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Graco 3A2497BPro User's Manual

1. are not available separately 24N785 CAP spring includes item 37a I 112080 TOOL needle shipped loose Ta 197624 SPRING compression I N 67 Parts Smart Air Assisted Spray Gun Assembly Part No H60M18 60 kV Electrostatic Air Assisted Spray Gun Series A includes items 1 61 Part No 24M508 Unshielded Waterborne Fluid Hose 101 sold separately 37 20a 20 60 ti19997a 62 3A249 7B Parts Part No H60M18 60 kV Electrostatic Air Assisted Spray Gun Series A includes items 1 61 Part No 24M508 Unshielded Waterborne Fluid Hose 101 sold separately No 24N745 BODY gun 185116 SPRING compression 188749 PACKING u cup 24N699 GASKET body i 24N740 SCREW hex socket package of 2 7 4N742 BRACKET 249323 VALVE exhaust 2 a 112085 O RING 24N747 RING conductive 2 1 24N662 POWER SUPPLY 60 kV gun 11a 4N979 SPRING 2 24N663 TRIGGER includes item 13 oO 24A445 SCREW trigger package of 2 24N664 See Alternator Assembly page 67 24P745 HANDLE smart 60 kV AA gun O Mii ul I 0 24N781 NEEDLE ASSEMBLY includes item 20a 20a 24N782 SPRING fluid needle 1 24N626 SWIVEL air inlet M12 x 1 4 npsm m left hand thread 24N793 RING retainer includes 22a 22a 1198307 PACKING u cup UHMWPE part of 22 24N633 VALVE air 276733 SEAL 24N725 HOUSING seat 24N727
2. Models Models which are FM Approved and Compliant with EN50059 FM approved for use with fluids that meet the following condition C US e Material does not sustain burning in accordance with the Standard Test Method APPROVED for Sustained Burning of Liquid Mixtures ASTM D4206 0 35 J with Models Compliant with EN 50059 when used 24M508 Hose with fluids that meet the following criteria FM12ATEX0080 7 90059 e Materials which cannot be ignited in any mixture with air by an energy source Ta 0 C 50 C of less than 500 mJ Perno f Mosel peste 24N551 WB3000 Waterborne Isolation Enclosure 24N550 with standard electrostatic air assisted spray gun H60T 18 grounded air hose 235070 and unshielded waterborne fluid hose 24M508 24P632 WB3000 Waterborne Isolation Enclosure 24N550 with smart electrostatic air assisted spray gun H60M18 grounded air hose 235070 and unshielded waterborne fluid hose 24M508 24N550 WB3000 Waterborne Isolation Enclosure for unshielded hoses Does not include hoses and gun H60T18 Pro Xp 60 AA WB Standard Electrostatic Air assisted Spray Gun for waterborne coatings H60M18 Pro Xp 60 AA WB Smart Electrostatic Air assisted Spray Gun for waterborne coatings 24M508 Unshielded Waterborne Fluid Hose Assembly 25 ft 7 6 m CE 3A249 B 3 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclamation po
3. Parts Ref Part No Description Qty No 30a NUT valve aoe steve id These parts are included in Air Seal Repair Kit 24N789 purchase separately Parts labeled are not available separately 69 Parts Air Cap Assembly Smart Module Assembly Part No 24N727 Air Cap Assembly Part No 24N756 Smart Module Assembly 25b ti18652a No a anoe RECTROOE pe di 1 ti19442b No ste carmine it 24N734 O RING ptfe package of 5 also available in package of 10 order 24E459 fase AR one EN 25d 24N726 GUARD tip orange do Parts labeled are not available separately Rise screw ares ET screw Parts labeled are not available separately These parts are included in Smart Module Screw Kit 24N757 purchase separately 70 3A249 7B 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 Orifice Fluid Output Maximum Pattern Width at 12 in 305 mm Size fl oz min l min in mm in 2 4 4 6 6 8 8 10 10 12 12 14 14 16 16 18 50 100 150 200 250 300 350 400 100 150 200 250 300 350 400 450 mm Spray Tip Spray Tip O FF D a S S 0 178 0 1 0 15 ele ka eee
4. The Hz indicator functions the same as the ES indicator on standard guns The indicator lights to show the alternator speed status and has three colors e Green indicates the alternator speed is correct e If the indicator changes to amber after 1 second increase the air pressure e If the indicator changes to red after 1 second reduce the air pressure 3A249 B Gun Overview Voltage Adjustment Switch The voltage adjustment switch VA allows the operator to change from low to high voltage e The high voltage setting is determined by the maximum voltage of the gun and is not adjustable e The low voltage indicator LO lights when the switch is set to LO The low voltage setting is user adjustable See Adjusting the Low Voltage Setting page 10 NOTE If the Error display appears the Smart module has lost communication with the power supply See Error Display page 10 for further information ti19121a Figure 2 Smart Gun Module in Operating Mode Gun Overview Error Display NOTE After 2 seconds of inactivity the display will return to the Operating Screen 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 11 This can occur in Operating Mode or Diagnostic Mode See Electrical Troubleshooting page 45 Communication must be restored to make the Smart module functional
5. also see Adjustment A be irsed to decrease Smart Guns page 9 Valve pattern width oe ee ee Atomizing Air Adjusts atomizing air flow Air Swivel 1 4 npsm m left hand Adjustment Inlet thread for Graco Valve red colored grounded Trigger Safety Locks trigger to prevent a ae ES On Off Turns electrostatics ON hose ae or OFF O ES Indica Lit when ES is ON I Exhaust exhaust tube tor standard Color indicates alternator Air Cap Tip See Spray Tip Selection gun only for frequency See the LED Guard and Chart page 71 for avail Smart gun in indicator table on page 30 Spray Tip able sizes dicator see Operating Mode page LU ti20020a Figure 1 Gun Overview 8 3A249 7B 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 e Operating Mode e Diagnostic Mode Operating Mode Bar Graph See Fig 2 and Table 1 on page 11 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 The bar graph range is from 0 to 100 for each value If the uA bar graph LEDs are blue the gun is ready to spray If the LEDs are yellow or red the current is too high See Electrical Troubleshooting page 45 Hz Indicator
6. 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 100 ohms Follow the grounding instructions below The following are minimum grounding requirements for a basic electrostatic waterborne system Your system may include other equipment or objects which must be grounded Check your local electrical code for detailed grounding instructions Your system must be connected to a true earth ground Voltage Isolation System Electrically connect the voltage isolation system to a true earth ground See Ground the Cabinet page 16 ti18723a e Electrostatic Air Assisted Spray Gun ground the gun by connecting the red colored Graco Grounded Air Hose to the gun and connecting the air hose ground wire to a true earth ground See Check Gun Electrical Grounding page 23 3A249 B Gun Setup Object being sprayed keep the workpiece hangers clean and grounded at all times ti18753a All electrically conductive objects or devices in the spray area must be properly grounded ti18728a 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 cat
7. necessary d Install the o ring 8a on the exhaust valve 8 Lubricate the o ring with a light coating of non silicone grease e Install the exhaust valve 8 in the handle 16 f Apply thread sealant to the top threads of the swivel 21 Position the bracket and screw the swivel into the gun handle 16 Torque to 75 85 in Ib 3 4 9 6 Nem g Install the tube 36 and clamp 43 3 To replace the air inlet swivel 3A249 B a Unscrew the swivel 21 from the gun handle 16 The swivel is a left hand thread 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 Nem ti20012a Figure 44 Air Inlet Fitting and Air Exhaust Valve 59 Parts Parts Standard Air Assisted Spray Gun Assembly Part No H60T18 60 kV Electrostatic Air Assisted Spray Gun Series A includes items 1 61 Part No 24M508 Unshielded Waterborne Fluid Hose 101 sold separately 37 20a ti19996a 60 3A249 7B Parts Part No H60T18 60 kV Electrostatic Air Assisted Spray Gun Series A includes items 1 61 Part No 24M508 Unshielded Waterborne Fluid Hose 101 sold separately No eee package of 2 j Ta 2 oO 24N664 See Alternator Assembly page 67 24P746 HANDLE 60 kV AA gun O Mii ul I 0 24N781 NEEDLE ASSEMBLY includes item 20a 20a 24N782 SPRING fluid needle 1 24N626 SWIVEL ai
8. particular needs contact your Graco distributor Ventilate the Spray Booth Provide fresh air ventilation to reduce the risk of fire or explosion caused by the buildup of flammable or toxic vapors when spraying flushing or cleaning the gun Do not operate the gun unless ventilation fans are operating Check and follow all local state and national codes regarding air exhaust velocity requirements High velocity air exhaust will decrease the operating efficiency of the electrostatic system The minimum allowable air exhaust velocity is 60 linear ft min 18 3 linear meters minute 15 Installation Air Supply Line 1 See Fig 12 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 Trapped air can cause the fluid supply unit to moisture can ruin the appearance of your finished cycle unexpectedly which can result in serious workpiece and can cause the gun to malfunction injury including splashing fluid in the eyes or on the skin Do not operate the equipment without the bleed type air valve B installed 2 The WB3000 system includes a bleed type air regulator N on the gun air supply line P to control air pressure to the gun 4 The WB3000 system includes a bleed type air valve B The bleed type air valve is required to shut off all air to the system and relieve air trapped between the valve and the fluid supply unit after the air r
9. ual ansa SCREW hex hd 1 4 20 x 5 8 in 16 mm zas E WASHER plains 1am 6 mm 16 _ ea yellow stripe E npt x 5 32 in 4 mm tube NUT hex 10 32 56 162449 NIPPLE reducing 1 2 npt x 1 4 npt o a ill 16 mm eel 6 mm assi R N NIN Cc NIO NO O1 Ss N O1 NO 1 oO NO NI N N Ol VI N NI N N O N HOLDER tie SCREW button hd 10 24 x 1 5 in 38 mm 266 SCREW button hd 10 32 x 1 0 in 25 mm 268 _ WASHER lock no 10 65 Parts No 116991 TEE run manifold 271 203953 SCREW hex hd cap with patch 1 10 24 x 3 8 in 10 mm 273 WIRE ground 14 gauge green A R with yellow stripe 155541 UNION swivel 1 4 npt pe BULKHEAD CONNECTOR 1 4 1 not 279 113319 CONNECTOR tube 1 4 nptx 2 3 8 in 10 mm OD tube 281 FITTING tube 1 8 npt x 5 32 in 1 4 mm OD tube 4 Replacement Danger and Warning labels tags and cards are available at no cost The air hose 300 and gun 301 are not included with the 24N550 Isolation Enclosure They are shown 66 No oo 6 mm OD tube id ce 4 mm OD tube aas _ TUBE ven 10 mm 0D__ AR_ 300 235070 HOSE air grounded 0 315 in 1 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread red cover with stainless steel braid ground path 25 ft 7 6 m long Spray Gun Assembly page 60 Spray Gun Assembly page 62 for illustrative purposes only See page 3 for a l
10. until performing the Fluid Voltage Discharge and Grounding Procedure page 25 Figure 16 Electrostatic Gun Controls ti18785a Follow the Fluid Voltage Discharge and Grounding 1 Turn OFF O the ES On Off switch J Procedure page 25 when you stop spraying and whenever you are instructed to discharge the voltage To reduce the risk of component rupture which can cause serious injury do not exceed the maximum working pressure of the lowest rated system component This equipment has a 100 psi 0 7 MPa 7 bar maximum air working pressure and a 3000 psi 21 MPa 210 bar maximum fluid working pressure 28 3A249 7B 3 Check gun resistance See Test Gun Resistance page 36 4 Follow all steps under Grounding page 21 Follow all steps under Check Gun Electrical Grounding page 23 Reading must be less than 100 ohms 6 Connect the exhaust tube and secure with the clamp provided To reduce the risk of a skin in jection injury always follow the Pressure Relief Procedure page 26 before removing or installing the spray tip air cap or tip guard 8 The fluid output and pattern width depend on the size of the spray tip the fluid viscosity and the fluid pressure Use the Spray Tip Selection Chart page 71 as a guide for selecting the appropriate spray tip for your application 9 Align the spray tip tab with the groove in the air cap Install the tip 10 Install the air cap and retainin
11. 11 See Power Supply Removal and Replacement page 52 2 Remove the alternator 15 from the power supply See Alternator Removal and Replacement page 53 3 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 Gun Barrel Resistance page 38 4 Be sure the spring 11a is in place before reinstalling the power supply ti18735a Figure 18 Test Power Supply Resistance 3A249 B 3 Electrical Tests Test Gun Barrel Resistance 1 Insert a conductive rod B into the gun barrel NOTICE which was removed for the power supply test ma and against the metal contact C in the front of The conductive ring 9 is a conductive metal the barrel contact ring not a sealing o ring For best performance and to avoid potential damage to 2 Measure the resistance between the conductive the spray gun do not remove the conductive rod B and the conductive ring 9 The ring 9 except to replace it and never operate resistance should be 10 30 megohms If the the gun without the conductive ring in place resistance is incorrect make sure the metal Do not replace the conductive ring with contact C in the barrel and the conductive ring anything but a genuine Graco part 9 are clean and undamaged 5 If the resistance is still outside the range replace 3 If the resist
12. 8 Reassemble the retaining ring 30d Unscrew the valve stem from the housing until it is stopped by the retaining ring 9 Screw the valve assembly 30 into the gun handle 16 using a wrench on the flats of the housing Torque to 15 in Ib 1 7 Nem 30b 30c 30a 30d ti18647a Figure 37 Fan Air Adjustment Valve 3A249 B Repair Atomizing Air Adjustment Valve Repair 1 See Prepare the Gun for Service page 47 2 Place a wrench on the flats of the valve assembly 29 and unscrew it from the handle 16 3 Inspect the valve assembly If damaged install a new valve 29 4 Before installing the valve assembly in the handle unscrew the valve stem 29b from the housing 29a until it stops 5 Install the valve assembly into the gun handle Torque the valve housing 29a to 15 in Ib 1 7 Nem ti18649a Figure 38 Atomizing Air Adjustment Valve 55 Repair ES On Off Valve Repair 1 See Prepare the Gun for Service page 47 4 Clean and inspect parts for damage Replace 2 Loosen the captive screw 26p Remove the if necessary valve 26 from the handle NOTE The protrusion on the retainer plate 26f 3 Lubricate the o rings 26b and 26g with must point upward non silicone grease Part No 111265 Do not 5 Reinstall the valve Torque the screw 26p to over lubricate 15 25 in Ib 1 7 2 8 Nem NOTE Do not over lubricate parts Excessive lubricant on the o rings can
13. Check that the u cup 22a is in place on the retaining ring 22 The lips of the u cup must face forward NOTICE To avoid damaging the tip guard orient the air cap assembly 25 before tightening the retaining ring 22 Do not turn the air cap when the retaining ring is tight Orientate the air cap and tighten the retaining ring securely See Test Gun Resistance page 36 3A249 B Repair Electrode Replacement NOTICE For best performance and to avoid potential damage to the spray gun do not operate the spray gun without the electrode installed in the air cap 1 See Prepare the Gun for Service page 47 2 Remove the air cap assembly 25 See Air Cap Spray Tip and Fluid Seat Housing Replacement page 48 3 Pull the electrode 25a out of the back of the air cap using a needle nose pliers 4 Push the new electrode through the air cap hole Make sure the short end BB of the electrode engages the hole CC in the back of the air cap Press the electrode in place firmly with your fingers 5 Install the air cap assembly 6 See Test Gun Resistance page 36 ti19524a Figure 26 Replace Electrode 49 Repair Gun Barrel Removal See Prepare the Gun for Service page 47 Remove the air inlet fitting 21 and take the bracket B off the gun handle 16 Loosen the two screws 6 NOTICE To avoid damaging the power supply 11 pull the gun barrel straight away from th
14. NOTE The low voltage setting may be locked See Lock Symbol page 10 NOTE It takes 8 seconds for the Error display to appear If the gun has been disassembled wait 8 seconds before spraying to ensure that an Error condition has not occurred NOTE If there is no power to the gun the Error display will not appear ti19122a Figure 4 Low Voltage Setting Screen Unlocked Lock Symbol The low voltage setting may be locked When locked an image LK appears on the screen See Fig 5 and Table 1 on page 11 e When in HI mode the low voltage setting is always locked The lock symbol will appear when the LO SET button is pressed e When in LO mode the lock symbol will only appear if the lock is enabled See Low Voltage Lock Screen page 14 to lock or ti19338a unlock the low voltage setting Figure 3 Error Display Adjusting the Low Voltage Setting The low voltage setting is user adjustable To access the low voltage setting screen when in Operating Mode press the LO SET button LS momentarily The screen will display the current low voltage setting See Fig 4 and Table 1 on page 11 The range is 30 60 kV Set the Voltage Adjustment switch VA to LO Press the LO SET button repeatedly to increase the setting ti19337a in increments of 5 When the display reaches the Figure 5 Low Voltage Setting Screen Locked maximum setting 60 kV it will return to the minimum setting 30 kV Continue pressing the but
15. be pushed into the gun air passage and blemish the finish on the workpiece 26d 26f 26b 26g 26e ti18648a Figure 39 ES On Off Valve 56 3A249 7B Air Valve Repair 1 See Prepare the Gun for Service page 47 2 See Gun Barrel Removal page 50 3 Remove the screws 13 and trigger 12 4 Remove the ES On Off Valve See ES On Off Valve Repair page 56 on Remove the spring 2 Push on the front of the air valve shaft to force it out the back of the handle Inspect the rubber seal 23a and replace if damaged 7 Inspect the u cup 3 Do not remove the u cup unless damaged If removed install the new one with its lips facing into the gun handle 16 Place the u cup on the shaft of the air valve to help seat it in the gun handle ti19724a Figure 40 Install U Cup 3A249 B 10 11 Repair Install the air valve 23 and spring 2 into the gun handle 16 Install the ES On Off Valve See ES On Off Valve Repair page 56 Install the trigger 12 and screws 13 See Gun Barrel Installation page 50 ti20013a Figure 41 Air Valve 5 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 47 2 Remove the pivo
16. ee I 0 229 0 2 0 27 fees leg fm 0 279 0 3 0 4 o ei da RP 0 330 0 4 0 5 fee ten P et a 0 381 0 5 0 7 feaalgn lee I A 0 432 0 7 0 85 cole ka T TP 0 483 0 8 1 09 fece lia dee a a a a 0 533 1 0 1 36 fel ee PT ete 0 584 1 2 1 56 le eee T fa 0 635 1 5 1 94 alta kal T 0 736 1 9 2 65 ic la al l 0 787 2 2 3 03 cola kal T 0 838 2 5 3 42 0 037 108 0 140 0 a 0 939 3 1 4 20 0 039 118 0 153 0 0 990 3 4 4 59 Tips are tested in water Fluid output Q at other pressures P can be calculated by this formula Q 0 041 QT v P where QT fluid output fl oz min at 600 psi from the above table for the selected orifice size t These tip sizes include a 150 mesh filter 3A249 B 11 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 Orifice Fluid Output Maximum Pattern Width at 12 in 305 mm Size fl oz min l min in mm 2t600 psi at 1000 6 8 150 8 10 10 12 12 14 14 16 16 18 4 1 MPa psi 7 0 200 200 250 250 300 300 350 350 400 400 450 41 bar MPa 70 bar Spray Tip 0 010
17. 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 e Flush with a non flammable solvent that is compatible with the fluid being dispensed and the equipment wetted parts To reduce the risk of fire explosion or electric shock turn OFF O the ES On Off switch before flushing the gun Follow the Fluid Voltage Discharge and Grounding Procedure page 25 before flushing Only flush purge or clean the gun with fluids that meet the following flammability requirements e 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 500mJ NOTICE Only use non flammable solvents when flushing or cleaning equipment 3A249 B Maintenance Turn OFF O the ES On Off switch Wait 30 seconds for the voltage to bleed off s ti18730a Discharge the system voltage See Fluid Voltage Discharge and Grounding Procedure page 25 Follow the Pressure Relief Procedure page 26 Remove and clean the air cap and spray tip Change the fluid source to non flammable solvent Point the gun into a grounded metal pail Flush until clean s
18. ft 1 22 m locally 40 110272 SCREW set socket hd 1 1 4 20 x 1 4 in 6 mm aoe _ 103916 NUT conar agito 1 _ O 02 03 04 05 06 8 404 i ti2137a 3A249 B 75 Dimensions Dimensions ti19533a Figure 45 Gun Model A in mm B in mm C in mm Weight without bracket oz g H60T18 10 7 272 8 9 226 2 4 61 22 0 623 H60M18 10 8 274 9 6 244 2 4 61 24 4 692 76 3A249 7B Technical Data Technical Data Electrostatic Ar Assisted Spray Waterbome Guns lt CC o oos o Maximum Fluid Operating 120 F 48 C Temperature Short Circuit Current Output 125 microamperes Voltage Output Energy 0 35 J with fluid hose 24M508 installed H60T18 60 kV H60M18 30 60 kV Sound Power measured per ISO at 40 psi 90 4 dB A at 0 28 MPa 2 8 bar 90 4 dB A Standard 9216 aa at 100 psi 105 4 dB A at 0 7 MPa 7 0 bar 105 4 dB A Sound Pressure measured 1 m at 40 psi 87 0 dB A at 0 28 MPa 2 8 bar 87 0 dB A f Ogun at 100 psi 99 0 dB A at 0 7 MPa 7 0 bar 99 0 dB A Air Inlet Fitting 1 4 npsm m left hand thread Fluid Inlet Fitting Custom inlet for Graco waterborne fluid hose Isolation Enclosure Air Inlet Fitting 1 4 npt Isolation Enclosure Fluid Inlet 3 8 in OD tube fitting 10 mm OD tube fitting Fitting Wetted Parts Gun Stainless Steel PEEK UHMWPE Fluoroelastomer Acetal Nylon Polyethylene Tungsten Wire Waterborne Fluid Hose P
19. partially plugged tip Clean See Clean the Gun Daily page 33 Worn damaged tip or air cap holes Clean or replace ti18798a Pattern pushed to one side air Air cap holes plugged Clean See cap gets dirty Clean the Gun Daily page 33 Tails in pattern Air pressure too low Open atomizing air adjustment valve Fluid pressure too low Increase ti18797a Fluid buildup on air cap tip guard Air pressure too high Air cap holes plugged Clean See Clean the Gun Daily page 33 3A2497B 43 Troubleshooting Gun Operation Troubleshooting 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 Orange Peel finish Atomizing air pressure too low Open atomizing air valve more or increase gun air inlet pressure use lowest air pressure necessary Spray tip is too large Use smaller tip See Spray Tip Selection Chart page 71 Poorly mixed or filtered fluid Remix or refilter fluid Fluid too thick Reduce viscosity Fluid leaks from the fluid packing Worn fluid needle packings or rod See Fluid Needle Replacement area page 51 Air leaks from the front of the gun Air valve is not seating properly See Air Valve Repair page 57 Fluid leakage from the front of the Worn or damaged fluid needle ball See Fluid Needle Replacement gun page 51 Wo
20. path and conceal a potential failure area Position the end of the hose as far as possible away from any grounded surface The end of the hose must be at least 1 ft 0 3 m from any ground Make sure that no one is within 3 ft 0 9 m of the end of the hose Turn the ES ON OFF valve to ON and trigger the gun just enough to turn on the air to the gun but not the fluid Measure the voltage at the gun electrode with a voltage probe and meter Discharge the system voltage by waiting 30 seconds and then touching the gun electrode with a grounded rod Check the meter reading e If the meter reading is 40 to 50 kV the gun and fluid hose are okay and the problem is in the voltage isolation system e If the meter reading is below 40 kV the problem is in the gun or fluid hose Flush the fluid hose and gun with enough air to dry out the fluid passages Turn the ES ON OFF valve to ON and trigger the gun Measure the voltage at the gun electrode with a voltage probe and meter 11 13 14 e If the meter reading is 40 50 kV the gun power supply is okay and there is probably a dielectric breakdown somewhere in the fluid hose or gun Continue with step 11 e If the meter reading is below 40 kV do the Electrical Tests page 36 to check the gun and power supply resistance If those tests show the gun and power supply are okay continue with step 11 A dielectric breakdown is most likely in one of the following three ar
21. pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection 6 Trigger the gun into a grounded metal waste splashing fluid and moving parts follow the container to relieve the fluid pressure Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing the equipment 1 Turn OFF O the ES On Off switch I 7 Engage the trigger lock N K 8 Open the pump drain valve having a waste container ready to catch the drainage Leave 2 Follow the Fluid Voltage Discharge and the pump drain valve open until you are ready Grounding Procedure page 25 to spray again 3 Engage the trigger lock 9 Ifthe spray tip or hose is completely clogged or pressure is not fully relieved slowly loosen the 4 Turn off the air bleed valves to the fluid source hose end coupling Now clear the spray tip or and to the gun hose 26 3A249 7B Fill the Fluid Supply 1 Follow the Fluid Voltage Discharge and Grounding Procedure page 25 2 Follow the Pressure Relief Procedure page 26 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 NOTICE Be sure to wipe up a
22. removed from the hazardous area Or all spraying devices in the hazardous area are turned off ventilation fans in the hazardous area are operating and there are no flammable vapors in the area such as open solvent containers or fumes from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage Graco Part No 241079 Megohmmeter is available as an accessory to check that the gun is properly grounded 1 Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose 2 Turn OFF O the ES On Off switch sl SY N N 1 4 3A249 B gt ti18730a Gun Setup Turn off the air and fluid supply to the gun Follow the Pressure Relief Procedure page 26 Disconnect the fluid hose Make sure the grounded air hose is connected and the hose ground wire is connected to a true earth ground ad DI Ae Measure the resistance between the gun handle BB and a true earth ground CC Use an applied voltage of 500 minimum to 1000 volts maximum The resistance should not exceed 100 ohms See Fig 14 BB OA A C E Sar T AA Si to S55 cc 3 lt gt ti18787a Figure 14 Check Gun Electrical Grounding 23 Gun Setup 7 Ifthe resistance is greater than 100 ohms check the tightness of the ground connections and be sure the air hose ground wire is connec
23. side motion free the power supply alternator assembly from the gun handle 16 then carefully pull it straight out On Smart OA IC E Models only disconnect the flexible circuit 40 A z from the socket at the top of the handle ZY K Inspect the power supply and alternator for lle N damage zZ 4 To separate the power supply 11 from the alternator 15 disconnect the 3 wire ribbon cA IE nE connector PC from the power supply On Smart A 221 Models only disconnect the 6 pin flexible circuit a ts 40 from the power supply Slide the alternator Figure 32 Connect Flexible Circuit up and off the power supply 10 Make sure the gasket 5 ground spring 37a See Test Power Supply Resistance page 37 and power supply spring 11a are in place Replace the power supply if necessary Assemble the barrel 1 to the handle 16 See To repair the alternator see Gun Barrel Installation page 50 Alternator Removal and Replacement page 53 11 See Test Gun Resistance page 36 Smart models only connect the 6 pin flexible circuit 40 to the power suppl
24. the barrel connector 101a and screw it into the fluid inlet Apply dielectric grease to the threads of the hose 101 and screw it into the barrel connector 101a Align the bracket B holes with the air inlet and exhaust outlet Secure with the air inlet fitting 21 Press the exhaust tube 35 onto the exhaust valve Secure with the clamp 36 Slide the other end of the hose through the hole in the side of the isolated enclosure Connect the swivel Z to the fluid outlet of the pump Secure the hose to the side of the enclosure with the bracket W NOTE The Graco warranty and approvals are void if the electrostatic spray gun is connected to a non Graco voltage isolation system or if the gun is operated above 60 kV a Me ia a an a J ti20010a D ti20019a Figure 11 Unshielded Hose 24M508 Connection at Figure 10 Connect the Fluid Hose WB3000 Enclosure 3A249 B 17 Installation i jane PINO Tn PATTO ERR _ ti20008a Figure 12 Typical Installation Pro Xp Waterborne System 3A249 7B 18 Typical Installation Key Bleed Type Air Shutoff Valve Pump Air Pressure Gauge Pump Air Pressure Regulator kV Meter Fo Pump oe Suction Hose K Enclosure Safety Interlock Gun Air Pressure Regulator Graco Red Grounded Air Hose left hand threads Q Gun Air Hose Ground Wire Graco Waterborne Fluid Hose 3A249
25. with air by an energy source of less than 500mJ When connected to a voltage isolation system all of the fluid in the spray gun fluid hose and isolated fluid supply is charged to high voltage which means that the system has more electrical energy than a solvent based system Therefore only non flammable fluids as defined under Models page 3 can be sprayed with the system or be used to clean flush or purge the system Precautions must be taken when using electrostatic waterborne equipment to avoid potential shock hazards When the spray gun charges the isolated fluid to high voltage it is similar to charging a capacitor or a battery The system will store some of the energy while spraying and retain some of that energy after the spray gun is shut off Do not touch the gun nozzle or come within 4 in 102 mm of the electrode until the stored energy is discharged The amount of time it takes to discharge the energy depends on the system design Follow the Fluid Voltage Discharge and Grounding Procedure page 25 before approaching the front of the gun The Graco warranty and approvals are void if the electrostatic spray gun is connected to a non Graco voltage isolation system or if the gun is operated above 60 kV Gun Overview Controls Indicators and Components The electrostatic gun includes the following controls indicators and components see Fig Fan Ai Adjusts fan size and shape 1 For information on Smart guns
26. 201 286 282 2a 280 283 00 252 215 214 253 216 Si m TA 279 276 ua 283 wv W SS 258 n 228 953 268 Bi lt lt 262 DB 257 257 Sia 262 226 227 243 ti20024a 64 3A249 7B Parts Part No 24N550 Waterborne Isolation Enclosure for use with unshielded waterborne fluid hose includes items 201 286 No 201 CABINET includes 201a 15A947 DOOR cabinet 116993 CASTER brake 154551 T HANDLE latch 154545 STEM handle door 154524 HOUSING latch 113061 SWITCH push air 24N548 PUMP see 3A0732 i 210 SCREW hex hd cap 5 16 18 x 4 5 5 in 140 mm ie WASHER plain 0 344 in ID NUT lock 5 16 18 sai LUG ground 116989 VALVE air 111804 REGULATOR air 113060 GAUGE air 1 8 npt 116473 BALL VALVE 1 4 npt f CART NIPPLE 1 4 npt x 1 4 npsm RESISTOR bleed CYLINDER ROD HOUSING cylinder rod REGULATOR air aaa BUSHING plastic 3 4 x 1 2 npt LABEL warning STRAP tie 239 222011 GROUND WIRE 25 ft 7 6 m 40 234018 STRIP grounding aluminum 241 110209 NUT regulator NUT lock SOT LUG ground VANE ar REGULATOR ar GAUGE ai 8 BALL VALVE a Ri o oo NIPPLE TA m TA mom _ RESISTOR bleed CYLINDER ROD HOUSING oyinderrod REGULATOR ar BUSHING pasti 4x 12 not LABEL warning STRAP 239 _ 222011_ GROUND WIRE 251 7 6 m STRIP grounding aluminum _ NUT reo NO 3A249 B No 242 114051 WASHER shim atch 243 210084 ROD ground 1
27. 5a out the front of the housing 15d 3A249 B 11 Repair ti19740b 15b2 M 15a 15g 15f W do a PC 15h 15d 15b1 S Figure 35 Alternator Cross Section NOTICE Do not scratch or damage the magnet M or shaft S Do not pinch or damage the 3 wire connector PC when disassembling and reassembling the bearings Hold the coil assembly 15a on a workbench with the fan end facing up Using a wide blade screwdriver pry the fan 15e off the shaft S Remove the top bearing 15b2 Remove the bottom bearing 15b1 Install the new bottom bearing 15b1 on the long end of the shaft S The flatter side of the bearing must face away from the magnet M Install in the coil 15a so the bearing blades are flush with the surface of the coll Press the new top bearing 15b2 onto the short end of the shaft so the bearing blades are flush with the surface of the coil 15a The flatter side of the bearing must face away from the coil 53 Repair 12 13 14 54 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 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 35 Be sure the coil alignment pins P are positioned a
28. 9 5 0 28 12 5 410 710 0 254 0 37 310 0 012 12 0 16 0 312 412 712 0 305 0 35 0 47 0 014 16 0 21 0 314 0 356 0 47 0 62 0 016 20 0 26 5 0 406 0 59 0 78 Tips are tested in water 414 714 Fluid output Q at other pressures P can be calculated by this formula Q 0 041 QT V P where QT fluid output fl oz min at 600 psi from the above table for the selected orifice size t These tip sizes include a 150 mesh filter 72 3A249 B 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 60 kV Waterborne Electrostatic 24N789 Air Seal Repair Kit manual Air Assisted Spray Waterborne Guns Air Assisted SIA Spray Guns Instructions Parts Alternator Bearing Repair Kit Operator Accessories ARTE ae n 24N319 Round Spray Kit To convert a operator fatigue Medium size standard air assisted spray gun to 24N521 a round spray air cap See manual 3A2499 24N604 Gun Covers Box of 10 24N758 Display Covers Keeps Smart display clean Package of 5 System Accessories 24P170 Metal Trigger Kit 24P172 Quick Adjust Valve For quick change of fan size 222011 Ground Wire and Clamp 185105 Non swivel Air Inlet 1 4 18 npsm m left hand thread Comfort Grip Snap on grip increases handle size to reduce operator fatigue Lar
29. B Installation Waterborne Electrostatic Air Assisted Spray Gun XY Pam a Supp Line YY Grounaing Cynder Pump Fluid Outlet Fitting Isolated Enclosure Door not shown to illustrate internal components Door must be closed and locked to operate system Enclosure T Handle Locking Screw part of door assembly CC Accessory Bleed Type Air Shutoff Valve These items are required for safe operation They are included with the WB3000 system 19 Installation Agitator Kit Accessory To add an agitator to the Graco isolation system order Part No 245895 See 245895 Agitator Kit page 75 for the kit parts list 1 20 Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure page 25 Relieve the pressure see Pressure Relief Procedure page 26 Open the isolated enclosure door Remove the back of the control box 258 Remove tube A2 from elbow 282 at the air manifold see Install the Y fitting 402 into the elbow Install tubes A2 and 407 into the Y fitting Route the agitator tube 407 into the cabinet Replace the back of the control box 258 Assemble the other parts of the kit as shown secure the agitator with the setscrew 408 Return the system to service ti2137a Figure 13 245895 Agitator Kit 3A249 7B Gun Setup Grounding When operating the electrostatic gun any ungrounded objects in the spray area people containers tools etc
30. Instructions Parts gt g WB3000 Isolation System amp Pro Xp 60 AA WB Gun AARE S Air assisted spray system for use when electrostatically spraying conductive waterborne fluids that meet at least one of the conditions for non flammability listed on page 3 For professional use only Important Safety Instructions Read all warnings and instructions in this manual Save these instructions 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 PROVEN QUALITY LEADING TECHNOLOGY Contents AKELE LE e ene ee On eee Re A Oe NA E Ee TEC ae A WVAamMNis e alieni GUN OVE O a olii ibi el ls How the Electrostatic AA Spray Gun VWOTKS asili Spraying Waterborne Fluids Electrostatically Controls Indicators and Components Smart GUNS lella Installation a a tiene ace neo System Requirements VWamnNg Slasa Install the System Ventilate the Spray Booth AIP SUDDIY LING aisetiaisatacatuaistee ees Ground the Cabinet Connect the Waterborne Fluid Hose Agitator Kit Accessory GUNSSUpiroa lia CSF OCINGIING Litta Check Gun Electrical Grounding Flush Before Using Eq
31. See Air Cap Assembly page 70 24N643 ELECTRODE package of 5 1 page 68 AEFxxx choice includes item 27a a Replacement Danger and Warning labels tags and cards are available at no cost kl N These parts are included in Air Seal Repair Kit 24N789 purchase separately 3A249 B No ADJUSTMENT VALVE page 69 page 70 24E404 STOP trigger includes item 32a PIN dowel 185103 TUBE exhaust 1 4 in 6 mm ID shipped loose i O 110231 CLAMP 24N785 CAP spring includes item 37a N Ta 197624 SPRING compression W 8 24N786 PLUG fan control option shipped loose for use in place of item 29 245265 CIRCUIT flexible 24N783 HOOK includes screw AK a I 24N604 COVER gun package of 10 54 222385 CARD warning not shown 64 186118 SIGN warning not shown 116553 GREASE dielectric 1 oz 30 ml tube not shown 117824 GLOVE conductive medium package of 12 also available in small 117823 and large 107460 TOOL wrench ball end shipped loose 276741 MULTI TOOL shipped loose 101 24M508 HOSE unshielded waterborne fluid includes 101a 101a si CONNECTOR barrel Q1 112080 TOOL needle shipped loose N Parts labeled are not available separately 63 Parts Isolation Enclosure Part No 24N550 Waterborne Isolation Enclosure for use with unshielded waterborne fluid hose includes items
32. TFE Suction Tube Polyethylene Stainless Steel Merkur Pump See manual 3A0732 3A249 B 7 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 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 This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of str
33. To enter Diagnostic Mode press and hold the LO SET LS button for approximately 5 seconds The display will go to the Voltage kiloVolts Screen page 13 To advance to the next screen press the LO SET button again To exit Diagnostic Mode press and hold the LO SET button for approximately 5 seconds The screen will return to Operating Mode NOTE If the gun is detriggered while in Diagnostic Mode the last screen viewed will be displayed when the gun is retriggered NOTE Diagnostic Mode cannot be exited from the Low Voltage Lock Screen See Low Voltage Lock Screen page 14 for details Voltage kiloVolts Screen The Voltage kiloVolts Screen is the first screen to appear after entering Diagnostic Mode See Fig 6 and Table 1 on page 11 To enter this screen press and hold the LO SET button for approximately 5 seconds while in the Operating Mode This screen displays the spraying voltage of the gun as a number kV rounded to the nearest 5 kV The two top right LEDs VI of the display panel light indicating that the Voltage kiloVolts Screen is displayed The display is a readout and cannot be changed Press the LO SET button to advance to the Current microAmperes Screen page 13 Press and hold for approximately 5 seconds to return to Operating Mode 3A249 B Gun Overview ti19123a Figure 6 Voltage kiloVolts Screen Current microAmperes Screen The Current microAmperes Screen is the second scree
34. an the air cap holes Do not use metal tools ti18773a 34 10 Align the spray tip tab with the groove in the air cap Install the tip ti19765a 11 Install the air cap and retaining ring Orientate the air cap and tighten the retaining ring securely ti19542a 3A249 7B Daily System Care 1 6 Follow the instructions under Clean the Gun Daily page 33 Follow the Pressure Relief Procedure page 26 Clean the fluid and air filters Check for fluid leaks Tighten all fittings Clean workpiece hangers Use non sparking tools Check the movement of the trigger and valves Lubricate if necessary Check Gun Electrical Grounding page 23 3A249 B Maintenance 7 Hang the gun from its hook with the nozzle pointing down 8 Clean the cabinet e 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 Apply silicone free grease to the threads when necessary Visually inspect the ground strip 240 for damage Replace if needed Measure the resistance weekly See Test Ground Strip Resistance page 39 ti2162a 35 Electrical Tests Electrical Tests Use the following procedures to test the condition Test Gun R
35. ance is still outside the range the gun barrel remove the conductive ring 9 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 9 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 G ti19901a ti19544a Figure 19 Test Gun Barrel Resistance 36 3A249 7B Test Ground Strip 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 240 206 GRACO ti2165a Figure 20 Test Ground Strip Resistance 3A249 B Electrical Tests Test Cylinder Resistance 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 If greater than 100 ohms replace the grounding cylinder pal ti20018a Figure 21 Test Cylinder tg 39 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 service this equipment unless yo
36. ate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Keep spray area free of debris including solvent rags and gasoline Keep a working fire extinguisher in the work area SKIN INJECTION 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 immediate surgical treatment Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately PLASTIC PARTS CLEANING SOLVENT HAZARD Many solvents can degrade plastic parts and cause them to fail which could cause serious injury or property damage MPafbar PSI 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 solve
37. cement 52 Alternator Removal and Replacement 53 Fan Air Adjustment Valve Repair 55 Atomizing Air Adjustment Valve REPA lie iaia 55 ES On Off Valve Repair 56 Air Valve Repair 57 Smart Module Replacement 58 Air Swivel and Exhaust Valve Replacement 59 Palio Ae elba 60 Standard Air Assisted Spray Gun ASSE mbl y irern tati 60 Smart Air Assisted Spray Gun ASSE mD Voria i 62 Isolation Enclosure 64 Alternator Assembly cece cece ee eeeeeeees 67 ES On Off Valve AssemDlY 68 Fan Air Valve Assembly 69 Air Cap Assembly 70 Smart Module ASSemMDIY 70 Spray Tip Selection Chart 71 AEM Fine Finish Spray TipsS 71 AEF Fine Finish Pre Orifice Spray TIPS siii iaia 72 Repair Kits Related Manuals and AGCESSONES sile 73 Gun ACCESSONES sack inietta 73 Operator Accessories 73 System ACCESSOries 73 FIO SCS tite lia 14 POSE EB QUIDMENE suriin a 74 245895 Agitator Kit cece cece seen eees 75 DIMEensionsa ideale lle 76 Teennicel Data Tf Graco Pro Xp Warranty 78 3A249 B Models
38. ch the excess fluid must be electrically conductive and grounded Air compressors ground the equipment according to the manufacturer s recommendations All air lines must be properly grounded Use only grounded hoses with a maximum of 100 feet 30 5 m combined hose length to ensure grounding continuity 27 Gun Setup e The floor of the spray area must be electrically All persons entering the spray area must wear conductive and grounded Do not cover the floor shoes having conductive soles such as leather with cardboard or any non conductive material or wear personal grounding straps Do not which would interrupt grounding continuity wear shoes with non conductive soles such as jiza rubber or plastic 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 YAA grounded gun handle ti18731a fai e All solvent pails use only approved grounded metal containers which are conductive Do not use plastic containers Only use non flammable solvents Do not store more than the quantity needed for one shift ti18724a 22 3A249 B Check Gun Electrical Grounding Megohmmeter Part No 241079 AA see Fig 14 is not approved for use in a hazardous area To reduce the risk of sparking do not use the megohmmeter to check electrical grounding unless e The gun has been
39. e fluid supply unit must be electrically connected to the bleed resistor A Safety interlock that automatically discharges the system voltage when anyone opens the isolation enclosure NOTICE The system should not have any severe arcing occurring when the isolation mechanism opens and closes Severe arcing will shorten the life of the system components NOTE The Graco warranty and approvals are void if the electrostatic spray gun is connected to a non Graco voltage isolation system or if the gun is operated above 60 kV Warning Sign Mount warning signs in the spray area where they can easily be seen and read by all operators An English Warning Sign is provided with the gun 3A249 B Installation Install the System Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly e Do not install or service this equipment unless you are trained and qualified Be sure your installation complies with local state and national codes for the installation of electrical apparatus in a Class Div Hazardous Location or Group Il Zone Explosive Atmosphere Location Comply with all applicable local state and national fire electrical and other safety regulations Fig 12 shows a typical electrostatic air assisted spray system It is not an actual system design For assistance in designing a system to suit your
40. e gun handle If necessary gently move the gun barrel from side to side to free it from the gun handle Hold the gun handle 16 with one hand and pull the barrel 1 straight off the handle 60 ti20014a Figure 27 Gun Barrel Removal 50 Gun Barrel Installation 1 Be sure the gasket 5 and grounding spring 37a are in place Make sure the gasket air holes are aligned properly Replace the gasket if damaged 2 Make sure the spring 11a is in place on the tip of the power supply 11 Liberally apply dielectric grease 57 to the tip of the power supply Place the gun barrel 1 over the power supply and onto the gun handle 16 3 Tighten the two screws 6 oppositely and evenly about a half turn past snug Do not over tighten the screws 6 4 Position the bracket B on the gun handle 16 and secure with the air inlet fitting 21 5 See Test Gun Resistance page 36 ti20015a Figure 28 Gun Barrel Installation 3A249 7B Fluid Needle Replacement See Prepare the Gun for Service page 47 Remove the air cap assembly and fluid seat housing See Air Cap Spray Tip and Fluid Seat Housing Replacement page 48 Remove the gun barrel See Gun Barrel Removal page 50 Remove the trigger screws 13 and trigger 12 Unscrew the spring cap 37 Remove the spring 20a Insert the supplied driver 60 in the socket at the back of the fluid needle Press forward so the two segments of th
41. e needle engage R This allows the needle to be unscrewed from the gun body Using the multi tool 61 pull back on the packing nut N to remove the fluid needle assembly Install the fluid needle assembly in the gun barrel Push in on the needle with the driver 60 and tighten Install the spring 20a Install the spring cap 37 Make sure the grounding spring 37a is in place Install the trigger 12 and screws 13 Install the gun barrel See Gun Barrel Installation page 50 Install the seat housing and air cap assembly See Air Cap Spray Tip and Fluid Seat Housing Replacement page 48 See Test Gun Resistance page 36 3A249 B Figure 29 Remove Cap and Springs Figure 31 Replace Fluid Needle ti20021a 60 ti20023a Repair 57 Repair Power Supply Removal and Replacement Inspect the gun handle power supply cavity for dirt align the connector of the 6 pin flexible circuit or moisture Clean with a clean dry rag 40 with the socket CS at the top of the handle Do not expose gasket 5 to solvents 1 2 52 Push the connector securely into the socket as you slide the power supply alternator assembly See Prepare the Gun for Service page 47 into the handle See Gun Barrel Removal page 50 lt gt NOTICE Be careful when handling the power supply CS 11 to avoid damaging it Grasp the power supply 11 with your hand With a gentle side to
42. eas Repair or replace the component that is failing a Fluid hose e Check for leakage or any bulges in the outer cover which may indicate a pin hole leak through the inner layer Disconnect the fluid hose from the gun and look for signs of fluid contamination on the outside of the inner portion of the fluid tube e Inspect the end of the hose connected to the voltage isolation system Look for cuts or nicks b Fluid needle Remove the fluid needle from the gun see Fluid Needle Replacement page 51 and look for signs of fluid leakage or any blackened areas which would indicate arcing is occurring along the packing rod c Fluid hose connection to the spray gun A breakdown at the fluid hose connection joint would be caused by fluid leaking past the hose fittings Remove the hose at the gun connection and look for signs of fluid leakage Before reassembling the gun clean and dry the gun fluid inlet tube Repack the inner spacer of the fluid packing rod with dielectric grease and reassemble the gun Reconnect the fluid hose Check the gun voltage with the voltage probe and meter before filling the gun with fluid 3A249 B Troubleshooting Spray Pattern Troubleshooting NOTE Some spray pattern problems are caused by the improper balance between air and fluid Fluttering or spitting spray No fluid Refill supply Air in fluid supply Check fluid source Refill Irregular pattern Fluid buildup
43. een the gun and the isolated fluid supply causing a low voltage reading on the isolation system voltage meter Voltage Isolation System e Fluid leakage e Dirty interior 3A249 7B 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 Check that the interior of the isolated enclosure is clean 4 Check that the spray gun and voltage isolation system have sufficient air pressure 5 Check that the gun ES ON OFF valve is in the ON position and that the gun ES indicator light is on If the ES indicator light is not on remove the spray gun for service and complete the Electrical Tests page 36 6 Check that the voltage isolation system s enclosure door is closed and that any safety interlocks are engaged and working properly 3A249 B 10 Troubleshooting Make sure the voltage isolation system is in the isolate mode where it is isolating the fluid voltage from ground To eliminate air gaps in the fluid column spray enough fluid to purge the air out between the voltage isolati
44. egulator is shut off Connect the To reduce the risk of electric shock or other main air supply line A to the bleed valve serious injury you must use the red colored 5 Graco Electrically Conductive Air Hose for the gun air supply and you must connect the hose ground wire to a true earth ground Do not use the black or gray colored Graco air hoses Install an additional bleed type air valve CC upstream of the air filter M to isolate the filter for servicing Ground the Cabinet 3 Connect the red colored Graco Electrically Conductive Air Hose P between the gun air regulator N and the gun s air inlet The gun air inlet fitting has a left hand thread Connect the air supply hose ground wire Q to a true earth ground Connect the main ground wire V to a true earth ground 16 3A249 7B Connect the Waterborne Fluid Hose Always use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun fluid inlet Before connecting the waterborne fluid hose to the gun blow it out with air and flush with water to remove contaminants Flush the gun before using it To reduce the risk of electric shock install only one continuous Graco waterborne hose between the isolated fluid supply and the gun Do not splice hoses together 1 Remove the gun air inlet fitting 21 Installation Make sure the barrel fluid inlet is clean and dry Apply dielectric grease to the threads of
45. elief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations 6 3A249 7B Gun Overview 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 atomizes and shapes the fluid into a fan pattern as does a conventional airless spray tip Air from the air cap further atomizes the fluid and completes the atomization of the fluid tails to produce a uniform pattern As the gun is triggered part of the regulated air operates the alternator turbine and the rest of the air helps atomize the fluid being sprayed The alternator gene
46. esistance of the power supply and gun body and electrical continuity between components 1 Flush and dry the fluid passage NOTICE 2 Measure resistance between the electrode i needle tip 25a and the air swivel 21 The gun body resistor cartridge is part of the body The resistance should be 104 150 and is not replaceable To avoid destroying the gun megohms If outside this range go to body do not attempt to remove the body resistor Test Power Supply Resistance page 37 If in range see Electrical Troubleshooting page 45 for Use megohmmeter Part No 241079 AA with an other possible causes of poor performance or applied voltage of 500 V Connect the leads as contact your Graco distributor shown Megohmmeter Part No 241079 AA see Fig 17 is not approved for use in a hazardous area To reduce the risk of sparking do not use the megohmmeter to check electrical grounding unless e The gun has been removed from the hazardous area Or all spraying devices in the hazardous area are turned off ventilation fans in the hazardous area are operating and there are no flammable vapors in the area such as open solvent containers or fumes from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage ti18794a Figure 17 Test Gun Resistance 36 3A249 7B Electrical Tests Test Power Supply Resistance 1 Remove the power supply
47. g ring Orientate the air cap and tighten the retaining ring securely ti18801a 3A249 B Operation 11 Close the atomizing air adjustment valve G and the fan air adjustment valve F 12 Check that the ES On Off switch is OFF O 13 Start the pump Set the fluid regulator to 400 psi 2 8 MPa 28 bar 14 Spray a test pattern Examine the particle size in the center of the pattern tails will be removed in step 18 Increase the pressure in small increments Spray another pattern Compare particle size Continue increasing pressure until the particle size remains constant Do not exceed 3000 psi 21 MPa 210 bar ti18806a 15 Turn ON I the ES On Off switch 29 Operation 16 Check that the ES indicator Hz indicator on Smart guns is lit or check that the kV indicator on the isolated enclosure reads 30 50 kV The actual spraying voltage for AA waterborne systems is 40 50 kV but because the charging electrode does not directly contact the fluid the voltage measured by the WB3000 kV meter will be 5 10 kV lower See the following table Table 2 LED Indicator Colors Indicator Description Color Green When spraying the indicator should remain green indicating sufficient air pressure to the alternator turbine Amber If the indicator turns amber after 1 second the air pressure is too low Increase air pressure until the indicator is green If the indicator
48. ge size 186118 English Warning Sign Available at no charge from Graco 24N642 Air Inlet Ball Swivel 1 4 18 npsm m left hand thread 185493 Air Hose Adapter 1 4 npt m x 1 4 18 npsm m left hand thread 112534 Air Line Quick Disconnect Fitting 3A249 B 73 Repair Kits Related Manuals and Accessories Hoses Grounded Air Hoses 700 psi 0 7 MPa 7 bar Maximum Working Pressure 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread Grounded Air Hose with stainless steel braid ground path Red 235068 6 ft 1 8 m 235069 15 ft 4 6 m 50 ft 15 m 74 Test Equipment 241079 Megohmmeter 500 V output 0 01 2000 megohms Use for ground continuity and gun resistance tests Not for use in hazardous areas 245277 Test Fixture High Voltage Probe and kV Meter Use to test the electrostatic voltage of the gun and the condition of the alternator and power supply when being serviced See manual 309455 3A249 B Repair Kits Related Manuals and Accessories Ref Part No Description Qty N 401 112698 ELBOW swivel 1 8 npt m x 1 1 4 in 6 mm OD tube 14158 FITTING adapter Y 1 4 in 6 1 mm OD tube mxfxf 193315 COLLAR mounting agitator 245895 Agitator Kit To keep fluid mixed and prevent settling out Includes items 401 408 197298 COVER pail 5 gal 19 liter 224571 AGITATOR see manual 1 306565 407 pur TUBE nylon 1 4 in 6 mm 1 chase OD 4
49. if the Smart module loses communication with the power supply See Fig 3 Voltage Indicator In Diagnostic Mode the two top right LEDs of the screen light indicating that the value displayed is in kV See Fig 6 11 Gun Overview Ren poemi Current Indicator Alternator Speed Display Alternator Speed Indicator 12 In Diagnostic Mode the two bottom right LEDs of the screen light indicating that the value displayed is in uA See Fig 7 In Diagnostic Mode Hz level is displayed as a number See Fig 8 In Operating Mode indicator color varies to show the alternator speed status e green indicates the alternator speed is at the correct level If the indicator changes to amber after 1 second the alternator speed is too low If the indicator changes to red after 1 second the alternator speed is too high The indicator will also turn red if the Error display appears In Diagnostic Mode the indicator is green when in the Alternator Speed Hertz screen 3A249 B Diagnostic Mode Diagnostic Mode includes four screens which display gun data e Voltage kiloVolts Screen e Current microAmperes Screen e Alternator Speed Hertz Screen e 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
50. igure 22 Remove Air Cap 3 Disassemble the air cap assembly Check the condition of the u cup 22a o ring 25b and tip gasket 27a Replace any damaged parts 25b 25 22a 2 25a ti19521a Figure 23 Disassemble Air Cap Assembly ti19766a Figure 24 Tip Gasket 4 To replace the electrode 25a see Electrode Replacement page 49 48 NOTICE The conductive ring 9 is a conductive metal contact ring not a sealing o ring For best performance and to avoid potential damage to the spray gun do not remove the conductive ring 9 except to replace it and never operate the gun without the conductive ring in place Do not replace the conductive ring with anything but a genuine Graco part Trigger the gun and remove the fluid seat housing 24 using the multi tool 61 ti20017a Figure 25 Replace Fluid Seat Housing 3A249 7B 6 11 12 NOTICE Do not overtighten the fluid seat housing 24 Overtightening may damage the housing and the gun barrel resulting in improper fluid shutoff Trigger the gun and install the fluid seat housing 24 Tighten until snug then 1 4 turn more Check that the spray tip gasket 27a is in place Align the spray tip tab with the groove in the air cap 25 Install the spray tip 27 in the air cap Make sure that the electrode 25a is installed correctly in the air cap Check that the air cap o ring 25b is in place
51. int symbol alerts you to a general warning and the hazard symbol refers 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 ELECTRIC SHOCK HAZARD Improper grounding setup or usage of an isolated waterborne system can result in electric shock To help prevent electric shock Ground all equipment personnel object being sprayed and conductive objects in or close to spray area See Grounding instructions Connect the electrostatic gun to a voltage isolation system that will discharge the system voltage when not in use All components of the isolation system that are charged to high voltage must be contained within an isolation enclosure that prevents personnel from making contact with the high voltage components before the system voltage is discharged Follow the Fluid Voltage Discharge and Grounding Procedure when instructed to discharge the voltage before cleaning flushing or servicing the system before approaching the front of the gun and before opening the isolation enclosure for the isolated fluid supply Do not enter a high voltage or hazardous area until all high voltage equipment has been discharged Do not touch the gun nozzle or electrode or come within 4 in 102 mm of the electrode during gun operation Foll
52. ipment 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 To reduce the risk of injury follow the Pressure Relief Procedure page 26 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure e Check all possible remedies in Troubleshooting page 40 before disassembling the gun 3A249 B Repair Use a vise with padded jaws to prevent damage to plastic parts Lubricate the some needle assembly parts 20 and certain fluid fittings with dielectric grease 57 as specified in the text Lightly lubricate o rings and seals with non silicone grease Order Part No 111265 Lubricant Do not over lubricate 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 Kit parts are marked with an asterisk for example 3 Flush the gun See Flushing page 31 Relieve the pressure See Pressure Relief Procedure page 26 Disconnect the gun air and fluid lines Remove the gun from the worksite Repair area must be clean 4 Repair Air Cap Spray Tip and Fluid Seat Housing Replacement 1 See Prepare the Gun for Service page 47 2 Remove the retainer ring 22 and air cap tip guard assembly 25 ti20016a F
53. ist of models which include an air hose and gun 3A249 7B Parts Alternator Assembly Part No 24N664 Alternator Assembly 15f 15e 15g 15h ti18639b Ref Part Description Qty Ref Part Description Qty No No No No 15a 24N705 COIL alternator 1 15f CAP housing part of item 1 15d 15g 110073 110073 O RING 15b 24N706 BEARING KIT includes two 1 bearings item 15e fan and one item 15h clip 15h 24N709 CLIP package of 5 one clip 1 included with item 15b 15d 24N707 HOUSING includes item 15f These parts are included in Air Seal Repair Kit Parts labeled are not available separately 24N789 purchase separately These parts are included in Bearing Kit 24N706 purchase separately 3A249 B 67 Parts ES On Off Valve Assembly Part No 24N632 ES On Off Valve Assembly 26d 26f 26b P 26g 26e 26p ti18648a Ref Part No Description Qty No No ase SGREW set societ esa 2 ase screw canive it po sar femme p PISTON valve si valve PISTON vave sd sd La ies LEVER ES on off includes item 26e These parts are included in Air Seal Repair Kit Parts labeled are not available separately 24N789 purchase separately 68 3A249 7B Fan Air Valve Assembly Part No 24N634 Fan Air Valve Assembly 30b 30c 30a 30d ti18647a 3A249 B
54. ll fluid spills in the isolated enclosure Fluid can create a conductive path and cause the system to short out 3A249 B Operation Clean up any fluid spills in the enclosure using a soft cloth and a non flammable compatible solvent Fill the supply pail with fluid and return it to the enclosure Clean up any spills Reinstall the pail cover holding a rag over the suction tube strainer to prevent fluid spills while you place the pump suction tube in the pail Close the isolated enclosure door and fasten securely with the T handle locking screw 2 Operation Adjust the Spray Pattern To reduce the risk of an injury follow the Pressure Relief Procedure page 26 whenever you are instructed to relieve the pressure To reduce the risk of fire and explosion fluids used must meet the following flammability requirements e 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 500m4J Follow the steps below to establish the correct fluid flow and air flow See Fig 16 to locate the electrostatic gun controls Contact with the charged components of the spray gun will cause an electric shock Do not touch the gun nozzle or electrode or come within 4 in 102 mm of the electrode during operation or
55. lowing flammability requirements e 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 500mJ 3A249 B 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 To avoid an electric shock follow the Fluid Voltage Discharge and Grounding Procedure whenever you are instructed to discharge the voltage before cleaning flushing or servicing the system equipment before approaching the front of the gun or before opening the isolation enclosure for the isolated fluid supply Turn the ES ON OFF valve OFF and wait 30 seconds to allow the voltage to discharge through the bleed resistor O ti18730a Fully unscrew the door T handle locking screw This will shut off the air to the gun and trigger the grounding cylinder to discharge any remaining electrical charge Use the grounding rod to touch the pump and supply pail If you see any arcs see Electrical Troubleshooting page 45 25 Operation Pressure Relief Procedure 5 Disengage the trigger lock This equipment stays
56. n in the Diagnostic Mode See Fig 7 and Table 1 on page 11 To enter this screen press the LO SET button while in the Voltage kiloVolts Screen This screen displays the spraying current of the gun as a number uA rounded to the nearest 5 uA The two bottom right LEDs Cl of the display panel light indicating that the Current microAmperes Screen is displayed The display is a readout and cannot be changed Press the LO SET button to advance to the Alternator Speed Hertz Screen page 14 Press and hold for approximately 5 seconds to return to Operating Mode ti19124a Figure 7 Current microAmperes Screen 13 Gun Overview Alternator Speed Hertz Screen The Alternator Speed Hertz Screen is the third screen in the Diagnostic Mode See Fig 8 and Table 1 on page 11 To enter this screen press the LO SET button while in the Current microAmperes Screen This screen displays the alternator speed as a 3 digit number AS rounded to the nearest 5 Hz The display is a readout and cannot be changed If the alternator speed is greater than 999 Hz the display will show 999 The Hz indicator lights green to show that you are viewing the Alternator Speed Hertz Screen Press the LO SET button to advance to the Low Voltage Lock Screen page 14 Press and hold for approximately 5 seconds to return to Operating Mode AS H E eS HEI LO Hz VA LS ti19125a Figure 8 Alternator Speed Her
57. nt manufacturers MSDSs and recommendations 3A249 B 5 Warnings TOXIC FLUID OR FUMES Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDSs to know the specific hazards of the fluids you are using Store hazardous fluid in approved containers and dispose of it according to applicable guidelines 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 e 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 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 system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure R
58. olvent flows from the gun ti18792a 31 Maintenance 7 Follow the Pressure Relief Procedure page 26 10 Open the isolated enclosure door Leave the Engage the trigger lock flushing fluid in the system until you are ready to spray again 11 Hang the gun from its hook with the nozzle pointing down Be sure to keep the gun from grounding out 8 Align the spray tip tab with the groove in the air cap Install the tip 12 Before using the system electrostatically again make sure no flammable vapors are present 32 3A249 7B Clean the Gun Daily 1 Turn OFF O the ES On Off switch Z NO z LONS N ww gt ti18730a 2 Discharge the system voltage See Fluid Voltage Discharge and Grounding Procedure page 25 Follow the Pressure Relief Procedure page 26 4 Remove the air cap tip guard and spray tip ti19765a 5 Flush the gun see Flushing page 31 6 Follow the Pressure Relief Procedure page 26 3A249 B Maintenance Clean the outside of the gun with a non flammable solvent as defined under Flushing page 31 Use a soft cloth Point the gun down to prevent solvent from entering the gun passages Do not immerse the gun ti18809a ti18810a ti18811a 33 Maintenance 8 Clean the air cap tip guard and spray tip with a soft brush and non flammable solvent ti19539a 9 If necessary use a toothpick or other soft tool to cle
59. on system and the spray gun An air gap in the fluid hose can break the electrical continuity between the spray gun and the isolated fluid supply and cause a low voltage reading on a voltage meter connected to the isolated fluid supply Check the spray gun cover and barrel for accumulated overspray Excessive overspray can create a conductive path back to the grounded gun handle Install a new gun cover and clean the exterior of the gun Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found Pay special attention to the following areas Packing area of the spray gun e Fluid hose check for leakage or any bulges in the outer cover which may indicate an internal leak e Internal voltage isolation system components 41 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 10 42 Flush the system with water and leave the lines filled with water Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure page 25 Follow the Pressure Relief Procedure page 26 Disconnect the fluid hose from the voltage isolation system Avoid allowing any water to leak out of the fluid hose as that could cause a significant air gap in the fluid column up to the gun electrode which can break the conductivity
60. ow the Fluid Voltage Discharge and Grounding Procedure Interlock the gun air supply with the voltage isolation system to shut off the air supply anytime the isolation system enclosure is opened Only use the red colored Graco electrically conductive gun air hose with this gun Do not use black or gray colored Graco air hoses Do not splice hoses together Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the spray gun 4 3A249 B Warnings FIRE AND EXPLOSION HAZARD Combustible dust in work area can ignite or explode To help prevent fire and explosion e Fluids used must meet the following flammability requirements e 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 500mdJ Stop operation immediately if static sparking occurs or you feel a shock Do not use equipment until you identify and correct the problem Check gun resistance hose resistance and electrical grounding daily Use and clean equipment only in well ventilated area Interlock the gun air supply to prevent operation unless ventilating fans are on Only use non flammable solvents when flushing or cleaning equipment Always turn the electrostatics off when flushing cleaning or servicing equipment Elimin
61. r inlet M12 x 1 4 npsm m left hand thread 24N793 RING retainer includes 22a 22a 1198307 PACKING u cup UHMWPE part of 22 24N633 VALVE air 276733 SEAL 24N725 HOUSING seat 24N727 See Air Cap Assembly page 70 24N643 ELECTRODE package of 5 1 24N632 See ES On Off Valve Assembly page 68 a Replacement Danger and Warning labels tags and cards are available at no cost kl N These parts are included in Air Seal Repair Kit 24N789 purchase separately 3A249 B TIP ASSEMBLY customer s AEFxxx choice includes item 27a Ta 183459 GASKET tip 9 24N792 ATOMIZING AIR ADJUSTMENT VALVE 24N634 See Fan Air Valve Assembly page 69 24E404 STOP trigger includes item 32a PN dont 185103 TUBE exhaust 1 4 in 6 mm ID shipped loose 110231 CLAMP NI O WI W WWW Wt NIN NIZ S NIO Q 8 24N786 PLUG fan control option shipped loose for use in place of item 29 24N783 HOOK includes screw N 24N604 COVER gun package of 10 54 222385 CARD warning not shown 64 186118 SIGN warning not shown 116553 GREASE dielectric 1 oz 30 ml tube not shown 117824 GLOVE conductive medium package of 12 also available in small 117823 and large 07460 TOOL wrench ball end shipped loose 276741 MULTI TOOL shipped loose 101 24M508 HOSE unshielded waterborne fluid includes 101a 101a se CONNECTOR barrel Parts labeled
62. rates power which is converted by the power cartridge to supply high voltage to the gun s electrode The gun s internal power supply provides high voltage The fluid is electrostatically charged as it passes the electrode The charged fluid is attracted to the grounded workpiece wrapping around and evenly coating all surfaces The regulated air that is directed to the air cap can be further controlled using the gun s atomizing air adjustment valve This valve can be used to restrict air flow to the air cap while maintaining sufficient air flow to the alternator The atomizing air adjustment valve does not control pattern width To change pattern width use a new tip size or use the fan adjustment to narrow the pattern width The high working fluid pressure of this gun provides the power needed to atomize higher solids materials NOTE For airless atomization if desired turn the gun s atomizing air adjustment valve completely off Closing this valve does not affect alternator operation 3A249 B Gun Overview Spraying Waterborne Fluids Electrostatically This electrostatic air assisted spray gun is designed to spray only waterborne fluids which meet the following flammability requirements e FM FMc Approved Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures ASTM D4206 e CE EN 50059 Compliant Materials which cannot be ignited in any mixture
63. rn fluid seat housing See Air Cap Spray Tip and Fluid Seat Housing Replacement page 48 Loose spray tip Tighten retaining ring Damaged tip seal See Air Cap Spray Tip and Fluid Seat Housing Replacement page 48 Gun does not spray Low fluid supply Add fluid if necessary Dirty or clogged spray tip Clean See Clean the Gun Daily page 33 Damaged fluid needle See Fluid Needle Replacement page 51 Dirty air cap Damaged or plugged air cap Clean air cap See Clean the Gun Daily page 33 Excessive paint wrap back to Poor grounding See Grounding page 21 Operator Incorrect distance from gun to part Should be 8 12 in 200 300 mm 44 3A249 B Troubleshooting Electrical Troubleshooting 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 Atomizing air pressure too high 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 100 ohms or less Clean workpiece hangers Faulty gun resistance See Test Gun Resistance page 36 Fluid leaks from the fluid needle See Fluid Needle Replacement packings and causes a short page 51 Faulty alternator See Alternator Removal and Replacement page 53 ES or Hz indicator is not lit ES On Off switch i
64. s OFF O Turn ON I No power Check power supply alternator and alternator ribbon cable See Power Supply Removal and Replacement page 52 and Alternator Removal and Replacement page 53 Operator gets mild shock Operator not grounded or is near See Grounding page 21 ungrounded object Gun not grounded See Check Gun Electrical Grounding page 23 and Test Gun Resistance page 36 Operator gets shock from Workpiece not grounded Resistance must be 100 ohms or workpiece less Clean workpiece hangers 3A2497B 45 Troubleshooting 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 Dirty gun See Clean the Gun Daily page 33 ES or Hz indicator is amber Air turbine speed is too low Increase air pressure until indicator is green To avoid over atomization use the atomizing air restrictor valve to reduce the atomizing air to the air cap ES or Hz indicator is red Air turbine speed is too high Decrease air pressure until indicator is green Error display appears and Hz Smart module has lost Check for good connections indicator is red Smart guns only communication with the power between Smart Module and supply power supply See Smart Module Replacement page 58 and Power Supply Removal and Replacement page 52 46 3A249 7B Repair Prepare the Gun for Service Installing and repairing this equ
65. s shown in Fig 34 Rotate the fan 15e so its blades clear the four bearing tabs T at the back of the housing 15f 15e ti19739b Figure 36 Alternator 15 16 17 Ensure that the blades of the bottom bearing 15b1 align with the tabs Seat the coil fully into the housing 15d Secure with the clip 15h ensuring that its tabs engage the slots in the housing Ensure that the o ring 15g is in place Install the cap 15f Install the alternator on the power supply and install both parts in the handle See Power Supply Removal and Replacement page 52 15h 3A249 7B Fan Air Adjustment Valve Repair 1 See Prepare the Gun for Service page 47 2 Place awrench on the flats of the valve assembly 30 and unscrew it from the handle 16 NOTE You may replace the valve as an assembly go to step 9 or as individual parts steps 3 9 Remove the retaining ring 30d 4 Turn the valve shaft 30b counterclockwise until it comes free from the valve housing 30a Remove the o ring 30c 6 Clean all parts and inspect for wear or damage NOTE Use non silicone grease Part No 111265 Do not over lubricate 7 When reassembling the fan air valve 30 lightly lubricate the valve threads and screw the shaft 30b fully into the housing 30a until bottomed Install the o ring 30c lubricate and unscrew the valve stem until the o ring enters the housing
66. s the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original Instructions This manual contains English MM 3A2497 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2012 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised July 2013
67. t 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 Pull the Smart Module out the back of the gun Disconnect the ribbon cable RC from the connector GC in the gun handle 5 Remove the gasket 31b 6 Install a new gasket 31b on the new cartridge 31a Make sure the notched corners of the gasket are at the top 7 Align the module s ribbon cable RC with the gun s cable GC and slide them securely together as shown Tuck the connected cables into the recess of the gun handle Install the module flush to the back of the gun handle 8 Install the pivot screw 31e o ring 31f and ES HI LO switch in the bottom left corner of the cartridge 31a 9 Install the three remaining screws 31d Torque to 7 9 in Ib 0 8 1 0 Nem 58 Figure 42 Figure 43 31f 8 Y 31c 31e Smart Module GC ti21701a Align Ribbon Cables ti19455b 9 31d 3A249 7B Repair Air Swivel and Exhaust Valve Replacement See Prepare the Gun for Service page 47 2 To replace the air exhaust valve a Remove the clamp 36 and the exhaust tube 35 b Unscrew the swivel 21 from the gun handle 16 The swivel is a left hand thread Move the bracket out of the way c Pull the exhaust valve 8 from the handle 16 Inspect the o ring 8a and replace if
68. ted to a true earth ground If the resistance is still too high replace the air hose 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 Ky 214 CC ti2163a Figure 15 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 24 3A249 B Operation Operating Checklist Check the following list daily before starting the system O All operators are properly trained to operate an electrostatic waterborne air assisted spray system as instructed in this manual O All operators are trained in the Pressure Relief Procedure page 26 O The electrostatics are turned off and system voltage is discharged according to the Fluid Voltage Discharge and Grounding Procedure page 25 before any person en ters the isolation enclosure before cleaning and before performing any maintenance or repair O The system is grounded according to the instructions in Grounding page 21 O The Graco waterborne fluid hose is in good condition with no cuts or abrasions of the inner layer Replace hose if damaged O Ventilation fans are operating properly O All debris including flammable fluids and rags is removed from the spray area O Fluids used must meet the fol
69. ton until you reach the desired setting 70 3A249 7B Q O D MEN Key for Figs 2 9 Item lt gt O lt c gt m Tr Tr m lt 3A249 B Gun Overview Two position switch sets smart gun voltage to low setting LO or Voltage Adjustment Switch high setting HI This switch is functional in Operating Mode and in Diagnostic Mode Low Voltage Mode Indicator Lights blue when the smart gun is set to Low Voltage Voltage kV Display Displays actual spraying voltage of the gun in kV In Operating Mode display is a bar graph In Diagnostic Mode voltage is displayed as a number Current uA Display Displays actual spraying current of the gun in uA In Operating Mode display is a bar graph In Diagnostic Mode current is displayed as a number LO SET button Press momentarily to enter the Low Voltage Setting screen Press and hold for approximately 5 seconds to enter or exit Diagnostic Mode While in Diagnostic Mode press momentarily to advance through screens While on the Low Voltage Lock Screen in Diagnostic Mode press and hold to turn the lock on or off Low Voltage Display Displays the low voltage setting as a number The setting can be changed See Fig 4 Low Voltage Locked Appears if the low voltage setting is locked See Fig 5 and Fig 9 Lo Display Appears on the Low Voltage Lock Screen See Fig 9 Error Display Appears
70. tured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la redaction du pr sente document sera en Anglais ainsi que tous documents avis et procedures judiciaires executes donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents To place an order contact your Graco Distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflect
71. turns red after 1 second the air pressure is too high Decrease air pressure until the indicator is green 17 Set the gun air regulator to deliver a minimum of 45 psi 0 32 MPa 3 2 bar at gun when triggered to ensure full spraying voltage See the table below Table 3 Pressure Drop Air Hose Length in ft m using 5 16 in 8 mm diameter hose 15 4 6 52 0 36 3 6 Air Regulator Setting in psi MPa bar with gun triggered 25 7 6 57 0 40 4 0 50 15 3 68 0 47 4 7 75 22 9 80 0 56 5 6 100 30 5 90 0 63 6 3 30 18 Turn the atomizing air adjustment valve counterclockwise until any tails disappear JAY ti18807a 19 If desired atomization is not achieved change the tip size The smaller the tip orifice the finer the atomization 20 Spray a test piece Examine the edges for coverage If wrap is poor see Troubleshooting page 40 ti18808a NOTE If a narrower pattern is needed occasionally open the fan air adjustment valve slightly Excessive fan air flow can cause paint buildup on the air cap Shutdown 1 Discharge the system voltage See Fluid Voltage Discharge and Grounding Procedure page 25 2 Flush the gun See Flushing page 31 Follow the Pressure Relief Procedure page 26 4 Hang the gun from its hook with the nozzle pointing down Be sure to keep the gun from grounding out 3A249 7B Maintenance Flushing e Flush before changing
72. tz Screen 14 Low Voltage Lock Screen The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode See Fig 9 and Table 1 on page 11 To enter this screen press the LO SET button while in the Alternator Speed Hertz Screen This screen displays the status of the Low Voltage Lock If the setting is locked the lock image LK appears to the left of the Lo display LD If the setting is unlocked the lock image does not appear To change the lock status press and hold the LO SET button until the lock image appears or disappears If the lock is set the image will also appear on the Low Voltage Setting Screen when in low voltage mode see Fig 4 NOTE Diagnostic Mode cannot be exited from this screen because pressing and holding the LO SET button is used to turn the lock on or off To exit press LO SET momentarily to return to the Voltage kiloVolts Screen then exit Diagnostic Mode from there ti19339a Figure 9 Low Voltage Lock Screen 3A249 B Installation System Requirements A Graco voltage isolation system must have the following features e 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 e A bleed resistor to drain off the system voltage when the spray gun is not in use A metal part of th
73. u are trained and qualified Follow the Fluid Voltage Discharge and Grounding Procedure page 25 before checking or servicing the system and whenever you are instructed to discharge the voltage To reduce the risk of a skin injection injury always follow the Pressure Relief Procedure page 26 whenever you are instructed to relieve the pressure NOTE Check all possible remedies in the Troubleshooting Chart before disassembling the gun Voltage Loss Troubleshooting Normal spraying voltage for a system using the waterborne gun is 40 50 kV The system voltage is lower due to spraying current demands and voltage isolation system losses A loss of spraying voltage can be caused by a problem with the spray gun fluid hose or voltage isolation system since all of the system components 40 are electrically connected through the conductive waterborne fluid Before troubleshooting or servicing the voltage isolation system itself you need to determine which component in the system is most likely causing a problem Possible causes include the following Spray Gun e Fluid leakage Dielectric breakdown at the fluid hose connection or fluid packings e Not enough air pressure for the alternator turbine e Faulty power supply Excessive overspray on gun surfaces e Fluid in the air passages Waterborne Fluid Hose e Dielectric failure of the hose pin hole leak in the inner layer e Air gap in the fluid column betw
74. uctures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED ECOLA PURPOSE ER TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufac
75. uipment Operaio Riza ta te la i ina Operating CheckliSt Fluid Voltage Discharge and Grounding PROCCOUIC as ihicnllaaiaa ion Pressure Relief Procedure Fill the Fluid SUpplY Adjust the Spray Pattern SNUdoWNasli ccnl Maintenanc piaccia ira FUSNIN Lusia abile Clean the Gun Daily es Daily System Care Flectrical restsi arari rate Test Gun Resistance Test Power Supply Resistance Test Gun Barrel Resistance Test Ground Strip Resistance Test Cylinder Resistance Troubleshooting Voltage Loss Troubleshooting Spray Pattern Troubleshooting Gun Operation Troubleshooting Electrical Troubleshooting Nepali 47 Prepare the Gun for Service 47 Air Cap Spray Tip and Fluid Seat Housing Replacement 48 Electrode Replacement 49 Gun Barrel Removal 50 Gun Barrel Installation 50 Fluid Needle Replacement 51 Power Supply Removal and Repla
76. y To prevent damage to the cable and possible interruption of the ground continuity bend the alternator s 3 wire ribbon cable PC upward and back so the bend faces the power supply and the connector is at the top Connect the 3 wire ribbon connector PC to the power supply Tuck the ribbon forward under the power supply Slide the alternator 15 down onto the power supply 11 Insert the power supply alternator assembly in the gun handle 16 Make sure the ground strips make contact with the handle On Smart models Figure 33 Power Supply ti19532a 3A249 7B 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 4 1 See Prepare the Gun for Service page 47 2 Remove the power supply alternator assembly and disconnect the alternator See Power Supply Removal and Replacement page 52 3 Measure resistance between the two outer terminals of the 3 wire connector PC it should be 2 0 6 0 ohms If outside this range replace the alternator coil 15a 4 Using a flat blade screwdriver pry the clip 15h off the housing 15d Remove the cap 15f using a thin blade or screwdriver 5 If necessary rotate the fan 15e so its blades clear the four bearing tabs T of the housing 15d ti19741b Figure 34 Fan Orientation 6 Push the fan and coil assembly 1

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