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Graco PRO 309292S manual

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Table of contents for the manual

  • Page 1

    Instr uctions Manual Electr ostatic PR O ™ Xs3 and PR O ™ Xs4 Air Spra y Guns For use in Class I, Div . I hazardous locations using Gr oup D spray materials. For use in Group II, Zone 1 areas using Gr oup IIA spray materials. For Pr ofessional Use ONL Y . 100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure 100 psi (0.7 MPa, 7 bar) Maximum W or [...]

  • Page 2

    2 309292S T ab le of Contents List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 W ar ning Sym bol . . . . . . . . . . . . . . . . . . . . . . . . . 4 Caution Symb ol . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Introduction . . . . . . . [...]

  • Page 3

    List of Models 309292S 3 List of Models Par t N o . Mo d e l Smart Display T ype of Coat ings Operation Manual Standard High Conductivity 244400, Series D PRO Xs3 X 309294/3W9294/ 3Z9294 244579, Series D PRO Xs3 (1.5 mm nozzle) XX 309294/3W9294/ 3Z9294 24A511, Series B PRO Xs3 (1.2 mm nozzle) 244575, Series D PRO Xs3 X 309294/3W9294/ 3Z9294 244576,[...]

  • Page 4

    Warnings 4 309292S Wa r n i n g s 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 equipment if y ou do not f ollow the instruc- tions. WARNING CAUTION WA R N I N G Fire, Explosion[...]

  • Page 5

    Warnings 309292S 5 W ARNING Equipment Misuse Hazar d 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 prof essional use only . • Read all man uals, tags , and labels bef ore oper ating the equipme nt. • Use the equipment only f or its intende [...]

  • Page 6

    Introduction 6 309292S Intr oduction How the Electr ostatic Air Spra y Gun W orks The air hose supplies air to the spr ay gun. P ar t of the air operat es the turbine and the rest of the air atomiz es the fluid being sp ray ed. The turbine generates po wer , which is conv er ted by t he power car tridge to supply high v olt- age current to t he gun[...]

  • Page 7

    Installation 309292S 7 Installation Install the System F IG . 2. shows a typical e lectrostatic air spra y sys tem. It is not an actual system des ign. F or assistance in designing a system to suit y our par ticular needs, contact yo ur Graco distributor . W arning Sign Mount warning signs in the spr ay area whe re they can easily be seen and read [...]

  • Page 8

    Installation 8 309292S Fig. 2. Typica l Installation Key I O ES ti1498a A B* C* D *E F G H J* K L M N O P Q* *R S T U* V W C G ES ON/OFF valv e: I is ON, 0 is OFF The air supply to the gun must be electri- cally interlocked with the ventilators to pre- vent the power supply from operating without ventilating fans on. Non-Hazardou s Area Hazardous A[...]

  • Page 9

    Installation 309292S 9 Connect the Air Line 1. Connect the Graco G rounded Air Supply Hose (R) between th e air supply line and the gun's air inlet (V). The gun air inlet fit ting has a left-hand thread. Connect th e air supply ho se ground wire (Q) to a true ear th ground. 2. Install an air line filter/w ater separator (O) on the gun air line[...]

  • Page 10

    Installation 10 309292S Select a Fluid Nozzle and Air Cap The gun is supplied with P ar t No . 197266 Nozzle and 24A376 Air Cap. If you require a different size, ref er t o T able 1 and T able 2 , and instruction manual 30941 9, or consult with your Graco distributor . See Air Cap/Nozz le Replacement on page 26. A wide pattern kit (P/N 24A43 1) is [...]

  • Page 11

    Installation 309292S 11 4. Remov e the fluid tube and fittings . 5. Remov e the fluid inlet br ack et. 6. Install the ne w brack et (3) from the kit loosely . See F IG . 3. 7. Place the spacer (5) in the barrel inlet. Ap ply Graco dielectric grease (4) to the o-rings (2a, 2b) and to both threads of the fluid fitting (2). Thread the fitt ing into th[...]

  • Page 12

    Installation 12 309292S Gr ounding The follo wing are minimum groundin g requiremen ts for a basic elect rostatic syste m. Y our system ma y include other equipment or objects which m ust be grounded. Check yo u r local electr ical code f or de tailed grounding instru ctions. Y our system must be connected to a true ear th ground . • Pump: ground[...]

  • Page 13

    Installation 309292S 13 Chec k Electrical Grounding 1. Hav e a q ualified electr ician ch eck the electrical groundin g continuity of t he spra y gun and air hose . 2. T urn the ES ON/O FF v a lv e OFF . 3. T ur n off the air and fluid supp ly to the gun. The f luid hose must not have any fluid in it. 4. Mak e sure the grounded a ir hose (R) is con[...]

  • Page 14

    Installation 14 309292S Chec k Fluid Resistivity Graco P ar t No . 722886 Resistance Meter and 72 2860 Probe are a vaila ble as accessories to chec k that the resistivity of the fluid b eing spray ed meets the require- ments of an electrostatic air spr ay system. F ollow the instr uctions in cluded with the meter and probe . Readings of 25 megohms-[...]

  • Page 15

    Operation 309292S 15 Operation Lo w V oltage Adjustment (Smar t Guns Onl y ) The ES HI/LO s witch enables y ou to s witch between full v oltage and a lower v oltage output. The low er voltage is f actor y set, but can be adjusted. 1. Set the ES HI/LO switch to LO . 2. Remove the LO V OL T AGE adjustment plug (53) . Set the desired voltage, using a [...]

  • Page 16

    Maintenance 16 309292S Maintenance Flush the Spra y Gun Flush the gun bef ore changing co lors, at the end of t he da y , bef ore storing, and befo re repair ing the gun. 1. T ur n th e ES ON/OFF valv e OFF . 2. Relie ve the pr essure. 3. Change the f luid source to solv ent, or disconnect the fluid line and connect a solv ent supply line to the gu[...]

  • Page 17

    Maintenance 309292S 17 7. Hang the gun from it s hook, with the nozzle pointing down. 8. When ready to spra y again, reconnect th e fluid sup- ply line. F ollow the Se tup procedure in the Opera - tion Man ual. ti1288a[...]

  • Page 18

    Electrical Tests 18 309292S Electrical T ests Electrical components inside the gun affect p erformance and safety . The f o llowing procedures test the condition of the pow er supply (18) and electrode (29), and electr i- cal continuity bet ween components . Use megohmmeter P ar t No . 241079 (AA) and an applied v oltage of 500 V . Connect the lead[...]

  • Page 19

    Electrical Tests 309292S 19 T est P o wer Supply Resistance 1. Remov e the po wer supply (18), page 30. 2. Remov e the turbine alt er nator (19) from t he power supply , page 31. 3. Measure resistance from the power su pply's ground strips (EE) to the spring (18b). See F IG . 7. 4. The resist ance should be 95-105 megohms f or the PRO Xs3, and[...]

  • Page 20

    Electrical Tests 20 309292S T est Electr ode Resistance 1. Inser t a conductiv e rod (B) into the gun barr el (remo ved f or the pow er supply test) and against th e metal conta ct (C) in the front of the barrel. 2. Measure the resist ance between the conductiv e rod (B) and the el ectrode (29). The resistance should be 20-30 megoh ms. See F IG . 8[...]

  • Page 21

    Troubleshooting 309292S 21 T r oub leshooting Chec k all possible remedies in the T roub leshooting Char t bef ore disassemb ling the gun. Spra y P attern T roub leshooting Some spra y pattern problems ar e caused by the improp er balance between air and flu id. WA R N I N G Electric Shoc k Hazard Installing and ser vic ing this equipment requires [...]

  • Page 22

    Troubleshooting 22 309292S Gun Operation T roub leshooting Problem Cause Solution Excessive spr ay f og. Atomizing air pressure too high. Close restr ictor valv e some, or decrease air p ressure as low as pos- sible; minimum 40 psi (0.28 MP a, 2.8 bar) needed at gun f or full v oltage. Fluid too thin. Increase viscosity . “Orange P eel” finish.[...]

  • Page 23

    Troubleshooting 309292S 23 Electrical T roub leshooting * ES indicator light is off when the gun is tr iggered. 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 gun; minim um 40 psi (0.28 MP a, 2.8 bar) ne eded at gun f or full voltag e. Atomizing air pressure too hig [...]

  • Page 24

    Repair 24 309292S Repair Pressure Relief Pr ocedure 1. T urn the ES ON/O FF v a lv e OFF . 2. T ur n off the air b leed valv es to the fluid sour ce and to the gun. 3. T r igger the gun int o a grounded metal waste con- tainer to r elie ve the fluid pr essure. 4. Open the pu mp drain valv e, having a w ast e con- tainer ready t o catch the drainage[...]

  • Page 25

    Repair 309292S 25 Prepare the Gun f or Ser vice • Check all possib le remedies in T roubles hooting 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 (18a), some pa ck- ing rod par ts (26), and cer ta in fluid fittings wit h dielectric grease (40) , as spe[...]

  • Page 26

    Repair 26 309292S Air Cap/Nozzle Replacement 1. Prepare gun f or service, page 25 . 2. Remove the retaining r ing (27) and air cap (9). See F IG . 11.. 3. P oint gun up and sq ueeze trigger while removin g the fluid nozzle (7) assembly with the m ulti-tool (37). Fig. 11. Air Cap/ Nozzle Replac ement Use non-silicone grease, P ar t No. 111265, on th[...]

  • Page 27

    Repair 309292S 27 Electr ode Replacement 1. Prepar e the gun for service, page 25. 2. Remov e the air cap and nozzle , page 26. 3. Unscrew the electrode (29) with the multi-to ol (37). Hold the packing rod end (26h) to pre vent it from tur ning, F IG . 12. 4. Apply low-strength (pur ple) Loctite ® or eq uivalent thread sealan t to the electrode an[...]

  • Page 28

    Repair 28 309292S Fluid P ac king Remov al 1. Prepare the gun f or ser vice, pa ge 25. 2. Remov e the air cap and fluid nozzl e, page 26. 3. Remove the electrode, page 27. 4. Loosen the trigger scre ws (8) and trigger (30). See F IG . 13.. 5. Remove the packing rod (26), using the multi-tool (37). 6. Chec k all par ts for w ear or damage and replac[...]

  • Page 29

    Repair 309292S 29 P ac king Rod Repair Y ou may r eplace the packing rod as individ ual par ts or as an assemb ly . The assemb ly is pre-adjusted at the f actor y . Bef ore installing the fluid pack ing rod into the gun barrel, mak e sure the inter nal surf aces of the barrel are clean. Remov e any residue with a soft brush or cloth. Check the insi[...]

  • Page 30

    Repair 30 309292S Barrel Remo val 1. Prepare the gun f or ser vice, pa ge 25. 2. Carefu lly loosen the nut (3 2 or 50d) from the brack e t fluid fitti ng (13). Pull the tube (14 or 50a) ou t of the fitting. Mak e sure both f errules and the nut stay with the tube. 3. Loosen the thre e screws (11). 4. Hold the gun handle (17) with one hand and pull [...]

  • Page 31

    Repair 309292S 31 P o wer Supply Remo v al and Replacement • Inspect the gun ha ndle power supply ca vity f or dir t or moisture. Clean wit h a clean, dr y rag. • Do not e xpose gask et (10) to solvents . 1. Prepare gun f or service, page 25. 2. Remov e the barrel (1 6), page 30. 3. Grasp the po wer supply (18) with your hand. With a gentle sid[...]

  • Page 32

    Repair 32 309292S T urbine Alternator Remo va l and Replacement Replace turbine alte r nator bearings after 2000 hours of operat ion. Order P ar t No. 22 3688 Bearing Kit. 1. Prepare gun f or service, page 25 . 2. Remov e the power supply/alter nator assembly , page 31. 3. Disconnect the alte r nator from the po wer supply , page 31. 4. Measure res[...]

  • Page 33

    Repair 309292S 33 F an Air Adjustment V alve Repair 1. Prepar e the gun for service, page 25. 2. Place a wrench on the flats of th e valv e assembly (20) and unscre w it from the handle (17). Y ou may r eplace the valv e as an asse mbly (go to step 9) or as individual parts (steps 3-9). 3. Remove the retaining r ing (20a). See F IG . 19.. 4. T urn [...]

  • Page 34

    Repair 34 309292S Fluid Adjustment V alve Repair 1. Prepare the gun f or ser vice, pa ge 25. 2. Remove the fluid adjust ment valv e (25). It can only be replaced as a complete assembly . See F IG . 20.. 3. Screw t he valv e (25) into t he gun handle. T orque to 15-25 in-lb (1 .7-2.8 N•m). Fig. 20. Fluid Adjustment Valve Air V alve Repair 1. Prepa[...]

  • Page 35

    Repair 309292S 35 Atomizing Air Restrictor V alve Remo val and Replacement 1. Prepar e the gun for service, page 25. 2. Remove the atomizing air restr ictor valv e (23). Inspect the o-ring (23c*). Rep lace if necessar y . See F IG . 22.. 3. Install a new atomizing air restr ictor valv e (23) , or disassemb le and replace par ts individually . The v[...]

  • Page 36

    Parts 36 309292S Pa r t s P ar t No. 244400 60 kV Electr ostatic Gun, Series C (items 1-48, 55 ) P ar t No. 244575 60 kV Electr ostatic Gun, Series C (items 4-30, 35 -55) P ar t No. 244401 85 kV Electr ostatic Gun, Series C (items 1-48, 55 ) 27 9 7 26 16 11 18 19 *10 17 28 20 22 25 15 21*** 23b 35 13 24 38 8 *6 ti1266a I O ES 7a 7b 11 *18a 18b 23a [...]

  • Page 37

    Parts 309292S 37 ti1601a Ref. No. 26: P acking Rod 26a** 26b** 26c** 26d** 26e 26f 26g** 26h TI1488A ti1492a TI491A TI1490A TI1487A TI1481a 31** 32 14 1 5** 22a* 22b* 22c 22d 22e 22f 22g 20a 20b* 20c 20d 19a* 19b 19b 19c 50a 50b 50c 50d 50e 50f 49 49a 49b 50d 50c 50b 5 5** 1 14 **31 32 Ref. No. 22: ES ON/OFF V alve Ref. No. 20: Fan Adjustment V alv[...]

  • Page 38

    Parts 38 309292S P ar t No. 244400 60 kV Electr ostatic Gun, Series C (items 1-48, 55 ) P ar t No. 244575 60 kV Electr ostatic Gun, Series C (items 4-30, 35 -55) P ar t No. 244401 85 kV Electr ostatic Gun, Series C (items 1-48, 55 ) Ref. No. P ar t No. Description Qty 1 110078 FITTING, tube, fluid; used on 244400 1 198587 FITTING, tu be, fluid; use[...]

  • Page 39

    Parts 309292S 39 * Included in Air Seal Repair Kit 244781. ** Included in Fluid Seal Repair Kit 244 911. *** Rubber seal is no t remov able. **** Optional repla cement Electrode Needle 277007 is av ailable f or ab rasiv e mater ials. ▲ Replacement Warning lab els, signs, tags , and ca rds are a vailab le at no cost. 23 244559 V AL VE, air , atomi[...]

  • Page 40

    Parts 40 309292S P ar t Nos. 244579 and 24A511 60 kV Electr ostatic Gun, Series C (it ems 1-48, 51-59) P ar t No. 244576 60 kV Electr ostatic Gun, Series C (items 1-30, 35 -59) P ar t No. 244580 85 kV Electr ostatic Gun, Series C (items 1-48, 51 -59) ti1253a 100 % KV μα 0 HI LO ES I O I O ES 27 9 7 26 16 11 18 19 17 28 20 25 15 21*** 23b 35 13 24[...]

  • Page 41

    Parts 309292S 41 ti1601a Ref. No. 26: P acking Rod ti1492a TI491A TI1490A 31** 32 14 1 5** 50a 50b 50c 50d 50e 50f 49 49a 49b 50d 50c 50b 5 5** 1 14 **31 32 Fluid T ube: Model 244579 Fluid T ube: Model 244576 Fluid T ube: Model 244580 TI1487A 20a 20b* 20c 20d Ref. No. 20: Fan Adjustment V alve TI1481a 19a* 19b 19b 19c Ref . No . 19: Alter nator 19d[...]

  • Page 42

    Parts 42 309292S P ar t No. 244579 and 24A511 60 kV Electr ostatic Gun, Series C (items 1- 48, 51-59) P ar t No. 244576 60 kV Electr ostatic Gun, Series C (items 1-30, 35 -59) P ar t No. 244580 85 kV Electr ostatic Gun, Series C (items 1-48, 51 -59) Ref. No. Pa r t No. Description Qty 1 110078 FITTING, tub e, fluid; used on 244579 1 198587 FITTING,[...]

  • Page 43

    Parts 309292S 43 * Included in Air Seal Repair Kit 244781. ** Included in Fluid Seal Repair Kit 244 911. *** Rubber seal is no t remov able. **** Optional repla cement Electrode Needle 277007 is av ailable f or ab rasiv e mater ials. ▲ Replacement Warning lab els, signs, tags , and ca rds are a vailab le at no cost. 26d** 178763 . P A CKING, rod;[...]

  • Page 44

    Accessories 44 309292S Accessories Air Line Accessories AirFlex ™ Flex ible Grounded Air Hose 100 psi (7 bar , 0.7 MP a) Maxim um 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 36 ft (1 1 m) 244967 50 ft (1 5 m) 244968 75 ft (2 3 m) 244969 100 [...]

  • Page 45

    Accessories 309292S 45 Gun Accessories Gun Repair Kits 244781 Air Seal Repair Kit 244911 Fluid Seal Repair Kit Round P attern Kits Consists of flu id tip , diffuser and a ir cap . 245217 4-6 in. (1 02-152 mm) diameter 245219 8-10 in. (203-254 mm) diamet er Adjustable Round P attern Kit 277851 Slo w velocity , bell shaped spra y pattern for e xcelle[...]

  • Page 46

    Technica l Data 46 309292S T echnical Data Loctite ® is a registere d trademark of th e Loctite Cor poration. Category Data Maximum W orking Fluid Pressure 100 psi (0.7 MP a, 7 bar) Maximum W orking Air Pressure 100 psi (0.7 MPa, 7 b ar) Minimum Air Press ure at Gun In let 40 p si (0.28 MPa, 2.8 bar) Maximum Fluid Operatin g T empe rature 120 ° F[...]

  • Page 47

    Technical Data 309292S 47[...]

  • Page 48

    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. Original instructions. T his manual contains English. MM 309292 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Kore[...]