INSTRUCTIONS-PARTS LIST 307912 Rev. AC This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. INSTRUCTIONS Model PRO 3500sc Electrostatic Air Spray Gun 65 kV, MANUAL GUN 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure Part No. 222300, Series B With Two-Finger Trigger Part No. 222600, Series B With Four-Finger Trigger Part No. 222300 shown 06443 NOTE: Any modification of genuine Graco parts or replacement of parts with non-Graco parts will void agency approvals. U.S.
Table of Contents Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 How the Electrostatic Air Spray Gun Works . . . . 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the System . . . . . . . . . . . . . . . . . . . . . . . . Warning Signs . . . . . . . . . . .
WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire, explosion, or electric shock. Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction manual. 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.
WARNING PRESSURIZED EQUIPMENT HAZARD Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin and cause a serious injury. Do not point the spray gun at anyone or any part of the body. Do not stop or deflect fluid leaks with your hand, body, glove, or rag. Follow the Pressure Relief Procedure on page 11 whenever you: are instructed to relieve the pressure; stop spraying; clean, check, or servicing the equipment; and install or clean the fluid nozzles.
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 voltage current to the gun’s ionizing electrode. The pump supplies fluid to the hose and gun, where the fluid is electrostatically charged as it passes the electrode.
Installation KEY A B* C* D E* F G H J* K L M N O Main Air Supply Line Ventilation Fan Interlock Solenoid Valve Main Air Supply Shutoff Valve (bleed-type) Air & Water Separator Pump Air Supply Shutoff Valve (bleed-type) Air Line Lubricator Air Pressure Regulator Pump Pump Ground Wire Fluid Filter Fluid Supply Line Shutoff Valve Fluid Pressure Regulator Fluid Supply Line Air Filter (20 micron) P Q* R* S T U* V W X Air Supply Line Shutoff Valve Air Hose Ground Wire Graco Electrically Conductive Air Hose Ele
Installation Connect the Air Line (Refer to Fig. 1) WARNING ELECTRIC SHOCK HAZARD To reduce the risk of an electric shock or other serious injury, the air supply hose must be electrically connected to a true earth ground. Use Only Graco Electrically Conductive Air Supply Hose. 5. Install an air line lubricator (F) as close to the pump (H) as possible. 6. Install an air shutoff valve (P) on each gun air supply line to shut off air to the gun(s).
Installation 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, explosion, or electric shock. Follow the grounding instructions below. The following are minimum grounding requirements for a basic electrostatic system.
Installation Check the Electrical Grounding (See Fig. 2) WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Megohmmeter P/N 241079 (AA-see Fig. 2) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless: b. If using a red turbine air hose, use an ohmmeter to measure the resistance. Resistance should not exceed 100 ohms. 6.
Notes 10 307912
Operation Pressure Relief Procedure Operating Checklist Check the following list daily, before starting to operate the system, to help ensure safe, efficient operation. WARNING PRESSURIZED EQUIPMENT HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. To reduce the risk of an injury from electric shock, accidental spray from the gun, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you: ____ 1.
Operation DD 31 26 45 43 05151A 20 1 06443 Fig. 4 Selecting a Fluid Nozzle and Air Cap WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 11 before removing or installing a fluid nozzle and/or air cap. The gun is supplied with a 0.059 in. (1.5 mm) fluid nozzle, P/N 185158, and air cap, P/N 193033.
Operation Operating the Spray Gun (continued) 1. Follow the Operating Checklist on page 11. 8. Adjust the pattern width with the fan air valve (43). Atomizing Air Valve Adjustment Air Cap Air Flow (%) 2. To adjust the air cap for a vertical or horizontal spray pattern, first make sure the pressure is relieved. Then loosen the air cap retaining nut, and rotate the air cap as directed in Fig. 5.
Operation 1. Relieve the pressure. Shutdown 2. Flush and clean the equipment. Follow the instruction in Maintenance. WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 11 whenever you stop spraying and whenever you are instructed to relieve pressure.
Maintenance Clean the Air Cap and Fluid Nozzle CAUTION Do not use metal tools to clean the air cap or spray nozzle holes as this could scratch them, and make sure the electrode wire is not damaged. Scratches in the air cap or spray nozzle or a damaged electrode wire can distort the spray pattern. WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 11 whenever you stop spraying and whenever you are instructed to relieve the pressure. 1.
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.
Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Fluid leakage from the fluid packing area The needle packings or shaft are worn. Replace the packings or shaft; see page 26. The packing nut is loose Tighten the packing nut; see page 26. The air valve is not seating properly. Clean and service the air valve; see page 31. The air valve o-ring is sticking. Lubricate the o-ring; see page 31. The needle is worn or damaged. Replace the needle; see page 26. The fluid seat is worn.
Troubleshooting Electrical Troubleshooting Problem Poor wrap-around Operator gets a mild shock Operator gets a shock when touching the workpiece Cause The ES ON-OFF lever is in the OFF (O) position.* Turn the lever to ON (1). The distance between the gun and workpiece is incorrect. Adjust the spraying distance to 8 to 12 inches (203 to 305 mm) The parts are poorly grounded. Clean the workpiece hangers. Check for proper grounding on the conveyer or track. The booth exhaust velocity is too high.
Electrical Tests The performance and safety of the spray gun are directly affected by the condition of the electrical components contained inside the gun. The electrical tests below can be used to determine the condition of the power supply (18) and the resistor stud (22) as well as the continuity of the electrical path between the components. Measure the resistance between the end of the electrode (20) and the gun air fitting (17). See Fig. 7. The resistance should be between 180 to 220 megohms.
Electrical Tests A Test Power Supply Resistance Remove the power cartridge (18) from the gun handle. See Power Cartridge Replacement on page 27. Remove the turbine alternator from the power cartridge. See Turbine Alternator Removal on page 28. Measure the resistance from the power supply’s ground contact point (EE) to the contact spring (18c) on the other end of the power supply. See Fig. 8. The resistance should be 157.5 to 192.5 megohms.
Electrical Tests Test Resistor Stud Resistance (continued) If the resistance is outside the specified range, remove the resistor stud (22). See Air Cap/Nozzle/Resistor Stud Replacement on page 22. Check the resistance between the black resistor stud contact ring (D) and the needle contact ring (E). Refer to Fig. 10. You may have to press down on the contact ring (D) in several places to get a good reading. D The resistance should be 21 to 29 megohms.
Service Prepare the Gun for Service 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.
Service 3. Unscrew and remove the fluid needle/electrode (20) with the multi-tool (62). See Fig. 13. Hold the needle shaft end to prevent it from turning. Air Cap/Nozzle/Resistor Stud Replacement (continued) 6. Trigger the gun while installing the fluid nozzle (21) and resistor stud (22) assembly with the multi-tool (62). Tighten until the fluid nozzle seats in the gun barrel. 7. Install the air cap assembly (1, 2, 8). Test the gun resistance as instructed on page 19.
Service Barrel Removal 1. Prepare the gun for service as instructed on page 22. 2. Carefully loosen the nut from the fluid fitting (10). Pull the tube (12) out of the fitting. Make sure both ferrules and the nut stay with the tube. See Fig. 14. 3 3. Using the wrench (63) supplied, loosen the three socket head cap screws (5). 7 4. Hold the gun handle (7) with one hand and pull the barrel (3) straight away from the handle to remove it. See Fig. 15.
Service Fluid Packing Removal 1. Prepare the gun for service as instructed on page 22. 2. Remove the air cap assembly, fluid nozzle and resistor stud and electrode as instructed on page 23. 3. Loosen the trigger screws (4) far enough to remove the trigger (13). 28 4. Remove the packing cartridge and needle assembly (28), using the multi-tool (62). See Fig. 16. 62 13 CAUTION Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits.
Service 3. Place the fluid packing (28e), needle packing (28d), and housing (28b) on the fluid needle (28a) as shown in Fig. 17. Fluid Packing and Needle Repair The fluid packings and needle can be replaced as individual parts or as assemblies. The overall assembly is pre-adjusted at the factory. 4. Lubricate the o-ring (28g) on the outside of the packing housing (28b). NOTE: Before installing the packing and needle assembly into the gun barrel, make sure the internal surfaces of the barrel are clean.
Service 35 18d 18 18a 18c 18b 7 F 37a Apply a very light coat of lubricant Do not expose to solvents 37b 37 05160 Fig. 18 Power Cartridge Replacement NOTE: The power cartridge consists of the alternator (37), power supply (18) and retaining ring (35). See Fig. 18. 1. Prepare the gun for service as instructed on page 22. 2. Remove the barrel as instructed on page 24. CAUTION Be careful when handling the power cartridge to avoid damaging it. 3. Grasp the power cartridge with your hand.
Service Turbine Alternator Replacement Barrel Installation NOTE: Replace turbine bearings after 2,000 hours of operation. See your authorized Graco representative. 1. Be sure the gaskets (34 and 18a) and spring (30) are in place. See Fig. 19. Replace if damaged. 1. Prepare the gun for service as instructed on page 22. 2. Place the barrel (3) over the power cartridge (18) and onto the gun handle (7). Make sure the fluid needle spring (30) is seated properly. 2.
Service DETAIL Fan Air Adjustment Valve Repair 1. Prepare the gun for service as instructed on page 22. 43b 2. Place a wrench on the flats of the valve housing and remove it from the handle. See Fig. 20. 43d 43c 43e NOTE: The fan air valve (43) can be replaced as an assembly or as individual parts. To disassemble the fan valve: 3. Remove the retaining ring (43b). Rotate the fan air adjustment knob (43c) counterclockwise until it is disengaged from the valve housing threads (43d).
Service Fluid Adjustment Assembly Repair DETAIL 1. Prepare the gun for service as instructed on page 22. 0636A 2. Using a 14 mm socket wrench, remove the fluid adjustment assembly (45). See Fig. 21. 45 45c 3. Turn the stem (45a) fully clockwise and remove the sleeve stop (45e). 45a 45b 45d 4. To completely disassemble the fluid adjustment assembly, the sleeve stop (45e) must be assembled back on to the stem (45a). Turn the stem until the sleeve is protruding about 0.4 inches (10 mm).
Service Air Trigger Valve Repair 1. Prepare the gun for service as instructed on page 22. 2. Using a 14 mm socket wrench, remove the fluid adjustment assembly (45), o-ring (23) and spring (44). See Fig. 21. CAUTION Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause the gun to malfunction. 3. Loosen the air valve packing nut (40) one full turn. Remove the air valve shaft (39) with a pliers.
Service ES ON-OFF Valve Repair 1. Prepare the gun for service as instructed on page 22. 2. Loosen the set screw (24) with the 2 mm hex key (69) provided. Remove the lever (26) from the valve. See Fig. 23. 7. Install the valve (38), with the regulator disc (46) and o-ring (36), into the gun handle. Install the spacer (32) on the valve. 8. Install the retaining ring (47) into the groove in the handle. Install the lever (26) and tighten the set screw (24).
Notes 307912 33
Parts DETAIL A 28d* 28g* 28b See Detail A 28c 28 28f* Item 18 includes items 18a to 18f Item 28 includes items 28a to 28h Item 37 includes items 37a and 37b Item 43 includes items 43b to 43e Item 45 includes items 45a to 45e 28a 20 28h* 25* 28e* 22 21 2 18d 1 18e 37a 8 37 37b 35 18c 18a 18b 18f 34 45c 43c 43e 5 45a 43d 43b 3 4 31 23 45b 45d 45e 44 19 39 41 13 24 *29 26 10 47 12 36 6 40 46 19 42 33 7 REF.
Parts WARNING Some PRO 3500sc Gun replacement parts look similar to other PRO Gun parts but are not interchangeable! When servicing, do not mix or use other PRO Gun parts! Use of parts other than those specified in the parts list below could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction and result in serious injury, fire, explosion or property damage. Part No. 222300, Series B Electrostatic Air Spray Gun, with two-finger trigger Ref No.
Accessories Use Only Genuine Graco Parts and Accessories AIR LINE ACCESSORIES Conductive Air Supply Hose; black 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure FM Approved; Color coded black; 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread 220444 218100 218101 218102 218103 220119 220120 6 ft (1.8 m) 15 ft (5 m) 25 ft (8 m) 36 ft (11 m) 50 ft (15 m) 75 ft (23 m) 100 ft (30.5 m) Conductive Air Supply Hose; gray 100 psi (7 bar, 0.
Accessories Use Only Genuine Graco Parts and Accessories FLUID LINE ACCESSORIES Fluid Hose Assemblies (Nylon) 225 psi (14 bar, 1.4 MPa) Maximum Working Pressure FM Approved; 1/4 in. (6.35 mm) ID, 3/8 npsm(fbe) 215637 215638 25 ft (8 m) 50 ft (15 m) Fluid Hose Assemblies (Nylon) 500 psi (35 bar, 3.5 MPa) Maximum Working Pressure FM Approved; 1/4 in. (6.35 mm) ID, 3/8 npsm(fbe) 216076 216077 216079 25 ft (8 m) 50 ft (15 m) 100 ft (30 m) Fluid Tube (PTFE) 185806 100 psi (7 bar, 0.
Accessories Use Only Genuine Graco Parts and Accessories MISCELLANEOUS ACCESSORIES Snap Ring Pliers 110090 For removing the ES ON-OFF Valve Retaining Ring (item 47 in Parts List). Paint Resistance Meter 722886 Used with 722860 Paint Probe to measure resistance of paint. Not for use in Hazardous areas. Paint Probe 722860 Used with 722886 Paint Resistance Meter to measure resistance of paint. Not for use in Hazardous areas. Grounding Clamp And Wire 222011 12 ga, 25 ft (7.
Technical Data Category Data Category Data Gun Weight 1.87 lb (0.85 Kg) Wetted Parts Gun Length 9.5 in. (240 mm) Maximum Working Pressure 100 psi (7 bar, 0.7 MPa) Stainless Steel, Polyethylene, Nylon, Acetal, PTFE, Ultra High Molecular Weight Polyethylene, Ceramic, Fluoroelastomer, Music Wire Air Pressure Operating Range 0–100 psi (0–7 bar, 0–0.7 MPa) Fluid Pressure Operating Range 0–100 psi (0–7 bar, 0–0.
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 by an authorized Graco distributor 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 from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
