Graco 333013B User Manual

Instructions-Parts

Pro Xp Auto

333013B

Waterborne AA Spray Gun

Air-assisted spray system for use when electrostatically spraying conductive, waterborne fluids that meet at least one of the following conditions for non-flammability:

•

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

•

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

For professional use only.

100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure 3000 psi (21 MPa, 210 bar) Maximum Working Fluid Pressure

Important Safety Instructions

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

See page 2 for Table of Contents.

WLD

Table of Contents

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

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

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

How the Electrostatic AA 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 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 . . . . . . . . . . . . . . . . . . . 17

Agitator Kit Accessory . . . . . . . . . . . . . . . . . . . . . . . . . 18

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Check Electrical Grounding . . . . . . . . . . . . . . . . . . . . 19

Install the Fabric Cover . . . . . . . . . . . . . . . . . . . . . . . . 20

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . 20

Flush Before Using Equipment . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fluid Voltage Discharge and Grounding

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 22

Select a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Fill the Fluid Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Set the Atomization Fluid Pressure . . . . . . . . . . . . . . . 23

Adjust the Electrostatics . . . . . . . . . . . . . . . . . . . . . . . 24

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Triggering the Fluid Alone . . . . . . . . . . . . . . . . . . . . . . 25

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Daily Care and Cleaning Checklist . . . . . . . . . . . . . . . 26

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Clean Outside of Gun . . . . . . . . . . . . . . . . . . . . . . . . . 27

Clean the Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . 27

Check for Fluid Leakage . . . . . . . . . . . . . . . . . . . . . . .28

Clean the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 29

Test Power Supply Resistance . . . . . . . . . . . . . . . . . . 29

Test Barrel Resistance . . . . . . . . . . . . . . . . . . . . . . . . 29

Test Ground Strip Resistance . . . . . . . . . . . . . . . . . . 30

Test Cylinder Resistance . . . . . . . . . . . . . . . . . . . . . . 30

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Voltage Loss Troubleshooting . . . . . . . . . . . . . . . . . . 31

Spray Pattern Troubleshooting . . . . . . . . . . . . . . . . . . 34

Gun Operation Troubleshooting . . . . . . . . . . . . . . . . . 35

Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . 37

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Prepare the Gun for Service . . . . . . . . . . . . . . . . . . . . 38

Remove the Gun from the Manifold . . . . . . . . . . . . . . 38

Install the Gun on the Manifold . . . . . . . . . . . . . . . . . . 38

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

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Electrode Replacement . . . . . . . . . . . . . . . . . . . . . . . 40

Fluid Needle Replacement . . . . . . . . . . . . . . . . . . . . . 40

Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . . . . . . 42

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Power Supply Removal and Replacement . . . . . . . . . 43

Turbine Removal and Replacement . . . . . . . . . . . . . . 44

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Standard Pro Xp Auto Waterborne AA Gun

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

HA1T18, Rear Manifold . . . . . . . . . . . . . . . . . . . . . . . 46

Smart Pro Xp Auto Waterborne AA Gun

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Air Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Waterborne Fluid Hose . . . . . . . . . . . . . . . . . . . . . . . . 50

Turbine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

WB 3000 Isolation Enclosure . . . . . . . . . . . . . . . . . . . 52

Tubing and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Agitator Kit 245895 . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Rear Inlet Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . 59

AEM Fine Finish Spray Tips . . . . . . . . . . . . . . . . . . . . 59

AEF Fine Finish Pre-Orifice Spray Tips . . . . . . . . . . . 60

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Graco Pro Xp Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2 333013B

List of Approved Models

Part No. kV

HA1M18 60

HA1T18 60

Part No. Description

24X288 WB 3000 Isolation Enclosure 24W599 25’ Waterborne Fluid Hose 24W077 50’ Waterborne Fluid Hose

0.35 J with 50 ft hose max FM14ATEX0082

EN 50059

Ta 0°C-50°C

1.5mm Nozzle

Standard

Model

✔✔ ✔ ✔✔ ✔

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

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

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 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

333013B 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 333013B

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.

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.

333013B 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.

6 333013B

Introduction

How the Electrostatic AA Spray Gun Works

This is not an air spray gun. To help prevent serious injury from pressurized fluid, such as skin injection, and splashing fluid, read and follow the Skin Injection Hazard Warnings on page 5.

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

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

Operating the Spray Function

Applying a minimum of 60 psi (0.42 MPa, 4.2 bar) air pressure to the gun manifold’s cylinder air fitting (CYL) will retract the gun piston, which opens the air valves and a short time later opens the fluid needle. This 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 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.

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

• Use a PLC to select a spray profile

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.

333013B 7

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

Introduction

Spraying Waterborne Fluids Electrostatically

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

FM, FMc Approved:

• 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 AA 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 Operating Checklist on page 22 before approaching the front of the gun.

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

8 333013B

System Overview

Typical Waterborne System Installation

IGURE

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

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

Also refer to system pneumatic connections in F

IGURE

Introduction

3, page 13.

FIG. 1 Typical Installation, Pro Auto Xp 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

N Pneumatic connection to turbine air interlock.

(Pressurized when isolation system door is closed)

333013B 9

Item Description

R Graco Waterborne Fluid Hose

T Grounding Rod

U Ground Terminal

V* Main Ground Wire

W Strain Relief Fitting

X Pump Air Supply Line

Y Grounding Cylinder

Z Pump Fluid Outlet Fitting

AA Isolated Enclosure Door (not shown, to illustrate

internal components. Door must be closed and locked to operate system).

BB Enclosure T-Handle Locking Screw (part of door

assembly)

* These items are required for safe operation. They are included with the WB3000 system.

Introduction

Gun Overview

CYL

EXH

Fig. 2. Gun Overview

Key

AAir Cap

B Spray Tip

C Retaining Ring

D Shroud

FManifold

G Turbine

H Power Supply

J Electrode

L Waterborne Fluid Hose

10 333013B

Manifold Markings

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

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.

• 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 57 for available hoses. The hose consists of an inner PTFE tube, a conductive layer covering the PTFE tube, and an outer cover.

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

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Do not operate the gun unless ventilation fans are operating.

Electrically interlock the gun turbine air supply (B) with the ventilators to prevent gun operation without 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.

333013B 11

Installation

Install the Air Line Accessories

1. Install a bleed-type 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 main air supply line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

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

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

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

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 Fluid Line Accessories

1. Install a fluid filter and drain valve at the pump outlet. Filtering the fluid will help remove coarse parti-

cles and sediment that could clog the spray tip.

The fluid drain valve is required in your system to assist in relieving fluid pressure in the displacement pump, hose, and gun. Triggering the gun to relieve pressure may not be sufficient. Install a drain valve close to the pump's fluid outlet. The drain valve reduces the risk of serious injury, including splashing in the eyes or on the skin.

12 333013B

IGURE

3 shows a typical electrostatic air-assisted spray system. It is not an actual system design. For assistance in

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

The turbine air supply (TA) must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on.

Installation

See Warning

Non-Hazardous Area

FIG. 3 . Typical Installation

Key to F

IGURE

above

Pneumatic

Interlock

Hazardous Area

Air Line

(Pressurized when

door is closed)

Manifold Back View

Voltage

Isolation

System

WB3000

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.

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)

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

333013B 13

Installation

Install the Gun

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

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

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

8.18 in.

(207.7 mm)

IGURE

2.88 in.

(73.2 mm)

nozzle tip

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 57 for further information about the hose.

2. Check the electrical grounding of the gun as instructed on page 19.

FIG. 4 Mounting Bracket

Install the Pro Xp Auto Control Module

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

Connect the Air Line

IGURE

3 shows a schematic of air line connections, and

IGURE

5 shows the manifold connections. Connect the

air lines as instructed.

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.

Ground the Cabinet

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

14 333013B

Manifold Connections

Installation

EXH

FIG. 5 Manifold Connection

A1 Atomization Air Inlet Fitting

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

A2 Fan Air Inlet Fitting

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

CYL Cylinder Air Inlet Fitting

Connect a 5/32 in. (4 mm) OD tube between this fitting and the solenoid. For quicker response, use the shortest hose length possible.

1 Fiber Optic Fitting Transmit (Operational on Smart models only)

Connect the Graco Fiber Optic cable (see page 17).

2 Fiber Optic Fitting Receive (Operational on Smart models only)

Connect the Graco Fiber Optic cable (see page 17).

EXH Exhaust

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

TA Turbine Air Inlet Fitting

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

CYL

333013B 15

Installation

Connect the Waterborne Fluid Hose

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

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

Always use a Graco Waterborne Fluid Hose between the voltage isolation system fluid outlet and the gun fluid inlet.

Before connecting the Waterborne Fluid Hose to the gun, blow it out with air and flush with water to remove contaminants. Flush the gun before using it. See Flush- ing, page 26.

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

1. Remove the air cap (25), spray tip (3), and shroud (26).

To reduce the risk of electric shock, the areas of the Graco Waterborne Fluid Hose that are accessible to personnel during normal operation must be covered by the black outer hose jacket.

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

Graco WB3000 Enclosure:

of the hose through the hole in the side of the isolated enclosure. Connect the swivel (Z) to the fluid outlet of the pump. Secure the hose to the side of the enclosure with the bracket (W).

Non-Graco Isolated Enclosure:

as instructed in the isolation system manual.

6. Reinstall the shroud (26), spray tip (3), and air cap (25).

7. Check the gun’s electrical grounding (see page 19).

Slide the other end

Connect hose

2. Ensure the barrel fluid inlet is clean and dry. Apply dielectric grease to the threads of the barrel connector (600a) and screw it in to the fluid inlet.

3. Apply dielectric grease to the threads of the hose (600) and screw it in to the barrel connector (600a).

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

Strain Relief Bracket

FIG. 6 Connect the Waterborne Fluid Hose

FIG. 7 . Unshielded Hose 24W599 Connection at WB3000 Enclosure

16 333013B

Fiber Optic Cable Connection

(Operational on Smart models only)

Installation

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

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. 8 . Making Fiber Optic Connections

Hazardous Area

Port 1

Key for F

H PRO Xp Auto Waterborne AA Spray Gun P 24 Volt Power Supply Connection Q Remote I/O Connection R Remote Control Module U Bulkhead V Fiber Optic Cable

IGURE

Port 2

Port 5

Port 6

Gun 1

Gun 2

FIG. 9 . Fiber Optic Schematic

333013B 17

Installation

Agitator Kit Accessory

To add an agitator to the Graco isolation system, order Part No. 245895. See Agitator Kit 245895, page 56, for the kit parts list.

1. Discharge the system voltage (see Fluid Voltage Discharge and Grounding Procedure, page 22).

2. Relieve the pressure (see Pressure Relief Proce- dure, page 22).

3. Open the isolated enclosure door.

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

5. Remove tube (A2) from elbow (282) at the air manifold; see Tubing and Wiring, page 54. Install the Y fitting (402) into the elbow. Install tubes (A2) and (407) into the Y fitting. Route the agitator tube (407) into the cabinet.

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

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

8. Return the system to service.

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 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 19

ground the gun by con-

401

406

403

408

404

406

FIG. 10 245895 Agitator Kit

407

402

•

Voltage Isolation System:

voltage isolation system to a true earth ground.

•

Air compressors and hydraulic power supplies:

ground the equipment according to the manufacturer's recommendations.

•

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.

electrically connect the

shoes must

keep the workpiece hangers

must be electrically con-

must be kept in

18 333013B

Installation

•

All electrically conductive objects or devices in the spray area:

including fluid containers and wash

cans, must be properly grounded.

•

Fluid and waste containers:

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

•

All solvent pails:

use only approved, grounded metal containers, which are conductive. Do not use plastic containers. Use only non-flammable solvents. Do not store more than the quantity needed for one shift.

Check Electrical Grounding

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

11)

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

WLD

Fig. 11. Check Gun Grounding

5. If using the WB3000 use an ohmmeter (AA) measure the resistance between the cabinet ground lug (214) and a true earth ground (CC). The resistance

must be less than 100 ohms.

214

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

FIG. 12 . Check Cabinet Grounding

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 22. The fluid hose must not have any fluid in it.

333013B 19

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