Graco 309297J - PRO Auto Xs, Automatic Electrostatic Air Spray Gun Instructions


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Graco 309297J - PRO Auto Xs, Automatic Electrostatic Air Spray Gun Instructions | Manualzz

Instructions/Parts List

AUTOMATIC ELECTROSTATIC AIR SPRAY GUN

PRO

Auto Xs

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

100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure

For use in Class I, Div. I hazardous locations using Group D spray materials.

# 53

For use in Group II, Zone 1 areas using Group IIA spray materials.

II 2 G EEx 0.24 mJ

For Professional Use ONLY.

U.S. Patent 7,226,004

309297J

ENG

TI1557A

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

See page 2 for Table of Contents and page 3 for

List of Models.

2

Table of Contents

List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

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

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

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

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

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

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

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 8

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 8

Install the Air Line Accessories . . . . . . . . . . . . . 10

Install the Fluid Line Accessories . . . . . . . . . . . 10

Install the Gun and Mounting Bracket . . . . . . . . 10

Connect the Air and Fluid Lines . . . . . . . . . . . . 11

Manifold Connections . . . . . . . . . . . . . . . . . . . . 11

Optional Fiber Optic Cable Connection . . . . . . . 12

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Check Electrical Grounding . . . . . . . . . . . . . . . . 14

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 15

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 15

Install the Fabric Cover . . . . . . . . . . . . . . . . . . . 15

245324 HC Conversion Kit . . . . . . . . . . . . . . . . 16

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pressure Relief Procedure . . . . . . . . . . . . . . . . 17

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

Select a Fluid Nozzle and Air Cap . . . . . . . . . . 18

Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 19

Adjust the Electrostatics . . . . . . . . . . . . . . . . . . 20

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Triggering the Fluid Alone . . . . . . . . . . . . . . . . . 21

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 22

Clean the Air Cap and Fluid Nozzle . . . . . . . . . 24

Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 25

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 26

Test Power Supply Resistance . . . . . . . . . . . . . 27

Test Electrode Resistance . . . . . . . . . . . . . . . . . 28

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Spray Pattern Troubleshooting . . . . . . . . . . . . . 29

Gun Operation Troubleshooting . . . . . . . . . . . . . 30

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 31

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Prepare the Gun for Service . . . . . . . . . . . . . . . 32

Remove the Gun from the Manifold . . . . . . . . . . 33

Install the Gun on the Manifold . . . . . . . . . . . . . 33

Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 34

Electrode Replacement . . . . . . . . . . . . . . . . . . . 35

Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 36

Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 37

Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . 39

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 40

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 41

Power Supply Removal and Replacement . . . . 42

Turbine Alternator Removal and Replacement . 43

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 52

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 52

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

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 54

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

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

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

309297J

List of Models

Part No.

Model Voltage

244589

244590

PRO Auto Xs 40-85 kV

PRO Auto Xs 40-85 kV

Standard

X

Type of Coatings

High Conductivity

X

List of Models

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.

309297J 3

4

Warning

WARNING

Fire, Explosion, and Electric Shock Hazard

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

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

• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See

Grounding instructions.

• Only use grounded Graco conductive air supply hoses.

• Check gun and hose resistance and electrical grounding daily.

• Use and clean equipment only in well ventilated area.

• Interlock the gun air supply to prevent operation unless ventilating fans are on.

• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment.

• Always turn the electrostatics off when flushing, cleaning or servicing equipment.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Keep work area free of debris, including solvent, rags and gasoline.

• Keep a working fire extinguisher in the work area.

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.

309297J

309297J

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 air and fluid pressure of this equipment is 100 psi (0.7 MPa, 7.0 bar).

• Use fluids and solvents that are compatible with the equipment wetted parts. See the Techni-

cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s 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.

Pressurized Equipment Hazard

Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin and cause serious injury.

• Do not point the spray gun at anyone or at any part of the body.

• Do not stop or deflect fluid leaks with your hand, body, glove, or rag.

Follow the steps under Prepare the Gun for Service, page 32, when you stop spraying and

before cleaning, checking, or repairing equipment.

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

• Tighten all fluid connections before each use.

5

6

Introduction

Introduction

How the Electrostatic Air

Spray Gun Works

The automatic electrostatic air spray gun operates very similar to a traditional air spray gun. The atomization and fan air are emitted from the air cap. The atomization air breaks up the fluid stream and controls the droplet size. The fan air controls the shape and width of the spray pattern. The fan and atomization air can be adjusted independently.

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 fluid and 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.

Operating the Electrostatics

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

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

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

Changing the kV Setting

The gun’s full voltage setting is 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.

The solenoid valves used to activate the KV1 and KV2 switches must bleed the air out of the lines for the switches to draw back to the higher voltage setting.

Table 1: KV1 and KV2 Switch Settings

KV1 Air

OFF

OFF

ON

ON

KV2 Air

OFF

ON

OFF

ON

Output Voltage (kV)

85

70

60

45

309297J

A C D

H

E

TI1557A

J

B

F

TA

CYL

A1

P1

TI1561A

TI1577A

Manifold Back View

Introduction

KV1

FO

KV2

A2

P2

EXH

G

Fig. 1: Gun Overview

Key

E

F

G

H

J

C

D

A

B

Air Cap

Fluid Nozzle

Retaining Ring

Shroud

Mounting Bracket

Manifold

Turbine

Power Supply

Electrode

309297J

A1

A2

Manifold Markings

Atomization Air Inlet Fitting

Fan Air Inlet Fitting

CYL Cylinder Air Inlet Fitting

EXH Shroud Exhaust Outlet Fitting

FO Fiber Optic Fitting (shipped unassembled)

KV1 kV Switch 1 Air Inlet

KV2 kV Switch 2 Air Inlet

P1

P2

TA

Fluid Supply Inlet Fitting

Fluid Return Inlet Fitting (optional)

Turbine Air Inlet Fitting

7

8

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, Div. I, Group D or a Group II,

Category 2G Hazardous Location.

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

F IGURE 2 shows a typical electrostatic air spray system, and F IGURE 3 shows possible system options. It is not

an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.

Warning Signs

Mount warning signs in the spray area where they can easily be seen and read by all operators. An English

Warning Sign is provided with the gun.

Ventilate the Spray Booth

Electrically interlock the gun turbine air supply (B) 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).

Key to F IGURE 2 and F IGURE 3

Q

R

N

P

J

K

L

M

U

V

S

T

W

G

H

E

F

C

D

A

B

X

Y

Air Hose Ground Wire

Graco Grounded Turbine Air Hose (TA)

Atomizing Air Hose, 3/8 in. (10 mm) OD (A1)

Fan Air Hose, 3/8 in. (10 mm) OD (A2)

Cylinder Air Hose, 5/32 in. (4 mm) OD (CYL)

Fluid Hose, 1/4-18 npsm gun fluid inlet (P1)

To Fluid Supply

Auto PRO Xs Air Spray Gun

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

Solenoid Valve, requires quick exhaust port

Bleed-Type Master Air Valve

Air Pressure Regulator

True Earth Ground

24 Volt Power Supply

4-20 microampere Outputs

Full Feature ES Display Module kV Only ES Display Module (battery operated)

Fiber Optic Y Cable

Bulkhead

Fiber Optic Cable

Main Air Line kV Switch Air Hose, 5/32 in. (4 mm) OD (optional; plug KV1 fitting if not used) kV Switch Air Hose, 5/32 in. (4 mm) OD (optional; plug KV2 fitting if not used)

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.

309297J

Installation

L W

See * above

L

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.

A

X Y B C D

TA

KV1

KV2

A1 A2

CYL

K P1

N

F

M

Non-Hazardous Area

E

G

Hazardous Area

J

TI1712A

Manifold Back View

Fig. 2: Typical Installation

Q

P

NOTE:

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

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

Non-Hazardous Area Hazardous Area

R T U**

KV

µA

V**

85.0 KV

H

TI1583A

S

Fig. 3: Optional Fiber Optic Connection to Voltage Display Module

309297J 9

Installation

Install the Air Line

Accessories

1.

Install a bleed-type air valve (L) on the main air line

(W) to shut off all air to the gun (H).

2.

Install an air line filter/water separator on the gun air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your 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, D, 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.

WARNING

Pressurized Equipment 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 splashing in the eyes or on the skin.

2.

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

Install the Gun and Mounting

Bracket

WARNING

Pressurized Equipment Hazard

Trapped air can cause the gun to spray unexpectedly, which can result in serious injury, including splashing fluid in the eyes or on the skin. The solenoid valves (K) must have a quick exhaust port so trapped air will be relieved between the valve and gun when the solenoids are shut off.

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 IGURE 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 IGURE 4.

Install the Fluid Line

Accessories

1.

Install a fluid filter and drain valve at the pump outlet.

2.88 in

(73.2 mm)

NN

102

103

9.22 in

(234.2 mm)

TI1570A

To nozzle tip

03460

Fig. 4: Mounting Bracket

10 309297J

Installation

Connect the Air and Fluid

Lines

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

tions, and F IGURE 5 shows the manifold connections.

Connect the air and fluid lines as instructed.

WARNING

Electric Shock Hazard

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

Air Supply Hose.

1.

Connect the Graco Grounded Air Supply Hose (B) to the gun's turbine air inlet (TA) and connect the hose ground wire (A) to a true earth ground (N). The gun turbine air inlet fitting has left-hand threads to prevent connecting another type of air hose to the

turbine air inlet. See Accessories on page 52 for

further information about the hose.

2.

Check the electrical grounding of the gun as

instructed on page 14.

3.

Before connecting the fluid line (P1), blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.

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 11).

kV Switch 1 Air Inlet Fitting

Connect a 5/32 in. (4 mm) OD tube between this fitting and the solenoid.

kV Switch 2 Air Inlet Fitting

Connect a 5/32 in. (4 mm) OD tube between this fitting and the solenoid.

Fluid Supply Inlet Fitting

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

Fluid Return Inlet Fitting (optional)

Order Part No. 233676 Fluid Recirculation Kit.

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

A1

P1

Manifold Connections

A1

A2

CYL

Atomization Air Inlet Fitting

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

Fan 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

TI1577A

KV1

FO

A2

P2

EXH

309297J 11

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 -

URE 3, page 9, 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 IGURE 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 IGURE 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

120

TI1580A

TI1581A

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

12 309297J

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 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 Ground-

ing, page 14.

• 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.

309297J 13

Installation

Check Electrical Grounding

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see

F IGURE 8) 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.

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 AA

TA

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. The fluid hose must not have any fluid in it.

B

Fig. 8. Check Gun Grounding

TI1584A

14 309297J

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.

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:

• 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.

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 IGURE 9.

2.

Route the exhaust tube (YY) outside the cover. This enables you to monitor the exhaust tube for the

presence of any paint or solvent. See Check for

Fluid Leakage on page 25. Strap down the exhaust

tube to prevent it from moving around.

YY

Fig. 9. Fabric Cover

XX ti1571a

YY

309297J

TI1579A

15

Installation

245324 HC Conversion Kit

Part No. 245324 Conversion Kit is available to convert

PRO Auto Xs standard coating guns (Part No. 244589) to high conductivity guns (244590).

The kit is for use with fluids with low resistivity values.

6.

Slide the loops of the hc tube (19) onto the gun barrel (9).

7.

Make sure the barrel threads are clean and dry.

Apply Graco Part No. 116553 dielectric grease to the fluid fitting (19d) threads and o-rings. Thread

the fitting into the barrel inlet. See F IGURE 10.

8.

Slide the nut (20) and ferrules (21, 22) onto the coiled tube (19). Insert the end of the tube into the fitting (23). Make sure the ferrules seat in the fitting.

Tighten the nut (20).

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

before installing this kit.

9

1.

Turn the turbine air (TA) off.

2.

Flush the gun.

3.

Relieve the pressure.

4.

Remove the retaining ring (1), air cap (3), and shroud (2).

5.

Refer to the parts drawing for Model 244589 on

page 45. Loosen the two nuts (20) and remove the

fluid tube (19) and ferrules (21, 22). Remove the other parts (14, 15, 16, 17, 18) at the gun barrel inlet.

19d

Fig. 10. HC Conversion Kit

19

21

22

20

23

TI1731A

16 309297J

Operation

Operation

Pressure Relief Procedure

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.

1.

Turn off all the air to the spray gun except the cylinder air, which triggers the gun. If an air pilot fluid regulator is used in the system, the air pressure is needed at the regulator air inlet.

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.

If an air pilot fluid regulator is used, turn off the air pressure at the regulator air inlet.

5.

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

6.

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

309297J 17

Operation

Operating Checklist

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

Select a Fluid Nozzle and Air

Cap

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

All operators are trained in the Pressure

Relief Procedure on page 17.

The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators.

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

area are properly grounded. See Grounding on page 13.

The condition of the gun’s electrical compo-

nents has been checked as instructed in Elec-

trical Tests on page 26.

Ventilation fans are operating properly.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

before removing or installing a fluid nozzle and/or air cap.

The gun is supplied with Part No. 197266 Nozzle and

24A438 Air Cap. If you require a different size, refer to

Table 2 and Table 3 , and instruction manual 309419, or

consult with your Graco distributor. See Air Cap/Nozzle

Replacement on page 34.

Part No.

197263

197264

197265

Table 2: Fluid Nozzles

Size, mm (in.)

Part No.

Size, mm (in.)

0.75 (.030)

1.0 (.042)

1.2 (.047)

197266

197267

197268

1.5 (.055)

1.8 (.070)

2.0 (.080)

Workpiece hangers are clean and grounded.

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

All flammable fluids in the spray booth are in approved, grounded containers.

All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded.

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

instructed in Check for Fluid Leakage on page 25.

Part No.

24A438

24A279

24A376*

24A274

24A439

Table 3: Air Caps

Pattern Shape and Length in.

(mm)

Recommended Fluids and

Production Rates

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

18 309297J

Operation

Adjust the Spray Pattern

Follow the steps below to establish the correct fluid flow and air flow. Do not turn on the turbine air (TA) yet.

4.

Use the air pressure regulator on the atomization air supply line (A1) to adjust the degree of atomization.

See F IGURE 12. For example, for a fluid flow rate of

10 ounces per minute (0.3 liters per minute), a typical atomization pressure would be 20-30 psi

(1.4-2.1 bar, 0.14-0.21 MPa) at the gun manifold.

5.

Use the air pressure regulator on the fan air supply line (A2) to adjust the pattern size.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

whenever you are instructed to relieve the pressure.

1.

Relieve the pressure.

2.

Loosen the air cap retaining ring, and rotate the air cap for a vertical or horizontal spray pattern. See

F IGURE 11. Tighten the retaining ring until the air

cap is held firmly in place; you should not be able to rotate the air cap horns by hand.

• 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.

See Spray Pattern Troubleshooting on page 29 to

correct spray pattern problems.

KV2

TA

CYL

KV1

Vertical Pattern A1

A2

Horizontal Pattern

Fig. 11. Air Cap Positions

3.

Adjust the fluid flow with the fluid pressure regulator.

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

Fig. 12. Manifold Air Connections

TI1577A

309297J 19

Operation

Adjust the Electrostatics

1.

Shut off the fluid supply.

2.

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

See F IGURE 12.

3.

Refer to Table 4 to set the proper pressure at the

turbine air hose inlet when air is flowing. Do not exceed these pressures as there is no added benefit and turbine life could be reduced.

Table 4: 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)

4.

Check the voltage output of the gun using a high voltage probe and meter or by reading the ES (kV)

Display Module.

The gun’s normal high voltage reading is 60-70 kV. If a ball end high voltage measurement probe is used, the gun voltage will rise to about 85 kV. This will happen with all resistive electrostatic guns.

See Electrical Troubleshooting on page 31 to correct

voltage problems.

20 309297J

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.

1.

Apply a minimum of 50 psi (3.5 bar, 0.35 MPa) air pressure to the cylinder air fitting (CYL) to activate the on/off sequence of atomization air (A1), fan air

(A2), and fluid (P1). See F IGURE 12.

2.

Turn the gun functions on and off by using the air solenoid valves on the cylinder (CYL) and turbine

(TA) air supply lines.

3.

To change to a lower voltage setting, activate the solenoids controlling the KV1 and KV2 ports. See

Changing the kV Setting on page 6.

Triggering the Fluid Alone

1.

Shut off and relieve the air pressure to the atomization (A1) and fan (A2) air lines, using the bleed-type air shutoff valves.

2.

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

Shutdown

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

when you stop spraying and whenever you are instructed to relieve the pressure.

1.

Relieve the pressure.

2.

Flush and clean the equipment. See Maintenance on page 22.

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 25.

309297J 21

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.

TI1573A

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

02027A

TI1574A

22 309297J

Maintenance

Daily Care and Cleaning, continued

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

before doing any maintenance on the gun or system.

• 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 and fluid nozzle daily, minimum.

Some applications require more frequent cleaning.

Replace the fluid nozzle and air cap if they are dam-

aged. See Clean the Air Cap and Fluid Nozzle, page 24.

• Check the electrode and replace if broken or dam-

aged. See Electrode Replacement on page 35.

• Check for fluid leakage from the gun and fluid

hoses. See Check for Fluid Leakage on page 25.

Tighten fittings or replace equipment as needed.

• 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.

309297J 23

Maintenance

Clean the Air Cap and Fluid

Nozzle

Equipment Needed

• soft bristle brush

• compatible solvent

Procedure

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.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

when you stop spraying and whenever you are instructed to relieve the pressure.

1.

Relieve the pressure.

2.

Remove the air cap assembly (1, 3) and shroud (2).

See F IGURE 13.

3.

Wipe the fluid nozzle (4), shroud (2), and exterior of the gun clean with a cloth dampened in solvent.

Avoid getting any solvent into the air passages.

Whenever possible, point the gun down when cleaning it.

4.

If it appears that there is paint inside the fluid nozzle

(4) air passages, remove the gun from the line for servicing.

5.

Clean the air cap (3) with the soft bristle brush and solvent or submerge the air cap in suitable solvent and wipe it clean.

6.

Slide the shroud (2) onto the gun.

7.

Carefully install the air cap (3). Be sure to insert the electrode (7) through the center hole of the air cap.

Rotate the air cap to the desired position.

8.

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 26.

2

TI1560A

1a 7 4

3 1

Fig. 13. Clean Air Cap and Fluid Nozzle

24 309297J

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

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

when you stop spraying and whenever you are instructed to relieve the pressure.

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

for the presence of fluid. See F IGURE 14. Fluid in these

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

If fluid is seen in these areas, stop spraying immediately. Relieve the pressure, then remove the gun for repair.

YY

ZZ

Fig. 14. Check for Fluid Leakage

ZZ ti1571a

YY

TI1579A

309297J 25

Electrical Tests

Electrical Tests

Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (12) and electrode (7), and electrical continuity between components.

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

TA

AA

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see

F IGURE 15) 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.

7

Fig. 15. Test Gun Resistance

Test Gun Resistance

1.

Flush and dry the fluid passage.

2.

Measure resistance between the electrode needle tip (7) and the gun body (32) or the turbine air inlet fitting (TA); it should be 156-180 megohms. If outside this range, remove the gun for service (page

32) and go to the next test. If in range, refer to Elec-

trical Troubleshooting on page 31 for other possi-

ble causes of poor performance.

TA

TI1585B

TI1577A

26 309297J

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 42.

2.

Remove the turbine alternator (13) from the power

supply, page 43.

3.

Measure resistance from the power supply's ground

strips (EE) to the spring (12b). See F IGURE 16.

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 31 for other possible causes

of poor performance, or contact your Graco distributor.

12b

Fig. 16. Test Power Supply Resistance

EE ti1599a

309297J 27

Electrical Tests

Test Electrode 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 electrode (7). The resistance should be

20-30 megohms. See F IGURE 17.

3.

If in range, refer to Electrical Troubleshooting on page 31 for other possible causes of poor perfor-

mance, or contact your Graco distributor.

4.

Remove the electrode (7), page 35. 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 IGURE 18.

5.

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

nozzle contact ring (4a, F IGURE 19), and the elec-

trode contacts (E) are clean and undamaged.

F

Fig. 18. Electrode

7 E ti1513a

Fig. 19. Nozzle Conductive O-Ring

4a ti1548a

C

7

Fig. 17. Test Electrode Resistance

B ti1499a

28 309297J

Troubleshooting

Troubleshooting

WARNING WARNING

Electric Shock Hazard Pressurized Equipment 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.

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

whenever you are instructed to relieve the pressure.

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 Solution

No fluid.

Refill supply.

Loose, dirty, damaged nozzle/seat.

Clean or replace nozzle, page 34.

Improper spray pattern.

Streaks.

Air in fluid supply.

Damaged nozzle or air cap.

Check fluid source. Refill.

Replace, page 34.

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 24.

Decrease.

Increase viscosity.

Increase.

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 34.

309297J 29

Troubleshooting

Gun Operation Troubleshooting

Problem Cause Solution

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

Atomizing air pressure too high.

Fluid too thin.

Atomizing air pressure too low.

Poorly mixed or filtered fluid.

Fluid too thick.

Worn packings or rod.

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

Worn or damaged packing rod (8).

Decrease air pressure as low as possible.

Increase viscosity.

Increase air pressure; use lowest air pressure necessary.

Remix or refilter fluid.

Reduce viscosity.

Replace packings or rod; see pages

36 or 37.

Replace; see page 38.

Replace; see page 36

Gun does not spray

Dirty air cap

Worn fluid seat.

Replace fluid nozzle (4) and/or elec-

trode needle (7); see pages 34 to 35.

Tighten; see page 34.

Loose fluid nozzle (4).

Damaged nozzle o-ring (4b).

Low fluid supply.

Damaged air cap (3).

Dirty or clogged fluid nozzle (4).

Damaged fluid nozzle (4).

Piston (34) not actuating.

Replace; see page 34.

Add fluid if necessary.

Replace; see page 34.

Clean; see page 34.

Replace; see page 34.

Check cylinder air. Check piston

u-cup (34d); see page 38.

Actuator arm (29) is out of position.

Check actuator arm and nuts. See

page 39.

Misaligned air cap (3) and fluid nozzle (4).

Clean fluid buildup off air cap and

fluid nozzle seat; see page 24.

Damaged nozzle orifice.

Fluid is coming on before the air.

Replace nozzle (4); see page 34.

Check actuator arm and nuts. See

page 39.

Air leaks from manifold Manifold is not tight.

Fluid leaks at the quick-disconnect.

Manifold is not tight.

Fluid hose o-rings are worn or missing.

Tighten manifold screws (106).

Tighten manifold screws (106).

Inspect or replace o-rings.

30 309297J

Troubleshooting

Electrical Troubleshooting

Problem Cause Solution

Poor wrap.

Turbine air is not turned on.

Booth exhaust velocity is too high.

Atomizing 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

26.

Low fluid resistivity.

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

Check fluid resistivity, page 15.

Clean the packing rod cavity.

Replace the packing rod. See page

37.

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 43.

Check the switch actuation; replace if needed.

No power.

Damaged fiber optic cable or connection.

Replace power supply. See page 42.

Check; replace damaged parts.

Turbine air is not turned on.

Poor wrap.

Turn on.

See causes and solutions under Poor

Wrap, above.

See Grounding on page 13.

Operator not grounded or is near ungrounded object.

Gun not grounded.

Operator gets shock from workpiece. Workpiece not grounded.

See Check Electrical Grounding on

page 14 and Test Gun Resistance on page 26.

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

309297J 31

Repair

Repair

Prepare the Gun for Service

Check all possible remedies in Troubleshooting

before disassembling the gun.

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.

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

• Lubricate the power supply o-ring (12a), some packing rod parts (8), and certain fluid fittings with Part

No. 116553 Dielectric Grease, as specified in the text.

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

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

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 17 before

1.

Flush and clean the gun, page 22.

2.

Relieve the pressure, page 17.

3.

Remove the gun from the manifold, page 33.

4.

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

32 309297J

Repair

Remove the Gun from the

Manifold

Install the Gun on the

Manifold

1.

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

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

20.

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.

1.

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

place on the manifold. See F IGURE 20. Inspect the

parts for damage and replace them as needed.

2.

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

3.

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

2.

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

3.

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

106

A

112

105

TI1559A

102

Fig. 20. Remove Gun from Manifold

309297J 33

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.

1.

Prepare gun for service, page 32.

2.

Remove the retaining ring (1) and air cap (3). See

F IGURE 21.

3.

Point gun up while removing the fluid nozzle (4) assembly with the multi-tool (40).

1, 3

40

1

4

7

4

4a

4b

TI1572A

Fig. 21. Air Cap/Nozzle Replacement

1a

3

WARNING

Fire, Explosion, and Electric Shock Hazard

The nozzle contact ring (4a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the nozzle contact ring (4a) except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine Graco part.

Use non-silicone grease, Part No. 111265, on the small o-ring (4b). Do not over-lubricate. Do not lubricate the contact ring (4a).

4.

Lightly lubricate the o-ring (4b). Install it and the contact ring (4a) on the nozzle (4).

Make sure the electrode needle (7) is finger- tight (page

35).

5.

Install the fluid nozzle (4) with the multi-tool (40).

Tighten until the fluid nozzle seats in the gun barrel

(1/8 to 1/4 turn past hand-tight).

6.

Carefully install the air cap (3). Be sure to insert the electrode (7) through the center hole of the air cap.

Rotate the air cap to the desired position.

7.

Make sure the u-cup (1a) is in place on the retaining ring (1). The lips must face forward. Tighten the retaining ring until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.

8.

Test gun resistance, page 26.

9.

Install the gun onto the manifold and bracket. See

page 33.

34 309297J

Electrode Replacement

1.

Prepare the gun for service, page 32.

2.

Remove the air cap and nozzle, page 34. Remove

the gun shroud (2).

3.

Unscrew the electrode (7) with the multi-tool (40).

Hold the packing rod end (8h) to prevent it from turn-

ing, F IGURE 22.

40

CAUTION

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

4.

Apply low-strength (purple) Loctite® or equivalent thread sealant to the electrode and packing rod threads. Install the electrode finger-tight. Do not overtighten.

5.

Install the fluid nozzle, page 34.

6.

Test gun resistance, page 26.

7.

Install the gun shroud (2) and air cap, page 34.

8.

Install the gun onto the manifold and bracket. See

page 33.

8h

Fig. 22. Electrode Replacement

TI1565A

Repair

309297J 35

Repair

Fluid Packing Removal

You may replace the packing rod as an assembly, as

described below, or as individual parts (see page 37).

The assembly is pre-adjusted at the factory.

1.

Prepare the gun for service, page 32.

2.

Remove the air cap, page 34. Remove the gun

shroud (2).

3.

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

page 38.

The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.

4.

Remove the fluid nozzle (4) and electrode (7). See

pages 34 and 35.

5.

Remove the packing rod (8), using the multi-tool

(40).

Before installing the packing rod, clean the internal surface of the barrel (9) with a soft cloth or brush. Check for marks from high voltage arcing. If marks are present, replace the barrel.

40

9

28

CAUTION

Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause the gun to malfunction.

TI1566A

Fig. 23. Fluid Packing Removal

6.

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

36 309297J

Repair

Packing Rod Repair

You may replace the packing rod as individual parts, as

described below, or as an assembly (see page 36). The

assembly is pre-adjusted at the factory.

Before installing the fluid packing rod into the gun barrel, make sure the internal surfaces of the barrel are clean.

Remove any residue with a soft brush or cloth. Check the inside of the barrel for marks from high voltage arcing. If marks are present, replace the barrel.

To assemble the individual parts:

1.

Place the packing nut (8e) and seal (8b) on the fluid rod (8h). Flats on the packing nut must face the back of the fluid rod. The seal o-ring must face away

from the packing nut. See F IGURE 24.

2.

Fill the inner cavity of the spacer (8g) with dielectric grease. Place the spacer on the fluid rod (8h) in the direction shown. Generously apply dielectric grease to the outside of the spacer.

3.

Place the rod packing (8d), packing spreader (8c), and housing (8f) on the packing rod (8h).

4.

Lightly tighten the packing nut (8e). The packing nut is properly tightened when there is 3 lb (13.3 N) of drag force when sliding the packing housing (8f) assembly along the rod. Tighten or loosen the packing nut as needed.

5.

Install the o-ring (8a) on the outside of housing (8f).

Lubricate the o-ring with non-silicone grease, Part

No. 111265. Do not over-lubricate.

6.

Install the spring (25) against the nut (E) as shown.

7.

Install the packing rod assembly (8) into the gun barrel. Using the multi-tool (40), tighten the assembly until just snug.

8.

Install the electrode, page 35 and nozzle, page 34.

9.

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

(28). See page 39.

10. Test gun resistance, page 26.

11. Install the gun shroud (2) and air cap, page 34.

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

page 33.

E

TI1489A

25

8h

8c

8d

8g

8b

8e

8f

8a

Fig. 24. Packing Rod

309297J 37

Repair

Piston Repair

1.

Prepare the gun for service, page 32.

2.

Remove the air cap, page 34. Remove the gun

shroud (2).

3.

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

adjustment nut (30). See F IGURE 25.

The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.

Table 5: Piston O-Rings

Description

Shaft O-Ring

(34g)

Front O-Ring

(34e)

Back O-Ring

(34f)

U-Cup (34d)

Function

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 fan and atomizing air.

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

TI1709A

28 29 30 34b

Fig. 25. Actuator Arm

4.

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

5.

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

ing (34d) for damage. See Table 5 and F

IGURE

26.

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 39.

34a

34c

34d

34e

34f

TI1575A

34g

34e

34f

34b

34d

Fan Air Side

Atomizing Air Side

34g

TI1576A

Fig. 26. Piston O-Rings

38 309297J

Repair

Adjust the Actuator Arm

The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.

1.

Install the adjustment nut (30), actuator arm (29), and jam nut (28) onto the piston rod (34b). Note that the jam nut (28) has a slightly larger hex and a thin-

ner profile than the adjustment nut (30). See F IGURE

25 on page 38.

2.

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

before the fluid. See F IGURE 27.

3.

Tighten the adjustment nut (30) against the actuator arm (29). Check that the 0.125 in. (3 mm) gap has been maintained. In addition, there should be 3-4 mm of electrode needle travel when the gun is triggered. Adjust the jam nut position to obtain these dimensions.

4.

Test gun resistance, page 26.

5.

Install the gun shroud (2) and air cap (3), page 34.

6.

Install the gun onto the manifold and bracket. See

page 33.

29

28

0.125 in. (3 mm) gap

30 34b

Fig. 27. Actuator Arm Adjustment

E

TI1567A

309297J 39

Repair

Barrel Removal

1.

Prepare the gun for service, page 32.

2.

Remove the air cap, page 34. Remove the gun

shroud (2).

3.

Carefully loosen the fluid fitting nut (20). Pull the tube (19) out of the fitting (23). Make sure both ferrules (21, 22) and the nut stay with the tube.

4.

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

page 38.

5.

Loosen the three screws (10, 33). See F IGURE 28.

6.

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

barrel (9) straight off the body. See F IGURE 28.

9

10

32

33

CAUTION

To avoid damaging the power supply (12), pull the gun barrel (9) straight away from the gun body (32). If necessary, gently move the gun barrel from side to side to free it from the gun body.

Fig. 28. Barrel Removal

32

9

TI1563A

29

28 30

19

TI1709A

20 23

Fig. 29. Disconnect Fluid Tube

40 309297J

Repair

Barrel Installation

1.

Be sure the gasket (11) and grounding spring (51) are in place. Make sure the air holes are aligned

properly. Replace if damaged. See F IGURE 30.

2.

Place the barrel (9) over the power supply (12) and onto the gun body (32).

3.

Tighten the three screws (10, 33) oppositely and evenly (about a half turn past snug).

4.

Assemble the fluid tube (19) into the fluid fitting (23).

Ensure that the ferrules (21, 22) are in place.

Tighten the nut (20).

5.

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

(28). See page 39.

6.

Test gun resistance, page 26.

7.

Install the gun shroud (2) and air cap, page 34.

8.

Install the gun onto the manifold and bracket. See

page 33.

CAUTION

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

32

9

10

11

12

TI1569A 33

51 28

29

19

20

23

Fig. 30. Barrel Installation

309297J 41

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 32.

Remove the barrel (9), page 40.

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 (39) from the socket at the top of the body

(32). See F IGURE 31.

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

(39) from the power supply.

5.

Check the power supply resistance, page 27.

Replace if necessary.

Before installing the power supply, make sure the o-rings (12a, 13a), spring (12b), and pads (13e) are in place.

6.

Connect the 6-pin flexible circuit (39) 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

(39) 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 (9), page 41.

12. Test gun resistance, page 26.

42 309297J

Repair

12

39

11

12a

12b

32

GG

13e

13

13a

TI1568A

Fig. 31. Power Supply

Turbine Alternator Removal and Replacement

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

1.

Prepare gun for service, page 32.

2.

Remove the power supply/alternator assembly,

page 42.

3.

Disconnect the alternator from the power supply,

page 42.

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 42.

7.

Install the power supply/alternator assembly, page

42.

309297J 43

Repair

Notes

44 309297J

Parts

Parts

Part No. 244589 PRO Auto Xs Electrostatic Gun, Series A, for standard coatings

7

1a

3

2

4

4a

4b

8

1

39

13

13a

29

10

11

12a

12b

12

13e

41

Ref. No. 13: Alternator Detail

13b

13a

26

9

14

15

16

25

27

19

51

22

21

20

17

18

34e

34f

34c

34d

34a

28

19 (Ref)

35

40

13b

13d 13c

13e

TI1481a

30

20 21 22

23

24

32

34b

33

34g

TI1558A

8f

31

8a

8c

8d

8g

8b

8e

8h ti1601a

Ref. No. 8: Packing Rod Detail

309297J 45

Parts

Part No. 244589 PRO Auto Xs Electrostatic Gun, Series A, for standard coatings

Ref.

No.

Part No.

Description

8f

8g*

8h

9

10

8b*

8c*

8d*

8e

7

8

8a*

4a

4b

5

1 244950 RING, retaining, air cap; includes

1a

. U-CUP 1a*† 198307

2

3

4

245312

197266

SHROUD

24A438 AIR CAP

NOZZLE; 1.5 mm orifice; includes

4a and 4b

111261

111507

198486

. O-RING, conductive

. O-RING; fluoroelastomer

CONNECTOR, tube, fiber optic;

pictured on page 51 (unassem-

bled)

NEEDLE, electrode 276697

244521

111316

116905

178409

178763

197641

185495

186069

244696

244394

197518

ROD, packing; includes 8a-8h

. O-RING; fluoroelastomer

. SEAL

. SPREADER, packing; uhmwpe

. PACKING, rod; acetal

. NUT, packing

. HOUSING, packing

. SPACER, packing; acetal

. ROD, packing

BARREL, gun

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

11*† 197517

12 244541

12a*† 103337

12b 197624

GASKET, barrel

POWER SUPPLY, 85 kV; includes

12a-12b

. O-RING; fluoroelastomer

. SPRING, compression

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

26

27

28

29

30

31

22*

23

24*

25

19

20

21*

189367

185122

101324

197919

102025

112689

198043

112644

111285

111286

189549

111450

185111

Ref.

No.

Part No.

Description

13

13b

32

244555

13a*† 110073

223688

13c 244577

13d 111745

13e 198821

14* 111316

15*

16

17

18

102982

189757

112642

111370

245662

TURBINE, alternator; includes

13a-13e

. O-RING; fluoroelastomer

. BEARING KIT; includes front and rear bearings and fan

. COIL

. RING, retaining

. PAD, pressure

O-RING

O-RING

FITTING, fluid

SPACER

CONNECTOR, elbow; includes items 20, 21, 22

TUBE, fluid

NUT

FERRULE, back

FERRULE, front

FITTING, fluid, quick-disconnect

O-RING

SPRING, compression

CAP, exhaust

MUFFLER

NUT, jam, hex

ARM, actuator

NUT, hex

SCREW, button-hd; 1/4-20 x 3/4 in. (19 mm)

BODY, gun

Qty

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

46 309297J

Parts

Ref.

No.

Part No.

Description

33 116575

34

39

40

244702

34a 197920

34b 189754

34c 189355

34d*† 189752

34e*† 111504

34f*† 112319

34g*† 111508

35 244586

245265

276741

SCREW, cap, socket-hd; 10-24; 3 in. (76 mm)

PISTON; includes 34a-34g

. PISTON

. ROD, piston

. STEM, piston

. PACKING, u-cup

. O-RING

. O-RING

. O-RING

MANIFOLD; see separate parts

list on page 51

CIRCUIT, flexible

MULTI-TOOL

Qty

2

1

1

2

2

2

1

1

1

1

1

1

Ref.

No.

Part No.

Description

41

42

43

44

51

107460

179791

180060

239945

197624

WRENCH, ball end; 4 mm

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

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

COVER, gun; box of 10 (not shown)

SPRING, grounding

Qty

1

1

1

1

1

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

† Included in repair kit 15D592.

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

309297J 47

Parts

Part No. 244590 PRO Auto Xs Electrostatic Gun, Series A, for high conductivity coatings

7 8

1a

3

2

4

4a

4b

1

39

13

13a

29

10

11

12

12a

12b

26

9

19

19a

19b

19 (Ref)

25

27

19d

19c

34f

34e

34c

34d

34a

28

19 (Ref)

13e

35

41

Ref. No. 13: Alternator Detail

13b

13b

TI1481a

13a

40

13d 13c

13e

30

20 21 22

23

24

32

34b

34g

33

31

8a

TI1586A

8f

8c

8d

8g

8b

8e

8h ti1601a

Ref. No. 8: Packing Rod Detail

48 309297J

Parts

Part No. 244590 PRO Auto Xs Electrostatic Gun, Series A, for high conductivity coatings

8b*

8c*

8d*

8e

7

8

8a*

8f

8g*

8h

9

10

276697

244521

111316

116905

178409

178763

197641

185495

186069

244696

244394

197518

1a*†

2

3

4

4a

4b

5

Ref.

No.

Part No.

Description

1 244950

11*†

12

198307

245312

24A438

197266

111261

111507

198486

197517

244541

12a*† 103337

12b 197624

RING, retaining, air cap; includes

1a

. U-CUP

SHROUD

AIR CAP

NOZZLE; 1.5 mm orifice; includes

4a and 4b

. O-RING, conductive

. O-RING; fluoroelastomer

CONNECTOR, tube, fiber optic;

pictured on page 51 (unassem-

bled)

NEEDLE, electrode

ROD, packing; includes 8a-8h

. O-RING; fluoroelastomer

. SEAL

. SPREADER, packing; uhmwpe

. PACKING, rod; acetal

. NUT, packing

. HOUSING, packing

. SPACER, packing; acetal

. ROD, packing

BARREL, gun

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

GASKET, barrel

POWER SUPPLY, 85 kV; includes

12a-12b

. O-RING; fluoroelastomer

. SPRING, compression

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Ref.

No.

Part No.

Description

13

13a*† 110073

13b

13c

13d

13e

19

244555

223688

244577

111745

198821

237297

TURBINE, alternator; includes

13a-13e

. O-RING; fluoroelastomer

. BEARING KIT; includes front and rear bearings and fan

. COIL

. RING, retaining

. PAD, pressure

TUBE, fluid; coiled; includes

19a-19d

. O-RING 19a* 102982

19b* 111450

19c* 103337

19d 186818

20

21*

22*

112644

111285

111286

. O-RING

. O-RING

. FITTING

NUT

FERRULE, back

FERRULE, front

FITTING, fluid, quick-disconnect

O-RING

27

28

29

30

31

23

24*

25

26

189549

111450

185111

189367

185122

101324

197919

102025

112689

SPRING, compression

CAP, exhaust

MUFFLER

NUT, jam, hex

ARM, actuator

NUT, hex

SCREW, button-hd; 1/4-20 x 3/4 in. (19 mm)

32

33

245662

116575

BODY, gun

SCREW, cap, socket-hd; 10-24; 3 in. (76 mm)

Continued on page 50.

Qty

1

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

309297J 49

Parts

Ref.

No.

Part No.

Description

34 244702

34a 197920

34b 189754

34c 189355

34d*† 189752

34e*† 111504

34f*† 112319

34g*† 111508

35 244586

39

40

245265

276741

PISTON; includes 34a-34g

. PISTON

. ROD, piston

. STEM, piston

. PACKING, u-cup

. O-RING

. O-RING

. O-RING

MANIFOLD; see separate parts

list on page 51

CIRCUIT, flexible

MULTI-TOOL

Qty

1

1

2

2

2

1

1

1

1

1

1

Ref.

No.

Part No.

Description

41

42

43

44

51

107460

179791

180060

239945

197624

WRENCH, ball end; 4 mm

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

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

COVER, gun; box of 10 (not shown)

SPRING, grounding

Qty

1

1

1

1

1

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

† Included in repair kit 15D592.

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

50 309297J

Parts

Part No. 244586 Manifold, Series A

101 (Ref) 106 (Ref)

112

113 105

5 (see pages 46 or 49)

101

116

116a

119

114

109

117 120

115

102

104

103

TI1582A

108

111

106

118

TI1578A

Ref.

No.

Part No.

Description

107

108

109

110

101

102

103

104

105

106

111

112†

113

198216

189581

110465

112689

112640

197518

111157

186845

110078

112646

189551

197925

108290

MANIFOLD

BRACKET, reciprocator

SCREW, set

SCREW, button-hd

SPRING, compression

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

FITTING, tube, exhaust

FITTING, turbine, air

FITTING, tube, air

PLUG

FITTING, quick-disconnect, fluid

GASKET, manifold

SCREW, machine

Qty

2

1

3

1

1

2

1

1

2

2

1

1

1

107

Ref.

No.

Part No.

Description

117

118

119

120

114

115

189365

198764

116 244772

116a† 112085

114263

111450

116621

112645

CAP, kV, HI/LO

RESTRICTOR

PISTON; includes 116a

. O-RING (1 per piston)

FITTING, tube, air

O-RING

SPRING, compression

PLUG

† Included in repair kit 15D592.

110

Qty

2

1

3

1

2

2

2

1

309297J 51

Accessories

Accessories

Air Line Accessories

AirFlex

Flexible Grounded Air Hose

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

0.315 in. (8 mm) ID; 1/4 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)

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.

Fluid Line Accessories

Fluid Hose

225 psi (14 bar, 1.4 MPa) Maximum Working Pressure

FM Approved; nylon; 3/8 npsm(fbe)

215637

215638

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

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

Fluid Shutoff/Drain Valve

500 psi (35 bar, 3.5 MPa) Maximum Working Pressure

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

208630

Drain Valve

1/2 npt(m) x 3/8 npt(f); carbon steel and

PTFE; for non-corrosive fluids

300 psi (21 bar, 2.1 MPa) Maximum Working Pressure

236853 Mounts directly to gun manifold for faster flushing and color changes. Must be used with 233676 Fluid Recirculation Kit.

Fluid Recirculation Kit

233676 Converts standard gun to a recirculating gun. Requires 236853 Drain Valve.

Gun Mounted Fluid Regulator

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

236854 Air-piloted fluid regulator mounts directly to gun manifold for precise fluid control.

52 309297J

Accessories

Miscellaneous Accessories

Ground Wire and Clamp

222011 For grounding pump and other components and equipment in the spray area.

12 gauge, 25 ft (7.6 m).

Megohmmeter

241079 500 Volt output; 0.01-2000 megohms.

Not for use in hazardous areas.

Paint Resistance Meter

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

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

See item T in F IGURE 3 on page 9. For use with 224117

Display Module only. Connect gun manifold and display module, or bulkhead connector and display module. See

308265.

224682

224684

224686

25 ft (7.6 m)

50 ft (15 m)

100 ft (30.5 m)

Fiber Optic Cables

See item V in F IGURE 3 on page 9. Connect gun mani-

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

224672

224674

25 ft (7.6 m)

50 ft (15 m)

224676 100 ft (30.5 m)

Power Supply

235301 Supplies low voltage DC power to 224117

Display Module. See 308265.

Remote Voltage Display

189762 Battery-operated meter displays actual spraying voltage. remote mount outside hazardous area. Connects to gun via fiber optic cable. See 308265.

Remote Voltage Display Kits

Include 189762 Remote Voltage Display and fiber optic cable.

236917

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.

309297J 53

Accessories

Gun Accessories

Round Pattern Kits

Consists of fluid tip, diffuser and air cap.

245217

245219

4-6 in. (102-152 mm) diameter

8-10 in. (203-254 mm) diameter

Dielectric Grease

116553 1 oz (28 g) tube of dielectric grease for the power supply o-ring (12a), some packing rod parts (8), and certain fluid fittings.

Gun Valve Lubricant

111265 4 oz (113 g) tube of sanitary (non-silicone) lubricant for fluid seals and wear areas.

Alternator Bearing Kit

223688 To repair the turbine alternator.

Cleaning Brush

105749 For cleaning air cap and fluid nozzle.

HC Conversion Kit

245324 Converts PRO Auto Xs standard coating gun (Part No. 244589) to high conductivity gun (244590). The kit is for use with fluids

with low resistivity values. See page 16.

54 309297J

Technical Data

Technical Data

Category

Maximum Working Fluid Pressure

Maximum Working Air Pressure

Minimum Air Pressure at Gun Inlet

Maximum Fluid Operating Temperature

Paint Resistivity Range

Short Circuit Current Output

Voltage Output

Sound Power (measured per ISO Standard 9216)

Sound Pressure (measured 1 m from gun)

Turbine air inlet fitting, left-hand thread

Atomizing air inlet fitting

Fan air inlet fitting

Cylinder air inlet fitting

Hi/Lo voltage selector air inlet fittings

Fluid inlet fitting

Gun Weight

Gun Length

Wetted Parts

Data

100 psi (0.7 MPa, 7 bar)

100 psi (0.7 MPa, 7 bar)

40 psi (0.28 MPa, 2.8 bar)

120

°

F (48

°

C)

3 megohm/cm to infinity

125 microamperes

40-85 kV at 40 psi (0.28 MPa, 2.8 bar): 90.4 dB(A) at 100 psi (0.7 MPa, 7 bar): 105.4 dB(A) at 40 psi (0.28 MPa, 2.8 bar): 87 dB(A) at 100 psi (0.7 MPa, 7 bar): 99 dB(A)

1/4 npsm(m)

3/8 in. OD nylon tube

3/8 in. OD nylon tube

5/32 in. OD nylon tube

5/32 in. OD nylon tube

1/4-18 npsm(m)

3.52 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.

309297J 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

For the latest information about Graco products, visit www.graco.com.

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

1-800-328-0211 Toll Free

612-623-6921

612-378-3505 Fax

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

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

This manual contains English. MM 309297

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

Copyright 2002, Graco Inc. is registered to ISO 9001 www.graco.com

Revised 10/2009

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