Instructions/Parts Automatic Electrostatic PRO™ Xs Auto Waterborne 313227C Air Spray Gun ENG For use with conductive spray materials (waterborne and other materials less than 1 megohm-cm). Part No. 24A206 100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure 100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure For use in Class I, Div. I hazardous locations using Group D spray materials. # 53 For use in Group II, Zone 1 areas using Group IIA spray materials. 0359 II 2 G EEx 0.
Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 How the Electrostatic Air Spray Gun Works . . . . 5 Operating the Spray Function . . . . . . . . . . . . . . . 5 Operating the Electrostatics . . . . . . . . . . . . . . . . 5 Gun Features and Options . . . . . . . . . . . . . . . . . 5 Changing the kV Setting . . . . . . . . . . . . . . . . . . . 5 Installation . . . . . . . . . . . .
Warnings Warnings Warning Symbol Notice WARNING NOTICE This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. A NOTICE alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions. The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk.
Warnings WARNING WARNING PRESSURIZED EQUIPMENT HAZARD Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury. • Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment. • Tighten all fluid connections before operating the equipment. • Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Overview Overview How the Electrostatic Air Spray Gun Works The automatic electrostatic air spray gun operates very similar to a traditional air spray gun. The atomization and fan air are emitted from the air cap. The atomization air breaks up the fluid stream and controls the droplet size. The fan air controls the shape and width of the spray pattern. The fan and atomization air can be adjusted independently.
Overview F KV1 TA FO CYL KV2 A1 TI13395a A C D A2 P1 E EXH G H TI1577A Manifold Back View B J TI13426a FIG. 1.
Installation Installation Install the System Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. • Do not install or service this equipment unless you are trained and qualified. • Be sure your installation complies with National, State and Local codes for the installation of electrical apparatus in a Class I, Div. I, Group D or a Group II, Category 2G Hazardous Location.
Installation L W NOTE: * The turbine air supply (TA) must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on. See * above A K KV1 TA K L X Y B C D KV2 K A1 L A2 CYL P1 K N E F M G Non-Hazardous Area J Hazardous Area TI1712A Manifold Back View FIG. 2. Typical Installation NOTE: ** A maximum of two splices with a total of 108 ft (33 m) of cable can be used.
Installation Connect the Charging Probe Install the Air Line Accessories 1. Apply dielectric grease to the charging probe socket. See FIG. 4. 1. Install a bleed-type air valve (L) on the main air line (W) to shut off all air to the gun (H). 2. Install an air line filter/water separator on the gun air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction. Probe Socket 3.
Installation Install the Gun and Mounting Bracket 1. Loosen the mounting bracket’s two set screws (103) and slide the bracket (102) onto a 1/2 in. (13 mm) mounting rod. See FIG. 6. Connect the Air and Fluid Lines FIG. 2 shows a schematic of air and fluid line connections, and FIG. 7 shows the manifold connections. Connect the air and fluid lines as instructed. 2. Position the gun and tighten the two set screws. NOTE: For added positioning reliability, insert a 1/8 in.
Installation Manifold Connections A1 Optional Fiber Optic Cable Connection Atomization Air Inlet Fitting Connect a 3/8 in. (10 mm) OD tube between this fitting and the air supply. A2 Fan Air Inlet Fitting Connect a 3/8 in. (10 mm) OD tube between this fitting and the air supply. CYL Cylinder Air Inlet Fitting Connect a 5/32 in. (4 mm) OD tube between this fitting and the solenoid. For quicker response, use the shortest hose length possible. EXH Shroud Exhaust Outlet Fitting Connect a 1/4 in.
Installation Grounding • Air compressors and hydraulic power supplies: ground the equipment according to the manufacturer's recommendations. • All air and fluid lines must be properly grounded. • All electrical cables must be properly grounded. • All persons entering the spray area: shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Do not wear shoes with non-conductive soles such as rubber or plastic.
Installation Check Electrical Grounding Fire, Explosion, and Electric Shock Hazard Megohmmeter Part No. 241079 (AA-see FIG. 10) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless: 5. If the resistance is greater than the maximum reading specified above for your hose, check the tightness of the ground connections and be sure the turbine air hose ground wire is connected to a true earth ground.
Installation Check Fluid Resistivity Check Fluid Viscosity To check fluid viscosity you will need: Fire, Explosion, and Electric Shock Hazard Check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area. Failure to follow this warning could cause fire, explosion, or electric shock and result in serious injury and property damage. Graco Part No.
Operation Operation Operating Checklist Pressure Relief Procedure Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation. The system pressure must be manually relieved to prevent the system from starting or spraying accidentally.
Operation Select a Fluid Nozzle and Air Cap The gun is supplied with Part No. 197266 Nozzle and 24A276 Air Cap. If you require a different size, refer to Table 2 and instruction manual 309419, or consult with your Graco distributor. See Replace Air Cap/Nozzle on page 30. Adjust the Spray Pattern Follow the steps below to establish the correct fluid flow and air flow. Do not turn on the turbine air (TA) yet. 1. Relieve pressure, page 15.
Operation 5. Use the air pressure regulator on the fan air supply line (A2) to adjust the pattern size. • • • For the most efficiency, always use the lowest air pressure possible. When increasing to a wide, flat pattern, it may be necessary to increase the supply of fluid to the gun to maintain the same amount of coverage over a large area. See Spray Pattern Troubleshooting on page 25 to correct spray pattern problems. KV2 KV1 TA CYL A1 A2 Adjust the Electrostatics 1. Shut off the fluid supply. 2.
Operation Spraying Triggering the Fluid Alone 1. Shut off and relieve the air pressure to the atomization (A1) and fan (A2) air lines, using the bleed-type air shutoff valves. To reduce the risk of electric shock, do not touch the gun electrode or come within 4 in. (10 cm) of the nozzle during gun operation. 1. Apply a minimum of 50 psi (3.5 bar, 0.35 MPa) air pressure to the cylinder air fitting (CYL) to activate the on/off sequence of atomization air (A1), fan air (A2), and fluid (P1). See FIG. 13. 2.
Maintenance Maintenance Clean the Gun Daily • Do not immerse the gun in fluid. Turn off the turbine air before flushing the gun or any part of the system. 1. Flush the gun. TI13430a 2. Relieve pressure, page 15. 3. Clean the outside of the gun as follows: • Clean all parts with a non-conductive, compatible solvent. Conductive solvents can cause the gun to malfunction. • Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components.
Maintenance 5. Clean the air cap and fluid nozzle daily, minimum. Some applications require more frequent cleaning. Replace the fluid nozzle and air cap if they are damaged. See Clean the Air Cap and Fluid Nozzle, page 20. 4. Wipe the fluid nozzle (4), shroud (48), and exterior of the gun clean with a cloth dampened in solvent. Avoid getting any solvent into the air passages. Whenever possible, point the gun down when cleaning it. 6. Check the electrode and replace if broken or damaged.
Maintenance 48 To reduce the risk of an injury, follow the Pressure Relief Procedure on page 15 when you stop spraying and whenever you are instructed to relieve the pressure. 1 3 1a 7 4 TI13431a During operation, periodically check the manifold exhaust tube (YY) and both ends of the gun shroud (ZZ) for the presence of fluid. See FIG. 15. Fluid in these areas indicates leakage into the shroud, which could be caused by leaks at the fluid tube connections or fluid packing leakage.
Electrical Tests Electrical Tests Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (12), barrel (9) and external charging probe (2), and electrical continuity between components. Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V. Connect the leads as shown. Test Total Gun Resistance 1. Flush and dry the fluid passage. 2.
Electrical Tests Test Gun Resistance Test Charging Probe Resistance Measure resistance between the turbine air inlet fitting (TA) and the charging probe socket (CC) (see FIG. 17); it should be 70-95 megohms. If outside this range, check the power supply and barrel resistance. If in range, test the charging probe resistance. Measure resistance between the metal spring in the charging probe (DD) and the charging probe tip (BB) (see FIG. 17); it should be 15-30 megohms.
Electrical Tests Test Power Supply Resistance Test Barrel Resistance 1. Remove the power supply (18), page 38. 1. Insert a conductive rod (GG) into the gun barrel (removed for the power supply test) and against the metal contact (HH) in the front of the barrel. 2. Remove the turbine alternator (19) from the power supply, page 39. 3. Measure resistance from the power supply's ground strips (EE) to the conductive contact in the center of the power supply seal (FF). See FIG. 19 2.
Troubleshooting Troubleshooting NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun. To reduce the risk of an injury, follow the Pressure Relief Procedure on page 15 when you stop spraying and whenever you are instructed to relieve the pressure. Spray Pattern Troubleshooting NOTE: Some spray pattern problems are caused by the improper balance between air and fluid. Problem Fluttering or spitting spray. Improper spray pattern. Streaks.
Troubleshooting Gun Operation Troubleshooting Problem Excessive spray fog. Cause Solution Atomizing air pressure too high. Decrease air pressure as low as possible. Fluid too thin. Increase viscosity. Atomizing air pressure too low. Increase air pressure; use lowest air pressure necessary. Poorly mixed or filtered fluid. Remix or refilter fluid. Fluid too thick. Reduce viscosity. Fluid leaks from the fluid packing area Worn packings or rod. Replace packings or rod; see pages 32 or 33.
Troubleshooting Electrical Troubleshooting Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or repair this equipment unless you are trained and qualified. Problem Cause Solution Poor wrap. Turbine air is not turned on. Turn on. (In general, a Pro Xs Waterborne gun will have less wrap than a Pro Xs solventborne gun.) Booth exhaust velocity is too high.
Gun Repair Gun Repair Prepare the Gun for Repair Installing and repairing 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. To reduce the risk of injury, follow the Pressure Relief Procedure procedure on page 15 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure.
Gun Repair Remove the Gun from the Manifold Install the Gun on the Manifold 1. Loosen but do not remove the bottom gun screw (31) until the gun sits loosely in the mounting bracket slot (A). See FIG. 21. NOTICE The piston return spring (105) is compressed between the manifold and the gun body when they are assembled. To avoid sudden movement of the gun body, loosen the bottom gun screw (31) before loosening the three manifold screws (106).
Gun Repair Replace Air Cap/Nozzle NOTICE Fire, Explosion, and Electric Shock Hazard The nozzle contact ring (4a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the nozzle contact ring (4a) except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine Graco part.
Gun Repair Replace Electrode Needle 5. Apply low-strength (purple) Loctite® or equivalent thread sealant to the electrode needle and packing rod threads. Install the electrode needle finger-tight. Do not overtighten. 1. Prepare gun for repair, page 28. 2. Remove the charging probe (2), see page 9. 6. Install the fluid nozzle (4), page 30. 3. Remove the air cap and nozzle, page 30. Remove the gun shroud (48). 4. Unscrew the electrode needle (7) with the multi-tool (37).
Gun Repair Remove Fluid Packing Rod 37 NOTE: You may replace the packing rod as an assembly, as described below, or as individual parts (see page 33). The assembly is pre-adjusted at the factory. 1. Prepare gun for repair, page 28. 2. Remove the charging probe (2), see page 9. 3. Remove the air cap (3), fluid nozzle (4), and gun shroud (48), page 30. 9 8 4. Remove the jam nut (28) and actuator arm (29). See page 34.
Gun Repair Repair Packing Rod You may replace the packing rod as individual parts or as an assembly. The assembly is pre-adjusted at the factory. NOTE: Before installing the fluid packing rod into the gun barrel, make sure the internal surfaces of the barrel are clean. Remove any residue with a soft brush or cloth. Check the inside of the barrel for marks from high voltage arcing. If marks are present, replace the barrel. To assemble the individual parts: 1.
Gun Repair Piston Repair Table 4: Piston O-Rings 1. Prepare gun for repair, page 28. Description 2. Remove the charging probe (2), see page 9. 3. Remove the air cap, page 30. Remove the gun shroud (48). 4. Remove the jam nut (28), actuator arm (29), and adjustment nut (30). See FIG. 26. The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm. Function Shaft O-Ring (16g) Seals cylinder air along the piston rod (16b). Replace if air leaks along rod.
Gun Repair Adjust the Actuator Arm The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm. 1. Install the adjustment nut (30), actuator arm (29), and jam nut (28) onto the piston rod (16b). Note that the jam nut (28) has a slightly larger hex and a thinner profile than the adjustment nut (30). See FIG. 26 on page 34. 2. Position the parts so there is a 0.125 in.
Gun Repair Remove Barrel 1. Prepare gun for repair, page 28. 2. Remove the charging probe (2), see page 9. 9 3. Remove the air cap, page 30. Remove the gun shroud (48). 10 4. Carefully loosen the fluid fitting nut (20). Pull the tube (19) out of the fitting (23). Make sure both ferrules (21, 22) and the nut stay with the tube. 5. Remove the jam nut (28) and actuator arm (29). See page 34. 15 6. Loosen the three screws (10, 32). See FIG. 29.
Gun Repair Install Barrel 1. Be sure the gasket (11) and grounding spring (14) are in place. Make sure the air holes are aligned properly. Replace if damaged. See FIG. 31. 2. Place the barrel (9) over the power supply (12) and onto the gun body (15). 4. Assemble the fluid tube (19) into the fluid fitting (23). Ensure that the ferrules (21, 22) are in place. Tighten the nut (20). 5. Install and adjust the actuator arm (29) and jam nut (28). See page 35. 6.
Gun Repair Power Supply Removal and Replacement • Inspect the gun body power supply cavity for dirt or moisture. Clean with a clean, dry rag. • 5. Check the power supply resistance, page 24. Replace if necessary. Before installing the power supply, make sure the o-rings (12a, 13a), spring (12b), and pads (13e) are in place. 6. Connect the 6-pin flexible circuit (36) to the power supply. Do not expose gasket (11) to solvents. 7. Connect the 3-wire connector (GG).
Gun Repair Turbine Alternator Removal and Replacement Replace turbine alternator bearings after 2000 hours of operation. Order Part No. 223688 Bearing Kit. 1. Prepare gun for repair, page 28. 2. Remove the power supply/alternator assembly, page 38. 3. Disconnect the alternator from the power supply, page 39. 4. Measure resistance between the two outer terminals of the 3-wire connector (GG); it should be 2.5-3.5 ohms. If outside this range, replace the alternator coil. 5.
Parts Parts Part No. 24A206 PRO Auto Xs Electrostatic Gun, Series A, for standard coatings 4b Supplied Tools 4a 48 37 See Ref. No. 8: Packing Rod Detail on page 42 7 4 38 †1a See Ref. No. 13: Alternator Detail on page 42 3 1 36 12 †11 12a 10 14 9 See Ref. No.
Parts Part No. 24A206 PRO Auto Xs Electrostatic Gun, Series A, for standard coatings Ref. No. Part No. Description 1 24B548 1a*† 2 198307 24A328 3 4 24A276 197266 4a 4b 5 111261 111507 198486 7 8 24A338 24A331 8a* 8b* 8c* 8d* 8e 8f 8g* 8h 9 10 111316 116905 178409 178763 197641 185495 186069 24A330 24A329 197518 11*† 12 197517 24A332 12a* 13 256267 244555 RING, retaining, air cap; includes 1a . U-CUP PROBE, external (one spare is provided) AIR CAP NOZZLE; 1.
Parts Ref. No. 13: Alternator Detail †13a 8h 13b 8b 8e 8g 8c 8d 8f 13e 13c TI13397a 8a TI12719a Ref. No.
Parts Ref. No. 17: Manifold Detail Part No. 244586, Series A 5 (see page 41) 101 (Ref) 106 (Ref) †112 101 117 116 116a† 119 120 109 114 115 102 108 104 106 TI1578A 113 103 105 118 111 TI1582A 107 Ref. No. Part No. Description 101 102 103 104 105 106 198216 189581 110465 112689 112640 197518 107 108 109 110 111 111157 186845 110078 112646 189551 MANIFOLD BRACKET, reciprocator SCREW, set SCREW, button-hd SPRING, compression SCREW; socket-hd; 10-24 x 3/4 in.
Accessories Accessories Air Line Accessories AirFlex™ Flexible Grounded Air Hose Fluid Line Accessories Fluid Hose 225 psi (14 bar, 1.4 MPa) Maximum Working Pressure 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure FM Approved; nylon; 3/8 npsm(fbe) 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread 244963 244964 244965 244966 244967 244968 244969 6 ft (1.8 m) 15 ft (4.6 m) 25 ft (7.6 m) 36 ft (11 m) 50 ft (15 m) 75 ft (23 m) 100 ft (30.
Accessories Miscellaneous Accessories Ground Wire and Clamp 222011 For grounding pump and other components and equipment in the spray area. 12 gauge, 25 ft (7.6 m). Megohmmeter 241079 500 Volt output; 0.01-2000 megohms. Not for use in hazardous areas. Paint Resistance Meter 722886 Use with 722860 Paint Probe to measure resistance of paint. Not for use in hazardous areas. Paint Probe 722860 Use with 722886 Paint Resistance Meter to measure resistance of paint. Not for use in hazardous areas.
Accessories Gun Accessories Dielectric Grease 116553 1 oz (28 g) tube of dielectric grease for the power supply o-ring (12a), some packing rod parts (8), and certain fluid fittings. Gun Valve Lubricant 111265 4 oz (113 g) tube of sanitary (non-silicone) lubricant for fluid seals and wear areas. Alternator Bearing Kit 223688 To repair the turbine alternator. Cleaning Brush 105749 46 For cleaning air cap and fluid nozzle.
Technical Data Technical Data Category Maximum Working Fluid Pressure Maximum Working Air Pressure Minimum Air Pressure at Turbine Air Inlet Maximum Fluid Operating Temperature Paint Resistivity Range Short Circuit Current Output Voltage Output Sound Power (measured per ISO Standard 9216) Sound Pressure (measured 1 m from gun) Turbine air inlet fitting, left-hand thread Atomizing air inlet fitting Fan air inlet fitting Cylinder air inlet fitting Hi/Lo voltage selector air inlet fittings Fluid inlet fitting
Graco Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months or two thousand hours of operation from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
