Graco Inc. 309291P manual

For use in Class I, Div . I hazardous locations using Gr oup D spray materials. For use in Group II, Zone 1 areas using Gr oup IIA spra y materials. For Prof essional Use ONL Y . P art No. 244399, Series C See page 2 f or Model 244399 inf ormation. 100 psi (0.7 MP a , 7 bar) Maximum Air Inlet Pr essure 100 psi (0.7 MP a , 7 bar) Maximum W orking Fl[...]

Table of Contents 2 309291P T ab le of Contents T able of Conte nts . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . 2 W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 H[...]

Warnings 309291P 3 Wa r n i n g s W a rning Symbol This symbol alerts yo u to the possibility of serious injury or death if you do not follow th e instructions. Caution Symbol This symbol alerts you to the possibility of damage to or destruction of equipment if you do not fo llow the instruc- tions. WARNING CAUTION WA R N I N G Fire, Explosion, and[...]

Warnings 4 309291P WA R N I N G Equipment Misuse Hazar d Equipment misuse can cause the equipm ent to rupture, malfu nction, or star t une xpectedly and result in a serious injur y . • This equipment is f or professional use only . • Read all man uals, tags, a nd labels bef ore operating the equipment. • Use the equipment only f or its intend[...]

Introduction 309291P 5 Intr oduction How the Electr ostatic Spray Gun Wo r k s The air hose supplies air to the spray gun. Part of the air operates the tur bine and the rest of the air atomizes th e fluid being sprayed. The t urbine generat es power, which is converted by the po wer cartridge to supply high volt- age curren t to the gun’s e lectr[...]

Installation 6 309291P Installation Install the System F IG . 2. shows a typical electrostat ic air spray system. It is not an actual system des ign. For assistance in designing a system t o suit your pa rticular needs, co ntact your Graco distributor. W arning Sign Mount warnin g signs in the spr ay area where th ey can easily be seen and read by [...]

Installation 309291P 7 Fig. 2. Typica l Installatio n Key I O ES TI1531a 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-Hazardous Hazardous Area A[...]

Installation 8 309291P Connect the Air Line 1. Connect the G raco Grounded Air Supply Hose (R) between the air supply line and the gun's a ir inlet (V). The gun a ir inlet fitting has a left-hand thread . Connect the air supply hose g round wire (Q) to a true ear th g round. 2. Install an air line filter/w ater separator ( O) on the gun air li[...]

Installation 309291P 9 Select a Fluid Nozzle and Air Cap The gun is supplied with Part No. 197266 Nozzle and 24A376 Air Cap. If yo u require a differen t size, refer to Table 1 and Tabl e 2 , and instruction ma nual 309419, or consult with your Graco distrib utor. See Air Cap/Nozzle Replacement on page 25 . A wide pattern kit (P/N 24A43 1) is inclu[...]

Installation 10 309291P Connect the Fluid Line 1. Bef ore connect ing the fluid line (N), b lo 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 fluid regulator (M) on the fluid line to co ntrol fluid pressure to t he gun. 3. Install a fluid f ilter (K) and drai n valv e (U) at[...]

Installation 309291P 11 Gr ounding The following are minimum gr ounding requirements for a basic elect rostatic system. Your system may include other equipment o r objects which must be grounded. Check your local electrical co de for detailed gr ounding instructions. Your system must be connected to a true earth groun d. • Pump: ground t he pump [...]

Installation 12 309291P Chec k Electrical Gr ounding 1. Ha ve a qua lified electrician check the electrical groundin g continuity of the spr a y gun and ai r hose. 2. T ur n the 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 ha ve any fluid in it. 4. Mak e sure the g rounded ai r hose (R) is conne[...]

Installation 309291P 13 Chec k Fluid Resistivity Graco Part No. 72288 6 Resistance Meter and 722860 Probe are available as acces sories to check that the resistivity of the fluid b eing sprayed meets the require- ments of an electrostatic air spray system. Follow the instructions in cluded with the meter and probe. Read ings of 25 megohms-cm and ab[...]

Operation 14 309291P Operation INSTRUCTIONS Refer to the gun operation manual (supplied) for Se tup, Shutdown, and Daily Care procedures.[...]

Maintenance 309291P 15 Maintenance Flush the Spra y Gun Flush the gun bef ore changing colors, at the end of the day, before storing , and before repairin g the gun. 1. T ur n the ES ON/OFF valv e OFF . 2. Relie ve the pressu re. 3. Change t he fluid so urce to solv ent, or disconnect the fluid line and connect a solv ent supply line to the gun. 4.[...]

Maintenance 16 309291P 6. Shut off or disconnect the solv ent line. 7. Hang the gun f rom its hook, with th e nozzle pointing down. 8. When ready to spr a y again, reconnect the fl uid sup- ply line. F ollow the Setup procedur e in the Opera- tion Manual. ti1288a[...]

Electrical Tests 309291P 17 Electrical T ests Electrical component s inside the gun affect perfo rmance and safety. The fo llowing procedures test the condit ion of the power supply (18) and ele ctrode (29), and elect ri- cal continuity between compon ents. Use megohmmeter Part No. 241079 (AA) and an applied voltag e of 500 V. Conn ect the leads as[...]

Electrical Tests 18 309291P T est P ower Suppl y Resistance 1. Remo v e the pow er supply (18) , page 29. 2. Remo ve the turbine alternator (19) fr om the pow er supply , page 30. 3. Measure re sistance from th e pow er supply's ground strips (EE) to the spring (18b). See F IG . 5.. 4. The resist ance should be 75-85 meg ohms. If out - side th[...]

Electrical Tests 309291P 19 T est Electr ode Resistance 1. Insert a conductive rod (B) into the gun barr el (remo ved f or the pow er supply test) an d against the metal conta ct (C) in the fron t of the bar rel. 2. Measure the resistance betwe en the conductiv e rod (B) and the elec trode (29). The re sistance should be 20-30 megoh ms. See F IG . [...]

Troubleshooting 20 309291P T r oubleshooting Chec k all possible r emedies in the T roub leshooting Char t bef ore disa ssembling t he gun. Spra y P attern T roub leshooting Some spra y patter n prob lems are caused b y the improper balance between air and fluid. WA R N I N G Electric Shoc k Hazar d Installing and ser vic ing this equipment require[...]

Troubleshooting 309291P 21 Gun Operation T roubleshooting Prob lem Cause Solution Excessive spr a y f og. Atomizing air pressure too high. Close restrictor v alv e some, or decrease air pressur e as low as pos- sible; minimum 40 psi (0.28 M P a, 2.8 bar) needed at gun f or full volt age. Fluid too thin. Increase viscosity . “Orange P eel” finis[...]

Troubleshooting 22 309291P Electrical T r oubleshooting * ES indicator light is off when the gun is trigg ered. Prob lem Cause Solution P oor wrap . ES ON/OFF v alv e OFF (0).* T urn ON (I). Gun air pressu re too low . Chec k air pressure to gu n; minimum 40 psi (0.28 MP a, 2.8 bar) needed at gun f or full v oltage . Atomizing air pressure too hig [...]

Repair 309291P 23 Repair Pressure Relief Pr ocedure 1. T ur n the ES ON/OFF valv e OFF . 2. T ur n off the air b leed v alv es to the fluid sour ce and to the gun. 3. T r igger the gun int o a grounded metal w aste con- tainer to r elie v e the fluid pressure. 4. Open the pump drain valve , having a waste con- tainer ready t o catch the dra inage. [...]

Repair 24 309291P Prepare the Gun f or Ser vice • Check all possib le remedies in T roub leshooting bef ore disasse mbling t he gun. • Use a vise with padded ja ws to pre v ent damage to plastic par ts . • Lubricate the pow er supply o-ring (18a) and some pac king rod part s (26) with dielectric grease ( 40), as specified in the te xt. • Li[...]

Repair 309291P 25 Air Cap/Nozzle Replacement 1. Prepare gun f or ser vice, page 24 . 2. Remove the retaining r ing (27) an d air cap (9). Se e F IG . 9.. 3. P oint gun up and squeez e trigger while remo ving the fluid nozzle (7) assembly with th e multi-tool ( 37). Fig. 9. Air Cap/No zzle Replacement Use non-silicone grease, P ar t No . 111265, on [...]

Repair 26 309291P Electr ode Replacement 1. Prepare the gun f or service, page 24. 2. Remo ve the air cap and nozzle, page 25. 3. Unscre w the electrode (29) wit h the multi-tool (3 7). Hold the pac king rod end (26h) to pre vent it from tur ning. See F IG . 10.. 4. Apply low-strength (pur ple) Loctite ® or equivalent thread seala nt to the electr[...]

Repair 309291P 27 Fluid P acking Remo v al 1. Prepare the gu n f or ser vice, page 24. 2. Remo ve the air cap and fluid nozzle , page 25. 3. Remove the electrode, page 26. 4. Remo ve the trigger scre ws (8) and trigger (30). See F IG . 11. 5. Remove the packing rod (26), using th e multi-tool (37). 6. Chec k all par ts f or wear or damage and repla[...]

Repair 28 309291P P acking Rod Repair You may replace the packing rod as individ ual parts or as an asse mbly. The assembly is pr e-adjusted at the factory. Bef ore installing the fluid pack ing rod into the gun barrel, mak e sure the internal surfa ces of the barrel are clea n. Remov e an y residue with a soft brush or cloth. Check the inside of t[...]

Repair 309291P 29 Barrel Remo v al 1. Prepare the gu n f or ser vice, page 24. 2. Carefully loosen th e nut (32) fro m the brac k et fluid fitting (13) . Pull the tube (14) out of the fit ting. Mak e sure both f err ules and the n ut sta y with the tube . 3. Loosen the th ree scre ws (11). 4. Hold the gu n handle (17) with one hand a nd pull the ba[...]

Repair 30 309291P P ower Suppl y Remo v al and Replacement • Inspect the gun handle power supply cavit y f or dir t or moisture. Clean w ith a clean, dr y rag. • Do not e xpose gask et (10) to solvent s. 1. Prepare g un f or service, page 24. 2. Remo ve the barrel (16), pag e 29. 3. Gr asp the pow er supply (18) with y our hand. With a gentle s[...]

Repair 309291P 31 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 24 . 2. Remo ve the pow er supply/alternator assemb ly , page 30. 3. Disconnect t he alternator from the pow er supply , page 30. 4. Measure re [...]

Repair 32 309291P F an Air Adjustment V alve Repair 1. Prepare the gun f or service, page 24. 2. Place a wrench on the fla ts of the v alv e assembly (20) and unscre w it from the handle ( 17). Y ou may replace the valv e as an assembly (go to step 9) or as individual par ts (steps 3-9). 3. Remov e the retaining r ing (20a). See F IG . 16.. 4. T ur[...]

Repair 309291P 33 Fluid Adjustment V a lve Repair 1. Prepare the gu n f or ser vice, page 24. 2. Remov e the fluid adjustment valve (25). It can only be replaced as a comp lete assembly . See F IG . 17 .. 3. Scre w the v alv e (25) in to the gun h andle. T orque to 15-25 in-lb (1 .7-2.8 N•m). Fig. 17. Fluid Adjustment Valve Air V alve Repair 1. P[...]

Repair 34 309291P Atomizing Air Restrictor V alve Remo v al and Replacement 1. Prepare the gun f or service, page 24. 2. Remov e the atomizing air r estrictor va lve (23). Inspect the o-ring (23c*). Rep lace if necessar y . See F IG . 19.. 3. Install a new atomizing air restr ictor valv e (23), or disassemb le and replace parts individually . The v[...]

Repair 309291P 35 ES ON/OFF V alve Repair 1. Prepare the gu n f or ser vice, page 24. 2. Loosen the scr ew (48). Remo v e the v alv e. 3. Lubricate the o-r ings (22a* and 22b*) with non-sili- cone grease, P ar t No . 11126 5. Do not ov er-lubr i- cate. 4. Clean and inspect parts for damage. Replace if nec- essar y . The protrusion on the reta iner [...]

Parts 36 309291P Pa r t s Part No. 244399 20 kV Electrostatic Gun, Series C 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 23c* 23d 24a* 27a* 29 30 37 36 39 47 4 See page 37 for detail vie ws of the alternator (1 9), fan adjustment valve (20), ES ON/OFF valve (22), and packing rod (26) . [...]

Parts 309291P 37 TI1488A TI1497a TI1487A TI1481a 22a* 22b* 22c 22d 22e 22f 22g 20a 20b* 20c 20d 26a** **26b 26d** 26c** 26e 26f 26g** 26h 19a* 19b 19b 19c Ref. No. 22: ES ON/OFF Valve Ref. No. 20: Fan Adjustment Valve Ref. No. 19: Alternator Ref. No. 26: Packing Rod 48 19d 19e[...]

Parts 38 309291P * Included in Air Seal Repair Kit 244781. ** Included in Fluid Seal Repair Kit 244 911. *** Rubber seal is not r emov ab le. **** Optional repla cement Electrode Needle 2770 07 is av ailable f or abrasive materials. ▲ Replacement Warning labels, signs, tags, and cards are a vailab le at no cost. Ref. No. P art No. Descriptio n Qt[...]

Accessories 309291P 39 Accessories Air Line Accessories AirFlex ™ Flex ible Gr ounded Air Hose 100 psi (7 bar, 0.7 MPa) Maxim um Working Pressure 0.315 in. (8 mm) I D; 1/4 npsm(f) x 1/4 npsm (f) left-hand thread. Use for maximum flexibility. 244963 6 ft (1.8 m) 244964 15 ft (4.6 m) 244965 25 ft (7.6 m) 244966 36 ft (11 m) 244967 50 ft (15 m) 2449[...]

Accessories 40 309291P Gun Accessories Gun Repair Kits 244781 Air Seal Repair Kit 244911 Fluid Seal Repair Kit Round P attern Kits Consists of fluid tip, diffuser and air cap. 245217 4-6 in. (1 02-152 mm) diameter 245219 8-10 in. (203-254 m m) diameter Adjustable Round P attern Kit 277851 Slo w ve locity , bell shaped spra y pattern f or e xcellent[...]

Technical Data 309291P 41 Te c h n i c a l D a t a Loctite ® is a registere d trademark of the Loctit e Cor poration. Category Data Maximum W or king Fluid Pressure 100 psi (0.7 MP a, 7 bar) Maximum W or king Air Pressure 100 psi (0.7 MP a, 7 bar) Minimum Air Press ure at Gun Inle t 40 psi (0.2 8 MP a, 2.8 bar) Maximum Fluid Operating T emperature[...]

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 309291 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. P.O. BOX 14[...]