Instructions - Parts WB100 Isolation System and Pro Xp™ 60 WB Gun 3A2496D EN Air spray system for use when electrostatically spraying conductive, waterborne fluids that meet at least non--flammability listed on page 3. one of the conditions for non For professional use only. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. 100 psi (0.7 MPa, 7.0 bar) Maximum Fluid Working Pressure 100 psi (0.7 MPa, 7.
Contents Models............................................................... 3 Models with FM Approval Only...................... 3 Models which are FM Approved and Compliant with EN50059................. 4 Warnings ........................................................... 5 Gun Overview .................................................... 8 How the Electrostatic Spray Gun Works ............................................ 8 Spraying Waterborne Fluids Electrostatically ..............................
Models Models Models with FM Approval Only FM approved for use with fluids that meet the following condition: • Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206. Part No. Model Description 24N580 WB100 Waterborne Isolation Enclosure 233825 with standard electrostatic air spray gun L60T17, grounded air hose 235070, and shielded waterborne fluid hose 24M732.
Models Models which are FM Approved and Compliant with EN50059 FM approved for use with fluids that meet the following condition: • Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206. 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 FIRE AND EXPLOSION HAZARD Combustible dust in work area can ignite or explode. To help prevent fire and explosion: • Fluids used must meet 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: • CE Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500mJ.
Warnings WARNING 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 eyewear, 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.
Gun Overview Gun Overview How the Electrostatic Spray Gun Works The air hose supplies air to the spray gun. Part of the air operates the alternator turbine and the rest of the air atomizes the fluid being sprayed. The alternator generates power, which is converted by the power cartridge to supply high voltage to the gun’s electrode. The pump supplies fluid to the fluid hose and gun, where the fluid is electrostatically charged as it passes the electrode.
Gun Overview Figure 1 Gun Overview Item Description Purpose Item Description Purpose A Air Swivel Inlet 1/4 npsm(m) left-hand thread, for Graco red-colored grounded air supply hose. G Atomizing Air Restrictor Valve Restricts air cap air flow. Replace with plug (included) if desired. H B Fluid Inlet Graco waterborne fluid supply hose Fluid Adjustment Knob C Turbine Air Exhaust Barbed fitting, for supplied exhaust tube. Adjusts fluid flow by limiting fluid needle travel.
Gun Overview Smart Guns The Smart Gun module displays spraying voltage, current, alternator speed, and the voltage setting (low or high). It also allows the user to change to a lower spraying voltage. The module has two modes: • Operating Mode • Diagnostic Mode Operating Mode Bar Graph See Fig. 2, and Table 1 on page 12. The Operating Mode displays gun data during normal spraying. The display uses a bar graph to show the voltage level in kiloVolts (kV) and the current level in microAmperes (uA).
Gun Overview Error Display If the Smart module loses communication with the power supply, the Error display appears, the Hz indicator turns red, and the Smart module is disabled. See Fig. 3, and Table 1 on page 12. This can occur in Operating Mode or Diagnostic Mode. See Electrical Troubleshooting, page 48. Communication must be restored to make the Smart module functional. NOTE: After 2 seconds of inactivity the display will return to the Operating Screen. NOTE: The low voltage setting may be locked.
Gun Overview Table 1 . Key for Figs. 2–9. Item Description Purpose VA Voltage Adjustment Switch Two-position switch sets smart gun voltage to low setting (LO) or high setting (HI). This switch is functional in Operating Mode and in Diagnostic Mode. LO Low Voltage Mode Indicator Lights (blue) when the smart gun is set to Low Voltage. kV Voltage (kV) Display Displays actual spraying voltage of the gun, in kV. In Operating Mode, display is a bar graph.
Gun Overview Item Description Purpose CI Current Indicator In Diagnostic Mode, the two bottom right LEDs of the screen light, indicating that the value displayed is in uA. See Fig. 7. AS Alternator Speed Display In Diagnostic Mode, Hz level is displayed as a number. See Fig. 8. Hz Alternator Speed Indicator In Operating Mode, indicator color varies to show the alternator speed status: • green indicates the alternator speed is at the correct level.
Gun Overview Diagnostic Mode Diagnostic Mode includes four screens which display gun data: • Voltage (kiloVolts) Screen • Current (microAmperes) Screen • Alternator Speed (Hertz) Screen • Low Voltage Lock Screen NOTE: You must be in Operating Mode to adjust the low voltage setting; the setting is not adjustable in Diagnostic Mode. However, the voltage adjustment switch (VA) can be set to HI or LO in Operating Mode and Diagnostic Mode.
Gun Overview Alternator Speed (Hertz) Screen Low Voltage Lock Screen The Alternator Speed (Hertz) Screen is the third screen in the Diagnostic Mode. See Fig. 8, and Table 1 on page 12. To enter this screen, press the LO SET button while in the Current (microAmperes) Screen. The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode. See Fig. 9, and Table 1 on page 12. To enter this screen, press the LO SET button while in the Alternator Speed (Hertz) Screen.
Installation Installation System Requirements Install the System A Graco voltage isolation system must have the following features: • An isolation enclosure that prevents persons from making contact with the high voltage components before the system voltage is discharged. All components of the isolation system that are charged to high voltage must be contained within the enclosure. • A bleed resistor to drain off the system voltage when the spray gun is not in use.
Installation Air Supply Line 1. See Fig. 19. Install an air line filter/water separator (M) 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. 2. The WB100 system includes a bleed-type air regulator (N) on the gun air supply line (P), to control air pressure to the gun.
Installation Connect the Waterborne Fluid Hose Always use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun fluid inlet. The waterborne fluid hose (101) consists of an inner PTFE tube (T) and an abrasion-resistant outer jacket (J). Shielded hose 24M732 also has a conductive layer (C), The conductive layer is connected to ground at the gun fitting bracket (104).
Installation 2. For the fluid hose to fit properly, it must be stripped and assembled to the dimensions shown in Fig. 12. Apply dielectric grease to the inner tube (T) of the hose. Slide the fitting (F) onto the tube (T). Press the barbed fitting (G) into the tube until its shoulder bottoms on the tube. A new Graco waterborne fluid hose comes fully assembled to these dimensions. NOTICE Be careful not to cut into the inner tube (T) of the hose when stripping the hose.
Installation 8. Connect the other end of the hose to the isolated fluid supply as follows: a. Graco WB100 Enclosure: Slide hose through the strain relief fitting (W). Ensure conductive layer (C) has passed through fitting. Tighten to 55 in-lb (6.2 N•m). Pull back on hose to check it is secure. Comply with the requirements in the Warning below. For Shielded Hose Systems: Conductive hose layer (C) must be grounded through its connection to the isolation system’s grounded enclosure (L) or grounded fence.
Installation b. Non-Graco Isolated Enclosure: Connect hose as instructed in the isolation system manual, and comply with the requirements in the Warning below. For Shielded Hose Systems: Conductive hose layer (C) must be grounded through its connection to the isolation system’s grounded enclosure (L) or grounded fence. To maintain grounding continuity, the conductive hose layer (C) must be engaged in the ferrule when the strain relief nut is tightened.
Installation Figure 19 Typical Installation, Pro Xp WB100 Waterborne System 22 3A2496D
Installation Typical Installation Key Item Description Item Description A Main Air Supply Line S B* Bleed-Type Air Shutoff Valve Waterborne Electrostatic Air Spray Gun C Pump Air Pressure Gauge T Grounding Rod U Ground Terminal V* Main Ground Wire W Strain Relief Fitting X Pump Air Supply Line Y Grounding Cylinder Z Pump Fluid Outlet Fitting AA Isolated Enclosure Door (not shown, to illustrate internal components. Door must be closed and locked to operate system).
Installation Agitator Kit Accessory To add an agitator to the Graco isolation system, order Part No. 245895. See 245895 Agitator Kit, page 94, for the kit parts list. 1. Discharge the system voltage (see Fluid Voltage Discharge and Grounding Procedure, page 30). 2. Relieve the pressure (see Pressure Relief Procedure, page 31). 3. Open the isolated enclosure door. 4. Remove the back of the control box (258). 5. Remove tube (A2) from elbow (282) at the air manifold; see Tubing and Wiring , page 77.
Installation Fluid Regulator Kit Accessory To add a fluid regulator to the Graco isolation system, order Part No. 245944. See 245944 Fluid Regulator Kit, page 95 for the kit parts list. 1. Discharge the system voltage (see Fluid Voltage Discharge and Grounding Procedure, page 30). 2. Relieve the pressure (see Pressure Relief Procedure, page 31). 3. Open the isolated enclosure door. holes used previously, to allow clearance for the fluid regulator. 12.
Gun Setup Gun Setup Select a Fluid Nozzle and Air Cap To reduce the risk of serious injury, including splashing fluid in the eyes or on the skin, follow the Pressure Relief Procedure, page 31, before removing or installing a fluid nozzle and/or air cap. NOTE: Standard and Smart Air Spray Guns are supplied with Part No. 24N616 Nozzle and 24N477 Air Cap. If you require a different size, see Air Caps and Fluid Nozzles, page 85, or consult with your Graco distributor.
Gun Setup • Object being sprayed: keep the workpiece hangers clean and grounded at all times. • 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. • All electrically conductive objects or devices in the spray area: must be properly grounded. • Fluid and waste containers: ground all fluid and waste containers in the spray area.
Gun Setup Check Gun Electrical Grounding 5. Make sure the red-colored grounded air hose (AH) is connected and the hose ground wire is connected to a true earth ground. Megohmmeter Part No. 241079 (AA-see Fig. 21) is not approved for use in a hazardous area.
Gun Setup 8. Using an ohmmeter (AA) measure the resistance between the cabinet ground lug (214) and a true earth ground (CC). The resistance must be less than 100 ohms. Figure 23 Check Cabinet Grounding 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.
Operation Operation Operating Checklist Fluid Voltage Discharge and Grounding Procedure Check the following list daily, before starting the system. ⃞ All operators are properly trained to safely operate an electrostatic waterborne air spray system as instructed in this manual. ⃞ All operators are trained in the Pressure Relief Procedure, page 31.
Operation Pressure Relief Procedure Fill the Fluid Supply 1. Follow the Fluid Voltage Discharge and Grounding Procedure, page 30. 2. Follow the Pressure Relief Procedure, page 31. 1. Turn OFF (O) the ES On/Off switch. 3. Open the isolated enclosure door. 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. 5. Remove the supply pail from the enclosure.
Operation Adjust the Spray Pattern Follow the steps below to establish the correct fluid flow and air flow. See Fig. 24 to locate the electrostatic gun controls. To reduce the risk of fire and explosion, fluids used must meet 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.
Operation 4. Position the air cap by loosening the air cap retaining ring, and rotating the air cap for a vertical or horizontal spray pattern. Tighten the retaining ring until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand. 5. Fully open the fan air adjustment valve (F) counterclockwise. 6. Fully open the fluid adjustment valve (H) counterclockwise. 8. Make sure the ES On-Off switch (J) is OFF (O). 9.
Operation 11. Spray a test pattern. Check the atomization. If over-atomization occurs at minimum pressure, adjust the restrictor valve. If atomization is inadequate, increase air pressure or decrease fluid flow. 14. Check that the ES indicator (Hz indicator on Smart guns) is lit, or check that the kV indicator on the isolated enclosure reads 45–55 kV. See the following table. Table 3 . LED Indicator Colors Indicator Color 12.
Operation Shutdown 1. Discharge the system voltage, see Fluid Voltage Discharge and Grounding Procedure, page 30. 4. Hang the gun from its hook, with the nozzle pointing down. Be sure to keep the gun from grounding out. 2. Flush the gun, see Flushing, page 36 3. Follow the Pressure Relief Procedure, page 31.
Maintenance Maintenance Flushing • Flush before changing fluids, before fluid can dry in the equipment, at the end of the day, before storing, and before repairing equipment. 3. Follow the Pressure Relief Procedure, page 31. • Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary. 4. Change the fluid source to solvent. To reduce the risk of fire, explosion, or electric shock, turn OFF (O) the ES On-Off switch before flushing the gun.
Maintenance Clean the Gun Daily 1. Turn OFF (O) the ES On-Off switch. 2. Flush the gun. See Flushing, page 36. 3. Follow the Pressure Relief Procedure, page 31. 5. Remove the air cap. 6. Clean the air cap, retaining ring, and nozzle with a soft brush and non-flammable solvent. 4. Clean the outside of the gun with a non-flammable solvent, as defined under Flushing, page 36. Use a soft cloth. Point the gun down to prevent solvent from entering the gun passages. Do not immerse the gun. 7.
Maintenance Daily System Care 1. Follow the Pressure Relief Procedure, page 31. 2. Clean the fluid and air filters. 3. Check for fluid leaks. Tighten all fittings. 8. Clean the cabinet: • Inspect the cabinet and clean up any spilled paint. Conductive paint residue allowed to contact grounded parts may short out the electrostatics. • Keep the inside of the cabinet clean, for proper operation. • Inspect the door T-handle locking screw regularly, to ensure the threads are well greased.
Electrical Tests Electrical Tests Use the following procedures to test the condition of the power supply and gun body, and electrical continuity between components. Power Supply Removal and Replacement, page 59. Test Gun Resistance Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V. Connect the leads as shown. 2. Trigger the gun and measure resistance between the electrode needle tip (3) and the air swivel (21).
Electrical Tests Test Power Supply Resistance 1. Follow the steps under Prepare the Gun for Service, page 50. 2. Remove the power supply (11). 3. Remove the turbine alternator (15) from the power supply. 4. Measure resistance from the power supply's ground strips (EE) to the spring (11a). The resistance should be 90–115 megohms. If outside this range, replace the power supply. If in range, go to Test Electrode Resistance, page 41. 5.
Electrical Tests Test Electrode Resistance 1. Follow the steps under Prepare the Gun for Service, page 50. 2. Insert a conductive rod (FF) into the gun barrel (which was removed for the power supply test) and against the metal contact (DD) in the front of the barrel. 3. Measure the resistance between the conductive rod (FF) and the electrode (3). The resistance should be 10–30 megohms (less than 5 megohms for Model L60M19). 4.
Electrical Tests Test Ground Strip Resistance Test Cylinder Resistance Using an ohmmeter, measure the resistance between the latch housing (206) and the ground lug (214). The ground strip is grounded through the cart back to the ground lug. Resistance must be less than 100 ohms. If greater than 100 ohms, replace the ground strip (240). Remove the enclosure door. Using an ohmmeter, measure the resistance from the pump (209) to the ground lug (214). Resistance must be less than 100 ohms.
Troubleshooting Troubleshooting are electrically connected through the conductive, waterborne fluid. 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, page 30 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 30). 3. Follow the Pressure Relief Procedure, page 31.
Troubleshooting Spray Pattern Troubleshooting Check all possible remedies in the Troubleshooting Chart before disassembling the gun. 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. Loose, dirty, damaged nozzle/seat. Clean or replace nozzle, see Clean the Gun Daily, page 37, or Air Cap and Nozzle Replacement, page 51. Air in fluid supply. Check fluid source. Refill.
Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Excessive spray fog. Atomizing air pressure too high. Close restrictor valve part way, or decrease air pressure as low as possible; minimum 45 psi (0.32 MPa, 3.2 bar) needed at gun for full voltage. Fluid too thin, or fluid flow is too low. Increase viscosity or increase fluid flow rate. Atomizing air pressure too low. Open atomizing air valve more or increase gun air inlet pressure; use lowest air pressure necessary.
Troubleshooting Electrical Troubleshooting Problem Cause Solution Voltage still present at gun after following the Fluid Voltage Discharge and Grounding Procedure, page 30. ES On/Off switch is not turned OFF (O). Turn OFF (O). Did not wait long enough for voltage to discharge. Wait longer before touching electrode with grounding rod. Check for bleed resistor failure. Air pocket in fluid line leaves fluid near gun isolated. Determine cause and correct. Purge air from fluid line.
Troubleshooting Problem Cause Solution Operator gets mild shock. Operator not grounded or is near ungrounded object. See Grounding, page 26. Gun not grounded. See Check Gun Electrical Grounding, page 28, and Test Gun Resistance, page 39. A weak static charge has built up on the surface of an unshielded fluid hose. This is a charge on the hose surface, not a failure of the hose insulation. Bundle and wrap the air and fluid hoses together. See Connect the Waterborne Fluid Hose, page 18.
Repair Repair Prepare the Gun for Service • Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate. To reduce the risk of fire, explosion, or electric shock:, before flushing the gun. • Only use genuine Graco parts. Do not mix or use parts from other Pro Gun models.
Repair Air Cap and Nozzle Replacement NOTICE Trigger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from entering the air passages. 7. Install the air cap (5) and retaining ring (6). Make sure the u-cup (6a*) is in place with the lips facing forward. 8. See Test Gun Resistance, page 39. 1. See Prepare the Gun for Service, page 50. 2. Remove the retaining ring (6) and air cap (5). 3.
Repair Air Cap, Spray Tip, and Nozzle Replacement (Model L60M19) 1. See Prepare the Gun for Service, page 50. 2. Remove the retainer ring (6) and air cap/tip guard assembly (5). 4. To replace the electrode (5a), pull the it out of the back of the air cap, using a needle-nose pliers. Push the new electrode through the air cap hole. Make sure the short end of the electrode engages the hole in the back of the air cap. Press the electrode in place firmly with your fingers.
Repair NOTICE Do not overtighten the nozzle (4). Overtightening may damage the housing and the gun barrel, resulting in improper fluid shutoff. 6. Ensure that the o-rings (4a, 4b, and 9) are in place on the nozzle. Trigger the gun and install the nozzle (4). Tighten until snug, then 1/4 turn more. 7. Check that the spray tip gasket (10a) is in place. Align the spray tip tab with the groove in the air cap (5). Install the spray tip (10) in the air cap. 8.
Repair Electrode Replacement 1. See Prepare the Gun for Service, page 50. 2. Remove the air cap and nozzle. See Air Cap and Nozzle Replacement, page 51. 3. Unscrew the electrode (3) with the multi-tool (41). NOTICE To avoid damaging the plastic threads, be very careful when installing the electrode. 4. Apply low-strength (purple) Loctite® or equivalent thread sealant to the electrode and packing rod threads. Install the electrode finger-tight. Do not overtighten. 5. Install the fluid nozzle and air cap.
Repair Needle Replacement (Model L60M19) 1. See Prepare the Gun for Service, page 50. 2. Remove the air cap and nozzle. See Air Cap, Spray Tip, and Nozzle Replacement (Model L60M19), page 52. 3. Unscrew the needle (3). 4. Apply low-strength (purple) Loctite® or equivalent thread sealant to the needle and packing rod threads. Install the needle finger-tight. Do not overtighten. 5. Install the fluid nozzle and air cap. See Air Cap, Spray Tip, and Nozzle Replacement (Model L60M19), page 52. 6.
Repair Fluid Packing Rod Removal 1. See Prepare the Gun for Service, page 50. 2. Remove the air cap and fluid nozzle. See Air Cap and Nozzle Replacement, page 51. 3. Remove the electrode. See Electrode Replacement, page 54. 4. Loosen the trigger screws (13) and remove the trigger (12). 5. Remove the packing rod (2), using the multi-tool (41). Remove the spring (17). 6. Check all parts for wear or damage and replace if necessary.
Repair Packing Rod Repair NOTE: You may replace the packing rod as individual parts or as an assembly. NOTE: Before installing the fluid packing rod into the gun barrel, make sure the internal surfaces of the barrel are clean. Remove any residue with a soft brush or cloth. Check the inside of the barrel for marks from high voltage arcing. If marks are present, replace the barrel. 1. Place the packing nut (2f) and seal (2b‡) on the fluid rod (2e).
Repair Barrel Removal Barrel Installation 1. See Prepare the Gun for Service, page 50. 1. Be sure the gasket (28*) and grounding spring (18) are in place. Make sure the gasket air holes are aligned properly. Replace the gasket if damaged. 2. Remove the air inlet fitting (21) and take the bracket (104) off the gun handle (16). 3. Loosen the two screws (27). NOTICE To avoid damaging the power supply (11), pull the gun barrel (1) straight away from the gun handle (16).
Repair 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 (28) to solvents. 1. See Prepare the Gun for Service, page 50. 2. See Barrel Removal, page 58. (EE) make contact with the handle. On Smart models, align the connector of the 6–pin flexible circuit (24) with the socket (CS) at the top of the handle.
Repair Alternator Removal and Replacement NOTE: Replace alternator bearings after 2000 hours of operation. Order Part No. 24N706 Bearing Kit. Parts included in the kit are marked with a symbol (♦). 1. See Prepare the Gun for Service, page 50. 2. Remove the power supply/alternator assembly and disconnect the alternator. See Power Supply Removal and Replacement, page 59. 3. Measure resistance between the two outer terminals of the 3-wire connector (PC); it should be 2.0–6.0 ohms.
Repair 12. Hold the coil assembly (15a) on a workbench with the fan end facing up. Press the fan (15e♦) onto the long end of the shaft (S). The fan blades must be oriented as shown. 13. Carefully press the coil assembly (15a) into the front of the housing (15d♦). The 3–wire connector (PC) must be positioned below the wider notch (W) of the housing tabs, as shown in Fig. 46. Be sure the coil alignment pins (P) are positioned as shown in Fig. 45. 14.
Repair Fan Air Adjustment Valve Repair 1. See Prepare the Gun for Service, page 50. 2. Place a wrench on the flats of the valve housing (30a) and unscrew the valve from the handle (16). NOTE: You may replace the valve as an assembly (go to step 9) or replace only the o-ring (steps 3–9). 8. Reassemble the retaining ring (30d). Unscrew the valve stem from the housing until it is stopped by the retaining ring. 9.
Repair Atomizing Air Restrictor Valve Repair 1. See Prepare the Gun for Service, page 50. 2. Place a wrench on the flats of the valve housing (29a) and unscrew the valve from the handle (16). NOTE: You may replace the valve as an assembly (go to step 9) or replace only the o-ring (steps 3–9). 3. Unscrew the valve stem (29e). Remove the retaining ring (29d). 4. Turn the valve body (29b) counterclockwise until it comes free from the valve housing (29a). Figure 49 Atomizing Air Restrictor Valve 5.
Repair On--Off and Fluid Adjustment Valve Repair ES On 1. See Prepare the Gun for Service, page 50. 2. Loosen the captive screw (26p). Remove the valve (26) from the handle. 3. Lubricate the o-rings (26b* and 26m*) with non-silicone grease, Part No. 111265. Do not over-lubricate. NOTE: Do not over-lubricate parts. Excessive lubricant on the o-rings can be pushed into the gun air passage and blemish the finish on the workpiece. 4. Clean and inspect parts for damage. Replace if necessary.
Repair Air Valve Repair 1. See Prepare the Gun for Service, page 50. 2. See Barrel Removal, page 58. 8. Install the air valve (23) and spring (34) into the gun handle (16). 3. Remove the screws (13) and trigger (12). 9. Install the ES On-Off Valve. See ES On-Off and Fluid Adjustment Valve Repair, page 64. 4. Remove the ES On-Off Valve. See ES On-Off and Fluid Adjustment Valve Repair, page 64. 10. Install the trigger (12) and screws (13). 5. Remove the spring (34). 11.
Repair Smart Module Replacement If the Error display appears, the Smart Module has lost communication with the power supply. Check for good connections between the Smart Module and the power supply. If the module’s LEDs are not lighting, replace the module. 1. See Prepare the Gun for Service, page 50. 2. Remove the pivot screw (31e), o-ring (31f), and ES HI/LO switch (31c) at the bottom left corner of the Smart Module cartridge (31a). 3. Remove the remaining three screws (31d) from the cartridge. 4.
Repair Air Swivel and Exhaust Valve Replacement a. Unscrew the swivel (21) from the gun handle (16). The swivel is a left-hand thread. 1. See Prepare the Gun for Service, page 50. b. Apply thread sealant to the top threads of the swivel. Screw the swivel into the gun handle. Torque to 75–85 in-lb (8.4–9.6 N•m). 2. To replace the air exhaust valve: a. Remove the clamp (43) and the exhaust tube (36). b. Unscrew the swivel (21) from the gun handle (16). The swivel is a left-hand thread.
Parts Parts Standard Waterborne Air Spray Gun Assembly Part No. L60T17 60 kV Electrostatic Waterborne Air Spray Gun, Series A includes items 1–48 Part No. L60T18 60 kV Electrostatic Waterborne Air Spray Gun, Series A includes items 1–48 Part No. 24M732 Shielded Waterborne Fluid Hose (101), sold separately for gun model L60T17 Part No.
Parts Part No. L60T17 60 kV Electrostatic Waterborne Air Spray Gun, Series A includes items 1–48 Part No. L60T18 60 kV Electrostatic Waterborne Air Spray Gun, Series A includes items 1–48 Part No. 24M732 Shielded Waterborne Fluid Hose (101), sold separately for gun model L60T17, Part No. 24M733 Unshielded Waterborne Fluid Hose (101), sold separately for gun model L60T18, Ref. No. 1 Part No. Description Qty 24N667 BODY, gun 1 2 24N655 See Packing Rod Assembly, 1 page 79 Ref. No. 34 Part No.
Parts Smart Waterborne Air Spray Gun Assembly Part No. L60M17 60 kV Electrostatic Waterborne Air Spray Gun, Series A Part No. L60M18 60 kV Electrostatic Waterborne Air Spray Gun, Series A Part No. 24M732 Shielded Waterborne Fluid Hose (101), sold separately for gun model L60M17, Part No.
Parts Part No. L60M17 60 kV Electrostatic Waterborne Air Spray Gun, Series A Part No. L60M18 60 kV Electrostatic Waterborne Air Spray Gun, Series A Part No. 24M732 Shielded Waterborne Fluid Hose (101), sold separately for gun model L60M17, Part No. 24M733 Unshielded Waterborne Fluid Hose (101), sold separately for gun model L60M18, Ref. No. 1 Part No. Description Qty 24N667 BODY, gun 1 2 24N655 See Packing Rod Assembly, 1 page 79 Ref. No. 31 Part No.
Parts Mold Release Smart Air Spray Gun Assembly Part No. L60M19 60 kV Electrostatic Mold Release Air Spray Gun, Series A Part No.
Parts Part No. L60M19 60 kV Electrostatic Mold Release Air Spray Gun, Series A Part No. 24M733 Unshielded Waterborne Fluid Hose (101), sold separately, Ref. No. 1 Part No. Description Qty Ref. No. 28* Part No.
Parts Isolation Enclosure Part No. 233825 Waterborne Isolation Enclosure, for use with shielded waterborne fluid hose Part No.
Parts Ref. No. 201 Part No. Description Qty ——— 1 201a 15A947 CABINET, enclosure; includes 201a DOOR, cabinet 1 202 116993 CASTER, brake 4 203 15A660 PLATE 1 204 15A551 T-HANDLE, latch 1 205 15A545 STEM, handle, door 1 206 15A524 HOUSING, latch 1 207 113061 SWITCH, push, air 1 208 ——— A/R 209 233501 Ref. No. 238 Part No. Description Qty 114958 STRAP, tie 3 239 222011 GROUND WIRE; 25 ft (7.
Parts Ref. No. 279 Part No. Description Qty 113319 2 280 ——— CONNECTOR, tube; 1/4 npt x 3/8 in. (10 mm) OD tube ELBOW, tube 281 ——— 1 282 ——— 283 ——— 285 112791 FITTING, tube; 1/8 npt x 5/32 in. (4 mm) OD tube SWIVEL, tube; 1/4 npt x 1/4 in. (6 mm) OD tube SWIVEL, tube; 1/8 npt x 5/32 in. (4 mm) OD tube CLAMP 286 ——— TUBE; 3/8 in. (10 mm) OD A/R 1 4 2 1 ▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.
Parts Tubing and Wiring Detail Views of Control Box 3A2496D Detail View of Door Interlock Switch 77
Parts Tubing and Wiring Chart Use the diagrams to find the connection points for the tubing and wiring listed below. Code Ref. No. Length in.
Parts Packing Rod Assembly Part No. 24N655 Packing Rod Assembly Includes items 2a-2k Ref. No. Part No. Description Qty Ref. No. Part No.
Parts Alternator Assembly Part No. 24N664 Alternator Assembly Ref. No. Part No. Description Qty Ref. No. Part No.
Parts On--Off and Fluid Adjustment Valve ES On Part No. 24N630 ES On-Off and Fluid Adjustment Valve Ref. No. Part No. Description Qty Ref. No. Part No.
Parts Fan Air Adjustment Valve Assembly Part No. 24N634 Fan Air Adjustment Valve Assembly (shown) Ref. No. Part No. Description Qty 30a ——— NUT, valve 1 30b ——— STEM, valve 1 30c* 111504 O-RING 1 30d 24N646 RING, retaining; package of 6 1 * These parts are included in Air Seal Repair Kit 24N789 (purchase separately). Parts labeled — — — are not available separately. Atomizing Air Restrictor Valve Assembly Part No. 24T304 Atomizing Air Restrictor Valve Assembly (shown) Ref. No.
Parts Air Cap Assembly Part No. 24N727 Air Cap Assembly Ref. No. Part No. Description Qty 5a 24N643 ELECTRODE; package of 5 1 5b 24N734 O-RING; ptfe; package of 5 (also available in package of 10; order 24E459) 1 5c ——— AIR CAP 1 5d 24N726 GUARD, tip, orange 1 Parts labeled — — — are not available separately.
Parts Smart Module Assembly Part No. 24N756 Smart Module Assembly Ref. No. Part No. Description Qty 31a ——— CARTRIDGE 1 31b 24P433 GASKET 1 31c 24N787 SWITCH, ES HI/LO 1 31d♦ ——— SCREW 3 31e♦ ——— SCREW, pivot 1 31f 112319 O-RING 1 Parts labeled — — — are not available separately. ♦ These parts are included in Smart Module Screw Kit 24N757 (purchase separately).
Air Caps and Fluid Nozzles Air Caps and Fluid Nozzles Fluid Nozzle Performance Charts Fluid Nozzle Selection Chart Use the following procedure to select the proper fluid nozzle for your application. NOTE: For Model L60M19 Mold Release Gun, only use Part No. 24N748 Nozzle. See Mold Release Smart Air Spray Gun Assembly, page 72. 1. For each fluid nozzle chart, find the point on the graph corresponding to your desired flow rate and viscosity. Mark the point on each graph with a pencil.
Air Caps and Fluid Nozzles Table 4 . Orifice Size: 0.75 mm (0.030 in.) Table 7 . Orifice Size: 1.5 mm (0.059 in.) FLUID PRESSURE: FLUID PRESSURE: bar, psi bar, psi FLUID FLOW: FLUID FLOW: oz/min, cc/min oz/min, cc/min Table 5 . Orifice Size: 1.0 mm (0.040 in.) Table 8 . Orifice Size: 1.8 mm (0.070 in.) FLUID PRESSURE: FLUID PRESSURE: bar, psi bar, psi FLUID FLOW: FLUID FLOW: oz/min, cc/min oz/min, cc/min Table 9 . Orifice Size: 2.0 mm (0.080 in.) Table 6 . Orifice Size: 1.2 mm (0.047 in.
Air Caps and Fluid Nozzles Air Cap Selection Chart NOTE: For Model L60M19 Mold Release Gun, only use Part No. 24N727 Air Cap. See Mold Release Smart Air Spray Gun Assembly, page 72. NOTE: All air cap pattern shapes and lengths in the following chart were measured under the following conditions. Pattern shape and length are material dependent. • Distance to target: 10 in. (254 mm) • Inlet air pressure: 50 psi (34 kPa, 3.
Air Caps and Fluid Nozzles Air Consumption Charts Key to Air Consumption Charts TEST CONDITIONS: Fan valve fully open; 85 kV gun. 5/16 in. x 25 ft (8 mm x 7.6 m) hose 5/16 in. x 50 ft (8 mm x 15.2 m) hose Table 10 . 24N438 Air Cap Table 12 . 24N439 Air Cap AIR CONSUMPTION AIR CONSUMPTION scfm scfm WALL PRESSURE WALL PRESSURE psi psi Table 11 . 24N376, 24N276, 24N277, and 24N278 Air Caps Table 13 .
Air Caps and Fluid Nozzles Table 14 . 24N274 Air Cap Table 16 . 24N453 Air Cap AIR CONSUMPTION AIR CONSUMPTION scfm scfm WALL PRESSURE WALL PRESSURE psi psi Table 15 . 24N275 Air Cap Table 17 .
Spray Tip Selection Chart (Model L60M19 MRG Gun Only) Spray Tip Selection Chart (Model L60M19 MRG Gun Only) AEM Fine Finish Spray Tips NOTE: for use with Model L60M19 MRG Gun only. 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) Fluid Output fl oz/min (l/min) at 1000 at 600 psi (4.1 psi (7.0 MPa, MPa, 41 bar) 70 bar) † 0.007 4.0 (0.178) (0.1) † 0.009 7.0 (0.229) (0.
Spray Tip Selection Chart (Model L60M19 MRG Gun Only) Pre--Orifice Spray AEF Fine Finish Pre Tips NOTE: for use with Model L60M19 MRG Gun only. 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. Orifice Size in. (mm) Maximum Pattern Width at 12 in. (305 mm) in.
Repair Kits, Related Manuals, and Accessories Repair Kits, Related Manuals, and Accessories Gun Part No. Description Manual Description Repair Kits Repair Kit Description All guns in this manual. 60 kV Waterborne Air Spray Guns 60 kV Mold Release Air Spray Guns Electrostatic Waterborne Air Spray Guns, Instructions-Parts 24N789 Air Seal Repair Kit 24N790 Fluid Seal Repair Kit 24N706 Alternator Bearing Repair Kit Gun Accessories Part No. Description Part No.
Repair Kits, Related Manuals, and Accessories Operator Accessories Test Equipment Part No. Description Part No. Description 117823 Conductive Gloves, box of 12 (small) 241079 117824 Conductive Gloves, box of 12 (medium) Megohmmeter. 500 V output, 0.01–2000 megohms. Use for ground continuity and gun resistance Not for use in hazardous areas. tests.Not 117825 Conductive Gloves, box of 12 (large) 245277 24N520 Comfort Grip. Snap-on grip increases handle size to reduce operator fatigue.
Repair Kits, Related Manuals, and Accessories 245895 Agitator Kit To keep fluid mixed and prevent settling out. Includes items 401–408. 94 Ref. No. Part No. Description Qty 401 112698 ELBOW, swivel; 1/8 npt(m) x 1/4 in. (6 mm) OD tube 1 402 114158 FITTING, adapter, Y; 1/4 in. (6 mm) OD tube; mxfxf 1 403 193315 COLLAR, mounting, agitator 1 404 193316 NUT, collar, agitator 1 405 197298 COVER, pail; 5 gal.
Repair Kits, Related Manuals, and Accessories 245944 Fluid Regulator Kit To allow precise fluid pressure regulation at the gun. Includes items 501–507. 3A2496D Ref. No. Part No. Description Qty 501 110078 FITTING, tube, fluid; 1/4 npt(m) x 3/8 in. (10 mm) tube 1 502 113070 NIPPLE, reducer; 3/8 npt x 1/4 npt 1 503 113576 PLUG; 1/4 npt 1 504 236281 REGULATOR, fluid; see manual 308325 1 505 C20350 ELBOW, 90°; 1/4 npt(f) x 1/4 in.
Dimensions Dimensions Gun Model A, in. (mm) B, in. (mm) C, in. (mm) Weight without bracket, oz (g) L60T17 10.5 (267) 8.9 (226) 2.4 (61) 21.7 (617) L60T18 10.5 (267) 8.9 (226) 2.4 (61) 21.7 (617) L60M18 10.5 (267) 9.6 (244) 2.4 (61) 24.2 (687) L60M19 10.8 (274) 9.7 (246) 2.4 (61) 22.
Technical Data Technical Data Electrostatic Air Spray Waterborne Guns U.S. Metric Maximum Working Fluid Pressure 100 psi 0.7 MPa, 7.0 bar Maximum Working Air Pressure 100 psi 0.7 MPa, 7.0 bar Minimum Air Pressure at Gun Inlet 45 psi 0.32 MPa, 3.2 bar Maximum Fluid Operating Temperature 120°F 48°C Short Circuit Current Output Voltage Output Energy 125 microamperes 0.35 J with fluid hose 24M733 installed.
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.
