Graco Gun Flush Box Module Operation manual

309227M
EN
Instructions-Parts List
Gun Flush Box
Module
Automated flushing system for manual spray guns.
For use with Graco proportioning systems.
For professional use only.
Part No. 244105
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual before using this equipment. Save
these instructions.
II 2 G Ex h IIB T6 Gb

2309227M
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
How the Gun Flush Box Works . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 8
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install the Gun Holder . . . . . . . . . . . . . . . . . . . . 10
Enclosed Waste Container . . . . . . . . . . . . . . . . 11
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connect Tubing to the Pneumatic Controls . . . . 12
Trigger Height Adjustment . . . . . . . . . . . . . . . . . . 13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Proportioner Controller Operation . . . . . . . . . . . 14
Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 14
Operating Instructions . . . . . . . . . . . . . . . . . . . . 15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 24
Related Manuals
Manual Description
312784 Gun Flush Box Kit for 2KS, 2KE, and
PD2K Proportioner systems

Warnings
309227M 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent
flowing through the equipment can cause static sparking. To help prevent fire, explosion, and electric
shock:
• Ground all equipment in the work area. See Grounding instructions.
• Only use grounded Graco conductive air supply hoses.
• Do not use pail liners unless they are conductive and grounded.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Use and clean equipment only in well ventilated area.
• Control flush pressures to less than 300 psi (2 MPa, 21 bar) to reduce material flow velocity and
reduce the static buildup that can occur with certain material chemistries.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static sparking).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep work area free of debris, including solvent, rags and gasoline.
• Keep a working fire extinguisher in the work area.
Electrostatic Gun Precautions
• Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements of this manual.
• Check gun resistance, hose resistance, and electrical grounding daily.
• Always turn the electrostatics off when flushing, cleaning or servicing equipment.
• Do not flush the system with the gun electrostatics turned on.
• Interlock the gun turbine air supply to prevent operation of the power supply during flushing.
• Do not turn on the gun electrostatics until all solvent is purged from the system.
• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment.
• Never spray or flush solvent at high pressure.
• To clean the exterior of the equipment, cleaning solvents must have a flash point at least 15°C
above ambient temperature. Non-ignitable fluids are preferred.

Warnings
4309227M
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause
serious injury.
• Follow the Pressure Relief Procedure in your system manual when you stop spraying/dispensing
and before cleaning, checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
• Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-
ponent. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request Safety Data Sheet (SDS) from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read Safety Data Sheet (SDS) to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
WARNING

Warnings
309227M 5
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in your system manual and disconnect all power sources.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not
limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

Introduction
6309227M
Introduction
How the Gun Flush Box Works
When used with a Graco proportioner system, the Gun
Flush Box (GBB) operates with a controller to
automatically flush manual guns into an enclosed waste
container.
The Gun Flush Box controller flushes the exact amount
of solvent required to clean the system. It also reduces
VOCs by preventing solvent from being atomized during
the flush cycle.
The Gun Flush Box prevents accidental gun triggering
with safety interlocks.
The interlocks will only allow atomizing air to the gun
when the gun is out of the Gun Flush Box and the lid of
the box is closed. If a switch fails or if system air is shut
off, atomizing air to the gun will be shut off.
When using an electrostatic gun, the Gun Flush Box
interlocks turn off atomizing air to the gun and ensures
the gun electrostatic turbine will be off when the
operator starts flushing.

Introduction
309227M 7
Component Identification
FIG. 1: Component Identification (Gun Flush Box)
Ref. Description Ref. Description
A Latch Knobs: Press the two knobs together to
open or close the GFB lid.
E Pneumatic Fittings: Four push-in tube fittings
connect the GFB to the proportioner system.
B Lid: Close the spring-loaded lid to secure the
gun inside the GFB or to place the system in a
spray-ready state. The lid must be closed to
send atomizing air to the spray gun.
F Trigger Cylinder Block and Arm: When the
proportioner begins flushing or filling, two
pneumatic cylinders extend to trigger the gun
inside the GFB.
C Pneumatic Limit Switches: Position of the two
switches indicates to the proportioner whether
the lid is open or closed and, if closed,
whether a gun is inside the GFB.
G Gun Holder (not included): Correctly positions
the gun inside the GFB. Order the gun holder
matching the gun being used.
D Grounding Clamp: Use to connect the GFB to
a true earth ground.
AB
C
G
E
F
D
C

Installation
8309227M
Installation
Typical Installation
Refer to the typical installation drawing in FIG. 2 page 9,
as a guide for installing the Gun Flush Box. Contact your
Graco distributor for an actual system design.
Ventilation
Location
Locate the Gun Flush Box in a properly vented spray
booth, in an area easily accessible to the operator and
away from the spray or application point, to help avoid
getting over-spray on the box.
TOXIC OR FLAMMABLE FUMES HAZARD
To avoid hazardous concentrations of flammable or
toxic fumes:
• Install the Gun Flush Box in a properly ventilated
spray booth.
• Electrically interlock the Gun Flush Box air supply
with the ventilating fans to prevent the box from
operating when ventilating fans are not operating.
• Never operate the Gun Flush Box unless ventila-
tion fans are operating.
• Follow all local codes and regulations regarding air
exhaust velocity requirements.

Installation
309227M 9
Typical Installation
FIG. 2: Typical Installation
Air Supply Station
(Customer Supplied)
Ventilation Interlock Valve
(Customer Supplied)
Proportioner
(Sold
Separately)
Spray Gun (Sold
Separately)
Fluid Supply
to Gun
Atomizing Air
Shutoff Valve
(Sold Separately)
Gun
Flush
Box
Waste
Container
(Customer
Supplied)
Main Air Inlet
(Customer Supplied)
S
C
A
P

Installation
10 309227M
Mounting
The Gun Flush Box can be wall, stand, or drum mounted in
the spray booth. Install the Gun Flush Box(es) using the
mounting holes as a template. See FIG. 3 for dimensions.
Make sure the mounting surface will withstand the weight
of the Gun Flush Box, hoses, and the stress of operation.
Install the Gun Holder
The correct gun holder is necessary to operate the Gun
Flush Box. Use the gun holder that matches the spray
gun to be used.
1. Order the correct gun holder for your gun. See
page 20.
2. Remove the two screws and washers (41, 8)
holding mounting bracket (40) to the right–hand side
of the Gun Flush Box. See FIG. 4 or FIG. 5.
3. Install the gun holder (GH), aligning its mounting
holes with the holes in the mounting bracket (40)
and the side of the Gun Flush Box. Attach using the
screws and washers (41, 8).
FIG. 3: Mounting Dimensions
14 in.
(356 mm)
9 in.
(229 mm) Width: 9 in.
(229 mm)
FIG. 4: Gun Holder Installation (Pro Xs3 and Xs4
Guns)
FIG. 5: Gun Holder Installation (Pro Xp 60kV Gun)
For Pro Xs3 and Pro Xs4 Guns,
install 198405 Gun Holder with
appropriate gun name facing
forward.
40
GH (198405 shown)
PROXS4
41,8
PROXS3
For the Pro Xp 60 kV Gun, install
24N528 Gun Holder with the
deeper section facing forward.
40
GH (24N528 shown)
41,8

Installation
309227M 11
Enclosed Waste Container
Connect the longest possible section of straight plastic
or grounded metal pipe (P) between the Gun Flush Box
fluid outlet (O) and an enclosed metal waste container
(W). See FIG. 6.
Grounding
Gun Flush Box: Connect a ground wire to the
grounding lug on the box. Connect the ground clamp to
a true earth ground. Refer to FIG. 7.
Waste Container: Connect a ground wire and clamp
between a metal waste container and a true earth
ground.
Spray Gun: See your gun instruction manual.
Flammable Liquids in the spray area must be kept in
approved, grounded containers.
To reduce the risk of splashing and static generation,
a minimum of two feet (0.6 m) of straight plastic or
grounded metal pipe must be connected between the
Gun Flush Box and an enclosed waste container for
the solvent.
FIG. 6: Enclosed Waste Container Requirements
Gun
Flush
Box
O
W
Waste
Container
P
To reduce the risk of fire, explosion, or electric shock,
the system must be properly grounded.
• Follow the warnings starting on page 3.
• Ground the Gun Flush Box and waste container as
instructed below.
• Ground your system as instructed in the system
manual.
FIG. 7: Grounding Lug

Installation
12 309227M
Connect Tubing to the Pneumatic Controls
FIG. 8 shows the bottom of the Gun Flush Box. The four
pneumatic fittings are labeled:
P = Supply air in
A = Output air signal: Air signal "on" when the gun is in
the box and the lid is closed.
C = Inlet air for gun trigger cylinder (activates the gun
trigger inside the GFB)
S = Output air signal to atomizing air shutoff valve: Air
signal is “on” when there is no gun in the box and the lid
is closed.
1. Connect a 5/32” (4 mm) OD tube from the user-
provided air supply to the Pfitting. Use a clean, dry
air supply; filtered to 10 microns.
2. Connect a 5/32” (4 mm) OD tube between the A
fitting and the return air input on the controller.
3. Connect a 5/32” (4 mm) OD tube between the C
fitting and the gun trigger solenoid output on
the solenoid box or the Gun Flush Box control box.
4. Connect a 5/32” (4 mm) OD tube between the S
fitting and the atomizing air safety shutoff valve pilot
port.
FIG. 8: Gun Flush Box Bottom View and Pneumatic
Fittings

Trigger Height Adjustment
309227M 13
Trigger Height Adjustment
Follow this procedure to ensure the gun triggers
properly during use.
1. Insert the gun into the gun holder, inside the Gun
Flush Box.
NOTE: If using a Pro Xp™Smart Gun model, the gun
must be rotated to clear the hinge spring during insertion
and removal.
2. Remove the four screws (9) that hold cover (5) to
the Gun Flush Box. See FIG. 9.
3. Force the cylinder triggers on by connecting air to
port C. Turn on the air to extend cylinder buttons
(31) and (35).
4. Loosen both screws (26) on the side of the box that
holds the cylinder block (28). See FIG. 10.
5. Raise cylinder block (28) until pin (35) opens the
trigger fully. See FIG. 10.
6. Tighten both screws (26) at the desired location for
cylinder block (28).
FIG. 9: Gun Flush Box Cover and Air Fittings
“C”
5
9
FIG. 10: Setting the Trigger Height
35
26
31
28

Operation
14 309227M
Operation
Proportioner Controller Operation
See your system manual for operation instructions.
Operating Checklist
Check the following list daily, before starting to operate
the system.
____ 1. Operators are trained to operate the system.
____ 2. If using electrostatics, operators are trained to
turn off the electrostatics (Z) before placing the
spray gun in the Gun Flush Box. See FIG. 11.
____ 3. The system is grounded, and the operator and
all persons entering the spray area are
properly grounded. See Grounding, page 11.
____ 4. Ventilation fans are operating properly.
____ 5. All debris, including rags, and non-essential
equipment, is removed from the spray area.
____ 6. All flammable liquids in the spray booth are in
approved, grounded containers.
____ 7. All electrically conductive objects in the spray
area, including paint containers, Gun Flush
Boxes, and wash cans, are grounded and the
floor of the spray area is electrically conductive
and grounded.
To reduce the risk of fire, explosion, or electric shock:
• Keep fluid pressure below 300 psi (2 MPa, 21
bar).
• For Electrostatic Guns:
- Turn off the electrostatics before placing the
gun in the Gun Flush Box and whenever you
stop spraying.
- In multiple gun systems, each gun must be
used only with its corresponding Gun Flush
Box for the interlocks to work. For example:
With a two gun system, placing gun #1 into
Gun Flush Box #2 will shut off the atomization
air for gun #2 and leave the atomization air on
for gun #1 during use.
FIG. 11: Turn Electrostatics Off Before Flushing
Z

Operation
309227M 15
Operating Instructions
1. If using an electrostatic gun, turn off the electrostat-
ics.
2. Insert the gun into the gun holder, inside the Gun
Flush Box.
3. Press the two spring-loaded latch knobs (11) inward
and close the Gun Flush Box lid.
NOTE: GFB interlock switches prevent filling or flushing
unless the gun is in the gun holder and the GFB lid is
closed.
4. Follow the instructions in your proportioner Opera-
tion manual or your control box manual to fill the gun
with paint or to flush solvent through the gun.
5. When the filling or flushing process is complete,
open the Gun Flush Box lid and remove the gun.
6. Close the Gun Flush Box lid.
See the following chart for a summary of Gun Flush Box
functions when using with a Graco proportioner.
Opening and closing the Gun Flush Box lid could
pinch or cut fingers or other body parts. Be careful
when pressing or releasing the latch knobs and keep
clear of the closing lid.
GFB
Lid
Gun in
GFB? Atomizing Air Status
Port A
Pressure?
Port S
Pressure?
Open Yes Locked out by safety shutoff valve No No
Open No Locked out by safety shutoff valve No No
Closed Yes Locked out by safety shutoff valve Yes No
Closed No Supplied to gun No Yes

Maintenance
16 309227M
Maintenance
Daily Weekly Every two weeks,
minimum
Gun Flush Box
Enclosure
Keep the inside as clean as
possible. Clean with a
compatible solvent.
Clean the inside and outside
of the enclosure with a
compatible solvent.
Lid Keep hinge holes as clean
as possible.
Grease hinges.
Cylinders Pull the cylinder rod forward
and coat with grease or
petroleum jelly.
Switches Clean and lubricate.
Fluid Outlet Pipe Check for buildup of mixed
material and replace if
restricted.

Troubleshooting
309227M 17
Troubleshooting
Problem Cause Solution
Gun is in the Gun Flush Box, but the
system will not purge or mix.
Air is shut off.
Gun switch is not activating.
Operator switch is not wired properly.
Tubing is not installed correctly.
Turn on the air to the system.
Test the switch. Replace if damaged.
Check the I/O to see if the proper
input is activating. Rewire the switch
if necessary.
Check tubing against the typical
installation drawing on page 9.
Gun Flush Box fails to purge after the
pot life time ends.
Gun is not in Gun Flush Box.
Gun switch is not activating.
Place the gun in the Gun Flush Box
when it is not in use.
Test the switch. Replace if damaged.
Gun does not trigger when the Gun
Flush Box controller activates it.
Tubing is not installed correctly.
Cylinder is damaged.
Gun is not properly set in the gun
holder.
Lower cylinder is out of adjustment.
Check tubing against the typical
installation drawing on page 9.
Clean cylinder rod or replace.
Check to make sure the gun holder is
not obstructed by buildup.
Adjust the cylinder block as
instructed in Trigger Height
Adjustment procedure on page 13.
Gun is out of the Gun Flush Box with
the lid closed but the atomizing air is
off.
Lid switch or gun switch failure.
No air flow to the Gun Flush Box.
Check the switches and replace if
necessary.
Check the air supply and tubing.

Parts
18 309227M
Parts
NOTE: Grease all cylinders and sensors with grease.
Clean threads thoroughly before applying. Use a primer to expedite drying. Apply Loctite®2760 or
equivalent adhesive to female threads. Be careful not to scratch cylinder. Wipe excess adhesive.
Optional Gun Holder shown; not included with assembly. Selection of correct gun holder required
for proper operation.
Install deeper cut portion of adaptor towards the front of the flush box to accommodate trigger, allowing lid to close.
Only applies with 85 kV electrostatic gun.
3
4
5
3
4
5
11
13
12
24
19
22 21 3
12
17
20
23
25
26
18
9
15
48
49
45
46
47
5
54
52
51
50
33
14
7
36
27
1
4
2
6
14
26
7
8
31
30
28
29 50
32
7
55
40
8
41
8
27
42
35 34
20
27
10
27
39
17 38
44 43
3
16
8
23

Parts
309227M 19
--- Item not available separately.
Replacement Danger and Warning labels, tags, and
cards are available at no cost.
Order length needed.
Keep these spare parts on hand to reduce down
time.
Ref. Part Description Qty.
1 196709 PANEL, cabinet, left 1
2 196710 PANEL, cabinet, right 1
3 196711 LID, cabinet 1
4 196712 WRAPPER, cabinet 1
5 626489 COVER, cylinder 1
6 626488 ROD, connecting 4
7 551789 SCREW, cap, 3/8 x 1 8
8 103975 WASHER, lock, 3/8 10
9 551787 SCREW, cap, 10–32 x 0.38 in. 4
10 551788 WASHER, lock, split, #10 4
11 626495 KNOB, latch 2
12 626496 PIN, latch 2
13 116174 SPRING, compression, 3.5 in. 1
14 551891 WASHER, 21/32 ID x 7/8
OD
2
15 196844 SPRING, torsion 1
16 551849 GROMMET, 5/16 ID x 1/2 OD 3
17 196703 SUPPORT, yoke, upper 1
18 196700 YOKE, gun, upper 1
19 196704 SWITCH, flag 1
20 116172 SWITCH, limit, pneumatic 2
21 116173 SPRING, compression, 2.25 in. 1
22 116193 PIN, dowel 2
23 108751 SCREW, cap, socket hd,
5/16 x 0.625 in.
2
24 C19800 SCREW, cap, socket hd, 1/4–20 x
0.5 in.
2
25 112598 SCREW, machine, truss hd, 8–32
x 0.75 in.
2
26 112944 SCREW, cap, button hd,
5/16 x 0.75 in.
4
27 104034 WASHER, plain, 5/16 6
28 626502 BLOCK, cover 1
29 551794 CYLINDER, air, 0.568 in. dia. 1
30 551795 NUT, hex head, 7/16–20 1
31 626504 BUTTON, cylinder 1
32 196708 ARM, lever 1
33551793 CYLINDER, air, 0.438 dia. 1
34 551890 NUT, jam, hex, 3/8–24 1
35626523 BUTTON, small cylinder 1
36 551786 SCREW, cap, 5/16 x 2 1
37 107542 WASHER, lock, split, no. 8 1
38 108946 NUT, hex, 5/16–18 1
39 626517 AXLE, support 1
40 196766 BRACKET, mounting 1
41 116194 SCREW, cap, button hd, 3/8–16 x
2.5 in.
2
42 116195 SCREW, cap, button hd,
8–32 x 1 in.
2
43 157021 WASHER, lock, internal tooth, no.
8
2
44 102931 NUT, machine, hex, 8–32 2
45 C19964 SCREW, cap, 6–32 x 1 in. 1
46 502473 VALVE, air, 4-way, spring return 1
47 501014 ACTUATOR, air, 1/8 npt(f) 1
48 598140 ELBOW, 5/32 tube 1-1/8 npt(m) 3
49 598141 TEE, 5/32 tube x 1/8 npt 1
50 514581 CONNECTOR, 5/32 in. tube x 10–
32
2
51 514896 TEE, 3-way, 5/32 OD (m x f) 1
52 113284 FITTING, pneumatic push-in, M10
x 1 x 5/32 in. tube
4
53 551731 TUBE, 5/32 OD, polyethylene,
white

54 222011 CLAMP, grounding 1
55180233 LABEL, warning, pinch point 2
57 C78216 CLAMP, Ty–Rap 1
58 103473 STRAP, tie; wire 1
Ref. Part Description Qty.

Accessories
20 309227M
Accessories
Gun Holder
* Brand names or marks are used for identification
purposes and are trademarks of their respective
owners.
‡Includes yoke. When using part 24N528 for ProXP
60 kV smart guns, rotate the gun clockwise and
insert the gun into the holder. After the gun is
seated, rotate the gun counter-clockwise so the lid
can be closed.
Part No. Description
198405 Graco Pro™ Xs3, Pro™ Xs4
198787 Graco Pro™ Xs2
196769 Graco Delta Spray™ Gun
196770 Graco Alpha Gun
196771 Graco Alpha Plus, Alpha Plus with RAC Tip
196767 Devilbiss JGA/MSA*
15T646 Graco AirPro™ Gun
15G093 Graco G15 AA Gun
15G346 Graco G40 AA Gun
24N528 ‡ Graco Pro Xp™60 & 85 kV Gun
24N529 Graco Pro Xp™40 kV Gun