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Graco 3A2496D User's Manual

1. 200 400 600 800 FLUID FLOW oz min cc min Table 9 Orifice Size 2 0 mm 0 080 in 200 400 600 800 FLUID FLOW oz min cc min 3A2496D Air Cap Selection Chart NOTE For Model L60M19 Mold Release Gun only use Part No 24N727 Air Cap See Mold Release Smart Air Spray Gun Assembly page 72 To reduce the risk of an injury follow the Pressure Relief Procedure page 31 before removing or installing a fluid nozzle and or air cap Part No Pattern Length color Shape in mm 24N438 Round 15 17 black end 381 432 24N279 Round 14 16 black end 356 406 Tapered 17 19 end 432 483 Recommended Fluid Viscosity in centipoise cp at 70 F 21 C Medium to heavy 70 260 cp and high solids 360 cp 24N376 black 24N276 blue 24N277 red 24N278 green Light to medium 20 70 cp Recommended Production Rates cc min cc min Air Caps and Fluid Nozzles NOTE All air cap pattern shapes and lengths in the following chart were measured under the following conditions Pattern shape and length are material dependent Distance to target 10 in 254 mm e nlet air pressure 50 psi 34 kPa 3 4 bar e Fan air adjusted for maximum width Fluid flow rate 10 oz min 300 cc min Atomiza Cleanli tion ness Transfer Efficiency Light to medium Up to 15 oz min 450 Better Best Good 20 70
2. 20 30 40 50 60 70 80 20 30 40 50 60 70 80 WALL PRESSURE WALL PRESSURE psi psi 88 3A2496D Air Caps and Fluid Nozzles Table 14 24N274 Air Cap Table 16 24N453 Air Cap AIR CON AIR CON SUMPTION SUMPTION scfm scfm 0 20 30 40 50 60 70 80 20 30 40 50 60 70 80 WALL PRESSURE WALL PRESSURE psi psi Table 15 24N275 Air Cap Table 17 24N477 24W279 Air Cap AIR CON AIR CON SUMPTION SUMPTION scfm scfm 0 20 30 40 50 60 70 80 20 30 40 50 60 70 80 WALL PRESSURE WALL PRESSURE psi psi 3A2496D 89 Spray Tip Selection Chart Model L60M19 MRG Gun Only Spray Tip Selection Chart Model L60M19 MRG Gun Only AEM Fine Finish Spray Tips NOTE for use with Model L60M19 MRG Gun only Recommended for high finish quality applications at low and medium pressures Order desired tip Part No AEMxxx where xxx 3 digit number from the matrix below Orifice Fluid Output Maximum Pattern Width at 12 in 305 mm Size fl oz min l min in mm in 24 4 6 6 8 8 10 10 12 12 14 14 16 16 18 mm i 4 i 7 50 100 150 200 250 300 350 400 100 150 200 250 om 350 400 450 if e T 178 ee dd E o 229 0 2 0 27 i 279 0 330 0 015 3 gt i oan 220 0 381 0 017 20 Ee 0 85 50 36 3 0 483
3. 4 Apply low strength purple Loctite or equivalent thread sealant to the needle and packing rod threads Install the needle finger tight Do not overtighten 5 Install the fluid nozzle and air cap See Air Cap Spray Tip and Nozzle Replacement Model L60M19 page 52 6 See Test Gun Resistance page 39 ti20258a Figure 38 Electrode Replacement 3A2496D 55 Repair Fluid Packing Rod Removal 1 2 56 See Prepare the Gun for Service page 50 Remove the air cap and fluid nozzle See Air Cap and Nozzle Replacement page 51 Remove the electrode See Electrode Replacement page 54 Loosen the trigger screws 13 and remove the trigger 12 Remove the packing rod 2 using the multi tool 41 Remove the spring 17 Check all parts for wear or damage and replace if necessary ti19896a Figure 39 Fluid Packing Rod Removal 3A2496D Packing Rod Repair NOTE You may replace the packing rod as individual parts or as an assembly 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 1 Place the packing nut 2f and seal 2b on the fluid rod 2e Flats on the packing nut must face the back of the fluid rod The seal o ring must face away from the packing nut 2
4. Relieve the pressure see Pressure Relief Procedure page 31 Open the isolated enclosure door Remove the 1 4 in 6 mm OD tube A1 from the pump air inlet see Tubing and Wiring page 77 Remove the waterborne fluid hose from the pump fluid outlet fitting 231 and remove the fitting Unscrew the two pump mounting screws S and remove the pump from the isolation enclosure Remove the back of the control box 258 Remove tube A2 from elbow 282 at the air manifold see Tubing and Wiring page 77 Install the Y fitting 506 in the elbow Install tubes A2 and 507 into the Y fitting Route the tube 507 into the cabinet Replace the back of the control box 258 Assemble the fluid regulator kit as shown Reinstall the pump in the isolation enclosure Use the two mounting holes to the left of the 3A2496D Installation holes used previously to allow clearance for the fluid regulator 12 Connect tube A1 to the air inlet of fluid regulator 504 Connect tube 507 to the pump air inlet 13 Connect the waterborne fluid hose to the fluid regulator outlet fitting 501 14 Return the system to service NOTE The cabinet air regulator and gauge 216 217 will now operate the air piloted fluid regulator 504 The pump will now operate at the inlet air pressure Figure 21 245944 Fluid Regulator Kit 25 Gun Setup Gun Setup Select a Fluid Nozzle and Air Cap The following are minimum g
5. 0 78 Tips are tested in water Fluid output Q at other pressures P can be calculated by this formula Q 0 041 QT VP where QT fluid output fl oz min at 600 psi from the above table for the selected orifice size t These tip sizes include a 150 mesh filter 3A2496D 91 Repair Kits Related Manuals and Accessories Repair Kits Related Manuals and Accessories Gun Part No Description Manual Description Repair Kits Repair Kit Description All guns in this 60 kV Waterborne Electrostatic 24N789 Air Seal Repair Kit manual Air Spray Guns Waterborne Air 24N790 60 kV Mold Release Spray Guns dal SFALRERAIE Air Spray Guns Instructions Parts 24N706 Alternator Bearing Repair Kit Gun Accessories 105749 Cleaning Brush 24P172 Quick Adjust Valve For quick 111265 Non silicone Lubricant 4 oz 113 g phange ortan Siam 185105 Non swivel Air Inlet 1 4 18 npsm m I 6553 Dielectric Grease 1 oz 30 ml BE left hand thread 24N318 Round Spray Kit To convert a E Tue standard air spray gun to a round sia fue ae a TAS Enparan spray air cap See manual 3A2498 left han read 185493 Air Hose Adapter 1 4 npt m x 24N604 Gun Covers Box of 10 pee 1 4 18 npsm m left hand thread ee een Package ofS 112534 Air Line Quick Disconnect Fitting clean Package of 5 112534 Air Line Quick Disconnect Fitting 24P170 Metal Trigger Kit 92 3A2496D Repair Kits Related Manuals and Accessories Op
6. Make sure the short end of the electrode engages the hole in the back of the air cap Press the electrode in place firmly with your fingers NOTICE 2 Remove the retainer ring 6 and air cap tip guard assembly 5 The conductive ring 4c is a conductive metal contact ring not a sealing o ring For best performance and to avoid potential damage to the spray gun do not remove the conductive ring 4c except to replace it and never operate the gun without the conductive ring in place Do not replace the conductive ring with ti18802a anything but a genuine Graco part Figure 33 Remove Air Cap 5 Trigger the gun and remove the nozzle 4 using 3 Disassemble the air cap assembly Check the an adjustable wrench condition of the u cup 6a electrode 5a o ring 5b and tip gasket 10a Replace any damaged parts 10a 5b ti20146a Figure 36 Replace Nozzle ti20144a Figure 34 Disassemble Air Cap Assembly 10a ti20145a Figure 35 Tip Gasket 52 3A2496D Repair NOTICE 9 Check that the air cap o ring 5b is in place 10 Check that the u cup 6a is in place on the retaining ring 6 The lips of the u cup must face forward Do not overtighten the nozzle 4 Overtightening may damage the housing and the gun barrel resulting in improper fluid shutoff NOTICE 6 Ensure that the o rings 4a 4b and 9 are in To avoid damaging the tip guard orient the place on t
7. Nozzle Replacement page 51 Fluid buildup on air cap or nozzle Clean See Clean the Gun Daily page 37 CD Streaks Did not apply 50 overlap Overlap strokes 50 Dirty or damaged air cap Clean or replace air cap See Clean the Gun Daily page 37 or Air Cap and Nozzle Replacement page 51 46 3A2496D Troubleshooting Gun Operation Troubleshooting Ee Gase E Excessive spray fog Atomizing air pressure too high Close restrictor valve part way or decrease air pressure as low as possible minimum 45 psi 0 32 MPa 3 2 bar needed at gun for full voltage Fluid too thin or fluid flow is too Increase viscosity or increase fluid low flow rate Orange Peel finish Atomizing air pressure too low Open atomizing air valve more or increase gun air inlet 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 Worn packings or rod See Packing Rod Repair page 57 area Air leaks from the front of the gun Air valve is not seating properly See Air Valve Repair page 65 Fluid leakage from the front of the Worn electrode See gun Electrode Replacement page 54 Worn fluid nozzle seat Replace nozzle 4 See Air Cap and Nozzle Replacement page 51 Loose fluid nozzle Tighten Damaged nozzle o ring See Air Cap and Nozzle Replacement page 51 Gun does not spray Low f
8. O Ventilation fans are operating properly O All debris including flammable fluids and Fully unscrew the door T handle locking screw rags is removed from the spray area This will shut off the air to the gun and trigger the grounding cylinder to discharge any remaining electrical charge O Fluids used must meet the following flammability requirements Use the grounding rod to touch the pump and supply pail If you see any arcs see e FM FMc Approved Electrical Troubleshooting page 48 Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures ASTM D4206 e CE EN 50059 Compliant Materials which cannot be ignited in any mixture with air by an energy source of less than 500mJ 30 3A2496D Pressure Relief Procedure 1 Follow the Fluid Voltage Discharge and Grounding Procedure page 30 Turn off the air bleed valves to the fluid source and to the gun w 4 ti18744a Trigger the gun into a grounded metal waste container to relieve the fluid pressure Relieve fluid pressure in the fluid supply unit as instructed in your fluid supply unit manual 3A2496D Operation Fill the Fluid Supply 1 Follow the Fluid Voltage Discharge and Grounding Procedure page 30 Follow the Pressure Relief Procedure page 31 Open the isolated enclosure door Remove the pail cover from the pail holding a rag over the suction
9. PACKING u cup UHMWPE TIP ASSEMBLY customer s AEF xxx _ choice includes item 27a a 183459 GASKET tip 24N662 POWER SUPPLY 60 kV gun N N NMOPENMI NM N co 24N633 VALVE air 276733 SEAL air valve 245265 CIRCUIT flexible Adjustment Valve page 81 24N740 SCREW hex socket 10 24 x 1 PATTO Ost package 12 a Replacement Danger and Warning labels tags and cards are available at no cost 24N643 ELECTRODE package of 5 245790 RING retainer includes 6a 197624 SPRING compression 3A2496D No ADJUSTMENT VALVE Assembly page 82 page 84 185116 _ SPRING compression 31 34 185116 SPRING compression 5 188749 PACKING u cup 6 185103 TUBE exhaust 1 4 in 6 mm ID shipped loose 107460 TOOL wrench ball end 4 mm shipped loose 276741 MULTI TOOL shipped loose 9 for use instead of item 29 loose GREASE dielectric 1 oz 30 ml tube not shown 117824 GLOVE conductive medium package of 12 also available in small 117823 and large 117825 46 24N604 COVER gun package of 10 84 186118 SIGN warning not shown wo A A i 0 24N783 HOOK includes screw 101 24M733 HOSE unshielded waterborne fluid includes 102 108 102 190863 FERRULE 03 15B932 HOUSING ferrule 104 197954 BRACKET fluid fitting 106 16N953 FITTING barrel 0 102982 O RING 108 16N916 FITTING seal als N These parts are i
10. See Fig 4 Low Voltage Locked Appears if the low voltage setting is locked See Fig 5 and Fig 9 Appears on the Low Voltage Lock Screen See Fig 9 Appears if the Smart module loses communication with the power supply See Fig 3 In Diagnostic Mode the two top right LEDs of the screen light indicating that the value displayed is in kV See Fig 6 3A2496D Gun Overview CI E I Current Indicator Alternator Speed Display Alternator Speed Indicator 3A2496D In Diagnostic Mode the two bottom right LEDs of the screen light indicating that the value displayed is in uA See Fig 7 In Diagnostic Mode Hz level is displayed as a number See Fig 8 In Operating Mode indicator color varies to show the alternator speed status e green indicates the alternator speed is at the correct level If the indicator changes to amber after 1 second the alternator speed is too low If the indicator changes to red after 1 second the alternator speed is too high The indicator will also turn red if the Error display appears In Diagnostic Mode the indicator is green when in the Alternator Speed Hertz screen 13 Gun Overview Diagnostic Mode Diagnostic Mode includes four screens which display gun data Voltage kiloVolts Screen e Current microAmperes Screen e Alternator Speed Hertz Screen e Low Voltage Lock Screen NOTE You must be in Operating Mode to adjust the low voltage sett
11. 14 ti19123a Figure 6 Voltage kiloVolts Screen Current microAmperes Screen The Current microAmperes Screen is the second screen in the Diagnostic Mode See Fig 7 and Table 1 on page 12 To enter this screen press the LO SET button while in the Voltage kiloVolts Screen This screen displays the spraying current of the gun as a number uA rounded to the nearest 5 uA The two bottom right LEDs Cl of the display panel light indicating that the Current microAmperes Screen is displayed The display is a readout and cannot be changed Press the LO SET button to advance to the Alternator Speed Hertz Screen page 15 Press and hold for approximately 5 seconds to return to Operating Mode ti19124a Figure 7 Current microAmperes Screen 3A2496D Alternator Speed Hertz Screen The Alternator Speed Hertz Screen is the third screen in the Diagnostic Mode See Fig 8 and Table 1 on page 12 To enter this screen press the LO SET button while in the Current microAmperes Screen This screen displays the alternator speed as a 3 digit number AS rounded to the nearest 5 Hz The display is a readout and cannot be changed If the alternator speed is greater than 999 Hz the display will show 999 The Hz indicator lights green to show that you are viewing the Alternator Speed Hertz Screen Press the LO SET button to advance to the Low Voltage Lock Screen pa
12. E WASHER shim atch 243 210084 ROD ground 244 Sii hex hd 1 4 20 x 5 8 16 mm ZE E Ei ae ce Lc 238_ TUBE ain mm OD nyon AR adi se ellow stripe asi CONNECTOR swivel tee 1 8 npt x 5 32 in 4 mm tube s NT nes 10 82 fi 162449 NIPPLE uu 1 2 npt x at npt ES OZ TeRWINAL rg dS Cac ie ane oe de ce 16 mm ol ied id 6mm 265 SPENT button hd 10 24 x 1 5 E in 38 mm 266 SCREW button hd 10 32 x 1 0 2 in 25 mm EA i CI CN see le 203953 SCREW hex hd cap with patch 1 wire 14 gauge Ea NE ground 14 gauge green ae with yellow stripe 155541 UNION swivel 1 4 npt mo 117314 BULKHEAD CONNECTOR 1 4 npt 75 Parts Pl ictal aca A INO 279 113319 CONNECTOR tube 1 4 nptx 2 3 8 in 10 mm OD tube 281 FITTING tube 1 8 npt x 5 32 in 1 4 mm OD tube Peo SWIVEL tube 1 4 npt x 1 4 in 6 mm OD tube ial 4 mm OD tube 206 TUBE 3 8 in 10 mm OD AIR Na na pese S INO 300 235070 HOSE air grounded 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread red cover with stainless steel braid path 25 ft 7 6 m long 301 L60T17 GUN see Standard Waterborne 1 L60T18 Air Spray Gun Assembly page 68 L60M18 Spray Gun Assembly page 70 L60M19 GUN see Mold Release Smart 1 Air Spray Gun Assembly page 72 4 Replacement Danger and Warning labels tags and cards are available at no cost x The air ho
13. Incorrect distance from gun to part Should be 8 12 in 200 300 mm Poorly grounded parts Resistance must be 1 megohm or less Clean workpiece hangers Faulty gun resistance See Test Gun Resistance page 39 Fluid leaks from the packing 2c and causes a short Clean the packing rod cavity or replace the packing rod See Packing Rod Repair page 57 Faulty alternator See Alternator Removal and Replacement page 60 ES HI LO switch is on LO Smart Check switch actuation replace if guns only needed Spilled paint dried paint or other Clean interior of enclosure contaminants inside the WB100 Enclosure causing a short circuit ES On Off switch is OFF O Turn ON I No power Check power supply alternator and alternator ribbon cable See Power Supply Removal and Replacement page 59 3A2496D Troubleshooting C E Operator gets mild shock Operator not grounded or is near See Grounding page 26 ungrounded object Gun not grounded See Check Gun Electrical Grounding page 28 and Test Gun Resistance page 39 A weak static charge has built up Bundle and wrap the air and fluid on the surface of an unshielded hoses together See Connect the fluid hose This is a charge on the Waterborne Fluid Hose page 18 hose surface not a failure of the hose insulation Operator gets shock from Workpiece not grounded Resistance must be 1 megohm or workpiece less Clean workpiece hangers Voltage
14. Off switch J Turn on the master air bleed valve to the gun 3A2496D 4 Position the air cap by loosening the air cap retaining ring and rotating the air cap for a vertical or horizontal spray pattern Tighten the retaining ring until the air cap is held firmly in place you should not be able to rotate the air cap horns by hand 5 Fully open the fan air adjustment valve F counterclockwise 6 Fully open the fluid adjustment valve H counterclockwise 7 Fully open the atomizing air restrictor valve G clockwise ti18765a 3A2496D Operation Make sure the ES On Off switch J is OFF O Adjust the pump air regulator to start the fluid supply unit Adjust the fluid flow with the air pressure regulator until the stream from the gun travels 8 12 in 200 300 mm before falling off Typically if fluid pressure is below 5 psi 04 MPa 0 4 bar or above 30 psi 0 21 MPa 2 1 bar a change of nozzle size is recommended ti19890a Set the gun air regulator to deliver a minimum 45 psi 0 32 MPa 3 2 bar at the gun when triggered to ensure full spraying voltage See the table below Table 2 Pressure Drop Air Hose Air Regulator Setting Length in ft m in psi MPa bar using 5 16 in 8 with gun triggered mm diameter hose 33 Operation 11 Spray a test pattern Check the atomization If 14 Check that the ES indicator Hz indicator on over atomization
15. Regulator Graco Red Grounded Air Hose left hand C Accessory Bleed Type threads Air Shutoff Valve Gun Air Hose Ground These items are required for safe operation They Wire are included with the WB100 system Graco Waterborne Fluid Hose 3A2496D 23 Installation Agitator Kit Accessory To add an agitator to the Graco isolation system order Part No 245895 See 245895 Agitator Kit page 94 for the kit parts list 1 24 Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure page 30 Relieve the pressure see Pressure Relief Procedure page 31 Open the isolated enclosure door Remove the back of the control box 258 Remove tube A2 from elbow 282 at the air manifold see Tubing and Wiring page 77 Install the Y fitting 402 into the elbow Install tubes A2 and 407 into the Y fitting Route the agitator tube 407 into the cabinet Replace the back of the control box 258 Assemble the other parts of the kit as shown Secure the agitator with the setscrew 408 Return the system to service 403 408 404 406 ti2137a Figure 20 245895 Agitator Kit 3A2496D Fluid Regulator Kit Accessory To add a fluid regulator to the Graco isolation system order Part No 245944 See 245944 Fluid Regulator Kit page 95 for the kit parts list 1 10 11 Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure page 30
16. mixture TL with air by an energy source of less than 500mJ o NOTICE 7 Open the isolated enclosure door Leave the flushing fluid in the system until you are ready Do not use methylene chloride as a flushing or to spray again cleaning solvent with this gun as it will damage nylon components 8 Hang the gun from its hook with the nozzle pointing down Be sure to keep the gun from 1 Turn OFF O the ES On Off switch Wait 30 grounding out seconds for the voltage to bleed off ti19891a 9 Before using the system electrostatically again make sure no flammable vapors are present 2 Discharge the system voltage See Fluid Voltage Discharge and Grounding Procedure page 30 36 3A2496D Clean the Gun Daily 1 Turn OFF O the ES On Off switch 2 Flush the gun See Flushing page 36 Follow the Pressure Relief Procedure page 31 4 Clean the outside of the gun with a non flammable solvent as defined under Flushing page 36 Use a soft cloth Point the gun down to prevent solvent from entering the gun passages Do not immerse the gun ti18769a ti18770a 3A2496D o 8 Maintenance Remove the air cap ti18771a Clean the air cap retaining ring and nozzle with a soft brush and non flammable solvent ti18772a If necessary use a toothpick or other soft tool to clean the air cap holes Do not use metal tools ti18773a Reinstall the a
17. of the isolation system that are charged to high voltage must be contained within the enclosure A bleed resistor to drain off the system voltage when the spray gun is not in use A metal part of the fluid supply unit must be electrically connected to the bleed resistor A Safety interlock that automatically discharges the system voltage when anyone opens the isolation enclosure NOTICE The system should not have any severe arcing occurring when the isolation mechanism opens and closes Severe arcing will shorten the life of the system components NOTE The Graco warranty and approvals are void if the electrostatic spray gun is connected to a non Graco voltage isolation system or if the gun is operated above 60 kV 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 16 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 e Be sure your installation complies with local state and national safety and fire codes NFPA 33 NEC 504 and 516 and OSHA standard 1910 107 Fig 19 shows a typical electrostatic air spray system It is not an actual system design For assistance in designing a system to suit yo
18. on the tube A new Graco waterborne fluid hose comes fully assembled to these dimensions NOTICE Be careful not to cut into the inner tube T of the hose when stripping the hose Nicks or cuts in the PTFE tube will cause premature hose failure A 6 50 in 165 mm ae B 2 00 in 50 mm ti19885a Figure 12 Shielded Hose 24M732 Dimensions at Gun 3A2496D Installation DEL A 1 40 in 36mm W ti19886a Figure 13 Unshielded Hose 24M733 Dimensions at Gun Generously apply dielectric grease 44 to the o ring 107 and the threads of the fitting 106 Pull the fitting back 1 1 2 in 38 mm and apply grease to the exposed PTFE hose to fill the area between the hose and the fitting Make sure the barrel inlet is clean and dry then screw the fitting into the fluid inlet of the gun barrel 1 Loosen the strain relief nut 102 so the bracket can move freely on the hose Align the bracket 104 holes with the air inlet and exhaust outlet Secure with the air inlet fitting 21 Tighten the strain relief nut 102 to secure the hose Check that the nut 105 is tightened securely to the ferrule housing 103 Press the exhaust tube 36 onto the exhaust valve barb C Secure with the clamp 43 19 Installation 8 Connect the other end of the hose to the isolated fluid supply as follows a 20 Graco WB100 Enclosure Slide hose through the strai
19. or air cap lower spray performance due to excessive fluid viscosity Orifice Size f mm in 3 From the marked point move across to the vertical scale to find the required fluid pressure If the required pressure is too high use the next 0 75 029 largest nozzle size If the fluid pressure is too low 1 0 042 lt 0 35 bar 3 5 kPa 5 psi use the next smallest nozzle size For 1 2 047 standard 1 5 055 Key to Fluid Nozzle Performance Charts coatings 1 8 070 NOTE Fluid pressures are measured at the spray gun inlet 2 0 079 0 55 022 0 75 029 With 1 0 042 hardened seat for 1 2 047 abrasives 1 5 055 and 1 8 070 metallics 2 0 079 260 Centipoise Fluid 160 Centipoise Fluid 70 Centipoise Fluid 20 Centipoise Fluid 3A2496D 85 Air Caps and Fluid Nozzles Table 4 Orifice Size 0 75 mm 0 030 in FLUID FLOW oz min cc min 200 400 600 800 FLUID FLOW oz min cc min Table 6 Orifice Size 1 2 mm 0 047 in T 200 400 600 800 FLUID FLOW oz min cc min 86 Table 7 Orifice Size 1 5 mm 0 059 in 15 Z 1 07 i 10 ig ee VA 0 5 1 l T T i 200 400 600 800 FLUID FLOW oz min cc min Table 8 Orifice Size 1 8 mm 0 070 in
20. symbol will appear when the LO SET button is pressed e When in LO mode the lock symbol will only appear if the lock is enabled See Low Voltage Lock Screen page 15 to lock or unlock the low voltage setting LK LV LO Hz VA LS ti19337a Figure 5 Low Voltage Setting Screen Locked 11 Gun Overview Table 1 Key for Figs 2 9 a Pupe VA Voltage Adjustment Switch kV Voltage kV Display Current uA Display LO SET button Low Voltage Display LO Display Error Display Voltage Indicator 12 Two position switch sets smart gun voltage to low setting LO or high setting HI This switch is functional in Operating Mode and in Diagnostic Mode Lights blue when the smart gun is set to Low Voltage Displays actual spraying voltage of the gun in kV In Operating Mode display is a bar graph In Diagnostic Mode voltage is displayed as a number Displays actual spraying current of the gun in uA In Operating Mode display is a bar graph In Diagnostic Mode current is displayed as a number Press momentarily to enter the Low Voltage Setting screen Press and hold for approximately 5 seconds to enter or exit Diagnostic Mode While in Diagnostic Mode press momentarily to advance through screens While on the Low Voltage Lock Screen in Diagnostic Mode press and hold to turn the lock on or off Displays the low voltage setting as a number The setting can be changed
21. tube strainer to prevent any fluid from dripping into the isolated enclosure Place the cover and suction tube outside the enclosure Remove the supply pail from the enclosure NOTICE Be sure to wipe up all fluid spills in the isolated enclosure Fluid can create a conductive path and cause the system to short out Clean up any fluid spills in the enclosure using a soft cloth and a non flammable compatible solvent Fill the supply pail with fluid and return it to the enclosure Clean up any spills Reinstall the pail cover holding a rag over the suction tube strainer to prevent fluid spills while you place the pump suction tube in the pail Close the isolated enclosure door and fasten securely with the T handle locking screw 31 Operation Adjust the Spray Pattern To reduce the risk of fire and explosion fluids used must meet the following flammability requirements e FM FMc Approved Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures ASTM D4206 CE EN 50059 Compliant Materials which cannot be ignited in any mixture with air by an energy source of less than 500mJ Contact with the charged components of the spray gun will cause an electric shock Do not touch the gun nozzle or electrode or come within 4 in 102 mm of the front of the gun during operation or until performing the Fluid Voltage Discharge and Grounding Procedure page
22. 1 09 0 021 50 45 4 0 533 1 36 0 432 0 019 0 584 1 56 1 94 E 7 3 3 J 7 A i 3 1 0 025 88 2 2 65 0 031 0 787 0 039 18 i 153 0 0 990 3 4 4 59 Tips are rest in water 0 635 101 1 3 03 0 033 Fluid output Q at other pressures P can be calculated by this formula Q 0 041 QT V P where QT 0 029 0 736 114 1 0 838 3 42 0 037 0 140 0 0 939 1 4 20 fluid output fl oz min at 600 psi from the above table for the selected orifice size t These tip sizes include a 150 mesh filter 90 3A2496D Spray Tip Selection Chart Model L60M19 MRG Gun Only AEF Fine Finish Pre Orifice Spray Tips NOTE for use with Model L60M19 MRG Gun only Recommended for high finish quality applications at low and medium pressures AEF tips have a pre orifice that assists in atomizing sheer thinning materials including lacquers Order desired tip Part No AEFxxx where xxx 3 digit number from the matrix below Fluid Output Maximum Pattern Width at 12 in 305 mm fl oz min l min in mm at 600 psi at 1000 6 8 150 8 10 10 12 12 14 14 16 16 18 4 1 MPa psi 7 0 200 200 250 250 300 300 350 350 400 400 450 41 bar MPa 70 bar Spray Tip t 0 010 9 5 0 28 12 5 310 410 510 610 710 0 254 0 37 0 012 12 0 16 0 312 412 512 612 712 812 0 305 0 35 0 47 0 014 16 0 21 0 314 414 514 614 714 814 0 356 0 47 0 62 0 016 20 0 26 5 416 516 616 716 0 406 0 59
23. 19 MRG GUN OMY s r i ei E 90 Repair Kits Related Manuals and Accessories 92 DIMENSIONS rasa ea e e eaa 96 Technical Dala a aa a a aa et 97 Graco Pro Xp Warranty 98 3A2496D Models Models Models with FM Approval Only FM approved for use with fluids that meet the following condition c US e Material does not sustain burning in accordance with the Standard Test Method for APPROVED Sustained Burning of Liquid Mixtures ASTM D4206 24N580 WB100 Waterborne Isolation Enclosure 233825 with standard electrostatic air spray gun L60T17 grounded air hose 235070 and shielded waterborne fluid hose 24M732 24P629 WB100 Waterborne Isolation Enclosure 233825 with smart electrostatic air spray gun L60M17 grounded air hose 235070 and shielded waterborne fluid hose 24M732 233825 WB100 Waterborne Isolation Enclosure for shielded hoses Does not include hoses and gun L60T17 Pro Xp 60 WB Standard Electrostatic Air Spray Gun for waterborne coatings L60M17 Pro Xp 60 WB Smart Electrostatic Air Spray Gun for waterborne coatings 24M732 W ShieldedWaterborneFluidHose Assembly 25 ft 7 6 m 3A2496D 3 Models Models which are FM Approved and Compliant with EN50059 FM approved for use with fluids that meet the following condition c US e Material does not sustain burning in accordance with the Standard Test Method APPROVED for Sustained Burning of Liquid Mixtures ASTM D4206 0 35
24. 24M733 Unshielded Waterborne Fluid Hose 101 sold separately for gun model L60T18 No See Packing Rod Assembly page 79 24N652 NEEDLE electrode black 1 4 24N616 NOZZLE 1 5 mm includes 4a 1 and 4b 24N645 O RING conductive 111507 O RING fluoroelastomer 24N477 AIR CAP 6e 24P892 RING retainer includes 6a 198307 PACKING u cup UHMWPE 24N662 POWER SUPPLY 60 kV gun 24N979 SPRING 24N663 TRIGGER 24A445 SCREW trigger package of 2 15 24N664 See 1 Alternator Assembly page 80 16 24P744 HANDLE for gun model L60T17 24P743 HANDLE for gun model L60T18 185111 SPRING compression 197624 SPRING compression 24P036 VALVE exhaust 112085 O RING 21 24N626 SWIVEL air inlet M12 x 1 4 1 npsm m left hand thread 24N633 VALVE air 276733 SEAL air valve Adjustment Valve page 81 0 53 in sst package of 2 Valve Assembly page 82 Assembly page 82 4 Replacement Danger and Warning labels tags and cards are available at no cost 3A2496D 34 185116 SPRING compression 35 188749 PACKING u cup ID shipped loose shipped loose Qty 1 1 1 1 1 1 4 for use instead of item 29 loose GREASE dielectric 1 oz 30 ml tube not shown 117824 GLOVE conductive medium package of 12 also available in small 117823 and large 24N604 COVER gun package of 10 186118 SIGN warning not shown 24N783 HOOK includes screw 24M732 HOSE shielded wate
25. 30 Follow the Fluid Voltage Discharge and Grounding Procedure page 30 when you stop spraying and whenever you are instructed to discharge the voltage To reduce the risk of component rupture which can cause serious injury do not exceed the maximum working pressure of the lowest rated system component This equipment has a 100 psi 0 7 MPa 7 bar maximum working air and fluid pressure To reduce the risk of an injury follow the Pressure Relief Procedure page 31 whenever you are instructed to relieve the pressure 32 Follow the steps below to establish the correct fluid flow and air flow See Fig 24 to locate the electrostatic gun controls La ti18721a Figure 24 Electrostatic Gun Controls 1 The gun is shipped with the fluid nozzle and air cap installed Check that the retaining ring is tight NOTE To select a different size fluid nozzle or air cap see Fluid Nozzle Selection Chart page 85 and Air Cap Selection Chart page 87 To install the nozzle and air cap see Air Cap and Nozzle Replacement page 51 Model L60M19 Mold Release Gun is supplied with Part No 24N748 Nozzle 24N727 Air Cap anda spray tip of choice If you require a different size spray tip see Spray Tip Selection Chart Model L60M19 MRG Gun Only page 90 or consult with your Graco distributor To install the tip see Air Cap Spray Tip and Nozzle Replacement Model L60M19 page 52 Turn OFF O the ES On
26. 4 in 6 mm chase OD 4 ft 1 22 m locally 4 110272 SCREW set socket hd 1 4 20 x 1 4 in 6 mm 4 4 4 4 4 4 404 406 ti2137a 94 3A2496D Repair Kits Related Manuals and Accessories No To allow precise fluid pressure regulation at the gun 501 110078 FITTING tube fluid 1 4 npt m 1 Includes items 501 507 x 3 8 in 10 mm tube 113070 NIPPLE reducer 3 8 npt x 1 4 npt 113576 PLUG 1 4 npt 236281 REGULATOR fluid see 1 manual 308325 C20350 ELBOW 90 1 4 npt f x 1 4 1 in 6 mm OD tube 506 114158 BIN adapter Y 1 4 in 6 1 OD tube mxfxf 507 TUBE nylon 1 4 in 6 mm 1 OD 4 ft 1 22 m locally ti2149a 3A2496D 95 Dimensions Dimensions ti19456a CN Jj e N RTO ES lo l Ah A L C sa A el bracket oz g L60M19 10 8 274 9 7 246 2 4 61 22 2 628 96 3A2496D Technical Data Technical Data Electrostatic Air Spray Waterbome Guns SSCS ss Wet Maximum Fluid Operating 120 F 48 C Temperature Short Circuit Current Output 125 microamperes Voltage Output Energy 0 35 J with fluid hose 24M733 installed L60T17 and L60T18 60 kV L60M17 L60M18 and L60M19 30 60 kV Sound Power measured per ISO at 40 psi 90 4 dB A at 0 28 MPa 2 8 bar 90 4 dB A SAT ZAS at 100 psi 105 4 dB A at 0 7 MPa 7 0 bar 105 4 dB A Sound Pressure measured 1 m at 40
27. Assembly 24N643 ELECTRODE package of 5 Part No 24N727 Air Cap Assembly 5b Ge farce id se anra uARD in one 1 Parts labeled are not available separately No 5b 24N734 O RING ptfe package of 5 also available in package of 10 order 24E459 5c 5d ti20147a 3A2496D 83 Parts Smart Module Assembly Part No 24N756 Smart Module Assembly 31d A GA Q G ti19442b 31f 31c 84 Ref Description Qty No 31a CARTRIDGE 24P433 GASKET use screw id free screw i id Parts labeled are not available separately These parts are included in Smart Module Screw Kit 24N757 purchase separately 3A2496D Air Caps and Fluid Nozzles Air Caps and Fluid Nozzles Fluid Nozzle Performance Charts Use the following procedure to select the proper fluid Fluid Nozzle Selection Chart nozzle for your application 1 For each fluid nozzle chart find the point on the Smart Air Spray Gun Assembly page 72 a pencil 2 The thick vertical line in each graph represents the target flow rate for that nozzle size Find the graph that has the marked point closest to the thick vertical line This is the recommended nozzle size for your application Significantly To reduce the risk of an injury follow the Pressure Relief Procedure page 31 before exceeding the target flow rate may result in removing or installing a fluid nozzle and
28. E To avoid damaging the power supply 11 pull the gun barrel 1 straight away from the gun handle 16 If necessary gently move the gun barrel from side to side to free it from the gun handle 4 Hold the gun handle 16 with one hand and pull the barrel 1 straight off the handle NOTE If the power supply remains in the barrel remove the alternator power supply assembly from the barrel 40 ti19897a Figure 41 Barrel Removal 58 Barrel Installation 1 Be sure the gasket 28 and grounding spring 18 are in place Make sure the gasket air holes are aligned properly Replace the gasket if damaged 2 Make sure the spring 11a is in place on the tip of the power supply 11 Liberally apply dielectric grease 44 to the tip of the power supply Place the barrel 1 over the power supply and onto the gun handle 16 3 Tighten the two screws 27 oppositely and evenly about a half turn past snug Do not over tighten the screws 27 4 Position the bracket 104 on the gun handle 16 and secure with the air inlet fitting 21 5 Apply dielectric grease 44 to the exposed inner tube of the fluid hose 101 6 Check that the nut 105 is tight on the ferrule housing 103 7 See Test Gun Resistance page 39 103 105 101 21 ti19898a ci 8 Figure 42 Barrel Installation 3A2496D Power Supply Removal and Replacement e Inspect the gun handle power supply cavi
29. Fill the inner cavity of the spacer 2ht with dielectric grease 44 Place the spacer on the fluid rod 2e in the direction shown Generously apply dielectric grease to the outside of the spacer 3 Place the fluid packing 2ct on the packing rod 2e with its lips facing the front of the rod Install the needle packing 2dt with the male end toward the fluid packing then install the housing 29 17 ti19450a Figure 40 Packing Rod 3A2496D Repair Lightly tighten the packing nut 2f The packing nut is properly tightened when there is 3 Ib 13 3 N of drag force when sliding the packing housing 2g assembly along the rod Tighten or loosen the packing nut as needed Install the o ring 2at on the outside of housing 2g Lubricate the o ring with non silicone grease Part No 111265 Do not over lubricate Install the spring 17 against the nut 2j as shown Install the packing rod assembly 2 into the gun barrel Using the multi tool 41 tighten the assembly until just snug Install the electrode See Electrode Replacement page 54 Install the nozzle and air cap See Air Cap and Nozzle Replacement page 51 Install the trigger 12 and screws 13 See Test Gun Resistance page 39 57 Repair Barrel Removal 1 See Prepare the Gun for Service page 50 2 Remove the air inlet fitting 21 and take the bracket 104 off the gun handle 16 3 Loosen the two screws 27 NOTIC
30. G retainer includes 6a 11a 24N979 SPRING 24N663 TRIGGER wo 24A445 SCREW trigger package of 2 oa Alternator Assembly page 80 L60M17 N 1 24N662 POWER SUPPLY 60 kV gun g 0 197624 SPRING compression 24P036 VALVE exhaust 19a 112085 O RING 24N626 SWIVEL air inlet M12 x 1 4 npsm m left hand thread 24N633 VALVE air 276733 SEAL air valve 245265 CIRCUIT flexible Adjustment Valve page 81 SCREW hex socket 10 24 x 0 53 in sst package of 2 E Valve Assembly page 82 Assembly page 82 4 Replacement Danger and Warning labels tags and cards are available at no cost o a a a ai N a 198307 PACKING u cup UHMWPE N NPM MI NM N N co 09 185111 SPRING compression 24P741 HANDLE smart for gun model L60M18 N W N Ce 3A2496D 31 24N756 See Smart Module Assembly page 84 185116 SPRING compression wo A No ol 188749 PACKING u cup 185103 TUBE exhaust 1 4 in 6 mm ID shipped loose 107460 TOOL wrench ball end 4 mm shipped loose for use instead of item 29 loose GREASE dielectric 1 oz 30 ml tube not shown 117824 GLOVE conductive medium package of 12 also available in small 117823 and large 117825 46 24N604 COVER gun package of 10 186118 SIGN warning not shown N A Al A AT BPR ASI ojlo So AI of oO oi 101 24M732 HOSE shielded waterborn
31. Instructions Parts GRACO WB100 Isolation System and Pro Xp 60 WB Gun RARA Air spray system for use when electrostatically spraying conductive waterborne fluids that meet at least one of the conditions for non flammability listed on page 3 For professional use only Important Safety Instructions Read all warnings and instructions in this manual Save these instructions 100 psi 0 7 MPa 7 0 bar Maximum Fluid Working Pressure 100 psi 0 7 MPa 7 0 bar Maximum Air Working Pressure See pages 3 and 4 for model part numbers and approval information ti19881a PROVEN QUALITY LEADING TECHNOLOGY Contents Models with FM Approval Only Models which are FM Approved and Compliant with EN50059 VWamings s iii Maks ia acd nti i Gun Overview i How the Electrostatic Spray Gun WOFKS i ei i Spraying Waterborne Fluids Electrostatically Controls Indicators and Components Smart Guns desiato ital Loi lattanti Installation ei ile eni System Requirements eere Warning Signe sensassion ioi i Install the SyStem i Ventilate the Spray Booth Air Supply Line nsaan e Ground the Cabinet eere Connect the Waterborne Fluid Hose Agitator Kit Accessory eeeeeeeeeeeenneeees Fluid Reg
32. J with Models Compliant with EN 50059 when used 24M733 Hose with fluids that meet the following criteria FM12ATEX0080 EN 50059 e Materials which cannot be ignited in any mixture with air by an energy source Ta 0 C 50 C of less than 500 mJ poe ee ee eed 24P630 WB100 Waterborne Isolation Enclosure 246511 with standard electrostatic air spray gun L60T18 grounded air hose 235070 and unshielded waterborne fluid hose 24M733 24P631 WB100 Waterborne Isolation Enclosure 246511 with smart electrostatic air spray gun L60M18 grounded air hose 235070 and unshielded waterborne fluid hose 24M733 24P734 WB100 Waterborne Isolation Enclosure 246511 with MRG smart electrostatic air spray gun L60M19 grounded air hose 235070 and unshielded waterborne fluid hose 24M733 246511 WB100 Waterborne Isolation Enclosure for unshielded hoses Does not include hoses and gun L60T18 Pro Xp 60 WB Standard Electrostatic Air Spray Gun for waterborne coatings L60M18 Pro Xp 60 WB Smart Electrostatic Air Spray Gun for waterborne coatings L60M19 Pro Xp 60 WB Smart Electrostatic Air Spray Gun for mold release MRG applications 24M733 Unshielded Waterborne Fluid Hose Assembly 25 ft 7 6 m CE 4 3A2496D Warnings Warnings 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 symbols refer to procedure
33. ange replace the power supply If in range go to Test Electrode Resistance page 41 Be sure the spring 11a is in place before reinstalling the power supply ti18735a Figure 26 Test Power Supply Resistance 3A2496D Test Electrode Resistance 1 Follow the steps under Prepare the Gun for Service page 50 2 Insert a conductive rod FF into the gun barrel which was removed for the power supply test and against the metal contact DD in the front of the barrel 3 Measure the resistance between the conductive rod FF and the electrode 3 The resistance should be 10 30 megohms less than 5 megohms for Model L60M19 4 If in range go to Electrical Troubleshooting page 48 for other possible causes of poor performance or contact your Graco distributor 5 Remove the electrode 3 see Electrode Replacement page 54 Measure the resistance between the contact HH and the electrode wire GG The resistance should be 10 30 megohms If out of range replace the electrode 6 Make sure the metal contact ring DD in the barrel the nozzle contact ring 4a and the electrode contact HH are clean and undamaged 3A2496D Electrical Tests ti18737a Figure 27 Test Electrode Resistance ti18736a Figure 28 Electrode 4a ti20143a Figure 29 Nozzle Conductive O Ring 47 Electrical Tests Te
34. astic drop cloths potential static arc Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Keep spray area free of debris including solvent rags and gasoline Keep a working fire extinguisher in the work area PRESSURIZED EQUIPMENT HAZARD Fluid from the equipment leaks or ruptured components can splash in the eyes or on skin and cause serious injury Follow the Pressure Relief Procedure when you stop spraying dispensing and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately PLASTIC PARTS CLEANING SOLVENT HAZARD Many solvents can degrade plastic parts and cause them to fail which could cause serious injury or property damage e Use only compatible water based solvents to clean plastic structural or pressure containing parts See Technical Data in this and all other equipment instruction manuals Read fluid and solvent manufacturer s MSDSs and recommendations TOXIC FLUID OR FUMES Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines 6 3A2496D Warnings PERSONAL PROTECTIVE EQUIPMENT Wear appropr
35. ate 26h must point upward Reinstall the valve Torque the screw 27 to 15 25 in lb 1 7 2 8 Nem 3A2496D Air Valve Repair 1 See Prepare the Gun for Service page 50 2 See Barrel Removal page 58 3 Remove the screws 13 and trigger 12 4 Remove the ES On Off Valve See ES On Off and Fluid Adjustment Valve Repair page 64 5 Remove the spring 34 6 Push on the front of the air valve shaft to force it out the back of the handle Inspect the rubber seal 23a and replace if damaged 7 Inspect the u cup 35 Do not remove the u cup unless damaged If removed install the new one with its lips facing into the gun handle 16 Place the u cup on the shaft of the air valve to help seat it in the gun handle f 4 GO gt nia Figure 52 Install U Cup 3A2496D 10 11 Repair Install the air valve 23 and spring 34 into the gun handle 16 Install the ES On Off Valve See ES On Off and Fluid Adjustment Valve Repair page 64 Install the trigger 12 and screws 13 See Barrel Installation page 58 26 ti19899a Figure 53 Air Valve 65 Repair Smart Module Replacement If the Error display appears the Smart Module has ti19455b lost communication with the power supply Check for good connections between the Smart Module and the power supply If the module s LEDs are not lighting replace the module 1 See Prepare the Gun for Service page 50 2 Remove the pivo
36. ce only the o ring steps 3 9 Remove the retaining ring 30d Turn the valve shaft 30b counterclockwise until it comes free from the valve housing 30a Inspect the o ring 30c Remove if damaged Clean all parts and inspect for wear or damage NOTE Use non silicone grease Part No 111265 Do not over lubricate When reassembling the fan air valve 30 lightly lubricate the valve threads and screw the shaft 30b fully into the housing 30a until bottomed Install the o ring 30c lubricate and unscrew the valve stem until the o ring enters the housing Reassemble the retaining ring 30d Unscrew the valve stem from the housing until it is stopped by the retaining ring Screw the valve assembly 30 into the gun handle 16 using a wrench on the flats of the housing Torque to 15 in Ib 1 7 Nem 30b 30c 30a ti18647a Figure 48 Fan Air Adjustment Valve 3A2496D Atomizing Air Restrictor Valve Repair 1 See Prepare the Gun for Service page 50 2 Place a wrench on the flats of the valve housing 29a and unscrew the valve from the handle 16 NOTE You may replace the valve as an assembly go to step 9 or replace only the o ring steps 3 9 3 Unscrew the valve stem 29e Remove the retaining ring 29d 4 Turn the valve body 29b counterclockwise until it comes free from the valve housing 29a Inspect the o ring 29c Remove if damaged 6 Clean all parts and inspect for
37. co Shielded Waterborne Fluid Hose 24M732 the hose is grounded through the conductive layer Install as instructed under Connect the Waterborne Fluid Hose page 18 When operating the electrostatic gun any ungrounded objects in the spray area people containers tools etc can become electrically charged Improper grounding can result in static sparking which can cause a fire explosion or electric shock Ground all equipment personnel object being sprayed and conductive objects in or close to the spray area Resistance must not exceed 1 megohm Follow the grounding instructions below 26 3A2496D Object being sprayed keep the workpiece hangers clean and grounded at all times ti18753a All electrically conductive objects or devices in the Spray area must be properly grounded ti18728a Fluid and waste containers ground all fluid and waste containers in the spray area Do not use pail liners unless they are conductive and grounded When flushing the spray gun the container used to catch the excess fluid must be electrically conductive and grounded Air compressors ground the equipment according to the manufacturer s recommendations All air lines must be properly grounded Use only grounded hoses with a maximum of 100 feet 30 5 m combined hose length to ensure grounding continuity The floor of the spray area must be electrically conductive and grounded Do not cover the floor with cardb
38. conds and then touching the gun electrode with a grounded rod Check the meter reading If the meter reading is 45 to 55 kV the gun and fluid hose are okay and the problem is in the voltage isolation system If the meter reading is below 45 kV the problem is in the gun or fluid hose Flush the fluid hose and gun with enough air to dry out the fluid passages Turn the ES ON OFF valve to ON and trigger the gun Measure the voltage at the gun electrode with a voltage probe and meter If the meter reading is 45 55 kV the gun power supply is okay and there is probably a dielectric breakdown somewhere in the fluid hose or gun Continue with step 11 3A2496D 13 14 Troubleshooting If the meter reading is below 45 kV do the Electrical Tests page 39 to check the gun and power supply resistance If those tests show the gun and power supply are okay continue with step 11 A dielectric breakdown is most likely in one of the following three areas Repair or replace the component that is failing a Fluid hose e Check for leakage or any bulges in the outer cover which may indicate a pin hole leak through the PTFE layer Disconnect the fluid hose from the gun and look for signs of fluid contamination on the outside of the PTFE portion of the fluid tube Inspect the end of the hose connected to the voltage isolation system Look for cuts or nicks e Make sure the hose is properly stripped see Conn
39. cp cc min Up to 15 oz min 450 Up to 15 oz min 450 24N274 Tapered 12 14 Light to medium Up to 15 oz min 450 Good Good Best black end 305 356 20 70 cp cc min 24N275 black Light to medium 20 70 cp and high solids 360 cp aerospace coatings Tapered 14 16 end 356 406 Tapered 11 13 end 279 330 Round 15 17 end 381 432 For use with 2 0 mm nozzles Medium to heavy 70 260 cp and high solids 360 cp Light to medium 20 70 cp 24N439 black 24N477 black 24W279 green Centipoise centistokes x fluid specific gravity Up to 25 oz min 750 cc min Up to 20 oz min 600 cc min Up to 15 oz min 450 cc min 24N453 Round 14 16 Light to medium Up to 15 oz min 450 Better Better Good black end 356 406 20 70 cp cc min 3A2496D 87 Air Caps and Fluid Nozzles Air Consumption Charts Key to Air Consumption Charts TEST CONDITIONS Fan valve fully open 85 kV gun 5 16 in x 25 ft 8 mm x 7 6 m hose 5 16 in x 50 ft 8 mm x 15 2 m hose Table 12 24N439 Air Cap AIR CON AIR CON SUMPTION SUMPTION scfm scfm 20 30 40 50 60 70 80 WALL PRESSURE psi Table 11 24N376 24N276 24N277 and 24N278 Table 13 24N279 Air Cap Air Caps AIR CON AIR CON SUMPTION SUMPTION scfm scfm
40. current display stays red Gun is too close to the part being Gun should be 8 12 in 200 300 smart guns only sprayed mm from the part Dirty gun See Clean the Gun Daily page 37 ES or Hz indicator is amber Alternator speed is too low Increase air pressure until indicator is green To avoid over atomization use the atomizing air restrictor valve to reduce the atomizing air to the air cap ES or Hz indicator is red Alternator speed is too high Decrease air pressure until indicator is green Error display appears and Hz Smart module has lost Check for good connections be indicator is red Smart guns only communication with the power tween the Smart Module and the supply power supply See Smart Module Replacement page 66 and Power Supply Removal and Replacement page 59 3A2496D 49 Repair Repair Prepare the Gun for Service To reduce the risk of fire explosion or electric shock before flushing the gun Follow the Fluid Voltage Discharge and Grounding Procedure page 30 and turn OFF O the ES On Off switch before flushing checking or servicing the system and whenever you are instructed to discharge the voltage Clean all parts with a non flammable fluid as defined under Models page 3 Do not service this equipment unless you are trained and qualified Do not touch the gun nozzle or come within 4 in 102 mm of the nozzle during gun operation or until you perform the Fluid Voltage Dischar
41. d Connect the air supply hose ground wire Q to a true earth ground 3A2496D Installation Trapped air can cause the fluid supply unit to cycle unexpectedly which can result in serious injury including splashing fluid in the eyes or on the skin Do not operate the equipment without the bleed type air valve B installed 4 The WB100 system includes a bleed type air valve B The bleed type air valve is required to shut off all air to the system and relieve air trapped between the valve and the fluid supply unit after the air regulator is shut off Connect the main air supply line A to the bleed valve 5 Install an additional bleed type air valve CC upstream of the air filter M to isolate the filter for servicing Ground the Cabinet Connect the main ground wire V to a true earth ground 17 Installation Connect the Waterborne Fluid Hose Always use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun fluid inlet The waterborne fluid hose 101 consists of an inner PTFE tube T and an abrasion resistant outer jacket J Shielded hose 24M732 also has a conductive layer C The conductive layer is connected to ground at the gun fitting bracket 104 Before connecting the waterborne fluid hose to the gun blow it out with air and flush with water to remove contaminants Flush the gun before using it To reduce the risk of electric shock install only one contin
42. d fluid supply is charged to high voltage which means that the system has more electrical energy than a solvent based system Therefore only non flammable fluids as defined under Models page 3 can be sprayed with the system or be used to clean flush or purge the system Precautions must be taken when using electrostatic waterborne equipment to avoid potential shock hazards When the spray gun charges the isolated fluid to high voltage it is similar to charging a capacitor or a battery The system will store some of the energy while spraying and retain some of that energy after the spray gun is shut off Do not touch the gun nozzle or come within 4 in 102 mm of the electrode until the stored energy is discharged The amount of time it takes to discharge the energy depends on the system design Follow the Fluid Voltage Discharge and Grounding Procedure page 30 before approaching the front of the gun NOTE The Graco warranty and approvals are void if the electrostatic spray gun is connected to a non Graco voltage isolation system or if the gun is operated above 60 kV Controls Indicators and Components The electrostatic gun includes the following controls indicators and components see Fig 1 For information on Smart guns also see Smart Guns page 10 3A2496D Fan Air Adjustment 3A2496D Atomizing Air Restrictor Valve 1 4 npsm m left hand thread for Graco red c
43. e FAN part of item 15b These parts are included in Bearing Kit 24N706 purchase separately 80 3A2496D Parts ES On Off and Fluid Adjustment Valve Part No 24N630 ES On Off and Fluid Adjustment Valve ti18645a Ref PartNo Description Qty Ref PartNo Description No o Pele HOUSING valve 26h 24N631 PLATE retaining 26 24N648 KNOB adjustment fluid e 12696 SCREW set socket head These parts are included in Air Seal Repair Kit Parts labeled are not available separately 24N789 purchase separately 3A2496D 81 Parts Fan Air Adjustment Valve Assembly Part No 24N634 Fan Air Adjustment Valve Assembly shown 30b 30c 30a 30d ti18647a Ref Description Qty No Go steam Sid These parts are included in Air Seal Repair Kit 24N789 purchase separately Parts labeled are not available separately 82 Atomizing Air Restrictor Valve Assembly Part No 24T304 Atomizing Air Restrictor Valve Assembly shown 29e 29d 29a 29c 29b ti18646b E E rouse ave i BODY valve BODY valve round spray only STEM valve 118907 RING retaining KNOB shaft round spray only SETSCREW knob round spray only These parts are included in Air Seal Repair Kit 24N789 purchase separately Parts labeled are not available separately 3A2496D Air Cap
44. e fluid for gun model L60M17 includes 102 108 24M733 HOSE unshielded waterborne 1 fluid for gun model L60M18 includes 102 108 102 198663 FERRULE for shielded hose 1 190863 FERRULE for unshielded hose hose unshielded hose 0 24N783 HOOK includes screw N These parts are included in Air Seal Repair Kit 24N789 purchase separately 71 Parts Mold Release Smart Air Spray Gun Assembly Part No L60M19 60 kV Electrostatic Mold Release Air Spray Gun Series A Part No 24M733 Unshielded Waterborne Fluid Hose 101 sold separately 40 ti19938a 72 3A2496D Parts Part No L60M19 60 kV Electrostatic Mold Release Air Spray Gun Series A Part No 24M733 Unshielded Waterborne Fluid Hose 101 sold separately 24N667 BODY gun See Packing Rod Assembly 1 page 79 2 4N749 NEEDLE 24N748 NOZZLE seat includes 4a 4c 24N645 O RING conductive 111507 O RING fluoroelastomer Z Qty 1 1 2 O ajl oaj By BR BY DA Dv 24P893 RING conductive 24N727 See Air Cap Assembly page 83 oO 11a 24N979 SPRING 2 24N663 TRIGGER wo 24A445 SCREW trigger package of 2 24N664 See Alternator Assembly page 80 24P741 HANDLE smart 185111 SPRING compression vo A _ Aq Aa lo oO 24P036 VALVE exhaust 19a 112085 O RING 24N626 SWIVEL air inlet M12 x 1 4 npsm m left hand thread 6a 198307
45. ect the Waterborne Fluid Hose page 18 Restrip or replace the hose b Fluid packings Remove the packing assembly from the gun see Fluid Packing Rod Removal page 56 and look for signs of fluid leakage or any blackened areas which would indicate arcing is occurring along the packing rod c Fluid hose connection to the spray gun A breakdown at the fluid hose connection joint would be caused by fluid leaking past the o ring seals on the end of the hose Remove the hose at the gun connection and look for signs of fluid leakage along the PTFE tube Before reassembling the gun clean and dry the gun fluid inlet tube Repack the inner spacer of the fluid packing rod with dielectric grease and reassemble the gun Reconnect the fluid hose Check the gun voltage with the voltage probe and meter before filling the gun with fluid 45 Troubleshooting Spray Pattern Troubleshooting Check all possible remedies in the Troubleshooting Some spray pattern problems are caused by the Chart before disassembling the gun improper balance between air and fluid Poem ossee i Sowtion O Fluttering or spitting spray No fluid Refill supply Loose dirty damaged Clean or replace nozzle see nozzle seat Clean the Gun Daily page 37 or Air Cap and Nozzle Replacement page 51 Air in fluid supply Check fluid source Refill Improper spray pattern Damaged or dirty nozzle or air cap Clean or replace See Air Cap and
46. eneral wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INGUUDINA BENE TOMIEO TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FORA Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incide
47. ent 3A2496D Gun Setup 29 Operation Operation Operating Checklist Fluid Voltage Discharge and Grounding Procedure Check the following list daily before starting the system O All operators are properly trained to safely operate an electrostatic waterborne air spray system as instructed in this manual The fluid supply is charged with high voltage until the voltage is discharged Contact with the charged components of the voltage isolation system or O All operators are trained in the spray gun electrode will cause an electric shock Pressure Relief Procedure page 31 To avoid an electric shock follow the Fluid Voltage Discharge and Grounding Procedure O The electrostatics are turned off and system whenever you are instructed to discharge the voltage is discharged according to the voltage Fluid Voltage Discharge and Grounding before cleaning flushing or servicing the system Procedure page 30 before any person en i equipment ters the isolation enclosure before cleaning and before performing any maintenance or before approaching the front of the gun repar or before opening the isolation enclosure for the isolated fluid supply O The system is grounded according to the instructions in Grounding page 26 Turn the ES ON OFF valve OFF and wait 30 seconds 1 The Graco waterborne fluid hose is in good condition with no cuts or abrasions of the PTFE layer Replace hose if damaged
48. equired for some of the troubleshooting tests that follow 1 44 Check that all of the air and fluid tubes and hoses are properly connected Check that the voltage isolation system valves and controls are properly set for operation Check that the interior of the isolated enclosure is clean Check that the spray gun and voltage isolation system have sufficient air pressure Check that the gun ES ON OFF valve is in the ON position and that the gun ES indicator light is on If the ES indicator light is not on remove the spray gun for service and complete the Electrical Tests page 39 Check that the voltage isolation system s enclosure door is closed and that any safety interlocks are engaged and working properly o 10 Make sure the voltage isolation system is in the isolate mode where it is isolating the fluid voltage from ground To eliminate air gaps in the fluid column spray enough fluid to purge the air out between the voltage isolation system and the spray gun An air gap in the fluid hose can break the electrical continuity between the spray gun and the isolated fluid supply and cause a low voltage reading on a voltage meter connected to the isolated fluid supply Check the spray gun cover and barrel for accumulated overspray Excessive overspray can create a conductive path back to the grounded gun handle Install a new gun cover and clean the exterior of the gun Inspect the entire system for a
49. erator Accessories Test Equipment 117823 Conductive Gloves box of 12 small 241079 Megohmmeter 500 V output 0 01 2000 megohms Use for ground continuity and gun resistance 117824 Conductive Gloves box of 12 medium tests Not for use in hazardous areas 117825 Conductive Gloves box of 12 large 245277 Test Fixture High Voltage Probe 24N520 Comfort Grip Snap on grip and kV Meter Use to test the increases handle size to reduce operator fatigue Medium size the condition of the alternator and electrostatic voltage of the gun and 24N521 Comfort Grip Snap on grip power supply when being serviced increases handle size to reduce See manual 309455 operator fatigue Large size System Accessories Hoses 100 psi 0 7 MPa 7 bar Maximum Working Pressure 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f AI ONT Glare left hand thread Grounded Air Hose with stainless steel braid ground path Red 235068 6 ft 1 8 m 235069 15 ft 4 6 m 3A2496D 93 Repair Kits Related Manuals and Accessories No To keep fluid mixed and prevent settling out Includes 401 112698 ELBOW swivel 1 8 npt m x 1 items 401 408 1 4 in 6 mm OD tube 114158 FITTING adapter Y 1 4 in 6 1 mm OD tube mxfxf 403 193315 COLLAR mounting agitator 02 03 i 04 193316 NUT collar agitator 05 197298 COVER pail 5 gal 19 liter 06 07 08 224571 AGITATOR see manual 1 306565 pur TUBE nylon 1
50. ge and Grounding Procedure page 30 e Check all possible remedies in Troubleshooting page 43 before disassembling the gun e Use a vise with padded jaws to prevent damage to plastic parts e Lubricate some packing rod parts 2 and certain fluid fittings with dielectric grease 44 as specified in the text 50 Lightly lubricate o rings and seals with non silicone grease Order Part No 111265 Lubricant Do not over lubricate Only use genuine Graco parts Do not mix or use parts from other Pro Gun models Air Seal Repair Kit 24N789 is available The kit must be purchased separately Kit parts are marked with an asterisk for example 6a Fluid Seal Repair Kit 24N790 is available The kit must be purchased separately Kit parts are marked with a symbol for example 2a Follow the Fluid Voltage Discharge and Grounding Procedure page 30 Flush the gun See Flushing page 36 Blow the fluid lines dry with air Relieve the pressure See Pressure Relief Procedure page 31 Disconnect the gun air and fluid lines at the isolation system Remove the gun from the worksite Repair area must be clean 3A2496D Repair Air Cap and Nozzle Replacement NOTICE 7 Install the air cap 5 and retaining ring 6 Make sure the u cup 6a is in place with the lips facing Trigger the gun while removing the nozzle to help forward drain the gun and prevent any paint or solvent left in the gun from entering the air
51. ge 15 Press and hold for approximately 5 seconds to return to Operating Mode ti19125a Figure 8 Alternator Speed Hertz Screen 3A2496D Gun Overview Low Voltage Lock Screen The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode See Fig 9 and Table 1 on page 12 To enter this screen press the LO SET button while in the Alternator Speed Hertz Screen This screen displays the status of the Low Voltage Lock If the setting is locked the lock image LK appears to the left of the Lo display LD If the setting is unlocked the lock image does not appear To change the lock status press and hold the LO SET button until the lock image appears or disappears If the lock is set the image will also appear on the Low Voltage Setting Screen when in low voltage mode see Fig 4 NOTE Diagnostic Mode cannot be exited from this screen because pressing and holding the LO SET button is used to turn the lock on or off To exit press LO SET momentarily to return to the Voltage kiloVolts Screen then exit Diagnostic Mode from there ti19339a Figure 9 Low Voltage Lock Screen 15 Installation Installation System Requirements A Graco voltage isolation system must have the following features An isolation enclosure that prevents persons from making contact with the high voltage components before the system voltage is discharged All components
52. gohmmeter is available as an accessory to check that the gun is properly grounded 1 Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose 2 Turn OFF O the ES On Off switch 3 Turn off the air and fluid supply to the gun Follow the Pressure Relief Procedure page 31 The fluid hose must not have any fluid in it 4 Disconnect the fluid hose 28 Make sure the red colored grounded air hose AH is connected and the hose ground wire is connected to a true earth ground Measure the resistance between the gun handle BB and a true earth ground CC Use an applied voltage of 500 minimum to 1000 volts maximum The resistance should not exceed 100 ohms See Fig 22 If the resistance is greater than 100 ohms check the tightness of the ground connections and be sure the air hose ground wire is connected to a true earth ground If the resistance is still too high replace the air hose BB ti18726a Figure 22 Check Gun Electrical Grounding 3A2496D Using an ohmmeter AA measure the resistance between the cabinet ground lug 214 and a true earth ground CC The resistance must be less than 100 ohms CC ti2163a Figure 23 Check Cabinet Grounding Flush Before Using Equipment The equipment was tested in fluid at the factory To avoid contaminating your fluid flush the equipment with a compatible solvent before using the equipm
53. grounded enclosure L or grounded fence To maintain grounding continuity the conductive hose layer C must be engaged in the ferrule when the strain relief nut is tightened Failure to properly install the hose in the strain relief could result in an electric shock 3A2496D Installation c ti19889a Figure 18 Shielded Fluid Hose Connection at Non Graco Isolation Enclosure c Connect the end of the tube T to the pump fluid outlet fitting Z NOTE The Graco warranty and approvals are void if the electrostatic spray gun is connected to a non Graco voltage isolation system or if the gun is operated above 60 kV 21 Installation may K ti19883a Figure 19 Typical Installation Pro Xp WB100 Waterborne System 22 3A2496D Installation Typical Installation Key Main Air Supply Line Waterborne Bleed Type Air Shutoff a Air Spray Valve DA Pump Air Pressure Grounding Rod Gauge U Ground Terminal Pump Air Pressure Main Ground Wire Regulator Strain Relief Fitting ee Pump Air Supply Line Grounding Cylinder Pump Suction Hose Pump Fluid Outlet Paint Container Fitting Bleed Resistor Isolated Enclosure Door Enclosure Safety not shown to illustrate Interlock internal components Door must be closed Isolated Enclosure and locked to operate Gun Air Line Filter system Enclosure T Handle Locking Screw part of door assembly un Air Pressure
54. he nozzle Trigger the gun and install air cap assembly 5 before tightening the the nozzle 4 Tighten until snug then 1 4 turn retaining ring 6 Do not turn the air cap when more the retaining ring is tight 7 Check that the spray tip gasket 10a is in place 11 Align the spray tip tab with the groove in the air cap 5 Install the spray tip 10 in the air cap Orientate the air cap and tighten the retaining ring securely 12 Test Resist i 8 Make sure that the electrode 5a is installed SESTA UA asd PADE ae correctly in the air cap 3A2496D 53 Repair Electrode Replacement 54 See Prepare the Gun for Service page 50 Remove the air cap and nozzle See Air Cap and Nozzle Replacement page 51 Unscrew the electrode 3 with the multi tool 41 NOTICE To avoid damaging the plastic threads be very careful when installing the electrode Apply low strength purple Loctite or equivalent thread sealant to the electrode and packing rod threads Install the electrode finger tight Do not overtighten Install the fluid nozzle and air cap See Air Cap and Nozzle Replacement page 51 See Test Gun Resistance page 39 ti19895a Figure 37 Electrode Replacement 3A2496D Repair Needle Replacement Model L60M19 1 See Prepare the Gun for Service page 50 3 2 Remove the air cap and nozzle See Air Cap Spray Tip and Nozzle Replacement Model L60M19 page 52 Unscrew the needle 3
55. he o ring with a light coating of non silicone grease Install the exhaust valve 19 in the handle 16 Apply thread sealant to the top threads of the swivel 21 Position the bracket 104 and screw the swivel into the gun handle 16 Torque to 75 85 in Ib 8 4 9 6 Nem Check that the nuts 102 105 are tight Install the tube 36 and clamp 43 3 To replace the air inlet swivel 3A2496D Repair Unscrew the swivel 21 from the gun handle 16 The swivel is a left hand thread Apply thread sealant to the top threads of the swivel Screw the swivel into the gun handle Torque to 75 85 in Ib 8 4 9 6 Nem ti19900a Figure 56 Air Inlet Fitting and Air Exhaust Valve 67 Parts Parts Standard Waterborne Air Spray Gun Assembly Part No L60T17 60 kV Electrostatic Waterborne Air Spray Gun Series A includes items 1 48 Part No L60T18 60 kV Electrostatic Waterborne Air Spray Gun Series A includes items 1 48 Part No 24M732 Shielded Waterborne Fluid Hose 101 sold separately for gun model L60T 17 Part No 24M733 Unshielded Waterborne Fluid Hose 101 sold separately for gun model L60T18 ti19904a 68 3A2496D Parts Part No L60T17 60 kV Electrostatic Waterborne Air Spray Gun Series A includes items 1 48 Part No L60T18 60 kV Electrostatic Waterborne Air Spray Gun Series A includes items 1 48 Part No 24M732 Shielded Waterborne Fluid Hose 101 sold separately for gun model L60T17 Part No
56. hutdown 1 Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure page 30 Flush the gun see Flushing page 36 Follow the Pressure Relief Procedure page 31 3A2496D Operation 4 Hang the gun from its hook with the nozzle pointing down Be sure to keep the gun from grounding out ti19891a 35 Maintenance Maintenance Flushing Flush before changing fluids before fluid can dry 3 Follow the Pressure Relief Procedure page 31 in the equipment at the end of the day before storing and before repairing equipment Flush at the lowest pressure possible Check connectors for leaks and tighten as necessary SS 4 Changethe fluid source to solvent NOTE For Model L60M19 Mold Release Gun remove the spray tip before flushing See Air Cap Spray Tip and Nozzle Replacement Model L60M19 page 52 5 Point the gun into a grounded metal pail Flush until clean solvent flows from the gun To reduce the risk of fire explosion or electric shock turn OFF O the ES On Off switch before flushing the gun Follow the Fluid Voltage Discharge and Grounding Procedure page 30 before flushing Only flush purge or clean the gun with fluids that ig meet the following flammability requirements C j FM FMc Approved Material does not sustain burning in accordance Burning of Liquid Mixtures ASTM D4206 7 CE EN 50059 Compliant 7 Materials which cannot be ignited in any
57. iate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This protective equipment includes but is not limited to e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 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 Use fluids and solvents that are compatible with equipment wetted parts See Technical Data MPa bar PSI in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipment only for its in
58. ing the setting is not adjustable in Diagnostic Mode However the voltage adjustment switch VA can be set to HI or LO in Operating Mode and Diagnostic Mode To enter Diagnostic Mode press and hold the LO SET LS button for approximately 5 seconds The display will go to the Voltage kiloVolts Screen page 14 To advance to the next screen press the LO SET button again To exit Diagnostic Mode press and hold the LO SET button for approximately 5 seconds The screen will return to Operating Mode NOTE If the gun is detriggered while in Diagnostic Mode the last screen viewed will be displayed when the gun is retriggered NOTE Diagnostic Mode cannot be exited from the Low Voltage Lock Screen See Low Voltage Lock Screen page 15 for details Voltage kiloVolts Screen The Voltage kiloVolts Screen is the first screen to appear after entering Diagnostic Mode See Fig 6 and Table 1 on page 12 To enter this screen press and hold the LO SET button for approximately 5 seconds while in the Operating Mode This screen displays the spraying voltage of the gun as a number kV rounded to the nearest 5 kV The two top right LEDs VI of the display panel light indicating that the Voltage kiloVolts Screen is displayed The display is a readout and cannot be changed Press the LO SET button to advance to the Current microAmperes Screen page 14 Press and hold for approximately 5 seconds to return to Operating Mode
59. ir cap Tighten securely ti18774a 37 Maintenance Daily System Care 1 2 3 38 Follow the Pressure Relief Procedure page 31 Clean the fluid and air filters Check for fluid leaks Tighten all fittings Clean workpiece hangers Use non sparking tools Check the movement of the trigger and valves Lubricate if necessary Check Gun Electrical Grounding page 28 Hang the gun from its hook with the nozzle pointing down Be sure to keep the gun from grounding out Clean the cabinet e Inspect the cabinet and clean up any spilled paint Conductive paint residue allowed to contact grounded parts may short out the electrostatics Keep the inside of the cabinet clean for proper operation Inspect the door T handle locking screw regularly to ensure the threads are well greased Apply silicone free grease to the threads when necessary Visually inspect the ground strip 240 for damage Replace if needed Measure the resistance weekly See Test Ground Strip Resistance page 42 ti2162a 3A2496D Electrical Tests Use the following procedures to test the condition of the power supply and gun body and electrical continuity between components Power Supply Removal and Replacement page 59 Use megohmmeter Part No 241079 AA and an applied voltage of 500 V Connect the leads as shown Megohmmeter Part No 241079 AA see Fig 25 is not ap
60. ire from external ground lug to 4 102 3 8 OD tube bulkhead to cart manifold B4 249 5 127 5 32 OD tube regulator 216 to gauge 217 16 407 red 14 gauge wire from 78 3A2496D Packing Rod Assembly Part No 24N655 Packing Rod Assembly Includes items 2a 2k 2k 2j ti18641a No 2e 24N703 ROD packing includes 1 items 2j and 2k 197641 NUT packing These parts are included in Fluid Seal Repair Kit 24N790 purchase separately These parts are included in Trigger Adjustment Nut Kit 24N700 purchase separately 3A2496D 2f Parts 2bt 2ht 2d 2g 29 185495 HOUSING packing 2ht 186069 SPACER packing NUT trigger adjustment part 1 of item 2e NUT trigger adjustment part 1 of item 2e Parts labeled are not available separately 2je 2k 79 Parts Alternator Assembly Part No 24N664 Alternator Assembly ti18639b Ref Part Description Qty Ref Part Description Qty No No No No 24N705 COIL alternator e CAP housing part of item 15d 15b 24N706 BEARING KIT includes two 1 A bearings item 15e fan and g 110073 O RING one item 1Shclip 15h 24N709 CLIP package of 5 one clip 1 included with item 15b These parts are included in Air Seal Repair Kit Parts labeled are not available separately 24N789 purchase separately 15d 24N707 HOUSING includes item 15f 15
61. judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents To place an order contact your Graco Distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 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 3A2496 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2012 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revision D June 2013
62. luid supply Add fluid if necessary Dirty or clogged fluid nozzle Clean See Clean the Gun Daily page 37 Closed or damaged fluid Open valve or see adjustment valve ES On Off and Fluid Adjustment Valve Repair page 64 Dirty air cap Misaligned air cap and fluid nozzle Clean fluid buildup off air cap and fluid nozzle seat See Clean the Gun Daily page 37 Excessive paint wrap back to Poor grounding See Grounding page 26 operator Incorrect distance from gun to part Should be 8 12 in 200 300 mm 3A2496D 47 Troubleshooting Electrical Troubleshooting a E Voltage still present at gun after following the Fluid Voltage Discharge and Grounding Procedure page 30 Poor wrap ES or Hz indicator is not lit 48 ES On Off switch is not turned Turn OFF 0 OFF O Did not wait long enough for Wait longer before touching voltage to discharge electrode with grounding rod Check for bleed resistor failure Air pocket in fluid line leaves fluid Determine cause and correct near gun isolated Purge air from fluid line Voltage isolation system failed Service voltage isolation system Grounding cylinder not operating See Test Cylinder Resistance page 42 Replace if needed ES On Off switch is OFF O Turn ON I Gun air pressure too low ES Check air pressure to gun indicator is amber minimum 45 psi 0 32 MPa 3 2 bar needed at gun for full voltage Atomizing air pressure too high
63. ment Model LOOMI9 z ettaro dirsi 52 Electrode Replacement 54 Needle Replacement Model L60M19 55 Fluid Packing Rod Removal 56 Packing Rod Repair 57 Barrel Removal 58 Barrel Installation nennen neern eneee 58 Power Supply Removal and Replacement 59 Alternator Removal and Replacement 60 Fan Air Adjustment Valve Repair 62 Atomizing Air Restrictor Valve Repair 63 ES On Off and Fluid Adjustment Valve REPAllilzn ara 64 Air Valve Repair nre enree rrenen 65 Smart Module Replacement 66 Air Swivel and Exhaust Valve Replacement nna 67 PartSis ite ola alal lia 68 Standard Waterborne Air Spray Gun Assembly faire 68 Smart Waterborne Air Spray Gun Assembly ss iii 70 Mold Release Smart Air Spray Gun Assembly ie 72 Isolation Enclosure nnee 74 Tubing and Wiring i 77 Packing Rod AssemblY 79 Alternator Assembly i 80 ES On Off and Fluid Adjustment Valve 81 Fan Air Adjustment Valve Assembly 82 Atomizing Air Restrictor Valve Assembly LL 82 Air Cap Assembly i 83 Smart Module AssemblY 84 Air Caps and Fluid Nozzles 85 Spray Tip Selection Chart Model L60M
64. n relief fitting W Ensure conductive layer C has passed through fitting Tighten to 55 in Ib 6 2 Nem Pull back on hose to check it is secure Comply with the requirements in the Warning below For Shielded Hose Systems Conductive hose layer C must be grounded through its connection to the isolation system s grounded enclosure L or grounded fence To maintain grounding continuity the conductive hose layer C must be engaged in the ferrule when the strain relief nut is tightened Failure to properly install the hose in the strain relief could result in an electric shock A 14 50 in 368 mm B 0 75 in 19 mm ti19887a Figure 14 Shielded Hose 24M732 Dimensions at WB100 Enclosure ip m YT g L ti1897a Figure 15 Shielded Hose 24M732 Connection at WB100 Enclosure J A 12 00 in 305 mm a ti19888a Figure 16 Unshielded Hose 24M733 Dimensions at WB100 Enclosure g ti2744a Figure 17 Unshielded Hose 24M733 Connection at WB100 Enclosure 3A2496D Non Graco Isolated Enclosure Connect hose as instructed in the isolation system manual and comply with the requirements in the Warning below For Shielded Hose Systems Conductive hose layer C must be grounded through its connection to the isolation system s
65. ncluded in Air Seal Repair Kit 24N789 purchase separately 73 Parts Isolation Enclosure Part No 233825 Waterbome Isolation Enclosure for use with shielded waterborne fluid hose Part No 246511 Waterborne Isolation Enclosure for use with unshielded waterborne fluid hose 282 da 280 lt I 252 Lo d 253 cite SIRO 267 Su 283 301 E 281 217 OS 228 os Na ni NY 262 4 ai i 206 di STE I de 235 N 227 n 275 268 243 213 ti19902a 74 3A2496D INO 201 pee a enclosure includes 201a 202 203 eeo PLATE Sa aah FP 15A524 HOUSING latch 113061 SWITCH push air Je a pol eth lene 309303 SCREW hex hd cap 5 16 18 x 5 5 in 140 mm ee ae I E 214 104029 LUG ground GR DE OT E O I I LI 216 111804 REGULATOR air ze 111804 REGULATOR 217 113060 GAUGE air 1 8 npt ar roo oE ai ei _ T 24P629 and 233825 24P631 and 246511 anq FERRULE for 24P630 24P631 E anq Ee IA E 104267 REGULATOR air 2907 BUSHING plastic 3 4 x 1 2 npt 10 mm OD tube ELBOW tube 3 8 npt x 1 2 in 13 mm OD tube 15A682 ILABEL warning o LABEL warning 00 ul iii 13 mm OD tube 237 28738 STRAINER 16 messe f N N N N ak a oa w N gt 3A2496D Parts INO 114958 STRAP tie 222011 GROUND WIRE 25 ft 7 6 m 234018 STRIP grounding aluminum 110209 NUT regulator
66. ntal or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures
67. ny visible fluid leakage and repair any fluid leaks that are found Pay special attention to the following areas e Packing area of the spray gun e Fluid hose check for leakage or any bulges in the outer cover which may indicate an internal leak Internal voltage isolation system components 3A2496D Tests If you still have no voltage separate the spray gun and hose from the voltage isolation system and check whether the gun and hose alone will hold voltage with the following test 1 10 Flush the system with water and leave the lines filled with water Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure page 30 Follow the Pressure Relief Procedure page 31 Disconnect the fluid hose from the voltage isolation system Avoid allowing any water to leak out of the fluid hose as that could cause a significant air gap in the fluid column up to the gun electrode which can break the conductivity path and conceal a potential failure area Position the end of the hose as far as possible away from any grounded surface The end of the hose must be at least 1 ft 0 3 m from any ground Make sure that no one is within 3 ft 0 9 m of the end of the hose Turn the ES ON OFF valve to ON and trigger the gun just enough to turn on the air to the gun but not the fluid Measure the voltage at the gun electrode with a voltage probe and meter Discharge the system voltage by waiting 30 se
68. o conductive or see Electrical Troubleshooting page 48 for other possible causes Hz Indicator The Hz indicator functions the same as the ES indicator on standard guns The indicator lights to show the alternator speed status and has three colors e Green indicates the alternator speed is correct e If the indicator changes to amber after 1 second increase the air pressure If the indicator changes to red after 1 second reduce the air pressure 10 Voltage Adjustment Switch The voltage adjustment switch VA allows the operator to change from low to high voltage e The high voltage setting is determined by the maximum voltage of the gun and is not adjustable e The low voltage indicator LO lights when the switch is set to LO The low voltage setting is user adjustable See Adjusting the Low Voltage Setting page 11 NOTE If the Error display appears the Smart module has lost communication with the power supply See Error Display page 11 for further information kV uA LO Hz VA LS ti19121a Figure 2 Smart Gun Module in Operating Mode 3A2496D Error Display If the Smart module loses communication with the power supply the Error display appears the Hz indicator turns red and the Smart module is disabled See Fig 3 and Table 1 on page 12 This can occur in Operating Mode or Diagnostic Mode See Electrical Troubleshooting page 48 Communication mu
69. oard or any non conductive material which would interrupt grounding continuity ti18725a GA x 3A2496D Gun Setup e All solvent pails use only approved grounded metal containers which are conductive Do not use plastic containers Use only non flammable solvents Do not store more than the quantity needed for one shift e All persons entering the spray area must wear shoes having conductive soles such as leather or wear personal grounding straps Do not wear shoes with non conductive soles such as rubber or plastic If gloves are necessary wear the conductive gloves 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 ti18731a 27 Gun Setup Check Gun Electrical Grounding Megohmmeter Part No 241079 AA see Fig 21 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 The gun has been removed from the hazardous area Or all spraying devices in the hazardous area are turned off ventilation fans in the hazardous area are operating and there are no flammable vapors in the area Such as open solvent containers or fumes from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage Graco Part No 241079 Me
70. occurs at minimum pressure Smart guns is lit or check that the kV indicator adjust the restrictor valve If atomization is on the isolated enclosure reads 45 55 kV See inadequate increase air pressure or decrease the following table fluid flow Table 3 LED Indicator Colors Green When spraying the indicator should remain green indicating sufficient air pressure to the alternator turbine If the indicator turns amber after 1 sec the air pressure is too low Increase air pressure until the indicator is green ti18759a If the indicator turns red after 1 sec the air pressure is too high Decrease air pressure until the indicator is green 12 Adjust the fan air adjustment valve clockwise for a narrower pattern counterclockwise for a wider pattern 15 Check the kV meter on the isolated enclosure When the ES On Off switch is turned ON I 45 55 kV is normal the fluid supply is charged with high voltage 16 Spray a test piece Examine the edges until the voltage is discharged Contact with for coverage If wrap is poor see the charged components of the spray gun will Spray Pattern Troubleshooting page 46 cause an electric shock Do not touch the gun nozzle or electrode or come within 4 in 102 mm of the front of the gun during operation 13 Turn ON I the ES On Off switch J c ti18729a ti18760a 17 When you finish spraying perform Shutdown page 35 34 3A2496D S
71. olored grounded air supply hose Fluid Adjustment Barbed fitting for supplied exhaust tube See Air Caps and Fluid Nozzles page 85 for available sizes Supplies electrostatic charge to the fluid Adjusts fan size and shape Can be used to decrease pattern width ti19882a ES On Off Valve K ES Indicator stan dard gun only for Smart gun indica tor see Operating Mode page 10 Gun Overview Restricts air cap air flow Replace with plug included if desired Adjusts fluid flow by limiting fluid needle travel Use only in low flow conditions to reduce wear Turns electrostatics ON I or OFF O Lit when ES is ON I Color indicates alternator frequency See the LED indicator table on page 36 Gun Overview Smart Guns The Smart Gun module displays spraying voltage current alternator speed and the voltage setting low or high It also allows the user to change to a lower spraying voltage The module has two modes e Operating Mode Diagnostic Mode Operating Mode Bar Graph See Fig 2 and Table 1 on page 12 The Operating Mode displays gun data during normal spraying The display uses a bar graph to show the voltage level in kiloVolts kV and the current level in microAmperes uA The bar graph range is from 0 to 100 for each value If the bar graph LEDs are blue the gun is ready to spray If the LEDs are yellow or red the current is too high The fluid may be to
72. op bearing 15b2 onto the short end of the shaft so the bearing blades are flush with the surface of the coil 15a The flatter side of the bearing must face away from the coil 3A2496D Repair 12 Hold the coil assembly 15a on a workbench Ensure that the blades of the bottom bearing with the fan end facing up Press the fan 15e 15b1 align with the tabs onto the long end of the shaft S The fan blades m st be oricated aS shown 15 Seat the coil fully into the housing 15d Secure with the clip 15h ensuring that its tabs engage 13 Carefully press the coil assembly 15a into the slots in the housing the front of the housing 15d The 3 wire i connector PC must be positioned below the 18 T es oring 15a i place Insiel wider notch W of the housing tabs as shown in Fig 46 Be sure the coil alignment pins P are 17 Install the alternator on the power supply and positioned as shown in Fig 45 install both parts in the handle See Power 14 Rotate the fan 15e so its blades clear the four SUPPI Removal and Replacement page 39 bearing tabs T at the back of the housing 15h ti19739b Figure 47 Alternator 3A2496D 61 Repair Fan Air Adjustment Valve Repair 1 2 62 See Prepare the Gun for Service page 50 Place a wrench on the flats of the valve housing 30a and unscrew the valve from the handle 16 NOTE You may replace the valve as an assembly go to step 9 or repla
73. p 15h off the housing 15d Remove the cap 15f using a thin blade or screwdriver 5 If necessary rotate the fan 15e so its blades clear the four bearing tabs T of the housing 15d ti19741b Figure 45 Fan Orientation 6 Push the fan and coil assembly 15a out the front of the housing 15d 60 11 ti19740b 15b2 M 15a 15g 15f VIII WAV DIR a era I AT VN i I NI F Y Tio ni 7 w E J US TI za TE OL PC 15h 15d 15b1 S Figure 46 Alternator Cross Section NOTICE Do not scratch or damage the magnet M or shaft S Do not pinch or damage the 3 wire connector PC when disassembling and reassembling the bearings Hold the coil assembly 15a on a workbench with the fan end facing up Using a wide blade screwdriver pry the fan 15e off the shaft S Remove the top bearing 15b2 Remove the bottom bearing 15b1 Install the new bottom bearing 15b1 on the long end of the shaft S The flatter side of the bearing must face away from the magnet M Install in the coil 15a so the bearing blades are flush with the surface of the coil Press the new t
74. passages 8 See Test Gun Resistance page 39 See Prepare the Gun for Service page 50 Remove the retaining ring 6 and air cap 5 Trigger the gun while removing the fluid nozzle 4 assembly with the multi tool 41 NOTICE The nozzle contact ring 4a is a conductive contact ring not a sealing o ring For best performance and to avoid potential damage to the spray gun 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 NOTICE Use non silicone grease Part No 111265 on the small o ring 4b Do not over lubricate Do not lubricate the conductive contact ring 4a 4 Make sure the conductive contact ring 4a and the small o ring 4b are in place on the nozzle 4 Lightly lubricate the small o ring 4b Make sure the electrode needle 3 is finger tight Trigger the gun while installing the fluid nozzle 4 with the multi tool 41 Tighten until the fluid nozzle seats in the gun barrel 1 8 to 1 4 turn past hand tight Figure 32 Air Cap and Nozzle Replacement ti19894a 3A2496D 57 Repair Air Cap Spray Tip and Nozzle Replacement Model L60M19 1 See Prepare the Gun for Service page 50 4 Toreplace the electrode 5a pull the it out of the back of the air cap using a needle nose pliers Push the new electrode through the air cap hole
75. proved for use in a hazardous area To reduce the risk of sparking do not use the megohmmeter to check electrical grounding unless The gun has been removed from the hazardous area Or all spraying devices in the hazardous area are turned off ventilation fans in the hazardous area are operating and there are no flammable vapors in the area such as open solvent containers or fumes from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage 3A2496D Electrical Tests Test Gun Resistance Follow the steps under Prepare the Gun for Service page 50 Trigger the gun and measure resistance between the electrode needle tip 3 and the air swivel 21 The resistance should be 104 150 megohms 90 120 megohms for Model L60M19 If outside this range go to Test Power Supply Resistance page 40 If in range see Voltage Loss Troubleshooting page 43 for other possible causes of poor performance or contact your Graco distributor ti18734a Figure 25 Test Gun Resistance 39 Electrical Tests Test Power Supply Resistance 1 40 Follow the steps under Prepare the Gun for Service page 50 Remove the power supply 11 Remove the turbine alternator 15 from the power supply Measure resistance from the power supply s ground strips EE to the spring 11a The resistance should be 90 115 megohms If outside this r
76. psi 87 0 dB A at 0 28 MPa 2 8 bar 87 0 dB A f rom gun at 100 psi 99 0 dB A at 0 7 MPa 7 0 bar 99 0 dB A Air Inlet Fitting 1 4 npsm m left hand thread Fluid Inlet Fitting Custom inlet for Graco waterborne fluid hose Isolation Enclosure Air Inlet Fitting 1 4 npt Isolation Enclosure Fluid Inlet 3 8 in OD tube fitting 10 mm OD tube fitting Fitting Wetted Parts Gun Stainless Steel PEEK UHMWPE Fluoroelastomer Acetal Nylon Polyethylene Tungsten Wire Waterborne Fluid Hose PTFE Suction Tube Polyethylene Stainless Steel Triton Pump See manual 309303 3A2496D 97 Graco Pro Xp Warranty Graco warrants all equipment referenced in this document which is 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 from the date of sale repair or replace any part of the equipment determined by Graco to be defective However any deficiency in the barrel handle trigger hook internal power supply and alternator excluding turbine bearings will be repaired or replaced for thirty six months from the date of sale This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for g
77. r supply spring 11a are in place Assemble the barrel 1 to the handle 16 See Barrel Installation page 58 To repair the alternator see 11 See Test Gun Resistance page 39 Alternator Removal and Replacement page 60 To prevent damage to the cable and possible interruption of the ground continuity bend the alternator s 3 wire ribbon cable PC upward and back so the bend faces the power supply and the connector is at the top 7 Smart models only connect the 6 pin flexible circuit 24 to the power supply 8 Connect the 3 wire ribbon connector PC to the power supply Tuck the ribbon forward under the power supply Slide the alternator 15 down onto the power supply 11 9 Insert the power supply alternator assembly in ti19453a the gun handle 16 Make sure the ground strips Figure 44 Power Supply 3A2496D 59 Repair Alternator Removal and Replacement NOTE Replace alternator bearings after 2000 hours of operation Order Part No 24N706 Bearing Kit Parts included in the kit are marked with a symbol 1 See Prepare the Gun for Service page 50 2 Remove the power supply alternator assembly and disconnect the alternator See Power Supply Removal and Replacement page 59 3 Measure resistance between the two outer terminals of the 3 wire connector PC it should be 2 0 6 0 ohms If outside this range replace the alternator coil 15a 4 Using a flat blade screwdriver pry the cli
78. rborne fluid for gun model L60T17 includes 102 108 2 4 4 4 4 3 45 6 0 5 fluid for gun model L60T18 includes 102 108 24M732 24M733 hose 24M732 unshielded hose 24M733 102982 O RING 16N916 FITTING seal 1 D A D gt 1 1 1 01 02 03 04 05 06 07 08 1 1 1 1 1 1 1 1 These parts are included in Air Seal Repair Kit 24N789 purchase separately 69 Parts Smart Waterborne Air Spray Gun Assembly Part No L60M17 60 kV Electrostatic Waterborne Air Spray Gun Series A Part No L60M18 60 kV Electrostatic Waterborne Air Spray Gun Series A Part No 24M732 Shielded Waterborne Fluid Hose 101 sold separately for gun model L60M17 Part No 24M733 Unshielded Waterborne Fluid Hose 101 sold separately for gun model L60M18 ti19937a 70 3A2496D Parts Part No L60M17 60 kV Electrostatic Waterborne Air Spray Gun Series A Part No L60M18 60 kV Electrostatic Waterborne Air Spray Gun Series A Part No 24M732 Shielded Waterborne Fluid Hose 101 sold separately for gun model L60M17 Part No 24M733 Unshielded Waterborne Fluid Hose 101 sold separately for gun model L60M18 4N667 BODY gun 24N667 BODY gun See Packing Rod Assembly page 79 2 4N652 NEEDLE electrode black 24N616 NOZZLE 1 5 mm includes 4a and 4b wo e 24N645 O RING conductive 111507 O RING fluoroelastomer 24N477 AIR CAP 24P892 RIN
79. rounding 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 connected to a true earth ground To reduce the risk of serious injury including splashing fluid in the eyes or on the skin follow the Pressure Relief Procedure page 31 before removing or installing a fluid nozzle and or air cap Voltage Isolation System Electrically connect the voltage isolation system to a true earth ground See Ground the Cabinet page 17 NOTE Standard and Smart Air Spray Guns are supplied with Part No 24N616 Nozzle and 24N477 Air Cap If you require a different size see Air Caps and Fluid Nozzles page 85 or consult with your Graco distributor See Air Cap and Nozzle Replacement page 51 Electrostatic Air Spray Gun ground the gun by connecting the red colored Graco Grounded Model L60M19 Mold Release Gun is supplied with Air Hose to the gun and connecting the air ran n ans Mezzo ZA Air Cap and a hose ground wire to a true earth ground See spray tip of choice If you require a different size Check Gun Electrical Grounding page 28 spray tip see Spray Tip Selection Chart Model DL L60M19 MRG Gun Only page 90 or consult with 3 Do your Graco distributor See Air Cap Spray Tip and E ua Nozzle Replacement Model L60M19 page 52 N Grounding eee Gra
80. se 300 and gun 301 are not included with 233825 and 246511 Isolation Enclosures They are shown for illustrative purposes only See pages 3 76 and 4 for listings of models which include an air hose and gun The pail is shown for illustrative purposes but is not included 3A2496D Tubing and Wiring Detail Views of Control Box c9 A1 A2 ti2145a C6 C7 C8 c6 ZE ti2143a 3A2496D Detail View of Door Interlock Switch ti2144a Parts 77 Parts Tubing and Wiring Chart Use the diagrams to find the connection points for the tubing and wiring listed below in mm in mm 216 to pump ground wire with pete 216 to manifold true earth ground to door interlock switch from external ground lug to ground probe B3 249 20 508 5 32 OD tube valve tee to cylinder C6 226 n a red wire from bleed resistor to pump door interlock switch clamp of bleed resistor to meter pump 209 to ground on C2 251 8 204 green yellow 14 gauge wire cylinder bracket from internal box ground bd green yellow 10 gauge wire lug to cylinder cap from meter to internal box ground lug C3 273 34 864 green yellow 10 gauge w
81. specific risks When these symbols appear in the body of this manual or on warning labels refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable ELECTRIC SHOCK HAZARD Improper grounding setup or usage of an isolated waterborne system can result in electric shock To help prevent electric shock Ground all equipment personnel object being sprayed and conductive objects in or close to spray area See Grounding instructions Connect the electrostatic gun to a voltage isolation system that will discharge the system voltage when not in use All components of the isolation system that are charged to high voltage must be contained within an isolation enclosure that prevents personnel from making contact with the high voltage components before the system voltage is discharged Follow the Fluid Voltage Discharge and Grounding Procedure when instructed to discharge the voltage before cleaning flushing or servicing the system before approaching the front of the gun and before opening the isolation enclosure for the isolated fluid supply Do not enter a high voltage or hazardous area until all high voltage equipment has been discharged Do not touch the gun nozzle or electrode or come within 4 in 102 mm of the electrode during gun operation Follow the Fluid Voltage Discharge and Grounding Procedure Interlock the gun air supply
82. st Ground Strip Resistance Using an ohmmeter measure the resistance between the latch housing 206 and the ground lug 214 The ground strip is grounded through the cart back to the ground lug Resistance must be less than 100 ohms If greater than 100 ohms replace the ground strip 240 206 ti2165a Figure 30 Test Ground Strip Resistance 42 Test Cylinder Resistance Remove the enclosure door Using an ohmmeter measure the resistance from the pump 209 to the ground lug 214 Resistance must be less than 100 ohms If greater than 100 ohms replace the grounding cylinder 227 209 Oo C 214 ti2164a Figure 31 Test Cylinder Resistance 3A2496D 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 Follow the Fluid Voltage Discharge and Grounding Procedure page 30 before checking or servicing the system and whenever you are instructed to discharge the voltage To reduce the risk of an injury follow the Pressure Relief Procedure page 31 whenever you are instructed to relieve the pressure Voltage Loss Troubleshoo
83. st be restored to make the Smart module functional NOTE It takes 8 seconds for the Error display to appear If the gun has been disassembled wait 8 seconds before spraying to ensure that an Error condition has not occurred NOTE If there is no power to the gun the Error display will not appear ER Hz ti19338a Figure 3 Error Display Adjusting the Low Voltage Setting The low voltage setting is user adjustable To access the low voltage setting screen when in Operating Mode press the LO SET button LS momentarily The screen will display the current low voltage setting See Fig 4 and Table 1 on page 12 The range is 30 60 kV Set the Voltage Adjustment switch VA to LO Press the LO SET button repeatedly to increase the setting in increments of 5 When the display reaches the maximum setting 60 kV it will return to the minimum setting 30 kV Continue pressing the button until you reach the desired setting 3A2496D Gun Overview NOTE After 2 seconds of inactivity the display will return to the Operating Screen NOTE The low voltage setting may be locked See Lock Symbol page 11 ti19122a Figure 4 Low Voltage Setting Screen Unlocked Lock Symbol The low voltage setting may be locked When locked an image LK appears on the screen See Fig 5 and Table 1 on page 12 e When in HI mode the low voltage setting is always locked The lock
84. t screw 31e o ring 31f and ES HI LO switch 31c at the bottom left corner of the Smart Module cartridge 31a 3 Remove the remaining three screws 31d from the cartridge 4 Pull the Smart Module out the back of the gun Disconnect the ribbon cable RC from the connector GC in the gun handle RC 5 Remove the gasket 31b i 6 Install a new gasket 31b on the new cartridge SS 31a Make sure the notched corners of the gasket are at the top Figure 54 Smart Module 7 Align the module s ribbon cable RC with Figure 55 Align Ribbon Cables the gun s cable GC and slide them securely together as shown Tuck the connected cables into the recess of the gun handle Install the module flush to the back of the gun handle 8 Install the pivot screw 31e o ring 31f and ES HI LO switch in the bottom left corner of the cartridge 31a 9 Install the three remaining screws 31d Torque to 7 9 in Ib 0 8 1 0 Nem 66 3A2496D Air Swivel and Exhaust Valve Replacement See Prepare the Gun for Service page 50 2 To replace the air exhaust valve a Remove the clamp 43 and the exhaust tube 36 Unscrew the swivel 21 from the gun handle 16 The swivel is a left hand thread Remove the bracket 104 Pull the exhaust valve 19 from the handle 16 Inspect the o ring 19a and replace if necessary Install the o ring 19a on the exhaust valve 19 Lubricate t
85. tended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations 3A2496D 7 Gun Overview Gun Overview How the Electrostatic Spray Gun Works The air hose supplies air to the spray gun Part of the air operates the alternator turbine and the rest of the air atomizes the fluid being sprayed The alternator generates power which is converted by the power cartridge to supply high voltage to the gun s electrode The pump supplies fluid to the fluid hose and gun where the fluid is electrostatically charged as it passes the electrode The charged fluid is attracted to the grounded workpiece wrapping around and evenly coating all surfaces Spraying Waterborne Fluids Electrostatically This electrostatic air spray gun is designed to spray only waterborne fluids which meet the following flammability requirements FM FMc Approved Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures ASTM D4206 CE EN 50059 Compliant Materials which cannot be ignited in any mixture with air by an energy source of less than 500mJ When connected to a voltage isolation system all of the fluid in the spray gun fluid hose and isolate
86. ting Normal spraying voltage for a system using the waterborne gun is 45 55 kV The system voltage is lower due to spraying current demands and voltage isolation system losses A loss of spraying voltage can be caused by a problem with the spray gun fluid hose or voltage isolation system since all of the system components 3A2496D Troubleshooting are electrically connected through the conductive waterborne fluid Before troubleshooting or servicing the voltage isolation system itself you need to determine which component in the system is most likely causing a problem Possible causes include the following Spray Gun e Fluid leakage Dielectric breakdown at the fluid hose connection or fluid packings e Not enough air pressure for the alternator turbine e Faulty power supply e Excessive overspray on gun surfaces e Fluid in the air passages Waterborne Fluid Hose e Dielectric failure of the hose pin hole leak in the PTFE layer e Air gap in the fluid column between the gun and the isolated fluid supply causing a low voltage reading on the isolation system voltage meter Voltage Isolation System e Fluid leakage e Dirty interior 43 Troubleshooting Visual Checks 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 245277 is helpful for diagnosing voltage problems and is r
87. ty for dirt or moisture Clean with a clean dry rag e Do not expose gasket 28 to solvents See Prepare the Gun for Service page 50 2 See Barrel Removal page 58 NOTICE Be careful when handling the power supply 11 to avoid damaging it 3 Grasp the power supply 11 with your hand With a gentle side to side motion free the power supply alternator assembly from the gun handle 16 then carefully pull it straight out On Smart Models only disconnect the flexible circuit 24 from the socket at the top of the handle 4 Inspect the power supply and alternator for damage 5 To separate the power supply 11 from the alternator 15 disconnect the 3 wire ribbon connector PC from the power supply On Smart Models only disconnect the 6 pin flexible circuit 24 from the power supply Slide the alternator up and off the power supply 6 See Test Power Supply Resistance page 40 Replace the power supply if necessary Repair EE make contact with the handle On Smart models align the connector of the 6 pin flexible circuit 24 with the socket CS at the top of the handle Push the connector securely into the socket as you slide the power supply alternator assembly into the handle it ti19742a Figure 43 Connect Flexible Circuit 10 Make sure the gasket 28 ground spring 18 and powe
88. ulator Kit Accessory GUNCSOtUP 4 cre e a ak ee ate Select a Fluid Nozzle and Air Cap GIOUNdINg urge elia faina Check Gun Electrical Grounding Flush Before Using Equipment Operations irta eee bane ed im lata lg Operating Checklist neee Fluid Voltage Discharge and Grounding Procedure Pressure Relief Procedure Fill the Fluid Supply ennnen Adjust the Spray Pattern ShUtdOWNI ciciii ai Maintenance en oraint neonas iea S e AES TIA aa FUSING enne aaa Clean the Gun Daily Daily System Care Electrical TeStS aaa Test Gun Resistance Test Power Supply Resistance Test Electrode Resistance Test Ground Strip Resistance Test Cylinder Resistance TroubleshoOting iii Voltage Loss Troubleshooting Spray Pattern Troubleshooting Gun Operation Troubleshooting Electrical Troubleshooting 48 Repallizo keira Earn 50 Prepare the Gun for Service 50 Air Cap and Nozzle Replacement 51 Air Cap Spray Tip and Nozzle Replace
89. uous Graco waterborne hose between the isolated fluid supply and the gun Do not splice hoses together 1 Remove the gun air inlet fitting 21 NOTE In a shielded hose system if a hose failure occurs where high voltage arcs through the inner tube voltage will be discharged to ground through the conductive hose layer When properly installed the conductive hose layer is grounded through its connection to the grounded enclosure Using unshielded fluid hoses minimizes the system capacitance resulting in faster response times and a large reduction in the energy stored in the system as compared to shielded hoses However without the ground shield a weak static charge can occasionally build up on the outer surface of the hose To minimize any static charge felt on the hose surface bundle the air and fluid hose together and wrap with a protective cover as shown 18 ti19884b Figure 10 Connect the Fluid Hose a wars gt 23 oF 27 SZ ILS 24 aa Le e Lie 27 Soe gt LZ Lr ff N X LS AG SL ti21059a Figure 11 Bundling the Air and Fluid Hoses gt SS SE L 3A2496D For the fluid hose to fit properly it must be stripped and assembled to the dimensions shown in Fig 12 Apply dielectric grease to the inner tube T of the hose Slide the fitting F onto the tube T Press the barbed fitting G into the tube until its shoulder bottoms
90. ur particular needs contact your Graco distributor Ventilate the Spray Booth Provide fresh air ventilation to reduce the risk of fire or explosion caused by the buildup of flammable or toxic vapors when spraying flushing or cleaning the gun Do not operate the gun unless ventilation fans are operating Check and follow all local state and national codes regarding air exhaust velocity requirements High velocity air exhaust will decrease the operating efficiency of the electrostatic system The minimum allowable air exhaust velocity is 60 linear ft min 18 3 linear meters minute 3A2496D Air Supply Line 1 See Fig 19 Install an air line filter water separator M on the main air supply 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 The WB100 system includes a bleed type air regulator N on the gun air supply line P to control air pressure to the gun To reduce the risk of electric shock or other serious injury you must use the red colored Graco Electrically Conductive Air Hose for the gun air supply and you must connect the hose ground wire to a true earth ground Do not use the black or gray colored Graco air hoses Connect the red colored Graco Electrically Conductive Air Hose P between the gun air regulator N and the gun s air inlet The gun air inlet fitting has a left hand threa
91. wear or damage NOTE Use non silicone grease Part No 111265 Do not over lubricate 7 When reassembling the atomizing air restrictor valve 29 lightly lubricate the o ring 29c and push the valve body 29b fully into the housing 29a until bottomed 8 Reassemble the retaining ring 29d Thread the valve stem 29e halfway into the valve body 29b 9 Align the slot S in the valve stem with the rib R in the gun handle Screw the valve assembly 29 into the gun handle 16 using a wrench on the flats of the housing Torque to 15 in Ib 1 7 Nem NOTE If the atomizing air restrictor valve is not desired install the supplied plug 42 3A2496D 29c ti18646b Figure 49 Atomizing Air Restrictor Valve OF ti21702a van fo Figure 50 Align Valve Stem Repair 63 Repair ES On Off and Fluid Adjustment Valve Repair 1 2 See Prepare the Gun for Service page 50 Loosen the captive screw 26p Remove the valve 26 from the handle Lubricate the o rings 26b and 26m with non silicone grease Part No 111265 Do not over lubricate NOTE Do not over lubricate parts Excessive lubricant on the o rings can be pushed into the ti18645a Figure 51 ES On Off and Fluid Adjustment Valve 64 gun air passage and blemish the finish on the workpiece Clean and inspect parts for damage Replace if necessary NOTE The protrusion on the retainer pl
92. with the voltage isolation system to shut off the air supply anytime the isolation system enclosure is opened Only use the red colored Graco electrically conductive gun air hose with this gun Do not use black or gray colored Graco air hoses Do not splice hoses together Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the spray gun 3A2496D 5 Warnings FIRE AND EXPLOSION HAZARD Combustible dust in work area can ignite or explode To help prevent fire and explosion e Fluids used must meet the following flammability requirements e FM FMc Approved Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures ASTM D4206 e CE EN 50059 Compliant Materials which cannot be ignited in any mixture with air by an energy source of less than 500mJ Stop operation immediately if static sparking occurs or you feel a shock Do not use equipment until you identify and correct the problem Check gun resistance hose resistance and electrical grounding daily Use and clean equipment only in well ventilated area Interlock the gun air supply to prevent operation unless ventilating fans are on Only use non flammable solvents when flushing or cleaning equipment Always turn the electrostatics off when flushing cleaning or servicing equipment Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and pl

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