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Graco 333013B User's Manual

1. Follow the Fluid Voltage Discharge and Ground ing Procedure page 22 2 Follow the Pressure Relief Procedure page 22 3 Open the isolated enclosure door 333013B Operation 4 Remove the pail cover from the pail holding a rag over the suction tube strainer to prevent any fluid from dripping into the isolated enclosure Place the cover and suction tube outside the enclosure 5 Remove the supply pail from the enclosure NOTICE Be sure to wipe up all fluid spills in the isolated enclo sure Fluid can create a conductive path and cause the system to short out 6 Clean up any fluid spills in the enclosure using a soft cloth and a non flammable compatible solvent 7 Fill the supply pail with fluid and return it to the enclosure Clean up any spills 8 Reinstall the pail cover holding a rag over the suc tion tube strainer to prevent fluid spills while you place the pump suction tube in the pail 9 Close the isolated enclosure door and fasten securely with the T handle locking screw Set the Atomization Fluid Pressure Atomization fluid pressure will vary based on the viscos ity of the fluid flow rate desired and other system char acteristics 1 Turn off the turbine air TA atomization air A1 and fan air A2 2 Start the pump Set the fluid regulator to 400 psi 2 8 MPa 28 bar 3 With the turbine air TA atomization air A1 and fan air A2 turned off spray a test pat
2. HOLDER tie a OND o_o Ref No 265 266 267 268 270 271 272 273 274 275 276 278 279 280 281 286 116991 203953 155541 114261 15A780 117314 113319 300 235070 301 HA1T18 Description Parts Qty SCREW button hd 10 24 x 1 5 in 38 2 mm SCREW button hd 10 32 x 1 0 in 25 2 mm NUT hex M5 x 0 8 WASHER lock no 10 TEE run manifold SCREW hex hd cap with patch 10 24 x 3 8 in 10 mm WIRE 14 gauge red 2 9 4 4 A R WIRE ground 14 gauge green with yel A R low stripe UNION swivel 1 4 npt TERMINAL ring no 10 PLUG hex hd BULKHEAD CONNECTOR 1 4 npt CONNECTOR tube 1 4 npt x 3 8 in 10 mm OD tube ELBOW tube 4 4 4 4 2 1 FITTING tube 1 8 npt x 5 32 in 4 mm 1 OD tube SWIVEL tube 1 4 npt x 1 4 in 6 mm OD tube 4 SWIVEL tube 1 8 npt x 5 32 in 4 mm 2 OD tube TUBE 3 8 in 10 mm OD 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 ground path 25 ft 7 6 m long GUN see HA1T18 Rear Manifold page 46 HA1M18 GUN see HA1M18 Rear Manifold page 48 A R 4 Replacement Danger and Warning labels tags and cards are available at no cost The air hose 300 and gun 301 are not included with 24N550 Isolation Enclosure They are shown for illus trative purposes only The pail is shown for il
3. Maximum Pattern Width at 12 in 305 mm in mm 8 10 10 12 12 14 14 16 200 250 250 300 300 350 350 410 412 414 416 Spray Tip 608 510 512 514 516 610 612 614 616 710 712 714 716 16 18 350 400 400 450 812 814 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 60 333013B Technical Data Technical Data Pro Xp Auto Waterborne AA Spray Gun C Mee YO Gun Weight Approximate 1 2 kg Voltage Output Standard Models Smart Models 60 kV 30 60 kV Sound Power measured per ISO Standard at 0 28 MPa 2 8 bar 90 4 dB A 9216 at 100 psi 105 4 dB A at 0 7 MPa 7 bar 105 4 dB A Sound Pressure measured 1 m from gun at 40 psi 87 dB A at 0 28 MPa 2 8 bar 87 dB A at 100 psi 99 dB A at 0 7 MPa 7 bar 99 dB A Inlet Outlet Sizes Turbine air inlet fitting left hand thread Atomizing air inlet fitting Fan air inlet fitting Cylinder air inlet fitting Hi Lo voltage selector air inlet fittings Fluid inlet fitting Materials of Construction Wetted Parts 1 4 nosm m 5 16 in OD nylon tube 5 16 in OD nylon tube 5 32 in OD nylon tube 5 32 in OD nylon tube Waterborne Hose Fitting Stainless Steel Nylon Acetal Ultra High Molecular Weight Poly ethylene Fluoroela
4. 239 240 241 242 243 244 245 246 247 248 249 251 252 253 256 257 258 259 260 261 262 263 264 222011 234018 110209 114051 210084 162449 101874 116990 113983 237933 113336 333013B Description CABINET enclosure includes 201a DOOR cabinet CASTER brake PLATE T HANDLE latch STEM handle door HOUSING latch SWITCH push air PUMP diaphragm sst see 3A0732 SCREW hex hd cap 5 16 18 x 5 5 in 140 mm WASHER plain 0 344 in ID NUT lock 5 16 18 LUG ground VALVE air REGULATOR air GAUGE air 1 8 npt BALL VALVE 1 4 npt f CART NIPPLE 1 4 npt x 1 4 npsm RESISTOR bleed CYLINDER ROD HOUSING cylinder rod REGULATOR air BUSHING plastic 3 4 x 1 2 npt LABEL warning GROUND WIRE 25 ft 7 6 m STRIP grounding aluminum NUT regulator WASHER plain 3 4 ROD ground SCREW hex hd 1 4 20 x 5 8 in 16 mm WASHER plain 1 4 in 6 mm NUT hex 1 4 20 SCREW thread forming TUBE 1 4 in 6 mm OD nylon GAUGE air Qty N a d AK a i i i do do do do do do do do do do do dl md pW NS WIRE 10 gauge green with yellow stripe 1 CONNECTOR swivel tee 1 8 npt x 5 32 1 in 4 mm tube NUT hex 10 32 NIPPLE reducing 1 2 npt x 1 4 npt TERMINAL ring BOX control RING retaining 1 2 in 13 mm METER 0 90 kV ADAPTER 1 4 npt SCREW pan hd 10 32 x 5 8 in 16 mm SCREW pan hd 10 32 x 1 4 in 6 mm
5. Atomizing Air Side 24131a FIG 33 Piston O Rings Table 3 Piston O Rings Shaft O Ring Seals cylinder air along the piston rod 119 34b Replace if air leaks along rod Air shutoff seal Replace if air leaks from air cap when gun is de triggered Separates cylinder air from fan and atom izing air Piston O Ring Replace if air leaks from small vent hole 11d at back of manifold when gun is triggered O rings included in air seal repair kit 24W390 41 Repair Adjust the Actuator Arm Barrel Removal NOTE The seat housing 4 must be in place when See FIGURE 36 removing or installing the jam nut and actuator arm 1 Prepare the gun for service and remove the gun See FIGURE 34 from the manifold page 38 1 Install the adjustment nut 16b actuator arm 15 2 Remove the adjustment nuts 16a 16b and actua and jam nut 16a onto the piston rod 11b tor arm 15 See FIGURE 34 2 Position the parts so there is a 0 125 in 3 mm gap 3 between the actuator arm 15 and the fluid packing Loosen the two screws 19 See FIGURE 36 rod nut E This allows the atomizing air to actuate NOTICE before the fluid To avoid damaging the power supply pull the gun bar 3 Tighten the adjustment nut 16b against the actua rel 1 straight away from the gun body 10 If neces tor arm 15 Check that the 0 125 in 3 mm gap sary gently move the gun barrel from side to side to has been maintained Tighten the jam
6. Fiber Optic Schematic 333013B Port 5 Installation For a 2 Gun System 1 Connect Port 1 of the gun 2 manifold to Port 5 of the Control Module 2 Connect Port 2 of the gun 2 manifold to Port 6 of the Control Module ti22401a FIG 8 Making Fiber Optic Connections Hazardous Area H Port 6 MM MM Gun 1 Ma gt AM Gun 2 17 Installation Agitator Kit Accessory To add an agitator to the Graco isolation system order Part No 245895 See Agitator Kit 245895 page 56 for the kit parts list 1 Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure page 22 2 Relieve the pressure see Pressure Relief Proce dure page 22 3 Open the isolated enclosure door 4 Remove the back of the control box 258 5 Remove tube A2 from elbow 282 at the air mani fold see Tubing and Wiring page 54 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 6 Replace the back of the control box 258 7 Assemble the other parts of the kit as shown Secure the agitator with the setscrew 408 8 Return the system to service ti2137a FIG 10 245895 Agitator Kit 18 Grounding AMAS When operating the electrostatic gun any ungrounded objects in the spray area people containers tools etc can become electrically charged Improper grounding can result
7. 10 11 1la 11b 11c 11d 12 13 14 15 16 18m 19 20 21 23 24 Part No 24W874 24N781 AEMxxx AEF xxx 183459 24N725 24N782 197624 24N662 24N979 24N644 110073 24N699 24W382 24W396 17B704 111504 112319 111508 112640 24W397 513505 24W398 100166 111450 24N740 24W392 24W399 24W411 24N644 333013B Description BODY gun assy includes 9 NEEDLE ASSEMBLY includes 5 TIP ASSEMBLY customer s choice GASKET tip HOUSING seat SPRING fluid needle SPRING compression POWER SUPPLY 60 kV WB SPRING See Turbine Assembly page 51 O RING packing GASKET barrel BODY assy Auto XP Standard PISTON assy actuation auto O RING packing O RING packing O RING packing O RING packing SPRING compression CAP piston actuation WASHER plain 10 SST ARM fluid actuator XP includes 16 qty 2 NUT full hex PACKING O RING SCREW ES gun includes 2 MANIFOLD rear inlet includes 18 21 23 27 28 29 30 51 SCREW modified 1 4 20 XP Auto pack of 2 FITTING Adapter M12 TO 1 4 LH XP RING retainer assy includes 24a Qty ZA Ss s ss FO YO kh A OF N NO Parts te Part No Description Qty 24am 198307 PACKING u cup UHMWPE 1 25 24N727 See Air Cap Assembly page 50 1 25a 24N643 ELECTRODE package of 5 1 26 24W389 COVER shroud Auto XP 1 27 114263 FITTING connector male 1 28 115950 FITTING connector 1 4npt M 3
8. following criteria FM14ATEX0082 EN 50059 l l o l l l Ta 0 C 50 C e Materials which cannot be ignited in any mixture with air by an energy source of less than 500 mJ C 0359 Related Manuals Manual No Description 332989 Instructions Pro Xp Auto Control Module 333013B Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbols refer to procedure 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 voltage 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 V
9. to the power supply 43 Repair Tuck the ribbon forward under the power supply Turbine Removal and Slide the turbine 8 down onto the power supply 7 Replacement NOTE Replace turbine bearings after 2000 hours of operation Order Part No 24N706 Bearing Kit Parts included in the kit are marked with a symbol See FIGURE 38 through FIGURE 41 8 Insert the power supply turbine assembly in the gun body 10 Make sure the ground strips EE make contact with the gun body Smart models only align the connector of the l 6 pin flexible circuit 30 with the socket CS atthe 1 See Prepare the Gun for Service page 38 top of the gun body See FIGURE 37 l 2 Remove the power supply turbine assembly and disconnect the turbine See Power Supply Push the connector securely into the socket as you Removal and Replacement page 43 slide the power supply turbine assembly into the gun body 3 Measure resistance between the two outer termi nals of the 3 wire connector PC it should be CS 30 2 0 6 0 ohms If outside this range replace the tur bine coil 8a 4 Using a flat blade screwdriver pry the clip 8h off the housing 8d Remove the cap 8f using a thin blade or screwdriver 5 If necessary rotate the fan 8e so its blades clear the four bearing tabs T of the housing 8d See FIGURE 39 Fic 37 Connect Flexible Circuit 9 Make sure the gasket 9 ground spring 6 and power su
10. unless you are trained and qualified Follow the Fluid Voltage Discharge and Grounding Procedure before checking or servicing the system and whenever you are instructed to discharge the voltage I i b MPa bar PSI Ali To reduce the risk of a fluid injection injury always follow the Pressure Relief Procedure when you stop spraying and whenever you are instructed to relieve the pressure NOTE Check all possible remedies in the Trouble shooting Chart before disassembling the gun Voltage Loss Troubleshooting Normal spraying voltage for a system using the water borne gun is 45 55 kV The system voltage is lower due to spraying current demands and voltage isolation sys tem losses A loss of spraying voltage can be caused by a problem with the spray gun fluid hose or voltage isolation sys tem since all of the system components are electrically connected through the conductive waterborne fluid 333013B Troubleshooting 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 e Dielectric breakdown at the fluid hose connection or fluid packings e Not enough air pressure for the turbine e Faulty power supply e Excessive overspray on gun surfaces e Fluid in the air passages Waterborne Fluid Hose
11. C 2 9 in 73 mm 0 53in 13 5 mm 2x 1 4 20 UNC 58 6 3 in 160 mm lt 2 6 in 66 mm gt 2 5 in 63 mm ti24373a 333013B Spray Tip Selection Chart AEM Fine Finish Spray Tips 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 Spray Tip Selection Chart mm 0 007 0 178 0 009 0 229 0 011 0 279 0 013 0 330 0 015 0 381 0 017 0 432 0 019 0 483 0 021 0 533 0 023 0 584 0 025 0 635 0 029 0 736 0 031 0 787 0 033 0 838 0 037 0 939 0 039 0 990 Orifice Size in Fluid Output fl oz min l min at 600 psi 4 1 MPa 41 bar 4 0 0 1 7 0 0 2 10 0 0 3 13 0 0 4 17 0 0 5 22 0 0 7 28 0 0 8 35 0 1 0 40 0 1 2 50 0 1 5 68 0 1 9 78 0 2 2 88 0 2 5 108 0 3 1 118 0 3 4 at 1000 psi 7 0 MPa 70 bar 5 2 0 15 9 1 0 27 13 0 0 4 16 9 0 5 22 0 0 7 28 5 0 85 36 3 1 09 45 4 1 36 51 9 1 56 64 8 1 94 88 2 2 65 101 1 3 03 114 1 3 42 140 0 4 20 153 0 4 59 Tips are tested in water 2 4 50 100 107 Maximum Pattern Width at 12 in 305 mm 4 6 100 150 207
12. Cause Poor wrap Turbine air is not turned on Turn on Booth exhaust velocity is too high Reduce velocity to within code limits Atomization air pressure too high Decrease Fluid pressure too high Decrease or replace worn tip 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 29 Fluid leaks from the fluid needle Clean the fluid needle cavity and see packings and causes a short Fluid Needle Replacement page 40 Faulty turbine See Turbine Removal and Replacement page 44 Faulty Power Supply Replace power supply see page 43 No voltage or low voltage reading on the Pro Xp Auto Control Module Damaged fiber optic cable or con nection Check replace damaged parts Turbine air is not turned on Turn on Spilled paint dried paint or other Clean contaminants inside the WB3000 Enclosure causing a short circuit Grounding cylinder not retracted Check operation of grounding cylin der Check power supply turbine turbine ribbon cable See Power Supply Removal and Replacement page ES or Hz indicator light is not lit standard models only 43 and Turbine Removal and Replacement page 44 ES indicator light is amber standard Turbine speed is too low models only Increase air pressure until indicator is green ES indicato
13. Grounding Procedure on page 22 All operators are trained in the Pressure Relief Procedure on page 22 The electrostatics are turned off and system voltage is discharged according to the Fluid Voltage Discharge and Grounding Procedure page 22 before any person enters the isolation enclosure before cleaning and before performing any maintenance or repair The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded See Grounding on page 18 The Graco Waterborne Fluid Hose is in good condition with no cuts or abrasions Replace hose if damaged The condition of the gun s electrical components has been checked as instructed in Electrical Tests on page 29 All fluid hose connections are tight Ventilation fans are operating properly Workpiece hangers are clean and grounded All debris including flammable fluids and rags is removed from the spray area All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded All flammable fluids in the spray booth are in approved grounded containers The manifold exhaust tubes have been checked for the presence of any fluid as instructed in Check for Fluid Leakage on page 28 Fluids used must meet the following flammability requirements F
14. Pro Xp Auto Control Module See 332989 Part No Description 24W599 25ft 7 6m 24W077 50ft 15 2 m System Accessories Part No Description 24X003 Fiber Optic Cable 25 ft 7 6 m 24X004 Fiber Optic Cable 50 ft 15 m 24X005 Fiber Optic Cable 100 ft 30 5 m Fiber Optic Cable Repair Kit Part No Description 222011 Ground wire for grounding pump and other com ponents and equipment in the spray area 12 gauge 25 ft 7 6 m 186118 English Warning Sign Available at no charge from Graco 24W875 Parts necessary to replace damaged ends on one cable assembly Test Equipment Air Line Accessories Grounded Air Hose with stainless steel braid ground path Red 100 psi 7 bar 0 7 MPa Maximum Working Pressure 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread Part No Description 241079 Megohmmeter 500 V output 0 01 2000 meg ohms Use for ground continuity and gun resis tance tests Not for use in hazardous areas 722886 Paint Resistance Meter Use for fluid resistivity test See manual 307263 Not for use in haz ardous areas 722860 Paint Probe Use for fluid resistivity test See manual 307263 Not for use in hazardous areas Part No Description 235068 6ft 1 8m 235069 15 ft 4 6 m 235070 25 ft 7 6 m 235071 36 ft 11 m 235072 50 ft 15 m 235073 75 ft 23 m 235074 1
15. closed until you are ready to spray again N If you suspect the fluid hose or tip is plugged or that pressure is not fully relieved after following the steps above slowly loosen the fluid hose fitting at the pump to relieve pressure gradually then loosen completely Select a Spray Tip The fluid output and pattern width depend on the size of the spray tip the fluid viscosity and the fluid pressure Use the Spray Tip Selection Chart page 59 as a guide for selecting the appropriate spray tip for your application 333013B Install the Spray Tip I ree MPa bar PSI de To reduce the risk of an injury follow the Pressure Relief Procedure before removing or installing the spray tip or air cap tip guard Install the spray tip as explained in Air Cap Tip Guard Spray Tip and Fluid Seat Housing Replacement page 39 1 Follow the Pressure Relief Procedure page 22 2 Align the spray tip tab with the groove in the air cap Install the tip ti19765a Fic 14 Spray Tip Alignment 3 Install the air cap and retaining ring Orientate the air cap and tighten the retaining ring securely Be careful not to damage the electrode Fic 15 Install Air Cap Assembly PA To reduce the risk of fire explosion or electric shock never operate the gun with a damaged electrode Fill the Fluid Supply I j C ree a Fi MPa bar PSI
16. dielectric breakdown is most likely in one of the following three areas Repair or replace the compo nent 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 fluid tube e Inspect the end of the hose connected to the voltage isolation system Look for cuts or nicks b Fluid needle e Remove the fluid needle from the gun see Fluid Needle Replacement page 40 and look for signs of fluid leakage or any black ened areas which would indicate arcing is occurring along the packing rod c Fluid hose connection to the spray gun e A breakdown at the fluid hose connection joint would be caused by fluid leaking past seals on the end of the hose Remove the hose at the gun connection and look for signs of fluid leakage along the 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 33 Troubleshooting Spray Pattern Troubleshooting NOTE Some spray pattern problems are caused by the improper balance between air and fluid a Fluttering or spitting spray No fluid Refill supply Air
17. electric shock turn off the turbine air TA before flushing the gun Follow the Fluid Voltage Discharge and Grounding Procedure page 22 before flushing Only flush purge or clean the gun with fluids that 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 NOTICE Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components 1 Turn off the turbine air and wait 30 seconds for the voltage to bleed off 2 Discharge the system voltage See Fluid Voltage Discharge and Grounding Procedure page 22 3 Follow the Pressure Relief Procedure page 22 4 Remove and clean the air cap and spray tip 5 Change the fluid source to non flammable solvent 6 Trigger the gun to flush the fluid passages clean 333013B Clean Outside of Gun NOTICE Clean all parts with a non conductive compatible solvent Conductive solvents can cause the gun to malfunction Fluid in the air passages could cause the gun to malfunction and could draw current and reduce the electrostatic effect Fluid in the power supply cavity can reduce the turbine life Whenever possible point the gun dow
18. max length TA Turbine Air Inlet Fitting Connect the Graco Electrically Conductive Air Hose between this fitting left hand thread and the solenoid Connect the air hose ground wire to a true earth ground 333013B 15 Installation Connect the Waterborne Fluid Hose NOTE The Graco warranty is void if the spray gun is connected to a non Graco voltage isolation system or if the gun is operated above 60 kV Always use a Graco Waterborne Fluid Hose between the voltage isolation system fluid outlet and the gun fluid inlet 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 See Flush ing page 26 MA MA To reduce the risk of electric shock the areas of the Graco Waterborne Fluid Hose that are accessible to personnel during normal operation must be covered by the black outer hose jacket To reduce the risk of electric shock install only one continuous Graco Waterborne Fluid Hose between the isolated fluid supply and the spray gun Do not splice hoses together 1 Remove the air cap 25 spray tip 3 and shroud 26 2 Ensure the barrel fluid inlet is clean and dry Apply dielectric grease to the threads of the barrel connec tor 600a and screw it in to the fluid inlet 3 Apply dielectric grease to the threads of the hose 600 and screw it in to
19. nut 16a free it from the gun body 4 Test gun resistance page 4 Hold the gun body 10 with one hand and pull the barrel 1 straight off the body See FIGURE 36 5 Install the gun shroud 26 and air cap tip guard assembly 25 page 39 6 Install the gun onto the manifold See page 38 lt 0 125 in 3 mm gap A 16a 15 16b 11b E Fic 34 Actuator Arm Adjustment 19 a ti24407a FIG 35 Barrel Removal 42 333013B Barrel Installation See FIGURE 36 1 Verify the gasket 9 and grounding spring 6 are in place and the gasket air holes are aligned properly Replace the gasket if damaged Make sure the spring is in place on the tip of the power supply 7 Liberally apply dielectric grease to the tip of the power supply Place the barrel 1 over the power supply and onto the gun body 10 Tighten the two barrel screws 19 oppositely and evenly about a half turn past snug or 20 in lbs Do not over tighten NOTICE To avoid damaging the gun barrel do not over tighten the screws 19 4 5 6 T Install and adjust the actuator arm 15 jam nut 16a and adjustment nut 16b See page 42 Test gun resistance page 29 Install the gun shroud 26 and air cap page 39 Install the gun onto the manifold See page 38 ti24409a Fic 36 Barrel Installation 333013B Repair Power Supply R
20. stop spraying immediately Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage MPa bar PSI To reduce the risk of an injury follow the Pressure Relief Procedure when you stop spraying and whenever you are instructed to relieve the pressure During operation periodically check all openings of the gun shroud ZZ for the presence of fluid See FIGURE 19 Fluid in these areas indicates leakage into the shroud which could be caused by leaks at the fluid tube connections or fluid packing leakage If fluid is seen in these areas stop spraying immedi ately Discharge the system voltage relieve the pres sure then remove the gun for repair ZZ ti24401a Fic 19 Check for Fluid Leakage ZZ 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 e Keep the inside of the cabinet clean for proper operation e Inspect the door T handle locking screw regularly to ensure the threads are well greased Apply sili cone free grease to the threads when necessary e Visually inspect the ground strip 240 for damage Replace if needed Measure the resistance weekly See Test Ground Strip Resistance page 30 333013B Electrical Tests Use the following procedures to test the condition of the po
21. 00 ft 30 5 m 245277 Test Fixture High Voltage Probe and kV Meter Use to test the electrostatic voltage of the gun and the condition of the turbine and power supply when being serviced See manual 309455 Also requires 24R038 Conversion Kit Bleed Type Master Air Valve 300 psi 21 bar 2 1 MPa Maximum Working Pressure Relieves air trapped in the air line between this valve and the pump air motor when closed 24R038 Voltage Tester Conversion Kit Converts the 245277 Test Fixture for use with the Pro Xp Gun turbine See manual 406999 Gun Accessories Part No Description 107141 3 4 npt Air Line Shutoff Valve 150 psi 10 bar 1 0 MPa Maximum Working Pressure For turning air to gun on or off Part No Description 105749 Cleaning brush 111265 Non silicone lubricant 4 oz 113g 116553 Dielectric grease 1 oz 30 ml 24V929 Gun Covers Conversion and Repair Kits Part No Description 224754 1 4 npsm m x 1 4 npsm f left hand thread 333013B Part No Description 24N319 Round Spray Kit To convert a standard air assisted spray gun to a round spray air cap See manual 3A2499 24W390 Air Seal Repair Kit 24N706 Turbine Bearing Repair Kit 57 Accessories Dimensions Rear Inlet Manifold 11 0 in 279 mm WW__ lt _ lt 104in 265mm ______ lt q 8 2 in 208 mm po
22. 209 211 213 215 217 6 8 150 200 307 309 311 313 315 317 319 in mm 8 10 10 12 200 250 250 300 Spray Tip 409 509 411 511 413 513 415 515 417 517 419 519 421 521 423 523 425 525 431 539 12 14 300 350 609 611 613 615 617 619 621 623 625 631 14 16 350 400 711 713 715 717 719 721 723 725 137 16 18 400 450 813 815 821 823 825 829 831 833 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 333013B 59 Spray Tip Selection Chart AEF Fine Finish Pre Orifice Spray Tips 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 Orifice Size in mm 0 008 0 203 0 010 0 254 0 0012 0 305 0 014 0 356 0 016 0 406 Tips are tested in water Fluid Output fl oz min l min at 600 psi at 1000 psi 4 1 MPa 7 0 MPa 70 41 bar bar 8 5 11 0 025 0 32 9 5 12 5 0 28 0 37 12 0 16 0 0 35 0 47 16 0 21 0 0 47 0 62 20 0 26 5 0 59 0 78 6 8 150 200 310 312 314
23. 3 GREASE dielectric 1 oz 30 ml tube not shown 24X482 FASTENER retainer Pack of 4 16P802 SIGN warning not shown 172479 TAG warning not shown 179791 TAG warning not shown 222385 TAG warning not shown 276741 TOOL wrench 4 mm not shown 107460 WRENCH ball end not shown 112080 TOOL wrench ball end 2mm not shown 117560 SCREW set socket 1 24W035 CONTROL MODULE Pro Xp Auto 1 not shown See 332989 Must be purchased separately 24W599 See Waterborne Fluid Hose page 50 GQ A pO ee ee ee bh 600a 24W599 See Waterborne Fluid Hose page 50 A Replacement Warning labels signs tags and cards are available at no cost Included in WB AA Hose Mount Kit 24W879 purchase separately E Included in air seal repair kit 24W390 purchase separately Included in Turbine Assembly 24N664 pur chase separately See Turbine Assembly page 51 49 Parts Air Cap Assembly Waterborne Fluid Hose Part No 24N727 Air Cap Assembly Part No 24W599 Waterborne Fluid Hose Ref No 3a 25a 25b 25C 25d 50 ti18652a Part No 183459 24N643 24N734 24N726 600a 600 Description Qty GASKET tip not shown See 5 page 46 ELECTRODE package of 5 1 O RING PTFE package of 5 1 also available in package of 10 order 24E459 AIR CAP 1 GUARD tip orange 1 ti25109a Ref No Part No Description Qty 600 HOSE 25 ft 7 6m 1 600a FI
24. 5 16T 29 110465 SCREW set 2 30 102207 SCREW set SCH 2 31 24N785 CAP spring includes 6 1 32 BRACKET strain relief WB tube 1 33 24N747 RING conductive 1 34 CLAMP strain relief WB tube 1 35 GC2248 SCREW SHDC SS 250x 50 3 36 116553 GREASE dielectric 1 oz 30 ml 1 tube not shown 37 24X482 FASTENER retainer pack of 4 1 424 179791 TAG warning not shown 1 44 276741 TOOL wrench not shown 1 45 107460 WRENCH ball end 4 mm not 1 shown 48 112080 WRENCH ball end 2 mm not 1 shown 51 117560 SCREW set socket 1 600 24W599 See Waterborne Fluid Hose page 50 600a 24W599 See Waterborne Fluid Hose page 50 A Replacement Warning labels signs tags and cards are available at no cost Included in WB AA Hose Mount Kit 24W879 purchase separately E Included in air seal repair kit 24W390 purchase separately Included in Turbine Assembly 24N664 pur chase separately See Turbine Assembly page 51 47 Parts Smart Pro Xp Auto Waterborne AA Gun Models HA1M18 Rear Manifold N Torque to 20 in lbs 2 Nem ti24413a 48 333013B HA1M18 Rear Manifold Ref No 4 2 3 3a oO Ol a Som One 10 11 t a 11b 11c 11d 12 13 14 15 16 18W 19 20 21 23 24 24am 25 25a 26 Part No 24W874 24N781 AEMxxx AEF xxx 183459 24N725 24N782 197624 24N662 24N979 24N644 110073 24N699 24W867 24W396 17B704 111504 112319 111508 112640 24W397 513505 24
25. ANUFACTURED 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 judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures 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
26. Gun Features 2 000 eee eee ees 7 Voltage Loss Troubleshooting 31 Spraying Waterborne Fluids Electrostatically 8 Spray Pattern Troubleshooting 34 System Overview 0 0 eee ees 9 Gun Operation Troubleshooting 35 Gun Overview 2 0 00 cece ee eee 10 Electrical Troubleshooting 37 INSTAlatlON orion 11 Repa ura E oa 38 System Requirements o o o oo oooooooooo 11 Prepare the Gun for Service o o oo o o 38 Install the System o oooocooocoooooooo 11 Remove the Gun from the Manifold 38 Warning SIQNS 0 cc o 11 Install the Gun on the Manifold 38 Ventilate the Spray Booth 11 Air Cap Tip Guard Spray Tip and Fluid Seat Housing Install the Air Line Accessories 12 Replacement 0c eee e eee eee 39 Install the Fluid Line Accessories 12 Electrode Replacement 40 Install the GUN ee seek bs ewe ee deen ees 14 Fluid Needle Replacement 40 Install the Pro Xp Auto Control Module 14 PISTON Repair 2 4 fii dec das 41 Connect the Air Line 14 Adjust the Actuator Arm 0000 eee o 42 Ground the Cabinet co e 14 Barrel Removal o o oooooooono oo 42 Manifold Connections o ooo e
27. IMENSIONS seaskan pe ii rd 58 Set the Atomization Fluid Pressure 23 Rear Inlet Manifold oocooocccocccrcc nn ss 58 Adjust the Electrostatics 24 Spray Tip Selection Chart 0ooooommmomm mo 59 SLAVING E T EEE E a bas T eins 25 AEM Fine Finish Spray Tips 0004 59 Triggering the Fluid Alone 25 AEF Fine Finish Pre Orifice Spray Tips 60 Shutdown ccc cece cece cece ee eee 95 Technical Dala cuidada a 61 Maintenance o e tated to 26 Graco Pro Xp Warranty ooooooccococc eee eee 62 Daily Care and Cleaning Checklist 26 FHS MG e cad dp to ae 26 Clean Outside of Gun 00 cee eee 27 Clean the Spray GUN 0 cee ees 27 Check for Fluid Leakage 28 Clean the cabinet 0 00 0 eee eee ees 28 2 333013B List of Approved Models List of Approved Models Standard Smart Bottom Rear kV Model Model Manifold Manifold HA1M18 60 Y Ao per HA1T18 60 Y Y pp Y Description WB 3000 Isolation Enclosure 25 Waterborne Fluid Hose 50 Waterborne Fluid Hose FM approved for use with fluids that meet the following condition C US e Material does not sustain burning in accordance with the Standard APPROVED Test Method for Sustained Burning of Liquid Mixtures ASTM D4206 Models Compliant with EN 50059 when used with fluids that meet the 0 35 J with 50 ft hose max oe
28. Instructions Parts gt GRACO Pro Xp Auto Waterborne AA Spray Gun AERES Air assisted spray system for use when electrostatically spraying conductive waterborne fluids that meet at least one of the following conditions for non flammability Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures ASTM D4206 Materials which cannot be ignited in any mixture with air by an energy source of less than 500 mJ For professional use only 100 psi 0 7 MPa 7 bar Maximum Air Inlet Pressure 3000 psi 21 MPa 210 bar Maximum Working Fluid Pressure Read all warnings and instructions in this manual A Important Safety Instructions Save these instructions See page 2 for Table of Contents ti22413a PROVEN QUALITY LEADING TECHNOLOGY Table of Contents List of Approved Models 000 cee eee 3 Electrical Tesis ii a 29 WarninGS lt 2 4 Test Gun Resistance o oooooooomoooo 29 INTFOGUCIION Ica a 7 Test Power Supply Resistance 29 How the Electrostatic AA Spray Gun Works 7 Test Barrel Resistance o o oooooooo 29 Operating the Spray Function 7 Test Ground Strip Resistance 30 Operating the Electrostatics 7 Test Cylinder Resistance o o ooooo o 30 Gun Features and Options oooooo 7 Troubleshooting euro ee ete 31 Smart
29. M 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 500muJ 333013B 21 Operation Fluid Voltage Discharge and Grounding Procedure MA The fluid supply is charged with high voltage until the voltage is discharged Contact with the charged components of the voltage isolation system or spray gun electrode will cause an electric shock To avoid an electric shock follow the Fluid Voltage Discharge and Grounding Procedure e whenever you are instructed to discharge the voltage e before cleaning flushing or servicing the sys tem equipment e before approaching the front of the gun e or before opening the isolation enclosure for the isolated fluid supply NOTE An accessory grounding rod part No 210084 is available to discharge any voltage remaining on a sys tem component Contact your Graco distributor to order 1 Turn off the turbine air to all spray guns connected to the isolated fluid supply and wait 30 seconds 2 Discharge the voltage at the voltage isolation sys tem by following the procedure specified in the volt age isolation system instruction manual For WB3000 fully unscrew the door T handle lock ing screw This will shut off the air to the gun and trigger the grou
30. MPa bar PSI Trapped air can cause the gun to spray unexpectedly which can result in serious injury including splashing fluid in the eyes or on the skin The solenoid valves K must have a quick exhaust port so trapped air will be relieved between the valve and gun when the solenoids are shut off 12 333013B Installation FIGURE 3 shows a typical electrostatic air assisted spray system It is not an actual system design For assistance in designing a system to suit your particular needs contact your Graco distributor A The turbine air supply TA must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on See Warning Pneumatic above Interlock Air Line Pressurized when door is closed Non Hazardous Area Hazardous Area G Voltage 7 Payee The turbine air must also be interlocked with the EO voltage isolation system to shut off the turbine air TA when the access to the isolation system is opened FIG 3 Typical Installation Key to FIGURE 3 A Air Hose Ground Wire Graco Grounded Turbine Air Hose TA C Atomizing Air Hose 5 16 in 8 mm OD A1 D Fan Air Hose 5 16 in 8 mm OD A2 E Cylinder Air Hose 5 32 in 4 mm OD CYL G Graco Waterborne Fluid Supply Hose 333013B Solenoid Valve requires quick exhaust po
31. TTING connector barrel WB 1 333013B Turbine Assembly Part No 24N664 Turbine Assembly 810 t119739b Ref Part No No 8a 24N705 COIL turbine 8b0 24N706 BEARING KIT includes two bear ings item 8e fan and one item 8h clip 8d 24N707 HOUSING includes item 8f 3es FAN part of item 8b CAP housing part of item 8d Description 333013B Qty Parts di tn Description Qty 8g 110073 O RING 1 8h 24N709 CLIP package of 5 one clip 1 included with item 15b 9 24N699 GASKET barrel not shown See 1 page 46 These parts are included in Air Seal Repair Kit 24W390 purchase separately These parts are included in Bearing Kit 24N706 purchase separately Parts labeled are not available separately 51 Parts WB 3000 Isolation Enclosure Part No 24N550 Waterborne Isolation Enclosure includes items 201 206 282 280 283 570 252 239 215 214 253 216 my 7 a Ws 279 276 ed 283 W a 258 e 2 228 253 249 268 m ae Sy 262 Oz 257 i 257 ae y e i n f XN l eN a SS Lan 262 a 228 LAZ LO 297 243 ti25583a 52 333013B Ref No 201 201a 202 203 204 205 206 207 209 210 211 212 214 215 216 217 218 219 220 226 227 228 229 230 Part No 15A947 116993 15A551 15A545 15A524 113061 24N548 104029 116989 111804 113060 116473 233824 116473 190410 116988 15A518 104267 2354 15A682
32. W398 100166 111450 24N740 24W392 24W399 24W411 24N793 198307 Description BODY gun assy includes 9 NEEDLE ASSEMBLY includes 5 TIP ASSEMBLY customer s choice GASKET tip HOUSING seat SPRING fluid needle SPRING compression POWER SUPPLY SPRING See Turbine Assembly page 51 O RING packing GASKET barrel BODY assy AA rear inlet PISTON assy actuation auto O RING packing O RING packing O RING packing O RING packing SPRING compression CAP piston actuation WASHER plain 10 SST ARM fluid actuator XP NUT full hex PACKING O RING SCREW ES gun Includes 2 MANIFOLD rear inlet includes 18 21 23 27 28 29 51 SCREW modified 1 4 20 XP Auto pack of 2 FITTING Adapter M12 TO 1 4 LH XP RING retainer assy includes 24a PACKING u cup UHMWPE See Air Cap Assembly page 50 24N643 24W388 333013B ELECTRODE package of 5 COVER shroud Auto XP Qty a RK OFF N Aa dd y NYO ad dk h ee bh mb Ref No 27 28 29 30 31 32 33 34 35 36 37 404 414 424 434 44 45 48 51 80 600 Parts Part No Description Qty 114263 FITTING connector male 1 115950 FITTING connector 1 4npt M 3 5 16T 110465 SCREW set 245265 CIRCUIT flexible 24N785 CAP spring includes 6 BRACKET strain relief WB tube 24N747 RING conductive CLAMP strain relief WB tube GC2248 SCREW SHDC SS 250x 50 11655
33. able 1 Set the proper pressure at the turbine air hose inlet when air is flowing Table 1 Approximate Dynamic Turbine Air Pressures Turbine Air Hose Length ft m 15 4 6 25 7 6 Air pressure at turbine air hose inlet for full voltage psi bar MPa 54 3 8 0 38 55 3 85 0 38 56 3 9 0 39 57 4 0 0 40 59 4 1 0 41 1 36 11 50 15 3 75 22 9 100 30 5 61 4 3 0 43 24 4 Check the turbine speed of the gun by checking the indicator light on the standard gun body or for the smart gun check the actual turbine speed on the Pro Xp Auto Control Module See Table 2 Adjust the air pressure as necessary to keep the indicator light green or the values within 100 750 Hz NOTE Smart models display values not color indicator lights Table 2 Indicator Colors Values Indicator Color Green When spraying the indicator should 400 750 Hz remain green indicating sufficient air pressure to the turbine Description If the indicator changes to amber after 1 second the air pressure is too low Increase air pressure until the indicator is green If the indicator changes to red after 1 sec ond the air pressure is too high Decrease air pressure until the indicator is green Excessive turbine speed can shorten the bearing life and will not increase the voltage output 5 Check the voltage output by reading the kV meter on the isolated enclosure 45 55 kV is normal See Elec
34. able safety regulations 6 333013B Introduction How the Electrostatic AA Spray Gun Works This is not an air spray gun To help prevent serious injury from pressurized fluid such as skin injection and splashing fluid read and follow the Skin Injection Hazard Warnings on page 5 The air assisted spray gun combines airless and air spraying concepts The spray tip shapes the fluid into a fan pattern as does a conventional airless spray tip Air from the air cap further atomizes the fluid and completes the atomization of the fluid tails to produce a uniform pattern The high working fluid pressure of this gun provides the power needed to atomize higher solids materials Operating the Spray Function Applying a minimum of 60 psi 0 42 MPa 4 2 bar air pressure to the gun manifold s cylinder air fitting CYL will retract the gun piston which opens the air valves and a short time later opens the fluid needle This pro vides the proper air lead and lag when triggering the gun A spring returns the piston when the cylinder air is shut off Operating the Electrostatics To operate the electrostatics apply air pressure to the gun manifold s turbine air fitting TA through a Graco Grounded Turbine Air Hose The air enters the manifold and is directed to the inlet of the power supply turbine The air spins the turbine which then provides electrical power to the internal high voltage power supply The fluid is charg
35. ace see Air Cap Tip Guard Spray Tip and Fluid Seat Housing Replacement page 39 Loose spray tip Tighten retaining ring 24 see Air Cap Tip Guard Spray Tip and Fluid Seat Housing Replacement page 39 Damaged tip seal 3a Replace see Air Cap Tip Guard Spray Tip and Fluid Seat Housing Replacement page 39 333013B 35 Troubleshooting Gun does not spray Low fluid supply Add fluid if necessary Damaged spray tip Replace see Air Cap Tip Guard Spray Tip and Fluid Seat Housing Replacement page 39 Dirty or clogged spray tip 3 Clean see Clean the Spray Gun page 27 Damaged fluid needle 2 Replace see Fluid Needle Replace ment page 40 Piston 11 not actuating Check cylinder air Check piston o ring 11d see Piston Repair page 41 Actuator arm 15 is out of position Check actuator arm and nuts See page 42 Dirty air cap Damaged or plugged air cap Clean see Clean the Spray Gun page 27 Air leaks from manifold Manifold is not tight Tighten manifold screws Fluid doesn t shut off properly Fluid buildup on fluid needle 2 Replace needle Fluid Needle Replacement page 40 Piston sticking Clean or replace o rings See Piston Repair page 41 Excessive paint wrap back to opera Poor grounding See Grounding page 18 tor Incorrect distance from gun to part Should be 8 12 in 200 300 mm 36 333013B Troubleshooting Electrical Troubleshooting Problem
36. aintenance on page 26 25 Maintenance Maintenance 1 j C h He li MPa bar PSI To reduce the risk of an injury follow the Pressure Relief Procedure and the Fluid Voltage Discharge and Grounding Procedure before doing any maintenance on the gun or system Daily Care and Cleaning Checklist Check the following list daily upon completion of equip ment usage Flush the gun See Flushing page 26 Clean the fluid and air line filters Clean the outside of the gun See Clean Out side of Gun page 27 Clean the air cap spray tip and tip guard daily minimum Some applications require more frequent cleaning Replace the parts if they are damaged See Clean the Spray Gun page 27 PF tJ UL Check the electrode and replace if broken or damaged See Electrode Replacement on page 40 E Check for fluid leakage from the gun and fluid hoses See Check for Fluid Leakage on page 28 Tighten fittings or replace equipment as needed Check Grounding page 18 M 26 Flushing e Flush before changing fluids before fluid can dry in the equipment at the end of the day before storing and before repairing equipment e Flush at the lowest pressure possible Check con nectors for leaks and tighten as necessary e Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts mw AA To reduce the risk of fire explosion or
37. al Repair Kit 24W396 is available The kit must be purchased separately Kit parts are marked with an asterisk for example 6a Remove the Gun from the Manifold 1 Follow the Fluid Voltage Discharge and Ground ing Procedure page 22 38 Lightly lubricate o rings and seals with non silicone grease Order Part No 111265 Lubricant Do not T Flush and clean the gun page 26 Follow the Pressure Relief Procedure page 22 Remove the air cap 25 and shroud 26 page 39 Loosen the strain relief bracket Disconnect the fluid hose fitting 600A from the gun barrel 1 Loosen two manifold screws 21 and remove gun NOTE The screws 21 should stay on the manifold and the five o rings 18 should stay on the gun ti24404a Fic 25 Remove Gun from Manifold Install the Gun on the Manifold 1 2 Make sure the five o rings 18 are in place Secure the gun to the manifold by tightening the two manifold screws 21 Make sure the hose fittings and barrel are clean and dry then reconnect the Waterborne Fluid Hose page 16 Tighten strain relief screws Reinstall the gun shroud 26 and air cap 25 page 39 333013B Repair Air Cap Tip Guard Spray Tip and Fluid Seat Housing Replacement 1 See Prepare the Gun for Service page 38 2 Remove the retaining ring 24 shroud 26 and air cap tip guard assembly 25 The conductive ring 33 is a conductive metal contact ring not a
38. e coil 8a so the bearing blades are flush with the sur face of the coil Press the new top bearing 8b2 onto the short end of the shaft so the bearing blades are flush with the surface of the coil 8a The flatter side of the bear ing must face away from the coil Hold the coil assembly 8a on a workbench with the fan end facing up Press the fan 8e onto the long end of the shaft S The fan blades must be oriented as shown in FIGURE 39 Carefully press the coil assembly 8a into the front of the housing 8d while aligning the pin on the coil with the slot in the housing The 3 wire connector PC must be positioned below the wider notch W of the housing tabs Rotate the fan 8e so its blades clear the four bear ing tabs T at the back of the housing Ensure that the blades of the bottom bearing 8b1 align with the tabs Seat the coil fully into the housing 8d Secure with the clip 8h ensuring that its tabs engage the slots in the housing Ensure that the o ring 8g is in place Install the cap 8f Install the turbine on the power supply and install both parts in the gun body See Power Supply Removal and Replacement page 43 45 Parts Parts Standard Pro Xp Auto Waterborne AA Gun Models HA1T18 Rear Manifold Az Torque to 20 in lbs 2 Nem ti24412a 46 333013B HA1T18 Rear Manifold Ref No 4 2 3 3a oO Ol a Som One
39. 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 e Dielectric breakdown of hoses seals or connec tions e Isolators not functioning properly 31 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 prob lems and is required for some of the troubleshooting tests that follow 1 32 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 sys tem have sufficient air pressure Check that the spray gun and voltage isolation sys tem have sufficient air pressure Check that the gun turbine air TA is turned on and the pressure is set correctly Check that the voltage isolation system s enclosure door is closed and that any safety interlocks are engaged and working properly 10 11 Make sure the voltage isolation system is in the iso late mode where it is is
40. ed by the spray gun electrode The charged fluid is attracted to the nearest grounded object wrap ping around and evenly coating all surfaces 333013B Introduction Gun Features and Options e The gun is designed for use with a reciprocator and can be mounted directly on a 1 2 in 13 mm rod With additional brackets the gun can be mounted for robotic applications e The gun s quick disconnect design enables its removal without disconnecting the air lines to the gun Gun functions are activated from a separate control ler that sends the appropriate signal to the actuating solenoids Smart Gun Features Smart gun models with the Pro Xp Auto Control Module have the ability to e Display the spraying voltage and current e Change the gun voltage setting e Display the gun turbine speed e Store spray profiles e Communicate equipment faults to a PLC e Display and set maintenance totalizers e Use a PLC to select a spray profile See the Pro Xp Auto Control Module manual 332989 for more information Introduction Spraying Waterborne Fluids Electrostatically This electrostatic air spray gun is designed to spray only waterborne fluids which meet at least one of the following flammability requirements FM FMc Approved e Material does not sustain burning in accordance with the Standard Test Method for Sustained Burn ing of Liquid Mixtures ASTM D4206 CE EN 50059 Compliant e Materials which cannot be ignited
41. ee 15 Barrel Installation o oo 43 Connect the Waterborne Fluid Hose 16 Power Supply Removal and Replacement 43 Fiber Optic Cable Connection 17 Turbine Removal and Replacement 44 Agitator Kit Accessory 000 0c eee eee 18 PONS sia 46 GOUGING sein ae dob eee Bases ncaa esd How eas 18 Standard Pro Xp Auto Waterborne AA Gun Check Electrical Grounding 19 Mode izada ia Leer 46 Install the Fabric Cover 0 00000 20 HA1T18 Rear Manifold 0 000 46 Check Fluid Viscosity 0 0 005 20 Smart Pro Xp Auto Waterborne AA Gun Flush Before Using Equipment 20 Models 6 6 eee eee eee eee ees 48 Operation 202ss s eteieceonceceetersete2S snes 21 Air Cap Assembly 6 eee eee eee nee 50 Operating Checklist u unanou inuuna 91 Waterborne Fluid H0Se o o o oooooo 50 Fluid Voltage Discharge and Grounding Turbine Assembly 0000 ce eee ees 51 Procedure ccc cece cece eee ee 29 WB 3000 Isolation Enclosure 52 Pressure Relief Procedure o o ooo 22 Tubing and Wiring ee cache tala aad ae 54 Selecta Spray Tip 0 cece eee eee eee 29 Agitator Kit 245895 0 ee 56 Install the Spray Tip 0 2 00 cece eee ee eee 93 ACCOSSOFIOS isidro 57 Fill the Fluid Supply 0 ce eee eee o 93 D
42. emoval and Replacement e Inspect the gun body power supply cavity for dirt or moisture Clean with a clean dry rag e Do not expose gasket 9 to solvents 1 See Prepare the Gun for Service page 38 2 See Barrel Removal page 42 NOTICE Be careful when handling the power supply 7 to avoid damaging it 3 Grasp the power supply 7 with your hand With a gentle side to side motion free the power sup ply turbine assembly from the gun body 10 then carefully pull it straight out Smart models only disconnect the flexible circuit 30 from the socket at the top of the gun body 4 Inspect the power supply and turbine for damage 5 To separate the power supply 7 from the turbine 8 disconnect the 3 wire ribbon connector PC from the power supply See FIGURE 37 Smart models only disconnect the 6 pin flexible circuit 30 from the power supply Slide the turbine up and off the power supply 6 See Test Power Supply Resistance page 29 Replace the power supply if necessary To repair the turbine see Turbine Removal and Replace ment page 44 NOTICE To prevent damage to the cable and possible inter ruption of the ground continuity bend the turbine s 3 wire ribbon cable PC upward and back so the bend faces the power supply and the connector is at the top 7 Connect the 3 wire ribbon connector PC to the power supply Smart models only connect the 6 pin flexible cir cuit 30
43. fold Route the exhaust tube YY outside the cover This enables you to monitor the exhaust tube for the presence of any paint or solvent See Check for Fluid Leakage on page 28 Strap down the exhaust tube to prevent it from moving around ti24401a ti24182a Fic 13 Fabric Cover 20 Check Fluid Viscosity To check fluid viscosity you will need a viscosity cup a stopwatch Completely submerge the viscosity cup in the fluid Lift the cup out quickly starting the stopwatch as soon as the cup is completely removed Watch the stream of fluid coming from the bottom of the cup As soon as there is a break in the stream shut off the stopwatch Record the fluid type elapsed time and size of the viscosity cup If the viscosity is too high or too low contact the material supplier Adjust as necessary 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 equipment See Flushing page 26 333013B Operation Operation Operating Checklist Check the following list daily before starting to operate the system to help ensure you of safe efficient operation PF LJ UI UU obo oo Uo Ll All operators are properly trained to safely operate an automatic electrostatic waterborne air spray system as instructed in this manual All operators are trained in the Fluid Voltage Discharge and
44. g a system to suit your particular needs contact your Graco distributor W pp Also refer to system pneumatic ls connections in FIGURE 3 page 13 K a x ear ge T AA jt ti25107a CS GS FiG 1 Typical Installation Pro Auto Xp Waterborne System tem Description tem Description Main Air Supply Line R Graco Waterborne Fluid Hose Bleed Type Air Shutoff Valve Grounding Rod Pump Air Pressure Gauge U Ground Terminal D Pump Air Pressure Regulator Main Ground Wire kV Meter Strain Relief Fitting F e Pi Str G Pump Suction Hose Grounding Cylinder H Paint Container Pump Fluid Outlet Fitting Bleed Resistor Isolated Enclosure Door not shown to illustrate Enclosure Safety Interlock internal components Door must be closed and k Sena locked to operate system solated Enclosure E PA OO Enclosure T Handle Locking Screw part of door M Air Line Filter assen Pneumatic connection to turbine air interlock These items are required for safe operation They are Pressurized when isolation system door is included with the WB3000 system closed 333013B 9 Introduction Gun Overview ti24397a Fig 2 Gun Overview Key Manifold Markings PAL Atomization Air Inlet Fitting Spray Tip A A B D Shroud o 2 Cylinder Air Inlet Fitting Fiber Optic Fitting Transmit Operational on Smart models only Power Supply Electrode L Waterborne Fluid Ho
45. g will shorten the life of the sys tem components Graco Waterborne Fluid Hose Use a Graco Waterborne Fluid Hose between the volt age isolation system fluid outlet and the gun fluid inlet See Accessories on page 57 for available hoses The hose consists of an inner PTFE tube a conductive layer covering the PTFE tube and an outer cover 333013B Installation Install the System MA Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly e Do not install or service this equipment unless you are trained and qualified e Comply with all applicable local state and national fire electrical and other safety regulations Warning Signs Mount warning signs in the spray area where they can easily be seen and read by all operators An English Warning Sign is provided with the gun Ventilate the Spray Booth DE Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying flushing or cleaning the gun Do not operate the gun unless ventilation fans are operating Electrically interlock the gun turbine air supply B with the ventilators to prevent gun operation without ventilat ing fans operating NOTE High velocity air exhaust will decrease the oper ating efficiency of the electrostatic system Check and follow all Nati
46. gun barrel Push in on the needle with the 2 mm ball end wrench 45 and tighten See FIGURE 32 8 Install the spring 5 9 Install the spring cap 31 making sure the ground ing spring 6 is in place Tighten until snug Do not overtighten 10 Install the barrel 1 page 43 NOTICE To avoid damaging the seat housing and gun barrel never overtighten the seat housing Overtightening may result in improper fluid shutoff 11 Install the seat housing and air cap page 39 12 Test Gun Resistance page 29 FIG 30 Spring Cap and Springs 333013B AA FIG 32 Fluid Needle Replacement Piston Repair 1 Prepare the gun for service page 38 2 Remove the air cap page 39 Remove the gun shroud 26 3 Remove the jam nut 16a actuator arm 15 and adjustment nut 16b See FIGURE 34 4 Remove piston cap 13 and spring 12 from the rear of the gun 5 Push on the piston rod 11 to push the piston out the back of the gun 6 Inspect the o rings 11d 11e 11f 11g for damage See Table 3 and FIGURE 33 7 Lubricate the o rings 11d 11e 11f 11g with non silicone grease Part No 111265 Do not over lubricate 8 Align the two stems 11c with the holes in the gun body and press the piston assembly into the back of the gun until it bottoms Install piston cap 13 and spring 12 9 Install and adjust the actuator arm page 42 333013B Repair ti24192a 11b A 11d
47. in any mixture with air by an energy source of less than 500 mu When connected to a voltage isolation system all of the fluid in the spray gun fluid hose and isolated fluid sup ply 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 above can be sprayed with the system or used to clean flush or purge the system Precautions must be taken when using electrostatic waterborne equipment to avoid potential shock hazards When the electrostatic AA spray gun charges the iso lated 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 noz zle 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 Operating Checklist on page 22 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 spray gun is operated above 60 kV 333013B Introduction System Overview Typical Waterborne System Installation FIGURE 1 shows a typical electrostatic waterborne AA spray system It is not an actual system design For assistance in designin
48. in fluid supply Check fluid source Refill Irregular pattern Fluid buildup partially plugged tip Clean See page 27 Worn damaged tip or air cap holes Clean or replace Pattern pushed to one side air cap Air cap holes plugged Clean See page 27 gets dirty Tails in pattern Atomization air pressure too low Increase atomization air pressure Fluid pressure too low Increase Fluid buildup on air cap tip guard Atomization air pressure too high Plugged or damaged air cap hole Clean see page 27 34 333013B Troubleshooting Gun Operation Troubleshooting O CO CS Excessive spray fog Atomizing air pressure too high Decrease air pressure A1 as low as possible Fluid too thin Increase viscosity or increase fluid flow rate Orange Peel finish Atomization air pressure too low Increase air pressure use lowest pressure necessary Spray tip is too large Use smaller tip see Spray Tip Selection Chart page 59 Poorly mixed or filtered fluid Remix or re filter fluid Fluid too thick Reduce viscosity Worn fluid needle packings or rod Replace fluid needle assembly 2 see Fluid Needle Replacement Fluid leaks from the fluid packing area page 40 Air leaks from the air cap Worn piston stem o rings 11e 11f Replace see Piston Repair page 41 Fluid leakage from the front of the Worn or damaged fluid needle ball See Fluid Needle Replacement gun page 40 Worn fluid seat housing Repl
49. 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 The following are minimum grounding requirements for a basic electrostatic waterborne system Your system may include other equipment or objects which must be grounded Check your local electrical code for detailed grounding instructions Your system must be connected to a true earth ground e Electrostatic Air Spray Gun ground the gun by con necting the red colored Graco Grounded Air Hose to the turbine air inlet and connecting the air hose ground wire to a true earth ground See Check Electrical Grounding page 19 e Voltage Isolation System electrically connect the voltage isolation system to a true earth ground e Air compressors and hydraulic power supplies ground the equipment according to the manufac turer s recommendations e All persons entering the spray area shoes must have conductive soles such as leather or personal grounding straps must be worn Do not wear shoes with non conductive soles such as rubber or plastic e Object being sprayed keep the workpiece hangers clean and grounded at all times Resistance must not exceed 1 megohm e The floor of the spray area must be electrically con ductive and grounded Do not cover
50. k 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 turbine air to the gun on Measure the volt age at the gun electrode with a voltage probe and meter Discharge the system voltage by waiting 30 sec onds and then touching the gun electrode with a grounded rod Check the meter reading e lf the meter reading is 45 to 55 kV the gun and fluid hose are okay and the problem is in the voltage isolation system e Ifthe 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 turbine air to the gun on Measure the volt age at the gun electrode with a voltage probe and meter If the meter reading is 55 60 kV the gun power sup ply is okay and there is probably a dielectric break 333013B Troubleshooting down somewhere in the fluid hose or gun Continue with step 12 If the reading is below 55 kV do the electrical tests on page 33 to check the gun and power supply resistance If those tests show the gun and power supply are okay continue with step 12 12 A
51. lug to cart n a green yellow 25 ft 7 6 m ground wire with clamp from external ground lug to true earth ground n a green yellow 10 gauge wire from exter nal ground lug to ground probe n a red wire from bleed resistor to pump 16 407 red 14 gauge wire from pump to pail cover with clamp red 14 gauge wire from pump 209 to ground on cylinder bracket n a green yellow 10 gauge wire from meter to internal box ground lug 3 8 OD tube bulkhead to manifold 12 305 4 102 55 Parts Agitator Kit 245895 To keep fluid mixed and prevent settling out Includes items 401 408 56 ti2137a 401 Ref No 401 402 403 404 405 406 407 408 Part No Description Qty 112698 ELBOW swivel 1 8 npt m x 1 4 in 6 1 mm OD tube 114158 FITTING adapter Y 1 4 in 6 mm OD 1 tube mxfxf 193315 COLLAR mounting agitator 193316 NUT collar agitator 197298 COVER pail 5 gal 19 liter 224571 AGITATOR see manual 306565 purchase TUBE nylon 1 4 in 6 mm OD 4 ft locally 1 22 m 110272 SCREW set socket hd 1 4 20 x 1 4 in 1 6 mm 333013B Accessories Smart Model Accessories and Fiber Optic Cables Accessories Fluid Line Accessories Waterborne Fluid Hose 3000 psi Part No Description 24W035 Pro Xp Auto Control Module See 332989 for details Fiber Optic Cables for Gun See item V in FIGURE 9 on page 17 Connect gun mani fold to
52. lustrative purposes but is not included 53 Parts Tubing and Wiring Detail Views of Control Box Co Al A2 C1 B4 B3 o C3 C4 C5 te D Da ES K XR ap d mi O E OH NE oH el Ha u Tinan E OLA o i V i B2 E1 C2 C9 Detail View of Door Interlock Switch Ts ee N amp R GTA YG Wiz EV B5 T B2 54 333013B Tubing and Wiring Chart Parts Use the diagrams to find the connection points for the tubing and wiring listed below Code A1 A2 B2 B3 B4 B5 C1 C2 Ref No 248 248 249 249 249 249 272 251 333013B Length in mm 20 508 1 4 OD tube regulator 216 to pump 9 229 1 4 OD tube regulator 216 to mani fold 17 432 5 32 OD tube manifold air to door interlock switch 20 508 5 32 OD tube valve tee to cylinder 5 127 5 32 OD tube regulator 216 to gauge 217 22 559 5 32 OD tube valve tee to door inter lock switch red 14 gauge wire from top of bleed resistor to meter green yellow 14 gauge wire from inter nal box ground lug to cylinder cap Description 9 229 8 204 Code C2 C4 C5 C6 C7 C8 C9 E1 Ref No 273 239 243 226 272 272 251 286 Length in mm Description 34 864 green yellow 10 gauge wire from exter nal ground
53. mbly 25 before tightening the retaining ring 24 Do not turn the air cap when the retaining ring is tight 11 Orientate the air cap and tighten the retaining ring securely 12 See Test Gun Resistance page 29 Electrode Replacement 1 See Prepare the Gun for Service page 38 2 Remove the air cap tip guard assembly 25 See Air Cap Tip Guard Spray Tip and Fluid Seat Housing Replacement page 39 3 Pull the electrode 25a out of the back of the aircap using a needle nose pliers 4 Push the new electrode through the air cap hole Make sure the short end BB of the electrode engages the hole CC in the back of the air cap Press the electrode in place firmly with your fingers 5 Install the air cap assembly 6 See Test Gun Resistance page 29 t119524 40 Fluid Needle Replacement 1 Prepare the gun for service page 38 2 Remove the air cap tip guard assembly and seat housing page 39 3 Remove the barrel 1 page 42 4 Remove the spring cap 31 and the spring 5 from the barrel See FIGURE 30 5 Be sure the seat housing 4 is removed Place the 2 mm ball end wrench 45 in the back of the fluid needle assembly Push the tool in and turn it coun terclockwise about 12 full turns to unthread the nee dle 6 Using the multi tool 48 pull back on the packing nut N to remove the fluid needle assembly See FIGURE 31 7 Install the fluid needle assembly in the
54. n when cleaning it Do not use any cleaning method which could allow fluid into the gun air passages Follow the Fluid Voltage Discharge and Ground ing Procedure page 22 Flush the gun See Flushing page 26 Follow the Pressure Relief Procedure page 22 Clean the outside of the gun with a compatible sol vent Use a soft cloth Wring out excess fluid from Maintenance MPa bar PSI To reduce the risk of an injury follow the Pressure Relief Procedure when you stop spraying and whenever you are instructed to relieve the pressure 1 Discharge the system voltage 2 Follow the Pressure Relief Procedure page 22 3 Remove the retaining ring 24 air cap tip guard 25 spray tip 3 and gun shroud 26 See page 39 4 Dip the end of a soft bristle brush into compatible solvent clean the front of the gun with the brush Avoid getting any solvent into the air passages Whenever possible point the gun down when cleaning it See FIGURE 17 If it appears that there is paint inside the air pas sages remove the gun from the line for servicing cloth Point the gun down to prevent solvent from entering the gun passages Do not immerse the gun Clean the Spray Gun Equipment Needed e soft bristle brush e compatible solvent Procedure MA Contact with the charged components of the spray gun will cause an electric shock Do not touch the gun nozzle or elec
55. nding cylinder to discharge any remaining electrical charge 3 Touch the pump supply pail and electrode of the gun with a grounded rod to make sure the voltage has been discharged If you see an arc verify that the electrostatics are turned off or see Electrical Troubleshooting page 37 or the voltage isolation system manual for other possible problems Resolve the problem before proceeding 22 Pressure Relief Procedure l Follow the Pressure Relief Procedure whenever you see this symbol Ne This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection and splashing fluid follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing the equipment Fy 1 Follow the Fluid Voltage Discharge and Ground ing Procedure page 22 2 Relieve fluid pressure in the fluid supply and voltage isolation system as instructed in their instruction manuals 3 Turn off all the air to the spray gun except the cylin der air which triggers the gun NOTE The air shut off device must bleed the air out of the system 4 Trigger the gun into a grounded metal waste con tainer to relieve the fluid pressure 5 Turn off all remaining air supplies to the gun 6 Turn off the main air supply by closing the bleed type master air valve on the main air supply line Leave the valve
56. ning could cause fire explosion and electric shock and result in serious injury and property damage Graco Part No 241079 Megohmmeter 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 turbine air hose Make sure the red colored turbine air hose B is connected and the hose ground wire is connected to a true earth ground Turn off the air and fluid supply to the gun Follow the Pressure Relief Procedure page 22 The fluid hose must not have any fluid in it 333013B Fig Installation Measure the resistance between the turbine air inlet fitting TA and a true earth ground N If the resis tance is greater than 100 ohms check the tightness of the ground connections and be sure the turbine air hose ground wire is connected to a true earth ground If the resistance is still too high replace the turbine air hose B ti22382a 11 Check Gun Grounding If using the WB3000 use an ohmmeter AA mea sure the resistance between the cabinet ground lug 214 and a true earth ground CC The resistance must be less than 100 ohms ti2163a Fic 12 Check Cabinet Grounding 19 Installation Install the Fabric Cover See FIGURE 13 1 Install a fabric cover XX over the front of the gun and slide it back to cover the exposed tubing and hoses at the back of the mani
57. not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately 333013B 5 Warnings 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 e See Technical Data in this and all other equipment instruction manuals Read fluid and solvent manufacturers MSDSs and recommendations TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e 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 PERSONAL PROTECTIVE EQUIPMENT Wear appropriate 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 eye wear and hearing protection e Re
58. nytime the enclosure is opened or entered e The ventilators to prevent operation of the power supply unless the ventilating fans are on 14 1 Connect the Graco Grounded Turbine Air Hose B to the gun s turbine air inlet TA and connect the hose ground wire A to a true earth ground N The gun turbine air inlet fitting has left hand threads to prevent connecting another type of air hose to the turbine air inlet See Accessories on page 57 for further information about the hose 2 Check the electrical grounding of the gun as instructed on page 19 Ground the Cabinet Connect the main ground wire V to a true earth ground 333013B Installation Manifold Connections 2 AD A1 EXH ti24373a Fig 5 Manifold Connection Atomization Air Inlet Fitting Connect a 5 16 in 8 mm OD tube between this fitting and the air supply Fan Air Inlet Fitting Connect a 5 16 in 8 mm OD tube between this fitting and the air supply CYL Cylinder Air Inlet Fitting Connect a 5 32 in 4 mm OD tube between this fitting and the solenoid For quicker response use the shortest hose length possible Fiber Optic Fitting Transmit Operational on Smart models only Connect the Graco Fiber Optic cable See page 17 Connect the Graco Fiber Optic cable see page 17 ka Fiber Optic Fitting Receive Operational on Smart models only Connect a 5 16 in OD exhaust tube to route the turbine exhaust air 3 ft
59. olating the fluid voltage from ground To eliminate air gaps in the fluid column spray enough fluid to purge the air out between the volt age 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 accumu lated overspray Excessive overspray can create a conductive path back to the grounded gun body Install a new gun cover and clean the exterior of the gun Inspect the entire system for any visible fluid leak age 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 e Internal voltage isolation system components 333013B 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 11 Flush the system with water and leave the lines filled with water Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure page 22 Follow the Pressure Relief Procedure on page 22 Disconnect the fluid hose from the voltage isolation system Avoid allowing any water to lea
60. oltage 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 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 air hose with this gun Do not use black or gray colored Graco air hoses Do not splice fluid hoses together Install only one continuous Graco Waterborne Fluid Hose between the isolated fluid supply and the spray gun 4 333013B Warnings FIRE AND EXPLOSION HAZARD Combustible dust in work area can ignite or explode To help prevent fire and explosion e Use only fluids that meet the following flammability requirements e Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures ASTM D4206 Materials which cannot be ignited in any mixture with air by an energy source of less than 500 mJ Stop operation immediately if static sparking occurs or you feel a shock Do not use eq
61. onal State and Local codes regarding air exhaust velocity requirements Air exhaust velocity of 100 ft min 31 linear meters min ute should be sufficient 11 Installation Install the Air Line Accessories Install the Fluid Line 1 Install a bleed type air valve L on the main air line Accessories W to shut off all air to the gun 1 Install a fluid filter and drain valve at the pump out let Filtering the fluid will help remove coarse parti cles and sediment that could clog the spray tip MPa bar PSI The fluid drain valve is required in your system to assist in relieving fluid pressure in the displacement pump hose and gun Triggering the gun to relieve pressure may not be sufficient Install a drain valve close to the pump s fluid outlet The drain valve reduces the risk of serious injury including splashing in the eyes or on the skin 2 Install an air line filter water separator 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 3 Install a bleed type air pressure regulator M on each of the air supply lines B C D E to control air pressure to the gun 4 Install a solenoid valve K on the cylinder air line E to actuate the gun The solenoid valve must have a quick exhaust port 5 Install a solenoid valve K to actuate the turbine
62. page 44 3 Measure resistance from the power supply s ground strips EE to the spring 7a See FIGURE 21 4 The resistance should be 90 115 megohms If out side this range replace the power supply If in range proceed to the next test 5 If you still have problems refer to Electrical Trou bleshooting page 37 for other possible causes of poor performance or contact your Graco distributor 6 Be sure the spring 7a is in place before reinstalling the power supply Fic 21 Test Power Supply Resistance Test Barrel Resistance 1 Insert a conductive rod B into the gun barrel removed for the power supply test and against the metal contact C in the front of the barrel 2 Measure the resistance between the conductive rod B and the conductive ring 33 See FIGURE 22 The resistance should be 10 30 megohms If the resistance is incorrect make sure the metal contact C in the barrel and the conductive ring 33 are clean and undamaged 29 Electrical Tests 3 Ifthe resistance is still outside the range remove the conductive ring 33 and measure the resistance between the conductive rod B and the wire lead at the bottom of the conductive ring groove 4 Ifthe resistance is in range replace the conductive ring 33 with a new one Insert the ends of the con ductive ring into the slots S at the front of the bar rel then press the ring firmly into the groove ti19901a The cond
63. pply spring 7a are in place Replace gas ket 9 if damaged Assemble the barrel 1 to the gun body 10 See Barrel Installation page 42 10 See Test Gun Resistance page 29 MEN Fic 39 Fan Orientation ti24411a FIG 38 Power Supply 44 333013B 6 Push the fan and coil assembly 8a out the front of the housing 8d ti19740b 8020 M 8a 89 810 do N d y gt PC 8N gd sbtes Fic 40 Turbine 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 10 Hold the coil assembly 8a on a workbench with the fan end facing up Using a wide blade screwdriver pry the fan 8e off the shaft S Remove the top bearing 8b2 Remove the bottom bearing 8b1 Install the new bottom bearing 8b1 on the long end of the shaft S The flatter side of the bearing ti19739b Fic 41 Turbine 333013B Repair must face away from the magnet M Install in th
64. r light is red standard Turbine speed is too high Decrease air pressure until indicator models only is green Pro Xp Auto Control Module displays See manual 332989 for Event Code event code smart models only Troubleshooting 333013B 37 Repair Repair Prepare the Gun for Service MA Installing and repairing this equipment requires access to parts that may cause electric shock or other serious injury if the work is not performed properly Do not install or service this equipment unless you are trained and qualified 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 MPa bar PSI To reduce the risk of injury follow the Pressure Relief Procedure before checking or servicing any part of the system and whenever you are instructed to relieve the pressure NOTE e Check all possible remedies in Troubleshooting 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 36 as specified in the text over lubricate e Only use genuine Graco parts Do not mix or use parts from other PRO Gun models e Air Se
65. ration 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 INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE 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 incidental 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 M
66. rt Bleed Type Master Air Valve Air Pressure Regulator True Earth Ground gs ZECPDA Main Air Line 13 Installation Install the Gun 1 Loosen the manifold s two set screws 29 and slide the manifold 20 onto a 1 2 in 13 mm mounting rod 2 Position the gun and tighten the two set screws NOTE For added positioning reliability insert a 1 8 in 3 mm locating pin into the slot NN in the bracket and through a hole in the rod See the detail in FIGURE 4 8 18 in 207 7 mm To gt nozzle tip FIG 4 Mounting Bracket Install the Pro Xp Auto Control Module The Pro Xp Auto Control Module is required for use with smart models To install a Pro Xp Auto Control Module see the module instruction manual 332989 Connect the Air Line FIGURE 3 shows a schematic of air line connections and FIGURE 5 shows the manifold connections Connect the airlines as instructed MA To reduce the risk of electric shock or other serious injury the red colored Graco Grounded Turbine Air Hose must be used for the turbine air supply hose and the hose ground wire must be connected to a true earth ground Do not use the black or gray colored Graco air hoses MA To reduce the risk of a fire explosion or electric shock the Graco Grounded Turbine Air Hose must be interlocked with e The isolation system to shut off the turbine air supply a
67. se Ko ES Indicator Light standard models only Turbine Air Inlet Fitting Exhaust Outlet Fitting C l 1 o Fiber Optic Fitting Receive Operational on Smart models only K i 10 333013B Installation System Requirements Basic Guidelines When spraying waterborne fluids electrostatically e The gun must be connected to a voltage isolation system which isolates the fluid supply from ground and allows voltage to be maintained at the tip of the gun e The gun must be connected to a voltage isolation system that will discharge the system voltage when the gun is not in use e There should be a bleed resistor to drain off the sys tem voltage when the spray gun is not in use e All components of the voltage isolation system that are charged to high voltage must be contained within an isolation enclosure that prevents person nel from making contact with the high voltage com ponents before the system voltage is discharged e The gun turbine air hose must be interlocked with the voltage isolation system to shut off the turbine air supply anytime the isolation system enclosure is opened or entered e The voltage isolation system must be interlocked with the spray area entrance to automatically dis charge the voltage and ground the fluid whenever someone opens the enclosure or enters the spray area e The system should not have any severe arcing occurring when the isolation mechanism opens and closes Severe arcin
68. sealing o ring To reduce the risk of fire explosion or electric shock e Do not remove the conductive ring except to replace it e Never operate the gun without the conductive ring In place e Do not replace the conductive ring with anything 24 ee but a genuine Graco part Fic 26 Remove Air Cap 5 Remove the fluid seat housing 4 using the 3 Disassemble the air cap assembly Check the con multi tool 48 dition of the u cup 24a o ring 25b and tip gasket 3a Replace any damaged parts 24a FIG 29 Seat Housing Replacement Fic 27 Disassemble Air Cap Assembly NOTICE To avoid damaging the seat housing and gun bar rel never overtighten the seat housing Overtight ening may affect the fluid shutoff 6 Install the fluid seat housing 4 Tighten until snug then 1 4 turn more ti19766a FIG 28 Tip Gasket l on 7 Check that the spray tip gasket 3a is in place 4 To replace the electrode 25a see Electrode Align the spray tip tab with the groove in the air cap Replacement page 40 25 Install the spray tip 3 in the air cap 8 Make sure that the electrode 25a is installed cor rectly in the air cap 9 Check that the air cap o ring 25b is in place 10 Check that the u cup 24a is in place on the retain ing ring 24 The lips of the u cup must face for ward 333013B 39 Repair NOTICE To avoid damaging the tip guard orient the air cap tip guard asse
69. spirators 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 in all equipment manuals Read fluid and solvent manufacturers 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 intended 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 applic
70. stomer PEEK Tungsten Carbide Polyethylene Loctite is a registered trademark of the Loctite Corporation 333013B 61 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 gun body 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 general 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 ope
71. tern holding the gun 12 in 305 mm from the surface Examine the particle size Do not be concerned about the presence of tails they will be removed in step 6 4 Increase the fluid pressure in small increments Spray another pattern and compare the particle size Smaller particle size indicates improved atomi zation f 1 h Het MPa bar PSI li To reduce the risk of injury never exceed the maximum working pressure on the lowest rated system component Maximum working pressure of this equipment is 3000 psi 21 MPa 210 bar 23 Operation 5 Continue to increase the fluid pressure and spray test patterns Do not exceed 3000 psi 21 MPa 210 bar fluid pressure When the particle size remains constant the fluid is being atomized at the lowest possible fluid pressure For improved atomization at lower fluid flow rates change to a smaller tip orifice size 6 Turn on the atomization air A1 and adjust the air pressure until the tails disappear See Spray Pattern Troubleshooting on page 34 to correct spray pattern problems 7 The pattern width can also be reduced by applying fan air pressure A2 Correct Too Little Air Amount of Air No Air FIG 16 Eliminating Tails Adjust the Electrostatics 1 Shut off the fluid supply 2 Prepare the isolation system for high voltage opera tion 3 Turn on the turbine air TA and adjust the air pres sure per the settings in T
72. the barrel connector 600a 4 Secure hose in strain relief bracket by tightening the four plastic screws Strain Relief Bracket Fic 6 Connect the Waterborne Fluid Hose 16 5 Connect the other end of the fluid hose to the iso lated fluid supply as follows a Graco WB3000 Enclosure Slide the other end of the hose through the hole in the side of the isolated enclosure Connect the swivel Z to the fluid outlet of the pump Secure the hose to the side of the enclosure with the bracket W b Non Graco Isolated Enclosure Connect hose as instructed in the isolation system manual 6 Reinstall the shroud 26 spray tip 3 and air cap 25 7 Check the gun s electrical grounding see page 19 tizO0010a Fic 7 Unshielded Hose 24W599 Connection at WB3000 Enclosure 333013B Fiber Optic Cable Connection Operational on Smart models only NOTE Only use the supplied fiber optic cable The fiber optic cable allows the gun to communicate with the Pro Xp Auto control module For a 1 Gun System 1 Connect Port 1 of the gun 1 manifold to Port 1 of the Control Module 2 Connect Port 2 of the gun 1 manifold to Port 2 of the Control Module Non Hazardous Area Port 2 MM IM Key for FIGURE 9 H PRO Xp Auto Waterborne AA Spray Gun P 24 Volt Power Supply Connection Q Remote I O Connection R Remote Control Module U Bulkhead V Fiber Optic Cable Fic 9
73. the floor with cardboard or any non conductive material which would interrupt grounding continuity e Flammable liquids in the spray area must be kept in approved grounded containers Do not use plastic containers Do not store more than the quantity needed for one shift 333013B All electrically conductive objects or devices in the spray area including fluid containers and wash cans must be properly grounded 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 conduc tive and grounded 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 Check Electrical Grounding A V A Megohmmeter Part No 241079 AA see FIGURE 11 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 war
74. trical Troubleshooting page 37 to correct voltage problems 333013B Spraying MA To reduce the risk of electric shock do not touch the gun electrode or come within 4 in 10 cm of the nozzle during gun operation 1 Apply a minimum of 60 psi 4 2 bar 0 42 MPa air pressure to the cylinder air fitting CYL to activate the on off sequence of atomization air A1 fan air A2 and fluid P1 See FIGURE 2 2 Turn the gun functions on and off by using the air solenoid valves on the cylinder CYL and turbine TA air supply lines 3 For smart gun models to change to a lower voltage setting see the Remote Control Module manual 332989 A If any fluid leakage from the gun is detected stop spraying immediately Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage See Check for Fluid Leakage page 28 333013B Operation Triggering the Fluid Alone Shut off and relieve the air pressure to the atomiza tion A1 and fan A2 air lines using the bleed type air shutoff valves 2 Apply 60 psi 4 2 bar 0 42 MPa air pressure to the cylinder air fitting CYL to trigger the fluid Shutdown 1 MPa bar PSI Follow the Fluid Voltage Discharge and Ground ing Procedure page 22 Follow the Pressure Relief Procedure page 22 Flush and clean the equipment See M
75. trode 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 333013B ti24288a 17 Clean Front of Gun Dampen a soft cloth with solvent and wring out the excess Wipe the exterior of the gun and shroud clean See FIGURE 18 18 Clean Gun Body Clean the retaining ring 24 air cap tip guard assembly 25 and spray tip 3 with a soft brush daily minimum Replace any damaged parts Be careful not to damage the electrode 25a 27 Maintenance NOTICE Do not use metal tools to clean the air cap tip guard or spray tip holes as this could scratch them and make sure the electrode is not dam aged Scratches in the air cap or spray tip or a damaged electrode can distort the spray pattern 7 Wipe off the parts with a dry cloth Be careful not to damage the electrode Mw A To reduce the risk of fire explosion or electric shock never operate the gun with a damaged electrode 8 Check the electrode 25a Replace if damaged 9 Check the condition of the spray tip gasket and install the spray tip in the aircap page 23 10 Install the spray tip and air cap tip guard shroud and retaining ring page 23 Be sure the electrode 25a is in place 11 Test Gun Resistance page 29 28 Check for Fluid Leakage ANA If any fluid leakage from the gun is detected
76. uctive ring 33 is a conductive metal con tact ring not a sealing o ring To reduce the risk of fire explosion or electric shock e Do not remove the conductive ring except to replace it e Never operate the gun without the conductive ring In place e Do not replace the conductive ring with anything but a genuine Graco part 5 Ifthe resistance is still outside the range replace the gun barrel ti24290a Fic 22 Test Gun Barrel Resistance 30 Test 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 ti2165a Fic 23 Test Electrode Resistance Test Cylinder Resistance Remove the enclosure door Using an ohmmeter mea sure 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 Tee ff all 209 MN CAL th il 2 re a ja Z a ti25108a Fic 24 Test Cylinder Resistance 333013B Troubleshooting MA 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
77. uipment until you identify and correct the problem Electrostatic equipment must be used only by trained qualified personnel who understand the requirements of this manual Ground all equipment personnel object being sprayed and conductive objects in or close to spray area Resistance must not exceed 1 megohm See Grounding instructions Do not use pail liners unless they are conductive and grounded 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 plastic 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 SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Do
78. wer supply and gun body and electrical continuity between components See Power Supply Removal and Replacement page 43 Use megohmmeter Part No 241079 AA and an applied voltage of 500 V Connect the leads as shown ANA Megohmmeter Part No 241079 AA see FIGURE 20 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 e The gun has been removed from the hazardous area e 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 Test Gun Resistance 1 Flush and dry the fluid passage 2 Measure the resistance between the electrode 25a and the turbine air fitting The resistance should be 104 150 megohms If outside this range go to Test Power Supply Resistance page 29 If in range see Voltage Loss Troubleshooting page 31 for other possible causes of poor performance or con tact your Graco distributor AA ti24403a Fic 20 Test Gun Resistance 333013B Electrical Tests Test Power Supply Resistance 1 Remove the power supply 7 page 43 2 Remove the turbine 8 from the power supply
79. 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 333013 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2014 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revision B December 2014

Graco 333013B User's Manual

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