Graco Inc. 308584 manual

308584 Rev . H U.S. P A TENT 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. P A TENT NO. 2,147,158; 2,142,559B; 2,140,327B French Patent No. 89 16305 Other U.S. and Foreign Patents Pending NOTE: The PRO 3500wb spray gun is Factory Mutual approved for use with Graco [...]

2 308584 T able of Contents Symbols 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W arnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spraying W aterborne Fluids Electrostatically 6 . . . . Opera[...]

308584 3 W ARNING ELECTRIC SHOCK HAZARD Improper grounding or an improper setup can cause a hazardous condition and result in an electric shock or other serious injury .  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. See Ground the System [...]

4 308584 W ARNING 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 stated in this instruction manual.  Ground the equipment, per[...]

308584 5 W ARNING INSTRUCTIONS 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 the instruction manuals, tags, and labels before operating the equipment.  Use the equipment only for its in[...]

6 308584 Introduction Spraying W aterborne 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 fro[...]

308584 7 Introduction KEY -Fig. 1 A Air Cap B Electrode C Retaining Nut D Gun Barrel E Gun Handle F Air Inlet G Fluid Inlet H T rigger J Fluid Adjustment Knob K Exhaust T ube L Hook M ES Indicator Light N ES ON-OFF Lever P Fan Air Adjustment V alve R Atomizing Air V alve S Power Supply T T urbine/Alternator 05404 Fig. 1 * 1 is ON 0 is OFF 05151A BA[...]

8 308584 Introduction Graco W aterborne 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):  Inner Hose Layer (EE): is a PT FE tube.  Conductive Hose Layer (DD): covers the PTFE tube.[...]

308584 9 Installation Installing the System W ARNING 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 .  Do not install or service this equipment unless you are trained and qualified.  Comply with all local, [...]

10 308584 Installation KEY -Fig. 3 A Air Regulator B Spray Gun Air Shut-of f V alve C Gun Fluid Regulator D Graco Waterborne Fluid Hose E Gun Fluid Inlet F PRO 3500wb Spray Gun G Gun Air Inlet H Graco Red Electrically Conductive Gun Air Hose K Air Supply Hose L Fluid Supply Hose M Gun Air Hose Ground Wire N T rue Earth Ground P Fluid Hose Port R H [...]

308584 11 Installation 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. 2. Install a bleed-type air regulator (A) on the [...]

12 308584 Installation 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:  A Graco waterborne fluid hose must be used between the voltage isolation system fluid outlet an[...]

308584 13 Installation 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. T ighten the hose ferrule (77) firmly with a wrench to about 50 in-lb (5.6 N ?[...]

14 308584 Installation Ground the System W ARNING 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 s[...]

308584 15 Installation 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. See Fig. 7. 3. The air and fluid supplie[...]

16 308584 Operation Fluid V oltage Discharge and Grounding Procedure W ARNING 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. T o avoid an elec- tric shock, follow t[...]

308584 17 Operation 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. ____ 2. All th[...]

18 308584 Operation Operating the Spray Gun W ARNING FIRE AND EXPLOSION HAZARD T o 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. W ARNING ELECTRIC SHOCK HAZARD Contact with the charged components of the spray gun will cause an electric shock. D[...]

308584 19 Operation 7. Set the atomizing air valve (R) about 1.5 turns out for most applications. The Atomizing Air V alve 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 V alve Adjustment 0 10 20 30 40 50 60 70 80 90 100 0.00 0[...]

20 308584 Operation Shutdown W ARNING PRESSURIZED EQUIPMENT HAZARD T o 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. 1. Relieve the pressure. 2. Flush and clean the equipment. Follow the instruc- tion in Maintenance . Maintenance W ARNIN[...]

308584 21 Maintenance Clean the Air Cap and Fluid Nozzle Equipment needed:  Soft bristle brush  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 d[...]

22 308584 T roubleshooting W ARNING 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. Follow the Fluid V oltage Discharge and Ground- in[...]

308584 23 T roubleshooting V oltage Loss T roubleshooting (continued) 7. T o 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 volt[...]

24 308584 T roubleshooting V oltage Loss T roubleshooting (continued) 1 1. 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 P TFE layer . Disconnect the fluid[...]

308584 25 T roubleshooting Spray Pattern T roubleshooting NOTE: Some spray pattern problems are caused by the improper balance between air and fluid. Problem Cause Solution Fluttering or spitting spray The fluid supply is insufficient. Adjust the fluid regulator , or fill the fluid supply . The fluid nozzle is loose, or the fluid nozzle taper seat [...]

26 308584 T roubleshooting Poor Electrostatic Wrap T roubleshooting Problem Cause Solution The system is holding voltage but there is poor electrostatic wrap on The distance between the gun and workpiece is incorrect. Adjust the spraying distance to 8 to 12 inches (203 to 305 mm). the part being sprayed The parts are poorly grounded. Clean the work[...]

308584 27 T roubleshooting Gun Operation T roubleshooting (continued) Excessive spray fog The air pressure is too high. Reduce the air cap air pressure by closing the atomizing air valve more or decreasing the gun air inlet pres- sure; use the least air pressure needed for good results. Do not re- duce below minimum pressure need- ed for full volta[...]

28 308584 Electrical T ests W ARNING ELECTRIC SHOCK HAZARD Follow the Fluid V oltage 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. W ARNING PRESSURIZED EQUIPMENT HAZARD T o reduc[...]

308584 29 Electrical T ests T est 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. Measure the resistance from the power supply ’ s ground contact po[...]

30 308584 Service T ools Included with the Gun  Multi-tool  Ball-end W rench  2 mm Hex Key Allen Wrench Prepare the Gun for Service NOTE:  Check all the possible remedies in T roubleshoot - ing before disassembling the gun.  If the plastic parts of the gun must be held in a vise, use padded vise jaws to avoid damaging parts.  Ligh[...]

308584 31 Service 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. W ARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD The resistor stud contact ring (D) is a conductive contact ring, not a sealing o-ring. See Fig. 16. T o reduce the risk of spar[...]

32 308584 Service 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. If the fluid rod turns, hold the back end [...]

308584 33 Service 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. T o avoid vo[...]

34 308584 Service 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. Place the spacer on the fluid rod ([...]

308584 35 Service Fan Air Adjustment V alve 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. See Fig. 21. 3. If the parts are purchased separately , install them as ins[...]

36 308584 Service Fluid Adjustment Assembly Repair (continued) 5. T o 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). 8. Carefully apply low strength (purple) Loctite  or equiva[...]

308584 37 Service Atomizing Air V alve 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 T o avoid damaging the atomizing air valve, the fan air adjustment valve must be removed before remov- ing the atomizing air valve. 3. Remove the atomizing air valve (31[...]

38 308584 Service ES ON-OFF V alve 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. W ARNING MOVING P ARTS HAZARD T o reduce the risk of an eye injury , wear safety glasses when removing or install- ing the retaining ring (47) [...]

308584 39 Service 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). 4. Hold the gun handle (7) with one hand and pull the barrel (3) str[...]

40 308584 Service 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 [...]

308584 41 Service T urbine 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. 4. Squeeze the two ends of the retaini[...]

42 308584 Service Graco W aterborne Fluid Hose Repair W ARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD T o reduce the risk of a fire, explosion, or electric shock:  Follow the Fluid V oltage 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 when[...]

308584 43 PRO 3500sc Gun Conversion NOTE: See page 48 to order the conversion kit, part no. 2231 14. 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. PRO 3500SC Gun Disassembly 1. Remove the air fitting[...]

44 308584 PRO 3500sc Gun Conversion Fig. 31 8* H 20* L 28*  N P M  *80 91  *75 *78 *76 *79 *77 D  E F  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 Loctite  to the air fitting (D) t[...]

308584 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. Apply dielectric grease (82) to the O.D. threads of the fluid inlet tube (75*). Thread the sleeve (91)[...]

46 308584 Spray Gun Parts 6 4 13 3 1 8 2 22 20 21 25* 28 35 **34 45d 23** 39 42** 66 17 15 19 33 26 24 36 46 38 47 32 31 41** **37a 37b 18a** 18b** 18c 30 5 18d 19** See Detail A 28a 28g* 28b 28d* 28e* 28f* 28c 43b 43d 43e** 43c 28h* 18f 18e DET AIL Item 18 includes 18a – 18f Item 28 includes 28a and 28h Item 37 includes 37a – 37b Item 43 inclu[...]

308584 47 Spray Gun Parts W ARNING 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. No. Part N o . Description [...]

48 308584 Accessories Use Only Genuine Graco Parts and Accessories W aterborne Fluid Hose Assembly 100 psi (0.7 MPa, 7 bar) Maximum Working Pressure T o connect between the Graco H 2 O PRO V oltage Block and the gun; 0.25 in. (6.35 mm) ID; PT FE Fluid Hose Assy . Part No. Hose Length 237924 25 ft. (7.6 m) 237925 36 ft. (1 1 m) 237926 50 ft. (15.3 m[...]

308584 49 Accessories Use Only Genuine Graco Parts and Accessories Snap Ring Pliers 1 10090 For removing the ES ON-OFF V alve Retaining Ring (item 47 in Parts List). Gun High V oltage Probe & Meter 217452 For direct measurement of the gun output voltage. Megohmmeter 218979 500 V olt output; 0.01 – 2000 megohms. Not for use in Hazardous areas.[...]

50 308584 N[...]

308584 51 T echnical Data Category Data Weight 1.87 lb (0.85 Kg) Gun Length 9.5 in. (240 mm) Maximum Working Pressure 100 psi (0.7 MPa, 7 bar) Air Pressure Operating Range 0 – 100 psi (0 – 0.7 MPa, 0 – 7 bar) Fluid Pressure Operating Range 0 – 100 psi (0 – 0.7 MPa, 0 – 7 bar) V oltage Output 0 – 65 kV* Air Inlet 1/4 npsm(m) L.H. Fluid[...]

52 308584 The Graco W arranty and Disclaimers W ARRANTY 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 peri[...]