Graco 3A2496D User manual

Brand: Graco

Model: 3A2496D

Category: Power fine-spray systems

Type: User manual

This manual is also suitable for

3A2496D, WB100 Isolation System and Pro Xp 60 WB Gun

Instructions-Parts

WB100 WB100

WB100

Isolation Isolation

Isolation

System System

System

and and

and

Pro Pro

Pro

Xp™ Xp™

Xp™

60 60

WB WB

Gun Gun

Gun

3A2496D

Air Air

Air

spray spray

spray

system system

system

for for

for

use use

use

when when

when

electrostatically electrostatically

electrostatically

spraying spraying

spraying

conductive, conductive,

conductive,

waterborne waterborne

waterborne

uids uids

uids

that that

that

meet meet

meet

at at

least least

least

one one

one

of of

the the

the

conditions conditions

conditions

for for

for

non non

non

- -

ammability ammability

ammability

listed listed

listed

on on

page page

page

3. 3.

For For

For

professional professional

professional

use use

use

only. only.

only.

Important Important

Important

Safety Safety

Safety

Instructions Instructions

Instructions

Readallwarningsandinstructionsinthismanual.

Save Save

Save

these these

these

instructions. instructions.

instructions.

100 psi (0.7 MPa, 7.0 bar) Maximum

Fluid Working Pressure

100 psi (0.7 MPa, 7.0 bar) Maximum Air

Working Pressure

See See

See

pages pages

pages

3 3

and and

and

4 4

for for

for

model model

model

part part

part

numbers numbers

numbers

and and

and

approval approval

approval

information. information.

information.

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents

Contents

Models...............................................................3

ModelswithFMApprovalOnly......................3

ModelswhichareFMApprovedand

CompliantwithEN50059.................4

Warnings...........................................................5

GunOverview....................................................8

HowtheElectrostaticSprayGun

Works............................................8

SprayingWaterborneFluids

Electrostatically..............................8

Controls,Indicators,andComponents...........8

SmartGuns.................................................10

Installation..........................................................16

SystemRequirements..................................16

WarningSign...............................................16

InstalltheSystem.........................................16

VentilatetheSprayBooth.............................16

AirSupplyLine............................................17

GroundtheCabinet......................................17

ConnecttheWaterborneFluidHose..............18

AgitatorKitAccessory..................................24

FluidRegulatorKitAccessory.......................25

GunSetup..........................................................26

SelectaFluidNozzleandAirCap.................26

Grounding...................................................26

CheckGunElectricalGrounding...................28

FlushBeforeUsingEquipment......................29

Operation...........................................................30

OperatingChecklist......................................30

FluidVoltageDischargeandGrounding

Procedure......................................30

PressureReliefProcedure............................31

FilltheFluidSupply......................................31

AdjusttheSprayPattern...............................32

Shutdown....................................................35

Maintenance......................................................36

Flushing......................................................36

CleantheGunDaily.....................................37

DailySystemCare.......................................38

ElectricalTests...................................................39

TestGunResistance....................................39

TestPowerSupplyResistance.....................40

TestElectrodeResistance............................41

TestGroundStripResistance.......................42

TestCylinderResistance..............................42

Troubleshooting..................................................43

VoltageLossTroubleshooting.......................43

SprayPatternTroubleshooting......................46

GunOperationTroubleshooting....................47

ElectricalTroubleshooting............................48

Repair................................................................50

PreparetheGunforService.........................50

AirCapandNozzleReplacement..................51

AirCap,SprayTip,andNozzle

Replacement(Model

L60M19)........................................52

ElectrodeReplacement................................54

NeedleReplacement(ModelL60M19)...........55

FluidPackingRodRemoval..........................56

PackingRodRepair.....................................57

BarrelRemoval............................................58

BarrelInstallation.........................................58

PowerSupplyRemovaland

Replacement..................................59

AlternatorRemovalandReplacement...........60

FanAirAdjustmentValveRepair..................62

AtomizingAirRestrictorValveRepair............63

ESOn-OffandFluidAdjustmentValve

Repair............................................64

AirValveRepair...........................................65

SmartModuleReplacement..........................66

AirSwivelandExhaustValve

Replacement..................................67

Parts..................................................................68

StandardWaterborneAirSprayGun

Assembly.......................................68

SmartWaterborneAirSprayGun

Assembly.......................................70

MoldReleaseSmartAirSprayGun

Assembly.......................................72

IsolationEnclosure.......................................74

TubingandWiring.......................................77

PackingRodAssembly.................................79

AlternatorAssembly.....................................80

ESOn-OffandFluidAdjustmentValve...........81

FanAirAdjustmentValveAssembly..............82

AtomizingAirRestrictorValve

Assembly.......................................82

AirCapAssembly........................................83

SmartModuleAssembly...............................84

AirCapsandFluidNozzles.................................85

SprayTipSelectionChart(ModelL60M19MRG

GunOnly).............................................90

RepairKits,RelatedManuals,and

Accessories..........................................92

Dimensions........................................................96

TechnicalData...................................................97

GracoProXpWarranty.......................................98

3A2496D

Models

Models Models

Models

Models Models

Models

with with

with

FM FM

Approval Approval

Approval

Only Only

Only

FM FM

approved approved

approved

for for

for

use use

use

with with

with

uids uids

uids

that that

that

meet meet

meet

the the

the

following following

following

condition: condition:

condition:

• •

•

Material Material

Material

does does

does

not not

not

sustain sustain

sustain

burning burning

burning

in in

accordance accordance

accordance

with with

with

the the

the

Standard Standard

Standard

Test Test

Test

Method Method

Method

for for

for

Sustained Sustained

Sustained

Burning Burning

Burning

of of

Liquid Liquid

Liquid

Mixtures, Mixtures,

Mixtures,

ASTM ASTM

ASTM

D4206. D4206.

D4206.

Part Part

Part

No. No.

No.

Model Model

Model

Description Description

Description

24N580WB100WaterborneIsolationEnclosure233825withstandardelectrostatic

airspraygunL60T17,groundedairhose235070,andshielded

waterborneuidhose24M732.

24P629WB100WaterborneIsolationEnclosure233825withsmartelectrostatic

airspraygunL60M17,groundedairhose235070,andshielded

waterborneuidhose24M732.

233825WB100

WaterborneIsolationEnclosureforshieldedhoses.Doesnot

includehosesandgun.

L60T17ProXp60WB

StandardElectrostaticAirSprayGun,forwaterbornecoatings.

L60M17ProXp60WB

SmartElectrostaticAirSprayGun,forwaterbornecoatings.

24M732

-——

ShieldedWaterborneFluidHoseAssembly,25ft(7.6m).

3A2496D 3

Models

Models Models

Models

which which

which

are are

are

FM FM

Approved Approved

Approved

and and

and

Compliant Compliant

Compliant

with with

with

EN50059 EN50059

EN50059

FM FM

approved approved

approved

for for

for

use use

use

with with

with

uids uids

uids

that that

that

meet meet

meet

the the

the

following following

following

condition: condition:

condition:

• •

•

Material Material

Material

does does

does

not not

not

sustain sustain

sustain

burning burning

burning

in in

accordance accordance

accordance

with with

with

the the

the

Standard Standard

Standard

Test Test

Test

Method Method

Method

for for

for

Sustained Sustained

Sustained

Burning Burning

Burning

of of

Liquid Liquid

Liquid

Mixtures, Mixtures,

Mixtures,

ASTM ASTM

ASTM

D4206. D4206.

D4206.

0.35 0.35

0.35

J, J,

with with

with

24M733 24M733

24M733

Hose Hose

Hose

FM12ATEX0080 FM12ATEX0080

FM12ATEX0080

EN EN

50059 50059

50059

Ta Ta

0°C 0°C

0°C

– –

–

50°C 50°C

50°C

Models Models

Models

Compliant Compliant

Compliant

with with

with

EN EN

50059 50059

50059

when when

when

used used

used

with with

with

uids uids

uids

that that

that

meet meet

meet

the the

the

following following

following

criteria: criteria:

criteria:

• •

•

Materials Materials

Materials

which which

which

cannot cannot

cannot

be be

ignited, ignited,

ignited,

in in

any any

any

mixture mixture

mixture

with with

with

air, air,

air,

by by

an an

energy energy

energy

source source

source

of of

less less

less

than than

than

500 500

500

mJ. mJ.

mJ.

Part Part

Part

No. No.

No.

Model Model

Model

Description Description

Description

24P630WB100WaterborneIsolationEnclosure246511withstandard

electrostaticairspraygunL60T18,groundedairhose235070,

andunshieldedwaterborneuidhose24M733.

24P631WB100WaterborneIsolationEnclosure246511withsmartelectrostatic

airspraygunL60M18,groundedairhose235070,and

unshieldedwaterborneuidhose24M733.

24P734WB100

WaterborneIsolationEnclosure246511withMRGsmart

electrostaticairspraygunL60M19,groundedairhose235070,

andunshieldedwaterborneuidhose24M733.

246511WB100

WaterborneIsolationEnclosureforunshieldedhoses.Doesnot

includehosesandgun.

L60T18ProXp60WB

StandardElectrostaticAirSprayGun,forwaterbornecoatings.

L60M18ProXp60WB

SmartElectrostaticAirSprayGun,forwaterbornecoatings.

L60M19ProXp60WB

MRG

SmartElectrostaticAirSprayGun,formoldrelease

applications.

24M733

-——

UnshieldedWaterborneFluidHoseAssembly,25ft(7.6m).

3A2496D

Warnings

Warnings Warnings

Warnings

Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The

exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-specic

risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese

Warnings.Product-specichazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout

thebodyofthismanualwhereapplicable.

WARNING WARNING

WARNING

ELECTRIC ELECTRIC

ELECTRIC

SHOCK SHOCK

SHOCK

HAZARD HAZARD

HAZARD

Impropergrounding,setup,orusageofanisolatedwaterbornesystemcanresultinelectric

shock.Tohelppreventelectricshock:

•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorclose

tosprayarea.SeeGrounding Grounding

Grounding

instructions.

•Connecttheelectrostaticguntoavoltageisolationsystemthatwilldischargethesystem

voltagewhennotinuse.

•Allcomponentsoftheisolationsystemthatarechargedtohighvoltagemustbecontained

withinanisolationenclosurethatpreventspersonnelfrommakingcontactwiththehigh

voltagecomponentsbeforethesystemvoltageisdischarged.

•FollowtheFluid Fluid

Fluid

Voltage Voltage

Voltage

Discharge Discharge

Discharge

and and

and

Grounding Grounding

Grounding

Procedure Procedure

Procedure

wheninstructedtodischarge

thevoltage;beforecleaning,ushing,orservicingthesystem;beforeapproachingthefrontof

thegun;andbeforeopeningtheisolationenclosurefortheisolateduidsupply.

•Donotenterahighvoltageorhazardousareauntilallhighvoltageequipmenthasbeen

discharged.

•Donottouchthegunnozzleorelectrode,orcomewithin4in.(102mm)oftheelectrode

duringgunoperation.FollowtheFluid Fluid

Fluid

Voltage Voltage

Voltage

Discharge Discharge

Discharge

and and

and

Grounding Grounding

Grounding

Procedure Procedure

Procedure

•Interlockthegunairsupplywiththevoltageisolationsystemtoshutofftheairsupplyanytime

theisolationsystemenclosureisopened.

•Onlyusethered-coloredGracoelectricallyconductivegunairhosewiththisgun.Donot

useblackorgray-coloredGracoairhoses.

•Donotsplicehosestogether.InstallonlyonecontinuousGracowaterborneuidhose

betweentheisolateduidsupplyandthespraygun.

3A2496D 5

Warnings

WARNING WARNING

WARNING

FIRE FIRE

FIRE

AND AND

AND

EXPLOSION EXPLOSION

EXPLOSION

HAZARD HAZARD

HAZARD

Combustibledustinwork work

work

area area

area

canigniteorexplode.Tohelppreventreandexplosion:

•Fluidsusedmustmeetthefollowingammabilityrequirements:

•FM, FM,

FM,

FMc FMc

FMc

Approved: Approved:

Approved:

MaterialdoesnotsustainburninginaccordancewiththeStandardTestMethodfor

SustainedBurningofLiquidMixtures,ASTMD4206.

•CE CE

- -

EN EN

50059 50059

50059

Compliant: Compliant:

Compliant:

Materialswhichcannotbeignited,inanymixturewithair,byanenergysourceof

lessthan500mJ.

•Stop Stop

Stop

operation operation

operation

immediately immediately

immediately

ifstaticsparkingoccursoryoufeelashock.Donotuse

equipmentuntilyouidentifyandcorrecttheproblem.

•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.

•Useandcleanequipmentonlyinwellventilatedarea.

•Interlockthegunairsupplytopreventoperationunlessventilatingfansareon.

•Onlyusenon-ammablesolventswhenushingorcleaningequipment.

•Alwaysturntheelectrostaticsoffwhenushing,cleaningorservicingequipment.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and

plasticdropcloths(potentialstaticarc).

•Donotplugorunplugpowercordsorturnlightsonoroffwhenammablefumesarepresent.

•Keepsprayareafreeofdebris,includingsolvent,ragsandgasoline.

•Keepaworkingreextinguisherintheworkarea.

PRESSURIZED PRESSURIZED

PRESSURIZED

EQUIPMENT EQUIPMENT

EQUIPMENT

HAZARD HAZARD

HAZARD

Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin

andcauseseriousinjury.

•FollowthePressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

whenyoustopspraying/dispensingandbefore

cleaning,checking,orservicingequipment.

•Tightenalluidconnectionsbeforeoperatingtheequipment.

•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

PLASTIC PLASTIC

PLASTIC

PARTS PARTS

PARTS

CLEANING CLEANING

CLEANING

SOLVENT SOLVENT

SOLVENT

HAZARD HAZARD

HAZARD

Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious

injuryorpropertydamage.

•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing

parts.

•SeeTechnical Technical

Technical

Data Data

Data

inthisandallotherequipmentinstructionmanuals.Readuidand

solventmanufacturer’sMSDSsandrecommendations.

TOXIC TOXIC

TOXIC

FLUID FLUID

FLUID

OR OR

FUMES FUMES

FUMES

Toxicuidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,

inhaled,orswallowed.

•ReadMSDSstoknowthespecichazardsoftheuidsyouareusing.

•Storehazardousuidinapprovedcontainers,anddisposeofitaccordingtoapplicable

guidelines.

6 3A2496D

Warnings

WARNING WARNING

WARNING

PERSONAL PERSONAL

PERSONAL

PROTECTIVE PROTECTIVE

PROTECTIVE

EQUIPMENT EQUIPMENT

EQUIPMENT

Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,

includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective

equipmentincludesbutisnotlimitedto:

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbytheuidandsolvent

manufacturer.

EQUIPMENT EQUIPMENT

EQUIPMENT

MISUSE MISUSE

MISUSE

HAZARD HAZARD

HAZARD

Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorundertheinuenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated

systemcomponent.SeeTechnical Technical

Technical

Data Data

Data

inallequipmentmanuals.

•Useuidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical

Technical

Data Data

Data

inallequipmentmanuals.Readuidandsolventmanufacturer’swarnings.Forcomplete

informationaboutyourmaterial,requestMSDSfromdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

whenequipmentisnotinuse.

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine

manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodicationsmayvoidagencyapprovals

andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtrafcareas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

3A2496D

GunOverview

Gun Gun

Gun

Overview Overview

Overview

How How

How

the the

the

Electrostatic Electrostatic

Electrostatic

Spray Spray

Spray

Gun Gun

Gun

Works Works

Works

Theairhosesuppliesairtothespraygun.Partof

theairoperatesthealternatorturbineandtherest

oftheairatomizestheuidbeingsprayed.The

alternatorgeneratespower,whichisconvertedby

thepowercartridgetosupplyhighvoltagetothe

gun’selectrode.

Thepumpsuppliesuidtotheuidhoseandgun,

wheretheuidiselectrostaticallychargedasit

passestheelectrode.Thechargeduidisattracted

tothegroundedworkpiece,wrappingaroundand

evenlycoatingallsurfaces.

Spraying Spraying

Spraying

Waterborne Waterborne

Waterborne

Fluids Fluids

Fluids

Electrostatically Electrostatically

Electrostatically

Thiselectrostaticairspraygunisdesignedtospray

only only

only

waterborneuidswhichmeetthefollowing

ammabilityrequirements:

•FM, FM,

FM,

FMc FMc

FMc

Approved: Approved:

Approved:

Materialdoesnotsustainburninginaccordance

withtheStandardTestMethodforSustained

BurningofLiquidMixtures,ASTMD4206.

•CE-EN CE-EN

CE-EN

50059 50059

50059

Compliant: Compliant:

Compliant:

Materialswhichcannotbeignited,inanymixture

withair,byanenergysourceoflessthan500mJ.

Whenconnectedtoavoltageisolationsystem,

alloftheuidinthespraygun,uidhose,and

isolateduidsupplyischargedtohighvoltage,

whichmeansthatthesystemhasmoreelectrical

energythanasolvent-basedsystem.Therefore,

onlynon-ammableuids(asdenedunder

Models,page3)canbesprayedwiththesystemor

beusedtoclean,ush,orpurgethesystem.

Precautionsmustbetakenwhenusingelectrostatic

waterborneequipmenttoavoidpotentialshock

hazards.Whenthespraygunchargestheisolated

uidtohighvoltage,itissimilartocharginga

capacitororabattery.Thesystemwillstoresomeof

theenergywhilesprayingandretainsomeofthat

energyafterthespraygunisshutoff.Donottouch

thegunnozzleorcomewithin4in.(102mm)of

theelectrodeuntilthestoredenergyisdischarged.

Theamountoftimeittakestodischargethe

energydependsonthesystemdesign.Followthe

FluidVoltageDischargeandGroundingProcedure,

page30,beforeapproachingthefrontofthegun.

NOTE: NOTE:

NOTE:

TheGracowarrantyandapprovalsare

voidiftheelectrostaticspraygunisconnectedtoa

non-Gracovoltageisolationsystemorifthegunis

operatedabove60kV.

Controls, Controls,

Controls,

Indicators, Indicators,

Indicators,

and and

and

Components Components

Components

Theelectrostaticgunincludesthefollowing

controls,indicators,andcomponents(seeFig.

1).ForinformationonSmartguns,alsosee

SmartGuns,page10.

8 3A2496D

GunOverview

Figure1GunOverview

Item Item

Item

Description Description

Description

Purpose Purpose

Purpose

AirSwivelInlet1/4npsm(m)

left-handthread,for

Gracored-colored

groundedairsupply

hose.

BFluidInlet

Gracowaterborne

uidsupplyhose

TurbineAirExhaust

Barbedtting,for

suppliedexhaust

tube.

AirCapandNozzleSee

AirCapsandFluid

Nozzles,page85,

foravailablesizes.

EElectrodeNeedle

Supplies

electrostaticcharge

totheuid.

FFanAirAdjustment

Valve

Adjustsfansizeand

shape.Canbeused

todecreasepattern

width.

Item Item

Item

Description Description

Description

Purpose Purpose

Purpose

AtomizingAir

RestrictorValve

Restrictsaircapair

ow.Replacewith

plug(included)if

desired.

HFluidAdjustment

Knob

Adjustsuidowby

limitinguidneedle

travel.Useonlyin

lowowconditions,

toreducewear.

ESOn-OffValve

Turnselectrostatics

ON(I)orOFF(O).

ESIndicator(stan-

dardgunonly;for

Smartgunindica-

tor,seeOperating

Mode,page10)

LitwhenESis

ON(I).Color

indicatesalternator

frequency.Seethe

LEDindicatortable

onpage36.

3A2496D 9

GunOverview

Smart Smart

Smart

Guns Guns

Guns

TheSmartGunmoduledisplayssprayingvoltage,

current,alternatorspeed,andthevoltagesetting(low

orhigh).Italsoallowstheusertochangetoalower

sprayingvoltage.Themodulehastwomodes:

•OperatingMode

•DiagnosticMode

Operating Operating

Operating

Mode Mode

Mode

Bar Bar

Bar

Graph Graph

Graph

SeeFig.2,andTable1onpage12.TheOperating

Modedisplaysgundataduringnormalspraying.The

displayusesabargraphtoshowthevoltagelevelin

kiloVolts(kV)andthecurrentlevelinmicroAmperes

(uA).Thebargraphrangeisfrom0to100%foreach

value.

IfthebargraphLEDsareblue,thegunisreadyto

spray.IftheLEDsareyelloworred,thecurrentis

toohigh.Theuidmaybetooconductive,orsee

ElectricalTroubleshooting,page48forotherpossible

causes.

Hz Hz

Indicator Indicator

Indicator

TheHzindicatorfunctionsthesameastheES

indicatoronstandardguns.Theindicatorlightsto

showthealternatorspeedstatus,andhasthree

colors:

•Greenindicatesthealternatorspeediscorrect.

•Iftheindicatorchangestoamberafter1second,

increasetheairpressure.

•Iftheindicatorchangestoredafter1second,

reducetheairpressure.

Voltage Voltage

Voltage

Adjustment Adjustment

Adjustment

Switch Switch

Switch

Thevoltageadjustmentswitch(VA)allowsthe

operatortochangefromlowtohighvoltage.

•Thehighvoltagesettingisdeterminedbythe

maximumvoltageofthegunandisnotadjustable.

•Thelowvoltageindicator(LO)lights

whentheswitchissettoLO.Thelow

voltagesettingisuseradjustable.See

AdjustingtheLowVoltageSetting,page11.

NOTE: NOTE:

NOTE:

IftheErrordisplayappears,theSmartmodule

haslostcommunicationwiththepowersupply.See

ErrorDisplay,page11forfurtherinformation.

Figure2SmartGunModuleinOperatingMode

10 3A2496D

GunOverview

Error Error

Error

Display Display

Display

IftheSmartmodulelosescommunicationwith

thepowersupply,theErrordisplayappears,the

Hzindicatorturnsred,andtheSmartmoduleis

disabled.SeeFig.3,andTable1onpage12.

ThiscanoccurinOperatingModeorDiagnostic

Mode.SeeElectricalTroubleshooting,page48.

CommunicationmustberestoredtomaketheSmart

modulefunctional.

NOTE: NOTE:

NOTE:

Ittakes8secondsfortheErrordisplayto

appear.Ifthegunhasbeendisassembled,wait8

secondsbeforesprayingtoensurethatanError

conditionhasnotoccurred.

NOTE: NOTE:

NOTE:

Ifthereisnopowertothegun,theError

displaywillnotappear.

Figure3ErrorDisplay

Adjusting Adjusting

Adjusting

the the

the

Low Low

Low

Voltage Voltage

Voltage

Setting Setting

Setting

Thelowvoltagesettingisuseradjustable.Toaccess

thelowvoltagesettingscreenwheninOperating

Mode,presstheLOSETbutton(LS)momentarily.

Thescreenwilldisplaythecurrentlowvoltage

setting.SeeFig.4,andTable1onpage12.The

rangeis30–60kV.

SettheVoltageAdjustmentswitch(VA)toLO.Press

theLOSETbuttonrepeatedlytoincreasethesetting

inincrementsof5.Whenthedisplayreachesthe

maximumsetting(60kV)itwillreturntotheminimum

setting(30kV).Continuepressingthebuttonuntil

youreachthedesiredsetting.

NOTE: NOTE:

NOTE:

After2secondsofinactivitythedisplaywill

returntotheOperatingScreen.

NOTE: NOTE:

NOTE:

Thelowvoltagesettingmaybelocked.See

LockSymbol,page11.

Figure4LowVoltageSettingScreen(Unlocked)

Lock Lock

Lock

Symbol Symbol

Symbol

Thelowvoltagesettingmaybelocked.Whenlocked,

animage(LK)appearsonthescreen.SeeFig.5,

andTable1onpage12.

•WheninHImode,thelowvoltagesettingisalways always

always

locked.ThelocksymbolwillappearwhentheLO

SETbuttonispressed.

•WheninLOmode,thelocksymbolwill

only only

only

appearifthelockisenabled.See

LowVoltageLockScreen,page15,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

3A2496D

GunOverview

Table Table

Table

1 1

. .

Key Key

Key

for for

for

Figs. Figs.

Figs.

2–9. 2–9.

2–9.

Item Item

Item

Description Description

Description

Purpose Purpose

Purpose

VoltageAdjustmentSwitch

Two-positionswitchsetssmart

gunvoltagetolowsetting(LO)or

highsetting(HI).Thisswitchis

functionalinOperatingModeand

inDiagnosticMode.

LowVoltageModeIndicator

Lights(blue)whenthesmartgun

issettoLowVoltage.

Voltage(kV)Display

Displaysactualsprayingvoltage

ofthegun,inkV.InOperating

Mode,displayisabargraph.

InDiagnosticMode,voltageis

displayedasanumber.

Current(uA)Display

Displaysactualsprayingcurrent

ofthegun,inuA.InOperating

Mode,displayisabargraph.

InDiagnosticMode,currentis

displayedasanumber.

LSLOSETbutton

Pressmomentarilytoenterthe

LowVoltageSettingscreen.

Pressandholdforapproximately5

secondstoenterorexitDiagnostic

Mode.

WhileinDiagnosticMode,press

momentarilytoadvancethrough

screens.

WhileontheLowVoltageLock

Screen(inDiagnosticMode),

pressandholdtoturnthelockon

oroff.

LVLowVoltageDisplayDisplaysthelowvoltagesetting

asanumber.Thesettingcanbe

changed.SeeFig.4.

LKLowVoltageLocked

Appearsifthelowvoltagesetting

islocked.SeeFig.5andFig.9.

LODisplay

AppearsontheLowVoltageLock

Screen.SeeFig.9.

ERErrorDisplay

AppearsiftheSmartmoduleloses

communicationwiththepower

supply.SeeFig.3.

VIVoltageIndicatorInDiagnosticMode,thetwotop

rightLEDsofthescreenlight,

indicatingthatthevaluedisplayed

isinkV.SeeFig.6.

3A2496D

GunOverview

Item Item

Item

Description Description

Description

Purpose Purpose

Purpose

CICurrentIndicator

InDiagnosticMode,thetwo

bottomrightLEDsofthescreen

light,indicatingthatthevalue

displayedisinuA.SeeFig.7.

ASAlternatorSpeedDisplay

InDiagnosticMode,Hzlevelis

displayedasanumber.SeeFig.

AlternatorSpeedIndicatorInOperatingMode,indicatorcolor

variestoshowthealternator

speedstatus:

•greenindicatesthealternator

speedisatthecorrectlevel.

•Iftheindicatorchangestoamber

after1second,thealternator

speedistoolow.

•Iftheindicatorchangestored

after1second,thealternator

speedistoohigh.Theindicator

willalsoturnrediftheError

displayappears.

InDiagnosticMode,theindicator

isgreenwhenintheAlternator

Speed(Hertz)screen.

3A2496D 13

GunOverview

Diagnostic Diagnostic

Diagnostic

Mode Mode

Mode

DiagnosticModeincludesfourscreenswhichdisplay

gundata:

•Voltage(kiloVolts)Screen

•Current(microAmperes)Screen

•AlternatorSpeed(Hertz)Screen

•LowVoltageLockScreen

NOTE: NOTE:

NOTE:

YoumustbeinOperatingModetoadjustthe

lowvoltagesetting;thesettingisnotadjustablein

DiagnosticMode.However,thevoltageadjustment

switch(VA)canbesettoHIorLOinOperatingMode

andDiagnosticMode.

ToenterDiagnosticMode,pressandholdtheLOSET

(LS)buttonforapproximately5seconds.Thedisplay

willgototheVoltage(kiloVolts)Screen,page14.

Toadvancetothenextscreen,presstheLOSET

buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET

buttonforapproximately5seconds.Thescreenwill

returntoOperatingMode.

NOTE: NOTE:

NOTE:

IfthegunisdetriggeredwhileinDiagnostic

Mode,thelastscreenviewedwillbedisplayedwhen

thegunisretriggered.

NOTE: NOTE:

NOTE:

DiagnosticModecannotbeexited

fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page15fordetails.

Voltage Voltage

Voltage

(kiloVolts) (kiloVolts)

(kiloVolts)

Screen Screen

Screen

TheVoltage(kiloVolts)Screenistherstscreento

appearafterenteringDiagnosticMode.SeeFig.6,

andTable1onpage12.Toenterthisscreen,press

andholdtheLOSETbuttonforapproximately5

secondswhileintheOperatingMode.

Thisscreendisplaysthesprayingvoltageofthe

gunasanumber(kV),roundedtothenearest5kV.

ThetwotoprightLEDs(VI)ofthedisplaypanel

light,indicatingthattheVoltage(kiloVolts)Screen

isdisplayed.Thedisplayisareadoutandcannot

bechanged.

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page14.Press

andholdforapproximately5secondstoreturnto

OperatingMode.

Figure6Voltage(kiloVolts)Screen

Current Current

Current

(microAmperes) (microAmperes)

(microAmperes)

Screen Screen

Screen

TheCurrent(microAmperes)Screenisthesecond

screenintheDiagnosticMode.SeeFig.7,andTable

1onpage12.Toenterthisscreen,presstheLO

SETbuttonwhileintheVoltage(kiloVolts)Screen.

Thisscreendisplaysthesprayingcurrentofthegun

asanumber(uA),roundedtothenearest5uA.The

twobottomrightLEDs(CI)ofthedisplaypanellight,

indicatingthattheCurrent(microAmperes)Screen

isdisplayed.Thedisplayisareadoutandcannot

bechanged.

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page15.Press

andholdforapproximately5secondstoreturnto

OperatingMode.

Figure7Current(microAmperes)Screen

3A2496D

GunOverview

Alternator Alternator

Alternator

Speed Speed

Speed

(Hertz) (Hertz)

(Hertz)

Screen Screen

Screen

TheAlternatorSpeed(Hertz)Screenisthethird

screenintheDiagnosticMode.SeeFig.8,andTable

1onpage12.Toenterthisscreen,presstheLOSET

buttonwhileintheCurrent(microAmperes)Screen.

Thisscreendisplaysthealternatorspeedasa3

digitnumber(AS),roundedtothenearest5Hz.The

displayisareadoutandcannotbechanged.Ifthe

alternatorspeedisgreaterthan999Hz,thedisplay

willshow999.

TheHzindicatorlightsgreentoshowthatyouare

viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page15.Pressandhold

forapproximately5secondstoreturntoOperating

Mode.

Figure8AlternatorSpeed(Hertz)Screen

Low Low

Low

Voltage Voltage

Voltage

Lock Lock

Lock

Screen Screen

Screen

TheLowVoltageLockScreenisthefourthscreenin

theDiagnosticMode.SeeFig.9,andTable1on

page12.Toenterthisscreen,presstheLOSET

buttonwhileintheAlternatorSpeed(Hertz)Screen.

ThisscreendisplaysthestatusoftheLowVoltage

Lock.Ifthesettingislocked,thelockimage(LK)

appearstotheleftoftheLodisplay(LD).Ifthesetting

isunlocked,thelockimagedoesnotappear.

Tochangethelockstatus,pressandholdthe

LOSETbuttonuntilthelockimageappearsor

disappears.Ifthelockisset,theimagewillalso

appearontheLowVoltageSettingScreenwhenin

lowvoltagemode(seeFig.4).

NOTE: NOTE:

NOTE:

DiagnosticModecannotbeexitedfromthis

screen,becausepressingandholdingtheLOSET

buttonisusedtoturnthelockonoroff.Toexit,

pressLOSETmomentarilytoreturntotheVoltage

(kiloVolts)Screen,thenexitDiagnosticModefrom

there.

Figure9LowVoltageLockScreen

3A2496D 15

Installation

Installation Installation

Installation

System System

System

Requirements Requirements

Requirements

AGracovoltageisolationsystemmusthavethe

followingfeatures:

•Anisolationenclosurethatpreventspersonsfrom

makingcontactwiththehighvoltagecomponents

beforethesystemvoltageisdischarged.All

componentsoftheisolationsystemthatare

chargedtohighvoltagemustbecontainedwithin

theenclosure.

•Ableedresistortodrainoffthesystemvoltage

whenthespraygunisnotinuse.Ametalpartof

theuidsupplyunitmustbeelectricallyconnected

tothebleedresistor.

•Asafetyinterlockthatautomaticallydischargesthe

systemvoltagewhenanyoneopenstheisolation

enclosure.

NOTICE NOTICE

NOTICE

Thesystemshouldnothaveanyseverearcing

occurringwhentheisolationmechanismopens

andcloses.Severearcingwillshortenthelifeof

thesystemcomponents.

NOTE: NOTE:

NOTE:

TheGracowarrantyandapprovalsare

voidiftheelectrostaticspraygunisconnectedtoa

non-Gracovoltageisolationsystemorifthegunis

operatedabove60kV.

Warning Warning

Warning

Sign Sign

Sign

Mountwarningsignsinthesprayareawherethey

caneasilybeseenandreadbyalloperators.An

EnglishWarningSignisprovidedwiththegun.

Install Install

Install

the the

the

System System

System

Installingandservicingthisequipmentrequires

accesstopartswhichmaycauseelectricshock

orotherseriousinjuryifworkisnotperformed

properly.

•Donotinstallorservicethisequipmentunless

youaretrainedandqualied.

•Besureyourinstallationcomplieswithlocal,

state,andnationalsafetyandrecodes,NFPA

33,NEC504and516,andOSHAstandard

1910.107.

Fig.19showsatypicalelectrostaticairspraysystem.

Itisnotanactualsystemdesign.Forassistance

indesigningasystemtosuityourparticularneeds,

contactyourGracodistributor.

Ventilate Ventilate

Ventilate

the the

the

Spray Spray

Spray

Booth Booth

Booth

Providefreshairventilationtoreducetheriskofre

orexplosioncausedbythebuildupofammableor

toxicvaporswhenspraying,ushing,orcleaning

thegun.Donotoperatethegununlessventilation

fansareoperating.

Checkandfollowalllocal,state,andnationalcodes

regardingairexhaustvelocityrequirements.

Highvelocityairexhaustwilldecreasetheoperating

efciencyoftheelectrostaticsystem.Theminimum

allowableairexhaustvelocityis60linearft/min(18.3

linearmeters/minute).

16 3A2496D

Installation

Air Air

Air

Supply Supply

Supply

Line Line

Line

1.SeeFig.19.Installanairlinelter/water

separator(M)onthemainairsupplylineto

ensureadry,cleanairsupplytothegun.Dirtand

moisturecanruintheappearanceofyournished

workpieceandcancausetheguntomalfunction.

2.TheWB100systemincludesableed-typeair

regulator(N)onthegunairsupplyline(P),to

controlairpressuretothegun.

Toreducetheriskofelectricshockorother

seriousinjury,youmustusethered-colored

GracoElectricallyConductiveAirHoseforthe

gunairsupply,andyoumustconnectthehose

groundwiretoatrueearthground.Donotuse

theblackorgray-coloredGracoairhoses.

3.Connectthered-coloredGracoElectrically

ConductiveAirHose(P)betweenthegunair

regulator(N)andthegun’sairinlet.Thegunair

inletttinghasaleft-handthread.Connectthe

airsupplyhosegroundwire(Q)toatrueearth

ground.

Trappedaircancausetheuidsupplyunitto

cycleunexpectedly,whichcanresultinserious

injury,includingsplashinguidintheeyesor

ontheskin.Donotoperatetheequipment

withoutthebleed-typeairvalve(B)installed.

4.TheWB100systemincludesableed-typeair

valve(B).Thebleed-typeairvalveisrequired

toshutoffallairtothesystemandrelieveair

trappedbetweenthevalveandtheuidsupply

unitaftertheairregulatorisshutoff.Connectthe

mainairsupplyline(A)tothebleedvalve.

5.Installanadditionalbleed-typeairvalve(CC)

upstreamoftheairlter(M)toisolatethelter

forservicing.

Ground Ground

Ground

the the

the

Cabinet Cabinet

Cabinet

Connectthemaingroundwire(V)toatrueearth

ground.

3A2496D

Installation

Connect Connect

Connect

the the

the

Waterborne Waterborne

Waterborne

Fluid Fluid

Fluid

Hose Hose

Hose

AlwaysuseaGracowaterborneuidhosebetween

thevoltageisolationsystemuidoutletandthegun

uidinlet.Thewaterborneuidhose(101)consists

ofaninnerPTFEtube(T)andanabrasion-resistant

outerjacket(J).Shieldedhose24M732alsohas

aconductivelayer(C),Theconductivelayeris

connectedtogroundatthegunttingbracket(104).

Beforeconnectingthewaterborneuidhosetothe

gun,blowitoutwithairandushwithwaterto

removecontaminants.Flushthegunbeforeusingit.

Toreducetheriskofelectricshock,installonly

onecontinuousGracowaterbornehosebetween

theisolateduidsupplyandthegun.Donotsplice

hosestogether.

1.Removethegunairinlettting(21).

NOTE: NOTE:

NOTE:

Inashieldedhosesystem,ifahose

failureoccurswherehighvoltagearcsthrough

theinnertube,voltagewillbedischargedto

groundthroughtheconductivehoselayer.When

properlyinstalled,theconductivehoselayeris

groundedthroughitsconnectiontothegrounded

enclosure.

Usingunshieldeduidhosesminimizesthe

systemcapacitance,resultinginfasterresponse

timesandalargereductionintheenergystored

inthesystem,ascomparedtoshieldedhoses.

However,withoutthegroundshield,aweak

staticchargecanoccasionallybuilduponthe

outersurfaceofthehose.Tominimizeany

staticchargefeltonthehosesurface,bundle

theairanduidhosetogether,andwrapwitha

protectivecover,asshown.

Figure10ConnecttheFluidHose

Figure11BundlingtheAirandFluidHoses

18 3A2496D

Installation

2.Fortheuidhosetotproperly,itmustbe

strippedandassembledtothedimensionsshown

inFig.12.Applydielectricgreasetotheinner

tube(T)ofthehose.Slidethetting(F)onto

thetube(T).Pressthebarbedtting(G)intothe

tubeuntilitsshoulderbottomsonthetube.A

newGracowaterborneuidhosecomesfully

assembledtothesedimensions.

NOTICE NOTICE

NOTICE

Becarefulnottocutintotheinnertube(T)of

thehosewhenstrippingthehose.Nicksor

cutsinthePTFEtubewillcausepremature

hosefailure.

Figure12ShieldedHose24M732Dimensions

atGun

Figure13UnshieldedHose24M733Dimensions

atGun

3.Generouslyapplydielectricgrease(44)tothe

o-ring(107)andthethreadsofthetting(106).

Pullthettingback1-1/2in.(38mm)andapply

greasetotheexposedPTFEhosetollthearea

betweenthehoseandthetting.Makesurethe

barrelinletiscleananddry,thenscrewthetting

intotheuidinletofthegunbarrel(1).

4.Loosenthestrainreliefnut(102)sothebracket

canmovefreelyonthehose.

5.Alignthebracket(104)holeswiththeairinletand

exhaustoutlet.Securewiththeairinlettting

(21).Tightenthestrainreliefnut(102)tosecure

thehose.

6.Checkthatthenut(105)istightenedsecurelyto

theferrulehousing(103).

7.Presstheexhausttube(36)ontotheexhaust

valvebarb(C).Securewiththeclamp(43).

3A2496D 19

Installation

8.Connecttheotherendofthehosetotheisolated

uidsupplyasfollows:

Graco WB100 Enclosure:

Slidehosethrough

thestrainrelieftting(W).Ensureconductive

layer(C)haspassedthroughtting.Tighten

to55in-lb(6.2N•m).Pullbackonhose

tocheckitissecure.Complywiththe

requirementsintheWarning Warning

Warning

below.

For For

For

Shielded Shielded

Shielded

Hose Hose

Hose

Systems: Systems:

Systems:

Conductivehoselayer(C)mustbe

groundedthroughitsconnectiontothe

isolationsystem’sgroundedenclosure(L)

orgroundedfence.Tomaintaingrounding

continuity,theconductivehoselayer(C)

mustbeengagedintheferrulewhenthe

strainreliefnutistightened.Failureto

properlyinstallthehoseinthestrainrelief

couldresultinanelectricshock.

Figure14ShieldedHose24M732

DimensionsatWB100Enclosure

Figure15ShieldedHose24M732

ConnectionatWB100Enclosure

Figure16UnshieldedHose24M733

DimensionsatWB100Enclosure

Figure17UnshieldedHose24M733

ConnectionatWB100Enclosure

20 3A2496D

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Graco 3A2496D User manual

Brand: Graco

Model: 3A2496D

Category: Power fine-spray systems

Type: User manual

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