Graco UNICARB 308936 Instructions-Parts List Manual
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Graco UNICARB 308936 Instructions-Parts List Manual

Graco UNICARB 308936 Instructions-Parts List Manual

85 kv electrostatic air-assisted spray gun 100 psi (7 bar, 0.7 mpa) maximum working air pressure 3000 psi (207 bar, 20.7 mpa) maximum working fluid pressure
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INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
85 KV ELECTROSTATIC
Model PRO AA4500t/UNICARBr
Air-Assisted Spray Gun
100 psi (7 bar, 0.7 MPa) Maximum Working Air Pressure
3000 psi (207 bar, 20.7 MPa) Maximum Working Fluid Pressure
For use with Class I, Group D paint spray materials
Part No. 965722, Series B
Spray Gun with basic power supply,
2-finger trigger
NOTE: Any modification of genuine Graco parts or replacement of parts with non-Graco parts will void agency approvals.
U.S. Patent No. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774; 5,063,350; 5,080,289; 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 U.S. and Foreign Patents Pending
UNICARB IS A REGISTERED TRADEMARK OF UNION CARBIDE, DANBURY CT.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
308936
Supersedes Rev. A
First choice when
quality counts.t
Rev. B
01944A

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Summary of Contents for Graco UNICARB 308936

  • Page 1 INSTRUCTIONS-PARTS LIST This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. INSTRUCTIONS 85 KV ELECTROSTATIC Model PRO AA4500t/UNICARBr Air-Assisted Spray Gun 100 psi (7 bar, 0.7 MPa) Maximum Working Air Pressure 3000 psi (207 bar, 20.7 MPa) Maximum Working Fluid Pressure For use with Class I, Group D paint spray materials Part No.
  • Page 2 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. D Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction manual.
  • Page 3 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 a serious injury. D Fluid injected into the skin might look like just a cut, but it is a serious injury.

  • Page 4: Table Of Contents

    Warnings ........Symbols ........Introduction .

  • Page 5: Introduction

    How the PRO AA4500/UNICARB Electrostatic Air-Assisted Spray Gun Operates WARNING Remember, this is not an air spray gun; for your safety be sure to read and follow the Warnings on pages 2 to 3 and throughout the text of this instruction manual.

  • Page 6: Warnings

    Installing 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. D Do not install or service this equip- ment unless you are trained and qualified.

  • Page 7: Fluid Line Accessories

    A* Bleed-type Air Shutoff Valve Air Line Filter Fluid Shutoff Valve Pressure Gauge L* Grounded Braid Type Fluid Hose with spring guards M Gun Fluid Inlet (1/4 npsm) Fig. 1 Fluid Line Accessories (Refer to Fig. 1) 1. Install a fluid filter (S) and drain valve (R) at the pump outlet.

  • Page 8: Ground The System

    Ground the System WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD When operating the electrostatic device, any ungrounded objects in the spray area (such as people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explo- sion, or electric shock.

  • Page 9: Operation

    Operating Checklist Check the following list daily, before starting to operate the system, to help ensure safe, efficient operation. ____ 1. All the operators are properly trained to safely operate an electrostatic air-assisted airless spray system as instructed in this manual.

  • Page 10: Pressure Relief Procedure

    Pressure Relief Procedure WARNING 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 11: Gun Setup

    1. Complete the Operating Checklist and follow the Warnings on pages 9 and 10. 2. Connect the Graco air hose. 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 12 3. Check the gun’s electrical grounding. WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Megohmmeter P/N 218979 (E) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electri- cal grounding unless: D The gun has been removed from the hazardous area;...
  • Page 13 5. Connect the fluid hose. A. Before connecting the fluid line, blow it out with air and flush it with solvent. Use solvent which is com- patible with the fluid to be sprayed. B. Connect the static-free fluid hose (F) to the 1/4–18 npsm gun fluid fitting (10).
  • Page 14 10. Install the pre-orifice WARNING To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 10 when you stop spraying and whenever you are instructed to relieve the pressure. A. Place the spray tip seal (9a) on a flat surface. B.
  • Page 15 12. Set the air pressure A. Atomizing air is not used in the UNICARB process. Close the air control valve (43) by turning it fully clockwise. B. Turn the ES ON-OFF lever (26) to ON. Fig. 12A-B C. Make sure the fluid supply is shut off. D.
  • Page 16 13. Setting the Atomization Fluid Pressure Atomization fluid pressure will vary based on the type of fluid used, the flow rate desired, the fluid tempera- ture, and the percentage of CO used. Follow the recommendations of your material and equipment supplier.

  • Page 17: Daily Gun Care, Flushing, And Cleaning

    Daily Gun Care, Flushing, and Cleaning WARNING INJECTION HAZARD To reduce the risk of serious injury, including fluid injection, splashing in the eyes or on the skin or electric shock, always follow the Pressure Relief Procedure Warning on page 10 when shutting off the system, when you stop spraying and before checking, servicing, installing, cleaning or changing any part in the system.
  • Page 18 Daily Gun Care, Flushing, and Cleaning General System Maintenance 1. Clean the fluid and air line filters daily. 2. Check all of the work hangers for material build-up; clean them if necessary. 3. Check for any fluid leakage from the gun and fluid hoses.
  • Page 19 Daily Gun Care, Flushing, and Cleaning 6. Lock the trigger safety latch and turn off the solvent supply. 7. Follow the Pressure Relief Procedure Warning on page 10. 8. Make sure the trigger safety latch is locked, then disconnect the solvent (F) and air (A) supply hoses from the gun.
  • Page 20 Daily Gun Care, Flushing, and Cleaning 13. Remove the bottom fluid tube fitting (P) and filter (14). Clean the filter in a compatible solvent. 14. Reinstall the filter and fitting. Do not over-tighten and make sure the top fluid tube fitting (Q) remains tightened. Fig.
  • Page 21 Daily Gun Care, Flushing, and Cleaning 19. Place the spray tip (9) in the air cap (1). Align the tab of the tip with the groove in the air cap. Be careful not to bend the electrode wire. WARNING ELECTRIC SHOCK HAZARD To reduce the risk of electric shock or explosion, never operate the spray gun with a bent, damaged or missing elec-...

  • Page 22: Spray Pattern Troubleshooting

    Spray Pattern Troubleshooting Installing and servicing this equipment requires access to parts which 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 23: Gun Operation Troubleshooting

    Gun Operation Troubleshooting PROBLEM Leakage from fluid needle area Air leakage from front of gun Fluid leakage from front of gun “Orange Peel” finish Excessive spray fog No fluid sprays from gun Equipment covered with fluid Paint build-up on air cap Fluid doesn’t shut off properly * Use the least fluid pressure needed for good results.

  • Page 24: Electrical Troubleshooting

    Electrical Troubleshooting NOTE: Additional gun troubleshooting can be done on Gun Part No. 236031 using the Remote Spraying Voltage Read- out (SVRt). See Accessories to order the SVR. PROBLEM Reduced fluid efficiency Operator gets shock Operator gets shock when touching workpiece No or low voltage output reading on gun display module NOTE: If using an ES Display Module, see its instruction manual, No.

  • Page 25: Electrical Tests

    The performance and safety of the spray gun are 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 (18) and the barrel resistor cartridge as well as the continuity of the electrical path between the components.

  • Page 26: Test Power Supply Resistance

    Electrical Tests Test Power Supply Resistance (See Fig. 5) Remove the power supply (18) from the gun. See page Measure the resistance from the power supply’s ground contact point (EE) to the contact inside of the power supply seal (18e) [the conductive rubber contact may be slightly recessed into the seal].

  • Page 27: Test Barrel Resistance

    Test Barrel Resistance (See Fig. 6) Measure the resistance between the barrel contact ring (3a) and the metal contact pin (E), using a metal rod (D) and megohmmeter as shown in Fig. 6. Be careful not to damage or scratch the inner surfaces of the barrel with the metal rod.

  • Page 28: Service

    Prepare the Gun for Service WARNING ELECTRIC SHOCK HAZARD Installing and servicing 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 29: Pre-Orifice, Tip Guard, Air Cap, Spray Tip, Or Seat Housing Replacement

    Pre-Orifice, Tip Guard, Air Cap, Spray Tip, or Seat Housing Replacement 1. Prepare the gun for service as instructed on page 2. Remove the retaining nut (8), tip guard, (2), air cap (1), and spray tip (9). See Fig. 7. You may have to turn the air cap with the tip guard to remove the air cap from the gun.

  • Page 30: Electrode Replacement

    Electrode Replacement WARNING ELECTRIC SHOCK HAZARD To reduce the risk of fire, explosion, or electric shock, do not operate the spray gun without the electrode installed in the air cap. 1. Prepare the gun for service as instructed on page 2.

  • Page 31: Fluid Tube Removal & Replacement

    Fluid Tube Removal & Replacement To remove the fluid tube assembly (12) for cleaning or replacement: 1. Prepare the gun for service as instructed on page 2. Disconnect the bottom fluid tube nut (C). See Fig. 10. 3. Carefully unscrew the top fluid tube nut (D). CAUTION Be careful not to damage the fluid tube assembly (12) when cleaning or installing it, especially the...

  • Page 32: Barrel Removal

    Barrel Removal 1. Prepare the gun for service as instructed on page 2. Disconnect the bottom fluid tube nut (C). See Fig. 12. NOTE: 2-finger trigger guns only It should not be necessary to remove the fluid fitting (10) from the bracket. If you must remove it, remove the two setscrews in the bracket that hold it in place.

  • Page 33: Fluid Packing Adjustment

    Fluid Packing Adjustment If fluid leaks from the fluid needle area, the fluid pack- ings may be loose. Tighten the packings, following the procedure below. 1. Prepare the gun for service as instructed on page 2. Remove the retaining nut (8), tip guard, (2), air cap (1), and spray tip (9).

  • Page 34: Fluid Needle Assembly Removal

    Fluid Needle Assembly Removal 1. Prepare the gun for service as instructed on page 2. Remove the retaining nut (8), tip guard, (2), air cap (1) and spray tip (9). See Fig. 7, page 29. You may have to turn the air cap with the tip guard to remove the air cap from the gun.

  • Page 35: Power Supply Removal And Replacement

    Fig. 16 Power Supply Removal and Replacement NOTES: a. To avoid a loss in electrostatic performance, inspect the gun handle’s power supply cavity for dirt or moisture. Clean the cavity with a clean, dry rag. b. Do not expose the seal (18e) or o-ring (37a) to solvents as it will damage them.

  • Page 36: Turbine Alternator Removal And Replacement

    Turbine Alternator Removal and Replacement NOTE: Replace turbine bearings after 2000 hours of operation. See your authorized Graco representative. 1. Prepare the gun for service as instructed on page 2. Remove the power supply from the gun handle as instructed on page 35. 3.

  • Page 37: Es On-Off Valve Repair

    ES ON-OFF Valve Repair 1. Prepare the gun for service as instructed on page 2. Loosen the set screw (24) with the 2 mm hex key (63), supplied. Remove the lever (26) from the valve. See Fig. 18. WARNING MOVING PARTS HAZARD To reduce the risk of eye injury, be sure to wear safety glasses when removing or installing the retaining ring (47) as the...

  • Page 38: Air Control Valve Repair

    Air Control Valve Repair NOTE: The air control valve (43) can be replaced as an assembly or as individual parts. To disassemble the air control valve, 1. Prepare the gun for service as instructed on page 2. Remove the retaining ring (43h). See Fig. 19. 3.

  • Page 39: Air Valve Repair

    Air Valve Repair 1. Prepare the gun for service as instructed on page 2. Using a screw driver, remove the air valve cap (45). See Fig. 20. 3. Remove the o-ring (23) and spring (44). CAUTION Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits.
  • Page 40 Notes...

  • Page 41: Technical Data

    Category Data Gun Weight 35 oz (1 kg) Gun Length 11.4 in (290 mm) Maximum Air 100 psi (7 bar, 0.7 MPa) Working Pressure Maximum Fluid 3000 psi (207 bar, Working Pressure 20.7 MPa) Sound Pressure { 86 Db(A) Typical Noise Level Sound Power } 88.9 Db(A) at 40 psi (2.8 bar, 0.28 MPa)*...

  • Page 42: Parts

    Item 1 includes item 1a Item 3 includes item 3a Item 18 includes items 18a to 18e Item 37 includes items 37a and 37b Item 43 includes items 43b to 43h Item 45 includes items 45a to 45e Parts REF 12...
  • Page 43 WARNING Some PRO 4500sc Gun replacement parts look similar to other PRO Gun parts but are not interchangeable! When servicing, do not mix or use other PRO Gun parts! Use of parts other than those specified in the parts list below could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction and result in serious injury, fire, explosion or...

  • Page 44: Accessories

    Use Only Genuine Graco Parts and Accessories AIR LINE ACCESSORIES Conductive Air Supply Hose; black 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure FM Approved; Color coded black; 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread 220444 6 ft (1.8 m) 218100...
  • Page 45 Use Only Genuine Graco Parts and Accessories FLUID LINE ACCESSORIES High Pressure Ball Valves 5000 psi (350 bar, 35 MPa) Maximum Working Pressure For turning fluid off or on to the gun and for relieving fluid line pressure at the pump 210657 1/2 npt(m), Vitonr seals 210658...
  • Page 46 Use Only Genuine Graco Parts and Accessories MISCELLANEOUS ACCESSORIES Grounding Clamp and Wire 222011 12 ga, 25 ft (7.6 m) wire Megohmmeter 218979 500 Volt output; 0.01–2000 megohms; Not for use in Hazardous areas Remote Spraying Voltage Readout (SVR (Requires Gun Power Supply change to 224100; see below) For monitoring the gun voltage during operation.

  • Page 47: Spray Tip Selection Chart

    Spray Tip Selection Chart Fan Width at Part No. 10 in. (260 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) GG3609 12–14 (300–350) GG3211 4–6 (100–150) GG3311 6–8 (150–200) GG3411 8–10 (200–250)

  • Page 48: The Graco Warranty And Disclaimers

    The Graco Warranty and Disclaimers WARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workman- ship on the date of sale by an authorized 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 equipment proven defective.

This manual is also suitable for:

Pro aa4500965722UnicarbPro aa4500 unicarb b seriesPro aa4500 unicarb 965722

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