Graco PRO 5500HC Instructions-Parts List Manual
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Graco PRO 5500HC Instructions-Parts List Manual

Graco PRO 5500HC Instructions-Parts List Manual

Automatic electrostatic high conductivity air spray gun
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INSTRUCTIONS–PARTS LIST
AUTOMATIC ELECTROSTATIC HIGH CONDUCTIVITY
Model PRO 5500HC Air Spray Gun
100 psi (7 bar) 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
Part No. 237–302
PRO 5500HC Recirculation Kit: to convert the PRO
5500SC
spray gun to the PRO 5500HC recirculating
spray gun
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
spray gun
COPYRIGHT 1994 GRACO INC.
308–442
Rev. A

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Summary of Contents for Graco PRO 5500HC

  • Page 1 Model PRO 5500HC Air Spray Gun 100 psi (7 bar) 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.

  • Page 3: Table Of Contents

    Daily Care and Cleaning ..... Graco Phone Numbers ....
  • Page 4 PRO 5500SC Electrostatic Air Spray Gun: obtain grounding through connection to a properly grounded air Use only non-sparking tools to clean residue from the booth supply hose. Use only Graco grounded air supply hose; and hangers. see Installation, page 10, to order. Connect the air hose ground wire to a true earth ground.
  • Page 5 EQUIPMENT MISUSE HAZARD General Safety Fluid Compatibility Any misuse of the spray equipment or accessories, such as Be sure all fluids and solvents used are chemically compat- over pressurizing, modifying parts, using incompatible chemi- ible with the “Wetted Parts” shown in the Technical Data, on cals and fluids, or using worn or damaged parts, can cause the back page.

  • Page 6: Introduction

    In an electrostatic spray gun, the fluid in the fluid tube becomes a path to ground when the high voltage is The PRO 5500HC gun can support high voltages when turned on. The amount of current drawn through the spraying conductive fluids because the longer fluid...
  • Page 7 The fluid is charged as it passes the The PRO 5500HC guns offer the capability of monitor- gun’s electrode. The charged fluid is attracted to the ing the actual spraying voltage with the optional fiber nearest grounded object, wrapping around and evenly optic spraying voltage readouts.

  • Page 8: Installation

    Wire Graco Grounded TURBINE AIR–TA Air Hose (see pg. 10 for P/Ns) solenoid KV HI/L0–KV* solenoid 1/4” O.D. ATOM AIR–A1 3/8” O.D. PRO 5500HC Spray Gun 3/8” O.D. bleed-type air shutoff FAN AIR–A2 1/4” O.D. valve CYLINDER AIR–CYL solenoid True 1/4-18.6 npsm...

  • Page 9: Installing The System

    (70.5 mm) For assistance in designing a system that is custom- PRO 5500 Gun ized for your application, contact your Graco represen- tative or Graco Technical Assistance (see back page). Warning Signs Mount warning signs in the spray area where they can 0.50 in.

  • Page 10: Connect The Air And Fluid Lines

    Electrostatic Shock Hazard, page 4. WARNING Trapped air can cause the gun to spray unexpect- Connect the Graco grounded air supply hose to the edly, which could result in serious injury, including gun turbine inlet and connect the hose ground wire to a splashing in the eyes or on the skin.

  • Page 11: Optional Fiber Optic Fitting

    Fig. 6 Fig. 5 Turbine Air Inlet–TA MANIFOLD BACK VIEW Connect Graco Grounded Air Supply Hose between fitting (left-hand thread) & solenoid. Connect the ground wire on the air hose to a true earth ground. Cylinder Air Inlet–CYL Connect a 1/4” OD tube between fitting and solenoid. For quicker trigger response, use the shortest hose length possible.

  • Page 12: Check The Electrical Grounding

    Installation Check the Electrical Grounding (See Fig. 8 ) a. If using a black or grey grounded air hose (G), use a megohmmeter (L) to measure the WARNING resistance. Use an applied voltage of 500 mini- mum to 1000 volts maximum. Resistance Proper electrical grounding of every part of your should not exceed 2 megohms.

  • Page 13: Install The Fabric Cover

    Installation Install the Fabric Cover (See Fig. 9 ) 2. Route the exhaust tube (N) outside the cover. This enables you to monitor the exhaust tube for the presence of any paint or solvent. See Check for 1. Install the fabric cover (M) over the front of the gun Fluid Leakage on page 18.

  • Page 14: Operation

    Operation WARNING 5. Be sure ventilation fans are operating properly. Pressure Relief Procedure To reduce the risk of serious injury, including 6. Be sure the workpiece hangers are clean splashing in the eyes or on the skin, injury from and grounded. Contact points must be sharp moving parts or electrostatic shock, always follow points or knife edges.

  • Page 15: Adjusting The Spray Pattern

    Operation Adjusting the Spray Pattern Activating and Adjusting the Electrostatics WARNING Follow the steps below to establish the correct fluid flow and air flow. Do not turn on the turbine/electros- The fan (A2) and atomizing (A1) air must be on before turning on the turbine air (TA).

  • Page 16: Maintenance

    Maintenance Daily Care and Cleaning CAUTION Clean all parts with a non-conductive solvent, com- WARNING patible with the fluid being sprayed. Conductive To reduce the risk of serious injury, including solvents can cause the gun to malfunction. splashing in the eyes or on the skin or electrostatic shock, always follow the Pressure Relief Proce- Methylene chloride is not recommended as a flush- dure Warning on page 14 when shutting off the...

  • Page 17: Clean The Air Cap And Fluid Nozzle

    Maintenance Daily Care and Cleaning (continued) 5. Clean the air cap (12) with the soft bristle brush and solvent or submerge the air cap in suitable solvent and wipe it clean. 1. Clean the fluid and air line filters daily. CAUTION 2.

  • Page 18: Check For Fluid Leakage

    Maintenance Check for Fluid Leakage (See Fig. 12 ) WARNING for the presence of fluid. Fluid in these areas would indicate fluid leakage into the shroud, which could be If any fluid leakage from the gun is detected, caused by leaks at the fluid tube connections or fluid stop spraying IMMEDIATELY! Fluid leakage into packing leakage.

  • Page 19: Troubleshooting

    Troubleshooting WARNING Installing and servicing this equipment requires access to parts which may cause electrostatic shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified. To reduce the risk of serious injury, including splashing fluid or solvent in the eyes or on the skin, always follow the Pressure Relief Procedure Warning on page 14 before checking, adjusting, cleaning or repairing the gun or any part of the system.

  • Page 20: Gun Operation Troubleshooting

    Troubleshooting Gun Operation Troubleshooting PROBLEM CAUSE SOLUTION Leakage from fluid Worn fluid rod packings or Replace packings or rod; fluid rod see page 29. packing area Fluid leakage from front Fluid rod worn or damaged Replace fluid rod; see page 29. of gun Worn fluid seat Replace fluid nozzle and/or electrode...

  • Page 21: Electrical Troubleshooting

    Troubleshooting Electrical Troubleshooting PROBLEM CAUSE SOLUTION Poor wrap-around Improper distance between gun Adjust spraying distance to and workpiece 8 to 12 inches (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 22: Electrical Tests

    Electrical Tests The performance of the spray gun is directly affected by the condition of the electrical components contained inside the gun. The electrical tests below can be used to determine the condition of the power supply (40) and the resistor stud (15) as well as the continuity of the electrical path between the components.

  • Page 23: Test Resistor Stud Resistance

    (S) from the resistor stud or operate the gun without the contact ring in place. Do not replace the resistor stud (15) with anything but a genuine Graco part.
  • Page 24 Service WARNING Notes: Installing and servicing this equipment requires If the plastic parts of the gun must be held in a vise, access to parts which may cause electrostatic only use padded vise jaws to avoid damaging parts. shock or other serious injury if the work is not per- formed properly.

  • Page 25: Air Cap/Nozzle/Resistor Stud Replacement

    Apply a very light coat of lubricant contact ring in place. Do not replace the resistor stud (15) with anything but a genuine Graco part. Tighten 1/8 to 1/4 turn past hand tight Fig. 17 4.

  • Page 26: Electrode Needle Replacement

    Service Electrode Needle Replacement 1. Remove the air cap, nozzle and resistor stud as described in Air Cap/Nozzle/Resistor Stud Replacement, page 25. 2. Unscrew and remove the electrode needle (13) with the electrode wrench (82), provided. Be care- ful not to damage the contact wire. See Fig. 19 . If the fluid rod turns, hold the back end of the fluid rod (C).

  • Page 27: Barrel Removal

    Service Barrel Removal 1. Carefully loosen the fluid fitting nut (43). Pull the tube (33) out of the fitting. See Fig. 21 . Make sure both ferrules and the nut stay with the tube. 2. Remove the jam nut (46) and actuator arm (19). NOTE: The fluid nozzle (14) must be in place when removing or installing the jam nut and actuator arm.
  • Page 28 Service Barrel Installation 5. Install the actuator arm (19) and jam nut (46), with the jam nut assembled flush to the end of the pis- 1. Be sure the gaskets (20, 27a) and spring (11) are ton rod. Make sure the entire fluid tube (33) is in place.

  • Page 29: Fluid Packing Removal

    Service Fluid Packing Removal NOTE: Before installing the fluid packing rod into the gun barrel, make sure the internal surfaces of the bar- 1. Remove the jam nut (46) and actuator arm (19). See rel are clean. Remove any residue with a soft brush or Fig.

  • Page 30: Power Supply Removal And Replacement

    NOTE: Replace turbine bearings after 2000 hours of 2. Grasp the power supply (27) with your hand. With operation. See your authorized Graco representative. a gentle side-to-side motion, being careful not to 1. Remove the power supply from the gun body as damage the power supply, pull the power supply described at left.

  • Page 31: Piston Repair

    Service Piston Repair Description Function O-Ring (23a) Seals cylinder air along the piston rod. If air 1. Remove the jam nut (46), actuator arm (19), and Shaft Air Seal leaks along the piston rod (23g), replace adjustment nut (36). See Fig. 26 . this o-ring (23a).

  • Page 32: Manifold Parts

    Manifold Parts FRONT VIEW 03462 BACK VIEW Apply low strength (purple) Loctite or equivalent to threads Press fit REF 101 Tighten until hex bottoms against manifold Left-hand threads Flush to outside surface Replace spring every 30,000 cycles Included with Part No. 236–831 Manifold only...
  • Page 33 Manifold Parts WARNING Ref. Part No. Description Qty. When servicing use only genuine Graco replace- ment parts. Use of other parts or any modification 108–290 SCREW; 8–32 x 1/4” of the gun could alter the grounding continuity of 236–696 KV SWITCH the gun or cause parts to rupture and result in 189–365...

  • Page 34: Standard Spray Gun Parts

    Standard Spray Gun Parts Part No. 236–685, Series A 28a, 28c–28h Standard PRO 5500HC Spray Gun; See page 35 Includes items 1–85 Item 23 includes 23a–23g Item 25 includes 25a & 25b Item 27 includes 27a–27e Item 28 includes 28a–28h...
  • Page 35 Standard Spray Gun Parts WARNING Ref. Part No. Description Qty. When servicing use only genuine Graco replace- ment parts. Use of other parts or any modification 224–747 PACKING ROD ASSY of the gun could alter the grounding continuity of Includes items 28a–28h the gun or cause parts to rupture and result in seri- 185–495...

  • Page 36: Recirculating Spray Gun Parts

    Recirculating Spray Gun Parts Part No. 236–686, Series A Item 23 includes 23a–23g 28a, 28c–28h Recirculating PRO 5500HC Spray Gun; Item 25 includes 25a & 25b See page 37 Includes items 1–89 Item 27 includes 27a–27e Item 28 includes 28a–28h REF 33 Adjust nut to create 0.125”...
  • Page 37 Recirculating Spray Gun Parts WARNING Ref. Part No. Description Qty. When servicing use only genuine Graco replace- ment parts. Use of other parts or any modification 185–495 HOUSING, packing of the gun could alter the grounding continuity of 223–981 ROD, fluid the gun or cause parts to rupture and result in seri- 185–488...

  • Page 38: Kit Parts And Installation

    Kit Parts and Installation Part No. 237–300 NOTE: If installing the recirculation kit, continue with PRO 5500HC Conversion Kit; To convert the PRO step 2 of Installing the Recirculation Kit. 5500SC spray gun to the PRO 5500HC spray gun; Includes items 201–204 8.
  • Page 39 Fig. 35 Fig. 34 Installing the Recirculation Kit 1. Follow steps 1 to 7 of Installing the PRO 5500HC Conversion Kit, page 38. 2. Remove the plug (E) from the manifold P2 port, and install the female fitting (306). See Fig. 35 .

  • Page 40: Technical Data

    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.

This manual is also suitable for:

236-685236-686237-300237-302

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