Graco Pro Xp 60 WB User manual

Instructions-Parts
Pro Pro
ProXp™ Xp™ Xp™60 60 60WB WB WBGun Gun Gun3A7504A
EN
An An
Anelectrostatic electrostatic electrostaticair air airspray spray spraygun gun gunfor for forspraying spraying sprayingconductive, conductive, conductive,waterborne waterborne waterborne󰘱uids 󰘱uids 󰘱uidsthat that thatmeet meet meetat at atleast least leastone one oneof of ofthe the the
conditions conditions
conditionsfor for fornon non non- - -󰘱ammability 󰘱ammability 󰘱ammabilitylisted listed listedon on onpage page page3. 3. 3.
For For
Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandintheisolation
systemmanualbeforeusingtheequipment.Save Save
Savethese these theseinstructions. instructions. instructions.
100 psi (0.7 MPa, 7.0 bar) MaximumFluid Working Pressure100 psi (0.7 MPa, 7.0 bar) Maximum AirWorking Pressure
See page 3 for model part numbers andapproval information.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Models...............................................................3
RelatedManuals................................................3
Warnings...........................................................4
GunOverview....................................................7
HowtheElectrostaticSprayGun
Works............................................7
SprayingWaterborneFluids
Electrostatically..............................7
Controls,Indicators,andComponents...........8
SmartGuns.................................................9
Installation..........................................................14
SystemRequirements..................................14
WarningSign...............................................14
InstalltheSystem.........................................14
VentilatetheSprayBooth.............................14
TypicalInstallation.......................................15
ConnecttheWaterborneFluidHose..............16
AirSupplyLine............................................17
Grounding...................................................18
GunSetup..........................................................20
GunSetupProcedure...................................20
SoftSprayGunSetupProcedure..................24
HVLPGunSetupProcedure.........................25
RoundSprayGunSetupProcedure..............26
AbrasiveMaterialGunSetup
Procedure......................................28
MoldReleaseGunSetupProcedure.............30
CheckGunElectricalGrounding...................32
FlushBeforeUsingEquipment......................32
Operation...........................................................33
PressureReliefProcedure............................33
FluidVoltageDischargeandGrounding
Procedure......................................33
Startup........................................................34
Shutdown....................................................34
Maintenance......................................................35
DailyCareandCleaningChecklist................35
Flushing......................................................35
CleantheGunDaily.....................................36
DailySystemCare.......................................38
ElectricalTests...................................................39
TestGunResistance....................................39
TestPowerSupplyResistance.....................39
TestElectrodeResistance............................40
Troubleshooting..................................................41
VoltageLossTroubleshooting.......................41
SprayPatternTroubleshooting......................44
GunOperationTroubleshooting....................45
ElectricalTroubleshooting............................46
Repair................................................................48
PreparetheGunforService.........................48
AirCapandNozzleReplacement..................49
AirCap,SprayTip,andNozzle
Replacement(Model
L60M19)........................................50
ElectrodeReplacement................................52
NeedleReplacement(ModelL60M19)...........52
FluidPackingRodRemoval..........................53
PackingRodRepair.....................................53
BarrelRemoval............................................55
BarrelInstallation.........................................55
PowerSupplyRemovaland
Replacement..................................56
AlternatorRemovalandReplacement...........57
FanAirAdjustmentValveRepair..................59
AtomizingAirRestrictorValveRepair............60
ESOn-OffandFluidAdjustmentValve
Repair............................................61
AirValveRepair...........................................62
SmartModuleReplacement..........................62
AirSwivelandExhaustValve
Replacement..................................63
Parts..................................................................64
StandardWaterborneAirSprayGun
Assembly.......................................64
SmartWaterborneAirSprayGun
Assembly.......................................66
MoldReleaseSmartAirSprayGun
Assembly.......................................68
PackingRodAssembly.................................70
AlternatorAssembly.....................................71
ESOn-OffandFluidAdjustmentValve...........72
FanAirAdjustmentValveAssembly..............73
AtomizingAirRestrictorValve
Assembly.......................................73
AirCapAssembly........................................74
SmartModuleAssembly...............................74
RoundSprayAssembly................................75
FluidNozzles.....................................................77
FluidNozzleSelectionChart.........................77
FluidNozzlePerformanceCharts..................78
AirCaps.............................................................80
AirCapSelectionGuide...............................80
AirConsumptionCharts...............................85
SprayTipSelectionChart(ModelL60M19MRG
GunOnly).............................................86
AEMFineFinishSprayTips..........................86
AEFFineFinishPre-Ori󰘰ceSpray
Tips...............................................87
RoundSprayTips........................................87
RepairKitsandAccessories................................88
FluidHoseAssemblyandRepair..................91
IgnitabilityofCoatingMaterials............................92
Dimensions........................................................93
TechnicalSpeci󰘰cations......................................94
CaliforniaProposition65.....................................94
Notes................................................................95
GracoProXpWarranty.......................................96
2
3A7504A

Models
Models Models
Models
Condition Condition
Conditionfor for fornon non non- - -󰘱ammability: 󰘱ammability: 󰘱ammability:
FM FM
FMapproved approved approvedfor for foruse use usewith with with󰘱uids 󰘱uids 󰘱uidsthat that thatmeet meet meetthe the thefollowing following followingcondition: condition: condition:
•Material Material
Materialdoes does doesnot not notsustain sustain sustainburning burning burningin in inaccordance accordance accordancewith with withthe the theStandard Standard StandardTest Test Test
Method Method
Methodfor for forSustained Sustained SustainedBurning Burning Burningof of ofLiquid Liquid LiquidMixtures, Mixtures, Mixtures,ASTM ASTM ASTMD4206. D4206. D4206.
Condition Condition
Conditionfor for fornon non non- - -󰘱ammability: 󰘱ammability: 󰘱ammability:
Models Models
Modelsare are arecompliant compliant compliantwith with withEN EN EN50059 50059 50059when when whenused used usedwith with with󰘱uids 󰘱uids 󰘱uidsthat that thatmeet meet meet
the the
thefollowing following followingcriteria: criteria: criteria:
•Material Material
Materialis is isclassi󰘰ed classi󰘰ed classi󰘰edas as asnon non non- - -ignitable ignitable ignitableas as asde󰘰ned de󰘰ned de󰘰nedby by byEN EN EN50059: 50059: 50059:2018. 2018. 2018.
Formoreinformation,seeIgnitabilityofCoatingMaterials,page92.
Part Part
PartNo No NoModel Model ModelDescription Description Description
L60T18ProXp60WBStandardElectrostaticAirSprayGun,forwaterbornecoatings.
L60M18ProXp60WBSmartElectrostaticAirSprayGun,forwaterbornecoatings.
L60M19ProXp60
WBMRG
SmartElectrostaticAirSprayGun,formoldreleaseapplications.
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNo. No. No.Description Description Description
3A2498RoundSprayKit
307263ProbeandMeter
309455TestFixture,HighVoltageProbe,andkVMeter
406999VoltageTesterConversionKit
3A7312HydroShield™AirSprayWaterborneIsolationSystems
3A2496WB100IsolationSystemandProXp™60WBGun
3A7504A 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
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Combustibledustor󰘱ammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanignite
orexplode.Tohelpprevent󰘰reandexplosion:
•Fluidsusedmustmeettheappropriate󰘱ammabilityrequirements:
•FM, FM,
FM,FMc FMc FMcApproved: Approved: Approved:
MaterialdoesnotsustainburninginaccordancewiththeStandardTestMethodfor
SustainedBurningofLiquidMixtures,ASTMD4206.
•CE CE
CE- - -EN EN EN50059 50059 50059Compliant: Compliant: Compliant:
Materialisclassi󰘰edasnon-ignitableasde󰘰nedbyEN50059:2018.
•Electrostaticequipmentmustbeusedonlybytrained,quali󰘰edpersonnelwhounderstand
therequirementsofthismanual.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.
•Useandcleanequipmentonlyinwellventilatedarea.
•Interlockthegunairsupplytopreventoperationunlessventilationair󰘱owisabovethe
minimumrequiredvalue.
•Onlyusenon-󰘱ammablesolventswhen󰘱ushingorcleaningequipment.
•Onlyusethered-coloredGracoelectricallyconductivegunairhosewiththisgun.Donot
useblackorgray-coloredGracoairhoses.
•Donotusepaillinersunlesstheyareconductiveandgrounded.
•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Keepaworking󰘰reextinguisherintheworkarea.
4
3A7504A

Warnings
WARNING WARNING
WARNING
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock:
•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorclose
tosprayarea.SeeGrounding Grounding
Groundinginstructions.
•Connecttheelectrostaticguntoavoltageisolationsystemthatwilldischargethesystem
voltagewhennotinuse.
•Allcomponentsoftheisolationsystemthatarechargedtohighvoltagemustbecontained
withinanisolationenclosurethatpreventspersonnelfrommakingcontactwiththehigh
voltagecomponentsbeforethesystemvoltageisdischarged.
•FollowtheFluid Fluid
FluidVoltage Voltage VoltageDischarge Discharge Dischargeand and andGrounding Grounding GroundingProcedure Procedure Procedurewheninstructedtodischarge
thevoltage;beforecleaning,󰘱ushing,orservicingthesystem;beforeapproachingthefrontof
thegun;andbeforeopeningtheisolationenclosurefortheisolated󰘱uidsupply.
•Donotenterahighvoltageorhazardousareauntilallhighvoltageequipmenthasbeen
discharged.
•Donottouchthegunnozzleorelectrode,orcomewithin4in.(102mm)oftheelectrode
duringgunoperation.FollowtheFluid Fluid
FluidVoltage Voltage VoltageDischarge Discharge Dischargeand and andGrounding Grounding GroundingProcedure Procedure Procedure.
•Interlockthegunairsupplywiththevoltageisolationsystemtoshutofftheairsupplyanytime
theisolationsystemenclosureisopened.
•Onlyusethered-coloredGracoelectricallyconductivegunairhosewiththisgun.Donot
useblackorgray-coloredGracoairhoses.
•Donotsplicehosestogether.InstallonlyonecontinuousGracowaterborne󰘱uidhose
betweentheisolated󰘱uidsupplyandthespraygun.
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.
3A7504A 5

Warnings
WARNING WARNING
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts..SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.
Forcompleteinformationaboutyourmaterial,requestaSafetyDataSheet(SDS)from
yourdistributororretailer.
•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.
PLASTIC PLASTIC
PLASTICPARTS PARTS PARTSCLEANING CLEANING CLEANINGSOLVENT SOLVENT SOLVENTHAZARD HAZARD HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.
•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.
•SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanualsformaterialsofconstruction.Consult
thesolventmanufacturerforinformationandrecommendationsaboutcompatibility.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰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.
6 3A7504A

GunOverview
Gun Gun
GunOverview Overview Overview
How How
Howthe the theElectrostatic Electrostatic ElectrostaticSpray Spray SprayGun Gun Gun
Works Works
Works
Theairhosesuppliesairtothespraygun.Partofthe
airoperatesthealternatorturbineandtherestofthe
airatomizesthe󰘱uidbeingsprayed.
Thealternatorgeneratespower,whichisconverted
bythepowercartridgetosupplyhighvoltagetothe
gun’selectrode.
Thepumpsupplies󰘱uidtothe󰘱uidhoseandgun,
wherethe󰘱uidiselectrostaticallychargedasit
passestheelectrode.Thecharged󰘱uidisattracted
tothegroundedworkpiece,wrappingaroundand
evenlycoatingallsurfaces.
Spraying Spraying
SprayingWaterborne Waterborne WaterborneFluids Fluids Fluids
Electrostatically Electrostatically
Electrostatically
Thiselectrostaticairspraygunisdesignedto
sprayonly only
onlywaterborne󰘱uidswhichmeetoneofthe
following󰘱ammabilityrequirements:
•FM, FM,
FM,FMc FMc FMcApproved: Approved: Approved:
Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.
•CE-EN CE-EN
CE-EN50059 50059 50059Compliant: Compliant: Compliant:
Materialisclassi󰘰edasnon-ignitableasde󰘰nedby
EN50059:2018.
Formoreinformation,see
IgnitabilityofCoatingMaterials,page92.
Whenconnectedtoavoltageisolationsystem,
allofthe󰘱uidinthespraygun,󰘱uidhose,and
isolated󰘱uidsupplyischargedtohighvoltage,
whichmeansthatthesystemhasmoreelectrical
energythanasolvent-basedsystem.Therefore,
onlynon-󰘱ammable󰘱uids(asde󰘰nedunder
Models,page3)canbesprayedwiththegunorbe
usedtoclean,󰘱ush,orpurgethegun.
Precautionsmustbetakenwhenusingelectrostatic
waterborneequipmenttoavoidpotentialshock
hazards.Whenthespraygunchargestheisolated
󰘱uidtohighvoltage,itissimilartocharginga
capacitororabattery.
Thesystemwillstoresomeoftheenergywhile
sprayingandretainsomeofthatenergyafterthe
spraygunisshutoff.Becauseittakessometime
forthatstoredenergytodischarge,itisimportant
toreadtheinstructions,includingtheFluidVoltage
DischargeandGroundingProcedure,page33,and
Grounding,page18,tounderstandwhenyoucan
approachortouchthegunnozzle.
Theamountoftimeittakestodischargethe
energydependsonthesystemdesign.Followthe
FluidVoltageDischargeandGroundingProcedure,
page33,beforeapproachingthefrontofthegun.
3A7504A
7

GunOverview
Controls, Controls,
Controls,Indicators, Indicators, Indicators,and and andComponents Components Components
Theelectrostaticgunincludesthefollowingcontrols,indicators,andcomponents.ForinformationonSmart
guns,alsoseeSmartGuns,page9.
Figure1GunOverview
Item Item
ItemDescription Description DescriptionPurpose Purpose Purpose
AAirSwivelInlet1/4npsm(m)left-handthread,forGracored-coloredgroundedair
supplyhose.
BFluidInletGracowaterborne󰘱uidsupplyhose
CTurbineAirExhaustBarbed󰘰tting,forsuppliedexhausttube.
DAirCapandNozzleForavailablesizes,seeAirCaps,page80and
FluidNozzles,page77.
EElectrodeNeedleSupplieselectrostaticchargetothe󰘱uid.
FFanAirAdjustmentValveAdjustsfansizeandshape.Canbeusedtodecreasepatternwidth.
GAtomizingAirRestrictor
Valve
Restrictsaircapair󰘱ow.Replacewithplug(included)ifdesired.
HFluidAdjustmentKnobAdjusts󰘱uid󰘱owbylimiting󰘱uidneedletravel.Useonlyinlow󰘱ow
conditions,toreducewear.
JESOn-OffValveTurnselectrostaticsON(I)orOFF(O).
KESIndicator(standard
gunonly;forSmart
gunindicator,see
OperatingMode,page9)
LitwhenESisON(I).Colorindicatesalternatorfrequency.Seethe
LEDindicatortableinGunSetupProcedure,page20.
8 3A7504A

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
SeeFigure2andSmartGunKey,page11.The
OperatingModedisplaysgundataduringnormal
spraying.Thedisplayusesabargraphtoshowthe
voltagelevelinkiloVolts(kV)andthecurrentlevelin
microAmperes(uA).Thebargraphrangeisfrom0
to100%foreachvalue.
IfthebargraphLEDsareblue,thegunisreadyto
spray.IftheLEDsareyelloworred,thecurrentis
toohigh.The󰘱uidmaybetooconductive,orsee
ElectricalTroubleshooting,page46forotherpossible
causes.
Hz Hz
HzIndicator Indicator Indicator
TheHzindicator(Hz)functionsthesameastheES
indicatoronstandardguns.Theindicatorlightsto
showthealternatorspeedstatus,andhasthree
colors:
•Greenindicatesthealternatorspeediscorrect.
•Iftheindicatorchangestoamberafteronesecond,
increasetheairpressure.
•Iftheindicatorchangestoredafteronesecond,
theairpressureistoohigh.Decreaseairpressure
untiltheindicatorisgreen.Tomaintainahigher
airpressure,installESOn/OffValveRestrictorKit
26A160.Then,adjustthepressureasneededto
ensuretheindicatorremainsgreen.
Voltage Voltage
VoltageAdjustment Adjustment AdjustmentSwitch Switch Switch
Thevoltageadjustmentswitch(VA)allowsthe
operatortochangebetweenlowandhighvoltage
settings.
•Thehighvoltagesettingisdeterminedbythe
maximumvoltageofthegunandisnotadjustable.
•Thelowvoltageindicator(LO)lights
whentheswitchissettoLO.Thelow
voltagesettingisuseradjustable.See
AdjustingtheLowVoltageSetting,page10.
Note
IftheErrordisplayappears,theSmart
modulehaslostcommunicationwiththe
powersupply.SeeErrorDisplay,page10for
furtherinformation.
Figure2SmartGunModuleinOperatingMode
3A7504A 9

GunOverview
Error Error
ErrorDisplay Display Display
IftheSmartmodulelosescommunicationwiththe
powersupply,theErrordisplayappears,theHz
indicatorturnsred,andtheSmartmoduleisdisabled.
Seethefollowing󰘰gureandSmartGunKey,page11.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page46.
CommunicationmustberestoredtomaketheSmart
modulefunctional.
Note
Ittakes8secondsfortheErrordisplayto
appear.Ifthegunhasbeendisassembled,
wait8secondsbeforesprayingtoensure
thatanErrorconditionhasnotoccurred.
Note
Ifthereisnopowertothegun,theError
displaywillnotappear.
Figure3ErrorDisplay
Adjusting Adjusting
Adjustingthe the theLow Low LowVoltage Voltage VoltageSetting Setting Setting
Thelowvoltagesettingisuseradjustable.To
accessthelowvoltagesettingscreenwhenin
OperatingMode,presstheLOSETbutton(LS)
momentarily.Thescreenwilldisplaythecurrent
lowvoltagesetting.Seethefollowing󰘰gureand
SmartGunKey,page11.Therangeis30–60kV.
SettheVoltageAdjustmentswitch(VA)toLO.Press
theLOSETbuttonrepeatedlytoincreasethesetting
inincrementsof5.Whenthedisplayreachesthe
maximumsetting(60kV)itwillreturntotheminimum
setting(30kV).Continuepressingthebuttonuntil
youreachthedesiredsetting.
Note
After2secondsofinactivitythedisplaywill
returntotheOperatingScreen.
Note
Thelowvoltagesettingmaybelocked.See
LockSymbol,page10.
Figure4LowVoltageSettingScreen(Unlocked)
Lock Lock
LockSymbol Symbol Symbol
Thelowvoltagesettingmaybelocked.Whenlocked,
animage(LK)appearsonthescreen.Seethe
following󰘰gureandSmartGunKey,page11.
•WheninHImode,thelowvoltagesettingisalways always
always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.
•WheninLOmode,thelocksymbolwill
only only
onlyappearifthelockisenabled.See
LowVoltageLockScreen,page13,tolockor
unlockthelowvoltagesetting.
Figure5LowVoltageSettingScreen(Locked)
10 3A7504A

GunOverview
Smart Smart
SmartGun Gun GunKey Key Key
Table Table
Table1 1 1Key Key Keyfor for forFigures Figures Figures2–9 2–9 2–9
Item Item
ItemDescription Description DescriptionPurpose Purpose Purpose
VAVoltageAdjustmentSwitchTwo-positionswitchsetsSmartgunvoltagetolowsetting(LO)or
highsetting(HI).ThisswitchisfunctionalinOperatingModeandin
DiagnosticMode.
LOLowVoltageMode
Indicator
Lights(blue)whentheSmartgunissettoLowVoltage.
kVVoltage(kV)DisplayDisplaysactualsprayingvoltageofthegun,inkV.InOperatingMode,
displayisabargraph.InDiagnosticMode,voltageisdisplayedas
anumber.
uACurrent(uA)DisplayDisplaysactualsprayingcurrentofthegun,inuA.InOperatingMode,
displayisabargraph.InDiagnosticMode,currentisdisplayedas
anumber.
LSLOSETbuttonPressmomentarilytoentertheLowVoltageSettingscreen.
Pressandholdforapproximately5secondstoenterorexitDiagnostic
Mode.
WhileinDiagnosticMode,pressmomentarilytoadvancethrough
screens.
WhileontheLowVoltageLockScreen(inDiagnosticMode),press
andholdtoturnthelockonoroff.
LVLowVoltageDisplayDisplaysthelowvoltagesettingasanumber.Thesettingcanbe
changed.SeeFigure4.
LKLowVoltageLockedAppearsifthelowvoltagesettingislocked.SeeFigure5andFigure9.
LDLODisplayAppearsontheLowVoltageLockScreen.SeeFigure9.
ERErrorDisplayAppearsiftheSmartmodulelosescommunicationwiththepower
supply.SeeFigure3.
VIVoltageIndicatorInDiagnosticMode,thetwotoprightLEDsofthescreenlight,
indicatingthatthevaluedisplayedisinkV.SeeFigure6.
CICurrentIndicatorInDiagnosticMode,thetwobottomrightLEDsofthescreenlight,
indicatingthatthevaluedisplayedisinuA.SeeFigure7.
ASAlternatorSpeedDisplayInDiagnosticMode,Hzlevelisdisplayedasanumber.SeeFigure8.
HzAlternatorSpeedIndicatorInOperatingMode,indicatorcolorvariestoshowthealternatorspeed
status:
•Greenindicatesthealternatorspeedisatthecorrectlevel.
•Iftheindicatorchangestoamberafteronesecond,thealternator
speedistoolow.
•Iftheindicatorchangestoredafteronesecond,thealternatorspeed
istoohigh.TheindicatoralsoturnsrediftheErrordisplayappears.
InDiagnosticMode,theindicatorisgreenwhenintheAlternator
Speed(Hertz)screen.
3A7504A
11

GunOverview
Diagnostic Diagnostic
DiagnosticMode Mode Mode
DiagnosticModeincludesfourscreenswhichdisplay
gundata:
•Voltage(kiloVolts)Screen
•Current(microAmperes)Screen
•AlternatorSpeed(Hertz)Screen
•LowVoltageLockScreen
Note
YoumustbeinOperatingModetoadjust
thelowvoltagesetting;thesettingisnot
adjustableinDiagnosticMode.However,the
voltageadjustmentswitch(VA)canbesetto
HIorLOinOperatingModeandDiagnostic
Mode.
ToenterDiagnosticMode,pressandholdtheLOSET
(LS)buttonforapproximately5seconds.Thedisplay
willgototheVoltage(kiloVolts)Screen,page12.
Toadvancetothenextscreen,presstheLOSET
buttonagain.
ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.
Note
Iftheguntriggerisreleasedwhilein
DiagnosticMode,thelastscreenviewedwill
bedisplayedwhenthegunisretriggered.
Note
DiagnosticModecannotbeexitedfrom
theLowVoltageLockScreen.See
LowVoltageLockScreen,page13for
details.
Voltage Voltage
Voltage(kiloVolts) (kiloVolts) (kiloVolts)Screen Screen Screen
TheVoltage(kiloVolts)Screenisthe󰘰rstscreen
toappearafterenteringDiagnosticMode.Seethe
following󰘰gureandSmartGunKey,page11.To
enterthisscreen,pressandholdtheLOSETbutton
forapproximately5secondswhileintheOperating
Mode.
Thisscreendisplaysthesprayingvoltageofthe
gunasanumber(kV),roundedtothenearest5kV.
ThetwotoprightLEDs(VI)ofthedisplaypanel
light,indicatingthattheVoltage(kiloVolts)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.
PresstheLOSETbuttontoadvancetothe
Current(microAmperes)Screen,page12.Press
andholdforapproximately5secondstoreturnto
OperatingMode.
Figure6Voltage(kiloVolts)Screen
Current Current
Current(microAmperes) (microAmperes) (microAmperes)Screen Screen Screen
TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.Seethefollowing
󰘰gureandSmartGunKey,page11.Toenterthis
screen,presstheLOSETbuttonwhileintheVoltage
(kiloVolts)Screen.
Thisscreendisplaysthesprayingcurrentofthegun
asanumber(uA),roundedtothenearest5uA.The
twobottomrightLEDs(CI)ofthedisplaypanellight,
indicatingthattheCurrent(microAmperes)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.
PresstheLOSETbuttontoadvancetothe
AlternatorSpeed(Hertz)Screen,page13.Press
andholdforapproximately5secondstoreturnto
OperatingMode.
Figure7Current(microAmperes)Screen
12
3A7504A

GunOverview
Alternator Alternator
AlternatorSpeed Speed Speed(Hertz) (Hertz) (Hertz)Screen Screen Screen
TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.Seethefollowing
󰘰gureandSmartGunKey,page11.Toenterthis
screen,presstheLOSETbuttonwhileintheCurrent
(microAmperes)Screen.
Thisscreendisplaysthealternatorspeedasa3
digitnumber(AS),roundedtothenearest5Hz.The
displayisareadoutandcannotbechanged.Ifthe
alternatorspeedisgreaterthan999Hz,thedisplay
willshow999.
TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.
PresstheLOSETbuttontoadvancetothe
LowVoltageLockScreen,page13.Pressandhold
forapproximately5secondstoreturntoOperating
Mode.
Figure8AlternatorSpeed(Hertz)Screen
Low Low
LowVoltage Voltage VoltageLock Lock LockScreen Screen Screen
TheLowVoltageLockScreenisthefourthscreenin
theDiagnosticMode.Seethefollowing󰘰gureand
SmartGunKey,page11.Toenterthisscreen,press
theLOSETbuttonwhileintheAlternatorSpeed
(Hertz)Screen.
ThisscreendisplaysthestatusoftheLowVoltage
Lock.Ifthesettingislocked,thelockimage(LK)
appearstotheleftoftheLodisplay(LD).Ifthesetting
isunlocked,thelockimagedoesnotappear.
Tochangethelockstatus,pressandholdthe
LOSETbuttonuntilthelockimageappears
ordisappears.Ifthelockisset,theimagewill
alsoappearontheLowVoltageSettingScreen
wheninlowvoltagemode.(Seethe󰘰gurein
AdjustingtheLowVoltageSetting,page10.)
Note
DiagnosticModecannotbeexitedfromthis
screen,becausepressingandholdingthe
LOSETbuttonisusedtoturnthelockonor
off.Toexit,pressLOSETmomentarilyto
returntotheVoltage(kiloVolts)Screen,then
exitDiagnosticModefromthere.
Figure9LowVoltageLockScreen
3A7504A 13

Installation
Installation Installation
Installation
System System
SystemRequirements Requirements Requirements
Theuseofmultiplegunswithoneisolationcabinet
maycauseelectricshock,󰘰re,orexplosion.To
helppreventinjuryorequipmentdamage,useonly
onegunperisolationcabinet.
Tospraywithelectrostatics,thespraygunmustbe
connectedtoavoltageisolationsystemsuchasa
GracoHydroShieldorWB100.
Avoltageisolationsystemmusthavethefollowing
features:
•Anisolationenclosurethatpreventspersonsfrom
makingcontactwiththehighvoltagecomponents
beforethesystemvoltageisdischarged.All
componentsoftheisolationsystemthatare
chargedtohighvoltagemustbecontainedwithin
theenclosure.
•Ableedresistortodrainoffthesystemvoltage
whenthespraygunisnotinuse.Ametalpartof
the󰘱uidsupplyunitmustbeelectricallyconnected
tothebleedresistor.
•Asafetyinterlockthatautomaticallydischargesthe
systemvoltagewhenanyoneopenstheisolation
enclosure.
Note
TheGracowarrantyandapprovalsarevoidif
theelectrostaticspraygunisconnectedtoa
non-Gracovoltageisolationsystemorifthe
gunisoperatedabove60kV.
Warning Warning
WarningSign Sign Sign
Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.
Install Install
Installthe the theSystem System System
Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.
•Donotinstallorservicethisequipmentunless
youaretrainedandquali󰘰ed.
•Complywithalllocalcodesandregulations
TypicalInstallation,page15showsatypical
electrostaticairspraysystem.Itisnotanactual
systemdesign.Forassistanceindesigningasystem
tosuityourparticularneeds,contactyourGraco
distributor.
Setupandinstalltheisolationsystemaccordingto
theinstructionsforyourisolationsystem.
Ventilate Ventilate
Ventilatethe the theSpray Spray SprayBooth Booth Booth
Donotoperatethegununlessventilatingair󰘱owis
abovetheminimumrequiredvalue.Providefresh
airventilationtoavoidthebuildupof󰘱ammableor
toxicvaporswhenspraying,󰘱ushing,orcleaning
thegun.Interlockthegunairand󰘱uidsupply
topreventoperationunlessventilatingair󰘱owis
abovetheminimumrequiredvalue.
Thesprayboothmusthaveaventilationsystem.
Electricallyinterlockthegunairand󰘱uidsupplywith
theventilatorstopreventgunoperationanytimethat
theventilationair󰘱owfallsbelowminimumvalues.
Checkandfollowalllocalcodesandregulations
regardingairexhaustvelocityrequirements.Verify
theoperationoftheinterlockatleastonceayear.
14
3A7504A

Installation
Typical Typical
TypicalInstallation Installation Installation
Figure10TypicalInstallationofaWaterborneGun
Key Key
Key
Item Item
ItemDescription Description Description
SWaterborneElectrostaticAirSprayGun
AMMainAirSupplyLine
AB*Bleed-TypeAirShutoffValve
HG*GracoRedGroundedAirHose(left-hand
threads)
CA*IsolatedSystem
PRGunAirPressureRegulator
Item Item
ItemDescription Description Description
ASGunAirLineFilter
GND*GunAirHoseGroundWire
SRStrainReliefFitting
FJ*GracoWaterborneFluidHose
*Theseitemsarerequiredforsafeoperation.
3A7504A 15

Installation
Connect Connect
Connectthe the theWaterborne Waterborne WaterborneFluid Fluid FluidHose Hose Hose
AlwaysuseaGracowaterborne󰘱uidhosebetween
thevoltageisolationsystem󰘱uidoutletandthegun
󰘱uidinlet.Thewaterborne󰘱uidhoseconsistsof
aninnerPTFEtube(FT),aconductivelayer(FC),
andanabrasion-resistantouterjacket(FJ).The
conductivelayerisconnectedtogroundatthegun
󰘰ttingbracket(104).
Beforeconnectingthewaterborne󰘱uidhosetothe
gun,blowitoutwithairand󰘱ushwithwaterto
removecontaminants.Flushthegunbeforeusingit.
Toreducetheriskofelectricshock,installonly
onecontinuousGracowaterbornehosebetween
theisolated󰘱uidsupplyandthegun.Donotsplice
hosestogether.
1.Removethegunairinlet󰘰tting(21)fromthegun.
Note
This󰘰ttingusesaleft-handthread.
2.Removetheo-ring(21a)andinstallthe󰘰ttingin
thebracket.Reassembletheo-ring.
Figure11ConnecttheFluidHose
3.AnewGracowaterborne󰘱uidhosecomes
fullyassembledandreadytoinstall.For󰘱uid
hoseassemblyandrepairinstructions,referto
FluidHoseAssemblyandRepair,page91.
4.Generouslyapplydielectricgrease(44)tothe
o-ring(107)andthethreadsofthebarrel󰘰tting
(106).Pullthe󰘰ttingback1-1/2in.(38mm)and
applygreasetotheexposedPTFEhoseto󰘰llthe
areabetweenthehoseandthe󰘰tting.Makesure
thebarrelinletiscleananddry,thenscrewthe
󰘰ttingintothe󰘱uidinletofthegunbarrel(1).
5.Loosenthestrainreliefnut(102)sothebracket
canmovefreelyonthehose.
6.Alignthebracket(104)holeswiththeairinletand
exhaustoutlet.Securewiththeairinlet󰘰tting
(21).Tightenthestrainreliefnut(102)tosecure
thehose.
7.Checkthatthenut(105)istightenedsecurelyto
theferrulehousing(103).
8.Presstheexhausttube(36)ontotheexhaust
valvebarb(FC).Securewiththeclamp(43).
9.Connecttheotherendofthehosetotheisolated
󰘱uidsupplyasinstructedintheisolationsystem
manual.Theconductivehoselayermustbe
groundedattheisolationsystem.
Conductivehoselayer(FC)mustbegrounded
throughitsconnectiontotheisolationsystem’s
groundedenclosure(CA)orgrounded
fence.Tomaintaingroundingcontinuity,the
conductivehoselayer(FC)mustbeengaged
intheferrulewhenthestrainreliefnutis
tightened.Failuretoproperlyinstallthehosein
thestrainreliefcouldresultinanelectricshock.
Figure12ShieldedFluidHoseConnectionat
Non-GracoIsolationEnclosure
16 3A7504A

Installation
Air Air
AirSupply Supply SupplyLine Line Line
Toreducetheriskofelectricshockorotherserious
injury,youmust:
•Usetheelectricallyconductivered-colored
GracoGroundedAirHoseforthegunairsupply.
•Donotusetheblackorgray-coloredGracoair
hoses.
•Connectthehosegroundwiretoatrueearth
ground.
1.Installanairline󰘰lter/waterseparator(AS)on
themainairsupplylinetoensureadry,cleanair
supplytothegun.
Note
Dirtandmoisturecanruinthe
appearanceofyour󰘰nishedworkpiece
andcancausetheguntomalfunction.
SeeTypicalInstallation,page15.
2.Installableedtypeairshut-offvalve(AB)and
airregulator(PR)onthegunairsupplylineto
controlairpressuretothegun.
3.Connectthered-coloredGracoElectrically
ConductiveAirHose(HG)betweenthegunair
regulator(PR)andthegun’sairinlet.Thegun
airinlet󰘰ttinghasaleft-handthread.Connect
theairsupplyhosegroundwire(GND)toatrue
earthground.
Note
Someisolationsystemsprovidecontrols
toregulatetheairtothespraygun.
Consulttheisolationsystemmanualfor
properinstallation.
3A7504A
17

Installation
Grounding Grounding
Grounding
Theequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundallequipment,personnel,objects
beingsprayed,andconductiveobjectsinorclose
tothesprayarea.Theresistancemustnotexceed
1megohm.Groundingprovidesanescapewire
fortheelectriccurrent.
Whenoperatingtheelectrostaticgun,any
ungroundedobjects(suchaspeople,containers,and
tools)inthespraylocationcanbecomeelectrically
charged.
Thefollowingareminimumgroundingrequirements
forabasicelectrostaticsystem.Yoursystemmay
includeotherequipmentorobjectswhichmustbe
grounded.Yoursystemmustbeconnectedtoa
trueearthground.Checkgroundconnectionsdaily.
Checkyourlocalelectricalcodesandregulationsfor
detailedgroundinginstructions.
•
Electrostatic Air Spray Gun: Groundthegun
byconnectingthered-coloredGracoGrounded
AirHosetothegun,andconnectingtheair
hosegroundwiretoatrueearthground.See
CheckGunElectricalGrounding,page32.
• All persons entering the spray area: mustwear
shoeshavingconductivesolessuchasleather,
orwearpersonalgroundingstraps.Donot
wearshoeswithnon-conductivesolessuchas
rubberorplastic.Ifglovesarenecessary,wear
theconductiveglovessuppliedwiththegun.If
non-Gracoglovesareworn,cutoff󰘰ngersorpalm
areaofglovestoensureyourhandcontactsthe
groundedgunhandle.
• Object being sprayed: Keeptheworkpiecehangers
cleanandgroundedatalltimes.
• Voltage Isolation System: Electricallyconnectthe
voltageisolationsystemtoatrueearthground.
Seeyourisolationsystemmanual.
• Graco Shielded Waterborne Fluid Hose:
Thehoseisgroundedthroughthe
conductivelayer.Installasinstructedunder
ConnecttheWaterborneFluidHose,page16.
• All electrically conductive objects or devices in the
spray area: mustbeproperlygrounded.
• Fluid and waste containers: Groundall󰘱uidand
wastecontainersinthesprayarea.Donotusepail
linersunlesstheyareconductiveandgrounded.
When󰘱ushingthespraygun,thecontainerused
tocatchtheexcess󰘱uidmustbeelectrically
conductiveandgrounded.
•
Air compressors: Groundtheequipmentaccording
tothemanufacturer'srecommendations.
18 3A7504A

Installation
• All air lines mustbeproperlygrounded.Useonly
groundedhoseswithamaximumof100feet(30.5
m)combinedhoselengthtoensuregrounding
continuity.
•
The 󰘱oor of the spray area: mustbeelectrically
conductiveandgrounded.Donotcoverthe󰘱oor
withcardboardoranynon-conductivematerial
whichwouldinterruptgroundingcontinuity.
• All solvent pails: Useonlyapproved,grounded
metalcontainers,whichareconductive.Donot
useplasticcontainers.Useonlynon-󰘱ammable
solvents.Donotstoremorethanthequantity
neededforoneshift.
3A7504A 19

GunSetup
Gun Gun
GunSetup Setup Setup
Gun Gun
GunSetup Setup SetupProcedure Procedure Procedure
Toreducetheriskof󰘰reandexplosion,󰘱uidsused
mustmeetthefollowing󰘱ammabilityrequirements:
•FM, FM,
FM,FMc FMc FMcApproved: Approved: Approved:
Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.
•CE CE
CE- - -EN EN EN50059 50059 50059Compliant: Compliant: Compliant:
Materialisclassi󰘰edasnon-ignitableasde󰘰ned
byEN50059:2018.
Formoreinformation,see
IgnitabilityofCoatingMaterials,page92.
Contactwiththechargedcomponentsofthespray
gunwillcauseanelectricshock.Donottouchthe
gunnozzleorelectrodeorcomewithin4in.(102
mm)ofthefrontofthegunduringoperationor
untilperformingtheFluidVoltageDischargeand
GroundingProcedure,page33.
FollowtheFluidVoltageDischargeandGrounding
Procedure,page33whenyoustopsprayingand
wheneveryouareinstructedtodischargethe
voltage.
Toreducetheriskofcomponentrupture,which
cancauseseriousinjury,donotexceedthe
maximumworkingpressureofthelowestrated
systemcomponent.Thisequipmenthasa100psi
(0.7MPa,7bar)maximumworkingairand󰘱uid
pressure.
Toreducetheriskofaninjury,followthe
PressureReliefProcedure,page33wheneveryou
areinstructedtorelievethepressure.
Foradditionalstepstosetupspecialtyguns,
seeSoftSprayGunSetupProcedure,page24,
RoundSprayGunSetupProcedure,page26,
HVLPGunSetupProcedure,page25,
AbrasiveMaterialGunSetupProcedure,page28,
andMoldReleaseGunSetupProcedure,page30.
Seethefollowing󰘰guretolocatetheelectrostatic
guncontrols.
Figure13ElectrostaticGunControls
1.Checkthattheretainingring(6)istight,securing
the󰘱uidnozzle(4)andaircap(5).
Note
Thegunisshippedwiththe󰘱uidnozzle
andaircapinstalled.Toselecta
differentsize󰘱uidnozzleoraircap,see
FluidNozzleSelectionChart,page77,
andAirCapSelectionGuide,page80.
Toinstallthenozzleandaircap,seeAir
CapandNozzleReplacement,page49.
2.TurnOFF(O)theESOn-Offswitch(J).
20 3A7504A