Graco HydroShield WMBH00 Parts list manual

Instructions-Parts
HydroShield™ HydroShield™
HydroShield™Air Air Air- - -Assisted Assisted AssistedBatch Batch Batch
Waterborne Waterborne
WaterborneIsolation Isolation IsolationSystems Systems Systems3A7370B
EN
Air Air
Air- - -assisted assisted assistedspray spray spraysystem system systemfor for foruse use usewhen when whenelectrostatically electrostatically electrostaticallyspraying spraying sprayingconductive, conductive, conductive,waterborne waterborne waterborne󰘱uids 󰘱uids 󰘱uidsthat that that
meet 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.
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.
100psi(0.7MPa,7.0bar)MaximumAir
WorkingPressure
Seepage6formodelinformation
includingmaximum󰘱uidworking
pressure.
NOTE:Thismanualcoversisolation
systemoperation.Forspraygun
operation,seemanual3A7503.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals..................................................3
IsolationSystemOverview....................................4
HowtheIsolationSystemWorks.....................4
SprayingWaterborneFluids
Electrostatically................................4
Models.................................................................5
ApprovedSystemComponents.......................5
Warnings.............................................................8
ComponentIdenti󰘰cation.....................................11
TypicalInstallation..............................................12
Installation..........................................................13
SystemRequirements..................................13
DisplayWarningSigns.................................13
InstallationLocation.....................................13
InstalltheSystem.........................................13
VentilatetheSprayBooth.............................13
MounttheCabinet........................................14
InstalltheLightTower..................................15
Grounding...................................................16
ConnecttheHoses......................................17
ConnecttheCANCables..............................21
ConnectthePowerSupply...........................22
ConnecttheGunFlushBox..........................22
ChecktheGroundingoftheSprayGunand
IsolationSystem.............................23
FlushtheEquipmentBeforeFirstUse...........24
Operation...........................................................25
OperationOverview.....................................25
FluidVoltageDischargeandGrounding
Procedure......................................25
PressureReliefProcedure............................26
FlushtheSystem.........................................27
GunFlushBoxOperation.............................28
PrimetheIsolationSystem...........................29
SpraywiththeIsolationSystem....................29
AdjusttheGunFluidandAirSettings............30
Shutdown....................................................31
ControlInterface.................................................32
MenuBar....................................................33
SoftKeyIcons.............................................33
RunScreensandSetupScreens..................33
ScreenIcons...............................................34
ControlInterfaceSetupandMaintenance.............35
EnableUSBData.........................................35
USBLogs....................................................35
SystemCon󰘰gurationSettingsFile................35
CustomLanguageFile.................................35
DownloadSystemData................................36
UploadSystemCon󰘰guration.......................37
CleantheScreenSurface.............................37
RunMenus........................................................38
HomeScreen..............................................38
EventsScreen.............................................39
StatusScreen..............................................40
SetupMenus......................................................41
AdvancedScreens.......................................41
CalibrateScreens........................................44
MaintenanceScreens...................................45
Presets........................................................49
Pumps........................................................49
System........................................................50
Maintenance......................................................51
Troubleshooting..................................................53
LEDDiagnosticInformation..........................53
TroubleshootingtheControlInterface............53
ErrorCodes........................................................54
Repair................................................................60
PreparetheIsolationSystemfor
Service..........................................60
ServicetheIsolationValve............................61
ServicethePump.........................................70
ServicetheElectricalControls......................75
PneumaticConnections................................77
WiringConnections......................................79
Parts..................................................................81
IsolationSystem..........................................81
25N030IsolationValveParts........................86
25N031PumpParts.....................................88
ElectronicControlParts...............................90
RepairKitsandAccessories................................92
Accessories.................................................92
IsolationValveKits.......................................93
PumpKits....................................................96
Performance......................................................97
IgnitabilityofCoatingMaterials............................98
Dimensions........................................................99
TechnicalSpeci󰘰cations....................................100
CaliforniaProposition65...................................101
GracoStandardWarranty..................................102
23A7370B

RelatedManuals
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNo. No. No.Description Description Description
3A7503ProXp™Air-AssistedWBGun
309455TestFixture,HighVoltageProbe,andkVMeter
312782AirActuatedDispenseValve
312794Merkur®PumpAssembly
307273FluidOutletFilter
309227GunFlushBoxModule
3A7370B3

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.The
lowpressure󰘱uidsupply󰘰rst󰘰llsaninternallow
pressurepumpreservoir,thatthenfeedsintoan
isolatedMerkurpumptosendhighpressure󰘱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:
•FM, FM,
FM,FMc FMc FMcApproved: Approved: Approved:
Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.
•CE-EN CE-EN
CE-EN50059 50059 50059Compliant: Compliant: Compliant:
Materialisclassi󰘰edasnon-ignitableasde󰘰nedby
EN50059:2018.
Formoreinformation,see
IgnitabilityofCoatingMaterials,page98.
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,
page25,andGrounding,page16,tounderstand
whenyoucanapproachortouchthegunnozzle.
Theamountoftimeittakestodischargethe
energydependsonthesystemdesign.Followthe
FluidVoltageDischargeandGroundingProcedure,
page25,beforeapproachingthefrontofthegun.
43A7370B

Models
Models Models
Models
Approved Approved
ApprovedSystem System SystemComponents Components Components
Anycombinationofthefollowingisolationcabinets,sprayguns,󰘱uidhoses,andairhosesareFM-approved
andmeettherequirementsofEN50059:2018.
Completeisolationsystemsareavailablewhichincludeanisolationcabinet,aspraygun,ahighpressure󰘱uid
hose,andanairhose.
SeeTable2Pre-packagedFM-approvedIsolationSystems,page6fordetailsaboutthecomponentsin
eachpackage.
Table Table
Table1 1 1FM FM FM- - -approved approved approvedand and andCE CE CE- - -compliant compliant compliantComponents Components Components
Isolation Isolation
IsolationCabinets Cabinets CabinetsSpray Spray SprayGuns Guns Guns
Fluid Fluid
FluidHoses Hoses Hoses
(Shielded (Shielded
(Shielded
waterborne) waterborne)
waterborne)
Air Air
AirHoses Hoses Hoses
(Grounded) (Grounded)
(Grounded)
WMBH00
Isolationcabinetformanual
air-assistedspray,30:1󰘱uid
pressureratio
WMBH01
Isolationcabinetformanual
air-assistedspray,equippedforgun
󰘱ushbox,30:1󰘱uidpressureratio
WMBH04
Isolationcabinetformanual
air-assistedspray,15:1󰘱uid
pressureratio
WMBH05
Isolationcabinetformanual
air-assistedspray,equippedforgun
󰘱ushbox,15:1󰘱uidpressureratio
H60T18ProXp™60AAWB
Standardelectrostaticair-assisted
gunforwaterbornecoatings
H60M18ProXp60AAWB
Smartelectrostaticair-assistedgun
forwaterbornecoatings
25R012
25ft.
(7.6m)
25R013
36ft.
(10.9m)
25R014
50ft.
(15.2m)
25R015
75ft.
(22.8m)
25R016
100ft.
(30.5m)
235068
6ft.
(1.8m)
235069
15ft.
(4.6m)
235070
25ft.
(7.6m)
235071
36ft.
(10.9m)
235072
50ft.
(15.2m)
235073
75ft.
(22.8m)
235074
100ft.
(30.5m)
Condition Condition
Conditionfor for fornon non non- - -󰘱ammability: 󰘱ammability: 󰘱ammability:
FM FM
FMapproved approved approvedfor for foruse use usewith with with󰘱uids 󰘱uids 󰘱uidsthat that thatmeet meet meetthe the thefollowing following followingcondition: condition: condition:
•Material Material
Materialdoes does doesnot not notsustain sustain sustainburning burning burningin in inaccordance accordance accordancewith with withthe the theStandard Standard Standard
Test Test
TestMethod Method Methodfor for forSustained Sustained SustainedBurning Burning Burningof of ofLiquid Liquid LiquidMixtures, Mixtures, Mixtures,ASTM ASTM ASTM
D4206. D4206.
D4206.
Condition Condition
Conditionfor for fornon non non- - -󰘱ammability: 󰘱ammability: 󰘱ammability:
Models Models
Modelsare are arecompliant compliant compliantwith with withEN EN EN50059 50059 50059when when whenused used usedwith with with󰘱uids 󰘱uids 󰘱uidsthat that thatmeet meet meet
the 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,page98.
3A7370B5

Models
Table Table
Table2 2 2Pre Pre Pre- - -packaged packaged packagedFM FM FM- - -approved approved approvedIsolation Isolation IsolationSystems Systems Systems
System System
System
Part Part
PartNo. No. No.Description Description Description
Isolation Isolation
Isolation
cabinet cabinet
cabinet
included included
included
Equipped Equipped
Equipped
for for
forgun gun gun
󰘱ush 󰘱ush
󰘱ushbox box box
Maximum Maximum
Maximum
Fluid Fluid
Fluid
Working Working
Working
Pressure* Pressure*
Pressure*
psi psi
psi(MPa, (MPa, (MPa,
bar bar
bar
Gun Gun
Gun
included included
included
Fluid Fluid
Fluid
hose hose
hose
included included
included
Air Air
Airhose hose hose
included included
included
WMBH20
•ProXp60AAWB
spraygun
•25ft.hoseset
•30:1󰘱uidpressure
ratio
WMBH00—3000
(20.7,
207)
H60T18
25R012
25ft.
(7.6m)
235070
25ft.
(7.6m)
WMBH40
•ProXp60AAWB
spraygun
•50ft.hoseset
•30:1󰘱uidpressure
ratio
WMBH00—3000
(20.7,
207)
H60T18
25R014
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBH41
•ProXp60AAWB
spraygun
•50ft.hoseset
•Equippedforagun
󰘱ushbox
•30:1󰘱uidpressure
ratio
WMBH014
3000
(20.7,
207)
H60T18
25R014
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBH44
•ProXp60AAWB
spraygun
•50ft.hoseset
•15:1󰘱uidpressure
ratio
WMBH04—1500
(10.3,
103)
H60T18
25R014
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBH45
•ProXp60AAWB
spraygun
•50ft.hoseset
•Equippedforagun
󰘱ushbox
•15:1󰘱uidpressure
ratio
WMBH054
1500
(10.3,
103)
H60T18
25R014
50ft.
(15.2m)
235072
50ft.
(15.2m)
*Allsystemshaveamaximuminletpressureof100psi.
63A7370B

Models
Table Table
Table3 3 3Isolation Isolation IsolationCabinets Cabinets Cabinets
MustpurchaseProXpgunandhosesseparately.
Part Part
PartNo. No. No.Description Description Description
Equipped Equipped
Equippedfor for forgun gun gun
󰘱ush 󰘱ush
󰘱ushbox box box
Maximum Maximum
Maximum
Fluid Fluid
FluidWorking Working Working
Pressure Pressure
Pressure
psi psi
psi(MPa, (MPa, (MPa,bar bar bar
WMBH00Isolationcabinetformanualair-assistedspray,30:1󰘱uid
pressureratio—3000(20.7,207)
WMBH01Isolationcabinetformanualair-assistedspray,equipped
forgun󰘱ushbox,30:1󰘱uidpressureratio43000(20.7,207)
WMBH04Isolationcabinetformanualair-assistedspray,15:1󰘱uid
pressureratio—1500(10.3,103)
WMBH05Isolationcabinetformanualair-assistedspray,equipped
forgun󰘱ushbox,15:1󰘱uidpressureratio41500(10.3,103)
3A7370B7

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:
•FM, FM,
FM,FMc FMc FMcApproved: Approved: Approved:
MaterialdoesnotsustainburninginaccordancewiththeStandardTestMethodfor
SustainedBurningofLiquidMixtures,ASTMD4206.
•CE CE
CE- - -EN EN EN50059 50059 50059Compliant: 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.
83A7370B

Warnings
WARNING WARNING
WARNING
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock:
•Turnoffanddisconnectpowercordbeforeservicingequipment.
•Connectonlytogroundedelectricaloutlets.
•Useonly3-wireextensioncords.
•Ensuregroundprongsareintactonpowerandextensioncords.
•Donotexposetorain.Storeindoors.
•Wait󰘰veminutesafterdisconnectingpowercordbeforeservicing.
•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorclose
tosprayarea.SeeGrounding Grounding
Groundinginstructions.
•Connecttheelectrostaticguntoavoltageisolationsystemthatwilldischargethesystem
voltagewhennotinuse.
•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.
•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.
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.
•Donotspraywithouttipguardinstalled.
•Engagetriggerlockwhennotspraying.
•Donotpointgunatanyoneoratanypartofthebody.
•Donotputyourhandoverthespraytip.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressureReliefProcedurewhenyoustopsprayingandbeforecleaning,checking,
orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
3A7370B9

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,requestaSafetyDataSheet(SDS)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.
•ReadSafetyDataSheet(SDS)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.
103A7370B

ComponentIdentication
Component Component
ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
Figure1ComponentsoftheAir-AssistedIsolationSysteminaTypicalWaterborneManualBatchSystem
Key Key
Key
Item Item
ItemDescription Description Description
AAirInlet
CControlInterface
DAirOutlettoGun
EFluidOutlettoGun
FFluidInlet
GIsolationValve
JFluidInletValve
KFluidPump
Item Item
ItemDescription Description Description
LMerkurAAFluidPump
MElectronicsPanel
NGroundRodandBleedResistor
PPowerSupply
RHand-heldGroundedRod
WWashFluidReservoir
ZFluidFilter(60mesh)
3A7370B11

TypicalInstallation
Typical Typical
TypicalInstallation Installation Installation
Figure2TypicalInstallation,Air-AssistedWaterborneIsolationSystem,Non-HazardousLocation
Key Key
Key
Item Item
ItemDescription Description Description
AB†BleedTypeAirValve
AM†MainAirSupplyLine
AS†OilSeparator
AVvAirShut-offValve
CAIsolationCabinet
FS†FluidSupplyLine
FVvFluidShut-offValve
GCGroundWire
GWProXpWaterborneElectrostatic
Air-AssistedSprayGun
Item Item
ItemDescription Description Description
HGGracoRedGroundedAirHose
(left-handthreadsatgun)
HWGracoWaterborneFluidHose
LTLightTower
PCPowerCord
†Required,notsupplied.
vOptional,notsupplied.
123A7370B

Installation
Installation Installation
Installation
System System
SystemRequirements Requirements Requirements
Theuseofmultiplegunswithoneisolationcabinet
maycauseelectricshock,󰘰re,orexplosion.To
helppreventinjuryorequipmentdamage,useonly
onegunperisolationcabinet.
TheGracovoltageisolationsystemhasthefollowing
features:
•Anisolationcabinetthatpreventspersonsfrom
makingcontactwiththehighvoltagecomponents
beforethesystemvoltageisdischarged.All
componentsoftheisolationsystemthatare
chargedtohighvoltagearecontainedwithinthe
cabinet.
•Ableedresistorthatdrainsoffthesystemvoltage
whenthespraygunisnotinuse.Allmetalparts
thatcontacthighvoltage󰘱uidareelectrically
connectedtothebleedresistor.
•Adoorswitchinterlockthatautomatically
dischargesthesystemvoltageanytimethe
isolationcabinetdoorisopen.
Note
TheGracowarrantyandapprovalsarevoid
ifanon-Gracoelectrostaticspraygunis
connectedtothevoltageisolationsystemor
ifthegunisoperatedabove60kV.
Display Display
DisplayWarning Warning WarningSigns Signs Signs
Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.
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,page12,showsa
typicalair-assistedwaterbornemanualbatchsystem.
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.
3A7370B13

Installation
Mount Mount
Mountthe the theCabinet Cabinet Cabinet
Toreducetheriskof󰘰reandexplosion,do
notinstallequipmentapprovedonlyfora
non-hazardouslocationinahazardouslocation.
Thecabinetcanbemountedonthewheelsthatare
providedwiththesystem,mountedonthewall,or
mountedonthe󰘱oor.
Install Install
Installthe the theOptional Optional OptionalWheels Wheels Wheels
Followthesestepstoinstallthewheelsthatare
includedwiththesystem.Ifwheelsarenotneeded,
useaforkliftortwopeopletomoveorliftthesystem.
1.Withtwopeople,removethesystemfromthe
pallet.
2.Installthewheels(95),washers(96),andnuts
(97).Tightenthenutssecurely.
3.Installtheendplugs(3a,3b).
4.Whenthesystemisinthedesiredlocation,lock
allfourwheels.
Figure3WheelMountParts
Mount Mount
Mounton on onthe the theWall Wall Wall
Beforemountingtheisolationcabinettothewall,
makesurethatthewallcansupporttheweightofthe
system.SeeTechnicalSpeci󰘰cations,page100for
theweight.
1.Selectandattachtheappropriatemounting
hardwaretothestand.
2.Drillholesintothewallbasedontheselected
hardware.
Amountingholepatternisprovidedoneachside
oftheframe.
Figure4HolePatternforWallMounting
3.Withtwopeople,removetheisolationsystem
fromtheshippingpallet.
143A7370B

Installation
4.Removethefeet(3a,3b,3c)fromtheframe.
Figure5RemovingtheFrameFeet
5.Securethesystemtothewall.
Mount Mount
Mounton on onthe the theFloor Floor Floor
1.Usetheboltpatterntodrillholesintothe󰘱oor.
Figure6BoltPatternforFloorMounting
2.Withtwopeople,removetheisolationsystem
fromtheshippingpallet.
3.Securethesystemtothe󰘱oor.
Install Install
Installthe the theLight Light LightTower Tower Tower
Thesystemisequippedwithalighttowerwhich
indicateshowmuchpaintisinthepumpasit󰘰llsand
dispenses.
1.Locatethelighttowerbracket(61)onthe
isolationcabinet(CA).Usescrews(66),washers
(67),andnuts(68)tomountthelighttower(LT)
ontothelighttowerbracket(61).
Thelighttowerbracketcanberemovedfromthe
isolationcabinetandinstalledinanotherlocation.
Ifrelocated,makesurethatthelighttoweris
installedinanon-hazardouslocationandthatthe
paintercanseeitfromthespraybooth.
Longerextensioncablesareavailable.See
Accessories,page92.
2.ConnecttheCANcableonthelighttower(LT)
tothecontrolinterface(C)sothattheisolation
systemcancommunicatewiththelight.A1
meter(3.28ft)cableisprovided.Longercables
areavailable.
3.Thebottomofthecontrollercontainstwo󰘰ttings.
ScrewtheendoftheCANcableintothe󰘰tting
(111).SeeConnecttheCANCables,page21.
Table Table
Table4 4 4Meaning Meaning Meaningof of ofLight Light LightTower Tower TowerColors Colors Colors
Light Light
LightDe󰘰nition De󰘰nition
De󰘰nition
Green(solid)Thepumpis50%fullormore.
Yellow(solid)Thepumpislessthan50%full
butmorethan10%full.
Red(solid)Thepumpislessthan10%full.
3A7370B15

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.
Aftergroundingthesystem,checktheresistance
betweentheexterioroftheisolationcabinetand
atrueearthground.Theresistancemustbeless
than100ohms.
•
Fluidsupply: Groundthe󰘱uidsupplybyconnecting
agroundwireandclamp.Seeyour󰘱uidsupply
instructionmanualforgroundinginstructions.
• Powersupply: Thepowersupplyisgrounded
throughthepowercordtoagroundedoutlet.
•
Spraygun: Groundthegunbyconnectingthe
red-coloredGracogroundedairhose(HG)tothe
gunandconnectingtheairhosegroundwiretoa
trueearthground.
Thiselectrostatichand-heldsprayingequipment
couldpresenthazardsifitisnotoperatedaccording
totheinformationgiveninthesprayguninstruction
manual.SeeRelatedManuals,page3.
• 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.
163A7370B

Installation
• Floorofthesprayarea: The󰘱oormustbe
electricallyconductiveandgrounded.Donotcover
the󰘱oorwithcardboardoranynon-conductive
materialwhichwouldinterruptgroundingcontinuity.
• Allsolventpails: Useonlygroundedmetal
containers,whichareconductive.Donotuse
plasticcontainers.Useonlynon-󰘱ammable
solvents.Donotstoremorethanthequantity
neededforoneshift.
•Allpersonsenteringthesprayareamustwear
shoeshavingconductivesolessuchasleather,
orwearpersonalgroundingstraps.Donot
wearshoeswithnon-conductivesolessuchas
rubberorplastic.Ifglovesarenecessary,wear
theconductiveglovessuppliedwiththegun.If
non-Gracoglovesareworn,cutoff󰘰ngersorpalm
areaofglovestoensureyourhandcontactsthe
groundedgunhandle.Conductiveglovesand
footwearmustnotexceed100megohmperEN
ISO20344,EN1149–5.
Connect Connect
Connectthe the theHoses Hoses Hoses
Toreducetheriskofelectricshock,installonly
onecontinuousGracowaterbornehosebetween
theisolationcabinetandthegun.Donotsplice
hosestogether.
AlwaysuseaGracowaterborne󰘱uidhosebetween
the󰘱uidoutletontheisolationcabinetandthegun
󰘱uidinlet.
Whensettinguptheisolationsystemforthe󰘰rsttime,
connectthehosesinthefollowingorder:
1.Fluidhosefromthegunto
theisolationcabinet.See
ConnecttheWaterborneFluidHose,page18.
2.Airhosefromtheguntotheisolationcabinet.
SeeConnecttheAirHosefromGuntothe
Cabinet,page19.
3.Airhosefromtheairsupplytotheisolation
cabinet.SeeConnecttheAirSupplyHosetothe
Cabinet,page20.
4.Fluidhosefromthe󰘱uidsupplytotheisolation
cabinet.SeeConnecttheFluidSupplyHoseto
theCabinet,page21.
Note
•Iftheairhoseorthe󰘱uidhosemustpass
throughthewallofaboothtotheisolation
cabinet,makesurethattheholethrough
theboothwalldoesnothavesharpedges
thatcoulddamagethehoses.
•Theholesinthewallmustbelargeenough
toallowthehose󰘰ttingstopassthrough.
3A7370B17

Installation
Connect Connect
Connectthe the theWaterborne Waterborne WaterborneFluid Fluid FluidHose Hose Hose
AlwaysuseaGracowaterborne󰘱uidhosebetween
thevoltageisolationsystem󰘱uidoutletandthegun
󰘱uidinlet.
Beforeconnectingthewaterborne󰘱uidhosetothe
gun,blowitoutwithairand󰘱ushwithwaterto
removecontaminants.Flushthegunbeforeusingit.
Toreducetheriskofelectricshock,installonly
onecontinuousGracowaterbornehosebetween
theisolated󰘱uidsupplyandthegun.Donotsplice
hosestogether.
1.Removethegunairinlet󰘰tting(21).
Note
This󰘰ttingusesaleft-handthread.
Figure7ConnecttheFluidHose
2.Removetheo-ring(21a)andassembletheinlet
󰘰ttingthroughthebracket(101b).Reassemble
theo-ring.
3.Makesurethebarrel󰘱uidinletiscleananddry.
Applydielectricgreasetothethreadsandfrontof
thebarrelconnector(101)andscrewitintothe
󰘱uidinletjustuntilsnug.Thencontinuetotighten
the󰘰ttingaminimumof1/2turnandcontinueto
rotateuntilthe󰘰ttingisorientedasshown.The
gapbetweenthe󰘰ttingandthebarrelmustbe
lessthan.125in(3.2mm).
Figure8OrientationofFittingandBarrel
4.Loosenthestrainreliefnut(101c).
5.Applydielectricgreasetothethreadsofthe
hoseconnector(101g).Pulltheconnectorback
andapplygreasetotheoutsidediameterofthe
hose.Threaditintothebarrelconnector(101)
untilsnugandthenaminimumof1/2turnmore.
Useawrenchtoholdthebarrelconnectorwhen
tightening.
6.Alignthebracket(101b)holeswiththeairinlet
andexhaustoutlet.Securewiththeairinlet󰘰tting
(21).
7.Tightenthestrainreliefnut(101c).
8.Presstheexhausttube(36)ontotheexhaust
valve.Securewiththeclamp(43).
Note
Wheneverpossible,keepthe󰘱uidhose
assembledtothegunbarrel.Toremove
thebarrel,disconnectthehosebracket
atthegunhandle.
9.Loosenthestrainreliefnutatthehoseinletend
(101c).
10.Slidetheotherendofthehosethroughtheholein
thesideoftheisolatedenclosure(CA).Connect
theswivel(101h)tothe󰘱uidoutletofthepump.
11.Securethehosetothesideoftheenclosure
withthebracket(101j).Abolt(S)assembles
throughtheholeinthebracketandscrewsinto
thesideoftheenclosure.Setscrew(101m)can
beloosenedtorotatethebracketifneeded.
183A7370B

Installation
12.Tightenthestrainreliefnut(101c)andsetscrew
(202m).
Note
TheGracowarrantyandapprovals
arevoidiftheelectrostaticspraygun
isconnectedtoanon-Gracovoltage
isolationsystemorifthegunisoperated
above60kV.
Figure9HoseConnectionatEnclosure
Figure10HoseConnectionatEnclosure
Connect Connect
Connectthe the theAir Air AirHose Hose Hosefrom from fromGun Gun Gunto to tothe the the
Cabinet Cabinet
Cabinet
Connectthegunairhosebetweentheairoutlet(D)
ontheisolationcabinetandthegunairinletswivel
onthegun.Beforebeginningthisprocedure,the󰘱uid
hoseshouldbeattachedtothegunbarrelandtheair
inletswivelshouldbepositionedthroughthebracket
atthegunhandle.
1.Installandtightentheairhoseontothegunair
inletswivel.
Note
This󰘰ttingconnectionisaleft-hand
thread.
2.Connecttheairhosefromtheguntotheairoutlet
(D)ontheisolationcabinet.
Figure11AirConnectionLocation
3.The󰘰ttingontheairhosehasaground
connectionforelectrostaticguns.Attachthe
otherendofthegroundwiretoatrueearth
ground.SeeGrounding,page16.
3A7370B19

Installation
Prepare Prepare
Preparethe the theIsolation Isolation IsolationValve Valve ValveBefore Before Beforethe the theFirst First First
Use Use
Use
Theisolationsystemmaybeshippedwithatiewrap
holdingtheisolationvalve(G)intheupmostposition
topreventmovement.Beforeoperation,removethe
tieand󰘰llthewash󰘱uidreservoir(W).
1.Usea󰘱atbladescrewdrivertoopenthecabinet.
2.Insidethecabinet,slidetheelectrostaticshield
(82)uptoremove.Opentheisolationvalve
cover(99).
3.Ifatiewrapissecuringtheisolationvalve(G),
cutandremovethetie.
4.Unscrewandremovethewash󰘱uidreservoir
(W).
5.Fillthewash󰘱uidreservoir(W)withclean
HydroShieldcleansingsolutionandreplaceitin
thecabinet.
Figure12ReplacingWashFluidReservoir
6.Closetheisolationvalvecover(99)andreinstall
theelectrostaticshield(82)insidethecabinet.
7.Closethecabinetdoorandusea󰘱atblade
screwdrivertosecurethedoorshut.
Connect Connect
Connectthe the theAir Air AirSupply Supply SupplyHose Hose Hoseto to tothe the theCabinet Cabinet Cabinet
Useawrenchtoconnecttheairsupplyhosebetween
theairsupplyandtheairinlet(A)ontheisolation
cabinet.Themaximumairpressureis100psi(0.7
MPa,7.0bar).Aminimumof70psi(0.5MPa,5.0
bar)isneededtooperatethesystem.
Forbestperformanceuseanairsupplyhosewitha
minimuminnerdiameterof3/8inch(10mm).Donot
usequickdisconnectconnectors.
Installableedtypeairvalve(AV)nearthecabinet
toeasilyturnofftheairsupplyduringinstallationor
service.
Figure13AirandFluidInlets
203A7370B