Graco 308387B AUTOMATIC ELECTROSTATIC Model PRO AA5500sc Air-Assisted Airless Spray Gun Owner's Manual

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Graco 308387B AUTOMATIC ELECTROSTATIC Model PRO AA5500sc Air-Assisted Airless Spray Gun Owner's Manual | Manualzz

INSTRUCTIONS–PARTS LIST

INSTRUCTIONS

This manual contains important warnings and information.

READ AND RETAIN FOR REFERENCE

308–387

Rev. B

Supersedes A

AUTOMATIC ELECTROSTATIC

Model PRO AA5500sc

Air-Assisted Airless Spray Gun

100 psi (7 bar) Maximum Working Air Pressure

3000 psi (207 bar) Maximum Working Fluid Pressure

For use with Class , Group D paint spray materials

U.S. PATENT NO. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774;

5,063,350; 5,080,289; 5,289,977

Patented 1986, 1987 Canada

Brevete 1986, 1987

U.K. PATENT NO. 2,147,158; 2,142,559B; 2,140,327–B

Other Foreign Patents Pending

Part No. 236–688, Series A

Complete Spray Gun: includes spray gun, shroud, manifold, and mounting bracket

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

COPYRIGHT 1994 GRACO INC.

Table of Contents

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How the PRO AA5500sc Electrostatic Air-Assisted

Airless Spray Gun Operates

Operating the Spray Function

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

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

Switching to the Higher or Lower kV Setting . . . . . . .

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

5

5

5

5

5

5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the System

Warning Signs

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

10

10

7

9

7

7

7

Connect the Air and Fluid Lines to the Gun Manifold . . . . . . . . . . . . . . . . . . . . . . . .

Optional Fiber Optic Cable Connection

Ground the System

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the Electrical Grounding

Install the Fabric Cover

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

11

12

13

14

15

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the Atomization Fluid Pressure . . . . . . . . . . .

Activating and Adjusting the Electrostatics . . . . . . . .

Activating the kV Switch

Spraying

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Triggering the Fluid Alone

Shutdown

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

16

16

17

17

18

19

19

19

20

20

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools Included with the Gun . . . . . . . . . . . . . . . . . . . .

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

Tip Guard, Air Cap, Spray Tip, or Seat

Housing Replacement

Electrode Replacement

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

Fluid Tube Removal and Replacement

Fluid Filter Replacement

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

Piston Repair

Barrel Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Packing Adjustment . . . . . . . . . . . . . . . . . . . . . .

Fluid Needle Assembly Removal . . . . . . . . . . . . . . . .

Power Supply Removal and Replacement . . . . . . . .

Lower Voltage Setting Adjustment . . . . . . . . . . . . . . .

Turbine Alternator Removal and Replacement . . . .

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install the Gun onto the Manifold and Mounting Bracket . . . . . . . . . . . . . . . . . . . . . .

30

30

30

35

36

37

37

38

32

33

34

34

38

39

40

41

Spray Gun Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Manifold Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . . . 46

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Manual Change Summary . . . . . . . . . . . . . . . . . . . . . 47

The Graco Warranty and Disclaimers . . . . . . . . . . 48

Graco Phone Numbers . . . . . . . . . . . . . . . . . . . . . . . 48

Symbols

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Flush the Spray Gun

Clean the Spray Gun

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

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

20

20

21

22

24

Warning Symbol

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

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Gun Operation Troubleshooting

Electrical Troubleshooting

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

25

25

26

27

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Test Power Supply Resistance

Test Barrel Resistance

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

28

28

28

29

Caution Symbol

CAUTION

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

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 a serious injury.

Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medical attention.

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

Do not put hand or fingers over the spray tip.

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

Do not “blow back” fluid; this is not an air spray system.

Always have the tip guard on the spray gun when spraying.

Follow the Pressure Relief Procedure on page 16 whenever you: are instructed to relieve pressure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.

Tighten all the fluid connections before operating the equipment.

Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately. Permanently coupled hoses cannot be repaired; replace the entire hose.

INSTRUCTIONS

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 the instruction manuals, tags, and labels before operating the equipment.

Use the equipment only for its intended purpose. If you are uncertain about the usage, call Graco

Technical Assistance at 1–800–543–0339.

Do not alter or modify this 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. This equipment has a 100 psi (7 bar) maximum working air and fluid pressure .

Use fluids that are compatible with the equipment wetted parts. See the Technical Data section of all the equipment manuals. Read the fluid 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).

Do not use the hoses to pull equipment.

Wear hearing protection when operating this equipment.

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

Warnings are continued on the next page.

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 stated in this instruction manual.

Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all other electrically conductive objects in the spray area. See Ground the System on page 13.

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

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Interlock the gun turbine air supply to prevent operation of the power supply unless the ventilating fans are on. See

Ventilate the Spray Booth on page 7.

When flushing or purging electrostatic equipment, use solvents with a flash point equal to or greater than that of the fluid being sprayed.

To clean the exterior of the electrostatic equipment , use solvents with a flash point higher than

100 F (38 C).

Do not flush the system with the gun electrostatics turned on.

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

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

Extinguish all open flames or pilot lights in the spray area.

Keep the spray area free of debris, including solvent, rags, and gasoline.

Do not store any flammable fluids in the spray area.

Do not turn on or off any light switch in the spray area while operating or if fumes are present.

Do not smoke in the spray area.

Do not operate a gasoline engine in the spray 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.

4 308-387

Introduction

How the PRO AA5500sc Electrostatic

Air-Assisted Airless Spray Gun Operates

(Refer to page 6)

The turbine air is exhausted into the shroud (E) and out the back of the manifold through the fitting marked

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

WARNING

INJECTION HAZARD

This is not an air spray gun. To reduce the risk of an injection injury, read and follow the Warnings on pages 3 to 4 and throughout the text of this instruction manual.

The air-assisted airless spray gun combines airless and air spraying concepts. The spray tip (B) shapes the fluid into a fan pattern, as does a conventional airless spray tip. Air from the air cap (A) further atomizes the fluid and completes the atomization of the paint tails into the pattern to produce a more uniform pattern. The ability of the PRO AA5500 Electrostatic

Spray Gun to spray at higher fluid pressures provides the additional power needed to atomize higher solids materials.

Operating the Spray Function

Applying a minimum of 50 psi (3.5 bar) air pressure to the gun manifold’s cylinder air fitting (which is marked

“CYL”, see page 6) 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.

Switching to the Higher or Lower kV Setting

The gun’s full high voltage setting is 85 kilovolts. The gun’s spraying voltage can be reduced by switching to the low voltage setting for spraying in areas where too much electrostatic wrap is not desirable. Applying a minimum of 50 psi (3.5 bar) air pressure to the kV switch air inlet (which is marked “KV”, see page 6) will activate it and switch to the lower voltage setting.

The lower voltage is factory set to 60 kilovolts at zero microamperes. This setting can be adjusted from 45 to

80 kilovolts, as instructed on page 38. The solenoid valve used to activate the kV switch must bleed the air out of the line for the switch to draw back to the higher voltage setting.

Gun Features and Options

The gun is designed for use with a reciprocator, and it can be directly mounted to a one-half inch rod. With additional brackets, the gun can be mounted for robotic applications.

The gun is designed for quick-disconnect, which enables the operator to quickly remove the spray gun without disconnecting the air lines to the gun.

The gun functions are activated from a separate controller that sends the appropriate signal to the actuating solenoids (S). See Fig. 1, page 8.

Operating the Electrostatics

To operate the electrostatics, air pressure is applied to the gun manifold’s turbine air fitting (which is marked

“TA”, see page 6) through a Graco electrically conductive air hose. The air enters the manifold and is directed to the inlet of the power supply turbine (H).

The air spins the turbine, which then provides electrical power to the internal high voltage power supply (J).

The fluid is charged by the spray gun electrode (K).

The charged fluid is attracted to the nearest grounded object, wrapping around and evenly coating all surfaces.

An optional fiber optic readout system can be installed to monitor the gun’s spraying voltage. A fiber optic cable (KK) connected to the gun manifold carries the signal from the gun to a remote ES

(electrostatic) display module. See Fig. 2, page 8.

An ES Display Module (GG), P/N 224–117, is available and will display the gun’s spraying voltage and current. A battery operated ES Display Module

(FF), P/N 189–762, is also available; it displays the gun’s spraying voltage only.

308-387 5

C

G

Introduction

TA

CYL

A1

P1

KV

F.O.

A2

EXH

P2

Manifold Back View

03616

A B D E F

03228

J

H

K

04799

KEY

A Air Cap (orange color)

B Spray Tip (orange color)

C Tip Guard (orange color)

D Retaining Nut

E Shroud

F Mounting Bracket

G Manifold

H Turbine

J Power Supply

K Electrode

6 308-387

Manifold Markings

A1 not used

A2 Atomization Air Inlet Fitting

CYL Cylinder Air Inlet Fitting

EXH Shroud Exhaust Outlet Fitting

F.O. Fiber Optic Fitting

KV kV Switch Air Inlet

P1 Fluid Supply Inlet Fitting

P2 not used

TA Turbine Air Inlet Fitting

Installing the System

Installation

WARNING

ELECTRIC SHOCK HAZARD

Installing and servicing this equipment requires access to parts which could cause an 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.

Warning Signs

Mount the 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. Additional English, French, German, and Spanish signs are available at no charge.

Part No.

180–060

180–061

180–062

180–063

Description

Warning Sign (English)

Warning Sign (French)

Warning Sign (German)

Warning Sign (Spanish)

Comply with all local, state, and national codes for the installation of electrical apparatus in a

Class , Group D Hazardous Location.

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

Ventilate the Spray Booth

WARNING

FLAMMABLE OR TOXIC

VAPOR HAZARD

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

Fig. 1, page 8, shows a typical Model PRO AA5500sc system. Fig. 2 shows some possible system options.

Accessories are available from your Graco representative. Refer to the Product Data Sheet for the gun,

Form No. 305–624. If you supply your own accessories, be sure they are adequately sized and pressure rated for your system.

For assistance in designing a system that is customized for your application, contact your Graco representative or Graco Technical Assistance (see back page).

Electrically interlock the gun turbine air supply line with the ventilators to prevent operation of the electrostatic power supply unless ventilating fans are on.

Check and follow all local, state, and national 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 feet/minute (19 linear meters/minute).

R A*

Q

Non-Hazardous Area

Installation

Hazardous Area

AA*

BB* S

S

CC

S

Z

Y

**

**

TA

KV

**

**

**

A2

CYL

P1

S

U*

V

FLUID IN-P1

R

F

G*

H

J*

K

*A

B

P *C *T D E

N

*M

Fig. 1

W

To FLUID IN-P1 at gun

L*

BASIC SYSTEM

X

DD

Non-Hazardous Area

GG HH

Hazardous Area

JJ*

SYSTEM OPTIONS

S

Spraying Voltage

Display Module

X kV m A

** F.O.

EE

KK kV

FF

Fig. 2 04802

Installation

KEY–Fig. 1 and 2

A* Bleed-type Master Air Valve

B Air Line Filter

C* Pump Air Regulator

D Air Line Lubricator

E Pump Runaway Valve

F Pump

G* Pump Ground Wire

H Fluid Shut-off Valve

J* Fluid Pressure Regulator

K Pressure Gauge

L* Grounded Fluid Hose with spring guards

M* Fluid Drain Valve

N Fluid Filter

P Pump Air Line

Q Gun Air Pressure Regulator

R Main Air Line

S Solenoid Valve, requires quick-exhaust port*

T* Bleed-type Air Shut-off Valve

U* True Earth Ground

V Fluid Hose, 1/4–18.6 npsm gun fluid inlet

W Mounting Bracket for 1/2 inch (127 mm) rod, P/N 189–581

X PRO AA5500sc Spray Gun, P/N 236–688

Y Atomizing Air Hose, 3/8 inch (9.5 mm) O.D.

Z Cylinder Air Hose, 1/4 inch (6.4 mm) O.D.

AA* Ground Wire on Graco Electrically Conductive Air Hose

BB* Graco Electrically Conductive Air Hose (Turbine Air Hose),

See page 11 for part numbers

CC kV Switch Air Hose, 1/4 inch (6.4 mm) O.D., plug the gun fitting if it is not used

DD 24 Volt Power Supply, P/N 235–301

EE 4–20 mA Outputs

FF kV Only ES Display Module (battery operated), P/N 189–762

GG Full Feature ES Display Module, P/N 224–117

HH Fiber Optic Cable, P/N 224–680 to 224–686

JJ Bulkhead, P/N 189–870

KK Fiber Optic Cable, P/N 224–670 to 224–676

The turbine air supply must be interlocked with the spray booth ventilation fans.

A maximum of two splices with a total of 108 feet (32.94 m) of cable can be used. For the strongest light signals, use a minimum number of bulkhead splices.

* Equipment required for safe operation of system. Must be purchased separately.

** See page 11 for a description of the manifold connections.

Install the Air Line Accessories

WARNING

COMPONENT RUPTURE HAZARD

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

D The pump pressure must be limited by the pump air regulator (C). See Fig. 1, page 8. Do not rely on the gun fluid regulator (J) 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 (207 bar) Maximum Working Pressure of the spray gun. For example, the air supply pressure to a 30:1 pump must not exceed 100 psi (7 bar).

D 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.

Install a bleed-type master air valve (A) on the main air supply line (R) to shut off all the air to the gun. See

Fig. 1, page 8.

To ensure a dry, clean air supply to the gun, install an air line filter and an air and water separator on the air lines. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

Install an air regulator (Q) on each of the air supply lines (BB, CC. Y. Z) to control the air pressure to the gun.

Install a solenoid valve (S) on the atomization air line

(Y) to actuate the gun and shut off the atomization air to the gun. The solenoid valve must have a quick exhaust port.

Install a bleed-type air shut-off valve (T) on the pump air line to shut off air to the pump. Install an additional bleed-type valve on each pump air supply line to relieve air trapped between this valve and the pump after the air regulator is shut off.

WARNING

PRESSURIZED EQUIPMENT HAZARD

Trapped air can cause the gun to spray unexpectedly, which could result in a serious injury, including injecting fluid through the skin. The solenoid valves (S) must have a quick-exhaust port so trapped air will be relieved between the valve and the gun when the solenoids are shut of f.

The bleed-type air shut-off valve (T) is required on the pump air line (P) so trapped air will be relieved between the valve and the pump after the valves or regulator are closed, which helps prevent the pump from cycling unexpectedly.

308-387 9

Installation

Fluid Line Accessories

Install a fluid filter (N) and drain valve (M) at the pump outlet. See Fig. 1, page 8. Filtering the fluid will help remove coarse particles and sediment that could clog the spray tip.

WARNING

PRESSURIZED EQUIPMENT HAZARD

The fluid drain valve (M) is required in your system to help relieve 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 property damage or serious injury, including splashing in the eyes or on the skin and contamination from hazardous fluids.

PRO AA5500sc Gun

2.775 in.

(70.5 mm)

103

0.50 in.

(12.7 mm) rod

103

9.32 in.

(236.7 mm)

Fig. 3

03619

NOTE: For added positioning reliability, the mounting bracket (MM) has an 1/8 in. (3.2 mm) slot where a locating pin (NN–not included) can be inserted through the mounting rod (PP). See Fig. 4.

NN

MM

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

Install the Gun and Mounting Bracket

1. Loosen the mounting bracket’s two square head bolts (103) and slide the mounting bracket onto a

0.50 in. (12.7 mm) mounting rod. See Fig. 3.

2. Position the gun and tighten the two bolts (103) securely.

Fig. 4

PP

03460

10 308-387

Installation

Connect the Air and Fluid Lines to the Gun Manifold

See Fig. 1 and 2, page 8, for a schematic of air and fluid connections. Connect the air and fluid lines to the gun manifold as instructed at right.

Fluid Line

Before connecting the fluid line to the gun, blow it out with air and flush it with solvent. Use solvent that is compatible with the fluid being sprayed.

Graco Electrically Conductive Air Hose

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of an electric shock or other serious injury, you must use the

Graco Electrically Conductive Air Hose for the turbine air hose, and you must connect the hose ground wire to a true earth ground.

Connect the Graco electrically conductive air hose

(BB) to the gun turbine air inlet and connect the hose ground wire (AA) to a true earth ground. See Fig. 1, page 8. Check the electrical grounding of the gun as instructed on page 14.

NOTE: The hose and the gun have special left-hand threads to prevent connecting another type of air hose to the gun turbine air inlet.

Graco Electrically Conductive Air Hose

Required for gun operation.

100 psi (7 bar) Maximum Working Pressure

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand

Length

6 ft. (1.8 m)

15 ft. (4.6 m)

25 ft. (7.6 m)

36 ft. (11.0 m)

50 ft. (15.2 m)

75 ft. (23.0 m)

100 ft. (30. 5 m)

Part No.

Black Hose Grey Hose Red Hose

220–444

218–100

218–101

218–102

218–103

220–119

220–120

223–068

223–069

223–070

223–071

223–072

223–073

223–074

235–068

235–069

235–070

235–071

235–072

235–073

235–074

Manifold Connections (See Fig. 5)

A2 Atomization Air Inlet Fitting

Connect a 3/8 inch O.D. tube between the fitting and the air supply.

CYL Cylinder Air Inlet Fitting

Connect a 1/4 inch O.D. tube between this fitting and the solenoid. For quicker trigger response, use the shortest hose length possible.

EXH Shroud Exhaust Outlet Fitting

Connect a 1/4 inch O.D. x 4 foot (1.22 m) long tube to the fitting.

F.O. Fiber Optic Fitting (Optional)

Connect the Graco Fiber Optic Cable as instructed on page 12.

KV kV Switch Air Inlet Fitting

Connect a 1/4 inch O.D. tube between the fitting and the air solenoid.

P1 Fluid Supply Inlet Fitting

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

TA 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.

KV

TA

F.O.

CYL

P1

A2

EXH

Black Hose: standard hose, semi-conductive nylon core, urethane outer

Grey Hose: more flexible (less durable) than black hose, modified semi-conductive polyamide core, urethane cover

Red Hose: conductive SST wire braid for grounding, polyurethane tube and cover Fig. 5

Manifold Back View

03616

308-387 11

Installation

Optional Fiber Optic Cable Connection

An optional fiber optic fitting (37) is shipped unassembled with the gun. If an ES (kV) display module is used, install the fitting in the manifold. See Fig. 2, page

8, for a schematic of the fiber optic connections.

5. See manual 308–265 to install a Graco ES Display

Module.

Optional Fiber Optic Lens Kit Installation

NOTE: The fiber optic lens kit is not included with the gun. Order it separately; the part number is 236–852.

1. Remove the 1/8 npt plug (115) from the manifold’s fiber optic port, and install the black fiber optic fitting (37). See Fig. 6.

1. Remove the gun from the manifold as instructed on page 30.

37

115

2. Make sure the lens (TT) is clean. Push the lens into the counterbore (VV) in the manifold fiber optic port (SS). See Fig. 8 and 9.

3. Press the lens retainer (UU) into the manifold fiber optic port (SS) until it is flush with the manifold surface.

4. Assemble the gun to the manifold as instructed on page 41.

Fig. 6 03620

2. Remove the nut (QQ) from the fiber optic fitting

(37), and slide the nut over the end of the fiber optic cable (RR). See Fig. 7.

3. Insert the cable (RR) into the fitting (37), and push the cable in until it bottoms out. Tighten the nut

(QQ) to secure the cable.

37

QQ

UU

TT

SS

04798 Fig. 8

RR

Fig. 7

03509A

4. If you have two bulkhead splices in your system, it is recommended that you install the fiber optic lens kit, as described at right.

NOTE: Most of the fiber optic light transmission loss occurs at the bulkhead splices. For the strongest light signals, use a minimum number of bulkhead splices. A maximum of two splices, with a total of 108 feet (32.94

m) of cable, is recommended.

Fig. 9

UU

SS

TT

VV

04485

12 308-387

Ground the System

WARNING

Installation

3.

PRO 5500sc Electrostatic Air Spray Gun: ground the gun by connecting the Graco Electrically Conductive Air Hose and connecting the air hose ground wire to a true earth ground. Check the electrical grounding of the gun as instructed on page 14.

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

When operating the electrostatic gun, any ungrounded objects in the spray area (such as 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.

4.

Air lines, fluid lines, and the electric cables: must be properly grounded.

5.

All persons entering the spray area: their shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Rubber or plastic soles are not conductive.

6.

Object being sprayed: keep the workpiece hangers clean and grounded at all times. Contact points must be sharp points or knife edges.

The following grounding instructions are minimum 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 for your area and type of equipment. Your system must be connected to a true earth ground.

7.

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.

1.

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

8.

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

2.

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

9.

All electrically conductive objects or devices in the spray area: including fluid containers and wash cans, must be properly grounded.

308-387 13

Installation

Check the Electrical Grounding (See Fig. 10)

WARNING a.

If using a black or grey turbine air hose, use a megohmmeter (WW) to measure the resistance. Use an applied voltage of 500 minimum to 1000 volts maximum. Resistance should not exceed 2 megohms.

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

Megohmmeter P/N 218–979 (WW-see

Fig. 10) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

All spraying devices in the hazardous area are turned off.

Ventilation fans in the hazardous area are operating.

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, electric shock and result in serious injury and property damage.

b.

If you are using a red turbine air hose, use an ohmmeter to measure the resistance.

Resistance should not exceed 100 ohms.

5. 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

WW

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. The air and fluid supplies to the gun must be turned off, and the fluid hose must not have any fluid in it when checking the continuity.

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

Fig. 10

B

03621

Installation

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 Fig. 11.

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 24. Strap down the exhaust tube to prevent it from moving around.

Fig. 11

YY

XX

03622

YY

Manifold Back

View

03623

Operation

Operating Checklist Pressure Relief Procedure

WARNING

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 injection, 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 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 fluid pressure.

4. Open the pump drain valve (required in system) to help relieve fluid pressure in the displacement pump. In addition, open the drain valve connected to the fluid pressure gauge (in a system with fluid regulation) to help relieve fluid pressure in the hose and gun. Triggering the gun to relieve pressure may not be sufficient. Have a container ready to catch the drainage.

5. Leave the pump drain valve open until you are ready to spray again.

6. Turn off the main air supply by closing the bleedtype master air valve on the main air supply line.

Leave the valve closed until you are ready to spray again.

7. If you suspect that the spray tip or hose is completely clogged or that pressure has not been 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

INJECTION HAZARD

The wallet-sized warning card,

P/N 179–960, provided with the gun, should be available and easily accessible at all times for anyone operating or servicing this equipment. The card contains important information on what to do if an injection injury occurs. Additional cards are available at no charge from Graco.

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

____ 1. Be sure all the operators are properly trained to safely operate an automatic, electrostatic air-assisted airless spray system as instructed in this manual.

____ 2. Be sure all the operators are trained how to properly relieve system pressure as instructed at left.

____ 3. Be sure anyone operating or servicing this equipment has access to the wallet-sized warning card provided with the gun.

____ 4. Be sure the warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators.

____ 5. Be sure the system is thoroughly grounded.

See Ground the System , page 13.

____ 6. Be sure the operator and all persons entering the spray area are properly grounded by wearing shoes with conductive soles or personal grounding straps.

____ 7. Be sure all the conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded.

____ 8. Be sure all flammable liquids in the spray booth are in approved, grounded containers.

____ 9. Be sure the workpiece hangers are clean and grounded. Contact points must be sharp points or knife edges.

____ 10.

Be sure the ventilation fans are operating properly.

____ 11.

Be sure all the debris, including flammable liquids and rags, is removed from the spray area.

____ 12.

Be sure to check the manifold exhaust tubes for the presence of any fluid as instructed in

Check for Fluid Leakage , page 24 .

Operation

Selecting 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 on page 45, as a guide for selecting an appropriate spray tip for your application or consult your authorized Graco distributor or Graco Technical Assistance (see back page).

3. Install the spray tip (13) and air cap (15), tip guard

(12), shroud (2), and retaining nut (1) onto the gun; tighten the retaining nut firmly. See Fig. 13.

Installing the Spray Tip

WARNING

INJECTION HAZARD

To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 16 when you stop spraying and whenever you are instructed to relieve the pressure.

WARNING

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

To reduce the risk of fire, explosion, and electric shock, never operate the spray gun with a bent, damaged or missing electrode (15a).

1. Make sure there is no pressure in the system before removing or installing a spray tip. Relieve the system pressure.

2. Place the spray tip (13) in the air cap (15), aligning the tab of the tip with the groove in the air cap.

See Fig. 12. Be careful not to bend the electrode wire (15a).

15

1

12

13, 15

2

Fig. 13

15a

Fig. 12

13 01995

308-387 17

Operation

Setting the Atomization Fluid Pressure

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

3. With the turbine air (TA) off and the atomization air

(A2) off, spray a test pattern across a piece of paper, holding the gun 12 inches (305 mm) from the surface.

Without being concerned about the presence of

“tails”, note the particle size. See Fig. 15.

Atomization Chart

Fluid Viscosity

40 or more seconds in #2

Zahn cup*

25–40 seconds in #2 Zahn cup**

25 or less seconds in #2

Zahn cup***

Starting Fluid

Pressure

1500 psi

(105 bar)

1000 psi

(70 bar)

500 psi

(35 bar)

Fluid Pressure

Increments

200 psi

(14 bar)

100 psi

(7 bar)

100 psi

(7 bar)

4. Increase the fluid pressure by the Fluid Pressure

Increment shown in the Atomization Chart for the type of fluid you are spraying.

5. Spray another test pattern across a piece of paper.

6. Without being concerned about the presence of

“tails”, compare the particle size of the two test patterns.

A decrease in particle size indicates improved atomization.

* Includes fluids with 60% volume solids or greater.

Examples: high-build high-solids protective polyurethanes and epoxies

** Includes fluids with 40 to 60% (medium) volume solids.

Examples: alkyd enamels, some protective polyurethanes and epoxies

*** Includes fluids with 40% volume solids or less.

Examples: stains, lacquers, and decorative urethanes

1. Make sure the turbine air (TA) and atomization air

(A2) are off. Refer to Fig. 16.

7. Continue to increase the fluid pressure by the increments shown in the chart until the particle size no longer reduces in size; do not exceed the gun’s Maximum Fluid Pressure of 3000 psi (207 bar).

When the particle size no longer reduces in size, the pattern is atomized at the lowest possible fluid pressure, but will still have tails.

8. Turn on the atomization air and adjust the air pressure until the tails are eliminated. See Fig. 15.

2. Set the fluid pressure with the gun fluid regulator for the type of fluid you are spraying, based on the

Starting Fluid Pressure in the Atomization Chart , above.

NOTE: See Spray Pattern Troubleshooting on page

25 to correct spray pattern problems.

Tails

Gun Fluid

Regulator

Fig. 14

01999

No Air

Fig. 15

Too Little Air Right Amount of Air

0792

18 308-387

Operation

Activating and Adjusting the Electrostatics

The solenoid valve used to activate the kV switch must bleed the air out of the line for the switch to draw back to the higher voltage setting.

WARNING

FIRE AND EXPLOSION HAZARD

The atomizing air (A2) must be on before turning on the turbine air (TA).

Actuating the turbine air without atomizing air flow could damage the gun and could create hazardous operating conditions and result in a serious injury and property damage.

TA

CYL

KV

A2

1. Make sure the atomizing air (A2) is on, then turn on the turbine air (TA). Refer to Fig. 16.

2. The turbine air pressure should be adjusted to 30 psi (2.1 bar) at the gun manifold inlet when air is flowing. Do not exceed 40 psi (2.8 bar) air pressure as there is no added benefit and turbine life could be reduced.

Use the chart below to set the proper pressure at the turbine hose inlet. Do not exceed these recommended pressures or turbine life will be reduced.

Turbine Air

Hose Length

15 ft. (4.6 m)

25 ft. (7.6 m)

50 ft. (15.3 m)

75 ft. (22.9 m)

100 ft. (30.5 m)

Dynamic pressure at the turbine hose inlet required for full voltage

36 psi (2.5 bar)

38 psi (2.7 bar)

40 psi (2.8 bar)

42 psi (2.9 bar)

45 psi (3.1 bar)

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

Display Module.

NOTE: The gun’s normal high voltage reading is 60 to

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 27 to correct voltage problems.

Activating the kV Switch

Apply a minimum of 50 psi (3.5 bar) air pressure to the kV switch air fitting (KV) to activate it and switch to the lower voltage setting. The lower voltage setting is factory set to 60 kilovolts at zero microamperes. To change this setting, see page 38.

Manifold Back View

Fig. 16

Spraying

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of an electric shock, do not touch the gun electrode or come within 4 inches (101.6 mm) of the nozzle during gun operation.

03616

1. Apply a minimum of 50 psi (3.5 bar) air pressure to the cylinder air fitting (CYL) to activate the on/off sequence of atomization air (A2) and fluid (P1).

Refer to Fig. 16.

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

(TA) air supply lines.

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 , page 24.

Operation

Triggering the Fluid Alone

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

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

Shutdown

WARNING

INJECTION HAZARD

To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 16 when you stop spraying and whenever you are instructed to relieve the pressure.

1. Relieve the system pressure.

2. Flush and clean the equipment. Follow the instructions in the Maintenance section, pages 20 to 24.

Maintenance

Daily Care and Cleaning

CAUTION

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

Methylene chloride is not recommended 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 while cleaning it. Do not use any cleaning method which could allow fluid into the gun air passages.

Do not immerse the gun in fluid.

Do not point the gun up while cleaning it.

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

03232

02027 03231

Maintenance

Daily Care and Cleaning (continued) Flush the Spray Gun

WARNING

INJECTION HAZARD

To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 16 before doing any maintenance on the gun or system..

WARNING

INJECTION HAZARD

To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 16 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. See Clean the Spray Gun , page 22. Replace the parts if they are damaged.

Check the electrode wire: straighten it if it is bent and replace it if it is broken or damaged. See Electrode Replacement , page 33.

Check for fluid leakage from the gun and fluid hoses. See Check for Fluid Leakage , page 24.

Tighten fittings or replace equipment as needed.

1. Relieve the system pressure.

2. Make sure the turbine air (TA) is turned off.

3. Remove the retaining nut (1), tip guard (12), air cap (15), fluid tip (13), and gun shroud (2). See

Fig. 17. Set these parts aside.

NOTE: You may have to turn the air cap with the tip guard to remove the air cap from the gun.

4. Make sure the air and paint supply is turned off.

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

6. Turn on the cylinder air to trigger the gun.

7. Flush the gun, spraying into a grounded metal container until there are no traces of paint in the solvent.

Check all of the work hangers for fluid buildup; clean them if necessary.

8. Turn off the solvent supply.

9. Relieve the system pressure.

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

2

WARNING

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

To reduce the risk of a fire, explosion, or electric shock, be sure the turbine air

(TA) is off before flushing the gun or any part of the system.

1

12

15

13

Fig. 17

308-387

3246

21

Maintenance

Clean the Spray Gun

Equipment needed:

Soft bristle brush (supplied)

Solvent compatible with fluid being sprayed

3. Dampen a soft cloth with solvent and wring out the excess fluid. Wipe the exterior of the gun and shroud clean. See Fig. 19.

WARNING

INJECTION HAZARD

To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 16 when you stop spraying and whenever you are instructed to relieve the pressure.

Procedure:

1. Relieve the system pressure.

2. Dip the end of a soft-bristle brush into a compatible solvent. Clean the front of the gun with the brush and solvent. See Fig. 18. Avoid getting any fluid into the air passages. Whenever possible, point the gun down while cleaning it.

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

Fig. 19

03235

4. Remove the bottom fluid tube fitting (P) and filter

(4). See Fig. 20. Clean the filter in a compatible solvent.

5. Reinstall the filter (4) and fitting (P). Do not overtighten the fitting (P) and make sure the top fluid tube fitting (Q) remains tightened.

Fig. 18

02007

03233 Fig. 20

Q

P

4

03234

Maintenance

Clean the Spray Gun

(continued)

6. Clean the retaining nut, tip guard, air cap and fluid tip with a soft brush daily, minimum. See Fig. 21.

Replace the parts if they are damaged. Be careful not to bend, damage, or disengage the electrode wire.

WARNING

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

To reduce the risk of fire, explosion, and electric shock, never operate the spray gun with a bent, damaged or missing electrode (15a).

9. Place the spray tip (13) in the air cap (15). Align the tab of the tip with the groove in the air cap.

See Fig. 22. Be careful not to bend the electrode wire (15a).

15

Fig. 21 03236

02001

CAUTION

Do not use metal tools to clean the air cap or spray tip holes as this could scratch them, and make sure the electrode wire is not damaged. Scratches in the air cap or spray tip or a damaged electrode wire can distort the spray pattern.

7. Wipe off the parts with a dry cloth. Be careful not to bend the electrode wire.

8. Check the electrode wire. Replace it if it is bent or damaged. See page 33.

15a

Fig. 22

13

01995

10. Install the spray tip (13) and air cap (15), tip guard

(12), shroud (2), and retaining nut (1). Tighten the retaining nut firmly. See Fig. 23.

11. Test the gun resistance as instructed on page 28.

1

12

13, 15

Fig. 23

2

03230

Maintenance

Check for Fluid Leakage (See Fig. 24)

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.

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

(ZZ) for the presence of fluid. Fluid in these areas would indicate fluid leakage into the shroud, which could be caused by leaks at the fluid tube connections or fluid packing leakage.

If fluid is seen in any of these areas, stop spraying immediately!

Relieve the system pressure, then remove the gun for repair.

WARNING

INJECTION HAZARD

To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 16 when you stop spraying and whenever you are instructed to relieve the pressure.

Fig. 24

YY

ZZ

ZZ

Check for signs of fluid leakage where indicated by arrows.

03622

YY

Manifold Back

View

03623

Troubleshooting

WARNING

ELECTRIC SHOCK HAZARD

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

WARNING

INJECTION HAZARD

To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 16 before doing any maintenance or service on the gun or system.

NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the gun.

Spray Pattern Troubleshooting

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

PROBLEM:

IMPROPER SPRAY

PATTERN

Fluttering or spitting spray

CAUSE SOLUTION

The fluid pressure or fluid supply is insufficient.

There is air in the fluid supply line.

Adjust the fluid regulator, or fill the fluid tank.

Check; tighten the siphon hose connections; bleed the air from the fluid line.

Irregular pattern

Pattern is pushed to one side; the air cap gets dirty

Tails in pattern

Excessive paint buildup on the air cap and tip guard

There is fluid buildup on the spray tip or the spray tip is partially plugged.

The spray tip or air cap holes are damaged or worn.

The air cap holes are partially or completely plugged.

The atomization air pressure is too low.

The fluid pressure is too low.

The atomization air pressure is too high.

The fluid pressure is too low.

Clean the spray tip; see page 22.

Replace the damaged or worn part; see page 32.

Clean the air cap holes with solvent and a soft brush; see page 22.

Increase the atomization air pressure.*

Increase the fluid pressure with the gun fluid regulator.*

Reduce the atomization air pressure.*

Increase the fluid pressure with the gun fluid regulator.*

* Use the least air/fluid pressure needed for good results.

Troubleshooting

Gun Operation Troubleshooting

PROBLEM CAUSE

Leakage from fluid needle area Fluid needle packings loose

Fluid needle packing damaged

Air leakage from front of gun

Fluid leakage from front of gun

“Orange Peel” finish

Excessive spray fog

No fluid sprays from gun

Piston air valve not seating properly

Fluid needle worn

Fluid seat loose or worn

Spray tip loose

Tip seal damaged

Atomization air pressure too low

Fluid pressure too low

Spray tip too large

Fluid poorly mixed or filtered

Improper thinner being used

Atomization air pressure too high

Fluid thinned too much

Fluid supply low

Cylinder air pressure too low

Equipment covered with fluid

Spray tip dirty or clogged

Spray tip damaged

Actuator arm not adjusted properly

Piston sticking

Fluid needle damaged

Booth exhaust air flow too low or not directed properly

Improper distance between gun and workpiece

Gun shroud loose or o-ring (9) missing

Paint build-up on air cap

Fluid doesn’t shut off properly

Air leakage from manifold

Atomization air pressure too high

Air cap dirty

Seat housing over-tightened

Fluid leakage buildup on fluid needle

Fluid packings too tight

Piston sticking

Manifold not tight

Worn or missing o-rings

SOLUTION

Tighten packing nut; See page 37

Replace fluid needle; See page 37

Clean, Service; See page 35

Replace fluid needle; See page 37

Tighten or replace fluid seat

Tighten retaining nut

Replace tip seal; See page 32

Increase atomization air pressure*

Increase fluid pressure with gun fluid regulator*

Use a smaller size spray tip; See page 45

Remix or refilter fluid

Use proper thinner

Reduce atomization air pressure*

Properly thin fluid

Check; Add fluid if necessary

Increase cylinder air pressure; 50 psi (3.5

bar) minimum required

Clean spray tip; See page 22

Check; Replace spray tip; See page 32

Adjust the actuator arm; See page 35

Service piston o-rings; See page 35

Replace fluid needle; See page 37

Check for proper CFM; Check baffles and direction of air flow

Adjust spraying distance to 8 to 12 inches

(203 to 305 mm)

Tighten retaining nut (1); Check o-ring (9);

See page 42

Reduce atomization air pressure*

Clean air cap; See page 22

Replace seat housing; See page 32

Replace fluid needle; See page 37

Adjust fluid packings; See page 37

Service piston o-rings; See page 35

Tighten manifold screws; See page 41

Inspect or replace o-rings (items 5 and 118); see pages 42 and 44

* Use the least air/fluid pressure needed for good results.

Troubleshooting

Electrical Troubleshooting

PROBLEM

Reduced fluid efficiency

Operator gets shock

CAUSE

Improper distance between gun and work-piece

Parts poorly grounded

High booth exhaust velocity

Atomizing air pressure too high

Fluid pressure too high

Improper fluid viscosity

Fluid resistivity too low

No or low voltage output

Turbine alternator not operating

Faulty gun resistance

Fluid leaks from needle packing and causes short

Faulty turbine alternator kV switch stuck on low

Operator not properly grounded or is near an ungrounded object

Gun not properly grounded

Operator gets shock when touching workpiece

No or low voltage output reading on gun display module

Workpiece not properly grounded.

Damaged fiber optic cable or connection

SOLUTION

Adjust spraying distance to 8 to 12 inches

(203 to 305 mm)

Clean hangers; Check for proper ground on conveyer or track

Reduce exhaust velocity within code limits

Reduce atomizing air pressure*

Reduce fluid pressure with gun fluid regulator*

Check supplier for proper fluid for electrostatic spray

Check fluid resistivity with paint meter and probe

Check possible causes listed below

Check air supply to turbine inlet; See page 19

Check gun resistance; See page 28

Clean needle cavity; Replace fluid needle;

See page 37

Be sure plug is in place on back of turbine alternator housing; Remove and test turbine alternator; See page 39

Check switch actuation; replace if needed

Be sure floor is properly grounded; Wear shoes with conductive soles or wear personal grounding straps; Be sure operator is not in contact with or carrying any metallic items which could build up electrical charge

See Check the Electrical Grounding , page 14

Clean workpiece hangers; Check for proper ground on conveyor or track

Check cables and connections; replace if damaged

See other causes under Problem –

Reduced fluid efficiency , above

* Use the least air/fluid pressure needed for good results.

NOTE: If using an ES Display Module, see its instruction manual, No. 308–265, for further troubleshooting.

Electrical Tests

The performance of the spray gun is directly affected by the condition of the electrical components contained inside the gun. The electrical tests below can be used to determine the condition of the power supply (27) and the barrel resistor cartridge as well as the continuity of the electrical path between the components.

CAUTION

The barrel resistor cartridge is part of the barrel and is not replaceable. Refer to page 32. To avoid destroying the gun barrel, do not attempt to remove the barrel resistor cartridge.

Measure the resistance from the power supply’s ground contact point (R) to the contact inside of the power supply seal (27d) [the conductive rubber contact may be slightly recessed into the seal].

The resistance should be 297 to 363 megohms. If the resistance is outside the specified range, the power supply is defective and must be replaced. If the resistance of the power supply is correct, proceed to the next test.

NOTE: Be sure the seal (27d) is in place on the end of the power supply before installing the power supply back into the gun.

Use megohmmeter P/N 218–979 (L) and an applied voltage of 500 volts to complete these electrical tests.

Connect the leads as shown.

Remove the gun from the manifold and bracket, as instructed on page 30, before performing the electrical tests.

WARNING

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

To reduce the risk of sparking, which could cause a fire, explosion, or electric shock and result in a serious injury, do not use the megohmmeter in the hazardous area. Remove the gun from the hazardous area before testing the gun.

15a

Fig. 25

L

29

03624

Test Gun Resistance (See Fig. 25)

Install the spray tip, air cap, tip guard, and retaining ring on the gun. Measure the resistance between the end of the electrode (15a) and the gun body (29). The resistance should be between 329 to 401 megohms. If the resistance is outside the specified range, go to the next test. If the resistance is correct, refer to Electrical

Troubleshooting on page 27 for other possible causes of poor performance.

Test Power Supply Resistance (See Fig. 26)

Remove the power supply (27) from the gun body (29) as instructed on page 38.

Fig. 26

27d 27

R

0441

Electrical Tests

Test Barrel Resistance (See Fig. 27)

Measure the resistance between the barrel contact ring (26a) and the metal contact pin (E), using a metal rod (D) and megohmmeter as shown in Fig. 27. Be careful not to damage or scratch the inner surfaces of the barrel with the metal rod.

The resistance should be 19 to 29 megohms. If the resistance is incorrect, make sure the metal contact pin (E) and the barrel contact ring (26a) are clean.

If the resistance is still outside the specified range:

1. Remove the barrel contact ring (26a) with a small pick. There is a wire lead in the groove that the contact ring was removed from.

2. With the metal rod (D) still inside the barrel as shown in Fig. 27, measure the resistance between the wire lead and the metal rod.

3. If the resistance is still outside the specified range, the gun barrel needs to be replaced.

If you still have problems, refer to Electrical Troubleshooting for other possible causes of poor performance, or contact the nearest authorized service agency.

E

If the resistance is correct, install a new contact ring (26a) and press it firmly into the groove on the front of the barrel.

Be sure the contact ring is in place before operating the gun.

WARNING

FIRE, EXPLOSION, AND ELECTRIC

SHOCK HAZARD

The barrel contact ring (26a) is a conductive contact ring, not a sealing o-ring.

See Fig. 27. To reduce the risk of sparking, which could cause a fire, explosion, or electric shock, do not remove the barrel contact ring from the barrel 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.

26a

Fig. 27

Wire lead in groove behind contact ring

D

03247

Tools Included with the Gun

Nozzle Wrench

Ball End Wrench

2 mm Socket Head Driver

9 mm Hex Nut Driver

Dielectric Grease

Prepare the Gun for Service

Service

NOTE:

Check all the possible remedies in Troubleshooting , pages 25 to 27, before disassembling the gun.

WARNING

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

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

Be sure the turbine air (TA) is off before flushing the gun or any part of the system.

Clean all the parts with a compatible solvent that is suitable for electrostatic equipment.

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

Do not touch the gun nozzle or come within 4 inches (101.6 mm) of the nozzle during gun operation.

If the plastic parts of the gun must be held in a vise, use padded vise jaws to avoid damaging parts.

Do not mix or install parts from different PRO gun models. Note that the air cap, spray tip, and tip guard for this gun are orange.

CAUTION

Methylene chloride is not recommended as a flushing or cleaning solvent with this gun as it will damage nylon components.

WARNING

EQUIPMENT MISUSE HAZARD

Do not mix or install parts from different

PRO gun models. Some PRO AA5500

Gun parts look similar to other PRO Gun parts but they have different part numbers and they are not interchangeable.

Use of parts other than those specified in the PRO AA5500 Gun parts list on page 43 could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction, which could result in a fire, explosion, electric shock, or injection injury.

WARNING

INJECTION HAZARD

To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 16 when you stop spraying, before servicing the gun, and whenever you are instructed to relieve the pressure.

1. Flush the gun with a compatible solvent.

2. Relieve the system pressure.

NOTE: The service area must be clean. Remove the gun from the worksite as instructed in the following steps.

Service

Prepare the Gun for Service (continued)

3. Remove the retaining nut and air cap assembly (1,

12, 13, 15) and the gun shroud (2). See Fig. 28.

You may have to turn the air cap with the tip guard to remove the air cap from the gun.

CAUTION

The piston return spring (105) is compressed between the manifold (101) and gun body when they are assembled. To avoid sudden movement of the gun, loosen the bottom gun screw (21) before loosening the three manifold bolts (106). This allows the gun to move forward gradually as the manifold bolts are loosened. Hold the gun firmly in hand while loosening the manifold bolts.

4. Disconnect the fluid hose from the fluid inlet fitting

(3– marked P1 on the manifold). Use an open end wrench to hold the fluid fitting hex and prevent it from turning.

6. Holding the gun (B) firmly in hand, loosen the three bolts (106) from the back of the manifold (101) with the ball end wrench (77– not shown).

5. Loosen the bottom gun screw (21) until the gun (B) sits loosely in the mounting bracket slot (A).

7. Remove the gun (B) from the manifold (101), and take it to the service area.

106

105

B

101

2

1, 12, 13, 15

102

21

3

A

03626

Fig. 28

308-387 31

Tip Guard, Air Cap, Spray Tip, or Seat

Housing Replacement

1. Prepare the gun for service as instructed on page 30.

Service

2. Replace the tip gasket (13a) if it is damaged.

3. Remove the seat housing (14) with the 9 mm driver (84), supplied. See Fig. 30.

CAUTION

The barrel resistor cartridge (B) is part of the barrel and is not replaceable. Refer to page 32. To avoid destroying the gun barrel, do not attempt to remove the barrel resistor cartridge.

WARNING

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

To reduce the risk of fire, explosion, and electric shock, never operate the spray gun with a bent, damaged or missing electrode (15a).

1

12

15

13

13a

2

WARNING

FIRE, EXPLOSION, AND ELECTRIC

SHOCK HAZARD

The barrel contact ring (26a) is a conductive contact ring, not a sealing o-ring.

Refer to Fig. 29. To reduce the risk of sparking, which could cause a fire, explosion, or electric shock, do not remove the barrel contact ring from the barrel 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.

Fig. 29

26a

03627

Tighten the seat housing (14) with the 9 mm driver (84) until it is snug, then tighten it 1/4 turn more; do not over-tighten it.

14 4. Install the seat housing (14) with the 9 mm driver

(84). Tighten the seat housing until it’s snug and then tighten it 1/4 turn more; do not over-tighten.

CAUTION

To avoid damaging the seat housing and gun barrel, never over-tighten the seat housing. Over-tightening may affect the fluid shut-off.

5. Make sure the electrode (15a) is not bent, damaged or missing from the air cap. See Fig. 31. See page 33 to install the electrode.

Fig. 30

84

B

03237

Service

Tip Guard, Air Cap, Spray Tip, or Seat

Housing Replacement (continued)

6. Place the spray tip (13) in the air cap (15). Align the tab of the tip with the groove in the air cap.

See Fig. 31. Do not bend the electrode wire (15a).

1. Prepare the gun for service as instructed on page 30.

2. Remove the retaining nut (1), tip guard, (12), air cap (15), spray tip (13), and gun shroud (2) as instructed on page 32.

7. Slide the shroud (2) onto the gun. See Fig. 29.

8. Install the spray tip (13) and air cap (15), tip guard

(12), and retaining nut (1). Tighten the retaining nut firmly.

9. Test the gun resistance as instructed on page 28.

10. Install the gun onto the manifold and bracket as instructed on page 41.

15

3. Pull the electrode (15a) out of the backside of the air cap with a needle nose pliers. Refer to Fig. 31.

4. Push the new electrode (15a) through the air cap hole. Place firm finger pressure on the electrode wire on the backside of the air cap, and make sure the short end (BB) of the electrode engages into the hole (CC) as shown in Fig. 32.

5. Slide the shroud (2) onto the gun.

6. Install the spray tip (13), air cap (15), tip guard

(12), and retaining nut (1) as instructed at left.

Tighten the retaining nut firmly.

7. Test the gun resistance as instructed on page 28.

8. Install the gun onto the manifold and bracket as instructed on page 41.

15a

Fig. 31

Electrode Replacement

13

01995

WARNING

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

To reduce the risk of fire, explosion, and electric shock, never operate the spray gun with a bent, damaged or missing electrode (15a).

15a 15

CC BB

Fig. 32

02013

Fluid Tube Removal and Replacement

Service

To remove the fluid tube assembly (18) for cleaning or replacement:

Fluid Filter Replacement

1. Prepare the gun for service as instructed on page 30.

1. Prepare the gun for service as instructed on page 30.

2. Disconnect the bottom fluid tube nut (C). See

Fig. 33.

3. Remove the fluid filter (4). Clean or replace the filter, as needed.

2. Disconnect the bottom fluid tube nut (C). See

Fig. 33.

3. Carefully unscrew the top fluid tube nut (D).

4. Install the fluid filter (4) and tighten the bottom fluid tube nut (C) onto the fluid fitting (3); make sure the top fluid tube nut (D) remains tightened.

CAUTION

Be careful not to damage the fluid tube assembly

(18) when cleaning or installing it, especially the sealing surface (E). See Fig. 34. If the sealing surface is damaged, the entire fluid tube assembly must be replaced.

5. Install the shroud (2), spray tip (13), air cap (15), tip guard (12), and retaining nut (1) as instructed on page 33. Tighten the retaining nut firmly.

6. Test the gun resistance as instructed on page 28.

7. Install the gun onto the manifold and bracket as instructed on page 41.

Tighten the nut (D) about 1/4 to 1/2 turn past hand-tight; there will be a gap between the nut and barrel; do not over-tighten it.

4. Apply dielectric grease to the entire length of the plastic extension on the end of the fluid tube (18).

See Fig. 34.

5. Apply a low strength thread sealer (such as purple

Loctite r ) to the fluid tube nut (D) threads.

6. Install the fluid tube into the gun barrel by tightening the top fluid tube nut (D) hand-tight, then turn it

1/4 to 1/2 turn with a wrench. See Fig. 33. There will be a gap between the nut and barrel. Do not over-tighten it.

7. Make sure the fluid filter (4) is in place, then tighten the bottom fluid tube nut (C) onto the fluid fitting (3); make sure the top fluid tube nut (D) remains tightened.

8. Install the shroud (2), spray tip (13), air cap (15), tip guard (12), and retaining nut (1) as instructed on page 33. Tighten the retaining nut firmly.

9. Test the gun resistance as instructed on page 28.

10. Install the gun onto the manifold and bracket as instructed on page 41.

D C 4

Fig. 33

03685

Apply low strength (purple) Loctite r or equivalent to the threads.

Apply dielectric grease to the entire length of the fluid tube plastic extension.

Fig. 34

E

D C

18

3

2079

34 308-387

Service

Piston Repair

1. Prepare the gun for service as instructed on page 30.

2. Remove the jam nut (8), actuator arm (19), and adjustment nut (17). See Fig. 35.

3. Push on the piston rod (23g) to push the piston assembly out the back of the gun.

4. Inspect the o-rings (23a, 23b, 23c) and u-cup packing (23f) for damage. See Fig. 37. Refer to

Fig. 38 to isolate any air leakage problems.

5. Lubricate the o-rings (23a, 23b, 23c) and u-cup packing (23f) with petroleum jelly.

6. Align the two stems (23d) with the holes in the gun body and press the piston assembly into the back of the gun until it bottoms.

7.

Installing the Actuator Arm and Nuts: a. Install the adjustment nut (17), actuator arm

(19), and jam nut (8) onto the piston rod (23g).

See Fig. 35.

NOTE: The jam nut (8) has a slightly larger hex and a thinner profile than the adjustment nut (17).

b. Thread the jam nut (8) flush with the end of the piston rod (23g).Tighten the adjustment nut

(17) against the actuator arm (19). When properly assembled, there should be about a 0.125

in. (3 mm) gap between the actuator arm (19) and the fluid packing rod nut (U), which allows the atomizing air to actuate before the fluid actuates. See Fig. 36.

8. Install the shroud (2), spray tip (13), air cap (15), tip guard (12), and retaining nut (1) as instructed on page 33. Tighten the retaining nut firmly.

9. Test the gun resistance as instructed on page 28.

10. Install the gun onto the manifold and bracket as instructed on page 41.

There should be a 0.125 in. (3 mm) gap between the actuator arm (19) and the fluid packing rod nut (U).

19 U

Fig. 36

Apply a very light coat of lubricant to the o-rings (23a, 23b, 23c) and u-cup (23f).

Align the two stems (23d) with the holes in the gun body and press the piston assembly until it bottoms.

Fig. 37

23b

23c

23d

23a

23g

23f

23e

04823

03530

Description Function

O-Ring (23a)

Shaft Air Seal

O-Ring (23b)

Front Air Seal

O-Ring (23c)

Back Air Seal

U-cup (23f)

Cylinder Air

Seal

It seals the cylinder air along the piston rod. If the air leaks along the piston rod

(23g), replace this o-ring (23a).

It is the air shut-off seal. If the air leaks from the air cap when the gun is detriggered, replace these o-rings.

It separates the cylinder air pressure from the atomizing air pressure.

If the air leaks from the small vent hole in the back of the manifold when the gun is triggered, replace the u-cup.

23b

23c

Fig. 35

8 19 17 23g

03628

Fig. 38

23f

23a

308-387

03531

35

Barrel Removal

1. Prepare the gun for service as instructed on page 30.

Service

5. Hold the gun body (29) with one hand and pull the barrel (26) straight away from the body to remove it. See Fig. 41.

2. Disconnect the bottom fluid tube nut (C). See

Fig. 39.

3. Remove the jam nut (8) and actuator arm (19).

4. Loosen the three screws (24) with the ball end wrench (77). See Fig. 40.

CAUTION

To avoid damaging the power supply (27), pull the gun barrel straight away from the gun body. If necessary, gently move the barrel from side to side to free the power supply from the gun body.

29

Fig. 39

26

8 19

C

03628

26

29

Fig. 40

36 308-387

77

24

03238

Fig. 41

27

03239

Service

Fluid Packing Adjustment

If fluid leaks from the fluid needle area, the fluid packings may be loose. Tighten the packings, following the procedure below.

4. Place the 2 mm driver (79) in the back of the fluid needle assembly (28). See Fig. 42. Push the tool in and turn it counterclockwise about 12 full turns to unthread the needle.

1. Prepare the gun for service as instructed on page 30.

5. Insert the 2 mm driver (79) into the front of the gun and push the fluid needle assembly (28) out the back of the gun body.

2. Remove the seat housing (14) with the 9 mm driver (84), supplied. See Fig. 30, page 32. The seat housing (14) must be removed before adjusting the fluid packings.

3. Remove the barrel as instructed on page 36.

CAUTION

To avoid damaging the fluid needle assembly (28), completely unthread the needle before pushing it out of the barrel.

4. Place the 2 mm driver (79) into the back of the fluid needle assembly. See Fig. 42. Push the tool in and turn it clockwise, slightly, to tighten the packings.

6. Apply petroleum jelly or dielectric grease to the new fluid needle assembly (28) and install it into the gun barrel. See Fig. 43.

5. Install the seat housing as instructed on page 32.

6. Assemble the gun as instructed on page 40.

7. Push in on the needle with the 2 mm driver (79) and tighten the assembly clockwise to 4.5–5.0 inlbs (0.5–0.6 N m) [about 1/4 to 1/2 turn past snug].

See Fig. 42.

79

8. Install the seat housing as instructed on page 32.

To tighten packings

9. Assemble the gun as instructed on page 40.

Apply petroleum jelly or dielectric grease to the fluid needle (28).

Tighten the fluid needle with the driver (79-see Fig. 42) to 4.5–5.0

in-lbs (0.5–0.6 N m) [about 1/4–1/2 turn past snug].

To remove needle

Fig. 42

Fluid Needle Assembly Removal

1. Prepare the gun for service as instructed on page 30.

2. Remove the seat housing (14) with the 9 mm driver (84), supplied. See Fig. 30, page 32.

3. Remove the barrel as instructed on page 36.

03241

Fig. 43

28

03242

Service

Power Supply Removal and Replacement

NOTES:

D To avoid a loss in electrostatic performance, inspect the gun body power supply cavity for dirt or moisture. Clean the cavity with a clean, dry rag.

D Do not expose the seal (27d) or o-ring (27a) to solvents as this will damage them.

5. Before installing the power supply, inspect the seal

(27d) for any damage or swelling; replace the seal if necessary. Make sure the gaskets and pads

(27a–27e) are in place.

6. Lubricate the o-ring (25a) and install the power supply in the gun body.

1. Prepare the gun for service as instructed on page 30.

2. Remove the barrel as instructed on page 36.

3. Grasp the power supply (27) with your hand. With a gentle side-to-side motion, being careful not to damage the power supply, pull the power supply free from the gun body (29), then pull it straight out. See Fig. 44.

4. Inspect the power supply for any physical damage.

Test the power supply electrical resistance as instructed on page 28. If necessary, replace the power supply.

7. Assemble the gun as instructed on page 40.

Lower Voltage Setting Adjustment

The kV switch, in the manifold, enables you to switch between full voltage and a lower voltage output. The lower voltage is factory set at 60 kV, but can be adjusted between 45 and 80 kV.

To adjust the low voltage setting, use a small blade end screw driver to turn the potentiometer (W). Turn it clockwise to increase the voltage or counterclockwise to decrease it; fully clockwise is 80 kV, fully counterclockwise is 45 kV.

Apply a very light coat of lubricant to the o-ring (25a).

Do not expose the seal (27d) or gasket (27a) to solvents.

27a

27

27b

W

27e

30

29

27c

26

27d

V

25b

25a

25

03243

Fig. 44

Turbine Alternator Removal and

Replacement

Service

3. Squeeze the two ends of the retaining ring (30) together and carefully pull the alternator (25) away from the power supply (27) until the wire connector

(V) disengages. See Fig. 44.

NOTE: Replace the turbine bearings after 2000 hours of operation. See your authorized Graco representative.

4. Use an ohmmeter to test the turbine alternator coil.

Measure the resistance between the two outer terminals of the 3-wire connector (V). Resistance should be 3 to 5 ohms. If the reading varies from this value, replace the alternator.

1. Prepare the gun for service as instructed on page 30.

5. Connect the 3-wire connector to the 3 prongs in the power supply. Push the alternator (25) onto the power supply (27) until the retaining ring (30) engages with the alternator.

2. Remove the power supply from the gun body as described on page 38.

6. Assemble the gun as instructed on page 40.

308-387 39

Service

Barrel Installation

1. Be sure the gaskets (11, 27a) and spring (20) are in place. See Fig. 45. Replace the parts if they are damaged.

4. Make sure the fluid filter (4) is in place, then tighten the bottom fluid tube nut (C) onto the fluid fitting (3); make sure the top fluid tube nut (D) remains tightened.

2. Place the barrel (26) over the power supply (27) and onto the gun body (29). Make sure the fluid needle spring (20) is seated properly.

3. Pressing the barrel and handle together, tighten the three screws (24) oppositely and evenly to 18 in-lbs (2 N m) maximum (about a half turn past snug), using the ball end wrench (77); do not overtighten.

5. Install and adjust the actuator arm (19) and jam nut (8) onto the piston rod (23g) as instructed on page 35.

6. Install the shroud (2), spray tip (13), air cap (15), tip guard (12), and retaining nut (1) as instructed on page 32. Tighten the retaining nut firmly.

CAUTION

To avoid damaging the gun, do not over-tighten the screws (24). Tighten them to 18 in-lbs (2 N m) maximum (about a half turn past snug), using the wrench (77) supplied.

7. Test the gun resistance as instructed on page 28.

8. Install the gun onto the manifold and bracket as instructed on page 41.

Tighten the screws (24) to 18 in-lbs (2 N m) maximum (about half turn past snug), using the wrench (77) provided.

29

11

27

27a

24

26

D

20 C

8

19

4

23g

17

3

03240

Fig. 45

40 308-387

Service

Install the Gun onto the Manifold and

Mounting Bracket

1. Remove the retaining nut (1), tip guard, (12), air cap (15), spray tip (13), and gun shroud (2). See

Fig. 46.

2. Make sure the gaskets (108, 121) and spring (105) are in place on the manifold (101). Inspect the parts for damage and replace them as needed.

4. Connect the fluid hose to the fluid inlet fitting

(3– marked P1 on the manifold). Use an open end wrench to hold the fluid fitting hex and prevent it from turning.

5. Secure the gun (B) to the mounting bracket (102) by tightening the screw (21) with the ball end wrench (77).

6. Slide the shroud (2) over the gun.

3. Secure the gun (B) to the manifold (101) by tightening the three screws (106) with the ball end wrench (77– not shown).

7. Install the spray tip (13), air cap (15), tip guard

(12), and retaining nut (1) as instructed on page

32. Tighten the retaining nut firmly.

B

121

108

105

106

101

2

1, 12, 13, 15

102

3

21

03626

Fig. 46

Item 23 includes 23a–23g

Item 25 includes 25a & 25b

Item 27 includes 27a–27e

9

2

12

15

Spray Gun Parts

24

26

13

13a

14

26a

27e

1

15a

27b

11

REF 18

27c

30

25b

25

25a

28

27

75

See page 45 to order parts 27a

27d

23b

23c

23d

23f

23e

19

17

8

6

7

20

23a

29

23g

10

21

4

3

18

03244

Spray Gun Parts

WARNING

EQUIPMENT MISUSE HAZARD

Use only genuine Graco replacement parts. Some

PRO AA5500 gun parts look similar to other PRO gun parts but they have different part numbers and they are not interchangeable. Use of parts other than those specified in the parts list below could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction, which could result in a fire, explosion, electric shock, or injection injury.

17

18

19

20

21

1

2

3

7

8

4

6

9 {

10

11 {

12

13

Part No. 236–688 Spray Gun Assembly

Includes items 1–84

Ref.

No.

Part No.

Description

13a

14

15

15a

Qty.

189–768

189–770

189–366

RETAINING NUT, air cap

SHROUD

FLUID FITTING

205–264 FLUID FILTER

189–367 CAP, exhaust

185–122 MUFFLER/FLAME ARRESTOR

101–324 NUT, hex jam; 1/4”–20

110–492 O-RING;

108–290 SCREW

PTFE r

185–113 GASKET, gun body; polyethylene

188–479 TIP GUARD

GG3–XXX SPRAY TIP, customer choice; Includes item 13a; See pg. 45 to order

1

1

183–459

235–797

S SEAL, spray tip

SEAT HOUSING

235–947 AIR CAP & ELECTRODE ASSY.;

1

1

1

1 Includes item 15a

188–676 S ELECTRODE; Order Electrode Kit, part no. 236–001, to receive

5 electrodes

102–025 NUT, hex; 1/4”-20

235–843 FLUID TUBE ASSY.

186–766 ARM, actuator

112–691 SPRING, compression

112–689 SCREW, socket; 1/4 x 0.75”

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Ref.

No.

Part No.

Description

23 236–826 PISTON ASSY;

27c

27d

27e

28

29

30

37

23a { 111–508

23b { 111–504

S

S

Includes items 23a–23g

O-RING; fluoroelastomer

O-RING; fluoroelastomer

23c { 112–319 S O-RING; fluoroelastomer

23d

23e

189–355 S STEM, piston

189–747 S PISTON

23f { 189–752 S PACKING, u-cup; UHMW polyethylene

23g

24

25

26

26a

27

189–754 S ROD, piston

185–096 SCREW, cap, relieved; M5 x 0.8

222–319 ALTERNATOR, turbine

Includes items 25a & 25b

25a { 110–073 S O-RING; Viton

25b 185–124 S CUSHION

235–827 BARREL, gun; Includes item 26a

27a

27b

111–261 S CONTACT RING, barrel

224–093 POWER SUPPLY ASSY; 85 kV

Includes items 27a–27e

186–840 S GASKET, power supply

185–099 S PAD

185–145 S PAD

186–637 S SEAL

185–141 S CUSHION

235–798 FLUID NEEDLE ASSY.

190–055 BODY, gun

185–114 RETAINER RING, alternator

112–638 FITTING, fiber optic (shown on page 44)

75

76 }

77 }

236–832 MANIFOLD ASSY.

See separate parts list on page 45

187–421

107–460

WRENCH, nozzle

WRENCH, ball end

78 }Y 180–060 SIGN, warning, English

79 } 112–080 DRIVER, socket head, 2 mm

80 }Y 222–385 WARNING CARD

81 }Y 179–791 TAG, warning

82 }

83

84

189–888

217–115

110–087

COVER, gun

GREASE, dielectric

DRIVER, hex nut, 9 mm

Qty.

1

1

1

3

2

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

{ These parts are included in Air Seal Repair Kit 236–827, which may be purchased separately .

} These parts are not shown in the parts drawing.

Y Replacement Danger and W arning labels, tags and cards are available at no cost. French, German, and Spanish warning signs are also available.

308-387 43

108

121

101

Manifold Parts

106

110

123

122

111

109

113

119

106

105

107

37

115

114

102

104

103

Front View

Ref. 101

& 102

03462

Apply low strength (purple) Loctite r or an equivalent sealant to the threads.

Press fit the spring (105)

Tighten the fitting until the hex bottoms against the manifold.

This fitting (113) has left-hand threads.

Install the kV cap (111) flush to the outside surface.

Concave side of the disk (114) faces toward the manifold.

Replace the spring (122) every 300,000 cycles.

An optional fiber optic fitting (37) is included with the gun assembly; see page 43. Remove the plug (115) and install the fitting (37) if a kV display is being used.

116

Back View

112

03629

44 308-387

Manifold Parts

WARNING

EQUIPMENT MISUSE HAZARD

Use only genuine Graco replacement parts. Some

PRO AA5500 gun parts look similar to other PRO gun parts but they have different part numbers and they are not interchangeable. Use of parts other than those specified in the parts list below could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction, which could result in a fire, explosion, electric shock, or injection injury.

Part No. 236–852 Optional Fiber Optic Kit

The kit is not included with the gun. The kit is only for use with the ES Display Part No. 224–117 to improve light transmission when two bulkhead splices are used.

The kit includes items 201–203.

Ref.

No.

Part No.

Description Qty.

201

202

203

112–638 FITTING, fiber optic; see item 37 on page 44

111–224 LENS

189–875 SLEEVE

1

1

1

Part No. 236–832 Manifold Assembly

Includes items 101–123

Ref.

No.

Part No.

Description

101

102

103

104

190–057 MANIFOLD

189–581 MOUNTING BRACKET

110–465 BOLT, square head

112–689 SCREW; 1/4–20 x 0.75”

105

106

112–640 SPRING, compression

186–846 BOLT, manifold; M5 x 0.8

107 111–157 FITTING, tube; for 1/4” OD tube

108 { 189–363 GASKET, manifold

109

110

111

108–290

236–696

189–365

SCREW; 8–32 x 1/4” kV SWITCH kV CAP

112

113

114

115

116

119

110–078 FITTING, tube; for 3/8” OD tube

186–845 FITTING, turbine; 1/4–18 npsm left hand thread

107–107 REGULATOR, disk

112–645 PLUG; 1/8–27 npt

112–646 PLUG; 5/8–18 x 5/8”

112–678 PLUG; 1/4 npt

121 {} 190–301 GASKET, foam

122 112–641 SPRING

123 { 111–316 O-RING, fluoroelastomer

Qty.

2

1

1

3

1

1

3

2

2

1

1

1

1

1

1

1

1

1

1

1

203

202

* These parts are included in Fluid Seal Repair Kit 236–828, which may be purchased separately .

{ These parts are included in Air Seal Repair Kit 236–827, which may be purchased separately .

} Optional gaskets are available:

Part No. 111–180: Viton r

Part No. 111–333: Ethylene Propylene

Spray Tip Selection Chart

Part No.

GG3–107

GG3–207

GG3–307

GG3–209

GG3–309

GG3–409

GG3–211

Fan Width at 10 in.

(260 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)

Orifice Size in. (mm)

0.007 (0.178)

0.009 (0.229)

0.011 (0.279)

GG3–311

GG3–411

GG3–511

GG3–611

GG3–213

GG3–313

GG3–413

GG3–513

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)

04798

0.013 (0.330)

308-387 45

GG3–613

GG3–215

GG3–315

GG3–415

GG3–515

GG3–615

GG3–217

GG3–317

GG3–417

GG3–517

GG3–617

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)

0.015 (0.381)

0.017 (0.432)

Part No.

GG3–319

GG3–419

GG3–519

GG3–619

GG3–719

GG3–421

GG3–521

GG3–621

GG3–721

GG3–821

GG3–423

GG3–523

GG3–623

GG3–723

GG3–823

GG3–425

GG3–525

GG3–625

GG3–725

GG3–825

Fan Width at

10 in. (260 mm) in. (mm)

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 (250–350)

12–14 (300–350)

14–16 (350–400)

16–18 (400–450)

Orifice Size in. (mm)

0.019 (0.483)

0.021 (0.533)

0.023 (0.584)

0.025 (0.635)

46 308-387

Technical Data

Weight (gun & manifold) . . . . . . . . . . . . 3.57 lb (1620 g)

Maximum Working Pressures

Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid . . . . . . . . . . . . . . . . . . . . . . .

100 psi (7 bar)

3000 psi (207 bar)

Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–85 kV

Short Circuit Current Output

Paint Resistivity Range

. . . . . . . . . . . . . . . .

. . . . .

120 m A

3 megohm-cm to infinity

Maximum Fluid Temperature

Turbine Air Inlet

. . . . . . . . . .

. . . . . . . . . . . . .

120 _ F (49 _ C)

1/4 npsm(m), left hand

Wetted Parts . . . . . . Stainless Steel, Nylon, Ultra High

Molecular W eight Polyethylene,

PEEK, Tungsten Carbide

Maximum Noise Level with fan and atomization air at

100 psi (7 bar):

Sound Pressure {

Sound Power }

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

97.0 Db(A)

107.0 Db(A)

{ Sound pressure was measured per Cagi Pneurop, 1969.

The measurement was taken 3.28 feet (1 meter) from the air cap.

} Sound power was measured per ISO–3744, 1981.

PTFE and V iton r are registered trademarks of the

Company.

Loctite r is a registered trademark of the Loctite Corporation.

Manual Change Summary

The following parts have been changed in this manual revison.

Additional Changes:

D Added FM, CSA, and CE marks.

Assembly

Changed

236–688

236–832

Part

Status

Old

New

Old

New

Old

New

Added

Old

New

Ref

No.

23d

23e

23f

37

121

Part No.

Name

106–560

111–508

168–518

111–504

168–110

112–319

112–638

111–180

190–301

O-Ring

O-Ring

O-Ring

F.O. Fitting

O-Ring

Gasket

D Updated drawings and procedures.

D Added 111–180 and 111–333 gaskets as optional replacements for reference no. 121.

D Added Optional Fiber Optic Kit 236–852.

D Added noise levels to Technical Data.

308-387 47

The Graco Warranty and Disclaimers

WARRANTY

Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty,

Graco will, for a period of twelve months or two thousand hours of operation from time of sale, repair or replace any part of the equipment proven 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 time 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, 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 with Graco equipment of 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 claim. 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.

DISCLAIMERS AND LIMITATIONS

The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non–contractual liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. in no case shall Graco’s liability exceed the amount of the purchase price. Any action for breach of warranty must be brought within two (2) years of the date of sale.

EQUIPMENT NOT COVERED BY GRACO WARRANTY

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motor, 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.

Graco Phone Numbers

TO PLACE AN ORDER , contact your Graco distributor, or call Graco: 1–800–367–4023 Toll Free

FOR TECHNICAL ASSIST ANCE, service repair information or answers about the application of Graco equipment, call: 1–800–543–0339 Toll Free

48

Sales Offices: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)

Foreign Offices: Canada; England; Switzerland; France; Germany; Hong Kong; Japan; Korea

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

PRINTED IN U.S.A. 308–387 June 1994, Revised February 1995

308-387

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