Graco Pro Xp 3A2494D Instructions Manual

Instructions-Parts

Pro Pro

Pro

Xp™ Xp™

Xp™

Electrostatic Electrostatic

Electrostatic

Air Air

Air

Spray Spray

Spray

Gun Gun

Gun

3A2494D

EN

For For

For

use use

use

in ininClass Class

Class

I, I,I,Div. Div.

Div.

I IIHazardous Hazardous

Hazardous

Locations Locations

Locations

using using

using

Group Group

Group

D DDspray spray

spray

materials. materials.

materials.

For For

For

use use

use

in in

in

Group Group

Group

II, II,

II,

Zone Zone

Zone

1 11Explosive Explosive

Explosive

Atmosphere Atmosphere

Atmosphere

Locations Locations

Locations

using using

using

Group Group

Group

IIA IIA

IIA

spray spray

spray

materials. materials.

materials.

For For

For

professional professional

professional

use use

use

only. only.

only.

Important Important

Important

Safety Safety

Safety

Instructions Instructions

Instructions
Readallwarningsandinstructionsinthismanual.
Save Save

Save

these these

these

instructions. instructions.

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 See

See

page page

page

3 33for for

for

model model

model

part part

part

numbers numbers

numbers

and and

and

approval approval

approval

information. information.

information.

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents

Contents

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

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

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

HowtheElectrostaticSprayGun

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

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

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

Installation..........................................................15

WarningSign...............................................15

VentilatetheSprayBooth.............................15

AirSupplyLine............................................16

FluidSupplyLine.........................................16

GunSetup..........................................................18

GunSetupChecklist....................................18

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

CheckGunElectricalGrounding...................25

CheckFluidResistivity.................................26

CheckFluidViscosity...................................26

FlushBeforeUsingEquipment......................26

GuidelinesforAbrasiveMaterials..................26

Operation...........................................................27

PressureReliefProcedure............................27

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

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

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

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

CleantheGunDaily.....................................29

DailySystemCare.......................................30

ElectricalTests...................................................31

TestGunResistance....................................31

TestPowerSupplyResistance.....................32

TestElectrodeResistance............................32

Troubleshooting..................................................33

SprayPatternTroubleshooting......................33

GunOperationTroubleshooting....................34

ElectricalTroubleshooting............................35

Repair................................................................37

PreparetheGunforService.........................37

AirCapandNozzleReplacement..................38

ElectrodeReplacement................................39

FluidPackingRodRemoval..........................40

PackingRodRepair.....................................40

BarrelRemoval............................................42

BarrelInstallation.........................................42

PowerSupplyRemovaland

Replacement..................................43

AlternatorRemovalandReplacement...........44

FluidTubeRemovalandReplacement...........46

FanAirAdjustmentValveRepair..................47

AtomizingAirRestrictorValveRepair............48

ESOn-OffandFluidAdjustmentValve

Repair............................................49

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

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

AirSwivelandExhaustValve

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

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

StandardAirSprayGunAssembly................53

RoundSprayAssembly................................55

StandardHighConductivityAirSprayGun

Assembly.......................................56

SmartHighConductivityAirSprayGun

Assembly.......................................58

SmartAirSprayGunAssembly.....................60

PackingRodAssembly.................................62

AlternatorAssembly.....................................63

ESOn-OffandFluidAdjustmentValve...........64

FanAirAdjustmentValveAssembly..............65

AtomizingAirRestrictorValve

Assembly.......................................65

SmartModuleAssembly...............................66

HighConductivityFluidTube

Assembly.......................................67

AirCapsandFluidNozzles.................................68

FluidNozzleSelectionChart.........................68

FluidNozzlePerformanceCharts..................68

AirCapSelectionChart................................70

AirConsumptionCharts...............................71

RepairKits,RelatedManuals,and

Accessories..........................................73

GunAccessories..........................................73

OperatorAccessories...................................74

SystemAccessories.....................................74

TestEquipment...........................................74

Hoses.........................................................75

Dimensions........................................................76

TechnicalData...................................................77

GracoProXpWarranty.......................................78

2

3A2494D

Models

Models Models

Models

Nozzle Nozzle

Nozzle

Part Part

Part

No. No.

No.

kV kV

kV

1.5 1.5

1.5
mm mm

mm

1.2 1.2

1.2
mm mm

mm

Round Round

Round
Spray Spray

Spray

Standard Standard

Standard
Display Display

Display

Smart Smart

Smart
Display Display

Display

Standard Standard

Standard
Coatings Coatings

Coatings

High High

High
Conductivity/ Conductivity/

Conductivity/
High High

High

Wear Wear

Wear

Increased Increased

Increased
Transfer Transfer

Transfer
Ef󰘰ciency Ef󰘰ciency

Ef󰘰ciency

L40T1040

✔✔✔

L40T1440

✔✔✔✔

L40T1540

✔✔✔✔

L40T1640

✔✔✔

L60T1060

✔✔✔

L60T1160

✔✔✔

L60T1260

✔✔✔

L60T1660

✔✔✔

L60M1060

✔✔✔

L60M1260

✔✔✔

L60M1660

✔✔✔

L85T1085

✔✔✔

L85T1685

✔✔✔

L85M1085

✔✔✔

L85M1685

✔✔✔

II IIII2 22G G

G

EEx0.24mJT6

FM12ATEX0068

EN50050

Ta0°C–50°C

3A2494D 3

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, FIRE,

FIRE,

EXPLOSION, EXPLOSION,

EXPLOSION,

AND AND

AND

ELECTRIC ELECTRIC

ELECTRIC

SHOCK SHOCK

SHOCK

HAZARD HAZARD

HAZARD

Flammablefumes,suchassolventandpaintfumes,inwork work

work

area area

area

canigniteorexplode.Tohelp

prevent󰘰re,explosion,andelectricshock:

•Electrostaticequipmentmustbeusedonlybytrained,quali󰘰edpersonnelwhounderstand
therequirementsofthismanual.

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

Grounding

instructions.

•OnlyusegroundedGracoconductiveairsupplyhoses.

•Donotusepaillinersunlesstheyareconductiveandgrounded.

•Stop Stop

Stop

operation operation

operation

immediately immediately

immediately

ifstaticsparkingoccursoryoufeelashock.Donotuse

equipmentuntilyouidentifyandcorrecttheproblem.

•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.

•Useandcleanequipmentonlyinwellventilatedarea.

•Interlockthegunairsupplytopreventoperationunlessventilatingfansareon.

•Usecleaningsolventswithhighestpossible󰘱ashpointwhen󰘱ushingorcleaningequipment.

•Tocleantheexterioroftheequipment,cleaningsolventsmusthavea󰘱ashpointatleast
5°Caboveambienttemperature.

•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).

•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.

•Keepsprayareafreeofdebris,includingsolvent,ragsandgasoline.

•Keepaworking󰘰reextinguisherintheworkarea.

4

3A2494D

Warnings

WARNING WARNING

WARNING

PRESSURIZED PRESSURIZED

PRESSURIZED

EQUIPMENT EQUIPMENT

EQUIPMENT

HAZARD HAZARD

HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.

•FollowthePressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

whenyoustopspraying/dispensingandbefore

cleaning,checking,orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

PLASTIC PLASTIC

PLASTIC

PARTS PARTS

PARTS

CLEANING CLEANING

CLEANING

SOLVENT SOLVENT

SOLVENT

HAZARD HAZARD

HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.

•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing

parts.

•SeeTechnical Technical

Technical

Data Data

Data

inthisandallotherequipmentinstructionmanuals.Read󰘱uidand

solventmanufacturer’sMSDSsandrecommendations.

TOXIC TOXIC

TOXIC

FLUID FLUID

FLUID

OR OR

OR

FUMES FUMES

FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.

•ReadMSDS’stoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable

guidelines.

PERSONAL PERSONAL

PERSONAL

PROTECTIVE PROTECTIVE

PROTECTIVE

EQUIPMENT EQUIPMENT

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

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent

manufacturer.

3A2494D 5

Warnings

WARNING WARNING

WARNING

EQUIPMENT EQUIPMENT

EQUIPMENT

MISUSE MISUSE

MISUSE

HAZARD HAZARD

HAZARD

Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical

Technical

Data Data

Data

inallequipmentmanuals.

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical

Technical

Data Data

Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

whenequipmentisnotinuse.

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

6 3A2494D

GunOverview

Gun Gun

Gun

Overview Overview

Overview

How How

How

the the

the

Electrostatic Electrostatic

Electrostatic

Spray Spray

Spray

Gun Gun

Gun

Works Works

Works

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

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

3A2494D

7

GunOverview

Controls, Controls,

Controls,

Indicators, Indicators,

Indicators,

and and

and

Components Components

Components

Theelectrostaticgunincludesthefollowing
controls,indicators,andcomponents(seeFig.

1).ForinformationonSmartguns,alsosee

SmartGuns,page9.

Figure1GunOverview

Item Item

Item

Descrip- Descrip-

Descrip­tion tion

tion

Purpose Purpose

Purpose

A

AirSwivel
Inlet

1/4npsm(m)left-handthread,
forGracogroundedairsupply
hose.

BFluidInlet

3/8npsm(m),for󰘱uidsupply
hose.

C

TurbineAir
Exhaust

Barbed󰘰tting,forsupplied
exhausttube.

D

AirCap
and
Nozzle

SeeAirCapsandFluid

Nozzles,page68,foravail-

ablesizes.

EElectrode

Needle

Supplieselectrostaticcharge
tothe󰘱uid.

FFanAir

Adjust­ment
Valve

Adjustsfansizeandshape.
Canbeusedtodecrease
patternwidth.

G

Atomizing
Air
Restrictor
Valve

Restrictsaircapair󰘱ow.
Replacewithplug(included)
ifdesired.

Item Item

Item

Descrip- Descrip-

Descrip­tion tion

tion

Purpose Purpose

Purpose

HFluidAd-

justment
Knob

Adjusts󰘱uid󰘱owbylimiting
󰘱uidneedletravel.Useonly
inlow󰘱owconditions,to
reducewear.

J

ESOn-Off
Valve

TurnselectrostaticsON(I)or
OFF(O).

K

ESIndica­tor(stan­dardgun
only;for
Smartgun
indica­tor,see

Operating
Mode,
page9)

LitwhenESisON(I).Colorin­dicatesalternatorfrequency.
SeetheLEDindicatortable
intheGunSetupChecklist,

page18.

8 3A2494D

GunOverview

Smart Smart

Smart

Guns Guns

Guns

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

•OperatingMode

•DiagnosticMode

Operating Operating

Operating

Mode Mode

Mode

Bar Bar

Bar

Graph Graph

Graph

SeeFig.2,andTable1onpage10.TheOperating
Modedisplaysgundataduringnormalspraying.The
displayusesabargraphtoshowthevoltagelevelin
kiloVolts(kV)andthecurrentlevelinmicroAmperes
(uA).Thebargraphrangeisfrom0to100%foreach
value.

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

ElectricalTroubleshooting,page35forotherpossible

causes.

Hz Hz

Hz

Indicator Indicator

Indicator

TheHzindicatorfunctionsthesameastheES
indicatoronstandardguns.Theindicatorlightsto
showthealternatorspeedstatus,andhasthree
colors:

•Greenindicatesthealternatorspeediscorrect.

•Iftheindicatorchangestoamberafter1second,
increasetheairpressure.

•Iftheindicatorchangestoredafter1second,
reducetheairpressure.

Voltage Voltage

Voltage

Adjustment Adjustment

Adjustment

Switch Switch

Switch

Thevoltageadjustmentswitch(VA)allowsthe
operatortochangefromlowtohighvoltage.

•Thehighvoltagesettingisdeterminedbythe
maximumvoltageofthegunandisnotadjustable.

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

AdjustingtheLowVoltageSetting,page10.

NOTE: NOTE:

NOTE:

IftheErrordisplayappears,theSmartmodule
haslostcommunicationwiththepowersupply.See

ErrorDisplay,page10,forfurtherinformation.

Figure2SmartGunModuleinOperatingMode

3A2494D 9

GunOverview

Error Error

Error

Display Display

Display

IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3,andTable1onpage10.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page35.
CommunicationmustberestoredtomaketheSmart
modulefunctional.

NOTE: NOTE:

NOTE:

Ittakes8secondsfortheErrordisplayto
appear.Ifthegunhasbeendisassembled,wait8
secondsbeforesprayingtoensurethatanError
conditionhasnotoccurred.

NOTE: NOTE:

NOTE:

Ifthereisnopowertothegun,theError
displaywillnotappear.

Figure3ErrorDisplay

Adjusting Adjusting

Adjusting

the the

the

Low Low

Low

Voltage Voltage

Voltage

Setting Setting

Setting

Thelowvoltagesettingisuseradjustable.Toaccess
thelowvoltagesettingscreenwheninOperating
Mode,presstheLOSETbutton(LS)momentarily.
Thescreenwilldisplaythecurrentlowvoltage
setting.SeeFig.4,andTable1onpage10.The
possiblerangesare:

•85kVguns:40–85kV

•60kVguns:30–60kV

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

foryourgun.Continuepressingthebuttonuntilyou
reachthedesiredsetting.

NOTE: NOTE:

NOTE:

After2secondsofinactivitythedisplaywill

returntotheOperatingScreen.

NOTE: NOTE:

NOTE:

Thelowvoltagesettingmaybelocked.See

LockSymbol,page10.

Figure4LowVoltageSettingScreen(Unlocked)

Lock Lock

Lock

Symbol Symbol

Symbol

Thelowvoltagesettingmaybelocked.Whenlocked,
animage(LK)appearsonthescreen.SeeFig.5,
andTable1onpage10.

•WheninHImode,thelowvoltagesettingisalways always

always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.

•WheninLOmode,thelocksymbolwill
only only

only

appearifthelockisenabled.See

LowVoltageLockScreen,page14,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

10 3A2494D

GunOverview

Table Table

Table

1 11. ..Key Key

Key

for for

for

Figs. Figs.

Figs.

2–9. 2–9.

2–9.

Item Item

Item

Description Description

Description

Purpose Purpose

Purpose

VA

VoltageAdjustmentSwitch

Two-positionswitchsetssmart
gunvoltagetolowsetting(LO)or
highsetting(HI).Thisswitchis
functionalinOperatingModeand
inDiagnosticMode.

LO

LowVoltageModeIndicator

Lights(blue)whenthesmartgun
issettoLowVoltage.

kV

Voltage(kV)Display

Displaysactualsprayingvoltage
ofthegun,inkV.InOperating
Mode,displayisabargraph.
InDiagnosticMode,voltageis
displayedasanumber.

uA

Current(uA)Display

Displaysactualsprayingcurrent
ofthegun,inuA.InOperating
Mode,displayisabargraph.
InDiagnosticMode,currentis
displayedasanumber.

LSLOSETbutton

Pressmomentarilytoenterthe
LowVoltageSettingscreen.

Pressandholdforapproximately5
secondstoenterorexitDiagnostic
Mode.

WhileinDiagnosticMode,press
momentarilytoadvancethrough
screens.

WhileontheLowVoltageLock
Screen(inDiagnosticMode),
pressandholdtoturnthelockon
oroff.

LVLowVoltageDisplayDisplaysthelowvoltagesetting

asanumber.Thesettingcanbe
changed.SeeFig.4.

LKLowVoltageLocked

Appearsifthelowvoltagesetting
islocked.SeeFig.5andFig.9.

3A2494D

11

GunOverview

Item Item

Item

Description Description

Description

Purpose Purpose

Purpose

LD

LODisplay

AppearsontheLowVoltageLock
Screen.SeeFig.9.

ERErrorDisplay

AppearsiftheSmartmoduleloses
communicationwiththepower
supply.SeeFig.3.

VIVoltageIndicatorInDiagnosticMode,thetwotop

rightLEDsofthescreenlight,
indicatingthatthevaluedisplayed
isinkV.SeeFig.6.

CICurrentIndicator

InDiagnosticMode,thetwo
bottomrightLEDsofthescreen
light,indicatingthatthevalue
displayedisinuA.SeeFig.7.

ASAlternatorSpeedDisplay

InDiagnosticMode,Hzlevelis
displayedasanumber.SeeFig.

8.

Hz

AlternatorSpeedIndicatorInOperatingMode,indicatorcolor

variestoshowthealternator
speedstatus:

•greenindicatesthealternator
speedisatthecorrectlevel.

•Iftheindicatorchangestoamber
after1second,thealternator
speedistoolow.

•Iftheindicatorchangestored
after1second,thealternator
speedistoohigh.Theindicator
willalsoturnrediftheError
displayappears.

InDiagnosticMode,theindicator
isgreenwhenintheAlternator
Speed(Hertz)screen.

12

3A2494D

GunOverview

Diagnostic Diagnostic

Diagnostic

Mode Mode

Mode

DiagnosticModeincludesfourscreenswhichdisplay
gundata:

•Voltage(kiloVolts)Screen

•Current(microAmperes)Screen

•AlternatorSpeed(Hertz)Screen

•LowVoltageLockScreen

NOTE: NOTE:

NOTE:

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

ToenterDiagnosticMode,pressandholdtheLOSET
(LS)buttonforapproximately5seconds.Thedisplay
willgototheVoltage(kiloVolts)Screen,page13.

Toadvancetothenextscreen,presstheLOSET
buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.

NOTE: NOTE:

NOTE:

IfthegunisdetriggeredwhileinDiagnostic
Mode,thelastscreenviewedwillbedisplayedwhen
thegunisretriggered.

NOTE: NOTE:

NOTE:

DiagnosticModecannotbeexited
fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page14fordetails.

Voltage Voltage

Voltage

(kiloVolts) (kiloVolts)

(kiloVolts)

Screen Screen

Screen

TheVoltage(kiloVolts)Screenisthe󰘰rstscreento
appearafterenteringDiagnosticMode.SeeFig.6,
andTable1onpage10.Toenterthisscreen,press
andholdtheLOSETbuttonforapproximately5
secondswhileintheOperatingMode.

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

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page13.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

Figure6Voltage(kiloVolts)Screen

Current Current

Current

(microAmperes) (microAmperes)

(microAmperes)

Screen Screen

Screen

TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7,andTable
1onpage10.Toenterthisscreen,presstheLO
SETbuttonwhileintheVoltage(kiloVolts)Screen.

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

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page14.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

Figure7Current(microAmperes)Screen

3A2494D 13

GunOverview

Alternator Alternator

Alternator

Speed Speed

Speed

(Hertz) (Hertz)

(Hertz)

Screen Screen

Screen

TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8,andTable
1onpage10.Toenterthisscreen,presstheLOSET
buttonwhileintheCurrent(microAmperes)Screen.

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

TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page14.Pressandhold

forapproximately5secondstoreturntoOperating
Mode.

Figure8AlternatorSpeed(Hertz)Screen

Low Low

Low

Voltage Voltage

Voltage

Lock Lock

Lock

Screen Screen

Screen

TheLowVoltageLockScreenisthefourthscreenin
theDiagnosticMode.SeeFig.9,andTable1on
page10.Toenterthisscreen,presstheLOSET
buttonwhileintheAlternatorSpeed(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:

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

Figure9LowVoltageLockScreen

14

3A2494D

Installation

Installation Installation

Installation

Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.

•Donotinstallorservicethisequipmentunless
youaretrainedandquali󰘰ed.

•Besureyourinstallationcomplieswithlocal,
state,andnationalcodesfortheinstallation
ofelectricalapparatusinaClassI,Div.I,
HazardousLocationoraGroupII,ZoneI
ExplosiveAtmosphereLocation.

•Complywithallapplicablelocal,state,and
national󰘰re,electrical,andothersafety
regulations.

Fig.10showsatypicalelectrostaticairspraysystem.
Itisnotanactualsystemdesign.Forassistance
indesigningasystemtosuityourparticularneeds,
contactyourGracodistributor.

Warning Warning

Warning

Sign Sign

Sign

Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.

Ventilate Ventilate

Ventilate

the the

the

Spray Spray

Spray

Booth Booth

Booth

Providefreshairventilationtoreducetheriskof󰘰re
orexplosioncausedbythebuildupof󰘱ammableor
toxicvaporswhenspraying,󰘱ushing,orcleaning
thegun.Donotoperatethegununlessventilation
fansareoperating.

Electricallyinterlockthegunairsupplywiththe
ventilatorstopreventgunoperationwithout
ventilatingfansoperating.Checkandfollowalllocal,
state,andnationalcodesregardingairexhaust
velocityrequirements.

Highvelocityairexhaustwilldecreasetheoperating
ef󰘰ciencyoftheelectrostaticsystem.Airexhaust
velocityof100ft/min(31linearmeters/minute)should
besuf󰘰cient.

3A2494D 15

Installation

Air Air

Air

Supply Supply

Supply

Line Line

Line

Toreducetheriskofelectricshock,theairsupply
hosemustbeelectricallyconnectedtoatrueearth
ground.Use Use

Use

only only

only

Graco Graco

Graco

Grounded Grounded

Grounded

Air Air

Air

Supply Supply

Supply

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.

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.

Fluid Fluid

Fluid

Supply Supply

Supply

Line Line

Line

1.Blowoutthe󰘱uidline(FL)withairand󰘱ushit
withsolvent.Usesolventwhichiscompatible
withthe󰘱uidtobesprayed.Donotconnectthe
󰘱uidsupplylinetothegun󰘱uidinletyet.

2.Installa󰘱uidregulator(FR)onthe󰘱uidlineto
control󰘱uidpressuretothegun.

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

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

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

16 3A2494D

Installation

NON NON

NON

- --HAZARDOUS HAZARDOUS

HAZARDOUS

AREA AREA

AREA

HAZARDOUS HAZARDOUS

HAZARDOUS

AREA AREA

AREA

Figure10TypicalInstallation

Typical Typical

Typical

Installation Installation

Installation

Key Key

Key

Item Item

Item

Description Description

Description

ADAirLineDrainValve

AF

AirFilter/WaterSeparator

AG*GunAirHoseGroundWire

AH*GracoGroundedAirHose(left-hand

threads)

ALPumpAirLineLubricator

BV*PumpBleed-TypeAirShutoffValve

EGElectrostaticAirSprayGun

FD*

FluidDrainValve

FFFluidFilter

FL

FluidSupplyLine

FRFluidPressureRegulator

Item Item

Item

Description Description

Description

FV

FluidShutoffValve

GRGunAirPressureRegulator

MA

MainAirSupplyLine

PG*PumpGroundWire

PRPumpAirPressureRegulator

SPSupplyPump

SV*VentilationFanInterlockSolenoidValve.

NOTE: NOTE:

NOTE:

Thesolenoidvalveisnotoffered

asaGracoaccessory.

*Theseitemsarerequiredforsafeoperation.They
mustbepurchasedseparately.

3A2494D

17

GunSetup

Gun Gun

Gun

Setup Setup

Setup

Gun Gun

Gun

Setup Setup

Setup

Checklist Checklist

Checklist

SeeFig.11tolocatetheelectrostaticguncontrols.

Figure11ElectrostaticGunControls

1.Thegunisshippedwiththe󰘱uidnozzleandair
capinstalled.Checkthattheretainingringis
tight.

NOTE: NOTE:

NOTE:

Toselectadifferent
size󰘱uidnozzleoraircap,see

FluidNozzleSelectionChart,page68and
AirCapSelectionChart,page70.To

installthenozzleandaircap,see

AirCapandNozzleReplacement,page38.

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

3.Shutofftheairbleedvalvetothegun.

4.Checkgunresistance.See

TestGunResistance,page31.

5.ConnecttheGracogroundedairhosetothegun
airinlet.Thegunairinlet󰘰ttinghasleft-hand
threads.

6.FollowallstepsunderGrounding,page21.

7.Followallstepsunder

CheckGunElectricalGrounding,page25.

Readingmustbelessthan1megohm.

8.Verifythatthematerialresistivitymeets
requirementsforelectrostaticspray.See

CheckFluidResistivity,page26.

9.Connecttheexhausttubeandsecurewiththe
clampprovided.

10.Connectthe󰘱uidhosetothegun󰘱uidinlet.

11.Flushifneeded,seeFlushing,page28.

12.Positiontheaircapasdesired.

18 3A2494D

GunSetup

13.Fullyopenthefanairadjustmentvalve(F)
counterclockwise.

14.Fullyopenthe󰘱uidadjustmentvalve(H)
counterclockwise.

15.Fullyopentheatomizingairrestrictorvalve(G)
clockwise.

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

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

Table Table

Table

2 22. ..Pressure Pressure

Pressure

Drop Drop

Drop

Air Air

Air

Hose Hose

Hose

Length Length

Length

in ininft ftft(m) (m)

(m)

(using (using

(using

5/16 5/16

5/16

in. in.

in.

[8 [8

[8

mm] mm]

mm]

diameter diameter

diameter

hose) hose)

hose)

Air Air

Air

Regulator Regulator

Regulator

Setting Setting

Setting

in ininpsi psi

psi

(MPa, (MPa,

(MPa,

bar) bar)

bar)

[with [with

[with

gun gun

gun

triggered] triggered]

triggered]

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.CheckthattheESindicator(K)[Hzindicatoron
Smartguns]islit.Seethefollowingtable.

Table Table

Table

3 33. ..LED LED

LED

Indicator Indicator

Indicator

Colors Colors

Colors

Indicator Indicator

Indicator

Color Color

Color

Description Description

Description

Green

Whenspraying,theindicator
shouldremaingreen,indicating
suf󰘰cientairpressuretothe
alternatorturbine.

Amber

Iftheindicatorchangestoamber
after1second,theairpressure
istoolow.Increaseairpressure
untiltheindicatorisgreen.

Red

Iftheindicatorchangestored
after1second,theairpressureis
toohigh.Decreaseairpressure
untiltheindicatorisgreen.

3A2494D 19

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.

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

22.Sprayatestpattern.Checktheatomization.If
over-atomizationoccursatminimumpressure,
adjusttherestrictorvalve.Ifatomizationis
inadequate,increaseairpressureordecrease
󰘱uid󰘱ow.

23.Adjustthefanairadjustmentvalve:clockwisefor
anarrowerpattern,counterclockwiseforawider
pattern.

24.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page33.

20 3A2494D

GunSetup

Grounding Grounding

Grounding

Whenoperatingtheelectrostaticgun,any
ungroundedobjectsinthesprayarea(people,
containers,tools,etc.)canbecomeelectrically
charged.Impropergroundingcanresultinstatic
sparking,whichcancausea󰘰re,explosion,or
electricshock.Groundallequipment,personnel,
objectbeingsprayed,andconductiveobjects
inorclosetothesprayarea.Resistancemust
notexceed1megohm.Followthegrounding
instructionsbelow.

Thefollowingareminimumgroundingrequirements
forabasicelectrostaticsystem(seeFigs.12–15).
Yoursystemmayincludeotherequipmentorobjects
whichmustbegrounded.Checkyourlocalelectrical
codefordetailedgroundinginstructions.Yoursystem
mustbeconnectedtoatrueearthground.

•

Pump/󰘱uid source:

groundthepump/󰘱uidsource
byconnectingitsgroundwiretoatrueearth
ground.

•

Electrostatic Air Spray Gun:

groundthegun
byconnectingtheGracoGroundedAirHose
(AH)tothegun,andconnectingtheairhose
groundwiretoatrueearthground.See

CheckGunElectricalGrounding,page25.

•

Object being sprayed:

keeptheworkpiecehangers

cleanandgroundedatalltimes.

•

All electrically conductive objects or devices in the
spray area:

mustbeproperlygrounded.

•

Fluid and waste containers:

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

•

Air compressors:

groundtheequipmentaccording

tothemanufacturer'srecommendations.

•

All air and 󰘱uid lines

mustbeproperlygrounded.
Useonlygroundedhoseswithamaximumof100
feet(30.5m)combinedhoselengthtoensure
groundingcontinuity.

3A2494D

21

GunSetup

•

The 󰘱oor of the spray area:

mustbeelectrically
conductiveandgrounded.Donotcoverthe󰘱oor
withcardboardoranynon-conductivematerial
whichwouldinterruptgroundingcontinuity.

•

Flammable liquids in the spray area:

mustbekept
inapproved,groundedcontainers.Donotuse
plasticcontainers.Donotstoremorethanthe
quantityneededforoneshift.

•

All persons entering the spray area:

mustwear
shoeshavingconductivesolessuchasleather,
orwearpersonalgroundingstraps.Donot
wearshoeswithnon-conductivesolessuchas
rubberorplastic.Ifglovesarenecessary,wear
theconductiveglovessuppliedwiththegun.If
non-Gracoglovesareworn,cutoff󰘰ngersorpalm
areaofglovestoensureyourhandcontactsthe
groundedgunhandle.

Key Key

Key

to totoFigs. Figs.

Figs.

12–15 12–15

12–15

Fig.12

Operatorisgroundedthrough
bareskincontactwiththegun
handleandconductiveshoes.A
conductiveglovecanalsobeused.

Fig.13

Objectbeingsprayedisgrounded
throughcontactwiththehanger
andconveyorsystem.

Fig.14

Gunisgroundedthroughthe
conductiveairhose.

Fig.15Fluidsupplylineandsourcemust

begrounded.

22

3A2494D

GunSetup

Figure12GroundtheOperator

Figure13GroundtheObjectBeingSprayed

3A2494D 23

GunSetup

Figure14GroundtheGun

Figure15GroundtheFluidSupply

24

3A2494D