Graco 222700, Instructions Manual

Page 1: ...s with non Graco parts will void agency approvals 05148B INSTRUCTIONS PARTS LIST INSTRUCTIONS This manual contains important warnings and information READ AND KEEP FOR REFERENCE Model PRO 3500wb Electrostatic Air Spray Gun 100 psi 0 7 MPa 7 bar Maximum Working Pressure Part No 222700 Series C For use when electrostatically spraying con ductive waterborne fluids that meet at least one of the follow...

Page 2: ...ostatic Wrap Troubleshooting 26 Gun Operation Troubleshooting 26 Electrical Tests 28 Test Gun Resistance 28 Test Power Supply Resistance 29 Test Resistor Stud Resistance 29 Service 30 Tools Included with the Gun 30 Prepare the Gun for Service 30 Air Cap Nozzle Resistor Stud Replacement 30 Electrode Needle Replacement 32 Fluid Packing Rod Removal and Repair 33 Fan Air Adjustment Valve Repair 35 Flu...

Page 3: ...n system enclosure Refer to Fig 6 page 13 Only use the red colored Graco electrically conductive gun air hose with this gun Do not use the 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 Follow the Fluid Voltage Discharge and Grounding Procedure on page 16 when instructed ...

Page 4: ...on Use only non sparking tools to clean residue from the booth and hangers Extinguish all open flames or pilot lights in the spray area Keep the spray area free of debris including solvent rags and gasoline Do not store any flammable fluids in the spray area Do not turn on or off any light switch in the spray area while operating or if fumes are present Do not smoke in the spray area Do not operat...

Page 5: ...s that are compatible with the equipment wetted parts See the Technical Data section of all the equipment manuals Read the fluid 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 Do not use the hoses to pull equipment Wear hearing protection when operating this equi...

Page 6: ... flush or purge the system Precautions must be taken when using electrostatic waterborne equipment to avoid potential shock haz ards When the spray gun charges the isolated fluid to high voltage it is similar to charging a capacitor or 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...

Page 7: ... Handle F Air Inlet G Fluid Inlet H Trigger J Fluid Adjustment Knob K Exhaust Tube L Hook M ES Indicator Light N ES ON OFF Lever P Fan Air Adjustment Valve R Atomizing Air Valve S Power Supply T Turbine Alternator 05404 Fig 1 1 is ON 0 is OFF 05151A B A C D L H G F K P N R M T S E J 05148B ...

Page 8: ...nductive hose layer DD When properly installed the conductive hose layer is grounded through its connection to the grounded safety fence or enclosure CC All areas of the fluid hose that are accessible to personnel must be covered by the outer hose jacket FF to avoid electric shock KEY Fig 2 DD Conductive Hose Layer EE Inner Hose Layer FF Outer Hose Jacket CC Grounded Enclosure The portion of the i...

Page 9: ...lly The gun must be connected to a voltage isolation system which isolates the fluid supply from ground and allows voltage to be maintained at the tip of the gun All components of the isolation system that are charged to high voltage must be contained within a fence or enclosure that prohibits personnel from making contact with the high voltage components The system should not have any severe arci...

Page 10: ...Graco Red Electrically Conductive Gun Air Hose K Air Supply Hose L Fluid Supply Hose M Gun Air Hose Ground Wire N True Earth Ground P Fluid Hose Port R H2O PRO Batch System Voltage Block Enclosure S Main Ground Wire T Ground Lug Fig 3 D E F G H B T K L C N R P 05310 M N PRO 3500wb Gun shown with the Graco H2O PRO Batch System Consult your isolation system manual for other configurations A S ...

Page 11: ...ct the hose ground wire to a true earth ground Do not use the black or grey colored Graco air hoses Connect the red colored Graco Electrically Conductive Air Hose H to the gun air inlet and connect the hose ground wire M to a true earth ground N Refer to Fig 3 page 10 Check the electrical grounding of the gun as instructed on page 15 See page 48 to order the air hose NOTE The hose and the gun have...

Page 12: ... be held securely the hose must be stripped and as sembled to the dimensions shown in Fig 4 Refer also to Fig 29 page 42 A new Graco waterborne fluid hose comes fully assembled to the proper dimensions CAUTION Be careful not to cut into the inner hose layer K when stripping the hose Nicks or cuts in the tube will cause premature hose failure 2 Inspect the condition of the o rings G on the hose bar...

Page 13: ...d Hose 75 Fluid Inlet Tube 77 Hose Ferrule 79 Hose Ferrule Housing Fig 5 75 77 79 Y Torque to 50 in lb 5 6 N m 05405B WARNING ELECTRIC SHOCK HAZARD To reduce the risk of an 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 H See Fig 6 CAUTION The Graco warranty is void if the spray gun is con nect...

Page 14: ...conduc tive air hose between the gun and air supply line and connect the air hose ground wire to a true earth ground Check the electrical grounding of the gun as instructed on page 15 3 Graco Waterborne Fluid Hose The conductive layer of the hose must be properly grounded by correct installation as instructed on pages 12 to 13 4 Voltage Isolation System Ground the system according to the manufactu...

Page 15: ...ust not have any fluid in it when checking the continuity 4 Turn the gun ES ON OFF lever DD to OFF 5 Measure the resistance between the gun handle AA and a true earth ground BB with an ohmme ter CC Resistance should not exceed 100 ohms 6 If the resistance is greater than 100 ohms check the tightness of the ground connections and be sure the air hose ground wire is connected to a true earth ground ...

Page 16: ...em instruction manual 3 Touch the electrode of the gun with a grounded rod to make sure that the voltage has been dis charged If an arc is seen verify that the electros tatics are turned off or see Troubleshooting page 24 or the voltage isolation system manual for other possible problems Resolve the problem before proceeding Pressure Relief Procedure WARNING PRESSURIZED EQUIPMENT HAZARD The system...

Page 17: ...ntering the spray area are properly grounded See Ground the System page 14 and Check the Electrical Grounding page 15 ____ 6 The condition of the electrical components of the spray gun has been checked as instructed in Electrical Tests page 28 ____ 7 All fluid hose connections are tight ____ 8 The ventilation fans are operating properly ____ 9 All the debris including flammable liquids and rags is...

Page 18: ...e Follow the steps below to establish the correct fluid flow and air flow Do not turn the ES ON OFF lever to ON yet 1 Follow the Operating Checklist on page 17 2 Make sure the system voltage is discharged Loosen the air cap retaining nut and rotate the air cap for a vertical or horizontal spray pattern See Fig 9 Then tighten the retaining nut until the air cap is held firmly in place you should no...

Page 19: ...alve in 9 Turn the ES ON OFF lever N to ON to begin spraying with the electrostatics When spraying the ES indicator light M should glow indicating the electrostatic charge NOTE See Spray Pattern Troubleshooting on page 25 to correct spray pattern problems See Voltage Loss Troubleshooting on page 22 to correct voltage problems 10 Operate the voltage isolation system as instructed in the system manu...

Page 20: ...Care and Cleaning CAUTION Fluid left in gun air passages could result in a poor quality paint finish and may draw current and reduce the electrostatic effect Fluid in the power supply cavity can reduce the alternator life Immersing the gun in fluid is not recom mended Do not use any cleaning method which may allow solvent into the gun air passages Point the gun down while cleaning to prevent fluid...

Page 21: ...line for servicing 5 Clean the exterior of the gun with a cloth damp ened in a non flammable cleaning fluid 6 Carefully install the air cap Be sure to insert the electrode wire through the center air cap hole and do not bend the wire Rotate the air cap horns to the desired position 7 Tighten the retaining nut until the air cap is held firmly in place you should not be able to rotate the air cap ho...

Page 22: ...t the fluid hose connection or fluid packings Not enough air pressure for the turbine Faulty power supply Excessive overspray on gun surfaces Fluid in the air passages Waterborne Fluid Hose 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 Bloc...

Page 23: ...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 4 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 305 mm from any ground Make sure that no one is within 3 ft 914 mm of the en...

Page 24: ... the inner spacer of the fluid packing rod with dielectric grease and reassemble the gun as instructed on page 34 13 Reconnect the fluid hose as instructed on page 12 14 Check the gun voltage with the voltage probe and meter before filling the gun with fluid Electrical Troubleshooting Problem Cause Solution Voltage is still present at the gun after following the Fluid Voltage Discharge and Groundi...

Page 25: ...water and wipe it clean see page 21 The electrode is bent Straighten the electrode The fluid nozzle or air cap holes are damaged Replace the damaged part see page 30 There is fluid buildup on the perimeter of the fluid nozzle orifice or a partially clogged fluid nozzle orifice Remove the obstruction never use wire or hard instruments see page 21 The electrode is bent Straighten the electrode wire ...

Page 26: ...packings or rod see page 33 The packing nut is loose Tighten the packing nut see page 33 Air leakage from the front of the gun The air valve is not seating properly Clean and service the air valve see page 36 The air valve o ring is sticking Lubricate the o ring see page 36 Fluid leakage from the front of the The fluid rod is worn or damaged Replace the fluid rod see page 33 gun The fluid seat is ...

Page 27: ...s dirty or clogged Clean the fluid nozzle see page 21 The fluid nozzle is damaged Replace the fluid nozzle see page 30 The equipment is covered with fluid The exhaust air flow is insufficient or not directed properly Check for the proper CFM check the baffles and direction of the air flow The distance between the gun and workpiece is incorrect Adjust the spraying distance to 8 to 12 inches 203 to ...

Page 28: ...xplosion electric shock and result in serious injury and property damage The performance and safety of the spray gun are directly affected by the condition of the electrical components contained inside the gun The electrical tests can be used to determine the condition of the power supply 18 and the resistor stud 22 as well as the continuity of the electrical path between the com ponents Use the m...

Page 29: ...tor stud 22 as instructed on page 30 3 Check the resistance between the black resistor stud contact ring D and the needle contact ring C See Fig 15 You may have to press down on the contact ring D in several places to get a good reading 4 The resistance should be 21 to 29 megohms If the resistance is correct make sure the metal contact in the gun barrel and the needle contact ring C are clean If t...

Page 30: ...uid Voltage Discharge and Grounding Procedure WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 16 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure 1 Discharge the voltage as instructed on page 16 2 Flush the gun with a non flammable cleaning fluid as instructed on page 21 3 P...

Page 31: ... in the fluid nozzle 21 with the multi tool 62 Tighten the resistor stud to 10 in lb 1 13 N m See Fig 17 4 Trigger the gun while installing the fluid nozzle 21 and resistor stud 22 assembly with the multi tool 62 Tighten the assembly until the fluid nozzle seats in the gun barrel 1 8 to 1 4 turn past hand tight See Fig 16 5 Test the gun resistance as instructed on page 28 6 Install the air cap 1 i...

Page 32: ... strength purple Loctite or equivalent thread sealant to the fluid rod threads Hold the back end of the fluid rod E to prevent it from turning while installing the new electrode needle 20 finger tight Do not over tighten the electrode needle CAUTION To avoid damaging the plastic threads or contact wire be very careful when installing the electrode needle 5 Install the fluid nozzle and resistor stu...

Page 33: ...0 x 8 80 The service interval would be 312 work days Procedure NOTE The fluid packing rod can be replaced as individual parts or as an assembly If the assembly is purchased it is pre adjusted at the factory 1 Prepare the gun for service as instructed on page 30 2 Remove the air cap assembly fluid nozzle and resistor stud and electrode as instructed on pages 30 to 32 3 Loosen the trigger screws 4 f...

Page 34: ...ousing 28b assembly along the shaft Tighten or loosen the packing nut as need ed 11 Lubricate the o ring 28g 12 Make sure the spring 30 is installed against the nut U as shown in Fig 20 13 Install the fluid packing rod assembly 28 into the gun barrel Using the multi tool 62 tighten the assembly until just snug 14 Install the trigger 13 and tighten the trigger screws 4 See Fig 19 15 Install the ele...

Page 35: ...the valve housing 43d and install the retaining ring 43b on the adjusting screw 43c Back the adjusting screw out of the valve housing until it bottoms out against the retaining ring 8 Apply PTFE paste to the threads of the valve housing 43d and install it in the handle Torque the housing to 10 to 12 in lb 1 1 to 1 4 N m DETAIL 43 43b 43d 43e 43c Fig 21 Apply a very light coat of lubricant to the o...

Page 36: ...g the air valve shaft 39 be careful not to damage the seat area 4 Check the o rings 41 23 for damage and replace them if necessary Apply a very light coat of petroleum jelly to the o rings CAUTION Do not over lubricate parts Excessive lubricant on the o ring 41 and air valve shaft 39 can be pushed into the gun air passage and blemish the finish on the workpiece 5 Unscrew the packing nut 40 to chec...

Page 37: ...tment valve must be removed before remov ing the atomizing air valve 3 Remove the atomizing air valve 31 and o ring 19 See Fig 23 4 Install a new atomizing air valve and o ring 5 Apply PTFE paste to the fan air valve 43 housing threads and install the valve in the handle Torque the housing to 10 to 12 in lb 1 1 to 1 4 N m Fig 23 43 31 19 Apply PTFE paste to the fan air valve housing threads Torque...

Page 38: ...ive lubricant on the o ring 36 can be pushed into the gun air pas sage and blemish the finish on the workpiece 6 Install the regulator disk 46 in the valve 38 with its bevelled side facing toward the valve CAUTION Be sure the regulator disk 46 is installed correctly A missing or incorrectly installed regulator disc can cause severe damage to the power supply turbine 7 Install the valve 38 with the...

Page 39: ...with the ball end wrench 63 4 Hold the gun handle 7 with one hand and pull the barrel 3 straight away from the handle to remove it Be prepared to catch the nut 78 See Fig 26 CAUTION To avoid damaging the power cartridge 18 always pull the gun barrel straight away from the gun han dle If necessary gently move the barrel from side to side to free the power supply from the gun handle 5 63 Fig 25 0515...

Page 40: ... essary replace the power supply 5 Inspect the power supply cavity in the handle for dirt or moisture Clean out the cavity with a clean dry rag to avoid a loss in electrostatic perfor mance 6 Lightly lubricate the o rings 18b 37a on the power supply with petroleum jelly CAUTION All the o rings 18b 37a and the compression spring 18c must be in place or the gun will malfunction 7 Be sure the gasket ...

Page 41: ...18 Push the alternator 37 onto the power supply until the retaining ring 35 engages with the alternator 8 Install the power supply in the gun handle as instructed on page 40 9 Install the barrel on the handle as instructed below Barrel Installation 1 Clean and dry the inside of the fluid inlet tube 75 See Fig 28 2 Be sure the gaskets 34 18a and spring 30 are in place Replace the parts if they are ...

Page 42: ...nd of the hose If the hose has a pin hole failure strip back the outer hose jacket H and the conductive layer J about 12 inches 105 mm on each hose end Look for the failure point which will be a very small pin hole discolored due to arcing Continue stripping back the hose until the failure point is found 5 Carefully cut through the outer hose jacket H and peel it back about 12 inches 105 mm Do not...

Page 43: ... the retaining nut G NOTE Keep all the following parts for reassembly 5 Point the front end of the gun up and squeeze the trigger while removing the fluid nozzle resistor stud assembly H with the nozzle wrench 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 electrode needle J with the...

Page 44: ... Check the inside of the barrel for marks from high voltage arcing If the marks are present replace the barrel 2 Lubricate the o ring on the outside of the fluid packing rod assembly Make sure the spring is in stalled on the fluid packing rod nut NOTE See Fig 20 page 34 for information on indi vidual fluid packing rod parts 3 Install the fluid packing rod assembly 28 into the gun barrel See Fig 31...

Page 45: ...all the air fitting to hold the bracket in place torque the fitting to 35 to 45 in lbs 4 to 5 1 N m 10 Tighten the nut 78 onto the ferrule housing 79 11 Press the exhaust tube E onto the barbed adapter on the bottom of the gun handle Secure the tube with the clamp F 12 Test the gun resistance as instructed on page 28 13 Mount the warning sign 71 in the spray area where it can easily be seen and re...

Page 46: ...32 31 41 37a 37b 18a 18b 18c 30 5 18d 19 See Detail A 28a 28g 28b 28d 28e 28f 28c 43b 43d 43e 43c 28h 18f 18e DETAIL Item 18 includes 18a 18f Item 28 includes 28a and 28h Item 37 includes 37a 37b Item 43 includes 43b 43e Item 45 includes 45a 45e 37 18 44 67 7 40 80 81 75 78 76 79 77 45e 45b 45a 45c 05165B 91 ...

Page 47: ...1 238927 VALVE atomizing air 1 32 185119 SPACER lever 1 Ref No Part No Description Qty 33 185112 ADAPTER exhaust hose 1 34 185113 GASKET manifold polyethylene 1 35 185114 RING retainer alternator 1 36 113746 O RING CV75 1 37 222319 ALTERNATOR turbine Includes items 37a 37b 1 37a 110073 O RING Viton 1 37b 185124 CUSHION 1 38 185118 VALVE electrostatic 1 39 224194 SHAFT ASSY air valve 1 40 185115 NU...

Page 48: ...re braid for grounding polyurethane tube and cover 0 315 inch I D 1 4 npsm f x 1 4 npsm f left hand thread the hose is color coded red Hose Part No Hose Length 235068 6 ft 1 8 m 235069 15 ft 4 6 m 235070 25 ft 7 6 m 235071 36 ft 11 0 m 235072 50 ft 15 2 m 235073 75 ft 23 0 m 235074 100 ft 30 5 m PRO 3500sc Gun Conversion Kit 223114 Ref No Part No Description Qty 8 223653 RETAINING NUT 1 20 186615 ...

Page 49: ...00 megohms Not for use in Hazardous areas Gun Cover 180209 Order Part No 218374 for package of 10 Gun Holster 236090 Mount the gun holster to the side of the spray booth Hang gun in holster while the voltage discharges Grounding Rod 210084 For use in the Fluid Voltage Discharge and Ground ing Procedure Manual Change Summary Rev D The manual was updated to change air cap part no 173033 to 193033 Re...

Page 50: ...50 308584 N ...

Page 51: ... fluid does not sustain burning when tested per ASTM Standard D4206 Sus tained Burn Test Category Data Wetted Parts Stainless Steel Brass Nylon Acetal PTFE Fluoroelastomer PTFE High Molecular Weight Polyethylene Ceramic Typical Noise Level with atomization air at 40 psi 280 kPa 2 8 bar and typical air flow Sound Pressure Sound Power 87 Db A 90 4 Db A Maximum Noise Level with atomization air at 100...

Page 52: ...ill be made at a reasonable charge which charges may include the costs of parts labor and transportation DISCLAIMERS AND LIMITATIONS The terms of this warranty constitute purchaser s sole and exclusive remedy and are in lieu of any other warranties express or implied including warranty of merchantability or warranty of fitness for a particular purpose and of any non contractual liabilities includi...