Instructions/Parts List
ELECTROSTATIC, WATERBORNE, AIR SPRAY
WB100 Isolation System and
™
PRO Xs3 Spray Gun
309293J
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure
For use when electrostatically spraying conductive,
waterborne fluids that meet at least one of the
following conditions for non-flammability:
FM Approved
•
•
The fluid has a flash point above 140°F (60°C)
and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93. FM
The fluid does not sustain burning when tested per
ASTM Standard D4206 Sustained Burn Test.
CE-EN 50059 Compliant
TI2139a
•
Materials which cannot be ignited, in any mixture
with air, by an energy source of less than 500 mJ.
WB 100
Isolation Enclosure
U.S. Patent No. 7,226,004
PRO Xs3
Smart Gun and
Fluid Hose
TI1681A
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
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List of Models
List of Models
FM Approved
Part No.
Gun Model
Description
245897
PRO Xs3
Waterborne Isolation Enclosure with standard electrostatic air
spray gun, grounded air hose, and shielded waterborne fluid
hose
245898
233825
PRO Xs3
Waterborne Isolation Enclosure with smart electrostatic air
spray gun, grounded air hose, and shielded waterborne fluid
hose
Waterborne Isolation Enclosure without hoses and gun.
244581,
Series B
PRO Xs3
Standard Electrostatic Air Spray Gun, for waterborne coatings
245301,
PRO Xs3
PRO Xs3
Part No. 244581 Gun, with 25 ft (7.6 m) waterborne fluid hose
Smart Electrostatic Air Spray Gun, for waterborne coatings,
244582,
Series B
245305
245252
PRO Xs3
Part No. 244582 Gun, with 25 ft (7.6 m) waterborne fluid hose
Shielded Waterborne Fluid Hose Assembly 25 ft (7.6 m)
EN 50059 Compliant
244581,
Series B
PRO Xs3
PRO Xs3
Standard Electrostatic Air Spray Gun, for waterborne coatings.
244582,
Series B
Smart Electrostatic Air Spray Gun, for waterborne coatings.
246511
246431
246592
Waterborne Isolation Enclosure, without hoses and gun
Unshielded Waterborne fluid hose assembly, 25 ft (7.6 m).
PRO Xs3
PRO Xs3
Waterborne Isolation Enclosure with standard electrostatic air
spray gun, grounded air hose, and unshielded waterborne fluid
hose
246593
PRO Xs3
Waterborne Isolation Enclosure with smart electrostatic air
spray gun, grounded air hose, and unshielded waterborne fluid
hose
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Symbols
Symbols
Warning Symbol
Caution Symbol
CAUTION
WARNING
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 instruc-
tions.
WARNING
Electric Shock Hazard
Improper grounding, setup, or usage of an isolated waterborne system can cause a hazardous
condition and result in electric shock or other serious injury.
•
•
•
Ground the equipment, all personnel in or close to the spray area, the object being sprayed,
The gun must be connected to a voltage isolation system that will discharge the system volt-
age 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 compo-
nents before the system voltage is discharged.
•
•
to discharge the voltage; before cleaning, flushing, or servicing the system; before approach-
ing 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
•
•
Electrically connect a metal part of the fluid supply unit to the bleed resistor.
The gun air supply must be interlocked with the isolation system to shut off the air supply any-
time the isolation system enclosure is opened.
•
•
•
Use only the red-colored Graco electrically conductive gun air hose with this gun. Do not use
black or grey-colored Graco air hoses.
Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and
the spray gun. Do not splice hoses together.
Do not enter a high voltage or hazardous area until all high voltage equipment has been dis-
charged.
4
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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,
•
•
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
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 flu-
ids, as defined on the front cover of this manual.
•
•
Do not flush with the gun electrostatics turned on.
Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the
spray area.
•
•
Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop
cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.
Use only non-sparking tools to clean residue from the booth and hangers.
Toxic Fluid Hazard
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on
the skin, swallowed, or inhaled.
•
•
Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all
local, state, and national guidelines.
•
Wear appropriate protective clothing, gloves, eyewear, and respirator.
309293J
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Warning
WARNING
Equipment Misuse Hazard
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in a serious injury.
•
•
•
This equipment is for professional use only.
Read all manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain, call your Graco distribu-
tor.
•
•
Do not alter or modify equipment. Use only genuine Graco parts and accessories.
Do not operate the power supply above 60 kV. Use only Graco Part No. 244542 Power Supply
with this gun.
•
•
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. Maxi-
mum working air and fluid pressure of this equipment is 100 psi (0.7 MPa, 7.0 bar).
•
•
Use fluids and solvents that are compatible with the equipment wetted parts. See the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warn-
ings.
Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180°F (82°C) or below -40°F (-40°C).
•
•
Wear hearing protection when operating this equipment.
Comply with all applicable local, state, and national fire, electrical, and other safety regula-
tions.
Pressurized Equipment Hazard
Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin
and cause serious injury.
•
•
•
Do not point the spray gun at anyone or at any part of the body.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
checking, or repairing equipment.
•
•
Check hoses and couplings daily. Replace worn, damaged, or loose parts immediately.
Tighten all fluid connections before each use.
6
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Introduction
Introduction
When connected to a voltage isolation system, all of the
fluid in the spray gun, fluid hose, and isolated fluid sup-
ply is charged to high voltage, which means that the sys-
tem 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.
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 volt-
age current to the gun’s electrode.
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
approaching the front of the gun.
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.
CAUTION
The Graco warranty is void if the spray gun is con-
nected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
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Introduction
•
•
•
ES ON/OFF valve. Turns electrostatics ON (I) or
OFF (0).
Gun Overview
The electrostatic gun includes the following controls
ES INDICATOR (standard gun only). Green when
ES is ON (I).
•
•
•
FLUID adjustment valve. Adjusts fluid rod travel.
Use only in low flow conditions, to reduce wear.
Voltage/current DISPLAY (smart models only).
Shows voltage (V) and current (A). Green=spray,
39.
Fan AIR adjustment valve. Adjusts fan size and
shape.
•
•
ES HI/LO switch (smart models only). Sets volt-
age to HI or LO (factory settings).
Atomizing air RESTRICTOR valve. Restricts
atomizing air flow. Replace with plug (included) if
desired.
LO VOLTAGE adjustment (smart models only).
Remove plug to adjust to four settings. Page 21.
DISPLAY
ES INDICATOR
LO VOLTAGE
100%
0
ES HI/LO
KV
μα
ES ON/OFF
HI
LO
ES
ES
I
O
ES ON/OFF
ES
I
O
RESTRICTOR
AIR
AIR
RESTRICTOR
FLUID
FLUID
ti1266a
ti1253a
Standard Model
Smart Model
TRIGGER
AIR INLET
AIR CAP
ELECTRODE
FLUID TUBE
TI1681A
Fig. 1. Gun Overview
8
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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 con-
tact with the high voltage components before the
system voltage is discharged.
Install the System
•
•
A bleed resistor to drain off the system voltage when
the spray gun is not in use.
WARNING
The system should not have any severe arcing
occurring when the isolation mechanism opens and
closes. Severe arcing will shorten the life of the sys-
tem components.
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.
•
The system must include a means for automatically
discharging the system voltage when anyone opens
the isolation enclosure.
• Do not install or service this equipment
unless you are trained and qualified.
• Be sure your installation complies with all
National, State and Local safety and fire
codes, NFPA 33, NEC 504 and 516, and
OSHA standard 1910.107.
CAUTION
The Graco warranty is void if the spray gun is con-
nected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
borne air spray system. For assistance in designing a
system to suit your particular needs, contact your Graco
distributor.
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Installation
B*
Gun ES ON/OFF valve: I is ON, 0 is OFF
BB
Q*
C
D E U
M
A
S
B*
P*
K*
X
L
AA
N
G
R
TI1896C
W
V*
T
J
Y
F
Z
H
TI1775C
Fig. 2. Typical Installation: PRO Xs Waterborne System
Key
R
S
T
Graco Waterborne Fluid Hose
A
Main Air Supply Line
Main Air Supply Shutoff Valve (bleed-type)
Pump Air Pressure Gauge
Pump Air Pressure Regulator
kV Meter
Waterborne Electrostatic Air Spray Gun
Grounding Rod
B*
C
D
E
U
Ground Terminal
V*
W
X
Main Ground Wire
Strain Relief/Ground Fitting
Pump Air Supply Line
Grounding Cylinder
F
Pump
G
H
J
Pump Suction Hose
Y
Paint Container
Z
Pump Fluid Outlet Fitting
Bleed Resistor
AA Isolated Enclosure Door
K*
L
Enclosure Safety Interlock
Isolated Enclosure
BB Enclosure T-Handle Locking Screw
M
N
P*
Q*
Gun Air Line Filter
*
Required for safe operation. Must be purchased separately.
Gun Air Pressure Regulator
Graco Red Grounded Air Supply Hose
Air Hose Ground Wire
10
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Installation
4. Connect the main air supply line (A) to the
Ventilate the Spray Booth
bleed-type air valve (B). The bleed valve shuts off all
air to the system. Install an additional bleed-type air
valve (B) upstream of the air filter (M) to isolate the
filter for servicing.
WARNING
Flammable or Toxic Vapor Hazard
WARNING
Provide fresh air ventilation to avoid the
buildup of flammable or toxic vapors. Do not
operate the gun unless ventilation fans are
operating.
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.
Check and follow all National, State, and Local codes
regarding air exhaust velocity requirements.
High velocity air exhaust will decrease the operating effi-
ciency of the electrostatic system. The minimum allow-
able air exhaust velocity is 60 linear ft/min (18.3 linear
meters/minute).
Ground the Cabinet
Connect the main ground wire (V) to a true earth
ground.
Connect the Air Line
Connect the Waterborne Fluid
Hose
Always use a Graco waterborne fluid hose between the
voltage isolation system fluid outlet and the gun fluid
inlet. See FIG. 3.. The waterborne fluid hose (101) con-
sists of an inner PTFE tube (T) and an abrasion-resis-
tant outer jacket (J). Shielded hose 245252 also has a
conductive layer (C), The conductive layer is connected
to ground at the gun fitting bracket (104).
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 con-
nect the hose ground wire to a true earth ground. Do
not use the black or grey-colored Graco air hoses.
Before connecting the waterborne fluid hose to the gun,
blow it out with air and flush with water to remove con-
taminants. Flush the gun before using it.
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 appear-
ance of your finished workpiece and can cause the
gun to malfunction.
WARNING
2. Install a bleed-type air regulator (N) on the gun air
line (P).
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.
3. Connect the red-colored Graco Grounded Air Sup-
ply Hose (P) between the gun air regulator (N) and
the gun's air inlet. The gun air inlet fitting has a
left-hand thread. Connect the air supply hose
ground wire (Q) to a true earth ground.
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Installation
1. Remove the gun air inlet fitting (35). See FIG. 3..
Shielded Hose 245252
C
J
B
T
F
A
A
B
7.40 in. (188 mm)
2.0 in. (50 mm)
A
16
104
108
Fig. 4. Waterborne Hose Dimensions (At Gun)
Unshielded
107
106
35
105
103
Hose 246431
38
39
C
102
TI2155A
J
101
T
Fig. 3. Connect the Fluid Hose
A
1.25 in (32 mm)
In a shielded hose system, if a hose failure occurs
where high voltage arcs through the inner tube, voltage
will be discharged to ground through the conductive
hose layer. When properly installed, the conductive hose
layer is grounded through its connection to the grounded
enclosure.
A
TI2742A
Fig. 5.
3. Generously apply dielectric grease (40) to the o-ring
(107) and the threads of the fitting (106). Pull the fit-
ting 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..
2. For the fluid hose to fit 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.
CAUTION
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.
6. Check that the nut (105) is tightened securely to the
ferrule housing (103).
7. Press the exhaust tube (38) onto the barbed
adapter (A). Secure with the clamp (39).
8. Connect the other end of the hose to the isolated
fluid supply as follows:
12
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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
C
See Warning below.
W
J
T
C
Shielded
Hose 245252
T
J
Z
B
L
A
B
14.5 in. (368 mm)
0.75 in. (19 mm)
TI2744
A
A
Fig. 9. Unshielded fluid connection
TI2166A
Fig. 6. Waterborne Hose Dimensions (At Graco
WB100 Enclosure)
WARNING
C
See Warning at right.
Electric Shock Hazard
For Shielded hose systems:
Conductive hose layer (C) must be
W
J
grounded through its connection to the iso-
lation system’s grounded enclosure (L) or
T
grounded safety fence. To maintain grounding conti-
nuity, 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.
Z
L
b. Non-Graco Isolated Enclosure: Connect hose
as instructed in the isolation system manual,
and comply with the requirements in the Warn-
ing at right. Refer to FIG. 10..
TI1897A
Fig. 7. Shielded Fluid Hose Connection at Graco
WB100
NOTE: Ground layer (C) of hose must
be grounded at isolation system.
Unshielded
Hose 246431
C
J
J
T
T
L
A
12.0 in (305 mm)
A
TI1966A
C (see note above)
TI2743A
Fig. 10. Shielded Fluid Hose Connection at Non-Gra-
co Isolated Enclosure
Fig. 8.
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Installation
c. Connect the end of the tube (T) to the pump
fluid outlet fitting (Z).
7. Assemble the other parts of the kit as shown.
Secure the agitator with the setscrew (408).
8. Return the system to service.
Connect to elbow (282)
inside control box (258)
CAUTION
402
407
The Graco warranty is void if the spray gun is con-
nected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
401
406
Install tube A2 here
403
CAUTION
Factory Mutual approval is valid only when this gun is
used with Factory Mutual approved voltage isolation
systems.
408
404
245895 Agitator Kit
To add an agitator to the Graco isolation system, order
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 mani-
Y fitting (402) into the elbow. Install tubes (A2) and
tor tube (407) into the cabinet.
TI2137A
6. Replace the back of the control box (258).
Fig. 11. 245895 Agitator Kit
14
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Installation
12. Connect tube (A1) to the air inlet of fluid regulator
245944 Fluid Regulator Kit
(504). Connect tube (507) to the pump air inlet.
To add a fluid regulator to the Graco isolation system,
13. Connect the waterborne fluid hose to the fluid regu-
lator outlet fitting (501).
14. Return the system to service.
The cabinet air regulator and gauge (216, 217) will now
operate the air piloted fluid regulator (504). The pump
will now operate at the inlet air pressure.
3. Open the isolated enclosure door.
4. Remove the 1/4 OD tube (A1) from the pump air
Connect to
Connect
waterborne
fluid hose here
elbow (282)
inside control
box (258)
Tube A1
5. Remove the waterborne fluid hose from the pump
fluid outlet fitting (231) and remove the fitting.
506
507
502
501
504
12.) and remove the pump from the isolation enclo-
sure.
7. Remove the back of the control box (258).
8. Remove tube (A2) from elbow (282) at the air mani-
elbow. Install tubes (A2) and (507) into the Y fitting.
Route the tube (507) into the cabinet.
505
Connect
tube A2
here
503
S
9. Replace the back of the control box (258).
TI2149A
Fig. 12. Fluid Regulator Kit
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.
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Installation
Select a Fluid Nozzle and Air
Cap
Table 1: Fluid Nozzles
Size,
Size,
mm (in.)
Part No.
Part No.
mm (in.)
197263
197264
197265
0.75 (.030)
1.0 (.042)
1.2 (.047)
197266
197267
197268
1.5 (.055)
1.8 (.070)
2.0 (.080)
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
before removing or installing a fluid nozzle
and/or air cap.
Table 2: Air Caps
Pattern Shape
Part No. and Length
in. (mm)
Recommended Fluids and
Production Rates
The gun is supplied with Part No. 197266 Nozzle and
197477 Air Cap. If you require a different size, refer to
consult with your Graco distributor. See Air Cap/Nozzle
Round end;
197477
Light to medium viscosity.
Medium to high production.
15-17 (381-432)
Round end;
197478
Light to medium viscosity.
Low to medium production.
15-17 (381-432)
Tapered end;
197479
Light to medium viscosity.
Medium to high production.
13-15 (330-381)
Medium to high viscosity
and high solids.
Low to medium production.
Round end;
197480
16-18 (406-457)
Medium to high viscosity
and high solids.
Medium to high production.
For use with 2.0 mm nozzle.
Tapered end;
197481
17-19 (432-483)
16
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Installation
•
•
Voltage Isolation System: electrically connect to a
true earth ground, as instructed in the voltage isola-
tion system manual.
Grounding
Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Resistance must
not exceed 1 megohm.
WARNING
Fire, Explosion, and Electric Shock Hazard
When operating the electrostatic gun, any
ungrounded objects in the spray area (peo-
ple, 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 floor of the spray area: must be electrically con-
ductive and grounded. Do not cover the floor with
cardboard or any non-conductive material which
would interrupt grounding continuity.
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 con-
necting the red-colored Graco Grounded Air Hose
and connecting the air hose ground wire to a true
earth ground. See Check Electrical Grounding,
•
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.
ti1259a
•
•
Graco Waterborne Fluid Hose: the hose is grounded
through the conductive layer. Install the hose as
•
All electrically conductive objects or devices in the
spray area: including fluid containers, tools, and
wash cans, must be properly grounded.
All persons entering the spray area: shoes must
have conductive soles, such as leather, or personal
grounding straps must be worn. Do not wear shoes
with non-conductive soles such as rubber or plastic.
If gloves are necessary, wear the conductive gloves
that are supplied with the gun. If non-Graco gloves
are worn, cut off fingers or palm area of glove to
ensure your hand contacts the grounded gun han-
dle.
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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.
ES
I
O
ti1273a
AA
3. Turn off the air and fluid supply to the gun. The fluid
hose must not have any fluid in it.
CC
TI2161A
4. Make sure the red-colored grounded air hose (R) is
connected and the hose ground wire is connected to
a true earth ground.
Fig. 13. Check Gun Grounding
7. Using an ohmmeter (AA), measure the resistance
between the cabinet ground lug (214) and a true
must be less than 100 ohms.
ti1259a
5. Using an ohmmeter (AA), measure the resistance
between the gun handle (BB) and a true earth
ground (CC). The resistance should not exceed 100
ohms. See FIG. 13..
6. If the resistance is greater than 100 ohms, check the
tightness of the ground connections and be sure the
air hose ground wire is connected to a true earth
ground. If the resistance is still too high, replace the
air hose.
214
AA
CC
TI2163A
Fig. 14. Check Cabinet Grounding
18
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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
All debris, including flammable fluids and rags,
is removed from the spray area.
The electrostatics are turned off and properly
grounded according to the.Fluid Voltage Dis-
charge and Grounding Procedure on page
20 before any person enters the safety enclo-
sure, before cleaning, and before performing
any maintenance or repair.
Only fluids with a flash point above 140°F
(60°C) and a maximum organic solvent con-
centration 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.
The system is thoroughly grounded and the
operator and all persons entering the spray
area are properly grounded. See Grounding
Fluid Hose is in good condition with no cuts or
abrasions of the PTFE layer. Replace hose if
damaged.
309293J
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Operation
Fluid Voltage Discharge and
Grounding Procedure
Pressure Relief Procedure
WARNING
WARNING
Pressurized Equipment Hazard
The system pressure must be manually
relieved to prevent the system from starting
or spraying accidentally. To reduce the risk
Electric Shock Hazard
The fluid supply is charged with high volt-
age until the voltage is discharged. Contact
with the charged components of the isola-
tion system or spray gun electrode will
cause an electric shock. To avoid an electric shock,
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
•
•
whenever you are instructed to discharge the
voltage
check or service any of the system equipment
or install or clean the fluid nozzle.
before cleaning, flushing, or servicing the system
equipment
•
•
before approaching the front of the gun
1. Turn the ES ON/OFF valve OFF.
ES
I
O
or before opening the safety enclosure for the
isolated fluid supply.
1. Turn the ES ON/OFF valve OFF and wait 30 sec-
onds.
ti1273a
ing Procedure at left.
ES
I
O
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.
ti1289a
4. Trigger the gun into a grounded metal waste con-
tainer to relieve the air and fluid pressure.
3. Use the grounding rod to touch the pump and sup-
ply pail. If you see any arcs, see Electrical Trouble-
ti1276a
5. Relieve fluid pressure in the fluid supply unit as
instructed in your fluid supply unit manual.
20
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Operation
Fill the Fluid Supply
WARNING
Fire and Explosion Hazard
To reduce the risk of fire and explosion, only
use this equipment with fluids that meet at
least one of the following conditions for
non-flammability:.
ti1276a
3. Open the isolated enclosure door.
•
•
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.
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 does not sustain burning when tested
per ASTM Standard D4206 Sustained Burn Test.
5. Remove the supply pail from the enclosure.
CAUTION
WARNING
Be sure to wipe up all fluid spills in the isolated enclo-
sure. Fluid can create a conductive path and cause
the system to short out.
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
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.
whenever you are instructed to discharge the voltage.
8. Reinstall the pail cover, holding a rag over the suc-
tion 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.
WARNING
Adjust the Spray Pattern
Follow the steps below to establish the correct fluid flow
and air flow.
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.
309293J
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Operation
4. Fully open the fan air adjustment valve.
100%
0
KV
μα
WARNING
HI
LO
ES
Pressurized Equipment Hazard
E
I
O
To reduce the risk of an injury, follow the
whenever you are instructed to relieve the
pressure.
ti1269a
1. Make sure the ES ON/OFF valve is OFF.
5. Fully open the fluid adjustment valve.
ES
I
O
100%
0
KV
μα
HI
LO
ES
ti1273a
E
I
O
2. Turn on the main air supply valve (B).
ti1267a
6. Fully open the atomizing air restrictor valve.
3. Position the air cap by loosening the air cap retain-
ing ring, and rotating the air cap for a vertical or hor-
izontal 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.
ti1272a
Vertical Pattern
7. Make sure the ES ON/OFF valve is OFF.
ES
I
O
Horizontal Pattern
ti1273a
22
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Operation
8. Adjust the pump air regulator to start the fluid supply
unit. Adjust the fluid flow with the air pressure regu-
lator 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.
10. Spray a test pattern. Check the atomization. If over-
atomization occurs at minimum pressure, adjust the
air atomizing restrictor valve. If atomization is inade-
quate, increase the air pressure.
8-12 in. (200-300 mm)
ti1282a
TI1760A
11. Adjust the fan air adjustment valve: clockwise for a
rounder pattern, counterclockwise for a wider pat-
tern.
9. Set the gun air regulator to deliver a minimum 40 psi
(0.28 MPa, 2.8 bar) at the gun when triggered, for
ti1283a
TI1281A
WARNING
Table 3: Air Regulator Settings
Electric Shock Hazard
Air Hose Length
Air Regulator Setting
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.
ft (m)
(5/16 in. [8 mm] diameter)
psi (MPa, bar)
(with gun triggered)
15 (4.6)
25 (7.6)
50 (15.3)
50 (0.35, 3.5)
60 (0.42, 4.2)
75 (0.52, 5.2)
12. Turn the ES ON/OFF switch ON (I).
•
•
For the most efficiency, always use the lowest air
pressure possible.
ES
I
O
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.
ti1284a
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Operation
13. Check that the ES indicator or display is lit, or check
that the kV indicator on the isolated enclosure reads
15. Spray a test piece. Examine the edges for coverage.
If wrap is poor, see Spray Pattern Troubleshoot-
100%
0
KV
μα
HI
ES
I
O
LO
ES
ES
I
O
ti1266a
ti1253a
ti1285a
14. Check the kV meter on the isolated enclosure;
45-55 kV is normal.
16. When you finish spraying, perform the Shutdown
24
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Operation
Shutdown
Low Voltage Adjustment (Smart
Guns Only)
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.
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
WARNING
OFF
ON
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on whenever
you are instructed to relieve the pressure.
2
1
100%
0
KV
μα
53
ti1529a
Fig. 15. Low Voltage Adjustment Switches
ti1276a
Table 4: Low Voltage Adjustment
1
ON
2
kV
50
40
35
30
4. Hang the gun from its hook or place it in the acces-
sory holster, with the nozzle pointing down. Be sure
to keep the gun from grounding out.
ON
OFF
ON
OFF
Factory Setting > ON
OFF
OFF
ti1288a
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Maintenance
Maintenance
1. Turn the ES ON/OFF valve OFF and wait 30 sec-
onds for the voltage to bleed off.
Flush the Spray Gun
Flush the gun before changing colors, at the end of the
day, before storing, and before repairing the gun.
ES
I
O
ti1273a
WARNING
Fire, Explosion, and Electric Shock Hazard
To reduce the risk of fire, explosion, or elec-
tric shock, turn the ES ON/OFF valve OFF
before flushing the gun.
ti1276a
flushing.
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
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.
ti1276a
6. Relieve the pressure.
•
The fluid does not sustain burning when tested
per ASTM Standard D4206 Sustained Burn Test.
ti1276a
7. Open the isolated enclosure door. Leave the flush-
ing fluid in the system until you are ready to spray
again.
WARNING
8. Hang the gun from its hook, with the nozzle pointing
down. Be sure to keep the gun from grounding out.
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
whenever you are instructed to relieve the
pressure.
ti1288a
9. Before using the system electrostatically again,
make sure no flammable vapors are present.
26
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Maintenance
Daily Care and Cleaning
CAUTION
•
Clean the outside of the gun daily with a soft cloth
Do not immerse the gun in fluid.
dampened with a non-flammable solvent, as
•
•
Check for fluid leaks. Tighten all fittings.
Clean the air cap and fluid nozzle daily, minimum.
quent 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.
ti1294a
•
•
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 wipe the gun with a cloth that is heavily satu-
rated; wring out the excess fluid.
ti1295a
ti1293a
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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.
240
28
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Maintenance
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.
Clean the Air Cap and Fluid
Nozzle
6. With the gun pointing down, clean the fluid nozzle
(7) and the front of the gun with a soft brush damp-
ened with non-flammable solvent.
Equipment Needed
•
soft bristle brush
If it appears that there is paint inside the fluid nozzle (7)
air passages, remove the gun from the line for servicing.
•
non-flammable solvent
Procedure
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.
1. Turn the ES ON/OFF valve OFF. Wait 30 seconds.
ES
I
O
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.
ti1273a
7
29
9
27
ti1297a
ti1276a
4. Remove the retaining ring (27) and air cap (9). See
FIG. 16..
Fig. 16. Clean Air Cap and Fluid Nozzle
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.
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.
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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 electri-
cal continuity between components.
Test Gun Resistance
1. Prepare the gun for service as instructed on page
41.
Use megohmmeter Part No. 241079 (AA) and an
applied voltage of 500 V. Connect the leads as shown.
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
of poor performance, or contact your Graco distribu-
tor.
WARNING
Fire, Explosion, and Electric Shock Hazard
Megohmmeter Part No. 241079 (AA-see
ardous area. To reduce the risk of sparking,
do not use the megohmmeter to check elec-
trical grounding unless:
AA
• The gun has been removed from the
hazardous area;
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. 17. Test Gun Resistance
30
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Electrical Tests
Test Power Supply Resistance
1. Prepare the gun for service as instructed on page
41.
3. Remove the turbine alternator (19) from the power
supply, page 47.
EE
4. Measure resistance from the power supply's ground
18b
5. The resistance should be 95-105 megohms. If out-
side this range, replace the power supply. If in
range, proceed to the next test.
ti1599a
Fig. 18. Test Power Supply Resistance
6. Be sure the spring (18b) is in place before reinstall-
ing the power supply.
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Electrical Tests
Test Electrode Resistance
1. Prepare the gun for service as instructed on page
41.
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
F
29
E
ti1548a
mance, or contact your Graco distributor.
resistance between the contact (E) and the elec-
trode wire (F). The resistance should be 20-30
megohms. If out of range, replace the electrode.
Fig. 20. Electrode
6. Make sure the metal contact (C) in the barrel, the
contact (E) are clean and undamaged.
7a
ti1513a
Fig. 21. Nozzle Conductive O-Ring
C
B
29
ti1499a
Fig. 19. Test Electrode Resistance
32
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Electrical Tests
Test Ground Strip Resistance
Test Cylinder Resistance
tance 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).
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.
214
209
206
214
TI2165A
Fig. 22. Test Ground Strip Resistance
TI2164A
Fig. 23. Test Cylinder Resistance
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Troubleshooting
Troubleshooting
A loss of spraying voltage can be caused by a problem
with the spray gun, fluid hose, or voltage isolation sys-
tem, since all of the system components are electrically
connected through the conductive, waterborne fluid.
WARNING
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:
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.
Spray Gun
•
Fluid leakage
•
Dielectric breakdown at the fluid hose connection or
fluid packings
Follow the Fluid Voltage Discharge and Grounding
the system and whenever you are instructed to dis-
charge the voltage.
•
•
•
•
Not enough air pressure for the turbine
Faulty power supply
Excessive overspray on gun surfaces
Fluid in the air passages
WARNING
Waterborne Fluid Hose
Pressurized Equipment Hazard
•
Dielectric failure of hose (pin-hole leak through
PTFE layer)
To reduce the risk of an injury, follow the
before checking or servicing any part of the
system and whenever you are instructed to
relieve the pressure.
•
Air gap in the fluid column between the gun and iso-
lated fluid supply, causing a low voltage reading on
the isolation system voltage meter.
Voltage Isolation System
Voltage Loss Troubleshooting
•
Fluid leakage
Normal spraying voltage for a system using the water-
borne gun is 45-55 kV. The system voltage is lower due
to spraying current demands and voltage isolation sys-
tem losses.
•
Dirty interior
34
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Troubleshooting
10. Inspect the entire system for any visible fluid leak-
age and repair any fluid leaks that are found. Pay
special attention to the following areas:
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 prob-
lems and is required for some of the troubleshooting
tests that follow.
•
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
1. Check that all of the air and fluid tubes and hoses
are properly connected.
Tests
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.
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.
1. Flush the system with water and leave the lines
filled with water.
4. Check that the spray gun and voltage isolation sys-
tem have sufficient air pressure.
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
4. Disconnect the fluid hose from the voltage isolation
system.
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 conductiv-
ity path and conceal a potential failure area.
6. Check that the voltage isolation system's enclosure
door is closed and that any safety interlocks are
engaged and working properly.
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.
7. Make sure the voltage isolation system is in the “iso-
late” 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 volt-
age 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.
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 sec-
onds and then touching the gun electrode with a
grounded rod.
9. Check the spray gun cover and barrel for accumu-
lated 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.
8. If the meter reading is 45 to 55 kV, the gun and fluid
hose are okay, and the problem is in the voltage iso-
lation system.
If the reading is below 45 kV, the problem is in the
gun or fluid hose.
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Troubleshooting
9. Flush the fluid hose and gun with enough air to dry
out the fluid passages.
Inspect the end of the hose connected to the volt-
age 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.
Fluid packings
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.
•
•
Remove the packing assembly from the gun as
leakage or any blackened areas, which would indi-
cate arcing is occurring along the packing rod.
Fluid hose connection joint to the spray gun
11. If the meter reading is 45-55 kV, the gun power sup-
ply is okay, and there is probably a dielectric break-
down somewhere in the fluid hose or gun. Continue
with step 12.
If the reading is below 45 kV, do the electrical tests
resistance. If those tests show the gun and power
supply are okay, continue with step 12.
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 leak-
age along the PTFE tube.
12. A dielectric breakdown is most likely in one of the
following three areas. Repair or replace the compo-
nent that is failing.
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.
•
Fluid hose
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 out-
side of the PTFE portion of the fluid tube.
14. Reconnect the fluid hose.
15. Check the gun voltage with the voltage probe and
meter before filling the gun with fluid.
36
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Troubleshooting
Spray Pattern Troubleshooting
Check all possible remedies in the Troubleshooting Chart before disassembling the gun.
Some spray pattern problems are caused by the improper balance between air and fluid.
Problem
Cause
Solution
Fluttering or spitting spray.
No fluid.
Refill supply.
Loose, dirty, damaged nozzle/seat.
Air in fluid supply.
Check fluid source. Refill.
Improper spray pattern.
Damaged nozzle or air cap.
Fluid buildup on air cap or nozzle.
Fan air pressure too high.
Decrease.
Fluid too thin.
Increase viscosity.
Increase.
Fluid pressure too low.
Fan air pressure too low.
Increase.
Fluid too thick.
Reduce viscosity.
Too much fluid.
Decrease flow.
Streaks.
Did not apply 50% overlap.
Dirty or damaged air cap.
Overlap strokes 50%.
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Troubleshooting
Gun Operation Troubleshooting
Problem
Cause
Solution
Excessive spray fog.
Atomizing air pressure too high.
Close restrictor valve some, or
decrease air pressure as low as pos-
sible; minimum 40 psi (0.28 MPa, 2.8
bar) needed at gun for full voltage.
Fluid too thin.
Increase viscosity.
“Orange Peel” finish.
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.
Fluid too thick.
Remix or refilter fluid.
Reduce viscosity.
Fluid leaks from the fluid packing
area
Worn packings or rod.
Replace packings or rod; see page
45.
Air leaks from the front of the gun
Air valve (21) is not seating properly. Clean and service air valve; see
Fluid leakage from the front of the
gun
Worn fluid seat.
Replace fluid nozzle and/or electrode
Loose fluid nozzle (7).
Replace; see page 42.
Add fluid if necessary.
Replace; see page 42.
Clean; see page 42.
Replace; see page 42.
Damaged nozzle o-ring (7b).
Low fluid supply.
Gun does not spray
Damaged air cap (9).
Dirty or clogged fluid nozzle (7).
Damaged fluid nozzle (7).
Dirty air cap
Misaligned air cap (9) and fluid noz- Clean fluid buildup off air cap and
zle (7).
38
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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
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
near gun isolated.
Determine cause and correct. Purge
air from fluid line.
Voltage isolation system failed.
Grounding cylinder not operating.
Service voltage isolation system.
Check resistance of grounding cylin-
Poor wrap.
ES ON/OFF valve OFF (0).*
Gun air pressure too low.
Turn ON (I).
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.
Fluid pressure too high.
Decrease.
Decrease.
Incorrect distance from gun to part.
Poorly grounded parts.
Should be 8-12 in. (200-300 mm).
Resistance must be 1 megohm or
less. Clean workpiece hangers.
Faulty gun resistance.
30.
Fluid leaks from the packing (26d)
and causes a short.
Clean the packing rod cavity.
Replace the packing rod. See page
45.
Faulty turbine alternator.
Be sure the plug is in place on the
back of the turbine alternator hous-
ing. Remove and test the turbine
The KV HI-LO lever is on LO.
Check the lever actuation; replace if
needed.
Spilled paint, dried paint, or other
contaminants inside WB100 enclo-
sure, causing a short circuit.
Clean interior of enclosure.
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Troubleshooting
Problem
Cause
Solution
ES indicator or voltage/current dis-
play is not lit.
ES ON/OFF valve OFF (0).*
Turn ON (I).
No power.
Should be 8-12 in. (200-300 mm).
Voltage/current display stays red
(smart guns only).
Gun too close to part.
Check fluid resistivity.
Dirty gun.
Operator gets mild shock.
Operator not grounded or is near
ungrounded object.
Gun not grounded.
on page 30.
Operator gets shock from workpiece. Workpiece not grounded.
* ES indicator light is off when the gun is triggered.
Resistance must be 1 megohm or
less. Clean workpiece hangers.
40
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Repair
Repair
Prepare the Gun for Service
•
•
•
Check all possible remedies in Troubleshooting
before disassembling the gun.
Use a vise with padded jaws to prevent damage to
plastic parts.
WARNING
Lubricate the power supply o-ring (18a), some pack-
ing rod parts (26), and certain fluid fittings with
dielectric grease (40), as specified in the text.
Fire, Explosion, and Electric Shock Hazard
To reduce the risk of a fire, explosion, or
electric shock:
•
Lightly lubricate o-rings and seals with non-silicone
grease. Order Part No. 111265 Lubricant. Do not
over-lubricate.
be sure the ES ON/OFF valve is OFF
before flushing, checking, or servicing
the system and whenever you are
•
•
Only use genuine Graco parts. Do not mix or use
parts from other PRO Gun models.
instructed to discharge the voltage.
Air Seal Repair Kit 244781 is available. The kit must
be purchased separately. Kit parts are marked with
an asterisk, for example (6*).
• Clean all parts with a non-flammable
fluid as defined on the front cover of this
manual.
•
Fluid Seal Repair Kit 244911 is available. The kit
must be purchased separately. Kit parts are marked
with a double asterisk, for example (26a**).
• 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
3. Blow the fluid lines dry with air.
WARNING
5. Disconnect the gun air and fluid lines at the isolation
system.
Pressurized Equipment Hazard
checking or servicing any part of the system
and whenever you are instructed to relieve the pres-
sure.
6. Remove the gun from the worksite. Repair area
must be clean.
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Repair
Air Cap/Nozzle Replacement
WARNING
CAUTION
Fire, Explosion, and Electric Shock Hazard
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 with-
out the contact ring in place. Do not replace
the contact ring with anything but a genuine
Graco part.
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 enter-
ing the air passages.
2. Remove the retaining ring (27) and air cap (9). See
Use non-silicone grease, Part No. 111265, on the small
o-ring (7b). Do not over-lubricate. Do not lubricate the
contact ring (7a).
3. Point gun up and squeeze trigger while removing
the fluid nozzle (7) assembly with the multi-tool (37).
4. Lightly lubricate the o-ring (7b). Install it and the
contact ring (7a) on the nozzle (7).
Make sure the electrode needle (29) is finger- tight
27
27a*
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
hand-tight).
9
6. Install the air cap (9) and retaining ring (27). Make
sure the u-cup (27a*) is in place with the lips facing
forward.
37
7
7a
7b
ti1501a
Fig. 24. Air Cap/Nozzle Replacement
42
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Repair
Electrode Replacement
3. Unscrew the electrode (29) with the multi-tool (37).
Hold the packing rod end (26h) to prevent it from
37
CAUTION
To avoid damaging the plastic threads, be very care-
ful 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
Fig. 25. Electrode Replacement
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Repair
Fluid Packing Removal
4. Loosen the trigger screws (8) and trigger (30). See
37
5. Remove the packing rod (26), using the multi-tool
(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.
Fig. 26. Fluid Packing Removal
44
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Repair
4. Lightly tighten the packing nut (26e). The packing
Packing Rod Repair
You may replace the packing rod as individual parts or
as an assembly. The assembly is pre-adjusted at the
factory.
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 pack-
ing nut as needed.
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 arc-
ing. If marks are present, replace the barrel.
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.
To assemble the individual parts:
7. Install the packing rod assembly (26) into the gun
barrel. Using the multi-tool (37), tighten the assem-
bly until just snug.
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
8. Install the trigger (30) and screws (8).
2. Fill the inner cavity of the spacer (26g**) with dielec-
tric grease (40). Place the spacer on the fluid rod
(26h) in the direction shown. Generously apply
dielectric grease to the outside of the spacer.
3. Place the packing spreader (26c**), rod packing
(26d**), and housing (26f) on the packing rod (26h).
4
E
TI1489A
26h
26e
**26b
**26g
**26c
**26d
26f
**26a
Fig. 27. Packing Rod
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Repair
5. Apply dielectric grease (40) to the exposed inner
tube of the fluid hose (101).
Barrel Removal
6. Check that the nut (105) is tight on the ferrule hous-
ing (103).
2. Remove the air inlet fitting (35) and take the bracket
(104) off the gun handle (17).
3. Loosen the three screws (11).
104
CAUTION
11
16
To avoid damaging the power supply (18), pull the
gun barrel straight away from the gun handle. If nec-
essary, gently move the gun barrel from side to side
to free it from the gun handle.
4. Hold the gun handle (17) with one hand and pull the
barrel (16) straight off the handle. See FIG. 28..
TI1690A
35
17
Barrel Installation
17
TI1691A
1. Be sure the gasket (10*) and grounding spring (55)
are in place. Make sure the gasket air holes are
Fig. 28. Barrel Removal
2. Place the barrel (16) over the power supply (18) and
onto the gun handle (17).
*10
18
11
3. Tighten the three screws (11) oppositely and evenly
(about a half turn past snug).
16
55
CAUTION
35
Do not over-tighten the screws (11).
101
105
104
4. Position the bracket (104) on the gun handle (17)
and secure with the air inlet fitting (35).
TI1692A
Fig. 29. Barrel Installation
46
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Repair
8. Lubricate the alternator o-ring (19a*) with non-sili-
Power Supply Removal and
Replacement
cone grease, Part No. 111265. Do not over-lubri-
cate.
9. Lubricate the power supply o-ring (18a*) with dielec-
tric grease (40).
•
•
Inspect the gun handle power supply cavity for dirt
or moisture. Clean with a clean, dry rag.
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, con-
nect 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.
Do not expose gasket (10) to solvents.
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 sup-
ply/alternator assembly from the gun handle (17),
then carefully pull it straight out. On Smart Models
only, disconnect the flexible circuit (59) from the
10*
19a*
19
19e
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 alterna-
tor for damage. On Smart Models only, disconnect
the 6-pin flexible circuit (59) from the power supply.
59
ti1505c
GG
Replace if necessary.
Before installing the power supply, make sure the
o-rings (18a*, 19a*), spring (18b), and pads (19e) are in
place.
6. On Smart Models only, connect the 6-pin flexible cir-
cuit (59) to the power supply.
18
7. Connect the 3-wire connector (GG). Slide the alter-
nator (19) down onto the power supply (18).
*18a
18b
Fig. 30. Power Supply
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Repair
4. Measure resistance between the two outer termi-
nals of the 3-wire connector (GG); it should be
2.5-3.5 ohms. If outside this range, replace the alter-
nator coil.
Turbine Alternator Removal and
Replacement
Replace turbine alternator bearings after 2000 hours of
operation. Order Part No. 223688 Bearing Kit.
5. Follow the bearing replacement procedure in the
bearing kit manual 308034.
6. Install the alternator on the power supply, page 47.
2. Remove the power supply/alternator assembly,
7. Install the power supply/alternator assembly, page
47.
3. Disconnect the alternator from the power supply,
48
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Repair
6. Clean all parts and inspect for wear or damage.
Use non-silicone grease, Part No. 111265. Do not
over-lubricate.
Fan Air Adjustment Valve Repair
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).
8. Reassemble the retaining ring (20a). Unscrew the
valve stem from the housing until it is stopped by the
retaining ring.
4. Turn the valve stem (20d) counterclockwise until it
comes free from the valve housing (20c).
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. 31. Fan Air Adjustment Valve
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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 flats.
Fluid Adjustment Valve Repair
2. Remove the fluid adjustment valve (25). It can only
CAUTION
When removing the air valve (21) be careful not to
damage the seat area.
3. Screw the valve (25) into the gun handle. Torque to
15-25 in-lb (1.7-2.8 N•m).
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).
7. Install the fluid adjustment valve (25). Torque to
15-25 in-lb (1.7-2.8 N•m).
25
TI1684A
Fig. 32. Fluid Adjustment Valve
Air Valve Repair
25
15
21
21a*
17
3. Remove the fluid adjustment valve (25) from the
*6
TI1685A
Fig. 33. Air Valve
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.
50
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Repair
2. Loosen the screw (48). Remove the valve.
Atomizing Air Restrictor Valve
Removal and Replacement
3. Lubricate the o-rings (22a* and 22b*) with non-sili-
cone grease, Part No. 111265. Do not over-lubri-
cate.
2. Remove the atomizing air restrictor valve (23).
Inspect the o-ring (23c*). Replace if necessary. See
CAUTION
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.
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.
If the atomizing air restrictor valve is not desired, install
the supplied plug (47).
4. Clean and inspect parts for damage. Replace if nec-
essary.
The protrusion on the retainer plate (22d) must point
upward.
4. Torque the valve housing (23a) to 15-20 in-lb
(1.7-2.3 N•m).
5. Reinstall the valve. Torque the screw (48) to 15-25
in-lb (1.7-2.8 N•m).
22g
22d
22f
22e
23c*
47
22b*
23a
22c
22a*
23d
23b
48
TI1488A
TI1686A
Fig. 34. Atomizing Air Restrictor Valve
Fig. 35. ES ON/OFF Valve
ES ON/OFF Valve Repair
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Parts
Parts
Part No. 244581 60 kV Electrostatic Gun, Series B (items 4-55)
Part No. 245301 60 kV Electrostatic Gun with Shielded waterborne fluid hose, Series A (items 4-55, 101-108)
valve (20), ES ON/OFF valve (22), and packing rod (26).
22
19a*
20
19
ES
I
O
19e
18
28
23d
39
25
ti1266a
18b
15
17
*18a
21
7b
7a
*10
25 (Ref)
21a*
7
16
9
11
11
27a*
23c*
27
*6
8
47
55
23a
24
23b
*24a
30
4
35***
38
105
36
104
103
102
108
26
107
106
29
101
TI1679A
37
52
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Parts
Ref. No. 19: Alternator
Ref. No. 20: Fan Adjustment Valve
20d
19a*
19b
TI1487A
20b*
20c
19b
TI1481a
20a
19e
19d
19c
Ref. No. 26: Packing Rod
Ref. No. 22: ES ON/OFF Valve
22f
ti1601a
26h
26e
26b**
26g**
26c**
26d**
22d
22e
22g
22b*
22c
22a*
26f
26a**
48
TI1488A
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Parts
Part No. 244581 60 kV Electrostatic Gun, Series B (items 4-55)
Part No. 245301 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-55, 101-108)
Ref.
Part No. Description
No.
Qty
Ref.
No.
Part No. Description
Qty
20d
21
197567
244557
. STEM, fan valve
VALVE, air
1
1
1
1
4
185111
188749
SPRING, compression
1
1
21a* 276733
22 244558
SEAL, fluoroelastomer
6*
PACKING, u-cup, air valve;
uhmwpe
VALVE, electrostatics, ON/OFF;
includes 22a-22g
7
197266
NOZZLE; 1.5 mm orifice; includes
7a and 7b
1
22a* 111516
22b* 113137
. O-RING; CV75
. O-RING; fluoroelastomer
. SHAFT, valve
. PLATE, retaining
. WASHER
1
1
1
1
1
1
1
1
7a
7b
8
111261
111507
197369
197477
197517
197518
. O-RING, conductive
. O-RING; fluoroelastomer
SCREW, trigger
1
1
2
1
1
3
22c
22d
22e
22f
22g
23
198403
198404
198453
198464
276753
244559
9
AIR CAP
10*
11
GASKET, barrel
. PIN
SCREW; socket-hd; 10-24 x 3/4
in. (19 mm)
. KNOB
VALVE, air, atomizing; includes
23a-23d
15
16
17
18
185116
244394
245292
244542
SPRING, compression
BARREL, gun
1
1
1
1
23a
23b
197594
197591
. HOUSING, valve
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
HANDLE, gun; includes item 28
. SHAFT
POWER SUPPLY, 60 kV; includes
18a-18d
23c* 168518
. O-RING; fluoroelastomer
. RING, retaining
23d
24
101021
249323
18a* 103337
. O-RING; fluoroelastomer
. SPRING, compression
1
1
1
VALVE, exhaust; includes 24a
. O-RING; fluorocarbon
VALVE, adjustment, fluid
ROD, packing; includes 26a-26h
. O-RING; fluoroelastomer
. SEAL
18b
19
197624
244555
24a* 112085
TURBINE, alternator; includes
19a-19e
25
26
244593
244521
19a* 110073
. O-RING; fluoroelastomer
1
1
19b
223688
. BEARING KIT; includes front
and rear bearings and fan
26a** 111316
26b** 116905
26c** 178409
26d** 178763
19c
19d
19e
20
244577
111745
198821
244556
. COIL
1
1
2
1
. SPREADER, packing; uhmwpe
. PACKING, rod; acetal
. NUT, packing
. RING, retaining
. PAD, pressure
26e
26f
197641
185495
VALVE, adjustment, fan; includes
20a-20d
. HOUSING, packing
. SPACER, packing; acetal
. ROD, packing
26g** 186069
20a
101021
. RING, retaining
1
1
1
26h
27
244696
245790
20b* 106560
. O-RING; fluorocarbon
. HOUSING, fan valve
RING, retaining; includes 27a
20c
197566
54
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Parts
Ref.
No.
Ref.
No.
Part No. Description
Qty
Part No. Description
Qty
27a* 198307
. PACKING, u-cup
HOOK
1
1
1
1
1
101
102
103
245252
246431
HOSE, shielded waterborne fluid;
1
1
28
29
30
276695
276867
276698
HOSE, unshielded waterborne
fluid; includes 102-108
NEEDLE, electrode; black
TRIGGER
198663
190863
. FERRULE (shielded hose
245252)
FERRULE (unshielded hose
246431)
1
1
35*** 245496
SWIVEL, air; 1/4 npsm(m);
left-hand threads
185547
15B932
. HOUSING, ferrule (shielded
hose 245252)
HOUSING, ferrule (unshielded
hose 246431)
1
1
36
37
38
39
40
107460
276741
185103
110231
116553
WRENCH, ball end; 4 mm
MULTI-TOOL
1
1
1
1
1
TUBE, exhaust
CLAMP
104
105
106
107
108
197954
185548
198643
102982
198640
. BRACKET, fluid fitting
. NUT
1
1
1
1
1
GREASE, dielectric, tube (not
shown)
. FITTING, barrel
. O-RING
41
42
43
244915
179791
180060
COVER, gun; box of 10 (not
shown)
1
1
1
. FITTING, seal
TAG, warning (not shown);
replacement available at no cost
* Included in Air Seal Repair Kit 244781.
** Included in Fluid Seal Repair Kit 244911.
*** Included in Swivel Repair Kit 244834.
SIGN, warning (not shown);
replacement available at no cost
47
48
55
197967
198058
197624
PLUG
1
1
1
SCREW, cap, socket hd
SPRING, grounding
Replacement Warning labels, signs, tags, and cards are
available at no cost.
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Parts
Part No. 244582 60 kV Electrostatic Gun, Series B (items 4-59)
Part No. 245305 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-59, 101-108)
valve (20), ES ON/OFF valve (22), and packing rod (26).
53 (Ref)
51 (Ref)
100%
0
KV
μα
19a*
59
HI
19
LO
ES
22
ES
20
I
O
18
28
51 54
21
53
25
52
18b
19e
ti1253a
15
11
*18a
7b
17
7a
*10
25 (Ref)
27
7
16
9
21a*
23c*
11
27a*
*6
47
23d
55
8
23b
23a
24
*24a
30
4
35***
105
36
104
26
38
108
103
102
107
29
106
101
TI1687A
39
37
56
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Parts
Ref. No. 19: Alternator
Ref. No. 20: Fan Adjustment Valve
20d
19a*
19b
TI1487A
20b*
20c
19b
TI1481a
20a
19e
19d
19c
Ref. No. 22: ES ON/OFF Valve
Ref. No. 26: Packing Rod
ti1601a
22f
26h
22d
26e
22e
22g
26b**
26g**
26c**
26d**
22b*
22c
22a*
26f
48
26a**
TI1488A
309293J
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Parts
Part No. 244582 60 kV Electrostatic Gun, Series B (items 4-59)
Part No. 245305 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-59, 101-108)
Ref.
Part No. Description
No.
Qty
Ref.
No.
Part No. Description
Qty
20b* 106560
. O-RING; fluorocarbon
. HOUSING, fan valve
. STEM, fan valve
1
1
1
1
1
1
20c
20d
21
197566
197567
244557
4
185111
188749
SPRING, compression
1
1
6*
PACKING, u-cup, air valve;
uhmwpe
VALVE, air; includes item 21a
. SEAL, fluoroelastomer
7
197266
NOZZLE; 1.5 mm orifice; includes
7a and 7b
1
21a* 276733
22 244558
VALVE, electrostatics, ON/OFF;
includes 22a-22g
7a
7b
8
111261
111507
197369
197477
197517
197518
. O-RING, conductive
. O-RING; fluoroelastomer
SCREW, trigger
1
1
2
1
1
3
22a* 111516
22b* 113137
. O-RING; CV75
. O-RING; fluoroelastomer
. SHAFT, valve
. PLATE, retaining
. WASHER
1
1
1
1
1
1
1
1
9
AIR CAP
22c
22d
22e
22f
22g
23
198403
198404
198453
198464
276753
244559
10*
11
GASKET, barrel
SCREW; socket-hd; 10-24 x 3/4
in. (19 mm)
. PIN
15
16
17
18
185116
244394
245293
244542
SPRING, compression
BARREL, gun
1
1
1
1
. KNOB
VALVE, air, atomizing; includes
23a-23d
HANDLE, gun; includes item 28
POWER SUPPLY, 60 kV; includes
18a-18d
23a
23b
197594
197591
. HOUSING, valve
1
1
2
1
1
1
1
1
1
1
1
1
1
. SHAFT
18a* 103337
. O-RING; fluoroelastomer
. SPRING, compression
1
1
1
23c* 168518
. O-RING; fluoroelastomer
. RING, retaining
18b
19
197624
244555
23d
24
101021
249323
TURBINE, alternator; includes
19a-19e
VALVE, exhaust; includes 24a
. O-RING; fluorocarbon
VALVE, adjustment, fluid
ROD, packing; includes 26a-26h
. O-RING; fluoroelastomer
. SEAL
19a* 110073
. O-RING; fluoroelastomer
1
1
24a* 112085
19b
223688
. BEARING KIT; includes front
and rear bearings and fan
25
26
244593
244521
19c
19d
19e
20
244577
111745
198821
244556
. COIL
1
1
2
1
26a** 111316
26b** 116905
26c** 178409
26d** 178763
. RING, retaining
. PAD, pressure
. SPREADER, packing; uhmwpe
. PACKING, rod; acetal
. NUT, packing
VALVE, adjustment, fan; includes
20a-20d
26e
197641
20a
101021
. RING, retaining
1
58
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Parts
Ref.
No.
Ref.
No.
Part No. Description
185495 . HOUSING, packing
Qty
Part No. Description
Qty
26f
1
1
1
1
53
276734
197910
197624
245265
245252
PLUG, LO voltage adjustment
1
1
1
1
1
26g** 186069
. SPACER, packing; acetal
. ROD, packing
54
SCREW, pivot
26h
27
244696
245790
55
SPRING, grounding
CIRCUIT, flexible
RING, retaining, air cap; includes
item 27a
59
101
HOSE, shielded waterborne fluid;
27a* 198307
. PACKING, u-cup
HOOK
1
1
1
1
1
246431
HOSE, unshielded waterborne
fluid; includes 102-108
1
28
29
30
276695
276867
276698
NEEDLE, electrode; black
TRIGGER
102
103
198663
190863
. FERRULE (shielded hose
245252)
FERRULE (unshielded hose
246431)
1
1
35*** 245496
SWIVEL, air; 1/4 npsm(m);
left-hand threads
185547
15B932
. HOUSING, ferrule (shielded
hose 245252)
HOUSING, ferrule (unshielded
hose 246431)
1
1
36
37
38
39
40
107460
276741
185103
110231
116553
WRENCH, ball end; 4 mm
MULTI-TOOL
1
1
1
1
1
TUBE, exhaust
CLAMP
104
105
106
107
108
197954
185548
198643
102982
198640
. BRACKET, fluid fitting
. NUT
1
1
1
1
1
GREASE, dielectric, tube (not
shown)
. FITTING, barrel
. O-RING
41
42
43
244915
179791
180060
COVER, gun; box of 10 (not
shown)
1
1
1
. FITTING, seal
TAG, warning (not shown);
replacement available at no cost
* Included in Air Seal Repair Kit 244781.
** Included in Fluid Seal Repair Kit 244911.
*** Included in Swivel Repair Kit 244834.
SIGN, warning (not shown);
replacement available at no cost
47
48
51
52
197967
198058
244627
111450
PLUG
1
1
1
1
Replacement Warning labels, signs, tags, and cards are
available at no cost.
SCREW, cap, socket hd
SWITCH, ES HI/LO
O-RING
Part No. 245897 Isolation Enclosure, Series A, with air
and shielded wb fluid hoses, standard Xs3 gun (items
201-301)
309293J
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Parts
Part No. 245897 Isolation Enclosure, Series A,
with air and wb fluid hose, 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, for shielded hoses without hoses and gun (items 201-286)
Part No. 246511 Isolation Enclosure, Series A, for unshielded hoses without hoses and gun (items 201-286)
282
280
252
239
271
253
276
283
270
216
283
214
215
279
301
258
260
228
249
241
300
253
268
281
217
268
262
262
257
204
259
206
261
224
256
218
274
257
256
229
247
226
227
242
205
235
220
278
279
222
221
203
267
207
262
225 223
240
201
201a
268
243
275
263
213
210
265
285
266
231
209
240
244
268
253
232
Ref. only;
not included
211
212
230
219
208
236
202
245
246
237
TI2138a
60
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Parts
Part No. 245897 Isolation Enclosure, Series A,
with air and wb fluid hose, 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, for shielded hoses without hoses and gun (items 201-286)
Ref.
No.
Part No. Description
Qty
Ref.
No.
Part No. Description
CABINET, enclosure; includes
Qty
224
225
226
227
228
229
230
231
154636
185548
190410
116988
15A518
104267
WASHER, plain; 0.625 in. ID
2
1
1
1
1
1
1
1
201
1
NUT
201a
RESISTOR, bleed
CYLINDER ROD
201a 15A947
DOOR, cabinet
CASTER, brake
PLATE
1
4
1
1
1
1
1
202
203
204
205
206
207
208
116993
15A660
15A551
15A545
15A524
113061
HOUSING, cylinder rod
REGULATOR, air
BUSHING; plastic; 3/4 x 1/2 npt
T-HANDLE, latch
STEM, handle, door
HOUSING, latch
SWITCH, push, air
114456
116315
ELBOW, tube; 3/8 npt x 3/8 in. (10
mm) OD tube
232
ELBOW, tube; 3/8 npt x 1/2 in. (13
mm) OD tube
1
TUBE; 1/2 in. (13 mm) OD; poly-
ethylene
A/R
235
236
15A682
116316
LABEL, warning
1
1
209
210
233501
PUMP, diaphragm; sst; see man-
ual 309303
1
FITTING, tube; 1/2 npt x 1/2 in.
(13 mm) OD tube
SCREW, hex hd cap; 5/16-18 x
5.5 in. (140 mm)
2
237
238
239
240
241
242
243
244
218798
114958
222011
234018
110209
114051
210084
STRAINER, 16 mesh; sst
STRAP, tie
1
3
211
212
213
214
215
216
217
218
219
220
221
WASHER, plain; 0.344 in. ID
NUT, lock; 5/16-18
COVER, pail
2
2
1
1
1
1
1
1
1
1
1
GROUND WIRE, 25 ft (7.6 m)
STRIP, grounding; aluminum
NUT, regulator
1
1
241005
104029
116989
111804
113060
116473
233824
162453
185547
1
LUG, ground
WASHER, shim, latch
ROD, ground
1
VALVE, air
1
REGULATOR, air
SCREW, hex hd; 1/4-20 x 5/8 in.
(16 mm)
16
GAUGE, air; 1/8 npt
VALVE, ball; 1/4 npt(fbe)
CART, enclosure
245
246
247
248
249
251
WASHER, plain; 1/4 in. (6 mm)
NUT, hex; 1/4-20
16
16
1
NIPPLE; 1/4 npt x 1/4 npsm
FERRULE, housing (233825)
107257
160430
SCREW, thread forming
TUBE; 1/4 in (6 mm) OD; nylon
GAUGE, air
A/R
1
15B932
198663
FERRULE, housing (246511)
FERRULE (233825)
1
1
222
223
WIRE, 10 gauge; green with yel-
low stripe
A/R
190863
101390
FERRULE (246511)
1
1
252
CONNECTOR, swivel tee; 1/8 npt
x 5/32 in. (4 mm) OD tube
1
WASHER, lock, internal tooth
309293J
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Parts
Ref.
No.
Ref.
No.
Part No. Description
Qty
Part No. Description
Qty
253
256
NUT, hex; 10-32
1
2
276
278
15A780
117314
PLUG, hex hd
1
1
162449
NIPPLE, reducing; 1/2 npt x 1/4
npt
BULKHEAD CONNECTOR; 1/4
npt
257
258
259
260
261
262
101874
116990
113983
237933
113336
TERMINAL, ring
BOX, control
5
1
1
1
1
4
279
113319
CONNECTOR, tube; 1/4 npt x 3/8
in. (10 mm) OD tube
2
280
281
ELBOW, tube
1
1
RING, retaining; 1/2 in. (13 mm)
METER, 0-90 kV
ADAPTER, 1/4 npt
FITTING, tube; 1/8 npt x 5/32 in.
(4 mm) tube
282
283
SWIVEL, tube; 1/4 npt x 1/4 in. (6
mm) OD tube
4
2
1
SCREW, pan hd; 10-32 x 5/8 in.
(16 mm)
SWIVEL, tube; 1/8 npt x 5/32 in. (4
mm) OD tube
263
SCREW, pan hd; 10-32 x 1/4 in. (6
mm)
1
285
286
300
112791
235070
CLAMP
264
265
HOLDER, tie
3
2
TUBE; 3/8 in. (10 mm) OD
A/R
1
SCREW, button hd; 10-24 x 1.5 in.
(38 mm)
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
266
SCREW, button hd; 10-32 x 1.0 in.
(25 mm)
2
267
268
270
271
NUT, hex; M5 x 0.8
WASHER, lock; no. 10
TEE, run, manifold
2
9
1
1
301
301
245301
245305
1
1
GUN, air spray, standard, elec-
trostatic, for waterborne coat-
Model 245897
116991
203953
SCREW, hex hd cap with patch;
10-24 x 3/8 in. (10 mm)
GUN, air spray, smart, electro-
static, for waterborne coat-
Model 245898
272
273
WIRE, 14 gauge; red
A/R
A/R
WIRE, ground, 14 gauge; green
with yellow stripe
Replacement Warning labels, signs, tags, and cards are
available at no cost.
274
275
155541
114261
UNION, swivel; 1/4 npt
TERMINAL, ring; no. 10
1
1
62
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Parts
Tubing and Wiring Chart
Ref. Length
No. in. (mm)
251 8 (204)
Code
Description
points for the tubing and wiring listed below.
C2
green/yellow 14 gauge wire from
internal box ground lug to cylinder
cap
C3
C4
273 34 (864) green/yellow 10 gauge wire from
external ground lug to cart
239 n/a
green/yellow 25 ft ground wire with
clamp, from external ground lug to
true earth ground
Ref. Length
No. in. (mm)
248 20 (508) 1/4 OD tube, regulator to pump
248 9 (229)
Code
Description
A1
A2
C5
243 n/a
226 n/a
green/yellow 10 gauge wire from
external ground lug to ground probe
red wire from bleed resistor to pump
1/4 OD tube, regulator (216) to mani-
fold
C6
C7
B2
249 17 (432) 5/32 OD tube, manifold air to door
interlock switch
249 20 (508) 5/32 OD tube, valve tee to cylinder
272 16 (407) red 14 gauge wire from pump to pail
cover with clamp
272 12 (305) red 14 gauge wire from pump (209)
to ground on cylinder bracket
B3
B4
C8
C9
E1
249 5 (127)
5/32 OD tube, regulator (216) to
gauge (2170
251 n/a
green/yellow 10 gauge wire from
meter + to internal box ground lug
3/8 OD tube, bulkhead to manifold
B5
C1
249 22 (559) 5/32 OD tube, valve tee to door inter-
lock switch
272 9 (229)
286 4 (102)
red 14 gauge wire from top of bleed
resistor to meter
309293J
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Accessories
Accessories
Air Hose Adapter Nipple
Air Line Accessories
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
Non-Swivel Air Inlet Fitting
185105
Replaces standard swivel. Left-hand thread.
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.
Extended Air Inlet Fitting
235068
235069
235070
235071
235072
235073
235074
6 ft (1.8 m)
189191
Replaces standard swivel to provide
extended handle grip area. Left-hand
thread.
15 ft (4.6 m)
25 ft (7.6 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
Fluid Line Accessories
245252 Shielded Waterborne Fluid Hose
Bleed-Type Master Air Valve
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
300 psi (21 bar, 2.1 MPa) Maximum Working Pressure
FM Approved; PTFE; 1/4 in. (6 mm) ID x 25 ft (7.6 m)
For FM approved systems
Relieves air trapped in the air line between this valve
and the fluid supply unit when closed.
107141
3/4 npt
Fluid Shutoff/Drain Valve
Air Line Shutoff Valve
500 psi (35 bar, 3.5 MPa) Maximum Working Pressure
150 psi (10 bar, 1.0 MPa) Maximum Working Pressure
For turning fluid on or off to the gun and for relieving fluid
line pressure at the fluid supply unit.
For turning air to gun on or off.
208630
1/2 npt(m) x 3/8 npt(f); carbon steel and
PTFE; for non-corrosive fluids
224754
1/4 npsm(m) x 1/4 npsm(f) left-hand thread.
Air Line Quick Disconnect
246431 Unshielded Waterborne Fluid Hose
112534
Swiveling quick disconnect replaces stan-
dard air inlet swivel.
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)
For compliance with EN 50059.
309293J
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Accessories
Cleaning Brush
Gun Accessories
105749
For cleaning air cap and fluid nozzle.
Gun Repair Kits
244781
244911
Air Seal Repair Kit
Fluid Seal Repair Kit
Miscellaneous Accessories
Ground Wire and Clamp
Round Pattern Kits
222011
For grounding fluid supply unit and other
components and equipment in the spray
area.
Consists of fluid tip, diffuser and air cap.
245217
245219
4-6 in. (102-152 mm) diameter
8-10 in. (203-254 mm) diameter
12 gauge, 25 ft (7.6 m).
Megohmmeter
241079 500 Volt output; 0.01-2000 megohms.
Not for use in hazardous areas.
Push/Pull Fan Air Valve
244912
For quick change of fan size.
Handle Grips
Safety Warning Sign
186118 English Warning Sign. FM Approved. Avail-
able at no charge from Graco.
245263
245264
Medium Grip
Large Grip
Gun Valve Lubricant
111265 4 oz (113 g) tube of sanitary (non-silicone)
lubricant for fluid seals and wear areas.
Electrostatic Conductive Gloves (box of 12)
117823
117824
117825
Small
Medium
Large
Alternator Bearing Kit
223688
To repair the turbine alternator.
66
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Accessories
Part No. 245895 Agitator Accessory Kit (items 401-407)
402
407
Ref.
No.
Part No. Description
Qty
401
401
402
112698
ELBOW, swivel, male; 1/8 npt(m) x
1/4 in. (6 mm) OD tube
1
1
406
403
114158
FITTING, adapter, Y; 1/4 in. (6
mm) OD tube; mxfxf
403
404
405
406
407
193315
193316
197298
224571
COLLAR, mounting, agitator
NUT, collar, agitator
1
1
1
1
1
COVER, pail; 5 gal. (19 liter)
AGITATOR; see manual 306565
408
404
purchase TUBE; nylon; 1/4 in. (6 mm) OD;
locally
4 ft (1.22 m)
408
110272
SCREW, set, socket-hd; 1/4-20 x
1/4 in. (6 mm)
1
406 (Ref)
TI2137A
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Accessories
Part No. 245944 Fluid Regulator Accessory Kit (items 501-507)
Ref.
No.
Part No. Description
Qty
501
504
506
501
110078
FITTING, tube, fluid; 1/4 npt(m) x
1
3/8 in. (10 mm) OD tube
NIPPLE, reducer; 3/8 npt x 1/4 npt
PLUG; 1/4 npt
507
502
503
504
113070
113576
236281
1
1
1
502
REGULATOR, fluid; see manual
308325
505
505
506
507
C20350
114158
1
1
1
ELBOW, 90°; 1/4 npt(f) x 1/4 in. (6
mm) OD tube
503
FITTING, adapter, Y; 1/4 in. (6
mm) OD tube; mxfxf
purchase TUBE; nylon; 1/4 in. (6 mm) OD;
locally 4 ft (1.22 m)
TI2149A
68
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Technical Data
Technical Data
Category
Data
Maximum Working Fluid Pressure
Maximum Working Air Pressure
Minimum Air Pressure at Gun Inlet
Maximum Fluid Operating Temperature
Short Circuit Current Output
Voltage Output Energy
100 psi (0.7 MPa, 7 bar)
100 psi (0.7 MPa, 7 bar)
40 psi (0.28 MPa, 2.8 bar)
120°F (48°C)
125 microamperes
.35 J with fluid hose 246431 installed
244581, 245301: 60 kV
244582, 245305: 30-60 kV
Sound Power (measured per ISO Standard 9216)
Sound Pressure (measured 1 m from gun)
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)
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
Gun Fluid Inlet Fitting
Gun Weight
1/4 npsm(m)
custom inlet for Graco waterborne fluid hose
27.8 oz (788 g)
Gun Length
11.1 in. (28.2 cm)
1/4 npt
3/8 in. OD tube fitting
125 lb (56.3 kg)
44 in. (1118 mm)
24 in. (610 mm)
Isolation Enclosure Air Inlet Fitting
Isolation Enclosure Fluid Inlet Fitting
Isolation Enclosure Weight
Isolation Enclosure Height
Isolation Enclosure Width
Isolation Enclosure Depth
Wetted Parts
29 in. (737 mm)
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
Loctite® is a registered trademark of the Loctite Corporation.
309293J
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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 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 Information
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1-800-328-0211 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.
This manual contains English. MM 309293
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
309293 02/2002 Rev. 9/2007
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