Graco HydroShield WABL01 Parts list manual

Instructions-Parts
HydroShield™ HydroShield™
HydroShield™Automatic Automatic AutomaticAir Air AirSpray Spray Spray
Batch Batch
BatchWaterborne Waterborne WaterborneIsolation Isolation IsolationSystems Systems Systems3A8493A
EN
Air Air
Airspray 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 beused used usedin in ina a a
permanent 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.Save Save
Savethese these theseinstructions. instructions. instructions.
100 psi (0.7 MPa, 7.0 bar) MaximumFluid Working Pressure100 psi (0.7 MPa, 7.0 bar) Maximum AirWorking Pressure
See page 5 for model information.
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..............................23
ConnectthePowerSupply...........................24
InstalltheOptionalSystemStopPneumatic
InputKit.........................................25
WiretheSystemStopDigitalInput................26
InstalltheOptionalSystemStatus
Output...........................................26
WiretheLowPaintDigitalOutput..................27
ChecktheGroundingoftheSprayGunand
IsolationSystem.............................28
FlushtheEquipmentBeforeFirstUse...........28
Operation...........................................................29
OperationOverview.....................................29
FluidVoltageDischargeandGrounding
Procedure......................................29
PressureReliefProcedure............................30
FlushtheSystem(SystemswithoutColor
Change).........................................31
FlushtheSystem(ColorChangeEnabled
Systems)........................................32
PrimetheIsolationSystem...........................33
SpraywiththeIsolationSystem....................33
AdjusttheGunFluidSettings........................34
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............................................65
Maintenance......................................................66
RoutineMaintenance...................................66
PreparetheSystemforService.....................67
CheckforFluidLeaks...................................67
ReplacetheWashFluid...............................68
CheckandLubricatetheGroundRod............69
ChecktheBleedResistor.............................69
ChecktheDoorSwitch.................................69
Troubleshooting..................................................70
GeneralTroubleshooting..............................70
LEDDiagnosticInformation..........................74
TroubleshootingtheControlInterface............74
VoltageLossTroubleshooting.......................75
TroubleshootingColorChangeSolenoid
Valves...........................................77
ErrorCodes........................................................80
Repair................................................................89
PreparetheIsolationSystemfor
Service..........................................89
ServicetheIsolationValve............................90
ServicetheIsolationFluidPump.................100
ServicetheElectricalControls....................105
PneumaticConnections..............................109
WiringConnections....................................110
ColorChange:PneumaticandWiring
Connections.................................112
Parts................................................................113
IsolationSystem........................................113
25N030IsolationValveParts......................119
25N031IsolationFluidPumpParts.............121
ElectronicControlParts.............................123
RepairKitsandAccessories..............................125
Accessories...............................................125
Kit26B400,SupplyPump...........................127
ColorChangeKit26B415...........................128
IsolationValveKits.....................................132
IsolationFluidPumpKits............................134
Performance....................................................135
IgnitabilityofCoatingMaterials..........................136
Dimensions......................................................137
TechnicalSpeci󰘰cations....................................138
2
3A8493A

RelatedManuals
CaliforniaProposition65...................................139GracoStandardWarranty..................................140
Related Related
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English English
EnglishDescription Description
Description
312782AirActuatedDispenseValve
312783ColorandCatalystChangeValveStacks
3A1244GracoControlArchitecture™ModuleProgramming
333012ProXp™AutoWaterborneGun
332992ProXpc™AutoGun
333266ProXpcElectrostaticController
334452ProBell®RotaryApplicator
334626ProBellHollowWristRotaryApplicator
3A3657ProBellElectrostaticController
307212StainlessSteel,WaterbaseCompatibleFluidPressureRegulators
309455TestFixture,HighVoltageProbe,andkVMeter
3A8493A 3

IsolationSystemOverview
Isolation Isolation
IsolationSystem System SystemOverview Overview Overview
How How
Howthe the theIsolation Isolation IsolationSystem System SystemWorks Works Works
WhenusingaHydroShieldAirSprayWaterborne
IsolationSystem,the󰘱uidsupplyremainsgrounded.
The󰘱uidsupplycanbeanypumporcirculation
system.Whentheisolationsystemhas󰘰lledwith
paint,theisolationvalveseparatesandraises.This
allowsthe󰘱uidinsidetheisolationsystemtobecome
electrostaticallychargedwhenthegunistriggered.
Thecharged󰘱uidisattractedtothegrounded
workpiece,wrappingaroundandevenlycoatingall
surfaces.Whentheguntriggerisreleased,the
isolation󰘱uidpumpautomaticallyre󰘰lls.
Spraying Spraying
SprayingWaterborne Waterborne WaterborneFluids Fluids Fluids
Electrostatically Electrostatically
Electrostatically
Thisisolationsystemandelectrostaticairspray
gunaredesignedtosprayonly only
onlywaterborne󰘱uids
whichmeetatleastoneofthefollowing󰘱ammability
requirements:
•Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.
•CE-EN CE-EN
CE-EN50348Compliant: 50348Compliant: 50348Compliant:
Materialisclassi󰘰edasnon-ignitableasde󰘰nedby
EN50059:2018.
SeeIgnitabilityofCoatingMaterials,page136.
Whenanelectrostaticgunisconnectedtoavoltage
isolationsystem,allofthe󰘱uidinthespraygun,
󰘱uidhose,andisolated󰘱uidsupplyischargedto
highvoltage,whichmeansthatthesystemhas
moreelectricalenergythanasolvent-basedsystem.
Therefore,onlynon-󰘱ammable󰘱uids(asde󰘰ned
underModels,page5)canbesprayedwiththe
systemorbeusedtoclean,󰘱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.
4
3A8493A

Models
Models Models
Models
Mustpurchasegunandhosesseparately.
Part Part
PartDescription Description DescriptionFluid Fluid
Fluid
regulator regulator
regulator
Color Color
Color
change change
change
WABL00Isolationcabinetforautomaticairspray.4—
WABL01Isolationcabinetforautomaticairspraywithout󰘱uidregulation.——
WABL02Isolationcabinetforautomaticairspray,equippedwithcolor
changeinletvalves.44
WABL03Isolationcabinetforautomaticairspraywithout󰘱uidregulation,
equippedwithcolorchangeinletvalves.—4
Condition Condition
Conditionfor for fornon non non- - -󰘱ammability: 󰘱ammability: 󰘱ammability:
Models Models
Modelsare are arecompliant compliant compliantwith with withEN 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,page136.
*Systemswithcolorchangeinletvalvesinstalledincludesix󰘱uidvalveswhichallowtheuseofthreecolors
andpurgesequences.Thesesystemsarealsoequippedfordumpvalveoperation.Seethecolorchangekit
informationinAccessories,page125.
3A8493A 5

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanual,referbacktotheseWarnings.Product-speci󰘰c
hazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughoutthebodyofthismanual
whereapplicable.
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.
•Onlyusethered-coloredGracoelectricallyconductivegunairhosewiththisgun.Donot
useblackorgray-coloredGracoairhoses.
•Donotusepaillinersunlesstheyareconductiveandgrounded.
•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Keepaworking󰘰reextinguisherintheworkarea.
6 3A8493A

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 andFounding Founding FoundingProcedure Procedure Procedurewheninstructedtodischarge
thevoltage;beforecleaning,󰘱ushing,orservicingthesystem;beforeapproachingthefrontof
thegun;andbeforeopeningtheisolationenclosurefortheisolated󰘱uidsupply.
•Donottouchthegunnozzleorelectrode,orcomewithin4in.(102mm)oftheelectrode
duringgunoperation.FollowtheFluid Fluid
FluidVoltage Voltage VoltageDischarge Discharge Dischargeand and andFounding Founding FoundingProcedure Procedure Procedure.
•Onlyusethered-coloredGracoelectricallyconductivegunairhosewiththisgun.Donot
useblackorgray-coloredGracoairhoses.
•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.
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
3A8493A
7

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,requestSafetyDataSheets(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.
8 3A8493A

ComponentIdentication
Component Component
ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
Figure1ComponentsoftheAutomaticAirSprayIsolationSystem.
Key Key
Key
Item Item
ItemDescription Description Description
AAirInlet
CControlInterface
CCColorChangeModule(oncolorchange
enabledsystems)
EFluidOutlettoGun
FFluidInlet
GIsolationValve
JFluidInletValve
KIsolationFluidPump
Item Item
ItemDescription Description Description
LFluidPressureRegulator
MElectronicsPanel
NGroundRodandBleedResistor
PPowerSupply
RHand-heldGroundedRod
VSColorChangeValveStack(oncolor
changeenabledsystems)
WWashFluidBottle
3A8493A 9

TypicalInstallation
Typical Typical
TypicalInstallation Installation Installation
Figure2TypicalInstallation,AutomaticAirSprayBatchWaterborneIsolationSystem,Non-Hazardous
Location
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
GCGroundLug
HWGracoWaterborneFluidHose
LTLightTower
PCPowerCord
†Required,notsupplied.
vOptional,notsupplied.
10 3A8493A

TypicalInstallation
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
Key Key
Key
3A8493A
11

TypicalInstallation
Item Item
ItemDescription Description Description
HWGracoWaterborneFluidHose
LFluidPressureRegulator
MEElectrostaticApplicator
Item Item
ItemDescription Description Description
MIIsolatedRegion
MMFluidManifold
12
3A8493A

Installation
Installation Installation
Installation
System System
SystemRequirements Requirements Requirements
Theuseofmultiplegunswithoneisolation
cabinetincreasestheriskofelectricshock,󰘰re,or
explosion.Whenonegunischargedallgunsare
charged.Besureallgunsareinasafeoperating
zonewhenvoltageisapplied.
TheGracovoltageisolationsystemhasthefollowing
features:
•Anisolationcabinetthatpreventspersonsfrom
makingcontactwiththehighvoltagecomponents
beforethesystemvoltageisdischarged.All
componentsoftheisolationsystemthatare
chargedtohighvoltagearecontainedwithinthe
cabinet.
•Ableedresistorthatdrainsoffthesystemvoltage
whenthespraygunisnotinuse.Allmetalparts
thatcontacthighvoltage󰘱uidareelectrically
connectedtothebleedresistor.
•Adoorswitchinterlockthatautomatically
dischargesthesystemvoltageanytimethe
isolationcabinetdoorisopen.
Note: Note:
Note:TheGracowarrantyandapprovalsarevoidif
anon-Gracoelectrostaticspraygunorapplicatoris
connectedtothevoltageisolationsystemorifthe
gunisoperatedabove60kV.
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,showsa
typicalwaterborneautomaticbatchsystem.Itisnot
anactualsystemdesign.
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.
3A8493A 13

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,page138for
theweight.
1.Selectandattachtheappropriatemounting
hardwaretothestand.
2.Drillholesintothewallbasedontheselected
hardware.
Amountingholepatternisprovidedoneachside
oftheframe.
Figure5HolePatternforWallMounting
3.Withtwopeople,removetheisolationsystem
fromtheshippingpallet.
14
3A8493A

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,page125.
2.ConnectthelighttowerCANcable(114)
tothecontroller(42)󰘰ttingsotheisolation
systemcancommunicatewiththelight.See
ConnecttheCANCables,page23.Longer
cablesareavailable.
3A8493A 15

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.
•
Isolation cabinet: Connectthesystemground
wiretoatrueearthground.Donotdisconnector
tamperwiththeinternalgroundwireconnections
insidethecabinet.Formoreinformation,see
TroubleshootingHydroShieldVoltage,page76.
Aftergroundingthesystem,checktheresistance
betweentheexterioroftheisolationcabinetand
atrueearthground.Theresistancemustbeless
than100ohms.
•
Fluid supply: Groundthe󰘱uidsupplybyconnecting
agroundwireandclamp.Seeyour󰘱uidsupply
instructionmanualforgroundinginstructions.
•
Power supply: Thepowersupplyisgrounded
throughthepowercordtoagroundedoutlet.
•
Spray gun: Groundthegunaccordingtothespray
guninstructionmanual.
•
Waterborne 󰘱uid hose: Thehosemustbeproperly
groundedthroughtheconductivelayer.
•
Object being sprayed: Keeptheworkpiecehangers
cleanandgroundedatalltimes.
• All electrically conductive objects or devices in
the spray area: Theseitemsmustbeproperly
grounded.
• Fluid and waste containers: Groundall󰘱uidand
wastecontainersinthesprayarea.Donotusepail
linersunlesstheyareconductiveandgrounded.
When󰘱ushingthespraygun,thecontainerused
tocatchtheexcess󰘱uidmustbeelectrically
conductiveandgrounded.
•
Air compressors: Groundtheequipmentaccording
tothemanufacturer'srecommendations.
•
All air lines: Thesemustbeproperlygrounded.
Useonlygroundedhoseswithamaximumof100
feet(30.5m)combinedhoselengthtoensure
groundingcontinuity.
•
Floor of the spray area: The󰘱oormustbe
electricallyconductiveandgrounded.Donotcover
the󰘱oorwithcardboardoranynon-conductive
materialwhichwouldinterruptgroundingcontinuity.
16 3A8493A

Installation
• All solvent pails: 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󰘱uidoutletontheisolationcabinetandthegun
󰘱uidinlet.
Ifusingmultiplegunsoraremotemounted󰘱uid
regulatormakesurethehoseconnectionsare
electricallyisolatedandproperlydischargedbefore
anymaintenanceisperformed.
Whensettinguptheisolationsystemforthe󰘰rsttime,
connectthehosesinthefollowingorder:
1.Fluidhosefromtheguntotheisolationcabinet.
SeeConnecttheFluidHosefromtheGuntothe
Cabinet,page18.
2.Airhosefromtheairsupplytotheisolation
cabinet.SeeConnecttheAirSupplyHosetothe
Cabinet,page22.
3.Fluidhosefromthe󰘱uidsupplytotheisolation
cabinet.SeeConnecttheFluidSupplyHoseto
theCabinet,page22.
Note
•Ifthe󰘱uidhosemustpassthroughthe
wallofaboothtotheisolationcabinet,
makesurethattheholethroughthebooth
walldoesnothavesharpedgesthatcould
damagethehose.
•Theholesinthewallmustbelargeenough
toallowthehose󰘰ttingstopassthrough.
3A8493A
17

Installation
Connect Connect
Connectthe the theFluid Fluid FluidHose Hose Hosefrom from fromthe the theGun Gun Gunto to tothe the the
Cabinet Cabinet
Cabinet
1.Blowthewaterborne󰘱uidhoseoutwithairand
󰘱ushwith󰘱ushing󰘱uidtoremovecontaminants.
2.ConnecttheGracowaterborne󰘱uidhosetothe
gunasdescribedinthespraygunmanual.See
thespraygunmanualforhoseinformationand
dimensions.
3.Connectthe󰘱uidhosetothe󰘱uidpressure
regulatorinsidetheisolationcabinet.Before
enteringthecabinet:
a.FollowtheFluidVoltageDischargeand
GroundingProcedure,page29.
b.Followthe
PressureReliefProcedure,page30.
c.Openthecabinetandslidetheelectrostatic
shield(12)uptoremove.
4.Removethe󰘱uidoutletstrainreliefferrule(38)
fromthestrainreliefhousing.
Figure8ShieldedHoseConnectionwithFluid
Regulator
Figure9ShieldedHoseConnectionwithout
FluidRegulator
5.Slidethestrainreliefferrule(38)overthe
conductivehoselayer(FC)untilitreachesthe
abrasionlayer(FJ)
Figure10FittingtoAbrasionLayeron
WaterborneFluidHose
6.Inthisposition,the󰘰ttingclampsontothe
conductivesegment(FC)ofthehosewhen
tightened.
Conductivehoselayer(FC)mustbegrounded
throughitsconnectiontotheisolationsystem’s
groundedcabinet(CA).Tomaintaingrounding
continuity,theconductivehoselayer(FC)must
beengagedintheferrulewhenthestrainrelief
nutistightened.Failuretoproperlyinstallthe
hoseinthestrainreliefcouldresultinanelectric
shock.
7.Feedthehosetube(FT)throughthestrainrelief
housingintothecabinetuntilitreachesthetube
compression󰘰tting(82)onthe󰘱uidregulatoror
pumpoutlet󰘰ttings.Unscrewthenutportion
ofthe󰘰tting.Thenutportioniscomprisedof3
pieces(82a,82b,82c).
18 3A8493A

Installation
8.Slidethenut(82a)ontothe󰘱uidhose,followed
bythefrontferrule(82b),andthentheback
ferrule(82c).Thewidersideofeachferrule(82b,
82c)facesthenut(82a).
Figure11FerruleOrientationontheFluidHose
9.Pullthenut(82a,82b,82c)backfromtheendof
thehose.Insertandpushthehose(FT)down
ontothetubecompression󰘰tting(82)untilit
isfullyseatedinthe󰘰ttingbody(82d).Usea
wrenchtotightenthe󰘰ttingto55in-lb(6.2N•m).
10.Threadthestrainreliefferrule(38)intothestrain
reliefhousingandtightento55in-lb(6.2N•m).
Toavoidcuttingthehose,donotovertighten.
11.Makesurethattheballvalve(39)isopen(handle
up)toallow󰘱uidto󰘱ow.
12.Reinstalltheelectrostaticshield(12)insidethe
cabinet.
13.Closethecabinetdoorandusea󰘱atblade
screwdrivertosecurethedoorshut.
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.
Figure12AirLineConnections
3A8493A 19

Installation
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(.5MPa,4.8
bar)toactivatetheinput.
Electrical Electrical
ElectricalInput Input Input
1.Preparetheelectricalcontrolsforservice.Follow
thestepsinPreparetheElectricalControlsfor
Service,page105.
2.RuntwowiresthroughtheI/Oportstrainreliefon
therightsideofthesystem.
Figure13I/OPorts
3.Feedthesewiresthroughthetoprightopening
intheelectronicscontrolpanel.
4.Connectthe24VDCsignaltoA1+andGND
toA2–oftheelectrostaticinputoptocoupler.
OnlyoneA2–portneedstobeconnectedto
GND,asthetwoportslabeledA2–areconnected
internally.
Figure14TerminalBlockWiring
LPO:LowPaintOutput
EI:ElectrostaticInput
DSI:DigitalStopInput
5.Apply24VDCtoA1+toactivatetheinput.
20 3A8493A