Graco HydroShield WMBL00 Parts list manual

Instructions-Parts
HydroShield™ HydroShield™
HydroShield™Air Air AirSpray Spray SprayBatch Batch Batch
Waterborne Waterborne
WaterborneIsolation Isolation IsolationSystems Systems Systems3A7312D
EN
Air Air
Airspray spray spraysystem system systemfor for foruse use usewhen when whenelectrostatically electrostatically electrostaticallyspraying spraying sprayingconductive, conductive, conductive,waterborne waterborne waterborne󰘱uids 󰘱uids 󰘱uidsthat that thatmeet meet meetat at at
least 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.Not Not Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosive
atmospheres 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.
100psi(0.7MPa,7.0bar)Maximum
FluidWorkingPressure
100psi(0.7MPa,7.0bar)MaximumAir
WorkingPressure
NOTE:Thismanualcoversisolation
systemoperation.Forspraygun
operation,seemanual3A7504.
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...........................23
ConnecttheGunFlushBox..........................23
InstalltheOptionalSystemStopPneumatic
InputKit.........................................25
WiretheSystemStopDigitalInput................26
InstalltheOptionalSystemStatus
Output...........................................26
ChecktheGroundingoftheSprayGunand
IsolationSystem.............................27
FlushtheEquipmentBeforeFirstUse...........28
Operation...........................................................29
OperationOverview.....................................29
FluidVoltageDischargeandGrounding
Procedure......................................29
PressureReliefProcedure............................30
FlushtheSystem(SystemswithoutColor
Change).........................................31
FlushtheSystem(ColorChangeEnabled
Systems)........................................32
GunFlushBoxOperation.............................33
PrimetheIsolationSystem...........................33
SpraywiththeIsolationSystem....................34
AdjusttheGunFluidandAirSettings............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........................................58
MaintenanceScreens...................................60
SystemScreen............................................66
Maintenance......................................................67
RoutineMaintenance...................................67
PreparetheSystemforService.....................68
CheckforFluidLeaks...................................68
ReplacetheWashFluid...............................69
CheckandLubricatetheGroundRod............70
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..............................111
WiringConnections....................................112
ColorChange:PneumaticandWiring
Connections.................................114
Parts................................................................115
IsolationSystem........................................115
25N030IsolationValveParts......................120
25N031IsolationFluidPumpParts.............122
ElectronicControlParts.............................124
RepairKitsandAccessories..............................127
Accessories...............................................127
Kit26B415,ColorChange..........................129
IsolationValveKits.....................................133
IsolationFluidPumpKits............................136
Performance....................................................137
IgnitabilityofCoatingMaterials..........................138
Dimensions......................................................139
TechnicalSpeci󰘰cations....................................140
23A7312D

RelatedManuals
CaliforniaProposition65...................................141GracoStandardWarranty..................................142
Related Related
RelatedManuals Manuals Manuals
Manual Manual
Manualin in in
English English
English
Description Description
Description
3A7504ProXp™60WBGun
309455TestFixture,HighVoltageProbe,andkVMeter
307212StainlessSteel,WaterbaseCompatibleFluidPressureRegulators
312782AirActuatedDispenseValve
309227GunFlushBoxModule
312783ColorandCatalystChangeValveStacks
3A1244GracoControlArchitecture™ModuleProgramming
3A7312D3

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:
•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.
SeeIgnitabilityofCoatingMaterials,page138.
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.
43A7312D

Models
Models Models
Models
Approved Approved
ApprovedSystem System SystemComponents Components Components
Anycombinationofthefollowingisolationcabinets,sprayguns,󰘱uidhoses,andairhosesareFM-approved
andmeettherequirementsofEN50059:2018.
Completeisolationsystemsareavailablewhichincludeanisolationcabinet,aspraygun,a󰘱uidhose,
andanairhose.SeeTable2Pre-packagedFM-approvedIsolationSystems,page6fordetailsaboutthe
componentsineachpackage.
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)
WMBL00
Isolationcabinetformanualair
spray.
WMBL01
Isolationcabinetformanualair
spray,equippedforgun󰘱ushbox.
WMBL02
Isolationcabinetformanualair
spray,equippedwithcolorchange
inletvalves.
WMBL03
Isolationcabinetformanualair
spray,equippedforgun󰘱ushbox
andcolorchangeinletvalves.
L60T18ProXp™60WB
StandardElectrostaticAirSpray
Gunforwaterbornecoatings
L60M18ProXp60WB
SmartElectrostaticAirSprayGun
forwaterbornecoatings
L60M19ProXp60WBMRG
SmartElectrostaticAirSprayGun
formoldreleaseapplications
25R002
25ft.
(7.6m)
25R003
36ft.
(10.9m)
25R004
50ft.
(15.2m)
25R005
75ft.
(22.8m)
25R006
100ft.
(30.5m)
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.
SeeIgnitabilityofCoatingMaterials,page138.
3A7312D5

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
Color Color
Color
change change
change
Gun Gun
Gun
included included
included
Fluid Fluid
Fluid
hose hose
hose
included included
included
Air Air
Airhose hose hose
included included
included
WMBL20•ProXpairspraygun
•25ft.hosesetWMBL00——L60T18
25R002
25ft.
(7.6m)
235070
25ft.
(7.6m)
WMBL40•ProXpairspraygun
•50ft.hosesetWMBL00——L60T18
25R004
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBL41
•ProXpairspraygun
•50ft.hoseset
•Equippedforgun
󰘱ushbox
WMBL014—L60T18
25R004
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBL42*
•ProXpairspraygun
•50ft.hoseset
•Colorchange
WMBL02—4L60T18
25R004
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBL43*
•ProXpairspraygun
•50ft.hoseset
•Colorchange
•Equippedforgun
󰘱ushbox
WMBL0344L60T18
25R004
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBL60
•ProXpmoldrelease
spraygun
•25ft.hoseset
WMBL00——L60M19
25R002
25ft.
(7.6m)
235070
25ft.
(7.6m)
WMBL80
•ProXpmoldrelease
spraygun
•50ft.hoseset
WMBL00——L60M19
25R004
50ft.
(15.2m)
235072
50ft.
(15.2m)
*Systemswithcolorchangeinletvalvesinstalledincludesix󰘱uidvalveswhichallowtheuseofthreecolors
andpurgesequences.Thesesystemsarealsoequippedfordumpvalveoperation.Seethecolorchangekit
informationinAccessories,page127.
63A7312D

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 boxColor Color Colorchange change change
WMBL00Isolationcabinetformanualairspray.——
WMBL01Isolationcabinetformanualairspray,equippedforgun
󰘱ushbox.4—
WMBL02Isolationcabinetformanualairspray,equippedwith
colorchangeinletvalves.—4
WMBL03Isolationcabinetformanualairspray,equippedforgun
󰘱ushboxandcolorchangeinletvalves.44
3A7312D7

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:
•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.
83A7312D

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.
•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.
3A7312D9

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.
103A7312D

ComponentIdentication
Component Component
ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
Figure1ComponentsoftheAirSprayIsolationSysteminaTypicalWaterborneManualBatchSystem
Key Key
Key
Item Item
ItemDescription Description Description
AAirInlet
CControlInterface
CCColorChangeModule(oncolorchange
enabledsystems)
DAirOutlettoGun
EFluidOutlettoGun
FFluidInlet
GIsolationValve
JFluidInletValve
Item Item
ItemDescription Description Description
KIsolationFluidPump
LFluidPressureRegulator
MElectronicsPanel
NGroundRodandBleedResistor
PPowerSupply
RHand-heldGroundedRod
VSColorChangeValveStack(oncolor
changeenabledsystems)
WWashFluidBottle
3A7312D11

TypicalInstallation
Typical Typical
TypicalInstallation Installation Installation
Figure2TypicalInstallation,AirSprayWaterborneManualBatchSystem,Non-HazardousLocation
Key Key
Key
Item Item
ItemDescription Description Description
AB†BleedTypeAirValve
AM†MainAirSupplyLine
AS†OilSeparator
AVvAirShut-offValve
CAIsolationCabinet
FS†FluidSupplyLine
FVvFluidShut-offValve
GCGroundLug
GWProXpWaterborneElectrostaticAir
SprayGun
Item Item
ItemDescription Description Description
HGGracoRedGroundedAirHose
(left-handthreadsatgun)
HWGracoWaterborneFluidHose
LTLightTower
PCPowerCord
†Required,notsupplied.
vOptional,notsupplied.
123A7312D

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: Note:
Note:TheGracowarrantyandapprovalsarevoidif
anon-Gracoelectrostaticspraygunisconnectedto
thevoltageisolationsystemorifthegunisoperated
above60kV.
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
typicalwaterbornemanualbatchsystem.Itisnotan
actualsystemdesign.
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.
3A7312D13

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,page140for
theweight.
1.Selectandattachtheappropriatemounting
hardwaretothestand.
2.Drillholesintothewallbasedontheselected
hardware.
Amountingholepatternisprovidedoneachside
oftheframe.
Figure4HolePatternforWallMounting
3.Withtwopeople,removetheisolationsystem
fromtheshippingpallet.
143A7312D

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
indicateshowmuchpaintisintheisolation󰘱uid
pump(K)asit󰘰llsanddispenses.
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,page127.
2.ConnecttheCANcableonthelighttower(LT)
tothecontrolinterface(C)sothattheisolation
systemcancommunicatewiththelight.Longer
cablesareavailable.
3.Thebottomofthecontrollercontainstwo󰘰ttings.
ScrewtheendoftheCANcableintothe󰘰tting
(111).SeeConnecttheCANCables,page21.
3A7312D15

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: Groundthegunbyconnectingthe
red-coloredGracogroundedairhose(HG)tothe
gunandconnectingtheairhosegroundwiretoa
trueearthground.
Thiselectrostatichand-heldsprayingequipment
couldpresenthazardsifitisnotoperatedaccording
totheinformationgiveninthesprayguninstruction
manual.SeeRelatedManuals,page3.
• Waterborne󰘱uidhose: Thehosemustbeproperly
groundedthroughtheconductivelayer.
•
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
163A7312D

Installation
feet(30.5m)combinedhoselengthtoensure
groundingcontinuity.
•
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.Fluidhosefromtheguntotheisolationcabinet.
SeeConnecttheFluidHosefromtheGuntothe
Cabinet,page18.
2.Airhosefromtheguntotheisolationcabinet.
SeeConnecttheAirHosefromGuntothe
Cabinet,page20.
3.Airhosefromtheairsupplytotheisolation
cabinet.SeeConnecttheAirSupplyHosetothe
Cabinet,page21.
4.Fluidhosefromthe󰘱uidsupplytotheisolation
cabinet.SeeConnecttheFluidSupplyHoseto
theCabinet,page21.
Note
•Iftheairhoseorthe󰘱uidhosemustpass
throughthewallofaboothtotheisolation
cabinet,makesurethattheholethrough
theboothwalldoesnothavesharpedges
thatcoulddamagethehoses.
•Theholesinthewallmustbelargeenough
toallowthehose󰘰ttingstopassthrough.
3A7312D17

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.AnewGracowaterborne󰘱uidhosecomesfully
assembledandreadytoinstall.Forinformation
abouthoserepairanddimensions,consultthe
spraygunmanual.
3.Removethegunairinlet󰘰tting(GW4)fromthe
gun.
Note
This󰘰ttingusesaleft-handthread.
4.Removetheo-ring(GW10)andinstallthe󰘰tting
throughthebracket(GW3).Reassemblethe
o-ring.
5.Generouslyapplydielectricgreasetotheo-ring
andthethreadsofthebarrel󰘰tting(HW1).Pull
the󰘰ttingback1-1/2in.(38mm)andapply
greasetotheexposedhoseto󰘰llthearea
betweenthehoseandthe󰘰tting.Makesurethe
barrelinletiscleananddry,thenscrewthe󰘰tting
intothe󰘱uidinletofthegunbarrel(GW1)and
tighten.
Figure7ConnecttheFluidHosetoGun
6.Loosenthestrainreliefnut(GW7)sothebracket
canmovefreelyonthe󰘱uidhose.
7.Alignthebracket(GW3)holeswiththeairinlet
andexhaustoutletandthreadintheairinlet
󰘰tting.Tightenthe󰘰ttingto75-85in.lb.(8.4-9.6
N•m).
8.Tightenthestrainreliefnut(GW7)tosecurethe
hose.
9.Checkthatthenut(GW5)istightenedsecurely
totheferrulehousing(GW6).
10.Presstheexhausttube(GW8)ontotheexhaust
valvebarb(GW2).Securewiththeclamp(GW9).
11.Thoroughlytightenthe󰘱uid󰘰tting(HW1).
12.Connectthe󰘱uidhosetothe󰘱uidpressure
regulatorinsidetheisolationcabinet.Before
enteringthecabinet:
a.Followthe
PressureReliefProcedure,page30.
b.Followthevoltagedischargeandground
procedure.SeeGrounding,page16.
c.Openthecabinetandslidetheelectrostatic
shield(12)uptoremove.
13.Removethe󰘱uidoutletstrainreliefferrule(38)
fromthestrainreliefhousing.
Figure8ShieldedHoseConnectionatIsolation
Cabinet
183A7312D

Installation
14.Slidethestrainreliefferrule(38)overthe
conductivehoselayer(FC)untilitreachesthe
abrasionlayer(FJ)
Figure9FittingtoAbrasionLayeronWaterborne
FluidHose
15.Inthisposition,the󰘰ttingclampsontothe
conductivesegment(FC)ofthehosewhen
tightened.
Conductivehoselayer(FC)mustbegrounded
throughitsconnectiontotheisolationsystem’s
groundedcabinet(CA).Tomaintaingrounding
continuity,theconductivehoselayer(FC)must
beengagedintheferrulewhenthestrainrelief
nutistightened.Failuretoproperlyinstallthe
hoseinthestrainreliefcouldresultinanelectric
shock.
16.Feedthehosetube(FT)throughthestrainrelief
housingintothecabinetuntilitreachesthetube
compression󰘰tting(82)onthe󰘱uidregulator.
Unscrewthenutportionofthe󰘰tting.Thenut
portioniscomprisedof3pieces(82a,82b,82c).
17.Slidethenut(82a)ontothe󰘱uidhose,followed
bythefrontferrule(82b),andthentheback
ferrule(82c).Thewidersideofeachferrule(82b,
82c)facesthenut(82a).
Figure10FerruleOrientationontheFluidHose
18.Pullthenut(82a,82b,82c)backfromtheendof
thehose.Insertandpushthehose(FT)down
ontothetubecompression󰘰tting(82)untilit
isfullyseatedinthe󰘰ttingbody(82d).Usea
wrenchtotightenthe󰘰ttingto55in-lb(6.2N•m).
19.Threadthestrainreliefferrule(38)intothestrain
reliefhousingandtightento55in-lb(6.2N•m).
Toavoidcuttingthehose,donotovertighten.
20.Makesurethattheballvalve(39)isopen(handle
up)toallow󰘱uidto󰘱ow.
21.Reinstalltheelectrostaticshield(12)insidethe
cabinet.
22.Closethecabinetdoorandusea󰘱atblade
screwdrivertosecurethedoorshut.
3A7312D19

Installation
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.
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󰘱uidbottle(W).
1.Usea󰘱atbladescrewdrivertoopenthecabinet.
2.Slidetheelectrostaticshield(12)uptoremove.
3.Toremovetheisolationvalvecover(99),loosen
thetopandbottomscrews(99a).
4.Ifatiewrapissecuringtheisolationvalve(G),
cutandremovethetie.
5.Disconnectthepush-to-connecttubefromthe
bottlecapofthewash󰘱uidbottle(W).
6.Liftthesealedwash󰘱uidbottle(W)outofthe
system.FillitwithcleanHydroShieldcleansing
solutionabovetheminimumlinemarkedonthe
bottle.Replaceitinthecabinet.
Figure12ReplacingWashFluidBottle
7.Reconnectthepush-to-connecttubetothebottle
capofthewash󰘱uidbottle(W).
8.Replacetheisolationvalvecover(99)andtighten
thetopandbottomscrews(99a).
9.Reinstalltheelectrostaticshield(12)insidethe
cabinet.
10.Closethecabinetdoorandusea󰘱atblade
screwdrivertosecurethedoorshut.
203A7312D