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

Installation

Install the Fabric Cover

See F

IGURE

13.

1. Install a fabric cover (XX) over the front of the gun and slide it back to cover the exposed tubing and hoses at the back of the manifold.

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

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

Flush Before Using Equipment

The equipment was tested in fluid at the factory. To avoid contaminating your fluid, flush the equipment with a compatible solvent before using the equipment. See Flushing, page 26.

WLD

FIG. 13 . Fabric Cover

20 333013B

Operation

Operating Checklist

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 waterborne air spray system as instructed in this manual.

All operators are trained in the Fluid Voltage Discharge and Grounding Procedure on page 22.

All operators are trained in the Pressure Relief Procedure on page 22.

The electrostatics are turned off and system voltage is discharged according to the Fluid Voltage Discharge and Grounding Procedure, page 22, before any person enters the isolation enclosure, before cleaning, and before performing any maintenance or repair.

The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators.

The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded. See Grounding on page 18.

The Graco Waterborne Fluid Hose is in good condition with no cuts or abrasions. Replace hose if damaged.

The condition of the gun’s electrical components has been checked as instructed in Electrical Tests on page

29.

All fluid hose connections are tight.

Ventilation fans are operating properly.

Workpiece hangers are clean and grounded.

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

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

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

The manifold exhaust tubes have been checked for the presence of any fluid as instructed in Check for Fluid Leakage on page 28.

Fluids used must meet the following flammability requirements:

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

CE-EN 50059 Compliant: Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500mJ.

333013B 21

Operation

Fluid Voltage Discharge and Grounding Procedure

The fluid supply is charged with high voltage until the voltage is discharged. Contact with the charged components of the voltage isolation system or spray gun electrode will cause an electric shock. To avoid an electric shock, follow the Fluid Voltage Discharge and Grounding Procedure:

• whenever you are instructed to discharge the voltage

• before cleaning, flushing, or servicing the system equipment

• before approaching the front of the gun

• or before opening the isolation enclosure for the isolated fluid supply.

NOTE: An accessory grounding rod, part No. 210084, is available to discharge any voltage remaining on a system component. Contact your Graco distributor to order.

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 and splashing fluid follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Follow the Fluid Voltage Discharge and Ground- ing Procedure, page 22.

2. Relieve fluid pressure in the fluid supply and voltage isolation system as instructed in their instruction manuals.

3. Turn off all the air to the spray gun except the cylinder air, which triggers the gun.

1. Turn off the turbine air to all spray guns connected to the isolated fluid supply and wait 30 seconds.

2. Discharge the voltage at the voltage isolation system by following the procedure specified in the voltage isolation system instruction manual.

For WB3000: fully unscrew the door T-handle locking screw. This will shut off the air to the gun and trigger the grounding cylinder to discharge any remaining electrical charge.

3. Touch the pump, supply pail, and electrode of the gun with a grounded rod to make sure the voltage has been discharged. If you see an arc, verify that the electrostatics are turned off or see Electrical Troubleshooting, page 37 or the voltage isolation system manual for other possible problems. Resolve the problem before proceeding.

NOTE: The air shut-off device must bleed the air out of the system.

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

5. Turn off all remaining air supplies to the gun.

6. Turn off the main air supply by closing the bleed-type master air valve on the main air supply line. Leave the valve closed until you are ready to spray again.

7. If you suspect the fluid hose or tip is plugged, or that pressure is not fully relieved after following the steps above, slowly loosen the fluid hose fitting at the pump to relieve pressure gradually, then loosen completely.

Select a Spray Tip

The fluid output and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pressure. Use the Spray Tip Selection Chart, page 59, as a guide for selecting the appropriate spray tip for your application.

22 333013B

Operation

Install the Spray Tip

To reduce the risk of an injury, follow the Pressure Relief Procedure before removing or installing the

spray tip or air cap/tip guard.

Install the spray tip as explained in Air Cap/Tip Guard, Spray Tip, and Fluid Seat Housing Replacement, page 39.

1. Follow the Pressure Relief Procedure, page 22.

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

WLD

FIG. 14 Spray Tip Alignment

4. Remove the pail cover from the pail, holding a rag over the suction tube strainer to prevent any fluid from dripping into the isolated enclosure. Place the cover and suction tube outside the enclosure.

5. Remove the supply pail from the enclosure.

NOTICE

Be sure to wipe up all fluid spills in the isolated enclosure. Fluid can create a conductive path and cause the system to short out.

6. Clean up any fluid spills in the enclosure, using a soft cloth and a non-flammable, compatible solvent.

7. Fill the supply pail with fluid and return it to the enclosure. Clean up any spills.

8. Reinstall the pail cover, holding a rag over the suction tube strainer to prevent fluid spills while you place the pump suction tube in the pail.

9. Close the isolated enclosure door and fasten securely with the T-handle locking screw.

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.

WLD

FIG. 15 Install Air Cap Assembly

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

Fill the Fluid Supply

Set the Atomization Fluid Pressure

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.

1. Follow the Fluid Voltage Discharge and Ground- ing Procedure, page 22.

2. Follow the Pressure Relief Procedure, page 22.

3. Open the isolated enclosure door.

333013B 23

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).

Operation

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

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

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

See Spray Pattern Troubleshooting on page 34 to correct spray pattern problems.

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

Correct

No Air

Too Little Air

Amount of Air

FIG. 16 Eliminating Tails

Adjust the Electrostatics

1. Shut off the fluid supply.

4. Check the turbine speed of the gun by checking the indicator light on the standard gun body or for the smart gun check the actual turbine speed on the Pro Xp Auto Control Module. See Table 2 . Adjust the air pressure as necessary to keep the indicator light green or the values within 100-750 Hz.

NOTE: Smart models display values not color indicator lights.

Table 2. Indicator Colors/Values

Indicator

Description

Color

Green

400-750 Hz

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

Amber

<400

If the indicator changes to amber after 1 second, the air pressure is too low. Increase air pressure until the indicator is green.

Red

>750

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.

5. Check the voltage output by reading the kV meter on the isolated enclosure. 45-55 kV is normal.

See Electrical Troubleshooting, page 37 to correct voltage problems.

2. Prepare the isolation system for high voltage operation.

3. 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

when air is

Table 1. Approximate Dynamic Turbine Air

Pressures

Turbine Air

Hose Length

ft (m)

Air pressure at turbine air hose inlet

for full voltage

psi (bar, MPa)

15 (4.6) 54 (3.8, 0.38)

25 (7.6) 55 (3.85, 0.38)

36 (11) 56 (3.9, 0.39)

50 (15.3) 57 (4.0, 0.40)

75 (22.9) 59 (4.1, 0.41)

100 (30.5) 61 (4.3, 0.43)

24 333013B

Operation

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 (P1). 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. For smart gun models, to change to a lower voltage setting, see the Remote 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, page 28.

IGURE

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

1. Follow the Fluid Voltage Discharge and Grounding Procedure, page 22.

2. Follow the Pressure Relief Procedure, page 22.

3. Flush and clean the equipment. See Maintenance on page 26.

333013B 25

Maintenance

To reduce the risk of an injury, follow the Pressure Relief Procedure and the Fluid Voltage Discharge and Grounding Procedure before doing any

maintenance on the gun or system.

Flushing

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

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

Daily Care and Cleaning Checklist

Check the following list daily upon completion of equipment usage.

Flush the gun. See Flushing, page 26.

Clean the fluid and air line filters.

Clean the outside of the gun. See Clean Out- side of Gun, page 27.

Clean the air cap, spray tip, and tip guard daily, minimum. Some applications require more frequent cleaning. Replace the parts if they are damaged. See Clean the Spray Gun, page 27.

Check the electrode and replace if broken or damaged. See Electrode Replacement on page 40.

Check for fluid leakage from the gun and fluid hoses. See Check for Fluid Leakage on page 28. Tighten fittings or replace equipment as needed.

Check Grounding,

page 18

• 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.

Follow the Fluid Voltage Discharge and Grounding Procedure, page 22, before flushing.

Only flush, purge, or clean the gun with fluids that meet the following flammability requirements:

FM, FMc Approved:

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

CE-EN 50059 Compliant:

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

NOTICE

Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components.

1. Turn off the turbine air and wait 30 seconds for the voltage to bleed off.

2. Discharge the system voltage. See Fluid Voltage Discharge and Grounding Procedure, page 22.

3. Follow the Pressure Relief Procedure, page 22.

4. Remove and clean the air cap and spray tip.

5. Change the fluid source to non-flammable solvent.

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

26 333013B

Clean Outside of Gun

NOTICE

• Clean all parts with a non-conductive, compatible solvent. Conductive solvents can cause the gun to malfunction.

• Fluid in the air passages could cause the gun to malfunction and could draw current and reduce the electrostatic effect. Fluid in the power supply cavity can reduce the turbine life. Whenever possible, point the gun down when cleaning it. Do not use any cleaning method which could allow fluid into the gun air passages.

1. Follow the Fluid Voltage Discharge and Ground- ing Procedure, page 22

2. Flush the gun. See Flushing, page 26

Maintenance

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

1. Discharge the system voltage.

2. Follow the Pressure Relief Procedure, page 22.

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

39.

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

IGURE

3. Follow the Pressure Relief Procedure, page 22.

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.

WLD

WLD

WLD

Clean the Spray Gun

Equipment Needed

• soft bristle brush

• compatible solvent

Procedure

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

02007

FIG. 17 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

18.

Contact with the charged components of the spray gun will cause an electric shock. Do not touch the

FIG. 18 Clean Gun Body

gun nozzle or electrode or come within 4 in. (102 mm) of the front of the gun during operation or until performing the Fluid Voltage Discharge and Grounding Procedure, page 22.

6. 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).

333013B 27

Maintenance

NOTICE

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

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

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

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

9. Check the condition of the spray tip gasket and install the spray tip in the aircap, page 23.

10. Install the spray tip and air cap/tip guard, shroud, and retaining ring, page 23. Be sure the electrode (25a) is in place.

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.

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

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

19. Fluid in these areas indicates leakage into the shroud, which could be caused by leaks at the fluid tube connections or fluid packing leakage.

If fluid is seen in these areas, stop spraying immediately. Discharge the system voltage, relieve the pressure, then remove the gun for repair.

IGURE

11. Test Gun Resistance, page 29.

FIG. 19 Check for Fluid Leakage

Clean the cabinet

• Inspect the cabinet and clean up any spilled paint. Conductive paint residue allowed to contact grounded parts may short out the electrostatics.

• Keep the inside of the cabinet clean, for proper operation.

• Inspect the door T-handle locking screw regularly, to ensure the threads are well greased. Apply silicone-free grease to the threads when necessary.

• Visually inspect the ground strip (240) for damage. Replace if needed. Measure the resistance weekly. See Test Ground Strip Resistance, page 30.

28 333013B

Electrical Tests

Use the following procedures to test the condition of the power supply and gun body, and electrical continuity between components. See Power Supply Removal and Replacement, page 43.

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

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;

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

IGURE

20)

Test Power Supply Resistance

1. Remove the power supply (7), page 43.

2. Remove the turbine (8) from the power supply, page

44.

3. Measure resistance from the power supply's ground strips (EE) to the spring (7a). See F

4. The resistance should be 90-115 megohms. If outside this range, replace the power supply. If in range, proceed to the next test.

5. If you still have problems, refer to Electrical Trou- bleshooting, page 37 for other possible causes of poor performance, or contact your Graco distributor.

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

IGURE

21.

Test Gun Resistance

1. Flush and dry the fluid passage.

2. Measure the resistance between the electrode (25a) and the turbine air fitting. The resistance should be 104–150 megohms. If outside this range, go to Test Power Supply Resistance, page 29. If in range, see Voltage Loss Troubleshooting, page 31 for other possible causes of poor performance, or contact your Graco distributor.

25a

FIG. 20 . Test Gun Resistance

FIG. 21 . Test Power Supply Resistance

Test Barrel Resistance

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

2. Measure the resistance between the conductive rod (B) and the conductive ring (33). See 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.

IGURE

22.

333013B 29

Electrical Tests

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.

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.

Test Ground Strip Resistance

Using an ohmmeter, measure the resistance between the latch housing (206) and the ground lug (214). The ground strip is grounded through the cart back to the ground lug. Resistance must be less than 100 ohms. If greater than 100 ohms, replace the ground strip (240).

206

214

FIG. 23 . Test Electrode Resistance

Test Cylinder Resistance

Remove the enclosure door. Using an ohmmeter, measure the resistance from the pump (209) to the ground lug (214). Resistance must be less than 100 ohms. If greater than 100 ohms, replace the grounding cylinder

(227).

FIG. 22 Test Gun Barrel Resistance

30 333013B

FIG. 24 Test Cylinder Resistance

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.

Follow the Fluid Voltage Discharge and Grounding Procedure before checking or servicing the system and whenever you are instructed to discharge the voltage.

Troubleshooting

Before troubleshooting or servicing the voltage isolation system itself, you need to determine which component in the system is most likely causing a problem. Possible causes include the following:

Spray Gun

• Fluid leakage

• Dielectric breakdown at the fluid hose connection or fluid packings

• Not enough air pressure for the turbine

• Faulty power supply

• Excessive overspray on gun surfaces

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

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

Voltage Loss Troubleshooting

Normal spraying voltage for a system using the waterborne gun is 45-55 kV. The system voltage is lower due to spraying current demands and voltage isolation system losses.

A loss of spraying voltage can be caused by a problem with the spray gun, fluid hose, or voltage isolation system, since all of the system components are electrically connected through the conductive, waterborne fluid.

• Fluid in the air passages

Waterborne Fluid Hose

• Dielectric failure of the hose (pin-hole leak in the PTFE layer)

• Air gap in the fluid column between the gun and the isolated fluid supply, causing a low voltage reading on the isolation system voltage meter.

Voltage Isolation System

• Fluid leakage

• Dirty interior

• Dielectric breakdown of hoses, seals, or connections

• Isolators not functioning properly

333013B 31

Troubleshooting

Visual Checks

First, check the system for any visible faults or errors to help isolate whether the spray gun, fluid hose or voltage isolation system has failed. A voltage probe and meter, part no. 245277, is helpful for diagnosing voltage problems and is required for some of the troubleshooting tests that follow.

1. Check that all of the air and fluid tubes and hoses are properly connected.

2. Check that the voltage isolation system valves and controls are properly set for operation.

3. Check that the interior of the isolated enclosure is clean.

4. Check that the spray gun and voltage isolation system have sufficient air pressure.

5. Check that the spray gun and voltage isolation system have sufficient air pressure.

6. Check that the gun turbine air (TA) is turned on and the pressure is set correctly.

7. Check that the voltage isolation system's enclosure door is closed and that any safety interlocks are engaged and working properly.

8. Make sure the voltage isolation system is in the “isolate” mode, where it is isolating the fluid voltage from ground.

9. To eliminate air gaps in the fluid column, spray enough fluid to purge the air out between the voltage isolation system and the spray gun. An air gap in the fluid hose can break the electrical continuity between the spray gun and the isolated fluid supply and cause a low voltage reading on a voltage meter connected to the isolated fluid supply.

10. Check the spray gun cover and barrel for accumulated overspray. Excessive overspray can create a conductive path back to the grounded gun body. Install a new gun cover and clean the exterior of the gun.

11. Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found. Pay special attention to the following areas:

• Packing area of the spray gun.

• Fluid hose: check for leakage or any bulges in

the outer cover, which may indicate an internal leak.

• Internal voltage isolation system components

32 333013B

Tests

Troubleshooting

If you still have no voltage, separate the spray gun and hose from the voltage isolation system and check whether the gun and hose alone will hold voltage with the following test.

1. Flush the system with water and leave the lines filled with water.

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

3. Follow the Pressure Relief Procedure on page 22.

4. Disconnect the fluid hose from the voltage isolation system.

Avoid allowing any water to leak out of the fluid hose as that could cause a significant air gap in the fluid column up to the gun electrode, which can break the conductivity path and conceal a potential failure area.

5. Position the end of the hose as far as possible away from any grounded surface. The end of the hose must be at least 1 ft. (0.3 m) from any ground. Make sure that no one is within 3 ft. (0.9 m) of the end of the hose.

6. Turn the turbine air to the gun on. Measure the voltage at the gun electrode with a voltage probe and meter.

7. Discharge the system voltage by waiting 30 seconds and then touching the gun electrode with a grounded rod.

8. Check the meter reading:

• If the meter reading is 45 to 55 kV, the gun and

fluid hose are okay, and the problem is in the voltage isolation system.

• If the meter reading is below 45 kV, the problem

is in the gun or fluid hose.

down somewhere in the fluid hose or gun. Continue with step 12.

If the reading is below 55 kV, do the electrical tests on page 33 to check the gun and power supply resistance. If those tests show the gun and power supply are okay, continue with step 12.

12. A dielectric breakdown is most likely in one of the following three areas. Repair or replace the component that is failing.

a. Fluid hose:

• Check for leakage or any bulges in the outer cover, which may indicate a pin-hole leak through the PTFE layer. Disconnect the fluid hose from the gun, and look for signs of fluid contamination on the outside of the fluid tube.

• Inspect the end of the hose connected to the voltage isolation system. Look for cuts or nicks.

b. Fluid needle:

• Remove the fluid needle from the gun (see Fluid Needle Replacement, page 40), and look for signs of fluid leakage or any blackened areas, which would indicate arcing is occurring along the packing rod.

c. Fluid hose connection to the spray gun:

• A breakdown at the fluid hose connection joint would be caused by fluid leaking past seals on the end of the hose. Remove the hose at the gun connection and look for signs of fluid leakage along the tube.

13. Before reassembling the gun, clean and dry the gun fluid inlet tube. Repack the inner spacer of the fluid packing rod with dielectric grease and reassemble the gun.

14. Reconnect the fluid hose.

9. Flush the fluid hose and gun with enough air to dry out the fluid passages.

10. Turn the turbine air to the gun on. Measure the voltage at the gun electrode with a voltage probe and meter.

11. If the meter reading is 55-60 kV, the gun power supply is okay, and there is probably a dielectric break-

333013B 33

15. Check the gun voltage with the voltage probe and meter before filling the gun with fluid.

Troubleshooting

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 27.

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.

Air cap holes plugged. Clean. See page 27.

Fluid pressure too low. Increase.

Plugged or damaged air cap hole Clean, see page 27.

34 333013B

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 59.

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 (2);

see Fluid Needle Replacement, page 40.

41.

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

page 40

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

Spray Tip, and Fluid Seat Housing Replacement page 39.

Loose spray tip. Tighten retaining ring (24); see Air

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

page 39.

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

Spray Tip, and Fluid Seat Housing Replacement page 39.

333013B 35

Troubleshooting

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 39.

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

page 27.

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

ment, page 40.

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

o-ring (11d); see Piston Repair, page 41.

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

page 42.

Dirty air cap Damaged or plugged air cap Clean; see Clean the Spray Gun,

page 27.

Air leaks from manifold Manifold is not tight Tighten manifold screws

Worn or missing o-rings Replace o-rings. See page 42

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

Replacement, page 40

Piston sticking Clean or replace o-rings. See Piston

Repair, page 41

Excessive paint wrap back to operator

Poor grounding See Grounding, page 18

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

36 333013B

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, page 29.

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

ES or Hz indicator light is not lit (standard models only)

ES indicator light is amber (standard models only)

ES indicator light is red (standard models only)

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

Faulty Power Supply Replace power supply, see page 43

Damaged fiber optic cable or connection.

Turbine air is not turned on. Turn on.

Spilled paint, dried paint, or other contaminants inside the WB3000 Enclosure, causing a short circuit.

Grounding cylinder not retracted Check operation of grounding cylin-

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

Clean the fluid needle cavity and see Fluid Needle Replacement, page 40

Replacement page 44

Check; replace damaged parts

Clean.

der.

ribbon cable. See Power Supply Removal and Replacement, page 43 and Turbine Removal and Replacement, page 44.

green.

is green

See manual 332989 for Event Code Troubleshooting.

Troubleshooting

333013B 37

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.

Contact with the charged components of the spray gun will cause an electric shock. Do not touch the gun nozzle or electrode or come within 4 in. (102 mm) of the front of the gun during operation or until performing the Fluid Voltage Discharge and

Grounding Procedure

To reduce the risk of injury, follow the Pressure Relief Procedure before checking or servicing any

part of the system and whenever you are instructed to relieve the pressure.

2. Flush and clean the gun, page 26.

3. Follow the Pressure Relief Procedure, page 22.

4. Remove the air cap (25) and shroud (26), page 39.

5. Loosen the strain relief bracket.

6. Disconnect the fluid hose fitting (600A) from the gun barrel (1).

7. Loosen two manifold screws (21) and remove gun.

NOTE: The screws (21) should stay on the manifold and the five o-rings (18) should stay on the gun.

NOTE:

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

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

• Lubricate some packing rod parts (2) and certain fluid fittings with dielectric grease (36), 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.

• Air Seal Repair Kit 24W396 is available. The kit must be purchased separately. Kit parts are marked with an asterisk, for example (6a*).

Remove the Gun from the Manifold

1. Follow the Fluid Voltage Discharge and Grounding Procedure, page 22.

FIG. 25 Remove Gun from Manifold

Install the Gun on the Manifold

1. Make sure the five o-rings (18) are in place.

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

3. Make sure the hose fittings and barrel are clean and dry, then reconnect the Waterborne Fluid Hose, page 16.

4. Tighten strain relief screws.

5. Reinstall the gun shroud (26) and air cap (25), page

39.

38 333013B

Repair

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

1. See Prepare the Gun for Service, page 38.

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

FIG. 26 Remove Air Cap

3. 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

24a

25a

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

WLD

FIG. 27 Disassemble Air Cap Assembly

WLD

FIG. 28 Tip Gasket

4. To replace the electrode (25a), see Electrode Replacement, page 40.

FIG. 29 Seat Housing Replacement

NOTICE

To avoid damaging the seat housing and gun barrel, never overtighten the seat housing. Overtightening may affect the fluid shutoff.

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

7. 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.

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

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

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

333013B 39

Repair

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.

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

12. See Test Gun Resistance, page 29.

Electrode Replacement

1. See Prepare the Gun for Service, page 38.

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

Air Cap/Tip Guard, Spray Tip, and Fluid Seat Housing Replacement, page 39.

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

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

5. Install the air cap assembly.

6. See Test Gun Resistance, page 29.

Fluid Needle Replacement

1. Prepare the gun for service, page 38.

2. Remove the air cap/tip guard assembly and seat housing, page 39.

3. Remove the barrel (1), page 42.

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

31.

7. Install the fluid needle assembly in the gun barrel. Push in on the needle with the 2 mm ball end wrench (45) and tighten. See F

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

overtighten.

10. Install the barrel (1), page 43.

IGURE

30.

IGURE

32.

25a

NOTICE

To avoid damaging the seat housing and gun barrel, never overtighten the seat housing. Overtightening may result in improper fluid shutoff.

11. Install the seat housing and air cap, page 39.

12. Test Gun Resistance, page 29.

ti19524

FIG. 30 Spring Cap and Springs

40 333013B

Repair

FIG. 31 Fluid Needle Removal

FIG. 32 Fluid Needle Replacement

11a

11d

11c

11f

11e

11b

WLD

11d

11g

11f

11e

Fan Air Side

Atomizing Air Side

WLD

FIG. 33 . Piston O-Rings

Piston Repair

1. Prepare the gun for service, page 38.

2. Remove the air cap, page 39. Remove the gun shroud (26).

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

33.

IGURE

34.

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.

9. Install and adjust the actuator arm, page 42.

333013B 41

Repair

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

34.

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.

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

4. Test gun resistance, page.

5. Install the gun shroud (26) and air cap/tip guard assembly (25), page 39.

6. Install the gun onto the manifold. See page 38.

Barrel Removal

See F

IGURE

1. Prepare the gun for service and remove the gun from the manifold, page 38.

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

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

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.

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

IGURE

34.

NOTICE

IGURE

36.

0.125 in. (3 mm) gap

WLD

16a

16b

11b

FIG. 34 . Actuator Arm Adjustment

FIG. 35 . Barrel Removal

42 333013B

Repair

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).

4. Install and adjust the actuator arm (15), jam nut (16a), and adjustment nut (16b). See page 42.

5. Test gun resistance, page 29.

6. Install the gun shroud (26) and air cap, page 39.

7. Install the gun onto the manifold. See page 38.

Power Supply Removal and Replacement

• Inspect the gun body 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 38.

2. See Barrel Removal, page 42.

NOTICE

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

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

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

4. Inspect the power supply and turbine for damage.

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

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

Slide the turbine up and off the power supply.

IGURE

37.

6. See Test Power Supply Resistance, page 29.

16a

16b

FIG. 36 . Barrel Installation

333013B 43

Replace the power supply if necessary. To repair the turbine, see Turbine Removal and Replace-

ment, page 44.

NOTICE

To prevent damage to the cable and possible 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.

Repair

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 gun body.

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

IGURE

37.

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

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

38 through F

1. See Prepare the Gun for Service, page 38.

2. Remove the power supply/turbine assembly and disconnect the turbine. See Power Supply Removal and Replacement, page 43.

3. Measure resistance between the two outer 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.

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

IGURE

39.

IGURE

41.

FIG. 37 . 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.

10. See Test Gun Resistance, page 29.

◆

WLD

WLE

FIG. 39 . Fan Orientation

◆

FIG. 38 . Power Supply

44 333013B

Repair

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

WLE

8h◆

8g8aM8b2◆

8b1◆

8f◆

FIG. 40 . Turbine Cross-Section.

NOTICE

Do not scratch or damage the magnet (M) or shaft (S). Do not pinch or damage the 3–wire connector (PC) when disassembling and reassembling the bearings.

must face away from the magnet (M). Install in the 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

39.

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.

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).

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

Slot

8f◆

◆

8g*

◆

8b1

◆

WLE

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

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 gun body. See Power Supply Removal and Replacement, page 43.

◆

8b2

FIG. 41 . Turbine

333013B 45

Parts

Standard Pro Xp Auto Waterborne AA Gun Models

HA1T18, Rear Manifold

Torque to 20 in-lbs (2 N•m)

46 333013B

HA1T18, Rear Manifold

Parts

Ref.

Part No. Description Qty

No.

1 24W874 BODY, gun assy (includes 9) 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 24N662 POWER SUPPLY, 60 kV, WB 1 7a 24N979 SPRING 1 8 24N644 See Turbine Assembly, page 51 8g

■

110073 O-RING, packing 1

■◆

24N699 GASKET, barrel 1

9 10 24W382 BODY, assy, Auto XP Standard 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 (includes 2) 4 20 24W392 MANIFOLD, rear inlet (includes 18,

21, 23, 27, 28, 29, 30, 51)

21 24W399 SCREW, modified, 1/4-20, XP

Auto (pack of 2)

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

LH, XP

24 24N644 RING, retainer, assy; includes 24a 1

Ref. No.

24a

Part No. Description Qty

■

198307 PACKING, u-cup; UHMWPE 1 25 24N727 See Air Cap Assembly, page 50 1 25a 24N643 ELECTRODE, package of 5 1

26 24W389 COVER, shroud, Auto XP 1 27 114263 FITTING, connector, male 1 28 115950 FITTING, connector, 1/4npt (M),

5/16T 29 110465 SCREW, set 2 30 102207 SCREW, set, SCH 2 31 24N785 CAP, spring includes 6 1 32* BRACKET, strain relief, WB tube 1 33 24N747 RING, conductive 1 34* CLAMP, strain relief, WB tube 1 35* GC2248 SCREW, SHDC, SS, .250x.50 3 36 116553 GREASE, dielectric; 1 oz (30 ml)

tube (not shown) 37* 24X482 FASTENER, retainer (pack of 4) 1 42

▲

179791 TAG, warning (not shown) 1 44 276741 TOOL, wrench (not shown) 1 45 107460 WRENCH, ball end, 4 mm (not

shown)

48 112080 WRENCH, ball end, 2 mm (not

shown)

51 117560 SCREW, set, socket 1 600 24W599 See Waterborne Fluid Hose, page 50 600a 24W599 See Waterborne Fluid Hose, page 50

▲

Replacement Warning labels, signs, tags, and

cards are available at no cost.

* Included in WB AA Hose Mount Kit 24W879

(purchase separately)

■

Included in air seal repair kit 24W390 (purchase

separately)

◆

Included in Turbine Assembly 24N664 (pur-

chase separately). See Turbine Assembly,

page 51.

333013B 47

Parts

Smart Pro Xp Auto Waterborne AA Gun Models

HA1M18, Rear Manifold

Torque to 20 in-lbs (2 N•m)

48 333013B

HA1M18, Rear Manifold

Parts

Ref.

Part No. Description Qty

No.

1 24W874 BODY, gun assy (includes 9) 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 24N662 POWER SUPPLY 1 7a 24N979 SPRING 1 8 24N644 See Turbine Assembly, page 51 8g

■

110073 O-RING, packing 1

■◆

24N699 GASKET, barrel 1

9 10 24W867 BODY, assy, AA, rear inlet 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 1 16 100166 NUT, full hex 2 18

■

111450 PACKING, O-RING 5 19 24N740 SCREW, ES gun (Includes 2) 4 20 24W392 MANIFOLD, rear inlet (includes 18,

21, 23, 27, 28, 29, 51)

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

■

198307 PACKING, u-cup; UHMWPE 1

24a 25 See Air Cap Assembly, page 50 1 25a 24N643 ELECTRODE, package of 5 1 26 24W388 COVER, shroud, Auto XP 1

Ref. No.

Part No. Description Qty

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* BRACKET, strain relief, WB tube 1 33 24N747 RING, conductive 1 34* CLAMP, strain relief, WB tube 1 35* GC2248 SCREW, SHDC, SS, .250x.50 3 36 116553 GREASE, dielectric; 1 oz (30 ml)

tube (not shown) 37* 24X482 FASTENER, retainer (Pack of 4) 1 40

▲

16P802 SIGN, warning (not shown) 1

▲

172479 TAG, warning (not shown) 1

▲

42 43

179791 TAG, warning (not shown) 1

▲

222385 TAG, warning (not shown) 1 44 276741 TOOL, wrench, 4 mm (not shown) 1 45 107460 WRENCH, ball end (not shown) 1 48 112080 TOOL, wrench, ball end, 2 mm

(not shown) 51 117560 SCREW, set, socket 1 80 24W035 CONTROL MODULE, Pro Xp Auto

(not shown). See 332989. Must be

purchased separately. 600 24W599 See Waterborne Fluid Hose, page 50 600a 24W599 See Waterborne Fluid Hose, page 50

▲

Replacement Warning labels, signs, tags, and cards are available at no cost.

* Included in WB AA Hose Mount Kit 24W879

(purchase separately)

■

Included in air seal repair kit 24W390 (purchase separately)

◆

Included in Turbine Assembly 24N664 (purchase separately). See Turbine Assembly, page 51.

333013B 49

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 46. 25a 24N643 ELECTRODE, package of 5 1 25b 24N734 O-RING; PTFE; package of 5

(also available in package of 10;

order 24E459) 25c ------ AIR CAP 1 25d 24N726 GUARD, tip, orange 1

Waterborne Fluid Hose

Part No. 24W599 Waterborne Fluid Hose

Ref.

Part No. Description Qty

No.

600 HOSE, 25 ft (7.6m) 1 600a FITTING, connector, barrel, WB 1

50 333013B

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

8h◆

Ref. No.

Part No.

Description Qty

8g* 110073 O-RING 1 8h

◆

24N709 CLIP; package of 5 (one clip

included with item 15b)

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

page 46.

* These parts are included in Air Seal Repair Kit

24W390 (purchase separately).

◆

These parts are included in Bearing Kit 24N706 (purchase separately).

Parts labeled ------ are not available separately

333013B 51

Parts

WB 3000 Isolation Enclosure

Part No. 24N550 Waterborne Isolation Enclosure; includes items 201-206

52 333013B

Ref.

Part

No.

201 ------ CABINET, enclosure; includes 201a 1 201a 15A947 DOOR, cabinet 1 202 116993 CASTER, brake 4 203 PLATE 1 204 15A551 T-HANDLE, latch 1 205 15A545 STEM, handle, door 1 206 15A524 HOUSING, latch 1 207 113061 SWITCH, push, air 1 209 24N548 PUMP, diaphragm; sst; see 3A0732 1 210 ------ SCREW, hex hd cap; 5/16–18 x 5.5 in.

211 ------ WASHER, plain; 0.344 in. ID 2 212 ------ NUT, lock; 5/16–18 2 214 104029 LUG, ground 1 215 116989 VALVE, air 1 216 111804 REGULATOR, air 1 217 113060 GAUGE, air; 1/8 npt 1 218 116473 BALL VALVE; 1/4 npt (f) 1 219 233824 CART 1 220 116473 NIPPLE; 1/4 npt x 1/4 npsm 1 226 190410 RESISTOR, bleed 1 227 116988 CYLINDER ROD 1 228 15A518 HOUSING, cylinder rod 1 229 104267 REGULATOR, air 1 230 ------ BUSHING; plastic; 3/4 x 1/2 npt 1 235▲ 15A682 LABEL, warning 1 239 222011 GROUND WIRE; 25 ft (7.6 m) 1 240 234018 STRIP, grounding; aluminum 1 241 110209 NUT, regulator 11 242 114051 WASHER, plain, 3/4” 1 243 210084 ROD, ground 1 244 ------ SCREW, hex hd; 1/4–20 x 5/8 in. (16

245 ------ WASHER, plain; 1/4 in. (6 mm) 16 246 ------ NUT, hex; 1/4–20 16 247 107257 SCREW, thread-forming 1 248 ------ TUBE; 1/4 in. (6 mm) OD; nylon A/R 249 160430 GAUGE, air 1 251 ------ WIRE, 10 gauge; green with yellow stripe 1 252 ------ CONNECTOR, swivel tee; 1/8 npt x 5/32

253 ------ NUT, hex; 10–32 1 256 162449 NIPPLE, reducing; 1/2 npt x 1/4 npt 2 257 101874 TERMINAL, ring 5 258 116990 BOX, control 1 259 113983 RING, retaining; 1/2 in. (13 mm) 1 260 237933 METER, 0–90 kV 1 261 113336 ADAPTER; 1/4 npt 1 262 ------ SCREW, pan hd; 10–32 x 5/8 in. (16

263 ------ SCREW, pan hd; 10–32 x 1/4 in. (6 mm) 1 264 ------ HOLDER, tie 3

Description Qty

(140 mm)

mm)

in. (4 mm) tube

mm)

Parts

Ref.

Part

No.

265 ------ SCREW, button hd; 10–24 x 1.5 in. (38

266 ------ SCREW, button hd; 10–32 x 1.0 in. (25

267 ------ NUT, hex; M5 x 0.8 2 268 ------ WASHER, lock; no. 10 9 270 116991 TEE, run, manifold 1 271 203953 SCREW, hex hd cap with patch; 10–24 x

272 ------ WIRE, 14 gauge; red A/R 273 ------ WIRE, ground, 14 gauge; green with yel-

274 155541 UNION, swivel; 1/4 npt 1 275 114261 TERMINAL, ring; no. 10 1 276 15A780 PLUG, hex hd 1 278 117314 BULKHEAD CONNECTOR; 1/4 npt 1 279 113319 CONNECTOR, tube; 1/4 npt x 3/8 in. (10

280 ------ ELBOW, tube 1 281 ------ FITTING, tube; 1/8 npt x 5/32 in. (4 mm)

282 ------ SWIVEL, tube; 1/4 npt x 1/4 in. (6 mm)

283 ------ SWIVEL, tube; 1/8 npt x 5/32 in. (4 mm)

286 ------ TUBE; 3/8 in. (10 mm) OD A/R 300★ 235070 HOSE, air, grounded; 0.315 in. (8 mm)

301★ HA1T18 GUN; see HA1T18, Rear Manifold,

HA1M18 GUN, see HA1M18, Rear Manifold,

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

★ The air hose (300) and gun (301) are not included with

24N550 Isolation Enclosure. They are shown for illustrative purposes only. The pail is shown for illustrative purposes but is not included.

Description Qty

mm)

3/8 in. (10 mm)

A/R

low stripe

mm) OD tube

OD tube

1 ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread; red cover with stainless steel braid ground path; 25 ft (7.6 m) long

1 page 46

1 page 48

333013B 53

Parts

Tubing and Wiring

Detail Views of Control Box

A1 A2

C3, C4, C5

B2 E1

Detail View of Door Interlock Switch

C2, C9

C6 C7 C8

54 333013B

Tubing and Wiring Chart

Use the diagrams to find the connection points for the tubing and wiring listed below

Ref.

Ref. No.

Length in.(mm)

Description

fold

interlock switch

(217)

lock switch

resistor to meter

nal box ground lug to cylinder cap

Code

A1 248 20 (508) 1/4 OD tube, regulator (216) to pump A2 248 9 (229) 1/4 OD tube, regulator (216) to mani-

B2 249 17 (432) 5/32 OD tube, manifold air to door

B3 249 20 (508) 5/32 OD tube, valve tee to cylinder B4 249 5 (127) 5/32 OD tube, regulator (216) to gauge

B5 249 22 (559) 5/32 OD tube, valve tee to door inter-

C1 272 9 (229) red 14 gauge wire from top of bleed

C2 251 8 (204) green/yellow 14 gauge wire from inter-

Code

C2 273 34 (864) green/yellow 10 gauge wire from exter-

C4 239 n/a green/yellow 25 ft (7.6 m) ground wire

C5 243 n/a green/yellow 10 gauge wire from exter-

C6 226 n/a red wire from bleed resistor to pump C7 272 16 (407) red 14 gauge wire from pump to pail

C8 272 12 (305) red 14 gauge wire from pump (209) to

C9 251 n/a green/yellow 10 gauge wire from meter

E1 286 4 (102) 3/8 OD tube, bulkhead to manifold

No.

Length in.(mm)

Description

nal ground lug to cart

with clamp, from external ground lug to true earth ground

nal ground lug to ground probe

cover with clamp

ground on cylinder bracket

(+) to internal box ground lug

Parts

333013B 55

Parts

Agitator Kit 245895

To keep fluid mixed and prevent settling out. Includes items 401-408.

401

402

407

406

403

408

404

406

Ref.

Part No. Description Qty

No.

401 112698 ELBOW, swivel; 1/8 npt(m) x 1/4 in. (6

mm) OD tube

402 114158 FITTING, adapter, Y; 1/4 in. (6 mm) OD

tube; mxfxf 403 193315 COLLAR, mounting, agitator 1 404 193316 NUT, collar, agitator 1 405 197298 COVER, pail; 5 gal. (19 liter) 1 406 224571 AGITATOR; see manual 306565 1 407 purchase

locally

408 110272 SCREW, set, socket hd; 1/4–20 x 1/4 in.

TUBE, nylon; 1/4 in. (6 mm) OD; 4 ft

(1.22 m)

(6 mm)

56 333013B

Accessories

Smart Model Accessories and Fiber Optic Cables

Part No. Description

24W035 Pro Xp Auto Control Module. See 332989 for

details.

Fiber Optic Cables for Gun

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

Part No. Description

24X003 Fiber Optic Cable, 25 ft (7.6 m) 24X004 Fiber Optic Cable, 50 ft (15 m) 24X005 Fiber Optic Cable, 100 ft (30.5 m)

Fiber Optic Cable Repair Kit 24W875 Parts necessary to replace damaged ends on

IGURE

9 on page 17. Connect gun mani-

one cable assembly.

Air Line Accessories

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

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

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

Part No. Description

235068 6ft(1.8m) 235069 15 ft (4.6 m) 235070 25 ft (7.6 m) 235071 36 ft (11 m) 235072 50 ft (15 m) 235073 75 ft (23 m) 235074 100 ft (30.5 m)

Bleed-Type Master Air 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

Waterborne Fluid Hose, 3000 psi Part No. Description

24W599 25 ft (7.6 m) 24W077 50 ft (15.2 m)

System Accessories

Part No. Description

222011 Ground wire for grounding pump and other com-

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

186118 English Warning Sign. Available at no charge

from Graco.

Test Equipment

Part No. Description

241079 Megohmmeter. 500 V output, 0.01–2000 meg-

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

722886 Paint Resistance Meter. Use for fluid resistivity

test. See manual 307263. Not for use in haz-

ardous areas.

722860 Paint Probe. Use for fluid resistivity test. See

manual 307263. Not for use in hazardous areas.

245277 Test Fixture, High Voltage Probe, and kV Meter.

Use to test the electrostatic voltage of the gun, and the condition of the turbine and power 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.

Gun Accessories

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

333013B 57

Accessories

Dimensions

Rear Inlet Manifold

11.0 in (279 mm)

10.4 in (265 mm)

8.2 in (208 mm)

2.9 in (73 mm)

0.53in (13.5 mm)

2x 1/4-20 UNC

6.3 in (160 mm)

2.6 in (66 mm)

2.5 in (63 mm

)

58 333013B

Spray Tip Selection Chart

AEM Fine Finish Spray Tips

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

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.

333013B 59

Spray Tip Selection Chart

AEF Fine Finish Pre-Orifice Spray Tips

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

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

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

(300 - 350)

608

12-14

14-16

(350 - 400)

16-18

(400 - 450)

60 333013B

Technical Data

Pro Xp Auto Waterborne 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

Paint resistivity range conductive waterborne fluid Short circuit current output 125 microamperes Gun Weight (Approximate) 2.7 lb 1.2 kg

Voltage Output

Standard Models 60 kV Smart Models 30-60 kV

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 Fan air inlet fitting 5/16 in. OD nylon tube Cylinder air inlet fitting 5/32 in. OD nylon tube Hi/Lo voltage selector air inlet fittings 5/32 in. OD nylon tube Fluid inlet fitting Waterborne Hose Fitting

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.

333013B 61

Graco Pro Xp Warranty

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

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, 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 333013

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revision B, December 2014

Graco 333013B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

List of Approved Models

Warnings

Introduction

How the Electrostatic AA Spray Gun Works

Operating the Spray Function

Gun Features and Options

Smart Gun Features

Operating the Electrostatics

Spraying Waterborne Fluids Electrostatically

System Overview

Gun Overview

Installation

System Requirements

Install the System

Warning Signs

Ventilate the Spray Booth

Install the Air Line Accessories

Install the Fluid Line Accessories

Install the Gun

Install the Pro Xp Auto Control Module

Connect the Air Line

Ground the Cabinet

Manifold Connections

Connect the Waterborne Fluid Hose

Fiber Optic Cable Connection

Agitator Kit Accessory

Grounding

Check Electrical Grounding

Install the Fabric Cover

Check Fluid Viscosity

Flush Before Using Equipment

Operation

Operating Checklist

Fluid Voltage Discharge and Grounding Procedure

Pressure Relief Procedure

Select a Spray Tip

Install the Spray Tip

Fill the Fluid Supply

Set the Atomization Fluid Pressure

Adjust the Electrostatics

Spraying

Triggering the Fluid Alone

Shutdown

Maintenance

Flushing

Daily Care and Cleaning Checklist

Clean Outside of Gun

Clean the Spray Gun

Check for Fluid Leakage

Clean the cabinet

Electrical Tests

Test Power Supply Resistance

Test Gun Resistance

Test Barrel Resistance

Test Ground Strip Resistance

Test Cylinder Resistance

Troubleshooting

Voltage Loss 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 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 Waterborne AA Gun Models