Graco HydroShield WABH00 Parts list manual

Instructions-Parts
HydroShield™ HydroShield™
HydroShield™Automatic Automatic AutomaticAir Air Air- - -Assisted Assisted Assisted
Batch Batch
BatchWaterborne Waterborne WaterborneIsolation Isolation IsolationSystems Systems Systems3A8492A
EN
Air Air
Air- - -assisted assisted assistedspray spray spraysystem system systemfor for foruse use usewith with withautomatic automatic automaticelectrostatic electrostatic electrostaticapplicators applicators applicatorswhen when whenspraying spraying sprayingconductive, conductive, conductive,
waterborne waterborne
waterborne󰘱uids 󰘱uids 󰘱uidsthat that thatmeet meet meetat at atleast least leastone one oneof of ofthe the theconditions conditions conditionsfor for fornon non non- - -󰘱ammability 󰘱ammability 󰘱ammabilitylisted listed listedon on onpage page page4. 4. 4.To To Tobe be be
used used
usedin in ina a apermanent permanent permanentlocation. location. location.Not Not Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or orhazardous hazardous hazardous(classi󰘰ed) (classi󰘰ed) (classi󰘰ed)
locations. locations.
locations.For For Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinthespray
gunmanualbeforeusingtheequipment.Savetheseinstructions
100psi(0.7MPa,7.0bar)Maximum
FluidInletWorkingPressure.
3,000psi(20.7MPa,207bar)Maximum
FluidOutletWorkingPressure.
Seepage5formodelinformation.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals..................................................3
IsolationSystemOverview....................................4
HowtheIsolationSystemWorks.....................4
SprayingWaterborneFluids
Electrostatically................................4
Models.................................................................5
Warnings.............................................................6
ComponentIdenti󰘰cation.......................................9
TypicalInstallation..............................................10
OptionalMultipleGunInstallation.........................11
Installation..........................................................13
SystemRequirements..................................13
DisplayWarningSigns.................................13
InstallationLocation.....................................13
InstalltheSystem.........................................13
VentilatetheSprayBooth.............................13
MounttheCabinet........................................14
InstalltheLightTower..................................15
Grounding...................................................16
ConnecttheHoses......................................17
ConnecttheCANCables..............................22
ConnectthePowerSupply...........................24
InstalltheOptionalSystemStopPneumatic
InputKit.........................................24
WiretheSystemStopDigitalInput................25
InstalltheOptionalSystemStatus
Output...........................................26
WiretheLowPaintDigitalOutput..................27
ChecktheGroundingoftheSprayGunand
IsolationSystem.............................27
FlushtheEquipmentBeforeFirstUse...........28
Operation...........................................................29
OperationOverview.....................................29
FluidVoltageDischargeandGrounding
Procedure......................................29
PressureReliefProcedure............................30
FlushtheSystem(SystemswithoutColor
Change).........................................31
FlushtheSystem(ColorChangeEnabled
Systems)........................................32
PrimetheIsolationSystem...........................33
SpraywiththeIsolationSystem....................34
AdjusttheGunFluidSettings........................35
Shutdown....................................................35
ControlInterface.................................................36
MenuBar....................................................37
SoftKeyIcons.............................................37
NavigatetheScreen.....................................37
RunScreensandSetupScreens..................38
ControlInterfaceSetupandMaintenance.............39
EnableUSBData.........................................39
USBLogs....................................................39
SystemCon󰘰gurationSettingsFile................39
CustomLanguageFile.................................39
DownloadSystemData................................40
UploadSystemCon󰘰guration.......................41
CleantheScreenSurface.............................41
UpdatetheSystemSoftware........................41
RunMenus........................................................45
HomeScreen..............................................45
EventsScreen.............................................50
StatusScreens............................................50
SetupMenus......................................................52
Presets........................................................52
PurgeScreens1–5......................................53
PumpScreens.............................................54
AdvancedScreens.......................................55
CalibrateScreens........................................57
MaintenanceScreens...................................59
SystemScreen............................................66
Maintenance......................................................67
RoutineMaintenance...................................67
PreparetheSystemforService.....................68
CheckforFluidLeaks...................................68
ReplacetheWashFluid...............................69
CheckandLubricatetheGroundRod............69
ChecktheBleedResistor.............................70
ChecktheDoorSwitch.................................70
Troubleshooting..................................................71
GeneralTroubleshooting..............................71
LEDDiagnosticInformation..........................75
TroubleshootingtheControlInterface............75
VoltageLossTroubleshooting.......................76
TroubleshootingColorChangeSolenoid
Valves...........................................78
ErrorCodes........................................................81
Repair................................................................90
PreparetheIsolationSystemfor
Service..........................................90
ServicetheIsolationValve............................91
ServicetheIsolationFluidPump.................101
ServicetheElectricalControls....................106
PneumaticConnections..............................110
WiringConnections....................................112
ColorChange:PneumaticandWiring
Connections.................................114
Parts................................................................115
IsolationSystem........................................115
25N030IsolationValveParts......................120
25N031IsolationFluidPumpParts.............122
ElectronicControlParts.............................124
RepairKitsandAccessories..............................126
Accessories...............................................126
Kit26B400,SupplyPump...........................128
ColorChangeComponents........................129
IsolationValveKits.....................................133
PumpKits..................................................135
Performance....................................................136
IgnitabilityofCoatingMaterials..........................137
Dimensions......................................................138
Notes..............................................................139
23A8492A

RelatedManuals
TechnicalSpeci󰘰cations....................................140
CaliforniaProposition65...................................141
GracoStandardWarranty..................................142
Related Related
RelatedManuals Manuals Manuals
Manual Manual
Manualin in in
English English
English
Description Description
Description
333013ProXp™AutoWaterborneAASprayGun
309455TestFixture,HighVoltageProbe,andkVMeter
312782AirActuatedDispenseValve
312794Merkur®PumpAssembly
307273FluidOutletFilter
312783ColorandCatalystChangeValveStacks
3A1244GracoControlArchitecture™ModuleProgramming
3A8492A3

IsolationSystemOverview
Isolation Isolation
IsolationSystem System SystemOverview Overview Overview
How How
Howthe the theIsolation Isolation IsolationSystem System SystemWorks Works Works
WhenusingaHydroShieldAir-AssistedBatch
WaterborneIsolationSystem,the󰘱uidsupply
remainsgrounded.The󰘱uidsupplycanbeany
lowpressurepumporcirculationsystem.Thelow
pressure󰘱uidsupply󰘰rst󰘰llsaninternallowpressure
pumpreservoir,thatthenfeedsintoanisolated
MerkurAA󰘱uidpumptosendhighpressure󰘱uidto
thegun.Aftertheisolationsystemhas󰘰lledwith
paint,theisolationvalveseparatesandraises.This
allowsthe󰘱uidinsidetheisolationsystemtobecome
electrostaticallychargedwhenthegunistriggered.
Thecharged󰘱uidisattractedtothegrounded
workpiece,wrappingaroundandevenlycoatingall
surfaces.Whentheguntriggerisreleased,the
isolationpumpautomaticallyre󰘰lls.
Spraying Spraying
SprayingWaterborne Waterborne WaterborneFluids Fluids Fluids
Electrostatically Electrostatically
Electrostatically
Thisisolationsystemandelectrostaticair-assisted
gunaredesignedtosprayonly only
onlywaterborne󰘱uids
whichmeetatleastoneofthefollowing󰘱ammability
requirements:
•Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.
•CE-EN CE-EN
CE-EN50348 50348 50348Compliant: Compliant: Compliant:
Materialisclassi󰘰edasnon-ignitableasde󰘰nedby
EN50059:2018.
SeeIgnitabilityofCoatingMaterials,page137.
Whenanelectrostaticgunisconnectedtoavoltage
isolationsystem,allofthe󰘱uidinthespraygun,
󰘱uidhose,andisolated󰘱uidsupplyischargedto
highvoltage,whichmeansthatthesystemhas
moreelectricalenergythanasolvent-basedsystem.
Therefore,onlynon-󰘱ammable󰘱uids(asde󰘰ned
aboveandinModels,page5)canbesprayedwith
thesystemorbeusedtoclean,󰘱ush,orpurgethe
system.
Precautionsmustbetakenwhenusingelectrostatic
waterborneequipmenttoavoidpotentialshock
hazards.Whenthespraygunchargestheisolated
󰘱uidtohighvoltage,itissimilartocharginga
capacitororabattery.Thesystemwillstoresomeof
theenergywhilesprayingandretainsomeofthat
energyafterthespraygunisshutoff.Becauseit
takessometimeforthatstoredenergytodischarge,
itisimportanttoreadtheinstructions,includingthe
FluidVoltageDischargeandGroundingProcedure,
page29,andGrounding,page16,tounderstand
whenyoucanapproachortouchthegunnozzle.
Theamountoftimeittakestodischargethe
energydependsonthesystemdesign.Followthe
FluidVoltageDischargeandGroundingProcedure,
page29,beforeapproachingthefrontofthegun.
43A8492A

Models
Models Models
Models
Mustpurchasegunandhosesseparately.
Part Part
PartDescription Description DescriptionColor Color Colorchange change change
WABH00Isolationcabinetforautomaticairassistspray.
WABH02Isolationcabinetforautomaticairassistspray,equippedwithcolor
changeinletvalves.3
Condition Condition
Conditionfor for fornon non non- - -󰘱ammability: 󰘱ammability: 󰘱ammability:
Models Models
Modelsare are arecompliant compliant compliantwith with withCE CE CE- - -EN EN EN50348 50348 50348when when whenused used usedwith with with󰘱uids 󰘱uids 󰘱uidsthat that thatmeet meet meetthe the thefollowing following followingcriteria: criteria: criteria:
•Material Material
Materialis is isclassi󰘰ed classi󰘰ed classi󰘰edas as asnon non non- - -ignitable ignitable ignitableas as asde󰘰ned de󰘰ned de󰘰nedby by byEN EN EN50059: 50059: 50059:2018. 2018. 2018.
Formoreinformation,seeIgnitabilityofCoatingMaterials,page137.
*Systemswithcolorchangeinletvalvesinstalledincludesix󰘱uidvalveswhichallowtheuseofthreecolors
andpurgesequences.Thesesystemsarealsoequippedfordumpvalveoperation.Seethecolorchangekit
informationinAccessories,page126.
3A8492A5

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Combustibledustor󰘱ammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanignite
orexplode.Tohelpprevent󰘰reandexplosion:
•Fluidsusedmustmeettheappropriate󰘱ammabilityrequirements:
•MaterialdoesnotsustainburninginaccordancewiththeStandardTestMethodfor
SustainedBurningofLiquidMixtures,ASTMD4206.
•CE CE
CE- - -EN EN EN50348 50348 50348Compliant: Compliant: Compliant:
Materialisclassi󰘰edasnon-ignitableasde󰘰nedbyEN50059:2018.
•Electrostaticequipmentmustbeusedonlybytrained,quali󰘰edpersonnelwhounderstand
therequirementsofthismanual.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.
•Useandcleanequipmentonlyinwellventilatedarea.
•Interlockthegunairsupplytopreventoperationunlessventilationair󰘱owisabovethe
minimumrequiredvalue.
•Onlyusenon-󰘱ammablesolventswhen󰘱ushingorcleaningequipment.
•Donotusepaillinersunlesstheyareconductiveandgrounded.
•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Keepaworking󰘰reextinguisherintheworkarea.
63A8492A

Warnings
WARNING WARNING
WARNING
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock:
•Turnoffanddisconnectpowercordbeforeservicingequipment.
•Connectonlytogroundedelectricaloutlets.
•Useonly3-wireextensioncords.
•Ensuregroundprongsareintactonpowerandextensioncords.
•Donotexposetorain.Storeindoors.
•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorclose
tosprayarea.SeeGrounding Grounding
Groundinginstructions.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
•FollowtheFluid Fluid
FluidVoltage Voltage VoltageDischarge Discharge Dischargeand and andGrounding Grounding GroundingProcedure Procedure Procedurewheninstructedtodischarge
thevoltage;beforecleaning,󰘱ushing,orservicingthesystem;beforeapproachingthefrontof
thegun;andbeforeopeningtheisolationenclosurefortheisolated󰘱uidsupply.
•Donottouchthegunnozzleorelectrode,orcomewithin4in.(102mm)oftheelectrode
duringgunoperation.FollowtheFluid Fluid
FluidVoltage Voltage VoltageDischarge Discharge Dischargeand and andGrounding Grounding GroundingProcedure Procedure Procedure.
•Donotsplicehosestogether.InstallonlyonecontinuousGracowaterborne󰘱uidhose
betweentheisolated󰘱uidsupplyandthespraygun.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinch,cutoramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Equipmentcanstartwithoutwarning.Beforechecking,moving,orservicingequipment,
followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay
looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Getimmediate immediate immediatesurgical surgical surgical
treatment. treatment.
treatment.
•Donotpointdispensingdeviceatanyoneoratanypartofthebody.
•Donotputyourhandoverthe󰘱uidoutlet.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopdispensingandbeforecleaning,
checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
3A8492A7

Warnings
WARNING WARNING
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.
Forcompleteinformationaboutyourmaterial,requestaSafetyDataSheets(SDSs)from
yourdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
PLASTIC PLASTIC
PLASTICPARTS PARTS PARTSCLEANING CLEANING CLEANINGSOLVENT SOLVENT SOLVENTHAZARD HAZARD HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.
•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.
•SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanualsformaterialsofconstruction.Consult
thesolventmanufacturerforinformationandrecommendationsaboutcompatibility.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheets(SDSs)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewearandhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
83A8492A

ComponentIdentication
Component Component
ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
Figure1ComponentsoftheautomaticAutomaticAir-AssistedIsolationSystem
Key Key
Key
Item Item
ItemDescription Description Description
AAirInlet
CControlInterface
CCColorChangeModule(oncolorchange
enabledsystems)
EFluidOutlettoGun
FFluidInlet
GIsolationValve
JFluidInletValve
KIsolationFluidPump
Item Item
ItemDescription Description Description
LMerkurAAFluidPump
MElectronicsPanel
NGroundRodandBleedResistor
PPowerSupply
RHand-heldGroundedRod
VSColorChangeValveStack(oncolor
changeenabledsystems)
WWashFluidBottle
ZFluidFilter(100mesh)
3A8492A9

TypicalInstallation
Typical Typical
TypicalInstallation Installation Installation
Figure2TypicalInstallation,AutomaticAir-AssistedWaterborneIsolationSystem,Non-HazardousLocation
Key Key
Key
Item Item
ItemDescription Description Description
AB†BleedTypeAirValve
AM†MainAirSupplyLine
AS†OilSeparator
AVvAirShut-offValve
CAIsolationCabinet
FS†FluidSupplyLine
FVvFluidShut-offValve
Item Item
ItemDescription Description Description
GCGroundWire
HWGracoWaterborneFluidHose
LTLightTower
PCPowerCord
†Required,notsupplied.
vOptional,notsupplied.
103A8492A

OptionalMultipleGunInstallation
Optional Optional
OptionalMultiple Multiple MultipleGun Gun GunInstallation Installation Installation
Chargedcomponents,suchasguns,regulators,
andmanifolds,maycauseelectricshock,󰘰re,or
explosion.Isolateallchargedcomponentsand
jointsinthehosetopreventinjuryorequipment
damage.SeeSystemRequirements,page13.
TheautomaticversionoftheHydroShieldcan
beusedwithupto4applicators(ME).Asingle
waterborne󰘱uidhose(HW)comesoutofthe
systemandthensplitsintoindividualhosestoeach
applicator.
Anylocationwherethereisajointinthewaterborne
󰘱uidhosemustbeelectricallyisolatedfromall
groundedobjects.Chargedcomponents,suchas
󰘱uidregulators(L)intheexample,shouldbeinstalled
inanenclosureorlocationthatpreventsusersfrom
comingincontactwithchargedcomponentsany
timeelectrostaticsareinuse.Itisuptotheperson
installingthesystemtoaccomplishthis.
Minimizethetotallengthofthe󰘱uidhoseasmuch
aspossible.Thishelpsreduce󰘱uidpressuredrop
totheapplicatorandlowersthedischargeenergy
ofthesystem.
TheHydroShieldonlyhasonesetofpainttrigger
andelectrostaticinputsandoutputs.Connectall
painttriggersignallinestogetherbeforeconnecting
tothesystem.Thesameshouldbedonewiththe
electrostaticrequestandenablesignals.Whenone
applicatorisoperating,allapplicatorsareassumed
tobeoperating.Thesameistrueregardingcharged
componentsastheyareallelectricallyconnectedby
theconductivewaterborne󰘱uid.
Figure3MultipleGunInstallationExample
3A8492A11

OptionalMultipleGunInstallation
Figure Figure
Figure3 3 3Key Key Key
Item Item
ItemDescription Description Description
HWGracoWaterborneFluidHose
LFluidPressureRegulator
MEElectrostaticApplicator
MIIsolatedRegion
MMFluidManifold
123A8492A

Installation
Installation Installation
Installation
System System
SystemRequirements Requirements Requirements
Theuseofmultiplegunswithoneisolation
cabinetincreasestheriskofelectricshock,󰘰re,
orexplosion.Whenonegunischargedallguns
arecharged.Besureallgunsareinasafe
operatingzonewhenvoltageisapplied.See
OptionalMultipleGunInstallation,page11.
TheGracovoltageisolationsystemhasthefollowing
features:
•Anisolationcabinetthatpreventspersonsfrom
makingcontactwiththehighvoltagecomponents
beforethesystemvoltageisdischarged.All
componentsoftheisolationsystemthatare
chargedtohighvoltagearecontainedwithinthe
cabinet.
•Ableedresistorthatdrainsoffthesystemvoltage
whenthespraygunisnotinuse.Allmetalparts
thatcontacthighvoltage󰘱uidareelectrically
connectedtothebleedresistor.
•Adoorswitchinterlockthatautomatically
dischargesthesystemvoltageanytimethe
isolationcabinetdoorisopen.
Note
TheGracowarrantyandapprovalsare
voidifanon-Gracoelectrostaticspraygun
orapplicatorisconnectedtothevoltage
isolationsystemorifthegunisoperated
above60kV.
Display Display
DisplayWarning Warning WarningSigns Signs Signs
Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.Each
Gracogun,soldseparately,includesawarningsign.
Installation Installation
InstallationLocation Location Location
Positiontheisolationsystemasclosetothespray
areaasfeasibletominimizethehoselengthtothe
gun.Minimizingthehoselengthminimizesthe
systemchargeanddischargetime.Positionthe
supplypumpascloseaspossibleforthefastest󰘰ll
time.Installinanon-hazardouslocation.
Install Install
Installthe the theSystem System System
Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.
•Donotinstallorservicethisequipmentunless
youaretrainedandquali󰘰ed.
•Complywithalllocalcodesandregulations.
The󰘰gureinTypicalInstallation,page10,shows
atypicalair-assistedwaterborneautomaticbatch
system.Itisnotanactualsystemdesign.
Ventilate Ventilate
Ventilatethe the theSpray Spray SprayBooth Booth Booth
Donotoperatethegununlessventilatingair󰘱owis
abovetheminimumrequiredvalue.Providefresh
airventilationtoavoidthebuildupof󰘱ammableor
toxicvaporswhenspraying,󰘱ushing,orcleaning
thegun.Interlockthegunairand󰘱uidsupply
topreventoperationunlessventilatingair󰘱owis
abovetheminimumrequiredvalue.
Thesprayboothmusthaveaventilationsystemthat
reliablycollectsandremovesoverspray.
Electricallyinterlockthegunairand󰘱uidsupplywith
theventilatorstopreventgunoperationanytimethat
theventilationair󰘱owfallsbelowminimumvalues.
Checkandfollowalllocalcodesandregulations
regardingairexhaustvelocityrequirements.Verify
theoperationoftheinterlockatleastonceayear.
Note
Highvelocityexhaustaircandecrease
theoperatingef󰘰ciencyoftheelectrostatic
system.
3A8492A13

Installation
Mount Mount
Mountthe the theCabinet Cabinet Cabinet
Toreducetheriskof󰘰reandexplosion,do
notinstallequipmentapprovedonlyfora
non-hazardouslocationinahazardouslocation.
Mountthecabinetonthewheels,onthewall,oron
the󰘱oor.
Alwaysuseproperequipment,suchasaforklift,to
moveorliftthesystem.
Install Install
Installthe the theOptional Optional OptionalWheels Wheels Wheels
Installwheelstohelpwithinstallation.
1.Withtwopeople,removethesystemfromthe
pallet.
2.Installthewheels(95),washers(96),andnuts
(97).Tightenthenutssecurely.
3.Installtheendplugs(3a,3b).
4.Whenthesystemisinthedesiredlocation,lock
allfourwheels.
Figure4WheelMountParts
Mount Mount
Mounton on onthe the theWall Wall Wall
Beforemountingtheisolationcabinettothewall,
makesurethatthewallcansupporttheweightofthe
system.SeeTechnicalSpeci󰘰cations,page140for
theweight.
1.Selectandattachtheappropriatemounting
hardwaretothestand.
2.Drillholesintothewallbasedontheselected
hardware.
Amountingholepatternisprovidedoneachside
oftheframe.
Figure5HolePatternforWallMounting
3.Withtwopeople,removetheisolationsystem
fromtheshippingpallet.
143A8492A

Installation
4.Removethefeet(3a,3b,3c)fromtheframe.
Figure6RemovingtheFrameFeet
5.Securethesystemtothewall.
Mount Mount
Mounton on onthe the theFloor Floor Floor
1.Usetheboltpatterntodrillholesintothe󰘱oor.
Figure7BoltPatternforFloorMounting
2.Withtwopeople,removetheisolationsystem
fromtheshippingpallet.
3.Securethesystemtothe󰘱oor.
Install Install
Installthe the theLight Light LightTower Tower Tower
Thesystemisequippedwithalighttowerwhich
indicateshowmuchpaintisintheisolation󰘱uid
pump(K)asit󰘰llsanddispenses.
1.Locatethelighttowerbracket(61)onthe
isolationcabinet(1).Usescrews(66),washers
(67),andnuts(68)tomountthelighttower(114)
ontothelighttowerbracket(61).
Thelighttowerbracketcanberemovedfromthe
isolationcabinetandinstalledinanotherlocation.
Ifrelocated,makesurethatthelighttoweris
installedinanon-hazardouslocationandthatthe
paintercanseeitfromthespraybooth.
Longerextensioncablesareavailable.See
Accessories,page126.
2.Connectthe.4mCANextensioncabletothelight
towerCANcable(114).
NOTE: NOTE:
NOTE:Useextensioncable121226.
3.ConnectthelighttowerCANcable(114)
tothecontroller(42)󰘰ttingsotheisolation
systemcancommunicatewiththelight.See
ConnecttheCANCables,page22.Longer
cablesareavailable.
3A8492A15

Installation
Grounding Grounding
Grounding
Theequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundallequipment,personnel,objects
beingsprayed,andconductiveobjectsinorclose
tothesprayarea.Theresistancemustnotexceed
1megohm.Groundingprovidesanescapewire
fortheelectriccurrent.
Whenoperatingtheelectrostaticgun,any
ungroundedobjects(suchaspeople,containers,and
tools)inthespraylocationcanbecomeelectrically
charged.
Thefollowingareminimumgroundingrequirements
forabasicelectrostaticsystem.Yoursystemmay
includeotherequipmentorobjectswhichmustbe
grounded.Yoursystemmustbeconnectedtoa
trueearthground.Checkgroundconnectionsdaily.
Checkyourlocalelectricalcodesandregulationsfor
detailedgroundinginstructions.
•
Isolationcabinet: Connectthesystemground
wiretoatrueearthground.Donotdisconnector
tamperwiththeinternalgroundwireconnections
insidethecabinet.Formoreinformation,see
TroubleshootingHydroShieldVoltage,page77.
Aftergroundingthesystem,checktheresistance
betweentheexterioroftheisolationcabinetand
atrueearthground.Theresistancemustbeless
than100ohms.
• Fluidsupply: Groundthe󰘱uidsupplybyconnecting
agroundwireandclamp.Seeyour󰘱uidsupply
instructionmanualforgroundinginstructions.
•
Powersupply: Thepowersupplyisgrounded
throughthepowercordtoagroundedoutlet.
•
Spraygun: Groundthegunaccordingtothespray
guninstructionmanual.
•
Waterborne󰘱uidhose: Thehosemustbedirectly
connectedtothe󰘱uidsupplyinsidethesystem.
•
Objectbeingsprayed: Keeptheworkpiecehangers
cleanandgroundedatalltimes.
• Allelectricallyconductiveobjectsordevicesin
thesprayarea: Theseitemsmustbeproperly
grounded.
• Fluidandwastecontainers: Groundall󰘱uidand
wastecontainersinthesprayarea.Donotusepail
linersunlesstheyareconductiveandgrounded.
When󰘱ushingthespraygun,thecontainerused
tocatchtheexcess󰘱uidmustbeelectrically
conductiveandgrounded.
• Aircompressors: Groundtheequipmentaccording
tothemanufacturer'srecommendations.
• Allairlines: Thesemustbeproperlygrounded.
Useonlygroundedhoseswithamaximumof100
feet(30.5m)combinedhoselengthtoensure
groundingcontinuity.
•
Floorofthesprayarea: The󰘱oormustbe
electricallyconductiveandgrounded.Donotcover
the󰘱oorwithcardboardoranynon-conductive
materialwhichwouldinterruptgroundingcontinuity.
163A8492A

Installation
• Allsolventpails: Useonlygroundedmetal
containers,whichareconductive.Donotuse
plasticcontainers.Useonlynon-󰘱ammable
solvents.Donotstoremorethanthequantity
neededforoneshift.
•Allpersonsenteringthesprayareamustwear
shoeshavingconductivesolessuchasleather,
orwearpersonalgroundingstraps.Donotwear
shoeswithnon-conductivesolessuchasrubber
orplastic.
Connect Connect
Connectthe the theHoses Hoses Hoses
Toreducetheriskofelectricshock,installonly
onecontinuousGracowaterbornehosebetween
theisolationcabinetandthegun.Donotsplice
hosestogether.
AlwaysuseaGracowaterborne󰘱uidhosebetween
the󰘱uidoutletontheisolationcabinetandthe
gun󰘱uidinlet.Ifusingmultiplegunsmakesure
thehoseconnectionsareelectricallyisolatedand
properlydischargedbeforeanymaintenanceis
performed.
Ifusingmultiplegunsoraremotemounted󰘱uid
regulatorthenmakesurethehoseconnectionsare
electricallyisolatedandproperlydischargedbefore
anymaintenanceisperformed.
Whensettinguptheisolationsystemforthe󰘰rsttime,
connectthehosesinthefollowingorder:
1.Fluidhosefromtheguntotheisolationcabinet.
SeeConnecttheFluidHosefromtheGuntothe
Cabinet,page18.
2.Airhosefromtheairsupplytotheisolation
cabinet.See.
3.Fluidhosefromthe󰘱uidsupplytotheisolation
cabinet.SeeConnecttheFluidSupplyHoseto
theCabinet,page22.
Note
•Ifthe󰘱uidhosemustpassthroughthe
wallofaboothtotheisolationcabinet,
makesurethattheholethroughthebooth
walldoesnothavesharpedgesthatcould
damagethehose.
•Theholesinthewallmustbelargeenough
toallowthehose󰘰ttingstopassthrough.
3A8492A17

Installation
Connect Connect
Connectthe the theFluid Fluid FluidHose Hose Hosefrom from fromthe the theGun Gun Gunto to tothe the theCabinet Cabinet Cabinet
1.Blowthewaterborne󰘱uidhoseoutwithairand
󰘱ushwith󰘱ushing󰘱uidtoremovecontaminants.
2.ConnecttheGracowaterborne󰘱uidhosetothe
gunasdescribedinthespraygunmanual.See
thespraygunmanualforhoseinformationand
dimensions.
3.Beforeenteringthecabinet:
a.FollowtheFluidVoltageDischargeand
GroundingProcedure,page29.
b.Followthe
PressureReliefProcedure,page30.
c.Openthecabinet.Slidetheelectrostatic
shield(82)uptoremove,andthenslidethe
electrostaticshield(12)tothelefttoremove.
4.Loosenthestrainreliefnutatthehoseinletend
(101c).
5.Slidetheotherendofthehosethroughtheholein
thesideoftheisolatedenclosure(CA).Connect
theswivel(101h)tothe󰘱uidoutletofthepump.
6.Securethehosetothesideoftheenclosure
withthebracket(101j).Abolt(S)assembles
throughtheholeinthebracketandscrewsinto
thesideoftheenclosure.Setscrew(101m)can
beloosenedtorotatethebracketifneeded.
7.Tightenthestrainreliefnut(101c)andsetscrew
(101m).
Figure8HoseConnectionatEnclosure
Figure9HoseConnectionatEnclosure
183A8492A

Installation
Connect Connect
Connectthe the thePaint Paint PaintTrigger Trigger TriggerInput Input Input
Thesystemreliesonapneumaticpainttriggersignal
toknowwhentodispensepaint.Whenthepaint
triggersignalisremoveditknowsitcanbeginthe
re󰘰llprocess.
1.Tapintothepainttriggerairlinegoingtothe
spraygun.
2.Runa5/32"airlinefromthespraygun'spaint
triggerlinetotheHydroShield.
3.Plugthe5/32"airlineintothepainttriggerinput
(PTI)portontherightsideofthesystem.
Figure10AirLineConnections
Connect Connect
Connectthe the theElectrostatic Electrostatic ElectrostaticRequest Request RequestInput Input Input
Thesystemneedstoknowwhentheuseof
electrostaticsisdesired.Withthissignalthesystem
willcon󰘰rmtherequestandenableanelectrostatic
outputifSpraymodeisactive.Connectthesignal
thatwouldnormallyenableelectrostaticstothisinput.
Therearepneumaticandelectricaloptionsforthis
input.
Pneumatic Pneumatic
PneumaticInput Input Input
1.Connecta5/32"airlinetotheelectrostatic
requestinput(ERI)portasshownin
ConnectthePaintTriggerInput,page19.
2.Supplyairpressureabove70psi(.48MPa,4.8
bar)toactivatetheinput.
Electrical Electrical
ElectricalInput Input Input
1.Preparetheelectricalcontrolsforservice.Follow
thestepsinPreparetheElectricalControlsfor
Service,page106.
2.RuntwowiresthroughtheI/Oportstrainreliefon
therightsideofthesystem.
Figure11I/OPorts
3.Feedthesewiresthroughthetoprightopening
intheelectronicscontrolpanel.
3A8492A19

Installation
4.Connectthe24VDCsignaltoA1+andGNDto
A2–oftheelectrostaticinputoptocoupler.
LPO:LowPaintOutput
EI:ElectrostaticInput
DSI:DigitalStopInput
Figure12TerminalBlockWiring
OnlyoneA2–portneedstobeconnectedto
GND,asthetwoportslabeledA2–areconnected
internally.
5.Apply24VDCtoA1+toactivatetheinput.
Connect Connect
Connectthe the theElectrostatic Electrostatic ElectrostaticEnable Enable EnableOutput Output Output
Whentheelectrostaticrequestinputisactiveand
thesystemisinSpraymode,theelectrostaticenable
outputwillbeactive.Thiswillsignalthespraygun
toturnonelectrostatics.Connectthissignaltothe
devicethatnormallyturnsonthegun'selectrostatics.
Therearepneumaticandelectricaloptionsforthis
output.
Pneumatic Pneumatic
PneumaticOutput Output Output
1.Connecta5/32"airlinetothe
electrostaticenableoutput(EEO)port
ontherightsideofthecabinet.See
ConnectthePaintTriggerInput,page19󰘰gure.
2.Runthislinetotheinputofthedevicethat
activateselectrostatics.
Note
Plugthisportifitisnotbeingused.
Itwillbepressurizedeverytimethe
electrostaticenableoutput(EEO)port
isactiveevenwhenusingtheelectrical
output.
Electrical Electrical
ElectricalOutput Output Output
1.Preparetheelectricalcontrolsforservice.Follow
thestepsinPreparetheElectricalControlsfor
Service,page106.
2.RuntwowiresthroughtheI/Oportstrainreliefon
therightsideofthesystem.SeeI/OPorts.
3.Feedthesewiresthroughthetoprightopening
intheelectronicscontrolpanel.
4.Connectterminalblock7tothegun'selectrostatic
controller.Whentheoutputisinactiveterminal
block7has4-5voltspresent.Whenthe
outputisactivethereis24Vpresent.See
TerminalBlockWiring.
5.Connectterminalblock8toGND.
Note
WhenusedwithGracoelectrostatic
controllers,terminalblock7signal
voltageisopticallyisolatedatthe
controller.Ifusinganyothercontrollerbe
suretouseanoptocouplerattheinputto
thedevice.
NOTICE NOTICE
NOTICE
Topreventdamagetoequipment,donotuse
theseterminalblockswithoutanoptocoupler
present.
203A8492A