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INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
AUTOMATIC ELECTROSTATIC, HIGH CONDUCTIVITY
Model PRO 5500hc Air Spray Gun
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
The PRO 5500hc spray gun offers increased electrostatic performance when spraying metallic
paints and highly conductive fluids. The gun is 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. 236–685, Series A
Complete PRO 5500hc Spray Gun: includes spray
gun, shroud, manifold, and mounting bracket
Part No. 236–686, Series A
Complete PRO 5500hc Recirculating Spray Gun:
same as part no. 236–685 spray gun only with part no.
237–302 recirculation kit installed
Part No. 237–300
PRO 5500hc Conversion Kit: to convert the PRO
5500sc
spray gun to the PRO 5500hc spray gun
Part No. 237–302
PRO 5500hc Recirculation Kit: to convert the PRO
5500sc spray gun to the PRO 5500hc recirculating
spray gun
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
COPYRIGHT 1994, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
308–442
Rev. C
Supersedes B
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Table of Contents
Troubleshooting
Related Manuals for Graco PRO 5500hc
Summary of Contents for Graco PRO 5500hc
- Page 1 PRO 5500hc Recirculation Kit: to convert the PRO 5500sc spray gun to the PRO 5500hc recirculating spray gun 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 COPYRIGHT 1994, GRACO INC.
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Page 2: Table Of Contents
Electrode Needle Replacement ....Comparison of a PRO 5500sc to a PRO 5500hc Fluid Packing Rod Removal and Repair .. -
Page 3: Warnings
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 4 Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 180 F (82 C) or below –40 F (–40 C). Do not use the hoses to pull equipment.
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Page 5: Introduction
8 in. (203.2 mm) fluid path 20 in. (711.2 mm) fluid path Comparison of a PRO 5500sc to a PRO The PRO 5500sc and PRO 5500hc guns will perform equally well when spraying fluids with high resistivity, 5500hc Spray Gun as shown in the graph below. -
Page 6: Spray Gun
(which is marked “KV”, see page 7) will activate it and switch to the lower voltage set- The PRO 5500hc guns offer the capability of monitor- ting. The lower voltage is factory set to 60 kilovolts at ing the actual spraying voltage with the optional fiber zero microamperes. - Page 7 Introduction F.O. Manifold Back View 03209 03213 04803 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...
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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 04801 Fig. 2 308–442... -
Page 9: Installing The System
Installation KEY–Fig. 1 and 2 Fig. 1, page 8, shows a typical Model PRO 5500hc system. Fig. 2 shows some possible system options. Ground Wire on Graco Electrically Conductive Air Hose Graco Electrically Conductive Air Hose (T urbine Air Hose), See page 11 for part numbers 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. Install a fluid regulator on the fluid line to control fluid pressure to the gun. 1. Install a bleed-type master air valve (X) on the main air supply line (W) to shut off all the air to the Install the Gun and Mounting Bracket gun. -
Page 11: Connect The Air And Fluid Lines
Use Only Graco Electrically Con- F.O. Fiber Optic Fitting (Optional) ductive Air Supply Hose. Connect the Graco Fiber Optic Cable as instructed on page 12. Connect the Graco electrically conductive air hose (B) kV Switch Air Inlet Fitting to the gun turbine air inlet and connect the hose Connect a 1/4 inch O.D. -
Page 12: Optional Fiber Optic Cable Connection
See Fig. 2, page 8, for a schematic of the fiber optic connections. 5. See manual 308–265 to install a Graco ES Display Module. 1. Remove the 1/8 npt plug (115) from the manifold’s... -
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 (See Fig. 11) 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 1. Install the fabric cover (XX) over the front of the gun and slide it back to cover the exposed tubing for Fluid Leakage on page 22. -
Page 16: Operation
____ 1. All the operators are properly trained to and air cap combination, use instruction manual safely operate an automatic electrostatic air 307–803 or consult your authorized Graco distributor spray system as instructed in this manual. to select the appropriate fluid nozzle and air cap. -
Page 17: 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 18: Activating And Adjusting The Electrostatics
Operation Activating and Adjusting the Activating the kV Switch Electrostatics Apply a minimum of 50 psi (3.5 bar, 0.35 MPa) air pressure to the kV switch air fitting (KV) to activate it and switch to the lower voltage setting. The lower 1. -
Page 19: 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 16 when you stop spraying and whenever you are instructed to relieve the pres- sure. - Page 20 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 Electrode Needle Replacement, page 30. WARNING Check for fluid leakage from the gun and fluid hoses.
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Page 21: 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: Soft bristle brush 7. Carefully install the air cap (12). Do not bend the Solvent compatible with fluid being sprayed electrode (13) and be sure to insert the electrode wire through the center air cap hole. -
Page 22: 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 immediately! -
Page 23: 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 16 before doing any mainte- injury if the work is not performed prop- nance or service on the gun or system. -
Page 24: 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 25: 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 26: Electrical Tests
Electrical Tests Test Gun Resistance (See Fig. 16) The performance and safety of the spray gun are directly affected by the condition of the electrical components contained inside the gun. The following Measure the resistance between the end of the elec- electrical tests can be used to determine the condition trode (13) and the gun body (29). -
Page 27: Test Power Supply Resistance
(S) or operate the gun without the contact ring in place. If the resistor stud (15) is 0442 Fig. 18 being replaced, only use a genuine Graco part. -
Page 28: Service
The piston return spring (105) is compressed Use of parts other than those specified between the manifold (101) and gun body when they in the PRO 5500hc Gun parts list on are assembled. To avoid sudden movement of the page 39 could alter the grounding conti-... - Page 29 (S) from the resistor 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. 0444A 5. Lightly lubricate the o-ring (16) with petroleum jelly Fig. 21 and install it on the resistor stud (15).
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Page 30: Electrode Needle 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 31: Fluid Packing Rod Removal And Repair
Service Fluid Packing Rod Removal and Repair 7. If the parts are purchased separately, assemble them as instructed in steps 8 to 11 and as shown in Fig. 24, on page 32. NOTE: The fluid packing rod can be replaced as individual parts or as an assembly. -
Page 32: 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. Make sure the spring (11) is installed against the 8. Place the packing nut (28c) and o-ring (28g) on the nut (U) as shown in Fig. - Page 33 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 assembly out the back of the gun.
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Page 34: Barrel Removal
Service Barrel Removal 1. Prepare the gun for service as instructed on page 28. 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 35: 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 36: Turbine Alternator Removal And Replacement
See Fig. 32. Replace the parts if they are NOTE: Replace the turbine bearings after 2000 hours damaged. of operation. See your authorized Graco representa- tive. 2. Place the barrel (26) over the power supply (27) and onto the gun body (29). Make sure the fluid 1. -
Page 37: Install The Gun Onto The Manifold
Service Tighten the screws (24) to 18 in-lbs (2 Nm) maximum (about half Adjust the nut (36) to create 0.125 in. (3 mm) gap between the turn past snug), using the wrench (77) provided. actuator arm (19) and the nut. Install the nut (46) flush to the end of the piston rod (23g). -
Page 38: Standard Spray Gun Parts
Standard Spray Gun Parts Part No. 236–685 28a, 28c–28h Standard PRO 5500hc Spray Gun See page 39 Item 23 includes 23a–23g Item 25 includes 25a & 25b Item 27 includes 27a–27e Item 28 includes 28a–28h REF 33 REF 33 03905A... - Page 39 WARNING Part No. Description Qty. 186–840 GASKET, power supply Some PRO 5500hc Gun replacement parts look similar to 185–099 other PRO Gun parts but are not interchangeable! When 185–145 servicing, do not mix or use other PRO Gun parts! 186–637...
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Page 40: Recirculating Spray Gun Parts
Recirculating Spray Gun Parts Item 23 includes 23a–23g Part No. 236–686 28a, 28c–28h Item 25 includes 25a & 25b Recirculating PRO 5500hc Spray Gun See page 39 Item 27 includes 27a–27e Item 28 includes 28a–28h REF 33 REF NO. 28, Packing Rod Assembly Includes items 28a–28h... - Page 41 Part No. Description Qty. 224–093 POWER SUPPLY ASSY; 85 kV Some PRO 5500hc Gun replacement parts look similar to Includes items 27a–27e other PRO Gun parts but are not interchangeable! When 186–840 GASKET, power supply servicing, do not mix or use other PRO Gun parts! 185–099...
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Page 42: Manifold Parts
Manifold Parts Front View 110a 03462 Back View Apply low strength (purple) Loctiter or an equivalent sealant to the threads. Press fit the spring (105) Tighten the fitting until the hex bottoms against Ref. 101 the manifold. This fitting (113) has left-hand threads. Install the KV cap (1 11) flush to the outside surface. - Page 43 The kit is not included with the gun. The kit is only for use with the ES Display Part No. 224–117 to improve Some PRO 5500hc Gun replacement parts look similar to light transmission when two bulkhead splices are used.
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Page 44: Kit Parts And Installation
Kit Parts and Installation Part No. 237–300 7. Position the coiled tube assembly so its threaded PRO 5500hc Conversion Kit; To convert the PRO inlet fitting (C) is aligned with the barrel fluid inlet 5500sc spray gun to the PRO 5500hc spray gun;... -
Page 45: Installing The Recirculation Kit
03956A Fig. 38 Installing the Recirculation Kit 1. Follow steps 1 to 7 of Installing the PRO 5500hc Conversion Kit, page 44. 2. Remove the plug (E) from the manifold P2 port, and install the female fitting (306). See Fig. 39. -
Page 46: Technical Data
Accessories Use Only Genuine Graco Parts and Accessories MISCELLANEOUS ACCESSORIES Safety Warning Signs FM Approved; Available at no charge from Graco. Must be ordered separately. Grounding Clamp and Wire 222–011 180–060 Warning Sign (English) 12 ga, 25 ft (7.6 m) wire 180–061... - Page 47 Accessories Use Only Genuine Graco Parts and Accessories CABLE ACCESSORIES Conductive Air Supply Hose; red 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure Fiber Optic Cable Assembly Meets CENELEC EN 50 050 requirement for metallic For connection between gun manifold and display ground path;...
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Page 48: The Graco Warranty And Disclaimers
Graco. These items sold, but not manufac tured by Graco (such as electric motor , switches, hose, etc.) are subject to the warranty , if any , of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. - Page 49 45 kV, fully counterclockwise is 80 kV. All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. May 6, 1999...