HP_(Hewlett-Packard)_Paint_Sprayer

Instructions/Parts List

ELECTROSTATIC, WATERBORNE, AIR SPRAY

WB100 Isolation System and

PRO??? Xs3 Spray Gun

309293J

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

???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

???The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.

CE-EN 50059 Compliant

???Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500 mJ.

TI2139a

WB 100

Isolation Enclosure

See page 3 for a List of Models

U.S. Patent No. 7,226,004

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

Symbols

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instruc- tions.

WARNING

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 resistor.

???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.

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.

???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 manufacturer???s 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.

Warning

WARNING

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 alter 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.

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 loose parts immediately.

???Tighten all fluid connections before each use.

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, 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.

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 F IG . 1.).

???FLUID adjustment valve. Adjusts fluid rod travel. Use only in low flow conditions, to reduce wear.

???Fan AIR adjustment valve. Adjusts fan size and shape.

???Atomizing air RESTRICTOR valve. Restricts atomizing air flow. Replace with plug (included) if desired.

???ES ON/OFF valve. Turns electrostatics ON (I) or OFF (0).

???ES INDICATOR (standard gun only). Green when ES is ON (I).

???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).

ES INDICATOR

ES ON/OFF

I ES O

AIR CAP

ELECTRODE

FLUID TUBE

???LO VOLTAGE adjustment (smart models only).

Remove plug to adjust to four settings. Page 21.

DISPLAY

LO VOLTAGE

LO ES

ES ON/OFF

I ES O

AIR

RESTRICTOR

FLUID

ti1253a

Smart Model

TRIGGER

AIR INLET

TI1681A

Fig. 1. Gun Overview

Installation

System Requirements

A safe, well designed voltage isolation system should have the following features:

???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.

???A bleed resistor to drain off the system voltage when the spray gun is not in use.

???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.

???The system must include a means for automatically discharging the system voltage when anyone opens the isolation enclosure.

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.

Installation

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.

Install the System

WARNING

Fire, Explosion, and Electric Shock Hazard

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.

??? Do not install or service this equipment unless you are trained and qualified.

???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.

F IG . 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

TI1775C

Fig. 2. Typical Installation: PRO Xs Waterborne System

Key

CPump Air Pressure Gauge

DPump Air Pressure Regulator

EkV Meter

FPump

GPump Suction Hose

HPaint Container

LIsolated Enclosure

MGun Air Line Filter

NGun Air Pressure Regulator

RGraco Waterborne Fluid Hose

SWaterborne Electrostatic Air Spray Gun

TGrounding Rod

UGround Terminal

WStrain Relief/Ground Fitting

XPump Air Supply Line

YGrounding Cylinder

ZPump Fluid Outlet Fitting

AAIsolated Enclosure Door

BBEnclosure T-Handle Locking Screw

*Required for safe operation. Must be purchased separately.

Ventilate the Spray Booth

WARNING

Flammable or Toxic Vapor Hazard

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Do not operate the gun unless ventilation fans are 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 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.

1.Install an air line filter/water separator (M) on the main air supply line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appear- ance of your finished workpiece and can cause the gun to malfunction.

2.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.

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

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 FIG. 3.. The waterborne fluid hose (101) con- sists of an inner PTFE tube (T) and an abrasion-resis- 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

To reduce the risk of electric shock, install only one continuous Graco waterborne hose between the isolated fluid supply and the gun. Do not splice hoses together.

Installation

1. Remove the gun air inlet fitting (35). See FIG. 3..

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.

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.

Shielded Hose 245252

A 7.40 in. (188 mm)

B 2.0 in. (50 mm)

Fig. 4. Waterborne Hose Dimensions (At Gun)

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:

a.Graco WB100 Enclosure: Slide hose through the strain relief fitting (W). Ensure conductive layer (C) has passed through fitting. Tighten to 55 in-lb (6.2 N???m). Pull back on hose to check it is secure. Comply with the requirements in Warning at right. See F IG . 6. and FIG. 7..

See Warning below.

Installation

AA 14.5 in. (368 mm) B 0.75 in. (19 mm)

TI2166A

Fig. 6. Waterborne Hose Dimensions (At Graco

WB100 Enclosure)

TI2744A

Fig. 9. Unshielded fluid connection

WARNING

See Warning at right.

Electric Shock Hazard

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

TI1897A

Fig. 7. Shielded Fluid Hose Connection at Graco

WB100

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 FIG. 10..

NOTE: Ground layer (C) of hose must be grounded at isolation system.

Fig. 10. Shielded Fluid Hose Connection at Non-Gra- co Isolated Enclosure

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.

CAUTION

Factory Mutual approval 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.Discharge the system voltage (page 20).

2.Relieve the pressure (page 20).

3.Open the isolated enclosure door.

4.Remove the back of the control box (258).

5.Remove tube (A2) from elbow (282) at the air 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 F IG . 11.. Route the agita- tor tube (407) into the cabinet.

6.Replace the back of the control box (258).

7.Assemble the other parts of the kit as shown. Secure the agitator with the setscrew (408).

8.Return the system to service.

Connect to elbow (282) 402 inside control box (258)

407

401

406

Install tube A2 here

403

408

404

406 (Ref)

TI2137A

Fig. 11. 245895 Agitator Kit

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 mounting screws (S, F IG . 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 F IG . 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.

Installation

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.

502

TI2149A

Fig. 12. Fluid Regulator Kit

Grounding

WARNING

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 can result in static sparking, which can cause a fire, explosion, or electric shock. Follow the grounding instructions below.

The following are minimum grounding requirements for a basic electrostatic waterborne system. Your system may include other equipment or objects which must be grounded. Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground.

???Electrostatic Air Spray Gun: ground the gun by con- necting the red-colored Graco Grounded Air Hose and connecting the air hose ground wire to a true earth ground. See Check Electrical Grounding, page 18.

ti1259a

???Graco Waterborne Fluid Hose: the hose is grounded through the conductive layer. Install the hose as instructed on page 11.

???All persons entering the spray area: shoes must have conductive soles, such as leather, or personal 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.

Installation

???Voltage Isolation System: electrically connect to a true earth ground, as instructed in the voltage isola- tion system manual.

???Object being sprayed: keep the workpiece hangers clean and grounded at all times. Resistance must not exceed 1 megohm.

???The floor of the spray area: must be electrically con- ductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.

???All solvent pails: use only grounded metal pails, which are conductive. Do not use plastic containers. Do not place the pail on a non-conductive surface such as paper or cardboard. Do not store more than the quantity needed for one shift.

???All electrically conductive objects or devices in the spray area: including fluid containers, tools, and wash cans, must be properly grounded.

Installation

Check Electrical Grounding

1.Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose.

2.Turn the ES ON/OFF valve OFF.

I ES O

ti1273a

3.Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it.

4.Make sure the red-colored grounded air hose (R) is connected and the hose ground wire is connected to a true earth ground.

ti1259a

5.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..

6.If the resistance is greater than 100 ohms, check the tightness of the ground connections 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

7.Using an ohmmeter (AA), measure the resistance between the cabinet ground lug (214) and a true earth ground (CC). See F IG . 14.. The resistance must be less than 100 ohms.

214

TI2163A

Fig. 14. Check Cabinet Grounding

Operation

Operating Checklist

Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.

All operators are properly trained to safely operate an 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 grounded.

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 20%, 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.

Operation

WARNING

Electric Shock Hazard

The fluid supply is charged with high volt- age until the voltage is discharged. Contact

with the 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:

???whenever you are instructed to discharge the voltage

???before cleaning, flushing, or servicing the system equipment

???before approaching the front of the gun

???or before opening the safety enclosure for the isolated fluid supply.

1.Turn the ES ON/OFF valve OFF and wait 30 sec- onds.

I ES O

ti1273a

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.

WARNING

Pressurized Equipment Hazard

The 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:

???are instructed to relieve the pressure

???stop spraying

???check or service any of the system equipment

???or install or clean the fluid nozzle.

1.Turn the ES ON/OFF valve OFF.

I ES O

ti1273a

2.Follow the Fluid Voltage Discharge and Ground- ing Procedure at left.

3.Turn off the main air supply valve (B).

ti1289a

4.Trigger the gun into a grounded metal waste con- tainer to relieve the air and fluid pressure.

ti1276a

5.Relieve fluid pressure in the fluid supply unit as instructed in your fluid supply unit manual.

Fill the Fluid Supply

1.Discharge the system voltage (page 20).

2.Relieve the pressure (page 20).

ti1276a

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:.

???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.

???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.

WARNING

Electric Shock Hazard

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 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

To reduce the risk of component rupture, which can cause serious injury, do not

exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi (0.7 MPa, 7 bar) maximum working air and fluid pressure.

Operation

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 20 whenever you are instructed to relieve the pressure.

1. Make sure the ES ON/OFF valve is OFF.

I ES O

ti1273a

2. Turn on the main air supply valve (B).

4. Fully open the fan air adjustment valve.

0 KV 100%

????

LO ES

I ES O

ti1269a

5. Fully open the fluid adjustment valve.

0 KV 100%

????

LO ES

I ES O

ti1267a

6. Fully open the atomizing air restrictor valve.

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.

ti1272a

I ES O

Horizontal Pattern

ti1273a

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.

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.

8-12 in. (200-300 mm)

TI1760A

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 .

ti1282a

11.Adjust the fan air adjustment valve: clockwise for a rounder pattern, counterclockwise for a wider pat- tern.

ti1283a

???For the most efficiency, always use the lowest air pressure possible.

???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.

WARNING

Electric Shock Hazard

When the ES ON/OFF switch is turned ON, the fluid supply is charged with high voltage 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).

I ES O

ti1284a

Shutdown

1.Discharge the system voltage (page 20).

2.Flush the spray gun. See page 26.

ti1276a

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on whenever you are instructed to relieve the pressure.

3. Relieve the pressure (page 20).

ti1276a

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.

ti1288a

Operation

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.

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..

OFF

2 1

0 KV 100%

????

ti1529a

Fig. 15. Low Voltage Adjustment Switches

Table 4: Low Voltage Adjustment

Maintenance

Flush the Spray Gun

Flush the gun before changing colors, at the end of the day, before storing, and before repairing the gun.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or elec- tric shock, turn the ES ON/OFF valve OFF before flushing the gun.

Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 before flushing.

Only flush, purge, or clean the gun with fluids that meet at least one of the following conditions for non-flammability:

???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.

???The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.

1.Turn the ES ON/OFF valve OFF and wait 30 sec- onds for the voltage to bleed off.

I ES O

ti1273a

2.Discharge the system voltage (page 20).

3.Relieve the pressure (page 20).

ti1276a

4.Change the fluid source to solvent.

5.Point the gun into a grounded metal pail. Flush until clean solvent flows from the gun.

ti1276a

6. Relieve the pressure.

ti1276a

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 20 whenever you are instructed to relieve the pressure.

7.Open the isolated enclosure door. Leave the flush- ing fluid in the system until you are ready to spray again.

8.Hang the gun from its hook, with the nozzle pointing down. Be sure to keep the gun from grounding out.

ti1288a

9.Before using the system electrostatically again, make sure no flammable vapors are present.

Clean the Air Cap and Fluid

Nozzle

Equipment Needed

???soft bristle brush

???non-flammable solvent

Procedure

1. Turn the ES ON/OFF valve OFF. Wait 30 seconds.

I ES O

ti1273a

2.Discharge the system voltage (page 20).

3.Relieve the pressure (page 20).

ti1276a

Maintenance

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.

If it appears that there is paint inside the fluid nozzle (7) air passages, remove the gun from the line for 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.

ti1297a

4.Remove the retaining ring (27) and air cap (9). See FIG. 16..

Fig. 16. Clean Air Cap and Fluid Nozzle

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.

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.

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 F IG . 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:

??? The gun has been removed from the hazardous area;

???Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes from spraying).

Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.

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.

Fig. 17. Test Gun Resistance

Electrical Tests

Test Electrode Resistance

1.Prepare the gun for service as instructed on page 41.

2.Insert a conductive rod (B) into the gun barrel (removed for the power supply test) and against the metal contact (C) in the front of the barrel.

3.Measure the resistance between the conductive rod

(B) and the electrode (29). The resistance should be 20-30 megohms. See F IG . 19..

4.If in range, refer to Electrical Troubleshooting on page 39 for other possible causes of poor perfor- mance, or contact your Graco distributor.

5.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 F IG . 20..

6.Make sure the metal contact (C) in the barrel, the nozzle contact ring (7a, F IG . 21.), and the electrode contact (E) are clean and undamaged.

ti1499a

F 29 E

ti1548a

Fig. 20. Electrode

ti1513a

Fig. 21. Nozzle Conductive O-Ring

Fig. 19. Test Electrode Resistance

Test Ground Strip Resistance

See F IG . 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).

Electrical Tests

Test Cylinder Resistance

See F IG . 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.

206

214

TI2165A

Fig. 22. Test Ground Strip Resistance

TI2164A

Fig. 23. Test Cylinder Resistance

Troubleshooting

WARNING

Electric Shock Hazard

Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if

the work is not performed properly. Do not install or repair this equipment unless you are trained and qualified.

Follow the Fluid Voltage Discharge and Grounding Procedure 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.

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

???Fluid leakage

???Dielectric breakdown at the fluid hose connection or fluid packings

???Not enough air pressure for the turbine

???Faulty power supply

???Excessive overspray on gun surfaces

???Fluid in the air passages

Waterborne Fluid Hose

???Dielectric failure of hose (pin-hole leak through PTFE layer)

???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 Loss Troubleshooting

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.

Voltage Isolation System

???Fluid leakage

???Dirty interior

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 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.

Troubleshooting

10. Inspect the entire system for any visible fluid leak- age and repair any fluid leaks that are found. Pay special attention to the following areas:

???Packing area of the spray gun

???Fluid hose: check for leakage or any bulges in the outer cover, which may indicate an internal leak

???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.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.

Troubleshooting

9.Flush the fluid hose and gun with enough air to dry out the fluid passages.

10.Turn the ES ON/OFF valve to ON and trigger the gun. Measure the voltage at the gun electrode with a voltage probe and meter.

11.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.

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 from 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.

13.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.

14.Reconnect the fluid hose.

15.Check the gun voltage with the voltage probe and meter before filling the gun with fluid.

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.

???Clean all parts with a non-flammable fluid as defined on the front cover of this manual.

???Do not service this equipment unless you are trained and qualified.

???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- 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.

Repair

???Check all possible remedies in Troubleshooting before disassembling the gun.

???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 Lubricant. Do not over-lubricate.

???Only use genuine Graco parts. Do not mix or use parts from other PRO Gun models.

???Air Seal Repair Kit 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**).

1.Follow the Fluid Voltage Discharge and Ground- ing Procedure on page 20.

2.Flush the gun, page 26.

3.Blow the fluid lines dry with air.

4.Relieve the pressure, page 20.

5.Disconnect the gun air and fluid lines at the isolation system.

6.Remove the gun from the worksite. Repair area must be clean.

Repair

Air Cap/Nozzle Replacement

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 F IG . 24..

3.Point gun up and squeeze trigger while removing the fluid nozzle (7) assembly with the multi-tool (37).

27 27a*

ti1501a

Fig. 24. Air Cap/Nozzle Replacement

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) 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.

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.

Repair

Fluid Packing Removal

1.Prepare the gun for service, page 41.

2.Remove the air cap and fluid nozzle, page 42.

3.Remove the electrode, page 43.

4.Loosen the trigger screws (8) and trigger (30). See F IG . 26..

5.Remove the packing rod (26), using the multi-tool (37).

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.

6.Check all parts for wear or damage and replace if necessary.

TI1683A

Fig. 26. Fluid Packing Removal

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 F IG . 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 direction 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).

26e

**26b

**26g **26c

**26d

26f

**26a

Repair

4.Lightly tighten the packing nut (26e). The packing nut is properly tightened when there is 3 lb (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.

5.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.

6.Install the spring (4) against the nut (E) as shown.

7.Install the packing rod assembly (26) into the gun barrel. Using the multi-tool (37), tighten the assem- bly until just snug.

8.Install the trigger (30) and screws (8).

9.Install the electrode, page 43.

10.Install the nozzle and air cap, page 42.

11.Test gun resistance, page 30.

TI1489A

26h

Fig. 27. Packing Rod

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).

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 handle (17) with one hand and pull the barrel (16) straight off the handle. See FIG. 28..

Barrel Installation

1.Be sure the gasket (10*) and grounding spring (55) are in place. Make sure the gasket air holes are aligned properly. Replace if damaged. See F IG . 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).

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.

104

TI1690A

35 17

TI1691A

Fig. 28. Barrel Removal

*10

101

104

Fig. 29. Barrel Installation

Power Supply Removal and

Replacement

???Inspect the gun handle power supply cavity for dirt or moisture. Clean with a clean, dry rag.

???Do not expose gasket (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 the handle (17). See F IG . 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).

Repair

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).

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.

10*

19a*

19e

ti1505c

*18a 18b

Fig. 30. Power Supply

Repair

Turbine Alternator Removal and

Replacement

Replace turbine alternator bearings after 2000 hours of operation. Order Part No. 223688 Bearing Kit.

1.Prepare gun for service, page 41.

2.Remove the power supply/alternator assembly, page 47.

3.Disconnect the alternator from the power supply, page 47.

4.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.

5.Follow the bearing replacement procedure in the bearing kit manual 308034.

6.Install the alternator on the power supply, page 47.

7.Install the power supply/alternator assembly, page 47.

Fan Air Adjustment Valve Repair

1.Prepare the gun for service, page 41.

2.Place a wrench on the flats of the valve assembly (20) and unscrew it from the handle (17).

You may replace the valve as an assembly (go to step 9) or as individual parts (steps 3-9).

3.Remove the retaining ring (20a). See F IG . 31..

4.Turn the valve stem (20d) counterclockwise until it comes free from the valve housing (20c).

5.Remove the o-ring (20b).

20b*

20c

20a

Repair

6.Clean all parts and inspect for wear or damage. Use non-silicone grease, Part No. 111265. Do not over-lubricate.

7.When reassembling the fan air valve (20), lightly lubricate the valve threads and screw the stem (20d) fully into the housing (20c) until bottomed. Install the o-ring (20b*), lubricate, and unscrew the valve stem until the o-ring enters the housing.

8.Reassemble the retaining ring (20a). Unscrew the valve stem from the housing until it is stopped by the retaining ring.

9.Screw the valve assembly (20) into the gun handle, using a wrench on the flats of the housing. Torque to 15-25 in-lb (1.7-2.8 N???m).

20d

TI1487A

Fig. 31. Fan Air Adjustment Valve

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 F IG . 32..

3.Screw the valve (25) into the gun handle. Torque to 15-25 in-lb (1.7-2.8 N???m).

TI1684A

Fig. 32. Fluid Adjustment Valve

Air Valve Repair

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.

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 air valve (21) and spring (15) into the gun handle (17).

7.Install the fluid adjustment valve (25). Torque to 15-25 in-lb (1.7-2.8 N???m).

8.Install the barrel, page 46.

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 F IG . 33..

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.

21a*

TI1685A

Fig. 33. Air Valve

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 F IG . 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-lb (1.7-2.3 N???m).

Repair

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.

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-lb (1.7-2.8 N???m).

TI1488A

TI1686A

Fig. 34. Atomizing Air Restrictor Valve

Fig. 35. ES ON/OFF Valve

ES ON/OFF Valve Repair

1. Prepare the gun for service, page 41.

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).

I ES O

ti1266a 18b

*18a

25 (Ref)

27a*

19a*

19e 19

108 107

106

101

*10

55 8

*24a

105

104

103

102

17 15

21a*

23c*

23d 47

23a 23b

35***

TI1679A

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)

0 KV 100%

????

51 (Ref)

19a*

LO ES

I ES

25(Ref)

18b

ti1253a

*18a

7a 7b

27a*

105

104

38 103

106

102

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)

271

253

276

301

228

262

268

204

257

226

227

262

213

265

259

206

242

235

210

231

209

211 212

TI2138a

Parts

Tubing and Wiring Diagrams

Detail of Control Box

C3, C4, C5

C9 A1 A2

C2, C9

B2 E1

TI2145A

Detail of Door Interlock Switch

C6, C7, C8

TI2144A

TI2143A

Accessories

Air Line Accessories

Grounded Air Hose (Red Cover)

100 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.

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.

Air Line Shutoff Valve

150 psi (10 bar, 1.0 MPa) Maximum Working Pressure

For turning air to gun on or off.

224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.

Air Line Quick Disconnect

112534 Swiveling quick disconnect replaces stan- dard air inlet swivel.

Accessories

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 Replaces standard swivel. Left-hand thread.

Extended Air Inlet Fitting

189191 Replaces standard swivel to provide extended handle grip area. Left-hand thread.

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 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.

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 4-6 in. (102-152 mm) diameter 245219 8-10 in. (203-254 mm) diameter

Push/Pull Fan Air Valve

244912 For quick change of fan size.

Handle Grips

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.

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

Technical Data