspecialtycoatings.

Part

Part Part

L40M10A40

L40T10

L40T12A40

L60M10

L60M12

L60T10

L60T12

L60T21A60

L85M10

L85M12A85

L85T10

L85T12A85

L85T50*

Gun

Gun Gun

No.

No. No.

Models

Models Models

Series

Series Series

C

C

C

C

C

C

C

A85

kV

kV kV

40

60

60

60

60

85

85

Display

Display Display

SmartStd1.5StdStdStd

StdStd1.5StdStdStd

StdStd1.2StdStdStd

SmartStd1.5StdStdStd

SmartStd1.2StdStdStd

StdStd1.5StdStdStd

StdStd1.2StdStdStd

StdStd1.0StdStdStd

SmartStd1.5StdStdStd

SmartStd1.2StdStdStd

StdStd1.5StdStdStd

StdStd1.2StdStdStd

StdStd1.5StdStdStd

Electrode

Electrode Electrode

Nozzle

Nozzle Nozzle

(mm)

(mm) (mm)

Air

Cap

Air Air

Cap Cap

Fluid

Tube

Fluid Fluid

Tube Tube

*Equippedwithaquick-adjustfanvalve

3A2494P3

Models

High

High High

EquippedwithalongerHighConductivity󰘱uidtubeforsprayinglowerresistivitymaterial.Mostmodelsare
alsoequippedwithhighwearelectrode,precisionhighwearnozzle,andstandardaircap.Forapplyinga
classA󰘰nishwithabrasiveandmetalliccoatings.

Conductivity

Conductivity Conductivity

Part

No.

Part Part

No. No.

L40M16A40

L40T13B40

L40T16

L40T26A40

L60M26A60

L60M16

L60T26A60

L60T13B60

L60T16

L85M16

L85M26A85

L85T16

Series

Series Series

C

C

C

C

C

Gun

Gun Gun

Models

Models Models

kV

kV kV

40

60

60

85

85

Display

Display Display

Smart

Std

Std

Std

Smart

Smart

Std

Std

Std

Smart

Smart

Std

Electrode

Electrode Electrode

HW1.5PHW

HW

HW1.5PHW

HW1.2PHW

HW1.2PHW

HW1.5PHW

HW1.2PHW

HW

HW1.5PHW

HW1.5PHW

HW1.2PHW

HW1.5PHW

Nozzle

Nozzle Nozzle
(mm)

(mm) (mm)

1.5StdStdHC

1.5StdStdHC

Air

Cap

Air Air

Cap Cap

StdHC

StdHC

StdHC

StdHC

StdHC

StdHC

StdHC

StdHC

StdHC

StdHC

Fluid

Tube

Fluid Fluid

Tube Tube

L85T26A85

L85T56*

*Equippedwithaquick-adjustfanvalve

kV

Booster

kV kV

Booster Booster

The40kVBoosterprovidesthetransferef󰘰ciencyofa60kVguninasmaller,morecompactsize.

Part

No.

Part Part

No. No.

L40M14A40

L40M15A40

L40T14

L40T15

A85

Gun

Gun Gun

Series

Series Series

C

C

Models

Models Models

kV

kV kV

40

40

Std

Std

Display

Display Display

SmartStd1.5StdStdStd

Smart

StdStd1.5StdStdStd

Std

HW1.2PHW

HW1.5PHW

Electrode

Electrode Electrode

HW1.5PHW

HW1.5PHW

StdHC

StdHC

Nozzle

Nozzle Nozzle
(mm)

(mm) (mm)

Air

Cap

Air Air

Cap Cap

StdHC

StdHC

Fluid

Tube

Fluid Fluid

Tube Tube

4

3A2494P

Models

Round

Round Round

Equippedwithroundspraynozzleandaircap.Forroundspraypatternapplications.

Part

Part Part

L40T31A40

L40T32A40

L60T11

L60T31A60

L60T32A60

L85T31A85

L85T32A85

Soft

Soft Soft

Equippedwithsoftsprayaircap.ForapplyingaclassA󰘰nishtosmall,lightweightparts.

Part

Part Part

L40T71A40

Spray

Spray Spray

No.

No. No.

Spray

Spray Spray

No.

No. No.

Gun

Gun Gun

Series

Series Series

C

Gun

Gun Gun

Series

Series Series

Models

Models Models

kV

kV kV

60

Models

Models Models

kV

kV kV

Display

Display Display

StdStdSmallPatternStd

StdStd

StdStd

StdStdSmallPatternStd

StdStd

StdStdSmallPatternStd

StdStd

Display

Display Display

StdStd1.0StdSoftSprayStd

Electrode

Electrode Electrode

Electrode

Electrode Electrode

Nozzle

Nozzle Nozzle

(mm)

(mm) (mm)

MediumPattern

LargePattern

MediumPattern

MediumPattern

Nozzle

Nozzle Nozzle

(mm)

(mm) (mm)

Fluid

Air

Cap

Air Air

Cap Cap

Air

Cap

Air Air

Cap Cap

Tube

Fluid Fluid

Tube Tube

Std

Std

Std

Std

Fluid

Tube

Fluid Fluid

Tube Tube

L60M71A60

L60M72A60

L60T71A60

L60T72A60

L85M71A85

L85T71A85

Aerospace

Aerospace Aerospace

Equippedwithaerospaceaircap,highwearelectrode,andprecisionhighwearnozzle.Forapplyinghigh
solidsandaerospacecoatings.

Part

No.

Part Part

No. No.

L85T73A85

L85T75A85

L85T78A85

Gun

Gun Gun

Series

Series Series

Models

Models Models

kV

kV kV

SmartStd1.0StdSoftSprayStd

SmartStd1.2StdSoftSprayStd

StdStd1.0StdSoftSprayStd

StdStd1.2StdSoftSprayStd

SmartStd1.0StdSoftSprayStd

StdStd1.0StdSoftSprayStd

Display

Display Display

Std

Std

Std

Electrode

Electrode Electrode

HW1.2PHW

HW1.5PHW

HW1.8PHW

Nozzle

Nozzle Nozzle

(mm)

(mm) (mm)

Air

Cap

Air Air

Cap Cap

AEROStd

AEROStd

AEROStd

Fluid

Fluid Fluid

Tube

Tube Tube

3A2494P5

Models

HVLP

HVLP HVLP

EquippedwithHVLPaircap.

Part

Part Part

L40M77A40

L40T77A40

L60M77A60

L60T77A60

L85M77A85

L85T77A85

High

High High

EquippedwithESOn-OffwithAirRestrictorandFluidAdjustmentValve,whichlimitsair󰘱owtotheturbine.
Forapplicationsthatrequirehighair󰘱owattheaircap.

Part

Part Part

L60M57A60

Gun

Gun Gun

No.

No. No.

Air

Air Air

No.

No. No.

Models

Models Models

Series

Series Series

Flow

Flow Flow

Series

Series Series

kV

kV kV

Gun

Gun Gun

kV

kV kV

Display

Display Display

SmartStd1.5Std

StdStd1.5Std

SmartStd1.5Std

StdStd1.5Std

SmartStd1.5Std

StdStd1.5Std

Models

Models Models

Display

Display Display

SmartStd1.5StdStdStd

Electrode

Electrode Electrode

Electrode

Electrode Electrode

Nozzle

Nozzle Nozzle
(mm)

(mm) (mm)

Nozzle

Nozzle Nozzle
(mm)

(mm) (mm)

Air

Cap

Air Air

Cap Cap

HVLP

HVLP

HVLP

HVLP

HVLP

HVLP

Air

Cap

Air Air

Cap Cap

Fluid

Tube

Fluid Fluid

Tube Tube

Std

Std

Std

Std

Std

Std

Fluid

Tube

Fluid Fluid

Tube Tube

L60T57A60

L85M57A85

L85T57A85

Fixed

Fixed Fixed

EquippedwithESOn-OffandFixedFluidValve,whichextendselectrodeandnozzlelife.Forapplicationswith
abrasive,metallic,andextremelyabrasivematerials.

Part

Part Part

L60T98A60

L60T99A60

L85T90A85

L85T96A85

Fluid

Fluid Fluid

No.

No. No.

Flow

Flow Flow

Series

Series Series

Gun

Gun Gun

kV

kV kV

StdStd1.5StdStdStd

SmartStd1.5StdStdStd

StdStd1.5StdStdStd

Models

Models Models

Display

Display Display

StdShort

StdShort

Std

Std

Electrode

Electrode Electrode

HW1.5PHW

HW1.5PHW

Nozzle

Nozzle Nozzle
(mm)

(mm) (mm)

1.5PHW

1.5PHW

Air

Cap

Air Air

Cap Cap

StdStd

StdHC

StdStd

StdHC

Fluid

Tube

Fluid Fluid

Tube Tube

63A2494P

Approvals

2575

Approvals

Approvals Approvals

G

II IIII2 22G G

0.24mJT6

FM12ATEX0068

EN50050-1

Ta0°C–50°C

Related

Related Related

Manual

Manual Manual

3A2498

3A6929

3A7005

3A6833

307263ProbeandMeter,Instructions

308393

309227

309455TestFixture,HighVoltageProbe,andkVMeter,Instructions

406999

No.

No. No.

Manuals

Manuals Manuals

Description

Description Description

RoundSprayKit,Instructions(largepattern)

RoundSprayKit,Instructions(smallandmediumpattern)

QuickAdjustFanValveKit,Instructions

HVLPVeri󰘰cationKit,Instructions

GunWasherKit,Instructions

GunFlushBoxModule,Instructions

VoltageTesterConversionKit,Instructions

3A2494P

7

Warnings

Warnings

Warnings Warnings

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

WARNING

WARNING WARNING

FIRE,

EXPLOSION,

FIRE, FIRE,

EXPLOSION, EXPLOSION,

Flammablefumes,suchassolventandpaintfumes,inworkareacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰re,
explosion,andelectricshock:

•Electrostaticequipmentmustbeusedonlybytrained,quali󰘰edpersonnelwhounderstand
therequirementsofthismanual.

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

•OnlyusegroundedGracoconductiveairsupplyhoses.

•Donotusepaillinersunlesstheyareconductiveandgrounded.
Stop

•Stop Stop

•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.

•Useandcleanequipmentonlyinwellventilatedarea.

•Interlockthegunairand󰘱uidsupplytopreventoperationunlessventilationair󰘱owisabove

•UseonlyGroupIIAorGroupDmaterials.

•Usecleaningsolventswithhighestpossible󰘱ashpointwhen󰘱ushingorcleaningequipment.

•Neversprayor󰘱ushsolventathighpressure.

•Tocleantheexterioroftheequipment,cleaningsolventsmusthavea󰘱ashpointatleast15°

•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.

•Eliminateallignitionsourcessuchaspilotlights,cigarettes,portableelectriclamps,and

•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.

•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.

•Keepthesprayareacleanatalltimes.Usenon-sparkingtoolstocleanresiduefromthe

•Keepaworking󰘰reextinguisherintheworkarea.

operation

operation operation

equipmentuntilyouidentifyandcorrecttheproblem.

theminimumrequiredvalue.

Cor59°Faboveambienttemperature.Non-ignitable󰘱uidsarepreferred.

plasticdropcloths(potentialstaticsparking).

boothandhangers.

AND

ELECTRIC

AND AND

ELECTRIC ELECTRIC

immediately

immediately immediately

ifstaticsparkingoccursoryoufeelashock.Donotuse

SHOCK

SHOCK SHOCK

HAZARD

HAZARD HAZARD

Grounding

instructions.

83A2494P

WARNING

WARNING WARNING

PRESSURIZED

PRESSURIZED PRESSURIZED
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.

EQUIPMENT

EQUIPMENT EQUIPMENT

HAZARD

HAZARD HAZARD

Warnings

•FollowthePressure Pressure
cleaning,checking,orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

EQUIPMENT

EQUIPMENT EQUIPMENT
Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical

Speci󰘰cations

Speci󰘰cations Speci󰘰cations
Forcompleteinformationaboutyourmaterial,requestaSafetyDataSheet(SDS)from
yourdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

PLASTIC

PLASTIC PLASTIC
Manycleaningsolventscandegradeplasticpartsandcausethemtofail,whichcouldcause
seriousinjuryorpropertydamage.

Pressure

MISUSE

MISUSE MISUSE

PARTS

PARTS PARTS

Relief

Procedure

Relief Relief

Procedure Procedure

HAZARD

HAZARD HAZARD

Technical

inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.

CLEANING

CLEANING CLEANING

SOLVENT

SOLVENT SOLVENT

whenyoustopspraying/dispensingandbefore

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

Pressure

HAZARD

HAZARD HAZARD

Relief

Relief Relief

inallequipmentmanuals.

Procedure

Procedure Procedure

whenequipmentisnotinuse.

Technical

•Useonlycompatiblesolventstocleanplasticstructuralorpressure-containingparts.

•SeeTechnical Technical

Technical

thesolventmanufacturerforinformationandrecommendationsaboutcompatibility.

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

inallequipmentmanualsformaterialsofconstruction.Consult

3A2494P9

Warnings

WARNING

WARNING WARNING

TOXIC

TOXIC TOXIC
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.

•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable

PERSONAL

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

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent

FLUID

FLUID FLUID

guidelines.

manufacturer.

OR

FUMES

OR OR

FUMES FUMES

PROTECTIVE

PROTECTIVE PROTECTIVE

HAZARD

HAZARD HAZARD

EQUIPMENT

EQUIPMENT EQUIPMENT

103A2494P

GunOverview

Gun

Gun Gun

How

How How

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

Overview

Overview Overview

the

Electrostatic

the the

Electrostatic Electrostatic

Spray

Spray Spray

Gun

Gun Gun

Works

Works Works

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

3A2494P

11

GunOverview

Controls,

Controls, Controls,

Theelectrostaticgunincludesthefollowingcontrols,indicators,andcomponents(seeFig.1).Forinformation
onSmartguns,seeSmartGuns,page13.

Figure1GunOverview

Item

Item Item

A

BFluidInlet

Indicators,

Indicators, Indicators,

Description

Description Description

AirSwivelInlet1/4npsm(m)left-handthread,forGracogroundedairsupplyhose.

and

Components

and and

Components Components

Purpose

Purpose Purpose

3/8npsm(m),for󰘱uidsupplyhose.

C

D

EElectrodeNeedle

FFanAirAdjustment

G

HFluidAdjustment

J

K

TurbineAir
Exhaust

AirCapandNozzleShapesthespraypattern.SeeAirCaps,page82and

Valve

AtomizingAir
RestrictorValve

Knob

ESOn-OffValveTurnselectrostaticsON(I)orOFF(O).

ESIndicator(stan­dardgunonly;for
Smartgunindica­tor,seeOperating

Mode,page13)

Barbed󰘰tting,forsuppliedexhausttube.

FluidNozzles,page79foravailablesizes.

Supplieselectrostaticchargetothe󰘱uid.See

ElectrodeSelectionChart,page88.

Adjustsfansizeandshape.Canbeusedtodecreasepatternlength.

Restrictsaircapair󰘱ow.Replacewithplug(included)ifdesired.

Adjusts󰘱uid󰘱owbylimiting󰘱uidneedletravel.Useonlyinlow󰘱ow
conditions,toreducewear.

LitwhenESisON(I).Colorindicatesalternatorfrequency.SeetheLED
indicatortableintheGunSetupProcedure,page25.

12

3A2494P

GunOverview

Smart

Smart Smart

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

•OperatingMode

•DiagnosticMode

Operating

Operating Operating

Bar

Bar Bar

SeeFig.2andSmartGunKey,page15.The
OperatingModedisplaysgundataduringnormal
spraying.Thedisplayusesabargraphtoshowthe
voltagelevelinkiloVolts(kV)andthecurrentlevelin
microAmperes(uA).Thebargraphrangeisfrom0
to100%foreachvalue.

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

ElectricalTroubleshooting,page46forotherpossible

causes.

Guns

Guns Guns

Mode

Mode Mode

Graph

Graph Graph

Voltage

Voltage Voltage

Thevoltageadjustmentswitch(VA)allowsthe
operatortochangefromlowtohighvoltage.

•Thehighvoltagesettingisdeterminedbythe
maximumvoltageofthegunandisnotadjustable.

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

AdjustingtheLowVoltageSetting,page14.

NOTE:

NOTE: NOTE:
haslostcommunicationwiththepowersupply.See

ErrorDisplay,page14,forfurtherinformation.

Adjustment

Adjustment Adjustment

IftheErrordisplayappears,theSmartmodule

Switch

Switch Switch

Hz

Indicator

Hz Hz

Indicator Indicator

TheHzindicatorfunctionsthesameastheES
indicatoronstandardguns.Theindicatorlightsto
showthealternatorspeedstatus,andhasthree
colors:

•Greenindicatesthealternatorspeediscorrect.

•Iftheindicatorchangestoamberafteronesecond,
increasetheairpressure.

•Iftheindicatorchangestoredafteronesecond,
theairpressureistoohigh.Decreaseairpressure
untiltheindicatorisgreen.Tomaintainahigher
airpressure,installESOn/OffValveRestrictorKit
26A160.Then,adjustthepressureasneededto
ensuretheindicatorremainsgreen.

Figure2SmartGunModuleinOperatingMode

3A2494P13

GunOverview

Error

Error Error

IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3andSmartGunKey,page15.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page46.
CommunicationmustberestoredtomaketheSmart
modulefunctional.

NOTE:

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

NOTE:

NOTE: NOTE:
displaywillnotappear.

Display

Display Display

Ittakes8secondsfortheErrordisplayto

Ifthereisnopowertothegun,theError

foryourgun.Continuepressingthebuttonuntilyou
reachthedesiredsetting.

NOTE:

NOTE: NOTE:
returntotheOperatingScreen.

NOTE:

NOTE: NOTE:

LockSymbol,page14.

Figure4LowVoltageSettingScreen(Unlocked)

Lock

Lock Lock

After2secondsofinactivitythedisplaywill

Thelowvoltagesettingmaybelocked.See

Symbol

Symbol Symbol

Figure3ErrorDisplay

Adjusting

Adjusting Adjusting

Thelowvoltagesettingisuseradjustable.Toaccess
thelowvoltagesettingscreenwheninOperating
Mode,presstheLOSETbutton(LS)momentarily.
Thescreenwilldisplaythecurrentlowvoltage
setting.SeeFig.4andSmartGunKey,page15.
Thepossiblerangesare:

•85kVguns:40–85kV

•60kVguns:30–60kV

•40kVguns:20–40kV

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

the

Low

the the

Voltage

Low Low

Voltage Voltage

Setting

Setting Setting

Thelowvoltagesettingmaybelocked.Whenlocked,
animage(LK)appearsonthescreen.SeeFig.5
andSmartGunKey,page15.

•WheninHImode,thelowvoltagesettingisalways always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.

•WheninLOmode,thelocksymbolwill
only

only only

appearifthelockisenabled.See

LowVoltageLockScreen,page17,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

always

14

3A2494P

GunOverview

Smart

Smart Smart

Table

Table Table

Item

Item Item

VA

LO

kV

uA

LSLOSETbuttonPressmomentarilytoentertheLowVoltageSettingscreen.

Gun

Key

Gun Gun

Key Key

Key

for

Figs.

1 11Key Key

for for

Description

Description Description

VoltageAdjustmentSwitchTwo-positionswitchsetsSmartgunvoltagetolowsetting(LO)or

LowVoltageMode
Indicator

Voltage(kV)DisplayDisplaysactualsprayingvoltageofthegun,inkV.InOperatingMode,

Current(uA)DisplayDisplaysactualsprayingcurrentofthegun,inuA.InOperatingMode,

2–9.

Figs. Figs.

2–9. 2–9.

Purpose

Purpose Purpose

highsetting(HI).ThisswitchisfunctionalinOperatingModeandin
DiagnosticMode.

Lights(blue)whentheSmartgunissettoLowVoltage.

displayisabargraph.InDiagnosticMode,voltageisdisplayedas
anumber.

displayisabargraph.InDiagnosticMode,currentisdisplayedas
anumber.

Pressandholdforapproximately5secondstoenterorexitDiagnostic
Mode.

WhileinDiagnosticMode,pressmomentarilytoadvancethrough
screens.

WhileontheLowVoltageLockScreen(inDiagnosticMode),press
andholdtoturnthelockonoroff.

LVLowVoltageDisplayDisplaysthelowvoltagesettingasanumber.Thesettingcanbe

changed.SeeFig.4.

LKLowVoltageLocked

LD

ERErrorDisplay

VIVoltageIndicator

CICurrentIndicatorInDiagnosticMode,thetwobottomrightLEDsofthescreenlight,

ASAlternatorSpeedDisplayInDiagnosticMode,Hzlevelisdisplayedasanumber.SeeFig.8.

Hz

LODisplayAppearsontheLowVoltageLockScreen.SeeFig.9.

AlternatorSpeedIndicatorInOperatingMode,indicatorcolorvariestoshowthealternatorspeed

Appearsifthelowvoltagesettingislocked.SeeFig.5andFig.9.

AppearsiftheSmartmodulelosescommunicationwiththepower
supply.SeeFig.3.

InDiagnosticMode,thetwotoprightLEDsofthescreenlight,
indicatingthatthevaluedisplayedisinkV.SeeFig.6.

indicatingthatthevaluedisplayedisinuA.SeeFig.7.

status:

•Greenindicatesthealternatorspeedisatthecorrectlevel.

•Iftheindicatorchangestoamberafteronesecond,thealternator
speedistoolow.

•Iftheindicatorchangestoredafteronesecond,thealternatorspeed
istoohigh.TheindicatoralsoturnsrediftheErrordisplayappears.

InDiagnosticMode,theindicatorisgreenwhenintheAlternator
Speed(Hertz)screen.

3A2494P15

GunOverview

Diagnostic

Diagnostic Diagnostic

DiagnosticModeincludesfourscreenswhichdisplay
gundata:

•Voltage(kiloVolts)Screen

•Current(microAmperes)Screen

•AlternatorSpeed(Hertz)Screen

•LowVoltageLockScreen

NOTE:

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

ToenterDiagnosticMode,pressandholdtheLOSET
(LS)buttonforapproximately5seconds.Thedisplay
willgototheVoltage(kiloVolts)Screen,page16.

Toadvancetothenextscreen,presstheLOSET
buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.

NOTE:

NOTE: NOTE:
Mode,thelastscreenviewedwillbedisplayedwhen
thegunisretriggered.

NOTE:

NOTE: NOTE:
fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page17fordetails.

Mode

Mode Mode

YoumustbeinOperatingModetoadjustthe

IfthegunisdetriggeredwhileinDiagnostic

DiagnosticModecannotbeexited

Figure6Voltage(kiloVolts)Screen

Current

Current Current

TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7and

SmartGunKey,page15.Toenterthisscreen,press

theLOSETbuttonwhileintheVoltage(kiloVolts)
Screen.

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

(microAmperes)

(microAmperes) (microAmperes)

Screen

Screen Screen

Voltage

Voltage Voltage

TheVoltage(kiloVolts)Screenisthe󰘰rstscreento
appearafterenteringDiagnosticMode.SeeFig.6
andSmartGunKey,page15.Toenterthisscreen,
pressandholdtheLOSETbuttonforapproximately
5secondswhileintheOperatingMode.

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

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page16.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

(kiloVolts)

(kiloVolts) (kiloVolts)

Screen

Screen Screen

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page17.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

Figure7Current(microAmperes)Screen

163A2494P

GunOverview

Alternator

Alternator Alternator

TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8and

SmartGunKey,page15.Toenterthisscreen,

presstheLOSETbuttonwhileintheCurrent
(microAmperes)Screen.

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

TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page17.Pressandhold

forapproximately5secondstoreturntoOperating
Mode.

Speed

Speed Speed

(Hertz)

(Hertz) (Hertz)

Screen

Screen Screen

Low

Voltage

Low Low

Voltage Voltage

TheLowVoltageLockScreenisthefourth
screenintheDiagnosticMode.SeeFig.9and

SmartGunKey,page15.Toenterthisscreen,press

theLOSETbuttonwhileintheAlternatorSpeed
(Hertz)Screen.

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

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

NOTE:

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

DiagnosticModecannotbeexitedfromthis

Lock

Screen

Lock Lock

Screen Screen

Figure8AlternatorSpeed(Hertz)Screen

Figure9LowVoltageLockScreen

3A2494P

17

Installation

Installation

Installation Installation

Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.

•Donotinstallorservicethisequipmentunless
youaretrainedandquali󰘰ed.

•Besureyourinstallationcomplieswithlocal,
state,andnationalcodesfortheinstallation
ofelectricalapparatusinaClassI,Div.I,
hazardouslocationoraGroupII,ZoneI
explosiveatmospherelocation.

•Complywithalllocalcodesandregulations.

Fig.10(TypicalInstallation)showsatypical
electrostaticairspraysystem.Itisnotanactual
systemdesign.Forassistanceindesigningasystem
tosuityourparticularneeds,contactyourGraco
distributor.

Warning

Warning Warning

Sign

Sign Sign

Ventilate

Ventilate Ventilate

Donotoperatethegununlessventilatingair󰘱owis
abovetheminimumrequiredvalue.Providefresh
airventilationtoavoidthebuildupof󰘱ammableor
toxicvaporswhenspraying,󰘱ushing,orcleaning
thegun.Interlockthegunairand󰘱uidsupply
topreventoperationunlessventilatingair󰘱owis
abovetheminimumrequiredvalue.

Thesprayboothmusthaveaventilationsystem.

Electricallyinterlockthegunairand󰘱uidsupplywith
theventilatorstopreventgunoperationanytimethat
theventilationair󰘱owfallsbelowminimumvalues.
Checkandfollowalllocalcodesandregulations
regardingairexhaustvelocityrequirements.Verify
theoperationoftheinterlockatleastonceayear.

NOTE:Theminimumallowableairexhaust
velocityis60feet/minute(19linearmeters/minute).
High-velocityairexhaustwilldecreasetheoperating
ef󰘰ciencyoftheelectrostaticsystem.

the

Spray

the the

Spray Spray

Booth

Booth Booth

Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.

183A2494P

Air

Supply

Air Air

Supply Supply

Toreducetheriskofelectricshock,theairsupply
hosemustbeelectricallyconnectedtoatrueearth
ground.Use Use
Hose.

Hose. Hose.

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

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

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

Line

Line Line

Use

only

Graco

only only

Graco Graco

Grounded

Grounded Grounded

Air

Supply

Air Air

Supply Supply

Installation

Fluid

Fluid Fluid

1.Blowoutthe󰘱uidline(FL)withairand󰘱ushit

2.Installa󰘱uidregulator(FR)onthe󰘱uidlineto

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

4.The󰘱uiddrainvalve(FD)isrequiredinyour

Supply

Supply Supply

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

control󰘱uidpressuretothegun.

removeparticlesandsedimentwhichcouldclog
thespraynozzle.

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

systemtoassistinrelieving󰘱uidpressureinthe
displacementpump,hose,andgun.Triggering
theguntorelievepressuremaynotbesuf󰘰cient.
Installadrainvalveclosetothepump's󰘱uid
outlet.

Line

Line Line

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

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

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

3A2494P19

Installation

NON

HAZARDOUS

NON NON

- --HAZARDOUS HAZARDOUS

LOCATION

LOCATION LOCATION

HAZARDOUS

HAZARDOUS HAZARDOUS

LOCATION

LOCATION LOCATION

Figure10TypicalInstallation

Typical

Typical Typical

Item

Item Item

ADAirLineDrainValve

AF

AG*GunAirHoseGroundWire

AH*GracoGroundedAirHose(left-hand

ALPumpAirLineLubricator

BV*PumpBleed-TypeAirShutoffValve

EGElectrostaticAirSprayGun

FD*

FFFluidFilter

FL

FRFluidPressureRegulator

Installation

Installation Installation

Description

Description Description

AirFilter/WaterSeparator

threads)

FluidDrainValve

FluidSupplyLine

Key

Key Key

Item

Item Item

FV

GRGunAirPressureRegulator

MA

PG*PumpGroundWire

PRPumpAirPressureRegulator

SPSupplyPump

SV*VentilationFanInterlockSolenoidValve.

*Theseitemsarerequiredforsafeoperation.They
mustbepurchasedseparately.

Description

Description Description

FluidShutoffValve

MainAirSupplyLine

NOTE:

NOTE: NOTE:
asaGracoaccessory.

Thesolenoidvalveisnotoffered

203A2494P

Installation

Grounding

Grounding Grounding

Theequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundallequipment,personnel,objects
beingsprayed,andconductiveobjectsinorclose
tothesprayarea.Theresistancemustnotexceed
1megohm.Groundingprovidesanescapewire
fortheelectriccurrent.

Whenoperatingtheelectrostaticgun,any
ungroundedobjects(suchaspeople,containers,and
tools)inthespraylocationcanbecomeelectrically
charged.

Thefollowingareminimumgroundingrequirements
forabasicelectrostaticsystem.Yoursystemmay
includeotherequipmentorobjectswhichmustbe
grounded.Yoursystemmustbeconnectedtoa
trueearthground.Checkgroundconnectionsdaily.
Checkyourlocalelectricalcodesandregulationsfor
detailedgroundinginstructions.

Allpersonsenteringthesprayarea

•

shoeshavingconductivesolessuchasleather,
orwearpersonalgroundingstraps.Donot
wearshoeswithnon-conductivesolessuchas
rubberorplastic.Ifglovesarenecessary,wear
theconductiveglovessuppliedwiththegun.If
non-Gracoglovesareworn,cutoff󰘰ngersorpalm
areaofglovestoensureyourhandcontactsthe
groundedgunhandle.Conductiveglovesand
footwearmustnotexceed100megohmperEN
ISO20344,EN1149–5.

•

Objectbeingsprayed:

cleanandgroundedatalltimes.

Keeptheworkpiecehangers

mustwear

•

ElectrostaticAirSprayGun:

byconnectingtheGracoGroundedAirHose
(AH)tothegun,andconnectingtheairhose
groundwiretoatrueearthground.See

CheckGunElectricalGrounding,page34.

•

Pump/󰘱uidsource:

byconnectingitsgroundwiretoatrueearth
ground.

•

Allelectricallyconductiveobjectsordevicesinthe
sprayarea

•

Fluidandwastecontainers:

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

Aircompressors:

•
tothemanufacturer'srecommendations.

•

Allairand󰘱uidlines

Useonlygroundedhoseswithamaximumof100
feet(30.5m)combinedhoselengthtoensure
groundingcontinuity.

mustbeproperlygrounded.

Groundthepump/󰘱uidsource

Groundtheequipmentaccording

mustbeproperlygrounded.

Groundthegun

Groundall󰘱uidand

3A2494P

21

Installation

•

The󰘱oorofthesprayarea

conductiveandgrounded.Donotcoverthe󰘱oor
withcardboardoranynon-conductivematerial
whichwouldinterruptgroundingcontinuity.

mustbeelectrically

•

Flammableliquidsinthesprayarea

inapproved,groundedcontainers.Donotuse
plasticcontainers.Donotstoremorethanthe
quantityneededforoneshift.

•

Allsolventpails:

metalcontainers,whichareconductive.Donot
useplasticcontainers.Useonlynon-󰘱ammable
solvents.Donotstoremorethanthequantity
neededforoneshift.

Useonlyapproved,grounded

mustbekept

22

3A2494P

Installation

Figure11GroundtheOperatorOperatorisgroundedthroughbareskincontactwith

thegunhandleandconductiveshoes.Aconductive
glovecanalsobeused.

Figure12GroundtheObjectBeingSprayedObjectbeingsprayedisgroundedthroughcontact

withthehangerandconveyorsystem.

3A2494P23

Installation

Figure13GroundtheGunGunisgroundedthroughtheconductiveairhose.

Figure14GroundtheFluidSupplyFluidsupplylineandsourcemustbegrounded.

24

3A2494P

GunSetup

Gun

Gun Gun

Gun

Gun Gun

Foradditionalstepstosetupspecialtyguns,
seeSoftSprayGunSetupProcedure,page28,

RoundSprayGunSetupProcedure,page31,
HVLPGunSetupProcedure,page29,and
AbrasiveMaterialGunSetupProcedure,page33.

Seethe󰘰gurebelowtolocatetheelectrostaticgun
controls.

Figure15ElectrostaticGunControls

Setup

Setup Setup

Setup

Setup Setup

Procedure

Procedure Procedure

4.Checkgunresistance.Followthestepsin

TestGunResistance,page42.

5.ConnecttheGracogroundedairhosetothegun

airinlet.Thegunairinlet󰘰ttinghasleft-hand
threads.

6.FollowallstepsinGrounding,page21.

7.Followallstepsin

CheckGunElectricalGrounding,page34.

Readingmustbelessthan1megohm.

8.Verifythatthematerialresistivitymeets

requirementsforelectrostaticspray.See

CheckFluidResistivity,page35.

9.Connecttheexhausttubeandsecurewiththe

clampprovided.

1.Thegunisshippedwiththe󰘱uidnozzleandair
capinstalled.Checkthattheretainingringis
tight.

NOTE:

NOTE: NOTE:
size󰘱uidnozzleoraircap,see

FluidNozzleSelectionChart,page79and
AirCapSelectionGuide,page82.

Toinstallthenozzleandaircap,see

AirCapandNozzleReplacement,page48.

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

3.Shutofftheairbleedvalvetothegun.

Toselectadifferent

10.Connectthe󰘱uidhosetothegun󰘱uidinlet.

11.Flushifneeded.SeeFlushing,page38.

12.Positiontheaircapasneeded.

3A2494P25

GunSetup

13.Fullyopenthefanairadjustmentvalve(F)
counterclockwise.

14.Fullyopenthe󰘱uidadjustmentvalve(H)
counterclockwise.

15.Fullyopentheatomizingairrestrictorvalve(G)
clockwise.

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

Table

Table Table

using

using using

mm)

mm) mm)

Pressure

2 22. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

in ininft ftft(m) (m)

5/16

5/16 5/16

diameter

diameter diameter

15(4.6)55(0.38,3.8)

25(7.6)65(0.45,4.5)

50(15.3)80(0.56,5.6)

Drop

Drop Drop

(m)

inch

(8

inch inch

(8 (8

hose

hose hose

Air

Regulator

Air Air

Regulator Regulator

psi

in ininpsi psi

with

gun

with with

gun gun

Setting

Setting Setting

(MPa,

(MPa, (MPa,

bar)

bar) bar)

triggered

triggered triggered

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

18.VerifythattheESindicator(K)[Hzindicatoron
Smartguns]islit.

Table

Table Table

Indicator

Indicator Indicator

Green

Amber

LED

3 33. ..LED LED

Color

Color Color

Red

Indicator

Indicator Indicator

Whenspraying,theindicator
shouldremaingreen,indicating
suf󰘰cientairpressuretothe
alternatorturbine.

Iftheindicatorchangestoamber
afteronesecond,theairpressure
istoolow.Increaseairpressure
untiltheindicatorisgreen.

Iftheindicatorchangestored
afteronesecond,theairpressure
istoohigh.Decreaseairpressure
untiltheindicatorisgreen.To
maintainahigherapplicationair
pressure,installESOn/OffValve
RestrictorKit26A160.Adjustthe
pressureasneededtoensurethe
indicatorremainsgreen.

Colors

Colors Colors

Description

Description Description

263A2494P

GunSetup

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

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

22.Sprayatestpattern.Checktheatomization.

•Ifover-atomizationoccursatminimum
pressure,adjusttheatomizingairrestrictor
valve.

•Ifatomizationisinadequate,increaseair
pressureordecrease󰘱uid󰘱ow.

23.Adjustthefanairadjustmentvalve.

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

•Fullyopenthefanairadjustmentvalve,
counterclockwise,forthelongestpattern.

•Turnthevalveclockwisetorestrictthefanair
andcreateashorterpattern.

24.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page44.

3A2494P

27

GunSetup

Soft

Spray

Soft Soft

Spray Spray

Gun

Gun Gun

Setup

Setup Setup

Procedure

Procedure Procedure

Toachieveasoftspraypatternforsmallorlightweight
parts,dothefollowing:

1.Selectasoftspraygunmodel.See

SoftSprayGunModels,page5.

•Toconvertagunforsoftspray,

installasoftsprayaircap.See

AirCapSelectionGuide,page82.

•Forbestresults,installa1.0

mmor1.2mmnozzle.See

FluidNozzleSelectionChart,page79.

2.Followsteps1–14inthe

GunSetupProcedure,page25.

3.Adjusttheatomizingair.Fullyclosetheatomizing
airrestrictorvalve(G)counterclockwise.Then,
opentheatomizingairrestrictorvalve(G)one
halfturntooneturn.

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

Table

Table Table

using

using using

mm)

mm) mm)

6.VerifythattheESindicator(K)[Hzindicatoron
Smartguns]islit.

Table

Table Table

Indicator

Indicator Indicator

Green

Amber

Pressure

4 44. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

Color

Color Color

Red

in ininft ftft(m) (m)

5/16

5/16 5/16

diameter

diameter diameter

15(4.6)55(0.38,3.8)

25(7.6)65(0.45,4.5)

50(15.3)80(0.56,5.6)

LED

5 55. ..LED LED

Drop

Drop Drop

(m)

inch

(8

inch inch

(8 (8

hose

hose hose

Indicator

Indicator Indicator

Whenspraying,theindicator
shouldremaingreen,indicating
suf󰘰cientairpressuretothe
alternatorturbine.

Iftheindicatorchangestoamber
afteronesecond,theairpressure
istoolow.Increaseairpressure
untiltheindicatorisgreen.

Iftheindicatorchangestored
afteronesecond,theairpressure
istoohigh.Decreaseairpressure
untiltheindicatorisgreen.To
maintainahigherapplicationair
pressure,installESOn/OffValve
RestrictorKit26A160.Adjustthe
pressureasneededtoensurethe
indicatorremainsgreen.

Colors

Colors Colors

Description

Description Description

Air

Regulator

Air Air

Regulator Regulator

psi

in ininpsi psi

with

gun

with with

gun gun

Setting

Setting Setting

(MPa,

(MPa, (MPa,

triggered

triggered triggered

bar)

bar) bar)

5.Setthegunairregulatortodeliveraminimum
45psi(0.32MPa,3.2bar)atthegunwhen
triggered,toensurefullsprayingvoltage.

7.Continuewithsteps19–24inthe

GunSetupProcedure,page25.

NOTE:

NOTE: NOTE:
productionrateof3.5oz/min(100cc/min).For
bestsoftsprayresults,limittheproductionrate
to7oz/min(200cc/min)orless.

NOTE:

NOTE: NOTE:
much,adjusttheatomizingairrestrictorvalve
(G)counterclockwiseslightlytolimittheair󰘱ow.
Toimproveatomization,adjusttheatomizingair
restrictorvalve(G)clockwiseslightlytoincrease
theair󰘱owordecreasethe󰘱uid󰘱ow.

Thesoftsprayaircapisoptimizedfora

Iftheobjectbeingsprayedismovingtoo

283A2494P

GunSetup

HVLP

HVLP HVLP

Mostairqualityauthoritiesacceptelectrostatic
sprayingasthemostef󰘰cientprocessandameans
tocomplywithenvironmentalregulation.Follow
theGunSetupProcedure,page25whenspraying
electrostaticallywithanHVLPaircap.
Whenelectrostaticsprayingcannotbeeffectively
usedoncertainpartsormaterials,anHVLPguncan
beusedtocomplywithenvironmentalregulationsin
mostareas.Tobeincompliancetheairpressures
attheaircapmustbelessthan10psi.Follow
theprocedurebelowtosetupthespraygunfor
non-electrostaticHVLPoperation.

1.SelectanHVLPgunmodel.See

2.Followsteps1–12inthe

3.Fullyopenthe󰘱uidadjustmentvalve(H)

Gun

Gun Gun

HVLPGunModels,page6.

ToconvertagunforHVLP,installanHVLPair
cap.SeeAirCapSelectionGuide,page82.

GunSetupProcedure,page25.

counterclockwise.

Setup

Setup Setup

Procedure

Procedure Procedure

b.Fullyopentheatomizingairrestrictorvalve

(G)clockwise.

c.TurnOFF(I)theESOn-Offswitch(J).

d.Setthegunairregulatortodeliver30

psi(0.21MPa,2.1bar)atthegunwhen
triggered.

4.Adjusttheairintheaircap.

a.Fullyopenthefanairadjustmentvalve(F)

counterclockwise.

Table

Table Table

5.Shutofftheairtothegun.

Pressure

6 66Pressure Pressure

Air

Hose

Air Air

Hose Hose

(m)

in ininft ftft(m) (m)

5/16

inch

5/16 5/16

inch inch

diameter

diameter diameter

15(4.6)43(0.29,3)

25(7.6)50(0.34,3.4)

50(15.3)70(0.48,4.8)

Drop

Drop Drop

Length

Length Length

using

using using

(8

mm)

(8 (8

mm) mm)

hose

hose hose

Air

Regulator

Air Air

Regulator Regulator

Setting

Setting Setting

(MPa,

(MPa, (MPa,

gun

gun gun

psi

in ininpsi psi

bar)

with

bar) bar)

with with

triggered

triggered triggered

3A2494P29