Graco 3A4795C, Pro Xp™ WBx Waterborne External Charge Electrostatic Air Spray Gun Instructions
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••• Material of Liquid
••• Material
Important
This equipment could present hazards if not operated according to the information in this manual. Read all warnings and instructions in
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100 psi (0.7 MPa, 7.0 bar) Maximum
Fluid Working Pressure
100 psi (0.7 MPa, 7.0 bar) Maximum Air
Working Pressure
3A4795C
EN
PROVEN QUALITY. LEADING TECHNOLOGY.
Models............................................................... 3
Approvals........................................................... 3
Related Manuals ................................................ 3
Warnings ........................................................... 4
Gun Overview .................................................... 7
How the Electrostatic Spray Gun
Works ............................................ 7
Controls, Indicators, and Components ........... 8
Smart Guns ................................................. 9
Installation.......................................................... 14
Warning Sign ............................................... 14
Ventilate the Spray Booth ............................. 14
Air Supply Line ............................................ 15
Fluid Supply Line ......................................... 15
Grounding ................................................... 17
Gun Setup.......................................................... 21
Gun Setup Procedure................................... 21
Check Gun Electrical Grounding ................... 25
Check Fluid Resistivity ................................. 26
Check Fluid Viscosity ................................... 26
Flush Before Using Equipment...................... 26
Guidelines for Abrasive Materials .................. 26
Operation ........................................................... 27
Pressure Relief Procedure............................ 27
Startup ........................................................ 28
Shutdown .................................................... 28
Maintenance ...................................................... 29
Daily Care and Cleaning Checklist ................ 29
Flushing ...................................................... 29
Clean the Gun Daily ..................................... 30
Daily System Care ....................................... 31
Electrical Tests ................................................... 32
Test Total Gun Resistance ........................... 32
Test Gun Resistance with Probe
Removed ....................................... 33
Test Charging Probe Resistance................... 33
Test Power Supply Resistance ..................... 34
Test Barrel Resistance ................................. 34
Troubleshooting.................................................. 35
Spray Pattern Troubleshooting...................... 35
Gun Operation Troubleshooting .................... 36
Electrical Troubleshooting ............................ 37
Repair................................................................ 38
Prepare the Gun for Service ......................... 38
Air Cap and Nozzle Replacement.................. 39
Electrode Replacement ................................ 40
Charging Probe Pin Replacement ................. 40
Fluid Packing Rod Removal.......................... 41
Packing Rod Repair ..................................... 41
Barrel Removal ............................................ 43
Barrel Installation ......................................... 43
Replacement .................................. 44
Alternator Removal and Replacement ........... 45
Fluid Tube Removal and Replacement ........... 47
Fan Air Adjustment Valve Repair .................. 47
Atomizing Air Restrictor Valve Repair ............ 48
ES On-Off and Fluid Adjustment Valve
Repair............................................ 49
Air Valve Repair........................................... 50
Smart Module Replacement.......................... 51
Replacement .................................. 52
Parts.................................................................. 53
Standard Waterborne External Charge
(L40T28) ........................................ 53
Smart Waterborne External Charge
(L40M28) ....................................... 54
Parts for Standard and Smart Air Spray
Gun Assemblies ............................. 55
Packing Rod Assembly................................. 57
Alternator Assembly ..................................... 58
ES On-Off and Fluid Adjustment Valve ........... 59
Fan Air Adjustment Valve Assembly .............. 60
Atomizing Air Restrictor Valve
Assembly ....................................... 60
Smart Module Assembly............................... 61
Round Spray Assembly ................................ 62
Fluid Nozzles ..................................................... 64
Fluid Nozzle Selection Chart......................... 64
Fluid Nozzle Performance Charts.................. 65
Air Caps............................................................. 67
Air Cap Selection Guide ............................... 67
Air Consumption Charts ............................... 72
Repair Kits and Accessories ................................ 73
Gun Accessories.......................................... 73
Operator Accessories................................... 74
System Accessories ..................................... 74
Signs .......................................................... 74
Test Equipment ........................................... 74
Hoses ......................................................... 75
Dimensions ........................................................ 76
Technical Specifications...................................... 77
Graco Pro Xp Warranty ....................................... 78
2 3A4795C
L40M28
L40T28
40
40
2575
EEx 0.24 mJ T6
FM12ATEX0068
EN 50050–1
Ta 0°C – 50°C
3A2498
307263
309455
406999
Round Spray Kit, Instructions
Probe and Meter, Instructions
Test Fixture, High Voltage Probe, and kV Meter, Instructions
Voltage Tester Conversion Kit, Instructions
Smart
Standard
3A4795C 3
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.
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, explosion, and electric shock:
• 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 instructions.
• Only use grounded Graco conductive air supply hoses.
• Do not use pail liners unless they are conductive and grounded.
equipment until you identify and correct the problem.
• Check gun resistance, hose resistance, and electrical grounding daily.
• Use and clean equipment only in well ventilated area.
• Interlock the gun air and fluid supply to prevent operation unless ventilation air flow is above the minimum required value.
• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment.
• Never spray or flush solvent at high pressure.
• To clean the exterior of the equipment, cleaning solvents must have a flash point at least 15° C or 59° F above ambient temperature. Non-ignitable fluids are preferred.
• Always turn the electrostatics off when flushing, cleaning or servicing equipment.
• Eliminate all ignition sources such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static sparking).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep work area free of debris, including solvent, rags and gasoline.
• 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.
• 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.
4 3A4795C
3A4795C
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.
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.
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest
• Use fluids and solvents that are compatible with equipment wetted parts. See manufacturer’s warnings. For complete information about your material, request a
Safety Data Sheet (SDS) from your distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
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.
Many cleaning solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.
• Use only compatible solvents to clean plastic structural or pressure-containing parts.
Consult the solvent manufacturer for information and recommendations about compatibility.
5
6
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.
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.
3A4795C
The air hose supplies air to the spray gun. Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed.
The turbine generates power, which is converted by the power cartridge to supply high voltage current to the gun’s external charging probe.
The pump supplies fluid to the hose and gun, where the fluid is atomized by the air cap and the atomized particles are electrostatically charged as they pass the external charging probe. The charged fluid is attracted to the grounded workpiece. The external charging allows the fluid supply to remain grounded at all times and therefore eliminates the need for an isolation system.
3A4795C 7
The electrostatic gun includes the following controls, indicators, and components. For information on Smart guns, see
8
E
F
J
K
L
M
C
D
A
B
Item Description
Air Swivel Inlet
G
H
Fluid Inlet
Turbine Air Exhaust
Air Cap and Nozzle
1/4 npsm(m) left-hand thread, for Graco grounded air supply hose.
3/8 npsm(m), for fluid supply hose.
Barbed fitting, for supplied exhaust tube.
Shapes the spray pattern. See
and
for available sizes.
Electrode Needle
Atomizing Air Restrictor
Valve
Shuts off the fluid flow and provides a ground point.
Fan Air Adjustment Valve Adjusts the fan size and shape. Can be used to decrease the pattern width.
Restricts the air cap air flow. Replace with plug (included) if desired.
Fluid Adjustment Knob Adjusts the fluid flow by limiting fluid needle travel. Use only in low flow conditions, to reduce wear.
Turns electrostatics ON (I) or OFF (O).
ES On-Off Valve
ES Indicator (standard gun only; for Smart gun indicator, see
Lit when ES is ON (I). Color indicates alternator frequency. See the LED indicator table in the
Gun Setup Procedure, page 21 .
Retaining Ring Attaches the air cap to the barrel.
External Charging Probe Supplies electrostatic charge to the fluid. Offered in a long and short length.
3A4795C
The Smart Gun module displays spraying voltage, current, alternator speed, and the voltage setting (low or high). It also allows the user to change to a lower spraying voltage. The module has two modes:
• Operating Mode
• Diagnostic Mode
The voltage adjustment switch (VA) allows the operator to change from low to high voltage.
• The high voltage setting is determined by the maximum voltage of the gun and is not adjustable.
• The low voltage indicator (LO) lights when the switch is set to LO. The low voltage setting is user adjustable. See
Adjusting the Low Voltage Setting, page 10 .
See Fig. 2 and
Operating Mode displays gun data during normal spraying. The display uses a bar graph to show the voltage level in kiloVolts (kV) and the current level in microAmperes (uA). The bar graph range is from 0 to 100% for each value.
If the bar graph LEDs are blue, the gun is ready to spray. If the LEDs are yellow or red, the current is too high. The fluid may be too conductive, or see
Electrical Troubleshooting, page 37
for other possible causes.
has lost communication with the power supply. See
, for further information.
The Hz indicator functions the same as the ES indicator on standard guns. The indicator lights to show the alternator speed status, and has three colors:
• Green indicates the alternator speed is correct.
• If the indicator changes to amber after one second, increase the air pressure.
• If the indicator changes to red after one second, the air pressure is too high. Decrease air pressure until the indicator is green. To maintain a higher air pressure, install ES On/Off Valve Restrictor Kit
26A160. Then, adjust the pressure as needed to ensure that the indicator remains green.
Figure 1 Smart Gun Module in Operating Mode
3A4795C 9
If the Smart module loses communication with the power supply, the Error display appears, the
Hz indicator turns red, and the Smart module is disabled. See Fig. 3 and
.
This can occur in Operating Mode or Diagnostic
Mode. See
Electrical Troubleshooting, page 37 .
Communication must be restored to make the Smart module functional.
appear. If the gun has been disassembled, wait 8 seconds before spraying to ensure that an Error condition has not occurred.
display will not appear.
for your gun. Continue pressing the button until you reach the desired setting.
return to the Operating Screen.
Figure 3 Low Voltage Setting Screen (Unlocked)
Figure 2 Error Display
The low voltage setting may be locked. When locked, an image (LK) appears on the screen. See Fig. 5 and
.
locked. The lock symbol will appear when the LO
SET button is pressed.
• When in LO mode, the lock symbol will
Low Voltage Lock Screen, page 13 , to lock or
unlock the low voltage setting.
The low voltage setting is user adjustable. To access the low voltage setting screen when in Operating
Mode, press the LO SET button (LS) momentarily.
The screen will display the current low voltage setting. See Fig. 4 and
The possible ranges are:
• 85 kV guns: 40–85 kV
• 60 kV guns: 30–60 kV
• 40 kV guns: 20–40 kV
Set the Voltage Adjustment switch (VA) to LO. Press the LO SET button repeatedly to increase the setting in increments of 5. When the display reaches the maximum setting it will return to the minimum setting Figure 4 Low Voltage Setting Screen (Locked)
10 3A4795C
VA
LO kV uA
LS
LV
LK
LD
ER
VI
CI
AS
Hz
Voltage Adjustment Switch Two-position switch sets Smart gun voltage to low setting (LO) or high setting (HI). This switch is functional in Operating Mode and in
Diagnostic Mode.
Lights (blue) when the Smart gun is set to Low Voltage.
Low Voltage Mode
Indicator
Voltage (kV) Display Displays actual spraying voltage of the gun, in kV. In Operating Mode, display is a bar graph. In Diagnostic Mode, voltage is displayed as a number.
Current (uA) Display
LO SET button
Displays actual spraying current of the gun, in uA. In Operating Mode, display is a bar graph. In Diagnostic Mode, current is displayed as a number.
Press momentarily to enter the Low Voltage Setting screen.
Press and hold for approximately 5 seconds to enter or exit Diagnostic
Mode.
Low Voltage Display
Low Voltage Locked
LO Display
Error Display
Voltage Indicator
While in Diagnostic Mode, press momentarily to advance through screens.
While on the Low Voltage Lock Screen (in Diagnostic Mode), press and hold to turn the lock on or off.
Displays the low voltage setting as a number. The setting can be changed. See Fig. 4.
Appears if the low voltage setting is locked. See Fig. 5 and Fig. 9.
Appears on the Low Voltage Lock Screen. See Fig. 9.
Appears if the Smart module loses communication with the power supply. See Fig. 3.
In Diagnostic Mode, the two top right LEDs of the screen light, indicating that the value displayed is in kV. See Fig. 6.
Current Indicator In Diagnostic Mode, the two bottom right LEDs of the screen light, indicating that the value displayed is in uA. See Fig. 7.
In Diagnostic Mode, Hz level is displayed as a number. See Fig. 8.
Alternator Speed Display
Alternator Speed Indicator In Operating Mode, indicator color varies to show the alternator speed status:
• Green indicates the alternator speed is at the correct level.
• If the indicator changes to amber after one second, the alternator speed is too low.
• If the indicator changes to red after one second, the alternator speed is too high. The indicator also turns red if the Error display appears.
In Diagnostic Mode, the indicator is green when in the Alternator
Speed (Hertz) screen.
3A4795C 11
Diagnostic Mode includes four screens which display gun data:
• Voltage (kiloVolts) Screen
• Current (microAmperes) Screen
• Alternator Speed (Hertz) Screen
• Low Voltage Lock Screen low voltage setting; the setting is not adjustable in
Diagnostic Mode. However, the voltage adjustment switch (VA) can be set to HI or LO in Operating Mode and in Diagnostic Mode.
To enter Diagnostic Mode, press and hold the LO SET
(LS) button for approximately 5 seconds. The display will go to the
Voltage (kiloVolts) Screen, page 12
.
To advance to the next screen, press the LO SET button again.
To exit Diagnostic Mode, press and hold the LO SET button for approximately 5 seconds. The screen will return to Operating Mode.
Mode, the last screen viewed will be displayed when the gun is retriggered.
from the Low Voltage Lock Screen. See
Low Voltage Lock Screen, page 13
for details.
Figure 5 Voltage (kiloVolts) Screen
The Current (microAmperes) Screen is the second screen in the Diagnostic Mode. See Fig. 7 and
Smart Gun Key, page 11 . To enter this screen, press
the LO SET button while in the Voltage (kiloVolts)
Screen.
This screen displays the spraying current of the gun as a number (uA), rounded to the nearest 5 uA. The two bottom right LEDs (CI) of the display panel light, indicating that the Current (microAmperes) Screen is displayed. The display is a readout and cannot be changed.
Press the LO SET button to advance to the
Alternator Speed (Hertz) Screen, page 13
. Press and hold for approximately 5 seconds to return to
Operating Mode.
The Voltage (kiloVolts) Screen is the first screen to appear after entering Diagnostic Mode. See Fig. 6 and
. To enter this screen, press and hold the LO SET button for approximately
5 seconds while in the Operating Mode.
This screen displays the spraying voltage of the gun as a number (kV), rounded to the nearest 5 kV.
The two top right LEDs (VI) of the display panel light, indicating that the Voltage (kiloVolts) Screen is displayed. The display is a readout and cannot be changed.
Press the LO SET button to advance to the
Current (microAmperes) Screen, page 12 . Press
and hold for approximately 5 seconds to return to
Operating Mode.
Figure 6 Current (microAmperes) Screen
12 3A4795C
The Alternator Speed (Hertz) Screen is the third screen in the Diagnostic Mode. See Fig. 8 and
. To enter this screen, press the LO SET button while in the Current
(microAmperes) Screen.
This screen displays the alternator speed as a 3 digit number (AS), rounded to the nearest 10 Hz. The display is a readout and cannot be changed. If the alternator speed is greater than 999 Hz, the display will show 999.
The Hz indicator lights green to show that you are viewing the Alternator Speed (Hertz) Screen.
Press the LO SET button to advance to the
Low Voltage Lock Screen, page 13
. Press and hold for approximately 5 seconds to return to Operating
Mode.
The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode. See Fig. 9 and
Smart Gun Key, page 11 . To enter this screen, press
the LO SET button while in the Alternator Speed
(Hertz) Screen.
This screen displays the status of the Low Voltage
Lock. If the setting is locked, the lock image (LK) appears to the left of the Lo display (LD). If the setting is unlocked, the lock image does not appear.
To change the lock status, press and hold the
LO SET button until the lock image appears or disappears. If the lock is set, the image will also appear on the Low Voltage Setting Screen when in low voltage mode (see Fig. 4).
screen, because pressing and holding the LO SET button is used to turn the lock on or off. To exit, press LO SET momentarily to return to the Voltage
(kiloVolts) Screen, then exit Diagnostic Mode from there.
Figure 7 Alternator Speed (Hertz) Screen
Figure 8 Low Voltage Lock Screen
3A4795C 13
Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.
• Do not install or service this equipment unless you are trained and qualified.
• Be sure your installation complies with local, state, and national codes for the installation of electrical apparatus in a Class I, Div. I, hazardous location or a Group II, Zone I explosive atmosphere location.
• Comply with all local codes and regulations.
Table 3 (Typical Installation) shows a typical electrostatic air spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.
Do not operate the gun unless ventilating air flow is above the minimum required value. Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Interlock the gun air and fluid supply to prevent operation unless ventilating air flow is above the minimum required value.
The spray booth must have a ventilation system.
Electrically interlock the gun air and fluid supply with the ventilators to prevent gun operation any time that the ventilation air flow falls below minimum values.
Check and follow all local codes and regulations regarding air exhaust velocity requirements. Verify the operation of the interlock at least once a year.
NOTE: The minimum allowable air exhaust velocity is 60 feet/minute (19 linear meters/minute). High velocity air exhaust will decrease the operating efficiency of the electrostatic system.
Mount warning signs in the spray area where they can easily be seen and read by all operators. An
English Warning Sign is provided with the gun.
14 3A4795C
To reduce the risk of electric shock, the air supply hose must be electrically connected to a true earth
4.
Install a bleed-type air valve (BV) on the pump air supply line. The bleed-type air valve (BV) is required in your system to shut off air to the pump and relieve air trapped between the valve and the pump after the air regulator is shut off. Install an additional bleed-type air valve on the main air line (MA) to isolate the accessories for servicing.
5.
Install an air bleed valve (BV) on each gun air supply line to shut off air to the gun(s) and relieve air trapped between the valve and the gun after the air regulator is shut off.
1.
See Table 3. Use the Graco grounded air supply hose (AH) to supply air to the gun. The gun air inlet fitting has a left-hand thread. The air supply hose ground wire (AG) must be connected to a true earth ground. Do not connect the air supply hose to the gun air inlet yet.
2.
Install an air line filter/water separator (AF) on the gun air line to ensure a dry, clean, air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.
3.
Install bleed-type air regulators (PR, GR) on the pump and gun air supply lines to control air pressure to the pump and gun.
1.
Blow out the fluid line (FL) with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed. Do not connect the fluid supply line to the gun fluid inlet yet.
2.
Install a fluid regulator (FR) on the fluid line to control fluid pressure to the gun.
3.
Install a fluid filter (FF) near the pump outlet to remove particles and sediment which could clog the spray nozzle.
Trapped air can cause the pump to cycle unexpectedly, which can result in serious injury, including splashing fluid in the eyes or on the skin. Do not operate the equipment without the bleed-type air valve (BV) installed.
To reduce the risk of serious injury, including splashing fluid in the eyes or on the skin, do not operate equipment without the fluid drain valve (FD) installed.
4.
The fluid drain valve (FD) is required in your system to assist in relieving fluid pressure in the displacement pump, hose, and gun. Triggering the gun to relieve pressure may not be sufficient.
Install a drain valve close to the pump fluid outlet.
3A4795C 15
AL
BV*
EG
FD*
Item Description
AD
AF
AG*
AH*
Air Line Drain Valve
Air Filter/Water Separator
Gun Air Hose Ground Wire
Graco Grounded Air Hose (left-hand threads)
Pump Air Line Lubricator
Pump Bleed-Type Air Shutoff Valve
Electrostatic Air Spray Gun
Fluid Drain Valve
FF
FL
FR
Fluid Filter
Fluid Supply Line
Fluid Pressure Regulator
Item Description
FV
GR
Fluid Shutoff Valve
Gun Air Pressure Regulator
MA
PG*
PR
SP
SV*
Main Air Supply Line
Pump Ground Wire
Pump Air Pressure Regulator
Supply Pump
Ventilation Fan Interlock Solenoid Valve.
as a Graco accessory.
* These items are required for safe operation. They must be purchased separately.
16 3A4795C
• Electrostatic air spray gun: Ground the gun by connecting the Graco Grounded Air Hose
(AH) to the gun, and connecting the air hose ground wire to a true earth ground. See
Check Gun Electrical Grounding, page 25 .
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. Ground all equipment, personnel, objects being sprayed, and conductive objects in or close to the spray area. The resistance must not exceed
1 megohm. Grounding provides an escape wire for the electric current.
When operating the electrostatic gun, any ungrounded objects (such as people, containers, and tools) in the spray location can become electrically charged.
The following are minimum grounding requirements for a basic electrostatic system. 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 codes and regulations for detailed grounding instructions.
• All persons entering the spray area must wear shoes having conductive soles such as leather, or wear personal grounding straps. Do not wear shoes with non-conductive soles such as rubber or plastic. If gloves are necessary, wear the conductive gloves supplied with the gun. If non-Graco gloves are worn, cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle. Conductive gloves and footwear must not exceed 100 megohm per EN
ISO 20344, EN 1149–5.
•
•
Pump/fluid source: Ground the pump/fluid source by connecting its ground wire to a true earth ground.
All electrically conductive objects or devices in the spray area must be properly grounded.
• Object being sprayed: Keep the workpiece hangers clean and grounded at all times.
• Fluid and waste containers: Ground all fluid and waste containers in the spray area. Do not use pail liners unless they are conductive and grounded.
When flushing the spray gun, the container used to catch the excess fluid must be electrically conductive and grounded.
• Air compressors: Ground the equipment according to the manufacturer's recommendations.
• All air and fluid lines must be properly grounded.
Use only grounded hoses with a maximum of 100 feet (30.5 m) combined hose length to ensure grounding continuity.
3A4795C 17
• The floor of the spray area must be electrically conductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.
• Flammable liquids in the spray area must be kept in approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift.
• All solvent pails: Use only approved, grounded metal containers, which are conductive. Do not use plastic containers. Use only non-flammable solvents. Do not store more than the quantity needed for one shift.
18 3A4795C
Figure 9 Ground the Operator Operator is grounded through bare skin contact with the gun handle and conductive shoes. A conductive glove can also be used.
Figure 10 Ground the Object Being Sprayed Object being sprayed is grounded through contact with the hanger and conveyor system.
3A4795C 19
Figure 11 Ground the Gun Gun is grounded through the conductive air hose.
Figure 12 Ground the Fluid Supply Fluid supply line and source must be grounded.
20 3A4795C
See the figure below to locate the electrostatic gun controls.
3.
Shut off the air bleed valve to the gun.
4.
Check gun resistance.
See
.
5.
Connect the Graco grounded air hose to the gun air inlet. The gun air inlet fitting has left-hand threads.
Figure 13 Electrostatic Gun Controls
1.
The gun is shipped with the fluid nozzle and air cap installed. Check that the retaining ring is tight.
size fluid nozzle or air cap, see
Fluid Nozzle Selection Chart, page 64
and
Air Cap Selection Guide, page 67 .
To install the nozzle and air cap, see
Air Cap and Nozzle Replacement, page 39
.
2.
Turn OFF (O) the ES On-Off switch (J).
6.
Select a charging probe. Two probes are included with the gun.
• Long charging probe: For the best transfer efficiency and wrap
• Short charging probe: For low profile electrostatic charging
3A4795C 21
7.
Connect the charging probe.
a.
Liberally apply dielectric grease to the probe fitting, charging probe, and the two o-rings
(CC and CR).
9.
Follow all steps under
Check Gun Electrical Grounding, page 25
.
Reading must be less than 100 ohms.
10. Verify that the material resistivity meets requirements for electrostatic spray. See
Check Fluid Resistivity, page 26
.
11. Connect the exhaust tube and secure with the clamp provided.
b.
Firmly press the charging probe onto the gun in the Connect/Disconnect position, where the probe pin passes by the fitting slot.
12. Connect the fluid hose to the gun fluid inlet.
13. Flush if needed, see
14. Position the air cap as desired.
c.
Press the probe towards the barrel and rotate the charging probe from the
Connect/Disconnect position (CP) to the spray position (SP). NOTE: For proper performance, do not operate electrostatics if the charging probe is not in the spray position.
15. Fully open the fan air adjustment valve (F) counterclockwise.
16. Fully open the fluid adjustment valve (H) counterclockwise.
8.
Follow all steps under
22 3A4795C
17. Fully open the atomizing air restrictor valve (G) clockwise.
20. Check that the ES indicator (K) [Hz indicator on
Smart guns] is lit. See the following table.
18. Turn ON (I) the ES On-Off switch (J).
19. Set the gun air regulator to deliver a minimum
45 psi (0.32 MPa, 3.2 bar) at the gun when triggered, to ensure full spraying voltage. See the table below.
Green
Amber
Red
When spraying, the indicator should remain green, indicating sufficient air pressure to the alternator turbine.
If the indicator changes to amber after one second, the air pressure is too low. Increase air pressure until the indicator is green.
If the indicator changes to red after one second, the air pressure is too high. Decrease air pressure until the indicator is green. If you want to maintain a higher application air pressure, install
ES On/Off Valve Restrictor Kit
26A160. Adjust the pressure as needed to ensure the indicator remains green.
21. Shut off the air to the gun. Turn OFF (O) the ES
On-Off switch (J).
15 (4.6)
25 (7.6)
50 (15.3)
55 (0.38, 3.8)
65 (0.45, 4.5)
80 (0.56, 5.6)
3A4795C 23
22. Start the pump. Adjust the fluid regulator until the stream from the gun travels 8-12 in. (200-300 mm) before falling off. Typically, if fluid pressure is below 5 psi (.04 MPa, 0.4 bar) or above 30 psi
(0.21 MPa, 2.1 bar), a change of nozzle size is recommended.
24. Spray a test pattern. Check the atomization. If over-atomization occurs at minimum pressure, adjust the restrictor valve. If atomization is inadequate, increase air pressure or decrease fluid flow.
23. Turn on the air to the gun. Turn ON (I) the ES
On-Off switch (J).
25. Adjust the fan air adjustment valve.
• Fully open the fan air adjustment valve, counterclockwise, for the longest pattern.
• Turn the valve clockwise to restrict the fan air and create a shorter pattern.
24 3A4795C
5.
Make sure the grounded air hose (AH) is connected and the hose ground wire is connected to a true earth ground.
Megohmmeter Part No. 241079 (AA, see Fig. 14) is not approved for use in a hazardous location.
To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:
• The gun 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, and electric shock and result in serious injury and property damage.
Graco Part No. 241079 Megohmmeter is available as an accessory to check that the gun is properly grounded.
1.
Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose.
2.
Turn OFF (O) the ES On-Off switch.
6.
Measure the resistance between the gun handle
(BB) and a true earth ground (CC). Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 1 megohm. See Fig. 14.
7.
If the resistance is greater than 1 megohm, check the tightness of the ground connections and be sure the air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the air hose.
3.
Turn off the air and fluid supply to the gun. Follow the
Pressure Relief Procedure, page 27 .
4.
Disconnect the fluid hose.
Figure 14 Check Gun Electrical Grounding
3A4795C 25
To reduce the risk of fire, explosion, or electric shock, check the fluid resistivity in a non-hazardous location only. Resistance Meter 722886 and Probe
722860 are not approved for use in a hazardous location.
Check that the resistivity of the fluid being sprayed meets the requirements for an electrostatic air spray system. Graco Part No. 722886 Resistance Meter and 722860 Probe are available as accessories.
Follow the instructions included with the meter and probe.
The Pro Xp WBx gun is intended to spray very conductive waterborne materials and other materials less than 1 megohm-cm.
A viscosity cup and stopwatch are needed to check fluid viscosity.
1.
Completely submerge the viscosity cup in the fluid. Lift the cup out quickly, starting the stopwatch as soon as the cup is completely removed.
2.
Watch the stream of fluid coming from the bottom of the cup. As soon as there is a break in the stream, shut off the stopwatch.
3.
Record the fluid type, elapsed time, and size of the viscosity cup.
4.
If the viscosity is too high or too low, contact the material supplier. Adjust as necessary.
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
When spraying abrasive materials, follow these guidelines:
• Size the nozzle properly to reduce fluid pressure below 30 psi (0.21 MPa, 2.1 bar), producing an
8–12 in. (200–300 mm) fluid stream.
• Operate the gun with the fluid adjustment knob in the full flow position at all times. Use an external fluid regulator, not the fluid adjustment knob, to set the fluid pressure.
• Use the minimum atomizing and fan air pressures possible to achieve a good pattern.
• Follow all procedures under
.
26 3A4795C
4.
Open the pump drain valve, having a waste container ready to catch the drainage. Leave the pump drain valve open until you are ready to spray again.
This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as splashing, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.
1.
Turn OFF (O) the ES On/Off switch.
5.
If the nozzle or hose is completely clogged or pressure is not fully relieved, slowly loosen the hose end coupling. Now clear the nozzle or hose.
2.
Turn off the air bleed valves to the fluid source and to the gun.
3.
Trigger the gun into a grounded metal waste container to relieve the fluid pressure.
3A4795C 27
Follow all steps under
.
Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.
• All operators are properly trained to safely operate an automatic electrostatic air spray system as instructed in this manual.
• All operators are trained in the
Pressure Relief Procedure, page 27 .
• The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators.
• The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded. See
.
• The condition of the gun’s electrical components has been checked as instructed in
.
• Ventilation fans are operating properly.
• Workpiece hangers are clean and grounded.
• All debris (including flammable fluids and rags) is removed from the spray area.
• All 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.
1.
Flush the gun, see
2.
Follow the
Pressure Relief Procedure, page 27
.
3.
Hang the gun from its hook, with the nozzle pointing down.
28 3A4795C
To reduce the risk of an injury, follow the
Pressure Relief Procedure, page 27 , whenever
you are instructed to relieve the pressure.
• Flush before changing fluids, before fluid can dry in the equipment, at the end of the day, before storing, and before repairing equipment.
• Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.
Check the following list daily upon completion of equipment usage.
⃞ Flush the gun. See
⃞ Clean the fluid and air line filters.
⃞ Clean the outside of the gun. See
Clean the Gun Daily, page 30 .
⃞ Clean the air cap and fluid nozzle daily, at a minimum. Some applications require more frequent cleaning. Replace the spray tip and air cap if they are damaged. See
Clean the Gun Daily, page 30 .
⃞ Check the electrode and replace if broken or damaged.
See
Electrode Replacement, page 40
.
⃞ Check for fluid leakage from the gun and fluid hoses. Tighten fittings or replace equipment as needed.
⃞ Check electrical grounding. See
Check Gun Electrical Grounding, page 25
.
To reduce the risk of fire and explosion:
• Turn OFF (O) the ES On-Off switch before flushing the gun.
• Always ground equipment and waste containers.
• Flush equipment only in a well-ventilated area.
• To avoid static sparking and injury from splashing, always flush at the lowest possible pressure.
Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components.
1.
Turn OFF (O) the ES On-Off switch.
3A4795C
2.
Follow the
Pressure Relief Procedure, page 27
.
3.
Change the fluid source to solvent, or disconnect the fluid line and connect a solvent supply line to the gun.
29
4.
Point the gun into a grounded metal pail. Flush until clean solvent flows from the gun.
5.
Follow the
Pressure Relief Procedure, page 27
.
• Clean all parts with a compatible solvent.
Conductive solvents can cause the gun to malfunction.
• Fluid in the air passages could cause the gun to malfunction and could draw current and reduce the electrostatic effect. Fluid in the power supply cavity can reduce the turbine life. Whenever possible, point the gun down when cleaning it.
Do not use any cleaning method which could allow fluid into the gun air passages.
1.
Turn OFF (O) the ES On-Off switch.
6.
Shut off or disconnect the solvent line.
7.
Hang the gun from its hook, with the nozzle pointing down.
8.
When ready to spray again, reconnect the fluid supply line. Follow the
Gun Setup Procedure, page 21 .
2.
Flush the gun. See
3.
Follow the
Pressure Relief Procedure, page 27
.
4.
Clean the outside of the gun with a compatible solvent. Use a soft cloth. Point the gun down to prevent solvent from entering the gun passages.
Do not immerse the gun.
30 3A4795C
5.
Clean the air cap.
a.
Remove the air cap.
1.
Follow the
Pressure Relief Procedure, page 27
.
2.
Clean the fluid and air filters.
3.
Check for fluid leaks. Tighten all fittings.
b.
Clean the air cap, retaining ring, and nozzle with a soft brush and compatible solvent. Do not soak the retaining ring.
4.
Clean workpiece hangers. Use non-sparking tools.
c.
If necessary, use a toothpick or other soft tool to clean the air cap holes. Do not use metal tools.
5.
Check the movement of the trigger and valves.
Lubricate if necessary.
d.
Clean the probe with a soft brush and compatible solvent.
6.
Check Gun Electrical Grounding, page 25
.
7.
Hang the gun from its hook, with the nozzle pointing down.
e.
Reinstall the air cap. Tighten securely.
3A4795C 31
Electrical components inside the gun affect performance and safety. Use the following procedures test the condition of the power supply, gun body, charging probe, and electrical continuity between components.
Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V. Connect the leads as shown.
Megohmmeter Part No. 241079 (AA-see Fig. 17) is not approved for use in a hazardous location.
To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:
• The gun 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, and electric shock and result in serious injury and property damage.
1.
Flush and dry the fluid passage.
2.
Measure resistance between the charging probe tip (BB) and the air swivel (35). The resistance should be 90–145 megohms for guns with the long charging probe installed. The resistance should be 75–115 megohms for guns with the short charging probe installed.
If outside this range, test the probe resistance and test the gun resistance separately. See
Test Charging Probe Resistance, page 33
and
Test Gun Resistance with Probe Removed, page 33
.
Figure 15 Test Total Gun Resistance
32 3A4795C
Measure the resistance between the air swivel (35) and the charging probe fitting (CC). The resistance should be 75-115 megohms. If outside this range, check the power supply and barrel resistance.
See
Test Power Supply Resistance, page 34
and
Test Barrel Resistance, page 34
.
Measure the resistance between the metal spring in the charging probe (DD) and the charging probe tip (BB).
• For long charging probes, the resistance should be
15–30 megohms.
• For short charging probes, the resistance should be 0 megohms.
If outside this range, replace the charging probe. If in range, inspect the spring and barrel socket for possible causes of poor continuity. Reassemble the charging probe and retest the total gun resistance.
Figure 16 Test Gun Resistance Figure 17 Test Charging Probe Resistance
3A4795C 33
1.
Remove the power supply (11). See
Supply Removal and Replacement, page 44
.
2.
Remove the alternator (15) from the power supply.
See
Alternator Removal and Replacement, page 45 .
3.
Measure resistance from the power supply's ground strips (EE) to the spring (11a). The resistance should be 60–85 megohms. If the resistance is outside this range, replace the power supply.
4.
Refer to
Electrical Troubleshooting, page 37
for other possible causes of poor performance.
5.
Be sure the spring (11a) is in place before reinstalling the power supply.
1.
Insert a conductive rod (GG) into the gun barrel
(removed for the power supply test) and against the metal contact (HH) in the front of the barrel.
2.
Measure the resistance between the conductive rod (GG) and the charging probe socket (CC).
The resistance should be 15-30 megohms.
• If the resistance is outside the range, replace the barrel.
• If resistance is in range, reassemble the gun and test the gun resistance.
• If you still have problems, refer to
Electrical Troubleshooting, page 37
for other possible causes of poor performance.
Figure 18 Test Power Supply Resistance Figure 19 Test Barrel Resistance
34 3A4795C
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.
To reduce the risk of an injury, follow the
Pressure Relief Procedure, page 27 , whenever
you are instructed to relieve the pressure.
Check all possible remedies in the Troubleshooting Chart before disassembling the gun.
Some spray pattern problems are caused by the improper balance between air and fluid.
Fluttering or spitting spray.
Improper spray pattern.
No fluid.
Loose, dirty, damaged nozzle/seat.
Refill supply.
Clean or replace nozzle. See
or
Air Cap and Nozzle Replacement, page 39 .
Check fluid source. Refill.
Air in fluid supply.
Damaged or dirty nozzle or air cap.
Clean or replace. See
.
Fluid buildup on air cap or nozzle.
Clean.
See
.
Fan air pressure too high.
Fluid too thin.
Fluid pressure too low.
Fan air pressure too low.
Fluid too thick.
Too much fluid.
Decrease.
Increase viscosity.
Increase.
Increase.
Reduce viscosity.
Decrease flow.
Streaks.
Did not apply 50% overlap.
Dirty or damaged air cap.
Overlap strokes 50%.
Clean or replace air cap. See
or
Air Cap and Nozzle Replacement, page 39 .
3A4795C 35
Excessive spray fog.
“Orange Peel” finish.
Atomizing air pressure too high.
Fluid too thin, or fluid flow is too low.
Atomizing air pressure too low.
Close restrictor valve part way, or decrease air pressure as low as possible; minimum 45 psi (0.32
MPa, 3.2 bar) needed at gun for full voltage.
Increase viscosity or increase fluid flow rate.
Open atomizing air valve more or increase gun air inlet pressure; use lowest air pressure necessary.
Fluid leaks from the fluid packing area.
Fluid leakage from the front of the gun.
Gun does not spray.
Dirty air cap.
Poorly mixed or filtered fluid.
Fluid too thick.
Worn packings or rod.
Air leaks from the front of the gun.
Air valve is not seating properly.
Remix or refilter fluid.
Reduce viscosity.
Replace packings. See
Replace air valve. See
.
Worn or damaged fluid packing rod or electrode.
Worn fluid nozzle seat.
Replace packing rod or electrode.
See
or
Electrode Replacement, page 40 .
Replace nozzle (4). See
Air Cap and Nozzle Replacement, page 39 .
Tighten.
Loose fluid nozzle.
Damaged nozzle o-ring.
Replace o-ring. See
.
Add fluid if necessary.
Low fluid supply.
Dirty or clogged fluid nozzle.
Clean.
See
.
Open valve.
Closed or damaged fluid adjustment valve.
Misaligned air cap and fluid nozzle.
Clean fluid buildup off air cap and fluid nozzle seat. See
.
36 3A4795C
Poor wrap
NOTE: In general, the external charge gun has less wrap than a direct charge waterborne Pro Xp.
ES or Hz indicator is not lit.
Operator gets mild shock.
Operator gets shock from workpiece.
Voltage/current display stays red
(Smart guns only).
ES or HZ indicator is amber.
ES or Hz indicator is red.
ES On/Off switch is OFF (O).
Gun air pressure too low (ES indicator is amber).
Faulty gun resistance.
Turn ON (I).
Check air pressure to gun; minimum 45 psi (0.32 MPa, 3.2
bar) needed at gun for full voltage.
Decrease.
Atomizing air pressure too high.
Incorrect distance from gun to part.
Should be 8-12 in. (200-300 mm).
Poorly grounded parts.
Resistance must be 1 megohm or less. Clean workpiece hangers.
Weak electrostatic field.
Install a long charging probe on the gun.
See
Faulty alternator.
ES On/Off switch is OFF (O).
No power.
Replace alternator.
Turn ON (I).
Check power supply, alternator, and alternator ribbon cable. See
and
See
Operator not grounded or is near ungrounded object.
Gun not grounded.
Workpiece not grounded.
Gun is too close to the part being sprayed.
Check fluid resistivity.
See
Test Gun Resistance with Probe
.
Resistance must be 1 megohm or less. Clean workpiece hangers.
Gun should be 8–12 in. (200–300 mm) from the part.
Dirty gun.
Alternator speed is too low.
Alternator speed is too high.
See
Check Fluid Resistivity, page 26 .
See
Clean the Gun Daily, page 30 .
Increase air pressure until indicator is green. To avoid over-atomization, use the atomizing air restrictor valve to reduce the atomizing air to the air cap.
Decrease air pressure until indicator is green.
3A4795C 37
Installing and repairing this equipment requires access to parts that may cause electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.
To reduce the risk of injury, follow the Pressure
Relief Procedure before checking or servicing any part of the system and whenever you are instructed to relieve the pressure.
• Check all possible remedies in
before disassembling the gun.
• Use a vise with padded jaws to prevent damage to plastic parts.
• Lubricate some packing rod parts (2) and certain fluid fittings with dielectric grease (44), as specified in the text.
• Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate.
• Only use genuine Graco parts. Do not mix or use parts from other Pro Gun models.
• Air Seal Repair Kit 24N789 is available. The kit must be purchased separately. Kit parts are marked with an asterisk, for example (6a*).
• Fluid Seal Repair Kit 24N790 is available. The kit must be purchased separately. Kit parts are marked with a symbol, for example (2a‡).
1.
Flush the gun. See
2.
Relieve the pressure. Follow the
Pressure Relief Procedure, page 27 .
3.
Disconnect the gun air and fluid lines.
4.
Remove the gun from the worksite. Repair area must be clean.
38 3A4795C
Trigger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from entering the air passages.
1.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
Remove the retaining ring (6) and air cap (5).
3.
Trigger the gun while removing the fluid nozzle
(4) assembly with the multi-tool (41).
7.
Install the air cap (5) and retaining ring (6). Make sure the u-cup (6a*) is in place with the lips facing forward.
The nozzle contact ring (4a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the nozzle contact ring (4a) except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine Graco part.
111265, on the small o-ring (4b). Do not over-lubricate. Do not lubricate the conductive contact ring (4a). Excessive grease can mix with paint and blemish the finish on the workpiece.
4.
Make sure the conductive contact ring (4a) and the small o-ring (4b) are in place on the nozzle
(4). Lightly lubricate the small o-ring (4b).
show some wear at the point where it makes contact with the barrel pin. This is normal and does not require replacement.
5.
Make sure the electrode needle (3) is finger-tight.
6.
Trigger the gun while installing the fluid nozzle
(4) with the multi-tool (41). Tighten until the fluid nozzle seats in the gun barrel (1/8 to 1/4 turn past hand-tight).
Figure 20 Air Cap and Nozzle Replacement
3A4795C 39
1.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
Remove the air cap and nozzle. See
Air Cap and Nozzle Replacement, page 39
.
3.
Unscrew the electrode (3) with the multi-tool (41).
4.
Apply low-strength purple threadlocker to the electrode and packing rod threads. Install the electrode finger-tight. Do not overtighten.
5.
Install the fluid nozzle and air cap. See
Air Cap and Nozzle Replacement, page 39
.
1.
Remove the charging probe from the gun.
2.
With a flathead screwdriver, unscrew the pin from the charging probe.
3.
Inspect the threads for damage. Replace the probe if it is damaged.
4.
Clean the threads on the charging probe.
5.
Apply low-strength thread sealant (purple
Loctite® or equivalent) to the new pin threads.
NOTE: Loctite® is a registered trademark of the
Loctite Corporation.
6.
Install the pin finger-tight.
7.
Clean off any excess thread sealant.
To avoid equipment damage, use only the electrode needle available in kit 26A416.
Alternate electrodes are not acceptable for use and do not fit the packing rod threads.
Figure 22 Charging Probe Pin Replacement
Figure 21 Electrode Replacement
40 3A4795C
1.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
Remove the air cap and fluid nozzle. See
Air Cap and Nozzle Replacement, page 39
.
3.
Remove the electrode.
See
Electrode Replacement, page 40 .
4.
Loosen the trigger screws (13) and remove the trigger (12).
5.
Remove the packing rod (2), using the multi-tool
(41). Remove the spring (17).
6.
Check all parts for wear or damage and replace if necessary.
parts or as an assembly.
is discharged and the fluid stops before the air flow stops. The packing rod assembly is pre-adjusted at the factory for proper air lead and lag. Adjust only if necessary, as follows.
1.
Remove the spring (17) from the nut (2k).
2.
Use a hex wrench to hold the end of the packing rod. Turn both adjustment nuts (2j, 2k) out to increase the lead/lag time for the air flow. The recommended adjustment is one half turn and not more than one full turn.
3.
Tighten the nuts together to fix them in the new position.
Figure 23 Fluid Packing Rod Removal
3A4795C 41
gun barrel, make sure the internal surfaces of the barrel are clean. Remove any residue with a soft brush or cloth. Check the inside of the barrel for marks from high voltage arcing. If marks are present, replace the barrel.
1.
Place the packing nut (2f) and seal (2b‡) on the fluid rod (2e). Flats on the packing nut must face the back of the fluid rod. The seal o-ring must face away from the packing nut.
2.
Fill the inner cavity of the spacer (2h‡) with dielectric grease (44). Place the spacer on the fluid rod (2e) in the direction shown. Generously apply dielectric grease to the outside of the spacer.
3.
Place the fluid packing (2c‡) on the packing rod
(2e) with its lips facing the front of the rod. Install the needle packing (2d‡) with the male end toward the fluid packing, then install the housing
(2g) .
4.
Lightly tighten the packing nut (2f). The packing nut is properly tightened when there is 3 lb (13.3
N) of drag force when sliding the packing housing
(2g) assembly along the rod. Tighten or loosen the packing nut as needed.
5.
Install the o-ring (2a‡) on the outside of housing
(2g). Lubricate the o-ring with non-silicone grease, Part No. 111265. Do not over-lubricate.
6.
Install the spring (17) against the nut (2j) as shown.
7.
Install the packing rod assembly (2) into the gun barrel. Using the multi-tool (41), tighten the assembly until just snug.
8.
Install the electrode.
See
Electrode Replacement, page 40
, step 4.
9.
Install the nozzle and air cap. See
Air Cap and Nozzle Replacement, page 39 ,
steps 5–7.
10. Install the trigger (12) and screws (13).
Figure 24 Packing Rod
42 3A4795C
1.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
Carefully loosen the nut (N) from the bracket fluid fitting (20). Pull the tube (T) out of the fitting.
Make sure both ferrules (7, 8) and the nut stay with the tube.
3.
Loosen the two screws (27).
1.
Be sure the gasket (28*) and grounding spring
(18) are in place. Make sure the gasket air holes are aligned properly. Replace the gasket if damaged.
2.
Make sure the spring (11a) is in place on the tip of grease (44) to the tip of the power supply. Place the barrel (1) over the power supply and onto the gun handle (16).
3.
Tighten the two screws (27) oppositely and evenly (about a half turn past snug or 15–25 in-lb,
1.7–2.8 N•m).
To avoid damaging the power supply (11), pull the gun barrel (1) straight away from the gun handle (16). If necessary, gently move the gun barrel from side to side to free it from the gun handle.
4.
Hold the gun handle (16) with one hand and pull the barrel (1) straight off the handle.
remove the alternator/power supply assembly from the barrel.
To avoid damaging the gun barrel, do not over-tighten the screws (27).
4.
Assemble the fluid tube (T) into the bracket fitting
(20). Ensure that the ferrules (7, 8) are in place.
Tighten the nut (N) securely onto the fitting.
Make sure the top fitting remains tight.
5.
Follow the steps in
Figure 25 Barrel Removal
3A4795C
Figure 26 Barrel Installation
43
• Inspect the gun handle power supply cavity for dirt or moisture. Clean with a clean, dry rag.
• Do not expose gasket (28) to solvents. Replace the gasket if damaged.
1.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
Follow the steps in
.
9.
Insert the power supply/alternator assembly in the gun handle (16). Make sure the ground strips
(EE) make contact with the handle. On Smart models, align the connector of the 6-pin flexible circuit (24) with the socket (CS) at the top of the handle. Push the connector securely into the socket as you slide the power supply/alternator assembly into the handle.
Be careful when handling the power supply
(11) to avoid damaging it.
3.
Grasp the power supply (11) with your hand.
With a gentle side to side motion, free the power supply/alternator assembly from the gun handle
(16), then carefully pull it straight out.
On Smart
Models only, disconnect the flexible circuit (24) from the socket at the top of the handle.
4.
Inspect the power supply and alternator for damage.
5.
To separate the power supply (11) from the alternator (15), disconnect the 3-wire ribbon connector (PC) from the power supply.
On Smart
Models only, disconnect the 6–pin flexible circuit
(24) from the power supply. Slide the alternator up and off the power supply.
6.
Follow the steps in
Test Power Supply Resistance, page 34 .
Replace the power supply if necessary.
To repair the alternator, see
Alternator Removal and Replacement, page 45 .
7.
Smart models only: Connect the 6–pin flexible circuit (24) to the power supply.
10. Make sure the gasket (28*), ground spring (18), and power supply spring (11a) are in place.
Assemble the barrel (1) to the handle (16). See
.
11. Follow the steps in
To prevent damage to the cable and possible interruption of the ground continuity, bend the alternator’s 3-wire ribbon cable (PC) upward and back, so the bend faces the power supply and the connector is at the top.
8.
Connect the 3-wire ribbon connector (PC) to the power supply. Tuck the ribbon forward, under the power supply. Slide the alternator (15) down onto the power supply (11).
Figure 27 Power Supply Removal and Replacement
44 3A4795C
of operation. Order Part No. 24N706 Bearing Kit.
Parts included in the kit are marked with a symbol (♦).
1.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
Remove the power supply/alternator assembly and disconnect the alternator. See
Removal and Replacement, page 44 .
3.
Measure resistance between the two outer terminals of the 3-wire connector (PC); it should be 2.0–6.0 ohms. If outside this range, replace the alternator coil (15a).
4.
Using a flat blade screwdriver, pry the clip (15h) off the housing (15d). Remove the cap (15f), using a thin blade or screwdriver.
5.
If necessary, rotate the fan (15e) so its blades clear the four bearing tabs (T) of the housing
(15d).
6.
Push the fan and coil assembly (15a) out the front of the housing (15d).
Figure 28 Fan Orientation
Figure 29 Alternator Cross-Section
(Ref. 28♦ is not shown in the figure.)
To prevent damage, do not scratch or damage the magnet (M) or shaft (S). Do not pinch or damage the 3–wire connector (PC) when disassembling and reassembling the bearings.
7.
Hold the coil assembly (15a) on a workbench with the fan end facing up. Using a wide blade screwdriver, pry the fan (15e) off the shaft (S).
8.
Remove the top bearing (15b2).
9.
Remove the bottom bearing (15b1).
10. Install the new bottom bearing (15b1♦) on the long end of the shaft (S). The flatter side of the bearing must face away from the magnet (M).
Install in the coil (15a) so the bearing blades are flush with the surface of the coil.
11. Press the new top bearing (15b2♦) onto the short end of the shaft so the bearing blades are flush with the surface of the coil (15a). The flatter side of the bearing must face away from the coil.
3A4795C 45
12. Hold the coil assembly (15a) on a workbench with the fan end facing up. Press the fan (15e♦) onto the long end of the shaft (S). The fan blades must be oriented as shown.
13. Carefully press the coil assembly (15a) into the front of the housing (15d♦) while aligning the pin on the coil with the slot in the housing. The
3–wire connector (PC) must be positioned below the wider notch (W) of the housing tabs, as shown in Fig. 45. Be sure the coil alignment pins
(P) are positioned as shown in Fig. 44.
14. Rotate the fan (15e) so its blades clear the four bearing tabs (T) at the back of the housing.
Ensure that the blades of the bottom bearing
(15b1♦) align with the tabs.
15. Seat the coil fully into the housing (15d♦). Secure with the clip (15h♦), ensuring that its tabs engage the slots in the housing.
16. Ensure that the o-ring (15g) is in place. Install the cap (15f♦).
17. Install the alternator on the power supply, and install both parts in the handle. See
Supply Removal and Replacement, page 44
.
Figure 30 Alternator
46 3A4795C
1.
Follow the
Pressure Relief Procedure, page 27
.
2.
Remove the nut (22) from the bracket (20).
3.
Inspect the tube and fittings for damage. Replace as needed.
4.
Loosen the fitting (9) to remove the fluid tube
(14) from the barrel (1).
5.
Apply dielectric grease (44) to the threads of the fitting (9) and the o-ring (10). Ensure the ferrules
(7, 8) are in place and ensure that the sleeve
(SL) is in place near the top of the fluid tube.
6.
Slide the fitting (9) onto the fluid tube (14) and thread the fitting into the barrel (1). Torque to
25–35 in-lb (2.8–3.9 N•m).
7.
With the ferrules (7, 8) seated to the bracket (20), screw the nut (22) securely onto the bracket.
Make sure the top fitting remains tight.
1.
3.
5.
6.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
Place a wrench on the flats of the valve housing
(30a) and unscrew the valve from the handle
(16).
assembly (go to step 9) or replace only the o-ring
(steps 3–9).
Remove the retaining ring (30d).
4.
Turn the valve shaft (30b) counterclockwise until it comes free from the valve housing (30a).
Inspect the o-ring (30c). Remove if damaged.
Clean all parts and inspect for wear or damage.
111265. Do not over-lubricate.
7.
When reassembling the fan air valve (30), lightly lubricate the valve threads and screw the shaft
(30b) fully into the housing (30a) until bottomed.
Install the o-ring (30c*), lubricate, and unscrew the valve stem until the o-ring enters the housing.
8.
Reassemble the retaining ring (30d). Unscrew the valve stem from the housing until it is stopped by the retaining ring.
9.
Screw the valve assembly (30) into the gun handle (16), using a wrench on the flats of the housing. Torque to 15 in-lb (1.7 N•m).
Figure 31 Fluid Tube
Figure 32 Fan Air Adjustment Valve
3A4795C 47
1.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
Place a wrench on the flats of the valve housing
(29a) and unscrew the valve from the handle
(16).
assembly (go to step 9) or replace only the o-ring
(steps 3–9).
3.
Unscrew the valve stem (29e). Remove the retaining ring (29d).
4.
Turn the valve body (29b) counterclockwise until it comes free from the valve housing (29a).
5.
Inspect the o-ring (29c). Remove if damaged.
6.
Clean all parts and inspect for wear or damage.
111265. Do not over-lubricate.
7.
When reassembling the atomizing air restrictor valve (29), lightly lubricate the o-ring (29c) and push the valve body (29b) fully into the housing
(29a) until bottomed.
8.
Reassemble the retaining ring (29d). Thread the valve stem (29e) halfway into the valve body
(29b).
9.
Align the slot (S) in the valve stem with the rib (R) in the gun handle. Screw the valve assembly (29) into the gun handle (16), using a wrench on the flats of the housing. Torque to 15 in-lb (1.7 N•m).
desired, install the supplied plug (42).
Figure 33 Atomizing Air Restrictor Valve
Figure 34 Align Valve Stem
48 3A4795C
1.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
Loosen the captive screw (26p). Remove the valve (26) from the handle.
3.
Lubricate the o-rings (26b* and 26m*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
lubricant on the o-rings can be pushed into the gun air passage and blemish the finish on the workpiece.
4.
Clean and inspect parts for damage. Replace if necessary.
must point upward.
5.
Reinstall the valve. Torque the screw (27) to
15-25 in-lb (1.7-2.8 N•m).
Figure 35 ES On-Off Valve Repair, 24N630 and
26A160
Figure 36 ES On-Off Valve Repair, 24N632
3A4795C 49
1.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
Follow the steps in
.
3.
Remove the screws (13) and trigger (12).
4.
Remove the ES On-Off Valve. See
ES On-Off and Fluid Adjustment Valve Repair, page 49
, steps 1 and 2.
5.
Remove the spring (34).
6.
Push on the front of the air valve shaft to force it out the back of the handle. Inspect the rubber seal (23a*) and replace if damaged.
7.
Inspect the u-cup (35). Do not remove the u-cup unless damaged. If removed, install the new one with its lips facing into the gun handle (16). Place the u-cup on the shaft of the air valve to help seat it in the gun handle.
8.
Install the air valve (23) and spring (34) into the gun handle (16).
9.
Install the ES On-Off Valve. See
Fluid Adjustment Valve Repair, page 49 , steps
3 and 5.
10. Install the trigger (12) and screws (13).
11. Follow the steps in
.
Figure 38 Air Valve
Figure 37 Install U-Cup
50 3A4795C
If the Error display appears, the Smart Module has lost communication with the power supply. Check for good connections between the Smart Module and the power supply.
If the module’s LEDs are not lighting, replace the module.
1.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
Remove the pivot screw (31e), o-ring (31f), and
ES HI/LO switch (31c) at the bottom left corner of the Smart Module cartridge (31a).
3.
Remove the remaining three screws (31d) from the cartridge.
4.
Pull the Smart Module out the back of the gun.
Disconnect the ribbon cable (RC) from the connector (GC) in the gun handle.
5.
Remove the gasket (31b).
6.
Install a new gasket (31b) on the new cartridge
(31a). Make sure the notched corners of the gasket are at the top.
7.
Align the module’s ribbon cable (RC) with the gun’s cable (GC) and slide them securely together, as shown. Tuck the connected cables into the recess of the gun handle. Install the module flush to the back of the gun handle.
8.
Install the pivot screw (31e), o-ring (31f), and
ES HI/LO switch in the bottom left corner of the cartridge (31a).
9.
Install the three remaining screws (31d). Torque to 7–9 in-lb (0.8–1.0 N•m).
Figure 39 Smart Module
Figure 40 Align Ribbon Cables
3A4795C 51
1.
Follow the steps in
Prepare the Gun for Service, page 38 .
2.
To replace the air exhaust valve: a.
Remove the clamp (43) and the exhaust tube
(36).
b.
Unscrew the swivel (21) from the gun handle
(16). The swivel is a left-hand thread.
Remove the bracket (20).
c.
Pull the exhaust valve (19) from the handle
(16). Inspect the o-ring (19a) and replace if necessary.
d.
Install the o-ring (19a*) on the exhaust valve
(19). Lubricate the o-ring with a light coating of non-silicone grease.
e.
Install the exhaust valve (19) in the handle
(16).
f.
Apply thread sealant to the top threads of the swivel (21). Position the bracket (20) and screw the swivel into the gun handle (16).
Torque to 75–85 in-lb (8.4–9.6 N•m).
g.
Install the tube (36) and clamp (43).
3.
To replace the air inlet swivel: a.
Unscrew the swivel (21) from the gun handle
(16). The swivel is a left-hand thread.
b.
Apply thread sealant to the top threads of the swivel. Screw the swivel into the gun handle.
Torque to 75–85 in-lb (8.4–9.6 N•m).
Figure 41 Air Inlet Fitting and Air Exhaust Valve
52 3A4795C
1 Torque to 20 in-lb (2 N•m).
3A4795C 53
54
1 Torque to 20 in-lb (2 N•m).
3A4795C
Part No.
Description
3
4
1■
2
25E636 BODY, gun, 40 kV waterborne 1
26A422 See
26A416 NEEDLE, electrode
1
1
25N896 NOZZLE, 1.2 mm; includes
4a and 4b. See
.
24N645 O-RING, conductive
111507 O-RING; fluoroelastomer
1
1
4a
4b
5
6
6a*
7‡★ 111286 FERRULE, front
8‡★ 111285 FERRULE, back
9 24N657 FITTING, fluid
10★ 102982 PACKING, o-ring
11
24N477 AIR CAP. See
24N644 RING, retainer; includes 6a
1
1
198307 PACKING, u-cup; UHMWPE 1
2
2
1
24N659 POWER SUPPLY, 40 kV
11a
12
24N979
24N663
SPRING
TRIGGER; includes item 13
1
1
1
1
13
14
15
16
24A445 SCREW, trigger; package of 2 1
24N696 TUBE, fluid, with sleeve 1
24N664 See
25E641 HANDLE, model L40T28
1
1
25E642 HANDLE, model L40M28
185111 SPRING, compression
1
1 17
18
19
197624 SPRING, compression
249323 VALVE, exhaust
19a* 112085 O-RING
20 24N741 BRACKET
21
22
23
24N626 SWIVEL, air inlet; M12 x 1/4 npsm(m); left-hand thread
24N698 NUT, non-high conductivity models
24N633 VALVE, air
23a* 276733 SEAL, air valve
1
24 245265 CIRCUIT, flexible; model
L40M28 only
26⁂ 24N630 VALVE, ES On/Off, Fluid; see
ES On-Off and Fluid Adjustment
1
1
1
1
1
1
1
1
1
▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.
3A4795C
Part No.
Description
27
28*
29
30
31
34
35*
36
40
41
24N740 SCREW, hex socket; sst; package of 2
25N921 GASKET, barrel
1
24T304 VALVE, air restrictor. See
Atomizing Air Restrictor Valve
24N634 VALVE, fan air. See
24N756 See
Smart Module Assembly, page 61
. Model L40M28 only.
185116 SPRING, compression
1
1
188749 PACKING, u-cup
185103 TUBE, exhaust; 1/4 in. (6 mm)
ID (shipped loose)
107460 TOOL, wrench, ball end; 4 mm
(shipped loose)
1
1
276741 MULTI-TOOL (shipped loose) 1
1
1
1
1
42
43
44
45
24N786 PLUG, restrictor (shipped loose; for use instead of item 29; not shown)
110231 CLAMP, exhaust tube (shipped loose)
116553 GREASE, dielectric; 1 oz (30 ml) tube (not shown)
117824 GLOVE, conductive, medium; package of 12; also available in small (117823) and large
(117825); not shown
46 24N603 COVER, gun; package of 10
(not shown)
47▲ 179791 TAG, warning (not shown)
1
1
1
1
1
1
48▲ 16P802 SIGN, warning (not shown)
50 24N783 HOOK; includes screw
51✥ 25E639 KIT, charging probe, long; includes 55; pack of 2
52✥ 25E664 KIT, charging probe, short; includes 55; pack of 2
53
54
55
118594 O-RING, fluoroelastomer; quantity of 6 included in kit
25E647
111516 O-RING, fluoroelastomer; quantity of 6 included in kit
24E433
25E644 KIT, replacement pin; pack of 6
(not shown)
1
1
1
1
1
1
1
* These parts are included in Air Seal Repair Kit 24N789
(purchase separately).
55
‡ These parts are included in Fluid Seal Repair Kit 24N790
(purchase separately).
■ Gun body (Ref. 1) includes the barrel gasket (Ref. 28).
✥ Two charging probes are included with the gun: A long charging probe for the best transfer efficiency and wrap, and a short charging probe for low profile electrostatic charging.
⁂ ES On/Off Valve Restrictor Kit 26A160 is available for customers with high atomization air pressure applications.
Use this accessory if the turbine light indicator is red and you need to maintain a higher application air pressure.
Install the kit, then adjust the pressure as needed to ensure the indicator remains green.
56 3A4795C
Includes items 2a-2k
Part No.
Description
2a‡ 111316 O-RING
2b‡ 116905 SEAL
2c‡ 178409 PACKING, fluid
2d‡ 178763 PACKING, needle
2e 25E633 ROD, packing, (includes items 2j and 2k)
2f 197641 NUT, packing
1
1
1
1
1
1
‡ These parts are included in Fluid Seal Repair Kit
24N790 (purchase separately).
◆ These parts are included in Trigger Adjustment Nut
Kit 24N700 (purchase separately).
Part No.
Description
2g 185495 HOUSING, packing
2h‡ 186069 SPACER, packing
2j◆
— — —
NUT, trigger adjustment (part of item 2e)
2k◆
— — —
NUT, trigger adjustment (part of item 2e)
1
1
1
1
Parts labeled — — — are not available separately.
3A4795C 57
15a 24N705 COIL, alternator
15b♦ 24N706 BEARING KIT (includes two bearings, item 15d housing, item 15e fan, item 15f cap, and one item 15h clip)
15c 24Y264 SHAFT KIT (includes shaft and magnet)
1
15d♦ 24N707 HOUSING; includes item 15f 1
1
1
* These parts are included in Air Seal Repair Kit
24N789 (purchase separately).
♦ These parts are included in Bearing Kit 24N706
(purchase separately).
15e♦
15f♦
— — —
FAN; part of item 15b
— — — CAP, housing; part of item
15d
15g* 110073 O-RING
15h♦ 24N709 CLIP; package of 5 (one clip included with item 15b)
28♦* 25N921 GASKET, barrel (not shown) 1
1
1
1
1
Parts labeled — — — are not available separately.
58 3A4795C
3A4795C
Part No.
Description
26a
— — —
— — —
HOUSING, valve; black for standard model 24N630, blue for restricted model 26A160
HOUSING, valve; model
24N632
26b* 15D371 O-RING
26c
— — —
PISTON, valve
26f 24N649 LEVER, ES on-off; includes
26g; models 24N630 and
36A160
26g
24N650 LEVER, ES on-off; includes
26g; model 24N632
GC2082 SCREW, set, socket head
26h
26j
24N631 PLATE, retaining
24N648 KNOB, adjustment, fluid; includes 26g; models 24N630 and 36A160
25E767 KNOB, adjustment, fluid; blue; includes 26g; models 24N630 and 36A160
26m* 113746 O-RING
26p 24N740 SCREW, captive; pack of 2
1
1
1
1
1
1
2
1
1
2
1
1
* These parts are included in Air Seal Repair Kit
24N789 (purchase separately).
Parts labeled — — — are not available separately.
59
Part No.
Description
30a
— — —
— — —
NUT, valve 1
30b
— — —
STEM, valve 1
STEM, valve; round spray only 1
30c* 111504 O-RING 1
30d 24N646 RING, retaining; package of 6 1
* These parts are included in Air Seal Repair Kit
24N789 (purchase separately).
Parts labeled — — — are not available separately.
Ref.
No.
Part No.
Description
29a
29b
— — —
— — —
HOUSING, valve
BODY, valve
— — —
BODY, valve; round spray only 1
29c* 111516 O-RING 1
29d 118907 RING, retaining
29e
— — —
STEM, valve
29f
— — —
KNOB, shaft; round spray only
1
1
1
29g
— — —
SETSCREW, knob; round spray only
1
1
1
* These parts are included in Air Seal Repair Kit
24N789 (purchase separately).
Parts labeled — — — are not available separately.
60 3A4795C
Part No.
Description
31a
31b
31c
31d♦
31e♦
31f
— — —
CARTRIDGE
24P433 GASKET
24N787 SWITCH, ES HI/LO
— — —
SCREW
— — —
SCREW, pivot
112319 O-RING
3
1
1
1
1
1
Parts labeled — — — are not available separately.
♦ These parts are included in Smart Module Screw
Kit 24N757 (purchase separately).
3A4795C 61
short charging probe.
reference and are not included in the kit.
Ref.
No.
4
4a
4b
5
29
30
49
Part No.
Description
24N729 NOZZLE, round spray; includes 4a and 4b. See
Fluid Nozzle Selection Chart, page 64 .
24N645 O-RING, conductive
111507 O-RING; fluoroelastomer
1
24N731 AIR CAP, round spray. See
.
24N733 ATOMIZING AIR
RESTRICTOR VALVE, round spray
24N732 FAN AIR ADJUSTMENT
VALVE, round spray
24N730 DIFFUSER, round spray
1
1
1
1
1
1
62 3A4795C
short charging probe.
reference and are not included in the kit.
3
3c
4
4a
4b
4c
4d
5
6
3a
3b
Part No.
Description
25N838 AIR CAP, inner, small pattern; includes 3a–3c
1
25N839 AIR CAP, inner, medium pattern; includes 3a–3c
1
25N938 DEFLECTOR, small pattern 1
25N939 DEFLECTOR, medium pattern 1
113137 O-RING, small pattern 1
113746 O-RING, medium pattern
— — —
DIFFUSER, small pattern
— — —
DIFFUSER, medium pattern
1
1
1
24N729 NOZZLE, round spray; includes 4a–4d
24N645 O-RING, conductive
1
1
111507 O-RING; fluoroelastomer
117610 O-RING
1
1
111516 CONDUCTIVE CONTACT
RING
25N840 AIR CAP, small pattern
25N841 AIR CAP, medium pattern
— — —
RETAINING RING
1
1
1
1
3A4795C 63
To reduce the risk of an injury, follow the
Pressure Relief Procedure, page 27 , before removing or installing
a fluid nozzle and/or air cap.
Color Description
24N619
24N613
25N895
25N896
24N616
25N897
24N618
25N831
25N832
25N833
25N834
24N620
24N621
24N622
24N623
24N624
24N625
24N729
25N835
0.55 (.022)
0.75 (.029)
1.0 (.042)
1.2 (.047)
1.5 (.055)
1.8 (.070)
2.0 (.079)
1.0 (.042)
1.2 (.047)
1.5 (.055)
1.8 (.070)
0.75 (.029)
1.0 (.042)
1.2 (.047)
1.5 (.055)
1.8 (.070)
2.0 (.079)
— — —
— — —
Black
Black
Green
Gray
Black
Brown
Black
Green
Gray
Black
Brown for standard coatings with hardened SST seat and damage resistant SST tip; for standard coatings, abrasives, and metallics
Blue with hardened ceramic seat, for abrasives and metallics
Black for use with large pattern round spray air cap only
Black for use with medium or small pattern round spray air caps only
64 3A4795C
Use the following procedure to select the proper fluid nozzle for your application.
1.
For each fluid nozzle chart, find the point on the graph corresponding to your desired flow rate and viscosity. Mark the point on each graph with a pencil.
2.
The thick vertical line in each graph represents the target flow rate for that nozzle size. Find the graph that has the marked point closest to the thick vertical line. This is the recommended nozzle size for your application. Significantly exceeding the target flow rate may result in lower spray performance due to excessive fluid velocity.
3.
From the marked point, move across to the vertical scale to find the required fluid pressure.
If the required pressure is too high, use the next largest nozzle size. If the fluid pressure is too low
(< 0.35 bar, 3.5 kPa, 5 psi), use the next smallest nozzle size.
260 Centipoise Fluid
160 Centipoise Fluid
70 Centipoise Fluid
20 Centipoise Fluid bar, psi oz/min, cc/min bar, psi oz/min, cc/min
3A4795C 65
bar, psi bar, psi oz/min, cc/min oz/min, cc/min bar, psi oz/min, cc/min bar, psi oz/min, cc/min
66 bar, psi oz/min, cc/min
3A4795C
To reduce the risk of an injury, follow the
Pressure Relief Procedure, page 27 , before
removing or installing a fluid nozzle and/or air cap.
The charts in this section can assist you in selecting an air cap.
• Keep in mind that more than one air cap can meet your finish requirements.
• When selecting an air cap, consider coating properties, part geometry, pattern shape, pattern size, and operator preferences.
All air cap pattern shapes and lengths in the following charts were measured under the following conditions, unless otherwise noted: material-dependent.
• Distance to target: 10 in. (254 mm)
• Inlet air pressure: 50 psi (34 kPa, 3.4 bar)
• Fan air: adjusted for maximum length
• Fluid flow rate: 10 oz/min (300 cc/min)
3A4795C 67
NOTE: Pattern shapes are influenced by the material viscosity, flow rate, and air pressure settings. The gun may not maintain the intended design shape under all conditions.
option for smaller parts or cut-in painting.
passes.
68 3A4795C
Part No.
Color
24N477 Black
24W479 Green
24N438 Black
24N376 Black
24N276 Blue
24N277 Red
24N278 Green
24N274 Black
Standard Most versatile air cap. Recommended for most materials and applications. Class
A finish. Often used in waterborne applications.
Alternate Similar to the standard air cap with an alternate arrangement of atomizing air.
Long Pattern Longest spray pattern, optimized for painting large parts with overlapping paint passes. Often used in waterborne applications.
Short Pattern Shorter pattern, optimized for painting with overlapping passes.
Part No.
Color
24N477 Black
24W479 Green
24N438 Black
Standard Round end
Alternate Round end
Long Pattern Tapered end
24N376 Black
24N276 Blue
24N277 Red
24N278 Green
24N274 Black Short Pattern Tapered end
Medium to heavy
High solids
70–360 cp
360+ cp
15-17
(381-432)
15-17
(381-432)
17-19
(432-483)
Light to medium
Light to medium
Light to medium
Low
High
Very High
Standard
Standard
Standard
*Fluid Viscosity, in centipoise (cp) at 70°F (21°C).
Centipoise = centistokes x fluid specific gravity.
Light to medium 20–70 cp
12-14
(305-356)
Light to medium Standard
**Recommended Production Rates
Standard
Best
Best
Better
Good
Good
Good
Better
Best
300 cc/min to 500 cc/min (10 oz/min to 17 oz/min)
100 cc/min to 300 cc/min (3 oz/min to 10 oz/min)
500 cc/min to 600 cc/min (17 oz/min to 20 oz/min)
600 cc/min to 750 cc/min (20 oz/min to 25 oz/min)
3A4795C 69
Part No.
Color
25E670 Black
24N275 Black
24N279
24N439
25E671
Black
Black
Black
Description Guidelines
Soft Spray For painting small, lightweight parts with a slow-moving spray pattern. Optimized for low production rates.
Aerospace Optimized for aerospace coatings.
• Class A finish
• Light, medium, and heavy viscosity, and high solid coatings
• Very high production rates
Solids
Solids High
Flow
HVLP
Optimized for medium and heavy viscosity and high solid coatings at standard production rates.
Required for use with 2.0 mm nozzles. Optimized for medium and heavy viscosity and high solid coatings at high production rates.
For applications where HVLP is required.
Part No.
Color
Pattern
Length
Production
Rates** ization
Cleanliness
25E670
24N275
24N279
24N439
25E671
Black
Black
Black
Black
Black
Soft Spray
Aerospace
Solids
Solids High
Flow
HVLP
Round end
Tapered end
Round end
Tapered end
Round end
10-12
(254-
305)***
14-16
(356-406)
14-16
(356-406)
11-13
(279-330)
14-16
(356-406)
Light to medium
Light, medium, and heavy viscosity, and high solids
Medium to heavy viscosity and high solids
Medium to heavy viscosity and high solids
Light to medium
Low
Very High
Standard
High
Standard
Better
Good
Better
Best
Good
Good
Best
Good
Better
Good
*Fluid Viscosity, in centipoise (cp) at 70°F (21°C).
Centipoise = centistokes x fluid specific gravity.
Light to medium 20–70 cp
**Recommended Production Rates
Medium to heavy
High solids
70–360 cp
360+ cp
Standard
Low
High
Very High
300 cc/min to 500 cc/min (10 oz/min to 17 oz/min)
100 cc/min to 300 cc/min (3 oz/min to 10 oz/min)
500 cc/min to 600 cc/min (17 oz/min to 20 oz/min)
600 cc/min to 750 cc/min (20 oz/min to 25 oz/min)
***The soft spray air cap was measured with the fluid flow rate adjusted to 3.5 oz/min (100 cc/min).
70 3A4795C
Part No.
24N318
25N837
Color
Black
Black
25N836 Black
Description Guidelines
Large
Pattern
Conventional round pattern design for larger patterns up to 8 in (20 cm). Swirling, slow, round cone pattern for excellent finish and transfer efficiency.
Medium
Pattern
Small
Pattern
Dual inner and outer atomizing air design for improved atomization at low air flows.
For medium patterns up to 6 inches (15cm). Swirling, slow, round cone pattern for excellent finish and transfer efficiency.
Dual inner and outer atomizing air design for improved atomization at low air flows.
For small patterns up to 4 inches (10cm). Swirling, slow, round cone pattern for excellent finish and transfer efficiency.
Part No.
Color
Pattern
Diameter
24N318
25N837
25N836
Black
Black
Black
Large Pattern Round end
Medium
Pattern
Round end
Small Pattern Round end
8 (203)
6 (152)
4 (102)
*Fluid Viscosity, in centipoise (cp) at 70°F (21°C).
Centipoise = centistokes x fluid specific gravity.
Light to medium 20–70 cp
Light to medium
Light to medium
Light to medium
Medium to heavy
High solids
70–360 cp
360+ cp
Production
Rates**
Low
Low
Low ization
Good
Better
Better
Cleanliness
Good
Good
Good
**Recommended Production Rates
Standard
Low
High
Very High
300 cc/min to 500 cc/min (10 oz/min to 17 oz/min)
100 cc/min to 300 cc/min (3 oz/min to 10 oz/min)
500 cc/min to 600 cc/min (17 oz/min to 20 oz/min)
600 cc/min to 750 cc/min (20 oz/min to 25 oz/min)
3A4795C 71
otherwise noted), 85kv gun.
5/16 in. x 25 ft (8 mm x 7.6 m) hose
5/16 in. x 50 ft (8 mm x 15.2 m) hose scfm scfm
25
20
15
10
5
0
60 62 64 66 68 70 72 74 76 78 psi
25
20
15
10
5
0
50 55 60 65 70 75 80 psi scfm
18
16
14
12
10
8
6
4
2
0
50 55 60 65 70 75 80 85 psi
25E670: Atomization valve opened one turn from close.
25E671: Fan valve closed one turn from open.
Atomization valve closed four turns from open.
72 3A4795C
24N789
24N790
24N706
Air Seal Repair Kit
Fluid Seal Repair Kit
Alternator Bearing Repair Kit
105749
111265
116553
24N603
24N758
Cleaning Brush
Non-silicone Lubricant, 4 oz (113 g)
Dielectric Grease, 1 oz (30 ml)
Gun Covers (box of 10)
Display Covers (package of 5).
Keeps Smart display clean.
112534
185105
185493
24N642
224754
Air Line Quick Disconnect Fitting
Non-swivel Air Inlet; 1/4–18 npsm(m)
(left-hand thread)
Air Hose Adapter; 1/4 npt(m) x
1/4–18 npsm(m) (left-hand thread)
Ball Swivel, for gun air inlet; 1/4 npsm (left-hand thread)
Valve, ball 1/4 npsm (left-hand thread)
24N633
24P170
24P171
24N520
24N521
Plastic Trigger Kit
Metal Trigger Kit
Four Finger Trigger Kit, to convert
Pro Xp air spray guns to a four finger trigger
Comfort Grip. Snap-on grip increases handle size to reduce operator fatigue. Medium size.
Comfort Grip. Snap-on grip increases handle size to reduce operator fatigue. Large size.
25E664
25E639
Short Charging Probe Replacement
(pack of two)
Long Charging Probe Replacement
(pack of two)
26A160
24P634
24N630
24N632
ES On/Off Valve Restrictor for high atomizing air applications. Use this accessory if the turbine light indicator is red and you want to maintain a higher application air pressure. Install the kit, then adjust the pressure as needed to ensure the indicator remains green.
ES Always ON and fluid adjustment valve. When this valve is installed, the electrostatics are on anytime air pressure is supplied to the gun. Fluid adjustment is possible. Must be used with 224754 ball valve installed at the gun air inlet. See manual 3A6840.
ES On-Off and Fluid Adjustment
Valve
ES On-Off and Fixed Fluid Valve.
Use to extend electrode and nozzle life in applications with abrasive, metallic, and extremely abrasive materials.
24N636 Low Profile Atomizing Air Restrictor
Valve
3A4795C 73
24N634
24N732
24P172
25N919
Standard fan air adjustment valve
Fan air adjustment valve for large pattern round spray
Quick adjust fan valve for quick change of fan size
Quick adjust fan valve with spring return
16P802
16P798
16P799
English Warning Sign. Available at no charge from Graco.
English Daily Care Sign.
English Setup Sign
24N318
25N837
25N836
Round Spray Kit, large pattern, to convert a standard air spray gun to a round spray air cap. See manual
3A2498.
Round Spray Kit, medium pattern, to convert a standard air spray gun to a round spray air cap. See manual
3A6829.
Round Spray Kit, small pattern, to convert a standard air spray gun to a round spray air cap. See manual
3A6829.
241079
722886
722860
Megohmmeter. 500 V output,
0.01–2000 megohms. Use for ground continuity and gun resistance
Paint Resistance Meter. Use for fluid resistivity test. See manual 307263.
Paint Probe. Use for fluid resistivity
117823
117824
117825
Conductive Gloves, box of 12 (small)
Conductive Gloves, box of 12
(medium)
Conductive Gloves, box of 12 (large)
245277
24R038
25E919
Test Fixture, High Voltage Probe, and kV Meter. Use to test the electrostatic voltage of the gun, and the condition of the alternator and power supply when being serviced.
See manual 309455. Also requires
24R038 Conversion Kit.
Voltage Tester Conversion Kit.
Converts the 245277 Test Fixture for use with the Pro Xp Gun alternator.
See manual 406999.
HVLP Air Cap Verification Kit. Use to verify air pressures in air caps in HVLP applications. For use with 25E671 air cap. See manual
3A6833.
222011
24N528
24N529
24P312
Ground Wire and Clamp.
Gun Flush Box Adapter for 60 and
85 kV guns. To convert existing gun flush boxes to hold Pro Xp guns.
Gun Flush Box Adapter for 40 kV guns. To convert existing gun flush boxes to hold Pro Xp guns.
Gun Washer Kit. To convert existing gun washers to clean Pro Xp guns.
74 3A4795C
100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread
223068
223069
223070
223071
223072
223073
223074
24A225
24A226
244963
244964
244965
24J138
24N736
244966
24N737
244967
24N738
244968
244969
6 ft (1.8 m)
15 ft (4.6 m)
25 ft (7.6 m)
31 ft (9.4 m)
25 ft (7.6 m), with 112534 Quick
Disconnect
36 ft (11 m)
36 ft (11 m), with 112534 Quick
Disconnect
50 ft (15 m)
50 ft (15 m), with 112534 Quick
Disconnect
75 ft (23 m)
100 ft (30.5 m)
235068
235069
235070
235071
235072
235073
235074
6 ft (1.8 m)
15 ft (4.6 m)
25 ft (7.6 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
0.188 in. (5 mm) ID; 1/4 npsm(m) x 1/4 npsm(f) left-hand thread
236130
236131
3 ft (0.9 m)
6 ft (1.8 m)
6 ft (1.8 m)
15 ft (4.6 m)
25 ft (7.6 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
225 psi (1.4 MPa, 14 bar) Maximum Working
Pressure
1/4 in. (6 mm) ID; 3/8 npsm(fbe); nylon
215637
215638
25 ft (7.6 m)
50 ft (15 m)
50 ft (15 m)
75 ft (23 m)
3A4795C 75
L40M28
L40T28
8.7 (221)
8.7 (221)
9.2 (234)
9.2 (234)
2.9 (74)
2.9 (74)
10.5 (267)
10.5 (267)
24.9 (705)
22.5 (631)
76 3A4795C
Maximum Working Fluid Pressure
Maximum Working Air Pressure
Minimum Air Pressure at Gun Inlet
Air Consumption
Required turbine air flow
Range of total air flow under normal spraying conditions
Maximum Fluid Operating
Temperature
Ambient Temperature
Air Inlet Fitting
Fluid Inlet Fitting
Output Voltage
Maximum Current Draw
Sound Power (measured per ISO
Standard 9216)
Sound Pressure (measured 1 m from gun)
Wetted Parts
100 psi
100 psi
45 psi
0.7 MPa, 7.0 bar
0.7 MPa, 7.0 bar
0.32 MPa, 3.2 bar
6 scfm
15–20 scfm
120°F
170 l/min
425–565 l/min
48°C
41°–122°F 5°–50°C
1/4 npsm(m) left-hand thread
3/8 npsm(m)
40 kV
125 microamperes at 40 psi: 90.4 dB(A) at 0.28 MPa, 2.8 bar: 90.4 dB(A) at 100 psi: 105.4 dB(A) at 40 psi: 87.0 dB(A) at 0.7 MPa, 7.0 bar: 105.4 dB(A) at 0.28 MPa, 2.8 bar: 87.0 dB(A) at 100 psi: 99.0 dB(A) at 0.7 MPa, 7.0 bar: 99.0 dB(A)
Stainless steel, fluoroelastomer, PEEK, UHMWPE, FEP,
PTFE, acetal, nylon, polyethylene
3A4795C 77
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deficiency in the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid.
If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS
INCLUDING
PARTICULAR
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
FITNESS
OR
Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
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.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English, MM 3A2494 www.graco.com
Revision C, 2019–05
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