Graco 334452J, ProBell Rotary Applicator, Standard Style Instructions
Instructions and Parts ProBell® Rotary Applicator 334452J EN For finishing and coating applications in Class I, Div. I hazardous locations or Group II, Zone 1 explosive atmospheres, using the following materials: Solventborne Models: • Group D materials. • Group IIA materials. Waterborne Models: 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. • Material is classified as non-ignitable or hard to ignite as defined by EN 50176. For professional use only. 100 psi (0.7 MPa, 7.0 bar) Maximum Air Inlet Pressure 150 psi (1.03 MPa, 10.3 bar) Maximum Fluid Working Pressure Important Safety Instructions This equipment could present hazards if not operated according to the information in this manual. Read all warnings and instructions in this manual and in all ProBell component manuals. Save all instructions. Table of Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Part Number Matrix . . . . . . . . . . . . . . . . . . . . . . . . . 3 Available Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrostatic Models . . . . . . . . . . . . . . . . . . . . . . 4 Non-Electrostatic Models . . . . . . . . . . . . . . . . . . 4 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 System Description . . . . . . . . . . . . . . . . . . . . . . . 9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Basic Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 11 Typical System Installation . . . . . . . . . . . . . . . . 12 Overview of Installation Steps . . . . . . . . . . . . . . 14 Step 1. Mount the Rotary Applicator . . . . . . . . . 14 Step 2. Connect All Lines at the Applicator . . . . 16 Connection Schematics . . . . . . . . . . . . . . . . . . 20 Step 3. Mount Controllers and Accessories . . . 22 Step 4. Connect Fluid Supply . . . . . . . . . . . . . . 24 Step 5. Connect the Air Lines . . . . . . . . . . . . . . 28 Step 6. Connect Power and Communication Cables 32 Step 7. Prepare the Spray Area . . . . . . . . . . . . 34 Step 8. Create Required System Interlocks . . . 34 Step 9. Ground the Equipment . . . . . . . . . . . . . 36 Check Electrical Grounding . . . . . . . . . . . . . . . 36 System Logic Controller Setup . . . . . . . . . . . . . 38 Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Pre-Operation Checklist . . . . . . . . . . . . . . . . . . 39 Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 40 Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 40 Spray Procedures . . . . . . . . . . . . . . . . . . . . . . . 40 Pressure Relief Procedure . . . . . . . . . . . . . . . . 43 Voltage Discharge and Grounding Procedure . 44 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Daily Care and Cleaning Checklist . . . . . . . . . . 46 Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 46 2 Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Test Full Electrostatic Applicator with Power Supply 47 Test Non-Electrostatic Applicator with Ground Plug 47 Test Power Supply in Main Housing . . . . . . . . . 49 Test Power Supply . . . . . . . . . . . . . . . . . . . . . . 51 Test Front Housing . . . . . . . . . . . . . . . . . . . . . . 51 Clean the Air Cap and Cup . . . . . . . . . . . . . . . . 52 Clean the Fluid Nozzle . . . . . . . . . . . . . . . . . . . 53 Clean the Outside of the Rotary Applicator . . . . 53 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Spray Pattern Troubleshooting . . . . . . . . . . . . . 54 Applicator Operation Troubleshooting . . . . . . . . 54 Electrical Troubleshooting . . . . . . . . . . . . . . . . . 56 Waterborne System Voltage Loss Troubleshooting 57 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Prepare for Cup or Air Cap Service . . . . . . . . . . 59 Prepare for Applicator Service . . . . . . . . . . . . . . 59 Replace Cup or Air Cap . . . . . . . . . . . . . . . . . . . 59 Service the Cup and Air Cap . . . . . . . . . . . . . . . 61 Replace Front Housing and Turbine Assembly . 64 Repair or Replace the Solvent Stud . . . . . . . . . 65 Repair Fluid Nozzle . . . . . . . . . . . . . . . . . . . . . . 65 Repair or Replace the Fluid Tube . . . . . . . . . . . 66 Replace Magnetic Pickup Sensor or Fiber Optic Extension Cable . . . . . . . . . . . . . . . . . . . . . 66 Repair Fluid Valves and Seats . . . . . . . . . . . . . 68 Repair Fluid Tube Fittings or Coiled Fluid Tubes 69 Repair the Power Supply . . . . . . . . . . . . . . . . . . 70 Replace an Air Tube Fitting . . . . . . . . . . . . . . . . 70 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Solventborne Models (R_A1_0) . . . . . . . . . . . . 71 Waterborne Models (R_A1_8) . . . . . . . . . . . . . . 74 Non-Electrostatic Models (R_A1_1) . . . . . . . . . 77 Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Main Housing Repair Kits . . . . . . . . . . . . . . . . . 80 O-Ring Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Fittings and Tools . . . . . . . . . . . . . . . . . . . . . . . 80 Cup Selection Charts . . . . . . . . . . . . . . . . . . . . . 81 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Mounting Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Fiber Optic Bulkhead Installation . . . . . . . . . . . . 83 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 60° Robot Mount - shown as shipped . . . . . . . . 86 334452J Related Manuals 60° Robot Mount - shown with mounting Kit 24Z179 87 Reciprocator Mount - shown with reciprocator mounting kit 24Z178 . . . . . . . . . . . . . . . . . . 88 Performance Charts . . . . . . . . . . . . . . . . . . . . . . . 89 Turbine Air Consumption Charts . . . . . . . . . . . . 89 Turbine Inlet Air Pressure Charts . . . . . . . . . . . 90 Shaping Air Consumption Charts . . . . . . . . . . . 92 Fluid Flow Rate Charts . . . . . . . . . . . . . . . . . . . 94 Fluid Pressure Loss Charts . . . . . . . . . . . . . . . . 97 Technical Specifications . . . . . . . . . . . . . . . . . . . . 99 California Proposition 65 . . . . . . . . . . . . . . . . . . . . 99 Graco Standard Warranty . . . . . . . . . . . . . . . . . . 100 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 100 Related Manuals Manual Description 334626 ProBell® Rotary Applicator, Hollow Wrist 3A3657 ProBell® Electrostatic Controller 3A3953 ProBell® Speed Controller 3A3954 ProBell® Air Controller 3A3955 ProBell® System Logic Controller 3A4232 ProBell® Cart Systems 3A4346 ProBell® Hose Bundle 3A4384 ProBell® System CGM Installation Kit 3A4738 ProBell® Reflective Speed Sensor Kit Part Number Matrix Check the identification plate (ID) for the part number of your applicator. The following matrix defines the components of your applicator based on the 6-digit part number. Sample Part Number R1A 1 3 0 15 mm Cup ProBell Standard Applicator 0.75 mm nozzle Solventborne Cup Size Description and Mounting Style Nozzle Size Applicator Type R1A 15 mm 1 R3A 30 mm R5A 50 mm 334452J 2 ProBell Standard Rotary Applicator - Stationary, Reciprocator, or Solid-Wrist Robot. ProBell Rotary Applicator - Hollow Wrist, 60° Robot Mount. See Manual 334626. 3 0.75 mm 0 Solventborne 4 1.0 mm 8 Waterborne 5 1.25 mm 1 Non-Electrostatic 6 1.5 mm 3 Available Models Available Models Solventborne, Waterborne, and Non-Electrostatic applicator types. Electrostatic Models Cup Size* Part No. 50 mm R5A140 R5A150 R5A160 R5A148 R5A158 R5A168 R3A130 R3A140 R3A150 R3A160 R3A138 R3A148 R3A158 R3A168 R1A130 R1A140 R1A150 R1A138 R1A148 R1A158 * 30 mm Nozzle Size 15 mm 0.75 mm 1.0 mm 1.25 mm Applicator Type 1.5 mm Maximum Output Voltage Series 100 kV B 100 kV B 100 kV B 60 kV B 60 kV B 60 kV B 100 kV B 100 kV B 100 kV B Solventborne Waterborne 100 kV B 60 kV B 60 kV B 60 kV B 60 kV B 100 kV C 100 kV C 100 kV C 60 kV C 60 kV C 60 kV C All applicator models ship with a serrated aluminum cup. See the Cup Selection Charts, page 83, to see all available cups. Non-Electrostatic Models Cup Size* 30 Part No. 50 mm mm Applicator Type Nozzle Size 15 mm 0.75 mm 1.0 mm 1.25 mm 1.5 mm Non-Electrostatic Maximum Output Voltage Series ----- B Non-Electrostatic R5A161 * 4 All applicator models ship with a serrated aluminum cup. See the Cup Selection Charts, page 83, to see all 334452J Available Models available cups. 334452J 5 Approvals Approvals Specific controllers, rotary applicators, and power supply cables must be used together. Refer to the table below for compatible models. Model Electrostatic Power Supply Controller Cables Applicator Type 24Z098 17J586 17J588 17J589 RxAxx8 24Z099 17J586 17J588 17J589 Waterborne RxAxx1 NA NA Non-Electrostatic RxAxx0 6 Applicator Approvals Solventborne 2575 II 2G < 350 mJ T6 PTB 16 ATEX 5005 EN 50176 Type B-L NA 334452J 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. FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion: • 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 the spray area. Resistance must not exceed 1 megohm. See Grounding instructions. • Do not use pail liners unless they are conductive and grounded. • Always use the required arc detection settings and maintain a safe distance of at least 6 inches (152 mm) between the applicator and the workpiece. • Stop operation immediately if static sparking or repeated arc detection errors occur. Do not use equipment until you identify and correct the problem. • Check applicator resistance and electrical grounding daily. • Use and clean equipment only in well ventilated area. • Always turn off and discharge the electrostatics when flushing, cleaning or servicing equipment. • Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static sparking). • Do not plug or unplug power cords or turn lights on or off when flammable fumes are present. • Keep the spray area clean at all times. Use non-sparking tools to clean residue from the booth and hangers. • Keep a working fire extinguisher in the work area. • Interlock the applicator air and fluid supply to prevent operation unless ventilation air flow is above the minimum required value. • Interlock the Electrostatic Controller and fluid supply with the booth ventilation system to disable operation if the air flow falls below minimum values. Follow your local codes. For solventborne systems only: Use only Group IIA or Group D materials. • Use cleaning solvents with highest possible flash point when flushing or cleaning equipment. • To clean the exterior of the equipment, cleaning solvents must have a flash point at least 15°C (59°F) above ambient temperature. Non-ignitable fluids are preferred. For waterborne systems only: Use 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. • Material is classified as non-ignitable or hard to ignite as defined by EN 50176. 334452J 7 Warnings ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock. • Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment. • Connect only to grounded power source. • All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. For waterborne systems: • Connect the applicator 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 Pressure Relief Procedure, including Voltage Discharge, when instructed to discharge the voltage; before cleaning, flushing, or servicing the system; before entering the spray area; and before opening the isolation enclosure for the isolated fluid supply. • Do not enter a high voltage or hazardous location until all high voltage equipment has been discharged. • Do not touch the applicator or enter the spray area during operation. Follow the Pressure Relief Procedure, including Voltage Discharge. • Interlock the Electrostatic Controller with the voltage isolation system to shut off the electrostatics anytime the isolation system enclosure is opened. • Do not splice fluid hoses together. Install only one continuous Graco Waterborne Fluid Hose between the isolated fluid supply and the applicator. PRESSURIZED EQUIPMENT HAZARD Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury. • Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning, checking, or servicing equipment. • Tighten all fluid connections before operating the equipment. • Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. 8 334452J Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Always operate in accordance with all information given in the instruction manuals. • 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 Specifications in all equipment manuals. • Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheet (SDS) from distributor or retailer. • 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. 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 Specifications in this and all other equipment instruction manuals. Read fluid and solvent manufacturer’s Safety Data Sheet (SDS) and recommendations. ENTANGLEMENT HAZARD Rotating parts can cause serious injury. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Do not wear loose clothing, jewelry or long hair while operating equipment. • Equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources. 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 Safety Data Sheet (SDS) 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. Protective equipment includes but is not limited to: • Protective eyewear, and hearing protection. • Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer. 334452J 9 Introduction Introduction System Description Applicator Type The ProBell Rotary Applicator is part of a spraying system designed for industrial painting applications. The following three components are needed in all ProBell spray systems that utilize electrostatics. The Solventborne Type is designed for use in Class 1, Div. I Hazardous Locations using Group D spray materials, or for use in Group II, Zone 1 Explosive Atmosphere Locations using Group IIA spray materials. • Rotary Applicator • Power Supply Cable • Electrostatic Controller The Waterborne Type is for use in Class 1, Div. I Hazardous Locations or in Group II, Zone 1 Explosive Atmosphere Locations with conductive waterborne fluids that meet at least one of the following conditions for non-flammability: NOTE: Non-electrostatic applicators do not require a power supply cable or electrostatic controller. See Typical System Installation, page 14, for other available system components. Rotary Applicator Applicator Style The ProBell Rotary Applicator, Standard style is designed for use on a stationary mount, a reciprocator, or a solid wrist robot. It has a straight body with all connections on the rear of the applicator. The ProBell Rotary Applicator, Hollow Wrist style is designed for use on a hollow wrist robot. The body has a 60° angle with all connections through a quick-disconnect plate. This design allows all connections to run inside the arm of the hollow wrist robot. See Manual 334626. • Material does not sustain burning in accordance with the Standard Test Methods for Sustained Burning of Liquid Mixtures, ASTM D4206. • Material is classified as non-ignitable or hard to ignite as defined by E. The Non-Electrostatic Type can be used with solventborne or waterborne materials. NOTE: Non-electrostatic rotary applicators are used without a ProBell Electrostatic Controller and power supply cable. Instructions and steps related to the electrostatic controller do not apply to Non-Electrostatic systems. Power Supply Cable The Power Supply Cable connects the ProBell Electrostatic Controller to the Power Supply in the ProBell Rotary Applicator. The Power Supply Cable is available in three lengths: 11 meters (36 ft.), 20 meters (66 ft.), and 30 meters (98 ft.). ProBell Electrostatic Controller The ProBell Electrostatic Controller (Manual 3A3657) provides the ability to display and set the voltage and current. It can operate remotely via discrete I/O or CAN communication. 10 334452J Introduction FIG. 1. Rotary Atomizer Components Ref. Component Description Ref. Component Description 1, 4 Main Housing 18, 19 Air Cap and Cover 13 Front Housing The housings direct the air, fluid and electrical charge from the customer connections to the front of the ProBell Rotary Applicator. The main housing contains three fluid valves (4). The Air Cap and Cover direct the shaping air to the correct diameter for the cup. There are three sizes of air cap components, to match the three cup sizes. 5 Speed Sensor Assembly The Speed Sensor Assembly detects the rotational speed of the magnets on the turbine assembly. 20 Cup 7, 9 Fluid Tube and Nozzle The Fluid Nozzle contains the paint flow orifice. There are six sizes: 0.75 mm, 1.0 mm, 1.25 mm, 1.5 mm, 1.8 mm, and 2.0 mm. The cup atomizes paint by rotating at speeds up to 60,000 RPM. There are three cup Sizes: 15 mm, 30 mm, and 50 mm. 27 Coiled Fluid Tube 10 Turbine Assembly The turbine is driven by compressed air and provides rotating speeds up to 60,000 RPM. 15 Retaining Ring Loosen and remove to access front-end components. Coiled fluid tubes are installed in each Rotary Applicator (3 for solventborne models and 1 for waterborne models). The coiled fluid tubes provide a more resistive path between the high voltage and ground for the paint, solvent, and dump lines (solvent only on waterborne). 334452J 11 Introduction Ref. Component Description 28 Power Supply or Plug The Power Supply contains an electrostatic multiplier with 100 kV maximum output. It has a resistor built in to provide a path to discharge the Rotary Applicator. The plug provides a ground path for the non-electrostatic applicator. 36 12 Mounting Bracket The mounting bracket is used with the correct optional mounting kit for either a reciprocator or a robot. 334452J Installation Installation Additional Electrostatic Waterborne System Installation Requirements Installing and servicing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. • Do not install or service this equipment unless you are trained and qualified. • Be sure your installation complies with National, State and Local codes for the installation of electrical apparatus in a Class I, Div. I, Group D Hazardous Location or a Group II, Zone 1 Explosive Atmosphere Location. • For waterborne electrostatic applications, ensure that the applicator is connected to a voltage isolation system that will discharge the system voltage when required. • Comply with all applicable local, state, and national fire, electrical, and other safety regulations. • The applicator must be connected to a voltage isolation system that isolates the fluid supply from ground and allows voltage to be maintained at the front of the applicator. • The applicator must be connected to a voltage isolation system with a bleed resistor that will discharge the system voltage when the applicator 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 controller must be interlocked with the voltage isolation system to shut off and discharge the electrostatics anytime the isolation enclosure is opened or entered. See Step 8. Create Required System Interlocks, page 36. • The voltage isolation system must be interlocked with the spray location entrance to automatically discharge the voltage and ground the fluid whenever someone opens the isolation enclosure or enters the spray location. See Step 8. Create Required System Interlocks, page 36. Basic Guidelines System Installation Requirements • Several interlocks must be provided to allow safe and reliable operation. See Step 8. Create Required System Interlocks, page 36. • Ventilation must be provided to prevent buildup of flammable or toxic vapors while spraying, flushing, or cleaning the applicator. See Step 7. Prepare the Spray Area, page 36. • Earth grounds must be provided for all specified system components. See Step 9. Ground the Equipment, page 38. 334452J NOTICE The system should not have severe arcing occurring when the isolation mechanism opens and closes. Severe arcing will shorten the life of the system components. 13 Installation Typical System Installation FIG. 2. shows a typical installation. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor. Non-Hazardous Location Hazardous Location FIG. 2. Typical Installation, Electronic Air Controller, with Fluid Isolation Box for Waterborne Systems 14 334452J Installation Typical Installation Components A Rotary Applicator B Bearing Air Supply Line BR Bearing Air Return Line BK Braking Air Supply Line C Air Controller D Dump Return Line DT Dump Valve Trigger Air Line F Fiber Optic Cable for Speed Control G Speed Controller H Electrostatic Controller J System Logic Controller L PLC (connected to a gateway inside the Speed Controller) N CAN Communication Cables P Paint Supply Line PT Paint Valve Trigger Air Line Q I/O Cable (for electrostatic control and interlocks) R Power Supply Cable S Solvent Supply Line SI Shaping Air (Inner) Air Line SO Shaping Air (Outer) Air Line ST Solvent Valve Trigger Air Line (cup wash) T Fluid Supply Isolation Equipment (for waterborne applicators only) TA Turbine Air Line U Fluid Pressure Regulator NOTE: See Step 9. Ground the Equipment, page 38, for required grounding information. 334452J 15 Installation Overview of Installation Steps The following steps are needed to install and connect your system. 1. Mount the rotary applicator, page 16. 1. Install the nut (104) and the bolt (103), but do not tighten. 2. Thread the post (101) into the mounting bracket (36) and tighten firmly. Use Loctite or other adhesive on the threads to prevent loosening. 3. Mount the controllers and accessories, page 24. 3. Position the mounting rod (102) on the post. Rotate to the desired angle. Use adapter (105) to adjust the diameter of the mounting rod, if needed. 4. Connect the fluid supply, page 26. 4. Tighten the nut (104) and bolt (103) securely. 2. Connect all lines at the applicator, page 18. 5. Connect the air lines, page 30. 6. Connect the power and communication cables, page 34. 7. Prepare the spray area, page 36. 8. Create required system interlocks, page 36. 9. Ground the equipment, page 38. Step 1. Mount the Rotary Applicator 36 101 104 To reduce the risk of fire and explosion due to sparking, all mounting hardware must be non-conductive or be properly grounded. Keep all grounded mounting hardware at least 10 in. (25.4 cm) away from the charged components. 103 102 105 FIG. 3. Reciprocator Mounting Kit Reciprocator Mounting Use Reciprocator Mounting Kit 24Z178 to mount the applicator to a stationary stand or to a reciprocator. See the Dimensions on page 90. 16 334452J Installation 60° Robot Mounting Distance to Workpiece Use 60° Robot Mounting Kit 24Z179 to mount the applicator to a solid wrist robot. See the Dimensions on page 88. 1. Remove screws (37) and bracket (36) from the applicator. 2. Install and tighten screws (108) to attach the adapter (105) to the mounting bracket (36). 3. Install and tighten screws (37) to reattach the mounting bracket (36) to the applicator. 4. Thread screw (107) through the robot mounting bracket (106) and into the bottom of the adapter (105) and tighten. 5. Thread screws (109) through the robot mounting bracket (106) and into the robot adapter plate (not shown). NOTE: To find the adapter plate that will work with your robot, see Accessories, page 84. To reduce the risk of fire and explosion, maintain a Safe Distance of at least 6 in. (15.2 cm) between the applicator and the workpiece at all times. Position the cup a minimum of 6 in. (15.2 cm) from the closest approach point of the workpiece. Take into account potential rotation or swaying of the part. The arc detection circuitry of the ProBell Electrostatic Controller helps minimize the risk of an arc should a workpiece approach too close to the charged cup. In addition, the Safe Distance of 6 in. (15.2 cm) must be maintained at all times. A typical spraying distance is 9-14 in. (23-36 cm). To reduce the risk of fire and explosion, the spray area must remain free of rusted steel. Frictional contact between aluminum components and rusted steel must be avoided. 108 (x4) 36 37 (x4) 105 109 (x4) 106 107 FIG. 4. 60° Robot Mount 334452J 17 Installation Step 2. Connect All Lines at the Applicator A total of 14 connections are needed for ProBell with electrostatic operation; 13 connections without electrostatics. NOTE: All lines must run through the manifold retaining ring (35), the adapter cover (34), and the shroud (33). 1. Screw off the manifold retaining ring (35) by hand. The adapter cover (34) will come with it. 2. Slide the shroud (33) off the back of the housing. All three fluid lines are connected at the fluid bracket at the back of the applicator. The fluid then flows through coiled fluid tubes and into the main housing. a. Connect the paint supply line to port P. b. Connect the solvent supply line to port S. This port is 6 mm (1/4 in.). c. If needed, connect the fluid dump line to port D. If not needed, plug Kit 25C201 is available to plug the dump passage in the applicator. d. Tighten all three connectors to secure the lines. The paint and dump line ports are 8 mm (5/16 in.). Refer to the Fluid Pressure Loss Charts, page 98, to help determine the best tubing for your application. An Alternate Fluid Bracket Kit 25A878 is available, for use in electrostatic applications with highly conductive materials. This kit includes a grounded fluid bracket that is mounted remotely. The fluid lines pass through the fluid bracket at the back of the applicator and connect directly into the main housing. The longer fluid lines create a more resistive fluid path. See manual 3A5223 Fluid Ground Bracket Kit. 3. Pass each line through these three pieces before connection at the applicator. TIP: Connect the lines in the order shown in this section. Label each line and bundle into groups, to avoid confusion later when the lines are connected to the fluid supply, air supply, and other system components. Fluid Lines for Solventborne Type and None-Electrostatic Type Applicators Fluid lines may contain high-voltage fluid. Sparking due to a hose leak could cause fire, explosion, or electrical shock. To reduce the risk of sparking: • Connect all fluid lines into the grounded fluid bracket. • Use only genuine Graco coiled fluid tubes. 18 FIG. 5. Fluid Connections 334452J Installation Fluid Lines for Waterborne Type Applicators. The fluid between the applicator and fluid supply will be charged. To reduce the risk of electric shock, use only Graco-supplied waterborne fluid hoses. See also Step 9. Ground the Equipment, page 38. NOTE: See Accessories, page 84, for a list of available waterborne hoses. 1. Connect the solvent supply line to fluid fitting S on the fluid bracket at the rear of the applicator. This port is 6 mm (1/4 in.). The solvent then flows through a coiled fluid tube and into the main housing. 32g 32f 32e 2. Blow out the paint supply hose and fluid dump hose (if used) with air and flush with water before connecting. 3. Pass the paint supply hose through the strain relief fitting (32e) on the fluid bracket and connect to port P on the main housing. Make sure the ferrule (32f) is in place on the outer jacket of the hose and properly oriented. Tighten the strain relief nut (32g). 4. Pass the dump hose through the strain relief fitting on the fluid bracket and connect to port D on the main housing. Tighten the strain relief nut. 5. The applicator end of the waterborne hose comes stripped to the correct dimensions. The shield (W) should pass through the strain relief fitting to minimize electrical stress. The strain relief fitting must be located on the outer jacket (X) of the hose. Ref. Shielded Unshielded U 5.75 in. 146 mm 1.5 in. V 1.25 in. 32 mm 38 mm N/A FIG. 6. Fluid Connections at the Applicator 3/8” Ø 334452J 19 Installation Air Lines—All Models A total of nine air line connections are needed. Remember to label each line, and bundle into groups. Pass the air lines through the manifold retaining ring (35), the adapter cover (34), and the shroud (33), then through the center of the rear manifold (30). Power Supply Cable (for Electrostatic Models) Connect the 4-pin end of the power supply cable to connector R on the applicator. Fiber Optic Cable (for optional Speed Controller) The applicator is equipped with a magnetic pickup sensor assembly that provides a signal used by the Speed Controller. On the applicator manifold, connect a fiber optic cable (F) to the F port that connects to the fiber optic extension cable (22). The amount of fiber extending past the nut should be 0.11 in. (2.8 mm). See Accessories, page 84, for available cables. NOTE: An alternate reflective speed sensor assembly is available, Kit 24Z183. F R FIG. 7. 1. Connect the three trigger air lines first – the paint valve trigger (PT), the solvent valve trigger (ST), and the dump valve trigger (DT). These lines are smaller because they provide only an air activation signal. Use 4 mm (5/32 in.) tubing. 2. Next, connect the bearing air return (BR), also a 4 mm (5/32 in.) tube. 22 NOTICE To avoid equipment damage route all hoses and cables away from sharp edges. Avoid sharp bends and excessive strain on hoses or cables. 3. Around the outer edge, connect the larger air supply lines, needed for bell operation. Use 8 mm (5/16 in.) OD tube with 1 mm (0.04 in.) wall to minimize pressure drop. a. b. c. d. e. 20 Connect the bearing air to port B. Connect the inner shaping air to port SI. Connect the outer shaping air to port SO. Connect the turbine air to port TA. Connect the braking air to port BK. 334452J Installation Connect the Ground Wire FIG. 8. NOTE: When all lines have been connected at the applicator, reinstall the shroud (33), the adapter cover (34) and the manifold retaining ring (35). Tip: If you have a Graco hose bundle, pull the hose bundle cover over the back of the adapter cover (34). Secure with a cable tie. Connect the ground wire (41) to the applicator manifold. 1. Remove the fluid bracket screw. 2. Pass the screw through the ground wire eyelet and reinstall. It is ok if the eyelet bends. 334452J 21 Installation Connection Schematics Z E E Main Housing (Solventborne and Waterborne Models) Fluid Bracket Solventborne Models Waterborne Models F R FIG. 9. Manifold Connections 22 334452J Installation B BK BR D DT E F P Bearing Air* Provides air for proper air bearing support. Braking Air* Slows the turbine speed. Bearing Air Return - 4 mm (5/32 in.) tube fitting Returns air to the controller for pressure check. Dump Line**- 8 mm (5/16 in.) tube fitting Waste line for flushing or color change. Dump Valve Trigger - 4 mm (5/32 in.) tube fitting Air activation signal for the dump valve. Turbine Exhaust Ports Fiber Optic Speed Sensor Port Paint In** - 8 mm (5/16 in.) tube fitting Fluid supply inlet fitting PT R S SI SO ST TA Z * Paint Valve Trigger - 4 mm (5/32 in.) tube fitting Air activation signal for the paint valve. Power Supply Connection Solvent In** - 6 mm (1/4 in.) tube fitting Cleaning solvent supply inlet fitting Shaping Air (Inner)* Shaping Air (Outer)* Solvent Valve Trigger (Cup Wash)4 mm (5/32 in.) tube fitting Air activation signal for the solvent valve. Turbine Air*† Operates the turbine. Weep Holes Drainage points for any leakage into the air section Use 8 mm (5/16 in.) OD tube with 1 mm (0.04 in.) wall to minimize pressure drop. ** For solventborne models, P, D, and S connections at the main housing are made at the factory. † The rotation speed or flow rate of a 50 mm cup may be limited due to pressure drop in the turbine air line. See Turbine Inlet Air Pressure Charts, page 92. 334452J 23 Installation Step 3. Mount Controllers and Accessories The following components are available to create a complete ProBell Rotary Applicator System. The ProBell controllers have been designed and optimized for use with the ProBell Rotary Applicator. Your system may use all Graco components, or a combination of Graco equipment and other controls. To reduce the risk of fire and explosion, do not install equipment approved only for a non-hazardous location in a hazardous location. ProBell Electrostatic Controller (Required for Electrostatic Models) Air Filters NOTICE Air that is not filtered to specification can clog bearing air passages and cause bearing failure. The warranty does not cover a turbine damaged by contaminated air. Three air filtration stages are required to prevent contamination of the paint finish and to prevent damage to the air bearing. Refer to Table 1 for the specifications of each filter. Use only these recommended filters, or filters that meet the same specifications. See Manual 309919 for filter details, installation, and pipe size recommendations. • The temperature of the air as it enters the Pre-Filter must be close to ambient. • Mount the Electrostatic Controller in the non-hazardous area. See ProBell Electrostatic Controller Manual 3A3657 for installation instructions. Air must be dehydrated to a dew point of 10°F (-12°C). • Filters must remove 99% of all aerosols. ProBell System Logic Controller • The rotary applicator system can be controlled with a System Logic Controller or with an existing PLC. A System Logic Controller is required if your system includes a Speed Controller or an Air Controller. Mount the System Logic Controller in the non-hazardous area. See Manual 3A3955 for installation instructions. Filters must remove particles of 0.5 microns and larger. Graco filter 234403 removes particles down to 0.01 microns. • Standard piping may be used only up to the pre-filters. All piping after the pre-filters should be brass, stainless steel, or plastic hose. • Do not use any type of thread sealant or PTFE tape downstream of the bearing air filter. Small particles may loosen and plug the air holes in the turbine air bearings. • Air that is heated above 120°F (49°C) will damage filter elements. ProBell Speed Controller (Optional) Mount the Speed Controller in the non-hazardous area, as close to the applicator as possible to minimize pressure loss in the air lines. See Manual 3A3953 for installation instructions. ProBell Air Controller (Optional) Graco offers two Air Controller options: Electronic and Manual. Mount the Air Controller in the non-hazardous area, as close to the applicator as possible to minimize pressure loss in the air lines. See Manual 3A3954 for installation instructions and to see features of each air controller. 24 334452J Installation FIG. 10. Air Filter Table 1. Required Air Filters PN Replacement Element PN Description and Specification Air Inlet and Outlet npt(f) 234402 Stage 1: Pre-Filter (A) 100 SCFM (rated flow of 100 SCFM minimum is required), removes coarse amounts of oil, moisture, and dirt to 3 microns. Use upstream of 234403. 16W405 1/2 in. 234403 16W407 Stage 2: Grade 6 Coalescing Filter (B) 50 SCFM (rated flow of 50 SCFM minimum is required), removes oil and submicronic particles down to 0.01 microns. Use one filter for each ProBell Applicator. 1/2 in. Not available. 1/4 in. push-lock, 17M754 In Control Box: Bearing Air Grade 6 Coalescing Filter (C) (m) 4 SCFM (rated flow of 4 SCFM minimum is required). One filter is Replace with included in ProBell Speed Controller 24X519 and in ProBell Man- assembly 17M754 ual Air Controller 24X520. Air Heaters Air heaters may be needed in some applications. If the surface temperature of the applicator falls below the dew point of the paint booth, condensation may form on the inside or outside of the applicator. This condensation is caused by supply air that is too cool, or by the cooling of the shaping and turbine airs as they exit the applicator. Set the heater as low as possible to maintain the applicator surface temperatures above the dew point in the booth. NOTE: The maximum air temperature at the bell must not exceed 120° F (49° C). A heater may be required to ensure that the temperature of the turbine exhaust air is above the dew point of the spray booth. Install heaters into the air supply lines (turbine, shaping airs). 334452J 25 Installation Step 4. Connect Fluid Supply Connect fluid lines at the applicator first. See Step 2. Connect All Lines at the Applicator, page 18. Solventborne Electrostatic Systems or Non-Electrostatic Systems. a. Paint Hose: The fluid hose connected to port P on the applicator must be connected to a regulated, filtered paint supply, such as a circulation system or a supply pump. This hose also must be connected to a regulated solvent supply to flush the system and an air supply to empty the lines. This figure shows a common way to make these connections. must also be connected to a regulated air supply to purge the cup wash passages with air. An air purge is recommended for use with conductive solvents to improve electrostatic performance NOTE: Not purging the lines of conductive solvents may cause low electrostatic voltage or system errors. Waterborne Systems b. Dump Hose: The fluid hose connected to port D on the applicator must go to a grounded waste container. The fluid between the applicator and the fluid supply will be charged. To reduce the risk of electric shock, follow hose requirements and instructions carefully. a. General Requirements: Waterborne isolation systems must meet these requirements: • Fluid Supply - All conductive components of the fluid supply (pump, filter, regulator, container, etc.) that are charged to high voltage must be bonded together. - If non-conductive containers are used, a conductive element bonded to the fluid supply must be in contact with the fluid. • Fluid Hose -Use only approved Graco Waterborne fluid hoses. c. Solvent Hose: The fluid hose connected to port S on the applicator must be connected to a regulated solvent supply that will be used to wash the cup. This line 26 334452J Installation - Unshielded waterborne fluid hoses must be routed such that a minimum distance of 0.25 cm/kV is maintained between the hose and grounded surfaces. - The conductive layer of shielded hoses must be grounded at the isolation system. • Enclosure - All components of the isolated fluid supply system must be housed in a protective enclosure to prevent contact with the charged components during operation. - Access to the enclosure must be interlocked with the high voltage supply to shut off and discharge the high voltage before any live parts can be reached. c. Dump Hose (optional): The most common system design for the dump line (connected to port D) is to connect a waterborne fluid hose to a grounded waste container. Flush and purge the dump line with air before turning on the electrostatics. A second dump option is to place the waste container in the voltage isolation enclosure. Connect a Graco Waterborne Fluid Hose between the voltage isolation system fluid outlet and the applicator dump port (D). d. Solvent Hose: The fluid hose connected to port S on the applicator must be connected to a regulated solvent supply that will be used to wash the cup. This line must also be connected to a regulated air supply to purge the cup wash passages with air. An air purge is required for very conductive waterborne fluids. b. Paint Hose: The fluid hose connected to port P on the applicator must be connected to a regulated, filtered paint supply. This hose also must be connected to a regulated solvent supply to flush the system. Connect an air supply to empty the lines, if needed. The illustration below shows a common way to make these connections. 334452J NOTE: Not purging the lines will cause low electrostatic voltage or system errors. An isolated solvent kit 25N021 is also available for waterborne systems that have the solvent supply inside the isolation system. 27 Installation Route unshielded hoses away from grounded objects. Maintain a distance of 0.25cm/kV between the hose and grounded objects. • A shielded hose consists of an inner PTFE tube (Y), a conductive layer covering the PTFE tube (W), and an outer cover (X). If a hose failure occurs where high voltage arcs through the inner tube, voltage will be discharged to ground through the conductive hose layer. When properly installed, the conductive hose layer is grounded through its connection to the grounded enclosure. The fluid supply end of the hose has been stripped at the factory for connection to a WB100 Isolation System, as shown below. If desired, the hose can be changed on this end, but the conductive layer (W) must be no closer than 8 in. (20.3 cm) to the end of the hose or any other high-voltage component. e. Hose-Stripping Requirements Hose-Stripping Requirements Ref. Shielded Unshielded U 14.5 in. 368 mm 14.5 in. V 0.75 in. 19 mm 368 mm NA • An unshielded hose consists of a PTFE tube (Y) with an outer covering (X). FIG. 12. Shielded Hose NOTICE Be careful not to cut into the inner tube (Y) of the hose when stripping the hose. Nicks or cuts in the PTFE tube will cause premature hose failure. FIG. 11. Unshielded Hose Connect one end of the hose to the applicator. Connect the other end to a fluid supply inside an isolation enclosure. 28 334452J Installation NOTE: Blow out the fluid supply hose and circulation hose (if used) with air and flush with water before connecting. • Connect the fluid hose(s) as follows: 2. Using an ohmmeter, verify continuity between the conductive layer closest to the applicator and the isolation enclosure ground. 3. Connect the dump hose (D) to a grounded or isolated waste container. Connect the waterborne hose as in step 1. To reduce the risk of electric shock, the areas of the Graco Waterborne Fluid Hose that are accessible to personnel during normal operation must be covered by the outer hose jacket (X). The portion of the inner PTFE tube (Y) not covered by the outer jacket (X) must be inside the isolation enclosure (T).The conductive hose layer (W) must be grounded at the isolation enclosure (T). 1. Pass the Graco waterborne fluid hose through a strain relief fitting at the wall of the isolated enclosure and connect the inner tube (Y) to the fluid supply outlet. Tighten the strain relief fitting (Z). For a shielded hose, the conductive layer of the hose (W) must be grounded to the isolation system ground (strain relief fittings must grab onto the outer jacket or conductive layer of the fluid hose). X Y Z W T W 334452J T X 29 Installation Step 5. Connect the Air Lines Connect all air lines to the applicator first (see Step 2. Connect All Lines at the Applicator, page 18). The air supply for each line can be regulated and actuated using the ProBell Speed Controller and/or one of the ProBell Air Controllers (see Table 2: Air Line Connections Availability by Controller Type, page 33). Spray parameters can be adjusted independently or saved as presets. ProBell controllers are labeled with the same reference letters as the applicator, for easier matching (see FIG. 14. or FIG. 15., page 32 for more detail). See the following sections for connection information. If your system is not using all of the ProBell controllers, see the following sections for specifications and requirements for each air line. NOTICE Take great care to connect the air lines to the correct ports on the control equipment. Incorrect air line connections will damage the applicator. Bearing Air NOTICE Bearing Air Line AT CV FIG. 13. Bearing Air Line with Accumulator Tank and Check Valve Bearing air requires at least 70 psi (0.48 MPa, 4.8 bar) pressure at the applicator at all times. A flow volume of 3 scfm is required. NOTICE For best performance, maintain 100 psi bearing air pressure. Bearing air pressure of less than 90 psi (0.62 MPa, 6.2 bar) increases the potential for turbine failure when running at speeds greater than 50 krpm. To avoid equipment damage • • bearing air must be on while the turbine is spinning and must not be turned off until the cup comes to a complete stop. bearing air must be filtered to precise requirements. See Air Filters, page 24. The bearing air provides proper bearing support. Connect the bearing air line to the port marked B on either the Speed Controller or the Manual Air Controller if only one controller is present in the system. If both Speed Controller and Manual Air Controller are present, the connection must be made to the Speed Controller. To provide additional protection for the bearing if the bearing air is turned off before the bell cup comes to a complete stop, install an air accumulator tank (AT) and a check valve (CV) in the bearing air line. The accumulator tank (AT) should be 3 gallons (11 liters) or greater. Bearing Air Return NOTICE Use of a bearing air return line will help prevent equipment damage. The bearing air return line is connected to a pressure monitoring device, to ensure that adequate bearing air pressure is maintained. Connect the bearing air return line to the port marked BR on either the ProBell Speed Controller or the ProBell Manual Air Controller if only one controller is present in the system. If both Speed Controller and Manual Air Controller are present, the connection must be made to the Speed Controller. If your system does not use the ProBell System Logic Controller, bearing air return must be interlocked with the turbine air so that the turbine air will not flow if the bearing air return pressure is under 70 psi (0.48 MPa, 4.8 bar). NOTE: While not advisable, if you choose not to use the bearing air return line, plug the bearing air return port (BR) on the applicator. 30 334452J Installation Turbine Air NOTICE Turbine air supplies must be regulated and adjusted to the right pressure before use. Excess air flow will over speed the turbine and will result in equipment damage. The turbine air rotates the cup. Connect the turbine air line to the port marked TA on either the Speed Controller or the Manual Air Controller if only one controller is present in the system. If both Speed Controller and Manual Air Controller are present, the connection must be made to the Speed Controller. For speed adjustment using a pressure regulator, see the Turbine Inlet Air Pressure Charts on page 92 for typical air requirements for a given bell speed. If your system does not use the ProBell System Logic Controller, interlock the turbine air with either the bearing air or the bearing return air, to ensure that the turbine air will flow only if the bearing air pressure is at least 70 psi (0.48 MPa, 4.8 bar). If your system does not use the ProBell System Logic Controller, interlock the turbine air with the brake air so they cannot flow at the same time. Braking Air To avoid injury, avoid excessive braking air. A cup that is not fully seated may disengage from the shaft. The braking air slows the turbine speed. Connect the braking air line to the port marked BK on the Speed Controller. The speed controller automatically engages the braking air as needed. For manual air braking applications, apply 20 psi (0.14 MPa, 1.4 bar) air for approximately 5 seconds. This pressure will slow the bell speed rapidly. Adjust the air pressure and time as needed for your system to stop cup rotation. NOTICE To prevent equipment damage, do not leave braking air on long enough to rotate the turbine in reverse. 334452J If your system does not use the ProBell System Logic Controller, interlock the turbine air with the brake air so they cannot flow at the same time. Shaping Airs The inner and outer shaping airs provide pattern control and keep the material particles moving toward the object being sprayed. Connect the inner shaping air line to the port marked SI on the Air Controller. Connect the outer shaping air line to the port marked SO on the Air Controller. See the Shaping Air Consumption Charts, page 94, for volume requirements. Use filtered, dry air for the best finish quality. Maintain an inner shaping air pressure of at least 10 psi (0.07 MPa, 0.7 bar) at all times to help keep the bell clean. Use both inner and outer shaping air for optimal pattern control. Adjust the pressures to achieve the best pattern for your application. Increase shaping air pressures to reduce the pattern size. Paint Valve Trigger The paint valve trigger provides an air activation signal for the paint valve. Actuate the paint trigger each time a part is sprayed. The acceptable pressure range is 70-100 psi (0.48-0.69 MPa, 4.8-6.9 bar). Connect the paint valve trigger air line to the port marked PT on the Air Controller. Interlock the paint trigger with the turbine air so the paint valve will not open to spray unless at the turbine speed is at least 10,000 rpm. The rotation is required to prevent fluid from flooding the turbine area. Interlock the paint trigger with the conveyor, so the paint valve will open to spray only when the conveyor is moving. See ProBell Air Controller Manual 3A3954 for options to create these interlocks. Paint Trigger Input The paint trigger input is included on the ProBell Air Controller (both manual and electronic models). This isolated input can be used to trigger the paint valve on a ProBell system from a PLC or robot. See the System Logic Controller Manual (3A3955) to configure how the paint is triggered in a ProBell system. See the ProBell Air Controller Manual (3A3954) to connect the paint trigger input. 31 Installation Solvent Valve Trigger (Cup Wash) The solvent valve trigger provides an air activation signal for the solvent valve and is used to perform a cup wash. Connect the solvent valve trigger air line to the port marked ST on the Air Controller. Interlock the solvent trigger with the turbine air so that the solvent valve will not open to spray unless the turbine speed is at least 10,000 rpm. The rotation is required to prevent fluid from flooding the turbine area. Interlock the solvent trigger with the electrostatics so that the solvent valve will open to flow only if the electrostatics are turned off and discharged. Dump Valve Trigger Speed Controller The dump valve trigger provides an air activation signal for the dump valve. The dump valve is used to purge the paint line. Connect the dump valve trigger air line to the port marked DT on the Air Controller. Auxiliary Ports Three auxiliary ports are provided on the Graco Air Controllers for other customized system needs. The user might use one to trigger a valve, for example, or to connect a shutoff signal to stop the conveyor system. Aux. 1, 2, 3 Electronic Air Controller FIG. 14. Air Connections, Electronic Air Controller with Speed Controller Aux 1, 2, 3 FIG. 15. Air Connections, Manual Air Controller . Air C 32 334452J Installation Table 2: Air Line Connections Availability by Controller Type Speed Controller Connections Air Line B (Bearing Air) BK (Braking Air) BR (Bearing Air Return) Electronic Air Controller Connections Manual Air Controller Connections DT (Dump Valve Trigger) PT (Paint Valve Trigger) SI (Shaping Air Inner) SO (Shaping Air Outer) ST (Solvent Trigger) TA (Turbine Air) Auxiliary Triggers 334452J 1, 2, 3, 33 Installation Step 6. Connect Power and Communication Cables Speed Controller End 0.440 in. (11.2 mm) Electrostatic Controller 1. Connect the 7-pin side of the power supply cable to connector R on the Electrostatic Controller. Applicator End 0.11 in. (2.8 mm) 2. Make Interlock connections. See Electrostatic Controller Manual 3A3657 for details. • • • • • • • Solvent supply Spray area doors and openings Conveyor Ventilation fans Fire control system Fluid supply Waterborne isolation system 3. Integrate the electrostatics. Integration of the electrostatic enable function typically depends on a part detection system. Two options are common: • • Use the electrostatic enable digital input on the Discrete I/O interface of the ProBell Electrostatic Controller. Connect per controller manual 3A3657. Provide a command from an external controller to the ProBell System Logic Controller to set the electrostatic enable register via a communication network. See Manual 3A3955. Speed Controller Connect the fiber optic cable to port F on the applicator and to port F on your Speed Controller. The amount of fiber extending past the nut should be 0.440 in. (11.2 mm) on the Speed Controller side. On the applicator side, the amount of extended fiber is 0.11 in. (2.8 mm). If you need to cut or repair the cable, use the tool included with the cable to cut. Available Fiber Optic Cables PN Length 24Z190 24Z191 24Z192 36 ft. (11 m) 66 ft. (20 m) 99 ft. (30 m) NOTE: An alternate reflective speed sensing kit is available, Kit 24Z183. The kit includes instructions for conversion and installation. See Fiber Optic Bulkhead Installation, page 85 for more information. System CAN Communication Cables System components communicate information via CAN cables. No CAN cables connect to the applicator. But, several are needed to interconnect other system components. Use CAN cables to network the Electrostatic Controller, Air Controller, Speed Controller, and the System Logic Controller (if used) in series, as shown in FIG. 15. One power supply is required in the CAN network, typically mounted on the speed controller. See Accessories, page 84, for a list of available CAN cables. To connect the ProBell system to an outside communication network, purchase and install a gateway (see 3A4384 CGM Installation Kit 24Z574) and configure per the System Logic Controller manual 3A3955. 34 334452J Installation FIG. 16. Power and Communication Cable Connections KEY C F G H J N R Air Controller Fiber Optic Port Speed Controller Electrostatic Controller System Logic Controller CAN Ports Applicator Power Supply Connector Port 334452J 35 Installation Step 7. Prepare the Spray Area Mount 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 rotary applicator. Ventilate the Spray Booth Step 8. Create Required System Interlocks To help prevent fire, explosion, or electric shock, check and follow all National, State, and Local codes regarding properly interlocking your spray system. NOTICE Do not operate the applicator unless ventilation fans are operating. Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the applicator. Interlock the electrostatic controller and fluid supply to prevent operation unless ventilating air flow is above the minimum required value. Electrically interlock the Electrostatic Controller and fluid supply with the ventilators so that the electrostatics turn off any time that the ventilation air flow falls below minimum values. Check and follow all National, State, and Local codes regarding air exhaust velocity requirements. Verify the operation of the interlock at least once per year. NOTE: High-velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 60 ft/minute (19 linear meters/minute). To avoid damage to the bearing it is recommended that the bearing air remain on at all times. The following system interlocks are needed to prevent fire, explosion, electric shock, or equipment damage. Turbine air and bearing air: Interlock so the turbine air will flow only if the air pressure on the bearing air return line is at 70 psi (483 kPa) or higher. This interlock is included in the ProBell System Logic Controller. Bearing air must be on when the turbine is operating. Bearing air should be turned off only at the main air source and only after the cup has stopped spinning. 4. Paint trigger and turbine air: Interlock so the rotary applicator will spray only when the turbine is spinning. A minimum of 10K rpm is recommended. This interlock is included in the ProBell System Logic Controller. 5. Electrostatic controller and solvent supply: Interlock so that electrostatics can be enabled only when solvent is not flowing in the solvent or paint lines. See Electrostatic Controller Manual 3A3657 for available interlocks. 6. Fluid supply and arc detection: Interlock the fluid supply to shut off in the event of an arc detection fault. 7. Braking air and turbine air: Interlock so the braking air flows only when the turbine air is off. 8. Electrostatic controller and all doors or openings in the spray area: Interlock so the electrostatics turn off and are fully discharged before live parts can be reached. See Electrostatic Controller Manual 3A3657. Check interlock function weekly. 9. Conveyor and paint trigger/electrostatics: Interlock so the rotary applicator stops spraying and the electrostatics turn off if the conveyor stops moving. 36 334452J Installation 10. Electrostatic controller, fluid supply, and ventilation fans: Interlock so the electrostatics and fluid supply turn off any time that the ventilation air flow falls below minimum required value. See Electrostatic Controller Manual 3A3657. 11. Electrostatic controller, fluid supply, and fire control system: Interlock so the electrostatics and fluid supply turn off any time the automatic fire extinguishing system is activated. See Electrostatic Controller Manual 3A3657.Check interlock function every 6 months. 12. Electrostatic controller and waterborne isolation system (for waterborne systems): Interlock so the electrostatics turn off and are fully discharged before live parts can be reached. See Electrostatic Controller Manual 3A3657. Check interlock function weekly. System Status Output A system status output is included in the ProBell Speed Controller. This output indicates when the ProBell system is in Off Mode, such as when an alarm occurs. The output can be used to interlock system functions with functions that are not controlled by the ProBell system. For example: If the paint trigger is outside the ProBell system, the paint trigger can be interlocked with the system status output to ensure that the paint flow is stopped in the event of a system alarm. See the ProBell Speed Controller Manual 3A3953 to connect the system status output. Optional Interlock Input An optional interlock input for the ProBell System Logic Controller can be installed in the ProBell Speed Controller or the ProBell Air Controller. When 24 VDC is applied to this input, the system goes to Off Mode. Install Kit 24Z226. See speed controller manual 3A3953 or air controller manual 3A3954. 334452J 37 Installation Step 9. Ground the Equipment • All electrical cables must be properly grounded. • All persons entering the spray area must wear shoes having conductive or dissipative soles, such as leather, or wear personal grounding straps. Do not wear shoes with non-conductive soles such as rubber or plastic. If gloves are necessary, wear the conductive gloves supplied with the gun. If nonGraco gloves are worn, cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle. The measured insulation resistance of gloves and footwear must not exceed 100 megohm per EN ISO 20344, EN1149-5. • 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. • Rotary Applicator: Ground the applicator by connecting the power supply cable on electrostatic models to a properly grounded electrostatic controller and connecting the ground wire to a true earth ground. The ground wire may be connected to the grounding lug on the electrostatic controller and then connected to a true earth ground. 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. • All electrically conductive objects or devices in the spray area: including fluid containers and wash cans, must be properly grounded. • Control Box Stand: The stand is grounded by connection to the Electrostatic Controller bracket. Check Electrical Grounding • Air Controller and Speed Controller: If not mounted on the Control Box Stand, use a ground wire and clamp to ground to a true earth ground. • Electrostatic Controller: Use the ground wire and clamp provided to connect the Electrostatic Controller to a true earth ground. • Pump: Ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual. • Voltage Isolation System (for waterborne systems): Follow the grounding procedure in the manufacturer’s instructions. • Fluid Hose (for waterborne systems only): The hose is grounded through the conductive layer. Install the hose as instructed, page 26. • Air compressors and hydraulic power supplies: Ground the equipment according to the manufacturer's recommendations. • All air and fluid lines must be properly grounded. The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current. When operating the rotary applicator, any ungrounded objects in the spray location (people, containers, tools, etc.) can become electrically charged. Your system may include other equipment or objects which must be grounded. Your system must be connected to a true earth ground. Check ground connections daily. Check your local electrical code for detailed grounding instructions. The following are minimum grounding requirements for a basic electrostatic system. • 38 Megohm meter Part No. 241079 is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohm meter to check electrical grounding unless: • The rotary applicator 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. Check ground connections daily. 334452J Installation Non-Hazardous Location Hazardous Location J G A C H T A Rotary Applicator C Air Controller G Speed Controller H Electrostatic Controller J System Logic Controller T Fluid Supply FIG. 17. Grounding the System 334452J 39 Installation System Logic Controller Setup After installation, the following setup steps are required before Operation. 1. Use the Setup Screens on the System Logic Controller to set the following operating parameters. Detailed instructions are in the System Logic Controller Manual 3A3955. • • • • • • Set the number of guns, type of guns, type of signal, idle timer and idle speed. See System Screen and Gun Screen 1. Enable or disable and configure the Air Controller, See Gun Screen 2. Set up the auxiliary solenoids on the Air Controller. See Gun Screen 3. Enable or disable and configure Speed Controller gun screen. See Gun Screen 4. Enable or disable and configure the Electrostatic Controller. See Gun Screen 5. Configure spray parameters for all recipes using Presets 0 through 98. See Preset Screens. • Provide all information needed for the Gateway to enable communication via DeviceNet, Ethernet IP, Modbus TCP or PROFINET. See Gateway screens. • Set language, date format, date, time, units, and other personal preferences. See Advanced Screens. 2. Use the Setup screens and the Configuration screens on the Electrostatic Controller to set up your system electrostatics. This setup is saved in the equipment memory, even when power is removed. All instructions are in the Electrostatic Controller Manual 3A3657. NOTE: If you are using a PLC with only the Electrostatic Controller, see the Discrete I/O section in the Electrostatic Controller Manual 3A3657. Verification After all installation steps are complete, and the System Logic Controller is configured, the system is ready for start up. Prior to running production, a knowledgeable person should check the functions shown in the table. This verification should be repeated on a regular basis. Test Requirement 1. Proper Grounding Verify proper grounding. See Step 9. Ground the Equipment, page 38. Verify proper clearance is maintained between the cup and parts. See Distance to Workpiece, page 17. Verify the function of the arc detection circuitry. See the arc detection information in the Electrostatic Controller Manual 3A3657. 2. Proper Clearance 3. Arc Detection 4. Interlock with Ventilation 5. Voltage Discharge 6. Waterborne System Requirements 7. Interlocks with Fluid 8. Fire Suppression 40 Verify proper operation of the interlock with the ventilation system. See Step 8. Create Required System Interlocks, page 36. Follow the Voltage Discharge and Grounding Procedure, page 46. Verify that access to the applicator (and the isolation system for waterborne) is prohibited until the discharge timer has elapsed and no residual voltage remains. Verify the fluid supply system meets the requirements on Step 4. Connect Fluid Supply, page 26, and verify the interlock between the enclosure access and the high voltage controller. Verify the proper operation of the interlocks with the solvent supply and fluid supply. See Step 8. Create Required System Interlocks, page 36. Verify the proper operation of the interlock with the fire suppression system. See Step 8. Create Required System Interlocks, page 36. Frequency Daily Weekly Every 6 Months and any time system parameters are changed Every 6 Months Each Cleaning Weekly Weekly Every 6 Months 334452J Operation Operation Pre-Operation Checklist Go through the Pre-Operation Checklist daily, before each use. All System Types All operators are properly trained to safely operate an automatic electrostatic rotary applicator system as instructed in this manual. All operators are trained in the Pressure Relief Procedure on page 45. The warning sign provided with the rotary applicator 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 Step 9. Ground the Equipment on page 38. The rotary applicator’s mechanical and electrical components are in good condition. Ventilation fans are operating properly. Applicator and hose connections show no signs of fluid leakage. All Setup is complete. Electrostatics are off and voltage is discharged according to Voltage Discharge and Grounding Procedure, page 46, before entering the spray area for any cleaning or maintenance work. Waterborne Systems Only Electrostatics are off and voltage is discharged according to Voltage Discharge and Grounding Procedure, page 46, before any person enters the isolation enclosure, before cleaning, and before performing any maintenance or repair. The Graco Waterborne Fluid Hoses (shielded or unshielded) are in good condition with no cuts or abrasions of the PTFE tube. Replace fluid hose if damaged. All fluids used meet one of the following flammability requirements: • Workpiece hangers are clean and grounded. • All debris is removed from the spray area, including flammable fluids and rags. Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206. Material is classified as non-ignitable or hard to ignite as defined by EN 50176. All flammable fluids in the spray booth are in approved, grounded containers. All conductive objects in the spray area are electrically grounded, and the floor of the spray area is electrically conductive and grounded. 334452J 41 Operation Check Fluid Resistivity Check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area. Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage. Graco Part No. 722886 Resistance Meter and 722860 Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the requirements of an electrostatic air spray system. Follow the instructions included with the meter and probe. Readings of 20 megohms-cm and above provide the best electrostatic results and are recommended. 1-7 Longer fluid hose may be needed* Megohms-cm 7-20 20-200 200-2000 Good Best Good electrostatic electrostatic results results Spray Procedures To reduce the risk of electric shock and to avoid injury due to contact with the spinning cup, do not enter the spray area during rotary applicator operation. If any fluid leakage from the rotary applicator is detected, stop spraying immediately. Fluid leakage into the shroud could cause fire or explosion and result in serious injury and property damage. Flush Before First Use 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 44. Load Material 1. Put the system in Purge mode. In this mode: * Included in kit #25A878. a. Ensure that electrostatics cannot be enabled. Check Fluid Viscosity b. The bell should be rotating at least 10k rpm. To check fluid viscosity you will need a viscosity cup and stopwatch. c. 1. Completely submerge the viscosity cup in the fluid. Lift the cup out quickly. Start the stopwatch as soon as the cup is completely removed. 2. Watch the stream of fluid coming from the bottom of the cup. As soon as there is a break in the stream, shut off the stopwatch. 3. Record the fluid type, elapsed time, and size of the viscosity cup. 4. Compare to the chart supplied by viscosity cup manufacturer to determine your fluid viscosity. 5. If the viscosity is too high or too low, contact the material supplier. Adjust as necessary. See Fluid Flow Rate Charts, page 96 to select the appropriate nozzle size. 42 The Inner Shaping Air should be a minimum of 10 psi (0.7 bar) to help keep the applicator clean. 2. Supply paint to the paint line P. 3. Actuate the dump valve trigger (DT) until paint reaches the applicator. Actuate the paint valve trigger (PT) to load the paint to the front of the applicator. NOTE: With this method, paint is returned through the dump line, rather than exiting out the front of the applicator. Paint remains in the dump line until the system is flushed. If your material has a low pot life, actuate the paint valve trigger (PT) to load paint. 4. Follow the Cup Wash procedure, page 44. 334452J Operation Check Flow Rate sure Charts, page 92, for the required pressure to achieve a given speed. These instructions begin with material loaded. 1. Follow the Cup Wash procedure, page 44. d. Actuate the paint valve trigger (PT). 2. Put the system in Maintenance Mode. In this mode: e. Increase the speed (or increase the turbine air pressure slowly) for finer atomization. • • • • The electrostatics are off. The shaping air is off. The turbine air is off (not rotating). The bearing air may remain on. f. Decrease the speed (or decrease the turbine air pressure slowly) for coarser atomization. 3. Remove cup and air cap. See 15 mm or 30 mm Cup, page 61, or 50 mm Cup, page 62. NOTE: Speed can be changed with the applicator triggered or not triggered. 4. Actuate the paint valve trigger (PT). 4. Adjust the pattern size: 5. Measure the flow into a container. Use a stop watch to measure the time. Calculate the flow rate. 6. To increase the flow rate: • Increase the regulated fluid pressure of the material. • Increase the size of the fluid nozzle. • Reduce the viscosity of the material. • Use a larger diameter fluid hose up to the bell. To decrease the flow rate: • Reduce the regulated fluid pressure of the material. • Reduce the size of the fluid nozzle. 7. Reinstall the cup and air cap. See 15 mm or 30 mm Cup, page 61, or 50 mm Cup, page 62. Adjust the Spray Pattern 1. Put the system in Spray mode. 2. Select Preset 0 so the spray parameters can be independently adjusted. 3. Adjust the atomization: a. Set the inner shaping air (SI) and outer shaping air (SO) to at least 10 psi (0.7 bar) at the bell to keep the bell clean. b. Set the speed to 25K rpm. c. 334452J If your system does not have a speed controller, start with the turbine air (TA) set at 0 and increase very slowly. Make sure not to over speed the turbine. See Turbine Inlet Air Pres- a. Start with 10 psi (0.7 bar) on both the inner and outer shaping airs (SI and SO). b. Increase the outer shaping air (SO) to reduce the pattern size or to improve applicator cleanliness (reduce wrap-back). c. Increase the inner shaping air (SI) for additional pattern control. 5. Adjust the electrostatics (where applicable): a. Start with the maximum settings (100 kV, 150 µA for Solventborne models; 60kV, 150 µA for Waterborne models). b. Decrease the voltage if test parts show evidence of thick edges or poorly covered recess areas (the Faraday effect). c. Increase the voltage for improved wrap. 6. Follow the Cup Wash procedure, page 44. Spray a Part 1. Put the system in Spray mode. In this mode: a. Inner and outer shaping airs (SI and SO) are on. b. The turbine is spinning at the desired speed. 2. Position a part, or position the applicator, for material application. 43 Operation 3. Turn on the electrostatics if used. The Safe Position input and other required interlocks must be satisfied. Flushing 4. Actuate the paint valve trigger (PT) until desired coverage is achieved. To avoid fire, explosion, and electric shock: • Always turn off the electrostatics and discharge voltage when flushing, cleaning, or servicing equipment. • Always ground the equipment and waste container. • Flush the equipment only in a well-ventilated area. • Use only Group IIA materials. Non-ignitable fluids are preferred. • To avoid static sparking and injury from splashing, always flush at the lowest possible pressure. NOTE: Excessive paint may wrap back toward the applicator if the applicator is sprayed without a target present and electrostatics on. 5. When finished, turn off the paint valve trigger first. 6. Turn off the electrostatics if used. 7. Short Breaks: Leave the shaping airs on and the turbine at speed. Longer Breaks: Follow the Cup Wash procedure, page 44. Put the system in Idle mode, which reduces the turbine speed and shaping airs to conserve energy. • Flush before changing fluids, before fluid can dry in the equipment, at the end of the day, before storing, and before repairing equipment. Cup Wash • Follow this cup wash procedure whenever you are done spraying parts, and as needed between parts depending on the material being sprayed and the rate of build-up. Some materials will require frequent cup washing. 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’s wetted parts. 1. Put the system in Purge mode. In this mode: a. Ensure that electrostatics cannot be enabled. b. The bell should be rotating at least 10k rpm. c. The inner shaping air (SI) should be a minimum of 10 psi (0.7 bar) to help keep the applicator clean. NOTICE Use the lowest practical solvent pressure to perform flushing and cup wash procedures. Excessive solvent flow can cause fluid to flood the turbine and damage it. 1. Put the system in Purge mode. In this mode: a. Ensure that electrostatics cannot be enabled. 2. Activate the solvent valve trigger (ST). b. The bell should be rotating at least 10k rpm. 3. Use air to purge the solvent. c. a. Provide air to the solvent line S. The inner shaping air (SI) should be a minimum of 10 psi (0.7 bar) to help keep the applicator clean. b. Actuate the solvent valve trigger (ST) to purge the cup wash solvent. 44 334452J Operation 2. Provide solvent to the paint line P. 3. Actuate the dump valve trigger (DT) to flush the lines to the applicator. Close the dump valve when clear solvent exits the dump line. (Actuate the Paint trigger if the dump valve is not being used.) 4. Actuate the paint trigger (PT) to flush the fluid tube and nozzle. 5. Actuate the solvent valve trigger (ST) to wash the cup. NOTE: If you need to purge all solvent, proceed with Step 6. 6. Use air to purge the solvent. NOTE: Turn off the main air supply (bearing air) only after the cup has stopped spinning. Electrostatic Systems 1. Turn off the electrostatics Complete Step 1 of the Voltage Discharge and Grounding Procedure. 2. Shut off the fluid and solvent supply. 3. Relieve the paint pressure. Actuate the dump valve trigger (DT) to relieve pressure in the paint and dump lines. If your system does not have a dump valve, actuate the paint valve trigger (PT). a. Provide air to the paint line P. 4. Relieve solvent pressure. Actuate the solvent valve trigger (ST) to relieve pressure in the solvent line. b. Actuate the dump valve trigger (DT) to purge the lines. 5. Turn off the turbine air and the shaping airs. Put the system in Off mode. c. 6. After the bell has stopped spinning, turn off the main air supply. Actuate the paint valve trigger (PT) to purge the applicator. d. Provide air to the solvent line S. e. Actuate the solvent valve trigger (ST) to purge the cup wash solvent. 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 splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. 7. Disable the electrostatics and verify the voltage has been discharged. Complete Steps 2-4 of the Voltage Discharge and Grounding Procedure Non-Electrostatic Systems 1. Shut off the fluid and solvent supply. 2. Relieve the paint pressure. Actuate the dump valve trigger (DT) to relieve pressure in the paint and dump lines. If your system does not have a dump valve, actuate the paint valve trigger (PT). 3. Relieve solvent pressure. Actuate the solvent valve trigger (ST) to relieve pressure in the solvent line. 4. Turn off the turbine air and the shaping airs. Put the system in Off mode. 5. After the bell has stopped spinning, turn off the main air supply. Follow these basic steps in the order shown to relieve the system pressure. The exact procedure to accomplish each step may vary based on your system design. Be certain that all steps are completed. 334452J 45 Operation Voltage Discharge and Grounding Procedure NOTE: The Voltage Discharge and Grounding Procedure applies to all systems where electrostatics are used. It does not apply to Non-Electrostatic Systems. The system is charged with high voltage until the voltage is discharged. Contact with the charged components of the applicator will cause an electric shock. For Waterborne systems, contact with the charge fluid supply system also will cause an electric shock. To avoid an electric shock, follow this procedure • • • • before entering the spray area whenever you are instructed to discharge the voltage before cleaning or servicing the system equipment before opening the isolation enclosure for the isolated fluid supply. To avoid fire or explosion during the test, all spraying devices in the hazardous area must be turned off and ventilation fans in the hazardous area must be operating. Conduct the test only when no flammable vapors are present in the area (such as open solvent containers or fumes from spraying). NOTE: An accessory grounding rod, part No. 210084, is available to discharge any voltage remaining on a system component. 1. Turn off the electrostatics by pressing on the Electrostatic Controller, by using an Electrostatic Enable I/O signal, or by using CAN communication. Switching to Purge mode also will shut off the electrostatics. Wait the amount of time set for your system to discharge. To avoid fire or explosion or electric shock, always wait for the full discharge time to elapse. Once the electrostatics are turned off, the display no longer tracks or displays the actual voltage. Do not use the controller display to determine if the system is discharged. NOTE: The procedure to set the discharge timer is found in the directions for Setup Screen 10 in the Electrostatic Controller manual (3A3657). 2. Put the system in Off mode. 3. Disable the electrostatics by powering off the Electrostatic Controller (set to off). NOTE: Electrostatics also can be disabled by removing an interlock, if preferred. An error will occur. When the procedure is finished, clear error to restart. 4. Verify that the system has discharged. a. For solventborne systems: Touch the air cap cover (19) with a grounded rod to make sure the voltage has been discharged. If you see an arc, verify that the electrostatics are turned off. Increase the discharge time, or see Electrical Troubleshooting, page 58. The default discharge time is 5 seconds. Resolve the problem before proceeding. b. For waterborne systems: Discharge the voltage at the voltage isolation system by following the procedure specified in the voltage isolation system instruction manual. Touch the pump, supply pail, and applicator air cap cover with a grounded rod to make sure the voltage has been discharged. If you see an arc, verify that the electrostatics are turned off. Increase the discharge time, or see Electrical Troubleshooting, page 58, or the voltage isolation system manual for other possible problems. The default discharge time is 60 seconds. Resolve the problem before proceeding. 5. Test voltage discharge weekly. Shutdown 1. Flush if needed. See Flushing, page 44. 46 334452J Operation 2. Follow the Pressure Relief Procedure, page 45, which includes Voltage Discharge and Grounding. 3. Clean the cup and exterior of the applicator. See Clean the Air Cap and Cup, page 54. See also, Clean the Outside of the Rotary Applicator, page 55. 334452J 47 Maintenance Maintenance Check for Fluid Leakage 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. Contact with the charged components of the rotary applicator will cause an electric shock. Contact with a rotating cup also may cause injury. Do not touch the bell or come within 3 ft. (0.9 m) of the front of the applicator during operation. If any fluid leakage from the applicator is detected, stop spraying immediately. Fluid leakage could cause fire or explosion, and result in serious injury and property damage. During operation, periodically remove the shroud to check for the presence of fluid. See FIG. 18. for location of potential leaks. To reduce the risk of an injury, follow the Pressure Relief Procedure, page 45, which includes Voltage Discharge and Grounding, before checking or servicing any part of the system, and whenever you are instructed to relieve the pressure. Daily Care and Cleaning Checklist Check the following list daily when finished using the equipment. Flush the applicator. Check the fluid and air line filters. Clean the cup and the outside of the applicator. See pages 54-55. Inspect the rotary applicator and the cup for nicks, scratches, or excessive wear. Check for fluid leakage from the applicator and fluid hoses. 48 FIG. 18. Check for Fluid Leakage Fluid in these locations indicates leakage, which could be caused by the fluid tube connectors, manifold o-rings, or fluid valve leakage. If fluid is seen in any of these locations: 1. Stop spraying immediately. 2. Follow the Pressure Relief Procedure, page 45, which includes Voltage Discharge and Grounding. 3. Follow the Shutdown Procedure, page 46. 4. Remove the applicator for repair. 334452J Electrical Tests Electrical Tests Test Full Electrostatic Applicator with Power Supply Megohm meter Part No. 241079 (AA-see FIG. 19.) is not approved for use in a hazardous location. To reduce the risk of sparking, do not use the megohm meter to check electrical grounding unless: • • See FIG. 19. Measure resistance between the air cap cover and power supply connector pins P1 through P4. The applicator has been removed from the hazardous location; Or all spraying devices in the hazardous location are turned off, ventilation fans in the hazardous location 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, or electric shock, and result in serious injury and property damage. Electrical components inside the applicator affect performance and safety. The following procedures test electrical continuity between applicator components. Use megohm meter (AA) and an applied voltage of 500 V. Connect the leads as shown. NOTE: Follow the Flushing Procedure, page 44, and dry the fluid passages prior to performing electrical tests. 334452J Pin Acceptable Range P1 120-160 megohms P2 120-160 megohms P3 120-160 megohms P4 9.0-11.0 gigohms • If resistance is within this range, testing is complete. • If resistance is outside this range, test the power supply and the front housing separately. Test Non-Electrostatic Applicator with Ground Plug See FIG. 19. Use an ohmeter to measure the resistance between the edge of the air cap to the fluid bracket. The reading should be less than 10 ohms. 49 Electrical Tests Non-Electrostatic AA Electrostatic 28 P4 P1 FIG. 19. Full Applicator and Power Supply 50 334452J Electrical Tests Test Power Supply in Main Housing See FIG. 20. and FIG. 21. Spring loaded contact points 1a threaded ball contact 1. Remove front housing and turbine assembly. See Replace Front Housing and Turbine Assembly, page 66 for removal instructions if needed. 2. Measure resistance between the main housing contact (1a) and the power supply connector pins P1 through P4. Pin • • P1 Acceptable Range 120-160 MΩ P2 120-160 MΩ P3 120-160 MΩ P4 9.0-11.0 GΩ If resistance is within range, proceed with testing the front housing. If resistance is out of range, test the power supply resistance and inspect the threaded ball contact. FIG. 20. Rotary Applicator Electrical Path 1a NOTE: The spring plunger housing must be flush or no more than .01 inch below the main housing surface. 334452J 51 Electrical Tests AA 28 P4 P1 FIG. 21. Full Applicator and Power Supply 52 334452J Electrical Tests Test Power Supply Test Front Housing See FIG. 22. 1. Remove front housing. See Replace Front Housing and Turbine Assembly, page 66, for removal instructions, if needed. 1. Remove the power supply (28). See Repair the Power Supply, page 72. 2. Measure resistance from the power supply (P1-P4) to the spring (28a). • Pin Acceptable Range P1 120-160 megohms P2 120-160 megohms P3 120-160 megohms P4 9.0-11.0 gigohms 2. Measure resistance from the brass plug to the ball contact. 3. If resistance is less than 0.1 megohm, reassemble and retest the full applicator. Make sure spring loaded contacts are clean and making contact with the mating surface. Refer to FIG. 23. 4. If resistance is 0.1 megohm or greater, replace the front housing. If resistance is outside this range, replace the power supply. If resistance is within this range, reassemble the power supply in the main housing and retest. Make sure the power supply spring is making contact in the housing. • . AA 28a 28 FIG. 23. Front Housing Resistance P4 P1 FIG. 22. Power Supply Resistance 334452J 53 Electrical Tests Clean the Air Cap and Cup NOTICE Use only tool 25C438 (Ref. 21, 15 mm), tool 25C200 (Ref. 45, 30 mm or 50 mm), or your thumb to remove the splash plate. Other tools could damage the surface finish, taper connection, or threads, making the cup inoperable. Equipment Needed • • soft bristle brush compatible solvent 4. Reinstall the splash plate (20a). 1. Remove the cup. See Replace Cup or Air Cap, page 61. a. 15 mm cups: Use tool (21) to turn the splash plate clockwise to 20-25 in-lbs (2.3-2.8 N•m). 2. Soak the cup in a compatible solvent until paint is loose. Remove all paint with a soft bristle brush dipped in solvent. b. 30 mm and 50 mm cups: Use your thumb to press the splash plate (20a) back in. 3. If necessary, clean the splash plate (20a) separately for easier access. Make sure the center holes of the splash plate are clean. a. 15 mm cups: Use tool (21). Turn counter clockwise to remove the splash plate. b. 30 mm and 50 mm cups: Place the cup face down on a soft and non-abrasive surface. Press out the splash plate with the post end of the fluid valve tool (45). 30 mm and 50 mm 15 mm NOTICE Do not use the fluid valve tool (45) to install the splash plate. It might slip and damage the cup. 5. If the press fit of the splash plate feels loose, service the split ring (20b). If the press fit is too tight, verify alignment. Remove and re-align if necessary. 6. Rinse the cup and dry it. 7. Clean the air cap with the soft bristle brush and solvent, or submerge the air cap in a suitable solvent and wipe it clean. Do not use metal tools. 8. To maximize pattern control, clean the shaping air holes and the air cap cover. Be sure they are not blocked. Soak the parts in solvent and use compressed air to clear any plugged holes. 9. Inspect the parts for damage or excessive wear. Replace if needed. 10. Reassemble. See Replace Cup or Air Cap, page 61. FIG. 24. Remove Splash Plate 54 334452J Electrical Tests Clean the Fluid Nozzle Equipment Needed: • • soft bristle brush compatible solvent Clean the Outside of the Rotary Applicator NOTICE • Clean all parts with a non-conductive, compatible solvent. Conductive solvents can cause the applicator to malfunction. • Fluid in the air passages could cause the applicator to malfunction and could draw current and reduce the electrostatic effect. Whenever possible, point the applicator down when cleaning it. Do not use any cleaning method which could allow fluid into the air passages. NOTE: The nozzle is reverse threaded. 1. Follow all steps in Repair Fluid Nozzle, page 67. 2. Remove o-ring (8). 3. Soak the nozzle in a compatible solvent until paint is loose. Remove all paint with a soft bristle brush dipped in solvent. 4. Rinse the nozzle and dry it. 1. Follow the Pressure Relief Procedure, page 45, which includes Voltage Discharge and Grounding. 2. Make sure the bell has stopped spinning. Then, clean the outside surfaces with a damp solvent rag. Do not allow solvent to get into the bell passages. 3. Dry the exterior surfaces. 334452J 55 Troubleshooting Troubleshooting 1. Follow Prepare for Applicator Service, page 61, before checking or repairing the applicator. 2. Check all possible problems and causes before disassembling the applicator. 3. See additional troubleshooting in the System Logic Controller manual (3A3955). Spray Pattern Troubleshooting Problem Poor Spray Pattern Fluttering or spitting spray. Poor wrap. Cause Solution The cup (20) is damaged. Replace. The air cap cover (19) is not tight. Tighten. O-ring (16, 18c, or 18d) is missing. Replace. Splash plate (20a) is dirty or damaged. Clean or replace. Fluid flow rate is incorrect. Check fluid pressure. Check nozzle size (9). Shaping air holes are clogged. Disassemble and clean the air cap cover (19). The fluid supply is empty. Refill supply. Air is in the fluid supply. Check fluid source. Refill. See Electrical Troubleshooting, page 58. Applicator Operation Troubleshooting Problem Rotary applicator does not spray 56 Cause Solution Turbine (10) is not rotating. Be sure the bearing air pressure is at least 70 psig and the turbine air pressure is sufficient. Inspect the turbine bearing for damage. If still not rotating freely, reference Spindle Inspection and Cleaning Service Instructions, 3A4794. Fluid supply is low. Add fluid if necessary. Increase fluid pressure if needed. Paint valve (4) is not opening. Verify at least 70 psig air pressure to the paint trigger line. Clean or replace paint valve. The fluid tube (7) or nozzle (9) is clogged. Remove and clean, replace if necessary. 334452J Troubleshooting Problem Cause Rotary applicator will not stop spray- The paint (4) valve is stuck open. ing. Solution Turn off the paint trigger air. If still spraying, turn off fluid supply and clean or replace paint valve. A valve seat (3) is damaged or worn. Inspect, clean, or replace as needed. Cannot reach desired fluid flow rate Fluid pressure is insufficient. Increase. Fluid nozzle (9) orifice is too small. Replace with the next larger size nozzle. Fluid tube (7) or nozzle (9) is partially Remove and clean, replace if necesclogged. sary. Fluid leakage from the front of the rotary applicator Fluid valve (4) is loose. Remove and clean. Tighten. Nozzle (9) is loose on fluid tube (7). Remove and clean. Tighten. An o-ring (2, 8, or 60) is missing or damaged. Inspect and clean. Replace as needed. The fluid valve seat (3) is damaged or Inspect, clean, or replace as needed. worn. Fluid leakage from the dump valve. Excessive vibration Dump valve (4) is loose. Remove and clean. Tighten. The valve seat (3) is damaged or worn. Inspect, clean, or replace as needed. The cup (20) is dirty. Remove and clean any dried paint or other contaminant. Cup (20) is not fully secured on turbineshaft (10). Inspect and clean the threads on the cup and shaft. Retorque. The cup (20) is damaged. Remove, clean, and inspect. Replace as needed. Turbine (10) is rotating too fast (being Decrease turbine air pressure. supplied with too much air). Speed Sensor Error 334452J Repair or replace fiber-optic cable. The fiber-optic cable between the applicator and the speed controller is damaged or has surpassed the bend radius. The fiber-optic cable is not properly adjusted. Adjust the amount of fiber extending past the nut. The fiber-optic connector is loose. Reinstall and tighten. The magnetic speed pick-up sensor is not generating light. Replace 57 Troubleshooting Electrical Troubleshooting Problem Voltage is still present after following the Voltage Discharge and Grounding Procedure, page 46. Cause Bleed resistor is damaged. Solution Measure power supply resistance. An air pocket in the fluid line has isolated Determine cause and correct. Purge the fluid near the applicator (waterborne air from fluid line. models). The voltage isolation system failed (waterborne models) Service the voltage isolation system. Poor part grounding. See Step 9. Ground the Equipment, page 38. The distance from applicator to part is incorrect. Should be 9-14 in. (23-36 cm) The shaping air is insufficient. Verify that shaping air is on. Increase setpoint if necessary. Operator is not grounded or is near an ungrounded object. See Step 9. Ground the Equipment, page 38. Applicator is not grounded. See Step 9. Ground the Equipment, page 38. Operator got too close to the applicator before the discharge time had elapsed. Wait for the full discharge time to elapse. Check power supply resistance - Pin 4. Increase discharge timer setting, if needed. Electrostatics are missing or voltage is insufficient. Turn ON at the Electrostatic Controller. Adjust and monitor as needed. Parts are insufficiently grounded. Properly ground so the electrical resistance between the part and ground is 1 megohm or lower. Shaping air pressure is too high. Decrease the shaping air (inner and outer) setpoints. Distance from applicator to part is incorrect. Should be 9-14 in. (23-36 cm). Fluid resistivity is low. See Operation, page 41. Electrostatic Controller won’t go over 60 kV. The controller is designed for use with a waterborne system. Purchase a controller designed for use with a solventborne system. The electrostatics are on, but there is no electrostatic effect from the applicator. There is an error in the system (indicated Refer to the Electrostatic Controller by an error code on the Electrostatic Manual (3A3657) to determine and Controller). address the cause. Excessive paint is wrapping back. Operator gets mild shock. Paint wraps poorly on parts. One or more parts have malfunctioned or Complete the Electrical Tests startneed service. ing on page 49. Replace any out-of-specification parts. Retest. The power supply cable is damaged. Test the power supply cable for continuity. See the Electrostatic Controller Manual (3A3657). Waterborne Systems: See Waterborne System Voltage Loss Troubleshooting, page 59, for possible causes and solutions. 58 334452J Troubleshooting Waterborne System Voltage Loss Troubleshooting Normal spraying voltage for a system using the waterborne applicator is 40-55 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 applicator, fluid hoses, or voltage isolation system, since all of the system components are electrically connected through the conductive, waterborne fluid. 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: Applicator • Fluid leakage • Dielectric breakdown at the fluid hose connections. • Faulty power supply • Excessive over spray on applicator surfaces • Fluid in the air passages Waterborne Fluid Hose • Dielectric failure of the hose (pin-hole leak in the PTFE layer) Voltage Isolation System • Fluid leakage • Dielectric breakdown of hoses, seals, or connections • Isolators not functioning properly Visual Checks First, check the system for any visible faults or errors to help isolate whether the applicator, fluid hose or voltage isolation system has failed. 1. Check that all of the air and fluid tubes and hoses are properly connected. Make sure the waterborne hoses are secured at the proper height at the strain relief. 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 voltage isolation system has sufficient air pressure. 5. Check that the electrostatics are turned on. 6. Check that the voltage isolation system's enclosure door is closed and that any safety interlocks are engaged and working properly. 7. Make sure the voltage isolation system is isolating the fluid voltage from ground. 8. To eliminate air gaps in the fluid column, spray enough fluid to purge the air out between the voltage isolation system and the applicator. An air gap in the fluid hose can break the electrical continuity between the applicator and the isolated fluid supply and cause a low voltage reading at the isolation system. 9. Check the outside of the applicator for accumulated overspray. Excessive overspray can create a conductive path back to a ground. Clean the exterior of the applicator. 10. Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found. Pay special attention to the following areas: • • • 334452J Applicator fluid valves Fluid hose: check for leakage or any bulges in the outer cover, which may indicate an internal leak. Internal voltage isolation system components 59 Troubleshooting Tests 8. Using the controller, turn on the electrostatics to the applicator. Observe the voltage and current level on the controller. If you still have no voltage, separate the applicator and fluid hoses from the voltage isolation system and check whether the applicator and hoses alone will hold voltage with the following test. 9. If the voltage is 40-55 kV, the applicator power supply is okay, and there is probably a dielectric breakdown somewhere in the fluid hoses or applicator. Continue with step 10. 1. Flush the system with water and leave the lines filled with water. If the voltage is below 40 kV, do the Electrical Troubleshooting, page 58, to check the applicator and power supply resistance. If those tests show the applicator and power supply are okay, continue with step 10. 2. Discharge the system voltage (see the Pressure Relief Procedure, page 45, which includes Voltage Discharge and Grounding). 10. A dielectric breakdown is most likely in one of the following three areas. Repair or replace the component that is failing. 3. Disconnect the fluid hoses from the voltage isolation system. Avoid allowing any water to leak out of the fluid hose(s) as that could cause a significant air gap in the fluid column up to the cup, which can break the conductivity path and conceal a potential failure area. 4. Position the end of the hose(s) 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. NOTE: The conductive layer of the hose must remain grounded. 5. Using the controller, turn on the electrostatics to the applicator. Observe the voltage and current level on the controller. • • If the voltage is 40 to 55 kV, the applicator and fluid hose are okay, and the problem is in the voltage isolation system. If the spraying voltage is below 40 kV, the problem is in the applicator or fluid hoses. a. Fluid hoses: • • • Check each hose for leakage or any bulges in the outer cover, which may indicate a pin-hole leak through the PTFE layer. Disconnect the fluid hoses from the applicator, and look for signs of fluid contamination on the outside of the PTFE portion of the fluid tube. Inspect the end of each hose connected to the voltage isolation system. Look for cuts or nicks. Make sure each hose is properly stripped (see Waterborne Systems, page 26). Re-strip or replace the hose. b. Fluid hose connection to the applicator: • A breakdown at the fluid hose connection joint is caused by fluid leaking past the fitting on the end of the hose. 11. Clean and dry the fluid tubes, then reassemble the applicator. 12. Reconnect the fluid hoses. Check the voltage before filling the applicator with fluid. 6. Discharge the system voltage (see Voltage Discharge and Grounding Procedure, page 45). 7. Flush the fluid hoses and applicator with enough air to dry out the fluid passages. 60 334452J Repair Repair Prepare for Applicator Service 1. Flush the fluid lines. 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. Contact with the charged components of the rotary applicator will cause an electric shock. Contact with a rotating cup also may cause injury. Do not touch the bell or come within 3 ft. (0.9 m) of the front of the applicator during operation. To reduce the risk of an injury, follow the Pressure Relief Procedure, page 45, which includes Voltage Discharge and Grounding, before checking or servicing any part of the system, and whenever you are instructed to relieve the pressure. 2. Follow the Pressure Relief Procedure, page 45, which includes Voltage Discharge and Grounding. 3. Screw off the manifold retaining ring (35) by hand. The adapter cover (34) will come with it. 4. Slide the shroud (33) off the back of the housing (1). 5. Disconnect all fluid, air, power, and communication lines. 6. Clean the applicator. See Daily Care and Cleaning Checklist, page 48. 7. Remove the bell applicator from the mounting. Perform service or repair at a work bench. NOTES: Replace Cup or Air Cap • Check all possible remedies in Troubleshooting before disassembling the applicator. • Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate. Use this section for a quick, on-line replacement of a damaged or worn cup. Cup replacement kits are available. • Only use genuine Graco parts. Prepare for Cup or Air Cap Service 15 mm or 30 mm Cup 1. Prepare for Cup or Air Cap Service, page 61. 2. Use the small end of the spanner wrench tool (44) to remove the air cap cover (19). 1. Follow the Pressure Relief Procedure, page 45, which includes Voltage Discharge and Grounding. 2. Clean the applicator. See Daily Care and Cleaning Checklist, page 48. 44 334452J 61 Repair 3. Remove the air cap (18). 50 mm Cup 4. Use the spanner wrench tool (44) to hold the turbine shaft, then screw off the cup (20). 1. Prepare for Cup or Air Cap Service, page 61. 2. Use the small end of the spanner wrench tool (44) to remove the air cap cover (19). 44 5. Hold the turbine shaft with the spanner wrench tool (44), and install the new cup (20) hand tight. Make sure that the mating tapers are fully seated. Install the air cap (18). 44 3. To hold the shaft steady, insert the fluid valve tool (45) into the rectangular opening on the air cap (18). To lock rotation, slowly rotate the cup until the tool engages the hole in the shaft. Then, screw off the cup (20). 44 6. Use the small end of the spanner wrench tool (44) to install the air cap cover (19). 45 4. Remove air cap (18). Inspect parts for damage and replace as needed. Reinstall the air cap (18) or install a new one. 44 19 62 334452J Repair 5. Start threading the new cup (20). Insert the fluid valve tool into the rectangular opening on the air cap (18). Slowly rotate the cup until the tool engages the hole in the shaft. Then, tighten the cup (20) until the mating tapers are fully seated. Service the Cup and Air Cap Use this section to remove your cup and air cap and fully disassemble each piece for cleaning or to replace any worn or damaged parts. NOTICE Use only tool 25C438 (Ref. 21, 15 mm), tool 25C200 (Ref. 45, 30 mm or 50 mm), or your thumb to remove the splash plate. Other tools could damage the surface finish, taper connection, or threads, making the cup inoperable. NOTICE 45 6. Use the spanner wrench tool (44) to install the air cap cover (19). Do not use the fluid valve tool (45) to install the splash plate. It might slip and damage the cup. 15 mm Cup 1. Prepare for Applicator Service, page 61. 2. Remove the air cap cover (19), cup (20) and air cap (18). See page 61. 44 334452J 3. Use tool (21). Turn counter-clockwise to remove the splash plate from the cup. Clean parts and inspect for damage. Replace parts as needed. 63 Repair 4. Use tool (21) to reinstall the splash plate (20a). Turn the splash plate clockwise to 20-25 in-lbs (2.3-2.8 N•m). 5. Grease the solvent stud o-ring (18c) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See page 61. 30 mm Cup 1. Prepare for Applicator Service, page 61. 2. Remove the air cap cover (19), cup (20) and air cap (18). See page 61. 3. Use the fluid valve tool (45) to push the splash plate (20a) out of the cup. Remove the split ring (20b). Clean all parts and inspect for damage. Replace parts as needed. 15 mm or 30 mm Air Cap 1. Prepare for Applicator Service, page 61. 2. Remove the air cap cover (19), cup (20) and air cap (18). See page 61. 3. Remove the solvent stud o-ring (60). Remove the solvent stud (59) only if you are experiencing a problem and need to replace it. 4. Remove the outer air cap (18b). Remove the o-ring (18c) from the inner air cap (18a). Clean all parts and inspect for damage. Replace parts as needed. 60 1 15 mm cup 59 18a 18c 1 18b 60 30 mm cup 1 59 18a 18c 1 18b 20 20b 20a 1 Apply lubricant. 5. Install the o-ring (60) on the solvent stud (59). 4. Install split ring (20b) on the splash plate (20a). Place the splash plate into the cup. Push in with your thumb until it is fully seated. 6. Install the o-ring (18c) on the inner air cap (18a), then fit the inner (18a) and outer (18b) air caps together. 5. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See page 61. 7. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See page 61. 64 334452J Repair 50 mm Cup 1. Prepare for Applicator Service, page 61. 2. Remove the air cap cover (19), cup (20), and air cap (18). See page 62. 3. Slide off the air cap (18). Remove the outer air cap (18b). Remove o-rings (18c, 18d). Remove the solvent stud o-ring (60). Remove the solvent stud (59) only if you are experiencing a problem and need to replace it. Clean all parts and inspect for damage. Replace parts as needed. 3. Use the fluid valve tool (45) to push the splash plate (20a) out of the cup. Remove split ring (20b). Clean all parts and inspect for damage. Replace parts as needed. 1 60 59 18a 18d 1 18c 18b 1 Apply lubricant. 4. Install the o-ring (60) on the solvent stud (59). 5. Install o-rings (18c and 18d) on the inner air cap (18a), then fit the inner (18a) and outer (18b) air caps together. 6. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See page 62. 4. Install the split ring (20b) on the splash plate (20a). Place the splash plate into the cup. Push in with your finger until it is fully seated. 5. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See page 62. 50 mm Air Cap 1. Prepare for Applicator Service, page 61. 2. Remove the air cap cover (19) and cup (20). See page 62. 334452J 65 Repair Replace Front Housing and Turbine Assembly 8. Clean all parts and inspect for damage. Replace parts as needed. 1. Prepare for Applicator Service, page 61. 1 Lubricate o-rings. 2. Remove the air cap cover (19), cup (20) and air cap (18). See 15 mm or 30 mm Cup, page 61, or 50 mm Cup, page 62. 3. Use the larger end of the spanner wrench tool (44) to remove the retaining ring (15). 1 1 44 4. Remove the front housing (13), which includes the turbine assembly (10). 5. Place the threaded end of the turbine assembly (10) on a padded bench. Press down on the housing (13) to separate the housing and the turbine assembly. NOTICE Be careful not to damage the threads when removing the turbine assembly from the front housing. 9. Install o-rings (11, 12, 14, and 17) on the front housing (13). Lubricate and install o-ring (16). 10. Install o-rings (10a, 10b, and 10c) on the turbine assembly (10). 11. Install the turbine assembly (10) into the front housing (13). 12. Grease the solvent stud o-ring (60). Use the solvent stud and the pins to align the front housing (13) with the main housing (1), then install the front housing. 13. Install the retaining ring (15). Use the larger end of the spanner wrench tool (44) to tighten it. 6. Remove the o-rings (11, 12, 14, 16, and 17) from the front housing. 7. Remove the o-rings (10a, 10b, and 10c) from the turbine assembly (10). 44 14. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See 15 mm or 30 mm Cup, page 61, or 50 mm Cup, page 62. 66 334452J Repair Repair or Replace the Solvent Stud The applicator has two solvent studs (59). One is on the main housing (1) and the other is on the air cap (18). 5. Use the middle hexagon on the spanner wrench tool (44) to remove the fluid nozzle (9). NOTE: The nozzle is reverse threaded. 1. Prepare for Cup or Air Cap Service, page 61. 2. Remove the air cap cover (19), cup (20), air cap (18), retaining ring (15), turbine (10) and front housing (13). 3. Use a 1/4 in. hex wrench to remove the solvent stud (59) from the main housing (1) or the air cap (18). Remove the o-rings (60). One of the solvent stud o-rings probably will remain in the opening when the solvent stud is removed. 4. Install the o-rings (60) on the solvent stud (59). Lubricate the o-rings and tighten the solvent stud into the main housing (1) or the air cap (18). Tip: You may find it easier to lubricate the bottom o-ring and install it in the hole. 5. Install the front housing (13, including turbine assembly, 10) and retaining ring (15). See steps12-13, page 66. 44 6. Inspect o-ring (8) and remove if damaged. 7. Install a new o-ring (8) on the nozzle (9). 8. Hold the fluid tube with a wrench. Use the middle hexagon on the spanner wrench to tighten the fluid nozzle. Torque to 58-62 in-lb (6.5-7.0 N•m). 1 Torque to 58-62 in-lb 6. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See 15 mm or 30 mm Cup, page 61, or 50 mm Cup, page 62. (6.5-7.0 N•m) Repair Fluid Nozzle 1 1. Prepare for Cup or Air Cap Service, page 61. 2. Flush the fluid lines. 44 3. Follow the Pressure Relief Procedure, page 45. 4. Remove the air cap cover (19), cup (20), air cap (18), retaining ring (15) and front housing (13). 9. Install the front housing (13, including turbine assembly, 10) and retaining ring (15). See steps12-13, page 66. 10. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See 15 mm or 30 mm Cup, page 61, or 50 mm Cup, page 62. 334452J 67 Repair Repair or Replace the Fluid Tube 1. Prepare for Cup or Air Cap Service, page 61. 2. Flush the fluid lines. 3. Follow the Pressure Relief Procedure, page 45, which includes Voltage Discharge and Grounding. 4. If not already disassembled, remove the air cap cover (19), cup (20), air cap (18), retaining ring (15) front housing (13), and fluid nozzle (9). 8. Screw in a new fluid tube hand tight, then use a 12 mm wrench to tighten. Torque to 78-82 in-lb (8.8-9.3 N•m). 1 Torque to 78-82 in-lb (8.8-9.3 N•m) 1 5. Use a 12 mm wrench to remove the fluid tube (7). 9. Install the front housing (13, including turbine assembly, 10) and retaining ring (15). See steps12-13, page 66. 10. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See 15 mm or 30 mm Cup, page 61, or 50 mm Cup, page 62. 6. Inspect o-rings (7a, 7b) and remove if damaged. 7. Lightly grease and install new o-rings (7a, 7b) on the fluid tube. Replace Magnetic Pickup Sensor or Fiber Optic Extension Cable 1. Prepare for Applicator Service, page 61. 2. Remove the air cap cover (19), cup (20), air cap (18), retaining ring (15) and front housing (13). 3. Screw off the manifold retaining ring (35) by hand. The adapter cover (34) will come with it. 4. Slide the shroud (33) off the back of the housing (1). 68 334452J Repair 11. At the front of the rear manifold, install the fiber optic extension cable (22) and tighten the connector. 22 5. Loosen the connector of the fiber optic extension cable (22) at the rear manifold. 6. At the front of the main housing, use a 3/32 inch hex wrench to remove screw (6). 7. Pull the sensor (5) out of the main housing (1). The fiber optic extension cable (22) comes with it. 8. Install the new magnetic pickup sensor (5) and/or the new fiber optic extension cable (22). Line up the flat cut with the hole for the screw. ti29024a 12. Install the front housing (13, including turbine assembly, 10) and retaining ring (15). See steps 12-13, page 66. 13. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See 15 mm or 30 mm Cup, page 61, or 50 mm Cup, page 62. 9. Use a 3/32 inch hex wrench to tighten the screw (6). Torque to 18-22 in-lb (2.0-2.5 N•m). 1 Torque to 18-22 in-lb (2.0-2.5 N•m) 22 5 6 1 10. Verify the amount of fiber extending past the nut is 0.11 in. (2.8 mm). 7.4 in. (18.8 cm) 2X 0.11 in. (2.8 mm) 334452J 22b 22a 69 Repair Repair Fluid Valves and Seats 1 Torque to 9-11 in-lb (1.0-1.2 N•m). 2 Torque to 35-40 in-lb (4.0-4.5 N•m). 3 Lubricate the o-ring. 1. Prepare for Applicator Service, page 61. 2. Flush the fluid lines. 3. Follow the Pressure Relief Procedure, page 45, which includes Voltage Discharge and Grounding. 4. Remove the manifold retaining ring (35), the adapter cover (34), and the shroud (33). 5. Put the 4-prong end of the fluid valve tool (45) into the recessed holes on the fluid valve (4). 3 1 2 9. Lubricate the o-ring (2). 10. Install the new seat (3), with the o-ring side down. 11. Use a 5/16 hex wrench to tighten the seat. Torque seat to 9-11 in-lb (1.0-1.2 N•m). 12. Install o-rings (4a and 4b) on the fluid valve. 6. Use the large center hex of the spanner wrench tool (44) to remove the fluid valve (4). Remove the outer o-rings (4a and 4b) from the fluid valve. One o-ring (4b) may have remained in the housing. Inspect o-rings and replace if damaged. 7. Use a 5/16 hex wrench to remove the seat (3). Remove the o-ring (2). 8. Inspect o-ring (2) and replace if damaged. 70 13. Lubricate the outside surfaces of the fluid valve. Avoid getting lubricant in the fluid path. Screw in the fluid valve, hand tight. 14. Put the 4-prong end of the fluid valve tool (45) into the recessed holes on the fluid valve (4). 15. Use the large center hex of the spanner wrench tool (44) to tighten the fluid valve (4). Torque to 35-40 in-lb (4.0-4.5 N•m). 16. Reinstall the shroud (33), the adapter cover (34) and the manifold retaining ring (35). 334452J Repair Repair Fluid Tube Fittings or Coiled Fluid Tubes 9. Insert the coiled fluid tubes into the fittings (32d, 32f, 25, 61) on the fluid bracket (32a) and main housing (1). Be sure both ferrules are in place as shown. Use a 9/16 or 1/2 in. wrench to tighten the nut on the new fitting. 1. Prepare for Applicator Service, page 61. 2. Use a 3/16 in. hex wrench to remove the 2 screws (42), that hold the fluid bracket (32). 3. Loosen the connector on the rear manifold and disconnect the fiber optic extension cable (22). 4. Use a 1/4 in. hex wrench to remove 3 tie rod screws (31), then remove the rear manifold (30). 10. Install the tie rods (29). Torque to 30-35 in-lb (3.4-4.0 N•m). 5. Use a 1/2 in. wrench to remove the tie rods (29). 6. Use a 9/16 or 1/2 in. wrench to loosen the nuts on the fluid fittings (25, 61). Disconnect the coiled fluid tubes (27, 62) from the fittings on the main housing (1). Note: Be careful not to lose the ferrules. 11. Use 3 screws (31) to reattach the rear manifold (30). Torque to 30-35 in-lb (3.4-4.0 N•m). 12. Use 2 screws (42) to reattach the fluid bracket (32). Torque to 30-35 in-lb (3.4-4.0 N•m). 7. Remove the coiled fluid tubes (27, 62) from the fittings on the fluid grounding bracket (32a), then remove the bracket. 13. Reattach the fiber optic extension cable (22) on the rear manifold (30). 8. Use a 1/2 in. wrench to remove the fittings (32d, 32e) and a 7/16 in. wrench to remove fitting 32f from the fluid grounding bracket (32a), as needed. Install new fittings. Add thread sealant and torque to 18-22 in-lb. (2.0-2.5 N•m). 1 Torque to 18-22 in-lb (2.0-2.5 N•m). 2 Torque to 30-35 in-lb (3.4-4.0 N•m). 3 Lubricate o-rings. 4 Apply dielectric grease to housing end. 14. Pass all hoses and cables through the shroud (33), the adapter cover (34) and the manifold retaining ring (35), then reconnect them to the applicator. 15. Reinstall the shroud (33), the adapter cover (34) and the manifold retaining ring (35). 1 1 2 61 29 62 27 2 1 2 1 2 31 25 1 32f 32a,b,c 28 3 4 32d 42 32d 1 30 32e 1 334452J 71 Repair Repair the Power Supply Replace an Air Tube Fitting 1. Prepare for Applicator Service, page 61. 1. Prepare for Applicator Service, page 61. 2. Use a 1/4 in. hex wrench to remove the three screws (31). 2. Remove the rear manifold (30). 3. Loosen the connector on the rear manifold and disconnect the fiber optic extension cable (22). 4. Pull the rear manifold (30) off of the tie rods. NOTE: If the hose bundle is still attached, maneuver the manifold off to side, away from the power supply (28). 3. NOTE: If the hose bundle is still attached, maneuver the manifold off to the side. Remove other parts as needed for access. 4. Inspect all air fittings (23, 24). Pry out to remove, if needed. Replace fittings and o-rings (38, 39) as required. 5. Align and reattach the rear manifold (30). 5. Unscrew the power supply (28) by hand and remove from the housing. Inspect the spring (28a) and o-ring (28b) on front of the power supply (28) for damage. Replace if needed. 6. Use a 1/4 in. hex wrench to tighten the tie rod screws (31). Do not overtighten. 6. Test Power Supply, page 53, resistance. 7. To reinstall, use dielectric grease to fill the concentric rings on the housing end of the new power supply (28). Lubricate the outer o-ring. 5X 39 5X 23 8. Tighten the power supply securely in place by hand. Be sure it is fully seated. 9. Test Full Electrostatic Applicator with Power Supply, page 49. 10. Align and reattach the rear manifold (30). 11. Use a 1/4 in. hex wrench to tighten the tie rod screws (31). Do not overtighten. 12. Reattach the fiber optic extension cable (22) on the rear manifold (30). 13. Pass all hoses and cables through the shroud (33), the adapter cover (34) and the manifold retaining ring (35), then reconnect them to the applicator. 14. Reinstall the shroud (33), the adapter cover (34) and the manifold retaining ring (35). 72 4X 24 4X 38 7. Pass all hoses and cables through the shroud (33), the adapter cover (34) and the manifold retaining ring (35), then reconnect them to the applicator. 8. Reinstall the shroud (33), the adapter cover (34) and the manifold retaining ring (35). 334452J Parts Parts Solventborne Models (R_A1_0) 334452J 73 Parts Parts for Solventborne Models (R_A1_0) 6 Ref. 1† 1a 2† 3† Part HOUSING, main, assembly SPRING, plunger contact O-RING, FX75 SEAT, fluid valve; includes o-ring (Ref. 2) 4† 25C243 VALVE, fluid; includes o-rings (Refs. 4a, 4b) and seat (Ref. 3) 4a† 117610 O-RING, FX75 4b† 120775 O-RING, FX75 5 25C279 SENSOR, magnetic; includes screw (Ref. 6) 6 GC0612 SCREW, button head, #8-32 x 0.25 7 25C280 FLUID TUBE, assembly; includes o-rings (Refs. 7a and 7b) 7a 120776 O-RING, FX75 7b 111516 O-RING, FX75 8 17B390 O-RING, FX75 9 NOZZLE, fluid; includes o-ring (Ref. 8) 25C206 0.75 mm. (0.03 in); for R_A13_ models 25C207 1 mm. (0.04 in); for R_A14_models 25C208 1.25 mm (0.05 in); or R_A15_ models 25C209 1.5 mm (0.06 in); for R_A16_ models 26A524 1.8 mm (0.07 in) 26A525 2.0 mm (0.08 in) 10 24W988 TURBINE, assembly; includes o-rings (10a-10c) 10a 17D878 O-RING, FX75 10b 17B495 O-RING, FX75 10c 17D877 O-RING, FX75 11 GC1936 O-RING, FX75 12 17D879 O-RING, FX75 13 25C281 HOUSING, front; includes o-rings (Refs. 11, 12, 14,16, 17) 14 111516 O-RING, FX75 15 25C218 RING, retaining 16 17B495 O-RING, FX75 17 125249 O-RING, FX75 18 AIR CAP, assembly; includes solvent stud (59) and o-ring (60) 24Z989 for R1A1_ _ models (15 mm); includes Refs. 18a-18c 25C220 for R3A1_ _ models (30 mm); includes Refs. 18a-18c 25C221 for R5A1_ _ models (50 mm); includes Refs. 18a-18d 18a ----AIR CAP, inner 18b ----AIR CAP, outer 74 ----25D453 127316 25C242 Description Qty 1 1 3 3 3 6 3 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 Ref. 18c Part Description Qty O-RING 17D877 O-RING - 30 mm 17S113 O-RING - 15mm 18d 17B494 O-RING 19 COVER, air cap 24Z985 for R1A1_ _ models (15 mm) 25C223 for R3A1_ _ models (30 mm) 25C224 for R5A1_ _ models (50 mm) 20 CUP, aluminum, serrated, includes splash plate (Ref. 20a); see Cup Selection Charts, page 83, for available cups 24Z088 for R1A1_0 models (15 mm); includes tool (Ref. 21) 24Z079 for R3A1_0 models (30 mm) 24Z084 for R5A1_0 models (50 mm) 20a PLATE, splash 25D455 for R1A1_0 models (15 mm); includes o-ring (Ref. 20c) 25C214 for R3A1_0 and R5A1_0 models; (30 mm and 50 mm) includes split ring (Ref. 20b) 20b 17A653 RING, split 20c 17B390 O-RING, FX75 21 25C438 TOOL, 15 mm splash plate (Not Shown) 22 25C315 CABLE, extension, fiber optic; includes nuts (22a) and fittings (22b) 22a ----NUT, fiber optic - see kit 24W872 22b ----FITTING, fiber optic - see kit 24W872 23† ----RETAINER, tubing, 5/16 in. 24† ----RETAINER, tubing, 5/32 in. 25† 111157 FITTING, tube, 1/4 in. with 1/8 in. npt threads 27 25C227 TUBE, coiled, 1/4 in. 28 25A692 POWER SUPPLY; includes spring (Ref. 28a) and o-ring (Ref. 28b) 28a 24Y773 SPRING 28b 16D531 O-RING, FX75 29 25C229 ROD, TIE 30 25C282 MANIFOLD, rear; includes bracket (Ref. 32) and screws (Ref. 42) 31 104035 SCREW, cap, socket head, 5/16-18 x 1 in. 32 25M454 BRACKET ASSEMBLY, fluid, grounding, includes 32a-32e 32a ----BRACKET 32b ----FITTING, fluid, 5/8-18 UNF-2A 32c ----NUT, 5/8-18 UNF-2B 32d 111157 FITTING, tube, 1/4 in. with 1/8 in. npt threads; included in Kit 25C225, page 82 1 1 1 1 1 1 1 1 2 2 5 4 1 1 1 1 1 3 1 3 1 1 3 3 4 334452J Parts Ref. Part Description 32e 17K719 33 34 35 36 25C216 17B385 17B386 25C284 37 38† 39† 41 42 17B496 17L763 17L764 223547 101682 59† 25C283 FITTING, tube, 5/16 in. with 1/8 in. npt threads; included in Kit 25C225, page 82 COVER, shroud COVER, adapter RING, retaining, manifold BRACKET, mounting; includes screws (Ref. 37) SCREW, socket head, 3/8-16 x 0.5 in. O-RING, FX75 O-RING, FX75 WIRE ASSEMBLY, Ground, 25 ft. SCREW, cap, socket head, 1/4-20 x 0.625 in. STUD, solvent; includes o-rings (Ref. 60) O-RING, FX75 COVER, gun; not shown, (Kit 24Z177, qty. 10) SIGN, warning TAG, warning TOOL, spanner wrench TOOL, fluid valve TOOL, Allen wrench, 5/16 in. TOOL, Allen wrench, 1/4 in. TOOL, Allen wrench, 3/16 in. TOOL, Allen wrench, 3/32 in. TOOL, Allen wrench 5/32” TOOL, Allen wrench 5/64” TOOL, Allen wrench 7/32” TOOL, Allen wrench TUBE, grease, dielectric 60† 112319 65 ----66 67 68 69‡ 70‡ 71‡ 72‡ 73‡* 74‡* 75‡* 76‡* 77‡* 78‡ 17L835 179791 25C199 25C200 --------------------------------116553 Qty 2 1 1 1 1 4 4 5 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 † Parts are included in Main Housing Kit 25C257. See also O-Ring Kits 25C210, 25C212, and 25C213. Parts are included in Air Fitting Quick Connect Kit 25C226. Replacement Danger and Warning labels, tags, and cards are available at no cost. ‡ Parts are included in Tool Kit 25C198. (Not Shown) * Only used on Hollow Wrist models. 334452J 75 Parts Waterborne Models (R_A1_8) 76 334452J Parts Parts for Waterborne Models (R_A1_8) Ref. Part 1† 1a 2† 3† ----25D453 127316 25C242 Description HOUSING, main, assembly SPRING, plunger contact O-RING, FX75 SEAT, fluid valve, includes o-ring (Ref. 2) 4† 25C243 VALVE, fluid, includes seat (Ref. 3) 4a† 117610 O-RING, FX75 4b† 120775 O-RING, FX75 5 25C279 SENSOR, magnetic; includes screw (Ref. 6) 6 GC0612 SCREW, button head, #8-32 x 0.25 7 25C280 FLUID TUBE, assembly; includes o-rings (Refs. 7a and 7b) 7a 120776 O-RING, FX75 7b 111516 O-RING, FX75 8 17B390 O-RING, FX75 9 NOZZLE, fluid; includes o-ring (Ref. 8) 25C206 0.75 mm. (0.03 in.); for R_A13_ models 25C207 1 mm. (0.04 in.); for R_A14_models 25C208 1.25 mm (0.05 in.); or R_A15_ models 25C209 1.5 mm (0.06 in.); for R_A16_ models 26A524 1.8 mm (0.07 in.) 26A525 2.0 mm (0.08 in.) 10 24W988 TURBINE, assembly; includes o-rings (10a-10c) 10a 17D878 O-RING, FX75 10b 17B495 O-RING, FX75 10c 17D877 O-RING, FX75 11 GC1936 O-RING, FX75 12 17D879 O-RING, FX75 13 25C281 HOUSING, front; includes o-rings (Refs. 11, 12, 14, 16, 17) 14 111516 O-RING, 0.35 in. (9 mm) OD 15 25C218 RING, retaining 16 17B495 O-RING, FX75 17 125249 O-RING, FX75 18 AIR CAP, assembly; includes solvent stud (59) and o-ring (60) 24Z989 for R1A1_ _ models (15 mm); includes Refs. 18a-18c 25C220 for R3A1_ _ models (30 mm); includes Refs. 18a-18c 25C221 for R5A1_ _ models (50 mm); includes Refs. 18a-18d 18a ----AIR CAP, inner 18b ----AIR CAP, outer 334452J Qty 1 1 3 3 3 6 3 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 Ref. Part 18c Description O-RING O-RING - 30 mm O-RING - 15mm O-RING COVER, air cap for R1A1_ _ models (15 mm) for R3A1_ _ models (30 mm) for R5A1_ _ models (50 mm) CUP, balanced, standard, serrated, includes splash plate (Ref. 20a); see Cup Selection Charts, page 83, for available cups 24Z088 for R1A1_ _ models (15 mm); includes tool (Ref. 21) 24Z079 for R3A1_ _ models (30 mm) 24Z084 for R5A1_ _ models (50 mm) 20a PLATE, splash 25D455 for R1A1_ _models (15 mm); includes o-ring (Ref. 20c) 25C214 for R3A1_ _and R5A1_ _ models (30 mm and 50 mm); includes split ring (Ref. 20b) 20b 17A653 RING, split 20c 17B390 O-RING, FX75 21 25C438 TOOL, 15 mm splash plate 22 25C315 CABLE, extension, fiber optic; includes nut (Ref. 22a) and fitting (Ref. 22b) 22a ----NUT, fiber optic 22b ----FITTING, fiber optic 23† ----RETAINER, tubing, 5/16 in. 24† ----RETAINER, tubing, 5/32 in. 25† 18A999 FITTING, tube, 3/16 in. with 1/8 in. npt threads 27 25P659 TUBE, coiled, 3/16 in. 28 25A692 POWER SUPPLY; includes 28a and 28b 28a 24Y773 SPRING 28b 16D531 O-RING, FX75 29 25C229 ROD, TIE 30 25M453 MANIFOLD, rear; includes screws (Ref. 31) and bracket (Ref. 32) 31 104035 SCREW, cap, socket head, 5/16 x 1 in. 32 25M455 BRACKET ASSEMBLY, fluid, grounding; includes 32a-32h, 42 32a ----BRACKET 32b ----FITTING, fluid, 5/8-18 UNF-2A 32c ----NUT, 5/8-18 UNF-2B 32d 111157 FITTING, tube, 1/4 in. with 1/8 in. npt threads; included in Kit 25C300, page 82 17D877 17S113 18d 17B494 19 24Z985 25C223 25C224 20 Qty 1 1 1 1 1 1 1 1 1 2 2 5 4 1 1 1 1 1 3 1 3 1 1 1 3 1 77 Parts Ref. 32e Part Description Qty ----- FITTING, strain relief; included in Kit 25C300, page 82 32f 17L670 FERRULE; included in Kit 25C300, page 82 32g 17L671 NUT, 5/8-18 UNF-2B; included in Kit 25C300, page 82 32h 18A999 FITTING, tube 3/16 with 1/8 in. npt threads; included in Kit 25C300, page 82 33 25C216 COVER, shroud 34 17B385 COVER, adapter 35 17B386 RING, retaining, manifold 36 25C284 BRACKET, mounting; includes screws (Ref. 37) 37 17B496 SCREW, socket head, 3/8-16 x 0.5in. 38† 17L763 O-RING, FX75 39† 17L764 O-RING, FX75 40† 17L617 FITTING, tube, 3/8 in. with 1/8 in. npt threads 41 223547 WIRE ASSEMBLY, ground, 25 ft. 42 101682 SCREW, cap, socket head, 1/4-20 x 0.625 in. ----COVER, gun; not shown, (Kit 24Z177, qty. 10) 17L836 SIGN, warning ‡ 25C199 TOOL, spanner wrench ‡ 25C200 TOOL, fluid valve ‡ ----TOOL, Allen wrench, 5/16 in. ‡ ----TOOL, Allen wrench, 1/4 in. ‡ ----TOOL, Allen wrench, 3/16 in. ‡ ----TOOL, Allen wrench, 3/32 in. ‡* ----TOOL, Allen wrench, 5/32 in. ‡* ----TOOL, Allen wrench, 5/64 in. ‡* ----TOOL, Allen wrench, 7/32 in. ‡ 116553 TUBE, grease, dielectric 179791 TAG, warning 59† 25C283 STUD, solvent; includes o-rings (Ref. 60) 60† 112319 O-RING, FX75 2 2 2 1 1 1 1 1 4 4 5 2 1 2 1 1 1 1 1 1 1 1 1 1 1 2 Replacement Danger and Warning labels, tags, and cards are available at no cost. † Parts are included in Main Housing Kit 26A244. See also O-Ring Kits 25C210, 25C212, and 25C213. ‡ Parts are included in Tool Kit 25C198. Parts are included in Air Fitting Quick Connect Kit 25C226. * 78 Only used on HW models. 334452J Parts Non-Electrostatic Models (R_A1_1) 334452J 79 Parts Parts for Non-Electrostatic Models (R_A1_1) 6 Ref. 1† 1a 2† 3† Part HOUSING, main, assembly SPRING, plunger contact O-RING, FX75 SEAT, fluid valve; includes o-ring (Ref. 2) 4† 25C243 VALVE, fluid; includes o-rings (Refs. 4a, 4b) and seat (Ref. 3) 4a† 117610 O-RING, FX75 4b† 120775 O-RING, FX75 5 25C279 SENSOR, magnetic; includes screw (Ref. 6) 6 GC0612 SCREW, button head, #8-32 x 0.25 7 25C280 FLUID TUBE, assembly; includes o-rings (Refs. 7a and 7b) 7a 120776 O-RING, FX75 7b 111516 O-RING, FX75 8 17B390 O-RING, FX75 9 NOZZLE, fluid; includes o-ring (Ref. 8) 25C206 0.75 mm. (0.03 in.); for R_A13_ models 25C207 1 mm. (0.04 in.); for R_A14_models 25C208 1.25 mm (0.05 in.); or R_A15_ models 25C209 1.5 mm (0.06 in.); for R_A16_ models 26A524 1.8 mm (0.07 in.) 26A525 2.0 mm (0.08 in.) 10 24W988 TURBINE, assembly; includes o-rings (10a-10c) 10a 17D878 O-RING, FX75 10b 17B495 O-RING, FX75 10c 17D877 O-RING, FX75 11 GC1936 O-RING, FX75 12 17D879 O-RING, FX75 13 25C281 HOUSING, front; includes o-rings (Refs. 11, 12, 14,16, 17) 14 111516 O-RING, FX75 15 25C218 RING, retaining 16 17B495 O-RING, FX75 17 125249 O-RING, FX75 18 AIR CAP, assembly; includes solvent stud (59) and o-ring (60) 24Z989 for R1A1_ _ models (15 mm); includes Refs. 18a-18c 25C220 for R3A1_ _ models (30 mm); includes Refs. 18a-18c 25C221 for R5A1_ _ models (50 mm); includes Refs. 18a-18d 18a ----AIR CAP, inner 18b ----AIR CAP, outer 80 ----25D453 127316 25C242 Description Qty 1 1 3 3 3 6 3 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 Ref. 18c Part Description Qty O-RING 17D877 O-RING - 30 mm 17S113 O-RING - 15mm 18d 17B494 O-RING 19 COVER, air cap 24Z985 for R1A1_ _ models (15 mm) 25C223 for R3A1_ _ models (30 mm) 25C224 for R5A1_ _ models (50 mm) 20 CUP, aluminum, serrated, includes splash plate (Ref. 20a); see Cup Selection Charts, page 83, for available cups 24Z088 for R1A1_0 models (15 mm); includes tool (Ref. 21) 24Z079 for R3A1_0 models (30 mm) 24Z084 for R5A1_0 models (50 mm) 20a PLATE, splash 25D455 for R1A1_0 models (15 mm); includes o-ring (Ref. 20c) 25C214 for R3A1_0 and R5A1_0 models; (30 mm and 50 mm) includes split ring (Ref. 20b) 20b 17A653 RING, split 20c 17B390 O-RING, FX75 21 25C438 TOOL, 15 mm splash plate (Not Shown) 22 25C315 CABLE, extension, fiber optic; includes nuts (22a) and fittings (22b) 22a ----NUT, fiber optic - see kit 24W872 22b ----FITTING, fiber optic - see kit 24W872 23† ----RETAINER, tubing, 5/16 in. 24† ----RETAINER, tubing, 5/32 in. 25† 111157 FITTING, tube, 1/4 in. with 1/8 in. npt threads 27 25C227 TUBE, coiled, 1/4 in. 28 25R010 PLUG, ground; includes nut (Ref. 28a) and o-ring (Ref. 28b), wire (28c) 28a 100179 NUT 28b 16D531 O-RING, FX75 28c 25R029 GROUND, wire 29 25C229 ROD, tie 30 25C282 MANIFOLD, rear; includes bracket (Ref. 32) and screws (Ref. 42) 31 104035 SCREW, cap, socket head, 5/16-18 x 1 in. 32 25M454 BRACKET ASSEMBLY, fluid, grounding, includes 32a-32f 32a ----BRACKET 32b ----FITTING, fluid, 5/8-18 UNF-2A 32c ----NUT, 5/8-18 UNF-2B 32d 111157 FITTING, tube, 1/4 in. with 1/8 in. npt threads; included in Kit 25C225, page 82 1 1 1 1 1 1 1 1 2 2 5 4 2 2 1 2 1 1 3 1 3 1 1 3 3 3 334452J Parts Ref. Part Description 32e 17K719 32f 18A999 33 34 35 36 25C216 17B385 17B386 25C284 37 38† 39† 41 42 17B496 17L763 17L764 223547 101682 59† 25C283 FITTING, tube, 5/16 in. with 1/8 in. npt threads; included in Kit 25C225, page 82 FITTING, tube, 3/16 in. with 1/8 in. npt threads; included in Kit 25C225, page 82 COVER, shroud COVER, adapter RING, retaining, manifold BRACKET, mounting; includes screws (Ref. 37) SCREW, socket head, 3/8-16 x 0.5 in. O-RING, FX75 O-RING, FX75 WIRE ASSEMBLY, Ground, 25 ft. SCREW, cap, socket head, 1/4-20 x 0.625 in. STUD, solvent; includes o-rings (Ref. 60) O-RING, FX75 FITTING, tube, 3/16 in. with 1/8 in. npt threads; included in Kit 25C225, page 82 TUBE, coiled, 3/16 in. COVER, gun; not shown, (Kit 24Z177, qty. 10) SIGN, warning TAG, warning TOOL, spanner wrench TOOL, fluid valve TOOL, Allen wrench, 5/16 in. TOOL, Allen wrench, 1/4 in. TOOL, Allen wrench, 3/16 in. TOOL, Allen wrench, 3/32 in. TOOL, Allen wrench 5/32 in. TOOL, Allen wrench 5/64 in. TOOL, Allen wrench 7/32 in. TOOL, Allen wrench TUBE, grease, dielectric 60† 112319 61 18A999 62 65 25P659 ----- 66 67 68 69‡ 70‡ 71‡ 72‡ 73‡* 74‡* 75‡* 76‡* 77‡* 78‡ 17L835 179791 25C199 25C200 --------------------------------116553 Qty 2 1 1 1 1 1 4 4 5 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 † Parts are included in Main Housing Kit 25C257. See also O-Ring Kits 25C210, 25C212, and 25C213. Parts are included in Air Fitting Quick Connect Kit 25C226. Replacement Danger and Warning labels, tags, and cards are available at no cost. ‡ Parts are included in Tool Kit 25C198. (Not Shown) * Only used on Hollow Wrist models. 334452J 81 Repair Kits Repair Kits Kit 25C213, Air Cap O-Rings (15 mm, 30 mm, 50 mm) Main Housing Repair Kits Kit 25C257, Main Housing Replacement, Solventborne† Ref. 1 2 3 4 23 24 25 38 39 59 60 61 Description HOUSING, main, assembly O-RING, FX75 SEAT, fluid valve VALVE, fluid, RETAINER, tubing, 5/16 in. RETAINER, tubing, 5/32 in. FITTING, tube, 1/4 in. with 1/8 in. npt threads O-RING, FX75 O-RING, FX75 STUD, solvent; includes o-rings (Ref. 60 O-RING, FX75 FITTING, tube, 3/16 in. with 1/8 in. npt threads Qty. 1 3 3 3 5 4 2 4 5 1 2 1 Kit 26A244, Main Housing Replacement, Waterborne† Ref. 1 2 3 4 23 24 25 38 39 40 59 60 Description HOUSING, main, assembly O-RING, FX75 SEAT, fluid valve VALVE, fluid, RETAINER, tubing, 5/16 in. RETAINER, tubing, 5/32 in. FITTING, tube, 3/16 in. with 1/8 in. npt threads O-RING, FX75 O-RING, FX75 FITTING, tube, 3/8 in. with 1/8 in. npt threads STUD, solvent; includes o-rings (Ref. 60 O-RING, FX75 Qty. 1 3 3 3 5 4 1 4 5 2 1 2 O-Ring Kits Kit 25C210, Front Housing O-Rings Ref. 11 12 14 16 17 Description O-RING, FX75 O-RING, FX75 O-RING, FX75 O-RING, FX75 O-RING, FX75 Qty. 1 1 6 1 1 Kit 25C212, Turbine O-Rings Ref. 10a 10b 10c 82 Description O-RING, FX75 O-RING, FX75 O-RING, FX75 Ref. 18c 18d 60 Description O-RING, FX75 O-RING, FX75 O-RING, FX75 Qty. 1 1 2 Fittings and Tools Kit 25C225, Fluid Fittings, Solventborne Ref. Description 32d FITTING, tube, 1/4 in. with 1/8 in. npt threads 32e FITTING, tube, 5/16 in. with 1/8 in. npt threads 32f FITTING, tube, 3/16 in. with 1/8 in. npt threads Qty. 4 2 2 Kit 25C300 Fluid Fittings, Waterborne Ref. Description 32d FITTING, tube, 1/4 in. with 1/8 in. npt threads 32e FITTING, strain relief 32f FERRULE 32g NUT 32h FITTING, tube, 3/16 in. with 1/8 in. npt threads Qty. 1 2 2 2 1 Kit 25C226, Air Fittings, Quick Connect Ref. 23 24 38 39 Description RETAINER, tubing, 5/16 in. RETAINER, tubing, 5/32 in. O-RING, FX75 O-RING, FX75 Qty. 5 4 4 5 Kit 25C198, Tool Box Ref. 44 45 53 54 55 56 57 58 59 60 Description TOOL, spanner wrench TOOL, fluid valve TOOL, Allen wrench, 5/16 in. TOOL, Allen wrench, 1/4 in. TOOL, Allen wrench, 3/16 in. TOOL, Allen wrench, 3/32 in. TOOL, Allen wrench, 5/32 in. TOOL, Allen wrench, 5/64 in. TOOL, Allen wrench, 7/32 in. TUBE, grease, dielectric Qty. 1 1 1 1 1 1 1 1 1 1 Qty. 1 1 1 334452J Repair Kits Cup Selection Charts NOTE: Pattern shape and diameter are material dependent. * Indicates the cup that is installed on the applicators at the factory. Other kits must be purchased separately. 15 mm Cups Kit 24Z086 Kit 24Z088* 24Z089 Kit 24Z087 Edge Type Smooth Serrated Serrated Smooth Material Aluminum Aluminum Aluminum Composite Splash Plate (20a, included) 25D455 25D455 25D455 25D455 Finish Standard Standard High-Wear None Air Cap and Cover Kit 25C285 Recommended Fluid Nozzles 25C206 (0.75 mm), 25C207 (1 mm), 25C208 (1.25 mm) Recommended Production Flow Rates 25-100 cc/min. Pattern Diameter Range < 4 in. (< 10 cm) 30 mm Cups Kit 24Z076 Kit 24Z079* 24Z080 Kit 24Z078 Edge Type Smooth Serrated Serrated Smooth Material Aluminum Aluminum Aluminum Composite Splash Plate (20a, included) 25C214 25C214 25C214 25C214 Finish Standard Standard High-wear None Air Cap and Cover Kit 25C286 Recommended Fluid Nozzles 25C206 (0.75 mm), 25C207 (1 mm), 25C208 (1.25 mm), 25C209 (1.5 mm) Recommended Production Flow Rates 25-400 cc/min. Pattern Diameter Range 4-12 in. (10-31 cm) 50 mm Cups Kit 24Z081 Kit 24Z084* 24Z085 Kit 24Z083 Edge Type Smooth Serrated Serrated Smooth Material Aluminum Aluminum Aluminum Composite Splash Plate (20a, included) 25C214 25C214 25C214 25C214 Finish Standard Standard High-Wear None Air Cap and Cover Kit 25C287 Recommended Fluid Nozzles 25C207 (1 mm), 25C208 (1.25 mm), 25C209 (1.5 mm) Recommended Production Flow Rates 50-500 cc/min. Pattern Diameter Range 4-18 in. (10-46 cm) 334452J 83 Accessories Accessories Robot Adapter Plates Adapter Plate Robot 24Y128 MOTOMAN EPX1250 24Y129 MOTOMAN PX1450 Bolt Circle Mounting Screws Locating Pin Circle Locating Pins 27.5 mm 1.08 in. 4 x M5 x 0.8 27.5 mm 1.08 in. 5 mm 1.3 in. 8 x M6 x 1.0 ----- ----- 32 mm MOTOMAN EPX2850 24Y172 ABB IRB 540 36 mm 1.4 in. 3 x M5 ----- ----- 24Y173 ABB IRB 1400 40 mm 1.6 in. 4 x M6 ----- ----- 24Y768 FANUC PAINT MATE 200iA 31.5 mm 1.2 in. 4 x M5 31.5 mm 1.24 in. 1 x 5 mm FANUC PAINT MATE 200iA/5L Mounting Kits Kit 24Z179, 60° Robot Mounting Kit 24Z178, Reciprocator Mounting 108 101 104 102 103 105 105 Ref. 101 102 103 104 105 84 Part Number 17C780 ---17K966 17K967 25C580 109 106 Description POST, mounting ROD, mounting SCREW, 1/2-13 x 1.5 in. NUT, 1/2-13 ADAPTER, 1.75 to 2.00 in Qty 1 1 1 1 1 107 Ref. 105 106 107 Part Number ------C19789 108 17E420 109 100644 Description ADAPTER, mounting BRACKET, robot mounting SCREW, cap, socket head, 5/8-11 x 1.5 in. SCREW, cap, socket head, 5/16-18 x 1.0 in. SCREW, cap, socket head, 1/4-20 x 0.75 in. Qty 1 1 1 4 4 334452J Accessories Fiber Optic Bulkhead Installation Plastic Bulkhead Stainless Steel Bulkhead 24W877 Plastic Bulkhead Installation Accepts Graco fiber optic cable fittings. Fits 1/2 inch (13 mm) panel hole. 24W876 Stainless Steel Bulkhead Installation 1. Drill a 1/2 in. to 9/16 in (12.7 mm to 14.2 mm) hole in booth wall or panel to allow bulkhead to pass through. 2. Fiber optic cable nut should be 0.31 in. (7.9 mm) from end of cable. 3. Insert bulkhead (6) into hole and attach nut (7) on either side. Thread in fiber optic cable fitting (2) until it bottoms out. Do not force cable further. Make sure cable marker numbers match to ensure proper communication. Accepts bare fiber optic cable. Fits 5/16” (8 mm) panel hole. 1. Drill a 5/16 in. to 3/8 in. (7.9 mm to 9.5 mm) hole in booth wall or panel to allow bulkhead to pass through. 2. Make a clean cut to the ends of the cable using fiber optic cutter tool. Ensure the ends of the cable are equal length. 3. Insert bulkhead (6) into hole and attach nut (7) on either side. Insert cable into bulkhead and tighten cinch nut down to a snug fit. 4. Repeat for second side of communications. 4. Repeat for second side of communications. 334452J 85 Accessories Kit 25C288, Dump Valve Plug Kit Kit 25N021, Waterborne Isolated Solvent Line Use to plug the dump passage in the applicator if a dump valve is not needed. Includes the hardware required to replace the grounded solvent line with an isolated waterborne fluid hose. Additional waterborne fluid hoses must be purchased separately. Part ----117610 120775 127316 Description PLUG O-RING, FX75 O-RING, FX75 O-RING, FX75 Qty 1 1 1 1 Kit 24Z183, Reflective Speed Sensing Kit Replaces the magnetic speed sensor with a dual fiber, optical speed sensor (25A537) and fiber optic source. See manual 3A4738 for details. Kit 25A537, Reflective Fiber Optic Cable Kit Dual fiber optical speed sensor only. Includes reflective fiber optic cable with housing and hardware required to install in a ProBell applicator. Part Description 17L617 FITTING, tube, 3/8 in. with 1/8 in. mpt threads ---------- FITTING, waterborne hose 17L670 FERRULE, waterborne hose 17L671 NUT, waterborne hose Qty 1 1 1 1 Applicator Power Cables Kit 17J586 17J588 17J589 Description CABLE, low voltage, 36 ft. (11 m) CABLE, low voltage, 66 ft. (20 m) CABLE, low voltage, 99 ft. (30 m) Qty 1 1 1 Fiber Optic Bulkheads Dual Strand Fiber Optic Cables Used to run fiber through walls. End nut must be adjusted to proper length for the applicator being used. Kit Description Qty 24W876 STAINLESS STEEL BULKHEAD requires 2 24W875 24W877 PLASTIC BULKHEAD 2 Part 24X003 24X004 24X005 Description CABLE, fiber optic, 25 ft. (7.6 m) CABLE, fiber optic, 50 ft. (15.25 m) CABLE, fiber optic, 100 ft. (30.5 m) Qty 1 1 1 Fiber Optic Cables, Reciprocator Models Standard single fiber. Kit 24Z190 24Z191 24Z192 Description CABLE, fiber optic, 36 ft. (11 m) CABLE, fiber optic, 66 ft. (20 m) CABLE, fiber optic, 99 ft. (30 m) Qty 1 1 1 Kit 24W875, Fiber Optic Cable Repair Includes hardware to repair/replace all fiber optic ends. Part ------------- Description FITTING, fiber optic NUT, fiber optic TOOL, cutter, fiber optic Qty 4 4 1 Kit 24W823, Fiber Optic Cable Cutting Tool Use to get clean cut ends. Part ----- 86 Description TOOL, cutter, fiber optic Qty 3 Kit 25A878, Remote Grounding Bracket and Hose High-conductivity hose kit includes fluid hoses (15 ft., 4.6 m). Part Description Qty 111157 FITTING, tube, 1/4 in. with 1/8 in. npt 3 threads ----- BRACKET 1 ----- FITTING, fluid, 5/8-18 UNF-2A 3 ----- NUT, 5/8-18 UNF-2B 3 ----- GROUND WIRE, 25 ft. (7.6 m) 1 17K719 FITTING, tube, 5/16 in. with 1/8 in. npt 6 threads 17L847 5/16 in. OD x 0.062 wall, PTFE fluid hose 15 ft. 054183 1/4 in. OD x 0.062 wall, FEP fluid hose 15 ft. Waterborne Fluid Hose Kits (Shielded); For Models R_A1_8 100 psi (0.69 MPa, 6.9 bar) Maximum Working Pressure Kit Description 17L886 HOSE, fluid, shielded, 36 ft. (11 m) 17L887 HOSE, fluid, shielded, 66 ft. (20 m) Qty 1 1 334452J Accessories Waterborne Fluid Hose Kits (Unshielded); For Models R_A1_8 100 psi (0.69 MPa, 6.9 bar) Maximum Working Pressure Kit 24Z177, Gun Cover Kit Description 17L884 HOSE, fluid, unshielded, 36 ft. (11 m) 17L885 HOSE, fluid, unshielded, 66 ft. (20 m) Air Cap and Cover Sets Qty 1 1 Solventborne Hose Bundles; For Models R_A_ _0 100 psi (0.69 MPa, 6.9 bar) Maximum Working Pressure Description HOSE BUNDLE, 36 ft. (11 m) HOSE BUNDLE, 66 ft. (20 m) HOSE BUNDLE, 99 ft. (30 m) Purchase as a replacement or to convert one bell model to another size. Each Kit includes the Air Cap Assembly (Ref. 18) and the Air Cap Cover (Ref. 19). Kit 25C285, 15 mm, for R1A1_ _ Models Kit 25C286, 30 mm, for R3A1_ _ Models The hose bundle includes a fiber optic cable, power cables, a ground wire, nylon air lines, and PFA fluid lines. See manual 3A4346 for details. Kit 24Z168 24Z169 24Z170 Kit includes 10 gun covers for the standard applicator. Kit 25C287, 50 mm, for R5A1_ _ Models Qty 1 1 1 Air Only Hose Bundles Test Equipment Part No. 241079 The hose bundle includes a fiber optic cable, power cables, a ground wire, and nylon air lines. Kit 24Z711 24Z712 24Z713 Description HOSE BUNDLE, 36 ft. (11 m) HOSE BUNDLE, 66 ft. (20 m) HOSE BUNDLE, 99 ft. (30 m) Qty 1 1 1 722886 722860 Hose Bundle Accessories Kit Description 24Z662 WRAP, spiral, 7 in. (18 cm) section, bag of 10 17A490 WRAP, blue, sold per foot Qty 10 up to 100 ft. Bulk Hose Tubing Maximum continuous purchase length is 100 ft., 30 m. 150 psi (1.03 MPa, 10.3 bar) Maximum Working Pressure Kit 057233* 057234* 057231 054754 598095 054753 054757 * 245277 Description 5/16 in. OD x 1/4 in. ID PFA fluid hose 1/4 in. OD x 3/16 in. ID, PFA fluid hose 5/16 in. nylon tubing 5/32 in. nylon tubing, red 5/32 in. nylon tubing, natural 5/32 in. nylon tubing, black 5/32 in. nylon tubing, green Description Megohmmeter. 500 V output, 0.01–2000 megohms. Use for ground continuity and gun resistance tests. Not for use in hazardous locations. Paint Resistance Meter. Use for fluid resistivity test. See manual 307263. Not for use in hazardous locations. Paint Probe. Use for fluid resistivity test. See manual 307263. Not for use in hazardous locations. Test Fixture, High Voltage Probe, and kV Meter. Use to test the electrostatic voltage of the gun, and the condition of the power supply when being serviced. See manual 309455. Miscellaneous Equipment Gun Accessories Part No. Description 111265 Non-silicone Lubricant, 4 oz (113 g). 116553 Dielectric Grease. 1 oz (30 ml) Not for use with high-voltage fluid. Kit 25C424, Grounding Plate Kit 249598, Unclogging Needle Kit includes 12 picks for unclogging gun air covers or nozzles. 334452J 87 Dimensions Dimensions 60° Robot Mount - shown as shipped Dimension Ref. A B C D E F 88 15 mm Cup Inches 4.25 3.0 5.125 17.864 10.93 6.934 Centimeters 1.67 1.18 2.01 7.03 4.30 2.72 30 mm Cup Inches 4.25 3.0 5.125 17.864 10.93 6.934 Centimeters 1.67 1.18 2.01 7.03 4.30 2.72 50 mm Cup Inches 4.25 3.0 5.125 17.864 10.93 6.934 Centimeters 1.67 1.18 2.01 7.03 4.30 2.72 334452J Dimensions 60° Robot Mount - shown with mounting Kit 24Z179 Bolt Hole Diameter 0.300 Dimension Ref. A B C D E F G H 334452J 15 mm Cup Inches 4.2 8.1 10.9 3.8 3.6 1.7 11.4 17.3 Centimeters 10.7 20.6 27.7 9.7 9.1 4.3 29.0 43.9 30 mm Cup Inches 4.2 8.1 10.9 3.9 3.6 1.7 11.4 17.3 Centimeters 10.7 20.6 27.7 9.9 9.1 4.3 29.0 43.9 50 mm Cup Inches 4.2 8.1 10.9 4.6 4.1 1.7 11.7 17.9 Centimeters 10.7 20.6 27.7 11.7 10.4 4.3 29.7 45.5 89 Dimensions Reciprocator Mount - shown with reciprocator mounting kit 24Z178 Dimension 15 mm Cup Ref. A B C D* E F G H Inches 4.2 3.0 2.4 1.75 17.3 5.1 6.4 29.1 Centimeters 10.7 7.6 6.1 4.3 43.9 12.9 16.3 73.9 30 mm Cup Inches 4.2 3.0 2.4 1.75 17.3 5.1 6.4 29.1 Centimeters 10.7 7.6 6.1 4.3 43.9 12.9 16.3 73.9 50 mm Cup Inches 4.2 3.0 2.4 1.75 17.9 5.7 6.9 29.7 Centimeters 10.7 7.6 6.1 4.3 45.5 14.5 17.5 75.4 * A sleeve adapter to convert dimension D from 1.75 inch to 2.0 inch is included with mounting kit 24Z178. 90 334452J Performance Charts Performance Charts Turbine Air Consumption Charts These charts show the air consumption in scfm (l/min.) by rotation speed for the three cup sizes. See the key for the flow rate represented by each line. 15 mm KEY: 50-100 cc/min. Air Consumption - SCFM (Liters/Min.) \ 9 (255) 8 (227) 7 (198) 6 (170) 5 (142) 4 (113) 3 (85) 2 (57) 1 (28) 0 15 mm Cup 0 300 cc/min. – — – — – 100 cc/min. Air Consumption - SCFM (Liters/Min. 30 mm KEY: 10000 10 (283) 9 (255) 8 (227) 7 (198) 6 (170) 5 (142) 4 (113) 3 (85) 2 (57) 1 (28) 0 20000 30000 40000 50000 60000 40000 50000 60000 Rotation Speed (rpm) 30 mm Cup 0 10000 20000 30000 Rotation Speed (rpm) 334452J 91 Performance Charts Turbine Air Consumption Charts (continued) 500 cc/min. – — – — – 300 cc/min. -------- 100 cc/min. Air Consumption - SCFM (Liters/Min.) 50 mm KEY: 14 (396) 50 mm Cup 12 (340) 10 (283) 8 (227) 6 (170) 4 (113) 2 (57) 0 0 10000 20000 30000 40000 Rotation Speed (rpm) 50000 60000 Turbine Inlet Air Pressure Charts These charts show the turbine inlet air pressure by rotation speed for the three cup sizes. See the key for the flow rate represented by each line. Pressure is measured within 1 ft. (0.3 m) of the rotary applicator. 15 mm KEY: Air Inlet Pressure in psi (MPa, bar) 100 cc/min. 35 (0.24, 2.4) 15 mm Cup 30 (0.21, 2.1) 25 (0.17, 1.7) 20 (0.14, 1.4) 15 (0.10, 1.0) 10 (0.07, 0.7) 5 (0.03, 0.3) 0 0 92 10000 20000 30000 Rotation Speed (rpm) 40000 50000 60000 334452J Performance Charts 30 mm KEY: 300 cc/min. – — – — – 100 cc/min. Turbine Air Inlet Pressure in psi (MPa, bar) Turbine Inlet Air Pressure Charts (continued) 40 (0.28, 2.8) 35 (0.24, 2.4) 30 mm Cup 30 (0.21, 2.1) 25 (0.17, 1.7) 20 (0.14, 1.4) 15 (0.10, 1.0) 10 (0.07, 0.7) 5 (0.03, 0.3) 0 50 mm KEY: 500 cc/min. – — – — – 300 cc/min. -------- 100 cc/min. Limit for 20 m tube length. See note. Limit for 30 m tube length. See note. Turbine Air Inlet Pressure in psi (MPa, bar) 0 10000 20000 30000 40000 50000 60000 40000 50000 60000 Rotation Speed (rpm) 45 (0.31, 3.1) 40 (0.28, 2.8) 35 (0.24, 2.4) 30 (0.21, 2.1) 25 (0.17, 1.7) 20 (0.14, 1.4) 15 (0.10, 1.0) 10 (0.07, 0.7) 5 (0.03, 0.3) 0 50 mm Cup 0 10000 20000 30000 Rotation Speed (rpm) NOTE: The rotation speed or flow rate of a 50 mm cup may be limited due to pressure drop in the turbine air line. The limits for the 8 mm OD tube are shown in the chart above. 100 PSI (0.69 MPa, 7.0 bar) system inlet pressure is assumed. For the full range of performance, use one of the following options: • • • a maximum of 11 m (35 ft.) length of 8 mm OD tube with a 1 mm wall (0.3125 in. OD tube with 0.04 in. wall). a maximum of 30 m (100 ft.) length of 10 mm OD tube with a 1 mm wall. a maximum of 30 m (100 ft.) length of 0.375 in. OD tube with a 0.05 in. wall. 334452J 93 Performance Charts Shaping Air Consumption Charts 15 mm KEY: Shaping air (inner and outer) Shaping Air Consumption - SCFM (Liters/Min.) These charts show shaping air consumption in scfm (liters per minute) for the three cup sizes. See the key for the type of shaping air (inner or outer) represented by each line. Pressure is measured within 1 ft. (0.3 m) of the rotary applicator. 12 (340) 15 mm Cup 10 (283) 8 (227) 6 (170) 4 (113) 2 (57) 0 0 10 (0.07) (0.7) 20 (0.14) (1.4) 30 (0.21) (2.1) 40 (0.28) (2.8) 50 (0.35) (3.5) 60 (0.42) (4.2) 30 mm KEY: Inner Shaping Air – — – — – Outer Shaping Air Shaping Air Consumption - SCFM (Liters/Min.) Inlet Pressure - PSI (MPa, bar) 14 (396) 30 mm Cup 12 (340) 10 (283) 8 (227) 6 (170) 4 (113) 2 (57) 0 0 10 20 30 40 45 5 15 25 35 (0.03) (0.07) (0.10) (0.14) (0.17) (0.21) (0.24) (0.28) (0.31) (0.7) (1.0) (1.4) (1.7) (2.1) (2.4) (2.8) (3.1) (0.3) Inlet Pressure - PSI (MPa, bar) 94 334452J Performance Charts 50 mm KEY: Inner Shaping Air – — – — – Outer Shaping Air Shaping Air Consumption - SCFM (Liters/Min.) Shaping Air Consumption Charts (continued) 14 (396) 50 mm Cup 12 (340) 10 (283) 8 (227) 6 (170) 4 (113) 2 (57) 0 0 10 (0.07) (0.7) 20 (0.14) (1.4) 30 (0.21) (2.1) 40 (0.28) (2.8) 50 (0.35) (3.5) 60 (0.42) (4.2) Inlet Pressure - PSI (MPa, bar) 334452J 95 Performance Charts Fluid Flow Rate Charts These charts show fluid flow rates in cc/minute by inlet pressure for four nozzle sizes. See the key for the viscosity represented by each line. Pressure is measured within 1 foot (0.3 m) of the rotary applicator. 600 Fluid Nozzle Size 0.75 mm Flow Rate in cc/min. 500 400 300 200 100 0 0 KEY: 50 cps 10 (0.07) (0.7) 20 (0.14) (1.4) 30 (0.21) (2.1) 40 (0.28) (2.8) 50 (0.35) (3.5) 60 (0.41) (4.1) 50 (0.35) (3.5) 60 (0.41) (4.1) Fluid Inlet Pressure in PSI (MPA, bar) – — – — – 100 cps -------- 150 cps 600 Fluid Nozzle Size 1.0 mm Flow Rate in cc/min. 500 400 300 200 100 0 0 10 (0.07) (0.7) 20 (0.14) (1.4) 30 (0.21) (2.1) 40 (0.28) (2.8) Fluid Inlet Pressure in PSI (MPA, bar) 96 334452J Performance Charts Fluid Flow Rate Charts (Continued) 600 Fluid Nozzle Size 1.2 mm Flow Rate in cc/min. 500 400 300 200 100 0 0 KEY: 10 (0.07) (0.7) 20 (0.14) (1.4) 30 (0.21) (2.1) 40 (0.28) (2.8) 50 (0.35) (3.5) 60 (0.41) (4.1) 50 (0.35) (3.5) 60 (0.41) (4.1) Fluid Inlet Pressure in PSI (MPA, bar) 50 cps – — – — – 100 cps -------- 150 cps 600 Fluid Nozzle Size 1.5 mm Flow Rate in cc/min. 500 400 300 200 100 0 0 10 (0.07) (0.7) 20 (0.14) (1.4) 30 (0.21) (2.1) 40 (0.28) (2.8) Fluid Inlet Pressure in PSI (MPA, bar) 334452J 97 Performance Charts Fluid Flow Rate Charts (Continued) 600 Fluid Nozzle Size 1.8 mm Flow Rate in cc/min. 500 400 300 200 100 0 0 KEY: 5 10 15 20 25 30 35 40 45 50 (0.03) (0.07) (0.10) (0.14) (0.17) (0.21) (0.24) (0.28) (0.31) (0.35) (0.3) (0.7) (1.0) (1.4) (1.7) (2.1) (2.4) (2.8) (3.1) (3.5) Fluid Inlet Pressure in PSI (MPA, bar) 50 cps – — – — – 100 cps -------- 150 cps 600 Fluid Nozzle Size 2.0 mm Flow Rate in cc/min. 500 400 300 200 100 0 0 5 10 15 20 25 30 35 40 45 50 (0.03) (0.07) (0.10) (0.14) (0.17) (0.21) (0.24) (0.28) (0.31) (0.35) (0.3) (0.7) (1.0) (1.4) (1.7) (2.1) (2.4) (2.8) (3.1) (3.5) Fluid Inlet Pressure in PSI (MPA, bar) 98 334452J Performance Charts Fluid Pressure Loss Charts These charts show the pressure loss per foot of hose in psi (MPa, bar) for three hose sizes. See the key for the viscosity represented by each line. Pressure Loss (per foot) in psi (MPa, bar) NOTE: tables use hose ID, while connection sizes refer to hose ODs. 5 (0.034) (0.34) 1/4-in. (6 mm) ID hose 4 (0.028) (0.28) 3 (0.021) (0.21) 2 (0.014) (0.14) 1 (0.007) (0.07) 0 KEY: 0 100 150 cps 200 300 Flow Rate in cc/min. 400 500 400 500 – — – — – 100 cps 50 cps Pressure Loss (per foot) in psi (MPa, bar) -------- 25 (0.17, 1.7) 3/16-in. (5 mm) ID hose 20 (0.14, 1.4) 15 (0.10, 1.0) 10 (0.07, 0.7) 5 (0.03, 0.3) 0 0 334452J 100 200 300 Flow Rate in cc/min. 99 KEY: 150 cps – — – — – 100 cps -------- 50 cps Pressure Loss (per foot) in psi (MPa, bar) Pressure Loss Charts (Continued) 25 (0.17, 1.7) 1/8-in. (3 mm) ID hose 20 (0.14, 1.4) 15 (0.10, 1.0) 10 (0.07, 0.7) 5 (0.03, 0.3) 0 0 100 200 300 Flow Rate in cc/min. 400 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 334452 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2016, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revision J, June 2020 500 Technical Specifications Technical Specifications ProBell Rotary Applicator Maximum air working pressure Maximum air consumption Bearing air minimum required Turbine and bearing air conditions Maximum dew point Aerosol limit Maximum particle size Maximum air and fluid temperature Maximum fluid working pressure Turbine speed - maximum operating Viscosity Range Maximum flow rate, 50 mm cup US Metric 100 psi 0.69 MPa, 7.0 bar 50 scfm (25 scfm is typical) 70 psi 0.5 MPa,5.0 bar 10° F - 12° C 99% aerosol free .00002 inches 120°F 150 psi 0.5 microns 49°C 1.03 MPa, 10.3 bar 60,000 rpm 30 - 150 centistokes 500 cc/min Maximum flow rate, 30 mm cup 400 cc/min Maximum flow rate, 15 mm cup 100 cc/min Solventborne systems: 1 megohm-cm to infinity Waterborne systems: Conductive waterborne fluids 9 lbs (4 kg) Solventborne systems: 100 kV Waterborne systems: 60 kV 150 micro-amperes 41° F to 104 °F 5° C to 40° C Paint resistivity range Weight Maximum output voltage Maximum current draw Ambient temperature range Sound pressure level at 60 rpm, 70 psi (0.48 MPa, 4.8 bar); measured per ISO 9614-2, 1 m from applicator Wetted parts 77 dB(A) acetal, 300 series stainless steel, fluoroelastomer,nylon, coated aluminum, FEP, PTFE, PEEK California Proposition 65 CALIFORNIA RESIDENTS WARNING: Cancer and reproductive harm. – www.P65warnings.ca.gov. 334452J 101 Graco Standard Warranty Graco Standard 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. 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 provide24 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: 612-378-350 102 334452J
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