Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
TI1681A
WB 100
Isolation Enclosure
PRO Xs3
Smart Gun and
Fluid Hose
TI2139a
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
• Materials which cannot be ignited, in any mixture
with air, by an energy source of less than 500 mJ.
See page 3 for a List of Models
U.S. Patent No. 7,226,004
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
309293J
Instructions/Parts List
ELECTROSTATIC, WATERBORNE, AIR SPRAY
WB100 Isolation System and
PRO
™
Xs3 Spray Gun
2 309293J
Table of Contents
List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 4
Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
How the Electrostatic Air Spray Gun Works . . . . 7
Spraying Waterborne Fluids Electrostatically . . . 7
Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Requirements . . . . . . . . . . . . . . . . . . . . . 9
Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install the System . . . . . . . . . . . . . . . . . . . . . . . . 9
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . 11
Connect the Air Line . . . . . . . . . . . . . . . . . . . . . 11
Ground the Cabinet . . . . . . . . . . . . . . . . . . . . . . 11
Connect the Waterborne Fluid Hose . . . . . . . . . 11
245895 Agitator Kit . . . . . . . . . . . . . . . . . . . . . . 14
245944 Fluid Regulator Kit . . . . . . . . . . . . . . . . 15
Select a Fluid Nozzle and Air Cap . . . . . . . . . . 16
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Check Electrical Grounding . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 19
Fluid Voltage Discharge and
Grounding Procedure . . . . . . . . . . . . . . . . . 20
Pressure Relief Procedure . . . . . . . . . . . . . . . . 20
Fill the Fluid Supply . . . . . . . . . . . . . . . . . . . . . . 21
Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 21
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Low Voltage Adjustment (Smart Guns Only) . . 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . 26
Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 27
Clean the Air Cap and Fluid Nozzle . . . . . . . . . 29
Grease Door Latch Threads . . . . . . . . . . . . . . . 29
Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 30
Test Power Supply Resistance . . . . . . . . . . . . . 31
Test Electrode Resistance . . . . . . . . . . . . . . . . . 32
Test Ground Strip Resistance . . . . . . . . . . . . . . 33
Test Cylinder Resistance . . . . . . . . . . . . . . . . . . 33
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Voltage Loss Troubleshooting . . . . . . . . . . . . . . 34
Spray Pattern Troubleshooting . . . . . . . . . . . . . 37
Gun Operation Troubleshooting . . . . . . . . . . . . . 38
Electrical Troubleshooting . . . . . . . . . . . . . . . . . 39
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Prepare the Gun for Service . . . . . . . . . . . . . . . 41
Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 42
Electrode Replacement . . . . . . . . . . . . . . . . . . . 43
Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 44
Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 45
Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 46
Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 46
Power Supply Removal and Replacement . . . . 47
Turbine Alternator Removal and Replacement . 48
Fan Air Adjustment Valve Repair . . . . . . . . . . . . 49
Fluid Adjustment Valve Repair . . . . . . . . . . . . . 50
Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . 50
Atomizing Air Restrictor Valve Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 51
ES ON/OFF Valve Repair . . . . . . . . . . . . . . . . . 51
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 65
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 65
Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 66
Miscellaneous Accessories . . . . . . . . . . . . . . . . 66
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 70
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 70
List of Models
309293J 3
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 PRO Xs3 Waterborne Isolation Enclosure with smart electrostatic air
spray gun, grounded air hose, and shielded waterborne fluid
hose
233825 Waterborne Isolation Enclosure without hoses and gun.
244581,
Series B
PRO Xs3 Standard Electrostatic Air Spray Gun, for waterborne coatings
245301, PRO Xs3 Part No. 244581 Gun, with 25 ft (7.6 m) waterborne fluid hose
244582,
Series B
PRO Xs3 Smart Electrostatic Air Spray Gun, for waterborne coatings,
245305 PRO Xs3 Part No. 244582 Gun, with 25 ft (7.6 m) waterborne fluid hose
245252 Shielded Waterborne Fluid Hose Assembly 25 ft (7.6 m)
EN 50059 Compliant
244581,
Series B
PRO Xs3 Standard Electrostatic Air Spray Gun, for waterborne coatings.
244582,
Series B
PRO Xs3 Smart Electrostatic Air Spray Gun, for waterborne coatings.
246511 Waterborne Isolation Enclosure, without hoses and gun
246431 PRO Xs3 Unshielded Waterborne fluid hose assembly, 25 ft (7.6 m).
246592 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
Symbols
4 309293J
Symbols
Warning Symbol
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
Caution Symbol
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the instruc-
tions.
WARNING
CAUTION
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,
and all conductive objects in the spray area. See Grounding, page 17.
• 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.
• Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 when instructed
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
Voltage Discharge and Grounding Procedure, page 20.
• 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.
Warning
309293J 5
WARNING
Fire and Explosion Hazard
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition
and result in a fire or explosion.
• Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements in this manual.
• Ground the equipment, all personnel in or close to the spray area, the object being sprayed,
and all other electrically conductive objects in the spray area. See Grounding, page 17.
• Check gun resistance daily. See Test Gun Resistance on page 30.
• If there is any static sparking while using the equipment, stop spraying immediately. Identify
and correct the problem.
• Provide fresh air ventilation to avoid buildup of flammable or toxic vapors. See Ventilate the
Spray Booth on page 11.
• Only use this equipment to spray non-flammable, waterborne fluids, as defined on the front
cover of this manual.
• Only flush, purge, or clean the electrostatic waterborne spray system with non-flammable 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.
Warning
6 309293J
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.
• Follow the Pressure Relief Procedure, page 20, when you stop spraying and before cleaning,
checking, or repairing equipment.
• Check hoses and couplings daily. Replace worn, damaged, or loose parts immediately.
• Tighten all fluid connections before each use.
Introduction
309293J 7
Introduction
How the Electrostatic Air Spray
Gun Works
The air hose supplies air to the spray gun. Part of the air
operates the turbine and the rest of the air atomizes the
fluid being sprayed. The turbine generates power, which
is converted by the power cartridge to supply high volt-
age current to the gun’s electrode.
The fluid source supplies fluid to the hose and gun. The
gun must be connected to a voltage isolation system to
maintain voltage at the gun. In an isolation system, the
entire fluid supply is electrostatically charged. The
charged fluid is attracted to the grounded workpiece,
wrapping around and evenly coating all surfaces.
Spraying Waterborne Fluids
Electrostatically
This electrostatic air spray gun is designed to spray only
waterborne fluids with a flash point above 140°F (60°C)
and a maximum organic solvent concentration of 20%,
by weight, per ASTM Standard D93. Also, the fluid must
not sustain burning when tested per ASTM Standard
D4206 Sustained Burn Test.
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.
Precautions must be taken when using electrostatic
waterborne equipment to avoid potential shock hazards.
When the spray gun charges the isolated fluid to high
voltage, it is similar to charging a capacitor or a battery.
The system will store some of the energy while spraying
and retain some of that energy after the spray gun is
shut off. It is not safe to touch the front end of the gun
until the stored energy is discharged. The amount of
time it takes to discharge the energy depends on the
system design. Follow the Fluid Voltage Discharge
and Grounding Procedure on page 20 before
approaching the front of the gun.
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.
Introduction
8 309293J
Gun Overview
The electrostatic gun includes the following controls
(see F
IG. 1.).
• FLUID adjustment valve. Adjusts fluid rod travel.
Use only in low flow conditions, to reduce wear.
• Fan AIR adjustment valve. Adjusts fan size and
shape.
• Atomizing air RESTRICTOR valve. Restricts
atomizing air flow. Replace with plug (included) if
desired.
• ES ON/OFF valve. Turns electrostatics ON (I) or
OFF (0).
• ES INDICATOR (standard gun only). Green when
ES is ON (I).
• Voltage/current DISPLAY (smart models only).
Shows voltage (V) and current (A). Green=spray,
yellow/red=see Electrical Troubleshooting, page
39.
• ES HI/LO switch (smart models only). Sets volt-
age to HI or LO (factory settings).
• LO VOLTAGE adjustment (smart models only).
Remove plug to adjust to four settings. Page 21.
Fig. 1. Gun Overview
TI1681A
ti1253a
100%
KV
μα
0
HI
LO
ES
I O
I O
ES
ti1266a
I O
ES
FLUID
LO VOLTAGE
ES HI/LO
DISPLAY
ES INDICATOR
ES ON/OFF
RESTRICTOR
AIR
RESTRICTOR
FLUID
ES ON/OFF
AIR
Standard Model Smart Model
TRIGGER
AIR INLET
FLUID TUBE
AIR CAP
ELECTRODE
Installation
309293J 9
Installation
System Requirements
A safe, well designed voltage isolation system should
have the following features:
• 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.
• A bleed resistor to drain off the system voltage when
the spray gun is not in use.
• The system should not have any severe arcing
occurring when the isolation mechanism opens and
closes. Severe arcing will shorten the life of the sys-
tem components.
• The system must include a means for automatically
discharging the system voltage when anyone opens
the isolation enclosure.
Warning Sign
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.
Install the System
FIG. 2. on page 10 shows a PRO Xs electrostatic water-
borne air spray system. For assistance in designing a
system to suit your particular needs, contact your Graco
distributor.
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.
WARNING
Fire, Explosion, and Electric Shock Hazard
Installing and servicing this equipment
requires access to parts which may cause
electric shock or other serious injury if work
is not performed properly.
• Do not install or service this equipment
unless you are trained and qualified.
• 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.
Installation
10 309293J
Fig. 2. Typical Installation: PRO Xs Waterborne System
Key
A
B*
DE
F
H
J
K*
L
M
N
P*
Q*
R
S
T
U
V*
C
G
TI1896C
Gun ES ON/OFF valve: I is ON, 0 is OFF
B*
BB
AA
Y
Z
X
W
TI1775C
A Main Air Supply Line
B* Main Air Supply Shutoff Valve (bleed-type)
C Pump Air Pressure Gauge
D Pump Air Pressure Regulator
EkV Meter
FPump
G Pump Suction Hose
H Paint Container
J Bleed Resistor
K* Enclosure Safety Interlock
L Isolated Enclosure
M Gun Air Line Filter
N Gun Air Pressure Regulator
P* Graco Red Grounded Air Supply Hose
Q* Air Hose Ground Wire
R Graco Waterborne Fluid Hose
S Waterborne Electrostatic Air Spray Gun
T Grounding Rod
U Ground Terminal
V* Main Ground Wire
W Strain Relief/Ground Fitting
X Pump Air Supply Line
Y Grounding Cylinder
Z Pump Fluid Outlet Fitting
AA Isolated Enclosure Door
BB Enclosure T-Handle Locking Screw
* Required for safe operation. Must be purchased separately.
Installation
309293J 11
Ventilate the Spray Booth
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).
Connect the Air Line
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.
2. Install a bleed-type air regulator (N) on the gun air
line (P).
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.
4. Connect the main air supply line (A) to the
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.
Ground the Cabinet
Connect the main ground wire (V) to a true earth
ground.
Connect the Waterborne Fluid
Hose
Always use a Graco waterborne fluid hose between the
voltage isolation system fluid outlet and the gun fluid
inlet. See F
IG. 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).
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.
WARNING
Flammable or Toxic Vapor Hazard
Provide fresh air ventilation to avoid the
buildup of flammable or toxic vapors. Do not
operate the gun unless ventilation fans are
operating.
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.
WARNING
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.
WARNING
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.
Installation
12 309293J
1. Remove the gun air inlet fitting (35). See FIG. 3..
Fig. 3. Connect the Fluid Hose
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.
2. For the fluid hose to fit properly, it must be stripped
and assembled to the dimensions in F
IG. 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.
Fig. 4. Waterborne Hose Dimensions (At Gun)
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 F
IG. 3..
4. Loosen the strain relief nut (102) so the bracket can
move freely on the hose.
5. Align the bracket (104) holes with the air inlet and
exhaust outlet. Secure with the air inlet fitting (35).
Tighten the strain relief nut (102) to secure the hose.
6. Check that the nut (105) is tightened securely to the
ferrule housing (103).
7. Press the exhaust tube (38) onto the barbed
adapter (A). Secure with the clamp (39).
8. Connect the other end of the hose to the isolated
fluid supply as follows:
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.
35
38
39
101
102
103
104
105
107
106
108
16
A
TI2155A
F
T
A
B
A 7.40 in. (188 mm)
B 2.0 in. (50 mm)
C
J
Shielded Hose 245252
T
C
A 1.25 in (32 mm)
J
A
TI2742A
Unshielded
Hose 246431
Installation
309293J 13
a. Graco WB100 Enclosure: Slide hose through
the strain relief fitting (W). Ensure conductive
layer (C) has passed through fitting. Tighten to
55 in-lb (6.2 N•m). Pull back on hose to check it
is secure. Comply with the requirements in
Warning at right. See F
IG. 6. and FIG. 7..
Fig. 6. Waterborne Hose Dimensions (At Graco
WB100 Enclosure)
Fig. 7. Shielded Fluid Hose Connection at Graco
WB100
Fig. 8.
Fig. 9. Unshielded fluid connection
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 F
IG. 10..
Fig. 10. Shielded Fluid Hose Connection at Non-Gra-
co Isolated Enclosure
T
C
A 14.5 in. (368 mm)
B 0.75 in. (19 mm)
J
A
B
TI2166A
Shielded
Hose 245252
TI1897A
T
C
J
W
Z
L
See Warning at right.
T
C
A 12.0 in (305 mm)
J
A
TI2743A
Unshielded
Hose 246431
WARNING
Electric Shock Hazard
For Shielded hose systems:
Conductive hose layer (C) must be
grounded through its connection to the iso-
lation system’s grounded enclosure (L) or
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.
T
C
J
W
Z
L
See Warning below.
TI2744
A
TI1966A
T
J
L
C (see note above)
NOTE: Ground layer (C) of hose must
be grounded at isolation system.
Installation
14 309293J
c. Connect the end of the tube (T) to the pump
fluid outlet fitting (Z).
245895 Agitator Kit
To add an agitator to the Graco isolation system, order
Part No. 245895. See page 67 for the kit parts list.
1. Discharge the system voltage (page 20).
2. Relieve the pressure (page 20).
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-
fold; see the tubing diagram on page 64. Install the
Y fitting (402) into the elbow. Install tubes (A2) and
(407) into the Y fitting. See F
IG. 11.. Route the agita-
tor tube (407) into the cabinet.
6. Replace the back of the control box (258).
7. Assemble the other parts of the kit as shown.
Secure the agitator with the setscrew (408).
8. Return the system to service.
Fig. 11. 245895 Agitator Kit
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.
CAUTION
Factory Mutual approval is valid only when this gun is
used with Factory Mutual approved voltage isolation
systems.
401
406
403
404
406 (Ref)
407
402
TI2137A
Install tube A2 here
Connect to elbow (282)
inside control box (258)
408
Installation
309293J 15
245944 Fluid Regulator Kit
To add a fluid regulator to the Graco isolation system,
order Part No. 245944. See page 68 for the kit parts list.
1. Discharge the system voltage (page 20).
2. Relieve the pressure (page 20).
3. Open the isolated enclosure door.
4. Remove the 1/4 OD tube (A1) from the pump air
inlet; see the tubing diagram on page 64.
5. Remove the waterborne fluid hose from the pump
fluid outlet fitting (231) and remove the fitting.
6. Unscrew the two pump mounting screws (S, F
IG.
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-
fold; see page 64. Install the Y fitting (506) in the
elbow. Install tubes (A2) and (507) into the Y fitting.
Route the tube (507) into the cabinet.
9. Replace the back of the control box (258).
10. Assemble the fluid regulator kit as shown in F
IG. 12..
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.
12. Connect tube (A1) to the air inlet of fluid regulator
(504). Connect tube (507) to the pump air inlet.
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.
Fig. 12. Fluid Regulator Kit
TI2149A
501
502
503
504
505
506
507
Connect
tube A2
here
S
Tube A1
Connect
waterborne
fluid hose here
Connect to
elbow (282)
inside control
box (258)
Installation
16 309293J
Select a Fluid Nozzle and Air
Cap
The gun is supplied with Part No. 197266 Nozzle and
197477 Air Cap. If you require a different size, refer to
Table 1 and Table 2 , and instruction manual 309419, or
consult with your Graco distributor. See Air Cap/Nozzle
Replacement on page 42.
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 20
before removing or installing a fluid nozzle
and/or air cap.
Table 1: Fluid Nozzles
Part No.
Size,
mm (in.)
Part No.
Size,
mm (in.)
197263 0.75 (.030) 197266 1.5 (.055)
197264 1.0 (.042) 197267 1.8 (.070)
197265 1.2 (.047) 197268 2.0 (.080)
Table 2: Air Caps
Part No.
Pattern Shape
and Length
in. (mm)
Recommended Fluids and
Production Rates
197477
Round end;
15-17 (381-432)
Light to medium viscosity.
Medium to high production.
197478
Round end;
15-17 (381-432)
Light to medium viscosity.
Low to medium production.
197479
Tapered end;
13-15 (330-381)
Light to medium viscosity.
Medium to high production.
197480
Round end;
16-18 (406-457)
Medium to high viscosity
and high solids.
Low to medium production.
197481
Tapered end;
17-19 (432-483)
Medium to high viscosity
and high solids.
Medium to high production.
For use with 2.0 mm nozzle.
Installation
309293J 17
Grounding
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,
page 18.
• Graco Waterborne Fluid Hose: the hose is grounded
through the conductive layer. Install the hose as
instructed on page 11.
• All persons entering the spray area: shoes must
have conductive soles, such as leather, or personal
grounding straps must be worn. Do not wear shoes
with non-conductive soles such as rubber or plastic.
If gloves are 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.
• Voltage Isolation System: electrically connect to a
true earth ground, as instructed in the voltage isola-
tion system manual.
• Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Resistance must
not exceed 1 megohm.
• The floor of the spray area: must be electrically con-
ductive and grounded. Do not cover the floor with
cardboard or any non-conductive material which
would interrupt grounding continuity.
• All solvent pails: use only grounded metal pails,
which are conductive. Do not use plastic containers.
Do not place the pail on a non-conductive surface
such as paper or cardboard. Do not store more than
the quantity needed for one shift.
• All electrically conductive objects or devices in the
spray area: including fluid containers, tools, and
wash cans, must be properly grounded.
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.
ti1259a
Installation
18 309293J
Check Electrical Grounding
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.
3. Turn off the air and fluid supply to the gun. The fluid
hose must not have any fluid in it.
4. Make sure the red-colored grounded air hose (R) is
connected and the hose ground wire is connected to
a true earth ground.
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 F
IG. 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.
Fig. 13. Check Gun Grounding
7. Using an ohmmeter (AA), measure the resistance
between the cabinet ground lug (214) and a true
earth ground (CC). See F
IG. 14.. The resistance
must be less than 100 ohms.
Fig. 14. Check Cabinet Grounding
I O
ES
ti1273a
ti1259a
AA
BB
CC
TI2161A
TI2163A
AA
214
CC
Operation
309293J 19
Operation
Operating Checklist
Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.
All operators are properly trained to safely
operate an electrostatic waterborne air spray
system as instructed in this manual.
All operators are trained in the Pressure
Relief Procedure on page 20.
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.
The system is thoroughly grounded and the
operator and all persons entering the spray
area are properly grounded. See Grounding
on page 17.
Fluid Hose is in good condition with no cuts or
abrasions of the PTFE layer. Replace hose if
damaged.
Ventilation fans are operating properly.
Workpiece hangers are clean and grounded.
All debris, including flammable fluids and rags,
is removed from the spray area.
Only fluids with a flash point above 140°F
(60°C) and a maximum organic solvent 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.
Operation
20 309293J
Fluid Voltage Discharge and
Grounding Procedure
1. Turn the ES ON/OFF valve OFF and wait 30 sec-
onds.
2. Remove the door T-handle locking screw. This will
shut off the air to the gun and trigger the grounding
cylinder to discharge any remaining electrical
charge.
3. Use the grounding rod to touch the pump and sup-
ply pail. If you see any arcs, see Electrical Trouble-
shooting on page 39.
Pressure Relief Procedure
1. Turn the ES ON/OFF valve OFF.
2. Follow the Fluid Voltage Discharge and Ground-
ing Procedure at left.
3. Turn off the main air supply valve (B).
4. Trigger the gun into a grounded metal waste con-
tainer to relieve the air and fluid pressure.
5. Relieve fluid pressure in the fluid supply unit as
instructed in your fluid supply unit manual.
WARNING
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,
follow the Fluid Voltage Discharge and Grounding
Procedure:
• whenever you are instructed to discharge the
voltage
• before cleaning, flushing, or servicing the system
equipment
• before approaching the front of the gun
• or before opening the safety enclosure for the
isolated fluid supply.
I O
ES
ti1273a
WARNING
Pressurized Equipment Hazard
The system pressure must be manually
relieved to prevent the system from starting
or spraying accidentally. To reduce the risk
of an injury from electric shock, accidental spray from
the gun, splashing fluid, or moving parts, follow the
Pressure Relief Procedure whenever you:
• are instructed to relieve the pressure
• stop spraying
• check or service any of the system equipment
• or install or clean the fluid nozzle.
I O
ES
ti1273a
ti1289a
ti1276a
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