Graco HydroShield User manual

Instructions-Parts
HydroShield™ HydroShield™
HydroShield™Air Air Air- - -Assisted Assisted AssistedBatch Batch Batch
Waterborne Waterborne
WaterborneIsolation Isolation IsolationSystems Systems Systems3A7370C
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 page5. 5. 5.Not Not Notapproved approved approvedfor for foruse use usein in in
explosive 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) Maximum AirWorking Pressure
See page 6 for model informationincluding maximum 󰘱uid workingpressure.
NOTE: This manual covers isolationsystem operation. For spray gunoperation, see manual 3A7503.
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............................31
FlushtheSystem(SystemswithoutColor
Change).........................................33
FlushtheSystem(ColorChangeEnabled
Systems)........................................35
GunFlushBoxOperation.............................36
PrimetheIsolationSystem...........................37
SpraywiththeIsolationSystem....................37
AdjusttheGunFluidandAirSettings............38
Shutdown....................................................39
ControlInterface.................................................40
MenuBar....................................................41
SoftKeyIcons.............................................41
NavigatetheScreen.....................................41
RunScreensandSetupScreens..................42
ControlInterfaceSetupandMaintenance.............43
EnableUSBData.........................................43
USBLogs....................................................43
SystemCon󰘰gurationSettingsFile................43
CustomLanguageFile.................................43
DownloadSystemData................................44
UploadSystemCon󰘰guration.......................45
CleantheScreenSurface.............................45
UpdatetheSystemSoftware........................45
RunMenus........................................................49
HomeScreen..............................................49
EventsScreen.............................................54
StatusScreens............................................54
SetupMenus......................................................56
Presets........................................................56
PurgeScreens1–5......................................57
PumpScreens.............................................58
AdvancedScreens.......................................59
CalibrateScreens........................................61
MaintenanceScreens...................................63
SystemScreen............................................69
Maintenance......................................................70
RoutineMaintenance...................................70
PreparetheSystemforService.....................71
CheckforFluidLeaks...................................71
ReplacetheWashFluid...............................72
CheckandLubricatetheGroundRod............72
ChecktheBleedResistor.............................73
ChecktheDoorSwitch.................................73
Troubleshooting..................................................74
GeneralTroubleshooting..............................74
LEDDiagnosticInformation..........................78
TroubleshootingtheControlInterface............78
VoltageLossTroubleshooting.......................79
TroubleshootingColorChangeSolenoid
Valves...........................................81
ErrorCodes........................................................84
Repair................................................................93
PreparetheIsolationSystemfor
Service..........................................93
ServicetheIsolationValve............................94
ServicetheIsolationFluidPump.................104
ServicetheElectricalControls....................109
PneumaticConnections..............................114
WiringConnections....................................116
ColorChange:PneumaticandWiring
Connections.................................118
Parts................................................................119
IsolationSystem........................................119
25N030IsolationValveParts......................125
25N031IsolationFluidPumpParts.............127
ElectronicControlParts.............................129
RepairKitsandAccessories..............................132
Accessories...............................................132
Kit26B400,SupplyPump...........................134
ColorChangeComponents........................135
IsolationValveKits.....................................139
PumpKits..................................................141
Performance....................................................142
IgnitabilityofCoatingMaterials..........................143
Dimensions......................................................144
2
3A7370C

RelatedManuals
Notes..............................................................145
TechnicalSpeci󰘰cations....................................146
CaliforniaProposition65...................................147
GracoStandardWarranty..................................148
Related Related
RelatedManuals Manuals Manuals
Manual Manual
Manualin in in
English English
English
Description Description
Description
3A7503ProXp™Air-AssistedWBGun
309455TestFixture,HighVoltageProbe,andkVMeter
312782AirActuatedDispenseValve
312794Merkur®PumpAssembly
307273FluidOutletFilter
309227GunFlushBoxModule
312783ColorandCatalystChangeValveStacks
3A1244GracoControlArchitecture™ModuleProgramming
3A7370C 3

IsolationSystemOverview
Isolation Isolation
IsolationSystem System SystemOverview Overview Overview
How How
Howthe the theIsolation Isolation IsolationSystem System SystemWorks Works Works
WhenusingaHydroShieldAir-AssistedBatch
WaterborneIsolationSystem,the󰘱uidsupply
remainsgrounded.The󰘱uidsupplycanbeany
lowpressurepumporcirculationsystem.Thelow
pressure󰘱uidsupply󰘰rst󰘰llsaninternallowpressure
pumpreservoir,thatthenfeedsintoanisolated
MerkurAA󰘱uidpumptosendhighpressure󰘱uidto
thegun.Aftertheisolationsystemhas󰘰lledwith
paint,theisolationvalveseparatesandraises.This
allowsthe󰘱uidinsidetheisolationsystemtobecome
electrostaticallychargedwhenthegunistriggered.
Thecharged󰘱uidisattractedtothegrounded
workpiece,wrappingaroundandevenlycoatingall
surfaces.Whentheguntriggerisreleased,the
isolationpumpautomaticallyre󰘰lls.
Spraying Spraying
SprayingWaterborne Waterborne WaterborneFluids Fluids Fluids
Electrostatically Electrostatically
Electrostatically
Thisisolationsystemandelectrostaticair-assisted
gunaredesignedtosprayonly only
onlywaterborne󰘱uids
whichmeetatleastoneofthefollowing󰘱ammability
requirements:
•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,page143.
Whenanelectrostaticgunisconnectedtoavoltage
isolationsystem,allofthe󰘱uidinthespraygun,
󰘱uidhose,andisolated󰘱uidsupplyischargedto
highvoltage,whichmeansthatthesystemhas
moreelectricalenergythanasolvent-basedsystem.
Therefore,onlynon-󰘱ammable󰘱uids(asde󰘰ned
aboveandinModels,page5)canbesprayedwith
thesystemorbeusedtoclean,󰘱ush,orpurgethe
system.
Precautionsmustbetakenwhenusingelectrostatic
waterborneequipmenttoavoidpotentialshock
hazards.Whenthespraygunchargestheisolated
󰘱uidtohighvoltage,itissimilartocharginga
capacitororabattery.Thesystemwillstoresomeof
theenergywhilesprayingandretainsomeofthat
energyafterthespraygunisshutoff.Becauseit
takessometimeforthatstoredenergytodischarge,
itisimportanttoreadtheinstructions,includingthe
FluidVoltageDischargeandGroundingProcedure,
page29,andGrounding,page16,tounderstand
whenyoucanapproachortouchthegunnozzle.
Theamountoftimeittakestodischargethe
energydependsonthesystemdesign.Followthe
FluidVoltageDischargeandGroundingProcedure,
page29,beforeapproachingthefrontofthegun.
4
3A7370C

Models
Models Models
Models
Approved Approved
ApprovedSystem System SystemComponents Components Components
Anycombinationofthefollowingisolationcabinets,sprayguns,󰘱uidhoses,andairhosesareFM-approved
andmeettherequirementsofEN50059:2018.
Completeisolationsystemsareavailablewhichincludeanisolationcabinet,aspraygun,ahighpressure
󰘱uidhose,andanairhose.SeeTable2Pre-packagedFM-approvedIsolationSystems,page6fordetails
aboutthecomponentsineachpackage.
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
Fluid
Hoses Hoses
Hoses
(Shielded (Shielded
(Shielded
water- water-
water-
borne) borne)
borne)
Air Air
AirHoses Hoses Hoses
(Grounded) (Grounded)
(Grounded)
WMBH00: WMBH00:
WMBH00:Isolationcabinetformanualair-assistedspray,
30:1󰘱uidpressureratio
WMBH01: WMBH01:
WMBH01:Isolationcabinetformanualair-assistedspray,
equippedforgun󰘱ushbox,30:1󰘱uidpressureratio
WMBH02: WMBH02:
WMBH02:Isolationcabinetformanualair-assistedspray,
installedcolorchangeinletvalves,30:1󰘱uidpressureratio
WMBH03: WMBH03:
WMBH03:Isolationcabinetformanualair-assistedspray,
installedcolorchangeinletvalves,equippedforgun󰘱ush
box,30:1󰘱uidpressureratio
WMBH04: WMBH04:
WMBH04:Isolationcabinetformanualair-assistedspray,
15:1󰘱uidpressureratio
WMBH05: WMBH05:
WMBH05:Isolationcabinetformanualair-assistedspray,
equippedforgun󰘱ushbox,15:1󰘱uidpressureratio
WMBH06: WMBH06:
WMBH06:Isolationcabinetformanualair-assistedspray,
installedcolorchangeinletvalves,15:1󰘱uidpressureratio
WMBH07: WMBH07:
WMBH07:Isolationcabinetformanualair-assistedspray,
installedcolorchangeinletvalves,equippedforgun󰘱ush
box,15:1󰘱uidpressureratio
H60T18 H60T18
H60T18Pro Pro ProXp™ Xp™ Xp™60 60 60
AA AA
AAWB WB WB
Standardelectrostatic
air-assistedgunfor
waterbornecoatings
H60M18 H60M18
H60M18Pro Pro ProXp™ Xp™ Xp™60 60 60
AA AA
AAWB WB WB
Smartelectrostatic
air-assistedgunfor
waterbornecoatings
25R012 25R012
25R012
25ft.
(7.6m)
25R013 25R013
25R013
36ft.
(10.9m)
25R014 25R014
25R014
50ft.
(15.2m)
25R015 25R015
25R015
75ft.
(22.8m)
25R016 25R016
25R016
100ft.
(30.5m)
235070 235070
235070
25ft.
(7.6m)
235071 235071
235071
36ft.
(10.9m)
235072 235072
235072
50ft.
(15.2m)
235073 235073
235073
75ft.
(22.8m)
235074 235074
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 StandardTest Test TestMethod Method Methodfor for for
Sustained Sustained
SustainedBurning Burning Burningof of ofLiquid Liquid LiquidMixtures, Mixtures, Mixtures,ASTM ASTM ASTMD4206. 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 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,page143.
3A7370C 5

Models
Table Table
Table2 2 2Pre Pre Pre- - -packaged packaged packagedFM FM FM- - -approved approved approvedIsolation Isolation IsolationSystems Systems Systems
System System
SystemPart Part Part
No. No.
No.
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*
Maximum Maximum
Maximum
Fluid Fluid
FluidWorking Working Working
Pressure** Pressure**
Pressure**
psi psi
psi(MPa, (MPa, (MPa,bar) bar) bar)
Gun Gun
Gunincluded included included
H60T18 H60T18
H60T18
Pro Pro
ProXp Xp Xp60 60 60AA AA AA
WB WB
WBspray spray spraygun gun gun
Fluid Fluid
Fluid
hose hose
hose
included included
included
Air Air
Airhose hose hose
included included
included
WMBH20WMBH00——3000(20.7,
207)4
25R012
25ft.
(7.6m)
235070
25ft.
(7.6m)
WMBH40WMBH00——3000(20.7,
207)4
25R014
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBH41WMBH014—3000(20.7,
207)4
25R014
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBH42WMBH02—43000(20.7,
207)4
25R014
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBH43WMBH03443000(20.7,
207)4
25R014
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBH44WMBH04——1500(10.3,
103)4
25R014
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBH45WMBH054—1500(10.3,
103)4
25R014
50ft.
(15.2m)
235072
50ft.
(15.2m)
WMBH47WMBH07441500(10.3,
103)4
25R014
50ft.
(15.2m)
235072
50ft.
(15.2m)
*Systemswithcolorchangeinletvalvesinstalledincludesix󰘱uidvalveswhichallowtheuseofthree
colorsandpurgesequences.Thesesystemsarealsoequippedfordumpvalveoperation.See
ColorChangeComponents,page135.
**Allsystemshaveamaximuminletpressureof100psi.
6 3A7370C

Models
Table Table
Table3 3 3Isolation Isolation IsolationCabinets Cabinets Cabinets
MustpurchaseProXpgunandhosesseparately.
Part Part
PartNo. No. No.Description Description Description
Equipped Equipped
Equippedfor for for
gun gun
gun󰘱ush 󰘱ush 󰘱ushbox box box
Color Color
Color
change change
change
Maximum Maximum
Maximum
Fluid Fluid
FluidWorking Working Working
Pressure Pressure
Pressure
psi psi
psi(MPa, (MPa, (MPa,bar) bar) bar)
WMBH00Isolationcabinetformanualair-assistedspray,
30:1󰘱uidpressureratio.——3000(20.7, 207)
WMBH01
Isolationcabinetformanualair-assistedspray,
equippedforgun󰘱ushbox,30:1󰘱uidpressure
ratio.
4—3000(20.7,
207)
WMBH02
Isolationcabinetformanualair-assistedspray,
installedcolorchangeinletvalves,30:1󰘱uid
pressureratio.
—43000(20.7,
207)
WMBH03
Isolationcabinetformanualair-assistedspray,
installedcolorchangeinletvalves,equippedfor
gun󰘱ushbox,30:1󰘱uidpressureratio.
443000(20.7,
207)
WMBH04Isolationcabinetformanualair-assistedspray,
15:1󰘱uidpressureratio.——1500(10.3,
103)
WMBH05
Isolationcabinetformanualair-assistedspray,
equippedforgun󰘱ushbox,15:1󰘱uidpressure
ratio.
4—1500(10.3,
103)
WMBH06
Isolationcabinetformanualair-assistedspray,
installedcolorchangeinletvalves,15:1󰘱uid
pressureratio.
—41500(10.3,
103)
WMBH07
Isolationcabinetformanualair-assistedspray,
installedcolorchangeinletvalves,equippedfor
gun󰘱ushbox,15:1󰘱uidpressureratio.
441500(10.3,
103)
3A7370C
7

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.
8 3A7370C

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.
3A7370C 9

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.
10 3A7370C

ComponentIdentication
Component Component
ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
Figure1ComponentsoftheAir-AssistedIsolationSysteminaTypicalWaterborneManualBatchSystem
Key Key
Key
Item Item
ItemDescription Description Description
AAirInlet
CControlInterface
CCColorChangeModule(oncolorchange
enabledsystems)
DAirOutlettoGun
EFluidOutlettoGun
FFluidInlet
GIsolationValve
JFluidInletValve
KIsolationFluidPump
Item Item
ItemDescription Description Description
LMerkurAAFluidPump
MElectronicsPanel
NGroundRodandBleedResistor
PPowerSupply
RHand-heldGroundedRod
VSColorChangeValveStack(oncolor
changeenabledsystems)
WWashFluidBottle
ZFluidFilter(100mesh)
3A7370C
11

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.
12
3A7370C

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.
3A7370C 13

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,page146for
theweight.
1.Selectandattachtheappropriatemounting
hardwaretothestand.
2.Drillholesintothewallbasedontheselected
hardware.
Amountingholepatternisprovidedoneachside
oftheframe.
Figure4HolePatternforWallMounting
3.Withtwopeople,removetheisolationsystem
fromtheshippingpallet.
14
3A7370C

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,page132.
2.ConnecttheCANextension(.4m)cable(121226)
totheCANcableonthelighttower(LT).
3.Connectcabletothecontrolinterface(C)sothat
theisolationsystemcancommunicatewiththe
light.Longercablesareavailable.
4.Thebottomofthecontrollercontainstwo󰘰ttings.
ScrewtheendoftheCANcableintothe󰘰tting
(111).SeeConnecttheCANCables,page21.
3A7370C 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,page80.
Aftergroundingthesystem,checktheresistance
betweentheexterioroftheisolationcabinetand
atrueearthground.Theresistancemustbeless
than100ohms.
•
Fluid supply: Groundthe󰘱uidsupplybyconnecting
agroundwireandclamp.Seeyour󰘱uidsupply
instructionmanualforgroundinginstructions.
•
Power supply: Thepowersupplyisgrounded
throughthepowercordtoagroundedoutlet.
•
Spray gun: Groundthegunbyconnectingthe
red-coloredGracogroundedairhose(HG)tothe
gunandconnectingtheairhosegroundwiretoa
trueearthground.
Thiselectrostatichand-heldsprayingequipment
couldpresenthazardsifitisnotoperatedaccording
totheinformationgiveninthesprayguninstruction
manual.SeeRelatedManuals,page3.
•
Waterborne 󰘱uid hose: Thehosemustbedirectly
connectedtothe󰘱uidsupplyinsidethesystem.
•
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
16 3A7370C

Installation
feet(30.5m)combinedhoselengthtoensure
groundingcontinuity.
•
Floor of the spray area: The󰘱oormustbe
electricallyconductiveandgrounded.Donotcover
the󰘱oorwithcardboardoranynon-conductive
materialwhichwouldinterruptgroundingcontinuity.
• All solvent pails: 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,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.
3A7370C
17

Installation
Connect Connect
Connectthe the theFluid Fluid FluidHose Hose Hosefrom from fromthe the theGun Gun Gunto to tothe the theCabinet Cabinet Cabinet
1.Removethegunairinlet󰘰tting(21).
Note
This󰘰ttingusesaleft-handthread.
Figure7ConnecttheFluidHose
2.Removetheo-ring(21a)andassembletheinlet
󰘰ttingthroughthebracket(101b).Reassemble
theo-ring.
3.Makesurethebarrel󰘱uidinletiscleananddry.
Applydielectricgreasetothethreadsandfrontof
thebarrelconnector(101a)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(101a)
untilsnugandthenaminimumof1/2turnmore.
Useawrenchtoholdthebarrelconnectorwhen
tightening.
6.Alignthebracket(101b)holeswiththeairinlet
andexhaustoutlet.Securewiththeairinlet󰘰tting
(21).
7.Tightenthestrainreliefnut(101c).
Note
Wheneverpossible,keepthe󰘱uidhose
assembledtothegunbarrel.Toremove
thebarrel,disconnectthehosebracket
atthegunhandle.
8.Presstheexhausttube(36)ontotheexhaust
valve.Securewiththeclamp(43).
9.Beforeenteringthecabinet:
a.FollowtheFluidVoltageDischargeand
GroundingProcedure,page29.
b.Followthe
PressureReliefProcedure,page31.
c.Openthecabinet.Slidetheelectrostatic
shield(82)uptoremove,andthenslidethe
electrostaticshield(12)tothelefttoremove.
10.Loosenthestrainreliefnutatthehoseinletend
(101c).
11.Slidetheotherendofthehosethroughtheholein
thesideoftheisolatedenclosure(CA).Connect
theswivel(101h)tothe󰘱uidoutletofthepump.
12.Securethehosetothesideoftheenclosure
withthebracket(101j).Abolt(S)assembles
throughtheholeinthebracketandscrewsinto
thesideoftheenclosure.Setscrew(101m)can
beloosenedtorotatethebracketifneeded.
18 3A7370C

Installation
13.Tightenthestrainreliefnut(101c)andsetscrew
(101m).
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.
3A7370C 19

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󰘱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.
Figure12ReplacingWashFluidReservoir
7.Reconnectthepush-to-connecttubetothebottle
capofthewash󰘱uidbottle(W).
8.Replacetheisolationvalvecover(99)andtighten
thetopandbottomscrews(99a).
9.Reinstalltheelectrostaticshield(12)insidethe
cabinet.
10.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
20 3A7370C