Graco 3A2497BPro- User Manual

Gun Overview Gun Overview How the Electrostatic AA Spray Gun Works This is not an air spray gun. To help prevent serious injury from pressurized fluid, such as skin injection, and splashing fluid, read and follow the Skin Injection Hazard Warnings on page 5. The air-assisted spray gun combines airless...

Gun Overview Smart Guns The Smart Gun module displays spraying voltage, current, alternator speed, and the voltage setting (low or high). It also allows the user to change to a lower spraying voltage. The module has two modes:• Operating Mode• Diagnostic Mode Operating Mode Bar Graph See Fig. 2, and...

Gun Overview Error Display If the Smart module loses communication with the power supply, the Error display appears, the Hz indicator turns red, and the Smart module is disabled. See Fig. 3, and Table 1 on page 11. This can occur in Operating Mode or Diagnostic Mode. See Electrical Troubleshooting, ...

Gun Overview Diagnostic Mode Diagnostic Mode includes four screens which display gun data:• Voltage (kiloVolts) Screen• Current (microAmperes) Screen• Alternator Speed (Hertz) Screen• Low Voltage Lock ScreenNOTE: You must be in Operating Mode to adjust the low voltage setting; the setting is not adj...

Gun Overview Alternator Speed (Hertz) Screen The Alternator Speed (Hertz) Screen is the third screen in the Diagnostic Mode. See Fig. 8, and Table 1 on page 11. To enter this screen, press the LO SET button while in the Current (microAmperes) Screen.This screen displays the alternator speed as a 3 d...

Installation Installation System Requirements A Graco voltage isolation system must have the following features:• An isolation enclosure that prevents persons from making contact with the high voltage components before the system voltage is discharged. All components of the isolation system that are...

Installation Air Supply Line 1. See Fig. 12. Install an air line filter/water separator (M) 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. The WB3000 system includes...

Installation Connect the Waterborne Fluid Hose Always use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun fluid inlet.Before connecting the waterborne fluid hose to the gun, blow it out with air and flush with water to remove contaminants. Flush the gun before ...

Installation Agitator Kit Accessory To add an agitator to the Graco isolation system, order Part No. 245895. See 245895 Agitator Kit, page 75 , for the kit parts list.1. Discharge the system voltage (see Fluid Voltage Discharge and Grounding Procedure, page 25 ). 2. Relieve the pressure (see Pressur...

Gun Setup Gun Setup Grounding When operating the electrostatic gun, any ungrounded objects in the spray area (people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock. Ground all equipment,...

Gun Setup Check Gun Electrical Grounding Megohmmeter Part No. 241079 (AA-see Fig. 14) 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:• The gun has been removed from the hazardous area; • Or all spraying dev...

Gun Setup 7. If the resistance is greater than 100 ohms, check the tightness of the ground connections and be sure the air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the air hose. 8. Using an ohmmeter (AA) measure the resistance between the cab...

Operation Operation Operating Checklist Check the following list daily, before starting the system. ⃞ All operators are properly trained to operate an electrostatic waterborne air-assisted spray system as instructed in this manual. ⃞ All operators are trained in the Pressure Relief Procedure, page 2...

Operation Pressure Relief Procedure This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, ch...

Operation Fill the Fluid Supply 1. Follow the Fluid Voltage Discharge and Grounding Procedure, page 25 . 2. Follow the Pressure Relief Procedure, page 26 . 3. Open the isolated enclosure door.4. Remove the pail cover from the pail, holding a rag over the suction tube strainer to prevent any fluid fro...

Operation Adjust the Spray Pattern To reduce the risk of fire and explosion, fluids used must meet the following flammability requirements:• FM, FMc Approved: Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206. • CE-EN 5005...

Operation 16. Check that the ES indicator (Hz indicator on Smart guns) is lit, or check that the kV indicator on the isolated enclosure reads 30–50 kV. The actual spraying voltage for AA waterborne systems is 40–50 kV, but because the charging electrode does not directly contact the fluid, the voltag...

Maintenance Maintenance Flushing • Flush before changing fluids, before fluid can dry in the equipment, at the end of the day, before storing, and before repairing equipment. • Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary. • Flush with a non-flammable solve...

Maintenance Clean the Gun Daily 1. Turn OFF (O) the ES On-Off switch. 2. Discharge the system voltage. See Fluid Voltage Discharge and Grounding Procedure, page 25 . 3. Follow the Pressure Relief Procedure, page 26 . 4. Remove the air cap/tip guard and spray tip. 5. Flush the gun, see Flushing, page...

Maintenance Daily System Care 1. Follow the instructions under Clean the Gun Daily, page 33 . Follow the Pressure Relief Procedure, page 26 . 2. Clean the fluid and air filters. 3. Check for fluid leaks. Tighten all fittings.4. Clean workpiece hangers. Use non-sparking tools. 5. Check the movement of th...

Electrical Tests Electrical Tests Use the following procedures to test the condition of the power supply and gun body, and electrical continuity between components. NOTICE The gun body resistor cartridge is part of the body and is not replaceable. To avoid destroying the gun body, do not attempt to ...

Electrical Tests Test Power Supply Resistance 1. Remove the power supply (11). See Power Supply Removal and Replacement, page 52 . 2. Remove the alternator (15) from the power supply. See Alternator Removal and Replacement, page 53 . 3. Measure resistance from the power supply's ground strips (EE) t...

Electrical Tests Test Gun Barrel Resistance 1. Insert a conductive rod (B) into the gun barrel (which was removed for the power supply test) and against the metal contact (C) in the front of the barrel. 2. Measure the resistance between the conductive rod (B) and the conductive ring (9). The resista...

Electrical Tests Test Ground Strip Resistance Using an ohmmeter, measure the resistance between the latch housing (206) and the ground lug (214). The ground strip is grounded through the cart back to the ground lug. Resistance must be less than 100 ohms. If greater than 100 ohms, replace the ground ...

Troubleshooting Troubleshooting 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.Follow the Fluid Voltage Disc...

Troubleshooting Visual Checks First, check the system for any visible faults or errors to help isolate whether the spray gun, fluid hose or voltage isolation system has failed. A voltage probe and meter, part no. 245277, is helpful for diagnosing voltage problems and is required for some of the troub...

Troubleshooting Tests If you still have no voltage, separate the spray gun and hose from the voltage isolation system and check whether the gun and hose alone will hold voltage with the following test.1. Flush the system with water and leave the lines filled with water. 2. Discharge the system voltag...

Troubleshooting Spray Pattern Troubleshooting NOTE: Some spray pattern problems are caused by the improper balance between air and fluid. Problem Cause Solution No fluid. Refill supply. Fluttering or spitting spray. Air in fluid supply. Check fluid source. Refill. Fluid buildup; partially plugged tip. Cle...

Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Atomizing air pressure too high. Close atomizing air valve part way, or decrease air pressure as low as possible; minimum 45 psi (0.32 MPa, 3.2 bar) needed at gun for full voltage. Excessive spray fog. Fluid too thin. Increase visc...

Troubleshooting Electrical Troubleshooting Problem Cause Solution ES On/Off switch is OFF (O). Turn ON (I). Gun air pressure too low (ES indicator is amber). Check air pressure to gun; minimum 45 psi (0.32 MPa, 3.2 bar) needed at gun for full voltage. Atomizing air pressure too high. Decrease. Fluid...

Repair Repair Prepare the Gun for Service Installing and repairing 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. To reduce the risk of ...

Repair Air Cap, Spray Tip, and Fluid Seat Housing Replacement 1. See Prepare the Gun for Service, page 47 . 2. Remove the retainer ring (22) and air cap/tip guard assembly (25). Figure 22 Remove Air Cap 3. Disassemble the air cap assembly. Check the condition of the u-cup (22a), o-ring (25b), and ti...

Repair NOTICE Do not overtighten the fluid seat housing (24). Overtightening may damage the housing and the gun barrel, resulting in improper fluid shutoff. 6. Trigger the gun and install the fluid seat housing (24). Tighten until snug, then 1/4 turn more. 7. Check that the spray tip gasket (27a) is in...

Repair Gun Barrel Removal 1. See Prepare the Gun for Service, page 47 . 2. Remove the air inlet fitting (21) and take the bracket (B) off the gun handle (16). 3. Loosen the two screws (6). NOTICE To avoid damaging the power supply (11), pull the gun barrel straight away from the gun handle. If necess...

Repair Fluid Needle Replacement 1. See Prepare the Gun for Service, page 47 . 2. Remove the air cap assembly and fluid seat housing. See Air Cap, Spray Tip, and Fluid Seat Housing Replacement, page 48 . 3. Remove the gun barrel. See Gun Barrel Removal, page 50 . 4. Remove the trigger screws (13) and ...

Repair Power Supply Removal and Replacement • Inspect the gun handle power supply cavity for dirt or moisture. Clean with a clean, dry rag. • Do not expose gasket (5) to solvents.1. See Prepare the Gun for Service, page 47 . 2. See Gun Barrel Removal, page 50 . NOTICE Be careful when handling the po...

Repair Alternator Removal and Replacement NOTE: Replace alternator bearings after 2000 hours of operation. Order Part No. 24N706 Bearing Kit. Parts included in the kit are marked with a symbol (♦).1. See Prepare the Gun for Service, page 47 . 2. Remove the power supply/alternator assembly and discon...

Repair Fan Air Adjustment Valve Repair 1. See Prepare the Gun for Service, page 47 . 2. Place a wrench on the flats of the valve assembly (30) and unscrew it from the handle (16).NOTE: You may replace the valve as an assembly (go to step 9 ) or as individual parts (steps 3 - 9 ). 3. Remove the retain...

Repair ES On-Off Valve Repair 1. See Prepare the Gun for Service, page 47 . 2. Loosen the captive screw (26p). Remove the valve (26) from the handle. 3. Lubricate the o-rings (26b* and 26g*) with non-silicone grease, Part No. 111265. Do not over-lubricate.NOTE: Do not over-lubricate parts. Excessive...

Repair Air Valve Repair 1. See Prepare the Gun for Service, page 47 . 2. See Gun Barrel Removal, page 50 . 3. Remove the screws (13) and trigger (12).4. Remove the ES On-Off Valve. See ES On-Off Valve Repair, page 56 . 5. Remove the spring (2).6. Push on the front of the air valve shaft to force it ...

Repair Smart Module Replacement If the Error display appears, the Smart Module has lost communication with the power supply. Check for good connections between the Smart Module and the power supply.If the module’s LEDs are not lighting, replace the module.1. See Prepare the Gun for Service, page 47 ...

Repair Air Swivel and Exhaust Valve Replacement 1. See Prepare the Gun for Service, page 47 . 2. To replace the air exhaust valve: a. Remove the clamp (36) and the exhaust tube (35). b. Unscrew the swivel (21) from the gun handle (16). The swivel is a left-hand thread. Move the bracket out of the wa...

Parts Parts Standard Air-Assisted Spray Gun Assembly Part No. H60T18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61 Part No. 24M508 Unshielded Waterborne Fluid Hose (101), sold separately 60 3A2497B

Parts Smart Air-Assisted Spray Gun Assembly Part No. H60M18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61 Part No. 24M508 Unshielded Waterborne Fluid Hose (101), sold separately 62 3A2497B

Parts Isolation Enclosure Part No. 24N550 Waterborne Isolation Enclosure, for use with unshielded waterborne fluid hose; includes items 201–286 64 3A2497B

Parts Alternator Assembly Part No. 24N664 Alternator Assembly Ref. No. Part No. Description Qty 15a 24N705 COIL, alternator 1 15b♦ 24N706 BEARING KIT (includes two bearings, item 15e fan, and one item 15h clip) 1 15d♦ 24N707 HOUSING; includes item 15f 1 15e♦ — — — FAN; part of item 15b 1 Ref. No. Pa...

Parts ES On-Off Valve Assembly Part No. 24N632 ES On-Off Valve Assembly Ref. No. Part No. Description Qty 26a — — — HOUSING, valve 1 26b* 15D371 O-RING 2 26c — — — PISTON, valve 1 26d 24N650 LEVER, ES on-off; includes item 26e 1 Ref. No. Part No. Description Qty 26e — — — SCREW, set, socket head 2 2...

Parts Fan Air Valve Assembly Part No. 24N634 Fan Air Valve Assembly Ref. No. Part No. Description Qty 30a — — — NUT, valve 1 30b — — — STEM, valve 1 30c* 111504 O-RING 1 30d 24N646 RING, retaining; package of 6 1 * These parts are included in Air Seal Repair Kit 24N789 (purchase separately).Parts la...

Parts Air Cap Assembly Part No. 24N727 Air Cap Assembly Ref. No. Part No. Description Qty 25a 24N643 ELECTRODE; package of 5 1 25b 24N734 O-RING; ptfe; package of 5 (also available in package of 10; order 24E459) 1 25c — — — AIR CAP 1 25d 24N726 GUARD, tip, orange 1 Parts labeled — — — are not avail...

Spray Tip Selection Chart Spray Tip Selection Chart AEM Fine Finish Spray Tips Recommended for high finish quality applications at low and medium pressures. Order desired tip, Part No. AEMxxx, where xxx = 3–digit number from the matrix below. Fluid Output fl oz/min (l/min) Maximum Pattern Width at 12 ...

Spray Tip Selection Chart AEF Fine Finish Pre-Orifice Spray Tips Recommended for high finish quality applications at low and medium pressures. AEF tips have a pre-orifice that assists in atomizing sheer thinning materials, including lacquers.Order desired tip, Part No. AEFxxx, where xxx = 3–digit numbe...

Repair Kits, Related Manuals, and Accessories Repair Kits, Related Manuals, and Accessories Gun Part No. Description Manual Description Repair Kits Repair Kit Description 24N789 Air Seal Repair Kit All guns in this manual. 60 kV Waterborne Air-Assisted Spray Guns Electrostatic Waterborne Air-Assiste...

Repair Kits, Related Manuals, and Accessories Hoses Grounded Air Hoses 100 psi (0.7 MPa, 7 bar) Maximum Working Pressure 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread Part No. Description Grounded Air Hose with stainless steel braid ground path (Red)235068 6 ft (1.8 m) 235069 15 ft...

Dimensions Dimensions Figure 45 Gun Model A, in. (mm) B, in. (mm) C, in. (mm) Weight without bracket, oz (g) H60T18 10.7 (272) 8.9 (226) 2.4 (61) 22.0 (623) H60M18 10.8 (274) 9.6 (244) 2.4 (61) 24.4 (692) 76 3A2497B

Technical Data Technical Data Electrostatic Air—Assisted Spray Waterborne Guns U.S. Metric Maximum Working Fluid Pressure 3000 psi 21 MPa, 210 bar Maximum Working Air Pressure 100 psi 0.7 MPa, 7.0 bar Minimum Air Pressure at Gun Inlet 45 psi 0.32 MPa, 3.2 bar Maximum Fluid Operating Temperature 120°...

Graco Pro Xp Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warran...