Graco 3A2497BPro User Manual

Instructions - Parts

WB3000 Isolation System &

Pro Xp™ 60 AA WB Gun

Air-assisted spray system for use when electrostatically spraying conductive, waterborne ﬂuids that meet at least one of the conditions for non-ﬂammability listed on page 3. For professional use only.

Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.

3000 psi ( Fluid Wor

100 psi ( Air Work

See pag and app

21 MPa, 210 bar) Maximum

king Pressure

0.7 MPa, 7 bar) Maximum

ing Pressure

e 3 for model part numbers

roval information.

3A2497B

PROVEN QUALITY. LEADING TECHNOLOGY.

Models............................................................... 3

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

Gun Overview .................................................... 7

How the Elect

Spraying Wat

Controls, I

Smart Guns ................................................. 9

Installation.......................................................... 15

System Requirements .................................. 15

Warning Sign............................................... 15

Install the System......................................... 15

Ventilate the Spray Booth ............................. 15

Air Supply Line ............................................ 16

Ground the Cabinet...................................... 16

Connect the Waterborne Fluid Hose.............. 17

Agitator Kit Accessory .................................. 20

Gun Setup

Operation........................................................... 25

Maint

Electrical Tests................................................... 36

ubleshooting.................................................. 40

Tro

.......................................................... 21

Groundi Check Gu Flush Be

Operating Checklist...................................... 25

Fluid Voltage Discharge and Grounding

Pressure Relief Procedure............................ 26

Fill the Fluid Supply...................................... 27

Adjust the Spray Pattern............................... 28

Shutdown.................................................... 30

enance ...................................................... 31

ing ...................................................... 31

Flush

the Gun Daily..................................... 33

Clean

System Care ....................................... 35

Daily

Test Gun Resistance.................................... 36

Test Power Supply Resistance ..................... 37

Test Gun Barrel Resistance.......................... 38

Test Ground Strip Resistance....................... 39

Test Cylinder Resistance.............................. 39

tage Loss Troubleshooting....................... 40

Vol

ay Pattern Troubleshooting...................... 43

Spr

Operation Troubleshooting .................... 44

Gun

ectrical Troubleshooting ............................ 45

rostatic AA Spray Gun

Works ............................................ 7

erborne Fluids

Electrosta

ndicators, and Components........... 8

ng ................................................... 21

n Electrical Grounding ................... 23

fore Using Equipment...................... 24

Procedure...................................... 25

tically .............................. 7

Repair................................................................ 47

Prepare the Gu Air Cap, Spray

Electrode Re Gun Barrel Re Gun Barrel In Fluid Needl Power Suppl

Alternator Fan Air Adj Atomizing

ES On-Off V Air Valve R Smart Mod Air Swive

Parts.................................................................. 60

Standard Air-Assisted Spray Gun

Smart Air-Assisted Spray Gun

Isolation Enclosure....................................... 64

Alternator Assembly ..................................... 67

ES On-Off Valve Assembly........................... 68

Fan Air Valve Assembly ............................... 69

Air Cap Assembly ........................................ 70

Smart Module Assembly............................... 70

Spray Tip Selection Chart.................................... 71

AEM Fine Finish Spray Tips..........................71

AEF Fine Finish Pre-Oriﬁce Spray

r Kits, Related Manuals, and

Repai

Acce

ccessories.......................................... 73

Gun A

ator Accessories................................... 73

Oper

em Accessories..................................... 73

Syst

s ......................................................... 74

Hose

t Equipment ........................................... 74

Tes

895 Agitator Kit ...................................... 75

245

Dimensions ........................................................ 76

Technical Data ...................................................77

aco Pro Xp Warranty ....................................... 78

n for Service ......................... 47

Tip, and Fluid Seat Housing

Replacement

placement ................................ 49

moval..................................... 50

stallation.................................. 50

e Replacement............................ 51

y Removal and

Replacemen

Removal and Replacement ........... 53

ustment Valve Repair .................. 55

Air Adjustment Valve

Repair............................................ 55

alve Repair ............................... 56

epair........................................... 57

ule Replacement.......................... 58

l and Exhaust Valve

Replacem

Assembly....................................... 60

Assembly....................................... 62

Tips ............................................... 72

ssories .......................................... 73

.................................. 48

t.................................. 52

ent.................................. 59

3A2497B

Models

Models which are FM Approved and Compliant with EN50059

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

0.35 J, with

24M508 Hose

FM12ATEX0080

EN 50059

Ta 0°C – 50°C

Part No. Model Description

24N551 WB3000 Waterborne Isolation Enclosure 24N550 with standard

24P632 WB3000 Waterborne Isolation Enclosure 24N550 with smart electrostatic

24N550 WB3000

H60T18 ProXp60AAWB

H60M18 ProXp60AAWB

24M508

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

-——

Models Compliant with EN 50059 when used

with ﬂuids that meet the following criteria:

of less than 500 mJ.

electrostatic air-assisted spray gun H60T18, grounded air hose 235070, and unshielded waterborne ﬂuid hose 24M508.

air-assisted spray gun H60M18, grounded air hose 235070, and unshielded waterborne ﬂuid hose 24M508.

Waterborne Isolation Enclosure for unshielded hoses. Does not include hoses and gun.

Standard Electrostatic Air-assisted Spray Gun, for waterborne coatings.

Smart Electrostatic Air-assisted Spray Gun, for waterborne coatings.

Unshielded Waterborne Fluid Hose Assembly, 25 ft (7.6 m).

3A2497B 3

Warnings

The following exclamation p risks. When th Warnings. Pr the body of th

warnings are for the setup, use, grounding, maintenance and repair of this equipment. The oint symbol alerts you to a general warning and the hazard symbol refers to procedure-speciﬁc

ese symbols appear in the body of this manual or on warning labels, refer backtothese

oduct-speciﬁc hazard symbols and warnings not covered in this section may appear throughout

is manual where applicable.

WARNING

ELECTRIC S

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.

•Allcompo within a voltage

• 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.

•Donott during

• 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 gun air hose with this gun. Do not use black or gray-colored Graco air hoses.

• Do not betw

HOCK HAZARD

nents of the isolation system that are charged to high voltage must be contained

n isolation enclosure that prevents personnel from making contact with thehigh

components before the system voltage is discharged.

ouch the gun nozzle or electrode, or come within 4 in. (102 mm) of the electrode

gun operation. Follow the Fluid Voltage Discharge and Grounding Procedure.

splice hoses together. Install only one continuous Graco waterborne ﬂuid hose

een the isolated ﬂuid supply and the spray gun.

3A2497B

WARNING

FIRE AND EXPLOSION HAZARD

Warnings

Combustible d

• Fluids used must meet the following ﬂammability requirements:

• FM, FMc Appro

• CE-EN 50059 Compliant:

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

• Check gun r

• Use and clean equipment only in well ventilated area.

• Interlock the gun air supply to prevent operation unless ventilating fansareon.

•Onlyusen

• 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 pl

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

• Keep a working ﬁre extinguisher in the work area.

SKIN IN

ressure ﬂuid from gun, hose leaks, or ruptured components will pierce skin.Thismay

High-p

ke just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

look li

ent.

treatm

ust in work area canigniteorexplode. Tohelppreventﬁreandexplosion:

ved: Material doe Sustained Bu

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

on-ﬂammable solvents when ﬂushing or cleaning equipment.

ug or unplug power cords or turn lights on or off when ﬂammable fumes are present.

JECTION HAZARD

s not sustain burning in accordance with the Standard Test Method for

rning of Liquid Mixtures, ASTM D4206.

esistance, hose resistance, and electrical grounding daily.

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

• Engag

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

• Do not put your hand over the spray tip.

•Dono

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking,

• Tighten all ﬂuid connections before operating the equipment.

• Chec

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

•Us

•SeeTechnical Data in this and all other equipment instruction manuals. Read ﬂuid and

e trigger lock when not spraying.

t stop or deﬂect leaks with your hand, body, glove, or rag.

or servicing equipment.

k hoses and couplings daily. Replace worn or damaged parts immediately.

e only compatible water-based solvents to clean plastic structural or pressure-containing

rts.

solvent manufacturer’s MSDSs and recommendations.

3A2497B 5

Warnings

WARNING

TOXIC FLUID OR FUMES Toxic ﬂuids or fumes can cause serious injury or death if splashed in the eyesoronskin, inhaled, or swallowed.

•ReadMSDSsto

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

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

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the ﬂuid and solvent manufacturer.

EQUIPMEN Misuse ca

• Do not operate the unit when fatigued or under the inﬂuence of drugs or alcohol.

• Do not ex system c

• 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.

•Turnof

• 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.

•Makes

• 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.

•Dono

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

T MISUSE HAZARD

n cause death or serious injury.

ceed the maximum working pressure or temperature rating of the lowest rated

omponent. See Technical Data in all equipment manuals.

f all equipment and follow the Pressure Relief Procedure when equipment is not in use.

ure all equipment is rated and approved for the environment in which you are using it.

t kink or over bend hoses or use hoses to pull equipment.

know the speciﬁc hazards of the ﬂuids you are using.

6 3A2497B

Gun Overview

How the Electr

ostatic 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 atomizes and 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.

As the gun is triggered, part of the regulated air operates the alternator turbine and the rest of the air helps atomize the ﬂuid being sprayed. The alternator generates power, which is converted by the power cartridge to supply high voltage to the gun’s electrode.

The gun’s internal power supply provides high voltage. The ﬂuid is electrostatically charged as it passes the electrode. The charged ﬂuid is attracted to the grounded workpiece, wrapping around and evenly coating all surfaces.

The regulated air that is directed to the air cap can be further controlled using the gun’s atomizing air adjustment valve. This valve can be used to restrict air ﬂow to the air cap while maintaining sufﬁcient air ﬂow to the alternator. The atomizing air adjustment valve does not control pattern width. To change pattern width, use a new tip size, or use the fan adjustment to narrow the pattern width.

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

Spraying Wate

rborne Fluids

Electrostatically

This electro to spray onl following ﬂ

• 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.

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 under

Models, page 3 ) can be sprayed with the system or

be used to clean, ﬂush, or purge the system.

Precau waterb hazard ﬂuid to capac the en energ the gu the el The a

gy depends on the system design. Follow the

ener

d Voltage Discharge and Grounding Procedure,

Flui page

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

static air-assisted spray gun is designed

y waterborne ﬂuids which meet the

ammability requirements:

tions must be taken when using electrostatic orne equipment to avoid potential shock s. When the spray gun charges the isolated

high voltage, it is similar to charging a

itor or a battery. The system will store some of

ergy while spraying and retain some of that

y after the spray gun is shut off. Do not touch

n nozzle or come within 4 in. (102 mm) of

ectrode until the stored energy is discharged.

mount of time it takes to discharge the

25 before approaching the front of the gun.

NOTE: For airless atomization, if desired, turn the gun’s atomizing air adjustment valve completely off. Closing this valve does not affect alternator operation.

3A2497B

Gun Overview

Controls, Ind

The electrostatic gun includes the following controls, indicators, and components (see Fig.

1). For information on Smart guns, also see

Smart Guns, page 9 .

Item Description Purpose

B Fluid Hose

EElectrode

Air Swivel Inlet

Turbine Air Exhaust

Air Cap/Tip Guard and Spray Tip

icators, and Components

1/4 npsm(m) left-hand thread, for Graco red-colored grounded air supply hose.

Graco wate hose

Barbed ﬁtting, for supplied exhaust tube.

See Spray Tip Selection

Chart, page 71, for avail-

able sizes.

Suppli charge

rborne ﬂuid

es electrostatic

to the ﬂuid.

Item Description Purpose

FFanAir

Adjustment Valve

Atomizing Air Adjustment Valve

Trigger Saf Lock

ES On-Off Valve

ES Indicator (standard gun only; for Smart gun indicator, see

Operating Mode, page

9 )

Adjusts fan si Canbeusedto pattern widt

Adjusts atomizing air ﬂow.

Locks trigger to prevent

ety

gun from spraying.

Turns electrostatics ON (I) or OFF (O).

Lit when ES is ON (I). Color indicates alternator frequency. See the LED indicator table on page 30.

ze and shape.

decrease

Figure 1 Gun Overview

8 3A2497B

Smart Guns

Gun Overview

The Smart Gun module displays spraying voltage, current, alternator speed, and the voltage setting (low or high). It also allows the user to change to a lower spraying voltage. The module has two modes:

• Operating Mo

• Diagnostic M

Operating M

ode

Bar Graph

See Fig. 2, Mode displ display u kiloVolt (uA). The value.

If the uA bar graph LEDs are blue, the gun is ready to spray. If the LEDs are yellow or red, the current is too high. See Electrical Troubleshooting, page 45.

and Table 1 on page 11. The Operating

ays gun data during normal spraying. The

ses a bar graph to show the voltage level in

s (kV) and the current level in microAmperes

bar graph range is from 0 to 100% for each

Hz Indicator

Voltage Adjustment Switch

The voltage adjustment switch (VA) allows the operator to change from low to high voltage.

• The high volt maximum volt

•Thelowvolt when the swi voltage set

Adjusting t

NOTE: If the Error display appears, the Smart module has lost communication with the power supply. See

Error Display, page 10 for further information.

age setting is determined by the

age of the gun and is not adjustable.

age indicator (LO) lights

tch is set to LO. The low

ting is user adjustable. See

he Low Voltage Setting, page 10.

The Hz indicator functions the same as the ES indicator on standard guns. The indicator lights to show the alternator speed status, and has three colors:

• Green indicates the alternator speed is correct.

• If the indicator changes to amber after 1 second, increase the air pressure.

• If the indicator changes to red after 1 second, reduce the air pressure.

Figure2 SmartGunModuleinOperatingMode

3A2497B 9

Gun Overview

Error Display

If the Smart module loses communication with the power supply, the Error display appears, the Hz indicator turns red, and the Smart module is disabled. See Fig. 3, and Table 1 on page 11. This can occur in Operating Mode or Diagnostic Mode. See Electrical Troubleshooting, page 45. Communication must be restored to make the Smart module functional.

NOTE: It tak appear. If t seconds bef condition h

NOTE: If there is no power to the gun, the Error display will not appear.

es 8 seconds for the Error display to

he gun has been disassembled, wait 8

ore spraying to ensure that an Error

as not occurred.

NOTE: After 2 seconds of inactivity the display will return to the Operating Screen.

NOTE: The low v

Lock Symbol, p

Figure 4 Low Voltage Setting Screen (Unlocked)

oltage setting may be locked. See

age 10.

Lock Symbol

The low voltage setting may be locked. When locked, an image (LK) appears on the screen. See Fig. 5, and Table 1 on page 11.

e3 ErrorDisplay

Figur

sting the Low Voltage Setting

Adju

ow voltage setting is user adjustable. To access

The l

ow voltage setting screen when in Operating

the l

, press the LO SET button (LS) momentarily.

Mode

screen will display the current low voltage

The

ting. SeeFig. 4,andTable1onpage11. The

set

ge is 30–60 kV.

ran

Set the Voltage Adjustment switch (VA) to LO. Press the LO SET button repeatedly to increase the setting in increments of 5. When the display reaches the maximum setting (60 kV) it will return to the minimum setting (30 kV). Continue pressing the button until you reach the desired setting.

• When in HI mode, the low voltage setting is always locked. The lock symbol will appear when the LO SET button is pressed.

• When in LO mode, the lock symbol will only appear if the lock is enabled. See

Low Voltage Lock Screen, page 14,tolockor

unlock the low voltage setting.

Figure 5 Low Voltage Setting Screen (Locked)

10 3A2497B

Table 1 . Key for Figs. 2–9.

Item Description Purpose

Gun Overview

LS LO SET bu

Voltage Adjustment Switch

Low Voltage Mode Indicator

Voltage (kV) Display

Current (uA) Display

tton

Two-position gun voltage to high setting ( functional i in Diagnosti

Lights (blue) when the smart gun is set to Low Voltage.

Displays ac of the gun, i Mode, disp In Diagnos displayed

Displays actual spraying current of the gun, in uA. In Operating Mode, display is a bar graph. In Diagnostic Mode, current is displayed as a number.

Press momentarily to enter the Low Voltage Setting screen.

Press an seconds Mode.

switch sets smart

low setting (LO) or

HI). This switch is

n Operating Mode and

c Mode.

tual spraying voltage

n kV. In Operating

lay is a bar graph.

tic Mode, voltage is

as a number.

d hold for approximately 5

to enter or exit Diagnostic

LV Low V

LK Low Voltage Locked

LD Lo D

ER Error Display

VI Vo

oltage Display

isplay

ltage Indicator

While in Diagnostic Mode, press momentarily to advance through screens.

While on the Low Voltage Lock Screen (in Diagnostic Mode), press and hold to turn the lock on or off.

lays the low voltage setting

Disp

umber. The setting can be

as a n

ged. See Fig. 4.

chan

Appears if the low voltage setting is locked. See Fig. 5 and Fig. 9.

ears on the Low Voltage Lock

App

een. See Fig. 9.

Scr

Appears if the Smart module loses communication with the power supply. See Fig. 3.

Diagnostic Mode, the two top

ight LEDs of the screen light,

ndicating that the value displayed

sinkV.SeeFig. 6.

3A2497B

Gun Overview

Item Description Purpose

CI Current Indicator

AS Alternator S

Alternator Speed Indicator In Operating Mode, indicator color

peed Display

In Diagnostic Mode, the two bottom right LEDs of the screen light, indicating that the value displayedisinuA.SeeFig. 7.

In Diagnostic Mode, Hz level is displayed as a number. See Fig.

varies to show the alternator speed status:

• green indicates the alternator speed is at the correct level.

• If the indicator changes to amber after 1 second, the alternator speed is too low.

• If the indicator changes to red after 1 second, the alternator speed is too high. The indicator will also turn red if the Error display appears.

In Diagn is green Speed (H

ostic Mode, the indicator

when in the Alternator

ertz) screen.

3A2497B

Diagnostic Mode

Diagnostic Mode includes four screens which display gun data:

Gun Overview

• Voltage (kilo

• Current (mic

• Alternator S

• Low Voltage L

NOTE: You must be in Operating Mode to adjust the low voltage setting; the setting is not adjustable in Diagnostic Mode. However, the voltage adjustment switch (VA) can be set to HI or LO in Operating Mode and Diagnostic Mode.

To enter Diagnostic Mode, press and hold the LO SET (LS) button for approximately 5 seconds. The display will go to the Voltage (kiloVolts) Screen, page 13.

To advanc button ag

To exit Diagnostic Mode, press and hold the LO SET button for approximately 5 seconds. The screen will return to Operating Mode.

NOTE: If the gun is detriggered while in Diagnostic Mode,thelastscreenviewedwillbedisplayedwhen the gun is retriggered.

NOTE: D from th

Low Vol

Volta

e Low Voltage Lock Screen. See

ge (kiloVolts) Screen

Volts) Screen

roAmperes) Screen

peed (Hertz) Screen

ock Screen

e to the next screen, press the LO SET

ain.

iagnostic Mode cannot be exited

tage Lock Screen, page 14 for details.

Figure 6 Voltage (kiloVolts) Screen

Current (microAmperes) Screen

The Current (microAmperes) Screen is the second screen in the Diagnostic Mode. See Fig. 7, and Table 1 on page 11. To enter this screen, press the LO SET button while in the Voltage (kiloVolts) Screen.

This screen displays the spraying current of the gun as a number (uA), rounded to the nearest 5 uA. The two bottom right LEDs (CI) of the display panel light, indicating that the Current (microAmperes) Screen is displayed. The display is a readout and cannot be changed.

Press the LO SET button to advance to the

Alternator Speed (Hertz) Screen, page 14.Press

and hold for approximately 5 seconds to return to Operating Mode.

The Vo appea and T and h seco

This screen displays the spraying voltage of the gun as a number (kV), rounded to the nearest 5 kV. The two top right LEDs (VI) of the display panel light, indicating that the Voltage (kiloVolts) Screen is displayed. The display is a readout and cannot be changed.

Press the LO SET button to advance to the

Current (microAmperes) Screen, page 13.Press

and hold for approximately 5 seconds to return to Operating Mode.

ltage (kiloVolts) Screen is the ﬁrst screen to

r after entering Diagnostic Mode. See Fig. 6, able 1 on page 11. To enter this screen, press old the LO SET button for approximately 5

nds while in the Operating Mode.

Figure 7 Current (microAmperes) Screen

3A2497B 13

Gun Overview

Alternator Speed (Hertz) Screen

The Alternator Speed (Hertz) Screen is the third screen in the Diagnostic Mode. See Fig. 8, and Table 1 on page 11. To enter this screen, press the LO SET button while in the Current (microAmperes) Screen.

This screen d digit number display is a r alternator s will show 99

The Hz indicator lights green to show that you are viewing the Alternator Speed (Hertz) Screen.

Press the LO SET button to advance to the

Low Voltage Lock Screen, page 14. Press and hold

for approximately 5 seconds to return to Operating Mode.

isplays the alternator speed as a 3

(AS), rounded to the nearest 5 Hz. The

eadout and cannot be changed. If the

peed is greater than 999 Hz, the display

Low Voltage Lock Screen

The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode. See Fig. 9, and Table 1 on page 11. To enter this screen, press the LO SET button while in the Alternator Speed (Hertz) Screen.

This screen d Lock. If the s appears to th is unlocked,

To change the lock status, press and hold the LO SET button until the lock image appears or disappears. If the lock is set, the image will also appear on the Low Voltage Setting Screen when in low voltage mode (see Fig. 4).

NOTE: Diagnostic Mode cannot be exited from this screen, because pressing and holding the LO SET button is used to turn the lock on or off. To exit, press LO SET momentarily to return to the Voltage (kiloVolts) Screen, then exit Diagnostic Mode from there.

isplays the status of the Low Voltage etting is locked, the lock image (LK)

e left of the Lo display (LD). If the setting

the lock image does not appear.

Figure 8 Alternator Speed (Hertz) Screen

Figure 9 Low Voltage Lock Screen

3A2497B

Installation

System Requirements

AGracovolta following fe

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

• A bleed resistor to drain off the system voltage when the spray gun is not in use. A metal part of the ﬂuid supply unit must be electrically connected to the bleed resistor.

• A safety interlock that automatically discharges the system voltage when anyone opens the isolation enclosure.

ge isolation system must have the

atures:

NOTICE

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.

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 gun is operated above 60 kV.

Install the System

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

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

• Be sure your installation complies with local, state, and national codes for the installation of electrical apparatus in a Class I, Div. I Hazardous Location or Group II, Zone I Explosive Atmosphere Location.

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

Fig. 12 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.

Ventilate the Spray Booth

Warning Sign

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.

3A2497B 15

Provide fresh air ventilation to reduce the risk of ﬁre or explosion caused by the buildup of ﬂammable or toxic vapors when spraying, ﬂushing, or cleaning the gun. Do not operate the gun unless ventilation fans are operating.

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

h velocity air exhaust will decrease the operating

Hig

ﬁciency of the electrostatic system. The minimum

lowable air exhaust velocity is 60 linear ft/min (18.3

near meters/minute).

Installation

Air Supply Lin

1. See Fig. 12. Install an air line ﬁlter/water separator (M) 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.

2. The WB3000 system includes a bleed-type air regulator (N) on the gun air supply line (P), to control air pressure to the gun.

To reduce the risk of electric shock or other serious injury, you must use the red-colored Graco Electrically Conductive Air Hose for the gun air supply, and you must connect the hose ground wire to a true earth ground. Do not use the black or gray-colored Graco air hoses.

3. Connect the red-colored Graco Electrically Conductive Air Hose (P) between the gun air regulator (N) and the gun’s air inlet. The gun air inlet ﬁtting has a left-hand thread. Connect the airsupplyhosegroundwire(Q)toatrueearth ground.

Trapped air can cause the ﬂuid supply unit to cycle unexpectedly, which can result in serious injury, including splashing ﬂuid in the eyes or on the skin. Do not operate the equipment without the bleed-type air valve (B) installed.

4. The WB3000 system includes a bleed-type air valve (B). The bleed-type air valve is required to shut off all air to the system and relieve air trapped between the valve and the ﬂuid supply unit after the air regulator is shut off. Connect the main air supply line (A) to the bleed valve.

5. Install an additional bleed-type air valve (CC) upstream of the air ﬁlter (M) to isolate the ﬁlter for servicing.

Ground the Cabinet

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

16 3A2497B

Installation

Connect the Wa

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.

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

1. Remove the gun air inlet ﬁtting (21).

terborne Fluid Hose

2. Make sure the barrel ﬂuid inlet is clean and dry.

Apply dielectric grease to the threads of the barrel connector (101a) and screw it into the ﬂuid inlet.

3. Apply dielectric grease to the threads of the

hose (101) and screw it into the barrel connector (101a).

4. Align the bracket (B) holes with the air inlet and

exhaust outlet. Secure with the air inlet ﬁtting (21).

5. Press the exhaust tube (35) onto the exhaust

valve. Secure with the clamp (36).

6. Slide the other end 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 thehosetothesideoftheenclosurewiththe bracket (W).

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 gun is operated above 60 kV.

Figure 10 Connect the Fluid Hose

3A2497B

Figure 11 Unshielded Hose 24M508 Connection at WB3000 Enclosure

Installation

Figure 12 Typical Installation, Pro Xp Waterborne System

18 3A2497B

Typical Installation Key

Installation

Item Description

B* Bleed-Type Ai

D Pump Air Pressure

E kV Meter

FPump

GPumpSuct

K* Enclos

L Isolated Enclosure

P* Graco Red Grounded

Q* Gun

Main Air Supply Line

r Shutoff

Valve

Pump Air Pressure Gauge

Regulator

ion Hose

Paint Container

Bleed Re

Interl

Gun Ai

Gun Air Pressure Regulator

Air Hose (left-hand threads)

Wir

Graco Waterborne Fluid Hose

sistor

ure Safety

ock

r Line Filter

Air Hose Ground

Item Description

V* Main Ground

AA Isolat

BB Enclosure T-Handle

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

Waterborne Electrostati Air-Assisted Gun

Grounding Rod

Ground Terminal

Strain Relief Fitting

Pump Air Supply Line

Groundin

Pump Fluid Outlet Fitting

(not sh intern Door mu and loc syste

Locking Screw (part of door assembly)

Accessory Bleed-Type Air Shutoff Valve

Spray

Wire

g Cylinder

ed Enclosure Door

own, to illustrate

al components.

st be closed

ked to operate

m).

3A2497B 19

Installation

Agitator Kit Accessory

To add an agita Part No. 24589 for the kit par

1. Discharge the system voltage (see Fluid Voltage

Discharge and Grounding Procedure, page 25).

2. Relieve the pressure (see

Pressure Relief Procedure, page 26).

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 . 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.

tor to the Graco isolation system, order

5. See 245895 Agitator Kit, page 75,

ts list.

Figure 13 245895 Agitator Kit

20 3A2497B

Gun Setup

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 100 ohms. 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.

•

Voltage Isolation System:

voltage isolation system to a true earth ground. See Ground the Cabinet, page 16.

Electrically connect the

•

Object being s

clean and gro

•

All electr spray area

•

Fluid and waste containers:

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

•

Air compressors:

to the manufacturer's recommendations.

•

All air lines

grounded hoses with a maximum of 100 feet (30.5 m) combined hose length to ensure grounding continuity.

prayed:

unded at all times.

ically conductive objects or devices in the

must be properly grounded.

must be properly grounded. Use only

keep the workpiece hangers

ground all ﬂuid and

ground the equipment according

•

Electrostatic Air-Assisted Spray Gun:

the gun by connecting the red-colored Graco Grounded Air Hose to the gun, and connecting the air hose ground wire to a true earth ground. See

Check Gun Electrical Grounding, page 23.

ground

3A2497B

Gun Setup

The ﬂoor of the spray area:

•

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

•

All solvent pails:

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

use only approved, grounded

must be electrically

•

All persons entering the spray area:

shoes having conductive soles such as leather, or wear personal grounding straps. Do not wear shoes with non-conductive soles such as rubber or plastic. If gloves are necessary, wear the conductive gloves supplied with the gun. If non-Graco gloves are worn, cut off ﬁngers or palm area of gloves to ensure your hand contacts the grounded gun handle.

must wear

3A2497B

Gun Setup

Check Gun Elec

Megohmmeter Part No. 241079 (AA-see Fig.

14) 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.

Graco Part No. 241079 Megohmmeter is available as an accessory to check that the gun is properly grounded.

trical Grounding

3. Turn off the ai the Pressure R

4. Disconnect th

5. Make sure the and the hose g earth ground

6. Measure the resistance between the gun handle (BB) and a true earth ground (CC). Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 100 ohms. See Fig. 14.

r and ﬂuid supply to the gun. Follow

elief Procedure, page 26.

eﬂuidhose.

grounded air hose is connected roundwireisconnectedtoatrue

1. Have a qualiﬁed electrician check the electrical grounding continuity of the spray gun and air hose.

2. Turn OFF (O) the ES On-Off switch.

Figure 14 Check Gun Electrical Grounding

3A2497B 23

Gun Setup

7. If the resistance is greater than 100 ohms, check the tightness of the ground connections and be suretheairhosegroundwireisconnectedtoa true earth ground. If the resistance is still too high, replace the air hose.

8. Using 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.

e 15 Check Cabinet Grounding

Figur

Flush Before Using Equipment

quipment was tested in ﬂuid at the factory. To

The e

d contaminating your ﬂuid, ﬂush the equipment

avoi

a compatible solvent before using the equipment.

with

3A2497B

Operation

Operating Checklist

Check the following list daily, before starting the system.



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



All operators are trained in the

Pressure Relief Procedure, page 26.



The electrostatics are turned off and system voltage is discharged according to the

Fluid Voltage Discharge and Grounding Procedure, page 25, before any person en-

ters the isolation enclosure, before cleaning, and before performing any maintenance or repair.



The system is grounded according to the instructions in Grounding, page 21.



The Graco waterborne ﬂuid hose is in good condition with no cuts or abrasions of the inner layer. Replace hose if damaged.

Fluid Voltage Discharge and Grounding Procedure

The ﬂuid su the voltag component spray gun e To avoid a Discharg

• 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.

1. Turn the ES ON/OFF valve OFF and wait 30 seconds, to allow the voltage to discharge through the bleed resistor.

pply is charged with high voltage until

e is discharged. Contact with the charged

s of the voltage isolation system or

lectrode will cause an electric shock.

n electric shock, follow the Fluid Voltage

e and Grounding Procedure:



Ventilation fans are operating properly.



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



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 mixturewithair,byanenergysourceof less than 500mJ.

2. 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. Use the grounding rod to touch the pump and supply pail. If you see any arcs, see

Electrical Troubleshooting, page 45.

3A2497B 25

Operation

Pressure Reli

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

1. Turn OFF (O) the ES On/Off switch.

2. Follow the Fluid Voltage Discharge and

Grounding Procedure, page 25.

3. Engage the trigger lock.

ef Procedure

5. Disengage the

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

7. Engage the trigger lock.

8. Open the pump drain valve, having a waste container ready to catch the drainage. Leave thepumpdrainvalveopenuntilyouareready to spray again.

trigger lock.

4. Turn off the air bleed valves to the ﬂuid source and to the gun.

9. If the spray tip or hose is completely clogged or pressure is not fully relieved, slowly loosen the hose end coupling. Now clear the spray tip or hose.

26 3A2497B

Operation

Fill the Fluid

1. Follow the Fluid Voltage Discharge and

Grounding Procedure, page 25.

2. Follow the Pressure Relief Procedure, page 26.

3. Open the isolated enclosure door.

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

5. Remove the supply pail from the enclosure.

Supply

NOTICE

Be sure to w enclosur and cause

ipe up all ﬂuid spills in the isolated

e. Fluid can create a conductive path

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.

3A2497B

Operation

Adjust the Spr

To reduce the risk of ﬁre and explosion, 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.

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 electrode during operation or until performing the Fluid Voltage Discharge and

Grounding Procedure, page 25.

Proced

whenev voltag

the Fluid Voltage Discharge and Grounding

ure, page 25 when you stop spraying and

er you are instructed to discharge the

ay Pattern

To reduce the risk of an injury, follow the

Pressure Relief Procedure, page 26 whenever you

are instructed to relieve the pressure.

Follow the steps below to establish the correct ﬂuid ﬂow and air ﬂow. See Fig. 16 to locate the electrostatic gun controls.

Figure 16 Electrostatic Gun Controls

1. Turn OFF (O) the ES On-Off switch (J).

To reduce the risk of component rupture, which can cause serious injury, do not exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi (0.7 MPa, 7 bar) maximum air working pressure and a 3000 psi (21 MPa, 210 bar) maximum ﬂuid working pressure.

2. Shut off the air bleed valve to the gun.

28 3A2497B

Operation

3. Check gun resistance. See

Test Gun Resistance, page 36.

4. Follow all steps under Grounding, page 21.

5. Follow all steps under

Check Gun Electrical Grounding, page 23.

Reading must be less than 100 ohms.

6. Connect the exhaust tube and secure with the clamp provided.

7. Flush if ne

To reduce the risk of a skin injection injury, always follow the

Pressure Relief Procedure, page 26,

before removing or installing the spray tip, air cap, or tip guard.

eded. See Flushing, page 31.

11. Close the atomizing air adjustment valve (G) and the fan air adjustment valve (F).

12. Check that the ES On-Off switch is OFF (O).

13. Start the pu (2.8 MPa, 28

14. Spray a tes the center in step 18) increment particle s the parti 3000 psi (

mp. Set the ﬂuid regulator to 400 psi

bar).

t pattern. Examine the particle size in of the pattern (tails will be removed . Increase the pressure in small

s. Spray another pattern. Compare

ize. Continue increasing pressure until

cle size remains constant. Do not exceed

21 MPa, 210 bar).

8. 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 71, as a guide

for selecting the appropriate spray tip for your application.

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

10. Install the air cap and retaining ring. Orientate the air cap and tighten the retaining ring securely.

15. Turn ON (I) the ES On-Off switch.

3A2497B 29

Operation

16. Check that the ES indicator (Hz indicator on Smart guns) is lit, or check that the kV indicator on the isolated enclosure reads 30–50 kV. The actual spraying voltage for AA waterborne systems is 40–50 kV, but because the charging electrode does not directly contact the ﬂuid, the voltage measured by the WB3000 kV meter will be 5–10 kV lower. See the following table.

Table 2 . LED Indicator Colors

Indicator

Color

Green

Amber

Red

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

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

If the in second, high. De the indi

Description

dicator turns red after 1

the air pressure is too crease air pressure until

cator is green.

18. Turn the atomizing air adjustment valve counterclockwise until any tails disappear.

19. If desired the tip siz the atomiz

20. Spray a tes for covera

Troubles

atomization is not achieved, change

e. The smaller the tip oriﬁce, the ﬁner

ation.

t piece. Examine the edges

ge. If wrap is poor, see

hooting, page 40.

17. Set the gun air regulator to deliver a minimum of 45 psi (0.32 MPa, 3.2 bar) at gun when triggered, to ensure full spraying voltage. See the table below.

Table 3 . Pressure Drop

Air Hose

Length in ft (m)

(using 5/16 in. [8

mm] diameter hose)

15 (4.6) 52 (0.36, 3.6)

25 (7.6) 57 (0.40, 4.0)

50 (15.3) 68 (0.47, 4.7)

75 (22.9) 80 (0.56, 5.6)

100 (30.5) 90 (0.63, 6.3)

Air Regulator Setting

in psi (MPa, bar)

[with gun triggered]

NOTE: If a narrower pattern is needed occasionally, open the fan air adjustment valve slightly. (Excessive fan air ﬂow can cause paint buildup on the air cap.)

Shutdown

1. Discharge the system voltage. See Fluid Voltage

Discharge and Grounding Procedure, page 25.

2. Flush the gun. See Flushing, page 31.

3. Follow the Pressure Relief Procedure, page 26.

4. Hang the gun from its hook, with the nozzle pointing down. Be sure to keep the gun from grounding out.

30 3A2497B

Maintenance

Flushing

Maintenance

•Flushbefore in the equipm storing, and

•Flushatthe connectors

•Flushwitha compatible equipment

To reduce the risk of ﬁre, explosion, or electric shock, turn OFF (O) the ES On-Off switch before ﬂushing the gun.

Follow the Fluid Voltage Discharge and Grounding

Procedure, page 25, 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.

changing ﬂuids, before ﬂuid can dry

ent, at the end of the day, before

before repairing equipment.

lowest pressure possible. Check

for leaks and tighten as necessary.

non-ﬂammable solvent that is

with the ﬂuid being dispensed and the

wetted parts.

1. Turn OFF (O) t seconds for t

2. Discharge the system voltage. See Fluid Voltage

Discharge and Grounding Procedure, page 25.

3. Follow the Pressure Relief Procedure, page 26.

4. Removeandcleantheaircapandspraytip.

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

6. Point the gun into a grounded metal pail. Flush until clean solvent ﬂows from the gun.

he ES On-Off switch. Wait 30

he voltage to bleed off.

NOTICE

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

3A2497B 31

Maintenance

7. Follow the Pressure Relief Procedure, page 26. Engage the trigger lock.

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

9. Reinstal

l the air cap, tip guard, and retaining ring.

10. Open the isolated enclosure door. Leave the ﬂushing ﬂuid in the system until you are ready to spray again.

11. Hang the gun from its hook, with the nozzle pointing down. Be sure to keep the gun from grounding out.

12. Before using the system electrostatically again, make sure no ﬂammable vapors are present.

32 3A2497B

Maintenance

Clean the Gun D

1. Turn OFF (O) the ES On-Off switch.

2. Discharge t

Discharge

3. Follow the

4. Remove the

he system voltage. See Fluid Voltage

and Grounding Procedure, page 25.

Pressure Relief Procedure, page 26.

air cap/tip guard and spray tip.

aily

7. Clean the outside of the gun with a non-ﬂammable solvent, as deﬁned under Flushing, page 31. Use a soft cloth. Point the gun down to prevent solvent from entering the gun passages. Do not immerse the gun.

5. Flush the gun, see Flushing, page 31.

6. Follow the Pressure Relief Procedure, page 26.

3A2497B 33

Maintenance

8. Clean the air cap/tip guard and spray tip with a soft brush and non-ﬂammable solvent.

9. If necessary, use a toothpick or other soft tool to clean the air cap holes. Do not use metal tools.

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

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

34 3A2497B

Maintenance

Daily System C

1. Follow the instructions under

Clean the Gun Daily, page 33. Follow

the Pressure Relief Procedure, page 26.

2. Clean the ﬂuid and air ﬁlters.

3. Check for ﬂuid leaks. Tighten all ﬁttings.

4. Clean workpiece hangers. Use non-sparking tools.

5. Check the movement of the trigger and valves. Lubricate if necessary.

are

7. Hang the gun from its hook, with the nozzle pointing down.

8. Clean the cabinet:

• Inspect the

paint. Cond contact gr electrost

•Keepthein

operation

• Inspect t

regularl greased. threads w

• Visuall

for dama Measure

Test Gro

cabinet and clean up any spilled

uctive paint residue allowed to

ounded parts may short out the

atics.

side of the cabinet clean, for proper

he door T-handle locking screw

y, to ensure the threads are well

Apply silicone-free grease to the hen necessary.

y inspect the ground strip (240)

ge. Replace if needed.

theresistanceweekly. See

und Strip Resistance, page 39.

6. Check Gun Electrical Grounding, page 23.

3A2497B 35

Electrical Test

Electrical Tests

Use the follow of the power su continuity be

ing procedures to test the condition

pply and gun body, and electrical

tween components.

NOTICE

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

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

Megohmmeter Part No. 241079 (AA-see Fig.

17) 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;

Test Gun Resis

1. Flush and dry the ﬂuid passage.

2. Measure resistance between the electrode needle tip (25a) and the air swivel (21). The resistance should be 104–150 megohms. If outside this range, go to

Test Power Supply Resistance, page 37.Ifin

range, see Electrical Troubleshooting, page 45 for other possible causes of poor performance, or contact your Graco distributor.

tance

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

Figure 17 Test Gun Resistance

36 3A2497B

Electrical Test

Test Power Sup

1. Remove the power supply (11). See Power

Supply Removal and Replacement, page 52.

2. Remove the alternator (15) from the power supply. See

Alternator Removal and Replacement, page 53.

3. Measure resistance from the power supply's ground strips (EE) to the spring (11a). The resistance should be 90–115 megohms. If outside this range, replace the power supply. If in range, go to Test Gun Barrel Resistance, page 38.

4. Be sure the spring (11a) is in place before reinstalling the power supply.

ply Resistance

Figure 18 Test Power Supply Resistance

3A2497B 37

Electrical Test

Test Gun Barre

1. Insert a conductive rod (B) into the gun barrel (which was 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 (9). 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 (9) are clean and undamaged.

3. If the resistance is still outside the range, remove the conductive ring (9) 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 (9) 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 intothegroove(G).

l Resistance

NOTICE

The conductive ring (9) is a conductive metal contact ring, not a sealing o-ring. For best performance and to avoid potential damage to the spray gun, do not remove the conductive ring (9) except to replace it and 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.

e 19 Test Gun Barrel Resistance

Figur

38 3A2497B

Electrical Test

Test Ground St

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).

rip Resistance

Test Cylinder

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.

Resistance

Figure 20 Test Ground Strip Resistance

e 21 Test Cylinder Resistance

Figur

3A2497B 39

Troubleshootin

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 service this equipment unless you are trained and qualiﬁed.

Follow the Fluid Voltage Discharge and Grounding

Procedure, page 25 before checking or servicing

the system and whenever you are instructed to discharge the voltage.

To reduce the risk of a skin injection injury, always follow the Pressure Relief Procedure, page 26, whenever you are instructed to relieve the pressure.

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

Voltage Loss Troubleshooting

are electrica waterborne ﬂu

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:

lly connected through the conductive,

id.

Spray Gun

• Fluid leakage

• Dielectric breakdown at the ﬂuid hose connection

or ﬂuid packings

• Not enough air pressure for the alternator turbine

• Faulty power supply

• Excessive overspray on gun surfaces

• Fluid in the air passages

Waterborne Fluid Hose

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

inner 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.

Normal spraying voltage for a system using the waterborne gun is 40–50 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

Voltage Isolation System

• Fluid leakage

• Dirty interior

40 3A2497B

Troubleshootin

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 al are properly

2. Check that t and control

3. Check that t is clean.

4. Check that system hav

5. Check that ON positi is on. If t the spray

Electric

6. Check th enclosu

cks are engaged and working properly.

interlo

l of the air and ﬂuid tubes and hoses

connected.

he voltage isolation system valves

s are properly set for operation.

he interior of the isolated enclosure

the spray gun and voltage isolation

e sufﬁcient air pressure.

the gun ES ON/OFF valve is in the

on and that the gun ES indicator light

he ES indicator light is not on, remove

gunforserviceandcompletethe

al Tests, page 36.

at the voltage isolation system's

re door is closed and that any safety

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

8. 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.

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

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

•Packinga

• Fluid hos

the outer leak.

• Interna

rea of the spray gun.

e: check for leakage or any bulges in

cover, which may indicate an internal

l voltage isolation system components

3A2497B

Troubleshootin

Tests

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

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

2. Discharge the system voltage (see Fluid Voltage

Discharge and Grounding Procedure, page 25).

3. Follow the Pressure Relief Procedure, page 26.

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 ES ON/OFF valve to ON and trigger the gun just enough to turn on the air to the gun but not the ﬂuid. 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 40 to 50 kV, the gun and

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

• If the meter reading is below 40 kV, the

problem is in the gun or ﬂuid hose.

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

urn the ES ON/OFF valve to ON and trigger the

10.T

un. Measure the voltage at the gun electrode

ith a voltage probe and meter.

• If the meter reading is 40-50 kV, the gun power supply is okay, and there is probably a dielectric breakdown somewhere in the ﬂuid hose or gun. Continue with step 11.

• If the meter reading is below 40 kV, do the Electrical Tests, page 36,tocheckthegun and power supply resistance. If those tests show the gun and power supply are okay, continue with step 11.

11. 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 inner layer. Disconnect the ﬂuid hose from the gun, and look for signs of ﬂuid contamination on the outside of the inner portion 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 51), 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:

kdown at the ﬂuid hose connection

Abrea

would be caused by ﬂuid leaking past

joint

se ﬁttings. Remove the hose at the

the ho

nnection and look for signs of ﬂuid

gun co

ge.

leaka

12. Befo

13. Reco

14. Che

re reassembling the gun, clean and dry the

uid inlet tube. Repack the inner spacer of

gun ﬂ

uid packing rod with dielectric grease and

the ﬂ

semble the gun.

reas

nnect the ﬂuid hose.

ck the gun voltage with the voltage probe

meter before ﬁlling the gun with ﬂuid.

and

3A2497B

Troubleshootin

Spray Pattern

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

Problem

Fluttering or spitting spray.

Irregular pattern.

Pattern pushed to one side; air cap gets dirty.

Tails in pattern.

Troubleshooting

Cause Solution

No ﬂuid. Reﬁll supply.

Air in ﬂuid supply. Check ﬂuid source. Reﬁll.

Fluid buildup; partially plugged tip.

Worn/damaged tip or air cap holes.

Air cap holes plugged.

Air pressure too low.

Clean. See

Clean the G

Clean or replace.

Clean. See

Clean the Gun Daily, page 33.

Open atomizing air adjustment valve.

un Daily, page 33.

Fluid buildup on air cap/tip guard.

Fluid pressure too low. Increase.

Air pressure too high. Decrease.

Fluid pressure too low. Increase.

Air cap holes plugged.

Clean. See

Clean the Gun Daily, page 33.

3A2497B 43

Troubleshootin

Gun Operation

Problem

Excessive spray fog.

“Orange Peel” ﬁnish.

Fluid leaks from the ﬂuid packing area.

Air leaks from the front of the gun.

leakage from the front of the

Fluid gun.

Troubleshooting

Cause Solution

Atomizing air

Fluid too thin. Increase viscosity.

Atomizing a

Spray tip

Poorly mixed or ﬁltered ﬂuid. Remix or reﬁlter ﬂuid.

Fluid to

Worn ﬂuid needle packings or rod. See Fluid Needle Replacement,

ve is not seating properly.

Air val

Worn o

pressure too high.

ir pressure too low.

is too large.

o thick.

r damaged ﬂuid needle ball.

Close atomizing air valve part way, or decrease air pressure as low as possible; minimum 45 psi (0.32 MPa, 3.2 bar) needed at gun for full voltage.

Open atomizing air valve more or increase gun air inlet pressure; use lowest air pressure necessary.

Use small

Selectio

Reduce v

page 51.

See Air Valve Repair, page 57.

See Fl

page 51.

er tip. See Spray Tip

n Chart, page 71.

iscosity.

uid Needle Replacement,

Worn ﬂuid seat housing. See Air Cap, Spray Tip, and Fluid

se spray tip.

Loo

Damaged tip seal.

Gun does not spray.

Dirty air cap. Damaged or plugged air cap.

Excessive paint wrap back to operator.

Low ﬂuid supply. Add ﬂuid if necessary.

Damaged spray tip. Replace.

irty or clogged spray tip.

Damaged ﬂuid needle. See Fluid Needle Replacement,

Poor grounding.

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

Seat Housing Replacement, page

48.

hten retaining ring.

Tig

See Air Cap, Spray Tip, and Fluid

Seat Housing Replacement, page

48.

Clean. See

Clean the Gun Daily, page 33.

page 51.

Clean air cap. See

Clean the Gun Daily, page 33.

See Grounding, page 21.

3A2497B

Electrical Troubleshooting

Troubleshootin

Problem

Poor wrap.

Cause Solution

ES On/Off switch is OFF (O). Turn ON (I).

Gun air pressure too low (ES indicator is amber).

Atomizing air pressure too high. Decrease.

Fluid press

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

Poorly gro

Faulty gun resistance.

Fluid leaks from the ﬂuid needle packings and causes a short.

Faulty alternator.

ES On/Off switch is OFF (O). Turn ON (I).ES or Hz indicator is not lit.

No pow

ure too high.

unded parts.

er.

Check air pressure to gun; minimum45psi(0.32MPa,3.2 bar) needed at gun for full voltage.

Decrease, o

Resistanc less. Cle

See

Test Gun Resistance, page 36.

See Fluid Needle Replacement,

page 51.

See Alt

Replac

Check power supply, alternator, and alternator ribbon cable. See

Power Supply Removal and Replacement, page 52 and Alternator Removal and Replacement, page 53.

r replace worn tip.

e must be 100 ohms or

an workpiece hangers.

ernator Removal and

ement, page 53.

rator gets mild shock.

Ope

Operator gets shock from workpiece.

rator not grounded or is near

Ope

rounded object.

ung

Gun not grounded. See Check Gun Electrical

rkpiece not grounded.

Grounding, page 21.

See

Grounding, page 23,and Test Gun Resistance, page 36.

sistance must be 100 ohms or

ess. Clean workpiece hangers.

3A2497B 45

Troubleshootin

Problem

Voltage/current display stays red (smart guns only).

ES or Hz indicator is amber.

ES or Hz indicator is red.

Error display appears and Hz indicator is red (Smart guns only).

Cause Solution

Gun is too clos sprayed.

Dirty gun.

Air turbine s

Air turbine speed is too high. Decrease air pressure until

Smart mod communic supply.

e to the part being

peed is too low.

ule has lost

ation with the power

Gun should be 8 mm) from the pa

See Clean the Gun Daily, page 33.

Increase air indicator is over-atomi atomizing a reduce the a cap.

indicator is green.

Check for between S power sup

Replacem Power Sup Replace

ment, page 52.

–12 in. (200–300 rt.

pressure until

green. To avoid

zation, use the

ir restrictor valve to

tomizing air to the air

good connections

mart Module and

ply. See Smart Module

ent, page 58,and

ply Removal and

46 3A2497B

Repair

Prepare the Gun for Service

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

To reduce the risk of injury, follow the

Pressure Relief Procedure, page 26, before

checking or servicing any part of the system and whenever you are instructed to relieve the pressure.

Repair

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

• Lubricate the some needle assembly parts (20) and certain ﬂuid ﬁttings with dielectric grease (57), 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 ge parts from

• Air Seal Repair Kit 24N789 is available. The kit must be purchased separately. Kit parts are marked with an asterisk, for example (3*).

1. Flush the gun. See Flushing, page 31.

2. Relieve the pressure. See

Pressure Relief Procedure, page 26.

nuine Graco parts. Do not mix or use

other PRO Gun models.

• Check all possible remedies in

Troubleshooting, page 40, before disassembling

the gun.

3. Disconnect the gun air and ﬂuid lines.

4. Remove the gun from the worksite. Repair area must be clean.

3A2497B

Repair

Air Cap, Spray

Tip, and Fluid Seat

Housing Replacement

1. See Prepare th

2. Remove the re guard assemb

Figure 22 Remove Air Cap

3. Disassemble the air cap assembly. Check the condition of the u-cup (22a), o-ring (25b), and tip gasket (27a). Replace any damaged parts.

e Gun for Service, page 47.

tainer ring (22) and air cap/tip

ly (25).

NOTICE

5. Trigger the (24), using

Figure 25 Replace Fluid Seat Housing

gun and remove the ﬂuid seat housing the multi-tool (61).

Figure 23 Disassemble Air Cap Assembly

Figure 24 Tip Gasket

4. To replace the electrode (25a), see

Electrode Replacement, page 49.

48 3A2497B

Repair

NOTICE

Do not overtighten the ﬂuid seat housing (24). Overtightening may damage the housing and the gun barrel, resulting in improper ﬂuid shutoff.

6. Trigger the g

(24). Tighte

7. Check that t

Align the sp cap (25). In

8. Make sure t

correctly

9. Check that

10. Check that

retainin face forw

un and install the ﬂuid seat housing

n until snug, then 1/4 turn more.

he spray tip gasket (27a) is in place.

ray tip tab with the groove in the air

stall the spray tip (27) in the air cap.

hat the electrode (25a) is installed

in the air cap.

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

the u-cup (22a) is in place on the

gring(22). Thelipsoftheu-cupmust

ard.

NOTICE

To avoid air cap a retaini when the

damaging the tip guard, orient the

ssembly (25) before tightening the

ng ring (22). Do not turn the air cap

retaining ring is tight.

Electrode Replacement

NOTICE

For best perfo damage to the s gun without t

1. See Prepare t

2. Remove the a

Air Cap, Spr Replacemen

3. Pull the el cap, using

4. Push the ne Make sure t engages th cap. Pres ﬁngers.

5. Install t

6. See Test

rmance and to avoid potential

pray gun, do not operate the spray

he electrode installed in the air cap.

he Gun for Service, page 47.

ir cap assembly (25). See

ay Tip, and Fluid Seat Housing t, page 48.

ectrode (25a) out of the back of the air

a needle-nose pliers.

w electrode through the air cap hole.

he short end (BB) of the electrode

ehole(CC)inthebackoftheair

s the electrode in place ﬁrmly with your

he air cap assembly.

Gun Resistance, page 36.

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

12. See Test Gun Resistance, page 36.

e 26 Replace Electrode

Figur

3A2497B 49

Repair

Gun Barrel Rem

1. See Prepare the Gun for Service, page 47.

2. Remove the air inlet ﬁtting (21) and take the bracket (B) off the gun handle (16).

osen the two screws (6).

3. Lo

oval

NOTICE

To avoid damaging the power supply (11), pull the gun barrel straight away from the gun handle. If necessary, gently move the gun barrel from side to side to free it from the gun handle.

4. Hold the gun handle (16) with one hand and pull the barrel (1) straight off the handle.

Gun Barrel Ins

1. Be sure the gasket (5*) and grounding spring (37a) are in place. Make sure the gasket air holes are aligned properly. Replace the gasket if damaged.

2. Make sure the spring (11a) is in place on the tip of the power supply (11). Liberally apply dielectric grease (57) to the tip of the power supply. Place the gun barrel (1) over the power supply and onto the gun handle (16).

3. Tighten the two screws (6) oppositely and evenly (about a half turn past snug). Do not over-tighten the screws (6).

4. Position the bracket (B) on the gun handle (16) and secure with the air inlet ﬁtting (21).

5. See Test Gun Resistance, page 36.

tallation

e27 GunBarrelRemoval

Figur

50 3A2497B

e 28 Gun Barrel Installation

Figur

Fluid Needle Replacement

Repair

1. See Prepare th

2. Remove the air housing. See A

Housing Repla

3. Remove the gu

Gun Barrel Re

4. Remove the tr

5. Unscrew the (20a).

6. Insert the s back of the segments o the needle

7. Using the m nut (N) to

8. Install t Push in on tighten.

9. Install

10. Install groundi

he ﬂuid needle assembly in the gun barrel.

the spring (20a).

the spring cap (37). Make sure the

igger screws (13) and trigger (12).

spring cap (37). Remove the spring

upplied driver (60) in the socket at the

ﬂuid needle. Press forward so the two

f the needle engage (R). This allows

to be unscrewed from the gun body.

ulti-tool (61), pull back on the packing

remove the ﬂuid needle assembly.

the needle with the driver (60) and

ng spring (37a) is in place.

e Gun for Service, page 47.

cap assembly and ﬂuid seat

ir Cap, Spray Tip, and Fluid Seat

cement, page 48.

nbarrel. See

moval, page 50.

Figure 29 Remove Cap and Springs

Figure 30 Remove Fluid Needle

11. Install

12. Instal

13. Instal

14. See Te

l the gun barrel. See

Gun Bar

l the seat housing and air cap assembly. See Air

Repla

the trigger (12) and screws (13).

rel Installation, page 50.

Cap, Spray Tip, and Fluid Seat Housing

cement, page 48.

st Gun Resistance, page 36.

Figure 31 Replace Fluid Needle

3A2497B 51

Repair

Power Supply R

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

• Do not expose gasket (5) to solvents.

1. See Prepare the Gun for Service, page 47.

2. See Gun Barrel Removal, page 50.

emoval and Replacement

NOTICE

Be careful when handling the power supply (11) to avoid damaging it.

3. Grasp the power supply (11) with your hand.

Withagentlesidetosidemotion,freethepower supply/alternator assembly from the gun handle (16), then carefully pull it straight out.

Models only,

from the socket at the top of the handle.

4. Inspect the power supply and alternator for

damage.

5. To separate the power supply (11) from the

alternator (15), disconnect the 3-wire ribbon connector (PC) from the power supply.

Models only,

(40) from the power supply. Slide the alternator up and off the power supply.

6. See Te

ce the power supply if necessary.

Repla To rep

rnator Removal and Replacement, page 53.

Alte

Smart models only:

circuit (40) to the power supply.

disconnect the ﬂexible circuit (40)

disconnect the 6–pin ﬂexible circuit

st Power Supply Resistance, page 37.

air the alternator, see

connect the 6–pin ﬂexible

On Smart

align the connector of the 6–pin ﬂexible circuit (40) with the socket (CS) at the top of the handle. Push the connector securely into the socket as you slide the power supply/alternator assembly into the handle.

Figure

10. Make su and pow Assemb

Gun Ba

11. See Te

32 Connect Flexible Circuit

re the gasket (5*), ground spring (37a), er supply spring (11a) are in place.

le the barrel (1) to the handle (16). See

rrel Installation, page 50.

st Gun Resistance, page 36.

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

8. Connect the 3-wire ribbon connector (PC) to the power supply. Tuck the ribbon forward, under the power supply. Slide the alternator (15) down onto the power supply (11).

9. Insert the power supply/alternator assembly in the gun handle (16). Make sure the ground strips make contact with the handle. On Smart models,

Figure 33 Power Supply

52 3A2497B

Alternator Removal and Replacement

Repair

NOTE: Replace of operation. Parts include

1. See Prepare the Gun for Service, page 47.

2. Remove the power supply/alternator assembly

and disconnect the alternator. See Power Supply

Removal and Replacement, page 52.

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 alternator coil (15a).

4. Using a ﬂat blade screwdriver, pry the clip (15h)

off the housing (15d). Remove the cap (15f), using a thin blade or screwdriver.

5. If necessary, rotate the fan (15e) so its blades

clear the four bearing tabs (T) of the housing (15d).

alternator bearings after 2000 hours

Order Part No. 24N706 Bearing Kit.

d in the kit are marked with a symbol (♦).

Figure 35

Alternator 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.

Figure 34 Fan Orientation

6. Push the fan and coil assembly (15a) out the

front of the housing (15d).

7. Hold th with th screwd

8. Remov

9. Remov

10. Insta

11. Pres

ll the new bottom bearing (15b1♦) on the

long e

ng must face away from the magnet (M).

beari

all in the coil (15a) so the bearing blades are

Inst

with the surface of the coil.

ﬂush

s the new top bearing (15b2♦) onto the short

end o

the surface of the coil (15a). The ﬂatter side

with

he bearing must face away from the coil.

of t

e coil assembly (15a) on a workbench

efanendfacingup. Usingawideblade

river, pry the fan (15e) off the shaft (S).

e the top bearing (15b2).

e the bottom bearing (15b1).

nd of the shaft (S). The ﬂatter side of the

f the shaft so the bearing blades are ﬂush

3A2497B 53

Repair

12. Hold the coil assembly (15a) on a workbench with the fan end facing up. Press the fan (15e♦) onto the long end of the shaft (S). The fan blades must be oriented as shown.

13. Carefully press the coil assembly (15a) into the front of the housing (15d♦). The 3–wire connector (PC) must be positioned below the wider notch (W) of the housing tabs, as shown in Fig. 35. Be sure the coil alignment pins (P) are positioned as shown in Fig. 34.

14. Rotate the fan (15e) so its blades clear the four bearing tabs (T) at the back of the housing.

Ensure that the blades of the bottom bearing (15b1♦) align with the tabs.

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

16. Ensurethattheo-ring(15g)isinplace. Install the cap (15f).

17. Install the alternator on the power supply, and install both parts in the handle. See Power

Supply Removal and Replacement, page 52.

Figure 36 Alternator

54 3A2497B

Repair

Fan Air Adjustment Valve Repair

1. See Prepare th

2. Place a wrench (30) and unscr

NOTE: You may assembly (go (steps 3-9).

3. Remove the re

4. Turn the val it comes fre

5. Remove the o

6. Clean all p

NOTE: Use n

111265. Do

7. When reas lubricat (30b) ful Install t the valve

8. Reassem the valv by the re

e the valve threads and screw the shaft

he o-ring (30c*), lubricate, and unscrew

e stem from the housing until it is stopped

e Gun for Service, page 47.

on the ﬂats of the valve assembly

ew it from the handle (16).

replace the valve as an

to step 9) or as individual parts

taining ring (30d).

ve shaft (30b) counterclockwise until

e from the valve housing (30a).

-ring (30c).

arts and inspect for wear or damage.

on-silicone grease, Part No.

not over-lubricate.

sembling the fan air valve (30), lightly

ly into the housing (30a) until bottomed.

stem until the o-ring enters the housing.

ble the retaining ring (30d). Unscrew

taining ring.

Atomizing Air Adjustment Valve Repair

1. See Prepare the Gun for Service, page 47.

2. Place a wrench on the ﬂats of the valve assembly (29) and unscrew it from the handle (16).

3. Inspect the valve assembly. If damaged, install a new valve (29).

4. Before installing the valve assembly in the handle, unscrew the valve stem (29b) from the housing (29a) until it stops.

5. Install the valve assembly into the gun handle. Torque the valve housing (29a) to 15 in-lb (1.7 N•m).

Figure 38 Atomizing Air Adjustment Valve

9. Screw th handle housin

Figure 37 Fan Air Adjustment Valve

e valve assembly (30) into the gun

(16),usingawrenchontheﬂatsofthe

g. Torque to 15 in-lb (1.7 N•m).

3A2497B 55

Repair

ES On-Off Valv

1. See Prepare the Gun for Service, page 47.

2. Loosen the captive screw (26p). Remove the valve (26) from the handle.

3. Lubricate the o-rings (26b* and 26g*) with non-silicone grease, Part No. 111265. Do not over-lubricate.

NOTE: Do not lubricant o gun air pass workpiece

ntheo-ringscanbepushedintothe

e Repair

over-lubricate parts. Excessive

age and blemish the ﬁnish on the

4. Clean and inspect parts for damage. Replace if necessary.

NOTE: The pro must point up

5. Reinstall th 15-25 in-lb (

trusion on the retainer plate (26f)

ward.

e valve. Torque the screw (26p) to

1.7-2.8 N•m).

Figure 39 ES On-Off Valve

56 3A2497B

Air Valve Repair

Repair

1. See Prepare th

2. See Gun Barrel

3. Remove the scr

4. Remove the ES

ES On-Off Val

5. Remove the sp

6. Push on the f out the back seal (23a*)

7. Inspect the unless dam with its li the u-cup o it in the gu

ve Repair, page 56.

ront of the air valve shaft to force it

of the handle. Inspect the rubber

and replace if damaged.

u-cup (3). Do not remove the u-cup aged. If removed, install the new one

ps facing into the gun handle (16). Place

n the shaft of the air valve to help seat

n handle.

e Gun for Service, page 47.

Removal, page 50.

ews (13) and trigger (12).

On-Off Valve. See

ring (2).

8. Install the ai gun handle (16

9. Install the ES

ES On-Off Valv

10. Install the t

11. See Gun Barre

r valve (23) and spring (2) into the

rigger (12) and screws (13).

On-Off Valve. See

e Repair, page 56.

l Installation, page 50.

Figure 40 Install U-Cup

Figure 41 Air Valve

3A2497B 57

Repair

Smart Module R

If the Error display appears, the Smart Module has lost communication with the power supply. Check for good connections between the Smart Module and the power supply.

If the module module.

1. See Prepare the Gun for Service, page 47.

2. Remove the pivot screw (31e), o-ring (31f), and ES HI/LO switch (31c) at the bottom left corner of the Smart Module cartridge (31a).

3. Remove the remaining three screws (31d) from the cartridge.

4. Pull the Smart Module out the back of the gun. Disconnect the ribbon cable (RC) from the connector (GC) in the gun handle.

5. Remove the gasket (31b).

6. Install a new gasket (31b) on the new cartridge (31a). Make sure the notched corners of the gasket are at the top.

’s LEDs are not lighting, replace the

eplacement

Figure 42 Smart Module

7. Align the module’s ribbon cable (RC) with the gun’s cable (GC) and slide them securely together, as shown. Tuck the connected cables into the recess of the gun handle. Install the module ﬂush to the back of the gun handle.

8. Install the pivot screw (31e), o-ring (31f), and ES HI/LO switch in the bottom left corner of the cartridge (31a).

9. Install the three remaining screws (31d). Torque to 7–9 in-lb (0.8–1.0 N•m).

Figure 43 Align Ribbon Cables

58 3A2497B

Repair

Air Swivel and

1. See Prepare the Gun for Service, page 47.

2. To replace the air exhaust valve:

a. Remove the clamp (36) and the exhaust tube

(35).

b. Unscrew the swivel (21) from the gun handle

(16). The swivel is a left-hand thread. Move thebracketoutoftheway.

c. Pull the exhaust valve (8) from the handle

(16). Inspect the o-ring (8a) and replace if necessary.

d. Install the o-ring (8a*) on the exhaust valve

(8). Lubricate the o-ring with a light coating of non-silicone grease.

e. Install the exhaust valve (8) in the handle

(16).

f. Apply thread sealant to the top threads of the

swivel (21). Position the bracket and screw the swivel into the gun handle (16). Torque to 75–85 in-lb (8.4–9.6 N•m).

g. Install the tube (36) and clamp (43).

3. To rep

lace the air inlet swivel:

Exhaust Valve Replacement

a. Unscrew the swivel (21) from the gun handle

(16). The swivel is a left-hand thread.

b. Apply thread sealant to the top threads of the

swivel. Screw the swivel into the gun handle. Torque to 75–85 in-lb (8.4–9.6 N•m).

Figure 4

4 Air Inlet Fitting and Air Exhaust Valve

3A2497B 59

Parts

Standard Air-Assisted Spray Gun Assembly

Part No. H60T Part No. 24M5

18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61

08 Unshielded Waterborne Fluid Hose (101), sold separately

60 3A2497B

Part No. H60T18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61 Part No. 24M508 Unshielded Waterborne Fluid Hose (101), sold separately

Ref. No.

2 185116

624N740

8 249323 VALVE, exhaust 1

8a*

924N747

11a

12 24N663

13 24A445

15 24N664

16 24P746 HANDLE; 60 kV AA gun 1

20a 24N782

21 24N626

22 24N793

22a*

23 24N633 VALVE, air 1

23a*

24 24N725

25 24N727

25a 24N643

26 24N632

Part No. Description

24N745

188749

24N699

24N742

112085

24N662

24N979

24N781

198307

276733

BODY, gun

SPRING, compression

PACKING, u-cup

GASKET, body

SCREW, hex socket; package of 2

BRACKET

O-RING

RING, conductive

POWER SUPPLY, 60 kV gun

SPRING

TRIGGER; includes item 13

SCREW, trigger; package of 2

See

Alternator Assembly, page 67

NEEDLE A item 20a SPRING, ﬂuid needle

SWIVEL, air inlet; M12 x 1/4 npsm(m); left-hand thread

RING, retainer; includes 22a

PACKING, u-cup; UHMWPE; part of 22

SEAL

ING, seat

HOUS

ir Cap Assembly, page 70

See A

TRODE; package of 5

ELEC

S On-Off Valve Assembly,

See E

e68

pag

SSEMBLY; includes

Qty

Ref. No. 27 AEMxxx

27a 183459

29 24N792

30 24N634

32 24E404

32a

35 185103

36 110231

37 24N785

37a 197624

38 24N786

50 24N783

51 112080

55▲

56▲ 186118

58 117824

60 107460

61 2767

101 24M5

101a

Part No. Description

TIP ASSEMBLY; customer’s

AEFxxx

———

24N604

222385

116553

———

choice; includes item 27a GASKET, tip

ATOMIZING AIR ADJUSTMENT VALVE See Fan Air V

page 69

STOP, trigger; includes item 32a

PIN, dowel 1

TUBE, exhaust; 1/4 in. (6 mm) ID (shipped loose)

CLAMP

CAP, spring; includes item 37a

SPRING, compression

PLUG, fan control; option, shipped loose for use in place of item 29 HOOK; includes screw

TOOL, needle (shipped loose)

COVER, gun; package of 10

CARD, warning (not shown)

SIGN, warning (not shown)

GREASE, dielectric; 1 oz (30 ml) tube (not shown)

GLOVE, conductive, medium; package of 12; also available in small (117823) and large (117825)

TOOL, wrench, ball end (shipped loose)

MULTI-TOOL (shipped loose)

HOSE, unshielded, waterborne ﬂuid; includes 101a CONNECTOR, barrel

alve Assembly,

Parts

Qty

▲ Replacement Danger and Warning labels, tags,

Parts labeled — — — are not available separately.

and cards are available at no cost.

* These parts are included in Air Seal Repair Kit 24N789 (purchase separately).

3A2497B 61

Parts

Smart Air-Ass

Part No. H60M18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61 Part No. 24M508 Unshielded Waterborne Fluid Hose (101), sold separately

isted Spray Gun Assembly

62 3A2497B

Part No. H60M18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61 Part No. 24M508 Unshielded Waterborne Fluid Hose (101), sold separately

Ref. No.

2 185116

624N740

8 249323 VALVE, exhaust 1

8a*

924N747

11a

12 24N663

13 24A445

15 24N664

16 24P745 HANDLE, smart; 60 kV AA gun 1

20a 24N782

21 24N626

22 24N793

22a*

23 24N633 VALVE, air 1

23a*

24 24N725

25 24N727

25a 24N643

26 24N632

27 AEMxxx

Part No. Description

24N745

188749

24N699

24N742

112085

24N662

24N979

24N781

198307

276733

AEFxxx

BODY, gun

SPRING, compression

PACKING, u-cup

GASKET, body

SCREW, hex socket; package of 2

BRACKET

O-RING

RING, conductive

POWER SUPPLY, 60 kV gun

SPRING

TRIGGER; includes item 13

SCREW, trigger; package of 2

See

Alternator Assembly, page 67

NEEDLE A item 20a SPRING, ﬂuid needle

SWIVEL, air inlet; M12 x 1/4 npsm(m); left-hand thread

RING, retainer; includes 22a

PACKING, u-cup; UHMWPE; part of 22

SEAL

ING, seat

HOUS

ir Cap Assembly, page 70

See A

TRODE; package of 5

ELEC

S On-Off Valve Assembly,

See E

e68

pag

TIP ASSEMBLY; customer’s choice; includes item 27a

SSEMBLY; includes

Qty

Ref. No. 27a 183459

29 24N792

30 24N634

31 24N756

32 24E404

32a

35 185103

36 110231

37 24N785

37a 197624

38 24N786

40 245265

50 24N783

51 112080

55▲

56▲ 186118

58 117824

60 107460

61 276741

101 24M508

101a

Part No. Description

GASKET, tip

ATOMIZING AIR ADJUSTMENT VALVE See Fan Air Valve Assembly,

page 69

See Smart Module Assembly,

page 70

STOP, trigger; includes item 32a

———

24N604

222385

116553

———

PIN, dowel 1

TUBE, exhaust; 1/4 in. (6 mm) ID (shipped loose)

CLAMP

CAP, spring; includes item 37a

SPRING, compression

PLUG, fan control; option, shipped loose for use in place of item 29 CIRCUIT

HOOK; in

TOOL, ne

COVER,

CARD, w

SIGN, w

GREASE ml) tub

GLOVE, conductive, medium; package of 12; also available in small (117823) and large (117825)

TOOL, wrench, ball end (shipped loose)

MULT

HOSE ﬂuid CONNECTOR, barrel

, ﬂexible

gun; package of 10

arning (not shown)

e(notshown)

I-TOOL (shipped loose)

, unshielded, waterborne

; includes 101a

cludes screw

edle (shipped loose)

, dielectric; 1 oz (30

Parts

Qty

▲ Replacement Danger and Warning labels, tags,

Parts labeled — — — are not available separately.

and cards are available at no cost.

hese parts are included in Air Seal Repair Kit

N789 (purchase separately).

3A2497B 63

Parts

Isolation Enclosure

Part No. 24N55 items 201–286

0 Waterborne Isolation Enclosure, for use with unshielded waterborne ﬂuid hose; includes

64 3A2497B

Parts

Part No. 24N550 Waterborne Isolation Enclosure, for use with unshielded waterborne ﬂuid hose; includes items 201–286

Ref. No. 201

201a 15A947

202 116993

203

204 15A551 T-HANDLE, latch 1

205 15A545

206 15A524

207 113061

209 24N548 PUMP; see 3A0732 1

210

211

212

214 104029

215 116989 VALVE, air 1

216 111804

217 113060

218 116473

219 233824

220 162453 NIPPLE; 1/4 npt x 1/4 npsm 1

226 190410

227 116988

228 15A518

229 104267

230

235▲ 15A682 LABEL, warning 1

238 114958

239 222011

240 234018

241 110209 NUT, regulator 11

Part No. Description

———

CABINET; includes 201a

DOOR, cabinet

CASTER, brake

———

PLATE 1

STEM, handle, door

HOUSING, latch

SWITCH, push, air

SCREW, hex hd cap; 5/16–18 x

5.5 in. (140 mm) WASHER, plain; 0.344 in. ID

NUT, lock; 5/16–18 4

LUG, ground

REGULATOR, air

GAUGE, air; 1/8 npt

BALL VALVE; 1/4 npt(f)

CART

RESISTOR, bleed

CYLINDER ROD

HOUSING, cylinder rod

REGULATOR, air

BUSHING; plastic; 3/4 x 1/2 npt

STRAP, tie

GROUNDWIRE;25ft(7.6m)

STRIP, grounding; aluminum

Qty

Ref. No. 242 114051

243 210084

244

245

246

247 107257

248

249 160430

251

252

253

256 162449 NIPPLE, reducing; 1/2 npt x 1/4

257 101874 TERMINAL, ring

258 116990

259 113983

260 237933 METER, 0–90 kV 1

261 113336 ADAPTER; 1/4 npt 1

262

263

264

265

266

267

268

Part No. Description

WASHER, shim, ;atch

ROD, ground

———

SCREW, hex hd; 1/4–20 x 5/8 in. (16 mm)

WASHER,plain;1/4in. (6mm)

NUT, hex; 1/4–20 16

SCREW, thread-forming

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

GAUGE, air

WIRE, 10 gauge; green with yellow stripe

CONNECTOR, swivel tee; 1/8 npt x 5/32 in. (4 mm) tube

NUT, hex; 10–32

npt

BOX, control

RING, retaining; 1/2 in. (13 mm)

SCREW, pan hd; 10–32 x 5/8 in. (16 mm)

SCREW, pan hd; 10–32 x 1/4 in. (6 mm)

HOLDER, tie

SCREW, button hd; 10–24 x 1.5 in. (38 mm)

SCREW, button hd; 10–32 x 1.0 in. (25 mm)

hex; M5 x 0.8

NUT,

WASHER, lock; no. 10

Qty

A/R

3A2497B 65

Parts

Ref. No. 270 116991

271 203953

272

273

274 155541

275 114261 TERMINAL, ring; no. 10 1

276 15A780

278 117314

279 113319

280

281

Part No. Description

TEE, run, mani

SCREW, hex hd c 10–24 x 3/8 in.

———

WIRE, 14 gauge; red A/R

WIRE, ground, 14 gauge; green with yellow stripe

UNION, swivel; 1/4 npt

PLUG, hex hd

BULKHEAD CONNECTOR; 1/4 npt

CONNECTOR 3/8 in. (10

ELBOW, tube

FITTING, tube; 1/8 npt x 5/32 in. (4 mm) OD tube

fold

ap with patch;

(10 mm)

, tube; 1/4 npt x

mm) OD tube

Qty

A/R

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

★ The air hose (300) and gun (301) are not included with the 24N550 Isolation Enclosure. They are shown

Ref. No. 282

283

286

300★ 235070

Part No. Description

———

H60T18

H60M18

SWIVEL, tube; (6 mm) OD tube

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

TUBE; 3/8 in. (10 mm) OD

HOSE, air, grounded; 0.315 in. (8 mm) 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

GUN; see Sta

Spray Gun As

GUN; see Smart Air-Assisted

Spray Gun Assembly, page 62

1/4 npt x 1/4 in.

ndard Air-Assisted

sembly, page 60

Qty

A/R

1301★

for illustrative purposes only. See page 3 for a list of models which include an air hose and gun.

66 3A2497B

Alternator Assembly

Parts

Part No. 24N66

4 Alternator Assembly

Ref. No.

15a 24N705

15b♦ 24N706

15d♦ 24N707

15e♦

*The 24N

Part No.

———

se parts are included in Air Seal Repair Kit

789 (purchase separately).

Description

COIL, alternator

BEARING KIT (includes two bearings, item 15e fan, and one item 15h clip)

HOUSING; includes item 15f

FAN; part of item 15b

Qty

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

Ref. No.

15f

15g*

15h♦ 24N709

Part

Part No.

———

110073

s labeled — — — are not available separately.

Description

CAP, housing; part of item 15d

O-RING

CLIP; package of 5 (one clip included with item 15b)

Qty

3A2497B 67

Parts

ES On-Off Valv

e Assembly

Part No. 24N632 ES On-Off Valve Assembly

Ref. No.

26a

26b*

26c

26d 24N650

Part No. Description

———

15D37

———

HOUSING, valve

O-RING

PISTON, valve

LEVER, ES on-off; includes item 26e

* These parts are included in Air Seal Repair Kit 24N789 (purchase separately).

Qty

Ref. No.

26e

26f

26g*

26p

Part No. Description

———

24N631 PLATE, retaining 1

113746

———

SCREW, set, socket head

O-RING

SCREW, captive

Qty

Parts labeled — — — are not available separately.

68 3A2497B

Parts

Fan Air Valve Assembly

Part No. 24N63

4 Fan Air Valve Assembly

Ref. No.

30a

30b

30c*

30d 24N646

Part No. Description

———

111504

NUT, valve 1

STEM, valve

O-RING

RING, retaining; package of 6

Qty

* These parts are included in Air Seal Repair Kit 24N789 (purchase separately).

Parts labeled — — — are not available separately.

3A2497B 69

Parts

Air Cap Assemb

Part No. 24N727 Air Cap Assembly

Ref. No.

25a 24N643

25b 24N734

25c

25d 24N726

Parts l

Part No. Description

ELECTRODE; package of 5

O-RING; ptfe; package of 5 (also available in package of 10; order 24E459)

———

AIR CAP

GUARD, tip, orange

abeled — — — are not available separately.

Qty

Smart Module A

ssembly

Part No. 24N756 Smart Module Assembly

Ref. No.

31a

31b 24P433

31c 24N787

31d♦

31e♦

31f

Part No. Description

———

112319

CARTRIDGE

GASKET

SWITCH, ES HI/LO

SCREW

SCREW, pivot

O-RING

Qty

Parts labeled — — — are not available separately.

♦ThesepartsareincludedinSmartModuleScrew Kit 24N757 (purchase separately).

70 3A2497B

Spray Tip Select

ion Chart

Spray Tip Sele

AEM Fine Finis

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.

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)

0.01

83)

(0.4

0.021 (0.533)

0.023 (0.584)

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.

Fluid Output

ﬂ oz/min (l/min) 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)

1.5)

(

68.0 (1.9)

78.0 (2.2)

88.0 (2.5)

108.0 (3.1)

118.0 (3.4)

h Spray Tips

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

)

(1.0

45.4 (1.36)

51.9 (1.56) 64

1.94)

(

88.2 (2.65)

101.1 (3.03)

114.1 (3.42)

140.0 (4.20)

153.0 (4.59)

ction Chart

2–4

(50–

100)

107 207 307

Maximum Pattern Width at 12 in. (305 mm)

in. (mm)

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

8-10

(200-

250)

Spray Tip

421 521 621 721 821

423 523 623 723 823

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 oriﬁcesize. † These tip sizes include a 150 mesh ﬁlter.

3A2497B

Spray Tip Select

ion Chart

AEF Fine Finis

h Pre-Oriﬁce Spray

Tips

Recommended f that assists

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

Oriﬁce

Size

in. (mm)

† 0.010 (0.254)

0.012 (0.305)

0.014 (0.356)

0.016 (0.406)

or high ﬁnish quality applications at low and medium pressures. AEF tips have a pre-oriﬁce

in atomizing sheer thinning materials, including lacquers.

Fluid Output

ﬂoz/min(l/min)

at 600 psi (4.1 MPa, 41 bar)

9.5 (0.28

12.0 (0.35)

16.0 (0.47)

20.0 (0.59)

)

at 1000 psi (7.0 MPa, 70 bar) Spray Tip

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)

12-14

(300-350)

14-16

(350-400)

16-18

(400-450)

* 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 oriﬁcesize.

† These tip sizes include a 150 mesh ﬁlter.

3A2497B

Repair Kits, Related Manuals, and Accessories

Repair Kits, Rel

ated Manuals, and Accessories

Gun Part No.

All guns in this manual.

Gun Accessories

Part No. Description

105749

111265

116553

24N319

24N604

Cleaning Brush.

Non-silicone Lubricant, 4 oz (113 g).

Dielectric Gre

Round Spray Kit. To convert a standard air—assisted spray gun to a round spray air cap. See manual 3A2499.

Gun Covers. Box of 10.

Description Manual Descri

60 kV Waterborne Air-Assisted Spray Guns

Electrostatic Waterborne Air-Assisted Spray Guns, Instructions-Parts

Operator Accessories

ase. 1 oz (30 ml)

ption

Part No. Description

117823

117824

117825

24N520

24N521

Repair Kits Repair Kit

24N789

24N706 Alternator

Conductive Gloves, box of 12 (small)

Conducti (medium)

Conductive Gloves, box of 12 (large)

Comfort Grip. Snap-on grip increases handle size to reduce operator fatigue. Medium size.

Comfor increa opera

ve Gloves, box of 12

t Grip. Snap-on grip

ses handle size to reduce

tor fatigue. Large size.

Description

Air Seal Repair Kit

Bearing

Repair Kit

24N758

24P170 Metal Trigger Kit.

24P172

185105

24N642

185493

112534

Display Cove clean. Packa

Quick Adjus change of f

Non-swivel Air Inlet; 1/4–18 npsm(m) (left-hand thread)

Air Inlet Ball Swivel; 1/4–18 npsm(m) (left-hand thread)

Air Hose 1/4–18 n

Air Line Quick Disconnect Fitting.

rs. Keeps Smart display

ge of 5.

t Valve. For quick

an size.

Adapter; 1/4 npt(m) x

psm(m) (left-hand thread)

Syste

Part No. Description

222011

186118

m Accessories

nd Wire and Clamp.

Grou

English Warning Sign. Available at no charge from Graco.

3A2497B 73

Repair Kits, Rel

ated Manuals, and Accessories

Hoses

Grounded Air H

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

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

Part No. Description

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

235068

235069

235070

235071

235072

235073

235074

oses

6ft(1.8m)

15 ft (4.6 m)

25 ft (7.6 m)

36 ft (11 m

50 ft (15 m)

75 ft (23 m)

100 ft (

)

30.5 m)

Test Equipment

Part No. Description

241079 Megohmmeter.

0.01–2000 meg ground contin tests.Not fo

245277 Test Fixture, High Voltage Probe,

and kV Meter. Use to test the electrostatic voltage of the gun, and the condition of the alternator and power supply when being serviced. See manual 309455.

500 V output,

ohms. Use for

uity and gun resistance

r use in hazardous areas.

3A2497B

Repair Kits, Rel

ated Manuals, and Accessories

245895 Agitat

or Kit

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

Ref. No.

401 112698

402 114158

403 193315

404 193316 NUT, collar, agitator 1

405 197298

406 224571

407

408 110272

Part No. Description

ELBOW, swivel; 1/8 npt(m) x 1/4 in. (6 mm) OD tube

FITTING, adapter, Y; 1/4 in. (6 mm) OD tube; mxfxf

COLLAR, mounting, agitator

COVER, pail; 5 gal. (19 liter)

AGITATOR; see manual 306565

purchase locally

TUBE, nylon; 1/4 in. (6 mm) OD; 4 ft (1.22 m)

SCREW, set, socket hd; 1/4–20 x 1/4 in. (6 mm)

Qty

3A2497B 75

Dimensions

Figure 45

Gun Model A, in. (mm) B, in. (mm) C, in. (mm)

H60T18

H60M18

10.7 (272) 8.9 (226) 2.4 (61) 22.0 (623)

10.8 (274) 9.6 (244) 2.4 (61) 24.4 (692)

Weight without bracket, oz (g)

76 3A2497B

Technical Data

Electrostatic Air—Assisted Spray Waterborne Guns

U.S.

Maximum Worki

Maximum Working Air Pressure 100 psi 0.7 MPa, 7.0 bar

Minimum Air Pressure at Gun Inlet

Maximum Fluid Operating Temperature

Short Circuit Current Output

Voltage Output Energy 0.35 J with ﬂuid hose 24M508 installed.

ng Fluid Pressure

3000 psi 21 MPa, 210 bar

45 psi 0.32 MPa, 3.2 bar

120°F 48°C

125 microamperes

Metric

H60T18: 6

H60M18: 30–60 kV

Sound Power (measured per ISO Standard 9216)

Sound Pressure (measured 1 m from gun)

Air Inlet Fitting

Fluid Inlet Fitting

Isolation Enclosure Air Inlet Fitting 1/4 npt

Isolation Enclosure Fluid Inlet Fitting

ted Parts

Wet

at 40 psi: 90.4 dB(A)

at 100 psi: 105.4 dB(A)

at 40 psi: 87.0 dB(A)

at 100 p

3/8 in. OD tube ﬁtting 10 mm OD tube ﬁtting

Gun: Stainless Steel, PEEK, UHMWPE, Fluoroelastomer, Acetal, Nylon, Polyethylene, Tungsten Wire

Waterborne Fluid Hose: PTFE

ction Tube: Polyethylene, Stainless Steel

Merkur Pump: See manual 3A0732.

si: 99.0 dB(A)

sm(m) left-hand thread

1/4 np

m inlet for Graco waterborne ﬂuid hose.

Custo

0kV

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

at 0.7 MPa, 7.0 bar: 105.4 dB(A)

at 0.28 MPa, 2.8 bar: 87.0 dB(A)

at 0.7 M

Pa, 7.0 bar: 99.0 dB(A)

3A2497B

Graco Pro Xp Warranty

Graco warrants all equipment referenced in this document which is manufacturedbyGracoandbearingitsnametobe 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,foraperiodoftwelvemonthsfromthedate of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deﬁciency in the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

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

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for veriﬁcation of the claimed defect. If the claimed defect is veriﬁed, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

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

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

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

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

FOR GRACO CANADA CUSTOMERS

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

Graco Information

For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents.

To place an order, contact your Graco Distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reﬂects the latest product information available at the time of publication.

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

Original Instructions. This manual contains English, MM 3A2497

Graco Headquarters: Minneapolis

International Ofﬁces: Belgium, China, Japan, Korea

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

www.graco.com

Revised July 2013

Graco 3A2497BPro User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Models

Warnings

Gun Overview

Smart Guns

Bar Graph

Hz Indicator

Voltage Adjustment Switch

Error Display

Lock Symbol

Table 1 . Key for Figs. 2–9.

Diagnostic Mode

Current (microAmperes) Screen

Alternator Speed (Hertz) Screen

Low Voltage Lock Screen

Installation

System Requirements

Install the System

Ventilate the Spray Booth

Warning Sign

Ground the Cabinet

Agitator Kit Accessory

Gun Setup

Grounding

Flush Before Using Equipment

Operation

Operating Checklist

Fluid Voltage Discharge and Grounding Procedure

Table 2 . LED Indicator Colors

Table 3 . Pressure Drop

Shutdown

Maintenance

Flushing

Electrical Tests

Troubleshooting

Voltage Loss Troubleshooting

Spray Gun

Waterborne Fluid Hose

Voltage Isolation System

Visual Checks

Tests

Electrical Troubleshooting

Repair

Prepare the Gun for Service

Electrode Replacement

Fluid Needle Replacement

Alternator Removal and Replacement

Fan Air Adjustment Valve Repair

Atomizing Air Adjustment Valve Repair

Air Valve Repair

Parts

Standard Air-Assisted Spray Gun Assembly

Isolation Enclosure

Alternator Assembly

Fan Air Valve Assembly

Repair Kits, Related Manuals, and Accessories

Gun Accessories

Operator Accessories

Hoses

Test Equipment

Dimensions

Technical Data

Graco Pro Xp Warranty

Graco Information