Instructions-Parts Pro Xp Auto AA Spray Gun 333011B EN 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 100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.
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 . . . . . . . . . . . . . . . .
List of Models 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 Related Manuals Manual No.
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.
Warnings WARNING WARNING 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.
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.
Introduction System Overview Typical System Installation FIGURE 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 * FIG.
Introduction Gun Overview K 1 B P 2 CYL TA A2 EXH F J A A1 C D H G FIG.
Installation Installation Install the System Install the Air Line Accessories See FIGURE 3. 1. Install a bleed-type master air valve (L) on the main air line (W) to shut off all air to the gun. 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.
Installation FIGURE 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. NOTE: The grounded turbine air hose (TA) must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on. L B A See Note above C D L K L W K Manifold Back View N M Non-Hazardous Area G E Hazardous Area FIG.
Installation Install the Gun Connect the Air and Fluid Lines 1. Loosen the manifold’s two set screws (29) and slide the manifold (20) onto a 1/2 in. (13 mm) mounting rod. FIGURE 3 shows a schematic of air and fluid line connections, and FIGURE 5 shows the manifold connections. Connect the air and fluid lines as instructed below. 2. Position the gun and tighten the two set screws. NOTE: For added positioning reliability, insert a 1/8 in.
Installation Manifold Connections Rear Inlet Bottom Inlet A2 A1 2 1 EXH P 1 TA CYL P 2 CYL TA A1 A2 EXH FIG. 5 Manifold Connections A1 Atomization Air Inlet Fitting Connect a 5/16 in. (8mm) OD tube between this fitting and the air supply. A2 Fan Air Inlet Fitting Connect a 5/16 in. (8 mm) OD tube between this fitting and the air supply. Cylinder Air Inlet Fitting CYL Connect a 5/32 in. (4 mm) OD tube between this fitting and the solenoid.
Installation Fiber Optic Cable Connection (Operational on Smart models only) For a 2 Gun System NOTE: Only use the supplied fiber optic cable. 1. Connect Port 1 of the gun 2 manifold to Port 5 of the Control Module. The fiber optic cable allows the gun to communicate with the Pro Xp Auto control module. 2. Connect Port 2 of the gun 2 manifold to Port 6 of the Control Module. For a 1 Gun System 1. Connect Port 1 of the gun 1 manifold to Port 1 of the Control Module. 2.
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.
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.
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.
Operation Install the Spray Tip Set the Atomization Fluid Pressure See FIGURE 5. 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 Procedure, page 16. 2. Align the spray tip tab with the groove in the air cap. Install the tip. WL D FIG. 10 Spray Tip Alignment 3. Install the air cap and retaining ring.
Operation Adjust the Electrostatics 1. Turn on the turbine air (TA) and adjust the air pressure 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 Air pressure at turbine air hose Hose Length inlet for full voltage ft (m) psi (bar, MPa) 15 (4.6) 54 (3.8, 0.38) 25 (7.6) 55 (3.85, 0.38) 36 (11) 56 (3.9, 0.39) 50 (15.3) 57 (4.0, 0.40) 75 (22.9) 59 (4.1, 0.41) 100 (30.5) 61 (4.3, 0.43) 2.
Maintenance Maintenance NOTICE Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components. To reduce the risk of an injury, follow the Pressure Relief Procedure before doing any maintenance on the gun or system. 1. Turn off the turbine air. 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.
Maintenance Clean the Spray Gun NOTE: Use two wrenches to remove the fluid tube fitting (C). Equipment Needed • • D soft bristle brush compatible solvent C Procedure 20 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.
Maintenance Check for Fluid Leakage 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 FIGURE 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.
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. AA 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. 25a TA Use Megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V.
Electrical Tests 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 FIGURE 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.
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.
Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Excessive spray fog. Atomizing air pressure too high. Decrease air pressure (A1) as low as possible Fluid too thin. Increase viscosity or increase fluid flow rate. Atomization air pressure too low. Increase air pressure; use lowest pressure necessary. Spray tip is too large. Use smaller tip; see Spray Tip Selection Chart., page 45. Poorly mixed or filtered fluid. Remix or re-filter fluid. Fluid too thick. Reduce viscosity.
Troubleshooting Problem Cause Solution Gun does not spray Low fluid supply. Add fluid if necessary. Damaged spray tip. Replace; see Air Cap/Tip Guard, Spray Tip, and Fluid Seat Housing Replacement page 29. Dirty or clogged spray tip (3). Clean; see Clean the Spray Gun, page 20. Damaged fluid needle (2). Replace, see Fluid Needle Replacement page 31. Piston (11) not actuating. Check cylinder air. Check piston o-ring (11d); see Piston Repair, page 32. Actuator arm (15) is out of position.
Troubleshooting Electrical Troubleshooting Problem Cause Solution Poor wrap. Turbine air is not turned on. Turn on. Booth exhaust velocity is too high. Reduce velocity to within code limits. Atomization air pressure too high. Decrease. Fluid pressure too high. 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.
Repair Repair Prepare the Gun for Service Remove the Gun from the Manifold See FIGURE 20. 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. 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.
Repair Install the Gun on the Manifold See FIGURE 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. 5. To replace the electrode (25a), see Electrode Replacement, page 30.
Repair Fluid Tube Replacement 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. 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). 14.
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). 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 FIGURE 28. 8. Install the spring (5). 9.
Repair Piston Repair Table 3. Piston O-Rings Description 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 FIGURE 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 FIGURE 29. 7.
Repair Barrel Removal See FIGURE 31 1. Prepare the gun for service and remove the manifold, 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 FIGURE 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.
Repair 5. To separate the power supply (7) from the turbine (8), disconnect the 3-wire ribbon connector (PC) from the power supply. See FIGURE 32. 10. See Test Gun Resistance, page 22. 10 CS Smart models only: disconnect the 6–pin flexible circuit (30) from the power supply. 9◆ 8 Slide the turbine up and off the power supply. PC 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.
Repair coil (8a) so the bearing blades are flush with the surface of the coil. 6. Push the fan and coil assembly (8a) out the front of the housing (8d). WL E PC 8b2◆ M 8a 8g 8f◆ 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.
Parts Parts Standard Pro Xp Auto AA Gun Models HA1T10, Rear Manifold HA2T10, Bottom Manifold 1 Torque to 20 in-lbs (2 N•m) 1 HA2T10 36 333011B
Parts Standard Pro Xp Auto AA Gun Models HA1T10, Rear Manifold HA2T10, Bottom Manifold Ref. No. 1 2 3 3a 4 5 6 7 7a 8 8g■ 9■◆ 10 11 11a 11b 11c 11d 12 13 14 15 Part No.
Parts Smart Pro Xp Auto AA Gun Models HA1M10, Rear Manifold HA2M10, Bottom Manifold 1 Torque to 20 in-lbs (2 N•m) 1 HA2M10 38 333011B
Parts Smart Pro Xp Auto AA Gun Models HA1M10, Rear Manifold HA2M10, Bottom Manifold Ref. No. 1 2 3 3a 4 5 6 7 7a 8 8g■ 9■◆ 10 Part No.
Parts Air Cap Assembly Part No. 24N727 Air Cap Assembly 25b 25a 25c 25d Ref. No. 3a 25a 25b 40 Part No. Description Qty 183459 GASKET, tip (not shown) See page 5 36. 24N643 ELECTRODE, package of 5 1 24N734 O-RING; PTFE; package of 5 1 24E459 O-RING; PTFE; package of 10 1 Ref. No. 25c 25d Part No.
Parts Turbine Assembly Part No. 24N664 Turbine Assembly 8f◆ 8e◆ 8g* 8d◆ 8b1◆ 8a 8b2◆ 8h◆ WL E Ref. Part No. 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 333011B Qty 1 1 1 1 1 1 Ref. Part No. No.
Accessories Accessories Smart Model Accessories and Fiber Optic Cables Part No. 24W035 Description Pro Xp Auto Control Module. See 332989 for details. Air Line Accessories AirFlex™ Flexible Grounded Air Hose 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 15 ft (4.6 m) 244965 25 ft (7.
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 75 ft (23 m) 235074 100 ft (30.5 m) Bleed-Type Master Air Valve 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.
Dimensions Dimensions Rear Inlet Manifold 2.6 in (66 mm) 11 in (279 mm) 2.5 in (63 mm) 10.4 in (265 mm) 2.9 in (73 mm) 5.0 in (127 mm) 8.2 in (208 mm) 0.53 in(13.5 mm) 2x 1/4-20 UNC Bottom Inlet Manifold 2.6 in (66 mm) 2.5 in (623 mm) 5.8 in (147 mm) 11.0 in (279 mm) 2x 1/4-20 UNC .60 in (15.24 mm) 3x 5/16-18 UNC 8.0 in (202 mm) 1.05 in (26.67 mm) .90 in (22.86 mm) 1.80 in (45.
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. Fluid Output fl oz/min (l/min) Orifice Size in. (mm) at 600 psi at 1000 psi (4.1 MPa, (7.0 MPa, 41 bar) 70 bar) 0.007 (0.178) 4.0 (0.1) 5.2 (0.15) 0.009 (0.229) 7.0 (0.2) 0.011 (0.279) Maximum Pattern Width at 12 in. (305 mm) in.
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) Maximum Pattern Width at 12 in. (305 mm) in. (mm) at 600 psi (4.
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) Inlet/Outlet Sizes Turbine air inlet fitting, left-hand thread Atomizing air inlet fitting Fan air inlet fitting Cylinder air i
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.
