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Graco 3A2495CPro User's Manual

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1. ti19767a Figure 32 Connect Flexible Circuit oee Test Power Supply Resistance page 33 Replace the power supply if necessary To repair the alternator see 11 See Test Gun Resistance page 32 Alternator Removal and Replacement page 46 Smart models only connect the 6 pin flexible circuit 40 to the power supply To prevent damage to the cable and possible interruption of the ground continuity bend the alternators 3 wire ribbon cable PC upward and back so the bend faces the power supply and the connector is at the top Connect the 3 wire ribbon connector PC to the power supply Tuck the ribbon forward under the power supply Slide the alternator 15 down onto the power supply 11 Insert the power supply alternator assembly in SRA the gun handle 16 Make sure the ground strips Figure 33 Power Supply 3A2495C 45 Repair Alternator Removal and Replacement NOTE Replace alternator bearings after 2000 hours of operation Order Part No 24N706 Bearing Kit Parts included in the kit are marked with a symbol 4 1 2 46 oee Prepare the Gun for Service page 39 Remove the power supply alternator assembly and disconnect the alternator See Power Supply Removal and Replacement page 45 Measure resistance between the two outer terminals of the 3 wire connector PC it should be 2 0 6 0 ohms If outside th
2. 45 Alternator Removal and Replacement 46 Fan Air Adjustment Valve Repair 48 Atomizing Air Adjustment Valve Exe Dll esisi E d contes 49 ES On Off Valve Repair 50 Air Valve Repall ccccceesceceaeseeeeeeaeaes 51 Smart Module Replacement 52 Air Swivel and Exhaust Valve Replacement 53 mi cR ND LED o4 Standard Air Assisted Spray Gun Assembly eeeeeeesess o4 omart Air Assisted Spray Gun ASSOIMDIY x5 eie iiaa 56 Alternator Assembly ssusesssse 58 ES On Off Valve Assembly o9 Fan Air Valve Assembly 60 Air Cap Assembly ccccccceeeeeeeeeeeeeeseees 61 Smart Module Assembly 61 Spray Tip Selection Chart 62 AEM Fine Finish Spray Tips 62 AEF Fine Finish Pre Orifice Spray TIDS recor ey aden ciate auc oL iure 63 Repair Kits Related Manuals and Accessories tenet centem ide utitiedus 64 Gun ACCESSONES stt ntvbis dari Det ve seven PTEUdS 64 System Accessories ueeeeeesesss 64 Test Equipment isre be cob ERO YS EUM EN nU EUNS 64 RIO SCS cie caseus tto eset cc duaetlanit t tatit 65 Operator Accessories eese 65 DIMENSIONS E NEED ovules 66 Technical Data
3. susssese 26 Flush Before Using Equipment 26 Seg e 2f Pressure Relief Procedure 2f SAMUD TC ren 2f SILC OW ena acdusts tus Sese xe aed e mter eia adt ond 2f Maintenance usse dene Podere tudu d ductores duc teet dedu 28 FUSANO EUR CMT cT 28 Clean the Gun Daily 29 Daily System Care eeseeeeeeeeeee 31 Electrical Tests ore ERE ants 32 Test Gun Resistance ssss 32 Test Power Supply Resistance 33 Test Gun Barrel Resistance 34 Troubleshooting eeeeeeeeeeeeee e 35 Spray Pattern Troubleshooting 35 Gun Operation Troubleshooting 36 Electrical Troubleshooting 37 FRE Dale ieee DIM bL e 39 Prepare the Gun for Service 39 Air Cap Spray Tip and Fluid Seat Housing Replacement 40 Electrode Replacement 41 Fluid Tube Removal and Replacement 42 Fluid Filter Replacement 42 Gun Barrel Remowval 43 Gun Barrel Installation 43 Fluid Needle Replacement 44 Power Supply Removal and Replacement
4. ti19543a Figure 41 Air Valve 57 Repair Smart Module Replacement If the Error display appears the Smart Module has lost communication with the power supply Check for good connections between the Smart Module and the power supply If the module s LEDs are not lighting replace the module 1 See Prepare the Gun for Service page 39 2 Remove the pivot screw 316 o ring 31f and ES HI LO switch 31c at the bottom left corner of the Smart Module cartridge 31a 3 Remove the remaining three screws 31d from the cartridge 4 Pull the Smart Module out the back of the gun Disconnect the ribbon cable RC from the connector GC in the gun handle o Remove the gasket 31b 6 Install a new gasket 31b on the new cartridge 31a Make sure the notched corners of the gasket are at the top 7 Align the module s ribbon cable RC with the gun s cable GC and slide them securely together as shown Tuck the connected cables into the recess of the gun handle Install the module flush to the back of the gun handle 8 Install the pivot screw 316 o ring 31f and ES HI LO switch in the bottom left corner of the cartridge 31a 9 Install the three remaining screws 31d Torque to 7 9 in lb 0 8 1 0 Nem 52 Figure 42 Figure 43 31f 8 Y 31c 31e Smart Module GC ti21701a Align Ribbon Cables ti19455b Qr 31d 3A2495C Repair Air Swivel
5. C2 24N604 COVER gun 85 kV guns package of 10 554 179791 TAG warning not shown 6 16P802 SIGN warning not shown 7 116553 GREASE dielectric 1 oz 30 ml tube not shown 8 117824 GLOVE conductive medium package of 12 also available in small 117823 and large 107460 TOOL wrench ball end shipped loose 276 41 MULTI TOOL shipped loose 24N783 HOOK includes screw m C1 NOTE 100 mesh Filter Kits 10 are available Order 238561 qty 3 or 224453 qty 5 Parts labeled are not available separately o5 Parts Smart Air Assisted Spray Gun Assembly Part No H60M10 60 kV Electrostatic Air Assisted Spray Gun Series A Part No H85M10 85 kV Electrostatic Air Assisted Spray Gun Series A 3 20 ti19520b 56 3A2495C Parts Part No H60M10 60 kV Electrostatic Air Assisted Spray Gun Series A Part No H85M10 85 kV Electrostatic Air Assisted Spray Gun Series A No BODY gun 60 kV gun BODY gun 85 kV gun ro led package of 2 s meus VALVE exhaust S mm RING nce i 238562 FILTER inline 100 mesh see note below 11 24N660 POWER SUPPLY 60kVgun 1 24N661 POWER SUPPLY 85 kV gun 1 24N663 TRIGGER includes item 13 24A445 SCREW trigger package of 2 15 24N664 See 1 Alternator Assembly page 58 16 HANDLE smart 60 kV AA gun E HANDLE smart 85 kV AA gun 1 TUBE fluid 60 kV gun TUBE fluid 85 kV gun 20 24N
6. Carefully separate the tube assembly T from the bracket 7 3 Loosen the two screws 6 NOTICE To avoid damaging the power supply 11 pull the gun barrel straight away from the gun handle If necessary gently move the gun barrel from side to side to free it from the gun handle 4 Hold the gun handle 16 with one hand and pull the barrel 1 straight off the handle NOTE If the power supply remains in the barrel remove the alternator power supply assembly from the barrel ti19530a Figure 27 Gun Barrel Removal 3A2495C Repair Gun Barrel Installation 1 Be sure the gasket 5 and grounding spring 37a are in place Make sure the gasket air holes are aligned properly Replace the gasket if damaged 2 Make sure the spring 11a is in place on the tip of the power supply 11 Liberally apply dielectric grease 57 to the tip of the power supply Place the gun barrel 1 over the power supply and onto the gun handle 16 3 Tighten the two screws 6 oppositely and evenly about a half turn past snug Do not over tighten the screws 6 4 Make sure the fluid filter 10 is in place in the fluid fitting Tighten the bottom nut N onto the fitting and torque to 140 150 in Ib 15 8 16 9 Nem Make sure the top nut remains tight 5 See Test Gun Resistance page 32 ti19531a Figure 28 Gun Barrel Installation 43 Repair Fluid Needle Replacement 1 2 11
7. Repair Prepare the Gun for Service Installing and repairing this equipment requires access to parts that may cause electric shock or other serious injury if the work is not performed properly Do not install or service this equipment unless you are trained and qualified To reduce the risk of injury follow the Pressure Relief Procedure page 27 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure Check all possible remedies in Troubleshooting page 35 before disassembling the gun 3A2495C Repair Use a vise with padded jaws to prevent damage to plastic parts Lubricate the some needle assembly parts 20 and certain fluid fittings with dielectric grease 57 as specified in the text Lightly lubricate o rings and seals with non silicone grease Order Part No 111265 Lubricant Do not over lubricate Only use genuine Graco parts Do not mix or use parts from other Pro Gun models Air Seal Repair Kit 24N789 is available The kit must be purchased separately Kit parts are marked with an asterisk for example 3 Flush the gun See Flushing page 28 Relieve the pressure See Pressure Relief Procedure page 27 Disconnect the gun air and fluid lines Remove the gun from the worksite Repair area must be clean 39 Repair Air Cap Spray Tip and Fluid Seat Housing Replacement 1 See Prepare the Gun for Service page 39 4 To replace the
8. or moisture Clean with a clean dry rag models align the connector of the 6 pin flexible circuit 40 with the socket CS at the top of the handle Push the connector securely into the See Prepare the Gun for Service page 39 socket as you slide the power supply alternator See Gun Barrel Removal page 43 assembly into the handle NOTICE Be careful when handling the power supply 11 to avoid damaging it Grasp the power supply 11 with your hand With a gentle side to side motion free the power supply alternator assembly from the gun handle 16 then carefully pull it straight out On Smart Models only disconnect the flexible circuit 40 from the socket at the top of the handle Inspect the power supply and alternator for damage To separate the power supply 11 from the alternator 15 disconnect the 3 wire ribbon connector PC from the power supply On Smart Models only disconnect the 6 pin flexible circuit 40 from the power supply Slide the alternator 10 Make sure the gasket 5 ground spring 37a up and off the power supply and power supply spring 11a are in place Assemble the barrel 1 to the handle 16 See Gun Barrel Installation page 43
9. 12 13 14 44 See Prepare the Gun for Service page 39 Remove the air cap assembly and fluid seat housing See Air Cap Spray Tip and Fluid Seat Housing Replacement page 40 Remove the gun barrel See Gun Barrel Removal page 43 Remove the trigger screws 13 and trigger 12 Unscrew the spring cap 37 Remove the spring 20a Insert the supplied driver 60 in the socket at the back of the fluid needle Press forward so the two segments of the needle engage R This allows the needle to be unscrewed from the gun body Using the multi tool 61 pull back on the packing nut N to remove the fluid needle assembly Install the fluid needle assembly in the gun barrel Push in on the needle with the driver 60 and tighten Install the spring 20a Install the spring cap 37 Make sure the grounding spring 37a is in place Install the trigger 12 and screws 13 Install the gun barrel See Gun Barrel Installation page 43 Install the seat housing and air cap assembly See Air Cap Spray Tip and Fluid Seat Housing Replacement page 40 oee Test Gun Resistance page 32 ti9527a Figure 29 Remove Cap and Springs g ti19528a ti19529a Figure 31 Replace Fluid Needle 3A2495C Repair Power Supply Removal and Replacement Inspect the gun handle power supply cavity for dirt EE make contact with the handle On Smart Do not expose gasket 5 to solvents 1 2
10. Do not use equipment until you identify and correct the problem Check gun resistance hose resistance and electrical grounding daily Use and clean equipment only in well ventilated area Interlock the gun air supply to prevent operation unless ventilating fans are on Use cleaning solvents with highest possible flash point when flushing or cleaning equipment To clean the exterior of the equipment cleaning solvents must have a flash point at least 5 C above ambient temperature Always turn the electrostatics off when flushing cleaning or servicing equipment Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Keep spray area free of debris including solvent rags and gasoline Keep a working fire extinguisher in the work area 4 3A2495C MPaibar P 51 3A2495C Warnings SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body gl
11. and Table 1 on page 11 To enter this screen press and hold the LO SET button for approximately 5 seconds while in the Operating Mode This screen displays the spraying voltage of the gun as a number kV rounded to the nearest 5 kV The two top right LEDs VI of the display panel light indicating that the Voltage kiloVolts Screen is displayed The display is a readout and cannot be changed Press the LO SET button to advance to the Current microAmperes Screen page 13 Press and hold for approximately 5 seconds to return to Operating Mode 3A2495C Gun Overview ti19123a Figure 6 Voltage kiloVolts Screen Current microAmperes Screen The Current microAmperes Screen is the second screen in the Diagnostic Mode See Fig 7 and Table 1 on page 11 To enter this screen press the LO SET button while in the Voltage kiloVolts Screen This screen displays the spraying current of the gun as a number uA rounded to the nearest 5 uA The two bottom right LEDs Cl of the display panel light indicating that the Current microAmperes Screen is displayed The display is a readout and cannot be changed Press the LO SET button to advance to the Alternator Speed Hertz Screen page 14 Press and hold for approximately 5 seconds to return to Operating Mode ti19124a Figure 7 Current microAmperes Screen 13 Gun Overview Alternator Speed Hertz Screen The Alternator Speed Hertz Screen is the third
12. screen in the Diagnostic Mode See Fig 8 and Table 1 on page 11 To enter this screen press the LO SET button while in the Current microAmperes Screen This screen displays the alternator speed as a 3 digit number AS rounded to the nearest 10 Hz The display is a readout and cannot be changed If the alternator speed is greater than 999 Hz the display will show 999 The Hz indicator lights green to show that you are viewing the Alternator Speed Hertz Screen Press the LO SET button to advance to the Low Voltage Lock Screen page 14 Press and hold for approximately 5 seconds to return to Operating Mode AS LS NM ME HN LO Hz VA LS ti19125a Figure 8 Alternator Speed Hertz Screen 14 Low Voltage Lock Screen The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode See Fig 9 and Table 1 on page 11 To enter this screen press the LO SET button while in the Alternator Speed Hertz Screen This screen displays the status of the Low Voltage Lock If the setting is locked the lock image LK appears to the left of the Lo display LD If the setting is unlocked the lock image does not appear To change the lock status press and hold the LO SET button until the lock image appears or disappears If the lock is set the image will also appear on the Low Voltage Setting Screen when in low voltage mode see Fig 4 NOTE Diagnostic Mode cannot be exited from this screen beca
13. Part No 24N634 Fan Air Valve Assembly 30b 30c 30a 30d ti18647a 60 No c wwe 5m sme These parts are included in Air Seal Repair Kit 24N789 purchase separately Parts labeled are not available separately 3A2495C Air Cap Assembly Part No 24N727 Air Cap Assembly ti18652a No Be unes uecrmcne pese i 24N734 O RING ptfe package of 5 also available in package of 10 order 24E459 25s NR one 3 25d 24N726 GUARD tip orange EM Parts labeled are not available separately 3A2495C Parts Smart Module Assembly Part No 24N756 Smart Module Assembly 31d ti19442b 31f 31c No 9a owmoce it we screw id cw sce me 1 Parts labeled are not available separately These parts are included in Smart Module Screw Kit 24N757 purchase separately 61 Spray Tip Selection Chart opray Tip Selection Chart AEM Fine Finish Spray Tips Recommended for high finish quality applications at low and medium pressures Order desired tip Part No AEMxxx where xxx 3 digit number from the matrix below Orifice Fluid Output Maximum Pattern Width at 12 in 305 mm Size fl oz min l min in mm in 4 6 6 8 8 10 10 12 12 14 14 16 16 18 mm i 4 i 7 50 100 150 200 250 300 350 400 100 150 20
14. ao cl eie uetus 67 Graco Pro Xp Warranty sseseseeeeeses 68 3A2495C Models Models Part No H60T10 Smart Display Standard Display 4 H85T10 H85M10 Jv CE M ii APPROVED II 2 G EEx 0 24 mJ T6 FM12ATEX0068 EN 50050 Ta 0 C 50 C a p T 7 3A2495C 3 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risks When these symbols appear in the body of this manual or on warning labels refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire explosion and electric shock Electrostatic equipment must be used only by trained qualified personnel who understand the requirements of this manual Ground all equipment personnel object being sprayed and conductive objects in or close to spray area Resistance must not exceed 1 megohm See Grounding instructions Only use grounded Graco conductive air supply hoses Do not use pail liners unless they are conductive and grounded Stop operation immediately if static sparking occurs or you feel a shock
15. are turned off ventilation fans in the hazardous area are operating and there are no flammable 6 Measure the resistance between the gun handle vapors in the area such as open solvent BB and a true earth ground CC Use an containers or fumes from spraying applied voltage of 500 minimum to 1000 volts maximum The resistance should not exceed 1 Failure to follow this warning could cause fire megohm See Fig 16 explosion and electric shock and result in serious injury and property damage 7 Ifthe resistance is greater than 1 megohm check the tightness of the ground connections and be Graco Part No 241079 Megohmmeter is available sure the air hose ground wire is connected to a as an accessory to check that the gun is properly true earth ground If the resistance is still too grounded high replace the air hose 1 Have a qualified electrician check the electrical BB grounding continuity of the spray gun and air hose 2 Turn OFF O the ES On Off switch e M Nj 7 N 1 4 E ti18730a 3 Turn off the air and fluid supply to the gun Follow the Pressure Relief Procedure page 27 ti18787a Figure 16 Check Gun Electrical Grounding 4 Disconnect the fluid hose 3A2495C 25 Gun Setup Check Fluid Resistivity To reduce the risk of fire explosion or electric shock check the fluid resistivity in a non hazardous area only Resistance Meter 722886 and Probe 722860 are not approv
16. electrode 25a see 2 Remove the retainer ring 22 and air cap tip Electrode Replacement page 41 guard assembly 25 The conductive ring 9 is a conductive metal contact ring not a sealing o ring To reduce the risk of fire explosion or electric shock e Do not remove the conductive ring except to replace it e Never operate the gun without the conductive ring in place Do not replace the conductive ring with Menge anything but a genuine Graco part Figure 20 Remove Air Cap 3 Disassemble the air cap assembly Check the 5 Trigger the gun and remove the fluid seat housing condition of the u cup 22a o ring 25b and tip 24 using the multi tool 61 gasket 27a Replace any damaged parts 25b 25 22a ti19523a Figure 23 Replace Fluid Seat Housing 2f ti19521a Figure 21 Disassemble Air Cap Assembly f LE IG D S 2fla NNNM NI JV ti19766a Figure 22 Tip Gasket 40 3A2495C 6 11 12 NOTICE Do not overtighten the fluid seat housing 24 Overtightening may damage the housing and the gun barrel resulting in improper fluid shutoff Trigger the gun and install the fluid seat housing 24 Tighten until snug then 1 4 turn more Check that the spray tip gasket 27a is in place Align the spray tip tab with the groove in the air cap 25 Install the spray tip 27 in the air cap Make sure that the electrode 25
17. for coverage If wrap is poor see of 45 psi 0 32 MPa 3 2 bar at the gun when Troubleshooting page 35 triggered to ensure full spraying voltage See the table below f 7 C Table 3 Pressure Drop E Air Hose Air Regulator Setting TTA Length in ft m in psi MPa bar using 5 16 in 8 with gun triggered NOTE If a narrower pattern is needed occasionally mm diameter hose open the fan air adjustment valve slightly Excessive 0 36 3 6 fan air flow can cause paint buildup on the air cap 5 0 40 4 0 22 9 80 0 56 5 6 100 30 5 90 0 63 6 3 15 4 2 1 68 0 47 4 7 75 22 0 30 20 3A2495C Grounding 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 Ground all equipment personnel object being sprayed and conductive objects in or close to the spray area Resistance must not exceed 1 megohm Follow the grounding instructions below The following are minimum grounding requirements for a basic electrostatic system see Figs 12 15 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 e Pump fluid source ground the pump flu
18. press the ring firmly into the groove G ti19901a 5 The conductive ring 9 is a conductive metal contact ring not a sealing o ring To reduce the risk of fire explosion or electric shock e Do not remove the conductive ring except to replace it Neveroperate the gun without the conductive ring in place Do not replace the conductive ring with anything but a genuine Graco part If the resistance is still outside the range replace the gun barrel ti19544a Figure 19 Test Gun Barrel Resistance 3A2495C Troubleshooting Troubleshooting Installing and servicing this equipment requires To reduce the risk of a skin injection injury always access to parts which may cause an electric shock follow the Pressure Relief Procedure page 27 or other serious injury if the work is not performed whenever you are instructed to relieve the properly Do not install or service this equipment pressure unless you are trained and qualified NOTE Check all possible remedies in the Troubleshooting Chart before disassembling the gun Spray Pattern Troubleshooting NOTE Some spray pattern problems are caused by the improper balance between air and fluid Fluttering or spitting spray No fluid Refill supply Air in fluid supply Check fluid source Refill Irregular pattern Fluid buildup partially plugged tip Clean See Clean the Gun Daily page 29 Worn damaged tip or air cap holes Cle
19. than the quantity needed for one shift D S ti18724a 22 e All persons entering the spray area must wear shoes having conductive soles such as leather or wear personal grounding straps Do not wear shoes with non conductive soles such as rubber or plastic If gloves are necessary wear the conductive gloves supplied with the gun If non Graco gloves are worn cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle ti18731a Key to Figs 12 15 Fig 12 Operator is grounded through the gun handle and conductive shoes Fig 13 Object being sprayed is grounded through contact with the hanger and conveyor system Fig 14 Gun is grounded through the conductive air hose Fig 15 Fluid supply line and source must be grounded 3A2495C Figure 12 Ground the Operator Figure 13 Ground the Object being Sprayed 3A2495C Gun Setup 23 Gun Setup Figure 15 Ground the Fluid Supply 24 3A2495C Gun Setup Check Gun Electrical Grounding 5 Make sure the grounded air hose is connected and the hose ground wire is connected to a true earth ground ti18727a Megohmmeter Part No 241079 AA see Fig 16 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
20. the alternator speed is too low If the indicator changes to red after 1 second the alternator speed is too high The indicator will also turn red if the Error display appears In Diagnostic Mode the indicator is green when in the Alternator opeed Hertz screen 12 3A2495C Diagnostic Mode Diagnostic Mode includes four screens which display gun data Voltage kiloVolts Screen Current microAmperes Screen e Alternator Speed Hertz Screen Low Voltage Lock Screen NOTE You must be in Operating Mode to adjust the low voltage setting the setting is not adjustable in Diagnostic Mode However the voltage adjustment switch VA can be set to HI or LO in Operating Mode and in Diagnostic Mode To enter Diagnostic Mode press and hold the LO SET LS button for approximately 5 seconds The display will go to the Voltage kiloVolts Screen page 13 To advance to the next screen press the LO SET button again To exit Diagnostic Mode press and hold the LO SET button for approximately 5 seconds The screen will return to Operating Mode NOTE If the gun is detriggered while in Diagnostic Mode the last screen viewed will be displayed when the gun is retriggered NOTE Diagnostic Mode cannot be exited from the Low Voltage Lock Screen See Low Voltage Lock Screen page 14 for details Voltage kiloVolts Screen The Voltage kiloVolts Screen is the first screen to appear after entering Diagnostic Mode See Fig 6
21. the valve as an assembly go to step 9 or as individual parts steps 3 9 Remove the retaining ring 30d 30b 4 Turn the valve shaft 30b counterclockwise until 30c it comes free from the valve housing 30a 30a Remove the o ring 30c 30d 6 Clean all parts and inspect for wear or damage NOTE Use non silicone grease Part No 111265 Do not over lubricate 7 When reassembling the fan air valve 30 lightly QS E lubricate the valve threads and screw the shaft 30b fully into the housing 30a until bottomed Figure 37 Fan Air Adjustment Valve Install the o ring 30c lubricate and unscrew the valve stem until the o ring enters the housing ti18647a 48 3A2495C Atomizing Air Adjustment Valve Repair 1 See Prepare the Gun for Service page 39 29b 29a 2 Place a wrench on the flats of the valve assembly 29 and unscrew it from the handle 16 3 Inspect the valve assembly If damaged install a new valve 29 ti18649a 4 Before installing the valve assembly in the Figure 38 Atomizing Air Adjustment Valve handle unscrew the valve stem 29b from the housing 29a until it stops 5 Install the valve assembly into the gun handle Torque the valve housing 29a to 15 in Ib 1 7 Nem 3A2495C Repair 49 Repair ES On Off Valve Repair 1 See Prepare the Gun for Service page 39 4 Clean and inspect parts for damage Replace 2 Loosen the captive screw 26p R
22. to damage the fluid tube assembly 19 when cleaning or installing it especially the sealing surface E If the sealing surface is damaged the entire fluid tube assembly must be replaced 4 Apply dielectric grease 57 to the entire length of the plastic extension on the fluid tube o Apply low strength sealant to the fluid tube nut threads 6 Install the fluid tube into the gun barrel and tighten the top nut D until snug then 1 2 turn tighter There will be a gap between the nut and barrel Do not over tighten the nut 7 Make sure the fluid filter 10 is in place in the fluid fitting Tighten the bottom nut C securely onto the fitting Make sure the top nut remains tight ti19525a Figure 25 Fluid Tube 42 Fluid Filter Replacement See Prepare the Gun for Service page 39 A Disconnect the bottom fluid tube nut C 3 Remove the fluid filter 10 from the fluid fitting Clean or replace the filter as needed 4 Install the fluid filter 10 in the fluid fitting Tighten the bottom nut C onto the fitting and torque to 140 150 in Ib 15 8 16 9 Nem Make sure the top nut remains tight at 20 30 in Ib 2 3 3 4 Nem NOTICE Be sure the fluid tube 19 is not twisted after tightening the bottom nut C ti19526a Figure 26 Replace Fluid Filter 3A2495C Gun Barrel Removal 1 See Prepare the Gun for Service page 39 2 Disconnect the bottom fluid tube nut N
23. 0 250 300 350 400 450 Eme I 0 178 0 1 0 15 EIE MEE 0 0 229 0 2 0 27 CA i777 0 279 0 3 0 4 lee tee Iv 0 330 0 4 0 5 eles te ee 0 381 0 5 0 7 ole ee 77717 0 432 0 7 0 85 le te a n A 0 483 0 8 1 09 le os EE 71 0 533 1 0 1 36 pe fes nee BERN 0 0 584 1 1 2 1 56 ole te ne ee 0 635 4 5 1 94 5 es LEES 0 736 1 9 2 65 le ELE EE 0 787 2 2 3 03 les Lf fo ot A 0 838 2 5 3 42 8 ELE 0 939 3 1 4 20 i s MEM 0 990 34 4 59 Fluid output Q at other pressures P can be calculated by this formula Q 0 041 QT V P where QT fluid output fl oz min at 600 psi from the above table for the selected orifice size T These tip sizes include a 150 mesh filter 62 3A2495C Spray Tip Selection Chart AEF Fine Finish Pre Orifice Spray Tips Recommended for high finish quality applications at low and medium pressures AEF tips have a pre orifice that assists in atomizing sheer thinning materials including lacquers Order desired tip Part No AEFxxx where xxx 3 digit number from the matrix below Orifice Fluid Output Maximum Pattern Width at 12 in 305 mm Size fl oz min l min in mm at 600 psi at 1000 6 8 150 8 10 10 12 12 14 14 16 16 18 4 1 MPa psi 7 0 200 200 250 250 300 300 350 350 400 400 450 41 bar MPa 70 Spray
24. 0 mesh Filter Kits 10 are available Order 238561 qty 3 or 224453 qty 5 51 54 554 564 57 58 61 62 Parts labeled are not available separately 57 Parts Alternator Assembly Part No 24N664 Alternator Assembly 15f ti18639b Ref Part Description Qty No No Ref Part Description Qty No No 15f CAP housing part of item 1 15d 15h 24N709 CLIP package of 5 one clip 1 included with item 15b These parts are included in Air Seal Repair Kit Parts labeled are not available separately 24N789 purchase separately 15d 24N707 HOUSING includes item 15f 15e FAN part of item 15b 15b 24N706 BEARING KIT includes two 1 bearings item 15e fan and one item 15h clip These parts are included in Bearing Kit 24N706 purchase separately 58 3A2495C Parts ES On Off Valve Assembly Part No 24N632 ES On Off Valve Assembly 26d 26f 26b 26e 26p ti18648a m HOUSNG wave cm soars onns 2 um No 262 scnew set socketnea 2 m mwew Pure meno t aay rims ORNG h m screw cam No 26a 26c PISTON valve 26d 24N650 LEVER ES on off includes 1 item 26e These parts are included in Air Seal Repair Kit Parts labeled are not available separately 24N789 purchase separately 3A2495C 59 Parts Fan Air Valve Assembly
25. 780 NEEDLE ASSEMBLY 60kV 1 gun includes item 20a 24N781 NEEDLE ASSEMBLY 85kV 1 gun includes item 20a 24N782 SPRING fluid needle 21 24N626 SWIVEL air inlet M12 x 1 4 npsm m left hand thread 24N793 RING retainer includes 22a 22a 198307 PACKING u cup UHMWPE part of 22 24N633 VALVE air 276733 SEAL Replacement Danger and Warning labels tags and cards are available at no cost These parts are included in Air Seal Repair Kit 24N789 purchase separately 3A2495C No page 59 AEFxxx choice includes item 27a ADJUSTMENT VALVE page 60 page 61 24E404 STOP trigger includes item 32a PIN dowel 185103 TUBE exhaust 1 4 in 6 mm ID shipped loose 110231 CLAMP 24N785 CAP spring includes item 37a N wl C2 OIOI Ol WI N dd ley Ol C2 fa 197624 SPRING compression 8 24N786 PLUG fan control option shipped loose for use in place of item 29 0 245265 CIRCUIT flexible 112080 TOOL needle shipped loose 24N603 COVER gun 60 kV guns package of 10 24N604 COVER gun 85 kV guns package of 10 179791 TAG warning not shown 16P802 SIGN warning not shown 116553 GREASE dielectric 1 oz 30 ml tube not shown 117824 GLOVE conductive medium package of 12 also available in small 117823 and large 107460 TOOL wrench ball end shipped loose 2 6 41 MULTI TOOL shipped loose 24N783 HOOK includes screw NOTE 10
26. A In Operating Mode display is a bar graph In Diagnostic Mode current is displayed as a number LO SET button Press momentarily to enter the Low Voltage Setting screen Press and hold for approximately 5 seconds to enter or exit Diagnostic Mode While in Diagnostic Mode press momentarily to advance through Screens While on the Low Voltage Lock Screen in Diagnostic Mode press and hold to turn the lock on or off Low Voltage Display Displays the low voltage setting as a number The setting can be changed See Fig 4 Low Voltage Locked Appears if the low voltage setting is locked See Fig 5 and Fig 9 Gun Overview em pen Pme LD Lo Display Appears on the Low Voltage Lock ocreen See Fig 9 ER Error Display Appears if the Smart module loses communication with the power supply See Fig 3 Voltage Indicator In Diagnostic Mode the two top right LEDs of the screen light indicating that the value displayed is in kV See Fig 6 Current Indicator In Diagnostic Mode the two bottom right LEDs of the screen light indicating that the value displayed is in uA See Fig 7 Alternator Speed Display In Diagnostic Mode Hz level is displayed as a number See Fig 8 Hz Alternator Speed Indicator In Operating Mode indicator color varies to show the alternator speed status green indicates the alternator speed is at the correct level If the indicator changes to amber after 1 second
27. ES On Off switch is OFF O Turn ON I No power Check power supply alternator and alternator ribbon cable See Power Supply Removal and Replacement page 45 and Alternator Removal and Replacement page 46 Operator gets mild shock Operator not grounded or is near See Grounding page 21 ungrounded object Gun not grounded See Check Gun Electrical Grounding page 25 and Test Gun Resistance page 32 Operator gets shock from Workpiece not grounded Resistance must be 1 megohm or workpiece less Clean workpiece hangers 3A2495C 3 Troubleshooting Voltage current display stays red Gun is too close to the part being Gun should be 8 12 in 200 300 smart guns only sprayed mm from the part Check fluid resistivity oee Check Fluid Resistivity page 26 Dirty gun See Clean the Gun Daily page 29 ES or Hz indicator is amber Alternator speed is too low Increase air pressure until indicator is green To avoid over atomization use the atomizing air restrictor valve to reduce the atomizing air to the air cap ES or Hz indicator is red Alternator speed is too high Decrease air pressure until indicator is green Error display appears and Hz omart module has lost Check for good connections indicator is red Smart guns only communication with the power between Smart Module and supply power supply See Smart Module Replacement page 52 and Power Supply Removal and Replacement page 45 38 3A2495C
28. Instructions Parts GG g Pro Xp M Electrostatic Air Assisted Spray Gun 3A2495C GRACO For use in Class Div Hazardous Locations using Group D spray materials For use in Group ll Zone 1 Explosive Atmosphere Locations using Group IIA spray materials For professional use only Important Safety Instructions Read all warnings and instructions in this manual Save these instructions 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 ti18643a PROVEN QUALITY LEADING TECHNOLOGY Contents JL 8X9 21 E SRER OR EROR ER ERE ERREUR LNS 3 NW MIMI S erai r E NOS 4 Gun Overview cece cece ec ee ec ecececeeeeeeeaeeenenteneeees 7 How the Electrostatic AA Spray Gun NA GIS oteuductetcteded toit enid ten tenes T Controls Indicators and Components 8 Smart GUFPiS ocius iste sU N etui Devs 9 HISTANAHON e E 15 VV ANG elle n TS 15 Ventilate the Spray Booth 15 Air Supply Line iuc tovs esie me go e exu eda txt 16 Fluid Supply Line 16 SUM SEUD ccce erred i eU d ecd da ag tt Vea diens 18 Gun Setup Checklist 18 Grondig Ec 21 Check Gun Electrical Grounding 25 Check Fluid Resistivity 26 Check Fluid Viscosity
29. Press the fan 15e onto the long end of the shaft S The fan blades must be oriented as shown Carefully press the coil assembly 15a into the front of the housing 15d The 3 wire connector PC must be positioned below the wider notch W of the housing tabs as shown in Fig 35 Be sure the coil alignment pins P are positioned as shown in Fig 34 Rotate the fan 156 so its blades clear the four bearing tabs T at the back of the housing 15f 15e ti19739b Figure 36 Alternator 3A2495C 15 16 17 Repair Ensure that the blades of the bottom bearing 15b194 align with the tabs Seat the coil fully into the housing 15d Secure with the clip 15h ensuring that its tabs engage the slots in the housing Ensure that the o ring 159 is in place Install the cap 15f Install the alternator on the power supply and install both parts in the handle See Power Supply Removal and Replacement page 45 15h 47 Repair Fan Air Adjustment Valve Repair 1 See Prepare the Gun for Service page 39 8 Reassemble the retaining ring 30d Unscrew the valve stem from the housing until it is stopped 2 Place a wrench on the flats of the valve assembly by the retaining ring 30 and unscrew it from the handle 16 9 Screw the valve assembly 30 into the gun handle 16 using a wrench on the flats of the housing Torque to 15 in Ib 1 7 N m NOTE You may replace
30. Tip t0010 95 028 12 5 3 710 0 254 0 37 0 012 12 0 3 0 305 0 35 0 47 0 014 16 0 21 0 3 0 356 0 47 0 62 0 016 20 0 26 5 416 516 616 716 0 406 0 59 0 78 Fluid output Q at other pressures P can be calculated by this formula Q 0 041 QT V P where QT fluid output fl oz min at 600 psi from the above table for the selected orifice size T These tip sizes include a 150 mesh filter 10 12 712 812 14 414 014 614 714 814 3A2495C 63 Repair Kits Related Manuals and Accessories Repair Kits Related Manuals and Accessories Gun Part No Description Manual Description Repair Kits Repair Kit Description All guns in this 60 kV and 85 kV Electrostatic 24N789 Air Seal Repair Kit manual Air Assisted Spray Air Assisted 24N706 Alternator Bearing Guns Spray Guns Repair Kit Instructions Parts System Accessories Gun Accessories Ground Wire and Clamp no charge from Graco 105749 Cleaning Brush 16P798 English Daily Care Sign 111265 Non silicone Lubricant 4 oz 113 g 16P798_ 2 2 S 16P799 English Setup Sign 116553 Dielectric Grease 1 oz 30 ml 24N34 24N528 Gun Flush Box Adapter To convert 319 Round Spray Kit To convert a existing gun flush boxes to hold Pro standard air assisted spray gun to Xp guns a round spray air cap See manual 3A2499 24P312 Gun Washer Kit To convert existing hers to cl Pro X ns 24N603 Gun Covers For 40 kV and 60 kV ee gun
31. a 210 bar Maximum Working Fluid Pressure of the gun For example the air supply pressure to a 30 1 ratio pump must not exceed 100 psi 0 7 MPa 7 bar Install bleed type air regulators PR GR on the pump and gun air supply lines to control air pressure to the pump and gun Trapped air can cause the pump to cycle unexpectedly which can result in serious injury including skin injection and splashing fluid in the eyes or on the skin Do not operate the equipment without the bleed type air valve BV installed Install a bleed type air valve BV on the pump air supply line The bleed type air valve BV is required in your system to shut off air to the pump and relieve air trapped between the valve and the pump after the air regulator is shut off Install an additional bleed type air valve on the main air line MA to isolate the accessories for servicing Install an air bleed valve BV on each gun air supply line to shut off air to the gun s and relieve air trapped between the valve and the gun after the air regulator is shut off Fluid Supply Line 1 Blow out the fluid line FL with air and flush it with solvent Use solvent which is compatible with the fluid to be sprayed Do not connect the fluid supply line to the gun fluid inlet yet Install a fluid pressure regulator FR on the fluid line to control fluid pressure to the gun Install a fluid filter FF near the pump outlet to remove particles and s
32. a is installed correctly in the air cap Check that the air cap o ring 25b is in place Check that the u cup 22a is in place on the retaining ring 22 The lips of the u cup must face forward NOTICE To avoid damaging the tip guard orient the air cap assembly 25 before tightening the retaining ring 22 Do not turn the air cap when the retaining ring is tight Orientate the air cap and tighten the retaining ring securely oee Test Gun Resistance page 32 3A2495C Repair Electrode Replacement To reduce the risk of fire explosion or electric shock do not operate the spray gun without the electrode installed in the air cap 1 See Prepare the Gun for Service page 39 2 Remove the air cap assembly 25 See Air Cap Spray Tip and Fluid Seat Housing Replacement page 40 3 Pull the electrode 25a out of the back of the air cap using a needle nose pliers 4 Push the new electrode through the air cap hole Make sure the short end BB of the electrode engages the hole CC in the back of the air cap Press the electrode in place firmly with your fingers 5 Install the air cap assembly oee Test Gun Resistance page 32 ti19524a Figure 24 Replace Electrode 41 Repair Fluid Tube Removal and Replacement 1 See Prepare the Gun for Service page 39 2 Disconnect the bottom fluid tube nut C Carefully unscrew the top fluid tube nut D NOTICE Be careful not
33. an or replace ti18798a Pattern pushed to one side air Air cap holes plugged Clean See cap gets dirty Clean the Gun Daily page 29 Tails in pattern Air pressure too low Open atomizing air adjustment valve Fluid pressure too low Increase ti18797a Fluid buildup on air cap tip guard Air pressure too high Air cap holes plugged Clean See Clean the Gun Daily page 29 3A2495C 35 Troubleshooting Gun Operation Troubleshooting Excessive spray fog Atomizing air pressure too high Close atomizing air valve part way or decrease air pressure as low as possible minimum 45 psi 0 32 MPa 3 2 bar needed at gun for full voltage Increase viscosity or increase fluid flow rate Open atomizing air valve more or increase gun air inlet pressure use lowest air pressure necessary opray tip is too large Use smaller tip See Spray Tip Selection Chart page 62 Poorly mixed or filtered fluid Remix or refilter fluid Fluid too thick Reduce viscosity Fluid leaks from the fluid packing Worn fluid needle packings or rod See Fluid Needle Replacement area page 44 Air leaks from the front of the gun Air valve is not seating properly oee Air Valve Repair page 51 Fluid leakage from the front of the Worn or damaged fluid needle ball See Fluid Needle Replacement gun page 44 Worn fluid seat housing See Air Cap Spray Tip and Fluid Seat Housing Replacement page 40 Loose spray tip Tig
34. and Exhaust Valve Replacement 1 See Prepare the Gun for Service page 39 2 To replace the air exhaust valve a g Remove the clamp 36 and the exhaust tube 35 Unscrew the swivel 21 from the gun handle 16 The swivel is a left hand thread Remove the bracket 7 Pull the exhaust valve 8 from the handle 16 Inspect the o ring 8a and replace if necessary Install the o ring 8a on the exhaust valve 8 Lubricate the o ring with a light coating of non silicone grease Install the exhaust valve 8 in the handle 16 Apply thread sealant to the top threads of the swivel 21 Position the bracket 7 and screw the swivel into the gun handle 16 Torque to 75 85 in lb 8 4 9 6 Nem Install the tube 35 and clamp 36 3 To replace the air inlet swivel a b Unscrew the swivel 21 from the gun handle 16 The swivel is a left hand thread Apply thread sealant to the top threads of the swivel Screw the swivel into the gun handle Torque to 75 85 in Ib 8 4 9 6 Nem 3A2495C 8a 36 ti19768a Figure 44 Air Inlet Fitting and Air Exhaust Valve 53 Parts Parts Standard Air Assisted Spray Gun Assembly Part No H60T10 60 kV Electrostatic Air Assisted Spray Gun Series A Part No H85T10 85 kV Electrostatic Air Assisted Spray Gun Series A 37 20 2f 22a S gt Oy 32a 84 9 O e 8 es 21 i 7 35
35. ation increments Spray another pattern Compare particle size Continue increasing pressure until the particle size remains constant Do not exceed 3000 psi 21 MPa 210 bar 12 Align the spray tip tab with the groove in the air cap Install the tip 13 Install the air cap and retaining ring Orientate the air cap and tighten the retaining ring securely L WV ti18806a 18 Turn ON I the ES On Off switch ti18801a 14 Close the atomizing air adjustment valve G and the fan air adjustment valve F 3A2495C 19 Gun Setup 19 Check that the ES indicator K Hz indicator on 21 Turn the atomizing air adjustment valve Smart guns is lit See the following table counterclockwise until any tails disappear Table 2 LED Indicator Colors Indicator Description Color Green When spraying the indicator should remain green indicating sufficient air pressure to the alternator turbine Amber If the indicator changes to amber after 1 second the air pressure q C is too low Increase air pressure until the indicator is green ti18807a If the indicator changes to red 22 If desired atomization is not achieved change after 1 second the air pressure Is the tip size The smaller the tip orifice the finer too high Decrease air pressure the atomization until the indicator is green 23 Spray a test piece Examine the edges 20 Set the gun air regulator to deliver a minimum
36. d 235068 6 ft 1 8 m 235069 15 ft 4 6 m 235070 235071 235072 235073 235074 3A2495C Repair Kits Related Manuals and Accessories Air Whip Hoses 700 psi 0 7 MPa 7 bar Maximum Working Pressure 0 188 in 5 mm ID 1 4 npsm m x 1 4 npsm f left hand thread Part No Air Whip Hose with stainless steel braid ground path Red 236130 3 ft 0 9 m 236131 6 ft 1 8 m Fluid Hoses 3300 psi 22 7 MPa 227 bar Maximum Working Pressure 1 4 in 6 mm ID 1 4 npsm fbe nylon 240793 25 ft 7 6 m 240794 50 ft 15 m Fluid Whip Hoses 3200 psi Z2 MPa 220 bar Maximum Working Pressure 1 8 in 3 mm ID 1 4 npsm f x 1 4 npt m nylon 236134 3 ft 0 9 m 236135 6 ft 1 8 m Operator Accessories 117823 Conductive Gloves box of 12 small 117824 Conductive Gloves box of 12 medium 117825 Conductive Gloves box of 12 large 24N520 Comfort Grip Snap on grip increases handle size to reduce operator fatigue Medium size 24N521 Comfort Grip Snap on grip increases handle size to reduce operator fatigue Large size 65 Dimensions Dimensions ti19533a Figure 45 Sc MUN NR o 234 8 A 4 9 1 H85T10 10 7 272 9 2 H60M10 9 8 249 9 9 251 2 4 61 25 7 728 9 9 H85M10 10 8 274 251 2 4 61 28 3 801 66 3A2495C Technical Data Technical Data Electrostatic Air Assisted Spray Guns Maximum Working Fluid Pressu
37. drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com To place an order contact your Graco Distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice For patent information see www graco com patents Original Instructions This manual contains English MM 3A2495 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2012 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised July 2013
38. e 10 NOTE If the Error display appears the Smart module has lost communication with the power supply See Error Display page 10 for further information ti9121a Figure 2 Smart Gun Module in Operating Mode Gun Overview Error Display for your gun Continue pressing the button until you reach the desired setting If the Smart module loses communication with the power supply the Error display appears the NOTE After 2 seconds of inactivity the display will Hz indicator turns red and the Smart module is return to the Operating Screen disabled See Fig 3 and Table 1 on page 11 This can occur in Operating Mode or Diagnostic Mode See Electrical Troubleshooting page 37 Communication must be restored to make the Smart module functional NOTE The low voltage setting may be locked See Lock Symbol page 10 NOTE It takes 8 seconds for the Error display to appear If the gun has been disassembled wait 8 seconds before spraying to ensure that an Error condition has not occurred NOTE If there is no power to the gun the Error display will not appear ti19122a Figure 4 Low Voltage Setting Screen Unlocked Lock Symbol The low voltage setting may be locked When locked an image LK appears on the screen See Fig 5 and Table 1 on page 11 When in HI mode the low voltage setting is always locked The lock symbol will appear when the LO SET button is pressed ti19338a In LO mode the lock symb
39. e resistance from the power supply s ground strips EE to the spring 11a The resistance should be e 86 110 megohms for 60kV guns e 130 160 megohms for 85kV guns If outside this range replace the power supply lf in range go to Test Gun Barrel Resistance page 34 If you still have problems refer to Electrical Troubleshooting on page 23 for other possible causes of poor performance or contact your Graco distributor 3A2495C Electrical Tests 6 Be sure the spring 11a is in place before reinstalling the power supply ti18 35a Figure 18 Test Power Supply Resistance 33 Electrical Tests Test Gun Barrel Resistance 34 Insert a conductive rod B into the gun barrel which was removed for the power supply test and against the metal contact C in the front of the barrel Measure the resistance between the conductive rod B and the conductive ring 9 The resistance should be 10 30 megohms If the resistance is incorrect make sure the metal contact C in the barrel and the conductive ring 9 are clean and undamaged If the resistance is still outside the range remove the conductive ring 9 and measure the resistance between the conductive rod B and the wire lead at the bottom of the conductive ring groove If the resistance is in range replace the conductive ring 9 with a new one Insert the ends of the conductive ring into the slots S at the front of the barrel then
40. e setting low or high It also allows the user to change to a lower spraying voltage The module has two modes Operating Mode Diagnostic Mode Operating Mode Bar Graph See Fig 2 and Table 1 on page 11 The Operating Mode displays gun data during normal spraying The display uses a bar graph to show the voltage level in kiloVolts KV and the current level in microAmperes uA The bar graph range is from O to 10096 for each value If the uA bar graph LEDs are blue the gun is ready to spray If the LEDs are yellow or red the current is too high The fluid may be too conductive or see Electrical Troubleshooting page 37 for other possible causes Hz Indicator The Hz indicator functions the same as the ES indicator on standard guns The indicator lights to show the alternator speed status and has three colors Green indicates the alternator speed is correct e If the indicator changes to amber after 1 second increase the air pressure e If the indicator changes to red after 1 second reduce the air pressure 3A2495C Gun Overview Voltage Adjustment Switch The voltage adjustment switch VA allows the operator to change from low to high voltage he high voltage setting is determined by the maximum voltage of the gun and is not adjustable e The low voltage indicator LO lights when the switch is set to LO The low voltage setting is user adjustable See Adjusting the Low Voltage Setting pag
41. ectrode needle tip 25a and the air swivel 21 The resistance should be The gun body resistor cartridge is part of the body and is not replaceable To avoid destroying the gun body do not attempt to remove the body resistor e 106 150 megohms for 60 kV guns e 150 195 megohms for 85 kV guns Use megohmmeter Part No 241079 AA with an applied voltage of 500 V Connect the leads as If outside this range go to shown Test Power Supply Resistance page 33 If in range see Electrical Troubleshooting page 37 for other possible causes of poor performance Megohmmeter Part No 241079 AA see Fig 17 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 and electric shock and result in serious injury and property damage ti18794a Figure 17 Test Gun Resistance 32 3A2495C Test Power Supply Resistance 1 Remove the power supply 11 See Power Supply Removal and Replacement page 45 Remove the alternator 15 from the power supply See Alternator Removal and Replacement page 46 Measur
42. ed 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 assisted spray system Follow the instructions included with the meter and probe Readings of 25 megohms cm and above provide the best electrostatic results Table 4 Fluid Resistivity Levels Good elec Best elec Good elec trostatic trostatic trostatic results results results Test elec trostatic perfor mance 26 Check Fluid Viscosity To check fluid viscosity you will need e 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 If the viscosity is too high or too low contact the material supplier Adjust as necessary Flush Before Using Equipment The equipment was tested in fluid at the factory To avoid contaminating your fluid flush the equipment with a compatible solvent before using the equipment 3A2495C Operation Pr
43. ediment which could clog the spray nozzle NOTE The gun includes an inline fluid filter for additional filtration To reduce the risk of serious injury including skin injection and splashing fluid in the eyes or on the skin do not operate equipment without the fluid drain valve FD installed The fluid drain valve FD is required in your system to assist in relieving fluid pressure in the displacement pump hose and gun Triggering the gun to relieve pressure may not be sufficient Install a drain valve close to the pump s fluid outlet 3A2495C NON HAZARDOUS AREA AF BV MA L BI BH HBE T BV PR AL Figure 10 Typical Installation Typical Installation Key Air Filter Water Separator Gun Air Hose Ground Wire AH Graco Grounded Air Hose left hand threads Pump Air Line Lubricator Pump Bleed Type Air Shutoff Valve Electrostatic Air Spray Gun FD Fluid Drain Valve Ip Fluid Filter ee Fluid Pressure Gauge La Fluid Supply Line Fluid Pressure Regulator 3A2495C Installation HAZARDOUS AREA SV AF BV al FE ce ma 1 B jE STIS da EI ti18813a PR Pump Ar Pressure Requator Rv Pump Runaway vae se Sion rome ANN Ventilation Fan Interlock Solenoid Valve NOTE The solenoid valve is not offered as a Graco accessory These items are required for safe operation They must be purchased separately 17 Gun Setup Gun Setup Gun Set
44. emove the if necessary valve 26 from the handle NOTE The protrusion on the retainer plate 26f 3 Lubricate the o rings 26b and 26g with must point upward non silicone grease Part No 111265 Do not 5 Reinstall the valve Torque the screw 26p to over lubricate 15 25 in Ib 1 7 2 8 Nem NOTE Do not over lubricate parts Excessive lubricant on the o rings can be pushed into the gun air passage and blemish the finish on the workpiece 26d 26f 26b 26g 26e ti18648a Figure 39 ES On Off Valve 50 3A2495C Air Valve Repair 1 See Prepare the Gun for Service page 39 2 See Gun Barrel Removal page 43 3 Remove the screws 13 and trigger 12 4 Remove the ES On Off Valve See ES On Off Valve Repair page 50 em Remove the spring 2 Push on the front of the air valve shaft to force it out the back of the handle Inspect the rubber seal 23a and replace if damaged 7 Inspect the u cup 3 Do not remove the u cup unless damaged If removed install the new one with its lips facing into the gun handle 16 Place the u cup on the shaft of the air valve to help seat it in the gun handle ti19724a Figure 40 Install U Cup 3A2495C 10 11 Repair Install the air valve 23 and spring 2 into the gun handle 16 Install the ES On Off Valve See ES On Off Valve Repair page 50 Install the trigger 12 and screws 13 oee Gun Barrel Installation page 43
45. essure Relief Procedure This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashing fluid and moving parts follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing the equipment 1 Turn OFF O the ES On Off switch 2 Engage the trigger lock 3 Turn off the air bleed valves to the fluid source and to the gun 4 Disengage the trigger lock M p Z 5 Trigger the gun into a grounded metal waste container to relieve the fluid pressure 3A2495C Operation Engage the trigger lock Open the pump drain valve having a waste container ready to catch the drainage Leave the pump drain valve open until you are ready to spray again If the spray tip or hose is completely clogged or pressure is not fully relieved slowly loosen the hose end coupling Now clear the spray tip or hose Startup Follow all steps under Gun Setup Checklist page 18 Shutdown Flush the gun See Flushing page 28 Follow the Pressure Relief Procedure page 27 Hang the gun from its hook with the nozzle pointing down 2 Maintenance Maintenance Flushing Flush before changing fluids before fluid can dry 5 Point the gun into a grounded metal pail Flush in the equipment at the end of the day before until clean solvent flows from the gun stor
46. gation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be
47. hten retaining ring Damaged tip seal See Air Cap Spray Tip and Fluid Seat Housing Replacement page 40 Gun does not spray Low fluid supply Add fluid if necessary Dirty or clogged spray tip Clean See Clean the Gun Daily page 29 Damaged fluid needle See Fluid Needle Replacement page 44 Dirty air cap Damaged or plugged air cap Clean air cap See Clean the Gun Daily page 29 Excessive paint wrap back to Poor grounding See Grounding page 21 operaron Incorrect distance from gun to part Should be 8 12 in 200 300 mm Fluid too thin Orange Peel finish Atomizing air pressure too low 36 3A2495C Troubleshooting Electrical Troubleshooting Poor wrap ES On Off switch is OFF O Turn ON I Gun air pressure too low ES Check air pressure to gun indicator is amber minimum 45 psi 0 32 MPa 3 2 bar needed at gun for full voltage Atomizing air pressure too high Fluid pressure too high Decrease or replace worn tip Incorrect distance from gun to part Should be 8 12 in 200 300 mm Poorly grounded parts Resistance must be 1 megohm or less Clean workpiece hangers Faulty gun resistance See Test Gun Resistance page 32 Low fluid resistivity See Check Fluid Resistivity page 26 Fluid leaks from the fluid needle See Fluid Needle Replacement packings and causes a short page 44 Faulty alternator See Alternator Removal and Replacement page 46 ES or Hz indicator is not lit
48. ic ti18644b 54 3A2495C Parts Part No H60T10 60 kV Electrostatic Air Assisted Spray Gun Series A Part No H85T10 85 kV Electrostatic Air Assisted Spray Gun Series A No BODY gun 60 kV gun BODY gun 85 kV gun i ed 0p package of 2 a 219823 VALVE eas 5 S mm RING nce i 238562 FILTER inline 100 mesh see note below 11 24N660 POWER SUPPLY 60kVgun 1 24N661 POWER SUPPLY 85 kV gun 1 24N663 TRIGGER includes item 13 24A445 SCREW trigger package of 2 15 24N664 See 1 Alternator Assembly page 58 16 HANDLE 60 kV AA gun a HANDLE 85 kV AA gun TUBE fluid 60 kV gun TUBE fluid 85 kV gun mE gun includes item 20a gun includes item 20a npsm m left hand thread PACKING u cup UHMWPE part of 22 Replacement Danger and Warning labels tags and cards are available at no cost These parts are included in Air Seal Repair Kit 24N789 purchase separately 3A2495C No 24N727 See Air Cap Assembly page 61 24N643 ELECTRODE package of 5 1 page 59 AEFxxx choice includes item 27a ADJUSTMENT VALVE page 60 24E404 STOP trigger includes item 32a PIN dowel 185103 TUBE exhaust 1 4 in 6 mm ID shipped loose 110231 CLAMP 24N785 CAP spring includes item 37a Ta 197624 SPRING compression 8 24N786 PLUG fan control option shipped loose for use in place of item 29 T 24N603 COVER gun 60 kV guns package of 10 l NO Q
49. id source by connecting its ground wire to a true earth ground ti18723a e Electrostatic Air Assisted Spray Gun ground the gun by connecting the Graco Grounded Air Hose to the gun and connecting the air hose ground wire to a true earth ground See Check Gun Electrical Grounding page 25 Ns or ti18727a 3A2495C Gun Setup Object being sprayed keep the workpiece hangers clean and grounded at all times ti18753a e All electrically conductive objects or devices in the spray area must be properly grounded ti18728a e Fluid and waste containers ground all fluid and waste containers in the spray area Do not use pail liners unless they are conductive and grounded When flushing the spray gun the container used to catch the excess fluid must be electrically conductive and grounded e Air compressors ground the equipment according to the manufacturer s recommendations e 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 27 Gun Setup e 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 ti18725a e Flammable liquids in the spray area must be kept in approved grounded containers Do not use plastic containers Do not store more
50. if desired turn the gun s atomizing air adjustment valve completely off Closing this valve does not affect alternator operation Gun Overview Controls Indicators and Components The electrostatic gun includes the following controls indicators and components see Fig Atomizing Air Adjusts atomizing air flow 1 For information on Smart guns also see Adjustment omart Guns page 9 Valve LOL IW Trigger Safety Locks trigger to prevent Air Swivel 1 4 npsm m left hand Lock gun from spraying Inlet thread for Graco grounded ES On Off Turns electrostatics ON air supply hose Valve or OFF O a Fluid Inlet 1 4 npsm m for fluid ES Indica Lit when ES is ON 1 supply hose tor standard Color indicates alternator Turbine Air Barbed fitting for supplied gun only for frequency See the LED Exhaust exhaust tube omart gun in indicator table in the Gun dicator Setup Checklist 18 Air Cap Tip oee Spray Tip Selection visi ds AAEE ISDN queue Operating Guard and Chart page 62 for avail Mode page opray Tip able sizes 9 i Electrode e a Inline Fluid Provides final filtration of charge to the flui Filter fluid Located inside fluid Fan Air Adjusts fan size and shape tube fitting Adjustment Can be used to decrease Valve pattern width B ti18784a Figure 1 Gun Overview 8 3A2495C Smart Guns The Smart Gun module displays spraying voltage current alternator speed and the voltag
51. ing and before repairing equipment Flush at the lowest pressure possible Check connectors for leaks and tighten as necessary Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts 6 Follow the Pressure Relief Procedure page 27 Engage the trigger lock To reduce the risk of fire explosion or electric shock turn OFF O the ES On Off switch before flushing the gun NOTICE 7 Shut off or disconnect the solvent line Do not use methylene chloride as a flushing or 8 Align the spray tip tab with the groove in the air cleaning solvent with this gun as it will damage cap Install the tip nylon components 1 Turn OFF O the ES On Off switch s ti18730a 2 Follow the Pressure Relief Procedure page 27 10 Hang the gun from its hook with the nozzle 3 Remove and clean the air cap and spray tip a pointing down 4 Change the fluid source to solvent or disconnect the fluid line and connect a solvent supply line to the gun 11 When ready to spray again reconnect the fluid supply line Follow the Gun Setup Checklist page 18 26 3A2495C Clean the Gun Daily 1 Turn OFF O the ES On Off switch f wO Z Ors SOO 2 Follow the Pressure Relief Procedure page 27 3 Remove the air cap tip guard and spray tip 4 Flush the gun see Flushing page 28 5 Follow the Pressure Relief P
52. is range replace the alternator coil 15a Using a flat blade screwdriver pry the clip 15h off the housing 15d Remove the cap 15f using a thin blade or screwdriver If necessary rotate the fan 15e so its blades clear the four bearing tabs T of the housing 15d ti19741b Figure 34 Fan Orientation Push the fan and coil assembly 15a out the front of the housing 15d 11 ti19740b 15b29 M 15a 15g 15f W E JA 15b1 S PC 15h 15d Figure 35 Alternator Cross Section NOTICE Do not scratch or damage the magnet M or shaft S Do not pinch or damage the 3 wire connector PC when disassembling and reassembling the bearings Hold the coil assembly 15a on a workbench with the fan end facing up Using a wide blade screwdriver pry the fan 15e off the shaft S Remove the top bearing 1552 Remove the bottom bearing 15b1 Install the new bottom bearing 15b19 on the long end of the shaft S The flatter side of the bearing must face away from the magnet M Install in the coil 15a so the bearing blades are flush with the surface of the coil Press the new top bearing 15b294 onto the short end of the shaft so the bearing blades are flush with the surface of the coil 15a The flatter side of the bearing must face away from the coil 3A2495C 12 13 14 Hold the coil assembly 15a on a workbench with the fan end facing up
53. njury from pressurized fluid such as skin injection and splashing fluid read and follow the Skin Injection Hazard Warnings on page 5 The air assisted spray gun combines airless and air spraying concepts The spray tip atomizes and shapes the fluid into a fan pattern as does a conventional airless spray tip Air from the air cap further atomizes the fluid and completes the atomization of the fluid tails to produce a uniform pattern As the gun is triggered part of the regulated air operates the alternator turbine and the rest of the air helps atomize the fluid being sprayed The 3A2495C Gun Overview alternator generates power which is converted by the power cartridge to supply high voltage to the gun s electrode 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 The regulated air that is directed to the air cap can be further controlled using the gun s atomizing air adjustment valve This valve can be used to restrict air flow to the air cap while maintaining sufficient air flow to the alternator The atomizing air adjustment valve does not control pattern width To change pattern width use a new tip size or use the fan adjustment to narrow the pattern width The high working fluid pressure of this gun provides the power needed to atomize higher solids materials NOTE For airless atomization
54. ns are operating Electrically interlock the gun air supply with the ventilators to prevent gun operation without ventilating fans operating Check and follow all local state and national 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 15 Installation Air Supply Line To reduce the risk of electric shock the air supply hose must be electrically connected to a true earth ground Use only Graco Grounded Air Supply Hose 3 16 See Fig 10 Use the Graco Grounded Air Supply Hose AH to supply air to the gun The gun air inlet fitting has a left hand thread The air supply hose ground wire AG must be connected to a true earth ground Do not connect the air supply hose to the gun air inlet yet Install an air line filter water separator AF on the gun air line to ensure a dry clean air supply to the gun Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction To reduce the risk of serious injury due to component rupture including skin injection pump pressure must be limited by the pump air regulator Do not rely on the gun fluid regulator to limit the fluid pressure to the gun The fluid supply pump must be prevented from producing a fluid pressure greater than the 3000 psi 21 MP
55. ol will only appear if the lock is enabled See Low Voltage Lock Screen page 14 to lock or unlock the low voltage setting Figure 3 Error Display Adjusting the Low Voltage Setting The low voltage setting is user adjustable To access the low voltage setting screen when in Operating Mode press the LO SET button LS momentarily The screen will display the current low voltage setting See Fig 4 and Table 1 on page 11 The possible ranges are e 85 kV guns 40 85 kV 60 kV guns 30 60 kV Set the Voltage Adjustment switch VA to LO Press the LO SET button repeatedly to increase the setting in increments of 5 When the display reaches the ti19337a maximum setting it will return to the minimum setting Figure 5 Low Voltage Setting Screen Locked 70 3A2495C Q ie D Key for Figs 2 9 Item lt gt C Cp O lt gt lt 3A2495C Gun Overview Two position switch sets smart gun voltage to low setting LO or Voltage Adjustment Switch high setting HI This switch is functional in Operating Mode and in Diagnostic Mode Low Voltage Mode Indicator Lights blue when the smart gun is set to Low Voltage Voltage kV Display Displays actual spraying voltage of the gun in kV In Operating Mode display is a bar graph In Diagnostic Mode voltage is displayed as a number Current uA Display Displays actual spraying current of the gun in u
56. ove or rag Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately PLASTIC PARTS CLEANING SOLVENT HAZARD Many solvents can degrade plastic parts and cause them to fail which could cause serious injury or property damage Use only compatible water based solvents to clean plastic structural or pressure containing parts e See Technical Data in this and all other equipment instruction manuals Read fluid and solvent manufacturer s MSDSs and recommendations TOXIC FLUID OR FUMES Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This protective equipment includes but is not limited to Protective eyewear and hearing protection Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious inj
57. re Maximum Working Air Pressure Minimum Air Pressure at Gun Inlet Maximum Fluid Operating Temperature Paint Resistivity Range Air Inlet Fitting Fluid Inlet Fitting Output Voltage Maximum Current Draw Sound Power measured per ISO Standard 9216 Sound Pressure measured 1 m from gun Wetted Parts 3A2495C i 3 megohm cm to infinity 1 4 npsm m left hand thread 1 4 18 npsm m Pro Xp60 Models 60 kV Pro Xp85 Models 85 kV 125 microamperes at 40 psi 88 9 dB A at 0 28 MPa 2 8 bar 88 9 dB A at 100 psi 99 7 dB A at 0 7 MPa 7 0 bar 99 7 dB A at 40 psi 86 0 dB A at 0 28 MPa 2 8 bar 86 0 dB A at 100 psi 95 0 dB A at 0 7 MPa 7 0 bar 95 0 dB A PEEK UHMWPE FEP PTFE acetal nylon polyethylene 67 Graco Pro Xp Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective However any deficiency in the barrel handle trigger hook internal power supply and alternator excluding turbine bearings will be repaired or replaced for thirty six months from the date of sale This warranty applies only when the eq
58. rocedure page 27 3A2495C Maintenance Clean the outside of the gun with a compatible solvent Use a soft cloth Point the gun down to prevent solvent from entering the gun passages Do not immerse the gun ti18809a ti18810a ti18811a 29 Maintenance 7 Clean the air cap tip guard and spray tip with a soft brush and compatible solvent ti19539a 8 f necessary use a toothpick or other soft tool to clean the air cap holes Do not use metal tools ti18773a 30 9 Align the spray tip tab with the groove in the air cap Install the tip 10 Install the air cap and retaining ring Orientate the air cap and tighten the retaining ring securely ti18801a 3A2495C Maintenance Daily System Care 5 Check the movement of the trigger and valves Lubricate if necessary 1 Follow the instructions under Clean the Gun Daily page 29 Follow the Pressure Relief Procedure page 27 2 Clean the fluid and air filters 6 Check Gun Electrical Grounding page 25 7 Hang the gun from its hook with the nozzle pointing down C ti18761a 4 Clean workpiece hangers Use non sparking tools 3A2495C 31 Electrical Tests Electrical Tests Use the following procedures to test the condition Test Gun Resistance of the power supply and gun body and electrical continuity between components 1 Flush and dry the fluid passage NOTICE 2 Measure resistance between the el
59. s Box of 10 24N604 Gun Covers For 85 kV guns Box Test Equipment of 10 Ball Swivel for gun air inlet 1 4 NPEL Nana yes 241079 Megohmmeter 500 V output 24N758 Display Covers Keeps Smart display 0 01 2000 megohms Use for clean Package of 5 ground continuity and gun resistance tests Not for use in hazardous areas 24P170 Metal Trigger Kit 722886 Paint Resistance Meter Use for fluid resistivity test See manual 307263 Not for use in hazardous areas 24P172 Quick Adjust Valve For quick change of fan size 185105 Non swivel Air Inlet 1 4 18 npsm m left hand thread 185493 Air Hose Adapter 1 4 npt m x 1 4 18 npsm m left hand thread 722860 Paint Probe Use for fluid resistivity test See manual 307263 Not for use in hazardous areas 112534 Air Line Quick Disconnect Fitting 245277 Test Fixture High Voltage Probe and kV Meter Use to test the electrostatic voltage of the gun and the condition of the alternator and power supply when being serviced See manual 309455 64 3A2495C Hoses Grounded Air Hoses 700 psi 0 7 MPa 7 bar Maximum Working Pressure 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread Part No Standard Grounded Air Hose Gray 223068 223069 223070 223071 223072 0 375 in 10 mm ID 3 8 npsm f x 1 4 npsm f left hand thread 24A225 50 ft 15 m 75 ft 23 m 24A226 Grounded Air Hose with stainless steel braid ground path Re
60. uipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED BARCA PURPOSE ER TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A Graco s sole obli
61. up Checklist See Fig 11 to locate the electrostatic gun controls 4 Connect the Graco grounded air hose to the gun air inlet The gun air inlet fitting has left hand d threads 5 Follow all steps under Grounding page 21 G 6 Follow all steps under Check Gun Electrical Grounding page 25 1187852 Reading must be less than 1 megohm Figure 11 Electrostatic Gun Controls 7 Verify that the material resistivity meets 1 Turn OFF O the ES On Off switch J requirements for electrostatic spray See Check Fluid Resistivity page 26 8 Connect the exhaust tube and secure with the clamp provided 3 Check gun resistance See Test Gun Resistance page 32 10 Flush if needed See Flushing page 28 18 3A2495C Gun Setup 15 Check that the ES On Off switch is OFF O To reduce the risk of a skin in jection injury always follow the Pressure Relief Procedure page 27 before removing or installing the spray tip air cap or tip guard 16 Start the pump Set the fluid regulator to 400 psi 11 The fluid output and pattern width depend 2 8 MPa 28 bar on the size of the spray tip the fluid viscosity and the fluid pressure Use the 17 Spray a test pattern Examine the particle size in Spray Tip Selection Chart page 62 as a guide the center of the pattern tails will be removed for selecting the appropriate spray tip for your in step 21 Increase the pressure in small applic
62. ury Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations 6 3A2495C Gun Overview How the Electrostatic AA Spray Gun Works This is not an air spray gun To help prevent serious i
63. use pressing and holding the LO SET button is used to turn the lock on or off To exit press LO SET momentarily to return to the Voltage kiloVolts Screen then exit Diagnostic Mode from there ti19339a Figure 9 Low Voltage Lock Screen 3A2495C Installation Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly Do not install or service this equipment unless you are trained and qualified Be sure your installation complies with local state and national codes for the installation of electrical apparatus in a Class I Div Hazardous Location or a Group Il Zone Explosive Atmosphere Location Comply with all applicable local state and national fire electrical and other safety regulations Fig 10 shows a typical electrostatic air assisted spray system It is not an actual system design For assistance in designing a system to suit your particular needs contact your Graco distributor 3A2495C Installation 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 Provide fresh air ventilation to reduce the risk of fire or explosion caused by the buildup of flammable or toxic vapors when spraying flushing or cleaning the gun Do not operate the gun unless ventilation fa

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