Graco 334452E, ProBell Rotary Applicator, Standard Style Instructions
Advertisement
Advertisement
Instructions and Parts
ProBell
®
Rotary
Applicator
334452E
EN
For electrostatic finishing and coating applications in Class I, Div. I hazardous locations or
Group II, Zone 1 explosive atmospheres, using the following materials:
•
Solventborne Models:
Group D materials.
•
•
Group IIA materials.
Waterborne Models:
Conductive waterborne fluids that meet at least one of the following conditions for non-flammability:
Material does not sustain burning in accordance with the Standard Test Method for
Sustained Burning of Liquid Mixtures, ASTM D4206.
•
Material is classified as non-ignitable or hard to ignite as defined by EN 50176.
For professional use only.
100 psi (0.7 MPa, 7.0 bar) Maximum Air Inlet Pressure
150 psi (1.03 MPa, 10.3 bar) Maximum Fluid Working
Pressure
Important Safety Instructions
This equipment could present hazards if not operated according to the information in this manual.
Read all warnings and instructions in this manual and in all ProBell component manuals.
Save all instructions.
2
Table of Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Part Number Matrix . . . . . . . . . . . . . . . . . . . . . . . . . 3
Available Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System Description . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 10
Typical System Installation . . . . . . . . . . . . . . . . 11
Overview of Installation Steps . . . . . . . . . . . . . . 13
Step 1. Mount the Rotary Applicator . . . . . . . . . 13
Step 2. Connect All Lines at the Applicator . . . . 15
Connection Schematics . . . . . . . . . . . . . . . . . . 19
Step 3. Mount Controllers and Accessories . . . 21
Step 4. Connect Fluid Supply . . . . . . . . . . . . . . 23
Step 5. Connect the Air Lines . . . . . . . . . . . . . . 27
Step 6. Connect Power and Communication Cables
Step 7. Prepare the Spray Area . . . . . . . . . . . . 33
Step 8. Create Required System Interlocks . . . 33
Step 9. Ground the Equipment . . . . . . . . . . . . . 34
Check Electrical Grounding . . . . . . . . . . . . . . . . 35
System Logic Controller Setup . . . . . . . . . . . . . 37
Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pre-Operation Checklist . . . . . . . . . . . . . . . . . . 38
Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 39
Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 39
Spray Procedures . . . . . . . . . . . . . . . . . . . . . . . 39
Pressure Relief Procedure . . . . . . . . . . . . . . . . 42
Voltage Discharge and Grounding Procedure . . 42
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Daily Care and Cleaning Checklist . . . . . . . . . . 44
Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 44
Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Test Full Applicator with Power Supply . . . . . . . 45
Test Power Supply in Main Housing . . . . . . . . . 46
Test Power Supply . . . . . . . . . . . . . . . . . . . . . . . 48
Test Front Housing . . . . . . . . . . . . . . . . . . . . . . 48
Clean the Air Cap and Cup . . . . . . . . . . . . . . . . 49
Clean the Fluid Nozzle . . . . . . . . . . . . . . . . . . . 50
Clean the Outside of the Rotary Applicator . . . . 50
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Spray Pattern Troubleshooting . . . . . . . . . . . . . 51
Applicator Operation Troubleshooting . . . . . . . . 51
Electrical Troubleshooting . . . . . . . . . . . . . . . . . 53
Waterborne System Voltage Loss Troubleshooting
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Prepare for Cup or Air Cap Service . . . . . . . . . . 56
Prepare for Applicator Service . . . . . . . . . . . . . . 56
Replace Cup or Air Cap . . . . . . . . . . . . . . . . . . . 56
Service the Cup and Air Cap . . . . . . . . . . . . . . . 58
Replace Front Housing and Turbine Assembly . 61
Repair or Replace the Solvent Stud . . . . . . . . . 62
Repair Fluid Nozzle . . . . . . . . . . . . . . . . . . . . . . 62
Repair or Replace the Fluid Tube . . . . . . . . . . . 63
Replace Magnetic Pickup Sensor or Fiber Optic
Extension Cable . . . . . . . . . . . . . . . . . . . . . 63
Repair Fluid Valves and Seats . . . . . . . . . . . . . 65
Repair Fluid Tube Fittings or Coiled Fluid Tubes 66
Repair the Power Supply . . . . . . . . . . . . . . . . . . 67
Replace an Air Tube Fitting . . . . . . . . . . . . . . . . 67
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Solventborne Models (R_A1_0) . . . . . . . . . . . . 68
Waterborne Models (R_A1_8) . . . . . . . . . . . . . . 71
Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Main Housing Repair Kits . . . . . . . . . . . . . . . . . 74
O-Ring Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Fittings and Tools . . . . . . . . . . . . . . . . . . . . . . . . 74
Cup Selection Charts . . . . . . . . . . . . . . . . . . . . 75
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Mounting Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Fiber Optic Bulkhead Installation . . . . . . . . . . . . 77
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
60° Robot Mount - shown as shipped . . . . . . . . 80
60° Robot Mount - shown with mounting Kit 24Z179
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 83
Turbine Air Consumption Charts . . . . . . . . . . . . 83
Turbine Inlet Air Pressure Charts . . . . . . . . . . . 84
Shaping Air Consumption Charts . . . . . . . . . . . 86
Fluid Flow Rate Charts . . . . . . . . . . . . . . . . . . . 88
Fluid Pressure Loss Charts . . . . . . . . . . . . . . . . 91
Technical Specifications . . . . . . . . . . . . . . . . . . . . 93
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 94
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 94
334452E
Related Manuals
Related Manuals
Manual Description
334626
3A3657
3A3953
3A3954
3A3955
3A4232
3A4346
3A4384
3A4738
ProBell
®
Rotary Applicator, Hollow Wrist
ProBell
®
Electrostatic Controller
ProBell
®
Speed Controller
ProBell
®
Air Controller
ProBell
®
System Logic Controller
ProBell
®
Cart Systems
ProBell
®
Hose Bundle
ProBell
®
System CGM Installation Kit
ProBell
®
Reflective Speed Sensor Kit
Part Number Matrix
Check the identification plate (ID) for the part number of your applicator. The following matrix defines the components of your applicator based on the 6-digit part number.
Sample Part Number
R1A
15 mm Cup
1
ProBell Standard Applicator
3
0.75 mm nozzle
0
Solventborne
Cup Size
R1A 15 mm
R3A 30 mm
R5A 50 mm
Description and Mounting Style
1 ProBell Standard Rotary Applicator - Stationary,
Reciprocator, or Solid-Wrist Robot.
2 ProBell Rotary Applicator - Hollow Wrist, 60°
Robot Mount. See Manual 334626.
Nozzle Size
3 0.75 mm
4 1.0 mm
5 1.25 mm
6 1.5 mm
Fluid Type
0 Solventborne
8 Waterborne
334452E 3
Available Models
4
Available Models
Cup Size* Nozzle Size Fluid Type**
Part No.
R5A140
R5A150
R5A160
R5A148
R5A158
R5A168
R3A130
R3A140
R3A150
R3A160
R3A138
R3A148
R3A158
R3A168
R1A130
R1A140
R1A150
R1A138
R1A148
R1A158
50 mm
30 mm 15 mm
0.75 mm 1.0 mm
1.25 mm
1.5 mm
Solventborne
Waterborne
* All applicator models ship with a serrated aluminum cup. See the
Cup Selection Charts , page 75, to see all
available cups.
Maximum
Output Voltage
100 kV
100 kV
100 kV
60 kV
60 kV
60 kV
100 kV
100 kV
100 kV
100 kV
60 kV
60 kV
60 kV
60 kV
100 kV
100 kV
100 kV
60 kV
60 kV
60 kV
Approvals
Specific controllers, rotary applicators, and power supply cables must be used together. Refer to the table below for compatible models.
Model
RxAxx0
Electrostatic
Controller
24Z098
Power Supply
Cables Product Type
17J586
17J588
17J589
Solventborne
RxAxx8 24Z099
17J586
17J588
17J589
Waterborne
Applicator Approvals
0359
II 2G < 350 mJ T6
PTB 16 ATEX 5005
EN 50176 Type B-L
334452E
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements of this manual.
• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to the spray area. Resistance must not exceed 1 megohm. See Grounding instructions.
• Do not use pail liners unless they are conductive and grounded.
• Always use the required arc detection settings and maintain a safe distance of at least 6 inches
(152 mm) between the applicator and the workpiece.
• Stop operation immediately if static sparking or repeated arc detection errors occur. Do not use equipment until you identify and correct the problem.
• Check applicator resistance and electrical grounding daily.
• Use and clean equipment only in well ventilated area.
• Always turn off and discharge the electrostatics when flushing, cleaning or servicing equipment.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static sparking).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep the spray area clean at all times. Use non-sparking tools to clean residue from the booth and hangers.
• Keep a working fire extinguisher in the work area.
• Interlock the applicator air and fluid supply to prevent operation unless ventilation air flow is above the minimum required value.
• Interlock the Electrostatic Controller and fluid supply with the booth ventilation system to disable operation if the air flow falls below minimum values. Follow your local codes.
For solventborne systems only:
Use only Group IIA or Group D materials.
• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment.
• To clean the exterior of the equipment, cleaning solvents must have a flash point at least 15°C (59°F) above ambient temperature. Non-ignitable fluids are preferred.
For waterborne systems only:
Use conductive waterborne fluids that meet at least one of the following conditions for non-flammability:
• Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206.
• Material is classified as non-ignitable or hard to ignite as defined by EN 50176.
334452E 5
Warnings
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
For waterborne systems:
• Connect the applicator to a voltage isolation system that will discharge the system voltage when not in use.
• All components of the voltage isolation system that are charged to high voltage must be contained within an isolation enclosure that prevents personnel from making contact with the high voltage components before the system voltage is discharged.
• Follow the
Pressure Relief Procedure , including
Voltage Discharge , when instructed to discharge the voltage; before cleaning, flushing, or servicing the system; before entering the spray area; and before opening the isolation enclosure for the isolated fluid supply.
• Do not enter a high voltage or hazardous location until all high voltage equipment has been discharged.
• Do not touch the applicator or enter the spray area during operation. Follow the
Pressure Relief Procedure , including
Voltage Discharge.
• Interlock the Electrostatic Controller with the voltage isolation system to shut off the electrostatics anytime the isolation system enclosure is opened.
• Do not splice fluid hoses together. Install only one continuous Graco Waterborne Fluid Hose between the isolated fluid supply and the applicator.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.
• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning, checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
6 334452E
Warnings
334452E
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Always operate in accordance with all information given in the instruction manuals.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheet (SDS) from distributor or retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.
• See Technical Specifications in this and all other equipment instruction manuals. Read fluid and solvent manufacturer’s Safety Data Sheet (SDS) and recommendations.
ENTANGLEMENT HAZARD
Rotating parts can cause serious injury.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Do not wear loose clothing, jewelry or long hair while operating equipment.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
• Read Safety Data Sheet (SDS) to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
7
8
Introduction
Introduction
System Description
The ProBell Rotary Applicator is part of an electrostatic spraying system designed for industrial painting applications. The following three components are needed in all
ProBell spray systems.
• Rotary Applicator
• Power Supply Cable
• Electrostatic Controller
See
Typical System Installation , page 11, for other
available system components.
Rotary Applicator
Applicator Style
The ProBell Rotary Applicator, Standard style is designed for use on a stationary mount, a reciprocator, or a solid wrist robot. It has a straight body with all connections on the rear of the applicator.
The ProBell Rotary Applicator, Hollow Wrist style is designed for use on a hollow wrist robot. The body has a
60° angle with all connections through a quick-disconnect plate. This design allows all connections to run inside the arm of the hollow wrist robot. See Manual
334626.
Applicator Type
The Solventborne type is designed for use in Class 1,
Div. I Hazardous Locations using Group D spray materials, or for use in Group II, Zone 1 Explosive Atmosphere
Locations using Group IIA spray materials.
The Waterborne Type is for use in Class 1, Div. I Hazardous Locations or in Group II, Zone 1 Explosive Atmosphere Locations with conductive waterborne fluids that meet at least one of the following conditions for non-flammability:
• Material does not sustain burning in accordance with the Standard Test Methods for Sustained Burning of Liquid Mixtures, ASTM D4206.
• Material is classified as non-ignitable or hard to ignite as defined by EN 50176.
Power Supply Cable
The Power Supply Cable connects the ProBell Electrostatic Controller to the Power Supply in the ProBell
Rotary Applicator. The Power Supply Cable is available in three lengths: 11 meters (36 ft), 20 meters (66 ft), and
30 meters (98 ft).
ProBell Electrostatic Controller
The ProBell Electrostatic Controller (Manual 3A3657) provides the ability to display and set the voltage and current. It can operate remotely via discrete I/O or CAN communication.
334452E
Introduction
F IG . 1. Rotary Atomizer Components
Ref.
Component Description
1, 4 Main
Housing
13 Front
Housing
5
7, 9
10
15
18,
19
Speed Sensor Assembly
Fluid Tube and Nozzle
Turbine
Assembly
Retaining
Ring
Air Cap and
Cover
The housings direct the air, fluid and electrical charge from the customer connections to the front of the ProBell
Rotary Applicator. The main housing contains three fluid valves (4).
The Speed Sensor Assembly detects the rotational speed of the magnets on the turbine assembly.
The Fluid Nozzle contains the paint flow orifice. There are six sizes:
0.75 mm, 1.0 mm, 1.25 mm, 1.5 mm,
1.8 mm, and 2.0 mm.
The turbine is driven by compressed air and provides rotating speeds up to
60,000 RPM.
Loosen and remove to access front-end components.
The Air Cap and Cover direct the shaping air to the correct diameter for the cup. There are three sizes of air cap components, to match the three cup sizes.
334452E
Ref.
Component Description
20
27
28
36
Cup
Coiled Fluid
Tube
Power
Supply
Mounting
Bracket
The cup atomizes paint by rotating at speeds up to 60,000 RPM. There are three cup Sizes: 15 mm, 30 mm, and
50 mm.
Coiled fluid tubes are installed in each
Rotary Applicator (3 for solventborne models and 1 for waterborne models).
The coiled fluid tubes provide a more resistive path between the high voltage and ground for the paint, solvent, and dump lines (solvent only on waterborne).
The Power Supply contains an electrostatic multiplier with 100 kV maximum output. It has a resistor built in to provide a path to discharge the Rotary
Applicator.
The mounting bracket is used with the correct optional mounting kit for either a reciprocator or a robot.
9
Installation
Installation
Installing and servicing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly.
• Do not install or service this equipment unless you are trained and qualified.
• Be sure your installation complies with National,
State and Local codes for the installation of electrical apparatus in a Class I, Div. I, Group D Hazardous Location or a Group II, Zone 1 Explosive
Atmosphere Location.
• If using a waterborne material, ensure that the applicator is connected to a voltage isolation system that will discharge the system voltage when required.
• Comply with all applicable local, state, and national fire, electrical, and other safety regulations.
Basic Guidelines
System Installation Requirements
• Several interlocks must be provided to allow safe and reliable operation. See
Required System Interlocks , page 33.
• Ventilation must be provided to prevent buildup of flammable or toxic vapors while spraying, flushing, or cleaning the applicator. See
• Earth grounds must be provided for all specified
system components. See Step 9. Ground the
Additional Waterborne System Installation
Requirements
• The applicator must be connected to a voltage isolation system that isolates the fluid supply from ground and allows voltage to be maintained at the front of the applicator.
• The applicator must be connected to a voltage isolation system with a bleed resistor that will discharge the system voltage when the applicator is not in use.
• All components of the voltage isolation system that are charged to high voltage must be contained within an isolation enclosure that prevents personnel from making contact with the high voltage components before the system voltage is discharged.
• The controller must be interlocked with the voltage isolation system to shut off and discharge the electrostatics anytime the isolation enclosure is opened or entered. See
Step 8. Create Required System
• The voltage isolation system must be interlocked with the spray location entrance to automatically discharge the voltage and ground the fluid whenever someone opens the isolation enclosure or enters
the spray location. See Step 8. Create Required
NOTICE
The system should not have severe arcing occurring when the isolation mechanism opens and closes.
Severe arcing will shorten the life of the system components.
10 334452E
Installation
Typical System Installation
F IG . 2 shows a typical installation. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.
Non-Hazardous Location Hazardous Location
F IG . 2. Typical Installation, Electronic Air Controller, with Fluid Isolation Box for Waterborne Systems
334452E 11
Installation
N
P
PT
Q
H
J
F
G
L
Typical Installation Components
A Rotary Applicator
B Bearing Air Supply Line
BR Bearing Air Return Line
BK Braking Air Supply Line
C Air Controller
D Dump Return Line
DT Dump Valve Trigger Air Line
Fiber Optic Cable for Speed Control
Speed Controller
Electrostatic Controller
System Logic Controller
PLC (connected to a gateway inside the
Speed Controller)
CAN Communication Cables
Paint Supply Line
Paint Valve Trigger Air Line
I/O Cable (for electrostatic control and interlocks)
R
S
Power Supply Cable
Solvent Supply Line
SI Shaping Air (Inner) Air Line
SO Shaping Air (Outer) Air Line
ST
T
TA
U
Solvent Valve Trigger Air Line (cup wash)
Fluid Supply Isolation Equipment (for waterborne applicators only)
Turbine Air Line
Fluid Pressure Regulator
NOTE: See
Step 9. Ground the Equipment , page 34,
for required grounding information.
12 334452E
Installation
Overview of Installation Steps
The following steps are needed to install and connect your system.
1.
Mount the rotary applicator, page 13.
2.
Connect all lines at the applicator, page 15.
3.
Mount the controllers and accessories, page 21.
4.
Connect the fluid supply, page 23.
5.
Connect the air lines, page 27.
6.
Connect the power and communication cables,
7.
Prepare the spray area, page 33.
8.
Create required system interlocks, page 33.
9.
Ground the equipment, page 34.
Step 1. Mount the Rotary
Applicator
1.
Install the nut (104) and the bolt (103), but do not tighten.
2.
Thread the post (101) into the mounting bracket (36) and tighten firmly. Use Loctite or other adhesive on the threads to prevent loosening.
3.
Position the mounting rod (102) on the post. Rotate to the desired angle. Use adapter (105) to adjust the diameter of the mounting rod, if needed.
4.
Tighten the nut (104) and bolt (103) securely.
36
101
104
To reduce the risk of fire and explosion due to sparking, all mounting hardware must be non-conductive or be properly grounded. Keep all grounded mounting hardware at least 10 in. (25.4 cm) away from the charged components.
Reciprocator Mounting
Use Reciprocator Mounting Kit 24Z178 to mount the applicator to a stationary stand or to a reciprocator. See
103
102
105
F IG . 3 Reciprocator Mounting Kit
334452E 13
Installation
60° Robot Mounting
Use 60° Robot Mounting Kit 24Z179 to mount the applicator to a solid wrist robot. See the Dimensions on page
1.
Remove screws (37) and bracket (36) from the applicator.
2.
Install and tighten screws (108) to attach the adapter (105) to the mounting bracket (36).
3.
Install and tighten screws (37) to reattach the mounting bracket (36) to the applicator.
4.
Thread screw (107) through the robot mounting bracket (106) and into the bottom of the adapter
(105) and tighten.
5.
Thread screws (109) through the robot mounting bracket (106) and into the robot adapter plate (not shown).
NOTE: To find the adapter plate that will work with your robot, see
Distance to Workpiece
To reduce the risk of fire and explosion, maintain a
Safe Distance of at least 6 in. (15.2 cm) between the applicator and the workpiece at all times.
Position the cup a minimum of 6 in. (15.2 cm) from the closest approach point of the workpiece. Take into account potential rotation or swaying of the part. The arc detection circuitry of the ProBell Electrostatic Controller helps minimize the risk of an arc should a workpiece approach too close to the charged cup. In addition, the
Safe Distance of 6 in. (15.2 cm) must be maintained at all times.
A typical spraying distance is 9-14 in. (23-36 cm).
To reduce the risk of fire and explosion, the spray area must remain free of rusted steel. Frictional contact between aluminum components and rusted steel must be avoided.
108 (x4)
36
37 (x4)
105
109 (x4)
106
107
F IG . 4 60° Robot Mount
14 334452E
Installation
Step 2. Connect All Lines at the
Applicator
A total of 14 connections are needed for ProBell operation.
NOTE: All lines must run through the manifold retaining ring (35), the adapter cover (34), and the shroud (33).
1.
Screw off the manifold retaining ring (35) by hand.
The adapter cover (34) will come with it.
2.
Slide the shroud (33) off the back of the housing.
a.
Connect the paint supply line to port P .
b.
Connect the solvent supply line to port S. This port is 6 mm (1/4 in.).
c.
If needed, connect the fluid dump line to port D.
If not needed, plug Kit 25C201 is available to plug the dump passage in the applicator.
d.
Tighten all three connectors to secure the lines.
The paint and dump line ports are 8 mm (5/16 in.). Refer
to the Fluid Flow Rate Charts (Continued) , page 90,
to help determine the best tubing for your application.
An Alternate Fluid Bracket Kit 25A878 is available, for use with highly conductive materials. This kit includes a grounded fluid bracket that is mounted remotely. The fluid lines pass through the fluid bracket at the back of the applicator and connect directly into the main housing. The longer fluid lines create a more resistive fluid path. See manual 3A5223 Fluid Ground Bracket Kit ,
3.
Pass each line through these three pieces before connection at the applicator.
TIP: Connect the lines in the order shown in this section.
Label each line and bundle into groups , to avoid confusion later when the lines are connected to the fluid supply, air supply, and other system components.
Fluid Lines for Solventborne Materials
Fluid lines may contain high-voltage fluid. Sparking due to a hose leak could cause fire, explosion, or electrical shock. To reduce the risk of sparking:
• Connect all fluid lines into the grounded fluid bracket.
• Use only genuine Graco coiled fluid tubes.
All three solventborne fluid lines are connected at the fluid bracket at the back of the applicator. The fluid then flows through coiled fluid tubes and into the main housing.
F IG . 5. Fluid Connections
334452E 15
Installation
Fluid Lines for Waterborne Materials.
The fluid between the applicator and fluid supply will be charged. To reduce the risk of electric shock, use only Graco-supplied waterborne fluid hoses. See
also Step 9. Ground the Equipment , page 34.
NOTE:
See Accessories , page 76, for a list of available
waterborne hoses.
1.
Connect the solvent supply line to fluid fitting S on the fluid bracket at the rear of the applicator. This port is 6 mm (1/4 in.). The solvent then flows through a coiled fluid tube and into the main housing.
2.
Blow out the paint supply hose and fluid dump hose
(if used) with air and flush with water before connecting.
3.
Pass the paint supply hose through the strain relief fitting (32e) on the fluid bracket and connect to port
P on the main housing. Make sure the ferrule (32f) is in place on the outer jacket of the hose and properly oriented. Tighten the strain relief nut (32g).
4.
Pass the dump hose through the strain relief fitting on the fluid bracket and connect to port D on the main housing. Tighten the strain relief nut.
5.
The applicator end of the waterborne hose comes stripped to the correct dimensions. The shield (W) should pass through the strain relief fitting to minimize electrical stress. The strain relief fitting must be located on the outer jacket (X) of the hose.
Ref.
U
V
Shielded Unshielded
5.75 in. 146 mm 1.5 in.
1.25 in. 32 mm
38 mm
N/A
32g 32f 32e
F IG . 6. Fluid connections at the applicator
3/8”
Ø
16 334452E
Installation
Air Lines
A total of nine air line connections are needed. Remember to label each line, and bundle into groups. Pass the air lines through the manifold retaining ring (35), the adapter cover (34), and the shroud (33), then through the center of the rear manifold (30).
Power Supply Cable
Connect the 4-pin end of the power supply cable to connector R on the applicator.
Fiber Optic Cable (for optional Speed Controller)
The applicator is equipped with a magnetic pickup sensor assembly that provides a signal used by the Speed
Controller. On the applicator manifold, connect a fiber optic cable (F) to the F port that connects to the fiber optic extension cable (22). The amount of fiber extending past the nut should be 0.11 in. (2.8 mm). See
Accessories , page 76, for available cables.
NOTE: An alternate reflective speed sensor assembly is available, Kit 24Z183.
F
R
F IG . 7
1.
Connect the three trigger air lines first – the paint valve trigger ( PT), the solvent valve trigger ( ST), and the dump valve trigger ( DT) . These lines are smaller because they provide only an air activation signal.
Use 4 mm (5/32 in.) tubing.
2.
Next, connect the bearing air return ( BR), also a
4 mm (5/32 in.) tube.
3.
Around the outer edge, connect the larger air supply lines, needed for bell operation. Use 8 mm (5/16 in.)
OD tube with 1 mm (0.04 in) wall to minimize pressure drop.
a.
Connect the bearing air to port B.
b.
Connect the inner shaping air to port SI.
c.
Connect the outer shaping air to port SO.
d.
Connect the turbine air to port TA.
e.
Connect the braking air to port BK.
22
NOTICE
To avoid equipment damage route all hoses and cables away from sharp edges. Avoid sharp bends and excessive strain on hoses or cables.
334452E 17
Installation
Connect the Ground Wire
NOTE: When all lines have been connected at the applicator, reinstall the shroud (33), the adapter cover (34) and the manifold retaining ring (35).
F IG . 8
Connect the ground wire (41) to the applicator manifold.
1.
Remove the fluid bracket screw.
2.
Pass the screw through the ground wire eyelet and reinstall. It is ok if the eyelet bends.
Tip: If you have a Graco hose bundle, pull the hose bundle cover over the back of the adapter cover (34).
Secure with a cable tie.
18 334452E
Installation
Connection Schematics
Z
E
E
Main Housing (Solventborne and Waterborne Models)
Waterborne Models
Fluid Bracket
Solventborne Models
F
R
F IG . 9. Manifold Connections
334452E 19
Installation
E
F
P
B
BK
BR
D
DT
Bearing Air*
Provides air for proper air bearing support.
Braking Air*
Slows the turbine speed.
Bearing Air Return - 4 mm (5/32 in) tube fitting
Returns air to the controller for pressure check.
Dump Line**- 8 mm (5/16 in) tube fitting
Waste line for flushing or color change.
Dump Valve Trigger - 4 mm (5/32 in) tube fitting
Air activation signal for the dump valve.
Turbine Exhaust Ports
Fiber Optic Speed Sensor Port
Paint In** - 8 mm (5/16 in) tube fitting
Fluid supply inlet fitting
PT
R
S
SI
SO
ST
TA
Z
Paint Valve Trigger 4 mm (5/32 in) tube fitting
Air activation signal for the paint valve.
Power Supply Connection
Solvent In** - 6 mm (1/4 in) tube fitting
Cleaning solvent supply inlet fitting
Shaping Air (Inner)*
Shaping Air (Outer)*
Solvent Valve Trigger (Cup Wash)-
4 mm (5/32 in) tube fitting
Air activation signal for the solvent valve.
Turbine Air*†
Operates the turbine.
Weep Holes
Drainage points for any leakage into the air section
* Use 8 mm (5/16 in) OD tube with 1 mm (0.04 in) wall to minimize pressure drop.
** For solventborne models, P, D, and S connections at the main housing are made at the factory.
† The rotation speed or flow rate of a 50 mm cup may be limited due to pressure drop in the turbine air line.
See
Turbine Inlet Air Pressure Charts , page 84.
20 334452E
Installation
Step 3. Mount Controllers and
Accessories
The following components are available to create a complete ProBell Rotary Applicator System. The ProBell controllers have been designed and optimized for use with the ProBell Rotary Applicator. Your system may use all Graco components, or a combination of Graco equipment and other controls.
Air Filters
NOTICE
Air that is not filtered to specification can clog bearing air passages and cause bearing failure. The warranty does not cover a turbine damaged by contaminated air.
To reduce the risk of fire and explosion, do not install equipment approved only for a non-hazardous location in a hazardous location.
ProBell Electrostatic Controller (Required)
Mount the Electrostatic Controller in the non-hazardous area. See ProBell Electrostatic Controller Manual
3A3657 for installation instructions.
ProBell System Logic Controller
The rotary applicator system can be controlled with a
System Logic Controller or with an existing PLC. A System Logic Controller is required if your system includes a Speed Controller or an Air Controller. Mount the System Logic Controller in the non-hazardous area. See
Manual 3A3955 for installation instructions.
ProBell Speed Controller (Optional)
Mount the Speed Controller in the non-hazardous area, as close to the applicator as possible to minimize pressure loss in the air lines. See Manual 3A3953 for installation instructions.
ProBell Air Controller (Optional)
Graco offers two Air Controller options: Electronic and
Manual. Mount the Air Controller in the non-hazardous area, as close to the applicator as possible to minimize pressure loss in the air lines. See Manual 3A3954 for installation instructions and to see features of each air controller.
Three air filtration stages are required to prevent contamination of the paint finish and to prevent damage to
the air bearing. Refer to Table 1 for the specifications of
each filter. Use only these recommended filters, or filters that meet the same specifications. See Manual 309919 for filter details, installation, and pipe size recommendations.
• The temperature of the air as it enters the Pre-Filter must be close to ambient.
• Air must be dehydrated to a dew point of 10°F
(-12°C).
• Filters must remove 99% of all aerosols.
• Filters must remove particles of 0.5 microns and larger. Graco filter 234403 removes particles down to 0.01 microns.
• Standard piping may be used only up to the pre-filters. All piping after the pre-filters should be brass, stainless steel, or plastic hose.
• Do not use any type of thread sealant or PTFE tape downstream of the bearing air filter. Small particles may loosen and plug the air holes in the turbine air bearings.
• Air that is heated above 120°F (49°C) will damage filter elements.
334452E 21
Installation
F IG . 10. Air Filter
Table 1. Required Air Filters
PN Description and Specification
Replacement
Element PN
234402 Stage 1: Pre-Filter (A)
100 SCFM (rated flow of 100 SCFM minimum is required), removes coarse amounts of oil, moisture, and dirt to 3 microns.
Use upstream of 234403.
234403 Stage 2: Grade 6 Coalescing Filter (B)
50 SCFM (rated flow of 50 SCFM minimum is required), removes oil and submicronic particles down to 0.01 microns. Use one filter for each ProBell Applicator.
16W405
16W407
17M754 In Control Box: Bearing Air Grade 6 Coalescing Filter (C)
4 SCFM (rated flow of 4 SCFM minimum is required). One filter is included in ProBell Speed Controller 24X519 and in ProBell Manual Air Controller 24X520.
Not available.
Replace with assembly 17M754
Air Inlet and
Outlet npt(f)
1/2 in.
1/2 in.
1/4 in. push-lock,
(m)
Air Heaters
Air heaters may be needed in some applications. If the surface temperature of the applicator falls below the dew point of the paint booth, condensation may form on the inside or outside of the applicator. This condensation is caused by supply air that is too cool, or by the cooling of the shaping and turbine airs as they exit the applicator.
A heater may be required to ensure that the temperature of the turbine exhaust air is above the dew point of the spray booth. Install heaters into the air supply lines (turbine, shaping airs).
Set the heater as low as possible to maintain the applicator surface temperatures above the dew point in the booth.
NOTE: The maximum air temperature at the bell must not exceed 120° F (49° C).
22 334452E
Installation
Step 4. Connect Fluid Supply
Connect fluid lines at the applicator first. See Step 2.
Connect All Lines at the Applicator , page 15.
Solventborne Systems
a.
Paint Hose: The fluid hose connected to port P on the applicator must be connected to a regulated, filtered paint supply, such as a circulation system or a supply pump. This hose also must be connected to a regulated solvent supply to flush the system and an air supply to empty the lines. This figure shows a common way to make these connections.
must also be connected to a regulated air supply to purge the cup wash passages with air.
An air purge is recommended for use with conductive solvents to improve electrostatic performance
NOTE: Not purging the lines of conductive solvents may cause low electrostatic voltage or system errors.
Waterborne Systems
b.
Dump Hose: The fluid hose connected to port D on the applicator must go to a grounded waste container.
c.
Solvent Hose: The fluid hose connected to port S on the applicator must be connected to a regulated solvent supply that will be used to wash the cup. This line
The fluid between the applicator and the fluid supply will be charged. To reduce the risk of electric shock, follow hose requirements and instructions carefully.
a.
General Requirements: Waterborne isolation systems must meet these requirements:
• Fluid Supply
- All conductive components of the fluid supply
(pump, filter, regulator, container, etc.) that are charged to high voltage must be bonded together.
- If non-conductive containers are used, a conductive element bonded to the fluid supply must be in contact with the fluid.
• Fluid Hose
-Use only approved Graco Waterborne fluid hoses.
334452E 23
Installation
- Unshielded waterborne fluid hoses must be routed such that a minimum distance of 0.25 cm/kV is maintained between the hose and grounded surfaces.
- The conductive layer of shielded hoses must be grounded at the isolation system.
• Enclosure
- All components of the isolated fluid supply system must be housed in a protective enclosure to prevent contact with the charged components during operation.
- Access to the enclosure must be interlocked with the high voltage supply to shut off and discharge the high voltage before any live parts can be reached.
b.
Paint Hose: The fluid hose connected to port P on the applicator must be connected to a regulated, filtered paint supply. This hose also must be connected to a regulated solvent supply to flush the system. Connect an air supply to empty the lines, if needed. The illustration below shows a common way to make these connections. c.
Dump Hose (optional): The most common system design for the dump line (connected to port D ) is to connect a waterborne fluid hose to a grounded waste container. Flush and purge the dump line with air before turning on the electrostatics.
A second dump option is to place the waste container in the voltage isolation enclosure. Connect a Graco Waterborne Fluid Hose between the voltage isolation system fluid outlet and the applicator dump port ( D) .
d.
Solvent Hose: The fluid hose connected to port S on the applicator must be connected to a regulated solvent supply that will be used to wash the cup. This line must also be connected to a regulated air supply to purge the cup wash passages with air. An air purge is required for very conductive waterborne fluids.
NOTE: Not purging the lines will cause low electrostatic voltage or system errors.
24 334452E
e.
Hose-Stripping Requirements
Hose-Stripping Requirements
Ref.
Shielded Unshielded
U 14.5 in.
368 mm 14.5 in.
368 mm
V 0.75 in.
19 mm NA
• An unshielded hose consists of a PTFE tube (Y) with an outer covering (X).
Installation
Route unshielded hoses away from grounded objects. Maintain a distance of 0.25cm/kV between the hose and grounded objects.
• A shielded hose consists of an inner PTFE tube
(Y), a conductive layer covering the PTFE tube
(W), and an outer cover (X).
If a hose failure occurs where high voltage arcs through the inner tube, voltage will be discharged to ground through the conductive hose layer.
When properly installed, the conductive hose layer is grounded through its connection to the grounded enclosure.
The fluid supply end of the hose has been stripped at the factory for connection to a WB100
Isolation System, as shown below. If desired, the hose can be changed on this end, but the conductive layer (W) must be no closer than 8 in.
(20.3 cm) to the end of the hose or any other high-voltage component.
F IG . 11. Unshielded hose
Connect one end of the hose to the applicator.
Connect the other end to a fluid supply inside an isolation enclosure.
F IG . 12. Shielded Hose
NOTICE
Be careful not to cut into the inner tube (Y) of the hose when stripping the hose. Nicks or cuts in the
PTFE tube will cause premature hose failure.
334452E 25
Installation
N OTE: Blow out the fluid supply hose and circulation hose (if used) with air and flush with water before connecting.
• Connect the fluid hose(s) as follows:
2. Using an ohmmeter, verify continuity between the conductive layer closest to the applicator and the isolation enclosure ground.
3. Connect the dump hose (D) to a grounded or isolated waste container. Connect the waterborne hose as in step 1.
To reduce the risk of electric shock, the areas of the
Graco Waterborne Fluid Hose that are accessible to personnel during normal operation must be covered by the outer hose jacket (X). The portion of the inner PTFE tube (Y) not covered by the outer jacket (X) must be inside the isolation enclosure (T).The conductive hose layer (W) must be grounded at the isolation enclosure (T).
1. Pass the Graco waterborne fluid hose through a strain relief fitting at the wall of the isolated enclosure and connect the inner tube
(Y) to the fluid supply outlet. Tighten the strain relief fitting (Z). For a shielded hose, the conductive layer of the hose (W) must be grounded to the isolation system ground (strain relief fittings must grab onto the outer jacket or conductive layer of the fluid hose).
Y
X
Z
W
W
T
T
X
26 334452E
Installation
Step 5. Connect the Air Lines
Connect all air lines to the applicator first (See Step 2.
Connect All Lines at the Applicator , page 15). The air
supply for each line can be regulated and actuated using the ProBell Speed Controller and/or one of the
parameters can be adjusted independently or saved as presets. ProBell controllers are labeled with the same reference letters as the applicator, for easier matching
or F IG . 15
, page 29 for more detail). See the
following sections for connection information.
If your system is not using all of the ProBell controllers, see the following sections for specifications and requirements for each air line.
Take great care to connect the air lines to the correct ports on the control equipment. Incorrect air line connections will damage the applicator.
Bearing Air
NOTICE
NOTICE
To avoid equipment damage
• bearing air must be on while the turbine is spinning and must not be turned off until the cup comes to a complete stop.
• bearing air must be filtered to precise require-
ments. See Air Filters , page 21.
The bearing air provides proper bearing support. Connect the bearing air line to the port marked B on either the Speed Controller or the Manual Air Controller if only one controller is present in the system. If both Speed
Controller and Manual Air Controller are present, the connection must be made to the Speed Controller.
To provide additional protection for the bearing if the bearing air is turned off before the bell cup comes to a complete stop, install an air accumulator tank (AT) and a check valve (CV) in the bearing air line. The accumulator tank (AT) should be 3 gallons (11 liters) or greater.
Bearing
Air Line
CV
F IG . 13 Bearing air line with accumulator tank and check valve
Bearing air requires at least 70 psi (0.48 MPa, 4.8 bar) pressure at the applicator at all times. A flow volume of
3 scfm is required.
NOTICE
For best performance, maintain 100 psi bearing air pressure. Bearing air pressure of less than 90 psi
(0.62 MPa, 6.2 bar) increases the potential for turbine failure when running at speeds greater than
50 krpm.
Bearing Air Return
AT
NOTICE
Use of a bearing air return line will help prevent equipment damage.
The bearing air return line is connected to a pressure monitoring device, to ensure that adequate bearing air pressure is maintained. Connect the bearing air return line to the port marked BR on either the ProBell Speed
Controller or the ProBell Manual Air Controller if only one controller is present in the system. If both Speed
Controller and Manual Air Controller are present, the connection must be made to the Speed Controller.
If your system does not use the ProBell System Logic
Controller, bearing air return must be interlocked with the turbine air so that the turbine air will not flow if the bearing air return pressure is under 70 psi (0.48 MPa,
4.8 bar).
NOTE: While not advisable, if you choose not to use the bearing air return line, plug the bearing air return port
(BR) on the applicator.
334452E 27
Installation
Turbine Air
NOTICE
Turbine air supplies must be regulated and adjusted to the right pressure before use. Excess air flow will over speed the turbine and will result in equipment damage.
The turbine air rotates the cup. Connect the turbine air line to the port marked TA on either the Speed Controller or the Manual Air Controller if only one controller is present in the system. If both Speed Controller and
Manual Air Controller are present, the connection must be made to the Speed Controller.
For speed adjustment using a pressure regulator, see the
Turbine Inlet Air Pressure Charts on page 84 for
typical air requirements for a given bell speed.
If your system does not use the ProBell System Logic
Controller, interlock the turbine air with either the bearing air or the bearing return air, to ensure that the turbine air will flow only if the bearing air pressure is at least 70 psi (0.48 MPa, 4.8 bar).
If your system does not use the ProBell System Logic
Controller, interlock the turbine air with the brake air so they cannot flow at the same time.
Braking Air
To avoid injury, avoid excessive braking air. A cup that is not fully seated may disengage from the shaft.
The braking air slows the turbine speed. Connect the braking air line to the port marked BK on the Speed
Controller. The speed controller automatically engages the braking air as needed.
For manual air braking applications, apply 20 psi
(0.14 MPa, 1.4 bar) air for approximately 5 seconds.
This pressure will slow the bell speed rapidly. Adjust the air pressure and time as needed for your system to stop cup rotation.
NOTICE
To prevent equipment damage, do not leave braking air on long enough to rotate the turbine in reverse.
If your system does not use the ProBell System Logic
Controller, interlock the turbine air with the brake air so they cannot flow at the same time.
Shaping Airs
The inner and outer shaping airs provide pattern control and keep the material particles moving toward the object being sprayed. Connect the inner shaping air line to the port marked SI on the Air Controller. Connect the outer shaping air line to the port marked SO on the Air
Controller.
See the Shaping Air Consumption Charts , page 86,
for volume requirements. Use filtered, dry air for the best finish quality.
Maintain an inner shaping air pressure of at least 10 psi
(0.07 MPa, 0.7 bar) at all times to help keep the bell clean. Use both inner and outer shaping air for optimal pattern control. Adjust the pressures to achieve the best pattern for your application. Increase shaping air pressures to reduce the pattern size.
Paint Valve Trigger
The paint valve trigger provides an air activation signal for the paint valve. Actuate the paint trigger each time a part is sprayed. The acceptable pressure range is
70-100 psi (0.48-0.69 MPa, 4.8-6.9 bar). Connect the paint valve trigger air line to the port marked PT on the
Air Controller.
Interlock the paint trigger with the turbine air so the paint valve will not open to spray unless at the turbine speed is at least 10,000 rpm. The rotation is required to prevent fluid from flooding the turbine area.
Interlock the paint trigger with the conveyor, so the paint valve will open to spray only when the conveyor is moving.
See ProBell Air Controller Manual 3A3954 for options to create these interlocks.
Paint Trigger Input
The paint trigger input is included on the ProBell Air
Controller (both manual and electronic models). This isolated input can be used to trigger the paint valve on a
ProBell system from a PLC or robot. See the System
Logic Controller Manual (3A3955) to configure how the paint is triggered in a ProBell system. See the ProBell
Air Controller Manual (3A3954) to connect the paint trigger input.
28 334452E
Installation
Solvent Valve Trigger (Cup Wash)
The solvent valve trigger provides an air activation signal for the solvent valve and is used to perform a cup wash. Connect the solvent valve trigger air line to the port marked ST on the Air Controller.
Interlock the solvent trigger with the turbine air so that the solvent valve will not open to spray unless the turbine speed is at least 10,000 rpm. The rotation is required to prevent fluid from flooding the turbine area.
Interlock the solvent trigger with the electrostatics so that the solvent valve will open to flow only if the electrostatics are turned off and discharged.
Dump Valve Trigger
The dump valve trigger provides an air activation signal for the dump valve. The dump valve is used to purge the paint line. Connect the dump valve trigger air line to the port marked DT on the Air Controller.
Auxiliary Ports
Three auxiliary ports are provided on the Graco Air Controllers for other customized system needs. The user might use one to trigger a valve, for example, or to connect a shutoff signal to stop the conveyor system.
Speed Controller
Aux. 1, 2, 3
Electronic Air Controller
F
IG
. 14. Air Connections, Electronic Air Controller with Speed Controller
Aux 1, 2, 3
. Air C
334452E
F IG . 15. Air Connections, Manual Air Controller
29
Installation
Air Line
B (Bearing Air)
Table 2: Air Line Connections Availability by Controller Type
Speed Controller
Connections
Electronic Air
Controller
Connections
Manual Air Controller
Connections
BK (Braking Air)
BR (Bearing Air Return)
DT (Dump Valve Trigger)
PT (Paint Valve Trigger)
SI (Shaping Air Inner)
SO (Shaping Air Outer)
ST (Solvent Trigger)
TA (Turbine Air)
Auxiliary Triggers
1, 2, 3,
30 334452E
Installation
Step 6. Connect Power and
Communication Cables
Speed Controller End
0.440 in. (11.2 mm)
Electrostatic Controller
1.
Connect the 7-pin side of the power supply cable to connector R on the Electrostatic Controller.
2.
Make Interlock connections. See Electrostatic Controller Manual 3A3657 for details.
• Solvent supply
• Spray area doors and openings
• Conveyor
• Ventilation fans
• Fire control system
• Fluid supply
• Waterborne isolation system
3.
Integrate the electrostatics. Integration of the electrostatic enable function typically depends on a part detection system. Two options are common:
• Use the electrostatic enable digital input on the
Discrete I/O interface of the ProBell Electrostatic Controller. Connect per controller manual
3A3657.
• Provide a command from an external controller to the ProBell System Logic Controller to set the electrostatic enable register via a communication network. See Manual 3A3955.
Speed Controller
Connect the fiber optic cable to port F on the applicator and to port F on your Speed Controller. The amount of fiber extending past the nut should be 0.440 in. (11.2 mm) on the Speed Controller side. On the applicator side, the amount of extended fiber is 0.11 in. (2.8 mm). If you need to cut or repair the cable, use the tool included with the cable to cut.
Applicator End
0.11 in. (2.8 mm)
Available Fiber Optic Cables
PN
24Z190
24Z191
24Z192
Length
36 ft (11 m)
66 ft (20 m)
99 ft (30 m)
NOTE: An alternate reflective speed sensing kit is available, Kit 24Z183. The kit includes instructions for conversion and installation.
See
Fiber Optic Bulkhead Installation, page 77 for
more information.
System CAN Communication Cables
System components communicate information via CAN cables. No CAN cables connect to the applicator. But, several are needed to interconnect other system components.
Use CAN cables to network the Electrostatic Controller,
Air Controller, Speed Controller, and the System Logic
Controller (if used) in series, as shown in figure 15. One power supply is required in the CAN network, typically
mounted on the speed controller. See Accessories
,
page 76, for a list of available CAN cables.
To connect the ProBell system to an outside communication network, purchase and install a gateway (see
3A4384 CGM Installation Kit 24Z574 ) and configure per the System Logic Controller manual 3A3955.
334452E 31
Installation
F IG . 16. Power and Communication Cable Connections
KEY
J
N
R
C
F
G
H
Air Controller
Fiber Optic Port
Speed Controller
Electrostatic Controller
System Logic Controller
CAN Ports
Applicator Power Supply Connector Port
32 334452E
Installation
Step 7. Prepare the Spray Area Step 8. Create Required System
Interlocks
Mount Warning Signs
Mount warning signs in the spray area where they can easily be seen and read by all operators. An English
Warning Sign is provided with the rotary applicator.
Ventilate the Spray Booth
To help prevent fire, explosion, or electric shock, check and follow all National, State, and Local codes regarding properly interlocking your spray system.
NOTICE
To avoid damage to the bearing it is recommended that the bearing air remain on at all times.
Do not operate the applicator unless ventilation fans are operating. Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the applicator. Interlock the electrostatic controller and fluid supply to prevent operation unless ventilating air flow is above the minimum required value.
Electrically interlock the Electrostatic Controller and fluid supply with the ventilators so that the electrostatics turn off any time that the ventilation air flow falls below minimum values. Check and follow all National, State, and
Local codes regarding air exhaust velocity requirements. Verify the operation of the interlock at least once per year.
NOTE: High-velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 60 ft/minute
(19 linear meters/minute).
The following system interlocks are needed to prevent fire, explosion, electric shock, or equipment damage.
1.
Turbine air and bearing air: Interlock so the turbine air will flow only if the air pressure on the bearing air return line is at 70 psi (483 kPa) or higher.
This interlock is included in the ProBell System
Logic Controller. Bearing air must be on when the turbine is operating. Bearing air should be turned off only at the main air source and only after the cup has stopped spinning.
2.
Paint trigger and turbine air: Interlock so the rotary applicator will spray only when the turbine is spinning. A minimum of 10K rpm is recommended.
This interlock is included in the ProBell System
Logic Controller.
3.
Electrostatic controller and solvent supply:
Interlock so that electrostatics can be enabled only when solvent is not flowing in the solvent or paint lines. See Electrostatic Controller Manual 3A3657 for available interlocks.
4.
Fluid supply and arc detection: Interlock the fluid supply to shut off in the event of an arc detection fault.
5.
Braking air and turbine air: Interlock so the braking air flows only when the turbine air is off.
6.
Electrostatic controller and all doors or openings in the spray area: Interlock so the electrostatics turn off and are fully discharged before live parts can be reached. See Electrostatic Controller Manual
3A3657. Check interlock function weekly.
334452E 33
Installation
7.
Conveyor and paint trigger/electrostatics: Interlock so the rotary applicator stops spraying and the electrostatics turn off if the conveyor stops moving.
8.
Electrostatic controller, fluid supply, and ventilation fans: Interlock so the electrostatics and fluid supply turn off any time that the ventilation air flow falls below minimum required value. See Electrostatic Controller Manual 3A3657.
9.
Electrostatic controller, fluid supply, and fire control system: Interlock so the electrostatics and fluid supply turn off any time the automatic fire extinguishing system is activated. See Electrostatic Controller Manual 3A3657.Check interlock function every 6 months.
10.
Electrostatic controller and waterborne isolation system (for waterborne systems): Interlock so the electrostatics turn off and are fully discharged before live parts can be reached. See Electrostatic
Controller Manual 3A3657. Check interlock function weekly.
System Status Output
A system status output is included in the ProBell Speed
Controller. This output indicates when the ProBell system is in Off Mode, such as when an alarm occurs. The output can be used to interlock system functions with functions that are not controlled by the ProBell system.
For example: If the paint trigger is outside the ProBell system, the paint trigger can be interlocked with the system status output to ensure that the paint flow is stopped in the event of a system alarm. See the ProBell
Speed Controller Manual 3A3953 to connect the system status output.
Optional Interlock Input
An optional interlock input for the ProBell System Logic
Controller can be installed in the ProBell Speed Controller or the ProBell Air Controller. When 24 VDC is applied to this input, the system goes to Off Mode. Install
Kit 24Z226. See speed controller manual 3A3953 or air controller manual 3A3954.
Step 9. Ground the Equipment
The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric current.
When operating the rotary applicator, any ungrounded objects in the spray location (people, containers, tools, etc.) can become electrically charged. Your system may include other equipment or objects which must be grounded. Your system must be connected to a true earth ground. Check ground connections daily. Check your local electrical code for detailed grounding instructions. The following are minimum grounding requirements for a basic electrostatic system.
• Rotary Applicator: Ground the applicator by connecting the power supply cable to a properly grounded electrostatic controller and connecting the ground wire to a true earth ground. The ground wire may be connected to the grounding lug on the electrostatic controller and then connected to a true earth ground.
• Control Box Stand: The stand is grounded by connection to the Electrostatic Controller bracket.
• Air Controller and Speed Controller: If not mounted on the Control Box Stand, use a ground wire and clamp to ground to a true earth ground.
• Electrostatic Controller: Use the ground wire and clamp provided to connect the Electrostatic Controller to a true earth ground.
• Pump: Ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual.
• Voltage Isolation System (for waterborne systems): Follow the grounding procedure in the manufacturer’s instructions.
• Fluid Hose (for waterborne systems only): The hose is grounded through the conductive layer.
Install the hose as instructed, page 23.
• Air compressors and hydraulic power supplies:
Ground the equipment according to the manufacturer's recommendations.
• All air and fluid lines must be properly grounded.
34 334452E
Installation
• All electrical cables must be properly grounded.
• All persons entering the spray area must wear shoes having conductive or dissipative soles, such as leather, or wear personal grounding straps. Do not wear shoes with non-conductive soles such as rubber or plastic. If gloves are necessary, wear the conductive gloves supplied with the gun. If non-
Graco gloves are worn, cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle. The measured insulation resistance of gloves and footwear must not exceed
100 megohm per EN ISO 20344, EN1149-5.
• Object being sprayed: Keep the workpiece hangers clean and grounded at all times. Resistance must not exceed 1 megohm.
• The floor of the spray area: must be electrically conductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.
• Flammable liquids in the spray area: must be kept in approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift.
• All electrically conductive objects or devices in the spray area: including fluid containers and wash cans, must be properly grounded.
Check Electrical Grounding
Megohm meter Part No. 241079 is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohm meter to check electrical grounding unless:
• The rotary applicator has been removed from the hazardous area;
• Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes from spraying).
Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.
Check ground connections daily.
334452E 35
Installation
Non-Hazardous Location
J
G
Hazardous Location
A
C
H
F IG . 17. Grounding the System
36
T
G
H
A
C
J
T
Rotary Applicator
Air Controller
Speed Controller
Electrostatic Controller
System Logic Controller
Fluid Supply
334452E
Installation
System Logic Controller Setup
After installation, the following setup steps are required before Operation.
1.
Use the Setup Screens on the System Logic Controller to set the following operating parameters.
Detailed instructions are in the System Logic Controller Manual 3A3955.
• Set the number of guns, type of guns, type of signal, idle timer and idle speed. See System
Screen and Gun Screen 1.
• Enable or disable and configure the Air Controller, See Gun Screen 2.
• Set up the auxiliary solenoids on the Air Controller. See Gun Screen 3.
• Enable or disable and configure Speed Controller gun screen. See Gun Screen 4.
• Enable or disable and configure the Electrostatic Controller. See Gun Screen 5.
• Configure spray parameters for all recipes using
Presets 0 through 98. See Preset Screens.
• Provide all information needed for the Gateway to enable communication via DeviceNet, Ethernet IP, Modbus TCP or PROFINET. See Gateway screens.
• Set language, date format, date, time, units, and other personal preferences. See Advanced
Screens.
2.
Use the Setup screens and the Configuration screens on the Electrostatic Controller to set up your system electrostatics. This setup is saved in the equipment memory, even when power is removed. All instructions are in the Electrostatic
Controller Manual 3A3657.
NOTE: If you are using a PLC with only the Electrostatic
Controller, see the Discrete I/O section in the Electrostatic Controller Manual 3A3657.
Verification
After all installation steps are complete, and the System
Logic Controller is configured, the system is ready for start up. Prior to running production, a knowledgeable person should check the functions shown in the table.
This verification should be repeated on a regular basis.
Test
1. Proper Grounding
2. Proper Clearance
3. Arc Detection
Requirement
Verify proper grounding. See
Step 9. Ground the Equipment , page 34.
Verify proper clearance is maintained between the cup and parts. See
Distance to Workpiece , page 14.
Verify the function of the arc detection circuitry. See the arc detection information in the Electrostatic Controller Manual
3A3657.
Frequency
Daily
Weekly
Every 6 Months and any time system parameters are changed
Every 6 Months 4. Interlock with Ventilation Verify proper operation of the interlock with the ventilation system. See
Step 8. Create Required System Interlocks , page 33.
5. Voltage Discharge Follow the
Voltage Discharge and Grounding
Procedure , page 42. Verify that access to the applicator
(and the isolation system for waterborne) is prohibited until the discharge timer has elapsed and no residual voltage remains.
6. Waterborne System
Requirements
7. Interlocks with Fluid
8. Fire Suppression
Verify the fluid supply system meets the requirements on
Step 4. Connect Fluid Supply, page 23
, and verify the interlock between the enclosure access and the high voltage controller.
Verify the proper operation of the interlocks with the sol-
vent supply and fluid supply. See Step 8. Create Required
Verify the proper operation of the interlock with the fire sup-
pression system. See Step 8. Create Required System
Each Cleaning
Weekly
Weekly
Every 6 Months
334452E 37
Operation
Operation
Pre-Operation Checklist
Go through the Pre-Operation Checklist daily, before each use.
All System Types
All operators are properly trained to safely operate an automatic electrostatic rotary applicator system as instructed in this manual.
All operators are trained in the
Applicator and hose connections show no signs of fluid leakage.
All Setup is complete.
The warning sign provided with the rotary applicator is mounted in the spray area where it can be easily seen and read by all operators.
The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded. See
Ground the Equipment on page 34.
The rotary applicator’s mechanical and electrical components are in good condition.
Ventilation fans are operating properly.
Workpiece hangers are clean and grounded.
Electrostatics are off and voltage is discharged according to
,
, before entering the spray area for any cleaning or maintenance work.
Waterborne systems only
Electrostatics are off and voltage is discharged according to
Grounding Procedure , page 42, before any
person enters the isolation enclosure, before cleaning, and before performing any maintenance or repair.
The Graco Waterborne Fluid Hoses (shielded or unshielded) are in good condition with no cuts or abrasions of the PTFE tube. Replace fluid hose if damaged.
All fluids used meet one of the following flammability requirements:
• Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures,
ASTM D4206.
• Material is classified as non-ignitable or hard to ignite as defined by EN 50176.
All debris is removed from the spray area, including flammable fluids and rags.
All flammable fluids in the spray booth are in approved, grounded containers.
All conductive objects in the spray area are electrically grounded, and the floor of the spray area is electrically conductive and grounded.
38 334452E
Operation
Check Fluid Resistivity Spray Procedures
Check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area.
Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.
Graco Part No. 722886 Resistance Meter and 722860
Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the requirements of an electrostatic air spray system.
Follow the instructions included with the meter and probe. Readings of 20 megohms-cm and above provide the best electrostatic results and are recommended.
1-7
Longer fluid hose may be needed*
Megohms-cm
7-20
Good
20-200
Best electrostatic results
200-2000
Good electrostatic results
* Included in kit #25A878.
Check Fluid Viscosity
To check fluid viscosity you will need a viscosity cup and stopwatch.
1.
Completely submerge the viscosity cup in the fluid.
Lift the cup out quickly. Start the stopwatch as soon as the cup is completely removed.
2.
Watch the stream of fluid coming from the bottom of the cup. As soon as there is a break in the stream, shut off the stopwatch.
3.
Record the fluid type, elapsed time, and size of the viscosity cup.
4.
Compare to the chart supplied by viscosity cup manufacturer to determine your fluid viscosity.
5.
If the viscosity is too high or too low, contact the material supplier. Adjust as necessary. See
Flow Rate Charts , page 88 to select the appropri-
ate nozzle size.
To reduce the risk of electric shock and to avoid injury due to contact with the spinning cup, do not enter the spray area during rotary applicator operation.
If any fluid leakage from the rotary applicator is detected, stop spraying immediately. Fluid leakage into the shroud could cause fire or explosion and result in serious injury and property damage.
Flush Before First Use
The equipment was tested in fluid at the factory. To avoid contaminating your fluid, flush the equipment with a compatible solvent before using the equipment. See
Load Material
1.
Put the system in Purge mode. In this mode: a.
Ensure that electrostatics cannot be enabled.
b.
The bell should be rotating at least 10k rpm.
c.
The Inner Shaping Air should be a minimum of
10 psi (0.7 bar) to help keep the applicator clean.
2.
Supply paint to the paint line P.
3.
Actuate the dump valve trigger (DT) until paint reaches the applicator. Actuate the paint valve trigger (PT) to load the paint to the front of the applicator.
NOTE: With this method, paint is returned through the dump line, rather than exiting out the front of the applicator. Paint remains in the dump line until the system is flushed. If your material has a low pot life, actuate the paint valve trigger (PT) to load paint.
4.
Follow the
334452E 39
Operation
Check Flow Rate
These instructions begin with material loaded.
1.
Follow the
2.
Put the system in Maintenance Mode. In this mode:
• The electrostatics are off.
• The shaping air is off.
• The turbine air is off (not rotating).
• The bearing air may remain on.
3.
Remove cup and air cap. See
, page 56, or 50 mm Cup , page 57.
4.
Actuate the paint valve trigger (PT).
5.
Measure the flow into a container. Use a stop watch to measure the time. Calculate the flow rate.
6.
To increase the flow rate:
• Increase the regulated fluid pressure of the material.
• Increase the size of the fluid nozzle.
• Reduce the viscosity of the material.
• Use a larger diameter fluid hose up to the bell.
To decrease the flow rate:
• Reduce the regulated fluid pressure of the material.
• Reduce the size of the fluid nozzle.
7.
Reinstall the cup and air cap. See
, page 56, or 50 mm Cup , page 57.
Adjust the Spray Pattern
1.
Put the system in Spray mode.
2.
Select Preset 0 so the spray parameters can be independently adjusted.
3.
Adjust the atomization: a.
Set the inner shaping air (SI) and outer shaping air (SO) to at least 10 psi (0.7 bar) to keep the bell clean.
b.
Set the speed to 25K rpm.
c.
If your system does not have a speed controller, start with the turbine air (TA) set at 0 and increase very slowly. Make sure not to over speed the turbine. See
Turbine Inlet Air Pressure Charts , page 84, for the required pressure
to achieve a given speed.
d.
Actuate the paint valve trigger (PT).
e.
Increase the speed (or increase the turbine air pressure slowly) for finer atomization. f.
Decrease the speed (or decrease the turbine air pressure slowly) for coarser atomization.
NOTE: Speed can be changed with the applicator triggered or not triggered.
4.
Adjust the pattern size: a.
Start with 10 psi (0.7 bar) on both the inner and outer shaping airs (SI and SO).
b.
Increase the outer shaping air (SO) to reduce the pattern size or to improve applicator cleanliness (reduce wrap-back).
c.
Increase the inner shaping air (SI) for additional pattern control.
5.
Adjust the electrostatics: a.
Start with the maximum settings (100 kV,
150
µ
A for Solventborne models; 60kV, 150
µ
A for Waterborne models).
b.
Decrease the voltage if test parts show evidence of thick edges or poorly covered recess areas (the Faraday effect).
c.
Increase the voltage for improved wrap.
6.
Follow the Cup Wash procedure, page 41.
Spray a Part
1.
Put the system in Spray mode. In this mode: a.
Inner and outer shaping airs (SI and SO) are on.
b.
The turbine is spinning at the desired speed.
2.
Position a part, or position the applicator, for material application.
40 334452E
Operation
3.
Turn on the electrostatics. The Safe Position input and other required interlocks must be satisfied.
4.
Actuate the paint valve trigger (PT) until desired coverage is achieved.
NOTE: Excessive paint may wrap back toward the applicator if the applicator is sprayed without a target present.
5.
When finished, turn off the paint valve trigger first.
6.
Then, turn off the electrostatics.
7.
Short Breaks: Leave the shaping airs on and the turbine at speed.
Longer Breaks:
Follow the Cup Wash procedure, page 41. Put the system in Idle mode, which
reduces the turbine speed and shaping airs to conserve energy.
Cup Wash
Follow this cup wash procedure whenever you are done spraying parts, and as needed between parts depending on the material being sprayed and the rate of build-up. Some materials will require frequent cup washing.
1.
Put the system in Purge mode. In this mode: a.
Ensure that electrostatics cannot be enabled.
b.
The bell should be rotating at least 10k rpm.
c.
The inner shaping air (SI) should be a minimum of 10 psi (0.7 bar) to help keep the applicator clean.
2.
Activate the solvent valve trigger (ST).
3.
Use air to purge the solvent.
a.
Provide air to the solvent line S.
b.
Actuate the solvent valve trigger (ST) to purge the cup wash solvent.
Flushing
To avoid fire, explosion, and electric shock:
• Always turn off the electrostatics and discharge voltage when flushing, cleaning, or servicing equipment.
• Always ground the equipment and waste container.
• Flush the equipment only in a well-ventilated area.
• Use only Group IIA materials. Non-ignitable fluids are preferred.
• To avoid static sparking and injury from splashing, always flush at the lowest possible pressure.
• Flush before changing fluids, before fluid can dry in the equipment, at the end of the day, before storing, and before repairing equipment.
• Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid being dispensed and the equipment’s wetted parts.
NOTICE
Use the lowest practical solvent pressure to perform flushing and cup wash procedures. Excessive solvent flow can cause fluid to flood the turbine and damage it.
1.
Put the system in Purge mode. In this mode: a.
Ensure that electrostatics cannot be enabled.
b.
The bell should be rotating at least 10k rpm.
c.
The inner shaping air (SI) should be a minimum of 10 psi (0.7 bar) to help keep the applicator clean.
334452E 41
Operation
2.
Provide solvent to the paint line P.
3.
Actuate the dump valve trigger (DT) to flush the lines to the applicator. Close the dump valve when clear solvent exits the dump line. (Actuate the Paint trigger if the dump valve is not being used.)
4.
Actuate the paint trigger (PT) to flush the fluid tube and nozzle.
5.
Actuate the solvent valve trigger (ST) to wash the cup.
NOTE: If you need to purge all solvent, proceed with
6.
Use air to purge the solvent.
a.
Provide air to the paint line P.
b.
Actuate the dump valve trigger (DT) to purge the lines.
c.
Actuate the paint valve trigger (PT) to purge the applicator.
d.
Provide air to the solvent line S.
e.
Actuate the solvent valve trigger (ST) to purge the cup wash solvent.
NOTE: Turn off the main air supply (bearing air) only after the cup has stopped spinning.
1.
Turn off the electrostatics.
Complete Step 1 of the
.
2.
Shut off the fluid and solvent supply.
3.
Relieve the paint pressure.
Actuate the dump valve trigger (DT) to relieve pressure in the paint and dump lines. If your system does not have a dump valve, actuate the paint valve trigger (PT).
4.
Relieve Solvent Pressure.
Actuate the solvent valve trigger (ST) to relieve pressure in the solvent line.
5.
Turn off the turbine air and the shaping airs.
Put the system in Off mode.
6.
After the bell has stopped spinning, turn off the main air supply.
7.
Disable the electrostatics and verify the voltage has been discharged.
Complete Steps 2-4 of the
.
Voltage Discharge and
Grounding Procedure
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever you see this symbol.
This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.
Follow these basic steps in the order shown to relieve the system pressure. The exact procedure to accomplish each step may vary based on your system design.
Be certain that all steps are completed.
The system is charged with high voltage until the voltage is discharged. Contact with the charged components of the applicator will cause an electric shock. For Waterborne systems, contact with the charge fluid supply system also will cause an electric shock. To avoid an electric shock, follow this procedure
• before entering the spray area
• whenever you are instructed to discharge the voltage
• before cleaning or servicing the system equipment
• before opening the isolation enclosure for the isolated fluid supply.
42 334452E
Operation
To avoid fire or explosion during the test, all spraying devices in the hazardous area must be turned off and ventilation fans in the hazardous area must be operating. Conduct the test only when no flammable vapors are present in the area (such as open solvent containers or fumes from spraying).
NOTE: An accessory grounding rod, part No. 210084, is available to discharge any voltage remaining on a system component.
1.
Turn off the electrostatics by pressing on the
Electrostatic Controller, by using an Electrostatic
Enable I/O signal, or by using CAN communication.
Switching to Purge mode also will shut off the electrostatics. Wait the amount of time set for your system to discharge.
b.
For waterborne systems: Discharge the voltage at the voltage isolation system by following the procedure specified in the voltage isolation system instruction manual. Touch the pump, supply pail, and applicator air cap cover with a grounded rod to make sure the voltage has been discharged. If you see an arc, verify that the electrostatics are turned off. Increase the
discharge time, or see Electrical Troubleshooting , page 53, or the voltage isolation sys-
tem manual for other possible problems. The default discharge time is 60 seconds. Resolve the problem before proceeding.
5.
Test voltage discharge weekly.
Shutdown
1.
Flush if needed. See Flushing , page 41.
2.
Follow the
Pressure Relief Procedure , page 42,
which includes Voltage Discharge and Grounding.
3.
Clean the cup and exterior of the applicator. See
Clean the Air Cap and Cup , page 49. See also,
Clean the Outside of the Rotary Applicator , page
To avoid fire or explosion or electric shock, always wait for the full discharge time to elapse. Once the electrostatics are turned off, the display no longer tracks or displays the actual voltage. Do not use the controller display to determine if the system is discharged.
NOTE: The procedure to set the discharge timer is found in the directions for Setup Screen 10 in the
Electrostatic Controller manual (3A3657).
2.
Put the system in Off mode.
3.
Disable the electrostatics by powering off the
Electrostatic Controller (set to off). NOTE:
Electrostatics also can be disabled by removing an interlock, if preferred. An error will occur. When the procedure is finished, clear error to restart.
4.
Verify that the system has discharged.
a.
For solventborne systems: Touch the air cap cover (19) with a grounded rod to make sure the voltage has been discharged. If you see an arc, verify that the electrostatics are turned off.
Increase the discharge time, or see
Troubleshooting , page 53. The default dis-
charge time is 5 seconds. Resolve the problem before proceeding.
334452E 43
Maintenance
Maintenance
Check for Fluid Leakage
Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or repair this equipment unless you are trained and qualified.
Contact with the charged components of the rotary applicator will cause an electric shock. Contact with a rotating cup also may cause injury. Do not touch the bell or come within 3 ft.(0.9 m) of the front of the applicator during operation.
To reduce the risk of an injury, follow the
Relief Procedure , page 42, which includes
Voltage
Discharge and Grounding, before checking or servicing any part of the system, and whenever you are instructed to relieve the pressure.
Daily Care and Cleaning
Checklist
If any fluid leakage from the applicator is detected, stop spraying immediately. Fluid leakage could cause fire or explosion, and result in serious injury and property damage.
During operation, periodically remove the shroud to check for the presence of fluid. See F IG . 18 for location of potential leaks.
Check the following list daily when finished using the equipment.
Flush the applicator.
Check the fluid and air line filters.
Clean the cup and the outside of the applica-
Inspect the rotary applicator and the cup for nicks, scratches, or excessive wear.
Check for fluid leakage from the applicator and fluid hoses.
F IG . 18 Check for Fluid Leakage
Fluid in these locations indicates leakage, which could be caused by the fluid tube connectors, manifold o-rings, or fluid valve leakage.
If fluid is seen in any of these locations:
1.
Stop spraying immediately.
2.
Follow the Pressure Relief Procedure , page 42,
which includes Voltage Discharge and Grounding.
3.
Follow the Shutdown Procedure, page 43.
4.
Remove the applicator for repair.
44 334452E
Electrical Tests
Electrical Tests
Megohm meter Part No. 241079 (AA-see F IG . 19) is not approved for use in a hazardous location. To reduce the risk of sparking, do not use the megohm meter to check electrical grounding unless:
• The applicator has been removed from the hazardous location;
• Or all spraying devices in the hazardous location are turned off, ventilation fans in the hazardous location are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes from spraying).
Failure to follow this warning could cause fire, explosion, or electric shock, and result in serious injury and property damage.
Electrical components inside the applicator affect performance and safety. The following procedures test electrical continuity between applicator components.
Use megohm meter (AA) and an applied voltage of
500 V. Connect the leads as shown.
NOTE:
Follow the Flushing Procedure, page 41, and
dry the fluid passages prior to performing electrical tests.
Test Full Applicator with Power
Supply
See F IG . 19.
Measure resistance between the air cap cover and power supply connector pins P1 and p4.
Pin
P1, P2, P3
P4
Acceptable Range
120-160 megohms
9.0-11.0 gigohms
- If resistance is within this range, testing is complete.
- If resistance is outside this range, test the power supply and the front housing separately.
AA
F IG . 19 Full Applicator and Power Supply
334452E
28
P4 P1
45
Electrical Tests
Spring Loaded
Contact Points
1a Threaded
Ball Contact
Test Power Supply in Main
Housing
1.
Remove front housing and turbine assembly. See
Replace Front Housing and Turbine Assembly, page 61
for removal instructions if needed.
2.
Measure resistance between the main housing contact and the power supply connector pins 1 and 4.
Pin
1, 2, 3
4
Acceptable Range
120 - 160 M Ω
9.0 - 11.0 G Ω
- If resistance is within range, proceed with testing the front housing.
- If resistance is out of range, test the power supply resistance and inspect the threaded ball contact.
F IG . 20 Rotary Applicator Electrical Path
1a
NOTE: The spring plunger housing must be flush or no more than .01 inch below the main housing surface.
46 334452E
AA
F
IG
. 21 Full Applicator and Power Supply
28
P4 P1
Electrical Tests
334452E 47
Electrical Tests
.
Test Power Supply
See F IG . 22.
1.
Remove the power supply (28). See Repair the
2.
Measure resistance from the power supply (at P) to the spring (28a).
Pin
P1, P2,
P3
P4
Acceptable Range
120-160 megohms
9.0-11.0 gigohms
• If resistance is outside this range, replace the power supply.
• If resistance is within this range, reassemble the power supply in the main housing and retest.
Make sure the power supply spring is making contact in the housing.
Test Front Housing
1.
Remove front housing. See Replace Front Housing and Turbine Assembly , page 61, for removal
instructions, if needed.
2.
Measure resistance from the brass plug to the ball contact.
3.
If resistance is less than 0.1 megohm, reassemble and retest the full applicator. Make sure spring loaded contacts are clean and making contact with
the mating surface. Refer to F IG . 23.
4.
If resistance is 0.1 megohm or greater, replace the front housing.
AA
28a
28
F IG . 23 Front Housing Resistance
P4
F IG . 22 Power Supply Resistance
P1
48 334452E
Electrical Tests
Clean the Air Cap and Cup
Equipment Needed
• soft bristle brush
• compatible solvent
1.
Remove the cup. See
,
2.
Soak the cup in a compatible solvent until paint is loose. Remove all paint with a soft bristle brush dipped in solvent.
3.
If necessary, clean the splash plate (20a) separately for easier access. Make sure the center holes of the splash plate are clean.
a.
15 mm cups: Use tool (21). Turn counter clockwise to remove the splash plate.
b.
30 mm and 50 mm cups: Place the cup face down on a soft and non-abrasive surface. Press out the splash plate with the post end of the fluid valve tool (45).
15 mm
30 mm and 50 mm
NOTICE
Use only tool 25C438 (Ref. 21, 15 mm), tool
25C200 (Ref. 45, 30 mm or 50 mm), or your thumb to remove the splash plate. Other tools could damage the surface finish, taper connection, or threads, making the cup inoperable.
4.
Reinstall the splash plate (20a).
a.
15 mm cups: Use tool (21) to turn the splash plate clockwise to 20-25 in-lbs (2.3-2.8 N•m).
b.
30 mm and 50 mm cups: Use your thumb to press the splash plate (20a) back in.
NOTICE
Do not use the fluid valve tool (45) to install the splash plate. It might slip and damage the cup.
5.
If the press fit of the splash plate feels loose, service the split ring (20b). If the press fit is too tight, verify alignment. Remove and re-align if necessary.
6.
Rinse the cup and dry it.
7.
Clean the air cap with the soft bristle brush and solvent, or submerge the air cap in a suitable solvent and wipe it clean. Do not use metal tools.
8.
To maximize pattern control, clean the shaping air holes and the air cap cover. Be sure they are not blocked. Soak the parts in solvent and use compressed air to clear any plugged holes.
9.
Inspect the parts for damage or excessive wear.
Replace if needed.
10. Reassemble. See
F
IG
. 24. Remove Splash Plate
334452E 49
Electrical Tests
Clean the Fluid Nozzle
Equipment Needed:
• soft bristle brush
• compatible solvent
NOTE: The nozzle is reverse threaded.
1.
Follow all steps in
Repair Fluid Nozzle , page 62.
2.
Remove o-ring (8).
3.
Soak the nozzle in a compatible solvent until paint is loose. Remove all paint with a soft bristle brush dipped in solvent.
4.
Rinse the nozzle and dry it.
Clean the Outside of the Rotary
Applicator
NOTICE
• Clean all parts with a non-conductive, compatible solvent. Conductive solvents can cause the applicator to malfunction.
• Fluid in the air passages could cause the applicator to malfunction and could draw current and reduce the electrostatic effect. Whenever possible, point the applicator down when cleaning it. Do not use any cleaning method which could allow fluid into the air passages.
1.
Follow the Pressure Relief Procedure , page 42,
which includes Voltage Discharge and Grounding.
2.
Make sure the bell has stopped spinning. Then, clean the outside surfaces with a damp solvent rag.
Do not allow solvent to get into the bell passages.
3.
Dry the exterior surfaces.
50 334452E
Troubleshooting
Troubleshooting
1.
Follow
Prepare for Applicator Service , page 56,
before checking or repairing the applicator.
2.
Check all possible problems and causes before disassembling the applicator.
3.
See additional troubleshooting in the System Logic
Controller manual (3A3955) .
Spray Pattern Troubleshooting
Problem
Poor Spray Pattern
Fluttering or spitting spray.
Poor wrap.
Cause
The cup (20) is damaged.
The air cap cover (19) is not tight.
O-ring (16, 18c, or 18d) is missing.
Replace.
Tighten.
Replace.
Solution
Splash plate (20a) is dirty or damaged.
Clean or replace.
Fluid flow rate is incorrect.
Shaping air holes are clogged.
Check fluid pressure.
Check nozzle size (9).
Disassemble and clean the air cap cover (19).
The fluid supply is empty.
Air is in the fluid supply.
See Electrical Troubleshooting, page 53.
Refill supply.
Check fluid source. Refill.
Applicator Operation Troubleshooting
Problem
Rotary applicator does not spray
Cause
Turbine (10) is not rotating.
Fluid supply is low.
Paint valve (4) is not opening.
The fluid tube (7) or nozzle (9) is clogged.
Solution
Be sure the bearing air pressure is at least 70 psi and the turbine air pressure is sufficient.
Inspect the turbine bearing for damage.
If still not rotating freely, reference
Spindle Inspection and Cleaning Service Instructions, 3A4794.
Add fluid if necessary.
Increase fluid pressure if needed.
Verify at least 70 psig air pressure to the paint trigger line.
Clean or replace paint valve.
Remove and clean, replace if necessary.
334452E 51
Troubleshooting
Rotary applicator will not stop spraying.
Problem Cause
The paint (4) valve is stuck open.
Solution
Turn off the paint trigger air. If still spraying, turn off fluid supply and clean or replace paint valve.
A valve seat (3) is damaged or worn. Inspect, clean, or replace as needed.
Cannot reach desired fluid flow rate Fluid pressure is insufficient.
Increase.
Fluid leakage from the front of the rotary applicator
Fluid nozzle (9) orifice is too small.
Replace with the next larger size nozzle.
Fluid tube (7) or nozzle (9) is partially clogged.
Remove and clean, replace if necessary.
Fluid valve (4) is loose.
Remove and clean. Tighten.
Nozzle (9) is loose on fluid tube (7).
Remove and clean. Tighten.
Fluid leakage from the dump valve.
Dump valve (4) is loose.
Excessive vibration
The valve seat (3) is damaged or worn.
The cup (20) is dirty.
Remove and clean. Tighten.
Inspect, clean, or replace as needed.
Cup (20) is not fully secured on turbineshaft (10).
The cup (20) is damaged.
Remove and clean any dried paint or other contaminant.
Inspect and clean the threads on the cup and shaft. Retorque.
Remove, clean, and inspect. Replace as needed.
Turbine (10) is rotating too fast (being supplied with too much air).
Decrease turbine air pressure.
Speed Sensor Error
An o-ring (2, 8, or 60) is missing or damaged.
Inspect and clean. Replace as needed.
The fluid valve seat (3) is damaged or worn.
Inspect, clean, or replace as needed.
The fiber-optic cable between the applicator and the speed controller is damaged or has surpassed the bend radius.
Repair or replace fiber-optic cable.
The fiber-optic cable is not properly adjusted.
The fiber-optic connector is loose.
The magnetic speed pick-up sensor is not generating light.
Adjust the amount of fiber extending past the nut.
Reinstall and tighten.
Replace
52 334452E
Troubleshooting
Electrical Troubleshooting
Problem Cause Solution
Voltage is still present after follow-
Grounding Procedure , page 42.
Bleed resistor is damaged.
Measure power supply resistance.
An air pocket in the fluid line has isolated the fluid near the applicator (waterborne models).
Determine cause and correct. Purge air from fluid line.
The voltage isolation system failed
(waterborne models)
Excessive paint is wrapping back.
Poor part grounding.
Service the voltage isolation system.
See
Step 9. Ground the Equipment , page 34.
Should be 9-14 in. (23-36 cm) The distance from applicator to part is incorrect.
The shaping air is insufficient.
Operator gets mild shock.
Paint wraps poorly on parts.
Operator is not grounded or is near an ungrounded object.
Applicator is not grounded.
Operator got too close to the applicator before the discharge time had elapsed.
Electrostatics are missing or voltage is insufficient.
Parts are insufficiently grounded.
Verify that shaping air is on.
Increase setpoint if necessary.
See
Step 9. Ground the Equipment , page 34.
See
Step 9. Ground the Equipment , page 34.
Wait for the full discharge time to elapse. Check power supply resistance - Pin 4. Increase discharge timer setting, if needed.
Turn ON at the Electrostatic Controller. Adjust and monitor as needed.
Properly ground so the electrical resistance between the part and ground is 1 megohm or lower.
Electrostatic Controller won’t go over 60 kV.
The electrostatics are on, but there is no electrostatic effect from the applicator.
Shaping air pressure is too high.
Decrease the shaping air (inner and outer) setpoints.
Should be 9-14 in. (23-36 cm).
Distance from applicator to part is incorrect.
Fluid resistivity is low.
The controller is designed for use with a waterborne system.
See
Purchase a controller designed for use with a solventborne system.
There is an error in the system (indicated by an error code on the Electrostatic
Controller).
Refer to the Electrostatic Controller
Manual (3A3657) to determine and address the cause.
One or more parts have malfunctioned or need service.
Complete the Electrical Tests starting on page 45. Replace any
out-of-specification parts. Retest.
The power supply cable is damaged.
Test the power supply cable for continuity. See the Electrostatic Controller Manual (3A3657).
Waterborne Systems: See
Waterborne System Voltage Loss Troubleshooting , page 54, for possible causes and solutions.
334452E 53
Troubleshooting
Waterborne System Voltage
Loss Troubleshooting
Normal spraying voltage for a system using the waterborne applicator is 40-55 kV. The system voltage is lower due to spraying current demands and voltage isolation system losses.
A loss of spraying voltage can be caused by a problem with the applicator, fluid hoses, or voltage isolation system, since all of the system components are electrically connected through the conductive, waterborne fluid.
Before troubleshooting or servicing the voltage isolation system itself, you need to determine which component in the system is most likely causing a problem. Possible causes include the following:
Applicator
• Fluid leakage
• Dielectric breakdown at the fluid hose connections.
• Faulty power supply
• Excessive over spray on applicator surfaces
• Fluid in the air passages
Waterborne Fluid Hose
• Dielectric failure of the hose (pin-hole leak in the
PTFE layer)
Voltage Isolation System
• Fluid leakage
• Dielectric breakdown of hoses, seals, or connections
• Isolators not functioning properly
Visual Checks
First, check the system for any visible faults or errors to help isolate whether the applicator, fluid hose or voltage isolation system has failed.
1.
Check that all of the air and fluid tubes and hoses are properly connected. Make sure the waterborne hoses are secured at the proper height at the strain relief.
2.
Check that the voltage isolation system valves and controls are properly set for operation.
3.
Check that the interior of the isolated enclosure is clean.
4.
Check that the voltage isolation system has sufficient air pressure.
5.
Check that the electrostatics are turned on.
6.
Check that the voltage isolation system's enclosure door is closed and that any safety interlocks are engaged and working properly.
7.
Make sure the voltage isolation system is isolating the fluid voltage from ground.
8.
To eliminate air gaps in the fluid column, spray enough fluid to purge the air out between the voltage isolation system and the applicator. An air gap in the fluid hose can break the electrical continuity between the applicator and the isolated fluid supply and cause a low voltage reading at the isolation system.
9.
Check the outside of the applicator for accumulated overspray. Excessive overspray can create a conductive path back to a ground. Clean the exterior of the applicator.
10. Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found.
Pay special attention to the following areas:
• Applicator fluid valves
• Fluid hose: check for leakage or any bulges in the outer cover, which may indicate an internal leak.
• Internal voltage isolation system components
54 334452E
Troubleshooting
Tests
If you still have no voltage, separate the applicator and fluid hoses from the voltage isolation system and check whether the applicator and hoses alone will hold voltage with the following test.
1.
Flush the system with water and leave the lines filled with water.
2.
Discharge the system voltage (see the Pressure
Relief Procedure , page 42, which includes
Voltage
Discharge and Grounding).
3.
Disconnect the fluid hoses from the voltage isolation system.
Avoid allowing any water to leak out of the fluid hose(s) as that could cause a significant air gap in the fluid column up to the cup, which can break the conductivity path and conceal a potential failure area.
4.
Position the end of the hose(s) as far as possible away from any grounded surface. The end of the hose must be at least 1 ft. (0.3 m) from any ground.
Make sure that no one is within 3 ft. (0.9 m) of the end of the hose.
NOTE: The conductive layer of the hose must remain grounded.
5.
Using the controller, turn on the electrostatics to the applicator. Observe the voltage and current level on the controller.
• If the voltage is 40 to 55 kV, the applicator and fluid hose are okay, and the problem is in the voltage isolation system.
• If the spraying voltage is below 40 kV, the problem is in the applicator or fluid hoses.
6.
Discharge the system voltage (see Voltage
Discharge and Grounding Procedure , page 42).
7.
Flush the fluid hoses and applicator with enough air to dry out the fluid passages.
8.
Using the controller, turn on the electrostatics to the applicator. Observe the voltage and current level on the controller.
9.
If the voltage is 40-55 kV, the applicator power supply is okay, and there is probably a dielectric breakdown somewhere in the fluid hoses or applicator.
Continue with step 10.
supply resistance. If those tests show the applicator and power supply are okay, continue with step 10.
10. A dielectric breakdown is most likely in one of the following three areas. Repair or replace the component that is failing.
a.
Fluid hoses:
• Check each hose for leakage or any bulges in the outer cover, which may indicate a pin-hole leak through the PTFE layer. Disconnect the fluid hoses from the applicator, and look for signs of fluid contamination on the outside of the PTFE portion of the fluid tube.
• Inspect the end of each hose connected to the voltage isolation system. Look for cuts or nicks.
• Make sure each hose is properly stripped (see
Waterborne Systems , page 23). Re-strip or
replace the hose.
b.
Fluid hose connection to the applicator:
• A breakdown at the fluid hose connection joint is caused by fluid leaking past the fitting on the end of the hose.
11. Clean and dry the fluid tubes, then reassemble the applicator.
12. Reconnect the fluid hoses.
Check the voltage before filling the applicator with fluid.
334452E 55
Repair
Repair
Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or repair this equipment unless you are trained and qualified.
Contact with the charged components of the rotary applicator will cause an electric shock. Contact with a rotating cup also may cause injury. Do not touch the bell or come within 3 ft. (0.9 m) of the front of the applicator during operation.
To reduce the risk of an injury, follow the
Relief Procedure , page 42, which includes
Voltage
Discharge and Grounding, before checking or servicing any part of the system, and whenever you are instructed to relieve the pressure.
NOTES:
•
Check all possible remedies in Troubleshooting
before disassembling the applicator.
• Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate.
• Only use genuine Graco parts.
Prepare for Cup or Air Cap
Service
1.
Follow the
Pressure Relief Procedure , page 42,
which includes Voltage Discharge and Grounding.
2.
Clean the applicator. See Daily Care and Cleaning
Prepare for Applicator Service
1.
Flush the fluid lines.
2.
Follow the Pressure Relief Procedure , page 42,
which includes Voltage Discharge and Grounding.
3.
Screw off the manifold retaining ring (35) by hand.
The adapter cover (34) will come with it.
4.
Slide the shroud (33) off the back of the housing (1).
5.
Disconnect all fluid, air, power, and communication lines.
6.
Clean the applicator. See Daily Care and Cleaning
7.
Remove the bell applicator from the mounting. Perform service or repair at a work bench.
Replace Cup or Air Cap
Use this section for a quick, on-line replacement of a damaged or worn cup. Cup replacement kits are available.
15 mm or 30 mm Cup
1.
Prepare for Cup or Air Cap Service , page 56.
2.
Use the small end of the spanner wrench tool (44) to remove the air cap cover (19).
44
56 334452E
Repair
3.
Remove the air cap (18).
4.
Use the spanner wrench tool (44) to hold the turbine shaft, then screw off the cup (20).
50 mm Cup
1.
Prepare for Cup or Air Cap Service , page 56.
2.
Use the small end of the spanner wrench tool (44) to remove the air cap cover (19).
44
5.
Hold the turbine shaft with the spanner wrench tool
(44), and install the new cup (20) hand tight. Make sure that the mating tapers are fully seated. Install the air cap (18).
44
3.
To hold the shaft steady, insert the fluid valve tool (45) into the rectangular opening on the air cap (18). To lock rotation, slowly rotate the cup until the tool engages the hole in the shaft. Then, screw off the cup (20).
44
45
6.
Use the small end of the spanner wrench tool (44) to install the air cap cover (19).
4.
Remove air cap (18). Inspect parts for damage and replace as needed. Reinstall the air cap (18) or install a new one.
44
19
334452E 57
Repair
5.
Start threading the new cup (20). Insert the fluid valve tool into the rectangular opening on the air cap (18). Slowly rotate the cup until the tool engages the hole in the shaft. Then, tighten the cup (20) until the mating tapers are fully seated.
45
6.
Use the spanner wrench tool (44) to install the air cap cover (19).
44
Service the Cup and Air Cap
Use this section to remove your cup and air cap and fully disassemble each piece for cleaning or to replace any worn or damaged parts.
NOTICE
Use only tool 25C438 (Ref. 21, 15 mm), tool
25C200 (Ref. 45, 30 mm or 50 mm), or your thumb to remove the splash plate. Other tools could damage the surface finish, taper connection, or threads, making the cup inoperable.
NOTICE
Do not use the fluid valve tool (45) to install the splash plate. It might slip and damage the cup.
15 mm Cup
1.
Prepare for Applicator Service , page 56.
2.
Remove the air cap cover (19), cup (20) and air cap
3.
Use tool (21). Turn counter-clockwise to remove the splash plate from the cup. Clean parts and inspect for damage. Replace parts as needed.
58 334452E
Repair
4.
Use tool (21) to reinstall the splash plate (20a). Turn the splash plate clockwise to 20-25 in-lbs
(2.3-2.8 N•m).
5.
Grease the solvent stud o-ring (18c) and install the air cap (18), the cup (20), and the air cap cover (19)
on the applicator. See page 56.
30 mm Cup
1.
Prepare for Applicator Service , page 56.
2.
Remove the air cap cover (19), cup (20) and air cap
3.
Use the fluid valve tool (45) to push the splash plate
(20a) out of the cup. Remove the split ring (20b).
Clean all parts and inspect for damage. Replace parts as needed.
15 mm or 30 mm Air Cap
1.
Prepare for Applicator Service , page 56.
2.
Remove the air cap cover (19), cup (20) and air cap
3.
Remove the solvent stud o-ring (60). Remove the solvent stud (59) only if you are experiencing a problem and need to replace it.
4.
Remove the outer air cap (18b). Remove the o-ring
(18c) from the inner air cap (18a). Clean all parts and inspect for damage. Replace parts as needed.
15 mm cup 60 1
59
18a
18c 1
18b
30 mm cup
60
59
1
18a
18c 1
20
20b
20a
4.
Install split ring (20b) on the splash plate (20a).
Place the splash plate into the cup. Push in with your thumb until it is fully seated.
5.
Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19)
on the applicator. See page 56.
18b
1
Apply lubricant.
5.
Install the o-ring (60) on the solvent stud (59).
6.
Install the o-ring (18c) on the inner air cap (18a), then fit the inner (18a) and outer (18b) air caps together.
7.
Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19)
on the applicator. See page 56.
334452E 59
Repair
50 mm Cup
1.
Prepare for Applicator Service , page 56.
2.
Remove the air cap cover (19), cup (20), and air cap
3.
Use the fluid valve tool (45) to push the splash plate
(20a) out of the cup. Remove split ring (20b). Clean all parts and inspect for damage. Replace parts as needed.
3.
Slide off the air cap (18). Remove the outer air cap
(18b). Remove o-rings (18c, 18d). Remove the solvent stud o-ring (60). Remove the solvent stud (59) only if you are experiencing a problem and need to replace it. Clean all parts and inspect for damage.
Replace parts as needed.
59
1
60
18a
4.
Install the split ring (20b) on the splash plate (20a).
Place the splash plate into the cup. Push in with your finger until it is fully seated.
5.
Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19)
on the applicator. See page 57.
50 mm Air Cap
1.
Prepare for Applicator Service , page 56.
2.
Remove the air cap cover (19) and cup (20). See
18d 1
18c
18b
1
Apply lubricant.
4.
Install the o-ring (60) on the solvent stud (59).
5.
Install o-rings (18c and 18d) on the inner air cap
(18a), then fit the inner (18a) and outer (18b) air caps together.
6.
Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19)
on the applicator. See page 57.
60 334452E
Repair
Replace Front Housing and
Turbine Assembly
1.
Prepare for Applicator Service , page 56.
2.
Remove the air cap cover (19), cup (20) and air cap
(18). See 15 mm or 30 mm Cup , page 56, or
3.
Use the larger end of the spanner wrench tool (44) to remove the retaining ring (15).
8.
Clean all parts and inspect for damage. Replace parts as needed.
1
1
Lubricate o-rings.
1
44
4.
Remove the front housing (13), which includes the turbine assembly (10).
5.
Place the threaded end of the turbine assembly (10) on a padded bench. Press down on the housing
(13) to separate the housing and the turbine assembly.
9.
Install o-rings (11, 12, 14, and 17) on the front housing (13). Lubricate and install o-ring (16).
10. Install o-rings (10a, 10b, and 10c) on the turbine assembly (10).
11. Install the turbine assembly (10) into the front housing (13).
12. Grease the solvent stud o-ring (60). Use the solvent stud and the pins to align the front housing (13) with the main housing (1), then install the front housing.
13. Install the retaining ring (15). Use the larger end of the spanner wrench tool (44) to tighten it.
NOTICE
Be careful not to damage the threads when removing the turbine assembly from the front housing.
6.
Remove the o-rings (11, 12, 14, 16, and 17) from the front housing.
7.
Remove the o-rings (10a, 10b, and 10c) from the turbine assembly (10).
44
334452E
14. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See
61
Repair
Repair or Replace the Solvent
Stud
The applicator has two solvent studs (59). One is on the main housing (1) and the other is on the air cap (18).
1.
Prepare for Cup or Air Cap Service , page 56.
2.
Remove the air cap cover (19), cup (20), air cap
(18), retaining ring (15), turbine (10) and front housing (13).
3.
Use a 1/4 in. hex wrench to remove the solvent stud
(59) from the main housing (1) or the air cap (18).
Remove the o-rings (60). One of the solvent stud o-rings probably will remain in the opening when the solvent stud is removed.
4.
Install the o-rings (60) on the solvent stud (59).
Lubricate the o-rings and tighten the solvent stud into the main housing (1) or the air cap (18). Tip:
You may find it easier to lubricate the bottom o-ring and install it in the hole.
5.
Install the front housing (13, including turbine assembly, 10) and retaining ring (15). See
6.
Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19)
on the applicator. See 15 mm or 30 mm Cup , page
5.
Use the middle hexagon on the spanner wrench tool
(44) to remove the fluid nozzle (9).
NOTE: The nozzle is reverse threaded.
44
6.
Inspect o-ring (8) and remove if damaged.
7.
Install a new o-ring (8) on the nozzle (9).
8.
Hold the fluid tube with a wrench. Use the middle hexagon on the spanner wrench to tighten the fluid nozzle. Torque to 58-62 in-lb (6.5-7.0 N•m).
1
Torque to 58-62 in-lb
(6.5-7.0 N•m)
Repair Fluid Nozzle
1.
Prepare for Cup or Air Cap Service , page 56.
2.
Flush the fluid lines.
3.
Follow the
Pressure Relief Procedure , page 42.
4.
Remove the air cap cover (19), cup (20), air cap
(18), retaining ring (15) and front housing (13).
44
1
9.
Install the front housing (13, including turbine assembly, 10) and retaining ring (15). See
10. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19)
on the applicator. See 15 mm or 30 mm Cup
, page
62 334452E
Repair
Repair or Replace the Fluid Tube
1.
Prepare for Cup or Air Cap Service , page 56.
2.
Flush the fluid lines.
3.
Follow the Pressure Relief Procedure , page 42,
which includes Voltage Discharge and Grounding.
4.
If not already disassembled, remove the air cap cover (19), cup (20), air cap (18), retaining ring (15) front housing (13), and fluid nozzle (9).
5.
Use a 12 mm wrench to remove the fluid tube (7).
8.
Screw in a new fluid tube hand tight, then use a
12 mm wrench to tighten. Torque to 78-82 in-lb
(8.8-9.3 N•m).
1
Torque to 78-82 in-lb
(8.8-9.3 N•m)
1
6.
Inspect o-rings (7a, 7b) and remove if damaged.
7.
Lightly grease and install new o-rings (7a, 7b) on the fluid tube.
9.
Install the front housing (13, including turbine assembly, 10) and retaining ring (15). See
10. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19) on the applicator. See
Replace Magnetic Pickup
Sensor or Fiber Optic Extension
Cable
1.
Prepare for Applicator Service , page 56.
2.
Remove the air cap cover (19), cup (20), air cap
(18), retaining ring (15) and front housing (13).
3.
Screw off the manifold retaining ring (35) by hand.
The adapter cover (34) will come with it.
4.
Slide the shroud (33) off the back of the housing (1).
334452E 63
Repair
11. At the front of the rear manifold, install the fiber optic extension cable (22) and tighten the connector.
22
5.
Loosen the connector of the fiber optic extension cable (22) at the rear manifold.
6.
At the front of the main housing, use a 3/32 inch hex wrench to remove screw (6).
7.
Pull the sensor (5) out of the main housing (1). The fiber optic extension cable (22) comes with it.
8.
Install the new magnetic pickup sensor (5) and/or the new fiber optic extension cable (22). Line up the flat cut with the hole for the screw.
9.
Use a 3/32 inch hex wrench to tighten the screw (6).
Torque to 18-22 in-lb (2.0-2.5 N•m).
ti29024a
12. Install the front housing (13, including turbine assembly, 10) and retaining ring (15). See
13. Grease the solvent stud o-ring (60) and install the air cap (18), the cup (20), and the air cap cover (19)
on the applicator. See 15 mm or 30 mm Cup
, page
1
Torque to 18-22 in-lb
(2.0-2.5 N•m)
22
5
6 1
10. Verify the amount of fiber extending past the nut is
0.11 in. (2.8 mm).
7.4 in.
(18.8 cm)
2X 0.11 in.
(2.8 mm)
22b
22a
64 334452E
Repair
Repair Fluid Valves and Seats
1.
Prepare for Applicator Service , page 56.
2.
Flush the fluid lines.
3.
Follow the Pressure Relief Procedure , page 42,
which includes Voltage Discharge and Grounding.
4.
Remove the manifold retaining ring (35), the adapter cover (34), and the shroud (33).
5.
Put the 4-prong end of the fluid valve tool (45) into the recessed holes on the fluid valve (4).
1 Torque to 9-11 in-lb
(1.0-1.2 N•m).
3
2 Torque to 35-40 in-lb
(4.0-4.5 N•m).
Lubricate the o-ring.
3
1
6.
Use the large center hex of the spanner wrench tool
(44) to remove the fluid valve (4). Remove the outer o-rings (4a and 4b) from the fluid valve. One o-ring
(4b) may have remained in the housing. Inspect o-rings and replace if damaged.
7.
Use a 5/16 hex wrench to remove the seat (3).
Remove the o-ring (2).
8.
Inspect o-ring (2) and replace if damaged.
2
9.
Lubricate the o-ring (2).
10. Install the new seat (3), with the o-ring side down.
11. Use a 5/16 hex wrench to tighten the seat. Torque seat to 9-11 in-lb (1.0-1.2 N•m).
12. Install o-rings (4a and 4b) on the fluid valve.
13. Lubricate the outside surfaces of the fluid valve.
Avoid getting lubricant in the fluid path. Screw in the fluid valve, hand tight.
14. Put the 4-prong end of the fluid valve tool (45) into the recessed holes on the fluid valve (4).
15. Use the large center hex of the spanner wrench tool
(44) to tighten the fluid valve (4). Torque to
35-40 in-lb (4.0-4.5 N•m).
16. Reinstall the shroud (33), the adapter cover (34) and the manifold retaining ring (35).
334452E 65
Repair
Repair Fluid Tube Fittings or
Coiled Fluid Tubes
1.
Prepare for Applicator Service , page 56.
2.
Use a 3/16 hex wrench to remove the 2 screws (42), that hold the fluid bracket (32).
3.
Loosen the connector on the rear manifold and disconnect the fiber optic extension cable (22).
4.
Use a 1/4 hex wrench to remove 3 tie rod screws
(31), then remove the rear manifold (30).
5.
Use a 1/2 in. wrench to remove the tie rods (29).
6.
Use a 9/16 wrench to loosen the nuts on the fluid fittings (25). Disconnect the coiled fluid tubes (27) from the fittings on the main housing (1). Note: Be careful not to lose the ferrules.
7.
Remove the coiled fluid tubes (27) from the fittings on the fluid grounding bracket (32), then remove the bracket.
8.
Use a 1/2 in. wrench to remove the fittings (32d,
32e) from the fluid grounding bracket (32a), as needed. Install new fittings. Torque to 18-22 in-lb.
(2.0-2.5 N•m).
9.
Insert the coiled fluid tubes into the fittings (32d) on the fluid bracket. Be sure both ferrules are in place as shown. Use the 9/16 wrench to tighten the nut on the new fitting.
10. Install the tie rods (29). Torque to 30-35 in-lb
(3.4-4.0 N•m).
11. Use 3 screws (31) to reattach the rear manifold (30).
Torque to 30-35 in-lb (3.4-4.0 N•m).
12. Use 2 screws (42) to reattach the fluid bracket (32).
Torque to 30-35 in-lb (3.4-4.0 N•m).
13. Reattach the fiber optic extension cable (22) on the rear manifold (30).
14. Pass all hoses and cables through the shroud (33), the adapter cover (34) and the manifold retaining ring (35), then reconnect them to the applicator.
15. Reinstall the shroud (33), the adapter cover (34) and the manifold retaining ring (35).
1
2
Torque to 18-22 in-lb
(2.0-2.5 N•m).
Torque to 30-35 in-lb
(3.4-4.0 N•m).
3
4
Lubricate o-rings.
Apply dielectric grease to housing end.
27
2 29
1 25
1
2 31
2 42
1 32d
2
1
32d
32a,b,c
28 3 4
32e
1
66 334452E
Repair
Repair the Power Supply
1.
Prepare for Applicator Service , page 56.
2.
Use a 1/4 hex wrench to remove the three screws
(31).
3.
Loosen the connector on the rear manifold and disconnect the fiber optic extension cable (22).
4.
Pull the rear manifold (30) off of the tie rods.
NOTE: If the hose bundle is still attached, maneuver the manifold off to side, away from the power supply (28).
5.
Unscrew the power supply (28) by hand and remove from the housing. Inspect the spring (28a) and o-ring (28b) on front of the power supply (28) for damage. Replace if needed.
6.
Test Power Supply, page 48 , resistance.
7.
To reinstall, use dielectric grease to fill the concentric rings on the housing end of the new power supply (28). Lubricate the outer o-ring.
8.
Tighten the power supply securely in place by hand.
Be sure it is fully seated.
9.
Test Full Applicator with Power Supply , page 45.
10. Align and reattach the rear manifold (30).
11. Use a 1/4 hex wrench to tighten the tie rod screws
(31). Do not overtighten.
12. Reattach the fiber optic extension cable (22) on the rear manifold (30).
13. Pass all hoses and cables through the shroud (33), the adapter cover (34) and the manifold retaining ring (35), then reconnect them to the applicator.
14. Reinstall the shroud (33), the adapter cover (34) and the manifold retaining ring (35).
Replace an Air Tube Fitting
1.
Prepare for Applicator Service , page 56.
2.
Remove the rear manifold (30).
3.
NOTE: If the hose bundle is still attached, maneuver the manifold off to the side. Remove other parts as needed for access.
4.
Inspect all air fittings (23, 24). Pry out to remove, if needed. Replace fittings and o-rings (38, 39) as required.
5.
Align and reattach the rear manifold (30).
6.
Use a 1/4 hex wrench to tighten the tie rod screws
(31). Do not overtighten.
5X 23
4X 24
5X 39
4X
38
7.
Pass all hoses and cables through the shroud (33), the adapter cover (34) and the manifold retaining ring (35), then reconnect them to the applicator.
8.
Reinstall the shroud (33), the adapter cover (34) and the manifold retaining ring (35).
334452E 67
Parts
Parts
Solventborne Models (R_A1_0)
68 334452E
Parts
Parts for Solventborne Models (R_A1_0)
6
Ref.
Part Description
1†
1a
----HOUSING, main, assembly
25D453 SPRING, plunger contact
8
9
7a
7b
2†
3†
6
7
127316 O-RING, FX75
25C242 SEAT, fluid valve; includes o-ring (Ref.
2)
4†
4a† 117610 O-RING, FX75
4b† 120775 O-RING, FX75
5
25C243 VALVE, fluid; includes o-rings
(Refs. 4a, 4b) and seat (Ref. 3)
25C279 SENSOR, magnetic; includes screw
(Ref. 6)
GC0612 SCREW, button head, #8-32 x 0.25
25C280 FLUID TUBE, assembly; includes o-rings (Refs. 7a and 7b)
120776 O-RING, FX75
111516 O-RING, FX75
17B390 O-RING, FX75
25C206
NOZZLE, fluid; includes o-ring
(Ref. 8)
0.75 mm. (0.03 in); for R_A13_ models
25C207
25C208
1 mm. (0.04 in); for R_A14_models
1.25 mm (0.05 in); or R_A15_ models
25C209
26A524
26A525
1.5 mm (0.06 in); for R_A16_ models
1.8 mm (0.07 in)
2.0 mm (0.08 in)
10 24W988 TURBINE, assembly; includes o-rings
(10a-10c)
10a 17D878 O-RING, FX75
10b 17B495 O-RING, FX75
10c 17D877 O-RING, FX75
11 GC1936 O-RING, FX75
12 17D879 O-RING, FX75
13 25C281 HOUSING, front; includes o-rings
(Refs. 11, 12, 14,16, 17)
14 111516 O-RING, FX75
15 25C218 RING, retaining
16 17B495 O-RING, FX75
17 125249 O-RING, FX75
18 AIR CAP, assembly; includes solvent stud (59) and o-ring (60)
24Z989
25C220 for R1A1_ _ models (15 mm); includes Refs. 18a-18c for R3A1_ _ models (30 mm); includes Refs. 18a-18c
18a
18b
25C221 for R5A1_ _ models (50 mm); includes Refs. 18a-18d
----AIR CAP, inner
----AIR CAP, outer
Qty
3
3
1
1
3
1
1
1
1
1
6
3
1
1
1
1
1
1
1
1
1
1
6
1
1
Ref.
Part Description
18c
17D877
17S113
O-RING - 30 mm
O-RING - 15mm
18d 17B494 O-RING
19
24Z985
25C223
25C224
O-RING
COVER, air cap for R1A1_ _ models (15 mm) for R3A1_ _ models (30 mm) for R5A1_ _ models (50 mm)
20
24Z088
CUP, aluminum, serrated, includes splash plate (Ref. 20a);
Selection Charts , page 75, for avail-
able cups for R1A1_0 models (15 mm); includes tool (Ref. 21)
20a
24Z079
24Z084
25D455 for R3A1_0 models (30 mm) for R5A1_0 models (50 mm)
PLATE, splash for R1A1_0 models (15 mm); includes o-ring (Ref. 20c)
25C214 for R3A1_0 and R5A1_0 models;
(30 mm and 50 mm) includes split ring (Ref. 20b)
20b 17Z653 RING, split
20c 17B390 O-RING, FX75
21 25C438 TOOL, 15 mm splash plate
(Not Shown)
22 25C315 CABLE, extension, fiber optic; includes nuts (22a) and fittings (22b)
22a ----NUT, fiber optic - see kit 24W872
FITTING, fiber optic - see kit 24W872 22b -----
23† -----
24† -----
RETAINER, tubing, 5/16 in.
RETAINER, tubing, 5/32 in.
25† 111157 FITTING, tube, 1/4 in. with 1/8 in. npt threads
27
28
25C227 TUBE, coiled, 1/4 in.
25A692 POWER SUPPLY; includes spring
(Ref. 28a) and o-ring (Ref. 28b)
28a 24Y773 SPRING
28b 16D531 O-RING, FX75
29
30
31
25C229 ROD, TIE
25C282 MANIFOLD, rear; includes bracket
(Ref. 32) and screws (Ref. 42)
104035 SCREW, cap, socket head, 5/16-18 x
1 in.
32 25M454 BRACKET ASSEMBLY, fluid, grounding, includes 32a-32e
32a -----
32b -----
BRACKET
FITTING, fluid, 5/8-18 UNF-2A
32c ----NUT, 5/8-18 UNF-2B
32d 111157 FITTING, tube, 1/4 in. with 1/8 in. npt threads;
Qty
1
1
1
1
3
1
1
1
1
1
1
1
5
4
2
2
1
3
1
1
1
3
4
1
3
334452E 69
Parts
Ref.
Part Description
32e 17K719 FITTING, tube, 5/16 in. with 1/8 in. npt threads;
33 25C216 COVER, shroud
34
35
17B385 COVER, adapter
17B386 RING, retaining, manifold
36 25C284 BRACKET, mounting; includes screws
(Ref. 37)
37 17B496 SCREW, socket head, 3/8-16 x 0.5 in.
38† 17L763 O-RING, FX75
39† 17L764 O-RING, FX75
41
42
223547 WIRE ASSEMBLY, Ground, 25 ft.
101682 SCREW, cap, socket head, 1/4-20 x
0.625 in.
59† 25C283 STUD, solvent; includes o-rings (Ref.
60)
60† 112319 O-RING, FX75
65 ----COVER, gun; not shown, (Kit 24Z177, qty. 10)
66 17L835 SIGN, warning
67 179791 TAG, warning
68 25C199 TOOL, spanner wrench
69‡ 25C200 TOOL, fluid valve
70‡ -----
71‡ -----
TOOL, Allen wrench, 5/16 in.
TOOL, Allen wrench, 1/4 in.
72‡ -----
73‡* -----
74‡* -----
75‡* -----
TOOL, Allen wrench, 3/16 in.
TOOL, Allen wrench, 3/32 in.
TOOL, Allen wrench 5/32”
TOOL, Allen wrench 5/64”
76‡* -----
77‡* -----
TOOL, Allen wrench 7/32”
TOOL, Allen wrench
78‡ 116553 TUBE, grease, dielectric
Qty
2
1
2
1
1
1
5
1
4
4
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
† Parts are included in Main Housing Kit 25C257.
See also O-Ring Kits 25C210, 25C212, and 25C213.
Parts are included in Air Fitting Quick Connect Kit
25C226.
Replacement Danger and Warning labels, tags, and cards are available at no cost.
‡ Parts are included in Tool Kit 25C198. (Not Shown)
* Only used on Hollow Wrist models.
70 334452E
Waterborne Models (R_A1_8)
Parts
334452E 71
Parts
Parts for Waterborne Models (R_A1_8)
Ref.
Part Description
1†
1a
2†
----HOUSING, main, assembly
25D453 SPRING, plunger contact
127316 O-RING, FX75
8
9
7a
7b
3† 25C242 SEAT, fluid valve, includes o-ring
(Ref. 2)
4† 25C243 VALVE, fluid, includes seat (Ref. 3)
4a† 117610 O-RING, FX75
6
7
4b† 120775 O-RING, FX75
5 25C279 SENSOR, magnetic; includes screw
(Ref. 6)
GC0612 SCREW, button head, #8-32 x 0.25
25C280 FLUID TUBE, assembly; includes o-rings (Refs. 7a and 7b)
120776 O-RING, FX75
111516 O-RING, FX75
17B390 O-RING, FX75
NOZZLE, fluid; includes o-ring
(Ref. 8)
25C206
25C207
0.75 mm. (0.03 in); for R_A13_ models
1 mm. (0.04 in); for R_A14_models
25C208
25C209
1.25 mm (0.05 in); or R_A15_ models
1.5 mm (0.06 in); for R_A16_ models
26A524
26A525
1.8 mm (0.07 in)
2.0 mm (0.08 in)
10 24W988 TURBINE, assembly; includes o-rings (10a-10c)
10a 17D878 O-RING, FX75
10b 17B495 O-RING, FX75
10c 17D877 O-RING, FX75
11 GC1936 O-RING, FX75
12 17D879 O-RING, FX75
13 25C281 HOUSING, front; includes o-rings
(Refs. 11, 12, 14, 16, 17)
14 111516 O-RING, 0.35 in (9 mm) OD
15 25C218 RING, retaining
16 17B495 O-RING, FX75
17 125249 O-RING, FX75
18
24Z989
AIR CAP, assembly; includes solvent stud (59) and o-ring (60) for R1A1_ _ models (15 mm); includes Refs. 18a-18c
18a
18b
25C220
25C221 for R3A1_ _ models (30 mm); includes Refs. 18a-18c for R5A1_ _ models (50 mm); includes Refs. 18a-18d
----AIR CAP, inner
----AIR CAP, outer
Qty
1
1
3
3
1
1
1
1
1
3
1
3
6
1
1
1
1
1
1
1
1
1
6
1
1
Ref.
Part Description
18c
17D877
17S113
O-RING - 30 mm
O-RING - 15mm
18d 17B494 O-RING
19
24Z985
25C223
25C224
O-RING
COVER, air cap for R1A1_ _ models (15 mm) for R3A1_ _ models (30 mm) for R5A1_ _ models (50 mm)
20
24Z088
CUP, balanced, standard, serrated, includes splash plate (Ref. 20a); see
Cup Selection Charts , page 75, for
available cups for R1A1_ _ models (15 mm); includes tool (Ref. 21)
20a
24Z079
24Z084
25D455 for R3A1_ _ models (30 mm) for R5A1_ _ models (50 mm)
PLATE, splash for R1A1_ _models (15 mm); includes o-ring (Ref. 20c)
25C214 for R3A1_ _and R5A1_ _ models
(30 mm and 50 mm); includes split ring (Ref. 20b)
20b 17A653 RING, split
20c 17B390 O-RING, FX75
21
22
22a
22b
23†
24†
-----
-----
-----
-----
NUT, fiber optic
FITTING, fiber optic
RETAINER, tubing, 5/16 in.
RETAINER, tubing, 5/32 in.
25† 111157 FITTING, tube, 1/4 in. with 1/8 in. npt threads
27
28
28a
28b
29
30
31
25C438 TOOL, 15 mm splash plate
25C315 CABLE, extension, fiber optic; includes nut (Ref. 22a) and fitting
(Ref. 22b)
25C227
25A692 POWER SUPPLY; includes 28a and
24Y773 SPRING
16D531 O-RING, FX75
25C229
TUBE, coiled, 1/4 in.
28b
ROD, TIE
25M453 MANIFOLD, rear; includes screws
(Ref. 31) and bracket (Ref. 32)
104035 SCREW, cap, socket head, 5/16 x 1 in.
32
32a
32b
25M455 BRACKET ASSEMBLY, fluid, grounding; includes 32a-32g, 42
-----
-----
BRACKET
FITTING, fluid, 5/8-18 UNF-2A
32c ----NUT, 5/8-18 UNF-2B
32d 111157 FITTING, tube, 1/4 in. with 1/8 in. npt threads; included in Kit 25C300,
Qty
1
1
1
3
1
1
1
1
1
1
1
1
1
5
4
2
2
1
3
1
1
1
3
2
1
1
72 334452E
Parts
Ref.
Part Description
32e
32f
----FITTING, strain relief; included in Kit
17L670 FERRULE; included in Kit 25C300,
32g 17L671 NUT, 5/8-18 UNF-2B; included in Kit
33
34
25C216
17B385
COVER, shroud
COVER, adapter
35
36
37 17B496 SCREW, socket head, 3/8-16 x 0.5in.
38† 17L763 O-RING, FX75
39† 17L764 O-RING, FX75
40† 17L617 FITTING, tube, 3/8 in. with 1/8 in. npt threads
41
42
17B386 RING, retaining, manifold
25C284 BRACKET, mounting; includes screws (Ref. 37)
223547 WIRE ASSEMBLY, ground, 25 ft.
101682 SCREW, cap, socket head, 1/4-20 x
0.625 in.
‡
‡
‡
----COVER, gun; not shown, (Kit
24Z177, qty. 10)
17L836
25C199
SIGN, warning
TOOL, spanner wrench
‡
‡
‡
‡*
25C200 TOOL, fluid valve
----TOOL, Allen wrench, 5/16 in.
-----
-----
TOOL, Allen wrench, 1/4 in.
TOOL, Allen wrench, 3/16 in.
‡*
‡*
‡
----TOOL, Allen wrench, 3/32 in.
----TOOL, Allen wrench, 5/32 in.
-----
-----
TOOL, Allen wrench, 5/64 in.
TOOL, Allen wrench, 7/32 in.
116553 TUBE, grease, dielectric
179791 TAG, warning
59† 25C283 STUD, solvent; includes o-rings (Ref.
60)
60† 112319 O-RING, FX75
Qty
2
2
2
1
2
1
2
1
1
1
1
5
2
4
4
1
1
1
1
1
1
1
1
1
1
Replacement Danger and Warning labels, tags, and cards are available at no cost.
† Parts are included in Main Housing Kit 26A244.
See also O-Ring Kits 25C210, 25C212, and 25C213.
‡ Parts are included in Tool Kit 25C198.
Parts are included in Air Fitting Quick Connect Kit
25C226.
* Only used on HW models.
334452E 73
Repair Kits
Repair Kits
Main Housing Repair Kits
Kit 25C257, Main Housing Replacement, Solventborne †
2
3
Ref. Description
1 HOUSING, main, assembly
O-RING, FX75
SEAT, fluid valve
4 VALVE, fluid,
23 RETAINER, tubing, 5/16 in.
24 RETAINER, tubing, 5/32 in.
4
25 FITTING, tube, 1/4 in. with 1/8 in. npt threads 3
3
5
3
3
Qty.
1
38 O-RING, FX75
39 O-RING, FX75
59 STUD, solvent; includes o-rings (Ref. 60
60 O-RING, FX75
1
2
4
5
Kit 26A244, Main Housing Replacement, Waterborne †
1
2
Ref. Description
HOUSING, main, assembly
O-RING, FX75
3
4
SEAT, fluid valve
VALVE, fluid,
23 RETAINER, tubing, 5/16 in.
24 RETAINER, tubing, 5/32 in.
25 FITTING, tube, 1/4 in. with 1/8 in. npt threads 3
38 O-RING, FX75 4
39 O-RING, FX75 5
40 FITTING, tube, 3/8 in. with 1/8 in. npt threads 2
59 STUD, solvent; includes o-rings (Ref. 60
60 O-RING, FX75
1
2
5
4
3
3
Qty.
1
3
O-Ring Kits
Kit 25C210, Front Housing O-Rings
Ref. Description
11 O-RING, FX75
12 O-RING, FX75
14 O-RING, FX75
16 O-RING, FX75
17 O-RING, FX75
Kit 25C212, Turbine O-Rings
Ref. Description
10a O-RING, FX75
10b O-RING, FX75
10c O-RING, FX75
Qty.
1
1
1
1
6
1
1
Qty.
1
Kit 25C213, Air Cap O-Rings (15 mm, 30 mm, 50 mm)
Ref. Description
18c O-RING, FX75
18d O-RING, FX75
60 O-RING, FX75
Qty.
1
1
2
Fittings and Tools
Kit 25C225, Fluid Fittings, Solventborne
Ref. Description
32d FITTING, tube, 1/4 in. with 1/8 in. npt threads
32e FITTING, tube, 5/16 in. with 1/8 in. npt threads
Kit 25C300 Fluid Fittings, Waterborne
Ref. Description
32d FITTING, tube, 1/4 in. with 1/8 in. npt threads
32e FITTING, strain relief
32f FERRULE
32g NUT
Kit 25C226, Air Fittings, Quick Connect
Ref. Description
23 RETAINER, tubing, 5/16 in.
24 RETAINER, tubing, 5/32 in.
38 O-RING, FX75
39 O-RING, FX75
Kit 25C198, Tool Box
Ref. Description
44 TOOL, spanner wrench
45 TOOL, fluid valve
53 TOOL, Allen wrench, 5/16 in.
54 TOOL, Allen wrench, 1/4 in.
55 TOOL, Allen wrench, 3/16 in.
56 TOOL, Allen wrench, 3/32 in.
57 TOOL, Allen wrench, 5/32 in.
58 TOOL, Allen wrench, 5/64 in.
59 TOOL, Allen wrench, 7/32 in.
60 TUBE, grease, dielectric
Qty.
4
2
4
4
Qty.
5
5
1
1
1
1
1
1
1
1
Qty.
1
1
2
2
2
Qty.
2
74 334452E
Repair Kits
Cup Selection Charts
NOTE: Pattern shape and diameter are material dependent.
15 mm Cups
Edge Type
Material
Splash Plate (20a, included)
Finish
Air Cap and Cover Kit
Recommended Fluid Nozzles
Recommended Production Flow Rates
Pattern Diameter Range
30 mm Cups
* Indicates the cup that is installed on the applicators at the factory. Other kits must be purchased separately.
Kit 24Z086
Smooth
Aluminum
Kit 24Z088*
Serrated
Aluminum
24Z089
Serrated
Aluminum
25D455
Standard
25D455
Standard
25D455
High-Wear
25D455
None
25C285
25C206 (0.75 mm), 25C207 (1 mm), 25C208 (1.25 mm)
25-100 cc/min.
< 4 in. (< 10 cm)
Kit 24Z087
Smooth
Composite
Edge Type
Material
Splash Plate (20a, included)
Finish
Air Cap and Cover Kit
Recommended Fluid Nozzles
Recommended Production Flow Rates
Pattern Diameter Range
50 mm Cups
Kit 24Z076
Smooth
Aluminum
25C214
Standard
Kit 24Z079*
Serrated
Aluminum
25C214
24Z080
Serrated
Aluminum
25C214
Standard
25C286
High-wear
25C206 (0.75 mm), 25C207 (1 mm),
25C208 (1.25 mm), 25C209 (1.5 mm)
25-400 cc/min.
4-12 in. (10-31 cm)
Kit 24Z078
Smooth
Composite
25C214
None
Edge Type
Material
Splash Plate (20a, included)
Finish
Air Cap and Cover Kit
Recommended Fluid Nozzles
Recommended Production Flow Rates
Pattern Diameter Range
Kit 24Z081
Smooth
Aluminum
Kit 24Z084*
Serrated
Aluminum
24Z085
Serrated
Aluminum
25C214
Standard
25C214
Standard
25C214
High-Wear
25C214
None
25C287
25C207 (1 mm), 25C208 (1.25 mm), 25C209 (1.5 mm)
50-500 cc/min.
4-18 in. (10-46 cm)
Kit 24Z083
Smooth
Composite
334452E 75
Accessories
Accessories
Robot Adapter Plates
Adapter
Plate Robot
24Y128 MOTOMAN EPX1250
24Y129 MOTOMAN PX1450
MOTOMAN EPX2850
24Y172 ABB IRB 540
24Y173 ABB IRB 1400
24Y768 FANUC PAINT MATE 200iA
FANUC PAINT MATE 200iA/5L
Bolt Circle
Mounting
Screws
Locating Pin
Circle
27.5 mm 1.08 in 4 x M5 x 0.8
27.5 mm 1.08 in
Locating Pins
5 mm
32 mm 1.3 in 8 x M6 x 1.0
36 mm 1.4 in
40 mm 1.6 in
31.5 mm 1.2 in.
3 x M5
4 x M6
4 x M5
-----
-----
-----
31.5 mm 1.24 in
-----
-----
-----
1 x 5 mm
Mounting Kits
Kit 24Z178, Reciprocator Mounting
Kit 24Z179, 60° Robot Mounting
108
101
104
102
103
105
Ref.
Part
Number
101 17C780
102 - - - -
103 17K966
104 17K967
105 25C580
Description
POST, mounting
ROD, mounting
SCREW, 1/2-13 x 1.5 in.
NUT, 1/2-13
ADAPTER, 1.75 to 2.00 in
105
109
106
107
Qty
1
1
1
1
1
Ref.
Part
Number
105 - - - -
106 - - - -
107 C19789
108
109
17E420
100644
Description
ADAPTER, mounting
BRACKET, robot mounting
SCREW, cap, socket head,
5/8-11 x 1.5 in.
SCREW, cap, socket head,
5/16-18 x 1.0 in.
SCREW, cap, socket head,
1/4-20 x 0.75 in.
Qty
1
1
1
4
4
76 334452E
Accessories
Fiber Optic Bulkhead
Installation
Stainless Steel Bulkhead
Accepts Graco fiber optic cable fittings. Fits 1/2 inch (13 mm) panel hole.
24W876 Stainless Steel Bulkhead Installation
1.
Drill a 1/2 in. to 9/16 in (12.7 mm to 14.2 mm) hole in booth wall or panel to allow bulkhead to pass through.
2.
Fiber optic cable nut should be 0.31 in. (7.9 mm) from end of cable.
3. Insert bulkhead (6) into hole and attach nut (7) on either side. Thread in fiber optic cable fitting (2) until it bottoms out. Do not force cable further.
Make sure cable marker numbers match to ensure proper communication.
4. Repeat for second side of communications.
Plastic Bulkhead
Accepts bare fiber optic cable. Fits 5/16” (8 mm) panel hole.
24W877 Plastic Bulkhead Installation
1.
Drill a 5/16 in. to 3/8 in (7.9 mm to 9.5 mm) hole in booth wall or panel to allow bulkhead to pass through.
2.
Make a clean cut to the ends of the cable using fiber optic cutter tool. Ensure the ends of the cable are equal length.
3.
Insert bulkhead (6) into hole and attach nut (7) on either side. Insert cable into bulkhead and tighten cinch nut down to a snug fit.
4.
Repeat for second side of communications.
334452E 77
Accessories
Kit 25C288, Dump Valve Plug Kit
Use to plug the dump passage in the applicator if a dump valve is not needed.
Part Description
----PLUG
117610 O-RING, FX75
120775 O-RING, FX75
127316 O-RING, FX75
Qty
1
1
1
1
Kit 24Z183, Reflective Speed Sensing Kit
Replaces the magnetic speed sensor with a dual fiber, optical speed sensor (25A537) and fiber optic source.
See manual 3A4738 for details.
Kit 25A537, Reflective Fiber Optic Cable Kit
Dual fiber optical speed sensor only. Includes reflective fiber optic cable with housing and hardware required to install in a ProBell applicator.
Dual Strand Fiber Optic Cables
End nut must be adjusted to proper length for the applicator being used.
Part Description
24X003 CABLE, fiber optic, 25 ft (7.6 m)
24X004 CABLE, fiber optic, 50 ft (15.25 m)
24X005 CABLE, fiber optic, 100 ft (30.5 m)
Qty
1
1
1
Fiber Optic Cables, Reciprocator Models
Standard single fiber.
Kit Description
24Z190 CABLE, fiber optic, 36 ft (11 m)
24Z191 CABLE, fiber optic, 66 ft (20 m)
24Z192 CABLE, fiber optic, 99 ft (30 m)
Qty
1
1
1
Kit 24W875, Fiber Optic Cable Repair
Includes hardware to repair/replace all fiber optic ends.
Part Description
----FITTING, fiber optic
----NUT, fiber optic
----TOOL, cutter, fiber optic
Qty
4
4
1
Kit 24W823, Fiber Optic Cable Cutting Tool
Use to get clean cut ends.
Part Description
----TOOL, cutter, fiber optic
Qty
3
Applicator Power Cables
Kit Description
17J586 CABLE, low voltage, 36 ft (11 m)
17J588 CABLE, low voltage, 66 ft (20 m)
17J589 CABLE, low voltage, 99 ft (30 m)
Qty
1
1
1
Fiber Optic Bulkheads
Used to run fiber through walls
Kit Description
24W876 STAINLESS STEEL BULKHEAD requires
24W875
24W877 PLASTIC BULKHEAD
Qty
2
2
Kit 25A878, Remote Grounding Bracket and Hose
High-conductivity hose kit includes fluid hoses (15 ft.,
4.6 m).
Part Description Qty
111157 FITTING, tube, 1/4 in. with 1/8 in npt 2
-----
-----
-----
----threads
BRACKET
FITTING, fluid, 5/8-18 UNF-2A
NUT, 5/8-18 UNF-2B
GROUND WIRE, 25 ft (7.6 m)
17K719 FITTING, tube, 5/16 in. with 1/8 in. npt threads
17L847 5/16 in. OD x 0.062 wall, PTFE fluid hose 15 ft.
054183 1/4 in. OD x 0.062 wall, FEP fluid hose 15 ft.
3
1
1
3
6
Waterborne Fluid Hose Kits (Shielded);
For Models R_A1_8
100 psi (0.69 MPa, 6.9 bar) Maximum Working Pressure
Kit Description
17L886 HOSE, fluid, shielded, 36 ft (11 m)
17L887 HOSE, fluid, shielded, 66 ft (20 m)
Qty
1
1
Waterborne Fluid Hose Kits (Unshielded);
For Models R_A1_8
100 psi (0.69 MPa, 6.9 bar) Maximum Working Pressure
Kit Description
17L884 HOSE, fluid, unshielded, 36 ft (11 m)
17L885 HOSE, fluid, unshielded, 66 ft (20 m)
Qty
1
1
Solventborne Hose Bundles;
For Models R_A_ _0
100 psi (0.69 MPa, 6.9 bar) Maximum Working Pressure
The hose bundle includes a fiber optic cable, power cables, a ground wire, nylon air lines, and PFA fluid lines. See manual 3A4346 for details.
Kit Description
24Z168 HOSE BUNDLE, 36 ft (11 m)
24Z169 HOSE BUNDLE, 66 ft (20 m)
24Z170 HOSE BUNDLE, 99 ft (30 m)
Qty
1
1
1
78 334452E
Accessories
Air Only Hose Bundles
The hose bundle includes a fiber optic cable, power cables, a ground wire, and nylon air lines.
Kit Description
24Z711 HOSE BUNDLE, 36 ft (11 m)
24Z712 HOSE BUNDLE, 66 ft (20 m)
24Z713 HOSE BUNDLE, 99 ft (30 m)
Qty
1
1
1
Hose Bundle Accessories
Kit Description Qty
24Z662 WRAP, spiral, 7 in. (18 cm) section, bag of 10
17A490 WRAP, blue, sold per foot
10 up to
100 ft.
Bulk Hose Tubing
Maximum continuous purchase length is 100 ft., 30 m.
150 psi (1.03 MPa, 10.3 bar) Maximum Working Pressure
Kit Description
057233* 5/16 in. OD x 1/4 in. ID PFA fluid hose
057234* 1/4 in. OD x 3/16 in. ID, PFA fluid hose
057231 5/16 in. nylon tubing
054754 5/32 in. nylon tubing, red
598095 5/32 in. nylon tubing, natural
054753 5/32 in. nylon tubing, black
054757 5/32 in. nylon tubing, green
* Not for use with high-voltage fluid.
Kit 25C424, Grounding Plate
Kit 249598, Unclogging Needle
Kit includes 12 picks for unclogging gun air covers or nozzles.
Kit 24Z177, Gun Cover
Kit includes 10 gun covers for the standard applicator.
Test Equipment
Part No.
Description
241079
722886
Megohmmeter. 500 V output, 0.01–2000 megohms. Use for ground continuity and gun resistance tests. Not for use in hazardous locations.
Paint Resistance Meter. Use for fluid resistivity test. See manual 307263. Not for use in hazardous locations.
722860
245277
Paint Probe. Use for fluid resistivity test. See manual 307263. Not for use in hazardous locations.
Test Fixture, High Voltage Probe, and kV
Meter. Use to test the electrostatic voltage of the gun, and the condition of the power supply when being serviced. See manual
309455.
Miscellaneous Equipment
Gun Accessories
Part No.
Description
111265 Non-silicone Lubricant, 4 oz (113 g).
116553 Dielectric Grease. 1 oz (30 ml)
Air Cap and Cover Sets
Purchase as a replacement or to convert one bell model to another size. Each Kit includes the Air Cap Assembly
(Ref. 18) and the Air Cap Cover (Ref. 19).
Kit 25C285, 15 mm, for R1A1_ _ Models
Kit 25C286, 30 mm, for R3A1_ _ Models
Kit 25C287, 50 mm, for R5A1_ _ Models
334452E 79
Dimensions
Dimensions
60° Robot Mount - shown as shipped
80
Ref.
A
B
C
D
E
F
15 mm Cup
Inches
4.25
3.0
5.125
17.864
10.93
6.934
Centimeters
1.67
1.18
2.01
7.03
4.30
2.72
Inches
4.25
3.0
5.125
17.864
10.93
6.934
Dimension
30 mm Cup
Centimeters
1.67
1.18
2.01
7.03
4.30
2.72
50 mm Cup
Inches
4.25
3.0
5.125
17.864
10.93
6.934
Centimeters
1.67
1.18
2.01
7.03
4.30
2.72
334452E
60° Robot Mount - shown with mounting Kit 24Z179
Dimensions
Bolt Hole
Diameter
0.300
Ref.
E
F
G
H
A
B
C
D
15 mm Cup
Inches
4.2
8.1
10.9
3.8
3.6
1.7
11.4
17.3
Centimeters
10.7
20.6
27.7
9.7
9.1
4.3
29.0
43.9
Dimension
30 mm Cup
Inches
4.2
8.1
10.9
3.9
3.6
1.7
11.4
17.3
Centimeters
10.7
20.6
27.7
9.9
9.1
4.3
29.0
43.9
50 mm Cup
Inches
4.2
8.1
10.9
4.6
4.1
1.7
11.7
17.9
Centimeters
10.7
20.6
27.7
11.7
10.4
4.3
29.7
45.5
334452E 81
Dimensions
Reciprocator Mount - shown with reciprocator mounting kit 24Z178
15 mm Cup
Dimension
30 mm Cup 50 mm Cup
Ref.
A
B
C
D*
E
F
G
H
Inches
4.2
3.0
2.4
1.75
17.3
5.1
6.4
29.1
Centimeters
10.7
7.6
6.1
4.3
43.9
12.9
16.3
73.9
Inches
4.2
3.0
2.4
1.75
17.3
5.1
6.4
29.1
Centimeters
10.7
7.6
6.1
4.3
43.9
12.9
16.3
73.9
Inches
4.2
3.0
2.4
1.75
17.9
5.7
6.9
29.7
* A sleeve adapter to convert dimension D from 1.75 inch to 2.0 inch is included with mounting kit 24Z178.
Centimeters
10.7
7.6
6.1
4.3
45.5
14.5
17.5
75.4
82 334452E
Performance Charts
Performance Charts
Turbine Air Consumption Charts
These charts show the air consumption in scfm (l/min.) by rotation speed for the three cup sizes. See the key for the flow rate represented by each line.
\
15 mm KEY:
50-100 cc/min.
15 mm Cup
5
(142)
4
(113)
3
(85)
2
(57)
1
(28)
0
9
(255)
8
(227)
7
(198)
6
(170)
0 10000 20000 30000 40000
Rotation Speed (rpm)
50000 60000
30 mm KEY:
300 cc/min.
– — – — – 100 cc/min.
334452E
5
(142)
4
(113)
3
(85)
2
(57)
1
(28)
10
(283)
9
(255)
8
(227)
7
(198)
6
(170)
0
0
30 mm Cup
10000 20000 30000 40000
Rotation Speed (rpm)
50000 60000
83
Performance Charts
Turbine Air Consumption Charts (continued)
50 mm KEY:
500 cc/min.
– — – — – 300 cc/min.
- - - - - - - - 100 cc/min.
14
(396)
12
(340)
10
(283)
8
(227)
6
(170)
4
(113)
2
(57)
0
0
50 mm Cup
10000 20000 30000 40000
Rotation Speed (rpm)
50000 60000
Turbine Inlet Air Pressure Charts
These charts show the turbine inlet air pressure by rotation speed for the three cup sizes. See the key for the flow rate represented by each line. Pressure is measured within 1 ft (0.3 m) of the rotary applicator.
15 mm KEY:
100 cc/min.
35
(0.24, 2.4)
30
(0.21, 2.1)
25
(0.17, 1.7)
20
(0.14, 1.4)
15
(0.10, 1.0)
10
(0.07, 0.7)
5
(0.03, 0.3)
0
0
15 mm Cup
10000 20000 30000
Rotation Speed (rpm)
40000 50000 60000
84 334452E
Performance Charts
Turbine Inlet Air Pressure Charts (continued)
30 mm KEY:
300 cc/min.
– — – — – 100 cc/min.
40
(0.28, 2.8)
35
(0.24, 2.4)
30
(0.21, 2.1)
25
(0.17, 1.7)
20
(0.14, 1.4)
15
(0.10, 1.0)
10
(0.07, 0.7)
5
(0.03, 0.3)
0
0
30 mm Cup
10000 20000 30000 40000
Rotation Speed (rpm)
50000 60000
50 mm KEY:
500 cc/min.
– — – — – 300 cc/min.
- - - - - - - - 100 cc/min.
Limit for 20 m tube length. See note.
Limit for 30 m tube length. See note.
50 mm Cup
Rotation Speed (rpm)
NOTE: The rotation speed or flow rate of a 50 mm cup may be limited due to pressure drop in the turbine air line.
The limits for the 8 mm OD tube are shown in the chart above. 100 PSI (0.69 MPa, 7.0 bar) system inlet pressure is assumed. For the full range of performance, use one of the following options:
• a maximum of 11 m (35 ft) length of 8 mm OD tube with a 1 mm wall (0.3125 in. OD tube with 0.04 in. wall).
• a maximum of 30 m (100 ft) length of 10 mm OD tube with a 1 mm wall.
• a maximum of 30 m (100 ft) length of 0.375 in. OD tube with a 0.05 in. wall.
334452E 85
Performance Charts
Shaping Air Consumption Charts
These charts show shaping air consumption in scfm (liters per minute) for the three cup sizes. See the key for the type of shaping air (inner or outer) represented by each line. Pressure is measured within 1 ft (0.3 m) of the rotary applicator.
15 mm KEY:
Shaping air
(inner and outer)
30 mm KEY:
Inner Shaping
Air
– — – — – Outer Shaping
Air
12
(340)
10
(283)
8
(227)
6
(170)
4
(113)
2
(57)
0
0
15 mm Cup
10
(0.07)
(0.7)
20
(0.14)
(1.4)
30
(0.21)
(2.1)
40
(0.28)
(2.8)
Inlet Pressure - PSI (MPa, bar)
50
(0.35)
(3.5)
60
(0.42)
(4.2)
8
(227)
6
(170)
4
(113)
2
(57)
0
14
(396)
12
(340)
10
(283)
0
30 mm Cup
5
(0.03)
(0.3)
10
(0.07)
(0.7)
15
(0.10)
(1.0)
20
(0.14)
(1.4)
25
(0.17)
(1.7)
30
(0.21)
(2.1)
35
(0.24)
(2.4)
Inlet Pressure - PSI (MPa, bar)
40
(0.28)
(2.8)
45
(0.31)
(3.1)
86 334452E
Performance Charts
Shaping Air Consumption Charts (continued)
50 mm KEY:
Inner Shaping
Air
– — – — – Outer Shaping
Air
8
(227)
6
(170)
4
(113)
2
(57)
0
14
(396)
12
(340)
10
(283)
0
50 mm Cup
10
(0.07)
(0.7)
20
(0.14)
(1.4)
30
(0.21)
(2.1)
40
(0.28)
(2.8)
Inlet Pressure - PSI (MPa, bar)
50
(0.35)
(3.5)
60
(0.42)
(4.2)
334452E 87
Performance Charts
Fluid Flow Rate Charts
These charts show fluid flow rates in cc/minute by inlet pressure for four nozzle sizes. See the key for the viscosity represented by each line. Pressure is measured within 1 foot (0.3 m) of the rotary applicator.
600
500
400
300
200
100
0
0
Fluid Nozzle Size 0.75 mm
KEY:
50 cps
– — – — – 100 cps
- - - - - - - - 150 cps
10
(0.07)
(0.7)
20
(0.14)
(1.4)
30
(0.21)
(2.1)
40
(0.28)
(2.8)
Fluid Inlet Pressure in PSI (MPA, bar)
50
(0.35)
(3.5)
60
(0.41)
(4.1)
600
500
400
300
200
100
0
0
Fluid Nozzle Size 1.0 mm
10
(0.07)
(0.7)
20
(0.14)
(1.4)
30
(0.21)
(2.1)
40
(0.28)
(2.8)
Fluid Inlet Pressure in PSI (MPA, bar)
50
(0.35)
(3.5)
60
(0.41)
(4.1)
88 334452E
Performance Charts
Fluid Flow Rate Charts (Continued)
600
500
400
300
200
100
0
0
KEY:
50 cps
– — – — – 100 cps
- - - - - - - - 150 cps 600
500
400
300
200
100
0
0
Fluid Nozzle Size 1.2 mm
10
(0.07)
(0.7)
20
(0.14)
(1.4)
30
(0.21)
(2.1)
40
(0.28)
(2.8)
Fluid Inlet Pressure in PSI (MPA, bar)
50
(0.35)
(3.5)
60
(0.41)
(4.1)
Fluid Nozzle Size 1.5 mm
10
(0.07)
(0.7)
20
(0.14)
(1.4)
30
(0.21)
(2.1)
40
(0.28)
(2.8)
Fluid Inlet Pressure in PSI (MPA, bar)
50
(0.35)
(3.5)
60
(0.41)
(4.1)
334452E 89
Performance Charts
Fluid Flow Rate Charts (Continued)
KEY:
50 cps
– — – — – 100 cps
- - - - - - - - 150 cps
600
500
400
300
200
Fluid Nozzle Size 1.8 mm
100
0
0 5
(0.03)
(0.3)
10
(0.07)
(0.7)
15
(0.10)
(1.0)
20
(0.14)
(1.4)
25
(0.17)
(1.7)
30
(0.21)
(2.1)
35
(0.24)
(2.4)
40
(0.28)
(2.8)
45
(0.31)
(3.1)
50
(0.35)
(3.5)
Fluid Inlet Pressure in PSI (MPA, bar)
600
500
400
300
200
Fluid Nozzle Size 2.0 mm
100
0
0 5
(0.03)
(0.3)
10
(0.07)
(0.7)
15
(0.10)
(1.0)
20
(0.14)
(1.4)
25
(0.17)
(1.7)
30
(0.21)
(2.1)
35
(0.24)
(2.4)
40
(0.28)
(2.8)
45
(0.31)
(3.1)
50
(0.35)
(3.5)
Fluid Inlet Pressure in PSI (MPA, bar)
90 334452E
Performance Charts
Fluid Pressure Loss Charts
These charts show the pressure loss per foot of hose in psi (MPa, bar) for three hose sizes. See the key for the viscosity represented by each line.
NOTE: tables use hose ID, while connection sizes refer to hose ODs.
5
(0.034)
(0.34)
4
(0.028)
(0.28)
3
(0.021)
(0.21)
2
(0.014)
(0.14)
1
(0.007)
(0.07)
0
0
1/4-in. (6 mm) ID hose
100 200
Flow Rate in cc/min.
300 400 500
KEY:
150 cps
– — – — – 100 cps
- - - - - - - - 50 cps
25
(0.17, 1.7)
20
(0.14, 1.4)
15
(0.10, 1.0)
10
(0.07, 0.7)
5
(0.03, 0.3)
0
0
3/16-in. (5 mm) ID hose
100 200
Flow Rate in cc/min.
300 400 500
334452E 91
Performance Charts
Pressure Loss Charts (Continued)
KEY:
150 cps
– — – — – 100 cps
- - - - - - - - 50 cps
25
(0.17, 1.7)
20
(0.14, 1.4)
15
(0.10, 1.0)
10
(0.07, 0.7)
5
(0.03, 0.3)
0
0
1/8-in. (3 mm) ID hose
100 200
Flow Rate in cc/min.
300 400 500
92 334452E
Technical Specifications
Technical Specifications
ProBell Rotary Applicator
Maximum air working pressure
Maximum air consumption
Bearing air minimum required
Turbine and bearing air conditions
Maximum dew point
Aerosol limit
Maximum particle size
Maximum air and fluid temperature
Maximum fluid working pressure
Turbine speed - maximum operating
Viscosity Range
Maximum flow rate, 50 mm cup
Maximum flow rate, 30 mm cup
Maximum flow rate, 15 mm cup
Maximum output voltage
Maximum current draw
Ambient temperature range
Sound pressure level at 60 rpm, 70 psi
(0.48 MPa, 4.8 bar); measured per ISO
9614-2, 1 m from applicator
Wetted parts
US
100 psi
50 scfm (25 scfm is typical)
Metric
0.69 MPa, 7.0 bar
70 psi 0.5 MPa,5.0 bar
10° F - 12° C
99% aerosol free
.00002 inches
120°F
150 psi
49°C
0.5 microns
1.03 MPa, 10.3 bar
60,000 rpm
30 - 150 centistokes
500 cc/min
400 cc/min
100 cc/min
100 kV for solventborne systems
60 kV for waterborne systems
150 micro-amperes
41° F to 104 °F 5° C to 40° C
77 dB(A) acetal, 300 series stainless steel, fluoroelastomer,nylon, coated aluminum, FEP, PTFE
334452E 93
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide24 purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com
.
For patent information, see www.graco.com/patents .
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-350
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions.
This manual contains English. MM 334452
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2016, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision E, October 2017

Public link updated
The public link to your chat has been updated.
Advertisement