Graco PRO 5500wb Instructions-Parts List Manual
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Graco PRO 5500wb Instructions-Parts List Manual

Graco PRO 5500wb Instructions-Parts List Manual

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INSTRUCTIONS-PARTS LIST
Parts
INSTRUCTIONS
AUTOMATIC, 60 kV, ELECTROSTATIC,
Model PRO 5500wbt
Air Spray Gun
100 psi (0.7 MPa, 7 bar) Maximum Working
Pressure
For use when electrostatically spraying conductive,
waterborne fluids that meet at least one of the follow-
ing conditions for non-flammability:
1. The fluid has a flash point above 140_F (60_C)
and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.
2. The fluid does not sustain burning when tested per
ASTM Standard D4206 Sustained Burn Test.
Part No. 237603*, Series A
Includes the spray gun, shroud, manifold, and
mounting bracket.
Part No. 236824, Series A
Includes the spray gun and shroud only.
Part No. 238091, Series A
Includes the spray gun, shroud, manifold, regulator,
and mounting bracket.
NOTE: The fluid hose must be ordered separately.
U.S. PATENT 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. PATENT NO. 2,147,158; 2,142,559B; 2,140,327–B
Other U.S. and Foreign Patents Pending
NOTE: The PRO 5500wb spray gun is Factory Mutual approved for use with Graco isolation systems. The spray gun is also
approved for use with other Factory Mutual approved voltage isolations systems provided that the fluid hose is assembled as
shown in Fig. 15, page 17. Any modification of genuine Graco parts or replacement of parts with non-Graco parts will void agency
approvals.
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
E COPYRIGHT 1994 GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Part No. 237603
Part No. 238091
308496
Rev. F
04299
05928

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  • Page 1 Other U.S. and Foreign Patents Pending NOTE: The PRO 5500wb spray gun is Factory Mutual approved for use with Graco isolation systems. The spray gun is also approved for use with other Factory Mutual approved voltage isolations systems provided that the fluid hose is assembled as shown in Fig.

  • Page 2: Table Of Contents

    ......Optional Fiber Optic Lens Kit Installation ..Graco Waterborne Fluid Hose Repair ..Install the Fluid Hose .
  • Page 3 The area on the hose that is not covered by the conductive hose layer must be inside the voltage isolation system enclosure. Refer to Fig. 15, page 17. D Only use the red-colored Graco electrically conductive gun air hose with this gun. Do not use the black or grey-colored Graco air hoses.

  • Page 4: Warnings

    WARNING FIRE AND EXPLOSION HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire or explosion. D Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction manual.
  • Page 5 D Do not alter or modify this equipment. Use only genuine Graco parts and accessories. D Do not operate the gun power supply above 60 kV. Use only the Graco power supply, part no. 237250, with this spray gun.

  • Page 6: Introduction

    Electrostatically ards. When the spray gun charges the isolated fluid to The PRO 5500wb spray gun is a 60 kV electrostatic high voltage, it is similar to charging a capacitor or spray gun that is designed to spray conductive, water- battery.
  • Page 7 Introduction F.O. (PA) Manifold Back View 04299 04302 04482 Manifold Markings Atomization Air Inlet Fitting Air Cap Fan Air Inlet Fitting Fluid Nozzle Cylinder Air Inlet Fitting Retaining Nut EXH (PA) Shroud Exhaust Outlet or Pilot Air Inlet Fitting Shroud F.O.
  • Page 8 Graco Waterborne Fluid Hose (purchased separately) O PRO Voltage Block connection shown A Graco waterborne fluid hose must be used between 05179 Fig. 1 the voltage isolation system fluid outlet and the spray gun fluid inlet.

  • Page 9: Installation

    Mount the warning signs, part no. 186118 and 290171, at the entrance to the spray booth, where it can easily Fig. 2, page 10, shows a typical Model PRO 5500wb be seen and read by all operators. Additional warning waterborne system. Fig. 3 shows the optional ES signs are available at no charge.
  • Page 10 W 24 Volt Power Supply, P/N 235301 Cylinder Air Hose, 1/4 inch (6.4 mm) O.D. 4–20 mA Outputs Graco Waterborne Fluid Hose, see page 56 for parts PRO 5500wb Spray Gun G Graco H O PRO Voltage Block Isolation System...

  • Page 11: Install The Air Line Accessories

    Installation Install the Air Line Accessories 1. Install an air line filter and an air and water separa- tor on the main air supply line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

  • Page 12: Connect The Air Lines

    Graco Electrically Conduc- tive Air Hose for the turbine air hose, and you must connect the hose ground wire to a true earth ground. Do not use the black or grey-colored Graco air hoses. Connect the red-colored Graco Electrically Conductive...

  • Page 13: Optional Fiber Optic Cable Connection

    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 308265 to install a Graco ES Display 04305 Fig. 8 Module.

  • Page 14: Optional Fiber Optic Lens Kit Installation

    Installation 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 236852. 1. Remove the gun from the manifold as instructed on page 35. 2. Make sure the lens (HH) is clean. Push the lens into the counterbore (KK) in the manifold fiber optic port (GG).

  • Page 15: Install The Fluid Hose

    (P1), and slide the nut onto the hose (H). NOTE: See Fig. 13. D A Graco waterborne fluid hose must be used between the voltage isolation system fluid outlet 4. Apply a light coat of dielectric grease (supplied and the spray gun fluid inlet. See page 56 to order...
  • Page 16 Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç CAUTION The Graco warranty is void if the spray gun is con- nected to a non-Graco voltage isolation system or if 05927 the gun is operated above 60 kV.

  • Page 17: Ground The System

    04574 Fig. 15 Ground the System 2. PRO 5500wb Electrostatic Air Spray Gun: Install the red-colored Graco electrically conduc- tive air hose between the gun and air supply line and connect the air hose ground wire to a true WARNING earth ground.

  • Page 18: Check The Electrical Grounding

    1. Install a fabric cover (AA) over the front of the gun, and slide it back to cover the exposed tubing and 2. Make sure the turbine air hose (M) [the red Graco hoses at the back of the manifold. See Fig. 17.

  • Page 19: Operation

    NOTE: An accessory grounding rod, part no. 210084, is available to discharge any voltage remaining on a 3. Turn off the fluid supply to the gun. system component. Contact your Graco representative 4. Turn off all the air to the spray gun except the to order it.

  • Page 20: Operating Checklist

    ____ 5. The condition of the electrical components of dure. the spray gun has been checked as instructed D Do not use the Graco ES Display Module in Electrical Tests, page 33. readings to determine if your system is discharged. Follow the Fluid Voltage Dis- ____ 6.
  • Page 21 Operation Operating the Spray Gun (continued) 5. Part No. 237603 and 236824 Spray Guns: Pres- surize the fluid supply, and adjust the fluid flow with the fluid pressure regulator installed in the Follow the steps below to establish the correct fluid fluid line.
  • Page 22 CAUTION be reduced. The Graco warranty is void if the spray gun is con- Use the chart below to set the proper pressure at nected to a non-Graco voltage isolation system or if the turbine hose inlet.

  • Page 23: Maintenance

    Maintenance Daily Care and Cleaning CAUTION Fluid in the air passages could cause the gun to WARNING malfunction and could draw current and reduce the electrostatic effect. Fluid in the power supply FIRE AND EXPLOSION HAZARD cavity can reduce the alternator life. Whenever To reduce the risk of fire and explosion: possible, point the gun down while cleaning it.

  • Page 24: Clean The Air Cap And Fluid Nozzle

    Maintenance Clean the Air Cap and Fluid Nozzle 6. Slide the shroud (2) onto the gun (P). Equipment needed: 7. Carefully install the air cap (12). Be sure to insert D Soft bristle brush the electrode (13) wire through the center air cap D Non-flammable cleaning fluid hole and do not bend the wire.

  • Page 25: Check For Fluid Leakage

    Maintenance Check for Fluid Leakage (See Fig. 21) During operation, periodically check the manifold CAUTION exhaust tube (N) and both ends of the gun shroud (Q) for the presence of fluid. Fluid in these areas would If any fluid leakage from the gun is detected, stop indicate fluid leakage into the shroud, which could be spraying immediately.

  • Page 26: Troubleshooting

    Troubleshooting Spray Gun WARNING D Fluid leakage D Dielectric breakdown at the fluid hose connection or ELECTRIC SHOCK HAZARD fluid packings Installing and servicing this equipment D Not enough air pressure for the turbine requires access to parts which may D Faulty power supply cause an electric shock or other serious D Excessive overspray on gun surfaces...
  • Page 27 Troubleshooting Voltage Loss Troubleshooting (continued) 4. Position the end of the hose as far as possible away from any grounded surface. The end of the 7. To eliminate air gaps in the fluid column, spray hose must be at least 1 ft. (305 mm) from any enough fluid to purge the air out between the ground.

  • Page 28: Poor Electrostatic Wrap Troubleshooting

    Troubleshooting Voltage Loss Troubleshooting (continued) Fluid packings Remove the packing assembly from the gun 11. A dielectric breakdown is most likely in one of the as instructed on page 38, and look for signs of following three areas. Repair or replace the com- fluid leakage or any blackened areas, which ponent that is failing.

  • Page 29: Electrical Troubleshooting

    Troubleshooting Electrical Troubleshooting Problem Cause Solution Voltage is still present at the gun Gun electrostatics (turbine air) are Turn off the gun electrostatics. after following the Fluid Voltage not turned off. Discharge and Grounding Pro- cedure Did not wait long enough for the volt- Wait a longer period of time before age to discharge through the voltage touching the electrode with a...

  • Page 30: Gun Operation Troubleshooting

    Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Fluid leakage from the fluid pack- The fluid rod packings or fluid rod are Replace the packings or rod; see ing area worn. page 38. Fluid leakage from the front of the The fluid rod is worn or damaged. Replace the fluid rod;...
  • Page 31 Troubleshooting Gun Operation Troubleshooting (continued) Problem Cause Solution Dirty air cap The air cap and fluid nozzle are mis- Check the air cap and fluid nozzle aligned. seat for fluid buildup. Clean or replace parts as needed; see page 24 Air Cap or 36.

  • Page 32: Spray Pattern Troubleshooting

    Troubleshooting Spray Pattern Troubleshooting NOTE: Some spray pattern problems are caused by the improper balance between air and fluid. Problem Cause Solution The fluid supply is insufficient. Adjust the fluid regulator, or fill the Fluttering or spitting spray fluid supply. The fluid nozzle is loose, or the fluid Tighten or replace the fluid nozzle;...

  • Page 33: Electrical Tests

    Electrical Tests WARNING WARNING ELECTRIC SHOCK HAZARD FIRE, EXPLOSION, AND ELECTRIC Follow the Fluid Voltage Discharge SHOCK HAZARD and Grounding Procedure on page 19 To reduce the risk of sparking, which before checking or servicing the system could cause fire, explosion, or electric and whenever you are instructed to discharge the shock and result in serious injury, do not voltage to ensure the voltage is discharged and...

  • Page 34: Test Power Supply Resistance

    (S) or operate the gun without the contact ring in place. Do not replace the resistor stud (15) with anything but a genuine Graco part. TI0378 Fig. 23 0442 Fig.

  • Page 35: Tools Included With The Gun

    D Lightly lubricate o-rings and seals with petroleum CAUTION jelly. Do not over-lubricate. D Only use genuine Graco parts. Do not mix or use The piston return spring (105) is compressed parts from other PRO Gun models. between the manifold (101) and gun body when they are assembled.

  • Page 36: Air Cap/Nozzle/Resistor Stud Replacement

    (S) or operate the gun without the contact ring in place. Do not replace the resistor stud (15) with 0444A Fig. 27 anything but a genuine Graco part. 308496...

  • Page 37: Electrode Needle Replacement

    Service Air Cap/Nozzle/Resistor Stud CAUTION Replacement (continued) To avoid damaging the plastic threads or contact Installation wire, be very careful when installing the electrode 1. Lightly lubricate the o-ring (16) with petroleum jelly needle. and install it on the resistor stud (15). See Fig. 26. 2.

  • Page 38: Fluid Packing Rod Removal And Repair

    Service Fluid Packing Rod Removal and Repair Preventative Maintenance CAUTION If the conductive fluid is allowed to leak through the packings, it will eventually cause an electrical short through the packings and along the gun barrel, resulting in a loss of voltage at the tip of the gun. Severe arcing can cause barrel damage.

  • Page 39: Piston Repair

    Service Fluid Packing Rod Removal and Repair 11. Lubricate the o-ring (28h) on the outside of the packing housing (28a). (continued) 7. Place the packing nut (28c) and o-ring (28g) on the 12. Make sure the spring (11) is installed against the fluid rod (28b).
  • Page 40 Service Piston Repair (continued) Apply a very light coat of lubricant to the o-rings (23a, 23b, 23c) and u-cup (23f). 4. Push on the piston rod (23g) to push the piston Align the two stems (23d) with the holes in the gun body and press the piston assembly until it bottoms.

  • Page 41: Barrel Removal

    Service Barrel Removal 4. Part No. 238091 Spray Gun: Disconnect the air pilot line from the fluid regulator fitting. 1. Prepare the gun for service as instructed on page 35. 5. Loosen the three screws (24) with the ball end wrench (77–not shown).

  • Page 42: Power Supply Removal And Replacement

    Service Power Supply Removal and Replacement 4. Inspect the power supply for any physical damage. Check the electrical resistance as instructed in NOTES: Test Power Supply Resistance, page 34. If D To avoid a loss in electrostatic performance, inspect necessary, replace the power supply. the gun body power supply cavity for dirt or mois- ture.

  • Page 43: Turbine Alternator Removal And Replacement

    3 to 5 ohms. If the reading varies from NOTE: Replace turbine bearings after 2,000 hours of this value, replace the alternator. operation. See your authorized Graco representative. 6. Measure the resistance between each outer terminal of the 3-wire connector (V) and the alter- 1.

  • Page 44: Barrel Installation

    Service Barrel Installation Install the Gun onto the Manifold 1. Be sure the gaskets (20, 27a) and spring (11) are in place. See Fig. 39. Replace the parts if they are 1. Make sure the gaskets (121, 108) and the spring damaged.
  • Page 45 Service Install the Gun onto the Manifold (continued) 7. To ensure the o-rings (C) on the barbed-fitting are seated in the gun, loosen the nut (D) and push the fluid hose into the gun until the barbed-fitting bottoms out. See Fig. 40. WARNING ELECTRIC SHOCK HAZARD Ç...

  • Page 46: Part No. 238039 Fluid Regulator Repair

    Service Part No. 238039 Fluid Regulator Repair 5. Replace the o-rings, seat, ball bearing, and dia- phragm with the parts included in the Regulator NOTE: The fluid regulator is item 17 in the parts list for Repair Kit, part no. 238148. the part no.

  • Page 47: Part No. 238147 Fluid Regulator Conversion Kit Installation

    Conversion Kit Installation tubing to the length needed. To add a fluid regulator to part no. 237603 and 236824 PRO 5500wb spray guns, follow this procedure: 10. Install the gun onto the manifold as instructed on page 44. 1. Prepare the gun for service as instructed on page 35.

  • Page 48: Graco Waterborne Fluid Hose Repair

    (130 + 2.5) (174 + 2.5) 1. Discharge the voltage as instructed on page 19. * The measurements specified are for use with the Graco O PRO Voltage Block isolation system. 2. Relieve the system pressure as instructed on page...
  • Page 49 Notes 308496...

  • Page 50: Spray Gun Parts

    Spray Gun Parts Part No. 237603 and 236824 Spray Gun See below Item 23 includes 23a–23g Item 25 includes 25a and 25b Item 27 includes 27a–27f Item 28 includes 28a–28h See page 55 to order the parts 04326B REF NO. 28, Packing Rod Assembly Includes items 28a–28h 0601...

  • Page 51: Part No. 237091

    223940 BARREL, gun EQUIPMENT MISUSE HAZARD 237250 POWER SUPPLY ASSY.; 60 kV Use only genuine Graco replacement parts. Using Includes items 27a–27f non-Graco parts could alter the gun’s grounding 186840 GASKET continuity or cause parts to rupture or fail, which...
  • Page 52 Spray Gun Parts Part No. 238091 Spray Gun See below Item 23 includes 23a–23g Item 25 includes 25a and 25b Item 27 includes 27a–27f Item 28 includes 28a–28h See page 55 to order the parts See page 46 to order the parts 05431B REF NO.
  • Page 53 Description Qty. 237250 POWER SUPPLY ASSY.; 60 kV EQUIPMENT MISUSE HAZARD Includes items 27a–27f Use only genuine Graco replacement parts. Using 186840 GASKET non-Graco parts could alter the gun’s grounding 185099 continuity or cause parts to rupture or fail, which...

  • Page 54: Manifold Parts

    Manifold Parts Front View 04323 Apply low strength (purple) Loctiter or an equiv- alent sealant to the threads. REF. 101 Apply high strength (green) Loctiter or an equivalent sealant to the threads. Tighten the fitting until the hex bottoms against the manifold.
  • Page 55 ES Display Part No. 224117 to improve EQUIPMENT MISUSE HAZARD light transmission when two bulkhead splices are used. Use only genuine Graco replacement parts. Using The kit includes items 201203. non-Graco parts could alter the gun’s grounding Ref.

  • Page 56: Accessories

    The three o-rings are included in Fluid Seal Repair Kit 05342 237765. The three o-rings are included in Fluid Seal Repair Kit ** The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system. 237765. Unshielded Hoses for use with the Graco H...
  • Page 57 100 psi (0.7 MPa, 7 bar) Maximum Working Pressure To add a fluid regulator to the part no. 237603 and 236824 PRO 5500wb spray guns. See page 47 for kit For connection between the air supply and the spray installation instructions.

  • Page 58: Technical Data

    Do not exceed 60 kV. Operating the gun above 60 kV will Fluid Specification For use with fluids that void the Graco warranty. The gun’s normal high voltage reading is 45 to 55 kV due to spraying current demands meet at least one of the and isolation system losses.
  • Page 59 Notes 308496...

  • Page 60: Graco Standard Warranty

    Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.

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