Graco 3A2497BPro User Manual

Instructions - Parts

WB3000 Isolation System &

Pro Xp™ 60 AA WB Gun

Air-assisted spray system for use when electrostatically spraying conductive, waterborne ﬂuids that meet at least one of the conditions for non-ﬂammability listed on page 3. For professional use only.

Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.

3000 psi ( Fluid Wor

100 psi ( Air Work

See pag and app

21 MPa, 210 bar) Maximum

king Pressure

0.7 MPa, 7 bar) Maximum

ing Pressure

e 3 for model part numbers

roval information.

3A2497B

PROVEN QUALITY. LEADING TECHNOLOGY.

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

Warnings ........................................................... 4

Gun Overview .................................................... 7

How the Elect

Spraying Wat

Controls, I

Smart Guns ................................................. 9

Installation.......................................................... 15

System Requirements .................................. 15

Warning Sign............................................... 15

Install the System......................................... 15

Ventilate the Spray Booth ............................. 15

Air Supply Line ............................................ 16

Ground the Cabinet...................................... 16

Connect the Waterborne Fluid Hose.............. 17

Agitator Kit Accessory .................................. 20

Gun Setup

Operation........................................................... 25

Maint

Electrical Tests................................................... 36

ubleshooting.................................................. 40

Tro

.......................................................... 21

Groundi Check Gu Flush Be

Operating Checklist...................................... 25

Fluid Voltage Discharge and Grounding

Pressure Relief Procedure............................ 26

Fill the Fluid Supply...................................... 27

Adjust the Spray Pattern............................... 28

Shutdown.................................................... 30

enance ...................................................... 31

ing ...................................................... 31

Flush

the Gun Daily..................................... 33

Clean

System Care ....................................... 35

Daily

Test Gun Resistance.................................... 36

Test Power Supply Resistance ..................... 37

Test Gun Barrel Resistance.......................... 38

Test Ground Strip Resistance....................... 39

Test Cylinder Resistance.............................. 39

tage Loss Troubleshooting....................... 40

Vol

ay Pattern Troubleshooting...................... 43

Spr

Operation Troubleshooting .................... 44

Gun

ectrical Troubleshooting ............................ 45

rostatic AA Spray Gun

Works ............................................ 7

erborne Fluids

Electrosta

ndicators, and Components........... 8

ng ................................................... 21

n Electrical Grounding ................... 23

fore Using Equipment...................... 24

Procedure...................................... 25

tically .............................. 7

Repair................................................................ 47

Prepare the Gu Air Cap, Spray

Electrode Re Gun Barrel Re Gun Barrel In Fluid Needl Power Suppl

Alternator Fan Air Adj Atomizing

ES On-Off V Air Valve R Smart Mod Air Swive

Parts.................................................................. 60

Standard Air-Assisted Spray Gun

Smart Air-Assisted Spray Gun

Isolation Enclosure....................................... 64

Alternator Assembly ..................................... 67

ES On-Off Valve Assembly........................... 68

Fan Air Valve Assembly ............................... 69

Air Cap Assembly ........................................ 70

Smart Module Assembly............................... 70

Spray Tip Selection Chart.................................... 71

AEM Fine Finish Spray Tips..........................71

AEF Fine Finish Pre-Oriﬁce Spray

r Kits, Related Manuals, and

Repai

Acce

ccessories.......................................... 73

Gun A

ator Accessories................................... 73

Oper

em Accessories..................................... 73

Syst

s ......................................................... 74

Hose

t Equipment ........................................... 74

Tes

895 Agitator Kit ...................................... 75

245

Dimensions ........................................................ 76

Technical Data ...................................................77

aco Pro Xp Warranty ....................................... 78

n for Service ......................... 47

Tip, and Fluid Seat Housing

Replacement

placement ................................ 49

moval..................................... 50

stallation.................................. 50

e Replacement............................ 51

y Removal and

Replacemen

Removal and Replacement ........... 53

ustment Valve Repair .................. 55

Air Adjustment Valve

Repair............................................ 55

alve Repair ............................... 56

epair........................................... 57

ule Replacement.......................... 58

l and Exhaust Valve

Replacem

Assembly....................................... 60

Assembly....................................... 62

Tips ............................................... 72

ssories .......................................... 73

.................................. 48

t.................................. 52

ent.................................. 59

3A2497B

Models

Models which are FM Approved and Compliant with EN50059

FM approved for use with ﬂuids that meet the following condition:

• Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206.

Models

0.35 J, with

24M508 Hose

FM12ATEX0080

EN 50059

Ta 0°C – 50°C

Part No. Model Description

24N551 WB3000 Waterborne Isolation Enclosure 24N550 with standard

24P632 WB3000 Waterborne Isolation Enclosure 24N550 with smart electrostatic

24N550 WB3000

H60T18 ProXp60AAWB

H60M18 ProXp60AAWB

24M508

• Materials which cannot be ignited, in any mixture with air, by an energy source

-——

Models Compliant with EN 50059 when used

with ﬂuids that meet the following criteria:

of less than 500 mJ.

electrostatic air-assisted spray gun H60T18, grounded air hose 235070, and unshielded waterborne ﬂuid hose 24M508.

air-assisted spray gun H60M18, grounded air hose 235070, and unshielded waterborne ﬂuid hose 24M508.

Waterborne Isolation Enclosure for unshielded hoses. Does not include hoses and gun.

Standard Electrostatic Air-assisted Spray Gun, for waterborne coatings.

Smart Electrostatic Air-assisted Spray Gun, for waterborne coatings.

Unshielded Waterborne Fluid Hose Assembly, 25 ft (7.6 m).

3A2497B 3

Warnings

The following exclamation p risks. When th Warnings. Pr the body of th

warnings are for the setup, use, grounding, maintenance and repair of this equipment. The oint symbol alerts you to a general warning and the hazard symbol refers to procedure-speciﬁc

ese symbols appear in the body of this manual or on warning labels, refer backtothese

oduct-speciﬁc hazard symbols and warnings not covered in this section may appear throughout

is manual where applicable.

WARNING

ELECTRIC S

Improper grounding, setup, or usage of an isolated waterborne system can result in electric shock. To help prevent electric shock:

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

• Connect the electrostatic gun to a voltage isolation system that will discharge the system voltage when not in use.

•Allcompo within a voltage

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

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

•Donott during

• Interlock the gun air supply with the voltage isolation system to shut off the air supply anytime the isolation system enclosure is opened.

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

• Do not betw

HOCK HAZARD

nents of the isolation system that are charged to high voltage must be contained

n isolation enclosure that prevents personnel from making contact with thehigh

components before the system voltage is discharged.

ouch the gun nozzle or electrode, or come within 4 in. (102 mm) of the electrode

gun operation. Follow the Fluid Voltage Discharge and Grounding Procedure.

splice hoses together. Install only one continuous Graco waterborne ﬂuid hose

een the isolated ﬂuid supply and the spray gun.

3A2497B

WARNING

FIRE AND EXPLOSION HAZARD

Warnings

Combustible d

• Fluids used must meet the following ﬂammability requirements:

• FM, FMc Appro

• CE-EN 50059 Compliant:

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Check gun r

• Use and clean equipment only in well ventilated area.

• Interlock the gun air supply to prevent operation unless ventilating fansareon.

•Onlyusen

• Always turn the electrostatics off when ﬂushing, cleaning or servicing equipment.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Do not pl

• Keep spray area free of debris, including solvent, rags and gasoline.

• Keep a working ﬁre extinguisher in the work area.

SKIN IN

ressure ﬂuid from gun, hose leaks, or ruptured components will pierce skin.Thismay

High-p

ke just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

look li

ent.

treatm

ust in work area canigniteorexplode. Tohelppreventﬁreandexplosion:

ved: Material doe Sustained Bu

Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500mJ.

on-ﬂammable solvents when ﬂushing or cleaning equipment.

ug or unplug power cords or turn lights on or off when ﬂammable fumes are present.

JECTION HAZARD

s not sustain burning in accordance with the Standard Test Method for

rning of Liquid Mixtures, ASTM D4206.

esistance, hose resistance, and electrical grounding daily.

• Do not spray without tip guard and trigger guard installed.

• Engag

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

•Dono

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking,

• Tighten all ﬂuid connections before operating the equipment.

• Chec

PLASTIC PARTS CLEANING SOLVENT HAZARD Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.

•Us

•SeeTechnical Data in this and all other equipment instruction manuals. Read ﬂuid and

e trigger lock when not spraying.

t stop or deﬂect leaks with your hand, body, glove, or rag.

or servicing equipment.

k hoses and couplings daily. Replace worn or damaged parts immediately.

e only compatible water-based solvents to clean plastic structural or pressure-containing

rts.

solvent manufacturer’s MSDSs and recommendations.

3A2497B 5

Warnings

WARNING

TOXIC FLUID OR FUMES Toxic ﬂuids or fumes can cause serious injury or death if splashed in the eyesoronskin, inhaled, or swallowed.

•ReadMSDSsto

• Store hazardous ﬂuid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the ﬂuid and solvent manufacturer.

EQUIPMEN Misuse ca

• Do not operate the unit when fatigued or under the inﬂuence of drugs or alcohol.

• Do not ex system c

• Use ﬂuids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read ﬂuid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

•Turnof

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modiﬁcations may void agency approvals and create safety hazards.

•Makes

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from trafﬁc areas, sharp edges, moving parts, and hot surfaces.

•Dono

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

T MISUSE HAZARD

n cause death or serious injury.

ceed the maximum working pressure or temperature rating of the lowest rated

omponent. See Technical Data in all equipment manuals.

f all equipment and follow the Pressure Relief Procedure when equipment is not in use.

ure all equipment is rated and approved for the environment in which you are using it.

t kink or over bend hoses or use hoses to pull equipment.

know the speciﬁc hazards of the ﬂuids you are using.

6 3A2497B

Gun Overview

How the Electr

ostatic AA Spray Gun

Works

This is not an air spray gun. To help prevent serious injury from pressurized ﬂuid, such as skin injection, and splashing ﬂuid, read and follow the Skin Injection Hazard Warnings on page 5.

The air-assisted spray gun combines airless and air spraying concepts. The spray tip atomizes and shapes the ﬂuid into a fan pattern, as does a conventional airless spray tip. Air from the air cap further atomizes the ﬂuid and completes the atomization of the ﬂuid tails to produce a uniform pattern.

As the gun is triggered, part of the regulated air operates the alternator turbine and the rest of the air helps atomize the ﬂuid being sprayed. The alternator generates power, which is converted by the power cartridge to supply high voltage to the gun’s electrode.

The gun’s internal power supply provides high voltage. The ﬂuid is electrostatically charged as it passes the electrode. The charged ﬂuid is attracted to the grounded workpiece, wrapping around and evenly coating all surfaces.

The regulated air that is directed to the air cap can be further controlled using the gun’s atomizing air adjustment valve. This valve can be used to restrict air ﬂow to the air cap while maintaining sufﬁcient air ﬂow to the alternator. The atomizing air adjustment valve does not control pattern width. To change pattern width, use a new tip size, or use the fan adjustment to narrow the pattern width.

The high working ﬂuid pressure of this gun provides the power needed to atomize higher solids materials.

Spraying Wate

rborne Fluids

Electrostatically

This electro to spray onl following ﬂ

• FM, FMc Approved: Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206.

• CE-EN 50059 Compliant: Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500mJ.

When connected to a voltage isolation system, all of the ﬂuid in the spray gun, ﬂuid hose, and isolated 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 under

Models, page 3 ) can be sprayed with the system or

be used to clean, ﬂush, or purge the system.

Precau waterb hazard ﬂuid to capac the en energ the gu the el The a

gy depends on the system design. Follow the

ener

d Voltage Discharge and Grounding Procedure,

Flui page

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

static air-assisted spray gun is designed

y waterborne ﬂuids which meet the

ammability requirements:

tions must be taken when using electrostatic orne equipment to avoid potential shock s. When the spray gun charges the isolated

high voltage, it is similar to charging a

itor or a battery. The system will store some of

ergy while spraying and retain some of that

y after the spray gun is shut off. Do not touch

n nozzle or come within 4 in. (102 mm) of

ectrode until the stored energy is discharged.

mount of time it takes to discharge the

25 before approaching the front of the gun.

NOTE: For airless atomization, if desired, turn the gun’s atomizing air adjustment valve completely off. Closing this valve does not affect alternator operation.

3A2497B

Gun Overview

Controls, Ind

The electrostatic gun includes the following controls, indicators, and components (see Fig.

1). For information on Smart guns, also see

Smart Guns, page 9 .

Item Description Purpose

B Fluid Hose

EElectrode

Air Swivel Inlet

Turbine Air Exhaust

Air Cap/Tip Guard and Spray Tip

icators, and Components

1/4 npsm(m) left-hand thread, for Graco red-colored grounded air supply hose.

Graco wate hose

Barbed ﬁtting, for supplied exhaust tube.

See Spray Tip Selection

Chart, page 71, for avail-

able sizes.

Suppli charge

rborne ﬂuid

es electrostatic

to the ﬂuid.

Item Description Purpose

FFanAir

Adjustment Valve

Atomizing Air Adjustment Valve

Trigger Saf Lock

ES On-Off Valve

ES Indicator (standard gun only; for Smart gun indicator, see

Operating Mode, page

9 )

Adjusts fan si Canbeusedto pattern widt

Adjusts atomizing air ﬂow.

Locks trigger to prevent

ety

gun from spraying.

Turns electrostatics ON (I) or OFF (O).

Lit when ES is ON (I). Color indicates alternator frequency. See the LED indicator table on page 30.

ze and shape.

decrease

Figure 1 Gun Overview

8 3A2497B

Smart Guns

Gun Overview

The Smart Gun module displays spraying voltage, current, alternator speed, and the voltage setting (low or high). It also allows the user to change to a lower spraying voltage. The module has two modes:

• Operating Mo

• Diagnostic M

Operating M

ode

Bar Graph

See Fig. 2, Mode displ display u kiloVolt (uA). The value.

If the uA bar graph LEDs are blue, the gun is ready to spray. If the LEDs are yellow or red, the current is too high. See Electrical Troubleshooting, page 45.

and Table 1 on page 11. The Operating

ays gun data during normal spraying. The

ses a bar graph to show the voltage level in

s (kV) and the current level in microAmperes

bar graph range is from 0 to 100% for each

Hz Indicator

Voltage Adjustment Switch

The voltage adjustment switch (VA) allows the operator to change from low to high voltage.

• The high volt maximum volt

•Thelowvolt when the swi voltage set

Adjusting t

NOTE: If the Error display appears, the Smart module has lost communication with the power supply. See

Error Display, page 10 for further information.

age setting is determined by the

age of the gun and is not adjustable.

age indicator (LO) lights

tch is set to LO. The low

ting is user adjustable. See

he Low Voltage Setting, page 10.

The Hz indicator functions the same as the ES indicator on standard guns. The indicator lights to show the alternator speed status, and has three colors:

• Green indicates the alternator speed is correct.

• If the indicator changes to amber after 1 second, increase the air pressure.

• If the indicator changes to red after 1 second, reduce the air pressure.

Figure2 SmartGunModuleinOperatingMode

3A2497B 9

Gun Overview

Error Display

If the Smart module loses communication with the power supply, the Error display appears, the Hz indicator turns red, and the Smart module is disabled. See Fig. 3, and Table 1 on page 11. This can occur in Operating Mode or Diagnostic Mode. See Electrical Troubleshooting, page 45. Communication must be restored to make the Smart module functional.

NOTE: It tak appear. If t seconds bef condition h

NOTE: If there is no power to the gun, the Error display will not appear.

es 8 seconds for the Error display to

he gun has been disassembled, wait 8

ore spraying to ensure that an Error

as not occurred.

NOTE: After 2 seconds of inactivity the display will return to the Operating Screen.

NOTE: The low v

Lock Symbol, p

Figure 4 Low Voltage Setting Screen (Unlocked)

oltage setting may be locked. See

age 10.

Lock Symbol

The low voltage setting may be locked. When locked, an image (LK) appears on the screen. See Fig. 5, and Table 1 on page 11.

e3 ErrorDisplay

Figur

sting the Low Voltage Setting

Adju

ow voltage setting is user adjustable. To access

The l

ow voltage setting screen when in Operating

the l

, press the LO SET button (LS) momentarily.

Mode

screen will display the current low voltage

The

ting. SeeFig. 4,andTable1onpage11. The

set

ge is 30–60 kV.

ran

Set the Voltage Adjustment switch (VA) to LO. Press the LO SET button repeatedly to increase the setting in increments of 5. When the display reaches the maximum setting (60 kV) it will return to the minimum setting (30 kV). Continue pressing the button until you reach the desired setting.

• When in HI mode, the low voltage setting is always locked. The lock symbol will appear when the LO SET button is pressed.

• When in LO mode, the lock symbol will only appear if the lock is enabled. See

Low Voltage Lock Screen, page 14,tolockor

unlock the low voltage setting.

Figure 5 Low Voltage Setting Screen (Locked)

10 3A2497B

Table 1 . Key for Figs. 2–9.

Item Description Purpose

Gun Overview

LS LO SET bu

Voltage Adjustment Switch

Low Voltage Mode Indicator

Voltage (kV) Display

Current (uA) Display

tton

Two-position gun voltage to high setting ( functional i in Diagnosti

Lights (blue) when the smart gun is set to Low Voltage.

Displays ac of the gun, i Mode, disp In Diagnos displayed

Displays actual spraying current of the gun, in uA. In Operating Mode, display is a bar graph. In Diagnostic Mode, current is displayed as a number.

Press momentarily to enter the Low Voltage Setting screen.

Press an seconds Mode.

switch sets smart

low setting (LO) or

HI). This switch is

n Operating Mode and

c Mode.

tual spraying voltage

n kV. In Operating

lay is a bar graph.

tic Mode, voltage is

as a number.

d hold for approximately 5

to enter or exit Diagnostic

LV Low V

LK Low Voltage Locked

LD Lo D

ER Error Display

VI Vo

oltage Display

isplay

ltage Indicator

While in Diagnostic Mode, press momentarily to advance through screens.

While on the Low Voltage Lock Screen (in Diagnostic Mode), press and hold to turn the lock on or off.

lays the low voltage setting

Disp

umber. The setting can be

as a n

ged. See Fig. 4.

chan

Appears if the low voltage setting is locked. See Fig. 5 and Fig. 9.

ears on the Low Voltage Lock

App

een. See Fig. 9.

Scr

Appears if the Smart module loses communication with the power supply. See Fig. 3.

Diagnostic Mode, the two top

ight LEDs of the screen light,

ndicating that the value displayed

sinkV.SeeFig. 6.

3A2497B

Gun Overview

Item Description Purpose

CI Current Indicator

AS Alternator S

Alternator Speed Indicator In Operating Mode, indicator color

peed Display

In Diagnostic Mode, the two bottom right LEDs of the screen light, indicating that the value displayedisinuA.SeeFig. 7.

In Diagnostic Mode, Hz level is displayed as a number. See Fig.

varies to show the alternator speed status:

• green indicates the alternator speed is at the correct level.

• If the indicator changes to amber after 1 second, the alternator speed is too low.

• If the indicator changes to red after 1 second, the alternator speed is too high. The indicator will also turn red if the Error display appears.

In Diagn is green Speed (H

ostic Mode, the indicator

when in the Alternator

ertz) screen.

3A2497B

Diagnostic Mode

Diagnostic Mode includes four screens which display gun data:

Gun Overview

• Voltage (kilo

• Current (mic

• Alternator S

• Low Voltage L

NOTE: You must be in Operating Mode to adjust the low voltage setting; the setting is not adjustable in Diagnostic Mode. However, the voltage adjustment switch (VA) can be set to HI or LO in Operating Mode and Diagnostic Mode.

To enter Diagnostic Mode, press and hold the LO SET (LS) button for approximately 5 seconds. The display will go to the Voltage (kiloVolts) Screen, page 13.

To advanc button ag

To exit Diagnostic Mode, press and hold the LO SET button for approximately 5 seconds. The screen will return to Operating Mode.

NOTE: If the gun is detriggered while in Diagnostic Mode,thelastscreenviewedwillbedisplayedwhen the gun is retriggered.

NOTE: D from th

Low Vol

Volta

e Low Voltage Lock Screen. See

ge (kiloVolts) Screen

Volts) Screen

roAmperes) Screen

peed (Hertz) Screen

ock Screen

e to the next screen, press the LO SET

ain.

iagnostic Mode cannot be exited

tage Lock Screen, page 14 for details.

Figure 6 Voltage (kiloVolts) Screen

Current (microAmperes) Screen

The Current (microAmperes) Screen is the second screen in the Diagnostic Mode. See Fig. 7, and Table 1 on page 11. To enter this screen, press the LO SET button while in the Voltage (kiloVolts) Screen.

This screen displays the spraying current of the gun as a number (uA), rounded to the nearest 5 uA. The two bottom right LEDs (CI) of the display panel light, indicating that the Current (microAmperes) Screen is displayed. The display is a readout and cannot be changed.

Press the LO SET button to advance to the

Alternator Speed (Hertz) Screen, page 14.Press

and hold for approximately 5 seconds to return to Operating Mode.

The Vo appea and T and h seco

This screen displays the spraying voltage of the gun as a number (kV), rounded to the nearest 5 kV. The two top right LEDs (VI) of the display panel light, indicating that the Voltage (kiloVolts) Screen is displayed. The display is a readout and cannot be changed.

Press the LO SET button to advance to the

Current (microAmperes) Screen, page 13.Press

and hold for approximately 5 seconds to return to Operating Mode.

ltage (kiloVolts) Screen is the ﬁrst screen to

r after entering Diagnostic Mode. See Fig. 6, able 1 on page 11. To enter this screen, press old the LO SET button for approximately 5

nds while in the Operating Mode.

Figure 7 Current (microAmperes) Screen

3A2497B 13

Gun Overview

Alternator Speed (Hertz) Screen

The Alternator Speed (Hertz) Screen is the third screen in the Diagnostic Mode. See Fig. 8, and Table 1 on page 11. To enter this screen, press the LO SET button while in the Current (microAmperes) Screen.

This screen d digit number display is a r alternator s will show 99

The Hz indicator lights green to show that you are viewing the Alternator Speed (Hertz) Screen.

Press the LO SET button to advance to the

Low Voltage Lock Screen, page 14. Press and hold

for approximately 5 seconds to return to Operating Mode.

isplays the alternator speed as a 3

(AS), rounded to the nearest 5 Hz. The

eadout and cannot be changed. If the

peed is greater than 999 Hz, the display

Low Voltage Lock Screen

The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode. See Fig. 9, and Table 1 on page 11. To enter this screen, press the LO SET button while in the Alternator Speed (Hertz) Screen.

This screen d Lock. If the s appears to th is unlocked,

To change the lock status, press and hold the LO SET button until the lock image appears or disappears. If the lock is set, the image will also appear on the Low Voltage Setting Screen when in low voltage mode (see Fig. 4).

NOTE: Diagnostic Mode cannot be exited from this screen, because pressing and holding the LO SET button is used to turn the lock on or off. To exit, press LO SET momentarily to return to the Voltage (kiloVolts) Screen, then exit Diagnostic Mode from there.

isplays the status of the Low Voltage etting is locked, the lock image (LK)

e left of the Lo display (LD). If the setting

the lock image does not appear.

Figure 8 Alternator Speed (Hertz) Screen

Figure 9 Low Voltage Lock Screen

3A2497B

Installation

System Requirements

AGracovolta following fe

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

• A bleed resistor to drain off the system voltage when the spray gun is not in use. A metal part of the ﬂuid supply unit must be electrically connected to the bleed resistor.

• A safety interlock that automatically discharges the system voltage when anyone opens the isolation enclosure.

ge isolation system must have the

atures:

NOTICE

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.

NOTE: The Graco warranty and approvals are void if the electrostatic spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.

Install the System

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 local, state, and national codes for the installation of electrical apparatus in a Class I, Div. I Hazardous Location or Group II, Zone I Explosive Atmosphere Location.

• Comply with all applicable local, state, and national ﬁre, electrical, and other safety regulations.

Fig. 12 shows a typical electrostatic air-assisted spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.

Ventilate the Spray Booth

Warning Sign

Mount warning signs in the spray area where they can easily be seen and read by all operators. An English Warning Sign is provided with the gun.

3A2497B 15

Provide fresh air ventilation to reduce the risk of ﬁre or explosion caused by the buildup of ﬂammable or toxic vapors when spraying, ﬂushing, or cleaning the gun. Do not operate the gun unless ventilation fans are operating.

Check and follow all local, state, and national codes regarding air exhaust velocity requirements.

h velocity air exhaust will decrease the operating

Hig

ﬁciency of the electrostatic system. The minimum

lowable air exhaust velocity is 60 linear ft/min (18.3

near meters/minute).

Installation

Air Supply Lin

1. See Fig. 12. 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. The WB3000 system includes a bleed-type air regulator (N) on the gun air supply line (P), to control air pressure to the gun.

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

3. Connect the red-colored Graco Electrically Conductive Air 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 airsupplyhosegroundwire(Q)toatrueearth ground.

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. Do not operate the equipment without the bleed-type air valve (B) installed.

4. The WB3000 system includes a bleed-type air valve (B). The bleed-type air valve is required to shut off all air to the system and relieve air trapped between the valve and the ﬂuid supply unit after the air regulator is shut off. Connect the main air supply line (A) to the bleed valve.

5. Install an additional bleed-type air valve (CC) upstream of the air ﬁlter (M) to isolate the ﬁlter for servicing.

Ground the Cabinet

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

16 3A2497B

Installation

Connect the Wa

Always use a Graco waterborne ﬂuid hose between the voltage isolation system ﬂuid outlet and the gun ﬂuid inlet.

Before connecting the waterborne ﬂuid hose to the gun, blow it out with air and ﬂush with water to remove contaminants. Flush the gun before using it.

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.

1. Remove the gun air inlet ﬁtting (21).

terborne Fluid Hose

2. Make sure the barrel ﬂuid inlet is clean and dry.

Apply dielectric grease to the threads of the barrel connector (101a) and screw it into the ﬂuid inlet.

3. Apply dielectric grease to the threads of the

hose (101) and screw it into the barrel connector (101a).

4. Align the bracket (B) holes with the air inlet and

exhaust outlet. Secure with the air inlet ﬁtting (21).

5. Press the exhaust tube (35) onto the exhaust

valve. Secure with the clamp (36).

6. Slide the other end of the hose through the hole

in the side of the isolated enclosure. Connect the swivel (Z) to the ﬂuid outlet of the pump. Secure thehosetothesideoftheenclosurewiththe bracket (W).

NOTE: The Graco warranty and approvals are void if the electrostatic spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.

Figure 10 Connect the Fluid Hose

3A2497B

Figure 11 Unshielded Hose 24M508 Connection at WB3000 Enclosure

Installation

Figure 12 Typical Installation, Pro Xp Waterborne System

18 3A2497B

Typical Installation Key

Installation

Item Description

B* Bleed-Type Ai

D Pump Air Pressure

E kV Meter

FPump

GPumpSuct

K* Enclos

L Isolated Enclosure

P* Graco Red Grounded

Q* Gun

Main Air Supply Line

r Shutoff

Valve

Pump Air Pressure Gauge

Regulator

ion Hose

Paint Container

Bleed Re

Interl

Gun Ai

Gun Air Pressure Regulator

Air Hose (left-hand threads)

Wir

Graco Waterborne Fluid Hose

sistor

ure Safety

ock

r Line Filter

Air Hose Ground

Item Description

V* Main Ground

AA Isolat

BB Enclosure T-Handle

* These items are required for safe operation. They are included with the WB3000 system.

Waterborne Electrostati Air-Assisted Gun

Grounding Rod

Ground Terminal

Strain Relief Fitting

Pump Air Supply Line

Groundin

Pump Fluid Outlet Fitting

(not sh intern Door mu and loc syste

Locking Screw (part of door assembly)

Accessory Bleed-Type Air Shutoff Valve

Spray

Wire

g Cylinder

ed Enclosure Door

own, to illustrate

al components.

st be closed

ked to operate

m).

3A2497B 19

Installation

Agitator Kit Accessory

To add an agita Part No. 24589 for the kit par

1. Discharge the system voltage (see Fluid Voltage

Discharge and Grounding Procedure, page 25).

2. Relieve the pressure (see

Pressure Relief Procedure, page 26).

3. Open the isolated enclosure door.

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

5. Remove tube (A2) from elbow (282) at the air manifold; see . Install the Y ﬁtting (402) into the elbow. Install tubes (A2) and (407) into the Y ﬁtting. Route the agitator tube (407) into the cabinet.

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

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

8. Return the system to service.

tor to the Graco isolation system, order

5. See 245895 Agitator Kit, page 75,

ts list.

Figure 13 245895 Agitator Kit

20 3A2497B

Gun Setup

Grounding

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. Ground all equipment, personnel, object being sprayed, and conductive objects in or close to the spray area. Resistance must not exceed 100 ohms. 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 must be connected to a true earth ground.

•

Voltage Isolation System:

voltage isolation system to a true earth ground. See Ground the Cabinet, page 16.

Electrically connect the

•

Object being s

clean and gro

•

All electr spray area

•

Fluid and waste containers:

waste containers in the spray area. Do not use pail liners unless they are conductive and grounded. When ﬂushing the spray gun, the container used to catch the excess ﬂuid must be electrically conductive and grounded.

•

Air compressors:

to the manufacturer's recommendations.

•

All air lines

grounded hoses with a maximum of 100 feet (30.5 m) combined hose length to ensure grounding continuity.

prayed:

unded at all times.

ically conductive objects or devices in the

must be properly grounded.

must be properly grounded. Use only

keep the workpiece hangers

ground all ﬂuid and

ground the equipment according

•

Electrostatic Air-Assisted Spray Gun:

the gun by connecting the red-colored Graco Grounded Air Hose to the gun, and connecting the air hose ground wire to a true earth ground. See

Check Gun Electrical Grounding, page 23.

ground

3A2497B

Gun Setup

The ﬂoor of the spray area:

•

conductive and grounded. Do not cover the ﬂoor with cardboard or any non-conductive material which would interrupt grounding continuity.

•

All solvent pails:

metal containers, which are conductive. Do not use plastic containers. Only use non-ﬂammable solvents. Do not store more than the quantity needed for one shift.

use only approved, grounded

must be electrically

•

All persons entering the spray area:

shoes having conductive soles such as leather, or wear personal grounding straps. Do not wear shoes with non-conductive soles such as rubber or plastic. If gloves are necessary, wear the conductive gloves supplied with the gun. If non-Graco gloves are worn, cut off ﬁngers or palm area of gloves to ensure your hand contacts the grounded gun handle.

must wear

3A2497B

Gun Setup

Check Gun Elec

Megohmmeter Part No. 241079 (AA-see Fig.

14) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous area;

• Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no ﬂammable vapors in the area (such as open solvent containers or fumes from spraying).

Failure to follow this warning could cause ﬁre, explosion, and electric shock and result in serious injury and property damage.

Graco Part No. 241079 Megohmmeter is available as an accessory to check that the gun is properly grounded.

trical Grounding

3. Turn off the ai the Pressure R

4. Disconnect th

5. Make sure the and the hose g earth ground

6. Measure the resistance between the gun handle (BB) and a true earth ground (CC). Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 100 ohms. See Fig. 14.

r and ﬂuid supply to the gun. Follow

elief Procedure, page 26.

eﬂuidhose.

grounded air hose is connected roundwireisconnectedtoatrue

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

2. Turn OFF (O) the ES On-Off switch.

Figure 14 Check Gun Electrical Grounding

3A2497B 23

Gun Setup

7. If the resistance is greater than 100 ohms, check the tightness of the ground connections and be suretheairhosegroundwireisconnectedtoa true earth ground. If the resistance is still too high, replace the air hose.

8. Using an ohmmeter (AA) measure the resistance between the cabinet ground lug (214) and a true earth ground (CC). The resistance must be less than 100 ohms.

e 15 Check Cabinet Grounding

Figur

Flush Before Using Equipment

quipment was tested in ﬂuid at the factory. To

The e

d contaminating your ﬂuid, ﬂush the equipment

avoi

a compatible solvent before using the equipment.

with

3A2497B

+ 54 hidden pages

Graco 3A2497BPro User Manual

Contents

Models

Warnings

Gun Overview

Smart Guns

Bar Graph

Hz Indicator

Voltage Adjustment Switch

Error Display

Lock Symbol

Table 1 . Key for Figs. 2–9.

Diagnostic Mode

Current (microAmperes) Screen

Alternator Speed (Hertz) Screen

Low Voltage Lock Screen

Installation

System Requirements

Install the System

Ventilate the Spray Booth

Warning Sign

Ground the Cabinet

Agitator Kit Accessory

Gun Setup

Grounding

Flush Before Using Equipment