Graco 3A2497H Instruction Manual

Instructions-Parts

WB3000

WB3000 WB3000 60

60 60

AA AA

Air

assisted

Air Air

- --assisted assisted

meet

meet meet For

For For

3000psi(21MPa,210bar)Maximum FluidWorkingPressure 100psi(0.7MPa,7bar)MaximumAir WorkingPressure

Seepage3formodelpartnumbersand approvalinformation.

least

at at

least least

professional

professional professional

Important

Important Important Readallwarningsandinstructionsinthismanualbeforeusingthe equipment.Save Save

Isolation

Isolation Isolation

WB WB

spray

spray spray

one

one one

Gun

Gun Gun

system

system system

of of

use

use use

Safety

Safety Safety

Save

for

for for

the

conditions

the the

conditions conditions

only.

only. only.

Instructions

Instructions Instructions

these

these these

System

System System

Pro

& &

Pro Pro

Xp™

Xp™ Xp™

3A2497H

use

when

use use

instructions.

instructions. instructions.

electrostatically

when when

electrostatically electrostatically

for

non

for for

󰘱ammability

non non

- --󰘱ammability 󰘱ammability

spraying

spraying spraying

listed

listed listed

conductive,

conductive, conductive,

page

on on

page page

3. 3.

waterborne

waterborne waterborne

󰘱uids

that

󰘱uids 󰘱uids

that that

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents

Contents Contents

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

RelatedManuals................................................3

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

GunOverview....................................................7

HowtheElectrostaticAASprayGun

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

SprayingWaterborneFluids

Electrostatically..............................7

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

SmartGuns.................................................9

Installation..........................................................14

SystemRequirements..................................14

WarningSign...............................................14

InstalltheSystem.........................................14

VentilatetheSprayBooth.............................14

AirSupplyLine............................................15

GroundtheCabinet......................................15

Grounding...................................................16

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

AgitatorKitAccessory..................................22

GunSetup..........................................................23

GunSetupProcedure...................................23

CheckGunElectricalGrounding...................26

FlushBeforeUsingEquipment......................27

Operation...........................................................28

PressureReliefProcedure............................28

OperatingChecklist......................................29

FluidVoltageDischargeandGrounding

Procedure......................................29

FilltheFluidSupply......................................30

Startup........................................................30

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

Maintenance......................................................31

DailyCareandCleaningChecklist................31

Flushing......................................................31

CleantheGunDaily.....................................33

DailySystemCare.......................................35

ElectricalTests...................................................36

TestGunResistance....................................36

TestPowerSupplyResistance.....................37

TestGunBarrelResistance..........................37

TestGroundStripResistance.......................38

TestCylinderResistance..............................38

Troubleshooting..................................................39

VoltageLossTroubleshooting.......................39

SprayPatternTroubleshooting......................41

GunOperationTroubleshooting....................42

ElectricalTroubleshooting............................43

Repair................................................................44

PreparetheGunforService.........................44

AirCap,SprayTip,andFluidSeatHousing

Replacement..................................44

ElectrodeReplacement................................45

GunBarrelRemoval.....................................46

GunBarrelInstallation..................................46

FluidNeedleReplacement............................47

PowerSupplyRemovaland

Replacement..................................48

AlternatorRemovalandReplacement...........49

FanAirAdjustmentValveRepair..................51

AtomizingAirAdjustmentValve

Repair............................................51

ESOn-OffValveRepair...............................52

AirValveRepair...........................................53

SmartModuleReplacement..........................53

AirSwivelandExhaustValve

Replacement..................................54

Parts..................................................................55

StandardAir-AssistedSprayGun

Assembly.......................................55

SmartAir-AssistedSprayGun

Assembly.......................................57

IsolationEnclosure.......................................59

TubingandWiring.......................................62

AlternatorAssembly.....................................64

ESOn-OffValveAssembly...........................65

FanAirAdjustmentValveAssembly..............66

AirCapAssembly........................................66

SmartModuleAssembly...............................67

SprayTipSelectionChart....................................68

AEMFineFinishSprayTips..........................68

AEFFineFinishPre-Ori󰘰ceSpray

Tips...............................................69

RoundSprayTips........................................69

RepairKitsandAccessories................................70

GunAccessories..........................................70

OperatorAccessories...................................71

SystemAccessories.....................................71

Signs..........................................................71

TestEquipment...........................................71

Hoses.........................................................71

245895AgitatorKit......................................72

IgnitabilityofCoatingMaterials............................73

Dimensions........................................................74

TechnicalSpeci󰘰cations......................................75

CaliforniaProposition65.....................................75

3A2497H

Models

Models Models

Models

Models Models

Part

Part Part

24N551WB3000WaterborneIsolationEnclosure24N550withstandard

24P632WB3000WaterborneIsolationEnclosure24N550withsmartelectrostatic

24N550WB3000

H60T18ProXp60AAWB

which

are

which which

are are

No.

No. No.

Approved

FM FM

Approved Approved

FM FM

• ••Material Material

Models

Models Models criteria:

criteria: criteria:

• ••Material Material

and

Compliant

and and

Compliant Compliant

approved

approved approved

Material for

Sustained

for for

Sustained Sustained

Material

For

For For

more more

Model

Model Model

for

for for

does

does does

Compliant

Compliant Compliant

classi󰘰ed

is isisclassi󰘰ed classi󰘰ed

information,

information, information,

with

EN50059

with with

EN50059 EN50059

use

with

󰘱uids

that

meet

the

use use

with with

󰘱uids 󰘱uids

that that

meet meet

not

sustain

not not

sustain sustain

Burning

Burning Burning

with

with with

Description

Description Description

electrostaticair-assistedspraygunH60T18,groundedairhose 235070,andunshieldedwaterborne󰘱uidhose24M508.

air-assistedspraygunH60M18,groundedairhose235070, andunshieldedwaterborne󰘱uidhose24M508.

WaterborneIsolationEnclosureforunshieldedhoses.Doesnot includehosesandgun.

StandardElectrostaticAir-assistedSprayGun,forwaterborne coatings.

burning

burning burning

Liquid

of ofofLiquid Liquid

50059

EN EN

50059 50059

non

as as

ignitable

non non

- --ignitable ignitable

see

Ignitability

see see

Ignitability Ignitability

accordance

in ininaccordance accordance

Mixtures,

Mixtures, Mixtures,

when

when when

following

the the

following following

ASTM

ASTM ASTM

used

with

used used

with with

de󰘰ned

as as

de󰘰ned de󰘰ned

Coating

of ofofCoating Coating

condition:

condition: condition:

with

with with

D4206.

D4206. D4206.

󰘱uids

󰘱uids 󰘱uids

by by

EN EN

Materials,

Materials, Materials,

the

Standard

the the

Standard Standard

that

meet

that that

meet meet

50059:

50059: 50059:

page

page page

Test

Method

Test Test

Method Method

the

following

the the

following following

2018.

2018. 2018.

73 73

. .

H60M18ProXp60AAWB

25R012

25R014

Related Related

Manual

Manual Manual

3A2498

307263ProbeandMeter,Instructions

309455TestFixture,HighVoltageProbe,andkVMeter,Instructions

406999

No.

No. No.

Manuals

Manuals Manuals

Description

Description Description

RoundSprayKit,Instructions

VoltageTesterConversionKit,Instructions

-------

SmartElectrostaticAir-assistedSprayGun,forwaterborne coatings.

WaterborneFluidHoseAssembly,25ft(7.6m)

WaterborneFluidHoseAssembly,50ft(15.2m)

3A2497H3

Warnings

Warnings Warnings

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

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.

EXPLOSION

AND AND

EXPLOSION EXPLOSION

FM,

FMc

•FM, FM,

MaterialdoesnotsustainburninginaccordancewiththeStandardTestMethodfor SustainedBurningofLiquidMixtures,ASTMD4206.

•CE CE

Materialisclassi󰘰edasnon-ignitableasde󰘰nedbyEN50059:2018.

operation

operation operation

Approved:

FMc FMc

Approved: Approved:

50059

- --EN EN

50059 50059

immediately

immediately immediately

HAZARD

HAZARD HAZARD

work

area

area area

canigniteorexplode.Tohelpprevent󰘰reandexplosion:

Compliant:

Compliant: Compliant:

ifstaticsparkingoccursoryoufeelashock.Donotuse

3A2497H

Warnings

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.

SKIN

SKIN SKIN High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get treatment.

treatment. treatment.

SHOCK

SHOCK SHOCK

Fluid

INJECTION

INJECTION INJECTION

HAZARD

HAZARD HAZARD

Grounding

Voltage

Voltage Voltage

HAZARD

HAZARD HAZARD

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

Get

immediate

immediate immediate

surgical

surgical surgical

•Donotspraywithouttipguardandtriggerguardinstalled.

•Engagetriggerlockwhennotspraying.

•Donotpointgunatanyoneoratanypartofthebody.

•Donotputyourhandoverthespraytip.

•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.

•FollowthePressure Pressure orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.

Pressure

Relief

Procedure

Relief Relief

Procedure Procedure

whenyoustopsprayingandbeforecleaning,checking,

3A2497H5

Warnings

WARNING

WARNING WARNING

EQUIPMENT

EQUIPMENT EQUIPMENT Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated systemcomponent.SeeTechnical Technical

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical Speci󰘰cations

Speci󰘰cations Speci󰘰cations Forcompleteinformationaboutyourmaterial,requestaSafetyDataSheet(SDS)from yourdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

PLASTIC

PLASTIC PLASTIC Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious injuryorpropertydamage.

MISUSE

MISUSE MISUSE

PARTS

PARTS PARTS

HAZARD

HAZARD HAZARD

Technical

inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.

CLEANING

CLEANING CLEANING

SOLVENT

SOLVENT SOLVENT

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

Pressure

HAZARD

HAZARD HAZARD

Relief

Relief Relief

inallequipmentmanuals.

Procedure

Procedure Procedure

whenequipmentisnotinuse.

Technical

•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing parts.

•SeeTechnical Technical

TOXIC

TOXIC TOXIC Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin, inhaled,orswallowed.

•ReadSafetyDataSheets(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable

PERSONAL

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

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent

Technical

andsolventmanufacturer’sSafetyDataSheet(SDS)andrecommendations.

FLUID

FLUID FLUID

guidelines.

manufacturer.

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

FUMES

OR OR

FUMES FUMES

PROTECTIVE

PROTECTIVE PROTECTIVE

inthisandallotherequipmentinstructionmanuals.Read󰘱uid

EQUIPMENT

EQUIPMENT EQUIPMENT

63A2497H

GunOverview

Gun

Gun Gun

How

How How Works

Works Works

Thisisnotanairspraygun.Tohelpprevent seriousinjuryfrompressurized󰘱uid,suchasskin injection,andsplashing󰘱uid,readandfollowthe Skin

Skin Skin

Theair-assistedsprayguncombinesairlessand airsprayingconcepts.Thespraytipatomizes andshapesthe󰘱uidintoafanpattern,asdoes aconventionalairlessspraytip.Airfromtheair capfurtheratomizesthe󰘱uidandcompletesthe atomizationofthe󰘱uidtailstoproduceauniform pattern.

Asthegunistriggered,partoftheregulatedair operatesthealternatorturbineandtherestofthe airhelpsatomizethe󰘱uidbeingsprayed.The alternatorgeneratespower,whichisconvertedby thepowercartridgetosupplyhighvoltagetothe gun’selectrode.

Thegun’sinternalpowersupplyprovideshigh voltage.The󰘱uidiselectrostaticallychargedasit passestheelectrode.Thecharged󰘱uidisattracted tothegroundedworkpiece,wrappingaroundand evenlycoatingallsurfaces.

Theregulatedairthatisdirectedtotheaircapcan befurthercontrolledusingthegun’satomizingair adjustmentvalve.Thisvalvecanbeusedtorestrict air󰘱owtotheaircapwhilemaintainingsuf󰘰cientair 󰘱owtothealternator.Theatomizingairadjustment valvedoesnotcontrolpatternwidth.Tochange patternwidth,useanewtipsize,orusethefan adjustmenttonarrowthepatternwidth.

Thehighworking󰘱uidpressureofthisgunprovides thepowerneededtoatomizehighersolidsmaterials.

Overview

Overview Overview

the

Electrostatic

the the

Electrostatic Electrostatic

Injection

Injection Injection

Note

Forairlessatomization,ifdesired,turn thegun’satomizingairadjustmentvalve completelyoff.Closingthisvalvedoesnot affectalternatoroperation.

Hazard

Hazard Hazard

Warnings

Warnings Warnings

AA AA

Spray

Spray Spray

onpage5.

Gun

Gun Gun

Spraying

Spraying Spraying Electrostatically

Electrostatically Electrostatically

Thiselectrostaticair-assistedspraygunisdesigned tosprayonly only following󰘱ammabilityrequirements:

FM,

FMc

•FM, FM,

FMc FMc

Materialdoesnotsustainburninginaccordance withtheStandardTestMethodforSustained BurningofLiquidMixtures,ASTMD4206.

CE-EN

•CE-EN CE-EN

•Materialisclassi󰘰edasnon-ignitableasde󰘰nedby EN50059:2018.

Formoreinformation,see

IgnitabilityofCoatingMaterials,page73.

Whenconnectedtoavoltageisolationsystem, allofthe󰘱uidinthespraygun,󰘱uidhose,and isolated󰘱uidsupplyischargedtohighvoltage, whichmeansthatthesystemhasmoreelectrical energythanasolvent-basedsystem.Therefore, onlynon-󰘱ammable󰘱uids(asde󰘰nedunder

Models,page3)canbesprayedwiththesystemor

beusedtoclean,󰘱ush,orpurgethesystem.

Precautionsmustbetakenwhenusingelectrostatic waterborneequipmenttoavoidpotentialshock hazards.Whenthespraygunchargestheisolated 󰘱uidtohighvoltage,itissimilartocharginga capacitororabattery.Thesystemwillstoresomeof theenergywhilesprayingandretainsomeofthat energyafterthespraygunisshutoff.Donottouch thegunnozzleorcomewithin4in.(102mm)of theelectrodeuntilthestoredenergyisdischarged. Theamountoftimeittakestodischargethe energydependsonthesystemdesign.Followthe

FluidVoltageDischargeandGroundingProcedure, page29beforeapproachingthefrontofthegun.

TheGracowarrantyandapprovalsarevoidifthe electrostaticspraygunisconnectedtoanon-Graco voltageisolationsystemorifthegunisoperated above60kV.

Waterborne

Waterborne Waterborne

only

waterborne󰘱uidswhichmeetthe

Approved:

Approved: Approved:

50059

50059 50059

Compliant:

Compliant: Compliant:

Fluids

Fluids Fluids

3A2497H

GunOverview

Controls,

Controls, Controls,

Theelectrostaticgunincludesthefollowing controls,indicators,andcomponents(seeFig.

1).ForinformationonSmartguns,alsosee

SmartGuns,page9.

Figure1GunOverview

Indicators,

Indicators, Indicators,

and

Components

and and

Components Components

Item

Item Item

BFluidHose

EElectrode

FFanAirAdjustment

Description

Description Description

AirSwivelInlet1/4npsm(m)left-handthread,forGracored-coloredgroundedairsupply

TurbineAirExhaust

AirCap/TipGuard andSprayTip

Valve

AtomizingAir AdjustmentValve

TriggerSafetyLockLockstriggertopreventgunfromspraying.

ESOn-OffValveTurnselectrostaticsON(I)orOFF(O).

ESIndicator(standardgunonly;for Smartgunindicator, seeOperatingMode,

page9)

Purpose

Purpose Purpose

hose.

Gracowaterborne󰘱uidhose

Barbed󰘰tting,forsuppliedexhausttube.

SeeSprayTipSelectionChart,page68,foravailablesizes.

Supplieselectrostaticchargetothe󰘱uid.

Adjustsfansizeandshape.Canbeusedtodecreasepatternwidth.

Adjustsatomizingair󰘱ow.

LitwhenESisON(I).Colorindicatesalternatorfrequency.SeetheLED indicatortableinGunSetup,page23.

83A2497H

GunOverview

Smart

Smart Smart

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

•OperatingMode

•DiagnosticMode

Operating

Operating Operating

Bar

Bar Bar

SeeFig.2andSmartGunKey,page11.The OperatingModedisplaysgundataduringnormal spraying.Thedisplayusesabargraphtoshowthe voltagelevelinkiloVolts(kV)andthecurrentlevelin microAmperes(uA).Thebargraphrangeisfrom0 to100%foreachvalue.

IftheuAbargraphLEDsareblue,thegunisready tospray.IftheLEDsareyelloworred,thecurrentis toohigh.SeeElectricalTroubleshooting,page43.

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,page10.

Adjustment

Adjustment Adjustment

Note

IftheErrordisplayappears,theSmart modulehaslostcommunicationwiththe powersupply.SeeErrorDisplay,page10for furtherinformation.

Switch

Switch Switch

Indicator

Hz Hz

Indicator Indicator

TheHzindicatorfunctionsthesameastheES indicatoronstandardguns.Theindicatorlightsto showthealternatorspeedstatus,andhasthree colors:

•Greenindicatesthealternatorspeediscorrect.

•Iftheindicatorchangestoamberafteronesecond, increasetheairpressure.

•Iftheindicatorchangestoredafteronesecond, reducetheairpressure.Decreaseairpressure untiltheindicatorisgreen.Tomaintainahigher airpressure,installESOn/OffValveRestrictorKit 26A294.Then,adjustthepressureasneededto ensurethattheindicatorremainsgreen.

Figure2SmartGunModuleinOperatingMode

3A2497H9

GunOverview

Error

Error Error

IftheSmartmodulelosescommunicationwith thepowersupply,theErrordisplayappears,the Hzindicatorturnsred,andtheSmartmoduleis disabled.SeeFig.3andSmartGunKey,page11. ThiscanoccurinOperatingModeorDiagnostic Mode.SeeElectricalTroubleshooting,page43. CommunicationmustberestoredtomaketheSmart modulefunctional.

Display

Display Display

Note

Ittakes8secondsfortheErrordisplayto appear.Ifthegunhasbeendisassembled, wait8secondsbeforesprayingtoensure thatanErrorconditionhasnotoccurred.

Note

Ifthereisnopowertothegun,theError displaywillnotappear.

Note

After2secondsofinactivitythedisplaywill returntotheOperatingScreen.

Note

Thelowvoltagesettingmaybelocked.See

LockSymbol,page10.

Figure4LowVoltageSettingScreen(Unlocked)

Lock

Symbol

Lock Lock

Symbol Symbol

Figure3ErrorDisplay

Adjusting

Adjusting Adjusting

Thelowvoltagesettingisuseradjustable.Toaccess thelowvoltagesettingscreenwheninOperating Mode,presstheLOSETbutton(LS)momentarily. Thescreenwilldisplaythecurrentlowvoltage setting.SeeFig.4andSmartGunKey,page11. Therangeis30–60kV.

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

Thelowvoltagesettingmaybelocked.Whenlocked, animage(LK)appearsonthescreen.SeeFig.5 andSmartGunKey,page11.

•WheninHImode,thelowvoltagesettingisalways always locked.ThelocksymbolwillappearwhentheLO SETbuttonispressed.

•WheninLOmode,thelocksymbolwill

only

only only

appearifthelockisenabled.See

LowVoltageLockScreen,page13,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

always

103A2497H

GunOverview

Smart

Smart Smart

Table

Table Table

Item

Item Item

LSLOSETbuttonPressmomentarilytoentertheLowVoltageSettingscreen.

Gun

Key

Gun Gun

Key Key

Key

for

Figs.

1 11Key Key

for for

Description

Description Description

VoltageAdjustmentSwitchTwo-positionswitchsetsSmartgunvoltagetolowsetting(LO)or

LowVoltageMode Indicator

Voltage(kV)DisplayDisplaysactualsprayingvoltageofthegun,inkV.InOperatingMode,

Current(uA)DisplayDisplaysactualsprayingcurrentofthegun,inuA.InOperatingMode,

2–9.

Figs. Figs.

2–9. 2–9.

Purpose

Purpose Purpose

highsetting(HI).ThisswitchisfunctionalinOperatingModeandin DiagnosticMode.

Lights(blue)whentheSmartgunissettoLowVoltage.

displayisabargraph.InDiagnosticMode,voltageisdisplayedas anumber.

displayisabargraph.InDiagnosticMode,currentisdisplayedas anumber.

Pressandholdforapproximately5secondstoenterorexitDiagnostic Mode.

WhileinDiagnosticMode,pressmomentarilytoadvancethrough screens.

WhileontheLowVoltageLockScreen(inDiagnosticMode),press andholdtoturnthelockonoroff.

LVLowVoltageDisplayDisplaysthelowvoltagesettingasanumber.Thesettingcanbe

changed.SeeFig.4.

LKLowVoltageLocked

ERErrorDisplay

VIVoltageIndicator

CICurrentIndicatorInDiagnosticMode,thetwobottomrightLEDsofthescreenlight,

ASAlternatorSpeedDisplayInDiagnosticMode,Hzlevelisdisplayedasanumber.SeeFig.8.

LODisplayAppearsontheLowVoltageLockScreen.SeeFig.9.

AlternatorSpeedIndicatorInOperatingMode,indicatorcolorvariestoshowthealternatorspeed

Appearsifthelowvoltagesettingislocked.SeeFig.5andFig.9.

AppearsiftheSmartmodulelosescommunicationwiththepower supply.SeeFig.3.

InDiagnosticMode,thetwotoprightLEDsofthescreenlight, indicatingthatthevaluedisplayedisinkV.SeeFig.6.

indicatingthatthevaluedisplayedisinuA.SeeFig.7.

status:

•Greenindicatesthealternatorspeedisatthecorrectlevel.

•Iftheindicatorchangestoamberafteronesecond,thealternator speedistoolow.

•Iftheindicatorchangestoredafteronesecond,thealternatorspeed istoohigh.TheindicatoralsoturnsrediftheErrordisplayappears.

InDiagnosticMode,theindicatorisgreenwhenintheAlternator Speed(Hertz)screen.

3A2497H

GunOverview

Diagnostic

Diagnostic Diagnostic

DiagnosticModeincludesfourscreenswhichdisplay gundata:

•Voltage(kiloVolts)Screen

•Current(microAmperes)Screen

•AlternatorSpeed(Hertz)Screen

•LowVoltageLockScreen

Note

YoumustbeinOperatingModetoadjust thelowvoltagesetting;thesettingisnot adjustableinDiagnosticMode.However,the voltageadjustmentswitch(VA)canbesetto HIorLOinOperatingModeandDiagnostic Mode.

ToenterDiagnosticMode,pressandholdtheLOSET (LS)buttonforapproximately5seconds.Thedisplay willgototheVoltage(kiloVolts)Screen,page12.

Toadvancetothenextscreen,presstheLOSET buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET buttonforapproximately5seconds.Thescreenwill returntoOperatingMode.

Note

Iftheguntriggerisreleasedwhilein DiagnosticMode,thelastscreenviewedwill bedisplayedwhenthegunistriggeredagain.

Note

DiagnosticModecannotbeexitedfromthe LowVoltageLockScreen.Fordetails,see

LowVoltageLockScreen,page13.

Mode

Mode Mode

Figure6Voltage(kiloVolts)Screen

Current

Current Current

TheCurrent(microAmperes)Screenisthesecond screenintheDiagnosticMode.SeeFig.7and

SmartGunKey,page11.Toenterthisscreen,press

theLOSETbuttonwhileintheVoltage(kiloVolts) Screen.

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

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page13.Press

andholdforapproximately5secondstoreturnto OperatingMode.

(microAmperes)

(microAmperes) (microAmperes)

Screen

Screen Screen

Voltage

Voltage Voltage

TheVoltage(kiloVolts)Screenisthe󰘰rstscreento appearafterenteringDiagnosticMode.SeeFig.6 andSmartGunKey,page11.Toenterthisscreen, pressandholdtheLOSETbuttonforapproximately 5secondswhileintheOperatingMode.

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

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page12.Press

andholdforapproximately5secondstoreturnto OperatingMode.

(kiloVolts)

(kiloVolts) (kiloVolts)

Screen

Screen Screen

Figure7Current(microAmperes)Screen

3A2497H

GunOverview

Alternator

Alternator Alternator

TheAlternatorSpeed(Hertz)Screenisthethird screenintheDiagnosticMode.SeeFig.8and

SmartGunKey,page11.Toenterthisscreen,

presstheLOSETbuttonwhileintheCurrent (microAmperes)Screen.

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

TheHzindicatorlightsgreentoshowthatyouare viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page13.Pressandhold

forapproximately5secondstoreturntoOperating Mode.

Speed

Speed Speed

(Hertz)

(Hertz) (Hertz)

Screen

Screen Screen

Low

Voltage

Low Low

Voltage Voltage

TheLowVoltageLockScreenisthefourth screenintheDiagnosticMode.SeeFig.9and

SmartGunKey,page11.Toenterthisscreen,press

theLOSETbuttonwhileintheAlternatorSpeed (Hertz)Screen.

ThisscreendisplaysthestatusoftheLowVoltage Lock.Ifthesettingislocked,thelockimage(LK) appearstotheleftoftheLodisplay(LD).Ifthesetting isunlocked,thelockimagedoesnotappear.

Tochangethelockstatus,pressandholdthe LOSETbuttonuntilthelockimageappearsor disappears.Ifthelockisset,theimagewillalso appearontheLowVoltageSettingScreenwhenin lowvoltagemode(seeFig.4).

Note

DiagnosticModecannotbeexitedfromthis screen,becausepressingandholdingthe LOSETbuttonisusedtoturnthelockonor off.Toexit,pressLOSETmomentarilyto returntotheVoltage(kiloVolts)Screen,then exitDiagnosticModefromthere.

Lock

Screen

Lock Lock

Screen Screen

Figure8AlternatorSpeed(Hertz)Screen

Figure9LowVoltageLockScreen

3A2497H13

Installation

Installation Installation

System

System System

Theuseofmultiplegunswithoneisolationcabinet maycauseelectricshock,󰘰re,orexplosion.To helppreventinjuryorequipmentdamage,useonly onegunperisolationcabinet.

AGracovoltageisolationsystemmusthavethe followingfeatures:

•Anisolationenclosurethatpreventspersonsfrom makingcontactwiththehighvoltagecomponents beforethesystemvoltageisdischarged.All componentsoftheisolationsystemthatare chargedtohighvoltagemustbecontainedwithin theenclosure.

•Ableedresistortodrainoffthesystemvoltage whenthespraygunisnotinuse.Ametalpartof the󰘱uidsupplyunitmustbeelectricallyconnected tothebleedresistor.

•Asafetyinterlockthatautomaticallydischargesthe systemvoltagewhenanyoneopenstheisolation enclosure.

Requirements

Requirements Requirements

Install

Install Install

Installingandservicingthisequipmentrequires accesstopartswhichmaycauseelectricshock orotherseriousinjuryifworkisnotperformed properly.

•Donotinstallorservicethisequipmentunless

•Complywithalllocalcodesandregulations.

Fig.12(TypicalInstallation)showsatypical electrostaticair-assistedspraysystem.Itisnotan actualsystemdesign.Forassistanceindesigning asystemtosuityourparticularneeds,contactyour Gracodistributor.

Ventilate

Ventilate Ventilate

the

the the

youaretrainedandquali󰘰ed.

System

System System

the

Spray

the the

Spray Spray

Booth

Booth Booth

NOTICE

NOTICE NOTICE

Thesystemshouldnothaveanyseverearcing occurringwhentheisolationmechanismopens andcloses.Severearcingwillshortenthelifeof thesystemcomponents.

Note

TheGracowarrantyandapprovalsarevoidif theelectrostaticspraygunisconnectedtoa non-Gracovoltageisolationsystemorifthe gunisoperatedabove60kV.

Warning

Warning Warning

Mountwarningsignsinthesprayareawherethey caneasilybeseenandreadbyalloperators.An EnglishWarningSignisprovidedwiththegun.

Sign

Sign Sign

Donotoperatethegununlessventilatingair󰘱owis abovetheminimumrequiredvalue.Providefresh airventilationtoavoidthebuildupof󰘱ammableor toxicvaporswhenspraying,󰘱ushing,orcleaning thegun.Interlockthegunairand󰘱uidsupply topreventoperationunlessventilatingair󰘱owis abovetheminimumrequiredvalue.

Thesprayboothmusthaveaventilationsystem.

Electricallyinterlockthegunairand󰘱uidsupplywith theventilatorstopreventgunoperationanytimethat theventilationair󰘱owfallsbelowminimumvalues. Checkandfollowalllocalcodesandregulations regardingairexhaustvelocityrequirements.Verify theoperationoftheinterlockatleastonceayear.

3A2497H

Air

Supply

Air Air

Supply Supply

Toreducetheriskofelectricshock,theairsupply hosemustbeelectricallyconnectedtoatrueearth ground.Use Use Hose.

Hose. Hose.

Toreducetheriskofelectricshockorother seriousinjury,youmustusethered-coloredGraco ElectricallyConductiveAirHoseforthegunair supply.Donotusetheblackorgray-coloredGraco airhoses.

1.SeeFig.12.Installanairline󰘰lter/water separator(M)onthemainairsupplylineto ensureadry,cleanairsupplytothegun.Dirtand moisturecanruintheappearanceofyour󰘰nished workpieceandcancausetheguntomalfunction.

2.TheWB3000systemincludesableed-typeair regulator(N)onthegunairsupplyline(P),to controlairpressuretothegun.

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

Line

Line Line

Use

only

Graco

only only

Graco Graco

Grounded

Grounded Grounded

Air

Supply

Air Air

Supply Supply

Ground

Ground Ground

Connectthemaingroundwire(V)toatrueearth ground.

the

Cabinet

the the

Cabinet Cabinet

Installation

Trappedaircancausethe󰘱uidsupplyunitto cycleunexpectedly,whichcanresultinserious injury,includingsplashing󰘱uidintheeyesor ontheskin.Donotoperatetheequipment withoutthebleed-typeairvalve(B)installed.

4.TheWB3000systemincludesableed-typeair valve(B).Thebleed-typeairvalveisrequired toshutoffallairtothesystemandrelieveair trappedbetweenthevalveandthe󰘱uidsupply unitaftertheairregulatorisshutoff.Connectthe mainairsupplyline(A)tothebleedvalve.

5.Installanadditionalbleed-typeairvalve(CC) upstreamoftheair󰘰lter(M)toisolatethe󰘰lter forservicing.

3A2497H15

Installation

Grounding

Grounding Grounding

Theequipmentmustbegroundedtoreducethe riskofstaticsparkingandelectricshock.Electric orstaticsparkingcancausefumestoigniteor explode.Impropergroundingcancauseelectric shock.Groundallequipment,personnel,objects beingsprayed,andconductiveobjectsinorclose tothesprayarea.Theresistancemustnotexceed 100ohms.Groundingprovidesanescapewirefor theelectriccurrent.

Whenoperatingtheelectrostaticgun,any ungroundedobjects(suchaspeople,containers,and tools)inthespraylocationcanbecomeelectrically charged.

Thefollowingareminimumgroundingrequirements forabasicelectrostaticwaterbornesystem.Your systemmayincludeotherequipmentorobjects whichmustbegrounded.Yoursystemmustbe connectedtoatrueearthground.Checkground connectionsdaily.Checkyourlocalelectricalcodes andregulationsfordetailedgroundinginstructions.

Allpersonsenteringthesprayarea:

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

•

Objectbeingsprayed:

cleanandgroundedatalltimes.

Keeptheworkpiecehangers

mustwear

•

VoltageIsolationSystem:

voltageisolationsystemtoatrueearthground. SeeGroundtheCabinet,page15.

•

ElectrostaticAir-AssistedSprayGun:

thegunbyconnectingthered-coloredGraco GroundedAirHosetothegun,andconnectingthe airhosegroundwiretoatrueearthground.See

CheckGunElectricalGrounding,page26.

•

Allelectricallyconductiveobjectsordevicesinthe sprayarea:

•

Fluidandwastecontainers:

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

Aircompressors:

• tothemanufacturer'srecommendations.

•

Allairlines

groundedhoseswithamaximumof100feet(30.5 m)combinedhoselengthtoensuregrounding continuity.

mustbeproperlygrounded.

Groundtheequipmentaccording

mustbeproperlygrounded.Useonly

Electricallyconnectthe

Groundall󰘱uidand

Ground

163A2497H

•

The󰘱oorofthesprayarea:

conductiveandgrounded.Donotcoverthe󰘱oor withcardboardoranynon-conductivematerial whichwouldinterruptgroundingcontinuity.

mustbeelectrically

•

Allsolventpails:

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

Useonlyapproved,grounded

Installation

3A2497H

Installation

Connect

Connect Connect

AlwaysuseaGracowaterborne󰘱uidhosebetween thevoltageisolationsystem󰘱uidoutletandthegun 󰘱uidinlet.

Beforeconnectingthewaterborne󰘱uidhosetothe gun,blowitoutwithairand󰘱ushwithwaterto removecontaminants.Flushthegunbeforeusingit.

Toreducetheriskofelectricshock,installonly onecontinuousGracowaterbornehosebetween theisolated󰘱uidsupplyandthegun.Donotsplice hosestogether.

1.Removethegunairinlet󰘰tting(21).

the

Waterborne

the the

Waterborne Waterborne

Fluid

Fluid Fluid

Hose

Hose Hose

3.Makesurethebarrel󰘱uidinletiscleananddry.

Applydielectricgreasetothethreadsandfrontof thebarrelconnector(101a)andscrewitintothe 󰘱uidinletjustuntilsnug.Thencontinuetotighten the󰘰ttingaminimumof1/2turnandcontinueto rotateuntilthe󰘰ttingisorientedasshown.The gapbetweenthe󰘰ttingandthebarrelmustbe lessthan.125in(3.2mm).

Figure10ConnecttheFluidHose

2.Removetheo-ring(21a)andassembletheinlet 󰘰ttingthroughthebracket.Reassemblethe o-ring.

Figure11OrientationofFittingandBarrel

4.Loosenthestrainreliefnut(101c).

5.Applydielectricgreasetothethreadsofthe hoseconnector(101g).Pulltheconnectorback andapplygreasetotheoutsidediameterofthe hose.Threaditintothebarrelconnector(101n) untilsnugandthenaminimumof1/2turnmore. Useawrenchtoholdthebarrelconnectorwhen tightening.

6.Alignthebracket(101b)holeswiththeairinlet andexhaustoutlet.Securewiththeairinlet󰘰tting (21).

7.Tightenthestrainreliefnut(101c).

8.Presstheexhausttube(36)ontotheexhaust valve.Securewiththeclamp(43).

Note

Wheneverpossible,keepthe󰘱uidhose assembledtothegunbarrel.Toremove thebarrel,disconnectthehosebracket atthegunhandle.

9.Loosenthestrainreliefnutatthehoseinletend.

10.Slidetheotherendofthehosethroughthehole inthesideoftheisolatedenclosure.Connectthe swivel(Z)tothe󰘱uidoutletofthepump.

183A2497H

11.Securethehosetothesideoftheenclosurewith thebracket(W).Aboltassemblesthroughthe holeinthebracketandscrewsintothesideof theenclosure.

12.Tightenthestrainreliefnut.

Note

TheGracowarrantyandapprovals arevoidiftheelectrostaticspraygun isconnectedtoanon-Gracovoltage isolationsystemorifthegunisoperated above60kV.

Installation

Figure12HoseConnectionatWB3000Enclosure

3A2497H19

Installation

Figure13TypicalInstallation,ProXpWaterborne System

203A2497H

Installation

Typical

Typical Typical

Item

Item Item

B*Bleed-TypeAirShutoffValve

CPumpAirPressureGauge

DPumpAirPressureRegulator

EkVMeter

FPump

GPumpSuctionHose

K*EnclosureSafetyInterlock

LIsolatedEnclosure

P*GracoRedGroundedAirHose(left-hand

Q*GunAirHoseGroundWire

Installation

Installation Installation

Description

Description Description

MainAirSupplyLine

PaintContainer

BleedResistor

GunAirLineFilter

GunAirPressureRegulator

threads)

Key

Key Key

Item

Item Item

V*MainGroundWire

CCAccessoryBleed-TypeAirShutoffValve

*Theseitemsarerequiredforsafeoperation.They areincludedwiththeWB3000system.

Description

Description Description

WaterborneElectrostaticAir-Assisted SprayGun

GroundingRod

GroundTerminal

StrainReliefFitting

PumpAirSupplyLine

GroundingCylinder

PumpFluidOutletFitting

IsolatedEnclosureDoor(notshown,to illustrateinternalcomponents.Doormust beclosedandlockedtooperatesystem).

EnclosureT-HandleLockingScrew(part ofdoorassembly)

GracoWaterborneFluidHose

3A2497H

Installation

Agitator

Agitator Agitator

ToaddanagitatortotheGracoisolationsystem,order PartNo.245895.See245895AgitatorKit,page72, forthekitpartslist.

1.Dischargethesystemvoltage(seeFluidVoltage

DischargeandGroundingProcedure,page29).

2.Relievethepressure(see

PressureReliefProcedure,page28).

3.Opentheisolatedenclosuredoor.

4.Removethebackofthecontrolbox(258).

5.Removetube(A2)fromelbow(282)attheair manifold;seeTubingandWiring,page62. 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

Figure14245895AgitatorKit

3A2497H

GunSetup

Gun

Gun Gun

Gun

Gun Gun

Toreducetheriskof󰘰reandexplosion,󰘱uidsused mustmeetthefollowing󰘱ammabilityrequirements:

•FM, FM,

•CE CE

Setup

Setup Setup

Setup

Setup Setup

FM,

FMc

FMc FMc

Materialdoesnotsustainburninginaccordance withtheStandardTestMethodforSustained BurningofLiquidMixtures,ASTMD4206.

- --EN EN

Materialisclassi󰘰edasnon-ignitableasde󰘰ned byEN50059:2018.

Formoreinformation,see

IgnitabilityofCoatingMaterials,page73.

Procedure

Procedure Procedure

Approved:

Approved: Approved:

50059

50059 50059

Compliant:

Compliant: Compliant:

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page28wheneveryou

areinstructedtorelievethepressure.

Seethe󰘰gurebelowtolocatetheelectrostaticgun controls.

Contactwiththechargedcomponentsofthespray gunwillcauseanelectricshock.Donottouch thegunnozzleorelectrodeorcomewithin4in. (102mm)oftheelectrodeduringoperationor untilperformingtheFluidVoltageDischargeand

GroundingProcedure,page29.

FollowtheFluidVoltageDischargeandGrounding

Procedure,page29whenyoustopsprayingand

wheneveryouareinstructedtodischargethe voltage.

Toreducetheriskofcomponentrupture,which cancauseseriousinjury,donotexceedthe maximumworkingpressureofthelowestrated systemcomponent.Thisequipmenthasa100psi (0.7MPa,7bar)maximumairworkingpressure anda3000psi(21MPa,210bar)maximum󰘱uid workingpressure.

Figure15ElectrostaticGunControls

1.TurnOFF(O)theESOn-Offswitch(J).

2.Shutofftheairbleedvalvetothegun.

3A2497H23

+ 53 hidden pages