HP TI1681A User Manual
Instructions/Parts List
ELECTROSTATIC, WATERBORNE, AIR SPRAY
WB100 Isolation System and
PRO™ Xs3 Spray Gun
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure
For use when electrostatically spraying conductive,
waterborne fluids that meet at least one of the
following conditions for non-flammability:
309293J
FM Approved
• The fluid has a flash point above 140°F (60°C)
and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93. FM
• The fluid does not sustain burning when tested per
ASTM Standard D4206 Sustained Burn Test.
CE-EN 50059 Compliant
• Materials which cannot be ignited, in any mixture
with air, by an energy source of less than 500 mJ.
See page 3 for a List of Models
U.S. Patent No. 7,226,004
PRO Xs3
Smart Gun and
Fluid Hose
TI2139a
WB 100
Isolation Enclosure
TI1681A
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 4
Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
How the Electrostatic Air Spray Gun Works . . . . 7
Spraying Waterborne Fluids Electrostatically . . . 7
Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Requirements . . . . . . . . . . . . . . . . . . . . . 9
Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install the System . . . . . . . . . . . . . . . . . . . . . . . . 9
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . 11
Connect the Air Line . . . . . . . . . . . . . . . . . . . . . 11
Ground the Cabinet . . . . . . . . . . . . . . . . . . . . . . 11
Connect the Waterborne Fluid Hose . . . . . . . . . 11
245895 Agitator Kit . . . . . . . . . . . . . . . . . . . . . . 14
245944 Fluid Regulator Kit . . . . . . . . . . . . . . . . 15
Select a Fluid Nozzle and Air Cap . . . . . . . . . . 16
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Check Electrical Grounding . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 19
Fluid Voltage Discharge and
Grounding Procedure . . . . . . . . . . . . . . . . . 20
Pressure Relief Procedure . . . . . . . . . . . . . . . . 20
Fill the Fluid Supply . . . . . . . . . . . . . . . . . . . . . . 21
Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 21
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Low Voltage Adjustment (Smart Guns Only) . . 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . 26
Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 27
Clean the Air Cap and Fluid Nozzle . . . . . . . . . 29
Grease Door Latch Threads . . . . . . . . . . . . . . . 29
Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 30
Test Power Supply Resistance . . . . . . . . . . . . . 31
Test Electrode Resistance . . . . . . . . . . . . . . . . . 32
Test Ground Strip Resistance . . . . . . . . . . . . . . 33
Test Cylinder Resistance . . . . . . . . . . . . . . . . . . 33
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Voltage Loss Troubleshooting . . . . . . . . . . . . . . 34
Spray Pattern Troubleshooting . . . . . . . . . . . . . 37
Gun Operation Troubleshooting . . . . . . . . . . . . . 38
Electrical Troubleshooting . . . . . . . . . . . . . . . . . 39
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Prepare the Gun for Service . . . . . . . . . . . . . . . 41
Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 42
Electrode Replacement . . . . . . . . . . . . . . . . . . . 43
Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 44
Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 45
Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 46
Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 46
Power Supply Removal and Replacement . . . . 47
Turbine Alternator Removal and Replacement . 48
Fan Air Adjustment Valve Repair . . . . . . . . . . . . 49
Fluid Adjustment Valve Repair . . . . . . . . . . . . . 50
Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . 50
Atomizing Air Restrictor Valve Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 51
ES ON/OFF Valve Repair . . . . . . . . . . . . . . . . . 51
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 65
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 65
Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 66
Miscellaneous Accessories . . . . . . . . . . . . . . . . 66
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 70
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 70
2 309293J
List of Models
Part No. Gun Model Description
245897 PRO Xs3 Waterborne Isolation Enclosure with standard electrostatic air
245898 PRO Xs3 Waterborne Isolation Enclosure with smart electrostatic air
233825 Waterborne Isolation Enclosure without hoses and gun.
List of Models
FM Approved
spray gun, grounded air hose, and shielded waterborne fluid
hose
spray gun, grounded air hose, and shielded waterborne fluid
hose
244581,
Series B
245301, PRO Xs3 Part No. 244581 Gun, with 25 ft (7.6 m) waterborne fluid hose
244582,
Series B
245305 PRO Xs3 Part No. 244582 Gun, with 25 ft (7.6 m) waterborne fluid hose
245252 Shielded Waterborne Fluid Hose Assembly 25 ft (7.6 m)
PRO Xs3 Standard Electrostatic Air Spray Gun, for waterborne coatings
PRO Xs3 Smart Electrostatic Air Spray Gun, for waterborne coatings,
EN 50059 Compliant
244581,
Series B
244582,
Series B
246511 Waterborne Isolation Enclosure, without hoses and gun
246431 PRO Xs3 Unshielded Waterborne fluid hose assembly, 25 ft (7.6 m).
246592 PRO Xs3 Waterborne Isolation Enclosure with standard electrostatic air
PRO Xs3 Standard Electrostatic Air Spray Gun, for waterborne coatings.
PRO Xs3 Smart Electrostatic Air Spray Gun, for waterborne coatings.
spray gun, grounded air hose, and unshielded waterborne fluid
hose
246593 PRO Xs3 Waterborne Isolation Enclosure with smart electrostatic air
spray gun, grounded air hose, and unshielded waterborne fluid
hose
309293J 3
Symbols
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
WARNING
Electric Shock Hazard
Improper grounding, setup, or usage of an isolated waterborne system can cause a hazardous
condition and result in electric shock or other serious injury.
• Ground the equipment, all personnel in or close to the spray area, the object being sprayed,
and all conductive objects in the spray area. See Grounding, page 17.
• The gun must be connected to a voltage isolation system that will discharge the system voltage when the gun is not in use.
• All components of the isolation system that are charged to high voltage must be contained
within an enclosure that prohibits personnel from making contact with the high voltage components before the system voltage is discharged.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the instructions.
• Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 when instructed
to discharge the voltage; before cleaning, flushing, or servicing the system; before approaching the front of the gun; and before opening the safety enclosure for the isolated fluid supply.
• Do not touch the gun nozzle or come within 4 in. (102 mm) of the nozzle during gun operation
or for 30 seconds after operation stops, to allow the voltage to discharge through the bleed
resistor. Place the gun in the holster (accessory) during this 30 second period. Refer to Fluid
Voltage Discharge and Grounding Procedure, page 20.
• Electrically connect a metal part of the fluid supply unit to the bleed resistor.
• The gun air supply must be interlocked with the isolation system to shut off the air supply any-
time the isolation system enclosure is opened.
• Use only the red-colored Graco electrically conductive gun air hose with this gun. Do not use
black or grey-colored Graco air hoses.
• Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and
the spray gun. Do not splice hoses together.
• Do not enter a high voltage or hazardous area until all high voltage equipment has been discharged.
4 309293J
Warning
WARNING
Fire and Explosion Hazard
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition
and result in a fire or explosion.
• Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements in this manual.
• Ground the equipment, all personnel in or close to the spray area, the object being sprayed,
and all other electrically conductive objects in the spray area. See Grounding, page 17.
• Check gun resistance daily. See Test Gun Resistance on page 30.
• If there is any static sparking while using the equipment, stop spraying immediately. Identify
and correct the problem.
• Provide fresh air ventilation to avoid buildup of flammable or toxic vapors. See Ventilate the
Spray Booth on page 11.
• Only use this equipment to spray non-flammable, waterborne fluids, as defined on the front
cover of this manual.
• Only flush, purge, or clean the electrostatic waterborne spray system with non-flammable fluids, as defined on the front cover of this manual.
• Do not flush with the gun electrostatics turned on.
• Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the
spray area.
• Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop
cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.
• Use only non-sparking tools to clean residue from the booth and hangers.
Toxic Fluid Hazard
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on
the skin, swallowed, or inhaled.
• Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
• Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all
local, state, and national guidelines.
• Wear appropriate protective clothing, gloves, eyewear, and respirator.
309293J 5
Warning
WARNING
Equipment Misuse Hazard
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in a serious injury.
• This equipment is for professional use only.
• Read all manuals, tags, and labels before operating the equipment.
• Use the equipment only for its intended purpose. If you are uncertain, call your Graco distribu-
tor.
• Do not alter or modify equipment. Use only genuine Graco parts and accessories.
• Do not operate the power supply above 60 kV. Use only Graco Part No. 244542 Power Supply
with this gun.
• Check the equipment daily. Repair or replace worn or damaged parts immediately.
• Do not exceed the maximum working pressure of the lowest rated system component. Maxi-
mum working air and fluid pressure of this equipment is 100 psi (0.7 MPa, 7.0 bar).
• Use fluids and solvents that are compatible with the equipment wetted parts. See the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warn-
ings.
• Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180°F (82°C) or below -40°F (-40°C).
• Wear hearing protection when operating this equipment.
• Comply with all applicable local, state, and national fire, electrical, and other safety regula-
tions.
Pressurized Equipment Hazard
Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin
and cause serious injury.
• Do not point the spray gun at anyone or at any part of the body.
• Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure, page 20, when you stop spraying and before cleaning,
checking, or repairing equipment.
• Check hoses and couplings daily. Replace worn, damaged, or loose parts immediately.
• Tighten all fluid connections before each use.
6 309293J
Introduction
Introduction
How the Electrostatic Air Spray
Gun Works
The air hose supplies air to the spray gun. Part of the air
operates the turbine and the rest of the air atomizes the
fluid being sprayed. The turbine generates power, which
is converted by the power cartridge to supply high voltage current to the gun’s electrode.
The fluid source supplies fluid to the hose and gun. The
gun must be connected to a voltage isolation system to
maintain voltage at the gun. In an isolation system, the
entire fluid supply is electrostatically charged. The
charged fluid is attracted to the grounded workpiece,
wrapping around and evenly coating all surfaces.
Spraying Waterborne Fluids
Electrostatically
This electrostatic air spray gun is designed to spray only
waterborne fluids with a flash point above 140°F (60°C)
and a maximum organic solvent concentration of 20%,
by weight, per ASTM Standard D93. Also, the fluid must
not sustain burning when tested per ASTM Standard
D4206 Sustained Burn Test.
When connected to a voltage isolation system, all of the
fluid in the spray gun, fluid hose, and isolated fluid supply is charged to high voltage, which means that the system has more electrical energy than a solvent-based
system. Therefore, only non-flammable fluids (as
defined on the front cover of this manual) can be
sprayed with the system or be used to clean, flush, or
purge the system.
Precautions must be taken when using electrostatic
waterborne equipment to avoid potential shock hazards.
When the spray gun charges the isolated fluid to high
voltage, it is similar to charging a capacitor or a battery.
The system will store some of the energy while spraying
and retain some of that energy after the spray gun is
shut off. It is not safe to touch the front end of the gun
until the stored energy is discharged. The amount of
time it takes to discharge the energy depends on the
system design. Follow the Fluid Voltage Discharge
and Grounding Procedure on page 20 before
approaching the front of the gun.
CAUTION
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
309293J 7
Introduction
I O
Gun Overview
The electrostatic gun includes the following controls
(see F
IG. 1.).
• FLUID adjustment valve. Adjusts fluid rod travel.
Use only in low flow conditions, to reduce wear.
• Fan AIR adjustment valve. Adjusts fan size and
shape.
• Atomizing air RESTRICTOR valve. Restricts
atomizing air flow. Replace with plug (included) if
desired.
ES INDICATOR
ES ON/OFF
ES
I O
RESTRICTOR
AIR
• ES ON/OFF valve. Turns electrostatics ON (I) or
OFF (0).
• ES INDICATOR (standard gun only). Green when
ES is ON (I).
• Voltage/current DISPLAY (smart models only).
Shows voltage (V) and current (A). Green=spray,
yellow/red=see Electrical Troubleshooting, page
39.
• ES HI/LO switch (smart models only). Sets volt-
age to HI or LO (factory settings).
• LO VOLTAGE adjustment (smart models only).
Remove plug to adjust to four settings. Page 21.
100%
LO
ES
I O
0
KV
μα
HI
ES
ES HI/LO
ES ON/OFF
RESTRICTOR
DISPLAY
LO VOLTAGE
AIR
Standard Model Smart Model
AIR CAP
ELECTRODE
Fig. 1. Gun Overview
ti1266a
FLUID TUBE
FLUID
FLUID
ti1253a
TRIGGER
AIR INLET
TI1681A
8 309293J
Installation
Installation
System Requirements
A safe, well designed voltage isolation system should
have the following features:
• All components of the isolation system that are
charged to high voltage must be contained within an
enclosure that prohibits persons from making contact with the high voltage components before the
system voltage is discharged.
• A bleed resistor to drain off the system voltage when
the spray gun is not in use.
• The system should not have any severe arcing
occurring when the isolation mechanism opens and
closes. Severe arcing will shorten the life of the system components.
• The system must include a means for automatically
discharging the system voltage when anyone opens
the isolation enclosure.
CAUTION
Warning Sign
Mount the warning sign, Part No. 186118, in the spray
area where it can be seen and read by all operators.
Additional warning signs are available at no charge.
Install the System
WARNING
Fire, Explosion, and Electric Shock Hazard
Installing and servicing this equipment
requires access to parts which may cause
electric shock or other serious injury if work
is not performed properly.
• Do not install or service this equipment
unless you are trained and qualified.
• Be sure your installation complies with all
National, State and Local safety and fire
codes, NFPA 33, NEC 504 and 516, and
OSHA standard 1910.107.
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
FIG. 2. on page 10 shows a PRO Xs electrostatic waterborne air spray system. For assistance in designing a
system to suit your particular needs, contact your Graco
distributor.
309293J 9
Installation
B*
AA
BB
TI1896C
K*
Gun ES ON/OFF valve: I is ON, 0 is OFF
Q*
DE
M
A
C
B*
L
U
S
P*
X
N
G
W
J
R
V*
Y
T
F
Z
H
Fig. 2. Typical Installation: PRO Xs Waterborne System
Key
A Main Air Supply Line
B* Main Air Supply Shutoff Valve (bleed-type)
C Pump Air Pressure Gauge
D Pump Air Pressure Regulator
EkV Meter
FPump
G Pump Suction Hose
H Paint Container
J Bleed Resistor
K* Enclosure Safety Interlock
L Isolated Enclosure
M Gun Air Line Filter
N Gun Air Pressure Regulator
P* Graco Red Grounded Air Supply Hose
Q* Air Hose Ground Wire
TI1775C
R Graco Waterborne Fluid Hose
S Waterborne Electrostatic Air Spray Gun
T Grounding Rod
U Ground Terminal
V* Main Ground Wire
W Strain Relief/Ground Fitting
X Pump Air Supply Line
Y Grounding Cylinder
Z Pump Fluid Outlet Fitting
AA Isolated Enclosure Door
BB Enclosure T-Handle Locking Screw
* Required for safe operation. Must be purchased separately.
10 309293J
Installation
Ventilate the Spray Booth
WARNING
Flammable or Toxic Vapor Hazard
Provide fresh air ventilation to avoid the
buildup of flammable or toxic vapors. Do not
operate the gun unless ventilation fans are
operating.
Check and follow all National, State, and Local codes
regarding air exhaust velocity requirements.
High velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 60 linear ft/min (18.3 linear
meters/minute).
Connect the Air Line
4. Connect the main air supply line (A) to the
bleed-type air valve (B). The bleed valve shuts off all
air to the system. Install an additional bleed-type air
valve (B) upstream of the air filter (M) to isolate the
filter for servicing.
WARNING
Pressurized Equipment Hazard
The bleed-type air valve (B) is required in
your system to relieve air trapped between
the valve and the fluid supply unit after the
air regulator (D) is shut off. Trapped air can cause the
fluid supply unit to cycle unexpectedly, which can
result in serious injury, including splashing fluid in the
eyes or on the skin.
Ground the Cabinet
Connect the main ground wire (V) to a true earth
ground.
WARNING
Electric Shock Hazard
To reduce the risk of electric shock or other
serious injury, you must use the red-colored
Graco Electrically Conductive Air Hose for
the gun air supply hose, and you must connect the hose ground wire to a true earth ground. Do
not use the black or grey-colored Graco air hoses.
1. Install an air line filter/water separator (M) on the
main air supply line to ensure a dry, clean air supply
to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the
gun to malfunction.
2. Install a bleed-type air regulator (N) on the gun air
line (P).
3. Connect the red-colored Graco Grounded Air Supply Hose (P) between the gun air regulator (N) and
the gun's air inlet. The gun air inlet fitting has a
left-hand thread. Connect the air supply hose
ground wire (Q) to a true earth ground.
Connect the Waterborne Fluid
Hose
Always use a Graco waterborne fluid hose between the
voltage isolation system fluid outlet and the gun fluid
inlet. See F
sists of an inner PTFE tube (T) and an abrasion-resistant outer jacket (J). Shielded hose 245252 also has a
conductive layer (C), The conductive layer is connected
to ground at the gun fitting bracket (104).
Before connecting the waterborne fluid hose to the gun,
blow it out with air and flush with water to remove contaminants. Flush the gun before using it.
IG. 3.. The waterborne fluid hose (101) con-
WARNING
Electric Shock Hazard
To reduce the risk of electric shock, install
only one continuous Graco waterborne
hose between the isolated fluid supply and
the gun. Do not splice hoses together.
309293J 11
Installation
1. Remove the gun air inlet fitting (35). See FIG. 3..
Shielded Hose 245252
C
A
16
104
108
107
35
106
105
38
103
102
101
39
TI2155A
Fig. 3. Connect the Fluid Hose
In a shielded hose system, if a hose failure occurs
where high voltage arcs through the inner tube, voltage
will be discharged to ground through the conductive
hose layer. When properly installed, the conductive hose
layer is grounded through its connection to the grounded
enclosure.
2. For the fluid hose to fit properly, it must be stripped
and assembled to the dimensions in F
IG. 4.. Push
the inner tube (T) into the fitting (F) until the tube
bottoms. A new Graco waterborne fluid hose comes
fully assembled to these dimensions.
B
J
T
F
A
A 7.40 in. (188 mm)
B 2.0 in. (50 mm)
Fig. 4. Waterborne Hose Dimensions (At Gun)
Unshielded
Hose 246431
T
C
J
A
A 1.25 in (32 mm)
TI2742A
Fig. 5.
3. Generously apply dielectric grease (40) to the o-ring
(107) and the threads of the fitting (106). Pull the fitting back 1-1/2 in. (38 mm) and apply grease to the
exposed PTFE hose to fill the area between the
hose and the fitting. Make sure the barrel inlet is
clean and dry, then screw the fitting into the fluid
inlet of the gun barrel (16). See F
IG. 3..
4. Loosen the strain relief nut (102) so the bracket can
move freely on the hose.
CAUTION
5. Align the bracket (104) holes with the air inlet and
exhaust outlet. Secure with the air inlet fitting (35).
Be careful not to cut into the inner tube (T) of the
Tighten the strain relief nut (102) to secure the hose.
hose when stripping the hose. Nicks or cuts in the
PTFE tube will cause premature hose failure.
6. Check that the nut (105) is tightened securely to the
ferrule housing (103).
7. Press the exhaust tube (38) onto the barbed
adapter (A). Secure with the clamp (39).
8. Connect the other end of the hose to the isolated
fluid supply as follows:
12 309293J
a. Graco WB100 Enclosure: Slide hose through
the strain relief fitting (W). Ensure conductive
layer (C) has passed through fitting. Tighten to
55 in-lb (6.2 N•m). Pull back on hose to check it
is secure. Comply with the requirements in
Warning at right. See F
IG. 6. and FIG. 7..
See Warning below.
Installation
C
W
J
Shielded
C
Hose 245252
T
J
B
A
A 14.5 in. (368 mm)
B 0.75 in. (19 mm)
TI2166A
Fig. 6. Waterborne Hose Dimensions (At Graco
WB100 Enclosure)
C
See Warning at right.
W
J
T
Z
L
T
Z
L
TI2744
A
Fig. 9. Unshielded fluid connection
WARNING
Electric Shock Hazard
For Shielded hose systems:
Conductive hose layer (C) must be
grounded through its connection to the iso-
lation system’s grounded enclosure (L) or
grounded safety fence. To maintain grounding continuity, the conductive hose layer (C) must be engaged
in the ferrule when the strain relief nut is tightened.
Failure to properly install the hose in the strain relief
could result in an electric shock.
TI1897A
b. Non-Graco Isolated Enclosure: Connect hose
as instructed in the isolation system manual,
and comply with the requirements in the Warn-
Fig. 7. Shielded Fluid Hose Connection at Graco
ing at right. Refer to F
IG. 10..
WB100
Unshielded
Hose 246431
T
C
J
NOTE: Ground layer (C) of hose must
be grounded at isolation system.
J
T
L
A
Fig. 8.
309293J 13
A 12.0 in (305 mm)
TI2743A
C (see note above)
TI1966A
Fig. 10. Shielded Fluid Hose Connection at Non-Graco Isolated Enclosure
Installation
c. Connect the end of the tube (T) to the pump
fluid outlet fitting (Z).
CAUTION
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
CAUTION
Factory Mutual approval is valid only when this gun is
used with Factory Mutual approved voltage isolation
systems.
245895 Agitator Kit
7. Assemble the other parts of the kit as shown.
Secure the agitator with the setscrew (408).
8. Return the system to service.
Connect to elbow (282)
inside control box (258)
407
401
406
403
408
404
402
Install tube A2 here
To add an agitator to the Graco isolation system, order
Part No. 245895. See page 67 for the kit parts list.
1. Discharge the system voltage (page 20).
2. Relieve the pressure (page 20).
3. Open the isolated enclosure door.
4. Remove the back of the control box (258).
5. Remove tube (A2) from elbow (282) at the air manifold; see the tubing diagram on page 64. Install the
Y fitting (402) into the elbow. Install tubes (A2) and
(407) into the Y fitting. See F
tor tube (407) into the cabinet.
6. Replace the back of the control box (258).
IG. 11.. Route the agita-
406 (Ref)
TI2137A
Fig. 11. 245895 Agitator Kit
14 309293J
Installation
245944 Fluid Regulator Kit
To add a fluid regulator to the Graco isolation system,
order Part No. 245944. See page 68 for the kit parts list.
1. Discharge the system voltage (page 20).
2. Relieve the pressure (page 20).
3. Open the isolated enclosure door.
4. Remove the 1/4 OD tube (A1) from the pump air
inlet; see the tubing diagram on page 64.
5. Remove the waterborne fluid hose from the pump
fluid outlet fitting (231) and remove the fitting.
6. Unscrew the two pump mounting screws (S, F
12.) and remove the pump from the isolation enclosure.
7. Remove the back of the control box (258).
IG.
12. Connect tube (A1) to the air inlet of fluid regulator
(504). Connect tube (507) to the pump air inlet.
13. Connect the waterborne fluid hose to the fluid regulator outlet fitting (501).
14. Return the system to service.
The cabinet air regulator and gauge (216, 217) will now
operate the air piloted fluid regulator (504). The pump
will now operate at the inlet air pressure.
Connect to
elbow (282)
inside control
box (258)
506
507
Connect
waterborne
fluid hose here
501
504
Tube A1
502
8. Remove tube (A2) from elbow (282) at the air manifold; see page 64. Install the Y fitting (506) in the
elbow. Install tubes (A2) and (507) into the Y fitting.
Route the tube (507) into the cabinet.
9. Replace the back of the control box (258).
10. Assemble the fluid regulator kit as shown in F
IG. 12..
11. Reinstall the pump in the isolation enclosure. Use
the two mounting holes to the left of the holes used
previously, to allow clearance for the fluid regulator.
Connect
tube A2
here
Fig. 12. Fluid Regulator Kit
505
503
S
TI2149A
309293J 15
Installation
Select a Fluid Nozzle and Air
Cap
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 20
before removing or installing a fluid nozzle
and/or air cap.
The gun is supplied with Part No. 197266 Nozzle and
197477 Air Cap. If you require a different size, refer to
Table 1 and Table 2 , and instruction manual 309419, or
consult with your Graco distributor. See Air Cap/Nozzle
Replacement on page 42.
Table 1: Fluid Nozzles
Part No.
197263 0.75 (.030) 197266 1.5 (.055)
197264 1.0 (.042) 197267 1.8 (.070)
197265 1.2 (.047) 197268 2.0 (.080)
Size,
mm (in.)
Part No.
Size,
mm (in.)
Table 2: Air Caps
Part No.
197477
197478
197479
197480
197481
Pattern Shape
and Length
in. (mm)
Round end;
15-17 (381-432)
Round end;
15-17 (381-432)
Tapered end;
13-15 (330-381)
Round end;
16-18 (406-457)
Tapered end;
17-19 (432-483)
Recommended Fluids and
Production Rates
Light to medium viscosity.
Medium to high production.
Light to medium viscosity.
Low to medium production.
Light to medium viscosity.
Medium to high production.
Medium to high viscosity
and high solids.
Low to medium production.
Medium to high viscosity
and high solids.
Medium to high production.
For use with 2.0 mm nozzle.
16 309293J
Installation
Grounding
WARNING
Fire, Explosion, and Electric Shock Hazard
When operating the electrostatic gun, any
ungrounded objects in the spray area (people, containers, tools, etc.) can become
electrically charged. Improper grounding
can result in static sparking, which can
cause a fire, explosion, or electric shock.
Follow the grounding instructions below.
The following are minimum grounding requirements for
a basic electrostatic waterborne system. Your system
may include other equipment or objects which must be
grounded. Check your local electrical code for detailed
grounding instructions. Your system must be connected
to a true earth ground.
• Voltage Isolation System: electrically connect to a
true earth ground, as instructed in the voltage isolation system manual.
• Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Resistance must
not exceed 1 megohm.
• The floor of the spray area: must be electrically con-
ductive and grounded. Do not cover the floor with
cardboard or any non-conductive material which
would interrupt grounding continuity.
• Electrostatic Air Spray Gun: ground the gun by con-
necting the red-colored Graco Grounded Air Hose
and connecting the air hose ground wire to a true
earth ground. See Check Electrical Grounding,
page 18.
ti1259a
• Graco Waterborne Fluid Hose: the hose is grounded
through the conductive layer. Install the hose as
instructed on page 11.
• All persons entering the spray area: shoes must
have conductive soles, such as leather, or personal
grounding straps must be worn. Do not wear shoes
with non-conductive soles such as rubber or plastic.
If gloves are necessary, wear the conductive gloves
that are supplied with the gun. If non-Graco gloves
are worn, cut off fingers or palm area of glove to
ensure your hand contacts the grounded gun handle.
• All solvent pails: use only grounded metal pails,
which are conductive. Do not use plastic containers.
Do not place the pail on a non-conductive surface
such as paper or cardboard. Do not store more than
the quantity needed for one shift.
• All electrically conductive objects or devices in the
spray area: including fluid containers, tools, and
wash cans, must be properly grounded.
309293J 17
Installation
Check Electrical Grounding
1. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
2. Turn the ES ON/OFF valve OFF.
ES
I O
ti1273a
3. Turn off the air and fluid supply to the gun. The fluid
hose must not have any fluid in it.
4. Make sure the red-colored grounded air hose (R) is
connected and the hose ground wire is connected to
a true earth ground.
ti1259a
5. Using an ohmmeter (AA), measure the resistance
between the gun handle (BB) and a true earth
ground (CC). The resistance should not exceed 100
ohms. See F
IG. 13..
BB
AA
CC
TI2161A
Fig. 13. Check Gun Grounding
7. Using an ohmmeter (AA), measure the resistance
between the cabinet ground lug (214) and a true
earth ground (CC). See F
IG. 14.. The resistance
must be less than 100 ohms.
6. If the resistance is greater than 100 ohms, check the
tightness of the ground connections and be sure the
air hose ground wire is connected to a true earth
ground. If the resistance is still too high, replace the
air hose.
214
AA
CC
TI2163A
Fig. 14. Check Cabinet Grounding
18 309293J
Operation
Operation
Operating Checklist
Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.
Ventilation fans are operating properly.
All operators are properly trained to safely
operate an electrostatic waterborne air spray
system as instructed in this manual.
All operators are trained in the Pressure
Relief Procedure on page 20.
The electrostatics are turned off and properly
grounded according to the.Fluid Voltage Dis-
charge and Grounding Procedure on page
20 before any person enters the safety enclosure, before cleaning, and before performing
any maintenance or repair.
The system is thoroughly grounded and the
operator and all persons entering the spray
area are properly grounded. See Grounding
on page 17.
Fluid Hose is in good condition with no cuts or
abrasions of the PTFE layer. Replace hose if
damaged.
Workpiece hangers are clean and grounded.
All debris, including flammable fluids and rags,
is removed from the spray area.
Only fluids with a flash point above 140°F
(60°C) and a maximum organic solvent concentration of 20%, by weight, may be in the
spray area.
All conductive objects in the spray area are
electrically grounded and the floor of the spray
area is electrically conductive and grounded.
309293J 19
Operation
Fluid Voltage Discharge and
Grounding Procedure
WARNING
Electric Shock Hazard
The fluid supply is charged with high voltage until the voltage is discharged. Contact
with the charged components of the isolation system or spray gun electrode will
cause an electric shock. To avoid an electric shock,
follow the Fluid Voltage Discharge and Grounding
Procedure:
• whenever you are instructed to discharge the
voltage
• before cleaning, flushing, or servicing the system
equipment
Pressure Relief Procedure
WARNING
Pressurized Equipment Hazard
The system pressure must be manually
relieved to prevent the system from starting
or spraying accidentally. To reduce the risk
of an injury from electric shock, accidental spray from
the gun, splashing fluid, or moving parts, follow the
Pressure Relief Procedure whenever you:
• are instructed to relieve the pressure
• stop spraying
• check or service any of the system equipment
• or install or clean the fluid nozzle.
• before approaching the front of the gun
• or before opening the safety enclosure for the
isolated fluid supply.
1. Turn the ES ON/OFF valve OFF and wait 30 seconds.
ES
I O
ti1273a
2. Remove the door T-handle locking screw. This will
shut off the air to the gun and trigger the grounding
cylinder to discharge any remaining electrical
charge.
3. Use the grounding rod to touch the pump and supply pail. If you see any arcs, see Electrical Trouble-
shooting on page 39.
1. Turn the ES ON/OFF valve OFF.
ES
I O
ti1273a
2. Follow the Fluid Voltage Discharge and Ground-
ing Procedure at left.
3. Turn off the main air supply valve (B).
ti1289a
4. Trigger the gun into a grounded metal waste container to relieve the air and fluid pressure.
ti1276a
5. Relieve fluid pressure in the fluid supply unit as
instructed in your fluid supply unit manual.
20 309293J
Fill the Fluid Supply
Operation
1. Discharge the system voltage (page 20).
2. Relieve the pressure (page 20).
ti1276a
3. Open the isolated enclosure door.
4. Remove the pail cover from the pail, holding a rag
over the suction tube strainer to prevent any fluid
from dripping into the isolated enclosure. Place the
cover and suction tube outside the enclosure.
5. Remove the supply pail from the enclosure.
CAUTION
Be sure to wipe up all fluid spills in the isolated enclosure. Fluid can create a conductive path and cause
the system to short out.
6. Clean up any fluid spills in the enclosure, using a
soft cloth and a non-flammable, compatible solvent.
7. Fill the supply pail with fluid and return it to the
enclosure. Clean up any spills.
8. Reinstall the pail cover, holding a rag over the suction tube strainer to prevent fluid spills while you
place the pump suction tube in the pail.
WARNING
Fire and Explosion Hazard
To reduce the risk of fire and explosion, only
use this equipment with fluids that meet at
least one of the following conditions for
non-flammability:.
• The fluid has a flash point above 140°F (60°C)
and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.
• The fluid does not sustain burning when tested
per ASTM Standard D4206 Sustained Burn Test.
WARNING
Electric Shock Hazard
Contact with the charged components of
the spray gun will cause an electric shock.
Do not touch the gun nozzle or electrode or
come within 4 in. (102 mm) of the front of the gun
during operation or until performing the Fluid Voltage
Discharge and Grounding Procedure on page 20.
Follow the Fluid Voltage Discharge and Grounding
Procedure on page 20 when you stop spraying and
whenever you are instructed to discharge the voltage.
9. Close the isolated enclosure door and fasten
securely with the T-handle locking screw.
WARNING
Adjust the Spray Pattern
Follow the steps below to establish the correct fluid flow
and air flow.
309293J 21
Component Rupture Hazard
To reduce the risk of component rupture,
which can cause serious injury, do not
exceed the maximum working pressure of
the lowest rated system component. This equipment
has a 100 psi (0.7 MPa, 7 bar) maximum working air
and fluid pressure.
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