INSTRUCTIONS-PARTS LIST 308584 Rev. H This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. INSTRUCTIONS Model PRO 3500wb Electrostatic Air Spray Gun 100 psi (0.7 MPa, 7 bar) Maximum Working Pressure Part No. 222700, Series C For use when electrostatically spraying conductive, waterborne fluids that meet at least one of the following conditions for non-flammability: 1.
Table of Contents Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spraying Waterborne Fluids Electrostatically . . . . Operating the Electrostatics . . . . . . . . . . . . . . . . . . Graco Waterborne Fluid Hose . . . . . . . . . . . . . . . . 2 3 6 6 6 8 Installation . . . . . . . . . . . . . . . . . .
WARNING 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 on page 14. The gun must be connected to a voltage isolation system that will discharge the system voltage when the gun is not in use.
WARNING 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, 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 on page 14.
WARNING EQUIPMENT MISUSE HAZARD INSTRUCTIONS 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 intended purpose. If you are uncertain about usage, call your Graco distributor. Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Introduction Spraying Waterborne Fluids Electrostatically The PRO 3500wb spray gun is a 60 kV electrostatic spray gun that is designed to spray conductive, waterborne, non-flammable fluids. When spraying waterborne fluids electrostatically, the gun must be connected to a voltage isolation system, which isolates the fluid supply from ground and allows voltage to be maintained at the tip of the gun.
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 Trigger J K L M N P R S T Fluid Adjustment Knob Exhaust Tube Hook ES Indicator Light ES ON-OFF Lever Fan Air Adjustment Valve Atomizing Air Valve Power Supply Turbine/Alternator M L D E *N J P R 05151A * 1 is ON 0 is OFF B A F C K 05148B H G S T 05404 Fig.
Introduction 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): Inner Hose Layer (EE): is a PTFE tube. KEY-Fig.
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. Do not install or service this equipment unless you are trained and qualified. Comply with all local, state, and national codes for the installation of electrical apparatus in a Class I, Group D, Hazardous Location.
Installation KEY-Fig.
Installation Install the Air Line Accessories 1. Install an air line filter and an air and water separator 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 pump and gun air supply lines to control air pressure to the pump and gun. Refer to Fig. 3, page 10. 3.
Installation Filter the Fluid CAUTION 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 Be careful not to cut into the inner hose layer (K) when stripping the hose. Nicks or cuts in the tube will cause premature hose failure. 2. Inspect the condition of the o-rings (G) on the hose barbed-fitting. Replace the o-rings if they are worn or damaged.
Installation Connect the Fluid Hose (continued) WARNING 5. Insert the hose (Y) into the hose ferrule housing (79). See Fig. 5. ELECTRIC SHOCK HAZARD To reduce the risk of an electric shock, the areas of the waterborne fluid hose that are accessible to personnel during normal operation must be covered by the outer hose jacket (H). See Fig. 6. 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.
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 grounding instructions are minimum requirements for a basic electrostatic, waterborne system.
Installation Check the Electrical Grounding KEY- Fig. 7 1. Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose. AA BB CC DD EE Gun Handle True Earth Ground Ohmmeter ES ON-OFF Lever Graco Electrically Conductive Air Hose EE 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. DD AA 3.
Operation Fluid Voltage Discharge and Grounding Procedure Pressure Relief Procedure WARNING WARNING ELECTRIC SHOCK HAZARD The high voltage fluid supply is charged with high voltage until the voltage is discharged. Contact with the charged components of the isolation system or spray gun electrode will cause an electric shock.
Operation Operating Checklist 3 in. (76 mm) square cut out and finger of glove cut off 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 the operators are trained how to properly relieve system pressure as instructed on page 16. ____ 3.
Operation Operating the Spray Gun WARNING FIRE AND EXPLOSION HAZARD To reduce the risk of fire and explosion, only use this equipment to spray nonflammable, waterborne fluids as defined on the front cover of this manual. 1. Follow the Operating Checklist on page 17. 2. Make sure the system voltage is discharged. Loosen the air cap retaining nut, and rotate the air cap for a vertical or horizontal spray pattern. See Fig. 9.
Operation 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 atomizing air valve adjustment on the air cap air flow. 8. Adjust the pattern width with the fan air valve (P). 11. Use the same spraying technique you would use with a conventional air spray system to coat the workpiece. 12. Relieve the pressure and discharge the voltage when you stop spraying.
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 16 whenever you stop spraying and whenever you are instructed to relieve pressure.
Maintenance Clean the Air Cap and Fluid Nozzle Flush the Spray Gun Equipment needed: 1. Relieve the pressure and discharge the system voltage as instructed on page 16. 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 distort the spray pattern. 2.
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 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 supply. 8. Check the spray gun cover and barrel for accumulated overspray.
Troubleshooting Voltage Loss Troubleshooting (continued) Remove the packing assembly from the gun as instructed on page 33, and look for signs of fluid leakage or any blackened areas, which would indicate arcing is occurring along the packing rod. 11. A dielectric breakdown is most likely in one of the following three areas. Repair or replace the component 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.
Troubleshooting Spray Pattern Troubleshooting 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 is damaged. Tighten or replace the fluid nozzle; see page 30. There is dirt between the fluid nozzle, taper seat, and gun body. Clean the parts; see page 21.
Troubleshooting Poor Electrostatic Wrap Troubleshooting Problem Cause Solution The system is holding voltage but The distance between the gun and there is poor electrostatic wrap on workpiece is incorrect. the part being sprayed The parts are poorly grounded. Adjust the spraying distance to 8 to 12 inches (203 to 305 mm). Booth exhaust velocity is too high. Reduce the exhaust velocity within the code limits. The atomizing air pressure is too high. Reduce the atomizing air pressure.
Troubleshooting Gun Operation Troubleshooting (continued) Excessive spray fog No fluid sprays from the gun The equipment is covered with fluid Dirty air cap 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 pressure; use the least air pressure needed for good results. Do not reduce below minimum pressure needed for full voltage. See page 18. The fluid is thinned too much. Properly thin the fluid.
Electrical Tests WARNING ELECTRIC SHOCK HAZARD Follow the Fluid Voltage Discharge and Grounding Procedure on page 16 before checking or servicing and whenever you are instructed to discharge the voltage to ensure the voltage is discharged and avoid serious injury from an electric shock. Use the megohmmeter (A), part no. 218979, and an applied voltage of 500 volts to complete these electrical tests. Connect the leads as shown.
Electrical Tests Test Power Supply Resistance Test Resistor Stud Resistance 1. Prepare the gun for service as instructed on page 30. 1. Prepare the gun for service as instructed on page 30. 2. Remove the resistor stud (22) 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.
Service Tools Included with the Gun Multi-tool Ball-end Wrench 2 mm Hex Key Allen Wrench Prepare the Gun for Service WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 16 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure. NOTE: 1. Discharge the voltage as instructed on page 16. Check all the possible remedies in Troubleshooting before disassembling the gun. 2.
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. WARNING 8. Tighten the retaining nut (8) until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand. Apply a very light coat of lubricant to the o-ring (25). Tighten the nozzle (21) hand-tight, then 1/8 to 1/4 turn more.
Service Electrode Needle Replacement Apply low-strength (purple) Loctite or equivalent to the fluid rod threads, then install the electrode needle (20). 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.
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. To avoid voltage loss and possible barrel damage, preventative maintenance of the fluid packing assembly must be performed at regular intervals.
Service Fluid Packing Rod Removal and Repair (continued) 11. Lubricate the o-ring (28g). 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. 12. Make sure the spring (30) is installed against the nut (U) as shown in Fig. 20. 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 (28a), in the direction shown in Fig. 20.
Service 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. Apply a very light coat of lubricant to the o-rings (43e) and adjusting screw (43c) threads. Apply PTFE paste to the valve housing (43d) threads and tighten the housing into the handle to 10–12 in-lb (1.1–1.4 N m). DETAIL 43d 43b 43c 43e 2.
Service 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). 8. Carefully apply low strength (purple) Loctite or equivalent thread sealant to the sleeve (45d) external threads. Turn the sleeve in with the sleeve stop (45e) until it is bottomed out, then back it out 1/8 turn.
Service Atomizing Air Valve Repair Apply PTFE paste to the fan air valve housing threads; Torque to 10–12 in-lb (1.1–1.4 N m) 1. Prepare the gun for service as instructed on page 30. 31 19 2. Remove the fan air adjustment valve (43) as instructed on page 35. CAUTION 43 To avoid damaging the atomizing air valve, the fan air adjustment valve must be removed before removing the atomizing air valve. 3. Remove the atomizing air valve (31) and o-ring (19). See Fig. 23. 4.
Service 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. 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.
Service Barrel Removal 78 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 ballend wrench (63). 3 4. Hold the gun handle (7) with one hand and pull the barrel (3) straight away from the handle to remove it. Be prepared to catch the nut (78). See Fig. 26.
Service 5. Inspect the power supply cavity in the handle for dirt or moisture. Clean out the cavity with a clean, dry rag to avoid a loss in electrostatic performance. Power Supply Replacement 1. Prepare the gun for service as instructed on page 30. 2. Remove the barrel as instructed on page 39. 6. Lightly lubricate the o-rings (18b, 37a) on the power supply with petroleum jelly. CAUTION CAUTION Be careful when handling the power supply to avoid damaging it. 3. Grasp the power supply with your hand.
Service 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. Place the barrel (3) over the power supply (18) and onto the gun handle (7). Make sure the fluid needle spring (30) is seated properly, and align the fluid inlet tube (75) with the bracket port. Slide the nut (78) onto the end of the fluid inlet tube. 4.
Service Graco Waterborne Fluid Hose Repair WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD To reduce the risk of a fire, explosion, or electric shock: 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 discharge the voltage. Clean all the parts with a non-flammable fluid as defined on the front cover of this manual.
PRO 3500sc Gun Conversion NOTE: See page 48 to order the conversion kit, part no. 223114. The fluid hose and air hose are not included 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. 6. Unscrew and remove the electrode needle (J) with the electrode tool. Be careful not to damage the contact wire.
PRO 3500sc Gun Conversion H Z P 8* L D M *80 28* *81 20* E 91 *75 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) threads. Torque the fitting to 35 to 45 in-lbs (4 to 5.1 N m). F *78 *76 *79 *77 N Fig.
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. 11. Press the exhaust tube (E) onto the barbed adapter on the bottom of the gun handle. Secure the tube with the clamp (F). 7. Screw the fluid inlet tube (75*) into the barrel inlet until it bottoms out. 12. Test the gun resistance as instructed on page 28. a. Apply dielectric grease (82) to the O.D. threads of the fluid inlet tube (75*).
Spray Gun Parts Item 18 includes 18a–18f 28a Item 28 includes 28a and 28h See Detail A Item 37 includes 37a–37b Item 43 includes 43b–43e 20 Item 45 includes 45a–45e 25* 28 22 37 21 2 18e 1 18d 18 8 **37a 18c 37b 18b** 18a** **34 35 45c 18f 43c 23** 43e** 5 43d 43b 3 45b 44 4 31 45e 39 19** 45a 24 41** 45d 13 6 30 *80 *81 7 36 15 19 42** 40 32 47 26 38 46 33 75 17 66 67 28d* 28b 28g* 91 DETAIL 78 28h* 28e* 28c 28f* 76 79 77 05165B 46 308584
Spray Gun Parts 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. No. Part No.
Accessories Use Only Genuine Graco Parts and Accessories Waterborne Fluid Hose Assembly PRO 3500sc Gun Conversion Kit 223114 100 psi (0.7 MPa, 7 bar) Maximum Working Pressure To connect between the Graco H2O PRO Voltage Block and the gun; 0.25 in. (6.35 mm) ID; PTFE Fluid Hose Assy. Part No. Hose Length 237924 25 ft. (7.6 m) 237925 36 ft. (11 m) 237926 50 ft. (15.3 m) Waterborne Fluid Hose Replacement Parts Ref. No. Part No.
Accessories 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; 0.01–2000 megohms. Not for use in Hazardous areas. Gun Cover 180209 Order Part No. 218374 for package of 10. Gun Holster 236090 Mount the gun holster to the side of the spray booth. Hang gun in holster while the voltage discharges.
N 50 308584
Technical Data Category Data Category Data Weight 1.87 lb (0.85 Kg) Wetted Parts Gun Length 9.5 in. (240 mm) Maximum Working Pressure 100 psi (0.7 MPa, 7 bar) Stainless Steel, Brass, Nylon, Acetal, PTFE, Fluoroelastomer, PTFE High Molecular Weight Polyethylene, Ceramic 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) Voltage Output 0–65 kV* Air Inlet 1/4 npsm(m) L.H.
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 defective.
