Graco 333013B User's Manual

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Graco 333013B User's Manual | Manualzz
Instructions-Parts
Pro Xp Auto
Waterborne AA Spray Gun
333013B
EN
Air-assisted spray system for use when electrostatically spraying conductive, waterborne
fluids that meet at least one of the following conditions for non-flammability:
•
Material does not sustain burning in accordance with the Standard Test Method for
Sustained Burning of Liquid Mixtures, ASTM D4206.
•
Materials which cannot be ignited, in any mixture with air, by an energy source of less
than 500 mJ.
For professional use only.
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
3000 psi (21 MPa, 210 bar) Maximum Working Fluid Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents.
WLD
Table of Contents
List of Approved Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
How the Electrostatic AA Spray Gun Works . . . . . . . . . 7
Operating the Spray Function . . . . . . . . . . . . . . . . . . . . 7
Operating the Electrostatics . . . . . . . . . . . . . . . . . . . . . 7
Gun Features and Options . . . . . . . . . . . . . . . . . . . . . . 7
Smart Gun Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Spraying Waterborne Fluids Electrostatically . . . . . . . . 8
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . . . 11
Install the Air Line Accessories . . . . . . . . . . . . . . . . . . 12
Install the Fluid Line Accessories . . . . . . . . . . . . . . . . 12
Install the Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install the Pro Xp Auto Control Module . . . . . . . . . . . . 14
Connect the Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Ground the Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Manifold Connections . . . . . . . . . . . . . . . . . . . . . . . . . 15
Connect the Waterborne Fluid Hose . . . . . . . . . . . . . . 16
Fiber Optic Cable Connection . . . . . . . . . . . . . . . . . . . 17
Agitator Kit Accessory . . . . . . . . . . . . . . . . . . . . . . . . . 18
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Check Electrical Grounding . . . . . . . . . . . . . . . . . . . . 19
Install the Fabric Cover . . . . . . . . . . . . . . . . . . . . . . . . 20
Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . 20
Flush Before Using Equipment . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fluid Voltage Discharge and Grounding
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 22
Select a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fill the Fluid Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Set the Atomization Fluid Pressure . . . . . . . . . . . . . . . 23
Adjust the Electrostatics . . . . . . . . . . . . . . . . . . . . . . . 24
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Triggering the Fluid Alone . . . . . . . . . . . . . . . . . . . . . . 25
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Daily Care and Cleaning Checklist . . . . . . . . . . . . . . . 26
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Clean Outside of Gun . . . . . . . . . . . . . . . . . . . . . . . . . 27
Clean the Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check for Fluid Leakage . . . . . . . . . . . . . . . . . . . . . . . 28
Clean the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2
Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 29
Test Power Supply Resistance . . . . . . . . . . . . . . . . . . 29
Test Barrel Resistance . . . . . . . . . . . . . . . . . . . . . . . . 29
Test Ground Strip Resistance . . . . . . . . . . . . . . . . . . 30
Test Cylinder Resistance . . . . . . . . . . . . . . . . . . . . . . 30
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Voltage Loss Troubleshooting . . . . . . . . . . . . . . . . . . 31
Spray Pattern Troubleshooting . . . . . . . . . . . . . . . . . . 34
Gun Operation Troubleshooting . . . . . . . . . . . . . . . . . 35
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . 37
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Prepare the Gun for Service . . . . . . . . . . . . . . . . . . . . 38
Remove the Gun from the Manifold . . . . . . . . . . . . . . 38
Install the Gun on the Manifold . . . . . . . . . . . . . . . . . . 38
Air Cap/Tip Guard, Spray Tip, and Fluid Seat Housing
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electrode Replacement . . . . . . . . . . . . . . . . . . . . . . . 40
Fluid Needle Replacement . . . . . . . . . . . . . . . . . . . . . 40
Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . . . . . . 42
Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Power Supply Removal and Replacement . . . . . . . . . 43
Turbine Removal and Replacement . . . . . . . . . . . . . . 44
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Standard Pro Xp Auto Waterborne AA Gun
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
HA1T18, Rear Manifold . . . . . . . . . . . . . . . . . . . . . . . 46
Smart Pro Xp Auto Waterborne AA Gun
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Air Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Waterborne Fluid Hose . . . . . . . . . . . . . . . . . . . . . . . . 50
Turbine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
WB 3000 Isolation Enclosure . . . . . . . . . . . . . . . . . . . 52
Tubing and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Agitator Kit 245895 . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Rear Inlet Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . 59
AEM Fine Finish Spray Tips . . . . . . . . . . . . . . . . . . . . 59
AEF Fine Finish Pre-Orifice Spray Tips . . . . . . . . . . . 60
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Graco Pro Xp Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . 62
333013B
List of Approved Models
List of Approved Models
Part No.
HA1M18
HA1T18
kV
60
60
1.5mm Standard
Nozzle Model
✔
✔
✔
Part No.
24X288
24W599
24W077
Smart
Model
✔
Bottom
Manifold
Rear
Manifold
✔
✔
Description
WB 3000 Isolation Enclosure
25’ Waterborne Fluid Hose
50’ Waterborne Fluid Hose
FM approved for use with fluids that meet the following condition:
•
0.35 J with 50 ft hose max
FM14ATEX0082
EN 50059
Ta 0°C-50°C
Material does not sustain burning in accordance with the Standard
Test Method for Sustained Burning of Liquid Mixtures, ASTM
D4206
Models Compliant with EN 50059 when used with fluids that meet the
following criteria:
•
Materials which cannot be ignited, in any mixture with air, by an
energy source of less than 500 mJ.
0359
Related Manuals
Manual No.
332989
333013B
Description
Instructions - Pro Xp Auto Control Module
3
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of an isolated waterborne system can result in electric shock. To
help prevent electric shock:
• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to spray
area. See Grounding instructions.
• Connect the electrostatic gun to a voltage isolation system that will discharge the system voltage
when not in use.
• All components of the voltage isolation system that are charged to high voltage must be contained
within an isolation enclosure that prevents personnel from making contact with the high voltage
components before the system voltage is discharged.
• Follow the Fluid Voltage Discharge and Grounding Procedure when instructed to discharge the
voltage; before cleaning, flushing, or servicing the system; before approaching the front of the gun;
and before opening the isolation enclosure for the isolated fluid supply.
• Do not enter a high voltage or hazardous area until all high voltage equipment has been
discharged.
• Do not touch the gun nozzle or electrode, or come within 4 in. (102 mm) of the electrode during gun
operation. Follow the Fluid Voltage Discharge and Grounding Procedure.
• Interlock the gun air supply with the voltage isolation system to shut off the air supply anytime the
isolation system enclosure is opened.
• Only use the red-colored Graco electrically conductive air hose with this gun. Do not use black or
gray-colored Graco air hoses.
• Do not splice fluid hoses together. Install only one continuous Graco Waterborne Fluid Hose
between the isolated fluid supply and the spray gun.
4
333013B
Warnings
WARNING
WARNING
FIRE AND EXPLOSION HAZARD
Combustible dust in work area can ignite or explode. To help prevent fire and explosion:
• Use only fluids that meet the following flammability requirements:
•
Material does not sustain burning in accordance with the Standard Test Method for Sustained
Burning of Liquid Mixtures, ASTM D4206.
• Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500
mJ.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
• Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements of this manual.
• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to spray
area. Resistance must not exceed 1 megohm. See Grounding instructions.
• Do not use pail liners unless they are conductive and grounded.
• Check gun resistance, hose resistance, and electrical grounding daily.
• Use and clean equipment only in well ventilated area.
• Interlock the gun air supply to prevent operation unless ventilating fans are on.
• Only use non-flammable solvents when flushing or cleaning equipment.
• Always turn the electrostatics off when flushing, cleaning or servicing equipment.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static arc).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep spray area free of debris, including solvent, rags and gasoline.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
333013B
5
Warnings
WARNING
WARNING
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or
property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.
• See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent
manufacturer’s MSDSs and recommendations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is
not limited to:
• Protective eye wear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
6
333013B
Introduction
Introduction
How the Electrostatic AA Spray
Gun Works
This is not an air spray gun. To help prevent serious
injury from pressurized fluid, such as skin injection,
and splashing fluid, read and follow the Skin Injection
Hazard Warnings on page 5.
The air-assisted spray gun combines airless and air
spraying concepts. The spray tip shapes the fluid into a
fan pattern, as does a conventional airless spray tip. Air
from the air cap further atomizes the fluid and completes
the atomization of the fluid tails to produce a uniform
pattern.
Gun Features and Options
•
The gun is designed for use with a reciprocator, and
can be mounted directly on a 1/2 in. (13 mm) rod.
With additional brackets, the gun can be mounted
for robotic applications.
•
The gun’s quick-disconnect design enables its
removal without disconnecting the air lines to the
gun.
•
Gun functions are activated from a separate controller that sends the appropriate signal to the actuating
solenoids.
Smart Gun Features
The high working fluid pressure of this gun provides the
power needed to atomize higher solids materials.
Smart gun models with the Pro Xp Auto Control Module
have the ability to:
Operating the Spray Function
•
Display the spraying voltage and current
•
Change the gun voltage setting
•
Display the gun turbine speed
•
Store spray profiles
•
Communicate equipment faults to a PLC
•
Display and set maintenance totalizers
•
Use a PLC to select a spray profile
Applying a minimum of 60 psi (0.42 MPa, 4.2 bar) air
pressure to the gun manifold’s cylinder air fitting (CYL)
will retract the gun piston, which opens the air valves
and a short time later opens the fluid needle. This provides the proper air lead and lag when triggering the
gun. A spring returns the piston when the cylinder air is
shut off.
Operating the Electrostatics
To operate the electrostatics, apply air pressure to the
gun manifold’s turbine air fitting (TA) through a Graco
Grounded Turbine Air Hose. The air enters the manifold
and is directed to the inlet of the power supply turbine.
The air spins the turbine, which then provides electrical
power to the internal high voltage power supply. The
fluid is charged by the spray gun electrode. The charged
fluid is attracted to the nearest grounded object, wrapping around and evenly coating all surfaces.
333013B
See the Pro Xp Auto Control Module manual 332989 for
more information.
7
Introduction
Spraying Waterborne Fluids Electrostatically
This electrostatic air spray gun is designed to spray
only waterborne fluids which meet at least one of the
following flammability requirements:
FM, FMc Approved:
• Material does not sustain burning in accordance
with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206.
CE-EN 50059 Compliant:
• Materials which cannot be ignited, in any mixture
with air, by an energy source of less than 500 mJ.
When connected to a voltage isolation system, all of the
fluid in the spray gun, fluid hose, and isolated fluid supply is charged to high voltage, which means that the
system has more electrical energy than a solvent-based
system. Therefore, only non-flammable fluids (as
defined above) can be sprayed with the system or used
to clean, flush, or purge the system.
8
Precautions must be taken when using electrostatic
waterborne equipment to avoid potential shock hazards.
When the electrostatic AA spray gun charges the isolated fluid to high voltage, it is similar to charging a
capacitor or a battery. The system will store some of the
energy while spraying and retain some of that energy
after the spray gun is shut off. Do not touch the gun nozzle or come within 4 in. (102 mm) of the electrode until
the stored energy is discharged. The amount of time it
takes to discharge the energy depends on the system
design. Follow the Operating Checklist on page 22
before approaching the front of the gun.
NOTE: The Graco warranty and approvals are void if
the electrostatic spray gun is connected to a non-Graco
voltage isolation system or if the spray gun is operated
above 60 kV.
333013B
Introduction
System Overview
Typical Waterborne System Installation
FIGURE 1 shows a typical electrostatic waterborne AA spray system. It is not an actual system design. For assistance
in designing a system to suit your particular needs, contact your Graco distributor.
Also refer to system pneumatic
connections in FIGURE 3, page 13.
FIG. 1 Typical Installation, Pro Auto Xp Waterborne System
Item Description
Item Description
A
Main Air Supply Line
R
Graco Waterborne Fluid Hose
B*
Bleed-Type Air Shutoff Valve
T
Grounding Rod
C
Pump Air Pressure Gauge
U
Ground Terminal
D
Pump Air Pressure Regulator
V*
Main Ground Wire
E
kV Meter
W
Strain Relief Fitting
F
Pump
X
Pump Air Supply Line
G
Pump Suction Hose
Y
Grounding Cylinder
H
Paint Container
Z
Pump Fluid Outlet Fitting
J*
Bleed Resistor
AA
K*
Enclosure Safety Interlock
L
Isolated Enclosure
Isolated Enclosure Door (not shown, to illustrate
internal components. Door must be closed and
locked to operate system).
M
Air Line Filter
BB
Enclosure T-Handle Locking Screw (part of door
assembly)
N
Pneumatic connection to turbine air interlock.
(Pressurized when isolation system door is
closed)
333013B
* These items are required for safe operation. They are
included with the WB3000 system.
9
Introduction
Gun Overview
K
1
B
2
CYL
TA
A1
A2
F
J
C
EXH
D
A
H
G
L
Fig. 2. Gun Overview
Manifold Markings
Key
A
Air Cap
A1
Atomization Air Inlet Fitting
B
Spray Tip
A2
Fan Air Inlet Fitting
C
Retaining Ring
CYL
Cylinder Air Inlet Fitting
D
Shroud
1
F
Manifold
Fiber Optic Fitting Transmit
(Operational on Smart models only)
G
Turbine
2
H
Power Supply
Fiber Optic Fitting Receive
(Operational on Smart models only)
J
Electrode
K
ES Indicator Light (standard models only)
L
Waterborne Fluid Hose
TA
Turbine Air Inlet Fitting
EXH
Exhaust Outlet Fitting
10
333013B
Installation
Installation
System Requirements
Install the System
Basic Guidelines
When spraying waterborne fluids electrostatically:
•
The gun must be connected to a voltage isolation
system, which isolates the fluid supply from ground
and allows voltage to be maintained at the tip of the
gun.
•
The gun must be connected to a voltage isolation
system that will discharge the system voltage when
the gun is not in use.
•
There should be a bleed resistor to drain off the system voltage when the spray gun is not in use.
•
All components of the voltage isolation system that
are charged to high voltage must be contained
within an isolation enclosure that prevents personnel from making contact with the high voltage components before the system voltage is discharged.
•
•
•
The gun turbine air hose must be interlocked with
the voltage isolation system to shut off the turbine
air supply anytime the isolation system enclosure is
opened or entered.
The voltage isolation system must be interlocked
with the spray area entrance to automatically discharge the voltage and ground the fluid whenever
someone opens the enclosure or enters the spray
area.
The system should not have any severe arcing
occurring when the isolation mechanism opens and
closes. Severe arcing will shorten the life of the system components.
Installing and servicing this equipment requires
access to parts which may cause electric shock or
other serious injury if work is not performed properly.
• Do not install or service this equipment unless
you are trained and qualified.
• Comply with all applicable local, state, and
national fire, electrical, and other safety
regulations.
Warning Signs
Mount warning signs in the spray area where they can
easily be seen and read by all operators. An English
Warning Sign is provided with the gun.
Ventilate the Spray Booth
Provide fresh air ventilation to avoid the buildup of
flammable or toxic vapors when spraying, flushing,
or cleaning the gun. Do not operate the gun unless
ventilation fans are operating.
Electrically interlock the gun turbine air supply (B) with
the ventilators to prevent gun operation without ventilating fans operating.
NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Check and
follow all National, State, and Local codes regarding air
exhaust velocity requirements.
Graco Waterborne Fluid Hose
Use a Graco Waterborne Fluid Hose between the voltage isolation system fluid outlet and the gun fluid inlet.
See Accessories on page 57 for available hoses. The
hose consists of an inner PTFE tube, a conductive layer
covering the PTFE tube, and an outer cover.
333013B
Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufficient.
11
Installation
Install the Air Line Accessories
1. Install a bleed-type air valve (L) on the main air line
(W) to shut off all air to the gun.
2. Install an air line filter/water separator on the main
air supply line to ensure a dry, clean air supply to
the gun. Dirt and moisture can ruin the appearance
of your finished workpiece and can cause the gun to
malfunction.
3. Install a bleed-type air pressure regulator (M) on
each of the air supply lines (B, C, D, E) to control air
pressure to the gun.
4. Install a solenoid valve (K) on the cylinder air line
(E) to actuate the gun. The solenoid valve must
have a quick exhaust port.
Install the Fluid Line
Accessories
1. Install a fluid filter and drain valve at the pump outlet. Filtering the fluid will help remove coarse particles and sediment that could clog the spray tip.
The fluid drain valve is required in your system to
assist in relieving fluid pressure in the displacement
pump, hose, and gun. Triggering the gun to relieve
pressure may not be sufficient. Install a drain valve
close to the pump's fluid outlet. The drain valve
reduces the risk of serious injury, including splashing
in the eyes or on the skin.
5. Install a solenoid valve (K) to actuate the turbine.
Trapped air can cause the gun to spray unexpectedly,
which can result in serious injury, including splashing
fluid in the eyes or on the skin. The solenoid valves (K)
must have a quick exhaust port so trapped air will be
relieved between the valve and gun when the
solenoids are shut off.
12
333013B
Installation
FIGURE 3 shows a typical electrostatic air-assisted spray system. It is not an actual system design. For assistance in
designing a system to suit your particular needs, contact your Graco distributor.
The turbine air supply (TA) must be electrically interlocked
with the spray booth ventilation fans to prevent the power
supply from operating without ventilating fans on.
See Warning
above
L
Pneumatic
Interlock
A
K
C
B
D
L
L
W
K
N
M
Non-Hazardous Area
E
Air Line
(Pressurized when
door is closed)
Hazardous Area
G
Manifold Back View
Voltage
Isolation
System
WB3000
The turbine air must also be interlocked with the
voltage isolation system to shut off the turbine air
when the access to the isolation system is opened.
FIG. 3 . Typical Installation
Key to FIGURE 3
A
Air Hose Ground Wire
K
Solenoid Valve, requires quick exhaust port
B
Graco Grounded Turbine Air Hose (TA)
L
Bleed-Type Master Air Valve
C
Atomizing Air Hose, 5/16 in. (8 mm) OD (A1)
M
Air Pressure Regulator
D
Fan Air Hose, 5/16 in. (8 mm) OD (A2)
N
True Earth Ground
E
Cylinder Air Hose, 5/32 in. (4 mm) OD (CYL)
W
Main Air Line
G
Graco Waterborne Fluid Supply Hose
333013B
13
Installation
Install the Gun
1. Loosen the manifold’s two set screws (29) and slide
the manifold (20) onto a 1/2 in. (13 mm) mounting
rod.
2. Position the gun and tighten the two set screws.
NOTE: For added positioning reliability, insert a 1/8 in.
(3 mm) locating pin into the slot (NN) in the bracket and
through a hole in the rod. See the detail in FIGURE 4.
20
NN
2.88 in.
(73.2 mm)
29
8.18 in.
(207.7 mm)
To
nozzle tip
FIG. 4 Mounting Bracket
Install the Pro Xp Auto Control
Module
To reduce the risk of electric shock or other serious
injury, the red-colored Graco Grounded Turbine Air
Hose must be used for the turbine air supply hose,
and the hose ground wire must be connected to a
true earth ground. Do not use the black or
gray-colored Graco air hoses.
1. Connect the Graco Grounded Turbine Air Hose (B)
to the gun's turbine air inlet (TA) and connect the
hose ground wire (A) to a true earth ground (N). The
gun turbine air inlet fitting has left-hand threads to
prevent connecting another type of air hose to the
turbine air inlet. See Accessories, on page 57 for
further information about the hose.
2. Check the electrical grounding of the gun as
instructed on page 19.
Ground the Cabinet
Connect the main ground wire (V) to a true earth
ground.
The Pro Xp Auto Control Module is required for use with
smart models. To install a Pro Xp Auto Control Module,
see the module instruction manual 332989.
Connect the Air Line
FIGURE 3 shows a schematic of air line connections, and
FIGURE 5 shows the manifold connections. Connect the
air lines as instructed.
To reduce the risk of a fire, explosion, or electric
shock, the Graco Grounded Turbine Air Hose must
be interlocked with:
• The isolation system to shut off the turbine air
supply anytime the enclosure is opened or
entered.
• The ventilators to prevent operation of the power
supply unless the ventilating fans are on.
14
333013B
Installation
Manifold Connections
1
2
CYL
TA
A2
A1
EXH
FIG. 5 Manifold Connection
A1
Atomization Air Inlet Fitting
Connect a 5/16” in. (8 mm) OD tube between this fitting and the air supply.
A2
Fan Air Inlet Fitting
Connect a 5/16” in. (8 mm) OD tube between this fitting and the air supply.
CYL Cylinder Air Inlet Fitting
Connect a 5/32 in. (4 mm) OD tube between this fitting and the solenoid. For quicker response, use the
shortest hose length possible.
1
Fiber Optic Fitting Transmit (Operational on Smart models only)
Connect the Graco Fiber Optic cable (see page 17).
2
Fiber Optic Fitting Receive (Operational on Smart models only)
Connect the Graco Fiber Optic cable (see page 17).
EXH Exhaust
Connect a 5/16 in OD exhaust tube to route the turbine exhaust air. (3 ft. max length)
TA
333013B
Turbine Air Inlet Fitting
Connect the Graco Electrically Conductive Air Hose between this fitting (left-hand thread) and the solenoid.
Connect the air hose ground wire to a true earth ground.
15
Installation
Connect the Waterborne Fluid
Hose
NOTE: The Graco warranty is void if the spray gun is
connected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
To reduce the risk of electric shock, the areas of the
Graco Waterborne Fluid Hose that are accessible to
personnel during normal operation must be covered
by the black outer hose jacket.
Always use a Graco Waterborne Fluid Hose between
the voltage isolation system fluid outlet and the gun fluid
inlet.
5. Connect the other end of the fluid hose to the isolated fluid supply as follows:
Before connecting the Waterborne Fluid Hose to the
gun, blow it out with air and flush with water to remove
contaminants. Flush the gun before using it. See Flushing, page 26.
a. Graco WB3000 Enclosure: 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 the hose to the
side of the enclosure with the bracket (W).
b. Non-Graco Isolated Enclosure: Connect hose
as instructed in the isolation system manual.
To reduce the risk of electric shock, install only one
continuous Graco Waterborne Fluid Hose between
the isolated fluid supply and the spray gun. Do not
splice hoses together.
6. Reinstall the shroud (26), spray tip (3), and air cap
(25).
7. Check the gun’s electrical grounding (see page 19).
1. Remove the air cap (25), spray tip (3), and shroud
(26).
2. Ensure the barrel fluid inlet is clean and dry. Apply
dielectric grease to the threads of the barrel connector (600a) and screw it in to the fluid inlet.
3. Apply dielectric grease to the threads of the hose
(600) and screw it in to the barrel connector (600a).
4. Secure hose in strain relief bracket by tightening the
four plastic screws.
FIG. 7 . Unshielded Hose 24W599 Connection at
WB3000 Enclosure
Strain Relief Bracket
FIG. 6 Connect the Waterborne Fluid Hose
16
333013B
Installation
Fiber Optic Cable Connection
(Operational on Smart models only)
For a 2 Gun System
NOTE: Only use the supplied fiber optic cable.
1. Connect Port 1 of the gun 2 manifold to Port 5 of the
Control Module.
The fiber optic cable allows the gun to communicate
with the Pro Xp Auto control module.
2. Connect Port 2 of the gun 2 manifold to Port 6 of the
Control Module.
For a 1 Gun System
1. Connect Port 1 of the gun 1 manifold to Port 1 of the
Control Module.
2. Connect Port 2 of the gun 1 manifold to Port 2 of the
Control Module.
FIG. 8 . Making Fiber Optic Connections
Non-Hazardous Area
Hazardous Area
H
V
U
Port 2
Port 5
Port 6
1
2
Port 1
R
Gun 1
H
P
Q
Key for FIGURE 9
H
P
Q
R
U
V
PRO Xp Auto Waterborne AA Spray Gun
24 Volt Power Supply Connection
Remote I/O Connection
Remote Control Module
Bulkhead
Fiber Optic Cable
V
Gun 2
FIG. 9 . Fiber Optic Schematic
333013B
17
Installation
Agitator Kit Accessory
Grounding
To add an agitator to the Graco isolation system, order
Part No. 245895. See Agitator Kit 245895, page 56, for
the kit parts list.
When operating the electrostatic gun, any
ungrounded objects in the spray area (people,
containers, tools, etc.) can become electrically
charged. Improper grounding can result in static
sparking, which can cause a fire, explosion, or
electric shock. Ground all equipment, personnel,
object being sprayed, and conductive objects in or
close to the spray area. Resistance must not exceed
1 megohm. Follow the grounding instructions below.
1. Discharge the system voltage (see Fluid Voltage
Discharge and Grounding Procedure, page 22).
2. Relieve the pressure (see Pressure Relief Procedure, page 22).
3. Open the isolated enclosure door.
4. Remove the back of the control box (258).
5. Remove tube (A2) from elbow (282) at the air manifold; see Tubing and Wiring, page 54. Install the Y
fitting (402) into the elbow. Install tubes (A2) and
(407) into the Y fitting. Route the agitator tube (407)
into the cabinet.
6. Replace the back of the control box (258).
7. Assemble the other parts of the kit as shown.
Secure the agitator with the setscrew (408).
The following are minimum grounding requirements for
a basic electrostatic waterborne system. Your system
may include other equipment or objects which must be
grounded. Check your local electrical code for detailed
grounding instructions. Your system must be connected
to a true earth ground.
•
Electrostatic Air Spray Gun: ground the gun by connecting the red-colored Graco Grounded Air Hose
to the turbine air inlet and connecting the air hose
ground wire to a true earth ground. See Check
Electrical Grounding, page 19
•
Voltage Isolation System: electrically connect the
voltage isolation system to a true earth ground.
•
Air compressors and hydraulic power supplies:
ground the equipment according to the manufacturer's recommendations.
•
All persons entering the spray area: shoes must
have conductive soles, such as leather, or personal
grounding straps must be worn. Do not wear shoes
with non-conductive soles such as rubber or plastic.
•
Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Resistance must
not exceed 1 megohm.
•
The floor of the spray area: must be electrically conductive and grounded. Do not cover the floor with
cardboard or any non-conductive material which
would interrupt grounding continuity.
•
Flammable liquids in the spray area: must be kept in
approved, grounded containers. Do not use plastic
containers. Do not store more than the quantity
needed for one shift.
8. Return the system to service.
401
407
402
1
2
406
403
408
404
406
FIG. 10 245895 Agitator Kit
18
333013B
Installation
•
All electrically conductive objects or devices in the
spray area: including fluid containers and wash
cans, must be properly grounded.
•
Fluid and waste containers: ground all fluid and
waste containers in the spray area. Do not use pail
liners unless they are conductive and grounded.
When flushing the spray gun, the container used to
catch the excess fluid must be electrically conductive and grounded.
•
4. Measure the resistance between the turbine air inlet
fitting (TA) and a true earth ground (N). If the resistance is greater than 100 ohms, check the tightness
of the ground connections and be sure the turbine
air hose ground wire is connected to a true earth
ground. If the resistance is still too high, replace the
turbine air hose
N
TA
All solvent pails: use only approved, grounded metal
containers, which are conductive. Do not use plastic
containers. Use only non-flammable solvents. Do
not store more than the quantity needed for one
shift.
Check Electrical Grounding
AA
WLD
Megohmmeter Part No. 241079 (AA-see FIGURE 11)
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.
B
Fig. 11. Check Gun Grounding
5. If using the WB3000 use an ohmmeter (AA) measure the resistance between the cabinet ground lug
(214) and a true earth ground (CC). The resistance
must be less than 100 ohms.
214
AA
1. Have a qualified electrician check the electrical
grounding continuity of the spray gun and turbine air
hose.
2. Make sure the red-colored turbine air hose (B) is
connected and the hose ground wire is connected to
a true earth ground.
CC
FIG. 12 . Check Cabinet Grounding
3. Turn off the air and fluid supply to the gun. Follow
the Pressure Relief Procedure, page 22. The fluid
hose must not have any fluid in it.
333013B
19
Installation
Install the Fabric Cover
Check Fluid Viscosity
See FIGURE 13.
To check fluid viscosity you will need:
1. Install a fabric cover (XX) over the front of the gun
and slide it back to cover the exposed tubing and
hoses at the back of the manifold.
•
•
2. Route the exhaust tube (YY) outside the cover. This
enables you to monitor the exhaust tube for the
presence of any paint or solvent. See Check for
Fluid Leakage on page 28. Strap down the exhaust
tube to prevent it from moving around.
a viscosity cup
a stopwatch
1. Completely submerge the viscosity cup in the fluid.
Lift the cup out quickly, starting the stopwatch as
soon as the cup is completely removed.
2. Watch the stream of fluid coming from the bottom of
the cup. As soon as there is a break in the stream,
shut off the stopwatch.
3. Record the fluid type, elapsed time, and size of the
viscosity cup.
YY
4. If the viscosity is too high or too low, contact the
material supplier. Adjust as necessary.
XX
Flush Before Using Equipment
The equipment was tested in fluid at the factory. To
avoid contaminating your fluid, flush the equipment with
a compatible solvent before using the equipment. See
Flushing, page 26.
YY
WLD
FIG. 13 . Fabric Cover
20
333013B
Operation
Operation
Operating Checklist
Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.
All operators are properly trained to safely operate an automatic electrostatic waterborne air spray system as
instructed in this manual.
All operators are trained in the Fluid Voltage Discharge and Grounding Procedure on page 22.
All operators are trained in the Pressure Relief Procedure on page 22.
The electrostatics are turned off and system voltage is discharged according to the Fluid Voltage Discharge
and Grounding Procedure, page 22, before any person enters the isolation enclosure, before cleaning, and
before performing any maintenance or repair.
The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by
all operators.
The system is thoroughly grounded and the operator and all persons entering the spray area are properly
grounded. See Grounding on page 18.
The Graco Waterborne Fluid Hose is in good condition with no cuts or abrasions. Replace hose if damaged.
The condition of the gun’s electrical components has been checked as instructed in Electrical Tests on page
29.
All fluid hose connections are tight.
Ventilation fans are operating properly.
Workpiece hangers are clean and grounded.
All debris, including flammable fluids and rags, is removed from the spray area.
All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically
conductive and grounded.
All flammable fluids in the spray booth are in approved, grounded containers.
The manifold exhaust tubes have been checked for the presence of any fluid as instructed in Check for Fluid
Leakage on page 28.
Fluids used must meet the following flammability requirements:
FM, FMc Approved:
Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid
Mixtures, ASTM D4206.
CE-EN 50059 Compliant:
Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500mJ.
333013B
21
Operation
Fluid Voltage Discharge and
Grounding Procedure
The fluid supply is charged with high voltage until the
voltage is discharged. Contact with the charged
components of the voltage isolation system or spray
gun electrode will cause an electric shock. To avoid
an electric shock, follow the Fluid Voltage
Discharge and Grounding Procedure:
•
•
•
•
whenever you are instructed to discharge the
voltage
before cleaning, flushing, or servicing the system equipment
before approaching the front of the gun
or before opening the isolation enclosure for
the isolated fluid supply.
NOTE: An accessory grounding rod, part No. 210084, is
available to discharge any voltage remaining on a system component. Contact your Graco distributor to order.
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
from pressurized fluid, such as skin injection and
splashing fluid follow the Pressure Relief Procedure
when you stop spraying and before cleaning,
checking, or servicing the equipment.
1. Follow the Fluid Voltage Discharge and Grounding Procedure, page 22.
2. Relieve fluid pressure in the fluid supply and voltage
isolation system as instructed in their instruction
manuals.
3. Turn off all the air to the spray gun except the cylinder air, which triggers the gun.
1. Turn off the turbine air to all spray guns connected
to the isolated fluid supply and wait 30 seconds.
NOTE: The air shut-off device must bleed the air out of
the system.
2. Discharge the voltage at the voltage isolation system by following the procedure specified in the voltage isolation system instruction manual.
4. Trigger the gun into a grounded metal waste container to relieve the fluid pressure.
5. Turn off all remaining air supplies to the gun.
For WB3000: fully unscrew the door T-handle locking screw. This will shut off the air to the gun and
trigger the grounding cylinder to discharge any
remaining electrical charge.
3. Touch the pump, supply pail, and electrode of the
gun with a grounded rod to make sure the voltage
has been discharged. If you see an arc, verify that
the electrostatics are turned off or see Electrical
Troubleshooting, page 37 or the voltage isolation
system manual for other possible problems.
Resolve the problem before proceeding.
6. Turn off the main air supply by closing the
bleed-type master air valve on the main air supply
line. Leave the valve closed until you are ready to
spray again.
7. If you suspect the fluid hose or tip is plugged, or that
pressure is not fully relieved after following the steps
above, slowly loosen the fluid hose fitting at the
pump to relieve pressure gradually, then loosen
completely.
Select a Spray Tip
The fluid output and pattern width depend on the size of
the spray tip, the fluid viscosity, and the fluid pressure.
Use the Spray Tip Selection Chart, page 59, as a
guide for selecting the appropriate spray tip for your
application.
22
333013B
Operation
Install the Spray Tip
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.
To reduce the risk of an injury, follow the Pressure
Relief Procedure before removing or installing the
spray tip or air cap/tip guard.
Install the spray tip as explained in Air Cap/Tip Guard,
Spray Tip, and Fluid Seat Housing Replacement,
page 39.
1. Follow the Pressure Relief Procedure, page 22.
2. Align the spray tip tab with the groove in the air cap.
Install the tip.
5. Remove the supply pail from the enclosure.
NOTICE
Be sure to wipe up all fluid spills in the isolated enclosure. Fluid can create a conductive path and cause the
system to short out.
6. Clean up any fluid spills in the enclosure, using a
soft cloth and a non-flammable, compatible solvent.
7. Fill the supply pail with fluid and return it to the
enclosure. Clean up any spills.
8. Reinstall the pail cover, holding a rag over the suction tube strainer to prevent fluid spills while you
place the pump suction tube in the pail.
FIG. 14 Spray Tip Alignment
9. Close the isolated enclosure door and fasten
securely with the T-handle locking screw.
3. Install the air cap and retaining ring. Orientate the
air cap and tighten the retaining ring securely. Be
careful not to damage the electrode.
Set the Atomization Fluid
Pressure
WLD
Atomization fluid pressure will vary based on the viscosity of the fluid, flow rate desired, and other system characteristics.
WLD
FIG. 15 Install Air Cap Assembly
To reduce the risk of fire, explosion, or electric
shock, never operate the gun with a damaged
electrode.
Fill the Fluid Supply
1. Follow the Fluid Voltage Discharge and Grounding Procedure, page 22.
2. Follow the Pressure Relief Procedure, page 22.
3. Open the isolated enclosure door.
333013B
1. Turn off the turbine air (TA), atomization air (A1),
and fan air (A2).
2. Start the pump. Set the fluid regulator to 400 psi (2.8
MPa, 28 bar).
3. With the turbine air (TA), atomization air (A1), and
fan air (A2) turned off, spray a test pattern, holding
the gun 12 in. (305 mm) from the surface. Examine
the particle size. Do not be concerned about the
presence of tails; they will be removed in step 6.
4. Increase the fluid pressure in small increments.
Spray another pattern and compare the particle
size. Smaller particle size indicates improved atomization.
To reduce the risk of injury, never exceed the
maximum working pressure on the lowest rated
system component. Maximum working pressure of
this equipment is 3000 psi (21 MPa, 210 bar).
23
Operation
5. Continue to increase the fluid pressure and spray
test patterns. Do not exceed 3000 psi (21 MPa, 210
bar) fluid pressure. When the particle size remains
constant, the fluid is being atomized at the lowest
possible fluid pressure.
For improved atomization at lower fluid flow rates,
change to a smaller tip orifice size.
6. Turn on the atomization air (A1) and adjust the air
pressure until the tails disappear.
See Spray Pattern Troubleshooting on page 34 to
correct spray pattern problems.
7. The pattern width can also be reduced by applying
fan air pressure (A2).
Too Little Air
Correct
Amount of Air
No Air
FIG. 16 Eliminating Tails
Adjust the Electrostatics
1. Shut off the fluid supply.
4. Check the turbine speed of the gun by checking the
indicator light on the standard gun body or for the
smart gun check the actual turbine speed on the Pro
Xp Auto Control Module. See Table 2 . Adjust the
air pressure as necessary to keep the indicator light
green or the values within 100-750 Hz.
NOTE: Smart models display values not color indicator
lights.
Table 2. Indicator Colors/Values
Indicator
Color
Description
Green
When spraying, the indicator should
400-750 Hz remain green, indicating sufficient air
pressure to the turbine.
Amber
<400
If the indicator changes to amber after 1
second, the air pressure is too low.
Increase air pressure until the indicator is
green.
Red
>750
If the indicator changes to red after 1 second, the air pressure is too high.
Decrease air pressure until the indicator is
green. Excessive turbine speed can
shorten the bearing life and will not
increase the voltage output.
5. Check the voltage output by reading the kV meter
on the isolated enclosure. 45-55 kV is normal.
See Electrical Troubleshooting, page 37 to correct
voltage problems.
2. Prepare the isolation system for high voltage operation.
3. Turn on the turbine air (TA) and adjust the air pressure per the settings in Table 1 . Set the proper
pressure at the turbine air hose inlet when air is
flowing.
Table 1. Approximate Dynamic Turbine Air
Pressures
Turbine Air
Hose Length
ft (m)
Air pressure at turbine air hose inlet
for full voltage
psi (bar, MPa)
15 (4.6)
54 (3.8, 0.38)
25 (7.6)
55 (3.85, 0.38)
36 (11)
56 (3.9, 0.39)
50 (15.3)
57 (4.0, 0.40)
75 (22.9)
59 (4.1, 0.41)
100 (30.5)
61 (4.3, 0.43)
24
333013B
Operation
Spraying
To reduce the risk of electric shock, do not touch the
gun electrode or come within 4 in. (10 cm) of the
nozzle during gun operation.
1. Apply a minimum of 60 psi (4.2 bar, 0.42 MPa) air
pressure to the cylinder air fitting (CYL) to activate
the on/off sequence of atomization air (A1), fan air
(A2), and fluid (P1). See FIGURE 2.
2. Turn the gun functions on and off by using the air
solenoid valves on the cylinder (CYL) and turbine
(TA) air supply lines.
3. For smart gun models, to change to a lower voltage
setting, see the Remote Control Module manual
332989.
Triggering the Fluid Alone
1. Shut off and relieve the air pressure to the atomization (A1) and fan (A2) air lines, using the bleed-type
air shutoff valves.
2. Apply 60 psi (4.2 bar, 0.42 MPa) air pressure to the
cylinder air fitting (CYL) to trigger the fluid.
Shutdown
1. Follow the Fluid Voltage Discharge and Grounding Procedure, page 22.
2. Follow the Pressure Relief Procedure, page 22.
3. Flush and clean the equipment. See Maintenance
on page 26.
If any fluid leakage from the gun is detected, stop
spraying immediately. Fluid leakage into the gun
shroud could cause fire or explosion and result in
serious injury and property damage. See Check for
Fluid Leakage, page 28.
333013B
25
Maintenance
Maintenance
Flushing
To reduce the risk of an injury, follow the Pressure
Relief Procedure and the Fluid Voltage Discharge
and Grounding Procedure before doing any
maintenance on the gun or system.
Daily Care and Cleaning
Checklist
•
Flush before changing fluids, before fluid can dry in
the equipment, at the end of the day, before storing,
and before repairing equipment.
•
Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary.
•
Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts.
Check the following list daily upon completion of equipment usage.
Flush the gun. See Flushing, page 26.
To reduce the risk of fire, explosion, or electric
shock, turn off the turbine air (TA) before flushing the
gun.
Clean the fluid and air line filters.
Clean the outside of the gun. See Clean Outside of Gun, page 27.
Clean the air cap, spray tip, and tip guard
daily, minimum. Some applications require
more frequent cleaning. Replace the parts if
they are damaged. See Clean the Spray
Gun, page 27.
Check the electrode and replace if broken or
damaged. See Electrode Replacement on
page 40.
Check for fluid leakage from the gun and fluid
hoses. See Check for Fluid Leakage on
page 28. Tighten fittings or replace equipment
as needed.
Check Grounding, page 18.
Follow the Fluid Voltage Discharge and Grounding
Procedure, page 22, before flushing.
Only flush, purge, or clean the gun with fluids that
meet the following flammability requirements:
FM, FMc Approved:
Material does not sustain burning in accordance with
the Standard Test Method for Sustained Burning of
Liquid Mixtures, ASTM D4206.
CE-EN 50059 Compliant:
Materials which cannot be ignited, in any mixture with
air, by an energy source of less than 500mJ.
NOTICE
Do not use methylene chloride as a flushing or
cleaning solvent with this gun as it will damage nylon
components.
1. Turn off the turbine air and wait 30 seconds for the
voltage to bleed off.
2. Discharge the system voltage. See Fluid Voltage
Discharge and Grounding Procedure, page 22.
3. Follow the Pressure Relief Procedure, page 22.
4. Remove and clean the air cap and spray tip.
5. Change the fluid source to non-flammable solvent.
6. Trigger the gun to flush the fluid passages clean.
26
333013B
Maintenance
Clean Outside of Gun
NOTICE
•
Clean all parts with a non-conductive, compatible
solvent. Conductive solvents can cause the gun to
malfunction.
•
Fluid in the air passages could cause the gun to
malfunction and could draw current and reduce the
electrostatic effect. Fluid in the power supply cavity
can reduce the turbine life. Whenever possible,
point the gun down when cleaning it. Do not use
any cleaning method which could allow fluid into
the gun air passages.
1. Follow the Fluid Voltage Discharge and Grounding Procedure, page 22
2. Flush the gun. See Flushing, page 26
3. Follow the Pressure Relief Procedure, page 22.
4. Clean the outside of the gun with a compatible solvent. Use a soft cloth. Wring out excess fluid from
cloth. Point the gun down to prevent solvent from
entering the gun passages. Do not immerse the
gun.
To reduce the risk of an injury, follow the Pressure
Relief Procedure when you stop spraying and
whenever you are instructed to relieve the pressure.
1. Discharge the system voltage.
2. Follow the Pressure Relief Procedure, page 22.
3. Remove the retaining ring (24), air cap/tip guard
(25), spray tip (3), and gun shroud (26). See page
39.
4. Dip the end of a soft bristle brush into compatible
solvent. clean the front of the gun with the brush.
Avoid getting any solvent into the air passages.
Whenever possible, point the gun down when
cleaning it. See FIGURE 17
If it appears that there is paint inside the air passages, remove the gun from the line for servicing.
02007
WLD
WLD
WLD
Clean the Spray Gun
Equipment Needed
•
•
soft bristle brush
compatible solvent
FIG. 17 Clean Front of Gun
5. Dampen a soft cloth with solvent and wring out the
excess. Wipe the exterior of the gun and shroud
clean. See FIGURE 18.
Procedure
Contact with the charged components of the spray
gun will cause an electric shock. Do not touch the
gun nozzle or electrode or come within 4 in. (102
mm) of the front of the gun during operation or until
performing the Fluid Voltage Discharge and
Grounding Procedure, page 22.
333013B
FIG. 18 Clean Gun Body
6. Clean the retaining ring (24), air cap/tip guard
assembly (25), and spray tip (3) with a soft brush
daily, minimum. Replace any damaged parts. Be
careful not to damage the electrode (25a).
27
Maintenance
NOTICE
Check for Fluid Leakage
Do not use metal tools to clean the
air cap/tip guard or spray tip holes
as this could scratch them, and
make sure the electrode is not damaged. Scratches in the air cap or
spray tip or a damaged electrode
can distort the spray pattern.
If any fluid leakage from the gun is detected, stop
spraying immediately. Fluid leakage into the gun
shroud could cause fire or explosion and result in
serious injury and property damage.
7. Wipe off the parts with a dry cloth. Be careful not to
damage the electrode.
To reduce the risk of fire, explosion, or electric
shock, never operate the gun with a damaged
electrode.
8. Check the electrode (25a). Replace if damaged.
9. Check the condition of the spray tip gasket and
install the spray tip in the aircap, page 23.
10. Install the spray tip and air cap/tip guard, shroud,
and retaining ring, page 23. Be sure the electrode
(25a) is in place.
To reduce the risk of an injury, follow the Pressure
Relief Procedure when you stop spraying and
whenever you are instructed to relieve the pressure.
During operation, periodically check all openings of the
gun shroud (ZZ) for the presence of fluid. See FIGURE
19. Fluid in these areas indicates leakage into the
shroud, which could be caused by leaks at the fluid tube
connections or fluid packing leakage.
If fluid is seen in these areas, stop spraying immediately. Discharge the system voltage, relieve the pressure, then remove the gun for repair.
11. Test Gun Resistance, page 29.
ZZ
ZZ
FIG. 19 Check for Fluid Leakage
Clean the cabinet
28
•
Inspect the cabinet and clean up any spilled paint.
Conductive paint residue allowed to contact
grounded parts may short out the electrostatics.
•
Keep the inside of the cabinet clean, for proper
operation.
•
Inspect the door T-handle locking screw regularly,
to ensure the threads are well greased. Apply silicone-free grease to the threads when necessary.
•
Visually inspect the ground strip (240) for damage.
Replace if needed. Measure the resistance weekly.
See Test Ground Strip Resistance, page 30.
333013B
Electrical Tests
Electrical Tests
Use the following procedures to test the condition of the
power supply and gun body, and electrical continuity
between components. See Power Supply Removal
and Replacement, page 43.
Test Power Supply Resistance
Use megohmmeter Part No. 241079 (AA) and an
applied voltage of 500 V. Connect the leads as shown.
2. Remove the turbine (8) from the power supply, page
44.
1. Remove the power supply (7), page 43.
3. Measure resistance from the power supply's ground
strips (EE) to the spring (7a). See FIGURE 21.
Megohmmeter Part No. 241079 (AA-see FIGURE 20)
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).
4. The resistance should be 90-115 megohms. If outside this range, replace the power supply. If in
range, proceed to the next test.
5. If you still have problems, refer to Electrical Troubleshooting, page 37 for other possible causes of
poor performance, or contact your Graco distributor.
6. Be sure the spring (7a) is in place before reinstalling
the power supply.
Failure to follow this warning could cause fire,
explosion, and electric shock and result in serious
injury and property damage.
Test Gun Resistance
1. Flush and dry the fluid passage.
7a
2. Measure the resistance between the electrode (25a)
and the turbine air fitting. The resistance should be
104–150 megohms. If outside this range, go to Test
Power Supply Resistance, page 29. If in range,
see Voltage Loss Troubleshooting, page 31 for
other possible causes of poor performance, or contact your Graco distributor.
AA
25a
FIG. 20 . Test Gun Resistance
333013B
EE
FIG. 21 . Test Power Supply Resistance
Test Barrel Resistance
1. Insert a conductive rod (B) into the gun barrel
(removed for the power supply test) and against the
metal contact (C) in the front of the barrel.
TA
2. Measure the resistance between the conductive rod
(B) and the conductive ring (33). See FIGURE 22.
The resistance should be 10-30 megohms. If the
resistance is incorrect, make sure the metal contact
(C) in the barrel and the conductive ring (33) are
clean and undamaged.
TA
29
Electrical Tests
3. If the resistance is still outside the range, remove
the conductive ring (33) and measure the resistance
between the conductive rod (B) and the wire lead at
the bottom of the conductive ring groove.
4. If the resistance is in range, replace the conductive
ring (33) with a new one. Insert the ends of the conductive ring into the slots (S) at the front of the barrel, then press the ring firmly into the groove.
Test Ground Strip Resistance
Using an ohmmeter, measure the resistance between
the latch housing (206) and the ground lug (214). The
ground strip is grounded through the cart back to the
ground lug. Resistance must be less than 100 ohms. If
greater than 100 ohms, replace the ground strip (240).
206
S
G
214
The conductive ring (33) is a conductive (metal) contact ring, not a sealing o-ring. To reduce the risk of fire,
explosion, or electric shock:
• Do not remove the conductive ring except to
replace it.
• Never operate the gun without the conductive ring
in place.
• Do not replace the conductive ring with anything
but a genuine Graco part.
5. If the resistance is still outside the range, replace
the gun barrel.
33
C
FIG. 23 . Test Electrode Resistance
Test Cylinder Resistance
Remove the enclosure door. Using an ohmmeter, measure the resistance from the pump (209) to the ground
lug (214). Resistance must be less than 100 ohms. If
greater than 100 ohms, replace the grounding cylinder
(227).
B
FIG. 22 Test Gun Barrel Resistance
FIG. 24 Test Cylinder Resistance
30
333013B
Troubleshooting
Troubleshooting
Installing and servicing this equipment requires
access to parts which may cause an electric shock or
other serious injury if the work is not performed
properly. Do not install or repair this equipment
unless you are trained and qualified.
Follow the Fluid Voltage Discharge and
Grounding Procedure before checking or servicing
the system and whenever you are instructed to
discharge the voltage.
To reduce the risk of a fluid injection injury, always
follow the Pressure Relief Procedure when you
stop spraying and whenever you are instructed to
relieve the pressure.
Before troubleshooting or servicing the voltage isolation
system itself, you need to determine which component
in the system is most likely causing a problem. Possible
causes include the following:
Spray Gun
•
Fluid leakage
•
Dielectric breakdown at the fluid hose connection or
fluid packings
•
Not enough air pressure for the turbine
•
Faulty power supply
•
Excessive overspray on gun surfaces
•
Fluid in the air passages
Waterborne Fluid Hose
•
Dielectric failure of the hose (pin-hole leak in the
PTFE layer)
•
Air gap in the fluid column between the gun and the
isolated fluid supply, causing a low voltage reading
on the isolation system voltage meter.
NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun.
Voltage Loss Troubleshooting
Normal spraying voltage for a system using the waterborne gun is 45-55 kV. The system voltage is lower due
to spraying current demands and voltage isolation system losses.
A loss of spraying voltage can be caused by a problem
with the spray gun, fluid hose, or voltage isolation system, since all of the system components are electrically
connected through the conductive, waterborne fluid.
333013B
Voltage Isolation System
•
Fluid leakage
•
Dirty interior
•
Dielectric breakdown of hoses, seals, or connections
•
Isolators not functioning properly
31
Troubleshooting
Visual Checks
First, check the system for any visible faults or errors to
help isolate whether the spray gun, fluid hose or voltage
isolation system has failed. A voltage probe and meter,
part no. 245277, is helpful for diagnosing voltage problems and is required for some of the troubleshooting
tests that follow.
1. Check that all of the air and fluid tubes and hoses
are properly connected.
2. Check that the voltage isolation system valves and
controls are properly set for operation.
3. Check that the interior of the isolated enclosure is
clean.
4. Check that the spray gun and voltage isolation system have sufficient air pressure.
5. Check that the spray gun and voltage isolation system have sufficient air pressure.
6. Check that the gun turbine air (TA) is turned on and
the pressure is set correctly.
7. Check that the voltage isolation system's enclosure
door is closed and that any safety interlocks are
engaged and working properly.
32
8. Make sure the voltage isolation system is in the “isolate” mode, where it is isolating the fluid voltage
from ground.
9. To eliminate air gaps in the fluid column, spray
enough fluid to purge the air out between the voltage isolation system and the spray gun. An air gap
in the fluid hose can break the electrical continuity
between the spray gun and the isolated fluid supply
and cause a low voltage reading on a voltage meter
connected to the isolated fluid supply.
10. Check the spray gun cover and barrel for accumulated overspray. Excessive overspray can create a
conductive path back to the grounded gun body.
Install a new gun cover and clean the exterior of the
gun.
11. Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found. Pay
special attention to the following areas:
•
Packing area of the spray gun.
•
Fluid hose: check for leakage or any bulges in
the outer cover, which may indicate an internal
leak.
•
Internal voltage isolation system components
333013B
Troubleshooting
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 22.)
down somewhere in the fluid hose or gun. Continue
with step 12.
If the reading is below 55 kV, do the electrical tests on
page 33 to check the gun and power supply resistance.
If those tests show the gun and power supply are okay,
continue with step 12.
12. A dielectric breakdown is most likely in one of the
following three areas. Repair or replace the component that is failing.
3. Follow the Pressure Relief Procedure on page 22.
a. Fluid hose:
4. Disconnect the fluid hose from the voltage isolation
system.
•
Check for leakage or any bulges in the
outer cover, which may indicate a pin-hole
leak through the PTFE layer. Disconnect
the fluid hose from the gun, and look for
signs of fluid contamination on the outside
of the fluid tube.
•
Inspect the end of the hose connected to
the voltage isolation system. Look for cuts
or nicks.
Avoid allowing any water to leak out of the fluid hose
as that could cause a significant air gap in the fluid
column up to the gun electrode, which can break the
conductivity path and conceal a potential failure
area.
5. Position the end of the hose as far as possible away
from any grounded surface. The end of the hose
must be at least 1 ft. (0.3 m) from any ground. Make
sure that no one is within 3 ft. (0.9 m) of the end of
the hose.
6. Turn the turbine air to the gun on. Measure the voltage at the gun electrode with a voltage probe and
meter.
7. Discharge the system voltage by waiting 30 seconds and then touching the gun electrode with a
grounded rod.
8. Check the meter reading:
•
If the meter reading is 45 to 55 kV, the gun and
fluid hose are okay, and the problem is in the
voltage isolation system.
•
If the meter reading is below 45 kV, the problem
is in the gun or fluid hose.
9. Flush the fluid hose and gun with enough air to dry
out the fluid passages.
b. Fluid needle:
• Remove the fluid needle from the gun (see
Fluid Needle Replacement, page 40), and
look for signs of fluid leakage or any blackened areas, which would indicate arcing is
occurring along the packing rod.
c.
Fluid hose connection to the spray gun:
• A breakdown at the fluid hose connection
joint would be caused by fluid leaking past
seals on the end of the hose. Remove the
hose at the gun connection and look for
signs of fluid leakage along the tube.
13. Before reassembling the gun, clean and dry the gun
fluid inlet tube. Repack the inner spacer of the fluid
packing rod with dielectric grease and reassemble
the gun.
14. Reconnect the fluid hose.
15. Check the gun voltage with the voltage probe and
meter before filling the gun with fluid.
10. Turn the turbine air to the gun on. Measure the voltage at the gun electrode with a voltage probe and
meter.
11. If the meter reading is 55-60 kV, the gun power supply is okay, and there is probably a dielectric break-
333013B
33
Troubleshooting
Spray Pattern Troubleshooting
NOTE: Some spray pattern problems are caused by the improper balance between air and fluid.
Problem
Cause
Solution
Fluttering or spitting spray.
No fluid.
Refill supply.
Air in fluid supply.
Check fluid source. Refill.
Fluid buildup; partially plugged tip.
Clean. See page 27.
Worn/damaged tip or air cap holes.
Clean or replace.
Pattern pushed to one side; air cap
gets dirty.
Air cap holes plugged.
Clean. See page 27.
Tails in pattern.
Atomization air pressure too low.
Increase atomization air pressure.
Fluid pressure too low.
Increase.
Atomization air pressure too high.
Decrease.
Fluid pressure too low.
Increase.
Plugged or damaged air cap hole
Clean, see page 27.
Irregular pattern.
Fluid buildup on air cap/tip guard.
34
333013B
Troubleshooting
Gun Operation Troubleshooting
Problem
Cause
Solution
Excessive spray fog.
Atomizing air pressure too high.
Decrease air pressure (A1) as low as
possible
Fluid too thin.
Increase viscosity or increase fluid
flow rate.
Atomization air pressure too low.
Increase air pressure; use lowest
pressure necessary.
Spray tip is too large.
Use smaller tip; see Spray Tip
Selection Chart., page 59.
Poorly mixed or filtered fluid.
Remix or re-filter fluid.
Fluid too thick.
Reduce viscosity.
Fluid leaks from the fluid packing
area
Worn fluid needle packings or rod.
Replace fluid needle assembly (2);
see Fluid Needle Replacement,
page 40.
Air leaks from the air cap
Worn piston stem o-rings (11e, 11f)
Replace, see Piston Repair, page
41.
Fluid leakage from the front of the
gun
Worn or damaged fluid needle ball.
See Fluid Needle Replacement,
page 40
Worn fluid seat housing.
Replace; see Air Cap/Tip Guard,
Spray Tip, and Fluid Seat Housing
Replacement page 39.
Loose spray tip.
Tighten retaining ring (24); see Air
Cap/Tip Guard, Spray Tip, and
Fluid Seat Housing Replacement
page 39.
Damaged tip seal (3a).
Replace; see Air Cap/Tip Guard,
Spray Tip, and Fluid Seat Housing
Replacement page 39.
“Orange Peel” finish.
333013B
35
Troubleshooting
Problem
Cause
Solution
Gun does not spray
Low fluid supply.
Add fluid if necessary.
Damaged spray tip.
Replace; see Air Cap/Tip Guard,
Spray Tip, and Fluid Seat Housing
Replacement page 39.
Dirty or clogged spray tip (3).
Clean; see Clean the Spray Gun,
page 27.
Damaged fluid needle (2).
Replace, see Fluid Needle Replacement, page 40.
Piston (11) not actuating.
Check cylinder air. Check piston
o-ring (11d); see Piston Repair,
page 41.
Actuator arm (15) is out of position.
Check actuator arm and nuts. See
page 42.
Dirty air cap
Damaged or plugged air cap
Clean; see Clean the Spray Gun,
page 27.
Air leaks from manifold
Manifold is not tight
Tighten manifold screws
Worn or missing o-rings
Replace o-rings. See page 42
Fluid buildup on fluid needle (2)
Replace needle; Fluid Needle
Replacement, page 40
Piston sticking
Clean or replace o-rings. See Piston
Repair, page 41
Fluid doesn’t shut off properly
Excessive paint wrap back to opera- Poor grounding
tor
Incorrect distance from gun to part
36
See Grounding, page 18
Should be 8-12 in. (200-300 mm).
333013B
Troubleshooting
Electrical Troubleshooting
Problem
Cause
Solution
Poor wrap.
Turbine air is not turned on.
Turn on.
Booth exhaust velocity is too high.
Reduce velocity to within code limits.
Atomization air pressure too high.
Decrease.
Fluid pressure too high.
Decrease, or replace worn tip.
Incorrect distance from gun to part.
Should be 8-12 in. (200-300 mm).
Poorly grounded parts.
Resistance must be 1 megohm or
less. Clean workpiece hangers.
Faulty gun resistance.
See Test Gun Resistance, page 29.
Fluid leaks from the fluid needle
packings and causes a short
Clean the fluid needle cavity and see
Fluid Needle Replacement, page
40
Faulty turbine
See Turbine Removal and
Replacement page 44
Faulty Power Supply
Replace power supply, see page 43
No voltage or low voltage reading on Damaged fiber optic cable or conthe Pro Xp Auto Control Module
nection.
ES or Hz indicator light is not lit
(standard models only)
Check; replace damaged parts
Turbine air is not turned on.
Turn on.
Spilled paint, dried paint, or other
contaminants inside the WB3000
Enclosure, causing a short circuit.
Clean.
Grounding cylinder not retracted
Check operation of grounding cylinder.
No power
Check power supply, turbine, turbine
ribbon cable. See Power Supply
Removal and Replacement, page
43 and Turbine Removal and
Replacement, page 44.
ES indicator light is amber (standard Turbine speed is too low
models only)
Increase air pressure until indicator is
green.
ES indicator light is red (standard
models only)
Decrease air pressure until indicator
is green
Pro Xp Auto Control Module displays
event code (smart models only)
333013B
Turbine speed is too high
See manual 332989 for Event Code
Troubleshooting.
37
Repair
Repair
Prepare the Gun for Service
2. Flush and clean the gun, page 26.
3. Follow the Pressure Relief Procedure, page 22.
4. Remove the air cap (25) and shroud (26), page 39.
Installing and repairing this equipment requires
access to parts that may cause electric shock or
other serious injury if the work is not performed
properly. Do not install or service this equipment
unless you are trained and qualified.
Contact with the charged components of the spray
gun will cause an electric shock. Do not touch the
gun nozzle or electrode or come within 4 in. (102
mm) of the front of the gun during operation or until
performing the Fluid Voltage Discharge and
Grounding Procedure
To reduce the risk of injury, follow the Pressure
Relief Procedure before checking or servicing any
part of the system and whenever you are instructed
to relieve the pressure.
NOTE:
•
Check all possible remedies in Troubleshooting
before disassembling the gun.
•
Use a vise with padded jaws to prevent damage to
plastic parts.
•
Lubricate some packing rod parts (2) and certain
fluid fittings with dielectric grease (36), as specified
in the text.
•
Lightly lubricate o-rings and seals with non-silicone
grease. Order Part No. 111265 Lubricant. Do not
over-lubricate.
•
Only use genuine Graco parts. Do not mix or use
parts from other PRO Gun models.
•
Air Seal Repair Kit 24W396 is available. The kit
must be purchased separately. Kit parts are marked
with an asterisk, for example (6a*).
5. Loosen the strain relief bracket.
6. Disconnect the fluid hose fitting (600A) from the gun
barrel (1).
7. Loosen two manifold screws (21) and remove gun.
NOTE: The screws (21) should stay on the manifold and
the five o-rings (18) should stay on the gun.
18
21
21
FIG. 25 Remove Gun from Manifold
Install the Gun on the Manifold
1. Make sure the five o-rings (18) are in place.
2. Secure the gun to the manifold by tightening the two
manifold screws (21).
3. Make sure the hose fittings and barrel are clean and
dry, then reconnect the Waterborne Fluid Hose,
page 16.
4. Tighten strain relief screws.
5. Reinstall the gun shroud (26) and air cap (25), page
39.
Remove the Gun from the
Manifold
1. Follow the Fluid Voltage Discharge and Grounding Procedure, page 22.
38
333013B
Repair
Air Cap/Tip Guard, Spray Tip, and Fluid Seat Housing Replacement
1. See Prepare the Gun for Service, page 38.
2. Remove the retaining ring (24), shroud (26), and air
cap/tip guard assembly (25).
The conductive ring (33) is a conductive metal
contact ring, not a sealing o-ring. To reduce the risk
of fire, explosion, or electric shock:
26
25
24
FIG. 26 Remove Air Cap
3. Disassemble the air cap assembly. Check the condition of the u-cup (24a), o-ring (25b), and tip gasket
(3a). Replace any damaged parts.
40b
25
24a
• Do not remove the conductive ring except to
replace it.
• Never operate the gun without the conductive ring
in place.
• Do not replace the conductive ring with anything
but a genuine Graco part.
5. Remove the fluid seat housing (4) using the
multi-tool (48).
48
4
24
3
25a
WLD
FIG. 29 Seat Housing Replacement
FIG. 27 Disassemble Air Cap Assembly
NOTICE
3a
WLD
FIG. 28 Tip Gasket
4. To replace the electrode (25a), see Electrode
Replacement, page 40.
To avoid damaging the seat housing and gun barrel, never overtighten the seat housing. Overtightening may affect the fluid shutoff.
6. Install the fluid seat housing (4). Tighten until snug,
then 1/4 turn more.
7. Check that the spray tip gasket (3a) is in place.
Align the spray tip tab with the groove in the air cap
(25). Install the spray tip (3) in the air cap.
8. Make sure that the electrode (25a) is installed correctly in the air cap.
9. Check that the air cap o-ring (25b) is in place.
10. Check that the u-cup (24a) is in place on the retaining ring (24). The lips of the u-cup must face forward.
333013B
39
Repair
Fluid Needle Replacement
NOTICE
To avoid damaging the tip guard, orient the air
cap/tip guard assembly (25) before tightening the
retaining ring (24). Do not turn the air cap when the
retaining ring is tight.
1. Prepare the gun for service, page 38.
2. Remove the air cap/tip guard assembly and seat
housing, page 39.
11. Orientate the air cap and tighten the retaining ring
securely.
3. Remove the barrel (1), page 42.
12. See Test Gun Resistance, page 29.
4. Remove the spring cap (31) and the spring (5) from
the barrel. See FIGURE 30.
Electrode Replacement
1. See Prepare the Gun for Service, page 38.
2. Remove the air cap/tip guard assembly (25). See
Air Cap/Tip Guard, Spray Tip, and Fluid Seat
Housing Replacement, page 39.
3. Pull the electrode (25a) out of the back of the aircap,
using a needle-nose pliers.
4. Push the new electrode through the air cap hole.
Make sure the short end (BB) of the electrode
engages the hole (CC) in the back of the air cap.
Press the electrode in place firmly with your fingers.
5. Install the air cap assembly.
6. See Test Gun Resistance, page 29.
25a
5. Be sure the seat housing (4) is removed. Place the
2 mm ball end wrench (45) in the back of the fluid
needle assembly. Push the tool in and turn it counterclockwise about 12 full turns to unthread the needle.
6. Using the multi-tool (48), pull back on the packing
nut (N) to remove the fluid needle assembly. See
FIGURE 31.
7. Install the fluid needle assembly in the gun barrel.
Push in on the needle with the 2 mm ball end
wrench (45) and tighten. See FIGURE 32.
8. Install the spring (5).
9. Install the spring cap (31), making sure the grounding spring (6) is in place. Tighten until snug. Do not
overtighten.
10. Install the barrel (1), page 43.
NOTICE
CC BB
To avoid damaging the seat housing and gun barrel,
never overtighten the seat housing. Overtightening
may result in improper fluid shutoff.
11. Install the seat housing and air cap, page 39.
12. Test Gun Resistance, page 29.
ti19524
6
31
5
FIG. 30 Spring Cap and Springs
40
333013B
Repair
11a
N
11d
11c
11f
11e
48
11b
WLD
11d
FIG. 31 Fluid Needle Removal
11g
11g
11f
11e
Fan Air Side
Atomizing Air Side
FIG. 32 Fluid Needle Replacement
FIG. 33 . Piston O-Rings
Piston Repair
1. Prepare the gun for service, page 38.
WLD
Table 3. Piston O-Rings
Description
Function
2. Remove the air cap, page 39. Remove the gun
shroud (26).
Shaft O-Ring
(11g)
Seals cylinder air along the piston rod
(34b). Replace if air leaks along rod.
3. Remove the jam nut (16a), actuator arm (15), and
adjustment nut (16b). See FIGURE 34.
Front O-Ring
(11e)
Air shutoff seal. Replace if air leaks from
air cap when gun is de-triggered.
Back O-Ring
(11f)
Separates cylinder air from fan and atomizing air.
Piston O-Ring
(11d)
Replace if air leaks from small vent hole
at back of manifold when gun is triggered.
4. Remove piston cap (13) and spring (12) from the
rear of the gun.
5. Push on the piston rod (11) to push the piston out
the back of the gun.
O-rings included in air seal repair kit 24W390
6. Inspect the o-rings (11d, 11e, 11f, 11g) for damage.
See Table 3 and FIGURE 33.
7. Lubricate the o-rings (11d, 11e, 11f, 11g) with
non-silicone grease, Part No. 111265. Do not
over-lubricate.
8. Align the two stems (11c) with the holes in the gun
body and press the piston assembly into the back of
the gun until it bottoms. Install piston cap (13) and
spring (12).
9. Install and adjust the actuator arm, page 42.
333013B
41
Repair
Adjust the Actuator Arm
Barrel Removal
NOTE: The seat housing (4) must be in place when
removing or installing the jam nut and actuator arm.
See FIGURE 36
See FIGURE 34.
1. Prepare the gun for service and remove the gun
from the manifold, page 38.
1. Install the adjustment nut (16b), actuator arm (15),
and jam nut (16a) onto the piston rod (11b).
2. Remove the adjustment nuts (16a, 16b) and actuator arm (15). See FIGURE 34.
2. Position the parts so there is a 0.125 in. (3 mm) gap
between the actuator arm (15) and the fluid packing
rod nut (E). This allows the atomizing air to actuate
before the fluid.
3. Loosen the two screws (19). See FIGURE 36.
3. Tighten the adjustment nut (16b) against the actuator arm (15). Check that the 0.125 in. (3 mm) gap
has been maintained. Tighten the jam nut (16a)
4. Test gun resistance, page.
NOTICE
To avoid damaging the power supply, pull the gun barrel (1) straight away from the gun body (10). If necessary, gently move the gun barrel from side to side to
free it from the gun body.
4. Hold the gun body (10) with one hand and pull the
barrel (1) straight off the body. See FIGURE 36.
5. Install the gun shroud (26) and air cap/tip guard
assembly (25), page 39.
6. Install the gun onto the manifold. See page 38.
0.125 in. (3 mm) gap
1
WLD
16a
15
16b 11b
E
FIG. 34 . Actuator Arm Adjustment
10
19
FIG. 35 . Barrel Removal
42
333013B
Repair
Barrel Installation
Power Supply Removal and
Replacement
See FIGURE 36
1. Verify the gasket (9) and grounding spring (6) are in
place and the gasket air holes are aligned properly.
Replace the gasket if damaged.
2. Make sure the spring is in place on the tip of the
power supply (7). Liberally apply dielectric grease to
the tip of the power supply. Place the barrel (1) over
the power supply and onto the gun body (10).
3. Tighten the two barrel screws (19) oppositely and
evenly (about a half turn past snug or 20 in-lbs). Do
not over-tighten.
NOTICE
To avoid damaging the gun barrel, do not over-tighten
the screws (19).
4. Install and adjust the actuator arm (15), jam nut
(16a), and adjustment nut (16b). See page 42.
•
Inspect the gun body power supply cavity for dirt or
moisture. Clean with a clean, dry rag.
•
Do not expose gasket (9) to solvents.
1. See Prepare the Gun for Service, page 38.
2. See Barrel Removal, page 42.
NOTICE
Be careful when handling the power supply (7) to
avoid damaging it.
3. Grasp the power supply (7) with your hand. With a
gentle side to side motion, free the power supply/turbine assembly from the gun body (10), then
carefully pull it straight out.
Smart models only: disconnect the flexible circuit
(30) from the socket at the top of the gun body.
5. Test gun resistance, page 29.
6. Install the gun shroud (26) and air cap, page 39.
7. Install the gun onto the manifold. See page 38.
4. Inspect the power supply and turbine for damage.
5. To separate the power supply (7) from the turbine
(8), disconnect the 3-wire ribbon connector (PC)
from the power supply. See FIGURE 37.
19
Smart models only: disconnect the 6–pin flexible
circuit (30) from the power supply.
10
7
9
Slide the turbine up and off the power supply.
1
16a
15 16b 6
FIG. 36 . Barrel Installation
6. See Test Power Supply Resistance, page 29.
Replace the power supply if necessary. To repair
the turbine, see Turbine Removal and Replacement, page 44.
NOTICE
To prevent damage to the cable and possible interruption of the ground continuity, bend the turbine’s
3–wire ribbon cable (PC) upward and back, so the
bend faces the power supply and the connector is at
the top.
7. Connect the 3-wire ribbon connector (PC) to the
power supply.
Smart models only: connect the 6–pin flexible circuit (30) to the power supply.
333013B
43
Repair
Tuck the ribbon forward, under the power supply.
Slide the turbine (8) down onto the power supply
(7).
8. Insert the power supply/turbine assembly in the gun
body (10). Make sure the ground strips (EE) make
contact with the gun body.
Smart models only: align the connector of the
6–pin flexible circuit (30) with the socket (CS) at the
top of the gun body. See FIGURE 37.
Push the connector securely into the socket as you
slide the power supply/turbine assembly into the
gun body.
30
CS
Turbine Removal and
Replacement
NOTE: Replace turbine bearings after 2000 hours of
operation. Order Part No. 24N706 Bearing Kit. Parts
included in the kit are marked with a symbol (◆). See
FIGURE 38 through FIGURE 41.
1. See Prepare the Gun for Service, page 38.
2. Remove the power supply/turbine assembly and
disconnect the turbine. See Power Supply
Removal and Replacement, page 43.
3. Measure resistance between the two outer terminals of the 3-wire connector (PC); it should be
2.0–6.0 ohms. If outside this range, replace the turbine coil (8a).
4. Using a flat blade screwdriver, pry the clip (8h) off
the housing (8d). Remove the cap (8f), using a thin
blade or screwdriver.
5. If necessary, rotate the fan (8e) so its blades clear
the four bearing tabs (T) of the housing (8d). See
FIGURE 39.
8e◆
T
FIG. 37 . Connect Flexible Circuit
9. Make sure the gasket (9), ground spring (6), and
power supply spring (7a) are in place. Replace gasket (9) if damaged. Assemble the barrel (1) to the
gun body (10). See Barrel Installation, page 42.
10. See Test Gun Resistance, page 29.
WLE
P
FIG. 39 . Fan Orientation
10
CS
9◆
8
PC
30
EE
7a
WLD
7
FIG. 38 . Power Supply
44
333013B
Repair
must face away from the magnet (M). Install in the
coil (8a) so the bearing blades are flush with the surface of the coil.
6. Push the fan and coil assembly (8a) out the front of
the housing (8d).
8b2◆ M 8a 8g
WLE
8f◆
11. Press the new top bearing (8b2.) onto the short end
of the shaft so the bearing blades are flush with the
surface of the coil (8a). The flatter side of the bearing must face away from the coil.
12. Hold the coil assembly (8a) on a workbench with the
fan end facing up. Press the fan (8e.) onto the long
end of the shaft (S).The fan blades must be oriented
as shown in FIGURE 39.
PC
13. Carefully press the coil assembly (8a) into the front
of the housing (8d.) while aligning the pin on the coil
with the slot in the housing. The 3–wire connector
(PC) must be positioned below the wider notch (W)
of the housing tabs.
8h◆
8b1◆ S
8d
FIG. 40 . Turbine Cross-Section.
NOTICE
14. Rotate the fan (8e) so its blades clear the four bearing tabs (T) at the back of the housing. Ensure that
the blades of the bottom bearing (8b1.) align with
the tabs.
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.
15. Seat the coil fully into the housing (8d.). Secure with
the clip (8h.),ensuring that its tabs engage the slots
in the housing.
7. Hold the coil assembly (8a) on a workbench with the
fan end facing up. Using a wide blade screwdriver,
pry the fan (8e)off the shaft (S).
16. Ensure that the o-ring (8g) is in place. Install the cap
(8f).
8. Remove the top bearing (8b2).
9. Remove the bottom bearing (8b1).
17. Install the turbine on the power supply, and install
both parts in the gun body. See Power Supply
Removal and Replacement, page 43.
10. Install the new bottom bearing (8b1.) on the long
end of the shaft (S). The flatter side of the bearing
Slot
8f◆
S
8e◆
M
8g*
Pin
8d◆
W
8b1◆
PC
8h◆
8a
8b2◆
WLE
FIG. 41 . Turbine
333013B
45
Parts
Parts
Standard Pro Xp Auto Waterborne AA Gun Models
HA1T18, Rear Manifold
1 Torque to 20 in-lbs (2 N•m)
1
46
333013B
Parts
HA1T18, Rear Manifold
Ref.
No.
1
2
3
Part No. Description
3a
4
5
6
7
7a
8
8g■
9■◆
10
11
11a
11b
11c
11d
12
13
14
15
24W874
24N781
AEMxxx
AEFxxx
183459
24N725
24N782
197624
24N662
24N979
24N644
110073
24N699
24W382
24W396
17B704
111504
112319
111508
112640
24W397
513505
24W398
16
18■
19
20
100166
111450
24N740
24W392
21
24W399
23
24W411
24
24N644
333013B
BODY, gun assy (includes 9)
NEEDLE ASSEMBLY, includes 5
TIP ASSEMBLY; customer’s
choice
GASKET, tip
HOUSING, seat
SPRING, fluid needle
SPRING, compression
POWER SUPPLY, 60 kV, WB
SPRING
See Turbine Assembly, page 51
O-RING, packing
GASKET, barrel
BODY, assy, Auto XP Standard
PISTON, assy, actuation, auto
O-RING, packing
O-RING, packing
O-RING, packing
O-RING, packing
SPRING, compression
CAP, piston, actuation
WASHER, plain #10 SST
ARM, fluid actuator, XP
(includes 16, qty 2)
NUT, full hex
PACKING, O-RING
SCREW, ES gun (includes 2)
MANIFOLD, rear inlet (includes 18,
21, 23, 27, 28, 29, 30, 51)
SCREW, modified, 1/4-20, XP
Auto (pack of 2)
FITTING, Adapter, M12 TO 1/4,
LH, XP
RING, retainer, assy; includes 24a
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
5
4
1
2
1
1
Ref.
No.
Part No. Description
24a■
25
25a
26
27
28
198307
24N727
24N643
24W389
114263
115950
Qty
PACKING, u-cup; UHMWPE
1
See Air Cap Assembly, page 50
1
ELECTRODE, package of 5
1
COVER, shroud, Auto XP
1
FITTING, connector, male
1
FITTING, connector, 1/4npt (M),
3
5/16T
29
110465 SCREW, set
2
30
102207 SCREW, set, SCH
2
31
24N785 CAP, spring includes 6
1
32*
BRACKET, strain relief, WB tube
1
33
24N747 RING, conductive
1
34*
CLAMP, strain relief, WB tube
1
35*
GC2248 SCREW, SHDC, SS, .250x.50
3
36
116553 GREASE, dielectric; 1 oz (30 ml)
1
tube (not shown)
37*
24X482 FASTENER, retainer (pack of 4)
1
42▲ 179791 TAG, warning (not shown)
1
44
276741 TOOL, wrench (not shown)
1
45
107460 WRENCH, ball end, 4 mm (not
1
shown)
48
112080 WRENCH, ball end, 2 mm (not
1
shown)
51
117560 SCREW, set, socket
1
600 24W599 See Waterborne Fluid Hose, page 50
600a 24W599 See Waterborne Fluid Hose, page 50
▲ Replacement Warning labels, signs, tags, and
cards are available at no cost.
* Included in WB AA Hose Mount Kit 24W879
(purchase separately)
■ Included in air seal repair kit 24W390 (purchase
separately)
◆ Included in Turbine Assembly 24N664 (purchase separately). See Turbine Assembly,
page 51.
47
Parts
Smart Pro Xp Auto Waterborne AA Gun Models
HA1M18, Rear Manifold
1 Torque to 20 in-lbs (2 N•m)
1
48
333013B
Parts
HA1M18, Rear Manifold
Ref.
No.
1
2
3
Part No. Description
24W874
24N781
AEMxxx
AEFxxx
183459
24N725
24N782
197624
24N662
24N979
24N644
110073
24N699
24W867
24W396
17B704
111504
112319
111508
112640
24W397
513505
24W398
100166
111450
24N740
24W392
BODY, gun assy (includes 9)
NEEDLE ASSEMBLY, includes 5
TIP ASSEMBLY; customer’s
choice
3a
GASKET, tip
4
HOUSING, seat
5
SPRING, fluid needle
6
SPRING, compression
7
POWER SUPPLY
7a
SPRING
8
See Turbine Assembly, page 51
8g■
O-RING, packing
GASKET, barrel
9■◆
10
BODY, assy, AA, rear inlet
11
PISTON, assy, actuation, auto
11a
O-RING, packing
11b
O-RING, packing
11c
O-RING, packing
11d
O-RING, packing
12
SPRING, compression
13
CAP, piston, actuation
14
WASHER, plain #10 SST
15
ARM, fluid actuator, XP
16
NUT, full hex
18■
PACKING, O-RING
19
SCREW, ES gun (Includes 2)
20
MANIFOLD, rear inlet (includes 18,
21, 23, 27, 28, 29, 51)
21
24W399 SCREW, modified, 1/4-20, XP
Auto (pack of 2)
23
24W411 FITTING, Adapter, M12 TO 1/4,
LH, XP
24
24N793 RING, retainer, assy; includes 24a
24a■ 198307 PACKING, u-cup; UHMWPE
25
See Air Cap Assembly, page 50
25a 24N643 ELECTRODE, package of 5
26
24W388 COVER, shroud, Auto XP
333013B
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
5
4
1
Ref.
No.
Part No. Description
Qty
27
28
114263 FITTING, connector, male
1
115950 FITTING, connector, 1/4npt (M),
3
5/16T
29
110465 SCREW, set
2
30
245265 CIRCUIT, flexible
1
31
24N785 CAP, spring includes 6
1
32*
BRACKET, strain relief, WB tube
1
33
24N747 RING, conductive
1
34*
CLAMP, strain relief, WB tube
1
35*
GC2248 SCREW, SHDC, SS, .250x.50
3
36
116553 GREASE, dielectric; 1 oz (30 ml)
1
tube (not shown)
37*
24X482 FASTENER, retainer (Pack of 4)
1
40▲ 16P802 SIGN, warning (not shown)
1
41▲ 172479 TAG, warning (not shown)
1
1
42▲ 179791 TAG, warning (not shown)
43▲ 222385 TAG, warning (not shown)
1
44
276741 TOOL, wrench, 4 mm (not shown)
1
45
107460 WRENCH, ball end (not shown)
1
48
112080 TOOL, wrench, ball end, 2 mm
1
(not shown)
51
117560 SCREW, set, socket
1
80
24W035 CONTROL MODULE, Pro Xp Auto
1
(not shown). See 332989. Must be
purchased separately.
600 24W599 See Waterborne Fluid Hose, page 50
600a 24W599 See Waterborne Fluid Hose, page 50
▲ Replacement Warning labels, signs, tags, and
1
1
1
1
1
1
1
cards are available at no cost.
* Included in WB AA Hose Mount Kit 24W879
(purchase separately)
■ Included in air seal repair kit 24W390 (purchase
separately)
◆ Included in Turbine Assembly 24N664 (purchase separately). See Turbine Assembly,
page 51.
49
Parts
Air Cap Assembly
Waterborne Fluid Hose
Part No. 24N727 Air Cap Assembly
Part No. 24W599 Waterborne Fluid Hose
25b
25a
25c
25d
Ref.
No.
3a
25a
25b
25c
25d
50
Part No. Description
Qty
183459 GASKET, tip (not shown) See
5
page 46.
24N643 ELECTRODE, package of 5
1
24N734 O-RING; PTFE; package of 5
1
(also available in package of 10;
order 24E459)
-----AIR CAP
1
24N726 GUARD, tip, orange
1
Ref.
Part No. Description
No.
Qty
600
600a
1
1
HOSE, 25 ft (7.6m)
FITTING, connector, barrel, WB
333013B
Parts
Turbine Assembly
Part No. 24N664 Turbine Assembly
8f◆
8e◆
8g*
8d◆
8b1◆
8a
8b2◆
8h◆
WLE
Ref. Part
No. No.
Description
8a 24N705 COIL, turbine
8b◆ 24N706 BEARING KIT (includes two bearings, item 8e fan, and one item 8h
clip)
8d◆ 24N707 HOUSING; includes item 8f
8e◆ ------ FAN; part of item 8b
8f◆
------ CAP, housing; part of item 8d
333013B
Qty
1
1
1
1
1
Ref. Part
No. No.
Description
Qty
8g* 110073 O-RING
1
8h◆ 24N709 CLIP; package of 5 (one clip
1
included with item 15b)
9*◆ 24N699 GASKET, barrel (not shown) See
1
page 46.
* These parts are included in Air Seal Repair Kit
24W390 (purchase separately).
◆ These parts are included in Bearing Kit 24N706
(purchase separately).
Parts labeled ------ are not available separately
51
Parts
WB 3000 Isolation Enclosure
Part No. 24N550 Waterborne Isolation Enclosure; includes items 201-206
52
333013B
Parts
Ref. Part
No. No.
201
201a
202
203
204
205
206
207
209
210
Description
Qty
-----CABINET, enclosure; includes 201a
1
15A947 DOOR, cabinet
1
116993 CASTER, brake
4
PLATE
1
15A551 T-HANDLE, latch
1
15A545 STEM, handle, door
1
15A524 HOUSING, latch
1
113061 SWITCH, push, air
1
24N548 PUMP, diaphragm; sst; see 3A0732
1
-----SCREW, hex hd cap; 5/16–18 x 5.5 in. 2
(140 mm)
211 -----WASHER, plain; 0.344 in. ID
2
212 -----NUT, lock; 5/16–18
2
214 104029 LUG, ground
1
215 116989 VALVE, air
1
216 111804 REGULATOR, air
1
217 113060 GAUGE, air; 1/8 npt
1
218 116473 BALL VALVE; 1/4 npt (f)
1
219 233824 CART
1
220 116473 NIPPLE; 1/4 npt x 1/4 npsm
1
226 190410 RESISTOR, bleed
1
227 116988 CYLINDER ROD
1
228 15A518 HOUSING, cylinder rod
1
229 104267 REGULATOR, air
1
230 -----BUSHING; plastic; 3/4 x 1/2 npt
1
235▲ 15A682 LABEL, warning
1
239 222011 GROUND WIRE; 25 ft (7.6 m)
1
240 234018 STRIP, grounding; aluminum
1
241 110209 NUT, regulator
11
242 114051 WASHER, plain, 3/4”
1
243 210084 ROD, ground
1
244 -----SCREW, hex hd; 1/4–20 x 5/8 in. (16
16
mm)
245 -----WASHER, plain; 1/4 in. (6 mm)
16
246 -----NUT, hex; 1/4–20
16
247 107257 SCREW, thread-forming
1
248 -----TUBE; 1/4 in. (6 mm) OD; nylon
A/R
249 160430 GAUGE, air
1
251 -----WIRE, 10 gauge; green with yellow stripe 1
252 -----CONNECTOR, swivel tee; 1/8 npt x 5/32 1
in. (4 mm) tube
253 -----NUT, hex; 10–32
1
256 162449 NIPPLE, reducing; 1/2 npt x 1/4 npt
2
257 101874 TERMINAL, ring
5
258 116990 BOX, control
1
259 113983 RING, retaining; 1/2 in. (13 mm)
1
260 237933 METER, 0–90 kV
1
261 113336 ADAPTER; 1/4 npt
1
4
262 -----SCREW, pan hd; 10–32 x 5/8 in. (16
mm)
263 -----SCREW, pan hd; 10–32 x 1/4 in. (6 mm) 1
264 -----HOLDER, tie
3
333013B
Ref. Part
No. No.
265
SCREW, button hd; 10–24 x 1.5 in. (38
mm)
266 -----SCREW, button hd; 10–32 x 1.0 in. (25
mm)
267 -----NUT, hex; M5 x 0.8
268 -----WASHER, lock; no. 10
270 116991 TEE, run, manifold
271 203953 SCREW, hex hd cap with patch; 10–24 x
3/8 in. (10 mm)
272 -----WIRE, 14 gauge; red
273 -----WIRE, ground, 14 gauge; green with yellow stripe
274 155541 UNION, swivel; 1/4 npt
275 114261 TERMINAL, ring; no. 10
276 15A780 PLUG, hex hd
278 117314 BULKHEAD CONNECTOR; 1/4 npt
279 113319 CONNECTOR, tube; 1/4 npt x 3/8 in. (10
mm) OD tube
280 -----ELBOW, tube
281 -----FITTING, tube; 1/8 npt x 5/32 in. (4 mm)
OD tube
282 -----SWIVEL, tube; 1/4 npt x 1/4 in. (6 mm)
OD tube
283 -----SWIVEL, tube; 1/8 npt x 5/32 in. (4 mm)
OD tube
286 -----TUBE; 3/8 in. (10 mm) OD
300★ 235070 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
301★ HA1T18 GUN; see HA1T18, Rear Manifold,
page 46
HA1M18 GUN, see HA1M18, Rear Manifold,
page 48
▲
★
------
Description
Qty
2
2
2
9
1
1
A/R
A/R
1
1
1
1
2
1
1
4
2
A/R
1
1
1
Replacement Danger and Warning labels, tags, and
cards are available at no cost.
The air hose (300) and gun (301) are not included with
24N550 Isolation Enclosure. They are shown for illustrative purposes only. The pail is shown for illustrative
purposes but is not included.
53
Parts
Tubing and Wiring
Detail Views of Control Box
C9
A1 A2
C1
C2
B3
B4
B3
C2, C9
C1
C3, C4, C5
C8
A1
C6
C7
C8
C6
B2
E1
C3
Detail View of Door Interlock Switch
B5
B2
54
333013B
Parts
Tubing and Wiring Chart
Use the diagrams to find the connection points for the tubing and wiring listed below
Code
Ref. Length
Description
No. in.(mm)
Code
Ref. Length
Description
No. in.(mm)
A1
A2
248
248
C2
273
C4
239
B2
249
B3
B4
249
249
C5
243
B5
249
C6
C7
226
272
C1
272
C8
272
C2
251
C9
251
E1
286
333013B
20 (508) 1/4 OD tube, regulator (216) to pump
9 (229) 1/4 OD tube, regulator (216) to manifold
17 (432) 5/32 OD tube, manifold air to door
interlock switch
20 (508) 5/32 OD tube, valve tee to cylinder
5 (127) 5/32 OD tube, regulator (216) to gauge
(217)
22 (559) 5/32 OD tube, valve tee to door interlock switch
9 (229) red 14 gauge wire from top of bleed
resistor to meter
8 (204) green/yellow 14 gauge wire from internal box ground lug to cylinder cap
34 (864) green/yellow 10 gauge wire from external ground lug to cart
n/a
green/yellow 25 ft (7.6 m) ground wire
with clamp, from external ground lug to
true earth ground
n/a
green/yellow 10 gauge wire from external ground lug to ground probe
n/a
red wire from bleed resistor to pump
16 (407) red 14 gauge wire from pump to pail
cover with clamp
12 (305) red 14 gauge wire from pump (209) to
ground on cylinder bracket
n/a
green/yellow 10 gauge wire from meter
(+) to internal box ground lug
4 (102) 3/8 OD tube, bulkhead to manifold
55
Parts
Agitator Kit 245895
To keep fluid mixed and prevent settling out. Includes
items 401-408.
401
407
402
1
2
406
403
Ref.
Part No. Description
No.
Qty
401 112698
1
ELBOW, swivel; 1/8 npt(m) x 1/4 in. (6
mm) OD tube
402 114158 FITTING, adapter, Y; 1/4 in. (6 mm) OD
tube; mxfxf
403 193315 COLLAR, mounting, agitator
404 193316 NUT, collar, agitator
405 197298 COVER, pail; 5 gal. (19 liter)
406 224571 AGITATOR; see manual 306565
407 purchase TUBE, nylon; 1/4 in. (6 mm) OD; 4 ft
locally
(1.22 m)
408 110272 SCREW, set, socket hd; 1/4–20 x 1/4 in.
(6 mm)
1
1
1
1
1
1
1
408
404
406
56
333013B
Accessories
Accessories
Smart Model Accessories and Fiber Optic
Cables
Fluid Line Accessories
Part No.
Description
Waterborne Fluid Hose, 3000 psi
Part No. Description
24W035
Pro Xp Auto Control Module. See 332989 for
details.
24W599
24W077
Fiber Optic Cables for Gun
See item V in FIGURE 9 on page 17. Connect gun manifold to Pro Xp Auto Control Module. See 332989.
Part No. Description
24X003
24X004
24X005
Fiber Optic Cable, 25 ft (7.6 m)
Fiber Optic Cable, 50 ft (15 m)
Fiber Optic Cable, 100 ft (30.5 m)
Fiber Optic Cable Repair Kit
24W875 Parts necessary to replace damaged ends on
one cable assembly.
Air Line Accessories
System Accessories
Part No.
Description
222011
Ground wire for grounding pump and other components and equipment in the spray area. 12
gauge, 25 ft (7.6 m).
English Warning Sign. Available at no charge
from Graco.
186118
Test Equipment
Part No.
Description
241079
Megohmmeter. 500 V output, 0.01–2000 megohms. Use for ground continuity and gun resistance tests. Not for use in hazardous areas.
Paint Resistance Meter. Use for fluid resistivity
test. See manual 307263. Not for use in hazardous areas.
Paint Probe. Use for fluid resistivity test. See
manual 307263. Not for use in hazardous
areas.
Test Fixture, High Voltage Probe, and kV Meter.
Use to test the electrostatic voltage of the gun,
and the condition of the turbine and power supply
when being serviced. See manual 309455. Also
requires 24R038 Conversion Kit.
Voltage Tester Conversion Kit. Converts the
245277 Test Fixture for use with the Pro Xp Gun
turbine. See manual 406999.
Grounded Air Hose with stainless steel braid
ground path (Red)
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread
Part No.
Description
235068
235069
235070
235071
235072
235073
235074
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)
722886
722860
245277
24R038
Bleed-Type Master Air Valve
300 psi (21 bar, 2.1 MPa) Maximum Working Pressure
Relieves air trapped in the air line between this valve and the
pump air motor when closed.
25 ft (7.6 m)
50 ft (15.2 m)
Gun Accessories
Part No.
Description
Part No.
Description
107141
3/4 npt
105749
111265
116553
24V929
Cleaning brush
Non-silicone lubricant, 4 oz (113g)
Dielectric grease 1 oz (30 ml)
Gun Covers
Air Line Shutoff Valve
150 psi (10 bar, 1.0 MPa) Maximum Working Pressure
For turning air to gun on or off.
Part No.
Description
224754
1/4 npsm(m) x 1/4 npsm(f) left-hand thread.
Conversion and Repair Kits
Part No.
Description
24N319
Round Spray Kit. To convert a standard air
assisted spray gun to a round spray air cap. See
manual 3A2499.
Air Seal Repair Kit
Turbine Bearing Repair Kit
24W390
24N706
333013B
57
Accessories
Dimensions
Rear Inlet Manifold
2.6 in (66 mm)
2.5 in (63 mm)
11.0 in (279 mm)
10.4 in (265 mm)
2.9 in (73 mm)
6.3 in (160 mm)
8.2 in (208 mm)
0.53in (13.5 mm)
2x 1/4-20 UNC
58
333013B
Spray Tip Selection Chart
Spray Tip Selection Chart
AEM Fine Finish Spray Tips
Recommended for high finish quality applications at low and medium pressures. Order desired tip, Part No. AEMxxx,
where xxx = 3-digit number from the matrix below.
Fluid Output
fl oz/min (l/min)
Orifice
Size in.
(mm)
at 600 psi at 1000 psi
(4.1 MPa, (7.0 MPa,
41 bar)
70 bar)
0.007
(0.178)
4.0
(0.1)
5.2
(0.15)
0.009
(0.229)
7.0
(0.2)
0.011
(0.279)
Maximum Pattern Width at 12 in. (305 mm)
in. (mm)
2-4
(50 100)
4-6
(100 150)
6-8
(150 200)
8 - 10
(200 250)
10 - 12
(250 300)
12 - 14
(300 350)
14 - 16
(350 400)
16 - 18
(400 450)
Spray Tip
107
207
307
9.1
(0.27)
209
309
409
509
609
10.0
(0.3)
13.0
(0.4)
211
311
411
511
611
711
0.013
(0.330)
13.0
(0.4)
16.9
(0.5)
213
313
413
513
613
713
813
0.015
(0.381)
17.0
(0.5)
22.0
(0.7)
215
315
415
515
615
715
815
0.017
(0.432)
22.0
(0.7)
28.5
(0.85)
217
317
417
517
617
717
0.019
(0.483)
28.0
(0.8)
36.3
(1.09)
319
419
519
619
719
0.021
(0.533)
35.0
(1.0)
45.4
(1.36)
421
521
621
721
821
0.023
(0.584)
40.0
(1.2)
51.9
(1.56)
423
523
623
723
823
0.025
(0.635)
50.0
(1.5)
64.8
(1.94)
425
525
625
725
825
0.029
(0.736)
68.0
(1.9)
88.2
(2.65)
0.031
(0.787)
78.0
(2.2)
101.1
(3.03)
0.033
(0.838)
88.0
(2.5)
114.1
(3.42)
0.037
(0.939)
108.0
(3.1)
140.0
(4.20)
0.039
(0.990)
118.0
(3.4)
153.0
(4.59)
829
431
631
831
833
737
539
* Tips are tested in water.
Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT)
output (fl oz/min) at 600 psi from the above table for the selected orifice size.
333013B
where QT = fluid
59
Spray Tip Selection Chart
AEF Fine Finish Pre-Orifice Spray Tips
Recommended for high finish quality applications at low and medium pressures. AEF tips have a pre-orifice that
assists in atomizing sheer thinning materials, including lacquers.
Order desired tip, Part No. AEFxxx, where xxx = 3-digit number from the matrix below.
Fluid Output
fl oz/min (l/min)
Maximum Pattern Width at 12 in. (305 mm)
in. (mm)
at 600 psi
(4.1 MPa,
41 bar)
6-8
8-10
10-12
12-14
14-16
16-18
at 1000 psi
(150
200)
(200
250)
(250
300)
(300
350)
(350
400)
(400
- 450)
(7.0 MPa, 70
bar)
Spray Tip
0.008
(0.203)
8.5
(.025)
11.0
(0.32)
0.010
(0.254)
9.5
(0.28)
12.5
(0.37)
310
410
510
610
710
0.0012
(0.305)
12.0
(0.35)
16.0
(0.47)
312
412
512
612
712
812
0.014
(0.356)
16.0
(0.47)
21.0
(0.62)
314
414
514
614
714
814
0.016
(0.406)
20.0
(0.59)
26.5
(0.78)
416
516
616
716
Orifice
Size in.
(mm)
608
* Tips are tested in water.
Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT)
output (fl oz/min) at 600 psi from the above table for the selected orifice size.
60
where QT = fluid
333013B
Technical Data
Technical Data
Pro Xp Auto Waterborne AA Spray Gun
Maximum fluid working pressure
Maximum working air pressure
Maximum fluid operating temperature
Paint resistivity range
Short circuit current output
Gun Weight (Approximate)
Voltage Output
Standard Models
Smart Models
Noise (dBa)
Sound Power (measured per ISO Standard
9216)
Sound Pressure (measured 1 m from gun)
Inlet/Outlet Sizes
Turbine air inlet fitting, left-hand thread
Atomizing air inlet fitting
Fan air inlet fitting
Cylinder air inlet fitting
Hi/Lo voltage selector air inlet fittings
Fluid inlet fitting
Materials of Construction
Wetted Parts
US
3000 psi
100 psi
Metric
21 MPa, 210 bar
0.7 MPa, 7 bar
48°C
120°F
2.7 lb
conductive waterborne fluid
125 microamperes
1.2 kg
60 kV
30-60 kV
at 40 psi: 90.4 dB(A)
at 100 psi: 105.4 dB(A)
at 40 psi: 87 dB(A)
at 100 psi: 99 dB(A)
at 0.28 MPa, 2.8 bar: 90.4 dB(A)
at 0.7 MPa, 7 bar: 105.4 dB(A)
at 0.28 MPa, 2.8 bar: 87 dB(A)
at 0.7 MPa, 7 bar: 99 dB(A)
1/4 npsm(m)
5/16 in. OD nylon tube
5/16 in. OD nylon tube
5/32 in. OD nylon tube
5/32 in. OD nylon tube
Waterborne Hose Fitting
Stainless Steel; Nylon, Acetal, Ultra-High Molecular Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten Carbide, Polyethylene
Notes
Loctite® is a registered trademark of the Loctite Corporation.
333013B
61
Graco Pro Xp Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. However, any deficiency in the barrel, gun body, trigger, hook, internal power supply, and alternator (excluding turbine
bearings) will be repaired or replaced for thirty-six months from the date of sale. This warranty applies only when the equipment is installed,
operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs
will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 333013
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision B, December 2014

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