Instruction/ maintenance manual of the product 309293K Graco Inc.
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WB 100 Isolation Enclosure PR O Xs3 Smar t Gun and Fluid Hose TI2139a TI1681A 309293K Instructions/P ar ts List ELECTR OST A TIC, W A TERBORNE, AIR SPRA Y WB100 Isolation System and PR O ™ Xs3 Spr a y Gun 100 psi (0.7 MP a, 7 bar) Maximum Air Inlet Pressure 100 psi (0.
2 309293K T able of Contents List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 W arnin g Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 4 Caution Symb ol .
List of Models 309293K 3 List of Models FM Appro ved P art No. Gun Model Description 245897 PRO Xs3 W aterborne Isolation Enclosur e with standard electro static air spra y gun, g rounded air hose , a.
Symbols 4 309293K Symbols W arning Symbol This symbol aler ts you to t he possibility of serious injur y or death if y ou do not f o llo w the instructions. Caution Symbol This symbol aler ts you to t he possibility of damage to or destruction of equipment if y ou do not follo w the instruc- tions.
Warning 309293K 5 W ARNING Fire and Explosion Hazar d Improper g rounding, poor air ve ntilation, open fl ames, or sparks can cause a hazardous condition and result in a fir e or e xplosion. • Electrostatic equipment m ust be used only b y trained, qu alified personnel who unde rstand the requirements in this manual.
Warning 6 309293K WA R N I N G Equipment Misuse Hazard Equipment misu se can cause the equipmen t to rupture, malf unction, or start une xpectedly and result in a serious injur y . • This equipment is f or professiona l use only . • Read all manuals , tags , and labels be f ore oper ating the equipme nt.
Introduction 309293K 7 Intr oduction How the Electr ostatic Air Spray Gun W orks The air hose supplies air to the spr a y gun. P ar t of the air operat es the turbine and the rest of t he air atomiz es the fluid being sp ra y ed.
Introduction 8 309293K Gun Overview The electrostatic gu n includes the f ollowing co ntrols (see F IG . 1 .). • FLUID adjustment v alve. Adjusts fluid rod trav el. Use only in low flo w conditions, to reduce wear . • Fan AIR adjustment valve. Adjusts f an size and shape.
Installation 309293K 9 Installation System Requirements A saf e, well designed v oltage isolation system should hav e the f ollo wing f eatures: • All components of the isola tion system that are ch.
Installation 10 309293K Fig. 2. Typica l Installatio n: 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 valv e: I is ON, 0 is OFF B* BB AA Y Z X W TI1775.
Installation 309293K 11 V entilate the Spray Booth Check a nd f ollow all National, Sta te, and Local codes regarding ai r e xhaust v elocity re quirements . High v elocity air exhaust will decrease the oper ating effi- ciency of the electrosta tic system.
Installation 12 309293K 1. Remov e the gun air inlet fitting (35). See F IG . 3.. Fig. 3. Connect the Fluid Hose In a shielded hose system, if a hose fa ilure occurs where high v oltage arcs t hrough the inner tube, v oltage will be discharged to ground through the conductive hose la y er .
Installation 309293K 13 a. Graco WB100 Enclo sure: Slide hose through the strain relief fitting (W). Ensure conductive la ye r (C) has passed t hrough fittin g. Tighten to 55 in-lb (6.2 N•m). Pull back o n hose to chec k it is secure. Comply with the requiremen ts in Wa r n i n g at right.
Installation 14 309293K c. Connect the end of the tube (T) to the pu mp fluid outlet f itting (Z). 245895 Agitator Kit T o add an agitator t o the Graco iso lation system, orde r P art No. 245 895. See page 67 f o r the kit par ts list. 1. Discharge the system v olta ge (page 20).
Installation 309293K 15 245944 Fluid Regulator Kit T o add a fluid regulator to the Graco isolatio n system, order Part No . 245944. See page 68 for the kit par ts list. 1. Discharge the system v olta ge (page 20). 2. Reliev e the pressure (page 20). 3.
Installation 16 309293K Select a Fluid Nozzle and Air Cap The gun is supplied with P ar t No . 197266 Nozzle and 24A276 Air Cap. If you require a different size, ref er to T abl e 1 and T able 2 , and instruction manual 309419, or consult with y our Graco distr ibutor .
Installation 309293K 17 Gr ounding The follo wing are mi nimum grounding require ments for a basic elect rostatic waterb or ne system. Y our system ma y include other equipmen t or objects which must be grounded. Check y our local electrical code f or detailed grounding inst ructions.
Installation 18 309293K Chec k Electrical Gr ounding 1. Hav e a qualified electrician chec k the electrical groundin g continuit y of the spr a y gun and air hose . 2. T ur n the ES ON/OFF valve OFF . 3. T urn off the air and fluid supply to the gun. The fl uid hose must not hav e any fluid in it.
Operation 309293K 19 Operation Operating Chec klist Chec k the f ollowing list daily , before starting to operate th e system, to help ensure y ou of saf e, efficient oper ation. All operators ar e properly trained to saf ely operat e an electrostatic w aterborne air spra y system as instru cted in this man ual.
Operation 20 309293K Fluid V oltage Dischar ge and Gr ounding Pr ocedure 1. T ur n the ES ON/OFF valve OFF and w ait 30 sec- onds . 2. Remov e the door T -handle loc king screw . This will shut off the air to t he gun and trigger the gr ounding cylinder to discharge an y remaining electrical charge.
Operation 309293K 21 Fill the Fluid Suppl y 1. Discharge the system v olta ge (page 20). 2. Reliev e the pressure (page 20). 3. Open the isolated enclosur e door . 4. Remove the pail cov er from the pail, holding a rag ov er th e suction tube str ainer to pre vent any f luid from dripping into the isolated enclosure.
Operation 22 309293K 1. Make sure the ES ON /OFF valv e is OFF . 2. T ur n on t he main air supp ly v alve (B). 3. P osition the air cap by loosening the a ir cap retain- ing ring, and rotating the air cap fo r a vertical or hor- izontal spra y patter n.
Operation 309293K 23 8. Adjust the pump air re gulator to start the fluid supply unit. Adjust the f luid flow wit h the air pressure regu- lator until the stream from th e gun trav els 8-12 in. (200-300 mm) bef ore f alling off . T ypically , if fluid pressure is belo w 5 psi (.
Operation 24 309293K 13. Chec k that the ES ind icator or displa y is lit, or chec k that the kV indicator on the isolated enclosure read s 45-55 kV . If not, see Electrical T r oubleshootin g on page 39 for possible problems. 14. Check the kV meter on the isolated enclosure; 45-55 kV is normal.
Operation 309293K 25 Shutdown 1. Discharge the system v olta ge (page 20). 2. Flush the spr a y gun. See page 26. 3. Reliev e the pressure (page 20). 4. Hang the gun from its hook or place it in the acces- sor y holster , with the nozzle pointing down.
Maintenance 26 309293K Maintenance Flush the Spra y Gun Flush the gun bef ore changing colors , at the end of the da y , before st oring, and bef ore repairing the gun. 1. T ur n the ES ON/OFF v alv e OFF and w ait 30 sec- onds f or the v oltage to ble ed off .
Maintenance 309293K 27 Dail y Care and Cleaning CA UTION • Clean the outside of the gun daily with a soft cloth dampened with a non -flammab le solv ent, as defined on pa ge 26. • Chec k f or fluid leaks . Tighten all fitt ings. • Clean the air cap and flu id nozzle daily , minimum.
Maintenance 28 309293K CA UTION • Inspect the cabinet and cl ean up any spilled paint. Conductiv e paint residue allo wed t o contact grounded par ts ma y shor t out the elect rostatics. • K eep the inside of the cabinet clean, f or proper operat ion.
Maintenance 309293K 29 Clean the Air Cap and Fluid Nozzle Equipment Needed • soft bris tle brush • non-flamma ble so lv ent Procedure 1. T ur n the ES O N/OFF v alve OFF . W ait 30 seconds. 2. Discharge the system v olta ge (page 20). 3. Reliev e the pressure (page 20).
Electrical Tests 30 309293K Electrical T ests Electrical components inside the gun aff ect perf or mance and safety . Th e f ollowing procedures te st the condition of the pow er supply (18) and elect rode (29), and electri- cal continuity bet ween components .
Electrical Tests 309293K 31 T est P ower Suppl y Resistance 1. Prepare the gun f or ser vice as instructed on page 41. 2. Remov e the power su pply (18), page 46. 3. Remov e the turbine alternator (19) from the po wer supply , page 47. 4. Measure resistance from the po wer supply's g round strips (EE) to the spring (18b).
Electrical Tests 32 309293K T est Electr ode Resistance 1. Prepare the gun f or service as instr ucted on pa ge 41. 2. Inser t a conductiv e rod (B) into the gun barrel (remo v ed f or the po wer supply t est) and against th e metal conta ct (C) in the fr ont of the bar rel.
Electrical Tests 309293K 33 T est Gr ound Strip Resistance See F IG . 22.. Using an oh mmeter , measure the resis- tance between the latch housing (2 06) and the ground lug (214). The g round strip is grou nded through th e car t back to the ground lug.
Troubleshooting 34 309293K T r oub leshooting V oltage Loss T roub leshooting Normal spra ying v oltage f or a system using th e water- borne gun is 45-55 kV . The system v oltage is low er due to spra ying current demands and vo ltage isolation sys- tem losses.
Troubleshooting 309293K 35 Visual Check First, check the system f or any visible f aults or errors to help isolate whether th e spra y gun, fluid hose or v oltage isolation system has f ailed.
Troubleshooting 36 309293K 9. Flush the fluid ho se and gun with enough air to dr y out the fluid passage s. 10. T ur n the ES ON /OFF valv e to ON and tr igger the gun.
Troubleshooting 309293K 37 Spra y P attern T roub leshooting Chec k all possible remedies in the T roub leshooting Chart before disassemb ling the gu n. Some spra y patter n prob lems are caused b y the improp er balance betw een air and fluid. Prob lem Cause Solution Fluttering or spitting spray .
Troubleshooting 38 309293K Gun Operation T r oubleshooting Problem Cause Solution Excessive spr a y f og. Atomizing air pressure too high. Close restrictor valve some , or decrease air p ressure as low as pos- sible; minimum 40 psi (0. 28 MP a, 2.8 bar) needed at gun f or full volt age.
Troubleshooting 309293K 39 Electrical T r oubleshooting Prob lem Cause Solution V oltage still present at gun after fol- lowing the Fluid V oltage Dischar ge and Gr ounding Pr ocedure ES ON/OFF v alv e is not turned OFF . T urn OFF . Did not wa it long enough f or v oltage to discharge.
Troubleshooting 40 309293K * ES indicator light is off when the gun is triggered. Problem Cause Solution ES indicator or v oltage/current dis- pla y is not lit. ES ON/OFF v alve OFF (0 ).* T ur n ON (I). No pow er . Replace po wer supply . See page 47.
Repair 309293K 41 Repair Prepare the Gun f or Service • Check all possib le remedies in T roub leshooting before disassembling the gun. • Use a vise with padded ja ws to pre v ent damage to plastic par ts.
Repair 42 309293K Air Cap/Nozzle Replacement 1. Prepare gun f or ser vice, page 41. 2. Remove the retaining r ing (27) an d air cap (9). Se e F IG . 24.. 3. P oint gun up and squeez e trigger while removing the fluid nozzle (7) assembly with the multi-to ol (37).
Repair 309293K 43 Electr ode Replacement 1. Prepar e the gun f or ser vice, page 41. 2. Remov e the air cap and nozzle, pag e 42. 3. Unscrew the electrode (29) with the multi-tool (37) . Hold the packing rod end (26h) to pre v ent it from tur ning, F IG .
Repair 44 309293K Fluid P acking Remo v al 1. Prepare the gun f or service, page 41. 2. Remov e the air cap and fluid nozzle , page 42. 3. Remove the electrode, page 43. 4. Loosen the trigger scre ws (8) and trigger (30). See F IG . 26.. 5. Remove the packing rod (26), usin g the multi-tool (37).
Repair 309293K 45 P acking Rod Repair Y ou ma y replace the packing rod as individ ual par ts or as an assemb ly . The assembly is pre-ad justed at the f actor y . Bef ore installing the fluid pack ing rod into the gun barrel, mak e sure the internal surfa ces of the barrel are clea n.
Repair 46 309293K Barrel Remo v al 1. Prepare the gun f or service, page 41. 2. Remove the air inlet fitting (35) an d take the brac ket (104) off th e gun handle (17). 3. Loosen the thre e screws (11 ). 4. Hold the gun handle (17) with one hand and p ull the barrel (16) st raight off the handle.
Repair 309293K 47 P ower Suppl y Remo v al and Replacement • Inspect the gun handle power supply ca vity f or dir t or moisture. Clean w ith a clean, dr y rag. • Do not e xpose gask et (10) to solve nts. 1. Prepare gun f or ser vice, page 41. 2. Remov e the bar rel (16), page 46 .
Repair 48 309293K T urbine Alternator Remov al and Replacement Replace turbine alte rnator bearings after 2000 hours of operat ion. Order P ar t No . 223688 Bearing Kit. 1. Prepare gun f or ser vice, page 41. 2. Remov e the power supply/alternator assembly , page 47.
Repair 309293K 49 F an Air Adjustment V alve Repair 1. Prepar e the gun f or ser vice, page 41. 2. Place a wrench on the flats of th e v alve assemb ly (20) and unscre w it from the han dle (17). Y ou may rep lace the v alv e as an assemb ly (go to step 9) or as individual part s (steps 3-9).
Repair 50 309293K Fluid Adjustment V alve Repair 1. Prepare the gun f or service, page 41. 2. Remove the fluid adjustm ent v alve (25). It can on ly be replaced as a complete assemb ly . See F IG . 32.. 3. Screw t he v alv e (25) in to the gun h andle.
Repair 309293K 51 Atomizing Air Restrictor V alve Remo v al and Replacement 1. Prepar e the gun f or ser vice, page 41. 2. Remove the atomizing air restr ictor v alve (23). Inspect the o-ring (23c*). Rep lace if necessary . See F IG . 34.. 3. Install a new atomizing air restr ictor valv e (23), or disassemb le and replace pa r ts individually .
Parts 52 309293K Pa r t s P art No. 244581 60 kV Electr ostatic Gun, Series B (items 4-55) P art No. 245301 60 kV Electr ostatic Gun with Shielded wa terborne fluid hos e, Series A (items 4-55, 10 1-1.
Parts 309293K 53 ti1601a Ref . No . 26: P ac king Rod TI1488A TI1487A TI1481a 22a* 22b* 22c 22d 22e 22f 22g 20a 20b* 20c 20d 26a** 26b** 26d** 26c** 26e 26f 26g** 26h 19a* 19b 19b 19c Ref . No . 22: ES ON/OFF V alve Ref . No . 20: F an Adjustment V alve Ref .
Parts 54 309293K P art No. 244581 60 kV Electr ostatic Gun, Series B (items 4-55) P art No. 245301 60 kV Electr ostatic Gun with waterb orne fluid h ose, Series A (i tems 4-55, 101 -108) Ref. No. Part No. Description Qty 4 185111 SPRING, compression 1 6* 188749 P ACKING, u-cup , air valve; uhmwpe 1 7 197266 NOZZLE; 1.
Parts 309293K 55 * Included in Air Seal Repair Kit 244781. ** Included in Fluid Seal Repair Kit 244 911. *** Included in Swiv el Repair Kit 244834. Replacement W ar ning labels , signs , tags, and cards are ava il abl e at no co s t.
Parts 56 309293K P art No. 244582 60 kV Electr ostatic Gun, Series B (items 4-59) P art No. 245305 60 kV Electr ostatic Gun with waterb orne fluid h ose, Series A (i tems 4-59, 101 -108) TI1687A ti125.
Parts 309293K 57 ti1601a Ref . No . 26: P ac king Rod TI1487A 20a 20b* 20c 20d Ref . No . 20: F an Adjustment V alve TI1481a 19a* 19b 19b 19c Ref . No .
Parts 58 309293K P art No. 244582 60 kV Electr ostatic Gun, Seri es B (items 4-59) P art No. 245305 60 kV Electr ostatic Gun with waterborne flu id hose, Series A (items 4 -59, 101-108) Ref. No. Pa rt No. Description Qty 4 185111 SPRING, compression 1 6* 188749 P ACKING, u-cup , air valve; uhmwpe 1 7 197266 NOZZLE; 1.
Parts 309293K 59 * Included in Air Seal Repair Kit 244781. ** Included in Fluid Seal Repair Kit 244 911. *** Included in Swiv el Repair Kit 244834. Replacement W ar ning labels , signs , tags, and cards are ava il abl e at no co s t.
Parts 60 309293K P art No. 245897 Isolat ion Enc losure, Series A, with air and wb fluid hose, standard Xs3 gun (items 201-301) P art No. 245898 Isolat ion Enc losure, Series A, with air and wb fluid hoses, smart Xs3 gun (items 201-301) P art No.
Parts 309293K 61 P art No. 245897 Isolat ion Enc losure, Series A, with air and wb fluid hose, standard Xs3 gun (items 201-301) P art No. 245898 Isolat ion Enc losure, Series A, with air and wb fluid hoses, smart Xs3 gun (items 201-301) P art No. 233825 Isolation Enc losure, Series A, f or shielded hoses wit hout hoses and gun (items 201-2 86) Ref.
Parts 62 309293K Replacement W ar ning labels , signs, tags, and cards are ava il abl e at no co s t. 253 NUT , hex; 10-32 1 256 162449 NIPPL E, reducing; 1/2 npt x 1/4 npt 2 257 101874 TERMINAL, r ing 5 258 116990 BO X, control 1 259 113983 RING, retaining; 1/2 in.
Parts 309293K 63 T ubing and Wiring Char t Use the diagr ams on page 64 to find t he connection points f or the t ubing and wiring listed below . Code Ref.
Parts 64 309293K T ubing and Wiring Diagrams C1 Detail of Co ntr ol Box Detail of Door Interlock Switch C9 A1 A2 B4 C2, C9 E1 B2 A2 B5 B3 C3, C4, C5 C1 C6 B3 A1 C8 C6, C7, C8 B5 B2 C2 TI2145A TI2144A .
Accessories 309293K 65 Accessories Air Line Accessories Grounded Air Hose (Red Co ver) 100 psi (7 bar , 0.7 MP a) Maxim um W orking Pressure 0.315 in. (8 mm) I D; 1/4 npsm(f) x 1/4 npsm (f) left-hand thread; red co v er with stainless steel braid ground pat h.
Accessories 66 309293K Gun Accessories Gun Repair Kits 244781 Air Seal Repair Kit 244911 Fluid Seal Repair Kit Round P attern Kits Consists of flu id tip , diffuser and air cap . 245217 4-6 in. (1 02-152 mm) diamet er 245219 8-10 in. (203-254 mm) diameter Push/Pull Fan Air V a lve 244912 F or qu ick change of f an siz e.
Accessories 309293K 67 P art No. 245895 Agitator Acc essory Kit (items 401-407) 401 406 403 404 406 (Ref) 407 402 TI2137A 408 Ref. No. Pa rt No. De scription Qty 401 112698 ELBOW , swivel, male; 1/8 npt(m) x 1/4 in. (6 mm) OD tube 1 402 114158 FITTING, ada pter , Y ; 1/4 in.
Accessories 68 309293K P art No. 245944 Fluid Re gulator Accessory Kit (it ems 501-507) Ref. No. Part No. Description Qty 501 110078 FITTING, tube, fluid; 1/4 npt(m) x 3/8 in.
Technical Data 309293K 69 Te c h n i c a l D a t a Loctite® is a registered t rademark of the Loct ite Cor pora tion. Category Data Maximum W or king Fluid Pressure 100 psi (0.7 MP a, 7 bar) Maximum W or king Air Pressure 1 00 psi (0.7 MP a, 7 bar) Minimum Air Press ure at Gun Inle t 40 psi (0.
All written and visual data contained in this document reflects the latest product information available at the time of publica tion. Graco reserves the right to make changes a t any time without notice. This manual contains English. MM 309293 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC.
An important point after buying a device Graco Inc. 309293K (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Graco Inc. 309293K yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Graco Inc. 309293K - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Graco Inc. 309293K you will learn all the available features of the product, as well as information on its operation. The information that you get Graco Inc. 309293K will certainly help you make a decision on the purchase.
If you already are a holder of Graco Inc. 309293K, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Graco Inc. 309293K.
However, one of the most important roles played by the user manual is to help in solving problems with Graco Inc. 309293K. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Graco Inc. 309293K along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
