Instructions Manual Electrostatic PRO™ Xs Waterborne Air Spray Gun For use with conductive spray materials (waterborne and other materials less than 1 megohm-cm). For professional use ONLY. 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. II 2 G EEx 0.24 mJ 247936 Standard Model 247937 Smart Model 100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure 100 psi (0.
Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 3 Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 How the Electrostatic Air Spray Gun Works . . . . 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install the System . . . . . . . . . . . . . . . . . . . . . . .
Warnings Warnings Warning Symbol Notice WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. NOTICE 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 EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. • Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use.
Overview Overview How the Electrostatic Air Spray Gun Works The air hose supplies air to the spray gun. Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed. The turbine generates power, which is converted by the power cartridge to supply high voltage current to the gun’s external charging probe.
Overview A. Air swivel inlet. Left-hand thread. ti1254a A B. Fluid inlet. ti1254a B C. Turbine air exhaust. C D. ti1254a Air cap and nozzle. See page 13 for sizes. ti1255a D E. Fluid needle. Shuts off fluid flow and provides a ground point.
Overview F. Fluid adjustment valve. Adjusts fluid needle travel. Use only in low flow conditions, to reduce needle wear. 0 MAX FLUID WPR: 100 PSI (7bar, 0.7 Mpa) HI LO 100% KV Ma ES MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa) ES I O F G. Fan air adjustment valve. Adjusts fan size and shape. 0 KV Ma HI LO ES MAX FLUID WPR: 100 PSI (7bar, 0.7 Mpa) G MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa) ES I H. 100% O Atomizing air restrictor valve. Restricts atomizing air flow.
Overview J. ES indicator (247936 only). Green when ES is ON (I). MAX FLUID WPR: 100 PSI (7bar, 0.7 Mpa) MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa) J To avoid shock or explosion •Use properly grounded air hose •Read instruction manual I O ES ti12581 K. Voltage (247937 only). Shows voltage and current. Green/yellow=spray, red=see Electrical Troubleshooting, page 22. Voltage K 0 Current KV Ma HI LO ES NOTE: Normal current draw for this model is higher and the yellow current bar will be lit.
Installation Installation Install the System Warning Sign Mount warning signs in the spray area where they can easily be seen and read by all operators. An English Warning Sign is provided with the gun. 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.
Installation a m d ‡e c‡ c‡ o b‡ ES ON/OFF valve: I is ON, O is OFF h g f ti12721 j‡ l v s g ‡r w p k n u‡ q‡ t ti1498ax Fig. 1.
Installation Connect the Air Line 5. Install an air shutoff valve (P) on each gun air supply line to shut off air to the gun(s). Connect the Charging Probe To reduce the risk of electric shock or other serious injury, the air supply hose must be electrically connected to a true earth ground. Use only Graco Grounded Air Supply Hose. 1. Connect the Graco Grounded Air Supply Hose (R) between the air supply line and the gun's air inlet (V) (FIG. 2). The gun air inlet fitting has a left-hand thread.
Installation Connect the Exhaust Tube Press the exhaust tube (38) onto the barbed adapter on the bottom of the gun handle. Secure the tube with the clamp (39) (FIG. 5). W Barbed adapter N ti1277a ti1277 FIG. 6 38 5. Before running any paint through the spray gun, flush it with a compatible solvent. 39 Filter the Fluid ti1275a FIG. 5 Install a fluid filter (K) to remove particles and sediment that could clog the spray nozzle. Connect the Fluid Line 1.
Installation 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 1 and Table 2 , and instruction manual 309419, or consult with your Graco distributor. See Replace Air Cap/Nozzle on page 28. A wide pattern kit (P/N 24A431) is included with the gun and if installed, will provide more fan air for wider spray patterns. (If pattern becomes split, use the fan air valve to reduce the amount of fan air.
Installation Grounding • 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. If gloves are necessary, wear the conductive gloves that are supplied with the gun. If non-Graco gloves are worn, cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle.
Installation Check Electrical Grounding BB Fire, Explosion, and Electric Shock Hazard Megohmmeter Part No. 241079 (AA-see FIG. 7.) is not approved for use in a hazardous area.
Installation Check Fluid Viscosity 4. Fully open atomizing air restrictor valve. To check fluid viscosity you will need: • a viscosity cup • a stopwatch. ti1272a 1. Completely submerge the viscosity cup in the fluid. Lift the cup out quickly, starting the stopwatch as soon as the cup is completely removed. 2. Watch the stream of fluid coming from the bottom of the cup. As soon as there is a break in the stream, shut off the stopwatch. 3.
Installation 7. Set gun air regulator to deliver minimum 40 psi (0.28 MPa, 2.8 bar) at gun when triggered, for maximum transfer efficiency. See table at right. 10. Turn ES ON/OFF switch ON (I). HI LO ES I MAX FLUID WPR: 100 PSI (7bar, 0.7 Mpa) MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa) ES O ti12732 TI1281A Air Hose* Length ft (m) Regulator Setting** psi (MPa, bar) 15 (4.6) 50 (0.35, 3.5) 25 (7.6) 60 (0.42, 4.2) 50 (15.3) 75 (0.52, 5.2) 11. Check that ES indicator or display is lit.
Installation Flush 3. Change fluid source to solvent, or disconnect fluid line and connect solvent supply line to gun. Fire, Explosion, and Electric Shock Hazard Read Fire and Explosion, and Electric Shock Hazards, page 3. Follow steps 1-6 below to flush the gun when using gun first time, changing colors, before fluid dries, at end of day, and before storing gun. NOTICE This gun has nylon components which will be damaged if you use methylene chloride as a flushing or cleaning solvent. ti1287a 4.
Pressure Relief Pressure Relief 5. If the nozzle or hose is completely clogged or pressure is not fully relieved, slowly loosen the hose end coupling. Now clear the nozzle or hose. Pressurized Equipment Hazard The system pressure must be manually relieved to prevent the system from starting or spraying accidentally.
Maintenance Maintenance Clean Gun Daily 4. Clean air cap, retaining ring, and nozzle with soft brush and non-conductive, compatible solvent. 1. Flush, page 18. ti1297a 2. a. Clean outside of gun with non-conductive, compatible solvent. Point gun down. b. Use soft, damp cloth. c. Do not immerse gun. 5. Clean probe with soft brush and compatible solvent. ti12716 ti1295a ti1292a 6. Use toothpick or other soft tool to clean air cap holes. Do not use metal tools. ti1293a ti1294a 7.
Maintenance Daily System Care 1. Relieve pressure, page 19. 5. Check movement of trigger (T) and valves (V). Lubricate if necessary. T V ti1934 2. Clean fluid and air filters. ti12658 3. Check for fluid leaks. Tighten all fittings. ti1291a 4. Clean workpiece hangers. Use non-sparking tools.
Electrical Troubleshooting Electrical Troubleshooting NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun. Electric Shock Hazard 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. ES ON/OFF valve OFF (0).* Turn ON (I).
Electrical Tests Electrical Tests Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (18), barrel (16) and charging probe (31), and electrical continuity between components. Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V. Connect the leads as shown. Test Gun Resistance Measure resistance between the air swivel (35) and the charging probe socket (CC) (see FIG. 9); it should be 70-95 megohms.
Electrical Tests Test Power Supply Resistance Test Barrel Resistance 1. Remove the power supply (18), page 31. 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 32. 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. 11. 2.
Spray Pattern Troubleshooting Spray Pattern Troubleshooting Electric Shock Hazard 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. Pressurized Equipment Hazard To reduce the risk of an injury, follow the Pressure Relief procedure on page 19 whenever you are instructed to relieve the pressure.
Gun Operation Troubleshooting Gun Operation Troubleshooting Electric Shock Hazard 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. Pressurized Equipment Hazard To reduce the risk of an injury, follow the Pressure Relief procedure on page 19 whenever you are instructed to relieve the pressure.
Gun Repair Gun Repair Prepare the Gun for Repair Electric Shock Hazard 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.
Gun Repair Replace Air Cap/Nozzle NOTICE Hold the front end of the gun up and trigger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from entering the air passages. 1. Prepare gun for repair page 27. 5. Lightly lubricate the o-ring (7b). Install it and the contact ring (7a) on the nozzle (7). Make sure the fluid needle (29) is finger- tight (page 28). 6. Trigger gun while installing the fluid nozzle (7) with the multi-tool (37).
Gun Repair Remove Fluid Packing 1. Prepare the gun for repair, page 27. 2. Remove the air cap and fluid nozzle, page 28. 3. Remove the fluid needle, page 28. 4. Loosen the trigger screws (8) and trigger (30). See FIG. 14. 5. Remove the packing rod (26), using the multi-tool (37). 37 30 NOTICE Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause the gun to malfunction. 8 6.
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. 4. Lightly tighten the packing nut (26g). The packing nut is properly tightened when there is 3 lb (13.3 N) of drag force when sliding the packing housing (26b) assembly along the rod. Tighten or loosen the packing nut as needed. Before installing the fluid packing rod into the gun barrel, make sure the internal surfaces of the barrel are clean.
Gun Repair Remove Barrel Install Barrel 1. Prepare the gun for repair, page 27. 1. Be sure the gasket (10*) and grounding spring (53) are in place. Make sure the air holes are aligned properly. Replace if damaged. See FIG. 17. 2. Carefully loosen the nut (54) from the bracket fluid fitting (13). Pull the tube (14 or 50a) out of the fitting. Make sure both ferrules and the nut stay with the tube. 3. Loosen the three screws (11). 3.
Gun Repair Remove and Replace Power Supply • Inspect the gun handle power supply cavity for dirt or moisture. Clean with a clean, dry rag. • Do not expose gasket (10) to solvents. 11. Install the barrel (16), page 31. Ensure the ground spring (53) is in place. 12. Test gun resistance, page 23. 17 1. Prepare gun for service, page 27. 10* 2. Remove the barrel (16), page 31. NOTICE Be careful when handling the power supply (18) to avoid damaging it. 19a* 19 19e 3.
Gun Repair Remove and Replace Turbine Alternator Replace turbine alternator bearings after 2000 hours of operation. Order Part No. 223688 Bearing Kit. Repair Fan Air Adjustment Valve 1. Prepare the gun for service, page 27. 2. Place a wrench on the flats of the valve assembly (20) and unscrew it from the handle (17). 1. Prepare gun for repair, page 27. 2. Remove the power supply/alternator assembly, page 32. You may replace the valve as an assembly (go to step 9) or as individual parts (steps 3-9). 3.
Gun Repair Repair Fluid Adjustment Valve 1. Prepare the gun for repair, page 27. 2. Remove the fluid adjustment valve (25). It can only be replaced as a complete assembly. See FIG. 20.. 3. Screw the valve (25) into the gun handle. Torque to 15-25 in-lb (1.7-2.8 N•m). 5. Inspect the u-cup (6*). Do not remove the u-cup unless damaged. If removed, install the new one with its lips facing into the gun handle (17). 6. Install the air valve (21) and spring (15) into the gun handle (17). 7.
Gun Repair Remove and Replace Atomizing Air Restrictor Valve 1. Prepare the gun for repair, page 27. Repair ES ON/OFF Valve 1. Prepare the gun for repair, page 27. 2. Loosen the screw (48). Remove the valve. 2. Remove the atomizing air restrictor valve (23). Inspect the o-ring (23c*). Replace if necessary. See FIG. 22. 3. Lubricate the o-rings (22a* and 22b*) with non-silicone grease, Part No. 111265. Do not over-lubricate. NOTICE Do not over-lubricate parts.
Parts Parts Part No. 247936 60 kV Electrostatic Gun, Series A (Standard model) See page 38 for detail views of the alternator (19), fan adjustment valve (20), ES ON/OFF valve (22), and packing rod (26). 10* 1 Maximum torque 10 in-lb (1.1 N•m) 1 60 31 8 11 16 53 8 1 26 7 7b 30 9 27a* 4 27 22 1 6* 29 3 20 7a 19 25 15 21 18 23 18a 32 55 2 17 13 Ref. No.
Parts Part No. 247937 60 kV Electrostatic Gun, Series A (Smart model) See page 38 for detail views of the alternator (19), fan adjustment valve (20), ES ON/OFF valve (22), and packing rod (26). 10* 1 Maximum torque 10 in-lb (1.1 N•m) 31 60 1 8 11 16 53 8 1 26 7 7b 30 9 27a* 4 27 58 5 1 22 6* 57 29 7a 59 56 3 20 19 25 15 21 18 18a 23 32 55 2 17 13 Ref. No.
Parts Ref. No. 19: Alternator Ref. No. 20: Fan Adjustment Valve 20d 19a* 19b TI1487A 20b* 20c 19b 20a TI1481a 19e Ref. No. 26: Packing Rod 26a 19d 19c Ref. No. 22: ES ON/OFF Valve 26f† 22g 26g 26e† 22e 26d† 22d 26c† 26b 22b* 22c 22a* 22f ti12719 26h† ti12720 247937 (Smart Model) controls Ref. No. 37: Multi-tool 247936 (Standard Model) controls 0 MAX FLUID WPR: 100 PSI (7bar, 0.7 Mpa) MAX AIR WPR: 100 PSI (7bar, 0.
Parts Part No. 247936 60 kV Electrostatic Gun, Series A (Standard model) Part No. 247937 60 kV Electrostatic Gun, Series A (Smart model) Ref. No. Part No. Description 1 111157 FITTING, tube, fluid 1 2 197967 PLUG, handle 1 3 198058 SCREW, cap, socket head 1 4 185111 SPRING, compression 1 5 111450 PACKING, o-ring (247937 only) 1 6* 188749 PACKING, u-cup, air valve; UHMWPE 1 Qty Ref. No. Part No. Description 20 244556 VALVE, adjustment, fan; includes 20a-20d 1 20a 101021 .
Parts Ref. No. Part No. Description 42▲ 179791 TAG, warning (not shown); replacement available at no cost 1 43▲ 180060 SIGN, warning (not shown); replacement available at no cost 1 1 53 197624 SPRING, compression 1 . PACKING, fluid 1 54 112644 NUT, swagelock 1 186069 . SPACER, packing 1 55 111286 FERRULE, front 1 26f† 116905 . SEAL 1 56 197910 SCREW, pivot, ES HI/LO (247937 only) 1 26g 197641 .
Accessories Accessories Air Line Accessories AirFlex™ Flexible Grounded Air Hose 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure 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 (30.5 m) Air Line Quick Disconnect 112534 Swiveling quick disconnect replaces standard air inlet swivel. Air Hose Adapter Nipple 185493 Use to connect multiple air hoses.
Accessories Gun Accessories Gun Repair Kits 244781 244911 Air Seal Repair Kit Fluid Seal Repair Kit Miscellaneous Accessories Ground Wire and Clamp 222011 Push/Pull Fan Air Valve 244912 For quick change of fan size. ES Always On Kit 244913 Replaces inlet fitting with ball valve to shut off air during flushing. Converts ES ON/OFF valve to always ON condition.
Technical Data Technical Data Category Maximum Working Fluid Pressure.................................... Maximum Working Air Pressure ........................................ Maximum Fluid Operating Temperature ............................ Maximum voltage output ................................................... Sound Pressure (measured per ISO Standard 9216) ....... Sound Pressure (measured 1 m from gun) ....................... Air inlet fitting, left-hand thread.........................................
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.
