Graco 3500WB - Manual

308584 5 WARNING INSTRUCTIONS EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and resultin a serious injury. This equipment is for professional use only. Read all the instruction manuals, tags, and labels before operating the equipment....

6 308584 Introduction Spraying Waterborne FluidsElectrostatically The PRO 3500wb spray gun is a 60 kV electrostaticspray 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 ...

8 308584 Introduction Graco Waterborne Fluid Hose (purchasedseparately) A Graco waterborne fluid hose must be used betweenthe voltage isolation system fluid outlet and the spraygun fluid inlet. This fluid hose consists of three layers(see Fig. 2): Inner Hose Layer (EE): is a PTFE tube. Conductive Ho...

308584 9 Installation Installing the System WARNING ELECTRIC SHOCK HAZARDInstalling and servicing this equipmentrequires access to parts which couldcause an electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unlessyou are trained an...

10 308584 Installation KEY-Fig. 3 A Air Regulator B Spray Gun Air Shut-off Valve 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 W...

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 canruin the appearance of your finished workpieceand can cause the gun to malfunction. 2. I...

12 308584 Installation Filter the Fluid Filter the fluid to remove coarse particles and sedimentwhich could clog the fluid nozzle. The filter must beinstalled at the grounded fluid inlet to the voltageisolation system. Connect the Fluid Hose NOTE: A Graco waterborne fluid hose must be usedbetween th...

14 308584 Installation Ground the System WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARDWhen operating the electrostatic device,any ungrounded objects in the sprayarea (such as people, containers, tools,etc.) can become electrically charged.Improper grounding can result in staticsparking, which c...

308584 15 Installation Check the Electrical Grounding 1. Have a qualified electrician check the electricalgrounding continuity of the spray gun and air hose. 2. Make sure the red Graco electrically conductive airhose (EE) is connected to the gun and the hoseground wire is connected to a true earth g...

16 308584 Operation Fluid Voltage Discharge and GroundingProcedure WARNING ELECTRIC SHOCK HAZARDThe high voltage fluid supply is chargedwith 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 sho...

308584 17 Operation Operating Checklist Check the following list daily, before starting to operatethe system, to help ensure safe, efficient operation. ____ 1. All the operators are properly trained to safely operate an electrostatic, waterborne, air spraysystem as instructed in this manual and thev...

18 308584 Operation Operating the Spray Gun WARNING FIRE AND EXPLOSION HAZARDTo reduce the risk of fire and explosion,only use this equipment to spray non-flammable, waterborne fluids as definedon the front cover of this manual. WARNING ELECTRIC SHOCK HAZARDContact with the charged components ofthe ...

308584 19 Operation 7. Set the atomizing air valve (R) about 1.5 turns outfor most applications. The Atomizing Air ValveAdjustment 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 Valve Adjust...

20 308584 Operation Shutdown WARNING PRESSURIZED EQUIPMENT HAZARDTo reduce the risk of an injury, follow the PressureRelief Procedure on page 16 whenever you stopspraying and whenever you are instructed torelieve pressure. 1. Relieve the pressure. 2. Flush and clean the equipment. Follow the instruc...

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 fluidnozzle holes as this could scratch them, and makesure the electrode wire is not damaged. Scratches inthe air cap or n...

22 308584 Troubleshooting WARNING ELECTRIC SHOCK HAZARDInstalling and servicing this equipmentrequires access to parts which maycause an electric shock or other serious injury if the work is not performed properly. Do notinstall or service this equipment unless you aretrained and qualified. Follow t...

308584 23 Troubleshooting Voltage Loss Troubleshooting (continued) 7. To eliminate air gaps in the fluid column, sprayenough fluid to purge the air out between thevoltage isolation system and the spray gun. An airgap in the fluid hose can break the electricalcontinuity between the spray gun and the ...

24 308584 Troubleshooting Voltage Loss Troubleshooting (continued) 11. 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 outerjacket, which may indicate a pin-hole leakthrough...

308584 25 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 thefluid supply. The fluid noz...

26 308584 Troubleshooting Poor Electrostatic Wrap Troubleshooting Problem Cause Solution The system is holding voltage butthere is poor electrostatic wrap on The distance between the gun andworkpiece is incorrect. Adjust the spraying distance to 8 to12 inches (203 to 305 mm). the part being sprayed ...

308584 27 Troubleshooting Gun Operation Troubleshooting (continued) Excessive spray fog The air pressure is too high. Reduce the air cap air pressure byclosing the atomizing air valve moreor decreasing the gun air inlet pres-sure; use the least air pressureneeded for good results. Do not re-duce bel...

28 308584 Electrical Tests WARNING ELECTRIC SHOCK HAZARDFollow the Fluid Voltage Dischargeand Grounding Procedure on page 16before checking or servicing and when- ever you are instructed to discharge the voltage toensure the voltage is discharged and avoid seriousinjury from an electric shock. WARNI...

308584 29 Electrical Tests Test Power Supply Resistance 1. Prepare the gun for service as instructed onpage 30. 2. Remove the power supply (18) from the gunhandle as instructed on page 40. 3. Remove the turbine alternator (37) from the powersupply as instructed on page 41. 4. Measure the resistance ...

30 308584 Service Tools Included with the Gun Multi-tool Ball-end Wrench 2 mm Hex Key Allen Wrench Prepare the Gun for Service NOTE: Check all the possible remedies in Troubleshoot -ing before disassembling the gun. If the plastic parts of the gun must be held in a vise,use padded vise jaws to avoid...

32 308584 Service Electrode Needle Replacement 1. Prepare the gun for service as instructed onpage 30. 2. Remove the air cap, nozzle and resistor stud asinstructed on page 30. 3. Unscrew and remove the electrode needle (20)with the multi-tool (62). See Fig. 18. Be careful notto damage the contact wi...

308584 33 Service Fluid Packing Rod Removal and Repair Preventative Maintenance CAUTION If the conductive fluid is allowed to leak through thepackings, it will eventually cause an electrical shortthrough the packings and along the gun barrel,resulting in a loss of voltage at the tip of the gun.Sever...

308584 35 Service Fan Air Adjustment Valve Repair NOTE: The fan air valve (43) can be replaced as anassembly or as individual parts. 1. Prepare the gun for service as instructed onpage 30. 2. Place a wrench on the flats of the valve housingand remove it from the handle. See Fig. 21. 3. If the parts ...

36 308584 Service Fluid Adjustment Assembly Repair(continued) 5. To remove the sleeve (45d), hold the cap (45c)and turn the sleeve stop (45e) counterclockwisewith a pliers. 6. Remove the stem (45a) and o-ring (45b). 7. Repair or replace any damaged parts. Lubricatethe o-ring (45b). 8. Carefully appl...

308584 37 Service Atomizing Air Valve Repair 1. Prepare the gun for service as instructed onpage 30. 2. Remove the fan air adjustment valve (43) asinstructed on page 35. CAUTION To avoid damaging the atomizing air valve, the fanair adjustment valve must be removed before remov-ing the atomizing air ...

38 308584 Service ES ON-OFF Valve Repair 1. Prepare the gun for service as instructed onpage 30. 2. Loosen the set screw (24) with the 2 mm hex key(69). Remove the lever (26) from the valve. SeeFig. 24. WARNING MOVING PARTS HAZARDTo reduce the risk of an eye injury, wearsafety glasses when removing ...

308584 39 Service Barrel Removal 1. Prepare the gun for service as instructed onpage 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...

40 308584 Service Power Supply Replacement 1. Prepare the gun for service as instructed onpage 30. 2. Remove the barrel as instructed on page 39. CAUTION Be careful when handling the power supply to avoiddamaging it. 3. Grasp the power supply with your hand. With agentle side to side motion, loosen ...

308584 41 Service Turbine Alternator Replacement NOTE: Replace turbine bearings after 2,000 hours ofoperation. See your authorized Graco representative. 1. Prepare the gun for service as instructed onpage 30. 2. Remove the barrel as instructed on page 39. 3. Remove the power supply as instructed onp...

42 308584 Service Graco Waterborne Fluid Hose Repair WARNING FIRE, EXPLOSION, AND ELECTRICSHOCK HAZARDTo reduce the risk of a fire, explosion, orelectric shock: Follow the Fluid Voltage Dischargeand Grounding Procedure on page16 and be sure the ES ON-OFF leveris turned to OFF before flushing,checkin...

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 theoutside 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 a...

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 DETAIL Item 18 includes 18a–18f Item 28 includes 28a and 2...

48 308584 Accessories Use Only Genuine Graco Parts and Accessories Waterborne Fluid Hose Assembly 100 psi (0.7 MPa, 7 bar) Maximum Working Pressure To connect between the Graco H 2 O 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...

308584 49 Accessories Use Only Genuine Graco Parts and Accessories Snap Ring Pliers 110090For removing the ES ON-OFF Valve Retaining Ring(item 47 in Parts List). Gun High Voltage Probe & Meter 217452For direct measurement of the gun output voltage. Megohmmeter 218979500 Volt output; 0.01–2000 me...

308584 51 Technical Data Category Data Weight 1.87 lb (0.85 Kg) Gun Length 9.5 in. (240 mm) Maximum WorkingPressure 100 psi (0.7 MPa, 7 bar) Air Pressure OperatingRange 0–100 psi (0–0.7 MPa,0–7 bar) Fluid Pressure OperatingRange 0–100 psi (0–0.7 MPa,0–7 bar) Voltage Output 0–65 kV* Air Inlet 1/4 nps...