Graco 308504D Owner's Manual

INSTRUCTIONS-PARTS LIST
308–504
Rev. D
Supersedes C
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
H2O PROt
Continuous Flow System
100 psi (0.7 MPa, 7 bar) Maximum Working Air and Fluid Pressure
Part No. 237–928
Waterborne Voltage Block
For use with Graco PRO 5500wbt and PRO
3500wbt guns when electrostatically spraying
conductive, waterborne fluids that meet at
least one of the following conditions of nonflammability:
1. The fluid has a flash point above 140_F
(60_C) and a maximum organic solvent
concentration of 20%, by weight, as determined in accord with the Standard Method
of Testing for Flash Point by the PenskyMartens Closed Tester, ASTM D93.
2. The fluid does not sustain burning characteristics in accordance with the Standard
Method for Sustained Burning of Liquid
Mixtures by the Setaflash Apparatus,
ASTM D4206.
U.S. Patent No. 5,526,986
05307A
GRACO INC.
P.O. BOX 1441
MINNEAPOLIS, MN
ECOPYRIGHT 1995, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
55440–1441
Table of Contents
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . .
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
...
Voltage Block Component Identification . . . . . . . . 7
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . .10
.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
..
Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
..
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . .12
.
Fluid Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . 12
..
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
..
Leveling the Voltage Block . . . . . . . . . . . . . . . . . 12
.
Remote Terminal Strip . . . . . . . . . . . . . . . . . . . . .13
.
Interlock the Gun Turbine Air Supply . . . . . . . . .13
Connect the Hoses . . . . . . . . . . . . . . . . . . . . . . . 14
..
Ground the System. . . . . . . . . . . . . . . . . . . . . . . .16
.
Check the System Grounding . . . . . . . . . . . . . . 16
.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
...
Fluid Voltage Discharge and Grounding
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
..
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 19
.
Emergency Fluid Shutoff . . . . . . . . . . . . . . . . . . .19
.
Operating Checklist . . . . . . . . . . . . . . . . . . . . . . .19
.
2
308–504
Voltage Block Startup Procedure . . . . . . . . . . . . .20
Operating the Voltage Block . . . . . . . . . . . . . . . . 22
.
Flushing and Shutdown . . . . . . . . . . . . . . . . . . . .23
.
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
..
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
..
Cycle Counting . . . . . . . . . . . . . . . . . . . . . . . . . . 27
..
TSL System Maintenance . . . . . . . . . . . . . . . . . .27
.
PTFE Tubing Replacement
. . . . . . . . . . . . . . . 27
.
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
...
Isolator Service . . . . . . . . . . . . . . . . . . . . . . . . . . 28
..
Accumulator Service . . . . . . . . . . . . . . . . . . . . . .33
.
Voltage Block Assembly Parts . . . . . . . . . . . . . . . 36
.
Accumulator Assembly Parts . . . . . . . . . . . . . . . . 40
.
Isolator Assembly Parts . . . . . . . . . . . . . . . . . . . . .42
.
Air Logic Schematic and Parts . . . . . . . . . . . . . . . 44
.
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
..
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
..
The Graco Warranty and Disclaimers . . . . . . . . . .48
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . .48
.
Symbols
Warning Symbol
Caution Symbol
WARNING
CAUTION
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion.
Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements stated in this instruction manual.
Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all
other electrically conductive objects in the spray area. See Ground the System on page 16.
Provide fresh air ventilation to avoid the buildup of toxic vapors. Interlock the automatic gun air
supply to prevent operation of the power supply unless the ventilating fans are on. See Ventilate
the Spray Booth on page 12.
Only use this equipment to spray non-flammable, waterborne fluids, as defined on the front cover
of this manual.
Only flush, purge, or clean the electrostatic, waterborne spray system with non-flammable fluids,
as defined on the front cover of this manual.
Do not flush the system with the gun electrostatics turned on.
Use only non-sparking tools to clean residue from the booth and hangers.
Extinguish all open flames or pilot lights in the spray area.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Do not store any flammable fluids in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not smoke in the spray area.
Do not operate a gasoline engine in the spray area.
Warnings are continued on the next page.
308–504
3
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding or an improper setup and usage of the voltage block system can cause a
hazardous condition and result in an electric shock or other serious injury.
Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all
other electrically conductive objects in the spray area. See Ground the System on page 16.
The components of the voltage block system that are charged with high voltage when the spray
gun is operating are inside the voltage block enclosure to make these components inaccessible to
personnel and prevent electric shock. The enclosure door must be closed when any gun connected
to the system is operating. The enclosure door has a switch that moves the isolator to discharge
the voltage if the door is opened, which helps prevent personnel from making contact with the
components when they are charged with high voltage. Do not tamper with or bypass the door
switch or other safety devices.
The automatic gun air supply must be interlocked with the voltage block system to shut of f the
turbine air supply whenever the enclosure door is opened.
Only use the red-colored Graco electrically conductive gun air hose with this system. Do not use
the black or grey-colored Graco air hoses.
The areas of the Graco waterborne fluid hose that are accessible to the personnel must be covered by the conductive, grounded hose layer. The area on the hose that is not covered by the
conductive hose layer must be inside the voltage block system enclosure.
Install only one continuous Graco waterborne fluid hose between the voltage block system and the
spray gun. Do not splice hoses together.
Follow the Fluid Voltage Discharge and Grounding Procedure on page 18 when instructed to
discharge the voltage; before cleaning, flushing, or servicing the system; before approaching the
gun; and when opening the voltage block enclosure door.
Do not touch the gun electrode or come within 4 inches (101.6 mm) of the nozzle during gun
operation until the Fluid Voltage Discharge and Grounding Procedure , page 18, has been
completed.
Do not enter a high voltage or hazardous area until all high voltage equipment has been
discharged.
If there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.
Follow the warnings and instructions in the spray gun manual.
PRESSURIZED EQUIPMENT HAZARD
Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin
and cause a serious injury.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure on page 19 whenever you: are instructed to relieve the
pressure; stop spraying; clean, check, or service the equipment; and install or clean the fluid
nozzles.
Tighten all the fluid connections before each use.
Check the hoses, tubes and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
4
308–504
Warnings are continued on the next page.
WARNING
EQUIPMENT MISUSE HAZARD
INSTRUCTIONS
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
in a serious injury.
Only use the Graco PRO 5500wb automatic gun or PRO 3500wb hand-held gun with this system.
This equipment is for professional use only.
Read all the instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi (0.7 MPa, 7 bar) maximum working air and fluid pressure .
Do not lift pressurized equipment.
Use fluids that are compatible with the equipment wetted parts. See the Technical Data section of
all the equipment manuals. Read the fluid manufacturer’s warnings. Do not use MEK or any ketone
solvent mixture to flush the system.
Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180F (82C) or below –40F (–40C).
Do not use the hoses to pull equipment.
Comply with all applicable local, state, and national fire, electrical, and other safety regulations.
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
Know the specific hazards of the fluid you are using. Read the fluid manufacturer ’s warnings.
Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all
local, state, and national guidelines.
Wear appropriate protective clothing, gloves, eyewear, and respirator.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers. Keep clear of moving isolator parts.
308–504
5
6
308–504
Voltage Block Component Identification
20
Fluid Pressure Air Pilot Regulator
The air pilot regulator is used to adjust the pressure
setting of the fluid regulator (2) at the voltage block
fluid outlet.
72
Fluid Pressure Gauge
The gauge shows the air pilot regulator (20) pressure,
which controls the fluid regulator (2) pressure.
See Fig. 2
YY Remote Terminal Strip
72
The remote terminal strip provides 8 ports for sending
input or output signals to operate the system remotely.
See page 13.
20
A B
C
Fig. 1
ZZ Optional Pneumatic Counter Kit (purchased
separately)
05316
See Fig. 1. Refer to Fig. 2 and 3.
A
Fill/Run Button
The Fill/Run Button is pressed to initially fill the accumulators (74) or restart operation after a period when
spraying had stopped or the door has been opened.
B
Flush/Reset Button
The pneumatic counter kit, part no. 238–026, counts
the number of isolator cycles for maintenance tracking.
99
Air Logic Assembly
The air logic assembly is mounted inside, on the
enclosure door. It receives and sends signals that
enable the voltage block to operate properly. No adjustments to the air logic assembly are necessary. Do
not alter components or connections.
The Flush/Reset Button has the following uses:
To reset the air logic assembly (99) components
when initially starting the system or when the air
logic was shut down due to air supply depressurization.
ZZ
YY
To pressurize the accumulators (74) to prepare to
flush the system.
To prepare to empty the accumulators (74) and
depressurize the voltage control fluid section before
shutting down the system.
99
To stop the filling process.
C
Optional kV Display (purchased separately)
The kV display, part no. 238–095, is an accessory that
can be added to the voltage block to provide a system
voltage reading.
05826
Fig. 2
308–504
7
Voltage Block Component Identification
13
22
90
76
77
53
74
4
138
waste
supply
43
75
106
D
103
2
SIDE 1
SIDE 2
SIDE 1
SIDE 2
05315B
Fig. 3
See Fig. 3
2
D
The voltage block fluid regulator regulates the fluid
pressure to the gun. The setting is adjusted with the air
pilot regulator (20–see Fig. 1). A small air bleed hole
constantly bleeds the pilot air for fluid control accuracy.
Graco Waterborne Fluid Hose (purchased
separately)
A Graco waterborne fluid hose must be used between
the voltage block fluid regulator (2) outlet and the
spray gun. This fluid hose consists of three layers (see
Fig. 5, page 15):
Inner Hose Layer: is a PTFE tube. Conductive Hose Layer: covers the PTFE tube.
Outer Hose Jacket: is a protective polyethylene
hose cover.
If a hose failure occurs, where the high voltage arcs
through the PTFE core, the voltage will be discharged
to ground through the conductive hose layer. When
properly installed, the hose is grounded through its
connection to the enclosure. All areas of the fluid hose
that are accessible to personnel must be covered by
the conductive hose layer.
8
308–504
4
Fluid Regulator
TSL Supply Bottle
The TSL supply bottle contains fresh throat seal liquid
(TSL) for lubricating the isolator assembly (75) rod
and seals.
13
Air Inlet Quick-disconnect
The connector for the voltage block air supply hose.
The quick-disconnect allows for quick disconnection of
the air line to shutdown the system in an emergency.
22
Voltage Block Air Pressure Regulator
This air regulator is used to adjust air pressure to the
voltage block components.
Voltage Block Component Identification
See Fig. 3
43
Voltage Bleed Resistor
The voltage bleed resistor completely bleeds off the
voltage from the gun in about 30 seconds after the gun
trigger is released. The actual time depends on the
hose length.
53
Door Switch
When the enclosure door is opened, the door switch
signals the isolator (75) to ground the fluid in the
voltage block and bleed off the high voltage.
74
Accumulator
The accumulator is a container inside the voltage block
enclosure (106). It fills with fluid from the fluid supply
unit and supplies that fluid to the spray gun. The
accumulator has a full level switch (76) and low level
switch (77) for the fluid.
75
Isolator
The isolator can move up or down on the isolator rod.
The position the isolator is in depends on which operating phase the voltage block is in.
Spraying Position: is the upward position of the
isolator. This position isolates the waterborne fluid
in the accumulator (74) (which is connected to the
isolator) from the fluid supply (which is at ground)
and enables the fluid to be sprayed electrostatically.
Fill Position: is the downward position of the
isolator. In this position, the valve in the isolator rod
opens so the accumulator (74) can be refilled by
the fluid supply.
76
Full Level Switch
When the accumulator (74) is filling, the full level
switch sets the maximum amount of fluid the accumulator will allow. To reduce the number of times the
accumulator has to refill and decrease the wear on the
equipment, set the full level at the highest setting.
77
Low Level Switch
When the fluid in the accumulator (74) reaches this
switch and the gun is triggered, the Voltage Block will
begin supplying fluid to the spray gun from the second
accumulator and will also refill the accumulator that is
low on fluid.
90
TSL Pump
The TSL pump circulates the TSL through the isolator
(75) fluid block and seals.
103 Fluid Inlet Connector
The connector for the voltage block fluid supply hose.
106 Enclosure
The enclosure houses the internal components of the
voltage block and helps prevent personnel from coming in contact with the components when they are
charged with high voltage.
138 TSL Waste Bottle
The TSL waste bottle receives the used throat seal
liquid (TSL).
See Fig. 4, page 15
25
Ground Lug
The ground lug is used to ground the voltage block by
connecting the main ground wire (123) between the lug
and a true earth ground.
123 Main Ground Wire
The ground wire is connected between the ground lug
(25) and a true earth ground.
308–504
9
Sequence of Operation
The following charts show the sequence of how the system or voltage block operates during various operation
modes. The charts do not cover how to actually operate the system or voltage block. For operating instructions, see
the Operation section.
NOTE: Refer to Fig. 3, page 8.
Key:
Vented – accumulator is filling
Pressurized – accumulator is dispensing fluid
Air Blocked – accumulator piston is holding its current position, it is neither filling or dispensing.
FILL/RUN
FILL Sequence
Isolator 1
Position
Accumulator 1
Isolator 2
Position
Accumulator 2
1. Accumulator 1 starts
filling
down
vented
up
pressurized
2. Accumulator 1 is full
down
vented
up
pressurized
3. Accumulator 1 dispenses to Accumulator 2
up
pressurized
down
vented
4. Accumulator 2 is full
up
pressurized
down
air blocked
5. Accumulator 1 starts
refilling
down
vented
up
air blocked
6. Accumulator 1 is full
up
pressurized
down
air blocked
7. System is ready to
spray
up
pressurized
down
air blocked
Isolator 1
Position
Accumulator 1
Isolator 2
Position
Accumulator 2
1. Accumulator 1 dispenses to spray gun
up
pressurized
down
air blocked
2. Accumulator 1 is
empty
down
vented
up
pressurized
3. Accumulator 2 dispenses to spray gun
while Accumulator 1
starts refilling
down
vented
up
pressurized
4. Accumulator 1 is full
down
vented
up
pressurized
5. Accumulator 1 dispenses to spray gun
and refills Accumulator 2
up
pressurized
down
vented
6. Accumulator 2 is full
up
pressurized
down
air blocked
RUN Sequence
Operation
Operation
7. Operation continues with the Run Sequence, steps 2 to 6, until the operator stops spraying
10
308–504
Sequence of Operation
FLUSH/RESET
FLUSH
Sequence–
through gun
Operation
Isolator 1
Position
Accumulator 1
Isolator 2
Position
Accumulator 2
1. Both accumulators
dispense to spray gun
up
pressurized
down
pressurized
2. Both accumulators
are empty
down
pressurized
down
pressurized
3. Water supply flushes
down
through the system
until clear fluid is seen
pressurized
down
pressurized
4. Voltage block remains
in this mode until the
fill sequence is activated
pressurized
down
pressurized
down
Paint Saver
This operation sequence pushes the fluid in the accumulator back into the fluid supply to help save fluid. Refer to
page 23.
Paint Saver
Sequence
Operation
Isolator 1
Position
Accumulator 1
Isolator 2
Position
Accumulator 2
1. Both accumulators
dispense their fluid
back to the depressurized fluid supply or to
a container
down
pressurized
down
pressurized
2. Both accumulators
are empty
down
pressurized
down
pressurized
3. Remains in this mode
until the enclosure
door is closed and the
Fill/Run button is
pressed.
down
pressurized
down
pressurized
308–504
11
Installation
IMPORTANT: Only use the Graco PRO 5500wb
automatic gun or PRO 3500wb hand-held gun with this
system. The instructions in this manual are based on a
typical system, where one of these Graco guns would
be used.
WARNING
ELECTRIC SHOCK HAZARD
Installing and servicing this equipment
requires access to parts which could
cause an electric shock or other serious
injury if the work is not performed properly.
Electrically interlock the gun air supply with the ventilators to prevent operation of the electrostatic power
supply unless the ventilating fans are on.
Check and follow all local, state, and national codes
regarding air exhaust velocity requirements. High
velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum
allowable air exhaust velocity is 60 ft./min. (19 linear
meters/min.).
Fluid Supply Unit
Do not install or service this equipment unless
you are trained and qualified.
Comply with all local, state, and national codes
for the installation of electrical apparatus in a
Class I, Group D, Hazardous Location.
Comply with all applicable local, state, and
national fire, electrical, and other safety regulations.
Warning Signs
Mount the warning sign, part no. 186–118 (included
with the PRO 5500wb automatic gun or PRO 3500wb
hand-held gun), in the spray area where it can easily
be seen and read by all operators. Read the warning
and instruction labels on the enclosure. Additional
warning labels and signs are available at no charge.
Ventilate the Spray Booth
WARNING
TOXIC FLUID HAZARD
Provide fresh air ventilation to avoid the
buildup of toxic vapors. The gun air supply must be interlocked with the ventilators to prevent operation of the electrostatic power supply unless the ventilating
fans are on.
12
308–504
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of serious injury due
to component rupture, do not exceed the
maximum working pressure of the lowest
rated system component. This equipment has a
100 psi (0.7 MPa, 7 bar) maximum air and fluid
working pressure.
Follow the installation instructions in the manual for
your fluid supply unit. It is recommended that the fluid
be filtered with a 60 mesh filter.
Air Supply
The air supply must be filtered and dry for the voltage
block to operate properly. At a minimum, use a 40
micron filter. A Graco air filter, part no. 106–148, is
available.
Leveling the Voltage Block
The voltage block must be level to ensure proper
alignment of the door latches and for system stability.
Loosen the jam nut (86) and adjust the leg leveler (12)
until the voltage block is level. See the parts drawing
on page 36.
Installation
Remote Terminal Strip
The remote terminal strip is mounted on the inside of
the clear plastic cover that covers the air logic assembly. See Fig. 2, page 7. There are 8 ports available to
connect to for sending or receiving air signals to operate the system remotely from an external control, such
as a PLC (programmable logic controller) system.
Use polyethylene, 5/32 in. (4 mm) O.D., tubing for
connection to the terminal strip ports. This tubing is
available from Graco in 100 ft. (30.5 m) lengths. The
chart below shows the part numbers and colors.
Tubing Part No.
Color
054–730
Natural (clear)
054–731
Blue
054–732
Red
054–733
Yellow
054–734
Black
NOTE: See page 44 for the air logic assembly schematic.
The 8 ports are labeled in the air logic circuit as:
#1 FILL/RUN: Accepts an input air signal (minimum
60 psi [410 kPa, 4.1 bar]) from an external source
that duplicates the FILL/RUN button on the voltage
block door.
#2 FLUSH/RESET: Accepts an input air signal (minimum 60 psi [410 kPa, 4.1 bar]) from an external
source that duplicates the FLUSH/RESET button
on the voltage block door.
#3 QUICK DUMP: Accepts an input air signal (minimum 60 psi (410 kPa, 4.1 bar]) from an external
source that duplicates the function of opening the
voltage block door to initiate the “paint saver” option. In order for this function to operate, the installation must also be set up to activate color change
valves to close the paint inlet line and open a
dump valve line.
#4 FLUID PRESSURE: Accepts an input air signal
from an external source that duplicates the air
pressure setting from the air pilot regulator on the
voltage block door, which controls the fluid regulator.
#5 READY TO FLUSH: Sends an output air signal to
an external controller or indicator to signal when
both of the accumulators have dispensed the fluid
and are in their empty position, ready for water
flushing.
#6 READY TO SPRAY: Sends an output air signal to
an external controller or indicator to signal when
both of the accumulators are full and have actuated their full level switches.
#7 DOOR OPEN: Sends an output air signal to an
external controller or indicator to signal when the
door switch is activated “open” and it is an unsafe
condition for spraying.
#8 VOLTAGE DUMP: Accepts an input air signal from
an external source that duplicates the door open
switch operation that sends both of the isolators
down to immediately ground out the high voltage
charge of the fluid.
Interlock the Gun Turbine Air Supply
WARNING
ELECTRIC SHOCK HAZARD
If the PRO 5500wb Automatic Gun is
being used, the turbine air supply must
be interlocked with the voltage block
system to shut off the turbine air supply anytime
the voltage block door is opened. The remote terminal strip must be used to interlock the turbine air
supply and the voltage block door, by using the
door open port (see description of port #7, above).
To reduce the risk of an electric shock, do not tamper with or bypass the air line interlock.
308–504
13
Installation
Connect the Hoses
3. Connect the gun air supply line(s) as instructed in
the gun manual.
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock:
Install only one continuous Graco waterborne fluid hose between the voltage block and the spray gun. Do not
splice hoses together.
The areas of the waterborne fluid hose that are
accessible to personnel during normal operation
must be covered by the outer hose jacket (FF).
See Fig. 5.
NOTE: If multiple automatic gun operation is needed,
contact your Graco representative for ordering
requirements for the Multiple Gun Fluid Manifold Kit,
part no. 237–965, for the PRO 5500wb Automatic
Guns.
WARNING
ELECTRIC SHOCK HAZARD
The Multiple Gun Fluid Manifold Kit can
only be used with automatic guns. Regulations applying to this type of equipment prohibit the use of multiple hand-held guns.
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock or
other serious injury, you must use the
red Graco Electrically Conductive Air
Hose for a hand-held gun’s air supply hose or for
an automatic gun’s turbine air hose, and you must
connect the hose ground wire to a true earth
ground. Do not use the black or grey-colored Graco
air hoses.
Graco Electrically Conductive Air Hose Part Numbers
100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
Conductive SST wire braid for grounding; polyurethane tube
and cover; 0.315 inch I.D.; 1/4 npsm(f) x 1/4 npsm(f) left-hand
thread; the hose is color-coded red
Part No.
Length
235–068
235–069
235–070
235–071
235–072
235–073
235–074
6 ft. (1.8 m)
15 ft. (4.6 m)
25 ft. (7.6 m)
36 ft. (11.0 m)
50 ft. (15.2 m)
75 ft. (23.0 m)
100 ft. (30. 5 m)
4. Loosen the fluid hose ferrule nut (8) and hose
compression nut (AA). See Fig. 5.
1. Connect the air supply hose between the air
supply and the air inlet quick-disconnect (13). See
Fig. 4.
5. Install the Graco waterborne fluid supply hose
through the fluid hose port (P) in the enclosure and
into the fluid regulator fitting (49). See Fig. 4 and 5.
2. Connect the fluid supply hose between the
grounded fluid supply and the 3/8 npsm voltage
block fluid inlet (103). Use a 5/16 in. (7.9 mm) or
3/8 in. (9.5 mm) I.D. hose for minimal pressure
drop.
6. Hand-tighten the hose compression nut (AA)
securely. See Fig. 5.
Graco Waterborne Fluid Hoses Part Numbers
100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
0.25 in. (6.35 mm) I.D.; PTFE Spray Gun Model
Hose Part No.
Length
Manual PRO
3500wb Spray Gun
237–924
237–925
237–926
25 ft. (7.6 m)
36 ft. (11.0 m)
50 ft. (15.2 m)
Automatic PRO
5500wb Spray Gun
237–920
237–921
237–922
25 ft. (7.6 m)
36 ft. (11.0 m)
50 ft. (15.2 m)
14
308–504
NOTE: The two hose ferrules (BB & CC) must be
orientated as shown in Fig. 5, with the taper of the
solid ferrule (BB) facing toward the fluid regulator (2)
and the taper of the split ferrule (CC) facing away from
the fluid regulator.
7. The hose ferrule nut (8) grounds the conductive
layer (DD) of the Graco waterborne fluid hose and
provides strain relief for the hose. See Fig. 5.
Tighten the hose ferrule nut securely.
8. Connect the other end of the fluid hose to the gun
fluid inlet. Read the instructions on fluid hose
connection in your gun manual.
Installation
KEY-Fig. 4
N
P
13
22
25
True Earth Ground
Enclosure Fluid Hose Port
Voltage Block Air Inlet (quick-disconnect)
Voltage Block Air Regulator
Ground Lug
49 Fluid Regulator Nut
103 Voltage Block Fluid Inlet
106 Voltage Block Enclosure
119 Main Ground Wire Clamp
123 Main Ground Wire
22
106
25
13
123
119
N
P
103
49
2
05318A
Fig. 4
KEY-Fig. 5
AA Hose Compression Nut
BB Hose Ferrule
CC Hose Ferrule
DD Conductive Hose Layer
EE Inner Hose Layer
FF Outer Hose Jacket
8 Hose Ferrule Nut
2 Fluid Regulator
49 Fluid Regulator Fitting
106 Voltage Block Enclosure
The areas of the waterborne fluid hose that are accessible to
personnel during normal operation must be covered by the outer
hose jacket (FF).
The portion of the inner hose layer (EE) that is not covered by the
outer hose jacket (FF) must be inside the enclosure (106).
2
49 BB
CC
AA
8
EE FF
DD
106
05375
Fig. 5
308–504
15
Installation
Ground the System
See Fig. 4
2. Fluid Supply: Ground the fluid supply by connecting a ground wire and clamp. See your fluid supply
instruction manual for grounding instructions.
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
When operating the electrostatic gun,
any ungrounded objects in the spray
area (such as people, containers, tools,
etc.) can become electrically charged.
Improper grounding can result in static
sparking, which can cause a fire, explosion, or electric shock. Follow the
grounding instructions below.
The following grounding instructions are minimum
requirements for a basic electrostatic, waterborne
system. Your system may include other equipment or
objects which must be grounded. Check your local
electrical code for detailed grounding instructions for
your area and type of equipment. Your system must be
connected to a true earth ground.
1. Voltage Block: Connect one end of the main
ground wire (123), which is included with the
system, to the ground lug (25) on the outside of
the voltage block enclosure. Connect the other end
of the ground wire to a true earth ground (N).
Do not disconnect or tamper with the internal
ground wire connections (112) inside the voltage
block enclosure. They should be connected as
shown in Fig. 6.
112
3. Gun Air Supply Hose or Turbine Air Supply on
the PRO 5500wb Automatic Gun: You must use
the red-colored Graco electrically conductive gun
air hose. Do not use the black or grey-colored
Graco air hoses. Ground the hose by connecting
the air hose ground wire to a true earth ground.
4. Graco PRO 5500wb or PRO 3500wb
Spray Gun: Ground the gun by connecting the
grounded red-colored Graco electrically conductive
air hose to the gun. Check the electrical grounding
of the gun as instructed in the spray gun manual.
5. Graco Waterborne Fluid Hose: The hose must
be properly grounded as instructed on page 14
and in the spray gun manual.
6. All persons entering the spray area: Their
shoes must have conductive soles, such as
leather, or personal grounding straps must be
worn. Rubber or plastic soles are not conductive.
7. Object being sprayed: Keep the workpiece
hangers clean and grounded at all times. Contact
points must be sharp points or knife edges.
8. The floor of the spray area: The floor must be
electrically conductive and grounded. Do not cover
the floor with cardboard or any non-conductive
material which would interrupt grounding continuity.
9. All electrically conductive objects or devices
in the spray area: They must be properly
grounded.
W
Check the System Grounding
05322B
Fig. 6
16
308–504
After grounding the system, check the resistance
between the exterior of the voltage block enclosure
and a true earth ground. The resistance must be less
than 20 ohms.
Notes
308–504
17
Operation
WARNING
ELECTRIC SHOCK HAZARD
The voltage block door switch helps to
prohibit personnel from making contact
with the enclosed voltage block components before the system voltage is discharged. To
reduce the risk of an electric shock, do not tamper
with or bypass the voltage block door switch.
IMPORTANT: Only use the Graco PRO 5500wb
automatic gun or PRO 3500wb hand-held gun with this
system. The instructions in this manual are based on a
typical system, where one of these Graco guns would
be used.
NOTE: When the voltage block is used with a 60 kV
Graco spray gun, the typical “actual” voltage on the
voltage block system is in the 45 to 55 kV range when
the gun tip is at least 1 ft. (305 mm) away from a
grounded object.
Fluid Voltage Discharge and Grounding
Procedure
WARNING
ELECTRIC SHOCK HAZARD
The voltage block is charged with high
voltage until the voltage is discharged.
Contact with the charged components of
the isolation system or spray gun will cause an
electric shock. To avoid an electric shock, follow
the Fluid Voltage Discharge and Grounding
Procedure:
For Manual Spray Guns
1. Turn off the gun electrostatics. If the PRO 3500wb
is being used, turn the ES lever on the gun to the
OFF position.
2. Wait at least 30 seconds for the voltage to discharge through the voltage block bleed resistor. If
the voltage block has the optional kV meter, wait
until the meter registers zero kV before proceeding.
3. Touch the electrode of the gun with a grounded rod
to make sure that the voltage has been discharged. If an arc is seen, verify that the electrostatics are turned off or see Troubleshooting ,
page 25, or your gun instruction manual for other
possible problems. Resolve the problem before
proceeding.
4. Cleaning or typical adjustments of the gun, such
as air cap positioning or cleaning, can be made
after completing step 3. Before doing further
service, such as gun or voltage block servicing,
complete steps 5 and 6.
5. Unscrew the voltage block door latches to bring
the isolators down and ground the high voltage
charge of the fluid.
6. Touch the wire connector (R) of the fluid regulator
with a grounded rod to make sure that the voltage
has been discharged. See Fig. 7. If an arc is seen,
see Troubleshooting , page 25, or your gun
instruction manual for other possible problems.
Resolve the problem before proceeding.
NOTE: After service is complete and the doors are
closed, the FILL/RUN button must be pressed to
restart operation.
when instructed to discharge the voltage,
before cleaning, flushing, or servicing the system equipment,
before approaching the gun,
and before opening the voltage block door.
NOTE:
The metal enclosure of the H 2O PRO voltage block
is always grounded if properly connected to a true
earth ground by the main ground wire.
An accessory grounding rod, part no. 210–084, is
available to discharge any voltage remaining on a
system component. Contact your Graco representative to order it.
18
308–504
R
Fig. 7
05816A
Operation
Fluid Voltage Discharge and Grounding
Procedure (continued)
For Automatic Spray Guns
1. Turn off the gun electrostatics to all the spray guns
connected to the voltage block.
2. Unscrew the voltage block door latches to bring
the isolators down and ground the high voltage
charge of the fluid.
3. Touch the wire connector (R) of the fluid regulator
with a grounded rod to make sure that the voltage
has been discharged. See Fig. 7. If an arc is seen,
see Troubleshooting , page 25, or your gun
instruction manual for other possible problems.
Resolve the problem before proceeding.
4. If servicing the spray gun(s), touch the electrode of
the gun with a grounded rod to make sure that the
voltage has been discharged. If an arc is seen,
verify that the electrostatics are turned off or see
Troubleshooting , page 25, or your gun instruction
manual for other possible problems. Resolve the
problem before proceeding.
NOTE: After service is complete and the doors are
closed, the FILL/RUN button must be pressed to
restart operation.
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying accidentally. To reduce the risk of an injury from accidental spray from the gun, splashing fluid, or
moving parts, follow the Pressure Relief Procedure whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray nozzle.
1. Follow the Fluid Voltage Discharge and
Grounding Procedure , page 18.
2. Shut off the fluid supply to the voltage block.
3. Shut off the air supply to the voltage block. The
shut-off device must bleed the air out of the system.
4. Trigger the gun(s) to relieve the pressure in the
fluid lines.
5. For automatic guns, shut off any other air supplies
to the spray gun(s). Use bleed-type shut-off valves
to relieve the pressure in the air lines.
NOTE: After service is complete and the doors are
closed, press the FLUSH/RESET button, then press
the FILL/RUN button to restart operation.
Emergency Fluid Shutoff
Use this procedure if rapid fluid depressurization is
needed, such as in the case of a hose leak.
1. Disconnect the air line from the voltage block
quick-disconnect air inlet. The air pressure will
bleed off to zero.
2. Turn the fluid supply unit off. The accumulator
pistons will slowly rise until the fluid and air pressures are both at zero.
Operating Checklist
Check the following list daily, before starting to operate
the system, to help ensure safe, efficient operation.
____ 1. Be sure all the operators are properly trained
to safely operate an electrostatic, waterborne,
air spray system as instructed in this manual
and the gun manual.
____ 2. Be sure all the operators are trained how to
properly relieve system pressure as instructed
at left and in the gun manual.
____ 3. Be sure all the operators are trained how to
properly discharge the voltage as instructed on
page 18.
____ 4. Be sure the system is thoroughly grounded
and the operator and all persons entering the
spray area are properly grounded. See
Ground the System, page 16.
____ 5. Be sure the ventilation fans are operating
properly.
____ 6. Be sure all the debris, including flammable liquids and rags, is removed from the spray area.
308–504
19
Operation
Voltage Block Startup Procedure
1. Install and ground the system as instructed in the
Installation section.
2. Remove the TSL supply bottles (4) and (toward
front door side) and replace them with the full TSL
bottles (4) sent with the system. See to Fig. 3,
page 8.
NOTE: To help ensure fresh TSL always enters the
seal area, replace the TSL supply bottle periodically as
instructed on page 27.
3. If adjusting the position of the accumulator full
level switch (76), be sure to push the switch bracket (AB) fully to the left and hold it in place until the
screws (39) are tight. See Fig. 8.
CAUTION
Do not set the air pressure to the voltage block
below 60 psi (410 kPa, 4.1 bar) or the voltage block
will not operate properly.
6. Repeatedly push the manual switch button near
the TSL pump (90) until all air is purged out
through the tubing and is visibly pumping into the
waste container. Refer to Fig. 3, page 8.
CAUTION
Make sure that the fluid inlet pressure is a minimum
of 5 psi (34 kPa, 0.34 bar) lower than the voltage
block air regulator (22 – Fig. 9) pressure or the
accumulators will fill during step 6.
AB
39
NOTE: Be sure to turn on the air to the voltage block
before pressing the FLUSH/RESET button or the
system components will not operate.
76
7. Check the voltage block operation and check for
fluid leaks with water before connecting the paint.
05894
Fig. 8
4. If using a hand-held gun, remove the air cap from
the gun.
5. With the voltage block door open, turn on the air to
the voltage block. Set the air pressure between
80–100 psi (0.5–0.7 MPa, 5.5–7 bar).
The air inlet pressure is set with the air regulator
(22) installed at the voltage block air inlet. See
Fig. 9.
20
308–504
22
Fig. 9
05323
Operation
8. Set the fluid outlet pressure to the gun by adjusting
the air pilot regulator (20) on the front cover of the
voltage block. See Fig. 10.
NOTE: The voltage block fluid inlet pressure will affect
the accumulators fill time only.
13. Press the FILL/RUN button (A) to fill the accumulators.
14. Wipe off the fluid nozzle, and install the air cap.
15. Follow the procedure Operating the Voltage
Block, page 22, to begin spraying.
9. Trigger the gun until all the air is purged through
the voltage block and fluid lines.
10. Close the door and press the FILL/RUN button (A)
to fill and dispense the accumulators. See Fig. 10.
Press the FLUSH/RESET button (B), and dispense all water out of the accumulators.
11. Shut off the water supply, and connect the paint
supply line.
12. Trigger the gun until the water is purged and paint
starts to dispense from the gun nozzle.
20
Fig. 10
A B
308–504
05316
21
Operation
Operating the Voltage Block
WARNING
FIRE, EXPLOSION AND ELECTRIC
SHOCK HAZARD
To reduce the risk of fire, explosion, and
electric shock:
Only use this equipment to spray
non-flammable, waterborne fluids as
defined on the front cover of this
manual.
The voltage block door must be
closed when any gun connected to
the system is operating. Do not tamper with or bypass the door switch or
other safety devices.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of component rupture,
which can cause serious injury, do not
exceed the maximum working pressure
of the lowest rated system component. This equipment has a 100 psi (0.7 MPa, 7 bar) maximum
working air and fluid pressure .
1. Turn on the air to the voltage block. Set the air
pressure between 80–100 psi (0.5–0.7 MPa, 5.5
–7 bar).
22
308–504
The air inlet pressure is set with the air regulator
(22) installed at the voltage block air inlet. See Fig.
9, page 20.
NOTE: Be sure to turn on the air to the voltage block
before pressing the FLUSH/RESET button or the
system components will not operate.
CAUTION
Do not set the air pressure to the voltage block
below 60 psi (410 kPa, 4.1 bar) or the voltage block
will not operate properly.
2. Press the FLUSH/RESET button (B) to reset the
air logic components. See Fig. 10, page 21.
3. Set the voltage block fluid pressure for the desired
fluid flow through the gun. Set the fluid pressure
with the regulator knob (20) on the voltage block
door.
4. Turn on the fluid supply to the voltage block.
NOTE: The voltage block fluid inlet pressure will affect
the accumulators fill time only.
5. Press the FILL/RUN button (A) to fill the accumulators.
6. Open the gun air supply.
7. Follow the gun operation instructions in the gun
manual. Use the same spraying technique you
would use without the voltage block to coat the
workpiece.
Operation
Flushing and Shutdown
WARNING
FIRE AND EXPLOSION HAZARD
To reduce the risk of fire and explosion:
Only flush, purge, or clean the electrostatic, waterborne spray system
with non-flammable fluids, as defined
on the front cover of this manual.
Do not flush the system with the gun electrostatics turned on.
WARNING
ELECTRIC SHOCK HAZARD
Follow the Fluid Voltage Discharge
and Grounding Procedure on page 18
when shutting down the system to
ensure the voltage is discharged and avoid serious
injury from an electric shock.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury from accidental
spray from the gun, splashing fluid, or moving
parts, follow the Pressure Relief Procedure on
page 19 when you stop spraying and whenever you
are instructed to relieve the pressure.
To save the fluid in the accumulator, follow the Paint
Saver Option procedure, below. For general gun
flushing and shutdown, follow the General Flushing
and Shutdown procedure, at right.
Paint Saver Option
To save fluid at shutdown:
1. Follow the Fluid Voltage Discharge and
Grounding Procedure on page 18.
2. Depressurize the fluid supply to the voltage block.
3. Open the voltage block door latch enough to
actuate the door switch, which will send both the
isolators down and allow the fluid in the accumulators to be pushed back to the fluid supply.
4. Continue with the General Flushing and Shutdown procedure.
General Flushing and Shutdown
NOTE: Before flushing, make sure the fluid inlet pressure is a minimum of 5 psi (34 kPa, 0.3 bar) lower than
the voltage block air pressure regulator (22) setting or
the accumulators will fill during the flush cycle. Refer to
Fig. 9, page 20.
1. Follow the Fluid Voltage Discharge and
Grounding Procedure on page 18.
2. Shut off the fluid supply. Trigger the gun until the
fluid pressure is relieved.
3. If using a hand-held gun, remove the air cap from
the gun.
4. Change the fluid supply to water or the appropriate
flushing material. Do not use MEK or related
ketone mixtures.
5. Press the FLUSH/RESET button.
6. Turn off the air supply to the gun, except the air to
actuate the gun trigger if it is an automatic gun. If
the automatic gun has an air pilot regulator, the
pilot air must also be left on.
7. Make sure the gun electrostatics are turned off.
8. Trigger the gun to dispense the fluid out of the
voltage block until the fluid section is completely
flushed.
NOTE: After the accumulators empty, the first isolator
will connect to the water supply.
9. Shut off the fluid supply. Trigger the gun until the
fluid pressure is relieved.
10. Do not purge the system with air; leave water in
the fluid lines until you operate the system again.
11. Shut off the air supply to the enclosure.
12. Wipe the gun clean. If the gun air cap was
removed, wipe off the fluid nozzle and install the
air cap.
13. Make sure that the voltage block door is closed
and that the main ground wire is connected
between the enclosure ground lug and a true earth
ground before operating the system again.
308–504
23
Troubleshooting
WARNING
ELECTRIC SHOCK HAZARD
Follow the Fluid Voltage Discharge
and Grounding Procedure on page 18
before checking or servicing the system
to ensure the voltage is discharged and avoid serious injury from an electric shock.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury from accidental
spray from the gun, splashing fluid, or moving
parts, follow the Pressure Relief Procedure on
page 19 before checking or servicing any part of
the system and whenever you are instructed to
relieve the pressure.
Problem: Voltage Loss
A loss of spraying voltage can be caused by a problem
with the spray gun, fluid hose, or voltage block, since
all of the system components are electrically connected through the conductive, waterborne fluid.
Before troubleshooting or servicing the voltage block
itself, determine which component in the system is
most likely causing a problem. Possible causes include:
Spray Gun
Fluid leakage
Dielectric breakdown at the fluid hose connection or
fluid packings
Not enough air pressure for the turbine
Faulty power supply
Excessive overspray on gun surfaces
Fluid in the air passages
Waterborne Fluid Hose
Dielectric failure of hose (pin-hole leak through
PTFElayer)
Air gap in the fluid column between the gun and
isolated fluid supply
Voltage Block
Fluid leakage
Dielectric breakdown of hoses, seals, or connections
Isolators not functioning properly
24
308–504
First, check the system for any visible faults or errors
to help isolate whether the spray gun, fluid hose or
voltage block has failed.
1. Check that all of the air and fluid tubes and hoses
are properly connected.
2. Check that the valves and controls are properly set
for operation. Refer to the Operation procedures.
3. Check that the spray gun power supply and voltage block have sufficient air pressure.
4. PRO 3500wb Gun Only: Check that the spray gun
ES lever is in the ON position and that the gun ES
indicator light comes on. If the ES indicator light
does not come on, remove the spray gun for
service.
5. Check that the voltage block door is closed and
that any safety interlocks are engaged and working
properly.
6. To eliminate air gaps in the fluid column, spray
enough fluid to purge the air out between the
voltage block and the spray gun. An air gap in the
fluid hose can break the electrical continuity
between the spray gun and the fluid in the voltage
block accumulators and cause a low voltage
reading on the optional kV meter connected to the
voltage block accumulators.
7. Check the spray gun cover and barrel for accumulated overspray. Excessive overspray can create a
conductive path back to the grounded gun handle.
Install a new gun cover and clean the exterior of
the barrel.
8. Inspect the entire system for any visible fluid
leakage, paying special attention to the following
areas:
Packing area of the spray gun
Fluid hose: check for leakage or any bulges in the
outer jacket, which may indicate an internal leak
Internal voltage block components
If you still have no voltage, separate the spray gun and
hose from the voltage block and check them for problems as instructed in the spray gun manual.
The optional kV Probe and Meter, part no. 236–003, is
recommended to measure voltage levels at key points
in the system.
Follow the troubleshooting chart for more detailed
checking of the voltage block.
Troubleshooting
Problem
Cause
Solution
Voltage loss*
Voltage block enclosure door is not
closed
Close the door.
Voltage block is in the end of the
flush mode and the fluid is connected
to a grounded fluid supply
Push the FILL/RUN button.
Waterborne fluid hose has a pin-hole
leak through the PTFE layer, causing dielectric failure
Check for leakage or any bulges in
the outer jacket, which may indicate
an internal leak. Inspect the end of
the hose connected to the voltage
block. Look for cuts or nicks. Make
sure the hose is properly stripped;
see the spray gun manual for hose
stripping dimensions. Restrip or
replace the hose.
Fluid is leaking at the gun fluid hose
connection
Remove the hose at the gun connection. Clean and dry the gun barrel I.D.
and the hose O.D. Lubricate the hose
O.D. and o-rings with dielectric
grease and reinstall them.
Excessive fluid overspray on the
outside of the gun barrel, shroud, or
gun cover
Clean the outside of the gun barrel or
shroud. Replace the gun cover.
Excessive waterborne fluid leaking
into the TSL return line
Make sure the TSL supply bottle is
full. See Service. If the problem reoccurs quickly, replace the isolator seals
with the seal kit.
Fluid is leaking on the components
inside the voltage block
Replace the seals as necessary.
Air in the fluid line to the gun (can
cause low voltage reading on the
optional voltage block kV meter)
Trigger the gun until the air is purged
out through the gun nozzle.
Gun electrostatics (turbine air or gun
ES lever) not turned off
Turn off the gun electrostatics.
Did not wait long enough for the voltage to discharge through the voltage
bleed resistor
Wait the 30 second time period before making contact with the gun or
internal voltage block components.
Air pocket in the fluid lines
Purge the air out of the fluid lines.
Faulty bleed resistor
Check for loose wire connection or
replace the bleed resistor if necessary.
Voltage is still present at the gun
or fluid regulator after following
the Fluid Voltage Discharge
and Grounding Procedure
* Normal spraying voltage is 45 to 55 kV.
308–504
25
Troubleshooting
Problem
Cause
Solution
TSL waste bottle level is rising
quickly
Waterborne fluid is leaking into the
TSL lines
Replace the isolator seals with the
seal kit. See Service.
TSL supply bottle level is dropping quickly
TSL is leaking or slowly evaporating
with use
Refill the TSL bottle or replace the
isolator seals.
TSL, TSL tubing, or TSL waste
bottle color changing to color of
waterborne fluid
This is normal unless the kV level is
dropping (see Voltage Loss, page
25)
No action necessary. The dirty TSL
can be pumped out with clean TSL as
necessary.
Cartridge seals worn allowing excessive fluid into the TSL ports
Replace the isolator seals with the
seal kit.
TSL circulating pump seals worn
Replace TSL pump seals with the
pump fluid seal repair kit.
Check valve(s) in TSL tubing line(s)
failed
Replace check valve(s) and tubing if
necessary with TSL tube repair kit.
Air restrictor to TSL pump closed too
far
Open the adjustment screw on the
restrictor 1/2 turn and test with the
manual pump actuator.
Retaining collar nut has loosened
causing loss of spring pressure
Re-tighten the collar. Secure the
collar with its retaining screw. See
Service.
Rod o-ring is worn or damaged
Replace the o-ring and cartridge
seals with the replacement seal kit.
See Service.
Fitting nut is not tight
Hand-tighten the nut. Hand-tighten
only; do not use tools.
Fitting threads are stripped
Replace the fitting. Install the new
hose or nut assembly as needed.
Isolator air cylinder moving too
slow or too fast (normal speed is
approximately 2 seconds per
stroke)
Cylinder restrictors misadjusted or
plugged
Adjust air cylinder exhaust port for
speed adjustment of about 2 seconds
per stroke.
Isolator cylinder is not operating
properly
Voltage block air pressure set below
60 psi (410 kPa, 4.1 bar); recommended pressure is 65–95 psi
(450–650 kPa, 4.5–6.5 bar)
Set air to proper pressure. See
Operation.
Accumulator fills past the full setting switch
Switch position is not adjusted
properly
Re-adjust the switch position.
Air leak at fluid regulator pilot air
fitting
Constant air exhaust from small hole
in pilot air fitting is normal and used
for pressure control accuracy.
No action necessary.
TSL not circulating
Fluid leak at isolator rod seam
PTFE fluid hose connections are
leaking
26
308–504
Maintenance
Cycle Counting
Gradual reduction of the spraying voltage.
A Pneumatic Cycle Counter Kit, part no. 238–026, is
available to count the number of isolator cycles for
maintenance tracking.
If the Cycle Counter Kit is not installed, time how long
one voltage block cycle takes during normal operation.
Use the following formula to convert the voltage block
cycles to production hours:
Fluid Seal Time in Hours =
(15,000 x Cycle Time in minutes)
60
TSL System Maintenance
To prolong the life of the isolator and to avoid expensive repairs and downtime, perform the following
maintenance:
1. Replace the isolator seals every 15,000 voltage
block cycles, or every four months, whichever
comes first. See page 28.
2. Inspect the condition of the TSL fluid in the sight
glass and in the TSL waste bottle (138) daily.
Refer to Fig. 11, page 28. Signs of excessive TSL
contamination include:
Greatly increased discoloration of the TSL in
the waste bottle
Quick rise in the TSL level in the waste bottle
3. Make sure that only fresh TSL enters the seal area
by checking the TSL supply bottle (4) level daily.
CAUTION
Do not allow the TSL supply bottle to become empty
or voltage breakdown could quickly occur.
4. Once a week, manually check the operation of the
TSL pump (90). Refer to Fig. 11. The isolator
must be in the down position* and the voltage
block must be pressurized for the pump to operate. Operate the TSL pump by pressing the button
on the pump. Watch the sight glass in the TSL line
to see if the fluid is moving.
*
The isolator will automatically stop in the down
position when the voltage block door is opened.
PTFETubing Replacement
The PTFE flared tube assembly (101) will fatigue over
time. To prevent failure during operation, replace the
tube assembly after dispensing about 50,000 gal.
(189,250 liters) of fluid or after about 6,000 hours of
operation. If a cycle counter is used, replace the tube
assembly every 70,000 cycles.
308–504
27
Service
Isolator Service
WARNING
ELECTRIC SHOCK HAZARD
Follow the Fluid Voltage Discharge
and Grounding Procedure on page 18
before checking or servicing the system
to ensure the voltage is discharged and avoid serious injury from an electric shock.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury from accidental
spray from the gun, splashing fluid, or moving
parts, follow the Pressure Relief Procedure on
page 19 before checking or servicing any part of
the system and whenever you are instructed to
relieve the pressure.
3. Disconnect the TSL supply bottle outlet tube (A)
from the fluid block (330). See Fig. 11. Drain the
TSL into a waste container.
4. Disconnect the two air tubes from the air cylinder
connectors (B). Mark or tag the tubes so it is
apparent which connector they attach to for
reassembly.
5. Disconnect the two PTFE fluid tubes (C) from the
isolator elbows.
6. Disconnect the TSL return tube (E) from the fluid
block (330) fitting.
7. Remove the screw (305), and disconnect the
ground wire from the air cylinder. Reinstall the
screw to avoid losing it.
8. Remove the four 3/8” screws (97), and remove the
isolator assembly (75) from the enclosure (106).
9. Take the isolator to a clean service bench.
NOTE: An Isolator Seal Kit, part no. 237–977, is
available. It includes the o-rings (302, 306, 308, 309,
319) and seals (320) for the seal cartridges.
Replace the isolator seals every 15,000 voltage block
cycles, or every four months, whichever comes first.
When installing the Isolator Seal Kit, inspect the isolator parts for signs of arcing or carbon tracking. A
carbon track will look like a pencil line, which you can
feel with your fingernail. It will typically appear near the
bottom of the rod connection seam. Replace any parts
that look damaged to avoid system failure.
90
L
A
suppy
waste
4
138
B
305
330
E
Isolator Disassembly
1. Follow the General Flushing and Shutdown
procedure on page 23.
C
NOTE: As part of the General Flushing and Shutdown, the Fluid Voltage Discharge and Grounding
Procedure, page 18, and the Pressure Relief Procedure, page 19, should have been completed. Do not
proceed until you have followed those procedures.
Follow the steps below to remove either one or both of
the isolators.
2. Remove the TSL supply bottle (4) from the supply
tube.
28
308–504
106
Fig. 11
75
97
101
05817B
Service
Isolator Disassembly (continued)
10. Remove the retainer screw (343) from the bottom
support (331). See Fig. 12.
19. While holding the parts over a waste container, pull
the isolator rod (334) out of the fluid block (330).
Be careful not to nick or scratch the rod surfaces.
11. Remove the spring retainer collar (336).
20. Remove the isolator rod o-ring (319).
12. If servicing the right side isolator, rotate the fluid
tube (335) until the arc bypass wire assembly
(354) is accessible. Remove the screw (338) and
washer (350).
21. Remove both seal cartridges (332, 333), the high
voltage electrode (326), plug (325), and o-ring
(306) from the fluid block (330).
13. Pull the fluid tube (335) out of the bottom support
(331). Remove the plug (325) and o-ring (306).
14. Remove the bottom support (331) by removing the
four screws (318) that fasten it to the mounting
brackets (324, 337).
15. Loosen the screw (307) holding the cover retainer
(328), and rotate the cover retainer off of the
cylinder rod cover (327).
16. Push the cylinder rod cover (327) up until the air
cylinder rod (G) is accessible. Unscrew the cylinder rod from the adapter in the fluid block (330).
17. Remove the plastic screw (304) holding the isolator rod (334).
18. Slide the fluid block (330) [with the isolator rod still
in place] off the metal guide rod (321).
CAUTION
Be careful not to nick or scratch the cartridges (332,
333) surfaces when removing o-rings and seals.
Note the o-ring and seal sizes and positions as they
are removed to ensure they are reinstalled correctly.
22. Remove all the o-rings (302, 308, 309) from both
seal cartridges (332, 333).
23. Use a dental pick to remove the wiping seals (320)
from both seal cartridges (332, 333). Be careful
not to scratch the cartridges surfaces.
24. Thoroughly clean and inspect all the parts. Inspect
the fluid tube (335) and isolator rod (334) for nicks,
grooves, and high voltage burn marks on sealing
and wiping surfaces. Inspect the guide rod bearings (312) for wear. Replace all the parts that
appear to be worn or damaged.
Continue on page 31
308–504
29
Service
320 311
308* 304 A
305
324
337
333 329
320 G
334
320* 319*
332 306*
348
325 350
352
338
351
*309
349
*302
B
354
A
321
*320
353
B
335
318
331
327
343 326 307
313
325 328
306*
336 330
F
Fig. 12
30
8565A
Apply lubricant.
Torque to 15 in-lbs (1.7 NSm).
Torque to 8 in-lbs (0.9 NSm).
Tighten securely, until bottomed out.
Lips face down
308–504
Lips face up
On right isolator only
On left isolator only
* Included in Kit 237–977
Service
Isolator Assembly
NOTE: Parts that are marked with an asterisk (*) are
included with the Isolator Seal Kit, part no. 237–977.
1. Lubricate the new seals (320*) and install them
into the cartridges (332, 333), orientated as shown
in Fig. 12, page 30. Make sure the seals sit
straight in the cartridge and that the seal quad-ring
is in place.
2. Lubricate the new o-rings (302*, 308*, 309*) and
install them in the grooves on the cartridges (332,
333) in the order shown in Fig. 12.
3. Install the o-ring (306*), plug (325), and high
voltage electrode (326) in the fluid block (330).
Tighten the plug and the electrode until they bottom out.
4. Carefully install the seal cartridges (332, 333) into
the fluid block (330). Tighten the cartridges until
they bottom out.
5. Install the o-ring (319*) on the end of the isolator
rod (334).
6. Slide the tapered end of the isolator rod (334)
through the seal cartridges (332, 333) in the fluid
block (330).
7. Place the cylinder rod cover (327) in the locating
groove (F). Do not fasten the cover with the
retainer (328) and screw (307) yet.
11. Secure the bottom support (331) to the mounting
brackets (324, 337) with the four screws (318).
Tighten the screws to 15 in-lbs (1.7 N m).
12. Install the fluid tube (335) into the bottom support
(331).
13. On the right side isolator, secure the arc bypass
wire assembly (354) to the fluid tube (335) with the
washer (350) and screw (338).
14. Install the spring (313) into the retainer collar
(336), and screw the collar into the bottom support
(331) until the collar bottoms out. Secure the collar
with the retainer screw (343).
15. Secure the isolator assembly (75) into the enclosure (106), using the four 3/8” screws (97). See
Fig. 11, page 28.
16. Connect the two air tubes to the air cylinder connectors (B).
17. Connect the two PTFEfluid tubes (C) to the
isolator elbows.
CAUTION
Tighten the tube retaining nuts by hand only to avoid
damaging the threads.
18. Remove the screw (305). Connect the ground wire
to the air cylinder, and secure the wire with the
screw.
8. Slide the fluid block (330) onto the metal guide rod
(321). Push the isolator rod (334) into the counterbore in the top support (329), and secure the rod
with the plastic screw (304). Tighten the screw to 8
in-lbs (0.9 N m).
19. Connect the TSL supply tube (A) to the fluid block
(330). See Fig. 11, page 28.
9. Push the fluid block (330) partially down to slide
the cylinder rod cover (327) up and tighten the air
cylinder rod (G). Tighten the rod until it bottoms
out.
21. Turn on the air inlet pressure to the voltage block.
10. Slide the cylinder rod cover (327) down and secure
the cover with the retainer (328) and screw (307).
Tighten the screw to 8 in-lbs (0.9 N m).
20. Connect the TSL return tube (E) to the fluid block
(330).
22. Press the button on the TSL pump (90) to manually activate it and flush the remaining TSL out of the
pump and into the waste bottle. Press the button
on the TSL pump repeatedly until all air and contaminated TSL are purged from the tubing. View
the air pockets in the sight tube.
308–504
31
Notes
32
308–504
Service
Accumulator Service
WARNING
ELECTRIC SHOCK HAZARD
Follow the Fluid Voltage Discharge
and Grounding Procedure on page 18
before checking or servicing the system
to ensure the voltage is discharged and avoid serious injury from an electric shock.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury from accidental
spray from the gun, splashing fluid, or moving
parts, follow the Pressure Relief Procedure on
page 19 before checking or servicing any part of
the system and whenever you are instructed to
relieve the pressure.
Signs of accumulator piston seal failure include a
noticeable and repeated spitting of fluid while spraying
(indicating that air is entering into the fluid stream) or a
visible amount of fluid in the top air exhaust line that is
exiting through the enclosure bottom.
NOTE: An Accumulator Seal Kit, part no. 237–976, is
available. It includes the o-rings (211) and u-cups (208,
214).
Accumulator Disassembly
4. Disconnect the air pilot tube from the fluid regulator air pilot connector (48).
5. Loosen the hose ferrule nut (8).
6. Loosen (but do not remove) the hose compression
nut (AA) connecting the gun fluid supply hose to
the fluid regulator outlet. Pull the hose out of the
fitting.
7. Remove the four top plastic screws (54) that
secure the accumulator (74) to the mounting plate
(X) in the enclosure.
8. Remove the accumulator (74) from the mounting
plate (X).
9. Remove the four thread caps (225) and cap plugs
(224). See Fig. 14.
10. Loosen the four hex nuts (213) evenly.
11. Remove the four 12.6” screws (212), washers
(204), and high voltage shields (223).
12. Tap the end blocks (216, 217) off of the cylinder
(219).
13. Remove the piston assembly (221, 222, 214 1, 220)
from the cylinder (219).
14. Remove the u-cups (208, 2142) and o-rings (201,
202, 211). Clean and inspect the parts. Replace all
the parts that are worn or damaged.
Continue on page 35
1. Follow the General Flushing and Shutdown
procedure on page 23.
H
NOTE: As part of the General Flushing and Shutdown, the Fluid Voltage Discharge and Grounding
Procedure, page 18, and the Pressure Relief Procedure, page 19, should have been completed. Do not
proceed until you have followed those procedures.
54
74
X
Follow the steps below to remove either one or both of
the accumulators.
J
8
2. Disconnect the exhaust air tube from the top
accumulator fitting (H). See Fig. 13.
AA
3. Disconnect the fluid hose nut (J) from the fluid inlet
flared hose end.
NOTE: Follow steps 4 to 6 to disconnect the fluid
regulator (2), which is connected to accumulator #2,
from the system. If disconnecting accumulator #1 only,
disconnect the fluid tube from the accumulator outlet
fitting and continue with step 7.
48
2
Fig. 13
05817B
308–504
33
Service
225
211* 202
213
219 210
201
217
223
*208
201
221
215
*2142
222
211* 216
*2141
220
204
212 202 224
05296
Fig. 14
Install the u-cups (2141, 2142) with the lips facing to the outside of
the piston (220).
Install the piston assembly (221, 222, 2141, 220) into the end of
the cylinder (219) with the internal chamfer
. The cylinder end with
the chamfer must face toward the upper end block (217).
Apply lubricant to the seal contact surfaces.
34
308–504
Do not use lubricant on the o-rings (202) that are in the cap
plugs (224).
Torque to 15 ft-lbs (20.25 NSm).
Torque to 15 in-lbs (1.7 NSm).
Apply dielectric lubricant to the o-ring.
* Included in Kit 237–976
Service
Accumulator Assembly
NOTE:
Parts that are marked with an asterisk (*) are
included with the Accumulator Seal Kit, part no.
237–976.
Lubricate the o-rings and u-cups as directed in Fig.
14, page 34. Do not use lubricant on the o-rings
(202) that are in the cap plugs (224).
1. Install the u-cup (2141*) on the air side of the
piston (220) with the lips of the u-cup facing up,
away from the piston, as shown in Fig. 14. Using a
blunt instrument, carefully press around all sides of
the u-cup lips until it is completely engaged in the
piston (220) groove. Lightly lubricate the outside
edge of the u-cup.
2. Secure the piston extension (222) to the piston
(220) with the four screws (215). Tighten the
screws to 15 in-lbs (1.7 Nm).
3. Install the piston assembly (221, 222, 214 1, 220)
into the end of the cylinder (219) with the internal
chamfer. Make sure the fluid side of the piston
faces down into the cylinder. See Fig. 14.
4. Push the piston assembly to the the bottom of the
cylinder until the bottom edge of the piston (220) is
exposed.
5. Install the u-cup (2142*) on the piston (220) with
the lips of the u-cup facing down away from the
piston, as shown in Fig. 14. Using a blunt instrument, carefully press around all sides of the u-cup
lips until it is completely engaged in the piston
(220) groove. Lightly lubricate the outside edge of
the u-cup.
6. Install the new piston rod u-cup (208*) with the
u-cup lips facing toward the piston (220). Lightly
lubricate the outside edge of the u-cup.
7. Install the two new o-rings (211*) into the end
blocks (216, 217). Lightly lubricate the o-rings.
8. Install the eight o-rings (201) into the grooves in
the end block (216, 217) ports. Apply dielectric
grease to the o-rings.
9. Place the upper end block (217) on the end of the
cylinder (219) with the internal chamfer.
10. Install the o-rings (201) and high voltage shields
(223) into the upper end block (217).
11. Place the lower end block (216) on the other end
of the cylinder. Make sure the eight o-rings (201)
stay correctly placed in the end blocks.
12. Secure the end blocks (216, 217) with the washers
(204), screws (212), and nuts (213). Tighten the
screws oppositely and evenly to 15 ft-lbs (20.25
Nm).
13. Install the o-rings (202) into the thread caps (225)
and onto the grooves on the cap plugs (224).
14. Apply dielectric grease to the o-rings (202) in the
thread caps (225). Do not apply grease to the
o-rings (202) on the cap plugs (224).
15. Install the thread caps (225) and cap plugs (224).
16. Add 0.7 oz. (20 cc) of TSL into the top end (piston
rod end) of the accumulator. Remove the top air
fitting for easier access if necessary.
17. Secure the accumulator (74) to the mounting plate
(X) with the four plastic screws (54). See Fig. 13,
page 33. Tighten the screws until they are snug;
do not over-tighten them.
18. Reconnect the Graco waterborne fluid hose as
instructed on page 14.
19. Connect the exhaust air tube to the top
accumulator fitting (H). See Fig. 13, page 33.
NOTE: If installing accumulator #1, connect the fluid
tube to the accumulator outlet fitting.
20. Connect the fluid hose nut (J) to the fluid inlet
flared hose end.
21. Connect the air pilot tube to the fluid regulator air
pilot connector (48).
308–504
35
Parts
Part No. 237–928
Waterborne Voltage Block
DETAIL C
136
129
137
141
143
106
138
79
65
24
29
140
57
Ref.
31
25
4
139
53
See DETAIL B, below, and page 44 for
replaceable air logic assembly parts
142
144
10
7
17
9
51 52
60
21
8
73
22
30
71
16
11
48
31
72
13
103
See DETAIL C.
83
61
20
18
6
34
38
35
68
15
59
58
See page 38 for parts. See
DETAIL A for tube parts.
46
44
120
14
86
12
DETAIL A
100
** NOTE: The washers (80) are installed for
grounding continuity. Install them in the location shown, not next to the nuts (56).
DETAIL B
**80
99 110
93
56
113
107
101
05819A
36
308–504
Parts
Part No. 237–928
Waterborne Voltage Block
NOTE: Parts for the voltage block assembly are continued on the next page.
Ref.
No.
Part No.
Description
6
7
8
9
10
11
12
13
290–098
101–390
185–549
185–548
185–547
114–558
110–544
169–970
14
15
16
17
18
20
109–570
113–348
156–971
154–636
112–308
110–438
21
22
110–436
111–804
24
25
29
30
31
110–911
104–029
100–732
100–731
104–641
35
38
44
46
48
100–307
100–056
113–078
113–080
113–058
51
52
113–069
113–068
53
56
57
58
113–067
113–127
113–128
113–129
59
60
113–130
290–089
61
290–090
WARNING LABEL
LOCK WASHER
HOSE FERRULE
NUT, 5/8–24
FERRULE HOUSING
AIR LINE COUPLING
LEG LEVELER
AIR LINE FITTING,
quick-disconnect
WASHER
LOCK WASHER
SHORT NIPPLE
WASHER
NUT, regulator panel
AIR REGULATOR, self
relieving, 0–100 psi (0–0.7
Mpa, 0–7 bar)
AIR PRESSURE GAUGE
AIR REGULATOR, self
relieving, 0–125 psi (0–0.85
Mpa, 0–8.5 bar)
HEX JAM NUT
GROUND LUG
LOCK WASHER
WASHER
FITTING, 3/8 npt(f) x
3/4–20 unef–2a
HEX NUT
HEX JAM NUT
SCREW
SCREW RETAINER
CONNECTOR, 5/32 x 1/4
npt(m)
90 ELBOW, 1/4 npt(f)
CONNECTOR, 5/32 x 1/8
npt(m)
PNEUMATIC SWITCH
NUT, hex, 1/4–20, nylon
STANDOFF; 3/4” (19 mm)
CAP SCREW, 1/4–20 x
1.25”
WASHER
LABEL, air inlet, max.
pressure
LABEL, fluid inlet, max.
pressure
Ref.
No.
Part No.
Description
65
113–179
68
71
72
113–062
113–268
113–060
73
79
113–061
113–150
80
83
86
93
99
100
101
100–985
100–333
100–338
113–154
113–167
113–170
113–181
103
190–715
2
2
2
4
1
106
190–721
107
113–180
110
113
190–712
113–182
4
1
2
2
3
120
136
137
138
190–734
114–599
193–641
102–379
139
140
193–474
110–823
141
142
143
144
100–015
100–016
193–618
193–619
CONNECTOR, 1/4 npt(m),
for 1/4” O.D. tube
UNION
BUSHING
FLUID PRESSURE
GAUGE; 0–100 psi (0–0.7
Mpa, 0–7 bar)
PUSH SWITCH
STANDOFF; 1–1/4”
(32 mm)
WASHER
CAP SCREW
JAM NUT
AIR LOGIC COVER
AIR LOGIC ASSEMBLY
ADAPTER NUT
FLARED TUBE ASSY.,
15.5” (394 mm)
BULKHEAD FITTING,
3/8–18.6 special form
straight pipe thread
VOLTAGE BLOCK
ENCLOSURE
FLARED TUBE ASSY., 23”
(584 mm)
AIR LOGIC STANDOFF
FLARED TUBE ASSY., 5.5”
(139.7 mm)
PEDESTAL
BUSHINGS, 3/8”
CAP, spout
BOTTLE, empty; 1 quart
(0.95 liter)
BRACKET, dual bottle
SCREW, pan hd. 1/4–20 x
1”
NUT, hex; 1/4–20
LOCK WASHER, 1/4”
TUBE, drain
TUBE, supply
Qty.
1
1
1
1
1
1
4
1
4
1
1
1
2
1
1
1
1
4
1
4
4
2
4
1
Qty.
1
2
1
1
2
4
4
8
4
1
1
1
1
1
1
2
4
1
2
4
4
2
2
4
4
4
2
2
Replacement Danger and Warning labels, tags and
cards are available at no cost.
1
308–504
37
Parts
Part No. 237–928
Waterborne Voltage Block
96
39
52
90
104
88
98
39
105
109
76
116
77
*117
34
*1
87
129
27
39
39
74
See parts on page 40
32
B
121
134
94
]122
37
19
43
42
41
B
50
42
49
54
97
A
75
See parts on page 42
2
95
Isolator 2
92
Isolator 1
115
Accumulator 1
36
102
48
47
Accumulator 2
]The other cable end connects to the ground lug (25) inside the enclosure (106).
38
Tapered end of the check valve (1) must face up.
308–504
05820B
Parts
Part No. 237–928
Waterborne Voltage Block
Ref.
No.
Part No.
Description
1*
2
M71–256
238–159
CHECK VALVE
FLUID REGULATOR,
3–100 psi (0.021–0.7 MPa,
0.2–7 bar), see manual
308–325 for parts
TSL FLUID, 1 qt. (0.95 liter)
bottle (not shown)
SCREW, nylon
MACHINE SCREW
MACHINE SCREW
WASHER
MACHINE SCREW
HEX NUT
MACHINE SCREW
TSL TUBING (not shown)
CRUSH RING
WASHER
BLEED RESISTOR
90_ ELBOW, 1/4 npt(f)
CONNECTOR, male, 5/32
x 1/4 npt
TUBE ADAPTER, male,
1/4 npt(m), for 3/8” O.D.
tube
REDUCER NIPPLE,
3/8–1/4 npt(m)
CONNECTOR, male, 5/32
x 1/8 npt
CAP SCREW, 3/8–16 x 2”
ACCUMULATOR, see page
40 for parts
ISOLATOR ASSY., see
page 42 for parts
FULL LEVEL SWITCH
LOW LEVEL SWITCH
TSL PUMP SWITCH
SWITCH BRACKET
TSL PUMP
TUBE ADAPTER 90_
ELBOW, 3/8 npt(f), for 3/8”
O.D. tube
BLEED RESISTOR
CLAMP
TUBE ADAPTER, 3/8
npt(f), for 1/2” O.D. tube
BLOCKING EXHAUST
VALVE
CAP SCREW, 3/8–16 x 1”
EXHAUST VALVE
RESISTOR FITTING,
10–24 unc–2b x 1/4–18
npt(m)
4*
206–995
19
27
32
34
36
37
39
40*
41
42
43
47
48
110–620
101–816
110–823
100–527
100–268
100–166
103–774
–
113–135
113–075
190–410
113–071
113–058
49
113–081
50
113–070
52
113–068
54
74
113–125
237–929
75
237–930
76
77
87
88
90l
92
113–123
113–124
113–174
113–175
113–143
113–151
94
113–155
95
113–152
96
113–166
97
98
102
113–126
113–165
190–714
Qty.
Ref.
No.
Part No.
Description
2
1
104
105
191–971
190–719
109
190–733
112
237–939
115
113–169
116
112–698
SWITCH BRACKET
SWITCH BRACKET NUT,
10–24 unc–2b
ACCUMULATOR ROD
GUIDE
WIRE ASSY., component
to ground (not shown–refer
to Fig. 6, page 16)
TUBE ADAPTER, 3/8
npt(m), for 1/2” O.D. tube
ADAPTER
SWIVEL ELBOW,
1/8 npt(m)
BARB FLUID
CONNECTOR
HOSE CLAMP (not shown)
CABLE CLAMP (not shown)
NUT
WIRE ASSY., bleed resistor
to ground
WIRE ASSY, 25 ft. (7.6 m)
(not shown)
TOOL KIT, Includes items
124a & 124b (not shown),
Required to install pump
seal repair kit, part no.
237–969.
S PUMP ASSY. TOOL
S PUMP O-RING TOOL
CLAMP, tube
TUBE, sight
2
2
4
4
12
1
3
12
–
2
16
1
1
3
1
117*
–
118
119
121
122
113–190
113–191
181–328
237–938
123
237–569
124
237–968
124a
124b
129
134
113–226
113–227
113–894
191–077
1
4
8
2
Qty.
2
6
2
2
1
4
4
2
9
2
1
1
1
1
1
16
2
2
*
2
2
2
2
2
1
l A pump fluid seal repair kit, part no. 237–969, is
available. An installation tool kit, part no. 237–968,
is required for seal installation.
2
Use polyethylene, 5/32 in. (4 mm) O.D., tubing. This tubing is
available from Graco in 100 ft. (30.5 m) lengths. The chart
below shows the part numbers and colors.
1
1
8
1
1
These parts are available to order as part of a TSL
Tube Repair Kit, part no. 238–024. The kit also
includes ref. no. 310, listed on page 43.
AIR LOGIC TUBING
Tubing Part No.
Color
054–730
Natural (clear)
054–731
Blue
054–732
Red
054–733
Yellow
054–734
Black
308–504
39
Parts
Item 74: Part No. 237–929
Accumulator Assembly
225
211{ 202
213
219 210
201
203
217
223
226
207
214{ 209
201
{208
205
221
218
206 215
{211
216
222
{214
204
220
226
207
209
212 202 224
40
Install the u-cups (214) with the lips facing to the outside of the
piston (220).
Install the piston assembly (222, 214, 220) into the end of the
cylinder (219) with the internal chamfer. The cylinder end with the
chamfer must face toward the upper end block (217).
Apply lubricant to the seal contact surfaces.
308–504
Do not use lubricant on the o-rings (202) that are in the cap
plugs (224).
Apply anaerobic pipe sealant on the threads.
Torque to 15 ft-lbs (20.25 NSm).
Torque to 15 in-lbs (1.7 NSm).
Apply dielectric lubricant to the o-ring.
Parts
Item 74: Part No. 237–929
Accumulator Assembly
Ref.
No.
Part No.
Description
201
202
203
722–834
188–555
113–058
204
205
206
109–570
113–135
113–074
207
208{
209
210
211{
212
113–075
–
113–164
113–066
–
113–140
213
113–141
O-RING, Vitonr
O-RING, Viton
CONNECTOR, 5/32 x
1/4 npt
WASHER
CRUSH RING
TUBE ADAPTER 90_
elbow, 3/8 npt(m), for 1/2”
O.D. tube
WASHER
U-CUP, urethane
CAP SCREW, 3/8–16 x 1.5”
WASHER
O-RING, Viton
CAP SCREW, 1/2–13 x
12.625”
HEX NUT, 1/2”
Qty.
8
8
1
4
1
1
4
1
4
4
2
4
4
Ref.
No.
Part No.
214{
–
215 108–630
216
217
218
219
220
221
222
223
224
225
226
190–693
190–694
190–695
190–696
190–697
190–698
190–699
190–700
190–701
190–702
190–703
Description
Qty.
U-CUP, hytrel & Viton
MACHINE SCREW, 10–24
x 0.75”
LOWER END BLOCK
UPPER END BLOCK
SHOULDER PIN
CYLINDER
PISTON
PISTON ROD
PISTON EXTENSION
HIGH VOLTAGE SHIELD
CAP PLUG
THREAD CAP
SUPPORT BLOCK
2
4
1
1
3
1
1
1
1
4
4
4
4
{ These parts are available to order as part of an
Accumulator Seal Kit, part no. 237–976Parts
308–504
41
Item 75: Part No. 237–930
Isolator Assembly
320 311
308* 304 A
305
324
337
333 329
320 G
334
320* 319*
332 306*
348
325 350
352
338
351
*309
349
*302
B
354
A
321
*320
353
B
335
318
331
327
343 326 307
313
325 328
306*
336 330
F
8565A
42
Apply lubricant.
Torque to 15 in-lbs (1.7 NSm).
Torque to 8 in-lbs (0.9 NSm).
Tighten securely, until bottomed out.
Lips face down
308–504
Lips face up
On right isolator only
On left isolator only.
* Included in Kit 237–977
Parts
Item 75: Part No. 237–930
Isolator Assembly
Ref.
No.
Part No.
302}
–
304 112–325
305
111–788
306}
–
307 110–620
308}
309}
310*
311
313
314
315
–
–
113–213
113–131
113–136
113–135
113–074
316 113–134
318 113–126
319}
–
320}
–
321
322
323
324
325
326
190–636
190–637
190–638
190–639
190–640
190–641
327
328
190–717
190–718
Description
O-RING, Vitonr
THUMB SCREW, 1/4–20
nc x 1”
CAP SCREW, 1/4–20
unc–3a x 0.75”
O-RING, Viton
SCREW, 10–24 unc–2a
x 0.5”
O-RING, Viton
O-RING, Viton
BARBED HOSE FITTING
AIR CYLINDER
COMPRESSION SPRING
CRUSH RING
TUBE ADAPTER 90_
elbow, 3/8 npt(m), for 1/2”
O.D. tube
JAM NUT, 1–1/4 uns–2b
CAP SCREW, 3/8–16 x 1”
O-RING, CV75
WIPING SEAL, lubrithane
& Vitonr
GUIDE ROD
AIR CYLINDER ADAPTER
CAP PLUG
BRACKET, isolator, left
GROUND PLUG
HIGH VOLTAGE
ELECTRODE
CYLINDER ROD COVER
COVER RETAINER
Qty.
Ref.
No.
Part No.
Description
1
1
329
330
331
332
333
190–642
239–017
190–644
190–645
190–646
334
335
336
337
338
190–647
190–689
238–085
240–691
103–310
343
100–609
344
346
192–840
113–058
347
348
349
113–184
240–680
240–656
350
112–905
351
352
353
110–755
113–127
114–590
354
240–657
TOP SUPPORT
FLUID BLOCK
BOTTOM SUPPORT
TOP SEAL CARTRIDGE
BOTTOM SEAL
CARTRIDGE
ISOLATOR ROD
FLUID TUBE
SPRING RETAINER
BRACKET, isolator, right
MACHINE SCREW, 8–32
unc–2a x 1/4”
MACHINE SCREW, 1/4–20
unc–2a x 0.375”, right
isolator only
WARNING LABEL
CONNECTOR, male, 5/32
x 1/4 npt
ELBOW ADAPTER
ROLLER, arc bypass
WIRE ASSY., left isolator
only
WASHER, flat, #8 , right
isolator only
WASHER, flat
NUT, hex, 1/4–20, nylon
SCREW, cap, hex head,
1/4–20 x 3/4”
WIRE ASSY., right isolator
only
1
2
1
3
2
4
1
1
1
1
1
8
1
4
1
1
1
1
2
1
1
1
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
2
2
1
} These parts are available to order as part of an Isolator Seal Kit, part no. 237–977.
*
This part (along with items 1, 4, 40, and 117) is
included in TSL Tube Repair Kit 238–024, which
may be purchased separately.
308–504
43
1
2
QUICK
DUMP
46
10
PB
YEL 47
OUTER
PORT
11
RED
22
5
A1
SM2
22
PRT
SM3
19 A1
A–
C–
23
PRT
SM4
28 B1
B+
SM5
D+
13
12
13
21
A+
C+
12
C1
C0
30
53
INSIDE
PORT
A
PB
26
08
51
22
YEL
16
P
2
14
16
20
RED
8
15
OUTER
113–279
push-in tube fitting plug
VOLT
DUMP
8
7
PA
09
BLUE
6
21
V2
8.5”
TYP.
READY TO
FLASH
INDICATOR
5
READY TO
SPRAY
INDICATOR
EV1
PAINT SOURCE
V3
E
A
25 P
OUTER
PORT
B
PA
E
V4
21
LOOSE HOSE
DOOR OPEN
INDICATOR
PA
E
SIDE
PORT
41
B PORT
BLUE
BLUE
113–284
push-in tube fitting
A B PORT
EX
INSIDE
PORT
RED
49
16
07
BLUE
PB
16
P
TOP PORT
15
5
PB
25
20
INSIDE
PORT
44
29
BOT.
PORT
OUTER
PORT
DOOR
06
TSL
V1
24
20
18
YEL
PA
E
28
OUTER
24
01
14
PB
05
02
A2
FULL
10
20
B–
D–
40
OUTER
A B PORT
P
26
X
PRT SM1
29 BO
5
OUTER
PORT
18
OUTER
PORT
04
13
17
19
INSIDE
PORT
03
23
12
A2
LOW
010
5
16
13
&
52
3
18
OUTER
PORT
PA
YEL
43
A
B
14
A1
FULL
TSL
INSIDE
PORT 17
10
V5
YEL 48
OUTER
PORT
55
REGULATED
AIR INLET
12
P
E
A1
LOW
pneumatic AND valve
10
OUTER
PORT
YEL
FILL/
RUN
113–282
A1
RED
Air Logic Schematic and Parts
YEL
pneumatic OR valve
3
11
FLUSH/
RESET
4-way remote air valve
O1 to O10 113–281
3
2
113–338
SIGNAL WILL ONLY APPEAR
WHEN 2ND ACCUMULATOR
IS FULL
ACCUM. #1
15
42
BOT.
PORT
EV2
ACCUM. #2
308–504
REMOTE
FLUSH/
RESET
Part No. Description
V1 to V5
44
REMOTE
FILL/RUN
Item
05327
113–284
push-in tube fitting
Dimensions
Measurements, inches (mm)
AA
BB
AA
BB
CC
DD
Width*
53.625
(1362)
49.625
(1260)
37.50
(953)
51.0
(1295)
17.0
(432)
* Width at the widest point of the voltage block
assembly
CC
DD
05332A
308–504
45
Technical Data
Category
Data
Maximum Working Pressure
100 psi (0.7 MPa, 7 bar)
Air Pressure Operating Range
60–100 psi (0.4–0.7 MPa, 4.1–7 bar); Typical Pressure 80 psi (0.5 MPa,
5.5 bar)
Fluid Pressure Operating Range
0–100 psi (0–0.7 MPa. 0–7 bar)
Maximum Voltage
60 kV
Fluid Specification
For use with Graco PRO 5500wbt and PRO 3500wbt guns when
electrostatically spraying conductive, waterborne fluids that meet at least
one of the following conditions of non-flammability:
D The fluid has a flash point above 140_F (60_C) and a maximum organic solvent concentration of 20%, by weight, as determined in accord with the Standard Method of Testing for Flash Point by the
Pensky-Martens Closed Tester, ASTM D93.
D The fluid does not sustain burning characteristics in accordance with
the Standard Method for Sustained Burning of Liquid Mixtures by the
Setaflash Apparatus, ASTM D4206.
Accumulator Capacity
100 oz. (3 liters)
Maximum Fluid Temperature
120_F (49_C)
Weight
257.0 lbs. (115.65 kg)
Air Inlet
1/4 npt(f) quick-disconnect
Fluid Inlet
3/8–18 npsm (R3/8–19) compound thread
Wetted Parts
304 SST, PTFE,rPEEK, Vitonr, Epoxy, Acetal
Sound Pressure at 80 psi (550 kPa,
5.5 bar){
74.6 Db(A)
{
Sound pressure was measured per a time weighted average over a 4 minute complete dispense/refill cycle.
Vitonr r
46
308–504
Notes
308–504
47
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from
defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use.
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. This warranty applies only when theipment
equ
is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear
, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering,
or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibilit
y of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture
,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributo
r for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defecti
ve parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose
any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER W
ARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees no
thatother
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person operty,
or pr or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two ears
(2) yof the
date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD
BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches,
hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistan
ce in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equi
pment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedi
ngs
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parti
es reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciai
res
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Manual
Change Summary
Graco Phone
Number
TO PLACE AN ORDER , contact your Graco distributor, or call this number to identify the distributor closest
to you: 1–800–367–4023 Toll Free
The manual was revised per ECO V5284.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit
Foreign Offices: Belgium, England, Korea, France, Germany, Hong Kong, Japan
GRACO INC.
P.O. BOX 1441
MINNEAPOLIS, MN
55440–1441
http://www.graco.com
48
308–504
PRINTED IN U.S.A. 308–504 July 1995 Revised October 1998

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