Graco PRO 3500WB Manual

Electrostatic air spray water-base system

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ELECTROSTATIC AIR SPRAY

WATER-BASE SYSTEM

Model PRO 3500WB

U.S. PA TENT NO. D313,064; 4,978,075

Model WB3500

For use with Electrostatic Air Spray Systems when spraying conductive, water-based fluids having

flash points above 140

COMPONENTS OF THE PRO 3500WB SYSTEM

ISOLATION STAND

Part No. 223–445; 15 gallon (57 liters)

Part No. 727–212; 55 gallon (209 liters)

WB3500 VOLTAGE CONTROL

Part No. 223–477

PRO 3500WB SPRAY GUN WITH AIR & FLUID HOSES

Part No. 223–518; 25 ft (7.6 m) hose length

Part No. 223–519; 36 ft (11.0 m) hose length

Part No. 223–520; 50 ft (15.3 m) hose length

SAFETY FENCE

Part No. 110–614

CONVERSION KIT

Part No. 223–114

GUN HOLSTER

Part No. 236–090

NOTE: See the PARTS DRAWINGS and LISTS for a complete list of part numbers.

Warnings

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Typical Installation

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Introduction

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Installation

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Operation

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Cleaning and Maintenance

Troubleshooting Charts

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Spray Gun Electrical Tests

Spray Gun Service

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Voltage Control Service

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Converting PRO 3500SC Gun to PRO 3500WB Gun

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

Air Spray Gun

Voltage Control

F (60 C) and a maximum 20%, by weight, organic solvent concentration.

CONTENTS

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Spray Gun Service Notes

Spray Gun Parts Drawing

Spray Gun Parts List

Voltage Control Parts Drawing

Voltage Control Parts List

Isolation Stand Parts Drawing and List

Fluid Hose Assembly Parts Drawing and List

Accessories

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Spray Gun Technical Data

Warranty

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307–978

Supersedes J

Includes K

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Rev. L

Back Cover

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Summary of Contents for Graco PRO 3500WB

Page 1 Part No. 727–212; 55 gallon (209 liters) WB3500 VOLTAGE CONTROL Part No. 223–477 PRO 3500WB SPRAY GUN WITH AIR & FLUID HOSES Part No. 223–518; 25 ft (7.6 m) hose length Part No. 223–519; 36 ft (11.0 m) hose length Part No.
Page 2 20%, by weight, organic solvent concentration. When Gun Air Supply Hose: use ONLY Graco Electrically Con- spraying water-base fluid electrostatically, the entire fluid supply ductive Air Supply Hose as specified in this manual; see is isolated from ground to maintain voltage at the tip of the gun.
Page 3 FIRE, EXPLOSION, OR ELECTRIC SHOCK HAZARD Voltage Discharge Procedure Be sure the spray gun ES valve lever is OFF and the equip- ment has been properly grounded before flushing or clean- To reduce the risk of electric shock, which could cause serious ing any part of the spray system.
Page 4 TYPICAL INSTALLATION WARNING *Equipment that must be installed for safe operation of a water -base system SPRAY GUN INTRODUCTION This system is designed to be used ONLY with water- base fluids, with flashpoints above 140 F (60 C) and REF C* less than 20%, by weight, organic solvent concentration.
Page 5 For assistance in read by all operators. Mount warning sign 186–119 designing a system, contact your Graco representative. (included with the voltage control) on the safety fence gate, as designated on the bottom of the sign. Additional warning signs are available at no charge.
Page 6 INSTALLATION Ventilate the Spray Booth WARNING To prevent hazardous concentrations of toxic and/ or flammable vapors, spray only in a properly venti- 6 ft. lated spray booth. Never operate the spray gun (1.83 m) unless ventilation fans are operating. The air supply to the gun must be electrically interlocked with the ventilators to prevent operation of the power supply unless ventilating fans are running.
Page 7 INSTALLATION Install the Voltage Control Install the Strain Relief/Ground Terminal and Fluid Hose Assembly The voltage control (L) contains a bleed resistor, which continually bleeds current to ground, and a quick-dump Two plates (311 & 312) are provided to relieve strain and switch, which dumps the charge to ground whenever the ground the fluid hose conductive hose layer.
Page 8 INSTALLATION Install the Interconnect Cables Install the Grounding Rod 1. Connect the interconnect cable (406) between the Connect the grounding rod to the strain relief/ground ter- terminal block and voltage control. See Fig 6. Fasten minal. See Fig 6. Hook the grounding rod onto the fence the cable in cable clamp to provide strain relief.
Page 9 Use Only Graco Electrically Conductive Air Supply Hose, as specified in the ACCESSORIES section of this manual. This hose, and the gun, have spe- cial threads which prevent using any other type of hose with the gun.
Page 10 INSTALLATION Ohmmeter Check the Electrical Grounding True Earth Ground Grounded WARNING Air Hose Proper electrical grounding of your system is essential. For your safety, read the warning section, FIRE, EXPLOSION, OR ELECTRIC SHOCK HAZARD, on page 2. Ground the system as explained there.
Page 11 NOTES...
Page 12 OPERATION Operating Checklist WARNING To reduce risk of electric shock, which could cause se- Check the following list daily, before starting to operate rious injury, ALWAYS follow the Voltage Discharge the system, to help ensure safe, efficient operation. Procedure , below, when entering the safety fence. 1.
Page 13 OPERATION Safety Fence Grounding Cable C-clamp Fluid Supply Voltage Control Fig 10 Removing Fluid Supply from Isolated Area Placing Fluid Supply in Isolated Area 1. Follow the Voltage Discharge Procedure and 1. Place the fluid supply on the isolation stand. Refer to Pressure Relief Procedure , on page 12.
Page 14 OPERATION ES Indicator Light ES On–Off Lever 1 is ON 0 is OFF Fan Air Optional Air Control Cap Control Valve Valve (See ACCESSORIES) Air Cap Fluid Adjustment Screw Fig 11...
Page 15 OPERATION Filter the Fluid NOTE: If the fluid supply is a pump, the fluid regulator MUST be installed at the pump outlet, not Filter the fluid to remove coarse particles and sediment remote from the pump. which could clog the spray nozzle. 2.
Page 16 CLEANING AND MAINTENANCE Daily Care and Cleaning Cleaning the Voltage Control WARNING Thoroughly clean the outer surfaces of the voltage con- Before checking, adjusting, cleaning, or servicing trol with a soft cloth dampened in a solvent that’s suitable for use in an electrostatic water-base system. any part of the spray system, and whenever entering the safety fence, ALWAYS follow the Pressure Re - lief Procedure and the V oltage Discharge Proce -...
Page 17 CLEANING AND MAINTENANCE Flush the Spray Gun WARNING To reduce the risk of electric shock, which could result in serious injury, the ES On-Off lever must be OFF (0) before flushing. WARNING To reduce the risk of serious injury and property damage, ONLY use solvents with flashpoints over 140 F (60 C) and with less than 20%, by weight, organic solvent content.
Page 18 SPRAY PATTERN TROUBLESHOOTING CHART WARNING Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.
Page 19 GUN OPERATION TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Leakage from fluid Loose packing nut. Tighten. See page 27. packing area. Worn needle packings or shaft. Replace needle packings or shaft. See page 27. Air leakage from front Air valve not seating properly. Clean, service.
Page 20 ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Low or no electrostatic *ES On–Off lever in OFF (0) position. Turn lever to ON (1) . wrap. Improper distance between gun and Adjust spraying distance to workpiece. 8–12 in. (203–305 mm). Parts poorly grounded. Clean hangers, check for proper ground on conveyer or track.
Page 21 ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Arc detected with grounding Voltage control not connected to Connect voltage control to isolation rod. isolation stand. stand terminal as shown on page 8. Fluid supply not electrically con- Connect fluid supply to isolation stand nected to isolation stand terminal.
Page 22 SPRAY GUN ELECTRICAL TESTS The performance of the spray gun is directly affected by the condition of the electrical components contained Megohmmeter inside the gun. The electrical tests below can be used to Metal Contact determine the condition of the power supply (18) and the Air Fitting resistor stud (22) as well as the continuity of the electrical path between the components.
Page 23 DO NOT remove the resistor stud contact ring (D) from the resistor stud or operate the gun without the contact ring in place. DO NOT replace the re- sistor stud with anything but a genuine Graco part.
Page 24 DO NOT replace the resistor stud with anything but a genuine 1. Do not install or service this equipment unless Graco part. you are trained and qualified. 2. Follow the Voltage Discharge Procedure...
Page 25 SPRAY GUN SERVICE Electrode Replacement 1. Remove the air cap, nozzle and resistor stud as Cap/Nozzle/Resistor Stud described Cap Screws Replacement . Wrench 2. Unscrew and remove the fluid needle/electrode (20) with the electrode tool (64) provided. See Fig 19. If the needle shaft turns, hold the needle shaft assem- bly by placing a screw driver blade into the slot on the shaft, near the trigger.
Page 26 SPRAY GUN SERVICE Barrel Installation 1. Be sure the gaskets (34 & 18a) and spring (30) are in 3. Tighten the three socket head cap screws (5) place. See Fig 22. Replace if damaged. oppositely and evenly with the wrench (63) supplied. Tighten the cap screws to 18 in-lbs (2 N m) MAXI- 2.
Page 27 SPRAY GUN SERVICE Fluid Packing Removal 1. Remove the air cap assembly, fluid nozzle and resis- Trigger Screws tor stud, and electrode as described under Elec- Trigger Fluid Packing/Needle Assembly trode Replacement . Driver 2. Loosen the trigger screws (4) far enough to remove the trigger (13).
Page 28 NOTE: The power cartridge consists of the alternator NOTE: Replace turbine bearings after 2,000 hours of (37), power supply (18) and retaining ring (35). operation. See your authorized Graco represen- See Fig 25. tative. 1. Remove the barrel as described in Barrel Removal .
Page 29 SPRAY GUN SERVICE Fan Air Adjustment Valve Repair Air Trigger Valve Repair 1. Place a wrench on the flats of the valve housing and 1. Using a screwdriver, remove the cap (45), o-ring (23) remove it from the handle. See Fig 26. and spring (44).
Page 30 SPRAY GUN SERVICE ES On–Off Valve Repair 7. Install the retaining ring (47) into the groove in the handle. Install the lever (26) and tighten the set 1. Loosen the set screw (24) with the 2 mm hex key (69) screw (24).
Page 31 VOLTAGE CONTROL SERVICE Replacing the Voltage Control Rod Seal 9. Empty the oil from the oil cup (208) into a clean con- tainer. If the oil is clean, it can be reused. If there is a 1. Disconnect the cable (117) connected between the black carbon residue, replace the oil with electrical dump switch and bleed resistor.
Page 32 CONVERTING PRO 3500SC GUN TO PRO 3500WB GUN NOTE: See page 41 to order Conversion Kit 223–114. The fluid hose and air hose are not included with this kit. See pages 40 and 42 to order hoses. Use ONLY the electrically conductive air supply hose specified in this manual. A larger fluid nozzle may be required for some water-base paints.
Page 33 CONVERTING PRO 3500SC GUN TO PRO 3500WB GUN Nozzle/Resistor Stud Assembly Needle/Electrode Trigger Screws Trigger Fluid Hose Assembly (not included with kit) Air Cap Retaining Nut 28* Fluid Needle Assembly 71* Warning Sign (not shown) *Parts included with Conversion Kit 223–1 14.
Page 34 SPRAY GUN SERVICE NOTES Do not overtighten Packing Cartridge into gun barrel Loosen slightly if Packing Rod jams Lubricate O-Rings Resistor Stud Set Packing for Tighten into nozzle 2 lb drag on shaft [10 in-lb (1.12 N m)] Apply low strength (purple) Loctite or equivalent to threads Nozzle Air Cap...
Page 35 NOTES...
Page 36 SPRAY GUN PARTS DRAWING DETAIL A See Detail A 28d* 28g* 28f* Includes 28a–28h 28h* 28e* Includes 37a & 37b **37a 18b** 18a** 34** Includes 18a–18f 23** Includes 43a–43e 43e** 19** 41** 42** Air Seal Repair Kit 223–021 Must be ordered separately. Includes: Fluid Seal Repair Kit 223–020 Ref No.
Page 37 3. Order all parts from your nearest Graco distributor. explosion or property damage. 6 digit...
Page 38 VOLTAGE CONTROL PARTS DRAWING REF 102 REF 220...
Page 39 2. Check the parts list to identify the correct part number; do not use the ref. no. when ordering. 223–141 WATER-BASE SWITCH 3. Order all parts from your nearest Graco distributor. See separate Parts List, at right 6 digit 223–318...
Page 40 2. Check the parts list to identify the correct part number; do not use the ref. no. when ordering. Fluid Hose 3. Order all parts from your nearest Graco distributor. Assy. Part No. Hose Length 6 digit Part 223–192...
Page 41 ISOLATION STAND PARTS DRAWING AND LIST Part No. 223–445 Isolation Stand Assembly 403,407 For 15 gallon (57 liter) fluid container NO. PART NO. DESCRIPTION 185–468 STAND, bare 185–946 GRATE. grounding 110–629 CLAMP, cable 110–757 U-BOLT, clip 223–539 CABLE ASSEMBLY, 36” (914 mm) (from terminal block to fluid supply unit) 223–529...
Page 42 ACCESSORIES Accessories must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. WARNING NEVER operate your equipment at a working pressure rating that is higher than the lowest rated component in your system. Lower rated components may not be able to withstand the pressure developed by the pump and may rupture, causing serious bodily injury or property damage.
Page 43 ACCESSORIES Accessories must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. AIR ADAPTER NIPPLE 185–493 GUN COVER 180–209 For connecting two or more grounded gun air supply Order Part No. 218–374 for package of 10. hoses. 1/4 npt x 1/4 npsm LH ES ON/OFF CONVERSION KIT 223–976...
Page 44 Graco’s liability exceed the amount of the purchase price. Any action for breach of warranty must be brought within two (2) years of the date of sale.
Page 45 For Applications with a 15 Gallons (57 Liters) or Less Fluid Supply Waterbase Systems Waterbase Conversion Systems These systems include a PRO 3500WB electrostatic For converting an existing PRO 3500SC system to a PRO spray gun, fluid hose, air hose, voltage control switch, 3500WB system.
Page 46 Refer to this drawing in place of the typical installation drawing on page 4: To Gun To Gun WARNING 03585 *Equipment that must be installed for safe operation of a water -base system On page 22: Megohmmeter Test Gun Resistance 17 Air Fitting Change the procedure to the following: 20 Electrode...
Page 47 Use this chart in place of the chart on page 5: KEY TO TYPICAL INSTALLATION DRAWING Ref Letter Part No. Description Assembly Included With See Page – Grounded Main Air Supply Line – – 206–199 Gun Air Pressure Regulator – 235–070 (25’) Gun Grounded Air Supply Hose See front cover...
Page 48 Refer to this drawing in place of the drawing on page 13: Safety Fence Grounding Cable Fluid C-clamp Supply Voltage Control 03570 Fig. 10 On page 40: Change the part number for Ref. No. 316 from 107–048 to 112–480. On page 39: Change the quantity for Ref.

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