Graco 3A2494D User manual

Instructions-Parts

Pro Pro

Pro

Xp™ Xp™

Xp™

Electrostatic Electrostatic

Electrostatic

Air Air

Air

Spray Spray

Spray

Gun Gun

Gun

3A2494D

EN

For For

For

use use

use

in in

in

Class Class

Class

I, I,

I,

Div. Div.

Div.

I I

I

Hazardous Hazardous

Hazardous

Locations Locations

Locations

using using

using

Group Group

Group

D D

D

spray spray

spray

materials. materials.

materials.

For For

For

use use

use

in in

in

Group Group

Group

II, II,

II,

Zone Zone

Zone

1 1

1

Explosive Explosive

Explosive

Atmosphere Atmosphere

Atmosphere

Locations Locations

Locations

using using

using

Group Group

Group

IIA IIA

IIA

spray spray

spray

materials. materials.

materials.

For For

For

professional professional

professional

use use

use

only. only.

only.

Important Important

Important

Safety Safety

Safety

Instructions Instructions

Instructions

Readallwarningsandinstructionsinthismanual.

Save Save

Save

these these

these

instructions. instructions.

instructions.

100 psi (0.7 MPa, 7.0 bar) Maximum

Fluid Working Pressure

100 psi (0.7 MPa, 7.0 bar) Maximum Air

Working Pressure

See See

See

page page

page

3 3

3

for for

for

model model

model

part part

part

numbers numbers

numbers

and and

and

approval approval

approval

information. information.

information.

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents

Contents

Models...............................................................3

Warnings...........................................................4

GunOverview....................................................7

HowtheElectrostaticSprayGun

Works............................................7

Controls,Indicators,andComponents...........8

SmartGuns.................................................9

Installation..........................................................15

WarningSign...............................................15

VentilatetheSprayBooth.............................15

AirSupplyLine............................................16

FluidSupplyLine.........................................16

GunSetup..........................................................18

GunSetupChecklist....................................18

Grounding...................................................21

CheckGunElectricalGrounding...................25

CheckFluidResistivity.................................26

CheckFluidViscosity...................................26

FlushBeforeUsingEquipment......................26

GuidelinesforAbrasiveMaterials..................26

Operation...........................................................27

PressureReliefProcedure............................27

Startup........................................................27

Shutdown....................................................27

Maintenance......................................................28

Flushing......................................................28

CleantheGunDaily.....................................29

DailySystemCare.......................................30

ElectricalTests...................................................31

TestGunResistance....................................31

TestPowerSupplyResistance.....................32

TestElectrodeResistance............................32

Troubleshooting..................................................33

SprayPatternTroubleshooting......................33

GunOperationTroubleshooting....................34

ElectricalTroubleshooting............................35

Repair................................................................37

PreparetheGunforService.........................37

AirCapandNozzleReplacement..................38

ElectrodeReplacement................................39

FluidPackingRodRemoval..........................40

PackingRodRepair.....................................40

BarrelRemoval............................................42

BarrelInstallation.........................................42

PowerSupplyRemovaland

Replacement..................................43

AlternatorRemovalandReplacement...........44

FluidTubeRemovalandReplacement...........46

FanAirAdjustmentValveRepair..................47

AtomizingAirRestrictorValveRepair............48

ESOn-OffandFluidAdjustmentValve

Repair............................................49

AirValveRepair...........................................50

SmartModuleReplacement..........................51

AirSwivelandExhaustValve

Replacement..................................52

Parts..................................................................53

StandardAirSprayGunAssembly................53

RoundSprayAssembly................................55

StandardHighConductivityAirSprayGun

Assembly.......................................56

SmartHighConductivityAirSprayGun

Assembly.......................................58

SmartAirSprayGunAssembly.....................60

PackingRodAssembly.................................62

AlternatorAssembly.....................................63

ESOn-OffandFluidAdjustmentValve...........64

FanAirAdjustmentValveAssembly..............65

AtomizingAirRestrictorValve

Assembly.......................................65

SmartModuleAssembly...............................66

HighConductivityFluidTube

Assembly.......................................67

AirCapsandFluidNozzles.................................68

FluidNozzleSelectionChart.........................68

FluidNozzlePerformanceCharts..................68

AirCapSelectionChart................................70

AirConsumptionCharts...............................71

RepairKits,RelatedManuals,and

Accessories..........................................73

GunAccessories..........................................73

OperatorAccessories...................................74

SystemAccessories.....................................74

TestEquipment...........................................74

Hoses.........................................................75

Dimensions........................................................76

TechnicalData...................................................77

GracoProXpWarranty.......................................78

2

3A2494D

Models

Models Models

Models

Nozzle Nozzle

Nozzle

Part Part

Part

No. No.

No.

kV kV

kV

1.5 1.5

1.5

mm mm

mm

1.2 1.2

1.2

mm mm

mm

Round Round

Round

Spray Spray

Spray

Standard Standard

Standard

Display Display

Display

Smart Smart

Smart

Display Display

Display

Standard Standard

Standard

Coatings Coatings

Coatings

High High

High

Conductivity/ Conductivity/

Conductivity/

High High

High

Wear Wear

Wear

Increased Increased

Increased

Transfer Transfer

Transfer

Efciency Efciency

Efciency

L40T1040

✔✔✔

L40T1440

✔✔✔✔

L40T1540

✔✔✔✔

L40T1640

✔✔✔

L60T1060

✔✔✔

L60T1160

✔✔✔

L60T1260

✔✔✔

L60T1660

✔✔✔

L60M1060

✔✔✔

L60M1260

✔✔✔

L60M1660

✔✔✔

L85T1085

✔✔✔

L85T1685

✔✔✔

L85M1085

✔✔✔

L85M1685

✔✔✔

II II

II

2 2

2

G G

G

EEx0.24mJT6

FM12ATEX0068

EN50050

Ta0°C–50°C

3A2494D 3

Warnings

Warnings Warnings

Warnings

Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The

exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-specic

risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese

Warnings.Product-specichazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout

thebodyofthismanualwhereapplicable.

WARNING WARNING

WARNING

FIRE, FIRE,

FIRE,

EXPLOSION, EXPLOSION,

EXPLOSION,

AND AND

AND

ELECTRIC ELECTRIC

ELECTRIC

SHOCK SHOCK

SHOCK

HAZARD HAZARD

HAZARD

Flammablefumes,suchassolventandpaintfumes,inwork work

work

area area

area

canigniteorexplode.Tohelp

preventre,explosion,andelectricshock:

•Electrostaticequipmentmustbeusedonlybytrained,qualiedpersonnelwhounderstand

therequirementsofthismanual.

•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorcloseto

sprayarea.Resistancemustnotexceed1megohm.SeeGrounding Grounding

Grounding

instructions.

•OnlyusegroundedGracoconductiveairsupplyhoses.

•Donotusepaillinersunlesstheyareconductiveandgrounded.

•Stop Stop

Stop

operation operation

operation

immediately immediately

immediately

ifstaticsparkingoccursoryoufeelashock.Donotuse

equipmentuntilyouidentifyandcorrecttheproblem.

•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.

•Useandcleanequipmentonlyinwellventilatedarea.

•Interlockthegunairsupplytopreventoperationunlessventilatingfansareon.

•Usecleaningsolventswithhighestpossibleashpointwhenushingorcleaningequipment.

•Tocleantheexterioroftheequipment,cleaningsolventsmusthaveaashpointatleast

5°Caboveambienttemperature.

•Alwaysturntheelectrostaticsoffwhenushing,cleaningorservicingequipment.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and

plasticdropcloths(potentialstaticarc).

•Donotplugorunplugpowercordsorturnlightsonoroffwhenammablefumesarepresent.

•Keepsprayareafreeofdebris,includingsolvent,ragsandgasoline.

•Keepaworkingreextinguisherintheworkarea.

4

3A2494D

Warnings

WARNING WARNING

WARNING

PRESSURIZED PRESSURIZED

PRESSURIZED

EQUIPMENT EQUIPMENT

EQUIPMENT

HAZARD HAZARD

HAZARD

Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin

andcauseseriousinjury.

•FollowthePressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

whenyoustopspraying/dispensingandbefore

cleaning,checking,orservicingequipment.

•Tightenalluidconnectionsbeforeoperatingtheequipment.

•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

PLASTIC PLASTIC

PLASTIC

PARTS PARTS

PARTS

CLEANING CLEANING

CLEANING

SOLVENT SOLVENT

SOLVENT

HAZARD HAZARD

HAZARD

Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious

injuryorpropertydamage.

•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing

parts.

•SeeTechnical Technical

Technical

Data Data

Data

inthisandallotherequipmentinstructionmanuals.Readuidand

solventmanufacturer’sMSDSsandrecommendations.

TOXIC TOXIC

TOXIC

FLUID FLUID

FLUID

OR OR

OR

FUMES FUMES

FUMES

Toxicuidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,

inhaled,orswallowed.

•ReadMSDS’stoknowthespecichazardsoftheuidsyouareusing.

•Storehazardousuidinapprovedcontainers,anddisposeofitaccordingtoapplicable

guidelines.

PERSONAL PERSONAL

PERSONAL

PROTECTIVE PROTECTIVE

PROTECTIVE

EQUIPMENT EQUIPMENT

EQUIPMENT

Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,

includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective

equipmentincludesbutisnotlimitedto:

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbytheuidandsolvent

manufacturer.

3A2494D 5

Warnings

WARNING WARNING

WARNING

EQUIPMENT EQUIPMENT

EQUIPMENT

MISUSE MISUSE

MISUSE

HAZARD HAZARD

HAZARD

Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorundertheinuenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated

systemcomponent.SeeTechnical Technical

Technical

Data Data

Data

inallequipmentmanuals.

•Useuidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical

Technical

Data Data

Data

inallequipmentmanuals.Readuidandsolventmanufacturer’swarnings.Forcomplete

informationaboutyourmaterial,requestMSDSfromdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

whenequipmentisnotinuse.

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine

manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodicationsmayvoidagencyapprovals

andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtrafcareas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

6 3A2494D

GunOverview

Gun Gun

Gun

Overview Overview

Overview

How How

How

the the

the

Electrostatic Electrostatic

Electrostatic

Spray Spray

Spray

Gun Gun

Gun

Works Works

Works

Theairhosesuppliesairtothespraygun.Partof

theairoperatesthealternatorturbineandtherest

oftheairatomizestheuidbeingsprayed.The

alternatorgeneratespower,whichisconvertedby

thepowercartridgetosupplyhighvoltagetothe

gun’selectrode.

Thepumpsuppliesuidtotheuidhoseandgun,

wheretheuidiselectrostaticallychargedasit

passestheelectrode.Thechargeduidisattracted

tothegroundedworkpiece,wrappingaroundand

evenlycoatingallsurfaces.

3A2494D

7

GunOverview

Controls, Controls,

Controls,

Indicators, Indicators,

Indicators,

and and

and

Components Components

Components

Theelectrostaticgunincludesthefollowing

controls,indicators,andcomponents(seeFig.

1).ForinformationonSmartguns,alsosee

SmartGuns,page9.

Figure1GunOverview

Item Item

Item

Descrip- Descrip-

Descrip-

tion tion

tion

Purpose Purpose

Purpose

A

AirSwivel

Inlet

1/4npsm(m)left-handthread,

forGracogroundedairsupply

hose.

BFluidInlet

3/8npsm(m),foruidsupply

hose.

C

TurbineAir

Exhaust

Barbedtting,forsupplied

exhausttube.

D

AirCap

and

Nozzle

SeeAirCapsandFluid

Nozzles,page68,foravail-

ablesizes.

EElectrode

Needle

Supplieselectrostaticcharge

totheuid.

FFanAir

Adjust-

ment

Valve

Adjustsfansizeandshape.

Canbeusedtodecrease

patternwidth.

G

Atomizing

Air

Restrictor

Valve

Restrictsaircapairow.

Replacewithplug(included)

ifdesired.

Item Item

Item

Descrip- Descrip-

Descrip-

tion tion

tion

Purpose Purpose

Purpose

HFluidAd-

justment

Knob

Adjustsuidowbylimiting

uidneedletravel.Useonly

inlowowconditions,to

reducewear.

J

ESOn-Off

Valve

TurnselectrostaticsON(I)or

OFF(O).

K

ESIndica-

tor(stan-

dardgun

only;for

Smartgun

indica-

tor,see

Operating

Mode,

page9)

LitwhenESisON(I).Colorin-

dicatesalternatorfrequency.

SeetheLEDindicatortable

intheGunSetupChecklist,

page18.

8 3A2494D

GunOverview

Smart Smart

Smart

Guns Guns

Guns

TheSmartGunmoduledisplayssprayingvoltage,

current,alternatorspeed,andthevoltagesetting(low

orhigh).Italsoallowstheusertochangetoalower

sprayingvoltage.Themodulehastwomodes:

•OperatingMode

•DiagnosticMode

Operating Operating

Operating

Mode Mode

Mode

Bar Bar

Bar

Graph Graph

Graph

SeeFig.2,andTable1onpage10.TheOperating

Modedisplaysgundataduringnormalspraying.The

displayusesabargraphtoshowthevoltagelevelin

kiloVolts(kV)andthecurrentlevelinmicroAmperes

(uA).Thebargraphrangeisfrom0to100%foreach

value.

IfthebargraphLEDsareblue,thegunisreadyto

spray.IftheLEDsareyelloworred,thecurrentis

toohigh.Theuidmaybetooconductive,orsee

ElectricalTroubleshooting,page35forotherpossible

causes.

Hz Hz

Hz

Indicator Indicator

Indicator

TheHzindicatorfunctionsthesameastheES

indicatoronstandardguns.Theindicatorlightsto

showthealternatorspeedstatus,andhasthree

colors:

•Greenindicatesthealternatorspeediscorrect.

•Iftheindicatorchangestoamberafter1second,

increasetheairpressure.

•Iftheindicatorchangestoredafter1second,

reducetheairpressure.

Voltage Voltage

Voltage

Adjustment Adjustment

Adjustment

Switch Switch

Switch

Thevoltageadjustmentswitch(VA)allowsthe

operatortochangefromlowtohighvoltage.

•Thehighvoltagesettingisdeterminedbythe

maximumvoltageofthegunandisnotadjustable.

•Thelowvoltageindicator(LO)lights

whentheswitchissettoLO.Thelow

voltagesettingisuseradjustable.See

AdjustingtheLowVoltageSetting,page10.

NOTE: NOTE:

NOTE:

IftheErrordisplayappears,theSmartmodule

haslostcommunicationwiththepowersupply.See

ErrorDisplay,page10,forfurtherinformation.

Figure2SmartGunModuleinOperatingMode

3A2494D 9

GunOverview

Error Error

Error

Display Display

Display

IftheSmartmodulelosescommunicationwith

thepowersupply,theErrordisplayappears,the

Hzindicatorturnsred,andtheSmartmoduleis

disabled.SeeFig.3,andTable1onpage10.

ThiscanoccurinOperatingModeorDiagnostic

Mode.SeeElectricalTroubleshooting,page35.

CommunicationmustberestoredtomaketheSmart

modulefunctional.

NOTE: NOTE:

NOTE:

Ittakes8secondsfortheErrordisplayto

appear.Ifthegunhasbeendisassembled,wait8

secondsbeforesprayingtoensurethatanError

conditionhasnotoccurred.

NOTE: NOTE:

NOTE:

Ifthereisnopowertothegun,theError

displaywillnotappear.

Figure3ErrorDisplay

Adjusting Adjusting

Adjusting

the the

the

Low Low

Low

Voltage Voltage

Voltage

Setting Setting

Setting

Thelowvoltagesettingisuseradjustable.Toaccess

thelowvoltagesettingscreenwheninOperating

Mode,presstheLOSETbutton(LS)momentarily.

Thescreenwilldisplaythecurrentlowvoltage

setting.SeeFig.4,andTable1onpage10.The

possiblerangesare:

•85kVguns:40–85kV

•60kVguns:30–60kV

SettheVoltageAdjustmentswitch(VA)toLO.Press

theLOSETbuttonrepeatedlytoincreasethesetting

inincrementsof5.Whenthedisplayreachesthe

maximumsettingitwillreturntotheminimumsetting

foryourgun.Continuepressingthebuttonuntilyou

reachthedesiredsetting.

NOTE: NOTE:

NOTE:

After2secondsofinactivitythedisplaywill

returntotheOperatingScreen.

NOTE: NOTE:

NOTE:

Thelowvoltagesettingmaybelocked.See

LockSymbol,page10.

Figure4LowVoltageSettingScreen(Unlocked)

Lock Lock

Lock

Symbol Symbol

Symbol

Thelowvoltagesettingmaybelocked.Whenlocked,

animage(LK)appearsonthescreen.SeeFig.5,

andTable1onpage10.

•WheninHImode,thelowvoltagesettingisalways always

always

locked.ThelocksymbolwillappearwhentheLO

SETbuttonispressed.

•WheninLOmode,thelocksymbolwill

only only

only

appearifthelockisenabled.See

LowVoltageLockScreen,page14,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

10 3A2494D

GunOverview

Table Table

Table

1 1

1

. .

.

Key Key

Key

for for

for

Figs. Figs.

Figs.

2–9. 2–9.

2–9.

Item Item

Item

Description Description

Description

Purpose Purpose

Purpose

VA

VoltageAdjustmentSwitch

Two-positionswitchsetssmart

gunvoltagetolowsetting(LO)or

highsetting(HI).Thisswitchis

functionalinOperatingModeand

inDiagnosticMode.

LO

LowVoltageModeIndicator

Lights(blue)whenthesmartgun

issettoLowVoltage.

kV

Voltage(kV)Display

Displaysactualsprayingvoltage

ofthegun,inkV.InOperating

Mode,displayisabargraph.

InDiagnosticMode,voltageis

displayedasanumber.

uA

Current(uA)Display

Displaysactualsprayingcurrent

ofthegun,inuA.InOperating

Mode,displayisabargraph.

InDiagnosticMode,currentis

displayedasanumber.

LSLOSETbutton

Pressmomentarilytoenterthe

LowVoltageSettingscreen.

Pressandholdforapproximately5

secondstoenterorexitDiagnostic

Mode.

WhileinDiagnosticMode,press

momentarilytoadvancethrough

screens.

WhileontheLowVoltageLock

Screen(inDiagnosticMode),

pressandholdtoturnthelockon

oroff.

LVLowVoltageDisplayDisplaysthelowvoltagesetting

asanumber.Thesettingcanbe

changed.SeeFig.4.

LKLowVoltageLocked

Appearsifthelowvoltagesetting

islocked.SeeFig.5andFig.9.

3A2494D

11

GunOverview

Item Item

Item

Description Description

Description

Purpose Purpose

Purpose

LD

LODisplay

AppearsontheLowVoltageLock

Screen.SeeFig.9.

ERErrorDisplay

AppearsiftheSmartmoduleloses

communicationwiththepower

supply.SeeFig.3.

VIVoltageIndicatorInDiagnosticMode,thetwotop

rightLEDsofthescreenlight,

indicatingthatthevaluedisplayed

isinkV.SeeFig.6.

CICurrentIndicator

InDiagnosticMode,thetwo

bottomrightLEDsofthescreen

light,indicatingthatthevalue

displayedisinuA.SeeFig.7.

ASAlternatorSpeedDisplay

InDiagnosticMode,Hzlevelis

displayedasanumber.SeeFig.

8.

Hz

AlternatorSpeedIndicatorInOperatingMode,indicatorcolor

variestoshowthealternator

speedstatus:

•greenindicatesthealternator

speedisatthecorrectlevel.

•Iftheindicatorchangestoamber

after1second,thealternator

speedistoolow.

•Iftheindicatorchangestored

after1second,thealternator

speedistoohigh.Theindicator

willalsoturnrediftheError

displayappears.

InDiagnosticMode,theindicator

isgreenwhenintheAlternator

Speed(Hertz)screen.

12

3A2494D

GunOverview

Diagnostic Diagnostic

Diagnostic

Mode Mode

Mode

DiagnosticModeincludesfourscreenswhichdisplay

gundata:

•Voltage(kiloVolts)Screen

•Current(microAmperes)Screen

•AlternatorSpeed(Hertz)Screen

•LowVoltageLockScreen

NOTE: NOTE:

NOTE:

YoumustbeinOperatingModetoadjustthe

lowvoltagesetting;thesettingisnotadjustablein

DiagnosticMode.However,thevoltageadjustment

switch(VA)canbesettoHIorLOinOperatingMode

andinDiagnosticMode.

ToenterDiagnosticMode,pressandholdtheLOSET

(LS)buttonforapproximately5seconds.Thedisplay

willgototheVoltage(kiloVolts)Screen,page13.

Toadvancetothenextscreen,presstheLOSET

buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET

buttonforapproximately5seconds.Thescreenwill

returntoOperatingMode.

NOTE: NOTE:

NOTE:

IfthegunisdetriggeredwhileinDiagnostic

Mode,thelastscreenviewedwillbedisplayedwhen

thegunisretriggered.

NOTE: NOTE:

NOTE:

DiagnosticModecannotbeexited

fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page14fordetails.

Voltage Voltage

Voltage

(kiloVolts) (kiloVolts)

(kiloVolts)

Screen Screen

Screen

TheVoltage(kiloVolts)Screenistherstscreento

appearafterenteringDiagnosticMode.SeeFig.6,

andTable1onpage10.Toenterthisscreen,press

andholdtheLOSETbuttonforapproximately5

secondswhileintheOperatingMode.

Thisscreendisplaysthesprayingvoltageofthe

gunasanumber(kV),roundedtothenearest5kV.

ThetwotoprightLEDs(VI)ofthedisplaypanel

light,indicatingthattheVoltage(kiloVolts)Screen

isdisplayed.Thedisplayisareadoutandcannot

bechanged.

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page13.Press

andholdforapproximately5secondstoreturnto

OperatingMode.

Figure6Voltage(kiloVolts)Screen

Current Current

Current

(microAmperes) (microAmperes)

(microAmperes)

Screen Screen

Screen

TheCurrent(microAmperes)Screenisthesecond

screenintheDiagnosticMode.SeeFig.7,andTable

1onpage10.Toenterthisscreen,presstheLO

SETbuttonwhileintheVoltage(kiloVolts)Screen.

Thisscreendisplaysthesprayingcurrentofthegun

asanumber(uA),roundedtothenearest5uA.The

twobottomrightLEDs(CI)ofthedisplaypanellight,

indicatingthattheCurrent(microAmperes)Screen

isdisplayed.Thedisplayisareadoutandcannot

bechanged.

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page14.Press

andholdforapproximately5secondstoreturnto

OperatingMode.

Figure7Current(microAmperes)Screen

3A2494D 13

GunOverview

Alternator Alternator

Alternator

Speed Speed

Speed

(Hertz) (Hertz)

(Hertz)

Screen Screen

Screen

TheAlternatorSpeed(Hertz)Screenisthethird

screenintheDiagnosticMode.SeeFig.8,andTable

1onpage10.Toenterthisscreen,presstheLOSET

buttonwhileintheCurrent(microAmperes)Screen.

Thisscreendisplaysthealternatorspeedasa3digit

number(AS),roundedtothenearest10Hz.The

displayisareadoutandcannotbechanged.Ifthe

alternatorspeedisgreaterthan999Hz,thedisplay

willshow999.

TheHzindicatorlightsgreentoshowthatyouare

viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page14.Pressandhold

forapproximately5secondstoreturntoOperating

Mode.

Figure8AlternatorSpeed(Hertz)Screen

Low Low

Low

Voltage Voltage

Voltage

Lock Lock

Lock

Screen Screen

Screen

TheLowVoltageLockScreenisthefourthscreenin

theDiagnosticMode.SeeFig.9,andTable1on

page10.Toenterthisscreen,presstheLOSET

buttonwhileintheAlternatorSpeed(Hertz)Screen.

ThisscreendisplaysthestatusoftheLowVoltage

Lock.Ifthesettingislocked,thelockimage(LK)

appearstotheleftoftheLodisplay(LD).Ifthesetting

isunlocked,thelockimagedoesnotappear.

Tochangethelockstatus,pressandholdthe

LOSETbuttonuntilthelockimageappearsor

disappears.Ifthelockisset,theimagewillalso

appearontheLowVoltageSettingScreenwhenin

lowvoltagemode(seeFig.4).

NOTE: NOTE:

NOTE:

DiagnosticModecannotbeexitedfromthis

screen,becausepressingandholdingtheLOSET

buttonisusedtoturnthelockonoroff.Toexit,

pressLOSETmomentarilytoreturntotheVoltage

(kiloVolts)Screen,thenexitDiagnosticModefrom

there.

Figure9LowVoltageLockScreen

14

3A2494D

Installation

Installation Installation

Installation

Installingandservicingthisequipmentrequires

accesstopartswhichmaycauseelectricshock

orotherseriousinjuryifworkisnotperformed

properly.

•Donotinstallorservicethisequipmentunless

youaretrainedandqualied.

•Besureyourinstallationcomplieswithlocal,

state,andnationalcodesfortheinstallation

ofelectricalapparatusinaClassI,Div.I,

HazardousLocationoraGroupII,ZoneI

ExplosiveAtmosphereLocation.

•Complywithallapplicablelocal,state,and

nationalre,electrical,andothersafety

regulations.

Fig.10showsatypicalelectrostaticairspraysystem.

Itisnotanactualsystemdesign.Forassistance

indesigningasystemtosuityourparticularneeds,

contactyourGracodistributor.

Warning Warning

Warning

Sign Sign

Sign

Mountwarningsignsinthesprayareawherethey

caneasilybeseenandreadbyalloperators.An

EnglishWarningSignisprovidedwiththegun.

Ventilate Ventilate

Ventilate

the the

the

Spray Spray

Spray

Booth Booth

Booth

Providefreshairventilationtoreducetheriskofre

orexplosioncausedbythebuildupofammableor

toxicvaporswhenspraying,ushing,orcleaning

thegun.Donotoperatethegununlessventilation

fansareoperating.

Electricallyinterlockthegunairsupplywiththe

ventilatorstopreventgunoperationwithout

ventilatingfansoperating.Checkandfollowalllocal,

state,andnationalcodesregardingairexhaust

velocityrequirements.

Highvelocityairexhaustwilldecreasetheoperating

efciencyoftheelectrostaticsystem.Airexhaust

velocityof100ft/min(31linearmeters/minute)should

besufcient.

3A2494D 15

Installation

Air Air

Air

Supply Supply

Supply

Line Line

Line

Toreducetheriskofelectricshock,theairsupply

hosemustbeelectricallyconnectedtoatrueearth

ground.Use Use

Use

only only

only

Graco Graco

Graco

Grounded Grounded

Grounded

Air Air

Air

Supply Supply

Supply

Hose. Hose.

Hose.

1.SeeFig.10.UsetheGracoGroundedAirSupply

Hose(AH)tosupplyairtothegun.Thegunair

inletttinghasaleft-handthread.Theairsupply

hosegroundwire(AG)mustbeconnectedtoa

trueearthground.Donotconnecttheairsupply

hosetothegunairinletyet.

2.Installanairlinelter/waterseparator(AF)onthe

gunairlinetoensureadry,cleanairsupplytothe

gun.Dirtandmoisturecanruintheappearance

ofyournishedworkpieceandcancausethe

guntomalfunction.

3.Installbleed-typeairregulators(PR,GR)on

thepumpandgunairsupplylinestocontrolair

pressuretothepumpandgun.

Trappedaircancausethepumptocycle

unexpectedly,whichcanresultinserious

injury,includingsplashinguidintheeyesor

ontheskin.Donotoperatetheequipment

withoutthebleed-typeairvalve(BV)installed.

4.Installableed-typeairvalve(BV)onthepump

airsupplyline.Thebleed-typeairvalve(BV)is

requiredinyoursystemtoshutoffairtothepump

andrelieveairtrappedbetweenthevalveand

thepumpaftertheairregulatorisshutoff.Install

anadditionalbleed-typeairvalveonthemainair

line(MA)toisolatetheaccessoriesforservicing.

5.Installanairbleedvalve(BV)oneachgunair

supplylinetoshutoffairtothegun(s)andrelieve

airtrappedbetweenthevalveandthegunafter

theairregulatorisshutoff.

Fluid Fluid

Fluid

Supply Supply

Supply

Line Line

Line

1.Blowouttheuidline(FL)withairandushit

withsolvent.Usesolventwhichiscompatible

withtheuidtobesprayed.Donotconnectthe

uidsupplylinetothegunuidinletyet.

2.Installauidregulator(FR)ontheuidlineto

controluidpressuretothegun.

3.Installauidlter(FF)nearthepumpoutlet,to

removeparticlesandsedimentwhichcouldclog

thespraynozzle.

Toreducetheriskofseriousinjury,including

splashinguidintheeyesorontheskin,do

notoperateequipmentwithouttheuiddrain

valve(FD)installed.

4.Theuiddrainvalve(FD)isrequiredinyour

systemtoassistinrelievinguidpressureinthe

displacementpump,hose,andgun.Triggering

theguntorelievepressuremaynotbesufcient.

Installadrainvalveclosetothepump'suid

outlet.

16 3A2494D

Installation

NON NON

NON

- -

-

HAZARDOUS HAZARDOUS

HAZARDOUS

AREA AREA

AREA

HAZARDOUS HAZARDOUS

HAZARDOUS

AREA AREA

AREA

Figure10TypicalInstallation

Typical Typical

Typical

Installation Installation

Installation

Key Key

Key

Item Item

Item

Description Description

Description

ADAirLineDrainValve

AF

AirFilter/WaterSeparator

AG*GunAirHoseGroundWire

AH*GracoGroundedAirHose(left-hand

threads)

ALPumpAirLineLubricator

BV*PumpBleed-TypeAirShutoffValve

EGElectrostaticAirSprayGun

FD*

FluidDrainValve

FFFluidFilter

FL

FluidSupplyLine

FRFluidPressureRegulator

Item Item

Item

Description Description

Description

FV

FluidShutoffValve

GRGunAirPressureRegulator

MA

MainAirSupplyLine

PG*PumpGroundWire

PRPumpAirPressureRegulator

SPSupplyPump

SV*VentilationFanInterlockSolenoidValve.

NOTE: NOTE:

NOTE:

Thesolenoidvalveisnotoffered

asaGracoaccessory.

*Theseitemsarerequiredforsafeoperation.They

mustbepurchasedseparately.

3A2494D

17

GunSetup

Gun Gun

Gun

Setup Setup

Setup

Gun Gun

Gun

Setup Setup

Setup

Checklist Checklist

Checklist

SeeFig.11tolocatetheelectrostaticguncontrols.

Figure11ElectrostaticGunControls

1.Thegunisshippedwiththeuidnozzleandair

capinstalled.Checkthattheretainingringis

tight.

NOTE: NOTE:

NOTE:

Toselectadifferent

sizeuidnozzleoraircap,see

FluidNozzleSelectionChart,page68and

AirCapSelectionChart,page70.To

installthenozzleandaircap,see

AirCapandNozzleReplacement,page38.

2.TurnOFF(O)theESOn-Offswitch(J).

3.Shutofftheairbleedvalvetothegun.

4.Checkgunresistance.See

TestGunResistance,page31.

5.ConnecttheGracogroundedairhosetothegun

airinlet.Thegunairinletttinghasleft-hand

threads.

6.FollowallstepsunderGrounding,page21.

7.Followallstepsunder

CheckGunElectricalGrounding,page25.

Readingmustbelessthan1megohm.

8.Verifythatthematerialresistivitymeets

requirementsforelectrostaticspray.See

CheckFluidResistivity,page26.

9.Connecttheexhausttubeandsecurewiththe

clampprovided.

10.Connecttheuidhosetothegunuidinlet.

11.Flushifneeded,seeFlushing,page28.

12.Positiontheaircapasdesired.

18 3A2494D

GunSetup

13.Fullyopenthefanairadjustmentvalve(F)

counterclockwise.

14.Fullyopentheuidadjustmentvalve(H)

counterclockwise.

15.Fullyopentheatomizingairrestrictorvalve(G)

clockwise.

16.TurnON(I)theESOn-Offswitch(J).

17.Setthegunairregulatortodeliveraminimum

45psi(0.32MPa,3.2bar)atthegunwhen

triggered,toensurefullsprayingvoltage.See

thetablebelow.

Table Table

Table

2 2

2

. .

.

Pressure Pressure

Pressure

Drop Drop

Drop

Air Air

Air

Hose Hose

Hose

Length Length

Length

in in

in

ft ft

ft

(m) (m)

(m)

(using (using

(using

5/16 5/16

5/16

in. in.

in.

[8 [8

[8

mm] mm]

mm]

diameter diameter

diameter

hose) hose)

hose)

Air Air

Air

Regulator Regulator

Regulator

Setting Setting

Setting

in in

in

psi psi

psi

(MPa, (MPa,

(MPa,

bar) bar)

bar)

[with [with

[with

gun gun

gun

triggered] triggered]

triggered]

15(4.6)55(0.38,3.8)

25(7.6)65(0.45,4.5)

50(15.3)80(0.56,5.6)

18.CheckthattheESindicator(K)[Hzindicatoron

Smartguns]islit.Seethefollowingtable.

Table Table

Table

3 3

3

. .

.

LED LED

LED

Indicator Indicator

Indicator

Colors Colors

Colors

Indicator Indicator

Indicator

Color Color

Color

Description Description

Description

Green

Whenspraying,theindicator

shouldremaingreen,indicating

sufcientairpressuretothe

alternatorturbine.

Amber

Iftheindicatorchangestoamber

after1second,theairpressure

istoolow.Increaseairpressure

untiltheindicatorisgreen.

Red

Iftheindicatorchangestored

after1second,theairpressureis

toohigh.Decreaseairpressure

untiltheindicatorisgreen.

3A2494D 19

GunSetup

19.Shutofftheairtothegun.TurnOFF(O)theES

On-Offswitch(J).

20.Startthepump.Adjusttheuidregulatoruntilthe

streamfromtheguntravels8-12in.(200-300

mm)beforefallingoff.Typically,ifuidpressure

isbelow5psi(.04MPa,0.4bar)orabove30psi

(0.21MPa,2.1bar),achangeofnozzlesizeis

recommended.

21.Turnontheairtothegun.TurnON(I)theES

On-Offswitch(J).

22.Sprayatestpattern.Checktheatomization.If

over-atomizationoccursatminimumpressure,

adjusttherestrictorvalve.Ifatomizationis

inadequate,increaseairpressureordecrease

uidow.

23.Adjustthefanairadjustmentvalve:clockwisefor

anarrowerpattern,counterclockwiseforawider

pattern.

24.Sprayatestpiece.Examinetheedges

forcoverage.Ifwrapispoor,see

Troubleshooting,page33.

20 3A2494D

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