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

Graco PRO Auto Xs Instructions-Parts List Manual

Air spray gun
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Instructions/Parts List
ELECTROSTATIC, FOR WATERBORNE COATINGS
™
PRO
Auto Xs
Air Spray Gun
Part No. 244591, Series A
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure
For use when electrostatically spraying conductive,
waterborne fluids that meet at least one of the
following conditions for non-flammability:
•
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.
•
The fluid does not sustain burning when tested per
ASTM Standard D4206 Sustained Burn Test.
NOTE: Fluid hose must be ordered separately.
For patent information, see www.graco.com/patents
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents.
309457G
EN
TI1557A

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  • Page 1 • The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test. NOTE: Fluid hose must be ordered separately. For patent information, see www.graco.com/patents TI1557A Important Safety Instructions Read all warnings and instructions in this manual.

  • Page 2: Table Of Contents

    Operating Checklist ..... . 22 Graco Information ......60 Select a Fluid Nozzle and Air Cap .

  • Page 3: Warnings

    The area of the hose that is not covered by the conductive hose layer must be inside the voltage isolation system enclosure. • Only use the red-colored Graco grounded turbine air hose with this gun. Do not use the black or grey-colored 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. • Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements in this manual.
  • Page 5 • Do not alter or modify equipment. Use only genuine Graco parts and accessories. • Do not operate the power supply above 60 kV. Use only Graco Part No. 244542 Power Supply with this gun. • Check the equipment daily. Repair or replace worn or damaged parts immediately.

  • Page 6: Introduction

    CAUTION enclosure that prohibits persons from making con- tact with the high voltage components before the The Graco warranty is void if the spray gun is con- system voltage is discharged. nected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.

  • Page 7: Operating The Spray Function

    To operate the electrostatics, apply air pressure to the ries the signal from the gun to a remote display gun manifold’s turbine air fitting (TA) through a Graco module. Part No. 224117 Display Module displays grounded air hose. The air enters the manifold and is the gun’s spraying voltage and current.
  • Page 8 Introduction TI1557A TI1790A Manifold Back TI1780A 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 9: Installation

    For assistance in designing a sys- • The voltage isolation system must be interlocked tem to suit your particular needs, contact your Graco with the spray area entrance to automatically dis- distributor. charge the voltage and ground the fluid whenever someone enters the spray area.

  • Page 10: Warning Signs

    Mount warning signs in the spray area where they can Air Hose Ground Wire easily be seen and read by all operators. An English Graco Grounded Turbine Air Hose (TA) Warning Sign is provided with the gun. Atomizing Air Hose, 3/8 in. (10 mm) OD (A1) Fan Air Hose, 3/8 in.
  • Page 11 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. above Non-Hazardous Hazardous Area TI1801A Manifold Back Fig. 2. Typical Installation NOTE: ** A maximum of two splices with a total of 108 ft (33 m) of cable can be used.

  • Page 12: Install The Air Line Accessories

    Installation Install the Air Line Accessories Install the Gun and Mounting Bracket 1. Install a bleed-type air valve (L) on the main air line (W) to shut off all air to the gun (H). 1. Loosen the mounting bracket’s two set screws (103) and slide the bracket (102) onto a 1/2 in.

  • Page 13: Connect The Air Line

    Fiber Optic Fitting (Optional) •The isolation system to shut off the turbine Connect the Graco Fiber Optic cable (see page 17). air supply anytime the enclosure or kV Switch 1 Air Inlet Fitting safety fence is opened.

  • Page 14: Connect The Waterborne Fluid Hose

    Hose A 9.75 in. (248 mm) B 1.5 in. (38 mm) CAUTION The Graco warranty is void if the spray gun is con- nected to a non-Graco voltage isolation system or if the gun is operated above 60 kV. TI1806A •...
  • Page 15 Installation TI1802A TI1793A *Ferrule (M) and nut (N) are part of the waterborne hose assembly (purchase separately). Fig. 7. Connect the Waterborne Fluid Hose 309457G...
  • Page 16 Installation 6. Slide the inner tube (T) of the hose through the slot 10. Connect the other end of the hose to the fluid outlet and into the fluid inlet port (P1) of the manifold. of the isolated fluid supply. See F .

  • Page 17: Optional Fiber Optic Cable Connection

    1. Remove the plug (120) from the fiber optic port, and install the fiber optic fitting (5, shipped loose with the 4. See manual 308265 to install a Graco ES Display gun). See F . 9.. Module.

  • Page 18: Grounding

    See Check Electrical Grounding, page 19. • Graco Waterborne Fluid Hose: the hose is grounded through the conductive layer. Install the hose as instructed on page 14. •...

  • Page 19: Check Electrical Grounding

    Installation Check Electrical Grounding WARNING Fire, Explosion, and Electric Shock Hazard Megohmmeter Part No. 241079 (AA-see . 11.) is not approved for use in a haz- ardous area. To reduce the risk of sparking, do not use the megohmmeter to check elec- trical grounding unless: •The gun has been removed from the haz- ardous area;...

  • Page 20: 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 the presence of any paint or solvent. See Check for 1. Install a fabric cover (XX) over the front of the gun Fluid Leakage on page 29.

  • Page 21: Operation

    Contact your Graco distributor to order. 3. Turn off all the air to the spray gun except the cylin- der air, which triggers the gun. If an air pilot fluid 1.

  • Page 22: Operating Checklist

    Table 2 and Table 3 , and instruction manual 309419, or The warning sign provided with the gun is consult with your Graco distributor. See Air Cap/Nozzle mounted in the spray area where it can be Replacement on page 41.

  • Page 23: Adjust The Spray Pattern

    Operation Adjust the Spray Pattern WARNING Follow the steps below to establish the correct fluid flow and air flow. Do not turn on the turbine air (TA) yet. Component Rupture Hazard To reduce the risk of component rupture, WARNING which can cause serious injury, do not exceed the maximum working pressure of the lowest rated system component.
  • Page 24 Operation 5. Use the air pressure regulator on the atomization air supply line (A1) to adjust the degree of atomization. See F . 14.. For example, for a fluid flow rate of 10 ounces per minute (0.3 liters per minute), a typical atomization pressure would be 20-30 psi (1.4-2.1 bar, 0.14-0.21 MPa) at the gun manifold.

  • Page 25: Adjust The Electrostatics

    Operation Adjust the Electrostatics Spraying WARNING 1. Shut off the fluid supply. Electric Shock Hazard 2. Prepare the isolation system for high voltage opera- tion. To reduce the risk of electric shock, do not touch the gun electrode or come within 2 ft 3.

  • Page 26: 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 27 Maintenance WARNING WARNING Pressurized Equipment Hazard Fire, Explosion, and Electric Shock Hazard To reduce the risk of an injury, follow the To reduce the risk of fire, explosion, or elec- Pressure Relief Procedure on page 21 tric shock, turn off the turbine air (TA) before before doing any maintenance on the gun flushing the gun or any part of the system.

  • Page 28: Clean The Air Cap And Fluid Nozzle

    Maintenance Clean the Air Cap and Fluid 9. Make sure the u-cup (1a) is in place on the retaining ring (1). The lips must face forward. Tighten the Nozzle retaining ring until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.

  • Page 29: Check For Fluid Leakage

    Maintenance Check for Fluid Leakage During operation, periodically check the manifold exhaust tube (YY) and both ends of the gun shroud (ZZ) for the presence of fluid. See F . 16.. Fluid in these areas indicates leakage into the shroud, which could be WARNING caused by leaks at the fluid tube connections or fluid packing leakage.

  • Page 30: Electrical Tests

    Electrical Tests Electrical Tests Test Gun Resistance 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 1. Flush and dry the fluid passage. continuity between components. 2.

  • Page 31: Test Power Supply Resistance

    5. If you still have problems, refer to Electrical Trou- bleshooting on page 38 for other possible causes ti1599a of poor performance, or contact your Graco distribu- tor. Fig. 18. Test Power Supply Resistance 309457G...

  • Page 32: Test Electrode Resistance

    . 19.. 3. If in range, refer to Electrical Troubleshooting on page 38 for other possible causes of poor perfor- mance, or contact your Graco distributor. ti1548a 4. Remove the electrode (7), page 42. Measure the resistance between the contact (E) and the elec- trode wire (F).

  • Page 33: Troubleshooting

    Troubleshooting Troubleshooting Voltage Loss Troubleshooting WARNING Normal spraying voltage for a system using the water- borne gun is 45-55 kV. The system voltage is lower due Electric Shock Hazard to spraying current demands and voltage isolation sys- tem losses. Installing and servicing this equipment requires access to parts which may cause A loss of spraying voltage can be caused by a problem an electric shock or other serious injury if...
  • Page 34 Troubleshooting Visual Check Tests First, check the system for any visible faults or errors to If you still have no voltage, separate the spray gun and help isolate whether the spray gun, fluid hose or voltage hose from the voltage isolation system and check isolation system has failed.
  • Page 35 Troubleshooting 11. If the meter reading is 55-60 kV, the gun power sup- 13. Before reassembling the gun, clean and dry the gun ply is okay, and there is probably a dielectric break- fluid inlet tube. Repack the inner spacer of the fluid down somewhere in the fluid hose or gun.

  • Page 36: Spray Pattern Troubleshooting

    Troubleshooting Spray Pattern Troubleshooting NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun. NOTE: Some spray pattern problems are caused by the improper balance between air and fluid. Problem Cause Solution Fluttering or spitting spray. No fluid. Refill supply.

  • Page 37: 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 38: Electrical Troubleshooting

    Troubleshooting Electrical Troubleshooting Problem Cause Solution Voltage still present at gun after fol- Turbine air is not turned off. Turn off. lowing the Fluid Voltage Discharge and Grounding Procedure Did not wait long enough for voltage Wait longer before touching electrode to discharge.

  • Page 39: Repair

    No. 116553 Dielectric Grease, as specified in the text. • Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate. • Only use genuine Graco parts. Do not mix or use parts from other PRO Gun models. 309457G...

  • Page 40: Remove The Gun From The Manifold

    Repair Remove the Gun from the Manifold 1. Discharge the system voltage, page 21. 2. Flush and clean the gun, page 26. 3. Relieve the pressure, page 21. 4. Remove the air cap (3) and shroud (2), page 41. TI1778A 5.

  • Page 41: Air Cap/Nozzle Replacement

    Do not replace 1. Prepare gun for service, page 39. the contact ring with anything but a genuine Graco part. 2. Remove the retaining ring (1) and air cap (3). See . 23.. NOTE: Use non-silicone grease, Part No. 111265, on the small o-ring (4b).

  • Page 42: Electrode Replacement

    Repair Electrode Replacement 1. Prepare the gun for service, page 39. 2. Remove the air cap and nozzle, page 41. 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 .

  • Page 43: Fluid Packing Removal

    Repair Fluid Packing Removal NOTE: You may replace the packing rod as an assem- bly, as described below, or as individual parts (see page 44). The assembly is pre-adjusted at the factory. 1. Prepare the gun for service, page 39. 2.

  • Page 44: 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) NOTE: You may replace the packing rod as individual assembly along the rod.

  • Page 45: Piston Repair

    Repair Piston Repair Table 5: Piston O-Rings Front O-Ring Air shutoff seal. Replace if air leaks from 1. Prepare the gun for service, page 39. (34e) air cap when gun is de-triggered. Back O-Ring Separates cylinder air from fan and 2.

  • Page 46: Adjust The Actuator Arm

    Repair Adjust the Actuator Arm 0.125 in. (3 mm) gap NOTE: The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm. 1. Install the adjustment nut (30), actuator arm (29), and jam nut (28) onto the piston rod (34b). Note that the jam nut (28) has a slightly larger hex and a thin- ner profile than the adjustment nut (30).

  • Page 47: 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 . 30.. 1. Prepare the gun for service, page 39. 2. Remove the air cap, page 41. Remove the gun shroud (2).

  • Page 48: 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 49: Power Supply Removal And Replacement

    Repair Power Supply Removal and 10. Insert the power supply/alternator assembly in the gun body (32). Make sure the ground strips make Replacement contact with the body. Connect the flexible circuit (39) to the socket at the top of the body. Push the •...

  • Page 50: Turbine Alternator Removal And Replacement

    Repair TI1784A Fig. 33. Power Supply Turbine Alternator Removal and 7. Install the power supply/alternator assembly, page Replacement NOTE: Replace turbine alternator bearings after 2000 hours of operation. Order Part No. 223688 Bearing Kit. 1. Prepare gun for service, page 39. 2.
  • Page 51 Repair 309457G...

  • Page 52: Parts

    Parts Parts Part No. 244591 PRO Auto Xs Electrostatic Gun, Series A, for waterborne coatings Ref. No. 13: Alternator De- tail TI1481a TI1777A ti1601a Ref. No. 8: Packing Rod De- 309457G...
  • Page 53 Parts Part No. 244591 PRO Auto Xs Electrostatic Gun, Series A, for waterborne 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 1a*† 198307 .
  • Page 54 Parts Ref. Part No. Description 244938 MANIFOLD; see separate parts list on page 55 245265 CIRCUIT, flexible 276741 MULTI-TOOL 189888 COVER, gun; box of 10 (not shown) 116553 TUBE, grease, lubricant 290171 SIGN, warning (not shown); replacement available at no cost 24A431 KIT, wide pattern * Recommended spare parts.
  • Page 55 Parts Part No. 244938 Manifold, Series A 5 (see pages 53 or 55) 101 (Ref) 106 (Ref) 116a TI1791A TI1796A Ref. Part No. Description Ref. Part No. Description 198764 RESTRICTOR 198362 MANIFOLD 244772 PISTON; includes 116a 189581 BRACKET, reciprocator 116a† 112085 .

  • Page 56: Accessories

    Accessories Accessories Air Line Accessories Fluid Line Accessories Grounded Air Hose (Red Cover) Shielded Waterborne Fluid Hose 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand PTFE;...

  • Page 57: Miscellaneous Accessories

    224117 Receives fiber optic transmission from the 236921 100 ft (30.5 m) PRO Auto Xs gun and displays the gun’s output voltage and current. Mounts in a Fiber Optic Cables standard 19 in. DIN rack. See 308265. See item V in F .

  • Page 58: Gun Accessories

    Accessories Gun Accessories Round Pattern Kits Gun Valve Lubricant Consists of fluid tip, diffuser and air cap. 111265 4 oz (113 g) tube of sanitary (non-silicone) lubricant for fluid seals and wear areas. 245217 4-6 in. (102-152 mm) diameter Alternator Bearing Kit 245219 8-10 in.

  • Page 59: 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) Short Circuit Current Output 125 microamperes...

  • Page 60: 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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