Graco Pro Xp H60T10 Instructions Manual

Electrostatic air-assisted spray gun

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Instructions - Parts

Pro Xp™

Xp™ Electrostatic

Electrostatic

Pro

Xp™

Electrostatic

Air

Air - - - Assisted

Assisted Spray

Assisted

For use

use in in in Class

Class I, I, I, Div.

Div. I I I Hazardous

For

use

Class

Div.

For

For use

use in in in Group

use

Group II, II, II, Zone

Group

Zone 1 1 1 Explosive

Zone

use only.

only.

use

only.

Important

Important Safety

Important

Safety

Safety Instructions

This equipment could present hazards if not operated according to

the information in this manual. Read

this manual

manual before

before using

this

manual

before

3000 psi (21 MPa, 210 bar) Maximum

Fluid Working Pressure

100 psi (0.7 MPa, 7 bar) Maximum Air

Working Pressure

See page 3 for model part numbers and

approval information.

Spray Gun

Spray

Gun

Hazardous Locations

Locations using

Hazardous

Locations

Explosive Atmosphere

Explosive

Atmosphere Locations

Atmosphere

Instructions

Read all all all warnings

warnings and

Read

warnings

using the

the equipment.

equipment. Save

using

the

equipment.

PROVEN QUALITY. LEADING TECHNOLOGY.

using Group

Group D D D materials.

materials.

using

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Locations using

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and

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Save these

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instructions.

Save

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Group IIA

Group

IIA materials.

IIA

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For

3A2495K

professional

Table of Contents

Troubleshooting

Summary of Contents for Graco Pro Xp H60T10

Page 1 Instructions - Parts Pro Xp™ Xp™ Electrostatic Electrostatic Xp™ Electrostatic 3A2495K Air - - - Assisted Assisted Spray Assisted Spray Spray Gun For use use in in in Class Class I, I, I, Div. Div. I I I Hazardous Hazardous Locations Locations using using Group Group D D D materials.
Page 2: Table Of Contents
Electrical Troubleshooting ......37 Hoses ............67 Repair..............39 Dimensions ............68 Prepare the Gun for Service ......39 Technical Specifications........69 Air Cap, Spray Tip, and Fluid Seat Housing Replacement ........40 Graco Pro Xp Warranty ........70 3A2495K...
Page 3: Models
Models Models Models Models Part Part Part No. Display Display Display H60T10 Standard H60M10 Smart H85T10 Standard H85M10 Smart H85T57* Standard H85M57* Smart * High Air Flow Gun Models, equipped with ES On-Off with Air Restrictor Valve, which limits air flow to the turbine.
Page 4: Warnings
• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to Grounding instructions. spray area. Resistance must not exceed 1 megohm. See Grounding Grounding • Only use grounded Graco conductive air supply hoses. • Do not use pail liners unless they are conductive and grounded. Stop operation operation immediately immediately if static sparking occurs or you feel a shock.
Page 5 Warnings WARNING WARNING WARNING SKIN SKIN SKIN INJECTION INJECTION INJECTION HAZARD HAZARD HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get Get immediate immediate surgical immediate...
Page 6 Warnings WARNING WARNING WARNING EQUIPMENT EQUIPMENT EQUIPMENT MISUSE MISUSE HAZARD MISUSE HAZARD HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated Technical Specifications Specifications in all equipment manuals.
Page 7: Gun Overview
Gun Overview Gun Overview Overview Overview How the the Electrostatic Electrostatic AA AA Spray Spray Gun Electrostatic Spray alternator generates power, which is converted by the power cartridge to supply high voltage to the Works Works Works gun’s electrode. The fluid is electrostatically charged as it passes the electrode.
Page 8: Controls, Indicators, And Components
Description Description Purpose Purpose Purpose Air Swivel Inlet 1/4 npsm(m) left-hand thread, for Graco grounded air supply hose. Fluid Inlet 1/4 npsm(m), for fluid supply hose. Turbine Air Exhaust Barbed fitting, for supplied exhaust tube. Air Cap/Tip Guard and Spray Tip Selection Chart, page 61, for available sizes.
Page 9: Smart Guns
Gun Overview Smart Guns Guns Smart Smart Guns Voltage Adjustment Adjustment Switch Switch Voltage Voltage Adjustment Switch 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 The voltage adjustment switch (VA) allows the spraying voltage.
Page 10 Gun Overview Error Error Error Display Display Display for your gun. Continue pressing the button until you reach the desired setting. If the Smart module loses communication with NOTE: NOTE: After 2 seconds of inactivity the display will NOTE: the power supply, the Error display appears, the return to the Operating Screen.
Page 11 Gun Overview Smart Smart Smart Gun Gun Key Table Table 1 1 1 Key Table Key for for Figs. Figs. Figs. 2–9. 2–9. 2–9. Item Item Item Description Description Description Purpose Purpose Purpose Voltage Adjustment Switch Two-position switch sets Smart gun voltage to low setting (LO) or high setting (HI).
Page 12 Gun Overview Diagnostic Diagnostic Diagnostic Mode Mode 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: NOTE: NOTE: You must be in Operating Mode to adjust the low voltage setting;...
Page 13 Gun Overview Alternator Alternator Alternator Speed Speed (Hertz) Speed (Hertz) (Hertz) Screen Screen Screen Low Voltage Voltage Lock Voltage Lock Screen Lock Screen Screen The Alternator Speed (Hertz) Screen is the third The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode.
Page 14: Installation
NOTE: The minimum allowable air exhaust Graco distributor. velocity is 60 feet/minute (19 linear meters/minute). High-velocity air exhaust will decrease the operating efficiency of the electrostatic system.
Page 15: Air Supply Line
1. See Fig. 10. Use the Graco Grounded Air Supply the air regulator is shut off. Hose (AH) to supply air to the gun. The gun air inlet fitting has a left-hand thread.
Page 16: Fluid Supply Line
Description Description Air Filter/Water Separator Fluid Shutoff Valve Gun Air Hose Ground Wire Gun Air Pressure Regulator Graco Grounded Air Hose (left-hand Main Air Supply Line threads) Pump Ground Wire Pump Air Line Lubricator Pump Air Pressure Regulator Pump Bleed-Type Air Shutoff Valve...
Page 17: Grounding
If gloves are necessary, wear the conductive gloves supplied with the gun. If non-Graco gloves are worn, cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle. Conductive gloves and footwear must not exceed 100 megohm per EN ISO 20344, EN 1149–5.
Page 18 Installation plastic containers. Do not store more than the quantity needed for one shift. All solvent pails: • Use only approved, grounded metal containers, which are conductive. Do not use plastic containers. Use only non-flammable • Flammable liquids in the spray area: must be kept solvents.
Page 19 Installation Figure 11 Ground the Operator Operator is grounded through the gun handle and conductive shoes. Figure 12 Ground the Object being Sprayed Object being sprayed is grounded through contact with the hanger and conveyor system. 3A2495K...
Page 20 Installation Figure 13 Ground the Gun Gun is grounded through the conductive air hose. Figure 14 Ground the Fluid Supply Fluid supply line and source must be grounded. 3A2495K...
Page 21: Gun Setup
Setup Procedure Procedure Setup Procedure See the figure below to locate the electrostatic gun 4. Connect the Graco grounded air hose to the gun controls. air inlet. The gun air inlet fitting has left-hand threads. 5. Follow all steps under Grounding, page 6.
Page 22: Gun Setup Procedure
Gun Setup 15. Check that the ES On-Off switch is OFF (O). To reduce the risk of a skin in- jection injury, always follow the Pressure Relief Procedure, page before removing or installing the spray tip, air cap, or tip guard. 16.
Page 23 Gun Setup 19. Check that the ES indicator (K) [Hz indicator on 21. Turn the atomizing air adjustment valve Smart guns] is lit. See the following table. counterclockwise until any tails disappear. Table 2 2 2 . . . LED LED Indicator Indicator Colors Colors...
Page 24: Check Gun Electrical Grounding
7. If the resistance is greater than 1 megohm, check the tightness of the ground connections and be Graco Part No. 241079 Megohmmeter is available sure the air hose ground wire is connected to a as an accessory to check that the gun is properly true earth ground.
Page 25: Check Fluid Resistivity
Check that the resistivity of the fluid being sprayed the viscosity cup. meets the requirements for an electrostatic air spray system. Graco Part No. 722886 Resistance Meter 4. If the viscosity is too high or too low, contact the and 722860 Probe are available as accessories.
Page 26: Operation
Operation Operation Operation Operation Pressure Relief Relief Procedure Procedure Pressure Pressure Relief Procedure 4. Disengage the trigger lock. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, 5. Trigger the gun into a grounded metal waste splashing fluid and moving parts, follow the container to relieve the fluid pressure.
Page 27: Pressure Relief Procedure
Operation Startup Shutdown Startup Startup Shutdown Shutdown Follow all steps under Gun Setup Procedure, page Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation. To reduce the risk of an injury, follow the •...
Page 28: Maintenance
Maintenance Maintenance Maintenance Maintenance Daily Daily Daily Care Care Care and and Cleaning Cleaning Checklist Cleaning Checklist Checklist Flushing Flushing Flushing • Flush before changing fluids, before fluid can dry Check the following list daily upon completion of equipment usage. in the equipment, at the end of the day, before storing, and before repairing equipment.
Page 29 Maintenance 4. Change the fluid source to solvent, or disconnect 9. Reinstall the air cap, tip guard, and retaining ring. the fluid line and connect a solvent supply line to the gun. 5. Point the gun into a grounded metal pail. Flush until clean solvent flows from the gun.
Page 30 Maintenance Clean the the Gun Gun Daily Daily Clean Clean Daily 6. Clean the outside of the gun with a compatible solvent. Use a soft cloth. Point the gun down to prevent solvent from entering the gun passages. NOTICE NOTICE NOTICE Do not immerse the gun.
Page 31: Daily System Care
Maintenance Daily System System Care Care Daily Daily System Care 7. Clean the air cap/tip guard and spray tip with a soft brush and compatible solvent. 1. Follow the Pressure Relief Procedure, page 2. Clean the fluid and air filters. 3.
Page 32: Electrical Tests
Electrical Tests Electrical Tests Tests Electrical Electrical Tests Test Gun Gun Resistance Resistance Test Test Resistance Electrical components inside the gun affect performance and safety. Use the following procedures to test the condition of the power supply 1. Flush and dry the fluid passage. and gun body, and electrical continuity between 2.
Page 33: Test Power Supply Resistance
Troubleshooting, , , page page 37 37, , , for Electrical Electrical Troubleshooting page other possible causes of poor performance, or contact your Graco distributor. 6. Be sure the spring (11a) is in place before reinstalling the power supply. 3A2495K...
Page 34 • Never operate the gun without the conductive ring in place. • Do not replace the conductive ring with anything but a genuine Graco part. 5. If the resistance is still outside the range, replace the gun barrel. 3A2495K...
Page 35: Troubleshooting
Troubleshooting Troubleshooting Troubleshooting Troubleshooting To reduce the risk of a skin injection injury, always Installing and servicing this equipment requires follow the Pressure Relief Procedure, page access to parts which may cause an electric shock whenever you are instructed to relieve the or other serious injury if the work is not performed pressure.
Page 36: Gun Operation Troubleshooting
Troubleshooting Gun Operation Operation Troubleshooting Troubleshooting Operation Troubleshooting Problem Problem Problem Cause Cause Cause Solution Solution Solution Excessive spray fog. Atomizing air pressure too high. Close atomizing air 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.
Page 37: Electrical Troubleshooting
Troubleshooting Electrical Troubleshooting Troubleshooting Electrical Electrical Troubleshooting Problem Problem Problem Cause Cause Cause Solution Solution Solution Poor wrap. ES On/Off switch is OFF (O). Turn ON (I). Gun air pressure too low (ES Check air pressure to gun; indicator is amber). minimum 45 psi (0.32 MPa, 3.2 bar) needed at gun for full voltage.
Page 38 Troubleshooting Problem Cause Solution Problem Problem Cause Cause Solution Solution Voltage/current display stays red Gun is too close to the part being Gun should be 8–12 in. (200–300 (smart guns only). sprayed. mm) from the part. Check fluid resistivity. Check Fluid Resistivity, page Dirty gun.
Page 39: Repair
Do not install or service this equipment over-lubricate. unless you are trained and qualified. • Only use genuine Graco parts. Do not mix or use parts from other Pro Gun models. • Air Seal Repair Kit 24N789 is available. The kit must be purchased separately.
Page 40 • Never operate the gun without the conductive ring in place. • Do not replace the conductive ring with anything but a genuine Graco part. Figure 20 Remove Air Cap 5. Trigger the gun and remove the fluid seat housing 3.
Page 41: Prepare The Gun For Service
Repair Electrode Replacement Replacement Electrode Electrode Replacement NOTICE NOTICE NOTICE Do not overtighten the fluid seat housing (24). Overtightening may damage the housing and the gun barrel, resulting in improper fluid shutoff. 6. Trigger the gun and install the fluid seat housing To reduce the risk of fire, explosion, or electric (24).
Page 42: Fluid Filter Replacement
Repair Fluid Tube Tube Removal Removal and and Replacement Replacement Fluid Filter Filter Replacement Replacement Fluid Fluid Tube Removal Replacement Fluid Fluid Filter Replacement 1. See Prepare the Gun for Service, page 1. See Prepare the Gun for Service, page 2.
Page 43: Gun Barrel Removal
Repair Gun Barrel Barrel Removal Removal Gun Barrel Barrel Installation Installation Barrel Removal Barrel Installation 1. See Prepare the Gun for Service, page 1. Be sure the gasket (5*) and grounding spring (37a) are in place. Make sure the gasket air 2.
Page 44: Gun Barrel Installation
Repair Fluid Needle Needle Replacement Replacement Fluid Fluid Needle Replacement 1. See Prepare the Gun for Service, page 2. Remove the air cap assembly and fluid seat housing. See Air Cap, Spray Tip, and Fluid Seat Housing Replacement, page 3. Remove the gun barrel. See Gun Barrel Removal, page 4.
Page 45: Alternator Removal And Replacement
Repair Power Supply Supply Removal Removal and and Replacement Replacement Power Power Supply Removal Replacement • Inspect the gun handle power supply cavity for dirt 9. Insert the power supply/alternator assembly in or moisture. Clean with a clean, dry rag. the gun handle (16).
Page 46 Repair Alternator Removal Removal and and Replacement Replacement Alternator Alternator Removal Replacement NOTE: NOTE: NOTE: Replace alternator bearings after 2000 hours 6. Push the fan and coil assembly (15a) out the of operation. Order Part No. 24N706 Bearing Kit. front of the housing (15d). Parts included in the kit are marked with a symbol (♦).
Page 47 Repair 12. Hold the coil assembly (15a) on a workbench 15. Seat the coil fully into the housing (15d♦). Secure with the fan end facing up. Press the fan (15e♦) with the clip (15h♦), ensuring that its tabs engage onto the long end of the shaft (S). The fan blades the slots in the housing.
Page 48: Atomizing Air Adjustment Valve
Repair Fan Air Air Adjustment Adjustment Valve Valve Repair Repair Atomizing Air Air Adjustment Adjustment Valve Valve Adjustment Valve Repair Atomizing Atomizing Adjustment Valve Repair Repair Repair 1. Follow the steps in Prepare the Gun for Service, page 1. Follow the steps in Prepare the Gun for Service, page 2.
Page 49 Repair ES On On - - - Off Off Valve Valve Repair Repair Valve Repair 1. Follow the steps in 4. Clean and inspect parts for damage. Replace Prepare the Gun for Service, page if necessary. 2. Loosen the captive screw (26p). Remove the NOTE: NOTE: NOTE: The protrusion on the retainer plate (26f)
Page 50: Es On-Off Valve Repair
Repair Air Valve Valve Repair Repair Valve Repair 1. Follow the steps in 8. Install the air valve (23) and spring (2) into the Prepare the Gun for Service, page gun handle (16). 2. Follow the steps in Gun Barrel Removal, page 9.
Page 51: Smart Module Replacement
Repair Smart Module Module Replacement Replacement Smart 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.
Page 52 Repair Air Swivel Swivel and and Exhaust Exhaust Valve Valve Replacement Replacement Swivel Exhaust Valve Replacement 1. Follow the steps in Prepare the Gun for Service, page 2. To replace the air exhaust valve: a. Remove the clamp (36) and the exhaust tube (35).
Page 53: Parts
Parts Parts Parts Parts Standard Air Air - - - Assisted Assisted Spray Spray Gun Gun Assembly Assembly Standard Standard Assisted Spray Assembly Part No. No. H60T10 H60T10 60 60 kV kV Electrostatic Electrostatic Air-Assisted Air-Assisted Spray Spray Gun, Gun, Series Series C C C Part Part...
Page 54: Assembly
Parts Part No. No. H60T10 H60T10 60 60 kV kV Electrostatic Electrostatic Air-Assisted Air-Assisted Spray Spray Gun, Gun, Series Series C C C Part Part H60T10 Electrostatic Air-Assisted Spray Gun, Series Part Part Part No. No. H85T10 H85T10 H85T10 85 85 kV kV Electrostatic Electrostatic...
Page 55 Parts Smart Air Air - - - Assisted Assisted Spray Spray Gun Gun Assembly Assembly Smart Smart Assisted Spray Assembly Part Part No. Part No. H60M10 H60M10 60 H60M10 60 kV kV Electrostatic Electrostatic Electrostatic Air-Assisted Air-Assisted Spray Air-Assisted Spray Gun, Spray Gun, Gun, Series...
Page 56 Parts Part No. No. H60M10 H60M10 60 60 kV kV Electrostatic Electrostatic Air-Assisted Air-Assisted Spray Spray Gun, Gun, Series Series C C C Part Part H60M10 Electrostatic Air-Assisted Spray Gun, Series Part Part Part No. No. H85M10 H85M10 H85M10 85 85 kV kV Electrostatic Electrostatic...
Page 57 Parts Alternator Assembly Assembly Alternator Alternator Assembly Part Part No. Part No. 24N664 24N664 Alternator 24N664 Alternator Alternator Assembly Assembly Assembly Part Description Part Description Ref. Ref. Ref. Part Part Description Description Ref. Ref. Ref. Part Part Description Description — — — 24N705 COIL, alternator 15f♦...
Page 58 Parts ES On On - - - Off Off Valve Valve Assembly Assembly Valve Assembly Part Part Part No. No. 24N632 24N632 ES 24N632 ES On-Off On-Off Valve On-Off Valve Valve Assembly Assembly Assembly Part Part Part No. No. 26A294 26A294 26A294 ES ES On-Off...
Page 59: Fan Air Adjustment Valve Assembly
Parts Fan Air Air Adjustment Adjustment Valve Valve Assembly Assembly Adjustment Valve Assembly Part Part No. Part No. 24N634 24N634 24N634 Fan Fan Air Air Adjustment Adjustment Adjustment Valve Valve Valve Assembly Assembly Assembly Ref. Ref. Ref. Part Part No. Part Description Description...
Page 60: Air Cap Assembly
Parts Air Cap Cap Assembly Assembly Smart Module Module Assembly Assembly Assembly Smart Smart Module Assembly Part Part Part No. No. 24N727 24N727 Air 24N727 Air Cap Cap Assembly Assembly Assembly Part Part No. Part No. 24N756 24N756 Smart 24N756 Smart Smart Module Module...
Page 61: Spray Tip Selection Chart
Spray Tip Selection Chart Spray Tip Tip Selection Selection Chart Chart Spray Spray Selection Chart AEM Fine Fine Finish Finish Spray Spray Tips Tips Fine Finish Spray Tips Recommended for high finish quality applications at low and medium pressures. Order desired tip, Part Part Part No.
Page 62 Spray Tip Selection Chart AEF Fine Fine Finish Finish Pre Pre - - - Orifice Orifice Spray Spray Tips Tips Fine Finish 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.
Page 63: Round Spray Tips
Spray Tip Selection Chart Round Spray Spray Tips Tips Round Round Spray Tips To convert the gun to a round spray pattern, use round spray conversion kit 24N391. See manual 3A2499. Part No. Part Part Size Size No. Size Approximate Approximate Flow Approximate Flow...
Page 64: Recommended Filter Sizes
Spray Tip Selection Chart Recommended Filter Filter Sizes Sizes Recommended Recommended Filter Sizes Filter Size Size Filter Part Part Orifice Size Size Round Round Spray Round Spray Spray Tips Tips Tips Filter Filter Size Filter Filter Part Orifice Orifice Size in.
Page 65: Repair Kits And Accessories
Repair Kits and Accessories Repair Kits Kits and and Accessories Accessories Repair Repair Kits Accessories Adapter Adapter Adapter and and Fitting Fitting Fitting Accessories Accessories Accessories Repair Kits Kits Repair Kit Kit Description Description Repair Repair Kits Repair Repair Description Part No.
Page 66: Operator Accessories
Part No. Description Description Description 117823 16P802 Conductive Gloves, box of 12 (small) English Warning Sign, available at no charge from Graco 117824 Conductive Gloves, box of 12 (medium) 16P798 English Daily Care Sign 117825 Conductive Gloves, box of 12 (large)
Page 67: Hoses
Repair Kits and Accessories Hoses Hoses Hoses Grounded Grounded Air Grounded Air Hoses Hoses Hoses Part Part Part No. Description Description Description 100 psi (0.7 MPa, 7 bar) Maximum Working Pressure Grounded Grounded Grounded Air Air Hose Hose with Hose with stainless with stainless...
Page 68: Dimensions
Dimensions Dimensions Dimensions Dimensions Figure 45 Gun Model Model A, A, A, in. in. in. (mm) (mm) B, B, B, in. in. in. (mm) (mm) C, C, C, in. in. in. (mm) (mm) Weight, oz oz oz (g) Model (mm) (mm) (mm) Weight,...
Page 69: Technical Specifications
Technical Specifications Technical Specifications Specifications Technical Technical Specifications Electrostatic Air Air- - - Assisted Assisted Spray Spray Guns Guns Electrostatic Electrostatic Assisted Spray Guns U.S. Metric U.S. U.S. Metric Metric Maximum Working Fluid Pressure 3000 psi 21 MPa, 210 bar Maximum Working Air Pressure 100 psi 0.7 MPa, 7.0 bar...
Page 70 Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deficiency in the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months from the date of sale.

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Pro xp h85t10 Pro xp h85m10 Pro xp h60m10 Pro xp h85m57 Pro xp h85t57

Graco Pro Xp H60T10 Instructions Manual

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