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Graco 309457G User's Manual

1. TI1780A Fig 1 Gun Overview Manifold Markings Atomization Air Inlet Fitting A2 Fan Air Inlet Fitting Cylinder Air Inlet Fitting Shroud Exhaust Outlet Fitting FO Fiber Optic Fitting shipped unassembled CALLS Retaining Ring Shroud E Mounting Bracket P Manifold kV Switch 1 Air Inlet kV Switch 2 Air Inlet Fluid Supply Inlet Fitting Not Used Turbine Air Inlet Fitting E F Electrode 8 309457G Installation Install the System 4h WARNING Fire Explosion and Electric Shock Hazard Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly eDo not install or service this equipment unless you are trained and qualified eBe sure your installation complies with all National State and Local safety and fire codes NFPA 33 NEC 504 and 516 and OSHA standard 1910 107 FIG 2 shows a typical electrostatic air spray system and FIG 3 shows possible system options It is not an actual system design For assistance in designing a sys tem to suit your particular needs contact your Graco distributor 309457G Installation Basic Guidelines When spraying waterborne fluids electrostatically e The gun must be connected to a voltage isolation system which isolates the fluid supply from ground and allows voltage to be maintained at the tip of the gun e The gun must be connected to a volt
2. o o o oooo 9 Warning SIQNS o o ooocoonoonooo 10 Ventilate the Spray Booth 10 Install the Air Line Accessories 12 Install the Gun and Mounting Bracket 12 Connect the Air Line 13 Manifold Connections 13 Connect the Waterborne Fluid Hose 14 Optional Fiber Optic Cable Connection 17 CP OUIGUING resida 18 Check Electrical Grounding 19 Install the Fabric Cover 20 Operation culiar shia eX wees 21 Fluid Voltage Discharge and Grounding Procedure 21 Pressure Relief Procedure 21 Operating Checklist 22 Select a Fluid Nozzle and Air Cap 22 Adjust the Spray Pattern 23 Adjust the Electrostatics 25 SPrayiNd 22 certera i esas we nek ake 25 Triggering the Fluid Alone 25 SHULGOWN abusar wad a Eve dae 25 Maintenance io Seeks wae hae 26 Daily Care and Cleaning 26 Clean the Air Cap and Fluid Nozzle 28 Check for Fluid Leakage 29 Electrical TESIS esa ia 30 Test Gun Resistance o o oooooo 30 Test Power Supply Resistance 31 Test Electrode Resistance 32 Troubleshooting 0o oooooooomooooo o 33 Voltage Loss Troubleshooting 33 Spray Pattern Troubleshooting 36 Gun Operation
3. 2 NOTE For added positioning reliability insert a 1 8 in 3 mm locating pin into the slot NN in the bracket and through a hole in the rod See the detail in FIG 4 slats Loosen the mounting bracket s two set screws 103 and slide the bracket 102 onto a 1 2 in 13 mm mounting rod See FIG 4 Position the gun and tighten the two set screws if ie y Rh AR LN A Fig 4 Mounting Bracket 309457G Installation Connect the Air Line Manifold Connections FIG 3 shows a schematic of air line connections and Atomization Air Inlet Fitting FIG 5 shows the manifold connections Connect the air Connect a 3 8 in 10 mm OD tube between this fitting and lines as instructed the air supply Fan Air Inlet Fitting Connect a 3 8 in 10 mm OD tube between this fitting and A WAR N N e the air supply Cylinder Air Inlet Fitting Connect a 5 32 in 4 mm OD tube between this fitting and Fire Explosion and Electric Shock Hazard the solenoid For quicker response use the shortest hose To reduce the risk of a fire explosion or length possible electric shock the gun turbine air supply Shroud Exhaust Outlet Fitting must be interlocked with Connect a 1 4 in 6 mm OD x 4 ft 1 22 m long tube to this fitting eThe isol
4. battery operated Fiber Optic Y Cable Bulkhead Fiber Optic Cable Main Air Line kV Switch Air Hose 5 32 in 4 mm OD optional plug KV1 fitting if not used kV Switch Air Hose 5 32 in 4 mm OD optional plug KV2 fitting if not used 309457G Installation NOTE See The turbine air supply TA must be electrically interlocked with the spray booth ventilation fans to prevent L W above the power supply from operating without ventilating fans on _ j dA E Z 5 o f S TA HH 200 ae O Non Hazardous Hazardous Area a B TI1801A Manifold Back K a E NN C D HO 4 fy Magias j A 2 l A S e PO AA AQ A A Fig 2 Typical Installation NOTE A maximum of two splices with a total of 108 ft 33 m of cable can be used For the strongest light signals use a minimum number of bulkhead splices See Accessories on page 57 Non Hazardous Hazardous Area Do not use the Display Module readings to determine if your 7 system is discharged The display modules only display the E system voltage while the gun s power supply is operating Fol a E low t
5. e All persons entering the spray area shoes must have conductive soles such as leather or personal grounding straps must be worn Do not wear shoes with non conductive soles such as rubber or plastic e Object being sprayed keep the workpiece hangers clean and grounded at all times Resistance must not exceed 1 megohm 18 309457G Installation Check Electrical Grounding WARNING Fire Explosion and Electric Shock Hazard Megohmmeter Part No 241079 AA see FIG 11 is not approved for use in a haz ardous area To reduce the risk of sparking do not use the megohmmeter to check elec trical grounding unless eThe gun has been removed from the haz ardous area eOr all spraying devices in the hazardous area are turned off ventilation fans in the hazardous area are operating and there Fig 11 Check Gun Grounding are no flammable vapors in the area Such as open solvent containers or fumes from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage 1 Have a qualified electrician check the electrical grounding continuity of the spray gun and turbine air hose 2 Make sure the red colored turbine air hose B is connected and the hose ground wire is connected to a true earth ground 3 Turn off the air and fluid supply to the gun The fluid hose must not have any fluid in it 4 Measure the resistance between the tu
6. ID 1 4 nosm f x 1 4 npsm f left hand thread red cover with stainless steel braid ground path 235068 6ft 1 8m 235069 15 ft 4 6 m 235070 25 ft 7 6 m 235071 36ft 11 m 235072 50 ft 15 m 235073 75 ft 23 m 235074 100 ft 30 5 m Bleed Type Master Air Valve 300 psi 21 bar 2 1 MPa Maximum Working Pressure Relieves air trapped in the air line between this valve and the pump air motor when closed 107141 3 4 npt Air Line Shutoff Valve 150 psi 10 bar 1 0 MPa Maximum Working Pressure For turning air to gun on or off 224754 56 1 4 nosm m x 1 4 npsm f left hand thread Fluid Line Accessories Shielded Waterborne Fluid Hose 100 psi 7 bar 0 7 MPa Maximum Working Pressure PTFE 1 4 in 6 mm ID 245327 245328 25 ft 7 6 m 36 ft 11 m Unshielded Waterborne Fluid Hose 100 psi 7 bar 0 7 MPa Maximum Working Pressure PTFE 1 4 in 6 mm ID See manual 308688 for instal lation requirements 245329 245330 25 ft 7 6 m 36 ft 11 m Fluid Shutoff Drain Valve 500 psi 35 bar 3 5 MPa Maximum Working Pressure For turning fluid on or off to the gun and for relieving fluid line pressure at the pump 208630 1 2 npt m x 3 8 npt f carbon steel and PTFE for non corrosive fluids Drain Valve 300 psi 21 bar 2 1 MPa Maximum Working Pressure 236853 Mounts directly to gun manifold for faster flushing and color changes Must be used with 233676 Fluid Recirculation Kit 309457
7. Measure the resistance between the conductive rod B and the electrode 7 The resistance should be 20 30 megohms See FIG 19 If in range refer to Electrical Troubleshooting on page 38 for other possible causes of poor perfor mance or contact your Graco distributor Remove the electrode 7 page 42 Measure the resistance between the contact E and the elec trode wire F The resistance should be 20 30 meg ohms If out of range replace the electrode See FIG 20 Make sure the metal contact C in the barrel the nozzle contact ring 4a FIG 21 and the electrode contacts E are clean and undamaged ALE ti1499a O E E Fig 19 Test Electrode Resistance 32 1 Ay F 7 E re M Fig 20 Electrode DN Fig 21 Nozzle Conductive O Ring 309457G Troubleshooting AA WARNING Electric Shock Hazard requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly Do not install or repair this equipment unless you are trained and qualified ly Installing and servicing this equipment Y Follow the Fluid Voltage Discharge and Grounding Procedure on page 21 before checking or servicing the system and whenever you are instructed to dis charge the voltage A WARNING Pressurized Equip
8. SPACER packing acetal ROD packing BARREL gun SCREW socket hd 10 24 x 3 4 in 19 mm GASKET barrel POWER SUPPLY 60 kV includes 12a 12b O RING fluoroelastomer SPRING compression Qty 1 1 Ref No 13 13a T 13b 13c 13d 13e 15 19 25 26 27 28 29 30 31 32 33 34 34a 34b 34c 34d t 34e T 34f t 34g t Part No 244555 110073 223688 244577 111745 198821 107460 179791 186118 197624 185111 189367 185122 101324 197919 102025 112689 198363 116575 244702 197920 189754 189355 189752 111504 112319 111508 Description TURBINE alternator includes 13a 13e O RING fluoroelastomer BEARING KIT includes front and rear bearings and fan COIL RING retaining PAD pressure TOOL wrench ball end not shown TAG warning not shown replacement available at no cost SIGN warning not shown replacement available at no cost SPRING grounding SPRING compression CAP exhaust MUFFLER NUT jam hex ARM actuator NUT hex SCREW button hd 1 4 20 x 3 4 in 19 mm BODY gun auto WB SCREW cap socket hd 10 24 3 in 76 mm PISTON includes 34a 34g PISTON ROD piston STEM piston PACKING u cup O RING O RING O RING Pa Qty N N rts 53 Parts Ref No Part No Description Qty 35 244938 MANIFOLD see separate parts 1 liston page 55 37 245265 CIRCUIT flexible 1 39
9. flushing or servicing the system equipment before approaching the front of the gun or before opening the safety fence or enclosure for the isolated fluid supply NOTE An accessory grounding rod part No 210084 is available to discharge any voltage remaining on a sys tem component Contact your Graco distributor to order 1 Turn off the turbine air to all spray guns connected to the isolated fluid supply 2 Discharge the voltage at the voltage isolation sys tem by following the procedure specified in the volt age isolation system instruction manual 3 Touch the electrode of the gun with a grounded rod to make sure the voltage has been discharged If you see an arc verify that the electrostatics are turned off or see Electrical Troubleshooting on page 38 or the voltage isolation system manual for other possible problems Resolve the problem before proceeding 309457G Operation Pressure Relief Procedure A WARNING Pressurized Equipment Hazard The system pressure must be manually jt relieved to prevent the system from starting or spraying accidentally To reduce the risk of an injury from electric shock accidental spray from the gun splashing fluid or moving parts follow the Pressure Relief Procedure whenever you e are instructed to relieve the pressure stop spraying check or service any of the system equipment e or install or clean the fluid nozzle 1 Follow the Fluid Voltage Discharge
10. 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 4h WARNING Flammable or Toxic Vapor Hazard Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying flushing or cleaning the gun Do not operate the gun unless ventilation fans are operating Electrically interlock the gun turbine air supply B with the ventilators to prevent gun operation without ventilat ing fans operating Check and follow all National State and Local codes regarding air exhaust velocity require ments NOTE High velocity air exhaust will decrease the oper ating efficiency of the electrostatic system The mini mum allowable air exhaust velocity is 60 ft minute 19 linear meters minute 10 Key to FIG 2 and FIG 3 S lt SCA1A0D0OUZZEFACIOSMNMMOUO Y gt A lt Air Hose Ground Wire Graco Grounded Turbine Air Hose TA Atomizing Air Hose 3 8 in 10 mm OD A1 Fan Air Hose 3 8 in 10 mm OD A2 Cylinder Air Hose 5 32 in 4 mm OD CYL Graco Waterborne Fluid Hose P1 To Isolated Fluid Supply System Auto PRO Xs Air Spray Gun Mounting Bracket for 1 2 in 13 mm rod Solenoid Valve requires quick exhaust port Bleed Type Master Air Valve Air Pressure Regulator True Earth Ground 24 Volt Power Supply 4 20 microampere Outputs Full Feature ES Display Module kV Only ES Display Module
11. is 3 lb 13 3 N of drag force when sliding the packing housing 8f assembly along the rod Tighten or loosen the pack ing nut as needed 5 Install the o ring 8a on the outside of housing 8f Lubricate the o ring with non silicone grease Part No 111265 Do not over lubricate 6 Install the spring 25 against the nut E as shown 7 Install the packing rod assembly 8 into the gun barrel Using the multi tool 40 tighten the assem bly until just snug 8 Install the electrode page 42 and nozzle page 41 9 Install and adjust the actuator arm 29 and jam nut 28 See page 46 10 Test gun resistance page 30 11 Install the gun shroud 2 and air cap page 41 12 Install the gun onto the manifold and bracket See page 40 8h 309457G Piston Repair 1 Prepare the gun for service page 39 2 Remove the air cap page 41 Remove the gun shroud 2 3 Remove the jam nut 28 actuator arm 29 and adjustment nut 30 See FIG 27 NOTE The fluid nozzle 4 must be in place when removing or installing the jam nut and actuator arm TI1800A 28 29 30 34b Fig 27 Actuator Arm 4 Push on the piston rod 34b to push the piston out the back of the gun 5 Inspect the o rings 34e 34f 34g and u cup pack ing 34d for damage See Table 5 and FIG 28 6 Lubricate the o rings 34e 34f 34g and u cup packing 34d with non silico
12. on page 43 and look for signs of fluid leakage or any blackened areas which would indicate arcing is occurring along the packing rod Fluid hose connection joint to the spray gun A breakdown at the fluid hose connection joint would be caused by fluid leaking past the o ring seals on the end of the hose Remove the hose at the gun connection and look for signs of fluid leakage along the PTFE tube 309457G Troubleshooting 13 Before reassembling the gun clean and dry the gu n fluid inlet tube Repack the inner spacer of the fluid packing rod with dielectric grease and reassemble the gun 14 Reconnect the fluid hose 15 Check the gun voltage with the voltage probe and meter before filling the gun with fluid 35 Troubleshooting Spray Pattern Troubleshooting NOTE Check all possible remedies in the Troubleshooting Chart before disassembling the gun NOTE Some spray pattern problems are caused by the improper balance between air and fluid Problem eee an O Fluttering or spitting spray No fluid Refill supply Loose dirty damaged nozzle seat Clean or replace nozzle page 41 Air in fluid supply Check fluid source Refil Improper spray pattern Damaged nozzle or air cap Replace page 41 oOo AH Fluid buildup on air cap or nozzle Clean See page 28 Fluid too thin Increase viscosity Fluid pressure too low Increase Fan air pressure too low Increase Mala ae 36 309457G Troubles
13. property damage Y EA YY ZZ Fig 16 Check for Fluid Leakage 309457G WD A ti1787A Sur gt y ZZ Ap 29 Electrical Tests Electrical Tests Electrical components inside the gun affect performance and safety The following procedures test the condition of the power supply 12 and electrode 7 and electrical continuity between components Use megohmmeter Part No 241079 AA and an applied voltage of 500 V Connect the leads as shown WARNING Fire Explosion and Electric Shock Hazard Megohmmeter Part No 241079 AA see FIG 17 is not approved for use in a haz ardous area To reduce the risk of sparking do not use the megohmmeter to check elec trical grounding unless eThe gun has been removed from the haz ardous area eOr all spraying devices in the hazardous area are turned off ventilation fans in the hazardous area are operating and there are no flammable vapors in the area Such as open solvent containers or fumes from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage 30 Test Gun Resistance 1 Flush and dry the fluid passage 2 Measure resistance between the electrode needle tip 7 and the turbine air inlet fitting TA it should be 117 137 megohms If outside this
14. range remove the gun for service page 39 and go to the next test If in range refer to Electrical Troubleshooting on page 38 for other possible causes of poor perfor mance m f o ohe TI1799A Fig 17 Test Gun Resistance 309457G Electrical Tests Test Power Supply Resistance 6 Be sure the spring 12b is in place before reinstall ing the power supply 1 Remove the power supply 12 page 49 2 Remove the turbine alternator 13 from the power supply page 50 l 3 Measure resistance from the power supply s ground strips EE to the spring 12b See FIG 18 A ll 4 The resistance should be 95 105 megohms If out side this range replace the power supply If in range proceed to the next test 12b Pa EE 5 Ifyou still have problems refer to Electrical Trou bleshooting on page 38 for other possible causes 1 z of poor performance or contact your Graco distribu t11599a tor Fig 18 Test Power Supply Resistance 309457G 31 Electrical Tests Test Electrode Resistance Insert a conductive rod B into the gun barrel removed for the power supply test and against the metal contact C in the front of the barrel
15. the Pressure Relief Procedure page 21 when you stop spraying and before cleaning checking or repairing equipment e Check hoses and couplings daily Replace worn damaged or loose parts immediately e Tighten all fluid connections before each use 309457G 5 Introduction Introduction How the Electrostatic Air Spray Gun Works The automatic electrostatic air spray gun operates very similar to a traditional air spray gun The atomization and fan air are emitted from the air cap The atomization air breaks up the fluid stream and controls the droplet size The fan air controls the shape and width of the spray pattern The fan and atomization air can be adjusted independently Spraying Waterborne Fluids Electrostatically N CAUTION The Graco warranty is void if the spray gun is con nected to a non Graco voltage isolation system or if the gun is operated above 60 kV This electrostatic air spray gun is designed to spray only waterborne fluids with a flash point above 140 F 60 C and a maximum organic solvent concentration of 20 by weight per ASTM Standard D93 Also the fluid must not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test When connected to a voltage isolation system all of the fluid in the spray gun fluid hose and isolated fluid sup ply is charged to high voltage which means that the sys tem has more electrical energy than a solvent based system Therefore only non flamm
16. while using the equipment stop spraying immediately Identify and correct the problem Eliminate all ignition sources such as pilot lights cigarettes and static arcs from plastic drop cloths Do not plug in or unplug power cords or turn lights on or off in the spray area Check gun resistance daily See Test Gun Resistance on page 30 Only use this equipment to spray non flammable waterborne fluids as defined on the front cover of this manual Only flush purge or clean the electrostatic waterborne spray system with non flammable flu ids as defined on the front cover of this manual Keep the spray area free of debris and rags Do not store solvent and flammable fluids in the spray area Use only non sparking tools to clean residue from the booth and hangers Toxic Fluid Hazard Hazardous fluids or toxic fumes can cause a serious injury or death if solashed in the eyes or on the skin swallowed or inhaled e Know the specific hazards of the fluid you are using Read the fluid manufacturer s warnings e Store hazardous fluid in an approved container Dispose of the hazardous fluid according to all local state and national guidelines e Wear appropriate protective clothing gloves eyewear and respirator 4 309457G Warnings WINE Equipment Misuse Hazard Equipment misuse can cause the equipment to rupture malfunction or start unexpectedly and result in a serious injury This equipment is for professio
17. 1 before loosen ing the three manifold screws 106 This allows the gun to move forward gradually as the manifold screws are loosened Hold the gun firmly in hand while loosening the manifold screws 7 Holding the gun firmly in hand loosen the three screws 106 from the back of the manifold 8 Remove the gun from the manifold and take it to the service area 40 Fig 22 Remove Gun from Manifold Install the Gun on the Manifold 1 Make sure the gasket 112 and spring 105 are in place on the manifold See FIG 22 Inspect the parts for damage and replace them as needed 2 Secure the gun to the manifold by tightening the three screws 106 3 Secure the gun to the mounting bracket 102 by tightening the bottom screw 31 4 Make sure the fittings and barrel are clean and dry then reconnect the waterborne fluid hose page 14 5 Reinstall the gun shroud 2 and air cap 3 page 41 309457G Repair Air Cap Nozzle Replacement A WARNING Fire Explosion and Electric Shock Hazard N CAUTION 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 with out the contact ring in place Do not replace 1 Prepare gun for service page 39 the contact ring with anything but a genuine Graco part Hold the front end of the gun up and tri
18. 197265 1 2 047 197268 2 0 080 Table 3 Air Caps Size mm in 24A438 24A279 24A376 24A274 24A439 Also available in the following colors 24A276 blue 24A277 red 24A278 green Pattern Shape and Length in mm Round end 15 17 381 432 Round end 14 16 356 406 Tapered end 17 19 432 483 Tapered end 12 14 305 356 Round end 11 13 279 330 Recommended Fluids and Production Rates Light to medium viscosity Up to 15 oz min 450 cc min Medium to high viscosity and high solids Up to 15 oz min 450 cc min Light to medium viscosity Up to 15 oz min 450 cc min Light to medium viscosity Up to 15 oz min 450 cc min Medium to high viscosity and high solids Up to 15 oz min 450 cc min For use with 2 0 mm nozzle 309457G Adjust the Spray Pattern Follow the steps below to establish the correct fluid flow and air flow Do not turn on the turbine air TA yet WARNING Fire and Explosion Hazard The fluid has a flash point above 140 F 60 C and a maximum organic solvent concentration of 20 by weight per ASTM Standard D93 To reduce the risk of fire and explosion only use this equipment with fluids that meet at least one of the following conditions for non flammability The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test A WARNING Electric Shock Hazard Contact with the charged components of W the
19. 276741 MULTI TOOL 1 40 189888 COVER gun box of 10 not 1 shown 42 116553 TUBE grease lubricant 1 48 290171 SIGN warning not shown 1 replacement available at no cost 56 24A431 KIT wide pattern 1 Recommended spare parts Keep on hand to reduce downtime f Included in repair kit 15D592 NOTE Replacement Warning labels signs tags and cards are available at no cost 54 309457G Part No 244938 Manifold Series A Ref No 101 102 103 104 105 106 107 108 109 110 112T 113 114 Part No 198362 189581 110465 112689 112640 197518 111157 186845 110078 112646 197925 108290 189365 309457G 101 Ref Description MANIFOLD BRACKET reciprocator SCREW set SCREW button hd SPRING compression SCREW socket hd 10 24 x 3 4 in 19 mm FITTING tube FITTING turbine FITTING tube fluid PLUG GASKET manifold SCREW machine CAP kV HI LO 106 Ref Qty Ref No 115 116 116aT 117 119 120 Part No 198764 244772 112085 114263 116621 112645 Parts 5 see pages 53 or 55 101 ft Included in repair kit 15D592 107 Description Qty RESTRICTOR 1 PISTON includes 116a 2 O RING 1 FITTING connector 3 SPRING compression 2 PLUG 1 55 Accessories Accessories Air Line Accessories Grounded Air Hose Red Cover 100 psi 7 bar 0 7 MPa Maximum Working Pressure 0 315 in 8 mm
20. G Miscellaneous Accessories Ground Wire and Clamp 222011 For grounding pump and other components and equipment in the spray area 12 gauge 25 ft 7 6 m Megohmmeter 241079 500 Volt output 0 01 2000 megohms Not for use in hazardous areas Grounding Rod 210084 Use to discharge voltage from voltage isola tion system enclosure Safety Warning Signs 180060 English Warning Sign FM Approved Avail able at no charge from Graco ES Display Module 224117 Receives fiber optic transmission from the PRO Auto Xs gun and displays the gun s output voltage and current Mounts in a standard 19 in DIN rack See 308265 Power Supply 235301 Supplies low voltage DC power to 224117 Display Module See 308265 309457G Accessories Fiber Optic Y Cables See item T in FIG 3 on page 11 For use with 224117 Display Module only Connect gun manifold and display module or bulkhead connector and display module See 308265 224682 25 ft 7 6 m 224684 50 ft 15 m 224686 100 ft 30 5 m Remote Voltage Display 189762 Battery operated meter displays actual spraying voltage remote mount outside hazardous area Connects to gun via fiber optic cable See 308265 Remote Voltage Display Kits Include 189762 Remote Voltage Display and fiber optic cable 236917 25 ft 7 6 m 236919 50 ft 15 m 236921 100 ft 30 5 m Fiber Optic Cables See item V in FIG 3 on page 11 Connect gun manifold and remote voltage di
21. Instructions Parts List O ELECTROSTATIC FOR WATERBORNE COATINGS a PRO Auto Xs Air Spray Gun aan Part No 244591 Series A 100 psi 0 7 MPa 7 bar Maximum Air Inlet Pressure 100 psi 0 7 MPa 7 bar Maximum Working Fluid Pressure For use when electrostatically spraying conductive waterborne fluids that meet at least one of the following conditions for non flammability e The fluid has a flash point above 140 F 60 C and a maximum organic solvent concentration of 20 by weight per ASTM Standard D93 e The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test NOTE Fluid hose must be ordered separately For patent information see www graco com patents TI1557A s d Save these instructions Important Safety Instructions A Read all warnings and instructions in this manual See page 2 for Table of Contents CE PROVEN QUALITY LEADING TECHNOLOGY Table of Contents WAarninOS serroeribrlirr ee Chee 3 Warning Symbol o o ooocooocoooo o 3 Caution Symbol naana anaana 3 INTOQUCUION 2 3 costras ari 6 How the Electrostatic Air Spray Gun Works 6 Spraying Waterborne Fluids Electrostatically 6 Gun Features and Options 6 Operating the Spray Function 7 Operating the Electrostatics 7 Changing the kV Setting 7 installation ira eee ee Hee 9 Install the System
22. MPa 2 8 bar 120 F 48 C 125 microamperes 30 60 kV at 40 psi 0 28 MPa 2 8 bar 90 4 dB A at 100 psi 0 7 MPa 7 bar 105 4 dB A at 40 psi 0 28 MPa 2 8 bar 87 dB A at 100 psi 0 7 MPa 7 bar 99 dB A 1 4 npsm m 3 8 in OD nylon tube 3 8 in OD nylon tube 5 32 in OD nylon tube 5 32 in OD nylon tube custom 3 52 Ib 1 6 kg 12 25 in 31 1 cm Stainless Steel Nylon Acetal Ultra High Molecular Weight Polyethylene Fluoroelastomer PEEK Tungsten Wire Polyethylene Loctite is a registered trademark of the Loctite Corporation 309457G 59 Graco Standard Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months or two thousand hours of operation from the date of sale repair or replace any part of the equipment determined by Graco to be defective However any deficiency in the gun barrel gun body manifold mounting bracket internal power supply and alternator excluding turbine bearings will be repaired or replaced for thirty six months or six thousand hours of operation 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 no
23. Troubleshooting 37 Electrical Troubleshooting 38 ReDIF dais a do er rs tee 39 Prepare the Gun for Service 39 Remove the Gun from the Manifold 40 Install the Gun on the Manifold 40 Air Cap Nozzle Replacement 41 Electrode Replacement 42 Fluid Packing Removal 43 Packing Rod Repair oo oo ooo 44 FIStON ACDGIE tc bon a es td 45 Adjust the Actuator Arm 46 Barrel Removal o ooo oo 47 Barrel Installation 48 Power Supply Removal and Replacement 49 Turbine Alternator Removal and Replacement 50 PARES card id 52 Accessories 2 53 26052 ie idad 56 Air Line Accessories o ooooooo 56 Fluid Line Accessories o ooo o 56 Miscellaneous Accessories 57 Gun Accessories 2 0 0 cee ee 58 Technical Dala isis a ere 59 Graco Standard Warranty 60 Graco Information 0 ocoooooooo ooo 60 309457G Warnings Warnings Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious injury This symbol alerts you to the possibility of damage to or or death if you do not follow the instructions destruction of equipment if you do not follow the instruc tions IWS TE Electric Shock Hazard Improper grounding setup or usage of a
24. able fluids as defined on the front cover of this manual can be sprayed with the system or be used to clean flush or purge the system Precautions must be taken when using electrostatic waterborne equipment to avoid potential shock hazards When the spray gun charges the isolated fluid to high voltage it is similar to charging a capacitor or a battery The system will store some of the energy while spraying and retain some of that energy after the spray gun is shut off It is not safe to touch the front end of the gun until the stored energy is discharged The amount of time it takes to discharge the energy depends on the system design Follow the Fluid Voltage Discharge and Grounding Procedure on page 21 before approaching the front of the gun A safe well designed voltage isolation system should have the following features e All components of the isolation system that are charged to high voltage must be contained within an enclosure that prohibits persons from making con tact with the high voltage components before the system voltage is discharged e The voltage isolation system must be interlocked with the spray area entrance to automatically dis charge the voltage and ground the fluid whenever someone opens the enclosure or enters the spray area e A bleed resistor to drain off the system voltage when the spray gun is not in use e The system should not have any severe arcing occurring when the isolation mechanism opens
25. about the hose P1 P2 2 Check the electrical grounding of the gun as instructed on page 19 EXH TI1790A Fig 5 Manifold Connections 309457G 13 Installation Connect the Waterborne Fluid Hose N CAUTION The Graco warranty is void if the spray gun is con nected to a non Graco voltage isolation system or if the gun is operated above 60 kV e Always use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun fluid inlet See page 56 for available Graco water borne hoses e Before connecting the waterborne fluid hose to the gun blow it out with air and flush with water to remove contaminants WARNING Electric Shock Hazard only one continuous Graco waterborne hose between the isolated fluid supply and the gun Do not splice hoses together D To reduce the risk of electric shock install W 1 Remove the air cap 3 and shroud 2 See page 41 2 For the fluid hose to seal properly it must be stripped and assembled to the dimensions shown in FIG 6 Push the inner tube T into the barrel fitting F until the tube bottoms A new Graco waterborne fluid hose comes fully assembled to these dimen sions CAUTION Be careful not to cut into the inner tube T of the hose when stripping the hose Nicks or cuts in the PTFE tube will cause premature hose failure 14 Key to FIG 6 A 9 75 in 248 mm B 1 5 in 38 mm F Fig 6 Wat
26. age isolation system that will discharge the system voltage when the gun is not in use e All components of the isolation system that are charged to high voltage must be contained within a fence or enclosure that prohibits persons from mak ing contact with the high voltage components before the system voltage is discharged e The gun turbine air supply must be interlocked with the isolation system to shut off the turbine air supply anytime the isolation system enclosure or safety fence is opened e The voltage isolation system must be interlocked with the spray area entrance to automatically dis charge the voltage and ground the fluid whenever someone enters the spray area e The system should not have any severe arcing occurring when the isolation mechanism opens and closes Severe arcing will shorten the life of the sys tem components Graco Waterborne Fluid Hose Use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun fluid inlet See Accessories on page 56 for available hoses The hose consists of an inner PTFE tube a conductive layer cov ering the PTFE tube and an outer cover If a hose failure occurs where high voltage arcs through the inner tube voltage will be discharged to ground through the conductive hose layer When properly installed the conductive hose layer is grounded through its connection to the grounded enclosure Installation Warning Signs Mount warning signs
27. agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la redaction du pr sente document
28. air to actuate before the fluid See FIG 29 28 30 34b E 3 Tighten the adjustment nut 30 against the actuator Fig 29 Actuator Arm Adjustment arm 29 Check that the 0 125 in 8 mm gap has been maintained In addition there should be 3 4 mm of electrode needle travel when the gun is trig gered Adjust the jam nut position to obtain these dimensions 4 Test gun resistance page 30 5 Install the gun shroud 2 and air cap 3 page 41 6 Install the gun onto the manifold and bracket See page 40 46 309457G Repair Barrel Removal 6 Hold the gun body 32 with one hand and pull the barrel 9 straight off the body See FIG 30 1 Prepare the gun for service page 39 2 Remove the air cap page 41 Remove the gun shroud 2 3 Carefully loosen the fluid fitting nut 20 Pull the tube 19 out of the fitting 23 Make sure both fer rules 21 22 and the nut stay with the tube 4 Remove the jam nut 28 and actuator arm 29 See page 45 5 Loosen the three screws 10 33 See FIG 30 N CAUTION To avoid damaging the power supply 12 pull the gun barrel 9 straight away from the gun body 32 If necessary gently move the gun barrel from side to side to free it from the gun body TI1800A 28 30 19 Fig 31 Disconnect Fluid Tube 309457G TI1781A 47 Repair Barrel Installation 4 Assemble the fluid tube 19 into the fluid
29. and closes Severe arcing will shorten the life of the sys tem components Gun Features and Options e The gun is designed for use with a reciprocator and can be mounted directly on a 1 2 in 13 mm rod With additional brackets the gun can be mounted for robotic applications e Gun functions are activated from a separate control ler that sends the appropriate signal to the actuating solenoids 309457G e The optional fiber optic readout system can be installed to monitor the gun s spraying voltage A fiber optic cable connected to the gun manifold car ries the signal from the gun to a remote display module Part No 224117 Display Module displays the gun s spraying voltage and current Bat tery operated Display Module 189762 displays the gun s spraying voltage only WARNING Electric Shock Hazard use the Graco ES Display Module readings to determine if your system is discharged The display modules will only display the system volt age while the gun s power supply is operating Follow the Fluid Voltage Discharge and Grounding Pro cedure on page 21 to ensure the system is dis charged gt D To reduce the risk of electric shock do not W Operating the Spray Function Applying a minimum of 50 psi 0 35 MPa 3 5 bar air pressure to the gun manifold s cylinder air fitting CYL will retract the gun piston which opens the air valves and a short time later opens the fluid needle This pro vides the pr
30. and Ground ing Procedure on page 21 2 Relieve fluid pressure in the fluid supply and voltage isolation system as instructed in their instruction manuals 3 Turn off all the air to the spray gun except the cylin der air which triggers the gun If an air pilot fluid regulator is used in the system air pressure is also needed at the regulator air inlet NOTE The air shut off device must bleed the air out of the system 4 Trigger the gun into a grounded metal waste con tainer to relieve the fluid pressure 5 Turn off all remaining air supplies to the gun 6 Turn off the main air supply by closing the bleed type master air valve on the main air supply line Leave the valve closed until you are ready to spray again 21 Operation Operating Checklist Check the following list daily before starting to operate the system to help ensure you of safe efficient opera tion All operators are properly trained to safely operate an automatic electrostatic water borne air spray system as instructed in this manual All operators are trained in the Fluid Voltage Discharge and Grounding Procedure on page 21 All operators are trained in the Pressure Relief Procedure The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded See Groun
31. and air line filters daily W e Clean the outside of the gun daily with a soft cloth dampened in a compatible solvent e Clean the air cap and fluid nozzle daily minimum Some applications require more frequent cleaning Replace the fluid nozzle and air cap if they are dam aged See Clean the Air Cap and Fluid Nozzle page 28 e Check the electrode and replace if broken or dam aged See Electrode Replacement on page 42 e Check for fluid leakage from the gun and fluid hoses See Check for Fluid Leakage on page 29 Tighten fittings or replace equipment as needed e Flush the gun before changing colors and whenever you are done operating the gun 309457G 27 Maintenance Clean the Air Cap and Fluid 9 Make sure the u cup 1a is in place on the retaining ring 1 The lips must face forward Tighten the Nozzle retaining ring until the air cap is held firmly in place you should not be able to rotate the air cap horns by Equipment Needed nang e soft bristle brush 10 Test gun resistance page 30 e compatible solvent Procedure 1 Discharge the system voltage page 21 2 Relieve the pressure page 21 TI1779A 3 Remove the air cap assembly 1 3 and shroud 2 See FIG 15 4 Wipe the fluid nozzle 4 shroud 2 and exterior of the gun clean with a cloth dampened in non flam mable solvent Avoid getting any solvent into the air passages Whenever possible point the gun down when cleaning it 5 If
32. ation system to shut off the turbine Fiber Optic Fitting Optional air supply anytime the enclosure or Connect the Graco Fiber Optic cable see page 17 safety fence is opened kV Switch 1 Air Inlet Fitting Connect a 5 32 in 4 mm OD tube between this fitting and The ventilators to prevent operation of the the solenoid power supply unless the ventilating fans kV Switch 2 Air Inlet Fitting are on Connect a 5 32 in 4 mm OD tube between this fitting and the solenoid Fluid Supply Inlet Connect a Graco waterborne fluid hose WARNING Pousa o Turbine Air Inlet Fitting Electric Shock Hazard Connect the red colored Graco Grounded Air Hose between this fitting left hand thread and the solenoid W To reduce the risk of electric shock or other Connect the air hose ground wire to a true earth ground serious injury you must use the red colored Graco grounded air hose for the turbine air supply hose and you must connect the hose ground wire to a true earth ground Do not use the black or grey colored Graco air hoses 1 Connect the red colored Graco Grounded Air Sup CYL ply Hose B to the gun s turbine air inlet TA and connect the hose ground wire A to a true earth A1 ground N The gun turbine air inlet fitting has AZ left hand threads to prevent connecting another type of air hose to the turbine air inlet See Accessories on page 56 for further information
33. ck to the grounded gun Install a new gun cover and clean the exterior of the gun 9 Inspect the entire system for any visible fluid leak age and repair any fluid leaks that are found Pay special attention to the following areas e Packing area of the spray gun e Fluid hose check for leakage or any bulges in the outer cover which may indicate an internal leak e Internal voltage isolation system components 34 Tests If you still have no voltage separate the spray gun and hose from the voltage isolation system and check whether the gun and hose alone will hold voltage with the following test 1 Flush the system with water and leave the lines filled with water 2 Discharge the system voltage page 21 3 Relieve the pressure page 21 4 Disconnect the fluid hose from the voltage isolation system Avoid allowing any water to leak out of the fluid hose as that could cause a significant air gap in the fluid column up to the gun electrode which can break the conductivity path and conceal a potential failure area 5 Position the end of the hose as far as possible away from any grounded surface The end of the hose must be at least 1 ft 0 3 m from any ground Make sure that no one is within 3 ft 0 9 m of the end of the hose 6 Turn the turbine air to the gun on Measure the volt age at the gun electrode with a voltage probe and meter 7 Discharge the system voltage by waiting 30 sec onds and then touchi
34. ding on page 18 The condition of the gun s electrical compo nents has been checked as instructed in Elec trical Tests on page 30 All fluid hose connections are tight Ventilation fans are operating properly Workpiece hangers are clean and grounded All debris including flammable fluids and rags is removed from the spray area All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded The manifold exhaust tubes have been checked for the presence of any fluid as instructed in Check for Fluid Leakage on page 29 d O U U U UOU U lll Ll 22 Select a Fluid Nozzle and Air Cap WARNING Pressurized Equipment Hazard To reduce the risk of an injury follow the a Pressure Relief Procedure on page 21 before removing or installing a fluid nozzle and or air cap The gun is supplied with Part No 197266 Nozzle and 24A276 Air Cap If you require a different size refer to Table 2 and Table 3 and instruction manual 309419 or consult with your Graco distributor See Air Cap Nozzle Replacement on page 41 A wide pattern kit P N 24A431 is included with the gun and if installed will provide more fan air for wider spray patterns If pattern becomes split use the fan air valve to reduce the amount of fan air Table 2 Fluid Nozzles Size mm in 197263 0 75 030 197266 1 5 055 197264 1 0 042 197267 1 8 070
35. e o rings ing Hose not seated properly Make sure the hose was stripped and installed correctly See page 14 309457G 37 Troubleshooting Electrical Troubleshooting TO CT Voltage still present at gun after fol lowing the Fluid Voltage Discharge and Grounding Procedure Turbine air is not turned off Turn off Did not wait long enough for voltage to discharge Wait longer before touching electrode with grounded rod Check for bleed resistor failure Air pocket in fluid line leaves fluid Determine cause and correct Purge near gun isolated air from fluid line Voltage isolation system failed Service voltage isolation system Poor wrap Turbine air is not turned on Booth exhaust velocity is too high Reduce velocity to within code limits 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 on page Low fluid resistivity Check fluid resistivity page 20 Fluid leaks from the packing 8d and Clean the packing rod cavity causes a short Replace the packing rod See page 44 Faulty turbine alternator Be sure the plug is in place on the back of the turbine alternator hous ing Remove and test the turbine alternator See page 50 The KV switch is stuck on low Check the switch actuation replace if needed Replace power supply See page 49 No vol
36. erborne Hose Dimensions Inspect the o ring R on the barrel fitting F of the hose Replace if worn or damaged See FIG 7 Lubricate the o ring R on the barrel fitting F with dielectric grease Screw the fitting into the fluid inlet of the gun barrel 9 and tighten Unscrew the strain relief nut N from the hose fer rule M and slide the nut up the hose 309457G ES n TI1793A Ferrule M and nut N are part of the waterborne hose assembly purchase separately Fig 7 Connect the Waterborne Fluid Hose 309457G TI1802A Installation 15 Installation 6 Slide the inner tube T of the hose through the slot 10 Connect the other end of the hose to the fluid outlet and into the fluid inlet port P1 of the manifold of the isolated fluid supply See FIG 8 Screw the hose ferrule M into the port Ah WARNING WARNING Electric Shock Hazard Electric Shock Hazard areas of the waterborne fluid hose that are accessible to personnel during normal operation must be covered by the outer hose jacket J The portion of the inner hose layer T not covered by the outer jacket must be inside the voltage isolation system enclosure E gt
37. ether Follow the Fluid Voltage Discharge and Grounding Procedure on page 21 when instructed to discharge the voltage before cleaning flushing or servicing the system before approach ing the front of the gun and before opening the enclosure for the isolated fluid supply Do not enter a high voltage or hazardous area until all high voltage equipment has been dis charged Do not come within 2 ft 0 61 m of the gun nozzle during gun operation or until you follow the Fluid Voltage Discharge and Grounding Procedure Follow the warnings and instructions in the voltage system isolation system manual 309457G 3 Warnings WT Fire and Explosion Hazard Improper grounding poor air ventilation open flames or sparks can cause a hazardous condition and result in a fire or explosion e Electrostatic equipment must be used only by trained qualified personnel who understand the requirements in this manual Ground the equipment all personnel in or close to the spray area the object being sprayed and all other electrically conductive objects in the spray area See Grounding page 18 Provide fresh air ventilation to avoid buildup of flammable or toxic vapors when spraying flush ing or cleaning the gun Interlock the gun air supply to prevent operation of the power supply unless ventilating fans are on See Ventilate the Spray Booth on page 10 Do not flush with the gun electrostatics turned on If there is any static sparking
38. fitting 23 Ensure that the ferrules 21 22 are in place Tighten the nut 20 1 Be sure the gasket 11 and grounding spring 51 are in place Make sure the air holes are aligned 5 Install and adjust the actuator arm 29 and jam nut properly Replace if damaged See FIG 32 28 See page 46 2 Place the barrel 9 over the power supply 12 and 6 Test gun resistance page 30 onto the gun body 32 Oros pag 7 Install the gun shroud 2 and air cap page 41 3 Tighten the three screws 10 33 oppositely and gu ud 2 p Pag evenly about a half turn past snug 8 Install the gun onto the manifold and bracket See page 40 N CAUTION Do not over tighten the screws 10 33 Di x 33 TI1785A 51 28 Fig 32 Barrel Installation 48 309457G Power Supply Removal and Replacement Inspect the gun body power supply cavity for dirt or moisture Clean with a clean dry rag Do not expose gasket 11 to solvents Prepare gun for service page 39 Remove the barrel 9 page 47 N CAUTION Be careful when handling the power supply 12 to avoid damaging it Grasp the power supply 12 with your hand With a gentle side to side motion free the power sup ply alternator assembly from the gun body 32 then carefully pull it straight out Disconnect the flex ble circuit 39 from the socket at the top of the body 32 See FIG 33 page 50 Disconnect the 3 wire con
39. fold See FIG 3 page 11 for a schematic of the fiber optic connec tions 1 Remove the plug 120 from the fiber optic port and install the fiber optic fitting 5 shipped loose with the gun See FIG 9 JO FR Mees 120 A EN ES LY PON IAS Fig 9 Fiber Optic Fitting 309457G Installation 2 Remove the nut AA from the fiber optic fitting 5 and slide the nut over the end of the fiber optic cable BB See FIG 10 3 Push the cable BB into the fitting 5 until it bot toms out Tighten the nut AA to secure the cable Fig 10 Fiber Optic Cable NOTE Most of the fiber optic light transmission loss occurs at the bulkhead splices For the strongest light signals use a minimum number of bulkhead splices A maximum of two splices with a total of 108 ft 33 m of cable is recommended 4 See manual 308265 to install a Graco ES Display Module 17 Installation Groundi ng e The floor of the spray area must be electrically con ductive and grounded Do not cover the floor with cardboard or any non conductive material which A WARNING would interrupt grounding continuity e Flammable liquids in the spray area must be kept in Fire Explosion and Electric Shock Hazard approved grounded containers Do not use plastic containers D
40. ge 49 Measure resistance between the two outer termi nals of the 3 wire connector GG it should be 2 5 3 5 ohms If outside this range replace the alter nator coil Follow the bearing replacement procedure in the bearing kit manual 308034 Install the alternator on the power supply page 49 T T11784A Install the power supply alternator assembly page 309457G Repair 309457G 51 Parts Parts Part No 244591 PRO Auto Xs Electrostatic Gun Series A for waterborne coatings Ref No 13 Alternator De 13a tail 13b E a PA CN G gt Z O ae fa A N 13d 13c 52 309457G Part No 244591 PRO Auto Xs Electrostatic Gun Series A for waterborne coatings Ref No ta i 4a 4b 8a 8b 8c 8d 8e 8f 8g 8h 12a T 12b Part No 244950 198307 245325 24A276 197266 111261 111507 198486 276867 244521 111316 116905 178409 178763 197641 185495 186069 244696 244394 197518 197517 244542 103337 197624 309457G Description RING retaining air cap includes la U CUP SHROUD AIR CAP NOZZLE 1 5 mm orifice includes 4a and 4b O RING conductive O RING fluoroelastomer CONNECTOR tube fiber optic see page 55 unassembled NEEDLE electrode WB ROD packing includes 8a 8h O RING fluoroelastomer SEAL SPREADER packing unmwpe PACKING rod acetal NUT packing HOUSING packing
41. gger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from enter ing the air passages 2 Remove the retaining ring 1 and air cap 3 See FIG 23 NOTE Use non silicone grease Part No 111265 on the small o ring 4b Do not over lubricate Do not lubri 3 Point gun up while removing the fluid nozzle 4 cate the contact ring 4a assembly with the multi tool 40 4 Lightly lubricate the o ring 4b Install it and the contact ring 4a on the nozzle 4 NOTE Make sure the electrode needle 7 is finger tight page 42 5 Install the fluid nozzle 4 with the multi tool 40 Tighten until the fluid nozzle seats in the gun barrel 1 8 to 1 4 turn past hand tight 6 Carefully install the air cap 3 Be sure to insert the electrode 7 through the center hole of the air cap Rotate the air cap to the desired position 7 Make sure the u cup 1a is in place on the retaining ring 1 The lips must face forward Tighten the retaining ring until the air cap is held firmly in place you should not be able to rotate the air cap horns by hand 8 Test gun resistance page 30 9 Install the gun onto the manifold and bracket See TI1572A Fig 23 Air Cap Nozzle Replacement page 40 309457G 41 Repair Electrode Replacement 1 Prepare the gun for service page 39 2 Remove the air cap and nozzle page 41 Remove the gun shroud 2 3 Un
42. he Fluid Voltage Discharge and Grounding Procedure on page 21 to ensure the system is discharged H AL KV eh ES mA _ oo E ae 85 0 KV TI1797A S Fig 3 Optional Fiber Optic Connection to Voltage Display Module 309457G 11 Installation Install the Air Line Accessories Install a bleed type air valve L on the main air line W to shut off all air to the gun H Install an air line filter water separator on the gun air line to ensure a dry clean air Supply to the gun Dirt and moisture can ruin the appearance of your fin ished workpiece and can cause the gun to malfunc tion Install a bleed type air regulator M on each of the air supply lines B C D E X Y to control air pres sure to the gun Install a solenoid valve K on the cylinder air line E to actuate the gun The solenoid valve must have a quick exhaust port 4h WARNING Pressurized Equipment Hazard 12 rrr uO Trapped air can cause the gun to spray unexpectedly which can result in serious injury including splashing fluid in the eyes or on the skin The solenoid valves K must have a quick exhaust port so trapped air will be relieved between the valve and gun when the solenoids are shut off Install the Gun and Mounting Bracket
43. hooting Gun Operation Troubleshooting omm CO CN Excessive spray fog Atomizing air pressure too high Decrease air pressure as low as pos sible Orange Peel finish Atomizing air pressure too low Increase air 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 Replace packings or rod see pages area 43 or 44 Air leaks from the air cap Worn piston stem o rings 34e 34f Replace see page 45 Fluid leakage from the front of the Worn or damaged packing rod 8 Replace see page 43 gun Worn fluid seat Replace fluid nozzle 4 and or elec trode needle 7 see pages 41 to 42 Replace see page 41 Gun does nat spray Piston 34 not actuating Check cylinder air Check piston u cup 34d see page 45 Actuator arm 29 is out of position Check actuator arm and nuts See page 46 Dirty air cap Misaligned air cap 3 and fluid noz Clean fluid buildup off air cap and zle 4 fluid nozzle seat see page 28 Damaged nozzle orifice Replace nozzle 4 see page 41 Fluid is coming on before the air Check actuator arm and nuts See page 46 Air leaks from manifold Manifold is not tight Tighten manifold screws 106 Fluid leaks at the quick disconnect Manifold is not tight Tighten manifold screws 106 Fluid hose o rings are worn or miss Inspect or replac
44. it appears that there is fluid inside the fluid nozzle 4 air passages remove the gun from the line for servicing Fig 15 Clean Air Cap and Fluid Nozzle 6 Clean the air cap 3 with the soft bristle brush and solvent or submerge the air cap in suitable solvent and wipe it clean N CAUTION Do not use metal tools to clean the air cap or fluid nozzle holes as this could scratch them and make sure the electrode is not damaged Scratches in the air cap or nozzle or a damaged electrode can distort the spray pattern 7 Slide the shroud 2 onto the gun 8 Carefully install the air cap 3 Be sure to insert the electrode 7 through the center hole of the air cap Rotate the air cap to the desired position 28 309457G Maintenance Check for Fluid Leakage During operation periodically check the manifold exhaust tube YY and both ends of the gun shroud ZZ for the presence of fluid See FIG 16 Fluid in these areas indicates leakage into the shroud which could be A WARNING caused by leaks at the fluid tube connections or fluid Fire and Explosion Hazard If any fluid leakage from the gun is detected stop spraying immediately Fluid leakage into the gun shroud could cause packing leakage If fluid is seen in these areas stop spraying immediately Discharge the voltage page 21 relieve the pressure page 21 and then remove the gun for repair fire or explosion and result in serious injury and
45. mM To reduce the risk of electric shock the ductive hose layer C must be engaged in the ferrule M when the nut N is tight ened Failure to properly install the hose in the fitting could result in an electric shock Yul To maintain grounding continuity the con 7 Screw the strain relief nut N onto the hose ferrule M Tighten to about 55 in Ib 6 2 Nem Pull back Wide Lolli al ld ae ld on the hose to make sure itis secure through its connection to the isolation system s grounded enclosure E 8 Reinstall the shroud 2 and air cap 3 9 Check the gun s electrical grounding see page 19 F r n T11805A Fig 8 Hose Connection at Isolated Fluid Supply 16 309457G Optional Fiber Optic Cable Connection A WARNING Electric Shock Hazard use the Graco ES Display Module readings to determine if your system is discharged The display module will only display the system voltage while the gun s power supply is oper ating Follow the Fluid Voltage Discharge and Grounding Procedure on page 21 to ensure that the system is discharged X D To reduce the risk of electric shock do not W An optional fiber optic fitting is shipped unassembled with the gun If an ES kV display module is used install the fitting in the FO port of the mani
46. ment Hazard To reduce the risk of an injury follow the a Pressure Relief Procedure on page 21 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure 309457G Troubleshooting Voltage Loss Troubleshooting Normal spraying voltage for a system using the water borne gun is 45 55 kV The system voltage is lower due to spraying current demands and voltage isolation sys tem losses A loss of spraying voltage can be caused by a problem with the spray gun fluid hose or voltage isolation sys tem since all of the system components are electrically connected through the conductive waterborne fluid Before troubleshooting or servicing the voltage isolation system itself you need to determine which component in the system is most likely causing a problem Possible causes include the following Spray Gun e Fluid leakage e Dielectric breakdown at the fluid hose connection or fluid packings e Not enough air pressure for the turbine e Faulty power supply e Excessive overspray on gun surfaces e Fluid in the air passages Waterborne Fluid Hose e Dielectric failure of hose pin hole leak through PTFE layer e Air gap in the fluid column between the gun and iso lated fluid supply causing a low voltage reading on the isolation system voltage meter Voltage Isolation System e Fluid leakage e Dielectric breakdown of hoses seals or connec tions e Isolators n
47. n isolated waterborne system can cause a hazardous condition and result in electric shock or other serious injury e Ground the equipment all personnel in or close to the spray area the object being sprayed and all conductive objects in the spray area See Grounding page 18 The gun must be connected to a voltage isolation system that will discharge the system volt age when the gun is not in use All components of the isolation system that are charged to high voltage must be contained within an enclosure that prohibits personnel from making contact with the high voltage compo nents before the system voltage is discharged The gun turbine air supply must be interlocked with the isolation system to shut off the turbine air supply anytime the isolation system enclosure is opened The voltage isolation system must be interlocked with the spray area entrance to automatically discharge the voltage and ground the fluid whenever someone enters the spray area The areas of the waterborne hose that are accessible to personnel must be covered by the conductive hose layer The area of the hose that is not covered by the conductive hose layer must be inside the voltage isolation system enclosure Only use the red colored Graco grounded turbine air hose with this gun Do not use the black or grey colored air hoses Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the spray gun Do not splice hoses tog
48. nal use only Read all manuals tags and labels before operating the equipment Use the equipment only for its intended purpose If you are uncertain call your Graco distribu tor Do not alter or modify equipment Use only genuine Graco parts and accessories Do not operate the power supply above 60 kV Use only Graco Part No 244542 Power Supply with this gun Check the equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system component Maxi mum working air and fluid pressure of this equipment is 100 psi 0 7 MPa 7 0 bar Use fluids and solvents that are compatible with the equipment wetted parts See the Techni cal Data section of all equipment manuals Read the fluid and solvent manufacturer s warn ings Route the hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 40 F 40 C Wear hearing protection when operating this equipment Comply with all applicable local state and national fire electrical and other safety regula tions Pressurized Equipment Hazard Ho Spray from the gun hose leaks or ruptured components can splash fluid in the eyes or on the skin and cause serious injury e Do not point the spray gun at anyone or at any part of the body e Do not stop or deflect fluid leaks with your hand body glove or rag e Follow
49. nd replace if necessary NOTE Before installing the packing rod clean the inter nal surface of the barrel 9 with a soft cloth or brush Check for marks from high voltage arcing If marks are present replace the barrel 309457G T11783A Fig 25 Fluid Packing Removal Repair 43 Repair Packing Rod Repair NOTE You may replace the packing rod as individual parts as described below or as an assembly see page 43 The assembly is pre adjusted at the factory NOTE Before installing the fluid packing rod into the gun barrel make sure the internal surfaces of the barrel 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 To assemble the individual parts 1 2 3 Place the packing nut 8e and seal 8b on the fluid rod 8h Flats on the packing nut must face the back of the fluid rod The seal o ring must face away from the packing nut See FIG 26 Fill the inner cavity of the spacer 8g with dielectric grease Place the spacer on the fluid rod 8h in the direction shown Generously apply dielectric grease to the outside of the spacer Place the rod packing 8d packing spreader 8c and housing 8f on the packing rod 8h Sf NO 8a N q O y Fig 26 Packing Rod 44 4 Lightly tighten the packing nut 8e The packing nut is properly tightened when there
50. ne grease Part No 111265 Do not over lubricate 7 Align the two stems 34c with the holes in the gun body and press the piston assembly into the back of the gun until it bottoms 8 Install and adjust the actuator arm page 46 Table 5 Piston O Rings Description Shaft O Ring 34g 34b Replace if air leaks along rod Seals cylinder air along the piston rod 309457G Repair Table 5 Piston O Rings Air shutoff seal Replace if air leaks from air cap when gun is de triggered Separates cylinder air from fan and atomizing air U Cup 34d Replace if air leaks from small vent hole at back of manifold when gun is trig gered pe TI1575A Gy 34e A Fan Air A se 34g TI1576A Atomizing Air Side Fig 28 Piston O Rings 45 Repair Adjust the Actuator Arm NOTE The fluid nozzle 4 must be in place when removing or installing the jam nut and actuator arm ed 0 125 in 3 mm gap 1 Install the adjustment nut 30 actuator arm 29 and jam nut 28 onto the piston rod 34b Note that the jam nut 28 has a slightly larger hex and a thin ner profile than the adjustment nut 30 See FIG 27 on page 45 2 Position the parts so there is a 0 125 in 3 mm gap between the actuator arm 29 and the fluid packing rod nut E which allows the atomizing
51. nector GG from the power supply Slide the alternator up and off the power supply Inspect the power supply and alterna tor for damage Disconnect the 6 pin flexible circuit 39 from the power supply Check the power supply resistance page 31 Replace if necessary SN Before installing the power supply make sure the o rings 12a 13a spring 12b and pads 13e are in place Connect the 6 pin flexible circuit 39 to the power supply Connect the 3 wire connector GG Slide the alter nator 13 down onto the power supply 12 Lubricate the alternator o ring 13a with non sili cone grease Part No 111265 Do not over lubri cate Lubricate the power supply o ring 12a with dielec tric grease 309457G 10 Repair Insert the power supply alternator assembly in the gun body 32 Make sure the ground strips make contact with the body Connect the flexible circuit 39 to the socket at the top of the body Push the 6 pin connector into the socket to ensure it is prop erly connected Install the barrel 9 page 48 Test gun resistance page 30 49 Repair Fig 33 Power Supply Turbine Alternator Removal and Replacement NOTE Replace turbine alternator bearings after 2000 hours of operation Order Part No 223688 Bearing Kit 1 2 50 Prepare gun for service page 39 Remove the power supply alternator assembly page 49 Disconnect the alternator from the power supply pa
52. ng the gun electrode with a grounded rod 8 Ifthe meter reading is 45 to 55 kV the gun and fluid hose are okay and the problem is in the voltage iso lation system If the reading is below 45 kV the problem is in the gun or fluid hose 9 Flush the fluid hose and gun with enough air to dry out the fluid passages 10 Turn the turbine air to the gun on Measure the volt age at the gun electrode with a voltage probe and meter 309457G 11 If the meter reading is 55 60 kV the gun power sup ply is okay and there is probably a dielectric break down somewhere in the fluid hose or gun Continue with step 12 12 If the reading is below 55 kV do the electrical tests on page 30 to check the gun and power supply resistance lf those tests show the gun and power supply are okay continue with step 12 A dielectric breakdown is most likely in one of the following three areas Repair or replace the compo nent that is failing Fluid hose Check for leakage or any bulges in the outer cover which may indicate a pin hole leak through the PTFE layer Disconnect the fluid hose from the gun and look for signs of fluid contamination on the outside of the PTFE por tion of the fluid tube Inspect the end of the hose connected to the voltage isolation system Look for cuts or nicks Make sure the hose is properly stripped Restrip or replace the hose Fluid packings Remove the packing assembly from the gun as instructed
53. o not store more than the quantity When operating the electrostatic gun any reeded Torone shif ungrounded objects in the spray area peo e All electrically conductive objects or devices in the spray area including fluid containers and wash cans must be properly grounded electrically charged Improper grounding can result in static sparking which can W cause a fire explosion or electric shock Follow the grounding instructions below ple containers tools etc can become The following are minimum grounding requirements for a basic electrostatic waterborne system Your system may include other equipment or objects which must be grounded Check your local electrical code for detailed grounding instructions Your system must be connected to a true earth ground e Electrostatic Air Spray Gun ground the gun by con necting the red colored Graco Grounded Air Hose to the turbine air inlet and connecting the air hose ground wire to a true earth ground See Check Electrical Grounding page 19 e Graco Waterborne Fluid Hose the hose is grounded through the conductive layer Install the hose as instructed on page 14 e Voltage Isolation System electrically connect to a true earth ground e Air compressors and hydraulic power supplies ground the equipment according to the manufac turer s recommendations e All air and fluid lines must be properly grounded e All electrical cables must be properly grounded
54. oper air lead and lag when triggering the gun A spring returns the piston when the cylinder air is shut off 309457G Introduction Operating the Electrostatics To operate the electrostatics apply air pressure to the gun manifold s turbine air fitting TA through a Graco grounded air hose The air enters the manifold and is directed to the inlet of the power supply turbine The air spins the turbine which then provides electrical power to the internal high voltage power supply The fluid is charged by the spray gun electrode The charged fluid is attracted to the nearest grounded object wrapping around and evenly coating all surfaces The turbine air is exhausted into the shroud and out the back of the manifold through the exhaust fitting EXH The exhaust air helps keep contaminants out and helps keep the gun clean Changing the kV Setting The gun s full voltage setting is 60 kV Three lower volt age settings are possible by actuating the KV1 and KV2 switches Supply 50 psi 0 35 MPa 3 5 bar air pressure to the KV1 and KV2 ports Turn the air on or off as shown in Table 1 to set the desired voltage NOTE The solenoid valves used to activate the KV1 and KV2 switches must bleed the air out of the lines for the switches to draw back to the higher voltage setting Table 1 Low Voltage Adjustment Introduction KV1 KV2 A2 P2 Manifold
55. ot functioning properly 33 Troubleshooting Visual Check First check the system for any visible faults or errors to help isolate whether the spray gun fluid hose or voltage isolation system has failed A voltage probe and meter part no 236003 is helpful for diagnosing voltage prob lems and is required for some of the troubleshooting tests that follow 1 Check that all of the air and fluid tubes and hoses are properly connected 2 Check that the voltage isolation system valves and controls are properly set for operation 3 Check that the spray gun and voltage isolation sys tem have sufficient air pressure 4 Check that the gun turbine air TA is turned on and the pressure is set correctly 5 Check that the voltage isolation system s enclosure door is closed and that any safety interlocks are engaged and working properly 6 Make sure the voltage isolation system is in the iso late mode where it is isolating the fluid voltage from ground 7 To eliminate air gaps in the fluid column spray enough fluid to purge the air out between the volt age isolation system and the spray gun An air gap in the fluid hose can break the electrical continuity between the spray gun and the isolated fluid supply and cause a low voltage reading on a voltage meter connected to the isolated fluid supply 8 Check the spray gun cover and barrel for accumu lated overspray Excessive overspray can create a conductive path ba
56. peration or until after following the Fluid Voltage Discharge and Grounding Proce dure 4h WARNING Pressurized Equipment Hazard To reduce the risk of injury follow the Pres sa sure Relief Procedure on page 21 before checking or servicing any part of the system and whenever you are instructed to relieve the pres sure e Check all possible remedies in Troubleshooting before disassembling the gun e Use a vise with padded jaws to prevent damage to plastic parts e Lubricate the power supply o ring 12a some pack ing rod parts 8 and certain fluid fittings with Part No 116553 Dielectric Grease as specified in the text e Lightly lubricate o rings and seals with non silicone grease Order Part No 111265 Lubricant Do not over lubricate e Only use genuine Graco parts Do not mix or use parts from other PRO Gun models 309457G 39 Repair Remove the Gun from the Manifold 1 Discharge the system voltage page 21 2 Flush and clean the gun page 26 3 Relieve the pressure page 21 4 Remove the air cap 3 and shroud 2 page 41 5 Disconnect the fluid hose fitting F from the gun barrel 9 6 Loosen the bottom gun screw 31 until the gun sits loosely in the mounting bracket slot A See FIG 22 N CAUTION The piston return spring 105 is compressed between the manifold and the gun body when they are assembled To avoid sudden movement of the gun loosen the bottom gun screw 3
57. r air fitting CYL to activate turbine air hose inlet when air is flowing Do not the on off sequence of atomization air A1 fan air exceed these pressures as there is no added bene A2 and fluid P1 See FIG 14 fit and turbine life could be reduced 2 Turn the gun functions on and off by using the air Table 4 Turbine Air Pressures solenoid valves on the cylinder CYL and turbine TA air supply lines Turbine Air Air pressure at turbine air hose Hose Length inlet for full voltage 3 To change to a lower voltage setting activate the ft m psi bar MPa solenoids controlling the KV1 and KV2 ports See 15 4 6 54 3 8 0 38 Changing the kV Setting on page 7 A WARNING Fire and Explosion Hazard 25 7 6 55 3 85 0 38 If any fluid leakage from the gun is detected stop spraying immediately Fluid leakage into the gun shroud could cause 100 30 5 61 4 3 0 43 fire or explosion and result in serious injury and property damage See Check for Fluid 5 Check the voltage output of the gun using a high Leakage on page 29 voltage probe and meter or by reading the ES kV Display Module Triggering the Fluid Alone NOTE The gun s normal high voltage reading is 45 55 kV 1 Shut off and relieve the air pressure to the atomiza tion A1 and fan A2 air lines using the bleed type See Electrical Troubleshooting on page 38 to correct air shutoff valves voltage problems 2 Apply 50 psi 3 5 bar 0 35 MPa air press
58. rbine air inlet fitting TA and a true earth ground N using an ohmmeter The resistance should not exceed 100 ohms 5 Ifthe resistance is greater than 100 ohms check the tightness of the ground connections and be sure the turbine air hose ground wire is connected to a true earth ground If the resistance is still too high replace the turbine air hose 309457G 19 Installation 2 Route the exhaust tube YY outside the cover This enables you to monitor the exhaust tube for the presence of any paint or solvent See Check for 1 Install a fabric cover XX over the front of the gun Fluid Leakage on page 29 Strap down the exhaust and slide it back to cover the exposed tubing and tube to prevent it from moving around hoses at the back of the manifold See FIG 12 Install the Fabric Cover gt a Mi YY NS XX Fig 12 Fabric Cover 20 309457G Operation Fluid Voltage Discharge and Grounding Procedure A WARNING Electric Shock Hazard The high voltage fluid supply is charged alll with high voltage until the voltage is dis charged Contact with the charged compo nents of the isolation system or spray gun electrode will cause an electric shock To avoid an electric shock follow the Fluid Voltage Discharge and Grounding Procedure e when instructed to discharge the voltage before cleaning
59. screw the electrode 7 with the multi tool 40 Hold the packing rod end 8h to prevent it from turn ing FIG 24 40 To avoid damaging the plastic threads be very care ful 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 page 41 6 Test gun resistance page 30 7 Install the gun shroud 2 and air cap page 41 8 Install the gun onto the manifold and bracket See T11782A page 40 Fig 24 Electrode Replacement 42 309457G Fluid Packing Removal NOTE You may replace the packing rod as an assem bly as described below or as individual parts see page 44 The assembly is pre adjusted at the factory 1 Prepare the gun for service page 39 2 Remove the air cap page 41 Remove the gun shroud 2 3 Remove the jam nut 28 and actuator arm 29 See page 45 NOTE The fluid nozzle 4 must be in place when removing or installing the jam nut and actuator arm 4 Remove the fluid nozzle 4 and electrode 7 See pages 41 and 42 5 Remove the packing rod 8 using the multi tool 40 N CAUTION Clean all parts in non conductive solvent compatible with the fluid being used such as xylol or mineral spirits Use of conductive solvents can cause the gun to malfunction 6 Check all parts for wear or damage a
60. sera en Anglais ainsi que tous documents avis et procedures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Information TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free 612 623 6921 612 378 3505 Fax 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 Original instructions This manual contains English MM 309457 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2002 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised April 2012
61. size of the fluid nozzle being used 23 Operation e 24 Use the air pressure regulator on the atomization air supply line A1 to adjust the degree of atomization See FIG 14 For example for a fluid flow rate of 10 ounces per minute 0 3 liters per minute a typical atomization pressure would be 20 30 psi 1 4 2 1 bar 0 14 0 21 MPa at the gun manifold Use the air pressure regulator on the fan air supply line A2 to adjust the pattern size e For the most efficiency always use the lowest air pressure possible e When increasing to a wide flat pattern it may be necessary to increase the supply of fluid to the gun to maintain the same amount of cover age over a large area e See Spray Pattern Troubleshooting on page 36 to correct spray pattern problems KV2 TA CYL A1 OA Fig 14 Manifold Air Connections KV1 A2 309457G Operation Adjust the Electrostatics Spraying 1 Shut off the fluid supply WARNING 2 Prepare the isolation system for high voltage opera Electric Shock Hazard tion touch the gun electrode or come within 2 ft X D To reduce the risk of electric shock do not 6 1 m of the nozzle during gun operation 3 Trigger the gun then turn on the turbine air TA See FIG 14 1 Apply a minimum of 50 psi 3 5 bar 0 35 MPa air 4 Referto Table 4 to set the proper pressure at the pressure to the cylinde
62. splay bulknead connector and remote display or bulknead connector and gun mani fold See 308265 224672 25 ft 7 6 m 224674 50 ft 15 m 224676 100 ft 30 5 m Bulkhead Connector 189870 For connecting two fiber optic cables 57 Accessories Gun Accessories Round Pattern Kits Consists of fluid tip diffuser and air cap 245217 245219 4 6 in 102 152 mm diameter 8 10 in 203 254 mm diameter Dielectric Grease 116553 1 oz 28 g tube of dielectric grease for the power supply o ring 12a some packing rod parts 8 and certain fluid fittings 58 Gun Valve Lubricant 111265 4 oz 113 g tube of sanitary non silicone lubricant for fluid seals and wear areas Alternator Bearing Kit 223688 To repair the turbine alternator Cleaning Brush 105749 For cleaning air cap and fluid nozzle 309457G Technical Data Category Maximum Working Fluid Pressure Maximum Working Air Pressure Minimum Air Pressure at Gun Inlet Maximum Fluid Operating Temperature Short Circuit Current Output Voltage Output Sound Power measured per ISO Standard 9216 Sound Pressure measured 1 m from gun Turbine air inlet fitting left hand thread Atomizing air inlet fitting Fan air inlet fitting Cylinder air inlet fitting Hi Lo voltage selector air inlet fittings Fluid inlet fitting Gun Weight Gun Length Wetted Parts Technical Data Data 100 psi 0 7 MPa 7 bar 100 psi 0 7 MPa 7 bar 40 psi 0 28
63. spray gun will cause an electric shock r Do not touch the gun nozzle or electrode or come within 2 ft 0 61 m of the front of the gun during operation or until performing the Fluid Voltage Discharge and Grounding Procedure on page 21 Follow the Fluid Voltage Discharge and Grounding Procedure on page 21 when you stop spraying and whenever you are instructed to discharge the voltage 309457G Operation A WARNING Component Rupture Hazard To reduce the risk of component rupture ls which can cause serious injury do not exceed the maximum working pressure of the lowest rated system component This equipment has a 100 psi 0 7 MPa 7 bar maximum working air and fluid pressure WARNING Pressurized Equipment Hazard To reduce the risk of an injury follow the a Pressure Relief Procedure on page 21 whenever you are instructed to relieve the pressure 1 Discharge the system voltage page 21 2 Relieve the pressure page 21 3 Loosen the air cap retaining ring and rotate the air cap for a vertical or horizontal spray pattern See FIG 13 Tighten the retaining ring until the air cap is held firmly in place you should not be able to rotate the air cap horns by hand WS Vertical Pat Horizontal Pat Fig 13 Air Cap Positions 4 Adjust the fluid flow with the fluid pressure regulator Refer to instruction manual 309419 to set the fluid pressure for various fluid flows according to the
64. t cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer
65. tage or low voltage reading on Dam asa fiber optic cable or connec Check replace damaged parts the gun ES display module tion Turbine airis not turnedon Turbine airis not turnedon is not turned on Turnon Turnon Poor wrap See causes and solutions under Poor Wrap above Operator gets mild shock Operator not grounded or is near See Grounding on page 18 ungrounded object Gun not grounded See Check Electrical Grounding on page 19 and Test Gun Resistance on page 30 Operator gets shock from workpiece Workpiece not grounded Resistance must be 1 megohm or less Clean workpiece hangers 38 309457G Repair Repair Prepare the Gun for Service 1 Discharge the system voltage page 21 2 Flush and clean the gun page 26 WARNING Fire Explosion and Electric Shock Hazard 3 Relieve the pressure page 21 To reduce the risk of a fire explosion or 4 Remove the gun from the manifold page 40 electric shock 5 Remove the gun from the worksite Repair area must be clean eFollow the Fluid Voltage Discharge and Grounding Procedure on page 21 W before flushing checking or servicing w the system and whenever you are instructed to discharge the voltage e Clean all the parts with a non flammable solvent as defined on the front cover of this manual Do not service this equipment unless you are trained and qualified Do not come within 2 ft 0 6 m of the gun nozzle during gun o
66. ure to the cylinder air fitting CYL to trigger the fluid Shutdown 1 Discharge the system voltage page 21 2 Flush and clean the equipment See Maintenance on page 26 3 Relieve the pressure page 21 309457G 25 Maintenance Maintenance Daily Care and Cleaning CAUTION Clean all parts with a non conductive compatible Do not immerse the gun in fluid solvent Conductive solvents can cause the gun to malfunction Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components Fluid in the air passages could cause the gun to malfunction and could draw current and reduce the electrostatic effect Fluid in the power supply cavity can reduce the alternator life Whenever possible point the gun down when cleaning it Do not use any cleaning method which could allow fluid into the gun air passages Do not point the gun up while cleaning it Do not wipe the gun with a cloth that is heavily satu rated wring out the excess fluid 26 309457G Maintenance 4h WARNING WARNING Pressurized Equipment Hazard Fire Explosion and Electric Shock Hazard To reduce the risk of an injury follow the To reduce the risk of fire explosion or elec a Pressure Relief Procedure on page 21 y tric shock turn off the turbine air TA before before doing any maintenance on the gun flushing the gun or any part of the system or system W e Clean the fluid

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