Graco Pro Xp Instruction Manual

Instructions - Parts

Pro Xp™ Electrostatic

Air Spray Gun	3A2494P
	EN

For use in Class I, Div. I Hazardous Locations using Group D materials.

ForuseinGroupII,Zone1ExplosiveAtmosphereLocationsusingGroupIIAmaterials. Forprofessional use only.

Important Safety Instructions

This equipment could present hazards if not operated according to the information in this manual. Read all warnings and instructions in this manual before using the equipment. Save these instructions.

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

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

See page 3 for model part numbers and approval information.

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Models...............................................................	3
Approvals...........................................................	7
Related Manuals ................................................	7
Warnings ...........................................................	8
Gun Overview ....................................................	11
How the Electrostatic Spray Gun
Works............................................	11
Controls, Indicators, and Components...........	12
Smart Guns.................................................	13
Installation..........................................................	18
Warning Sign...............................................	18
Ventilate the Spray Booth.............................	18
Air Supply Line ............................................	19
Fluid Supply Line .........................................	19
Grounding ...................................................	21
Gun Setup..........................................................	25
Gun Setup Procedure...................................	25
Soft Spray Gun Setup Procedure..................	28
HVLP Gun Setup Procedure.........................	29
Round Spray Gun Setup Procedure..............	31
Abrasive Material Gun Setup
Procedure......................................	33
Check Gun Electrical Grounding...................	34
Check Fluid Resistivity .................................	35
Check Fluid Viscosity...................................	35
Flush Before Using Equipment......................	35
Operation...........................................................	36
Pressure Relief Procedure............................	36
Startup........................................................	37
Shutdown....................................................	37
Maintenance ......................................................	38
Daily Care and Cleaning Checklist ................	38
Flushing......................................................	38
Clean the Gun Daily.....................................	40
Daily System Care.......................................	41
Electrical Tests...................................................	42
Test Gun Resistance....................................	42
Test Power Supply Resistance .....................	43
Test Electrode Resistance............................	43
Troubleshooting..................................................	44
Spray Pattern Troubleshooting......................	44
Gun Operation Troubleshooting....................	45
Electrical Troubleshooting ............................	46
Repair................................................................	47
Prepare the Gun for Service .........................	47
Air Cap and Nozzle Replacement..................	48
Electrode Replacement................................	49
Fluid Packing Rod Removal..........................	50

Packing Rod Repair.....................................	50
Barrel Removal............................................	52
Barrel Installation.........................................	52
Power Supply Removal and
Replacement..................................	53
Alternator Removal and Replacement ...........	54
FluidTubeRemovalandReplacement...........	56
Fan Air Adjustment Valve Repair ..................	57
Atomizing Air Restrictor Valve Repair............	58
ES On-Off and Fluid Adjustment Valve
Repair............................................	59
Air Valve Repair...........................................	60
Smart Module Replacement..........................	61
Air Swivel and Exhaust Valve
Replacement..................................	62
Parts..................................................................	63
Gun Models with Standard Display................	63
Gun Models with Smart Display ....................	66
Packing Rod Assembly.................................	69
Alternator Assembly.....................................	70
ESOn-OffandFluidAdjustmentValve...........	71
Fan Air Adjustment Valve Assembly..............	72
Quick Adjust Fan Valve Assembly.................	72
Atomizing Air Restrictor Valve
Assembly.......................................	73
Smart Module Assembly...............................	74
Round Spray Assembly................................	75
High Conductivity Fluid Tube Assembly: 40
kV..................................................	77
High Conductivity Fluid Tube Assembly: 60
kV and 85 kV..................................	78
Fluid Nozzles .....................................................	79
Fluid Nozzle Selection Chart.........................	79
Fluid Nozzle Performance Charts..................	80
Air Caps.............................................................	82
Air Cap Selection Guide ...............................	82
Air Consumption Charts ...............................	87
Electrode Selection Chart....................................	88
Repair Kits and Accessories................................	89
Gun Accessories..........................................	89
Inline Fluid Filter Kit Accessories...................	90
Operator Accessories...................................	90
System Accessories.....................................	90
Signs ..........................................................	91
Test Equipment ...........................................	91
Hoses .........................................................	92
Dimensions........................................................	93
Technical Specifications......................................	94
California Proposition 65.....................................	94

3A2494P

Models

General Gun Models

Equipped with standard electrode, nozzle, air cap and fluid tube. For applying a Class A finish with standard and specialty coatings.

Part No.	Series	kV	Display	Electrode	Nozzle	Air Cap	Fluid Tube
					(mm)
L40M10	A	40	Smart	Std	1.5 Std	Std	Std
L40T10	C	40	Std	Std	1.5 Std	Std	Std
L40T12	A	40	Std	Std	1.2 Std	Std	Std
L60M10	C	60	Smart	Std	1.5 Std	Std	Std
L60M12	C	60	Smart	Std	1.2 Std	Std	Std
L60T10	C	60	Std	Std	1.5 Std	Std	Std
L60T12	C	60	Std	Std	1.2 Std	Std	Std
L60T21	A	60	Std	Std	1.0 Std	Std	Std
L85M10	C	85	Smart	Std	1.5 Std	Std	Std
L85M12	A	85	Smart	Std	1.2 Std	Std	Std
L85T10	C	85	Std	Std	1.5 Std	Std	Std
L85T12	A	85	Std	Std	1.2 Std	Std	Std

L85T50*	A	85	Std	Std	1.5 Std	Std	Std

*Equipped with a quick-adjust fan valve

3A2494P

Models

High Conductivity Gun Models

Equipped with a longer High Conductivity fluid tube for spraying lower resistivity material. Most models are also equipped with high wear electrode, precision high wear nozzle, and standard air cap. For applying a class A finish with abrasive and metallic coatings.

Part No.	Series	kV	Display	Electrode	Nozzle	Air Cap	Fluid Tube
					(mm)
L40M16	A	40	Smart	HW	1.5 PHW	Std	HC

L40T13	B	40	Std	HW	1.5 Std	Std	HC

L40T16	C	40	Std	HW	1.5 PHW	Std	HC

L40T26	A	40	Std	HW	1.2 PHW	Std	HC

L60M26	A	60	Smart	HW	1.2 PHW	Std	HC
L60M16	C	60	Smart	HW	1.5 PHW	Std	HC
L60T26	A	60	Std	HW	1.2 PHW	Std	HC
L60T13	B	60	Std	HW	1.5 Std	Std	HC
L60T16	C	60	Std	HW	1.5 PHW	Std	HC
L85M16	C	85	Smart	HW	1.5 PHW	Std	HC

L85M26	A	85	Smart	HW	1.2 PHW	Std	HC

L85T16	C	85	Std	HW	1.5 PHW	Std	HC

L85T26	A	85	Std	HW	1.2 PHW	Std	HC

L85T56*	A	85	Std	HW	1.5 PHW	Std	HC

*Equipped with a quick-adjust fan valve

kV Booster Gun Models

The 40 kV Booster provides the transfer efficiency of a 60 kV gun in a smaller, more compact size.

Part No.	Series	kV	Display	Electrode	Nozzle	Air Cap	Fluid Tube
					(mm)
L40M14	A	40	Smart	Std	1.5 Std	Std	Std

L40M15	A	40	Smart	HW	1.5 PHW	Std	HC

L40T14	C	40	Std	Std	1.5 Std	Std	Std

L40T15	C	40	Std	HW	1.5 PHW	Std	HC

3A2494P

Models

Round Spray Gun Models

Equipped with round spray nozzle and air cap. For round spray pattern applications.

Part No.	Series	kV	Display	Electrode	Nozzle	Air Cap	Fluid Tube
					(mm)
L40T31	A	40	Std	Std	Small Pattern		Std

L40T32	A	40	Std	Std	Medium Pattern		Std

L60T11	C	60	Std	Std	Large Pattern		Std

L60T31	A	60	Std	Std	Small Pattern		Std

L60T32	A	60	Std	Std	Medium Pattern		Std

L85T31	A	85	Std	Std	Small Pattern		Std

L85T32	A	85	Std	Std	Medium Pattern		Std

Soft Spray Gun Models

Equipped with soft spray air cap. For applying a class A finish to small, lightweight parts.

Part No.	Series	kV	Display	Electrode	Nozzle	Air Cap	Fluid Tube
					(mm)
L40T71	A	40	Std	Std	1.0 Std	Soft Spray	Std

L60M71	A	60	Smart	Std	1.0 Std	Soft Spray	Std

L60M72	A	60	Smart	Std	1.2 Std	Soft Spray	Std

L60T71	A	60	Std	Std	1.0 Std	Soft Spray	Std

L60T72	A	60	Std	Std	1.2 Std	Soft Spray	Std

L85M71	A	85	Smart	Std	1.0 Std	Soft Spray	Std

L85T71	A	85	Std	Std	1.0 Std	Soft Spray	Std

Aerospace Gun Models

Equipped with aerospace air cap, high wear electrode, and precision high wear nozzle. For applying high solids and aerospace coatings.

Part No.	Series	kV	Display	Electrode	Nozzle	Air Cap	Fluid Tube
					(mm)
L85T73	A	85	Std	HW	1.2 PHW	AERO	Std

L85T75	A	85	Std	HW	1.5 PHW	AERO	Std

L85T78	A	85	Std	HW	1.8 PHW	AERO	Std

3A2494P

Models

HVLP Gun Models

Equipped with HVLP air cap.

Part No.	Series	kV	Display	Electrode	Nozzle	Air Cap	Fluid Tube
					(mm)
L40M77	A	40	Smart	Std	1.5 Std	HVLP	Std

L40T77	A	40	Std	Std	1.5 Std	HVLP	Std

L60M77	A	60	Smart	Std	1.5 Std	HVLP	Std

L60T77	A	60	Std	Std	1.5 Std	HVLP	Std

L85M77	A	85	Smart	Std	1.5 Std	HVLP	Std

L85T77	A	85	Std	Std	1.5 Std	HVLP	Std

High Air Flow Gun Models

Equipped with ES On-Off with Air Restrictor and Fluid Adjustment Valve, which limits air flow to the turbine. For applications that require high air flow at the air cap.

Part No.	Series	kV	Display	Electrode	Nozzle	Air Cap	Fluid Tube
					(mm)
L60M57	A	60	Smart	Std	1.5 Std	Std	Std

L60T57	A	60	Std	Std	1.5 Std	Std	Std

L85M57	A	85	Smart	Std	1.5 Std	Std	Std

L85T57	A	85	Std	Std	1.5 Std	Std	Std

Fixed Fluid Flow Gun Models

Equipped with ES On-Off and Fixed Fluid Valve, which extends electrode and nozzle life. For applications with abrasive, metallic, and extremely abrasive materials.

Part No.	Series	kV	Display	Electrode	Nozzle	Air Cap	Fluid Tube
					(mm)
L60T98	A	60	Std	Short	1.5 PHW	Std	Std

L60T99	A	60	Std	Short	1.5 PHW	Std	HC

L85T90	A	85	Std	HW	1.5 PHW	Std	Std

L85T96	A	85	Std	HW	1.5 PHW	Std	HC

3A2494P

Approvals

	II 2 G
	0.24 mJ T6
	FM12ATEX0068
	EN 50050-1
	Ta 0°C – 50°C
Related Manuals

Manual No.	Description

3A2498	Round Spray Kit, Instructions (large pattern)

3A6929	Round Spray Kit, Instructions (small and medium pattern)

3A7005	Quick Adjust Fan Valve Kit, Instructions

3A6833	HVLP Verification Kit, Instructions

307263	Probe and Meter, Instructions

308393	Gun Washer Kit, Instructions

309227	Gun Flush Box Module, Instructions

309455	Test Fixture, High Voltage Probe, and kV Meter, Instructions

406999	Voltage Tester Conversion Kit, Instructions

3A2494P

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. To help prevent fire, explosion, and electric shock:

• Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements of this manual.

• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to spray area. Resistance must not exceed 1 megohm. See Grounding instructions.

• Only use grounded Graco conductive air supply hoses.

• Do not use pail liners unless they are conductive and grounded.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

•Check gun resistance, hose resistance, and electrical grounding daily.

•Use and clean equipment only in well ventilated area.

•Interlock the gun air and fluid supply to prevent operation unless ventilation air flow is above the minimum required value.

•Use only Group IIA or Group D materials.

•Use cleaning solvents with highest possible flash point when flushing or cleaning equipment.

•Never spray or flush solvent at high pressure.

•To clean the exterior of the equipment, cleaning solvents must have a flash point at least 15°

C or 59° F above ambient temperature. Non-ignitable fluids are preferred.

•Always turn the electrostatics off when flushing, cleaning or servicing equipment.

•Eliminate all ignition sources such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static sparking).

•Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

•Keep work area free of debris, including solvent, rags and gasoline.

•Keep the spray area clean at all times. Use non-sparking tools to clean residue from the booth and hangers.

•Keep a working fire extinguisher in the work area.

3A2494P

Warnings

WARNING

PRESSURIZED EQUIPMENT HAZARD

Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

•Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning, checking, or servicing equipment.

•Tighten all fluid connections before operating the equipment.

•Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

•	Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•	Do not exceed the maximum working pressure or temperature rating of the lowest rated
	system component. See Technical Specifications in all equipment manuals.
•	Use fluids and solvents that are compatible with equipment wetted parts. See Technical
	Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings.
	For complete information about your material, request a Safety Data Sheet (SDS) from
	your distributor or retailer.

•Do not leave the work area while equipment is energized or under pressure.

•Turn off all equipment and follow the PressureReliefProcedurewhen equipment is not in use.

•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

•Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

•Make sure all equipment is rated and approved for the environment in which you are using it.

•Use equipment only for its intended purpose. Call your distributor for information.

•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

•Do not kink or over bend hoses or use hoses to pull equipment.

•Keep children and animals away from work area.

•Comply with all applicable safety regulations.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many cleaning solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.

•Use only compatible solvents to clean plastic structural or pressure-containing parts.

•See Technical Specifications in all equipment manuals for materials of construction. Consult

the solvent manufacturer for information and recommendations about compatibility.

3A2494P

Warnings

WARNING

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

•Read Safety Data Sheet (SDS) to know the specific hazards of the fluids you are using.

•Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

•Protective eyewear, and hearing protection.

•Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

3A2494P

Gun Overview

How the Electrostatic Spray Gun Works

The air hose supplies air to the spray gun. Part of the air operates the alternator turbine and the rest of the air atomizes the fluid being sprayed. The alternator generates power, which is converted by the power cartridge to supply high voltage to the gun’s electrode.

The pump supplies fluid to the fluid hose and gun, where the fluid is electrostatically charged as it passes the electrode. The charged fluid is attracted to the grounded workpiece, wrapping around and evenly coating all surfaces.

3A2494P

Gun Overview

Controls, Indicators, and Components

The electrostatic gun includes the following controls, indicators, and components (see Fig. 1). For information on Smart guns, see Smart Guns, page 13.

Figure 1	Gun Overview
Item	Description	Purpose

A	Air Swivel Inlet	1/4 npsm(m) left-hand thread, for Graco grounded air supply hose.

B	Fluid Inlet	3/8 npsm(m), for fluid supply hose.

C	Turbine Air	Barbed fitting, for supplied exhaust tube.
	Exhaust
D	Air Cap and Nozzle	Shapes the spray pattern. See Air Caps, page 82 and
		Fluid Nozzles, page 79 for available sizes.
E	Electrode Needle	Supplies electrostatic charge to the fluid. See
		Electrode Selection Chart, page 88.
F	Fan Air Adjustment	Adjusts fan size and shape. Can be used to decrease pattern length.
	Valve
G	Atomizing Air	Restricts air cap air flow. Replace with plug (included) if desired.
	Restrictor Valve
H	Fluid Adjustment	Adjusts fluid flow by limiting fluid needle travel. Use only in low flow
	Knob	conditions, to reduce wear.
J	ES On-Off Valve	Turns electrostatics ON (I) or OFF (O).

K	ES Indicator (stan-	Lit when ES is ON (I). Color indicates alternator frequency. See the LED
	dard gun only; for	indicator table in the Gun Setup Procedure, page 25.
	Smart gun indica-
	tor, see Operating
	Mode, page 13)

3A2494P

Smart Guns

The Smart Gun module displays spraying voltage, current, alternator speed, and the voltage setting (low or high). It also allows the user to change to a lower spraying voltage. The module has two modes:

•Operating Mode

•Diagnostic Mode

Operating Mode

Bar Graph

See Fig. 2 and Smart Gun Key, page 15. The Operating Mode displays gun data during normal spraying. The display uses a bar graph to show the voltage level in kiloVolts (kV) and the current level in microAmperes (uA). The bar graph range is from 0 to 100% for each value.

If the bar graph LEDs are blue, the gun is ready to spray. If the LEDs are yellow or red, the current is too high. The fluid may be too conductive, or see Electrical Troubleshooting, page 46 for other possible causes.

Hz Indicator

The Hz indicator functions the same as the ES indicator on standard guns. The indicator lights to show the alternator speed status, and has three colors:

•Green indicates the alternator speed is correct.

•If the indicator changes to amber after one second, increase the air pressure.

•If the indicator changes to red after one second, the air pressure is too high. Decrease air pressure until the indicator is green. To maintain a higher air pressure, install ES On/Off Valve Restrictor Kit 26A160. Then, adjust the pressure as needed to ensure the indicator remains green.

Gun Overview

Voltage Adjustment Switch

The voltage adjustment switch (VA) allows the operator to change from low to high voltage.

•The high voltage setting is determined by the maximum voltage of the gun and is not adjustable.

•The low voltage indicator (LO) lights when the switch is set to LO. The low voltage setting is user adjustable. See Adjusting the Low Voltage Setting, page 14.

NOTE:If the Error display appears, the Smart module has lost communication with the power supply. See Error Display, page 14, for further information.

Figure 2 Smart Gun Module in Operating Mode

3A2494P

Gun Overview

Error Display

If the Smart module loses communication with the power supply, the Error display appears, the Hz indicator turns red, and the Smart module is disabled. See Fig. 3 and Smart Gun Key, page 15. This can occur in Operating Mode or Diagnostic Mode. See Electrical Troubleshooting, page 46.

Communication must be restored to make the Smart module functional.

NOTE: It takes 8 seconds for the Error display to appear. If the gun has been disassembled, wait 8 seconds before spraying to ensure that an Error condition has not occurred.

NOTE: If there is no power to the gun, the Error display will not appear.

for your gun. Continue pressing the button until you reach the desired setting.

NOTE: After 2 seconds of inactivity the display will return to the Operating Screen.

NOTE: The low voltage setting may be locked. See Lock Symbol, page 14.

Figure 3 Error Display

Adjusting the Low Voltage Setting

The low voltage setting is user adjustable. To access the low voltage setting screen when in Operating Mode, press the LO SET button (LS) momentarily. The screen will display the current low voltage setting. See Fig. 4 and Smart Gun Key, page 15. The possible ranges are:

•85 kV guns: 40–85 kV

•60 kV guns: 30–60 kV

•40 kV guns: 20–40 kV

Set the Voltage Adjustment switch (VA) to LO. Press the LO SET button repeatedly to increase the setting in increments of 5. When the display reaches the maximum setting it will return to the minimum setting

Figure 4 Low Voltage Setting Screen (Unlocked)

Lock Symbol

The low voltage setting may be locked. When locked, an image (LK) appears on the screen. See Fig. 5 and Smart Gun Key, page 15.

•When in HI mode, the low voltage setting is always locked. The lock symbol will appear when the LO SET button is pressed.

•When in LO mode, the lock symbol will only appear if the lock is enabled. See Low Voltage Lock Screen, page 17, to lock or unlock the low voltage setting.

Figure 5 Low Voltage Setting Screen (Locked)

3A2494P

Gun Overview

Smart Gun Key

Table 1 Key for Figs. 2–9.

Item	Description	Purpose

VA	Voltage Adjustment Switch	Two-position switch sets Smart gun voltage to low setting (LO) or
		high setting (HI). This switch is functional in Operating Mode and in
		Diagnostic Mode.
LO	Low Voltage Mode	Lights (blue) when the Smart gun is set to Low Voltage.
	Indicator
kV	Voltage (kV) Display	Displays actual spraying voltage of the gun, in kV. In Operating Mode,
		display is a bar graph. In Diagnostic Mode, voltage is displayed as
		a number.
uA	Current (uA) Display	Displays actual spraying current of the gun, in uA. In Operating Mode,
		display is a bar graph. In Diagnostic Mode, current is displayed as
		a number.
LS	LO SET button	Press momentarily to enter the Low Voltage Setting screen.
		Press and hold for approximately 5 seconds to enter or exit Diagnostic
		Mode.
		While in Diagnostic Mode, press momentarily to advance through
		screens.
		While on the Low Voltage Lock Screen (in Diagnostic Mode), press
		and hold to turn the lock on or off.
LV	Low Voltage Display	Displays the low voltage setting as a number. The setting can be
		changed. See Fig. 4.
LK	Low Voltage Locked	Appears if the low voltage setting is locked. See Fig. 5 and Fig. 9.
LD	LO Display	Appears on the Low Voltage Lock Screen. See Fig. 9.
ER	Error Display	Appears if the Smart module loses communication with the power
		supply. See Fig. 3.
VI	Voltage Indicator	In Diagnostic Mode, the two top right LEDs of the screen light,
		indicating that the value displayed is in kV. See Fig. 6.
CI	Current Indicator	In Diagnostic Mode, the two bottom right LEDs of the screen light,
		indicating that the value displayed is in uA. See Fig. 7.
AS	Alternator Speed Display	In Diagnostic Mode, Hz level is displayed as a number. See Fig. 8.

Hz	Alternator Speed Indicator	In Operating Mode, indicator color varies to show the alternator speed
		status:
		•	Green indicates the alternator speed is at the correct level.
		•	If the indicator changes to amber after one second, the alternator
			speed is too low.
		• If the indicator changes to red after one second, the alternator speed
			is too high. The indicator also turns red if the Error display appears.
		In Diagnostic Mode, the indicator is green when in the Alternator
		Speed (Hertz) screen.

3A2494P

Gun Overview

Diagnostic Mode

Diagnostic Mode includes four screens which display gun data:

•Voltage (kiloVolts) Screen

•Current (microAmperes) Screen

•Alternator Speed (Hertz) Screen

•Low Voltage Lock Screen

NOTE: You must be in Operating Mode to adjust the low voltage setting; the setting is not adjustable in Diagnostic Mode. However, the voltage adjustment switch (VA) can be set to HI or LO in Operating Mode and in Diagnostic Mode.

ToenterDiagnosticMode, pressandholdtheLOSET (LS) button for approximately 5 seconds. The display will go to the Voltage (kiloVolts) Screen, page 16.

To advance to the next screen, press the LO SET button again.

To exit Diagnostic Mode, press and hold the LO SET button for approximately 5 seconds. The screen will return to Operating Mode.

NOTE: If the gun is detriggered while in Diagnostic Mode, the last screen viewed will be displayed when the gun is retriggered.

NOTE: Diagnostic Mode cannot be exited from the Low Voltage Lock Screen. See Low Voltage Lock Screen, page 17 for details.

Voltage (kiloVolts) Screen

The Voltage (kiloVolts) Screen is the first screen to appear after entering Diagnostic Mode. See Fig. 6 and Smart Gun Key, page 15. To enter this screen, press and hold the LO SET button for approximately 5 seconds while in the Operating Mode.

This screen displays the spraying voltage of the gun as a number (kV), rounded to the nearest 5 kV. The two top right LEDs (VI) of the display panel light, indicating that the Voltage (kiloVolts) Screen is displayed. The display is a readout and cannot be changed.

Press the LO SET button to advance to the Current (microAmperes) Screen, page 16. Press and hold for approximately 5 seconds to return to Operating Mode.

Figure 6 Voltage (kiloVolts) Screen

Current (microAmperes) Screen

The Current (microAmperes) Screen is the second screen in the Diagnostic Mode. See Fig. 7 and Smart Gun Key, page 15. To enter this screen, press the LO SET button while in the Voltage (kiloVolts) Screen.

This screen displays the spraying current of the gun as a number (uA), rounded to the nearest 5 uA. The two bottom right LEDs (CI) of the display panel light, indicating that the Current (microAmperes) Screen is displayed. The display is a readout and cannot be changed.

Press the LO SET button to advance to the Alternator Speed (Hertz) Screen, page 17. Press and hold for approximately 5 seconds to return to Operating Mode.

Figure 7 Current (microAmperes) Screen

3A2494P

Gun Overview

Alternator Speed (Hertz) Screen

Low Voltage Lock Screen

The Alternator Speed (Hertz) Screen is the third screen in the Diagnostic Mode. See Fig. 8 and Smart Gun Key, page 15. To enter this screen, press the LO SET button while in the Current (microAmperes) Screen.

This screen displays the alternator speed as a 3 digit number (AS), rounded to the nearest 10 Hz. The display is a readout and cannot be changed. If the alternator speed is greater than 999 Hz, the display will show 999.

The Hz indicator lights green to show that you are viewing the Alternator Speed (Hertz) Screen.

Press the LO SET button to advance to the

Low Voltage Lock Screen, page 17. Press and hold for approximately 5 seconds to return to Operating Mode.

Figure 8 Alternator Speed (Hertz) Screen

The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode. See Fig. 9 and Smart Gun Key, page 15. To enter this screen, press the LO SET button while in the Alternator Speed (Hertz) Screen.

This screen displays the status of the Low Voltage Lock. If the setting is locked, the lock image (LK) appears to the left of the Lo display (LD). If the setting is unlocked, the lock image does not appear.

To change the lock status, press and hold the LO SET button until the lock image appears or disappears. If the lock is set, the image will also appear on the Low Voltage Setting Screen when in low voltage mode (see Fig. 4).

NOTE: Diagnostic Mode cannot be exited from this screen, because pressing and holding the LO SET button is used to turn the lock on or off. To exit, press LO SET momentarily to return to the Voltage (kiloVolts) Screen, then exit Diagnostic Mode from there.

Figure 9 Low Voltage Lock Screen

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Installation

Ventilate the Spray Booth

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.

•Do not install or service this equipment unless you are trained and qualified.

•Be sure your installation complies with local, state, and national codes for the installation of electrical apparatus in a Class I, Div. I, hazardous location or a Group II, Zone I explosive atmosphere location.

•Comply with all local codes and regulations.

Fig. 10 (Typical Installation) shows a typical electrostatic air spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.

Warning Sign

Mount warning signs in the spray area where they can easily be seen and read by all operators. An English Warning Sign is provided with the gun.

Do not operate the gun unless ventilating air flow is above the minimum required value. Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Interlock the gun air and fluid supply

to prevent operation unless ventilating air flow is above the minimum required value.

The spray booth must have a ventilation system.

Electrically interlock the gun air and fluid supply with the ventilators to prevent gun operation any time that the ventilation air flow falls below minimum values. Check and follow all local codes and regulations regarding air exhaust velocity requirements. Verify the operation of the interlock at least once a year.

NOTE: The minimum allowable air exhaust velocity is 60 feet/minute (19 linear meters/minute). High-velocity air exhaust will decrease the operating efficiency of the electrostatic system.

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Installation

Air Supply Line

Fluid Supply Line

To reduce the risk of electric shock, the air supply hose must be electrically connected to a true earth ground. Use only Graco Grounded Air Supply

Hose.

1.See Fig. 10. Use the Graco Grounded Air Supply Hose (AH) to supply air to the gun. The gun air inlet fitting has a left-hand thread. The air supply hose ground wire (AG) must be connected to a true earth ground. Do not connect the air supply hose to the gun air inlet yet.

2.Install an air line filter/water separator (AF) on the gun air 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.

3.Install bleed-type air regulators (PR, GR) on the pump and gun air supply lines to control air pressure to the pump and gun.

Trapped air can cause the pump to cycle unexpectedly, which can result in serious injury, including splashing fluid in the eyes or on the skin. Do not operate the equipment without the bleed-type air valve (BV) installed.

4.Install a bleed-type air valve (BV) on the pump air supply line. The bleed-type air valve (BV) is required in your system to shut off air to the pump and relieve air trapped between the valve and the pump after the air regulator is shut off. Install an additional bleed-type air valve on the main air line (MA) to isolate the accessories for servicing.

5.Install an air bleed valve (BV) on each gun air supply line to shut off air to the gun(s) and relieve air trapped between the valve and the gun after the air regulator is shut off.

1.Blow out the fluid line (FL) with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed. Do not connect the fluid supply line to the gun fluid inlet yet.

2.Install a fluid regulator (FR) on the fluid line to control fluid pressure to the gun.

3.Install a fluid filter (FF) near the pump outlet, to remove particles and sediment which could clog the spray nozzle.

To reduce the risk of serious injury, including splashing fluid in the eyes or on the skin, do not operate equipment without the fluid drain valve (FD) installed.

4.The fluid drain valve (FD) 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.

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Installation

NON-HAZARDOUS LOCATION

HAZARDOUS LOCATION

Figure 10 Typical Installation

Typical Installation Key

Item	Description
AD	Air Line Drain Valve
AF	Air Filter/Water Separator
AG*	Gun Air Hose Ground Wire
AH*	Graco Grounded Air Hose (left-hand
	threads)
AL	Pump Air Line Lubricator

BV*	Pump Bleed-Type Air Shutoff Valve

EG	Electrostatic Air Spray Gun

FD*	Fluid Drain Valve

FF	Fluid Filter

FL	Fluid Supply Line

FR	Fluid Pressure Regulator

Item	Description
FV	Fluid Shutoff Valve
GR	Gun Air Pressure Regulator
MA	Main Air Supply Line
PG*	Pump Ground Wire
PR	Pump Air Pressure Regulator
SP	Supply Pump
SV*	Ventilation Fan Interlock Solenoid Valve.
	NOTE: The solenoid valve is not offered
	as a Graco accessory.

* These items are required for safe operation. They must be purchased separately.

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Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Ground all equipment, personnel, objects being sprayed, and conductive objects in or close to the spray area. The resistance must not exceed 1 megohm. Grounding provides an escape wire for the electric current.

When operating the electrostatic gun, any ungrounded objects (such as people, containers, and tools) in the spray location can become electrically charged.

The following are minimum grounding requirements for a basic electrostatic system. Your system may include other equipment or objects which must be grounded. Your system must be connected to a true earth ground. Check ground connections daily. Check your local electrical codes and regulations for detailed grounding instructions.

•All persons entering the spray area must wear shoes having conductive soles such as leather, or wear personal grounding straps. Do not wear shoes with non-conductive soles such as rubber or plastic. If gloves are necessary, wear the conductive gloves supplied with the gun. If non-Graco gloves are worn, cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle. Conductive gloves and footwear must not exceed 100 megohm per EN ISO 20344, EN 1149–5.

•Object being sprayed: Keep the workpiece hangers clean and grounded at all times.

Installation

•Electrostatic Air Spray Gun: Ground the gun by connecting the Graco Grounded Air Hose (AH) to the gun, and connecting the air hose ground wire to a true earth ground. See Check Gun Electrical Grounding, page 34.

•Pump/fluid source: Ground the pump/fluid source by connecting its ground wire to a true earth ground.

•All electrically conductive objects or devices in the spray area must be properly grounded.

•Fluid and waste containers: Ground all fluid and waste containers in the spray area. Do not use pail liners unless they are conductive and grounded. When flushing the spray gun, the container used to catch the excess fluid must be electrically conductive and grounded.

•Air compressors: Ground the equipment according to the manufacturer's recommendations.

•All air and fluid lines must be properly grounded. Use only grounded hoses with a maximum of 100 feet (30.5 m) combined hose length to ensure grounding continuity.

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Installation

•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.

•Flammable liquids in the spray area must be kept in approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift.

•All solvent pails: Use only approved, grounded metal containers, which are conductive. Do not use plastic containers. Use only non-flammable solvents. Do not store more than the quantity needed for one shift.

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Installation

Figure 11 Ground the Operator	Operator is grounded through bare skin contact with
	the gun handle and conductive shoes. A conductive
	glove can also be used.

Figure 12 Ground the Object Being Sprayed	Object being sprayed is grounded through contact
	with the hanger and conveyor system.

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Installation

Figure 13 Ground the Gun

Gun is grounded through the conductive air hose.

Figure 14 Ground the Fluid Supply

Fluid supply line and source must be grounded.

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Gun Setup

Gun Setup Procedure

For additional steps to set up specialty guns, see Soft Spray Gun Setup Procedure, page 28, Round Spray Gun Setup Procedure, page 31, HVLP Gun Setup Procedure, page 29, and Abrasive Material Gun Setup Procedure, page 33.

See the figure below to locate the electrostatic gun controls.

Figure 15 Electrostatic Gun Controls

1.The gun is shipped with the fluid nozzle and air cap installed. Check that the retaining ring is tight.

NOTE: To select a different size fluid nozzle or air cap, see

Fluid Nozzle Selection Chart, page 79 and Air Cap Selection Guide, page 82.

To install the nozzle and air cap, see Air Cap and Nozzle Replacement, page 48.

2.Turn OFF (O) the ES On-Off switch (J).

3. Shut off the air bleed valve to the gun.

Gun Setup

4.Check gun resistance. Follow the steps in Test Gun Resistance, page 42.

5.Connect the Graco grounded air hose to the gun air inlet. The gun air inlet fitting has left-hand threads.

6.Follow all steps in Grounding, page 21.

7.Follow all steps in

Check Gun Electrical Grounding, page 34. Reading must be less than 1 megohm.

8.Verify that the material resistivity meets requirements for electrostatic spray. See Check Fluid Resistivity, page 35.

9.Connect the exhaust tube and secure with the clamp provided.

10.Connect the fluid hose to the gun fluid inlet.

11.Flush if needed. See Flushing, page 38.

12.Position the air cap as needed.

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Gun Setup

13.Fully open the fan air adjustment valve (F) counterclockwise.

14.Fully open the fluid adjustment valve (H) counterclockwise.

15.Fully open the atomizing air restrictor valve (G) clockwise.

16. Turn ON (I) the ES On-Off switch (J).

17.Set the gun air regulator to deliver a minimum 45 psi (0.32 MPa, 3.2 bar) at the gun when triggered, to ensure full spraying voltage.

Table 2 . Pressure Drop

Air	Hose	Air Regulator Setting
Length in ft (m)		in psi (MPa, bar)
using 5/16 inch (8		with gun triggered
mm) diameter hose
15	(4.6)	55	(0.38, 3.8)

25	(7.6)	65	(0.45, 4.5)

50 (15.3)		80	(0.56, 5.6)

18.Verify that the ES indicator (K) [Hz indicator on Smart guns] is lit.

Table 3 . LED Indicator Colors

Indicator	Description
Color
Green	When spraying, the indicator
	should remain green, indicating
	sufficient air pressure to the
	alternator turbine.
Amber	If the indicator changes to amber
	after one second, the air pressure
	is too low. Increase air pressure
	until the indicator is green.
Red	If the indicator changes to red
	after one second, the air pressure
	is too high. Decrease air pressure
	until the indicator is green. To
	maintain a higher application air
	pressure, install ES On/Off Valve
	Restrictor Kit 26A160. Adjust the
	pressure as needed to ensure the
	indicator remains green.

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19.Shut off the air to the gun. Turn OFF (O) the ES On-Off switch (J).

20.Start the pump. Adjust the fluid regulator until the stream from the gun travels 8-12 in. (200-300 mm) before falling off. Typically, if fluid pressure is below 5 psi (.04 MPa, 0.4 bar) or above 30 psi (0.21 MPa, 2.1 bar), a change of nozzle size is recommended.

21.Turn on the air to the gun. Turn ON (I) the ES On-Off switch (J).

Gun Setup

22.Spray a test pattern. Check the atomization.

•If over-atomization occurs at minimum pressure, adjust the atomizing air restrictor valve.

•If atomization is inadequate, increase air pressure or decrease fluid flow.

23.Adjust the fan air adjustment valve.

•Fully open the fan air adjustment valve, counterclockwise, for the longest pattern.

•Turn the valve clockwise to restrict the fan air and create a shorter pattern.

24.Spray a test piece. Examine the edges for coverage. If wrap is poor, see Troubleshooting, page 44.

3A2494P

Gun Setup

Soft Spray Gun Setup Procedure

To achieve a soft spray pattern for small or lightweight parts, do the following:

1.Select a soft spray gun model. See Soft Spray Gun Models, page 5 .

•To convert a gun for soft spray, install a soft spray air cap. See Air Cap Selection Guide, page 82.

•For best results, install a 1.0 mm or 1.2 mm nozzle. See

Fluid Nozzle Selection Chart, page 79.

2.Follow steps 1–14 in the Gun Setup Procedure, page 25.

3.Adjust the atomizing air. Fully close the atomizing air restrictor valve (G) counterclockwise. Then, open the atomizing air restrictor valve (G) one half turn to one turn.

4. Turn ON (I) the ES On-Off switch (J).

5.Set the gun air regulator to deliver a minimum 45 psi (0.32 MPa, 3.2 bar) at the gun when triggered, to ensure full spraying voltage.

Table 4 . Pressure Drop

Air	Hose	Air Regulator Setting
Length in ft (m)		in psi (MPa, bar)
using 5/16 inch (8		with gun triggered
mm) diameter hose
15	(4.6)	55	(0.38, 3.8)

25	(7.6)	65	(0.45, 4.5)

50 (15.3)		80	(0.56, 5.6)

6.Verify that the ES indicator (K) [Hz indicator on Smart guns] is lit.

Table 5 . LED Indicator Colors

Indicator	Description
Color
Green	When spraying, the indicator
	should remain green, indicating
	sufficient air pressure to the
	alternator turbine.
Amber	If the indicator changes to amber
	after one second, the air pressure
	is too low. Increase air pressure
	until the indicator is green.
Red	If the indicator changes to red
	after one second, the air pressure
	is too high. Decrease air pressure
	until the indicator is green. To
	maintain a higher application air
	pressure, install ES On/Off Valve
	Restrictor Kit 26A160. Adjust the
	pressure as needed to ensure the
	indicator remains green.

7.Continue with steps 19–24 in the Gun Setup Procedure, page 25.

NOTE: The soft spray air cap is optimized for a production rate of 3.5 oz/min (100 cc/min). For best soft spray results, limit the production rate to 7 oz/min (200 cc/min) or less.

NOTE: If the object being sprayed is moving too much, adjust the atomizing air restrictor valve

(G) counterclockwise slightly to limit the air flow. To improve atomization, adjust the atomizing air restrictor valve (G) clockwise slightly to increase the air flow or decrease the fluid flow.

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HVLP Gun Setup Procedure

Most air quality authorities accept electrostatic spraying as the most efficient process and a means to comply with environmental regulation. Follow the Gun Setup Procedure, page 25when spraying electrostatically with an HVLP aircap.

When electrostatic spraying cannot be effectively used on certain parts or materials, an HVLP gun can be used to comply with environmental regulations in most areas. To be in compliance the air pressures at the aircap must be less than 10 psi. Follow

the procedure below to set up the spray gun for non-electrostatic HVLP operation.

1.Select an HVLP gun model. See HVLP Gun Models, page 6 .

To convert a gun for HVLP, install an HVLP air cap. See Air Cap Selection Guide, page 82.

2.Follow steps 1–12 in the Gun Setup Procedure, page 25.

3.Fully open the fluid adjustment valve (H) counterclockwise.

4.Adjust the air in the air cap.

a.Fully open the fan air adjustment valve (F) counterclockwise.

Gun Setup

b.Fully open the atomizing air restrictor valve

(G) clockwise.

c.Turn OFF(I) the ES On-Off switch (J).

d.Set the gun air regulator to deliver 30 psi (0.21 MPa, 2.1 bar) at the gun when triggered.

Table 6 Pressure Drop

Air Hose Length		Air Regulator
in ft (m) using		Setting in psi
5/16 inch (8 mm)		(MPa, bar) with
diameter hose		gun triggered
15	(4.6)	43 (0.29, 3)
25	(7.6)	50	(0.34, 3.4)
50 (15.3)		70	(0.48, 4.8)

5. Shut off the air to the gun.

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+ 66 hidden pages

Graco Pro Xp Instruction Manual

Models

Approvals

Related Manuals

Warnings

Gun Overview

How the Electrostatic Spray Gun Works

Controls, Indicators, and Components

Smart Guns

Operating Mode

Error Display

Adjusting the Low Voltage Setting

Lock Symbol

Smart Gun Key

Diagnostic Mode

Installation

Ventilate the Spray Booth

Warning Sign

Air Supply Line

Fluid Supply Line

Grounding

Gun Setup

Gun Setup Procedure

Soft Spray Gun Setup Procedure

HVLP Gun Setup Procedure