Graco 333011C- Pro Xp Auto Electrostatic Air Assisted Spray Gun Instructions

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Graco 333011C- Pro Xp Auto Electrostatic Air Assisted Spray Gun Instructions | Manualzz

Instructions-Parts

Pro Xp

Auto AA Spray Gun

333011C

EN

Automatic Electrostatic Gun for use in Class I, Div. I Hazardous Locations using Group D spray materials.

Automatic Electrostatic Gun for use in Group II, Zone 1 Explosive Atmosphere Locations using Group IIA spray materials.

For professional use only.

100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Press

3000 psi (21 MPa, 210 bar) Maximum Working Fluid Pressure

Important Safety Instructions

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

See page 2 for Table of Contents and page 3 for

List of Models.

WLD

Table of Contents

Table of Contents

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2

List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

How the Electrostatic AA Spray Gun Works . . . . 6

Operating the Spray Function . . . . . . . . . . . . . . . 6

Operating the Electrostatics . . . . . . . . . . . . . . . . 6

Gun Features and Options . . . . . . . . . . . . . . . . . 6

Smart Gun Features . . . . . . . . . . . . . . . . . . . . . . 6

System Overview . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical System Installation . . . . . . . . . . . . . . . . . 7

Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 9

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 9

Install the Air Line Accessories . . . . . . . . . . . . . . 9

Install Fluid Line Accessories . . . . . . . . . . . . . . . 9

Install the Gun . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Install the Pro Xp Auto Control Module . . . . . . . 11

Connect the Air and Fluid Lines . . . . . . . . . . . . 11

Manifold Connections . . . . . . . . . . . . . . . . . . . . 12

Fiber Optic Cable Connection . . . . . . . . . . . . . . 13

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Check Electrical Grounding . . . . . . . . . . . . . . . . 14

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 15

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 15

Install the Fabric Cover . . . . . . . . . . . . . . . . . . . 15

Flush Before Using Equipment . . . . . . . . . . . . . 15

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pressure Relief Procedure . . . . . . . . . . . . . . . . 16

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Select a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . 16

Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . 17

Set the Atomization Fluid Pressure . . . . . . . . . . 17

Adjust the Electrostatics . . . . . . . . . . . . . . . . . . 18

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Triggering the Fluid Alone . . . . . . . . . . . . . . . . . 18

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Daily Care and Cleaning Checklist . . . . . . . . . . 19

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Clean Outside of Gun . . . . . . . . . . . . . . . . . . . . 20

Clean the Spray Gun . . . . . . . . . . . . . . . . . . . . . 20

Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 21

2

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 22

Test Power Supply Resistance . . . . . . . . . . . . . 22

Test Barrel Resistance . . . . . . . . . . . . . . . . . . . . 23

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Spray Pattern Troubleshooting . . . . . . . . . . . . . 24

Gun Operation Troubleshooting . . . . . . . . . . . . . 25

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 27

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Prepare the Gun for Service . . . . . . . . . . . . . . . 28

Remove the Gun from the Manifold . . . . . . . . . . 28

Install the Gun on the Manifold . . . . . . . . . . . . . 29

Air Cap/Tip Guard, Spray Tip, and Fluid Seat

Housing Replacement . . . . . . . . . . . . . . . . . 29

Electrode Replacement . . . . . . . . . . . . . . . . . . . 30

Fluid Tube Replacement . . . . . . . . . . . . . . . . . . 30

Fluid Filter Removal . . . . . . . . . . . . . . . . . . . . . . 31

Fluid Needle Replacement . . . . . . . . . . . . . . . . 31

Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . 32

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 33

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 33

Power Supply Removal and Replacement . . . . 33

Turbine Removal and Replacement . . . . . . . . . . 34

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Standard Pro Xp Auto AA Gun Models . . . . . . . 36

Smart Pro Xp Auto AA Gun Models . . . . . . . . . 38

Air Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . 40

Turbine Assembly . . . . . . . . . . . . . . . . . . . . . . . 41

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . 45

AEM Fine Finish Spray Tips . . . . . . . . . . . . . . . 45

AEF Fine Finish Pre-Orifice Spray Tips . . . . . . . 46

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Graco Pro Xp Warranty . . . . . . . . . . . . . . . . . . . . . 48

333011C

List of Models

Part No.

kV

HA1M10 85

HA1T10 85

HA2M10 85

HA2T10 85

Standard

Model

Smart

Model

Bottom

Manifold

Rear

Manifold

Approvals

0.24 mJ

FM14ATEX0081

EN 50050-1

Ta 0°C-50°C

List of Models

Related Manuals

Manual No.

Description

332989 Instructions - Pro Xp Auto Control Module

333011C 3

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

4

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion and electric shock:

• Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements of this manual.

• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to spray

area. Resistance must not exceed 1 megohm. See Grounding instructions.

• Only use grounded Graco conductive air supply hoses.

• Do not use pail liners unless they are conductive and grounded.

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

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

• Use and clean equipment only in well ventilated area.

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

• 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 5°C (9°F) above ambient temperature.

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

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

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

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

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

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

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

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

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

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

servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

333011C

333011C

Warnings

PLASTIC PARTS CLEANING SOLVENT HAZARD

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

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

• See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent

manufacturer’s MSDSs and recommendations.

TOXIC FLUID OR FUMES HAZARD

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

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

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

PERSONAL PROTECTIVE EQUIPMENT

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

• Protective eye wear, and hearing protection.

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

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

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

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

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

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

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

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

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

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

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

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

5

6

Introduction

Introduction

How the Electrostatic AA Spray

Gun Works

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

Hazard Warnings on page 4.

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

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

Gun Features and Options

• The gun's full voltage setting is 85kV.

• The gun is designed for use with a reciprocator, and can be mounted directly on a 1/2 in. (13 mm) rod.

With additional brackets, the gun can be mounted for robotic applications.

• The gun’s quick-disconnect design enables its removal without disconnecting air lines to the gun.

• Gun functions are activated from a separate controller that sends the appropriate signal to the actuating solenoids.

Operating the Spray Function

Applying a minimum of 60 psi (0.42 MPa, 4.2 bar) air pressure to the gun manifold’s cylinder air fitting (CYL) will retract the gun piston, which opens the air valves and a short time later opens the fluid needle. This provides the proper air lead and lag when triggering the gun. A spring returns the piston when the cylinder air is shut off.

Operating the Electrostatics

To operate the electrostatics, apply air pressure to the gun manifold’s turbine air fitting (TA) through a Graco

Grounded Turbine Air Hose. The air enters the manifold and is directed to the inlet of the power supply turbine.

The air spins the turbine, which then provides electrical power to the internal high voltage power supply. The fluid is charged by the spray gun electrode. The charged fluid is attracted to the nearest grounded object, wrapping around and evenly coating all surfaces.

Smart Gun Features

Smart gun models with the Pro Xp Auto Control Module have the ability to:

• Display the spraying voltage and current

• Change the gun voltage setting

• Display the gun turbine speed

• Store spray profiles

• Communicate equipment faults to a PLC

• Display and set maintenance totalizers

• Use a PLC to select a spray profile

See the Pro Xp Auto Control Module manual 332989 for more information.

333011C

Introduction

System Overview

Typical System Installation

F IGURE 1 shows a typical electrostatic air spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.

Non-Hazardous Area Hazardous Area

*

F IG . 1 Typical System Installation

C

D

A

B

Gun

Graco Grounded Turbine Air Hose

Atomizer, Fan, and Cylinder Air

Air Supply and controls

E Fluid Supply and controls

* Approved for hazardous locations

333011C

J

K

L

Smart System Components

F Programmable Logic Controller (PLC)

G

H

Pro Xp Auto Control Module

Power Supply (24 Volt)

Bulkhead (optional)

F/O Cable

I/O Cable

7

Introduction

Gun Overview

B

K

2

1

TA

A2

EXH

P

CYL

A1

J A

C

D

H

F

G

F IG . 2 Gun Overview

Key

F

G

H

J

A

B

C

D

Air Cap

Spray Tip

Retaining Ring

Shroud

Manifold

Turbine

Power Supply

Electrode

8

Manifold Fittings and Indicators

A1 Atomization Air Inlet Fitting

A2 Fan Air Inlet Fitting

CYL Cylinder Air Inlet Fitting

1

Fiber Optic Fitting Transmit

(Operational on Smart models only)

2

K

Fiber Optic Fitting Receive

(Operational on Smart models only)

ES Indicator Light (standard models only)

P Fluid Supply Inlet Fitting

TA Turbine Air Inlet Fitting (to drive turbine)

EXH Exhaust Outlet Fitting

333011C

Installation

Installation

Install the System

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

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

• Be sure your installation complies with local, state, and national codes for the installation of electrical apparatus in a Class I, Div. I, hazardous location or a Group II, Zone I explosive atmosphere location.

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

Warning Signs

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

Warning Sign is provided with the gun.

Ventilate the Spray Booth

Provide fresh air ventilation to reduce the risk of fire or explosion caused by the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun.

Do not operate the gun unless ventilation fans are operating.

Electrically interlock the gun turbine air supply (B) with the ventilators to prevent gun operation without ventilating fans operating. Check and follow all local, state, and national codes regarding air exhaust velocity requirements.

NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufficient.

Install the Air Line Accessories

See F IGURE 3.

1.

Install a bleed-type master air valve (L) on the main air line (W) to shut off all air to the gun.

2.

Install an air line filter/water separator on the gun air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

3.

Install a bleed-type air pressure regulator (M) on each of the air supply lines (B, C, D, E) to control air pressure to the gun.

Trapped air can cause the gun to spray unexpectedly, which can result in serious injury, including splashing fluid in the eyes or on the skin. The solenoid valves (K) must have a quick exhaust port so trapped air will be relieved between the valve and gun when the solenoids are shut off.

4.

Install a solenoid valve (K) on the cylinder air line

(E) to actuate the gun. The solenoid valve must have a quick exhaust port.

5.

Install a solenoid valve (K) to actuate the turbine.

Install Fluid Line Accessories

1.

Install a fluid filter and drain valve at the pump outlet. Filtering the fluid will help remove coarse particles and sediment that could clog the spray tip. The fluid drain valve is required in your system to assist in relieving fluid pressure in the displacement pump, hose, and gun. Triggering the gun to relieve pressure may not be sufficient. Install a drain valve close to the pump's fluid outlet.

NOTE: The gun includes an inline fluid filter for additional filtration.

2.

Install a fluid regulator on the fluid line to control fluid pressure to the gun.

333011C 9

Installation

F

IGURE

3 shows a typical electrostatic spray system. It is not an actual system design. For assistance in designing a

system to suit your particular needs, contact your Graco distributor.

The turbine air (TA) must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on.

L

See Warning above A B C D

K

L

L

W

K

Manifold Back View

M N

E

Non-Hazardous Area

F

IG

. 3 Typical Installation

Key to F

IGURE

3

A Air Hose Ground Wire

B Graco Grounded Turbine Air Hose (TA)

C Atomizing Air Hose, 5/16 in. (8 mm) OD (A1)

D Fan Air Hose, 5/16 in. (8 mm) OD (A2)

E Cylinder Air Hose, 5/32 in. (4 mm) OD (CYL)

G

High Pressure Fluid Supply Hose to 1/4-18 npsm gun fluid inlet (P)

Hazardous Area

K

L

M

N

Solenoid Valve, requires quick exhaust port

Bleed-Type Master Air Valve

Air Pressure Regulator

True Earth Ground

W Main Air Line

G

10 333011C

Installation

Install the Gun

1.

Loosen the manifold’s two set screws (29) and slide the manifold (20) onto a 1/2 in. (13 mm) mounting rod.

2.

Position the gun and tighten the two set screws.

NOTE: For added positioning reliability, insert a 1/8 in.

(3 mm) locating pin into the slot (NN) in the bracket and

through a hole in the rod. See the detail in F IGURE 4.

Connect the Air and Fluid Lines

F IGURE 3 shows a schematic of air and fluid line connec-

tions, and F IGURE 5 shows the manifold connections.

Connect the air and fluid lines as instructed below.

NN 29

8.00 in.

(203.2 mm)

20

F IG . 4 Mounting Bracket

2.88 in.

(73.2 mm)

To nozzle tip

Install the Pro Xp Auto Control

Module

The Pro Xp Auto Control Module is required for use with smart models. To install a Pro Xp Auto Control Module, see the module instruction manual 332989.

To reduce the risk of electric shock, the turbine air supply hose must be electrically connected to a true earth ground. Use only Graco Grounded Turbine

Air Hose.

1.

Connect the Graco Grounded Turbine Air Hose (B) to the gun's turbine air inlet (TA) and connect the hose ground wire (A) to a true earth ground (N). The gun turbine air inlet fitting has left-hand threads to prevent connecting another type of air hose to the turbine air inlet.

2.

Check the electrical grounding of the gun as

instructed on page 14.

3.

Before connecting the high pressure fluid hose (P), blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.

333011C 11

Installation

Manifold Connections

Rear Inlet Bottom Inlet

A2

A1

EXH

P

CYL

2

TA

1

1

2

TA

P

CYL

A1

A2

EXH

F IG . 5 Manifold Connections

12

A1

A2

CYL

1

2

P

TA

EXH

Atomization Air Inlet Fitting

Connect a 5/16 in. (8mm) OD tube between this fitting and the air supply.

Fan Air Inlet Fitting

Connect a 5/16 in. (8 mm) OD tube between this fitting and the air supply.

Cylinder Air Inlet Fitting

Connect a 5/32 in. (4 mm) OD tube between this fitting and the solenoid. For quicker response, use the shortest hose length possible.

Fiber Optic Fitting Transmit (Operational on Smart models only)

Connect the Graco Fiber Optic cable (see page 13).

Fiber Optic Fitting Receive (Operational on Smart models only)

Connect the Graco Fiber Optic cable (see page 13).

Fluid Supply Inlet Fitting

Connect a 1/4 npsm swivel fitting between this fitting and the fluid supply.

Turbine Air Inlet Fitting

Connect the Graco Grounded Turbine Air Hose between this fitting (left-hand thread) and the solenoid. Connect the air hose ground wire to a true earth ground.

Exhaust

Connect an exhaust tube to route the turbine exhaust air. Fitting is for a 5/16 in OD tube.

333011C

Installation

Fiber Optic Cable Connection

(Operational on Smart models only)

NOTE: Only use the supplied fiber optic cable.

The fiber optic cable allows the gun to communicate with the Pro Xp Auto control module.

For a 1 Gun System

1.

Connect Port 1 of the gun 1 manifold to Port 1 of the

Control Module.

2.

Connect Port 2 of the gun 1 manifold to Port 2 of the

Control Module.

For a 2 Gun System

1.

Connect Port 1 of the gun 2 manifold to Port 5 of the

Control Module.

2.

Connect Port 2 of the gun 2 manifold to Port 6 of the

Control Module.

F IG . 6 . Making Fiber Optic Connections

R

Port 1

V

Non-Hazardous Area

U

Port 2

Port 5 Port 6

Hazardous Area H*

1

2

Gun 1

Q

V

Key for F IGURE 7

H

P

Q

R

U

Pro Xp Auto AA Gun

24 Volt Power Supply Connection

Remote I/O Connection

Pro Xp Auto Control Module

Bulkhead (optional)

V Fiber Optic Cable

* Approved for hazardous locations.

F IG . 7 . Fiber Optic Schematic

333011C

P

Gun 2

13

Installation

Grounding

When operating the electrostatic gun, any ungrounded objects in the spray area (people, containers, tools, etc.) can become electrically charged.

Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock.

Ground all equipment, personnel, object being sprayed, and conductive objects in or close to the spray area. Resistance must not exceed 1 megohm.

Follow the grounding instructions below.

The following are minimum grounding requirements for a basic electrostatic system. Your system may include other equipment or objects which must be grounded.

Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground.

Pump: ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual.

Electrostatic Air Assisted Spray Gun: ground the gun by connecting the Graco Grounded Turbine Air

Hose to the turbine air inlet and connecting the air

hose ground wire to a true earth ground. See Check

Electrical Grounding, page 14.

• Air compressors and hydraulic power supplies: ground the equipment according to the manufacturer's recommendations.

All air and fluid lines must be properly grounded.

All electrical cables must be properly grounded.

All persons entering the spray area: shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Do not wear shoes with non-conductive soles such as rubber or plastic.

Object being sprayed: keep the workpiece hangers clean and grounded at all times. Resistance must not exceed 1 megohm.

The floor of the spray area: must be electrically conductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.

Flammable liquids in the spray area: must be kept in approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift.

14

• All electrically conductive objects or devices in the

spray area including fluid containers and wash cans, must be properly grounded.

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

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

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

Check Electrical Grounding

Megohmmeter Part No. 241079 (AA-see F IGURE 8) is

not approved for use in a hazardous area. To reduce the risk of sparking, do not use the Megohmmeter to check electrical grounding unless:

The gun has been removed from the hazardous area

Or

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

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

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

1.

Have a qualified electrician check the electrical grounding continuity of the spray gun and turbine air hose.

2.

Make sure the turbine air hose (B) is connected and the hose ground wire is connected to a true earth ground (N).

3.

Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it.

4.

Measure the resistance between the turbine air inlet fitting (TA) and a true earth ground (N). a.

If using a black or gray turbine air hose, use a

Megohmmeter to measure the resistance. Use

333011C

Installation an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 1 megohm.

b.

If using a red turbine air hose, use an ohmmeter to measure the resistance. The resistance should not exceed 100 ohms.

5.

If the resistance is greater than the maximum reading specified above for your hose, check the tightness of the ground connections and be sure the turbine air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the turbine air hose.

N

TA

Check Fluid Viscosity

To check fluid viscosity you will need:

• a viscosity cup

• a stopwatch

1.

Completely submerge the viscosity cup in the fluid.

Lift the cup out quickly, starting the stopwatch as soon as the cup is completely removed.

2.

Watch the stream of fluid coming from the bottom of the cup. As soon as there is a break in the stream, shut off the stopwatch.

3.

Record the fluid type, elapsed time, and size of the viscosity cup.

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.

AA

B

F IG . 8 Check Gun Grounding

Check Fluid Resistivity

Check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area.

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

Graco Part No. 722886 Resistance Meter and 722860

Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the requirements of an electrostatic air spray system.

Follow the instructions included with the meter and probe. Readings of 25 megohms-cm and above provide the best electrostatic results.

1-5

Test electrostatic performance

Megohms-cm

5-25

Good electrostatic results

25-200

Best electrostatic results

200-2000

Good electrostatic results

Install the Fabric Cover

See F IGURE 9.

1.

Install a fabric cover (XX) over the front of the gun and slide it back to cover the exposed tubing and hoses at the back of the manifold.

2.

Route the exhaust tube (YY) outside the cover. This enables you to monitor the exhaust tube for the

presence of any paint or solvent. See Check for

Fluid Leakage on page 21. Strap down the exhaust

tube to prevent it from moving around.

YY

F IG . 9 . Fabric Cover

XX

WLD

YY

Flush Before Using Equipment

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

Flushing, page 19.

333011C 15

Operation

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

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

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

1.

Turn off all the air to the spray gun except the cylinder air, which triggers the gun. If an air pilot fluid regulator is used in the system, the air pressure is needed at the regulator air inlet.

2.

Turn off the fluid supply to the gun.

3.

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

4.

If an air pilot fluid regulator is used, turn off the air pressure at the regulator air inlet.

5.

Relieve fluid pressure in the fluid supply equipment as instructed in its instruction manual.

6.

Open the pump drain valve and all other drain valves in the system, having a waste container ready to catch the drainage. Triggering the gun to relieve pressure may not be sufficient. Leave the drain valve open until you are ready to spray again

7.

Close the bleed-type master air valve on the main air supply line to shut off the air. Leave the valve closed until you are ready to spray again.

8.

If you suspect that the spray tip or hose is still clogged or that pressure is not fully relieved after following the steps above, very slowly loosen the hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose obstruction.

Startup

Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.

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

All operators are trained in the Pressure Relief

Procedure on page 16.

The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators.

The system is thoroughly grounded and the operator and all persons entering the spray

area are properly grounded. See Grounding on page 14.

The condition of the gun’s electrical compo-

nents has been checked as instructed in Elec-

trical Tests on page 22.

Ventilation fans are operating properly.

Workpiece hangers are clean and grounded.

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

All flammable fluids in the spray booth are in approved, grounded containers.

All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded.

The manifold exhaust tubes have been checked for the presence of any fluid as

instructed in Check for Fluid Leakage on page 21.

Select a Spray Tip

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

Use the Spray Tip Selection Chart, page 45, as a

guide for selecting the appropriate spray tip for your application.

16 333011C

Operation

Install the Spray Tip

To reduce the risk of skin injection and splashing,

follow the Pressure Relief Procedure before

removing or installing the spray tip or air cap/tip guard.

1.

Relieve the pressure. Follow Pressure Relief Pro-

cedure, page 16.

2.

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

Install the tip.

WLD

F IG . 10 Spray Tip Alignment

3.

Install the air cap and retaining ring. Orientate the air cap and tighten the retaining ring securely. Be careful not to damage the electrode.

Set the Atomization Fluid

Pressure

See F

IGURE

5.

Atomization fluid pressure will vary based on the viscosity of the fluid, flow rate desired, and other system characteristics.

1.

Turn off the turbine air (TA), atomization air (A1), and fan air (A2).

2.

Start the pump. Set the fluid regulator to 400 psi (2.8

MPa, 28 bar).

3.

With the turbine air (TA), atomization air (A1), and fan air (A2) turned off, spray a test pattern, holding the gun 12 in. (305 mm) from the surface. Examine the particle size. Do not be concerned about the

presence of tails; they will be removed in step 6.

4.

Increase the fluid pressure in small increments.

Spray another pattern and compare the particle size. Smaller particle size indicates improved atomization.

WLD

F IG . 11 Install Air Cap Assembly

To reduce the risk of fire, explosion, or electric shock, never operate the gun with a damaged electrode.

To reduce the risk of injury, never exceed the maximum working pressure on the lowest rated system component. Maximum working pressure of this equipment is 3000 psi (21 MPa, 210 bar).

5.

Continue to increase the fluid pressure and spray test patterns. Do not exceed 3000 psi (21 MPa, 210 bar) fluid pressure. When the particle size remains constant, the fluid is being atomized at the lowest possible fluid pressure.

For improved atomization at lower fluid flow rates, change to a smaller tip orifice size.

6.

Turn on the atomization air (A1) and adjust the air pressure until the tails disappear.

See Spray Pattern Troubleshooting on page 24 to

correct spray pattern problems.

7.

The pattern width can also be reduced by applying fan air pressure (A2).

Too Little Air

No Air

F IG . 12 Eliminating Tails

Correct

Amount of Air

333011C 17

Operation

Adjust the Electrostatics

1.

Turn on the turbine air (TA) and adjust the air pres-

sure per the settings in Table 1 . Set the proper

pressure at the turbine air hose inlet when air is

flowing.

Table 1. Approximate Dynamic Turbine Air

Pressures

Turbine Air

Hose Length ft (m)

Air pressure at turbine air hose inlet for full voltage psi (bar, MPa)

15 (4.6)

25 (7.6)

36 (11)

50 (15.3)

75 (22.9)

100 (30.5)

54 (3.8, 0.38)

55 (3.85, 0.38)

56 (3.9, 0.39)

57 (4.0, 0.40)

59 (4.1, 0.41)

61 (4.3, 0.43)

2.

Check the turbine speed of the gun by checking the indicator light on the standard gun body or for the smart gun check the actual turbine speed on the Pro

Xp Auto Control Module. See the following table.

Adjust the air pressure as necessary to keep the indicator light green or the values within 400-750

Hz.

NOTE: Smart models display values not color indicator lights.

Indicator

Color

Table 2. Indicator Colors/Values

Description

Green

400-750

Hz

Amber

<400

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

If the indicator changes to amber after 1 second, the air pressure is too low. Increase air pressure until the indicator is green.

Red

>750

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

Excessive turbine speed can shorten the bearing life and will not increase the voltage output.

Check the voltage output of the gun using a high voltage probe and meter or by reading the Pro Xp Auto Control

Module.

NOTE: The gun’s normal high voltage reading is 60-70 kV. If a ball end high voltage measurement probe is used, the gun voltage will rise to about 85 kV. This will happen with all resistive electrostatic guns.

See Electrical Troubleshooting on page 27 to correct

voltage problems.

18

Spraying

To reduce the risk of electric shock, do not touch the gun electrode or come within 4 in. (10 cm) of the nozzle during gun operation.

1.

Apply a minimum of 60 psi (4.2 bar, 0.42 MPa) air pressure to the cylinder air fitting (CYL) to activate the on/off sequence of atomization air (A1), fan air

(A2), and fluid (P). See F IGURE 2.

2.

Turn the gun functions on and off by using the air solenoid valves on the cylinder (CYL) and turbine

(TA) air supply lines.

3.

To change a smart model to a lower voltage setting, see the Pro Xp Auto Control Module manual

332989.

If any fluid leakage from the gun is detected, stop spraying immediately. Fluid leakage into the gun shroud could cause fire or explosion and result in

serious injury and property damage. See Check for

Fluid Leakage on page 21.

Triggering the Fluid Alone

1.

Shut off and relieve the air pressure to the atomization (A1) and fan (A2) air lines, using the bleed-type air shutoff valves.

2.

Apply 60 psi (4.2 bar, 0.42 MPa) air pressure to the cylinder air fitting (CYL) to trigger the fluid.

Shutdown

To reduce the risk of an injury, follow the Pressure

Relief Procedure when you stop spraying and

whenever you are instructed to relieve the pressure.

1.

Flush the gun, see Flushing, page 19.

2.

Follow the Pressure Relief Procedure, page 16.

3.

Clean the equipment. See Maintenance on page

19.

333011C

Maintenance

Maintenance

To reduce the risk of an injury, follow the Pressure

Relief Procedure before doing any maintenance on

the gun or system.

Daily Care and Cleaning

Checklist

Check the following list daily upon completion of equipment usage.

Flush the gun. See Flushing, page 19.

Clean the fluid and air line filters.

Clean the outside of the gun. See Clean Out-

side of Gun, page 20.

Clean the air cap, spray tip, and tip guard daily, minimum. Some applications require more frequent cleaning. Replace the parts if they are

damaged. See Clean the Spray Gun, page

20.

Check the electrode and replace if broken or

damaged. See Electrode Replacement on page 30.

Check for fluid leakage from the gun and fluid

hoses. See Check for Fluid Leakage on page

21. Tighten fittings or replace equipment as

needed.

Check Electrical Grounding, page 14.

To reduce the risk of fire and explosion, turn off the turbine air (TA) before flushing the gun and always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at lowest possible pressure.

NOTICE

Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components.

1.

Turn off the turbine air.

2.

Switch the fluid supply to a compatible solvent.

3.

Trigger the gun to flush the fluid passages clean.

Flushing

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

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

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

333011C 19

Maintenance

Clean Outside of Gun

NOTICE

• Clean all parts with a non-conductive, compatible solvent. Conductive solvents can cause the gun to malfunction.

• Fluid in the air passages could cause the gun to malfunction and could draw current and reduce the electrostatic effect. Fluid in the power supply cavity can reduce the turbine life. Whenever possible, point the gun down when cleaning it. Do not use any cleaning method which could allow fluid into the gun air passages.

1.

Turn off turbine air (TA).

2.

Flush the gun. See Flushing, page 19

3.

Follow the Pressure Relief Procedure, page 16.

4.

Clean the outside of the gun with a compatible solvent. Use a soft cloth. Wring out excess fluid from cloth. Point the gun down to prevent solvent from entering the gun passages. Do not immerse the gun

Clean the Spray Gun

Equipment Needed

• soft bristle brush

• compatible solvent

Procedure

1.

Be sure the turbine air (TA) is turned off.

2.

Relieve the pressure.

3.

Remove the retaining ring (24), air cap/tip guard

(25), spray tip (3), and gun shroud (26). See page

29.

4.

Dip the end of a soft bristle brush into compatible solvent. clean the front of the gun with the brush.

Avoid getting any solvent into the air passages.

Whenever possible, point the gun down when clean-

ing it. See F IGURE 13

If it appears that there is paint inside the air passages, remove the gun from the line for servicing.

WLD

WLD

WLD

02007

F IG . 13 Clean Front of Gun

5.

Dampen a soft cloth with solvent and wring out the excess. Wipe the exterior of the gun and shroud

clean. See F IGURE 14.

20

F IG . 14 Clean Gun Body

6.

Remove the bottom fluid tube fitting (C) and fluid fil-

ter (20). See F IGURE 15. Clean the filter in compati-

ble solvent.

333011C

Maintenance

NOTE: Use two wrenches to remove the fluid tube fitting

(C).

13. Test Gun Resistance, page 22.

Check for Fluid Leakage

D

C

20

F IG . 15 Clean the Inline Fluid Filter

7.

Reinstall the filter (20) and fitting (C). Do not over tighten the fitting, and make sure the top fitting (D) remains tight.

NOTE: Use two wrenches to install the fluid tube fitting

(C).

8.

Clean the retaining ring (24), air cap/tip guard assembly (25), and spray tip (3) with a soft brush daily, minimum. Replace any damaged parts. Be careful not to damage the electrode (25a).

NOTICE

Do not use metal tools to clean the air cap/tip guard or spray tip holes as this could scratch them, and make sure the electrode is not damaged.

Scratches in the air cap or spray tip or a damaged electrode can distort the spray pattern.

9.

Wipe off the parts with a dry cloth. Be careful not to damage the electrode.

If any fluid leakage from the gun is detected, stop spraying immediately. Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage.

During operation, periodically check all openings of the

gun shroud (ZZ) for the presence of fluid. See F IGURE

12. Fluid in these areas indicates leakage into the

shroud, which could be caused by leaks at the fluid tube connections or fluid packing leakage.

If fluid is seen in these areas, stop spraying immediately.

Relieve the pressure, then remove the gun for repair.

ZZ ZZ

F IG . 16 Check for Fluid Leakage

WLD

To reduce the risk of fire, explosion, or electric shock, never operate the gun with a damaged electrode.

10. Check the electrode (25a). Replace if damaged.

11. Install the spray tip, page 17.

12. Install the spray tip and air cap/tip guard, shroud,

and retaining ring, page 17. Be sure the electrode

(25a) is in place.

333011C 21

Electrical Tests

Electrical Tests

Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (7) and electrode (25a), and electrical continuity between components.

NOTICE

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

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

AA

25a

TA

TA

F IG . 17 . Test Gun Resistance

Megohmmeter Part No. 241079 (AA-see F IGURE 17) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the

Megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous area;

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

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

Test Power Supply Resistance

1.

Remove the power supply (7). See Power Supply

Removal and Replacement, page 33.

2.

Remove the turbine (8) from the power supply. See

Turbine Removal and Replacement, page 34.

3.

Measure resistance from the power supply's ground strips (EE) to the spring (7a). The resistance should

be 130–160 megohms for 85kV guns. See F IGURE

18.

If outside this range, replace the power supply. If in range, and there are performance concerns, go to

Test Barrel Resistance, page 23.

4.

Refer to Electrical Troubleshooting, page 27 for

other possible causes of poor performance.

Test Gun Resistance

1.

Flush and dry the fluid passage.

2.

Measure resistance between the electrode needle tip (25a) and the turbine air inlet fitting (TA); it should be 148-193 megohms.

3.

If outside this range go to Test Power Supply

Resistance, page 22. If in range, and there are per-

formance concerns, see Electrical Troubleshoot-

ing, page 27 for other possible causes of poor

performance.

7a EE

WLD

F IG . 18 Test Power Supply Resistance

5.

Be sure the spring (7a) is in place before reinstalling the power supply.

22 333011C

Test Barrel Resistance

1.

Insert a conductive rod (B) into the gun barrel

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

2.

Measure the resistance between the conductive rod

(B) and the conductive ring (33). See F IGURE 19.

The resistance should be 10-30 megohms. If the resistance is incorrect, make sure the metal contact

(C) in the barrel and the conductive ring (33) are clean and undamaged.

3.

If the resistance is still outside the range, remove the conductive ring (33) and measure the resistance between the conductive rod (B) and the wire lead at the bottom of the conductive ring groove.

4.

If the resistance is in range, replace the conductive ring (33) with a new one. Insert the ends of the conductive ring into the slots (S) at the front of the barrel, then press the ring firmly into the groove.

33

C

F IG . 19 Test Gun Barrel Resistance

B

Electrical Tests

S

G

The conductive ring (33) is a conductive (metal) contact ring, not a sealing o-ring. To reduce the risk of fire, explosion, or electric shock:

• Do not remove the conductive ring except to replace it.

• Never operate the gun without the conductive ring in place.

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

5.

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

333011C 23

Troubleshooting

Troubleshooting

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

To reduce the risk of a fluid injection injury, always

follow the Pressure Relief Procedure on page 16

when you stop spraying and whenever you are instructed to relieve the pressure.

NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun.

Spray Pattern Troubleshooting

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

Problem

Fluttering or spitting spray.

Cause

No fluid.

Air in fluid supply.

Solution

Refill supply.

Check fluid source. Refill.

Irregular pattern.

Fluid buildup; partially plugged tip.

Clean. See page 20.

Worn/damaged tip or air cap holes.

Clean or replace.

Pattern pushed to one side; air cap gets dirty.

Tails in pattern.

Air cap holes plugged.

Atomization air pressure too low.

Fluid pressure too low.

Clean. See page 20.

Increase atomization air pressure.

Increase.

Fluid buildup on air cap/tip guard.

Atomization air pressure too high.

Fluid pressure too low.

Plugged or damaged air cap hole

Decrease.

Increase.

Clean air cap, see page 20

24 333011C

Troubleshooting

Gun Operation Troubleshooting

Problem

Excessive spray fog.

“Orange Peel” finish.

Fluid leaks from the fluid packing area

Air leaks from the air cap

Fluid leakage from the front of the gun

Cause Solution

Atomizing air pressure too high.

Fluid too thin.

Atomization air pressure too low.

Spray tip is too large.

Poorly mixed or filtered fluid.

Fluid too thick.

Worn fluid needle packings or rod.

Decrease air pressure (A1) as low as possible

Increase viscosity or increase fluid flow rate.

Increase air pressure; use lowest pressure necessary.

Use smaller tip; see Spray Tip

Selection Chart., page 45.

Remix or re-filter fluid.

Reduce viscosity.

Replace fluid needle assembly (8); see

Fluid Needle Replacement, page 31.

Worn piston stem o-rings (11e, 11f)

Replace, see Piston Repair, page

32.

Worn or damaged fluid needle ball.

See Fluid Needle Replacement, page 31

Worn fluid seat housing.

Replace; see Air Cap/Tip Guard,

Spray Tip, and Fluid Seat Housing

Replacement page 29.

Loose spray tip.

Damaged tip seal (3a).

Tighten retaining ring (1); see Air

Cap/Tip Guard, Spray Tip, and

Fluid Seat Housing Replacement page 29.

Replace; see Air Cap/Tip Guard,

Spray Tip, and Fluid Seat Housing

Replacement page 29.

333011C 25

Troubleshooting

Problem

Gun does not spray

Air leaks from manifold

Fluid doesn’t shut off properly

Excessive paint wrap back to operator

Cause Solution

Low fluid supply.

Damaged spray tip.

Dirty or clogged spray tip (3).

Damaged fluid needle (2).

Piston (11) not actuating.

Add fluid if necessary.

Replace; see Air Cap/Tip Guard,

Spray Tip, and Fluid Seat Housing

Replacement page 29.

Clean; see Clean the Spray Gun, page 20.

Replace, see Fluid Needle Replace-

ment page 31.

Check cylinder air. Check piston

o-ring (11d); see Piston Repair, page 32.

Actuator arm (15) is out of position.

Check actuator arm and nuts. See

page 32.

Gun is not securely tightened to manifold

Tighten manifold screws

Worn or missing o-rings

Fluid buildup on fluid needle (2)

Replace o-rings. See page 32

Replace needle; Fluid Needle

Replacement, page 31

Piston sticking

Poor grounding

Incorrect distance from gun to part

Clean or replace o-rings. See Piston

Repair, page 32

See Grounding, page 14

Should be 8-12 in. (200-300 mm).

26 333011C

Troubleshooting

Electrical Troubleshooting

Problem Cause Solution

Poor wrap.

ES indicator light is not lit (standard models only)

Turbine air is not turned on.

Booth exhaust velocity is too high.

Atomization air pressure too high.

Fluid pressure too high.

Turn on.

Reduce velocity to within code limits.

Decrease.

Decrease, or replace worn tip.

Incorrect distance from gun to part.

Should be 8-12 in. (200-300 mm).

Poorly grounded parts.

Resistance must be 1 megohm or less. Clean workpiece hangers.

Faulty gun resistance.

See Test Gun Resistance on page

22.

Check Fluid Resistivity, page 15.

Low fluid resistivity.

Fluid leaks from the fluid needle packings and causes a short

Faulty turbine

No power.

No power

Clean the fluid needle cavity and see

Fluid Needle Replacement, page 31

See Turbine Removal and Replace-

ment page 34

Replace power supply, see page 33

Check power supply, turbine, turbine

ribbon cable. See Power Supply

Removal and Replacement, page

33 and Turbine Removal and

Replacement, page 34.

ES indicator light is amber (standard models only)

Turbine speed is too low

Turbine speed is too high ES indicator light is red (standard models only)

No voltage or low voltage reading on the Pro Xp Auto Control module

Damaged fiber optic cable or connection.

Increase air pressure until indicator is green.

Decrease air pressure until indicator is green

Check; replace damaged parts. See

Pro Xp Auto Control Module manual

332989.

Pro Xp Auto Control Module displays event code (smart models only)

Turbine air is not turned on.

Turn on.

See manual 332989 for Event Code

Troubleshooting.

333011C 27

Repair

Repair

Prepare the Gun for Service

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

Remove the Gun from the

Manifold

See F IGURE 20.

1.

Disconnect fluid hose from manifold.

2.

Holding the gun firmly in hand, loosen the two screws (21) from the back and bottom of the manifold.

NOTE: The screws (21) should stay on the manifold.

3.

Remove the gun from the manifold and take it to the service area.

NOTE: The five o-rings (18) should stay on the gun.

To reduce the risk of a fluid injection injury, always

follow the Pressure Relief Procedure when you

stop spraying and whenever you are instructed to relieve the pressure.

NOTE:

Check all possible remedies in Troubleshooting

before disassembling the gun.

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

• Lubricate the power supply, some fluid needle parts

(8), and certain fluid fittings with Part No. 116553

Dielectric Grease, as specified in the text.

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

• Only use genuine Graco parts. Do not mix or use parts from other PRO Gun models.

1.

Flush and clean the gun, page 20.

2.

Relieve the pressure. Follow the Pressure Relief

Procedure, page 16.

3.

Remove the gun from the manifold.

4.

Remove the gun from the work site. Repair area must be clean.

18

18

21

Rear Manifold

21

Bottom Manifold

F IG . 20 . Remove Gun from Manifold

28 333011C

Repair

Install the Gun on the Manifold

See F IGURE 20.

1.

Make sure the five o-rings (18) are in place on the gun. Inspect the parts for damage and replace them as needed.

2.

Secure the gun to the manifold by tightening the two screws (21).

3.

Reconnect the fluid hose to the manifold.

Air Cap/Tip Guard, Spray Tip, and Fluid Seat Housing

Replacement

1.

See Prepare the Gun for Service, page 28.

2.

Remove the retaining ring (24), shroud (26) and air cap/tip guard assembly (25).

26

5.

To replace the electrode (25a), see Electrode

Replacement, page 30.

The conductive ring (33) is a conductive metal contact ring, not a sealing o-ring. To reduce the risk of fire, explosion, or electric shock:

• Do not remove the conductive ring except to replace it.

• Never operate the gun without the conductive ring in place.

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

6.

Remove the fluid seat housing (4) using the multi-tool (48).

48

25

F IG . 21 Remove Air Cap

24

3.

Remove shroud (26).

4.

Disassemble the air cap assembly. Check the condition of the u-cup (24a), o-ring (25b), and tip gasket

(3a). Replace any damaged parts.

25

24a

3

24

40b 25a

WLD

F IG . 22 Disassemble Air Cap Assembly

WLD

3a

F

IG

. 24 Seat Housing Replacement

NOTICE

To avoid damaging the seat housing and gun barrel, never over tighten the seat housing. Over tightening may affect the fluid shutoff.

7.

Install the fluid seat housing (4). Tighten until snug, then 1/4 turn more.

8.

Check that the spray tip gasket (3a) is in place. Align the spray tip tab with the groove in the air cap (25).

Install the spray tip (3) in the air cap.

9.

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

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

11. Check that the u-cup (24a) is in place on the retaining ring (24). The lips of the u-cup must face forward.

F IG . 23 Tip Gasket

333011C 29

Repair

12. Install the shroud.

NOTICE

To avoid damaging the tip guard, orient the air cap/tip guard assembly (25) before tightening the retaining ring (24). Do not turn the air cap when the retaining ring is tight.

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

14. See Test Gun Resistance, page 22.

Electrode Replacement

Fluid Tube Replacement

There are no replaceable parts in the fluid tube assembly. Only remove when necessary.

1.

Prepare the gun for service, page 28.

2.

Remove the air cap assembly, page 29. Remove the

shroud (26).

3.

Disconnect the bottom fluid tube nut (C). See F IG -

URE 25.

NOTE: Use two wrenches to remove the fluid tube fitting

(C).

4.

Carefully unscrew the top fluid tube nut (D).

NOTICE

Be careful not to damage the fluid tube assembly (35) when cleaning or installing it, especially the sealing surface (E). If the sealing surface is damaged, the entire fluid tube assembly must be replaced.

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

1.

See Prepare the Gun for Service, page 28.

2.

Remove the air cap/tip guard assembly (25). See

Air Cap/Tip Guard, Spray Tip, and Fluid Seat

Housing Replacement, page 29.

3.

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

4.

Push the new electrode through the air cap hole.

Make sure the short end (BB) of the electrode engages the hole (CC) in the back of the air cap.

Press the electrode in place firmly with your fingers.

5.

Install the air cap assembly.

6.

See Test Gun Resistance, page 22.

CC

BB

25a

5.

Apply Part No. 116553 dielectric grease to the entire length of the plastic extension on the end of the fluid tube (35).

6.

Apply low strength thread sealant to the fluid tube nut threads.

7.

Install the fluid tube into the gun barrel and tighten the top nut (D) hand-tight, then 1/4 to 1/2 turn with a wrench. There will be a gap between the nut and barrel. Do not over tighten the nut.

8.

Make sure the fluid filter (34) is in place. Tighten the bottom fluid tube nut (C) onto the fitting (32) and torque to 20-30 in-lb (2.3-3.4 N•m). Make sure the top nut remains tight.

NOTE: Use two wrenches to install the fluid tube fitting

(C).

9.

Reinstall the shroud and air cap assembly, page 29.

10. Test gun resistance, page 22.

C

E

D

34 ti19524

F IG . 25 Fluid Tube Replacement

30 333011C

Repair

Fluid Filter Removal

1.

Prepare the gun for service, page 28.

2.

Remove the air cap assembly, page 29. Remove the

shroud (26).

3.

Disconnect the bottom fluid tube nut (C).

NOTE: Use two wrenches to remove the fluid tube fitting

(C).

4.

Remove the fluid filter (34). Clean or replace the filter, as needed.

5.

Install the fluid filter. Tighten the bottom fluid tube nut (C) onto the fitting (32) and torque to 20-30 in-lb

(2.3-3.4 N•m). Make sure the top nut (D) remains tight.

NOTE: Use two wrenches to install the fluid tube fitting

(C).

7.

Install the fluid needle assembly in the gun barrel.

Lubricate the front of the needle with dielectric grease, if not already lubricated. Push in on the needle with the 2 mm ball end wrench (45) and tighten.

See F

IGURE

28.

8.

Install the spring (5).

9.

Install the spring cap (31), making sure the grounding spring (6) is in place. Tighten until snug. Do not over tighten.

10. Install the barrel (1), page 33.

NOTICE

To avoid damaging the seat housing and gun barrel, never over tighten the seat housing. Over tightening may result in improper fluid shutoff.

11. Install the seat housing and air cap, page 29.

12. Test gun resistance, page 22.

NOTICE

Be sure the fluid tube (35) is not twisted after tightening the bottom nut (C).

5

31

6

6.

Reinstall the shroud and air cap assembly, page 29.

7.

Test gun resistance, page 22.

Fluid Needle Replacement

1.

Prepare the gun for service, page 28.

2.

Remove the air cap/tip guard assembly and seat

housing, page 29.

3.

Remove the barrel (1), page 33.

4.

Remove the spring cap (31) and the spring (5) from

the barrel. See F IGURE 26.

5.

Be sure the seat housing (4) is removed. Place the

2 mm ball end wrench (45) in the back of the fluid needle assembly. Push the tool in and turn it counterclockwise about 12 full turns to unthread the needle.

6.

Using the multi-tool (48), pull back on the packing nut (N) to remove the fluid needle assembly. See

F IGURE 27.

F

IG

. 26 Spring Cap and Springs

F IG . 27 Fluid Needle Removal

N

48

F IG . 28 Fluid Needle Replacement

333011C 31

Repair

Piston Repair

1.

Prepare the gun for service, page 28.

2.

Remove the air cap, page 29. Remove the gun

shroud (26).

3.

Remove the jam nut (16a), actuator arm (15), and adjustment nut (16b). See F IGURE 30.

4.

Remove piston cap (13) and spring (12) from the rear of the gun.

5.

Push on the piston rod (11) to push the piston out the back of the gun.

6.

Inspect the o-rings (11d, 11e, 11f, 11g) for damage.

See Table 3 and F IGURE 29.

7.

Lubricate the o-rings (11d, 11e, 11f, 11g) with non-silicone grease, Part No. 111265. Do not over-lubricate.

8.

Align the two stems (11c) with the holes in the gun body and press the piston assembly into the back of the gun until it bottoms. Install piston cap (13) and spring (12).

9.

Install and adjust the actuator arm, page 32.

11e

11f

11c

11d

11b

11a

WLD

Table 3. Piston O-Rings

Description

Shaft O-Ring

(11g)

Function

Seals cylinder air along the piston rod

(34b). Replace if air leaks along rod.

Front O-Ring

(11e)

Back O-Ring

(11f)

Piston O-Ring

(11d)

Air shutoff seal. Replace if air leaks from air cap when gun is de-triggered.

Separates cylinder air from fan and atomizing air.

Replace if air leaks from small vent hole at back of manifold when gun is triggered.

O-rings included in air seal repair kit 24W390.

Adjust the Actuator Arm

NOTE: The seat housing (4) must be in place when removing or installing the jam nut and actuator arm.

See F

IGURE

30.

1.

Install the adjustment nut (16b), actuator arm (15), and jam nut (16a) onto the piston rod (11b).

2.

Position the parts so there is a 0.125 in. (3 mm) gap between the actuator arm (15) and the fluid packing rod nut (E). This allows the atomizing air to actuate before the fluid.

3.

Tighten the adjustment nut (16a) against the actuator arm (15). Check that the 0.125 in. (3 mm) gap has been maintained. Tighten the jam nut (16a).

4.

Test gun resistance, page 22.

5.

Install the gun shroud (26) and air cap/tip guard

assembly (25), page 29.

6.

Install the gun onto the manifold. See page 29.

0.125 in. (3 mm) gap

11d

11g

11e

11f

11g

Fan Air Side

15

WLD

16a 16b 11b

E

F IG . 30 . Actuator Arm Adjustment

Atomizing Air Side

F IG . 29 . Piston O-Rings

32

WLD

333011C

Repair

Barrel Removal

See F IGURE 31

1.

Prepare the gun for service and remove the mani-

fold, page 28.

2.

Remove the air cap and tip, page 29. Remove the

gun shroud (26).

3.

Carefully loosen the fluid fitting nut (C). Pull the tube

(35) out of the fitting (32). See F IGURE 31.

NOTE: Use two wrenches to remove the fluid tube fitting

(C).

4.

Remove the adjustment nuts (16a, 16b) and actuator arm (15). See F IGURE 30.

5.

Loosen the two screws (19). See F IGURE 31.

NOTICE

To avoid damaging the power supply, pull the gun barrel

(1) straight away from the gun body (10). If necessary, gently move the gun barrel from side to side to free it from the gun body.

6.

Hold the gun body (10) with one hand and pull the barrel (1) straight off the body. See F IGURE 31.

NOTE: Use two wrenches to install the fluid tube fitting

(C).

5.

Install and adjust the actuator arm (15), jam nut

(16a), and adjustment nut (16b). See page 32.

6.

Test gun resistance, page 22.

7.

Install the gun shroud (26) and air cap, page 29.

8.

Install the gun onto the manifold. See page 29.

19

10

7

9

32

34

F IG . 31 . Barrel

C

16a

15

16b 6

35

1

Barrel Installation

See F IGURE 31

1.

Verify the gasket (9) and grounding spring (6) are in place and the gasket air holes are aligned properly.

Replace the gasket if damaged.

2.

Make sure the spring is in place on the tip of the power supply (7). Liberally apply dielectric grease to the tip of the power supply. Place the barrel (1) over the power supply and onto the gun body (10).

3.

Tighten the two barrel screws (19) oppositely and evenly (about a half turn past snug or 20 in-lbs). Do not over-tighten.

NOTICE

To avoid damaging the gun barrel, do not over-tighten the screws (19).

4.

Make sure the fluid filter (34) is in place. Tighten the bottom nut (C) onto the fitting (32) and torque to

20-30 in-lb (2.3-3.4 N•m). Make sure the top nut (D) remains tight.

Power Supply Removal and

Replacement

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

• Do not expose gasket (9) to solvents.

1.

See Prepare the Gun for Service, page 28.

2.

See Barrel Removal, page 33.

NOTICE

Be careful when handling the power supply (7) to avoid damaging it.

3.

Grasp the power supply (7) with your hand. With a gentle side to side motion, free the power supply/turbine assembly from the gun body (10), then carefully pull it straight out.

Smart models only: disconnect the flexible circuit

(30) from the socket at the top of the gun body.

4.

Inspect the power supply and turbine for damage.

333011C 33

Repair

5.

To separate the power supply (7) from the turbine

(8), disconnect the 3-wire ribbon connector (PC) from the power supply. See F

IGURE

32.

Smart models only: disconnect the 6–pin flexible circuit (30) from the power supply.

Slide the turbine up and off the power supply.

6.

See Test Power Supply Resistance, page 22.

Replace the power supply if necessary. To repair the

turbine, see Turbine Removal and Replacement, page 34.

NOTICE

To prevent damage to the cable and possible interruption of the ground continuity, bend the turbine’s

3–wire ribbon cable (PC) upward and back, so the bend faces the power supply and the connector is at the top.

10. See Test Gun Resistance, page 22.

EE

10

WLD

F IG . 33 . Power Supply

7

CS

9

8

PC

30

7.

Connect the 3-wire ribbon connector (PC) to the power supply.

Smart models only: connect the 6–pin flexible circuit (30) to the power supply.

Tuck the ribbon forward, under the power supply.

Slide the turbine (8) down onto the power supply (7).

8.

Insert the power supply/turbine assembly in the gun body (10). Make sure the ground strips (EE) make contact with the handle.

Smart models only: align the connector of the

6–pin flexible circuit (30) with the socket (CS) at the top of the handle. See F

IGURE

32.

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

CS 30

7a

Turbine Removal and

Replacement

NOTE: Replace turbine bearings after 2000 hours of operation. Order Part No. 24N706 Bearing Kit. Parts included in the kit are marked with a symbol ( ◆ ). See

F

IGURE

33 through F

IGURE

36.

1.

See Prepare the Gun for Service, page 28.

2.

Remove the power supply/turbine assembly and

disconnect the turbine. See Power Supply

Removal and Replacement, page 33.

3.

Measure resistance between the two outer terminals of the 3-wire connector (PC); it should be

2.0–6.0 ohms. If outside this range, replace the turbine coil (8a).

4.

Using a flat blade screwdriver, pry the clip (8h) off the housing (8d). Remove the cap (8f), using a thin blade or screwdriver.

5.

If necessary, rotate the fan (8e) so its blades clear the four bearing tabs (T) of the housing (8d). See

F

IGURE

34.

8e ◆

T

F IG . 32 . Connect Flexible Circuit

9.

Make sure the gasket (9), ground spring (6), and power supply spring (7a) are in place. Replace gasket (9) if damaged. Assemble the barrel (1) to the gun body (10). See Barrel Installation, page 42.

WLE

F IG . 34 . Fan Orientation

P

34 333011C

Repair

6.

Push the fan and coil assembly (8a) out the front of the housing (8d).

WLE

PC

8b2

8h

M 8a 8g

8d 8b1

S

F IG . 35 . Turbine Cross-Section.

NOTICE

8f

Do not scratch or damage the magnet (M) or shaft (S).

Do not pinch or damage the 3–wire connector (PC) when disassembling and reassembling the bearings.

7.

Hold the coil assembly (8a) on a workbench with the fan end facing up. Using a wide blade screwdriver, pry the fan (8e)off the shaft (S).

8.

Remove the top bearing (8b2).

9.

Remove the bottom bearing (8b1).

10. Install the new bottom bearing (8b1.) on the long end of the shaft (S). The flatter side of the bearing must face away from the magnet (M). Install in the coil (8a) so the bearing blades are flush with the surface of the coil.

11. Press the new top bearing (8b2.) onto the short end of the shaft so the bearing blades are flush with the surface of the coil (8a). The flatter side of the bearing must face away from the coil.

12. Hold the coil assembly (8a) on a workbench with the fan end facing up. Press the fan (8e.) onto the long end of the shaft (S).The fan blades must be oriented

as shown in F

IGURE

34.

13. Carefully press the coil assembly (8a) into the front of the housing (8d.) while aligning the pin on the coil with the slot in the housing. The 3–wire connector

(PC) must be positioned below the wider notch (W) of the housing tabs.

14. Rotate the fan (8e) so its blades clear the four bearing tabs (T) at the back of the housing. Ensure that the blades of the bottom bearing (8b1.) align with the tabs.

15. Seat the coil fully into the housing (8d.). Secure with the clip (8h.),ensuring that its tabs engage the slots in the housing.

16. Ensure that the o-ring (8g) is in place. Install the cap

(8f).

17. Install the turbine on the power supply, and install

both parts in the handle. See Power Supply

Removal and Replacement, page 33.

F

IG

. 36 . Turbine

8f ◆

8e ◆

8g*

8d ◆

W

8b1 ◆

Slot

S

M

Pin

8a

8b2 ◆

WLE

PC

8h ◆

333011C 35

Parts

Parts

Standard Pro Xp Auto AA Gun Models

HA1T10, Rear Manifold

HA2T10, Bottom Manifold

1

Torque to 20 in-lbs (2 N•m)

36

HA2T10

1

333011C

Parts

Standard Pro Xp Auto AA Gun Models

HA1T10, Rear Manifold

HA2T10, Bottom Manifold

Ref.

No.

Part No. Description Qty

1

2

3

5

6

3a

4

24W874 BODY, gun assy, includes 9, 33

24N781 NEEDLE ASSEMBLY, includes 5

AEMxxx

AEFxxx

TIP ASSEMBLY; customer’s choice 1

1

1

183459 GASKET, tip

24N725 HOUSING, seat

24N782 SPRING, fluid needle

197624 SPRING, compression 1

1

1

1

7

7a

24N661 POWER SUPPLY, 85 kV

24N979 SPRING

8

24N664 See Turbine Assembly, page 41

8g ■ 110073 O-RING, packing

9 ■◆ 24N699 GASKET, barrel

10 24W380 BODY, assy, AA. Includes 18, 19

11

11a

11b

24W396 PISTON, assy, actuation, auto

17B704 O-RING, packing

111504 O-RING, packing

11c 112319 O-RING, packing

1

1

1

1

1

2

1

1

11d

12

13

14

15

111508 O-RING, packing

112640 SPRING, compression

24W397 CAP, piston, actuation

513505 WASHER, plain #10 SST

24W398 ARM, fluid actuator, XP

(includes 16, qty 2)

1

1

2

1

1

1

16 100166 NUT, full hex

18 ■ 111450 PACKING, O-RING

19 24N740 SCREW, ES gun (pack of 2)

20 24W394 MANIFOLD, rear inlet (HA1T10) 1

24W395 MANIFOLD, bottom inlet (HA2T10) 1

21 ❖

23

24W399 SCREW, modified, 1/4-20, XP Auto

(pack of 2)

24W411 FITTING, Adapter, M12 TO 1/4,

LH, XP

2

1

24 24N793 RING, retainer, assy; includes 24a 1

24a ■ 198307 PACKING, u-cup; UHMWPE 1

25

24N727 See Air Cap Assembly, page 40

1

2

5

4

Ref.

No.

Part No. Description

25a 24N643 ELECTRODE, package of 5

26

27 ❖

28 ❖

29 ❖

30

24W388 COVER, shroud, Auto XP

114263 FITTING, connector, male

115950 FITTING, connector, 1/4npt (M),

5/16T

110465 SCREW, set (HA1T10 only)

102207 SCREW, set, SCH

31

32

24N785 CAP, spring, includes 6

24W752 FITTING, fluid, AA hose includes

19 qty 1

33

34

24N747 RING, conductive

238561 FILTER, tip (3 pack)

35 24W387 HOSE, assy

36 ★ 117560 SCREW, set

37 116553 GREASE, dielectric; 1 oz (30 ml) tube (not shown)

40 ▲ 16P802 SIGN, warning (not shown)

42 ▲ 179791 TAG, warning (not shown)

43 ▲ 222385 TAG, warning (not shown)

44 276741 MULTI-TOOL (not shown)

45

46

107460 WRENCH, ball end, 4 mm

(not shown)

112080 WRENCH, ball end, 2 mm

(not shown)

Qty

3

2

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

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

Included in Air Seal Repair Kit 24W390 (purchase separately)

❖ Included in Rear Manifold Repair Kit 24W394

(purchase separately)

★ Included in Bottom Manifold Repair Kit 24W395

(purchase separately)

Included in Turbine Assembly 24N664 (pur-

chase separately). See Turbine Assembly, page 41.

333011C 37

Parts

Smart Pro Xp Auto AA Gun Models

HA1M10, Rear Manifold

HA2M10, Bottom Manifold

1

Torque to 20 in-lbs (2 N•m)

38

HA2M10

1

333011C

Parts

Smart Pro Xp Auto AA Gun Models

HA1M10, Rear Manifold

HA2M10, Bottom Manifold

Ref.

No.

Part No. Description Qty

1

2

3

5

6

3a

4

24W874 BODY, gun assy, includes 9, 33

24N781 NEEDLE ASSEMBLY, includes 5

AEMxxx

AEFxxx

TIP ASSEMBLY; customer’s choice 1

1

1

183459 GASKET, tip

24N725 HOUSING, seat

24N782 SPRING, fluid needle

197624 SPRING, compression 1

1

1

1

7

7a

24N661 POWER SUPPLY, 85 kV

24N979 SPRING

8

10

24N664 See Turbine Assembly, page 41

8g ■ 110073 O-RING, packing

9 ■◆ 24N699 GASKET, barrel

24W869 BODY, assy, AA, bottom inlet

HA2M10

24W384 BODY, assy, AA, rear inlet

HA1M10, includes 18, 19

1

1

1

1

1

1

11 24W396 PISTON, assy, actuation, auto

11a 17B704 O-RING, packing

11b 111504 O-RING, packing

11c 112319 O-RING, packing

11d 111508 O-RING, packing

12 112640 SPRING, compression

13

14

24W397 CAP, piston, actuation

513505 WASHER, plain #10 SST

1

1

1

1

2

2

1

1

15 24W398 ARM, fluid actuator, XP (includes

16, qty 2)

16 100166 NUT, full hex

18 ■ 111450 PACKING, O-RING

19

20

24N740 SCREW, ES gun (Includes 2)

24W394 MANIFOLD, rear inlet HA1M10

1

24W395 MANIFOLD, bottom inlet HA2M10 1

21

23 ❖

24W399 SCREW, modified, 1/4-20, XP Auto

(pack of 2)

24W411 FITTING, Adapter, M12 TO 1/4,

LH, XP

2

1

24 24N793 RING, retainer, assy; includes 24a 1

24a ■ 198307 PACKING, u-cup; UHMWPE 1

25

24N727 See Air Cap Assembly, page 40

1

25a 24N643 ELECTRODE, package of 5 1

4

1

2

5

Ref.

No.

Part No. Description

26

27 ❖

28 ❖

29 ❖

30

31

32

24W388 COVER, shroud, Auto XP

114263 FITTING, connector, male

115950 FITTING, connector, 1/4npt (M),

5/16T

110465 SCREW, set

245265 CIRCUIT, flexible

24N785 CAP, spring includes 6

24W752 FITTING, fluid, AA hose Includes

19 qty 1

33

34

24N747 RING, conductive

238561 FILTER, tip (3 pack)

35 24W387 HOSE, assy

36 ★ 117560 SCREW, set

37 116553 GREASE, dielectric; 1 oz (30 ml) tube (not shown)

40 ▲ 16P802 SIGN, warning (not shown)

42 ▲ 179791 TAG, warning (not shown)

43 ▲ 222385 TAG, warning (not shown)

44 276741 MULTI-TOOL (not shown)

45

46

107460 WRENCH, ball end, 4mm

(not shown)

112080 WRENCH, ball end, 2mm

(not shown)

80 24W035 CONTROL MODULE, Pro Xp Auto

(not shown). See 332989. Must be purchased separately.

Qty

3

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

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

Included in Air Seal Repair Kit 24W390 (purchase separately)

❖ Included in Rear Manifold Repair Kit 24W394

(purchase separately)

★ Included in Bottom Manifold Repair Kit 24W395

(purchase separately)

Included in Turbine Assembly 24N664 (pur-

chase separately). See Turbine Assembly, page 41.

333011C 39

Parts

Air Cap Assembly

Part No. 24N727 Air Cap Assembly

25b

25a

25c

25d

Ref.

No.

Part No. Description

3a 183459 GASKET, tip (not shown) See page

36.

25a 24N643 ELECTRODE, package of 5

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

24E459 O-RING; PTFE; package of 10

Qty

5

1

1

1

Ref.

No.

Part No. Description

25c -----AIR CAP

25d 24N726 GUARD, tip, orange

Qty

1

1

40 333011C

Parts

Turbine Assembly

Part No. 24N664 Turbine Assembly

8f ◆

8e

8g*

8d ◆

8b1

8a

8b2 ◆

8h ◆

WLE

Ref.

No.

Part

No.

Description

8a 24N705 COIL, turbine

8b ◆ 24N706 BEARING KIT (includes two bearings, item 8e fan, and one item 8h clip)

8d ◆ 24N707 HOUSING; includes item 8f

8e ◆ -----FAN; part of item 8b

8f

-----CAP, housing; part of item 8d

8g* 110073 O-RING

Qty

1

1

1

1

1

1

Ref.

No.

Part

No.

Description Qty

8h ◆ 24N709 CLIP; package of 5 (one clip included with item 15b)

9*

24N699 GASKET, barrel (not shown) See

page 36.

* These parts are included in Air Seal Repair Kit

24W390 (purchase separately).

◆ These parts are included in Bearing Kit 24N706

(purchase separately).

Parts labeled ------ are not available separately

1

1

333011C 41

Accessories

Accessories

Smart Model Accessories and Fiber Optic

Cables

Part No.

Description

24W035 Pro Xp Auto Control Module. See 332989 for details.

Fiber Optic Cables

See item V in F IGURE 7 on page 13. Connect gun manifold to Pro Xp Auto Control Module. See 332989.

Models with Rear Manifolds

(Model numbers LA1xxx or HA1xxx)

Part No. Description

24X003 Fiber Optic Cable, 25 ft (7.6 m)

24X004 Fiber Optic Cable, 50 ft (15 m)

24X005 Fiber Optic Cable, 100 ft (30.5 m)

Air Line Accessories

AirFlex

Flexible Grounded Air Hose (Grey)

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

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

Part No.

Description

244963 6 ft (1.8 m)

244964

244965

15 ft (4.6 m)

25 ft (7.6 m)

244966

244967

244968

244969

36 ft (11 m)

50 ft (15 m)

75 ft (23 m)

100 ft (30.5 m)

Models with Bottom Manifolds

(Model numbers LA2xxx or HA2xxx)

Part No. Description

24X006 Fiber Optic Cable, 25 ft (7.6 m)

24X007 Fiber Optic Cable, 50 ft (15 m)

24X008 Fiber Optic Cable, 100 ft (30.5 m)

Fiber Optic Cable Kit

24W875 Parts necessary to replace damaged ends on one cable assembly.

Standard Grounded Air Hose (Grey)

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

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

Part No.

Description

223068 6 ft (1.8 m)

223069

223070

223071

223072

223073

223074

15 ft (4.6 m)

25 ft (7.6 m)

36 ft (11 m)

50 ft (15 m)

75 ft (23 m)

100 ft (30.5 m)

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

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

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

Part No.

Description

235068 6ft(1.8m)

235069 15 ft (4.6 m)

235070

235071

235072

25 ft (7.6 m)

36 ft (11 m)

50 ft (15 m)

42 333011C

Accessories

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

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

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

235073

235074

75 ft (23 m)

100 ft (30.5 m)

System Accessories

Part No.

Description

222011 Ground wire for grounding pump and other components and equipment in the spray area. 12 gauge, 25 ft (7.6 m).

16P802 English Warning Sign. Available at no charge from Graco.

Bleed-Type Master Air Valve

300 psi (21 bar, 2.1 MPa) Maximum Working Pressure

Relieves air trapped in the air line between this valve and the pump air motor when closed.

Part No.

Description

107141 3/4 npt

Air Line Shutoff Valve

150 psi (10 bar, 1.0 MPa) Maximum Working Pressure

For turning air to gun on or off.

Part No.

Description

224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.

Fluid Line Accessories

Fluid Hose

3300 psi (22.7 MPa, 227 bar) Maximum Working Pressure

1/4 in. (6 mm) ID; 1/4 npsm (fbe); nylon.

Part No.

Description

240793 25 ft (7.6 m)

240794 50 ft (15.2 m)

Test Equipment

Part No.

Description

241079 Megohmmeter. 500 V output, 0.01–2000 megohms. Use for ground continuity and gun resistance tests.Not for use in hazardous areas.

722886

722860

Paint Resistance Meter. Use for fluid resistivity test. See manual 307263. Not for use in hazardous areas.

Paint Probe. Use for fluid resistivity test. See manual 307263. Not for use in hazardous areas.

245277 Test Fixture, High Voltage Probe, and kV

Meter. Use to test the electrostatic voltage of the gun, and the condition of the turbine and power supply when being serviced. See manual 309455. Also requires 24R038 Conversion Kit.

24R038 Voltage Tester Conversion Kit. Converts the

245277 Test Fixture for use with the Pro Xp

Gun turbine. See manual 406999.

Fluid Recirculation Fitting

5000 psi (340 bar, 34 Mpa) Maximum Working Pressure

Part No.

Description

24X634 Stainless steel recirculation fitting that mounts directly to the gun fluid inlet fitting.

1/4-18 npsm inlet and outlet.

Miscellaneous Equipment

Gun Accessories

Part No.

Description

105749 Cleaning brush

111265

116553

Non-silicone lubricant, 4 oz (113g)

Dielectric grease 1 oz (30 ml)

24V929 Gun Covers

333011C

Conversion and Repair Kits

Part No.

Description

24N319 Round Spray Kit. To convert a standard air assisted spray gun to a round spray air cap.

See manual 3A2499.

24W390 Air Seal Repair Kit

24N706 Turbine Bearing Repair Kit

43

Dimensions

Dimensions

Rear Inlet Manifold

11 in (279 mm)

10.4 in (265 mm)

8.2 in (208 mm)

2.6 in (66 mm)

2.5 in (63 mm )

Bottom Inlet Manifold

11.0 in (279 mm)

0.53 in(13.5 mm) 2x 1/4-20 UNC

2.6 in (66 mm)

2.5 in (623 mm )

44

2x 1/4-20 UNC

.60 in (15.24 mm)

8.0 in (202 mm)

3x 5/16-18 UNC

1.05 in (26.67 mm)

.90 in (22.86 mm)

1.80 in (45.72mm)

333011C

Spray Tip Selection Chart

Spray Tip Selection Chart

AEM Fine Finish Spray Tips

Recommended for high finish quality applications at low and medium pressures. Order desired tip, Part No. AEMxxx, where xxx = 3-digit number from the matrix below.

Orifice

Size in.

(mm)

0.007

(0.178)

0.009

(0.229)

0.019

(0.483)

0.021

(0.533)

0.023

(0.584)

0.025

(0.635)

0.011

(0.279)

0.013

(0.330)

0.015

(0.381)

0.017

(0.432)

4.0

(0.1)

7.0

(0.2)

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

(4.1 MPa,

41 bar)

28.0

(0.8)

35.0

(1.0)

40.0

(1.2)

50.0

(1.5)

10.0

(0.3)

13.0

(0.4)

17.0

(0.5)

22.0

(0.7) at 1000 psi

(7.0 MPa,

70 bar)

5.2

(0.15)

9.1

(0.27)

13.0

(0.4)

16.9

(0.5)

22.0

(0.7)

28.5

(0.85)

0.029

(0.736)

0.031

(0.787)

0.033

(0.838)

68.0

(1.9)

78.0

(2.2)

88.0

(2.5)

88.2

(2.65)

101.1

(3.03)

114.1

(3.42)

0.037

(0.939)

0.039

(0.990)

108.0

(3.1)

118.0

(3.4)

140.0

(4.20)

153.0

(4.59)

* Tips are tested in water.

36.3

(1.09)

45.4

(1.36)

51.9

(1.56)

64.8

(1.94)

2 - 4

(50 -

100)

107

Maximum Pattern Width at 12 in. (305 mm)

4 - 6

(100 -

150)

207

209

211

213

215

217

6 - 8

(150 -

200)

307

309

311

313

315

317

319 in. (mm)

8 - 10

(200 -

250)

10 - 12

(250 -

300)

Spray Tip

409

411

413

415

417

419

421

423

425

431

509

511

513

515

517

519

521

523

525

539

12 - 14

(300 -

350)

609

611

613

615

617

619

621

623

625

631

14 - 16

(350 -

400)

711

713

715

717

719

721

723

725

737

16 - 18

(400 -

450)

813

815

821

823

825

829

831

833

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

where QT = fluid

333011C 45

Spray Tip Selection Chart

AEF Fine Finish Pre-Orifice Spray Tips

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

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

.

Fluid Output fl oz/min (l/min)

Orifice

Size in.

(mm)

0.008

(0.203)

0.010

(0.254) at 600 psi

(4.1 MPa,

41 bar)

8.5

(.025)

9.5

(0.28) at 1000 psi

(7.0 MPa, 70 bar)

0.0012

(0.305)

0.014

(0.356)

12.0

(0.35)

16.0

(0.47)

0.016

(0.406)

20.0

(0.59)

* Tips are tested in water.

26.5

(0.78)

11.0

(0.32)

12.5

(0.37)

16.0

(0.47)

21.0

(0.62)

6-8

(150 - 200)

310

312

314

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

8-10

(200 - 250)

10-12

(250 - 300)

12-14

(300 - 350)

14-16

(350 - 400)

Spray Tip

608

16-18

(400 - 450)

410

412

414

416

510

512

514

516

610

612

614

616

710

712

714

716

812

814

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

where QT = fluid

46 333011C

Technical Data

Technical Data

Pro Xp Auto AA Spray Gun

Maximum fluid working pressure

Maximum working air pressure

Maximum fluid operating temperature

Short circuit current output

Paint resistivity range

Voltage Output

Standard Models

Smart Models

Voltage output

Gun Weight (Approximate)

Noise (dBa)

Sound Power (measured per ISO Standard

9216)

Sound Pressure (measured 1 m from gun)

US

3000 psi

100 psi

120°F

2.7 lb at 40 psi: 90.4 dB(A) at 100 psi: 105.4 dB(A) at 40 psi: 87 dB(A) at 100 psi: 99 dB(A)

Metric

21 MPa, 210 bar

0.7 MPa, 7 bar

48°C

125 microamperes

3 megohm/cm to infinity

85 kV

40-85 kV

40-85 kV

1.2 kg at 0.28 MPa, 2.8 bar: 90.4 dB(A) at 0.7 MPa, 7 bar: 105.4 dB(A) at 0.28 MPa, 2.8 bar: 87 dB(A) at 0.7 MPa, 7 bar: 99 dB(A)

Inlet/Outlet Sizes

Turbine air inlet fitting, left-hand thread

Atomizing air inlet fitting

Fan air inlet fitting

Cylinder air inlet fitting

Fluid inlet fitting

Materials of Construction

Wetted Parts

1/4 npsm(m)

5/16 in. OD nylon tube (8 mm)

5/16 in. OD nylon tube (8 mm)

5/32 in. OD nylon tube (4 mm)

1/4-18 npsm(m)

Stainless Steel; Nylon, Acetal, Ultra-High Molecular Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten Carbide, Polyethylene

333011C 47

Graco Pro Xp Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. However, any deficiency in the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED

TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

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

FOR GRACO CANADA CUSTOMERS

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

Graco Information

For the latest information about Graco products, visit www.graco.com

.

For patent information, see www.graco.com/patents .

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

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

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

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

Original instructions.

This manual contains English. MM 333011

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision C, March 2015

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