Home

Graco Inc. 244581 Paint Sprayer User Manual

1. a jl L l m al a EE NG TI1897A NG Fig 7 Shielded Fluid Hose Connection at Graco WB100 Unshielded Hose 246431 12 0 in 305 mm TI2743A 309293K Installation See Warning below Pe as TI2744A Fig 9 Unshielded fluid connection WARNING Electric Shock Hazard W For Shielded hose systems Conductive hose layer C must be grounded through its connection to the iso lation system s grounded enclosure L or grounded safety fence To maintain grounding conti nuity the conductive hose layer C must be engaged in the ferrule when the strain relief nut is tightened Failure to properly install the hose in the strain relief could result in an electric shock b Non Graco Isolated Enclosure Connect hose as instructed in the isolation system manual and comply with the requirements in the Warn ing at right Refer to Fic 10 NOTE Ground layer C of hose must be grounded at isolation system C see note above m Fig 10 Shielded Fluid Hose Connection at Non Gra co Isolated Enclosure 13 Installation c Connect the end of the tube T to the pump fluid outlet fitting Z CAUTION The Graco warranty is void if the spray gun is con nected to a non Graco voltage isolation system or if the gun is operated above 60 kV N CAUTION Factory Mutual app
2. 22d 22 22g 22e N Y 22b N NG 22c NG a 22a Ng Na T N a N Fig 35 ES ON OFF Valve 51 Parts Parts Part No 244581 60 kV Electrostatic Gun Series B items 4 55 Part No 245301 60 kV Electrostatic Gun with Shielded waterborne fluid hose Series A items 4 55 101 108 See page 53 for detail views of the alternator 19 fan adjustment valve 20 ES ON OFF valve 22 and packing rod 26 S pho ad a 4 A Cy EANN H A 35 oa e 38 Y 39 37 T11679A 52 309293K Parts Ref No 19 Alternator Ref No 20 Fan Adjustment Valve 19d 19c Ref No 26 Packing Rod Ref No 22 ES ON OFF Valve 26h 26e 26b 2ef Lo 22 229 A w NG eva G sa 26d 26f NG 26a N Ni 309293K 53 Parts Part No 244581 60 kV Electrostatic Gun Series B items 4 55 Part No 245301 60 kV Electrostatic Gun with waterborne fluid hose Series A items 4 55 101 108 Ref No 6 7a 7b 10 11 15 16 17 18 18a 18b 19 19a 19b 19c 19d 19e 20 20a 20b 20c 54 Part No 185111 188749 197266 111261 111507 197369 24A276 197517 197518 185116 244394 245292 244542 103337 197624 244555 110073 223688 244577 111745 198821 244556 101021 106560 197566 Description SPRING compression PACKING u cup air valve uhmwpe NOZZLE 1 5 mm orifice includes 7a and 7b O R
3. Fig 4 Waterborne Hose Dimensions At Gun Unshielded Hose 246431 C A 1 25 in 32 mm TI2742A Fig 5 3 Generously apply dielectric grease 40 to the o ring 107 and the threads of the fitting 106 Pull the fit ting back 1 1 2 in 38 mm and apply grease to the exposed PTFE hose to fill the area between the hose and the fitting Make sure the barrel inlet is clean and dry then screw the fitting into the fluid inlet of the gun barrel 16 See FIG 3 4 Loosen the strain relief nut 102 so the bracket can move freely on the hose 5 Align the bracket 104 holes with the air inlet and exhaust outlet Secure with the air inlet fitting 35 Tighten the strain relief nut 102 to secure the hose 6 Check that the nut 105 is tightened securely to the ferrule housing 103 7 Press the exhaust tube 38 onto the barbed adapter A Secure with the clamp 39 8 Connect the other end of the hose to the isolated fluid supply as follows 309293K a Graco WB100 Enclosure Slide hose through the strain relief fitting W Ensure conductive layer C has passed through fitting Tighten to 55 in Ib 6 2 Nem Pull back on hose to check it is secure Comply with the requirements in Warning at right See FIG 6 and Fic 7 Shielded C Hose 245252 14 5 in 368 mm B 0 75in 19 mm TI2166A Fig 6 Waterborne Hose Dimensions At Graco WB100 Enclosure See Warning at right
4. Included in Fluid Seal Repair Kit 244911 Included in Swivel Repair Kit 244834 Replacement Warning labels signs tags and cards are available at no cost 55 Parts Part No 244582 60 kV Electrostatic Gun Series B items 4 59 Part No 245305 60 kV Electrostatic Gun with waterborne fluid hose Series A items 4 59 101 108 See page 57 for detail views of the alternator 19 fan adjustment 53 Ref valve 20 ES ON OFF valve 22 and packing rod 26 SG O s A ITI ax 39 TH687A 56 309293K Ref No 19 Alternator Parts Ref No 20 Fan Adjustment Valve 19d 19c Ref No 22 ES ON OFF Valve 29g 22f 22e AN 22 y massa 309293K Ref No 26 Packing Rod 26b 26g 26c 26d na f 26f NG fa ee 26a N Ni 57 Parts 58 Part No 244582 60 kV Electrostatic Gun Series B items 4 59 Part No 245305 60 kV Electrostatic Gun with waterborne fluid hose Series A items 4 59 101 108 Ref No 6 7a 7b 10 11 15 16 17 18 18a 18b 19 19a 19b 19c 19d 19e 20 20a Part No 185111 188749 197266 111261 111507 197369 24A276 197517 197518 185116 244394 245293 244542 103337 197624 244555 110073 223688 244577 111745 198821 244556 101021 Description SPRING compression PACKING u cup air valve uhmwpe NOZZLE 1 5 mm orifice includes 7a and 7b
5. E q o 7 E j T RACO 214 Fig 22 Test Ground Strip Resistance Test Cylinder Resistance TI2165A See FIG 23 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 309293K Electrical Tests 209 p j 7 i SR LATINA f K CA N Anos GI Fig 23 Test Cylinder Resistance TI2164A 33 Troubleshooting Troubleshooting A WARNING Electric Shock Hazard requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly Do not install or repair this equipment unless you are trained and qualified W Installing and servicing this equipment Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 before checking or servicing the system and whenever you are instructed to dis charge the voltage WARNING Pressurized Equipment Hazard To reduce the risk of an injury follow the Pressure Relief Procedure on page 20 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure mam Voltage Loss Troublesh
6. 9 Set the gun air regulator to deliver a minimum 40 psi 0 28 MPa 2 8 bar at the gun when triggered for maximum transfer efficiency See Table 3 Ps il Ib IS TI1281A Table 3 Air Regulator Settings Air Hose Length Air Regulator Setting ft m psi MPa bar 5 16 in 8 mm diameter with gun triggered 15 4 6 50 0 35 3 5 25 7 6 60 0 42 4 2 50 15 3 75 0 52 5 2 e For the most efficiency always use the lowest air pressure possible e When increasing to a wide flat pattern it may be necessary to increase the supply of fluid to the gun to maintain the same amount of coverage over a large area 309293K Operation 10 Spray a test pattern Check the atomization If over atomization occurs at minimum pressure adjust the air atomizing restrictor valve If atomization is inade quate increase the air pressure ti1282a 11 Adjust the fan air adjustment valve clockwise for a rounder pattern counterclockwise for a wider pat tern ti1283a WARNING Electric Shock Hazard When the ES ON OFF switch is turned ON W the fluid supply is charged with high voltage w until the voltage is discharged 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 front of the gun during operation 12 Turn the ES ON OFF switch ON I 23 Operation
7. Only flush purge or clean the electrostatic waterborne spray system with non flammable flu ids as defined on the front cover of this manual Do not flush with the gun electrostatics turned on Keep the spray area free of debris and rags Do not store solvent and flammable fluids in the spray area Eliminate all ignition sources such as pilot lights cigarettes and static arcs from plastic drop cloths Do not plug in or unplug power cords or turn lights on or off in the spray area Use only non sparking tools to clean residue from the booth and hangers Toxic Fluid Hazard Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin swallowed or inhaled Know the specific hazards of the fluid you are using Read the fluid manufacturers warnings Store hazardous fluid in an approved container Dispose of the hazardous fluid according to all local state and national guidelines Wear appropriate protective clothing gloves eyewear and respirator 309293K Warning WARNING RA Equipment Misuse Hazard Equipment misuse can cause the equipment to rupture malfunction or start unexpectedly and result in a serious injury This equipment is for professional use only Read all manuals tags and labels before operating the equipment Use the equipment only for its intended purpose If you are uncertain call your Graco distribu tor Do not alt
8. O RING conductive O RING fluoroelastomer SCREW trigger AIR CAP GASKET barrel SCREW socket hd 10 24 x 3 4 in 19 mm SPRING compression BARREL gun HANDLE gun includes item 28 POWER SUPPLY 60 kV includes 18a 18d O RING fluoroelastomer SPRING compression TURBINE alternator includes 19a 19e O RING fluoroelastomer BEARING KIT includes front and rear bearings and fan COIL RING retaining PAD pressure VALVE adjustment fan includes 20a 20d RING retaining Qty Ref No 20b 20c 20d 21 21a 22 22a 22b 22c 22d 22e 22f 22g 23 23a 23b 23c 23d 24 24a 25 26 26a 26b 26c 26d 26e Part No 106560 197566 197567 244557 276733 244558 111516 113137 198403 198404 198453 198464 276753 244559 197594 197591 168518 101021 249323 112085 244593 244521 111316 116905 178409 178763 197641 Description O RING fluorocarbon HOUSING fan valve STEM fan valve VALVE air includes item 21a SEAL fluoroelastomer VALVE electrostatics ON OFF includes 22a 22g O RING CV75 O RING fluoroelastomer SHAFT valve PLATE retaining WASHER PIN KNOB VALVE air atomizing includes 23a 23d HOUSING valve SHAFT O RING fluoroelastomer RING retaining VALVE exhaust includes 24a O RING fluorocarbon VALVE adjustment fluid ROD packing includes 26a 26h O RING
9. To reduce the risk of component rupture iam 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 working air and fluid pressure f Operation WARNING Pressurized Equipment Hazard To reduce the risk of an injury follow the ha Pressure Relief Procedure on page 20 whenever you are instructed to relieve the pressure 1 Make sure the ES ON OFF valve is OFF 3 Position the air cap by loosening the air cap retain ing ring and rotating the air cap for a vertical or hor izontal spray pattern Tighten the retaining ring until the air cap is held firmly in place you should not be able to rotate the air cap horns by hand Horizontal Pattern 22 4 Fully open the fan air adjustment valve ti1269a RIGARD Uly ti1272a 7 Make sure the ES ON OFF valve is OFF 309293K 8 Adjust the pump air regulator to start the fluid supply unit Adjust the fluid flow with the air pressure regu lator until the stream from the gun travels 8 12 in 200 300 mm before falling off Typically if fluid pressure is below 5 psi 04 MPa 0 4 bar or above 20 psi 0 14 MPa 1 4 bar a change of nozzle size is recommended Refer to instruction manual 309419 to set the fluid pressure for various fluid flows according to the size of the fluid nozzle being used TI1760A
10. except to replace it and never operate the gun with out the contact ring in place Do not replace the contact ring with anything but a genuine Graco part lt ER Use non silicone grease Part No 111265 on the small o ring 7b Do not over lubricate Do not lubricate the contact ring 7a 4 Lightly lubricate the o ring 7b Install it and the contact ring 7a on the nozzle 7 Make sure the electrode needle 29 is finger tight page 43 5 Trigger gun while installing the fluid nozzle 7 with the multi tool 37 Tighten until the fluid nozzle seats in the gun barrel 1 8 to 1 4 turn past hand tight 6 Install the air cap 9 and retaining ring 27 Make sure the u cup 27a is in place with the lips facing forward 7 Test gun resistance page 30 309293K Electrode Replacement 1 Prepare the gun for service page 41 2 Remove the air cap and nozzle page 42 3 Unscrew the electrode 29 with the multi tool 37 Hold the packing rod end 26h to prevent it from turning FIG 25 N CAUTION To avoid damaging the plastic threads be very care ful when installing the electrode 4 Apply low strength purple Loctite or equivalent thread sealant to the electrode and packing rod threads Install the electrode finger tight Do not overtighten 5 Install the fluid nozzle and air cap page 42 6 Test gun resistance page 30 37 TI1682a Fig 25 E
11. 15 Low Voltage Adjustment Switches Table 4 Low Voltage Adjustment 1 2 kV ON ON 50 Factory Setting gt ON OFF 40 OFF ON 35 OFF OFF 30 25 Maintenance Maintenance Flush the Spray Gun 1 Turn the ES ON OFF valve OFF and wait 30 sec onds for the voltage to bleed off Flush the gun before changing colors at the end of the day before storing and before repairing the gun A WARNING 2 Discharge the system voltage page 20 Fire Explosion and Electric Shock Hazard 3 Relieve the pressure page 20 To reduce the risk of fire explosion or elec pA tric shock turn the ES ON OFF valve OFF before flushing the gun Follow the Fluid Voltage Discharge and ul Grounding Procedure on page 20 before 4 Change the fluid source to solvent flushing f l 5 Point the gun into a grounded metal pail Flush until Only flush purge or clean the gun with fluids that clean solvent flows from the gun meet at least one of the following conditions for non flammability e The fluid has a flash point above 140 F 60 C and a maximum organic solvent concentration of 20 by weight per ASTM Standard D93 6 Relieve the pressure e The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test 7 Open the isolated enclosure door Leave the flush ing fluid in the system until you are ready to spray WARNING bia Pressurized Equipment
12. Gun Air Line Filter Gun Air Pressure Regulator Graco Red Grounded Air Supply Hose Air Hose Ground Wire Graco Waterborne Fluid Hose Waterborne Electrostatic Air Spray Gun F H TI1775C Grounding Rod Ground Terminal Main Ground Wire Strain Relief Ground Fitting Pump Air Supply Line Grounding Cylinder Pump Fluid Outlet Fitting Isolated Enclosure Door Enclosure T Handle Locking Screw Required for safe operation Must be purchased separately 309293K Ventilate the Spray Booth WARNING Flammable or Toxic Vapor Hazard Provide fresh air ventilation to avoid the pA buildup of flammable or toxic vapors Do not a operate the gun unless ventilation fans are AA operating Check and follow all National State and Local codes regarding air exhaust velocity requirements High velocity air exhaust will decrease the operating effi ciency of the electrostatic system The minimum allow able air exhaust velocity is 60 linear ft min 18 3 linear meters minute Connect the Air Line WARNING Electric Shock Hazard To reduce the risk of electric shock or other W serious injury you must use the red colored Graco Electrically Conductive Air Hose for the gun air supply hose and you must con nect the hose ground wire to a true earth ground Do not use the black or grey colored Graco air hoses ah Install an air line filter water separator M on the main air sup
13. Hazard 8 Hang the gun from its hook with the nozzle pointing down Be sure to keep the gun from grounding out To reduce the risk of an injury follow the ft Pressure Relief Procedure on page 20 P73 whenever you are instructed to relieve the LENA pressure ENT 9 Before using the system electrostatically again make sure no flammable vapors are present 26 309293K Daily Care and Cleaning Maintenance CAUTION e Clean the outside of the gun daily with a soft cloth dampened with a non flammable solvent as defined on page 26 e Check for fluid leaks Tighten all fittings e Clean the air cap and fluid nozzle daily minimum See page 29 Some applications require more fre quent cleaning e Fluid in the air passages could cause the gun to malfunction and could draw current and reduce the electrostatic effect Fluid in the power supply cavity can reduce the alternator life Do not use any cleaning method which could allow fluid into the gun air passages e Hang the gun with its nozzle pointing down when it is not being used e Clean the workpiece hangers with non sparking tools e Clean the fluid and air line filters daily e Check the movement of the trigger and valves Lubricate if necessary Do not immerse the gun in fluid ti1294a Do not point the gun up while cleaning it ti1295a Do not wipe the gun with a cloth that is heavily satu rated wring out the exc
14. If the meter reading is 45 to 55 kV the gun and fluid hose are okay and the problem is in the voltage iso lation system If the reading is below 45 kV the problem is in the gun or fluid hose 35 Troubleshooting 10 11 12 13 14 36 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 If the meter reading is 45 55 kV the gun power sup ply is okay and there is probably a dielectric break down somewhere in the fluid hose or gun Continue with step 12 If the reading is below 45 kV do the electrical tests on page 30 to check the gun and power supply resistance If those tests show the gun and power supply are okay continue with step 12 A dielectric breakdown is most likely in one of the following three areas Repair or replace the compo nent that is failing Fluid hose Check for leakage or any bulges in the outer cover which may indicate a pin hole leak through the PTFE layer Disconnect the fluid hose from the gun and look for signs of fluid contamination on the out side of the PTFE portion of the fluid tube Inspect the end of the hose connected to the volt age isolation system Look for cuts or nicks Make sure the hose is properly stripped see step 2 on page 12 Restrip or replace the hose Fluid packings Remove the packing assembly f
15. 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 It is not safe to touch the front end of the gun 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 on page 20 before approaching the front of the gun 309293K Introduction N CAUTION The Graco warranty is void if the spray gun is con nected to a non Graco voltage isolation system or if the gun is operated above 60 kV Introduction Gun Overview The electrostatic gun includes the following controls see FIG 1 e FLUID adjustment valve Adjusts fluid rod travel Use only in low flow conditions to reduce wear e Fan AIR adjustment valve Adjusts fan size and shape e Atomizing air RESTRICTOR valve Restricts atomizing air flow Replace with plug included if desired ES INDICATOR ES ON OFF RESTRICTOR AIR FLUID ti1266a Standard Model AIR CAP ELECTRODE A FLUID TUBE Fig 1 Gun Overview ES ON OFF valve Turns electrostatics ON I or OFF 0 ES INDICATOR standard g
16. 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 sys tem 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 on pages 30 32 6 Check that the voltage isolation system s enclosure door is closed and that any safety interlocks are engaged and working properly 7 Make sure the voltage isolation system is in the iso late mode where it is isolating the fluid voltage from ground 8 To eliminate air gaps in the fluid column spray enough fluid to purge the air out between the volt age isolation 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 9 Check the spray gun cover and barrel for accumu lated 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 309293K Troubleshooting 10 Inspect the entire system for a
17. hoses without hoses and gun items 201 286 Ref No 201 201a 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 Part No 15A947 116993 15A660 15A551 15A545 15A524 113061 233501 241005 104029 116989 111804 113060 116473 233824 162453 185547 15B932 198663 190863 101390 309293K Description CABINET enclosure includes 201a DOOR cabinet CASTER brake PLATE T HANDLE latch STEM handle door HOUSING latch SWITCH push air TUBE 1 2 in 13 mm OD poly ethylene PUMP diaphragm sst see man ual 309303 SCREW hex hd cap 5 16 18 x 5 5 in 140 mm WASHER plain 0 344 in ID NUT lock 5 16 18 COVER pail LUG ground VALVE air REGULATOR air GAUGE air 1 8 npt VALVE ball 1 4 npt fbe CART enclosure NIPPLE 1 4 npt x 1 4 npsm FERRULE housing 233825 FERRULE housing 246511 FERRULE 233825 FERRULE 246511 WASHER lock internal tooth Qty A R Ref No 224 225 226 227 228 229 230 231 232 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 251 252 Part No 154636 185548 190410 116988 15A518 104267 114456 116315 15A682 116316 218798 114958 222011 234018 110209 114051 210084 107257 160430 Description WASHER plain 0 625 in ID NUT RESISTOR bleed CYLINDER ROD HOUSING cylinder rod REGULATOR ai
18. off when the gun is triggered 40 309293K Repair Prepare the Gun for Service WARNING Fire Explosion and Electric Shock Hazard To reduce the risk of a fire explosion or electric shock Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 and be sure the ES ON OFF valve is OFF before flushing checking or servicing the system and whenever you are instructed to discharge the voltage SER e Clean all parts with a non flammable fluid as defined on the front cover of this manual e Do not service this equipment unless you are trained and qualified e Do not touch the gun nozzle or come within 4 in 102 mm of the nozzle during gun operation or until you perform the Fluid Voltage Discharge and Ground ing Procedure on page 20 WARNING Pressurized Equipment Hazard To reduce the risk of injury follow the Pres i sure Relief Procedure on page 20 before checking or servicing any part of the system and whenever you are instructed to relieve the pres sure e Check all possible remedies in Troubleshooting before disassembling the gun 309293K Repair Use a vise with padded jaws to prevent damage to plastic parts Lubricate the power supply o ring 18a some pack ing rod parts 26 and certain fluid fittings with dielectric grease 40 as specified in the text Lightly lubricate o rings and seals with non silicone grease Order Part No 111265 Lubric
19. servicing 7 Carefully install the air cap 9 Be sure to insert the electrode 29 through the center hole of the air cap Rotate the air cap to the desired position 8 Tighten the retaining ring 27 until the air cap is held firmly in place you should not be able to rotate the air cap horns by hand 9 Test gun resistance page 30 Fig 16 Clean Air Cap and Fluid Nozzle Grease Door Latch Threads Inspect the door T handle locking screw regularly to ensure the threads are well greased Apply silicone free grease to the threads when necessary 29 Electrical Tests Electrical Tests Electrical components inside the gun affect performance and safety The following procedures test the condition of the power supply 18 and electrode 29 and electri cal continuity between components Use megohmmeter Part No 241079 AA and an applied voltage of 500 V Connect the leads as shown WARNING Fire Explosion and Electric Shock Hazard Megohmmeter Part No 241079 AA see FIG 17 is not approved for use in a haz ardous area To reduce the risk of sparking do not use the megohmmeter to check elec trical grounding unless SER e The gun has been removed from the hazardous area e 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 Fa
20. system pressure must be manually relieved to prevent the system from starting or spraying accidentally To reduce the risk of an injury from electric shock accidental spray from the gun splashing fluid or moving parts follow the Pressure Relief Procedure whenever you im e are instructed to relieve the pressure e stop spraying e check or service any of the system equipment e or install or clean the fluid nozzle 1 Turn the ES ON OFF valve OFF 2 Follow the Fluid Voltage Discharge and Ground ing Procedure at left 3 Turn off the main air supply valve B 4 Trigger the gun into a grounded metal waste con tainer to relieve the air and fluid pressure 5 Relieve fluid pressure in the fluid supply unit as instructed in your fluid supply unit manual 309293K Fill the Fluid Supply 1 Discharge the system voltage page 20 2 Relieve the pressure page 20 3 Open the isolated enclosure door 4 Remove the pail cover from the pail holding a rag over the suction tube strainer to prevent any fluid from dripping into the isolated enclosure Place the cover and suction tube outside the enclosure 5 Remove the supply pail from the enclosure Operation WARNING Fire and Explosion Hazard To reduce the risk of fire and explosion only use this equipment with fluids that meet at least one of the following conditions for non flammability e The fluid has a
21. 00 psi 7 bar 0 7 MPa Maximum Working Pressure 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread red cover with stainless steel braid ground path 235068 6ft 1 8m 235069 15 ft 4 6 m 235070 25 ft 7 6 m 235071 36fi 11 m 235072 50 ft 15 m 235073 75 ft 23 m 235074 100 ft 30 5 m Bleed Type Master Air Valve 300 psi 21 bar 2 1 MPa Maximum Working Pressure Relieves air trapped in the air line between this valve and the fluid supply unit when closed 107141 3 4 npt Air Line Shutoff Valve 150 psi 10 bar 1 0 MPa Maximum Working Pressure For turning air to gun on or off 224754 Air Line Quick Disconnect 112534 Swiveling quick disconnect replaces stan dard air inlet swivel Air Hose Adapter Nipple 185493 Use to connect multiple air hoses 1 4 npt x 1 4 npsm left hand thread Non Swivel Air Inlet Fitting 185105 Extended Air Inlet Fitting 189191 Replaces standard swivel to provide extended handle grip area Left hand thread 309293K 1 4 npsm m x 1 4 npsm f left hand thread Replaces standard swivel Left hand thread Accessories Fluid Line Accessories 245252 Shielded Waterborne Fluid Hose 100 psi 7 bar 0 7 MPa Maximum Working Pressure FM Approved PTFE 1 4 in 6 mm ID x 25 ft 7 6 m For FM approved systems Fluid Shutoff Drain Valve 500 psi 35 bar 3 5 MPa Maximum Working Pressure For turning fluid on or off to the gun and for relieving fluid line pressure
22. 13 Check that the ES indicator or display is lit or check that the kV indicator on the isolated enclosure reads 45 55 kV If not see Electrical Troubleshooting on page 39 for possible problems 14 Check the kV meter on the isolated enclosure 45 55 kV is normal 15 Spray a test piece Examine the edges for coverage If wrap is poor see Spray Pattern Troubleshoot ing on page 37 16 When you finish spraying perform the Shutdown procedure on page 25 24 309293K Shutdown 1 Discharge the system voltage page 20 2 Flush the spray gun See page 26 WARNING Pressurized Equipment Hazard To reduce the risk of an injury follow the ci Pressure Relief Procedure on whenever you are instructed to relieve the pressure 3 Relieve the pressure page 20 4 Hang the gun from its hook or place it in the acces sory holster with the nozzle pointing down Be sure to keep the gun from grounding out Low Voltage Adjustment Smart Guns Only The ES HI LO switch enables you to switch between full voltage and a lower voltage output The lower voltage is factory set but can be adjusted 1 Set the ES HI LO switch to LO 309293K Operation 2 Remove the LO VOLTAGE adjustment plug 53 Set the desired voltage using a small screwdriver to slide switches 1 and 2 ON or OFF according to Table 4 Also see FIG 15 a ti1529a Fig
23. 29 8 204 34 864 n a n a n a 16 407 12 305 n a 4 102 Description 1 4 OD tube regulator to pump 1 4 OD tube regulator 216 to mani fold 5 32 OD tube manifold air to door interlock switch 5 32 OD tube valve tee to cylinder 5 32 OD tube regulator 216 to gauge 2170 5 32 OD tube valve tee to door inter lock switch red 14 gauge wire from top of bleed resistor to meter green yellow 14 gauge wire from internal box ground lug to cylinder cap green yellow 10 gauge wire from external ground lug to cart green yellow 25 ft ground wire with clamp from external ground lug to true earth ground green yellow 10 gauge wire from external ground lug to ground probe red wire from bleed resistor to pump red 14 gauge wire from pump to pail cover with clamp red 14 gauge wire from pump 209 to ground on cylinder bracket green yellow 10 gauge wire from meter to internal box ground lug 3 8 OD tube bulkhead to manifold Parts 63 Parts Tubing and Wiring Diagrams 64 L TI2145A Detail of Door Interlock Switch C8 A1 C6 C7 C8 A NA NA Pi Pa TI2144A B2 TI2143A 309293K Accessories Air Line Accessories Grounded Air Hose Red Cover 1
24. 46431 HOUSING ferrule shielded hose 245252 HOUSING ferrule unshielded hose 246431 BRACKET fluid fitting NUT FITTING barrel O RING FITTING seal KIT wide pattern not shown Included in Air Seal Repair Kit 244781 Included in Fluid Seal Repair Kit 244911 Included in Swivel Repair Kit 244834 Parts Qty Replacement Warning labels signs tags and cards are available at no cost Part No 245897 Isolation Enclosure Series A with air and shielded wb fluid hoses standard Xs3 gun items 201 301 59 Parts Part No 245897 Isolation Enclosure Series A with air and wb fluid hose standard Xs3 gun items 201 301 Part No 245898 Isolation Enclosure Series A with air and wb fluid hoses smart Xs3 gun items 201 301 Part No 233825 Isolation Enclosure Series A for shielded hoses without hoses and gun items 201 286 Part No 246511 Isolation Enclosure Series A for unshielded hoses without hoses and gun items 201 286 282 252 271 283 214 253 a aie mg gt P 276 Ng 283 ka Kea if 301 va Ref only not included TI2138a 60 309293K Part No 245897 Isolation Enclosure Series A with air and wb fluid hose standard Xs3 gun items 201 301 Part No 245898 Isolation Enclosure Series A with air and wb fluid hoses smart Xs3 gun items 201 301 Part No 233825 Isolation Enclosure Series A for shielded
25. 9 Screw the valve assembly 20 into the gun handle 5 Remove the o ring 20b using a wrench on the flats of the housing Torque to 15 25 in Ib 1 7 2 8 Nem DN j A TI DA 9 TI1487A 20c NGO A 20a Fig 31 Fan Air Adjustment Valve 309293K 49 Repair Fluid Adjustment Valve Repair 1 Prepare the gun for service page 41 2 Remove the fluid adjustment valve 25 It can only be replaced as a complete assembly See FIG 32 3 Screw the valve 25 into the gun handle Torque to 15 25 in Ib 1 7 2 8 Nem Fig 32 Fluid Adjustment Valve Air Valve Repair 1 Prepare the gun for service page 41 2 Remove the barrel page 46 3 Remove the fluid adjustment valve 25 from the handle 17 Remove the spring 15 See FIG 33 4 Remove the air valve 21 with a pliers Inspect the seal 21a and replace if damaged Be sure the seal is pressed securely onto the valve so the outer cone is flats CAUTION When removing the air valve 21 be careful not to damage the seat area CAUTION Clean all parts in non conductive solvent compatible with the fluid being used such as xylol or mineral spirits Use of conductive solvents can cause the gun to malfunction 50 5 Inspect the u cup 6 Do not remove the u cup unless damaged If removed install the new one with its lips facing into the gun handle 17 6 Install the ai
26. ING conductive O RING fluoroelastomer SCREW trigger AIR CAP GASKET barrel SCREW socket hd 10 24 x 3 4 in 19 mm SPRING compression BARREL gun HANDLE gun includes item 28 POWER SUPPLY 60 kV includes 18a 18d O RING fluoroelastomer SPRING compression TURBINE alternator includes 19a 19e O RING fluoroelastomer BEARING KIT includes front and rear bearings and fan COIL RING retaining PAD pressure VALVE adjustment fan includes 20a 20d RING retaining O RING fluorocarbon HOUSING fan valve Qty Ref No 20d 21 21a 22 22a 22b 22c 22d 22e 22f 22g 23 23a 23b 23c 23d 24 24a 25 26 26a 26b 26c 26d 26e 26f 26g 26h 27 Part No 197567 244557 276733 244558 111516 113137 198403 198404 198453 198464 276753 244559 197594 197591 168518 101021 249323 112085 244593 244521 111316 116905 178409 178763 197641 185495 186069 244696 245790 Description STEM fan valve VALVE air SEAL fluoroelastomer VALVE electrostatics ON OFF includes 22a 22g O RING CV75 O RING fluoroelastomer SHAFT valve PLATE retaining WASHER PIN KNOB VALVE air atomizing includes 23a 23d HOUSING valve SHAFT O RING fluoroelastomer RING retaining VALVE exhaust includes 24a O RING fluorocarbon VALVE adjustment fluid ROD packing includes 26a 26h O RING fl
27. Instructions Parts List o ELECTROSTATIC WATERBORNE AIR SPRAY SEARA WB100 Isolation System and PRO Xs3 Spray Gun M 309293K Important Safety Instructions Read all warnings and instructions in this manual Save these instructions 100 psi 0 7 MPa 7 bar Maximum Air Inlet Pressure 100 psi 0 7 MPa 7 bar Maximum Working Fluid Pressure For use when electrostatically spraying conductive waterborne fluids that meet at least one of the following conditions for non flammability FM Approved Pa e The fluid has a flash point above 140 F 60 C and a maximum organic solvent concentration of 20 by weight per ASTM Standard D93 FM e The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test CE EN 50059 Compliant TI2139a WB 100 Isolation Enclosure e Materials which cannot be ignited in any mixture with air by an energy source of less than 500 mJ See page 3 for a List of Models U S Patent No 7 226 004 TI1681A HO03 CE ec PROVEN QUALITY LEADING TECHNOLOGY Table of Contents List of Models eee eee eee eeee 3 SYMbOIs AA 4 Warning Symbol eee eee 4 Caution Symbol 0c eee eee 4 Warning a ae ease ie eae teary 4 Introduction a aT eee ove eee NG 7 How the Electrostatic Air Spray Gun Works 7 Spraying Waterborne Fluids Electrostatically 7 Gun Overview 2 8 Installation 00 eee 9 System Requi
28. ant Do not over lubricate Only use genuine Graco parts Do not mix or use parts from other PRO Gun models Air Seal Repair Kit 244781 is available The kit must be purchased separately Kit parts are marked with an asterisk for example 6 Fluid Seal Repair Kit 244911 is available The kit must be purchased separately Kit parts are marked with a double asterisk for example 26a Follow the Fluid Voltage Discharge and Ground ing Procedure on page 20 Flush the gun page 26 Blow the fluid lines dry with air Relieve the pressure page 20 Disconnect the gun air and fluid lines at the isolation system Remove the gun from the worksite Repair area must be clean 41 Repair Air Cap Nozzle Replacement Z N CAUTION Hold the front end of the gun up and trigger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from enter ing the air passages 1 Prepare gun for service page 41 2 Remove the retaining ring 27 and air cap 9 See FIG 24 3 Point gun up and squeeze trigger while removing the fluid nozzle 7 assembly with the multi tool 37 ti1501a Fig 24 Air Cap Nozzle Replacement 42 WARNING Fire Explosion and Electric Shock Hazard The nozzle contact ring 7a is a conductive contact ring not a sealing o ring To reduce the risk of sparking or electric shock do not remove the nozzle contact ring 7a
29. at the fluid supply unit 208630 1 2 npt m x 3 8 npt f carbon steel and PTFE for non corrosive fluids 246431 Unshielded Waterborne Fluid Hose 100 psi 7 bar 0 7 MPa Maximum Working Pressure FM Approved PTFE 1 4 in 6 mm ID x 25 ft 7 6 m For compliance with EN 50059 65 Accessories Gun Accessories Gun Repair Kits 244781 Air Seal Repair Kit 244911 Fluid Seal Repair Kit Round Pattern Kits Consists of fluid tip diffuser and air cap 245217 245219 4 6 in 102 152 mm diameter 8 10 in 203 254 mm diameter Push Pull Fan Air Valve 244912 For quick change of fan size Handle Grips 245263 Medium Grip 245264 Large Grip Gun Valve Lubricant 111265 4 oz 113 g tube of sanitary non silicone lubricant for fluid seals and wear areas Alternator Bearing Kit 223688 To repair the turbine alternator Cleaning Brush 105749 For cleaning air cap and fluid nozzle 66 Miscellaneous Accessories Ground Wire and Clamp 222011 For grounding fluid supply unit and other components and equipment in the spray area 12 gauge 25 ft 7 6 m Megohmmeter 241079 500 Volt output 0 01 2000 megohms Not for use in hazardous areas Safety Warning Sign 186118 English Warning Sign FM Approved Avail able at no charge from Graco Electrostatic Conductive Gloves box of 12 117823 Small 117824 Medium 117825 Large 309293K Part No 245895 Agitator Accessory Kit items 401 407 406 Re
30. cess to parts which may cause electric shock or other serious injury if work is not performed properly e Be sure your installation complies with all National State and Local safety and fire codes NFPA 33 NEC 504 and 516 and OSHA standard 1910 107 CAUTION The Graco warranty is void if the spray gun is con nected to a non Graco voltage isolation system or if the gun is operated above 60 kV Warning Sign Mount the warning sign Part No 186118 in the spray area where it can be seen and read by all operators Additional warning signs are available at no charge 309293K FIG 2 on page 10 shows a PRO Xs electrostatic water borne air spray system For assistance in designing a system to suit your particular needs contact your Graco distributor Installation ap B BB ri q no pr Gun ES ON OFF valve is ON O is OFF CEA TS TNT TI1896C Fig 2 Typical Installation PRO Xs Waterborne System Key cc ID NTN M O O a N pr Q 10 T Main Air Supply Line U Main Air Supply Shutoff Valve bleed type ve Pump Air Pressure Gauge W Pump Air Pressure Regulator X kV Meter Y Pump Z Pump Suction Hose AA Paint Container BB Bleed Resistor Enclosure Safety Interlock kc Isolated Enclosure
31. e handle See FIG 28 Barrel Installation 1 Be sure the gasket 107 and grounding spring 55 are in place Make sure the gasket air holes are aligned properly Replace if damaged See FIG 29 2 Place the barrel 16 over the power supply 18 and onto the gun handle 17 3 Tighten the three screws 11 oppositely and evenly about a half turn past snug N CAUTION Do not over tighten the screws 11 4 Position the bracket 104 on the gun handle 17 and secure with the air inlet fitting 35 5 Apply dielectric grease 40 to the exposed inner tube of the fluid hose 101 6 Check that the nut 105 is tight on the ferrule hous ing 103 7 Test gun resistance page 30 46 mea Fig 28 Barrel Removal TI1692A Fig 29 Barrel Installation 309293K Power Supply Removal and Replacement e Inspect the gun handle power supply cavity for dirt or moisture Clean with a clean dry rag e Do not expose gasket 10 to solvents 1 Prepare gun for service page 41 2 Remove the barrel 16 page 46 CAUTION Be careful when handling the power supply 18 to avoid damaging it 3 Grasp the power supply 18 with your hand With a gentle side to side motion free the power sup ply alternator assembly from the gun handle 17 then carefully pull it straight out On Smart Models only disconnect the flexible circuit 59 from the socket at the top of t
32. earing Kit 1 2 48 Prepare gun for service page 41 Remove the power supply alternator assembly page 47 Disconnect the alternator from the power supply page 47 Measure resistance between the two outer termi nals of the 3 wire connector GG it should be 2 5 3 5 ohms If outside this range replace the alter nator coil Follow the bearing replacement procedure in the bearing kit manual 308034 Install the alternator on the power supply page 47 Install the power supply alternator assembly page 47 309293K Repair Fan Air Adjustment Valve Repair 6 Clean all parts and inspect for wear or damage Use non silicone grease Part No 111265 Do not f over lubricate 1 Prepare the gun for service page 41 7 When reassembling the fan air valve 20 lightly 2 Place a wrench on the flats of the valve assembly lubricate the valve threads and screw the stem 20d 20 and unscrew it from the handle 17 fully into the housing 20c until bottomed Install the You may replace the valve as an assembly go to step 9 o ring 20b lubricate and unscrew the valve stem or as individual parts steps 3 9 until the o ring enters the housing 3 Remove the retaining ring 20a See Fic 31 8 Reassemble the retaining ring 20a Unscrew the valve stem from the housing until it is stopped by the 4 Turn the valve stem 20d counterclockwise until it retaining ring comes free from the valve housing 20c
33. ections and be sure the air hose ground wire is connected to a true earth ground If the resistance is still too high replace the air hose TI2161A Fig 13 Check Gun Grounding 18 Using an ohmmeter AA measure the resistance between the cabinet ground lug 214 and a true earth ground CC See Fic 14 The resistance must be less than 100 ohms TI2163A Fig 14 Check Cabinet Grounding 309293K Operation Operating Checklist Operation Check the following list daily before starting to operate the system to help ensure you of safe efficient operation 309293K All operators are properly trained to safely operate an electrostatic waterborne air spray system as instructed in this manual All operators are trained in the Pressure Relief Procedure on page 20 The electrostatics are turned off and properly grounded according to the Fluid Voltage Dis charge and Grounding Procedure on page 20 before any person enters the safety enclo sure before cleaning and before performing any maintenance or repair The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded See Grounding on page 17 Fluid Hose is in good condition with no cuts or abrasions of the PTFE layer Replace hose if damaged Ventilation fans are operating properly Workpiece hangers are clean and gr
34. eft hand thread Gun Fluid Inlet Fitting Gun Weight Gun Length Isolation Enclosure Air Inlet Fitting Isolation Enclosure Fluid Inlet Fitting Isolation Enclosure Weight Isolation Enclosure Height Isolation Enclosure Width Isolation Enclosure Depth Wetted Parts Technical Data Data 100 psi 0 7 MPa 7 bar 100 psi 0 7 MPa 7 bar 40 psi 0 28 MPa 2 8 bar 120 F 48 C 125 microamperes 35 J with fluid hose 246431 installed 244581 245301 60 kV 244582 245305 30 60 kV at 40 psi 0 28 MPa 2 8 bar 90 4 dB A at 100 psi 0 7 MPa 7 bar 105 4 dB A at 40 psi 0 28 MPa 2 8 bar 87 dB A at 100 psi 0 7 MPa 7 bar 99 dB A 1 4 npsm m custom inlet for Graco waterborne fluid hose 27 8 oz 788 g 11 1 in 28 2 cm 1 4 npt 3 8 in OD tube fitting 125 Ib 56 3 kg 44 in 1118 mm 24 in 610 mm 29 in 737 mm Gun Stainless Steel Nylon Acetal Ultra High Molecular Weight Polyethylene Fluoroelastomer PEEK Tungsten Wire Polyethylene Waterborne Fluid Hose PTFE Suction Tube Polyethylene Stainless Steel Triton Pump See manual 309303 Loctite is a registered trademark of the Loctite Corporation 309293K 69 Graco Standard Warranty Graco warrants all equipment 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 b
35. er or modify equipment Use only genuine Graco parts and accessories Do not operate the power supply above 60 kV Use only Graco Part No 244542 Power Supply with this gun Check the equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system component Maxi mum working air and fluid pressure of this equipment is 100 psi 0 7 MPa 7 0 bar Use fluids and solvents that are compatible with the equipment wetted parts See the Techni cal Data section of all equipment manuals Read the fluid and solvent manufacturer s warn ings Route the hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 40 F 40 C Wear hearing protection when operating this equipment Comply with all applicable local state and national fire electrical and other safety regula tions rr CP in Pressurized Equipment Hazard Spray from the gun hose leaks or ruptured components can splash fluid in the eyes or on the skin and cause serious injury Do not point the spray gun at anyone or at any part of the body Do not stop or deflect fluid leaks with your hand body glove or rag Follow the Pressure Relief Procedure page 20 when you stop spraying and before cleaning checking or repairing equipment Check hoses and couplings daily Replace worn damaged or
36. ess fluid ti1293a 309293K 27 Maintenance CAUTION 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 Visually inspect the ground strip 240 for damage Replace if needed Measure the resistance weekly See page 33 28 309293K Clean the Air Cap and Fluid Nozzle Equipment Needed e soft bristle brush e non flammable solvent Procedure 1 Turn the ES ON OFF valve OFF Wait 30 seconds 2 Discharge the system voltage page 20 3 Relieve the pressure page 20 4 Remove the retaining ring 27 and air cap 9 See FIG 16 N CAUTION Do not use metal tools to clean the air cap or fluid nozzle holes as this could scratch them and make sure the electrode is not damaged Scratches in the air cap or nozzle or a damaged electrode can distort the spray pattern 5 Clean the air cap 9 with the soft bristle brush and non flammable solvent or submerge the air cap in solvent and wipe it clean 6 With the gun pointing down clean the fluid nozzle 7 and the front of the gun with a soft brush damp ened with non flammable solvent 309293K Maintenance If it appears that there is paint inside the fluid nozzle 7 air passages remove the gun from the line for
37. f 309293K TI2137A Ref No 401 402 403 404 405 406 407 408 Part No 112698 114158 193315 193316 197298 224571 purchase locally 110272 Accessories Description ELBOW swivel male 1 8 npt m x 1 4 in 6 mm OD tube FITTING adapter Y 1 4 in 6 mm OD tube mxfxf COLLAR mounting agitator NUT collar agitator COVER pail 5 gal 19 liter AGITATOR see manual 306565 TUBE nylon 1 4 in 6 mm OD 4 ft 1 22 m SCREW set socket hd 1 4 20 x 1 4 in 6 mm 67 Accessories Part No 245944 Fluid Regulator Accessory Kit items 501 507 Ref No 501 502 503 504 505 506 507 68 Part No 110078 113070 113576 236281 C20350 114158 purchase locally TI2149A Description Qty FITTING tube fluid 1 4 npt m x 1 3 8 in 10 mm OD tube NIPPLE reducer 3 8 npt x 1 4 npt 1 PLUG 1 4 npt 1 REGULATOR fluid see manual 1 308325 ELBOW 90 1 4 npt f x 1 4 in 6 1 mm OD tube FITTING adapter Y 1 4 in 6 1 mm OD tube mxfxf TUBE nylon 1 4 in 6 mm OD 1 4 ft 1 22 m 309293K Technical Data Category Maximum Working Fluid Pressure Maximum Working Air Pressure Minimum Air Pressure at Gun Inlet Maximum Fluid Operating Temperature Short Circuit Current Output Voltage Output Energy Sound Power measured per ISO Standard 9216 Sound Pressure measured 1 m from gun Gun Air Inlet Fitting l
38. flash point above 140 F 60 C and a maximum organic solvent concentration of 20 by weight per ASTM Standard D93 e The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test CAUTION Be sure to wipe up all fluid spills in the isolated enclo sure Fluid can create a conductive path and cause the system to short out 6 Clean up any fluid spills in the enclosure using a soft cloth and a non flammable compatible solvent 7 Fill the supply pail with fluid and return it to the enclosure Clean up any spills 8 Reinstall the pail cover holding a rag over the suc tion tube strainer to prevent fluid spills while you place the pump suction tube in the pail 9 Close the isolated enclosure door and fasten securely with the T handle locking screw Adjust the Spray Pattern Follow the steps below to establish the correct fluid flow and air flow 309293K WARNING Electric Shock Hazard Contact with the charged components of Wy the spray gun will cause an electric shock w Do not touch the gun nozzle or electrode or come within 4 in 102 mm of the front of the gun during operation or until performing the Fluid Voltage Discharge and Grounding Procedure on page 20 Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 when you stop spraying and whenever you are instructed to discharge the voltage WARNING Component Rupture Hazard
39. fluoroelastomer SEAL SPREADER packing uhmwpe PACKING rod acetal NUT packing 309293K Qty Ref No 26f 26g 26h 27 27a 28 29 30 aga 36 37 38 39 40 41 42 43 47 48 51 52 53 54 55 59 101 Part No 185495 186069 244696 245790 198307 276695 276867 276698 245496 107460 276741 185103 110231 116553 244915 179791 180060 197967 198058 244627 111450 276734 197910 197624 245265 245252 246431 309293K Description HOUSING packing SPACER packing acetal ROD packing RING retaining air cap includes item 27a PACKING u cup HOOK NEEDLE electrode black TRIGGER SWIVEL air 1 4 npsm m left hand threads WRENCH ball end 4 mm MULTI TOOL TUBE exhaust CLAMP GREASE dielectric tube not shown COVER gun box of 10 not shown TAG warning not shown replacement available at no cost SIGN warning not shown replacement available at no cost PLUG SCREW cap socket hd SWITCH ES HI LO O RING PLUG LO voltage adjustment SCREW pivot SPRING grounding CIRCUIT flexible HOSE shielded waterborne fluid HOSE unshielded waterborne fluid includes 102 108 Qty Ref No 102 103 104 105 106 107 108 109 Part No 198663 190863 185547 15B932 197954 185548 198643 102982 198640 24A431 Description FERRULE shielded hose 245252 FERRULE unshielded hose 2
40. he handle 17 See Fia 30 4 Disconnect the 3 wire connector GG from the power supply Slide the alternator up and off the power supply Inspect the power supply and alterna tor for damage On Smart Models only disconnect the 6 pin flexible circuit 59 from the power supply 5 Check the power supply resistance page 31 Replace if necessary Before installing the power supply make sure the o rings 18a 19a spring 18b and pads 19e are in place 6 On Smart Models only connect the 6 pin flexible cir cuit 59 to the power supply 7 Connect the 3 wire connector GG Slide the alter nator 19 down onto the power supply 18 8 Lubricate the alternator o ring 19a with non sili cone grease Part No 111265 Do not over lubri cate 9 Lubricate the power supply o ring 18a with dielec tric grease 40 309293K Repair 10 Insert the power supply alternator assembly in the gun handle 17 Make sure the ground strips make contact with the handle On Smart Models only con nect the flexible circuit 59 to the socket at the top of the handle Push the 6 pin connector into the socket to ensure it is properly connected 11 Install the barrel 16 page 46 12 Test gun resistance page 30 ti1505c 18a 18b Fig 30 Power Supply 47 Repair Turbine Alternator Removal and Replacement Replace turbine alternator bearings after 2000 hours of operation Order Part No 223688 B
41. ilure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage Test Gun Resistance 1 Prepare the gun for service as instructed on page 41 2 Measure resistance between the electrode needle tip 29 and the air swivel 35 it should be 117 137 megohms If outside this range go to the next test If you still have problems refer to Voltage Loss Trou bleshooting on page 34 for other possible causes of poor performance or contact your Graco distribu tor 30 AA Fig 17 Test Gun Resistance TH1688B 309293K Test Power Supply Resistance 1 Prepare the gun for service as instructed on page 41 2 Remove the power supply 18 page 46 3 Remove the turbine alternator 19 from the power supply page 47 4 Measure resistance from the power supply s ground strips EE to the spring 18b See FIG 18 5 The resistance should be 95 105 megohms If out side this range replace the power supply If in range proceed to the next test 6 Be sure the spring 18b is in place before reinstall ing the power supply AHE y4 A ti1599a Fig 18 Test Power Supply Resistance 309293K Electrical Tests 31 Electrical Tests Test Electrode Resistance Prepare the gun for service as instructed on page 41 Insert a conductive r
42. ipment if you do not follow the instruc tions WARNING W w Electric Shock Hazard Improper grounding setup or usage of an isolated waterborne system can cause a hazardous condition and result in electric shock or other serious injury Ground the equipment all personnel in or close to the spray area the object being sprayed and all conductive objects in the spray area See Grounding page 17 The gun must be connected to a voltage isolation system that will discharge the system volt age when the gun is not in use All components of the isolation system that are charged to high voltage must be contained within an enclosure that prohibits personnel from making contact with the high voltage compo nents before the system voltage is discharged Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 when instructed to discharge the voltage before cleaning flushing or servicing the system before approach ing the front of the gun and before opening the safety enclosure for the isolated fluid supply Do not touch the gun nozzle or come within 4 in 102 mm of the nozzle during gun operation or for 30 seconds after operation stops to allow the voltage to discharge through the bleed resistor Place the gun in the holster accessory during this 30 second period Refer to Fluid Voltage Discharge and Grounding Procedure page 20 Electrically connect a metal part of the fluid supply unit to the bleed resis
43. lectrode Replacement 309293K Repair 43 Repair Fluid Packing Removal 1 Prepare the gun for service page 41 N 2 Remove the air cap and fluid nozzle page 42 N 3 Remove the electrode page 43 4 Loosen the trigger screws 8 and trigger 30 See FIG 26 5 Remove the packing rod 26 using the multi tool 37 N CAUTION Clean all parts in non conductive solvent compatible with the fluid being used such as xylol or mineral PANGA spirits Use of conductive solvents can cause the gun IN f Ss to malfunction TI1683A 6 Check all parts for wear or damage and replace if HA Fig 26 Fluid Packing Removal 44 309293K Packing Rod Repair You may replace the packing rod as individual parts or as an assembly The assembly is pre adjusted at the factory Before installing the fluid packing rod into the gun barrel make sure the internal surfaces of the barrel are clean Remove any residue with a soft brush or cloth Check the inside of the barrel for marks from high voltage arc ing If marks are present replace the barrel To assemble the individual parts 1 Place the packing nut 26e and seal 26b on the fluid rod 26h Flats on the packing nut must face the back of the fluid rod The seal o ring must face away from the packing nut See FIG 27 2 Fill the inner cavity of the spacer 26g with dielec tric grease 40 Place the spacer on the fluid rod 26h in the direc
44. loose parts immediately Tighten all fluid connections before each use 309293K Introduction How the Electrostatic Air Spray Gun Works The air hose supplies air to the spray gun Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed The turbine generates power which is converted by the power cartridge to supply high volt age current to the gun s electrode The fluid source supplies fluid to the hose and gun The gun must be connected to a voltage isolation system to maintain voltage at the gun In an isolation system the entire fluid supply is electrostatically charged The charged fluid is attracted to the grounded workpiece wrapping around and evenly coating all surfaces Spraying Waterborne Fluids Electrostatically This electrostatic air spray gun is designed to spray only waterborne fluids with a flash point above 140 F 60 C and a maximum organic solvent concentration of 20 by weight per ASTM Standard D93 Also the fluid must not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test When connected to a voltage isolation system all of the fluid in the spray gun fluid hose and isolated fluid sup ply is charged to high voltage which means that the sys tem has more electrical energy than a solvent based system Therefore only non flammable fluids as defined on the front cover of this manual can be sprayed with the system or be used to clean
45. mm WIRE 14 gauge red A R WIRE ground 14 gauge green A R with yellow stripe UNION swivel 1 4 npt 1 TERMINAL ring no 10 1 PLUG hex hd 1 BULKHEAD CONNECTOR 1 4 1 npt CONNECTOR tube 1 4 npt x 3 8 2 in 10 mm OD tube ELBOW tube 1 FITTING tube 1 8 npt x 5 32 in 1 4 mm tube SWIVEL tube 1 4 npt x 1 4 in 6 4 mm OD tube Ref No 283 285 286 300 301 301 Part No 112791 235070 245301 245305 Description Qty SWIVEL tube 1 8 npt x 5 32 in 4 2 mm OD tube CLAMP 1 TUBE 3 8 in 10 mm OD A R 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 GUN air spray standard elec 1 trostatic for waterborne coat ings see page 52 used on Model 245897 GUN air spray smart electro 1 static for waterborne coat ings see page 56 used on Model 245898 Replacement Warning labels signs tags and cards are available at no cost 309293K Tubing and Wiring Chart Use the diagrams on page 64 to find the connection points for the tubing and wiring listed below Code A1 B2 B3 B4 B5 C1 C2 C3 C4 C5 C6 C7 C8 C9 E1 Ref No 248 248 249 249 249 249 272 251 273 239 243 226 272 272 251 286 309293K Length in mm 20 508 9 229 17 432 20 508 5 127 22 559 9 2
46. n air pressure too low Increase o Fluid too thick Reduce viscosity Too much fluid Decrease flow Streaks Did not apply 50 overlap Overlap strokes 50 Dirty or damaged air cap Clean or replace page 42 309293K 37 Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Excessive spray fog Atomizing air pressure too high Close restrictor valve some or decrease air pressure as low as pos sible minimum 40 psi 0 28 MPa 2 8 bar needed at gun for full voltage Fluid too thin Increase viscosity Orange Peel finish Atomizing air pressure too low Open atomizing air valve more or increase gun air inlet pressure use lowest air pressure necessary Poorly mixed or filtered fluid Remix or refilter fluid Fluid too thick Reduce viscosity Fluid leaks from the fluid packing area Worn packings or rod Replace packings or rod see page 45 Air leaks from the front of the gun Air valve 21 is not seating properly Clean and service air valve see page 50 Fluid leakage from the front of the gun Worn or damaged packing rod 26 Replace see page 45 Worn fluid seat Replace fluid nozzle and or electrode needle see pages 42 to 43 Loose fluid nozzle 7 Tighten see page 42 Damaged nozzle o ring 7b Replace see page 42 Gun does not spray L
47. n conductive surface such as paper or cardboard Do not store more than the quantity needed for one shift e Graco Waterborne Fluid Hose the hose is grounded through the conductive layer Install the hose as instructed on page 11 e All electrically conductive objects or devices in the e All persons entering the spray area shoes must spray area including fluid containers tools and have conductive soles such as leather or personal wash cans must be properly grounded grounding straps must be worn Do not wear shoes with non conductive soles such as rubber or plastic If gloves are necessary wear the conductive gloves that are supplied with the gun If non Graco gloves are worn cut off fingers or palm area of glove to ensure your hand contacts the grounded gun han dle 309293K 17 Installation Check Electrical Grounding Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose Turn the ES ON OFF valve OFF Turn off the air and fluid supply to the gun The fluid hose must not have any fluid in it Make sure the red colored grounded air hose R is connected and the hose ground wire is connected to a true earth ground Using an ohmmeter AA measure the resistance between the gun handle BB and a true earth ground CC The resistance should not exceed 100 ohms See FIG 13 If the resistance is greater than 100 ohms check the tightness of the ground conn
48. ng screws S FIG 12 and remove the pump from the isolation enclo sure 7 Remove the back of the control box 258 8 Remove tube A2 from elbow 282 at the air mani fold see page 64 Install the Y fitting 506 in the elbow Install tubes A2 and 507 into the Y fitting Route the tube 507 into the cabinet 9 Replace the back of the control box 258 10 Assemble the fluid regulator kit as shown in FIG 12 11 Reinstall the pump in the isolation enclosure Use the two mounting holes to the left of the holes used previously to allow clearance for the fluid regulator 12 Connect tube A1 to the air inlet of fluid regulator 504 Connect tube 507 to the pump air inlet 13 Connect the waterborne fluid hose to the fluid regu lator outlet fitting 501 14 Return the system to service The cabinet air regulator and gauge 216 217 will now operate the air piloted fluid regulator 504 The pump will now operate at the inlet air pressure 309293K Installation Connect to elbow 282 Connect inside control waterborne Tube A1 box 258 fluid hose here Connect i tube A2 here TI2149A Fig 12 Fluid Regulator Kit 15 Installation Select a Fluid Nozzle and Air Cap WARNING Pressurized Equipment Hazard To reduce the risk of an injury follow the iHa Pressure Relief Procedure on page 20 before removing or installing a fluid nozzle and or air cap Table 1 Fluid Nozzle
49. nt 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 INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE 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 manufactured 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 re
50. ny visible fluid leak age and repair any fluid leaks that are found Pay special attention to the following areas e 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 Tests If you still have no voltage separate the spray gun and hose from the voltage isolation system and check whether the gun and hose alone will hold voltage with the following test 1 Flush the system with water and leave the lines filled with water 2 Discharge the system voltage page 20 3 Relieve the pressure page 20 4 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 conductiv ity path and conceal a potential failure area 5 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 6 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 7 Discharge the system voltage by waiting 30 sec onds and then touching the gun electrode with a grounded rod 8
51. od B into the gun barrel removed for the power supply test and against the metal contact C in the front of the barrel Measure the resistance between the conductive rod B and the electrode 29 The resistance should be 20 30 megohms See FIG 19 If in range refer to Electrical Troubleshooting on page 39 for other possible causes of poor perfor mance or contact your Graco distributor Remove the electrode 29 page 43 Measure the resistance between the contact E and the elec trode wire F The resistance should be 20 30 megohms If out of range replace the electrode See FIG 20 Make sure the metal contact C in the barrel the nozzle contact ring 7a FIG 21 and the electrode contact E are clean and undamaged 7 ALE C 29 B bt ti1499a O CJ Co may c Fig 19 Test Electrode Resistance 32 ALE F 29 E dd SSS Fig 20 Electrode Fig 21 Nozzle Conductive O Ring ti1548a 309293K Test Ground Strip Resistance See FIG 22 Using an ohmmeter measure the resis tance 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 o
52. om gun to part Should be 8 12 in 200 300 mm Poorly grounded parts Resistance must be 1 megohm or less Clean workpiece hangers Faulty gun resistance See Test Gun Resistance on page 30 Fluid leaks from the packing 26d Clean the packing rod cavity and causes a short Replace the packing rod See page 45 Faulty turbine alternator Be sure the plug is in place on the back of the turbine alternator hous ing Remove and test the turbine alternator See page 48 The KV HI LO lever is on LO Check the lever actuation replace if needed Spilled paint dried paint or other Clean interior of enclosure contaminants inside WB100 enclo sure causing a short circuit 309293K 39 Troubleshooting Problem Cause Solution ES indicator or voltage current dis ES ON OFF valve OFF 0 Turn ON I play is not lit No power Replace power supply See page 47 Voltage current display stays red Gun too close to part Should be 8 12 in 200 300 mm smart guns only Check fluid resistivity See Operation on page 19 Dirty gun Clean See page 27 Operator gets mild shock Operator not grounded or is near See Grounding on page 17 ungrounded object Gun not grounded See Check Electrical Grounding on page 18 and Test Gun Resistance on page 30 Operator gets shock from workpiece Workpiece not grounded Resistance must be 1 megohm or less Clean workpiece hangers ES indicator light is
53. ooting Normal spraying voltage for a system using the water borne gun is 45 55 kV The system voltage is lower due to spraying current demands and voltage isolation sys tem losses A loss of spraying voltage can be caused by a problem with the spray gun fluid hose or voltage isolation sys tem since all of the system components 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 e Dielectric breakdown at the fluid hose connection or fluid packings e Not enough air pressure for the turbine e Faulty power supply e Excessive overspray on gun surfaces e Fluid in the air passages Waterborne Fluid Hose e Dielectric failure of hose pin hole leak through PTFE layer e Air gap in the fluid column between the gun and iso lated fluid supply causing a low voltage reading on the isolation system voltage meter Voltage Isolation System e Fluid leakage e Dirty interior 309293K Visual Check 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 236003 is helpful for diagnosing voltage prob lems and is required for some of the troubleshooting tests that
54. orne Isolation Enclosure with smart electrostatic air spray gun grounded air hose and shielded waterborne fluid hose 233825 Waterborne Isolation Enclosure without hoses and gun 244581 PRO Xs3 Standard Electrostatic Air Spray Gun for waterborne coatings Series B 245301 PRO Xs3 Part No 244581 Gun with 25 ft 7 6 m waterborne fluid hose 244582 PRO Xs3 Smart Electrostatic Air Spray Gun for waterborne coatings Series B 245305 PRO Xs3 Part No 244582 Gun with 25 ft 7 6 m waterborne fluid hose 245252 Shielded Waterborne Fluid Hose Assembly 25 ft 7 6 m EN 50059 Compliant 244581 PRO Xs3 Standard Electrostatic Air Spray Gun for waterborne coatings Series B 244582 PRO Xs3 Smart Electrostatic Air Spray Gun for waterborne coatings Series B 246511 Waterborne Isolation Enclosure without hoses and gun 246431 PRO Xs3 Unshielded Waterborne fluid hose assembly 25 ft 7 6 m 246592 PRO Xs3 Waterborne Isolation Enclosure with standard electrostatic air spray gun grounded air hose and unshielded waterborne fluid hose 246593 PRO Xs3 Waterborne Isolation Enclosure with smart electrostatic air spray gun grounded air hose and unshielded waterborne fluid hose 309293K 3 Symbols Symbols Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious injury This symbol alerts you to the possibility of damage to or or death if you do not follow the instructions destruction of equ
55. oubleshooting 37 Gun Operation Troubleshooting 38 Electrical Troubleshooting 39 Repa ae ee BN Dna NG 41 Prepare the Gun for Service 41 Air Cap Nozzle Replacement 42 Electrode Replacement 43 Fluid Packing Removal 44 Packing Rod Repair a 45 Barrel Removal eee eee 46 Barrel Installation AA 46 Power Supply Removal and Replacement 47 Turbine Alternator Removal and Replacement 48 Fan Air Adjustment Valve Repair 49 Fluid Adjustment Valve Repair 50 Air Valve Repair an 50 Atomizing Air Restrictor Valve Removal and Replacement a 51 ES ON OFF Valve Repair 51 Pana a ee eee eke Be 52 AccessorieS 2002 eee cece eee eee eee 65 Air Line Accessories 65 Fluid Line Accessories 65 Gun Accessories eee eee 66 Miscellaneous Accessories 66 Technical Data aa 69 Graco Standard Warranty 20005 70 Graco Information aaa 70 309293K List of Models List of Models FM Approved Part No Gun Model Description 245897 PRO Xs3 Waterborne Isolation Enclosure with standard electrostatic air spray gun grounded air hose and shielded waterborne fluid hose 245898 PRO Xs3 Waterb
56. ounded All debris including flammable fluids and rags is removed from the spray area Only fluids with a flash point above 140 F 60 C and a maximum organic solvent con centration of 2096 by weight may be in the spray area All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded 19 Operation Fluid Voltage Discharge and Grounding Procedure WARNING Electric Shock Hazard The fluid supply is charged with high volt ul age until the voltage is discharged Contact W withthe charged components of the isola tion system or spray gun electrode will cause an electric shock To avoid an electric shock follow the Fluid Voltage Discharge and Grounding Procedure e whenever you are instructed to discharge the voltage e before cleaning flushing or servicing the system equipment e before approaching the front of the gun e or before opening the safety enclosure for the isolated fluid supply 1 Turn the ES ON OFF valve OFF and wait 30 sec onds 2 Remove 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 3 Use the grounding rod to touch the pump and sup ply pail If you see any arcs see Electrical Trouble shooting on page 39 20 Pressure Relief Procedure WARNING Pressurized Equipment Hazard The
57. ow fluid supply Add fluid if necessary Damaged air cap 9 Replace see page 42 Dirty or clogged fluid nozzle 7 Clean see page 42 Damaged fluid nozzle 7 Replace see page 42 Damaged fluid adjustment valve 25 Replace see page 50 Dirty air cap Misaligned air cap 9 and fluid noz zle 7 Clean fluid buildup off air cap and fluid nozzle seat see page 29 38 309293K Electrical Troubleshooting Troubleshooting Problem Cause Solution Voltage still present at gun after fol lowing the Fluid Voltage Discharge and Grounding Procedure ES ON OFF valve is not turned OFF Turn OFF Did not wait long enough for voltage to discharge Wait longer before touching electrode with grounded rod Check for bleed resistor failure Air pocket in fluid line leaves fluid near gun isolated Determine cause and correct Purge air from fluid line Voltage isolation system failed Service voltage isolation system Grounding cylinder not operating Check resistance of grounding cylin der page 33 Replace if needed Poor wrap ES ON OFF valve OFF 0 Turn ON I Gun air pressure too low Check air pressure to gun minimum 40 psi 0 28 MPa 2 8 bar needed at gun for full voltage Atomizing air pressure too high Decrease Fluid pressure too high Decrease Incorrect distance fr
58. ply line to ensure a dry clean air supply to the gun Dirt and moisture can ruin the appear ance of your finished workpiece and can cause the gun to malfunction N Install a bleed type air regulator N on the gun air line P 3 Connect the red colored Graco Grounded Air Sup ply 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 309293K Installation 4 Connect the main air supply line A to the bleed type air valve B The bleed valve shuts off all air to the system Install an additional bleed type air valve B upstream of the air filter M to isolate the filter for servicing WARNING Pressurized Equipment Hazard The bleed type air valve B is required in fi your system to relieve air trapped between the valve and the fluid supply unit after the air regulator D is shut off Trapped air can cause the fluid supply unit to cycle unexpectedly which can result in serious injury including splashing fluid in the eyes or on the skin Ground the Cabinet Connect the main ground wire V to a true earth ground Connect the Waterborne Fluid Hose Always use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun fluid inlet See Fic 3 The waterborne fluid hose 101 con sists of an inner PTFE tube T and an abrasion resi
59. r BUSHING plastic 3 4 x 1 2 npt ELBOW tube 3 8 npt x 3 8 in 10 mm OD tube ELBOW tube 3 8 npt x 1 2 in 13 mm OD tube LABEL warning FITTING tube 1 2 npt x 1 2 in 13 mm OD tube STRAINER 16 mesh sst STRAP tie GROUND WIRE 25 ft 7 6 m STRIP grounding aluminum NUT regulator WASHER shim latch ROD ground SCREW hex hd 1 4 20 x 5 8 in 16 mm WASHER plain 1 4 in 6 mm NUT hex 1 4 20 SCREW thread forming TUBE 1 4 in 6 mm OD nylon GAUGE air WIRE 10 gauge green with yel low stripe CONNECTOR swivel tee 1 8 npt x 5 32 in 4 mm OD tube Parts Qty 16 16 16 1 A R 1 A R 1 61 Parts Ref No 253 256 257 258 259 260 261 262 263 264 265 266 267 268 270 271 272 273 274 275 276 278 279 280 281 282 62 Part No 162449 101874 116990 113983 237933 113336 116991 203953 155541 114261 15A780 117314 113319 Description Qty NUT hex 10 32 1 NIPPLE reducing 1 2 npt x 1 4 2 npt TERMINAL ring 5 BOX control 1 RING retaining 1 2 in 13 mm 1 METER 0 90 kV 1 ADAPTER 1 4 npt 1 SCREW pan hd 10 32 x 5 8 in 4 16 mm SCREW pan hd 10 32 x 1 4 in 6 1 mm HOLDER tie 3 SCREW button hd 10 24 x 1 5 in 2 38 mm SCREW button hd 10 32 x 1 0 in 2 25 mm NUT hex M5 x 0 8 2 WASHER lock no 10 9 TEE run manifold 1 SCREW hex hd cap with patch 1 10 24 x 3 8 in 10
60. r valve 21 and spring 15 into the gun handle 17 7 Install the fluid adjustment valve 25 Torque to 15 25 in Ib 1 7 2 8 Nem 8 Install the barrel page 46 15 aa 6 TI1685A Fig 33 Air Valve 309293K Atomizing Air Restrictor Valve Removal and Replacement 1 Prepare the gun for service page 41 2 Remove the atomizing air restrictor valve 23 Inspect the o ring 23c Replace if necessary See FIG 34 3 Install a new atomizing air restrictor valve 23 or disassemble and replace parts individually The valve protrusion must be oriented to clear the air valve 21 shaft If the atomizing air restrictor valve is not desired install the supplied plug 47 4 Torque the valve housing 23a to 15 20 in Ib 1 7 2 3 Nem TI1686A Fig 34 Atomizing Air Restrictor Valve ES ON OFF Valve Repair 1 Prepare the gun for service page 41 2 Loosen the screw 48 Remove the valve 3 Lubricate the o rings 22a and 22b with non sili cone grease Part No 111265 Do not over lubri cate 309293K Repair CAUTION Do not over lubricate parts Excessive lubricant on the o rings can be pushed into the gun air passage and blemish the finish on the workpiece 4 Clean and inspect parts for damage Replace if nec essary The protrusion on the retainer plate 22d must point upward 5 Reinstall the valve Torque the screw 48 to 15 25 in Ib 1 7 2 8 Nem
61. rements 000005 9 Warning Sign 9 Install the System 0 a 9 Ventilate the Spray Booth 11 Connect the Air Line 0005 11 Ground the Cabinet 00 11 Connect the Waterborne Fluid Hose 11 245895 Agitator Kit 000 14 245944 Fluid Regulator Kit 15 Selecta Fluid Nozzle and Air Cap 16 GrOUNdING e ise PRN NANDUN AGA beeen es Hie 17 Check Electrical Grounding 18 Operation nA ee BANA a AG NA ba 19 Operating Checklist 19 Fluid Voltage Discharge and Grounding Procedure 20 Pressure Relief Procedure 20 Fill the Fluid Supply a 21 Adjust the Spray Pattern 21 ShUtdOWN soos ket cain ane pA 25 Low Voltage Adjustment Smart Guns Only 25 Maintenance eee eee eee 26 Flush the Spray Gun aaa 26 Daily Care and Cleaning 27 Clean the Air Cap and Fluid Nozzle 29 Grease Door Latch Threads 29 Electrical Tests cece eens 30 Test Gun Resistance 30 Test Power Supply Resistance 31 Test Electrode Resistance 32 Test Ground Strip Resistance 33 Test Cylinder Resistance 33 2 Troubleshooting seen eeeee 34 Voltage Loss Troubleshooting 34 Spray Pattern Tr
62. rom the gun as instructed on page 44 and look for signs of fluid leakage or any blackened areas which would indi cate arcing is occurring along the packing rod Fluid hose connection joint to the spray gun A breakdown at the fluid hose connection joint would be caused by fluid leaking past the o ring seals on the end of the hose Remove the hose at the gun connection and look for signs of fluid leak age along the PTFE tube 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 15 Check the gun voltage with the voltage probe and meter before filling the gun with fluid 309293K Spray Pattern Troubleshooting Troubleshooting Check all possible remedies in the Troubleshooting Chart before disassembling the gun Some spray pattern problems are caused by the improper balance between air and fluid Problem Cause Solution Fluttering or spitting spray No fluid Refill supply Loose dirty damaged nozzle seat Clean or replace nozzle page 42 Air in fluid supply Check fluid source Refill Improper spray pattern Damaged nozzle or air cap Replace page 42 Fluid buildup on air cap or nozzle Clean See page 29 F A Fan air pressure too high Decrease Fluid too thin Increase viscosity Fluid pressure too low Increase Fa
63. roval is valid only when this gun is used with Factory Mutual approved voltage isolation systems 245895 Agitator Kit To add an agitator to the Graco isolation system order Part No 245895 See page 67 for the kit parts list 1 2 Discharge the system voltage page 20 Relieve the pressure page 20 Open the isolated enclosure door Remove the back of the control box 258 Remove tube A2 from elbow 282 at the air mani fold see the tubing diagram on page 64 Install the Y fitting 402 into the elbow Install tubes A2 and 407 into the Y fitting See FIG 11 Route the agita tor 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 14 Connect to elbow 282 inside control box 258 403 408 404 406 Ref TI2137A Fig 11 245895 Agitator Kit 309293K 245944 Fluid Regulator Kit To add a fluid regulator to the Graco isolation system order Part No 245944 See page 68 for the kit parts list 1 Discharge the system voltage page 20 2 Relieve the pressure page 20 3 Open the isolated enclosure door 4 Remove the 1 4 OD tube A1 from the pump air inlet see the tubing diagram on page 64 5 Remove the waterborne fluid hose from the pump fluid outlet fitting 231 and remove the fitting 6 Unscrew the two pump mounti
64. s The gun is supplied with Part No 197266 Nozzle and 24A276 Air Cap If you require a different size refer to Table 1 and Table 2 and instruction manual 309419 or consult with your Graco distributor See Air Cap Nozzle Replacement on page 42 A wide pattern kit P N 24A431 is included with the gun and if installed will provide fan air for wider spray pat terns If pattern becomes split use the fan air valve to reduce the amount of fan air 16 Part No ore Part No Sizes mm in mm in 197263 0 75 030 197266 1 5 055 197264 1 0 042 197267 1 8 070 197265 1 2 047 197268 2 0 080 Table 2 Air Caps penn shape Recommended Fluids and Part No and Length in 5 Production Rates mm Light to medium viscosity Round end f 24A438 15 17 381 432 Up to 15 oz min 450 cc min Medium to high viscosity Round end and high solids PENET 14 16 356 406 Up to 15 oz min 450 cc min Light to medium viscosity Tapered end 3 24A376 17 19 432 483 Up to 15 oz min 450 cc min Light to medium viscosity Tapered end 24A274 12 14 305 356 Up to 15 oz min 450 cc min Medium to high viscosity and high solids Round end i 24A439 11 13 279 330 Up to 15 oz min 450 cc min For use with 2 0 mm nozzle Also available in the following colors 24A276 blue 24A277 red 24A278 green 309293K Installation Grounding e Vol
65. s tant outer jacket J Shielded hose 245252 also has a conductive layer C The conductive layer is connected to ground at the gun fitting bracket 104 Before connecting the waterborne fluid hose to the gun blow it out with air and flush with water to remove con taminants Flush the gun before using it WARNING Electric Shock Hazard X To reduce the risk of electric shock install uy only one continuous Graco waterborne hose between the isolated fluid supply and the gun Do not splice hoses together 11 Installation 1 Remove the gun air inlet fitting 35 See FIG 3 TI2155A Fig 3 Connect the Fluid Hose In a shielded hose system if a hose failure occurs where high voltage arcs through the inner tube voltage will be discharged to ground through the conductive hose layer When properly installed the conductive hose layer is grounded through its connection to the grounded enclosure 2 For the fluid hose to fit properly it must be stripped and assembled to the dimensions in FIG 4 Push the inner tube T into the fitting F until the tube bottoms A new Graco waterborne fluid hose comes fully assembled to these dimensions Z N CAUTION Be careful not to cut into the inner tube T of the hose when stripping the hose Nicks or cuts in the PTFE tube will cause premature hose failure 12 Shielded Hose 245252 A 7 40 in 188 mm B 2 0 in 50 mm
66. sulting 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 presente document sera en Anglais ainsi que tous documents avis et procedures judiciaires ex cut s donnes ou intentes a la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Information TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free 612 623 6921 612 378 3505 Fax All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice This manual contains English MM 309293 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2002 Graco Inc is registered to ISO 9001 www graco com Revised 1 2009
67. tage Isolation System electrically connect to a true earth ground as instructed in the voltage isola tion system manual e Object being sprayed keep the workpiece hangers NN WARN ING clean and grounded at all times Resistance must not exceed 1 megohm Fire Explosion and Electric Shock Hazard When operating the electrostatic gun any ungrounded objects in the spray area peo ple containers tools etc can become electrically charged Improper grounding ren can result in static sparking which can cause a fire explosion or electric shock e The floor of the spray area must be electrically con Follow the grounding instructions below ductive and grounded Do not cover the floor with cardboard or any non conductive material which would interrupt grounding continuity 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 e Electrostatic Air Spray Gun ground the gun by con f i necting the red colored Graco Grounded Air Hose A and connecting the air hose ground wire to a true earth ground See Check Electrical Grounding e All solvent pails use only grounded metal pails page 18 which are conductive Do not use plastic containers Do not place the pail on a no
68. tion shown Generously apply dielectric grease to the outside of the spacer 3 Place the packing spreader 26c rod packing 26d and housing 26f on the packing rod 26h Fig 27 Packing Rod 309293K 11 Repair Lightly tighten the packing nut 26e The packing nut is properly tightened when there is 3 Ib 13 3 N of drag force when sliding the packing housing 26f assembly along the rod Tighten or loosen the pack ing nut as needed Install the o ring 26a on the outside of housing 26f Lubricate the o ring with non silicone grease Part No 111265 Do not over lubricate Install the spring 4 against the nut E as shown Install the packing rod assembly 26 into the gun barrel Using the multi tool 37 tighten the assem bly until just snug Install the trigger 30 and screws 8 Install the electrode page 43 Install the nozzle and air cap page 42 Test gun resistance page 30 TIt489a 45 Repair Barrel Removal 1 Prepare the gun for service page 41 2 Remove the air inlet fitting 35 and take the bracket 104 off the gun handle 17 3 Loosen the three screws 11 Z N CAUTION To avoid damaging the power supply 18 pull the gun barrel straight away from the gun handle If nec essary gently move the gun barrel from side to side to free it from the gun handle 4 Hold the gun hanale 17 with one hand and pull the barrel 16 straight off th
69. tor The gun air supply must be interlocked with the isolation system to shut off the air supply any time the isolation system enclosure is opened Use only the red colored Graco electrically conductive gun air hose with this gun Do not use black or grey colored Graco air hoses Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the spray gun Do not splice hoses together Do not enter a high voltage or hazardous area until all high voltage equipment has been dis charged 309293K Ch Warning WARNING Fire and Explosion Hazard Improper grounding poor air ventilation open flames or sparks can cause a hazardous condition and result in a fire or explosion Electrostatic equipment must be used only by trained qualified personnel who understand the requirements in this manual Ground the equipment all personnel in or close to the spray area the object being sprayed and all other electrically conductive objects in the spray area See Grounding page 17 Check gun resistance daily See Test Gun Resistance on page 30 If there is any static sparking while using the equipment stop spraying immediately Identify and correct the problem Provide fresh air ventilation to avoid buildup of flammable or toxic vapors See Ventilate the Spray Booth on page 11 Only use this equipment to spray non flammable waterborne fluids as defined on the front cover of this manual
70. un only Green when ES is ON l Voltage current DISPLAY smart models only Shows voltage V and current A Green spray yellow red see Electrical Troubleshooting page 39 ES HI LO switch smart models only Sets volt age to HI or LO factory settings LO VOLTAGE adjustment smart models only Remove plug to adjust to four settings Page 21 DISPLAY LO VOLTAGE AIR FLUID ti1253a Gg Smart Model TRIGGER AIR INLET TI1681A 309293K Installation System Requirements A safe well designed voltage isolation system should have the following features e All components of the isolation system that are charged to high voltage must be contained within an enclosure that prohibits persons from making con tact with the high voltage components before the system voltage is discharged e A bleed resistor to drain off the system voltage when the spray gun is not in use e The system should not have any severe arcing occurring when the isolation mechanism opens and closes Severe arcing will shorten the life of the sys tem components e The system must include a means for automatically discharging the system voltage when anyone opens the isolation enclosure Installation Install the System WARNING Fire Explosion and Electric Shock Hazard si M W e Do not install or service this equipment unless you are trained and qualified Installing and servicing this equipment requires ac
71. uoroelastomer SEAL SPREADER packing unmwpe PACKING rod acetal NUT packing HOUSING packing SPACER packing acetal ROD packing RING retaining includes 27a Qty 309293K Ref No 27a 28 29 30 35 36 37 38 39 40 41 42 43 47 48 55 101 102 103 104 105 106 107 108 109 Part No 198307 276695 276867 276698 245496 107460 276741 185103 110231 116553 244915 179791 180060 197967 198058 197624 245252 246431 198663 190863 185547 15B932 197954 185548 198643 102982 198640 24A431 309293K Description PACKING u cup HOOK NEEDLE electrode black TRIGGER SWIVEL air 1 4 npsm m left hand threads WRENCH ball end 4 mm MULTI TOOL TUBE exhaust CLAMP GREASE dielectric tube not shown COVER gun box of 10 not shown TAG warning not shown replacement available at no cost SIGN warning not shown replacement available at no cost PLUG SCREW cap socket hd SPRING grounding HOSE shielded waterborne fluid HOSE unshielded waterborne fluid includes 102 108 FERRULE shielded hose 245252 FERRULE unshielded hose 246431 HOUSING ferrule shielded hose 245252 HOUSING ferrule unshielded hose 246431 BRACKET fluid fitting NUT FITTING barrel O RING FITTING seal KIT wide pattern not shown Qty Parts Included in Air Seal Repair Kit 244781
72. y Graco Graco will for a period of twelve months or two thousand hours of operation 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 or six thousand hours of operation 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 structures 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 equipme

Graco Inc. 244581 Paint Sprayer User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents