Graco PRO 5500sc Instruction Manual
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Graco PRO 5500sc Instruction Manual

Graco PRO 5500sc Instruction Manual

Automatic electrostatic air spray gun
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INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
AUTOMATIC ELECTROSTATIC
Model PRO 5500sc Air Spray Gun
100 psi (7 bar) Maximum Working Pressure
For use with Class , Group D paint spray materials
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 Foreign Patents Pending
Part No. 236–683, Series A
Complete Standard PRO 5500sc Spray Gun: includes
spray gun, shroud, manifold, and mounting bracket
Part No. 236–684, Series A
Complete PRO 5500sc Recirculating Spray Gun: same
as part no. 236–683 spray gun only with part no.
236–851 recirculation kit installed
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
COPYRIGHT 1994 GRACO INC.
308–385
Rev. C
Supersedes A
and PCN B

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  • Page 1 U.K. PATENT NO. 2,147,158; 2,142,559B; 2,140,327–B Other Foreign Patents Pending Part No. 236–683, Series A Complete Standard PRO 5500sc Spray Gun: includes spray gun, shroud, manifold, and mounting bracket Part No. 236–684, Series A Complete PRO 5500sc Recirculating Spray Gun: same as part no.
  • Page 2 Notes...

  • Page 3: Table Of Contents

    ....Introduction Service How the PRO 5500sc Electrostatic Tools Included with the Gun ....

  • Page 4: Warnings

    WARNING 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. Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction manual.
  • Page 5 This equipment is for professional use only. Read all the instruction manuals, tags, and labels before operating the equipment. Use the equipment only for its intended purpose. If you are uncertain about the usage, call Graco Technical Assistance at 1–800–543–0339.

  • Page 6: Introduction

    Setting The gun’s full high voltage setting is 85 kilovolts. The The PRO 5500sc spray gun operates very similar to a gun’s spraying voltage can be reduced by switching to traditional air spray gun. The atomization and fan air the low voltage setting for spraying in areas where too are emitted from the air cap (A).
  • Page 7 Introduction F.O. Manifold Back View Manifold Markings A1 Atomization Air Inlet Fitting Air Cap A2 Fan Air Inlet Fitting Fluid Nozzle CYL Cylinder Air Inlet Fitting Retaining Nut EXH Shroud Exhaust Outlet Fitting Shroud F.O. Fiber Optic Fitting Mounting Bracket KV kV Switch Air Inlet Manifold P1 Fluid Supply Inlet Fitting...

  • Page 8: Installation

    Installation BASIC SYSTEM Non-Hazardous Area Hazardous Area Fig. 1 Non-Hazardous Area Hazardous Area SYSTEM OPTIONS Spraying Voltage Display Module F.O. Air Pilot Fluid Regulator Dump Valve TOP VIEW Fig. 2...

  • Page 9: Installing The System

    Installation KEY–Fig. 1 and 2 Fig. 1, page 8, shows a typical Model PRO 5500sc system. Fig. 2 shows some possible system options. Ground Wire on Graco Electrically Conductive Air Hose Graco Electrically Conductive Air Hose (Turbine Air Hose), See page 11 for part numbers Accessories are available from your Graco representa- Atomizing Air Hose, 3/8 inch (9.5 mm) O.D.

  • Page 10: Install The Air Line Accessories

    Installation Install the Air Line Accessories 2. Position the gun and tighten the two bolts (103) securely. Install a bleed-type master air valve (X) on the main air supply line (W) to shut off all the air to the gun. See 2.775 in.

  • Page 11: Connect The Air And Fluid Lines

    F.O. Fiber Optic Fitting (Optional) hose ground wire to a true earth ground. Connect the Graco Fiber Optic Cable as instructed on page 13. Connect the Graco electrically conductive air hose (B)
  • Page 12 Notes...

  • 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. Fig. 9 5. See manual 308–265 to install a Graco ES Display Module.

  • Page 14: Ground The System

    Installation Ground the System 3. PRO 5500sc Electrostatic Air Spray Gun: ground the gun by connecting the Graco Electrically Con- WARNING ductive Air Hose and connecting the air hose ground wire to a true earth ground. Check the electrical grounding of the gun as instructed on FIRE, EXPLOSION, AND page 15.

  • Page 15: 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 mini- WARNING mum to 1000 volts maximum. Resistance should not exceed 2 megohms.

  • Page 16: 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 23.

  • Page 17: Operation

    307–803 or con- ____ 1. Be sure all the operators are properly trained sult your authorized Graco distributor or Graco Techni- to safely operate an automatic, electrostatic cal Assistance (see back page) to select the appropri- air spray system as instructed in this manual.

  • Page 18: Adjusting The Spray Pattern

    Operation Adjusting the Spray Pattern 4. Use the air pressure regulator on the atomization air supply line (A1) to adjust the degree of atom- Follow the steps below to establish the correct fluid ization. Refer to Fig. 13. For example, for a fluid flow and air flow.

  • Page 19: Activating And Adjusting The Electrostatics

    Operation Activating and Adjusting the Electrostatics Activating the kV Switch Apply a minimum of 50 psi (3.5 bar) air pressure to the WARNING kV switch air fitting (KV) to activate it and switch to the lower voltage setting. Refer to Fig. 13. The lower volt- FIRE AND EXPLOSION HAZARD age setting is factory set to 60 kilovolts at zero micro- The fan (A2) and atomizing (A1) air must...

  • Page 20: Shutdown

    Operation Shutdown 1. Relieve the system pressure. WARNING 2. Flush and clean the equipment. Follow the instruc- tions in the Maintenance section, below. PRESSURIZED EQUIPMENT To reduce the risk of a serious injury, follow the Pressure Relief Procedure on page 17 when you stop spraying and whenever you are instructed to relieve the pres- sure.
  • Page 21 Maintenance Daily Care and Cleaning (continued) Check the electrode wire: straighten it if it is bent and replace it if it is broken or damaged. See Elec- trode Needle Replacement, page 31. WARNING Check for fluid leakage from the gun and fluid hoses.

  • Page 22: Clean The Air Cap And Fluid Nozzle

    Maintenance Clean the Air Cap and Fluid Nozzle 6. Slide the shroud (2) onto the gun (P). Make sure the shroud o-ring (121) is in place. Equipment needed: 7. Carefully install the air cap (12). Avoid bending the Soft bristle brush (supplied) electrode (13) and be sure to insert the electrode Solvent compatible with fluid being sprayed wire through the center air cap hole.

  • Page 23: Check For Fluid Leakage

    Maintenance Check for Fluid Leakage (See Fig. 15) 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...

  • Page 24: Troubleshooting

    Troubleshooting WARNING WARNING ELECTRIC SHOCK HAZARD PRESSURIZED EQUIPMENT Installing and servicing this equipment To reduce the risk of a serious injury, requires access to parts which may follow the Pressure Relief Procedure cause an electric shock or other serious on page 17 before doing any mainte- injury if the work is not performed properly.

  • Page 25: Gun Operation Troubleshooting

    Troubleshooting Gun Operation Troubleshooting PROBLEM CAUSE SOLUTION Fluid leakage from the fluid packing The fluid rod packings or fluid rod are Replace the packings or rod; see page area worn. Fluid leakage from the front of the The fluid rod is worn or damaged. Replace the fluid rod;...

  • Page 26: Electrical Troubleshooting

    ES (kV) display module damaged. replace the parts if they are damaged. The turbine air is not on. Turn on the turbine air. See other causes under Problem – Poor wrap-around, above. Refer also to the Graco ES display mod- ule manual 308–265.

  • Page 27: Electrical Tests

    Electrical Tests Test Gun Resistance (See Fig. 16) The performance of the spray gun is directly affected by the condition of the electrical components contained Measure the resistance between the end of the elec- inside the gun. The electrical tests at right and on page trode (13) and the gun body (29).

  • Page 28: Test Power Supply Resistance

    (S) from the re- sistor stud or operate the gun without the contact ring in place. If the resistor stud (15) is being replaced, only use a 0442 Fig. 18 genuine Graco part.

  • Page 29: Service

    Service Tools Included with the Gun 1. Flush the gun with a compatible solvent. Nozzle Wrench 2. Relieve the system pressure. Electrode Wrench Ball End Wrench NOTE: The service area must be clean. Remove the 8 mm Allen Wrench gun from the worksite as instructed in the following 9 mm Hex Nut Driver steps.
  • Page 30 (S) from the re- sistor stud or operate the gun without the contact ring in place. If the resistor stud (15) is being replaced, only use a genuine Graco part. 0444 Fig. 21 5. Lightly lubricate the o-ring (16) with petroleum jelly and install it on the resistor stud (15).

  • Page 31: Air Cap/Nozzle/Resistor Stud Replacement

    Service Air Cap/Nozzle/Resistor Stud CAUTION Replacement (continued) To avoid damaging the plastic threads or contact 6. Make sure the electrode needle (13) is tightened wire, be very careful when installing the electrode properly. Refer to Fig. 22. needle. 7. Install the resistor stud (15) in the fluid nozzle (14). Tighten to 10 in-lb (1.12 N m).

  • Page 32: Fluid Packing Rod Removal And Repair

    Service Fluid Packing Rod Removal and Repair CAUTION NOTE: The fluid packing rod can be replaced as indi- Clean all the parts in non-conductive solvent com- vidual parts or as an assembly. If the assembly is pur- patible with the fluid being used, such as xylol or chased, it is pre-adjusted at the factory.

  • Page 33: Piston Repair

    Service Fluid Packing Rod Removal and Repair 12. Lubricate the o-ring (28h) on the outside of the packing housing (28a). (continued) 13. Install the fluid packing rod assembly (28) into the 8. Place the packing nut (28c) and o-ring (28g) on the gun barrel.
  • Page 34 Service Piston Repair (continued) 8. Installing the Actuator Arm and Nuts: a. Install the adjustment nut (36), actuator arm 4. Push on the piston rod (23g) to push the piston (19), and jam nut (46) onto the piston rod assembly out the back of the gun. (23g).

  • Page 35: Barrel Removal

    Service Barrel Removal 1. Prepare the gun for service as instructed on page 29. 2. Remove the air cap assembly and the shroud from the gun. 3. Carefully loosen the fluid fitting nut (43). See Fig. 30. Pull the tube (33) out of the fitting. Make sure that both ferrules and the nut stay with the tube.

  • Page 36: Power Supply Removal And Replacement

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

  • Page 37: Turbine Alternator Removal And Replacement

    3-wire connector (V). Resistance NOTE: Replace the turbine bearings after 2000 hours should be 3 to 5 ohms. If the reading varies from of operation. See your authorized Graco represen- this value, replace the alternator. tative. 5. Connect the 3-wire connector to the 3 prongs in 1.

  • Page 38: Barrel Installation

    Service Barrel Installation CAUTION To avoid damaging the gun, do not over-tighten the 1. Be sure the gaskets (20, 27a) and spring (11) are screws (24). Tighten them to 18 in-lbs (2 N m) in place. See Fig. 32. Replace the parts if they are maximum (about a half turn past snug), using the damaged.

  • Page 39: Install The Gun Onto The Manifold

    Service Install the Gun onto the Manifold 1. Make sure the gaskets (108, 121) and spring (105) are in place on the manifold (101). See Fig. 33. Inspect the parts for damage and replace them as needed. 2. Secure the gun (B) to the manifold (101) by tight- ening the three screws (106) with the ball end wrench (77–...

  • Page 40: Standard Spray Gun Parts

    Standard Spray Gun Parts Part No. 236–683 Standard PRO 5500sc Spray Gun 28a, 28c–28h See below Item 23 includes 23a–23g Item 25 includes 25a & 25b Item 27 includes 27a–27e Item 28 includes 28a–28h Item 31 includes 31a–31c REF 33...
  • Page 41 Qty. EQUIPMENT MISUSE HAZARD 224–093 POWER SUPPLY ASSY; 85 kV Includes items 27a–27e Use only genuine Graco replacement parts. Using 186–840 GASKET, power supply non-Graco parts could alter the gun’s grounding 185–099 continuity or cause parts to rupture or fail, which 185–145...

  • Page 42: Recirculating Spray Gun Parts

    Recirculating Spray Gun Parts 28a, 28c–28h Part No. 236–684 See below Recirculating PRO 5500sc Spray Gun Item 23 includes 23a–23g Item 25 includes 25a & 25b Item 27 includes 27a–27e Item 28 includes 28a–28h Item 31 includes 31a–31c REF 33...
  • Page 43 Qty. EQUIPMENT MISUSE HAZARD 224–093 POWER SUPPLY ASSY; 85 kV Includes items 27a–27e Use only genuine Graco replacement parts. Using 186–840 GASKET, power supply non-Graco parts could alter the gun’s grounding 185–099 continuity or cause parts to rupture or fail, which 185–145...

  • Page 44: Manifold Parts

    Manifold Parts Front View 03462 Back View Apply low strength (purple) Loctite or an equivalent sealant to the threads. Press fit the spring (105) Tighten the fitting until the hex bottoms Ref. 101 against the manifold. This fitting (113) has left-hand threads. Install the kV cap (111) flush to the outside surface.
  • Page 45 PLUG; 5/8–18 x 5/8” 189–551 FITTING, fluid, quick-disconnect PRO 5500sc Recirculation Kit 118* 111–450 O-RING; CV–75 To convert the standard PRO 5500sc spray gun to a 190–301 GASKET, foam recirculating spray gun. The kit includes the following 112–641 SPRING parts: 111–316...

  • Page 46: Technical Data

    Technical Data Weight (gun & manifold) ... . 3.57 lb (1620 g) Maximum Noise Level with fan and atomization air at 100 psi (7 bar): Maximum Working Pressure ..100 psi (7 bar) Sound Pressure .
  • Page 47 Notes...

  • Page 48: Warranty

    Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months or two thousand hours of operation from time of sale, repair or replace any part of the equip- ment proven defective.

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