Graco 333011B User Manual

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Page 1

Instructions-Parts

333011B

Pro Xp Auto AA Spray Gun

For use in Class I, Div. I Hazardous Locations using Group D spray materials.

Automatic Electrostatic Gun for use in Group II, Zone 1 explosive atmosphere locations using Group IIA spray materials.

For professional use only.

100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Press 100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 2 for Table of Contents and page 3 for List of Models.

WLD

Page 2

Table of Contents

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2

List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

How the Electrostatic AA Spray Gun Works . . . . 6

Operating the Spray Function . . . . . . . . . . . . . . . 6

Operating the Electrostatics . . . . . . . . . . . . . . . . 6

Gun Features and Options . . . . . . . . . . . . . . . . . 6

Smart Gun Features . . . . . . . . . . . . . . . . . . . . . . 6

System Overview . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical System Installation . . . . . . . . . . . . . . . . . 7

Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 9

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 9

Install the Air Line Accessories . . . . . . . . . . . . . . 9

Install Fluid Line Accessories . . . . . . . . . . . . . . . 9

Install the Gun . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Install the Pro Xp Auto Control Module . . . . . . . 11

Connect the Air and Fluid Lines . . . . . . . . . . . . 11

Manifold Connections . . . . . . . . . . . . . . . . . . . . 12

Fiber Optic Cable Connection . . . . . . . . . . . . . . 13

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Check Electrical Grounding . . . . . . . . . . . . . . . 14

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 15

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 15

Install the Fabric Cover . . . . . . . . . . . . . . . . . . . 15

Flush Before Using Equipment . . . . . . . . . . . . . 15

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pressure Relief Procedure . . . . . . . . . . . . . . . . 16

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Select a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . 16

Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . 17

Set the Atomization Fluid Pressure . . . . . . . . . . 17

Adjust the Electrostatics . . . . . . . . . . . . . . . . . . 18

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Triggering the Fluid Alone . . . . . . . . . . . . . . . . . 18

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Daily Care and Cleaning Checklist . . . . . . . . . . 19

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Clean Outside of Gun . . . . . . . . . . . . . . . . . . . . 19

Clean the Spray Gun . . . . . . . . . . . . . . . . . . . . 20

Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 21

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 22

Test Power Supply Resistance . . . . . . . . . . . . . 22

Test Barrel Resistance . . . . . . . . . . . . . . . . . . . 23

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Spray Pattern Troubleshooting . . . . . . . . . . . . . 24

Gun Operation Troubleshooting . . . . . . . . . . . . 25

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 27

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Prepare the Gun for Service . . . . . . . . . . . . . . . 28

Remove the Gun from the Manifold . . . . . . . . . . 28

Install the Gun on the Manifold . . . . . . . . . . . . . 29

Air Cap/Tip Guard, Spray Tip, and Fluid Seat

Housing Replacement . . . . . . . . . . . . . . . . . 29

Electrode Replacement . . . . . . . . . . . . . . . . . . . 30

Fluid Tube Replacement . . . . . . . . . . . . . . . . . . 30

Fluid Filter Removal . . . . . . . . . . . . . . . . . . . . . . 31

Fluid Needle Replacement . . . . . . . . . . . . . . . . 31

Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . . 32

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 33

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 33

Power Supply Removal and Replacement . . . . 33

Turbine Removal and Replacement . . . . . . . . . 34

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Standard Pro Xp Auto AA Gun Models . . . . . . . 36

Smart Pro Xp Auto AA Gun Models . . . . . . . . . 38

Air Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . 40

Turbine Assembly . . . . . . . . . . . . . . . . . . . . . . . 41

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . 45

AEM Fine Finish Spray Tips . . . . . . . . . . . . . . . 45

AEF Fine Finish Pre-Orifice Spray Tips . . . . . . . 46

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Graco Pro Xp Warranty . . . . . . . . . . . . . . . . . . . . . 48

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Page 3

List of Models

Standard

Part No. kV

HA1M10 85

HA1T10 85

HA2M10 85

HA2T10 85

Model

Approvals

Smart Model

✔✔

Bottom

Manifold

0.24 mJ FM14ATEX0081 EN 50050-1 Ta 0°C-50°C

Rear

Manifold

Related Manuals

Manual No. Description

332989 Instructions - Pro Xp Auto Control Module

333011B 3

Page 4

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-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.

WARNING

WARNINGWARNINGWARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion and electric shock:

• 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.

• Only use grounded Graco conductive air supply hoses.

• Do not use pail liners unless they are conductive and grounded.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Check gun resistance, hose resistance, and electrical grounding daily.

• Use and clean equipment only in well ventilated area.

• Interlock the gun air supply to prevent operation unless ventilating fans are on.

• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment.

• To clean the exterior of the equipment, cleaning solvents must have a flash point at least 5°C above ambient temperature.

• Always turn the electrostatics off when flushing, cleaning or servicing equipment.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Keep spray area free of debris, including solvent, rags and gasoline.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

4 333011B

Page 5

Warnings

WARNING

WARNINGWARNINGWARNING

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.

• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.

•See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent manufacturer’s MSDSs and recommendations.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eye wear, and hearing protection.

• 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 distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

333011B 5

Page 6

Introduction

How the Electrostatic AA Spray Gun Works

This is not an air spray gun. To help prevent serious injury from pressurized fluid, such as skin injection, and splashing fluid, read and follow the Skin Injection Hazard Warnings on page 4.

The electrostatic air-assisted spray gun combines airless and air spraying concepts. The spray tip shapes the fluid into a fan pattern, as does a conventional airless spray tip. Air from the air cap further atomizes the fluid and completes the atomization of the fluid tails to produce a uniform pattern.

The high working fluid pressure of this gun provides the power needed to atomize higher solid materials.

Operating the Spray Function

Applying a minimum of 60 psi (0.42 MPa, 4.2 bar) air pressure to the gun manifold’s cylinder air fitting (CYL) will retract the gun piston, which opens the air valves and a short time later opens the fluid needle. This provides the proper air lead and lag when triggering the gun. A spring returns the piston when the cylinder air is shut off.

Gun Features and Options

• The gun's full voltage setting is 85kV.

• 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.

• The gun’s quick-disconnect design enables its removal without disconnecting air lines to the gun.

• Gun functions are activated from a separate controller that sends the appropriate signal to the actuating solenoids.

Smart Gun Features

Smart gun models with the Pro Xp Auto Control Module have the ability to:

• Display the spraying voltage and current

• Change the gun voltage setting

• Display the gun turbine speed

• Store spray profiles

• Communicate equipment faults to a PLC

• Display and set maintenance totalizers

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 charged by the spray gun electrode. The charged fluid is attracted to the nearest grounded object, wrapping around and evenly coating all surfaces.

6 333011B

• Use a PLC to select a spray profile

See the Pro Xp Auto Control Module manual 332989 for more information.

Page 7

System Overview

Typical System Installation

IGURE

1 shows a typical electrostatic 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.

Introduction

Non-Hazardous Area

Hazardous Area

FIG. 1 Typical System Installation

AGun

B Graco Grounded Turbine Air Hose

C Atomizer, Fan, and Cylinder Air

D Air Supply and controls

E Fluid Supply and controls

* Approved for hazardous locations

333011B 7

Smart System Components

F Programmable Logic Controller (PLC)

G Pro Xp Auto Control Module

H Power Supply (24 Volt)

J Bulkhead (optional)

K F/O Cable

L I/O Cable

Page 8

Introduction

Gun Overview

EXH

CYL

FIG. 2 Gun Overview

Key

AAir Cap

B Spray Tip

C Retaining Ring

D Shroud

FManifold

G Turbine

H Power Supply

J Electrode

8 333011B

Manifold Fittings and Indicators

A1 Atomization Air Inlet Fitting

A2 Fan Air Inlet Fitting

CYL Cylinder Air Inlet Fitting

K ES Indicator Light (standard models only)

P Fluid Supply Inlet Fitting

TA Turbine Air Inlet Fitting (to drive turbine)

EXH Exhaust Outlet Fitting

Fiber Optic Fitting Transmit (Operational on Smart models only)

Fiber Optic Fitting Receive (Operational on Smart models only)

Page 9

Installation

Install the System

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.

• Do not install or service this equipment unless you are trained and qualified.

• Be sure your installation complies with local, state, and national codes for the installation of electrical apparatus in a Class I, Div. I, hazardous location or a Group II, Zone I explosive atmosphere location.

• Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

Warning Signs

Mount warning signs in the spray area where they can easily be seen and read by all operators. An English Warning Sign is provided with the gun.

Ventilate the Spray Booth

Install the Air Line Accessories

See F

IGURE

1. Install a bleed-type master air valve (L) on the main air line (W) to shut off all air to the gun.

2. Install an air line filter/water separator on the gun air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

3. Install a bleed-type air pressure regulator (M) on each of the air supply lines (B, C, D, E) to control air

pressure to the gun.

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.

4. Install a solenoid valve (K) on the cylinder air line (E) to actuate the gun. The solenoid valve must have a quick exhaust port.

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 ventilating fans operating. Check and follow all local, state, and national codes regarding air exhaust velocity requirements.

NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufficient.

5. Install a solenoid valve (K) to actuate the turbine.

Install Fluid Line Accessories

1. Install a fluid filter and drain valve at the pump outlet. Filtering the fluid will help remove coarse particles and sediment that could clog the spray tip.

NOTE: The gun includes an inline fluid filter for additional filtration.

To reduce the risk of serious injury, including splashing in the eyes or on the skin, do not operate equipment without the fluid drain valve installed.

2. Install a fluid regulator on the fluid line to control fluid pressure to the gun.

3. The fluid drain valve is required in your system to assist in relieving fluid pressure in the displacement pump, hose, and gun. Triggering the gun to relieve pressure may not be sufficient. Install a drain valve close to the pump's fluid outlet.

333011B 9

Page 10

Installation

IGURE

3 shows a typical electrostatic spray 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.

See Note above

Non-Hazardous Area Hazardous Area

. 3 Typical Installation

IGURE

Key to F

A Air Hose Ground Wire B Graco Grounded Turbine Air Hose (TA) C Atomizing Air Hose, 5/16 in. (8 mm) OD (A1) D Fan Air Hose, 5/16 in. (8 mm) OD (A2) E Cylinder Air Hose, 5/32 in. (4 mm) OD (CYL)

High Pressure Fluid Supply Hose to 1/4-18 npsm

gun fluid inlet (P)

BCD

Manifold Back View

K Solenoid Valve, requires quick exhaust port L Bleed-Type Master Air Valve M Air Pressure Regulator N True Earth Ground W Main Air Line

10 333011B

Page 11

Installation

Install the Gun

1. Loosen the manifold’s two set screws (29) and slide the manifold (20) onto a 1/2 in. (13 mm) mounting rod.

2. Position the gun and tighten the two set screws.

NOTE: For added positioning reliability, insert a 1/8 in. (3 mm) locating pin into the slot (NN) in the bracket and through a hole in the rod. See the detail in F

FIG. 4 Mounting Bracket

8.00 in. (203.2 mm)

IGURE

2.88 in. (73.2 mm)

To nozzle tip

Install the Pro Xp Auto Control Module

Connect the Air and Fluid Lines

IGURE

3 shows a schematic of air and fluid line connections, and F Connect the air and fluid lines as instructed below.

To reduce the risk of electric shock, the turbine air supply hose must be electrically connected to a true earth ground. Use only Graco Grounded Turbine

Air Hose.

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.

2. Check the electrical grounding of the gun as

instructed on page 14.

3. Before connecting the high pressure fluid hose (P),

blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.

IGURE

5 shows the manifold connections.

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.

333011B 11

Page 12

Installation

Manifold Connections

Rear Inlet

CYL

EXH

CYL

Bottom Inlet

EXH

FIG. 5 Manifold Connections

Atomization Air Inlet Fitting

Connect a 5/16 in. (8mm) 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 shortest hose length possible.

Fiber Optic Fitting Transmit (Operational on Smart models only)

Connect the Graco Fiber Optic cable (see page 13).

Fiber Optic Fitting Receive (Operational on Smart models only)

Connect the Graco Fiber Optic cable (see page 13).

Fluid Supply Inlet Fitting

Connect a 1/4 npsm swivel fitting between this fitting and the fluid supply.

Turbine Air Inlet Fitting

Connect the Graco Grounded Turbine Air Hose between this fitting (left-hand thread) and the solenoid. Connect the air hose ground wire to a true earth ground.

Exhaust

EXH

Connect an exhaust tube to route the turbine exhaust air. Fitting is for a 5/16 in OD tube.

12 333011B

Page 13

Fiber Optic Cable Connection

(Operational on Smart models only)

Installation

For a 2 Gun System

NOTE: Only use the supplied fiber optic cable.

The fiber optic cable allows the gun to communicate with the Pro Xp Auto control module.

For a 1 Gun System

1. Connect Port 1 of the gun 1 manifold to Port 1 of the Control Module.

2. Connect Port 2 of the gun 1 manifold to Port 2 of the Control Module.

Non-Hazardous Area

1. Connect Port 1 of the gun 2 manifold to Port 5 of the Control Module.

2. Connect Port 2 of the gun 2 manifold to Port 6 of the Control Module.

FIG. 6 . Making Fiber Optic Connections

Hazardous Area

Port 1

Key for F

H Pro Xp Auto AA Gun P 24 Volt Power Supply Connection Q Remote I/O Connection R Pro Xp Auto Control Module U Bulkhead (optional) V Fiber Optic Cable

IGURE

* Approved for hazardous locations.

Port 2

Port 5

Port 6

Gun 1

HVH*

Gun 2

FIG. 7 . Fiber Optic Schematic

333011B 13

Page 14

Installation

Grounding

When operating the electrostatic gun, any ungrounded objects in the spray area (people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock. Ground all equipment, personnel, object being sprayed, and conductive objects in or close to the spray area. Resistance must not exceed 1 megohm. Follow the grounding instructions below.

The following are minimum grounding requirements for a basic electrostatic 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.

•

Pump:

wire and clamp as described in your separate pump instruction manual.

•

Electrostatic Air Assisted Spray Gun:

gun by connecting the Graco Grounded Turbine Air Hose to the turbine air inlet and connecting the air hose ground wire to a true earth ground. See Check Electrical Grounding, page 14.

•

Air compressors and hydraulic power supplies:

ground the equipment according to the manufacturer's recommendations.

•

All air and fluid lines

•

All electrical cables

All persons entering the spray area:

• 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.

•

Object being sprayed:

ers clean and grounded at all times. Resistance must not exceed 1 megohm.

•

The floor of the spray area:

conductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.

•

Flammable liquids in the spray area:

kept in approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift.

ground the pump by connecting a ground

ground the

must be properly grounded.

shoes must

keep the workpiece hang-

must be electrically

must be

All electrically conductive objects or devices in the

•

spray area

cans, must be properly grounded.

•

Fluid and waste containers:

waste containers in the spray area. Do not use pail liners unless they are conductive and grounded. When flushing the spray gun, the container used to catch the excess fluid must be electrically conductive and grounded.

•

All solvent pails:

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.

including fluid containers and wash

ground all fluid and

use only approved, grounded

Check Electrical Grounding

Megohmmeter Part No. 241079 (AA-see F not approved for use in a hazardous area. To reduce the risk of sparking, do not use the Megohmmeter to check electrical grounding unless:

The gun has been removed from the hazardous area Or All spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes from spraying).

Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.

Graco Part No. 241079 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 turbine air hose (B) is connected and the hose ground wire is connected to a true earth ground (N).

3. Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it.

4. Measure the resistance between the turbine air inlet fitting (TA) and a true earth ground (N).

If using a black or gray turbine air hose,

Megohmmeter to measure the resistance. Use

IGURE

8) is

use a

14 333011B

Page 15

Installation

an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 1 megohm.

If using a red turbine air hose,

use an ohmmeter to measure the resistance. The resistance should not exceed 100 ohms.

5. If the resistance is greater than the maximum reading specified above for your hose, 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.

FIG. 8 Check Gun Grounding

Check Fluid Resistivity

Check Fluid Viscosity

To check fluid viscosity you will need:

• a viscosity cup

• a stopwatch

1. Completely submerge the viscosity cup in the fluid. Lift the cup out quickly, starting the stopwatch as soon as the cup is completely removed.

2. 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.

3. Record the fluid type, elapsed time, and size of the viscosity cup.

4. Compare to the chart supplied by viscosity cup manufacturer to determine your fluid viscosity.

5. If the viscosity is too high or too low, contact the material supplier. Adjust as necessary.

Install the Fabric Cover

See F

IGURE

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.

Check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area.

Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.

Graco Part No. 722886 Resistance Meter and 722860 Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the requirements of an electrostatic air spray system.

Follow the instructions included with the meter and probe. Readings of 25 megohms-cm and above provide the best electrostatic results.

Megohms-cm

1-5 5-25 25-200 200-2000

Test

electrostatic

performance

Good

electrostatic

results

Best

electrostatic

results

Good

electrostatic

results

2. 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 21. Strap down the exhaust tube to prevent it from moving around.

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FIG. 9 . Fabric Cover

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 19.

333011B 15

Page 16

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Turn off all the air to the spray gun except the cylinder air, which triggers the gun. If an air pilot fluid regulator is used in the system, the air pressure is needed at the regulator air inlet.

2. Turn off the fluid supply to the gun.

3. Trigger the gun into a grounded metal waste container to relieve the fluid pressure.

Startup

Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.

All operators are properly trained to safely operate an automatic electrostatic air-assisted spray system as instructed in this manual.

All operators are trained in the Pressure Relief Procedure on page 16.

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 14.

The condition of the gun’s electrical components has been checked as instructed in Elec- trical Tests on page 22.

Ventilation fans are operating properly.

4. If an air pilot fluid regulator is used, turn off the air pressure at the regulator air inlet.

5. Relieve fluid pressure in the fluid supply equipment as instructed in its instruction manual.

6. Open the pump drain valve and all other drain valves in the system, having a waste container ready to catch the drainage. Triggering the gun to relieve pressure may not be sufficient. Leave the drain valve open until you are ready to spray again

7. Close the bleed-type master air valve on the main air supply line to shut off the air. Leave the valve closed until you are ready to spray again.

8. If you suspect that the spray tip or hose is still clogged or that pressure is not fully relieved after following the steps above, very slowly loosen the hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose obstruction.

Workpiece hangers are clean and grounded.

All debris, including flammable fluids and rags, is removed from the spray area.

All flammable fluids in the spray booth are in approved, grounded containers.

All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded.

The manifold exhaust tubes have been checked for the presence of any fluid as instructed in Check for Fluid Leakage on page 21.

Select a Spray Tip

The fluid output and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pressure. Use the Spray Tip Selection Chart, page 45, as a guide for selecting the appropriate spray tip for your application.

16 333011B

Page 17

Operation

Install the Spray Tip

To reduce the risk of skin injection and splashing, follow the Pressure Relief Procedure before removing or installing the spray tip or air cap/tip guard.

1. Relieve the pressure. Follow Pressure Relief Pro- cedure, page 16.

2. Align the spray tip tab with the groove in the air cap. Install the tip.

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FIG. 10 Spray Tip Alignment

3. Install the air cap and retaining ring. Orientate the air cap and tighten the retaining ring securely. Be careful not to damage the electrode.

Set the Atomization Fluid Pressure

See F

IGURE

Atomization fluid pressure will vary based on the viscosity of the fluid, flow rate desired, and other system characteristics.

1. Turn off the turbine air (TA), atomization air (A1), and fan air (A2).

2. Start the pump. Set the fluid regulator to 400 psi (2.8 MPa, 28 bar).

3. With the turbine air (TA), atomization air (A1), and fan air (A2) turned off, spray a test pattern, holding the gun 12 in. (305 mm) from the surface. Examine the particle size. Do not be concerned about the presence of tails; they will be removed in step 6.

4. Increase the fluid pressure in small increments. Spray another pattern and compare the particle size. Smaller particle size indicates improved atomization.

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FIG. 11 Install Air Cap Assembly

To reduce the risk of fire, explosion, or electric shock, never operate the gun with a damaged electrode.

To reduce the risk of injury, never exceed the maximum working pressure on the lowest rated system component. Maximum working pressure of this equipment is 3000 psi (21 MPa, 210 bar).

5. Continue to increase the fluid pressure and spray test patterns. Do not exceed 3000 psi (21 MPa, 210 bar) fluid pressure. When the particle size remains constant, the fluid is being atomized at the lowest possible fluid pressure.

For improved atomization at lower fluid flow rates, change to a smaller tip orifice size.

6. Turn on the atomization air (A1) and adjust the air pressure until the tails disappear.

See Spray Pattern Troubleshooting on page 24 to correct spray pattern problems.

7. The pattern width can also be reduced by applying fan air pressure (A2).

Correct

No Air

Too Little Air

Amount of Air

FIG. 12 Eliminating Tails

333011B 17

Page 18

Operation

Adjust the Electrostatics

1. Turn on the turbine air (TA) and adjust the air pressure per the settings in Table 1 . Set the proper pressure at the turbine air hose inlet

flowing

Turbine Air

Hose Length

50 (15.3) 57 (4.0, 0.40) 75 (22.9) 59 (4.1, 0.41)

100 (30.5) 61 (4.3, 0.43)

2. 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 table. Adjust the air pressure as necessary to keep the indicator light green or the values within 400-750 Hz.

NOTE: Smart models display values not color indicator lights.

Table 1. Approximate Dynamic Turbine Air

Pressures

Air pressure at turbine air hose

inlet for full voltage

ft (m) 15 (4.6) 54 (3.8, 0.38) 25 (7.6) 55 (3.85, 0.38)

36 (11) 56 (3.9, 0.39)

psi (bar, MPa)

when air is

Spraying

To reduce the risk of electric shock, do not touch the gun electrode or come within 4 in. (10 cm) of the nozzle during gun operation.

1. Apply a minimum of 60 psi (4.2 bar, 0.42 MPa) air pressure to the cylinder air fitting (CYL) to activate the on/off sequence of atomization air (A1), fan air (A2), and fluid (P). See F

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 a smart model to a lower voltage setting, see the Pro Xp Auto Control Module manual

332989.

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 21.

IGURE

Table 2. Indicator Colors/Values

Indicator

Color

Green

400-750

Amber

<400

Red

>750

Check the voltage output of the gun using a high voltage probe and meter or by reading the Pro Xp Auto Control Module.

NOTE: The gun’s normal high voltage reading is 60-70 kV. If a ball end high voltage measurement probe is used, the gun voltage will rise to about 85 kV. This will happen with all resistive electrostatic guns.

See Electrical Troubleshooting on page 27 to correct voltage problems.

When spraying, the indicator should remain green, indicating sufficient air pressure to the turbine.

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 second, 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.

Description

Triggering the Fluid Alone

1. Shut off and relieve the air pressure to the atomization (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

To reduce the risk of an injury, follow the Pressure Relief Procedure when you stop spraying and

whenever you are instructed to relieve the pressure.

1. Flush the gun, see Flushing, page 19.

2. Follow the Pressure Relief Procedure, page 16.

3. Clean the equipment. See Maintenance on page

19.

18 333011B

Page 19

Maintenance

To reduce the risk of an injury, follow the Pressure Relief Procedure before doing any maintenance on

the gun or system.

Daily Care and Cleaning Checklist

Check the following list daily upon completion of equipment usage.

Flush the gun. See Flushing, page 19.

Maintenance

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.

2. Switch the fluid supply to a compatible solvent.

3. Trigger the gun to flush the fluid passages clean.

Clean Outside of Gun

Clean the fluid and air line filters.

Clean the outside of the gun. See Clean Out- side of Gun, page 19. Clean the air cap, spray tip, and tip guard daily, minimum. Some applications require more frequent cleaning. Replace the parts if they are damaged. See Clean the Spray Gun, page

20. Check the electrode and replace if broken or damaged. See Electrode Replacement on page 30. Check for fluid leakage from the gun and fluid hoses. See Check for Fluid Leakage on page

21. Tighten fittings or replace equipment as needed.

Check Electrical Grounding, page 14.

Flushing

• Flush before changing fluids, before fluid can dry in the equipment, at the end of the day, before storing, and before repairing equipment.

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. Turn off turbine air (TA).

2. Flush the gun. See Flushing, page 19

3. Follow the Pressure Relief Procedure, page 16.

4. Clean the outside of the gun with a compatible solvent. 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

• Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary.

• Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.

To reduce the risk of fire, explosion, or electric shock, turn off the turbine air (TA) before flushing the gun.

333011B 19

WLD

WLD

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Page 20

Maintenance

Clean the Spray Gun

Equipment Needed

• soft bristle brush

• compatible solvent

Procedure

1. Be sure the turbine air (TA) is turned off.

2. Relieve the pressure.

3. Remove the retaining ring (24), air cap/tip guard (25), spray tip (3), and gun shroud (26). See page

29.

4. Dip the end of a soft bristle brush into compatible solvent. clean the front of the gun with the brush. Avoid getting any solvent into the air passages. Whenever possible, point the gun down when cleaning it. See F

If it appears that there is paint inside the air passages, remove the gun from the line for servicing.

IGURE

NOTE: Use two wrenches to remove the fluid tube fitting (C).

FIG. 15 Clean the Inline Fluid Filter

7. Reinstall the filter (20) and fitting (C). Do not over tighten the fitting, and make sure the top fitting (D) remains tight.

NOTE: Use two wrenches to install the fluid tube fitting (C).

02007

FIG. 13 Clean Front of Gun

5. Dampen a soft cloth with solvent and wring out the excess. Wipe the exterior of the gun and shroud clean. See F

IGURE

14.

FIG. 14 Clean Gun Body

6. Remove the bottom fluid tube fitting (C) and fluid filter (20). See F

IGURE

15. Clean the filter in compati-

ble solvent.

8. Clean the retaining ring (24), air cap/tip guard assembly (25), and spray tip (3) with a soft brush daily, minimum. Replace any damaged parts. Be careful not to damage the electrode (25a).

NOTICE

Do not use metal tools to clean the air cap/tip guard or spray tip holes as this could scratch them, and make sure the electrode is not damaged. Scratches in the air cap or spray tip or a damaged electrode can distort the spray pattern.

9. Wipe off the parts with a dry cloth. Be careful not to damage the electrode.

To reduce the risk of fire, explosion, or electric shock, never operate the gun with a damaged electrode.

10. Check the electrode (25a). Replace if damaged.

11. Install the spray tip, page 17.

12. Install the spray tip and air cap/tip guard, shroud, and retaining ring, page 17. Be sure the electrode (25a) is in place.

13. Test Gun Resistance, page 22.

20 333011B

Page 21

Check for Fluid Leakage

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.

During operation, periodically check all openings of the gun shroud (ZZ) for the presence of fluid. See F

12. 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 immediately. Relieve the pressure, then remove the gun for repair.

IGURE

Maintenance

ZZ ZZ

FIG. 16 Check for Fluid Leakage

WLD

333011B 21

Page 22

Electrical Tests

Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (7) and electrode (25a), and electrical continuity between components.

NOTICE

The barrel resistor cartridge is part of the barrel and is not replaceable. To avoid destroying the gun barrel, do not attempt to remove the barrel resistor.

Use Megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V. Connect the leads as shown.

Megohmmeter Part No. 241079 (AA-see F is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the Megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous area;

• Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes from spraying).

Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.

IGURE

17)

25a

FIG. 17 . Test Gun Resistance

Test Power Supply Resistance

1. Remove the power supply (7). See Power Supply Removal and Replacement, page 33.

2. Remove the turbine (8) from the power supply. See Turbine Removal and Replacement, page 34.

3. Measure resistance from the power supply's ground strips (EE) to the spring (7a). The resistance should be 130–160 megohms for 85kV guns. See F

18.

If outside this range, replace the power supply. If in range, and there are performance concerns, go to Test Barrel Resistance, page 23.

IGURE

Test Gun Resistance

1. Flush and dry the fluid passage.

2. Measure resistance between the electrode needle tip (25a) and the turbine air inlet fitting (TA); it should be 148-193 megohms.

3. If outside this range go to Test Power Supply Resistance, page 22. If in range, and there are performance concerns, see Electrical Troubleshoot- ing, page 27 for other possible causes of poor performance.

22 333011B

4. Refer to Electrical Troubleshooting, page 27 for other possible causes of poor performance.

WLD

FIG. 18 Test Power Supply Resistance

5. Be sure the spring (7a) is in place before reinstalling the power supply.

Page 23

Test Barrel Resistance

1. Insert a conductive rod (B) into the gun barrel (removed for the power supply test) and against the metal contact (C) in the front of the barrel.

2. Measure the resistance between the conductive rod (B) and the conductive ring (33). See F The resistance should be 10-30 megohms. If the resistance is incorrect, make sure the metal contact (C) in the barrel and the conductive ring (33) are clean and undamaged.

3. If the resistance is still outside the range, remove the conductive ring (33) and measure the resistance between the conductive rod (B) and the wire lead at the bottom of the conductive ring groove.

4. If the resistance is in range, replace the conductive ring (33) with a new one. Insert the ends of the conductive ring into the slots (S) at the front of the barrel, then press the ring firmly into the groove.

IGURE

19. 33

FIG. 19 Test Gun Barrel Resistance

Electrical Tests

The conductive ring (33) is a conductive (metal) contact ring, not a sealing o-ring. To reduce the risk of fire, explosion, or electric shock:

• Do not remove the conductive ring except to replace it.

• Never operate the gun without the conductive ring in place.

• Do not replace the conductive ring with anything but a genuine Graco part.

5. If the resistance is still outside the range, replace the gun barrel.

333011B 23

Page 24

Troubleshooting

Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or repair this equipment unless you are trained and qualified.

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Procedure on page 16 when you stop spraying and whenever you are instructed to relieve the pressure.

NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun.

Spray Pattern Troubleshooting

NOTE: Some spray pattern problems are caused by the improper balance between air and fluid.

Problem Cause Solution

Fluttering or spitting spray. No fluid. Refill supply.

Air in fluid supply. Check fluid source. Refill.

Irregular pattern. Fluid buildup; partially plugged tip. Clean. See page 20.

Worn/damaged tip or air cap holes. Clean or replace.

Pattern pushed to one side; air cap gets dirty.

Tails in pattern. Atomization air pressure too low. Increase atomization air pressure.

Fluid buildup on air cap/tip guard. Atomization air pressure too high. Decrease.

24 333011B

Air cap holes plugged. Clean. See page 20.

Fluid pressure too low. Increase.

Plugged or damaged air cap hole Clean air cap, see page 20

Page 25

Troubleshooting

Gun Operation Troubleshooting

Problem Cause Solution

Excessive spray fog. Atomizing air pressure too high. Decrease air pressure (A1) as low as

possible

Fluid too thin. Increase viscosity or increase fluid

flow rate.

“Orange Peel” finish. Atomization air pressure too low. Increase air pressure; use lowest

pressure necessary.

Spray tip is too large. Use smaller tip; see Spray Tip

Selection Chart., page 45.

Poorly mixed or filtered fluid. Remix or re-filter fluid.

Fluid too thick. Reduce viscosity.

Fluid leaks from the fluid packing area

Air leaks from the air cap Worn piston stem o-rings (11e, 11f) Replace, see Piston Repair, page

Fluid leakage from the front of the gun

Worn fluid needle packings or rod. Replace fluid needle assembly (8);

see Fluid Needle Replacement, page 31.

32.

Worn or damaged fluid needle ball. See Fluid Needle Replacement,

page 31

Worn fluid seat housing. Replace; see Air Cap/Tip Guard,

Spray Tip, and Fluid Seat Housing Replacement page 29.

Loose spray tip. Tighten retaining ring (1); see Air

Cap/Tip Guard, Spray Tip, and Fluid Seat Housing Replacement

page 29.

Damaged tip seal (3a). Replace; see Air Cap/Tip Guard,

Spray Tip, and Fluid Seat Housing Replacement page 29.

333011B 25

Page 26

Troubleshooting

Problem Cause Solution

Gun does not spray Low fluid supply. Add fluid if necessary.

Damaged spray tip. Replace; see Air Cap/Tip Guard,

Spray Tip, and Fluid Seat Housing Replacement page 29.

Dirty or clogged spray tip (3). Clean; see Clean the Spray Gun,

page 20.

Damaged fluid needle (2). Replace, see Fluid Needle Replace-

ment page 31.

Piston (11) not actuating. Check cylinder air. Check piston

o-ring (11d); see Piston Repair, page 32.

Actuator arm (15) is out of position. Check actuator arm and nuts. See

page 32.

Air leaks from manifold Gun is not securely tightened to

Tighten manifold screws

manifold

Worn or missing o-rings Replace o-rings. See page 32

Fluid doesn’t shut off properly Fluid buildup on fluid needle (2) Replace needle; Fluid Needle

Replacement, page 31

Piston sticking Clean or replace o-rings. See Piston

Repair, page 32

Excessive paint wrap back to operator

Poor grounding See Grounding, page 14

Incorrect distance from gun to part Should be 8-12 in. (200-300 mm).

26 333011B

Page 27

Electrical Troubleshooting

Problem Cause Solution

Poor wrap. Turbine air is not turned on. Turn on.

Booth exhaust velocity is too high. Reduce velocity to within code limits.

Atomization air pressure too high. Decrease.

Fluid pressure too high. Decrease, or replace worn tip.

Incorrect distance from gun to part. Should be 8-12 in. (200-300 mm).

Poorly grounded parts. Resistance must be 1 megohm or

less. Clean workpiece hangers.

Faulty gun resistance. See Test Gun Resistance on page

22.

Low fluid resistivity. Check Fluid Resistivity, page 15.

ES indicator light is not lit (standard models only)

ES indicator light is amber (standard models only)

ES indicator light is red (standard models only)

No voltage or low voltage reading on the Pro Xp Auto Control module

Pro Xp Auto Control Module displays event code (smart models only)

Fluid leaks from the fluid needle packings and causes a short

Faulty turbine See Turbine Removal and

No power. Replace power supply, see page 33

No power Check power supply, turbine, turbine

Turbine speed is too low Increase air pressure until indicator is

Turbine speed is too high Decrease air pressure until indicator

Damaged fiber optic cable or connection.

Turbine air is not turned on. Turn on.

Clean the fluid needle cavity and see Fluid Needle Replacement, page 31

Replacement page 34

ribbon cable. See Power Supply Removal and Replacement, page 33 and Turbine Removal and Replacement, page 34.

green.

is green

Check; replace damaged parts. See Pro Xp Auto Control Module manual

332989.

See manual 332989 for Event Code Troubleshooting.

Troubleshooting

333011B 27

Page 28

Repair

Prepare the Gun for Service

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.

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Procedure when you stop spraying and whenever you are instructed to relieve the pressure.

NOTE:

• Check all possible remedies in Troubleshooting before disassembling the gun.

Remove the Gun from the Manifold

See F

IGURE

20.

1. Disconnect fluid hose from manifold.

2. Holding the gun firmly in hand, loosen the two screws (21) from the back and bottom of the manifold.

NOTE: The screws (21) should stay on the manifold.

3. Remove the gun from the manifold and take it to the service area.

NOTE: The five o-rings (18) should stay on the gun.

• Use a vise with padded jaws to prevent damage to plastic parts.

• Lubricate the power supply, some fluid needle parts (8), and certain fluid fittings with Part No. 116553 Dielectric Grease, as specified in the text.

• Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate.

• Only use genuine Graco parts. Do not mix or use parts from other PRO Gun models.

1. Flush and clean the gun, page 19.

2. Relieve the pressure. Follow the Pressure Relief Procedure, page 16.

3. Remove the gun from the manifold.

4. Remove the gun from the work site. Repair area must be clean.

Rear Manifold

Bottom Manifold

FIG. 20 . Remove Gun from Manifold

28 333011B

Page 29

Repair

Install the Gun on the Manifold

See F

IGURE

20.

1. Make sure the five o-rings (18) are in place on the gun. Inspect the parts for damage and replace them as needed.

2. Secure the gun to the manifold by tightening the two screws (21).

3. Reconnect the fluid hose to the manifold.

Air Cap/Tip Guard, Spray Tip, and Fluid Seat Housing Replacement

1. See Prepare the Gun for Service, page 28.

2. Remove the retaining ring (24), shroud (26) and air cap/tip guard assembly (25).

5. To replace the electrode (25a), see Electrode Replacement, page 30.

The conductive ring (33) is a conductive metal contact ring, not a sealing o-ring. To reduce the risk of fire, explosion, or electric shock:

• Do not remove the conductive ring except to replace it.

• Never operate the gun without the conductive ring in place.

• Do not replace the conductive ring with anything but a genuine Graco part.

6. Remove the fluid seat housing (4) using the multi-tool (48).

FIG. 21 Remove Air Cap

3. Remove shroud (26).

4. Disassemble the air cap assembly. Check the condition of the u-cup (24a), o-ring (25b), and tip gasket (3a). Replace any damaged parts.

40b

25a

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FIG. 22 Disassemble Air Cap Assembly

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FIG. 23 Tip Gasket

WLD

24a

FIG. 24 Seat Housing Replacement

NOTICE

To avoid damaging the seat housing and gun barrel, never over tighten the seat housing. Over tightening may affect the fluid shutoff.

7. Install the fluid seat housing (4). Tighten until snug, then 1/4 turn more.

8. Check that the spray tip gasket (3a) is in place. Align the spray tip tab with the groove in the air cap (25). Install the spray tip (3) in the air cap.

9. Make sure that the electrode (25a) is installed correctly in the air cap.

10. Check that the air cap o-ring (25b) is in place.

11. Check that the u-cup (24a) is in place on the retaining ring (24). The lips of the u-cup must face forward.

333011B 29

Page 30

Repair

12. Install the shroud.

NOTICE

To avoid damaging the tip guard, orient the air cap/tip guard assembly (25) before tightening the retaining ring (24). Do not turn the air cap when the retaining ring is tight.

13. Orientate the air cap and tighten the retaining ring securely.

14. See Test Gun Resistance, page 22.

Electrode Replacement

1. See Prepare the Gun for Service, page 28.

2. Remove the air cap/tip guard assembly (25). See

Air Cap/Tip Guard, Spray Tip, and Fluid Seat Housing Replacement, page 29.

Fluid Tube Replacement

There are no replaceable parts in the fluid tube assembly. Only remove when necessary.

1. Prepare the gun for service, page 28.

2. Remove the air cap assembly, page 29. Remove the shroud (26).

3. Disconnect the bottom fluid tube nut (C). See F

URE

25.

NOTE: Use two wrenches to remove the fluid tube fitting (C).

4. Carefully unscrew the top fluid tube nut (D).

NOTICE

Be careful not to damage the fluid tube assembly (35) when cleaning or installing it, especially the sealing surface (E). If the sealing surface is damaged, the entire fluid tube assembly must be replaced.

5. Apply Part No. 116553 dielectric grease to the entire length of the plastic extension on the end of the fluid tube (35).

6. Apply low strength thread sealant to the fluid tube nut threads.

3. Pull the electrode (25a) out of the back of the air cap, using a needle-nose pliers.

4. Push the new electrode through the air cap hole. Make sure the short end (BB) of the electrode engages the hole (CC) in the back of the air cap. Press the electrode in place firmly with your fingers.

5. Install the air cap assembly.

6. See Test Gun Resistance, page 22.

25a

7. Install the fluid tube into the gun barrel and tighten the top nut (D) hand-tight, then 1/4 to 1/2 turn with a wrench. There will be a gap between the nut and barrel. Do not over tighten the nut.

8. Make sure the fluid filter (34) is in place. Tighten the bottom fluid tube nut (C) onto the fitting (32) and torque to 20-30 in-lb (2.3-3.4 N•m). Make sure the top nut remains tight.

NOTE: Use two wrenches to install the fluid tube fitting (C).

9. Reinstall the shroud and air cap assembly, page 29.

10. Test gun resistance, page 22.

FIG. 25 Fluid Tube Replacement

30 333011B

Page 31

Repair

Fluid Filter Removal

1. Prepare the gun for service, page 28.

2. Remove the air cap assembly, page 29. Remove the shroud (26).

3. Disconnect the bottom fluid tube nut (C).

NOTE: Use two wrenches to remove the fluid tube fitting (C).

4. Remove the fluid filter (34). Clean or replace the filter, as needed.

5. Install the fluid filter. Tighten the bottom fluid tube nut (C) onto the fitting (32) and torque to 20-30 in-lb (2.3-3.4 N•m). Make sure the top nut (D) remains tight.

NOTE: Use two wrenches to install the fluid tube fitting (C).

NOTICE

Be sure the fluid tube (35) is not twisted after tightening the bottom nut (C).

6. Reinstall the shroud and air cap assembly, page 29.

7. Install the fluid needle assembly in the gun barrel. Lubricate the front of the needle with dielectric grease, if not already lubricated. Push in on the needle with the 2 mm ball end wrench (45) and tighten. See F

IGURE

28.

8. Install the spring (5).

9. Install the spring cap (31), making sure the grounding spring (6) is in place. Tighten until snug. Do not

over tighten.

10. Install the barrel (1), page 33.

NOTICE

To avoid damaging the seat housing and gun barrel, never over tighten the seat housing. Over tightening may result in improper fluid shutoff.

11. Install the seat housing and air cap, page 29.

12. Test gun resistance, page 22.

7. Test gun resistance, page 22.

Fluid Needle Replacement

1. Prepare the gun for service, page 28.

2. Remove the air cap/tip guard assembly and seat housing, page 29.

3. Remove the barrel (1), page 33.

4. Remove the spring cap (31) and the spring (5) from the barrel. See F

5. Be sure the seat housing (4) is removed. Place the 2 mm ball end wrench (45) in the back of the fluid needle assembly. Push the tool in and turn it counterclockwise about 12 full turns to unthread the needle.

6. Using the multi-tool (48), pull back on the packing nut (N) to remove the fluid needle assembly. See F

IGURE

27.

IGURE

26.

FIG. 26 Spring Cap and Springs

FIG. 27 Fluid Needle Removal

FIG. 28 Fluid Needle Replacement

333011B 31

Page 32

Repair

Piston Repair

1. Prepare the gun for service, page 28.

2. Remove the air cap, page 29. Remove the gun shroud (26).

3. Remove the jam nut (16a), actuator arm (15), and adjustment nut (16b). See F

4. Remove piston cap (13) and spring (12) from the rear of the gun.

5. Push on the piston rod (11) to push the piston out the back of the gun.

6. Inspect the o-rings (11d, 11e, 11f, 11g) for damage. See Table 3 and F

IGURE

7. Lubricate the o-rings (11d, 11e, 11f, 11g) with non-silicone grease, Part No. 111265. Do not over-lubricate.

8. Align the two stems (11c) with the holes in the gun body and press the piston assembly into the back of the gun until it bottoms. Install piston cap (13) and spring (12).

9. Install and adjust the actuator arm, page 32.

29.

IGURE

30.

Table 3. Piston O-Rings

Description Function

Shaft O-Ring

(11g)

Front O-Ring

(11e)

Back O-Ring

(11f)

Piston O-Ring

(11d)

O-rings included in air seal repair kit 24W390.

Seals cylinder air along the piston rod (34b). Replace if air leaks along rod.

Air shutoff seal. Replace if air leaks from air cap when gun is de-triggered.

Separates cylinder air from fan and atomizing air.

Replace if air leaks from small vent hole at back of manifold when gun is triggered.

Adjust the Actuator Arm

NOTE: The seat housing (4) must be in place when

removing or installing the jam nut and actuator arm.

See F

IGURE

30.

1. Install the adjustment nut (16b), actuator arm (15), and jam nut (16a) onto the piston rod (11b).

2. Position the parts so there is a 0.125 in. (3 mm) gap between the actuator arm (15) and the fluid packing rod nut (E). This allows the atomizing air to actuate before the fluid.

11a

11d

3. Tighten the adjustment nut (16a) against the actuator arm (15). Check that the 0.125 in. (3 mm) gap has been maintained. Tighten the jam nut (16a).

11c

4. Test gun resistance, page 22.

11f

11e

5. Install the gun shroud (26) and air cap/tip guard assembly (25), page 29.

6. Install the gun onto the manifold. See page 29.

11b

WLD

0.125 in. (3 mm) gap

11d

11g

11f

11e

Fan Air Side

WLD

16a

16b

11b

FIG. 30 . Actuator Arm Adjustment

Atomizing Air Side

WLD

FIG. 29 . Piston O-Rings

32 333011B

Page 33

Repair

Barrel Removal

See F

IGURE

1. Prepare the gun for service and remove the manifold, page 28.

2. Remove the air cap and tip, page 29. Remove the gun shroud (26).

3. Carefully loosen the fluid fitting nut (C). Pull the tube (35) out of the fitting (32). See F

NOTE: Use two wrenches to remove the fluid tube fitting (C).

4. Remove the adjustment nuts (16a, 16b) and actuator arm (15). See F

IGURE

30.

5. Loosen the two screws (19). See F

NOTICE

To avoid damaging the power supply, pull the gun barrel (1) straight away from the gun body (10). If necessary, gently move the gun barrel from side to side to free it from the gun body.

IGURE

31.

NOTE: Use two wrenches to install the fluid tube fitting (C).

5. Install and adjust the actuator arm (15), jam nut (16a), and adjustment nut (16b). See page 32.

6. Test gun resistance, page 22.

7. Install the gun shroud (26) and air cap, page 29.

8. Install the gun onto the manifold. See page 29.

16a

16b

6. Hold the gun body (10) with one hand and pull the barrel (1) straight off the body. See F

IGURE

31.

Barrel Installation

See F

IGURE

1. Verify the gasket (9) and grounding spring (6) are in place and the gasket air holes are aligned properly. Replace the gasket if damaged.

2. Make sure the spring is in place on the tip of the power supply (7). Liberally apply dielectric grease to the tip of the power supply. Place the barrel (1) over the power supply and onto the gun body (10).

3. Tighten the two barrel screws (19) oppositely and evenly (about a half turn past snug or 20 in-lbs). Do

not over-tighten.

NOTICE

To avoid damaging the gun barrel, do not over-tighten the screws (19).

FIG. 31 . Barrel

Power Supply Removal and Replacement

• Inspect the gun handle power supply cavity for dirt or moisture. Clean with a clean, dry rag.

• Do not expose gasket (9) to solvents.

1. See Prepare the Gun for Service, page 28.

2. See Barrel Removal, page 33.

NOTICE

Be careful when handling the power supply (7) to avoid damaging it.

3. Grasp the power supply (7) with your hand. With a gentle side to side motion, free the power supply/turbine assembly from the gun body (10), then carefully pull it straight out.

4. Make sure the fluid filter (34) is in place. Tighten the bottom nut (C) onto the fitting (32) and torque to

Smart models only: disconnect the flexible circuit (30) from the socket at the top of the gun body.

20-30 in-lb (2.3-3.4 N•m). Make sure the top nut (D) remains tight.

333011B 33

4. Inspect the power supply and turbine for damage.

Page 34

Repair

5. To separate the power supply (7) from the turbine (8), disconnect the 3-wire ribbon connector (PC) from the power supply. See F

IGURE

32.

Smart models only: disconnect the 6–pin flexible circuit (30) from the power supply.

Slide the turbine up and off the power supply.

6. See Test Power Supply Resistance, page 22. Replace the power supply if necessary. To repair the turbine, see Turbine Removal and Replace-

ment, page 34.

NOTICE

To prevent damage to the cable and possible interruption of the ground continuity, bend the turbine’s 3–wire ribbon cable (PC) upward and back, so the bend faces the power supply and the connector is at the top.

7. Connect the 3-wire ribbon connector (PC) to the power supply.

Smart models only: connect the 6–pin flexible circuit (30) to the power supply.

Tuck the ribbon forward, under the power supply. Slide the turbine (8) down onto the power supply (7).

8. Insert the power supply/turbine assembly in the gun body (10). Make sure the ground strips (EE) make contact with the handle.

Smart models only: align the connector of the 6–pin flexible circuit (30) with the socket (CS) at the top of the handle. See F

IGURE

32.

Push the connector securely into the socket as you slide the power supply/turbine assembly into the handle.

10. See Test Gun Resistance, page 22.

◆

WLD

FIG. 33 . 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 F

IGURE

33 through F

1. See Prepare the Gun for Service, page 28.

2. Remove the power supply/turbine assembly and disconnect the turbine. See Power Supply Removal and Replacement, page 33.

3. Measure resistance between the two outer terminals of the 3-wire connector (PC); it should be

2.0–6.0 ohms. If outside this range, replace the turbine 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.

IGURE

36.

5. If necessary, rotate the fan (8e) so its blades clear the four bearing tabs (T) of the housing (8d). See F

IGURE

34.

◆

FIG. 32 . Connect Flexible Circuit

9. Make sure the gasket (9), ground spring (6), and power supply spring (7a) are in place. Replace gasket (9) if damaged. Assemble the barrel (1) to the gun body (10). See Barrel Installation, page 42.

34 333011B

FIG. 34 . Fan Orientation

WLE

Page 35

Repair

◆

6. Push the fan and coil assembly (8a) out the front of the housing (8d).

WLE

8h◆

8g8aM8b2◆ 8f◆

8b1◆

FIG. 35 . 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.

7. 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).

8. Remove the top bearing (8b2).

coil (8a) so the bearing blades are flush with the surface of the coil.

11. 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 bearing must face away from the coil.

12. 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 F

IGURE

34.

13. 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.

14. Rotate the fan (8e) so its blades clear the four bearing tabs (T) at the back of the housing. Ensure that the blades of the bottom bearing (8b1.) align with the tabs.

15. Seat the coil fully into the housing (8d.). Secure with the clip (8h.),ensuring that its tabs engage the slots in the housing.

9. Remove the bottom bearing (8b1).

10. 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

◆

8g*

◆

8b1

WLE

FIG. 36 . Turbine

16. Ensure that the o-ring (8g) is in place. Install the cap (8f).

17. Install the turbine on the power supply, and install both parts in the handle. See Power Supply Removal and Replacement, page 33.

Slot

◆

8b2

◆

333011B 35

Page 36

Parts

Standard Pro Xp Auto AA Gun Models

HA1T10, Rear Manifold HA2T10, Bottom Manifold

Torque to 20 in-lbs (2 N•m)

HA2T10

36 333011B

Page 37

Standard Pro Xp Auto AA Gun Models

HA1T10, Rear Manifold HA2T10, Bottom Manifold

Parts

Ref. No.

Part No. Description Qty

1 24W874 BODY, gun assy, includes 9, 33 1 2 24N781 NEEDLE ASSEMBLY, includes 5 1 3AEMxxx

AEFxxx

TIP ASSEMBLY; customer’s

choice 3a 183459 GASKET, tip 4 24N725 HOUSING, seat 1 5 24N782 SPRING, fluid needle 1 6 197624 SPRING, compression 1 7 24N661 POWER SUPPLY, 85 kV 1 7a 24N979 SPRING 1 8 24N664 See Turbine Assembly, page 41 1 8g

■

110073 O-RING, packing 1

■◆

24N699 GASKET, barrel 1 10 24W380 BODY, assy, AA. Includes 18, 19 1 11 24W396 PISTON, assy, actuation, auto 1 11a 17B704 O-RING, packing 1 11b 111504 O-RING, packing 2 11c 112319 O-RING, packing 2 11d 111508 O-RING, packing 1 12 112640 SPRING, compression 1 13 24W397 CAP, piston, actuation 1 14 513505 WASHER, plain #10 SST 1 15 24W398 ARM, fluid actuator, XP

(includes 16, qty 2) 16 100166 NUT, full hex 2 18

■

111450 PACKING, O-RING 5 19 24N740 SCREW, ES gun (pack of 2) 4 20 24W394 MANIFOLD, rear inlet (HA1T10) 1

24W395 MANIFOLD, bottom inlet (HA2T10) 1 21❖ ★ 24W399 SCREW, modified, 1/4-20, XP

Auto (pack of 2)

23❖ ★ 24W411 FITTING, Adapter, M12 TO 1/4,

LH, XP 24 24N793 RING, retainer, assy; includes 24a 1 24a

■

198307 PACKING, u-cup; UHMWPE 1

Ref.

Part No. Description Qty

No.

25 24N727 See Air Cap Assembly, page 40 1 25a 24N643 ELECTRODE, package of 5 1 26 24W388 COVER, shroud, Auto XP 1

27❖ ★ 114263 FITTING, connector, male 1 28❖ ★ 115950 FITTING, connector, 1/4npt (M),

5/16T 29❖ ★ 110465 SCREW, set (HA1T10 only) 2 30 102207 SCREW, set, SCH 2 31 24N785 CAP, spring, includes 6 1 32 24W752 FITTING, fluid, AA hose includes

19 qty 1 33 24N747 RING, conductive 1 34 238561 FILTER, tip (3 pack) 1 35 24W387 HOSE, assy 1 36 ★ 117560 SCREW, set 1 37 116553 GREASE, dielectric; 1 oz (30 ml)

tube (not shown) 40

▲

16P802 SIGN, warning (not shown) 1

▲

179791 TAG, warning (not shown) 1

42 43

▲

222385 TAG, warning (not shown) 1 44 276741 MULTI-TOOL (not shown) 1 45 107460 WRENCH, ball end, 4 mm

(not shown)

46 112080 WRENCH, ball end, 2 mm

(not shown)

▲

Replacement Warning labels, signs, tags, and

cards are available at no cost.

■

Included in Air Seal Repair Kit 24W390 (pur-

chase separately)

❖ Included in Rear Manifold Repair Kit 24W394

(purchase separately)

★ Included in Bottom Manifold Repair Kit 24W395

(purchase separately)

◆

Included in Turbine Assembly 24N664 (pur-

chase separately). See Turbine Assembly,

page 41.

333011B 37

Page 38

Parts

Smart Pro Xp Auto AA Gun Models

HA1M10, Rear Manifold HA2M10, Bottom Manifold

Torque to 20 in-lbs (2 N•m)

HA2M10

38 333011B

Page 39

Smart Pro Xp Auto AA Gun Models

HA1M10, Rear Manifold HA2M10, Bottom Manifold

Parts

Ref. No.

Part No. Description Qty

1 24W874 BODY, gun assy, includes 9, 33 1 2 24N781 NEEDLE ASSEMBLY, includes 5 1 3AEMxxx

AEFxxx

TIP ASSEMBLY; customer’s

■

110073 O-RING, packing 1

■◆

24N699 GASKET, barrel 1

10 24W869 BODY, assy, AA, bottom inlet

HA2M10

24W384 BODY, assy, AA, rear inlet

HA1M10, includes 18, 19 11 24W396 PISTON, assy, actuation, auto 1 11a 17B704 O-RING, packing 1 11b 111504 O-RING, packing 2 11c 112319 O-RING, packing 2 11d 111508 O-RING, packing 1 12 112640 SPRING, compression 1 13 24W397 CAP, piston, actuation 1 14 513505 WASHER, plain #10 SST 1 15 24W398 ARM, fluid actuator, XP (includes

16, qty 2) 16 100166 NUT, full hex 2 18

■

111450 PACKING, O-RING 5 19 24N740 SCREW, ES gun (Includes 2) 4 20 24W394 MANIFOLD, rear inlet HA1M10 1

24W395 MANIFOLD, bottom inlet HA2M10 1 21❖ ★ 24W399 SCREW, modified, 1/4-20, XP

Auto (pack of 2)

23❖ ★ 24W411 FITTING, Adapter, M12 TO 1/4,

LH, XP

24 24N793 RING, retainer, assy; includes 24a 1

■

24a

198307 PACKING, u-cup; UHMWPE 1 25 24N727 See Air Cap Assembly, page 40 1

Ref.

Part No. Description Qty

No.

25a 24N643 ELECTRODE, package of 5 1 26 24W388 COVER, shroud, Auto XP 1 27❖ ★ 114263 FITTING, connector, male 1

28❖ ★ 115950 FITTING, connector, 1/4npt (M),

5/16T 29❖ ★ 110465 SCREW, set 2 30 245265 CIRCUIT, flexible 1 31 24N785 CAP, spring includes 6 1 32 24W752 FITTING, fluid, AA hose Includes

19 qty 1 33 24N747 RING, conductive 1 34 238561 FILTER, tip (3 pack) 1 35 24W387 HOSE, assy 1 36★ 117560 SCREW, set 1

37 116553 GREASE, dielectric; 1 oz (30 ml)

▲

16P802 SIGN, warning (not shown) 1

▲

179791 TAG, warning (not shown) 1

▲

222385 TAG, warning (not shown) 1

tube (not shown)

44 276741 MULTI-TOOL (not shown) 1 45 107460 WRENCH, ball end, 4mm

(not shown) 46 112080 WRENCH, ball end, 2mm

(not shown) 80 24W035 CONTROL MODULE, Pro Xp Auto

(not shown). See 332989. Must be

▲

Replacement Warning labels, signs, tags, and

purchased separately.

cards are available at no cost.

■

Included in Air Seal Repair Kit 24W390 (purchase separately)

❖ Included in Rear Manifold Repair Kit 24W394

(purchase separately)

★ Included in Bottom Manifold Repair Kit 24W395

(purchase separately)

◆

Included in Turbine Assembly 24N664 (purchase separately). See Turbine Assembly, page 41.

333011B 39

Page 40

Parts

Air Cap Assembly

Part No. 24N727 Air Cap Assembly

25b

25a

25c

25d

Ref. No. Part No. Description Qty

3a 183459 GASKET, tip (not shown) See page

36. 25a 24N643 ELECTRODE, package of 5 1 25b 24N734 O-RING; PTFE; package of 5 1

24E459 O-RING; PTFE; package of 10 1

Ref. No. Part No. Description Qty

25c ------ AIR CAP 1

25d 24N726 GUARD, tip, orange 1

40 333011B

Page 41

Turbine Assembly

Part No. 24N664 Turbine Assembly

8f◆

8e◆

8g*

Parts

8d◆

8b1◆

8b2◆

WLE

Ref. No.

Part No.

Description Qty

8a 24N705 COIL, turbine 1 8b

◆

24N706 BEARING KIT (includes two bear-

ings, item 8e fan, and one item 8h clip)

◆

24N707 HOUSING; includes item 8f 1

◆

------ FAN; part of item 8b 1 8f◆ ------ CAP, housing; part of item 8d 1 8g* 110073 O-RING 1

Ref.

Part

No.

◆

24N709 CLIP; package of 5 (one clip

Description Qty

included with item 15b)

9*◆ 24N699 GASKET, barrel (not shown) See

page 36.

* 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

8h◆

333011B 41

Page 42

Accessories

Smart Model Accessories and Fiber Optic Cables

Part No. Description 24W035 Pro Xp Auto Control Module. See 332989

for details.

Fiber Optic Cables

See item V in F fold to Pro Xp Auto Control Module. See 332989.

Models with Rear Manifolds (Model numbers LA1xxx or HA1xxx)

Part No. Description

24X003 Fiber Optic Cable, 25 ft (7.6 m)

24X004 Fiber Optic Cable, 50 ft (15 m)

24X005 Fiber Optic Cable, 100 ft (30.5 m)

Models with Bottom Manifolds (Model numbers LA2xxx or HA2xxx)

Part No. Description

24X006 Fiber Optic Cable, 25 ft (7.6 m)

24X007 Fiber Optic Cable, 50 ft (15 m)

24X008 Fiber Optic Cable, 100 ft (30.5 m)

Fiber Optic Cable Kit

24W875 Parts necessary to replace damaged ends on

IGURE

7 on page 13. Connect gun mani-

one cable assembly.

Air Line Accessories

AirFlex™ Flexible Grounded Air Hose

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

Part No. Description

244963 6 ft (1.8 m)

244964 15 ft (4.6 m)

244965 25 ft (7.6 m)

244966 36 ft (11 m)

244967 50 ft (15 m)

244968 75 ft (23 m)

244969 100 ft (30.5 m)

Standard Grounded Air Hose (Grey)

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

Part No. Description

223068 6 ft (1.8 m)

223069 15 ft (4.6 m)

223070 25 ft (7.6 m)

223071 36 ft (11 m)

223072 50 ft (15 m)

223073 75 ft (23 m)

223074 100 ft (30.5 m)

Grounded Air Hose with stainless steel braid ground path (Red)

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

Part No. Description

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)

42 333011B

Page 43

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

235073 75 ft (23 m)

235074 100 ft (30.5 m)

Bleed-Type Master Air Valve

300 psi (21 bar, 2.1 MPa) Maximum Working Pressure

Relieves air trapped in the air line between this valve and the pump air motor when closed.

Part No. Description

107141 3/4 npt

Air Line Shutoff Valve

150 psi (10 bar, 1.0 MPa) Maximum Working Pressure

For turning air to gun on or off.

Part No. Description

224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.

Fluid Line Accessories

Fluid Hose

3300 psi (22.7 MPa, 227 bar) Maximum Working Pressure

1/4 in. (6 mm) ID; 1/4 npsm (fbe); nylon.

Part No. Description

240793 25 ft (7.6 m)

240794 50 ft (15.2 m)

System Accessories

Part No. Description

222011 Ground wire for grounding pump and other

components and equipment in the spray area. 12 gauge, 25 ft (7.6 m).

16P802 English Warning Sign. Available at no

charge from Graco.

Test Equipment

Part No. Description

241079 Megohmmeter. 500 V output, 0.01–2000

megohms. Use for ground continuity and gun resistance tests.Not for use in hazardous areas.

722886 Paint Resistance Meter. Use for fluid resis-

tivity test. See manual 307263. Not for use

in hazardous 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 supply when being serviced. See manual 309455. Also requires 24R038 Conversion Kit.

24R038 Voltage Tester Conversion Kit. Converts the

245277 Test Fixture for use with the Pro Xp Gun turbine. See manual 406999.

Miscellaneous Equipment

Gun Accessories

Fluid Recirculation Fitting

5000 psi (340 bar, 34 Mpa) Maximum Working Pressure

Part No. Description 24X634 Stainless steel recirculation fitting that

mounts directly to the gun fluid inlet fitting. 1/4-18 npsm inlet and outlet.

Part No. Description

105749 Cleaning brush

111265 Non-silicone lubricant, 4 oz (113g)

116553 Dielectric grease 1 oz (30 ml)

24V929 Gun Covers

Conversion and Repair Kits

Part No. Description

24N319 Round Spray Kit. To convert a standard air

assisted spray gun to a round spray air cap. See manual 3A2499.

24W390 Air Seal Repair Kit

24N706 Turbine Bearing Repair Kit

333011B 43

Page 44

Dimensions

Rear Inlet Manifold

2.9 in (73 mm)

Bottom Inlet Manifold

11 in (279 mm)

10.4 in (265 mm)

8.2 in (208 mm)

0.53 in(13.5 mm)

2x 1/4-20 UNC

2.6 in (66 mm)

2.5 in (63 mm

5.0 in (127 mm)

)

11.0 in (279 mm)

.60 in (15.24 mm)

8.0 in (202 mm)

2x 1/4-20 UNC

1.05 in (26.67 mm)

)

5.8 in (147 mm

.90 in (22.86 mm)

2.6 in (66 mm)

2.5 in (623 mm

3x 5/16-18 UNC

1.80 in (45.72mm)

)

44 333011B

Page 45

Spray Tip Selection Chart

AEM Fine Finish Spray Tips

Recommended for high finish quality applications at low and medium pressures. Order desired tip, Part No. AEMxxx, where xxx = 3-digit number from the matrix below.

Fluid Output

fl oz/min (l/min)

Orifice

Size in.

(mm)

0.007 (0.178)

0.009 (0.229)

0.011 (0.279)

0.013 (0.330)

0.015 (0.381)

0.017 (0.432)

0.019 (0.483)

0.021 (0.533)

0.023 (0.584)

0.025 (0.635)

0.029 (0.736)

0.031 (0.787)

0.033 (0.838)

0.037 (0.939)

0.039 (0.990)

* Tips are tested in water.

at 600 psi (4.1 MPa, 41 bar)

4.0 (0.1)

7.0 (0.2)

10.0 (0.3)

13.0 (0.4)

17.0 (0.5)

22.0 (0.7)

28.0 (0.8)

35.0 (1.0)

40.0 (1.2)

50.0 (1.5)

68.0 (1.9)

78.0 (2.2)

88.0 (2.5)

108.0 (3.1)

118.0 (3.4)

at 1000 psi (7.0 MPa, 70 bar)

5.2 (0.15)

9.1 (0.27)

13.0 (0.4)

16.9 (0.5)

22.0 (0.7)

28.5 (0.85)

36.3 (1.09)

45.4 (1.36)

51.9 (1.56)

64.8 (1.94)

88.2 (2.65)

101.1 (3.03)

114.1 (3.42)

140.0 (4.20)

153.0 (4.59)

Maximum Pattern Width at 12 in. (305 mm)

2 - 4 (50 -

100)

107 207 307

4 - 6

(100 -

150)

209 309 409 509 609

211 311 411 511 611 711

213 313 413 513 613 713 813

215 315 415 515 615 715 815

217 317 417 517 617 717

6 - 8

(150 -

200)

319 419 519 619 719

in. (mm)

8 - 10 (200 -

250)

Spray Tip

421 521 621 721 821

423 523 623 723 823

425 525 625 725 825

431 631 831

10 - 12

(250 -

300)

539

12 - 14

(300 -

350)

14 - 16

(350 -

400)

737

16 - 18

(400 -

450)

829

833

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) where QT = fluid output (fl oz/min) at 600 psi from the above table for the selected orifice size.

333011B 45

Page 46

Spray Tip Selection Chart

AEF Fine Finish Pre-Orifice Spray Tips

Recommended for high finish quality applications at low and medium pressures. AEF tips have a pre-orifice that assists in atomizing sheer thinning materials, including lacquers.

Order desired tip, Part No. AEFxxx, where xxx = 3-digit number from the matrix below

Fluid Output

fl oz/min (l/min)

Orifice

Size in.

(mm)

0.008 (0.203)

0.010 (0.254)

0.0012 (0.305)

0.014 (0.356)

0.016 (0.406)

* Tips are tested in water.

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) where QT = fluid output (fl oz/min) at 600 psi from the above table for the selected orifice size.

at 600 psi (4.1 MPa, 41 bar)

8.5 (.025)

9.5 (0.28)

12.0 (0.35)

16.0 (0.47)

20.0 (0.59)

at 1000 psi (7.0 MPa, 70 bar)

11.0 (0.32)

12.5 (0.37)

16.0 (0.47)

21.0 (0.62)

26.5 (0.78)

6-8

(150 - 200)

310 410 510 610 710

312 412 512 612 712 812

314 414 514 614 714 814

Maximum Pattern Width at 12 in. (305 mm)

in. (mm)

8-10

(200 - 250)

416 516 616 716

10-12

(250 - 300)

Spray Tip

608

12-14

(300 - 350)

14-16

(350 - 400)

16-18

(400 - 450)

46 333011B

Page 47

Technical Data

Pro Xp Auto AA Spray Gun

US Metric

Maximum fluid working pressure 3000 psi 21 MPa, 210 bar Maximum working air pressure 100 psi 0.7 MPa, 7 bar Maximum fluid operating temperature

Short circuit current output 125 microamperes Paint resistivity range 3 megohm/cm to infinity

Voltage Output

Standard Models 85 kV Smart Models 40-85 kV Voltage output 40-85 kV Gun Weight (Approximate) 2.7 lb 1.2 kg

Noise (dBa)

Sound Power (measured per ISO Standard

9216) Sound Pressure (measured 1 m from gun) at 40 psi: 87 dB(A)

Inlet/Outlet Sizes

Turbine air inlet fitting, left-hand thread 1/4 npsm(m) Atomizing air inlet fitting 5/16 in. OD nylon tube (8 mm) Fan air inlet fitting 5/16 in. OD nylon tube (8 mm) Cylinder air inlet fitting 5/32 in. OD nylon tube (4 mm) Fluid inlet fitting 1/4-18 npsm(m)

Materials of Construction

Wetted Parts Stainless Steel; Nylon, Acetal, Ultra-High Molecular Weight Poly-

Notes

at 40 psi: 90.4 dB(A) at 100 psi: 105.4 dB(A)

at 100 psi: 99 dB(A)

ethylene, Fluoroelastomer, PEEK, Tungsten Carbide, Polyethylene

120°F

at 0.28 MPa, 2.8 bar: 90.4 dB(A) at 0.7 MPa, 7 bar: 105.4 dB(A)

at 0.28 MPa, 2.8 bar: 87 dB(A) at 0.7 MPa, 7 bar: 99 dB(A)

48°C

Loctite® is a registered trademark of the Loctite Corporation.

333011B 47

Page 48

Graco Pro Xp Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deficiency in the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for 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.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

Original instructions.

This manual contains English. MM 333011

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revision B, December 2014

Graco 333011B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

List of Models

Warnings

Introduction

How the Electrostatic AA Spray Gun Works

Operating the Spray Function

Gun Features and Options

Smart Gun Features

Operating the Electrostatics

System Overview

Typical System Installation

Gun Overview

Installation

Install the System

Warning Signs

Ventilate the Spray Booth

Install the Air Line Accessories

Install Fluid Line Accessories

Install the Gun

Install the Pro Xp Auto Control Module

Connect the Air and Fluid Lines

Manifold Connections

Fiber Optic Cable Connection

Grounding

Check Electrical Grounding

Check Fluid Resistivity

Check Fluid Viscosity

Install the Fabric Cover

Flush Before Using Equipment

Operation

Pressure Relief Procedure

Startup

Select a Spray Tip

Install the Spray Tip

Set the Atomization Fluid Pressure

Adjust the Electrostatics

Spraying

Triggering the Fluid Alone

Shutdown

Maintenance

Daily Care and Cleaning Checklist

Clean Outside of Gun

Flushing

Clean the Spray Gun

Check for Fluid Leakage

Electrical Tests

Test Power Supply Resistance

Test Gun Resistance

Test Barrel Resistance

Troubleshooting

Spray Pattern Troubleshooting

Gun Operation Troubleshooting

Electrical Troubleshooting

Repair

Prepare the Gun for Service

Remove the Gun from the Manifold

Install the Gun on the Manifold

Air Cap/Tip Guard, Spray Tip, and Fluid Seat Housing Replacement

Electrode Replacement

Fluid Tube Replacement

Fluid Filter Removal

Fluid Needle Replacement

Piston Repair

Adjust the Actuator Arm

Barrel Removal

Barrel Installation

Power Supply Removal and Replacement

Turbine Removal and Replacement

Parts

Standard Pro Xp Auto AA Gun Models

Smart Pro Xp Auto AA Gun Models

Air Cap Assembly

Turbine Assembly

Accessories

Dimensions

Spray Tip Selection Chart