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Graco 309297L User's Manual

1. URE 3 page 9 for a schematic of the fiber optic connec a SA tions WH 1 Remove the plug 120 from the fiber optic port and a wie install the fiber optic fitting 5 shipped loose with the AA me gun See FIGURE 6 Ig SS A j SL b Fig 7 Fiber Optic Cable 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 rec ommended 4 See manual 308265 to install a Graco ES Display Module Fig 6 Fiber Optic Fitting 12 309297L Installation G roun d I n g e Air compressors and hydraulic power supplies ground the equipment according to the manufac turer s recommendations e Allair and fluid lines must be properly grounded A WARNING pers e All electrical cables must be properly grounded Fire Explosion and Electric Shock Hazard e All persons entering the spray area shoes must When operating the electrostatic gun any have conductive soles such as leather or personal ungrounded objects in the spray area peo grounding straps must be worn Do not wear shoes ple containers tools etc can become with non conductive soles such as rubber or plastic W electrically charged Improper grounding can result in static sparking which can e Object be
2. al o GA Q se a oa ore 234 2 mm To nozzle tip rR S gt NNN Fig 4 Mounting Bracket 309297L Installation Con nect the Al r and Fl u id Shroud Exhaust Outlet Fitting Connect a 1 4 in 6 mm OD x 4 ft 1 22 m long tube to Lines this fitting Fiber Optic Fitting Optional Connect the Graco Fiber Optic cable see page 11 kV Switch 1 Air Inlet Fitting Connect a 5 32 in 4 mm OD tube between this fitting and the solenoid kV Switch 2 Air Inlet Fitting Connect a 5 32 in 4 mm OD tube between this fitting and A WARNING the solenoid Fluid Supply Inlet Fitting Connect a 1 4 npsm swivel fitting between this fitting and FIGURE 3 shows a schematic of air and fluid line connec tions and FIGURE 5 shows the manifold connections Connect the air and fluid lines as instructed serious injury the turbine air supply hose must be electrically connected to a true earth ground Use only Graco Grounded between this fitting left hand thread and the solenoid Air Supply Hose Connect the air hose ground wire to a true earth ground W To reduce the risk of electric shock or other A Turbine Air Inlet Fitting Connect the Graco Electrically Conductive Air Hose 1 Connect the Graco Grounded Air Supply Hose B to the gun s turbine air inlet TA and connect the hose ground wire A to a true earth ground N The gun turbine a
3. oO im QO i a ES J I o Non Hazardous Area Hazardous Area ie T11712A Manifold Back View XS eae FO AA ARAQ Fig 2 Typical Installation NOTE A maximum of two splices with a total of 108 ft 83 m of cable can be used For the stron gest light signals use a minimum number of bulkhead splices See Accessories on page 53 Non Hazardous Area Hazardous Area P i YY R T KV UA rr Q 85 0 KV T11583A S Fig 3 Optional Fiber Optic Connection to Voltage Display Module 309297L 9 Installation Install the Air Line Accessories 1 Install a bleed type air valve L on the main air line W to shut off all air to the gun H 2 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 3 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 4 Install a solenoid valve K on the cylinder air line E to actuate the gun The solenoid valve must have a quick exhaust p
4. Fluid leakage from the front of the Worn or damaged packing rod 8 Replace see page 36 gun Worn fluid seat Replace fluid nozzle 4 and or elec trode needle 7 see pages 34 to 35 Gun does not spray Damaged fluid nozzle 4 Replace see page 34 Piston 34 not actuating Check cylinder air Check piston u cup 34d see page 38 Actuator arm 29 is out of position Check actuator arm and nuts See page 39 Dirty air cap Misaligned air cap 3 and fluid noz Clean fluid buildup off air cap and zle 4 fluid nozzle seat see page 24 Damaged nozzle orifice Replace nozzle 4 see page 34 Fluid is coming on before the air Check actuator arm and nuts See page 39 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 replace o rings ing 30 309297L Troubleshooting Electrical Troubleshooting pomm o o yio Poorly grounded parts Resistance must be 1 megohm or less Clean workpiece hangers Faulty gun resistance See Test Gun Resistance on page 26 Low fluid resistivity Check fluid resistivity page 15 Fluid leaks from the packing 8d and Clean the packing rod cavity Causes a short Replace the packing rod See page 37 Faulty turbine alternator Be sure the plug is in place on the back of the turbine alternator hous
5. Test gun resistance page 26 Install the gun shroud 2 and air cap page 34 Install the gun onto the manifold and bracket See page 33 41 Repair Power Supply Removal and Replacement e Inspect the gun body power supply cavity for dirt or moisture Clean with a clean dry rag e Do not expose gasket 11 to solvents 1 Prepare gun for service page 32 2 Remove the barrel 9 page 40 N CAUTION Be careful when handling the power supply 12 to avoid damaging it 3 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 82 then carefully pull it straight out Disconnect the flex ible circuit 39 from the socket at the top of the body 82 See FIGURE 31 42 4 Disconnect the 3 wire connector 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 5 Check the power supply resistance page 27 Replace if necessary Before installing the power supply make sure the o rings 12a 13a spring 12b and pads 13e are in place 6 Connect the 6 pin flexible circuit 89 to the power supply 7 Connect the 3 wire connector GG Slide the alter nator 13 down onto the power supply 12 8 Lubricate the alternator o ring 13a with non sili cone grease Pa
6. eDo not install or service this equipment unless you are trained and qualified eBe sure your installation complies with National State and Local codes for the installation of electrical apparatus in a Class Div I Group D or a Group Il Category 2G Hazardous Location e Comply with all applicable local state and national fire electrical and other safety regula tions FIGURE 2 shows a typical electrostatic air spray system and FIGURE 3 shows possible system options It is not an actual system design For assistance in designing a system to suit your particular needs contact your Graco distributor Warning Signs Mount warning signs in the spray area where they can easily be seen and read by all operators An English Warning Sign is provided with the gun Ventilate the Spray Booth WARNING Flammable or Toxic Vapor Hazard Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying flushing or cleaning the gun Do not operate the gun unless ven tilation 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 High velocity air exhaust will decrease the operating effi ciency of the electrostatic system The minimum allow able air exhaust velocity is 60 ft minute
7. AND SUBSIDIARIES e P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2002 Graco Inc is registered to ISO 9001 www graco com Rev L 12 2014
8. To reduce the risk of fire explosion or elec e Clean the outside of the gun daily with a soft cloth tric shock turn off the turbine air TA dampened in a compatible solvent before flushing the gun or any part of the system 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 24 309297L 23 Maintenance Clean the Air Cap and Fluid Nozzle Equipment Needed e soft bristle brush e compatible solvent Procedure WARNING Pressurized Equipment Hazard To reduce the risk of an injury follow the Pressure Relief Procedure on page 17 when you stop spraying and whenever you are instructed to relieve the pressure 1 Relieve the pressure 2 Remove the air cap assembly 1 3 and shroud 2 See FIGURE 13 3 Wipe the fluid nozzle 4 shroud 2 and exterior of the gun clean with a cloth dampened in solvent Avoid getting any solvent into the air passages Whenever possible point the gun down when cleaning it 4 Ifitappears that there is paint inside the fluid nozzle 4 air passages remove the gun from the line for servicing 5 Clean the air cap 8 with the soft bristle brush and solvent or submerge the air cap in suitable solvent and wipe it clean 24 N CAUTION Do not use metal tools to clean the air cap or fluid nozzle holes as th
9. 19 linear meters minute Key to FIGURE 2 and FIGURE 3 s lt cHwW DOVZEZATACTrAmAMI 0OBD gt x lt 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 Fluid Hose 1 4 18 npsm gun fluid inlet P1 To Fluid Supply 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 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 309297L 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 1 j aA 1 E K B i Ow o TA K l KV2 K L a Al A2 L eve
10. 8f 185495 HOUSING packing 1 26 189367 CAP exhaust 8g 186069 SPACER packing acetal 1 o7 185122 MUFFLER 8h 244696 ROD packing 1 28 101324 NUT jam hex Zo AE PARRE gun 1 29 197919 APM actuator 1 10 197518 SCREW socket hd 10 24 x 3 4 1 30 102025 NUT hex in 19 mm 11 t 197517 GASKET barrel i 31 112689 SCREW button hd 1 4 20 x 3 4 1 in 19 mm 12 244541 POWER SUPPLY 85 kV includes 1 30 245662 BODY gun 12a 12b 12a t 103337 O RING fluoroelastomer 1 oe INGOTS O R Gap ROCKERNE MORA a a in 76 mm 12b 197624 SPRING compression 1 Continued on page 50 309297L 49 Parts Ref No 34 34a 34b 34c 34d t 34e T 34f t 34g t 35 39 40 50 Part No 244702 197920 189754 189355 189752 111504 112319 111508 244586 245265 276741 Description PISTON includes 34a 34g PISTON ROD piston STEM piston PACKING u cup O RING O RING O RING MANIFOLD see separate parts list on page 51 CIRCUIT flexible MULTI TOOL Qty Ref No 41 42 43 44 51 Part No 107460 179791 180060 239945 197624 Description WRENCH ball end 4 mm TAG warning not shown replacement available at no cost SIGN warning not shown replacement available at no cost COVER gun box of 10 not shown SPRING grounding Qty Recommended spare parts Keep on hand to reduce downtime T Included in repair kit 15D592 Replacement Warning
11. Gun Series B for standard coatings Ref No 1a t 4a 4b 8a 8b 8c 8d 8e 8f 8g 8h 12a T 12b 46 Part No 244950 198307 245312 24A438 197266 111261 111507 198486 276697 244521 111316 116905 178409 178763 197641 185495 186069 244696 244394 197518 197517 244541 103337 197624 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 pictured on page 51 unassem bled NEEDLE electrode ROD packing includes 8a 8h O RING fluoroelastomer SEAL SPREADER packing uhnmwpe PACKING rod acetal NUT packing HOUSING packing SPACER packing acetal ROD packing BARREL gun SCREW socket hd 10 24 x 3 4 in 19 mm GASKET barrel POWER SUPPLY 85 kV includes 12a 12b O RING fluoroelastomer SPRING compression Qty 1 Ref No 13 13a T 13b 13c 13d 13e 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Part No 244555 110073 223688 244577 111745 198821 111316 102982 189757 112642 111370 198043 112644 111285 111286 189549 111450 185111 189367 185122 101324 197919 102025 112689 245662 Description TURBINE alternator includes 13a 13e O RING fluoroelastomer BEARING KIT includes front and rear bearin
12. If fluid is seen in these areas stop spraying immedi ately Relieve the pressure then remove the gun for repair yy eh j ti1571a ZZ ZZ Fig 14 Check for Fluid Leakage 309297L 25 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 yg Megohmmeter Part No 241079 AA see amp FIGURE 15 is not approved for use in a haz ardous area To reduce the risk of sparking W do not use the megohmmeter to check electrical grounding unless u 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 Test Gun Resistance 1 Flush and dry the fluid passage 2 Measure resistance between the
13. and a true earth ground N a Ifusing a black or grey turbine air hose use a megohmmeter to measure the resistance Use an applied voltage of 500 minimum to 1000 A WARNING volts maximum The resistance should not Fire Explosion and Electric Shock Hazard exceed 1 megohm Megohmmeter Part No 241079 AA see b fusing a red turbine air hose use an ohmmeter FIGURE 8 is not approved for use in a haz to measure the resistance The resistance ardous area To reduce the risk of sparking should not exceed 100 ohms do not use the megohmme ter to check electrical grounding unless 3 Ifthe resistance is greater than the maximum read ing specified above for your hose check the tight ness 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 e 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 N fumes from spraying AA D k a Failure to follow this warning could cause OS gt fire explosion and electric shock and result SO A in serious injury and property damage SS TA Y 1 Have a qualified electrician check the electrical SK oN a grounding continuity of the spray gun an
14. labels signs tags and cards are available at no cost 309297L Part No 244586 Manifold Series A Ref No 101 102 103 104 105 106 107 108 109 110 111 112T 113 Part No 198216 189581 110465 112689 112640 197518 111157 186845 110078 112646 189551 197925 108290 309297L 101 Ref y es 102 Description MANIFOLD BRACKET reciprocator SCREW set SCREW button hd SPRING compression SCREW socket hd 10 24 x 3 4 in 19 mm FITTING tube exhaust FITTING turbine air FITTING tube air PLUG FITTING quick disconnect fluid GASKET manifold SCREW machine W 106 Ref 116 116a 119 Pa 114 Qty Y a Ref No 114 115 116 116aT 117 118 119 120 109 Part No 189365 198764 244772 112085 114263 111450 116621 112645 5 see pages 46 or 49 Description CAP kV HI LO RESTRICTOR PISTON includes 116a O RING 1 per piston FITTING tube air O RING SPRING compression PLUG T Included in repair kit 15D592 Parts 101 Qty 51 Accessories Accessories Air Line Accessories AirFlex Flexible Grounded Air Hose 100 psi 7 bar 0 7 MPa Maximum Working Pressure 0 315 in 8 mm ID 1 4 nposm f x 1 4 npsm f left hand thread 244963 s G ft 1 8 m 244964 15 ft 4 6m 244965 25 ft 7 6m 244966 _ 36 ft 11 m 244967 50 ft 15 m
15. 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 26 9 Install the gun onto the manifold and bracket See page 33 T11572A Fig 21 Air Cap Nozzle Replacement 34 309297L Repair Electrode Replacement 1 Prepare the gun for service page 32 2 Remove the air cap and nozzle page 34 Remove the gun shroud 2 3 Unscrew the electrode 7 with the multi tool 40 Hold the packing rod end 8h to prevent it from turning FIGURE 22 N CAUTION 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 34 6 Test gun resistance page 26 7 Install the gun shroud 2 and air cap page 34 Fig 22 Electrode Replacement 8 Install the gun onto the manifold and bracket See page 33 309297L 35 Repair Fluid Packing Removal Before
16. 15 oz min 450 cc min For use with 2 0 mm nozzle 309297L 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 Pressurized Equipment Hazard To reduce the risk of an injury follow the Pressure Relief Procedure on page 17 whenever you are instructed to relieve the pressure 1 Relieve the pressure 2 Loosen the air cap retaining ring and rotate the air cap for a vertical or horizontal spray pattern See FIGURE 11 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 Horizontal Pattern Fig 11 Air Cap Positions 3 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 size of the fluid nozzle being used 309297L Operation 4 Use the air pressure regulator on the atomization air supply line A1 to adjust the degree of atomization See FIGURE 12 For example for a fluid flow rate of 10 ounces per minute 0 3 liters per minute a typi cal atomization pressure would be 20 30 psi 1 4 2 1 bar 0 14 0 21 MPa at the gun manifold 5 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 w
17. 244968 75 ft 23 m 244969 100 ft 30 5 m Standard Grounded Air Hose Grey 100 psi 7 bar 0 7 MPa Maximum Working Pressure 0 315 in 8 mm ID 1 4 nposm f x 1 4 npsm f left hand thread 223068 6 ft 1 8 m 223069 15 ft 4 6m 223070 25 ft 7 6 m 223071 36 ft 11m 223072 50 ft 15m 223073 75 ft 23 m 223074 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 52 Air Line Shutoff Valve 150 psi 10 bar 1 0 MPa Maximum Working Pressure For turning air to gun on or off 224754 1 4 nosm m x 1 4 npsm f left hand thread Fluid Line Accessories Fluid Hose 225 psi 14 bar 1 4 MPa Maximum Working Pressure FM Approved nylon 3 8 nosm fbe 215637 1 4 in 6 mm ID x 25 ft 7 6 m 215638 1 4 in 6 mm ID x 50 ft 15 2 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 Fluid Recirculation Kit 233676 Converts standard gun to a recirculating gun Requires 23685
18. 3 Drain Valve Gun Mounted Fluid Regulator 100 psi 7 bar 0 7 MPa Maximum Working Pressure 236854 Air piloted fluid regulator mounts directly to gun manifold for precise fluid control 309297L 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 Paint Resistance Meter 722886 Use with 722860 Paint Probe to measure resistance of paint Not for use in hazardous areas Paint Probe 722860 Use with 722886 Paint Resistance Meter to measure resistance of paint Not for use in hazardous areas 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 Fiber Optic Y Cables See item T in FIGURE 3 on page 9 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 15m 224686 100 ft 30 5 m 309297L Accessories Fiber Optic Cables See item V in FIGURE 3 on page 9 Connect gun mani fold and remote voltage display bulkhead connector and remote display or bulkhead connector and gun ma
19. Care and Cleaning N CAUTION Clean all parts with a non conductive compatible 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 22 Do not immerse the gun in fluid Do not wipe the gun with a cloth that is heavily saturated wring out the excess fluid 02027A 309297L Maintenance i e Check the electrode and replace if broken or dam Daily Care and Cleaning aged See Electrode Replacement on page 35 continued e Check for fluid leakage from the gun and fluid hoses See Check for Fluid Leakage on page 25 Tighten fittings or replace equipment as needed WARNING Pressurized Equipment Hazard e Flush the gun before changing colors and whenever you are done operating the gun To reduce the risk of an injury follow the a Pressure Relief Procedure on page 17 before doing any maintenance on the gun or system WARNING Fire Explosion and Electric Shock Hazard e Clean the fluid and air line filters daily
20. Instructions Parts List gt GRACO AUTOMATIC ELECTROSTATIC AIR SPRAY GUN 309297L PRO Auto Xs 100 psi 0 7 MPa 7 bar Maximum Air Inlet Pressure 100 psi 0 7 MPa 7 bar Maximum Working Fluid Pressure For use in Class I Div hazardous locations using Group D spray materials O APPROVED For use in Group ll Zone 1 areas using Group IIA spray materials C Edn 2 G EEx 0 24 mJ For Professional Use ONLY U S Patent 7 226 004 TI1557A Important Safety Instructions A Read all warnings and instructions in this manual Save these instructions See page 2 for Table of Contents and page 3 for List of Models PROVEN QUALITY LEADING TECHNOLOGY Table of Contents LISEOTIMOGEIS ye id ewe aaa 3 MaAIntGnanGe ss0 s20 sse s eee eared aide were es 22 SVMDOIS s cs eect tebe ee tetne ede ne 3 Daily Care and Cleaning 22 Warning Symbol 0 0000 e eae 3 Clean the Air Cap and Fluid Nozzle 24 Caution SYMDOl s i 04 0 eniai a 3 Check for Fluid Leakage 25 Warning asrianiasr haw b tte Aer See oe 4 Electrical TESlS ccnn epee be cele eos 26 INTFOGUCUON sirarsa Gta sot e rsa dere eke 6 Test Gun Resistance 0005 26 How the Electrostatic Air Spray Gun Works 6 Test Power Supply Resistance 27 Operating the Spray Function 6 Test Electrode Resistance 28 Operating the Electr
21. cedure on page 17 whenever you are instructed to relieve the pressure repair this equipment unless you are trained and qualified 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 pomm o i e O o S Fluttering or spitting spray No fluid Refill supply Loose dirty damaged nozzle seat Clean or replace nozzle page 34 Air in fluid supply Check fluid source Refill Improper spray pattern Damaged nozzle or air cap Replace page 34 oOo Fluid buildup on air cap or nozzle Clean See page 24 Decrease Fan air pressure too high Fluid too thin Increase viscosity Fluid pressure too low Increase Fan air pressure too low Increase Streaks Did not apply 50 overlap nine a 309297L 29 Troubleshooting Gun Operation Troubleshooting proven ome Set 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 36 or 37 Air leaks from the air cap Worn piston stem o rings 34e 34f Replace see page 38
22. ch 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 Record the fluid type elapsed time and size of the viscosity cup If the viscosity is too high or too low contact the material supplier Adjust as necessary Install the Fabric Cover 1 Install a fabric cover XX over the front of the gun and slide it back to cover the exposed tubing and hoses at the back of the manifold See FIGURE 9 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 Fluid Leakage on page 25 Strap down the exhaust tube to prevent it from moving around 15 Installation 245324 HC Conversion Kit 6 rN loops of the hc tube 19 onto the gun bar Part No 245324 Conversion Kit is available to convert _ Make sure the barrel threads are clean and dry PRO Auto Xs standard coating guns Part No 244589 Apply Graco Part No 116553 dielectric grease to Og GON EUV UNE AE the fluid fitting 19d threads and o rings Thread 7 oo the fitting into the barrel inlet See FIGURE 10 The kit is for use with fluids with low resistivity values 8 Slide the nut 20 and ferrules 21 22 onto the coiled tube 19 Insert the end of the tube into the A WARN te fitting 23 Make sure the ferrules seat in the fitting Tighten the nut 20 Pressurized Equipment Hazard To reduce t
23. 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 Measure the resistance between the conductive rod B and the electrode 7 The resistance should be 20 30 megohms See FIGURE 17 If in range refer to Electrical Troubleshooting on page 31 for other possible causes of poor perfor mance or contact your Graco distributor Remove the electrode 7 page 35 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 FIGURE 18 Make sure the metal contact C in the barrel the nozzle contact ring 4a FIGURE 19 and the elec trode contacts E are clean and undamaged 1 ALTE ti1499a Fig 17 Test Electrode Resistance 28 O a F J Fig 18 Electrode ti1513a Fig 19 Nozzle Conductive O Ring 309297L Troubleshooting 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 W Installing and servicing this equipment w Troubleshooting WARNING Pressurized Equipment Hazard To reduce the risk of an injury follow the Pressure Relief Pro
24. conductivity coatings Ref No 13 Alternator Detail 13a 13b TI1586A NI 8h Wy 8e N W 8g PA 8d 6 19 Ref 20 2122 31 lt 2 Ref No 8 Packing Rod Detail I 8a x Na OA 48 309297L Parts Part No 244590 PRO Auto Xs Electrostatic Gun Series B for high conductivity coatings lt Part No Description Qty Ref partNo Descripti Qt No AOE Shae non y 13 244555 TURBINE alternator includes 1 13a 13 e 1 244950 RING retaining air cap includes 1 1a 13a t 110073 O RING fluoroelastomer 1 ta t 198307 _ U CUP 1 13b 223688 BEARING KIT includes front 1 and rear bearings and fan 2 245312 SHROUD 1 13c 244577 COIL 1 3 24A438 AIR CAP 1 13d 111745 RING retaining 1 4 197266 NOZZLE 1 5 mm orifice includes 1 4a and 4b 13e 198821 PAD pressure 2 4a 111261 O RING conductive 1 19 237297 TUBE fluid coiled includes 1 19a 19d 4b 111507 O RING fluoroelastomer 1 19a 102982 O RING 1 5 198486 CONNECTOR tube fiber optic 1 pictured on page 51 unassem 19b 111450 O RING 1 bled 19c 103337 O RING 2 7 2 6697 NEEDLE electrode 1 19d 186818 FITTING 3 8 244521 ROD packing includes 8a 8h 1 20 112644 NUT J 8a 111316 O RING fluoroelastomer 1 24 111285 FERRULE back J 9D 110905 x SEAN 1 o 111286 FERRULE front I go MO 63 econ ela packing UNmwpe 1 23 189549 FITTING fluid quick disconnect 8d 178409 PACKING rod acetal 1 24 111450 O RING 1 Be Leer saat pacing 25 185111 SPRING compression 1
25. d turbine air hose B Ss G G 2 Make sure the turbine air hose B is connected and Ce 6 the hose ground wire is connected to a true earth Ga A ground 3 Turn off the air and fluid supply to the gun The fluid Fig 8 Check Gun Grounding hose must not have any fluid in it 14 309297L Check Fluid Resistivity WARNING Fire Explosion and Electric Shock Hazard Check the fluid resistivity in a non hazard ous area only Resistance Meter 722886 and Probe 722860 are not approved for use w in a hazardous area Failure to follow this warning could cause fire explosion or electric shock and result in serious injury and property damage Graco Part No 722886 Resistance Meter and 722860 Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the require ments 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 Fig 9 Fabric Cover 309297L Installation Check Fluid Viscosity To check fluid viscosity you will need a viscosity cup a stopwatch Completely submerge the viscosity cup in the fluid Lift the cup out quickly starting the stopwatch as soon as the cup is completely removed Wat
26. e in place on the manifold See FIGURE 20 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 33 Repair Air Cap Nozzle Replacement WARNING Fire Explosion and Electric Shock Hazard N CAUTION The nozzle contact ring 4a is a conductive Hold the front end of the gun up and trigger 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 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 1 Prepare gun for service page 32 replace the contact ring with anything but a genuine Graco part 2 Remove the retaining ring 1 and air cap 3 See FIGURE 21 Use non silicone grease Part No 111265 on the small o ring 4b Do not over lubricate Do not lubricate the 3 Point gun up while removing the fluid nozzle 4 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 Make sure the electrode needle 7 is finger tight page 35 5 Install the fluid nozzle 4 with the multi tool 40 Tighten until the fluid
27. een checked for the presence of any fluid as instructed in Check for Fluid Leakage on page 25 fF LJ LJ U UU Uo ou vo vo 18 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 17 before removing or installing a fluid nozzle and or air cap The gun is supplied with Part No 197266 Nozzle and 24A438 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 34 Table 2 Fluid Nozzles ize Size in mm in 197263 0 75 030 197266 1 5 055 197264 1 0 042 197267 1 8 070 197265 1 2 047 197268 2 0 080 Table 3 Air Caps Pattern Shape and Length in mm Round end ganas 15 17 381 432 Round end anneal 14 16 356 406 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 Tapered end ne 17 19 482 483 Tapered end ARELA 12 14 305 356 Round end PARRIN 11 13 279 330 Also available in the following colors 24A276 blue 24A277 red 24A278 green Light to medium viscosity Up to 15 oz min 450 cc min Medium to high viscosity and high solids Up to
28. egulator air inlet Relieve fluid pressure in the fluid supply equipment as instructed in its instruction manual 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 17 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 air spray system as instructed in this manual i All operators are trained in the Pressure Relief Procedure on page 17 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 Grounding on page 13 The condition of the gun s electrical compo nents has been checked as instructed in Elec trical Tests on page 26 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 flammable fluids in the spray booth are in approved grounded containers 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 b
29. electrode needle tip 7 and the gun body 32 or the turbine air inlet fitting TA it should be 156 180 megohms If out side this range remove the gun for service page 32 and go to the next test If in range refer to Elec trical Troubleshooting on page 31 for other possi ble causes of poor performance 26 TA AA L o y i T Li ie TI577A Fig 15 Test Gun Resistance T11585B 309297L Test Power Supply Resistance 1 2 Remove the power supply 12 page 42 Remove the turbine alternator 13 from the power supply page 43 Measure resistance from the power supply s ground strips EE to the spring 12b See FIGURE 16 The resistance should be 135 150 megohms If out side this range replace the power supply If in range proceed to the next test If you still have problems refer to Electrical Trou bleshooting on page 31 for other possible causes of poor performance or contact your Graco distribu tor 309297L Electrical Tests 6 Be sure the spring 12b is in place before reinstall ing the power supply 1 ALE i ea aa il Fig 16 Test Power Supply Resistance ti1599a 27 Electrical Tests Test Electrode Resistance Insert a
30. gs and fan COIL RING retaining PAD pressure O RING O RING FITTING fluid SPACER CONNECTOR elbow includes items 20 21 22 TUBE fluid NUT FERRULE back FERRULE front FITTING fluid quick disconnect O RING 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 Qty 309297L Ref No 33 34 34a 34b 34c 34d t 34e T 34f t 34g t 35 39 40 Part No 116575 244702 197920 189754 189355 189752 111504 112319 111508 244586 245265 276741 309297L Description 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 MANIFOLD see separate parts list on page 51 CIRCUIT flexible MULTI TOOL Qty 2 Ref No 41 42 43 44 51 Part No 107460 179791 180060 239945 197624 Description WRENCH ball end 4 mm TAG warning not shown replacement available at no cost SIGN warning not shown replacement available at no cost COVER gun box of 10 not shown SPRING grounding Parts Qty Recommended spare parts Keep on hand to reduce downtime f Included in repair kit 15D592 Replacement Warning labels signs tags and cards are available at no cost 47 Parts Part No 244590 PRO Auto Xs Electrostatic Gun Series B for high
31. he 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 Changing the kV Setting The gun s full voltage setting is 85 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 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 KV1 and KV2 Switch Settings OFF 309297L Fig 1 Gun Overview Key Dfa 309297L Introduction KV1 KV2 A2 P2 EXH TI1577A Manifold Back View TIH561A Manifold Markings Atomization Air Inlet Fitting Fan Air Inlet Fitting Cylinder Air Inlet Fitting Shroud Exhaust Outlet Fitting Fiber Optic Fitting shipped unassembled kV Switch 1 Air Inlet oui are Turbine Air Inlet Fitting Installation Installation Install the System WARNING Fire Explosion and Electric Shock Hazard Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly
32. he risk of an injury follow the a Pressure Relief Procedure on page 17 before installing this kit 1 Turn the turbine air TA off 2 Flush the gun 3 Relieve the pressure 4 Remove the retaining ring 1 air cap 3 and shroud 2 5 Refer to the parts drawing for Model 244589 on page 45 Loosen the two nuts 20 and remove the fluid tube 19 and ferrules 21 22 Remove the other parts 14 15 16 17 18 at the gun barrel inlet Fig 10 HC Conversion Kit 20 16 309297L Operation Pressure Relief Procedure WARNING Pressurized Equipment Hazard The system pressure must be manually am 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 are instructed to relieve the pressure stop spraying check or service any of the system equipment or install or clean the fluid nozzle 1 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 the air pressure is needed at the regulator air inlet 309297L Operation Turn off the fluid supply to the gun Trigger the gun into a grounded metal waste con tainer to relieve the fluid pressure If an air pilot fluid regulator is used turn off the air pressure at the r
33. hin 4 in 10 cm of the nozzle during gun operation 1 Apply a minimum of 50 psi 3 5 bar 0 35 MPa air pressure to the cylinder air fitting CYL to activate the on off sequence of atomization air A1 fan air A2 and fluid P1 See FIGURE 12 2 Turn the gun functions on and off by using the air solenoid valves on the cylinder CYL and turbine TA air supply lines 3 To change to a lower voltage setting activate the solenoids controlling the KV1 and KV2 ports See Changing the kV Setting on page 6 WARNING Fire and Explosion Hazard If any fluid leakage from the gun is detected stop spraying immediately Fluid fire or explosion and result in serious injury and property damage See Check for Fluid Leakage on page 25 j leakage into the gun shroud could cause 309297L Operation Triggering the Fluid Alone 1 Shut off and relieve the air pressure to the atomiza tion A1 and fan A2 air lines using the bleed type air shutoff valves 2 Apply 50 psi 3 5 bar 0 35 MPa air pressure to the cylinder air fitting CYL to trigger the fluid Shutdown WARNING Pressurized Equipment Hazard To reduce the risk of an injury follow the Pressure Relief Procedure on page 17 when you stop spraying and whenever you are instructed to relieve the pressure 1 Relieve the pressure 2 Flush and clean the equipment See Maintenance on page 22 21 Maintenance Maintenance Daily
34. ide flat pattern it may be necessary to increase the supply of fluid to the gun to maintain the same amount of coverage over a large area e See Spray Pattern Troubleshooting on page 29 to correct spray pattern problems ate KV1 TA CYL A1 AD TI1577A Fig 12 Manifold Air Connections 19 Operation Adjust the Electrostatics 1 Shut off the fluid supply 2 Trigger the gun then turn on the turbine air TA See FIGURE 12 3 Refer to Table 4 to set the proper pressure at the turbine air hose inlet when air is flowing Do not exceed these pressures as there is no added bene fit and turbine life could be reduced 20 Table 4 Dynamic Turbine Air Pressures Turbine Air Air pressure at turbine air hose Hose Length inlet for full voltage ft m psi bar MPa 15 4 6 54 3 8 0 38 25 7 6 55 3 85 0 38 36 11 56 3 9 0 39 4 Check the voltage output of the gun using a high voltage probe and meter or by reading the ES kV Display Module The gun s normal high voltage reading is 60 70 kV If a ball end high voltage measurement probe is used the gun voltage will rise to about 85 kV This will happen with all resistive electrostatic guns See Electrical Troubleshooting on page 31 to correct voltage problems 309297L Spraying WARNING Electric Shock Hazard To reduce the risk of electric shock do not W touch the gun electrode or come wit
35. ig gered 34f 5 34e oN S wy SD D Atomizing Air Side Fig 26 Piston O Rings 34 34a TI1575A TI1576A 309297L Adjust the Actuator Arm The fluid nozzle 4 must be in place when removing or installing the jam nut and actuator arm 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 FIGURE 25 on page 38 2 Position the parts so there is a 0 125 in 8 mm gap between the actuator arm 29 and the fluid packing rod nut E which allows the atomizing air to actuate before the fluid See FIGURE 27 3 Tighten the adjustment nut 30 against the actuator 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 26 309297L Repair 5 Install the gun shroud 2 and air cap 3 page 34 6 Install the gun onto the manifold and bracket See page 33 gt 0 125 in 3 mm gap 28 30 34b E Fig 27 Actuator Arm Adjustment 39 Repair 6 Hold the gun body 32 with one hand and pull the Barrel Removal barre
36. ing Remove and test the turbine alternator See page 43 The KV switch is stuck on low Check the switch actuation replace if needed Replace power supply See page 42 No voltage or low voltage reading on Damaged fiber optic cable or connec Check replace damaged parts the gun ES display module tion Turbine air is not turned on Turn on Poor wrap See causes and solutions under Poor Wrap above Operator gets mild shock Operator not grounded or is near See Grounding on page 13 ungrounded object Gun not grounded See Check Electrical Grounding on page 14 and Test Gun Resistance on page 26 Operator gets shock from workpiece Workpiece not grounded Resistance must be 1 megohm or less Clean workpiece hangers 309297L 31 Repair Repair Prepare the Gun for Service WARNING Electric Shock Hazard requires access to parts that may cause electric shock or other serious injury if the work is not performed properly Do not install or ser vice this equipment unless you are trained and quali fied W Installing and repairing this equipment WARNING Pressurized Equipment Hazard To reduce the risk of injury follow the Pres cf sure Relief Procedure on page 17 before checking or servicing any part of the system and whenever you are instructed to relieve the pres sure 32 Check all possible remedies in Troubleshooting before disassembling the gun Use a vise with padded ja
37. ing sprayed keep the workpiece hangers W cause a fire explosion or electric shock clean and grounded at all times Resistance must Follow the grounding instructions below not exceed 1 megohm e The floor of the spray area must be electrically con The following are minimum grounding requirements for ductive and grounded Do not cover the floor with a basic electrostatic system Your system may include cardboard or any non conductive material which other equipment or objects which must be grounded would interrupt grounding continuity Check your local electrical code for detailed grounding instructions Your system must be connected to a true e Flammable liquids in the spray area must be kept in earth ground approved grounded containers Do not use plastic containers Do not store more than the quantity e Pump ground the pump by connecting a ground needed for one shift wire and clamp as described in your separate pump instruction manual e All electrically conductive objects or devices in the Spray area including fluid containers and wash e Electrostatic Air Spray Gun ground the gun by con cans must be properly grounded necting the Graco Grounded Air Hose to the turbine air inlet and connecting the air hose ground wire to a true earth ground See Check Electrical Ground ing page 14 309297L 13 Installation H M 4 Measure the resistance between the turbine air inlet Check Electrical Grounding fitting TA
38. installing the packing rod clean the internal sur face of the barrel 9 with a soft cloth or brush Check for marks from high voltage arcing If marks are present You may replace the packing rod as an assembly as replace the barrel described below or as individual parts see page 37 The assembly is pre adjusted at the factory 1 Prepare the gun for service page 32 2 Remove the air cap page 34 Remove the gun shroud 2 3 Remove the jam nut 28 and actuator arm 29 See page 38 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 34 and 35 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 TI1566A 6 Check all parts for wear or damage and replace if Fig 23 Fluid Packing Removal necessary 36 309297L Packing Rod Repair You may replace the packing rod as individual parts as described below or as an assembly see page 36 The assembly is pre adjusted at the factory 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 v
39. ion and Electric Shock Hazard Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion e Electrostatic equipment must be used only by trained qualified personnel who understand the requirements of this manual Ground equipment personnel object being sprayed and conductive objects in work area See Grounding instructions Only use grounded Graco conductive air supply hoses Check gun and 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 comply with EN50050 requirements 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 If there is static sparking or you feel a shock stop operation immediately Do not use equip ment until you identify and correct the problem Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plas tic drop cloths potential static arc Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Keep work area free of debris including solvent rags and gasoline Keep a working fire extinguisher in the work area Toxic Fluid Haza
40. ir inlet fitting has left hand threads to prevent connecting another type of air hose to the turbine air inlet See Accessories on page 52 for further information about the hose 2 Check the electrical grounding of the gun as instructed on page 14 3 Before connecting the fluid line P1 blow it out with air and flush it with solvent Use solvent which is compatible with the fluid to be sprayed Manifold Connections Atomization Air Inlet Fitting Connect a 3 8 in 10 mm OD tube between this fitting and the air supply Fan Air Inlet Fitting Fig 5 Manifold Connections Connect a 3 8 in 10 mm OD tube between this fitting and the air supply TI1577A Cylinder Air Inlet Fitting Connect a 5 32 in 4 mm OD tube between this fitting and the solenoid For quicker response use the shortest hose length possible 309297L 17 Installation Optional Fiber Optic Cable 2 Remove the nut AA from the fiber optic fitting 5 and slide the nut over the end of the fiber optic cable Con nection BB See FIGURE 7 ee 3 Push the cable BB into the fitting 5 until it bot An optional fiber optic fitting is shipped unassembled toms out Tighten the nut AA to secure the cable with the gun If an ES kV display module is used 119 install the fitting in the FO port of the manifold See FIG
41. is 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 Slide the shroud 2 onto the gun 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 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 Test gun resistance page 26 TI1560A Fig 13 Clean Air Cap and Fluid Nozzle 309297L Maintenance Check for Fluid Leakage WARNING Pressurized Equipment Hazard WARNING Fire and Explosion Hazard To reduce the risk of an injury follow the Pressure Relief Procedure on page 17 when you stop spraying and whenever you If any fluid leakage from the gun is Me J J are instructed to relieve the pressure 4 detected stop spraying immediately Fluid leakage into the gun shroud could cause W fire or explosion and result in serious injury During operation periodically check the manifold and property damage exhaust tube YY and both ends of the gun shroud ZZ for the presence of fluid See FIGURE 14 Fluid in these areas indicates leakage into the shroud which could be caused by leaks at the fluid tube connections or fluid packing leakage
42. ive 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 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 con
43. k Fluid Viscosity 05 15 Power Supply Removal and Replacement 42 Install the Fabric Cover 15 Turbine Alternator Removal and Replacement 43 245324 HC Conversion Kit 16 Parts veg bo iad hoy tee hats ee Gace ee 45 Operation i tc 2s se tha bata bee went 17 Accessories oie aia ie ew eG ede Stee eae 52 Pressure Relief Procedure 17 Air Line Accessories 20000 ee 52 Operating Checklist 0 18 Fluid Line Accessories 005 52 Select a Fluid Nozzle and AirCap 18 Miscellaneous Accessories 53 Adjust the Spray Pattern 19 Gun AccessorieS 0 000 c eee eee eee 54 Adjust the Electrostatics 20 Technical Data 62 ieee is wees eater dslnoe os 55 Spraying aers rnr Meas cd oe eee aes eats 21 Graco Standard Warranty 005 56 Triggering the Fluid Alone 21 SILO WIN orean arc al aaa war od nape Mi Saran dod es 21 2 309297L List of Models List of Models Type of Coatings Voltage High Conductivity Symbols 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 309297L 3 Warning WARNING Fire Explos
44. l 9 straight off the body See FIGURE 28 1 Prepare the gun for service page 32 2 Remove the air cap page 34 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 38 5 Loosen the three screws 10 33 See FIGURE 28 N CAUTION TI1563A To avoid damaging the power supply 12 pull the gun barrel 9 straight away from the gun body 32 If Fig 28 Barrel Removal necessary gently move the gun barrel from side to side to free it from the gun body 32 29 SZ im n jE Ri TI1709A 28 30 19 20 23 Fig 29 Disconnect Fluid Tube 40 309297L Barrel Installation 1 Be sure the gasket 11 and grounding spring 51 are in place Make sure the air holes are aligned properly Replace if damaged See FIGURE 30 2 Place the barrel 9 over the power supply 12 and onto the gun body 32 3 Tighten the three screws 10 33 oppositely and evenly about a half turn past snug N CAUTION Do not over tighten the screws 10 33 Fig 30 Barrel Installation 309297L Repair Assemble the fluid tube 19 into the fluid fitting 23 Ensure that the ferrules 21 22 are in place Tighten the nut 20 Install and adjust the actuator arm 29 and jam nut 28 See page 39
45. nifold See 308265 224672 25 ft 7 6 m 224674 50 ft 15 m 224676 100 ft 30 5 m Power Supply 235301 Supplies low voltage DC power to 224117 Display Module See 308265 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 6m 236919 50 ft 15m 236921 100 ft 30 5 m Bulkhead Connector 189870 For connecting two fiber optic cables 53 Accessories Gun Accessories Round Pattern Kits Consists of fluid tip diffuser and air cap 245217 4 6 in 102 152 mm diameter 245219 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 54 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 HC Conversion Kit 245324 Converts PRO Auto Xs standard coating gun Part No 244589 to high conductivity gun 244590 The kit is for use with fluids with low resistivity values See page 16 309297L Technical Data Category Maximum Working Fluid Pressure Maximum W
46. oltage arc ing If marks are present replace the barrel To assemble the individual parts 1 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 FIGURE 24 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 N 8a 5 Fig 24 Packing Rod 309297L Repair 4 Lightly tighten the packing nut 8e The packing nut is properly tightened when there is 3 Ib 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 35 and nozzle page 34 9 Install and adjust the actuator arm 29 and jam nut 28 See page 39 10 Test gun resistance page 26 11 Install the gun shroud 2 and air cap page 34 12 Install the gun onto
47. orking Air Pressure Minimum Air Pressure at Gun Inlet Maximum Fluid Operating Temperature Paint Resistivity Range 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 MPa 2 8 bar 120 F 48 C 3 megohm cm to infinity 125 microamperes 40 85 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 1 4 18 npsm m 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 309297L 55 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 publi
48. ort WARNING Pressurized Equipment Hazard 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 Fluid Line Accessories 1 Install a fluid filter and drain valve at the pump out let 10 WARNING Pressurized Equipment Hazard The fluid drain valve is required in your sys tem to assist in relieving fluid pressure in the displacement pump hose and gun Triggering the gun to relieve pressure may not be sufficient Install a drain valve close to the pump s fluid outlet The drain valve reduces the risk of serious injury including splashing in the eyes or on the skin 2 Install a fluid regulator on the fluid line to control fluid pressure to the gun Install the Gun and Mounting Bracket 1 Loosen the mounting bracket s two set screws 103 and slide the bracket 102 onto a 1 2 in 13 mm mounting rod See FIGURE 4 2 Position the gun and tighten the two set screws 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 FIGURE 4 WE 73 2 mm
49. ostatics 6 Troubleshooting 000 00 eee eee eee 29 Gun Features and Options 6 Spray Pattern Troubleshooting 29 Changing the kV Setting 6 Gun Operation Troubleshooting 30 NS tAMAUOM oiean SGede onl ceeee erate ee 8 Electrical Troubleshooting 31 Install the System 0000 00 eeaee 8 Repa 2 26244 i60 seu eee tue tocar ee aS 32 Warning SignS 00 5005 e eee eee 8 Prepare the Gun for Service 32 Ventilate the Spray Booth 8 Remove the Gun from the Manifold 33 Install the Air Line Accessories 10 Install the Gun on the Manifold 33 Install the Fluid Line Accessories 10 Air Cap Nozzle Replacement 34 Install the Gun and Mounting Bracket 10 Electrode Replacement 35 Connect the Air and Fluid Lines 11 Fluid Packing Removal 05 36 Manifold Connections 005 11 Packing Rod Repair 0000e 37 Optional Fiber Optic Cable Connection 12 Piston Repair 4 4 0 44 000 eid aeahaaaus ave 38 GlOUNGING si orn osewde kdewa EAT eden caex 13 Adjust the Actuator Arm 045 39 Check Electrical Grounding 14 Barrel Removal 000 e eee 40 Check Fluid Resistivity 15 Barrel Installation 00005 41 Chec
50. rd Hazardous fluids or toxic fumes can cause a serious injury or death if splashed 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 Store hazardous fluid in an approved container Dispose of the hazardous fluid according to all local state and national guidelines Wear appropriate protective clothing gloves eyewear and respirator 4 309297L Warning WARNING Equipment Misuse Hazard Equipment misuse can cause the equipment to rupture malfunction or start unexpectedly and result in a serious injury This equipment is for professional use only Read all manuals tags and labels before operating the equipment Use the equipment only for its intended purpose If you are uncertain call your Graco distribu tor Do not alter or modify equipment Use only genuine Graco parts and accessories Check the equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system component 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 e
51. rt No 111265 Do not over lubri cate 9 Lubricate the power supply o ring 12a with dielec tric grease 10 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 11 Install the barrel 9 page 41 12 Test gun resistance page 26 309297L Fig 31 Power Supply Turbine Alternator Removal and Replacement Replace turbine alternator bearings after 2000 hours of operation Order Part No 223688 Bearing Kit 1 Prepare gun for service page 32 2 Remove the power supply alternator assembly page 42 3 Disconnect the alternator from the power supply page 42 309297L Repair TI1568A 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 42 Install the power supply alternator assembly page 42 43 Repair 44 Notes 309297L Parts Parts Part No 244589 PRO Auto Xs Electrostatic Gun Series B for standard coatings TI1558A 19 Ref 20 2122 31 G D 309297L 45 Parts Part No 244589 PRO Auto Xs Electrostatic
52. sequential 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 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 procedures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents 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 Original instructions This manual contains English MM 309297 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC
53. shed 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 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 defect
54. short time later opens the fluid needle This pro vides the proper air lead and lag when triggering the gun A spring returns the piston when the cylinder air is shut off 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 helos keep contaminants out and helps keep the gun clean 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 The gun s quick disconnect design enables its removal without disconnecting the fluid and air lines to the gun e Gun functions are activated from a separate control ler that sends the appropriate signal to the actuating solenoids e The optional fiber optic readout system can be installed to monitor the gun s spraying voltage A fiber optic cable connected to t
55. the manifold and bracket See page 33 SK 25 8h 37 Repair Piston Repair 3 Prepare the gun for service page 32 Remove the air cap page 34 Remove the gun shroud 2 Remove the jam nut 28 actuator arm 29 and adjustment nut 30 See FIGURE 25 The fluid nozzle 4 must be in place when removing or installing the jam nut and actuator arm TI1709A 28 29 30 34b Fig 25 Actuator Arm 4 38 Push on the piston rod 34b to push the piston out the back of the gun Inspect the o rings 34e 34f 34g and u cup pack ing 34d for damage See Table 5 and FIGURE 26 Lubricate the o rings 34e 34f 34g and u cup packing 34d with non silicone grease Part No 111265 Do not over lubricate 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 Install and adjust the actuator arm page 39 Table 5 Piston O Rings Bescon Fen Shaft O Ring Seals cylinder air along the piston rod 34g 34b Replace if air leaks along rod Front O Ring Air shutoff seal Replace if air leaks from 34e air cap when gun is de triggered Back O Ring Separates cylinder air from fan and 34f atomizing air U Cup 34d Replace if air leaks from small vent hole at back of manifold when gun is tr
56. ws to prevent damage to plastic parts 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 Lightly lubricate o rings and seals with non silicone grease Order Part No 111265 Lubricant Do not over lubricate Only use genuine Graco parts Do not mix or use parts from other PRO Gun models Flush and clean the gun page 22 Relieve the pressure page 17 Remove the gun from the manifold page 33 Remove the gun from the worksite Repair area must be clean 309297L Remove the Gun from the Manifold 1 Loosen the bottom gun screw 31 until the gun sits loosely in the mounting bracket slot A See FIGURE 20 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 31 before loos ening 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 2 Holding the gun firmly in hand loosen the three screws 106 from the back of the manifold 3 Remove the gun from the manifold and take it to the service area TI1559A Fig 20 Remove Gun from Manifold 309297L Repair Install the Gun on the Manifold 1 Make sure the gasket 112 and spring 105 ar
57. xpose 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 Spray from the gun hose leaks or ruptured components can splash fluid in the eyes or on the skin and cause serious injury Do not point the spray gun at anyone or at any part of the body Do not stop or deflect fluid leaks with your hand body glove or rag Follow the steps under Prepare the Gun for Service page 32 when you stop spraying and before cleaning checking or repairing equipment Check hoses and couplings daily Replace worn damaged or loose parts immediately Tighten all fluid connections before each use 3092971 5 Introduction Introduction How the Electrostatic Air Spray Gun Works The automatic electrostatic air soray gun operates very similar to a traditional air soray 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 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

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