INSTRUCTIONS-PARTS LIST This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. 308936 Rev. B Supersedes Rev. A First choice when quality counts. INSTRUCTIONS 85 KV ELECTROSTATIC Model PRO AA4500 /UNICARB Air-Assisted Spray Gun 100 psi (7 bar, 0.7 MPa) Maximum Working Air Pressure 3000 psi (207 bar, 20.7 MPa) Maximum Working Fluid Pressure For use with Class I, Group D paint spray materials Part No.
WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire, explosion, or electric shock. Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction manual. Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all other electrically conductive objects in the spray area.
WARNING INJECTION HAZARD Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause a serious injury. Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medical attention. Do not point the spray gun at anyone or any part of the body. Do not put hand or fingers over the spray tip.
Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the System . . . . . . . . . . . . . . . . . . . . . . . . Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction The ability of the PRO AA4500/UNICARB Electrostatic Spray Gun to spray at higher fluid pressures, combined with the addition of CO2 from the UNICARB process, provides the additional power needed to atomize higher solids materials. How the PRO AA4500/UNICARB Electrostatic Air-Assisted Spray Gun Operates WARNING The gun’s internal power cartridge provides high voltage current. The fluid is electrostatically charged as it passes the gun’s electrode.
Installation Installing the System Ventilate the Spray Booth WARNING WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD 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 N B H W P L K Q R X M S R WARNING SIGN Y 01945B KEY A* B H K L* Bleed-type Air Shutoff Valve Air Line Filter Fluid Shutoff Valve Pressure Gauge Grounded Braid Type Fluid Hose with spring guards M Gun Fluid Inlet (1/4 npsm) N Gun Air Regulator P Gun Air Shut-off Valve Q* Graco Electrically Conductive Air Supply Hose (1/4 npsm x 1/4 npsm LH) R* Fluid Drain Valve S Fluid Filter W PRO AA4500/UNICARB Spray Gun X Gun Air Inlet (1/4 npsm LH) Y Shrouded/Vented Waste Container * Equi
Installation Ground the System WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD When operating the electrostatic device, any ungrounded objects in the spray area (such as people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock. Follow the grounding instructions below. 4. All air and fluid lines must be properly grounded.
Operation Operating Checklist Check the following list daily, before starting to operate the system, to help ensure safe, efficient operation. ____ 1. All the operators are properly trained to safely operate an electrostatic air-assisted airless spray system as instructed in this manual. ____ 2. All the operators are trained how to properly relieve pressure, using the Pressure Relief Procedure on page 10.
Operation Pressure Relief Procedure WARNING INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury.
Gun Setup 1. Complete the Operating Checklist and follow the Warnings on pages 9 and 10. B. Connect the other end of the air supply hose (A) to a filtered and regulated air supply line (B). 2. Connect the Graco air hose. C. Connect the air supply hose ground wire (C) to a true earth ground. C WARNING ELECTRIC SHOCK HAZARD To reduce the risk of electric shock or other serious injury, the air supply hose must be electrically connected to a true earth ground.
Gun Setup 3. Check the gun’s electrical grounding. WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Megohmmeter P/N 218979 (E) 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: F. 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 air hose ground wire is connected to a true earth ground.
Gun Setup 5. Connect the fluid hose. 6. Flush the spray gun. A. Before connecting the fluid line, blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed. B. Connect the static-free fluid hose (F) to the 1/4–18 npsm gun fluid fitting (10). Before running any paint through the spray gun, make sure the trigger safety latch is in the locked position, and the ES ON-OFF lever is turned to OFF, then remove the spray tip.
Gun Setup A. Make sure there is no pressure in the system before removing or installing a spray tip. Relieve the system pressure. 10. Install the pre-orifice WARNING To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 10 when you stop spraying and whenever you are instructed to relieve the pressure. B. Place the spray tip (9) in the air cap (1), aligning the tab of the tip with the groove in the air cap.
Gun Setup 12. Set the air pressure. A. Atomizing air is not used in the UNICARB process. Close the air control valve (43) by turning it fully clockwise. B. Turn the ES ON-OFF lever (26) to ON. H 01997 Fig. 12D Recommended Air Hose Inlet Pressure 26 ON Fig. 12A-B 43 close Air Hose Length Recommended Air Hose Inlet Pressure 6 ft ((1.8 m) 40 psi (2.8 bar) 15 ft (5 m) 43 psi (3.0 bar) 25 ft (8 m) 45 psi (3.1 bar) 36 ft (11 m) 47 psi (3.2 bar) 50 ft (15 m) 50 psi (3.
Gun Setup 13. Setting the Atomization Fluid Pressure Atomization fluid pressure will vary based on the type of fluid used, the flow rate desired, the fluid temperature, and the percentage of CO2 used. Follow the recommendations of your material and equipment supplier. 14. Using the Electrostatics Turn the ES ON-OFF lever (26) to ON. This will activate the electrostatics.
Daily Gun Care, Flushing, and Cleaning CAUTION WARNING INJECTION HAZARD To reduce the risk of serious injury, including fluid injection, splashing in the eyes or on the skin or electric shock, always follow the Pressure Relief Procedure Warning on page 10 when shutting off the system, when you stop spraying and before checking, servicing, installing, cleaning or changing any part in the system. Clean all parts with a non-conductive solvent, compatible with the fluid being sprayed.
Daily Gun Care, Flushing, and Cleaning General System Maintenance 1 9 2 1. Clean the fluid and air line filters daily. 2. Check all of the work hangers for material build-up; clean them if necessary. 8 3. Check for any fluid leakage from the gun and fluid hoses. Tighten fittings or replace equipment as needed. 4. Flush the gun before changing colors and whenever you are done operating the gun. Fig.
Daily Gun Care, Flushing, and Cleaning 6. Lock the trigger safety latch and turn off the solvent supply. 7. Follow the Pressure Relief Procedure Warning on page 10. 11. Dip the end of a soft-bristle brush into a compatible solvent. Then point the gun down and clean the front with the brush and solvent. 8. Make sure the trigger safety latch is locked, then disconnect the solvent (F) and air (A) supply hoses from the gun. 02007 F A 02341 02338 Fig. 8 9.
Daily Gun Care, Flushing, and Cleaning 13. Remove the bottom fluid tube fitting (P) and filter (14). Clean the filter in a compatible solvent. 14. Reinstall the filter and fitting. Do not over-tighten and make sure the top fluid tube fitting (Q) remains tightened. 16. Clean the retaining nut, tip guard, air cap and fluid tip with a soft brush daily, minimum. Clean the parts with a soft brush and replace them if they are damaged. Be careful not to bend, damage, or disengage the electrode wire.
Daily Gun Care, Flushing, and Cleaning 19. Place the spray tip (9) in the air cap (1). 21. Hang up the gun until it is used again. Align the tab of the tip with the groove in the air cap. Be careful not to bend the electrode wire. WARNING ELECTRIC SHOCK HAZARD To reduce the risk of electric shock or explosion, never operate the spray gun with a bent, damaged or missing electrode. 1 02012B Fig. 21 CAUTION 9 Fig. 19 8800A 20.
Spray Pattern Troubleshooting WARNING Installing and servicing this equipment requires access to parts which 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 Operation Troubleshooting PROBLEM CAUSE SOLUTION Leakage from fluid needle area Fluid needle packings loose Tighten packing nut; See page 33 Fluid needle packing damaged Replace fluid needle; See page 34 Air valve not turned off Turn off air (43).
Electrical Troubleshooting NOTE: Additional gun troubleshooting can be done on Gun Part No. 236031 using the Remote Spraying Voltage Readout (SVR ). See Accessories to order the SVR.
Electrical Tests The performance and safety of the spray gun are directly affected by the condition of the electrical components contained inside the gun. The electrical tests below can be used to determine the condition of the power supply (18) and the barrel resistor cartridge as well as the continuity of the electrical path between the components. CAUTION The barrel resistor cartridge is part of the barrel and is not replaceable.
Electrical Tests A Test Power Supply Resistance (See Fig. 5) Remove the power supply (18) from the gun. See page 35. Measure the resistance from the power supply’s ground contact point (EE) to the contact inside of the power supply seal (18e) [the conductive rubber contact may be slightly recessed into the seal]. See Fig. 5. The resistance should be 297 to 363 megohms. If the resistance is outside the specified range, the power supply is defective and must be replaced.
Electrical Tests Test Barrel Resistance (See Fig. 6) WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD The barrel contact ring (3a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the barrel contact ring from the barrel 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.
Service Prepare the Gun for Service WARNING ELECTRIC SHOCK HAZARD Installing and servicing 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.
Service Pre-Orifice, Tip Guard, Air Cap, Spray Tip, or Seat Housing Replacement 1. Prepare the gun for service as instructed on page 28. 2. Remove the retaining nut (8), tip guard, (2), air cap (1), and spray tip (9). See Fig. 7. You may have to turn the air cap with the tip guard to remove the air cap from the gun. CAUTION To avoid damaging the tip guard (2), orientate the air cap (1) before tightening the retaining nut (8). Do not turn the air cap when the retaining nut is tight. 7.
Service Electrode Replacement WARNING ELECTRIC SHOCK HAZARD To reduce the risk of fire, explosion, or electric shock, do not operate the spray gun without the electrode installed in the air cap. 5. Assemble the spray tip, air cap, and tip guard. Then install them on the gun, securing them with the retaining nut. Tighten the retaining nut firmly. 6. Test the gun resistance as instructed on page 25. 1a 1 1. Prepare the gun for service as instructed on page 28. 2.
Service Fluid Tube Removal & Replacement To remove the fluid tube assembly (12) for cleaning or replacement: Fluid Filter Removal 1. Prepare the gun for service as instructed on page 28. 2. Disconnect the bottom fluid tube nut (C). See Fig. 10. 1. Prepare the gun for service as instructed on page 28. 3. Remove the fluid filter (14) from the fluid fitting (10). Clean or replace the filter, as needed. 2. Disconnect the bottom fluid tube nut (C). See Fig. 10. 4.
Service Barrel Removal 1. Prepare the gun for service as instructed on page 28. 2. Disconnect the bottom fluid tube nut (C). See Fig. 12. NOTE: 2-finger trigger guns only It should not be necessary to remove the fluid fitting (10) from the bracket. If you must remove it, remove the two setscrews in the bracket that hold it in place. Apply a low strength (purple) Loctite to setscrews before re-installing them. 3. Loosen the three cap screws (5), using the 4 mm driver (55), supplied. 4.
Service Fluid Packing Adjustment If fluid leaks from the fluid needle area, the fluid packings may be loose. Tighten the packings, following the procedure below. 1. Prepare the gun for service as instructed on page 28. 2. Remove the retaining nut (8), tip guard, (2), air cap (1), and spray tip (9). See Fig. 7, page 29. You may have to turn the air cap with the tip guard to remove the air cap from the gun. 3. Trigger the gun and remove the seat housing (21) with the 9 mm driver (64), supplied. See Fig.
Service Fluid Needle Assembly Removal 1. Prepare the gun for service as instructed on page 28. 2. Remove the retaining nut (8), tip guard, (2), air cap (1) and spray tip (9). See Fig. 7, page 29. You may have to turn the air cap with the tip guard to remove the air cap from the gun. 3. Trigger the gun and remove the seat housing (21) with the 9 mm driver (64). See Fig. 8, page 29. 10. Assemble the barrel as instructed on page 36. 11.
Service 35 18d 18 18b 7 18a 18c 18e F 37a 3 37b 37 01953A Fig. 16 Power Supply Removal and Replacement NOTES: a. To avoid a loss in electrostatic performance, inspect the gun handle’s power supply cavity for dirt or moisture. Clean the cavity with a clean, dry rag. b. Do not expose the seal (18e) or o-ring (37a) to solvents as it will damage them. c. Be careful when handling the power supply to avoid damaging it. 1. Prepare the gun for service as instructed on page 28. 2.
Service Turbine Alternator Removal and Replacement NOTE: Replace turbine bearings after 2000 hours of operation. See your authorized Graco representative. 3. Pressing the barrel and handle together, tighten the three cap screws (5) oppositely and evenly with the 4 mm driver (55). Tighten the cap screws to 18 in-lbs (2 N m) maximum (about a half turn past snug). Do not over-tighten. 1. Prepare the gun for service as instructed on page 28. 2.
Service ES ON-OFF Valve Repair 1. Prepare the gun for service as instructed on page 28. 2. Loosen the set screw (24) with the 2 mm hex key (63), supplied. Remove the lever (26) from the valve. See Fig. 18. WARNING MOVING PARTS HAZARD To reduce the risk of eye injury, be sure to wear safety glasses when removing or installing the retaining ring (47) as the retaining ring could slip off the tool when compressed. 3. Use internal snap ring pliers to remove the retaining ring (47) from the handle.
Service DETAIL Air Control Valve Repair 43b NOTE: The air control valve (43) can be replaced as an assembly or as individual parts. 43d 43g To disassemble the air control valve, 1. Prepare the gun for service as instructed on page 28. 2. Remove the retaining ring (43h). See Fig. 19. 3. Slide the KV HI-LO lever (43g) up, place a wrench on the flats of the valve housing and remove the air control valve assembly (43). 4. Remove the retaining ring (43b).
Service 7. Install the air valve shaft, with the o-ring (41) into the back of the gun handle (7). Air Valve Repair 1. Prepare the gun for service as instructed on page 28. 2. Using a screw driver, remove the air valve cap (45). See Fig. 20. 3. Remove the o-ring (23) and spring (44). 8. If removed, install the u-cup with its lips facing into the gun handle. 9. Tighten the air valve packing nut (40) until it bottoms. 10. Install the spring (44), o-ring (23) and air valve cap (45).
Notes 40 308936
Technical Data Category Data Gun Weight 35 oz (1 kg) Gun Length 11.4 in (290 mm) Maximum Air Working Pressure 100 psi (7 bar, 0.7 MPa) Maximum Fluid Working Pressure 3000 psi (207 bar, 20.7 MPa) Typical Noise Level at 40 psi (2.8 bar, 0.28 MPa)* Sound Pressure 86 Db(A) Sound Power 88.9 Db(A) Maximum Noise Level at 100 psi (7 bar, 0.7 MPa)** Sound Pressure 95 Db(A) Sound Power 99.
Parts 5 4 3 3a 21 9b 13 9a 9 REF 12 1 2 37a 1a 37 8 37b 18d 35 18b 18 18e 18a 18c 34 28 43c 43e 43h 31 19 43f 43g 43d 43b 45 23 6 44 41 39 24 30 26 42 47 32 40 36 38 15 7 46 19 Item 1 includes item 1a Item 3 includes item 3a Item 18 includes items 18a to 18e Item 37 includes items 37a and 37b Item 43 includes items 43b to 43h Item 45 includes items 45a to 45e 33 16 17 12 14 42 308936 56 57 01956D
Parts WARNING Some PRO 4500sc Gun replacement parts look similar to other PRO Gun parts but are not interchangeable! When servicing, do not mix or use other PRO Gun parts! Use of parts other than those specified in the parts list below could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction and result in serious injury, fire, explosion or property damage. Part No. 965722, Series B Includes items 1–8, 10–67 Ref No. Part No.
Accessories Use Only Genuine Graco Parts and Accessories AIR LINE ACCESSORIES Conductive Air Supply Hose; black 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure FM Approved; Color coded black; 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread 220444 218100 218101 218102 218103 220119 220120 6 ft (1.8 m) 15 ft (5 m) 25 ft (8 m) 36 ft (11 m) 50 ft (15 m) 75 ft (23 m) 100 ft (30.5 m) Conductive Air Supply Hose; gray 100 psi (7 bar, 0.
Accessories Use Only Genuine Graco Parts and Accessories FLUID LINE ACCESSORIES GUN ACCESSORIES High Pressure Ball Valves 5000 psi (350 bar, 35 MPa) Maximum Working Pressure Electrostatic Gun Cleaning Kit 236659 Required when using Graco Gun Washers 112634, 112635, and 112636 to clean this gun.
Accessories Use Only Genuine Graco Parts and Accessories Gun High Voltage Probe and Meter 236003 For direct measurement of gun output voltage MISCELLANEOUS ACCESSORIES Grounding Clamp and Wire 222011 12 ga, 25 ft (7.6 m) wire Paint Resistance Meter 722886 Used with 722860 Paint Probe to measure resistance of paint; Not for use in Hazardous areas 0189 Megohmmeter 218979 500 Volt output; 0.
Spray Tip Selection Chart Fan Width at 10 in. (260 mm) in. (mm) Part No. Orifice Size in. (mm) Part No. 0.007 (0.178) Fan Width at 10 in. (260 mm) in.
The Graco Warranty and Disclaimers WARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months or two thousand hours of operation from time of sale, repair or replace any part of the equipment proven defective.
