Graco 3A2496D User Manual

Instructions-Parts

WB100

WB100 WB100

Pro

Pro Pro

Air

Air Air
one

one one
For

For For

100 psi (0.7 MPa, 7.0 bar) Maximum
Fluid Working Pressure
100 psi (0.7 MPa, 7.0 bar) Maximum Air
Working Pressure

Xp™

Xp™ Xp™

spray

system

spray spray

system system

of

the

of of

professional

professional professional

conditions

the the

conditions conditions

Important

Important Important
Readallwarningsandinstructionsinthismanual.
Save

Save Save

Isolation

Isolation Isolation

60

60 60

for

use

for for

use use

for

for for

use

only.

use use

only. only.

Safety

Safety Safety

these

instructions.

these these

instructions. instructions.

WB

WB WB

when

when when
non

󰘱ammability

non non

- --󰘱ammability 󰘱ammability

Instructions

Instructions Instructions

System

System System

and

and and

3A2496D

Gun

Gun Gun

electrostatically

electrostatically electrostatically

spraying

spraying spraying

listed

on

listed listed

on on

conductive,

conductive, conductive,

page

3.

page page

3. 3.

waterborne

waterborne waterborne

󰘱uids

that

󰘱uids 󰘱uids

meet

that that

meet meet

EN

at

least

at at

least least

See

pages

See See

pages pages

part

numbers

part part

numbers numbers

information.

information. information.

and

3 33and and

and

and and

for

model

4 44for for

model model

approval

approval approval

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents

Contents Contents

Models...............................................................3

ModelswithFMApprovalOnly......................3

ModelswhichareFMApprovedand

CompliantwithEN50059.................4

Warnings...........................................................5

GunOverview....................................................8

HowtheElectrostaticSprayGun

Works............................................8

SprayingWaterborneFluids

Electrostatically..............................8

Controls,Indicators,andComponents...........8

SmartGuns.................................................10

Installation..........................................................16

SystemRequirements..................................16

WarningSign...............................................16

InstalltheSystem.........................................16

VentilatetheSprayBooth.............................16

AirSupplyLine............................................17

GroundtheCabinet......................................17

ConnecttheWaterborneFluidHose..............18

AgitatorKitAccessory..................................24

FluidRegulatorKitAccessory.......................25

GunSetup..........................................................26

SelectaFluidNozzleandAirCap.................26

Grounding...................................................26

CheckGunElectricalGrounding...................28

FlushBeforeUsingEquipment......................29

Operation...........................................................30

OperatingChecklist......................................30

FluidVoltageDischargeandGrounding

Procedure......................................30

PressureReliefProcedure............................31

FilltheFluidSupply......................................31

AdjusttheSprayPattern...............................32

Shutdown....................................................35

Maintenance......................................................36

Flushing......................................................36

CleantheGunDaily.....................................37

DailySystemCare.......................................38

ElectricalTests...................................................39

TestGunResistance....................................39

TestPowerSupplyResistance.....................40

TestElectrodeResistance............................41

TestGroundStripResistance.......................42

TestCylinderResistance..............................42

Troubleshooting..................................................43

VoltageLossTroubleshooting.......................43

SprayPatternTroubleshooting......................46

GunOperationTroubleshooting....................47

ElectricalTroubleshooting............................48

Repair................................................................50

PreparetheGunforService.........................50

AirCapandNozzleReplacement..................51

AirCap,SprayTip,andNozzle

Replacement(Model

L60M19)........................................52

ElectrodeReplacement................................54

NeedleReplacement(ModelL60M19)...........55

FluidPackingRodRemoval..........................56

PackingRodRepair.....................................57

BarrelRemoval............................................58

BarrelInstallation.........................................58

PowerSupplyRemovaland

Replacement..................................59

AlternatorRemovalandReplacement...........60

FanAirAdjustmentValveRepair..................62

AtomizingAirRestrictorValveRepair............63

ESOn-OffandFluidAdjustmentValve

Repair............................................64

AirValveRepair...........................................65

SmartModuleReplacement..........................66

AirSwivelandExhaustValve

Replacement..................................67

Parts..................................................................68

StandardWaterborneAirSprayGun

Assembly.......................................68

SmartWaterborneAirSprayGun

Assembly.......................................70

MoldReleaseSmartAirSprayGun

Assembly.......................................72

IsolationEnclosure.......................................74

TubingandWiring.......................................77

PackingRodAssembly.................................79

AlternatorAssembly.....................................80

ESOn-OffandFluidAdjustmentValve...........81

FanAirAdjustmentValveAssembly..............82

AtomizingAirRestrictorValve

Assembly.......................................82

AirCapAssembly........................................83

SmartModuleAssembly...............................84

AirCapsandFluidNozzles.................................85

SprayTipSelectionChart(ModelL60M19MRG

GunOnly).............................................90

RepairKits,RelatedManuals,and

Accessories..........................................92

Dimensions........................................................96

TechnicalData...................................................97

GracoProXpWarranty.......................................98

2

3A2496D

Models

Models

Models Models

Models

Models Models

Part

Part Part

24N580WB100WaterborneIsolationEnclosure233825withstandardelectrostatic

24P629WB100WaterborneIsolationEnclosure233825withsmartelectrostatic

233825WB100

L60T17ProXp60WB

L60M17ProXp60WB

24M732

with

FM

with with

No.

No. No.

Approval

FM FM

Approval Approval

Material

• ••Material Material

Model

Model Model

-——

Only

Only Only

FM

approved

FM FM

approved approved

does

not

does does

not not

for

use

with

󰘱uids

that

meet

the

for for

use use

with with

󰘱uids 󰘱uids

that that

meet meet

sustain

sustain sustain

Sustained

Sustained Sustained

burning

burning burning

Burning

Burning Burning

Description

Description Description

airspraygunL60T17,groundedairhose235070,andshielded
waterborne󰘱uidhose24M732.

airspraygunL60M17,groundedairhose235070,andshielded
waterborne󰘱uidhose24M732.

WaterborneIsolationEnclosureforshieldedhoses.Doesnot
includehosesandgun.

StandardElectrostaticAirSprayGun,forwaterbornecoatings.

SmartElectrostaticAirSprayGun,forwaterbornecoatings.

ShieldedWaterborneFluidHoseAssembly,25ft(7.6m).

accordance

in ininaccordance accordance

Liquid

of ofofLiquid Liquid

with

with with

Mixtures,

Mixtures, Mixtures,

following

the the

following following

the

Standard

the the

Standard Standard

ASTM

ASTM ASTM

condition:

condition: condition:

Test

Method

Test Test

Method Method

D4206.

D4206. D4206.

for

for for

3A2496D 3

Models

Models

Models Models
Compliant

Compliant Compliant

FM12ATEX0080

FM12ATEX0080 FM12ATEX0080

Part

Part Part

24P630WB100WaterborneIsolationEnclosure246511withstandard

24P631WB100WaterborneIsolationEnclosure246511withsmartelectrostatic

24P734WB100

which

which which

0.35

0.35 0.35

J, J,J,with with

24M733

24M733 24M733

EN

50059

EN EN

50059 50059

Ta

0°C

Ta Ta

0°C 0°C

– ––50°C 50°C

No.

No. No.

are

FM

are are

with

EN50059

with with

EN50059 EN50059

with

Hose

Hose Hose

50°C

Approved

FM FM

Approved Approved

FM

approved

FM FM

approved approved

Material

• ••Material Material

Materials

• ••Materials Materials

does

does does

which

which which

Model

Model Model

and

and and

for

use

with

󰘱uids

that

meet

for for

use use

with with

󰘱uids 󰘱uids

that that

not

sustain

not not

sustain sustain

for

Sustained

for for

Sustained Sustained

Models

Models Models

with

with with

cannot

cannot cannot

Description

Description Description

electrostaticairspraygunL60T18,groundedairhose235070,
andunshieldedwaterborne󰘱uidhose24M733.

airspraygunL60M18,groundedairhose235070,and
unshieldedwaterborne󰘱uidhose24M733.

WaterborneIsolationEnclosure246511withMRGsmart
electrostaticairspraygunL60M19,groundedairhose235070,
andunshieldedwaterborne󰘱uidhose24M733.

burning

burning burning

Burning

Burning Burning

Compliant

Compliant Compliant

󰘱uids

that

󰘱uids 󰘱uids

that that

be

ignited,

be be

ignited, ignited,

accordance

in ininaccordance accordance

Liquid

of ofofLiquid Liquid

with

EN

with with

EN EN

meet

the

meet meet

the the

any

in ininany any

less

of ofofless less

mixture

mixture mixture

than

than than

the

meet meet

the the

with

with with

Mixtures,

Mixtures, Mixtures,

50059

50059 50059

following

following following

500

500 500

when

when when

with

with with

mJ.

mJ. mJ.

following

following following

the

the the

ASTM

ASTM ASTM

criteria:

criteria: criteria:

air,

air, air,

condition:

condition: condition:

Standard

Standard Standard

used

used used

by

by by

Test

Method

Test Test

Method Method

D4206.

D4206. D4206.

an

energy

an an

energy energy

source

source source

246511WB100

L60T18ProXp60WB

L60M18ProXp60WB

L60M19ProXp60WB

MRG

24M733

-——

WaterborneIsolationEnclosureforunshieldedhoses.Doesnot
includehosesandgun.

StandardElectrostaticAirSprayGun,forwaterbornecoatings.

SmartElectrostaticAirSprayGun,forwaterbornecoatings.

SmartElectrostaticAirSprayGun,formoldrelease
applications.

UnshieldedWaterborneFluidHoseAssembly,25ft(7.6m).

4

3A2496D

Warnings

Warnings Warnings

Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.

WARNING

WARNING WARNING

ELECTRIC

ELECTRIC ELECTRIC

Impropergrounding,setup,orusageofanisolatedwaterbornesystemcanresultinelectric
shock.Tohelppreventelectricshock:

•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorclose
tosprayarea.SeeGrounding Grounding

•Connecttheelectrostaticguntoavoltageisolationsystemthatwilldischargethesystem
voltagewhennotinuse.

•Allcomponentsoftheisolationsystemthatarechargedtohighvoltagemustbecontained
withinanisolationenclosurethatpreventspersonnelfrommakingcontactwiththehigh
voltagecomponentsbeforethesystemvoltageisdischarged.

•FollowtheFluid Fluid
thevoltage;beforecleaning,󰘱ushing,orservicingthesystem;beforeapproachingthefrontof
thegun;andbeforeopeningtheisolationenclosurefortheisolated󰘱uidsupply.

•Donotenterahighvoltageorhazardousareauntilallhighvoltageequipmenthasbeen
discharged.

•Donottouchthegunnozzleorelectrode,orcomewithin4in.(102mm)oftheelectrode
duringgunoperation.FollowtheFluid Fluid

•Interlockthegunairsupplywiththevoltageisolationsystemtoshutofftheairsupplyanytime
theisolationsystemenclosureisopened.

•Onlyusethered-coloredGracoelectricallyconductivegunairhosewiththisgun.Donot
useblackorgray-coloredGracoairhoses.

•Donotsplicehosestogether.InstallonlyonecontinuousGracowaterborne󰘱uidhose
betweentheisolated󰘱uidsupplyandthespraygun.

SHOCK

SHOCK SHOCK

Fluid

HAZARD

HAZARD HAZARD

Grounding

Voltage

Voltage Voltage

instructions.

Discharge

Discharge Discharge

and

Grounding

and and

Grounding Grounding

Fluid

Voltage

Voltage Voltage

Procedure

Procedure Procedure

Discharge

Discharge Discharge

and

and and

wheninstructedtodischarge

Grounding

Grounding Grounding

Procedure

Procedure Procedure

Warnings

.

3A2496D 5

Warnings

WARNING

WARNING WARNING

FIRE

AND

FIRE FIRE

Combustibledustinwork work

•Fluidsusedmustmeetthefollowing󰘱ammabilityrequirements:

Stop

•Stop Stop
equipmentuntilyouidentifyandcorrecttheproblem.

•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.

•Useandcleanequipmentonlyinwellventilatedarea.

•Interlockthegunairsupplytopreventoperationunlessventilatingfansareon.

•Onlyusenon-󰘱ammablesolventswhen󰘱ushingorcleaningequipment.

•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).

•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.

•Keepsprayareafreeofdebris,includingsolvent,ragsandgasoline.

•Keepaworking󰘰reextinguisherintheworkarea.

PRESSURIZED

PRESSURIZED PRESSURIZED
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.

EXPLOSION

AND AND

EXPLOSION EXPLOSION

FM,

FMc

•FM, FM,
MaterialdoesnotsustainburninginaccordancewiththeStandardTestMethodfor
SustainedBurningofLiquidMixtures,ASTMD4206.

CE

•CE CE
Materialswhichcannotbeignited,inanymixturewithair,byanenergysourceof
lessthan500mJ.

operation

operation operation

Approved:

FMc FMc

Approved: Approved:

EN

50059

- --EN EN

50059 50059

immediately

immediately immediately

EQUIPMENT

EQUIPMENT EQUIPMENT

HAZARD

HAZARD HAZARD

work

area

area area

canigniteorexplode.Tohelpprevent󰘰reandexplosion:

Compliant:

Compliant: Compliant:

ifstaticsparkingoccursoryoufeelashock.Donotuse

HAZARD

HAZARD HAZARD

•FollowthePressure Pressure
cleaning,checking,orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

PLASTIC

PLASTIC PLASTIC
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.

•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.

•SeeTechnical Technical
solventmanufacturer’sMSDSsandrecommendations.

TOXIC

TOXIC TOXIC
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.

•ReadMSDSstoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.

Pressure

PARTS

PARTS PARTS

Technical

FLUID

FLUID FLUID

OR

OR OR

Relief

Procedure

Relief Relief

Procedure Procedure

CLEANING

CLEANING CLEANING

Data

Data Data

inthisandallotherequipmentinstructionmanuals.Read󰘱uidand

FUMES

FUMES FUMES

SOLVENT

SOLVENT SOLVENT

whenyoustopspraying/dispensingandbefore

HAZARD

HAZARD HAZARD

6 3A2496D

Warnings

WARNING

WARNING WARNING

PERSONAL

PERSONAL PERSONAL
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.

EQUIPMENT

EQUIPMENT EQUIPMENT
Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

PROTECTIVE

PROTECTIVE PROTECTIVE

MISUSE

MISUSE MISUSE

EQUIPMENT

EQUIPMENT EQUIPMENT

HAZARD

HAZARD HAZARD

Technical

Data

Data Data

Pressure

inallequipmentmanuals.

Relief

Relief Relief

Technical

Procedure

Procedure Procedure

whenequipmentisnotinuse.

Data

Data Data

3A2496D

7

GunOverview

Gun

Gun Gun

How

How How
Works

Works Works

Theairhosesuppliesairtothespraygun.Partof
theairoperatesthealternatorturbineandtherest
oftheairatomizesthe󰘱uidbeingsprayed.The
alternatorgeneratespower,whichisconvertedby
thepowercartridgetosupplyhighvoltagetothe
gun’selectrode.

Thepumpsupplies󰘱uidtothe󰘱uidhoseandgun,
wherethe󰘱uidiselectrostaticallychargedasit
passestheelectrode.Thecharged󰘱uidisattracted
tothegroundedworkpiece,wrappingaroundand
evenlycoatingallsurfaces.

Spraying

Spraying Spraying
Electrostatically

Electrostatically Electrostatically

Thiselectrostaticairspraygunisdesignedtospray
only

only only
󰘱ammabilityrequirements:

FM,

•FM, FM,
Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.

CE-EN

•CE-EN CE-EN
Materialswhichcannotbeignited,inanymixture
withair,byanenergysourceoflessthan500mJ.

Whenconnectedtoavoltageisolationsystem,
allofthe󰘱uidinthespraygun,󰘱uidhose,and

Overview

Overview Overview

the

Electrostatic

the the

Electrostatic Electrostatic

Waterborne

Waterborne Waterborne

waterborne󰘱uidswhichmeetthefollowing

FMc

Approved:

FMc FMc

Approved: Approved:

50059

Compliant:

50059 50059

Compliant: Compliant:

Spray

Spray Spray

Fluids

Fluids Fluids

Gun

Gun Gun

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,
page30,beforeapproachingthefrontofthegun.

NOTE:

NOTE: NOTE:
voidiftheelectrostaticspraygunisconnectedtoa
non-Gracovoltageisolationsystemorifthegunis
operatedabove60kV.

Controls,

Controls, Controls,

Theelectrostaticgunincludesthefollowing
controls,indicators,andcomponents(seeFig.

1).ForinformationonSmartguns,alsosee

SmartGuns,page10.

TheGracowarrantyandapprovalsare

Indicators,

Indicators, Indicators,

and

Components

and and

Components Components

8 3A2496D

Figure1GunOverview

GunOverview

Item

Item Item

A

BFluidInlet

C

D

EElectrodeNeedle

FFanAirAdjustment

Description

Description Description

AirSwivelInlet1/4npsm(m)

TurbineAirExhaust

AirCapandNozzleSee

Valve

Purpose

Purpose Purpose

left-handthread,for
Gracored-colored
groundedairsupply
hose.

Gracowaterborne
󰘱uidsupplyhose

Barbed󰘰tting,for
suppliedexhaust
tube.

AirCapsandFluid
Nozzles,page85,

foravailablesizes.

Supplies
electrostaticcharge
tothe󰘱uid.

Adjustsfansizeand
shape.Canbeused
todecreasepattern
width.

Item

Item Item

G

HFluidAdjustment

J

K

Description

Description Description

AtomizingAir
RestrictorValve

Knob

ESOn-OffValve

ESIndicator(stan­dardgunonly;for
Smartgunindica­tor,seeOperating

Mode,page10)

Purpose

Purpose Purpose

Restrictsaircapair
󰘱ow.Replacewith
plug(included)if
desired.

Adjusts󰘱uid󰘱owby
limiting󰘱uidneedle
travel.Useonlyin
low󰘱owconditions,
toreducewear.

Turnselectrostatics
ON(I)orOFF(O).

LitwhenESis
ON(I).Color
indicatesalternator
frequency.Seethe
LEDindicatortable
onpage36.

3A2496D 9

GunOverview

Smart

Smart Smart

TheSmartGunmoduledisplayssprayingvoltage,
current,alternatorspeed,andthevoltagesetting(low
orhigh).Italsoallowstheusertochangetoalower
sprayingvoltage.Themodulehastwomodes:

•OperatingMode

•DiagnosticMode

Operating

Operating Operating

Bar

Bar Bar

SeeFig.2,andTable1onpage12.TheOperating
Modedisplaysgundataduringnormalspraying.The
displayusesabargraphtoshowthevoltagelevelin
kiloVolts(kV)andthecurrentlevelinmicroAmperes
(uA).Thebargraphrangeisfrom0to100%foreach
value.

IfthebargraphLEDsareblue,thegunisreadyto
spray.IftheLEDsareyelloworred,thecurrentis
toohigh.The󰘱uidmaybetooconductive,orsee

ElectricalTroubleshooting,page48forotherpossible

causes.

Guns

Guns Guns

Mode

Mode Mode

Graph

Graph Graph

Voltage

Voltage Voltage

Thevoltageadjustmentswitch(VA)allowsthe
operatortochangefromlowtohighvoltage.

•Thehighvoltagesettingisdeterminedbythe
maximumvoltageofthegunandisnotadjustable.

•Thelowvoltageindicator(LO)lights
whentheswitchissettoLO.Thelow
voltagesettingisuseradjustable.See

AdjustingtheLowVoltageSetting,page11.

NOTE:

NOTE: NOTE:
haslostcommunicationwiththepowersupply.See

ErrorDisplay,page11forfurtherinformation.

Adjustment

Adjustment Adjustment

IftheErrordisplayappears,theSmartmodule

Switch

Switch Switch

Hz

Indicator

Hz Hz

Indicator Indicator

TheHzindicatorfunctionsthesameastheES
indicatoronstandardguns.Theindicatorlightsto
showthealternatorspeedstatus,andhasthree
colors:

•Greenindicatesthealternatorspeediscorrect.

•Iftheindicatorchangestoamberafter1second,
increasetheairpressure.

•Iftheindicatorchangestoredafter1second,
reducetheairpressure.

Figure2SmartGunModuleinOperatingMode

10 3A2496D

GunOverview

Error

Error Error

IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3,andTable1onpage12.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page48.
CommunicationmustberestoredtomaketheSmart
modulefunctional.

NOTE:

NOTE: NOTE:
appear.Ifthegunhasbeendisassembled,wait8
secondsbeforesprayingtoensurethatanError
conditionhasnotoccurred.

NOTE:

NOTE: NOTE:
displaywillnotappear.

Display

Display Display

Ittakes8secondsfortheErrordisplayto

Ifthereisnopowertothegun,theError

NOTE:

NOTE: NOTE:
returntotheOperatingScreen.

NOTE:

NOTE: NOTE:

LockSymbol,page11.

Figure4LowVoltageSettingScreen(Unlocked)

Lock

Lock Lock

Thelowvoltagesettingmaybelocked.Whenlocked,
animage(LK)appearsonthescreen.SeeFig.5,
andTable1onpage12.

After2secondsofinactivitythedisplaywill

Thelowvoltagesettingmaybelocked.See

Symbol

Symbol Symbol

Figure3ErrorDisplay

Adjusting

Adjusting Adjusting

Thelowvoltagesettingisuseradjustable.Toaccess
thelowvoltagesettingscreenwheninOperating
Mode,presstheLOSETbutton(LS)momentarily.
Thescreenwilldisplaythecurrentlowvoltage
setting.SeeFig.4,andTable1onpage12.The
rangeis30–60kV.

SettheVoltageAdjustmentswitch(VA)toLO.Press
theLOSETbuttonrepeatedlytoincreasethesetting
inincrementsof5.Whenthedisplayreachesthe
maximumsetting(60kV)itwillreturntotheminimum
setting(30kV).Continuepressingthebuttonuntil
youreachthedesiredsetting.

the

Low

the the

Voltage

Low Low

Voltage Voltage

Setting

Setting Setting

•WheninHImode,thelowvoltagesettingisalways always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.

•WheninLOmode,thelocksymbolwill
only

only only

appearifthelockisenabled.See

LowVoltageLockScreen,page15,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

always

3A2496D

11

GunOverview

Table

Table Table

Item

Item Item

VA

LO

kV

uA

LSLOSETbutton

Key

for

Figs.

1 11. ..Key Key

for for

2–9.

Figs. Figs.

2–9. 2–9.

Description

Description Description

VoltageAdjustmentSwitch

LowVoltageModeIndicator

Voltage(kV)Display

Current(uA)Display

Purpose

Purpose Purpose

Two-positionswitchsetssmart
gunvoltagetolowsetting(LO)or
highsetting(HI).Thisswitchis
functionalinOperatingModeand
inDiagnosticMode.

Lights(blue)whenthesmartgun
issettoLowVoltage.

Displaysactualsprayingvoltage
ofthegun,inkV.InOperating
Mode,displayisabargraph.
InDiagnosticMode,voltageis
displayedasanumber.

Displaysactualsprayingcurrent
ofthegun,inuA.InOperating
Mode,displayisabargraph.
InDiagnosticMode,currentis
displayedasanumber.

Pressmomentarilytoenterthe
LowVoltageSettingscreen.

Pressandholdforapproximately5
secondstoenterorexitDiagnostic
Mode.

WhileinDiagnosticMode,press
momentarilytoadvancethrough
screens.

WhileontheLowVoltageLock
Screen(inDiagnosticMode),
pressandholdtoturnthelockon
oroff.

LVLowVoltageDisplayDisplaysthelowvoltagesetting

asanumber.Thesettingcanbe
changed.SeeFig.4.

LKLowVoltageLocked

LD

ERErrorDisplay

VIVoltageIndicatorInDiagnosticMode,thetwotop

LODisplay

Appearsifthelowvoltagesetting
islocked.SeeFig.5andFig.9.

AppearsontheLowVoltageLock
Screen.SeeFig.9.

AppearsiftheSmartmoduleloses
communicationwiththepower
supply.SeeFig.3.

rightLEDsofthescreenlight,
indicatingthatthevaluedisplayed
isinkV.SeeFig.6.

12

3A2496D

GunOverview

Item

Item Item

CICurrentIndicator

ASAlternatorSpeedDisplay

Hz

Description

Description Description

AlternatorSpeedIndicatorInOperatingMode,indicatorcolor

Purpose

Purpose Purpose

InDiagnosticMode,thetwo
bottomrightLEDsofthescreen
light,indicatingthatthevalue
displayedisinuA.SeeFig.7.

InDiagnosticMode,Hzlevelis
displayedasanumber.SeeFig.

8.

variestoshowthealternator
speedstatus:

•greenindicatesthealternator
speedisatthecorrectlevel.

•Iftheindicatorchangestoamber
after1second,thealternator
speedistoolow.

•Iftheindicatorchangestored
after1second,thealternator
speedistoohigh.Theindicator
willalsoturnrediftheError
displayappears.

InDiagnosticMode,theindicator
isgreenwhenintheAlternator
Speed(Hertz)screen.

3A2496D 13

GunOverview

Diagnostic

Diagnostic Diagnostic

DiagnosticModeincludesfourscreenswhichdisplay
gundata:

•Voltage(kiloVolts)Screen

•Current(microAmperes)Screen

•AlternatorSpeed(Hertz)Screen

•LowVoltageLockScreen

NOTE:

NOTE: NOTE:
lowvoltagesetting;thesettingisnotadjustablein
DiagnosticMode.However,thevoltageadjustment
switch(VA)canbesettoHIorLOinOperatingMode
andDiagnosticMode.

ToenterDiagnosticMode,pressandholdtheLOSET
(LS)buttonforapproximately5seconds.Thedisplay
willgototheVoltage(kiloVolts)Screen,page14.

Toadvancetothenextscreen,presstheLOSET
buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.

NOTE:

NOTE: NOTE:
Mode,thelastscreenviewedwillbedisplayedwhen
thegunisretriggered.

NOTE:

NOTE: NOTE:
fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page15fordetails.

Voltage

Voltage Voltage

Mode

Mode Mode

YoumustbeinOperatingModetoadjustthe

IfthegunisdetriggeredwhileinDiagnostic

DiagnosticModecannotbeexited

(kiloVolts)

(kiloVolts) (kiloVolts)

Screen

Screen Screen

Figure6Voltage(kiloVolts)Screen

Current

Current Current

TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7,andTable
1onpage12.Toenterthisscreen,presstheLO
SETbuttonwhileintheVoltage(kiloVolts)Screen.

Thisscreendisplaysthesprayingcurrentofthegun
asanumber(uA),roundedtothenearest5uA.The
twobottomrightLEDs(CI)ofthedisplaypanellight,
indicatingthattheCurrent(microAmperes)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page15.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

(microAmperes)

(microAmperes) (microAmperes)

Screen

Screen Screen

TheVoltage(kiloVolts)Screenisthe󰘰rstscreento
appearafterenteringDiagnosticMode.SeeFig.6,
andTable1onpage12.Toenterthisscreen,press
andholdtheLOSETbuttonforapproximately5
secondswhileintheOperatingMode.

Thisscreendisplaysthesprayingvoltageofthe
gunasanumber(kV),roundedtothenearest5kV.
ThetwotoprightLEDs(VI)ofthedisplaypanel
light,indicatingthattheVoltage(kiloVolts)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page14.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

14

Figure7Current(microAmperes)Screen

3A2496D

GunOverview

Alternator

Alternator Alternator

TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8,andTable
1onpage12.Toenterthisscreen,presstheLOSET
buttonwhileintheCurrent(microAmperes)Screen.

Thisscreendisplaysthealternatorspeedasa3
digitnumber(AS),roundedtothenearest5Hz.The
displayisareadoutandcannotbechanged.Ifthe
alternatorspeedisgreaterthan999Hz,thedisplay
willshow999.

TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page15.Pressandhold

forapproximately5secondstoreturntoOperating
Mode.

Speed

Speed Speed

(Hertz)

(Hertz) (Hertz)

Screen

Screen Screen

Low

Voltage

Low Low

Voltage Voltage

TheLowVoltageLockScreenisthefourthscreenin
theDiagnosticMode.SeeFig.9,andTable1on
page12.Toenterthisscreen,presstheLOSET
buttonwhileintheAlternatorSpeed(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:
screen,becausepressingandholdingtheLOSET
buttonisusedtoturnthelockonoroff.Toexit,
pressLOSETmomentarilytoreturntotheVoltage
(kiloVolts)Screen,thenexitDiagnosticModefrom
there.

DiagnosticModecannotbeexitedfromthis

Lock

Screen

Lock Lock

Screen Screen

Figure8AlternatorSpeed(Hertz)Screen

Figure9LowVoltageLockScreen

3A2496D 15

Installation

Installation

Installation Installation

System

System System

AGracovoltageisolationsystemmusthavethe
followingfeatures:

•Anisolationenclosurethatpreventspersonsfrom
makingcontactwiththehighvoltagecomponents
beforethesystemvoltageisdischarged.All
componentsoftheisolationsystemthatare
chargedtohighvoltagemustbecontainedwithin
theenclosure.

•Ableedresistortodrainoffthesystemvoltage
whenthespraygunisnotinuse.Ametalpartof
the󰘱uidsupplyunitmustbeelectricallyconnected
tothebleedresistor.

•Asafetyinterlockthatautomaticallydischargesthe
systemvoltagewhenanyoneopenstheisolation
enclosure.

Thesystemshouldnothaveanyseverearcing
occurringwhentheisolationmechanismopens
andcloses.Severearcingwillshortenthelifeof
thesystemcomponents.

Requirements

Requirements Requirements

NOTICE

NOTICE NOTICE

Install

Install Install

Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.

•Donotinstallorservicethisequipmentunless

•Besureyourinstallationcomplieswithlocal,

Fig.19showsatypicalelectrostaticairspraysystem.
Itisnotanactualsystemdesign.Forassistance
indesigningasystemtosuityourparticularneeds,
contactyourGracodistributor.

Ventilate

Ventilate Ventilate

the

System

the the

System System

youaretrainedandquali󰘰ed.

state,andnationalsafetyand󰘰recodes,NFPA
33,NEC504and516,andOSHAstandard

1910.107.

the

Spray

the the

Spray Spray

Booth

Booth Booth

NOTE:

NOTE: NOTE:
voidiftheelectrostaticspraygunisconnectedtoa
non-Gracovoltageisolationsystemorifthegunis
operatedabove60kV.

Warning

Warning Warning

Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.

TheGracowarrantyandapprovalsare

Sign

Sign Sign

Providefreshairventilationtoreducetheriskof󰘰re
orexplosioncausedbythebuildupof󰘱ammableor
toxicvaporswhenspraying,󰘱ushing,orcleaning
thegun.Donotoperatethegununlessventilation
fansareoperating.

Checkandfollowalllocal,state,andnationalcodes
regardingairexhaustvelocityrequirements.

Highvelocityairexhaustwilldecreasetheoperating
ef󰘰ciencyoftheelectrostaticsystem.Theminimum
allowableairexhaustvelocityis60linearft/min(18.3
linearmeters/minute).

16 3A2496D

Air

Supply

Air Air

Supply Supply

1.SeeFig.19.Installanairline󰘰lter/water
separator(M)onthemainairsupplylineto
ensureadry,cleanairsupplytothegun.Dirtand
moisturecanruintheappearanceofyour󰘰nished
workpieceandcancausetheguntomalfunction.

2.TheWB100systemincludesableed-typeair
regulator(N)onthegunairsupplyline(P),to
controlairpressuretothegun.

Toreducetheriskofelectricshockorother
seriousinjury,youmustusethered-colored
GracoElectricallyConductiveAirHoseforthe
gunairsupply,andyoumustconnectthehose
groundwiretoatrueearthground.Donotuse
theblackorgray-coloredGracoairhoses.

3.Connectthered-coloredGracoElectrically
ConductiveAirHose(P)betweenthegunair
regulator(N)andthegun’sairinlet.Thegunair
inlet󰘰ttinghasaleft-handthread.Connectthe
airsupplyhosegroundwire(Q)toatrueearth
ground.

Line

Line Line

Installation

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 Ground

Connectthemaingroundwire(V)toatrueearth
ground.

the

Cabinet

the the

Cabinet Cabinet

3A2496D

17

Installation

Connect

Connect Connect

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:
failureoccurswherehighvoltagearcsthrough
theinnertube,voltagewillbedischargedto
groundthroughtheconductivehoselayer.When
properlyinstalled,theconductivehoselayeris
groundedthroughitsconnectiontothegrounded
enclosure.

the

Waterborne

the the

Waterborne Waterborne

Inashieldedhosesystem,ifahose

Fluid

Fluid Fluid

Hose

Hose Hose

Figure10ConnecttheFluidHose

Usingunshielded󰘱uidhosesminimizesthe
systemcapacitance,resultinginfasterresponse
timesandalargereductionintheenergystored
inthesystem,ascomparedtoshieldedhoses.
However,withoutthegroundshield,aweak
staticchargecanoccasionallybuilduponthe
outersurfaceofthehose.Tominimizeany
staticchargefeltonthehosesurface,bundle
theairand󰘱uidhosetogether,andwrapwitha
protectivecover,asshown.

Figure11BundlingtheAirandFluidHoses

18 3A2496D

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.

Installation

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).

Figure12ShieldedHose24M732Dimensions
atGun

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).

3A2496D 19

Installation

8.Connecttheotherendofthehosetotheisolated
󰘱uidsupplyasfollows:

Graco WB100 Enclosure:

a.

thestrainrelief󰘰tting(W).Ensureconductive
layer(C)haspassedthrough󰘰tting.Tighten
to55in-lb(6.2N•m).Pullbackonhose
tocheckitissecure.Complywiththe
requirementsintheWarning Warning

For

Shielded

For For

Shielded Shielded

Conductivehoselayer(C)mustbe
groundedthroughitsconnectiontothe
isolationsystem’sgroundedenclosure(L)
orgroundedfence.Tomaintaingrounding
continuity,theconductivehoselayer(C)
mustbeengagedintheferrulewhenthe
strainreliefnutistightened.Failureto
properlyinstallthehoseinthestrainrelief
couldresultinanelectricshock.

Warning

Hose

Systems:

Hose Hose

Systems: Systems:

Slidehosethrough

below.

Figure15ShieldedHose24M732
ConnectionatWB100Enclosure

Figure14ShieldedHose24M732
DimensionsatWB100Enclosure

Figure16UnshieldedHose24M733
DimensionsatWB100Enclosure

Figure17UnshieldedHose24M733
ConnectionatWB100Enclosure

20 3A2496D

b.

Non-Graco Isolated Enclosure:

hoseasinstructedintheisolationsystem
manual,andcomplywiththerequirements

Warning

intheWarning Warning

For

Shielded

For For

Shielded Shielded

Conductivehoselayer(C)mustbe
groundedthroughitsconnectiontothe
isolationsystem’sgroundedenclosure(L)
orgroundedfence.Tomaintaingrounding
continuity,theconductivehoselayer(C)
mustbeengagedintheferrulewhenthe
strainreliefnutistightened.Failureto
properlyinstallthehoseinthestrainrelief
couldresultinanelectricshock.

below.

Hose

Systems:

Hose Hose

Systems: Systems:

Installation

Connect

Figure18ShieldedFluidHoseConnection
atNon-GracoIsolationEnclosure

c.Connecttheendofthetube(T)tothepump

󰘱uidoutlet󰘰tting(Z).

NOTE:

NOTE: NOTE:
voidiftheelectrostaticspraygunisconnected
toanon-Gracovoltageisolationsystemorifthe
gunisoperatedabove60kV.

TheGracowarrantyandapprovalsare

3A2496D

21

Installation

Figure19TypicalInstallation,ProXpWB100
WaterborneSystem

22

3A2496D

Installation

Typical

Typical Typical

Installation

Installation Installation

Item

Item Item

A

B*Bleed-TypeAirShutoff

C

DPumpAirPressure

EkVMeter

FPump

GPumpSuctionHose

H

J*

K*EnclosureSafety

LIsolatedEnclosure

M

N

P*GracoRedGrounded

Q*GunAirHoseGround

Key

Key Key

Description

Description Description

MainAirSupplyLine

Valve

PumpAirPressure
Gauge

Regulator

PaintContainer

BleedResistor

Interlock

GunAirLineFilter

GunAirPressure
Regulator

AirHose(left-hand
threads)

Wire

Item

Item Item

S

T

U

V*MainGroundWire

W

X

Y

Z

AAIsolatedEnclosureDoor

BBEnclosureT-Handle

CC

*Theseitemsarerequiredforsafeoperation.They
areincludedwiththeWB100system.

Description

Description Description

Waterborne
ElectrostaticAirSpray
Gun

GroundingRod

GroundTerminal

StrainReliefFitting

PumpAirSupplyLine

GroundingCylinder

PumpFluidOutlet
Fitting

(notshown,toillustrate
internalcomponents.
Doormustbeclosed
andlockedtooperate
system).

LockingScrew(partof
doorassembly)

AccessoryBleed-Type
AirShutoffValve

R

GracoWaterborneFluid
Hose

3A2496D 23

Installation

Agitator

Agitator Agitator

ToaddanagitatortotheGracoisolationsystem,order
PartNo.245895.See245895AgitatorKit,page94,
forthekitpartslist.

1.Dischargethesystemvoltage(seeFluidVoltage

DischargeandGroundingProcedure,page30).

2.Relievethepressure(see

PressureReliefProcedure,page31).

3.Opentheisolatedenclosuredoor.

4.Removethebackofthecontrolbox(258).

5.Removetube(A2)fromelbow(282)attheair
manifold;seeTubingandWiring,page77.
InstalltheY󰘰tting(402)intotheelbow.Install
tubes(A2)and(407)intotheY󰘰tting.Routethe
agitatortube(407)intothecabinet.

6.Replacethebackofthecontrolbox(258).

7.Assembletheotherpartsofthekitasshown.
Securetheagitatorwiththesetscrew(408).

8.Returnthesystemtoservice.

Kit

Accessory

Kit Kit

Accessory Accessory

Figure20245895AgitatorKit

24

3A2496D

Installation

Fluid

Fluid Fluid

Toadda󰘱uidregulatortotheGracoisolation
system,orderPartNo.245944.See

245944FluidRegulatorKit,page95forthe

kitpartslist.

1.Dischargethesystemvoltage(seeFluidVoltage

2.Relievethepressure(see

3.Opentheisolatedenclosuredoor.

4.Removethe1/4in.(6mm)ODtube(A1)fromthe

5.Removethewaterborne󰘱uidhosefromthepump

6.Unscrewthetwopumpmountingscrews(S)and

7.Removethebackofthecontrolbox(258).

8.Removetube(A2)fromelbow(282)attheair

Regulator

Regulator Regulator

DischargeandGroundingProcedure,page30).

PressureReliefProcedure,page31).

pumpairinlet;seeTubingandWiring,page77.

󰘱uidoutlet󰘰tting(231)andremovethe󰘰tting.

removethepumpfromtheisolationenclosure.

manifold;seeTubingandWiring,page77.
InstalltheY󰘰tting(506)intheelbow.Install
tubes(A2)and(507)intotheY󰘰tting.Routethe
tube(507)intothecabinet.

Kit

Accessory

Kit Kit

Accessory Accessory

holesusedpreviously,toallowclearanceforthe
󰘱uidregulator.

12.Connecttube(A1)totheairinletof󰘱uidregulator
(504).Connecttube(507)tothepumpairinlet.

13.Connectthewaterborne󰘱uidhosetothe󰘱uid
regulatoroutlet󰘰tting(501).

14.Returnthesystemtoservice.

NOTE:

NOTE: NOTE:

217)willnowoperatetheairpiloted󰘱uidregulator

(504).Thepumpwillnowoperateattheinletair
pressure.

Thecabinetairregulatorandgauge(216,

9.Replacethebackofthecontrolbox(258).

10.Assemblethe󰘱uidregulatorkitasshown.

11.Reinstallthepumpintheisolationenclosure.
Usethetwomountingholestotheleftofthe

Figure21245944FluidRegulatorKit

3A2496D 25

GunSetup

Gun

Gun Gun

Select

Select Select

Toreducetheriskofseriousinjury,including
splashing󰘱uidintheeyesorontheskin,follow
thePressureReliefProcedure,page31,before
removingorinstallinga󰘱uidnozzleand/oraircap.

NOTE:

NOTE: NOTE:
aresuppliedwithPartNo.24N616Nozzle
and24N477AirCap.Ifyourequireadifferent
size,seeAirCapsandFluidNozzles,page85,
orconsultwithyourGracodistributor.See

AirCapandNozzleReplacement,page51.

ModelL60M19MoldReleaseGunissuppliedwith
PartNo.24N748Nozzle,24N727AirCap,anda
spraytipofchoice.Ifyourequireadifferentsize
spraytip,seeSprayTipSelectionChart(Model

L60M19MRGGunOnly),page90,orconsultwith

yourGracodistributor.SeeAirCap,SprayTip,and

NozzleReplacement(ModelL60M19),page52.

Setup

Setup Setup

Fluid

a aaFluid Fluid

StandardandSmartAirSprayGuns

Nozzle

Nozzle Nozzle

and

and and

Air

Cap

Air Air

Cap Cap

Thefollowingareminimumgroundingrequirements
forabasicelectrostaticwaterbornesystem.Your
systemmayincludeotherequipmentorobjectswhich
mustbegrounded.Checkyourlocalelectricalcode
fordetailedgroundinginstructions.Yoursystemmust
beconnectedtoatrueearthground.

Voltage Isolation System:

•
voltageisolationsystemtoatrueearthground.
SeeGroundtheCabinet,page17.

•

Electrostatic Air Spray Gun:

connectingthered-coloredGracoGrounded
AirHosetothegun,andconnectingtheair
hosegroundwiretoatrueearthground.See

CheckGunElectricalGrounding,page28.

Electricallyconnectthe

groundthegunby

Grounding

Grounding Grounding

Whenoperatingtheelectrostaticgun,any
ungroundedobjectsinthesprayarea(people,
containers,tools,etc.)canbecomeelectrically
charged.Impropergroundingcanresultinstatic
sparking,whichcancausea󰘰re,explosion,or
electricshock.Groundallequipment,personnel,
objectbeingsprayed,andconductiveobjects
inorclosetothesprayarea.Resistancemust
notexceed1megohm.Followthegrounding
instructionsbelow.

•

Graco Shielded Waterborne Fluid Hose
(24M732):

conductivelayer.Installasinstructedunder

ConnecttheWaterborneFluidHose,page18.

thehoseisgroundedthroughthe

26 3A2496D

•

Object being sprayed:

cleanandgroundedatalltimes.

•

All electrically conductive objects or devices in the
spray area:

•

Fluid and waste containers:

wastecontainersinthesprayarea.Donotusepail
linersunlesstheyareconductiveandgrounded.
When󰘱ushingthespraygun,thecontainerused
tocatchtheexcess󰘱uidmustbeelectrically
conductiveandgrounded.

mustbeproperlygrounded.

keeptheworkpiecehangers

groundall󰘱uidand

GunSetup

•

All solvent pails:

metalcontainers,whichareconductive.Donot
useplasticcontainers.Useonlynon-󰘱ammable
solvents.Donotstoremorethanthequantity
neededforoneshift.

•

All persons entering the spray area:

shoeshavingconductivesolessuchasleather,
orwearpersonalgroundingstraps.Donot
wearshoeswithnon-conductivesolessuchas
rubberorplastic.Ifglovesarenecessary,wear
theconductiveglovessuppliedwiththegun.If
non-Gracoglovesareworn,cutoff󰘰ngersorpalm
areaofglovestoensureyourhandcontactsthe
groundedgunhandle.

useonlyapproved,grounded

mustwear

•

Air compressors:

tothemanufacturer'srecommendations.

All air lines

•
groundedhoseswithamaximumof100feet(30.5
m)combinedhoselengthtoensuregrounding
continuity.

•

The 󰘱oor of the spray area:

conductiveandgrounded.Donotcoverthe󰘱oor
withcardboardoranynon-conductivematerial
whichwouldinterruptgroundingcontinuity.

groundtheequipmentaccording

mustbeproperlygrounded.Useonly

mustbeelectrically

3A2496D

27

GunSetup

Check

Check Check

MegohmmeterPartNo.241079(AA-seeFig.

21)isnotapprovedforuseinahazardousarea.
Toreducetheriskofsparking,donotusethe
megohmmetertocheckelectricalgrounding
unless:

•Thegunhasbeenremovedfromthehazardous

•Orallsprayingdevicesinthehazardousarea

Failuretofollowthiswarningcouldcause󰘰re,
explosion,andelectricshockandresultinserious
injuryandpropertydamage.

GracoPartNo.241079Megohmmeterisavailable
asanaccessorytocheckthatthegunisproperly
grounded.

Gun

Gun Gun

area;

areturnedoff,ventilationfansinthehazardous
areaareoperating,andthereareno󰘱ammable
vaporsinthearea(suchasopensolvent
containersorfumesfromspraying).

Electrical

Electrical Electrical

Grounding

Grounding Grounding

5.Makesurethered-coloredgroundedairhose
(AH)isconnectedandthehosegroundwireis
connectedtoatrueearthground.

6.Measuretheresistancebetweenthegunhandle
(BB)andatrueearthground(CC).Usean
appliedvoltageof500minimumto1000volts
maximum.Theresistanceshouldnotexceed
100ohms.SeeFig.22.

7.Iftheresistanceisgreaterthan100ohms,check
thetightnessofthegroundconnectionsandbe
suretheairhosegroundwireisconnectedtoa
trueearthground.Iftheresistanceisstilltoo
high,replacetheairhose.

1.Haveaquali󰘰edelectricianchecktheelectrical
groundingcontinuityofthespraygunandair
hose.

2.TurnOFF(O)theESOn-Offswitch.

3.Turnofftheairand󰘱uidsupplytothegun.Follow
thePressureReliefProcedure,page31.The
󰘱uidhosemustnothaveany󰘱uidinit.

4.Disconnectthe󰘱uidhose.

Figure22CheckGunElectricalGrounding

28 3A2496D

8.Usinganohmmeter(AA)measuretheresistance

betweenthecabinetgroundlug(214)andatrue
earthground(CC).Theresistancemustbeless
than100ohms.

GunSetup

Figure23CheckCabinetGrounding

Flush

Flush Flush

Theequipmentwastestedin󰘱uidatthefactory.To
avoidcontaminatingyour󰘱uid,󰘱ushtheequipment
withacompatiblesolventbeforeusingtheequipment.

Before

Before Before

Using

Using Using

Equipment

Equipment Equipment

3A2496D 29

Operation

Operation

Operation Operation

Operating

Operating Operating

Checkthefollowinglistdaily,beforestartingthe
system.



Alloperatorsareproperlytrainedtosafely
operateanelectrostaticwaterborneairspray
systemasinstructedinthismanual.



Alloperatorsaretrainedinthe

PressureReliefProcedure,page31.



Theelectrostaticsareturnedoffandsystem
voltageisdischargedaccordingtothe

FluidVoltageDischargeandGrounding
Procedure,page30,beforeanypersonen-

terstheisolationenclosure,beforecleaning,
andbeforeperforminganymaintenanceor
repair.



Thesystemisgroundedaccordingtothe
instructionsinGrounding,page26.

Checklist

Checklist Checklist

Fluid

Fluid Fluid
Grounding

Grounding Grounding

The󰘱uidsupplyischargedwithhighvoltageuntil
thevoltageisdischarged.Contactwiththecharged
componentsofthevoltageisolationsystemor
spraygunelectrodewillcauseanelectricshock.
Toavoidanelectricshock,followtheFluid Fluid
Discharge

Discharge Discharge

•wheneveryouareinstructedtodischargethe

•beforecleaning,󰘱ushing,orservicingthesystem

•beforeapproachingthefrontofthegun

•orbeforeopeningtheisolationenclosureforthe

1.TurntheESON/OFFvalveOFFandwait30

voltage

equipment

isolated󰘱uidsupply.

seconds.

Voltage

Voltage Voltage

and

and and

Discharge

Discharge Discharge

Procedure

Procedure Procedure

Grounding

Grounding Grounding

Procedure:

Procedure: Procedure:

and

and and

Fluid

Voltage

Voltage Voltage



TheGracowaterborne󰘱uidhoseisingood
conditionwithnocutsorabrasionsofthe
PTFElayer.Replacehoseifdamaged.



Ventilationfansareoperatingproperly.



Alldebris,including󰘱ammable󰘱uidsand
rags,isremovedfromthesprayarea.



Fluidsusedmustmeetthefollowing
󰘱ammabilityrequirements:

FM,

FMc

•FM, FM,
Materialdoesnotsustainburningin
accordancewiththeStandardTestMethod
forSustainedBurningofLiquidMixtures,
ASTMD4206.

CE

•CE CE
Materialswhichcannotbeignited,inany
mixturewithair,byanenergysourceof
lessthan500mJ.

Approved:

FMc FMc

Approved: Approved:

EN

50059

- --EN EN

50059 50059

Compliant:

Compliant: Compliant:

2.FullyunscrewthedoorT-handlelockingscrew.
Thiswillshutofftheairtothegunandtriggerthe
groundingcylindertodischargeanyremaining
electricalcharge.

3.Usethegroundingrodtotouchthepump
andsupplypail.Ifyouseeanyarcs,see

ElectricalTroubleshooting,page48.

30 3A2496D