Graco 309298E, PRO Auto Xs AA, Automatic Electrostatic Air Assisted Spray gun Owner's Manual

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Graco 309298E, PRO Auto Xs AA, Automatic Electrostatic Air Assisted Spray gun Owner's Manual | Manualzz

Instructions/Parts List

AUTOMATIC ELECTROSTATIC AIR-ASSISTED

SPRAY GUN

PRO

Auto Xs AA

Part No. 244592, Series A

100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure

3000 psi (21 MPa, 210 bar) Maximum Working Fluid Pressure

U.S. Patent 7,226,004

For use with Class I Group D spray materials.

For use with Group II Category 2 G spray materials.

0.24 mJ

309298E

TI1713A

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

See page 2 for Table of Contents.

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001

2

Table of Contents

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 3

Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

How the Electrostatic AA Spray Gun Works . . . . 6

Operating the Spray Function . . . . . . . . . . . . . . . 6

Operating the Electrostatics . . . . . . . . . . . . . . . . 6

Gun Features and Options . . . . . . . . . . . . . . . . . 6

Changing the kV Setting . . . . . . . . . . . . . . . . . . . 6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 9

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 9

Install the Air Line Accessories . . . . . . . . . . . . . 11

Install the Fluid Line Accessories . . . . . . . . . . . 11

Install the Gun and Mounting Bracket . . . . . . . . 12

Connect the Air and Fluid Lines . . . . . . . . . . . . 13

Manifold Connections . . . . . . . . . . . . . . . . . . . . 13

Optional Fiber Optic Cable Connection . . . . . . . 14

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Check Electrical Grounding . . . . . . . . . . . . . . . . 16

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 17

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 17

Install the Fabric Cover . . . . . . . . . . . . . . . . . . . 17

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pressure Relief Procedure . . . . . . . . . . . . . . . . 18

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 18

Select a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . 19

Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . 19

Set the Atomization Fluid Pressure . . . . . . . . . . 20

Adjust the Electrostatics . . . . . . . . . . . . . . . . . . 21

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Triggering the Fluid Alone . . . . . . . . . . . . . . . . . 22

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 23

Daily Care and Cleaning, continued . . . . . . . . . 24

Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . 25

Clean the Spray Gun . . . . . . . . . . . . . . . . . . . . . 26

Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 28

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 29

Test Power Supply Resistance . . . . . . . . . . . . . 30

Test Barrel Resistance . . . . . . . . . . . . . . . . . . . . 31

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Spray Pattern Troubleshooting . . . . . . . . . . . . . 32

Gun Operation Troubleshooting . . . . . . . . . . . . . 33

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 34

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Prepare the Gun for Service . . . . . . . . . . . . . . . 35

Remove the Gun from the Manifold . . . . . . . . . . 36

Install the Gun on the Manifold . . . . . . . . . . . . . 36

Tip Guard, Air Cap, Spray Tip, or Seat Housing

Replacement . . . . . . . . . . . . . . . . . . . . . . . . 37

Electrode Replacement . . . . . . . . . . . . . . . . . . . 39

Fluid Tube Replacement . . . . . . . . . . . . . . . . . . 40

Fluid Filter Removal . . . . . . . . . . . . . . . . . . . . . . 40

Fluid Needle Replacement . . . . . . . . . . . . . . . . 41

Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . 43

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 44

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 45

Power Supply Removal and Replacement . . . . 46

Turbine Alternator Removal and Replacement . 47

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . 52

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 53

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 53

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 53

Miscellaneous Accessories . . . . . . . . . . . . . . . . 53

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 56

309298E

Symbols

Symbols

Warning Symbol Caution Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

309298E

WARNING

Fire, Explosion, and Electric Shock Hazard

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire, explosion, or electric shock.

• Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements in this manual.

• Ground the equipment, all personnel in or close to the spray area, the object being sprayed,

and all conductive objects in the spray area. See Grounding, page 15.

• Provide fresh air ventilation to avoid buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Interlock the gun air supply to prevent operation unless ventilating

fans are on. See Ventilate the Spray Booth on page 9.

• Do not flush with the gun electrostatics on. Do not turn on the gun electrostatics until all solvent is removed from the system.

• If there is any static sparking while using the equipment, stop spraying immediately. Identify and correct the problem.

• Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.

Check gun resistance daily. See Test Gun Resistance on page 29.

• Use cleaning solvents with the highest possible flash point, preferably above ambient temperature.

• Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the spray area.

• Use only non-sparking tools to clean residue from the booth and hangers.

3

Warning

WARNING

Skin Injection Hazard

Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause serious injury.

• Fluid injected into the skin might look like just a cut, but is a serious injury. Get immediate surgical treatment.

• Do not point the gun at anyone or at any part of the body. Do not put your hand or fingers over the spray tip. Do not stop or deflect fluid leaks with your hand, body, glove, or rag.

• Never spray without the tip guard in place.

Follow the steps under Prepare the Gun for Service, page 35, when you stop spraying and

before cleaning, checking, or repairing equipment.

• Check the hoses and couplings daily. Replace worn, damaged, or loose parts immediately.

Permanently coupled hoses cannot be repaired; replace the entire hose.

• Tighten all fluid connections before each use.

Toxic Fluid Hazard

Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin, swallowed, or inhaled.

• 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 309298E

309298E

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 distributor.

• 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. Maximum working fluid pressure of this equipment is 3000 psi (21 MPa, 210 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 warnings.

• Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 180

°

F (82

°

C) or below -40

°

F (-40

°

C).

• Wear hearing protection when operating this equipment.

• Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

5

Introduction

Introduction

6

How the Electrostatic AA

Spray Gun Works

WARNING

Skin Injection Hazard

Remember, this is not an air spray gun.

For your safety, read and follow all Warnings in this manual.

Operating the Electrostatics

To operate the electrostatics, apply air pressure to the gun manifold’s turbine air fitting (TA) through a Graco grounded air hose. The air enters the manifold and is directed to the inlet of the power supply turbine. The air spins the turbine, which then provides electrical power to the internal high voltage power supply. The fluid is charged by the spray gun electrode. The charged fluid is attracted to the nearest grounded object, wrapping around and evenly coating all surfaces.

The turbine air is exhausted into the shroud and out the back of the manifold through the exhaust fitting (EXH).

The exhaust air helps keep contaminants out and helps keep the gun clean.

The air-assisted spray gun combines airless and air spraying concepts. The spray tip shapes the fluid into a fan pattern, as does a conventional airless spray tip. Air from the air cap further atomizes the fluid and completes the atomization of the fluid tails to produce a uniform pattern.

The high working fluid pressure of this gun provides the power needed to atomize higher solids materials.

Operating the Spray

Function

Applying a minimum of 50 psi (0.35 MPa, 3.5 bar) air pressure to the gun manifold’s cylinder air fitting (CYL) will retract the gun piston, which opens the air valves and a short time later opens the fluid needle. This provides the proper air lead and lag when triggering the gun. A spring returns the piston when the cylinder air is shut off.

Gun Features and Options

• 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.

• The gun’s quick-disconnect design enables its removal without disconnecting the air lines to the gun.

• Gun functions are activated from a separate controller that sends the appropriate signal to the actuating solenoids.

• The optional fiber optic readout system can be installed to monitor the gun’s spraying voltage. A fiber optic cable connected to the gun manifold carries the signal from the gun to a remote display module. Part No. 224117 Display Module displays the gun’s spraying voltage and current. Battery-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 voltage 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.

309298E

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.

Introduction

Table 1: KV1 and KV2 Switch Settings

OFF

OFF

ON

ON

OFF

ON

OFF

ON

85

70

60

45

Table 1: KV1 and KV2 Switch Settings

KV1 Air KV2 Air Output Voltage (kV)

309298E 7

Introduction

B

C

A

E

J

F

TI1713A

H

G

TA

CYL

P1

TI1714A

Manifold Back View

TI1739A

EXH

KV1

FO

KV2

A2

K

D

Fig. 1. Gun Overview

Key

J

K

E

F

G

H

C

D

A

B

Air Cap

Spray Tip

Tip Guard

Retaining Ring

Shroud

Mounting Bracket

Manifold

Turbine

Power Supply

Electrode

A1

A2

FO

P1

P2

TA

Manifold Markings not used

Atomization Air Inlet Fitting

CYL Cylinder Air Inlet Fitting

EXH Shroud Exhaust Outlet Fitting

Fiber Optic Fitting

KV1 kV Switch 1 Air Inlet

KV2 kV Switch 2 Air Inlet

Fluid Supply Inlet Fitting not used

Turbine Air Inlet Fitting

8 309298E

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.

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

Be sure your installation complies with

National, State and Local codes for the installation of electrical apparatus in a

Class I, Group D or a Group II Category

2 G Hazardous Location.

Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

T

U

R

S

P

Q

M

N

V

W

X

Y

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)

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

F IG . 2. shows a typical electrostatic air-assisted spray system, and F IG . 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.

Key to F IG . 2. and F IG . 3.

H

J

F

G

K

L

C

E

A

B

Air Hose Ground Wire

Graco Grounded Turbine Air Hose (TA)

Atomizing 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-Assisted Spray Gun

Mounting Bracket for 1/2 in. (13 mm) rod

Solenoid Valve, requires quick exhaust port

Bleed-Type Master Air Valve

WARNING

Flammable or Toxic Vapor Hazard

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Do not operate the gun unless ventilation fans are operating.

Electrically interlock the gun turbine air supply with the ventilators to prevent gun operation without ventilating fans operating. Check and follow all National, State, and

Local codes regarding air exhaust velocity requirements.

High velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 60 ft/minute (19 linear meters/minute).

309298E 9

Installation

L

W

See * above

L

K

K

K

NOTE:

* The turbine air supply (TA) must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on.

X Y B C

A

TA KV1

CYL

KV2

A2

M

K

Non-Hazardous Area

N

E

G

Hazardous Area

F

P1

J

TI1741A

Manifold Back View

Fig. 2. Typical Installation

P

NOTE:

** A maximum of two splices with a total of 108 ft (33 m) of cable can be used. For the strongest

light signals, use a minimum number of bulkhead splices. See Accessories on page 53.

Non-Hazardous Area Hazardous Area

R T U**

KV mA

V**

Q

85.0 KV

H

TI1715A

S

Fig. 3. Optional Fiber Optic Connection

10 309298E

Installation

Install the Air Line

Accessories

WARNING

Component Rupture Hazard

To reduce the risk of serious injury due to component rupture:

The pump pressure must be limited by the pump air regulator. Do not rely on the gun fluid regulator to limit the fluid pressure to the gun.

The fluid supply pump must be prevented from producing a fluid pressure greater than the 3000 psi (21

MPa, 210 bar) Maximum Working Fluid Pressure of the gun. For example, the air supply pressure to a

30:1 ratio pump must not exceed 100 psi (0.7 MPa, 7 bar).

Be sure that all spray equipment and accessories added to the spray system are properly rated to withstand the maximum working pressure of your system.

WARNING

Skin Injection Hazard

Trapped air can cause the gun to spray unexpectedly, which can result in serious injury, including injecting fluid through 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.

The bleed-type master air valve (L) is required on the pump air line so trapped air will be relieved between the valve and the pump after the valves or regulator are closed.

Install the Fluid Line

Accessories

1.

Install a fluid filter and drain valve at the pump outlet. Filtering the fluid will help remove coarse particles and sediment that could clog the spray tip.

The gun includes an inline fluid filter (20) for additional filtration.

1.

Install a bleed-type master 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 finished workpiece and can cause the gun to malfunction.

3.

Install a bleed-type air regulator (M) on each of the air supply lines (B, C, E, X, Y) to control air pressure 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 port.

5.

Install a bleed-type master air valve (L) on each pump air line to shut off all air to the pump (H).

WARNING

Skin Injection Hazard

The fluid drain valve is required in your system to assist in relieving fluid pressure in the displacement pump, hose and gun. Triggering the gun to relieve pressure may not be sufficient. Install a drain valve close to the pump's fluid outlet. The drain valve reduces the risk of serious injury, including fluid injection and splashing in the eyes or on the skin.

2.

Install a fluid regulator on the fluid line to control fluid pressure to the gun.

309298E 11

Installation

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 F IG . 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 F IG . 4..

102

103

9.24 in

(234.7 mm)

Fig. 4. Mounting Bracket

NN

2.88 in

(73.2 mm)

To

TI1738A Nozzle

Tip

12 309298E

Installation

Connect the Air and Fluid

Lines

F IG . 3. shows a schematic of air and fluid line connec-

tions, and F IG . 5. shows the manifold connections. Con-

nect the air and fluid lines as instructed.

WARNING

Electric Shock Hazard

To reduce the risk of electric shock or other serious injury, the air supply hose must be electrically connected to a true earth ground. Use only Graco Grounded Air

Supply Hose.

1.

Connect the Graco Grounded Turbine 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 air inlet fitting has a left-hand thread to prevent connecting another type of air

hose to the turbine air inlet. See Accessories on page 53 for further information about the hose.

2.

Check the electrical grounding of the gun as

instructed on page 16.

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

EXH

FO

KV1

KV2

P1

P2

TA

Shroud Exhaust Outlet Fitting

Connect a 1/4 in. (6 mm) OD x 4 ft (1.22 m) long tube to this fitting.

Fiber Optic Fitting (Optional)

Connect the Graco Fiber Optic cable (see page 14).

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 the solenoid.

Fluid Supply Inlet Fitting

Connect a 1/4 npsm swivel fitting between this fitting and the fluid supply.

Not Used

Turbine Air Inlet Fitting

Connect the Graco Electrically Conductive Air Hose between this fitting (left-hand thread) and the solenoid.

Connect the air hose ground wire to a true earth ground.

KV2

TA

CYL

P1

TI1739A

KV1

FO

A2

EXH

A1

A2

CYL

Not Used

Atomization Air Inlet Fitting

Connect a 3/8 in. (10 mm) OD tube between this fitting and the air supply.

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.

Fig. 5. Manifold Connections

309298E 13

Installation

Optional Fiber Optic Cable

Connection

An optional fiber optic fitting is shipped unassembled with the gun. If an ES (kV) display module is used,

install the fitting in the FO port of the manifold. See F IG .

3., page 10, for a schematic of the fiber optic connec-

tions.

1.

Remove the plug (120) from the fiber optic port, and install the fiber optic fitting (5, shipped loose with the

gun). See F IG . 6..

5

2.

Remove the nut (AA) from the fiber optic fitting (5) and slide the nut over the end of the fiber optic cable

(BB). See F IG . 7..

3.

Push the cable (BB) into the fitting (5) until it bottoms out. Tighten the nut (AA) to secure the cable.

5

BB

AA

TI1581A

120

TI1737A

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 recommended.

4.

See manual 308265 to install a Graco ES Display

Module.

Fig. 6. Fiber Optic Fitting

14 309298E

Installation

Grounding

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 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.

Pump: ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual.

Electrostatic Air-Assisted Spray Gun: ground the gun by connecting 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 Grounding, page 16.

• Air compressors and hydraulic power supplies: ground the equipment according to the manufacturer's recommendations.

All air and fluid lines must be properly grounded.

All electrical cables must be properly grounded.

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.

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

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.

Flammable liquids in the spray area: must be kept in approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift.

• All electrically conductive objects or devices in the

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

309298E 15

Installation

Check Electrical Grounding

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see

F IG . 8.) is not approved for use in a hazard-

ous 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.

4.

Measure the resistance between the turbine air inlet fitting (TA) and a true earth ground (N). a.

If using a black or grey turbine air hose, use a megohmmeter to measure the resistance. Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 1 megohm.

b.

If using a red turbine air hose, use an ohmmeter to measure the resistance. The resistance should not exceed 100 ohms.

3.

If the resistance is greater than the maximum reading specified above for your hose, check the tightness of the ground connections and be sure the turbine air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the turbine air hose.

N

1.

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

2.

Make sure the turbine air hose (B) is connected and the hose ground wire is connected to a true earth ground.

3.

Turn off the air and fluid supply to the gun.

B

Fig. 8. Check Gun Grounding

AA

TA

TI1735A

16 309298E

Installation

Check Fluid Resistivity

WARNING

Fire, Explosion, and Electric Shock Hazard

Check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area.

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

• a viscosity cup

• a stopwatch.

1.

Completely submerge the viscosity cup in the fluid.

Lift the cup out quickly, starting the stopwatch as soon as the cup is completely removed.

2.

Watch the stream of fluid coming from the bottom of the cup. As soon as there is a break in the stream, shut off the stopwatch.

3.

Record the fluid type, elapsed time, and size of the viscosity cup.

4.

If the viscosity is too high or too low, contact the material supplier. Adjust as necessary.

Graco Part No. 722886 Resistance Meter and 722860

Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the requirements of an electrostatic air spray system.

Follow the instructions included with the meter and probe. Readings of 25 megohms-cm and above provide the best electrostatic results.

Check Fluid Viscosity

To check fluid viscosity you will need:

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 F IG . 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 28. Strap down the exhaust

tube to prevent it from moving around.

YY

Fig. 9. Fabric Cover

XX

TI1716A

YY

TI1736A

309298E 17

Operation

Operation

Pressure Relief Procedure

7.

If you suspect that the spray tip or hose is still clogged or that pressure is not fully relieved after following the steps above, very slowly loosen the hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose obstruction.

WARNING

Skin Injection Hazard

The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from fluid injection, splashing fluid, or electric shock, 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 spray tip.

1.

Turn off all the air to the spray gun except the cylinder air, which triggers the gun.

2.

Turn off the fluid supply to the gun.

3.

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

4.

Open the pump drain valve and all other drain valves in the system, having a waste container ready to catch the drainage. Triggering the gun to relieve pressure may not be sufficient. Leave the drain valve open until you are ready to spray again

5.

Relieve fluid pressure in the fluid supply equipment as instructed in its instruction manual.

6.

Close the bleed-type master air valve on the main air supply line to shut off the air. Leave the valve closed until you are ready to spray again.

Operating Checklist

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

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

All operators are trained in the Pressure

Relief Procedure at left.

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, the operator, and all persons entering the spray area are properly

grounded. See Grounding on page 15.

The condition of the gun’s electrical compo-

nents has been checked as instructed in Elec-

trical Tests on page 29.

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. The floor of the spray area is electrically conductive and grounded.

The manifold exhaust tubes have been checked for the presence of any fluid. See

Check for Fluid Leakage on page 28.

18 309298E

Operation

Select a Spray Tip

The fluid output and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pressure.

Use the Spray Tip Selection Chart, page 52, as a

guide for selecting the appropriate spray tip for your application.

3.

Install the spray tip and air cap, tip guard (3), shroud

(2), and retaining ring (1) onto the gun. Be sure the electrode (40a) is in place. Tighten the retaining ring firmly.

Install the Spray Tip

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, never operate the gun with a damaged electrode.

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury,

always follow the Pressure Relief Proce-

dure on page 18, before removing or

installing the spray tip, air cap, or tip guard.

2

40

1.

Relieve the pressure.

2.

Place the spray tip (4) in the air cap (40), aligning the tab on the tip with the groove in the air cap. Be careful not to damage the electrode (40a).

1

1a

3

TI1717A

40

Fig. 11. Install Air Cap Assembly

01995

40a

Fig. 10. Install Spray Tip

4

309298E 19

Operation

Set the Atomization Fluid

Pressure

Atomization fluid pressure will vary based on the viscosity of the fluid, flow rate desired, and other system characteristics.

1.

Turn off the turbine air (TA) and atomization air (A2).

2.

Start the pump. Set the fluid regulator to 400 psi (2.8

MPa, 28 bar).

3.

With the turbine air (TA) and atomization air (A2) turned off, spray a test pattern, holding the gun 12 in. (305 mm) from the surface. Examine the particle size. Do not be concerned about the presence of

tails; they will be removed in step 6.

4.

Increase the fluid pressure in small increments.

Spray another pattern and compare the particle size. Smaller particle size indicates improved atomization.

6.

Turn on the atomization air (A2) and adjust the air pressure until the tails disappear.

See Spray Pattern Troubleshooting on page 32 to cor-

rect spray pattern problems.

KV2

TA

CYL

KV1

A2

TI1739A

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, never exceed the maximum working pressure of the lowest rated system component. Maximum working fluid pressure of this equipment is

3000 psi (21 MPa, 210 bar).

Fig. 12. Manifold Air Connections

5.

Continue to increase the fluid pressure and spray test patterns. Do not exceed 3000 psi (21 MPa, 210 bar) fluid pressure. When the particle size remains constant, the fluid is being atomized at the lowest possible fluid pressure.

For improved atomization at lower fluid flow rates, change to a smaller tip orifice size.

No Air Too Little

Air

Correct

Amount of Air

Fig. 13. Eliminating Tails

20 309298E

Operation

Adjust the Electrostatics

1.

Shut off the fluid supply.

1.

Trigger the gun, then turn on the turbine air (TA).

See F IG . 12..

2.

Refer to Table 2 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 benefit and turbine life could be reduced.

Table 2: Dynamic Turbine Air Pressures

Turbine Air

Hose Length ft (m)

15 (4.6)

25 (7.6)

36 (11)

50 (15.3)

75 (22.9)

100 (30.5)

Air pressure at turbine air hose inlet for full voltage psi (bar, MPa)

54 (3.8, 0.38)

55 (3.85, 0.38)

56 (3.9, 0.39)

57 (4.0, 0.40)

59 (4.1, 0.41)

61 (4.3, 0.43)

3.

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 34 to correct

voltage problems.

309298E 21

Operation

Spraying

WARNING

Electric Shock Hazard

To reduce the risk of electric shock, do not touch the gun electrode or come within 4 in.

(10 cm) of the nozzle during gun operation.

Triggering the Fluid Alone

1.

Shut off and relieve the air pressure to the atomization (A2) air line, using the bleed-type air shutoff valve.

2.

Apply 50 psi (3.5 bar, 0.35 MPa) air pressure to the cylinder air fitting (CYL) to trigger the fluid.

Shutdown

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 (A2) and fluid

(P1). See F IG . 12..

2.

Turn the gun functions off and on 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

Skin Injection Hazard

To reduce the risk of a fluid injection injury,

always follow the Pressure Relief Proce-

dure on page 18 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 23.

WARNING

Fire and Explosion Hazard

If any fluid leakage from the gun is detected, stop spraying immediately. Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury

and property damage. See Check for Fluid

Leakage on page 28.

22 309298E

Maintenance

Maintenance

Daily Care and Cleaning

CAUTION

• Clean all parts with a non-conductive, compatible solvent. Conductive solvents can cause the gun to malfunction.

Do not immerse the gun in fluid.

• 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.

TI1742A

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

02027A

TI1734A

309298E 23

Maintenance

Daily Care and Cleaning, continued

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury,

always follow the Pressure Relief Proce-

dure on page 18 when you stop spraying

and whenever you are instructed to relieve the pressure.

• Clean the fluid and air line filters daily.

• Clean the outside of the gun daily with a soft cloth dampened in a compatible solvent.

• Clean the air cap, spray tip, and tip guard daily, minimum. Some applications require more frequent cleaning. Replace the parts if they are damaged.

See Clean the Spray Gun, page 26.

• Check the electrode and replace if broken or dam-

aged. See Electrode Replacement on page 39.

• Check for fluid leakage from the gun and fluid

hoses. See Check for Fluid Leakage on page 28.

Tighten fittings or replace equipment as needed.

• Check all work hangers for fluid buildup; clean if necessary.

• Flush the gun before changing colors and whenever you are done operating the gun.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, turn off the turbine air (TA) before flushing the gun or any part of the system.

24 309298E

Flush the Spray Gun

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury,

always follow the Pressure Relief Proce-

dure on page 18 when you stop spraying

and whenever you are instructed to relieve the pressure.

1.

Relieve the pressure.

Maintenance

3.

Remove the retaining ring (1), tip guard (3), air cap

(40), spray tip (4), and gun shroud (2). See F IG . 14..

Clean these parts and set them aside.

4.

Turn on the solvent supply. Use the lowest possible fluid pressure when flushing.

5.

Turn on the cylinder air (CYL) to trigger the gun.

6.

Flush the gun, spraying into a grounded metal container until clean solvent comes from the gun.

7.

Turn off the solvent supply.

8.

Relieve the pressure.

9.

Install the spray tip (4) and air cap (40), tip guard

(3), shroud (2), and retaining ring (1) onto the gun.

Tighten the retaining ring firmly.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, turn off the turbine air (TA) before flushing the gun or any part of the system.

1

1a

3

40

4

4a

2

TI1723A

2.

Be sure the turbine air (TA) is turned off.

Fig. 14. Remove Spray Tip Before Flushing

309298E 25

Maintenance

Clean the Spray Gun

Equipment Needed

• soft bristle brush

• compatible solvent

Procedure

TI1719A

02007

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury,

always follow the Pressure Relief Proce-

dure on page 18 when you stop spraying

and whenever you are instructed to relieve the pressure.

Fig. 15. Clean Front of Gun

5.

Dampen a soft cloth with solvent and wring out the excess. Wipe the exterior of the gun and shroud

clean. See F

IG

. 16..

1.

Relieve the pressure.

2.

Be sure the turbine air (TA) is turned off.

3.

Remove the retaining ring (1), tip guard (3), air cap

(40), spray tip (4), and gun shroud (2). See page 19.

4.

Dip the end of a soft bristle brush into compatible solvent. clean the front of the gun with the brush.

Avoid getting any solvent into the air passages.

Whenever possible, point the gun down when clean-

ing it. See F IG . 15..

If it appears that there is paint inside the air passages, remove the gun from the line for servicing.

TI1720A

Fig. 16. Clean Gun Body

6.

Remove the bottom fluid tube fitting (P) and fluid fil-

ter (20). See F IG . 17.. Clean the filter in compatible

solvent.

7.

Reinstall the filter (20) and fitting (P). Do not overtighten the fitting, and make sure the top fitting (Q) remains tight.

26 309298E

Maintenance

9.

Wipe off the parts with a dry cloth. Be careful not to damage the electrode.

Q

TI1725A

P

20

Fig. 17. Clean the Inline Fluid Filter

8.

Clean the retaining ring (1), tip guard (3), air cap

(40), and spray tip (4) with a soft brush daily, minimum. Replace any damaged parts. Be careful not to damage the electrode (40a).

CAUTION

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, never operate the gun with a damaged electrode.

10. Check the electrode (40a). Replace if damaged.

11. Install the spray tip, page 19.

12. Install the spray tip and air cap, tip guard, shroud,

and retaining ring, page 19. Be sure the electrode

(40a) is in place.

13. Test gun resistance, page 29.

Do not use metal tools to clean the air cap or spray tip holes as this could scratch them, and make sure the electrode is not damaged.

Scratches in the air cap or spray tip or a damaged electrode can distort the spray pattern.

309298E 27

Maintenance

Check for Fluid Leakage

WARNING

Fire and Explosion Hazard

If any fluid leakage from the gun is detected, stop spraying immediately. Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage.

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury,

always follow the Pressure Relief Proce-

dure on page 18 when you stop spraying

and whenever you are instructed to relieve the pressure.

During operation, periodically check the manifold exhaust tube (YY) and both ends of the gun shroud (ZZ)

for the presence of fluid. See F IG . 18.. Fluid in these

areas indicates leakage into the shroud, which could be caused by leaks at the fluid tube connections or fluid packing leakage.

If fluid is seen in these areas, stop spraying immediately.

Relieve the pressure, then remove the gun for repair.

YY

ZZ

Fig. 18. Check for Fluid Leakage

ZZ

TI1716A

YY

TI1736A

28 309298E

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 barrel (6), and electrical continuity between components.

CAUTION

The barrel resistor cartridge is part of the barrel and is not replaceable. To avoid destroying the gun barrel, do not attempt to remove the barrel resistor.

Test Gun Resistance

1.

Flush and dry the fluid passage.

2.

Measure resistance between the electrode needle tip (40a) and the turbine air inlet fitting (TA); it should be 156-180 megohms. If outside this range, relieve

pressure and remove the air cap (page 37). Inspect

the electrode (40a) and the barrel conductive ring

(6a) for damage and proper position, to ensure that the electrode makes contact with the conductive ring. Reinstall the air cap and repeat the measurement. If it is still outside this range, remove the gun for service.

Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V. Connect the leads as shown.

TA

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see

F

IG

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

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.

AA

40a

Fig. 19. Test Gun Resistance

TA

TI1733B

TI1739A

309298E 29

Electrical Tests

Test Power Supply

Resistance

6.

Be sure the spring (12b) is in place before reinstalling the power supply.

1.

Remove the power supply (12), page 46.

2.

Remove the turbine alternator (13) from the power

supply, page 47.

3.

Measure resistance from the power supply's ground

strips (EE) to the spring (12b). See F IG . 20..

4.

The resistance should be 135-150 megohms. If outside this range, replace the power supply. If in range, proceed to the next test.

5.

If you still have problems, refer to Electrical Trou-

bleshooting on page 34 for other possible causes

of poor performance, or contact your Graco distributor.

12b

Fig. 20. Test Power Supply Resistance

EE ti1599a

30 309298E

Electrical Tests

Test Barrel Resistance

1.

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.

2.

Measure the resistance between the conductive rod

(B) and the barrel contact ring (6a). See F IG . 21..

The resistance should be 19-29 megohms. If the resistance is incorrect, make sure the metal contact

(C) in the barrel and the barrel contact ring (6a) are clean and undamaged.

3.

If the resistance is still outside the range, remove the barrel contact ring (6a) and measure the resistance between the conductive rod (B) and the wire lead at the bottom of the contact ring groove.

4.

If the resistance is in range, replace the contact ring

(6a) with a new one. Press the contact ring firmly into the groove on the front of the barrel.

6a

C

Fig. 21. Test Barrel Resistance

WARNING

Fire, Explosion, and Electric Shock Hazard

The barrel contact ring (6a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the barrel contact ring (6a) 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.

5.

If the resistance is still outside the range, replace the barrel.

B ti1515b

309298E 31

Troubleshooting

Troubleshooting

WARNING 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.

Skin Injection Hazard

To reduce the risk of a fluid injection injury,

always follow the Pressure Relief Proce-

dure on page 18 before doing any mainte-

nance or service on this gun or system.

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.

Problem

Fluttering or spitting spray.

Cause

No fluid.

Air in fluid supply.

Solution

Refill supply.

Check fluid source. Refill.

Irregular pattern.

Fluid buildup; partially plugged tip.

Clean. See page 26.

Worn/damaged tip or air cap holes.

Clean or replace.

Pattern pushed to one side; air cap gets dirty.

Tails in pattern.

Air cap holes plugged.

Atomization air pressure too low.

Fluid pressure too low.

Clean. See page 26.

Increase atomization air pressure.

Increase.

Fluid buildup on air cap/tip guard.

Atomization air pressure too high.

Fluid pressure too low.

Decrease.

Increase.

32 309298E

Troubleshooting

Gun Operation Troubleshooting

Problem

Excessive spray fog.

“Orange Peel” finish.

Fluid leaks from the fluid packing area

Air leaks from the air cap

Fluid leakage from the front of the gun

Gun does not spray

Paint buildup on air cap

Air leaks from manifold

Fluid doesn’t shut off properly.

Cause Solution

Atomization air pressure too high.

Fluid too thin.

Atomization air pressure too low.

Decrease air pressure as low as possible.

Increase viscosity.

Increase air pressure; use lowest pressure necessary.

Use smaller tip; see page 52.

Remix or refilter fluid.

Spray tip (4) too large.

Poorly mixed or filtered fluid.

Fluid too thick.

Reduce viscosity.

Worn fluid needle packings or shaft.

Replace fluid needle assembly (8);

see page 41.

Worn piston stem o-rings (34e, 34f).

Replace; see page 42.

Worn or damaged fluid needle (8).

Replace; see page 41

Worn fluid seat housing (5).

Loose spray tip (4).

Damaged tip seal (4a).

Low fluid supply.

Dirty or clogged spray tip (4).

Damaged spray tip (4).

Replace; see page 37.

Tighten retaining ring (1); see page

37.

Replace; see page 37.

Add fluid if necessary.

Clean; see page 37.

Replace; see page 37.

Damaged fluid needle (8).

Piston (34) not actuating.

Replace; see page 41.

Check cylinder air. Check piston

u-cup (34d); see page 48.

Actuator arm (29) is out of position.

Check actuator arm and nuts. See

page 43.

Atomization air pressure too high.

Reduce.

Dirty air cap.

Manifold is not tight.

Worn or missing o-rings.

Seat housing (5) too tight.

Fluid buildup on fluid needle (8).

Piston sticking.

Clean; see page 37.

Tighten manifold screws (106).

Replace o-rings. See page 43.

Replace; see page 37.

Replace needle; see page 41.

Clean or replace o-rings. See page

43.

309298E 33

Troubleshooting

Electrical Troubleshooting

Problem Cause Solution

Poor wrap.

Turbine air is not turned on.

Booth exhaust velocity is too high.

Atomization air pressure too high.

Turn on.

Reduce velocity to within code limits.

Decrease.

Fluid pressure too high.

Decrease.

Incorrect distance from gun to part.

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

Poorly grounded parts.

Faulty gun resistance.

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

See Test Gun Resistance on page

29.

Low fluid resistivity.

Fluid leaks from the packing (8d) and causes a short.

Check fluid resistivity, page 17.

Clean the packing rod cavity.

Replace the packing rod. See page

41.

No voltage or low voltage reading on the gun ES display module

Operator gets mild shock.

Faulty turbine alternator.

The KV switch is stuck on low.

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

alternator. See page 47.

Check the switch actuation; replace if needed.

No power.

Damaged fiber optic cable or connection.

Turbine air is not turned on.

Poor wrap.

Replace power supply. See page 46.

Check; replace damaged parts.

Turn on.

See causes and solutions under Poor

Wrap, above.

Operator not grounded or is near ungrounded object.

Gun not grounded.

See Grounding on page 15.

Operator gets shock from workpiece. Workpiece not grounded.

See Check Electrical Grounding on

page 16 and Test Gun Resistance on page 29.

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

34 309298E

Repair

Repair

Prepare the Gun for Service

WARNING

Electric Shock Hazard

Installing and repairing this equipment requires access to parts that may cause electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.

Check all possible remedies in Troubleshooting

before disassembling the gun.

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

• Lubricate the power supply o-ring (12a), some fluid needle 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.

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury,

always follow the Pressure Relief Proce-

dure on page 18 when you stop spraying,

before servicing the gun, and whenever you are instructed to relieve the pressure.

1.

Flush and clean the gun, page 23.

2.

Relieve the pressure, page 18.

3.

Remove the gun from the manifold, page 36.

4.

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

309298E 35

Repair

Remove the Gun from the

Manifold

1.

Remove the fluid supply hose from the fluid fitting

(22).

2.

Loosen the bottom gun screw (31) until the gun sits

loosely in the mounting bracket slot (A). See F IG .

22..

105

112

A

106

TI1721A

22

102

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 loosening 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.

Fig. 22. Remove Gun from Manifold

Install the Gun on the

Manifold

3.

Holding the gun firmly in hand, loosen the three screws (106) from the back of the manifold.

4.

Remove the gun from the manifold and take it to the service area.

1.

Make sure the gasket (112) and spring (105) are in

place on the manifold. See F

IG

. 22.. Inspect the

parts for damage and replace them as needed.

2.

Secure the gun to the manifold by tightening the three screws (106).

3.

Secure the gun to the mounting bracket (102) by tightening the bottom screw (31).

36 309298E

Repair

Tip Guard, Air Cap, Spray

Tip, or Seat Housing

Replacement

1.

Prepare gun for service, page 35.

2.

Remove the retaining ring (1), tip guard (3), air cap

(40), spray tip (4), and shroud (2). You may have to turn the air cap with the tip guard to remove it. See

F IG . 23..

3.

Remove the seat housing (5) with the tool (37) pro-

vided. See F IG . 24..

WARNING

Fire, Explosion, and Electric Shock Hazard

The barrel contact ring (6a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the barrel contact ring (6a) 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.

1

1a

3

40

4

4a

2

TI1723A

37

B

Fig. 23. Tip Guard, Air Cap, and Spray Tip Replacement

Fig. 24. Seat Housing Replacement

CAUTION

The barrel resistor cartridge (B) is part of the barrel and is not replaceable. To avoid destroying the gun barrel, do not attempt to remove the barrel resistor.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, never operate the gun with a missing or damaged electrode.

309298E

4.

Make sure the electrode (40a) is not damaged or

missing. See page 39 to install the electrode.

37

Repair

5.

Install the seat housing (5) with the tool (14) provided. Tighten until snug, then 1/4 turn more; do not

overtighten. See F IG . 24..

CAUTION

To avoid damaging the seat housing and gun barrel, never overtighten the seat housing. Overtightening may affect the fluid shutoff.

7.

Slide the shroud (2) onto the gun.

8.

Install the spray tip (4) and air cap (40), tip guard

(3), shroud (2), and retaining ring (1) onto the gun.

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.

9.

Test gun resistance, page 29.

10. Install the gun onto the manifold and bracket. See

page 36.

6.

Place the spray tip (4) in the air cap (40). Align the tab of the tip with the groove in the air cap. Be careful not to damage the electrode (40a).

38 309298E

Repair

Electrode Replacement

WARNING

Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, do not operate the spray gun without the electrode installed in the air cap.

4.

Push the new electrode through the air cap hole.

Make sure the short end (BB) of the electrode engages the hole (CC) in the back of the air cap.

Press the electrode in place firmly with your fingers.

See F IG . 25..

5.

Install the air cap assembly, page 37.

6.

Test gun resistance, page 29.

40a

1.

Prepare the gun for service, page 35.

2.

Remove the air cap assembly, page 37.

3.

Pull the electrode (40a) out of the back of the air cap, using a needle-nose pliers.

CC

BB

Fig. 25. Electrode Replacement

02013

309298E 39

Repair

Fluid Tube Replacement

There are no replaceable parts in the fluid tube assembly. Only remove when necessary.

1.

Prepare the gun for service, page 35.

2.

Remove the air cap assembly, page 37. Remove the

shroud (2).

3.

Disconnect the bottom fluid tube nut (C). See F IG .

26..

4.

Carefully unscrew the top fluid tube nut (D).

E

D

Fig. 26. Fluid Tube Replacement

Fluid Filter Removal

ti1524a

C

20

CAUTION

Be careful not to damage the fluid tube assembly (19) when cleaning or installing it, especially the sealing surface (E). If the sealing surface is damaged, the entire fluid tube assembly must be replaced.

5.

Apply Part No. 116553 dielectric grease to the entire length of the plastic extension on the end of the fluid tube (19).

6.

Apply low strength thread sealant to the fluid tube nut threads.

7.

Install the fluid tube into the gun barrel and tighten the top nut (D) hand-tight, then 1/4 to 1/2 turn with a wrench. There will be a gap between the nut and barrel. Do not overtighten the nut.

8.

Make sure the fluid filter (20) is in place. Tighten the bottom nut (C) onto the fitting (22) and torque to

20-30 in-lb (2.3-3.4 N•m). Make sure the top nut remains tight.

9.

Reinstall the shroud and air cap assembly, page 37.

10. Test gun resistance, page 29.

1.

Prepare the gun for service, page 35.

2.

Remove the air cap assembly, page 37. Remove the

shroud (2).

3.

Disconnect the bottom fluid tube nut (C).

4.

Remove the fluid filter (20). Clean or replace the filter, as needed.

Replacement filters are available in 100 mesh (stan-

dard) or 60 mesh sizes. See page 53.

5.

Install the fluid filter. Tighten the bottom nut (C) onto the fitting (22) and torque to 20-30 in-lb (2.3-3.4

N•m). Make sure the top nut (D) remains tight.

CAUTION

Be sure the fluid tube (19) is not twisted after tightening the bottom nut (C).

6.

Reinstall the shroud and air cap assembly, page 37.

7.

Test gun resistance, page 29.

40 309298E

Repair

Fluid Needle Replacement

1.

Prepare the gun for service, page 35.

2.

Remove the air cap assembly and seat housing,

page 37.

3.

Remove the barrel (6), page 44.

4.

Remove the spring cap (45) and the spring (8a)

from the barrel. See F IG . 27..

5.

Be sure the seat housing (5) is removed. Place the

2 mm ball end wrench (44) in the back of the fluid needle assembly. Push the tool in and turn it counterclockwise about 12 full turns to unthread the needle.

6.

Using the multi-tool (37), pull back on the packing nut (N) to remove the fluid needle assembly. See

F IG . 28..

7.

Install the fluid needle assembly in the gun barrel.

Push in on the needle with the 2 mm ball end

wrench (44) and tighten. See F IG . 29..

8.

Install the spring (8a).

9.

Install the spring cap (45), making sure the grounding spring (25) is in place. Tighten until snug. Do not overtighten.

10. Install the barrel (6), page 45.

Fig. 27. Spring Cap and Springs

Fig. 28. Fluid Needle Removal

N

37

8a

45

25

CAUTION

To avoid damaging the seat housing and gun barrel, never overtighten the seat housing. Overtightening may result in improper fluid shutoff.

11. Install the seat housing and air cap, page 37.

12. Test gun resistance, page 29.

Fig. 29. Fluid Needle Replacement

309298E 41

Repair

Piston Repair

1.

Prepare the gun for service, page 35.

2.

Remove the air cap, page 37. Remove the gun

shroud (2).

3.

Remove the jam nut (28), actuator arm (29), and

adjustment nut (30). See F IG . 30..

Shaft O-Ring

(34g)

Front O-Ring

(34e)

Back O-Ring

(34f)

U-Cup (34d)

Table 3: Piston O-Rings

Seals cylinder air along the piston rod

(34b). Replace if air leaks along rod.

Air shutoff seal. Replace if air leaks from air cap when gun is de-triggered.

Separates cylinder air from atomizing air.

Replace if air leaks from small vent hole at back of manifold when gun is triggered.

34a

34c

34d

TI1732A

28

29 30 34b

34e

34f

Fig. 30. Actuator Arm

4.

Push on the piston rod (34b) to push the piston out the back of the gun.

5.

Inspect the o-rings (34e, 34f, 34g) and u-cup pack-

ing (34d) for damage. See Table 3 and F

IG

. 31..

6.

Lubricate the o-rings (34e, 34f, 34g) and u-cup packing (34d) with non-silicone grease, Part No.

111265. Do not over-lubricate.

7.

Align the two stems (34c) with the holes in the gun body and press the piston assembly into the back of the gun until it bottoms.

8.

Install and adjust the actuator arm, page 43.

Table 3: Piston O-Rings

Description Function

34g

34e

34f

34b

34d

Fig. 31. Piston O-Rings

TI1575A

34g

TI1576A

42 309298E

Repair

Adjust the 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 F IG .

30. on page 42.

2.

Position the parts so there is a 0.125 in. (3 mm) gap between the actuator arm (29) and the fluid packing rod nut (U), which allows the atomizing air to actuate

before the fluid. See F IG . 32..

3.

Tighten the adjustment nut (30) against the actuator arm (29). Check that the 0.125 in. (3 mm) gap has

been maintained. See F IG . 32..

4.

Test gun resistance, page 29.

5.

Install the gun shroud (2) and air cap, page 37.

6.

Install the gun onto the manifold and bracket. See

page 36.

U

29

0.125 in. (3 mm) gap

TI1567A

28 30 34b

Fig. 32. Actuator Arm Adjustment

309298E 43

Repair

Barrel Removal

1.

Prepare the gun for service, page 35.

2.

Remove the air cap, page 37. Remove the gun

shroud (2).

3.

Disconnect the fluid tube nut (C).

4.

Remove the jam nut (28) and actuator arm (29). See

page 42.

5.

Loosen the three screws (10, 33). See F IG . 33..

6.

Hold the gun body (32) with one hand and pull the

barrel (6) straight off the body. See F IG . 33..

C

6

10

32

CAUTION

To avoid damaging the power supply (12), pull the gun barrel (6) straight away from the gun body (32). If necessary, gently move the gun barrel from side to side to free it from the gun body.

33

Fig. 33. Barrel Removal

32

6

TI1728A

29

28 30

19

C

TI1732A

Fig. 34. Disconnect Fluid Tube

44 309298E

Repair

Barrel Installation

1.

Be sure the gasket (11) and grounding spring (25) are in place. Make sure the air holes are aligned

properly. Replace if damaged. See F IG . 35..

2.

Place the barrel (6) 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).

4.

Make sure the fluid filter (20) is in place. Tighten the bottom nut (C) onto the fitting (22) and torque to

20-30 in-lb (2.3-3.4 N•m). Make sure the top nut (D) remains tight.

5.

Install and adjust the actuator arm (29) and jam nut

(28). See page 43.

6.

Test gun resistance, page 29.

7.

Install the gun shroud (2) and air cap, page 37.

8.

Install the gun onto the manifold and bracket. See

page 36.

CAUTION

Do not over-tighten the screws (10, 33).

32

Fig. 35. Barrel Installation

12

10

11

9

D

19

25

28

29

C

20

22

TI1729A

309298E 45

Repair

Power Supply Removal and

Replacement

1.

2.

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

Do not expose gasket (11) to solvents.

Prepare gun for service, page 35.

Remove the barrel (9), page 44.

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 supply/alternator assembly from the gun body (32), then carefully pull it straight out. Disconnect the flexible circuit (23) from the socket at the top of the body

(32). See F IG . 36..

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 alternator for damage. Disconnect the 6-pin flexible circuit

(23) from the power supply.

5.

Check the power supply resistance, page 30.

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 (23) to the power supply.

7.

Connect the 3-wire connector (GG). Slide the alternator (13) down onto the power supply (12).

8.

Lubricate the alternator o-ring (13a) with non-silicone grease, Part No. 111265. Do not over-lubricate.

9.

Lubricate the power supply o-ring (12a) with dielectric 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

(23) to the socket at the top of the body. Push the

6-pin connector into the socket to ensure it is properly connected.

11. Install the barrel (6), page 45.

12. Test gun resistance, page 29.

46 309298E

12

23

11

12a

12b

32

GG

13e

13

13a

TI1730A

Fig. 36. 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 35.

2.

Remove the power supply/alternator assembly,

page 46.

3.

Disconnect the alternator from the power supply,

page 46.

4.

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.

5.

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

6.

Install the alternator on the power supply, page 46.

7.

Install the power supply/alternator assembly, page

46.

Parts

Parts

Part No. 244592 PRO Auto Xs AA Electrostatic Gun, Series A

10

1

1a

3

40

2 4

4a

5

6a

6

19

8

12a

12b

12

28

29

23

26

27

25

11

13e

13

40a

13a

34e

34f

34c

34d

34a

30

8a

45

19 (Ref)

20

22

35

34g

33

32

31

14

37

44

34b

Ref. No. 13: Alternator Detail

13b

13b

13e

TI1481a

13a*

13d 13c

48 309298E

Parts

Part No. 244592 PRO Auto Xs AA Electrostatic Gun, Series A

Ref.

No.

Part No.

Description

8

8a

10

4a

5

6

6a

1 244950 RING, retaining, air cap; includes

1a

. U-CUP 1a*† 198307

2

3

4

197916

276767

GG3XXX

SHROUD

TIP GUARD

SPRAY TIP (customer’s choice); includes item 4a

183459

245280

244531

197486

. SEAL, spray tip

HOUSING, seat

BARREL, gun; includes item 6a

. O-RING; conductive

244714

112691

197518

11*†

12

12a*† 103337

12b 197624

13

13a*† 110073

13b

13c

13d

13e 198821

14 107460

15

16

197517

244541

244555

223688

244577

111745

179791

180060

NEEDLE, fluid; includes item 8a

. SPRING, compression

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

TURBINE, alternator; includes

13a-13e

. O-RING; fluoroelastomer

. BEARING KIT; includes front and rear bearings and fan

. COIL

. RING, retaining

. PAD, pressure

WRENCH, ball end; 4 mm

TAG, warning (not shown); replacement available at no cost

SIGN, warning (not shown); replacement available at no cost

Qty

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

23

25

26

27

19

20

22

28

29

30

31

101324

197919

102025

112689

32

33

245662

116575

34 244702

34a 197920

235843

205264

189366

245265

197624

189367

185122

34b 189754

34c 189355

34d† 189752

34e† 111504

34f† 112319

34g† 111508

35 244843

Ref.

No.

Part No.

Description

17 239945

37

39

40

40a

44

45

276741

198486

245276

244917

112080

198516

COVER, gun; box of 10 (not shown)

TUBE, fluid

FILTER, fluid, inline

FITTING, fluid

CIRCUIT, flexible

SPRING, grounding

CAP, exhaust

MUFFLER

NUT, jam, hex

ARM, actuator

NUT, hex

SCREW, button-hd

BODY, gun

SCREW, cap, socket-hd

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

MULTI-TOOL

CONNECTOR, tube

AIR CAP; includes 40a

. ELECTRODE (kit of 5)

TOOL, needle; 2 mm

CAP, spring

Qty

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

2

1

2

309298E 49

Parts

* Recommended spare parts. Keep on hand to reduce downtime.

Replacement Warning labels, signs, tags, and cards are available at no cost.

† Included in repair kit 15D592.

50 309298E

Parts

Part No. 244843 Manifold, Series A, for standard and high conductivity coatings

5 (see page 49)

101 (Ref) 106 (Ref)

112

113 105

116

116a

119

114

110

117

102

104

TI1582A

103

108

106

120

115

101

TI1740A

Ref.

No.

Part No.

Description

101 198220

102 189581

103 110465

104 112689

105 112640

106 197518

107

108

109

110

111157

186845

110078

112646

MANIFOLD

BRACKET, reciprocator

SCREW, set

SCREW, button-hd

SPRING, compression

SCREW; socket-hd; 10-24 x 3/4 in. (19 mm)

FITTING, tube

FITTING, turbine

FITTING, tube

PLUG

Qty

2

1

1

1

2

1

3

1

1

2

107

Ref.

No.

Part No.

Description

112† 197925

113 108290

114 189365

115 198764

116 244772

116a† 112085

117 114263

119 116621

120 112645

GASKET, manifold

SCREW, machine

CAP, kV, HI/LO

RESTRICTOR

PISTON; includes 116a

. O-RING

FITTING, connector

SPRING, compression

PLUG

110

† Included in repair kit 15D592.

Qty

1

3

1

2

2

1

1

2

2

309298E 51

Spray Tip Selection Chart

Spray Tip Selection Chart

Part No.

GG3411

GG3511

GG3611

GG3213

GG3313

GG3413

GG3513

GG3613

GG3107

GG3207

GG3307

GG3209

GG3309

GG3409

GG3211

GG3311

GG3215

GG3315

GG3415

GG3515

GG3615

Fan Width at

10 in. (250 mm) in. (mm)

2-4 (50-100)

4-6 (100-150)

6-8 (150-200)

4-6 (100-150)

6-8 (150-200)

8-10 (200-250)

4-6 (100-150)

6-8 (150-200)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

4-6 (100-150)

6-8 (150-200)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

4-6 (100-150)

6-8 (150-200)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

Orifice Size in. (mm)

0.007 (0.178)

0.009 (0.229)

0.011 (0.279)

0.013 (0.330)

0.015 (0.381)

Part No.

GG3619

GG3719

GG3421

GG3521

GG3621

GG3721

GG3821

GG3423

GG3217

GG3317

GG3417

GG3517

GG3617

GG3319

GG3419

GG3519

GG3523

GG3623

GG3723

GG3823

GG3425

GG3525

GG3625

GG3725

GG3825

Fan Width at

10 in. (250 mm) in. (mm)

4-6 (100-150)

6-8 (150-200)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

6-8 (150-200)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

14-16 (350-400)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

14-16 (350-400)

16-18 (400-450)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

14-16 (350-400)

16-18 (400-450)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

14-16 (350-400)

16-18 (400-450)

Orifice Size in. (mm)

0.017 (0.432)

0.019 (0.483)

0.021 (0.533)

0.023 (0.584)

0.025 (0.635)

52 309298E

Accessories

Accessories

Gun Accessories

Electrode Replacement Kit

244917 Includes five electrodes.

Inline Fluid Filters

238561

238563

100 mesh filter. Set of three.

60 mesh filter. Set of three.

Round Pattern Kit

Provides higher level of performance to electrostatic spraying.

245298 Includes tip of choice.

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.

223072

223073

50 ft (15 m)

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

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 npsm(m) x 1/4 npsm(f) left-hand thread.

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 npsm(f) x 1/4 npsm(f) left-hand thread

244963

244964

244965

244966

6 ft (1.8 m)

15 ft (4.6 m)

25 ft (7.6 m)

36 ft (11 m)

244967

244968

50 ft (15 m)

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 npsm(f) x 1/4 npsm(f) left-hand thread

223068

223069

223070

223071

6 ft (1.8 m)

15 ft (4.6 m)

25 ft (7.6 m)

36 ft (11 m)

Fluid Line Accessories

Nylon Fluid Hose

3000 psi (210 bar, 21 MPa) Maximum Working Pressure

223540

223541

1/4 in. (6 mm) ID x 25 ft (7.6 m), 1/4 npsm

1/4 in. (6 mm) ID x 50 ft (15.2 m), 1/4 npsm

Fluid Shutoff/Drain Valve

5000 psi (350 bar, 35 MPa) Maximum Working Pressure

For turning fluid on or off to the gun and for relieving fluid line pressure at the pump.

210657

210658

210659

214037

1/2 npt(m), fluoroelastomer seals

3/8 npt(m), fluoroelastomer seals

3/8 npt x 1/4 npt(m), fluoroelastomer seals

1/4 npt(m), PTFE seals

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.

309298E 53

Accessories

Paint Resistance Meter

722886 Use with 722860 Paint Probe to measure resistance of paint.

Paint Probe

Not for use in hazardous areas.

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. Available 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

For use with 224117 Display Module only. Connect gun manifold and display module, or bulkhead connector and display module. See 308265.

224682

224684

224686

25 ft (7.6 m)

50 ft (15 m)

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.

Fiber Optic Cables

Connect gun manifold and remote display, bulkhead connector and remote display, or gun manifold and bulkhead connector. See 308265.

224672

224674

25 ft (7.6 m)

50 ft (15 m)

224676 100 ft (30.5 m)

Remote Voltage Display Kits

Include 189762 Remote Voltage Display and fiber optic cable.

236917

236919

25 ft (7.6 m)

50 ft (15 m)

236921 100 ft (30.5 m)

Bulkhead Connector

189870 For connecting two fiber optic cables.

54 309298E

Technical Data

Technical Data

Category

Maximum Working Fluid Pressure

Maximum Working Air Pressure

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

Cylinder air inlet fitting

Hi/Lo voltage selector air inlet fittings

Fluid inlet fitting

Gun Weight

Gun Length

Wetted Parts

Data

3000 psi (21 MPa, 210 bar)

100 psi (0.7 MPa, 7 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

5/32 in. OD nylon tube

5/32 in. OD nylon tube

1/4-18 npsm(m)

3.52 lb (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.

309298E 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 published by Graco, Graco will, for a period of twelve months or two thousand hours of operation from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deficiency in the gun barrel, gun body, manifold, mounting bracket, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months or six thousand hours of operation from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco's written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, 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 consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

Graco Information

TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:

1-800-367-4023 Toll Free

612-623-6921

612-378-3505 Fax

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

This manual contains English. MM 309298

Sales Office: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 www.graco.com

309298E Revised 7/2007

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