Graco PRO 3500WB User manual

This manual contains IMPORT ANT
W
ARNINGS AND INSTRUCTIONS
READ AND RET AIN FOR REFERENCE

Rev. L
Supersedes J
Includes K
307–978
ELECTROSTATIC AIR SPRAY
WATER-BASE SYSTEM
Model PRO 3500WB Air Spray Gun
U.S. P A TENT NO. D313,064; 4,978,075
Model WB3500 Voltage Control
For use with Electrostatic Air Spray Systems when spraying conductive, water-based fluids having
flash points above 140  F (60 C) and a maximum 20%, by weight, organic solvent concentration.
COMPONENTS OF THE PRO 3500WB SYSTEM
ISOLATION STAND
Part No. 223–445; 15 gallon (57 liters)
Part No. 727–212; 55 gallon (209 liters)
WB3500 VOLTAGE CONTROL
Part No. 223–477
PRO 3500WB SPRAY GUN WITH AIR & FLUID HOSES
Part No. 223–518; 25 ft (7.6 m) hose length
Part No. 223–519; 36 ft (1 1.0 m) hose length
Part No. 223–520; 50 ft (15.3 m) hose length
SAFETY FENCE
Part No. 1 10–614
CONVERSION KIT
Part No. 223–1 14
GUN HOLSTER
Part No. 236–090
NOTE: See the P ARTS DRA WINGS and LISTS for a complete list of part numbers.
CONTENTS
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Maintenance 16. . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Charts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Gun Electrical T ests 22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Gun Service 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Control Service 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converting PRO 3500SC Gun to PRO 3500WB Gun 32. . . .
Spray Gun Service Notes 34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Gun Parts Drawing 36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Gun Parts List 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Control Parts Drawing 38. . . . . . . . . . . . . . . . . . . . . . .
Voltage Control Parts List 39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Isolation Stand Parts Drawing and List 40. . . . . . . . . . . . . . . .
Fluid Hose Assembly Parts Drawing and List 41. . . . . . . . . . .
Accessories 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Gun T echnical Data Back Cover. . . . . . . . . . . . . . . . . . .
Warranty Back Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
 COPYRIGHT 1989, GRACO INC.

 
WARNINGS
SERIOUS BODILY INJURY, EXPLOSION, FIRE, OR ELECTRIC SHOCK CAN
OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED.
READ
AND UNDERST AND ALL INSTRUCTION MANUALS, T AGS, AND W ARNING
LABELS BEFORE OPERATING EQUIPMENT.
ELECTROSTATIC
EQUIPMENT SHALL ONL Y BE USED BY TRAINED, QUALIFIED
PERSONNEL WHO SHALL BE FULL Y CONVERSANT WITH THE REQUIREMENTS
STATED WITHIN THIS INSTRUCTION MANUAL.
FIRE, EXPLOSION, OR ELECTRIC SHOCK HAZARD
This system is designed to be used ONLY to dispense water-
base
fluids, with flashpoints above 140  F (60  C) and less
than 20%, by weight, organic solvent concentration. When
spraying
water-base fluid electrostatically , the entire fluid supply
is isolated from ground to maintain voltage at the tip of the gun.
To reduce the risk of fire, explosion, or electric shock, which may
result from electrical discharge:
 Ground the electrostatic system.
 Ground all personnel in or close to the spray area.
Ground all electrically conductive objects or devices in the
spray
area, including paint containers, wash cans and tools.
Electrically connect a metal part of the fluid supply unit to the
voltage control.
 Enclose the fluid supply in a safety fence that prohibits per -
sonnel
from approaching the fluid supply before discharging
the system.
Do not touch the gun nozzle or come within 4 in. (101.6 mm)
of the nozzle during gun operation or for 30 seconds after op -
eration stops to allow the voltage to discharge through the
voltage
control. It is recommended that the operator hold the
gun in hand or hang it in the gun holster during this 30 second
period. See ACCESSORIES to order the gun holster .
When
operating the electrostatic gun, any ungrounded objects
in the spray area (such as people, containers, tools, etc.) can
become
electrically charged. Arcing may occur if these objects
then come in contact or close to ground.
Static electricity can also be generated by flow of fluid through
the fluid supply unit, hose, gun, and nozzle, but it is dissipated
through proper grounding as described in Grounding , below .
If
you experience any arcing or feel even a slight shock, STOP
SPRAYING
IMMEDIA TELY . Check for proper grounding of the
entire system. Be sure you have corrected the problem before
starting to spray again.
Grounding
The following are minimum requirements for grounding a basic
electrostatic system. Y our system may include other equipment
or objects which must also be grounded. Always check your
local
electrical code for detailed grounding instructions. Be sure
your system is connected to a true earth ground.
1. Air compressors and hydraulic power supplies: ground
according
to the manufacturer ’ s recommendations.
2. Gun Air Supply Hose: use ONLY Graco Electrically Con-
ductive Air Supply Hose as specified in this manual; see
the
ACCESSORIES section to order . Connect the air hose
ground cable to a true earth ground.
3. Electrostatic Air Spray Gun: obtain grounding through con -
nection
to a properly grounded Graco Electrically Conduc -
tive
Air Supply Hose.
4. Voltage Control: electrically connect to a true earth ground.
5. Safety Fence: electrically connect to a true earth ground.
6. Grounding Rod: electrically connect to a true earth ground.
7. Object being sprayed: keep the work piece hangers clean
and grounded at all times. Contact points must be sharp
points
or knife edges.
8. All persons entering the spray area: shoes must have con -
ductive soles, such as leather, and personal grounding
straps
must be worn. Rubber or plastic soles are not con -
ductive.
The operator must not wear gloves which insulate
the hand from the spray gun. The gloves must be conduc -
tive
or modified as shown on page 12.
9. The floor of the spray area must be electrically conductive
and grounded. Do not cover the floor with cardboard or any
non-conductive material which would interrupt grounding
continuity.
10.
All electrically conductive objects or devices in the spray
area, including paint containers and wash cans, must be
properly
grounded.
11. All solvent pails: use only grounded metal pails, which are
conductive. Do not place the pail on any non-conductive
surface,
such as cardboard or paper , which would interrupt
grounding continuity .
Isolate High V oltage Equipment
The fluid supply MUST be isolated from all personnel. Place a
safety fence around the fluid supply to ensure it is safely iso-
lated.
A safety fence air line interlock MUST be installed to shut
off the high voltage anytime the gate is opened. See the TYPI-
CAL INSTALLATION drawing and read and follow the
INSTALLATION
instructions.


FIRE, EXPLOSION, OR ELECTRIC SHOCK HAZARD
Voltage Discharge Procedure
To reduce the risk of electric shock, which could cause serious
injury , AL WA YS follow this procedure when entering the safety
fence.
1. Disengage
the air line interlock. This will turn of f the air to
the gun and trigger the dump switch to discharge the elec -
trical
charge.
2. Enter the safety fence area and remove the grounding rod
from the fence. Grasp the grounding rod by the hook end of
the handle. T ouch the exposed wire of the grounding rod to
a metal surface of the fluid source; see Fig 10, page 13. If
an arc is detected, correct the problem before doing any-
thing
further with the system. See TROUBLESHOOTING
on
page 21.
3. Before leaving the safety fence, ALWAYS make sure that
the paint source is connected to the voltage control.
Flushing and Cleaning Safety
To reduce the risk of static sparking or splashing, always follow
the Pressure Relief Procedure , below , before flushing.
Be sure the spray gun ES valve lever is OFF and the equip -
ment
has been properly grounded before flushing or clean -
ing
any part of the spray system.
Use the lowest possible pressure to flush. T rigger the gun into a
grounded metal waste container .
ALWA YS use solvents with a flash point above 140  F (60  C)
to
flush, purge, or clean the gun or spray system.
ALWAYS remove all solvent from the system before reactivating
the spray gun.
Use only non-sparking tools to clean residue from the booth and
hangers.
Ventilate the Spray Booth
To prevent hazardous concentrations of toxic and/or flammable
vapors, spray only in a properly ventilated spray booth.
Check and follow all National, State and Local codes regarding
air exhaust velocity requirements. Check and follow all local
safety
and fire codes and OSHA standard 1910.107.
NEVER operate the spray gun unless the ventilating fans are
operating.
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray equipment or accessories, such as
over pressurizing, modifying parts, using incompatible chemi-
cals and fluids, or using worn or damaged parts, can cause
them
to rupture and result in serious bodily injury , fire, explosion
or property damage.
NEVER point the spray gun at anyone or at any part of the body .
NEVER
put hand or fingers over the spray nozzle.
ALWAYS follow the V oltage Discharge Procedure and Pres-
sure Relief Procedure
, at right, before cleaning or removing
the
fluid nozzle or servicing any system equipment.
NEVER try to stop or deflect leaks with your hand or body .
NEVER alter or modify any part of this equipment; doing so
could
cause it to malfunction.
NEVER enter a high voltage or hazardous area until after all
high
voltage equipment has been discharged. A safety fence air
line
interlock MUST be installed to shut of f the high voltage any -
time
the gate is opened.
CHECK all spray equipment regularly and repair or replace
worn
or damaged parts immediately .
System Pressure
This system has a MAXIMUM WORKING PRESSURE of 100
psi (7 bar). Never exceed the maximum working pressure of
any component or accessory used in the system.
Fluid Compatibility
Only use fluids having flashpoints above 140F (60C) and
less than 20%, by weight, organic solvent concentration. BE
SURE all fluids and solvents used are chemically compatible
with wetted parts in your system. (The gun wetted parts are
listed on the back page.) Always read the fluid and solvent
manufacturer’s
literature before using the fluid or solvent in the
system.
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including splashing in
the eyes or on the skin, injury from moving parts or electric
shock,
AL WA YS follow this procedure when shutting of f the sys -
tem,
when checking or servicing any part of the spray system,
when installing, cleaning or changing fluid nozzles, and when -
ever
you stop spraying.
1. T urn the spray gun ES On-Off valve lever to OFF .
2.
Follow the V oltage Discharge Procedure , above.
3. T urn of f the fluid supply to the gun.
4. Trigger the gun into a grounded metal waste container to
relieve
air and fluid pressure.
5. Relieve fluid pressure in the fluid supply unit as instructed
in your fluid supply unit manual.
HOSE SAFETY
TIGHTEN all fluid connections securely before each use.
HANDLE AND ROUTE HOSES CAREFULLY. The fluid hose
MUST be routed over head from the safety fence to the spray
area. Do not pull on hoses to move equipment.
DO NOT use fluids or solvents that are not compatible with the
inner tube and cover of the hose. Read Fluid Compatibility ,
above,
and refer to the hose description in ACCESSORIES on
page
42.
NEVER use a damaged hose. Before each use, check the en -
tire
hose for cuts, leaks, abrasion, bulging cover , or damage or
movement of the hose couplings. If any of these conditions
exist,
replace the hose immediately .
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards––particularly the
General Standards, Part 1910.107 and any other appropriate regulations––should be consulted in connection with the installation, operation, and
maintenance of electrostatic spray painting equipment.

AIR MANIFOLD ASSEMBL Y
Gun Grounded Air Supply Hose Connector
Safety Fence Air Line Interlock Connector
Plug
V
oltage Control Air Hose Connector
Pressure Pot Connector; includes check valve to minimize the
volume of air discharged when air line interlock is disconnected
1
2
34
5
1
2
3
4
5
3
 
TYPICAL INSTALLATION
F* P* N* C* A*
J*
L* K* M
BH*
E
Q*
R
S*
WARNING
T
U*
*Equipment that must be installed for safe operation of a water -base system
G
V
X*
W*
Y*
D
REF C*
REF F*
SPRA Y GUN
INTRODUCTION
This system is designed to be used ONLY with water-
base
fluids, with flashpoints above 140 F (60 C) and
less than 20%, by weight, organic solvent concentration.
When you use conductive, water-base fluids in an elec -
trostatic
system, the fluids in the spray gun (D), fluid line
(F), and fluid supply unit (M) are charged to high voltage.
The entire fluid supply is isolated from ground to maintain
voltage at the tip of the gun.
For proper operation and safety , this high voltage MUST
be isolated both from ground and from contact with peo -
ple.
The high voltage is isolated from ground by the insu -
lated
fluid line (F), isolation stand (K), and voltage control
(L). Safety protection is provided by the safety fence (J),
air-line interlock (H), and voltage control (L).


INSTALLATION
KEY T O TYPICAL INST ALLA TION DRA WING
Ref Letter Part No. Description Assembly Included W ith See Page
A* – Grounded Main Air Supply Line – –
B206–199 Gun Air Pressure Regulator – 43
C* 235–070 (25’)
235–071 (36’)
235–072 (50’)
Gun Grounded Air Supply Hose 223–518 (25’) See
223–519 (36’) front
223–520 (50’) cover
42
D222–700 W ater-base Electrostatic Spray Gun 223–518 (25’) See
223–519 (36’) front
223–520 (50’) cover
37
E– Fluid Supply Air Pressure Regulator SST Pressure T anks 42
F* 185–918 (25’)
185–919 (36’)
185–920 (50’)
Gun Insulated Fluid Supply Hose 223–192 (25’)
223–193 (36’)
223–194 (50’)
40
G223–640 Air Manifold Assembly 223–477 39
H* – Safety Fence Air Line Interlock 223–640 See page 39 –
J* 110–614 Safety Fence – 42
K* 223–445 or 727–212 Isolation Stand – 41 or 42
L* 223–639 V oltage Control 223–477 39
M– Fluid Supply Unit – 42
N* 208–591 Fluid Supply Unit Non-conductive Air
Supply Hose
223–477 39
P* 185–972 & 185–971 Strain Relief/Ground T erminal 223–192 (25’)
223–193 (36’)
223–194 (50’)
40
Q* – Gun Air Hose Ground Wire 218–663 (25’)
218–664 (36’)
218–665 (50’)
42
R223–446 V oltage Control Air Hose 223–477 39
S* 223–447 Safety Fence Interlock Air Hose 223–477 39
T186–119 Safety Fence W arning Sign 223–477 39
U* 210–084 Grounding Rod 223–477 39
V* 110–790 U-Bolts and Plate 223–477 39
W* 223–685 Fence Ground Wire 223–477 39
X* 223–547 Main Ground Wire 223–477 39
Y* 223–548 V oltage Control Ground Wire 223–639 39
A safety fence (J), non-conductive hoses, isolation
stand
(K), and voltage control (L) MUST be installed
to isolate the fluid in the fluid line (F), and fluid supply
unit (M) from ground and to prevent people from con -
tacting portions of the system that are charged to
high voltage. This helps reduce the risk of electric
shock,
which could cause serious injury .
WARNING
The
T ypical Installation shown on page 4 is only a guide
for selecting and installing a water-base electrostatic air
spray system. It is not an actual system design. The par -
ticular type and size system for your operation must be
custom designed for your needs. For assistance in
designing
a system, contact your Graco representative.
WARNING
Installing and servicing this equipment requires
access
to parts which may cause electrostatic shock
or other serious bodily injury if work is not performed
properly. Do not install or service this equipment
unless you are trained and qualified.
Check and follow all local safety and fire codes,
NFPA 33, NEC 504 and 516, and OSHA standard
1910.107.
Warning Signs
Mount warning sign 186–118 (included with the spray
gun) in the spray area where it can easily be seen and
read by all operators. Mount warning sign 186–119
(included with the voltage control) on the safety fence
gate,
as designated on the bottom of the sign. Additional
warning signs are available at no charge. See the spray
gun and voltage control PARTS LISTS or the
ACCESSORIES
section to order them.

 
INSTALLATION
Ventilate the Spray Booth
WARNING
To prevent hazardous concentrations of toxic and/
or
flammable vapors, spray only in a properly venti -
lated spray booth. Never operate the spray gun
unless ventilation fans are operating. The air
supply to the gun must be electrically interlocked
with the ventilators to prevent operation of the
power
supply unless ventilating fans are running.
Check and follow all National, State and Local
codes
regarding air exhaust velocity requirements.
NOTE: High velocity air exhaust will decrease the oper -
ating efficiency of the electrostatic system. Air
exhaust velocity of 100 ft/min (31 linear meters/
minute) should be suf ficient.
Install the Safety Fence
Install the safety fence as shown in Fig 1 or an equivalent
safety fence as specified below . Anchor the fence to the
floor as specified in Fig 2.
Safety Fence Specifications
1. The fence MUST provide at least a 6 x 6 x 6 ft. (1.83
x 1.83 x 1.83 m) protective area. See Fig 1.
2. This area MUST ONLY be accessible through a
single
gate. This gate MUST be hinged and latched
so it only opens outwards.
3. The fence MUST be constructed so it can be bolted
to the floor and and can withstand any forces induced
by vehicles, equipment, or personnel in the area,
without
reducing the protection provided. See Fig 2.
4. The fence MUST be constructed so there is no more
than 6 inches (152 mm) of clearance between the
bottom of any portion of the fence and the building
floor.
5. The
shape of the mesh pattern in the fence sides and
gate is optional, but it MUST restrict a 2.5 inch
(64 mm) diameter spherical object from passing
through
it.
6. The fence MUST be painted a high visibility yellow .
7. A
means MUST be provided to connect the fence to
true earth ground. There must be electrical continuity
between all sides of the fence and the gate.
Install the Isolation Stand
1. Position the isolation stand inside the safety fence.
The
isolation stand MUST be placed in the center of
the fence so it is a minimum of 20 inches (508 mm)
from
any side of the fence.
2. To help keep the stand from moving, install one
1/2 inch (13 mm) bolt in the floor in the position of the
one hole in the bottom of the isolation stand. Refer to
Fig 2 and 3.
Fig 1
6 ft.
(1.83 m)
6 ft.
(1.83 m)
6 ft.
(1.83 m)
Fig 2
1/2 in. (13 mm) dia. “Red Head”
Anchor Bolt (or equivalent)
with maximum 2 ft. (0.6 m)
spacing on fence flange Safety Fence
Concrete Floor
4 in.
(102 mm)
minimum
Fig 3
Bolt
Hole
ISOLA TION ST AND: BOTT OM VIEW
3. Place the isolation stand’s bolt hole over the bolt in
the
floor .


INSTALLATION
Install the Voltage Control
The voltage control (L) contains a bleed resistor, which
continually bleeds current to ground, and a quick-dump
switch,
which dumps the charge to ground whenever the
safety fence air-line interlock (G) is disconnected to open
the gate. Refer to the T ypical Installation Drawing.
1. Place the voltage control 4 inches (102 mm) from the
edge of the isolation stand.
2. Measure the resistance between the isolation stand
grounding grate and the voltage control ground. The
resistance should be less than 20 ohms.
3. Secure the voltage control to the floor with four 1/2
inch
(13 mm) anchor bolts. See Fig 4.
Fig 4
4.75 in.
(121 mm)
4.75 in.
(121 mm)
VOLTAGE CONTROL: BOTT OM VIEW
Install the Strain Relief/Ground Terminal
and Fluid Hose Assembly
Two plates (31 1 & 312) are provided to relieve strain and
ground the fluid hose conductive hose layer. They also
function
as a grounding terminal as shown in Fig 6, page
8. Mount the plates, with the fluid hose, to the side of the
fence as shown in Fig 5.
Connect the Fluid Hose to the Spray Gun
1. Remove the exhaust tube clamp (67) and air fitting
(17)
from the spray gun. See Fig 5.
2. Using petroleum jelly , lubricate o-ring (304) on hose
barbed insert (301). Then push the hose barbed
insert into the gun barrel until the gun barrel is
pressed
against shoulder of the barbed insert (301).
3. Tighten the fitting (302) until the o-ring on the fitting is
compressed to about half its original thickness.
4. T ighten the nut (305) against the fitting (302).
5. Align the bracket (309) holes with the air inlet and ex -
haust outlet, and secure the bracket with the air
fitting (17) and exhaust tube clamp (67).
NOTE: The fluid hose (306) consists of an insulated
layer,
a conductive layer , and an abrasion-resis -
tant outer layer. The conductive layer is con-
nected to ground at the strain relief/ground ter-
minal (31
1 & 312) and gun fitting bracket (309).
Fig 5
Conductive
Hose
Layer
Outer
Hose
Jacket
67
17
309
302
305
306
307 308 309
310
306
KEY
17 Air Fitting
67 Exhaust T ube Clamp
301 Barbed Insert
302 Fitting
304 O–Ring
305 Nut
306
Fluid Hose
307 Ferrule
308 Ferrule
Housing
309
Gun Fitting
Bracket
311/312 Strain Relief/
Ground T erminal Plates
REF
306
312 Safety
Fence
308
Outer
Hose
Jacket
312 311
301 304 302 305
Conductive Hose Layer
MUST NOT extend
beyond ferrule (307)
311

 
INSTALLATION
Install the Interconnect Cables
1. Connect the interconnect cable (406) between the
terminal
block and voltage control. See Fig 6. Fasten
the cable in cable clamp to provide strain relief.
2. Connect the voltage control ground cable (127) to
the
strain relief/ground terminal.
3. Connect the strain relief/ground terminal cable (X) to
a true earth ground.
4. Connect the strain relief/ground terminal cable (W) to
the safety fence.
Install the Grounding Rod
Connect the grounding rod to the strain relief/ground ter -
minal.
See Fig 6. Hook the grounding rod onto the fence
near the gate, as shown in T ypical Installation.
Install the Fluid Supply Unit
1. Place the fluid supply unit on the isolation stand. See
Fig 6.
2. Connect the cable’ s (405) c-clamp from the isolation
stand terminal block to a metal part of the fluid supply
unit.
Fig
6
Isolation
Stand
V
oltage
Control
Strain Relief/
Ground Terminal
Connect cable
223–529 (406)
between terminal
block & voltage control
Connect cable 223–548
(127) between voltage
control base-plate & strain
relief ground terminal
Connect cable 223–547
(X) between strain relief/
ground terminal & true
earth ground (approx. 25 ft
(7.6 m) long)
Connect cable 223–539
(405) between terminal
block
& metal part of fluid
supply unit
Fluid Supply Unit
Grounding Grate
T
erminal Block
Isolation Stand
V oltage Control Cable
Fluid Supply
Cable
Electrically
Conductive
Gun Air
Supply Hose
Grounding
Rod
Connect cable 223–685
(W) between strain relief/
ground terminal & safety fence
(approx. 1 ft (0.3 m) long)
Cable Clamp
406
404
405
402
401


INSTALLATION
Install the Air Line Interlock
Install the air line interlock. Use the u-bolts and brackets
to secure the air line in place. Mount the air manifold to
the
safety fence. See T ypical Installation.
WARNING
Never tamper with or bypass the air-line interlock
as this could cause electric shock and result in
serious
injury .
Connect the Air Lines
1. Connect the 1/4 in. ID nylon non-conductive air hose
(N) between the air manifold and the fluid supply.
Refer to the TYPICAL INSTALLATION drawing on
page
4.
2. Connect the 3/8 in. ID air hose (S) between the main
air supply line and the air manifold air line interlock
fitting.
3. Connect
the 5/16 in. ID air hose (R) between the air
manifold and the voltage control air inlet.
4. Install a bleed-type air regulator on the fluid supply
unit
and gun air supply lines to control air pressure to
the fluid supply unit and gun.
5. Connect the gun’s electrically conductive air supply
hose
(C) between the air regulator and the gun’ s air
inlet. (The gun air inlet fitting has a left hand thread.)
Connect the air supply hose ground cable (Q) to the
strain relief/ground terminal.
WARNING
To
reduce the risk of electric shock or other serious
bodily injury , the gun air supply hose must be elec -
trically
connected to a true earth ground. Use Only
Graco Electrically Conductive Air Supply
Hose,
as specified in the ACCESSORIES section
of this manual. This hose, and the gun, have spe -
cial
threads which prevent using any other type of
hose with the gun.
6. Install an air line filter and an air and water separator
on the air line to ensure a dry , clean air supply to the
gun. Dirt and moisture can ruin the appearance of
your finished workpiece and can cause the gun to
malfunction. A combination air filter/moisture sepa-
rator
is shown in the ACCESSORIES section.
7. Install a bleed-type air shutoff valve on the main air
line
and the fluid supply unit line to shut of f air to the
fluid supply unit and/or gun(s). Install an additional
bleed-type
valve on each fluid supply unit’ s air supply
line to relieve air trapped between this valve and the
fluid supply unit after the air regulator is shut of f.
WARNING
The
bleed-type air shutoff valve is required in your
system to relieve air trapped between this valve
and the fluid supply unit after the air regulator is
closed. Trapped air can cause the gun to spray
unexpectedly,
which could result in serious bodily
injury, including splashing in the eyes or on the skin
and injury from moving parts.
8. Install an air shutof f valve on each gun air supply line
to shut of f air to the gun(s).
Connect the Fluid Line
1. Install a fluid regulator (E) on the fluid line to control
fluid pressure to the gun.
2. Install a fluid filter at the fluid supply unit outlet.
3. Connect the fluid line to the fluid supply unit.

 
INSTALLATION
Check the Electrical Grounding
WARNING
Proper electrical grounding of your system is
essential. For your safety, read the warning
section, FIRE, EXPLOSION, OR ELECTRIC
SHOCK HAZARD , on page 2. Ground the system
as explained there. Then check your system as
explained
below .
1. Turn
the gun ES On–Of f V alve Lever to OFF (O) . See
Fig 11, page 14, for the location of the ES On–Off
lever.
2. Turn
of f the air and fluid supply to the gun.
3. Have a qualified electrician check the electrical
grounding
continuity of the spray gun and air hose.
a. With the electrically conductive air hose con-
nected and properly grounded, use an ohmme-
ter to measure the resistance between the
gun
handle
and a true earth ground . See Fig 8.
b. If the resistance is greater than 100 ohms, check
the tightness of the ground connections, and be
sure the air supply hose ground cable is con-
nected
to a true earth ground. If the resistance is
still greater than 100 ohms, replace the air sup -
ply hose.
Fig 7
Fig 8
Gun Handle
True Earth
Ground Grounded
Air Hose
Ohmmeter


NOTES

 
OPERATION
Operating Checklist
Check the following list daily, before starting to operate
the
system, to help ensure safe, efficient operation.
1. Be sure all operators are properly trained to
safely operate a water-base electrostatic air
spray
system.
2. Be sure all operators are trained how to prop -
erly and completely relieve system pressure
according
to the Pressure Relief Procedure ,
at
right.
3. Be sure the system is thoroughly grounded.
See FIRE, EXPLOSION, OR ELECTRIC
SHOCK
HAZARD , page 2 and 3, and Check
the
Electrical Grounding , page 10.
4. Be sure the electrostatics are turned off and
grounded
according to the V oltage Discharge
Procedure , at right, when any person enters
the safety fence, before cleaning, and before
performing
any maintenance.
5. Be sure the operator and all persons entering
the spray area are properly grounded by wear -
ing
shoes with conductive soles and personal
grounding straps.
6. Operator must not wear gloves which insulate
the hand from the spray gun. If worn, gloves
must be conductive or modified as shown in
Fig 9 so as not to interfere with operator
grounding
through the gun.
7. Be sure ventilation fans are operating properly .
8. Be
sure the workpiece hangers are clean and
grounded. Contact points must be sharp
points
or knife edges.
9. Be sure all refuse is removed from spray booth.
10. Only fluids having flashpoints above 140F
(60
C) and less than 20%, by weight, organic
solvent concentration may be in the spray
area.
11. Be
sure all conductive objects in the spray area
are electrically grounded and the floor of the
spray area is electrically conductive and
grounded. WARNING
To
reduce the risk of serious bodily injury , includ -
ing
splashing in the eyes or on the skin, injury from
moving parts or electric shock, ALWAYS follow
the
Pressure Relief Procedure , at right, when
shutting off system, when checking or servicing
any part of the spray system, when installing,
cleaning
or changing fluid nozzles, and whenever
you stop spraying.
WARNING
To
reduce risk of electric shock, which could cause se -
rious injury, ALWAYS follow the
Voltage Discharge
Procedure
, below , when entering the safety fence.
Do not touch the gun nozzle or come within 4 in.
(101.6 mm) of the nozzle during gun operation or for
30
seconds after operation stops to allow the voltage
to discharge through the voltage control. It is recom-
mended
that the operator hold the gun in hand or hang
it in the gun holster during this 30 second period. See
ACCESSORIES to order the gun holster .
Voltage Discharge Procedure
1. Turn the spray gun ES On-Off valve lever to
OFF
(0) . See Fig 1 1, page 14.
2. Disengage the air line interlock. This will turn of f the
air to the gun and trigger the dump switch to dis-
charge
the electrical charge.
3. Enter the safety fence area and remove the ground -
ing rod from the fence. Grasp the grounding rod by
the
hook end of the handle. T ouch the exposed wire
of the grounding rod to a metal surface of the fluid
source; See Fig 10, page 13. If an arc is detected,
correct the problem before doing anything further
with the system. See TROUBLESHOOTING on
page
21.
4. Before leaving the safety fence, AL WA YS make sure
that the fluid source is connected to the voltage
control.
Pressure Relief Procedure
1. Turn the spray gun ES On-Off valve lever to
OFF
(0) . See Fig 1 1, page 14.
2. Follow the V oltage Discharge Procedure , above.
3. T urn of f the fluid supply to the gun.
4. Trigger the gun into a grounded metal waste con-
tainer
to relieve air and fluid pressure.
5. Relieve fluid pressure in the fluid supply unit as
instructed
in your fluid supply unit manual.
Fig 9
3 in. (76 mm)
Square Cut Out
and Finger of
Glove Cut Off
NOTE: If gloves are worn, they must
be conductive or modified as shown
so as not to interfere with operator
grounding
through the gun.


OPERATION
Fig 10
Grounding
Rod
Safety
Fence
Fluid
Supply
Voltage
Control
Cable
C-clamp
Removing Fluid Supply from Isolated Area
1. Follow the Voltage Discharge Procedure and
Pressure Relief Procedure , on page 12.
2. Disconnect the cable c-clamp from the fluid supply.
Refer
to Fig 10.
3. Remove the fluid supply .
Placing Fluid Supply in Isolated Area
1. Place the fluid supply on the isolation stand. Refer to
Fig 10.
2. Connect the cable c-clamp from the isolation stand
terminal
to a metal part of the fluid supply .
3. Exit the fenced area.
4. Connect the safety fence gate interlock.

 
OPERATION
Fig 1 1
Air Cap
Fluid Adjustment Screw
ES On–Off Lever
1is ON 0 is OFF
Fan Air
Control
Valve
IO
ES
ES Indicator
Light
Optional Air
Cap Control
V
alve (See
ACCESSORIES)


OPERATION
Filter the Fluid
Filter the fluid to remove coarse particles and sediment
which
could clog the spray nozzle.
Install the Fluid Nozzle and Air Cap
WARNING
To
reduce the risk of serious bodily injury , including
splashing in the eyes or on the skin or electric
shock, always follow the
Pressure Relief Proce-
dure
on page 12 before installing, or removing the
fluid nozzle/air cap assembly .
Do not touch the gun nozzle or come within 4 in.
(101.6 mm) of the nozzle during gun operation or
for 30 seconds after operation stops to allow the
voltage
to discharge through the voltage control. It
is recommended that the operator hold the gun in
hand
or hang it in the gun holster during this 30 se -
cond
period. See ACCESSORIES to order the gun
holster.
1. Choose
the correct fluid nozzle and air cap combina -
tion for your application. See Manual 307–803 to
select
a fluid nozzle and air cap.
2. Be sure the spray gun ES On-Off Lever is OFF
(0) . See Fig 1 1.
3. Install
the air cap and fluid nozzle into the gun barrel
as described in Air Cap/Nozzle/Resistor Stud
Replacement
on page 24.
Adjust the Spray Pattern
Follow these steps to establish the correct fluid flow and
air flow . DO NOT turn the ES On-Of f lever to ON (1) yet:
1. Adjust the fluid flow by using the fluid pressure
regulator installed in the fluid line at the pressure
source.
NOTE: If the fluid supply is a pump, the fluid regulator
MUST be installed at the pump outlet, not
remote
from the pump.
2. First, complete all the checks under the Operating
Checklist
on page 12. Then turn the ES On-Of f lever
to ON (1) . When spraying, the ES indicator light
should glow , indicating the electrostatic charge.
3. Use an air pressure regulator to adjust the degree of
atomization. Always use the lowest air pressure pos -
sible
for the most ef ficiency.
4. A
minimum of 2.8 bar (40 psi) air supply is required to
ensure full voltage from the power supply. The gun
may be operated at a lower air pressure/voltage if
required,
but may lose some electrostatic wrap.
5. If the flow to the air cap is still excessive after lower -
ing the inlet pressure below 40 psi, the optional
air
cap control valve
(see Fig 11) can be installed and
used
to limit air to the air cap. See ACCESSORIES.
6. Use
the fan air control valve to change the shape of
the spray pattern. When increasing to a wide, flat pat -
tern, it may be necessary to increase the supply of
fluid to the gun to maintain the same amount of
coverage
over a large area.
NOTE: See SPRAY PATTERN TROUBLESHOOTING
CHART on page 18 to correct spray pattern
problems.
CAUTION
ALWAYS hang the gun with its nozzle pointing
down to avoid having solvent run into the gun air
passages. Solvent in the gun air passages can
cause
poor atomization and excessive current de -
mands
and damage the gun.

 
CLEANING AND MAINTENANCE
Daily Care and Cleaning
WARNING
Before checking, adjusting, cleaning, or servicing
any
part of the spray system, and whenever entering
the safety fence, AL WA YS follow the Pressure Re -
lief
Procedure and the V oltage Discharge Proce -
dure
on page 12. This will help reduce the risk of se -
rious
bodily injury , including splashing in the eyes or
on the skin and injury from moving parts or electric
shock.
WARNING
To
reduce the risk of fire or explosion, which could
cause serious injury and property damage, ONL Y
use
solvents with flashpoints over 140  F (60  C)
and with less than 20%, by weight, organic solvent
content.
CAUTION
Methylene chloride is not recommended as a
flushing
or cleaning solvent with this gun as it will
damage nylon components.
Immersing the gun in solvent is not recommended
as a cleaning method. Solvent left in gun passages
could result in a poor quality paint finish and may
draw current and reduce the electrostatic effect.
Solvent
in the power supply cavity can reduce the
alternator life.
1. Clean the fluid and air line filters daily .
2. Clean the outside of the gun daily with a soft cloth
dampened
in a compatible solvent.
3. Clean the air cap and fluid nozzle daily, minimum.
Some applications require more frequent cleaning.
Replace
the fluid nozzle and air cap if they are dam -
aged.
See Clean the Air Cap and Fluid Nozzle .
4. Check
all of the work hangers for build-up of material;
clean them, if necessary .
Cleaning the Isolation Stand
WARNING
The grounding grate MUST be kept clean to
ensure a good ground connection.This helps re-
duce
the risk of electric shock, which could result
in serious injury .
Make sure that all the surfaces of the stand are free of
paint,
including the grounding grate. Refer to Fig 6. Clean
with a soft cloth dampened in a solvent that’ s suitable for
use in an electrostatic water-base system.
Cleaning the Voltage Control
Thoroughly clean the outer surfaces of the voltage con-
trol
with a soft cloth dampened in a solvent that’ s suitable
for use in an electrostatic water-base system.
Clean the Air Cap and Fluid Nozzle
CAUTION
Do
not use metal tools to clean the air cap holes as
this may scratch them. Scratches in the air cap
holes
can distort the spray pattern.
Do not use any cleaning method which may
allow solvent into the gun air passages.
Clogged
air passages cause poor atomization and
excessive current demands. Point the gun down
while cleaning to prevent dirty solvent from run-
ning
back into the air passages.
WARNING
Do not touch the gun nozzle or come within 4 in.
(101.6 mm) of the nozzle during gun operation or
for 30 seconds after operation stops to allow the
voltage
to discharge through the voltage control. It
is recommended that the operator hold the gun in
hand
or hang it in the gun holster during this 30 se -
cond
period. See ACCESSORIES to order the gun
holster.
Equipment needed:
Soft bristle brush (supplied).
Solvent compatible with fluid being sprayed.
Procedure:
1. Follow the Voltage Discharge Procedure and
Pressure Relief Procedure on page 12.
2. Remove the air cap assembly .
3. With
the front of the gun pointed down, clean the air
cap, fluid nozzle, and front of the gun, using the soft
bristle brush and solvent. See Fig 12.
4. Reinstall air cap assembly . T ighten the retaining nut
until it is snug, allowing the air cap to turn with resis -
tance.


CLEANING AND MAINTENANCE
Fig 12
Flush the Spray Gun
WARNING
To reduce the risk of electric shock, which could
result in serious injury, the ES On-Off lever must
be OFF (0) before flushing.
WARNING
To reduce the risk of serious injury and property
damage,
ONL Y use solvents with flashpoints over
140 F (60  C) and with less than 20%, by weight,
organic solvent content.
CAUTION
Methylene chloride is not recommended as a
flushing
or cleaning solvent with this gun as it will
damage nylon components.
1. Follow the Voltage Discharge Procedure and
Pressure Relief Procedure on page 12.
2. Connect the fluid line to the solvent supply unit.
4. Flush the gun with solvent until it is clean.
5. Follow the Pressure Relief Procedure ,then dis-
connect
the fluid line from the solvent supply unit.
6. Reconnect the fluid line to the paint/fluid supply unit.
7. Turn on the fluid and air supplies.
8. T rigger the gun until it is clear of solvent.

 
SPRAY PA TTERN TROUBLESHOOTING CHART
WARNING
Installing
and servicing this equipment requires access to parts which may cause electric shock or other serious
bodily injury if the work is not performed properly . Do not install or service this equipment unless you are trained and
qualified.
Before
checking, adjusting, cleaning, or servicing any part of the spray system, and whenever entering the safety
fence, AL WA YS follow the Pressure Relief Procedure and the V oltage Discharge Procedure on page 12. This
will help reduce the risk of serious bodily injury , including splashing in the eyes or on the skin and injury from moving
parts or electric shock.
NOTE: Check all possible remedies in the T roubleshooting Charts before disassembling the gun.
PROBLEM: CAUSE SOLUTION
IMPROPER SPRA Y
PATTERN
Insuf ficient fluid supply . Adjust fluid regulator or fill fluid tank.
Loose fluid nozzle or damaged T ighten or replace fluid nozzle.
fluid nozzle taper seat. See page 24.
Dirt between fluid nozzle, taper Clean. See page 16.
seat and body .
Loose or cracked coupler at T ighten or repair .
fluid inlet.
Loose fluid tube in tank. Tighten.
Fluid build-up on air cap; partially Clean with soft implement or
clogged horn holes. Full air pres- submerge in suitable solvent and
sure from clean horn hole forces wipe clean. See page 16.
fan pattern toward clogged end.
Damaged fluid nozzle or air Replace damaged part. See
cap holes. page 24.
Fluid build-up on the perimeter Remove obstruction. Never use
of fluid nozzle orifice, or partially wire or hard instruments. See
clogged fluid nozzle orifice page 16.
T oo high fan air pressure. Adjust fan air adjusting valve.
Fluid too thin. Regulate fluid viscosity .
Not enough fluid pressure Increase fluid pressure.
Low air pressure Increase air pressure.
Fluid too thick Regulate fluid viscosity .
T
oo much fluid. Reduce fluid flow . Reduce fluid
pressure on pressure feed guns
and/or adjust fluid adjusting screw
until proper pattern is obtained.
Last coat of fluid applied too wet. Apply drier finish with multiple
strokes.
T
oo much air pressure. Use least air pressure necessary .
Insuf
ficient air pressure. Increase air pressure.
Non-uniform spray pattern. Clean or replace air cap. See
page 16.
Fluttering or spitting spray
Streaks
NOTE: Some improper patterns are caused by the improper balance between air and fluid.


GUN OPERA TION TROUBLESHOOTING CHART
Misalignment between air cap Remove and clean air cap and fluid
and fluid nozzle. nozzle. See page 16. Then reinstall
them.
Or replace fluid nozzle and air cap.
See page 24.
PROBLEM CAUSE SOLUTION
Loose packing nut. T ighten. See page 27.
W orn needle packings or shaft. Replace needle packings or shaft.
See page 27.
Air leakage from front
of gun.
Fluid leakage from front
of gun.
Air valve not seating properly . Clean, service. See page 29.
Air valve o-ring sticking.
Lubricate o-ring. See page 29.
T oo much air pressure. Reduce,use least air pressure
needed for good results.
Fluid thinned too much. Properly thin fluid.
Needle worn or damaged. Replace needle. See page 27.
W orn fluid seat. Replace fluid nozzle and/or
electrode. See page 25 and 27.
Fluid packing too tight. Lubricate and adjust packing nut.
See page 27.
Loose resistor stud. T ighten resistor stud. See page 24.
Loose fluid nozzle. T ighten fluid nozzle. See page 10.
Damaged resistor stud o-ring. Replace o-ring. See page 24.
Excessive spray fog.
Leakage from fluid
packing area.
Insuf ficient air pressure. Increase, use least air pressure
needed for good results.
Fluid poorly mixed or filtered. Remix or refilter fluid.
Improper thinner being used. Use proper thinner .
“Orange Peel” finish.
Fluid low . Check, add fluid if necessary .
Damaged air cap. Replace air cap. See page 24.
Dirty or clogged fluid nozzle. Clean fluid nozzle. See page 16.
Damaged fluid nozzle. Check, replace fluid nozzle.
See page 24.
No fluid sprays from gun.
Exhaust air flow insufficient Check for proper CFM, check
or not directed properly . baf fles and direction of air flow .
Improper distance between gun Adjust distance to 8 to 12 in.
and work piece. (203 to 305 mm).
Equipment covered
with fluid.
Dirty air cap.
Air Cap
Fluid Nozzle
ALIGNED MISALIGNED

 
ELECTRICAL TROUBLESHOOTING CHART
PROBLEM CAUSE SOLUTION
*ES On–Of f lever in OFF (0) position.
Improper distance between gun and
workpiece.
Parts poorly grounded.
High booth exhaust velocity .
Atomizing air pressure too high.
Fluid pressure too high.
Improper fluid viscosity .
*T
urbine alternator not operating
Faulty gun resistance.
Faulty resistor stud resistance.
Fluid leaks from needle packing and
causes short.
*Faulty turbine alternator .
Isolation stand voltage control not ac -
tuating to isolate fluid supply when
gun is triggered or actuated.
Fluid hose breakdown.
Fluid hose shorting to ground.
Conductive air hose used from fluid
supply unit to grounded air supply .
Air supply for gun taken from isolated
fluid supply using conductive air hose.
Excess moisture in air lines.
V oltage control dump switch closed.
Bleed resistor shorted.
Isolation stand too close to fence.
V oltage control too close to fence.
Low or no electrostatic
wrap. T
urn lever to ON (1) .
Adjust spraying distance to
8–12 in. (203–305 mm).
Clean hangers, check for proper
ground on conveyer or track.
Reduce within code limits.
Reduce air pressure.
Reduce fluid pressure.
Check supplier for proper fluid for
water-base electrostatic spray .
Check if ES On-Of f lever is ON (1) .
Check air supply to gun. Check for dirt
or moisture in turbine. See page 28.
Check gun resistance. See page 22.
Check resistor stud resistance.
See page 23.
Clean needle cavity , tighten or
replace packing. See page 27.
Be sure plug is in place on back of
turbine alternator housing. Remove
and test turbine alternator . See
page 28.
Check operation of voltage control
quick dump switch. Replace if
defective.
Replace fluid hose, if damaged.
Support fluid hose away from ground.
Must use non-conductive air hose.
Must use non-conductive air hose.
Use air filter-moisture separator .
Air pressure below 30 psi ( bar).
Adjust the inlet air pressure.
V oltage control seals damaged.
Replace seals. See page 31.
Replace voltage control bleed resistor .
Center isolation stand in safety fence.
See page 6.
Locate voltage control in safety fence
as described on page 7.
*ES indicator light not on when gun is triggered.