Graco 3A2495C User manual

Instructions - Parts

Pro Xp™ Electro

static

Air-Assisted

Spray Gun

3A2495C

EN

For use in Class I, Div. I Hazardous Locations using Group D spray materials.

For use in Group II, Zone 1 Explosive Atmosphere Locations using Group IIA spray materials. For

professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these

instructions.

3000 psi (

21 MPa, 210 bar) Maximum

Fluid Wor

king Pressure

100 psi (

0.7 MPa, 7 bar) Maximum

Air Work

ing Pressure

See pag

e 3 for model part numbers

and app

roval information.

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents

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

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

Gun Overview .................................................... 7

How the Electrostatic AA Spray Gun

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

Controls, Indicators, and Components........... 8

Smart Guns ................................................. 9

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

Warning Sign............................................... 15

Ventilate the Spray Booth ............................. 15

Air Supply Line ............................................ 16

Fluid Supply Line ......................................... 16

Gun Setup.......................................................... 18

Gun Setup Checklist .................................... 18

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

Check Gun Electrical Grounding ................... 25

Check Fluid Resistivity ................................. 26

Check Fluid Viscosity ................................... 26

Flush Before Using Equipment...................... 26

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

Pressure Relief Procedure............................ 27

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

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

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

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

Clean the Gun Daily ..................................... 29

Daily System Care ....................................... 31

Electrical Tests................................................... 32

Test Gun Resistance.................................... 32

Test Power Supply Resistance ..................... 33

Test Gun Barrel Resistance.......................... 34

Troubleshooting.................................................. 35

Spray Pattern Troubleshooting...................... 35

Gun Operation Troubleshooting .................... 36

Electrical Troubleshooting ............................ 37

Rep

air................................................................ 39

Pre

pare the Gun for Service ......................... 39

Air

Cap, Spray Tip, and Fluid Seat Housing

Re

placement.................................. 40

El

ectrode Replacement ................................ 41

Fluid Tube Rem

oval and Replacement........... 42

Fluid Filter R

eplacement............................... 42

Gun Barrel Rem

oval..................................... 43

Gun Barrel In

stallation.................................. 43

Fluid Needle

Replacement............................ 44

Power Supply

Removal and

Replacement

.................................. 45

Alternator

Removal and Replacement ........... 46

Fan Air Adju

stment Valve Repair .................. 48

Atomizing A

ir Adjustment Valve

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

ES On-Off V

alve Repair ............................... 50

Air Valve R

epair........................................... 51

Smart Modu

le Replacement.......................... 52

Air Swivel

and Exhaust Valve

Replaceme

nt.................................. 53

Parts.................................................................. 54

Standard Air-Assisted Spray Gun

Assembly ....................................... 54

Smart Air-Assisted Spray Gun

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

Alternator Assembly ..................................... 58

ES On-Off Valve Assembly........................... 59

Fan Air Valve Assembly ............................... 60

Air Cap Assembly ........................................ 61

Smart Module Assembly............................... 61

Spray Tip Selection Chart.................................... 62

AEM Fine Finish Spray Tips.......................... 62

AEF Fine Finish Pre-Oriﬁce Spray

Tips ............................................... 63

Repai

r Kits, Related Manuals, and

Acces

sories .......................................... 64

Gun Ac

cessories.......................................... 64

Syste

m Accessories..................................... 64

Test E

quipment ........................................... 64

Hose

s ......................................................... 65

Oper

ator Accessories................................... 65

Dimensions ........................................................ 66

Technical Data ...................................................67

Gra

co Pro Xp Warranty....................................... 68

2

3A2495C

Models

Part No. kV

Smart Display Standard Display

H60T10 60

✔

H60M10 60

✔

H85T10 85

✔

H85M10 85

✔

II 2 G

EEx 0.24 mJ T6

FM12ATEX0068

EN 50050

Ta 0°C – 50°C

3A2495C 3

Warnings

The following

warnings are for the setup, use, grounding, maintenance and repair of this equipment. The

exclamation p

oint symbol alerts you to a general warning and the hazard symbol refers to procedure-speciﬁc

risks. When th

ese symbols appear in the body of this manual or on warning labels, refer backtothese

Warnings. Pr

oduct-speciﬁc hazard symbols and warnings not covered in this section may appear throughout

the body of th

is manual where applicable.

WARNING

FIRE, EXPL

OSION, AND ELECTRIC SHOCK HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help

prevent ﬁre, explosion, and electric shock:

• Electrostatic equipment must be used only by trained, qualiﬁed personnel who understand

the requirements of this manual.

• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to

spray area. Resistance must not exceed 1 megohm. See Grounding instructions.

•Onlyuseg

rounded Graco conductive air supply hoses.

• Do not use pail liners unless they are conductive and grounded.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use

equipment until you identify and correct the problem.

• Check gu

n resistance, hose resistance, and electrical grounding daily.

• Use and clean equipment only in well ventilated area.

• Interlock the gun air supply to prevent operation unless ventilating fansareon.

• Use cle

aning solvents with highest possible ﬂash point when ﬂushing or cleaning equipment.

• To clean the exterior of the equipment, cleaning solvents must have a ﬂash point at least

5°C above ambient temperature.

• Always turn the electrostatics off when ﬂushing, cleaning or servicing equipment.

• Elimi

nate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and

plast

ic drop cloths (potential static arc).

• Do not plug or unplug power cords or turn lights on or off when ﬂammable fumes are present.

• Keep spray area free of debris, including solvent, rags and gasoline.

•Keep

a working ﬁre extinguisher in the work area.

4

3A2495C

Warnings

WARNING

SKIN INJECTION HAZARD

High-pressure ﬂuid from gun, hose leaks, or ruptured components will pierce skin. This may

look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not spray w

ithout tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

•Donotputyo

ur hand over the spray tip.

• Do not stop or deﬂect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking,

or servicing equipment.

• Tighten al

l ﬂuid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious

injury or property damage.

• Use only compatible water-based solvents to clean plastic structural or pressure-containing

parts.

•SeeTechnical Data in this and all other equipment instruction manuals. Read ﬂuid and

solvent manufacturer’s MSDSs and recommendations.

TOXIC F

LUID OR FUMES

Toxic ﬂ

uids or fumes can cause serious injury or death if splashed in the eyes or on skin,

inhale

d, or swallowed.

• Read MSDSs to know the speciﬁc hazards of the ﬂuids you are using.

•Store

hazardous ﬂuid in approved containers, and dispose of it according to applicable

guide

lines.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury,

including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective

equipment includes but is not limited to:

•Prot

ective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the ﬂuid and solvent

manufacturer.

3A2495C 5

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operat

e the unit when fatigued or under the inﬂuence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated

system component. See Technical Data in all equipment manuals.

• Use ﬂuids and solvents that are compatible with equipment wetted parts. See Technical Data

in all equipment manuals. Read ﬂuid and solvent manufacturer’s warnings. For complete

information about your material, request MSDS from distributor or retailer.

• Do not leave

the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine

manufacturer’s replacement parts only.

• Do not alte

r or modify equipment. Alterations or modiﬁcations may void agency approvals

and create

safety hazards.

• Make sure all equipment is rated and approved for the environment in which youareusingit.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hos

es and cables away from trafﬁc areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

•Complyw

ith all applicable safety regulations.

6 3A2495C

Gun Overview

How the Electr

ostatic AA Spray Gun

Works

This is not an air spray gun. To help prevent

serious injury from pressurized ﬂuid, such as skin

injection, and splashing ﬂuid, read and follow the

Skin Injection Hazard Warnings on page 5.

The air-assisted spray gun combines airless and

air spraying concepts. The spray tip atomizes

and shapes the ﬂuid into a fan pattern, as does

a conventional airless spray tip. Air from the air

cap further atomizes the ﬂuid and completes the

atomization of the ﬂuid tails to produce a uniform

pattern.

As the gun is triggered, part of the regulated air

operates the alternator turbine and the rest of the

air helps atomize the ﬂuid being sprayed. The

alternator ge

nerates power, which is converted by

the power car

tridge to supply high voltage to the

gun’s electr

ode.

The ﬂuid is electrostatically charged as it passes

the electrode. The charged ﬂuid is attracted to the

grounded workpiece, wrapping around and evenly

coating all surfaces.

The regulated air that is directed to the air cap can

be further controlled using the gun’s atomizing air

adjustment valve. This valve can be used to restrict

air ﬂow to the air cap while maintaining sufﬁcient air

ﬂow to the alternator. The atomizing air adjustment

valve does not control pattern width. To change

patternwidth,useanewtipsize,orusethefan

adjustment to narrow the pattern width.

Thehighw

orking ﬂuid pressure of this gun provides

the power

needed to atomize higher solids materials.

NOTE: For airless atomization, if desired, turn the

gun’s atomizing air adjustment valve completely off.

Closing this valve does not affect alternator operation.

3A2495C

7

Gun Overview

Controls, Ind

icators, and Components

The electrostatic gun includes the following

controls, indicators, and components (see Fig.

1). For information on Smart guns, also see

Smart Guns, page 9 .

Item Description Purpose

A

Air Swivel

Inlet

1/4 npsm(m) left-hand

thread, for Graco grounded

air supply hose.

B Fluid Inlet

1/4 npsm(m

), for ﬂuid

supply hos

e.

C

Turbine Air

Exhaust

Barbed ﬁtting, for supplied

exhaust tube.

D

Air Cap/Tip

Guard and

Spray Tip

See Spray Tip Selection

Chart, page 62, for avail-

able sizes.

EElectrode

Supplie

s electrostatic

charge

to the ﬂuid.

FFanAir

Adjustment

Valve

Adjusts fan size and shape.

Canbeusedtodecrease

pattern width.

Item Description Purpose

G

Atomizing Air

Adjustment

Valve

Adjusts atomi

zing air ﬂow.

H

Trigger Safety

Lock

Locks trigge

rtoprevent

gun from spra

ying.

J

ES On-Off

Valve

Turns elect

rostatics ON (I)

or OFF (O).

K

ES Indica-

tor (standard

gun only; for

Smart gun in-

dicator, see

Operating

Mode, page

9 )

Lit when ES is ON (I).

Color indicates alternator

frequency. See the LED

indicator table in the Gun

Setup Checklist, page 18.

L Inline F

luid

Filter

Provides ﬁnal ﬁltration of

ﬂuid. Located inside ﬂuid

tube ﬁtting.

Figure 1 Gun Overview

8 3A2495C

Gun Overview

Smart Guns

The Smart Gun module displays spraying voltage,

current, alternator speed, and the voltage setting (low

or high). It also allows the user to change to a lower

spraying voltage. The module has two modes:

• Operating Mo

de

• Diagnostic M

ode

Operating M

ode

Bar Graph

See Fig. 2,

and Table 1 on page 11. The Operating

Mode displ

ays gun data during normal spraying. The

display u

ses a bar graph to show the voltage level in

kiloVolt

s (kV) and the current level in microAmperes

(uA). The

bar graph range is from 0 to 100% for each

value.

If the uA bar graph LEDs are blue, the gun is ready

to spray. If the LEDs are yellow or red, the current is

too high. The ﬂuid may be too conductive, or see

Electrical Troubleshooting, page 37 for other possible

causes.

Hz Indicator

The Hz indicator functions the same as the ES

indicator on standard guns. The indicator lights to

show the alternator speed status, and has three

colors:

• Green indicates the alternator speed is correct.

• If the indicator changes to amber after 1 second,

increase the air pressure.

• If the indicator changes to red after 1 second,

reduce the air pressure.

Voltage Adjustment Switch

The voltage adjustment switch (VA) allows the

operator to change from low to high voltage.

• The high volt

age setting is determined by the

maximum volt

age of the gun and is not adjustable.

•Thelowvolt

age indicator (LO) lights

when the swi

tch is set to LO. The low

voltage set

ting is user adjustable. See

Adjusting t

he Low Voltage Setting, page 10.

NOTE: If the Error display appears, the Smart module

has lost communication with the power supply. See

Error Display, page 10, for further information.

Figure2 SmartGunModuleinOperatingMode

3A2495C 9

Gun Overview

Error Display

If the Smart module loses communication with

the power supply, the Error display appears, the

Hz indicator turns red, and the Smart module is

disabled. See Fig. 3, and Table 1 on page 11.

This can occur in Operating Mode or Diagnostic

Mode. See Electrical Troubleshooting, page 37.

Communication must be restored to make the Smart

module functional.

NOTE: It takes 8 seconds for the Error display to

appear. If the gun has been disassembled, wait 8

seconds before spraying to ensure that an Error

condition has not occurred.

NOTE: If there is no power to the gun, the Error

display will not appear.

Figure 3 Error Display

Adjusting the Low Voltage Setting

The low voltage setting is user adjustable. To access

the low voltage setting screen when in Operating

Mode, press the LO SET button (LS) momentarily.

The screen will display the current low voltage

setting. SeeFig. 4,andTable1onpage11. The

possible ranges are:

• 85 kV guns: 40–85 kV

• 60 kV guns: 30–60 kV

Se

t the Voltage Adjustment switch (VA) to LO. Press

th

e LO SET button repeatedly to increase the setting

i

n increments of 5. When the display reaches the

m

aximum setting it will return to the minimum setting

for your gun. Continue pressing the button until you

reach the desired setting.

NOTE: After 2 s

econds of inactivity the display will

return to the O

perating Screen.

NOTE: The low voltage setting may be locked. See

Lock Symbol, page 10.

Figure 4 Low Voltage Setting Screen (Unlocked)

Lock Symbol

The low voltage setting may be locked. When locked,

an image (LK) appears on the screen. See Fig. 5,

and Table 1 on page 11.

• When in HI mode, the low voltage setting is always

locked. The lock symbol will appear when the LO

SET button is pressed.

• In LO mode, the lock symbol will only

appear if the lock is enabled. See

Low Voltage Lock Screen, page 14,tolock

or unlock the low voltage setting.

Fi

gure 5 Low Voltage Setting Screen (Locked)

10 3A2495C

Gun Overview

Table 1 . Key for Figs. 2–9.

Item Description Purpose

VA

Voltage Adjustment Switch

Two-position

switch sets smart

gun voltage to

low setting (LO) or

high setting (

HI). This switch is

functional i

n Operating Mode and

in Diagnosti

c Mode.

LO

Low Voltage Mode Indicator

Lights (blue) when the smart gun

is set to Low Voltage.

kV

Voltage (kV) Display

Displays ac

tual spraying voltage

of the gun, i

n kV. In Operating

Mode, disp

lay is a bar graph.

In Diagnos

tic Mode, voltage is

displayed

as a number.

uA

Current (uA) Display

Displays actual spraying current

of the gun, in uA. In Operating

Mode, display is a bar graph.

In Diagnostic Mode, current is

displayed as a number.

LS LO SET bu

tton

Press momentarily to enter the

Low Voltage Setting screen.

Press an

d hold for approximately 5

seconds

to enter or exit Diagnostic

Mode.

While in Diagnostic Mode, press

momentarily to advance through

screens.

While on the Low Voltage Lock

Screen (in Diagnostic Mode),

press and hold to turn the lock on

or off.

LV Low V

oltage Display

Disp

lays the low voltage setting

as a n

umber. The setting can be

chan

ged. See Fig. 4.

LK Low Voltage Locked

Appears if the low voltage setting

is locked. See Fig. 5 and Fig. 9.

3A2495C

11

Gun Overview

Item Description Purpose

LD Lo Display Appears on the Low Voltage Lock

Screen. See Fig. 9.

ER Error Display

Appears if the

Smart module loses

communicatio

nwiththepower

supply. See F

ig. 3.

VI Voltage Indicator In Diagnostic Mode, the two top

right LEDs of the screen light,

indicating that the value displayed

is in kV. See Fig. 6.

CI Current Ind

icator

In Diagnostic Mode, the two

bottom right LEDs of the screen

light, indicating that the value

displayedisinuA.SeeFig.7.

AS Alternator Speed Display

In Diagnos

tic Mode, Hz level is

displaye

d as a number. See Fig.

8.

Hz

Alternator Speed Indicator In Operating Mode, indicator color

varies to show the alternator

speed status:

• green in

dicates the alternator

speed is

at the correct level.

•Ifthei

ndicator changes to amber

after 1

second, the alternator

speed i

stoolow.

•Ifthei

ndicator changes to red

after

1 second, the alternator

speed

is too high. The indicator

will a

lsoturnrediftheError

displ

ay appears.

In Diagnostic Mode, the indicator

is green when in the Alternator

Speed (Hertz) screen.

1

2

3A2495C

Gun Overview

Diagnostic Mode

Diagnostic Mode includes four screens which display

gun data:

• Voltage (kilo

Volts) Screen

• Current (mic

roAmperes) Screen

• Alternator S

peed (Hertz) Screen

• Low Voltage L

ock Screen

NOTE: You must be in Operating Mode to adjust the

low voltage setting; the setting is not adjustable in

Diagnostic Mode. However, the voltage adjustment

switch (VA) can be set to HI or LO in Operating Mode

and in Diagnostic Mode.

To enter Diagnostic Mode, press and hold the LO SET

(LS) button for approximately 5 seconds. The display

will go to the Voltage (kiloVolts) Screen, page 13.

To advanc

e to the next screen, press the LO SET

button ag

ain.

To exit Diagnostic Mode, press and hold the LO SET

button for approximately 5 seconds. The screen will

return to Operating Mode.

NOTE: If the gun is detriggered while in Diagnostic

Mode,thelastscreenviewedwillbedisplayedwhen

the gun is retriggered.

NOTE: D

iagnostic Mode cannot be exited

from th

e Low Voltage Lock Screen. See

Low Vol

tage Lock Screen, page 14 for details.

Volta

ge (kiloVolts) Screen

The Vo

ltage (kiloVolts) Screen is the ﬁrst screen to

appea

r after entering Diagnostic Mode. See Fig. 6,

and T

able 1 on page 11. To enter this screen, press

and h

old the LO SET button for approximately 5

seco

nds while in the Operating Mode.

This screen displays the spraying voltage of the

gun as a number (kV), rounded to the nearest 5 kV.

The two top right LEDs (VI) of the display panel

light, indicating that the Voltage (kiloVolts) Screen

is displayed. The display is a readout and cannot

be changed.

Press the LO SET button to advance to the

Current (microAmperes) Screen, page 13.Press

and hold for approximately 5 seconds to return to

Operating Mode.

Figure 6 Voltage (kiloVolts) Screen

Current (microAmperes) Screen

The Current (microAmperes) Screen is the second

screen in the Diagnostic Mode. See Fig. 7, and Table

1 on page 11. To enter this screen, press the LO

SET button while in the Voltage (kiloVolts) Screen.

This screen displays the spraying current of the gun

as a number (uA), rounded to the nearest 5 uA. The

two bottom right LEDs (CI) of the display panel light,

indicating that the Current (microAmperes) Screen

is displayed. The display is a readout and cannot

be changed.

Press the LO SET button to advance to the

Alternator Speed (Hertz) Screen, page 14.Press

and hold for approximately 5 seconds to return to

Operating Mode.

Figure 7 Current (microAmperes) Screen

3A2495C 13

Gun Overview

Alternator Speed (Hertz) Screen

The Alternator Speed (Hertz) Screen is the third

screen in the Diagnostic Mode. See Fig. 8, and Table

1 on page 11. To enter this screen, press the LO SET

button while in the Current (microAmperes) Screen.

This screen d

isplays the alternator speed as a 3 digit

number (AS),

rounded to the nearest 10 Hz. The

display is a r

eadout and cannot be changed. If the

alternator s

peed is greater than 999 Hz, the display

will show 99

9.

The Hz indicator lights green to show that you are

viewing the Alternator Speed (Hertz) Screen.

Press the LO SET button to advance to the

Low Voltage Lock Screen, page 14. Press and hold

for approximately 5 seconds to return to Operating

Mode.

Figure 8 Alternator Speed (Hertz) Screen

Low Voltage Lock Screen

The Low Voltage Lock Screen is the fourth screen in

the Diagnostic Mode. See Fig. 9, and Table 1 on

page 11. To enter this screen, press the LO SET

button while in the Alternator Speed (Hertz) Screen.

This screen d

isplays the status of the Low Voltage

Lock. If the s

etting is locked, the lock image (LK)

appears to th

e left of the Lo display (LD). If the setting

is unlocked,

the lock image does not appear.

To change the lock status, press and hold the

LO SET button until the lock image appears or

disappears. If the lock is set, the image will also

appear on the Low Voltage Setting Screen when in

low voltage mode (see Fig. 4).

NOTE: Diagnostic Mode cannot be exited from this

screen, because pressing and holding the LO SET

button is used to turn the lock on or off. To exit,

press LO SET momentarily to return to the Voltage

(kiloVolts) Screen, then exit Diagnostic Mode from

there.

Figure 9 Low Voltage Lock Screen

1

4

3A2495C

Installation

Installing and servicing this equipment requires

access to parts which may cause electric shock

or other serious injury if work is not performed

properly.

• Do not install or service this equipment unless

you are trained and qualiﬁed.

• Be sure your installation complies with local,

state, and national codes for the installation

of electrical apparatus in a Class I, Div. I

Hazardous Location or a Group II, Zone I

Explosive Atmosphere Location.

• Comply with all applicable local, state, and

national ﬁre, electrical, and other safety

regulations.

Fig. 10 shows a typical electrostatic air-assisted

spray system. It is not an actual system design.

For assistance in designing a system to suit your

particular needs, contact your Graco distributor.

Warning Sign

Mount warning signs in the spray area where they

can easily be seen and read by all operators. An

English Warning Sign is provided with the gun.

Ventilate the Spray Booth

Provide fresh air ventilation to reduce the risk of ﬁre

or explosion caused by the buildup of ﬂammable or

toxic vapors when spraying, ﬂushing, or cleaning

the gun. Do not operate the gun unless ventilation

fans are operating.

Electrically interlock the gun air supply with the

ventilators to prevent gun operation without

ventilating fans operating. Check and follow all local,

state, and national codes regarding air exhaust

velocity requirements.

High velocity air exhaust will decrease the operating

efﬁciency of the electrostatic system. Air exhaust

velocity of 100 ft/min (31 linear meters/minute) should

be sufﬁcient.

3A2495C 15

Installation

Air Supply Lin

e

To reduce the risk of electric shock, the air supply

hose must be electrically connected to a true earth

ground. Use only Graco Grounded Air Supply

Hose.

1. See Fig. 10. Use the Graco Grounded Air Supply

Hose (AH) to supply air to the gun. The gun air

inlet ﬁtting has a left-hand thread. The air supply

hose ground wire (AG) must be connected to a

true earth ground. Do not connect the air supply

hose to the gun air inlet yet.

2. Install an air line ﬁlter/water separator (AF) on the

gunairlinetoensureadry,cleanairsupplytothe

gun. Dirt and moisture can ruin the appearance

of your ﬁnished workpiece and can cause the

gun to malfunction.

To reduce the risk of serious injury due to

component rupture, including skin injection,

pump pressure must be limited by the pump air

regulator. Do not rely on the gun ﬂuid regulator

tolimittheﬂuidpressuretothegun.

The ﬂu

id supply pump must be prevented from

produ

cing a ﬂuid pressure greater than the

3000 p

si (21 MPa, 210 bar)

Maximum Working

Fluid

Pressure

of the gun. For example, the air

supp

ly pressure to a 30:1 ratio pump must not

exce

ed 100 psi (0.7 MPa, 7 bar).

3. Install bleed-type air regulators (PR, GR) on

the pump and gun air supply lines to control air

pressure to the pump and gun.

Trapped air can cause the pump to cycle

unexpectedly, which can result in serious

injury, including skin injection and splashing

ﬂuid in the eyes or on the skin. Do not operate

the equipment without the bleed-type air valve

(BV) installed.

4. Install a blee

d-type air valve (BV) on the pump

air supply lin

e. The bleed-type air valve (BV) is

required in yo

ur system to shut off air to the pump

and relieve a

ir trapped between the valve and

the pump afte

r the air regulator is shut off. Install

an additiona

l bleed-type air valve on the main air

line(MA)toi

solate the accessories for servicing.

5. Install an a

ir bleed valve (BV) on each gun air

supply line

to shut off air to the gun(s) and relieve

air trapped

between the valve and the gun after

the air reg

ulator is shut off.

Fluid Supply Line

1. Blow out t

he ﬂuid line (FL) with air and ﬂush it

with solv

ent. Use solvent which is compatible

with the ﬂ

uid to be sprayed. Do not connect the

ﬂuid supp

lylinetothegunﬂuidinletyet.

2. Install

a ﬂuid pressure regulator (FR) on the ﬂuid

linetoc

ontrol ﬂuid pressure to the gun.

3. Install

a ﬂuid ﬁlter (FF) near the pump outlet, to

remove

particles and sediment which could clog

the spr

ay nozzle.

NOTE: T

he gun includes an inline ﬂuid ﬁlter for

additi

onal ﬁltration.

To reduce the risk of serious injury, including

skin injection and splashing ﬂuid in the eyes or

on the skin, do not operate equipment without

the ﬂuid drain valve (FD) installed.

4. Theﬂuiddrainvalve(FD)isrequiredinyour

system to assist in relieving ﬂuid pressure in the

displacement pump, hose, and gun. Triggering

the gun to relieve pressure may not be sufﬁcient.

Install a drain valve close to the pump's ﬂuid

outlet.

16 3A2495C

Installation

NON-HAZARDOUS AREA HAZARDOUS AREA

Figure 10 Typical Installation

Typical Installation Key

Item Description

AF

Air Filter/Water Separator

AG* Gun Air Hose Ground Wire

AH* Graco Grounded Air Hose (left-hand

threads)

AL Pump Air Line Lubricator

BV* Pump Bleed-Type Air Shutoff Valve

EG Electrostatic Air Spray Gun

FD*

Fluid Drain Valve

FF Fluid Filter

FG Fluid Pressure Gauge

FL

Fluid Supply Line

FR Fluid Pressure Regulator

Item Description

FV

Fluid Shutoff Valve

GR Gun Air Pressure Regulator

MA

Main Air Supply Line

PG* Pump Ground Wire

PR Pump Air Pressure Regulator

RV Pump Runaway Valve

SP Supply Pump

SV* Ventilation Fan Interlock Solenoid Valve

NOTE: The solenoid valve is not offered as

a Graco accessory.

* These items are required for safe operation. They

must be purchased separately.

3A2495C

17

Gun Setup

Gun Setup Chec

klist

See Fig. 11 to locate the electrostatic gun controls.

Figure 11 Electrostatic Gun Controls

1. Turn OFF (O) the ES On-Off switch (J).

2. Shut off the air bleed valve to the gun.

3. Check gun resistance. See

Test Gun Resistance, page 32.

4. Connect the Graco grounded air hose to the gun

air inlet. The gun air inlet ﬁtting has left-hand

threads.

5. Follow all steps under Grounding, page 21.

6. Follow all steps under

Check Gun Electrical Grounding, page 25.

Readingmustbelessthan1megohm.

7. Verify that the material resistivity meets

requirements for electrostatic spray. See

Check Fluid Resistivity, page 26.

8. Connect the exhaust tube and secure with the

clamp provided.

9. Connect the ﬂuid hose to the gun ﬂuid inlet.

10. Flush if needed. See Flushing, page 28.

18 3A2495C

Gun Setup

To reduce the risk of a skin in-

jection injury, always follow the

Pressure Relief Procedure, page 27,

before removing or installing the spray tip, air

cap, or tip guard.

11. The ﬂuid output and pattern width depend

on the size of the spray tip, the ﬂuid

viscosity, and the ﬂuid pressure. Use the

Spray Tip Selection Chart, page 62, as a guide

for selecting the appropriate spray tip for your

application.

12. Align the spray tip tab with the groove in the air

cap. Install the tip.

13. Install the air cap and retaining ring. Orientate

the air cap and tighten the retaining ring securely.

14. Close the atomizing air adjustment valve (G) and

the fan air adjustment valve (F).

15. Check that the ES On-Off switch is OFF (O).

16. Start the pum

p. Set the ﬂuid regulator to 400 psi

(2.8 MPa, 28

bar).

17. Spray a test

pattern. Examine the particle size in

the center o

f the pattern (tails will be removed

in step 21)

. Increase the pressure in small

increment

s. Spray another pattern. Compare

particle s

ize. Continue increasing pressure until

the partic

le size remains constant. Do not exceed

3000 psi (2

1 MPa, 210 bar).

18. Turn ON (I) the ES On-Off switch.

3A2495C 19

Gun Setup

19. Check that the ES indicator (K) [Hz indicator on

Smart guns] is lit. See the following table.

Table 2 . LED Indicator Colors

Indicator

Color

Description

Green

When spraying, the indicator

should remain green, indicating

sufﬁcient air pressure to the

alternator turbine.

Amber

If the indicator changes to amber

after 1 second, the air pressure

is too low. Increase air pressure

until the indicator is green.

Red

If the indi

cator changes to red

after 1 se

cond, the air pressure is

too high.

Decrease air pressure

until the

indicator is green.

20. Set the gun air regulator to deliver a minimum

of 45 psi (0.32 MPa, 3.2 bar) at the gun when

triggered, to ensure full spraying voltage. See

the table below.

Table 3 . Pressure Drop

Air Hose

Length in ft (m)

(using 5/16 in. [8

mm] diameter hose)

Air Regulator Setting

in psi (MPa, bar)

[with gun triggered]

15 (4.6) 52 (0.36, 3.6)

25 (7.6) 57 (0.40, 4.0)

50 (15.3) 68 (0.47, 4.7)

75 (22.9) 80 (0.56, 5.6)

100 (30.5) 90 (0.63, 6.3)

21. Turn the atomizing air adjustment valve

counterclockwise until any tails disappear.

22. If desired atomization is not achieved, change

the tip size. The smaller the tip oriﬁce, the ﬁner

the atomization.

23. Spray a test piece. Examine the edges

for coverage. If wrap is poor, see

Troubleshooting, page 35.

NOTE: If a narrower pattern is needed occasionally,

open the fan air adjustment valve slightly. (Excessive

fan air ﬂow can cause paint buildup on the air cap.)

20 3A2495C

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