Graco PRO AA5500SC User manual

308–937
Rev. D
Supersedes Rev. A
03228
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
AUTOMATIC ELECTROSTATIC
Model PRO AA5500sc/UNICARB
Air-Assisted Spray Gun
100 psi (7 bar, 0.7 MPa) Maximum Working Air Pressure
3000 psi (207 bar, 20.7 MPa) Maximum Working Fluid Pressure
For use with Class I, Group D paint spray materials
Part No. 965721, Series B
Complete Spray Gun: includes spray gun, shroud,
manifold, and mounting bracket
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
UNICARB IS A REGISTERED TRADEMARK OF UNION
CARBIDE, DANBURY CT.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1994, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

2 308937
WARNING
FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire, explosion, or electric shock.
Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements 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 14.
Check the spray gun resistance daily. See Test Gun Resistance, page 29.
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 8.
When cleaning, flushing, or purging electrostatic equipment, use solvents that comply with your
local regulations. For countries following the U.S. National Fire Protection Association (NFPA) 33
requirements, use solvents with a flash point higher than 100F (38 C) or a solvent normally
used in spray operations. For European Countries complying with EN 50053, use solvents with a
flash point as high as possible and higher than the ambient temperatures.
Use only non-sparking tools to clean residue from the booth and hangers.
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.
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.

308937 3
WARNING
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 medi-
cal attention.
Do not point the spray gun at anyone or 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.
This gun differs from other Graco high-pressure electrostatic guns in that there is no diffuser in the
fluid seat. Always follow the Pressure Relief Procedure on page 17 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 usage, call your Graco
distributor.
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 equip-
ment has a 100 psi (7 bar, 0.7 MPa) maximum working air pressure and 3000 psi (207 bar,
20.7 MPa) maximum working 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.

4 308937
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How the PRO AA5500sc/UNICAB Electrostatic
Air-Assisted Spray Gun Operates 5. . . . . . . . . . . . . . . . .
Operating the Spray Function 5. . . . . . . . . . . . . . . . . . . .
Operating the Electrostatics 5. . . . . . . . . . . . . . . . . . . . . .
Switching to the Higher or Lower kV Setting 5. . . . . . . .
Gun Features and Options 5. . . . . . . . . . . . . . . . . . . . . . .
Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the System 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Signs 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilate the Spray Booth 8. . . . . . . . . . . . . . . . . . . . . . . .
Install the Air Line Accessories 10. . . . . . . . . . . . . . . . . .
Fluid Line Accessories 11. . . . . . . . . . . . . . . . . . . . . . . . .
Install the Gun and Mounting Bracket 11. . . . . . . . . . . .
Connect the Air and Fluid Lines
to the Gun Manifold 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Fiber Optic Cable Connection 13. . . . . . . . . . .
Optional Fiber Optic Lens Kit Installation 13. . . . . . . . .
Ground the System 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the Electrical Grounding 15. . . . . . . . . . . . . . . . . .
Install the Fabric Cover 16. . . . . . . . . . . . . . . . . . . . . . . . .
Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 17. . . . . . . . . . . . . . . . . . . . . .
Operating Checklist 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a Spray Tip 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Spray Tip 19. . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Atomization Fluid Pressure 20. . . . . . . . . . .
Activating and Adjusting the Electrostatics 20. . . . . . . .
Activating the kV Switch 20. . . . . . . . . . . . . . . . . . . . . . . .
Spraying 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily Care and Cleaning 21. . . . . . . . . . . . . . . . . . . . . . . .
Flush the Spray Gun 22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the Spray Gun 23. . . . . . . . . . . . . . . . . . . . . . . . . .
Check for Fluid Leakage 25. . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Pattern Troubleshooting 26. . . . . . . . . . . . . . . . . .
Gun Operation Troubleshooting 27. . . . . . . . . . . . . . . . .
Electrical Troubleshooting 28. . . . . . . . . . . . . . . . . . . . . .
Electrical Tests 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Gun Resistance 29. . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Power Supply Resistance 29. . . . . . . . . . . . . . . . . .
Test Barrel Resistance 30. . . . . . . . . . . . . . . . . . . . . . . . .
Service 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools Included with the Gun 31. . . . . . . . . . . . . . . . . . . . .
Prepare the Gun for Service 31. . . . . . . . . . . . . . . . . . . .
Tip Guard, Air Cap, Spray Tip, or Seat
Housing Replacement 33. . . . . . . . . . . . . . . . . . . . . . . . . .
Electrode Replacement 34. . . . . . . . . . . . . . . . . . . . . . . .
Fluid Tube Removal and Replacement 35. . . . . . . . . . .
Fluid Filter Replacement 35. . . . . . . . . . . . . . . . . . . . . . .
Piston Repair 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Barrel Removal 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Packing Adjustment 39. . . . . . . . . . . . . . . . . . . . . . .
Fluid Needle Assembly Removal 39. . . . . . . . . . . . . . . .
Power Supply Removal and Replacement 40. . . . . . . .
Lower Voltage Setting Adjustment 40. . . . . . . . . . . . . . .
Turbine Alternator Removal and Replacement 41. . . . .
Barrel Installation 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install the Gun onto the Manifold
and Mounting Bracket 43. . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Gun Parts 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Parts 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip Selection Chart 51. . . . . . . . . . . . . . . . . . . . .
Pre-orifice Selection Chart 51. . . . . . . . . . . . . . . . . . . .
Technical Data 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Graco Warranty and Disclaimers 54. . . . . . . . . .
Graco Phone Number 54. . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.

308937 5
Introduction
How the PRO AA5500sc Electrostatic
Air-Assisted Spray Gun Operates
(Refer to page 6)
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 2 and 3
and throughout the text of this instruction manual.
The spray tip (B) shapes the fluid into a fan pattern.
The ability of the PRO AA5500 Electrostatic Spray
Gun to spray at higher fluid pressures combined with
the addition of CO2from the UNICARB process pro-
vides the additional power needed to atomize higher
solids materials.
Operating the Spray Function
Applying a minimum of 65 psi (4.5 bar, 0.45 MPa) 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.
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 con-
ductive 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 (V).
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 sur-
faces.
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.
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, 0.35 MPa) 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 40. 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 9.
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 man-
ifold carries the signal from the gun to a remote ES
(electrostatic) display module. See Fig. 2, page 9.
An ES Display Module (GG), P/N 224117, is avail-
able and will display the gun’s spraying voltage and
current. A battery operated ES Display Module
(FF), P/N 189762, is also available; it displays the
gun’s spraying voltage only.

6 308937
Introduction
03228
TA
CYL
A2
03616
AB D E F
G
C
A1
P1
F.O.
EXH
KV
P2
Manifold Back View
H
J
K
04799
KEY
A Air Cap (black 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
Manifold Markings
A1 not used
A2 Not used
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

308937 7

8 308937
Installation
Installing the System
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
Installing and servicing this equipment
requires access to parts which may
cause electric shock or other serious
injury if work is not performed properly.
Do not install or service this equip-
ment unless you are trained and
qualified.
Be sure your installation complies with National,
State and Local codes for the installation of
electrical apparatus in a Class I, Group D
Hazardous Location.
Comply with all applicable local, state, and
national fire, electrical, and other safety regula-
tions.
Fig. 1, page 9, shows a typical Model PRO
AA5500sc/UNICARB system. Fig. 2 shows some
possible system options.
Accessories are available from your Graco representa-
tive. Refer to the Product Data Sheet for the gun,
Form No. 305624. 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 custom-
ized for your application, contact your Graco distribu-
tor.
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. Addi-
tional English, French, German, and Spanish signs are
available at no charge.
Part No. Description
180060 Warning Sign (English)
180061 Warning Sign (French)
180062 Warning Sign (German)
180063 Warning Sign (Spanish)
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.
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 effi-
ciency of the electrostatic system. The minimum
allowable air exhaust velocity is 60 feet/minute (19
linear meters/minute).

308937 9
Installation
Non-Hazardous Area Hazardous Area BASIC SYSTEM
Fig. 1
To FLUID IN-P1 at gun
K
*M
AA*
BB*
S
Z
U*
S
A*R
S
CC
TA
CYL
W
X
P1
**
**
**
**
KV
FLUID IN-P1 V
Q

H
V
Y
From coating/CO2supply equipment
SYSTEM OPTIONS
Spraying Voltage
Display Module
kV
mA
kV
Non-Hazardous Area Hazardous Area
04802
Fig. 2
F.O.
EE
GG HH
KK
X
JJ* 
FF
**
DD

10 308937
Installation
KEY–Fig. 1 and 2
A* Bleed-type Master Air Valve
H Fluid Shut-off Valve
K Pressure Gauge
L* Grounded Fluid Hose with spring guards
M* Fluid Drain Valve
Q Gun Air Pressure Regulator
R Main Air Line
S Solenoid Valve, requires quick-exhaust port*
U* True Earth Ground
V Fluid Hose, 1/4–18 npsm gun fluid inlet
W Mounting Bracket for 1/2 inch (127 mm) rod, P/N 189581
X PRO AA5500sc/UNICARB Spray Gun, P/N 965721
Y Shrouded/Vented waste container
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 12 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 235301
EE 4–20 mA Outputs
FF kV Only ES Display Module (battery operated), P/N 189762
GG Full Feature ES Display Module, P/N 224117
HH Fiber Optic Cable, P/N 224680 to 224686
JJ Bulkhead, P/N 189870
KK Fiber Optic Cable, P/N 224670 to 224676
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 pur-
chased separately.
** See page 12 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:
The fluid supply pump must be prevented
from producing a fluid pressure greater than
the 3000 psi (207 bar, 20.7 MPa) Maximum
Working Pressure of the spray gun. For ex-
ample, the air supply pressure to a 30:1
pump must not exceed 100 psi (7 bar, 0.7
MPa).
Be sure that all spray equipment and acces-
sories added to the spray system are prop-
erly rated to withstand the maximum working
pressure of your system.
1. 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 9.
2. 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 appear-
ance of your finished workpiece and can cause the
gun to malfunction.
3. Install an air regulator (Q) on each of the air supply
lines (BB, CC, Z) to control the air pressure to the
gun.
WARNING
INJECTION HAZARD
Trapped air can cause the pump to cycle
or 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 off.
In a UNICARB process system, the compressed
CO2in the fluid lines provides fluid pressure even
after the fluid supply has been turned off. To reduce
the risk of injection, always relieve the fluid pres-
sure with a fluid drain valve (M), prior to any servic-
ing or adjustments. The fluid drain line must vent
into a shrouded/vented waste container (Y) or into
a water wash booth to help shield personnel from
fluid atomized by the CO2expansion.

308937 11
Installation
Fluid Line Accessories
1. Install a fluid filter (N) and drain valve (M) in the
fluid supply. Filtering the fluid will help remove
coarse particles and sediment that could clog the
spray tip.
WARNING
INJECTION HAZARD
The fluid drain valve (M) is required in
your system to help relieve fluid pres-
sure in the fluid supply, hose and gun;
triggering the gun to relieve pressure may not be
sufficient. Install a drain valve close to the fluid
supply. The drain valve reduces the risk of serious
injury, including fluid injection and splashing in the
eyes or on the skin.
2. Install a fluid regulator in the fluid supply system 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.
03619
Fig. 3
PRO AA5500sc Gun
2.775 in.
(70.5 mm)
9.32 in.
(236.7 mm)
0.50 in.
(12.7 mm)
rod
103
103
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.
Fig. 4 03460
NN
PP
MM

12 308937
Installation
Connect the Air and Fluid Lines
to the Gun Manifold
See Fig. 1 and 2, page 9, for a schematic of air and
fluid connections. Connect the air and fluid lines to the
gun manifold as instructed at right.
Graco Electrically Conductive Air Hose
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of electric shock or
other serious injury, the air supply hose
must be electrically connected to a true
earth ground. Use Only Graco Electrically Con-
ductive Air Supply Hose.
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 9. Check the electrical grounding of the gun as
instructed on page 15.
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, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand
Part No.
Length Black Hose Grey Hose Red Hose
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)
220444
218100
218101
218102
218103
220119
220120
223068
223069
223070
223071
223072
223073
223074
235068
235069
235070
235071
235072
235073
235074
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, polyure-
thane tube and cover
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.
Manifold Connections (See Fig. 5)
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 13.
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.
03616
Manifold Back View
TA
CYL
P1
KV
EXH
F.O.
Fig. 5

308937 13
Installation
Optional Fiber Optic Cable Connection
An optional fiber optic fitting (37) is shipped unas-
sembled with the gun. If an ES (kV) display module is
used, install the fitting in the manifold. See Fig. 2, page
9, for a schematic of the fiber optic connections.
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.
03620
Fig. 6
115
37
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.
Fig. 7 03509A
QQ
RR
37
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.
5. See manual 308265 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 236852.
1. Remove the gun from the manifold as instructed
on page 31.
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 43.
Fig. 8 04798
TT
UU
SS
Fig. 9 04485
UU
TT
VVSS

14 308937
Installation
Ground the System
WARNING
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, explo-
sion, or electric shock. Follow the
grounding instructions below.
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. Your system must be
connected to a true earth ground.
1. Pump: ground the pump by connecting a ground
wire and clamp as described in your separate
pump instruction manual.
2. Air compressors and hydraulic power supplies:
ground the equipment according to the manufac-
turer’s recommendations.
3. Electrostatic Air Spray Gun: ground the gun by
connecting the Graco Electrically Conductive Air
Hose to the turbine air inlet and connecting the air
hose ground wire to a true earth ground. Check
the electrical grounding of the gun as instructed on
page 15.
4. All air and fluid lines must be properly grounded.
5. All electric cables must be properly grounded.
6. 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.
7. Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Contact points
must be sharp points or knife edges.
8. 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.
9. Flammable liquids in the spray area: must be kept
in approved, grounded containers. Do not store
more than the quantity needed for one shift.
10. All electrically conductive objects or devices in the
spray area: including fluid containers and wash
cans, must be properly grounded.

308937 15
Installation
Check the Electrical Grounding (See Fig. 10)
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
Megohmmeter P/N 218979 (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:
The gun has been removed from the
hazardous area;
Or all spraying devices in the hazardous area
are turned off, ventilation fans in the hazardous
area are operating, and there are no flammable
vapors in the area (such as open solvent con-
tainers or fumes from spraying).
Failure to follow this warning could cause fire,
explosion, electric shock and result in serious injury
and property damage.
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).
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.
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.
Fig. 10
WW
N
B
TA
0362
1

16 308937
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 25. Strap down the
exhaust tube to prevent it from moving around.
Fig. 11
XX
YY
YY
03623
03622
Manifold Back View

308937 17
Operation
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 electric
shock, follow the Pressure Relief Procedure
whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tip.
1. Turn off all the air to the spray gun except the
cylinder air, which triggers the gun.
2. Turn off the fluid supply to the gun.
3. Trigger the gun into a grounded, shrouded and
vented metal waste container to relieve fluid
pressure. This may take several minutes.
4. Open the fluid supply drain valve (required in
system) to help relieve fluid pressure. In addition,
open the drain valve connected to the fluid pres-
sure 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 bleed-
type 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 com-
pletely 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.
Operating Checklist
WARNING
INJECTION HAZARD
The wallet sized warning card 179960,
provided with the gun, should be avail-
able and easily accessible at all times for
anyone operating or servicing this equipment. The
card contains important information on what to do if
a fluid 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 safe, efficient operation.
____ 1. All the operators are properly trained to
safely operate an automatic electrostatic
air-assisted spray system as instructed in
this manual.
____ 2. All the operators are trained how to properly
relieve pressure, using the Pressure Relief
Procedure at left.
____ 3. Anyone operating or servicing this equipment
has access to the wallet-sized warning card
provided with the gun.
____ 4. 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. The system is thoroughly grounded and the
operator and all persons entering the spray
area are properly grounded. See Ground
the System, page 14.
____ 6. The condition of the electrical components of
the spray gun has been checked as
instructed in Electrical Tests, page 29.
____ 7. The ventilation fans are operating properly.
____ 8. The workpiece hangers are clean and
grounded. Contact points must be sharp
points or like knife edges.
____ 9. All the debris, including flammable liquids
and rags, is removed from the spray area.
____ 10. All flammable liquids in the spray booth are
in approved, grounded containers.
____ 11. All conductive objects in the spray area are
electrically grounded and the floor of the
spray area is electrically conductive and
grounded.
____ 12. The manifold exhaust tubes have been
checked for the presence of any fluid as
instructed in Check for Fluid Leakage, page
25.

18 308937
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 pres-
sure. Use the Spray Tip Selection Chart on page 51,
as a guide for selecting an appropriate spray tip for
your application or consult your authorized Graco
distributor. The orifice size of the spray tip is typically
one or two sizes larger than the pre-orifice size
selected below.
Selecting a Pre-Orifice
The fluid flow rate in UNICARB systems is controlled
by the pre-orifice size, in conjuction with the fluid
pressure. Use the pre-orifice selection chart on page
49 as a guide for selection.
Installing the Pre-Orifice
WARNING
To reduce the risk of a serious injury, including fluid
injection, follow the Pressure Relief Procedure on
page 17 when you stop spraying and whenever you
are instructed to relieve the pressure.
1. Place the spray tip seal (13a) on a flat surface.
See Fig. 12.
2. Note that the hole through the pre-orifice (13b) is
larger on one side than the other.
3. Place the pre-orifice (13b), with its larger hole
facing up, on top of the tip seal (13a) hole.
4. Use a large, flat object to press the pre-orifice
(13b) into the tip seal (13a), as shown in Fig. 12.
Fig. 12 8799A
13a
13b
PRESS DOWN
with a large, flat
object
5. Turn over the tip seal and pre-orifice (13a, 13b)
and insert them into the spray tip (13), wih the
pre-orifice side facing down into the spray tip. See
Fig. 13.
Fig. 13 8799A
13
13a, 13b

308937 19
Operation
Installing the Spray Tip
WARNING
To reduce the risk of a serious injury, including fluid
injection, follow the Pressure Relief Procedure on
page 17 when you stop spraying and whenever you
are instructed to relieve the pressure.
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. 14. Be careful not to bend the electrode
wire (15a).
Fig. 14 8800A
13
15
15a
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. 15.
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
Fig. 15
12
13, 15
8802A
2

20 308937
Operation
Setting the Atomization Fluid Pressure
Atomization fluid pressure will vary based on the type
of fluid used, the flow rate desired, the fluid tempera-
ture, and the percentage of CO2used. Follow the
recommendations of your material and equipment
supplier.
Activating and Adjusting the
Electrostatics
1. Turn on the turbine air (TA). Refer to Fig. 16.
2. The turbine air pressure should be adjusted to 30
psi (2.1 bar, 0.21 MPa) at the gun manifold inlet
when air is flowing. Do not exceed 40 psi (2.8 bar,
0.28 MPa) 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 recom-
mended pressures or turbine life will be reduced.
Turbine Air
Hose Length
ft. (m)
Dynamic pressure at the turbine
hose inlet required for full voltage
psi (bar, MPa)
15 (4.6) 36 (2.5, 0.25)
25 (7.6) 38 (2.7, 0.27)
50 (15.3) 40 (2.8, 0.28)
75 (22.9) 42 (2.9, 0.29)
100 (30.5) 45 (3.1 , 0.31)
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 28 to cor-
rect voltage problems.
Activating the kV Switch
Apply a minimum of 50 psi (3.5 bar, 0.35 MPa) 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 40.
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.
TA
CYL
KV
0361
6
Fig. 16
Manifold Back View
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.
1. Apply a minimum of 65 psi (4.5 bar, 0.45 MPa) 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 de-
tected, 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 25.