Graco 309457G- User Manual

Warnings 309457G 5 Equipment Misuse Hazard Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in a serious injury. • This equipment is for professional use only. • Read all manuals, tags, and labels before operating the equipment. • Use the equipment o...

Introduction 6 309457G Introduction 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 drop...

Introduction 309457G 7 • The optional fiber optic readout system can be installed to monitor the gun’s spraying voltage. A fiber optic cable connected to the gun manifold car-ries the signal from the gun to a remote display module. Part No. 224117 Display Module displays the gun’s spraying voltage a...

Introduction 8 309457G Fig. 1. Gun OverviewKey TI1790A TI1780A TI1557A Manifold Back A B C D E F G H J A1 A2 CYL EXH FO KV2 P1 P2 TA KV1 A Air Cap B Fluid Nozzle C Retaining Ring D Shroud E Mounting Bracket F Manifold G Turbine H Power Supply J Electrode Manifold Markings A1 Atomization Air Inlet Fi...

Installation 309457G 9 Installation Install the System F IG . 2. shows a typical electrostatic air spray system, and F IG . 3. shows possible system options. It is not an actual system design. For assistance in designing a sys-tem to suit your particular needs, contact your Graco distributor. Basic ...

Installation 10 309457G Warning Signs 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. Ventilate the Spray Booth Electrically interlock the gun turbine air supply (B) with the ventilators to prevent gun o...

Installation 309457G 11 Fig. 2. Typical Installation Fig. 3. Optional Fiber Optic Connection to Voltage Display Module TI1801A A B C D E F J K M N G NOTE: * The turbine air supply (TA) must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating w...

Installation 12 309457G Install the Air Line Accessories 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 a...

Installation 309457G 13 Connect the Air Line F IG . 3. shows a schematic of air line connections, and F IG . 5. shows the manifold connections. Connect the air lines as instructed. 1. Connect the red-colored Graco Grounded Air Sup-ply Hose (B) to the gun's turbine air inlet (TA) and connect the hose...

Installation 18 309457G Grounding The following are minimum grounding requirements for a basic electrostatic waterborne system. Your system may include other equipment or objects which must be grounded. Check your local electrical code for detailed grounding instructions. Your system must be connect...

Installation 309457G 19 Check Electrical Grounding 1. Have a qualified electrician check the electrical grounding continuity of the spray gun and turbine air hose. 2. Make sure the red-colored turbine air hose (B) is connected and the hose ground wire is connected to a true earth ground. 3. Turn off...

Installation 20 309457G Install the Fabric Cover 1. Install a fabric cover (XX) over the front of the gun and slide it back to cover the exposed tubing and hoses at the back of the manifold. See F IG . 12.. 2. Route the exhaust tube (YY) outside the cover. This enables you to monitor the exhaust tub...

Operation 309457G 21 Operation Fluid Voltage Discharge and Grounding Procedure NOTE: An accessory grounding rod, par t No. 210084, is available to discharge any voltage remaining on a sys-tem component. Contact your Graco distributor to order. 1. Turn off the turbine air to all spray guns connected ...

Operation 22 309457G Operating Checklist Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient opera-tion. 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, ref...

Operation 309457G 23 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. Discharge the system voltage (page 21). 2. Relieve the pressure (page 21). 3. Loosen the air cap retaining ring, and rotate the air cap f...

Operation 309457G 25 Adjust the Electrostatics 1. Shut off the fluid supply. 2. Prepare the isolation system for high voltage opera-tion. 3. Trigger the gun, then turn on the turbine air (TA). See F IG . 14.. 4. Refer to Table 4 to set the proper pressure at the turbine air hose inlet when air is fl...

Maintenance 26 309457G Maintenance Daily Care and Cleaning CAUTION • 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 28 309457G Clean the Air Cap and Fluid Nozzle Equipment Needed • soft bristle brush • compatible solvent Procedure 1. Discharge the system voltage, page 21. 2. Relieve the pressure, page 21. 3. Remove the air cap assembly (1, 3) and shroud (2). See F IG . 15.. 4. Wipe the fluid nozzle (4...

Maintenance 309457G 29 Check for Fluid Leakage During operation, periodically check the manifold exhaust tube (YY) and both ends of the gun shroud (ZZ) for the presence of fluid. See F IG . 16.. Fluid in these areas indicates leakage into the shroud, which could be caused by leaks at the fluid tube ...

Electrical Tests 30 309457G Electrical Tests Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (12) and electrode (7), and electrical continuity between components. Use megohmmeter Par t No. 241079 (AA) and an applied ...

Electrical Tests 309457G 31 Test Power Supply Resistance 1. Remove the power supply (12), page 49. 2. Remove the turbine alternator (13) from the power supply, page 50. 3. Measure resistance from the power supply's ground strips (EE) to the spring (12b). See F IG . 18.. 4. The resistance should be 9...

Electrical Tests 32 309457G Test Electrode Resistance 1. Insert a conductive rod (B) into the gun barrel (removed for the power supply test) and against the metal contact (C) in the front of the barrel. 2. Measure the resistance between the conductive rod (B) and the electrode (7). The resistance sh...

Troubleshooting 309457G 33 Troubleshooting Voltage Loss Troubleshooting Normal spraying voltage for a system using the water-borne gun is 45-55 kV. The system voltage is lower due to spraying current demands and voltage isolation sys-tem losses. A loss of spraying voltage can be caused by a problem ...

Troubleshooting 34 309457G Visual Check First, check the system for any visible faults or errors to help isolate whether the spray gun, fluid hose or voltage isolation system has failed. A voltage probe and meter, part no. 236003, is helpful for diagnosing voltage prob-lems and is required for some ...

Troubleshooting 36 309457G Spray Pattern Troubleshooting NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun. NOTE: Some spray pattern problems are caused by the improper balance between air and fluid. Problem Cause Solution Fluttering or spitting spray. No fl...

Troubleshooting 309457G 37 Gun Operation Troubleshooting Problem Cause Solution Excessive spray fog. Atomizing air pressure too high. Decrease air pressure as low as pos-sible. Fluid too thin. Increase viscosity. “Orange Peel” finish. Atomizing air pressure too low. Increase air pressure; use lowest...

Troubleshooting 38 309457G Electrical Troubleshooting Problem Cause Solution Voltage still present at gun after fol-lowing the Fluid Voltage Discharge and Grounding Procedure Turbine air is not turned off. Turn off. Did not wait long enough for voltage to discharge. Wait longer before touching elect...

Repair 309457G 39 Repair Prepare the Gun for Service • Check all possible remedies in Troubleshooting before disassembling the gun. • Use a vise with padded jaws to prevent damage to plastic par ts. • Lubricate the power supply o-ring (12a), some pack-ing rod parts (8), and certain fluid fittings wi...

Repair 40 309457G Remove the Gun from the Manifold 1. Discharge the system voltage, page 21. 2. Flush and clean the gun, page 26. 3. Relieve the pressure, page 21. 4. Remove the air cap (3) and shroud (2), page 41. 5. Disconnect the fluid hose fitting (F) from the gun barrel (9). 6. Loosen the botto...

Repair 309457G 41 Air Cap/Nozzle Replacement 1. Prepare gun for service, page 39. 2. Remove the retaining ring (1) and air cap (3). See F IG . 23.. 3. Point gun up while removing the fluid nozzle (4) assembly with the multi-tool (40). Fig. 23. Air Cap/Nozzle Replacement NOTE: Use non-silicone grease...

Repair 42 309457G Electrode Replacement 1. Prepare the gun for service, page 39. 2. Remove the air cap and nozzle, page 41. Remove the gun shroud (2). 3. Unscrew the electrode (7) with the multi-tool (40). Hold the packing rod end (8h) to prevent it from turn-ing, F IG . 24.. 4. Apply low-strength (...

Repair 309457G 43 Fluid Packing Removal NOTE: You may replace the packing rod as an assem-bly, as described below, or as individual parts (see page 44). The assembly is pre-adjusted at the factory. 1. Prepare the gun for service, page 39. 2. Remove the air cap, page 41. Remove the gun shroud (2). 3....

Repair 44 309457G Packing Rod Repair NOTE: You may replace the packing rod as individual parts, as described below, or as an assembly (see page 43). 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 ...

Repair 309457G 45 Piston Repair 1. Prepare the gun for service, page 39. 2. Remove the air cap, page 41. Remove the gun shroud (2). 3. Remove the jam nut (28), actuator arm (29), and adjustment nut (30). See F IG . 27.. NOTE: The fluid nozzle (4) must be in place when removing or installing the jam ...

Repair 46 309457G Adjust the Actuator Arm NOTE: 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 (34b). Note that the jam nut (28) has a slightly larger hex and ...

Repair 309457G 47 Barrel Removal 1. Prepare the gun for service, page 39. 2. Remove the air cap, page 41. Remove the gun shroud (2). 3. Carefully loosen the fluid fitting nut (20). Pull the tube (19) out of the fitting (23). Make sure both fer-rules (21, 22) and the nut stay with the tube. 4. Remove...

Repair 48 309457G Barrel Installation 1. Be sure the gasket (11) and grounding spring (51) are in place. Make sure the air holes are aligned properly. Replace if damaged. See F IG . 32.. 2. Place the barrel (9) over the power supply (12) and onto the gun body (32). 3. Tighten the three screws (10, 3...

Parts 52 309457G Parts Part No. 244591 PRO Auto Xs Electrostatic Gun, Series A, for waterborne coatings TI1777A ti1601a 7 12 34a 35 9 4a 4b 10 12a 12b 32 2 34d 1 3 4 8 11 13 13e 13a 34c 34f 34e 34g 34b 30 27 26 29 28 31 25 TI1481a 13a 13b 13b 13c Ref. No. 13: Alternator De-tail 13d 13e 8a 8b 8c 8d 8...

Accessories 56 309457G Accessories Air Line Accessories Grounded Air Hose (Red Cover) 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; red cover with stainless steel braid ground path. 235068 6 ft (1.8 m) 235069 15 ft (4.6 m) 235070 2...

Accessories 309457G 57 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. Grounding Rod 210084 Use to discharge ...

Accessories 58 309457G Gun Accessories Round Pattern Kits Consists of fluid tip, diffuser and air cap. 245217 4-6 in. (102-152 mm) diameter 245219 8-10 in. (203-254 mm) diameter Dielectric Grease 116553 1 oz (28 g) tube of dielectric grease for the power supply o-ring (12a), some packing rod parts (...

Technical Data 309457G 59 Technical Data Loctite® is a registered trademark of the Loctite Corporation. Category Data Maximum Working Fluid Pressure 100 psi (0.7 MPa, 7 bar) Maximum Working Air Pressure 100 psi (0.7 MPa, 7 bar) Minimum Air Pressure at Gun Inlet 40 psi (0.28 MPa, 2.8 bar) Maximum Flu...

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English. MM 309457 Graco Headquarters: Minneapolis Int...