Graco PRO 3500WB, Manual

Page 1: ...gth Part No 223 519 36 ft 11 0 m hose length Part No 223 520 50 ft 15 3 m hose length SAFETY FENCE Part No 110 614 CONVERSION KIT Part No 223 114 GUN HOLSTER Part No 236 090 NOTE See the PARTS DRAWINGS and LISTS for a complete list of part numbers CONTENTS Warnings 2 Typical Installation 4 Introduction 5 Installation 5 Operation 12 Cleaning and Maintenance 16 Troubleshooting Charts 18 Spray Gun El...

Page 2: ...em Be sure you have corrected the problem before starting to spray again Grounding The following are minimum requirements for grounding a basic electrostatic system Your system may include other equipment or objects which must also be grounded Always check your local electrical code for detailed grounding instructions Be sure your system is connected to a true earth ground 1 Air compressors and hy...

Page 3: ...r deflect leaks with your hand or body NEVER alter or modify any part of this equipment doing so could cause it to malfunction NEVER enter a high voltage or hazardous area until after all high voltage equipment has been discharged A safety fence air line interlock MUST be installed to shut off the high voltage any time the gate is opened CHECK all spray equipment regularly and repair or replace wo...

Page 4: ... be used ONLY with water base fluids with flashpoints above 140 F 60 C and less than 20 by weight organic solvent concentration When you use conductive water base fluids in an elec trostatic system the fluids in the spray gun D fluid line F and fluid supply unit M are charged to high voltage The entire fluid supply is isolated from ground to maintain voltage at the tip of the gun For proper operat...

Page 5: ...77 39 Y 223 548 Voltage Control Ground Wire 223 639 39 A safety fence J non conductive hoses isolation stand K and voltage control L MUST be installed to isolate the fluid in the fluid line F and fluid supply unit M from ground and to prevent people from con tacting portions of the system that are charged to high voltage This helps reduce the risk of electric shock which could cause serious injury...

Page 6: ...nd and can withstand any forces induced by vehicles equipment or personnel in the area without reducing the protection provided See Fig 2 4 The fence MUST be constructed so there is no more than 6 inches 152 mm of clearance between the bottom of any portion of the fence and the building floor 5 The shape of the mesh pattern in the fence sides and gate is optional but it MUST restrict a 2 5 inch 64...

Page 7: ...Gun 1 Remove the exhaust tube clamp 67 and air fitting 17 from the spray gun See Fig 5 2 Using petroleum jelly lubricate o ring 304 on hose barbed insert 301 Then push the hose barbed insert into the gun barrel until the gun barrel is pressed against shoulder of the barbed insert 301 3 Tighten the fitting 302 until the o ring on the fitting is compressed to about half its original thickness 4 Tigh...

Page 8: ...supply unit on the isolation stand See Fig 6 2 Connect the cable s 405 c clamp from the isolation stand terminal block to a metal part of the fluid supply unit Fig 6 Isolation Stand Voltage Control Strain Relief Ground Terminal Connect cable 223 529 406 between terminal block voltage control Connect cable 223 548 127 between voltage control base plate strain relief ground terminal Connect cable 22...

Page 9: ...trically Conductive Air Supply Hose as specified in the ACCESSORIES section of this manual This hose and the gun have spe cial threads which prevent using any other type of hose with the gun 6 Install an air line filter and an air and water separator on the air 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 gu...

Page 10: ...upply to the gun 3 Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose a With the electrically conductive air hose con nected and properly grounded use an ohmme ter to measure the resistance between the gun handle and a true earth ground See Fig 8 b If the resistance is greater than 100 ohms check the tightness of the ground connections and be sure ...

Page 11: ... NOTES ...

Page 12: ...Relief Procedure at right when shutting off system when checking or servicing any part of the spray system when installing cleaning or changing fluid nozzles and whenever you stop spraying WARNING To reduce risk of electric shock which could cause se rious injury ALWAYS follow the Voltage Discharge Procedure below when entering the safety fence Do not touch the gun nozzle or come within 4 in 101 6...

Page 13: ...elief Procedure on page 12 2 Disconnect the cable c clamp from the fluid supply Refer to Fig 10 3 Remove the fluid supply Placing Fluid Supply in Isolated Area 1 Place the fluid supply on the isolation stand Refer to Fig 10 2 Connect the cable c clamp from the isolation stand terminal to a metal part of the fluid supply 3 Exit the fenced area 4 Connect the safety fence gate interlock ...

Page 14: ... OPERATION Fig 11 Air Cap Fluid Adjustment Screw ES On Off Lever 1 is ON 0 is OFF Fan Air Control Valve I O ES ES Indicator Light Optional Air Cap Control Valve See ACCESSORIES ...

Page 15: ...tor installed in the fluid line at the pressure source NOTE If the fluid supply is a pump the fluid regulator MUST be installed at the pump outlet not remote from the pump 2 First complete all the checks under the Operating Checklist on page 12 Then turn the ES On Off lever to ON 1 When spraying the ES indicator light should glow indicating the electrostatic charge 3 Use an air pressure regulator ...

Page 16: ...lps re duce the risk of electric shock which could result in serious injury Make sure that all the surfaces of the stand are free of paint including the grounding grate Refer to Fig 6 Clean with a soft cloth dampened in a solvent that s suitable for use in an electrostatic water base system Cleaning the Voltage Control Thoroughly clean the outer surfaces of the voltage con trol with a soft cloth d...

Page 17: ...ent CAUTION Methylene chloride is not recommended as a flushing or cleaning solvent with this gun as it will damage nylon components 1 Follow the Voltage Discharge Procedure and Pressure Relief Procedure on page 12 2 Connect the fluid line to the solvent supply unit 4 Flush the gun with solvent until it is clean 5 Follow the Pressure Relief Procedure then dis connect the fluid line from the solven...

Page 18: ...en or repair fluid inlet Loose fluid tube in tank Tighten Fluid build up on air cap partially Clean with soft implement or clogged horn holes Full air pres submerge in suitable solvent and sure from clean horn hole forces wipe clean See page 16 fan pattern toward clogged end Damaged fluid nozzle or air Replace damaged part See cap holes page 24 Fluid build up on the perimeter Remove obstruction Ne...

Page 19: ...t Lubricate and adjust packing nut See page 27 Loose resistor stud Tighten resistor stud See page 24 Loose fluid nozzle Tighten fluid nozzle See page 10 Damaged resistor stud o ring Replace o ring See page 24 Excessive spray fog Leakage from fluid packing area Insufficient air pressure Increase use least air pressure needed for good results Fluid poorly mixed or filtered Remix or refilter fluid Im...

Page 20: ...st spraying distance to 8 12 in 203 305 mm Clean hangers check for proper ground on conveyer or track Reduce within code limits Reduce air pressure Reduce fluid pressure Check supplier for proper fluid for water base electrostatic spray Check if ES On Off lever is ON 1 Check air supply to gun Check for dirt or moisture in turbine See page 28 Check gun resistance See page 22 Check resistor stud res...

Page 21: ...onnect voltage control to isolation stand terminal as shown on page 8 Connect fluid supply to isolation stand terminal as shown on page 8 Clean grate and or fluid container Check connection between terminal block and fluid supply See page 8 NEVER by pass air line interlock See page 4 Voltage control seals damaged Replace seals See page 31 Be sure floor is properly grounded Wear shoes with conducti...

Page 22: ...ig 13 The resistance should be between 157 5 to 192 5 megohms If the resistance is outside the specified range go to the next test If the resistance is correct test the resistor stud resistance as shown on page 23 Test Power Supply Resistance Remove the power cartridge from the gun handle 7 See Power Cartridge Replacement Remove the turbine alternator 37 from the power car tridge See Turbine Alter...

Page 23: ...contact wire E are clean If the resistance is outside the specified range the resistor is defective and the resistor stud 22 must be replaced See Air Cap Nozzle Resistor Stud Replacement WARNING The resistor stud contact ring D is a conductive contact ring NOT a sealing o ring To reduce the risk of sparking which could cause fire explosion or electrostatic shock and result in serious injury DO NOT...

Page 24: ...moving nozzle and resistor stud This helps drain the gun and prevent any paint or sol vent left in the gun from entering air passages 1 Remove the air cap assembly Point the front end of the gun up and squeeze the trigger while removing the fluid nozzle resistor stud 21 22 assembly with the nozzle wrench 70 Refer to Fig 17 If the resistor stud remains in the gun when the fluid nozzle is removed st...

Page 25: ...er tighten CAUTION To avoid damaging the plastic threads or contact wire be very careful when installing the electrode 4 Trigger the gun while installing the fluid nozzle and resistor stud assembly Install the air cap assembly Test the gun resistance as instructed on page 22 KEY 20 Electrode 64 Electrode Tool Fig 19 64 20 Apply low strength purple Loctite or equivalent Fig 20 KEY 5 Cap Screws 63 W...

Page 26: ...the wrench 63 supplied Tighten the cap screws to 18 in lbs 2 N m MAXI MUM about a half turn past snug DO NOT over tighten 4 Assemble the fluid and air hose assemblies back into the gun Test the gun resistance as instructed on page 22 Fig 22 KEY 3 Gun Barrel 5 Cap Screws 7 Gun Handle 18 Power Cartridge 18a Gasket 30 Spring 34 Gasket 3 34 30 18 5 7 18a CAUTION To avoid damaging the gun DO NOT overti...

Page 27: ...n the fluid needle 28a Flats on the packing nut must be facing toward the back of the fluid needle 2 Fill the entire inner cavity of the spacer 28h with petroleum jelly Place the spacer on the fluid needle 28a in the direction shown in Fig 24 Generously apply petroleum jelly to the outside of the spacer 3 Place the fluid packing 28e needle packing 28d and housing 28b on the fluid needle 28a as sho...

Page 28: ...on 3 Insert the new power cartridge in the gun handle Be sure the gasket 18a is in place 4 Install the barrel on the handle as described under Barrel Removal Turbine Alternator Replacement NOTE Replace turbine bearings after 2 000 hours of operation See your authorized Graco represen tative 1 Remove the power cartridge from the gun handle as described in Power Cartridge Replacement 2 Squeeze the t...

Page 29: ...d spring 44 See Fig 27 CAUTION Clean all parts in non conductive solvent compat ible with the fluid being used such as xylol or min eral spirits Use of conductive solvents can cause the gun to malfunction 2 Loosen the air valve packing nut 40 one full turn Remove the air valve shaft 39 with a pliers CAUTION When removing the air valve shaft 39 be careful not to damage the seat area 3 Check the o r...

Page 30: ...be pushed into the gun air passage and blemish the finish on the workpiece 5 Install the regulator disk 46 in the valve 38 with its bevelled side facing in toward the valve CAUTION BE SURE the regulator disk 46 is installed correct ly A missing or incorrectly installed regulator disc can cause severe damage to the turbine alternator 6 Install the valve 38 with the regulator disc 46 and o ring 36 i...

Page 31: ...o a clean con tainer If the oil is clean it can be reused If there is a black carbon residue replace the oil with electrical insulating oil such as Diala Ax Oil Shell Oil Com pany or an equivalent oil that meets ANSI ASTM D3487 and NEMA TR P8 1975 specifications 10 Remove the electrode 209 from the cylinder rod B 11 Remove the seal flange 217 from the oil cup 208 12 Remove the two seals 206 Replac...

Page 32: ...nd resistor stud to prevent any paint or solvent left in the gun from entering the air passages NOTE If the resistor stud remains in the gun when the fluid nozzle is removed start the nozzle thread onto the stud and pull the stud out 6 Unscrew and remove the fluid needle electrode J with the electrode tool supplied with the gun If the needle shaft turns hold the needle shaft assembly by placing a ...

Page 33: ... until the fluid noz zle seats in the gun barrel 7 Install the air cap P Screw on the retaining nut 8 finger tight 8 Mount the warning sign 71 in the spray area where it can easily be seen and read by all operators 9 Follow the additional warnings installation operation service and other instructions given in this manual for a water base system Order replace ment parts for the gun from the parts l...

Page 34: ...ver Valve Rod Lubricate Push Muffler in by installing Exhaust Adapter Left hand thread Apply high strength Loctite Torque to 35 to 45 in lbs 4 to 5 1 N m Left hand thread Press Exhaust Tube onto Barb Align Retaining Ring holes with flat on Spacer to ease assembly disassembly CAUTION To avoid dam aging gun DO NOT over tighten screws Tighten to 18 in lbs 2 N m MAXI MUM about half turn past snug usin...

Page 35: ... NOTES ...

Page 36: ...ludes 18a 18f Includes 37a 37b 49 67 DETAIL A 28a Includes 28a 28h 28g 28b 28d 28e 28f 28c 43a 43b 43d 43e 43c Includes 43a 43e 28h Fluid Seal Repair Kit 223 020 Must be ordered separately Includes Ref No Qty 25 1 28d 1 28e 1 28f 1 28g 1 28h 1 Air Seal Repair Kit 223 021 Must be ordered separately Includes Ref No Qty 18a 1 18b 1 19 2 23 1 34 1 37a 1 41 1 42 1 43e 2 18f 18e 51 50 ...

Page 37: ...85 118 VALVE electrostatic 1 39 222 320 SHAFT ASSY air valve 1 40 185 115 NUT packing 1 41 111 508 O RING trigger valve fluoroelastomer 1 42 105 452 U CUP PTFE 1 43 222 321 VALVE ASSY fan air Includes items 43a 43e 1 43a 181 383 SEAL valve 1 43b 105 681 RING retaining 1 43c 185 089 SCREW adjusting 1 43d 185 090 HOUSING valve 1 43e 103 557 O RING Viton 2 44 185 116 SPRING compression air valve 1 45...

Page 38: ...TAGE CONTROL PARTS DRAWING 213 215 212 214 209 210 102 208 206 217 216 223 REF 220 221 220 222 204 203 205 211 224 218 106 105 117 REF 102 103 111 112 133 108 116 127 104 107 108 109 110 133 108 225 106 A A ...

Page 39: ... 737 FITTING air 1 111 110 745 BUSHING strap 4 112 110 620 SCREW nylon 10 24 UNC 2A x 1 2 in 4 116 223 609 CABLE ASSEMBLY 3 in 76 2 mm bleed resistor to plate 1 117 223 528 CABLE ASSEMBLY 4 in 102 mm switch to bleed resistor 1 127 223 548 CABLE ASSEMBLY 6 5 ft 1 98 m base plate to strain relief ground 1 133 100 718 WASHER 3 Ref No 101 Part No 223 141 Water base Switch REF NO PART NO DESCRIPTION QT...

Page 40: ...ref no when ordering 3 Order all parts from your nearest Graco distributor 6 digit Part Number Qty Part Description REF NO PART NO DESCRIPTION QTY 301 186 052 INSERT barbed 1 302 180 553 FITTING male 1 303 107 305 O RING Viton 1 304 110 736 O RING Viton 1 305 107 208 NUT ferrule 1 185 918 HOSE fluid 25 ft 7 6 m Part No 223 192 ONLY 1 306 185 919 HOSE fluid 36 ft 1 m Part No 223 193 ONLY 1 185 920 ...

Page 41: ...IPTION QTY 8 223 653 NUT air cap retaining 1 20 186 615 ELECTRODE 1 28 223 444 ROD packing assembly 1 71 186 118 SIGN warning not shown 1 The Kit Ref Nos correspond with the Gun Ref Nos on page 37 8 20 Manual Change Summary The following parts have been changed in this revison Assembly Changed Part Status Ref No Part No Name 222 700 Spray Gun Old New 45 45 185 117 188 486 Cap air valve Cap air val...

Page 42: ...t 1 83 m 6 ft 1 83 m 6 ft 1 83 m STAINLESS STEEL PRESSURE TANKS 100 psi 7 bar MAXIMUM WORKING PRESSURE Size Models with Agitator Models without Agitator 5 gallon 19 liter 222 179 222 183 10 gallon 38 liter 222 180 222 184 15 gallon 57 liter 222 181 222 185 The accessories below and on page 43 have not been tested by Factory Mutual AIR LINE ACCESSORIES GROUNDED GUN AIR SUPPLY HOSE 100 psi 7 bar MAX...

Page 43: ...LVE 222 322 Allows air cap air to be restricted without losing alternator power SNAP RING PLIERS 110 090 For removing the ES ON OFF Valve Retaining Ring item 47 in Parts List GUN COVER 180 209 Order Part No 218 374 for package of 10 ES ON OFF CONVERSION KIT 223 976 Converts the ES ON OFF Valve to a constant on setting A ball valve is included for complete air shut off at gun PUSH PULL PATTERN ADJU...

Page 44: ...ctures accessories equipment or materials not supplied by Graco or the improper design manu facture 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 claim If the claimed defect is verifie...

Page 45: ...ray gun fluid hose air hose voltage control switch isolation stand gun holster and isolation fence Part No Hose Length 236 909 25 feet 7 6 meters 236 910 36 feet 11 meters 236 911 50 feet 15 3 meters Waterbase Conversion Systems For converting an existing PRO 3500SC system to a PRO 3500WB system These systems include a spray gun conversion kit fluid hose air hose voltage control switch isolation s...

Page 46: ... J S V On page 22 Test Gun Resistance Change the procedure to the following Measure the resistance between the electrode 20 and the gun air fitting 17 See Fig 13 The resistance should be between 180 to 220 megohms If the resistance is outside the specified range go to the next test If the resistance is correct test the resistor stud resistance as shown on page 23 On page 23 Test Resistor Stud Resi...

Page 47: ... item S Safety Fence Air Line Interlock 223 477 J 110 614 Safety Fence See front cover 42 K 223 445 or 727 212 Isolation Stand See front cover 41 or 42 L 223 639 Voltage Control 223 477 39 M Fluid Supply Unit 42 N 208 591 Fluid Supply Unit Non conductive Air Supply Hose 223 477 39 P 185 972 185 971 Strain Relief Ground Terminal 223 192 25 223 193 36 223 194 50 40 Q Gun Air Hose Ground Wire 235 070...

Page 48: ... 39 Change the quantity for Ref No 213 from 2 to 1 the hex nut has been replaced by a star washer part number 100 985 Use the following pressure tank part numbers in place of those listed on page 42 Stainless Steel Pressure Tanks 100 psi 7 bar Maximum Working Pressure Size Models with Agitator Models without Agitator 5 gallon 19 liter 236 149 236 152 10 gallon 38 liter 236 150 236 153 15 gallon 57...