Graco HydroShield Instructions Manual
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Graco HydroShield Instructions Manual

Air-assisted batch waterborne isolation systems
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Instructions - Parts
HydroShield™ Air
HydroShield™
HydroShield™
Waterborne
Waterborne
Waterborne Isolation
Air- - - assisted
assisted spray
spray system
system for
Air
Air
assisted
spray
system
meet
meet at at at least
meet
least one
least
one of of of the
one
the conditions
the
explosive
explosive
explosive atmospheres
atmospheres
atmospheres or or or hazardous
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
100 psi (0.7 MPa, 7.0 bar) Maximum Air
Working Pressure
See page 6 for model information
including maximum fluid working
pressure.
NOTE: This manual covers isolation
system operation. For spray gun
operation, see manual 3A7503.
Air - - - Assisted
Assisted Batch
Air
Assisted
Isolation Systems
Isolation
Systems
Systems
for use
use when
when electrostatically
electrostatically spraying
for
use
when
electrostatically
conditions for
conditions
for non
for
non- - - flammability
non
flammability listed
flammability
hazardous (classified)
hazardous
(classified) locations.
(classified)
Instructions
Instructions
PROVEN QUALITY. LEADING TECHNOLOGY.
Batch
Batch
spraying conductive,
conductive, waterborne
spraying
conductive,
listed on
listed
on page
on
page
page 5. 5. 5. Not
locations. For
locations.
For
For professional
professional use
professional
Save these
Save
these instructions.
these
instructions.
instructions.
3A7370C
waterborne fluids
fluids that
waterborne
fluids
Not approved
Not
approved for
approved
for use
for
use in in in
use
use only.
use
only.
only.
EN
that
that

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Summary of Contents for Graco HydroShield

  • Page 1 Instructions - Parts HydroShield™ Air Air - - - Assisted Assisted Batch Batch HydroShield™ HydroShield™ Assisted Batch Waterborne Waterborne Waterborne Isolation Isolation Systems Isolation Systems Systems 3A7370C Air- - - assisted assisted spray spray system system for for use use when...

  • Page 2: Table Of Contents

    Contents Contents Contents Related Manuals ..........3 Upload System Configuration ....... 45 Clean the Screen Surface......45 Isolation System Overview ........4 Update the System Software ......45 How the Isolation System Works ..... 4 Spraying Waterborne Fluids Run Menus ............49 Electrostatically ........

  • Page 3: Related Manuals

    Test Fixture, High Voltage Probe, and kV Meter 312782 Air Actuated Dispense Valve 312794 Merkur ® Pump Assembly 307273 Fluid Outlet Filter 309227 Gun Flush Box Module 312783 Color and Catalyst Change Valve Stacks 3A1244 Graco Control Architecture™ Module Programming 3A7370C...

  • Page 4: Isolation System Overview

    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. The fluid supply can be any only waterborne fluids gun are designed to spray only only low pressure pump or circulation system.

  • Page 5: Models

    Models Models Models Models Approved System System Components Components Approved Approved System Components Any combination of the following isolation cabinets, spray guns, fluid hoses, and air hoses are FM-approved and meet the requirements of EN 50059: 2018. Complete isolation systems are available which include an isolation cabinet, a spray gun, a high pressure fluid hose, and an air hose.
  • Page 6 Models Table 2 2 2 Pre Pre- - - packaged packaged FM FM- - - approved approved Isolation Isolation Systems Systems Table Table packaged approved Isolation Systems Gun included included included Maximum Maximum Maximum Fluid Working Working H60T18 Fluid Fluid Working H60T18 H60T18...
  • Page 7 Models Table 3 3 3 Isolation Isolation Cabinets Cabinets Table Table Isolation Cabinets Must purchase Pro Xp gun and hoses separately. Maximum Maximum Maximum Fluid Fluid Fluid Working Working Working Pressure Pressure Pressure Equipped Equipped Equipped for Color Color Color Part No.

  • Page 8: Warnings

    • Only use non-flammable solvents when flushing or cleaning equipment. • Only use the red-colored Graco electrically conductive gun air hose with this gun. Do not use black or gray-colored Graco air hoses. • Do not use pail liners unless they are conductive and grounded.
  • Page 9 Discharge Grounding Procedure • Only use the red-colored Graco electrically conductive gun air hose with this gun. Do not use black or gray-colored Graco air hoses. • Do not splice hoses together. Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the spray gun.
  • Page 10 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 11: Component Identification

    Component Identification Component Identification Identification Component Component Identification Figure 1 Components of the Air-Assisted Isolation System in a Typical Waterborne Manual Batch System Item Description Item Description Item Item Description Description Item Item Description Description Air Inlet Merkur AA Fluid Pump Control Interface Electronics Panel Ground Rod and Bleed Resistor...

  • Page 12: Typical Installation

    Item Description Description Item Item Description Description AB † Bleed Type Air Valve Graco Red Grounded Air Hose (left-hand threads at gun) AM † Main Air Supply Line Graco Waterborne Fluid Hose AS † Oil Separator Light Tower AV �...

  • Page 13: Installation

    • Do not install or service this equipment unless The Graco voltage isolation system has the following you are trained and qualified. features: • Comply with all local codes and regulations.

  • 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 146 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

    Spray gun: All air lines: • Ground the gun by connecting the • These must be properly grounded. red-colored Graco grounded air hose (HG) to the Use only grounded hoses with a maximum of 100 3A7370C...

  • Page 17: Connect The Hoses

    If gloves are necessary, wear the conductive gloves supplied with the gun. If non-Graco gloves are worn, cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle. Conductive gloves and footwear must not exceed 100 megohm per EN ISO 20344, EN 1149–5.
  • Page 18 Installation Connect Connect Connect the the Fluid Fluid Fluid Hose Hose Hose from from the from the Gun Gun to to to the the Cabinet Cabinet Cabinet 1. Remove the gun air inlet fitting (21). 4. Loosen the strain relief nut (101c). 5.
  • Page 19 Installation Connect Connect the Connect the Air Air Hose Hose Hose from from Gun from Gun to to to the 13. Tighten the strain relief nut (101c) and set screw (101m). Cabinet Cabinet Cabinet Connect the gun air hose between the air outlet (D) on the isolation cabinet and the gun air inlet swivel on the gun.
  • Page 20 (W). 6. Lift the sealed wash fluid bottle (W) out of the system. Fill it with clean HydroShield cleansing solution above the minimum line marked on the bottle. Replace it in the cabinet.

  • Page 21: Connect The Can Cables

    Installation Connect Connect Connect the the Fluid Fluid Supply Fluid Supply Hose Supply Hose to to to the Hose Valve Number Number Valve Purpose Purpose Valve Valve Number Valve Valve Purpose Cabinet Cabinet Cabinet Valve 4 Color 1 On systems that are not color change enabled: Valve 5 Color 2 Use a wrench to connect the fluid supply hose...
  • Page 22 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...

  • Page 23: Connect The Power Supply

    Power cords with regional plugs are also supplied. Additional parts or kits are required to add gun flush Use a supplied power cord or purchase a regional box capability to a HydroShield system. The parts plug separately. needed depend on whether the model is equipped for a gun flush box.
  • Page 24 Gun Flush Flush Box Flush Box Connections Connections for Connections for Use Use with with with a a a HydroShield Isolation Isolation System System HydroShield HydroShield Isolation System Figure 19 Gun Flush Box Tube Connections on Isolation System Purpose Purpose...

  • Page 25: Input Kit

    The optional System Stop Pneumatic Input Kit 26B414 provides a pneumatic means to signal the HydroShield system to stop. This contact is normally open, but turns the system off when activated with a pressure above the set pressure.

  • Page 26: Wire The System Stop Digital Input

    Output Output The System Stop Digital input provides a means to signal the HydroShield system to stop. This normally The optional System Status Output provides a means open contact turns the system off when activated. to signal connected devices that the HydroShield is If the input is read as CLOSED, it stops system running.

  • Page 27: Isolation System

    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 grounding continuity of the spray gun and air hose.

  • Page 28: Flush The Equipment Before First Use

    Installation 6. Use an ohmmeter (or megohmmeter in the ohm 8. Use an ohmmeter (or megohmmeter in the ohm range) to measure the resistance between the range) to measure the resistance between the gun handle (BB) and a true earth ground (CC). cabinet ground lug (214) and a true earth ground The resistance should not exceed 100 ohms.

  • Page 29: Operation

    Operation Operation Operation Operation Operation Overview Overview Fluid Voltage Voltage Discharge Discharge and Operation Operation Overview Fluid Fluid Voltage Discharge Grounding Procedure Procedure Grounding Grounding Procedure 1. Plug in the system. The system powers up and enters Off mode. See Connect the Power Supply, page 2.
  • Page 30 Operation 3. When the gun trigger is released and the ground 4. Press the Stop button on the control rod delay time elapses, the ground rod (N) inside interface to change to Off mode. the isolation cabinet lowers and discharges the system.

  • Page 31: Procedure

    Operation Pressure Relief Relief Procedure Procedure Pressure Pressure Relief Procedure 4. Push the Stop button on the control interface to change to Off mode. See Control Interface, page 5. Turn off the air supply and fluid supply to the system. This equipment stays pressurized until pressure is manually relieved.
  • Page 32 Operation 9. If the objective is to shut down and then service the system, relieve any residual pressure in the two flexible fluid lines between the inlet valves (J) and the isolation fluid pump (K). Note The contents of the isolation fluid pump (K) may spill into the cabinet at this point.

  • Page 33: Flush The System (Systems Without Color 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, engage the trigger lock, follow the steps in Flush the System (Color Change and turn off electrostatics by turning the ES Enabled Systems), page...
  • Page 34 Operation 16. Align the spray tip tab with the groove in the air 12. Activate the Do Not Fill button so that the cap. Install the tip. isolation fluid pump will not refill after it is empty. Home Screen, page 13.

  • Page 35: Systems)

    Operation Flush the the System System (Color (Color Change Change Enabled Enabled Systems) Systems) Flush Flush System (Color Change Enabled Systems) 6. Use the control interface to put the system into Standby. Then change the mode to Purge mode: To avoid fire and explosion, always ground 7.

  • Page 36: Gun Flush Box Operation

    Operation To purge purge manually: manually: purge manually: 11. Align the spray tip tab with the groove in the air cap. Install the tip. 1. If using purge profile 0, the system must be manually flushed. On the left side of the screen, three icons appear that activate the dump, flush material, and air inlet valves.

  • Page 37: Prime The Isolation System

    Operation Prime the the Isolation Isolation System System Spray with with the the Isolation Isolation System System Prime Prime Isolation System Spray Spray with Isolation System Use the following steps to load the system with paint, change paint colors, or change from flushing fluid to paint.

  • Page 38: Adjust The Gun Fluid And Air Settings

    Operation Adjust the the Gun Gun Fluid Fluid and and Air Air Settings Settings Adjust Adjust Fluid Settings 5. When the gun is triggered: • The control interface displays the voltage Preset 0 allows operators to change the gun fluid and building in the system.

  • Page 39: Shutdown

    Operation Shutdown Shutdown Shutdown To use use Preset Preset 1 1 1 through through 99: Preset through 1. Press the right arrow until Home appears 1. Discharge the system voltage. Follow the on the menu bar. Fluid Voltage Discharge and Grounding Procedure, page 2.

  • Page 40: 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 41: 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 42: Run Screens And Setup Screens

    Control Interface Run Screens Screens and and Setup Setup Screens Screens Screens Setup Screens – Calibrate (See Calibrate Screens, page 61.) – System (See System Screen, page 69.) The control interface uses two sets of screens: – Pumps (See Pump Screens, page 58.) •...

  • Page 43: 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 44: 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 45: Upload System Configuration

    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 46 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 60.
  • Page 47 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 48 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 49: Run Menus

    Run Menus Run Menus Menus Menus Home Screen Screen Home Home Screen The Home screen is the primary screen that the Soft Key Key Function Function Soft Soft Function operator uses while painting. When the system is Purge Purge Purge powered, it enters Off mode.
  • Page 50 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 51 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. 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 52 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 Air...
  • Page 53 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 54: Events Screen

    Run Menus Events Screen Screen Status Screens Screens Events Events Screen Status Status Screens The Status screens display a summary of the input Use the Events screen to view the last 99 status signals that are monitored by the system and the messages generated by the isolation system.
  • Page 55 Run Menus Status Status Screen Status Screen Screen 2 2 2 Solenoids Solenoids Solenoids Electrical to pneumatic actuators that drive system Status screen 2 displays the current status of the activity. solenoids that drive activity for the color change valves. Shuttle Down: Down: Drives the isolation valve down and •...

  • Page 56: 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 57: 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 58: 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 59: 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 60 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 61: Calibrate Screens

    Setup Menus Calibrate Screens Screens Calibrate Calibrate Screens Calibrate Calibrate Calibrate 1: 1: 1: Calibrate Calibrate Calibrate Pump Pump Pump 2. When the pump volume and mV values stop changing, the pump is full. Press the Set Full button. The stored mV value also displays next to Use the Calibrate 1 screen to calibrate the linear the button.
  • Page 62 Setup Menus Calibrate Calibrate Calibrate 2: 2: 2: Air Air and and 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 air and fluid.

  • Page 63: 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 64 The system returns to Standby. Note In addition to the HydroShield, this test checks the hose connections and gun. If the test fails, repeat the test with the fluid pressure set to 0. This will prevent high...
  • Page 65 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 66 Setup Menus Maintenance Maintenance Maintenance 6: 6: 6: Output Output Resets Output Resets Resets and and Test Test Test Isolation Valve Valve Seal: Seal: Monitors the life of the fluid Isolation Isolation Valve Seal: seals in the isolation valve assembly. Use this screen to view system output counts, reset Wash Wash Fluid:...
  • Page 67 Setup Menus Maintenance Maintenance Maintenance 9: 9: 9: V/P Maintenance Maintenance 11: Maintenance 11: Color Color Color Change Change Valves Change Valves Valves Reset Reset and Reset and Test Test Test Use the V/P (Voltage to Pressure) screen to test the function of the electro/pneumatic regulator (415) and View the color change valve actuation counts, reset determine whether air pressure and fluid pressure...
  • Page 68 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 69: System Screen

    Setup Menus System Screen Screen System System Screen two settings: the Ground Rod Delay time and the Fill Start Delay time. For example, if the Fill Start Delay is set to 7 and the Ground Rod Delay is set to 5: 1.

  • Page 70: 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 71: 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 72: Replace The Wash Fluid

    7. Lift the sealed wash fluid bottle (W) out of the 4. Slide the electrostatic shield (82) up to remove. system. Fill it with clean HydroShield cleansing solution above the minimum line marked on the 5. Slide the electrostatic shield (12) to the left to bottle.

  • Page 73: 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 74: Troubleshooting

    Troubleshooting Troubleshooting Troubleshooting Troubleshooting To reduce the risk of an injury, follow the Installing and servicing this equipment requires Pressure Relief Procedure, page 31, whenever access to parts which may cause an electric shock you are instructed to relieve the pressure. or other serious injury if the work is not performed properly.
  • Page 75 Troubleshooting Problem Diagnosis Solution Problem Problem Diagnosis Diagnosis Solution Solution Spray The system thinks the gun is The system does not fill. Check for debris in the air flow triggered. An air flow switch signal switch that may be keeping the is seen as being ON.
  • Page 76 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 77 Troubleshooting Problem Diagnosis Solution Problem Problem Diagnosis Diagnosis Solution Solution Low or no spraying voltage. • The ground rod (18) is not Voltage Loss raising. Troubleshooting, page • The isolation valve (227) is not raising. • The components or cabinet (9) is dirty.

  • Page 78: Led Diagnostic Information

    Troubleshooting Problem Diagnosis Solution Problem Problem Diagnosis Diagnosis Solution Solution Other issues Paint build-up on the isolation 1. Follow the steps in Replace 1. Dirty wash fluid can no longer valve stem. clean properly. the Wash Fluid, page 2. The U-cup seals are not wiping 2.

  • Page 79: Voltage Loss Troubleshooting

    2. Check for connections between high voltage components and grounded components Note within the isolation system. The figure in Troubleshooting HydroShield Voltage, page For the ground rod to activate, either identifies the high voltage, the isolation, and the cabinet door must be closed or the grounded components.
  • Page 80 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 81: 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 82 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 33 Color Change Board 3A7370C...
  • Page 83 Troubleshooting Table 9 9 9 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 84: 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. 3A7370C...
  • Page 85 Error Codes Table 11 11 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 86 CAN ID as another module. Duplicate Solenoid multiple solenoid CDC1 Alarm Controller controllers set to the • Adjust the selector switches on the same identifier. solenoid controller board. Table 12 12 HydroShield HydroShield Errors Errors Table Table HydroShield Errors Code Type Name Description...
  • Page 87 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 88 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 89 Error Codes Table 14 14 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 90 Follow token. the steps in Update the System Software, page WX00 Alarm An unexpected Software Errors Call Graco technical support. software error has occurred. WE00 Advisory Ground Rod Failure Hydroshield detects Check ground rod operation. electrostatic voltage when the ground rod is down.
  • Page 91 Error Codes Table 16 16 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 92 Error Codes Table 17 17 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 93: 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 94: 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 Valve into into the into the Cabinet Cabinet Cabinet Use this procedure to reinstall the entire isolation Remove the the Isolation Isolation Valve Valve from...
  • Page 95 If the position was not indicated, follow the steps in Adjust the Isolation Valve Sensors, page 7. Fill the wash fluid bottle (W) with HydroShield cleansing solution above the minimum line marked on the bottle. Replace it in the cabinet.
  • Page 96 Repair Adjust Adjust Adjust the the Isolation Isolation Valve Isolation Valve Valve Sensors Sensors Sensors Replace Replace an Replace an Isolation Isolation Isolation Valve 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 97 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 98 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 99 Repair Remove Remove Remove the the Isolation Isolation Isolation Valve Valve Valve Stem Stem Stem Replace Replace the Replace the Isolation Isolation Isolation Valve Valve Stem Valve 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 100 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 101 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 102 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 103 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 104: 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 105 Repair Reinstall Reinstall Reinstall the the Isolation Isolation Isolation Fluid Fluid Pump Fluid Pump Pump in in in the 4. Disassemble the fluid section of the pump: Cabinet Cabinet Cabinet a. Loosen the four tie rod screws (312) with a socket wrench.
  • Page 106 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 107 Repair Reassemble Reassemble the Reassemble the Isolation Isolation Isolation Fluid 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 108 Repair Remove Remove the Remove the Merkur Merkur Pump Merkur Pump Pump from from from the 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 109: 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 110 Repair Replace Replace Replace an an Electro/pneumatic Electro/pneumatic (V2P) Electro/pneumatic (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 111 Repair Convert Convert Convert a a a Standard Standard System Standard System System to to to be be Equipped Equipped Equipped Replace Replace the Replace the Color Color Color Change Change Board Change Board Fuse Board Fuse Fuse for a a a Gun Gun Flush Flush Box Flush...
  • Page 112 Repair Electrical Electrical Electrical Schematics Schematics Schematics Figure 53 Electrical Schematic for 26C896 Electrical Control (standard, not equipped for gun flush box) 3A7370C...
  • Page 113 Repair Figure 54 Electrical Schematic for 26C716 Electrical Control (equipped for gun flush box) 3A7370C...

  • Page 114: 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 Number Part Number Number 5/32 inch tubing 598095 3/8 inch tubing 054134 GUN FLUSH BOX EQUIPPED NO GUN FLUSH BOX...
  • Page 115 Repair Table 18 18 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 116: 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. VIEW ADM-ADM CONTR OL CONTR OL kV BOARD INTERFACE INTERFACE (25R197) CABLE SIDE W ALL ISOMETRIC VIEW CABLE GCA CUBE BASE (289697) INSIDE WALL SECTION CABLE-CABLE...
  • Page 117 Repair ID ID ID Part No. Description ID ID ID Part No. Description Part Part Description Description Part Part Description Description 17D923 Bulkhead Cable (59) 24W120 Proximity Sensor (lower; labeled P4) (447) 121001 CAN Cable (43) 25R034 Bleed Resistor (24) 17D923 Bulkhead Cable (59) 26C774...

  • Page 118: Connections

    Repair Color Change: Change: Pneumatic Pneumatic and and Wiring Wiring Connections Connections Color Color Change: Pneumatic Wiring Connections ADM BOTTOM VIEW Figure 57 Color Change Module Wiring and Pneumatic Connections Table Table Table 19 19 Color Color Change Color Change Pneumatic Change Pneumatic Pneumatic Connections...

  • Page 119: Parts

    Parts Parts Parts Parts Isolation System System Isolation Isolation System Figure 58 Isolation Cabinet Isolation Cabinet Interior for a detailed view. 3A7370C...
  • Page 120 Parts Figure 59 Isolation Cabinet Interior Details C1 show the parts that come with a standard system. Detail C2 shows the parts that come with a color change system. If adding color change capability to a system, the parts in C1 must be changed out with parts in C2.
  • Page 121 BRACKET, MOUNTING, BOOTH Electronic Control Parts , page 129. CONTROL 26C716 CONTROL, ELECTRICAL; 26B099 KIT, ADM/CONTROL INTERFACE equipped for gun flush box (includes ADM and HydroShield software token) 25N030 VALVE, WATERBORNE ISOLATION 121002 CABLE, CAN, FEMALE / FEMALE 1.0M For details, see...
  • Page 122 Parts Ref. Part No. Description Ref. Part No. Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description 555388 NUT, HEX, JAM, 8-32 25A517 HOSE, COUPLED, .625 FEET, PTFE 16A079 KIT, VALVE, DUMP, ACCESSORY Color change enabled systems. Qty 2: Color change enabled systems.
  • Page 123 Parts Ref. Part No. Description Ref. Part No. Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description 551903 SCREW, CAP SCH 1/4-20 X 1/2 21/1 121818 BULKHEAD, TUBE, 5/32 INCH (not shown) Qty 21: Color change enabled systems.
  • Page 124 Parts Ref. Part No. Description Ref. Part No. Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description 618† 256292 VALVE, CLR/CAT CHG, LP, 5-CLR 621† 128820 FITTING, BUSHING Color change enabled systems Color change enabled systems only.

  • Page 125: 25N030 Isolation Valve Parts

    Parts 25N030 Isolation Isolation Valve Valve Parts Parts 25N030 25N030 Isolation Valve Parts Figure 60 Isolation Valve 3A7370C...
  • Page 126 Parts Ref. Part No. Description Ref. Part No. Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description ------- HOUSING, BASE, ISOLATION 221* 19A448 SLEEVE, ISOLATION VALVE VALVE ------- STEM, ISOLATION VALVE 202* 19A375 RETAINER, U-CUP, ISOLATION ------- BEARING, SHUTTLE, ISOLATION VALVE...

  • Page 127: 25N031 Isolation Fluid Pump Parts

    Parts 25N031 Isolation Isolation Fluid Fluid Pump Pump Parts Parts 25N031 25N031 Isolation Fluid Pump Parts Figure 61 Isolation Fluid Pump 3A7370C...
  • Page 128 Parts Ref. Part No. Description Ref. Part No. 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 PACKING, U-CUP, 4.08 X .335 ------- PISTON, AIR, ISOLATION PUMP 304*...

  • Page 129: Electronic Control Parts

    Parts Electronic Control Control Parts Parts Electronic Electronic Control Parts The following figure shows 26C716. Figure 62 Electronic Controls Note Use air tubing (470) to connect the gun flush box pressure switch (420) to the bulkhead (460). 26C716 contains two switches. The gun flush pressure switch is the switch on the right.
  • Page 130 Parts Ref. Part No. Description Ref. Part No. Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description ------- PANEL, WATERBORNE, 113418 PACKING, O-RING PAINTED Model 26C716: Qty 1 ------- COVER, ELECTRICAL, Model 26C896: Qty 2 WATERBORNE 25R197 ENCLOSURE, ASSEMBLY, KV 25D312...
  • Page 131 Parts Ref. Part No. Description Ref. Part No. Description Ref. Ref. Part Part Description Description Ref. Ref. Part Part Description Description 112512 FERRULE, WIRE ORANGE 120490 COVER, END Model 26C716: Qty 21 120491 BLOCK, TERMINAL Model 26C896: Qty 19 Model 26C716: Qty 6 102478 STRAP, TIE WIRING Model 26C896: Qty 8...

  • Page 132: Repair Kits And Accessories

    Box Installation Installation Kit Installation 25R012 25 ft (7.6 m) This kit is required for HydroShield systems that were 25R013 36 ft (11 m) not equipped for a gun flush box. For installation details, see Convert a Standard System to be...
  • Page 133 104361 PACKING, O-RING This kit provides a pneumatic means to signal the 166846 FITTING, ADAPTER HydroShield system to stop. Install kit 26B414 to use the optional System Stop: Air input. For details about 167026 STRAINER, MESH SCREEN this input, see Status Screen 1, page Part No.

  • Page 134: Kit 26B400, Supply Pump

    This kit contains a Triton 1:1 pump to be assembled Ref. Ref. Ref. Part Part Part No. Description Description Description to the inlet side of the HydroShield system. 19Y578 BAR, MOUNTING 100731 WASHER, 3/8” 121592 SCREW, CAP, HEX HEAD, 3/8” 101566 NUT, LOCK, 3/8” 100639 WASHER, LOCK, 3/8”...

  • Page 135: 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 No. Part Description Description Description ------- Converts a standard system to a color change BAR, MOUNTING system.
  • Page 136 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 137 Repair Kits and Accessories Figure 65 Control Module Repair (Non-IS Module Shown) Ref. Part No. Description Ref. Part No. 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 138 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 139: Isolation Valve Kits

    Repair Kits and Accessories Isolation Valve Valve Kits Kits Isolation Isolation Valve Kits Kit 26B401, 26B401, Stem, Stem, Sleeve, Sleeve, Piston Piston Kit 26B402, 26B402, Housing Housing Assembly Assembly 26B401, Stem, Sleeve, Piston 26B402, Housing Assembly Replacements Replacements Replacements Part No. Description Ref.
  • Page 140 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 100.

  • Page 141: 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 Ref. Part Part No. Part Description Description Description Ref. Ref. Ref. Ref. Ref. Part Part Part No.

  • Page 142: 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 21...

  • Page 143: 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 144: 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 35.5 in. 85.1 cm 36.2 in. 92.1 cm 38.5 in. 97.8 cm 65.3 in. 165.9 cm 48.9 in.

  • Page 145: Notes

    Notes Notes Notes Notes 3A7370C...

  • Page 146: Technical Specifications

    Technical Specifications Technical Specifications Specifications Technical Technical Specifications Air- - - Assisted Assisted Waterborne Waterborne Isolation Isolation System System Assisted Waterborne Isolation System U.S. Metric U.S. U.S. Metric Metric 20.7 MPa, 206.8 bar: WMBH00, 3000 psi: WMBH00, WMBH01, WMBH01, WMBH20, WMBH40, WMBH20, WMBH40, WMBH41 WMBH41 Maximum Fluid Working Pressure...

  • Page 147: California Proposition 65

    California Proposition 65 Air- - - Assisted Assisted Assisted Waterborne Waterborne Isolation Waterborne Isolation Isolation System System System U.S. Metric U.S. U.S. Metric Metric Straight IEC 320–C13 male connector. Also included: North America NEMA 5-15 male plug Power Connection China / Australia AS/NZS 3112 male plug Continental Europe CEE 7/7 male plug 100-240VAC, 50-60Hz, 2 amp maximum draw, 15 amp External Power Requirements...

  • Page 148: Graco Standard Warranty

    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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