Graco PRO 309292S Instructions Manual
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Graco PRO 309292S Instructions Manual

Graco PRO 309292S Instructions Manual

Manual electrostatic air spray guns 100 psi (0.7 mpa, 7 bar) maximum air inlet pressure 100 psi (0.7 mpa, 7 bar) maximum working fluid pressure
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Instructions
Manual Electrostatic
PRO
™
Air Spray Guns
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 0.24 mJ
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 and page 3 for
List of Models.
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure
U.S. Patent 7,226,004
Standard Model
Xs3 and PRO
Xs4
™
Smart Model
ti1248a
309292S
ENG
ti1600a

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  • Page 1 Instructions Manual Electrostatic Xs3 and PRO ™ Air Spray Guns 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 0.24 mJ For Professional Use ONLY.

  • 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 244400, PRO Xs3 Series D 244579, PRO Xs3 Series D (1.5 mm nozzle) 24A511, PRO Xs3 Series B (1.2 mm nozzle) 244575, PRO Xs3 Series D 244576, PRO Xs3 Series D 244401, PRO Xs4 Series D 244580, PRO Xs4...

  • 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 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. •...

  • Page 6: Introduction

    Introduction Introduction How the Electrostatic Air Spray Gun Works The air hose supplies air to the spray gun. Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed. The turbine generates power, which is converted by the power cartridge to supply high volt- age current to the gun’s electrode.

  • Page 7: 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 8 Installation Fig. 2. Typical Installation Main Air Supply Line Ventilation Fan Interlock Solenoid Valve Main Air Supply Shutoff Valve (bleed-type) Pump 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...

  • Page 9: Connect The Air Line

    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. Connect the Graco Grounded Air Supply Hose (R) between the air supply line and the gun's air inlet (V).

  • Page 10: Select A Fluid Nozzle And Air Cap

    Installation Select a Fluid Nozzle and Air The gun is supplied with Part No. 197266 Nozzle and 24A376 Air Cap. If you require a different size, refer to Table 1 and Table 2 , and instruction manual 309419, or consult with your Graco distributor. See Air Cap/Nozzle Replacement on page 26.
  • Page 11 4. Remove the fluid tube and fittings. 5. Remove the fluid inlet bracket. 6. Install the new bracket (3) from the kit loosely. See . 3. 7. Place the spacer (5) in the barrel inlet. Apply Graco dielectric grease (4) to the o-rings (2a, 2b) and to both threads of the fluid fitting (2).

  • 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 . 4.) 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: •The gun has been removed from the haz- ardous area;...

  • 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, or electric shock and result in serious injury and property damage.

  • Page 15: Operation

    Operation 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. 1. Set the ES HI/LO switch to LO. 2.

  • Page 16: Maintenance

    Maintenance Maintenance 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- tric shock, turn the ES ON/OFF valve OFF before flushing the gun.
  • Page 17 7. Hang the gun from its hook, with the nozzle pointing down. 309292S 8. When ready to spray again, reconnect the fluid sup- ply line. Follow the Setup procedure in the Opera- tion Manual. ti1288a Maintenance...

  • 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 electrode (29), and electri- cal continuity between components. Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V.

  • Page 19: Test Power Supply Resistance

    Test Power Supply Resistance 1. Remove the power supply (18), page 30. 2. Remove the turbine alternator (19) from the power supply, page 31. 3. Measure resistance from the power supply's ground strips (EE) to the spring (18b). See F 4.

  • Page 20: Test Electrode Resistance

    Electrical Tests Test Electrode 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 electrode (29).

  • 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 repair 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. 309292S Cause ES ON/OFF valve OFF (0).*...

  • Page 24: Repair

    Repair Repair Pressure Relief Procedure WARNING Pressurized Equipment Hazard The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. To reduce the risk of an injury from electric shock, accidental spray from the gun, splashing fluid, or mov- ing parts, follow the Pressure Relief Pro- cedure whenever you: •are instructed to relieve the pressure...

  • 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 service this equipment unless you are trained and qualified.

  • Page 26: Air Cap/Nozzle Replacement

    Repair Air Cap/Nozzle Replacement CAUTION Hold the front end of the gun up and trigger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from entering the air passages. 1.

  • Page 27: Electrode Replacement

    Electrode Replacement 1. Prepare the gun for service, page 25. 2. Remove the air cap and nozzle, page 26. 3. Unscrew the electrode (29) with the multi-tool (37). Hold the packing rod end (26h) to prevent it from turning, F .

  • Page 28: Fluid Packing Removal

    Repair Fluid Packing Removal 1. Prepare the gun for service, page 25. 2. Remove the air cap and fluid nozzle, page 26. 3. Remove the electrode, page 27. 4. Loosen the trigger screws (8) and trigger (30). See . 13.. 5.

  • Page 29: Packing Rod Repair

    Packing Rod Repair You may replace the packing rod as individual parts or as an assembly. The assembly is pre-adjusted at the factory. Before installing the fluid packing rod into the gun barrel, make sure the internal surfaces of the barrel are clean. Remove any residue with a soft brush or cloth.

  • Page 30: Barrel Removal

    Repair Barrel Removal 1. Prepare the gun for service, page 25. 2. Carefully loosen the nut (32 or 50d) from the bracket fluid fitting (13). Pull the tube (14 or 50a) out of the fitting. Make sure both ferrules and the nut stay with the tube.

  • Page 31: Power Supply Removal And Replacement

    Power Supply Removal and Replacement • 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. Remove the barrel (16), page 30. CAUTION Be careful when handling the power supply (18) to avoid damaging it.

  • Page 32: Turbine Alternator Removal And Replacement

    Repair 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 25. 2. Remove the power supply/alternator assembly, page 31. 3. Disconnect the alternator from the power supply, page 31.

  • Page 33: Fan Air Adjustment Valve Repair

    Fan 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). You may replace the valve as an assembly (go to step 9) or as individual parts (steps 3-9).

  • Page 34: Fluid Adjustment Valve Repair

    Repair Fluid Adjustment Valve Repair 1. Prepare the gun for service, page 25. 2. Remove the fluid adjustment valve (25). It can only be replaced as a complete assembly. See F 3. Screw the valve (25) into the gun handle. Torque to 15-25 in-lb (1.7-2.8 N•m).

  • Page 35: Atomizing Air Restrictor Valve Removal And Replacement

    Atomizing Air Restrictor Valve Removal and Replacement 1. Prepare the gun for service, page 25. 2. Remove the atomizing air restrictor valve (23). Inspect the o-ring (23c*). Replace if necessary. See . 22.. 3. Install a new atomizing air restrictor valve (23), or disassemble and replace parts individually.

  • Page 36: Parts

    Parts Parts Part No. 244400 60 kV Electrostatic Gun, Series C (items 1-48, 55) Part No. 244575 60 kV Electrostatic Gun, Series C (items 4-30, 35-55) Part No. 244401 85 kV Electrostatic Gun, Series C (items 1-48, 55) ti1266a *18a 25 (Ref) 27a* See page 37 for detail views of the fluid tube assemblies, alternator...
  • Page 37 Ref. No. 19: Alternator Ref. No. 22: ES ON/OFF Valve 22b* 22a* TI1488A Fluid Tube: Model 244400 31** ti1492a 309292S Ref. No. 20: Fan Adjustment Valve 19a* TI1481a Ref. No. 26: Packing Rod 26c** 26a** Fluid Tube: Model 244575 20b* 26b** 26g** 26d**...
  • Page 38 Parts Part No. 244400 60 kV Electrostatic Gun, Series C (items 1-48, 55) Part No. 244575 60 kV Electrostatic Gun, Series C (items 4-30, 35-55) Part No. 244401 85 kV Electrostatic Gun, Series C (items 1-48, 55) Ref. Part No. Description 110078 FITTING, tube, fluid;...
  • Page 39 Ref. Part No. Description 244559 VALVE, air, atomizing; includes 23a-23d 197594 . HOUSING, valve 197591 . SHAFT 23c* 111504 . O-RING; fluoroelastomer 101021 . RING, retaining 249323 VALVE, exhaust; includes 24a 24a* 112085 . O-RING; fluorocarbon 244593 VALVE, adjustment, fluid 244597 ROD, packing;...
  • Page 40 Parts Part Nos. 244579 and 24A511 60 kV Electrostatic Gun, Series C (items 1-48, 51-59) Part No. 244576 60 kV Electrostatic Gun, Series C (items 1-30, 35-59) Part No. 244580 85 kV Electrostatic Gun, Series C (items 1-48, 51-59) 53 (Ref) 51 (Ref) ti1253a *18a...
  • Page 41 Ref. No. 19: Alternator Ref. No. 22: ES ON/OFF Valve 22b* 22a* TI1488A Fluid Tube: Model 244579 31** ti1492a 309292S Ref. No. 20: Fan Adjustment Valve 19a* TI1481a Ref. No. 26: Packing Rod 26c** 26a** Fluid Tube: Model 244576 20b* 26b** 26g** 26d**...
  • Page 42 Parts Part No. 244579 and 24A511 60 kV Electrostatic Gun, Series C (items 1-48, 51-59) Part No. 244576 60 kV Electrostatic Gun, Series C (items 1-30, 35-59) Part No. 244580 85 kV Electrostatic Gun, Series C (items 1-48, 51-59) Ref. Part No.
  • Page 43 Ref. Part No. Description 26d** 178763 . PACKING, rod; acetal 197641 . NUT, packing 185495 . HOUSING, packing 26g** 186069 . SPACER, packing; acetal 244695 . ROD, packing; used on 244579 and 244576 244696 . ROD, packing; used on 244580 244927 RING, retaining, air cap;...

  • 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 Kits 244781 Air Seal Repair Kit 244911 Fluid Seal Repair Kit Round Pattern Kits Consists of fluid tip, diffuser and air cap. 245217 4-6 in. (102-152 mm) diameter 245219 8-10 in. (203-254 mm) diameter Adjustable Round Pattern Kit 277851 Slow velocity, bell shaped spray pattern for excellent transfer efficiency.

  • Page 46: Technical Data

    Technical Data Technical Data Category Maximum Working Fluid Pressure Maximum Working Air Pressure Minimum Air Pressure at 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 47 Technical Data 309292S...

  • 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.

This manual is also suitable for:

Pro ti1248aPro ti1600aPro xs3Pro xs4244400244579 ... Show all

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