Graco Inc UNICARB 308936, UNICARB 965722, AA4500 User Manual
INSTRUCTIONS-PARTS LIST
308936
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
First choice when
quality counts.
Supersedes Rev. A
85 KV ELECTROSTATIC
Model PRO AA4500/UNICARB
Air-Assisted Spray Gun
100 psi (7 bar, 0.7 MPa) Maximum Working Air Pressure
3000 psi (207 bar, 20.7 MPa) Maximum Working Fluid Pressure
For use with Class I, Group D paint spray materials
Part No. 965722, Series B
Spray Gun with basic power supply,
2-finger trigger
Rev. B
NOTE: Any modification of genuine Graco parts or replacement of parts with non-Graco parts will void agency approvals.
U.S. Patent No. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774; 5,063,350; 5,080,289; 5,289,977
Patented 1986, 1987 Canada
Brevete 1986, 1987
U.K. Patent No. 2,147,158; 2,142,559B; 2,140,327–B
Other U.S. and Foreign Patents Pending
UNICARB IS A REGISTERED TRADEMARK OF UNION CARBIDE, DANBURY CT.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
01944A
WARNING
FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire, explosion, or electric shock.
Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements stated in this instruction manual.
Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all
other electrically conductive objects in the spray area. See Ground the System on page 8.
Check the spray gun resistance daily. See Test Gun Resistance, page 25.
If there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Interlock the gun
turbine air supply to prevent operation of the power supply unless the ventilating fans are on. See
Ventilate the Spray Booth on page 6.
When cleaning, flushing, or purging electrostatic equipment, use solvents that comply with your
local regulations. For countries following the U.S. National Fire Protection Association (NFPA) 33
requirements, use solvents with a flash point higher than 100 F (38 C) or a solvent normally
used in spray operations. For European Countries complying with EN 50053, use solvents with a
flash point as high as possible and higher than the ambient temperatures.
Use only non-sparking tools to clean residue from the booth and hangers.
Do not flush the system with the gun electrostatics turned on.
Do not turn on the gun electrostatics until all solvent is removed from the system.
Extinguish all open flames or pilot lights in the spray area.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Do not store any flammable fluids in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not smoke in the spray area.
Do not operate a gasoline engine in the spray area.
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all
local, state, and national guidelines.
Wear appropriate protective clothing, gloves, eyewear, and respirator.
2 308936
WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an
extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause a serious injury.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
Do not point the spray gun at anyone or any part of the body.
Do not put hand or fingers over the spray tip.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard on the spray gun when spraying.
Check the gun diffuser operation weekly.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 10 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
INSTRUCTIONS
Tighten all the fluid connections before operating the equipment.
Check the hoses, tubes and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
in a serious injury.
This equipment is for professional use only.
Read all the instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 100 psi (7 bar, 0.7 MPa) maximum working air pressure and 3000 psi (207 bar,
20.7 MPa) maximum working fluid pressure.
Use fluids that are compatible with the equipment wetted parts. See the Technical Data section of
all the equipment manuals. Read the fluid manufacturer’s warnings.
Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180F (82C) or below –40F (–40C).
Do not use the hoses to pull equipment.
Wear hearing protection when operating this equipment.
Comply with all applicable local, state, and national fire, electrical, and other safety regulations.
308936 3
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the System 6. . . . . . . . . . . . . . . . . . . . . . . .
Warning Signs 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilate the Spray Booth 6. . . . . . . . . . . . . . . . . . . .
Air Line Accessories 6. . . . . . . . . . . . . . . . . . . . . . . .
Fluid Line Accessories 7. . . . . . . . . . . . . . . . . . . . . . .
Ground the System 8. . . . . . . . . . . . . . . . . . . . . . . . .
Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Checklist 9. . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 10. . . . . . . . . . . . . . . . . .
Gun Setup 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily Gun Care, Flushing, and Cleaning 17. . . . . . .
Spray Pattern Troubleshooting 22. . . . . . . . . . . . . . . .
Gun Operation Troubleshooting 23. . . . . . . . . . . . . . .
Electrical Troubleshooting 24. . . . . . . . . . . . . . . . . . . .
Fluid Packing Adjustment 33. . . . . . . . . . . . . . . . . . .
Fluid Needle Assembly Removal 34. . . . . . . . . . . . .
Power Supply Removal and Replacement 35. . . . .
Power Supply Adjustment 35. . . . . . . . . . . . . . . . . . .
Turbine Alternator Removal and Replacement 36.
Barrel Installation 36. . . . . . . . . . . . . . . . . . . . . . . . . .
ES ON-OFF Valve Repair 37. . . . . . . . . . . . . . . . . . .
Air Control Valve Repair 38. . . . . . . . . . . . . . . . . . . .
Air Valve Repair 39. . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip Selection Chart 47. . . . . . . . . . . . . . . . . . . . .
Pre-orifice Selection Chart 47. . . . . . . . . . . . . . . . . . . .
The Graco Warranty and Disclaimers 48. . . . . . . . . .
Graco Phone Number 48. . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Electrical Tests 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Gun Resistance 25. . . . . . . . . . . . . . . . . . . . . . .
Test Power Supply Resistance 26. . . . . . . . . . . . . . .
Test Barrel Resistance 27. . . . . . . . . . . . . . . . . . . . . .
Service 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prepare the Gun for Service 28. . . . . . . . . . . . . . . . .
Tools Needed 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Orifice, Tip Guard, Air Cap, Spray Tip,
or Seat Housing Replacement 29. . . . . . . . . . . . . .
Electrode Replacement 30. . . . . . . . . . . . . . . . . . . . .
Fluid Tube Removal & Replacement 31. . . . . . . . . .
Fluid Filter Removal 31. . . . . . . . . . . . . . . . . . . . . . . .
Barrel Removal 32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.
4 308936
Introduction
How the PRO AA4500/UNICARB
Electrostatic Air-Assisted Spray Gun
Operates
WARNING
Remember, this is not an air spray gun; for your
safety be sure to read and follow the Warnings on
pages 2 to 3 and throughout the text of this
instruction manual.
The spray tip shapes the fluid into a fan pattern.
As the gun is triggered, the regulated air is directed to
the power cartridge turbine.
The air control valve does not control pattern width. To
change pattern width, a new tip size must be used.
Tip Guard
(orange)
The ability of the PRO AA4500/UNICARB Electrostatic
Spray Gun to spray at higher fluid pressures, combined with the addition of CO
process, provides the additional power needed to
atomize higher solids materials.
The gun’s internal power cartridge provides high
voltage current. The fluid is electrostatically charged as
it passes the gun’s electrode. The charged fluid is
attracted to the grounded object, wrapping around and
evenly coating all surfaces.
NOTE: The gun’s air control valve must be completely
turned off to have airless atomization. Closing the air
control valve does not effect the operation of the
turbine.
Power Supply’s Adjustable Lower Voltage Setting
The gun’s lower voltage setting (LO) is adjustable. The
LO setting can be adjusted from 45 to 80 kV; it is
preset by the factory at 60 kV. See page 35 to change
the setting. NOTE: The gun’s full (HI) voltage setting is
85 kV.
2
from the UNICARB
ES Indicator
Light
Air Control
Valve
Air
Cap
(black)
Spray
Tip
(orange)
Retaining
Nut
Trigger Safety
Latch
01944A
ES ON-OFF
Lever
Back View of Gun
308936 5
ES HI-LO
Lever
01947
Installation
Installing the System
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
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 equip-
ment unless you are trained and
qualified.
Be sure your installation complies with National,
State and Local codes for the installation of
electrical apparatus in a Class I, Group D
Hazardous Location.
Comply with all applicable local, state, and
national fire, electrical, and other safety regulations.
Ventilate the Spray Booth
WARNING
FLAMMABLE OR TOXIC
VAPOR HAZARD
Provide fresh air ventilation to avoid the
buildup of flammable or toxic vapors. Do
not operate the gun unless ventilation
fans are operating.
Electrically interlock the gun air supply with the ventilators to prevent gun operation without ventilating fans
operating. Check and follow all National, State, and
Local codes regarding air exhaust velocity
requirements.
NOTE: High velocity air exhaust will decrease the
operating efficiency of the electrostatic system. Air
exhaust velocity of 100 ft/min (31 linear meters/minute)
should be sufficient.
Air Line Accessories (Refer to Fig. 1)
1. Install an air shut-off valve ( P) on each gun air
supply line (Q) to shut off air to the gun(s).
Fig. 1 shows a typical electrostatic UNICARB spray
system. It is not an actual system design. The particular type and size system for your operation must be
custom designed for your needs. For assistance in
designing a system, contact your Graco distributor.
Warning Signs
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. Additional
English, French, German, and Spanish signs are
available at no charge. See Accessories to order
them.
2. Install an air regulator (N) on the gun air supply
line to control air pressure to the gun.
3. Install an air line filter (B) on the air supply line to
ensure a dry, clean air supply to the gun. Dirt and
moisture can cause the gun to malfunction.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of serious injury due
to component rupture, supply pressure
must be limited.
The fluid supply system must be prevented from
producing a fluid pressure greater than the 3000
psi (207 bar, 20.7 MPa) Maximum Working Pres-
sure of the spray gun.
6 308936
Installation
A
S
R
KEY
A* Bleed-type Air Shutoff Valve
B Air Line Filter
H Fluid Shutoff Valve
K Pressure Gauge
L* Grounded Braid Type Fluid Hose
with spring guards
M Gun Fluid Inlet (1/4 npsm)
HK
L
R
Y
N Gun Air Regulator
P Gun Air Shut-off Valve
Q* Graco Electrically Conductive
Air Supply Hose
(1/4 npsm x 1/4 npsm LH)
R* Fluid Drain Valve
S Fluid Filter
N
B
P
W
Q
X
W PRO AA4500/UNICARB Spray Gun
X Gun Air Inlet (1/4 npsm LH)
Y Shrouded/Vented Waste Container
* Equipment required for safe operation of
system. Must be purchased separately.
See ACCESSORIES.
M
WARNING
SIGN
01945B
Fig. 1
Fluid Line Accessories (Refer to Fig. 1)
1. Install a fluid filter (S) and drain valve (R) at the
pump outlet. Filtering the fluid will help remove
coarse particles and sediment that could clog the
spray tip.
WARNING
INJECTION HAZARD
The fluid drain valve (R) is required in
your system to assist in relieving fluid
pressure in the supply system, hose and
gun; triggering the gun to relieve pressure may not
be sufficient. Install a drain valve close to the
pump’s fluid outlet. The drain valve reduces the risk
of serious injury, including fluid injection and
splashing in the eyes or on the skin.
2. Install a fluid regulator (J) on the fluid line to control fluid pressure to the gun.
308936 7
Installation
Ground the System
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
When operating the electrostatic device,
any ungrounded objects in the spray
area (such as people, containers, tools,
etc.) can become electrically charged.
Improper grounding can result in static
sparking, which can cause a fire, explosion, or electric shock. Follow the
grounding instructions below.
The following are minimum requirements for grounding
a basic electrostatic system. Your system may include
other equipment or objects which must be grounded.
Check your local electrical code for detailed grounding
instructions. Your system must be connected to a true
earth ground.
1. Pump: ground the pump by connecting a ground
wire and clamp as described in your separate
pump instruction manual.
4. All air and fluid lines must be properly grounded.
Use only grounded hoses with a maximum of 500
feet (150 m) combined hose length to ensure
grounding continuity.
5. All electric cables must be properly grounded.
6. All persons entering the spray area: their shoes
must have conductive soles, such as leather, or
personal grounding straps must be worn. Rubber
or plastic soles are not conductive. The operator
must not wear gloves that insulate the hand from
the spray gun. The gloves must be conductive or
modified as shown in Fig. 2, page 9.
7. Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Contact points
must be sharp points or like knife edges.
8. 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.
2. Air compressors and hydraulic power supplies:
ground the equipment according to the manufacturer’s recommendations.
3. Electrostatic Spray Gun: ground the gun by connecting the Graco Electrically Conductive Air Hose
and connecting the air hose ground wire to a true
earth ground. Check the electrical grounding of the
gun as instructed on page 12.
9. Flammable liquids in the spray area: must be kept
in approved, grounded containers. Do not store
more than the quantity needed for one shift.
10. All electrically conductive objects or devices in the
spray area: including fluid containers and wash
cans, must be properly grounded.
8 308936
Operation
Operating Checklist
Check the following list daily, before starting to operate
the system, to help ensure safe, efficient operation.
____ 1. All the operators are properly trained to
safely operate an electrostatic air-assisted
airless spray system as instructed in this
manual.
____ 2. All the operators are trained how to properly
relieve pressure, using the Pressure Relief
Procedure on page 10.
____ 3. The system is thoroughly grounded and the
operator and all persons entering the spray
area are properly grounded. See Ground
the System, page 8.
____ 4. The warning sign provided with the gun is
mounted in the spray area where it can be
easily seen and read by all operators.
____ 5. The operator and all persons entering the
spray area are properly grounded by wearing
shoes with conductive soles or personal
grounding straps.
WARNING
INJECTION HAZARD
Be sure the wallet sized warning card
179960, provided with the gun, is avail-
able and easily accessible, at all times,
for anyone operating or servicing this equipment.
The card contains important information on what to
do if an injection injury occurs. Additional cards are
available at no charge from Graco.
____ 6. The operator is not wearing gloves which
insulate the hand from the spray gun. If
worn, gloves must be conductive or modified
as shown in Fig. 2 so as not to interfere with
the operator grounding through the gun.
____ 7. The condition of the electrical components of
the spray gun has been checked as
instructed in Electrical Tests, page 25.
____ 8. The ventilation fans are operating properly.
____ 9. The workpiece hangers are clean and
grounded. Contact points must be sharp
points or like knife edges.
____ 10. All the debris, including flammable liquids
and rags, is removed from the spray area.
____ 11. All flammable liquids in the spray booth are
in approved, grounded containers.
____ 12. All conductive objects in the spray area are
electrically grounded and the floor of the
spray area is electrically conductive and
grounded.
3 in. (76 mm) square cut out and finger of glove cut off
NOTE: If gloves are worn, they must be conductive or
modified as shown so they do not interfere with operator
grounding through the gun.
Fig. 2
06445
308936 9
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid or electric
shock, follow the Pressure Relief Procedure
whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tip.
1. Lock the spray gun trigger safety latch. See Fig. 3.
2. Turn the ES ON-OFF lever to OFF.
Trigger Safety
Latch Unlocked
3. Turn off the fluid supply to the gun.
4. Close the bleed-type master air valve (required in
system).
5. Close the air valve for the gun air supply line.
6. Unlock the gun trigger safety latch.
7. Trigger the gun into a grounded, shrouded and
vented metal waste container to relieve fluid and
air pressure. This may take several minutes.
8. Lock the gun trigger safety latch again.
9. Open the fluid drain valve (required in system) to
help relieve fluid pressure. In addition, open the
drain valve connected to the fluid pressure gauge
(in a system with fluid regulation) to help relieve
fluid pressure in the hose and gun. Triggering the
gun to relieve pressure may not be sufficient. Have
a container ready to catch the drainage.
10. Leave the drain valve(s) open until you are ready
to spray again.
11. If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully
relieved after following the steps above, very
slowly loosen the hose end coupling and relieve
pressure gradually, then loosen completely. Now
clear the tip or hose obstruction.
Fig. 3
Trigger Safety
Latch Locked
01988A
10 308936
Gun Setup
1. Complete the Operating Checklist and
follow the Warnings on pages 9 and 10.
2. Connect the Graco air hose.
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of electric shock or
other serious injury, the air supply hose
must be electrically connected to a true
earth ground. Use Only Graco Electrically Con-
ductive Air Supply Hose.
NOTE: The Graco air hose and the gun have special
left-hand threads to prevent connecting another type of
air supply hose to the gun air inlet and is available in
lengths ranging from 6 to 100 feet (1.83 to 30.5 m).
See Accessories to order the hose.
A. Connect the 1/4 npsm(f) left-hand end of the
Graco conductive air supply hose (A) to the gun air
fitting (17).
B. Connect the other end of the air supply hose (A) to
a filtered and regulated air supply line (B).
C. Connect the air supply hose ground wire (C) to a
true earth ground.
C
B
A
Fig. 2B-C
NOTE: To connect two or more air hoses, use air
adapter nipple 185493. See Accessories.
Continued on the next page.
01990
Left-hand thread
Fig. 2A
17
A
01989A
308936 11
Gun Setup
3. Check the gun’s electrical grounding.
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
Megohmmeter P/N 218979 (E) is not
approved for use in a hazardous area.
To reduce the risk of sparking, do not
use the megohmmeter to check electrical grounding unless:
The gun has been removed from the
hazardous area;
Or all spraying devices in the hazardous area
are turned off, ventilation fans in the hazardous
area are operating, and there are no flammable
vapors in the area (such as open solvent containers or fumes from spraying).
Failure to follow this warning could cause fire,
explosion, electric shock and result in serious injury
and property damage.
F. If the resistance is greater than the maximum
reading specified above for your hose, check the
tightness of the ground connections and be sure
the air hose ground wire is connected to a true
earth ground. If the resistance is still too high, replace the air hose.
A
7
D
A. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
B. Turn the ES ON-OFF Lever to OFF.
C. Turn off the air and fluid supply to the gun. The
fluid hose must not have any fluid in it.
D. Make sure the air hose (A) is connected and the
hose ground wire is connected to a true earth
ground.
E. Measure the resistance between the gun handle
(7) and a true earth ground (D).
a. If using a black or grey air hose, use a me-
gohmmeter E) to measure the resistance. Use
an applied voltage of 500 minimum to 1000
volts maximum. The resistance should not
exceed 2 megohms.
E
Fig. 3D–E
01946A
4. Connect the gun exhaust tube.
Press the exhaust tube (56) onto the barbed adapter
on the bottom of the gun handle. Secure the tube with
the clamp (57) provided.
56
b. If using a red turbine air hose, use an ohmme-
ter to measure the resistance. Resistance
should not exceed 100 ohms.
12 308936
Fig. 4
57
01992A
Gun Setup
5. Connect the fluid hose.
A. Before connecting the fluid line, blow it out with air
and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.
B. Connect the static-free fluid hose (F) to the 1/4–18
npsm gun fluid fitting (10).
10
F
Fig. 5B
NOTE: The PRO AA4500 spray gun has a 100 mesh
in-line fluid inlet filter. A 60 mesh filter is also available.
See Accessories.
C. Connect the other end of the fluid hose (F) to a
grounded, filtered, and regulated fluid line (G).
01993A
6. Flush the spray gun.
Before running any paint through the spray gun, make
sure the trigger safety latch is in the locked position,
and the ES ON-OFF lever is turned to OFF, then
remove the spray tip. Flush the gun out with a solvent
that is compatible with the fluid to be sprayed, using
the lowest possible pressure.
7. Follow the Pressure Relief Procedure.
WARNING
INJECTION HAZARD
To reduce the risk of a fluid injection
injury, always follow the Pressure Relief
Procedure on page 10 before removing
or installing the spray tip, pre-orifice air cap or tip
guard.
8. Select a spray tip.
The fluid output and pattern width depend on the size
of the spray tip, the fluid viscosity, and the fluid pressure. Use the Spray Tip Selection Chart on page 47,
as a guide for selecting an appropriate spray tip for
your application or consult your authorized Graco
distributor. The orifice size of the spray tip is typically
one or two sizes larger than the pre-orifice size
selected below.
Fig. 5C
G
9. Select a pre-orifice
The fluid flow rate in UNICARB systems is controlled
by the pre-orifice size, in conjuction with the fluid
pressure. Use the pre-orifice selection chart on page
47 as a guide for selection.
F
01994A
308936 13
Gun Setup
10.Install the pre-orifice
WARNING
To reduce the risk of a serious injury, including fluid
injection, follow the Pressure Relief Procedure on
page 10 when you stop spraying and whenever you
are instructed to relieve the pressure.
A. Place the spray tip seal (9a) on a flat surface.
B. Note that the hole through the pre-orifice (9b) is
larger on one side than the other.
C. Place the pre-orifice (9b), with its larger hole facing
up, on top of the tip seal (9a) hole.
D. Use a large, flat object to press the pre-orifice (9b)
into the tip seal (9a).
PRESS DOWN
with a large, flat
object
9b
9a
A. Make sure there is no pressure in the system
before removing or installing a spray tip. Relieve
the system pressure.
B. Place the spray tip (9) in the air cap (1), aligning
the tab of the tip with the groove in the air cap.
Be careful not to bend the electrode wire (1a).
1
9
Fig. 11B
C. Install the spray tip (9) and air cap (1), tip guard
(2), and retaining nut (8) onto the gun; tighten the
retaining nut firmly.
8800A
Fig. 10A–D
E. Turn over the tip seal and pre-orifice (9a, 9b) and
insert them into the spray tip (9), wih the pre-orifice
side facing down into the spray tip.
9a, 9b
9
Fig. 10E
8799A
8799A
11. Install the spray tip
WARNING
To reduce the risk of a serious injury, including fluid
injection, follow the Pressure Relief Procedure on
page 10 when you stop spraying and whenever you
are instructed to relieve the pressure.
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
To reduce the risk of fire, explosion, and
electric shock, never operate the spray
gun with a bent, damaged or missing
electrode (1a).
1, 9
2
8
02088B
Fig. 11C
14 308936
Gun Setup
12.Set the air pressure.
A. Atomizing air is not used in the UNICARB process.
Close the air control valve (43) by turning it fully
clockwise.
B. Turn the ES ON-OFF lever (26) to ON.
26
ON
Fig. 12A-B
C. Make sure the fluid supply is shut off.
43
close
01947
H
Fig. 12D
01997
Recommended Air Hose Inlet Pressure
Recommended Air
Air Hose Length
6 ft ((1.8 m) 40 psi (2.8 bar)
15 ft (5 m) 43 psi (3.0 bar)
25 ft (8 m) 45 psi (3.1 bar)
36 ft (11 m) 47 psi (3.2 bar)
50 ft (15 m) 50 psi (3.5 bar)
75 ft (23 m) 55 psi (3.8 bar)
100 ft (30.5 m) 60 psi (4.1 bar)
NOTE: Using higher than recommended air pressures
can reduce the life of the turbine/alternator. Lower
pressures can be used but may reduce electrostatic
wrap.
E. Check the voltage output of the gun using a high
voltage probe and meter.
Hose Inlet Pressure
D. Trigger the gun and adjust the air pressure with the
gun air regulator (H); use the Recommended Air
Hose Inlet Pressure chart, below, as a guide.
NOTE: The gun’s normal high voltage reading is 60 to
70 KV. If a ball end high voltage probe is used, the gun
voltage will rise to about 85 KV. This will happen with
all resistive electrostatic guns.
308936 15
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