INSTRUCTIONS-PARTS LIST 308018 This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. Rev. W INSTRUCTIONS Model PRO 3500hc Electrostatic Air Spray Gun 65 kV, HIGH CONDUCTIVITY, MANUAL GUN 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure For use with electrically conductive, solvent based coatings, including metal flake paint Part No. 222625, Series B PRO 3500hc Electrostatic High Conductivity Air Spray Gun Part No.
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Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 How the Electrostatic Air Spray Gun Works . . . . 6 Converting a PRO 3500sc Gun to a PRO 3500hc Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 13 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.
Converting a PRO 3500sc Gun to a PRO 3500hc Gun H G L M A K J D E B C F Fig. A 06619 06616 Fig. C H G 12 L M 12a 28 J 10 Fig. B 12b 10 12 D 06618 E F 06617 Fig.
Installation A M ES ON-OFF Lever 1 is ON 0 is OFF N H E* S O B* C* D G J* V G X F W R K P L U* Q* WARNING SIGN T Non-hazardous Area Hazardous Area The air supply to the gun must be electrically interlocked with the ventilators to prevent the power supply from operating without ventilating fans on.
Installation Installing the System WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. Do not install or service this equipment unless you are trained and qualified. Be sure your installation complies with National, State and Local codes for the installation of electrical apparatus in a Class I, Group D Hazardous Location.
Installation Connect the Exhaust Tube Press the exhaust tube (provided) onto the barbed adapter on the bottom of the gun handle. Secure the tube with the clamp provided. Refer to page 36. The following are minimum grounding requirements for a basic electrostatic system. Your system may include other equipment or objects which must be grounded. Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground. Connect the Fluid Line (Refer to Fig.
Installation a. If using a black or grey air hose, use a megohmmeter (AA) to measure the resistance. Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 2 megohms. 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.
Notes 12 308018
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.
Operation DD 26 45 43 31 05151A 1 06615 20 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 13 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 7. Set the atomizing air valve (31) about 1.5 turns out for most applications. The Atomizing Air Valve Adjustment chart shows the effect of the atomizing air valve adjustment on the air cap air flow. Operating the Spray Gun (continued) 1. Follow the Operating Checklist on page 13. 8. Adjust the pattern width with the fan air valve (43). Atomizing Air Valve Adjustment Air Cap Air Flow (%) 2.
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 13 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 tip holes as this could scratch them, and make sure the electrode wire is not damaged. Scratches in the air cap or spray tip or a damaged electrode wire can distort the spray pattern.
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 28. The packing nut is loose Tighten the packing nut; see page 28. 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 28. 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 elec- Use megohmmeter P/N 241079 (A) and an applied voltage of 500 volts to complete these electrical tests.
Electrical Tests Test Power Supply Resistance Test Resistor Stud Resistance Remove the power cartridge (18) from the gun handle. See Power Cartridge Replacement on page 29. Insert a conductive rod (B) into the gun barrel (re- Remove the turbine alternator from the power cartridge. See Turbine Alternator Removal on page 30. 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.
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 24. 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. 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 that may cause 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 Air Cap/Nozzle/Resistor Stud Replacement (continued) Electrode Replacement 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 21. 1. Prepare the gun for service as instructed on page 24. 1. Remove the air cap, nozzle and resistor stud as instructed on page 24. 2.
Service Barrel Removal 1. Prepare the gun for service as instructed on page 24. 2. Carefully loosen the nut (14) from the bracket/fluid fitting (16). 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 24. 2. Remove the air cap assembly, fluid nozzle and resistor stud, and electrode as instructed on page 25. 3. Loosen the trigger screws (4) far enough to remove the trigger (13). 28 62 4. Remove the packing cartridge and needle assembly (28), using the multi-tool (62). See Fig. 16. 13 CAUTION Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits.
Service 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. NOTE: Before installing the packing and needle assembly into the gun barrel, make sure the internal surfaces of the barrel are clean. Remove any residue with a soft brush or cloth. Check the inside of the barrel for marks from high voltage arcing. If the marks are present, replace the barrel.
Service 18 18a 18c 35 18d 18b 7 F 37a 37b Apply a very light coat of lubricant Do not expose to solvents 37 06629 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 24. 2. Remove the barrel as instructed on page 26. 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 distributor. 1. Be sure the gaskets (34 & 18a) and spring (30) are in place. See Fig. 19. Replace if damaged. 1. Prepare the gun for service as instructed on page 24. 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 24. 43b 43d 43c 2. Place a wrench on the flats of the valve housing and remove it from the handle. See Fig. 20. 43e NOTE: The fan air valve (43) can be replaced as an assembly or as individual parts. To disassemble the fan valve: 43 3. Remove the retaining ring (43b). Rotate the 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 24. 2. Using a 14 mm socket wrench, remove the fluid adjustment assembly (45). See Fig. 21. 0636A 45 3. Turn the stem (45a) fully clockwise and remove the sleeve stop (45e). 45c 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 24. 2. Using a 14 mm socket wrench, remove the fluid adjustment assembly (45), o-ring (23) and spring (44). See Fig. 21. Atomizing Air Valve Removal and Replacement 1. Prepare the gun for service as instructed on page 24. 2. Remove the fan air valve (43). See Fig. 22. CAUTION Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits.
Service ES ON-OFF Valve Repair 7. Install the valve (38) with the regulator disc (46) and o-ring (36) into the gun handle. Install the 1. Prepare the gun for service as instructed on page 24. 2. Loosen the set screw (24) with the 2 mm hex key (69) provided. Remove the lever (26) from the valve. See Fig. 23. spacer (32) on the valve. 8. Install the retaining ring (47) into the groove in the handle. Install the lever (26) and tighten set screw (24).
Service Tube and Shroud Removal/Replacement 9. Loosen the fluid tube fitting from the gun barrel. 1. Prepare the gun for service as instructed on page 24. 10. Replace any worn or damaged parts. 2. Remove the air cap, nozzle and resistor stud, and electrode as instructed on page 29. 11. Reassemble the gun as instructed in Converting a PRO 3500SC Spray Gun to a PRO 3500HC Spray Gun on page 6. 3. Loosen the nut (14) and disconnect the fluid tube (12) from the bracket/fluid fitting (16).
Parts DETAIL A Item 12 includes items 12a to 12e 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 28d 28b 28c 28g 28f 28h See Detail A 28e 28a 28 20 25 22 21 2 18d 1 18e 8 18b* 34* 37a* 37b 18c 37 35 45c 18a* 18f 5 3 43c 31 4 19* 43e* 23* 45a 45b 43d 43b 13 45d 45e 44 39 12a 12b 10 6 41* 24 30 15 36 19 12 47 38 46 40 42* 12d REF.
Parts WARNING Some PRO 3500hc 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. 222625, Series B, Electrostatic High Conductivity Air Spray Gun Ref No. Part No.
Parts Part No. 223451 Conversion Kit Kit must be purchased separately. Ref No. Part No. Description 10 12 186102 223450 12a 12b 12c 12d 12e 28 111450 110749 110079 110077 111450 223444 SHROUD 1 TUBE, fluid Includes items 12a–12e 1 O-RING; fluoroelastomer 1 O-RING; fluoroelastomer 1 NUT, fluid tube 1 FERRULES, fluid tube 1 O-RING; fluoroelastomer 1 FLUID PACKING & NEEDLE ASSY Includes items 28a–28h 1 Ref No. Part 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 MISCELLANEOUS ACCESSORIES Fluid Hose Assemblies (Nylon) 225 psi (14 bar, 1.4 MPa) Maximum Working Pressure Snap Ring Pliers 110090 For removing the ES ON-OFF Valve Retaining Ring (item 47 in Parts List). 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.
Technical Data Category Data Category Data Gun Weight 1.89 lb (0.86 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.
Notes 42 308018
Notes 308018 43
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.
