Graco 3A2497A, WB3000 Isolation System and Pro Xp 60 AA WB Gun Instructions

Instructions - Parts

WB3000 Isolation System &

Pro Xp™ 60 AA WB Gun

3A2497A

EN

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

For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

3000 psi (21 MPa, 210 bar) Maximum

Fluid Working Pressure

100 psi (0.7 MPa, 7 bar) Maximum

Air Working Pressure

See page 3 for model part numbers and approval information.

PROVEN QUALITY. LEADING TECHNOLOGY.

2

Contents

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

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

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

How the Electrostatic AA Spray Gun

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

Spraying Waterborne Fluids

Electrostatically .............................. 7

Controls, Indicators, and Components........... 8

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

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

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

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

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

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

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

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

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

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

Gun Setup.......................................................... 21

Grounding ................................................... 21

Check Gun Electrical Grounding ................... 23

Flush Before Using Equipment...................... 24

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

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

Fluid Voltage Discharge and Grounding

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

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

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

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

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

Maintenance ...................................................... 31

Flushing ...................................................... 31

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

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

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

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

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

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

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

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

Troubleshooting.................................................. 40

Voltage Loss Troubleshooting....................... 40

Spray Pattern Troubleshooting...................... 43

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

Electrical Troubleshooting ............................ 45

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

Prepare the Gun for Service ......................... 47

Air Cap, Spray Tip, and Fluid Seat Housing

Replacement.................................. 48

Electrode Replacement ................................ 49

Gun Barrel Removal..................................... 50

Gun Barrel Installation.................................. 50

Fluid Needle Replacement............................ 51

Power Supply Removal and

Replacement.................................. 52

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

Fan Air Adjustment Valve Repair .................. 55

Atomizing Air Adjustment Valve

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

ES On-Off Valve Repair ............................... 56

Air Valve Repair........................................... 57

Smart Module Replacement.......................... 58

Air Swivel and Exhaust Valve

Replacement.................................. 59

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

Standard Air-Assisted Spray Gun

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

Smart Air-Assisted Spray Gun

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

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

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

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

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

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

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

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

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

AEF Fine Finish Pre-Orifice Spray

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

Repair Kits, Related Manuals, and

Accessories .......................................... 73

Gun Accessories.......................................... 73

Operator Accessories................................... 73

System Accessories..................................... 73

Hoses ......................................................... 74

Test Equipment ........................................... 74

245895 Agitator Kit ...................................... 75

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

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

Graco Pro Xp Warranty....................................... 78

3A2497A

Models

Models

Models which are FM Approved and Compliant with EN50059

FM approved for use with fluids that meet the following condition:

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

Models Compliant with EN 50059 when used with fluids that meet the following criteria:

0.35 J, with

24M508 Hose

FM12ATEX0080

EN 50059

Ta 0°C – 50°C

Part No.

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

Model Description of less than 500 mJ.

24N551

24P632

24N550

H60T18

H60M18

24M508

WB3000

WB3000

WB3000

Waterborne Isolation Enclosure 24N550 with standard electrostatic air-assisted spray gun H60T18, grounded air hose

235070, and unshielded waterborne fluid hose 24M508.

Waterborne Isolation Enclosure 24N550 with smart electrostatic air-assisted spray gun H60M18, grounded air hose 235070, and unshielded waterborne fluid hose 24M508.

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

Pro Xp 60 AA WB Standard Electrostatic Air-assisted Spray Gun, for waterborne coatings.

Pro Xp 60 AA WB Smart Electrostatic Air-assisted Spray Gun, for waterborne coatings.

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

3A2497A 3

4

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers 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.

ELECTRIC SHOCK HAZARD

WARNING

Improper grounding, setup, or usage of an isolated waterborne system can result in electric shock. To help prevent electric shock:

• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to spray area. See Grounding instructions.

• Connect the electrostatic gun to a voltage isolation system that will discharge the system voltage when not in use.

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

• Follow the Fluid Voltage Discharge and Grounding Procedure when instructed to discharge the voltage; before cleaning, flushing, or servicing the system; before approaching the front of the gun; and before opening the isolation enclosure for the isolated fluid supply.

• Do not enter a high voltage or hazardous area until all high voltage equipment has been discharged.

• Do not touch the gun nozzle or electrode, or come within 4 in. (102 mm) of the electrode during gun operation. Follow the Fluid Voltage Discharge and Grounding Procedure.

• Interlock the gun air supply with the voltage isolation system to shut off the air supply anytime the isolation system enclosure is opened.

• Only use the red-colored Graco electrically conductive gun air hose with this gun. Do not use black or gray-colored Graco air hoses.

• Do not splice hoses together. Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the spray gun.

3A2497A

3A2497A

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Combustible dust in work area can ignite or explode. To help prevent fire and explosion:

• Fluids used must meet the following flammability requirements:

• FM, FMc Approved:

Material does not sustain burning in accordance with the Standard Test Method for

Sustained Burning of Liquid Mixtures, ASTM D4206.

• CE-EN 50059 Compliant:

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

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

• Check gun resistance, hose resistance, and electrical grounding daily.

• Use and clean equipment only in well ventilated area.

• Interlock the gun air supply to prevent operation unless ventilating fans are on.

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

• Always turn the electrostatics off when flushing, cleaning or servicing equipment.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

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

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

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

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

PLASTIC PARTS CLEANING SOLVENT HAZARD

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

• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.

• See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent manufacturer’s MSDSs and recommendations.

5

6

Warnings

WARNING

TOXIC FLUID OR FUMES

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

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

PERSONAL PROTECTIVE EQUIPMENT

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

• Protective eyewear, and hearing protection.

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

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

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

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

3A2497A

Gun Overview

Gun Overview

How the Electrostatic AA Spray Gun

Works

This is not an air spray gun. To help prevent serious injury from pressurized fluid, such as skin injection, and splashing fluid, read and follow the

Skin Injection Hazard Warnings on page 5.

The air-assisted spray gun combines airless and air spraying concepts. The spray tip atomizes and shapes the fluid into a fan pattern, as does a conventional airless spray tip. Air from the air cap further atomizes the fluid and completes the atomization of the fluid tails to produce a uniform pattern.

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

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

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

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

NOTE: For airless atomization, if desired, turn the gun’s atomizing air adjustment valve completely off.

Closing this valve does not affect alternator operation.

Spraying Waterborne Fluids

Electrostatically

This electrostatic air-assisted spray gun is designed to spray only waterborne fluids which meet the following flammability requirements:


Material does not sustain burning in accordance with the Standard Test Method for Sustained

Burning of Liquid Mixtures, ASTM D4206.



When connected to a voltage isolation system, all of the fluid in the spray gun, fluid hose, and isolated fluid supply is charged to high voltage, which means that the system has more electrical energy than a solvent-based system. Therefore, only non-flammable fluids (as defined under

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

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

Precautions must be taken when using electrostatic waterborne equipment to avoid potential shock hazards. When the spray gun charges the isolated fluid to high voltage, it is similar to charging a capacitor or a battery. The system will store some of the energy while spraying and retain some of that energy after the spray gun is shut off. Do not touch the gun nozzle or come within 4 in. (102 mm) of the electrode until the stored energy is discharged.

The amount of time it takes to discharge the energy depends on the system design. Follow the

Fluid Voltage Discharge and Grounding Procedure, page 25

before approaching the front of the gun.

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

3A2497A 7

Gun Overview

Controls, Indicators, and Components

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

1). For information on Smart guns, also see

Smart Guns, page 9

.

Item Description

A Air Swivel

Inlet

B

C

D

E

Fluid Hose

Turbine Air

Exhaust

Air Cap/Tip

Guard and

Spray Tip

Electrode

Purpose

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

Graco waterborne fluid hose

Barbed fitting, for supplied exhaust tube.

See

Spray Tip Selection

Chart, page 71 , for avail-

able sizes.

Supplies electrostatic charge to the fluid.

Item Description

F Fan Air

Adjustment

Valve

G Atomizing Air

Adjustment

Valve

H

J

K

Trigger Safety

Lock

ES On-Off

Valve

ES Indicator (standard gun only; for

Smart gun indicator, see

Operating

Mode, page

9 )

Purpose

Adjusts fan size and shape.

Can be used to decrease pattern width.

Adjusts atomizing air flow.

Locks trigger to prevent gun from spraying.

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

Lit when ES is ON (I).

Color indicates alternator frequency. See the LED indicator table on page 30.

Figure 1 Gun Overview

8 3A2497A

Gun Overview

Smart Guns

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

Operating Mode

Bar Graph

See Fig. 2, and Table 1 on page 11. The 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 uA bar graph LEDs are blue, the gun is ready to spray. If the LEDs are yellow or red, the current is too high. See

Electrical Troubleshooting, page 45

.

Hz Indicator

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

• Green indicates the alternator speed is correct.

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

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

Voltage Adjustment Switch

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

.

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

Error Display, page 10

for further information.

Figure 2 Smart Gun Module in Operating Mode

3A2497A 9

Gun Overview

Error Display

If the Smart module loses communication with the power supply, the Error display appears, the

Hz indicator turns red, and the Smart module is disabled. See Fig. 3, and Table 1 on page 11.

This can occur in Operating Mode or Diagnostic

Mode. See


.

Communication must be restored to make the Smart module functional.

NOTE: It takes 8 seconds for the Error display to appear. If the gun has been disassembled, wait 8 seconds before spraying to ensure that an Error condition has not occurred.

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

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

NOTE: The low voltage setting may be locked. See

Lock Symbol, page 10

.

Figure 4 Low Voltage Setting Screen (Unlocked)

Lock Symbol

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

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

SET button is pressed.

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

Low Voltage Lock Screen, page 14 , to lock or

unlock the low voltage setting.

Figure 3 Error Display

Adjusting 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 Table 1 on page 11. The range is 30–60 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 (60 kV) it will return to the minimum setting (30 kV). Continue pressing the button until you reach the desired setting.

Figure 5 Low Voltage Setting Screen (Locked)

10 3A2497A

Gun Overview

LV

LK

LD

ER

VI

Table 1 . Key for Figs. 2–9.

Item

VA

LO kV uA

LS

Description

Voltage Adjustment Switch

Low Voltage Mode Indicator

Voltage (kV) Display

Current (uA) Display

LO SET button

Low Voltage Display

Low Voltage Locked

Lo Display

Error Display

Voltage Indicator

Purpose

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.

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.

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.

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.

3A2497A 11

AS

Hz

Gun Overview

Item

CI

Description

Current Indicator

Alternator Speed Display

Alternator Speed Indicator

Purpose

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.

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 1 second, the alternator speed is too low.

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

In Diagnostic Mode, the indicator is green when in the Alternator

Speed (Hertz) screen.

12 3A2497A

Gun Overview

Diagnostic Mode

Diagnostic Mode includes four screens which display gun data:

• Voltage (kiloVolts) Screen

• Current (microAmperes) Screen

• Alternator Speed (Hertz) Screen

• Low Voltage Lock Screen

NOTE: You must be in Operating Mode to adjust the low voltage setting; the setting is not adjustable in

Diagnostic Mode. However, the voltage adjustment switch (VA) can be set to HI or LO in Operating Mode and Diagnostic Mode.

To enter Diagnostic Mode, press and hold the LO SET

(LS) button for approximately 5 seconds. The display will go to the

Voltage (kiloVolts) Screen, page 13

.

To 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.

NOTE: If the gun is detriggered while in Diagnostic

Mode, the last screen viewed will be displayed when the gun is retriggered.

NOTE: Diagnostic Mode cannot be exited from the Low Voltage Lock Screen. See

Low Voltage Lock Screen, page 14

for details.

Voltage (kiloVolts) Screen

The Voltage (kiloVolts) Screen is the first screen to appear after entering Diagnostic Mode. See Fig. 6, and Table 1 on page 11. 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 13 . Press

and hold for approximately 5 seconds to return to

Operating Mode.

Figure 6 Voltage (kiloVolts) Screen

Current (microAmperes) Screen

The Current (microAmperes) Screen is the second screen in the Diagnostic Mode. See Fig. 7, and Table

1 on page 11. To enter this screen, press the LO

SET button while in the Voltage (kiloVolts) Screen.

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


Alternator Speed (Hertz) Screen, page 14

. Press and hold for approximately 5 seconds to return to

Operating Mode.

Figure 7 Current (microAmperes) Screen

3A2497A 13

Gun Overview

Alternator Speed (Hertz) Screen

The Alternator Speed (Hertz) Screen is the third screen in the Diagnostic Mode. See Fig. 8, and Table

1 on page 11. To enter this screen, press the LO SET button while in the Current (microAmperes) Screen.

This screen displays the alternator speed as a 3 digit number (AS), rounded to the nearest 5 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.


Low Voltage Lock Screen, page 14 . Press and hold

for approximately 5 seconds to return to Operating

Mode.

Low Voltage Lock Screen

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

This screen 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).

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

(kiloVolts) Screen, then exit Diagnostic Mode from there.

Figure 8 Alternator Speed (Hertz) Screen

Figure 9 Low Voltage Lock Screen

14 3A2497A

Installation

Installation

System Requirements

A Graco voltage isolation system must have the following features:

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

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

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

NOTICE

The system should not have any severe arcing occurring when the isolation mechanism opens and closes. Severe arcing will shorten the life of the system components.

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

Install the System

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

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

• Be sure your installation complies with local, state, and national codes for the installation of electrical apparatus in a Class I, Div. I

Hazardous Location or Group II, Zone I

Explosive Atmosphere Location.

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

Fig. 12 shows a typical electrostatic air-assisted spray system. It is not an actual system design.

For assistance in designing a system to suit your particular needs, contact your Graco distributor.

Ventilate the Spray Booth

Warning Sign

Mount warning signs in the spray area where they can easily be seen and read by all operators. An

English Warning Sign is provided with the gun.

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

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

High velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 60 linear ft/min (18.3

linear meters/minute).

3A2497A 15

Installation

Air Supply Line

1. See Fig. 12. Install an air line filter/water separator (M) on the main air supply line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

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

To reduce the risk of electric shock or other serious injury, you must use the red-colored

Graco Electrically Conductive Air Hose for the gun air supply, and you must connect the hose ground wire to a true earth ground. Do not use the black or gray-colored Graco air hoses.

3. Connect the red-colored Graco Electrically

Conductive Air Hose (P) between the gun air regulator (N) and the gun’s air inlet. The gun air inlet fitting has a left-hand thread. Connect the air supply hose ground wire (Q) to a true earth ground.

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

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

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

Ground the Cabinet

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

16 3A2497A

Installation

Connect the Waterborne Fluid Hose

Always use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun fluid inlet.

Before connecting the waterborne fluid hose to the gun, blow it out with air and flush with water to remove contaminants. Flush the gun before using it.

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

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

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

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

3. Apply dielectric grease to the threads of the hose (101) and screw it into the barrel connector

(101a).

4. Align the bracket (B) holes with the air inlet and exhaust outlet. Secure with the air inlet fitting

(21).

5. Press the exhaust tube (35) onto the exhaust valve. Secure with the clamp (36).

6. Slide the other end of the hose through the hole in the side of the isolated enclosure. Connect the swivel (Z) to the fluid outlet of the pump. Secure the hose to the side of the enclosure with the bracket (W).

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

Figure 10 Connect the Fluid Hose

Figure 11 Unshielded Hose 24M508 Connection at

WB3000 Enclosure

3A2497A 17

Installation

Figure 12 Typical Installation, Pro Xp Waterborne

System

18 3A2497A

Installation

E

F

G

H

J*

K*

L

M

N

P*

C

D

Typical Installation Key

Item

A

B*

Q*

R

Description

Main Air Supply Line

Bleed-Type Air Shutoff

Valve

Pump Air Pressure

Gauge

Pump Air Pressure

Regulator kV Meter

Pump

Pump Suction Hose

Paint Container

Bleed Resistor

Enclosure Safety

Interlock

Isolated Enclosure

Gun Air Line Filter

Gun Air Pressure

Regulator

Graco Red Grounded

Air Hose (left-hand threads)

Gun Air Hose Ground

Wire

Graco Waterborne Fluid

Hose

Item

S

Description

Waterborne

Electrostatic

Air-Assisted Spray

Gun

Grounding Rod T

U

V*

W

Ground Terminal

Main Ground Wire

Strain Relief Fitting

Pump Air Supply Line X

Y

Z

AA

BB

Grounding Cylinder

Pump Fluid Outlet

Fitting

Isolated Enclosure Door

(not shown, to illustrate internal components.

Door must be closed and locked to operate system).

Enclosure T-Handle

Locking Screw (part of door assembly)

CC Accessory Bleed-Type

Air Shutoff Valve

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

3A2497A 19

Installation

Agitator Kit Accessory

To add an agitator to the Graco isolation system, order

Part No. 245895. See

245895 Agitator Kit, page 75

,

for the kit parts list.

1. Discharge the system voltage (see

Fluid Voltage

Discharge and Grounding Procedure, page 25 ).

2. Relieve the pressure (see

Pressure Relief Procedure, page 26

).

3. Open the isolated enclosure door.

4. Remove the back of the control box (258).

5. Remove tube (A2) from elbow (282) at the air manifold; see . Install the Y fitting (402) into the elbow. Install tubes (A2) and (407) into the

Y fitting. Route the agitator tube (407) into the cabinet.

6. Replace the back of the control box (258).

7. Assemble the other parts of the kit as shown.

Secure the agitator with the setscrew (408).

8. Return the system to service.

Figure 13 245895 Agitator Kit

20 3A2497A

Gun Setup

Gun Setup

Grounding

• Object being sprayed: keep the workpiece hangers clean and grounded at all times.

When operating the electrostatic gun, any ungrounded objects in the spray area (people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock. Ground all equipment, personnel, object being sprayed, and conductive objects in or close to the spray area. Resistance must not exceed 100 ohms. Follow the grounding instructions below.

•

The following are minimum grounding requirements for a basic electrostatic waterborne system. Your system may include other equipment or objects which must be grounded. Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground.

Voltage Isolation System: Electrically connect the voltage isolation system to a true earth ground.

See

Ground the Cabinet, page 16 .

• All electrically conductive objects or devices in the spray area: must be properly grounded.

•

•

•

Fluid and waste containers: ground all fluid and waste containers in the spray area. Do not use pail liners unless they are conductive and grounded.

When flushing the spray gun, the container used to catch the excess fluid must be electrically conductive and grounded.

Air compressors: ground the equipment according to the manufacturer's recommendations.

All air 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.

• Electrostatic Air-Assisted Spray Gun: ground the gun by connecting the red-colored Graco

Grounded Air Hose to the gun, and connecting the air hose ground wire to a true earth ground. See

Check Gun Electrical Grounding, page 23 .

3A2497A 21

Gun Setup

• 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.

• 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.

• All solvent pails: use only approved, grounded metal containers, which are conductive. Do not use plastic containers. Only use non-flammable solvents. Do not store more than the quantity needed for one shift.

22 3A2497A

Gun Setup

Check Gun Electrical Grounding

Megohmmeter Part No. 241079 (AA-see Fig.

14) is not approved for use in a hazardous area.

To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous area;

• Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes from spraying).

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

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

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.

3. Turn off the air and fluid supply to the gun. Follow the

Pressure Relief Procedure, page 26 .

4. Disconnect the fluid hose.

5. Make sure the grounded air hose is connected and the hose ground wire is connected to a true earth ground.

6. Measure the resistance between the gun handle

(BB) and a true earth ground (CC). Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed

100 ohms. See Fig. 14.

Figure 14 Check Gun Electrical Grounding

3A2497A 23

Gun Setup

7. If the resistance is greater than 100 ohms, 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.

8. Using an ohmmeter (AA) measure the resistance between the cabinet ground lug (214) and a true earth ground (CC). The resistance must be less than 100 ohms.

Figure 15 Check Cabinet Grounding

Flush Before Using Equipment

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

24 3A2497A

Operation

Operation

Operating Checklist

Check the following list daily, before starting the system.

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

⃞ All operators are trained in the


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


Procedure, page 25

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

⃞ The system is grounded according to the instructions in

Grounding, page 21

.

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

⃞ Ventilation fans are operating properly.

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

⃞ Fluids used must meet the following flammability requirements:


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

ASTM D4206.



Fluid Voltage Discharge and

Grounding Procedure

The fluid supply is charged with high voltage until the voltage is discharged. Contact with the charged components of the voltage isolation system or spray gun electrode will cause an electric shock.

To avoid an electric shock, follow the Fluid Voltage

Discharge and Grounding Procedure:

• whenever you are instructed to discharge the voltage

• before cleaning, flushing, or servicing the system equipment

• before approaching the front of the gun

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

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

2. Fully unscrew the door T-handle locking screw.

This will shut off the air to the gun and trigger the grounding cylinder to discharge any remaining electrical charge.

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


.

3A2497A 25

Operation

Pressure Relief Procedure

5. Disengage the trigger lock.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the

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

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

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

7. Engage the trigger lock.

2. Follow the


Grounding Procedure, page 25 .

3. Engage the trigger lock.

8. 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.

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

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

26 3A2497A

Operation

Fill the Fluid Supply

1. Follow the


Grounding Procedure, page 25

.

2. Follow the


.

3. Open the isolated enclosure door.

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

5. Remove the supply pail from the enclosure.

NOTICE

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

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

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

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

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

3A2497A 27

Operation

Adjust the Spray Pattern

To reduce the risk of fire and explosion, fluids used must meet the following flammability requirements:






To reduce the risk of an injury, follow the


whenever you are instructed to relieve the pressure.

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

Contact with the charged components of the spray gun will cause an electric shock. Do not touch the gun nozzle or electrode or come within 4 in.

(102 mm) of the electrode during operation or until performing the


Grounding Procedure, page 25

.

Follow the


Procedure, page 25

when you stop spraying and whenever you are instructed to discharge the voltage.

Figure 16 Electrostatic Gun Controls

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

To reduce the risk of component rupture, which can cause serious injury, do not exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi

(0.7 MPa, 7 bar) maximum air working pressure and a 3000 psi (21 MPa, 210 bar) maximum fluid working pressure.

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

28 3A2497A

3. Check gun resistance. See

Test Gun Resistance, page 36

.

4. Follow all steps under

Grounding, page 21 .

5. Follow all steps under

Check Gun Electrical Grounding, page 23

.

Reading must be less than 100 ohms.

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

the fan air adjustment valve (F).

Operation

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

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

7. Flush if needed. See

Flushing, page 31 .

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

Pressure Relief Procedure, page 26 ,

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

8. The fluid output and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pressure. Use the

Spray Tip Selection Chart, page 71 , as a guide

for selecting the appropriate spray tip for your application.

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

13. Start the pump. Set the fluid regulator to 400 psi

(2.8 MPa, 28 bar).

14. Spray a test pattern. Examine the particle size in the center of the pattern (tails will be removed in step 18). Increase the pressure in small increments. Spray another pattern. Compare particle size. Continue increasing pressure until the particle size remains constant. Do not exceed

3000 psi (21 MPa, 210 bar).

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

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

3A2497A 29

Operation

16. Check that the ES indicator (Hz indicator on

Smart guns) is lit, or check that the kV indicator on the isolated enclosure reads 30–50 kV.

The actual spraying voltage for AA waterborne systems is 40–50 kV, but because the charging electrode does not directly contact the fluid, the voltage measured by the WB3000 kV meter will be 5–10 kV lower. See the following table.

Table 2 . LED Indicator Colors

Indicator

Color

Green

Description

Amber

Red

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

If the indicator turns amber after

1 second, the air pressure is too low. Increase air pressure until the indicator is green.

If the indicator turns red after 1 second, the air pressure is too high. Decrease air pressure until the indicator is green.

17. Set the gun air regulator to deliver a minimum of

45 psi (0.32 MPa, 3.2 bar) at gun when triggered, to ensure full spraying voltage. See the table below.

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

19. If desired atomization is not achieved, change the tip size. The smaller the tip orifice, the finer the atomization.

20. Spray a test piece. Examine the edges for coverage. If wrap is poor, see

Troubleshooting, page 40

.

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

Table 3 . Pressure Drop

Air Hose

Length in ft (m)

(using 5/16 in. [8 mm] diameter hose)

15 (4.6)

25 (7.6)

50 (15.3)

75 (22.9)

100 (30.5)

Air Regulator Setting in psi (MPa, bar)

[with gun triggered]

52 (0.36, 3.6)

57 (0.40, 4.0)

68 (0.47, 4.7)

80 (0.56, 5.6)

90 (0.63, 6.3)

Shutdown

1. Discharge the system voltage. See

Fluid Voltage

Discharge and Grounding Procedure, page 25

.

2. Flush the gun. See

Flushing, page 31 .

3. Follow the


.

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

30 3A2497A

Maintenance

Maintenance

Flushing

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

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

• Flush with a non-flammable solvent that is compatible with the fluid being dispensed and the equipment wetted parts.

1. Turn OFF (O) the ES On-Off switch. Wait 30 seconds for the voltage to bleed off.

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

Follow the


Procedure, page 25 , before flushing.

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






NOTICE

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


Fluid Voltage


.

3. Follow the


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

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

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

3A2497A 31

Maintenance

7. Follow the


.

Engage the trigger lock.

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

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


9. Reinstall the air cap, tip guard, and retaining ring.

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

32 3A2497A

Clean the Gun Daily

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

Maintenance

7. Clean the outside of the gun with a non-flammable solvent, as defined under

Flushing, page 31 .

Use a soft cloth. Point the gun down to prevent solvent from entering the gun passages. Do not immerse the gun.


Fluid Voltage


.

3. Follow the


.

4. Remove the air cap/tip guard and spray tip.

5. Flush the gun, see

Flushing, page 31

.

6. Follow the


.

3A2497A 33

Maintenance

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


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

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

34 3A2497A

Daily System Care

1. Follow the instructions under

Clean the Gun Daily, page 33

. Follow the


.

2. Clean the fluid and air filters.

Maintenance

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

3. Check for fluid leaks. Tighten all fittings.

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

5. Check the movement of the trigger and valves.

Lubricate if necessary.

8. Clean the cabinet:

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

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

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

• Visually inspect the ground strip (240) for damage. Replace if needed.

Measure the resistance weekly. See

Test Ground Strip Resistance, page 39

.

6.

Check Gun Electrical Grounding, page 23

.

3A2497A 35

Electrical Tests

Electrical Tests

Use the following procedures to test the condition of the power supply and gun body, and electrical continuity between components.

NOTICE

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

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

Test Gun Resistance

1. Flush and dry the fluid passage.

2. Measure resistance between the electrode needle tip (25a) and the air swivel (21).

The resistance should be 104–150 megohms. If outside this range, go to

Test Power Supply Resistance, page 37

. If in

range, see


for other possible causes of poor performance, or contact your Graco distributor.

Megohmmeter Part No. 241079 (AA-see Fig.

17) is not approved for use in a hazardous area.

To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous area;

• Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes from spraying).

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

Figure 17 Test Gun Resistance

36 3A2497A

Electrical Tests

Test Power Supply Resistance

1. Remove the power supply (11). See

Power

Supply Removal and Replacement, page 52 .

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

Alternator Removal and Replacement, page 53 .

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

Test Gun Barrel Resistance, page 38

.

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

Figure 18 Test Power Supply Resistance

3A2497A 37

Electrical Tests

Test Gun Barrel Resistance

1. Insert a conductive rod (B) into the gun barrel

(which was removed for the power supply test) and against the metal contact (C) in the front of the barrel.

2. Measure the resistance between the conductive rod (B) and the conductive ring (9). The resistance should be 10–30 megohms. If the resistance is incorrect, make sure the metal contact (C) in the barrel and the conductive ring

(9) are clean and undamaged.

3. If the resistance is still outside the range, remove the conductive ring (9) and measure the resistance between the conductive rod (B) and the wire lead at the bottom of the conductive ring groove.

4. If the resistance is in range, replace the conductive ring (9) with a new one. Insert the ends of the conductive ring into the slots (S) at the front of the barrel, then press the ring firmly into the groove (G).

NOTICE

The conductive ring (9) is a conductive metal contact ring, not a sealing o-ring. For best performance and to avoid potential damage to the spray gun, do not remove the conductive ring (9) except to replace it and never operate the gun without the conductive ring in place.

Do not replace the conductive ring with anything but a genuine Graco part.

5. If the resistance is still outside the range, replace the gun barrel.

Figure 19 Test Gun Barrel Resistance

38 3A2497A

Test Ground Strip Resistance

Using an ohmmeter, measure the resistance between the latch housing (206) and the ground lug (214).

The ground strip is grounded through the cart back to the ground lug. Resistance must be less than 100 ohms. If greater than 100 ohms, replace the ground strip (240).

Electrical Tests

Test Cylinder Resistance

Remove the enclosure door. Using an ohmmeter, measure the resistance from the pump (209) to the ground lug (214). Resistance must be less than

100 ohms. If greater than 100 ohms, replace the grounding cylinder.

Figure 20 Test Ground Strip Resistance

Figure 21 Test Cylinder Resistance

3A2497A 39

Troubleshooting

Troubleshooting

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

Follow the


Procedure, page 25

before checking or servicing the system and whenever you are instructed to discharge the voltage.

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

Pressure Relief Procedure, page 26 ,

whenever you are instructed to relieve the pressure.

NOTE: Check all possible remedies in the

Troubleshooting Chart before disassembling the gun.

Voltage Loss Troubleshooting

Normal spraying voltage for a system using the waterborne gun is 40–50 kV. The system voltage is lower due to spraying current demands and voltage isolation system losses.

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

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

Spray Gun

• Fluid leakage

• Dielectric breakdown at the fluid hose connection or fluid packings

• Not enough air pressure for the alternator turbine

• Faulty power supply

• Excessive overspray on gun surfaces

• Fluid in the air passages

Waterborne Fluid Hose

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

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

Voltage Isolation System

• Fluid leakage

• Dirty interior

40 3A2497A

Troubleshooting

Visual Checks

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

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

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

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

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

5. Check that the gun ES ON/OFF valve is in the

ON position and that the gun ES indicator light is on. If the ES indicator light is not on, remove the spray gun for service and complete the

Electrical Tests, page 36

.

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

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

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

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

10. Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found.

Pay special attention to the following areas:

• Packing area of the spray gun.

• Fluid hose: check for leakage or any bulges in the outer cover, which may indicate an internal leak.

• Internal voltage isolation system components

3A2497A 41

Troubleshooting

Tests

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

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

2. Discharge the system voltage (see

Fluid Voltage

Discharge and Grounding Procedure, page 25 ).

3. Follow the


.

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

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

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

m) of the end of the hose.

6. Turn the ES ON/OFF valve to ON and trigger the gun just enough to turn on the air to the gun but not the fluid. Measure the voltage at the gun electrode with a voltage probe and meter.

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

8. Check the meter reading:

• If the meter reading is 40 to 50 kV, the gun and fluid hose are okay, and the problem is in the voltage isolation system.

• If the meter reading is below 40 kV, the problem is in the gun or fluid hose.

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

10. Turn the ES ON/OFF valve to ON and trigger the gun. Measure the voltage at the gun electrode with a voltage probe and meter.

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

• If the meter reading is below 40 kV, do

the

Electrical Tests, page 36 , to check the gun

and power supply resistance. If those tests show the gun and power supply are okay, continue with step 11.

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

a. Fluid hose:

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

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

b. Fluid needle:

Remove the fluid needle from the gun

(see

Fluid Needle Replacement, page 51

), and look for signs of fluid leakage or any blackened areas, which would indicate arcing is occurring along the packing rod.

c. Fluid hose connection to the spray gun:

A breakdown at the fluid hose connection joint would be caused by fluid leaking past the hose fittings. Remove the hose at the gun connection and look for signs of fluid leakage.

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

13. Reconnect the fluid hose.

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

42 3A2497A

Troubleshooting

Spray Pattern Troubleshooting

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

Problem

Fluttering or spitting spray.

Cause

No fluid.

Air in fluid supply.

Solution

Refill supply.

Check fluid source. Refill.

Irregular pattern.

Pattern pushed to one side; air cap gets dirty.

Tails in pattern.

Fluid buildup; partially plugged tip. Clean.

See

Clean the Gun Daily, page 33 .

Worn/damaged tip or air cap holes. Clean or replace.

Air cap holes plugged.

Air pressure too low.

Fluid pressure too low.

Clean.

See


Open atomizing air adjustment valve.

Increase.

Fluid buildup on air cap/tip guard.

Air pressure too high.

Fluid pressure too low.

Air cap holes plugged.

Decrease.

Increase.

Clean.

See


3A2497A 43

Troubleshooting

Gun Operation Troubleshooting

Problem

Excessive spray fog.

“Orange Peel” finish.

Dirty air cap.

Cause

Atomizing air pressure too high.

Fluid too thin.

Atomizing air pressure too low.

Spray tip is too large.

Damaged fluid needle.

Damaged or plugged air cap.

Solution

Close atomizing air valve part way, or decrease air pressure as low as possible; minimum 45 psi (0.32

MPa, 3.2 bar) needed at gun for full voltage.

Increase viscosity.

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

Use smaller tip. See

Spray Tip

Selection Chart, page 71

.

Poorly mixed or filtered fluid.

Fluid too thick.

Remix or refilter fluid.

Reduce viscosity.

Fluid leaks from the fluid packing area.

Worn fluid needle packings or rod. See

Air leaks from the front of the gun. Air valve is not seating properly.

page 51

.

See

Fluid Needle Replacement,

Air Valve Repair, page 57 .

Fluid leakage from the front of the gun.

Worn or damaged fluid needle ball. See

Worn fluid seat housing.

page 51

See


.

Seat Housing Replacement, page

48 .

Air Cap, Spray Tip, and Fluid

Loose spray tip.

Damaged tip seal.

Tighten retaining ring.

See

Air Cap, Spray Tip, and Fluid

Seat Housing Replacement, page

48 .

Gun does not spray.

Low fluid supply.

Damaged spray tip.

Dirty or clogged spray tip.

Add fluid if necessary.

Replace.

Clean.

See


See


page 51

.

Clean air cap. See


44 3A2497A

Troubleshooting

Electrical Troubleshooting

Problem

Poor wrap.

ES or Hz indicator is not lit.

Operator gets mild shock.

Operator gets shock from workpiece.

Cause

ES On/Off switch is OFF (O).

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

Solution

Turn ON (I).

Check air pressure to gun; minimum 45 psi (0.32 MPa, 3.2

bar) needed at gun for full voltage.

Atomizing air pressure too high.

Fluid pressure too high.

ES On/Off switch is OFF (O).

No power.

Decrease.

Decrease, or replace worn tip.

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

Poorly grounded parts.

Resistance must be 100 ohms or less. Clean workpiece hangers.

Faulty gun resistance.

See


.

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

Faulty alternator.

See

Fluid Needle Replacement, page 51

.

See

Alternator Removal and

Replacement, page 53 .

Turn ON (I).

Operator not grounded or is near ungrounded object.

Gun not grounded.

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


Replacement, page 52

and

Alternator Removal and


See

Grounding, page 21 .

Workpiece not grounded.

See

Check Gun Electrical

Grounding, page 23

, and


.

Resistance must be 100 ohms or less. Clean workpiece hangers.

3A2497A 45

Troubleshooting

Problem

Voltage/current display stays red

(smart guns only).

ES or Hz indicator is amber.

ES or Hz indicator is red.

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

Cause

Gun is too close to the part being sprayed.

Dirty gun.

Air turbine speed is too low.

Air turbine speed is too high.

Smart module has lost communication with the power supply.

Solution

Gun should be 8–12 in. (200–300 mm) from the part.

See


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.

Check for good connections between Smart Module and power supply. See

Smart Module


, and



46 3A2497A

Repair

Repair

Prepare the Gun for Service

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

To reduce the risk of injury, follow the


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

• Check all possible remedies in

Troubleshooting, page 40 , before disassembling

the gun.

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

• Lubricate the some needle assembly parts (20) and certain fluid fittings with dielectric grease (57), as specified in the text.

• Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate.

• Only use 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 (3*).

1. Flush the gun. See

Flushing, page 31 .

2. Relieve the pressure. See


3. Disconnect the gun air and fluid lines.

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

3A2497A 47

Repair

Air Cap, Spray Tip, and Fluid Seat

Housing Replacement

1. See

Prepare the Gun for Service, page 47 .

2. Remove the retainer ring (22) and air cap/tip guard assembly (25).

NOTICE

The conductive ring (9) is a conductive metal contact ring, not a sealing o-ring. For best performance and to avoid potential damage to the spray gun, do not remove the conductive ring (9) except to replace it and never operate the gun without the conductive ring in place.

Do not replace the conductive ring with anything but a genuine Graco part.

5. Trigger the gun and remove the fluid seat housing

(24), using the multi-tool (61).

Figure 22 Remove Air Cap

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

Figure 25 Replace Fluid Seat Housing

Figure 23 Disassemble Air Cap Assembly

Figure 24 Tip Gasket

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

Electrode Replacement, page 49

.

48 3A2497A

NOTICE

Do not overtighten the fluid seat housing (24).

Overtightening may damage the housing and the gun barrel, resulting in improper fluid shutoff.

6. Trigger the gun and install the fluid seat housing

(24). Tighten until snug, then 1/4 turn more.

7. Check that the spray tip gasket (27a) is in place.

Align the spray tip tab with the groove in the air cap (25). Install the spray tip (27) in the air cap.

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

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

10. Check that the u-cup (22a) is in place on the retaining ring (22). The lips of the u-cup must face forward.

NOTICE

To avoid damaging the tip guard, orient the air cap assembly (25) before tightening the retaining ring (22). Do not turn the air cap when the retaining ring is tight.

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

12. See

Test Gun Resistance, page 36 .

Repair

Electrode Replacement

NOTICE

For best performance and to avoid potential damage to the spray gun, do not operate the spray gun without the electrode installed in the air cap.

1. See

Prepare the Gun for Service, page 47

.

2. Remove the air cap assembly (25). See



.

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

4. Push the new electrode through the air cap hole.

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

5. Install the air cap assembly.

6. See


.

Figure 26 Replace Electrode

3A2497A 49

Repair

Gun Barrel Removal

1. See


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

3. Loosen the two screws (6).

NOTICE

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

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

Gun Barrel Installation

1. Be sure the gasket (5*) and grounding spring

(37a) are in place. Make sure the gasket air holes are aligned properly. Replace the gasket if damaged.

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

3. Tighten the two screws (6) oppositely and evenly

(about a half turn past snug). Do not over-tighten the screws (6).

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

5. See


.

Figure 27 Gun Barrel Removal Figure 28 Gun Barrel Installation

50 3A2497A

Fluid Needle Replacement

1. See


2. Remove the air cap assembly and fluid seat housing. See

Air Cap, Spray Tip, and Fluid Seat

Housing Replacement, page 48

.

3. Remove the gun barrel. See

Gun Barrel Removal, page 50 .

4. Remove the trigger screws (13) and trigger (12).

5. Unscrew the spring cap (37). Remove the spring

(20a).

6. Insert the supplied driver (60) in the socket at the back of the fluid needle. Press forward so the two segments of the needle engage (R). This allows the needle to be unscrewed from the gun body.

7. Using the multi-tool (61), pull back on the packing nut (N) to remove the fluid needle assembly.

8. Install the fluid needle assembly in the gun barrel.

Push in on the needle with the driver (60) and tighten.

9. Install the spring (20a).

10. Install the spring cap (37). Make sure the grounding spring (37a) is in place.

11. Install the trigger (12) and screws (13).

12. Install the gun barrel. See

Gun Barrel Installation, page 50

.

13. Install the seat housing and air cap assembly.

See



.

14. See

Test Gun Resistance, page 36 .

Figure 29 Remove Cap and Springs

Figure 30 Remove Fluid Needle

Figure 31 Replace Fluid Needle

Repair

3A2497A 51

Repair

Power Supply Removal and Replacement

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

• Do not expose gasket (5) to solvents.

1. See


2. See

Gun Barrel Removal, page 50

.

NOTICE

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 (40) 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

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

6. See

Test Power Supply Resistance, page 37 .

Replace the power supply if necessary.

To repair the alternator, see

Alternator Removal and Replacement, page 53 .

7.

Smart models only: connect the 6–pin flexible circuit (40) to the power supply.

align the connector of the 6–pin flexible circuit

(40) with the socket (CS) at the top of the handle.

Push the connector securely into the socket as you slide the power supply/alternator assembly into the handle.

Figure 32 Connect Flexible Circuit

10. Make sure the gasket (5*), ground spring (37a), and power supply spring (11a) are in place.

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

Gun Barrel Installation, page 50 .

11. See


.

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

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

9. Insert the power supply/alternator assembly in the gun handle (16). Make sure the ground strips make contact with the handle. On Smart models, Figure 33 Power Supply

52 3A2497A

Repair

Alternator Removal and Replacement

NOTE: Replace alternator bearings after 2000 hours of operation. Order Part No. 24N706 Bearing Kit.

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

1. See


2. Remove the power supply/alternator assembly and disconnect the alternator. See

Power Supply

Removal and Replacement, page 52

.

3. Measure resistance between the two outer terminals of the 3-wire connector (PC); it should be 2.0–6.0 ohms. If outside this range, replace the alternator coil (15a).

4. Using a flat blade screwdriver, pry the clip (15h) off the housing (15d). Remove the cap (15f), using a thin blade or screwdriver.

5. If necessary, rotate the fan (15e) so its blades clear the four bearing tabs (T) of the housing

(15d).

Figure 34 Fan Orientation

6. Push the fan and coil assembly (15a) out the front of the housing (15d).

Figure 35 Alternator Cross-Section

NOTICE

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

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.

3A2497A 53

Repair

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

13. Carefully press the coil assembly (15a) into the front of the housing (15d♦). The 3–wire connector (PC) must be positioned below the wider notch (W) of the housing tabs, as shown in

Fig. 35. Be sure the coil alignment pins (P) are positioned as shown in Fig. 34.

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

Ensure that the blades of the bottom bearing

(15b1♦) align with the tabs.

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

16. 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

Power

Supply Removal and Replacement, page 52

.

Figure 36 Alternator

54 3A2497A

Fan Air Adjustment Valve Repair

1. See


2. Place a wrench on the flats of the valve assembly

(30) and unscrew it from the handle (16).

NOTE: You may replace the valve as an assembly (go to step 9 ) or as individual parts

(steps 3 9 ).

3. Remove the retaining ring (30d).

4. Turn the valve shaft (30b) counterclockwise until it comes free from the valve housing (30a).

5. Remove the o-ring (30c).

6. Clean all parts and inspect for wear or damage.

NOTE: Use non-silicone grease, Part No.

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 38 Atomizing Air Adjustment Valve

Repair

Atomizing Air Adjustment Valve

Repair

1. See

Prepare the Gun for Service, page 47

.

2. Place a wrench on the flats of the valve assembly

(29) and unscrew it from the handle (16).

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

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

5. Install the valve assembly into the gun handle.

Torque the valve housing (29a) to 15 in-lb (1.7

N•m).

Figure 37 Fan Air Adjustment Valve

3A2497A 55

Repair

ES On-Off Valve Repair

1. See


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

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

NOTE: Do not over-lubricate parts. Excessive 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.

NOTE: The protrusion on the retainer plate (26f) must point upward.

5. Reinstall the valve. Torque the screw (26p) to

15-25 in-lb (1.7-2.8 N•m).

Figure 39 ES On-Off Valve

56 3A2497A

Repair

Air Valve Repair

1. See


2. See

Gun Barrel Removal, page 50 .

3. Remove the screws (13) and trigger (12).

4. Remove the ES On-Off Valve. See

ES On-Off Valve Repair, page 56

.

5. Remove the spring (2).

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 (3). 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 (2) into the gun handle (16).

9. Install the ES On-Off Valve. See

ES On-Off Valve Repair, page 56

.

10. Install the trigger (12) and screws (13).

11. See

Gun Barrel Installation, page 50

.

Figure 41 Air Valve

Figure 40 Install U-Cup

3A2497A 57

Repair

Smart Module Replacement

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. See


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 connector (GC) in the gun handle and slide it back toward the module to connect. 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 42 Smart Module

58 3A2497A

Repair

Air Swivel and Exhaust Valve Replacement

1. See


2. To replace the air exhaust valve: a. Remove the clamp (36) and the exhaust tube

(35).

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

(16). The swivel is a left-hand thread. Move the bracket out of the way.

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

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

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

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

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

(16).

f. Apply thread sealant to the top threads of the swivel (21). Position the bracket and screw the swivel into the gun handle (16). Torque to 75–85 in-lb (8.4–9.6 N•m).

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

3. To 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 43 Air Inlet Fitting and Air Exhaust Valve

3A2497A 59

Parts

Parts

Standard Air-Assisted Spray Gun Assembly

Part No. H60T18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61

Part No. 24M508 Unshielded Waterborne Fluid Hose (101), sold separately

60 3A2497A

Parts

Part No. H60T18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61


3*

5*

6

Ref.

No.

1

2

Part No. Description

24N745 BODY, gun

185116 SPRING, compression

188749 PACKING, u-cup

24N699 GASKET, body

24N740 SCREW, hex socket; package of 2

24N742 BRACKET

249323 VALVE, exhaust

Qty

7

8

8a*

9

112085 O-RING

24N747 RING, conductive

11 24N662 POWER SUPPLY, 60 kV gun 1

11a 24N979 SPRING 1

12 24N663 TRIGGER; includes item 13 1

13 24A445 SCREW, trigger; package of 2 1

1

1

1

1

1

1

1

1

1

15

16

24N664 See

Alternator Assembly, page 67

24P746 HANDLE; 60 kV AA gun

20 24N781 NEEDLE ASSEMBLY; includes item 20a

20a 24N782 SPRING, fluid needle

21

22

24N626 SWIVEL, air inlet; M12 x 1/4 npsm(m); left-hand thread

24N793 RING, retainer; includes 22a

22a* 198307 PACKING, u-cup; UHMWPE; part of 22

23 24N633 VALVE, air

1

23a* 276733 SEAL

24 24N725 HOUSING, seat

25 24N727 See

Air Cap Assembly, page 70

1

25a 24N643 ELECTRODE; package of 5 1

26 24N632 See

ES On-Off Valve Assembly,

page 68

1

1

1

1

1

1

1

1

1

1

Ref.

No.

27


AEMxxx

AEFxxx

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

27a 183459 GASKET, tip

Qty

1

1

29

30

32

24N792 ATOMIZING AIR

ADJUSTMENT VALVE

24N634 See

Fan Air Valve Assembly,

page 69

1

1

24E404 STOP, trigger; includes item 32a 1

32a — — — PIN, dowel 1

35

36

37

185103 TUBE, exhaust; 1/4 in. (6 mm)

ID (shipped loose)

110231 CLAMP

1

1

24N785 CAP, spring; includes item 37a 1

37a 197624 SPRING, compression

38

50

51

24N786 PLUG, fan control; option, shipped loose for use in place of item 29

24N783 HOOK; includes screw 1

112080 TOOL, needle (shipped loose) 1

1

1

54 24N604 COVER, gun; package of 10

55▲ 222385 CARD, warning (not shown)

1

1

56▲ 186118 SIGN, warning (not shown)

57

58

60

61

116553 GREASE, dielectric; 1 oz (30 ml) tube (not shown)

117824 GLOVE, conductive, medium; package of 12; also available

1

1

1 in small (117823) and large

(117825)

107460 TOOL, wrench, ball end

(shipped loose)

1

276741 MULTI-TOOL (shipped loose) 1

101 24M508 HOSE, unshielded, waterborne fluid; includes 101a

101a — — — CONNECTOR, barrel

1

1

Parts labeled — — — are not available separately.

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

* These parts are included in Air Seal Repair Kit

24N789 (purchase separately).

3A2497A 61

Parts

Smart Air-Assisted Spray Gun Assembly

Part No. H60M18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61


62 3A2497A

Parts

Part No. H60M18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61


3*

5*

6

Ref.

No.

1

2


24N745 BODY, gun

185116 SPRING, compression

188749 PACKING, u-cup

24N699 GASKET, body

24N740 SCREW, hex socket; package of 2

24N742 BRACKET

249323 VALVE, exhaust

Qty

7

8

8a*

9

112085 O-RING

24N747 RING, conductive

11 24N662 POWER SUPPLY, 60 kV gun 1

11a 24N979 SPRING 1

12 24N663 TRIGGER; includes item 13 1

13 24A445 SCREW, trigger; package of 2 1

1

1

15

16

20

24N664 See

Alternator Assembly, page 67

1

24P745 HANDLE, smart; 60 kV AA gun 1

24N781 NEEDLE ASSEMBLY; includes item 20a

20a 24N782 SPRING, fluid needle

1

1

1 21

22

24N626 SWIVEL, air inlet; M12 x 1/4 npsm(m); left-hand thread

24N793 RING, retainer; includes 22a

22a* 198307 PACKING, u-cup; UHMWPE; part of 22

23 24N633 VALVE, air 1

1

1

1

1

1

1

1

1

1

23a* 276733 SEAL

24 24N725 HOUSING, seat

25 24N727 See

Air Cap Assembly, page 70

1

25a 24N643 ELECTRODE; package of 5 1

26

27

24N632 See

ES On-Off Valve Assembly,

page 68

AEMxxx

AEFxxx

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

1

1

1

1

Ref.

No.


27a 183459 GASKET, tip

Qty

1

29

30

31

32

24N792 ATOMIZING AIR

ADJUSTMENT VALVE

24N634 See

Fan Air Valve Assembly,

page 69

24N756 See

Smart Module Assembly, page 70

24E404

32a — — — PIN, dowel

1

1

1

STOP, trigger; includes item 32a 1

1

35

36

185103 TUBE, exhaust; 1/4 in. (6 mm)

ID (shipped loose)

110231 CLAMP

1

1

37 24N785 CAP, spring; includes item 37a 1

37a 197624 SPRING, compression 1

38

40

24N786 PLUG, fan control; option, shipped loose for use in place of item 29

245265 CIRCUIT, flexible

24N783 HOOK; includes screw

1

1

50 1

51 112080 TOOL, needle (shipped loose) 1

54 24N604 COVER, gun; package of 10

55▲ 222385 CARD, warning (not shown)

1

1

56▲ 186118 SIGN, warning (not shown)

57

58

60

61

116553 GREASE, dielectric; 1 oz (30 ml) tube (not shown)

117824 GLOVE, conductive, medium; package of 12; also available

1

1

1 in small (117823) and large

(117825)

107460 TOOL, wrench, ball end

(shipped loose)

1

276741 MULTI-TOOL (shipped loose) 1

101 24M508 HOSE, unshielded, waterborne fluid; includes 101a

101a — — — CONNECTOR, barrel

1

1





3A2497A 63

Parts

Isolation Enclosure

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

64 3A2497A

Parts

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

Ref.

No.


201 — — — CABINET; includes 201a

201a 15A947 DOOR, cabinet

202 116993 CASTER, brake

203 — — — PLATE

Qty

204 15A551 T-HANDLE, latch

205 15A545 STEM, handle, door

206 15A524 HOUSING, latch

207 113061 SWITCH, push, air

209 24N548 PUMP; see 3A0732

210 — — — SCREW, hex hd cap; 5/16–18 x

5.5 in. (140 mm)

211 — — — WASHER, plain; 0.344 in. ID

212

214

— — — NUT, lock; 5/16–18

104029 LUG, ground

215 116989 VALVE, air

216 111804 REGULATOR, air

217 113060 GAUGE, air; 1/8 npt

218 116473 BALL VALVE; 1/4 npt(f)

219 233824 CART

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

226 190410 RESISTOR, bleed

227 116988 CYLINDER ROD

228 15A518 HOUSING, cylinder rod 1

229 104267 REGULATOR, air 1

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

235▲ 15A682 LABEL, warning 1

1

1

1

1

1

1

1

1

4

4

1

1

1

1

1

1

4

4

1

1

1

238 114958 STRAP, tie 5

239 222011 GROUND WIRE; 25 ft (7.6 m) 1

240 234018 STRIP, grounding; aluminum

241 110209 NUT, regulator

1

11

Ref.

No.


242 114051 WASHER, shim, ;atch

Qty

1

243 210084 ROD, ground 1

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

16

245 — — — WASHER, plain; 1/4 in. (6 mm) 16

246 — — — NUT, hex; 1/4–20 16

247 107257 SCREW, thread-forming 1

248 — — — TUBE; 1/4 in. (6 mm) OD; nylon A/R

249 160430 GAUGE, air

251 — — — WIRE, 10 gauge; green with yellow stripe

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

253 — — — NUT, hex; 10–32

1

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

257

258

101874

116990

TERMINAL, ring

BOX, control

259 113983 RING, retaining; 1/2 in. (13 mm) 1

260 237933 METER, 0–90 kV 1

5

1

5

2

1

1

261 113336 ADAPTER; 1/4 npt

262 — — — SCREW, pan hd; 10–32 x 5/8 in.

(16 mm)

263 — — — SCREW, pan hd; 10–32 x 1/4 in.

(6 mm)

264 — — — HOLDER, tie

265 — — — SCREW, button hd; 10–24 x 1.5

in. (38 mm)

266 — — — SCREW, button hd; 10–32 x 1.0

in. (25 mm)

267 — — — NUT, hex; M5 x 0.8

268 — — — WASHER, lock; no. 10

1

2

1

4

3

2

1

9

3A2497A 65

Parts

Ref.

No.


270 116991 TEE, run, manifold

271 203953 SCREW, hex hd cap with patch;

10–24 x 3/8 in. (10 mm)

272 — — — WIRE, 14 gauge; red

273 — — — WIRE, ground, 14 gauge; green with yellow stripe

274 155541 UNION, swivel; 1/4 npt

275 114261 TERMINAL, ring; no. 10

276 15A780 PLUG, hex hd

278 117314 BULKHEAD CONNECTOR; 1/4 npt

279 113319 CONNECTOR, tube; 1/4 npt x

3/8 in. (10 mm) OD tube

280 — — — ELBOW, tube

281 — — — FITTING, tube; 1/8 npt x 5/32 in.

(4 mm) OD tube

Qty

A/R

A/R

2

1

1

1

1

1

1

1

1


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

Ref.

No.


282 — — — SWIVEL, tube; 1/4 npt x 1/4 in.

(6 mm) OD tube

283 — — — SWIVEL, tube; 1/8 npt x 5/32 in.

(4 mm) OD tube

286 — — — TUBE; 3/8 in. (10 mm) OD

300★ 235070 HOSE, air, grounded; 0.315 in.

(8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread; red cover with stainless steel braid

301★ ground path; 25 ft (7.6 m) long

H60T18 GUN; see

Standard Air-Assisted

Spray Gun Assembly, page 60

H60M18 GUN; see

Smart Air-Assisted

Spray Gun Assembly, page 62

Qty

4

2

A/R

1

1

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

66 3A2497A

Alternator Assembly

Part No. 24N664 Alternator Assembly

Parts

Ref.

No.

15a

Part

No.

Description

24N705 COIL, alternator

Qty

1

15b♦ 24N706 BEARING KIT (includes two bearings, item 15e fan, and one item 15h clip)

1

15d♦ 24N707 HOUSING; includes item 15f 1

15e♦ — — — FAN; part of item 15b 1



♦ These parts are included in Bearing Kit 24N706

(purchase separately).

Ref.

No.

15f

Part

No.

Description

— — — CAP, housing; part of item

15d

110073 O-RING 15g*

15h♦ 24N709 CLIP; package of 5 (one clip included with item 15b)

1

1

Qty

1


3A2497A 67

Parts

ES On-Off Valve Assembly

Part No. 24N632 ES On-Off Valve Assembly

Ref.

No.


26a — — — HOUSING, valve

Qty

1

26b* 15D371 O-RING

26c — — — PISTON, valve

26d 24N650 LEVER, ES on-off; includes item 26e



2

1

1

Ref.

No.


26e — — — SCREW, set, socket head

26f 24N631 PLATE, retaining

26g* 113746 O-RING

26p — — — SCREW, captive


Qty

1

1

2

1

68 3A2497A

Fan Air Valve Assembly

Part No. 24N634 Fan Air Valve Assembly

Parts

Ref.

No.


30a — — — NUT, valve

Qty

1

30b — — — STEM, valve 1

30c* 111504 O-RING 1

30d 24N646 RING, retaining; package of 6 1




3A2497A 69

Parts

Air Cap Assembly

Part No. 24N727 Air Cap Assembly

Smart Module Assembly

Part No. 24N756 Smart Module Assembly

Ref.

No.


25a 24N643 ELECTRODE; package of 5

25b 24N734 O-RING; ptfe; package of 5

(also available in package of

10; order 24E459)

25c — — — AIR CAP

Qty

1

1

1

25d 24N726 GUARD, tip, orange 1


Ref.

No.

31a

31b

31c

31d♦

31e♦

31f

Part No.

Description

— — — CARTRIDGE

24P433 GASKET

24N787 SWITCH, ES HI/LO

— — — SCREW

— — — SCREW, pivot

112319 O-RING


♦ These parts are included in Smart Module Screw

Kit 24N757 (purchase separately).

Qty

1

3

1

1

1

1

70 3A2497A

Spray Tip Selection Chart

Spray Tip Selection Chart

AEM Fine Finish Spray Tips

Recommended for high finish quality applications at low and medium pressures. Order desired tip, Part No.

AEMxxx, where xxx = 3–digit number from the matrix below.

Orifice

Size in.

(mm)

Fluid Output fl oz/min (l/min) at 600 psi (4.1

MPa,

41 bar) at 1000 psi (7.0

MPa,

70 bar)

† 0.007

(0.178)

† 0.009

(0.229)

† 0.011

(0.279)

0.013

(0.330)

0.015

(0.381)

0.017

(0.432)

0.019

(0.483)

0.021

(0.533)

0.023

(0.584)

0.025

(0.635)

0.029

(0.736)

0.031

(0.787)

0.033

(0.838)

0.037

(0.939)

0.039

(0.990)

* Tips are tested in water.

40.0

(1.2)

50.0

(1.5)

68.0

(1.9)

78.0

(2.2)

88.0

(2.5)

108.0

(3.1)

118.0

(3.4)

17.0

(0.5)

22.0

(0.7)

28.0

(0.8)

35.0

(1.0)

4.0

(0.1)

7.0

(0.2)

10.0

(0.3)

13.0

(0.4)

51.9

(1.56)

64.8

(1.94)

88.2

(2.65)

101.1

(3.03)

114.1

(3.42)

140.0

(4.20)

153.0

(4.59)

22.0

(0.7)

28.5

(0.85)

36.3

(1.09)

45.4

(1.36)

5.2

(0.15)

9.1

(0.27)

13.0

(0.4)

16.9

(0.5)

2–4

(50–

100)

107

4–6

(100–

Maximum Pattern Width at 12 in. (305 mm) in. (mm)

150)

6-8

(150-

200)

8-10

(200-

250)

10-12

(250-

300)

12-14

(300-

350)

14-16

(350-

400)

Spray Tip

207 307

209

211

213

215

217

309

311

313

315

317

319

409

411

413

415

417

419

421

423

425

431

509

511

513

515

517

519

521

523

525

539

609

611

613

615

617

619

621

623

625

631

711

713

715

717

719

721

723

725

737

16-18

(400-

450)

813

815

821

823

825

829

831

833

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) fluid output (fl oz/min) at 600 psi from the above table for the selected orifice size.

† These tip sizes include a 150 mesh filter.

where QT =

3A2497A 71

Spray Tip Selection Chart

AEF Fine Finish Pre-Orifice Spray

Tips

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

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

Orifice

Size

Fluid Output fl oz/min (l/min) in. (mm) at 600 psi

(4.1 MPa,

41 bar) at 1000 psi (7.0

MPa, 70 bar)

† 0.010

(0.254)

0.012

(0.305)

9.5 (0.28) 12.5

12.0

(0.35)

(0.37)

16.0

(0.47)

0.014

(0.356)

0.016

(0.406)

16.0

(0.47)

20.0

(0.59)

21.0

(0.62)

26.5

(0.78)

* Tips are tested in water.

6-8 (150-

200)

310

312

314

Maximum Pattern Width at 12 in. (305 mm) in. (mm)

8-10

(200-250)

10-12

(250-300)

12-14

(300-350)

14-16

(350-400)

410

412

414

416

510

512

514

516

Spray Tip

610

612

614

616

710

712

714

716

16-18

(400-450)

812

814

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) fluid output (fl oz/min) at 600 psi from the above table for the selected orifice size.

† These tip sizes include a 150 mesh filter.

where QT =

72 3A2497A

Repair Kits, Related Manuals, and Accessories

Repair Kits, Related

Manuals, and Accessories

Gun Part No.

All guns in this manual.

Description

60 kV Waterborne

Air-Assisted Spray

Guns

Gun Accessories

Part No.

105749

111265

116553

24N319

24N604

24N758

24P170

24P172

185105

24N642

185493

112534

Description

Cleaning Brush.

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

Dielectric Grease. 1 oz (30 ml)

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

3A2499.

Gun Covers. Box of 10.

Display Covers. Keeps Smart display clean. Package of 5.

Metal Trigger Kit.

Quick Adjust Valve. For quick change of fan size.

Non-swivel Air Inlet; 1/4–18 npsm(m)

(left-hand thread)

Air Inlet Ball Swivel; 1/4–18 npsm(m)

(left-hand thread)

Air Hose Adapter; 1/4 npt(m) x

1/4–18 npsm(m) (left-hand thread)

Air Line Quick Disconnect Fitting.

Manual Description Repair Kits

Electrostatic

Waterborne

Air-Assisted

Spray Guns,

Instructions-Parts

24N789

24N706

Operator Accessories

Repair Kit

Description

Air Seal Repair Kit

Alternator Bearing

Repair Kit

Part No.

117823

117824

117825

24N520

24N521

Description

Conductive Gloves, box of 12 (small)

Conductive Gloves, box of 12

(medium)

Conductive Gloves, box of 12 (large)

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.

System Accessories

Part No.

222011

186118

Description

Ground Wire and Clamp.

English Warning Sign. Available at no charge from Graco.

3A2497A 73


Hoses

Grounded Air Hoses

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

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

Part No.

Description

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

235068

235069

235070

235071

6 ft (1.8 m)

15 ft (4.6 m)

25 ft (7.6 m)

36 ft (11 m)

50 ft (15 m) 235072

235073

235074

75 ft (23 m)

100 ft (30.5 m)

Test Equipment

Part No.

241079

245277

Description

Megohmmeter. 500 V output,

0.01–2000 megohms. Use for ground continuity and gun resistance tests.Not for use in hazardous areas.

Test Fixture, High Voltage Probe, and kV Meter. Use to test the electrostatic voltage of the gun, and the condition of the alternator and power supply when being serviced.

See manual 309455.

74 3A2497A

245895 Agitator Kit

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


Ref.

No.


401 112698 ELBOW, swivel; 1/8 npt(m) x

1/4 in. (6 mm) OD tube

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

403 193315 COLLAR, mounting, agitator

404 193316 NUT, collar, agitator

405 197298 COVER, pail; 5 gal. (19 liter)

406 224571 AGITATOR; see manual

306565

407 purchase locally

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

OD; 4 ft (1.22 m)

408 110272 SCREW, set, socket hd;

1/4–20 x 1/4 in. (6 mm)

Qty

1

1

1

1

1

1

1

1

3A2497A 75

Dimensions

Dimensions

Figure 44

Gun Model

H60T18

H60M18

A, in. (mm)

10.7 (272)

10.8 (274)

B, in. (mm)

8.9 (226)

9.6 (244)

C, in. (mm)

2.4 (61)

2.4 (61)

Weight without bracket, oz (g)

22.0 (623)

24.4 (692)

76 3A2497A

Technical Data

Technical Data

Electrostatic Air—Assisted Spray Waterborne Guns

Maximum Working Fluid Pressure

Maximum Working Air Pressure

Minimum Air Pressure at Gun Inlet

Maximum Fluid Operating

Temperature

U.S.

3000 psi

100 psi

45 psi

120°F

Short Circuit Current Output

Voltage Output Energy

Metric

21 MPa, 210 bar

0.7 MPa, 7.0 bar

0.32 MPa, 3.2 bar

48°C

125 microamperes

0.35 J with fluid hose 24M508 installed.

Sound Power (measured per ISO

Standard 9216)

H60T18: 60 kV

H60M18: 30–60 kV at 40 psi: 90.4 dB(A) at 0.28 MPa, 2.8 bar: 90.4 dB(A)

Sound Pressure (measured 1 m from gun)

Air Inlet Fitting

Fluid Inlet Fitting

Isolation Enclosure Air Inlet Fitting

Isolation Enclosure Fluid Inlet

Fitting

Wetted Parts 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)

1/4 npsm(m) left-hand thread

Custom inlet for Graco waterborne fluid hose.

1/4 npt

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

Gun: Stainless Steel, PEEK, UHMWPE, Fluoroelastomer, Acetal,

Nylon, Polyethylene, Tungsten Wire

Waterborne Fluid Hose: PTFE

Suction Tube: Polyethylene, Stainless Steel

Merkur Pump: See manual 3A0732.

3A2497A 77

Graco Pro Xp Warranty

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 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 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.

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.

FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR

COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco

(such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

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

FOR GRACO CANADA CUSTOMERS

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

Graco Information

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

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

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

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

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

Original Instructions. This manual contains English, MM 3A2497

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

Copyright 2012, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

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