Graco PRO AA5500SC Instruction Manual
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Graco PRO AA5500SC Instruction Manual

Graco PRO AA5500SC Instruction Manual

Air-assisted airless spray gun
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INSTRUCTIONS-PARTS LIST
Parts
INSTRUCTIONS
AUTOMATIC ELECTROSTATIC
Model PRO AA5500sct
Air-Assisted Airless Spray Gun
100 psi (7 bar, 0.7 MPa) Maximum Working Air Pressure
3000 psi (207 bar, 20.7 MPa) Maximum Working Fluid Pressure
For use with Class I, Group D paint spray materials
Part No. 236688, Series B
Complete Spray Gun: includes spray gun, shroud,
manifold, and mounting bracket
U.S. PATENT NO. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774;
5,063,350; 5,080,289; 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 Foreign Patents Pending
NOTE: 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
ECOPYRIGHT 1994, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
308387
Rev. J
03228

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  • Page 1 03228 NOTE: Any modification of genuine Graco parts or replacement of parts with non-Graco parts will void agency approvals. GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 ECOPYRIGHT 1994, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...
  • Page 2 WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire, explosion, or electric shock. D Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction manual.
  • Page 3 D This equipment is for professional use only. D Read all the instruction manuals, tags, and labels before operating the equipment. D Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco distributor.

  • Page 4: Table Of Contents

    Housing Replacement ......How the PRO AA5500sc Electrostatic Air-Assisted Electrode Replacement ......

  • Page 5: Introduction

    D An optional fiber optic readout system can be the gun manifold’s turbine air fitting (which is marked “TA”, see page 6) through a Graco electrically con- installed to monitor the gun’s spraying voltage. A ductive air hose. The air enters the manifold and is fiber optic cable (KK) connected to the gun man- directed to the inlet of the power supply turbine (H).
  • Page 6 Introduction F.O. Manifold Back View 03228 03616 04799 Manifold Markings A1 not used Air Cap (orange color) A2 Atomization Air Inlet Fitting Spray Tip (orange color) CYL Cylinder Air Inlet Fitting Tip Guard (orange color) EXH Shroud Exhaust Outlet Fitting Retaining Nut F.O.

  • Page 7: Warnings

    Fig. 1, page 8, shows a typical Model PRO AA5500sc system. Fig. 2 shows some possible system options. Electrically interlock the gun turbine air supply line with the ventilators to prevent operation of the electrostatic Accessories are available from your Graco representa- power supply unless ventilating fans are on.
  • Page 8 Installation BASIC SYSTEM Non-Hazardous Area Hazardous Area FLUID IN-P1 To FLUID IN-P1 at gun Fig. 1 SYSTEM OPTIONS S Spraying Voltage Non-Hazardous Area Hazardous Area Display Module JJ*  F.O. 04802 Fig. 2 308387...

  • Page 9: Install The Air Line Accessories

    Atomizing Air Hose, 3/8 inch (9.5 mm) O.D. Air Line Filter Cylinder Air Hose, 1/4 inch (6.4 mm) O.D. C* Pump Air Regulator AA*Ground Wire on Graco Electrically Conductive Air Hose Air Line Lubricator BB*Graco Electrically Conductive Air Hose (Turbine Air Hose), Pump Runaway Valve...

  • Page 10: Fluid Line Accessories

    (70.5 mm) 1. Install a fluid filter (N) and drain valve (M) at the pump outlet. See Fig. 1, page 8. Filtering the fluid PRO AA5500sc Gun will help remove coarse particles and sediment that could clog the spray tip.

  • Page 11: Connect The Air And Fluid Lines To The Gun Manifold

    Air Supply Hose. F.O. Fiber Optic Fitting (Optional) Connect the Graco Fiber Optic Cable as instructed on Connect the Graco electrically conductive air hose page 12. (BB) to the gun turbine air inlet and connect the hose kV Switch Air Inlet Fitting ground wire (AA) to a true earth ground.

  • Page 12: Optional Fiber Optic Cable Connection

    A maximum of two splices, with a total of 108 feet (32.94 m) of cable, is recommended. 04485 Fig. 9 5. See manual 308265 to install a Graco ES Display Module. 308387...

  • Page 13: Ground The System

    Installation Ground the System 3. Electrostatic Air Spray Gun: ground the gun by connecting the Graco Electrically Conductive Air Hose to the turbine air inlet and connecting the air WARNING hose ground wire to a true earth ground. Check the electrical grounding of the gun as instructed on FIRE, EXPLOSION, AND page 14.

  • Page 14: Check The Electrical Grounding

    Installation Check the Electrical Grounding (See Fig. 10) a. If using a black or grey turbine air hose, use a megohmmeter (WW) to measure the resistance. Use an applied voltage of 500 WARNING minimum to 1000 volts maximum. Resistance should not exceed 2 megohms. FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD b.

  • Page 15: Install The Fabric Cover

    Installation Install the Fabric Cover 2. Route the exhaust tube (YY) outside the cover. This enables you to monitor the exhaust tube for 1. Install a fabric cover (XX) over the front of the gun the presence of any paint or solvent. See Check and slide it back to cover the exposed tubing and for Fluid Leakage on page 24.

  • Page 16: Operation

    Additional cards are shock, follow the Pressure Relief Procedure available at no charge from Graco. whenever you: D are instructed to relieve the pressure, Check the following list daily, before starting to operate D stop spraying, the system, to help ensure safe, efficient operation.

  • Page 17: Selecting A Spray Tip

    Use the Spray Tip Selection Chart on page 49, as a guide for selecting an appropriate spray tip for your application or consult your authorized Graco WARNING distributor.

  • Page 18: Setting The Atomization Fluid Pressure

    Operation Setting the Atomization Fluid Pressure 3. With the turbine air (TA) off and the atomization air (A2) off, spray a test pattern across a piece of NOTE: Atomization fluid pressure will vary based on paper, holding the gun 12 inches (305 mm) from the viscosity of the fluid, the flow rate desired, and the surface.

  • Page 19: Activating And Adjusting The Electrostatics

    Operation Activating and Adjusting the Electrostatics 1. Make sure the atomizing air (A2) is on, then turn on the turbine air (TA). Refer to Fig. 16. 2. The turbine air pressure should be adjusted to 30 psi (2.1 bar, 0.21 MPa) at the gun manifold inlet when air is flowing.

  • Page 20: Triggering The Fluid Alone

    Operation Triggering the Fluid Alone Shutdown 1. Shut off and relieve the air pressure to the atom- WARNING ization air (A2) line, using the bleed-type air shut- off valve. INJECTION HAZARD To reduce the risk of a serious injury, 2. Apply 50 psi (3.5 bar, 0.35 MPa) air pressure to including fluid injection, follow the Pres- the cylinder air fitting (CYL) to trigger the fluid.

  • Page 21: Flush The Spray Gun

    Maintenance Daily Care and Cleaning (continued) Flush the Spray Gun WARNING WARNING INJECTION HAZARD INJECTION HAZARD To reduce the risk of a serious injury, To reduce the risk of a serious injury, including fluid injection, follow the Pres- including fluid injection, follow the Pres- sure Relief Procedure on page 16 sure Relief Procedure on page 16 when you stop spraying and whenever you are...

  • Page 22: Clean The Spray Gun

    Maintenance Clean the Spray Gun 3. Dampen a soft cloth with solvent and wring out the excess fluid. Wipe the exterior of the gun and Equipment needed: shroud clean. See Fig. 19. D Soft bristle brush D Solvent compatible with fluid being sprayed WARNING INJECTION HAZARD To reduce the risk of a serious injury,...
  • Page 23 Maintenance Clean the Spray Gun WARNING (continued) FIRE, EXPLOSION, AND 6. Clean the retaining nut, tip guard, air cap and fluid ELECTRIC SHOCK HAZARD tip with a soft brush daily, minimum. See Fig. 21. To reduce the risk of fire, explosion, and Replace the parts if they are damaged.

  • Page 24: Check For Fluid Leakage

    Maintenance Check for Fluid Leakage (See Fig. 24) During operation, periodically check the manifold WARNING exhaust tube (YY) and both ends of the gun shroud (ZZ) for the presence of fluid. Fluid in these areas FIRE AND EXPLOSION HAZARD would indicate fluid leakage into the shroud, which If any fluid leakage from the gun is de- could be caused by leaks at the fluid tube connections tected, stop spraying immediately!

  • Page 25: Troubleshooting

    Troubleshooting WARNING WARNING ELECTRIC SHOCK HAZARD INJECTION HAZARD Installing and servicing this equipment To reduce the risk of a serious injury, requires access to parts which may including fluid injection, follow the Pres- cause an electric shock or other serious sure Relief Procedure on page 16 injury if the work is not performed prop- before doing any maintenance or service on the...

  • Page 26: Gun Operation Troubleshooting

    Troubleshooting Gun Operation Troubleshooting PROBLEM CAUSE SOLUTION Leakage from fluid needle area Fluid needle packings loose Tighten packing nut; See page 37 Fluid needle packing damaged Replace fluid needle; See page 37 Air leakage from front of gun Piston air valve not seating properly Clean, Service;...

  • Page 27: Electrical Troubleshooting

    Troubleshooting Electrical Troubleshooting PROBLEM CAUSE SOLUTION Reduced fluid efficiency Improper distance between gun and Adjust spraying distance to 8 to 12 inches work-piece (203 to 305 mm) Parts poorly grounded Clean hangers; Check for proper ground on conveyer or track High booth exhaust velocity Reduce exhaust velocity within code limits Atomizing air pressure too high...

  • Page 28: Electrical Tests

    Electrical Tests The performance and safety of the spray gun are refer to Electrical Troubleshooting on page 27 for directly affected by the condition of the electrical other possible causes of poor performance, or contact components contained inside the gun. The electrical the nearest authorized service agency.

  • Page 29: Test Barrel Resistance

    (E) and the barrel contact ring (26a) are clean. replace the contact ring with anything but a genuine Graco part. If the resistance is still outside the specified range: 1. Remove the barrel contact ring (26a) with a small pick.

  • Page 30: Service

    D If the plastic parts of the gun must be held in a vise, use padded vise jaws to avoid damaging parts. CAUTION D Only use genuine Graco parts. Do not mix or install Methylene chloride is not recommended as a flush- parts from other PRO gun models. Note that the air...
  • Page 31 Service Prepare the Gun for Service (continued) CAUTION The piston return spring (105) is compressed 4. Remove the retaining nut and air cap assembly (1, between the manifold (101) and gun body when they 12, 13, 15) and the gun shroud (2). See Fig. 28. are assembled.

  • Page 32: Tip Guard, Air Cap, Spray Tip, Or Seat Housing Replacement

    1/4 turn more; do not over-tighten it. in place. Do not replace the contact ring with anything but a genuine Graco part. 4. Install the seat housing (14) with the 9 mm driver (84). Tighten the seat housing until it’s snug and then tighten it 1/4 turn more;...

  • Page 33: Electrode Replacement

    Service Tip Guard, Air Cap, Spray Tip, or Seat Electrode Replacement Housing Replacement (continued) WARNING 6. Place the spray tip (13) in the air cap (15). Align the tab of the tip with the groove in the air cap. FIRE, EXPLOSION, AND See Fig.

  • Page 34: Fluid Tube Removal And Replacement

    Service Fluid Tube Removal and Replacement Fluid Filter Replacement 1. Prepare the gun for service as instructed on To remove the fluid tube assembly (18) for cleaning or page 30. replacement: 2. Disconnect the bottom fluid tube nut (C). See Fig.

  • Page 35: Piston Repair

    Service Piston Repair There should be a 0.125 in. (3 mm) gap between the actuator arm (19) and the fluid packing rod nut (U). 1. Prepare the gun for service as instructed on page 30. 2. Remove the jam nut (8), actuator arm (19), and adjustment nut (17).

  • Page 36: Barrel Removal

    Service Barrel Removal 5. Hold the gun body (29) with one hand and pull the barrel (26) straight away from the body to remove 1. Prepare the gun for service as instructed on it. See Fig. 41. page 30. 2. Disconnect the bottom fluid tube nut (C). See CAUTION Fig.

  • Page 37: Fluid Packing Adjustment

    Service Fluid Packing Adjustment 4. Place the 2 mm driver (79) in the back of the fluid needle assembly (28). See Fig. 42. Push the tool If fluid leaks from the fluid needle area, the fluid pack- in and turn it counterclockwise about 12 full turns ings may be loose.

  • Page 38: Power Supply Removal And Replacement

    Service Power Supply Removal and Replacement 5. Before installing the power supply, inspect the seal (D) for any damage or swelling. Make sure the NOTES: gaskets and pads (27a–27f) are in place. D To avoid a loss in electrostatic performance, inspect the gun body power supply cavity for dirt or mois- 6.

  • Page 39: Turbine Alternator Removal And Replacement

    (V) disengages. See Fig. 44. NOTE: Replace the turbine bearings after 2000 hours 4. Use an ohmmeter to test the turbine alternator coil. of operation. See your authorized Graco represen- Measure the resistance between the two outer tative. terminals of the 3-wire connector (V). Resistance should be 3 to 5 ohms.

  • Page 40: Barrel Installation

    Service Barrel Installation 4. Make sure the fluid filter (4) is in place, then tighten the bottom fluid tube nut (C) onto the fluid 1. Be sure the gaskets (11, 27a) and spring (20) are fitting (3); make sure the top fluid tube nut (D) in place.

  • Page 41: Install The Gun Onto The Manifold And Mounting Bracket

    Service Install the Gun onto the Manifold and 4. Connect the fluid hose to the fluid inlet fitting (3–marked P1 on the manifold). Use an open end Mounting Bracket wrench to hold the fluid fitting hex and prevent it from turning. 1.

  • Page 42: Spray Gun Parts

    Spray Gun Parts Item 23 includes 23a–23g Item 25 includes 25a & 25b Item 27 includes 27a–27f REF 18 See page 45 to order parts 03244B 308387...
  • Page 43 Spray Gun Parts Ref. WARNING Part No. Description Qty. 236826 PISTON ASSY; EQUIPMENT MISUSE HAZARD Includes items 23a–23g Use only genuine Graco replacement 23a{ 111508 O-RING; fluoroelastomer 23b{ 111504 O-RING; fluoroelastomer parts. Some PRO AA5500 gun parts 23c{ 112319 O-RING; fluoroelastomer...

  • Page 44: Manifold Parts

    Manifold Parts Front View 03462 Apply low strength (purple) Loctiter or an equivalent sealant to the threads. Press fit the spring (105) Ref. 101 Tighten the fitting until the hex bottoms against & 102 the manifold. This fitting (113) has left-hand threads. Install the kV cap (111) flush to the outside surface.
  • Page 45 The kit is not included with the gun. The kit is only for use with the ES Display Part No. 224117 to improve EQUIPMENT MISUSE HAZARD light transmission when two bulkhead splices are used. Use only genuine Graco replacement The kit includes items 201–203. parts. Some PRO AA5500 gun parts Ref.

  • Page 46: Accessories

    Accessories Use Only Genuine Graco Parts and Accessories AIR LINE ACCESSORIES Bleed-type Master Air Valve 107141 300 psi (21 bar, 2.1 MPa) Maximum Working Pressure Conductive Air Supply Hose; black 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure Relieves air trapped in the air line between the paint pump air motor FM Approved;...
  • Page 47 Accessories Use Only Genuine Graco Parts and Accessories GUN CONTROL AND MONITORING CABLE ACCESSORIES ACCESSORIES Fiber Optic Cable Assembly For more information about gun controls and monitoring For connection between gun manifold and display accessories contact your Graco representative. module or between bulkhead connector and display KV Display Module 189762 module.
  • Page 48 Accessories Use Only Genuine Graco Parts and Accessories MISCELLANEOUS ACCESSORIES Gun High Voltage Probe and Meter 236003 For direct measurement of gun output voltage Electrode Replacement Kit 236001 Includes five electrodes Grounding Clamp and Wire 222011 Paint Resistance Meter 722886 12 ga, 25 ft (7.6 m) wire...

  • Page 49: Spray Tip Selection Chart

    Spray Tip Selection Chart Fan Width at Fan Width at Part No. Part No. 10 in. (260 mm) Orifice Size 10 in. (260 mm) Orifice Size in. (mm) in. (mm) in. (mm) in. (mm) GG3107 2–4 (50–100) 0.007 (0.178) GG3319 6–8 (150–200) 0.019 (0.483) GG3207...

  • Page 50: Technical Data

    Technical Data Category Data Category Data Weight (gun and 3.57 lb (1620 g) Maximum Fluid 120_F (49_C) manifold) Temperature Maximum Air 100 psi (7 bar, 0.7 MPa) Turbine Air Inlet 1/4 npsm(m), left-hand Working Pressure Fluid Inlet 1/4 npsm(m) Maximum Fluid 3000 psi (207 bar, Wetted Parts Stainless Steel, Nylon, PEEK,...
  • Page 51 Notes 308387...

  • Page 52: The Graco Warranty And Disclaimers

    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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