Graco Pro Xp 3A2494D User manual

Instructions-Parts
Pro Pro
ProXp™ Xp™ Xp™Electrostatic Electrostatic ElectrostaticAir Air AirSpray Spray Spray
Gun Gun
Gun3A2494D
EN
For For
Foruse use usein in inClass Class ClassI, I, I,Div. Div. Div.I I IHazardous Hazardous HazardousLocations Locations Locationsusing using usingGroup Group GroupD D Dspray spray spraymaterials. materials. materials.
For For
Foruse use usein in inGroup Group GroupII, II, II,Zone Zone Zone1 1 1Explosive Explosive ExplosiveAtmosphere Atmosphere AtmosphereLocations Locations Locationsusing using usingGroup Group GroupIIA IIA IIAspray spray spraymaterials. materials. materials.For For For
professional professional
professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanual.
Save Save
Savethese these theseinstructions. instructions. instructions.
100 psi (0.7 MPa, 7.0 bar) Maximum
Fluid Working Pressure
100 psi (0.7 MPa, 7.0 bar) Maximum Air
Working Pressure
See See
Seepage page page3 3 3for for formodel model modelpart part part
numbers numbers
numbersand and andapproval approval approval
information. information.
information.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Models...............................................................3
Warnings...........................................................4
GunOverview....................................................7
HowtheElectrostaticSprayGun
Works............................................7
Controls,Indicators,andComponents...........8
SmartGuns.................................................9
Installation..........................................................15
WarningSign...............................................15
VentilatetheSprayBooth.............................15
AirSupplyLine............................................16
FluidSupplyLine.........................................16
GunSetup..........................................................18
GunSetupChecklist....................................18
Grounding...................................................21
CheckGunElectricalGrounding...................25
CheckFluidResistivity.................................26
CheckFluidViscosity...................................26
FlushBeforeUsingEquipment......................26
GuidelinesforAbrasiveMaterials..................26
Operation...........................................................27
PressureReliefProcedure............................27
Startup........................................................27
Shutdown....................................................27
Maintenance......................................................28
Flushing......................................................28
CleantheGunDaily.....................................29
DailySystemCare.......................................30
ElectricalTests...................................................31
TestGunResistance....................................31
TestPowerSupplyResistance.....................32
TestElectrodeResistance............................32
Troubleshooting..................................................33
SprayPatternTroubleshooting......................33
GunOperationTroubleshooting....................34
ElectricalTroubleshooting............................35
Repair................................................................37
PreparetheGunforService.........................37
AirCapandNozzleReplacement..................38
ElectrodeReplacement................................39
FluidPackingRodRemoval..........................40
PackingRodRepair.....................................40
BarrelRemoval............................................42
BarrelInstallation.........................................42
PowerSupplyRemovaland
Replacement..................................43
AlternatorRemovalandReplacement...........44
FluidTubeRemovalandReplacement...........46
FanAirAdjustmentValveRepair..................47
AtomizingAirRestrictorValveRepair............48
ESOn-OffandFluidAdjustmentValve
Repair............................................49
AirValveRepair...........................................50
SmartModuleReplacement..........................51
AirSwivelandExhaustValve
Replacement..................................52
Parts..................................................................53
StandardAirSprayGunAssembly................53
RoundSprayAssembly................................55
StandardHighConductivityAirSprayGun
Assembly.......................................56
SmartHighConductivityAirSprayGun
Assembly.......................................58
SmartAirSprayGunAssembly.....................60
PackingRodAssembly.................................62
AlternatorAssembly.....................................63
ESOn-OffandFluidAdjustmentValve...........64
FanAirAdjustmentValveAssembly..............65
AtomizingAirRestrictorValve
Assembly.......................................65
SmartModuleAssembly...............................66
HighConductivityFluidTube
Assembly.......................................67
AirCapsandFluidNozzles.................................68
FluidNozzleSelectionChart.........................68
FluidNozzlePerformanceCharts..................68
AirCapSelectionChart................................70
AirConsumptionCharts...............................71
RepairKits,RelatedManuals,and
Accessories..........................................73
GunAccessories..........................................73
OperatorAccessories...................................74
SystemAccessories.....................................74
TestEquipment...........................................74
Hoses.........................................................75
Dimensions........................................................76
TechnicalData...................................................77
GracoProXpWarranty.......................................78
2
3A2494D

Models
Models Models
Models
Nozzle Nozzle
Nozzle
Part Part
PartNo. No. No.kV kV kV
1.5 1.5
1.5
mm mm
mm
1.2 1.2
1.2
mm mm
mm
Round Round
Round
Spray Spray
Spray
Standard Standard
Standard
Display Display
Display
Smart Smart
Smart
Display Display
Display
Standard Standard
Standard
Coatings Coatings
Coatings
High High
High
Conductivity/ Conductivity/
Conductivity/
High High
HighWear Wear Wear
Increased Increased
Increased
Transfer Transfer
Transfer
Ef󰘰ciency Ef󰘰ciency
Ef󰘰ciency
L40T1040✔✔✔
L40T1440✔✔✔✔
L40T1540✔✔✔✔
L40T1640✔✔✔
L60T1060✔✔✔
L60T1160✔✔✔
L60T1260✔✔✔
L60T1660✔✔✔
L60M1060✔✔✔
L60M1260✔✔✔
L60M1660✔✔✔
L85T1085✔✔✔
L85T1685✔✔✔
L85M1085✔✔✔
L85M1685✔✔✔
II II
II2 2 2G G G
EEx0.24mJT6
FM12ATEX0068
EN50050
Ta0°C–50°C
3A2494D 3

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE, FIRE,
FIRE,EXPLOSION, EXPLOSION, EXPLOSION,AND AND ANDELECTRIC ELECTRIC ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Tohelp
prevent󰘰re,explosion,andelectricshock:
•Electrostaticequipmentmustbeusedonlybytrained,quali󰘰edpersonnelwhounderstand
therequirementsofthismanual.
•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorcloseto
sprayarea.Resistancemustnotexceed1megohm.SeeGrounding Grounding
Groundinginstructions.
•OnlyusegroundedGracoconductiveairsupplyhoses.
•Donotusepaillinersunlesstheyareconductiveandgrounded.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.
•Useandcleanequipmentonlyinwellventilatedarea.
•Interlockthegunairsupplytopreventoperationunlessventilatingfansareon.
•Usecleaningsolventswithhighestpossible󰘱ashpointwhen󰘱ushingorcleaningequipment.
•Tocleantheexterioroftheequipment,cleaningsolventsmusthavea󰘱ashpointatleast
5°Caboveambienttemperature.
•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.
•Keepsprayareafreeofdebris,includingsolvent,ragsandgasoline.
•Keepaworking󰘰reextinguisherintheworkarea.
4
3A2494D

Warnings
WARNING WARNING
WARNING
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
PLASTIC PLASTIC
PLASTICPARTS PARTS PARTSCLEANING CLEANING CLEANINGSOLVENT SOLVENT SOLVENTHAZARD HAZARD HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.
•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.
•SeeTechnical Technical
TechnicalData Data Datainthisandallotherequipmentinstructionmanuals.Read󰘱uidand
solventmanufacturer’sMSDSsandrecommendations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadMSDS’stoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
3A2494D 5

Warnings
WARNING WARNING
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
6 3A2494D

GunOverview
Gun Gun
GunOverview Overview Overview
How How
Howthe the theElectrostatic Electrostatic ElectrostaticSpray Spray SprayGun Gun GunWorks Works Works
Theairhosesuppliesairtothespraygun.Partof
theairoperatesthealternatorturbineandtherest
oftheairatomizesthe󰘱uidbeingsprayed.The
alternatorgeneratespower,whichisconvertedby
thepowercartridgetosupplyhighvoltagetothe
gun’selectrode.
Thepumpsupplies󰘱uidtothe󰘱uidhoseandgun,
wherethe󰘱uidiselectrostaticallychargedasit
passestheelectrode.Thecharged󰘱uidisattracted
tothegroundedworkpiece,wrappingaroundand
evenlycoatingallsurfaces.
3A2494D
7

GunOverview
Controls, Controls,
Controls,Indicators, Indicators, Indicators,and and andComponents Components Components
Theelectrostaticgunincludesthefollowing
controls,indicators,andcomponents(seeFig.
1).ForinformationonSmartguns,alsosee
SmartGuns,page9.
Figure1GunOverview
Item Item
ItemDescrip- Descrip- Descrip-
tion tion
tion
Purpose Purpose
Purpose
AAirSwivel
Inlet
1/4npsm(m)left-handthread,
forGracogroundedairsupply
hose.
BFluidInlet3/8npsm(m),for󰘱uidsupply
hose.
CTurbineAir
Exhaust
Barbed󰘰tting,forsupplied
exhausttube.
DAirCap
and
Nozzle
SeeAirCapsandFluid
Nozzles,page68,foravail-
ablesizes.
EElectrode
Needle
Supplieselectrostaticcharge
tothe󰘱uid.
FFanAir
Adjust-
ment
Valve
Adjustsfansizeandshape.
Canbeusedtodecrease
patternwidth.
GAtomizing
Air
Restrictor
Valve
Restrictsaircapair󰘱ow.
Replacewithplug(included)
ifdesired.
Item Item
ItemDescrip- Descrip- Descrip-
tion tion
tion
Purpose Purpose
Purpose
HFluidAd-
justment
Knob
Adjusts󰘱uid󰘱owbylimiting
󰘱uidneedletravel.Useonly
inlow󰘱owconditions,to
reducewear.
JESOn-Off
Valve
TurnselectrostaticsON(I)or
OFF(O).
KESIndica-
tor(stan-
dardgun
only;for
Smartgun
indica-
tor,see
Operating
Mode,
page9)
LitwhenESisON(I).Colorin-
dicatesalternatorfrequency.
SeetheLEDindicatortable
intheGunSetupChecklist,
page18.
8 3A2494D

GunOverview
Smart Smart
SmartGuns Guns Guns
TheSmartGunmoduledisplayssprayingvoltage,
current,alternatorspeed,andthevoltagesetting(low
orhigh).Italsoallowstheusertochangetoalower
sprayingvoltage.Themodulehastwomodes:
•OperatingMode
•DiagnosticMode
Operating Operating
OperatingMode Mode Mode
Bar Bar
BarGraph Graph Graph
SeeFig.2,andTable1onpage10.TheOperating
Modedisplaysgundataduringnormalspraying.The
displayusesabargraphtoshowthevoltagelevelin
kiloVolts(kV)andthecurrentlevelinmicroAmperes
(uA).Thebargraphrangeisfrom0to100%foreach
value.
IfthebargraphLEDsareblue,thegunisreadyto
spray.IftheLEDsareyelloworred,thecurrentis
toohigh.The󰘱uidmaybetooconductive,orsee
ElectricalTroubleshooting,page35forotherpossible
causes.
Hz Hz
HzIndicator Indicator Indicator
TheHzindicatorfunctionsthesameastheES
indicatoronstandardguns.Theindicatorlightsto
showthealternatorspeedstatus,andhasthree
colors:
•Greenindicatesthealternatorspeediscorrect.
•Iftheindicatorchangestoamberafter1second,
increasetheairpressure.
•Iftheindicatorchangestoredafter1second,
reducetheairpressure.
Voltage Voltage
VoltageAdjustment Adjustment AdjustmentSwitch Switch Switch
Thevoltageadjustmentswitch(VA)allowsthe
operatortochangefromlowtohighvoltage.
•Thehighvoltagesettingisdeterminedbythe
maximumvoltageofthegunandisnotadjustable.
•Thelowvoltageindicator(LO)lights
whentheswitchissettoLO.Thelow
voltagesettingisuseradjustable.See
AdjustingtheLowVoltageSetting,page10.
NOTE: NOTE:
NOTE:IftheErrordisplayappears,theSmartmodule
haslostcommunicationwiththepowersupply.See
ErrorDisplay,page10,forfurtherinformation.
Figure2SmartGunModuleinOperatingMode
3A2494D 9

GunOverview
Error Error
ErrorDisplay Display Display
IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3,andTable1onpage10.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page35.
CommunicationmustberestoredtomaketheSmart
modulefunctional.
NOTE: NOTE:
NOTE:Ittakes8secondsfortheErrordisplayto
appear.Ifthegunhasbeendisassembled,wait8
secondsbeforesprayingtoensurethatanError
conditionhasnotoccurred.
NOTE: NOTE:
NOTE:Ifthereisnopowertothegun,theError
displaywillnotappear.
Figure3ErrorDisplay
Adjusting Adjusting
Adjustingthe the theLow Low LowVoltage Voltage VoltageSetting Setting Setting
Thelowvoltagesettingisuseradjustable.Toaccess
thelowvoltagesettingscreenwheninOperating
Mode,presstheLOSETbutton(LS)momentarily.
Thescreenwilldisplaythecurrentlowvoltage
setting.SeeFig.4,andTable1onpage10.The
possiblerangesare:
•85kVguns:40–85kV
•60kVguns:30–60kV
SettheVoltageAdjustmentswitch(VA)toLO.Press
theLOSETbuttonrepeatedlytoincreasethesetting
inincrementsof5.Whenthedisplayreachesthe
maximumsettingitwillreturntotheminimumsetting
foryourgun.Continuepressingthebuttonuntilyou
reachthedesiredsetting.
NOTE: NOTE:
NOTE:After2secondsofinactivitythedisplaywill
returntotheOperatingScreen.
NOTE: NOTE:
NOTE:Thelowvoltagesettingmaybelocked.See
LockSymbol,page10.
Figure4LowVoltageSettingScreen(Unlocked)
Lock Lock
LockSymbol Symbol Symbol
Thelowvoltagesettingmaybelocked.Whenlocked,
animage(LK)appearsonthescreen.SeeFig.5,
andTable1onpage10.
•WheninHImode,thelowvoltagesettingisalways always
always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.
•WheninLOmode,thelocksymbolwill
only only
onlyappearifthelockisenabled.See
LowVoltageLockScreen,page14,tolockor
unlockthelowvoltagesetting.
Figure5LowVoltageSettingScreen(Locked)
10 3A2494D

GunOverview
Table Table
Table1 1 1. . .Key Key Keyfor for forFigs. Figs. Figs.2–9. 2–9. 2–9.
Item Item
ItemDescription Description DescriptionPurpose Purpose Purpose
VAVoltageAdjustmentSwitchTwo-positionswitchsetssmart
gunvoltagetolowsetting(LO)or
highsetting(HI).Thisswitchis
functionalinOperatingModeand
inDiagnosticMode.
LOLowVoltageModeIndicatorLights(blue)whenthesmartgun
issettoLowVoltage.
kVVoltage(kV)DisplayDisplaysactualsprayingvoltage
ofthegun,inkV.InOperating
Mode,displayisabargraph.
InDiagnosticMode,voltageis
displayedasanumber.
uACurrent(uA)DisplayDisplaysactualsprayingcurrent
ofthegun,inuA.InOperating
Mode,displayisabargraph.
InDiagnosticMode,currentis
displayedasanumber.
LSLOSETbuttonPressmomentarilytoenterthe
LowVoltageSettingscreen.
Pressandholdforapproximately5
secondstoenterorexitDiagnostic
Mode.
WhileinDiagnosticMode,press
momentarilytoadvancethrough
screens.
WhileontheLowVoltageLock
Screen(inDiagnosticMode),
pressandholdtoturnthelockon
oroff.
LVLowVoltageDisplayDisplaysthelowvoltagesetting
asanumber.Thesettingcanbe
changed.SeeFig.4.
LKLowVoltageLockedAppearsifthelowvoltagesetting
islocked.SeeFig.5andFig.9.
3A2494D
11

GunOverview
Item Item
ItemDescription Description DescriptionPurpose Purpose Purpose
LDLODisplayAppearsontheLowVoltageLock
Screen.SeeFig.9.
ERErrorDisplayAppearsiftheSmartmoduleloses
communicationwiththepower
supply.SeeFig.3.
VIVoltageIndicatorInDiagnosticMode,thetwotop
rightLEDsofthescreenlight,
indicatingthatthevaluedisplayed
isinkV.SeeFig.6.
CICurrentIndicatorInDiagnosticMode,thetwo
bottomrightLEDsofthescreen
light,indicatingthatthevalue
displayedisinuA.SeeFig.7.
ASAlternatorSpeedDisplayInDiagnosticMode,Hzlevelis
displayedasanumber.SeeFig.
8.
HzAlternatorSpeedIndicatorInOperatingMode,indicatorcolor
variestoshowthealternator
speedstatus:
•greenindicatesthealternator
speedisatthecorrectlevel.
•Iftheindicatorchangestoamber
after1second,thealternator
speedistoolow.
•Iftheindicatorchangestored
after1second,thealternator
speedistoohigh.Theindicator
willalsoturnrediftheError
displayappears.
InDiagnosticMode,theindicator
isgreenwhenintheAlternator
Speed(Hertz)screen.
12
3A2494D

GunOverview
Diagnostic Diagnostic
DiagnosticMode Mode Mode
DiagnosticModeincludesfourscreenswhichdisplay
gundata:
•Voltage(kiloVolts)Screen
•Current(microAmperes)Screen
•AlternatorSpeed(Hertz)Screen
•LowVoltageLockScreen
NOTE: NOTE:
NOTE:YoumustbeinOperatingModetoadjustthe
lowvoltagesetting;thesettingisnotadjustablein
DiagnosticMode.However,thevoltageadjustment
switch(VA)canbesettoHIorLOinOperatingMode
andinDiagnosticMode.
ToenterDiagnosticMode,pressandholdtheLOSET
(LS)buttonforapproximately5seconds.Thedisplay
willgototheVoltage(kiloVolts)Screen,page13.
Toadvancetothenextscreen,presstheLOSET
buttonagain.
ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.
NOTE: NOTE:
NOTE:IfthegunisdetriggeredwhileinDiagnostic
Mode,thelastscreenviewedwillbedisplayedwhen
thegunisretriggered.
NOTE: NOTE:
NOTE:DiagnosticModecannotbeexited
fromtheLowVoltageLockScreen.See
LowVoltageLockScreen,page14fordetails.
Voltage Voltage
Voltage(kiloVolts) (kiloVolts) (kiloVolts)Screen Screen Screen
TheVoltage(kiloVolts)Screenisthe󰘰rstscreento
appearafterenteringDiagnosticMode.SeeFig.6,
andTable1onpage10.Toenterthisscreen,press
andholdtheLOSETbuttonforapproximately5
secondswhileintheOperatingMode.
Thisscreendisplaysthesprayingvoltageofthe
gunasanumber(kV),roundedtothenearest5kV.
ThetwotoprightLEDs(VI)ofthedisplaypanel
light,indicatingthattheVoltage(kiloVolts)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.
PresstheLOSETbuttontoadvancetothe
Current(microAmperes)Screen,page13.Press
andholdforapproximately5secondstoreturnto
OperatingMode.
Figure6Voltage(kiloVolts)Screen
Current Current
Current(microAmperes) (microAmperes) (microAmperes)Screen Screen Screen
TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7,andTable
1onpage10.Toenterthisscreen,presstheLO
SETbuttonwhileintheVoltage(kiloVolts)Screen.
Thisscreendisplaysthesprayingcurrentofthegun
asanumber(uA),roundedtothenearest5uA.The
twobottomrightLEDs(CI)ofthedisplaypanellight,
indicatingthattheCurrent(microAmperes)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.
PresstheLOSETbuttontoadvancetothe
AlternatorSpeed(Hertz)Screen,page14.Press
andholdforapproximately5secondstoreturnto
OperatingMode.
Figure7Current(microAmperes)Screen
3A2494D 13

GunOverview
Alternator Alternator
AlternatorSpeed Speed Speed(Hertz) (Hertz) (Hertz)Screen Screen Screen
TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8,andTable
1onpage10.Toenterthisscreen,presstheLOSET
buttonwhileintheCurrent(microAmperes)Screen.
Thisscreendisplaysthealternatorspeedasa3digit
number(AS),roundedtothenearest10Hz.The
displayisareadoutandcannotbechanged.Ifthe
alternatorspeedisgreaterthan999Hz,thedisplay
willshow999.
TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.
PresstheLOSETbuttontoadvancetothe
LowVoltageLockScreen,page14.Pressandhold
forapproximately5secondstoreturntoOperating
Mode.
Figure8AlternatorSpeed(Hertz)Screen
Low Low
LowVoltage Voltage VoltageLock Lock LockScreen Screen Screen
TheLowVoltageLockScreenisthefourthscreenin
theDiagnosticMode.SeeFig.9,andTable1on
page10.Toenterthisscreen,presstheLOSET
buttonwhileintheAlternatorSpeed(Hertz)Screen.
ThisscreendisplaysthestatusoftheLowVoltage
Lock.Ifthesettingislocked,thelockimage(LK)
appearstotheleftoftheLodisplay(LD).Ifthesetting
isunlocked,thelockimagedoesnotappear.
Tochangethelockstatus,pressandholdthe
LOSETbuttonuntilthelockimageappearsor
disappears.Ifthelockisset,theimagewillalso
appearontheLowVoltageSettingScreenwhenin
lowvoltagemode(seeFig.4).
NOTE: NOTE:
NOTE:DiagnosticModecannotbeexitedfromthis
screen,becausepressingandholdingtheLOSET
buttonisusedtoturnthelockonoroff.Toexit,
pressLOSETmomentarilytoreturntotheVoltage
(kiloVolts)Screen,thenexitDiagnosticModefrom
there.
Figure9LowVoltageLockScreen
14
3A2494D

Installation
Installation Installation
Installation
Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.
•Donotinstallorservicethisequipmentunless
youaretrainedandquali󰘰ed.
•Besureyourinstallationcomplieswithlocal,
state,andnationalcodesfortheinstallation
ofelectricalapparatusinaClassI,Div.I,
HazardousLocationoraGroupII,ZoneI
ExplosiveAtmosphereLocation.
•Complywithallapplicablelocal,state,and
national󰘰re,electrical,andothersafety
regulations.
Fig.10showsatypicalelectrostaticairspraysystem.
Itisnotanactualsystemdesign.Forassistance
indesigningasystemtosuityourparticularneeds,
contactyourGracodistributor.
Warning Warning
WarningSign Sign Sign
Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.
Ventilate Ventilate
Ventilatethe the theSpray Spray SprayBooth Booth Booth
Providefreshairventilationtoreducetheriskof󰘰re
orexplosioncausedbythebuildupof󰘱ammableor
toxicvaporswhenspraying,󰘱ushing,orcleaning
thegun.Donotoperatethegununlessventilation
fansareoperating.
Electricallyinterlockthegunairsupplywiththe
ventilatorstopreventgunoperationwithout
ventilatingfansoperating.Checkandfollowalllocal,
state,andnationalcodesregardingairexhaust
velocityrequirements.
Highvelocityairexhaustwilldecreasetheoperating
ef󰘰ciencyoftheelectrostaticsystem.Airexhaust
velocityof100ft/min(31linearmeters/minute)should
besuf󰘰cient.
3A2494D 15

Installation
Air Air
AirSupply Supply SupplyLine Line Line
Toreducetheriskofelectricshock,theairsupply
hosemustbeelectricallyconnectedtoatrueearth
ground.Use Use
Useonly only onlyGraco Graco GracoGrounded Grounded GroundedAir Air AirSupply Supply Supply
Hose. Hose.
Hose.
1.SeeFig.10.UsetheGracoGroundedAirSupply
Hose(AH)tosupplyairtothegun.Thegunair
inlet󰘰ttinghasaleft-handthread.Theairsupply
hosegroundwire(AG)mustbeconnectedtoa
trueearthground.Donotconnecttheairsupply
hosetothegunairinletyet.
2.Installanairline󰘰lter/waterseparator(AF)onthe
gunairlinetoensureadry,cleanairsupplytothe
gun.Dirtandmoisturecanruintheappearance
ofyour󰘰nishedworkpieceandcancausethe
guntomalfunction.
3.Installbleed-typeairregulators(PR,GR)on
thepumpandgunairsupplylinestocontrolair
pressuretothepumpandgun.
Trappedaircancausethepumptocycle
unexpectedly,whichcanresultinserious
injury,includingsplashing󰘱uidintheeyesor
ontheskin.Donotoperatetheequipment
withoutthebleed-typeairvalve(BV)installed.
4.Installableed-typeairvalve(BV)onthepump
airsupplyline.Thebleed-typeairvalve(BV)is
requiredinyoursystemtoshutoffairtothepump
andrelieveairtrappedbetweenthevalveand
thepumpaftertheairregulatorisshutoff.Install
anadditionalbleed-typeairvalveonthemainair
line(MA)toisolatetheaccessoriesforservicing.
5.Installanairbleedvalve(BV)oneachgunair
supplylinetoshutoffairtothegun(s)andrelieve
airtrappedbetweenthevalveandthegunafter
theairregulatorisshutoff.
Fluid Fluid
FluidSupply Supply SupplyLine Line Line
1.Blowoutthe󰘱uidline(FL)withairand󰘱ushit
withsolvent.Usesolventwhichiscompatible
withthe󰘱uidtobesprayed.Donotconnectthe
󰘱uidsupplylinetothegun󰘱uidinletyet.
2.Installa󰘱uidregulator(FR)onthe󰘱uidlineto
control󰘱uidpressuretothegun.
3.Installa󰘱uid󰘰lter(FF)nearthepumpoutlet,to
removeparticlesandsedimentwhichcouldclog
thespraynozzle.
Toreducetheriskofseriousinjury,including
splashing󰘱uidintheeyesorontheskin,do
notoperateequipmentwithoutthe󰘱uiddrain
valve(FD)installed.
4.The󰘱uiddrainvalve(FD)isrequiredinyour
systemtoassistinrelieving󰘱uidpressureinthe
displacementpump,hose,andgun.Triggering
theguntorelievepressuremaynotbesuf󰘰cient.
Installadrainvalveclosetothepump's󰘱uid
outlet.
16 3A2494D

Installation
NON NON
NON- - -HAZARDOUS HAZARDOUS HAZARDOUSAREA AREA AREAHAZARDOUS HAZARDOUS HAZARDOUSAREA AREA AREA
Figure10TypicalInstallation
Typical Typical
TypicalInstallation Installation InstallationKey Key Key
Item Item
ItemDescription Description Description
ADAirLineDrainValve
AFAirFilter/WaterSeparator
AG*GunAirHoseGroundWire
AH*GracoGroundedAirHose(left-hand
threads)
ALPumpAirLineLubricator
BV*PumpBleed-TypeAirShutoffValve
EGElectrostaticAirSprayGun
FD*FluidDrainValve
FFFluidFilter
FLFluidSupplyLine
FRFluidPressureRegulator
Item Item
ItemDescription Description Description
FVFluidShutoffValve
GRGunAirPressureRegulator
MAMainAirSupplyLine
PG*PumpGroundWire
PRPumpAirPressureRegulator
SPSupplyPump
SV*VentilationFanInterlockSolenoidValve.
NOTE: NOTE:
NOTE:Thesolenoidvalveisnotoffered
asaGracoaccessory.
*Theseitemsarerequiredforsafeoperation.They
mustbepurchasedseparately.
3A2494D
17

GunSetup
Gun Gun
GunSetup Setup Setup
Gun Gun
GunSetup Setup SetupChecklist Checklist Checklist
SeeFig.11tolocatetheelectrostaticguncontrols.
Figure11ElectrostaticGunControls
1.Thegunisshippedwiththe󰘱uidnozzleandair
capinstalled.Checkthattheretainingringis
tight.
NOTE: NOTE:
NOTE:Toselectadifferent
size󰘱uidnozzleoraircap,see
FluidNozzleSelectionChart,page68and
AirCapSelectionChart,page70.To
installthenozzleandaircap,see
AirCapandNozzleReplacement,page38.
2.TurnOFF(O)theESOn-Offswitch(J).
3.Shutofftheairbleedvalvetothegun.
4.Checkgunresistance.See
TestGunResistance,page31.
5.ConnecttheGracogroundedairhosetothegun
airinlet.Thegunairinlet󰘰ttinghasleft-hand
threads.
6.FollowallstepsunderGrounding,page21.
7.Followallstepsunder
CheckGunElectricalGrounding,page25.
Readingmustbelessthan1megohm.
8.Verifythatthematerialresistivitymeets
requirementsforelectrostaticspray.See
CheckFluidResistivity,page26.
9.Connecttheexhausttubeandsecurewiththe
clampprovided.
10.Connectthe󰘱uidhosetothegun󰘱uidinlet.
11.Flushifneeded,seeFlushing,page28.
12.Positiontheaircapasdesired.
18 3A2494D

GunSetup
13.Fullyopenthefanairadjustmentvalve(F)
counterclockwise.
14.Fullyopenthe󰘱uidadjustmentvalve(H)
counterclockwise.
15.Fullyopentheatomizingairrestrictorvalve(G)
clockwise.
16.TurnON(I)theESOn-Offswitch(J).
17.Setthegunairregulatortodeliveraminimum
45psi(0.32MPa,3.2bar)atthegunwhen
triggered,toensurefullsprayingvoltage.See
thetablebelow.
Table Table
Table2 2 2. . .Pressure Pressure PressureDrop Drop Drop
Air Air
AirHose Hose Hose
Length Length
Lengthin in inft ft ft(m) (m) (m)
(using (using
(using5/16 5/16 5/16in. in. in.[8 [8 [8
mm] mm]
mm]diameter diameter diameterhose) hose) hose)
Air Air
AirRegulator Regulator RegulatorSetting Setting Setting
in in
inpsi psi psi(MPa, (MPa, (MPa,bar) bar) bar)
[with [with
[withgun gun guntriggered] triggered] triggered]
15(4.6)55(0.38,3.8)
25(7.6)65(0.45,4.5)
50(15.3)80(0.56,5.6)
18.CheckthattheESindicator(K)[Hzindicatoron
Smartguns]islit.Seethefollowingtable.
Table Table
Table3 3 3. . .LED LED LEDIndicator Indicator IndicatorColors Colors Colors
Indicator Indicator
Indicator
Color Color
Color
Description Description
Description
GreenWhenspraying,theindicator
shouldremaingreen,indicating
suf󰘰cientairpressuretothe
alternatorturbine.
AmberIftheindicatorchangestoamber
after1second,theairpressure
istoolow.Increaseairpressure
untiltheindicatorisgreen.
RedIftheindicatorchangestored
after1second,theairpressureis
toohigh.Decreaseairpressure
untiltheindicatorisgreen.
3A2494D 19

GunSetup
19.Shutofftheairtothegun.TurnOFF(O)theES
On-Offswitch(J).
20.Startthepump.Adjustthe󰘱uidregulatoruntilthe
streamfromtheguntravels8-12in.(200-300
mm)beforefallingoff.Typically,if󰘱uidpressure
isbelow5psi(.04MPa,0.4bar)orabove30psi
(0.21MPa,2.1bar),achangeofnozzlesizeis
recommended.
21.Turnontheairtothegun.TurnON(I)theES
On-Offswitch(J).
22.Sprayatestpattern.Checktheatomization.If
over-atomizationoccursatminimumpressure,
adjusttherestrictorvalve.Ifatomizationis
inadequate,increaseairpressureordecrease
󰘱uid󰘱ow.
23.Adjustthefanairadjustmentvalve:clockwisefor
anarrowerpattern,counterclockwiseforawider
pattern.
24.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see
Troubleshooting,page33.
20 3A2494D