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AUTOMATIC ELECTROSTATIC AIR-ASSISTED SPRAY GUN
™
PRO
Auto Xs AA
Part No. 244592, Series A
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
3000 psi (21 MPa, 210 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 0.24MJ
For Professional Use ONLY.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents.
U.S. Patent 7,226,004
309298J
ENG
TI1713A
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Table of Contents
Troubleshooting
Related Manuals for Graco 244592
Summary of Contents for Graco 244592
- Page 1 AUTOMATIC ELECTROSTATIC AIR-ASSISTED SPRAY GUN ™ Auto Xs AA Part No. 244592, Series A 100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure 3000 psi (21 MPa, 210 bar) Maximum Working Fluid Pressure For use in Class I, Div. I hazardous locations using Group D spray materials.
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Page 2: Table Of Contents
Symbols ........3 Warning Symbol ......3 Caution Symbol . -
Page 3: Symbols
Symbols Warning Symbol WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. WARNING Fire, Explosion, and Electric Shock Hazard Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: •... - Page 4 Warning WARNING Skin Injection Hazard Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause serious injury. •...
- Page 5 WARNING Equipment Misuse Hazard Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in a serious injury. • This equipment is for professional use only. • Read all manuals, tags, and labels before operating the equipment. •...
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Page 6: Introduction
Introduction Introduction How the Electrostatic AA Spray Gun Works WARNING Skin Injection Hazard Remember, this is not an air spray gun. For your safety, read and follow all Warn- ings in this manual. The air-assisted spray gun combines airless and air spraying concepts. -
Page 7: Changing The Kv Setting
Changing the kV Setting The gun’s full voltage setting is 85 kV. Three lower volt- age settings are possible by actuating the KV1 and KV2 switches. Supply 50 psi (0.35 MPa, 3.5 bar) air pressure to the KV1 and KV2 ports. Turn the air on or off as shown in Table 1 to set the desired voltage. - Page 8 Introduction Fig. 1. Gun Overview Air Cap Spray Tip Tip Guard Retaining Ring Shroud Mounting Bracket Manifold Turbine Power Supply Electrode TI1713A Manifold Markings not used Atomization Air Inlet Fitting Cylinder Air Inlet Fitting Shroud Exhaust Outlet Fitting Fiber Optic Fitting kV Switch 1 Air Inlet kV Switch 2 Air Inlet Fluid Supply Inlet Fitting...
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Page 9: Installation
Installation Install the System WARNING Fire, Explosion, and Electric Shock Hazard Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. •Do not install or service this equipment unless you are trained and qualified. - Page 10 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. See * above Non-Hazardous Area Fig. 2. Typical Installation NOTE: ** A maximum of two splices with a total of 108 ft (33 m) of cable can be used. For the strongest light signals, use a minimum number of bulkhead splices.
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Page 11: Install The Air Line Accessories
Install the Air Line Accessories WARNING Component Rupture Hazard To reduce the risk of serious injury due to component rupture: The pump pressure must be limited by the pump air regulator. Do not rely on the gun fluid regulator to limit the fluid pressure to the gun. -
Page 12: Install The Gun And Mounting Bracket
Installation Install the Gun and Mounting Bracket 1. Loosen the mounting bracket’s two set screws (103) and slide the bracket (102) onto a 1/2 in. (13 mm) mounting rod. See F . 4.. 2. Position the gun and tighten the two set screws. For added positioning reliability, insert a 1/8 in. -
Page 13: Connect The Air And Fluid Lines
Connect the Air and Fluid Lines . 3. shows a schematic of air and fluid line connec- tions, and F . 5. shows the manifold connections. Con- nect the air and fluid lines as instructed. WARNING Electric Shock Hazard To reduce the risk of electric shock or other serious injury, the air supply hose must be electrically connected to a true earth ground. -
Page 14: Optional Fiber Optic Cable Connection
Installation Optional Fiber Optic Cable Connection An optional fiber optic fitting is shipped unassembled with the gun. If an ES (kV) display module is used, install the fitting in the FO port of the manifold. See F 3., page 10, for a schematic of the fiber optic connec- tions. -
Page 15: Grounding
Grounding WARNING Fire, Explosion, and Electric Shock Hazard When operating the electrostatic gun, any ungrounded objects in the spray area (peo- ple, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock. Follow the grounding instructions below. -
Page 16: Check Electrical Grounding
Installation Check Electrical Grounding WARNING Fire, Explosion, and Electric Shock Hazard Megohmmeter Part No. 241079 (AA-see . 8.) is not approved for use in a hazard- ous area. To reduce the risk of sparking, do not use the megohmmeter to check electri- cal grounding unless: •... -
Page 17: Check Fluid Resistivity
Check Fluid Resistivity WARNING Fire, Explosion, and Electric Shock Hazard Check the fluid resistivity in a non-hazard- ous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area. Failure to follow this warning could cause fire, explosion, or electric shock and result in serious injury and property damage. -
Page 18: Operation
Operation Operation Pressure Relief Procedure WARNING Skin Injection Hazard The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from fluid injection, splashing fluid, or electric shock, follow the Pressure Relief Procedure whenever you: •... -
Page 19: Select A Spray Tip
Select a Spray Tip The fluid output and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pressure. Use the Spray Tip Selection Chart, page 51, as a guide for selecting the appropriate spray tip for your application. -
Page 20: Set The Atomization Fluid Pressure
Operation Set the Atomization Fluid Pressure Atomization fluid pressure will vary based on the viscos- ity of the fluid, flow rate desired, and other system char- acteristics. 1. Turn off the turbine air (TA) and atomization air (A2). 2. Start the pump. Set the fluid regulator to 400 psi (2.8 MPa, 28 bar). -
Page 21: Adjust The Electrostatics
Adjust the Electrostatics 1. Shut off the fluid supply. 1. Trigger the gun, then turn on the turbine air (TA). See F . 12.. 2. Refer to Table 2 to set the proper pressure at the turbine air hose inlet when air is flowing. Do not exceed these pressures as there is no added bene- fit and turbine life could be reduced. -
Page 22: Spraying
Operation Spraying WARNING Electric Shock Hazard To reduce the risk of electric shock, do not touch the gun electrode or come within 4 in. (10 cm) of the nozzle during gun operation. 1. Apply a minimum of 50 psi (3.5 bar, 0.35 MPa) air pressure to the cylinder air fitting (CYL) to activate the on/off sequence of atomization air (A2) and fluid (P1). -
Page 23: Maintenance
Maintenance Daily Care and Cleaning • Clean all parts with a non-conductive, compatible 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 24: Daily Care And Cleaning, Continued
Maintenance Daily Care and Cleaning, continued WARNING Skin Injection Hazard To reduce the risk of a fluid injection injury, always follow the Pressure Relief Proce- dure on page 18 when you stop spraying and whenever you are instructed to relieve the pressure. -
Page 25: Flush The Spray Gun
Flush the Spray Gun WARNING Skin Injection Hazard To reduce the risk of a fluid injection injury, always follow the Pressure Relief Proce- dure on page 18 when you stop spraying and whenever you are instructed to relieve the pressure. 1. -
Page 26: Clean The Spray Gun
Maintenance Clean the Spray Gun Equipment Needed • soft bristle brush • compatible solvent Procedure WARNING Skin Injection Hazard To reduce the risk of a fluid injection injury, always follow the Pressure Relief Proce- dure on page 18 when you stop spraying and whenever you are instructed to relieve the pressure. - Page 27 Fig. 17. Clean the Inline Fluid Filter 8. Clean the retaining ring (1), tip guard (3), air cap (40), and spray tip (4) with a soft brush daily, mini- mum. Replace any damaged parts. Be careful not to damage the electrode (40a). CAUTION Do not use metal tools to clean the air cap or spray tip holes as this...
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Page 28: Check For Fluid Leakage
Maintenance Check for Fluid Leakage WARNING Fire and Explosion Hazard If any fluid leakage from the gun is detected, stop spraying immediately. Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage. Fig. -
Page 29: 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 barrel (6), and electrical continuity between components. CAUTION The barrel resistor cartridge is part of the barrel and is not replaceable. -
Page 30: Test Power Supply Resistance
Electrical Tests Test Power Supply Resistance 1. Remove the power supply (12), page 46. 2. Remove the turbine alternator (13) from the power supply, page 47. 3. Measure resistance from the power supply's ground strips (EE) to the spring (12b). See F 4. -
Page 31: Test Barrel Resistance
Test Barrel Resistance 1. Insert a conductive rod (B) into the gun barrel (removed for the power supply test) and against the metal contact (C) in the front of the barrel. 2. Measure the resistance between the conductive rod (B) and the barrel contact ring (6a). See F The resistance should be 19-29 megohms. -
Page 32: Troubleshooting
Troubleshooting Troubleshooting WARNING Electric Shock Hazard Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or repair this equipment unless you are trained and qualified. -
Page 33: Gun Operation Troubleshooting
Gun Operation Troubleshooting Problem Excessive spray fog. “Orange Peel” finish. Fluid leaks from the fluid packing area Air leaks from the air cap Fluid leakage from the front of the Gun does not spray Paint buildup on air cap Air leaks from manifold Fluid doesn’t shut off properly. -
Page 34: Electrical Troubleshooting
Troubleshooting Electrical Troubleshooting Problem Poor wrap. No voltage or low voltage reading on the gun ES display module Operator gets mild shock. Operator gets shock from workpiece. Workpiece not grounded. Cause Turbine air is not turned on. Booth exhaust velocity is too high. Atomization air pressure too high. -
Page 35: Repair
Repair Prepare the Gun for Service WARNING Electric Shock Hazard Installing and repairing this equipment requires access to parts that may cause electric shock or other serious injury if the work is not performed properly. Do not install or ser- vice this equipment unless you are trained and quali- fied. -
Page 36: Remove The Gun From The Manifold
Repair Remove the Gun from the Manifold 1. Remove the fluid supply hose from the fluid fitting (22). 2. Loosen the bottom gun screw (31) until the gun sits loosely in the mounting bracket slot (A). See F 22.. CAUTION The piston return spring (105) is compressed between the manifold and the gun body when they are assembled. -
Page 37: Tip Guard, Air Cap, Spray Tip, Or Seat Housing Replacement
Tip Guard, Air Cap, Spray Tip, or Seat Housing Replacement 1. Prepare gun for service, page 35. 2. Remove the retaining ring (1), tip guard (3), air cap (40), spray tip (4), and shroud (2). You may have to turn the air cap with the tip guard to remove it. See . - Page 38 Repair 5. Install the seat housing (5) with the tool (14) pro- vided. Tighten until snug, then 1/4 turn more; do not overtighten. See F . 24.. CAUTION To avoid damaging the seat housing and gun barrel, never overtighten the seat housing. Overtightening may affect the fluid shutoff.
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Page 39: Electrode Replacement
Electrode Replacement WARNING Electric Shock Hazard To reduce the risk of fire, explosion, or elec- tric shock, do not operate the spray gun without the electrode installed in the air cap. 1. Prepare the gun for service, page 35. 2. Remove the air cap assembly, page 37. 3. -
Page 40: Fluid Tube Replacement
Repair Fluid Tube Replacement There are no replaceable parts in the fluid tube assem- bly. Only remove when necessary. 1. Prepare the gun for service, page 35. 2. Remove the air cap assembly, page 37. Remove the shroud (2). 3. Disconnect the bottom fluid tube nut (C). See F 26.. -
Page 41: Fluid Needle Replacement
Fluid Needle Replacement 1. Prepare the gun for service, page 35. 2. Remove the air cap assembly and seat housing, page 37. 3. Remove the barrel (6), page 44. 4. Remove the spring cap (45) and the spring (8a) from the barrel. See F . -
Page 42: Piston Repair
Repair Piston Repair 1. Prepare the gun for service, page 35. 2. Remove the air cap, page 37. Remove the gun shroud (2). 3. Remove the jam nut (28), actuator arm (29), and adjustment nut (30). See F . 30.. 29 30 34b Fig. -
Page 43: Adjust The Actuator Arm
Adjust the 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). See F 30. -
Page 44: Barrel Removal
Repair Barrel Removal 1. Prepare the gun for service, page 35. 2. Remove the air cap, page 37. Remove the gun shroud (2). 3. Disconnect the fluid tube nut (C). 4. Remove the jam nut (28) and actuator arm (29). See page 42. -
Page 45: Barrel Installation
Barrel Installation 1. Be sure the gasket (11) and grounding spring (25) are in place. Make sure the air holes are aligned properly. Replace if damaged. See F 2. Place the barrel (6) over the power supply (12) and onto the gun body (32). 3. -
Page 46: Power Supply Removal And Replacement
Repair Power Supply Removal and Replacement • Inspect the gun body power supply cavity for dirt or moisture. Clean with a clean, dry rag. • Do not expose gasket (11) to solvents. 1. Prepare gun for service, page 35. 2. Remove the barrel (9), page 44. CAUTION Be careful when handling the power supply (12) to avoid damaging it. -
Page 47: Turbine Alternator Removal And Replacement
Fig. 36. Power Supply Turbine Alternator Removal and Replacement Replace turbine alternator bearings after 2000 hours of operation. Order Part No. 223688 Bearing Kit. 1. Prepare gun for service, page 35. 2. Remove the power supply/alternator assembly, page 46. 3. Disconnect the alternator from the power supply, page 46. -
Page 48: Parts
Parts Parts Part No. 244592 PRO Auto Xs AA Electrostatic Gun, Series A 19 (Ref) ti1722 Ref. No. 13: Alternator Detail 13a* TI1481a 309298J... - Page 49 Part No. 244592 PRO Auto Xs AA Electrostatic Gun, Series A Ref. Part No. Description 244950 RING, retaining, air cap; includes 1a*† 198307 . U-CUP 197916 SHROUD 276767 TIP GUARD GG3XXX SPRAY TIP (customer’s choice); includes item 4a 183459 . SEAL, spray tip...
- Page 50 Parts Part No. 244843 Manifold, Series A, for standard and high conductivity coatings 101 (Ref) Ref. Part No. Description 198220 MANIFOLD 189581 BRACKET, reciprocator 110465 SCREW, set 112689 SCREW, button-hd 112640 SPRING, compression 197518 SCREW; socket-hd; 10-24 x 3/4 in. (19 mm) 111157 FITTING, tube 186845...
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Page 51: Spray Tip Selection Chart
Spray Tip Selection Chart Fan Width at Part No. 10 in. (250 mm) in. (mm) GG3107 2-4 (50-100) GG3207 4-6 (100-150) GG3307 6-8 (150-200) GG3209 4-6 (100-150) GG3309 6-8 (150-200) GG3409 8-10 (200-250) GG3211 4-6 (100-150) GG3311 6-8 (150-200) GG3411 8-10 (200-250) GG3511 10-12 (250-300) -
Page 52: Accessories
Accessories Accessories Gun Accessories Electrode Replacement Kit 244917 Includes five electrodes. Inline Fluid Filters 238561 100 mesh filter. Set of three. 238563 60 mesh filter. Set of three. Round Pattern Kit Provides higher level of performance to electrostatic spraying. 245298 Includes tip of choice. - Page 53 Paint Probe 722860 Use with 722886 Paint Resistance Meter to measure resistance of paint. Not for use in hazardous areas. Safety Warning Signs 180060 English Warning Sign. FM Approved. Avail- able at no charge from Graco. ES Display Module 224117 Receives fiber optic transmission from the PRO Auto Xs gun and displays the gun’s output voltage and current.
- Page 54 Accessories 309298J...
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Page 55: Technical Data
Technical Data Category Maximum Working Fluid Pressure Maximum Working Air Pressure Maximum Fluid Operating Temperature Paint Resistivity Range Short Circuit Current Output Voltage Output Sound Power (measured per ISO Standard 9216) Sound Pressure (measured 1 m from gun) Turbine air inlet fitting, left-hand thread Atomizing air inlet fitting Cylinder air inlet fitting Hi/Lo voltage selector air inlet fittings... -
Page 56: Graco Standard Warranty
Graco Standard Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. 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.