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Graco 3A2494D User's Manual

1. 26 Guidelines for Abrasive Materials 26 Operation da 27 Pressure Relief Procedure oooocoooocccociccnccccnoo 27 ELE LEE O E E EA S it 27 SOUTO Nc die a e AE 27 E 28 FIUSMING coros atado tees 28 Clean the Gun Daily ooocccccnonccccccnoncccccnnnanccnns 29 Daily System Care s an 30 Electrical TEStS yeaa aa aaea atire eaa 31 Test Gun Resistance ccceeeeeeeeeeee ees 31 Test Power Supply Resistance 32 Test Electrode Resistance ccceeeeeeee 32 Troubleshooting sesan nira E 33 Spray Pattern Troubleshooting 33 Gun Operation Troubleshooting 34 Electrical Troubleshooting ocooonnnncccnnncn 35 Real iva ici ibid ezo 37 Prepare the Gun for Service ocooocccocicccnccccoo 37 Air Cap and Nozzle Replacement 38 Electrode Replacement ooocococccccccccccccccnnncnnns 39 Fluid Packing Rod Removal 40 Packing Rod Repair aeee 40 Barrel Removal 2 c ceceeeeeeeeeeeeeeeeeeeaes 42 Barrel Installation ceeeeeeeeeeeeeeeeees 42 Power Supply Removal and Replacement 22 ceeeeeeeeeeees 43 Alternator Removal and Replacement 44 Fluid Tube Removal and Replacement 46 Fan Air Adjustment Valve Repair 47 Atomizing Air Restrictor Valve Repair 48 ES On Off and Fluid Adjustment Valve A EE 49 Air Valve RepaliPooooooocccnc
2. 3A2494D Table 1 Key for Figs 2 9 Gun Overview CO O SOUS Voltage Adjustment Switch Voltage kV Display Current uA Display i Low Voltage Display Two position switch sets smart gun voltage to low setting LO or high setting HI This switch is functional in Operating Mode and in Diagnostic Mode Lights blue when the smart gun is set to Low Voltage 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 Displays actual spraying current of the gun in uA In Operating Mode display is a bar graph In Diagnostic Mode current is displayed as a number 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 Displays the low voltage setting as a number The setting can be changed See Fig 4 LK Low Voltage Locked Appears if the low voltage setting is locked See Fig 5 and Fig 9 3A2494D 11 Gun Overview CO ON CI LD LO Display Appears on the Low Voltage Lock Screen 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
3. 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 screen in the Diagnostic Mode See Fig 8 and Table 1 on page 10 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 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 10 To enter
4. 100 psi 0 7 MPa 7 bar Maximum Working Pressure 1 4 in 6 mm ID 3 8 npsm f x 5 8 20 m ptfe FM approved 24N994 26 8 ft 8 2 m Dimensions Dimensions ti19456a CN Jj e N RTO ff 3 E lo j i y NI e yr e 1G el a A L40T14 8 7 221 9 2 234 2 4 61 L40T15 8 7 221 9 2 234 sort 24 1 L60T16 9 5 241 9 2 234 2 4 61 22 6 642 23 7 673 76 3A2494D Technical Data Technical Data Electrostatic Ar Spray Guns O Oooo S PSS Maximum Fluid Operating 120 F 48 C Temperature Paint Resistivity Range 3 megohm cm to infinity For a table of electrostatic results at different resistance levels see Check Fluid Resistivity page 26 Air Inlet Fitting 1 4 npsm m left hand thread Fluid Inlet Fitting 3 8 npsm m Output Voltage Pro Xp40 Models 40 kV Pro Xp60 Models 60 kV Pro Xp85 Models 85 kV Sound Power measured per ISO at 40 psi 90 4 dB A at 0 28 MPa 2 8 bar 90 4 dB A Sound Pressure measured 1 m at 40 psi 87 0 dB A at 0 28 MPa 2 8 bar 87 0 dB A Wetted Parts PEEK UHMWPE FEP PTFE acetal nylon polyethylene 3A2494D 77 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 ex
5. e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury 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 MPa bar PSI 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
6. ti18758a 21 Turn on the air to the gun Turn ON I the ES On Off switch J 20 22 Spray a test pattern Check the atomization If over atomization occurs at minimum pressure adjust the restrictor valve If atomization is inadequate increase air pressure or decrease be ti18759a 23 Adjust the fan air adjustment valve clockwise for a narrower pattern counterclockwise for a wider pattern 24 Spray a test piece Examine the edges for coverage If wrap is poor see Troubleshooting page 33 ti18760a 3A2494D 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 Pump fluid source ground the pump fluid source by connecting its ground wire to a true earth ground ti18723a e Electro
7. 8 4 9 6 Nem Install the tube 36 and clamp 43 3 To replace the air inlet swivel 52 a Unscrew the swivel 21 from the gun handle 16 The swivel is a left hand thread b Apply thread sealant to the top threads of the swivel Screw the swivel into the gun handle Torque to 75 85 in lb 8 4 9 6 Nem Ds Figure 40 Air Inlet Fitting and Air Exhaust Valve ti19725a 3A2494D Parts Standard Air Spray Gun Assembly Part No L40T10 40 kV Electrostatic Air Spray Gun Series A Part No L40T14 40 kV High Efficiency Electrostatic Air Spray Gun Series A Part No L60T10 60 kV Electrostatic Air Spray Gun Series A Part No L60T11 60 kV Electrostatic Round Spray Gun Series A Part No L60T12 60 kV Electrostatic Air Spray Gun Series A with 1 2 mm Nozzle Part No L85T10 85 kV Electrostatic Air Spray Gun Series A 40 3A2494D ti18636b Parts 53 Parts Part No L40T10 40 kV Electrostatic Air Spray Gun Series A Part No L40T14 40 kV High Efficiency Electrostatic Air Spray Gun Series A Part No L60T10 60 kV Electrostatic Air Spray Gun Series A Part No L60T11 60 kV Electrostatic Round Spray Gun Series A see Round Spray Assembly page 55 Part No L60T12 60 kV Electrostatic Air Spray Gun Series A with 1 2 mm Nozzle Part No L85T10 85 kV Electrostatic Air Spray Gun Series A A ce A 1 24N665 BODY gun 40 kV gun 24N666 BODY gun 60 kV gun 24N667 BODY gun 85 kV gun 24N668 B
8. ER Hz ti19338a 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 10 The possible ranges are e 85 kV guns 40 85 kV e 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 maximum setting it will return to the minimum setting 10 for your gun Continue pressing the button until you reach the desired setting NOTE After 2 seconds of inactivity the display will return to the Operating Screen NOTE The low voltage setting may be locked See Lock Symbol page 10 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 10 e When in HI mode the low voltage setting is always locked The lock symbol will appear when the LO SET button is pressed e When in LO mode the lock symbol will only appear if the lock is enabled See Low Voltage Lock Screen page 14 to lock or unlock the low voltage setting ti19337a Figure 5 Low Voltage Setting Screen Locked
9. SPRING compression in small 117823 and large 19 249323 VALVE exhaust 46 24N603 COVER 60 kV 1 19a 1112085 O RING gan ne ia package of 10 24N604 COVER gun 85 kV guns 21 24A626 SWIVEL air inlet M12 x 1 4 1 package of 10 aa ee ee ce fase 278783 SEAL arvave Jr o 4 Replacement Danger and Warning labels tags These parts are included in Air Seal Repair Kit and cards are available at no cost 24N789 purchase separately 2 24N663 TRIGGER includes item 13 3 24A445 SCREW trigger package of 2 1 Assembly page 67 Alternator Assembly page 63 wo e o 3A2494D 59 Parts Smart Air Spray Gun Assembly Part No L60M10 60 kV Electrostatic Air Spray Gun Series A Part No L60M12 60 kV Electrostatic Air Spray Gun Series A with 1 2 mm Nozzle Part No L85M10 85 kV Electrostatic Air Spray Gun Series A 40 ti19443b 60 3A2494D Parts Part No L60M10 60 kV Electrostatic Air Spray Gun Series A Part No L60M12 60 kV Electrostatic Air Spray Gun Series A with 1 2 mm Nozzle Part No L85M10 85 kV Electrostatic Air Spray Gun Series A 1 24N666 BODY gun 60 kV gun 24N667 BODY gun 85 kV gun See Packing Rod Assembly page 62 24N651 NEEDLE electrode and 4b Se and 4b p al id 198307 PACKING u cup UHMWPE 111286 FERRULE front 111285 FERRULE back 24N657 FITTING fluid 60 kV gun 24N658 _ FITTING fluid 85 kV gun 102982 PACKING o ri
10. 3A2494D Air Caps and Fluid Nozzles Table 5 Orifice Size 0 75 mm 0 030 in Table 8 Orifice Size 1 5 mm 0 059 in FLUID FLOW FLUID FLOW oz min cc min oz min cc min FLUID FLOW FLUID FLOW oz min cc min oz min cc min Table 7 Orifice Size 10 15 20 25 30 rH 7 gt 4 7 T e AA FLUID FLOW oz min cc min FLUID FLOW oz min cc min 3A2494D 69 Air Caps and Fluid Nozzles Air Cap Selection Chart To reduce the risk of an injury follow the Pressure Relief Procedure page 27 before removing or installing a fluid nozzle and or air cap Part No Pattern Length Recommended color Shape in mm Fluid Viscosity in centipoise cp at 70 F 21 C 0 NOTE All air cap pattern shapes and lengths in the following chart were measured under the following conditions Pattern shape and length are material dependent e Distance to target 10 in 254 mm Inlet air pressure 50 psi 34 kPa 3 4 bar e Fan air adjusted for maximum width e Fluid flow rate 10 oz min 300 cc min Cleanli ness Atomiza tion Transfer Efficiency Recommended Production Rates 24N438 Round 15 17 Light to medium Up to 15 oz min 450 Better Best Good black end 381 432 20 70 cp cc min 24N279 black 24N376 black 24N276 blue 24N277 red 24N278 green Tapered 17 19 Light to medium end 432 483 20 70 cp Round 14 16 Medium to heavy end 356 406
11. 70 260 cp and high solids 360 cp Up to 15 oz min 450 cc min Up to 15 oz min 450 cc min 24N274 Tapered 12 14 Light to medium Up to 15 oz min 450 Good Good Best black end 305 356 20 70 cp cc min 24N275 black Tapered 14 16 Light to medium end 356 406 20 70 cp and high solids 360 cp aerospace coatings 24N439 black 24N477 black 24W279 green Round 15 17 Light to medium end 381 432 20 70 cp 4 Centipoise centistokes x fluid specific gravity Tapered 11 13 For use with 2 0 mm end 279 330 nozzles Medium to heavy 70 260 cp and high solids 360 cp Up to 25 oz min 750 cc min Up to 20 oz min 600 cc min Up to 15 oz min 450 cc min 24N453 Round 14 16 Light to medium Up to 15 oz min 450 Better Better Good black end 356 406 20 70 cp cc min 70 3A2494D Air Caps and Fluid Nozzles Air Consumption Charts Key to Air Consumption Charts TEST CONDITIONS Fan valve fully open 85 kV gun 5 16 in x 25 ft 8 mm x 7 6 m hose 5 16 in x 50 ft 8 mm x 15 2 m hose Table 13 24N439 Air Cap AIR CON AIR CON SUMPTION SUMPTION scfm scfm 20 30 40 50 60 70 80 WALL PRESSURE psi Table 12 24N376 24N276 24N277 and 24N278 Table 14 24N279 Air Cap Air Caps AIR CON AIR CON SUMPTION SUMPTION scfm scfm 20 30 40 50 60 70 80 20 30 40 50 60 70 80 WALL PRESSURE WALL PRESSURE psi psi 3A2494D 71 Air
12. 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 5 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 16 3A2494D NON HAZARDOUS AREA MA AF BV i el A CO Installation HAZARDOUS AREA SV AF BV l H aE mumnin O PG BV q SY PR HO Di I J A FD AD Figure 10 Typical Installation Typical Installation Key tem pesin O Graco Grounded Air Hose left hand threads 3A2494D ti18782a MA PR Pump Ar Pressure Regulator Fluid Shutoff Va
13. PSI 3A2494D Warnings PRESSURIZED EQUIPMENT HAZARD Fluid from the equipment leaks or ruptured components can splash in the eyes or on skin and cause serious injury e Follow the Pressure Relief Procedure when you stop spraying dispensing and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes 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 manufacturers 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 MSDS s to know the specific hazards of the fluids you are using 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 e Protective eyewear and hearing protection
14. See Pushing paga 2H 6 Clean the air cap retaining ring and nozzle with Follow the Pressure Relief Procedure page 27 a soft brush and compatible solvent 4 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 ti18772a 7 If necessary use a toothpick or other soft tool to clean the air cap holes Do not use metal tools t118773a 8 Reinstall the air cap Tighten securely ti18769a t118774a ti18770a 3A2494D 29 Maintenance Daily System Care 1 Follow the Pressure Relief Procedure page 27 4 Clean workpiece hangers Use non sparking 2 Clean the fluid and air filters tools 3 Check for fluid leaks Tighten all fittings Y TS Cpe E 5 Check the movement of the trigger and valves Lubricate if necessary o Check Gun Electrical Grounding page 25 N Hang the gun from its hook with the nozzle pointing down 30 3A2494D Electrical Tests Use the following procedures to test the condition of the power supply and gun body and electrical continuity between components Use megohmmeter Part No 241079 AA and an applied voltage of 500 V Connect the leads as shown 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 unl
15. an injury follow the or other serious injury if the work is not performed Pressure Relief Procedure page 27 whenever properly Do not install or repair this equipment you are instructed to relieve the pressure unless you are trained and qualified Installing and servicing this equipment requires Check all possible remedies in the Troubleshooting Chart before disassembling the gun Spray Pattern Troubleshooting Some spray pattern problems are caused by the improper balance between air and fluid Poem TO CN Fluttering or spitting spray No fluid Refill supply Loose dirty damaged Clean or replace nozzle see nozzle seat Clean the Gun Daily page 29 or D Air Cap and Nozzle Replacement page 38 Air in fluid supply Check fluid source Refill Improper spray pattern Damaged or dirty nozzle or air cap Clean or replace See Air Cap and Nozzle Replacement page 38 Fluid buildup on air cap or nozzle Clean See Clean the Gun Daily page 29 CD Streaks Did not apply 50 overlap Overlap strokes 50 Dirty or damaged air cap Clean or replace air cap See Clean the Gun Daily page 29 or Air Cap and Nozzle Replacement page 38 3A2494D 33 Troubleshooting Gun Operation Troubleshooting CT CAN CN Excessive spray fog Atomizing air pressure too high Close restrictor 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 volt
16. are clean Remove any residue with a soft brush or cloth Check the inside of the barrel for marks from high voltage arcing If marks are present replace the barrel 1 Place the packing nut 2f and seal 2b on the fluid rod 2e Flats on the packing nut must face the back of the fluid rod The seal o ring must face away from the packing nut 2 Fill the inner cavity of the spacer 2ht with dielectric grease 44 Place the spacer on the fluid rod 2e in the direction shown Generously apply dielectric grease to the outside of the spacer 3 Place the fluid packing 2c on the packing rod 2e with its lips facing the front of the rod Install the needle packing 2d with the male end toward the fluid packing then install the housing 29 17 ti19450a Figure 23 Packing Rod 3A2494D Repair Lightly tighten the packing nut 2f The packing nut is properly tightened when there is 3 Ib 13 3 N of drag force when sliding the packing housing 2g assembly along the rod Tighten or loosen the packing nut as needed Install the o ring 2a on the outside of housing 2g Lubricate the o ring with non silicone grease Part No 111265 Do not over lubricate Install the spring 17 against the nut 2j as shown Install the packing rod assembly 2 into the gun barrel Using the multi tool 41 tighten the assembly until just snug Install the electrode See Electrode Replacement page 39 Install the nozz
17. from work area Comply with all applicable safety regulations 6 3A2494D Gun Overview Gun Overview How the Electrostatic Spray Gun Works The air hose supplies air to the spray gun Part of The pump supplies fluid to the fluid hose and gun the air operates the alternator turbine and the rest where the fluid is electrostatically charged as it of the air atomizes the fluid being sprayed The passes the electrode The charged fluid is attracted alternator generates power which is converted by to the grounded workpiece wrapping around and the power cartridge to supply high voltage to the evenly coating all surfaces gun s electrode 3A2494D Gun Overview Controls Indicators and Components The electrostatic gun includes the following controls indicators and components see Fig 1 For information on Smart guns also see Smart Guns page 9 ti18752a Figure 1 Gun Overview Descrip Purpose Descrip Purpose tion tion Air Swivel 1 4 npsm m left hand thread Fluid Ad Adjusts fluid flow by limiting Inlet for Graco grounded air supply justment fluid needle travel Use only hose Knob in low flow conditions to Fluid Inlet 3 8 npsm m for fluid supply reduce wear hose bal ES On Off Turns electrostatics ON I o Turbine Air Barbed fitting for supplied Valve OFF 0 Exhaust exhaust tube ES Indica Litwhen ES is ON I Color in tor stan dicates alternato
18. 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 because 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 3A2494D 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 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 typica
19. 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 Hz Alternator Speed Indicator In Operating Mode indicator color varies to show the alternator speed status e green indicates the alternator speed is at the correct level If the indicator changes to amber after 1 second 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 Speed Hertz screen 12 3A2494D Diagnostic Mode Diagnostic Mode includes four screens which display gun data e Voltage kiloVolts Screen e Current microAmperes Screen e Alternator Speed Hertz Screen e 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 nex
20. y e 24N699 GASKET barrel 24N626 SWIVEL air inlet M12 x 1 4 npsm m left hand thread 24N733 For round spray gun only see Atomizing Air Restrictor Valve Assembly page 65 Assembly page 65 24N732 For round spray gun only see Fan Air Adjustment Valve Assembly page 65 35 PACKING u cup 6 24N630 See ES On Off and Fluid Adjustment Valve page 64 29 24T304 See Atomizing Air Restrictor Valve Assembly page 65 30 4 3A2494D Parts No 6 24N603 COVER gun 40 and 60 kV 1 guns package of 10 0 107460 TOOL wrench ball end 4 mm 1 24N604 COVER gun 85 kV guns 1 shipped loose package of 10 276741 MULTI TOOL shipped loose 179791 TAG warning not shown 4N786 PLUG restrictor shipped loose 84 16P802 SIGN warning not shown for use instead of item 29 9 24N730 DIFFUSER for round 1 110231 CLAMP exhaust tube shipped spray gun only see loose Round Spray Assembly page 55 4 116553 GREASE dielectric 1 oz 30 1 50 24N783 HOOK includes screw 1 Pl E e 45 117824 GLOVE conductive medium 1 package of 12 also available in small 117823 and large 117825 4 Replacement Danger and Warning labels tags Round Spray Assembly and cards are available at no cost No 36 185103 TUBE exhaust 1 4 in 6 mm 1 ID shipped loose These parts are included in Air Seal Repair Kit 24N789 purchase separately t These parts are included in Fluid Seal Repair Kit 24N7
21. 448a Figure 21 Electrode Replacement Repair 39 Repair Fluid Packing Rod Removal 1 2 See Prepare the Gun for Service page 37 Remove the air cap and fluid nozzle See Air Cap and Nozzle Replacement page 38 Remove the electrode See Electrode Replacement page 39 Loosen the trigger screws 13 and remove the trigger 12 Remove the packing rod 2 using the multi tool 41 Remove the spring 17 Check all parts for wear or damage and replace if necessary 13 ti19449a Figure 22 Fluid Packing Rod Removal 40 Packing Rod Repair NOTE You may replace the packing rod as individual parts or as an assembly Adjust the Air Flow Lead and Lag NOTE The gun begins emitting air before the fluid is discharged and the fluid stops before the air flow stops The packing rod assembly is pre adjusted at the factory for proper air lead and lag Adjust only if necessary as follows 1 2 Remove the spring 17 from the nut 2k Use a hex wrench to hold the end of the packing rod Turn both adjustment nuts 2j 2k out to increase the lead lag time for the air flow The recommended adjustment is one half turn and not more than one full turn 2K 2J Tighten the nuts together to fix them in the new position Jeet ti19723a 3A2494D Assemble the Packing Rod NOTE Before installing the fluid packing rod into the gun barrel make sure the internal surfaces of the barrel
22. 90 purchase separately NOTE On 40 kV guns the o ring 10 is not used and ferrules 7 and 8 are part of the top fitting 9 ti19726a 3A2494D 55 Parts Standard High Conductivity Air Spray Gun Assembly Part No L40T16 40 kV Electrostatic High Conductivity Air Spray Gun Series A Part No L40T15 40 kV High Efficiency Electrostatic Air Spray Gun Series A Part No L60T16 60 kV Electrostatic High Conductivity Air Spray Gun Series A Part No L85T16 85 kV Electrostatic High Conductivity Air Spray Gun Series A 43 Ql 40 56 ti18638b 3A2494D Parts Part No L40T16 40 kV Electrostatic High Conductivity Air Spray Gun Series A Part No L40T15 40 kV High Efficiency Electrostatic Air Spray Gun Series A Part No L60T16 60 kV Electrostatic High Conductivity Air Spray Gun Series A Part No L85T16 85 kV Electrostatic High Conductivity Air Spray Gun Series A 24N665 BODY gun 40 kV gun 24N666 BODY gun 60 kV gun efficiency gun See Packing Rod Assembly page 62 24A445 SCREW trigger package of 2 See High Conductivity Fluid Tube Assembly page 67 24N664 See Alternator Assembly page 63 24N751 HANDLE 40 kV gun 24N752 HANDLE 60 kV gun 1Z o m N al ala ala A FARDE 50 Von 197624 249323 19a 112085 24N741 24N626 N SPRING compression o VALVE exhaust O RING BRACKET SWIVEL air inlet M12 x 1 4 npsm m l
23. Caps and Fluid Nozzles Table 15 24N274 Air Cap AIR CON SUMPTION scfm 20 30 40 50 60 70 80 WALL PRESSURE psi Table 16 24N275 Air Cap AIR CON SUMPTION scfm 20 30 40 50 60 70 80 WALL PRESSURE psi 72 Table 17 24N453 Air Cap AIR CON SUMPTION scfm 0 20 30 40 50 60 70 80 WALL PRESSURE psi Table 18 24N477 24W279 Air Cap AIR CON SUMPTION scfm 20 30 40 50 60 70 80 WALL PRESSURE psi 3A2494D Repair Kits Related Manuals and Accessories Repair Kits Related Manuals and Accessories Manual Description Repair Kits Repair Kit Description No All guns in 40 kV 60 kV and 85 Electrostatic Air this manual kV Air Spray Guns Spray Guns Instructions Parts Gun Accessories Pan no Descrplion 24P170 Metal Trigger Kit 24P171 Four Finger Trigger Kit To convert eee air spray guns to a four finger 24N318 Round Spray Kit To convert a l 7 standard air spray gun to a round 24P172 as Doo For quick spray air cap See manual 3A2498 se ee 24N603 Gun Covers For 40 kV and 60 kV A re le a guns Box of 10 ethane thread 185493 Air Hose Adapter 1 4 npt m x 24N604 oa For 85 kV guns Box 1 4 18 npsm m left hand thread 24N636 Low Profile Atomizing Air Restrictor ioe ARAN OEK Diggonnect Fig Valve 24N627 High Conductivity Conversion ae 24N628 Kits To convert a standard Pro 24N642 Ball Swivel for gun air inlet 1 4 24N629 Xp air spray gun to an HC g
24. Instructions Parts GRACO Pro Xp Electrostatic Air Spray A2494D Gun 2 3 EN For use in Class Div Hazardous Locations using Group D spray materials For use in Group Il 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 100 psi 0 7 MPa 7 0 bar Maximum Fluid Working Pressure 100 psi 0 7 MPa 7 0 bar Maximum Air Working Pressure See page 3 for model part numbers and approval information ti18635a PROVEN QUALITY LEADING TECHNOLOGY Contents MOGelS ea asuna a A aaa a ree 3 Warnings isis dile PA LAAN EI EN ADAAN 4 Gun OVEIVICW cococcccnnccnnnccncnncnnnnnnnnnncnnnnnnnnnncnnnnnn 7 How the Electrostatic Spray Gun WOLK Sier inle aaae iio 7 Controls Indicators and Components 8 Smart GUNS ia a a Aaa 9 Installation wise eiei adia aa 15 Warning Sig eioan naasa iann e ERAT EENAA 15 Ventilate the Spray Booth cece 15 Air Supply Liness ana aN 16 Fluid Supply Line 2 cccceeeeeeeeeeeeeeeees 16 GUNCSetUp aac enciae ies et eee at ates 18 Gun Setup Checklist c cceeeeeeeeeee ees 18 A todd shade SE 21 Check Gun Electrical Grounding 25 Check Fluid Resistivity ooooccoononcccccnnnnncccos 26 Check Fluid Viscosity oooooccconnnncccccnnncncccns 26 Flush Before Using Equipment
25. ODY gun 40 kV high efficiency gun See Packing Rod Assembly page 62 24N651 NEEDLE electrode and 4b ial alae and 4b 24N729 NOZZLE round spray includes 4a and 4b see Round Spray Assembly page 55 4a 24N645 O RING conductive b 111507 O RING fluoroelastomer 24N477 AIR CAP 24N731 AIR CAP round spray see Round Spray Assembly page 55 24N644 RING retainer includes 6a Ga 198307 PACKING u cup UHMWPE t 1111286 FERRULE front 40 kV gun 111286 FERRULE front 60 and 85 kV guns 8t 111285 FERRULE back 40 kV gun al N 111285 FERRULE back 60 and 85 kV 2 guns 24N656 FITTING fluid 40 kV gun 24N657 FITTING fluid 60 kV gun 10 102982 PACKING o ring 60 and 85 kV guns onl 1 24N659 POWER SUPPLY 40 kV gun 24N660 POWER SUPPLY 60 kV gun 24N661 POWER SUPPLY 85 kV gun 11a 24N979 SPRING 2 24N663 TRIGGER includes item 13 24N658 FITTING fluid 85 kV gun E 54 ie i al 24A445 SCREW trigger package of 2 14 24N695 TUBE fluid 40 kV gun gun gun Alternator Assembly page 63 16 24N751 HANDLE 40 kV gun 24N752 HANDLE 60 kV gun 185111 SPRING compression 197624 SPRING compression o a a oa 00 249323 VALVE exhaust 19a 112085 O RING o N 24N741 BRACKET 3 24N633 VALVE air 3a 276733 SEAL air valve N 7 24N740 SCREW hex socket sst package of 2 24N753 HANDLE 85 kV gun n n
26. T into the bracket fitting 20 Ensure that the ferrules 7 8 are in place Tighten the nut N securely onto the fitting Make sure the top fitting remains tight 5 See Test Gun Resistance page 31 ti19452a Figure 25 Barrel Installation 3A2494D Power Supply Removal and Replacement e Inspect the gun handle power supply cavity for dirt or moisture Clean with a clean dry rag Do not expose gasket 28 to solvents 1 2 See Prepare the Gun for Service page 37 See Barrel Removal page 42 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 24 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 24 from the power supply Slide the alternator up and off the power supply See Test Power Supply Resistance page 32 Replace the power supply if necessary To repair the alternator see Alternator Removal and Replacement page 44 To prevent damage to the cable and possible interruption of the ground continui
27. a ete lee 76 Technical Data Psie a A 77 Graco Pro Xp Warran y ccseeeeeeeeeeeeeeeaaeeeees 78 3A2494D Models Models Part No Nozzle Standard Smart Standard High Increased ae ound Display Display Coatings Conductivity lc tomio ao v DICO Ea el ea E IS EA E EE TECATE 0 209 Ze PRI INIA ESE A isoris ls y vv Y pp isorio foo v pp ata AEREO dls isorrz oo Jef Y vv ae palo ao o AA AAA usomto so y Y v isomz jeo Jv Y vs usos so y Y estio ss v v v ee Ao A A ee A isso ss v _ Y vs ssm es y __ Y _v _ CE Ex Mz 0359 12G APPROVED EEx 0 24 mJ T6 FM12ATEX0068 EN 50050 Ta 0 C 50 C SIS 3A2494D 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 symbols refer 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 explosio
28. age Fluid too thin or fluid flow is too Increase viscosity or increase fluid low flow rate Orange Peel finish Atomizing air pressure too low Open atomizing air valve more or increase gun air inlet pressure use lowest air pressure necessary Poorly mixed or filtered fluid Remix or refilter fluid Fluid too thick Reduce viscosity Fluid leaks from the fluid packing Worn packings or rod See Packing Rod Repair page 40 area Air leaks from the front of the gun Air valve is not seating properly See Air Valve Repair page 50 Fluid leakage from the front of the Worn or damaged fluid packing Replace packing rod 2e gun rod or electrode or electrode 3 See Packing Rod Repair page 40 or Electrode Replacement page 39 Worn fluid nozzle seat Replace nozzle 4 See Air Cap and Nozzle Replacement page 38 Loose fluid nozzle Tighten Damaged nozzle o ring See Air Cap and Nozzle Replacement page 38 Gun does not spray Low fluid supply Add fluid if necessary Dirty or clogged fluid nozzle Clean See Clean the Gun Daily page 29 Closed or damaged fluid Open valve or see adjustment valve ES On Off and Fluid Adjustment Valve Repair page 49 Dirty air cap Misaligned air cap and fluid nozzle Clean fluid buildup off air cap and fluid nozzle seat See Clean the Gun Daily page 29 Excessive paint wrap back to Poor grounding See Grounding page 21 operator Incorrect distance from gun to pa
29. bricate Do not lubricate the conductive contact ring 4a 4 Make sure the conductive contact ring 4a and the small o ring 4b are in place on the nozzle 4 Lightly lubricate the small o ring 4b NOTE The conductive contact ring 4a may show some wear at the point where it makes contact with the barrel pin This is normal and does not require replacement 5 Make sure the electrode needle 3 is finger tight 6 Trigger the gun while installing the fluid nozzle 4 with the multi tool 41 Tighten until the fluid 38 nozzle seats in the gun barrel 1 8 to 1 4 turn past hand tight 7 Install the air cap 5 and retaining ring 6 Make sure the u cup 6a is in place with the lips facing forward 8 See Test Gun Resistance page 31 ti19447a Figure 20 Air Cap and Nozzle Replacement 3A2494D Electrode Replacement 1 See Prepare the Gun for Service page 37 2 Remove the air cap and nozzle See Air Cap and Nozzle Replacement page 38 3 Unscrew the electrode 3 with the multi tool 41 NOTICE To avoid damaging the plastic threads be very careful when installing the electrode 4 Apply low strength purple Loctite or equivalent thread sealant to the electrode and packing rod threads Install the electrode finger tight Do not overtighten 5 Install the fluid nozzle and air cap See Air Cap and Nozzle Replacement page 38 6 See Test Gun Resistance page 31 3A2494D ti19
30. cconnccconccccnoncnoncncnnnnnns 50 Smart Module Replacement 005 51 Air Swivel and Exhaust Valve Replacement 0 eeeeeeeeeeees 52 Pam ocio cer tiht hs Gi ta eii tbh o ese ios 53 Standard Air Spray Gun Assembly 53 Round Spray Assembly c ceeeeeeeeeeeees 55 Standard High Conductivity Air Spray Gun Assembly eer 56 Smart High Conductivity Air Spray Gun ASSOMDIY oc c ccececeedeecedeeteneseceeeeeenee 58 Smart Air Spray Gun Assembly 05 60 Packing Rod Assembly 62 Alternator Assembly c ceeeeeeneeeeeeeeeeeeees 63 ES On Off and Fluid Adjustment Valve 64 Fan Air Adjustment Valve Assembly 65 Atomizing Air Restrictor Valve Assembly ee 65 Smart Module Assembly 66 High Conductivity Fluid Tube Asset dc 67 Air Caps and Fluid Nozzles ooooooocccccccccoccccnncccnos 68 Fluid Nozzle Selection Chart 05 68 Fluid Nozzle Performance Charts 68 Air Cap Selection Chart ceeeeeeeeees 70 Air Consumption Charts 2 00ceeeeeeees 71 Repair Kits Related Manuals and Accessories coocoocccoocccccnccccnnnncncncncnnnnnnnnno 73 GUN ACCOESSOMCS sssri apinoista hatarii T3 Operator ACCESSOIIES 2 2 cceeeeeeeeeeeeee 74 System Accessories cc eeeeeeeeeeeeeeeeeeeeeeees 74 Test Equipment ceceeeeeeeeeeeeeeeeeeees 74 HOSE Serenan O 75 DIMENSIONS sse e a
31. der Part No 111265 Lubricant Do not over lubricate 3A2494D Repair 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 6a Fluid Seal Repair Kit 24N790 is available The kit must be purchased separately Kit parts are marked with a symbol for example 2a 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 37 Repair Air Cap and Nozzle Replacement NOTICE Trigger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from entering the air passages 1 See Prepare the Gun for Service page 37 2 Remove the retaining ring 6 and air cap 5 3 Trigger the gun while removing the fluid nozzle 4 assembly with the multi tool 41 The nozzle contact ring 4a is a conductive contact ring not a sealing o ring To reduce the risk of sparking or electric shock do not remove the nozzle contact ring 4a except to replace it and never operate the gun without the contact ring in place Do not replace the contact ring with anything but a genuine Graco part NOTICE Use non silicone grease Part No 111265 on the small o ring 4b Do not over lu
32. djustment Valve Repair page 49 Remove the spring 34 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 Inspect the u cup 35 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 m M IS N 9 IN ti19724a Figure 36 Install U Cup 10 11 Install the air valve 23 and spring 34 into the gun handle 16 Install the ES On Off Valve See ES On Off and Fluid Adjustment Valve Repair page 49 Install the trigger 12 and screws 13 See Barrel Installation page 42 26 ti19454a Figure 37 Air Valve 3A2494D 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 2 See Prepare the Gun for Service page 37 Remove the pivot screw 31e o ring 31f and ES HI LO switch 31c at the bottom left corner of the Smart Module cartridge 31a Remove the remaining three screws 31d from the cartridge Pull the Smart Module out the back of the gun Disconnect the ribbon cable RC from the connector GC in the gun handle Remove the gask
33. e 28 2 Follow the Pressure Relief Procedure page 27 Hang the gun from its hook with the nozzle pointing down 3A2494D 27 Maintenance Maintenance Flushing Flush before changing fluids before fluid can dry in the equipment at the end of the day before storing 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 To reduce the risk of fire explosion or electric shock turn OFF O the ES On Off switch before flushing the gun NOTICE Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components 1 Turn OFF O the ES On Off switch 28 Follow the Pressure Relief Procedure page 27 Change the fluid source to solvent or disconnect the fluid line and connect a solvent supply line to the gun Point the gun into a grounded metal pail Flush until clean solvent flows from the gun Shut off or disconnect the solvent line Hang the gun from its hook with the nozzle pointing down When ready to spray again reconnect the fluid supply line Follow the Gun Setup Checklist page 18 3A2494D Maintenance Clean the Gun Daily 1 Turn OFF O the ES On Off switch 5 Remove the air cap t118771a 2 Flushithe gun
34. e fluid line to control fluid pressure to the gun Hose 3 Install a fluid filter FF near the pump outlet to 1 See Fig 10 Use the Graco Grounded Air Supply remove particles and sediment which could clog Hose AH to supply air to the gun The gun air the spray nozzle 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 2 Install an air line filter water separator AF on the To reduce the risk of serious injury including gun air line to ensure a dry clean air supply to the splashing fluid in the eyes or on the skin do gun Dirt and moisture can ruin the appearance not operate equipment without the fluid drain of your finished workpiece and can cause the valve FD installed gun to malfunction 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 3 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 splashing fluid in the eyes or on the skin Do not operate the equipment without the bleed type air valve BV installed 4
35. e 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 A high conductivity kit or high conductivity hose may be required for readings less than 25 megohm cm Table 4 Fluid Resistivity Levels mac id High Con High Con Best elec ductivity ductivity trostatic Kit recom Kit may be results mended needed Good elec trostatic results 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 4 Ifthe 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
36. eft hand thread 4 Replacement Danger and Warning labels tags and cards are available at no cost o Mil 3A2494D 4N633 VALVE air N FR N 3a 276733 SEAL air valve 6 24N630 See ES On Off and Fluid Adjustment Valve page 64 24N740 SCREW hex socket sst package of 2 24N699 GASKET barrel 24T304 See Atomizing Air Restrictor Valve Assembly page 65 Y Si N 00 24N634 See Fan Air Adjustment Valve 1 Assembly page 65 185116 SPRING compression 35 188749 PACKING u cup 185103 TUBE exhaust 1 4 in 6 mm ID shipped loose wo oO N o 107460 TOOL wrench ball end 4 mm shipped loose for use instead of item 29 loose GREASE dielectric 1 oz 30 ml tube not shown 117824 GLOVE conductive medium package of 12 also available in small 117823 and large 117825 guns package of 10 package of 10 A o o 46 474 179791 TAG warning not shown 8 16P802 SIGN warning not shown 50 24N783 HOOK includes screw gt These parts are included in Air Seal Repair Kit 24N789 purchase separately 57 Parts Smart High Conductivity Air Spray Gun Assembly Part No L60M16 60 kV Electrostatic High Conductivity Air Spray Gun Series A Part No L85M16 85 kV Electrostatic High Conductivity Air Spray Gun Series A 6a 40 ti19445b 58 3A2494D Parts Part No L60M16 60 kV Electrostatic High Conduct
37. emove the alternator 15 from the power supply See Alternator Removal and Replacement page 44 Measure resistance from the power supply s ground strips EE to the spring 11a The resistance should be 60 85 megohms for 40kV guns e 86 110 megohms for 60kV guns e 130 160 megohms for 85kV guns If outside this range replace the power supply If in range go to Test Electrode Resistance page 32 If you still have problems refer to Electrical Troubleshooting page 35 for other possible causes of poor performance or contact your Graco distributor Be sure the spring 11a is in place before reinstalling the power supply ti18735a Figure 18 Test Power Supply Resistance 32 Test Electrode Resistance Remove the electrode 3 See Electrode Replacement page 39 Measure the resistance between the contact HH and the electrode wire GG The resistance should be 8 30 megohms If out of range replace the electrode NOTE If the gun resistance is still out of range after testing the power supply and electrode Check that the conductive o ring 4a is making contact with the barrel pin e Check that the power supply spring 11a is making contact with the barrel pin ti18736a Figure 19 Test Electrode Resistance 3A2494D Troubleshooting Troubleshooting access to parts which may cause an electric shock To reduce the risk of
38. ess Electrical Tests Test Gun Resistance Flush and dry the fluid passage For Model L40T14 and L40T15 guns only Test the barrel continuity to verify that the metal pin in the barrel is properly grounded Measure resistance between the metal pin GP and the air swivel 21 The resistance should be less than 100 ohms If the resistance is 100 ohms or more replace the gun body For all guns Trigger the gun and measure resistance between the electrode needle tip 3 and the air swivel 21 The resistance should be e 75 120 megohms for 40kV guns The gun has been removed from the hazardous P MOE eS eee area e 148 193 megohms for 85kV guns 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 If outside this range test the gun untriggered If still outside this range go to Test Power Supply Resistance page 32 If in range see Electrical Troubleshooting page 35 for other possible causes of poor performance Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage ti18734a Figure 17 Test Gun Resistance 3A2494D 37 Electrical Tests Test Power Supply Resistance 1 Remove the power supply 11 See Power Supply Removal and Replacement page 43 R
39. et 31b Install a new gasket 31b on the new cartridge 31a Make sure the notched corners of the gasket are at the top 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 Install the pivot screw 31e o ring 31f and ES HI LO switch in the bottom left corner of the cartridge 31a Install the three remaining screws 31d Torque to 7 9 in lb 0 8 1 0 Nem 3A2494D Repair ti19455b Figure 38 Smart Module pia RC GC ti21701a LJ Figure 39 Align Ribbon Cables 57 Repair Air Swivel and Exhaust Valve Replacement 1 2 See Prepare the Gun for Service page 37 To replace the air exhaust valve a g Remove the clamp 43 and the exhaust tube 36 Unscrew the swivel 21 from the gun handle 16 The swivel is a left hand thread Remove the bracket 20 Pull the exhaust valve 19 from the handle 16 Inspect the o ring 19a and replace if necessary Install the o ring 19a on the exhaust valve 19 Lubricate the o ring with a light coating of non silicone grease Install the exhaust valve 19 in the handle 16 Apply thread sealant to the top threads of the swivel 21 Position the bracket 20 and screw the swivel into the gun handle 16 Torque to 75 85 in lb
40. g 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 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 a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information 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 3A2494 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
41. ginal 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 CUA A TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A Graco s sole obligation 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 furnishin
42. he 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 3A2494D Gun Overview Voltage Adjustment Switch The voltage adjustment switch VA allows the operator to change from low to high voltage The 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 page 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 kV LS ti19121a Figure 2 Smart Gun Module in Operating Mode Gun Overview Error Display If the Smart module loses communication with the power supply the Error display appears the Hz indicator turns red and the Smart module is disabled See Fig 3 and Table 1 on page 10 This can occur in Operating Mode or Diagnostic Mode See Electrical Troubleshooting page 35 Communication must be restored to make the Smart module functional 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
43. hread the valve stem 29e halfway into the valve body 29b Align the slot S in the valve stem with the rib R in the gun handle Screw the valve assembly 29 into the gun handle 16 using a wrench on the flats of the housing Torque to 15 in Ib 1 7 Nem NOTE If the atomizing air restrictor valve is not desired install the supplied plug 42 48 oh ti18646b Figure 33 Atomizing Air Restrictor Valve On ti21702a Figure 34 Align Valve Stem 3A2494D See Prepare the Gun for Service page 37 Loosen the captive screw 26p Remove the valve 26 from the handle Lubricate the o rings 26b and 26m with non silicone grease Part No 111265 Do not over lubricate NOTE Do not over lubricate parts Excessive lubricant on the o rings can be pushed into the ti18645a Figure 35 ES On Off and Fluid Adjustment Valve 3A2494D Repair ES On Off and Fluid Adjustment Valve Repair gun air passage and blemish the finish on the workpiece Clean and inspect parts for damage Replace if necessary NOTE The protrusion on the retainer plate 26h must point upward Reinstall the valve Torque the screw 27 to 15 25 in lb 1 7 2 8 Nem 49 Repair Air Valve Repair P oe NS a 50 See Prepare the Gun for Service page 37 See Barrel Removal page 42 Remove the screws 13 and trigger 12 Remove the ES On Off Valve See ES On Off and Fluid A
44. in Air Seal Repair Kit 24N789 purchase separately 4 These parts are included in Bearing Kit 24N706 purchase separately 3A2494D Parts Ref Part Description No No 15f CAP housing part of item 15d 110073 O RING 15h 24N709 CLIP package of 5 one clip included with item 15b Parts labeled are not available separately 63 Parts ES On Off and Fluid Adjustment Valve Part No 24N630 ES On Off and Fluid Adjustment Valve 26c 26m Sy 0 re a 24N631 PLATE retaining ti18645a Ref PartNo Description No a a E AE Elo en EN screw copie a 2 Piston vee pr 256 screw set soetra These parts are included in Air Seal Repair Kit Parts labeled are not available separately 24N789 purchase separately 64 3A2494D Fan Air Adjustment Valve Assembly Part No 24N634 Fan Air Adjustment Valve Assembly shown Part No 24N732 Fan Air Adjustment Valve Assembly for round spray guns not shown 30b 30d ti18647a Ref Description Qty N 1 I soe EE CUATE o E stew vee id fren Od These parts are included in Air Seal Repair Kit 24N789 purchase separately STEM valve round spray only E Parts labeled are not available separately 3A2494D Parts Atomizing Air Restrictor Valve Assembly Part No 24T304 Atomizing Air Restrictor Valve Assembly shown Part No 24N733 Atomizing Ai
45. ivity Air Spray Gun Series A Part No L85M16 85 kV Electrostatic High Conductivity Air Spray Gun Series A No No 1 24N666 BODY gun 60 kV gun 24 245265 CIRCUIT flexible 24N667 BODY gun 85 kV gun 26 24N630 See ES On Off and Fluid See Packing Rod Assembly page 62 1 Adjustment Valve page 64 27 24N740 SCREW hex socket sst 24N704 NEEDLE electrode package of 2 4a 24N645 O RING conductive 29 24T304 See Atomizing Air Restrictor b 111507 O RING fluoroelastomer Valve Assembly page 65 30 2 5 24N477 AIR CAP 4N634 See Fan Air Adjustment Valve Assembly page 65 24N644 RING retainer includes 6a 31 24N756 See Smart Module Assembly 6a 198307 PACKING u cup UHMWPE 1 page 66 24N623 NOZZLE includes 4a and 4b 28 24N699 GASKET barrel 34 1185116 SPRING 1 7 24Ne60 POWER SUPPLY 60kV gun 1 185116 _ eee ee 24N661 POWER SUPPLY 85kV gun 1 35 _ 188749 PACKING u cup m 36 185103 TUBE exhaust 1 4 in 6 mm 1 der 220278 SPRING m paren ID shipped loose Po 107460 TOOL wrench ball end 4 mm 1 shipped loose 276741 MULTI TOOL shipped loose 24N786 PLUG restrictor shipped loose 1 for use instead of item 29 110231 CLAMP exhaust tube 6 24N754 HANDLE smart 60 kV gun 1 i i 116553 GREASE dielectric 1 oz 30 ml 24N755 HANDLE smart 85 kV gun 1 tube not shown 117824 GLOVE conductive medium 1 f POUT SPRING compression 1 package of 12 also available 8 197624
46. l 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 3A2494D 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 fans 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 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 To reduce the risk of electric shock the air supply fluid supply line to the gun fluid inlet yet hose must be electrically connected to a true earth 2 ground Use only Graco Grounded Air Supply Install a fluid regulator FR on th
47. le and air cap See Air Cap and Nozzle Replacement page 38 10 Install the trigger 12 and screws 13 11 See Test Gun Resistance page 31 47 Repair Barrel Removal 1 See Prepare the Gun for Service page 37 2 Carefully loosen the nut N from the bracket fluid fitting 20 Pull the tube T out of the fitting Make sure both ferrules 7 8 and the nut stay with the tube 3 Loosen the two screws 27 NOTICE To avoid damaging the power supply 11 pull the gun barrel 1 straight away from the gun handle 16 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 20 ti19451a Figure 24 Barrel Removal 42 Barrel Installation 1 Be sure the gasket 28 and grounding spring 18 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 44 to the tip of the power supply Place the barrel 1 over the power supply and onto the gun handle 16 3 Tighten the two screws 27 oppositely and evenly about a half turn past snug Do not over tighten the screws 27 4 Assemble the fluid tube
48. lve Supply Pump sv 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 Setup Checklist See Fig 11 to locate the electrostatic gun controls ti18721a Figure 11 Electrostatic Gun Controls 1 The gun is shipped with the fluid nozzle and air cap installed Check that the retaining ring is tight NOTE To select a different size fluid nozzle or air cap see Fluid Nozzle Selection Chart page 68 and Air Cap Selection Chart page 70 To install the nozzle and air cap see Air Cap and Nozzle Replacement page 38 2 Turn OFF O the ES On Off switch J 4 Check gun resistance See Test Gun Resistance page 31 18 N O g Connect the Graco grounded air hose to the gun air inlet The gun air inlet fitting has left hand threads ANI RA A ANS Follow all steps under Grounding page 21 Follow all steps under Check Gun Electrical Grounding page 25 Reading must be less than 1 megohm Verify that the material resistivity meets requirements for electrostatic spray See Check Fluid Resistivity page 26 Connect the exhaust tube and secure with the clamp provided 10 Connect the fluid hose to the gun fluid inlet 11187574 3A2494D Gun Setup 13 Ful
49. ly open the fan air adjustment valve F 17 Set the gun air regulator to deliver a minimum counterclockwise 45 psi 0 32 MPa 3 2 bar at the gun when triggered to ensure full spraying voltage See the table below Table 2 Pressure Drop Air H Air Regulat tti 14 Fully open the fluid adjustment valve H tana in E m sk ee ae counterclockwise using 5 16 in 8 with gun triggered mm diameter hose 18 Check that the ES indicator K Hz indicator on Smart guns is lit See the following table Table 3 LED Indicator Colors Indicator Description Color When spraying the indicator should remain green indicating sufficient air pressure to the alternator turbine 15 Fully open the atomizing air restrictor valve G clockwise If the indicator changes to amber after 1 second the air pressure is too low Increase air pressure until the indicator is green If the indicator changes to red i after 1 second the air pressure is TD too high Decrease air pressure i until the indicator is green ti18729a 3A2494D 19 Gun Setup 19 Shut off the air to the gun Turn OFF O the ES On Off switch J 20 Start the pump Adjust the fluid regulator until the stream from the gun travels 8 12 in 200 300 mm before falling off Typically if fluid pressure is below 5 psi 04 MPa 0 4 bar or above 30 psi 0 21 MPa 2 1 bar a change of nozzle size is recommended
50. mbly and disconnect the alternator See Power Supply Removal and Replacement page 43 3 Measure resistance between the two outer terminals of the 3 wire connector PC it should be 2 0 6 0 ohms If outside this range replace the alternator coil 15a 4 Using a flat blade screwdriver pry the clip 15h off the housing 15d Remove the cap 15f using a thin blade or screwdriver 5 If necessary rotate the fan 15e so its blades clear the four bearing tabs T of the housing 15d ti19741b Figure 28 Fan Orientation 6 Push the fan and coil assembly 15a out the front of the housing 15d 44 11 ti19740b 15b24 M 15a 15g 15f UA WAV AN D a y VAN NIN AN NN po F Y At TI 7 w pa J W US TT Ae j lt PC 15h 15d 15b1 S Figure 29 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
51. n 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 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 3A2494D MPa bar
52. ng 24N660 POWER SUPPLY 60 kV gun 24N661 POWER SUPPLY 85 kV gun 11a 24N979 SPRING 24N663 TRIGGER includes item 13 24A445 SCREW trigger package of 2 i gun gun Alternator Assembly page 63 24N754 HANDLE smart 60 kV gun 24N755 HANDLE smart 85 kV gun SPRING compression SPRING compression VALVE exhaust 19a O RING 0 BRACKET 4 Replacement Danger and Warning labels tags and cards are available at no cost o O a a ao a ala co N w N 00 A These parts are included in Air Seal Repair Kit 24N789 purchase separately 3A2494D 1 24N626 SWIVEL air inlet M12 x 1 4 npsm m left hand thread 24N633 VALVE air 1276733 SEAL air valve 245265 CIRCUIT flexible Z O N NPD NM NM NOT N N Wy el r 24N740 SCREW hex socket sst package of 2 N 5 Valve Assembly page 65 24N634 See Fan Air Adjustment Valve 1 PA page 66 i o 35 188749 PACKING u cup 185103 TUBE exhaust 1 4 in 6 mm ID shipped loose 107460 TOOL wrench ball end 4 mm shipped loose E 24N630 See ES On Off and Fluid Adjustment Valve page 64 for use instead of item 29 loose ml tube not shown 117824 GLOVE conductive medium package of 12 also available in small 117823 and large package of 10 package of 10 N A o o 46 7A 4 179791 TAG warning not shown 484 16P802 SIGN warning not shown 50 24N783 HOOK incl
53. o the part being Gun should be 8 12 in 200 300 smart guns only sprayed mm from the part Check fluid resistivity See 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 Smart module has lost Check for good connections be indicator is red Smart guns only communication with the power tween the Smart Module and the supply power supply See Smart Module Replacement page 51 and Power Supply Removal and Replacement page 43 36 3A2494D 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 Check all possible remedies in Troubleshooting page 33 before disassembling the gun Use a vise with padded jaws to prevent damage to plastic parts Lubricate some packing rod parts 2 and certain fluid fittings with dielectric grease 44 as specified in the text Lightly lubricate o rings and seals with non silicone grease Or
54. proper fluid nozzle for your application 1 For each fluid nozzle chart find the point on the To reduce the risk of an injury follow the graph corresponding to your desired flow rate Pressure Relief Procedure page 27 before and viscosity Mark the point on each graph with removing or installing a fluid nozzle and or air cap a pencil 2 The thick vertical line in each graph represents Color Description Orifice Size the target flow rate for that nozzle size Find mm in the graph that has the marked point closest to the thick vertical line This is the recommended 24N613 0 75 029 nozzle size for your application Significantly exceeding the target flow rate may result in 24N614 1 0 042 lower spray performance due to excessive fluid velocity 24N615 Eor 1 2 047 y Black 24N616 standard 1 5 055 3 From the marked point move across to the coatings 1 8 070 vertical scale to find the required fluid pressure dd 1 8 C070 If the required pressure is too high use the next 24N618 2 0 079 largest nozzle size If the fluid pressure is too low 24N619 i nozzle size 0 55 022 lt 0 35 bar 3 5 kPa 5 psi use the next smallest 24N620 0 75 029 With Key to Fluid Nozzle Performance Charts 24N621 ne 1 0 042 araene NOTE Fluid pressures are measured at the spray 24N623 Te 1 5 055 an 24N624 metallics 1 8 070 24N625 260 Centipoise Fluid 160 Centipoise Fluid 20 Centipoise Fluid 68
55. r Restrictor Valve Assembly for round spray guns not shown 29e 29d 29a ti18646b Pee ee aa oo vave rouna spray oni SETSCREW knob round spray only KNOB shaft round spray only These parts are included in Air Seal Repair Kit 24N789 purchase separately Parts labeled are not available separately 65 Parts Smart Module Assembly Part No 24N756 Smart Module Assembly 31d 04 CA Q a G ti19442b 31f 31c 66 Ref Description Qty No 31a CARTRIDGE 24P433 GASKET EX screw id EX screw id Parts labeled are not available separately 4 These parts are included in Smart Module Screw Kit 24N757 purchase separately 3A2494D Parts High Conductivity Fluid Tube Assembly Part No 24N627 40 kV High Conductivity Fluid Tube Assembly Includes items 14a 14c Part No 24N628 60 kV High Conductivity Fluid Tube Assembly Includes items 14a 14c Part No 24N629 85 kV High Conductivity Fluid Tube Assembly Includes items 14a 14c Part Description Qty No FERRULE E NUT bracket handle Included in 24N 735 HC Adapter Kit ADAPTER bracket handle 1 Parts labeled are not available separately 14a 14b 14c t118642a 3A2494D 67 Air Caps and Fluid Nozzles Air Caps and Fluid Nozzles Fluid Nozzle Selection Chart Fluid Nozzle Performance Charts Use the following procedure to select the
56. r frequency talle gti dard gun See the LED indicator table imei poge es Tor aval only for in the Gun Setup Checklist able sizes Smart gun page 18 Electrode Supplies electrostatic charge indica Needle to the fluid tor see Adjusts fan size and shape Operating Can be used to decrease Mode pattern width page 9 Atomizing Restricts air cap air flow Air Replace with plug included Restrictor if desired Valve 8 3A2494D Smart Guns The Smart Gun module displays spraying voltage current alternator speed and the voltage setting low or high It also allows the user to change to a lower spraying voltage The module has two modes Operating Mode e Diagnostic Mode Operating Mode Bar Graph See Fig 2 and Table 1 on page 10 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 0 to 100 for each value If the 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 35 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 e Green indicates the alternator speed is correct e If t
57. re 30 Alternator 3A2494D 45 Repair Fluid Tube Removal and Replacement 1 Remove the nut 22 from the bracket 20 2 Loosen the fitting 9 to remove the fluid tube 14 from the barrel 1 3 Apply dielectric grease 44 to the threads of the fitting 9 and the o ring 10 Ensure the ferrules 7 8 are in place NOTE On 40 kV guns the o ring 10 is not used and ferrules 7 and 8x are part of the top fitting 9 NOTE On 60 and 85 kV kV guns check that the sleeve SL is in place near the top of the fluid tube 4 Slide the fitting 9 onto the fluid tube 14 and thread the fitting into the barrel 1 Torque to 25 35 in lb 2 8 3 9 Nem 5 With the ferrules 7 8 seated to the bracket 20 screw the nut 22 securely onto the bracket Make sure the top fitting remains tight 46 18 Figure 31 Fluid Tube ti19462a 3A2494D Fan Air Adjustment Valve Repair See Prepare the Gun for Service page 37 Place a wrench on the flats of the valve housing 30a and unscrew the valve from the handle 16 NOTE You may replace the valve as an assembly go to step 9 or replace only the o ring steps 3 9 Remove the retaining ring 30d Turn the valve shaft 30b counterclockwise until it comes free from the valve housing 30a Inspect the o ring 30c Remove if damaged Clean all parts and inspect for wear or damage NOTE Use non silicone grease Part No 111265 Do not over lubrica
58. rt Should be 8 12 in 200 300 mm 34 3A2494D Troubleshooting Electrical Troubleshooting Prbem O CT 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 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 31 Low fluid resistivity See Check Fluid Resistivity page 26 Fluid leaks from the packing 2c See Packing Rod Repair page 40 and causes a short Faulty alternator See Alternator Removal and Replacement page 44 ES or Hz indicator is not lit ES On Off switch is OFF O Turn ON l Check power supply alternator and alternator ribbon cable See Power Supply Removal and Replacement page 43 and Alternator Removal and Replacement page 44 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 31 Operator gets shock from Workpiece not grounded Resistance must be 1 megohm or workpiece less Clean workpiece hangers 3A2494D 35 Troubleshooting Problem Sid Gause EN Voltage current display stays red Gun is too close t
59. s from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage Graco Part No 241079 Megohmmeter is available as an accessory to check that the gun is properly grounded 1 Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose 2 Turn OFF O the ES On Off switch 3 Turn off the air and fluid supply to the gun Follow the Pressure Relief Procedure page 27 4 Disconnect the fluid hose 3A2494D Gun Setup 5 Make sure the grounded air hose AH is connected and the hose ground wire is connected to a true earth ground ti18727a 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 Fig 16 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 BB ti18726a Figure 16 Check Gun Electrical Grounding 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 approved for use in a hazardous area Failur
60. s 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 ti18725a t118731a ti18722a ee Key to Figs 12 15 we Fig 12 Operator is grounded through bare skin contact with the gun handle and conductive shoes A conductive glove can also be used Flammable liquids in the spray area must be kept l in approved grounded containers Do not use 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 plastic containers Do not store more than the quantity needed for one shift t118724a 22 3A2494D Figure 12 Ground the Operator Figure 13 Ground the Object Being Sprayed 3A2494D Gun Setup 23 Gun Setup Figure 15 Ground the Fluid Supply 24 3A2494D Check Gun Electrical Grounding 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 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 fume
61. static Air Spray Gun ground the gun by connecting the Graco Grounded Air Hose AH to the gun and connecting the air hose ground wire to a true earth ground See Check Gun Electrical Grounding page 25 ti18727a 3A2494D 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 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 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 21 Gun Setup The floor of the spray area must be electrically All persons entering the spray area must wear conductive and grounded Do not cover the floor shoes having conductive soles such as leather with cardboard or any non conductive material or wear personal grounding straps Do not which would interrupt grounding continuity wear shoes with non conductive soles such as rubber or plastic If gloves are necessary wear the conductive glove
62. t 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 and Table 1 on page 10 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 3A2494D 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 10 To enter this screen press the LO SET button while in the Voltage kiloVolts Screen
63. te When reassembling the fan air valve 30 lightly lubricate the valve threads and screw the shaft 30b fully into the housing 30a until bottomed Install the o ring 30c lubricate and unscrew the valve stem until the o ring enters the housing 3A2494D Repair Reassemble the retaining ring 30d Unscrew the valve stem from the housing until it is stopped by the retaining ring Screw the valve assembly 30 into the gun handle 16 using a wrench on the flats of the housing Torque to 15 in lb 1 7 Nem 30b 30c 30a 30d ti18647a Figure 32 Fan Air Adjustment Valve 47 Repair Atomizing Air Restrictor Valve Repair 1 2 See Prepare the Gun for Service page 37 Place a wrench on the flats of the valve housing 29a and unscrew the valve from the handle 16 NOTE You may replace the valve as an assembly go to step 9 or replace only the o ring steps 3 9 Unscrew the valve stem 29e Remove the retaining ring 29d Turn the valve body 29b counterclockwise until it comes free from the valve housing 29a Inspect the o ring 29c Remove if damaged Clean all parts and inspect for wear or damage NOTE Use non silicone grease Part No 111265 Do not over lubricate When reassembling the atomizing air restrictor valve 29 lightly lubricate the o ring 29c and push the valve body 29b fully into the housing 29a until bottomed Reassemble the retaining ring 29d T
64. tended 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 equipment 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 ori
65. the top bearing 15b2 Remove the bottom bearing 15b1 Install the new bottom bearing 15b14 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 15b24 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 3A2494D Repair 12 Hold the coil assembly 15a on a workbench Ensure that the blades of the bottom bearing with the fan end facing up Press the fan 15e4 15b19 align with the tabs onto the long end of the shaft S The fan blades mustbe o e ted aS Shown 15 Seat the coil fully into the housing 15d Secure with the clip 15h ensuring that its tabs engage 13 Carefully press the coil assembly 15a into the slots in the housing the front of the housing 15d The 3 wire e connector PC must be positioned below the 16 T es caga Sit place Ispan wider notch W of the housing tabs as shown in Fig 45 Be sure the coil alignment pins P are 17 Install the alternator on the power supply and positioned as shown in Fig 44 install both parts in the handle See Power 14 Rotate the fan 15e so its blades clear the four SUPPI Removal and Replacement page lt 2 bearing tabs T at the back of the housing 15h ti19739b Figu
66. ty bend the alternator s 3 wire ribbon cable PC upward and back so the bend faces the power supply and the connector is at the top Smart models only connect the 6 pin flexible circuit 24 to the power supply Comnect 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 3A2494D ti19453a Repair Insert the power supply alternator assembly in the gun handle 16 Make sure the ground strips EE make contact with the handle On Smart models align the connector of the 6 pin flexible circuit 24 with the socket CS at the top of the handle Push the connector securely into the socket as you slide the power supply alternator assembly into the handle ti19742a Figure 26 Connect Flexible Circuit Make sure the gasket 28 ground spring 18 and power supply spring 11a are in place Assemble the barrel 1 to the handle 16 See Barrel Installation page 42 11 See Test Gun Resistance page 31 Figure 27 Power Supply 43 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 See Prepare the Gun for Service page 37 2 Remove the power supply alternator asse
67. ty test See manual 307263 Not for use in hazardous areas 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 Also requires 24R038 Conversion Kit Voltage Tester Conversion Kit Converts the 245277 Test Fixture for use with the Pro Xp Gun alternator See manual 406999 3A2494D Hoses Grounded Air Hoses 100 psi 0 7 MPa 7 bar Maximum Working Pressure Repair Kits Related Manuals and Accessories 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread 25 ft 7 6 m 25 ft 7 6 m with 112534 Quick Disconnect 36 ft 11 m 36 ft 11 m with 112534 Quick Disconnect 50 ft 15 m 50 ft 15 m with 112534 Quick Disconnect 75 ft 23 m 100 ft 30 5 m 244965 24N736 244966 24N737 244967 24N738 244968 244969 223072 223073 223074 0 375 in 10 mm ID 3 8 npsm f x 1 4 npsm f left hand thread 24A225 24A226 50 ft 15 m 75 ft 23 m 3A2494D Part No Description Grounded Air Hose with stainless steel braid ground path Red 6 ft 1 8 m 235068 100 ft 30 5 m Fluid Hoses 225 psi 1 4 MPa 14 bar Maximum Working Pressure 1 4 in 6 mm ID 3 8 npsm fbe nylon FM approved 215637 25 ft 7 6 m 215638 50 ft 15 m High Conductivity Fluid Hose For high conductivity materials For 60 kV guns only
68. udes screw t These parts are included in Fluid Seal Repair Kit 24N790 purchase separately 67 Parts Packing Rod Assembly Part No 24N653 40 kV Packing Rod Assembly Includes items 2a 2k Part No 24N654 60 kV Packing Rod Assembly Includes items 2a 2k Part No 24N655 85 kV Packing Rod Assembly Includes items 2a 2k 2k 2j 2e 2f 2b 2ht 2d 29 ti18641a pp pap cl No 2at 111316 O RING 2 197641 NUT packing 2bt 116905 SEAL 185495 HOUSING packing 2ct 178409 PACKING fluid 186069 SPACER packing EM 2dt 178763 PACKING needle 2je i j of item 2e 24N702 ROD packing 60 kV guns 1 includes items 2j and 2k 24N703 ROD packing 85 kV guns 1 includes items 2j and 2k t These parts are included in Fluid Seal Repair Kit Parts labeled are not available separately 24N790 purchase separately o NUT trigger adjustment part 2e 24N701 ROD packing 40 kV guns 1 of item 2e includes items 2j and 2k 2k ae NUT trigger adjustment part These parts are included in Trigger Adjustment Nut Kit 24N700 purchase separately 62 3A2494D Alternator Assembly Part No 24N664 Alternator Assembly 15f 15d4 ti18639b Ref Part Description Qty No No 15b4 24N706 BEARING KIT includes two bearings item 15e fan and one item 15h clip 15d0 24N707 HOUSING includes item 15f These parts are included
69. un npon ler vane read See High Conductivity Fluid Tube 24N704 Electrode Replacement Needle for Assembly page 67 Abrasive Materials Blue 24N758 Display Covers Keeps Smart display clean Package of 5 3A2494D 73 Repair Kits Related Manuals and Accessories Operator Accessories Test Equipment 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 24N521 operator fatigue Medium size System Accessories 222011 Ground Wire and Clamp 16P802 English Warning Sign Available at no charge from Graco 16P798 English Daily Care Sign 16P799 English Setup Sign 24N528 Gun Flush Box Adapter for 60 and 85 kV guns To convert existing gun flush boxes to hold Pro Xp guns 24N529 guns To convert existing gun flush boxes to hold Pro Xp guns 24P312 Gun Washer Kit To convert existing gun washers to clean Pro Xp guns 241079 722886 722860 245277 Comfort Grip Snap on grip increases handle size to reduce operator fatigue Large size 24R038 Gun Flush Box Adapter for 40 kV 74 Megohmmeter 500 V output 0 01 2000 megohms Use for ground continuity and gun resistance tests Not for use in hazardous areas Paint Resistance Meter Use for fluid resistivity test See manual 307263 Not for use in hazardous areas Paint Probe Use for fluid resistivi
70. with a compatible solvent before using the equipment Guidelines for Abrasive Materials When spraying abrasive materials follow these guidelines Order Part No 24N704 Electrode blue for abrasive materials e Size the nozzle properly to reduce fluid pressure below 30 psi 0 21 MPa 2 1 bar producing an 8 12 in 200 300 mm fluid stream Operate the gun with the fluid adjustment knob in the full flow position at all times Use an external fluid regulator not the fluid adjustment knob to set the fluid pressure Use the minimum atomizing and fan air pressures possible to achieve a good pattern Follow all procedures under Clean the Gun Daily page 29 Inspect the electrode daily and replace if damaged See Electrode Replacement page 39 3A2494D Operation Operation Pressure Relief Procedure 4 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 1187454 5 If the nozzle or hose is completely clogged or pressure is not fully relieved slowly loosen the hose end coupling Now clear the nozzle or hose 2 Turn off the air bleed valves to the fluid source and to the gun ay A t118744a Startup 3 Trigger the gun into a grounded metal waste container to relieve the fluid pressure Follow all steps under Gun Setup Checklist page 18 Shutdown 1 Flush the gun see Flushing pag
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Graco 3A2494D User's Manual

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