Graco PRO 5500sc User manual



INSTRUCTIONS–P ARTS LIST 308–385
Rev. C
Supersedes A
and PCN B
AUTOMATIC ELECTROSTATIC
Model PRO 5500sc  Air Spray Gun
100 psi (7 bar) Maximum Working Pressure
For use with Class , Group D paint spray materials
U.S. P A TENT NO. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774;
5,063,350; 5,073,709; 5,080,289; 5,093,625; 5,289,977
Patented 1986, 1987 Canada
Brevete 1986, 1987
U.K. PA TENT NO. 2,147,158; 2,142,559B; 2,140,327–B
Other Foreign Patents Pending
Part No. 236–683, Series A
Complete Standard PRO 5500sc Spray Gun: includes
spray gun, shroud, manifold, and mounting bracket
Part No. 236–684, Series A
Complete PRO 5500sc Recirculating Spray Gun: same
as part no. 236–683 spray gun only with part no.
236–851 recirculation kit installed
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
 COPYRIGHT 1994 GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
INSTRUCTIONS

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Notes

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Table of Contents
Symbols 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
How
the PRO 5500sc Electrostatic
Air Spray Gun Operates 6. . . . . . . . . . . . . . . . . . . . . .
Operating the Spray Function 6. . . . . . . . . . . . . . . . . .
Operating the Electrostatics 6. . . . . . . . . . . . . . . . . . .
Switching to the Higher or Lower kV Setting 6. . . . .
Gun Features and Options 6. . . . . . . . . . . . . . . . . . . .
Installation
Installing
the System 9. . . . . . . . . . . . . . . . . . . . . . . . .
Warning Signs 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilate the Spray Booth 9. . . . . . . . . . . . . . . . . . . . .
Install the Air Line Accessories 10. . . . . . . . . . . . . . . .
Install the Gun and Mounting Bracket 10. . . . . . . . . .
Connect the Air and Fluid Lines 11. . . . . . . . . . . . . . .
Optional Fiber Optic Cable Connection 13. . . . . . . . .
Optional Fiber Optic Lens Kit Installation 13. . . . . . .
Ground the System 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Check the Electrical Grounding 15. . . . . . . . . . . . . . .
Install the Fabric Cover 16. . . . . . . . . . . . . . . . . . . . . .
Operation
Pressure
Relief Procedure 17. . . . . . . . . . . . . . . . . . .
Operating Checklist 17. . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a Fluid Nozzle and Air Cap 17. . . . . . . . . .
Adjusting the Spray Pattern 18. . . . . . . . . . . . . . . . . .
Activating and Adjusting the Electrostatics 19. . . . . .
Activating the kV Switch 19. . . . . . . . . . . . . . . . . . . . .
Spraying 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Triggering the Fluid Alone 19. . . . . . . . . . . . . . . . . . . .
Shutdown 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance
Daily
Care and Cleaning 20. . . . . . . . . . . . . . . . . . . . .
Clean the Air Cap and Fluid Nozzle 22. . . . . . . . . . . .
Check for Fluid Leakage 23. . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Spray
Pattern T roubleshooting 24. . . . . . . . . . . . . . . .
Gun Operation T roubleshooting 25. . . . . . . . . . . . . . .
Electrical Troubleshooting 26. . . . . . . . . . . . . . . . . . . .
Electrical Tests
T
est Gun Resistance 27. . . . . . . . . . . . . . . . . . . . . . . .
Test Power Supply Resistance 28. . . . . . . . . . . . . . . .
Test Resistor Stud Resistance 28. . . . . . . . . . . . . . . .
Service
Tools
Included with the Gun 29. . . . . . . . . . . . . . . . . .
Prepare the Gun for Service 29. . . . . . . . . . . . . . . . . .
Air Cap/Nozzle/Resistor Stud Replacement 30. . . . .
Electrode Needle Replacement 31. . . . . . . . . . . . . . .
Fluid Packing Rod Removal and Repair 32. . . . . . . .
Piston Repair 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Barrel Removal 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Removal and Replacement 36. . . . . .
Power Supply Adjustment 36. . . . . . . . . . . . . . . . . . . .
Turbine Alternator Removal and Replacement 37. .
Barrel Installation 38. . . . . . . . . . . . . . . . . . . . . . . . . . .
Install the Gun onto the Manifold 39. . . . . . . . . . . . . .
Standard Spray Gun Parts 40. . . . . . . . . . . . . . . . . . . .
Recirculating Spray Gun Parts 42. . . . . . . . . . . . . . . .
Manifold Parts 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 48. . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
his symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.

4308-385
FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition
and result in a fire, explosion, or electric shock.
 Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements stated in this instruction manual.
 Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all
other electrically conductive objects in the spray area. See Ground the System on page 14.
 If there is any static sparking while using the equipment, stop spraying immediately . Identify
and correct the problem.
 Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Interlock the gun
turbine air supply to prevent operation of the power supply unless the ventilating fans are on. See
Ventilate the Spray Booth on page 9.
 When flushing or purging electrostatic equipment, use solvents with a flash point equal to or
greater than that of the fluid being sprayed.
T o clean the exterior of the electrostatic equipment , use solvents with a flash point higher than
100F (38C).

Do not flush the system with the gun electrostatics turned on.
 Do not turn on the gun electrostatics until all solvent is removed from the system.
 Use only non-sparking tools to clean residue from the booth and hangers.
 Extinguish all open flames or pilot lights in the spray area.
 Keep the spray area free of debris, including solvent, rags, and gasoline.
 Do not store any flammable fluids in the spray area.
 Do not turn on or of f any light switch in the spray area while operating or if fumes are present.
 Do not smoke in the spray area.
 Do not operate a gasoline engine in the spray area.
PRESSURIZED EQUIPMENT HAZARD
Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin
and cause a serious injury .
 Do not point the spray gun at anyone or any part of the body .

Do not stop or deflect fluid leaks with your hand, body , glove, or rag.
 Follow the Pressure Relief Procedure on page 17 whenever you: are instructed to relieve the
pressure; stop spraying; clean, check, or servicing the equipment; and install or clean the fluid
nozzles.
T
ighten all the fluid connections before operating the equipment.
 Check the hoses, tubes and couplings daily . Replace worn, damaged, or loose parts immediately .
Permanently coupled hoses cannot be repaired; replace the entire hose.
WARNING
WARNING

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EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
in a serious injury .

This equipment is for professional use only .

Read all the instruction manuals, tags, and labels before operating the equipment.
 Use the equipment only for its intended purpose. If you are uncertain about the usage, call Graco
T echnical Assistance at 1–800–543–0339.
 Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
 Check the equipment daily . Repair or replace worn or damaged parts immediately .

Do not exceed the maximum working pressure of the lowest rated system component. This
equipment has a 100 psi (7 bar) maximum working air and fluid pressure
.

Use fluids that are compatible with the equipment wetted parts. See the T echnical Data section
of all the equipment manuals. Read the fluid manufacturer ’ s warnings.
 Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180 F (82 C) or below –40 F (–40C).

Do not use the hoses to pull equipment.
W ear hearing protection when operating this equipment.
 Comply with all applicable local, state, and national fire, electrical, and other safety regulations.
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
 Know the specific hazards of the fluid you are using. Read the fluid manufacturer ’ s warnings.
 Store hazardous fluid in an approved container . Dispose of the hazardous fluid according to all
local, state, and national guidelines.
W ear appropriate protective clothing, gloves, eyewear , and respirator .
WARNING
WARNING
INSTRUCTIONS

6308-385
Introduction
How the PRO 5500sc Electrostatic Air Spray
Gun Operates (Refer to page 7)
The PRO 5500sc spray gun operates very similar to a
traditional air spray gun. The atomization and fan air
are emitted from the air cap (A). The atomization air
breaks up the fluid stream and controls the droplet
size. The fan air controls the shape and width of the
spray pattern. The fan and atomization air can be ad -
justed independently .
Operating the Spray Function
Applying a minimum of 50 psi (3.5 bar) air pressure to
the gun manifold’s cylinder air fitting (which is marked
“CYL”, see page 7) will retract the gun piston, which
opens the air valves and a short time later opens the
fluid needle. This provides the proper air lead and lag
when triggering the gun. A spring returns the piston
when the cylinder air is shut of f.
Operating the Electrostatics
To operate the electrostatics, air pressure is applied to
the gun manifold’ s turbine air fitting (which is marked
“T A”, see page 7) through a Graco electrically con -
ductive air hose. The air enters the manifold and is
directed to the inlet of the power supply turbine (G).
The air spins the turbine, which then provides electrical
power to the internal high voltage power supply (H).
The fluid is charged by the spray gun electrode (J).
The charged fluid is attracted to the nearest grounded
object, wrapping around and evenly coating all sur -
faces.
The turbine air is exhausted into the shroud (D) and
out the back of the manifold through the fitting marked
“EXH”. The exhaust air helps keep contaminants out
and helps keep the gun clean.
Switching to the Higher or Lower
kV Setting
The gun’ s full high voltage setting is 85 kilovolts. The
gun’ s spraying voltage can be reduced by switching to
the low voltage setting for spraying in areas where too
much electrostatic wrap is not desirable. Applying a
minimum of 50 psi (3.5 bar) air pressure to the kV
switch air inlet (which is marked “KV”, see page 7)
will activate it and switch to the lower voltage setting.
The lower voltage is factory set to 60 kilovolts at zero
microamperes. This setting can be adjusted from 45 to
80 kilovolts, as instructed on page 36. The solenoid
valve used to activate the kV switch must bleed the air
out of the line for the switch to draw back to the higher
voltage setting.
Gun Features and Options
The gun is designed for use with a reciprocator ,
and it can be directly mounted to a one-half inch
rod. With additional brackets, the gun can be
mounted for robotic applications.
 The gun is designed for quick-disconnect, which
enables the operator to quickly remove the spray
gun without disconnecting the fluid and air lines to
the gun.
 The gun functions are activated from a separate
controller that sends the appropriate signal to the
actuating solenoids (K). See Fig. 1, page 8.
 An optional fiber optic readout system can be
installed to monitor the gun’ s spraying voltage. A
fiber optic cable (V) connected to the gun manifold
carries the signal from the gun to a remote ES
(electrostatic) display module. See Fig. 2, page 8.
An ES Display Module (R), P/N 224–1 17, is avail -
able and will display the gun’ s spraying voltage and
current. A battery operated ES Display Module (S),
P/N 189–762, is also available; it displays the
gun’ s spraying voltage only .

308-3857
Introduction
Manifold Back V iew
0321303209
TA
CYL
A1
P1
F.O.
A2
EXH
AB C D E
F
G
H
J
KV
P2
04800
KEY
A Air
Cap
B Fluid Nozzle
C Retaining Nut
D Shroud
E
Mounting Bracket
F Manifold
G Turbine
H
Power Supply
J Electrode
Manifold Markings
A1 Atomization Air Inlet Fitting
A2 Fan Air Inlet Fitting
CYL Cylinder Air Inlet Fitting
EXH Shroud Exhaust Outlet Fitting
F.O. Fiber Optic Fitting
KV kV Switch Air Inlet
P1 Fluid Supply Inlet Fitting
P2 Fluid Return Inlet Fitting
TA T urbine Air Inlet Fitting


Installation
1.
04801
P1
P2
TOP VIEW
Non-Hazardous Area Hazardous Area BASIC SYSTEM
SYSTEM OPTIONS
SSpraying V oltage
Display Module
kV
A
Non-Hazardous Area Hazardous Area
SAir Pilot Fluid Regulator
SDump Valve
Fig. 1
Fig. 2
TA
A2
A1
CYL
A
B
K
K
J
G
H
P1
E
F
M
N
C
D
K
*
*
*
*

X
W
K
Y
F.O.
Q
P
RT
V
H
S
*
KV
ZGG
AA
DD
EE
CC
BB
FF
K
kV
*
U 
*

308-3859
Installation
KEY–Fig. 1 and 2
A Ground Wire on Graco Electrically Conductive Air Hose
B Graco Electrically Conductive Air Hose (T urbine Air Hose),
See page 1 1 for part numbers
C Atomizing Air Hose, 3/8 inch (9.5 mm) O.D.
D Fan Air Hose, 3/8 inch (9.5 mm) O.D.
E Cylinder Air Hose, 1/4 inch (6.4 mm) O.D.
F Fluid Hose, 1/4–18.6 npsm gun fluid inlet
GT o Fluid Supply
H PRO 5500sc Spray Gun, P/N 236–683
J Mounting Bracket for 1/2 inch (127 mm) rod, P/N 189–581
K Solenoid V alve, requires quick-exhaust port
M Air Pressure Regulator
N T rue Earth Ground
P 24 V olt Power Supply , P/N 235–301
Q 4–20 mA Outputs
R Full Feature ES Display Module, P/N 224–1 17
S
kV Only ES Display Module (battery operated), P/N 189–762
T Fiber Optic Cable, P/N 224–680 to 224–686
U Bulkhead, P/N 189–870
V Fiber Optic Cable, P/N 224–670 to 224–676
W Main Air Line
X Bleed-type Master Air V alve
YkV
Switch Air Hose, 1/4 inch (6.4 mm) O.D., plug the gun fitting if
it is not used
Z Air Pilot Fluid Regulator , P/N 236–854
AA Dump V alve, P/N 236–853, requires installation of item FF
BB Air Pilot Air Line, 1/4 inch (6.4 mm) O.D.
CC Fluid Supply Line, 3/8 inch (9.5 mm) O.D.
DD Dump T rigger Air Line, 1/4 inch (6.4 mm) O.D.
EE Fluid Return Line, 1/4 inch (6.4 mm) O.D.
FF Fluid Recirculation Kit P/N 236–851, Includes fittings and fluid
tube
GG
PRO 5500sc Recirculating Spray Gun, P/N 236–684, includes
item FF
 The turbine air supply must be interlocked with the spray booth
ventilation fans.
 A maximum of two splices with a total of 108 feet (32.94 m) of
cable can be used. For the strongest light signals, use a mini -
mum number of bulkhead splices.
* See page 1 1 for a description of the manifold connections.
Installing the System
ELECTRIC SHOCK HAZARD
Installing and servicing this equipment
requires access to parts which could
cause an electric shock or other serious
injury if the work is not performed properly .
D Do not install or service this equipment unless
you are trained and qualified.
D Comply with all local, state, and national codes
for the installation of electrical apparatus in a
Class I , Group D Hazardous Location.
D Comply with all applicable local, state, and
national fire, electrical, and other safety regula -
tions.
WARNING
Fig. 1, page 8, shows a typical Model PRO 5500sc
system. Fig. 2 shows some possible system options.
Accessories are available from your Graco representa -
tive. Refer to the Product Data Sheet for the gun,
Form No. 305–623.
For assistance in designing a system that is custom -
ized for your application, contact your Graco represen -
tative or Graco T echnical Assistance (see back page).
Warning Signs
Mount warning signs in the spray area where they can
easily be seen and read by all operators. An English
W arning Sign is provided with the gun. Additional
English, French, German, and Spanish signs are avail -
able at no charge.
Part No. Description
180–060 W arning Sign (English)
180–061 W arning Sign (French)
180–062 W arning Sign (German)
180–063 W arning Sign (Spanish)
Ventilate the Spray Booth
FLAMMABLE OR T OXIC
V APOR HAZARD
Provide fresh air ventilation to avoid the
buildup of flammable or toxic vapors. Do
not operate the gun unless ventilation
fans are operating.
WARNING
Electrically interlock the gun turbine air supply line with
the ventilators to prevent operation of the electrostatic
power supply unless ventilating fans are on.
Check and follow all local, state, and national codes
regarding air exhaust velocity requirements. High
velocity air exhaust will decrease the operating ef fi-
ciency of the electrostatic system. The minimum
allowable air exhaust velocity is 60 feet/minute (19 lin -
ear meters/minute).

10308-385
Installation
Install the Air Line Accessories
Install a bleed-type master air valve (X) on the main air
supply line (W) to shut of f all the air to the gun. See
Fig. 1, page 8.
T o ensure a dry , clean air supply to the gun, install an
air line filter and an air and water separator on the air
lines. Dirt and moisture can ruin the appearance of
your finished workpiece and can cause the gun to mal -
function.
Install an air regulator (M) on each of the air supply
lines (B, C, D, E, Y) to control the air pressure to the
gun.
Install a solenoid valve (K) on the fan and atomization
air lines (C, D) to actuate the gun and shut of f the fan
and atomization air to the gun. The solenoid valves
must have a quick exhaust port.
PRESSURIZED EQUIPMENT HAZARD
T rapped air can cause the gun to spray
unexpectedly , which could result in a
serious injury , including splashing in the
eyes or on the skin. The solenoid valves (K) must
have a quick-exhaust port so trapped air will be
relieved between the valve and the gun when the
solenoids are shut of f.
WARNING
Install the Gun and Mounting Bracket
1. Loosen the mounting bracket’ s two square head
bolts (103) and slide the mounting bracket onto a
0.50 in. (12.7 mm) mounting rod. See Fig. 3.
2. Position the gun and tighten the two bolts (103)
securely.
Fig. 3
PRO 5500 Gun
2.775 in.
(70.5 mm
)
9.32 in.
(236.7 mm)
0.50 in.
(12.7 mm)
rod
03444
103
103
NOTE: For added positioning reliability , the mounting
bracket (MM) has an 1/8 in. (3.2 mm) slot where a lo -
cating pin (NN–not included) can be inserted through
the mounting rod (PP). See Fig. 4.
Fig. 4
03460
NN
PP
MM

308-38511
Installation
Connect the Air and Fluid Lines
See Fig. 1 and 2, page 8, for a schematic of air and
fluid connections. Connect the air and fluid lines to the
gun manifold as instructed at right.
Graco Electrically Conductive Air Hose
ELECTRIC SHOCK HAZARD
T o reduce the risk of an electric shock or
other serious injury , you must use the
Graco Electrically Conductive Air Hose
for the turbine air hose, and you must connect the
hose ground wire to a true earth ground.
WARNING
Connect the Graco electrically conductive air hose (B)
to the gun turbine air inlet and connect the hose
ground wire (A) to a true earth ground. See Fig. 1,
page 8. Check the electrical grounding of the gun as
instructed on page 15.
NOTE: The hose and the gun have special left-hand
threads to prevent connecting another type of air hose
to the gun turbine air inlet.
Graco Electrically Conductive Air Hose
Required for gun operation.
100 psi (7 bar) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand
Part No.
Length Black Hose Grey Hose Red Hose
6 ft. (1.8 m)
15 ft. (4.6 m)
25 ft. (7.6 m)
36 ft. (1 1.0 m)
50 ft. (15.2 m)
75 ft. (23.0 m)
100 ft. (30. 5 m)
220–444
218–100
218–101
218–102
218–103
220–119
220–120
223–068
223–069
223–070
223–071
223–072
223–073
223–074
235–068
235–069
235–070
235–071
235–072
235–073
235–074
Black Hose: standard hose, semi-conductive nylon core,
urethane outer
Grey Hose: more flexible (less durable) than black hose,
modified semi-conductive polyamide core, urethane cover
Red Hose: conductive SST wire braid for grounding, polyure -
thane tube and cover
Fluid Line
Before connecting the fluid line, blow it out with air and
flush it with solvent. Use solvent that is compatible with
the fluid being sprayed.
Manifold Connections (See Fig. 5)
A1 Atomization Air Inlet Fitting
Connect a 3/8 inch O.D. tube between the fitting and
the air supply .
A2
Fan Air Inlet Fitting
Connect a 3/8 inch O.D. tube between the fitting and
the air supply .
CYL
Cylinder Air Inlet Fitting
Connect a 1/4 inch O.D. tube between this fitting and
the solenoid. For quicker trigger response, use the
shortest hose length possible.
EXH Shroud Exhaust Outlet Fitting
Connect a 1/4 inch O.D. x 4 foot (1.22 m) long tube to
the fitting.
F.O. Fiber Optic Fitting (Optional)
Connect the Graco Fiber Optic Cable as instructed on
page 13.
KV kV Switch Air Inlet Fitting
Connect a 1/4 inch O.D. tube between the fitting and
the air solenoid.
P1 Fluid Supply Inlet Fitting
Connect a 1/4 inch npsm swivel fitting between the
fitting and the fluid supply .
P2
Fluid Return Inlet Fitting (Optional)
Connect 1/4 inch O.D. tube between the fitting and the
dump valve for recirculation.
TA T urbine Air Inlet Fitting
Connect the Graco Electrically Conductive Air Hose
between this fitting (left-hand thread) and the solenoid.
Connect the air hose ground wire to a true earth
ground.
03213
Manifold Back V iew
TA
CYL
A1
P1
KV
A2
EXH
F.O.
P2
Fig.
5

12308-385
Notes

308-38513
Installation
Optional Fiber Optic Cable Connection
An optional fiber optic fitting (37) is shipped unas -
sembled with the gun. If an ES (kV) display module is
used, install the fitting in the manifold. See Fig. 2, page
8, for a schematic of the fiber optic connections.
1. Remove the 1/8 npt plug (1 15) from the manifold’ s
fiber optic port, and install the black fiber optic fit -
ting (37). See Fig. 6.
Fig. 6 03508
115
37
2.
Remove the nut (QQ) from the fiber optic fitting
(37), and slide the nut over the end of the fiber op -
tic cable (RR). See Fig. 7.
3. Insert the cable (RR) into the fitting (37), and push
the cable in until it bottoms out. Tighten the nut
(QQ) to secure the cable.
03509A
QQ
RR
37
Fig. 7
4. If you have two bulkhead splices in your system, it
is recommended that you install the fiber optic lens
kit, as described at right.
NOTE: Most of the fiber optic light transmission loss
occurs at the bulkhead splices. For the strongest light
signals, use a minimum number of bulkhead splices. A
maximum of two splices, with a total of 108 feet (32.94
m) of cable, is recommended.
5. See manual 308–265 to install a Graco ES Display
Module.
Optional Fiber Optic Lens Kit Installation
NOTE: The fiber optic lens kit is not included with the
gun. Order it separately; the part number is 236–852.
1. Remove the gun from the manifold as instructed
on page 29.
2. Make sure the lens (TT) is clean. Push the lens
into the counterbore (VV) in the manifold fiber optic
port (SS). See Fig. 8 and 9.
3. Press the lens retainer (UU) into the manifold fiber
optic port (SS) until it is flush with the manifold sur -
face.
4.
Assemble the gun to the manifold as instructed on
page 39.
04798
Fig. 8
TT
UU
SS
Fig. 9 04485
UU
TT
VV
SS


Installation
Ground the System
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
When operating the electrostatic gun,
any ungrounded objects in the spray
area (such as people, containers, tools,
etc.) can become electrically charged.
Improper grounding can result in static
sparking, which can cause a fire, explo -
sion, or electric shock. Follow the
grounding instructions below
.
WARNING
The following grounding instructions are minimum re -
quirements for a basic electrostatic system. Y our sys -
tem may include other equipment or objects which
must be grounded. Check your local electrical code for
detailed grounding instructions for your area and type
of equipment. Y our system must be connected to a
true earth ground.
1. Pump: ground the pump by connecting a ground
wire and clamp as described in your separate
pump instruction manual.
2. Air compressors and hydraulic power supplies:
ground the equipment according to the manufac -
turer’
s recommendations.
3. PRO 5500sc Electrostatic Air Spray Gun: ground
the gun by connecting the Graco Electrically Con -
ductive Air Hose and connecting the air hose
ground wire to a true earth ground. Check the
electrical grounding of the gun as instructed on
page 15.
4. Air lines, fluid lines, and the electric cables: must
be properly grounded.
5. All persons entering the spray area: their shoes
must have conductive soles, such as leather , or
personal grounding straps must be worn. Rubber
or plastic soles are not conductive.
6. Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Contact points
must be sharp points or knife edges.
7. The floor of the spray area: must be electrically
conductive and grounded. Do not cover the floor
with cardboard or any non-conductive material
which would interrupt grounding continuity .
8.
Flammable liquids in the spray area: must be kept
in approved, grounded containers. Do not store
more than the quantity needed for one shift.
9. All electrically conductive objects or devices in the
spray area: including fluid containers and wash
cans, must be properly grounded.

308-38515
Installation
Check the Electrical Grounding (See Fig. 10)
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
Megohmmeter P/N 218–979 (WW -see
Fig. 10) is not approved for use in a haz -
ardous area. T
o reduce the risk of spark -
ing, do not use the megohmmeter to
check electrical grounding unless:
 All spraying devices in the hazardous
area are turned of f.
V
entilation fans in the hazardous
area are operating.
 There are no flammable vapors in the area,
such as open solvent containers or fumes from
spraying.
Failure to follow this warning could cause fire,
explosion, electric shock and result in serious injury
and property damage.
WARNING
1. Have a qualified electrician check the electrical
grounding continuity of the spray gun and turbine
air hose.
2. Make sure the turbine air hose (B) is connected
and the hose ground wire is connected to a true
earth ground.
3. The air and fluid supplies to the gun must be
turned of f, and the fluid hose must not have any
fluid in it when checking the continuity .
4.
Measure the resistance between the turbine air
inlet fitting (T A) and a true earth ground (N).
a. If using a black or grey turbine air hose, use a
megohmmeter (WW) to measure the
resistance. Use an applied voltage of 500 mini -
mum to 1000 volts maximum. Resistance
should not exceed 2 megohms.
b. If you are using a red turbine air hose, use an
ohmmeter to measure the resistance.
Resistance should not exceed 100 ohms.
5. If the resistance is greater than the maximum
reading specified above for your hose, check the
tightness of the ground connections and be sure
the turbine air hose ground wire is connected to a
true earth ground. If the resistance is still too high,
replace the turbine air hose.
03214
Fig. 10
WW
N
B
TA


Installation
Install the Fabric Cover
1. Install a fabric cover (XX) over the front of the gun
and slide it back to cover the exposed tubing and
hoses at the back of the manifold. See Fig. 1
1.
2.
Route the exhaust tube (YY) outside the cover .
This enables you to monitor the exhaust tube for
the presence of any paint or solvent. See Check
for Fluid Leakage
on page 23. Strap down the
exhaust tube to prevent it from moving around.
03445
Fig. 11
XX
YY
YY
03446
Manifold Back
View


Operation
Pressure Relief Procedure
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally . To
reduce the risk of an injury from accidental spray
from the gun, splashing fluid, or moving parts, fol
-
low the Pressure Relief Procedure whenever you:
 are instructed to relieve the pressure,
 stop spraying,
 check or service any of the system equipment,
 and install or clean the fluid nozzle.
WARNING
1. T urn of f all the air to the spray gun except the cyl -
inder air , which triggers the gun. If an air pilot fluid
regulator is used in the system, the air pressure is
needed at the regulator air inlet.
2. T urn of f the fluid supply to the gun.
3. T rigger the gun into a grounded metal waste con -
tainer to relieve fluid pressure.
4. If the air pilot fluid regulator is used, turn of f the air
pressure at the regulator air inlet.
5. Relieve fluid pressure in the fluid supply equipment
as instructed in its instruction manual.
6. T urn of f the main air supply by closing the bleed-
type master air valve on the main air supply line.
Leave the valve closed until you are ready to spray
again.
Operating Checklist
Check the following list daily , before starting to operate
the system, to help ensure you of safe, ef ficient opera -
tion.
____ 1. Be sure all the operators are properly trained
to safely operate an automatic, electrostatic
air spray system as instructed in this manual.
____ 2. Be sure all the operators are trained how to
properly relieve system pressure as instructed
at left.
____ 3. Be sure the warning sign provided with the gun is
mounted in the spray area where it can be easily
seen and read by all operators.
____ 4. Be sure the system is thoroughly grounded.
See Ground the System , page 14.
____ 5. Be sure the operator and all persons entering
the spray area are properly grounded by wear -
ing shoes with conductive soles or personal
grounding straps.
____ 6. Be sure all the conductive objects in the spray
area are electrically grounded and the floor of
the spray area is electrically conductive and
grounded.
____ 7. Be sure all flammable liquids in the spray booth
are in approved, grounded containers.
____ 8. Be sure the workpiece hangers are clean and
grounded. Contact points must be sharp
points or knife edges.
____ 9. Be sure the ventilation fans are operating
properly.
____ 10. Be sure all the debris, including flammable
liquids and rags, is removed from the spray
area.
____ 1 1. Be sure to check the manifold exhaust tubes
for the presence of any fluid as instructed in
Check for Fluid Leakage
, page 23 .
Selecting a Fluid Nozzle and Air Cap
The gun is supplied with a 1.5 mm (0.06 in.) fluid
nozzle, P/N 185–158, and air cap, P/N 177–033. If
your application requires a different nozzle and air cap
combination, use instruction manual 307–803 or con
-
sult your authorized Graco distributor or Graco T echni-
cal Assistance (see back page) to select the appropri -
ate fluid nozzle and air cap.

18308-385
Operation
Adjusting the Spray Pattern
Follow the steps below to establish the correct fluid
flow and air flow . Do not turn on the turbine air (T A)
yet.
PRESSURIZED EQUIPMENT
T o reduce the risk of a serious injury ,
follow the Pressure Relief Procedure
on page 17 whenever you are instructed
to relieve the pressure.
WARNING
1. Make sure the system pressure is relieved.
2. Loosen the air cap retaining ring, and rotate the air
cap for a vertical or horizontal spray pattern. See
Fig. 12. Then tighten the retaining ring until the air
cap is held firmly in place; you should not be able
to rotate the air cap horns by hand.
Fig. 12
02020
Horizontal Pattern
V
ertical Pattern
3. Adjust the fluid flow with the fluid line pressure
regulator . Refer to instruction manual 307–803 to
set the fluid pressure for various fluid flows,
according to the size of the fluid nozzle being
used.
4.
Use the air pressure regulator on the atomization
air supply line (A1) to adjust the degree of atom -
ization. Refer to Fig. 13. For example, for a fluid
flow rate of 10 ounces per minute (0.3 liters/min.),
a typical atomization pressure would be 20 to 30
psi (1.4 to 2.1 bar) at the gun manifold.
5. Use the air pressure regulator on the fan air supply
line (A2) to adjust the pattern size.
NOTES:

For the most ef ficiency , always use the lowest air
pressure possible.
 When increasing to a wide, flat pattern, it may be
necessary to increase the supply of fluid to the gun
to maintain the same amount of coverage over a
large area.
 See Spray Pattern T roubleshooting on page 24
to correct spray pattern problems.
Fig. 13
03213
TA
CYL
A1
KV
A2
Manifold Back V iew


Operation
Activating and Adjusting the Electrostatics
FIRE AND EXPLOSION HAZARD
The fan (A2) and atomizing (A1) air must
be on before turning on the turbine air
(T A). Actuating the turbine air without
fan and atomizing air flow could damage
the gun and could create hazardous op -
erating conditions and result in a serious
injury and property damage.
WARNING
1. Make sure the fan (A2) and atomizing (A1) air are
on, then turn on the turbine air (T A). Refer to Fig.
13.
2.
The turbine air pressure should be adjusted to 30
psi (2.1 bar) at the gun manifold inlet
when air is
flowing. Do not exceed 40 psi (2.8 bar) air pres -
sure as there is no added benefit and turbine life
could be reduced.
Use the chart below to set the proper pressure at
the turbine hose inlet. Do not exceed these recom -
mended pressures or turbine life will be reduced.
T urbine Air
Hose Length
Dynamic pressure at the turbine
hose
i nle t r equire d f o r f ull v oltage
15 ft. (4.6 m) 36 psi (2.5 bar)
25 ft. (7.6 m) 38 psi (2.7 bar)
50 ft. (15.3 m) 40 psi (2.8 bar)
75 ft. (22.9 m) 42 psi (2.9 bar)
100 ft. (30.5 m) 45 psi (3.1 bar)
3. Check the voltage output of the gun using a high
voltage probe and meter or by reading the ES (kV)
Display Module.
NOTE: The gun’ s normal high voltage reading is 60 to
70 kV . If a ball end high voltage measurement probe is
used, the gun voltage will rise to about 85 kV . This will
happen with all resistive electrostatic guns.
See Electrical T roubleshooting on page 26 to cor -
rect voltage problems.
Activating the kV Switch
Apply a minimum of 50 psi (3.5 bar) air pressure to the
kV switch air fitting (KV) to activate it and switch to the
lower voltage setting. Refer to Fig. 13. The lower volt -
age setting is factory set to 60 kilovolts at zero micro -
amperes. T
o change this setting, see page 36.
The solenoid valve used to activate the kV switch must
bleed the air out of the line for the switch to draw back
to the higher voltage setting.
Spraying
ELECTRIC SHOCK HAZARD
T o reduce the risk of an electric shock,
do not touch the gun electrode or come
within 4 inches (101.6 mm) of the nozzle
during gun operation.
WARNING
1. Apply a minimum of 50 psi (3.5 bar) air pressure to
the cylinder air fitting (CYL) to activate the on/of f
sequence of atomization air (A1), fan air (A2), and
fluid (P1). Refer to Fig. 13.
2. T urn the gun functions off and on by using the air
solenoid valves on the cylinder (CYL) and turbine
(T A) air supply lines.
FIRE AND EXPLOSION HAZARD
If any fluid leakage from the gun is de -
tected, stop spraying immediately!
Fluid leakage into the gun shroud could
cause fire or explosion and result in
serious injury and property damage. See
Check for Fluid Leakage
, page 23.
WARNING
Triggering the Fluid Alone
1. Shut of f and relieve the air pressure to the atom -
ization (A1) and fan (A2) air lines, using the bleed-
type air shut-of f valves.
2. Apply 50 psi (3.5 bar) air pressure to the cylinder
air fitting (CYL) to trigger the fluid.


Operation
Shutdown
PRESSURIZED EQUIPMENT
T o reduce the risk of a serious injury ,
follow the Pressure Relief Procedure
on page 17 when you stop spraying and
whenever you are instructed to relieve the pres -
sure.
WARNING
1. Relieve the system pressure.
2. Flush and clean the equipment. Follow the instruc -
tions in the Maintenance section, below .
Maintenance
Daily Care and Cleaning
Clean all parts with a non-conductive solvent,
compatible with the fluid being sprayed. Conduc
-
tive solvents can cause the gun to malfunction.
 Methylene chloride is not recommended as a
flushing or cleaning solvent with this gun as it will
damage nylon components.
 Fluid in the air passages could cause the gun to
malfunction and could draw current and reduce
the electrostatic effect. Fluid in the power supply
cavity can reduce the alternator life. Whenever
possible, point the gun down while cleaning it. Do
not use any cleaning method which could allow
fluid into the gun air passages.
Do not point the gun up while cleaning it.
Do not immerse the gun in fluid.
03512
0202703513
Do not wipe the gun with a cloth that is
heavily saturated; wring out the excess fluid.
CAUTION