Graco 333012B User Manual

Instructions - Parts

Pro Xp Auto

333012B

Waterborne Air Spray Gun

Automatic Electrostatic Air spray gun for use when electrostatically spraying conductive waterborne fluids that meet at least one of the following conditions for non-flammability:

•

Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206.

•

Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500 mJ.

For professional use only.

100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure 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 Approved Models.

WLD

Table of Contents

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

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

How the Electrostatic Air Spray Gun Works . . . . . . . . . 7

Operating the Spray Function . . . . . . . . . . . . . . . . . . . . 7

Operating the Electrostatics . . . . . . . . . . . . . . . . . . . . . 7

Gun Features and Options . . . . . . . . . . . . . . . . . . . . . . 7

Smart Gun Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Spraying Waterborne Fluids Electrostatically . . . . . . . . 8

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 11

Install the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . . . 11

Install the Air Line Accessories . . . . . . . . . . . . . . . . . . 12

Install the Optional Fluid Line Accessories . . . . . . . . . 12

Install the Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Install the Pro Xp Auto Control Module . . . . . . . . . . . . 14

Connect the Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Ground the Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Manifold Connections . . . . . . . . . . . . . . . . . . . . . . . . . 15

Connect the Waterborne Fluid Hose . . . . . . . . . . . . . . 16

Fiber Optic Cable Connection . . . . . . . . . . . . . . . . . . . 18

Agitator Kit Accessory . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fluid Regulator Kit Accessory . . . . . . . . . . . . . . . . . . . 19

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Check Electrical Grounding . . . . . . . . . . . . . . . . . . . . 20

Install the Fabric Cover . . . . . . . . . . . . . . . . . . . . . . . . 22

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . 22

Flush Before Using Equipment . . . . . . . . . . . . . . . . . . 22

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Fluid Voltage Discharge and Grounding Procedure . . 24

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 24

Fill the Fluid Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Select a Fluid Nozzle and Air Cap . . . . . . . . . . . . . . . 25

Operating the Spray Function . . . . . . . . . . . . . . . . . . .25

Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . 25

Adjust the Electrostatics . . . . . . . . . . . . . . . . . . . . . . . 26

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Triggering the Fluid Alone . . . . . . . . . . . . . . . . . . . . . . 27

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Daily Care and Cleaning Checklist . . . . . . . . . . . . . . . 28

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Clean Outside of Gun . . . . . . . . . . . . . . . . . . . . . . . . . 29

Clean the Air Cap and Fluid Nozzle . . . . . . . . . . . . . . 29

Check for Fluid Leakage . . . . . . . . . . . . . . . . . . . . . . .30

Clean the Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 31

Test Power Supply Resistance . . . . . . . . . . . . . . . . . . 32

Test Electrode Resistance . . . . . . . . . . . . . . . . . . . . . 32

Test Ground Strip Resistance . . . . . . . . . . . . . . . . . . 33

Test Cylinder Resistance . . . . . . . . . . . . . . . . . . . . . . 33

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Voltage Loss Troubleshooting . . . . . . . . . . . . . . . . . . 34

Spray Pattern Troubleshooting . . . . . . . . . . . . . . . . . . 37

Gun Operation Troubleshooting . . . . . . . . . . . . . . . . . 38

Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . 39

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Prepare the Gun for Service . . . . . . . . . . . . . . . . . . . . 41

Remove the Gun from the Manifold . . . . . . . . . . . . . . 41

Install the Gun on the Manifold . . . . . . . . . . . . . . . . . . 41

Air Cap/Nozzle Replacement . . . . . . . . . . . . . . . . . . . 42

Electrode Replacement . . . . . . . . . . . . . . . . . . . . . . . 43

Fluid Packing Removal . . . . . . . . . . . . . . . . . . . . . . . . 43

Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . . . . . . 46

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Power Supply Removal and Replacement . . . . . . . . . 47

Turbine Removal and Replacement . . . . . . . . . . . . . . 48

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Standard Pro Xp Auto Waterborne Air Spray Gun Models

50 Smart Pro Xp Auto Waterborne Air Spray Gun Model 52

Packing Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . 54

Turbine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Air Caps and Fluid Nozzles . . . . . . . . . . . . . . . . . . . . . . . 56

Fluid Nozzle Selection Chart . . . . . . . . . . . . . . . . . . . 56

Fluid Nozzle Performance Charts . . . . . . . . . . . . . . . . 56

Air Cap Selection Chart . . . . . . . . . . . . . . . . . . . . . . . 58

Isolation Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Tubing and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Agitator Kit 245895 . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Fluid Regulator Kit 245944 . . . . . . . . . . . . . . . . . . . . . 65

Shielded Waterborne Fluid Hose 24W597 . . . . . . . . . 65

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Rear Inlet Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Graco Pro Xp Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . 70

2 333012B

List of Approved Models

Part No. kV

LA1M18 60

LA1T18 60

Part No. Description

24X287 WB 100 Isolation Enclosure 24W597 25’ Shielded Waterborne Fluid Hose 24W598 50’ Shielded Waterborne Fluid Hose

0.35 J with 50 ft hose max FM14ATEX0082

EN 50059

Ta 0°C-50°C

1.5mm Nozzle

FM approved for use with fluids that meet the following condition:

• Material does not sustain burning in accordance with the Standard

Models Compliant with EN 50059 when used with fluids that meet the following criteria:

• Materials which cannot be ignited, in any mixture with air, by an

Standard

Model

✔✔ ✔ ✔✔ ✔

Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206

energy source of less than 500 mJ.

Smart Model

Bottom

Manifold

Rear

Manifold

0359

Related Manuals

Manual No. Description

332989 Instructions - Pro Xp Auto Control Module

333012B 3

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

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of an isolated waterborne system can result in electric shock. To help prevent electric shock:

• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to spray area. See Grounding instructions.

• Connect the electrostatic gun to a voltage isolation system that will discharge the system voltage when not in use.

• All components of the voltage isolation system that are charged to high voltage must be contained within an isolation enclosure that prevents personnel from making contact with the high voltage components before the system voltage is discharged.

• Follow the Fluid Voltage Discharge and Grounding Procedure when instructed to discharge the voltage; before cleaning, flushing, or servicing the system; before approaching the front of the gun; and before opening the isolation enclosure for the isolated fluid supply.

• Do not enter a high voltage or hazardous area until all high voltage equipment has been discharged.

• Do not touch the gun nozzle or electrode, or come within 4 in. (102 mm) of the electrode during gun operation. Follow the Fluid Voltage Discharge and Grounding Procedure.

• Interlock the gun air supply with the voltage isolation system to shut off the air supply anytime the isolation system enclosure is opened.

• Only use the red-colored Graco electrically conductive air hose with this gun. Do not use black or gray-colored Graco air hoses.

• Do not splice fluid hoses together. Install only one continuous Graco Waterborne Fluid Hose between the isolated fluid supply and the spray gun.

4 333012B

Warnings

WARNING

WARNINGWARNINGWARNING

FIRE AND EXPLOSION HAZARD

Combustible dust in work area can ignite or explode. To help prevent fire and explosion:

• Use only fluids that meet the following flammability requirements:

• Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206.

• Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500 mJ.

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

• Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements of this manual.

• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to spray area. Resistance must not exceed 1 megohm. See Grounding instructions.

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

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

• Use and clean equipment only in well ventilated area.

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

• Only use non-flammable solvents when flushing or cleaning equipment.

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

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

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

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

• Keep a working fire extinguisher in the work area.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

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

• Tighten all fluid connections before operating the equipment.

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

PLASTIC PARTS CLEANING SOLVENT HAZARD

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

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

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

333012B 5

Warnings

WARNING

WARNINGWARNINGWARNING

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 eyewear, 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.

6 333012B

Introduction

How the Electrostatic Air Spray Gun Works

The automatic electrostatic air spray gun operates very similar to a traditional air spray gun. The atomization and fan air are emitted from the air cap. The atomization air breaks up the fluid stream and controls the droplet size. The fan air controls the shape and width of the spray pattern. The fan and atomization air can be adjusted independently.

Operating the Spray Function

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

Operating the Electrostatics

To operate the electrostatics, apply air pressure to the gun manifold’s turbine air fitting (TA) through a Graco Grounded Turbine Air Hose. The air enters the manifold and is directed to the inlet of the power supply turbine. The air spins the turbine, which then provides electrical power to the internal high voltage power supply. The fluid is charged by the spray gun electrode. The charged fluid is attracted to the nearest grounded object, wrapping around and evenly coating all surfaces.

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

• Use a PLC to select a spray profile

To reduce the risk of electric shock, do not use the optional Pro Xp Auto Control Module readings to determine if your system is discharged. The display modules will only display the system voltage while the gun’s power supply is operating. Follow the Fluid Voltage Discharge and Grounding Procedure on page 24 to ensure the system is discharged.

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

Gun Features and Options

• 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 the air lines to the gun.

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

333012B 7

Introduction

Spraying Waterborne Fluids Electrostatically

This electrostatic air spray gun is designed to spray only waterborne fluids which meet at least one of the following flammability requirements:

FM, FMc Approved:

• Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206.

CE-EN 50059 Compliant:

• Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500 mJ.

When connected to a voltage isolation system, all of the fluid in the spray gun, fluid hose, and isolated fluid supply is charged to high voltage, which means that the system has more electrical energy than a solvent-based system. Therefore, only non-flammable fluids (as defined above) can be sprayed with the system or used to clean, flush, or purge the system.

Precautions must be taken when using electrostatic waterborne equipment to avoid potential shock hazards. When the electrostatic air spray gun charges the isolated fluid to high voltage, it is similar to charging a capacitor or a battery. The system will store some of the energy while spraying and retain some of that energy after the spray gun is shut off. Do not touch the gun nozzle or come within 4 in. (102 mm) of the electrode until the stored energy is discharged. The amount of time it takes to discharge the energy depends on the system design. Follow the Fluid Voltage Discharge and Grounding Procedure on page 24 before approaching the front of the spray gun.

NOTE: The Graco warranty and approvals are void if the electrostatic air spray gun is connected to a non-Graco voltage isolation system or if the spray gun is operated above 60 kV.

8 333012B

System Overview

Typical Waterborne System Installation

IGURE

1 shows a typical electrostatic waterborne air spray system. It is not an actual system design. For assistance

in designing a system to suit your particular needs, contact your Graco distributor.

Introduction

FIG. 1 Typical Installation Pro Xp Auto Waterborne System

Item Description A Main Air Supply Line B* Bleed-Type Air Shutoff Valve C Pump Air Pressure Gauge D Pump Air Pressure Regulator EkV Meter FPump G Pump Suction Hose H Paint Container J* Bleed Resistor K* Enclosure Safety Interlock L Isolated Enclosure M Air Line Filter

333012B 9

Item Description N Pneumatic connection to turbine air

R Graco Waterborne Fluid Hose T Grounding Rod U Ground Terminal V* Main Ground Wire W Strain Relief/Ground Fitting X Pump Air Supply Line Y Grounding Cylinder Z Pump Fluid Outlet Fitting AA Isolated Enclosure Door BB Enclosure T-Handle Locking Screw * These items are required for safe operation and are included with the WB 100.

interlock. (Pressurized when isolation system door is closed)

Introduction

Gun Overview

FIG. 2 . Gun Overview

EXH

CYL

Key

AAir Cap

B Fluid Nozzle

C Retaining Ring

D Shroud

FManifold

GAlternator

H Power Supply

J Electrode

L Waterborne Fluid Hose

10 333012B

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)

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)

Installation

System Requirements

Basic Guidelines

When spraying waterborne fluids electrostatically:

• The gun must be connected to a voltage isolation system, which isolates the fluid supply from ground and allows voltage to be maintained at the tip of the gun.

• The gun must be connected to a voltage isolation system that will discharge the system voltage when the gun is not in use.

• There should be a bleed resistor to drain off the system voltage when the spray gun is not in use.

• The gun turbine air hose must be interlocked with the voltage isolation system to shut off the turbine air supply anytime the isolation system enclosure is opened or entered.

If a hose failure occurs where high voltage arcs through the inner tube, voltage will be discharged to ground through the conductive hose layer. When properly installed, the conductive hose layer is grounded through its connection to the grounded enclosure.

Install the System

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.

• 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

• The voltage isolation system must be interlocked with the spray area entrance to automatically discharge the voltage and ground the fluid whenever someone opens the enclosure or enters the spray area.

• The system should not have any severe arcing occurring when the isolation mechanism opens and closes. Severe arcing will shorten the life of the system components.

Graco Waterborne Fluid Hose

Use a Graco Waterborne Fluid Hose between the voltage isolation system fluid outlet and the gun fluid inlet. See Accessories on page 66 for available hoses. The hose consists of an inner PTFE tube, a conductive layer covering the PTFE tube, and an outer cover.

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.

NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Check and follow all National, State, and Local codes regarding air exhaust velocity requirements.

Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufficient.

333012B 11

Installation

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.

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

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

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.

Install the Optional Fluid Line Accessories

1. Install a fluid filter and drain valve at the pump outlet.

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

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

12 333012B

IGURE

3 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.

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.

Installation

See Warning

above

Non-Hazardous Area

FIG. 3 . Typical Installation

Pneumatic

Interlock

(Pressurized when

Hazardous Area

Air Line

door is closed)

Voltage

Isolation

System WB100

Manifold Back View

The turbine air must also be interlocked with the voltage isolation system to shut off the turbine air when the access to the isolation system is opened.

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)

IGURE

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

G Graco Waterborne Fluid Supply Hose

333012B 13

Installation

Install the Gun

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

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

IGURE

(73.2 mm)

2.88 in.

To reduce the risk of electric shock or other serious injury, the red-colored Graco Grounded Turbine Air Hose must be used for the turbine air supply hose, and the hose ground wire must be connected to a true earth ground. Do not use the black or gray-colored Graco air hoses.

1. Connect the Graco Grounded Turbine Air Hose (B) to the gun's turbine air inlet (TA) and connect the hose ground wire (A) to a true earth ground (N). The gun turbine air inlet fitting has left-hand threads to prevent connecting another type of air hose to the turbine air inlet. See Accessories on page 66 for further information about the hose.

8.00 in.

(203.2 mm)

FIG. 4 . Mounting

nozzle tip

Install the Pro Xp Auto Control Module

The Pro Xp Auto Control Module is required for use with smart models. To install a Pro Xp Auto Control Module, see the module instruction manual 332989.

Connect the Air Line

IGURE

3 shows a schematic of air line connections, and

IGURE

5 shows the manifold connections. Connect the

air lines as instructed.

2. Check the electrical grounding of the gun as instructed on page 20.

Ground the Cabinet

Connect the main ground wire (V) to a true earth ground.

To reduce the risk of a fire, explosion, or electric shock, the Graco Grounded Turbine Air Hose must be interlocked with:

• The isolation system to shut off the turbine air supply anytime the enclosure is opened or entered.

• The ventilators to prevent operation of the power supply unless the ventilating fans are on.

14 333012B

Manifold Connections

Installation

FIG. 5 Manifold Connections

Atomization Air Inlet Fitting

Connect a 5/16 in. (8 mm) OD tube between this fitting and the air supply.

Fan Air Inlet Fitting

Connect a 5/16 in. (8 mm) OD tube between this fitting and the air supply.

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 20).

Fiber Optic Fitting Receive (Operational on Smart models only)

Connect the Graco Fiber Optic cable (see page 20).

Exhaust

EXH

Connect a 5/16 in OD exhaust tube to route the turbine exhaust air. (3 ft. max length)

Turbine Air Inlet Fitting

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

CYL

EXH

333012B 15

Installation

Connect the Waterborne Fluid Hose

NOTE: The Graco warranty is void if the spray gun is

connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.

Always use a Graco Waterborne Fluid Hose between the voltage isolation system fluid outlet and the gun fluid inlet. The waterborne fluid hose (600) consists of an inner PTFE tube (T), a conductive layer (C), and an abrasion-resistant outer jacket (J). The conductive layer is connected to ground at the isolation enclosure.

Before connecting the waterborne fluid hose to the gun, blow it out with air and flush with water to remove contaminants. Flush the gun before using it. See Flushing, page 28.

To reduce the risk of electric shock, install only one continuous Graco Waterborne Fluid Hose between the isolated fluid supply and the spray gun. Do not splice hoses together.

Waterborne Fluid Hose comes fully assembled to these dimensions.

A 5.75 in. (146 mm)

B 1.5 in. (38 mm)

TI1806A

FIG. 6 . Waterborne Hose Dimensions

3. Generously apply dielectric grease (40) to the o-ring (603) and the threads of the fitting (602). Pull the fitting back 1-1/2 in. (38 mm) and apply grease to the exposed PTFE hose to fill the area between the hose and the fitting. Make sure the barrel inlet is clean and dry, then screw the fitting into the fluid inlet of the gun barrel (1).

1. Remove the air cap (25) and shroud (26).

NOTICE

Be careful not to cut into the inner tube (T) of the hose when stripping the hose. Nicks or cuts in the PTFE tube will cause premature hose failure.

2. For the waterborne fluid hose to fit properly, it must be stripped and assembled to the dimensions shown in F

IGURE

6. Apply dielectric grease to the inner tube (T) of the hose. Slide the fitting (F) onto the tub (T). Press the barbed fitting (G) into the tube until its shoulder bottoms on the tube. A new Graco

4. Secure hose in strain relief bracket on the gun by tightening the four plastic screws.

Strain Relief Bracket

FIG. 7 . Connect the Waterborne Fluid Hose

16 333012B

For Shielded Hose Systems:

Conductive hose layer (C) must be grounded through its connection to the isolation system’s grounded enclosure (L) or grounded fence. To maintain grounding continuity, the conductive hose layer (C) must be engaged in the ferrule when the strain relief nut is tightened. Failure to properly install the hose in the strain relief could result in an electric shock.

5. Connect the other end of the hose to the isolated fluid supply as follows:

Graco WB100 Enclosure:

the strain relief fitting (W). Ensure conductive layer (C) has passed through fitting. Tighten to 55 in-lb (6.2 N•m). Pull back on hose to check it is secure. Comply with the requirements in the following Warning.

Slide hose through

Installation

Non-Graco Isolated Enclosure:

as instructed in the isolation system manual.

FIG. 10 Shielded Fluid Hose Connection at Non-Graco Isolation Enclosure

c. Connect the end of the tube (T) to the pump

fluid outlet fitting.

6. Reinstall the shroud (26) and air cap (25).

7. Check the gun’s electrical grounding (see page 20).

8. Connect the other end of the fluid hose to the fluid outlet of the isolated fluid supply. See F

Connect hose

IGURE

FIG. 8 Shielded Hose Dimensions at WB100 Enclosure

To reduce the risk of electric shock, the areas of the Graco Waterborne Fluid Hose that are accessible to personnel during normal operation must be covered by the outer hose jacket (J). The portion of the inner hose layer (T) not covered by the outer jacket must be inside the voltage isolation system enclosure (E).

The conductive hose layer (C) must be grounded through its connection to the isolation system’s grounded enclosure (E).

FIG. 9 Shielded Hose Connection at WB100 Enclosure

333012B 17

Installation

Fiber Optic Cable Connection

(Operational on Smart models only)

NOTE: Only use the supplied fiber optic cable.

The fiber optic cable allows the gun to communicate with the Pro Xp Auto Control Module.

For a 1 Gun System

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

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

For a 2 Gun System

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

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

FIG. 11 . Making Fiber Optic Connections

Port 1

Key for F

IGURE

H PRO Xp Auto Waterborne Air Spray 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

Non-Hazardous Area

Hazardous Area

Port 2

Port 5

Port 6

Gun 1

Gun 2

FIG. 12 . Fiber Optic Schematic

18 333012B

Installation

Agitator Kit Accessory

To add an agitator to the Graco isolation system, order Part No. 245895. See Agitator Kit 245895, page 64, for the kit parts list.

1. Discharge the system voltage (see Fluid Voltage Discharge and Grounding Procedure, page 24).

2. Relieve the pressure (see Pressure Relief Proce- dure, page 24).

3. Open the isolated enclosure door.

4. Remove the back of the control box (258).

5. Remove tube (A2) from elbow (282) at the air manifold; see Tubing and Wiring, page 62. Install the Y fitting (402) into the elbow. Install tubes (A2) and (407) into the Y fitting. Route the agitator tube (407) into the cabinet.

6. Replace the back of the control box (258).

7. Assemble the other parts of the kit as shown. Secure the agitator with the setscrew (408).

8. Return the system to service.

401

407

402

Fluid Regulator Kit Accessory

To add a fluid regulator to the Graco isolation system, order Part No. 245944. See Fluid Regulator Kit 245944, page 65 for the kit parts list.

1. Discharge the system voltage (see Fluid Voltage Discharge and Grounding Procedure, page 24).

2. Relieve the pressure (see Pressure Relief Proce- dure, page 24).

3. Open the isolated enclosure door.

4. Remove the 1/4 in. (6 mm) OD tube (A1) from the pump air inlet; see Tubing and Wiring, page 62.

5. Remove the waterborne fluid hose from the pump fluid outlet fitting (231) and remove the fitting.

6. Unscrew the two pump mounting screws (S) and remove the pump from the isolation enclosure.

7. Remove the back of the control box (258).

8. Remove tube (A2) from elbow (282) at the air manifold; see Tubing and Wiring, page 62. Install the Y fitting (506) in the elbow. Install tubes (A2) and (507) into the Y fitting. Route the tube (507) into the cabinet.

9. Replace the back of the control box (258).

406

403

408

404

406

FIG. 13 245895 Agitator Kit

10. Assemble the fluid regulator kit as shown.

11. Reinstall the pump in the isolation enclosure. Use the two mounting holes to the left of the holes used previously, to allow clearance for the fluid regulator.

12. Connect tube (A1) to the air inlet of fluid regulator (504). Connect tube (507) to the pump air inlet.

13. Connect the waterborne fluid hose to the fluid regulator outlet fitting (501).

14. Return the system to service.

333012B 19

Installation

NOTE: The cabinet air regulator and gauge (216, 217) will now operate the air piloted fluid regulator (504). The

pump will now operate at the inlet air pressure.

501

506

507

FIG. 14 . 245944 Fluid Regulator Kit

504

502

505

503

Grounding

•

Air compressors and hydraulic power supplies:

ground the equipment according to the manufacturer's recommendations.

•

All air and fluid lines 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:

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

•

The floor of the spray area:

ductive 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:

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

must be properly grounded.

shoes must

keep the workpiece hangers

must be electrically con-

must be kept in

All

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 waterborne system. Your system may include other equipment or objects which must be grounded. Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground.

•

Electrostatic Air Spray Gun:

necting the red-colored Graco Grounded Air Hose to the turbine air inlet and connecting the air hose ground wire to a true earth ground. See Check Electrical Grounding, page 20

•

Graco Waterborne Fluid Hose:

grounded through the conductive layer. Install the hose as instructed on page 16.

ground the gun by con-

the hose is

•

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:

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 metal

Check Electrical Grounding

•

Voltage Isolation System:

voltage isolation system to a true earth ground.

20 333012B

electrically connect the

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

Installation

4. Measure the resistance between the turbine air inlet fitting (TA) and a true earth ground (N). If the resistance is greater than 100 ohms, check the tightness of the ground connections and be sure the turbine air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the

turbine air hose

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 red-colored turbine air hose (B) is connected and the hose ground wire is connected to a true earth ground.

3. Turn off the air and fluid supply to the gun. Follow the Pressure Relief Procedure, page 24. The fluid hose must not have any fluid in it.

WLD

FIG. 15 . Check Gun Grounding

5. If using the WB100 use an ohmmeter (AA) to measure the resistance between the cabinet ground lug (214) and a true earth ground (CC). The resistance

must be less than 100 ohms.

214

FIG. 16 . Check Cabinet Grounding

333012B 21

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