Graco Inc. 244581 Paint Sprayer User Manual

fold; see the tubing diagram on page 64. Install the

Open the isolated enclosure door.

Remove the back of the control box (258).

Remove tube (A2) from elbow (282) at the air mani-

Y fitting (402) into the elbow. Install tubes (A2) and

(407) into the Y fitting. See F

. 11.. Route the agita-

tor tube (407) into the cabinet.

Replace the back of the control box (258).

Assemble the other parts of the kit as shown.

Secure the agitator with the setscrew (408).

Return the system to service.

406 (Ref)

Fig. 11. 245895 Agitator Kit

Install tube A2 here

TI2137A

14 309293K

Installation

245944 Fluid Regulator Kit

To add a fluid regulator to the Graco isolation system,

order Part No. 245944. See page 68 for the kit parts list.

inlet; see the tubing diagram on page 64.

Open the isolated enclosure door.

Remove the 1/4 OD tube (A1) from the pump air

Remove the waterborne fluid hose from the pump fluid outlet fitting (231) and remove the fitting.

Unscrew the two pump mounting screws (S, F

12.) and remove the pump from the isolation enclo-

sure.

Remove the back of the control box (258).

Remove tube (A2) from elbow (282) at the air mani-

fold; see page 64. Install the Y fitting (506) in the

elbow. Install tubes (A2) and (507) into the Y fitting.

Route the tube (507) into the cabinet.

Replace the back of the control box (258).

10. Assemble the fluid regulator kit as shown in F

. 12..

11. Reinstall the pump in the isolation enclosure. Use the two mounting holes to the left of the holes used previously, to allow clearance for the fluid regulator.

12. Connect tube (A1) to the air inlet of fluid regulator

(504). Connect tube (507) to the pump air inlet.

13. Connect the waterborne fluid hose to the fluid regulator outlet fitting (501).

14. Return the system to service.

The cabinet air regulator and gauge (216, 217) will now operate the air piloted fluid regulator (504). The pump will now operate at the inlet air pressure.

Connect to elbow (282) inside control box (258)

Connect waterborne fluid hose here

506 501

507

502

504

Connect tube A2 here

Fig. 12. Fluid Regulator Kit

Tube A1

503

505

TI2149A

309293K 15

Installation

Select a Fluid Nozzle and Air

Cap

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Table 1 and Table 2 , and instruction manual 309419, or

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

consult with your Graco distributor. See Air Cap/Nozzle

Replacement on page 42.

A wide pattern kit (P/N 24A431) is included with the gun and if installed, will provide fan air for wider spray patterns. (If pattern becomes split, use the fan air valve to reduce the amount of fan air.)

Part No.

197263

197264

197265

Table 1: Fluid Nozzles

Size, mm (in.)

0.75 (.030)

1.0 (.042)

1.2 (.047)

Part No.

197266

197267

197268

Size, mm (in.)

1.5 (.055)

1.8 (.070)

2.0 (.080)

Table 2: Air Caps

Part No.

Pattern Shape and Length in.

(mm)

Recommended Fluids and

Production Rates

24A438

24A279

24A376*

24A274

24A439

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)

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.

* Also available in the following colors:

24A276 - blue

24A277 - red

24A278 - green

16 309293K

Installation

Grounding

•

Voltage Isolation System: electrically connect to a true earth ground, as instructed in the voltage isolation system manual.

•

Object being sprayed: keep the workpiece hangers clean and grounded at all times. Resistance must not exceed 1 megohm.

WARNING

Fire, Explosion, and Electric Shock Hazard

When operating the electrostatic gun, any ungrounded objects in the spray area (people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock.

Follow the grounding instructions below.

The following are minimum grounding requirements for a basic electrostatic 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.

•

Electrostatic Air Spray Gun: ground the gun by connecting the red-colored Graco Grounded Air Hose and connecting the air hose ground wire to a true

earth ground. See Check Electrical Grounding, page 18.

•

The floor of the spray area: must be electrically conductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.

•

All solvent pails: use only grounded metal pails, which are conductive. Do not use plastic containers.

Do not place the pail on a non-conductive surface such as paper or cardboard. Do not store more than the quantity needed for one shift. ti1259a

•

Graco Waterborne Fluid Hose: the hose is grounded through the conductive layer. Install the hose as

instructed on page 11.

•

All persons entering the spray area: shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Do not wear shoes with non-conductive soles such as rubber or plastic.

If gloves are necessary, wear the conductive gloves that are supplied with the gun. If non-Graco gloves are worn, cut off fingers or palm area of glove to ensure your hand contacts the grounded gun handle.

•

All electrically conductive objects or devices in the

spray area: including fluid containers, tools, and wash cans, must be properly grounded.

309293K 17

Installation

Check Electrical Grounding

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

Turn the ES ON/OFF valve OFF.

Using an ohmmeter (AA), measure the resistance between the cabinet ground lug (214) and a true

earth ground (CC). See F

. 14.. The resistance

must be less than 100 ohms.

ti1273a

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

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

AA ti1259a

Using an ohmmeter (AA), measure the resistance between the gun handle (BB) and a true earth ground (CC). The resistance should not exceed 100 ohms. See F

. 13..

If the resistance is greater than 100 ohms, check the tightness of the ground connections and be sure the air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the air hose.

Fig. 14. Check Cabinet Grounding

214

TI2163A

Fig. 13. Check Gun Grounding

TI2161A

18 309293K

Operation

Operating Checklist

Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.

All operators are properly trained to safely operate an electrostatic waterborne air spray system as instructed in this manual.

All operators are trained in the Pressure

Relief Procedure on page 20.

The electrostatics are turned off and properly

grounded according to the.Fluid Voltage Dis-

charge and Grounding Procedure on page

20 before any person enters the safety enclo-

sure, before cleaning, and before performing any maintenance or repair.

The system is thoroughly grounded and the operator and all persons entering the spray

area are properly grounded. See Grounding on page 17.

Fluid Hose is in good condition with no cuts or abrasions of the PTFE layer. Replace hose if damaged.

Ventilation fans are operating properly.

Workpiece hangers are clean and grounded.

All debris, including flammable fluids and rags, is removed from the spray area.

Only fluids with a flash point above 140

(60

C) and a maximum organic solvent concentration of 20%, by weight, may be in 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.

309293K 19

Operation

Fluid Voltage Discharge and

Grounding Procedure

Pressure Relief Procedure

WARNING

Electric Shock Hazard

The fluid supply is charged with high voltage until the voltage is discharged. Contact with the charged components 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:

•

whenever you are instructed to discharge the voltage

•

before cleaning, flushing, or servicing the system equipment

•

before approaching the front of the gun

•

or before opening the safety enclosure for the isolated fluid supply.

WARNING

Pressurized Equipment Hazard

The system pressure must be manually 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.

Turn the ES ON/OFF valve OFF.

Turn the ES ON/OFF valve OFF and wait 30 seconds. ti1273a ti1273a

Follow the Fluid Voltage Discharge and Ground-

ing Procedure at left.

Turn off the main air supply valve (B).

Remove the door T-handle locking screw. This will shut off the air to the gun and trigger the grounding cylinder to discharge any remaining electrical charge.

Use the grounding rod to touch the pump and sup-

ply pail. If you see any arcs, see Electrical Trouble-

shooting on page 39.

ti1289a

Trigger the gun into a grounded metal waste container to relieve the air and fluid pressure.

ti1276a

Relieve fluid pressure in the fluid supply unit as instructed in your fluid supply unit manual.

20 309293K

Operation

Fill the Fluid Supply

during operation or until performing the Fluid Voltage

ti1276a

Open the isolated enclosure door.

Remove the pail cover from the pail, holding a rag over the suction tube strainer to prevent any fluid from dripping into the isolated enclosure. Place the cover and suction tube outside the enclosure.

Remove the supply pail from the enclosure.

WARNING

Fire and Explosion Hazard

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 has a flash point above 140

F (60

C) and a maximum organic solvent concentration of

20%, by weight, per ASTM Standard D93.

•

The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.

CAUTION

Be sure to wipe up all fluid spills in the isolated enclosure. Fluid can create a conductive path and cause the system to short out.

Clean up any fluid spills in the enclosure, using a soft cloth and a non-flammable, compatible solvent.

Fill the supply pail with fluid and return it to the enclosure. Clean up any spills.

Reinstall the pail cover, holding a rag over the suction tube strainer to prevent fluid spills while you place the pump suction tube in the pail.

Close the isolated enclosure door and fasten securely with the T-handle locking screw.

Adjust the Spray Pattern

Follow the steps below to establish the correct fluid flow and air flow.

WARNING

Electric Shock Hazard

Contact with the charged components of the spray gun will cause an electric shock.

Do not touch the gun nozzle or electrode or come within 4 in. (102 mm) of the front of the gun

Discharge and Grounding Procedure on page 20.

Follow the Fluid Voltage Discharge and Grounding

Procedure on page 20 when you stop spraying and

whenever you are instructed to discharge the voltage.

WARNING

Component Rupture Hazard

To reduce the risk of component rupture, 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.

309293K 21

Operation

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

maximum transfer efficiency. See Table 3 .

whenever you are instructed to relieve the pressure.

Make sure the ES ON/OFF valve is OFF.

Fully open the fan air adjustment valve.

μα

100 %

Fully open the fluid adjustment valve.

ti1269a

μα

100 %

ti1273a

Turn on the main air supply valve (B).

ti1267a

Position the air cap by loosening the air cap retaining ring, and rotating the air cap for a vertical or horizontal spray pattern. 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.

Fully open the atomizing air restrictor valve. ti1272a

Vertical Pattern 7.

Make sure the ES ON/OFF valve is OFF.

Horizontal Pattern ti1273a

22 309293K

Operation

Adjust the pump air regulator to start the fluid supply unit. Adjust the fluid flow with the air pressure regulator until the stream from the gun travels 8-12 in.

(200-300 mm) before falling off. Typically, if fluid pressure is below 5 psi (.04 MPa, 0.4 bar) or above

20 psi (0.14 MPa, 1.4 bar), a change of nozzle size is recommended. Refer to instruction manual

309419 to set the fluid pressure for various fluid flows, according to the size of the fluid nozzle being used.

10. Spray a test pattern. Check the atomization. If overatomization occurs at minimum pressure, adjust the air atomizing restrictor valve. If atomization is inadequate, increase the air pressure.

8-12 in. (200-300 mm)

TI1760A

Set the gun air regulator to deliver a minimum 40 psi

(0.28 MPa, 2.8 bar) at the gun when triggered, for

ti1282a

11. Adjust the fan air adjustment valve: clockwise for a rounder pattern, counterclockwise for a wider pattern.

TI1281A

Table 3: Air Regulator Settings

Air Hose Length ft (m)

(5/16 in. [8 mm] diameter)

15 (4.6)

25 (7.6)

50 (15.3)

Air Regulator Setting psi (MPa, bar)

(with gun triggered)

50 (0.35, 3.5)

60 (0.42, 4.2)

75 (0.52, 5.2)

•

For the most efficiency, always use the lowest air pressure possible.

•

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 coverage over a large area.

WARNING

Electric Shock Hazard

When the ES ON/OFF switch is turned ON, the fluid supply is charged with high voltage until the voltage is discharged. Contact with the charged components of the spray gun will cause an electric shock. Do not touch the gun nozzle or electrode or come within 4 in. (102 mm) of the front of the gun during operation.

12. Turn the ES ON/OFF switch ON (I).

ti1284a ti1283a

309293K 23

Operation

13. Check that the ES indicator or display is lit, or check that the kV indicator on the isolated enclosure reads

45-55 kV. If not, see Electrical Troubleshooting on page 39 for possible problems.

μα

100 %

ti1266a ti1253a

14. Check the kV meter on the isolated enclosure;

45-55 kV is normal.

15. Spray a test piece. Examine the edges for coverage.

If wrap is poor, see Spray Pattern Troubleshoot-

ing on page 37.

ti1285a

16. When you finish spraying, perform the Shutdown procedure on page 25.

24 309293K

Shutdown

Flush the spray gun. See page 26.

Operation

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

Table 4 . Also see F

. 15..

ti1276a

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on whenever

you are instructed to relieve the pressure.

Follow the Fluid Voltage Discharge and

OFF

2 1

μα

100

ti1529a

Fig. 15. Low Voltage Adjustment Switches

Table 4: Low Voltage Adjustment

Factory Setting

> ON

OFF

30 ti1276a

Hang the gun from its hook or place it in the accessory holster, with the nozzle pointing down. Be sure to keep the gun from grounding out.

ti1288a

Low Voltage Adjustment (Smart

Guns Only)

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

Set the ES HI/LO switch to LO.

309293K 25

Maintenance

Flush the Spray Gun

Flush the gun before changing colors, at the end of the day, before storing, and before repairing the gun.

Turn the ES ON/OFF valve OFF and wait 30 seconds for the voltage to bleed off.

ti1273a

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, turn the ES ON/OFF valve OFF before flushing the gun.

Grounding Procedure on page 20 before

flushing.

Only flush, purge, or clean the gun with fluids that meet at least one of the following conditions for non-flammability:

•

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.

•

The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.

ti1276a

Change the fluid source to solvent.

Point the gun into a grounded metal pail. Flush until clean solvent flows from the gun.

Relieve the pressure.

ti1276a

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

See page 29. Some applications require more fre-

whenever you are instructed to relieve the pressure.

ti1276a

Open the isolated enclosure door. Leave the flushing fluid in the system until you are ready to spray again.

Hang the gun from its hook, with the nozzle pointing down. Be sure to keep the gun from grounding out.

ti1288a

Before using the system electrostatically again, make sure no flammable vapors are present.

26 309293K

Maintenance

Daily Care and Cleaning

CAUTION

•

Clean the outside of the gun daily with a soft cloth dampened with a non-flammable solvent, as

defined on page 26.

•

Check for fluid leaks. Tighten all fittings.

•

Clean the air cap and fluid nozzle daily, minimum.

quent cleaning.

•

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. Do not use any cleaning method which could allow fluid into the gun air passages.

Do not immerse the gun in fluid.

ti1294a

•

Hang the gun with its nozzle pointing down when it is not being used.

•

Clean the workpiece hangers with non-sparking tools.

•

Clean the fluid and air line filters daily.

•

Check the movement of the trigger and valves.

Lubricate if necessary.

Do not point the gun up while cleaning it.

Do not wipe the gun with a cloth that is heavily saturated; wring out the excess fluid.

ti1295a

309293K

ti1293a

Maintenance

CAUTION

•

Inspect the cabinet and clean up any spilled paint.

Conductive paint residue allowed to contact grounded parts may short out the electrostatics.

•

Keep the inside of the cabinet clean, for proper operation.

•

Visually inspect the ground strip (240) for damage.

Replace if needed. Measure the resistance weekly.

See page 33.

240

28 309293K

Maintenance

Clean the Air Cap and Fluid

Nozzle

Equipment Needed

•

soft bristle brush

•

non-flammable solvent

Procedure

Turn the ES ON/OFF valve OFF. Wait 30 seconds.

ti1273a

If it appears that there is paint inside the fluid nozzle (7) air passages, remove the gun from the line for servicing.

Carefully install the air cap (9). Be sure to insert the electrode (29) through the center hole of the air cap.

Rotate the air cap to the desired position.

Tighten the retaining ring (27) until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.

27 ti1297a

. 17.) is not approved for use in a haz-

Fig. 16. Clean Air Cap and Fluid Nozzle

ti1276a

Remove the retaining ring (27) and air cap (9). See

. 16..

Grease Door Latch Threads

Inspect the door T-handle locking screw regularly, to ensure the threads are well greased. Apply silicone-free grease to the threads when necessary.

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.

Clean the air cap (9) with the soft bristle brush and non-flammable solvent or submerge the air cap in solvent and wipe it clean.

With the gun pointing down, clean the fluid nozzle

(7) and the front of the gun with a soft brush dampened with non-flammable solvent.

309293K 29

Electrical Tests

Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (18) and electrode (29), 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

ardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous area;

• Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area

(such as open solvent containers or fumes from spraying).

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

Fig. 17. Test Gun Resistance

Test Gun Resistance

Prepare the gun for service as instructed on page

41.

Measure resistance between the electrode needle tip (29) and the air swivel (35); it should be 117-137 megohms. If outside this range, go to the next test. If

you still have problems, refer to Voltage Loss Trou-

bleshooting on page 34 for other possible causes

of poor performance, or contact your Graco distributor.

TI1688B

309293K

Test Power Supply Resistance

Prepare the gun for service as instructed on page

41.

Remove the power supply (18), page 46.

Remove the turbine alternator (19) from the power supply, page 47.

Measure resistance from the power supply's ground

strips (EE) to the spring (18b). See F

. 18..

The resistance should be 95-105 megohms. If outside this range, replace the power supply. If in range, proceed to the next test.

Be sure the spring (18b) is in place before reinstalling the power supply.

18b

Fig. 18. Test Power Supply Resistance

ti1599a

309293K

Electrical Tests

Test Electrode Resistance

Prepare the gun for service as instructed on page

41.

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.

Measure the resistance between the conductive rod

(B) and the electrode (29). The resistance should be

20-30 megohms. See F

. 19..

If in range, refer to Electrical Troubleshooting on page 39 for other possible causes of poor perfor-

mance, or contact your Graco distributor.

Remove the electrode (29), page 43. Measure the

resistance between the contact (E) and the electrode wire (F). The resistance should be 20-30 megohms. If out of range, replace the electrode.

See F

. 20..

Make sure the metal contact (C) in the barrel, the

nozzle contact ring (7a, F

. 21.), and the electrode

contact (E) are clean and undamaged.

Fig. 20. Electrode

29 E ti1513a

Fig. 21. Nozzle Conductive O-Ring

7a ti1548a

Fig. 19. Test Electrode Resistance

B ti1499a

32 309293K

Test Ground Strip Resistance

See F

. 22.. Using an ohmmeter, measure the resis-

tance between the latch housing (206) and the ground lug (214). The ground strip is grounded through the cart back to the ground lug. Resistance must be less than

100 ohms. If greater than 100 ohms, replace the ground strip (240).

209

Electrical Tests

214

206

214

TI2165A

Fig. 22. Test Ground Strip Resistance

Test Cylinder Resistance

See F

. 23.. Remove the enclosure door. Using an

ohmmeter, measure the resistance from the pump (209) to the ground lug (214). Resistance must be less than

100 ohms. If greater than 100 ohms, replace the grounding cylinder.

Fig. 23. Test Cylinder Resistance

TI2164A

309293K 33

Troubleshooting

WARNING

Electric Shock Hazard

Installing and servicing this equipment 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.

Follow the Fluid Voltage Discharge and Grounding

Procedure on page 20 before checking or servicing

the system and whenever you are instructed to discharge the voltage.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

before checking or servicing any part of the system and whenever you are instructed to relieve the pressure.

Spray Gun

•

Fluid leakage

•

Dielectric breakdown at the fluid hose connection or fluid packings

•

Not enough air pressure for the turbine

•

Faulty power supply

•

Excessive overspray on gun surfaces

•

Fluid in the air passages

Waterborne Fluid Hose

•

Dielectric failure of hose (pin-hole leak through

PTFE layer)

•

Air gap in the fluid column between the gun and isolated fluid supply, causing a low voltage reading on the isolation system voltage meter.

Voltage Isolation System

•

Fluid leakage

•

Dirty interior

Voltage Loss Troubleshooting

Normal spraying voltage for a system using the waterborne gun is 45-55 kV. The system voltage is lower due to spraying current demands and voltage isolation system losses.

A loss of spraying voltage can be caused by a problem with the spray gun, fluid hose, or voltage isolation system, 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:

34 309293K

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 problems and is required for some of the troubleshooting tests that follow.

Check that all of the air and fluid tubes and hoses are properly connected.

Check that the voltage isolation system valves and controls are properly set for operation.

Check that the interior of the isolated enclosure is clean.

Check that the spray gun and voltage isolation system have sufficient air pressure.

Check that the gun ES ON/OFF valve is in the ON position and that the gun ES indicator light is on. If the ES indicator light is not on, remove the spray gun for service and complete the electrical tests on

pages 30- 32.

Check that the voltage isolation system's enclosure door is closed and that any safety interlocks are engaged and working properly.

Make sure the voltage isolation system is in the “isolate” mode, where it is isolating the fluid voltage from ground.

To eliminate air gaps in the fluid column, spray enough fluid to purge the air out between the voltage 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.

Check the spray gun cover and barrel for accumulated overspray. Excessive overspray can create a conductive path back to the grounded gun handle.

Install a new gun cover and clean the exterior of the gun.

10. Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found. Pay special attention to the following areas:

•

Packing area of the spray gun

•

Fluid hose: check for leakage or any bulges in the outer cover, which may indicate an internal leak

•

Internal voltage isolation system components

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.

Flush the system with water and leave the lines filled with water.

on page 30 to check the gun and power supply

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.

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.

Turn the ES ON/OFF valve to ON and trigger the gun just enough to turn on the air to the gun but not the fluid. Measure the voltage at the gun electrode with a voltage probe and meter.

Discharge the system voltage by waiting 30 seconds and then touching the gun electrode with a grounded rod.

If the meter reading is 45 to 55 kV, the gun and fluid hose are okay, and the problem is in the voltage isolation system.

If the reading is below 45 kV, the problem is in the gun or fluid hose.

309293K 35

Troubleshooting

Flush the fluid hose and gun with enough air to dry out the fluid passages.

10. Turn the ES ON/OFF valve to ON and trigger the gun. Measure the voltage at the gun electrode with a voltage probe and meter.

11. If the meter reading is 45-55 kV, the gun power supply is okay, and there is probably a dielectric breakdown somewhere in the fluid hose or gun. Continue with step 12.

If the reading is below 45 kV, do the electrical tests

resistance. If those tests show the gun and power supply are okay, continue with step 12.

12. A dielectric breakdown is most likely in one of the following three areas. Repair or replace the component 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 portion 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 (see step 2 on page 12). Restrip or replace the hose.

•

Fluid packings

Remove the packing assembly from the gun as

instructed on page 44, 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.

13. Before reassembling the gun, clean and dry the gun 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.

36 309293K

Troubleshooting

Spray Pattern Troubleshooting

Check all possible remedies in the Troubleshooting Chart before disassembling the gun.

Some spray pattern problems are caused by the improper balance between air and fluid.

Problem

Fluttering or spitting spray.

Cause Solution

No fluid.

Refill supply.

Loose, dirty, damaged nozzle/seat.

Clean or replace nozzle, page 42.

Improper spray pattern.

Streaks.

Air in fluid supply.

Damaged nozzle or air cap.

Check fluid source. Refill.

Replace, page 42.

Fluid buildup on air cap or nozzle.

Fan air pressure too high.

Fluid too thin.

Fluid pressure too low.

Fan air pressure too low.

Clean. See page 29.

Decrease.

Increase viscosity.

Increase.

Fluid too thick.

Too much fluid.

Did not apply 50% overlap.

Dirty or damaged air cap.

Reduce viscosity.

Decrease flow.

Overlap strokes 50%.

Clean or replace, page 42.

309293K 37

Troubleshooting

Gun Operation Troubleshooting

Problem

Excessive spray fog.

“Orange Peel” finish.

Fluid leaks from the fluid packing area

Air leaks from the front of the gun

Fluid leakage from the front of the gun

Gun does not spray

Dirty air cap

Cause Solution

Atomizing air pressure too high.

Close restrictor valve some, or decrease air pressure as low as possible; minimum 40 psi (0.28 MPa, 2.8 bar) needed at gun for full voltage.

Increase viscosity.

Fluid too thin.

Atomizing air pressure too low.

Open atomizing air valve more or increase gun air inlet pressure; use lowest air pressure necessary.

Remix or refilter fluid.

Poorly mixed or filtered fluid.

Fluid too thick.

Worn packings or rod.

Reduce viscosity.

Replace packings or rod; see page

45.

Air valve (21) is not seating properly.

Clean and service air valve; see

page 50.

Worn or damaged packing rod (26).

Replace; see page 45

Worn fluid seat.

Replace fluid nozzle and/or electrode

needle; see pages 42 to 43.

Tighten; see page 42.

Loose fluid nozzle (7).

Damaged nozzle o-ring (7b).

Low fluid supply.

Damaged air cap (9).

Dirty or clogged fluid nozzle (7).

Replace; see page 42.

Add fluid if necessary.

Replace; see page 42.

Clean; see page 42.

Damaged fluid nozzle (7).

Replace; see page 42.

Damaged fluid adjustment valve (25). Replace; see page 50.

Misaligned air cap (9) and fluid nozzle (7).

Clean fluid buildup off air cap and

fluid nozzle seat; see page 29.

38 309293K

Troubleshooting

Electrical Troubleshooting

Problem Cause Solution

Voltage still present at gun after fol-

lowing the Fluid Voltage Discharge

and Grounding Procedure

ES ON/OFF valve is not turned OFF. Turn OFF.

Poor wrap.

Did not wait long enough for voltage to discharge.

Air pocket in fluid line leaves fluid near gun isolated.

Voltage isolation system failed.

Wait longer before touching electrode with grounded rod. Check for bleed resistor failure.

Determine cause and correct. Purge air from fluid line.

Service voltage isolation system.

Grounding cylinder not operating.

Check resistance of grounding cylin-

der, page 33. Replace if needed.

Turn ON (I).

ES ON/OFF valve OFF (0).*

Gun air pressure too low.

Faulty gun resistance.

Check air pressure to gun; minimum

40 psi (0.28 MPa, 2.8 bar) needed at gun for full voltage.

Decrease.

Atomizing air pressure too high.

Fluid pressure too high.

Decrease.

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.

See Test Gun Resistance on page

30.

Fluid leaks from the packing (26d) and causes a short.

Faulty turbine alternator.

The KV HI-LO lever is on LO.

Clean the packing rod cavity.

Replace the packing rod. See page

45.

Be sure the plug is in place on the back of the turbine alternator housing. Remove and test the turbine

alternator. See page 48.

Check the lever actuation; replace if needed.

Clean interior of enclosure.

Spilled paint, dried paint, or other contaminants inside WB100 enclosure, causing a short circuit.

309293K 39

Troubleshooting

Problem

ES indicator or voltage/current display is not lit.

Cause

ES ON/OFF valve OFF (0).*

Voltage/current display stays red

(smart guns only).

No power.

Gun too close to part.

Operator gets mild shock.

Check fluid resistivity.

Dirty gun.

Operator not grounded or is near ungrounded object.

Gun not grounded.

Operator gets shock from workpiece. Workpiece not grounded.

Solution

Turn ON (I).

Replace power supply. See page 47.

Should be 8-12 in. (200-300 mm).

See Operation on page 19.

Clean. See page 27.

See Grounding on page 17.

See Check Electrical Grounding on

page 18 and Test Gun Resistance on page 30.

Resistance must be 1 megohm or less. Clean workpiece hangers.

* ES indicator light is off when the gun is triggered.

40 309293K

Repair

Prepare the Gun for Service

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of a fire, explosion, or electric shock:

• Follow the Fluid Voltage Discharge and

Grounding Procedure on page 20 and

be sure the ES ON/OFF valve is OFF before flushing, checking, or servicing the system and whenever you are instructed to discharge the voltage.

• Clean all parts with a non-flammable fluid as defined on the front cover of this manual.

• Do not service this equipment unless you are trained and qualified.

• Do not touch the gun nozzle or come within 4 in. (102 mm) of the nozzle during gun operation or until you perform the

Fluid Voltage Discharge and Ground-

ing Procedure on page 20.

•

Use a vise with padded jaws to prevent damage to plastic parts.

•

Lubricate the power supply o-ring (18a), some packing rod parts (26), and certain fluid fittings with dielectric grease (40), as specified in the text.

•

Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate.

•

Only use genuine Graco parts. Do not mix or use parts from other PRO Gun models.

•

Air Seal Repair Kit 244781 is available. The kit must be purchased separately. Kit parts are marked with an asterisk, for example (6*).

•

Fluid Seal Repair Kit 244911 is available. The kit must be purchased separately. Kit parts are marked with a double asterisk, for example (26a**).

Follow the Fluid Voltage Discharge and Ground-

ing Procedure on page 20.

Flush the gun, page 26.

Blow the fluid lines dry with air.

Relieve the pressure, page 20.

Disconnect the gun air and fluid lines at the isolation system.

Remove the gun from the worksite. Repair area must be clean.

WARNING

Pressurized Equipment Hazard

checking or servicing any part of the system and whenever you are instructed to relieve the pressure.

To reduce the risk of injury, follow the Pres-

sure Relief Procedure on page 20 before

•

Check all possible remedies in Troubleshooting

before disassembling the gun.

309293K 41

Repair

Air Cap/Nozzle Replacement

CAUTION

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 entering the air passages.

WARNING

Fire, Explosion, and Electric Shock Hazard

The nozzle contact ring (7a) 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 (7a) except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine

Graco part.

Prepare gun for service, page 41.

Remove the retaining ring (27) and air cap (9). See

. 24..

Point gun up and squeeze trigger while removing the fluid nozzle (7) assembly with the multi-tool (37).

27a*

Use non-silicone grease, Part No. 111265, on the small o-ring (7b). Do not over-lubricate. Do not lubricate the contact ring (7a).

Lightly lubricate the o-ring (7b). Install it and the contact ring (7a) on the nozzle (7).

Make sure the electrode needle (29) is finger- tight

(page 43).

Trigger gun while installing the fluid nozzle (7) with the multi-tool (37). Tighten until the fluid nozzle seats in the gun barrel (1/8 to 1/4 turn past hand-tight).

Install the air cap (9) and retaining ring (27). Make sure the u-cup (27a*) is in place with the lips facing forward.

Fig. 24. Air Cap/Nozzle Replacement

ti1501a

42 309293K

Repair

Electrode Replacement

Remove the air cap and nozzle, page 42.

Unscrew the electrode (29) with the multi-tool (37).

Hold the packing rod end (26h) to prevent it from

turning, F

. 25..

CAUTION

To avoid damaging the plastic threads, be very careful when installing the electrode.

Apply low-strength (purple) Loctite

or equivalent thread sealant to the electrode and packing rod threads. Install the electrode finger-tight. Do not overtighten.

Install the fluid nozzle and air cap, page 42.

Fig. 25. Electrode Replacement

309293K

TI1682a

Repair

Fluid Packing Removal

Remove the air cap and fluid nozzle, page 42.

Remove the electrode, page 43.

Loosen the trigger screws (8) and trigger (30). See

. 26..

Remove the packing rod (26), using the multi-tool

(37).

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.

Check all parts for wear or damage and replace if necessary.

Fig. 26. Fluid Packing Removal

TI1683A

44 309293K

Repair

Packing Rod Repair

You may replace the packing rod as individual parts or as an assembly. 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 voltage arcing. If marks are present, replace the barrel.

To assemble the individual parts:

Place the packing nut (26e) and seal (26b**) on the fluid rod (26h). 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 F

. 27..

Fill the inner cavity of the spacer (26g**) with dielectric grease (40). Place the spacer on the fluid rod

(26h) in the direction shown. Generously apply dielectric grease to the outside of the spacer.

Place the packing spreader (26c**), rod packing

(26d**), and housing (26f) on the packing rod (26h).

Lightly tighten the packing nut (26e). The packing nut is properly tightened when there is 3 lb (13.3 N) of drag force when sliding the packing housing (26f) assembly along the rod. Tighten or loosen the packing nut as needed.

Install the o-ring (26a**) on the outside of housing

(26f). Lubricate the o-ring with non-silicone grease,

Part No. 111265. Do not over-lubricate.

Install the spring (4) against the nut (E) as shown.

Install the packing rod assembly (26) into the gun barrel. Using the multi-tool (37), tighten the assembly until just snug.

Install the trigger (30) and screws (8).

Install the electrode, page 43.

10. Install the nozzle and air cap, page 42.

11. Test gun resistance, page 30.

TI1489A

26h

**26a

26f

**26d

**26c

**26g

**26b

26e

Fig. 27. Packing Rod

309293K 45

Repair

Barrel Removal

aligned properly. Replace if damaged. See F

Remove the air inlet fitting (35) and take the bracket

(104) off the gun handle (17).

Loosen the three screws (11).

104

CAUTION

To avoid damaging the power supply (18), pull the gun barrel straight away from the gun handle. If necessary, gently move the gun barrel from side to side to free it from the gun handle.

TI1690A

Hold the gun handle (17) with one hand and pull the barrel (16) straight off the handle. See F

. 28..

Fig. 28. Barrel Removal

Barrel Installation

Be sure the gasket (10*) and grounding spring (55) are in place. Make sure the gasket air holes are

. 29..

Place the barrel (16) over the power supply (18) and onto the gun handle (17).

Tighten the three screws (11) oppositely and evenly

(about a half turn past snug).

CAUTION

Do not over-tighten the screws (11).

*10

101

105

Fig. 29. Barrel Installation

104

Position the bracket (104) on the gun handle (17) and secure with the air inlet fitting (35).

Apply dielectric grease (40) to the exposed inner tube of the fluid hose (101).

Check that the nut (105) is tight on the ferrule housing (103).

Prepare gun for service, page 41.

TI1692A

TI1691A

46 309293K

Repair

Power Supply Removal and

Replacement

•

Inspect the gun handle power supply cavity for dirt or moisture. Clean with a clean, dry rag.

•

Do not expose gasket (10) to solvents.

Remove the barrel (16), page 46.

10. Insert the power supply/alternator assembly in the gun handle (17). Make sure the ground strips make contact with the handle. On Smart Models only, connect the flexible circuit (59) to the socket at the top of the handle. Push the 6-pin connector into the socket to ensure it is properly connected.

11. Install the barrel (16), page 46.

12. Test gun resistance, page 30.

CAUTION

Be careful when handling the power supply (18) to avoid damaging it.

19e

19a*

10*

Grasp the power supply (18) with your hand. With a gentle side to side motion, free the power supply/alternator assembly from the gun handle (17), then carefully pull it straight out. On Smart Models

only, disconnect the flexible circuit (59) from the

socket at the top of the handle (17). See F

. 30..

Disconnect the 3-wire connector (GG) from the power supply. Slide the alternator up and off the power supply. Inspect the power supply and alternator for damage. On Smart Models only, disconnect the 6-pin flexible circuit (59) from the power supply.

Check the power supply resistance, page 31.

Replace if necessary.

Before installing the power supply, make sure the o-rings (18a*, 19a*), spring (18b), and pads (19e) are in place.

On Smart Models only, connect the 6-pin flexible circuit (59) to the power supply.

Connect the 3-wire connector (GG). Slide the alternator (19) down onto the power supply (18).

Lubricate the alternator o-ring (19a*) with non-silicone grease, Part No. 111265. Do not over-lubricate.

Lubricate the power supply o-ring (18a*) with dielectric grease (40).

*18a 18b

Fig. 30. Power Supply

18 ti1505c

309293K 47

Repair

Turbine Alternator Removal and

Replacement

Replace turbine alternator bearings after 2000 hours of operation. Order Part No. 223688 Bearing Kit.

Prepare gun for service, page 41.

Remove the power supply/alternator assembly,

page 47.

Disconnect the alternator from the power supply,

page 47.

Measure resistance between the two outer terminals of the 3-wire connector (GG); it should be

2.5-3.5 ohms. If outside this range, replace the alternator coil.

Follow the bearing replacement procedure in the bearing kit manual 308034.

Install the alternator on the power supply, page 47.

Install the power supply/alternator assembly, page

47.

48 309293K

Repair

Fan Air Adjustment Valve Repair

You may replace the valve as an assembly (go to step 9) or as individual parts (steps 3-9).

Place a wrench on the flats of the valve assembly

(20) and unscrew it from the handle (17).

Remove the retaining ring (20a). See F

. 31..

Turn the valve stem (20d) counterclockwise until it comes free from the valve housing (20c).

Remove the o-ring (20b).

Clean all parts and inspect for wear or damage.

Use non-silicone grease, Part No. 111265. Do not over-lubricate.

When reassembling the fan air valve (20), lightly lubricate the valve threads and screw the stem (20d) fully into the housing (20c) until bottomed. Install the o-ring (20b*), lubricate, and unscrew the valve stem until the o-ring enters the housing.

Reassemble the retaining ring (20a). Unscrew the valve stem from the housing until it is stopped by the retaining ring.

Screw the valve assembly (20) into the gun handle, using a wrench on the flats of the housing. Torque to

15-25 in-lb (1.7-2.8 N•m).

20d

TI1487A

20b*

20a

20c

Fig. 31. Fan Air Adjustment Valve

309293K 49

Repair

Fluid Adjustment Valve Repair

be replaced as a complete assembly. See F

Remove the fluid adjustment valve (25). It can only

. 32..

Screw the valve (25) into the gun handle. Torque to

15-25 in-lb (1.7-2.8 N•m).

Remove the air valve (21

) with a pliers. Inspect the seal (21a*) and replace if damaged. Be sure the seal is pressed securely onto the valve so the outer cone is flats.

CAUTION

When removing the air valve (21) be careful not to damage the seat area.

Inspect the u-cup (6*). Do not remove the u-cup unless damaged. If removed, install the new one with its lips facing into the gun handle (17).

Install the air valve (21) and spring (15) into the gun handle (17).

Install the fluid adjustment valve (25). Torque to

15-25 in-lb (1.7-2.8 N•m).

Install the barrel, page 46.

Fig. 32. Fluid Adjustment Valve

TI1684A

Air Valve Repair

Remove the barrel, page 46.

Remove the fluid adjustment valve (25) from the

handle (17). Remove the spring (15). See F

. 33..

21a*

TI1685A

Fig. 33. Air Valve

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.

50 309293K

Repair

Atomizing Air Restrictor Valve

Removal and Replacement

Remove the atomizing air restrictor valve (23).

Inspect the o-ring (23c*). Replace if necessary. See

. 34..

Install a new atomizing air restrictor valve (23), or disassemble and replace parts individually. The valve protrusion must be oriented to clear the air valve (21) shaft.

If the atomizing air restrictor valve is not desired, install the supplied plug (47).

Torque the valve housing (23a) to 15-20 in-lb

(1.7-2.3 N•m).

CAUTION

Do not over-lubricate parts. Excessive lubricant on the o-rings can be pushed into the gun air passage and blemish the finish on the workpiece.

Clean and inspect parts for damage. Replace if necessary.

The protrusion on the retainer plate (22d) must point upward.

Reinstall the valve. Torque the screw (48) to 15-25 in-lb (1.7-2.8 N•m).

22g

22b*

22e

22d

22f

22c

22a*

23c*

23a

TI1488A

23d

23b

Fig. 35. ES ON/OFF Valve

TI1686A

Fig. 34. Atomizing Air Restrictor Valve

ES ON/OFF Valve Repair