Graco 309292B WB100 Enclosure, PRO Xs3 wb Gun Owner's Manual

Parts
Instructions/Parts List
ELECTROSTATIC, WATERBORNE, AIR SPRAY
WB100 Isolation System and
PRO™ Xs3 Spray Gun
309293B
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:
•
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.
See page 3 for a List of Models
U.S. Patent Pending
TI2139a
Model 233825
Isolation Enclosure
Model 245305
Smart Gun and
Fluid Hose
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
TI1681A
Table of Contents
List of Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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. . . . . . . . . . . . 17
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Check Electrical Grounding . . . . . . . . . . . . . . . . . 19
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . 20
Fluid Voltage Discharge and
Grounding Procedure . . . . . . . . . . . . . . . . . . 21
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 21
Fill the Fluid Supply . . . . . . . . . . . . . . . . . . . . . . . 22
Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . . 22
Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Low Voltage Adjustment (Smart Guns Only) . . . . 26
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . . 27
Daily Care and Cleaning . . . . . . . . . . . . . . . . . . . 28
Clean the Air Cap and Fluid Nozzle . . . . . . . . . . 30
Grease Door Latch Threads . . . . . . . . . . . . . . . . 30
2
Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Gun Resistance . . . . . . . . . . . . . . . . . . . . .
Test Power Supply Resistance . . . . . . . . . . . . . .
Test Electrode Resistance . . . . . . . . . . . . . . . . .
Test Ground Strip Resistance . . . . . . . . . . . . . .
Test Cylinder Resistance . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Loss Troubleshooting . . . . . . . . . . . . . .
Spray Pattern Troubleshooting . . . . . . . . . . . . . .
Gun Operation Troubleshooting . . . . . . . . . . . . .
Electrical Troubleshooting . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prepare the Gun for Service . . . . . . . . . . . . . . .
Air Cap/Nozzle Replacement . . . . . . . . . . . . . . .
Electrode Replacement . . . . . . . . . . . . . . . . . . .
Fluid Packing Removal. . . . . . . . . . . . . . . . . . . .
Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . .
Barrel Removal. . . . . . . . . . . . . . . . . . . . . . . . . .
Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Removal and Replacement . . . . .
Turbine Alternator Removal and Replacement. .
Fan Air Adjustment Valve Repair . . . . . . . . . . . .
Fluid Adjustment Valve Repair . . . . . . . . . . . . . .
Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . .
Atomizing Air Restrictor Valve Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
ES ON/OFF Valve Repair. . . . . . . . . . . . . . . . . .
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Line Accessories. . . . . . . . . . . . . . . . . . . . . .
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . .
Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous Accessories . . . . . . . . . . . . . . . .
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
32
33
34
34
35
35
38
39
40
42
42
43
44
45
46
47
47
48
49
50
51
51
52
52
53
66
66
66
67
67
70
309293
List of Models
List of Models
Part No.
Gun Model
Description
245897
PRO Xs3
Waterborne Isolation Enclosure with standard electrostatic air
spray gun, grounded air hose, and waterborne fluid hose
245898
PRO Xs3
Waterborne Isolation Enclosure with smart electrostatic air
spray gun, grounded air hose, and waterborne fluid hose
233825
Waterborne Isolation Enclosure, without hoses and gun
244581
PRO Xs3
Standard Electrostatic Air Spray Gun, for waterborne coatings
245301
PRO Xs3
Part No. 244581 Gun, with 25 ft (7.6 m) waterborne fluid hose
244582
PRO Xs3
Smart Electrostatic Air Spray Gun, for waterborne coatings,
245305
PRO Xs3
Part No. 244582 Gun, with 25 ft (7.6 m) waterborne fluid hose
245895
Agitator Accessory Kit
245944
Fluid Regulator Accessory Kit
Symbols
Warning Symbol
Caution Symbol
WARNING
CAUTION
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the instructions.
309293
3
Warning
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.
4
•
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 18.
•
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.
•
Follow the “Fluid Voltage Discharge and Grounding Procedure” on page 21 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 21.
•
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 anytime 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.
309293
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 18.
•
Check gun resistance daily. See “Test Gun Resistance” on page 31.
•
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.
309293
•
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.
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 distributor.
•
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. Maximum 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 Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
•
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 regulations.
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.
6
•
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 21, 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.
309293
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.
309293
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 21 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.
7
Introduction
Gun Overview
•
ES ON/OFF valve. Turns electrostatics ON (I) or
OFF (0).
The electrostatic gun includes the following controls
(see Fig. 1).
•
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 40.
•
ES HI/LO switch (smart models only). Sets voltage to HI or LO (factory settings).
•
LO VOLTAGE adjustment (smart models only).
Remove plug to adjust to four settings. Page 22.
•
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.
DISPLAY
ES INDICATOR
LO VOLTAGE
ES HI/LO
0
KV
100%
µα
ES ON/OFF
HI
LO
I
ES
ES
ES ON/OFF
O
RESTRICTOR
I
AIR
ES
O
AIR
RESTRICTOR
FLUID
FLUID
ti1266a
ti1253a
Standard Model
Smart Model
TRIGGER
AIR CAP
ELECTRODE
AIR INLET
FLUID TUBE
TI1681A
Fig. 1. Gun Overview
8
309293
Installation
Installation
System Requirements
Warning Sign
A safe, well designed voltage isolation system should
have the following features:
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.
•
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.
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.
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.
• 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.
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.
309293
9
Installation
B*
Gun ES ON/OFF valve: I is ON, 0 is OFF
BB
Q*
M
C
A
D E U
S
B*
K*
AA
P*
L
X
N
G
TI1896C
R
W
J
V*
Y
Z
F
T
H
TI1775C
Fig. 2. Typical Installation: PRO Xs Waterborne System
Key
Q*
Air Hose Ground Wire
A
Main Air Supply Line
R
Graco Waterborne Fluid Hose
B*
Main Air Supply Shutoff Valve (bleed-type)
S
Waterborne Electrostatic Air Spray Gun
C
Pump Air Pressure Gauge
T
Grounding Rod
D
Pump Air Pressure Regulator
U
Ground Terminal
E
kV Meter
V*
Main Ground Wire
F
Pump
W
Strain Relief/Ground Fitting
G
Pump Suction Hose
X
Pump Air Supply Line
H
Paint Container
Y
Grounding Cylinder
J
Bleed Resistor
Z
Pump Fluid Outlet Fitting
K*
Enclosure Safety Interlock
AA
Isolated Enclosure Door
L
Isolated Enclosure
BB
Enclosure T-Handle Locking Screw
M
Gun Air Line Filter
N
Gun Air Pressure Regulator
*
Required for safe operation. Must be purchased separately.
P*
Graco Red Grounded Air Supply Hose
10
309293
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.
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 lefthand thread. Connect the air supply hose ground
wire (Q) to a true earth ground.
4. Connect the main air supply line (A) to the bleedtype 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
Check and follow all National, State, and Local codes
regarding air exhaust velocity requirements.
NOTE: 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
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).
309293
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.
Connect the Waterborne
Fluid Hose
Always use a Graco waterborne fluid hose between the
voltage isolation system fluid outlet and the gun fluid
inlet. Order Part No. 245252 25 ft (7.6 m) waterborne
hose for use with the manual PRO Xs3 spray gun. See
Fig. 3. The waterborne fluid hose (101) consists of an
inner PTFE tube (T), a conductive layer (C), and an
abrasion-resistant outer jacket (J). 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.
11
Installation
WARNING
CAUTION
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.
Be careful not to cut into the inner tube (T) of the
hose when stripping the hose. Nicks or cuts in the
PTFE tube will cause premature hose failure.
C
1. Remove the gun air inlet fitting (35). See Fig. 3.
J
TI1806A
B
T
F
A
104
108
107
106
35
105
103
102
101
Fig. 3. Connect the Fluid Hose
Fig. 1.
38
39
TI2155A
NOTE: 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.
12
7.40 in. (188 mm)
B
1.75 in. (45 mm)
Fig. 4. Waterborne Hose Dimensions (At Gun)
Fig. 1.
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 Fig. 3.
A
16
A
For the fluid hose to seal properly, it must be
stripped and assembled to the dimensions in Fig. 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.
4. Loosen the strain relief nut (102) so the bracket can
move freely on the hose.
5. Align the bracket (104) holes with the air inlet and
exhaust outlet. Secure with the air inlet fitting (35).
Tighten the strain relief nut (102) to secure the
hose.
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:
309293
Installation
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 Fig. 5 and Fig. 6.
J
B
A
A
14.5 in. (368 mm)
B
0.75 in. (19 mm)
TI2166A
Fig. 5. Waterborne Hose Dimensions (At Graco
WB100 Enclosure)
Fig. 1.
See Warning at right.
Electric Shock Hazard
To reduce the risk of electric shock, the
areas of the waterborne fluid hose that are
accessible to personnel during normal
operation must be covered by the outer
hose jacket (J). The portion of the inner hose layer
(T) not covered by the outer jacket must be inside the
voltage isolation system enclosure (L).
C
T
WARNING
Conductive hose layer (C) must be grounded through
its connection to the isolation 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.
C
b.
W
J
T
Non-Graco Isolated Enclosure: Connect hose
as instructed in the isolation system manual,
and comply with the requirements in the Warning at right. Refer to Fig. 7.
NOTE: Ground layer (C) of hose must
be grounded at isolation system.
Z
J
L
T
L
TI1897A
Fig. 6. Fluid Hose Connection at Graco WB100
Fig. 1.
C (see note above)
Fig. 7. Fluid Hose Connection at Non-Graco Isolated
Enclosure
Fig. 1.
TI1966A
Continued on page 14.
309293
13
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
To add an agitator to the Graco isolation system, order
Part No. 245895. See page 68 for the kit parts list.
7. Assemble the other parts of the kit as shown.
Secure the agitator with the setscrew (408).
8. Return the system to service.
407
402
Connect to elbow (282)
inside control box (258)
401
406
Install tube A2 here
403
408
404
1. Discharge the system voltage (page 21).
2. Relieve the pressure (page 21).
406 (Ref)
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 65. Install the
Y fitting (402) into the elbow. Install tubes (A2) and
(407) into the Y fitting. See Fig. 8. Route the agitator
tube (407) into the cabinet.
6. Replace the back of the control box (258).
TI2137A
Fig. 8. 245895 Agitator Kit
Fig. 1.
14
309293
Installation
245944 Fluid Regulator Kit
12. Connect tube (A1) to the air inlet of fluid regulator
(504). Connect tube (507) to the pump air inlet.
To add a fluid regulator to the Graco isolation system,
order Part No. 245944. See page 69 for the kit parts list.
13. Connect the waterborne fluid hose to the fluid regulator outlet fitting (501).
1. Discharge the system voltage (page 21).
14. Return the system to service.
2. Relieve the pressure (page 21).
NOTE: 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.
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 65.
5. Remove the waterborne fluid hose from the pump
fluid outlet fitting (231) and remove the fitting.
Connect to
elbow (282)
inside control
box (258)
506
6. Unscrew the two pump mounting screws (S, Fig. 9)
and remove the pump from the isolation enclosure.
Tube A1
501
507
7. Remove the back of the control box (258).
8. Remove tube (A2) from elbow (282) at the air manifold; see page 65. Install the Y fitting (506) in the
elbow. Install tubes (A2) and (507) into the Y fitting.
Route the tube (507) into the cabinet.
Connect
waterborne
fluid hose here
504
502
505
Connect
tube A2
here
503
S
9. Replace the back of the control box (258).
10. Assemble the fluid regulator kit as shown in Fig. 9.
TI2149A
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.
309293
Fig. 9. Fluid Regulator Kit
Fig. 1.
15
Installation
Notes
16
309293
Installation
Select a Fluid Nozzle and Air
Cap
WARNING
Table 1: Fluid Nozzles
Part No.
Size,
mm (in.)
Part No.
Size,
mm (in.)
197263
0.75 (.030)
197266
1.5 (.055)
197264
1.0 (.042)
197267
1.8 (.070)
197265
1.2 (.047)
197268
2.0 (.080)
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
“Pressure Relief Procedure” on page 21
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 43.
309293
Table 2: Air Caps
Part No.
Pattern Shape
and Length
in. (mm)
Recommended Fluids and
Production Rates
197477
Round end;
15-17 (381-432)
Light to medium viscosity.
Medium to high production.
197478
Round end;
15-17 (381-432)
Light to medium viscosity.
Low to medium production.
197479
Tapered end;
13-15 (330-381)
Light to medium viscosity.
Medium to high production.
197480
Round end;
16-18 (406-457)
Medium to high viscosity
and high solids.
Low to medium production.
197481
Tapered end;
17-19 (432-483)
Medium to high viscosity
and high solids.
Medium to high production.
For use with 2.0 mm nozzle.
17
Installation
Grounding
WARNING
•
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 conductive and grounded. Do not cover the floor with
cardboard or any non-conductive material which
would interrupt grounding continuity.
•
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.
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.
•
Electrostatic Air Spray Gun: ground the gun by connecting the red-colored Graco Grounded Air Hose
and connecting the air hose ground wire to a true
earth ground. See “Check Electrical Grounding”,
page 19.
ti1259a
•
•
18
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 worn, cut off fingers or cut out palm
area, to ensure your hand contacts the grounded
gun handle.
309293
Installation
Check Electrical Grounding
BB
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.
I
ES
O
ti1273a
AA
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
CC
TI2161A
Fig. 10. Check Gun Grounding
Fig. 1.
7. Using an ohmmeter (AA), measure the resistance
between the cabinet ground lug (214) and a true
earth ground (CC). See Fig. 11. The resistance
must be less than 100 ohms.
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 Fig. 10.
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. 11. Check Cabinet Grounding
Fig. 1.
309293
19
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.
Workpiece hangers are clean and grounded.
All operators are trained in the “Pressure
Relief Procedure” on page 21.
The electrostatics are turned off and properly
grounded according to the.“Fluid Voltage
Discharge and Grounding Procedure” on
page 21 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 18.
20
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.
309293
Operation
Fluid Voltage Discharge and
Grounding Procedure
Pressure Relief Procedure
WARNING
WARNING
Pressurized Equipment Hazard
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
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.
I
ES
O
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.
1. Turn the ES ON/OFF valve OFF.
I
ES
O
ti1273a
2. Follow the “Fluid Voltage Discharge and Grounding Procedure” at left.
3. Turn off the main air supply valve (B).
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 Troubleshooting” on page 40.
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.
309293
21
Operation
Fill the Fluid Supply
Adjust the Spray Pattern
1. Discharge the system voltage (page 21).
Follow the steps below to establish the correct fluid flow
and air flow.
2. Relieve the pressure (page 21) .
WARNING
ti1276a
Fire and Explosion Hazard
3. Open the isolated enclosure door.
To reduce the risk of fire and explosion, only
use this equipment with fluids that meet at
least one of the following conditions for nonflammability:.
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.
•
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.
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.
9. Close the isolated enclosure door and fasten
securely with the T-handle locking screw.
22
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 21.
Follow the “Fluid Voltage Discharge and Grounding Procedure” on page 21 when you stop spraying
and whenever you are instructed to discharge the
voltage.
309293
Operation
3. Position the air cap by loosening the air cap retaining ring, and rotating the air cap for a vertical or horizontal spray pattern. Tighten the retaining ring until
the air cap is held firmly in place; you should not be
able to rotate the air cap horns by hand.
WARNING
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.
Vertical Pattern
Horizontal Pattern
WARNING
4. Fully open the fan air adjustment valve.
Pressurized Equipment Hazard
0
KV
100%
µα
To reduce the risk of an injury, follow the
“Pressure Relief Procedure” on page 21
whenever you are instructed to relieve the
pressure.
HI
LO
ES
ES
I
O
1. Make sure the ES ON/OFF valve is OFF.
ti1269a
I
ES
O
5. Fully open the fluid adjustment valve.
0
KV
100%
µα
ti1273a
HI
2. Turn on the main air supply valve (B).
LO
ES
I
ES
O
ti1267a
6. Fully open the atomizing air restrictor valve.
ti1272a
309293
23
Operation
7. Make sure the ES ON/OFF valve is OFF.
Table 3: Air Regulator Settings
I
ES
O
Air Hose Length
ft (m)
Air Regulator Setting
psi (MPa, bar)
(5/16 in. [8 mm] diameter)
(with gun triggered)
15 (4.6)
50 (0.35, 3.5)
25 (7.6)
60 (0.42, 4.2)
50 (15.3)
75 (0.52, 5.2)
ti1273a
8. Adjust the pump air regulator to start the fluid supply unit. Adjust the fluid flow with the air pressure
regulator until the stream from the gun travels 8-12
in. (200-300 mm) before falling off. Typically, if fluid
pressure is below 5 psi (.04 MPa, 0.4 bar) or above
20 psi (0.14 MPa, 1.4 bar), a change of nozzle size
is recommended. Refer to instruction manual
309419 to set the fluid pressure for various fluid
flows, according to the size of the fluid nozzle being
used.
8-12 in. (200-300 mm)
TI1760A
NOTE:
•
For the most efficiency, always use the lowest air
pressure possible.
•
When increasing to a wide, flat pattern, it may be
necessary to increase the supply of fluid to the gun
to maintain the same amount of coverage over a
large area.
10. Spray a test pattern. Check the atomization. If overatomization occurs at minimum pressure, adjust the
air atomizing restrictor valve. If atomization is inadequate, increase the air pressure.
9. Set the gun air regulator to deliver a minimum 40 psi
(0.28 MPa, 2.8 bar) at the gun when triggered, for
maximum transfer efficiency. See Table 3 .
TI1281A
ti1282a
11. Adjust the fan air adjustment valve: clockwise for a
rounder pattern, counterclockwise for a wider pattern.
ti1283a
24
309293
Operation
14. Check the kV meter on the isolated enclosure; 4555 kV is normal.
WARNING
15. Spray a test piece. Examine the edges for coverage.
If wrap is poor, see “Spray Pattern Troubleshooting” on page 38.
Electric Shock Hazard
When the ES ON/OFF switch is turned ON,
the fluid supply is charged with high voltage
until the voltage is discharged. 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.
12. Turn the ES ON/OFF switch ON (I).
ES
I
O
ti1285a
ti1284a
16. When you finish spraying, perform the “Shutdown”
procedure on page 26.
13. Check that the ES indicator or display is lit, or check
that the kV indicator on the isolated enclosure reads
45-55 kV. If not, see “Electrical Troubleshooting”
on page 40 for possible problems.
0
KV
100%
µα
HI
I
ES
O
LO
ES
I
ES
O
ti1266a
ti1253a
309293
25
Operation
Shutdown
Low Voltage Adjustment
(Smart Guns Only)
1. Discharge the system voltage (page 21).
The ES HI/LO switch enables you to switch between full
voltage and a lower voltage output. The lower voltage is
factory set, but can be adjusted.
2. Flush the spray gun. See page 27.
1. Set the ES HI/LO switch to LO.
ti1276a
2. Remove the LO VOLTAGE adjustment plug (53). Set
the desired voltage, using a small screwdriver to
slide switches 1 and 2 ON or OFF, according to
Table 4 . Also see Fig. 12.
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
“Pressure Relief Procedure” on whenever you are instructed to relieve the pressure.
OFF
ON
2
0
KV
1
100%
µα
3. Relieve the pressure (page 21).
53
ti1529a
Fig. 12. Low Voltage Adjustment Switches
Fig. 1.
ti1276a
4. Hang the gun from its hook or place it in the accessory holster, with the nozzle pointing down. Be sure
to keep the gun from grounding out.
Table 4: Low Voltage Adjustment
Factory Setting
1
2
kV
ON
ON
50
OFF
40
OFF
ON
35
OFF
OFF
30
> ON
ti1288a
26
309293
Maintenance
Maintenance
Flush the Spray Gun
1. Turn the ES ON/OFF valve OFF and wait 30 seconds for the voltage to bleed off.
Flush the gun before changing colors, at the end of the
day, before storing, and before repairing the gun.
I
ES
O
ti1273a
WARNING
Fire, Explosion, and Electric Shock
Hazard
2. Discharge the system voltage (page 21).
3. Relieve the pressure (page 21) .
To reduce the risk of fire, explosion, or electric shock, turn the ES ON/OFF valve OFF
before flushing the gun.
Follow the “Fluid Voltage Discharge and
Grounding Procedure” on page 21 before
flushing.
ti1276a
4. Change the fluid source to solvent.
5. Point the gun into a grounded metal pail. Flush until
clean solvent flows from the gun.
Only flush, purge, or clean the gun with fluids that
meet at least one of the following conditions for nonflammability:
ti1276a
•
•
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.
6. Relieve the pressure.
The fluid does not sustain burning when tested
per ASTM Standard D4206 Sustained Burn Test.
ti1276a
WARNING
Pressurized Equipment Hazard
7. Open the isolated enclosure door. Leave the flushing fluid in the system until you are ready to spray
again.
8. Hang the gun from its hook, with the nozzle pointing
down. Be sure to keep the gun from grounding out.
To reduce the risk of an injury, follow the
“Pressure Relief Procedure” on page 21
whenever you are instructed to relieve the
pressure.
ti1288a
9. Before using the system electrostatically again,
make sure no flammable vapors are present.
309293
27
Maintenance
Daily Care and Cleaning
CAUTION
•
Clean the outside of the gun daily with a soft cloth
dampened with a non-flammable solvent, as
defined on page 27.
•
Check for fluid leaks. Tighten all fittings.
•
Clean the air cap and fluid nozzle daily, minimum.
See page 30. Some applications require more frequent cleaning.
•
Fluid in the air passages could cause the gun to
malfunction and could draw current and reduce the
electrostatic effect. Fluid in the power supply cavity
can reduce the alternator life. Do not use any
cleaning method which could allow fluid into the
gun air passages.
•
Hang the gun with its nozzle pointing down when it
is not being used.
•
Clean the workpiece hangers with non-sparking
tools.
•
Clean the fluid and air line filters daily.
•
Check the movement of the trigger and valves.
Lubricate if necessary.
Do not point the gun up while cleaning it.
Do not immerse the gun in fluid.
ti1294a
Do not wipe the gun with a cloth that is heavily
saturated; wring out the excess fluid.
ti1295a
ti1293a
28
309293
Maintenance
CAUTION
•
Inspect the cabinet and clean up any spilled paint.
Conductive paint residue allowed to contact
grounded parts may short out the electrostatics.
•
Keep the inside of the cabinet clean, for proper
operation.
•
Visually inspect the ground strip (240) for damage.
Replace if needed. Measure the resistance weekly.
See page 34.
240
309293
29
Maintenance
Clean the Air Cap and Fluid
Nozzle
5. Clean the air cap (9) with the soft bristle brush and
non-flammable solvent or submerge the air cap in
solvent and wipe it clean.
Equipment Needed
6. With the gun pointing down, clean the fluid nozzle
(7) and the front of the gun with a soft brush dampened with non-flammable solvent.
•
soft bristle brush
•
non-flammable solvent
NOTE: If it appears that there is paint inside the fluid
nozzle (7) air passages, remove the gun from the line for
servicing.
Procedure
1. Turn the ES ON/OFF valve OFF. Wait 30 seconds.
I
ES
7. Carefully install the air cap (9). Be sure to insert the
electrode (29) through the center hole of the air cap.
Rotate the air cap to the desired position.
8. Tighten the retaining ring (27) until the air cap is
held firmly in place; you should not be able to rotate
the air cap horns by hand.
O
ti1273a
9. Test gun resistance, page 31.
2. Discharge the system voltage (page 21).
7
3. Relieve the pressure (page 21).
29
9
27
ti1276a
ti1297a
4. Remove the retaining ring (27) and air cap (9). See
Fig. 13.
Fig. 13. Clean Air Cap and Fluid Nozzle
Fig. 1.
CAUTION
Do not use metal tools to clean the
air cap or fluid nozzle holes as this
could scratch them, and make sure
the electrode is not damaged.
Scratches in the air cap or nozzle or
a damaged electrode can distort the
spray pattern.
30
Grease Door Latch Threads
Inspect the door T-handle locking screw regularly, to
ensure the threads are well greased. Apply silicone-free
grease to the threads when necessary.
309293
Electrical Tests
Electrical Tests
Electrical components inside the gun affect performance and safety. The following procedures test the
condition of the power supply (18) and electrode (29),
and electrical continuity between components.
Use megohmmeter Part No. 241079 (AA) and an
applied voltage of 500 V. Connect the leads as shown.
WARNING
Test Gun Resistance
1. Prepare the gun for service as instructed on page
42.
2. Measure resistance between the electrode needle
tip (29) and the air swivel (35); it should be 117-137
megohms. If outside this range, go to the next test.
If you still have problems, refer to “Voltage Loss
Troubleshooting” on page 35 for other possible
causes of poor performance, or contact your Graco
distributor.
Fire, Explosion, and Electric Shock
Hazard
Megohmmeter Part No. 241079 (AA-see
Fig. 14) is not approved for use in a hazardous area. To reduce the risk of sparking, do
not use the megohmmeter to check electrical grounding unless:
•The gun has been removed from the hazardous area;
AA
29
•Or all spraying devices in the hazardous
area are turned off, ventilation fans in the
hazardous area are operating, and there
are no flammable vapors in the area
(such as open solvent containers or
fumes from spraying).
35
Failure to follow this warning could cause
fire, explosion, and electric shock and result
in serious injury and property damage.
TI1688B
Fig. 14. Test Gun Resistance
Fig. 1.
309293
31
Electrical Tests
Test Power Supply
Resistance
1. Prepare the gun for service as instructed on page
42.
2. Remove the power supply (18), page 47.
3. Remove the turbine alternator (19) from the power
supply, page 48.
18b
EE
4. Measure resistance from the power supply's ground
strips (EE) to the spring (18b). See Fig. 15.
ti1599a
5. The resistance should be 95-105 megohms. If outside this range, replace the power supply. If in
range, proceed to the next test.
Fig. 15. Test Power Supply Resistance
Fig. 1.
6. Be sure the spring (18b) is in place before reinstalling the power supply.
32
309293
Electrical Tests
Test Electrode Resistance
1. Prepare the gun for service as instructed on page
42.
2. Insert a conductive rod (B) into the gun barrel
(removed for the power supply test) and against the
metal contact (C) in the front of the barrel.
3. Measure the resistance between the conductive rod
(B) and the electrode (29). The resistance should be
20-30 megohms. See Fig. 16.
F
29
E
ti1548a
4. If in range, refer to “Electrical Troubleshooting”
on page 40 for other possible causes of poor performance, or contact your Graco distributor.
5. Remove the electrode (29), page 44. Measure the
resistance between the contact (E) and the electrode wire (F). The resistance should be 20-30
megohms. If out of range, replace the electrode.
See Fig. 17.
6. Make sure the metal contact (C) in the barrel, the
nozzle contact ring (7a, Fig. 18), and the electrode
contact (E) are clean and undamaged.
Fig. 17. Electrode
Fig. 1.
ti1513a
7a
Fig. 18. Nozzle Conductive O-Ring
Fig. 1.
C
29
B
ti1499a
Fig. 16. Test Electrode Resistance
Fig. 1.
309293
33
Electrical Tests
Test Ground Strip
Resistance
Test Cylinder Resistance
See Fig. 19. Using an ohmmeter, measure the resistance between the latch housing (206) and the ground
lug (214). The ground strip is grounded through the cart
back to the ground lug. Resistance must be less than
100 ohms. If greater than 100 ohms, replace the ground
strip (240).
See Fig. 20. Remove the enclosure door. Using an ohmmeter, measure the resistance from the pump (209) to
the ground lug (214). Resistance must be less than 100
ohms. If greater than 100 ohms, replace the grounding
cylinder.
209
214
206
214
TI2165A
Fig. 19. Test Ground Strip Resistance
Fig. 1.
TI2164A
Fig. 20. Test Cylinder Resistance
Fig. 1.
34
309293
Troubleshooting
Troubleshooting
WARNING
Electric Shock Hazard
Installing and servicing this equipment
requires access to parts which may cause
an electric shock or other serious injury if
the work is not performed properly. Do not install or
repair this equipment unless you are trained and
qualified.
A loss of spraying voltage can be caused by a problem
with the spray gun, fluid hose, or voltage isolation system, since all of the system components are electrically
connected through the conductive, waterborne fluid.
Before troubleshooting or servicing the voltage isolation
system itself, you need to determine which component
in the system is most likely causing a problem. Possible
causes include the following:
Spray Gun
•
Fluid leakage
•
Dielectric breakdown at the fluid hose connection or
fluid packings
•
Not enough air pressure for the turbine
•
Faulty power supply
WARNING
•
Excessive overspray on gun surfaces
Pressurized Equipment Hazard
•
Fluid in the air passages
Follow the “Fluid Voltage Discharge and Grounding Procedure” on page 21 before checking or servicing the system and whenever you are instructed to
discharge the voltage.
To reduce the risk of an injury, follow the
“Pressure Relief Procedure” on page 21
before checking or servicing any part of the
system and whenever you are instructed to
relieve the pressure.
Waterborne Fluid Hose
•
•
Voltage Loss
Troubleshooting
Normal spraying voltage for a system using the waterborne gun is 45-55 kV. The system voltage is lower due
to spraying current demands and voltage isolation system losses.
309293
Dielectric failure of hose (pin-hole leak through
PTFE layer)
Air gap in the fluid column between the gun and isolated fluid supply, causing a low voltage reading on
the isolation system voltage meter.
Voltage Isolation System
•
Fluid leakage
•
Dirty interior
35
Troubleshooting
Visual Check
First, check the system for any visible faults or errors to
help isolate whether the spray gun, fluid hose or voltage
isolation system has failed. A voltage probe and meter,
part no. 236003, is helpful for diagnosing voltage problems and is required for some of the troubleshooting
tests that follow.
1. Check that all of the air and fluid tubes and hoses
are properly connected.
10. Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found. Pay
special attention to the following areas:
•
Packing area of the spray gun
•
Fluid hose: check for leakage or any bulges in the
outer cover, which may indicate an internal leak
•
Internal voltage isolation system components
Tests
2. Check that the voltage isolation system valves and
controls are properly set for operation.
3. Check that the interior of the isolated enclosure is
clean.
If you still have no voltage, separate the spray gun and
hose from the voltage isolation system and check
whether the gun and hose alone will hold voltage with
the following test.
4. Check that the spray gun and voltage isolation system have sufficient air pressure.
1. Flush the system with water and leave the lines
filled with water.
5. Check that the gun ES ON/OFF valve is in the ON
position and that the gun ES indicator light is on. If
the ES indicator light is not on, remove the spray
gun for service and complete the electrical tests on
pages 31- 33.
2. Discharge the system voltage (page 21).
6. Check that the voltage isolation system's enclosure
door is closed and that any safety interlocks are
engaged and working properly.
7. Make sure the voltage isolation system is in the "isolate" mode, where it is isolating the fluid voltage
from ground.
8. To eliminate air gaps in the fluid column, spray
enough fluid to purge the air out between the voltage isolation system and the spray gun. An air gap
in the fluid hose can break the electrical continuity
between the spray gun and the isolated fluid supply
and cause a low voltage reading on a voltage meter
connected to the isolated fluid supply.
9. Check the spray gun cover and barrel for accumulated overspray. Excessive overspray can create a
conductive path back to the grounded gun handle.
Install a new gun cover and clean the exterior of the
gun.
36
3. Relieve the pressure (page 21).
4. Disconnect the fluid hose from the voltage isolation
system.
NOTE: Avoid allowing any water to leak out of the fluid
hose as that could cause a significant air gap in the fluid
column up to the gun electrode, which can break the
conductivity path and conceal a potential failure area.
5. Position the end of the hose as far as possible away
from any grounded surface. The end of the hose
must be at least 1 ft. (0.3 m) from any ground. Make
sure that no one is within 3 ft. (0.9 m) of the end of
the hose.
6. Turn the ES ON/OFF valve to ON and trigger the
gun just enough to turn on the air to the gun but not
the fluid. Measure the voltage at the gun electrode
with a voltage probe and meter.
7. Discharge the system voltage by waiting 30 seconds and then touching the gun electrode with a
grounded rod.
309293
Troubleshooting
8. If the meter reading is 45 to 55 kV, the gun and fluid
hose are okay, and the problem is in the voltage isolation system.
Inspect the end of the hose connected to the voltage isolation system. Look for cuts or nicks.
Make sure the hose is properly stripped (see step 2
on page 12). Restrip or replace the hose.
If the reading is below 45 kV, the problem is in the
gun or fluid hose.
•
9. Flush the fluid hose and gun with enough air to dry
out the fluid passages.
10. Turn the ES ON/OFF valve to ON and trigger the
gun. Measure the voltage at the gun electrode with
a voltage probe and meter.
11. If the meter reading is 45-55 kV, the gun power supply is okay, and there is probably a dielectric breakdown somewhere in the fluid hose or gun. Continue
with step 12.
If the reading is below 45 kV, do the electrical tests
on page 31 to check the gun and power supply
resistance. If those tests show the gun and power
supply are okay, continue with step 12.
12. A dielectric breakdown is most likely in one of the
following three areas. Repair or replace the component that is failing.
•
Fluid hose
Fluid packings
Remove the packing assembly from the gun as
instructed on page 45, and look for signs of fluid
leakage or any blackened areas, which would indicate arcing is occurring along the packing rod.
•
Fluid hose connection joint to the spray gun
A breakdown at the fluid hose connection joint
would be caused by fluid leaking past the o-ring
seals on the end of the hose. Remove the hose at
the gun connection and look for signs of fluid leakage along the PTFE tube.
13. Before reassembling the gun, clean and dry the gun
fluid inlet tube. Repack the inner spacer of the fluid
packing rod with dielectric grease and reassemble
the gun.
14. Reconnect the fluid hose.
15. Check the gun voltage with the voltage probe and
meter before filling the gun with fluid.
Check for leakage or any bulges in the outer cover,
which may indicate a pin-hole leak through the
PTFE layer. Disconnect the fluid hose from the gun,
and look for signs of fluid contamination on the outside of the PTFE portion of the fluid tube.
309293
37
Troubleshooting
Spray Pattern Troubleshooting
NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun.
NOTE: Some spray pattern problems are caused by the improper balance between air and fluid.
Problem
Cause
Solution
Fluttering or spitting spray.
No fluid.
Loose, dirty, damaged nozzle/seat.
Refill supply.
Clean or replace nozzle, page 43.
Air in fluid supply.
Damaged nozzle or air cap.
Check fluid source. Refill.
Replace, page 43.
Fluid buildup on air cap or nozzle.
Clean. See page 30.
Fan air pressure too high.
Decrease.
Fluid too thin.
Fluid pressure too low.
Fan air pressure too low.
Increase viscosity.
Increase.
Increase.
Fluid too thick.
Too much fluid.
Did not apply 50% overlap.
Dirty or damaged air cap.
Reduce viscosity.
Decrease flow.
Overlap strokes 50%.
Clean or replace, page 43.
Improper spray pattern.
Streaks.
38
309293
Troubleshooting
Gun Operation Troubleshooting
Problem
Cause
Excessive spray fog.
Atomizing air pressure too high.
“Orange Peel” finish.
Fluid leaks from the fluid packing
area
Air leaks from the front of the gun
Fluid leakage from the front of the
gun
Solution
Close restrictor valve some, or
decrease air pressure as low as possible; minimum 40 psi (0.28 MPa, 2.8
bar) needed at gun for full voltage.
Fluid too thin.
Increase viscosity.
Atomizing air pressure too low.
Open atomizing air valve more or
increase gun air inlet pressure; use
lowest air pressure necessary.
Poorly mixed or filtered fluid.
Remix or refilter fluid.
Fluid too thick.
Reduce viscosity.
Worn packings or rod.
Replace packings or rod; see page
46.
Air valve (21) is not seating properly. Clean and service air valve; see
page 51.
Worn or damaged packing rod (26). Replace; see page 46
Worn fluid seat.
Gun does not spray
Dirty air cap
309293
Replace fluid nozzle and/or electrode
needle; see pages 43 to 44.
Loose fluid nozzle (7).
Tighten; see page 43.
Damaged nozzle o-ring (7b).
Replace; see page 43.
Low fluid supply.
Add fluid if necessary.
Damaged air cap (9).
Replace; see page 43.
Dirty or clogged fluid nozzle (7).
Clean; see page 43.
Damaged fluid nozzle (7).
Replace; see page 43.
Damaged fluid adjustment valve (25). Replace; see page 51.
Misaligned air cap (9) and fluid noz- Clean fluid buildup off air cap and
zle (7).
fluid nozzle seat; see page 30.
39
Troubleshooting
Electrical Troubleshooting
Problem
Cause
Solution
Voltage still present at gun after fol- ES ON/OFF valve is not turned OFF. Turn OFF.
lowing the “Fluid Voltage Discharge
and Grounding Procedure”
Did not wait long enough for voltage Wait longer before touching electrode
to discharge.
with grounded rod. Check for bleed
resistor failure.
Air pocket in fluid line leaves fluid
Determine cause and correct. Purge
near gun isolated.
air from fluid line.
Voltage isolation system failed.
Service voltage isolation system.
Grounding cylinder not operating.
Check resistance of grounding cylinder, page 34. Replace if needed.
Poor wrap.
ES ON/OFF valve OFF (0).*
Turn ON (I).
Gun air pressure too low.
Check air pressure to gun; minimum
40 psi (0.28 MPa, 2.8 bar) needed at
gun for full voltage.
Atomizing air pressure too high.
Decrease.
Fluid pressure too high.
Decrease.
Incorrect distance from gun to part.
Should be 8-12 in. (200-300 mm).
Poorly grounded parts.
Resistance must be 1 megohm or
less. Clean workpiece hangers.
Faulty gun resistance.
See “Test Gun Resistance” on
page 31.
Fluid leaks from the packing (26d)
Clean the packing rod cavity.
and causes a short.
Replace the packing rod. See page
46.
Faulty turbine alternator.
Be sure the plug is in place on the
back of the turbine alternator housing. Remove and test the turbine
alternator. See page 49.
The KV HI-LO lever is on LO.
Check the lever actuation; replace if
needed.
Spilled paint, dried paint, or other
Clean interior of enclosure.
contaminants inside WB100 enclosure, causing a short circuit.
40
309293
Troubleshooting
Problem
Cause
Solution
ES indicator or voltage/current display is not lit.
ES ON/OFF valve OFF (0).*
Turn ON (I).
No power.
Gun too close to part.
Replace power supply. See page 48.
Should be 8-12 in. (200-300 mm).
Check fluid resistivity.
Dirty gun.
Operator not grounded or is near
ungrounded object.
Gun not grounded.
See “Operation” on page 20.
Clean. See page 28.
See “Grounding” on page 18.
Voltage/current display stays red
(smart guns only).
Operator gets mild shock.
Operator gets shock from workpiece. Workpiece not grounded.
See “Check Electrical Grounding”
on page 19 and “Test Gun Resistance” on page 31.
Resistance must be 1 megohm or
less. Clean workpiece hangers.
* ES indicator light is off when the gun is triggered.
309293
41
Repair
Repair
Prepare the Gun for Service
WARNING
Fire, Explosion, and Electric Shock
Hazard
To reduce the risk of a fire, explosion, or
electric shock:
• Follow the “Fluid Voltage Discharge
and Grounding Procedure” on page 21
and be sure the ES ON/OFF valve is
OFF before flushing, checking, or servicing the system and whenever you are
instructed to discharge the voltage.
• Clean all parts with a non-flammable
fluid as defined on the front cover of this
manual.
• Do not service this equipment unless you
are trained and qualified.
• Do not touch the gun nozzle or come
within 4 in. (102 mm) of the nozzle during
gun operation or until you perform the
“Fluid Voltage Discharge and Grounding Procedure” on page 21.
NOTE:
•
Check all possible remedies in “Troubleshooting”
before disassembling the gun.
•
Use a vise with padded jaws to prevent damage to
plastic parts.
•
Lubricate the power supply o-ring (18a), some
packing rod parts (26), and certain fluid fittings with
dielectric grease (40), as specified in the text.
•
Lightly lubricate o-rings and seals with non-silicone
grease. Order Part No. 111265 Lubricant. Do not
over-lubricate.
•
Only use genuine Graco parts. Do not mix or use
parts from other PRO Gun models.
•
Air Seal Repair Kit 244781 is available. The kit must
be purchased separately. Kit parts are marked with
an asterisk, for example (6*).
•
Fluid Seal Repair Kit 244911 is available. The kit
must be purchased separately. Kit parts are
marked with a double asterisk, for example (26a**).
1. Follow the “Fluid Voltage Discharge and Grounding Procedure” on page 21.
2. Flush the gun, page 27.
3. Blow the fluid lines dry with air.
WARNING
Pressurized Equipment Hazard
To reduce the risk of injury, follow the
“Pressure Relief Procedure” on page 21
before checking or servicing any part of the
system and whenever you are instructed to relieve
the pressure.
42
4. Relieve the pressure, page 21.
5. Disconnect the gun air and fluid lines at the isolation
system.
6. Remove the gun from the worksite. Repair area
must be clean.
309293
Repair
Air Cap/Nozzle Replacement
WARNING
Fire, Explosion, and Electric Shock
Hazard
CAUTION
Hold the front end of the gun up and trigger the gun
while removing the nozzle to help drain the gun and
prevent any paint or solvent left in the gun from entering the air passages.
1. Prepare gun for service, page 42.
2. Remove the retaining ring (27) and air cap (9). See
Fig. 21.
3. Point gun up and squeeze trigger while removing
the fluid nozzle (7) assembly with the multi-tool (37).
27
The nozzle contact ring (7a) is a conductive
contact ring, not a sealing o-ring. To reduce
the risk of sparking or electric shock, do not
remove the nozzle contact ring (7a) except
to replace it and never operate the gun without the contact ring in place. Do not replace
the contact ring with anything but a genuine
Graco part.
NOTE: Use non-silicone grease, Part No. 111265, on
the small o-ring (7b). Do not over-lubricate. Do not lubricate the contact ring (7a).
4. Lightly lubricate the o-ring (7b). Install it and the
contact ring (7a) on the nozzle (7).
27a*
NOTE: Make sure the electrode needle (29) is fingertight (page 44).
9
5. Trigger gun while installing the fluid nozzle (7) with
the multi-tool (37). Tighten until the fluid nozzle
seats in the gun barrel (1/8 to 1/4 turn past handtight).
37
7
7a
6. Install the air cap (9) and retaining ring (27). Make
sure the u-cup (27a*) is in place with the lips facing
forward.
7. Test gun resistance, page 31.
7b
ti1501a
Fig. 21. Air Cap/Nozzle Replacement
Fig. 1.
309293
43
Repair
Electrode Replacement
1. Prepare the gun for service, page 42.
2. Remove the air cap and nozzle, page 43.
3. Unscrew the electrode (29) with the multi-tool (37).
Hold the packing rod end (26h) to prevent it from
turning, Fig. 22.
37
CAUTION
To avoid damaging the plastic threads, be very careful when installing the electrode.
4. Apply low-strength (purple) Loctite® or equivalent
thread sealant to the electrode and packing rod
threads. Install the electrode finger-tight. Do not
overtighten.
TI1682a
5. Install the fluid nozzle and air cap, page 43.
6. Test gun resistance, page 31.
44
Fig. 22. Electrode Replacement
Fig. 1.
309293
Repair
Fluid Packing Removal
1. Prepare the gun for service, page 42.
2. Remove the air cap and fluid nozzle, page 43.
3. Remove the electrode, page 44.
4. Loosen the trigger screws (8) and trigger (30). See
Fig. 23.
5. Remove the packing rod (26), using the multi-tool
(37).
37
30
CAUTION
8
Clean all parts in non-conductive solvent compatible
with the fluid being used, such as xylol or mineral
spirits. Use of conductive solvents can cause the gun
to malfunction.
TI1683A
6. Check all parts for wear or damage and replace if
necessary.
309293
Fig. 23. Fluid Packing Removal
Fig. 1.
45
Repair
Packing Rod Repair
You may replace the packing rod as individual parts or
as an assembly. The assembly is pre-adjusted at the
factory.
NOTE: Before installing the fluid packing rod into the
gun barrel, make sure the internal surfaces of the barrel
are clean. Remove any residue with a soft brush or
cloth. Check the inside of the barrel for marks from high
voltage arcing. If marks are present, replace the barrel.
To assemble the individual parts:
1. Place the packing nut (26e) and seal (26b**) on the
fluid rod (26h). Flats on the packing nut must face
the back of the fluid rod. The seal o-ring must face
away from the packing nut. See Fig. 24.
4. Lightly tighten the packing nut (26e). The packing
nut is properly tightened when there is 3 lb (13.3 N)
of drag force when sliding the packing housing (26f)
assembly along the rod. Tighten or loosen the packing nut as needed.
5. Install the o-ring (26a**) on the outside of housing
(26f). Lubricate the o-ring with non-silicone grease,
Part No. 111265. Do not over-lubricate.
6. Install the spring (4) against the nut (E) as shown.
7. Install the packing rod assembly (26) into the gun
barrel. Using the multi-tool (37), tighten the assembly until just snug.
8. Install the trigger (30) and screws (8).
9. Install the electrode, page 44.
2. Fill the inner cavity of the spacer (26g**) with dielectric grease (40). Place the spacer on the fluid rod
(26h) in the direction shown. Generously apply
dielectric grease to the outside of the spacer.
10. Install the nozzle and air cap, page 43.
11. Test gun resistance, page 31.
3. Place the rod packing (26d**), packing spreader
(26c**), and housing (26f) on the packing rod (26h) .
4
E
TI1489A
26h
26e
**26b
**26d
**26c
**26g
26f
**26a
Fig. 24. Packing Rod
46
309293
Repair
Barrel Removal
5. Apply dielectric grease (40) to the exposed inner
tube of the fluid hose (101).
1. Prepare the gun for service, page 42.
6. Check that the nut (105) is tight on the ferrule housing (103).
2. Remove the air inlet fitting (35) and take the bracket
(104) off the gun handle (17).
7. Test gun resistance, page 31.
3. Loosen the three screws (11).
CAUTION
104
11
To avoid damaging the power supply (18), pull the
gun barrel straight away from the gun handle. If necessary, gently move the gun barrel from side to side
to free it from the gun handle.
16
4. Hold the gun handle (17) with one hand and pull the
barrel (16) straight off the handle. See Fig. 25.
TI1690A
35
Barrel Installation
17
17
1. Be sure the gasket (10*) and grounding spring (55)
are in place. Make sure the gasket air holes are
aligned properly. Replace if damaged. See Fig. 26.
TI1691A
Fig. 25. Barrel Removal
Fig. 1.
2. Place the barrel (16) over the power supply (18) and
onto the gun handle (17).
*10
18
3. Tighten the three screws (11) oppositely and evenly
(about a half turn past snug).
11
16
CAUTION
55
35
Do not over-tighten the screws (11).
101
4. Position the bracket (104) on the gun handle (17)
and secure with the air inlet fitting (35).
104
105
TI1692A
Fig. 26. Barrel Installation
Fig. 1.
309293
47
Repair
Power Supply Removal and
Replacement
8. Lubricate the alternator o-ring (19a*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
NOTE:
9. Lubricate the power supply o-ring (18a*) with dielectric grease (40).
•
Inspect the gun handle power supply cavity for dirt
or moisture. Clean with a clean, dry rag.
•
Do not expose gasket (10) to solvents.
1. Prepare gun for service, page 42.
2. Remove the barrel (16), page 47.
10. Insert the power supply/alternator assembly in the
gun handle (17). Make sure the ground strips make
contact with the handle. On Smart Models only, connect the flexible circuit (59) to the socket at the top
of the handle. Push the 6-pin connector into the
socket to ensure it is properly connected.
11. Install the barrel (16), page 47.
12. Test gun resistance, page 31.
CAUTION
Be careful when handling the power supply (18) to
avoid damaging it.
17
3. Grasp the power supply (18) with your hand. With a
gentle side to side motion, free the power supply/
alternator assembly from the gun handle (17), then
carefully pull it straight out. On Smart Models only,
disconnect the flexible circuit (59) from the socket at
the top of the handle (17). See Fig. 27.
4. Disconnect the 3-wire connector (GG) from the
power supply. Slide the alternator up and off the
power supply. Inspect the power supply and alternator for damage. On Smart Models only, disconnect
the 6-pin flexible circuit (59) from the power supply.
10*
19a*
19
19e
59
ti1505c
GG
5. Check the power supply resistance, page 32.
Replace if necessary.
NOTE: Before installing the power supply, make sure
the o-rings (18a*, 19a*), spring (18b), and pads (19e)
are in place.
18
6. On Smart Models only, connect the 6-pin flexible circuit (59) to the power supply.
*18a
7. Connect the 3-wire connector (GG). Slide the alternator (19) down onto the power supply (18).
48
18b
Fig. 27. Power Supply
Fig. 1.
309293
Repair
Turbine Alternator Removal
and Replacement
NOTE: Replace turbine alternator bearings after 2000
hours of operation. Order Part No. 223688 Bearing Kit.
1. Prepare gun for service, page 42.
2. Remove the power supply/alternator assembly,
page 48.
4. Measure resistance between the two outer terminals of the 3-wire connector (GG); it should be 2.53.5 ohms. If outside this range, replace the alternator coil.
5. Follow the bearing replacement procedure in the
bearing kit manual 308034.
6. Install the alternator on the power supply, page 48.
7. Install the power supply/alternator assembly, page
48.
3. Disconnect the alternator from the power supply,
page 48.
309293
49
Repair
Fan Air Adjustment Valve
Repair
6. Clean all parts and inspect for wear or damage.
1. Prepare the gun for service, page 42.
7. When reassembling the fan air valve (20), lightly
lubricate the valve threads and screw the stem
(20d) fully into the housing (20c) until bottomed.
Install the o-ring (20b*), lubricate, and unscrew the
valve stem until the o-ring enters the housing.
2. Place a wrench on the flats of the valve assembly
(20) and unscrew it from the handle (17).
NOTE: You may replace the valve as an assembly (go
to step 9) or as individual parts (steps 3-9).
3. Remove the retaining ring (20a). See Fig. 28.
4. Turn the valve stem (20d) counterclockwise until it
comes free from the valve housing (20c).
NOTE: Use non-silicone grease, Part No. 111265. Do
not over-lubricate.
8. Reassemble the retaining ring (20a). Unscrew the
valve stem from the housing until it is stopped by the
retaining ring.
9. Screw the valve assembly (20) into the gun handle,
using a wrench on the flats of the housing. Torque to
15-25 in-lb (1.7-2.8 N•m).
5. Remove the o-ring (20b).
20d
TI1487A
20b*
20c
20a
Fig. 28. Fan Air Adjustment Valve
50
309293
Repair
Fluid Adjustment Valve
Repair
4. Remove the air valve (21) with a pliers. Inspect the
seal (21a*) and replace if damaged. Be sure the
seal is pressed securely onto the valve so the outer
cone is flat.
1. Prepare the gun for service, page 42.
CAUTION
2. Remove the fluid adjustment valve (25). It can only
be replaced as a complete assembly. See Fig. 29.
3. Screw the valve (25) into the gun handle. Torque to
15-25 in-lb (1.7-2.8 N•m).
When removing the air valve (21) be careful not to
damage the seat area.
5. Inspect the u-cup (6*). Do not remove the u-cup
unless damaged. If removed, install the new one
with its lips facing into the gun handle (17).
6. Install the air valve (21) and spring (15) into the gun
handle (17).
25
7. Install the fluid adjustment valve (25). Torque to 1525 in-lb (1.7-2.8 N•m).
8. Install the barrel, page 47.
TI1684A
Fig. 29. Fluid Adjustment Valve
Fig. 1.
Air Valve Repair
21
15
25
21a*
17
1. Prepare the gun for service, page 42.
2. Remove the barrel, page 47.
*6
3. Remove the fluid adjustment valve (25) from the
handle (17). Remove the spring (15). See Fig. 30.
TI1685A
Fig. 30. Air Valve
Fig. 1.
CAUTION
Clean all parts in non-conductive solvent compatible
with the fluid being used, such as xylol or mineral
spirits. Use of conductive solvents can cause the gun
to malfunction.
309293
51
Repair
Atomizing Air Restrictor
Valve Removal and
Replacement
ES ON/OFF Valve Repair
1. Prepare the gun for service, page 42.
2. Loosen the screw (48). Remove the valve.
1. Prepare the gun for service, page 42.
2. Remove the atomizing air restrictor valve (23) .
Inspect the o-ring (23c*). Replace if necessary. See
Fig. 31.
3. Install a new atomizing air restrictor valve (23), or
disassemble and replace parts individually. The
valve protrusion must be oriented to clear the air
valve (21) shaft.
NOTE: If the atomizing air restrictor valve is not desired,
install the supplied plug (47).
4. Torque the valve housing (23a) to 15-20 in-lb (1.72.3 N•m).
3. Lubricate the o-rings (22a* and 22b*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
CAUTION
Do not over-lubricate parts. Excessive lubricant on
the o-rings can be pushed into the gun air passage
and blemish the finish on the workpiece.
4. Clean and inspect parts for damage. Replace if necessary.
NOTE: The protrusion on the retainer plate (22d) must
point upward.
5. Reinstall the valve. Torque the screw (48) to 15-25
in-lb (1.7-2.8 N•m).
23c*
23a 47
22d
22f
22g
22e
23d
22b*
23b
22c
TI1686A
22a*
Fig. 31. Atomizing Air Restrictor Valve
Fig. 1.
48
TI1488A
Fig. 32. ES ON/OFF Valve
Fig. 1.
52
309293
Parts
Parts
Part No. 244581 60 kV Electrostatic Gun, Series A (items 4-55)
Part No. 245301 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-55, 101-108)
See page 54 for detail views of the alternator (19), fan adjustment
valve (20), ES ON/OFF valve (22), and packing rod (26).
22
I
ES
19a*
20
O
19e
19
18
28
25
18b
ti1266a
15
17
*18a
7a
25 (Ref)
7b
21a*
*10
7
21
16
9
11
11
27a*
23c*
27
*6
55
8
23a
23b
24
*24a
4
47
23d
30
35
105
36
104
108 107
106
26
29
38
103
102
101
37
309293
39
TI1679A
53
Parts
Ref. No. 19: Alternator
Ref. No. 20: Fan Adjustment Valve
20d
19a*
19b
TI1487A
20b*
20c
19b
20a
TI1481a
19e
19d 19c
Ref. No. 26: Packing Rod
Ref. No. 22: ES ON/OFF Valve
22e
26b**
22d 22f
26h
ti1601a
26g**
26d**
22g
22b*
26e
26c**
22c
26f
22a*
48
26a**
TI1488A
54
309293
Parts
Part No. 244581 60 kV Electrostatic Gun, Series A (items 4-55)
Part No. 245301 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-55, 101-108)
Ref.
No.
Part No.
Description
4
185111
SPRING, compression
1
6*
188749
PACKING, u-cup, air valve;
uhmwpe
1
Qty
Ref.
No.
Part No.
Description
20c
197566
. HOUSING, fan valve
1
20d
197567
. STEM, fan valve
1
21
244557
VALVE, air; includes 21a
1
21a*
276733
. SEAL; fluoroelastomer
1
Qty
7
197266
NOZZLE; 1.5 mm orifice; includes
7a and 7b
1
22
244558
VALVE, electrostatics, ON/OFF;
includes 22a-22g
1
7a
111261
. O-RING, conductive
1
22a*
111516
. O-RING; CV75
1
7b
111507
. O-RING; fluoroelastomer
1
22b*
113137
. O-RING; fluoroelastomer
1
8
197369
SCREW, trigger
2
22c
198403
. SHAFT, valve
1
9
197477
AIR CAP
1
22d
198404
. PLATE, retaining
1
10*
197517
GASKET, barrel
1
22e
198453
. WASHER
1
11
197518
SCREW; socket-hd; 10-24 x 3/4
in. (19 mm)
3
22f
198464
. PIN
1
15
185116
SPRING, compression
1
22g
276753
. KNOB
1
16
244394
BARREL, gun
1
23
244559
VALVE, air, atomizing; includes
23a-23d
1
17
245292
HANDLE, gun
1
23a
197594
. HOUSING, valve
1
18
244542
POWER SUPPLY, 60 kV; includes
18a-18d
1
23b
197591
. SHAFT
1
18a*
103337
. O-RING; Viton®
1
23c*
168518
. O-RING; Viton®
2
18b
197624
. SPRING, compression
1
23d
101021
. RING, retaining
1
19
244555
TURBINE, alternator; includes
19a-19e
1
24
244560
VALVE, exhaust; includes 24a
1
24a*
106555
. O-RING; fluoroelastomer
1
19a*
110073
. O-RING; Viton®
1
25
244593
VALVE, adjustment, fluid
1
19b
223688
. BEARING KIT; includes front
and rear bearings and fan
1
26
244521
ROD, packing; includes 26a-26h
1
26a** 111316
. O-RING; fluoroelastomer
1
19c
244577
. COIL
1
26b** 116905
. SEAL
1
19d
111745
. RING, retaining
1
26c** 178409
. SPREADER, packing; uhmwpe
1
19e
198821
. PAD, pressure
2
26d** 178763
. PACKING, rod; acetal
1
20
244556
VALVE, adjustment, fan; includes
20a-20d
1
26e
197641
. NUT, packing
1
20a
101021
. RING, retaining
1
26f
185495
. HOUSING, packing
1
20b*
106560
. O-RING; fluorocarbon
1
26g** 186069
. SPACER, packing; Delrin®
1
309293
55
Parts
Ref.
No.
Part No.
Description
26h
244696
. ROD, packing
1
27
245790
RING, retaining; includes 27a
1
27a*
198307
. PACKING, u-cup
1
28
276695
HOOK
1
29
276867
NEEDLE, electrode; black
1
30
276698
TRIGGER
1
35
245496
SWIVEL, air; 1/4 npsm(m) ; lefthand threads
1
36
107460
WRENCH, ball end; 4 mm
1
37
276741
MULTI-TOOL
1
38
185103
TUBE, exhaust
1
39
110231
CLAMP
1
40
116553
GREASE, dielectric, tube (not
shown)
1
Qty
41
244915
COVER, gun; box of 10 (not
shown)
1
42
179791
TAG, warning (not shown);
replacement available at no cost
1
56
Ref.
No.
Part No.
Description
43
180060
SIGN, warning (not shown);
replacement available at no cost
1
47
197967
PLUG
1
48
198058
SCREW, cap, socket hd
1
55
197624
SPRING, grounding
1
101
245252
HOSE, fluid, waterborne; used on
245301 only; includes 102-108
1
102
198663
. FERRULE
1
103
185547
. HOUSING, ferrule
1
104
197954
. BRACKET, fluid fitting
1
105
185548
. NUT
1
106
198643
. FITTING, barrel
1
107
102982
. O-RING
1
108
198640
. FITTING, seal
1
Qty
* Included in Air Seal Repair Kit 244781.
** Included in Fluid Seal Repair Kit 244911.
NOTE: Replacement Warning labels, signs, tags, and
cards are available at no cost.
309293
Parts
Part No. 244582 60 kV Electrostatic Gun, Series A (items 4-59)
Part No. 245305 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-59, 101-108)
See page 58 for detail views of the alternator (19), fan adjustment
valve (20), ES ON/OFF valve (22), and packing rod (26).
53 (Ref)
0
KV
100%
µα
51 (Ref)
19a*
59
HI
LO
ES
I
19
22
ES
20
O
18
ti1253a
28
18b
19e
53
52
51
54
25
15
21
*18a
7a
25 (Ref)
7b
17
*10
7
16
9
21a*
11
27a*
11
23c*
27
*6
8
55
47
23d
23a
24
*24a
4
23b
30
35
105
36
104
38
26
29
108 107
103
106
37
309293
101
102
39
TI1687A
57
Parts
Ref. No. 19: Alternator
Ref. No. 20: Fan Adjustment Valve
19a*
20d
19b
TI1487A
20b*
20c
19b
TI1481a
20a
19e
19d 19c
Ref. No. 22: ES ON/OFF Valve
22e
Ref. No. 26: Packing Rod
22d 22f
22g
22b*
26b**
26g**
26d**
26c**
22c
22a*
26e
26h
ti1601a
26f
48
26a**
TI1488A
58
309293
Parts
Part No. 244582 60 kV Electrostatic Gun, Series A (items 4-59)
Part No. 245305 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-59, 101-108)
Ref.
No.
Part No.
Description
4
185111
SPRING, compression
1
6*
188749
PACKING, u-cup, air valve;
uhmwpe
1
Qty
Ref.
No.
Part No.
Description
20c
197566
. HOUSING, fan valve
1
20d
197567
. STEM, fan valve
1
21
244557
VALVE, air; includes item 21a
1
21a*
276733
. SEAL; fluoroelastomer
1
Qty
7
197266
NOZZLE; 1.5 mm orifice; includes
7a and 7b
1
22
244558
VALVE, electrostatics, ON/OFF;
includes 22a-22g
1
7a
111261
. O-RING, conductive
1
22a*
111516
. O-RING; CV75
1
7b
111507
. O-RING; fluoroelastomer
1
22b*
113137
. O-RING; fluoroelastomer
1
8
197369
SCREW, trigger
2
22c
198403
. SHAFT, valve
1
9
197477
AIR CAP
1
22d
198404
. PLATE, retaining
1
10*
197517
GASKET, barrel
1
22e
198453
. WASHER
1
11
197518
SCREW; socket-hd; 10-24 x 3/4
in. (19 mm)
3
22f
198464
. PIN
1
15
185116
SPRING, compression
1
22g
276753
. KNOB
1
16
244394
BARREL, gun
1
23
244559
VALVE, air, atomizing; includes
23a-23d
1
17
245293
HANDLE, gun
1
23a
197594
. HOUSING, valve
1
18
244542
POWER SUPPLY, 60 kV; includes
18a-18d
1
23b
197591
. SHAFT
1
18a*
103337
. O-RING; Viton®
1
23c*
168518
. O-RING; Viton®
2
18b
197624
. SPRING, compression
1
23d
101021
. RING, retaining
1
19
244555
TURBINE, alternator; includes
19a-19e
1
24
244560
VALVE, exhaust; includes 24a
1
24a*
106555
. O-RING; fluoroelastomer
1
19a*
110073
. O-RING; Viton®
1
25
244593
VALVE, adjustment, fluid
1
19b
223688
. BEARING KIT; includes front
and rear bearings and fan
1
26
244521
ROD, packing; includes 26a-26h
1
26a** 111316
. O-RING; fluoroelastomer
1
19c
244577
. COIL
1
26b** 116905
. SEAL
1
19d
111745
. RING, retaining
1
26c** 178409
. SPREADER, packing; uhmwpe
1
19e
198821
. PAD, pressure
2
26d** 178763
. PACKING, rod; acetal
1
20
244556
VALVE, adjustment, fan; includes
20a-20d
1
26e
197641
. NUT, packing
1
20a
101021
. RING, retaining
1
26f
185495
. HOUSING, packing
1
20b*
106560
. O-RING; fluorocarbon
1
26g** 186069
. SPACER, packing; Delrin®
1
309293
59
Parts
Ref.
No.
Part No.
Description
26h
244696
. ROD, packing
27
245790
27a*
Ref.
No.
Part No.
Description
1
48
198058
SCREW, cap, socket hd
1
RING, retaining, air cap; includes
item 27a
1
51
244627
SWITCH, ES HI/LO
1
52
111450
O-RING
1
198307
. PACKING, u-cup
1
53
276734
PLUG, LO voltage adjustment
1
28
276695
HOOK
1
54
197910
SCREW, pivot
1
29
276867
NEEDLE, electrode; black
1
55
197624
SPRING, grounding
1
30
276698
TRIGGER
1
59
245265
CIRCUIT, flexible
1
35
245496
SWIVEL, air; 1/4 npsm(m) ; lefthand threads
1
101
245252
HOSE, fluid, waterborne; used on
245305 only; includes 102-108
1
36
107460
WRENCH, ball end; 4 mm
1
102
198663
. FERRULE
1
37
276741
MULTI-TOOL
1
103
185547
. HOUSING, ferrule
1
38
185103
TUBE, exhaust
1
104
197954
. BRACKET, fluid fitting
1
39
110231
CLAMP
1
105
185548
. NUT
1
40
116553
GREASE, dielectric, tube (not
shown)
1
106
198643
. FITTING, barrel
1
41
244915
COVER, gun; box of 10 (not
shown)
1
107
102982
. O-RING
1
108
198640
. FITTING, seal
1
TAG, warning (not shown);
replacement available at no cost
1
42
179791
Qty
* Included in Air Seal Repair Kit 244781.
43
180060
SIGN, warning (not shown);
replacement available at no cost
1
47
197967
PLUG
1
60
Qty
** Included in Fluid Seal Repair Kit 244911.
NOTE: Replacement Warning labels, signs, tags, and
cards are available at no cost.
309293
Parts
Part No. 245897 Isolation Enclosure, Series A, with air and wb fluid hoses, standard Xs3 gun (items 201-301)
Part No. 245898 Isolation Enclosure, Series A, with air and wb fluid hoses, smart Xs3 gun (items 201-301)
Part No. 233825 Isolation Enclosure, Series A, without hoses and gun (items 201-286)
282
280
271
216
253
283
276
228
252
214
215
301
258
260
253
262
239
283
270
279
281
268
268
257
241 249 300
262
204
259
206
242
217
261
224
218
257
274
220
226
278
227
256
256
229
247
205
279
235
222
203
267
221
206
262
225 223
201
201a
243
240
275
268
263
213
210
265
285
266
231
244
268
253
Ref. only;
not included
209
240
230
232
219
202
245
246
309293
211
212
208
236
237
TI2138a
61
Parts
Part No. 245897 Isolation Enclosure, Series A, with air and wb fluid hoses, standard Xs3 gun (items 201-301)
Part No. 245898 Isolation Enclosure, Series A, with air and wb fluid hoses, smart Xs3 gun (items 201-301)
Part No. 233825 Isolation Enclosure, Series A, without hoses and gun (items 201-286)
Ref.
No.
Part No.
201
Description
Part No.
Description
224
154636
WASHER, plain; 0.625 in. ID
2
225
185548
NUT
1
226
190410
RESISTOR, bleed
1
227
116988
CYLINDER ROD
1
228
15A518
HOUSING, cylinder rod
1
229
104267
REGULATOR, air
1
BUSHING; plastic; 3/4 x 1/2 npt
1
Qty
Qty
CABINET, enclosure; includes
201a
1
201a
15A947
DOOR, cabinet
1
202
116993
CASTER, brake
4
203
15A660
PLATE
1
204
15A551
T-HANDLE, latch
1
205
15A545
STEM, handle, door
1
206
15A524
HOUSING, latch
1
207
113061
SWITCH, push, air
1
208
Ref.
No.
230
231
114456
ELBOW, tube; 3/8 npt x 3/8 in. (10
mm) OD tube
1
232
116315
ELBOW, tube; 3/8 npt x 1/2 in. (13
mm) OD tube
1
235
15A682
LABEL, warning
1
TUBE; 1/2 in. (13 mm) OD; polyethylene
A/R
PUMP, diaphragm; sst; see manual 309303
1
236
116316
FITTING, tube; 1/2 npt x 1/2 in.
(13 mm) OD tube
1
210
SCREW, hex hd cap; 5/16-18 x
5.5 in. (140 mm)
2
237
218798
STRAINER, 16 mesh; sst
1
211
WASHER, plain; 0.344 in. ID
2
238
114958
STRAP, tie
3
212
NUT, lock; 5/16-18
2
239
222011
GROUND WIRE, 25 ft (7.6 m)
1
240
234018
STRIP, grounding; aluminum
1
241
110209
NUT, regulator
1
242
114051
WASHER, shim, latch
1
243
210084
ROD, ground
1
209
233501
213
241005
COVER, pail
1
214
104029
LUG, ground
1
215
116989
VALVE, air
1
216
111804
REGULATOR, air
1
217
113060
GAUGE, air; 1/8 npt
1
218
116473
VALVE, ball; 1/4 npt(fbe)
219
233824
220
244
SCREW, hex hd; 1/4-20 x 5/8 in.
(16 mm)
16
1
245
WASHER, plain; 1/4 in. (6 mm)
16
CART, enclosure
1
246
NUT, hex; 1/4-20
16
162453
NIPPLE; 1/4 npt x 1/4 npsm
1
247
221
185547
FERRULE HOUSING, waterborne tube
1
248
222
198663
FERRULE
1
223
101390
WASHER, lock, internal tooth
1
62
249
251
107257
SCREW, thread forming
TUBE; 1/4 in (6 mm) OD; nylon
160430
GAUGE, air
WIRE, 10 gauge; green with yellow stripe
1
A/R
1
A/R
309293
Parts
Ref.
No.
Part No.
Description
Qty
252
CONNECTOR, swivel tee; 1/8 npt
x 5/32 in. (4 mm) OD tube
1
253
NUT, hex; 10-32
1
Ref.
No.
Part No.
Description
275
114261
TERMINAL, ring; no. 10
1
276
15A780
PLUG, hex hd
1
278
117314
BULKHEAD CONNECTOR; 1/4
npt
1
279
113319
CONNECTOR, tube; 1/4 npt x 3/8
in. (10 mm) OD tube
2
Qty
256
162449
NIPPLE, reducing; 1/2 npt x 1/4
npt
2
257
101874
TERMINAL, ring
5
258
116990
BOX, control
1
280
ELBOW, tube
1
259
113983
RING, retaining; 1/2 in. (13 mm)
1
281
1
260
237933
METER, 0-90 kV
1
FITTING, tube; 1/8 npt x 5/32 in.
(4 mm) tube
261
113336
ADAPTER, 1/4 npt
1
282
SWIVEL, tube; 1/4 npt x 1/4 in. (6
mm) OD tube
4
262
SCREW, pan hd; 10-32 x 5/8 in.
(16 mm)
4
283
SWIVEL, tube; 1/8 npt x 5/32 in. (4
mm) OD tube
2
263
SCREW, pan hd; 10-32 x 1/4 in. (6
mm)
1
285
CLAMP
1
264
HOLDER, tie
3
265
SCREW, button hd; 10-24 x 1.5 in.
(38 mm)
2
266
SCREW, button hd; 10-32 x 1.0 in.
(25 mm)
2
267
NUT, hex; M5 x 0.8
2
268
WASHER, lock; no. 10
9
270
116991
TEE, run, manifold
1
271
203953
SCREW, hex hd cap with patch;
10-24 x 3/8 in. (10 mm)
1
272
WIRE, 14 gauge; red
A/R
273
WIRE, ground, 14 gauge; green
with yellow stripe
A/R
274
155541
309293
UNION, swivel; 1/4 npt
1
112791
286
TUBE; 3/8 in. (10 mm) OD
A/R
300
235070
HOSE, air, grounded; 0.315 in.
(8 mm) ID; 1/4 npsm(f) x 1/4
npsm(f) left-hand thread; red
cover with stainless steel braid
ground path; 25 ft (7.6 m) long
1
301
245301
GUN, air spray, standard, electrostatic, for waterborne coatings; see page 53; used on
Model 245897
1
301
245305
GUN, air spray, smart, electrostatic, for waterborne coatings; see page 57; used on
Model 245898
1
NOTE: Replacement Warning labels, signs, tags, and
cards are available at no cost.
63
Parts
Tubing and Wiring Chart
Use the diagrams on page 65 to find the connection
points for the tubing and wiring listed below.
Code
Ref. Length
Description
No. in. (mm)
A1
248
20 (508) 1/4 OD tube, regulator to pump
A2
248
9 (229)
B2
249
17 (432) 5/32 OD tube, manifold air to door
interlock switch
B3
249
20 (508) 5/32 OD tube, valve tee to cylinder
B4
249
5 (127)
B5
249
22 (559) 5/32 OD tube, valve tee to door interlock switch
C1
272
9 (229)
64
1/4 OD tube, regulator (216) to manifold
5/32 OD tube, regulator (216) to
gauge (2170
red 14 gauge wire from top of bleed
resistor to meter
Code
Ref. Length
Description
No. in. (mm)
C2
251
8 (204)
C3
273
34 (864) green/yellow 10 gauge wire from
external ground lug to cart
C4
239
n/a
green/yellow 25 ft ground wire with
clamp, from external ground lug to
true earth ground
C5
243
n/a
green/yellow 10 gauge wire from
external ground lug to ground probe
C6
226
n/a
red wire from bleed resistor to pump
C7
272
16 (407) red 14 gauge wire from pump to pail
cover with clamp
C8
272
12 (305) red 14 gauge wire from pump (209)
to ground on cylinder bracket
C9
251
n/a
green/yellow 10 gauge wire from
meter + to internal box ground lug
E1
286
4 (102)
3/8 OD tube, bulkhead to manifold
green/yellow 14 gauge wire from
internal box ground lug to cylinder
cap
309293
Parts
Tubing and Wiring Diagrams
Detail of Control Box
C9
A1 A2
C1
B4
B3
C2, C9
C3, C4, C5
B5
A2
B2
E1
TI2145A
C2
B3
Detail of Door Interlock Switch
C8
C1
A1
C6, C7, C8
B5
C6
TI2144A
B2
C3
TI2143A
309293
65
Accessories
Accessories
Air Line Accessories
Air Hose Adapter Nipple
185493
Use to connect multiple air hoses. 1/4 npt x
1/4 npsm left-hand thread.
Grounded Air Hose (Red Cover)
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand
thread; red cover with stainless steel braid ground path.
235068
6 ft (1.8 m)
235069
15 ft (4.6 m)
235070
25 ft (7.6 m)
235071
36 ft (11 m)
235072
50 ft (15 m)
235073
75 ft (23 m)
235074
100 ft (30.5 m)
Bleed-Type Master Air Valve
300 psi (21 bar, 2.1 MPa) Maximum Working Pressure
Relieves air trapped in the air line between this valve
and the fluid supply unit when closed.
107141
3/4 npt
Air Line Shutoff Valve
150 psi (10 bar, 1.0 MPa) Maximum Working Pressure
For turning air to gun on or off.
224754
1/4 npsm(m) x 1/4 npsm(f) left-hand thread.
Air Line Quick Disconnect
112534
66
Non-Swivel Air Inlet Fitting
185105
Replaces standard swivel. Left-hand
thread.
Extended Air Inlet Fitting
189191
Replaces standard swivel to provide
extended handle grip area. Left-hand
thread.
Fluid Line Accessories
245252 Waterborne Fluid Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
FM Approved; PTFE 1/4 in. (6 mm) ID x 25 ft (7.6 m)
Fluid Shutoff/Drain Valve
500 psi (35 bar, 3.5 MPa) Maximum Working Pressure
For turning fluid on or off to the gun and for relieving
fluid line pressure at the fluid supply unit.
208630
1/2 npt(m) x 3/8 npt(f); carbon steel and
PTFE for non-corrosive fluids
Swiveling quick disconnect replaces standard air inlet swivel.
309293
Accessories
Gun Accessories
Alternator Bearing Kit
Gun Repair Kits
Cleaning Brush
244781
244911
Air Seal Repair Kit
Fluid Seal Repair Kit
223688
105749
To repair the turbine alternator.
For cleaning air cap and fluid nozzle.
Round Pattern Kits
Miscellaneous Accessories
Consists of fluid tip, diffuser and air cap.
245217
4-6 in. (102-152 mm) diameter
245219
8-10 in. (203-254 mm) diameter
Ground Wire and Clamp
222011
Push/Pull Fan Air Valve
244912
For quick change of fan size.
Handle Grips
245263
245264
Medium Grip
Large Grip
Gun Valve Lubricant
111265
309293
4 oz (113 g) tube of sanitary (non-silicone)
lubricant for fluid seals and wear areas.
For grounding fluid supply unit and other
components and equipment in the spray
area.
12 gauge, 25 ft (7.6 m).
Megohmmeter
241079
500 Volt output; 0.01-2000 megohms.
Not for use in hazardous areas.
Safety Warning Sign
186118
English Warning Sign. FM Approved. Available at no charge from Graco.
67
Accessories
Part No. 245895 Agitator Accessory Kit (items 401-407)
407
402
401
406
Ref.
No.
Part No.
Description
401
112698
ELBOW, swivel, male; 1/8 npt(m) x
1/4 in. (6 mm) OD tube
1
402
114158
FITTING, adapter, Y; 1/4 in. (6
mm) OD tube; mxfxf
1
403
193315
COLLAR, mounting, agitator
1
404
193316
NUT, collar, agitator
1
405
197298
COVER, pail; 5 gal. (19 liter)
1
406
224571
AGITATOR; see manual 306565
1
407
purchase
locally
TUBE; nylon; 1/4 in. (6 mm) OD;
4 ft (1.22 m)
1
408
110272
SCREW, set, socket-hd; 1/4-20 x
1/4 in. (6 mm)
1
Qty
403
408
404
406 (Ref)
TI2137A
68
309293
Accessories
Part No. 245944 Fluid Regulator Accessory Kit (items 501-507)
501
506
507
504
502
505
Ref.
No.
Part No.
Description
501
110078
FITTING, tube, fluid; 1/4 npt(m) x
3/8 in. (10 mm) OD tube
1
502
113070
NIPPLE, reducer; 3/8 npt x 1/4 npt
1
503
113576
PLUG; 1/4 npt
1
504
236281
REGULATOR, fluid; see manual
308325
1
505
C20350
ELBOW, 90°; 1/4 npt(f) x 1/4 in. (6
mm) OD tube
1
506
114158
FITTING, adapter, Y; 1/4 in. (6
mm) OD tube; mxfxf
1
507
purchase
locally
TUBE; nylon; 1/4 in. (6 mm) OD;
4 ft (1.22 m)
1
503
TI2149A
309293
Qty
69
Technical Data
Technical Data
Category
Data
Maximum Working Fluid Pressure
100 psi (0.7 MPa, 7 bar)
Maximum Working Air Pressure
100 psi (0.7 MPa, 7 bar)
Minimum Air Pressure at Gun Inlet
40 psi (0.28 MPa, 2.8 bar)
Maximum Fluid Operating Temperature
120°F (48°C)
Short Circuit Current Output
125 microamperes
Voltage Output
244581, 245301: 60 kV
244582, 245305: 30-60 kV
Sound Power (measured per ISO Standard 9216)
at 40 psi (0.28 MPa, 2.8 bar): 90.4 dB(A)
at 100 psi (0.7 MPa, 7 bar): 105.4 dB(A)
Sound Pressure (measured 1 m from gun)
at 40 psi (0.28 MPa, 2.8 bar): 87 dB(A)
at 100 psi (0.7 MPa, 7 bar): 99 dB(A)
Gun Air Inlet Fitting, left-hand thread
1/4 npsm(m)
Gun Fluid Inlet Fitting
custom inlet for Graco waterborne fluid hose
Gun Weight
27.8 oz (788 g)
Gun Length
11.1 in. (28.2 cm)
Isolation Enclosure Air Inlet Fitting
1/4 npt
Isolation Enclosure Fluid Inlet Fitting
3/8 in. OD tube fitting
Isolation Enclosure Weight
125 lb (56.3 kg)
Isolation Enclosure Height
44 in. (1118 mm)
Isolation Enclosure Width
24 in. (610 mm)
Isolation Enclosure Depth
29 in. (737 mm)
Wetted Parts
Gun: Stainless Steel; Nylon, Acetal, Ultra-High Molecular Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten Wire, Polyethylene
Waterborne Fluid Hose: PTFE
Suction Tube: Polyethylene, Stainless Steel
Triton Pump: See manual 309303
PTFE
Viton® and Delrin®
Loctite® is a registered trademark of the Loctite Corporation.
70
309293
Technical Data
Notes
309293
71
Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship
on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special,
extended, or limited warranty published by Graco, Graco will, for a period of twelve months or two thousand hours of operation
from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deficiency in
the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for
thirty-six months or six thousand hours of operation from the date of sale. This warranty applies only when the equipment is
installed, operated and maintained in accordance with Graco's written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused
by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering,
or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the
incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper
design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by
Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor
for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective
parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not
disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs
of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco's sole obligation and buyer's sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no
other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or
property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within
two (2) years of the date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not
manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer.
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying
equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach
of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal
proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les
parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et
procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les
procedures concernées.
Graco Phone Numbers
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1-800-367-4023 Toll Free
612-623-6921
612-378-3505 Fax
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit
International Offices: Belgium, Korea, Hong Kong, Japan
*5$&2 ,1& 32 %2; 0,11($32/,6 01 www.graco.com
PRINTED IN USA 309293 02/2002 Rev. B 04/2002

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