Graco Pro Xp H60T10 User manual

Instructions-Parts
Pro Pro
ProXp™ Xp™ Xp™Electrostatic Electrostatic Electrostatic
Air Air
Air- - -Assisted Assisted AssistedSpray Spray SprayGun Gun Gun3A2495K
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 Dmaterials. 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 IIAmaterials. materials. materials.For For Forprofessional professional professional
use use
useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Thisequipmentcouldpresenthazardsifnotoperatedaccordingto
theinformationinthismanual.Read Read
Readall all allwarnings warnings warningsand and andinstructions instructions instructionsin in in
this this
thismanual manual manualbefore before beforeusing using usingthe the theequipment. equipment. equipment.Save Save Savethese these theseinstructions. instructions. instructions.
3000psi(21MPa,210bar)Maximum
FluidWorkingPressure
100psi(0.7MPa,7bar)MaximumAir
WorkingPressure
Seepage3formodelpartnumbersand
approvalinformation.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Models...............................................................3
Approvals...........................................................3
RelatedManuals................................................3
Warnings...........................................................4
GunOverview....................................................7
HowtheElectrostaticAASprayGun
Works............................................7
Controls,Indicators,andComponents...........8
SmartGuns.................................................9
Installation..........................................................14
WarningSign...............................................14
VentilatetheSprayBooth.............................14
AirSupplyLine............................................15
FluidSupplyLine.........................................15
Grounding...................................................17
GunSetup..........................................................21
GunSetupProcedure...................................21
CheckGunElectricalGrounding...................24
CheckFluidResistivity.................................25
CheckFluidViscosity...................................25
FlushBeforeUsingEquipment......................25
Operation...........................................................26
PressureReliefProcedure............................26
Startup........................................................27
Shutdown....................................................27
Maintenance......................................................28
DailyCareandCleaningChecklist................28
Flushing......................................................28
CleantheGunDaily.....................................30
DailySystemCare.......................................31
ElectricalTests...................................................32
TestGunResistance....................................32
TestPowerSupplyResistance.....................33
TestGunBarrelResistance..........................34
Troubleshooting..................................................35
SprayPatternTroubleshooting......................35
GunOperationTroubleshooting....................36
ElectricalTroubleshooting............................37
Repair................................................................39
PreparetheGunforService.........................39
AirCap,SprayTip,andFluidSeatHousing
Replacement..................................40
ElectrodeReplacement................................41
FluidTubeRemovalandReplacement...........42
FluidFilterReplacement...............................42
GunBarrelRemoval.....................................43
GunBarrelInstallation..................................43
FluidNeedleReplacement............................44
PowerSupplyRemovaland
Replacement..................................45
AlternatorRemovalandReplacement...........46
FanAirAdjustmentValveRepair..................48
AtomizingAirAdjustmentValve
Repair............................................48
ESOn-OffValveRepair...............................49
AirValveRepair...........................................50
SmartModuleReplacement..........................51
AirSwivelandExhaustValve
Replacement..................................52
Parts..................................................................53
StandardAir-AssistedSprayGun
Assembly.......................................53
SmartAir-AssistedSprayGun
Assembly.......................................55
AlternatorAssembly.....................................57
ESOn-OffValveAssembly...........................58
FanAirAdjustmentValveAssembly..............59
AirCapAssembly........................................60
SmartModuleAssembly...............................60
SprayTipSelectionChart....................................61
AEMFineFinishSprayTips..........................61
AEFFineFinishPre-Ori󰘰ceSpray
Tips...............................................62
RoundSprayTips........................................63
RecommendedFilterSizes...........................64
RepairKitsandAccessories................................65
GunAccessories..........................................65
InlineFluidFilterKitAccessories...................65
OperatorAccessories...................................66
SystemAccessories.....................................66
Signs..........................................................66
TestEquipment...........................................66
Hoses.........................................................67
Dimensions........................................................68
TechnicalSpeci󰘰cations......................................69
GracoProXpWarranty.......................................70
23A2495K

Models
Models Models
Models
Part Part
PartNo. No. No.kV kV kVDisplay Display Display
H60T1060Standard
H60M1060Smart
H85T1085Standard
H85M1085Smart
H85T57*85Standard
H85M57*85Smart
*HighAirFlowGunModels,equippedwithESOn-OffwithAirRestrictorValve,whichlimitsair󰘱owtothe
turbine.Forapplicationsthatrequirehighair󰘱owattheaircap.
Approvals Approvals
Approvals
2575
II II
II2 2 2G G G
0.24mJT6
FM12ATEX0068
EN50050–1
Ta0°C–50°C
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNo. No. No.Description Description Description
3A2499RoundSprayKit,Instructions
307263ProbeandMeter,Instructions
308393GunWasherKit,Instructions
309227GunFlushBoxModule,Instructions
309455TestFixture,HighVoltageProbe,andkVMeter,Instructions
406999VoltageTesterConversionKit,Instructions
3A2495K3

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanual,referbacktotheseWarnings.Product-speci󰘰c
hazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughoutthebodyofthismanual
whereapplicable.
WARNING WARNING
WARNING
FIRE, FIRE,
FIRE,EXPLOSION, EXPLOSION, EXPLOSION,AND AND ANDELECTRIC ELECTRIC ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplodee.
Paintorsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent
󰘰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.
•Interlockthegunairand󰘱uidsupplytopreventoperationunlessventilationair󰘱owisabove
theminimumrequiredvalue.
•UseonlyGroupIIAorGroupDmaterials.
•Usecleaningsolventswithhighestpossible󰘱ashpointwhen󰘱ushingorcleaningequipment.
•Neversprayor󰘱ushsolventathighpressure.
•Tocleantheexterioroftheequipment,cleaningsolventsmusthavea󰘱ashpointatleast15°
Cor59°Faboveambienttemperature.Non-ignitable󰘱uidsarepreferred.
•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Keepthesprayareacleanatalltimes.Usenon-sparkingtoolstocleanresiduefromthe
boothandhangers.
•Keepaworking󰘰reextinguisherintheworkarea.
43A2495K

Warnings
WARNING WARNING
WARNING
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay
looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Getimmediate immediate immediatesurgical surgical surgical
treatment. treatment.
treatment.
•Donotspraywithouttipguardandtriggerguardinstalled.
•Engagetriggerlockwhennotspraying.
•Donotpointgunatanyoneoratanypartofthebody.
•Donotputyourhandoverthespraytip.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopsprayingandbeforecleaning,checking,
orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
3A2495K5

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,requestSafetyDataSheets(SDSs)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
Manycleaningsolventscandegradeplasticpartsandcausethemtofail,whichcouldcause
seriousinjuryorpropertydamage.
•Useonlycompatiblesolventstocleanplasticstructuralorpressure-containingparts.
•SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanualsformaterialsofconstruction.Consult
thesolventmanufacturerforinformationandrecommendationsaboutcompatibility.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
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.
63A2495K

GunOverview
Gun Gun
GunOverview Overview Overview
How How
Howthe the theElectrostatic Electrostatic ElectrostaticAA AA AASpray Spray SprayGun Gun Gun
Works Works
Works
Thisisnotanairspraygun.Tohelpprevent
seriousinjuryfrompressurized󰘱uid,suchasskin
injection,andsplashing󰘱uid,readandfollowthe
Skin Skin
SkinInjection Injection InjectionHazard Hazard HazardWarnings Warnings Warningsonpage5.
Theair-assistedsprayguncombinesairlessand
airsprayingconcepts.Thespraytipatomizes
andshapesthe󰘱uidintoafanpattern,asdoes
aconventionalairlessspraytip.Airfromtheair
capfurtheratomizesthe󰘱uidandcompletesthe
atomizationofthe󰘱uidtailstoproduceauniform
pattern.
Asthegunistriggered,partoftheregulatedair
operatesthealternatorturbineandtherestofthe
airhelpsatomizethe󰘱uidbeingsprayed.The
alternatorgeneratespower,whichisconvertedby
thepowercartridgetosupplyhighvoltagetothe
gun’selectrode.
The󰘱uidiselectrostaticallychargedasitpasses
theelectrode.Thecharged󰘱uidisattractedtothe
groundedworkpiece,wrappingaroundandevenly
coatingallsurfaces.
Theregulatedairthatisdirectedtotheaircapcan
befurthercontrolledusingthegun’satomizingair
adjustmentvalve.Thisvalvecanbeusedtorestrict
air󰘱owtotheaircapwhilemaintainingsuf󰘰cientair
󰘱owtothealternator.Theatomizingairadjustment
valvedoesnotcontrolpatternwidth.Tochange
patternwidth,useanewtipsize,orusethefan
adjustmenttonarrowthepatternwidth.
Thehighworking󰘱uidpressureofthisgunprovides
thepowerneededtoatomizehighersolidsmaterials.
NOTE: NOTE:
NOTE:Forairlessatomization,ifdesired,turnthe
gun’satomizingairadjustmentvalvecompletelyoff.
Closingthisvalvedoesnotaffectalternatoroperation.
3A2495K7

GunOverview
Controls, Controls,
Controls,Indicators, Indicators, Indicators,and and andComponents Components Components
Theelectrostaticgunincludesthefollowingcontrols,indicators,andcomponents(seeFig.1).Forinformation
onSmartguns,alsoseeSmartGuns,page9.
Figure1GunOverview
Item Item
ItemDescription Description DescriptionPurpose Purpose Purpose
AAirSwivelInlet1/4npsm(m)left-handthread,forGracogroundedairsupplyhose.
BFluidInlet1/4npsm(m),for󰘱uidsupplyhose.
CTurbineAirExhaustBarbed󰘰tting,forsuppliedexhausttube.
DAirCap/TipGuardand
SprayTip
SeeSprayTipSelectionChart,page61,foravailablesizes.
EElectrodeSupplieselectrostaticchargetothe󰘱uid.
FFanAirAdjustmentValveAdjustsfansizeandshape.Canbeusedtodecreasepatternwidth.
GAtomizingAirAdjustment
Valve
Adjustsatomizingair󰘱ow.
HTriggerSafetyLockLockstriggertopreventgunfromspraying.
JESOn-OffValveTurnselectrostaticsON(I)orOFF(O).
KESIndicator(standard
gunonly;forSmart
gunindicator,see
OperatingMode,page9)
LitwhenESisON(I).Colorindicatesalternatorfrequency.Seethe
LEDindicatortableintheGunSetupProcedure,page21.
LInlineFluidFilterProvides󰘰nal󰘰ltrationof󰘱uid.Locatedinside󰘱uidtube󰘰tting.
83A2495K

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.2andSmartGunKey,page11.The
OperatingModedisplaysgundataduringnormal
spraying.Thedisplayusesabargraphtoshowthe
voltagelevelinkiloVolts(kV)andthecurrentlevelin
microAmperes(uA).Thebargraphrangeisfrom0
to100%foreachvalue.
IftheuAbargraphLEDsareblue,thegunisready
tospray.IftheLEDsareyelloworred,thecurrentis
toohigh.The󰘱uidmaybetooconductive,orsee
ElectricalTroubleshooting,page37forotherpossible
causes.
Hz Hz
HzIndicator Indicator Indicator
TheHzindicatorfunctionsthesameastheES
indicatoronstandardguns.Theindicatorlightsto
showthealternatorspeedstatus,andhasthree
colors:
•Greenindicatesthealternatorspeediscorrect.
•Iftheindicatorchangestoamberafteronesecond,
increasetheairpressure.
•Iftheindicatorchangestoredafteronesecond,
theairpressureistoohigh.Decreaseairpressure
untiltheindicatorisgreen.Tomaintainahigher
airpressure,installESOn/OffValveRestrictorKit
26A294.Then,adjustthepressureasneededto
ensuretoensuretheindicatorremainsgreen.
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
3A2495K9

GunOverview
Error Error
ErrorDisplay Display Display
IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3andSmartGunKey,page11.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page37.
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.4andSmartGunKey,page11.
Thepossiblerangesare:
•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
andSmartGunKey,page11.
•WheninHImode,thelowvoltagesettingisalways always
always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.
•WheninLOmode,thelocksymbolwill
only only
onlyappearifthelockisenabled.See
LowVoltageLockScreen,page13,tolockor
unlockthelowvoltagesetting.
Figure5LowVoltageSettingScreen(Locked)
103A2495K

GunOverview
Smart Smart
SmartGun Gun GunKey Key Key
Table Table
Table1 1 1Key Key Keyfor for forFigs. Figs. Figs.2–9. 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.SeeFig.4.
LKLowVoltageLockedAppearsifthelowvoltagesettingislocked.SeeFig.5andFig.9.
LDLODisplayAppearsontheLowVoltageLockScreen.SeeFig.9.
ERErrorDisplayAppearsiftheSmartmodulelosescommunicationwiththepower
supply.SeeFig.3.
VIVoltageIndicatorInDiagnosticMode,thetwotoprightLEDsofthescreenlight,
indicatingthatthevaluedisplayedisinkV.SeeFig.6.
CICurrentIndicatorInDiagnosticMode,thetwobottomrightLEDsofthescreenlight,
indicatingthatthevaluedisplayedisinuA.SeeFig.7.
ASAlternatorSpeedDisplayInDiagnosticMode,Hzlevelisdisplayedasanumber.SeeFig.8.
HzAlternatorSpeedIndicatorInOperatingMode,indicatorcolorvariestoshowthealternatorspeed
status:
•Greenindicatesthealternatorspeedisatthecorrectlevel.
•Iftheindicatorchangestoamberafteronesecond,thealternator
speedistoolow.
•Iftheindicatorchangestoredafteronesecond,thealternatorspeed
istoohigh.TheindicatoralsoturnsrediftheErrordisplayappears.
InDiagnosticMode,theindicatorisgreenwhenintheAlternator
Speed(Hertz)screen.
3A2495K11

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,page12.
Toadvancetothenextscreen,presstheLOSET
buttonagain.
ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.
NOTE: NOTE:
NOTE:IfthegunisdetriggeredwhileinDiagnostic
Mode,thelastscreenviewedwillbedisplayedwhen
thegunisretriggered.
NOTE: NOTE:
NOTE:DiagnosticModecannotbeexited
fromtheLowVoltageLockScreen.See
LowVoltageLockScreen,page13fordetails.
Voltage Voltage
Voltage(kiloVolts) (kiloVolts) (kiloVolts)Screen Screen Screen
TheVoltage(kiloVolts)Screenisthe󰘰rstscreento
appearafterenteringDiagnosticMode.SeeFig.6
andSmartGunKey,page11.Toenterthisscreen,
pressandholdtheLOSETbuttonforapproximately
5secondswhileintheOperatingMode.
Thisscreendisplaysthesprayingvoltageofthe
gunasanumber(kV),roundedtothenearest5kV.
ThetwotoprightLEDs(VI)ofthedisplaypanel
light,indicatingthattheVoltage(kiloVolts)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.
PresstheLOSETbuttontoadvancetothe
Current(microAmperes)Screen,page12.Press
andholdforapproximately󰘰vesecondstoreturnto
OperatingMode.
Figure6Voltage(kiloVolts)Screen
Current Current
Current(microAmperes) (microAmperes) (microAmperes)Screen Screen Screen
TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7and
SmartGunKey,page11.Toenterthisscreen,press
theLOSETbuttonwhileintheVoltage(kiloVolts)
Screen.
Thisscreendisplaysthesprayingcurrentofthegun
asanumber(uA),roundedtothenearest5uA.The
twobottomrightLEDs(CI)ofthedisplaypanellight,
indicatingthattheCurrent(microAmperes)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.
PresstheLOSETbuttontoadvancetothe
AlternatorSpeed(Hertz)Screen,page13.Press
andholdforapproximately󰘰vesecondstoreturnto
OperatingMode.
Figure7Current(microAmperes)Screen
123A2495K

GunOverview
Alternator Alternator
AlternatorSpeed Speed Speed(Hertz) (Hertz) (Hertz)Screen Screen Screen
TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8and
SmartGunKey,page11.Toenterthisscreen,
presstheLOSETbuttonwhileintheCurrent
(microAmperes)Screen.
Thisscreendisplaysthealternatorspeedasa3digit
number(AS),roundedtothenearest10Hz.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
TheLowVoltageLockScreenisthefourth
screenintheDiagnosticMode.SeeFig.9and
SmartGunKey,page11.Toenterthisscreen,press
theLOSETbuttonwhileintheAlternatorSpeed
(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
3A2495K13

Installation
Installation Installation
Installation
Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.
•Donotinstallorservicethisequipmentunless
youaretrainedandquali󰘰ed.
•Besureyourinstallationcomplieswithlocal,
state,andnationalcodesfortheinstallation
ofelectricalapparatusinaClassI,Div.I,
hazardouslocationoraGroupII,ZoneI
explosiveatmospherelocation.
•Complywithalllocalcodesandregulations.
Fig.10(TypicalInstallation)showsatypical
electrostaticair-assistedspraysystem.Itisnotan
actualsystemdesign.Forassistanceindesigning
asystemtosuityourparticularneeds,contactyour
Gracodistributor.
Warning Warning
WarningSign Sign Sign
Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.
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.
NOTE:Theminimumallowableairexhaust
velocityis60feet/minute(19linearmeters/minute).
High-velocityairexhaustwilldecreasetheoperating
ef󰘰ciencyoftheelectrostaticsystem.
143A2495K

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.
Toreducetheriskofseriousinjurydueto
componentrupture,includingskininjection,
pumppressuremustbelimitedbythepumpair
regulator.Donotrelyonthegun󰘱uidregulator
tolimitthe󰘱uidpressuretothegun.
The󰘱uidsupplypumpmustbepreventedfrom
producinga󰘱uidpressuregreaterthanthe
3000psi(21MPa,210bar)
MaximumWorking
FluidPressure ofthegun.Forexample,theair
supplypressuretoa30:1ratiopumpmustnot
exceed100psi(0.7MPa,7bar).
3.Installbleed-typeairregulators(PR,GR)on
thepumpandgunairsupplylinestocontrolair
pressuretothepumpandgun.
Trappedaircancausethepumptocycle
unexpectedly,whichcanresultinserious
injury,includingskininjectionandsplashing
󰘱uidintheeyesorontheskin.Donotoperate
theequipmentwithoutthebleed-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󰘱uidpressureregulator(FR)onthe󰘱uid
linetocontrol󰘱uidpressuretothegun.
3.Installa󰘱uid󰘰lter(FF)nearthepumpoutlet,to
removeparticlesandsedimentwhichcouldclog
thespraynozzle.
NOTE: NOTE:
NOTE:Thegunincludesaninline󰘱uid󰘰lterfor
additional󰘰ltration.
Toreducetheriskofseriousinjury,including
skininjectionandsplashing󰘱uidintheeyesor
ontheskin,donotoperateequipmentwithout
the󰘱uiddrainvalve(FD)installed.
4.The󰘱uiddrainvalve(FD)isrequiredinyour
systemtoassistinrelieving󰘱uidpressureinthe
displacementpump,hose,andgun.Triggering
theguntorelievepressuremaynotbesuf󰘰cient.
Installadrainvalveclosetothepump's󰘱uid
outlet.
3A2495K15

Installation
NON NON
NON- - -HAZARDOUS HAZARDOUS HAZARDOUSLOCATION LOCATION LOCATIONHAZARDOUS HAZARDOUS HAZARDOUSLOCATION LOCATION LOCATION
Figure10TypicalInstallation
Typical Typical
TypicalInstallation Installation InstallationKey Key Key
Item Item
ItemDescription Description Description
AFAirFilter/WaterSeparator
AG*GunAirHoseGroundWire
AH*GracoGroundedAirHose(left-hand
threads)
ALPumpAirLineLubricator
BV*PumpBleed-TypeAirShutoffValve
EGElectrostaticAirSprayGun
FD*FluidDrainValve
FFFluidFilter
FGFluidPressureGauge
FLFluidSupplyLine
FRFluidPressureRegulator
Item Item
ItemDescription Description Description
FVFluidShutoffValve
GRGunAirPressureRegulator
MAMainAirSupplyLine
PG*PumpGroundWire
PRPumpAirPressureRegulator
RVPumpRunawayValve
SPSupplyPump
SV*VentilationFanInterlockSolenoidValve
NOTE: NOTE:
NOTE:Thesolenoidvalveisnotofferedas
aGracoaccessory.
*Theseitemsarerequiredforsafeoperation.They
mustbepurchasedseparately.
163A2495K

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.
•
Allpersonsenteringthesprayarea: mustwear
shoeshavingconductivesolessuchasleather,
orwearpersonalgroundingstraps.Donot
wearshoeswithnon-conductivesolessuchas
rubberorplastic.Ifglovesarenecessary,wear
theconductiveglovessuppliedwiththegun.If
non-Gracoglovesareworn,cutoff󰘰ngersorpalm
areaofglovestoensureyourhandcontactsthe
groundedgunhandle.Conductiveglovesand
footwearmustnotexceed100megohmperEN
ISO20344,EN1149–5.
• Objectbeingsprayed: Keeptheworkpiecehangers
cleanandgroundedatalltimes.
• ElectrostaticAir-AssistedSprayGun: Ground
thegunbyconnectingtheGracoGrounded
AirHosetothegun,andconnectingtheair
hosegroundwiretoatrueearthground.See
CheckGunElectricalGrounding,page24.
• Pump/󰘱uidsource: Groundthepump/󰘱uidsource
byconnectingitsgroundwiretoatrueearth
ground.
• Allelectricallyconductiveobjectsordevicesinthe
sprayarea: mustbeproperlygrounded.
• Fluidandwastecontainers: Groundall󰘱uidand
wastecontainersinthesprayarea.Donotusepail
linersunlesstheyareconductiveandgrounded.
When󰘱ushingthespraygun,thecontainerused
tocatchtheexcess󰘱uidmustbeelectrically
conductiveandgrounded.
• Aircompressors: Groundtheequipmentaccording
tothemanufacturer'srecommendations.
• Allairand󰘱uidlines mustbeproperlygrounded.
Useonlygroundedhoseswithamaximumof100
feet(30.5m)combinedhoselengthtoensure
groundingcontinuity
•
The󰘱oorofthesprayarea: mustbeelectrically
conductiveandgrounded.Donotcoverthe󰘱oor
withcardboardoranynon-conductivematerial
whichwouldinterruptgroundingcontinuity
3A2495K17

Installation
• Flammableliquidsinthesprayarea: mustbekept
inapproved,groundedcontainers.Donotuse
plasticcontainers.Donotstoremorethanthe
quantityneededforoneshift.
• Allsolventpails: Useonlyapproved,grounded
metalcontainers,whichareconductive.Donot
useplasticcontainers.Useonlynon-󰘱ammable
solvents.Donotstoremorethanthequantity
neededforoneshift.
183A2495K

Installation
Figure11GroundtheOperatorOperatorisgroundedthroughthegunhandleand
conductiveshoes.
Figure12GroundtheObjectbeingSprayedObjectbeingsprayedisgroundedthroughcontact
withthehangerandconveyorsystem.
3A2495K19

Installation
Figure13GroundtheGunGunisgroundedthroughtheconductiveairhose.
Figure14GroundtheFluidSupplyFluidsupplylineandsourcemustbegrounded.
203A2495K