Installation. Graco 3A4798F, Pro Xp Waterborne Auto Air Spray Gun

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Installation. Graco 3A4798F, Pro Xp Waterborne Auto Air Spray Gun | Manualzz

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 local codes and 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

Electrically interlock the gun air and fluid supply with the ventilators to prevent gun operation any time that the ventilation air flow falls below minimum values.

Check and follow all local codes and regulations regarding air exhaust velocity requirements. Verify the operation of the interlock at least once a year.

NOTE: The minimum allowable air exhaust velocity is

60 feet/minute (19 linear meters/minute). High velocity air exhaust will decrease the operating efficiency of the electrostatic system.

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 fin ished workpiece and can cause the gun to mal function.

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.

Do not operate the gun unless ventilating air flow is above the minimum required value. Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun.

Interlock the gun air and fluid supply to prevent oper ation unless ventilating air flow is above the minimum required value.

The spray booth must have a ventilation system.

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 sole noids 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.

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Installation

Install the Fluid Line Accessories

1. Install a fluid filter and drain valve at the pump out let.

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

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

ing 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

K

L

L

W

K

M

Non-Hazardous Location

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)

N

B C D

E

Hazardous Location

Manifold Back View

K Solenoid Valve, requires quick exhaust port

L Bleed-Type Master Air Valve

M Air Pressure Regulator

N True Earth Ground

W Main Air Line

G

3A4798F 11

Installation

Install the Gun

See F IGURE 4.

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.

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.

NN 29 b. Firmly press the charging probe onto the gun in the Connect/Disconnect position (CP), where the probe pin passes by the fitting slot.

2.88 in.

(73.2 mm)

20

F IG . 4. Mounting

8.00in.

(203.2 mm)

To nozzle tip

3. Select a charging probe. Two probes are included with the gun.

• Long charging probe: For the best transfer effi ciency and wrap

• Short charging probe: For low profile electro static charging

4. Connect the charging probe.

a. Liberally apply dielectric grease to the probe fitting, charging probe, and the two o-rings (CC and CR).

CC

CR

c. Press the probe towards the barrel and rotate the charging probe from the Connect/Discon nect Position (CP) to the spray position (SP).

NOTE: For proper performance, do not operate electrostatics if the charging probe is not in the spray position.

12 3A4798F

Installation

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.

Connect the Air and Fluid Lines

F IGURE 3 shows a schematic of air and fluid line con

-

nections, and F IGURE 5 shows the manifold connec

tions. Connect the air and fluid lines as instructed below.

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 Air Hoses.

1. Connect the Graco Grounded Turbine Air Hose (B) to the gun's turbine air inlet (TA) and connect the air 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 17.

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

3A4798F 13

Installation

Manifold Connections

Rear Inlet Bottom Inlet

2

1

TA

A2

P

CYL

A1

A1

EXH

P

A2

CYL

2

1

TA

EXH

F IG . 5. Manifold Connections

A1

A2

1

2

P

CYL

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 15).

Fiber Optic Fitting Receive (Operational on Smart models only)

Connect the Graco Fiber Optic cable (see page 15).

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 Electrically Conductive 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. 3 ft. max length. Fitting is for 5/16 in. OD tube.

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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 One-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 Two-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 Location

U

Port 2

Port 5 Port 6

Hazardous Location H

1

2

Gun 1

H*

Q

Q

R

H

P

U

V

Pro Xp Auto Air Spray Gun

24 Volt Power Supply Connection

Remote I/O Connection

Pro Xp Auto Control Module

Bulkhead (optional)

Fiber Optic Cable

P

V

U

Gun 2

F

IG

. 7. Fiber Optic Schematic

3A4798F 15

Installation

Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode.

Improper grounding can cause electric shock.

Ground all equipment, personnel, objects being sprayed, and conductive objects in or close to the spray area. The resistance must not exceed 1 meg ohm. Grounding provides an escape wire for the elec tric current.

When operating the electrostatic gun, any ungrounded objects (such as people, containers, and tools) in the spray location can become electrically charged.

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

Your system must be connected to a true earth ground.

Check ground connections daily. Check your local electrical codes and regulations for detailed grounding instructions.

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

• Electrostatic Air 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 Gun

Electrical Grounding, page 17.

• 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.

• 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.

16 3A4798F

Installation

Check Gun Electrical Grounding

earth ground. If the resistance is still too high, replace the turbine air hose.

N

TA

Megohmmeter Part No. 241079 (AA-see F IGURE 8) 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 gun has been removed from the hazardous location;

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

Failure to follow this warning could cause fire, explo sion, 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.

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 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 read ing specified above for your hose, check the tight ness of the ground connections and be sure the turbine air hose ground wire is connected to a true

AA

B

WLD

F IG . 8. Check Gun Electrical Grounding

3A4798F 17

Installation

Check Fluid Resistivity

To reduce the risk of fire, explosion, or electric shock, check the fluid resistivity in a non-hazardous location only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous location.

Check that the resistivity of the fluid being sprayed meets the requirements for an electrostatic air spray system. Graco Part No. 722886 Resistance Meter and

722860 Probe are available as accessories. Follow the instructions included with the meter and probe.

The Pro Xp Auto WBx gun is intended to spray very conductive waterborne materials and other materials less than 1 megohm-cm.

Check Fluid Viscosity

A viscosity cup and stopwatch are needed to check fluid viscosity.

1. Completely submerge the viscosity cup in the fluid.

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

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

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

4. 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.

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 24. Strap down the

exhaust tube to prevent it from moving around.

YY

XX

YY

WLD

F

IG

. 9. Fabric Cover

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 23.

18 3A4798F

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