Graco WB100, Pro Xp 60 WB MRG, Pro Xp 60 WB Instructions-parts List Manual

Instructions-Parts

WB100

WB100 WB100
Pro

Pro Pro

Air

Air Air
one

one one
For

For For

100psi(0.7MPa,7.0bar)Maximum
FluidWorkingPressure
100psi(0.7MPa,7.0bar)MaximumAir
WorkingPressure

Seepages3and4formodelpart
numbersandapprovalinformation.

Xp™

Xp™ Xp™

spray

spray spray

of

the

of of

the the

professional

professional professional

Important

Important Important
Readallwarningsandinstructionsinthismanual.Save Save
instructions.

instructions. instructions.

Isolation

Isolation Isolation

60

WB

60 60

WB WB

system

system system

conditions

conditions conditions

for

use

for for

use

use use

Safety

Safety Safety

when

use use

when when

for

non

for for

non non

- --󰘱ammability 󰘱ammability

only.

only. only.

Instructions

Instructions Instructions

System

System System

Gun

Gun Gun

electrostatically

electrostatically electrostatically

󰘱ammability

and

and and

3A2496H

EN

spraying

spraying spraying

listed

on

listed listed

on on

conductive,

conductive, conductive,

page

3.

page page

3. 3.

Save

these

these these

waterborne

waterborne waterborne

󰘱uids

that

meet

at

󰘱uids 󰘱uids

that that

meet meet

least

at at

least least

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents

Contents Contents

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

RelatedManuals..................................................4

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

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

HowtheElectrostaticSprayGunWorks...........8

SprayingWaterborneFluids

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

Controls,Indicators,andComponents.............9

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

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

SystemRequirements..................................15

WarningSign...............................................15

InstalltheSystem.........................................15

VentilatetheSprayBooth.............................15

AirSupplyLine............................................16

GroundtheCabinet......................................16

ConnecttheWaterborneFluidHose..............17

Grounding...................................................22

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

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

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

GunSetupProcedure...................................26

SoftSprayGunSetupProcedure..................30

HVLPGunSetupProcedure.........................31

RoundSprayGunSetupProcedure..............33

AbrasiveMaterialGunSetup

Procedure......................................35

MoldReleaseGunSetupProcedure.............36

CheckGunElectricalGrounding...................38

FlushBeforeUsingEquipment......................38

Operation...........................................................39

PressureReliefProcedure............................39

FluidVoltageDischargeandGrounding

Procedure......................................39

FilltheFluidSupply......................................40

Startup........................................................40

Shutdown....................................................41

Maintenance......................................................42

DailyCareandCleaningChecklist................42

Flushing......................................................42

CleantheGunDaily.....................................44

DailySystemCare.......................................46

ElectricalTests...................................................47

TestGunResistance....................................47

TestPowerSupplyResistance.....................48

TestElectrodeResistance............................49

TestGroundStripResistance.......................50

TestCylinderResistance..............................50

Troubleshooting..................................................51

VoltageLossTroubleshooting.......................51

SprayPatternTroubleshooting......................54

GunOperationTroubleshooting....................55

ElectricalTroubleshooting............................56

Repair................................................................58

PreparetheGunforService.........................58

AirCapandNozzleReplacement..................59

AirCap,SprayTip,andNozzle

Replacement(Model

L60M19)........................................60

ElectrodeReplacement................................61

NeedleReplacement(ModelL60M19)...........62

FluidPackingRodRemoval..........................62

PackingRodRepair.....................................63

BarrelRemoval............................................65

BarrelInstallation.........................................65

PowerSupplyRemovaland

Replacement..................................66

AlternatorRemovalandReplacement...........67

FanAirAdjustmentValveRepair..................69

AtomizingAirRestrictorValveRepair............70

ESOn-OffandFluidAdjustmentValve

Repair............................................71

AirValveRepair...........................................72

SmartModuleReplacement..........................73

AirSwivelandExhaustValve

Replacement..................................74

Parts..................................................................75

StandardWaterborneAirSprayGun

Assembly.......................................75

SmartWaterborneAirSprayGun

Assembly.......................................77

MoldReleaseSmartAirSprayGun

Assembly.......................................79

IsolationEnclosure.......................................81

TubingandWiring.......................................84

PackingRodAssembly.................................86

AlternatorAssembly.....................................87

ESOn-OffandFluidAdjustmentValve...........88

FanAirAdjustmentValveAssembly..............89

AtomizingAirRestrictorValve

Assembly.......................................89

AirCapAssembly........................................90

SmartModuleAssembly...............................90

RoundSprayAssembly................................91

FluidNozzles.....................................................93

FluidNozzleSelectionChart.........................93

FluidNozzlePerformanceCharts..................94

AirCaps.............................................................96

AirCapSelectionGuide...............................96

AirConsumptionCharts.............................101

SprayTipSelectionChart(ModelL60M19MRG

GunOnly)...........................................102

AEMFineFinishSprayTips........................102

AEFFineFinishPre-Ori󰘰ceSpray

Tips.............................................103

RoundSprayTips......................................104

RepairKitsandAccessories..............................105

Dimensions......................................................109

TechnicalSpeci󰘰cations....................................111

2

3A2496H

Models

2575

Models

Models Models

FMapprovedforusewith󰘱uidsthatmeetthefollowingcondition:

•MaterialdoesnotsustainburninginaccordancewiththeStandardTest
MethodforSustainedBurningofLiquidMixtures,ASTMD4206.

0.35

0.35 0.35

Part

Part Part

24N580WB100WaterborneIsolationEnclosure233825withstandardelectrostaticairspraygun

24P629WB100WaterborneIsolationEnclosure233825withsmartelectrostaticairspraygun

24P630WB100WaterborneIsolationEnclosure246511withstandardelectrostaticairspraygun

24P631WB100WaterborneIsolationEnclosure246511withsmartelectrostaticairspraygun

233825WB100

24P734WB100

246511WB100

L60T17ProXp60

with

50

hose

J, J,J,with with

FM12ATEX0080

FM12ATEX0080 FM12ATEX0080

No

No No

50 50

ft ftfthose hose

EN

50059

EN EN

50059 50059

Ta

0°C

Ta Ta

50°C

0°C 0°C

– ––50°C 50°C

Model

Model Model

WB

max

max max

•Materialswhichcannotbeignited,inanymixturewithair,byanenergy

Description

Description Description

L60T17,groundedairhose235070,andshieldedwaterborne󰘱uidhose24M732.

L60M17,groundedairhose235070,andshieldedwaterborne󰘱uidhose24M732.

L60T18,groundedairhose235070,andunshieldedwaterborne󰘱uidhose24M733.

L60M18,groundedairhose235070,andunshieldedwaterborne󰘱uidhose24M733.

WaterborneIsolationEnclosureforshieldedhoses.Doesnotincludehosesandgun.

WaterborneIsolationEnclosure246511withMRGsmartelectrostaticairspraygun
L60M19,groundedairhose235070,andunshieldedwaterborne󰘱uidhose24M733.

WaterborneIsolationEnclosureforunshieldedhoses.Doesnotincludehoses
andgun.

StandardElectrostaticAirSprayGun,forwaterbornecoatings.

ModelsCompliantwithEN50059whenused

with󰘱uidsthatmeetthefollowingcriteria:

sourceoflessthan500mJ.

L60M17ProXp60

L60T18ProXp60

L60M18ProXp60

L60M19ProXp60

WBMRG

24M732

24M733

25N916

25N917

-——

-——

-——

-——

WB

WB

WB

SmartElectrostaticAirSprayGun,forwaterbornecoatings.

StandardElectrostaticAirSprayGun,forwaterbornecoatings.

SmartElectrostaticAirSprayGun,forwaterbornecoatings.

SmartElectrostaticAirSprayGun,formoldreleaseapplications.

ShieldedWaterborneFluidHoseAssembly,25ft(7.6m).

UnshieldedWaterborneFluidHoseAssembly,25ft(7.6m).

ShieldedWaterborneFluidHoseAssembly,50ft(15.2m).

UnshieldedWaterborneFluidHoseAssembly,50ft(15.2m).

3A2496H3

RelatedManuals

Related

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

4

3A2496H

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.

•Interlockthegunairsupplytopreventoperationunlessventilationair󰘱owisabovethe
minimumrequiredvalue.

•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 CE
Materialswhichcannotbeignited,inanymixturewithair,byanenergysourceof
lessthan500mJ.

operation

operation operation

Approved:

FMc FMc

Approved: Approved:

EN

50059

- --EN EN

50059 50059

immediately

immediately immediately

HAZARD

HAZARD HAZARD

work

area

area area

canigniteorexplode.Tohelpprevent󰘰reandexplosion:

Compliant:

Compliant: Compliant:

ifstaticsparkingoccursoryoufeelashock.Donotuse

Warnings

3A2496H5

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.

PRESSURIZED

PRESSURIZED PRESSURIZED
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.

SHOCK

SHOCK SHOCK

Fluid

HAZARD

HAZARD HAZARD

Grounding

Voltage

Voltage Voltage

EQUIPMENT

EQUIPMENT EQUIPMENT

instructions.

Discharge

Discharge Discharge

HAZARD

HAZARD HAZARD

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

.

•FollowthePressure Pressure
cleaning,checking,orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

Pressure

Relief

Procedure

Relief Relief

Procedure Procedure

whenyoustopspraying/dispensingandbefore

63A2496H

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.

•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable

PERSONAL

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

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent

Technical

thesolventmanufacturerforinformationandrecommendationsaboutcompatibility.

FLUID

FLUID FLUID

guidelines.

manufacturer.

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

OR

FUMES

OR OR

FUMES FUMES

PROTECTIVE

PROTECTIVE PROTECTIVE

inallequipmentmanualsformaterialsofconstruction.Consult

EQUIPMENT

EQUIPMENT EQUIPMENT

3A2496H

7

GunOverview

Gun

Gun Gun

How

How How
Works

Works Works

Theairhosesuppliesairtothespraygun.Partofthe
airoperatesthealternatorturbineandtherestofthe
airatomizesthe󰘱uidbeingsprayed.

Thealternatorgeneratespower,whichisconverted
bythepowercartridgetosupplyhighvoltagetothe
gun’selectrode.

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

Spraying

Spraying Spraying
Electrostatically

Electrostatically Electrostatically

Thiselectrostaticairspraygunisdesignedtospray
only

only only
󰘱ammabilityrequirements:

Overview

Overview Overview

the

Electrostatic

the the

Electrostatic Electrostatic

Waterborne

Waterborne Waterborne

waterborne󰘱uidswhichmeetthefollowing

Spray

Spray Spray

Fluids

Fluids Fluids

Gun

Gun Gun

CE-EN

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

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,
page39,beforeapproachingthefrontofthegun.

50059

50059 50059

Compliant:

Compliant: Compliant:

FM,

FMc

•FM, FM,
Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.

Approved:

FMc FMc

Approved: Approved:

NOTE:

NOTE: NOTE:
voidiftheelectrostaticspraygunisconnectedtoa
non-Gracovoltageisolationsystemorifthegunis
operatedabove60kV.

TheGracowarrantyandapprovalsare

83A2496H

GunOverview

Controls,

Controls, Controls,

Theelectrostaticgunincludesthefollowingcontrols,indicators,andcomponents.ForinformationonSmart
guns,alsoseeSmartGuns,page10.

Figure1GunOverview

Item

Item Item

Indicators,

Indicators, Indicators,

Description

Description Description

and

Components

and and

Components Components

Purpose

Purpose Purpose

A

BFluidInlet

C

D

EElectrodeNeedle

FFanAirAdjustmentValve

G

HFluidAdjustmentKnob

J

K

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

TurbineAirExhaust

AirCapandNozzleSeeAirCaps,page96andFluidNozzles,page93foravailable

AtomizingAirRestrictor
Valve

ESOn-OffValveTurnselectrostaticsON(I)orOFF(O).

ESIndicator(standard
gunonly;forSmart
gunindicator,see

OperatingMode,page10)

supplyhose.

Gracowaterborne󰘱uidsupplyhose

Barbed󰘰tting,forsuppliedexhausttube.

sizes.

Supplieselectrostaticchargetothe󰘱uid.

Adjustsfansizeandshape.Canbeusedtodecreasepatternwidth.

Restrictsaircapair󰘱ow.Replacewithplug(included)ifdesired.

Adjusts󰘱uid󰘱owbylimiting󰘱uidneedletravel.Useonlyinlow󰘱ow
conditions,toreducewear.

LitwhenESisON(I).Colorindicatesalternatorfrequency.Seethe
LEDindicatortableonpage36.

3A2496H9

GunOverview

Smart

Smart Smart

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

•OperatingMode

•DiagnosticMode

Operating

Operating Operating

Bar

Bar Bar

SeeFig.2andSmartGunKey,page12.The
OperatingModedisplaysgundataduringnormal
spraying.Thedisplayusesabargraphtoshowthe
voltagelevelinkiloVolts(kV)andthecurrentlevelin
microAmperes(uA).Thebargraphrangeisfrom0
to100%foreachvalue.

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

ElectricalTroubleshooting,page56forotherpossible

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.

•Iftheindicatorchangestoamberafteronesecond,
increasetheairpressure.

•Iftheindicatorchangestoredafteronesecond,
theairpressureistoohigh.Decreaseairpressure
untiltheindicatorisgreen.Tomaintainahigher
airpressure,installESOn/OffValveRestrictorKit
26A160.Then,adjustthepressureasneededto
ensuretoensuretheindicatorremainsgreen.

Figure2SmartGunModuleinOperatingMode

103A2496H

GunOverview

Error

Error Error

IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3andSmartGunKey,page12.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page56.
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
andSmartGunKey,page12.

After2secondsofinactivitythedisplaywill

Thelowvoltagesettingmaybelocked.See

Symbol

Symbol Symbol

Figure3ErrorDisplay

Adjusting

Adjusting Adjusting

Thelowvoltagesettingisuseradjustable.Toaccess
thelowvoltagesettingscreenwheninOperating
Mode,presstheLOSETbutton(LS)momentarily.
Thescreenwilldisplaythecurrentlowvoltage
setting.SeeFig.4andSmartGunKey,page12.
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

•WheninHImode,thelowvoltagesettingisalways always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.

•WheninLOmode,thelocksymbolwill
only

only only

appearifthelockisenabled.See

LowVoltageLockScreen,page14,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

always

3A2496H

11

GunOverview

Smart

Smart Smart

Table

Table Table

Item

Item Item

VA

LO

kV

uA

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

LD

ERErrorDisplay

VIVoltageIndicator

CICurrentIndicatorInDiagnosticMode,thetwobottomrightLEDsofthescreenlight,

ASAlternatorSpeedDisplayInDiagnosticMode,Hzlevelisdisplayedasanumber.SeeFig.8.

Hz

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.

12

3A2496H

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,page13.

Toadvancetothenextscreen,presstheLOSET
buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.

NOTE:

NOTE: NOTE:
Mode,thelastscreenviewedwillbedisplayedwhen
thegunisretriggered.

NOTE:

NOTE: NOTE:
fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page14fordetails.

Mode

Mode Mode

YoumustbeinOperatingModetoadjustthe

IfthegunisdetriggeredwhileinDiagnostic

DiagnosticModecannotbeexited

Figure6Voltage(kiloVolts)Screen

Current

Current Current

TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7and

SmartGunKey,page12.Toenterthisscreen,press

theLOSETbuttonwhileintheVoltage(kiloVolts)
Screen.

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

(microAmperes)

(microAmperes) (microAmperes)

Screen

Screen Screen

Voltage

Voltage Voltage

TheVoltage(kiloVolts)Screenisthe󰘰rstscreento
appearafterenteringDiagnosticMode.SeeFig.6
andSmartGunKey,page12.Toenterthisscreen,
pressandholdtheLOSETbuttonforapproximately
5secondswhileintheOperatingMode.

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

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page13.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

(kiloVolts)

(kiloVolts) (kiloVolts)

Screen

Screen Screen

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page14.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

Figure7Current(microAmperes)Screen

3A2496H13

GunOverview

Alternator

Alternator Alternator

TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8and

SmartGunKey,page12.Toenterthisscreen,

presstheLOSETbuttonwhileintheCurrent
(microAmperes)Screen.

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

TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page14.Pressandhold

forapproximately5secondstoreturntoOperating
Mode.

Speed

Speed Speed

(Hertz)

(Hertz) (Hertz)

Screen

Screen Screen

Low

Voltage

Low Low

Voltage Voltage

TheLowVoltageLockScreenisthefourth
screenintheDiagnosticMode.SeeFig.9and

SmartGunKey,page12.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:

NOTE: NOTE:
screen,becausepressingandholdingtheLOSET
buttonisusedtoturnthelockonoroff.Toexit,
pressLOSETmomentarilytoreturntotheVoltage
(kiloVolts)Screen,thenexitDiagnosticModefrom
there.

DiagnosticModecannotbeexitedfromthis

Lock

Screen

Lock Lock

Screen Screen

Figure8AlternatorSpeed(Hertz)Screen

Figure9LowVoltageLockScreen

14

3A2496H

Installation

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.19showsatypicalelectrostaticairspraysystem.
Itisnotanactualsystemdesign.Forassistance
indesigningasystemtosuityourparticularneeds,
contactyourGracodistributor.

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:

NOTE: NOTE:
voidiftheelectrostaticspraygunisconnectedtoa
non-Gracovoltageisolationsystemorifthegunis
operatedabove60kV.

Warning

Warning Warning

Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.

TheGracowarrantyandapprovalsare

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.

NOTE:Theminimumallowableairexhaustvelocity
is60feet/minute(19linearmeters/minute).High
velocityairexhaustwilldecreasetheoperating
ef󰘰ciencyoftheelectrostaticsystem.

3A2496H15

Installation

Air

Supply

Air Air

Supply Supply

Toreducetheriskofelectricshock,theairsupply
hosemustbeelectricallyconnectedtoatrueearth
ground.Use Use
Hose.

Hose. Hose.

Toreducetheriskofelectricshockorother
seriousinjury,youmustusethered-coloredGraco
ElectricallyConductiveAirHoseforthegunair
supply,andyoumustconnectthehoseground
wiretoatrueearthground.Donotusetheblack
orgray-coloredGracoairhoses.

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

2.TheWB100systemincludesableed-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

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

163A2496H

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.

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

the

Waterborne

the the

Waterborne Waterborne

Inashieldedhosesystem,ifahose

Fluid

Fluid Fluid

Hose

Hose Hose

Figure10ConnecttheFluidHose

Figure11BundlingtheAirandFluidHoses

3A2496H

17

Installation

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.

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).

8.Connecttheotherendofthehosetotheisolated
󰘱uidsupplyasfollows:

GracoWB100Enclosure:

a.

thestrainrelief󰘰tting(W).Ensureconductive
layer(C)haspassedthrough󰘰tting.Tighten
to55in-lb(6.2N•m).Pullbackonhoseto
checkitissecure.

For

Shielded

For For

Shielded Shielded

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

Hose

Hose Hose

Slidehosethrough

Systems:

Systems: Systems:

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).

Figure14ShieldedHose24M732
DimensionsatWB100Enclosure

183A2496H

Installation

Figure15ShieldedHose24M732
ConnectionatWB100Enclosure

Non-GracoIsolatedEnclosure:

b.

hoseasinstructedintheisolationsystem
manual.

For

Shielded

For For

Shielded Shielded

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

Hose

Systems:

Hose Hose

Systems: Systems:

Connect

Figure16UnshieldedHose24M733
DimensionsatWB100Enclosure

Figure17UnshieldedHose24M733
ConnectionatWB100Enclosure

Figure18ShieldedFluidHoseConnection
atNon-GracoIsolationEnclosure

c.Connecttheendofthetube(T)tothepump

󰘱uidoutlet󰘰tting(Z).

NOTE:

NOTE: NOTE:
arevoidiftheelectrostaticspraygunis
connectedtoanon-Gracovoltageisolation
systemorifthegunisoperatedabove60kV.

TheGracowarrantyandapprovals

3A2496H19

Installation

Figure19TypicalInstallation,ProXpWB100
WaterborneSystem

203A2496H

Installation

Typical

Typical Typical

Installation

Installation Installation

Item

Item Item

A

B*Bleed-TypeAirShutoffValve

CPumpAirPressureGauge

DPumpAirPressureRegulator

EkVMeter

FPump

GPumpSuctionHose

H

J*

K*EnclosureSafetyInterlock

LIsolatedEnclosure

M

N

P*GracoRedGroundedAirHose(left-handthreads)

Q*GunAirHoseGroundWire

Key

Key Key

Description

Description Description

MainAirSupplyLine

PaintContainer

BleedResistor

GunAirLineFilter

GunAirPressureRegulator

R

SWaterborneElectrostaticAirSprayGun

T

U

V*MainGroundWire

W

X

Y

Z

AA

BB

CCAccessoryBleed-TypeAirShutoffValve

*Theseitemsarerequiredforsafeoperation.TheyareincludedwiththeWB100system.

GracoWaterborneFluidHose

GroundingRod

GroundTerminal

StrainReliefFitting

PumpAirSupplyLine

GroundingCylinder

PumpFluidOutletFitting

IsolatedEnclosureDoor(notshown,toillustrateinternalcomponents.Doormustbeclosed
andlockedtooperatesystem).

EnclosureT-HandleLockingScrew(partofdoorassembly)

3A2496H

21

Installation

Grounding

Grounding Grounding

Theequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundallequipment,personnel,objects
beingsprayed,andconductiveobjectsinorclose
tothesprayarea.Theresistancemustnotexceed
1megohm.Groundingprovidesanescapewire
fortheelectriccurrent.

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

Thefollowingareminimumgroundingrequirements
forabasicelectrostaticsystem.Yoursystemmay
includeotherequipmentorobjectswhichmustbe
grounded.Yoursystemmustbeconnectedtoa
trueearthground.Checkgroundconnectionsdaily.
Checkyourlocalelectricalcodesandregulationsfor
detailedgroundinginstructions.

Allpersonsenteringthesprayarea:

•

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

•

Objectbeingsprayed:

cleanandgroundedatalltimes.

Keeptheworkpiecehangers

mustwear

•

VoltageIsolationSystem:

voltageisolationsystemtoatrueearthground.
SeeGroundtheCabinet,page16.

•

ElectrostaticAirSprayGun:

byconnectingthered-coloredGracoGrounded
AirHosetothegun,andconnectingtheair
hosegroundwiretoatrueearthground.See

CheckGunElectricalGrounding,page38.

•

GracoShieldedWaterborneFluidHose
(24M732):

conductivelayer.Installasinstructedunder

ConnecttheWaterborneFluidHose,page17.

•

Allelectricallyconductiveobjectsordevicesinthe
sprayarea:

•

Fluidandwastecontainers:

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

Aircompressors:

•
tothemanufacturer'srecommendations.

•

Allairlines

groundedhoseswithamaximumof100feet(30.5
m)combinedhoselengthtoensuregrounding
continuity.

Thehoseisgroundedthroughthe

mustbeproperlygrounded.

Groundtheequipmentaccording

mustbeproperlygrounded.Useonly

Electricallyconnectthe

Groundthegun

Groundall󰘱uidand

22

3A2496H

•

The󰘱oorofthesprayarea:

conductiveandgrounded.Donotcoverthe󰘱oor
withcardboardoranynon-conductivematerial
whichwouldinterruptgroundingcontinuity.

mustbeelectrically

•

Allsolventpails:

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

Useonlyapproved,grounded

Installation

3A2496H23

Installation

Agitator

Agitator Agitator

ToaddanagitatortotheGracoisolationsystem,order
PartNo.245895.See245895AgitatorKit,page108,
forthekitpartslist.

1.Dischargethesystemvoltage(seeFluidVoltage

DischargeandGroundingProcedure,page39).

2.Relievethepressure(see

PressureReliefProcedure,page39).

3.Opentheisolatedenclosuredoor.

4.Removethebackofthecontrolbox(258).

5.Removetube(A2)fromelbow(282)attheair
manifold;seeTubingandWiring,page84.
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

3A2496H

Installation

Fluid

Fluid Fluid

Toadda󰘱uidregulatortotheGracoisolation
system,orderPartNo.245944.See

245944FluidRegulatorKit,page108forthe

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

9.Replacethebackofthecontrolbox(258).

10.Assemblethe󰘱uidregulatorkitasshown.

11.Reinstallthepumpintheisolationenclosure.

Regulator

Regulator Regulator

DischargeandGroundingProcedure,page39).

PressureReliefProcedure,page39).

pumpairinlet;seeTubingandWiring,page84.

󰘱uidoutlet󰘰tting(231)andremovethe󰘰tting.

removethepumpfromtheisolationenclosure.

manifold;seeTubingandWiring,page84.
InstalltheY󰘰tting(506)intheelbow.Install
tubes(A2)and(507)intotheY󰘰tting.Routethe
tube(507)intothecabinet.

Usethetwomountingholestotheleftofthe
holesusedpreviously,toallowclearanceforthe
󰘱uidregulator.

Kit

Accessory

Kit Kit

Accessory Accessory

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.

Figure21245944FluidRegulatorKit

Thecabinetairregulatorandgauge(216,

3A2496H25

GunSetup

Gun

Gun Gun

Gun

Gun Gun

Toreducetheriskof󰘰reandexplosion,󰘱uidsused
mustmeetthefollowing󰘱ammabilityrequirements:

•FM, FM,

•CE CE

Contactwiththechargedcomponentsofthespray
gunwillcauseanelectricshock.Donottouchthe
gunnozzleorelectrodeorcomewithin4in.(102
mm)ofthefrontofthegunduringoperationor
untilperformingtheFluidVoltageDischargeand

GroundingProcedure,page39.

FollowtheFluidVoltageDischargeandGrounding

Procedure,page39whenyoustopsprayingand

wheneveryouareinstructedtodischargethe
voltage.

Setup

Setup Setup

Setup

Setup Setup

FM,

FMc

FMc FMc
Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.

CE

EN

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

Procedure

Procedure Procedure

Approved:

Approved: Approved:

50059

50059 50059

Compliant:

Compliant: Compliant:

Foradditionalstepstosetupspecialtyguns,
seeSoftSprayGunSetupProcedure,page30,

RoundSprayGunSetupProcedure,page33,
HVLPGunSetupProcedure,page31,
AbrasiveMaterialGunSetupProcedure,page35,

andMoldReleaseGunSetupProcedure,page36.

Seethe󰘰gurebelowtolocatetheelectrostaticgun
controls.

Figure22ElectrostaticGunControls

1.Thegunisshippedwiththe󰘱uidnozzleandair
capinstalled.Checkthattheretainingringis
tight.

NOTE:

NOTE: NOTE:
size󰘱uidnozzleoraircap,see

FluidNozzleSelectionChart,page93and
AirCapSelectionGuide,page96.

Toinstallthenozzleandaircap,see

AirCapandNozzleReplacement,page59.

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

Toselectadifferent

Toreducetheriskofcomponentrupture,which
cancauseseriousinjury,donotexceedthe
maximumworkingpressureofthelowestrated
systemcomponent.Thisequipmenthasa100psi
(0.7MPa,7bar)maximumworkingairand󰘱uid
pressure.

3.Shutofftheairbleedvalvetothegun.

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page39wheneveryou

areinstructedtorelievethepressure.

4.Checkgunresistance.Followthestepsin

TestGunResistance,page47.

263A2496H

GunSetup

5.Connectthewaterbornehose.Followthesteps
inConnecttheWaterborneFluidHose,page17.

6.ConnecttheredGracogroundedairhosetothe
gunairinlet.Thegunairinlet󰘰ttinghasleft-hand
threads.SeeAirSupplyLine,page16.

7.FollowallstepsinGrounding,page22.

8.Followallstepsin

CheckGunElectricalGrounding,page38.

Readingmustbelessthan100ohms.

9.Connecttheexhausttubeandsecurewiththe
clampprovided.

10.Flushifneeded.SeeFlushing,page42.

11.Positiontheaircapasneeded.

13.Fullyopenthe󰘱uidadjustmentvalve(H)
counterclockwise.

14.Fullyopentheatomizingairrestrictorvalve(G)
clockwise.

15.TurnON(I)theESOn-Offswitch(J).

12.Fullyopenthefanairadjustmentvalve(F)
counterclockwise.

3A2496H

WhentheESOn-OffswitchisturnedON(I),
the󰘱uidsupplyischargedwithhighvoltage
untilthevoltageisdischarged.Contactwith
thechargedcomponentsofthespraygunwill
causeanelectricshock.Donottouchthegun
nozzleorelectrodeorcomewithin4in.(102
mm)ofthefrontofthegunduringoperation.

27

GunSetup

16.Setthegunairregulatortodeliveraminimum
45psi(0.32MPa,3.2bar)atthegunwhen
triggered,toensurefullsprayingvoltage.

Table

Table Table

using

using using

mm)

mm) mm)

Pressure

2 22. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

in ininft ftft(m) (m)

5/16

5/16 5/16

diameter

diameter diameter

15(4.6)55(0.38,3.8)

25(7.6)65(0.45,4.5)

50(15.3)80(0.56,5.6)

Drop

Drop Drop

(m)

inch

(8

inch inch

(8 (8

hose

hose hose

18.Shutofftheairtothegun.TurnOFF(O)theES
On-Offswitch(J).

19.Startthepump.Adjustthe󰘱uidregulatoruntilthe
streamfromtheguntravels8-12in.(200-300
mm)beforefallingoff.Typically,if󰘱uidpressure
isbelow5psi(.04MPa,0.4bar)orabove30psi
(0.21MPa,2.1bar),achangeofnozzlesizeis
recommended.

Air

Regulator

Air Air

Regulator Regulator

psi

in ininpsi psi

with

gun

with with

gun gun

Setting

Setting Setting

(MPa,

(MPa, (MPa,

bar)

bar) bar)

triggered

triggered triggered

17.VerifythattheESindicator(K)[Hzindicatoron
Smartguns]islit.

Table

Table Table

Indicator

Indicator Indicator

Amber

LED

3 33. ..LED LED

Color

Color Color

Green

Red

Indicator

Indicator Indicator

Whenspraying,theindicator
shouldremaingreen,indicating
suf󰘰cientairpressuretothe
alternatorturbine.

Iftheindicatorchangestoamber
afteronesecond,theairpressure
istoolow.Increaseairpressure
untiltheindicatorisgreen.

Iftheindicatorchangestored
afteronesecond,theairpressure
istoohigh.Decreaseairpressure
untiltheindicatorisgreen.To
maintainahigherapplicationair
pressure,installESOn/OffValve
RestrictorKit26A160.Adjustthe
pressureasneededtoensurethe
indicatorremainsgreen.

Colors

Colors Colors

Description

Description Description

20.Turnontheairtothegun.TurnON(I)theES
On-Offswitch(J).

283A2496H

GunSetup

21.Sprayatestpattern.Checktheatomization.

•Ifover-atomizationoccursatminimum
pressure,adjusttheatomizingairrestrictor
valve.

•Ifatomizationisinadequate,increaseair
pressureordecrease󰘱uid󰘱ow.

22.Adjustthefanairadjustmentvalve.

•Fullyopenthefanairadjustmentvalve,
counterclockwise,forthelongestpattern.

•Turnthevalveclockwisetorestrictthefanair
andcreateashorterpattern.

WhentheESOn-OffswitchisturnedON(I),
the󰘱uidsupplyischargedwithhighvoltage
untilthevoltageisdischarged.Contactwith
thechargedcomponentsofthespraygunwill
causeanelectricshock.Donottouchthegun
nozzleorelectrodeorcomewithin4in.(102
mm)ofthefrontofthegunduringoperation.

23.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page51.

3A2496H29

GunSetup

Soft

Spray

Soft Soft

Spray Spray

Gun

Gun Gun

Setup

Setup Setup

Procedure

Procedure Procedure

Toconvertaguntoachieveasoftspraypatternfor
smallorlightweightparts,dothefollowing:

1.Installasoftsprayaircap.See

AirCapSelectionGuide,page96.

2.Forbestresults,installa1.0mm
or1.2mm󰘱uidnozzle.See

FluidNozzleSelectionChart,page93.

3.Followsteps1–13inthe

GunSetupProcedure,page26.

4.Adjusttheatomizingair.Fullyclosetheatomizing
airrestrictorvalve(G)counterclockwise.Then,
opentheatomizingairrestrictorvalve(G)one
halfturntooneturn.

5.TurnON(I)theESOn-Offswitch(J).

Table

Table Table

using

using using

mm)

mm) mm)

7.VerifythattheESindicator(K)[Hzindicatoron
Smartguns]islit.

Table

Table Table

Indicator

Indicator Indicator

Amber

Pressure

4 44. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

Color

Color Color

Green

in ininft ftft(m) (m)

5/16

5/16 5/16

diameter

diameter diameter

15(4.6)55(0.38,3.8)

25(7.6)65(0.45,4.5)

50(15.3)80(0.56,5.6)

LED

5 55. ..LED LED

Drop

Drop Drop

(m)

inch

(8

inch inch

(8 (8

hose

hose hose

Indicator

Indicator Indicator

Whenspraying,theindicator
shouldremaingreen,indicating
suf󰘰cientairpressuretothe
alternatorturbine.

Iftheindicatorchangestoamber
afteronesecond,theairpressure
istoolow.Increaseairpressure
untiltheindicatorisgreen.

Colors

Colors Colors

Description

Description Description

Air

Regulator

Air Air

Regulator Regulator

psi

(MPa,

in ininpsi psi

(MPa, (MPa,

with

gun

with with

triggered

gun gun

triggered triggered

Setting

Setting Setting

bar)

bar) bar)

6.Setthegunairregulatortodeliveraminimum
45psi(0.32MPa,3.2bar)atthegunwhen
triggered,toensurefullsprayingvoltage.

Red

8.Continuewithsteps18–23inthe

GunSetupProcedure,page26.

NOTE:

NOTE: NOTE:
productionrateof3.5oz/min(100cc/min).For
bestsoftsprayresults,limittheproductionrate
to7oz/min(200cc/min)orless.

NOTE:

NOTE: NOTE:
much,adjusttheatomizingairrestrictorvalve
(G)counterclockwiseslightlytolimittheair󰘱ow.
Toimproveatomization,adjusttheatomizingair
restrictorvalve(G)clockwiseslightlytoincrease
theair󰘱owordecreasethe󰘱uid󰘱ow.

Iftheindicatorchangestored
afteronesecond,theairpressure
istoohigh.Decreaseairpressure
untiltheindicatorisgreen.To
maintainahigherapplicationair
pressure,installESOn/OffValve
RestrictorKit26A160.Adjustthe
pressureasneededtoensurethe
indicatorremainsgreen.

Thesoftsprayaircapisoptimizedfora

Iftheobjectbeingsprayedismovingtoo

303A2496H