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Instructions/Parts List
AUTOMATIC ELECTROSTATIC AIR-ASSISTED SPRAY GUN
309298J
™
PRO Auto Xs AA
ENG
Part No. 244592, Series A
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
3000 psi (21 MPa, 210 bar) Maximum Working Fluid Pressure
For use in Class I, Div. I hazardous locations using Group D spray materials.
For use in Group II, Zone 1 areas using Group IIA spray materials.
II 2 G EEx 0.24MJ
For Professional Use ONLY.
Important Safety Instructions
Read all warnings and instructions in this m
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Table of Contents Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 3 Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 23 Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Daily Care and Cleaning, continued . . . . . . . . . 24 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Symbols Symbols Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious injury This symbol alerts you to the possibility of damage to or or death if you do not follow the instructions. destruction of equipment if you do not follow the instruc- tions. WARNING Fire, Explosion, and Electric Shock Hazard Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: � Electrostatic equipment must
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Warning WARNING Skin Injection Hazard Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause serious injury. � Fluid injected into the skin might look like just a cut, but is a serious injury. Get immediate surgical treatment. � Do not point the gun at anyone or at any part of the body. Do not put your hand or fingers over the spr
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Warning WARNING 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 manuals, tags, and labels before operating the equipment. � Use the equipment only for its intended purpose. If you are uncertain, call your Graco distribu- tor. � Do not alter or modify equipment. Use only genuine Graco parts and accessories. � Check the equipment daily. Repair
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Introduction Introduction How the Electrostatic AA Operating the Electrostatics Spray Gun Works To operate the electrostatics, apply air pressure to the gun manifold’s turbine air fitting (TA) through a Graco grounded air hose. The air enters the manifold and is directed to the inlet of the power supply turbine. The air spins the turbine, which then provides electrical power to the internal high voltage power supply. The fluid is WARNING charged by the spray gun electrode. The charged flu
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Introduction Changing the kV Setting Table 1: KV1 and KV2 Switch Settings The gun’s full voltage setting is 85 kV. Three lower volt- age settings are possible by actuating the KV1 and KV2 KV1 Air KV2 Air Output Voltage (kV) switches. Supply 50 psi (0.35 MPa, 3.5 bar) air pressure OFF OFF 85 to the KV1 and KV2 ports. Turn the air on or off as OFF ON 70 shown in Table 1 to set the desired voltage. ON OFF 60 The solenoid valves used to activate the KV1 and KV2 ON ON 45 switches must bleed the
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Introduction G KV1 TA FO A CYL KV2 C A2 P1 TI1713A F H B EXH E J TI1739A TI1714A Manifold Back View D K Fig. 1. Gun Overview Key Manifold Markings A Air Cap A1 not used BSpray Tip A2 Atomization Air Inlet Fitting C Tip Guard CYL Cylinder Air Inlet Fitting D Retaining Ring EXH Shroud Exhaust Outlet Fitting E Shroud FO Fiber Optic Fitting F Mounting Bracket KV1 kV Switch 1 Air Inlet G Manifold KV2 kV Switch 2 Air Inlet H Turbine P1 Fluid Supply Inlet Fitting J Power Supply P2 not used KElectrode
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Installation Installation Electrically interlock the gun turbine air supply with the Install the System ventilators to prevent gun operation without ventilating fans operating. Check and follow all National, State, and Local codes regarding air exhaust velocity require- ments. WARNING High velocity air exhaust will decrease the operating effi- Fire, Explosion, and Electric Shock Hazard ciency of the electrostatic system. The minimum allow- able air exhaust velocity is 60 ft/minute (19 linear
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Installation NOTE: * The turbine air supply (TA) must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on. See * W L above X Y BC A TA KV1 K K KV2 A2 K CYL L K P1 N F E M G J TI1741A Non-Hazardous Area Hazardous Area Manifold Back View Fig. 2. Typical Installation NOTE: ** A maximum of two splices with a total of 108 ft (33 m) of cable can be used. For the strongest light signals, use a minimum number of b
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Installation Install the Air Line Accessories WARNING Skin Injection Hazard Trapped air can cause the gun to spray unexpectedly, which can result in serious WARNING injury, including injecting fluid through the skin. The solenoid valves (K) must have a quick Component Rupture Hazard exhaust port so trapped air will be relieved between To reduce the risk of serious injury due to the valve and gun when the solenoids are shut off. component rupture: The bleed-type master air valve (L) is re
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Installation Install the Gun and Mounting Bracket 1. Loosen the mounting bracket’s two set screws (103) and slide the bracket (102) onto a 1/2 in. (13 mm) 2.88 in mounting rod. See FIG. 4.. (73.2 mm) NN 102 2. Position the gun and tighten the two set screws. For added positioning reliability, insert a 1/8 in. (3 mm) locating pin into the slot (NN) in the bracket and through 103 To a hole in the rod. See the detail in FIG. 4.. TI1738A Nozzle 9.24 in Tip (234.7 mm) Fig. 4. Mounting Bracket
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Installation EXH Shroud Exhaust Outlet Fitting Connect the Air and Fluid Connect a 1/4 in. (6 mm) OD x 4 ft (1.22 m) long tube to this fitting. Lines FO Fiber Optic Fitting (Optional) Connect the Graco Fiber Optic cable (see page 14). FIG. 3. shows a schematic of air and fluid line connec- tions, and FIG. 5. shows the manifold connections. Con- KV1 kV Switch 1 Air Inlet Fitting Connect a 5/32 in. (4 mm) OD tube between this fitting and nect the air and fluid lines as instructed. the solenoid.
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Installation 2. Remove the nut (AA) from the fiber optic fitting (5) Optional Fiber Optic Cable and slide the nut over the end of the fiber optic cable (BB). See FIG. 7.. Connection 3. Push the cable (BB) into the fitting (5) until it bot- An optional fiber optic fitting is shipped unassembled toms out. Tighten the nut (AA) to secure the cable. with the gun. If an ES (kV) display module is used, install the fitting in the FO port of the manifold. See FIG. 5 3., page 10, for a schematic of
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Installation � Air compressors and hydraulic power supplies: Grounding ground the equipment according to the manufac- turer's recommendations. � All air and fluid lines must be properly grounded. WARNING � All electrical cables must be properly grounded. � All persons entering the spray area: shoes must Fire, Explosion, and Electric Shock Hazard have conductive soles, such as leather, or personal When operating the electrostatic gun, any grounding straps must be worn. Do not wear shoes ung
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Installation 4. Measure the resistance between the turbine air inlet Check Electrical Grounding fitting (TA) and a true earth ground (N). a. If using a black or grey turbine air hose, use a megohmmeter to measure the resistance. Use an applied voltage of 500 minimum to 1000 WARNING volts maximum. The resistance should not exceed 1 megohm. Fire, Explosion, and Electric Shock Hazard b. If using a red turbine air hose, use an ohmmeter Megohmmeter Part No. 241079 (AA-see to measure the resi
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Installation Check Fluid Resistivity Check Fluid Viscosity To check fluid viscosity you will need: � a viscosity cup � a stopwatch. WARNING 1. Completely submerge the viscosity cup in the fluid. Fire, Explosion, and Electric Shock Hazard Lift the cup out quickly, starting the stopwatch as Check the fluid resistivity in a non-hazard- soon as the cup is completely removed. ous area only. Resistance Meter 722886 and Probe 722860 are not approved for use 2. Watch the stream of fluid coming from
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Operation Operation 7. If you suspect that the spray tip or hose is still Pressure Relief Procedure clogged or that pressure is not fully relieved after fol- lowing the steps above, very slowly loosen the hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose obstruction. WARNING Operating Checklist Skin Injection Hazard Check the following list daily, before operating the sys- The system pressure must be manually tem, to help ensure you of safe
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Operation 3. Install the spray tip and air cap, tip guard (3), shroud Select a Spray Tip (2), and retaining ring (1) onto the gun. Be sure the electrode (40a) is in place. Tighten the retaining ring The fluid output and pattern width depend on the size of firmly. the spray tip, the fluid viscosity, and the fluid pressure. Use the Spray Tip Selection Chart, page 51, as a guide for selecting the appropriate spray tip for your application. WARNING Install the Spray Tip Fire, Explosion, and E
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Operation 6. Turn on the atomization air (A2) and adjust the air Set the Atomization Fluid pressure until the tails disappear. See Spray Pattern Troubleshooting on page 32 to cor- Pressure rect spray pattern problems. Atomization fluid pressure will vary based on the viscos- ity of the fluid, flow rate desired, and other system char- acteristics. KV2 1. Turn off the turbine air (TA) and atomization air (A2). KV1 TA 2. Start the pump. Set the fluid regulator to 400 psi (2.8 MPa, 28 bar). CYL
