Graco 244592 manual

Instructions/P ar ts List A UT OMA TIC ELECTROST A TIC A IR-ASSISTED SPRA Y GUN PR O ™ A uto Xs AA TI1713A 309298J ENG P ar t No. 244592, Series A 100 psi (0.7 M P a, 7 bar) Maximum Air Inlet Pressure 3000 psi (21 MP a, 210 bar) Maximu m Working Fluid Pressure For use in Class I, Di v . I hazardous locations using Gr oup D spray materials. For us[...]

2 309298J T able of Contents Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 W ar ning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 3 Caution Symb ol . . . . . . . . . . . . . . . . . . . . . . . . . . 3 W arning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . [...]

Symbols 309298J 3 Symbols W arning Symbol This symbol aler ts you to t he possibility of serious injur y or death if y ou do not f ollow the instructions. Caution Symbol This symbol aler ts you to t he possibility of damage to or destruction of equipmen t if you do not f ollow the instruc- tions . WARNING CAUTION WA R N I N G Fire, Explosion, and E[...]

Warning 4 309298J W ARNING Skin Injection Hazard Spra y from the gun, hose leaks , or ruptured components can inject f luid into your body a nd cause an e xtremely serious injur y , including the need f or amputation. Splashing fluid in the e yes or on the skin can also cause ser ious injury . • Fluid injected into the skin mig ht look like just [...]

Warning 309298J 5 W ARNING Equipment Misuse Hazard Equipment misu se can cause the equipment to rupture , malfunction, or start unexp ectedly and result in a serious injur y . • This equipment is f or professio nal use only . • Read all manuals , tags, and labels bef ore operating the equ ipment. • Use the equipment only f or its intended pur[...]

Introductio n 6 309298J 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 patter n, as does a conv entional airless spra y tip. Air from the air cap fur ther atomizes the fluid and completes the atomiza tion of the fluid tail[...]

Introduction 309298J 7 Changing the kV Setting The gun’ s full voltage setting is 85 kV . Three lo wer vo lt- age setting s are possible b y actuating the KV1 and KV2 s witches. Supply 50 psi ( 0.35 MP a, 3.5 bar) air pressure to the KV1 and KV2 ports. T ur n the air on or off as shown in T able 1 to set th e desired voltage . The solenoid valv e[...]

Introductio n 8 309298J Fig. 1. Gun Overview Key TI1739A TI1714A TI1713A Manif old Back Vie w C B D E F G H J K A2 CYL EXH FO KV2 P1 TA KV1 A A Air Cap BS p r a y T i p C Tip Guard D Retaining Ring E Shroud F Mounting Bra ck et G Manif old H T urbine J P ower Supply KE l e c t r o d e Manif old Markings A1 not used A2 Atomization Air Inlet Fitting [...]

Installation 309298J 9 Installation Install the System F IG . 2. show s a typical electr ostatic air-assisted spray system, and F IG . 3. shows possible system options. It is not an actual system design. F or assistance in design- ing a system to suit y our par ticular need s, contact y our Graco distrib utor . W arning Signs Mount w ar ning signs [...]

Installation 10 309298J Fig. 2. Typica l Installation Fig. 3. Optional Fiber Optic Connection TI1741A A BC E F J K M N G NO TE: * The turbine air supply (T A) must be electrically interl ocked with the spra y booth ventilation fans to pre vent the power supply from operating without v entilating fans on. Non-Hazar dous Area Hazardou s Area Y W P1 C[...]

Installation 309298J 11 Install the Air Line Accessories 1. Install a b leed-type master air v alve (L) on the main air line (W) t o shut off all air to the gun (H). 2. Install an ai r line filter/w ater separator on the gun air line to ensure a dr y , clean air supply t o the gun. Dir t and moisture can r uin the ap pearance of y our fin- ished wo[...]

Installation 12 309298J Install the Gun and Mounting Brac ket 1. Loosen the mount ing brack e t’ s two set scr ews (103) and slide the br acke t (102) onto a 1/2 in. (13 mm) mounting rod. See F IG . 4 .. 2. P osition the gun and tighten the two set screws . F or added positioning reliability , inser t a 1/8 in. (3 mm) locating p in into the slot [...]

Installation 309298J 13 Connect the Air and Fluid Lines F IG . 3. sho ws a schematic of air and fluid line conn ec- tions , and F IG . 5. sho ws the manif old connections. Con- nect the air and fluid lines as instr ucted. 1. Connect the Graco Grounded T urbine Air Supply Hose (B) to the gun's turbine air inlet (T A) and con- nect the hose g ro[...]

Installation 14 309298J Optional Fiber Optic Cable Connection An optional fi ber optic fitting is shipp ed unassembled with the gun. If an ES (kV) displa y module is used, install the fitt ing in the FO por t of the manif old. See F IG . 3., page 10, f or a schematic of the fiber optic connec- tions. 1. Remov e the plug (120) from t he fiber optic [...]

Installation 309298J 15 Gr ounding The follo wing are minimum grounding requ irements for a basic elect rostatic system. Y our system may include other equipment o r objects which must be grou nded. Check yo ur local electrical code f or de tailed grounding instructions. Y our system must be connected to a tr ue ear th g round. • Pump: ground t h[...]

Installation 16 309298J Chec k Electrical Grounding 1. Hav e a qualif ied electr ician chec k the electrical grounding continuity of the sp r ay gun and turbine air hose. 2. Mak e sure the turbine air hose (B) is connected an d the hose grou nd wire is connecte d to a true e ar th ground. 3. T ur n off th e air and fluid supply to the gun. 4. Measu[...]

Installation 309298J 17 Chec k Fluid Resistivity Graco P ar t No . 722886 Resistance Meter and 72286 0 Probe are a vaila ble as accessories to chec k that the resistivity of the fluid b eing spray e d mee ts the require- ments of a n electrostatic air spray system. F ollow the instr uctions in cluded with the meter and probe . Readings of 25 megohm[...]

Operation 18 309298J Operation Pressure Relief Pr ocedure 1. T ur n off all th e air to the spra y gun e xcept the cylin- der air , which triggers the gun. 2. T ur n off the fl uid supply to the gun. 3. T r igger t he gun into a grounded metal w aste con- tainer to reliev e the fluid press ure . 4. Open the pump dr ain valv e and all other drain va[...]

Operation 309298J 19 Select a Spra y Tip The fluid outpu t and pattern width depend on the size o f the spra y tip , the fluid viscosity , and the fluid pr essure. Use the Spra y Tip Selection Char t , page 51, as a guide f or selecting the approp r iate spr a y tip for y our application. Install the Spra y Tip 1. Relie ve the pressure. 2. Place th[...]

Operation 20 309298J Set the Atomization Fluid Pressure Atomization fluid pressure will va r y based on the viscos- ity of the fluid, flow ra te desired, and other system char- acter istics . 1. T ur n off the turbine air (T A) an d atomization air (A 2). 2. Star t the p ump. Se t the fluid regulator to 400 psi (2.8 MP a, 28 bar). 3. With the turbi[...]

Operation 309298J 21 Adjust the Electr ostatics 1. Shut off the fluid supp ly . 1. T r igger t he gun, then turn on the turbine air (T A). See F IG . 12.. 2. Refer to T a b le 2 to set the proper pressure at the turbine air hose inlet when air is flowing . Do not e xceed these pressures as there is no added bene- fit and turb ine lif e could b e re[...]

Operation 22 309298J Spra ying 1. Apply a minimum of 5 0 psi (3.5 bar , 0.35 MPa) air pressure to the cylinder air fitting (CYL) to activate the on/off sequence of atomization ai r (A2) and fluid (P1). See F IG . 12.. 2. T ur n the gun functions off and on by using the air solenoid v alves on the cyl inder (CYL) and turbine (T A) air supply lines. [...]

Maintenance 309298J 23 Maintenance Dail y Care and Cleaning CA UTION • Clean all par ts with a non- conductive , compatible solv ent. Conductiv e solvents can cause the gu n to malfunction. • Do not use meth ylene chlor ide as a flushing or cleaning solvent with th is gun as it will damage nylon components. • Fluid in the air passag es could [...]

Maintenance 24 309298J Dail y Care and Cleaning, continued • Clean the fluid and air line f ilters daily . • Clean the outside of the gun daily with a soft cloth dampened in a compatib le solv ent. • Clean the air cap , spra y tip, and tip guard daily , min- imum. Some app lications require more frequent cleaning. Replace the parts if they ar[...]

Maintenance 309298J 25 Flush the Spra y Gun 1. Relie ve the pressure. 2. Be sure th e turbine air (T A) is tur ned off. 3. Remov e the retaining ring (1), tip guard (3), air cap (40), spr ay t ip (4), and gun shrou d (2). See F IG . 14.. Clean these par ts and set t hem aside. 4. T ur n on the solv ent supply . Use the lowest po ssible fluid pressu[...]

Maintenance 26 309298J Clean the Spra y Gun Equipment Needed • soft brist le brush • compatible solv ent Procedure 1. Relie ve the pressure. 2. Be sure th e turbine air (T A) is tur ned off. 3. Remove the retaining r ing (1), tip guard (3), air c ap (40), spr ay tip (4), and gun shro ud (2). See page 19. 4. Dip the end of a soft bristle brush i[...]

Maintenance 309298J 27 Fig. 17. Clean the Inline Fluid Filter 8. Clean the retaining ring (1), tip guard (3), air cap (40), and spra y tip (4) with a soft br ush daily , mini- mum. Replace any damaged pa rts. Be careful no t to damage the electrode (40a). 9. Wipe off the parts with a dr y cloth. Be careful not to damage the electrode. 10. Chec k th[...]

Maintenance 28 309298J Chec k fo r Fluid Leakage During operation, p er iodically chec k the manif old exhaust tube (YY) and both ends of the gun shroud (ZZ) f or the presence of f luid. See F IG . 18.. Fluid in these areas indicate s leakage into the shroud, which could be caused by leaks at the fluid tube connec tions or fluid pac king leakage. I[...]

Electrical Tests 309298J 29 Electrical T ests Electrical components inside the gun affect p erformance and safety . The following procedures test the condition of the po wer supply (12) and barrel (6), and electrical continuit y between componen ts. Use megohmmeter P ar t No . 241079 (AA) and an applied v oltage of 500 V . Connect the leads as show[...]

Electrical Tests 30 309298J T est P o wer Supply Resistance 1. Remov e the power su pply (12), page 46. 2. Remov e the turbine alternator (13) from the po wer supply , page 47. 3. Measure resistan ce from the po wer supply's ground strips (EE) to the spring (12b). See F IG . 20.. 4. The resistance should be 135-150 megohms . If out- side this [...]

Electrical Tests 309298J 31 T est Barrel Resistance 1. Inser t a cond uctive rod (B) int o the gun barrel (remo ved f or the po wer supply test) and ag ainst the metal conta ct (C) in the front of the barrel. 2. Measure the resist ance between the conducti ve rod (B) and the ba rrel contact ring (6a). See F IG . 21.. The resist ance should be 19-29[...]

Troubleshooting 32 309298J T r oub leshooting Chec k all possible remedies in the T roub leshooting Char t bef ore disassembling t he gun. Spra y P attern T roub leshooting Some spra y patter n prob lems are caused by the improper balance betwe en air and fluid. WA R N I N G Electric Shoc k Hazard Installing and ser vic ing this equipment requires [...]

Troubleshooting 309298J 33 Gun Operation T r oubleshooting Prob lem Cause Solution Excessiv e spra y f og. Atomization air pressure too hig h. Decrease air p ressure as low as pos- si ble. Fluid too thin. Increase viscosity . “Orange P eel” finish. Atomization air pressure too lo w . Increase air pressure; use lo west pressure necessary . Spra [...]

Troubleshooting 34 309298J Electrical T r oubleshooting Problem Cause Solution P oor wrap . T urbine air is not turned on. T ur n on. Booth e xhaust v elocity is too high. Reduce velocity to withi n code limits. Atomization air pressure too high. Decrease. Fluid pressure too high . Decrease. Incorrect distance fro m gun to par t. Should be 8-12 in.[...]

Repair 309298J 35 Repair Prepare the Gun f or Service • Check all possib le remedies in T roubleshoot ing bef ore disassemb ling the gun. • Use a vise with padded ja ws to prev ent damage to plastic par ts . • Lubricate the pow er supply o-ring (12a), some fluid needle par ts (8) , and cer tain fluid fittings with P ar t No . 116553 Dielectri[...]

Repair 36 309298J Remo ve the Gun fr om the Manif old 1. Remov e the fluid supply hose from t he fluid fitting (22). 2. Loosen the bott om gun screw (31) until the gun sits loosely in the mounting br ack et slot (A). See F IG . 22.. 3. Holding the gun firmly in hand, loosen the three screw s (106) from the bac k of the manif old. 4. Remov e the gun[...]

Repair 309298J 37 Tip Guar d, Air Cap, Spra y Tip, or Seat Housing Replacement 1. Prepare gun f or ser vice, page 35. 2. Remove the retainin g ring (1), tip guard (3), air cap (40), spra y tip (4), and shroud (2). Y ou ma y hav e to turn the air cap with the tip guar d to remov e it. See F IG . 23.. 3. Remov e the seat housing (5 ) with the tool (3[...]

Repair 38 309298J 5. Install the seat housing ( 5) with the tool (14) pro- vided. Tighten until sn ug, then 1/4 turn more; do not ov er tighten. See F IG . 24.. 6. Place the spray tip (4) in the air cap (40). Align the tab of the tip with the groov e in t he air cap . Be ca re- ful not to damag e the electrode (40a). 7. Slide the shroud ( 2) onto t[...]

Repair 309298J 39 Electr ode Replacement 1. Prepar e the gun f or ser vice, page 35. 2. Remove the air cap as semb ly , page 37. 3. Pull the electrod e (40a) out of the bac k of the air cap , using a needle-nose pliers . 4. Push the new elect rode through the air cap hole . Mak e sure the shor t end ( BB) of the electrode engages the hole (CC) in t[...]

Repair 40 309298J Fluid T ube Replacement There are no rep laceable par ts in t he fluid tube assem- bly . On ly remo ve when necessary . 1. Prepare the gun for service, page 35. 2. Remov e the air cap assemb ly , page 37. Remo ve the shroud (2). 3. Disconnect the bot tom fluid tube nut (C). See F IG . 26.. 4. Carefully unscre w the top fluid tube [...]

Repair 309298J 41 Fluid Needle Replacement 1. Prepar e the gun f or ser vice, page 35. 2. Remov e the air cap assemb ly and seat housing, page 37. 3. Remove the barrel (6), page 44. 4. Remov e the spring cap (45) and the spring (8a) from the barr el. See F IG . 27.. 5. Be sure the seat housing (5) is remo ved. Place the 2 mm ball end wrenc h ( 44) [...]

Repair 42 309298J Piston Repair 1. Prepare the gun for service, page 35. 2. Remove the air cap, page 37. Remove the gun shroud (2). 3. Remov e the jam nut (28), actuator ar m (29), and adjustment nut ( 30). See F IG . 30.. Fig. 30. Actuator Arm 4. Push on the piston rod (34b ) to push the piston out the back of the gun. 5. Inspect the o- r ings ( 3[...]

Repair 309298J 43 Adjust the Actuator Arm 1. Install the adjustment nut (30), actuator arm (29), and jam n ut (28) onto the p iston rod (34b). Note that the jam nut (2 8) has a slight ly larger hex and a th in- ner profile than th e adjustment nut (30). See F IG . 30. on page 42. 2. P osition the par ts so there is a 0.125 in. (3 mm) gap between th[...]

Repair 44 309298J Barrel Remo v al 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 actuat or arm (29 ). See page 42. 5. Loosen the thre e screws (10, 33). See F IG . 33.. 6. Hold the gun body (32) with on e hand and pull the barr[...]

Repair 309298J 45 Barrel Installation 1. Be sure the gask et (11) and g rounding spring (25) are in place . Make sure the air h oles are aligned properly . Replace if damaged. See F IG . 35.. 2. Place the ba rrel (6) ov er the power supply (12) and onto the gun bod y (32 ). 3. Tighte n the three screws (10, 3 3) oppositely and e venly (abou t a hal[...]

Repair 46 309298J P o wer Supply Remo val and Replacement • Inspect the gun body po wer supply ca vity for dirt or moisture . Clean with a clean, dry rag. • Do not e xpose gask et (11) to solve nts. 1. Prepare gun f or ser vice, page 35. 2. Remove the barrel (9), page 44. 3. Grasp the po wer supply (1 2) with your hand. With a gentle side to si[...]

Fig. 36. Power Supply T urbine Alternator Remo val and Replacement Replace turbine alternator bearings after 2000 hours of operation . Order P ar t No . 223688 Bearing Kit. 1. Prepare gun f or ser vice , page 35. 2. Remov e the power supply/a lter nator assemb ly , page 46. 3. Disconnect the al ter nator fro m the pow er supply , page 46. 4. Measur[...]

Parts 48 309298J Pa r t s P ar t No . 244592 PRO A uto Xs AA Elec trostatic Gun, Seri es A 5 12 19 34a 35 4a 40 12a 12b 32 2 34d 1 3 4 10 11 13 13e 13a 34c 34f 34e 34g 34b 30 27 26 8 28 22 19 (Ref) 20 25 TI1481a 13a* 13b 13b 13c Ref. No. 13: Alternator Detail 13d 13e 1a 40a 6 31 23 8a 29 33 6a 45 14 37 44 ti1722[...]

Parts 309298J 49 P ar t No . 244592 PRO A uto Xs AA Electr ostatic Gun, Series A * Recommended spare parts. K eep on hand to reduce downtime . Replacement W ar ning labe ls, signs, t ags, and cards ar e ava ila bl e at no co st . † Included in repair kit 15D592. Ref. No. Part No. Description Qty 1 244950 RING, retaining, air cap; in cludes 1a 1 1[...]

Parts 50 309298J P ar t No . 244843 Manifol d, Series A, for sta ndard and high conduct ivity coatings † Included in repair kit 15D592. TI1582A TI1740A 101 101 (Ref) 102 103 104 105 106 (Ref) 107 106 110 119 114 112 117 113 116 116a 120 108 115 5 (see page 49) 110 Ref. No. P ar t No. Description Qty 101 198220 MANIFOLD 1 102 189581 BRACKET , reci[...]

Spray Tip Selection Chart 309298J 51 Spra y Tip Selection Char t Pa r t N o . Fan Width at 10 in. (250 mm) in. (mm) Orifice S ize in. (mm) GG3107 2-4 (50- 100) 0.007 (0 .178) 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[...]

Accessories 52 309298J Accessories Gun Accessories 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 three. Round P attern Kit Provides high er lev el of perf or mance to electrost atic spra ying. 245298 Includes tip of ch oice. Gun V alve Lubrica[...]

Accessories 309298J 53 P aint Probe 722860 Use with 72288 6 Paint Resistance Meter to measure resist ance of paint. Not for use in hazardous areas. Safety W arning Signs 180060 English W ar ning Sign. FM Appro ved. A vail- able at no charge from Graco . ES Displa y Module 224117 Receiv es fiber optic tra nsmission from the PRO A uto Xs gun and disp[...]

Accessories 54 309298J[...]

Technical Data 309298J 55 T echnical Data Loctite® is a registered t rademark of the Loctite Corporation. Category Data Maximum W or king Fluid Pre ssure 3000 psi (21 MP a, 210 bar) Maximum W or king Air Pressure 100 psi (0.7 MP a, 7 bar) Maximum Fluid Operating T emperature 120°F (48°C) P aint Resistivity Range 3 megohm/c m to infinity Shor t C[...]

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 309298 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. P.O. BOX 14[...]