Instructions-Parts Pro Xp Auto Waterborne AA Spray Gun 333013B EN Air-assisted spray system for use when electrostatically spraying conductive, waterborne fluids that meet at least one of the following conditions for non-flammability: • Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206. • Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500 mJ. For professional use only.
Table of Contents List of Approved Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 How the Electrostatic AA Spray Gun Works . . . . . . . . . 7 Operating the Spray Function . . . . . . . . . . . . . . . . . . . . 7 Operating the Electrostatics . . . . . . . . . . . . . . . . . . . . . 7 Gun Features and Options . . . . .
List of Approved Models List of Approved Models Part No. HA1M18 HA1T18 kV 60 60 1.5mm Standard Nozzle Model ✔ ✔ ✔ Part No. 24X288 24W599 24W077 Smart Model ✔ Bottom Manifold Rear Manifold ✔ ✔ Description WB 3000 Isolation Enclosure 25’ Waterborne Fluid Hose 50’ Waterborne Fluid Hose FM approved for use with fluids that meet the following condition: • 0.
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 FIRE AND EXPLOSION HAZARD Combustible dust in work area can ignite or explode. To help prevent fire and explosion: • Use only fluids that meet the following flammability requirements: • Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206. • Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500 mJ.
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 5. The 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 Spraying Waterborne Fluids Electrostatically This electrostatic air spray gun is designed to spray only waterborne fluids which meet at least one of the following flammability requirements: FM, FMc Approved: • Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206. CE-EN 50059 Compliant: • Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500 mJ.
Introduction System Overview Typical Waterborne System Installation FIGURE 1 shows a typical electrostatic waterborne AA spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor. Also refer to system pneumatic connections in FIGURE 3, page 13. FIG.
Introduction Gun Overview K 1 B 2 CYL TA A1 A2 F J C EXH D A H G L Fig. 2.
Installation Installation System Requirements Install the System Basic Guidelines When spraying waterborne fluids electrostatically: • The gun must be connected to a voltage isolation system, which isolates the fluid supply from ground and allows voltage to be maintained at the tip of the gun. • The gun must be connected to a voltage isolation system that will discharge the system voltage when the gun is not in use.
Installation Install the Air Line Accessories 1. Install a bleed-type 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 main air supply line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction. 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. 4.
Installation FIGURE 3 shows a typical electrostatic air-assisted spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor. The turbine air supply (TA) must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on.
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 FIGURE 4. 20 NN 2.88 in. (73.2 mm) 29 8.18 in. (207.7 mm) To nozzle tip FIG.
Installation Manifold Connections 1 2 CYL TA A2 A1 EXH FIG. 5 Manifold Connection A1 Atomization Air Inlet Fitting Connect a 5/16” in. (8 mm) 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. CYL 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.
Installation Connect the Waterborne Fluid Hose NOTE: The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV. To reduce the risk of electric shock, the areas of the Graco Waterborne Fluid Hose that are accessible to personnel during normal operation must be covered by the black outer hose jacket. Always use a Graco Waterborne Fluid Hose between the voltage isolation system fluid outlet and the gun fluid inlet. 5.
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 Agitator Kit Accessory Grounding To add an agitator to the Graco isolation system, order Part No. 245895. See Agitator Kit 245895, page 56, for the kit parts list. 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.
Installation • 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. • 4.
Installation Install the Fabric Cover Check Fluid Viscosity See FIGURE 13. To check fluid viscosity you will need: 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 28. Strap down the exhaust tube to prevent it from moving around.
Operation Operation Operating Checklist 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 waterborne air spray system as instructed in this manual. All operators are trained in the Fluid Voltage Discharge and Grounding Procedure on page 22. All operators are trained in the Pressure Relief Procedure on page 22.
Operation Fluid Voltage Discharge and Grounding Procedure The fluid supply is charged with high voltage until the voltage is discharged. Contact with the charged components of the voltage isolation system or spray gun electrode will cause an electric shock.
Operation Install the Spray Tip 4. Remove the pail cover from the pail, holding a rag over the suction tube strainer to prevent any fluid from dripping into the isolated enclosure. Place the cover and suction tube outside the enclosure. To reduce the risk of an injury, follow the Pressure Relief Procedure before removing or installing the spray tip or air cap/tip guard. Install the spray tip as explained in Air Cap/Tip Guard, Spray Tip, and Fluid Seat Housing Replacement, page 39. 1.
Operation 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 34 to correct spray pattern problems. 7.
Operation 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 (P1). See FIGURE 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.
Maintenance Maintenance Flushing To reduce the risk of an injury, follow the Pressure Relief Procedure and the Fluid Voltage Discharge and Grounding Procedure before doing any maintenance on the gun or system. Daily Care and Cleaning Checklist • 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.
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.
Maintenance NOTICE Check for Fluid Leakage 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. 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. 7. Wipe off the parts with a dry cloth.
Electrical Tests Electrical Tests Use the following procedures to test the condition of the power supply and gun body, and electrical continuity between components. See Power Supply Removal and Replacement, page 43. Test Power Supply Resistance Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V. Connect the leads as shown. 2. Remove the turbine (8) from the power supply, page 44. 1. Remove the power supply (7), page 43. 3.
Electrical Tests 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.
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. Follow the Fluid Voltage Discharge and Grounding Procedure before checking or servicing the system and whenever you are instructed to discharge the voltage.
Troubleshooting Visual Checks First, check the system for any visible faults or errors to help isolate whether the spray gun, fluid hose or voltage isolation system has failed. A voltage probe and meter, part no. 245277, is helpful for diagnosing voltage problems and is required for some of the troubleshooting tests that follow. 1. Check that all of the air and fluid tubes and hoses are properly connected. 2. Check that the voltage isolation system valves and controls are properly set for operation. 3.
Troubleshooting Tests If you still have no voltage, separate the spray gun and hose from the voltage isolation system and check whether the gun and hose alone will hold voltage with the following test. 1. Flush the system with water and leave the lines filled with water. 2. Discharge the system voltage (see Fluid Voltage Discharge and Grounding Procedure, page 22.) down somewhere in the fluid hose or gun. Continue with step 12.
Troubleshooting Spray Pattern Troubleshooting NOTE: Some spray pattern problems are caused by the improper balance between air and fluid. Problem Cause Solution Fluttering or spitting spray. No fluid. Refill supply. Air in fluid supply. Check fluid source. Refill. Fluid buildup; partially plugged tip. Clean. See page 27. Worn/damaged tip or air cap holes. Clean or replace. Pattern pushed to one side; air cap gets dirty. Air cap holes plugged. Clean. See page 27. Tails in pattern.
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 59. 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 39. Dirty or clogged spray tip (3). Clean; see Clean the Spray Gun, page 27. Damaged fluid needle (2). Replace, see Fluid Needle Replacement, page 40. Piston (11) not actuating. Check cylinder air. Check piston o-ring (11d); see Piston Repair, page 41. 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 2. Flush and clean the gun, page 26. 3. Follow the Pressure Relief Procedure, page 22. 4. Remove the air cap (25) and shroud (26), page 39. 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. Contact with the charged components of the spray gun will cause an electric shock.
Repair Air Cap/Tip Guard, Spray Tip, and Fluid Seat Housing Replacement 1. See Prepare the Gun for Service, page 38. 2. Remove the retaining ring (24), shroud (26), and air cap/tip guard assembly (25). 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: 26 25 24 FIG. 26 Remove Air Cap 3. Disassemble the air cap assembly. Check the condition of the u-cup (24a), o-ring (25b), and tip gasket (3a).
Repair Fluid Needle Replacement 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. 1. Prepare the gun for service, page 38. 2. Remove the air cap/tip guard assembly and seat housing, page 39. 11. Orientate the air cap and tighten the retaining ring securely. 3. Remove the barrel (1), page 42. 12. See Test Gun Resistance, page 29. 4.
Repair 11a N 11d 11c 11f 11e 48 11b WL D 11d FIG. 31 Fluid Needle Removal 11g 11g 11f 11e Fan Air Side Atomizing Air Side FIG. 32 Fluid Needle Replacement FIG. 33 . Piston O-Rings Piston Repair 1. Prepare the gun for service, page 38. WL D Table 3. Piston O-Rings Description Function 2. Remove the air cap, page 39. Remove the gun shroud (26). Shaft O-Ring (11g) Seals cylinder air along the piston rod (34b). Replace if air leaks along rod. 3.
Repair Adjust the Actuator Arm Barrel Removal NOTE: The seat housing (4) must be in place when removing or installing the jam nut and actuator arm. See FIGURE 36 See FIGURE 34. 1. Prepare the gun for service and remove the gun from the manifold, page 38. 1. Install the adjustment nut (16b), actuator arm (15), and jam nut (16a) onto the piston rod (11b). 2. Remove the adjustment nuts (16a, 16b) and actuator arm (15). See FIGURE 34. 2. Position the parts so there is a 0.125 in.
Repair Barrel Installation Power Supply Removal and Replacement See FIGURE 36 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.
Repair 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 gun body. Smart models only: align the connector of the 6–pin flexible circuit (30) with the socket (CS) at the top of the gun body. See FIGURE 37. Push the connector securely into the socket as you slide the power supply/turbine assembly into the gun body.
Repair must face away from the magnet (M). Install in the 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). 8b2◆ M 8a 8g WL E 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.
Parts Parts Standard Pro Xp Auto Waterborne AA Gun Models HA1T18, Rear Manifold 1 Torque to 20 in-lbs (2 N•m) 1 46 333013B
Parts HA1T18, Rear Manifold Ref. No. 1 2 3 Part No.
Parts Smart Pro Xp Auto Waterborne AA Gun Models HA1M18, Rear Manifold 1 Torque to 20 in-lbs (2 N•m) 1 48 333013B
Parts HA1M18, Rear Manifold Ref. No. 1 2 3 Part No.
Parts Air Cap Assembly Waterborne Fluid Hose Part No. 24N727 Air Cap Assembly Part No. 24W599 Waterborne Fluid Hose 25b 25a 25c 25d Ref. No. 3a 25a 25b 25c 25d 50 Part No. Description Qty 183459 GASKET, tip (not shown) See 5 page 46. 24N643 ELECTRODE, package of 5 1 24N734 O-RING; PTFE; package of 5 1 (also available in package of 10; order 24E459) -----AIR CAP 1 24N726 GUARD, tip, orange 1 Ref. Part No. Description No. Qty 600 600a 1 1 HOSE, 25 ft (7.
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 333013B Qty 1 1 1 1 1 Ref. Part No. No.
Parts WB 3000 Isolation Enclosure Part No.
Parts Ref. Part No. No. 201 201a 202 203 204 205 206 207 209 210 Description Qty -----CABINET, enclosure; includes 201a 1 15A947 DOOR, cabinet 1 116993 CASTER, brake 4 PLATE 1 15A551 T-HANDLE, latch 1 15A545 STEM, handle, door 1 15A524 HOUSING, latch 1 113061 SWITCH, push, air 1 24N548 PUMP, diaphragm; sst; see 3A0732 1 -----SCREW, hex hd cap; 5/16–18 x 5.5 in. 2 (140 mm) 211 -----WASHER, plain; 0.344 in.
Parts Tubing and Wiring Detail Views of Control Box C9 A1 A2 C1 C2 B3 B4 B3 C2, C9 C1 C3, C4, C5 C8 A1 C6 C7 C8 C6 B2 E1 C3 Detail View of Door Interlock Switch B5 B2 54 333013B
Parts Tubing and Wiring Chart Use the diagrams to find the connection points for the tubing and wiring listed below Code Ref. Length Description No. in.(mm) Code Ref. Length Description No. in.
Parts Agitator Kit 245895 To keep fluid mixed and prevent settling out. Includes items 401-408. 401 407 402 1 2 406 403 Ref. Part No. Description No. Qty 401 112698 1 ELBOW, swivel; 1/8 npt(m) x 1/4 in. (6 mm) OD tube 402 114158 FITTING, adapter, Y; 1/4 in. (6 mm) OD tube; mxfxf 403 193315 COLLAR, mounting, agitator 404 193316 NUT, collar, agitator 405 197298 COVER, pail; 5 gal. (19 liter) 406 224571 AGITATOR; see manual 306565 407 purchase TUBE, nylon; 1/4 in. (6 mm) OD; 4 ft locally (1.
Accessories Accessories Smart Model Accessories and Fiber Optic Cables Fluid Line Accessories Part No. Description Waterborne Fluid Hose, 3000 psi Part No. Description 24W035 Pro Xp Auto Control Module. See 332989 for details. 24W599 24W077 Fiber Optic Cables for Gun See item V in FIGURE 9 on page 17. Connect gun manifold to Pro Xp Auto Control Module. See 332989. Part No. Description 24X003 24X004 24X005 Fiber Optic Cable, 25 ft (7.
Accessories Dimensions Rear Inlet Manifold 2.6 in (66 mm) 2.5 in (63 mm) 11.0 in (279 mm) 10.4 in (265 mm) 2.9 in (73 mm) 6.3 in (160 mm) 8.2 in (208 mm) 0.53in (13.
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 Waterborne AA Spray Gun Maximum fluid working pressure Maximum working air pressure Maximum fluid operating temperature Paint resistivity range Short circuit current output Gun Weight (Approximate) Voltage Output Standard Models Smart Models 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 inlet
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.
