Table of Contents
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Instructions/Parts List
Manual Electrostatic Air-Assisted
PRO
™
Spray Gun
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.
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
3000 psi (21 MPa, 210 bar) Maximum Working Fluid Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See for page 2 Table of Contents and page 3 for List
of Models.
U.S. Patent 7,226,004
Xs4 AA
Standard Model
Smart Model
ti1332b
309295L
ENG
ti1509a
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Table of Contents
Troubleshooting
Related Manuals for Graco PRO 244572
Summary of Contents for Graco PRO 244572
- Page 1 Instructions/Parts List Manual Electrostatic Air-Assisted Xs4 AA ™ Spray Gun 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.
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Page 2: Table Of Contents
Table of Contents List of Models ......3 Warnings ....... . . 4 Warning Symbol . -
Page 3: List Of Models
List of Models Part No. Model 244572, Series C PRO Xs4 AA 244573, Series C PRO Xs4 AA 309295L Description Manual Air-Assisted Spray Gun Manual Air-Assisted Spray Gun with smart display List of Models Operation Manual 309296/3W9296/ 3Z9296 309296/3W9296/ 3Z9296... -
Page 4: Warnings
Warnings Warnings Warning Symbol WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. 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 5 Toxic Fluid Hazard Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin, swallowed, or inhaled. • Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings. •...
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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: Gun Overview
Gun Overview The electrostatic gun includes the following controls. See F . 1. • Air cap/tip guard and spray tip. Never spray with- out the tip guard. See page 46 for spray tip sizes. • Trigger safety lock. Prevents the gun from spray- ing. -
Page 8: Installation
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 9 Fig. 2. Typical Installation Main Air Supply Line Ventilation Fan Interlock Solenoid Valve Main Air Supply Shutoff Valve (bleed-type) Air Line Filter/Water Separator Pump Air Supply Shutoff Valve (bleed-type) Air Line Lubricator Air Pressure Regulator Pump Pump Ground Wire Fluid Filter Fluid Supply Line Shutoff Valve Fluid Pressure Regulator Grounded Fluid Supply Line, with spring guards...
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Page 10: Connect The Air Line
Installation Connect the Air Line 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. Use only Graco Grounded Air Supply Hose. 1. -
Page 11: Connect The Fluid Line
Connect the Fluid Line 1. Before connecting the fluid line (N), blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed. 2. Install a fluid regulator (M) on the fluid line to control fluid pressure to the gun. -
Page 12: Grounding
Installation 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 13: Check Electrical Grounding
Check Electrical Grounding WARNING Fire, Explosion, and Electric Shock Hazard Megohmmeter Part No. 241079 (AA-see . 3.) 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 14: Check Fluid Resistivity
Installation 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, electric shock and result in serious injury and property damage. -
Page 15: Operation
Operation Refer to the gun operation manual (supplied) for Setup, Shutdown, and Daily Care procedures. INSTRUCTIONS Low Voltage Adjustment (Smart Guns Only) The ES HI/LO switch enables you to switch between full voltage and a lower voltage output. The lower voltage is factory set, but can be adjusted. -
Page 16: Maintenance
Maintenance Maintenance Refer to the gun operation manual (supplied) for Daily Care and Cleaning procedures. INSTRUCTIONS Flush the Spray Gun Flush the gun before changing colors, at the end of the day, before storing, and before repairing the gun. WARNING Fire, Explosion, and Electric Shock Hazard To reduce the risk of fire, explosion, or elec-... - Page 17 4. Change the fluid source to solvent, or disconnect the fluid line and connect a solvent supply line to the gun. 5. Point the gun into a grounded metal pail. Flush until clean solvent flows from the gun. 309295L 6. Relieve the pressure. Lock the trigger. 7.
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Page 18: 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 (18) and barrel (16), and electrical continuity between components. CAUTION The barrel resistor cartridge is part of the barrel and is not replaceable. -
Page 19: Test Power Supply Resistance
Test Power Supply Resistance 1. Remove the power supply (18), page 32. 2. Remove the turbine alternator (19) from the power supply, page 33. 3. Measure resistance from the power supply's ground strips (EE) to the spring (18b). See F 4. -
Page 20: Test Barrel Resistance
Electrical Tests 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 (16a). -
Page 21: 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 service this equipment unless you are trained and qualified. -
Page 22: Gun Operation Troubleshooting
Troubleshooting Gun Operation Troubleshooting Problem Excessive spray fog. “Orange Peel” finish. Fluid leaks from the fluid packing area Air leaks from the front of the gun Fluid leakage from the front of the Gun does not spray Dirty air cap Cause Atomizing air pressure too high. -
Page 23: Electrical Troubleshooting
Electrical Troubleshooting Problem Poor wrap. ES indicator or voltage/current dis- play is not lit. Voltage/current display stays red (smart guns only). Operator gets mild shock. Operator gets shock from workpiece. Workpiece not grounded. * ES indicator light is off when the gun is triggered. 309295L Cause ES ON/OFF valve OFF (0).*... -
Page 24: Repair
Repair Repair 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 injection, splashing fluid, or electric shock, follow the Pressure Relief Procedure whenever you: •... -
Page 25: Prepare The Gun For Service
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 26: Tip Guard, Air Cap, Spray Tip, Or Seat Housing Replacement
Repair Tip Guard, Air Cap, Spray Tip, or Seat Housing Replacement 1. Prepare gun for service, page 25. 2. Remove the retaining ring (27), tip guard (4), air cap (9a), and spray tip (3). You may have to turn the air cap with the tip guard to remove it. - Page 27 CAUTION To avoid damaging the seat housing and gun barrel, never over-tighten the seat housing. Over-tightening may result in improper fluid shut-off. 5. Trigger the gun and install the gray-colored seat housing (2). Tighten until snug, then 1/4 turn more. 309295L CAUTION To avoid damaging the tip guard (4), orientate the air...
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Page 28: Electrode Replacement
Repair 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 25. 2. -
Page 29: Fluid Tube Replacement
Fluid Tube Replacement 1. Prepare the gun for service, page 25. 2. Disconnect the bottom fluid tube nut (C). See F 3. Carefully unscrew the top fluid tube nut (D). CAUTION Be careful not to damage the fluid tube assembly (14) when cleaning or installing it, especially the sealing surface (E). -
Page 30: Fluid Needle Replacement
Repair Fluid Needle Replacement 1. Prepare the gun for service, page 25. 2. Remove the air cap assembly and seat housing, page 26. 3. Remove the barrel (16), page 31. 4. Remove the trigger screws (8) and trigger (30). 5. Remove the spring cap (45) and the spring (26a) from the barrel. -
Page 31: Barrel Removal
Barrel Removal 1. Prepare the gun for service, page 25. 2. Carefully loosen the nut (C) from the bracket fluid fit- ting (13). See F . 16. 3. Loosen the three screws (11). CAUTION To avoid damaging the power supply (18), pull the gun barrel straight away from the gun handle. -
Page 32: Power Supply Removal And Replacement
Repair Power Supply Removal and Replacement NOTE: • Inspect the gun handle power supply cavity for dirt or moisture. Clean with a clean, dry rag. • Do not expose gasket (10) to solvents. 1. Prepare gun for service, page 25. 2. -
Page 33: Turbine Alternator Removal And Replacement
Turbine Alternator Removal and Replacement NOTE: Replace turbine bearings after 2000 hours of operation. Order Part No. 223688 Bearing Kit. 1. Prepare gun for service, page 25. 2. Remove the power supply/alternator assembly, page 32. 3. Disconnect the alternator from the power supply, page 32. -
Page 34: Atomizing Air Adjustment Valve Repair
Repair Atomizing Air Adjustment Valve Repair 1. Prepare the gun for service, page 25. 2. Place a wrench on the flats of the valve assembly (20) and unscrew it from the handle (17). NOTE: You may replace the valve as an assembly (go to step 9) or as individual parts (steps 3-9). -
Page 35: Air Valve Repair
Air Valve Repair 1. Prepare the gun for service, page 25. 2. Remove the barrel, page 31. 3. Remove the air valve cap (25) from the handle (17). Remove the spring (15). See F CAUTION Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. -
Page 36: Es On/Off Valve Repair
Repair ES ON/OFF Valve Repair 1. Prepare the gun for service, page 25. 2. Loosen the screw (48). Remove the valve. 3. Lubricate the o-rings (22a* and 22b*) with non-sili- cone grease, Part No. 111265. Do not over-lubri- cate. CAUTION Do not over-lubricate parts. -
Page 37: Parts
Parts Part No. 244572 85 kV Electrostatic Gun, Series C (items 1-50) ti1366a *18a 27a* 309295L See page 38 for detail views of the alternator (19), atomizing air adjustment valve (20), and ES ON/OFF valve (22). 14 (Ref) 19a* 21*** 24a* ti1511C Parts... - Page 38 Parts Ref. No. 19: Alternator Ref. No. 20: Atomizing Air Adjustment Valve 19a* TI1487A 20b* TI1481a Ref. No. 22: ES ON/OFF Valve 22b* 22a* TI1488A 309295L...
- Page 39 Part No. 244572 85 kV Electrostatic Gun, Series C (items 1-50) Ref. Part No. Description 205264 FILTER, fluid, inline 245280 HOUSING, seat GG3XXX SPRAY TIP (customer’s choice); includes item 3a 183459 . SEAL, spray tip 276767 TIP GUARD 188749 PACKING, u-cup, air valve; UHMWPE 197369 SCREW, trigger...
- Page 40 Parts Ref. Part No. Description 244915 COVER, gun; box of 10 (not shown) 179791 TAG, warning (not shown); replacement available at no cost 180060 SIGN, warning (not shown); replacement available at no cost 112080 TOOL, needle; 2 mm 198516 CAP, spring 197967 PLUG Ref.
- Page 41 Part No. 244573 85 kV Electrostatic Gun, Series C (items 1-59) 53 (Ref) 51 (Ref) ti1253a *18a 27a* 309295L See page 42 for detail views of the alternator (19), atomizing air adjustment valve (20), and ES ON/OFF valve (22). 19a* 14 (Ref) 21*** 24a*...
- Page 42 Parts Ref. No. 19: Alternator Ref. No. 22: ES ON/OFF Valve 22b* 22a* TI1488A Part No. 244573 85 kV Electrostatic Gun, Series C (items 1-59) Ref. Part No. Description 205264 FILTER, fluid, inline 245280 HOUSING, seat GG3XXX SPRAY TIP (customer’s choice); includes item 3a 183459 .
- Page 43 Ref. Part No. Description 244541 POWER SUPPLY, 85 kV; includes items 18a-18b 18a* 103337 . O-RING; fluoroelastomer 197624 . SPRING, compression 244555 TURBINE, alternator; includes items 19a-19e 19a* 110073 . O-RING; fluoroelastomer 223688 . BEARING KIT; includes front and rear bearings and fan 244577 .
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Page 44: Accessories
Accessories Accessories Air Line Accessories ™ AirFlex Flexible Grounded Air Hose 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 thread 244963 6 ft (1.8 m) 244964 15 ft (4.6 m) 244965 25 ft (7.6 m) 244966... -
Page 45: Gun Accessories
Gun Accessories Gun Repair Kit 244781 Air Seal Repair Kit 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. -
Page 46: Spray Tip Selection Chart
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... -
Page 47: Technical Data
Technical Data Category Maximum Working Fluid Pressure Maximum Working Air Pressure Minimum Air Pressure to Gun Inlet 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) Air inlet fitting, left-hand thread Fluid inlet fitting Gun Weight... -
Page 48: 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.