Graco Inc. Xs4 AA manual

For use in Class I, Div . I hazar dous locations usi ng Gr oup D spray materials. For use in Gr oup II, Zone 1 areas using Group IIA spra y materials. For Prof essional Use ONL Y . 100 psi (0.7 MP a, 7 bar ) Maximum Air Inlet Pressur e 3000 psi (21 MP a, 210 ba r) Maximum W orking Fluid Pressure U .S. P atent 7,226,004 Impor tant Safety Instruction[...]

2 309295L T able of Contents List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 W ar ning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 4 Caution Symb ol . . . . . . . . . . . . . . . . . . . . . . . . . . 4 W arning . . . . . . . . . . [...]

List of Models 309295L 3 List of Models P art No. Model Description Operation Manual 244572, Series C PRO Xs4 AA Manual Air-Assist ed Spra y Gun 309296/3W9296/ 3Z9296 244573, Series C PRO Xs4 AA Manual Air-Assist ed Spra y Gun with smart displa y 309296/3W9296/ 3Z9296[...]

Warnings 4 309295L Wa r n i n g s W arning Symbol This symbol aler ts you to t he possibility of ser ious injur y or death if y ou do not f o llow the inst ructions. Caution Symbol This symbol aler ts you to t he possibility of damage to or destruction of equipment if y ou do not follo w the instruc- tions. WARNING CAUTION WA R N I N G Fire, Explos[...]

Warning 309295L 5 T o xic Fluid Hazar d Hazardous fluids or to xic fumes can cause a serious injur y or death if splashed in the ey es or on the skin, s wallowed, or inhaled. • Know the sp ecific hazards of t he fluid yo u are using. Read the fluid man uf acturer’ s warnings. • Store hazard ous fluid in an appro v ed container . Dispose of th[...]

Introductio n 6 309295L Intr oduction How the Electr ostatic AA Spra y Gun W orks The air-assisted spra y gun combines airless and air spra ying concepts. The spra y tip shapes the fluid into a f an pattern, as does a con v entional airless spra y tip. Air from the air cap fur ther atomizes the f luid and co mpletes the atomiza tion of th e fluid t[...]

Introduction 309295L 7 Gun Overview The electrostatic gun includ es the fo llowing controls . See F IG . 1. • Air cap/tip guard and sp ray tip. Nev er spra y with- out the tip guar d. See page 46 f or spra y tip sizes . • T rigge r safety lock. Pre vents the gu n from spray- ing. • Atomizing AIR adjustment valve. Adjusts atomiz- ing air . •[...]

Installation 8 309295L Installation Install the System F IG . 2. show s a typical electr ostatic air-assisted spra y system. It is no t an actu al s ystem design. For assistance in designing a system to suit y our par ticular needs , con- tact y our Graco distribut or . W arning Sign Mount warning signs in the spr a y area where the y can easily be[...]

Installation 309295L 9 Fig. 2. Typica l Installatio n Key ti1514b AB * C* D *E F G H J* K L M N O P Q* *R S T U* V W C Non-Hazar dous Area Hazar dous Area D X The air supply to the gun must be electrically interlocked with the v entilators to prev ent the power supply from operating wit hout ventilating f ans on. A Main Air Supply Line B* V entilat[...]

Installation 10 309295L Connect the Air Line 1. Connect the G raco Ground ed Air Supply Hose (R) between the air supply line and th e gun's a ir inlet (V). The gun a ir inlet fitting has a left-h and thread . Connect the air supply hose g round wire (Q) to a true ear th ground . 2. Install an air line filter/water separator (D) on the air line[...]

Installation 309295L 11 Connect the Fluid Line 1. Bef ore connecting the fluid line (N), b low it out with air and flush it with solvent. Use solv ent which is compatible with the fluid to be spray ed . 2. Install a fluid regulator (M ) on the fluid line to cont rol fluid pressure to t he gun. 3. Install a dr ain v alve ( U) near the pump outlet . [...]

Installation 12 309295L Gr ounding The follo wing are m inimum grounding requirements for a basic elect rostatic sys tem. Y our system may include other equipment or objects which must be g rounded. Check yo ur local electric al code for detailed groundin g instru ctions. Y our system must be connected to a true ear th ground . • Pump: ground t h[...]

Installation 309295L 13 Chec k Electrical Gr ounding 1. Hav e a qualified e lectr ician check the electr ical groundin g continuity of the spr a y gun and air hose. 2. T urn the ES ON/OFF valv e OFF . 3. T ur n off the air and flui d supply to the gun. The flu id hose must no t hav e any fluid in it. 4. Mak e sure the g rounded air hose (R ) is con[...]

Installation 14 309295L Chec k Fluid Resistivity Graco P ar t No. 7228 86 Resistance Meter and 72286 0 Probe are a v ailab le as accessories to chec k that the resistivity of the fluid b eing spra yed meets the require- ments of an electrostatic air-assist ed spra y system. F ollow the instruc tions in cluded with the meter and probe . Readings of [...]

Operation 309295L 15 Operation Low V oltage Adjustment (Smar t Guns Only) The ES HI/LO s w itch enab les you to switch be tween full v oltage and a low er v oltage output. The lo wer v oltage is f actory set, but can be adjusted . 1. Set the ES HI/LO s witch to LO. 2. Remov e the LOW V OL T AGE adjustment plu g (53). Set the desired v oltage , usin[...]

Maintenance 16 309295L Maintenance Flush the Spra y Gun Flush the gun bef ore changing colors , at the end of the da y , bef ore storing, and before repairing the gun. 1. T ur n th e ES ON/OFF valv e OFF . 2. Relie ve the pressure . 3. Remo ve and clean the air cap and the spra y tip. Continued o n page 17. INSTRUCTIONS Ref er to the gun oper ation[...]

Maintenance 309295L 17 4. Change the flu id source to solv ent, or disconnect the fluid line an d connect a solv ent supply line to the gun. 5. P oint the gun into a grounded met al pail. Flush until clean solv ent flo ws from the gun. 6. Relie ve the pressure . Loc k the trigger . 7. Shut off or disconnect the solv ent line. 8. Hang the gu n from [...]

Electrical Tests 18 309295L Electrical T ests Electrical components inside the gun aff ect perf ormance and safety . The f ollowing procedures test the co ndition of the pow er supply (18) and ba rrel (16), and electrical continuit y between co mponents . Use megohmmeter P ar t No. 24 1079 (AA) with an applied v oltage of 500 V . Connect the leads [...]

Electrical Tests 309295L 19 T est P o wer Supply Resistance 1. Remo ve the pow er supply (18) , page 32. 2. Remo ve the turbine alternator (19) fr om the pow er supply , page 33. 3. Measure re sistance from the po wer supply's g round strips (EE) to the spring (18b). See F IG . 6. 4. The resi stance should be 13 5-150 megohms . If out- side th[...]

Electrical Tests 20 309295L T est Barrel Resistance 1. Insert a conductive rod (B) into the gun barrel (remo ved f or the pow er supply test) and ag ainst the metal conta ct (C) in t he front of the barre l. 2. Measure the resistance betwe en the conductiv e rod (B) and the ba rrel contact ring (16a). See F IG . 7. The resistance should be 19-29 me[...]

Troubleshooting 309295L 21 T r oubleshooting NO TE: Chec k all possible remedie s in the T roubleshoo t- ing Char t be f ore disasse mbling the gun. Spra y P attern T r oubleshooting NO TE: Some spra y pattern problems are caused b y the improper balance between air and fluid. WA R N I N G Electric Shock Hazar d Installing and ser vic ing this equi[...]

Troubleshooting 22 309295L Gun Operation T r oubleshooting Prob lem Cause Solution Excessiv e spra y f og. Atomizing air pressure too high. Close atomizing air v alv e some, or decrease air p ressure as low as pos- sible; minimum 40 psi (0.28 M P a, 2.8 bar) needed at gun f or full volt age. Fluid too thin. Increase viscosity . “Orange P eel” f[...]

Troubleshooting 309295L 23 Electrical T r oubleshooting * ES indicator light is off when the gun is triggered. Prob lem Cause Solution P oor wrap . ES ON/OFF v alve OFF (0 ).* T ur n ON (I). Gun air pressu re too low . Chec k air pressure to gu n; minimum 40 psi (0.28 MP a, 2.8 bar) needed at gun f or full v oltage. Atomizing air pressure too hig h[...]

Repair 24 309295L Repair Pressure Relief Pr ocedure 1. T urn the ES ON/OFF valv e OFF . 2. Lock the trigge r . 3. T ur n off the air b leed v alv es to the fluid source and to the gun. 4. Unloc k the trigger . 5. T rigger the gun into a grounded met al waste con- tainer to r elie ve the fluid pres sure. 6. Loc k the trigger . 7. Open the pump drain[...]

Repair 309295L 25 Prepare the Gun f or Service NO TE: • Check all possib le remedies in T roub leshooting before disassembling the gun. • Use a vise with padde d jaws to pre vent damage to plastic par ts. • Lubricate the po wer su pply o-ring (18a) and the plastic end of the flui d tube (14) with dielectric greas e (4 0) . • Lightly lubrica[...]

Repair 26 309295L Tip Guar d, Air Cap, Spra y Tip, or Seat Housing Replacement 1. Prepare g un f or service, page 25. 2. Remove the re taining r ing (27 ), tip guar d (4), air ca p (9a), and spra y tip (3). Y ou may hav e to tur n th e air cap with the tip guard to remov e it. See F IG . 8. 3. Replace the t ip gask et (3a) if damaged . Fig. 8. Tip [...]

Repair 309295L 27 5. T r igger the gun an d install the gr ay -colored seat housing (2). Tight en until snug, then 1/4 turn more. 6. Assemb le the spra y tip (3), air cap (9a), and tip guard (4). Mak e sure the electrode (9b) is not dam- aged or missing. In stall the air cap assemb ly with the retainin g ri ng (27). Th e u-cup (27a) lips must fa c [...]

Repair 28 309295L Electr ode Replacement 1. Prepare the gun f or service, page 25. 2. Remove the air cap as sembly , page 26. 3. Pull the el ectrode (9b) out of the bac k of the air cap , using a needle-nose pliers . 4. Push the new electr ode throug h the air ca p hole. Mak e sure the short end (BB) of the electro de engages the hole (CC) in t he [...]

Repair 309295L 29 Fluid T ube Replacement 1. Prepare the gu n f or ser vice, page 25. 2. Disconnect t he bottom fluid tube nut (C). See F IG . 11. 3. Carefully unscre w the top fl uid tube nut (D). 4. Apply dielectric grease (40) to the entire length of the plastic e xtension on the end of the fluid tub e (14). 5. Apply low strength thread seal ant[...]

Repair 30 309295L Fluid Needle Replacement 1. Prepare the gun f or service, page 25. 2. Remo ve the air cap assembly an d seat housing, page 26. 3. Remo ve the barrel (16), page 31 . 4. Remove the tr igger screws (8) and tr igger (30) . 5. Remo ve the spring cap (45) and the sp ring (26a) from the barr el. See F IG . 13. 6. Place the 2 mm dr iver ([...]

Repair 309295L 31 Barrel Remo v al 1. Prepare the gu n f or ser vice, page 25. 2. Carefully loose n the nut (C) from the bracket fluid fit- ting (13). S ee F IG . 16. 3. Loosen the th ree scre ws (11). 4. Hold the gu n handle (17) with one hand a nd pull the barrel (16) st raight off the handle. Fig. 16. Barrel Removal Barrel Installation 1. Be sur[...]

Repair 32 309295L P ower Suppl y Remo val and Replacement NO TE: • Inspect the gun ha ndle pow er supply ca vity f or dir t or moisture. Clean w ith a clean , dr y rag. • Do not e xpose gasket (10) to solve nts. 1. Prepare g un f or service, page 25. 2. Remo ve the barrel (16), page 31 . 3. Gr asp the pow er supply (18) with y our hand. With a [...]

Repair 309295L 33 T urbine Alternator Remo v al and Replacement NO TE: Replace turb ine bear ings a fter 2000 hours of operat ion. Order P ar t No . 223688 Bearing Kit. 1. Prepare gun f or ser vice, page 25. 2. Remo ve the powe r supply/alternator assemb ly , page 32. 3. Disconnect t he alternator from the pow er supply , page 32. 4. Measure re sis[...]

Repair 34 309295L Atomizing Air Adjustment Va l v e R e p a i r 1. Prepare the gun f or service, page 25. 2. Place a wrench on the fla ts of the v alv e assembly (20) and unscre w it from the handle ( 17). NO TE: Y ou ma y replace the v alve a s an assemb ly (go to step 9) or as individual pa r ts (steps 3-9) . 3. Remov e the retainin g ring (20 a)[...]

Repair 309295L 35 Air V alve Repair 1. Prepare the gu n f or ser vice, page 25. 2. Remo ve the barrel, page 31. 3. Remo ve the air v alve cap (25) from the h andle (17). Remov e the spring (15). See F IG . 20. 4. Remove the air valv e (21) with a pliers. Inspect the the rubber sealing su rf ace and replace the air v alv e if damaged. 5. Inspect th [...]

Repair 36 309295L ES ON/OFF V alve Repair 1. Prepare the gun f or service, page 25. 2. Loosen th e screw (48) . Remov e the v alv e. 3. Lubricate the o-r ings (2 2a* and 22b*) with non-sili- cone grease, P ar t No . 111265. Do not ov er-lubr i- cate. 4. Clean and inspect parts for damage. Re place if nec- essar y . NO TE: The prot rusion on the ret[...]

Parts 309295L 37 Pa r t s P art No. 244572 85 kV El ectrostatic Gun, Series C (items 1-50) I O ES ti1366a 4 9a 26 16 11 18 19 *10 17 28 20 22 25 15 21*** 35 13 24 38 8 *6 9b 11 *18a 18b 24a* 30 39 47 See page 38 f or detail vie w s of the altern ator (19), atomizing air adjustm ent valve (20), an d ES ON/OF F valve (22). 26a 14 14 (Ref) 3 2 55 45 1[...]

Parts 38 309295L TI1487A 20a 20b* 20c 20d Ref. No. 22: ES ON/OFF V alve Ref. No. 20: Atomizing Air Adjustment V a lve Ref. No. 19: Alternator TI1481a 19a* 19b 19b 19c 19d 19e TI1488A 22a* 22b* 22c 22d 22e 22f 22g 48[...]

Parts 309295L 39 P art No. 244572 85 kV El ectrostatic Gun, Series C (items 1-50) Ref. No. P art No. Description Qty 1 205264 FIL TER, fluid, inline 1 2 245280 HOUSING, seat 1 3 GG3XXX SPRA Y TIP (customer’ s choice); includes item 3a 1 3a 183459 . SEAL, spra y tip 1 4 276767 TIP GU ARD 1 6* 188749 P A CKING, u-cup , air va lve; UHMWPE 1 8 197369[...]

Parts 40 309295L * Included in Air Seal Repair Kit 244781. *** Rubber seal is not r emov abl e. Replacement W ar ning labels, signs, ta gs, and car ds are ava il a bl e at no c os t . 41 244915 CO VER, gun; box of 10 (not shown) 1 42 179791 T A G, warning (not shown); replacement av ailable at no cost 1 43 180060 SIGN, warning (not shown); replacem[...]

Parts 309295L 41 P art No. 244573 85 kV El ectrostatic Gun, Series C (items 1-59) ti1253a 100 % KV μα 0 HI LO ES I O I O ES 20 See page 42 f or detail vie ws of the alternato r (19), atomizing air adjustment valve (20), and ES ON/OFF valve (22). 22 53 (Ref) 51 (Ref) 27 4 9a 26 16 11 18 19 *10 17 28 25 15 21*** 35 13 24 38 8 *6 9b 11 *18a 18b 24a*[...]

Parts 42 309295L P art No. 244573 85 kV Electr ostatic Gun, Series C (items 1-59) TI1488A TI1487A TI1481a 20a 20b* 20c 20d Ref. No. 20: Atomizing Air Adjustment V a lve Ref. No. 19: Alternator Ref. No. 22: ES ON/OFF V alve 19a* 19b 19b 19c 19d 19e 22a* 22b* 22c 22d 22e 22f 22g 48 Ref. No. P art No. Description Qty 1 205264 FIL TER, fluid, inline 1 [...]

Parts 309295L 43 * Included in Air Seal Repair Kit 244781. *** Rubber seal is no t remov able. Replacement W ar ning labels , signs, tag s, and car ds are ava il a bl e at no c os t . 18 244541 POW ER SUPPL Y , 85 kV ; includes items 18a-18b 1 18a* 10333 7 . O-RING; fluoroelastomer 1 18b 197624 . SPRING, co mpression 1 19 244555 TURBINE, alter nato[...]

Accessories 44 309295L Accessories Air Line Accessories AirFlex ™ Flexib le Gr ounded Air Hose 100 psi (7 bar , 0.7 MP a) Maxim um W orking 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 36 ft (1 1 m) 244967 50 ft (1 5 m) 244968 75 ft (2 3 m) 244969 10[...]

Accessories 309295L 45 Gun Accessories Gun Repair Kit 244781 Air Seal Repair Kit Electr ode Replacement Kit 244917 Includes fiv e electrodes. Inline Fluid Filters 238561 100 mesh filter . Set of three. 238563 60 mesh filter . Set of thre e. Round P attern Kit Provides high er le vel of per fo r mance to electrostatic spra ying. 245282 Includes tip [...]

Spray Tip Selection Char t 46 309295L Spra y Tip Selection Char t Pa r t N o . Fan Width at 10 in. (250 mm) in. (mm) Orifice Siz e in. (mm) GG3107 2-4 (50-100) 0.007 (0.1 78) GG3207 4-6 (100-150) GG3307 6-8 (150-200) GG3209 4-6 (100-150) 0.009 (0.229) GG3309 6-8 (150-200) GG3409 8-10 (200 -250) GG3211 4-6 (100-150) 0.011 (0.279) GG3311 6-8 (150-200[...]

Technical Data 309295L 47 T echnical Data Loctite® is a registered t rademark of the Loctit e Cor poration. Category Data Maximum W or king Fluid Pressure 3000 psi (21 MP a, 210 bar) Maximum Working Air P ressure 100 psi (0 .7 MP a, 7 ba r) Minimum Air Pressur e to Gun Inlet 40 psi (0.2 8 MP a, 2.8 bar) Maximum Fluid Op erating T emperature 120°F[...]

All written and visual data contained in this document reflects the latest product information available at the time of publica tion. Graco reserves the right to make changes a t any time without notice. This manual contains English. MM 309295 Graco Headquarters: Minneapo lis International Offices: Belgium, China, Japan, Korea GRACO INC. P.O. BOX 1[...]