Graco PRO Auto Xs Series Instructions-Parts List Manual
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Graco PRO Auto Xs Series Instructions-Parts List Manual

Graco PRO Auto Xs Series Instructions-Parts List Manual

Automatic electrostatic air spray gun
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Instructions/Parts List
AUTOMATIC ELECTROSTATIC AIR SPRAY GUN
™
PRO
Auto Xs
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 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 0.24 mJ
For Professional Use ONLY.
U.S. Patent 7,226,004
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents and page 3 for
List of Models.
309297K
ENG
TI1557A

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  • Page 1 Instructions/Parts List AUTOMATIC ELECTROSTATIC AIR SPRAY GUN 309297K ™ Auto Xs 100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure 100 psi (0.7 MPa, 7 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.

  • Page 2: Table Of Contents

    245324 HC Conversion Kit ....16 Graco Information ......56 Operation .

  • Page 3: List Of Models

    List of Models List of Models Type of Coatings Part No. Model Voltage Standard High Conductivity 244589 PRO Auto Xs 40-85 kV 244590 PRO Auto Xs 40-85 kV 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.

  • Page 4: Warning

    • Ground equipment, personnel, object being sprayed, and conductive objects in work area. See Grounding instructions. • Only use grounded Graco conductive air supply hoses. • Check gun and hose resistance and electrical grounding daily. • Use and clean equipment only in well ventilated area.
  • Page 5 • 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.

  • Page 6: Introduction

    To operate the electrostatics, apply air pressure to the switches. Supply 50 psi (0.35 MPa, 3.5 bar) air pressure gun manifold’s turbine air fitting (TA) through a Graco to the KV1 and KV2 ports. Turn the air on or off as grounded air hose.
  • Page 7 Introduction TI1557A TI1577A Manifold Back View TI1561A Fig. 1: Gun Overview Manifold Markings Air Cap Atomization Air Inlet Fitting Fluid Nozzle Fan Air Inlet Fitting Retaining Ring Cylinder Air Inlet Fitting Shroud Shroud Exhaust Outlet Fitting Mounting Bracket Fiber Optic Fitting (shipped unassembled) Manifold kV Switch 1 Air Inlet Turbine...

  • Page 8: Installation

    IGURE 24 Volt Power Supply an actual system design. For assistance in designing a 4-20 microampere Outputs system to suit your particular needs, contact your Graco distributor. Full Feature ES Display Module kV Only ES Display Module (battery operated) Warning Signs...
  • Page 9 Installation NOTE: * The turbine air supply (TA) must be electrically interlocked with the spray booth ventilation fans to prevent See * the power supply from operating without ventilating fans on. above Non-Hazardous Area Hazardous Area TI1712A Manifold Back View Fig.

  • Page 10: Install The Air Line Accessories

    Installation Install the Air Line WARNING Accessories Pressurized Equipment Hazard 1. Install a bleed-type air valve (L) on the main air line (W) to shut off all air to the gun (H). The fluid drain valve is required in your sys- tem to assist in relieving fluid pressure in 2.

  • Page 11: Connect The Air And Fluid Lines

    Connect a 1/4 in. (6 mm) OD x 4 ft (1.22 m) long tube to Lines this fitting. Fiber Optic Fitting (Optional) Connect the Graco Fiber Optic cable (see page 11). 3 shows a schematic of air and fluid line connec- IGURE kV Switch 1 Air Inlet Fitting tions, and F 5 shows the manifold connections.

  • Page 12: Optional Fiber Optic Cable Connection

    A maximum of two splices, with a total of 108 ft (33 m) of cable, is rec- ommended. 4. See manual 308265 to install a Graco ES Display Module. TI1580A Fig. 6: Fiber Optic Fitting...

  • Page 13: Grounding

    Electrostatic Air Spray Gun: ground the gun by con- cans, must be properly grounded. necting the Graco Grounded Air Hose to the turbine air inlet and connecting the air hose ground wire to a true earth ground. See Check Electrical Ground- ing, page 14.

  • Page 14: Check Electrical Grounding

    Installation Check Electrical Grounding 4. Measure the resistance between the turbine air inlet 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 WARNING an applied voltage of 500 minimum to 1000 volts maximum.

  • Page 15: Check Fluid Resistivity

    3. Record the fluid type, elapsed time, and size of the viscosity cup. Graco Part No. 722886 Resistance Meter and 722860 Probe are available as accessories to check that the 4. If the viscosity is too high or too low, contact the resistivity of the fluid being sprayed meets the require- material supplier.

  • Page 16: 245324 Hc Conversion Kit

    7. Make sure the barrel threads are clean and dry. PRO Auto Xs standard coating guns (Part No. 244589) Apply Graco Part No. 116553 dielectric grease to to high conductivity guns (244590). the fluid fitting (19d) threads and o-rings. Thread the fitting into the barrel inlet.

  • Page 17: Operation

    Operation Operation Pressure Relief Procedure 2. Turn off the fluid supply to the gun. 3. Trigger the gun into a grounded metal waste con- tainer to relieve the fluid pressure. WARNING 4. If an air pilot fluid regulator is used, turn off the air pressure at the regulator air inlet.

  • Page 18: Operating Checklist

    24A438 Air Cap. If you require a different size, refer to easily seen and read by all operators. Table 2 and Table 3 , and instruction manual 309419, or consult with your Graco distributor. See Air Cap/Nozzle The system is thoroughly grounded and the Replacement on page 34.

  • Page 19: Adjust The Spray Pattern

    Operation Adjust the Spray Pattern 4. Use the air pressure regulator on the atomization air supply line (A1) to adjust the degree of atomization. See F 12. For example, for a fluid flow rate of IGURE Follow the steps below to establish the correct fluid flow 10 ounces per minute (0.3 liters per minute), a typi- and air flow.

  • Page 20: Adjust The Electrostatics

    Operation Adjust the Electrostatics Table 4: Dynamic Turbine Air Pressures 1. Shut off the fluid supply. Turbine Air Air pressure at turbine air hose Hose Length inlet for full voltage 2. Trigger the gun, then turn on the turbine air (TA). ft (m) psi (bar, MPa) See F...

  • Page 21: Spraying

    Operation Spraying Triggering the Fluid Alone 1. Shut off and relieve the air pressure to the atomiza- tion (A1) and fan (A2) air lines, using the bleed-type WARNING air shutoff valves. Electric Shock Hazard 2. Apply 50 psi (3.5 bar, 0.35 MPa) air pressure to the cylinder air fitting (CYL) to trigger the fluid.

  • Page 22: Maintenance

    Maintenance Maintenance Daily Care and Cleaning CAUTION • Clean all parts with a non-conductive, compatible Do not immerse the gun in fluid. solvent. Conductive solvents can cause the gun to malfunction. • Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components.
  • Page 23 Maintenance Daily Care and Cleaning, • Check the electrode and replace if broken or dam- aged. See Electrode Replacement on page 35. continued • Check for fluid leakage from the gun and fluid hoses. See Check for Fluid Leakage on page 25. Tighten fittings or replace equipment as needed.

  • Page 24: Clean The Air Cap And Fluid Nozzle

    Maintenance Clean the Air Cap and Fluid Nozzle CAUTION Equipment Needed Do not use metal tools to clean the • soft bristle brush air cap or fluid nozzle holes as this could scratch them, and make sure • compatible solvent the electrode is not damaged.

  • Page 25: Check For Fluid Leakage

    Maintenance Check for Fluid Leakage WARNING WARNING Pressurized Equipment Hazard To reduce the risk of an injury, follow the Fire and Explosion Hazard Pressure Relief Procedure on page 17 when you stop spraying and whenever you If any fluid leakage from the gun is are instructed to relieve the pressure.

  • Page 26: Electrical Tests

    Electrical Tests Electrical Tests Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (12) and electrode (7), and electrical continuity between components. Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V.

  • Page 27: Test Power Supply Resistance

    5. If you still have problems, refer to Electrical Trou- bleshooting on page 31 for other possible causes Fig. 16. Test Power Supply Resistance of poor performance, or contact your Graco distribu- tor. 309297K...

  • Page 28: Test Electrode Resistance

    IGURE 3. If in range, refer to Electrical Troubleshooting on page 31 for other possible causes of poor perfor- mance, or contact your Graco distributor. ti1548a 4. Remove the electrode (7), page 35. Measure the resistance between the contact (E) and the elec- trode wire (F).

  • Page 29: Troubleshooting

    Troubleshooting Troubleshooting WARNING WARNING Electric Shock Hazard Pressurized Equipment Hazard Installing and servicing this equipment To reduce the risk of an injury, follow the requires access to parts which may cause Pressure Relief Procedure on page 17 an electric shock or other serious injury if whenever you are instructed to relieve the the work is not performed properly.

  • Page 30: Gun Operation Troubleshooting

    Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Excessive spray fog. Atomizing air pressure too high. Decrease air pressure as low as pos- sible. Fluid too thin. Increase viscosity. “Orange Peel” finish. Atomizing air pressure too low. Increase air pressure; use lowest air pressure necessary.

  • Page 31: Electrical Troubleshooting

    Troubleshooting Electrical Troubleshooting Problem Cause Solution Poor wrap. Turbine air is not turned on. Turn on. Booth exhaust velocity is too high. Reduce velocity to within code limits. Atomizing air pressure too high. Decrease. Fluid pressure too high. Decrease. Incorrect distance from gun to part. Should be 8-12 in.

  • Page 32: Repair

    • Only use genuine Graco parts. Do not mix or use parts from other PRO Gun models. WARNING 1. Flush and clean the gun, page 22. Pressurized Equipment Hazard 2.

  • Page 33: Remove The Gun From The Manifold

    Repair Remove the Gun from the Install the Gun on the Manifold Manifold 1. Loosen the bottom gun screw (31) until the gun sits 1. Make sure the gasket (112) and spring (105) are in loosely in the mounting bracket slot (A). See F place on the manifold.

  • Page 34: Air Cap/Nozzle Replacement

    Do not replace the contact ring with anything but a 1. Prepare gun for service, page 32. genuine Graco part. 2. Remove the retaining ring (1) and air cap (3). See IGURE Use non-silicone grease, Part No. 111265, on the small o-ring (4b).

  • Page 35: Electrode Replacement

    Repair Electrode Replacement 1. Prepare the gun for service, page 32. 2. Remove the air cap and nozzle, page 34. Remove the gun shroud (2). 3. Unscrew the electrode (7) with the multi-tool (40). Hold the packing rod end (8h) to prevent it from turn- ing, F IGURE CAUTION...

  • Page 36: Fluid Packing Removal

    Repair Fluid Packing Removal Before installing the packing rod, clean the internal sur- face of the barrel (9) with a soft cloth or brush. Check for marks from high voltage arcing. If marks are present, You may replace the packing rod as an assembly, as replace the barrel.

  • Page 37: Packing Rod Repair

    Repair Packing Rod Repair 4. Lightly tighten the packing nut (8e). The packing nut is properly tightened when there is 3 lb (13.3 N) of drag force when sliding the packing housing (8f) You may replace the packing rod as individual parts, as assembly along the rod.

  • Page 38: Piston Repair

    Repair Piston Repair Table 5: Piston O-Rings 1. Prepare the gun for service, page 32. Description Function 2. Remove the air cap, page 34. Remove the gun Shaft O-Ring Seals cylinder air along the piston rod shroud (2). (34g) (34b). Replace if air leaks along rod. Front O-Ring Air shutoff seal.

  • Page 39: Adjust The Actuator Arm

    Repair Adjust the Actuator Arm 5. Install the gun shroud (2) and air cap (3), page 34. 6. Install the gun onto the manifold and bracket. See The fluid nozzle (4) must be in place when removing or page 33. installing the jam nut and actuator arm.

  • Page 40: Barrel Removal

    Repair Barrel Removal 6. Hold the gun body (32) with one hand and pull the barrel (9) straight off the body. See F IGURE 1. Prepare the gun for service, page 32. 2. Remove the air cap, page 34. Remove the gun shroud (2).

  • Page 41: Barrel Installation

    Repair Barrel Installation 4. Assemble the fluid tube (19) into the fluid fitting (23). Ensure that the ferrules (21, 22) are in place. Tighten the nut (20). 1. Be sure the gasket (11) and grounding spring (51) are in place. Make sure the air holes are aligned 5.

  • Page 42: Power Supply Removal And Replacement

    Repair Power Supply Removal and 4. Disconnect the 3-wire connector (GG) from the power supply. Slide the alternator up and off the Replacement power supply. Inspect the power supply and alterna- tor for damage. Disconnect the 6-pin flexible circuit (39) from the power supply. 5.

  • Page 43: Turbine Alternator Removal And Replacement

    Repair TI1568A Fig. 31. Power Supply Turbine Alternator Removal 4. Measure resistance between the two outer termi- nals of the 3-wire connector (GG); it should be and Replacement 2.5-3.5 ohms. If outside this range, replace the alter- nator coil. Replace turbine alternator bearings after 2000 hours of 5.
  • Page 44 Repair Notes 309297K...

  • Page 45: Parts

    Parts Parts Part No. 244589 PRO Auto Xs Electrostatic Gun, Series B, for standard coatings Ref. No. 13: Alternator Detail TI1481a TI1558A ti1601a Ref. No. 8: Packing Rod Detail 19 (Ref) 309297K...
  • Page 46 Parts Part No. 244589 PRO Auto Xs Electrostatic Gun, Series B, for standard coatings Ref. Part No. Description Ref. Part No. Description 244555 TURBINE, alternator; includes 13a-13e 244950 RING, retaining, air cap; includes 13a*† 110073 . O-RING; fluoroelastomer 223688 . BEARING KIT; includes front 1a*†...
  • Page 47 Parts Ref. Ref. Part No. Description Part No. Description 116575 SCREW, cap, socket-hd; 10-24; 3 107460 WRENCH, ball end; 4 mm in. (76 mm) 179791 TAG, warning (not shown); 244702 PISTON; includes 34a-34g replacement available at no cost 197920 . PISTON 180060 SIGN, warning (not shown);...
  • Page 48 Parts Part No. 244590 PRO Auto Xs Electrostatic Gun, Series B, for high conductivity coatings Ref. No. 13: Alternator Detail TI1481a 19 (Ref) TI1586A ti1601a Ref. No. 8: Packing Rod Detail 19 (Ref) 309297K...
  • Page 49 Parts Part No. 244590 PRO Auto Xs Electrostatic Gun, Series B, for high conductivity coatings Ref. Part No. Description Ref. Part No. Description 244555 TURBINE, alternator; includes 13a-13e 244950 RING, retaining, air cap; includes 13a*† 110073 . O-RING; fluoroelastomer 223688 .
  • Page 50 Parts Ref. Ref. Part No. Description Part No. Description 244702 PISTON; includes 34a-34g 107460 WRENCH, ball end; 4 mm 197920 . PISTON 179791 TAG, warning (not shown); replacement available at no cost 189754 . ROD, piston 180060 SIGN, warning (not shown); 189355 .
  • Page 51 Parts Part No. 244586 Manifold, Series A 5 (see pages 46 or 49) 101 (Ref) 106 (Ref) 116a TI1578A TI1582A Ref. Part No. Description Ref. Part No. Description 189365 CAP, kV, HI/LO 198216 MANIFOLD 198764 RESTRICTOR 189581 BRACKET, reciprocator 244772 PISTON;...

  • Page 52: Accessories

    Accessories Accessories Air Line Accessories Air Line Shutoff Valve 150 psi (10 bar, 1.0 MPa) Maximum Working Pressure ™ AirFlex Flexible Grounded Air Hose For turning air to gun on or off. 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure 224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.

  • Page 53: Miscellaneous Accessories

    Safety Warning Signs Include 189762 Remote Voltage Display and fiber optic 180060 English Warning Sign. FM Approved. Avail- cable. able at no charge from Graco. ES Display Module 236917 25 ft (7.6 m) 224117 Receives fiber optic transmission from the...

  • Page 54: Gun Accessories

    Accessories Gun Accessories Gun Valve Lubricant 111265 4 oz (113 g) tube of sanitary (non-silicone) Round Pattern Kits lubricant for fluid seals and wear areas. Alternator Bearing Kit Consists of fluid tip, diffuser and air cap. 223688 To repair the turbine alternator. Cleaning Brush 245217 4-6 in.

  • Page 55: Technical Data

    Technical Data Technical Data Category Data Maximum Working Fluid Pressure 100 psi (0.7 MPa, 7 bar) Maximum Working Air Pressure 100 psi (0.7 MPa, 7 bar) Minimum Air Pressure at Gun Inlet 40 psi (0.28 MPa, 2.8 bar) Maximum Fluid Operating Temperature 120°F (48°C) Paint Resistivity Range 3 megohm/cm to infinity...

  • Page 56: Graco Standard Warranty

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

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