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Graco PRO 222700 Instructions Manual

Electrostatic air spray gun
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INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
Model PRO 3500wbt
Electrostatic Air Spray Gun
100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
Part No. 222700, Series C
For use when electrostatically spraying con-
ductive, waterborne fluids that meet at least
one of the following conditions for non-flamma-
bility:
1. 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.
2. The fluid does not sustain burning when
tested per ASTM Standard D4206 Sus-
tained Burn Test.
NOTE: The PRO 3500wb spray gun is Factory Mutual
approved for use with Graco isolation systems. The spray
gun is also approved for use with other Factory Mutual
approved voltage isolations systems provided that the fluid
hose is assembled as shown in Fig. 6, page 13. Any
modification of genuine Graco parts or replacement of parts
with non-Graco parts will void agency approvals.
U.S. PATENT NO. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774 ; D313,064; 4,978,075
Patented 1986, 1987 Canada
Brevete 1986, 1987
U.K. PATENT NO. 2,147,158; 2,142,559B; 2,140,327B
French Patent No. 89 16305
Other U.S. and Foreign Patents Pending
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1995, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
308584
Rev. H

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  • Page 1 INSTRUCTIONS-PARTS LIST This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. INSTRUCTIONS Model PRO 3500wbt Electrostatic Air Spray Gun 100 psi (0.7 MPa, 7 bar) Maximum Working Pressure Part No. 222700, Series C For use when electrostatically spraying con- ductive, waterborne fluids that meet at least one of the following conditions for non-flamma- bility:...

  • Page 2: Table Of Contents

    Symbols ........Warnings .

  • Page 3: Warnings

    ELECTRIC SHOCK HAZARD Improper grounding or an improper setup can cause a hazardous condition and result in an electric shock or other serious injury. D Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all other electrically conductive objects in the spray area.
  • Page 4 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. D Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction manual. D Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all other electrically conductive objects in the spray area.
  • Page 5 EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result INSTRUCTIONS in a serious injury. D This equipment is for professional use only. D Read all the instruction manuals, tags, and labels before operating the equipment. D Use the equipment only for its intended purpose.

  • Page 6: Introduction

    Spraying Waterborne Fluids Electrostatically The PRO 3500wb spray gun is a 60 kV electrostatic spray gun that is designed to spray conductive, water- borne, non-flammable fluids. When spraying water- borne fluids electrostatically, the gun must be con- nected to a voltage isolation system, which isolates the fluid supply from ground and allows voltage to be maintained at the tip of the gun.
  • Page 7 KEY-Fig. 1 Air Cap Electrode Retaining Nut Gun Barrel Gun Handle Air Inlet G Fluid Inlet Trigger Fig. 1 Introduction Fluid Adjustment Knob Exhaust Tube Hook M ES Indicator Light ES ON-OFF Lever Fan Air Adjustment Valve Atomizing Air Valve Power Supply Turbine/Alternator * 1 is ON 0 is OFF...

  • Page 8: Graco Waterborne Fluid Hose

    Graco Waterborne Fluid Hose (purchased separately) A Graco waterborne fluid hose must be used between the voltage isolation system fluid outlet and the spray gun fluid inlet. This fluid hose consists of three layers (see Fig. 2): D Inner Hose Layer (EE): is a PTFE tube. D Conductive Hose Layer (DD): covers the PTFE tube.

  • Page 9: Installation

    Installing the System WARNING ELECTRIC SHOCK HAZARD Installing and servicing this equipment requires access to parts which could cause an electric shock or other serious injury if the work is not performed properly. D Do not install or service this equipment unless you are trained and qualified.
  • Page 10 KEY-Fig. 3 Air Regulator Spray Gun Air Shut-off Valve Gun Fluid Regulator Graco Waterborne Fluid Hose Gun Fluid Inlet PRO 3500wb Spray Gun G Gun Air Inlet Graco Red Electrically Conductive Gun Air Hose PRO 3500wb Gun shown with the Graco H O PRO Batch System Consult your isolation system...

  • Page 11: Install The Air Line Accessories

    Install the Air Line Accessories 1. Install an air line filter and an air and water separa- tor on the main air supply line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

  • Page 12: Filter The Fluid

    Filter the Fluid Filter the fluid to remove coarse particles and sediment which could clog the fluid nozzle. The filter must be installed at the grounded fluid inlet to the voltage isolation system. Connect the Fluid Hose NOTE: D A Graco waterborne fluid hose must be used between the voltage isolation system fluid outlet and the spray gun fluid inlet.
  • Page 13 Connect the Fluid Hose (continued) 5. Insert the hose (Y) into the hose ferrule housing (79). See Fig. 5. 6. Push the hose firmly through the fluid inlet tube (75) until the o-rings on the hose barbed fitting are seated and the hose bottoms out. 7.

  • Page 14: Ground The System

    Ground the System WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD When operating the electrostatic device, any ungrounded objects in the spray area (such as people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explo- sion, or electric shock.

  • Page 15: Check The Electrical Grounding

    Check the Electrical Grounding 1. Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose. 2. Make sure the red Graco electrically conductive air hose (EE) is connected to the gun and the hose ground wire is connected to a true earth ground.

  • Page 16: Operation

    Fluid Voltage Discharge and Grounding Procedure WARNING ELECTRIC SHOCK HAZARD The high voltage fluid supply is charged with high voltage until the voltage is dis- charged. Contact with the charged com- ponents of the isolation system or spray gun elec- trode will cause an electric shock.

  • Page 17: Operating Checklist

    Operating Checklist Check the following list daily, before starting to operate the system, to help ensure safe, efficient operation. ____ 1. All the operators are properly trained to safely operate an electrostatic, waterborne, air spray system as instructed in this manual and the voltage isolation system manual.

  • Page 18: Operating The Spray Gun

    Operating the Spray Gun WARNING FIRE AND EXPLOSION HAZARD To reduce the risk of fire and explosion, only use this equipment to spray non- flammable, waterborne fluids as defined on the front cover of this manual. WARNING ELECTRIC SHOCK HAZARD Contact with the charged components of the spray gun will cause an electric shock.
  • Page 19 7. Set the atomizing air valve (R) about 1.5 turns out for most applications. The Atomizing Air Valve Adjustment chart shows the effect of the atomiz- ing air valve adjustment on the air cap air flow. 8. Adjust the pattern width with the fan air valve (P). Atomizing Air Valve Adjustment 0.00 0.50 1.00 1.50 2.00 2.50 3.00 Fully Open...

  • Page 20: Maintenance

    Shutdown WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 16 whenever you stop spraying and whenever you are instructed to relieve pressure. WARNING FIRE AND EXPLOSION HAZARD To reduce the risk of fire and explosion: D Only flush, purge, or clean the PRO 3500wb spray gun with non-flam- mable fluids, as defined on the front...

  • Page 21: Clean The Air Cap And Fluid Nozzle

    Clean the Air Cap and Fluid Nozzle Equipment needed: D Soft bristle brush D Non-flammable cleaning fluid CAUTION Do not use metal tools to clean the air cap or fluid nozzle holes as this could scratch them, and make sure the electrode wire is not damaged. Scratches in the air cap or nozzle or a damaged electrode wire can distort the spray pattern.

  • Page 22: 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 service this equipment unless you are trained and qualified.
  • Page 23 Voltage Loss Troubleshooting (continued) 7. To eliminate air gaps in the fluid column, spray enough fluid to purge the air out between the voltage isolation system and the spray gun. An air gap in the fluid hose can break the electrical continuity between the spray gun and the isolated fluid supply and cause a low voltage reading on a voltage meter connected to the isolated fluid...

  • Page 24: Electrical Troubleshooting

    Voltage Loss Troubleshooting (continued) 11. A dielectric breakdown is most likely in one of the following three areas. Repair or replace the com- ponent that is failing. Fluid hose Check for leakage or any bulges in the outer jacket, which may indicate a pin-hole leak through the PTFE layer.

  • Page 25: Spray Pattern Troubleshooting

    Spray Pattern Troubleshooting NOTE: Some spray pattern problems are caused by the improper balance between air and fluid. Problem Fluttering or spitting spray Improper spray pattern Streaks Troubleshooting Cause The fluid supply is insufficient. The fluid nozzle is loose, or the fluid nozzle taper seat is damaged.

  • Page 26: Poor Electrostatic Wrap Troubleshooting

    Poor Electrostatic Wrap Troubleshooting Problem The system is holding voltage but there is poor electrostatic wrap on the part being sprayed Gun Operation Troubleshooting Problem Fluid leakage from the fluid pack- ing area Air leakage from the front of the Fluid leakage from the front of the The fluid rod is worn or damaged.
  • Page 27 Gun Operation Troubleshooting (continued) Excessive spray fog No fluid sprays from the gun The equipment is covered with fluid Dirty air cap Troubleshooting The air pressure is too high. The fluid is thinned too much. The fluid supply is low. The fluid nozzle is dirty or clogged.

  • Page 28: Electrical Tests

    WARNING ELECTRIC SHOCK HAZARD Follow the Fluid Voltage Discharge and Grounding Procedure on page 16 before checking or servicing and when- ever you are instructed to discharge the voltage to ensure the voltage is discharged and avoid serious injury from an electric shock. WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure...

  • Page 29: Test Power Supply Resistance

    Test Power Supply Resistance 1. Prepare the gun for service as instructed on page 30. 2. Remove the power supply (18) from the gun handle as instructed on page 40. 3. Remove the turbine alternator (37) from the power supply as instructed on page 41. 4.

  • Page 30: Service

    Tools Included with the Gun D Multi-tool D Ball-end Wrench D 2 mm Hex Key Allen Wrench Prepare the Gun for Service NOTE: D Check all the possible remedies in Troubleshoot- ing before disassembling the gun. D If the plastic parts of the gun must be held in a vise, use padded vise jaws to avoid damaging parts.
  • Page 31 Air Cap/Nozzle/Resistor Stud Replacement (continued) 4. Unscrew the resistor stud (22) from the fluid nozzle (21) with the multi-tool (62). See Fig. 17. WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD The resistor stud contact ring (D) is a conductive contact ring, not a sealing o-ring.

  • Page 32: Electrode Needle Replacement

    Electrode Needle Replacement 1. Prepare the gun for service as instructed on page 30. 2. Remove the air cap, nozzle and resistor stud as instructed on page 30. 3. Unscrew and remove the electrode needle (20) with the multi-tool (62). See Fig. 18. Be careful not to damage the contact wire.

  • Page 33: Fluid Packing Rod Removal And Repair

    Fluid Packing Rod Removal and Repair Preventative Maintenance CAUTION If the conductive fluid is allowed to leak through the packings, it will eventually cause an electrical short through the packings and along the gun barrel, resulting in a loss of voltage at the tip of the gun. Severe arcing can cause barrel damage.

  • Page 34: Fluid Packing Rod Removal And Repair

    Fluid Packing Rod Removal and Repair (continued) 7. Place the packing nut (28c) and o-ring (28f) on the fluid rod (28a). Flats on the packing nut must be facing toward the back of the fluid rod. 8. Fill the entire inner cavity of the spacer (28h) with the dielectric grease included with the gun.

  • Page 35: Fan Air Adjustment Valve Repair

    Fan Air Adjustment Valve Repair NOTE: The fan air valve (43) can be replaced as an assembly or as individual parts. 1. Prepare the gun for service as instructed on page 30. 2. Place a wrench on the flats of the valve housing and remove it from the handle.

  • Page 36: Air Trigger Valve Repair

    Fluid Adjustment Assembly Repair (continued) 5. To remove the sleeve (45d), hold the cap (45c) and turn the sleeve stop (45e) counterclockwise with a pliers. 6. Remove the stem (45a) and o-ring (45b). 7. Repair or replace any damaged parts. Lubricate the o-ring (45b).

  • Page 37: Atomizing Air Valve Repair

    Atomizing Air Valve Repair 1. Prepare the gun for service as instructed on page 30. 2. Remove the fan air adjustment valve (43) as instructed on page 35. CAUTION To avoid damaging the atomizing air valve, the fan air adjustment valve must be removed before remov- ing the atomizing air valve.

  • Page 38: Es On-Off Valve Repair

    ES ON-OFF Valve Repair 1. Prepare the gun for service as instructed on page 30. 2. Loosen the set screw (24) with the 2 mm hex key (69). Remove the lever (26) from the valve. See Fig. 24. WARNING MOVING PARTS HAZARD To reduce the risk of an eye injury, wear safety glasses when removing or install- ing the retaining ring (47) as the retain-...

  • Page 39: Barrel Removal

    Barrel Removal 1. Prepare the gun for service as instructed on page 30. 2. Loosen the nut (78) from the ferrule housing (79). Pull the ferrule housing through the gun bracket (76). See Fig. 25. 3. Loosen the three barrel screws (5) with the ball- end wrench (63).

  • Page 40: Power Supply Replacement

    Power Supply Replacement 1. Prepare the gun for service as instructed on page 30. 2. Remove the barrel as instructed on page 39. CAUTION Be careful when handling the power supply to avoid damaging it. 3. Grasp the power supply with your hand. With a gentle side to side motion, loosen the power supply from the gun handle (7), then pull it straight out.

  • Page 41: Turbine Alternator Replacement

    Turbine Alternator Replacement NOTE: Replace turbine bearings after 2,000 hours of operation. See your authorized Graco representative. 1. Prepare the gun for service as instructed on page 30. 2. Remove the barrel as instructed on page 39. 3. Remove the power supply as instructed on page 40.

  • Page 42: Graco Waterborne Fluid Hose Repair

    Graco Waterborne Fluid Hose Repair WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD To reduce the risk of a fire, explosion, or electric shock: D Follow the Fluid Voltage Discharge and Grounding Procedure on page 16 and be sure the ES ON-OFF lever is turned to OFF before flushing, checking, or servicing the system and whenever you are instructed to dis-...

  • Page 43: Pro 3500Sc Gun Conversion

    PRO 3500sc Gun Conversion NOTE: See page 48 to order the conversion kit, part no. 223114. The fluid hose and air hose are not in- cluded with this kit. See page 48 to order hoses. Use only the electrically conductive air supply hoses and waterborne fluid hoses specified in this manual.
  • Page 44 PRO 3500sc Gun Conversion Apply a very light coat of lubricant to the o-ring on the outside of the fluid packing rod (28). Apply dielectric grease to the o-rings (80, 81) and tube (75) threads. Apply high strength Loctiter to the air fitting (D) threads. Torque the fitting to 35 to 45 in-lbs (4 to 5.1 NSm).
  • Page 45 PRO 3500sc Gun Conversion 6. Assemble the two o-rings (80*, 81*) onto the fluid inlet tube (75*). Apply dielectric grease to the o-rings and tube threads. 7. Screw the fluid inlet tube (75*) into the barrel inlet until it bottoms out. a.

  • Page 46: Spray Gun Parts

    Item 18 includes 18a–18f Item 28 includes 28a and 28h Item 37 includes 37a–37b Item 43 includes 43b–43e Item 45 includes 45a–45e **34 DETAIL 28d* 28g* 28f* 28h* 28e* Spray Gun Parts See Detail A 18b** 18a** 43e** 19** 41** 42** **37a 23**...
  • Page 47 WARNING EQUIPMENT MISUSE HAZARD Use only genuine Graco replacement parts. Using non-Graco parts could alter the gun’s grounding continuity or cause parts to rupture or fail, which could result in a serious injury and property damage. Part No. 222700, Series C Model PRO 3500wb Spray Gun Ref.

  • Page 48: Accessories

    Use Only Genuine Graco Parts and Accessories Waterborne Fluid Hose Assembly 100 psi (0.7 MPa, 7 bar) Maximum Working Pressure To connect between the Graco H Block and the gun; 0.25 in. (6.35 mm) ID; PTFE Fluid Hose Assy. Part No. 237924 237925 237926...
  • Page 49 Use Only Genuine Graco Parts and Accessories Snap Ring Pliers 110090 For removing the ES ON-OFF Valve Retaining Ring (item 47 in Parts List). Gun High Voltage Probe & Meter 217452 For direct measurement of the gun output voltage. Megohmmeter 218979 500 Volt output;...

  • Page 51: Technical Data

    Category Data Weight 1.87 lb (0.85 Kg) Gun Length 9.5 in. (240 mm) Maximum Working 100 psi (0.7 MPa, 7 bar) Pressure Air Pressure Operating 0–100 psi (0–0.7 MPa, Range 0–7 bar) Fluid Pressure Operating 0–100 psi (0–0.7 MPa, Range 0–7 bar) Voltage Output 0–65 kV*...

  • Page 52: The Graco Warranty And Disclaimers

    The Graco Warranty and Disclaimers WARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defec- tive.

This manual is also suitable for:

Pro 308584Pro 3500wb222700

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