Graco Pro Xp 60 AA WB Parts list manual

Instructions-Parts
WB3000 WB3000
WB3000Isolation Isolation IsolationSystem System System& & &Pro Pro ProXp™ Xp™ Xp™
60 60
60AA AA AAWB WB WBGun Gun Gun3A2497H
EN
Air Air
Air- - -assisted assisted assistedspray spray spraysystem system systemfor for foruse use usewhen when whenelectrostatically electrostatically electrostaticallyspraying spraying sprayingconductive, conductive, conductive,waterborne waterborne waterborne󰘱uids 󰘱uids 󰘱uidsthat that that
meet meet
meetat at atleast least leastone one oneof of ofthe the theconditions conditions conditionsfor for fornon non non- - -󰘱ammability 󰘱ammability 󰘱ammabilitylisted listed listedon on onpage page page3. 3. 3.
For For
Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualbeforeusingthe
equipment.Save Save
Savethese these theseinstructions. instructions. instructions.
3000psi(21MPa,210bar)Maximum
FluidWorkingPressure
100psi(0.7MPa,7bar)MaximumAir
WorkingPressure
Seepage3formodelpartnumbersand
approvalinformation.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Models...............................................................3
RelatedManuals................................................3
Warnings...........................................................4
GunOverview....................................................7
HowtheElectrostaticAASprayGun
Works............................................7
SprayingWaterborneFluids
Electrostatically..............................7
Controls,Indicators,andComponents...........8
SmartGuns.................................................9
Installation..........................................................14
SystemRequirements..................................14
WarningSign...............................................14
InstalltheSystem.........................................14
VentilatetheSprayBooth.............................14
AirSupplyLine............................................15
GroundtheCabinet......................................15
Grounding...................................................16
ConnecttheWaterborneFluidHose..............18
AgitatorKitAccessory..................................22
GunSetup..........................................................23
GunSetupProcedure...................................23
CheckGunElectricalGrounding...................26
FlushBeforeUsingEquipment......................27
Operation...........................................................28
PressureReliefProcedure............................28
OperatingChecklist......................................29
FluidVoltageDischargeandGrounding
Procedure......................................29
FilltheFluidSupply......................................30
Startup........................................................30
Shutdown....................................................30
Maintenance......................................................31
DailyCareandCleaningChecklist................31
Flushing......................................................31
CleantheGunDaily.....................................33
DailySystemCare.......................................35
ElectricalTests...................................................36
TestGunResistance....................................36
TestPowerSupplyResistance.....................37
TestGunBarrelResistance..........................37
TestGroundStripResistance.......................38
TestCylinderResistance..............................38
Troubleshooting..................................................39
VoltageLossTroubleshooting.......................39
SprayPatternTroubleshooting......................41
GunOperationTroubleshooting....................42
ElectricalTroubleshooting............................43
Repair................................................................44
PreparetheGunforService.........................44
AirCap,SprayTip,andFluidSeatHousing
Replacement..................................44
ElectrodeReplacement................................45
GunBarrelRemoval.....................................46
GunBarrelInstallation..................................46
FluidNeedleReplacement............................47
PowerSupplyRemovaland
Replacement..................................48
AlternatorRemovalandReplacement...........49
FanAirAdjustmentValveRepair..................51
AtomizingAirAdjustmentValve
Repair............................................51
ESOn-OffValveRepair...............................52
AirValveRepair...........................................53
SmartModuleReplacement..........................53
AirSwivelandExhaustValve
Replacement..................................54
Parts..................................................................55
StandardAir-AssistedSprayGun
Assembly.......................................55
SmartAir-AssistedSprayGun
Assembly.......................................57
IsolationEnclosure.......................................59
TubingandWiring.......................................62
AlternatorAssembly.....................................64
ESOn-OffValveAssembly...........................65
FanAirAdjustmentValveAssembly..............66
AirCapAssembly........................................66
SmartModuleAssembly...............................67
SprayTipSelectionChart....................................68
AEMFineFinishSprayTips..........................68
AEFFineFinishPre-Ori󰘰ceSpray
Tips...............................................69
RoundSprayTips........................................69
RepairKitsandAccessories................................70
GunAccessories..........................................70
OperatorAccessories...................................71
SystemAccessories.....................................71
Signs..........................................................71
TestEquipment...........................................71
Hoses.........................................................71
245895AgitatorKit......................................72
IgnitabilityofCoatingMaterials............................73
Dimensions........................................................74
TechnicalSpeci󰘰cations......................................75
CaliforniaProposition65.....................................75
23A2497H

Models
Models Models
Models
Models Models
Modelswhich which whichare are areFM FM FMApproved Approved Approvedand and andCompliant Compliant Compliantwith with withEN50059 EN50059 EN50059
FM FM
FMapproved approved approvedfor for foruse use usewith with with󰘱uids 󰘱uids 󰘱uidsthat that thatmeet meet meetthe the thefollowing following followingcondition: condition: condition:
• •
•Material Material Materialdoes does doesnot not notsustain sustain sustainburning burning burningin in inaccordance accordance accordancewith with withthe the theStandard Standard StandardTest Test TestMethod Method Method
for for
forSustained Sustained SustainedBurning Burning Burningof of ofLiquid Liquid LiquidMixtures, Mixtures, Mixtures,ASTM ASTM ASTMD4206. D4206. D4206.
Models Models
ModelsCompliant Compliant Compliantwith with withEN EN EN50059 50059 50059when when whenused used usedwith with with󰘱uids 󰘱uids 󰘱uidsthat that thatmeet meet meetthe the thefollowing following following
criteria: criteria:
criteria:
• •
•Material Material Materialis is isclassi󰘰ed classi󰘰ed classi󰘰edas as asnon non non- - -ignitable ignitable ignitableas as asde󰘰ned de󰘰ned de󰘰nedby by byEN EN EN50059: 50059: 50059:2018. 2018. 2018.
For For
Formore more moreinformation, information, information,see see seeIgnitability Ignitability Ignitabilityof of ofCoating Coating CoatingMaterials, Materials, Materials,page page page73 73 73. . .
Part Part
PartNo. No. No.Model Model ModelDescription Description Description
24N551WB3000WaterborneIsolationEnclosure24N550withstandard
electrostaticair-assistedspraygunH60T18,groundedairhose
235070,andunshieldedwaterborne󰘱uidhose24M508.
24P632WB3000WaterborneIsolationEnclosure24N550withsmartelectrostatic
air-assistedspraygunH60M18,groundedairhose235070,
andunshieldedwaterborne󰘱uidhose24M508.
24N550WB3000WaterborneIsolationEnclosureforunshieldedhoses.Doesnot
includehosesandgun.
H60T18ProXp60AAWBStandardElectrostaticAir-assistedSprayGun,forwaterborne
coatings.
H60M18ProXp60AAWBSmartElectrostaticAir-assistedSprayGun,forwaterborne
coatings.
25R012-------WaterborneFluidHoseAssembly,25ft(7.6m)
25R014-------WaterborneFluidHoseAssembly,50ft(15.2m)
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNo. No. No.Description Description Description
3A2498RoundSprayKit,Instructions
307263ProbeandMeter,Instructions
309455TestFixture,HighVoltageProbe,andkVMeter,Instructions
406999VoltageTesterConversionKit,Instructions
3A2497H3

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Combustibledustinwork work
workarea area areacanigniteorexplode.Tohelpprevent󰘰reandexplosion:
•Fluidsusedmustmeetthefollowing󰘱ammabilityrequirements:
•FM, FM,
FM,FMc FMc FMcApproved: Approved: Approved:
MaterialdoesnotsustainburninginaccordancewiththeStandardTestMethodfor
SustainedBurningofLiquidMixtures,ASTMD4206.
•CE CE
CE- - -EN EN EN50059 50059 50059Compliant: Compliant: Compliant:
Materialisclassi󰘰edasnon-ignitableasde󰘰nedbyEN50059:2018.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.
•Useandcleanequipmentonlyinwellventilatedarea.
•Interlockthegunairsupplytopreventoperationunlessventilatingfansareon.
•Onlyusenon-󰘱ammablesolventswhen󰘱ushingorcleaningequipment.
•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.
•Keepsprayareafreeofdebris,includingsolvent,ragsandgasoline.
•Keepaworking󰘰reextinguisherintheworkarea.
43A2497H

Warnings
WARNING WARNING
WARNING
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Impropergrounding,setup,orusageofanisolatedwaterbornesystemcanresultinelectric
shock.Tohelppreventelectricshock:
•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorclose
tosprayarea.SeeGrounding Grounding
Groundinginstructions.
•Connecttheelectrostaticguntoavoltageisolationsystemthatwilldischargethesystem
voltagewhennotinuse.
•Allcomponentsoftheisolationsystemthatarechargedtohighvoltagemustbecontained
withinanisolationenclosurethatpreventspersonnelfrommakingcontactwiththehigh
voltagecomponentsbeforethesystemvoltageisdischarged.
•FollowtheFluid Fluid
FluidVoltage Voltage VoltageDischarge Discharge Dischargeand and andGrounding Grounding GroundingProcedure Procedure Procedurewheninstructedtodischarge
thevoltage;beforecleaning,󰘱ushing,orservicingthesystem;beforeapproachingthefrontof
thegun;andbeforeopeningtheisolationenclosurefortheisolated󰘱uidsupply.
•Donotenterahighvoltageorhazardousareauntilallhighvoltageequipmenthasbeen
discharged.
•Donottouchthegunnozzleorelectrode,orcomewithin4in.(102mm)oftheelectrode
duringgunoperation.FollowtheFluid Fluid
FluidVoltage Voltage VoltageDischarge Discharge Dischargeand and andGrounding Grounding GroundingProcedure Procedure Procedure.
•Interlockthegunairsupplywiththevoltageisolationsystemtoshutofftheairsupplyanytime
theisolationsystemenclosureisopened.
•Onlyusethered-coloredGracoelectricallyconductivegunairhosewiththisgun.Donot
useblackorgray-coloredGracoairhoses.
•Donotsplicehosestogether.InstallonlyonecontinuousGracowaterborne󰘱uidhose
betweentheisolated󰘱uidsupplyandthespraygun.
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay
looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Getimmediate immediate immediatesurgical surgical surgical
treatment. treatment.
treatment.
•Donotspraywithouttipguardandtriggerguardinstalled.
•Engagetriggerlockwhennotspraying.
•Donotpointgunatanyoneoratanypartofthebody.
•Donotputyourhandoverthespraytip.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopsprayingandbeforecleaning,checking,
orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
3A2497H5

Warnings
WARNING WARNING
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.
Forcompleteinformationaboutyourmaterial,requestaSafetyDataSheet(SDS)from
yourdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
PLASTIC PLASTIC
PLASTICPARTS PARTS PARTSCLEANING CLEANING CLEANINGSOLVENT SOLVENT SOLVENTHAZARD HAZARD HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.
•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.
•SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinthisandallotherequipmentinstructionmanuals.Read󰘱uid
andsolventmanufacturer’sSafetyDataSheet(SDS)andrecommendations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheets(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
63A2497H

GunOverview
Gun Gun
GunOverview Overview Overview
How How
Howthe the theElectrostatic Electrostatic ElectrostaticAA AA AASpray Spray SprayGun Gun Gun
Works Works
Works
Thisisnotanairspraygun.Tohelpprevent
seriousinjuryfrompressurized󰘱uid,suchasskin
injection,andsplashing󰘱uid,readandfollowthe
Skin Skin
SkinInjection Injection InjectionHazard Hazard HazardWarnings Warnings Warningsonpage5.
Theair-assistedsprayguncombinesairlessand
airsprayingconcepts.Thespraytipatomizes
andshapesthe󰘱uidintoafanpattern,asdoes
aconventionalairlessspraytip.Airfromtheair
capfurtheratomizesthe󰘱uidandcompletesthe
atomizationofthe󰘱uidtailstoproduceauniform
pattern.
Asthegunistriggered,partoftheregulatedair
operatesthealternatorturbineandtherestofthe
airhelpsatomizethe󰘱uidbeingsprayed.The
alternatorgeneratespower,whichisconvertedby
thepowercartridgetosupplyhighvoltagetothe
gun’selectrode.
Thegun’sinternalpowersupplyprovideshigh
voltage.The󰘱uidiselectrostaticallychargedasit
passestheelectrode.Thecharged󰘱uidisattracted
tothegroundedworkpiece,wrappingaroundand
evenlycoatingallsurfaces.
Theregulatedairthatisdirectedtotheaircapcan
befurthercontrolledusingthegun’satomizingair
adjustmentvalve.Thisvalvecanbeusedtorestrict
air󰘱owtotheaircapwhilemaintainingsuf󰘰cientair
󰘱owtothealternator.Theatomizingairadjustment
valvedoesnotcontrolpatternwidth.Tochange
patternwidth,useanewtipsize,orusethefan
adjustmenttonarrowthepatternwidth.
Thehighworking󰘱uidpressureofthisgunprovides
thepowerneededtoatomizehighersolidsmaterials.
Note
Forairlessatomization,ifdesired,turn
thegun’satomizingairadjustmentvalve
completelyoff.Closingthisvalvedoesnot
affectalternatoroperation.
Spraying Spraying
SprayingWaterborne Waterborne WaterborneFluids Fluids Fluids
Electrostatically Electrostatically
Electrostatically
Thiselectrostaticair-assistedspraygunisdesigned
tosprayonly only
onlywaterborne󰘱uidswhichmeetthe
following󰘱ammabilityrequirements:
•FM, FM,
FM,FMc FMc FMcApproved: Approved: Approved:
Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.
•CE-EN CE-EN
CE-EN50059 50059 50059Compliant: Compliant: Compliant:
•Materialisclassi󰘰edasnon-ignitableasde󰘰nedby
EN50059:2018.
Formoreinformation,see
IgnitabilityofCoatingMaterials,page73.
Whenconnectedtoavoltageisolationsystem,
allofthe󰘱uidinthespraygun,󰘱uidhose,and
isolated󰘱uidsupplyischargedtohighvoltage,
whichmeansthatthesystemhasmoreelectrical
energythanasolvent-basedsystem.Therefore,
onlynon-󰘱ammable󰘱uids(asde󰘰nedunder
Models,page3)canbesprayedwiththesystemor
beusedtoclean,󰘱ush,orpurgethesystem.
Precautionsmustbetakenwhenusingelectrostatic
waterborneequipmenttoavoidpotentialshock
hazards.Whenthespraygunchargestheisolated
󰘱uidtohighvoltage,itissimilartocharginga
capacitororabattery.Thesystemwillstoresomeof
theenergywhilesprayingandretainsomeofthat
energyafterthespraygunisshutoff.Donottouch
thegunnozzleorcomewithin4in.(102mm)of
theelectrodeuntilthestoredenergyisdischarged.
Theamountoftimeittakestodischargethe
energydependsonthesystemdesign.Followthe
FluidVoltageDischargeandGroundingProcedure,
page29beforeapproachingthefrontofthegun.
TheGracowarrantyandapprovalsarevoidifthe
electrostaticspraygunisconnectedtoanon-Graco
voltageisolationsystemorifthegunisoperated
above60kV.
3A2497H7

GunOverview
Controls, Controls,
Controls,Indicators, Indicators, Indicators,and and andComponents Components Components
Theelectrostaticgunincludesthefollowing
controls,indicators,andcomponents(seeFig.
1).ForinformationonSmartguns,alsosee
SmartGuns,page9.
Figure1GunOverview
Item Item
ItemDescription Description DescriptionPurpose Purpose Purpose
AAirSwivelInlet1/4npsm(m)left-handthread,forGracored-coloredgroundedairsupply
hose.
BFluidHoseGracowaterborne󰘱uidhose
CTurbineAirExhaustBarbed󰘰tting,forsuppliedexhausttube.
DAirCap/TipGuard
andSprayTip
SeeSprayTipSelectionChart,page68,foravailablesizes.
EElectrodeSupplieselectrostaticchargetothe󰘱uid.
FFanAirAdjustment
Valve
Adjustsfansizeandshape.Canbeusedtodecreasepatternwidth.
GAtomizingAir
AdjustmentValve
Adjustsatomizingair󰘱ow.
HTriggerSafetyLockLockstriggertopreventgunfromspraying.
JESOn-OffValveTurnselectrostaticsON(I)orOFF(O).
KESIndicator(stan-
dardgunonly;for
Smartgunindicator,
seeOperatingMode,
page9)
LitwhenESisON(I).Colorindicatesalternatorfrequency.SeetheLED
indicatortableinGunSetup,page23.
83A2497H

GunOverview
Smart Smart
SmartGuns Guns Guns
TheSmartGunmoduledisplayssprayingvoltage,
current,alternatorspeed,andthevoltagesetting(low
orhigh).Italsoallowstheusertochangetoalower
sprayingvoltage.Themodulehastwomodes:
•OperatingMode
•DiagnosticMode
Operating Operating
OperatingMode Mode Mode
Bar Bar
BarGraph Graph Graph
SeeFig.2andSmartGunKey,page11.The
OperatingModedisplaysgundataduringnormal
spraying.Thedisplayusesabargraphtoshowthe
voltagelevelinkiloVolts(kV)andthecurrentlevelin
microAmperes(uA).Thebargraphrangeisfrom0
to100%foreachvalue.
IftheuAbargraphLEDsareblue,thegunisready
tospray.IftheLEDsareyelloworred,thecurrentis
toohigh.SeeElectricalTroubleshooting,page43.
Hz Hz
HzIndicator Indicator Indicator
TheHzindicatorfunctionsthesameastheES
indicatoronstandardguns.Theindicatorlightsto
showthealternatorspeedstatus,andhasthree
colors:
•Greenindicatesthealternatorspeediscorrect.
•Iftheindicatorchangestoamberafteronesecond,
increasetheairpressure.
•Iftheindicatorchangestoredafteronesecond,
reducetheairpressure.Decreaseairpressure
untiltheindicatorisgreen.Tomaintainahigher
airpressure,installESOn/OffValveRestrictorKit
26A294.Then,adjustthepressureasneededto
ensurethattheindicatorremainsgreen.
Voltage Voltage
VoltageAdjustment Adjustment AdjustmentSwitch Switch Switch
Thevoltageadjustmentswitch(VA)allowsthe
operatortochangefromlowtohighvoltage.
•Thehighvoltagesettingisdeterminedbythe
maximumvoltageofthegunandisnotadjustable.
•Thelowvoltageindicator(LO)lights
whentheswitchissettoLO.Thelow
voltagesettingisuseradjustable.See
AdjustingtheLowVoltageSetting,page10.
Note
IftheErrordisplayappears,theSmart
modulehaslostcommunicationwiththe
powersupply.SeeErrorDisplay,page10for
furtherinformation.
Figure2SmartGunModuleinOperatingMode
3A2497H9

GunOverview
Error Error
ErrorDisplay Display Display
IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3andSmartGunKey,page11.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page43.
CommunicationmustberestoredtomaketheSmart
modulefunctional.
Note
Ittakes8secondsfortheErrordisplayto
appear.Ifthegunhasbeendisassembled,
wait8secondsbeforesprayingtoensure
thatanErrorconditionhasnotoccurred.
Note
Ifthereisnopowertothegun,theError
displaywillnotappear.
Figure3ErrorDisplay
Adjusting Adjusting
Adjustingthe the theLow Low LowVoltage Voltage VoltageSetting Setting Setting
Thelowvoltagesettingisuseradjustable.Toaccess
thelowvoltagesettingscreenwheninOperating
Mode,presstheLOSETbutton(LS)momentarily.
Thescreenwilldisplaythecurrentlowvoltage
setting.SeeFig.4andSmartGunKey,page11.
Therangeis30–60kV.
SettheVoltageAdjustmentswitch(VA)toLO.Press
theLOSETbuttonrepeatedlytoincreasethesetting
inincrementsof5.Whenthedisplayreachesthe
maximumsetting(60kV)itwillreturntotheminimum
setting(30kV).Continuepressingthebuttonuntil
youreachthedesiredsetting.
Note
After2secondsofinactivitythedisplaywill
returntotheOperatingScreen.
Note
Thelowvoltagesettingmaybelocked.See
LockSymbol,page10.
Figure4LowVoltageSettingScreen(Unlocked)
Lock Lock
LockSymbol Symbol Symbol
Thelowvoltagesettingmaybelocked.Whenlocked,
animage(LK)appearsonthescreen.SeeFig.5
andSmartGunKey,page11.
•WheninHImode,thelowvoltagesettingisalways always
always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.
•WheninLOmode,thelocksymbolwill
only only
onlyappearifthelockisenabled.See
LowVoltageLockScreen,page13,tolockor
unlockthelowvoltagesetting.
Figure5LowVoltageSettingScreen(Locked)
103A2497H

GunOverview
Smart Smart
SmartGun Gun GunKey Key Key
Table Table
Table1 1 1Key Key Keyfor for forFigs. Figs. Figs.2–9. 2–9. 2–9.
Item Item
ItemDescription Description DescriptionPurpose Purpose Purpose
VAVoltageAdjustmentSwitchTwo-positionswitchsetsSmartgunvoltagetolowsetting(LO)or
highsetting(HI).ThisswitchisfunctionalinOperatingModeandin
DiagnosticMode.
LOLowVoltageMode
Indicator
Lights(blue)whentheSmartgunissettoLowVoltage.
kVVoltage(kV)DisplayDisplaysactualsprayingvoltageofthegun,inkV.InOperatingMode,
displayisabargraph.InDiagnosticMode,voltageisdisplayedas
anumber.
uACurrent(uA)DisplayDisplaysactualsprayingcurrentofthegun,inuA.InOperatingMode,
displayisabargraph.InDiagnosticMode,currentisdisplayedas
anumber.
LSLOSETbuttonPressmomentarilytoentertheLowVoltageSettingscreen.
Pressandholdforapproximately5secondstoenterorexitDiagnostic
Mode.
WhileinDiagnosticMode,pressmomentarilytoadvancethrough
screens.
WhileontheLowVoltageLockScreen(inDiagnosticMode),press
andholdtoturnthelockonoroff.
LVLowVoltageDisplayDisplaysthelowvoltagesettingasanumber.Thesettingcanbe
changed.SeeFig.4.
LKLowVoltageLockedAppearsifthelowvoltagesettingislocked.SeeFig.5andFig.9.
LDLODisplayAppearsontheLowVoltageLockScreen.SeeFig.9.
ERErrorDisplayAppearsiftheSmartmodulelosescommunicationwiththepower
supply.SeeFig.3.
VIVoltageIndicatorInDiagnosticMode,thetwotoprightLEDsofthescreenlight,
indicatingthatthevaluedisplayedisinkV.SeeFig.6.
CICurrentIndicatorInDiagnosticMode,thetwobottomrightLEDsofthescreenlight,
indicatingthatthevaluedisplayedisinuA.SeeFig.7.
ASAlternatorSpeedDisplayInDiagnosticMode,Hzlevelisdisplayedasanumber.SeeFig.8.
HzAlternatorSpeedIndicatorInOperatingMode,indicatorcolorvariestoshowthealternatorspeed
status:
•Greenindicatesthealternatorspeedisatthecorrectlevel.
•Iftheindicatorchangestoamberafteronesecond,thealternator
speedistoolow.
•Iftheindicatorchangestoredafteronesecond,thealternatorspeed
istoohigh.TheindicatoralsoturnsrediftheErrordisplayappears.
InDiagnosticMode,theindicatorisgreenwhenintheAlternator
Speed(Hertz)screen.
3A2497H11

GunOverview
Diagnostic Diagnostic
DiagnosticMode Mode Mode
DiagnosticModeincludesfourscreenswhichdisplay
gundata:
•Voltage(kiloVolts)Screen
•Current(microAmperes)Screen
•AlternatorSpeed(Hertz)Screen
•LowVoltageLockScreen
Note
YoumustbeinOperatingModetoadjust
thelowvoltagesetting;thesettingisnot
adjustableinDiagnosticMode.However,the
voltageadjustmentswitch(VA)canbesetto
HIorLOinOperatingModeandDiagnostic
Mode.
ToenterDiagnosticMode,pressandholdtheLOSET
(LS)buttonforapproximately5seconds.Thedisplay
willgototheVoltage(kiloVolts)Screen,page12.
Toadvancetothenextscreen,presstheLOSET
buttonagain.
ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.
Note
Iftheguntriggerisreleasedwhilein
DiagnosticMode,thelastscreenviewedwill
bedisplayedwhenthegunistriggeredagain.
Note
DiagnosticModecannotbeexitedfromthe
LowVoltageLockScreen.Fordetails,see
LowVoltageLockScreen,page13.
Voltage Voltage
Voltage(kiloVolts) (kiloVolts) (kiloVolts)Screen Screen Screen
TheVoltage(kiloVolts)Screenisthe󰘰rstscreento
appearafterenteringDiagnosticMode.SeeFig.6
andSmartGunKey,page11.Toenterthisscreen,
pressandholdtheLOSETbuttonforapproximately
5secondswhileintheOperatingMode.
Thisscreendisplaysthesprayingvoltageofthe
gunasanumber(kV),roundedtothenearest5kV.
ThetwotoprightLEDs(VI)ofthedisplaypanel
light,indicatingthattheVoltage(kiloVolts)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.
PresstheLOSETbuttontoadvancetothe
Current(microAmperes)Screen,page12.Press
andholdforapproximately5secondstoreturnto
OperatingMode.
Figure6Voltage(kiloVolts)Screen
Current Current
Current(microAmperes) (microAmperes) (microAmperes)Screen Screen Screen
TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7and
SmartGunKey,page11.Toenterthisscreen,press
theLOSETbuttonwhileintheVoltage(kiloVolts)
Screen.
Thisscreendisplaysthesprayingcurrentofthegun
asanumber(uA),roundedtothenearest5uA.The
twobottomrightLEDs(CI)ofthedisplaypanellight,
indicatingthattheCurrent(microAmperes)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.
PresstheLOSETbuttontoadvancetothe
AlternatorSpeed(Hertz)Screen,page13.Press
andholdforapproximately5secondstoreturnto
OperatingMode.
Figure7Current(microAmperes)Screen
123A2497H

GunOverview
Alternator Alternator
AlternatorSpeed Speed Speed(Hertz) (Hertz) (Hertz)Screen Screen Screen
TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8and
SmartGunKey,page11.Toenterthisscreen,
presstheLOSETbuttonwhileintheCurrent
(microAmperes)Screen.
Thisscreendisplaysthealternatorspeedasa3
digitnumber(AS),roundedtothenearest5Hz.The
displayisareadoutandcannotbechanged.Ifthe
alternatorspeedisgreaterthan999Hz,thedisplay
willshow999.
TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.
PresstheLOSETbuttontoadvancetothe
LowVoltageLockScreen,page13.Pressandhold
forapproximately5secondstoreturntoOperating
Mode.
Figure8AlternatorSpeed(Hertz)Screen
Low Low
LowVoltage Voltage VoltageLock Lock LockScreen Screen Screen
TheLowVoltageLockScreenisthefourth
screenintheDiagnosticMode.SeeFig.9and
SmartGunKey,page11.Toenterthisscreen,press
theLOSETbuttonwhileintheAlternatorSpeed
(Hertz)Screen.
ThisscreendisplaysthestatusoftheLowVoltage
Lock.Ifthesettingislocked,thelockimage(LK)
appearstotheleftoftheLodisplay(LD).Ifthesetting
isunlocked,thelockimagedoesnotappear.
Tochangethelockstatus,pressandholdthe
LOSETbuttonuntilthelockimageappearsor
disappears.Ifthelockisset,theimagewillalso
appearontheLowVoltageSettingScreenwhenin
lowvoltagemode(seeFig.4).
Note
DiagnosticModecannotbeexitedfromthis
screen,becausepressingandholdingthe
LOSETbuttonisusedtoturnthelockonor
off.Toexit,pressLOSETmomentarilyto
returntotheVoltage(kiloVolts)Screen,then
exitDiagnosticModefromthere.
Figure9LowVoltageLockScreen
3A2497H13

Installation
Installation Installation
Installation
System System
SystemRequirements Requirements Requirements
Theuseofmultiplegunswithoneisolationcabinet
maycauseelectricshock,󰘰re,orexplosion.To
helppreventinjuryorequipmentdamage,useonly
onegunperisolationcabinet.
AGracovoltageisolationsystemmusthavethe
followingfeatures:
•Anisolationenclosurethatpreventspersonsfrom
makingcontactwiththehighvoltagecomponents
beforethesystemvoltageisdischarged.All
componentsoftheisolationsystemthatare
chargedtohighvoltagemustbecontainedwithin
theenclosure.
•Ableedresistortodrainoffthesystemvoltage
whenthespraygunisnotinuse.Ametalpartof
the󰘱uidsupplyunitmustbeelectricallyconnected
tothebleedresistor.
•Asafetyinterlockthatautomaticallydischargesthe
systemvoltagewhenanyoneopenstheisolation
enclosure.
NOTICE NOTICE
NOTICE
Thesystemshouldnothaveanyseverearcing
occurringwhentheisolationmechanismopens
andcloses.Severearcingwillshortenthelifeof
thesystemcomponents.
Note
TheGracowarrantyandapprovalsarevoidif
theelectrostaticspraygunisconnectedtoa
non-Gracovoltageisolationsystemorifthe
gunisoperatedabove60kV.
Warning Warning
WarningSign Sign Sign
Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.
Install Install
Installthe the theSystem System System
Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.
•Donotinstallorservicethisequipmentunless
youaretrainedandquali󰘰ed.
•Complywithalllocalcodesandregulations.
Fig.12(TypicalInstallation)showsatypical
electrostaticair-assistedspraysystem.Itisnotan
actualsystemdesign.Forassistanceindesigning
asystemtosuityourparticularneeds,contactyour
Gracodistributor.
Ventilate Ventilate
Ventilatethe the theSpray Spray SprayBooth Booth Booth
Donotoperatethegununlessventilatingair󰘱owis
abovetheminimumrequiredvalue.Providefresh
airventilationtoavoidthebuildupof󰘱ammableor
toxicvaporswhenspraying,󰘱ushing,orcleaning
thegun.Interlockthegunairand󰘱uidsupply
topreventoperationunlessventilatingair󰘱owis
abovetheminimumrequiredvalue.
Thesprayboothmusthaveaventilationsystem.
Electricallyinterlockthegunairand󰘱uidsupplywith
theventilatorstopreventgunoperationanytimethat
theventilationair󰘱owfallsbelowminimumvalues.
Checkandfollowalllocalcodesandregulations
regardingairexhaustvelocityrequirements.Verify
theoperationoftheinterlockatleastonceayear.
143A2497H

Installation
Air Air
AirSupply Supply SupplyLine Line Line
Toreducetheriskofelectricshock,theairsupply
hosemustbeelectricallyconnectedtoatrueearth
ground.Use Use
Useonly only onlyGraco Graco GracoGrounded Grounded GroundedAir Air AirSupply Supply Supply
Hose. Hose.
Hose.
Toreducetheriskofelectricshockorother
seriousinjury,youmustusethered-coloredGraco
ElectricallyConductiveAirHoseforthegunair
supply.Donotusetheblackorgray-coloredGraco
airhoses.
1.SeeFig.12.Installanairline󰘰lter/water
separator(M)onthemainairsupplylineto
ensureadry,cleanairsupplytothegun.Dirtand
moisturecanruintheappearanceofyour󰘰nished
workpieceandcancausetheguntomalfunction.
2.TheWB3000systemincludesableed-typeair
regulator(N)onthegunairsupplyline(P),to
controlairpressuretothegun.
3.Connectthered-coloredGracoElectrically
ConductiveAirHose(P)betweenthegunair
regulator(N)andthegun’sairinlet.Thegunair
inlet󰘰ttinghasaleft-handthread.Connectthe
airsupplyhosegroundwire(Q)toatrueearth
ground.
Trappedaircancausethe󰘱uidsupplyunitto
cycleunexpectedly,whichcanresultinserious
injury,includingsplashing󰘱uidintheeyesor
ontheskin.Donotoperatetheequipment
withoutthebleed-typeairvalve(B)installed.
4.TheWB3000systemincludesableed-typeair
valve(B).Thebleed-typeairvalveisrequired
toshutoffallairtothesystemandrelieveair
trappedbetweenthevalveandthe󰘱uidsupply
unitaftertheairregulatorisshutoff.Connectthe
mainairsupplyline(A)tothebleedvalve.
5.Installanadditionalbleed-typeairvalve(CC)
upstreamoftheair󰘰lter(M)toisolatethe󰘰lter
forservicing.
Ground Ground
Groundthe the theCabinet Cabinet Cabinet
Connectthemaingroundwire(V)toatrueearth
ground.
3A2497H15

Installation
Grounding Grounding
Grounding
Theequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundallequipment,personnel,objects
beingsprayed,andconductiveobjectsinorclose
tothesprayarea.Theresistancemustnotexceed
100ohms.Groundingprovidesanescapewirefor
theelectriccurrent.
Whenoperatingtheelectrostaticgun,any
ungroundedobjects(suchaspeople,containers,and
tools)inthespraylocationcanbecomeelectrically
charged.
Thefollowingareminimumgroundingrequirements
forabasicelectrostaticwaterbornesystem.Your
systemmayincludeotherequipmentorobjects
whichmustbegrounded.Yoursystemmustbe
connectedtoatrueearthground.Checkground
connectionsdaily.Checkyourlocalelectricalcodes
andregulationsfordetailedgroundinginstructions.
•
Allpersonsenteringthesprayarea: mustwear
shoeshavingconductivesolessuchasleather,
orwearpersonalgroundingstraps.Donot
wearshoeswithnon-conductivesolessuchas
rubberorplastic.Ifglovesarenecessary,wear
theconductiveglovessuppliedwiththegun.If
non-Gracoglovesareworn,cutoff󰘰ngersorpalm
areaofglovestoensureyourhandcontactsthe
groundedgunhandle.
• Objectbeingsprayed: Keeptheworkpiecehangers
cleanandgroundedatalltimes.
• VoltageIsolationSystem: Electricallyconnectthe
voltageisolationsystemtoatrueearthground.
SeeGroundtheCabinet,page15.
• ElectrostaticAir-AssistedSprayGun: Ground
thegunbyconnectingthered-coloredGraco
GroundedAirHosetothegun,andconnectingthe
airhosegroundwiretoatrueearthground.See
CheckGunElectricalGrounding,page26.
• Allelectricallyconductiveobjectsordevicesinthe
sprayarea: mustbeproperlygrounded.
• Fluidandwastecontainers: Groundall󰘱uidand
wastecontainersinthesprayarea.Donotusepail
linersunlesstheyareconductiveandgrounded.
When󰘱ushingthespraygun,thecontainerused
tocatchtheexcess󰘱uidmustbeelectrically
conductiveandgrounded.
•
Aircompressors: Groundtheequipmentaccording
tothemanufacturer'srecommendations.
• Allairlines mustbeproperlygrounded.Useonly
groundedhoseswithamaximumof100feet(30.5
m)combinedhoselengthtoensuregrounding
continuity.
163A2497H

Installation
• The󰘱oorofthesprayarea: mustbeelectrically
conductiveandgrounded.Donotcoverthe󰘱oor
withcardboardoranynon-conductivematerial
whichwouldinterruptgroundingcontinuity.
• Allsolventpails: Useonlyapproved,grounded
metalcontainers,whichareconductive.Donot
useplasticcontainers.Onlyusenon-󰘱ammable
solvents.Donotstoremorethanthequantity
neededforoneshift.
3A2497H17

Installation
Connect Connect
Connectthe the theWaterborne Waterborne WaterborneFluid Fluid FluidHose Hose Hose
AlwaysuseaGracowaterborne󰘱uidhosebetween
thevoltageisolationsystem󰘱uidoutletandthegun
󰘱uidinlet.
Beforeconnectingthewaterborne󰘱uidhosetothe
gun,blowitoutwithairand󰘱ushwithwaterto
removecontaminants.Flushthegunbeforeusingit.
Toreducetheriskofelectricshock,installonly
onecontinuousGracowaterbornehosebetween
theisolated󰘱uidsupplyandthegun.Donotsplice
hosestogether.
1.Removethegunairinlet󰘰tting(21).
Figure10ConnecttheFluidHose
2.Removetheo-ring(21a)andassembletheinlet
󰘰ttingthroughthebracket.Reassemblethe
o-ring.
3.Makesurethebarrel󰘱uidinletiscleananddry.
Applydielectricgreasetothethreadsandfrontof
thebarrelconnector(101a)andscrewitintothe
󰘱uidinletjustuntilsnug.Thencontinuetotighten
the󰘰ttingaminimumof1/2turnandcontinueto
rotateuntilthe󰘰ttingisorientedasshown.The
gapbetweenthe󰘰ttingandthebarrelmustbe
lessthan.125in(3.2mm).
Figure11OrientationofFittingandBarrel
4.Loosenthestrainreliefnut(101c).
5.Applydielectricgreasetothethreadsofthe
hoseconnector(101g).Pulltheconnectorback
andapplygreasetotheoutsidediameterofthe
hose.Threaditintothebarrelconnector(101n)
untilsnugandthenaminimumof1/2turnmore.
Useawrenchtoholdthebarrelconnectorwhen
tightening.
6.Alignthebracket(101b)holeswiththeairinlet
andexhaustoutlet.Securewiththeairinlet󰘰tting
(21).
7.Tightenthestrainreliefnut(101c).
8.Presstheexhausttube(36)ontotheexhaust
valve.Securewiththeclamp(43).
Note
Wheneverpossible,keepthe󰘱uidhose
assembledtothegunbarrel.Toremove
thebarrel,disconnectthehosebracket
atthegunhandle.
9.Loosenthestrainreliefnutatthehoseinletend.
10.Slidetheotherendofthehosethroughthehole
inthesideoftheisolatedenclosure.Connectthe
swivel(Z)tothe󰘱uidoutletofthepump.
183A2497H

Installation
11.Securethehosetothesideoftheenclosurewith
thebracket(W).Aboltassemblesthroughthe
holeinthebracketandscrewsintothesideof
theenclosure.
12.Tightenthestrainreliefnut.
Note
TheGracowarrantyandapprovals
arevoidiftheelectrostaticspraygun
isconnectedtoanon-Gracovoltage
isolationsystemorifthegunisoperated
above60kV.
Figure12HoseConnectionatWB3000Enclosure
3A2497H19

Installation
Figure13TypicalInstallation,ProXpWaterborne
System
203A2497H