Graco 309455C Operation manual

309455C
EN
Instructions/Parts List
Test Fixture, High Voltage
Probe, and kV Meter
For Graco Pro Xp and Pro Xs Electrostatic Spray Guns, to test the electrostatic voltage of
the spray gun, as well as the condition of the turbine alternator and power supply when
disassembled from the gun. For professional use only.
See page 2 for kit part numbers and descriptions.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
TI1877A
Part No. 245277 Shown

Models
2309455C
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Testing the Gun While It is Operating . . . . . . . . . 4
Testing the Turbine Alternator . . . . . . . . . . . . . . 5
Testing the Power Supply Cartridge . . . . . . . . . . 8
Testing the Smart Handle's ES HI/LO Setting . 10
Low Voltage Adjustment
(For PRO Xs Smart Guns Only) . . . . . . . . . 12
Low Voltage Adjustment
(For Pro Xp Smart Guns Only) . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 20
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 20
Models
Part No. 245277
Includes Test Fixture, High Voltage Test Probe, and kV
Meter to test the electrostatic voltage of the spray gun,
as well as the condition of the turbine alternator and
power supply when disassembled from the gun. See
page 16 for parts.
Part No. 236003
Includes High Voltage Test Probe and kV Meter to test
the electrostatic voltage of the spray gun. See page 16
for parts.

Warnings
309455C 3
Warnings
WARNING
Fire, Explosion, and Electric Shock Hazard
Equipment misuse can cause the equipment to malfunction and cause a fire, explosion, or electric
shock, resulting in death or serious injury. Improper grounding, poor air ventilation, open flames, or
sparks can cause a hazardous condition and result in a fire, explosion, or electric shock.
• This equipment is for professional use only.
• Read all manuals, tags, and labels before operating the equipment.
• Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements in this manual.
• Use the equipment only for its intended purpose. If you are uncertain, call your Graco distribu-
tor.
• Do not alter or modify equipment. Use only genuine Graco parts and accessories.
• Check the equipment daily. Repair or replace worn or damaged parts immediately.
• Only use the probe to test direct negative current (DC) electrostatic voltage.
• Only use this equipment to test Graco Pro Xs Electrostatic Gun Models. Never use it to test
“stiff” or “hot” systems.
• Always ground the fixture, probe, and kV meter as described in this manual.
• Ground or remove all metal and conductive objects, including tools, from the test area.
• Never touch the probe above its handle while testing.
• Never use the fixture to test the gun turbine alternator or power supply in a hazardous location.
• Never test the power supply without the probe shroud installed.

Operation
4309455C
Operation
Testing the Gun While It is
Operating
NOTE: The maximum voltage read by the kV meter and
probe may be less than the rated voltage of the gun or
power supply that you are testing. This is due to voltage
losses that are intrinsic to the measurement of high volt-
age in air. These losses include current draw through
the probe and meter and also the inability to capture
100% of the electrons being emitted by the gun elec-
trode.
1. Connect the probe’s red wire (D) to the kV meter (2)
and its green/yellow ground wire (C) to a true earth
ground (B). See FIG. 1.
2. Connect the kV meter’s green/yellow ground wire
(6) between the kV meter (2) ground connection and
a true earth ground (B).
3. Holding onto the probe (3) handle, touch the end of
the probe to the spray gun electrode (A). Move the
end of the probe slightly until the maximum kV read-
ing is obtained.
4. Read the voltage on the kV meter (2). Refer to
Table 1 for your gun model.
NOTE: When the kV meter (2) is not in use, place a
jumper wire across the kV meter connectors to prevent
excessive needle movement.
Fig. 1. Testing the Gun While It is Operating
WARNING
Pressurized Equipment Hazard
Before testing the gun, follow the Pressure
Relief Procedure in your gun manual to
reduce the risk of fluid injection or splashing
of fluid in the eyes or on the skin.
Table 1: Typical Gun Voltage Readings in Air
Gun Model Voltage
(kVdc)
Pro Xs2 15-25
Pro Xp 40 35-45
Pro Xs3 and
Pro Xp 60 55-65
Pro Xs4 and
Pro Xp 85 75-85
TI1878A
2
D
C
B
6A
3

Operation
309455C 5
Testing the Turbine Alternator
1. Remove the turbine alternator from the power sup-
ply as instructed in the spray gun manual. Bring the
equipment to a non-hazardous location to do the
testing.
2. Visually inspect the turbine alternator (L). See FIG.
2. If any of the holes (R) are plugged, unplug them.
If excess wear appears on the alternator bearings or
shaft, replace or rebuild the alternator. See Acces-
sories to order a Turbine Alternator Repair Kit.
Fig. 2. Turbine Alternator
3. Place the 3-pin connector (J) through the side win-
dow (M) and connect it to the turbine alternator con-
nector (K). The orientation of the 3-pin connector
does not affect the test. See FIG. 3.
4. Lubricate the alternator o-ring with non-silicone
grease, Part No. 111265. Do not over-lubricate.
NOTE: For Pro Xp alternators, insert the spacer
(22) into the fixture (H) before inserting the alterna-
tor (L).
5. Place the turbine alternator (L) inside the fixture (H),
with the slot (G) facing the side window (M). Use the
alignment tool (21) to push the alternator into the
housing cavity. Tighten the top locking screw (8)
until the screw extends past the alternator tab.
6. Connect the probe shroud (16) to the fixture (H) with
the screw (17).
WARNING
Sound Hazard
To reduce the risk of hearing loss or damage, always
wear hearing protection when operating the turbine
alternator.
CAUTION
To avoid demagnetization of the alternator, never
place it close to another alternator or any other ferro-
magnetic objects.
WARNING
Fire, Explosion, and Electric Shock Hazard
To reduce the risk of fire, explosion, or elec-
tric shock, which can result in serious injury
and property damage, never use the Graco
Pro Xs and Pro Xp Test Fixture to test the
gun turbine alternator or power supply in a
hazardous location.
TI1887A
L
R

Operation
6309455C
Fig. 3. Install Turbine Alternator in Fixture
TI1879B
L
JKM
H
8
16
17
G
21
For Pro Xs Guns
L
JK M
H
8
16
17
G
21
For Pro Xp Guns
22
TI1879C
1
Spacer (22) is for use with Pro Xp alternators only.
1

Operation
309455C 7
7. Connect the fixture’s grounding clamp (12) to a true
earth ground (B). See FIG. 4.
8. Connect an air line (E) to the fixture. Set the air
pressure to 26 psi (1.8 bar, 0.18 MPa).
9. Measure the turbine alternator AC voltage output
with a voltmeter (N), measuring across the fixture
terminals (9) as shown in FIG. 4.
NOTE: To measure frequency and voltage, you
need a multimeter. See Accessories.
The turbine alternator voltage should read in the
range shown in Table 2 . If the readings vary from
these values, replace the alternator or rebuild it. See
Accessories to order an Alternator Repair Kit.
10. Remove the probe shroud (16).
11. Disconnect the 3-pin connector (J) and loosen the
locking screw (8). Use the plunger (F)on the back of
the fixture to push out the turbine alternator.
12. Test the alternator coil by measuring the resistance
between the two outer terminals of the 3-pin con-
nector (K) with a multimeter. The resistance should
be 2.5-3.5 ohms.
Measure the resistance between each outer termi-
nal of the 3-pin connector and the exterior of the tur-
bine alternator (L). The resistance should be greater
than 400 ohms.
If the readings vary from these values, replace the
alternator coil.
Fig. 4. Testing the Turbine Alternator
Table 2: Turbine Alternator Voltage
Gun Model Frequency (Hz) Voltage (V)
All Pro Xs Models 625 Hz maximum 6.4 V minimum
All Pro Xp Models 575 Hz maximum 6.4 V minimum
TI1880A
TI1886A
Back View of Test Fixture
Ground clamp (12)
wire connection to test
fixture
F
E9
B12
N
16

Operation
8309455C
Testing the Power Supply
Cartridge
NOTE: You do not use the fixture's 3-pin connector (J)
to test the power supply cartridge.
1. Remove the power supply cartridge from the gun as
instructed in your spray gun manual and bring the
equipment to a non-hazardous location to do the
testing.
2. Lubricate the alternator o-ring with non-silicone
grease, Part No. 111265. Do not over-lubricate.
3. Install the power supply cartridge (P) into the fixture
(H), orientated as shown in FIG. 5. Note that for Pro
Xp guns, the cartridge must be rotated 15 degrees.
Push the cartridge into the fixture until the alternator
bottoms out in the cavity. Tighten the screw (8) until
snug. Do not overtighten.
4. Secure the shroud (16) to the fixture (H) with the
screw (17).
5. Lubricate the probe o-ring (5) to ease insertion into
the shroud.
6. Insert the probe (3) into the shroud (16) and touch
its tip to the end of the power supply.
7. Connect the probe's red wire (D) to the kV meter
and its green/yellow ground wire (C) to a true earth
ground (B). See FIG. 6.
8. Connect the kV meter's green/yellow ground wire
(6) between the kV meter and a true earth ground.
9. Connect the fixture's grounding clamp (12) to a true
earth ground.
10. Connect an air line (E) to the fixture. Set the air
pressure to 30 psi (0.21 MPa, 2.1 bar).
11. Read the power supply cartridge voltage output with
the kV meter. See Table 3 for typical readings.
WARNING
Fire, Explosion, and Electric Shock Hazard
To reduce the risk of fire, explosion, or elec-
tric shock, which can result in serious injury
and property damage:
•Never use the Graco Pro Xs Test Fixture to
test the gun turbine alternator or power
supply in a hazardous location.
•Never test the power supply without the
shroud (16) installed.
Table 3: Typical Power Supply Voltage Readings
with Test Fixture
Gun Model Voltage
(kVdc)
Pro Xs2 15-25
Pro Xp 40 35-45
Pro Xs3 and
Pro Xp 60 55-65
Pro Xs4 and
Pro Xp 85 75-85

Operation
309455C 9
Fig. 5. Install Power Supply in Fixture
Fig. 6. Testing the Power Supply
TI1881A
16
P
8
H
35
17
8
H
35
P
17 16
For Pro Xp Guns For Pro Xs Guns
TI1882A
TI1886A
Back View of Test Fixture
Ground clamp (12)
wire connection to
test fixture
E
2D
C
B
6
12

Operation
10 309455C
Testing the Smart Handle's ES
HI/LO Setting
NOTE: To test a Pro Xp gun smart handle, drill out the
gun air valve shaft hole (H) to 1/4 in. diameter. See
Detail A of FIG. 7.
1. Use the ES HI/LO switch on the back of the gun to
change the power supply output to either high volt-
age or low voltage setting. See Detail A of FIG. 7.
2. Connect the flexible circuit test adapter (20) to the
flex circuit (S) on the power supply cartridge (P).
Thread the connected circuits through the side win-
dow (M) of the fixture and connect to the smart han-
dle.
NOTE: To ensure the correct pin connections, make
sure there are no twists in the flexible cables.
3. Mount the smart handle (T) loosely to the fixture.
See Detail B.
4. Tighten the smart handle screws (U) to the fixture.
See Detail C.
Fig. 7. Testing the Smart Handle
TI1883A
TI1885A
TI1883A
Detail A: Connect the flexible circuit adapter.
Detail B: Install the smart handle loosely. Detail C: Tighten the smart handle to the fixture.
ES HI/LO Switch
20 M
SP
T
U
H
1
To test a Pro Xp gun smart handle,
drill out the gun air valve shaft hole
(H) to 1/4 in. diameter.
1