Instructions/Parts List ELECTROSTATIC, WATERBORNE, AIR SPRAY WB100 Isolation System and PRO Xs3 Spray Gun 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:...
Waterborne Isolation Enclosure without hoses and gun. Standard Electrostatic Air Spray Gun, for waterborne coatings Part No. 244581 Gun, with 25 ft (7.6 m) waterborne fluid hose Smart Electrostatic Air Spray Gun, for waterborne coatings, Part No. 244582 Gun, with 25 ft (7.6 m) waterborne fluid hose Shielded Waterborne Fluid Hose Assembly 25 ft (7.6 m)
Symbols Symbols Warning Symbol WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. 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.
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. •...
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. •...
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.
Introduction Gun Overview The electrostatic gun includes the following controls (see F . 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.
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.
Installation TI1896C Fig. 2. Typical Installation: PRO Xs Waterborne System Main Air Supply Line Main Air Supply Shutoff Valve (bleed-type) Pump Air Pressure Gauge Pump Air Pressure Regulator kV Meter Pump Pump Suction Hose Paint Container Bleed Resistor Enclosure Safety Interlock Isolated Enclosure Gun Air Line Filter Gun Air Pressure Regulator...
Ventilate the Spray Booth 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. Check and follow all National, State, and Local codes regarding air exhaust velocity requirements.
Installation 1. Remove the gun air inlet fitting (35). See F 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.
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.
Installation c. Connect the end of the tube (T) to the pump fluid outlet fitting (Z). 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...
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.
Installation Select a Fluid Nozzle and Air 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. The gun is supplied with Part No. 197266 Nozzle and 24A276 Air Cap.
Grounding 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.
Installation 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.
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.
Operation Fluid Voltage Discharge and Grounding Procedure 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.
Fill the Fluid Supply 1. Discharge the system voltage (page 20). 2. Relieve the pressure (page 20). 3. Open the isolated enclosure door. 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.
Operation WARNING Pressurized Equipment Hazard To reduce the risk of an injury, follow the Pressure Relief Procedure on page 20 whenever you are instructed to relieve the pressure. 1. Make sure the ES ON/OFF valve is OFF. 2. Turn on the main air supply valve (B). 3.
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.
Operation 13. Check that the ES indicator or display is lit, or check that the kV indicator on the isolated enclosure reads 45-55 kV. If not, see Electrical Troubleshooting on page 39 for possible problems. ti1266a 14. Check the kV meter on the isolated enclosure; 45-55 kV is normal.
Shutdown 1. Discharge the system voltage (page 20). 2. Flush the spray gun. See page 26. WARNING Pressurized Equipment Hazard To reduce the risk of an injury, follow the Pressure Relief Procedure on whenever you are instructed to relieve the pressure. 3.
Maintenance Maintenance Flush the Spray Gun Flush the gun before changing colors, at the end of the day, before storing, and before repairing the gun. 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.
Daily Care and Cleaning • Clean the outside of the gun daily with a soft cloth dampened with a non-flammable solvent, as defined on page 26. • Check for fluid leaks. Tighten all fittings. • Clean the air cap and fluid nozzle daily, minimum. See page 29.
Maintenance • 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.
Clean the Air Cap and Fluid Nozzle Equipment Needed • soft bristle brush • non-flammable solvent Procedure 1. Turn the ES ON/OFF valve OFF. Wait 30 seconds. 2. Discharge the system voltage (page 20). 3. Relieve the pressure (page 20). 4.
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. Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V.
Test Power Supply Resistance 1. Prepare the gun for service as instructed on page 2. Remove the power supply (18), page 46. 3. Remove the turbine alternator (19) from the power supply, page 47. 4. Measure resistance from the power supply's ground strips (EE) to the spring (18b).
Electrical Tests Test Electrode Resistance 1. Prepare the gun for service as instructed on page 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.
Test Ground Strip Resistance See F . 22.. Using an ohmmeter, measure the resis- 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.
Troubleshooting Troubleshooting WARNING 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.
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.
Troubleshooting 9. Flush the fluid hose and gun with enough air to dry out the fluid passages. 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. 11.
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 Fluttering or spitting spray. Improper spray pattern. Streaks. 309293K Cause No fluid.
Troubleshooting Gun Operation Troubleshooting Problem Excessive spray fog. “Orange Peel” finish. Fluid leaks from the fluid packing area Air leaks from the front of the gun Fluid leakage from the front of the Gun does not spray Dirty air cap Cause Atomizing air pressure too high.
Electrical Troubleshooting Problem Voltage still present at gun after fol- lowing the Fluid Voltage Discharge and Grounding Procedure Poor wrap. 309293K Cause ES ON/OFF valve is not turned OFF. Turn OFF. Did not wait long enough for voltage to discharge. Air pocket in fluid line leaves fluid near gun isolated.
Troubleshooting Problem ES indicator or voltage/current dis- play is not lit. Voltage/current display stays red (smart guns only). Operator gets mild shock. Operator gets shock from workpiece. Workpiece not grounded. * ES indicator light is off when the gun is triggered. Cause ES ON/OFF valve OFF (0).* No power.
Repair Prepare the Gun for Service WARNING Fire, Explosion, and Electric Shock Hazard To reduce the risk of a fire, explosion, or electric shock: • Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 and be sure the ES ON/OFF valve is OFF before flushing, checking, or servicing the system and whenever you are instructed to discharge the voltage.
Repair Air Cap/Nozzle Replacement CAUTION 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. 1.
Electrode Replacement 1. Prepare the gun for service, page 41. 2. Remove the air cap and nozzle, page 42. 3. Unscrew the electrode (29) with the multi-tool (37). Hold the packing rod end (26h) to prevent it from turning, F .
Repair Fluid Packing Removal 1. Prepare the gun for service, page 41. 2. Remove the air cap and fluid nozzle, page 42. 3. Remove the electrode, page 43. 4. Loosen the trigger screws (8) and trigger (30). See . 26.. 5.
Packing Rod Repair You may replace the packing rod as individual parts or as an assembly. The assembly is pre-adjusted at the factory. 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.
Repair Barrel Removal 1. Prepare the gun for service, page 41. 2. Remove the air inlet fitting (35) and take the bracket (104) off the gun handle (17). 3. Loosen the three screws (11). CAUTION To avoid damaging the power supply (18), pull the gun barrel straight away from the gun handle.
Power Supply Removal and Replacement • Inspect the gun handle power supply cavity for dirt or moisture. Clean with a clean, dry rag. • Do not expose gasket (10) to solvents. 1. Prepare gun for service, page 41. 2. Remove the barrel (16), page 46. CAUTION Be careful when handling the power supply (18) to avoid damaging it.
Repair Turbine Alternator Removal and Replacement Replace turbine alternator bearings after 2000 hours of operation. Order Part No. 223688 Bearing Kit. 1. Prepare gun for service, page 41. 2. Remove the power supply/alternator assembly, page 47. 3. Disconnect the alternator from the power supply, page 47.
Fan Air Adjustment Valve Repair 1. Prepare the gun for service, page 41. 2. Place a wrench on the flats of the valve assembly (20) and unscrew it from the handle (17). You may replace the valve as an assembly (go to step 9) or as individual parts (steps 3-9).
Repair Fluid Adjustment Valve Repair 1. Prepare the gun for service, page 41. 2. Remove the fluid adjustment valve (25). It can only be replaced as a complete assembly. See F 3. Screw the valve (25) into the gun handle. Torque to 15-25 in-lb (1.7-2.8 N•m).
Atomizing Air Restrictor Valve Removal and Replacement 1. Prepare the gun for service, page 41. 2. Remove the atomizing air restrictor valve (23). Inspect the o-ring (23c*). Replace if necessary. See . 34.. 3. Install a new atomizing air restrictor valve (23), or disassemble and replace parts individually.
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) ti1266a *18a 25 (Ref) 27a* See page 53 for detail views of the alternator (19), fan adjustment valve (20), ES ON/OFF valve (22), and packing rod (26).
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 185111 SPRING, compression 188749 PACKING, u-cup, air valve;...
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) 53 (Ref) 51 (Ref) ti1253a *18a 25 (Ref) 27a* See page 57 for detail views of the alternator (19), fan adjustment valve (20), ES ON/OFF valve (22), and packing rod (26).
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 185111 SPRING, compression 188749 PACKING, u-cup, air valve; uhmwpe 197266 NOZZLE;...
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.
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.
Parts Ref. Part No. Description NUT, hex; 10-32 162449 NIPPLE, reducing; 1/2 npt x 1/4 101874 TERMINAL, ring 116990 BOX, control 113983 RING, retaining; 1/2 in. (13 mm) 237933 METER, 0-90 kV 113336 ADAPTER, 1/4 npt SCREW, pan hd; 10-32 x 5/8 in. (16 mm) SCREW, pan hd;...
Tubing and Wiring Chart Use the diagrams on page 64 to find the connection points for the tubing and wiring listed below. Ref. Length Code Description in. (mm) 20 (508) 1/4 OD tube, regulator to pump 9 (229) 1/4 OD tube, regulator (216) to mani- fold 17 (432) 5/32 OD tube, manifold air to door interlock switch...
Accessories Air Line Accessories Grounded Air Hose (Red Cover) 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure 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. 235068 6 ft (1.8 m) 235069 15 ft (4.6 m) 235070...
Accessories Gun Accessories Gun Repair Kits 244781 Air Seal Repair Kit 244911 Fluid Seal Repair Kit Round Pattern Kits Consists of fluid tip, diffuser and air cap. 245217 4-6 in. (102-152 mm) diameter 245219 8-10 in. (203-254 mm) diameter Push/Pull Fan Air Valve 244912 For quick change of fan size.
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.