Graco WB100, 309293N Instructions Manual

WB 100 Isolation Enclosure

PRO Xs3 Smart Gun and Fluid

Instructions/Parts List

ELECTROSTATIC, WATERBORNE, AIR SPRAY

WB100 Isolation System and PRO™ Xs3 Spray Gun

For use when electrostatically spraying conductive, waterborne fluids that meet at least one of the following conditions for non-flammability. For professional use only.

FM Approved

• The fluid has a flash point above 140F (60C) and a maximum

organic solvent concentration of 20%, by weight, per ASTM Standard D93.

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

CE-EN 50059 Compliant

• Materials which cannot be ignited, in any mixture with air,

by an energy source of less than 500 mJ.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

309293N

100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure 100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure

See page 3 for a List of Models

For patent information, see www.graco.com/patents.

TI1681A

Table of Contents

List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 4

Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

How the Electrostatic Air Spray Gun Works . . . . 7

Spraying Waterborne Fluids Electrostatically . . . 7

Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

System Requirements . . . . . . . . . . . . . . . . . . . . . 9

Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 9

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . 11

Connect the Air Line . . . . . . . . . . . . . . . . . . . . . 11

Ground the Cabinet . . . . . . . . . . . . . . . . . . . . . . 11

Connect the Waterborne Fluid Hose . . . . . . . . . 11

245895 Agitator Kit . . . . . . . . . . . . . . . . . . . . . . 14

245944 Fluid Regulator Kit . . . . . . . . . . . . . . . . 15

Select a Fluid Nozzle and Air Cap . . . . . . . . . . 16

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Check Electrical Grounding . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 19

Fluid Voltage Discharge and Grounding Procedure

Pressure Relief Procedure . . . . . . . . . . . . . . . . 20

Fill the Fluid Supply . . . . . . . . . . . . . . . . . . . . . . 21

Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 21

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Low Voltage Adjustment (Smart Guns Only) . . 25

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . 26

Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 27

Clean the Air Cap and Fluid Nozzle . . . . . . . . . 29

Grease Door Latch Threads . . . . . . . . . . . . . . . 29

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . 30

Test Power Supply Resistance . . . . . . . . . . . . . 31

Test Electrode Resistance . . . . . . . . . . . . . . . . 32

Test Ground Strip Resistance . . . . . . . . . . . . . . 33

Test Cylinder Resistance . . . . . . . . . . . . . . . . . 33

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Voltage Loss Troubleshooting . . . . . . . . . . . . . . 34

Spray Pattern Troubleshooting . . . . . . . . . . . . . 37

Gun Operation Troubleshooting . . . . . . . . . . . . 38

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 39

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Prepare the Gun for Service . . . . . . . . . . . . . . . 41

Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 42

Electrode Replacement . . . . . . . . . . . . . . . . . . . 43

Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 44

Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 45

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 46

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 46

Power Supply Removal and Replacement . . . . 47

Turbine Alternator Removal and Replacement . 48

Fan Air Adjustment Valve Repair . . . . . . . . . . . 49

Fluid Adjustment Valve Repair . . . . . . . . . . . . . 50

Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . 50

Atomizing Air Restrictor Valve Removal and

Replacement . . . . . . . . . . . . . . . . . . . . . . . . 51

ES ON/OFF Valve Repair . . . . . . . . . . . . . . . . . 51

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 65

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . . 65

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 66

Miscellaneous Accessories . . . . . . . . . . . . . . . . 66

Technical Specifications . . . . . . . . . . . . . . . . . . . . 69

California Proposition 65 . . . . . . . . . . . . . . . . . . . 69

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 70

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 70

2 309293N

List of Models

Part No. Gun Model Description

245897 PRO Xs3 Waterborne Isolation Enclosure with standard electrostatic air

245898 PRO Xs3 Waterborne Isolation Enclosure with smart electrostatic air

233825 Waterborne Isolation Enclosure without hoses and gun.

List of Models

FM Approved

spray gun, grounded air hose, and shielded waterborne fluid hose

244581,

Series B

245301, PRO Xs3 Part No. 244581 Gun, with 25 ft (7.6 m) waterborne fluid hose 244582,

Series B

245305 PRO Xs3 Part No. 244582 Gun, with 25 ft (7.6 m) waterborne fluid hose 245252 Shielded Waterborne Fluid Hose Assembly 25 ft (7.6 m)

PRO Xs3 Standard Electrostatic Air Spray Gun, for waterborne coatings

PRO Xs3 Smart Electrostatic Air Spray Gun, for waterborne coatings,

EN 50059 Compliant

244581,

Series B

244582,

Series B

246511 Waterborne Isolat ion Enclosure, without hoses and gun 246431 PRO Xs3 Unshielded Waterborne fluid hose assembly, 25 ft (7.6 m). 246592 PRO Xs3 Waterborne Isolation Enclosure with standard electrostatic air

PRO Xs3 Standard Electrostatic Air Spray Gun, for waterborne coatings.

PRO Xs3 Smart Electrostatic Air Spray Gun, for waterborne coatings.

spray gun, grounded air hose, and unsh ielded waterborne flu id hose

246593 PRO Xs3 Waterborne Isolation Enclosure with smart electrostatic air

spray gun, grounded air hose, and unsh ielded waterborne flu id hose

309293N 3

Symbols

WARNING

CAUTION

Symbols

Warning Symbol

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

WARNING

Electric Shock Hazard

Improper grounding, setup, or usage of an isolated waterborne system can cause a hazardous condition and result in electric shock or other serious injury.

• Ground the equipment, all personnel in or close to the spray area, the object being sprayed, and all conductive objects in the spray area. See Grounding, page 17.

• The gun must be connected to a voltage isolation system that will discharge the system voltage when the gun is not in use.

• All components of the isolation system that are charged to high voltage must be contained within an enclosure that prohibits personnel from making contact with the high voltage components before the system voltage is discharged.

Caution Symbol

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

• Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 when inst ructed to discharge the voltage; before cleaning, flushing, or servicing the system; before approaching the front of the gun; and before opening the safety enclosure for the isolated fluid supply.

• Do not touch the gun nozzle or come within 4 in. (102 mm ) of th e no zzle du rin g gu n op erat ion or for 30 seconds after operation stops, to allow the voltage to discharge through the bleed resistor. Place the gun in the holster (accessor y) du rin g this 30 seco nd pe rio d. Refe r to Fluid

Voltage Discharge and Grounding Procedure, page 20.

• Electrically connect a metal part of the fluid supply unit to the bleed resistor.

• The gun air supply must be interlocked with the isolat ion system to shut off the air supply any-

time the isolation system enclosure is opened.

• Use only the red-colored Graco electrically conductive gun air hose with this gun. Do not use black or grey-colored Graco air hoses.

• Install only one continuous Graco waterborne flu id h ose bet ween the isol at ed f lu id sup ply and the spray gun. Do not splice hoses together.

• Do not enter a high voltage or hazardous area until all high voltage equipment has been discharged.

4 309293N

Warning

WARNING

Fire and Explosion Hazard

Improper grounding, poor air ventilation, ope n flam es, or sp ar ks can cause a hazardou s co ndit ion and result in a fire or explosion.

• Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements in this manual.

• Ground the equipment, all personnel in or close to the spray area, the object being sprayed, and all other electrically conductive objects in the spray area. See Grounding, page 17.

• Check gun resistance daily. See Test Gun Resistance on page 30.

• If there is any static sparking while using the equipment, st op spraying i mmediately. Identi fy

and correct the problem.

• Provide fresh air ventilation to avoid buildup of flammable or toxic vapors. See Ventilate the Spray Booth on page 11.

• Only use this equipment to spray non-flammable, waterborne fluids, as defined on the front

cover of this manual.

• Only flush, purge, or clean the electrostatic waterborne spray system with non-flammable fluids, as defined on the front cover of this manual.

• Do not flush with the gun electrostatics turned on.

• Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the

spray area.

• Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.

• Use only non-sparking tools to clean residue from the booth and hangers.

Toxic Fluid Hazard

Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin, swallowed, or inhaled.

• Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.

• Store hazardous fluid in an approved container. Dispo se of the hazardous fl uid according to all

local, state, and national guidelines.

• Wear appropriate protective clothing, gloves, eyewea r, and respirator.

309293N 5

Warning

WARNING

Equipment Misuse Hazard

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in a serious injury.

• This equipment is for professional use only.

• Read all manuals, tags, and labels before operating the equipment.

• Use the equipment only for its intended purpose. If you are uncertain, call your Graco distribu-

tor.

• Do not alter or modify equipment. Use only genuine Graco parts and accessories.

• Do not operate the power supply above 60 kV. Use only Graco Part No. 2 44542 Power Supply

with this gun.

• Check the equipment daily. Repair or replace worn or damaged parts immediately.

• Do not exceed the maximum working pressure of the lowest rated system component. Maxi-

mum working air and fluid pressure of this equipment is 100 psi (0.7 MPa, 7.0 bar).

• Use fluids and solvents that are compatible with the equipment wetted parts. See the Techni- cal Specifications section of all equipment manuals. Read the fluid and solvent manufac-

turer’s warnings.

• Route the hoses away from traffic areas, sharp edges, moving parts, a nd h ot surfaces. Do no t expose Graco hoses to temperatures above 180F (82C) or below -40F (- 40C).

• Wear hearing protection when operating this equipment.

• Comply with all applicable local, state, and national fire, electrical, and other safety regula-

tions.

Pressurized Equipment Hazard

Spray from the gun, hose leaks, or ruptured compone nts can splash fluid in the e yes or on the skin and cause serious injury.

• Do not point the spray gun at anyone or at any par t of the body.

• Do not stop or deflect fluid leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure, page 20, when you stop spraying and before cleanin g,

checking, or repairing equipment.

• Check hoses and couplings daily. Replace worn, damaged, or loose parts immediately.

• Tighten all fluid connections before each use.

6 309293N

Introduction

How the Electrostatic Air Spray Gun Works

Introduction

The air hose supplies air to the spray gun. Part of the ai r operates the turbine and the rest of t he a ir a to mizes the fluid being sprayed. The turbine generates power, which is converted by the power cartridge to supply high voltage current to the gun’s electrode.

The fluid source supplies fluid t o the h ose a nd g un. The gun must be connected to a voltage isolation system to maintain voltage at the gun. In an isolation system, the entire fluid supply is electrostatically charged. The charged fluid is attracted to the grounded workpiece, wrapping around and evenly coating all surfaces.

Spraying Waterborne Fluids Electrostatically

This electrostatic air spray gun is designed to spray only waterborne fluids with a flash point above 140 F (60C) and a maximum organic solvent concentration of 20%, by weight, per ASTM Standard D93. Also, the fluid must not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.

CAUTION

The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.

When connected to a voltage isolation system, all of the fluid in the spray gun, fluid hose, and isolat ed fluid supply is charged to high voltage, which means that the system has more electrical energy than a solvent-based system. Therefore, only non-flammable fluids (as defined on the front cover of this manual) can be sprayed with the system or be used to clean, flush, or purge the system.

Precautions must be taken when using electrostatic waterborne equipment to avoid potential shock haza rds. When the spray gun charges the isolated fluid to high voltage, it is similar to charging a capacitor or a battery. The system will store some of the energy while spraying and retain some of that energy after the spray gun is shut off. It is not safe to touch the front end of the gun until the stored energy is discharged. The amount of time it takes to discharge the energy depends on the system design. Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 before approaching the front of the gun.

309293N 7

Introduction

TI1681A

I O

ti1266a

I O

FLUID

LO VOLTAGE

ES HI/LO

DISPLAY

ES INDICATOR

ES ON/OFF

RESTRICTOR

AIR

RESTRICTOR

FLUID

ES ON/OFF

AIR

Standard Model Smart Model

TRIGGER

AIR INLET

FLUID TUBE

AIR CAP

ELECTRODE

Gun Overview

The electrostatic gun includes the following controls

IG. 1.).

(see F

• FLUID adjustment valve. Adjusts flu id rod travel. Use only in low flow conditions, to reduce wear.

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

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

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

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

• Voltage/current DISPLAY (smart models only).

Shows voltage (V) and current (A). Green=spray, yellow/red=see Electrical Troubleshooting, page

39.

• ES HI/LO switch (smart models only). Sets volt- age to HI or LO (factory settings).

• LO VOLTAGE adjustment (smart models only).

Remove plug to adjust to four settings. Page 21.

100

μα

I O

ti1253a

Fig. 1. Gun Overview

8 309293N

Installation

System Requirements

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

• All components of the isolation system that are charged to high voltage must be contained within an enclosure that prohibits persons from making contact with the high voltage components before the system voltage is discharged.

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

• The system should not have any severe arcing occurring when the isolation mechanism opens and closes. Severe arcing will shorten the life of the system components.

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

CAUTION

Install the System

WARNING

Fire, Explosion, and Electric Shock Hazard

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

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

•Be sure your installation complies with all National, State and Local safety and fire codes, NFPA 33, NEC 504 and 516, and OSHA standard 1910.107.

FIG. 2. on page 10 shows a PRO Xs electrostatic waterborne air spray system. For assistance in designing a system to suit your particular needs, contact your Graco distributor.

The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.

Warning Sign

Mount the warning sign, Part No. 186118, in the spr ay area where it can be seen and read by all operators. Additional warning signs are available at no charge.

309293N 9

Installation

Gun ES ON/OFF valve: I is ON, 0 is OFF

Y Z

TI1775C

TI1896C

Fig. 2. Typical Installation: PRO Xs Waterborne System Key

A Main Air Supply Line B* Main Air Supply Shutoff Valve (bleed-type) C Pump Air Pressure Gauge D Pump Air Pressure Regulator EkV Meter FPump G Pump Suction Hose H Paint Container J Bleed Resistor K* Enclosure Safety Interlock L Isolated Enclosure M Gun Air Line Filter N Gun Air Pressure Regulator P* Graco Red Grounded Air Supply Hose Q* Air Hose Ground Wire R Graco Waterborne Fluid Hose

S Waterborne Electrostatic Air Spray Gun T Grounding Rod U Ground Terminal V* Main Ground Wire W Strain Relief/Ground Fitting X Pump Air Supply Line Y Grounding Cylinder Z Pump Fluid Outlet Fitting AA Isolated Enclosure Door BB Enclosure T-Handle Locking Screw

* Required for safe operation. Must be purchased separately.

10 309293N

Installation

Ventilate the Spray Booth

WARNING

Flammable or Toxic Vapor Hazard

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

Check and follow all National, State, and Local codes regarding air exhaust velocity requirements.

NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 60 linear ft/min (18.3 linear meters/minute).

Connect the Air Line

4. Connect the main air supply line (A) to the bleed-type air valve (B). The bleed valve shuts off all air to the system. Install an additional bleed-type air valve (B) upstream of the air filter (M) to isolate the filter for servicing.

WARNING

Pressurized Equipment Hazard

The bleed-type air valve (B) is required in your system to relieve air trapped between

the valve and the fluid supply unit after the air regulator (D) is shut off. Trapped air can cause the fluid supply unit to cycle unexpectedly, which can result in serious injury, including splashing fluid in the eyes or on the skin.

Ground the Cabinet

Connect the main ground wire (V) to a true earth ground.

WARNING

Electric Shock Hazard

To reduce the risk of electric shock or other serious injury, you must use the red-colored Graco Electrically Conductive Air Hose for

the gun air supply hose, and you must connect the hose ground wire to a true earth ground. Do not use the black or grey-colored Graco air hoses.

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

2. Install a bleed-type air regulator (N) on the gun air line (P).

3. Connect the red-colored Graco Grounded Air Supply Hose (P) between the gun air regulator (N) and the gun's air inlet. The gun air inlet fitting has a left-hand thread. Connect the air supply hose ground wire (Q) to a true earth ground.

Connect the Waterborne Fluid Hose

Always use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gu n fluid inlet. See F sists of an inner PTFE tube (T) and an abrasion-resistant outer jacket (J). Shielded hose 245252 also has a conductive layer (C), The conductive layer is con nected to ground at the gun fitting bracket (104).

Before connecting the waterbor ne fl uid hose to t he gu n, blow it out with air and flush with water to remove contaminants. Flush the gun before using it.

IG. 3.. The waterborne fluid hose (101) con-

WARNING

Electric Shock Hazard

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

309293N 11

Installation

35 38

101

102

103

104

105

107 106

108

TI2155b

TI21188a

A 7.40 in. (188 mm) B 2.0 in. (50 mm)

Shielded Hose 245252

A 1.25 in (32 mm)

TI2742A

Unshielded Hose 246431

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

Fig. 3. Connect the Fluid Hose NOTE: In a shielded hose system, if a hose failure

occurs where high voltage arcs through the inner tube, voltage will be discharged to ground through the conductive hose layer. When properly installed, the conductive hose layer is grounded through its connection to the grounded enclosure.

2. For the fluid hose to fit properly, it must be stripped and assembled to the dimensions in F

IG. 5. Push

the inner tube (T) into the fitting (F) until the tube bottoms. A new Graco waterborne fluid hose comes fully assembled to these dimensions.

CAUTION

Be careful not to cut into the inner tube (T) of the hose when stripping the hose. Nicks or cuts in the PTFE tube will cause premature hose failure.

Fig. 5. Waterborne Hose Dimensions (At Gun)

Using unshielded fluid hoses minimizes the system capacitance, resulting in faster response times and a large reduction in the energy stored in the system, as compared to shielded hoses. However, without the ground shield, a weak static charge can occasionally build up on the outer surface of the hose. To minimize any static charge felt on the hose surface, bundle t he air and fluid hose together, and wrap with a pr otective cover, as shown in F

Fig. 4. Bundling the Air and Fluid Hoses

12 309293N

IG. 4.

Fig. 6.

3. Generously apply dielectric grease (40) to the o-ring (107) and the threads of the fitting (106). Pull the fitting back 1-1/2 in. (38 mm) and apply grease to the exposed PTFE hose to fill the area between the hose and the fitting. Make sure the barrel inlet is clean and dry, then screw the fitting into the fluid inlet of the gun barrel (16). See F

IG. 3.

4. Loosen the strain relief nut (102) so the br acket can move freely on the hose.

5. Align the bracket (104) holes with the air inlet and exhaust outlet. Secure with the air inlet fitting (35). Tighten the strain relief nut (102) to secure the hose.

6. Check that the nut (105) is tightened securely to th e

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

TI2166A

Shielded Hose 245252

See Warning at right.

A 12.0 in (305 mm)

TI2743A

Unshielded Hose 246431

See Warning below.

TI2744

ferrule housing (103).

7. Press the exhaust tube (38) onto the barbed adapter (A). Secure with the clamp (39).

8. Connect the other end of the hose to the isola ted fluid supply as follows:

a. Graco WB100 Enclosure: Slide hose through

the strain relief fitting (W). Ensure conductive layer (C) has passed through fitting. Tighten to 55 in-lb (6.2 N•m). Pull back on hose to check it is secure. Comply with the requirements in Warning at right. See F

IG. 7. and FIG. 8..

Installation

Fig. 9.

Fig. 7. Waterborne Hose Dimensions (At Graco WB100 Enclosure)

Fig. 8. Shielded Fluid Hose Connection at Graco WB100

309293N 13

Fig. 10. Unshielded fluid connection

WARNING

Electric Shock Hazard

For Shielded hose systems: Conductive hose layer (C) must be grounded through its connection to the iso-

lation system’s grounded enclosure (L) or grounded safety fence. To maintain grounding continuity, the conductive hose layer (C) must be engag ed in the ferrule when the strain relief nut is tightened. Failure to properly install the hose in the strain relief could result in an electric shock.

TI1897A

b. Non-Graco Isolated Enclosure: Connect hose

as instructed in the isolation system manual, and comply with the requirements in the Warn- ing at right. Refer to F

IG. 11..

Installation

C (see note above)

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

401

406

403

404

406 (Ref)

407

402

TI2137A

Install tube A2 here

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

408

TI1966A

Fig. 11. Shielded Fluid Hose Connection at Non-Graco Isolated Enclosure

c. Connect the end of the tube (T) to the pump

fluid outlet fitting (Z).

CAUTION

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

8. Return the system to service.

The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.

CAUTION

Factory Mutual approval is valid only when this gun is used with Factory Mutual approved voltage isolation systems.

245895 Agitator Kit

To add an agitator to the Graco isolation system, order Part No. 245895. See page 67 for the kit parts list.

1. Discharge the system voltage (page 20).

2. Relieve the pressure (page 20).

3. Open the isolated enclosure door.

Fig. 12. 245895 Agitator Kit

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

5. Remove tube (A2) from elbow (282) at the air manifold; see the tubing diagram on page 64. Install the Y fitting (402) into the elbow. Install tubes (A2) and (407) into the Y fitting. See F tor tube (407) into the cabinet.

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

14 309293N

IG. 12.. Route the agita-

245944 Fluid Regulator Kit

TI2149A

501

502

503

504

505

506

507

Connect

tube A2

here

Tube A1

Connect water-

borne fluid

hose here

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

To add a fluid regulator to the Graco isolation system, order Part No. 245944. See page 68 for the kit parts list.

1. Discharge the system voltage (page 20).

2. Relieve the pressure (page 20).

3. Open the isolated enclosure door.

4. Remove the 1/4 OD tube (A1) from the pump air inlet; see the tubing diagram on page 64.

5. Remove the waterborne fluid hose from the pump fluid outlet fitting (231) and remove the fittin g.

Installation

6. Unscrew the two pump mounting screws (S, F

IG.

13.) and remove the pump from the isolation enclosure.

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

8. Remove tube (A2) from elbow (282) at the air manifold; see page 64. Install the Y fitting (506) in the elbow. Install tubes (A2) and (507) into the Y fitting. Route the tube (507) into the cabinet.

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

10. Assemble the fluid regulator kit as shown in F

IG. 13..

11. Reinstall the pump in the isolation enclosu re. U se the two mounting holes to the left of the holes used previously, to allow clearance for the fluid regulator.

12. Connect tube (A1) to the air inlet of fluid regulator (504). Connect tube (507) to the pump air inlet.

13. Connect the waterborne fl uid hose to the fluid regulator outlet fitting (501).

Fig. 13. Fluid Regulator Kit

14. Return the system to service.

NOTE: The cabinet air regulator and gauge (216, 217) will now operate the air piloted fluid regulator (504). The pump will now operate at the inlet air pressure.

309293N 15

Installation

Select a Fluid Nozzle and Air Cap

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the Pressure Relief Procedure on page 20 before removing or installing a fluid nozzle and/or air cap.

The gun is supplied with Part No. 197266 Nozzle and 24A276 Air Cap. If you require a different size, refer to Table 1 and Table 2 , and instruction manual 309419, or consult with your Graco distributor. See Air Cap/Nozzle Replacement on page 42.

A wide pattern kit (P/N 24A431) is included with the gun and if installed, will provide fan air for wider spray patterns. (If pattern becomes split, use the fan air valve to reduce the amount of fan air.)

Table 1: Fluid Nozzles

Part No.

197263 0.75 (.030) 197266 1.5 (.055) 197264 1.0 (.042) 197267 1.8 (.070) 197265 1.2 (.047) 197268 2.0 (.080)

Size, mm (in.)

Part No.

Size, mm (in.)

Table 2: Air Caps

Part No.

24A438

24A279

24A376*

24A274

24A439

Pattern Shape and Length in. (mm)

Round end; 15-17 (381-432)

Round end; 14-16 (356-406)

Tapered end; 17-19 (432-483)

Tapered end; 12-14 (305-356)

Round end; 11-13 (279-330)

Recommended Fluids and Production Rates

Light to medium viscosity. Up to 15 oz/min (450 cc/min)

Medium to high viscosity and high solids. Up to 15 oz/min (450 cc/min)

Light to medium viscosity. Up to 15 oz/min (450 cc/min)

Medium to high viscosity and high solids. Up to 15 oz/min (450 cc/min) For use with 2.0 mm nozzle.

*Also available in the following colors:

24A276 - blue 24A277 - red 24A278 - green

16 309293N

Installation

ti1259a

Grounding

WARNING

Fire, Explosion, and Electric Shock Hazard

When operating the electrostatic gun, any ungrounded objects in the spray area (people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock. Follow the grounding instructions below.

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

• Voltage Isolation System: electrically connect to a true earth ground, as instructed in the voltage isolation system manual.

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

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

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

• Graco Waterborne Fluid Hose: the hose is gr ounded through the conductive layer. Install the hose as instructed on page 11.

• All persons entering the spray area: shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Do not wear shoes with non-conductive soles such as rubber or plastic. If gloves are necessary, wear the condu ctive gloves that are supplied with the gun. If non-Graco gloves are worn, cut off fingers or palm area of glove to ensure your hand contacts the grounded gun handle.

• All solvent pails: use only grounded metal pails, which are conductive. Do not use plastic containers. Do not place the pail on a non-conductive surface such as paper or cardboard. Do no t store more than the quantity needed for one shift.

• All electrically conductive objects or devices in the spray area: including fluid containers, tools, and

wash cans, must be properly grounded.

309293N 17

Installation

ti1259a

TI2161A

TI2163A

214

Check Electrical Grounding

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

2. Turn the ES ON/OFF valve OFF.

I O

ti1273a

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

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

7. Using an ohmmeter (AA), measure the re sist an ce between the cabinet ground lug (214) and a true earth ground (CC). See F

IG. 15.. The resistance

must be less than 100 ohms.

Fig. 15. Check Cabinet Grounding

5. Using an ohmmeter (AA), measure the resistance between the gun handle (BB) and a true earth ground (CC). The resistance should not e xceed 100 ohms. See F

IG. 14..

6. If the resistance is greater than 100 ohms, check th e tightness of the ground connections and be sure the air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the air hose.

Fig. 14. Check Gun Grounding

18 309293N

Operation

Operating Checklist

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

All operators are properly trained to safely operate an electrostatic waterborne air spray system as instructed in this manual.

All operators are trained in the Pressure Relief Procedure on page 20.

The electrostatics are turned off and properly grounded according to the.Fluid Voltage Dis- charge and Grounding Procedure on page 20 before any person enters the safety enclosure, before cleaning, and before performing any maintenance or repair.

The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded. See Grounding on page 17.

Fluid Hose is in good condition with no cuts or abrasions of the PTFE layer. Replace hose if damaged.

Ventilation fans are operating properly.

Workpiece hangers are clean and grounded.

All debris, including flammable fluids and rags, is removed from the spray area.

Only fluids with a flash point above 140F (60C) and a maximum organic solvent concentration of 20%, by weight, may be in the spray area.

All conductive objects in the spray area are electrically grounded and the floor of the spra y area is electrically conductive and grounded.

309293N 19

Operation

ti1289a

Fluid Voltage Discharge and Grounding Procedure

WARNING

Electric Shock Hazard

The fluid supply is charged with high voltage until the voltage is discharged. Contact with the charged components of the isola-

tion system or spray gun electrode will cause an electric shock. To avoid an electric shock, follow the Fluid Voltage Discharge and Grounding

Procedure:

• whenever you are instructed to discharge the

voltage

• before cleaning, flushing, or servicing the syst em

equipment

Pressure Relief Procedure

WARNING

Pressurized Equipment Hazard

The system pressure must be manually relieved to prevent the system from starting

or spraying accidentally. To reduce the risk of an injury from electric shock, accidental spray from the gun, splashing fluid, or moving parts, follow the

Pressure Relief Procedure whenever you:

• are instructed to relieve the pressu re

• stop spraying

• check or service any of the system equipment

• or install or clean the fluid nozzle.

• before approaching the front of the gun

• or before opening the safety enclosure for the

isolated fluid supply.

1. Turn the ES ON/OFF valve OFF and wait 30 seconds.

I O

ti1273a

2. Remove the door T-handle locking screw. This will shut off the air to the gun and trigger the grounding cylinder to discharge any remaining electrical charge.

3. Use the grounding rod to touch the pump and su pply pail. If you see any arcs, see Electrical Trouble- shooting on page 39.

1. Turn the ES ON/OFF valve OFF.

I O

ti1273a

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

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

4. Trigger the gun into a grounded metal was te co ntainer to relieve the air and fluid pressure.

ti1276a

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

20 309293N

Fill the Fluid Supply

Operation

1. Discharge the system voltage (page 20).

2. Relieve the pressure (page 20).

ti1276a

3. Open the isolated enclosure door.

4. Remove the pail cover from the pail, holding a rag over the suction tube strainer to prevent any fluid from dripping into the isolated enclosure. Place the cover and suction tube outside the enclosure.

5. Remove the supply pail from the enclosure.

CAUTION

Be sure to wipe up all fluid spills in the isolated enclosure. Fluid can create a conductive path and caus e the system to short out.

6. Clean up any fluid spills in the enclosure, using a soft cloth and a non-flammable, compatible solvent.

7. Fill the supply pail with fluid and return it to the enclosure. Clean up any spills.

8. Reinstall the pail cover, holding a rag over the suction tube strainer to prevent fluid spills while you place the pump suction tube in the pail.

WARNING

Fire and Explosion Hazard

To reduce the risk of fire and explosion, only use this equipment with fluids that meet at least one of the following conditions for non-flammability:.

• The fluid has a flash point above 140F (60C) and a maximum organic solvent concentration of 20%, by weight, per ASTM Standard D93.

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

WARNING

Electric Shock Hazard

Contact with the charged components of the spray gun will cause an electric shock.

Do not touch the gun nozzle or electrode or come within 4 in. (102 mm) of the front of the gun during operation or until performing the Fluid Voltage Discharge and Grounding Procedure on page 20.

Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 when you stop spraying and whenever you are instructed to discharge the volta ge.

9. Close the isolated enclosure door and fasten securely with the T-handle locking screw.

WARNING

Adjust the Spray Pattern

Follow the steps below to establish the correct fluid flow and air flow.

309293N 21

Component Rupture Hazard

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

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

+ 49 hidden pages