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Graco 333012B User's Manual

1. ws 8b2 M 8a8g efe E SN P VIUA LL Hl 3 Y QI SS d E NW UM ut dup Pc 8h d 8b19 s Fic 39 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 must face away from the magnet M Install in the ti19739b Fic 40 Turbine 333012B Repair 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 38 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 as shown in Fig 45
2. 0 0000 ee aee 43 Packing Rod Repair 000 e eee eee 44 PISLOMIACDAN 1t ubi RILEPRVEPIGC ERIS eI 45 Adjust the Actuator Arm 000000 e cues 46 Barrel Removal 00000 e eee eee eee 46 Barrel Installation 0 0 00 cece eee 47 Power Supply Removal and Replacement 47 Turbine Removal and Replacement 48 PAWS 12120228 EI Xue Ruerkerue nA nEn aR EE 50 Standard Pro Xp Auto Waterborne Air Spray Gun Models 50 Smart Pro Xp Auto Waterborne Air Spray Gun Model 52 Packing Rod Assembly 0 000 ee eae 54 Turbine Assembly 0 00 cc eee eee eee 55 Air Caps and Fluid Nozzles 56 Fluid Nozzle Selection Chart 56 Fluid Nozzle Performance Charts 56 Air Cap Selection Chart LL 58 Isolation Enclosure 00000 cee eee 59 Tubing and Wiring 000 eee eee 62 Agitator Ki 245995 ccs lg ss ie Stes Se ee ee 64 Fluid Regulator Kit 245944 65 Shielded Waterborne Fluid Hose 24W597 65 ACCOSSOFLIBS 22 12 ads dibus heen eed Hae ewes 66 DIMENSIONS x ed obit eee to pe eR E EEUU ae EREE 67 Rear Inlet Manifold 0 0 0 00 0000s 67 Technical Data LL 68 NOICS 32 PDC rE 69 Graco Pro Xp Warranty eee 70 333012B List of Approved Models List of Approved Models Standa
3. 67 Technical Data Technical Data Pro Xp Auto Waterborne Air Spray Gun ULLUS Mee Gun Weight Approximate 2 6 Ib 1 2 kg Voltage Output Standard Models Smart Models Noise dBa 60 kV 30 60 kV Sound Power measured per ISO Standard at 40 psi 90 4 dB A 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 1 4 npsm m 5 16 in OD nylon tube 8 mm 1 4 18 npsmim Materials of Construction Wetted Parts Stainless Steel Nylon Acetal Ultra High Molecular Weight Poly ethylene Fluoroelastomer PEEK Tungsten Carbide Polyethylene Loctite is a registered trademark of the Loctite Corporation o 8 333012B Notes Notes 333012B 69 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
4. ti24371a Fic 3 Typical Installation Key to FIGURE 3 A Air Hose Ground Wire Graco Grounded Turbine Air Hose TA Atomizing Air Hose 5 16 in 8 mm OD A1 Fan Air Hose 5 16 in 8 mm OD A2 Cylinder Air Hose 5 32 in 4 mm OD CYL Q m UU O W Graco Waterborne Fluid Supply Hose 333012B Isolation System WB100 Voltage The turbine air must also be interlocked with the voltage isolation system to shut off the turbine air when the access to the isolation system is opened Solenoid Valve requires quick exhaust port Bleed Type Master Air Valve Air Pressure Regulator True Earth Ground zz ETC XT 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 See FIGURE 4 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 cy 4 qp ge NN 2 88 in 29 73 2 mm Oo Oo 20 To oo nozzle tip 203 2 mm Fic 4 Mounting 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 Conne
5. 8 Connect the other end of the fluid hose to the fluid outlet of the isolated fluid supply See FIGURE 10 BA 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 outer hose jacket J The portion of the inner hose layer T not covered by the outer jacket must be inside the voltage isolation system enclosure E The conductive hose layer C must be grounded through its connection to the isolation system s grounded enclosure E 17 Installation 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 For a 2 Gun System 1 Connect Port 1 of the gun 2 manifold to Port 5 of the ti22401a Control Module 2 Connect Port 2 of the gun 2 manifold to Port 6 of the Sec t e MANNY Per PUE CONNECHONS Control Module Non Hazardous Area Hazardous Area H lt Port 2 Port 5 Port 6 E B S E mm Bh H Gun 1 Key for FIGURE 12 V H PRO Xp Auto Waterborne Air Spray Gun P 24 Volt Power Supply Connection Q Remote I O Connection U R P
6. Strain Relief Bracket Fic 7 Connect the Waterborne Fluid Hose 333012B AA For Shielded Hose Systems Conductive hose layer C must be grounded through its connection to the isolation system s grounded enclosure L or grounded fence To maintain ground ing continuity the conductive hose layer C must be engaged in the ferrule when the strain relief nut is tightened Failure to properly install the hose in the strain relief could result in an electric shock 5 Connect the other end of the hose to the isolated fluid supply as follows a Graco WB100 Enclosure Slide hose through the strain relief fitting W Ensure conductive layer C has passed through fitting Tighten to 55 in Ib 6 2 Nem Pull back on hose to check it is secure Comply with the requirements in the following Warning 14 50 in 368 mm B 0 75 in 19 mm ti19887a Fic 8 Shielded Hose Dimensions at WB100 Enclosure ti1897a Fic 9 Shielded Hose Connection at WB100 Enclosure 333012B Installation b Non Graco Isolated Enclosure Connect hose as instructed in the isolation system manual w H ti24383a Fic 10 Shielded Fluid Hose Connection at Non Graco Isolation Enclosure c Connect the end of the tube T to the pump fluid outlet fitting 6 Reinstall the shroud 26 and air cap 25 7 Check the gun s electrical grounding see page 20
7. 24X005 Fiber Optic Cable 100 ft 30 5 m 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 Fiber Optic Cable Repair Kit 24W875 Parts necessary to replace damaged ends on one cable assembly Test Equipment Part No Description 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 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 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 sup ply when being serviced See manual 309455 Also requires 24R038 Conversion Kit 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 100 ft 30 5 m Bleed Type Master Air V
8. ti24377a Fic 27 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 cover 26 and air cap 25 41 Repair Air Cap Nozzle Replacement Prepare gun for service page 41 Remove the retaining ring 24 and air cap 25 See FIGURE 28 Remove the fluid nozzle 4 assembly with the multi tool 44 ti22390a Fic 28 Air Cap Nozzle Replacement 42 PA The nozzle contact ring 4a is a conductive contact ring not a sealing o ring To reduce the risk of sparking or electric shock do not remove the nozzle contact ring 4a except to replace it and never operate the gun without the contact ring in place Do not replace the contact ring with anything but a genuine Graco part NOTE Use non silicone grease Part No 111265 on the small o ring 4b Do not over lubricate Do not lubri cate the contact ring 4a 4 Make sure the conductive contact ring 4a and the small o ring 4b are in place on the nozzle 4 Lightly lubricate the small o ring 4b NOTE Make sure the electrode needle 3 is finger tight page 43 5 Install the fluid nozzle 4 with the multi tool 44
9. 507 Part No 110078 113070 113576 236281 C20350 114158 purchase locally 333012B ti2149a Description Qty FITTING tube fluid 1 4 npt m x 3 8 in 1 10 mm tube NIPPLE reducer 3 8 npt x 1 4 npt 1 PLUG 1 4 npt 1 REGULATOR fluid see manual 308325 1 ELBOW 90 1 4 npt f x 1 4 in 6 mm 1 OD tube FITTING adapter Y 1 4 in 6 mm OD 1 tube m xf xf TUBE nylon 1 4 in 6 mm OD 4 ft 1 1 22 m Tubing and Wiring Shielded Waterborne Fluid Hose 24W597 ti24816a Ref N 600 24W597 24W598 600a 537107 600b 16N953 600c 102982 600d 16N916 Part No O 600 Description HOSE assy fluid WB 25 ft 7 6m HOSE assy fluid WB 50 ft 15 2 m HOSE PTFE 1 4 ID FITTING connector barrel WB PACKING o ring FITTING seal fluid WB Qty h ee I Ill 65 Accessories Accessories Smart Model Accessories and Fiber Optic Cables Fluid Line Accessories Shielded Waterborne Fluid Hose Part No Description Part No Description 24W035 Pro Xp Auto Control Module See 332989 24W597 25 ft 7 6 m for details 24W598 50 ft 15 2 m Fiber Optic Cables for Gun System Accessories See item V in FIGURE 12 on page 18 Connect gun man ifold to Pro Xp Auto Control Module See 332989 Part No Description Part No Description 24X003 Fiber Optic Cable 25 ft 7 6 m 24X004 Fiber Optic Cable 50 ft 15 m
10. 7 Install the gun onto the manifold See page 14 8 disconnect the 3 wire ribbon connector PC from the power supply 19 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 lest Power Supply Resistance page 32 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 ti24408a 3 wire ribbon cable PC upward and back so the bend faces the power supply and the connector is at Fic 35 Barrel Installation Pet 7 Connect the 3 wire ribbon connector PC to the power supply Smart models only connect the 6 pin flexible cir cuit 30 to the power supply 333012B 47 Repair FIG 10 FIG 48 Tuck the ribbon forward under the power supply Slide the turbine 8 down onto the power supply 7 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 6 pin flexible circuit 30 with the socket CS at the top of the gun body See FIGURE 36 Push the connector securely into the socket as you slide the power supply turbine assembly into the gun body CS 30 36 Connect Flexible Circuit Make sure th
11. 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 HOLDER tie SCREW button hd 10 24 x 1 5 in 38 mm SCREW button hd 10 32 x 1 0 in 25 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 KR LL a Og N oO O N 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 1 1 1 1 2 1 FITTING tube 1 8 npt x 5 32 in 4 mm 1 OD tube 333012B ie Part No Description Qty 282 SWIVEL tube 1 4 npt x 1 4 in 6mm 4 OD tube 283 SWIVEL tube 1 8 npt x 5 32 in 4mm 2 OD tube 285 112791 CLAMP 286 TUBE 3 8 in 10 mm OD A R 300 235070 HOSE air grounded 0 315 in 8 mm 1 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 301 LA1M18 GUN see Smart Pro Xp Auto Water 1 borne Air Spray Gun Model page 52 A Replacement Danger and Warning labels tags and cards are available at no cost Th
12. Decrease air pressure as low as pos sible Orange Peel finish Atomizing air pressure too low Increase air pressure use lowest air pressure necessary Poorly mixed or filtered fluid Hemix or refilter fluid Fluid too thick Reduce viscosity Fluid leaks from the fluid packing Worn packings or rod Replace see page 43 area Air leaks from the air cap Worn piston stem o rings Replace see page 45 Fluid leakage from the front of the Worn or damaged packing rod Replace see page 44 gun Worn fluid seat Heplace fluid nozzle 4 and or elec trode needle 3 See page 42 Piston not actuating Check cylinder air Check piston o ring 11d see page 45 Actuator arm is out of position Check actuator arm and nuts See page 46 Dirty air cap Misaligned air cap and fluid nozzle Clean fluid buildup off air cap and fluid nozzle seat see page 29 Damaged nozzle orifice Replace nozzle 4 see page 42 Fluid is coming on before the air Check actuator arm and nuts See page 46 Air leaks from manifold Manifold is not tight Tighten manifold screws Fluid leaks at the quick disconnect Manifold is not tight Tighten manifold screws Fluid hose o rings are worn or miss Inspect or replace o rings ing Hose not seated properly Make sure the hose was stripped and installed correctly See Connect the Waterborne Fluid Hose page 16 38 333012B Troubleshooting Electrical Troubleshooting Probl
13. Tighten until the fluid nozzle seats in the gun barrel 1 8 to 1 4 turn past hand tight 6 Assemble the shroud 7 Carefully install the air cap 25 Be sure to insert the electrode 3 through the center hole of the air cap Rotate the air cap to the desired position 8 Make sure the u cup 24a is in place on the retain ing ring 24 The lips must face forward Tighten the retaining ring until the air cap is held firmly in place you should not be able to rotate the air cap horns by hand 9 Test gun resistance page 31 10 Install the gun onto the manifold and bracket 333012B Electrode Replacement 1 Prepare the gun for service page 41 2 Remove the air cap and nozzle page 42 3 Unscrew the electrode 3 with the multi tool 44 FIGURE 29 NOTICE To avoid damaging the plastic threads be very careful when installing the electrode 4 Apply low strength purple or equivalent thread sealant to the electrode and packing rod threads Install the electrode finger tight Do not over tighten 5 Install the fluid nozzle page 42 6 Test gun resistance page 31 7 Install the air cap page 42 8 Install the gun onto the manifold and bracket Fic 29 Electrode Replacement 333012B Repair Fluid Packing Removal NOTE You may replace the packing rod as an assem bly as described below or as individual parts see page 44 The assembly is pre adjusted at the factory 1 Prepare the g
14. 16 actuator arm 15 and adjustment nut 16 See FIGURE 33 NOTE The fluid nozzle 4 must be in place when removing or installing the jam nut and actuator arm 4 Remove piston cap 13 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 32 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 9 Install and adjust the actuator arm page 46 333012B Repair A 11b ti24192a Atomizing Air Side ti24131a FIG 32 Piston O Rings Table 3 Piston O Rings ae eae Shaft O Ring Seals cylinder air along the piston rod 11g 34b Replace if air leaks along rod Front O Ring Air shutoff seal Replace if air leaks from 11e air cap when gun is de triggered Back O Ring Separates cylinder air from fan and atom 11f 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 45 Repair Adjust the Actuator Arm NOTE The fluid nozzle 4 must be in place when removing or installing the jam nut and actuator arm See FIGURE 33 1 Install the adjustment nut 16b actuato
15. Be sure the coil alignment pins P are positioned as shown in Fig 44 Rotate the fan 86 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 89 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 49 Parts Parts Standard Pro Xp Auto Waterborne Air Spray Gun Models LA1T18 Waterborne Rear Manifold 24 A Torque to 20 in Ibs 2 Nem e eo Ah NL Q RN 2 J 20 x 27 39 ti24379a 50 333012B LA1T18 Waterborne Rear Manifold by Part No 1 24W873 2 24N655 3 24N652 4 24N616 4a 24N645 4b 111507 5 185111 6 197624 7 24N662 7a 24N979 8 24N664 8g 110073 Om 24N699 10 24W381 11 24W396 11a 17B704 11b 111504 11c 112319 11d 111508 12 112640 13 24W397 14 513505 15 24W398 16 100166 18M 111450 19 24N740 20 24W392 21 24W399 23 24WA4 1 24 24N644 24aM 198307 333012B Description BODY gun assy includes 9 Qty 1 See Packing Rod Assembly page 54 NEEDLE electrode WB NOZZLE fluid includes 4a and 4b O RING conductive O RING fluoroelastomer SPRING compression SPR
16. Length in No 273 239 243 226 272 272 251 286 mm 34 864 n a n a n a 16 407 12 305 n a 102 Description green yellow 10 gauge wire from external ground lug to cart green yellow 25 ft 7 6 m ground wire with clamp from external ground lug to true earth ground green yellow 10 gauge wire from external ground lug to ground probe red wire from bleed resistor to pump red 14 gauge wire from pump to pail cover with clamp red 14 gauge wire from pump 209 to ground on cylinder bracket green yellow 10 gauge wire from meter to internal box ground lug 3 8 OD tube bulkhead to manifold 63 Tubing and Wiring Agitator Kit 245895 To keep fluid mixed and prevent settling out Includes items 401 408 64 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 m xf xf 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 333012B Fluid Regulator Kit 245944 To allow precise fluid pressure regulation at the gun Includes items 501 507 Ref No 501 502 503 504 505 506
17. 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 24 3 Follow the Pressure Relief Procedure page 24 4 Remove and clean the air cap 5 Change the fluid source to non flammable solvent 6 Trigger the gun to flush the fluid passages clean 333012B 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 down when cleaning it Do not use any cleaning method which could allow fluid into the gun air passages 1 Follow the Fluid Voltage Discharge and Ground ing Procedure page 24 2 Flush the gun See Flushing page 28 3 Follow the Pressure Relief Procedure page 24 4 Clean the outside of the gun with a compatible sol vent Use a soft cloth Wring out excess fluid from cloth Point the gun down to prevent solvent from entering the gun passages Do not immerse the gun Clean the Air Cap and Fluid Nozzle Equipment Needed e soft bristle brush e compatible solvent
18. Procedure 1 Follow the Fluid Voltage Discharge and Ground ing Procedure page 24 2 Flush the gun See Flushing page 28 333012B Operation Remove the air cap assembly 24 25 and shroud 26 See FIGURE 19 Wipe the fluid nozzle 4 shroud 26 and exterior of the gun clean with a cloth dampened in solvent Avoid getting any solvent into the air passages Whenever possible point the gun down when cleaning it If it appears that there is paint inside the fluid nozzle 4 air passages remove the gun from the line for servicing See Air Cap Nozzle Replacement page 42 to remove the fluid nozzle for cleaning or replacement Clean the air cap 25 with the soft bristle brush and solvent or submerge the air cap in suitable solvent and wipe it clean Do not use metal tools Slide the shroud 26 onto the gun Carefully install the air cap 25 Be sure to insert the electrode 3 through the center hole of the air cap Rotate the air cap to the desired position Make sure the u cup 24a is in place on the retain ing ring 1 The lips must face forward Tighten the retaining ring until the air cap is held firmly in place you should not be able to rotate the air cap horns by hand Test gun resistance page 31 ti22388a Fic 19 Clean Air Cap and Fluid Nozzle 29 Operation Check for Fluid Leakage Clean the Cabinet e Inspect the cabinet and clean up any spilled paint W A N Conductive paint res
19. SUPPLY 60 kV WB SPRING See Turbine Assembly page 55 O RING packing GASKET barrel BODY assy Auto XP WB Smart Rear includes 10 19 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 Auto XP includes 21 23 27 28 29 36 SCREW modified 1 4 20 XP Auto FITTING Adapter M12 TO 1 4 LH XP RING retainer assy includes 24a PACKING u cup UHMWPE AIR CAP machining black COVER shroud Auto XP WB FITTING connector male FITTING connector 1 4npt M 5 16T SCREW set CIRCUIT flexible BRACKET strain relief WB tube Qty IK 0O N e pO NO a NO Oo LL n NO Ref No 32 34 35 36 37 38 39 40 43A 44 45 80 600 600a 16N953 Parts Part No Description Qty CLAMP strain relief SM WB 1 GC2248 SCREW SHDC SS 250x 50 3 24X482 FASTENER retainer pack of 4 1 117560 SCREW set socket head 1 070303 GREASE lubricant 1 070311 SEALANT anaerobic 1 070321 GREASE lubricant 1 116553 GREASE dielectric 1 oz 30 ml 1 tube not shown TAG warning not shown MULTI TOOL shipped loose TOOL wrench ball end CONTROL MODULE Pro Xp Auto not shown See 332989 See Shielded Waterborne Fluid Hose 24W597 page
20. and are included with the WB 100 333012B 9 Introduction Gun Overview Fic 2 Gun Overview Key Bo Fluid Nozzle Retaining Ring D fea Manifold Alternator H Power Supply Electrode G Waterborne Fluid Hose 10 ti24370a Manifold Fittings and Indicators Atomization Air Inlet Fitting Fan Air Inlet Fitting Cylinder Air Inlet Fitting i Fiber Optic Fitting Transmit Operational on Smart models only Fiber Optic Fitting Receive Operational on Smart models only ES Indicator Light standard models only 2 Turbine Air Inlet Fitting to drive turbine Exhaust Outlet Fitting 333012B 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 th
21. door and fasten securely with the T handle locking screw The T handle must be fully engaged to activate the enclosure safety interlock switch to allow high volt age operation Select a Fluid Nozzle and Air To reduce the risk of an injury follow the Pressure Relief Procedure on page 24 before removing or installing a fluid nozzle and or air cap The gun is shipped with the fluid nozzle and air cap installed 333012B Operation Operating the Spray Function Applying a minimum of 60 psi 0 41 MPa 4 1 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 Adjust the Spray Pattern Follow the steps below to establish the correct fluid flow and air flow Do not turn on the turbine air TA yet A w To reduce the risk of fire and explosion only use this equipment with fluids that meet at least one of the following conditions for non flammability e Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures ASTM D4206 e Materials which cannot be ignited in any mixture with air by an energy source of less than 500 mJ BA Contact with the charged components of t
22. 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 30 Fluids used must meet the following flamma bility requirements FM FMc Approved Material does not sustain burning in accor dance with the Standard Test Method for Sus tained Burning of Liquid Mixtures ASTM D4206 CE EN 50059 Compliant Materials which cannot be ignited in any mix ture with air by an energy source of less than 500mJ 23 Operation Fluid Voltage Discharge and Grounding Procedure aA 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 Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol MPa bar PSI This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as splashing follow the Pressure
23. 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 operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation TH
24. off the fluid supply 2 Prepare the isolation system for high voltage opera tion See Fill the Fluid Supply page 25 3 Turm on the turbine air TA and adjust the air pres Horizontal Pattern sure per the settings in Table 1 Set the proper Fic 18 Air Cap Positions pressure at the turbine air hose inlet when air is flowing 5 Adjust the fluid flow with the fluid pressure regulator Refer to the Fluid Nozzle Performance Charts on Table 1 Approximate Dynamic Turbine Air page 56 to set the fluid pressure for various fluid Pressures flows according to the size of the fluid nozzle being Turbine Air Air pressure at turbine air hose inlet used Hose Length for full voltage amp UST ft m psi bar MPa Usethe air pressure regulator on the atomization air supply line A1 to adjust the degree of atomization See FIGURE 5 For example for a fluid flow rate of 25 7 6 55 3 85 0 38 10 ounces per minute 0 3 liters per minute a typi 36 11 56 3 9 0 39 cal atomization pressure would be 20 30 psi 1 4 2 1 bar 0 14 0 21 MPa at the gun manifold 50 15 3 is 57 59 4 1 0 41 7 Use the air pressure regulator on the fan air supply 100 30 5 61 4 3 0 43 line A2 to adjust the pattern size 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 the following
25. see Tubing and Wiring page 62 Remove the waterborne fluid hose from the pump fluid outlet fitting 231 and remove the fitting Unscrew the two pump mounting screws S and remove the pump from the isolation enclosure Hemove the back of the control box 258 Hemove tube A2 from elbow 282 at the air mani fold see Tubing and Wiring page 62 Install the Y fitting 506 in the elbow Install tubes A2 and 507 into the Y fitting Route the tube 507 into the cabinet Heplace the back of the control box 258 Assemble the fluid regulator kit as shown Reinstall the pump in the isolation enclosure Use the two mounting holes to the left of the holes used previously to allow clearance for the fluid regulator Connect tube A1 to the air inlet of fluid regulator 504 Connect tube 507 to the pump air inlet Connect the waterborne fluid hose to the fluid regu lator outlet fitting 501 Return the system to service 19 Installation NOTE The cabinet air regulator and gauge 216 217 will now operate the air piloted fluid regulator 504 The pump will now operate at the inlet air pressure ti2149a Fic 14 245944 Fluid Regulator Kit Grounding AAD When operating the electrostatic gun any ungrounded objects in the spray area people containers tools etc can become electrically charged Improper grounding can result in static sparking which can caus
26. table Adjust the air pressure as necessary to keep the indicator light green or the values within 400 750 Hz 26 333012B NOTE Smart models display values standard models display 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 alternator 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 Electrical Troubleshooting on page 39 to correct voltage problems Spraying Operation PA 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 on page 30 AA 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 M
27. the front of the spray gun NOTE The Graco warranty and approvals are void if the electrostatic air spray gun is connected to a non Graco voltage isolation system or if the spray gun is operated above 60 kV 333012B Introduction System Overview Typical Waterborne System Installation FIGURE 1 shows a typical electrostatic waterborne air spray system It is not an actual system design For assistance in designing a system to suit your particular needs contact your Graco distributor I fr EN H LeO EY INE ct i C A E HE dj N Y Sce j Pa Hf Z T F H AA i ti1896c 252082 _ 1 FiG 1 Typical Installation Pro Xp Auto Waterborne System Item Description Item Description A Main Air Supply Line N Pneumatic connection to turbine air B Bleed Type Air Shutoff Valve interlock Pressurized when isolation C Pump Air Pressure Gauge system door is closed D Pump Air Pressure Regulator R Graco Waterborne Fluid Hose E kV Meter T Grounding Rod F Pump U Ground Terminal G Pump Suction Hose V Main Ground Wire H Paint Container W Strain Relief Ground Fitting J Bleed Resistor X Pump Air Supply Line K Enclosure Safety Interlock Y Grounding Cylinder L Isolated Enclosure Z Pump Fluid Outlet Fitting M Air Line Filter AA Isolated Enclosure Door BB Enclosure T Handle Locking Screw These items are required for safe operation
28. 65 See Shielded Waterborne Fluid Hose 24W597 page 65 A Replacement Warning labels signs tags and cards are available at no cost Included in WB Hose Mount Kit 24W878 pur chase separately B Included in air seal repair kit 24W390 purchase separately Included in Turbine Assembly 24N664 pur chase separately See Turbine Assembly page 55 179791 2 6 41 107460 24W035 ee ee eee 24W597 53 Parts Packing Rod Assembly Part No 24N655 Packing Rod Assembly Includes items 2a 2k ti18641a Hera Description No No P 2a 111316 O RING 2b 116905 SEAL 2c 178409 PACKING fluid 2d 178763 PACKING needle 2e 24N703 ROD packing includes items 2j and 2k 2f 197641 NUT packing 2g 185495 HOUSING packing 2h 186069 SPACER packing 54 Qty i i i Ref Part No No Description Qty 2j NUT trigger adjustment part of item 1 26 2k NUT trigger adjustment part of item 1 26 ti These parts are included in Fluid Seal Repair Kit 24W391 purchase separately ve These parts are included in Trigger Adjustment Nut Kit 24N700 purchase separately Parts labeled are not available separately 333012B Turbine Assembly Part No 24N664 Turbine Assembly efe ti19739b Ref Part No No 8a 24N705 COIL turbine abe 24N706 BEARING KIT includes two bear ings item 8e fan and one item 8h clip ade 24N707 HOUSING includes item 8f 8
29. Adjust the Spray Pattern 0 25 Adjust the Electrostatics llus 26 Sa VINO auod chee tee a Se a e iE 27 Triggering the Fluid Alone 0000 27 SIUEGOWEL Daas iescue d uoto didit te a bla Ei ene 27 Maintenance sese 28 Daily Care and Cleaning Checklist 28 FIUSNING recreo nd e esti ier eRe deere de plns 28 Clean Outside of Gun 00002 eees 29 Clean the Air Cap and Fluid Nozzle 29 Check for Fluid Leakage 0000 eee 30 Clean the Cabinet 0 0 0 0 00 cece 30 Electrical Tests 5 2 ki bI oh ose ees REA RU 31 2 Test Gun Resistance lunes 31 Test Power Supply Resistance 32 Test Electrode Resistance 32 Test Ground Strip Resistance 33 Test Cylinder Resistance 33 Troubleshooting 1v rms 34 Voltage Loss Troubleshooting 34 Spray Pattern Troubleshooting 37 Gun Operation Troubleshooting 38 Electrical Troubleshooting 39 Repa un 4RbsUDI iS ad ke eee wie des ae ES 41 Prepare the Gun for Service 05 41 Remove the Gun from the Manifold 41 Install the Gun on the Manifold 41 Air Cap Nozzle Replacement 42 Electrode Replacement Lsss 43 Fluid Packing Removal
30. Clean the fluid and air line filters Clean the outside of the gun See Clean Out side of Gun page 29 Clean the air cap and fluid nozzle daily mini mum Some applications require more fre quent cleaning Replace the fluid nozzle and air cap if they are damaged See Clean the Air Cap and Fluid Nozzle page 29 OU a Check the electrode and replace if broken or damaged See Electrode Replacement on page 43 a Check for fluid leakage from the gun and fluid hoses See Check for Fluid Leakage on page 30 Tighten fittings or replace equipment as needed Check Electrical Grounding page 20 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 28 Follow the Fluid Voltage Discharge and Grounding Procedure page 24 before flushing Only flush purge or clean the gun with fluids that meet at least one of 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 500myJ
31. 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 Cylinder Air Inlet Fitting CYL Connect a 5 32 in 4 mm OD tube between this fitting and the solenoid For quicker response use the short est hose length possible Fiber Optic Fitting Transmit Operational on Smart models only Connect the Graco Fiber Optic cable see page 20 Connect the Graco Fiber Optic cable see page 20 Exhaust Connect a 5 16 in OD exhaust tube to route the turbine exhaust air 3 ft max length B Fiber Optic Fitting Receive Operational on Smart models only Turbine Air Inlet Fitting TA 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 333012B 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 The waterborne fluid hose 600 consists of an inner PTFE tube T a conductive layer C and an abrasion resistant outer jacket J The conductive layer is connected to ground at the isolation enclosure Before connecting the waterborne fluid hose to t
32. ING compression POWER SUPPLY 60 kV WB SPRING See Turbine Assembly page 55 O RING packing GASKET barrel BODY Auto XP STD WB includes 18 19 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 Auto XP includes 21 23 27 28 29 36 SCREW modified 1 4 20 XP Auto FITTING Adapter M12 TO 1 4 LH XP RING retainer assy includes 24a PACKING u cup UHMWPE ee Ll Ll NP D 2 AO N NO Ref No 25 26 27 28 29 30 31 32 34 35 36 37 38 39 40 43A 44 45 600 600a 16N953 Part No 24N477 24W389 114263 115950 110465 102207 GC2248 24X482 117560 070303 070311 070321 116553 179791 2 6 41 107460 24W597 Description AIR CAP machining black COVER shroud Auto XP WB FITTING connector male FITTING connector 1 4npt M 5 16T SCREW set SCREW set SCH BRACKET strain relief WB tube CLAMP strain relief SM WB SCREW SHDC SS 250x 50 FASTENER retainer pack of 4 SCREW set socket head LUBRICANT grease SEALANT anaerobic LUBRICANT grease GREASE dielectric 1 oz 30 ml tube not shown TAG warning not shown MULTI TOOL shipped loose TOOL wrench
33. IS 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 MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties ack
34. Instructions Parts gt GRACO Pro Xp Auto Waterborne Air Spray Gun Automatic Electrostatic Air spray gun for use when electrostatically spraying conductive waterborne fluids that meet at least one of the following conditions for non flammability e Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures ASTM D4206 e 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 100 psi 0 7 MPa 7 bar Maximum Working Fluid Pressure Important Safety Instructions e Read all warnings and instructions in this manual Save these instructions See page 2 for Table of Contents and page 3 for List of Approved Models S S TZ ie ti22373a PROVEN QUALITY LEADING TECHNOLOGY Table of Contents List of Approved Models 3 Related Manuals LL 3 Warnilgs 2 55 sete eet GS Sate ede Sed ee da be oe 4 Introdu clon es Go ae eer eee eee 7 How the Electrostatic Air Spray Gun Works 7 Operating the Spray Function 7 Operating the Electrostatics 7 Gun Features and Options LL 7 Smart Gun Features eee eee 7 Spraying Waterborne Fluids Electrostatically 8 System Overview
35. N616 Black POr ANAA to excessive fluid viscosity coatings 1 2 047 5 055 3 From the marked point move across to the vertical scale to find the required fluid pressure If the 55 022 75 029 0 24N619 0 55 022 required pressure is too high use the next largest 24N620 0 75 029 nozzle size If the fluid pressure is too low 0 35 bar 3 5 kPa 5 psi use the next smallest nozzle 24N621 With hardened 1 0 042 size 24N622 seat for abra 1 2 047 24N623 sives and metal 1 5 055 Key to Fluid Nozzle Performance Charts i NOTE Fluid pressures are measured at the spray gun 24N625 2 0 079 inlet 260 Centipoise Fluid 160 Centipoise Fluid 70 Centipoise Fluid 20 Centipoise Fluid 56 333012B Table 4 Orifice Size 1 0 mm 0 040 in FLUID PRESSURE bar psi FLUID PRESSURE bar psi FLUID PRESSURE bar psi 333012B FLUID FLOW oz min cc min Air Caps and Fluid Nozzles Table 7 Orifice Size 1 8 mm 0 070 in FLUID PRESSURE bar psi FLUID PRESSURE bar psi FLUID FLOW oz min cc min 57 Air Caps and Fluid Nozzles Air Cap Selection Chart NOTE All air cap pattern shapes and lengths in the fol 25 lowing chart were measured under the following condi NA ow tions Pattern shape and length are material dependent To red
36. Pa air pressure to the cylinder air fitting CYL to activate the on off sequence of atomization air A1 fan air A2 and fluid P 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 To change to a smart model lower voltage setting see the Pro Xp Auto Control Module manual 333012B Triggering the Fluid Alone 1 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 MPa bar PSI 1 Follow the Fluid Voltage Discharge and Ground ing Procedure page 24 2 Follow the Pressure Relief Procedure page 24 3 Flush and clean the equipment See Maintenance on page 28 27 Operation Maintenance I Eus Fi 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 PA To reduce the risk of fire explosion or electric shock turn off the turbine air TA before flushing the gun Daily Care and Cleaning Checklist Check the following list daily upon completion of equip ment usage Flush the gun See Flushing page 28
37. Relief Procedure when you stop spraying and before cleaning checking or servicing the equipment 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 WB100 fully unscrew the door T handle lock ing screw This will shut off the air to the gun and trigger the grounding 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 on page 39 or the voltage isola tion system manual for other possible problems Resolve the problem before proceeding 24 Follow the Fluid Voltage Discharge and Ground ing Procedure on page 24 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 If an air pilot fluid regulator is used in the system air pressure is also needed a
38. alve 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 105749 Cleaning Brush 111265 Non silicone Lubricant 4 oz 113 g Part No Description 116553 Dielectric Grease 1 oz 30 ml 107141 3 4 npt 24V929 Gun Covers Air Line Shutoff Valve 150 psi 10 bar 1 0 MPa Maximum Working Pressure For turning air to gun on or off Conversion and Repair Kits 24N318 Round Spray Kit To convert a standard air spray gun to a round spray air cap See manual 3A2498 Part No Description 224754 1 4 npsm m x 1 4 npsm f left hand thread 66 24W390 Air Seal Repair Kit 24W391 Fluid Seal Repair Kit 24N706 Turbine Bearing Repair Kit 333012B Dimensions Rear Inlet Manifold 10 6 in 269 mm ____ p a 10 2 in 259 mm __y q 8in 2083m mm p 2 9 in 73 mm 0 53 in 13 5 mm eae 2x 1 4 20 UNC 333012B 6 3 in 160 mm Dimensions 2 6 in 66 mm __ 2 5 in 63 mm ti24373a
39. alve K on the cylinder air line E to actuate the gun The solenoid valve must have a quick exhaust port Install a solenoid valve K to actuate the turbine 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 Install the Optional Fluid Line Accessories 1 Install a fluid filter and drain valve at the pump out let 2 Install a fluid regulator on the fluid line to control fluid pressure to the gun 3 To reduce the risk of serious injury including splashing in the eyes or on the skin do not operate equipment without the fluid drain FD valve installed 333012B Installation FIGURE 3 shows a typical electrostatic air soray system It is not an actual system design For assistance in designing a system to suit your particular needs contact your Graco distributor NOTE The grounded turbine air hose TA must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on Pneumatic See Warnin L i Ing A Interlock above Air Line Pressurized when door is closed _ Manifold Back View Non Hazardous Area Hazardous Area G
40. ardous area are operating and there are no flammable vapors in the area such as open solvent containers or fumes from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage Graco Part No 241079 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 2 Make sure the red colored turbine air hose B is connected and the hose ground wire is connected to a true earth ground 3 Turn off the air and fluid supply to the gun Follow the Pressure Relief Procedure page 24 The fluid hose must not have any fluid in it 333012B Installation 4 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 ti22382a Fic 15 Check Gun Grounding 5 If using the WB100 use an ohmmeter AA to 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 16 Check Cabinet Grounding 21 Installation Install the Fabric C
41. ations 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 Mus Provide fresh air ventilation to reduce the risk of fire or explosion caused by the buildup of flammable or toxic vapors when spraying flushing or cleaning the gun Do not operate the gun unless ventilation fans are operating 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 National 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 See FIGURE 3 1 Install a bleed type master air valve L on the main air line W to shut off all air to the gun Install an air line filter water separator on the gun air line to ensure a dry clean air supply to the gun Dirt and moisture can ruin the appearance of your fin ished workpiece and can cause the gun to malfunc tion 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 Install a solenoid v
42. ball end Parts Qty WO a 0 PM PO 1 1 1 See Shielded Waterborne Fluid Hose 24W597 page 65 See Shielded Waterborne Fluid Hose 24W597 page 65 cards are available at no cost B Included in air seal repair kit 24W390 purchase separately Included in WB hose mount kit 24W878 purchase separately Included in Rear Manifold Repair Kit 24W392 purchase separately A Replacement Warning labels signs tags and Included in Turbine Assembly 24N664 pur chase separately See Turbine Assembly page 55 51 Parts Smart Pro Xp Auto Waterborne Air Spray Gun Model LA1M18 Waterborne Rear Manifold Torque to 20 in lbs 2 Nem 35 ti24382a 52 333012B LA1M18 Waterborne Rear Manifold by Part No 1 24W873 2 24N655 3 24N652 4 24N616 4a 24N645 4b 111507 5 185111 6 197624 7 24N662 7a 24N979 8 24N644 8gm 110073 9N 24N699 10 24W866 11 24W396 11a 17B704 11b 111504 11c 112319 11d 111508 12 112640 13 24W397 14 513505 15 24W398 16 100166 18m 111450 19 24N740 20 24W392 21 24W399 23 24WA4 1 24 24J234 24am 198307 25 24N477 26 24W389 27 114263 28 115950 29 110465 30 245265 31 333012B Description BODY gun assy includes 9 See Packing Rod Assembly page 54 NEEDLE electrode NOZZLE fluid includes 4a and 4b O RING conductive O RING fluoroelastomer SPRING compression SPRING compression POWER
43. bine alternator 8 from the power supply page 48 3 Measure resistance from the power supply s ground strips EE to the spring 7a See FIGURE 22 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 Refer to Electrical Troubleshooting on page 39 for other possible causes of poor performance 6 Be sure the spring 7a is in place before reinstalling the power supply Fic 22 Test Power Supply Resistance 32 Test Electrode Resistance Remove the electrode 3 See Electrode Replace ment page 43 Measure the resistance between the contact HH and the electrode wire GG The resis tance should be 8 30 megohms If out of range replace the electrode NOTE If the gun resistance is still out of range after testing the power supply and electrode e Check that the conductive o ring 4a is making con tact with the barrel pin e Check that the power supply spring 7a is making contact with the barrel pin Fic 24 Nozzle Conductive O Ring 333012B 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 25 Test Electrode Resistance 333012B Electrica
44. celeres 9 GUN OvervieW 2 26 ee ee sk b x REESE IE 10 Inistallatlon esI eI Re eiu Rs RR RES E EET 11 System Requirements 0000 scenes 11 Install the System 200 c eee eee 11 Warning SIGNS em eirkati 9 px ee bea 11 Ventilate the Spray Booth 0005 11 Install the Air Line Accessories 12 Install the Optional Fluid Line Accessories 12 install the GUN serres edo Re ee RE EP ERR 14 Install the Pro Xp Auto Control Module 14 Connect the Air Line llllsssnn 14 Ground the Cabinet 00000 00s 14 Manifold Connections llsnn 15 Connect the Waterborne Fluid Hose 16 Fiber Optic Cable Connection 18 Agitator Kit Accessory 0 00 eee 19 Fluid Regulator Kit Accessory 0005 19 Grounding 43er de dente a dex n act de ERE 20 Check Electrical Grounding 20 Install the Fabric Cover 000 0 eee 22 Check Fluid Viscosity 0000 c eee eens 22 Flush Before Using Equipment 22 sl rtupnameCRECTT we eae kee ae eee Se 23 Operating Checklist llle 23 Fluid Voltage Discharge and Grounding Procedure 24 Pressure Relief Procedure 24 Fil the Fluid Supply 000000005 24 Select a Fluid Nozzle and Air Cap 25 Operating the Spray Function 25
45. ct the Air Line FIGURE 3 shows a schematic of air line connections and FIGURE 5 shows the manifold connections Connect the air lines as instructed EN 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 AMA 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 anytime 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 66 for further information about the hose 2 Check the electrical grounding of the gun as instructed on page 20 Ground the Cabinet Connect the main ground wire V to a true earth ground 333012B Installation Manifold Connections EXH ti24373a Fic 5 Manifold Connections Atomization Air Inlet
46. ctric 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 Voltage Discharge and Grounding Procedure when instructed to discharge the voltage before cleaning flushing or servicing the system before approaching the front of the gun and before opening the isolation enclosure for the isolated fluid supply Do not enter a high voltage or hazardous area until all high voltage equipment has been discharged Do not touch the gun nozzle or electrode or come within 4 in 102 mm of the electrode during gun operation Follow the Fluid Voltage Discharge and Grounding Procedure Interlock the gun air supply 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 su
47. ds 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 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 air 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 Fluid Voltage Discharge and Grounding Procedure on page 24 before approaching
48. e FAN part of item 8b CAP housing part of item 8d Description 333012B Qty Parts _ 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 50 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 55 Air Caps and Fluid Nozzles Air Caps and Fluid Nozzles Fluid Nozzle Selection Chart Fluid Nozzle Performance Charts A D A om Use the following procedure to select the proper fluid nozzle for your application To reduce the risk of an injury follow the Pressure Relief Procedure on page 24 before removing or 1 Foreach fluid nozzle performance chart find the installing a fluid nozzle and or air cap point on the graph corresponding to your desired 2 The thick vertical line in each graph represents the flow rate and viscosity Mark the point on each graph with a pencil Fluid Nozzle Col D ipti Orifice Size Part No nd Vind mm in target flow rate for that nozzle size Find the graph 0 75 029 that has the marked point closest to the thick verti cal line This is the recommended nozzle size for your application Significantly exceeding the target 24N615 2 047 flow rate may result in lower spray performance due 5 1 24
49. e 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 20 e Graco Waterborne Fluid Hose the hose is grounded through the conductive layer Install the hose as instructed on page 16 e Voltage Isolation System electrically connect the voltage isolation system to a true earth ground 20 e Air compressors and hydraulic power supplies ground the equipment according to the manufac turer s recommendations e Allair and fluid lines must be properly grounded All electrical cables must be properly grounded 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 wor
50. e air hose 300 and gun 301 are not included with 233825 Isolation Enclosure They are shown for illustra tive purposes only The pail is shown for illustrative pur poses but is not included 333012B Air Caps and Fluid Nozzles 61 Tubing and Wiring Tubing and Wiring Detail Views of Control Box C9 A1 A2 C1 B4 C3 C4 a MO E m Ss i Se o Ii E C2 C9 Detail View of Door Interlock Switch NYG H E NN p B5 B2 Tubing and Wiring Chart 62 333012B Tubing and Wiring 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 Length in No 248 248 249 249 249 249 272 251 333012B mm 20 508 9 229 17 432 20 508 5 127 22 559 9 229 8 204 Description 1 4 OD tube regulator 216 to pump 1 4 OD tube regulator 216 to mani fold 5 32 OD tube manifold air to door interlock switch 5 32 OD tube valve tee to cylinder 5 32 OD tube regulator 216 to gauge 217 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 internal box ground lug to cylinder cap Code C2 C4 C5 C6 C7 C8 C9 E1 Ref
51. e gasket 9 ground spring 6 and power supply spring 7a are in place Replace gas ket 9 if damaged Assemble the barrel 1 to the body 10 See Barrel Installation page 42 See Test Gun Resistance page 31 ti24411a 37 Power Supply Turbine Removal and 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 37 through FIGURE 40 1 See Prepare the Gun for Service page 37 2 Remove the power supply turbine assembly and disconnect the turbine See Power Supply Removal and Replacement page 43 3 Measure resistance between the two outer termi nals of the 3 wire connector PC it should be 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 ti19741b Fic 38 Fan Orientation 333012B 6 Push the fan and coil assembly 8a out the front of the housing 8d
52. e properly trained to safely operate an automatic electrostatic water borne air spray system as instructed in this manual All operators are trained in the Fluid Voltage Discharge and Grounding Procedure on page 24 All operators are trained in the Pressure Relief Procedure on page 24 The electrostatics are turned off and system voltage is discharged according to the Fluid Voltage Discharge and Grounding Proce dure page 24 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 20 The Graco Waterborne Fluid Hose is in good condition with no cuts or abrasions of the PTFE layer Replace hose if damaged The condition of the gun s electrical compo nents has been checked as instructed in Elec trical Tests on page 31 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 L E E Operation All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded All flammable
53. e 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 arcing 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 66 for available hoses The hose consists of an inner PTFE tube a conductive layer covering the PTFE tube and an outer cover 333012B Installation If a hose failure occurs where high voltage arcs through the inner tube voltage will be discharged to ground through the conductive hose layer When properly installed the conductive hose layer is grounded through its connection to the grounded enclosure Install the System PA 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 regul
54. electrical continuity between components See Power Supply Removal and Replacement page 47 Use megohmmeter Part No 241079 AA and an applied voltage of 500 V Connect the leads as shown PA Megohmmeter Part No 241079 AA see FIGURE 21 is not approved for use in a hazardous area To reduce the risk of sparking do not use the Megohmmeter to check electrical grounding unless 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 333012B Electrical Tests Test Gun Resistance 1 Flush and dry the fluid passage 2 Trigger the gun and measure resistance between the electrode needle tip 3 and the turbine air fitting The resistance should be 90 120 megohms If out side this range go to Test Power Supply Resis tance page 32 If in range and there are other performance concerns see Voltage Loss Trouble shooting page 34 for other possible causes of poor performance AA ti22389a TA Fic 21 Test Gun Resistance 31 Electrical Tests Test Power Supply Resistance 1 Remove the power supply 7 page 47 2 Remove the tur
55. em Cause Voltage still present at gun after fol Turbine air is not turned off Turn off lowing the Fluid Voltage Discharge and Grounding Procedure page 24 Did not wait long enough for voltage Wait longer before touching elec to discharge trode with grounded rod Check for bleed resistor failure Air pocket in fluid line leaves fluid Determine cause and correct Purge near gun isolated air from fluid line Voltage isolation system failed Service voltage isolation system Poor wrap Turbine air is not turned on Turn on Booth exhaust velocity is too high Reduce velocity to within code limits less Clean workpiece hangers Faulty gun resistance See Test Gun Resistance on page 31 Fluid leaks from the packing 2d and Clean the packing rod cavity or causes a short replace the packing rod See page page 44 Faulty turbine alternator See Turbine Removal and Replacement page 48 No power Check power supply alternator and alternator ribbon cable See Power Supply Removal and Replace ment page 47 Spilled paint dried paint or other contaminants inside the WB100 Enclosure causing a short circuit Check power supply alternator and alternator ribbon cable See Power Supply Removal and Replace ment page 47 Grounding cylinder not retracted Check operation of grounding cylin der 333012B 39 Troubleshooting ES indicator light is not lit standard No power Check power s
56. emoval and See FIGURE 35 Replacement 1 Verify the gasket 9 and grounding spring 6 arein Inspect the gun body power supply cavity for dirt or place and the gasket air holes are aligned properly moisture Clean with a clean dry rag Replace the gasket if damaged e Do not expose gasket 9 to solvents 2 Make sure the spring is in place on the tip of the 1 See Prepare the Gun for Service page 37 power supply 7 Liberally apply dielectric grease to the tip of the power supply Place the barrel 1 over 2 See Barrel Removal page 42 the power supply and onto the gun body 10 NOTICE 3 Tighten the two barrel screws 19 oppositely and evenly about a half turn past snug or 20 in Ibs Do Be careful when handling the power supply 7 to not over tighten avoid damaging it NOTICE 3 Grasp the power supply 7 with your hand With a To avoid damaging the gun barrel do not over tighten gentle side to side motion free the power sup the screws 19 ply turbine assembly from the gun body 10 then carefully pull it straight out 4 Install and adjust the actuator arm 15 jam nut 16 and adjustment nut 16 See page 46 Smart models only disconnect the flexible circuit 30 from the socket at the top of the gun body 5 Test gun resistance page 31 4 Inspect the power supply and turbine for damage 6 Install the gun shroud 26 and air cap page 42 5 To separate the power supply 7 from the turbine
57. ernal leak e Internal voltage isolation system components 35 Troubleshooting 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 Flush the system with water and leave the lines filled with water Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure on page 24 Follow the Pressure Relief Procedure on page 24 Disconnect the fluid hose from the voltage isolation system Avoid allowing any water to leak out of the fluid hose as that could cause a significant air gap in the fluid column up to the gun electrode which can break the conductivity path and conceal a potential failure area Position the end of the hose as far as possible away from any grounded surface The end of the hose must be at least 1 ft 0 3 m from any ground Make sure that no one is within 3 ft 0 9 m of the end of the hose Turn the 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 Ifthe 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 Fl
58. ged by the spray gun electrode The charged fluid is attracted to the nearest grounded object wrap ping around and evenly coating all surfaces 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 e Gun functions are activated from a separate control ler that sends the appropriate signal to the actuating solenoids 333012B Introduction Smart Gun Features omart 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 BA To reduce the risk of electric shock do not use the optional Pro Xp Auto Control Module readings to determine if your system is discharged The display modules will only display the system voltage while the gun s power supply is operating Follow the Fluid Voltage Discharge and Grounding Procedure on page 24 to ensure the system is discharged See the Pro Xp Auto Control Module manual 332989 for more information Introduction Spraying Waterborne Flui
59. he gun blow it out with air and flush with water to remove con taminants Flush the gun before using it See Flushing page 28 BA 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 and shroud 26 NOTICE Be careful not to cut into the inner tube T of the hose when stripping the hose Nicks or cuts in the PTFE tube will cause premature hose failure 2 For the waterborne fluid hose to fit properly it must be stripped and assembled to the dimensions shown in FIGURE 6 Apply dielectric grease to the inner tube T of the hose Slide the fitting F onto the tub T Press the barbed fitting G into the tube until its shoulder bottoms on the tube A new Graco 16 Waterborne Fluid Hose comes fully assembled to these dimensions 5 75 in 146 mm B 1 5 in 38 mm Fic 6 Waterborne Hose Dimensions 3 Generously apply dielectric grease 40 to the o ring 603 and the threads of the fitting 602 Pull the fit ting back 1 1 2 in 88 mm and apply grease to the exposed PTFE hose to fill the area between the hose and the fitting Make sure the barrel inlet is clean and dry then screw the fitting into the fluid inlet of the gun barrel 1 4 Secure hose in strain relief bracket on the gun by tightening the four plastic screws
60. he 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 To reduce the risk of component rupture which can cause serious injury do not exceed the maximum working pressure of the lowest rated system component This equipment has a 100 psi 0 7 MPa 7 bar maximum working air and fluid pressure 1 Follow the Fluid Voltage Discharge and Ground ing Procedure page 24 2 Follow the Pressure Relief Procedure page 24 25 Operation 3 Select and install the appropriate air cap for your NOTE application e For the most efficiency always use the lowest air NOTE To select a different size fluid nozzle or air cap pressure possible see Parts on page 50 To install the fluid nozzle and air e When increasing to a wide flat pattern it may be cap see Air Cap Nozzle Replacement on page 42 necessary to increase the supply of fluid to the gun to maintain the same amount of coverage over a 4 Loosen the air cap retaining ring and rotate the air large area cap for a vertical or horizontal spray pattern See e See Spray Pattern Troubleshooting on page 37 to FIGURE 18 Tighten the retaining ring until the air cap correct spray pattern problems is held firmly in place you should not be able to rotate the air cap horns by hand Adjust the Electrostatics 1 Shut
61. hose connection to the spray gun e A breakdown at the fluid hose connection joint would be caused by fluid leaking past the o ring seals on the end of the hose Hemove the hose at the gun connection and look for signs of fluid leakage along the PTFE tube Before reassembling the gun clean and dry the gun fluid inlet tube Repack the inner spacer of the fluid packing rod with dielectric grease and reassemble the gun Reconnect the fluid hose Check the gun voltage with the voltage probe and meter before filling the gun with fluid 333012B Troubleshooting Spray Pattern Troubleshooting NOTE Check all possible remedies in the Troubleshooting Chart before disassembling the gun NOTE Some spray pattern problems are caused by the improper balance between air and fluid LN Seton Fluttering or spitting spray No fluid Refill supply Loose dirty damaged nozzle seat Clean or replace nozzle page 42 Air in fluid supply Check fluid source Refill Improper spray pattern Damaged nozzle or air cap Replace page 42 e Fluid buildup on air cap or nozzle Clean See page 29 Fan air pressure too high Decrease Fluid too thin too thin Increase Increase viscosity ee pressure too low M Fan air pressure too low Increase Streaks Did not apply 5096 overlap 333012B 37 Troubleshooting Gun Operation Troubleshooting pom OO REN NE Excessive spray fog Atomizing air pressure too high
62. idue allowed to contact grounded parts may short out the electrostatics 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 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 9 cone free grease to the threads when necessary _ e Visually inspect the ground strip 240 for damage To reduce the risk of an injury follow the Pressure Replace if needed Measure the resistance weekly Relief Procedure on page 24 when you stop See Test Ground Strip Resistance page 33 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 20 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 ti24181a ZZ Fic 20 Check for Fluid Leakage 30 333012B Electrical Tests Use the following procedures to test the condition of the power supply and gun body and
63. kpiece 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 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 e All electrically conductive objects or devices in the Spray area including fluid containers and wash cans must be properly grounded e 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 e All solvent pails use only approved grounded metal containers which are conductive Do not use plastic containers Use only non flammable solvents Do not store more than the quantity needed for one shift Check Electrical Grounding 333012B PA Megohmmeter Part No 241079 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 Or all spraying devices in the hazardous area are turned off ventilation fans in the haz
64. l Tests 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 227 209 T TIN k S Ean Ut it 240 GS ti25108a Fic 26 Test Cylinder Resistance 33 Troubleshooting Troubleshooting AA Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly Do not install or repair this equipment unless you are trained and qualified Follow the Fluid Voltage Discharge and Grounding Procedure on page 24 before checking or servicing the system and whenever you are instructed to discharge the voltage MPa bar PSI To reduce the risk of an injury follow the Pressure Relief Procedure 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 si
65. n 24N453 Round end 14 16 n to medium 20 70 Up to 15 oz min 450 Better Better Good black 356 406 cc min Centipoise centistokes x fluid d gravity 58 333012B Air Caps and Fluid Nozzles Isolation Enclosure Part No 233825 Waterborne Isolation Enclosure for use with shielded waterborne fluid hose 282 280 283 271 i 270 253 216 M ct l 283 v a 267 d s S ii 281 t9 228 M 253 268 P4 x 262 pur 257 i 257 oN l EN 220 278 d 26777 e 205 B out d uu c 242 Ps d e 222 262 FC b 235 226 PP 227 ti24385a 333012B 59 Air Caps and Fluid Nozzles Ref No 201 201a 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 221 222 223 224 225 226 227 228 229 230 231 232 Part No 15A947 116993 15A660 15A551 15A545 15A524 113061 241005 104029 116989 111804 113060 116473 185547 15B932 198663 190863 101390 154636 185548 190410 116988 15A518 104267 114456 116315 235A 15A682 236 237 238 239 60 116316 218798 114958 222011 Description CABINET enclosure includes 201a DOOR cabinet CASTER brake PLATE T HANDLE latch STEM handle door HOUSING latch SWITCH push air TUBE 1 2 in 13 mm OD polyethylene PUMP diaphragm SST see 309303 SCREW hex hd cap 5 16 18 x 5 5 in 140 mm WASHER plain 0 344 in ID NUT l
66. nce all of the system components are electrically connected through the conductive waterborne fluid 34 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 alternator turbine e Faulty power supply e Excessive over spray on gun surfaces e Fluid in the air passages Waterborne Fluid Hose e Dielectric failure of the hose pin hole leak in the PTFE layer e Air gap in the fluid column between the gun and the isolated fluid supply causing a low voltage reading on the isolation system voltage meter Voltage Isolation System e Fluid leakage e Dirty interior e Dielectric breakdown of hoses seals or connec tions e solators not functioning properly 333012B 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 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 operati
67. nowledge 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 la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 333012 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 Hevision B December 2014
68. ock 5 16 18 COVER pail LUG ground VALVE air REGULATOR air GAUGE air 1 8 npt BALL VALVE 1 4 npt f FERRULE housing for 24N580 24P629 and 233825 FERRULE housing for 24P630 24P631 and 246511 FERRULE for 24N580 24P629 and 233825 FERRULE for 24P630 24P631 and 246511 WASHER lock internal tooth WASHER plain 0 625 in ID NUT RESISTOR bleed CYLINDER ROD HOUSING cylinder rod REGULATOR air BUSHING plastic 3 4 x 1 2 npt ELBOW tube 3 8 npt x 3 8 in 10 mm OD tube ELBOW tube 3 8 npt x 1 2 in 13 mm OD tube LABEL warning FITTING tube 1 2 npt x 1 2 in 13 mm OD tube STRAINER 16 mesh SST STRAP tie GROUND WIRE 25 ft 7 6 m Qty N Daaa na nha aa Ai non a M PN ONS Ref No 240 241 242 243 244 245 246 247 248 249 251 252 253 256 257 258 259 260 261 262 263 264 265 266 267 268 270 271 272 273 274 275 276 278 279 280 281 Part No Description 234018 110209 114051 210084 162449 101874 116990 113983 237933 113336 116991 203953 155541 114261 15A780 117314 113319 STHIP grounding aluminum NUT regulator WASHER shim latch 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 16 16 1 A R 1 WIRE 10 gauge green with yellow stripe 1
69. on 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 333012B 10 11 Troubleshooting Make sure the voltage isolation system is in the iso late mode where it is isolating the fluid voltage from ground To eliminate air gaps in the fluid column spray enough fluid to purge the air out between the 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 over spray Excessive over spray 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 int
70. on the packing nut must face the back of the fluid rod The seal o ring must face away from the packing nut Fill the inner cavity of the spacer 2ht with dielec tric grease 43 Place the spacer on the fluid rod 26 in the direction shown Generously apply dielectric grease to the outside of the spacer Place the fluid packing 2ct on the packing rod 26 with its lips facing the front of the rod Install the needle packing 2dt with the male end toward the fluid packing then install the housing 29 2k 2j ti19450a FiG 31 Packing Rod 44 Lightly tighten the packing nut 2f The packing nut is properly tightened when there is 3 Ib 13 3N of drag force when sliding the packing housing 29 assembly along the rod Tighten or loosen the pack ing nut as needed Install the o ring 2at on the outside of housing 2g Lubricate the o ring with non silicone grease Part No 111265 Do not over lubricate Install the spring 5 against the nut 2j as shown Install the packing rod assembly 2 into the gun barrel Using the multi tool 44 tighten the assem bly until just snug Install the electrode See Electrode Replacement page 39 Install the nozzle and air cap See Air Cap and Noz zle Replacement page 38 See Test Gun Resistance page 31 333012B Piston Repair 1 Prepare the gun for service page 41 2 Remove the air cap page 42 Remove the gun shroud 26 3 Remove the jam nut
71. or for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations 6 333012B Introduction How the Electrostatic Air Spray Gun Works The automatic electrostatic air spray gun operates very similar to a traditional air soray gun The atomization and fan air are emitted from the air cap The atomization air breaks up the fluid stream and controls the droplet size The fan air controls the shape and width of the spray pattern The fan and atomization air can be adjusted independently 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 char
72. over See FIGURE 17 1 Install a fabric cover XX over the front of the gun and slide it back to cover the exposed tubing and hoses at the back of the manifold 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 30 Strap down the exhaust tube to prevent it from moving around YY ti24376a ti24182a Fic 17 Fabric Cover 22 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 28 333012B Operation Operating Checklist Check the following list daily before starting to operate the system to help ensure you of safe efficient operation LI Li PF LJ LF U u u U 333012B All operators ar
73. pply and the spray gun 4 333012B Warnings FIRE AND EXPLOSION HAZARD Combustible dust in work area can ignite or explode To help prevent fire and explosion 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 equipment 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 a
74. r arm 15 and jam nut 16a onto the piston rod 11b Position the parts so there is a 0 125 in 8 mm gap between the actuator arm 15 and the fluid packing rod nut E This allows the atomizing air to actuate before the fluid Tighten the adjustment nut 16b against the actua tor arm 15 Check that the 0 125 in 8 mm gap has been maintained In addition there should be 3 mm of electrode needle travel when the gun is trig gered Adjust the jam nut position to obtain these dimensions Tighten the jam nut 16a Test gun resistance page 31 Install the gun shroud 26 and air cap 25 page 42 Install the gun onto the manifold See page 41 lt 0 125 in 3 mm gap ME ti24170a 16a 15 16b ib E FiG 33 Actuator Arm Adjustment 46 Barrel Removal 1 E Prepare the gun for service page 41 Remove the air cap page 42 Remove the gun shroud 26 Hemove the adjustment nuts 16a 16b and actua tor arm 15 See FiGURE 33 Loosen the two screws 19 See FIGURE 34 NOTICE To avoid damaging the power supply pull the gun bar rel 1 straight away from the gun body 10 If neces sary gently move the gun barrel from side to side to free it from the gun body 5 Hold the gun body 10 with one hand and pull the barrel 1 straight off the body See FIGURE 34 ti24378a Fic 34 Barrel Removal 333012B Repair Barrel Installation Power Supply R
75. rc 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 2 PRESSURIZED EQUIPMENT HAZARD Fluid from the equipment leaks or ruptured components can splash in the eyes or on skin and cause serious injury Follow the Pressure Relief Procedure when you stop spraying dispensing and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately PLASTIC PARTS CLEANING SOLVENT HAZARD Many solvents can degrade plastic parts and cause them to fail which could cause serious injury or property damage e Use only compatible water based solvents to clean plastic structural or pressure containing parts See Technical Data in this and all other equipment instruction manuals Read fluid and solvent manufacturer s MSDSs and recommendations 333012B 5 Warnings 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 eq
76. rd Smart Bottom Rear kV Model Model Manifold Manifold LAIMI8 60 Y v Vv A1T18 60 v V j YM Description 24X287 WB 100 Isolation Enclosure 25 Shielded Waterborne Fluid Hose 50 Shielded 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 0 35 J with 50 ft hose max Models Compliant with EN 50059 when used with fluids that meet the EM14ATEX0082 following criteria EN 50059 l l a l 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 Related Manuals Manual No Description 332989 Instructions Pro Xp Auto Control Module 333012B 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 ele
77. re 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 44 as specified in the text e Lightly lubricate o rings and seals with non silicone grease Order Part No 111265 Lubricant Do not over lubricate e Only use genuine Graco parts Do not mix or use parts from other PRO Gun models e Air Seal Repair Kit 24W390 is available The kit must be purchased separately Kit parts are marked with an asterisk for example 6a e Fluid Seal Repair Kit 24W391 is available The kit must be purchased separately Kit parts are marked with a symbol for example 2af 333012B Repair Remove the Gun from the Manifold 1 f Follow the Fluid Voltage Discharge and Ground ing Procedure page 24 Flush and clean the gun page 28 Follow the Pressure Relief Procedure page 24 Remove the air cap 25 and shroud 26 page 42 Loosen the fluid hose strain relief bracket Disconnect the fluid hose fitting 602 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
78. ro Xp Auto Control Module NMU mm U Bulkhead optional SS rmm V Fiber Optic Cable Gun 2 FiG 12 Fiber Optic Schematic 18 333012B Agitator Kit Accessory To add an agitator to the Graco isolation system order Part No 245895 See Agitator Kit 245895 page 64 for the kit parts list P Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure page 24 Helieve the pressure see Pressure Relief Proce dure page 24 Open the isolated enclosure door Remove the back of the control box 258 Remove tube A2 from elbow 282 at the air mani fold see Tubing and Wiring page 62 Install the Y fitting 402 into the elbow Install tubes A2 and 407 into the Y fitting Route the agitator tube 407 into the cabinet Replace the back of the control box 258 Assemble the other parts of the kit as shown Secure the agitator with the setscrew 408 Return the system to service ti2137a FiG 13 245895 Agitator Kit 333012B Installation Fluid Regulator Kit Accessory To add a fluid regulator to the Graco isolation system order Part No 245944 See Fluid Regulator Kit 245944 page 65 for the kit parts list 1 Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure page 24 Helieve the pressure see Pressure Relief Proce dure page 24 Open the isolated enclosure door Remove the 1 4 in 6 mm OD tube A1 from the pump air inlet
79. t the regulator air inlet 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 closed until you are ready to spray again 333012B Fill the Fluid Supply I C vis rates Eus Fi MPa bar PSI Follow the Fluid Voltage Discharge and Ground ing Procedure page 24 2 Follow the Pressure Relief Procedure page 24 3 Open the isolated enclosure door 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
80. uce the risk of an injury follow the Pressure Relief Procedure before removing or installing a fluid nozzle and or air cap e Distance to target 10 in 254 mm e Inlet air pressure 50 psi 34 kPa 3 4 bar e Fan air adjusted for maximum width e Fluid flow rate 10 oz min 300 cc min Pattern Length Recommended Fluid Recommended Transfer Atomiza Cleanli Shape in mm Viscosity in centi Production Rates Efficiency tion ness poise cp at 70 F 21 C 24N438 Round end 15 17 Light to medium 20 70 Up to 15 oz min 450 Better Illi coe black 381 432 cp cc min 24N279 Round end 14 16 Medium to heavy Up to 15 oz min 450 Better m m black 356 406 70 260 cp and high cc min solids 360 cp 24N376 Tapered 17 19 Light to medium 20 70 Up to 15 oz min 450 Best Better Better black end 432 483 cc min 24N276 blue 24N277 red 24N278 green 24N274 Tapered 12 14 Light to medium 20 70 Up to 15 oz min 450 Good Good Best black end 305 356 cp cc min 24N275 Tapered 14 16 Light to medium 20 70 Up to 25 oz min 750 Best Good Best black end 356 406 cp and high solids cc min 360 cp aerospace coatings Tapered 11 13 For use with 2 0 mm Up to 20 oz min 600 Good Best Better end 279 330 nozzles Medium to cc min heavy 70 260 cp and high solids 860 cp 24N477 Round end 15 17 A to medium 20 70 Up to 15 oz min 450 Better Best Good black 381 432 cc mi
81. uipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This protective equipment includes but is not limited to e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipment only for its intended purpose Call your distribut
82. un for service page 41 2 Remove the air cap page 42 Remove the gun shroud 26 3 Remove the jam nut 16 and actuator arm 15 and adjustment nut 16 See FiGURE 33 NOTE The fluid nozzle 4 must be in place when removing or installing the jam nut and actuator arm Remove the fluid nozzle 4 and electrode 3 See page 43 5 Remove the packing rod 2 using the multi tool 44 NOTICE Clean all parts in non conductive solvent compatible with the fluid being used such as xylol or mineral spirits Use of conductive solvents can cause the gun to malfunction 6 Check all parts for wear or damage and replace if necessary NOTE Before installing the packing rod clean the inter nal surface of the barrel 1 with a soft cloth or brush Check for marks from high voltage arcing If marks are present replace the barrel ti24132a Fic 30 Fluid Packing Removal 43 Repair Packing Rod Repair NOTE You may replace the packing rod as individual parts as described below or as an assembly see page 43 The assembly is pre adjusted at the factory NOTE Before installing the fluid packing rod into the gun barrel make sure the internal surfaces of the barrel are clean Remove any residue with a soft brush or cloth Check the inside of the barrel for marks from high voltage arcing If marks are present replace the barrel 1 Place the packing nut 2f and seal 2b1 on the fluid rod 2e Flats
83. upply turbine turbine models only ribbon cable See Power Supply Removal and Replacement page 47 and Turbine Removal and Replacement page 48 ES indicator light is amber standard Turbine speed is too low Increase air pressure until indicator is models only green ES indicator light is red standard Turbine speed is too high Decrease air pressure until indicator models only is green No voltage or low voltage reading on Damaged fiber optic cable or con Check replace damaged parts See the smart gun Pro Xp Auto Control nection the Pro Xp Auto Control Module Module manual 332989 Poor wrap See causes and solutions under Poor Wrap above Pro Xp Auto Control Module displays See manual 332989 for Event Code event code smart models only Troubleshooting 40 333012B Repair Prepare the Gun for Service BA 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 To reduce the risk of injury follow the Pressu
84. ush the fluid hose and gun with enough air to dry out the fluid passages 10 Turn the turbine air to the gun on Measure the volt 11 36 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 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 31 to check the gun and power supply resistance If those tests show the gun and power supply are okay continue with step 12 12 13 14 15 A 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 PTFE portion of the fluid tube e Inspect the end of the hose connected to the voltage isolation system Look for cuts or nicks e Make sure the hose is properly stripped see Connect the Waterborne Fluid Hose page 16 Restrip or replace the hose b Fluid packings e Remove the packing assembly from the gun see Fluid Packing Rod Removal page 56 and look for signs of fluid leakage or any blackened areas which would indicate arc ing is occurring along the packing rod c Fluid

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