Graco HydroShield WABH00 Instructions - Parts Manual
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Graco HydroShield WABH00 Instructions - Parts Manual

Automatic air-assisted batch waterborne isolation systems
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Instructions - Parts
HydroShield™ Automatic
HydroShield™
HydroShield™
Batch
Batch
Batch Waterborne
Waterborne Isolation
Waterborne
Air- - - assisted
assisted spray
spray system
system for
Air
Air
assisted
spray
system
waterborne
waterborne fluids
waterborne
fluids
fluids that
that meet
that
used
used in in in a a a permanent
used
permanent location.
permanent
location. Not
location.
locations. For
For professional
professional use
locations.
locations.
For
professional
Important
Important Safety
Important
Safety Instructions
Safety
Read all warnings and instructions in this manual and in the spray
gun manual before using the equipment. Save these instructions
100 psi (0.7 MPa, 7.0 bar) Maximum
Fluid Inlet Working Pressure.
3,000 psi (20.7 MPa, 207 bar) Maximum
Fluid Outlet Working Pressure.
See page 5 for model information.
Automatic Air
Automatic
Isolation Systems
Isolation
for use
use with
with automatic
automatic electrostatic
for
use
with
automatic
meet at at at least
meet
least one
least
one
one of of of the
the conditions
the
Not approved
Not
approved for
approved
use only.
only.
use
only.
Instructions
Instructions
PROVEN QUALITY. LEADING TECHNOLOGY.
Air - - - Assisted
Assisted
Air
Assisted
Systems
Systems
electrostatic applicators
applicators when
electrostatic
applicators
conditions
conditions for
for
for non
non- - - flammability
non
flammability listed
flammability
for use
for
use
use in in in explosive
explosive
explosive atmospheres
atmospheres or or or hazardous
atmospheres
3A8492A
when spraying
spraying conductive,
conductive,
when
spraying
conductive,
listed on
listed
on page
on
page 4. 4. 4. To
page
hazardous
hazardous (classified)
(classified)
(classified)
EN
To be
To
be
be

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Summary of Contents for Graco HydroShield WABH00

  • Page 1 Instructions - Parts HydroShield™ Automatic Automatic Air Air - - - Assisted Assisted HydroShield™ HydroShield™ Automatic Assisted Batch Batch Batch Waterborne Waterborne Isolation Waterborne Isolation Systems Isolation Systems Systems 3A8492A Air- - - assisted assisted spray spray system system for for use use with with automatic...

  • Page 2: Table Of Contents

    Contents Contents Contents Related Manuals ..........3 Clean the Screen Surface......41 Update the System Software ......41 Isolation System Overview ........4 How the Isolation System Works ..... 4 Run Menus ............45 Spraying Waterborne Fluids Home Screen ..........45 Electrostatically ........

  • Page 3: Related Manuals

    Pro Xp™ Auto Waterborne AA Spray Gun 309455 Test Fixture, High Voltage Probe, and kV Meter 312782 Air Actuated Dispense Valve 312794 Merkur ® Pump Assembly 307273 Fluid Outlet Filter 312783 Color and Catalyst Change Valve Stacks 3A1244 Graco Control Architecture™ Module Programming 3A8492A...

  • Page 4: Isolation System Overview

    Isolation System Overview Isolation System System Overview Overview Isolation Isolation System Overview How the the Isolation Isolation System System Works Works Spraying Waterborne Waterborne Fluids Fluids Isolation System Works Spraying Spraying Waterborne Fluids Electrostatically Electrostatically Electrostatically When using a HydroShield Air-Assisted Batch Waterborne Isolation System, the fluid supply This isolation system and electrostatic air-assisted remains grounded.

  • Page 5: Models

    Models Models Models Models Must purchase gun and hoses separately. Part Part Part Description Description Description Color Color Color change change change WABH00 Isolation cabinet for automatic air assist spray. Isolation cabinet for automatic air assist spray, equipped with color �...

  • Page 6: Warnings

    Warnings Warnings Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
  • Page 7 Discharge and Discharge and Grounding Grounding Grounding Procedure Procedure. Procedure • Do not splice hoses together. Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the spray gun. MOVING MOVING MOVING PARTS PARTS PARTS HAZARD...
  • Page 8 Warnings WARNING WARNING WARNING EQUIPMENT EQUIPMENT EQUIPMENT MISUSE MISUSE HAZARD MISUSE HAZARD HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.

  • Page 9: Component Identification

    Component Identification Component Identification Identification Component Component Identification Figure 1 Components of the automatic Automatic Air-Assisted Isolation System Item Description Item Description Item Item Description Description Item Item Description Description Air Inlet Merkur AA Fluid Pump Electronics Panel Control Interface Color Change Module (on color change Ground Rod and Bleed Resistor enabled systems)

  • Page 10: Typical Installation

    Item Description Description AB † Bleed Type Air Valve Ground Wire AM † Main Air Supply Line Graco Waterborne Fluid Hose AS † Oil Separator Light Tower AV � Air Shut-off Valve Power Cord Isolation Cabinet † Required, not supplied.

  • Page 11: Optional Multiple Gun Installation

    Optional Multiple Gun Installation Optional Multiple Multiple Gun Gun Installation Installation Optional Optional Multiple Installation fluid regulators (L) in the example, should be installed in an enclosure or location that prevents users from coming in contact with charged components any time electrostatics are in use.
  • Page 12 Optional Multiple Gun Installation Figure 3 3 3 Key Figure Figure Item Description Item Item Description Description Graco Waterborne Fluid Hose Fluid Pressure Regulator Electrostatic Applicator Isolated Region Fluid Manifold 3A8492A...

  • Page 13: Installation

    See • Do not install or service this equipment unless Optional Multiple Gun Installation, page you are trained and qualified. The Graco voltage isolation system has the following • Comply with all local codes and regulations. features: The figure in...

  • Page 14: Mount The Cabinet

    Installation Mount the the Cabinet Cabinet Mount Mount Cabinet Mount Mount on Mount on the the Wall Wall Wall Before mounting the isolation cabinet to the wall, make sure that the wall can support the weight of the system. See Technical Specifications, page 140 the weight.

  • Page 15: Install The Light Tower

    Installation Install the the Light Light Tower Tower Install Install Light Tower 4. Remove the feet (3a, 3b, 3c) from the frame. The system is equipped with a light tower which indicates how much paint is in the isolation fluid pump (K) as it fills and dispenses.

  • Page 16: Grounding

    Installation Grounding Grounding Grounding Power supply: • The power supply is grounded through the power cord to a grounded outlet. Spray gun: • Ground the gun according to the spray gun instruction manual. Waterborne fluid hose: • The hose must be directly connected to the fluid supply inside the system.

  • Page 17: Connect The Hoses

    Graco waterborne hose between the isolation cabinet and the gun. Do not splice hoses together. Always use a Graco waterborne fluid hose between the fluid outlet on the isolation cabinet and the gun fluid inlet. If using multiple guns make sure •...
  • Page 18 7. Tighten the strain relief nut (101c) and set screw flush with flushing fluid to remove contaminants. (101m). 2. Connect the Graco waterborne fluid hose to the gun as described in the spray gun manual. See the spray gun manual for hose information and dimensions.
  • Page 19 Installation Connect Connect Connect the the Paint Paint Trigger Paint Trigger Input Trigger Input Input Connect Connect the Connect the Electrostatic Electrostatic Request Electrostatic Request Request Input Input Input The system relies on a pneumatic paint trigger signal The system needs to know when the use of to know when to dispense paint.
  • Page 20 Terminal Block Wiring. 5. Connect terminal block 8 to GND. Note When used with Graco electrostatic controllers, terminal block 7 signal voltage is optically isolated at the controller. If using any other controller be sure to use an optocoupler at the input to the device.
  • Page 21 Installation Prepare Prepare Prepare the the Isolation Isolation Valve Isolation Valve Valve Before Before Before the the First First First Connect Connect the Connect the Air Air Supply Supply Hose Supply Hose Hose to to to the the Cabinet Cabinet Cabinet Use a wrench to connect the air supply hose between the air supply and the air inlet (A) on the isolation...

  • Page 22: Connect The Can Cables

    Installation Connect the the CAN CAN Cables Cables Connect Connect Cables Connect Connect Connect the the Fluid Fluid Fluid Supply Supply Supply Hose Hose Hose to to to the Cabinet Cabinet Cabinet Connect the Control Area Network (CAN) cables to On systems that are not color change enabled: the control interface (42) so that the interface can communicate with the isolation system.
  • Page 23 Installation 2. The system is equipped with another CAN To mount the controller in another location, remove cable (43) that is used to connect to the control bracket (41) from the system and mount it in interface: a convenient location. For information about available alternate length CAN cables, see On systems systems that...

  • Page 24: Connect The Power Supply

    Installation Connect the the Power Power Supply Supply Install the the Optional Optional System System Stop Stop Connect Connect Power Supply Install Install Optional System Stop Pneumatic Input Input Kit Pneumatic Pneumatic Input The power supply (47) with connector (X) is installed at the factory on the back of the isolation cabinet.

  • Page 25: Wire The System Stop Digital Input

    Installation Wire the the System System Stop Stop Digital Digital Input Input Wire Wire System Stop Digital Input 4. Remove the wires in the existing terminal blocks and install in the pressure switch ports as shown below: The System Stop Digital input provides a means to signal the HydroShield system to stop.

  • Page 26: Output

    Installation Install the the Optional Optional System System Status Status Install Install Optional System Status Function A1+ (relative (relative Function Function (relative Output Output Output to to to A2–) A2–) A2–) 13+ and 14 System Status 24 VDC The optional System Status Output provides a means Output Active connected to signal connected devices that the HydroShield is...

  • Page 27: Wire The Low Paint Digital Output

    Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury. Graco Part No. 241079 Megohmmeter (AB) is available as an accessory to check that the gun is properly grounded. 1. Have a qualified electrician check the electrical...

  • Page 28: Flush The Equipment Before First Use

    Installation Flush the the Equipment Equipment Before Before First First Use Flush Flush Equipment Before First 6. Use an ohmmeter (or megohmmeter in the ohm range) to measure the resistance between the cabinet ground lug (214) and a true earth ground The equipment was tested in fluid at the factory.

  • Page 29: Operation

    Operation Operation Operation Operation Operation Operation Operation Overview Overview Overview 1. Release the gun trigger. 2. Disable the electrostatic request signal to turn 1. Plug in the system. The system off electrostatics. powers up and enters Off mode. See 3. After the ground rod delay time elapses, the Connect the Power Supply, page ground rod (N) inside the isolation cabinet lowers 2.

  • Page 30: Procedure

    Operation Pressure Relief Relief Procedure Procedure Pressure Pressure Relief Procedure 6. Relieve fluid pressure in the fluid supply unit as instructed in your fluid supply unit manual. 7. If the objective is to shut down and then service Follow the Pressure Relief the system, relieve any residual pressure in the Procedure whenever you see this two flexible fluid lines between the inlet valves (J)

  • Page 31: Change)

    Operation Flush the the System System (Systems (Systems without without Color Color Change) Change) Flush Flush System (Systems without Color Change) To flush systems that are color change enabled, 1. Release the gun trigger and turn off electrostatics follow the steps in Flush the System (Color Change by disabling the electrostatic request signal.

  • Page 32: Systems)

    Operation Flush the the System System (Color (Color Change Change Enabled Enabled Systems) Systems) Flush Flush System (Color Change Enabled Systems) 2. Follow the Fluid Voltage Discharge and Grounding Procedure, page 3. Follow the Pressure Relief Procedure, page 4. Remove the air cap and spray tip. See the spray gun manual.

  • Page 33: Prime The Isolation System

    Operation Prime the the Isolation Isolation System System Prime Prime Isolation System To purge purge manually: manually: purge manually: 1. If using purge profile 0, the system must be Use the following steps to load the system with paint, manually flushed. On the left side of the screen, change paint colors, or change from flushing fluid three icons appear that activate the dump, flush to paint.

  • Page 34: Spray With The Isolation System

    Operation Spray with with the the Isolation Isolation System System Spray Spray with Isolation System 4. Turn on electrostatics by sending the system the ES request signal. • The control interface displays the voltage building in the system. • The system raises the ground rod (N) in the cabinet.

  • Page 35: Adjust The Gun Fluid Settings

    Operation Adjust the the Gun Gun Fluid Fluid Settings Settings Adjust Adjust Fluid Settings To use use Preset Preset 1 1 1 through through 99: Preset through 1. Press the right arrow until Home appears Preset 0 allows operators to change the gun fluid on the menu bar.

  • Page 36: Control Interface

    Control Interface Control Interface Interface Control Control Interface Soft Key Key Function Function Soft Soft Function Power Power Power The control interface displays graphical and text When the system is in Off mode, press information related to setup and spray operations. to activate the system.

  • Page 37: Menu Bar

    Control Interface Menu Bar Soft Key Key Icons Icons Menu Menu Soft Soft Icons The menu bar appears at the top of each screen. NOTICE NOTICE NOTICE To prevent damage to the soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

  • Page 38: Run Screens And Setup Screens

    Control Interface Run Screens Screens and and Setup Setup Screens Screens Screens Setup Screens – Calibrate (See Calibrate Screens, page 57.) – System (See System Screen, page 66.) The control interface uses two sets of screens: – Pumps (See Pump Screens, page 54.) •...

  • Page 39: Control Interface Setup And Maintenance

    For instructions on how to use this file, serial number on the control interface. When Upload System Configuration, page downloading from multiple controllers, there is one sub-folder in the GRACO folder for each control For the location of the USB port on the control interface. module, see Connect the CAN Cables, page Retrieve the SETTINGS.TXT file after all system...

  • Page 40: Download System Data

    Windows ® Explorer. The following rules must be followed in order for the 6. Open the Graco folder. installation process to succeed. 7. Open the system folder. If downloading data • The file name must be DISPTEXT.TXT. from more than one system, there is more •...

  • Page 41: Upload System Configuration

    5. Open the system folder. If working with more than one system, there is more than one folder If you already have a Graco black software update within the Graco folder. Each folder is labeled token, you can use it to update the HydroShield with the corresponding serial number of the system software.
  • Page 42 Control Interface Setup and Maintenance 4. Save the GTI software update file to the Transfer the software to the system: \GRACO\SOFTWARE\ folder on the USB drive. 1. Navigate to Advanced Screen 4. See To automatically create the SOFTWARE folder Advanced Screen 4, page 56.
  • Page 43 Control Interface Setup and Maintenance 6. When the process is ready to begin, the screen 3. Press the Power button to turn off the system. automatically transitions to the USB Software Note Update screen. If power is cycled while a token is •...
  • Page 44 0.01.002 of the 17X093 software will be copied on how to update the software version of from the USB drive and will overwrite version Graco Control Architecture Modules. See 0.01.001 of 17X083 on the token. Related Manuals, page The progress of writing the software update to Note the token can take several minutes to complete.

  • Page 45: Run Menus

    Run Menus Run Menus Menus Menus Home Home Home Screen Screen Screen The Home screen is the primary screen that the Soft Key Key Function Function Function Soft Soft operator uses while painting. When the system is Purge Purge Purge powered, it enters Off mode.
  • Page 46 Run Menus Home Screen Screen Without Without Color Color Change Change Home Screen Screen With With Color Color Change Change Enabled Enabled Home Home Screen Without Color Change Home Home Screen With Color Change Enabled Off Mode Mode Mode Standby Standby Standby Mode Mode...
  • Page 47 Run Menus Key or or or Field Field Field Description Description Description Do Not Not Fill Fill Fill Activate Do Not Fill to prevent the isolation fluid pump from refilling when the trigger is released and the ES request signal is disabled. Do Not Fill is commonly used at the end of a paint job. Once the pump is empty, the system waits until another mode is selected.
  • Page 48 Run Menus Key or or or Field Field Field Description Description Description Purge Purge Profile Purge Profile Profile Enter a purge profile number to purge the system automatically. (Available on color change enabled systems only.) The purge gun symbol indicates that the number is a purge profile number: To configure a purge sequence, see Purge Screens 1–5, page Gun Fluid...
  • Page 49 Run Menus Home Home Home Screen Screen in in in Purge Screen Purge Mode Purge Mode Mode Home Home Home Screen Screen With Screen With With Color Color Change Color Change Change Enabled Enabled Enabled Manual Purge Purge Screen Screen Purge Profile Profile Screen Screen...

  • Page 50: Events Screen

    Run Menus Events Screen Screen Events Events Screen Inputs are signals that the system acts on. When the status circle next to the input appears yellow, the sensor is activated. Use the Events screen to view the last 99 status messages generated by the isolation system.

  • Page 51: Status

    Run Menus Status Status Status Screen Screen 2 2 2 Screen Status Status Screen Status Screen Screen 3 3 3 Status screen 2 displays the current status of the Status screen 3 displays the inputs and outputs solenoids that drive activity for the color change related to automatic system operation.

  • Page 52: Setup Menus

    Setup Menus Setup Menus Menus Setup Setup Menus Presets Presets Presets To unlock the Setup menus, press the Setup key Use this screen to preconfigure spray settings for If a password is configured, enter the password. different fluids, parts, and scenarios. (Default: 0000.) To configure a password, see For information about using Preset 0-99, see Advanced Screen 1, page...

  • Page 53: Purge Screens 1-5

    Setup Menus Purge Screens Screens 1–5 1–5 Purge Purge Screens 1–5 Use the Purge screens to configure up to 5 purge Purge: Purge: Purge: Assign a number to the purge profile. profiles. Customize each purge profile to best suit The purge profile number can be used: different fluids.

  • Page 54: Pump Screens

    Setup Menus Pump Screens Screens Pump Pump Screens Pump Screen Screen 2: 2: 2: Override Override Purge Purge Pump Pump Screen Override Purge Use the Pump screens to enter volume information about the isolation fluid pump and to manually purge the system in the event of a problem.

  • Page 55: Advanced Screens

    Setup Menus Advanced Screens Screens Advanced Advanced Screens Advanced Screen Screen 2 2 2 Advanced Advanced Screen To edit the information on a screen press the Enter Screen key Use this screen to select the pressure units for the system. To advance to the next Advanced screen, press the down arrow Advanced...
  • Page 56 Screen 4 4 4 Screen Use this screen to update the software part numbers and versions for the system components. Refer to this screen when contacting a Graco distributor for technical assistance. Press the magnifying glass to return to the previous screen.

  • Page 57: Calibrate Screens

    Setup Menus Calibrate Screens Screens Calibrate Calibrate Screens Calibrate Calibrate Calibrate 1: 1: 1: Calibrate Calibrate Calibrate Pump Pump Pump Calibrate Calibrate the Calibrate the Pump Pump Pump Use the Calibrate 1 screen to calibrate the linear Before calibrating the isolation fluid pump, be sure position sensor in the isolation fluid pump.
  • Page 58 Setup Menus Calibrate Calibrate Calibrate 2: 2: 2: Fluid Fluid Fluid Calibrate Calibrate 3: 3: 3: Bleed Calibrate Bleed Bleed Resistor Resistor Resistor Use the Calibrate 2 screen to adjust the calibration Use the Calibrate 2 screen to adjust the value of the fluid.

  • Page 59: Maintenance Screens

    Setup Menus Maintenance Screens Screens Maintenance Maintenance Screens Maintenance Maintenance Maintenance 1: 1: 1: Maintenance Maintenance Maintenance Due Maintenance Maintenance 2: 2: 2: Pump Maintenance Pump Stall Pump Stall Stall Test Test Test Use the Maintenance Due screen to set maintenance Use the Pump Stall Test screen to test the isolation reminders for system components.
  • Page 60 Setup Menus Pump Pump Pump Stall Stall Test Stall Test Test Procedure Procedure Procedure Maintenance Maintenance 3: 3: 3: Shuttle Maintenance Shuttle Valve Shuttle Valve Resets Valve Resets Resets and Test Test Test Before stall testing the isolation fluid pump, be sure that air and fluid are supplied to the system.
  • Page 61 Setup Menus Maintenance Maintenance Maintenance 4: 4: 4: Fluid Fluid Fluid Valve Valve Valve Resets Resets Resets and and Test Test Test Maintenance Maintenance 5: 5: 5: Misc Maintenance Misc Misc Valve Valve Resets Valve Resets and Resets and Test Test Test View fluid valve actuation counts, reset those counts,...
  • Page 62 Setup Menus Maintenance Maintenance Maintenance 6: 6: 6: Output Output Resets Output Resets Resets and and Test Test Test Maintenance Maintenance 7: 7: 7: Isolation Maintenance Isolation Isolation Valve Valve Maintenance Valve Maintenance Maintenance Use this screen to view system output counts, reset Use this screen to view isolation valve actuation those counts, and test the output.
  • Page 63 Setup Menus Maintenance Maintenance Maintenance 8: 8: 8: Pump Pump Maintenance Pump Maintenance Maintenance Maintenance Maintenance 9: 9: 9: V/P Maintenance View information about maintaining the isolation fluid Use the V/P (Voltage to Pressure) screen to test the pump, including cycles and calendar days since the function of the electro/pneumatic regulator (415) and last stall test.
  • Page 64 Setup Menus Maintenance Maintenance Maintenance 10: 10: Color Color Change Color Change Change Valves Valves Valves Maintenance Maintenance 11: Maintenance 11: Color Color Color Change Change Valves Change Valves Valves Reset Reset Reset and and Test Test Test Reset Reset and Reset and Test Test...
  • Page 65 Setup Menus Maintenance Maintenance Maintenance 13: 13: Color Color Change Color Change Change Valves Valves Valves Maintenance Maintenance 15: Maintenance 15: Color Color Color Change Change Valves Change Valves Valves Reset Reset Reset and and Test Test Test Reset Reset and Reset and Test Test...

  • Page 66: System Screen

    Setup Menus System Screen Screen System System Screen 1. The gun trigger is released and the electrostatic request signal is disabled. 2. Fill Start Delay (7) and Ground Rod Delay (5) begin at the same time. 3. After 5 seconds, the ground rod lowers and discharges the system.

  • Page 67: Maintenance

    Maintenance Maintenance Maintenance Maintenance Servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. Moving parts, such as the isolation valve, can cut or amputate fingers. • Do not service this equipment unless you are trained and qualified. •...

  • Page 68: Prepare The System For Service

    Maintenance Prepare the the System System for for Service Service Prepare Prepare System Service the wash fluid bottle. Leaking isolation valve seals can cause the wash fluid level to change. 1. Discharge the voltage in the system. Follow • Connections to the isolation fluid pump (K) and Fluid Voltage Discharge and Grounding the inlet at the bottom of the Merkur AA fluid Procedure, page...

  • Page 69: Replace The Wash Fluid

    Maintenance Replace the the Wash Wash Fluid Fluid Check and and Lubricate Lubricate the the Ground Ground Rod Replace Replace Wash Fluid Check Check Lubricate Ground Check the wash fluid bottle level. If the level changes, 1. Check the ground rod (18): service the isolation valve seals.

  • Page 70: Check The Bleed Resistor

    Maintenance Check the the Bleed Bleed Resistor Resistor Check Check Bleed Resistor The bleed resistor (24) is used to help discharge the system voltage and to measure system performance. If the displayed voltage appears to be inaccurate, use the following procedure to check the resistance value of the bleed resistor.

  • Page 71: Troubleshooting

    Troubleshooting Troubleshooting Troubleshooting Troubleshooting Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or repair this equipment unless you are trained and qualified. Follow the Fluid Voltage Discharge and Grounding Procedure, page 29, before checking or servicing the...
  • Page 72 Troubleshooting Problem Diagnosis Solution Problem Problem Diagnosis Diagnosis Solution Solution Spray The system thinks the gun is Make sure that both the paint The system does not fill. triggered or electrostatics are trigger signal and the ES request being requested. Either the PT signal are inactive.
  • Page 73 Troubleshooting Problem Diagnosis Solution Problem Problem Diagnosis Diagnosis Solution Solution The system does not spray. 1. The system is not in Spray 1. Change to Spray mode. mode. 2. Give the system time to fill 2. The isolation fluid pump is before trying to paint.

  • Page 74: Replace The Wash Fluid, Page

    Troubleshooting Problem Diagnosis Solution Problem Problem Diagnosis Diagnosis Solution Solution Incorrect voltage level display Check system voltage using a probe (236003). Calibrate the bleed resistor as described in Calibrate the Bleed Resistor, page Check or replace the kV board as described in Replace a kV Board, page 106.

  • Page 75: Led Diagnostic Information

    Troubleshooting LED Diagnostic Diagnostic Information Information Diagnostic Information The following LED signals, diagnoses, and solutions apply to the control interface. LED Status Status Status Signal Signal Signal Diagnosis Diagnosis Diagnosis Solution Solution Solution — The system is powered up. Green on —...

  • Page 76: Voltage Loss Troubleshooting

    Troubleshooting Voltage Loss Loss Troubleshooting Troubleshooting Voltage Voltage Loss Troubleshooting 7. If the system is completely shorted out (0 kV) the fault may be with the mechanical operation of the isolation valve, grounding rod, or door Normal spraying voltage for a system is 45-55 switch.
  • Page 77 Troubleshooting Troubleshooting Troubleshooting Troubleshooting HydroShield HydroShield HydroShield Voltage Voltage Voltage Grounded components: • The cabinet. • All the parts mounted in the top half of the cabinet. • The top of the isolation valve. • The fluid inlet valve and hose. •...

  • Page 78: Valves

    Troubleshooting Troubleshooting Color Color Change Change Solenoid Solenoid Valves Valves Troubleshooting Troubleshooting Color Change Solenoid Valves All color change solenoid valves may be exercised individually for diagnostic purposes through the control interface starting with Maintenance screen 10. Cause Solution Cause Cause Solution Solution...
  • Page 79 Troubleshooting Color Color Color Change Change Change Board Board Board NOTICE NOTICE NOTICE To avoid damaging the circuit boards, wear Part No. 112190 grounding strap on your wrist and ground appropriately. To avoid electrical component damage, remove all system power before plugging any connectors. Figure 30 Color Change Board 3A8492A...
  • Page 80 Troubleshooting Table 5 5 5 Color Color Change Change Board Board Diagnostics Diagnostics Table Table Color Change Board Diagnostics Description Diagnosis Component Component or or or Component Description Description Diagnosis Diagnosis Indicator Indicator Indicator LED (green) Blinks (heartbeat) during normal operation. LED (green) Turns on when power is supplied to the board.

  • Page 81: Error Codes

    User installed an incompatible USB Repeat the process with a compatible Advisory device in the Control USB device. WXUD USB Download Error Interface USB port. An unexpected WX00 Alarm Software Error software error has Call Graco technical support. occurred. 3A8492A...
  • Page 82 Error Codes Table 7 7 7 Communications Communications Errors Errors Table Table Communications Errors Type Name Description Code Code Code Type Type Name Name Description Description Solution Solution Solution • Verify the CAN connection on the system. See Connect the CAN Cables, page The control •...
  • Page 83 Error Codes Code Type Name Description Solution Code Code Type Type Name Name Description Description Solution Solution • Verify CAN connection on the system. • Verify CAN connection on the The control solenoid controller board. interface has lost Communication Error communication with CAC2 Alarm...
  • Page 84 F7P0 Alarm Invalid Air Flow detected when it should be off. • Check Air V/P. • Contact Graco technical support. The gun flush box was left open when the SGD1 Alarm Gun Flush Box Open Close the gun flush box.
  • Page 85 Alarm V/P Cal Failed Air V/P calibration failed • Check V2P connections. for the Air V/P • Verify V2P operation • Contact Graco technical support. P513 Alarm V/P Cal Failed Fluid V/P Calibration failed • Check V2P connections. for the Fluid V/P •...
  • Page 86 Error Codes Table 10 10 Maintenance Maintenance Events Events Table Table Maintenance Events Type Name Description Code Code Code Type Type Name Name Description Description Solution Solution Solution ENT1 Advisory Stall Test Pass System successfully Not applicable. completed a stall test. DF01 Advisory Stall Test Full Fail...
  • Page 87 Follow token. the steps in Update the System Software, page WX00 Alarm Software Errors An unexpected Call Graco technical support. software error has occurred. WE00 Advisory Hydroshield detects Ground Rod Failure Check ground rod operation. electrostatic voltage when the ground rod is down.
  • Page 88 Error Codes Table 12 12 USB USB Events Events Table Table Events Type Name Description Code Code Code Type Type Name Name Description Description Solution Solution Solution EAUX Advisory USB Busy USB drive is inserted, Not applicable. download is in progress.
  • Page 89 Error Codes Table 13 13 Color Color Change Change Events Events Table Table Color Change Events Type Name Description Code Code Code Type Type Name Name Description Description Solution Solution Solution WSF0 Advisory Rejected Inlet Change User is unable to Changing of Color value is not change color/inlet allowed in Spray mode.

  • Page 90: Repair

    Repair Repair Prepare the the Isolation Isolation System System for Repair Repair Prepare Prepare Isolation System Service Service Service Before servicing any component inside the isolation cabinet, perform the following steps: 1. Discharge voltage in the system. Follow all of the steps in the Fluid Voltage Discharge and Grounding Procedure, page...

  • Page 91: Service The Isolation Valve

    Repair Service the the Isolation Isolation Valve Valve Service Service Isolation Valve Reinstall Reinstall the Reinstall the Isolation Isolation Valve Isolation Valve into Valve into the into the Cabinet Cabinet Cabinet Use this procedure to reinstall the entire isolation Remove Remove Remove the the Isolation...
  • Page 92 Repair 2. Attach the isolation valve to the bottom of the 9. Before enclosing the isolation valve in the cabinet stand (9): isolation valve cover (99), ensure that the isolation valve shuttle (218) has a clear path to a. Insert the two screws (54) through flat travel up and down: washers (19), the base housing (201), and then insert into the bottom two holes of the...
  • Page 93 Repair Adjust Adjust Adjust the the Isolation Isolation Isolation Valve Valve Valve Sensors Sensors Sensors Replace Replace an Replace an Isolation Isolation Valve Isolation Valve Sensor Valve Sensor Sensor When disassembling the isolation valve, you may The isolation valve sensor can be replaced while the have indicated the positions of the top and bottom isolation valve is in the cabinet or while it is removed valve sensors.
  • Page 94 Repair 3. Disconnect the two connecting rods (225) from 7. Disconnect the shuttle housing (218) assembly the base housing (201): from the air cylinder (227): a. Locate the flat section on the air cylinder a. Grip the flats of a connecting rod with an shaft and the flat on the collar.
  • Page 95 Repair 2. Apply medium strength, removable thread lock to the threads on the air cylinder (227). 3. Screw the retaining nut (229) onto the air cylinder (227) until it bottoms out. To tighten the nut, place the nut and air cylinder in a vise. Keep the block mount (224) lined up with the air fitting on the cylinder.
  • Page 96 Repair Remove Remove Remove the the Isolation Isolation Valve Isolation Valve Valve Stem Stem Stem Replace Replace the Replace the Isolation Isolation Valve Isolation Valve Valve Stem Stem O O O - - - rings Stem rings rings This procedure requires the sleeve tool (112) and Use this procedure to replace the three o-rings (219, stem tool (113).
  • Page 97 Repair Service Service the Service the Bottom Bottom Piston Bottom Piston Housing Piston Housing Housing 4. To reassemble: a. Insert the spring (220) and the sleeve (221) Use this procedure to replace the seals in the lower (wider end first) into the sleeve tool (112). piston housing.
  • Page 98 Repair 6. Replace the piston seals: 8. Remove the retainer (202). 9. Replace the retainer (202) seals: a. Place one U-cup (212) onto the piston (211). The U-cup must face the top (shaft of the a. Replace the O-ring (208) into the groove next piston).
  • Page 99 Repair Service Service Service and and Reassemble Reassemble Reassemble the the Top Top Housing Housing Housing 4. Remove the U-cup spacer (206) and the packing U-cup (204). of of of the the Isolation Isolation Isolation Valve Valve Valve 5. Replace the U-cup spacer (206) and the packing Use this procedure to replace the seals in the U-cup (204): top piston housing.
  • Page 100 Repair Reassemble Reassemble Reassemble the the Bottom Bottom Housing Bottom Housing of of of the Housing 4. Together, insert the piston tool (111) and piston (211) into the retainer (202) on the housing (201). Isolation Isolation Isolation Valve Valve Valve Push the piston (211) until the tool comes through the housing (201) and the piston (211) is in place.

  • Page 101: Service The Isolation Fluid Pump

    Repair Service the the Isolation Isolation Fluid Fluid Pump Pump Service Service Isolation Fluid Pump Remove Remove Remove the the Isolation Isolation Fluid Isolation Fluid Pump Fluid Pump from Pump from from the 8. Remove the two fluid tubes from the fittings (327) at the base of the pump.
  • Page 102 Repair Reinstall Reinstall Reinstall the the Isolation Isolation Isolation Fluid Fluid Pump Fluid Pump in in in the Pump 4. Disassemble the fluid section of the pump: Cabinet Cabinet Cabinet a. Loosen the four tie rod screws (312) with a socket wrench.
  • Page 103 Repair 5. Disassemble the air section of the pump: 7. To service the air piston (316): a. Loosen the four tie rod screws (312) with a a. Remove the o-ring (317) from the air piston socket wrench and remove. (316). b.
  • Page 104 Repair Reassemble Reassemble the Reassemble the Isolation Isolation Fluid Isolation Fluid Fluid Pump Pump Pump 11. To remove and replace the wiper seal (306): a. Inside the middle housing (307) on the fluid 1. Lay the isolation fluid pump on its side. side, remove the wiper seal (306).
  • Page 105 Repair Remove Remove the Remove the Merkur Merkur Merkur Pump Pump from Pump from the from the Cabinet Cabinet Cabinet 14. With the air cylinder (319) up, place the air cover (320) onto the air cylinder (319). Make sure that o-ring (318) is in place on the cover.

  • Page 106: Service The Electrical Controls

    Repair Service the the Electrical Electrical Controls Controls Service Service Electrical Controls Replace Replace a a a kV Replace kV Board Board Board 1. Prepare the electrical controls for service. Follow Use the procedures in this section to service the steps in Prepare the Electrical Controls for components of the electrical controls as Service, page...
  • Page 107 Repair Replace Replace Replace an an Electro/pneumatic Electro/pneumatic Electro/pneumatic (V2P) (V2P) (V2P) 8. Perform the zero clear procedure on the V2P (415): Regulator Regulator Regulator The top of the V2P (415) contains 3 keys: Down 1. Prepare the electrical controls for service. Follow arrow, Set (S), and Up arrow.
  • Page 108 Repair Replace Replace Replace the the Color Color Color Change Change Board Change Board Fuse Board Fuse Fuse Fuse Part Description Fuse Fuse Part Part Description Description 17U084 Fuse; 500 mA 1. Prepare the electrical controls for service. Follow the steps in Prepare the Electrical Controls for Service, page 106.
  • Page 109 Repair Electrical Electrical Electrical Schematics Schematics Schematics Figure 50 Electrical Schematic for 25E700 Electrical Control 3A8492A...

  • Page 110: Pneumatic Connections

    Repair Pneumatic Connections Connections Pneumatic Pneumatic Connections The numbers in the following figure represent point-to-point connections. For example, A4 connects to A4. Item Item Item Description Description Description Part Part Part 5/32 inch tubing 598095 3/8 inch tubing 054134 CONT ROL BOX LEFT SIDE VIEW ISO-VIEW M ERKUR...
  • Page 111 Repair Table 14 14 Isolation Isolation System System Pneumatic Pneumatic Connections Connections Notes Notes Table Table Isolation System Pneumatic Connections Notes ID ID ID Description Description Description Connects to active fluid valve on valve kit (16A079). Used only for color change enabled systems.

  • Page 112: Wiring Connections

    Repair Wiring Connections Connections Wiring Wiring Connections The numbers in the following figure represent point-to-point connections. For example, C1 connects to C1. VIE W ADM -ADM kV BOARD (25R197) CABLE SID E W ALL ISOMETR IC V IEW CABLE INSIDE W ALL UPPER ISOMETR IC V IEW GCA CUBE BASE (289697)
  • Page 113 Repair ID ID ID Part Description ID ID ID Part Description Part Part Description Description Part Part Description Description 17D923 Bulkhead Cable (59) 25R034 Bleed Resistor (24) 121002 CAN Cable (43) 26C774 Power Supply (47) 17D923 Bulkhead Cable (59) Green/Yellow (20 in./50.8 cm) Wire CAN Cable (611) (Used only Green/Yellow (5 in./12.7 cm)

  • Page 114: Connections

    Repair Color Change: Change: Pneumatic Pneumatic and and Wiring Wiring Connections Connections Color Color Change: Pneumatic Wiring Connections RIGHT S IDE VIEW ADM BOTTOM VIEW LEFT SIDE VIEW Figure 53 Color Change Module Wiring and Pneumatic Connections Table Table Table 15 15 Color Color Change Color...

  • Page 115: Parts

    Parts Parts Parts Parts Isolation System System Isolation Isolation System Figure 54 Isolation Cabinet Isolation Cabinet Interior for a detailed view. 3A8492A...
  • Page 116 Parts Figure 55 Isolation Cabinet Interior Detail C1 C1 shows the parts that come with a standard system. Replace the C1 C1 parts with C2 parts to add color change capability to a standard system. For more information, 25N031 Isolation Fluid Pump Parts, page 122.
  • Page 117 Parts Isolation System System Isolation Isolation System Ref. Part Description Ref. Part Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description ------- 17D918 ENCLOSURE, WATERBORNE, MANIFOLD, AIR, SPEED BATCH, AA CONTROL ------- 514930 SCREW, CAP, SKT HEAD 116343 SCREW, GROUND 158491...
  • Page 118 Parts Ref. Part Description Ref. Part Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description 598095 TUBE, 5/32 OD, NYLON 17 FEET 18C026 PLUG, HOLE, .437" (model , 250 PSI (not shown) WABH02) For connection details, see PLUG, HOLE, .437"...
  • Page 119 Parts Ref. Part Description Ref. Part Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description 245202 107129 POWER CORD with North America BOLT, ROUND HEAD NEMA 5-15 male plug (not shown) 17A237 NUT, HEX 124864 POWER CORD with 16F201 CASTER, SWIVEL, WITH BREAK China/Australia AS/NZS 3112...

  • Page 120: 25N030 Isolation Valve Parts

    Parts 25N030 Isolation Isolation Valve Valve Parts Parts 25N030 25N030 Isolation Valve Parts Figure 56 Isolation Valve 3A8492A...
  • Page 121 Parts Isolation Valve Valve Isolation Isolation Valve Ref. Part Description Ref. Part Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description ------- 19A448 HOUSING, BASE, ISOLATION 221* SLEEVE, ISOLATION VALVE VALVE ------- STEM, ISOLATION VALVE 202* 19A375 RETAINER, U-CUP, ISOLATION -------...

  • Page 122: 25N031 Isolation Fluid Pump Parts

    Parts 25N031 Isolation Isolation Fluid Fluid Pump Pump Parts Parts 25N031 25N031 Isolation Fluid Pump Parts Figure 57 Isolation Fluid Pump 3A8492A...
  • Page 123 Parts Isolation Fluid Fluid Pump Pump Isolation Isolation Fluid Pump Ref. Part Description Ref. Part Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description 19A952 PISTON, FLUID, ISOLATION 314* 15G747 MAGNET, LINEAR SENSOR PUMP 315* 160516 PACKING, O-RING, 214 302* 19A951...

  • Page 124: Electronic Control Parts

    Parts Electronic Control Control Parts Parts Electronic Electronic Control Parts The following figure shows 25E700. Figure 58 Electronic Controls 3A8492A...
  • Page 125 Parts Electronic Control Control Electronic Electronic Control Ref. Part Description Ref. Part Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description ------- 108982 PANEL, WATERBORNE, CONNECTOR, TUBE PAINTED 19Y588 ADAPTER, CABLE, CAN, IS TO ------- COVER, ELECTRICAL, NON-IS WATERBORNE -------...

  • Page 126: Repair Kits And Accessories

    Upgrade Token Upgrade Token Token This kit contains a Graco black software update token with the latest system software. A token is included when a replacement control interface is ordered. To use the token, see Update the System Software, page...
  • Page 127 Repair Kits and Accessories Kit 26B236, 26B236, 100 100 Mesh Mesh Fluid Fluid Filter Filter 26B236, Mesh Fluid Filter Part Description Part Part Description Description 110740 PLUG, PIPE 111697 PLUG, PIPE 104361 PACKING, O-RING 166846 FITTING, ADAPTER 167026 STRAINER, MESH SCREEN 186075 SUPPORT, FILTER 185632...

  • Page 128: Kit 26B400, Supply Pump

    Repair Kits and Accessories Kit 26B400, 26B400, Supply Supply Pump Pump 26B400, Supply Pump This kit contains a Triton 1:1 pump to be assembled Ref. Ref. Ref. Part Part Part Description Description Description to the inlet side of the HydroShield system. 19Y578 BAR, MOUNTING 100731...

  • Page 129: Color Change Components

    Repair Kits and Accessories Color Change Change Components Components Color Color Change Components Kit 26B415, 26B415, 26B415, Color Color Color Change Change Change Ref. Ref. Ref. Part Part Part Description Description Description ------- BAR, MOUNTING Converts a standard system to a color change 100731 WASHER, 3/8”...
  • Page 130 Repair Kits and Accessories Color Color Color Change Change Module Change Module Configuration Module Configuration Configuration Replace Replace the Replace the Color Color Change Color Change Board Change Board Board Configure each module according to its designated number, as follows: NOTICE NOTICE NOTICE...
  • Page 131 Repair Kits and Accessories Figure 61 Control Module Repair (Non-IS Module Shown) Ref. Part Description Ref. Part Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description 16P855 PANEL 113418 O-RING; buna-N BOARD, circuit; used with 100139 PLUG, pipe;...
  • Page 132 Repair Kits and Accessories Non-IS Control Control Module Module Part Part Quantities Quantities Non-IS Non-IS Control Module Part Quantities Find your module kit number in the left column and the desired reference number in the top row to find the part quantity used in your control module kit. 6 6 6 - - - Position Position Position...

  • Page 133: Isolation Valve Kits

    Repair Kits and Accessories Isolation Valve Valve Kits Kits Isolation Isolation Valve Kits Kit 26B401, 26B401, 26B401, Stem, Stem, Sleeve, Stem, Sleeve, Piston Sleeve, Piston Piston Kit 26B402, 26B402, 26B402, Housing Housing Housing Assembly Assembly Assembly Replacements Replacements Replacements Ref. Ref.
  • Page 134 Repair Kits and Accessories Kit 26B405, 26B405, 26B405, Cap, Cap, Piston Cap, Piston Retainer Piston Retainer Retainer Kit 26B410, 26B410, 26B410, Seal Seal Set Seal Set for for Service Service Service to to to Rebuild Rebuild Rebuild Bottom housing of the isolation valve. To replace, Be careful not to drop or scratch these parts when Service the Bottom Piston Housing, page handling.

  • Page 135: Pump Kits

    Repair Kits and Accessories Pump Kits Kits Pump Pump Kits Kit 24A914, 24A914, 24A914, Bumpers Bumpers Bumpers Kit 26B423, 26B423, Fluid 26B423, Fluid Cylinder Fluid Cylinder Cylinder Part Description Ref. Ref. Ref. Part Part Description Description Ref. Ref. Ref. Part Part Part Description...

  • Page 136: Performance

    Performance Performance Performance Performance The following figure shows how long it takes to fill the pump in the isolation system for a range of fluid viscosities. Dynamic Pressure at Fluid Inlet: 100 psi (.7 MPa, 6.9 bar) 80 psi (.6 MPa, 5.5 bar) 60 psi (.4 MPa, 4.1 bar) 40 psi (.3 MPa, 2.8 bar) Table 17...

  • Page 137: Ignitability Of Coating Materials

    Ignitability of Coating Materials Ignitability of of of Coating Coating Materials Materials Ignitability Ignitability Coating Materials Per EN 50059 From the Physikalisch-Technische Bundesanstalt, Braunschweig, Germany, June 26, 2019. General General General The fire and explosion protection of spraying systems can be facilitated considerably when processing coating materials with a low portion of solvents and a high flash point (generally water-based paints), provided that the spray cloud of the coating materials are considered to be non-ignitable.

  • Page 138: Dimensions

    Dimensions Dimensions Dimensions Dimensions Reference U.S. Metric Reference U.S. Metric Reference Reference U.S. U.S. Metric Metric Reference Reference U.S. U.S. Metric Metric 40.2 in. 102.2 cm 39.8 in. 101.1 cm 36.2 in. 92.1 cm 35.5 in. 85.1 cm 65.3 in. 165.9 cm 48.9 in.

  • Page 139: Notes

    Notes Notes Notes Notes 3A8492A...
  • Page 140 Technical Specifications Technical Specifications Specifications Technical Technical Specifications HydroShield Air Air- - - Assisted Assisted U.S. Metric HydroShield HydroShield Assisted U.S. U.S. Metric Metric Waterborne Waterborne Isolation Waterborne Isolation System Isolation System System Maximum Fluid Working Pressure 3000 psi 20.7 MPa, 206.8 bar Maximum Fluid Inlet Pressure 100 psi 0.7 MPa, 7.0 bar...
  • Page 141 California Proposition 65 California Proposition Proposition 65 California California Proposition CALIFORNIA RESIDENTS RESIDENTS CALIFORNIA CALIFORNIA RESIDENTS WARNING: Cancer and reproductive harm — www.P65warnings.ca.gov. WARNING: WARNING: 3A8492A...
  • Page 142 With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.

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