Graco Pro Xp User Manual

Instructions-Parts

Pro

Pro Pro Air

Air Air

For

For For For

For For use

use use

3000 psi (21 MPa, 210 bar) Maximum Fluid Working Pressure 100 psi (0.7 MPa, 7 bar) Maximum Air Working Pressure

See page 3 for model part numbers and approval information.

Xp™

Xp™ Xp™

Assisted

- --Assisted Assisted

use

use use use

use use

only.

only. only.

Class

in ininClass Class

Group

in ininGroup Group

Important

Important Important Thisequipmentcouldpresenthazardsifnotoperatedaccordingto theinformationinthismanual.Read Read this

manual

this this

manual manual

Electrostatic

Electrostatic Electrostatic

Spray

Spray Spray

Div.

I, I,I,Div. Div.

II,

II, II,

Safety

Safety Safety

before

before before

Hazardous

I IIHazardous Hazardous

Zone

Zone Zone

Explosive

1 11Explosive Explosive

Instructions

Instructions Instructions

using

using using

Gun

Gun Gun

Locations

Locations Locations

Atmosphere

Atmosphere Atmosphere

Read

the

equipment.

the the

equipment. equipment.

using

Group

using using

Group Group

Locations

Locations Locations

all

warnings

all all

warnings warnings

Save

Save Save

and

and and

these

instructions.

these these

instructions. instructions.

materials.

D DDmaterials. materials.

using

Group

using using

Group Group

instructions

instructions instructions

IIA

materials.

IIA IIA

materials. materials.

in in

3A2495L

For

professional

For For

professional professional

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents

Contents Contents

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

Approvals...........................................................3

RelatedManuals................................................3

Warnings...........................................................4

GunOverview....................................................7

HowtheElectrostaticAASprayGun

Works............................................7

Controls,Indicators,andComponents...........8

SmartGuns.................................................9

Installation..........................................................14

WarningSign...............................................14

VentilatetheSprayBooth.............................14

AirSupplyLine............................................15

FluidSupplyLine.........................................15

Grounding...................................................17

GunSetup..........................................................21

GunSetupProcedure...................................21

CheckGunElectricalGrounding...................24

CheckFluidResistivity.................................25

CheckFluidViscosity...................................25

FlushBeforeUsingEquipment......................25

Operation...........................................................26

PressureReliefProcedure............................26

Startup........................................................27

Shutdown....................................................27

Maintenance......................................................28

DailyCareandCleaningChecklist................28

Flushing......................................................28

CleantheGunDaily.....................................30

DailySystemCare.......................................31

ElectricalTests...................................................32

TestGunResistance....................................32

TestPowerSupplyResistance.....................33

TestGunBarrelResistance..........................34

Troubleshooting..................................................35

SprayPatternTroubleshooting......................35

GunOperationTroubleshooting....................36

ElectricalTroubleshooting............................37

Repair................................................................39

PreparetheGunforService.........................39

AirCap,SprayTip,andFluidSeatHousing

Replacement..................................40

ElectrodeReplacement................................41

FluidTubeRemovalandReplacement...........42

FluidFilterReplacement...............................42

GunBarrelRemoval.....................................43

GunBarrelInstallation..................................43

FluidNeedleReplacement............................44

PowerSupplyRemovaland

Replacement..................................45

AlternatorRemovalandReplacement...........46

FanAirAdjustmentValveRepair..................48

AtomizingAirAdjustmentValve

Repair............................................48

ESOn-OffValveRepair...............................49

AirValveRepair...........................................50

SmartModuleReplacement..........................51

AirSwivelandExhaustValve

Replacement..................................52

Parts..................................................................53

StandardAir-AssistedSprayGun

Assembly.......................................53

SmartAir-AssistedSprayGun

Assembly.......................................55

AlternatorAssembly.....................................57

ESOn-OffValveAssembly...........................58

FanAirAdjustmentValveAssembly..............59

AirCapAssembly........................................60

SmartModuleAssembly...............................60

SprayTipSelectionChart....................................61

AEMFineFinishSprayTips..........................61

AEFFineFinishPre-Ori󰘰ceSpray

Tips...............................................62

RoundSprayTips........................................63

RecommendedFilterSizes...........................64

RepairKitsandAccessories................................65

GunAccessories..........................................65

InlineFluidFilterKitAccessories...................65

OperatorAccessories...................................66

SystemAccessories.....................................66

Signs..........................................................66

TestEquipment...........................................66

Hoses.........................................................67

Dimensions........................................................68

TechnicalSpeci󰘰cations......................................69

CaliforniaProposition65.....................................69

GracoProXpWarranty.......................................70

3A2495L

Models

25 75

Models

Models Models

Part

No.

Part Part

No. No.

kV kV

Display

Display Display

H60T1060

H60M1060

H85T1085

H85M1085

H85T57*

H85M57*

*HighAirFlowGunModels,equippedwithESOn-OffwithAirRestrictorValve,whichlimitsair󰘱owtothe turbine.Forapplicationsthatrequirehighair󰘱owattheaircap.

Approvals

Approvals Approvals

II IIII2 22G G

0.24mJT6

Standard

Smart

Standard

Smart

Standard

Smart

FM12ATEX0068

EN50050–1

Ta0°C–50°C

Related Related

Manual

Manual Manual

3A2499

3A7005

307263ProbeandMeter,Instructions

308393

309227

309455TestFixture,HighVoltageProbe,andkVMeter,Instructions

406999

No.

No. No.

Manuals

Manuals Manuals

Description

Description Description

RoundSprayKit,Instructions

QuickAdjustFanValveKit,Instructions

GunWasherKit,Instructions

GunFlushBoxModule,Instructions

VoltageTesterConversionKit,Instructions

3A2495L 3

Warnings

Warnings Warnings

Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c risks.Whenthesesymbolsappearinthebodyofthismanual,referbacktotheseWarnings.Product-speci󰘰c hazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughoutthebodyofthismanual whereapplicable.

WARNING

WARNING WARNING

FIRE,

EXPLOSION,

FIRE, FIRE,

EXPLOSION, EXPLOSION,

Flammablefumes,suchassolventandpaintfumes,inwork work Paintorsolvent󰘱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.

•Eliminateallignitionsources;suchaspilotlights,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

work

area

area area

canigniteorexplodee.

Grounding

instructions.

3A2495L

WARNING

WARNING WARNING

SKIN

INJECTION

SKIN SKIN

INJECTION INJECTION High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get treatment.

treatment. treatment.

•Donotspraywithouttipguardandtriggerguardinstalled.

•Engagetriggerlockwhennotspraying.

•Donotpointgunatanyoneoratanypartofthebody.

•Donotputyourhandoverthespraytip.

•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.

•FollowthePressure Pressure

orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.

HAZARD

HAZARD HAZARD

Get

immediate

immediate immediate

Pressure

Relief

Procedure

Relief Relief

Procedure Procedure

whenyoustopsprayingandbeforecleaning,checking,

Warnings

surgical

surgical surgical

3A2495L 5

Warnings

WARNING

WARNING WARNING

EQUIPMENT

EQUIPMENT EQUIPMENT Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated systemcomponent.SeeTechnical Technical

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical Speci󰘰cations

Speci󰘰cations Speci󰘰cations Forcompleteinformationaboutyourmaterial,requestSafetyDataSheets(SDSs)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.

MISUSE

MISUSE MISUSE

PARTS

PARTS PARTS

HAZARD

HAZARD HAZARD

Technical

inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.

CLEANING

CLEANING CLEANING

SOLVENT

SOLVENT SOLVENT

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

Pressure

HAZARD

HAZARD HAZARD

Relief

Relief Relief

inallequipmentmanuals.

Procedure

Procedure Procedure

whenequipmentisnotinuse.

Technical

•Useonlycompatiblesolventstocleanplasticstructuralorpressure-containingparts.

•SeeTechnical Technical

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

Technical

thesolventmanufacturerforinformationandrecommendationsaboutcompatibility.

FLUID

FLUID FLUID

guidelines.

manufacturer.

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

FUMES

OR OR

FUMES FUMES

PROTECTIVE

PROTECTIVE PROTECTIVE

inallequipmentmanualsformaterialsofconstruction.Consult

HAZARD

HAZARD HAZARD

EQUIPMENT

EQUIPMENT EQUIPMENT

6 3A2495L

GunOverview

Gun

Gun Gun

How

How How Works

Works Works

Thisisnotanairspraygun.Tohelpprevent seriousinjuryfrompressurized󰘱uid,suchasskin injection,andsplashing󰘱uid,readandfollowthe Skin

Skin Skin

Theair-assistedsprayguncombinesairlessand airsprayingconcepts.Thespraytipatomizes andshapesthe󰘱uidintoafanpattern,asdoes aconventionalairlessspraytip.Airfromtheair capfurtheratomizesthe󰘱uidandcompletesthe atomizationofthe󰘱uidtailstoproduceauniform pattern.

Asthegunistriggered,partoftheregulatedair operatesthealternatorturbineandtherestofthe airhelpsatomizethe󰘱uidbeingsprayed.The

Overview

Overview Overview

the

Electrostatic

the the

Electrostatic Electrostatic

Injection

Injection Injection

Hazard

Hazard Hazard

Warnings

Warnings Warnings

AA AA

Spray

Spray Spray

onpage5.

Gun

Gun Gun

alternatorgeneratespower,whichisconvertedby thepowercartridgetosupplyhighvoltagetothe gun’selectrode.

The󰘱uidiselectrostaticallychargedasitpasses theelectrode.Thecharged󰘱uidisattractedtothe groundedworkpiece,wrappingaroundandevenly coatingallsurfaces.

Theregulatedairthatisdirectedtotheaircapcan befurthercontrolledusingthegun’satomizingair adjustmentvalve.Thisvalvecanbeusedtorestrict air󰘱owtotheaircapwhilemaintainingsuf󰘰cientair 󰘱owtothealternator.Theatomizingairadjustment valvedoesnotcontrolpatternwidth.Tochange patternwidth,useanewtipsize,orusethefan adjustmenttonarrowthepatternwidth.

Thehighworking󰘱uidpressureofthisgunprovides thepowerneededtoatomizehighersolidsmaterials.

NOTE:

NOTE: NOTE: gun’satomizingairadjustmentvalvecompletelyoff. Closingthisvalvedoesnotaffectalternatoroperation.

Forairlessatomization,ifdesired,turnthe

3A2495L

GunOverview

Controls,

Controls, Controls,

Theelectrostaticgunincludesthefollowingcontrols,indicators,andcomponents(seeFig.1).Forinformation onSmartguns,alsoseeSmartGuns,page9.

Figure1GunOverview

Item

Item Item

Indicators,

Indicators, Indicators,

Description

Description Description

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

and

Components

and and

Components Components

Purpose

Purpose Purpose

BFluidInlet

EElectrode

FFanAirAdjustmentValve

LInlineFluidFilter

TurbineAirExhaust

AirCap/TipGuardand SprayTip

AtomizingAirAdjustment Valve

TriggerSafetyLockLockstriggertopreventgunfromspraying.

ESOn-OffValveTurnselectrostaticsON(I)orOFF(O).

ESIndicator(standard gunonly;forSmart gunindicator,see

OperatingMode,page9)

1/4npsm(m),for󰘱uidsupplyhose.

Barbed󰘰tting,forsuppliedexhausttube.

SeeSprayTipSelectionChart,page61,foravailablesizes.

Supplieselectrostaticchargetothe󰘱uid.

Adjustsfansizeandshape.Canbeusedtodecreasepatternwidth.

Adjustsatomizingair󰘱ow.

LitwhenESisON(I).Colorindicatesalternatorfrequency.Seethe LEDindicatortableintheGunSetupProcedure,page21.

Provides󰘰nal󰘰ltrationof󰘱uid.Locatedinside󰘱uidtube󰘰tting.

8 3A2495L

GunOverview

Smart

Smart Smart

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

•OperatingMode

•DiagnosticMode

Operating

Operating Operating

Bar

Bar Bar

SeeFig.2andSmartGunKey,page11.The OperatingModedisplaysgundataduringnormal spraying.Thedisplayusesabargraphtoshowthe voltagelevelinkiloVolts(kV)andthecurrentlevelin microAmperes(uA).Thebargraphrangeisfrom0 to100%foreachvalue.

IftheuAbargraphLEDsareblue,thegunisready tospray.IftheLEDsareyelloworred,thecurrentis toohigh.The󰘱uidmaybetooconductive,orsee

ElectricalTroubleshooting,page37forotherpossible

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,page10.

NOTE:

NOTE: NOTE: haslostcommunicationwiththepowersupply.See

ErrorDisplay,page10,forfurtherinformation.

Adjustment

Adjustment Adjustment

IftheErrordisplayappears,theSmartmodule

Switch

Switch Switch

Indicator

Hz Hz

Indicator Indicator

TheHzindicatorfunctionsthesameastheES indicatoronstandardguns.Theindicatorlightsto showthealternatorspeedstatus,andhasthree colors:

•Greenindicatesthealternatorspeediscorrect.

•Iftheindicatorchangestoamberafteronesecond, increasetheairpressure.

•Iftheindicatorchangestoredafteronesecond, theairpressureistoohigh.Decreaseairpressure untiltheindicatorisgreen.Tomaintainahigher airpressure,installESOn/OffValveRestrictorKit 26A294.Then,adjustthepressureasneededto ensuretoensuretheindicatorremainsgreen.

Figure2SmartGunModuleinOperatingMode

3A2495L 9

GunOverview

Error

Error Error

IftheSmartmodulelosescommunicationwith thepowersupply,theErrordisplayappears,the Hzindicatorturnsred,andtheSmartmoduleis disabled.SeeFig.3andSmartGunKey,page11. ThiscanoccurinOperatingModeorDiagnostic Mode.SeeElectricalTroubleshooting,page37. 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,page10.

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,page11. Thepossiblerangesare:

•85kVguns:40–85kV

•60kVguns:30–60kV

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,page11.

•WheninHImode,thelowvoltagesettingisalways always locked.ThelocksymbolwillappearwhentheLO SETbuttonispressed.

•WheninLOmode,thelocksymbolwill only

only only

appearifthelockisenabled.See

LowVoltageLockScreen,page13,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

always

10 3A2495L

GunOverview

Smart

Smart Smart

Table

Table Table

Item

Item Item

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

ERErrorDisplay

VIVoltageIndicator

CICurrentIndicatorInDiagnosticMode,thetwobottomrightLEDsofthescreenlight,

ASAlternatorSpeedDisplayInDiagnosticMode,Hzlevelisdisplayedasanumber.SeeFig.8.

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.

3A2495L

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,page12.

Toadvancetothenextscreen,presstheLOSET buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET buttonforapproximately5seconds.Thescreenwill returntoOperatingMode.

NOTE:

NOTE: NOTE: Mode,thelastscreenviewedwillbedisplayedwhen thegunisretriggered.

NOTE:

NOTE: NOTE: fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page13fordetails.

Mode

Mode Mode

YoumustbeinOperatingModetoadjustthe

IfthegunisdetriggeredwhileinDiagnostic

DiagnosticModecannotbeexited

Figure6Voltage(kiloVolts)Screen

Current

Current Current

TheCurrent(microAmperes)Screenisthesecond screenintheDiagnosticMode.SeeFig.7and

SmartGunKey,page11.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,page11.Toenterthisscreen, pressandholdtheLOSETbuttonforapproximately 5secondswhileintheOperatingMode.

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

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page12.Press

andholdforapproximately󰘰vesecondstoreturnto OperatingMode.

(kiloVolts)

(kiloVolts) (kiloVolts)

Screen

Screen Screen

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page13.Press

andholdforapproximately󰘰vesecondstoreturnto OperatingMode.

Figure7Current(microAmperes)Screen

3A2495L

GunOverview

Alternator

Alternator Alternator

TheAlternatorSpeed(Hertz)Screenisthethird screenintheDiagnosticMode.SeeFig.8and

SmartGunKey,page11.Toenterthisscreen,

presstheLOSETbuttonwhileintheCurrent (microAmperes)Screen.

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

TheHzindicatorlightsgreentoshowthatyouare viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page13.Pressandhold

forapproximately5secondstoreturntoOperating Mode.

Speed

Speed Speed

(Hertz)

(Hertz) (Hertz)

Screen

Screen Screen

Low

Voltage

Low Low

Voltage Voltage

TheLowVoltageLockScreenisthefourth screenintheDiagnosticMode.SeeFig.9and

SmartGunKey,page11.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

3A2495L 13

Installation

Installation Installation

Installingandservicingthisequipmentrequires accesstopartswhichmaycauseelectricshock orotherseriousinjuryifworkisnotperformed properly.

•Donotinstallorservicethisequipmentunless youaretrainedandquali󰘰ed.

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

•Complywithalllocalcodesandregulations.

Fig.10(TypicalInstallation)showsatypical electrostaticair-assistedspraysystem.Itisnotan actualsystemdesign.Forassistanceindesigning asystemtosuityourparticularneeds,contactyour Gracodistributor.

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.

3A2495L

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.

Toreducetheriskofseriousinjurydueto componentrupture,includingskininjection, pumppressuremustbelimitedbythepumpair regulator.Donotrelyonthegun󰘱uidregulator tolimitthe󰘱uidpressuretothegun.

Line

Line Line

Use

only

Graco

only only

Graco Graco

Grounded

Grounded Grounded

Air

Supply

Air Air

Supply Supply

Installation

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.

Fluid

Fluid Fluid

1.Blowoutthe󰘱uidline(FL)withairand󰘱ushit

2.Installa󰘱uidpressureregulator(FR)onthe󰘱uid

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

Supply

Supply Supply

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

linetocontrol󰘱uidpressuretothegun.

removeparticlesandsedimentwhichcouldclog thespraynozzle.

NOTE:

NOTE: NOTE: additional󰘰ltration.

Thegunincludesaninline󰘱uid󰘰lterfor

Line

Line Line

The󰘱uidsupplypumpmustbepreventedfrom producinga󰘱uidpressuregreaterthanthe 3000psi(21MPa,210bar)

Fluid Pressure

supplypressuretoa30:1ratiopumpmustnot exceed100psi(0.7MPa,7bar).

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

Trappedaircancausethepumptocycle unexpectedly,whichcanresultinserious injury,includingskininjectionandsplashing 󰘱uidintheeyesorontheskin.Donotoperate theequipmentwithoutthebleed-typeairvalve (BV)installed.

ofthegun.Forexample,theair

Maximum Working

Toreducetheriskofseriousinjury,including skininjectionandsplashing󰘱uidintheeyesor ontheskin,donotoperateequipmentwithout the󰘱uiddrainvalve(FD)installed.

4.The󰘱uiddrainvalve(FD)isrequiredinyour systemtoassistinrelieving󰘱uidpressureinthe displacementpump,hose,andgun.Triggering theguntorelievepressuremaynotbesuf󰘰cient. Installadrainvalveclosetothepump's󰘱uid outlet.

3A2495L 15

Installation

NON

HAZARDOUS

NON NON

- --HAZARDOUS HAZARDOUS

LOCATION

LOCATION LOCATION

HAZARDOUS

HAZARDOUS HAZARDOUS

LOCATION

LOCATION LOCATION

Figure10TypicalInstallation

Typical

Typical Typical

Item

Item Item

AG*GunAirHoseGroundWire

AH*GracoGroundedAirHose(left-hand

ALPumpAirLineLubricator

BV*PumpBleed-TypeAirShutoffValve

EGElectrostaticAirSprayGun

FD*

FFFluidFilter

FGFluidPressureGauge

FRFluidPressureRegulator

Installation

Installation Installation

Description

Description Description

AirFilter/WaterSeparator

threads)

FluidDrainValve

FluidSupplyLine

Key

Key Key

Item

Item Item

GRGunAirPressureRegulator

PG*PumpGroundWire

PRPumpAirPressureRegulator

RVPumpRunawayValve

SPSupplyPump

SV*VentilationFanInterlockSolenoidValve

*Theseitemsarerequiredforsafeoperation.They mustbepurchasedseparately.

Description

Description Description

FluidShutoffValve

MainAirSupplyLine

NOTE:

NOTE: NOTE: aGracoaccessory.

Thesolenoidvalveisnotofferedas

16 3A2495L

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.

•

Electrostatic Air-Assisted Spray Gun:

thegunbyconnectingtheGracoGrounded AirHosetothegun,andconnectingtheair hosegroundwiretoatrueearthground.See

CheckGunElectricalGrounding,page24.

•

Pump/󰘱uid source:

byconnectingitsgroundwiretoatrueearth ground.

Groundthepump/󰘱uidsource

Installation

Ground

All persons entering the spray area:

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

•

Object being sprayed:

cleanandgroundedatalltimes.

Keeptheworkpiecehangers

mustwear

•

All electrically conductive objects or devices in the spray area:

•

Fluid and waste containers:

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

Air compressors:

• tothemanufacturer'srecommendations.

•

All air and 󰘱uid lines

Useonlygroundedhoseswithamaximumof100 feet(30.5m)combinedhoselengthtoensure groundingcontinuity

The 󰘱oor of the spray area:

• conductiveandgrounded.Donotcoverthe󰘱oor withcardboardoranynon-conductivematerial whichwouldinterruptgroundingcontinuity

mustbeproperlygrounded.

Groundall󰘱uidand

Groundtheequipmentaccording

mustbeproperlygrounded.

mustbeelectrically

3A2495L

Installation

•

Flammable liquids in the spray area:

inapproved,groundedcontainers.Donotuse

mustbekept

plasticcontainers.Donotstoremorethanthe quantityneededforoneshift.

•

All solvent pails:

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

Useonlyapproved,grounded

18 3A2495L

Installation

Figure11GroundtheOperatorOperatorisgroundedthroughthegunhandleand

conductiveshoes.

Figure12GroundtheObjectbeingSprayedObjectbeingsprayedisgroundedthroughcontact

withthehangerandconveyorsystem.

3A2495L 19

Installation

Figure13GroundtheGunGunisgroundedthroughtheconductiveairhose.

Figure14GroundtheFluidSupplyFluidsupplylineandsourcemustbegrounded.

20 3A2495L

GunSetup

Gun

Gun Gun

Gun

Gun Gun

Seethe󰘰gurebelowtolocatetheelectrostaticgun controls.

Figure15ElectrostaticGunControls

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

Setup

Setup Setup

Setup

Setup Setup

Procedure

Procedure Procedure

4.ConnecttheGracogroundedairhosetothegun

airinlet.Thegunairinlet󰘰ttinghasleft-hand threads.

5.FollowallstepsunderGrounding,page17.

6.Followallstepsunder

CheckGunElectricalGrounding,page24.

Readingmustbelessthan1megohm.

7.Verifythatthematerialresistivitymeets

requirementsforelectrostaticspray.See

CheckFluidResistivity,page25.

8.Connecttheexhausttubeandsecurewiththe

clampprovided.

2.Shutofftheairbleedvalvetothegun.

3.Checkgunresistance.See

TestGunResistance,page32.

9.Connectthe󰘱uidhosetothegun󰘱uidinlet.

10.Flushifneeded.SeeFlushing,page28.

3A2495L

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