Graco PRO XS3 309292L manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 Copyright 2001, Graco Inc. is r egistered to I. S. EN ISO 9001 ti1600a For use with Class I Gr oup D spra y materials. For use with Class II 2 G spray materials. 100 psi (0.7 MP a, 7 bar) Maximum Air Inlet Pressu re 100 psi (0.7 MP a, 7 bar) Maximum W or king Flu id Pressur e U .S. P atent 7,226,0[...]

2 309292L T able of Contents List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 W arning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 How the El[...]

List of Models 309292L 3 List of Models Pa r t N o. M o d e l Smart Displa y T ype of Co atings Operation Manual Standar d High Conductivity 244400, Series C PRO Xs3 X 309294/3W9294/ 3Z9294 244579, Series C PRO Xs3 XX 309294/3W9294/ 3Z9294 244575, Series C PRO Xs3 X 309294/3W9294/ 3Z9294 244576, Series C PRO Xs3 XX 309294/3W9294/ 3Z9294 244401, Ser[...]

Symbols 4 309292L Symbols 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 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 t he instruc- tions. WARNING CAUTION WA R N I N G Fire, Explosion, and [...]

Symbols 309292L 5 W ARNING Equipment Misuse Hazar d Equipment misu se can cause the equipment to rupture , malfunction, or st ar t une xpectedly and result in a serious injur y . • This equipment is f or prof essional use only . • Read all man uals, tags , and labels befo re operating the equipment. • Use the eq uipment on ly for its intended[...]

Introduction 6 309292L Intr oduction How the Electr ostatic Air Spray Gun W orks The air hose supplies air to the spr ay gu n. P ar t of the air operat es the turbine and the r est of the air atomiz es the fluid being sp ra yed. The t urbine generates po wer , which is conv er ted b y the pow er car tridge to supply high v olt- age current to t he [...]

Installation 309292L 7 Installation Install the System F IG . 2. shows a typical e lectrostatic a ir spray system. It is not an actual system des ign. For 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 ar ea where they can easily be seen and read b [...]

Installation 8 309292L 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[...]

Installation 309292L 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 hose ground w ire (Q) to a true ear th ground. 2. Install an air line filter/w ater separator (O ) on the gun air lin[...]

Installation 10 309292L Connect the Fluid Line 1. Bef ore connecting the fluid line ( N), blo w it out with air and flush it with solvent. Use solv ent which is compatible with the fluid to be spra yed. 2. Install a flu id regula tor (M) on th e fluid line to control fluid pressure to t he gun. 3. Install a fluid filter (K) and drain v alve (U) at [...]

Installation 309292L 11 244919 HC Con version Kit P ar t No . 244919 Con ve rsion Kit conv er ts PRO Xs3 standard coatin g guns (P ar t Nos. 244400 and 244579 ) to high conducti vity guns (244575 and 244 576). F or fur- ther instruction and parts, see manual 309453. The kit is f or use with fluids with lo w resistivity values . 1. T ur n the ES ON/[...]

Installation 12 309292L Gr ounding The follo wing a re minimum groundin g requirem ents for a basic elect rostatic sys tem. Y our syste m may include other equipment or objects which must be grou nded. Check yo ur local electr ical co de f or detailed groundin g instru ctions. Y our system must be connected to a tr ue ear th ground. • Pump: groun[...]

Installation 309292L 13 Chec k Electrical Grounding 1. Hav e a qu alified electr ician check the electr ical groundin g continuity of the spra y gun and ai r hose. 2. T ur n th e ES ON/OFF valv e OFF . 3. T ur n off the air and fluid supp ly to the gun. The fluid hose must not have any fluid in it. 4. Mak e sure the ground ed air hose (R) is connec[...]

Installation 14 309292L Chec k Fluid Resistivity Graco P ar t No . 722886 Resistance Meter and 722860 Probe are a v ailable as ac cessories to check that the resistivity of the fluid b eing spra yed meets the requir e- ments of an electrostatic air spr ay syst em. F ollow the instr uctions in cluded with the meter and probe . Readings of 25 megohms[...]

Operation 309292L 15 Operation Lo w V oltage Adjustment (Smar t Guns Onl y) The ES HI/LO s witch enab les you to s witch betwee n full v oltage and a low er voltage o utput. The lower 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 A GE ad justment plu g (53). Set the desired voltage, using [...]

Maintenance 16 309292L Maintenance Flush the Spra y Gun Flush the gun bef ore changing colors , at the end of the da y , bef ore storing, and bef ore repairing the gun. 1. T ur n the ES ON/OFF valv e OFF . 2. Relie ve th e pressure. 3. Change the f luid source to solvent, or disconnect the fluid line and connect a solv ent supply line to the gun. 4[...]

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

Electrical Tests 18 309292L Electrical T ests Electrical components inside the gun affect perfo r mance and safety . T he follo wing pr ocedures te st the cond ition of the pow er supply (18) and electrode (29 ), and electri- cal continuity bet ween components . Use megohmmeter P ar t No . 241079 (AA) and an applied v oltage of 500 V . Connect the [...]

Electrical Tests 309292L 19 T est P ower Suppl y Resistance 1. Remov e the power su pply (18), page 30. 2. Remov e the turbi ne alter nator (19) fr om the power supply , page 31. 3. Measure resistance from the pow er supply's ground strips (EE) to the spring (18b). See F IG . 7. 4. The resist ance should be 95-105 megoh ms for th e PRO Xs3, an[...]

Electrical Tests 20 309292L T est Electr ode Resistance 1. Inser t a conductiv e rod (B) into the gun barr el (remo ved f o r the po wer supply test) an d against the metal conta ct (C) in t he front of the barre l. 2. Measure the resist ance between the conduct ive rod (B) and the el ectrode (29). The resistan ce should be 20-30 megoh ms. See F IG[...]

Troubleshooting 309292L 21 T r oubleshooting Chec k all possible remedies in the T roubleshoot ing Char t bef ore disassemb ling the gun. Spra y P attern T r oubleshooting Some spra y patter n prob lems are caused by the impr oper balance between air and fluid. WA R N I N G Electric Shoc k Hazard Installing and ser vic ing this equipment requires a[...]

Troubleshooting 22 309292L Gun Operation T r oubleshooting Problem Cause Solution Excessive spr ay f o g. 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[...]

Troubleshooting 309292L 23 Electrical T r oubleshooting * 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; mi nimum 40 psi (0.28 MP a, 2.8 bar) needed at gun f or full volt age. Atomizing air pressure too hig [...]

Repair 24 309292L Repair Pressure Relief Pr ocedure 1. T ur n th e ES ON/OFF valv e OFF . 2. T ur n off the air b leed v alves to th e fluid source and to the gun. 3. T rigger the gun into 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 aste co n- tainer ready t o catch the drainage . [...]

Repair 309292L 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 pack- ing rod par ts (26), and cer tain fluid fittings with dielectric grease (40) , as specif[...]

Repair 26 309292L Air Cap/Nozzle Replacement 1. Prepare gun f or ser vice, page 25 . 2. Remove the retaining r ing ( 27) and air cap (9). Se e F IG . 11.. 3. P oint gun up and squeeze tr igger while remo ving 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[...]

Repair 309292L 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- tool (37). Hold the packing rod end (26h) to prev ent it from tur ning, F IG . 12. 4. Apply low-strength (pur ple) Loctite ® or eq uivalent thread sealan t to the electrode an[...]

Repair 28 309292L Fluid P a c king Remov al 1. Prepare the gun for service, page 2 5. 2. Remov e the air cap and fluid nozzle, 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 replace [...]

Repair 309292L 29 P ac king Rod Repair Y ou may replac e the packing rod as individua l 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 internal surfaces of t he barrel are clean. Remov e any r esidue with a soft brush or cloth. Check the insi[...]

Repair 30 309292L Barrel Remo va l 1. Prepare the gun for service, page 2 5. 2. Carefu lly loosen the nut (32 or 50d) from the brack et fluid fitti ng (13). Pull the tube (14 or 50a ) out of the fitting. Mak e sure both f err ules and the n ut sta y with the tube. 3. Loosen the thre e screws (11). 4. Hold the gun handle (17) with one hand and pull [...]

Repair 309292L 31 P ower Suppl y Remo val and Replacement • Inspect the gun ha ndle power supp ly cavity f or dir t or moisture. Clean wit h a clean, d r y rag. • Do not e xpose gasket (10) to solv ents. 1. Prepare gun f or ser vice, page 25. 2. Remov e the barrel (16), page 30. 3. Grasp the po wer supply (1 8) with your hand . With a gentle si[...]

Repair 32 309292L T urbine Alternator Remov al and Replacement Replace turbine alte r nator bearings after 2000 hours of operat ion. Order P ar t No . 223688 Bearing Kit. 1. Prepare gun f or ser vice, 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[...]

Repair 309292L 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 replac e the valv e as an assembly (go to step 9) or as individual parts (steps 3-9). 3. Remove the retaining r ing (20a). See F IG . 19.. 4. T ur n[...]

Repair 34 309292L Fluid Adjustment V alve Repair 1. Prepare the gun for service, page 2 5. 2. Remove the fluid adjust ment valv e (25). It can on ly be replaced as a complete assembly . See F IG . 20.. 3. Screw t he valv e (25) into the gun h andle. T orque to 15-25 in-lb (1 .7-2.8 N•m). Fig. 20. Fluid Adjustment Valve Air V alve Repair 1. Prepar[...]

Repair 309292L 35 Atomizing Air Restrictor V alve Remo val and Replacement 1. Prepar e the gun for service, page 25. 2. Remove the atomizing air re str 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 valve (23), or disassemb le and replace par ts individually . The v[...]

Parts 36 309292L Pa r t s P ar t No. 244400 60 kV Electrostat ic Gun, Series C (items 1-48, 55 ) P ar t No. 244575 60 kV Electrostat ic Gun, Series C (items 4-30, 35 -55) P ar t No. 244401 85 kV Electrostat ic 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 [...]

Parts 309292L 37 ti1601a Ref. No. 26: P ack ing 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 al[...]

Parts 38 309292L P ar t No. 244400 60 kV Electrostat ic Gun, Series C (items 1-48, 55 ) P ar t No. 244575 60 kV Electrostat ic Gun, Series C (items 4-30, 35 -55) P ar t No. 244401 85 kV Electrostat ic 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, tube, fluid; used[...]

Parts 309292L 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 277060 is av ailable f or abrasive materials. ▲ Replacement Warning lab els, signs, tags, and cards are a vailab le at no cost. 23 244559 V AL VE, air , atomizing[...]

Parts 40 309292L P ar t No. 244579 60 kV Electrostat ic Gun, Series C (items 1-48, 51 -59) P ar t No. 244576 60 kV Electrostat ic Gun, Series C (items 1-30, 35 -59) P ar t No. 244580 85 kV Electrostat ic 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 38 8 7a 7b [...]

Parts 309292L 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: Alternator 19d 1[...]

Parts 42 309292L P ar t No. 244579 60 kV Electrostat ic Gun, Series C (items 1-48, 51 -59) P ar t No. 244576 60 kV Electrostat ic Gun, Series C (items 1-30, 35 -59) P ar t No. 244580 85 kV Electrostat ic 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, tube, flui[...]

Parts 309292L 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 277060 is av ailable f or abrasive materials. ▲ Replacement Warning lab els, signs, tags, and cards are a vailab le at no cost. 26f 185495 . HOUSING, pack ing 1 2[...]

Accessories 44 309292L Accessories Air Line Accessories AirFlex ™ Flex ible Groun ded Air Hose 100 psi (7 bar , 0.7 MP a) Maximum W orking Pressure 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) lef t-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[...]

Accessories 309292L 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 air ca p . 245217 4-6 in. (1 02-152 mm) diameter 245219 8-10 in. (203-254 mm) dia meter Push/Pull Fan Air V alve 244912 F or quic k change of f an size . ES Alwa ys On Kit 244913 Rep[...]

Technica l Data 46 309292L T echnical Data Loctite ® is a registere d trademar k of the Loctite Cor poration. Category Data Maximum W o rking Fluid Pressure 100 psi (0.7 MP a, 7 bar) Maximum W o rking Air Pressure 1 00 psi (0.7 MP a, 7 bar) Minimum Air Press ure at Gun Inlet 40 psi (0.2 8 MP a, 2 .8 bar) Maximum Fluid Operatin g T emperatur e 120 [...]

Technical Data 309292L 47[...]

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 309292 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. P.O. BOX 14[...]