Graco WB100 Operation manual

Instructions-Parts
WB100 WB100
WB100Isolation Isolation IsolationSystem System Systemand and and
Pro Pro
ProXp™ Xp™ Xp™60 60 60WB WB WBGun Gun Gun3A2496H
EN
Air Air
Airspray spray spraysystem system systemfor for foruse use usewhen when whenelectrostatically electrostatically electrostaticallyspraying spraying sprayingconductive, conductive, conductive,waterborne waterborne waterborne󰘱uids 󰘱uids 󰘱uidsthat that thatmeet meet meetat at atleast least least
one 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
Readallwarningsandinstructionsinthismanual.Save Save
Savethese these these
instructions. instructions.
instructions.
100psi(0.7MPa,7.0bar)Maximum
FluidWorkingPressure
100psi(0.7MPa,7.0bar)MaximumAir
WorkingPressure
Seepages3and4formodelpart
numbersandapprovalinformation.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Models.................................................................3
RelatedManuals..................................................4
Warnings.............................................................5
GunOverview......................................................8
HowtheElectrostaticSprayGunWorks...........8
SprayingWaterborneFluids
Electrostatically................................8
Controls,Indicators,andComponents.............9
SmartGuns.................................................10
Installation..........................................................15
SystemRequirements..................................15
WarningSign...............................................15
InstalltheSystem.........................................15
VentilatetheSprayBooth.............................15
AirSupplyLine............................................16
GroundtheCabinet......................................16
ConnecttheWaterborneFluidHose..............17
Grounding...................................................22
AgitatorKitAccessory..................................24
FluidRegulatorKitAccessory.......................25
GunSetup..........................................................26
GunSetupProcedure...................................26
SoftSprayGunSetupProcedure..................30
HVLPGunSetupProcedure.........................31
RoundSprayGunSetupProcedure..............33
AbrasiveMaterialGunSetup
Procedure......................................35
MoldReleaseGunSetupProcedure.............36
CheckGunElectricalGrounding...................38
FlushBeforeUsingEquipment......................38
Operation...........................................................39
PressureReliefProcedure............................39
FluidVoltageDischargeandGrounding
Procedure......................................39
FilltheFluidSupply......................................40
Startup........................................................40
Shutdown....................................................41
Maintenance......................................................42
DailyCareandCleaningChecklist................42
Flushing......................................................42
CleantheGunDaily.....................................44
DailySystemCare.......................................46
ElectricalTests...................................................47
TestGunResistance....................................47
TestPowerSupplyResistance.....................48
TestElectrodeResistance............................49
TestGroundStripResistance.......................50
TestCylinderResistance..............................50
Troubleshooting..................................................51
VoltageLossTroubleshooting.......................51
SprayPatternTroubleshooting......................54
GunOperationTroubleshooting....................55
ElectricalTroubleshooting............................56
Repair................................................................58
PreparetheGunforService.........................58
AirCapandNozzleReplacement..................59
AirCap,SprayTip,andNozzle
Replacement(Model
L60M19)........................................60
ElectrodeReplacement................................61
NeedleReplacement(ModelL60M19)...........62
FluidPackingRodRemoval..........................62
PackingRodRepair.....................................63
BarrelRemoval............................................65
BarrelInstallation.........................................65
PowerSupplyRemovaland
Replacement..................................66
AlternatorRemovalandReplacement...........67
FanAirAdjustmentValveRepair..................69
AtomizingAirRestrictorValveRepair............70
ESOn-OffandFluidAdjustmentValve
Repair............................................71
AirValveRepair...........................................72
SmartModuleReplacement..........................73
AirSwivelandExhaustValve
Replacement..................................74
Parts..................................................................75
StandardWaterborneAirSprayGun
Assembly.......................................75
SmartWaterborneAirSprayGun
Assembly.......................................77
MoldReleaseSmartAirSprayGun
Assembly.......................................79
IsolationEnclosure.......................................81
TubingandWiring.......................................84
PackingRodAssembly.................................86
AlternatorAssembly.....................................87
ESOn-OffandFluidAdjustmentValve...........88
FanAirAdjustmentValveAssembly..............89
AtomizingAirRestrictorValve
Assembly.......................................89
AirCapAssembly........................................90
SmartModuleAssembly...............................90
RoundSprayAssembly................................91
FluidNozzles.....................................................93
FluidNozzleSelectionChart.........................93
FluidNozzlePerformanceCharts..................94
AirCaps.............................................................96
AirCapSelectionGuide...............................96
AirConsumptionCharts.............................101
SprayTipSelectionChart(ModelL60M19MRG
GunOnly)...........................................102
AEMFineFinishSprayTips........................102
AEFFineFinishPre-Ori󰘰ceSpray
Tips.............................................103
RoundSprayTips......................................104
RepairKitsandAccessories..............................105
Dimensions......................................................109
TechnicalSpeci󰘰cations....................................111
23A2496H

Models
Models Models
Models
FMapprovedforusewith󰘱uidsthatmeetthefollowingcondition:
•MaterialdoesnotsustainburninginaccordancewiththeStandardTest
MethodforSustainedBurningofLiquidMixtures,ASTMD4206.
0.35 0.35
0.35J, J, J,with with with50 50 50ft ft fthose hose hosemax max max
FM12ATEX0080 FM12ATEX0080
FM12ATEX0080
EN EN
EN50059 50059 50059
Ta Ta
Ta0°C 0°C 0°C– – –50°C 50°C 50°C
ModelsCompliantwithEN50059whenused
with󰘱uidsthatmeetthefollowingcriteria:
•Materialswhichcannotbeignited,inanymixturewithair,byanenergy
sourceoflessthan500mJ.
Part Part
PartNo No NoModel Model ModelDescription Description Description
24N580WB100WaterborneIsolationEnclosure233825withstandardelectrostaticairspraygun
L60T17,groundedairhose235070,andshieldedwaterborne󰘱uidhose24M732.
24P629WB100WaterborneIsolationEnclosure233825withsmartelectrostaticairspraygun
L60M17,groundedairhose235070,andshieldedwaterborne󰘱uidhose24M732.
24P630WB100WaterborneIsolationEnclosure246511withstandardelectrostaticairspraygun
L60T18,groundedairhose235070,andunshieldedwaterborne󰘱uidhose24M733.
24P631WB100WaterborneIsolationEnclosure246511withsmartelectrostaticairspraygun
L60M18,groundedairhose235070,andunshieldedwaterborne󰘱uidhose24M733.
233825WB100WaterborneIsolationEnclosureforshieldedhoses.Doesnotincludehosesandgun.
24P734WB100WaterborneIsolationEnclosure246511withMRGsmartelectrostaticairspraygun
L60M19,groundedairhose235070,andunshieldedwaterborne󰘱uidhose24M733.
246511WB100WaterborneIsolationEnclosureforunshieldedhoses.Doesnotincludehoses
andgun.
L60T17ProXp60
WB
StandardElectrostaticAirSprayGun,forwaterbornecoatings.
L60M17ProXp60
WB
SmartElectrostaticAirSprayGun,forwaterbornecoatings.
L60T18ProXp60
WB
StandardElectrostaticAirSprayGun,forwaterbornecoatings.
L60M18ProXp60
WB
SmartElectrostaticAirSprayGun,forwaterbornecoatings.
L60M19ProXp60
WBMRG
SmartElectrostaticAirSprayGun,formoldreleaseapplications.
24M732-——ShieldedWaterborneFluidHoseAssembly,25ft(7.6m).
24M733-——UnshieldedWaterborneFluidHoseAssembly,25ft(7.6m).
25N916-——ShieldedWaterborneFluidHoseAssembly,50ft(15.2m).
25N917-——UnshieldedWaterborneFluidHoseAssembly,50ft(15.2m).
2575
3A2496H3

RelatedManuals
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNo. No. No.Description Description Description
3A2498RoundSprayKit,Instructions
307263ProbeandMeter,Instructions
309455TestFixture,HighVoltageProbe,andkVMeter,Instructions
406999VoltageTesterConversionKit,Instructions
43A2496H

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:
Materialswhichcannotbeignited,inanymixturewithair,byanenergysourceof
lessthan500mJ.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.
•Useandcleanequipmentonlyinwellventilatedarea.
•Interlockthegunairsupplytopreventoperationunlessventilationair󰘱owisabovethe
minimumrequiredvalue.
•Onlyusenon-󰘱ammablesolventswhen󰘱ushingorcleaningequipment.
•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.
•Keepsprayareafreeofdebris,includingsolvent,ragsandgasoline.
•Keepaworking󰘰reextinguisherintheworkarea.
3A2496H5

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.
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
63A2496H

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󰘰cationsinallequipmentmanualsformaterialsofconstruction.Consult
thesolventmanufacturerforinformationandrecommendationsaboutcompatibility.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(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.
3A2496H7

GunOverview
Gun Gun
GunOverview Overview Overview
How How
Howthe the theElectrostatic Electrostatic ElectrostaticSpray Spray SprayGun Gun Gun
Works Works
Works
Theairhosesuppliesairtothespraygun.Partofthe
airoperatesthealternatorturbineandtherestofthe
airatomizesthe󰘱uidbeingsprayed.
Thealternatorgeneratespower,whichisconverted
bythepowercartridgetosupplyhighvoltagetothe
gun’selectrode.
Thepumpsupplies󰘱uidtothe󰘱uidhoseandgun,
wherethe󰘱uidiselectrostaticallychargedasit
passestheelectrode.Thecharged󰘱uidisattracted
tothegroundedworkpiece,wrappingaroundand
evenlycoatingallsurfaces.
Spraying Spraying
SprayingWaterborne Waterborne WaterborneFluids Fluids Fluids
Electrostatically Electrostatically
Electrostatically
Thiselectrostaticairspraygunisdesignedtospray
only only
onlywaterborne󰘱uidswhichmeetthefollowing
󰘱ammabilityrequirements:
•FM, FM,
FM,FMc FMc FMcApproved: Approved: Approved:
Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.
•CE-EN CE-EN
CE-EN50059 50059 50059Compliant: Compliant: Compliant:
Materialswhichcannotbeignited,inanymixture
withair,byanenergysourceoflessthan500mJ.
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,
page39,beforeapproachingthefrontofthegun.
NOTE: NOTE:
NOTE:TheGracowarrantyandapprovalsare
voidiftheelectrostaticspraygunisconnectedtoa
non-Gracovoltageisolationsystemorifthegunis
operatedabove60kV.
83A2496H

GunOverview
Controls, Controls,
Controls,Indicators, Indicators, Indicators,and and andComponents Components Components
Theelectrostaticgunincludesthefollowingcontrols,indicators,andcomponents.ForinformationonSmart
guns,alsoseeSmartGuns,page10.
Figure1GunOverview
Item Item
ItemDescription Description DescriptionPurpose Purpose Purpose
AAirSwivelInlet1/4npsm(m)left-handthread,forGracored-coloredgroundedair
supplyhose.
BFluidInletGracowaterborne󰘱uidsupplyhose
CTurbineAirExhaustBarbed󰘰tting,forsuppliedexhausttube.
DAirCapandNozzleSeeAirCaps,page96andFluidNozzles,page93foravailable
sizes.
EElectrodeNeedleSupplieselectrostaticchargetothe󰘱uid.
FFanAirAdjustmentValveAdjustsfansizeandshape.Canbeusedtodecreasepatternwidth.
GAtomizingAirRestrictor
Valve
Restrictsaircapair󰘱ow.Replacewithplug(included)ifdesired.
HFluidAdjustmentKnobAdjusts󰘱uid󰘱owbylimiting󰘱uidneedletravel.Useonlyinlow󰘱ow
conditions,toreducewear.
JESOn-OffValveTurnselectrostaticsON(I)orOFF(O).
KESIndicator(standard
gunonly;forSmart
gunindicator,see
OperatingMode,page10)
LitwhenESisON(I).Colorindicatesalternatorfrequency.Seethe
LEDindicatortableonpage36.
3A2496H9

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,page12.The
OperatingModedisplaysgundataduringnormal
spraying.Thedisplayusesabargraphtoshowthe
voltagelevelinkiloVolts(kV)andthecurrentlevelin
microAmperes(uA).Thebargraphrangeisfrom0
to100%foreachvalue.
IfthebargraphLEDsareblue,thegunisreadyto
spray.IftheLEDsareyelloworred,thecurrentis
toohigh.The󰘱uidmaybetooconductive,orsee
ElectricalTroubleshooting,page56forotherpossible
causes.
Hz Hz
HzIndicator Indicator Indicator
TheHzindicatorfunctionsthesameastheES
indicatoronstandardguns.Theindicatorlightsto
showthealternatorspeedstatus,andhasthree
colors:
•Greenindicatesthealternatorspeediscorrect.
•Iftheindicatorchangestoamberafteronesecond,
increasetheairpressure.
•Iftheindicatorchangestoredafteronesecond,
theairpressureistoohigh.Decreaseairpressure
untiltheindicatorisgreen.Tomaintainahigher
airpressure,installESOn/OffValveRestrictorKit
26A160.Then,adjustthepressureasneededto
ensuretoensuretheindicatorremainsgreen.
Voltage Voltage
VoltageAdjustment Adjustment AdjustmentSwitch Switch Switch
Thevoltageadjustmentswitch(VA)allowsthe
operatortochangefromlowtohighvoltage.
•Thehighvoltagesettingisdeterminedbythe
maximumvoltageofthegunandisnotadjustable.
•Thelowvoltageindicator(LO)lights
whentheswitchissettoLO.Thelow
voltagesettingisuseradjustable.See
AdjustingtheLowVoltageSetting,page11.
NOTE: NOTE:
NOTE:IftheErrordisplayappears,theSmartmodule
haslostcommunicationwiththepowersupply.See
ErrorDisplay,page11forfurtherinformation.
Figure2SmartGunModuleinOperatingMode
103A2496H

GunOverview
Error Error
ErrorDisplay Display Display
IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3andSmartGunKey,page12.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page56.
CommunicationmustberestoredtomaketheSmart
modulefunctional.
NOTE: NOTE:
NOTE:Ittakes8secondsfortheErrordisplayto
appear.Ifthegunhasbeendisassembled,wait8
secondsbeforesprayingtoensurethatanError
conditionhasnotoccurred.
NOTE: NOTE:
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,page12.
Therangeis30–60kV.
SettheVoltageAdjustmentswitch(VA)toLO.Press
theLOSETbuttonrepeatedlytoincreasethesetting
inincrementsof5.Whenthedisplayreachesthe
maximumsetting(60kV)itwillreturntotheminimum
setting(30kV).Continuepressingthebuttonuntil
youreachthedesiredsetting.
NOTE: NOTE:
NOTE:After2secondsofinactivitythedisplaywill
returntotheOperatingScreen.
NOTE: NOTE:
NOTE:Thelowvoltagesettingmaybelocked.See
LockSymbol,page11.
Figure4LowVoltageSettingScreen(Unlocked)
Lock Lock
LockSymbol Symbol Symbol
Thelowvoltagesettingmaybelocked.Whenlocked,
animage(LK)appearsonthescreen.SeeFig.5
andSmartGunKey,page12.
•WheninHImode,thelowvoltagesettingisalways always
always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.
•WheninLOmode,thelocksymbolwill
only only
onlyappearifthelockisenabled.See
LowVoltageLockScreen,page14,tolockor
unlockthelowvoltagesetting.
Figure5LowVoltageSettingScreen(Locked)
3A2496H11

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.
123A2496H

GunOverview
Diagnostic Diagnostic
DiagnosticMode Mode Mode
DiagnosticModeincludesfourscreenswhichdisplay
gundata:
•Voltage(kiloVolts)Screen
•Current(microAmperes)Screen
•AlternatorSpeed(Hertz)Screen
•LowVoltageLockScreen
NOTE: NOTE:
NOTE:YoumustbeinOperatingModetoadjustthe
lowvoltagesetting;thesettingisnotadjustablein
DiagnosticMode.However,thevoltageadjustment
switch(VA)canbesettoHIorLOinOperatingMode
andDiagnosticMode.
ToenterDiagnosticMode,pressandholdtheLOSET
(LS)buttonforapproximately5seconds.Thedisplay
willgototheVoltage(kiloVolts)Screen,page13.
Toadvancetothenextscreen,presstheLOSET
buttonagain.
ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.
NOTE: NOTE:
NOTE:IfthegunisdetriggeredwhileinDiagnostic
Mode,thelastscreenviewedwillbedisplayedwhen
thegunisretriggered.
NOTE: NOTE:
NOTE:DiagnosticModecannotbeexited
fromtheLowVoltageLockScreen.See
LowVoltageLockScreen,page14fordetails.
Voltage Voltage
Voltage(kiloVolts) (kiloVolts) (kiloVolts)Screen Screen Screen
TheVoltage(kiloVolts)Screenisthe󰘰rstscreento
appearafterenteringDiagnosticMode.SeeFig.6
andSmartGunKey,page12.Toenterthisscreen,
pressandholdtheLOSETbuttonforapproximately
5secondswhileintheOperatingMode.
Thisscreendisplaysthesprayingvoltageofthe
gunasanumber(kV),roundedtothenearest5kV.
ThetwotoprightLEDs(VI)ofthedisplaypanel
light,indicatingthattheVoltage(kiloVolts)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.
PresstheLOSETbuttontoadvancetothe
Current(microAmperes)Screen,page13.Press
andholdforapproximately5secondstoreturnto
OperatingMode.
Figure6Voltage(kiloVolts)Screen
Current Current
Current(microAmperes) (microAmperes) (microAmperes)Screen Screen Screen
TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7and
SmartGunKey,page12.Toenterthisscreen,press
theLOSETbuttonwhileintheVoltage(kiloVolts)
Screen.
Thisscreendisplaysthesprayingcurrentofthegun
asanumber(uA),roundedtothenearest5uA.The
twobottomrightLEDs(CI)ofthedisplaypanellight,
indicatingthattheCurrent(microAmperes)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.
PresstheLOSETbuttontoadvancetothe
AlternatorSpeed(Hertz)Screen,page14.Press
andholdforapproximately5secondstoreturnto
OperatingMode.
Figure7Current(microAmperes)Screen
3A2496H13

GunOverview
Alternator Alternator
AlternatorSpeed Speed Speed(Hertz) (Hertz) (Hertz)Screen Screen Screen
TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8and
SmartGunKey,page12.Toenterthisscreen,
presstheLOSETbuttonwhileintheCurrent
(microAmperes)Screen.
Thisscreendisplaysthealternatorspeedasa3
digitnumber(AS),roundedtothenearest5Hz.The
displayisareadoutandcannotbechanged.Ifthe
alternatorspeedisgreaterthan999Hz,thedisplay
willshow999.
TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.
PresstheLOSETbuttontoadvancetothe
LowVoltageLockScreen,page14.Pressandhold
forapproximately5secondstoreturntoOperating
Mode.
Figure8AlternatorSpeed(Hertz)Screen
Low Low
LowVoltage Voltage VoltageLock Lock LockScreen Screen Screen
TheLowVoltageLockScreenisthefourth
screenintheDiagnosticMode.SeeFig.9and
SmartGunKey,page12.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: NOTE:
NOTE:DiagnosticModecannotbeexitedfromthis
screen,becausepressingandholdingtheLOSET
buttonisusedtoturnthelockonoroff.Toexit,
pressLOSETmomentarilytoreturntotheVoltage
(kiloVolts)Screen,thenexitDiagnosticModefrom
there.
Figure9LowVoltageLockScreen
143A2496H

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: NOTE:
NOTE:TheGracowarrantyandapprovalsare
voidiftheelectrostaticspraygunisconnectedtoa
non-Gracovoltageisolationsystemorifthegunis
operatedabove60kV.
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.19showsatypicalelectrostaticairspraysystem.
Itisnotanactualsystemdesign.Forassistance
indesigningasystemtosuityourparticularneeds,
contactyourGracodistributor.
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.
NOTE:Theminimumallowableairexhaustvelocity
is60feet/minute(19linearmeters/minute).High
velocityairexhaustwilldecreasetheoperating
ef󰘰ciencyoftheelectrostaticsystem.
3A2496H15

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,andyoumustconnectthehoseground
wiretoatrueearthground.Donotusetheblack
orgray-coloredGracoairhoses.
1.SeeFig.19.Installanairline󰘰lter/water
separator(M)onthemainairsupplylineto
ensureadry,cleanairsupplytothegun.Dirtand
moisturecanruintheappearanceofyour󰘰nished
workpieceandcancausetheguntomalfunction.
2.TheWB100systemincludesableed-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.TheWB100systemincludesableed-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.
163A2496H

Installation
Connect Connect
Connectthe the theWaterborne Waterborne WaterborneFluid Fluid FluidHose Hose Hose
AlwaysuseaGracowaterborne󰘱uidhosebetween
thevoltageisolationsystem󰘱uidoutletandthegun
󰘱uidinlet.Thewaterborne󰘱uidhose(101)consists
ofaninnerPTFEtube(T)andanabrasion-resistant
outerjacket(J).Shieldedhose24M732alsohas
aconductivelayer(C),Theconductivelayeris
connectedtogroundatthegun󰘰ttingbracket(104).
Beforeconnectingthewaterborne󰘱uidhosetothe
gun,blowitoutwithairand󰘱ushwithwaterto
removecontaminants.Flushthegunbeforeusingit.
Toreducetheriskofelectricshock,installonly
onecontinuousGracowaterbornehosebetween
theisolated󰘱uidsupplyandthegun.Donotsplice
hosestogether.
1.Removethegunairinlet󰘰tting(21).
NOTE: NOTE:
NOTE:Inashieldedhosesystem,ifahose
failureoccurswherehighvoltagearcsthrough
theinnertube,voltagewillbedischargedto
groundthroughtheconductivehoselayer.When
properlyinstalled,theconductivehoselayeris
groundedthroughitsconnectiontothegrounded
enclosure.
Usingunshielded󰘱uidhosesminimizesthe
systemcapacitance,resultinginfasterresponse
timesandalargereductionintheenergystored
inthesystem,ascomparedtoshieldedhoses.
However,withoutthegroundshield,aweak
staticchargecanoccasionallybuilduponthe
outersurfaceofthehose.Tominimizeany
staticchargefeltonthehosesurface,bundle
theairand󰘱uidhosetogether,andwrapwitha
protectivecover,asshown.
Figure10ConnecttheFluidHose
Figure11BundlingtheAirandFluidHoses
3A2496H17

Installation
2.Forthe󰘱uidhoseto󰘰tproperly,itmustbe
strippedandassembledtothedimensionsshown
inFig.12.Applydielectricgreasetotheinner
tube(T)ofthehose.Slidethe󰘰tting(F)onto
thetube(T).Pressthebarbed󰘰tting(G)intothe
tubeuntilitsshoulderbottomsonthetube.A
newGracowaterborne󰘱uidhosecomesfully
assembledtothesedimensions.
NOTICE NOTICE
NOTICE
Becarefulnottocutintotheinnertube(T)of
thehosewhenstrippingthehose.Nicksor
cutsinthePTFEtubewillcausepremature
hosefailure.
Figure12ShieldedHose24M732Dimensions
atGun
Figure13UnshieldedHose24M733Dimensions
atGun
3.Generouslyapplydielectricgrease(44)tothe
o-ring(107)andthethreadsofthe󰘰tting(106).
Pullthe󰘰ttingback1-1/2in.(38mm)andapply
greasetotheexposedPTFEhoseto󰘰llthearea
betweenthehoseandthe󰘰tting.Makesurethe
barrelinletiscleananddry,thenscrewthe󰘰tting
intothe󰘱uidinletofthegunbarrel(1).
4.Loosenthestrainreliefnut(102)sothebracket
canmovefreelyonthehose.
5.Alignthebracket(104)holeswiththeairinletand
exhaustoutlet.Securewiththeairinlet󰘰tting
(21).Tightenthestrainreliefnut(102)tosecure
thehose.
6.Checkthatthenut(105)istightenedsecurelyto
theferrulehousing(103).
7.Presstheexhausttube(36)ontotheexhaust
valvebarb(C).Securewiththeclamp(43).
8.Connecttheotherendofthehosetotheisolated
󰘱uidsupplyasfollows:
a.
GracoWB100Enclosure: Slidehosethrough
thestrainrelief󰘰tting(W).Ensureconductive
layer(C)haspassedthrough󰘰tting.Tighten
to55in-lb(6.2N•m).Pullbackonhoseto
checkitissecure.
For For
ForShielded Shielded ShieldedHose Hose HoseSystems: Systems: Systems:
Conductivehoselayer(C)mustbe
groundedthroughitsconnectiontothe
isolationsystem’sgroundedenclosure(L)
orgroundedfence.Tomaintaingrounding
continuity,theconductivehoselayer(C)
mustbeengagedintheferrulewhenthe
strainreliefnutistightened.Failureto
properlyinstallthehoseinthestrainrelief
couldresultinanelectricshock.
Figure14ShieldedHose24M732
DimensionsatWB100Enclosure
183A2496H

Installation
Figure15ShieldedHose24M732
ConnectionatWB100Enclosure
Figure16UnshieldedHose24M733
DimensionsatWB100Enclosure
Figure17UnshieldedHose24M733
ConnectionatWB100Enclosure
b.
Non-GracoIsolatedEnclosure: Connect
hoseasinstructedintheisolationsystem
manual.
For For
ForShielded Shielded ShieldedHose Hose HoseSystems: Systems: Systems:
Conductivehoselayer(C)mustbe
groundedthroughitsconnectiontothe
isolationsystem’sgroundedenclosure(L)
orgroundedfence.Tomaintaingrounding
continuity,theconductivehoselayer(C)
mustbeengagedintheferrulewhenthe
strainreliefnutistightened.Failureto
properlyinstallthehoseinthestrainrelief
couldresultinanelectricshock.
Figure18ShieldedFluidHoseConnection
atNon-GracoIsolationEnclosure
c.Connecttheendofthetube(T)tothepump
󰘱uidoutlet󰘰tting(Z).
NOTE: NOTE:
NOTE:TheGracowarrantyandapprovals
arevoidiftheelectrostaticspraygunis
connectedtoanon-Gracovoltageisolation
systemorifthegunisoperatedabove60kV.
3A2496H19

Installation
Figure19TypicalInstallation,ProXpWB100
WaterborneSystem
203A2496H