Haier PRO XS3 User Manual

Instructions

Manual Electrostatic

PRO™ Xs3 and PRO™ Xs4 Air Spray Guns

For use with Class I Group D spray materials.

For use with Class II 2 G spray materials.

0.24 Mj

Important Safety Instructions:

Read all warnings and instructions in this manual. Save these instructions.

See page 2 for Table of Contents and page 3 for List of Models.

100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure

100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure

U.S. Patent 7,226,004

309292L

ti1248a

Standard Model

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

ti1600a

Smart Model

Table of Contents

List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

How the Electrostatic Air Spray Gun Works . . . . 6

Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 7

Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 7

Connect the Air Line . . . . . . . . . . . . . . . . . . . . . . 9

Connect the Exhaust Tube . . . . . . . . . . . . . . . . . 9

Connect the Fluid Line . . . . . . . . . . . . . . . . . . . 10

Filter the Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Select a Fluid Nozzle and Air Cap . . . . . . . . . . 10

244919 HC Conversion Kit . . . . . . . . . . . . . . . . 11

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Check Electrical Grounding . . . . . . . . . . . . . . . . 13

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 14

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 14

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Low Voltage Adjustment (Smart Guns Only) . . 15

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . 16

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 18

Test Power Supply Resistance . . . . . . . . . . . . . 19

Test Electrode Resistance . . . . . . . . . . . . . . . . . 20

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Spray Pattern Troubleshooting . . . . . . . . . . . . . 21

Gun Operation Troubleshooting . . . . . . . . . . . . 22

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 23

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pressure Relief Procedure . . . . . . . . . . . . . . . . 24

Prepare the Gun for Service . . . . . . . . . . . . . . . 25

Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 26

Electrode Replacement . . . . . . . . . . . . . . . . . . . 27

Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 28

Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 29

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 30

Power Supply Removal and Replacement . . . . 31

Turbine Alternator Removal and Replacement . 32 Fluid Tube Removal and Replacement (PRO Xs4

Guns Only) . . . . . . . . . . . . . . . . . . . . . . . . . 32

Fan Air Adjustment Valve Repair . . . . . . . . . . . . 33

Fluid Adjustment Valve Repair . . . . . . . . . . . . . 34

Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . 34

Atomizing Air Restrictor Valve Removal and

Replacement . . . . . . . . . . . . . . . . . . . . . . . . 35

ES ON/OFF Valve Repair . . . . . . . . . . . . . . . . . 35

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 44

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 44

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 45

Miscellaneous Accessories . . . . . . . . . . . . . . . . 45

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 48

2 309292L

List of Models

Part No. Model

244400, Series C

244579, Series C

244575, Series C

244576, Series C

244401, Series C

244580, Series C

PRO Xs3

PRO Xs4

Smart Display

Type of Coatings

Standard High Conductivity

Operation Manual

309294/3W9294/3Z9294

309292L 3

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

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 in this manual.

• Ground the equipment, all personnel in or close to the spray area, the object being sprayed, and all conductive objects in the spray area. See Grounding, page 12.

• Provide fresh air ventilation to avoid buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Interlock the gun air supply to prevent operation unless ventilating fans are on. See Ventilate the Spray Booth on page 7.

• Do not flush with the gun electrostatics on. Do not turn on the gun electrostatics until all solvent is removed from the system.

• If there is any static sparking while using the equipment, stop spraying immediately. Iden- tify and correct the problem.

• Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.

• Check gun resistance daily. See Test Gun Resistance on page 18.

• Use cleaning solvents with the highest possible flash point, preferably above ambient

temperature.

• Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the spray area.

• Use only non-sparking tools to clean residue from the booth and hangers.

• Keep a fire extinguisher in the work area.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

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.

4 309292L

Symbols

WARNING

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 manuals, tags, and labels before operating the equipment.

• Use the equipment only for its intended purpose. If you are uncertain, call your Graco dis-

tributor.

• Do not alter or modify 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. Max-

imum working air and fluid pressure of this equipment is 100 psi (0.7 MPa, 7.0 bar).

• Use fluids and solvents that are compatible with the equipment wetted parts. See the Tech- nical Data section of all equipment manuals. Read the fluid and solvent 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 180°F (82°C) or below -40°F (-40°C).

• Do not kink or overbend hoses or use hoses to pull equipment.

• Wear hearing protection when operating this equipment.

• Comply with all applicable local, state, and national fire, electrical, and other safety regula-

tions.

Pressurized Equipment Hazard

Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin and cause serious injury.

• Do not point the spray gun at anyone or at any part of the body.

• Do not stop or deflect fluid leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure, page 24, when you stop spraying and before clean-

ing, checking, or repairing equipment.

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

• Tighten all fluid connections before each use.

309292L 5

Introduction

I O

Introduction

How the Electrostatic Air Spray Gun Works

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

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

Gun Overview

The electrostatic gun includes the following controls (see F

IG. 1.).

• FLUID adjustment valve. Adjusts fluid rod travel.

Use only in low flow conditions, to reduce wear.

• Fan AIR adjustment valve. Adjusts fan size and

shape.

• Atomizing air RESTRICTOR valve. Restricts

atomizing air flow. Replace with plug (included) if desired.

• ES ON/OFF valve. Turns electrostatics ON (I) or

OFF (0).

• ES INDICATOR (standard gun only). Green when

ES is ON (I).

• Voltage/current DISPLAY (smart models only).

Shows voltage (V) and current (A). Green=spray, yellow/red=see Troubleshooting, page 23.

• ES HI/LO switch (smart models only). Sets volt-

age to HI or LO (factory settings).

• LO VOLTAGE adjustment (smart models only).

Remove plug to adjust to four settings.

ES INDICATOR

ES ON/OFF

RESTRICTOR

Standard Model Smart Model

Fig. 1. Gun Overview

I O

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AIR

FLUID

ES HI/LO

ES ON/OFF

RESTRICTOR

I O

DISPLAY

LO VOLTAGE

100%

μα

AIR

FLUID

ti1253a

6 309292L

Installation

Install 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 equipment

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 or a Class II 2G Hazardous Location.

• Comply with all applicable local, state,

and national fire, electrical, and other safety regulations.

FIG. 2. shows a typical electrostatic air spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.

Warning Sign

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

Ventilate the Spray Booth

WARNING

Flammable or Toxic Vapor Hazard

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. 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.

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.

309292L 7

Installation

ES ON/OFF valve: I is ON, 0 is OFF

I O

B*C*D

The air supply to the gun must be electrically interlocked with the ventilators to pre-

vent the power supply from operating without

ventilating fans on.

Non-Hazardous Area Hazardous Area

Fig. 2. Typical Installation

Key

A Main Air Supply Line B* Ventilation Fan Interlock Solenoid Valve C* Main Air Supply Shutoff Valve (bleed-type) D Pump Air Line Filter/Water Separator E* Pump Air Supply Shutoff Valve (bleed-type) F Air Line Lubricator G Air Pressure Regulator HPump J* Pump Ground Wire K Fluid Filter L Fluid Supply Line Shutoff Valve M Fluid Pressure Regulator

ti1498a

N Fluid Supply Line O Gun Air Line Filter/Water Separator P Gun Air Supply Line Shutoff Valve Q* Air Hose Ground Wire R* Graco Grounded Air Hose S Electrostatic Air Spray Gun T Air Line Drain Valve U* Fluid Drain Valve VGun Air Inlet W Gun Fluid Inlet * Required for safe operation. Must be purchased

separately. NOTE: Solenoid valve (B) is not offered as a Graco accessory.

8 309292L

Installation

Connect the Air Line

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 Grounded Air

Supply Hose.

1. Connect the Graco Grounded Air Supply Hose (R) between the air supply line and the gun's air inlet (V). The gun air inlet fitting has a left-hand thread. Connect the air supply hose ground wire (Q) to a true earth ground.

2. Install an air line filter/water separator (O) on the gun air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

3. Install a bleed-type air regulator (G) on the pump and gun air supply lines to control air pressure to the pump and gun.

4. Install a bleed-type air valve (E) on the pump air line to shut off air to the pump. Install an additional bleed-type air valve (C) on the main air line (A) to isolate the accessories for servicing.

WARNING

Pressurized Equipment Hazard

The bleed-type air valve (E) is required in your system to relieve air trapped between the valve and the pump after the air regulator is shut off. Trapped air can cause the pump to cycle unexpectedly, which can result in serious injury, including splashing fluid in the eyes or on the skin.

5. Install an air shutoff valve ( P) on each gun air supply line to shut off air to the gun(s).

Connect the Exhaust Tube

Press the exhaust tube (38) onto the barbed adapter on the bottom of the gun handle. Secure the tube with the clamp (39).

309292L 9

Installation

Connect the Fluid Line

1. Before connecting the fluid line (N), blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.

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

3. Install a fluid filter (K) and drain valve (U) at the pump outlet.

WARNING

Pressurized Equipment Hazard

The fluid drain valve (U) is required in your system to assist in relieving fluid pressure in the displacement pump, hose, and gun. Triggering the gun to relieve pressure may not be sufficient. Install a drain valve close to the pump's fluid outlet. The drain valve reduces the risk of serious injury, including splashing in the eyes or on the skin.

4. Connect the fluid line to the 3/8 npsm gun fluid inlet (W).

5. Before running any paint through the spray gun, flush it out with a compatible solvent.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the Pressure Relief Procedure on page 24 before removing or installing a fluid nozzle and/or air cap.

Table 1: Fluid Nozzles

Part No. Orifice Size

197263 0.75 mm (.030 in.) 197264 1.0 mm (.042 in.) 197265 1.2 mm (.047 in.) 197266 1.5 mm (.055 in.) 197267 1.8 mm (.070 in.) 197268 2.0 mm (.080 in.) 249920* 0.75 mm (.030 in.) 249921* 1.0 mm (.042 in.) 249922* 1.2 mm (.047 in.) 249923* 1.5 mm (.055 in.) 249924* 1.8 mm (.070 in.) 249925* 2.0 mm (.080 in.)

* Glass-reinforced acetal construction.

Filter the Fluid

Install a fluid filter (K) to remove particles and sediment which could clog the spray nozzle.

Part No.

197477

Select a Fluid Nozzle and Air Cap

The gun is supplied with Part No. 197266 Nozzle and 197477 Air Cap. If you require a different size, refer to Table 1 and Table 2 , and instruction manual 309419, or consult with your Graco distributor. See Air Cap/Nozzle Replacement on page 26.

10 309292L

197478

197479

197480

197481

Table 2: Air Caps

Pattern Shape and Length in. (mm)

Round end; 15-17 (381-432)

Tapered end; 13-15 (330-381)

Round end; 16-18 (406-457)

Tapered end; 17-19 (432-483)

Recommended Fluids and Production Rates

Light to medium viscosity. Medium to high production.

Light to medium viscosity. Low to medium production.

Light to medium viscosity. Medium to high production.

Medium to high viscosity and high solids. Low to medium production.

Medium to high viscosity and high solids. Medium to high production. For use with 2.0 mm nozzle.

Installation

244919 HC Conversion Kit

Part No. 244919 Conversion Kit converts PRO Xs3 standard coating guns (Part Nos. 244400 and 244579) to high conductivity guns (244575 and 244576). For further instruction and parts, see manual 309453.

The kit is for use with fluids with low resistivity values.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the Pressure Relief Procedure in your gun manual before installing this kit.

1. Turn the ES ON/OFF valve OFF.

2. Flush and relieve the pressure.

3. Disconnect the fluid and air lines to the gun.

4. Remove the fluid tube and fittings.

9. Slide the tube case (1e) onto the barrel inlet, over the o-ring (2b). The coiled tube (1a) will compress slightly.

10. Insert the end of the coiled tube (1a) into the bracket (3). Make sure the ferrules (1c, 1b) seat on the bracket.

11. Secure the bracket by tightening the swivel (A). Tighten the nut (1d). Reinstall the exhaust tube (B) and clamp (C).

12. Reconnect the fluid and air lines to the gun.

5 2a

5. Remove the fluid inlet bracket.

6. Install the new bracket (3) from the kit loosely. See F

IG. 3.

7. Place the spacer (5) in the barrel inlet. Apply Graco dielectric grease (4) to the o-rings (2a, 2b) and to both threads of the fluid fitting (2). Thread the fitting into the barrel inlet.

8. Thread the nut (1d) onto the fitting (2). Make sure the ferrules (1c and 1b) are on the tube (1a) and are seated on the fitting (2) before tightening the nut (1d).

FIG. 3: 244919 Conversion Kit

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309292L 11

Installation

Grounding

WARNING

Fire, Explosion, and Electric Shock Hazard

When operating the electrostatic gun, any ungrounded objects in the spray area (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 grounding requirements for 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.

• Pump: ground the pump by connecting a ground

wire and clamp as described in your separate pump instruction manual.

• All persons entering the spray area: shoes must

have conductive soles, such as leather, or personal grounding straps must be worn. Do not wear shoes with non-conductive soles such as rubber or plastic. If gloves are necessary, wear the conductive gloves that are supplied with the gun. If non-Graco gloves are worn, cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle.

• Object being sprayed: keep the workpiece hangers

clean and grounded at all times. Resistance must not exceed 1 megohm.

• The floor of the spray area: must be electrically con-

ductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.

• Electrostatic Air Spray Gun: ground the gun by con-

necting the Graco Grounded Air Hose and connecting the air hose ground wire to a true earth ground. See Check Electrical Grounding, page 13.

ti1259a

• Air compressors: ground the equipment according

to the manufacturer's recommendations.

• All air and fluid lines must be properly grounded.

Use only grounded hoses with a maximum of 100 feet (30.5 m) combined hose length to ensure grounding continuity.

• Flammable liquids in the spray area: must be kept in

approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift.

• All electrically conductive objects or devices in the

spray area: including fluid containers and wash

cans, must be properly grounded.

12 309292L

Installation

Check Electrical Grounding

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see F

IG. 4.) is not approved for use in a hazard-

ous 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, and electric shock and result in serious injury and property damage.

4. Make sure the grounded air hose (R) is connected and the hose ground wire is connected to a true earth ground.

ti1259a

5. Measure the resistance between the gun handle (BB) and a true earth ground (CC). Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 1 megohm. See F

IG. 4.

6. If the resistance is greater than 1 megohm, 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.

1. Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose.

2. Turn the ES ON/OFF valve OFF.

I O

ti1273a

3. Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it.

ti1274a

Fig. 4. Check Gun Grounding

309292L 13

Installation

Check Fluid Resistivity

WARNING

Fire, Explosion, and Electric Shock Hazard

Check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area.

Failure to follow this warning could cause fire, explosion, or electric shock and result in serious injury and property damage.

Graco Part No. 722886 Resistance Meter and 722860 Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the requirements of an electrostatic air spray system.

Follow the instructions included with the meter and probe. Readings of 25 megohms-cm and above provide the best electrostatic results.

Check Fluid Viscosity

To check fluid viscosity you will need:

• a viscosity cup

• a stopwatch.

1. Completely submerge the viscosity cup in the fluid. Lift the cup out quickly, starting the stopwatch as soon as the cup is completely removed.

2. Watch the stream of fluid coming from the bottom of the cup. As soon as there is a break in the stream, shut off the stopwatch.

3. Record the fluid type, elapsed time, and size of the viscosity cup.

4. If the viscosity is too high or too low, contact the material supplier. Adjust as necessary.

14 309292L

Operation

Refer to the gun operation manual (supplied) for Setup, Shutdown, and Daily Care procedures.

INSTRUCTIONS

Low Voltage Adjustment (Smart Guns Only)

Operation

The ES HI/LO switch enables you to switch between full voltage and a lower voltage output. The lower voltage is factory set, but can be adjusted.

1. Set the ES HI/LO switch to LO.

2. Remove the LO VOLTAGE adjustment plug (53). Set the desired voltage, using a small screwdriver to slide switches 1 and 2 ON or OFF, according to Table 3 . Also see F

IG. 5. Fig. 5. Low Voltage Adjustment Switches

Table 3: Low Voltage Adjustment

60 kV Guns 85 kV Guns

12kV12kV

ON ON 50 ON ON 70

Factory Setting

ON OFF 40 ON OFF 60 OFF ON 35 OFF ON 50 OFF OFF 30 OFF OFF 40

OFF

100%

μα

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309292L 15

+ 33 hidden pages