Graco 308581C H 2 O PRO Batch System Owner's Manual

INSTRUCTIONS-PARTS LIST

This manual contains important warnings and information.

READ AND KEEP FOR REFERENCE.

INSTRUCTIONS

H

2

O PRO Batch System

100 psi (7 bar) Maximum Working Air and Fluid Pressure

Part No. 237–927

Waterborne Voltage Block

For use with Graco PRO 5500wb and PRO

3500wb 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 Pensky-

Martens 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

308–581

Rev. C

Supersedes B

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT 1995, GRACO INC.

Graco Inc. is registered to I.S. EN ISO 9001

05308

Table of Contents

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Voltage Block Component Identification

Sequence of Operation

. . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

7

10

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilate the Spray Booth

Fluid Supply Unit

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the Voltage Block . . . . . . . . . . . . . . . . .

Remote Terminal Strip . . . . . . . . . . . . . . . . . . . . . .

Interlock the Gun Turbine Air Supply . . . . . . . . .

Connect the Hoses

Ground the System.

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

Check the System Grounding . . . . . . . . . . . . . . .

13

13

14

16

16

12

12

12

12

12

12

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Voltage Discharge and Grounding

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Relief Procedure . . . . . . . . . . . . . . . . . .

Emergency Fluid Shutoff

Operating Checklist

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

18

18

20

20

20

Voltage Block Startup Procedure

Operating the Voltage Block

. . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

Flushing and Shutdown . . . . . . . . . . . . . . . . . . . .

21

22

23

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cycle Counting . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TSL System Maintenance . . . . . . . . . . . . . . . . . .

Drain and Flush the TSL System

PTFE Tubing Replacement

. . . . . . . . . . . .

. . . . . . . . . . . . . . . .

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Isolator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accumulator Service . . . . . . . . . . . . . . . . . . . . . . .

24

28

27

27

28

28

29

29

34

Voltage Block Assembly Parts . . . . . . . . . . . . . . . .

Accumulator Assembly Parts

Isolator Assembly Parts

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

Air Logic Schematic and Parts . . . . . . . . . . . . . . . .

38

42

44

46

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Graco Warranty and Disclaimers . . . . . . . . . .

Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . .

47

47

48

48

2 308–581

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

Symbols

Caution Symbol

CAUTION

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. 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.

308–581 3

ELECTRIC SHOCK HAZARD

WARNING

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.

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 20 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.

Warnings are continued on the next page.

4 308–581

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 (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 180 F (82 C) or below –40 F (–40 C).

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.

308–581 5

6 308–581


72 Fluid Pressure Gauge

The gauge shows the air pilot regulator (20) pressure, which controls the fluid regulator (2) pressure.

72

See Fig. 2

X Time Delay

The time delay is part of the air logic assembly (99).

The time delay setting can be adjusted from 0 to 30 seconds. The setting determines how soon the accumulator (74–see Fig. 3) will start to refill after the gun is detriggered. It should be set to allow for brief gun detriggering without activating the fill cycle.

20

A B C

05316

Fig. 1

See Fig. 1. Refer to Fig. 2 and 3.

A Fill/Run Button

The Fill/Run Button is pressed to initially fill the accumulator (74) or restart operation after a period when spraying had stopped or the door has been opened.

B Flush/Reset Button

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.

To pressurize the accumulator (74) to prepare to flush the system.

To prepare to empty the accumulator (74) and depressurize the voltage control fluid section before shutting down the system.

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.

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.

YY Optional Remote Terminal Strip (purchase separately)

The remote terminal strip, part no. 238–025, provides

8 ports for sending input or output signals to operate the system remotely. See page 13.

ZZ Optional Pneumatic Counter Kit (purchased separately)

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. Other than the time delay (X) setting, no adjustments to the air logic assembly are necessary. Do not alter components or connections.

Fig. 2

99

YY

X

ZZ

05825

308–581 7


69

91 86 22 3

13

76 Y

90

75

77

74

43

53

D

103

2

106

Fig. 3

See Fig. 3

D 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.

05821A

Y Voltage Block Air Pressure Regulator

This air regulator is used to adjust air pressure to the voltage block components.

2 Fluid Regulator

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.

3 Gun Air Shut-off Valve

The air shut-off valve is required to shut off the air to the PRO 3500wb spray gun.

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 Gun Air Pressure Regulator

This air regulator is used to adjust air pressure to the

PRO 3500wb spray gun.

8 308–581


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.

69 Audible Alarm

The audible alarm signals when the low level switch

(77) has been reached to alert the operator to stop spraying soon so the accumulator (74) can refill.

77 Low Level Switch

When the fluid in the accumulator (74) reaches this switch and the gun is triggered, an audible alarm (69) will sound to alert the operator to stop spraying so the accumulator can refill. It should be set to a level where there will still be enough fluid available after the alarm sounds for the operator to sufficiently finish the operation before the accumulator is completely empty.

86 Gun Air Flow Switch

The gun air flow switch senses when air is flowing to the gun, which indicates the gun is spraying. When no air is flowing to the gun and the time delay (X–see Fig.

2) is exceeded, the gun air flow switch activates the isolator (75) to move to the fill position so the accumulator can refill.

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. When the low level switch is reached, an audible alarm (69) will sound.

90 TSL Pump

The TSL pump circulates the TSL through the isolator

(75) fluid block and seals.

91 TSL Container

The TSL container contains throat seal liquid (TSL) to lubricate the isolator (75) rod and seals.

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.

103 Fluid Inlet Connector

The connector for the voltage block fluid supply hose.

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.

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.

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.

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.

308–581 9


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.

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

RUN Sequence

Operation

1. Accumulator starts filling

2. Accumulator full level switch is actuated

3. System is ready to spray

Operation

Isolator Position down down up

Isolator Position

Accumulator vented vented pressurized

Accumulator

1. Accumulator dispenses to spray gun

2. Low level switch is actuated, alarm sounds, gun is detriggered, time delay starts up up pressurized pressurized

3. Time delay ends

4. Accumulator starts refilling down down vented vented

5. Accumulator full level switch is actuated down vented

6. Operation continues with the Run Sequence, steps 1 to 5, until the operator stops spraying

FLUSH/RESET

FLUSH Sequence– through gun

Operation Isolator Position

1. Accumulator dispenses to spray gun

2. Accumulator is empty

3. Water supply flushes through the system until clear fluid is seen

4. Voltage block remains in this mode until the fill sequence is activated up down down down

Accumulator pressurized pressurized pressurized pressurized

10 308–581


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

1. Accumulator dispenses its fluid back to the depressurized fluid supply or to a container

2. Accumulator is empty

3. Remains in this mode until the enclosure door is closed and the Fill/Run button is pressed.

Isolator Position down down down

Accumulator pressurized pressurized pressurized

308–581 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.

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.).

WARNING


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.

Do not install or service this equipment unless you are trained and qualified.

Fluid Supply Unit

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 (7 bar) maximum air and fluid working

pressure.

Comply with all local, state, and national codes for the installation of electrical apparatus in a

Class , Group D, Hazardous Location.

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.

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. Do not operate the gun unless the ventilating fans are on.

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.

Mounting the Voltage Block

Select a solid position on a vertical surface for the mounting bracket. See the Dimensions on page 47.

Be sure the mounting surface is capable of supporting the weight of the voltage block, the accessories that will be attached to it, the weight of the fluid used in the voltage block, and any stress or strain that may be applied to the mounting surface during system operation.

A Cart Kit accessory, part no. 237–966, is available to mount the voltage block onto a base with four casters.

There is space on the cart for a pressure pot or pailmounted Husky 307 pump.

12 308–581

Installation

Interlock the Gun Turbine Air Supply Remote Terminal Strip

An accessory remote terminal strip kit, part no.

238–025, is available that can be 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. Follow the instructions provided with the kit to install it.

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.

054–730

054–731

054–732

054–733

054–734

Color

Natural (clear)

Blue

Red

Yellow

Black

NOTE: See page 46 for the air logic assembly schematic.

WARNING


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 accessory remote terminal strip must be used to interlock the turbine air supply and the voltage block door. To reduce the risk of an electric shock, do not tamper with or bypass the air line interlock.

308–581 13

Installation

Connect the Hoses

WARNING


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.

3. Connect the red-colored Graco electrically conductive gun air hose (H) between the voltage block air shut-off valve (3) and the gun air inlet (G). Connect the hose ground wire (M) to a true earth ground

(N).

Graco Electrically Conductive Air Hose Part Numbers

100 psi (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

WARNING


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.

Part No.

235–068

235–069

235–070

235–071

235–072

235–073

235–074

Length

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)

1. Connect the air supply hose (K) between the air supply and the air inlet quick-disconnect (13). See

Fig. 4.

NOTE: If the PRO 5500wb gun is used, connect the atomizing air line from the voltage block air outlet port to sense when the gun is spraying.

4. Loosen the fluid hose ferrule nut (8) and hose compression nut (AA). See Fig. 5.

2. Connect the fluid supply hose (L) 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.

5. Install the Graco waterborne fluid supply hose (D) through the fluid hose port (P) in the enclosure and into the fluid regulator fitting (49). See Fig. 4 and 5.

Graco Waterborne Fluid Hose Part Numbers

100 psi (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

Automatic PRO

5500wb Spray Gun

237–924

237–925

237–926

237–920

237–921

237–922

25 ft. (7.6 m)

36 ft. (11.0 m)

50 ft. (15.2 m)

25 ft. (7.6 m)

36 ft. (11.0 m)

50 ft. (15.2 m)

6. Hand-tighten the hose compression nut (AA) securely. See Fig. 5.

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.

WARNING


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.

14 308–581

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 (D) to the gun fluid inlet (E). Read the instructions on fluid hose connection in your gun manual.

KEY-Fig. 4

D Graco Waterborne Fluid Hose

E Gun Fluid Inlet

F PRO 3500wb Spray Gun

G Gun Air Inlet

H Graco Electrically Conductive Gun Air Hose

J Mounting Bracket

K Air Supply Hose

L Fluid Supply Hose

M Gun Air Hose Ground Wire

N True Earth Ground

P Fluid Hose Port

Installation

N

M

2 Gun Fluid Regulator

3 Voltage Block Air Shut-off Valve

13 Voltage Block Air Inlet (quick-disconnect)

25 Ground Lug

49 Fluid Regulator Fitting

69 Audible Alarm

103 Voltage Block Fluid Inlet

106 Voltage Block Enclosure

119 Main Ground Wire Clamp

123 Main Ground Wire

H

G

F

69 106 3

N

119

123

25

J

E

D

13

K

L

2

49

P

103

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

Fig. 5

49 BB CC 8 FF

05310

AA EE DD

106

05375

308–581 15

Ground the System

See Fig. 4

Installation

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.

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 (H) . Do not use the black or grey-colored

Graco air hoses. Ground the hose by connecting the air hose ground wire (M) to a true earth ground

(N).

4.

Graco PRO 5500wb or PRO 3500wb

Spray Gun: Ground the gun by connecting the grounded red-colored Graco electrically conductive air hose (H) 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.

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).

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.

Do not disconnect or tamper with the internal ground wire connections (W) inside the voltage block enclosure. They should be connected as shown in Fig. 6.

7.

Object being sprayed: Keep the workpiece hangers clean and grounded at all times. Contact points must be sharp points or knife edges.

W

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.

W

Fig. 6

05822A

9.

All electrically conductive objects or devices

in the spray area: They must be properly grounded.

Check the System Grounding

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.

16 308–581

Notes

308–581 17

Operation

WARNING


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.

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.

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


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: 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.

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 latch to bring the isolator 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.

NOTE:

The metal enclosure of the H

2

O 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.

Fig. 7

R

05816

18 308–581

Operation

Fluid Voltage Discharge and Grounding

Procedure

(continued)

For Automatic Spray Guns

1. Turn off the gun electrostatics to the spray gun connected to the voltage block.

2. Unscrew the voltage block door latch to bring the isolator 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, 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.

308–581 19

Pressure Relief Procedure

Operation

Emergency Fluid Shutoff

Use this procedure if rapid fluid depressurization is needed, such as in the case of a hose leak.

WARNING


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 Proce-

dure 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. 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. Follow the Fluid Voltage Discharge and

Grounding Procedure, page 18.

____ 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. Shut off the fluid supply to the voltage block.

____ 2. Be sure all the operators are trained how to properly relieve system pressure as instructed at left and in the gun manual.

3. Shut off the air supply to the voltage block. The shut-off device must bleed the air out of the system.

____ 3. Be sure all the operators are trained how to properly discharge the voltage as instructed on page 18.

4. Trigger the gun to relieve the pressure in the fluid lines.

5. For automatic guns, shut off any other air supplies to the spray gun. Use bleed-type shut-off valves to relieve the pressure in the air lines.

____ 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.

NOTE: After service is complete and the doors are closed, press the FLUSH/RESET button, then press the FILL/RUN button to restart operation.

____ 6. Be sure all the debris, including flammable liquids and rags, is removed from the spray area.

20 308–581

Operation

Voltage Block Startup Procedure

1. Install and ground the system as instructed in the

Installation section.

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.

2. Remove the TSL container (91) and fill it about 1/2 full with the TSL provided. Refer to Fig. 3, page 8.

NOTE: The voltage block fluid inlet pressure will affect the accumulator fill time only.

NOTE: To help ensure only fresh TSL enters the seal area, change the TSL periodically as instructed on page 27.

9. Trigger the gun until all the air is purged through the voltage block and fluid lines.

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.

10. If desired, check the voltage block operation or check for fluid leaks with water before connecting the paint line. Close the door and press the FILL/

RUN button (A) to fill and dispense the accumulator. See Fig. 10. Press the FLUSH/RESET button

(B), and dispense all water out of the accumulator.

AB

76

39

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.

Fig. 8 05894

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 to 100 psi (5.6 to 7 bar).

The air inlet pressure is set with the air regulator

(Y) inside the voltage block. See Fig. 9.

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.

13. Press the FILL/RUN button (A) to fill the accumulator.

14. Wipe off the fluid nozzle, and install the air cap.

15. Follow the procedure Operating the Voltage

Block, page 22, to begin spraying.

CAUTION

Do not set the air pressure to the voltage block below 60 psi (4.2 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. Refer to Fig. 3, page 8.

CAUTION

Make sure that the fluid inlet pressure is a minimum of 5 psi (0.35 bar) lower than the set operating pressure of the voltage block or the accumulator will fill during step 6.

7. Connect a water supply to the voltage block.

Fig. 9

Fig. 10

20

Y

05324

A B

05315

308–581 21

Operation

4. Turn on the fluid supply to the voltage block.

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.

NOTE: The voltage block fluid inlet pressure will affect the accumulator fill time only.

5. Press the FILL/RUN button (A) to fill the accumulator.

6. Open the gun air supply shut-off valve.

7. Set the air pressure to the gun as recommended in the gun instruction manual.

8. 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.

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 (7 bar) maximum working air

and fluid pressure.

1. Turn on the air to the voltage block. Set the air pressure between 80 to 100 psi (5.6 to 7 bar).

The air inlet pressure is set with the air regulator

(Y) inside the voltage block. See Fig. 9, page 21.

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.

9. When the fluid in the accumulator is at the low level, the voltage block alarm will sound.

10. Release the gun trigger to shut off the alarm and activate the gun air flow switch.

The accumulator will start to refill after the time delay setting has been reached. For example, if the time delay is set for 10 seconds, the accumulator will begin to refill 10 seconds after the gun trigger is released.

NOTE:

The time delay is factory set for 3 seconds. The timer starts when the gun is detriggered.

The air flow switch will not operate if the gun air was not turned on as instructed in step 6. If the accumulator does not start refilling after the time delay, make sure the air to the gun was turned on.

For more information about the gun air flow switch operation, see page 9; item 86, or the FILL/RUN

Sequence on page 10.

The accumulator will not refill until the low level switch has been activated.

CAUTION

Do not set the air pressure to the voltage block below 60 psi (4.2 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.

11. After the accumulator is refilled, continue to spray with the gun.

NOTE: You do not have to wait until the accumulator is completely refilled to begin spraying again. If the gun is triggered during the fill mode, the voltage block will stop filling and switch to the run mode to dispense fluid.

22 308–581

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.

Operation

General Flushing and Shutdown

NOTE: Before flushing, make sure the fluid inlet pressure is a minimum of 5 psi (0.35 bar) lower than the voltage block air pressure regulator (Y) setting or the accumulator will fill during the flush cycle. Refer to Fig.

9, page 21.


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.

WARNING


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.

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.

WARNING


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 20 when you stop spraying and whenever you are instructed to relieve the pressure.

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 accumulator empties, the isolator will connect to the water supply.

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:


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 the isolator down and allow the fluid in the accumulator to be pushed back to the fluid supply.

4. Continue with the General Flushing and Shut-

down procedure.

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.

308–581 23

Troubleshooting

WARNING



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.

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.

WARNING


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 20 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

PTFE layer)

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

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 accumulator and cause a low voltage reading on the optional kV meter connected to the voltage block accumulator.

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.

24 308–581

Troubleshooting

Problem

Voltage loss*

Cause

Voltage block enclosure door is not closed

Voltage block is in the end of the flush mode and the fluid is connected to a grounded fluid supply

Waterborne fluid hose has a pin-hole leak through the PTFE ing dielectric failure

layer, caus-

Fluid is leaking at the gun fluid hose connection

Excessive fluid overspray on the outside of the gun barrel, shroud, or gun cover

Excessive waterborne fluid leaking into the TSL recirculating return line

Solution

Close the door.

Push the FILL/RUN button.

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.

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.

Clean the outside of the gun barrel or shroud. Replace the gun cover.

Flush and refill the TSL lines and container with clean TSL. See page

27. If the problem reoccurs quickly, replace the isolator seals with the seal kit.

Replace the seals as necessary.

Fluid is leaking on the components inside the voltage block

Air in the fluid line to the gun (can cause low voltage reading on the optional voltage block kV meter)

Gun electrostatics (turbine air or gun

ES lever) not turned off

Trigger the gun until the air is purged out through the gun nozzle.

Turn off the gun electrostatics.

Voltage is still present at the gun or fluid regulator after following the Fluid Voltage Discharge and Grounding Procedure

Did not wait long enough for the voltage to discharge through the voltage bleed resistor

Air pocket in the fluid lines

Faulty bleed resistor

Wait the 30 second time period before making contact with the gun or internal voltage block components.

Purge the air out of the fluid lines.

Check for loose wire connection or replace the bleed resistor if necessary.

* Normal spraying voltage is 45 to 55 kV.

308–581 25

Troubleshooting

Problem

TSL container level is rising

TSL container level is dropping

TSL, TSL tubing, or TSL container color changing to color of waterborne fluid

TSL not circulating

Fluid leak at isolator rod seam

PTFE leaking stroke) fluid hose connections are

Isolator air cylinder moving too slow or too fast (normal speed is approximately 2 seconds per

Isolator cylinder is not operating properly

Accumulator fills past the full setting switch

Accumulator does not refill

Air leak at fluid regulator pilot air fitting

Cause

Waterborne fluid is leaking into the

TSL lines

TSL is leaking or slowly evaporating with use

This is normal unless the kV level is dropping (see Voltage Loss, page

25)

Cartridge seals worn allowing excessive fluid into the TSL ports

TSL circulating pump seals worn

Solution

Replace the isolator seals with the seal kit. See Service.

Refill the TSL container or replace the TSL seals.

No action necessary. The dirty TSL can be pumped out and refilled as necessary.

Replace the isolator seals with the seal kit.

Replace TSL pump seals with the pump fluid seal repair kit.

Check valve in TSL tubing line failed Replace check valve 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

Rod o-ring is worn or damaged

Fitting nut is not tight

Fitting threads are stripped

Cylinder restrictors misadjusted or plugged

Re-tighten the collar. Secure the collar with its retaining screw. See

Service.

Replace the o-ring and cartridge seals with the replacement seal kit.

See Service.

Hand-tighten the nut. Hand-tighten only; do not use tools.

Replace the fitting. Install the new hose or nut assembly as needed.

Adjust air cylinder exhaust port for speed adjustment of about 2 seconds per stroke.

Voltage block air pressure set below

60 psi (4.2 bar); recommended pressure is 65–95 psi (4.5–6.6 bar)

Switch position is not adjusted properly

Low level switch has not been activated (no alarm sounded).

Set air to proper pressure. See

Operation.

Re-adjust the switch position.

Air to the gun was not turned on while spraying so the air flow switch is not operating.

Time delay has not run out yet.

Constant air exhaust from small hole in pilot air fitting is normal and used for pressure control accuracy.

Keep spraying until the low level switch is activated or re-adjust the switch position.

Turn on the air to the gun, trigger the gun to reactivate the system, then detrigger the gun to activate the gun air flow switch.

Wait for the time delay to end.

No action necessary.

26 308–581

Maintenance

Cycle Counting

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 formulas to convert the voltage block cycles to production hours:

2. Inspect the condition of the TSL fluid in the sight glass and in the TSL container (91) daily. Refer to

Fig. 11, page 29. Signs of TSL contamination include:

Discoloration of the TSL

Rise in the TSL level in the tank

Gradual reduction of the spraying voltage.

Fluid Seal Time in Hours =

(15,000 x Cycle Time in minutes) 60

TSL Change Time in Hours =

(4000 x Cycle Time in minutes) 60

3. To help ensure that only fresh TSL enters the seal area, change the TSL every 4000 cycles or sooner if it appears to be contaminated. Follow the Drain

and Flush the TSL System instructions, page 28.

TSL System Maintenance

To prolong the life of the isolator and to avoid expensive repairs and downtime, perform the following maintenance:

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.

1. Replace the isolator seals every 15,000 voltage block cycles, or every four months, whichever comes first. See page 29.

* The isolator will automatically stop in the down position when the voltage block door is opened.

308–581 27

Drain and Flush the TSL System

Maintenance

3. Remove the TSL return tube (E) from the TSL pump (90) fitting.

WARNING




4. Drain both tubes (A, E) into a waste container.

5. If the TSL container (91) still appears dirty after draining it, remove the TSL container and clean it with non-flammable fluids, which are defined on the front cover of this manual.

6. Reinstall the TSL container and TSL tubes.

WARNING



1. Follow the General Flushing and Shutdown procedure on page 23.

7. Disconnect the tube (L) from the tube connector

(M). Place the end of the tube into a waste container and fill the TSL container with TSL fluid (part no. 206–995).

8. Turn on the air inlet pressure to the voltage block.

9. 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 container. When the TSL tubes are purged of contaminated TSL and air, reconnect the tube (L) to the connector (M).

NOTE: As part of the General Flushing and Shut-

down, the Fluid Voltage Discharge and Grounding

Procedure, page 18, and the Pressure Relief Proce-

dure, page 20, should have been completed. Do not proceed until you have followed those procedures.

2. Remove the TSL container outlet tube (A) from the fluid block (330) fitting. See Fig. 11, page 29.

PTFE

Tubing 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.

28 308–581

Isolator Service

WARNING




Service

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 isolator elbows.

fluid tubes (C) from the

6. Remove the screw (305), and disconnect the ground wire from the air cylinder. Reinstall the screw to avoid losing it.

WARNING



7. Disconnect the TSL return tube (E) from the fluid block (330) fitting.

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. Replace any parts that look damaged to avoid system failure.

Isolator Disassembly






2. Remove the TSL container outlet tube (A) from the fluid block (330) fitting. See Fig. 11. Drain the TSL from the TSL container (91) into a waste container.

3. Remove the TSL container and clean it with nonflammable fluids, which are defined on the front cover of this manual. The remaining TSL system components will be flushed after the isolator service is completed.

B

305

330

E

C

90

106

Fig. 11

L M A 91

75 97 101

05821A

308–581 29

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.

20. Remove the isolator rod o-ring (319).

11. Remove the spring retainer collar (336).

12. Rotate the fluid tube (335) until the ground electrode (337) is accessible. Remove the screw (338) and ground electrode (337).

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).

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.

15. Loosen the screw (307) holding the cover retainer

(328), and rotate the cover retainer off of the cylinder rod cover (327).

22. Remove all the o-rings (302, 308, 309) from both seal cartridges (332, 333).

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).

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.

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).

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 32

30 308–581

Service

311

324

305

318

307

328

330

F

Fig. 12

Apply lubricant.

Torque to 15 in-lbs (1.7 N S m).


Tighten securely, until bottomed out.

304

329

G

320*

332

309*

302*

320*

327

326

325

306*

321

Lips face down

Lips face up

* Included in Kit 237–977

320

308*

325

306*

335

331

343

313

336

333

320

334

319*

337

338

05818A

308–581 31

Service

Isolator Assembly

NOTE: Parts that are marked with an asterisk (*) are included with the Isolator Seal Kit, part no. 237–977.

11. Secure the bottom support (331) to the mounting bracket (324) with the four screws (318). Tighten the screws to 15 in-lbs (1.7 N m).

1. Lubricate the new seals (320*) and install them into the cartridges (332, 333), orientated as shown in Fig. 12, page 31. Make sure the seals sit straight in the cartridge and that the seal quad-ring is in place.

12. 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).

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.

13. Secure the isolator assembly (75) into the enclosure (106), using the four 3/8” screws (97). See

Fig. 11, page 29.

14. Plug the TSL container (91) outlet tube, then fill the TSL container (91) with fresh TSL.

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.

15. Connect the two air tubes to the air cylinder connectors (B).

4. Carefully install the seal cartridges (332, 333) into the fluid block (330). Tighten the cartridges until they bottom out.

16. Connect the two PTFE isolator elbows.

fluid tubes (C) to the

5. Install the o-ring (319*) on the end of the isolator rod (334).

CAUTION

Tighten the tube retaining nuts by hand only to avoid damaging them.

6. Slide the tapered end of the isolator rod (334) through the seal cartridges (332, 333) in the fluid block (330).

17. Remove the screw (305). Connect the ground wire to the air cylinder, and secure the wire with the screw.

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.

18. Remove the plug from the TSL container outlet tube (A), and connect the tube to the fluid block

(330) fitting.

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 return tube (E) to the fluid block

(330) fitting.

20. Disconnect the tube (L) from the tube connector

(M). Place the end of the tube into a waste container and fill the TSL container.

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).

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 container. When the TSL tubes are purged of contaminated TSL and air, reconnect the tube (L) to the connector (M).

32 308–581

Notes

308–581 33

Accumulator Service

WARNING




Service

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).

WARNING



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).

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, 214 2 ) and o-rings (201,

202, 211). Clean and inspect the parts. Replace all the parts that are worn or damaged.

Continue on page 36

Accumulator Disassembly






H

X

J

54

74

8

2. Disconnect the exhaust air tube from the top accumulator fitting (H). See Fig. 13.

AA

48

3. Disconnect the fluid hose nut (J) from the fluid inlet flared hose end.

4. Disconnect the air pilot tube from the fluid regulator air pilot connector (48).

5. Loosen the hose ferrule nut (8).

Fig. 13

2

05821A

34 308–581

Service

217

225

202

213

210

211*

219

201

223

222

*214 1

220

*208

221

215

*214 2

212

202

224

Fig. 14

Install the u-cups (214 1 the piston (220).

, 214 2 ) with the lips facing to the outside of

Install the piston assembly (221, 222, 214 1 , 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.

Do not use lubricant on the o-rings (202) that are in the cap plugs (224).

Torque to 15 ft-lbs (20.25 N S m).


Apply dielectric lubricant to the o-ring.

* Included in Kit 237–976

05296

308–581 35

201

211*

216

204

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 35. Do not use lubricant on the o-rings

(202) that are in the cap plugs (224).

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).

1. Install the u-cup (214 1* ) 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.

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

N m).

2. Secure the piston extension (222) to the piston

(220) with the four screws (215). Tighten the screws to 15 in-lbs (1.7 N m).

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 (214 2 *) 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.

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 34. 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 34.

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.

20. Connect the fluid hose nut (J) to the fluid inlet flared hose end.

7. Install the two new o-rings (211*) into the end blocks (216, 217). Lightly lubricate the o-rings.

21. Connect the air pilot tube to the fluid regulator air pilot connector (48).

36 308–581

Notes

308–581 37

Part No. 237–927


115

Parts

115 48 81

12

52

65

83

48

96

16 79

16

22

16

69

14

5

55

115

48

12

16

5

14

95

12

20

48

21

115

Ref.

79

53

10

8

3

25

24

29

79

60

See DETAIL B, below, and page 46 for replaceable air logic assembly parts

9

17

57

7

51 52

20

73

11

13

71

Ref.

79

48

72

61

18 6

68

59

58

30

35

38

15

103

106

DETAIL A

44

46

See page 40 for parts. See

DETAIL A for tube parts.

05823

** 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

100

56

113 101

38 308–581

Parts

Part No. 237–927


NOTE: Parts for the voltage block assembly are continued on the next page.

Qty.

Ref.

No.

Part No.

Description

8

9

3 208–475 BALL VALVE

5 205–439 AIR LINE COUPLING, swivel, 3/8–18 npsm(f)

6 Y 290–098 WARNING LABEL

7 101–390 LOCK WASHER

185–549 HOSE FERRULE

185–548 NUT, 5/8–24

10 185–547 FERRULE HOUSING

11 208–536 AIR LINE COUPLING

12 165–198 REDUCING NIPPLE

13 169–971 AIR LINE FITTING; quick-disconnect

14 162–485 ADAPTER NIPPLE


16 156–849 PIPE NIPPLE

17 154–636 WASHER

18 112–308 NUT, regulator panel

20 110–438 AIR REGULATOR, self relieving, 0–100 psi (0–7 bar)

21 110–436 AIR PRESSURE GAUGE

22 109–075 AIR REGULATOR

24 106–086 HEX JAM NUT

25 104–029 GROUND LUG


30 100–731 WASHER

35 100–307 HEX NUT

38 100–056 HEX JAM NUT

44 113–078 SCREW

46 113–080 SCREW RETAINER

48 113–058 CONNECTOR, 5/32 x 1/4 npt(m)

51 113–069 90 _ ELBOW, 1/4 npt(f)

52 113–068 CONNECTOR, 5/32 x 1/8 npt(m)

53 113–067 PNEUMATIC SWITCH

55 061–134 HOSE, nylon

56 113–127 NUT

57 113–128 STANDOFF; 3/4” (19 mm)

58 113–129 CAP SCREW, 1/4–20 x

1.25”

59 113–130 WASHER

60 Y 290–089 LABEL, air inlet, max.

pressure

61 Y 290–090 LABEL, fluid inlet, max.

pressure

65 113–073 AIR REGULATOR, pilot operated

1

1

1

1

1

1

1

1

4

1

2

2

2

1

1

2

2 l

4

4

2

1

6

2

1

2

2

2

2

1

1

2

1

1

1

9

1

1

Ref.

No.

Part No.

Description

68 113–062 UNION

69 113–059 WHISTLE ALARM

71 113–268 BUSHING

72 113–060 FLUID PRESSURE

GAUGE; 0–100 psi (0–7 bar)

73 113–061 PUSH SWITCH

79 113–159 FITTING, 3/8 npt(f) x 1–14 uns–2a

80 100–985 WASHER

81 104–984 STREET TEE

83 113–264 PIPE CROSS, 1/4 npt

93 113–153 AIR LOGIC COVER

95 113–157 PIPE CROSS, 3/8 npt

96 803–088 STREET TEE, 3/8 npt

99 113–168 AIR LOGIC ASSEMBLY

100 113–170 ADAPTER NUT

101 113–180 FLARED TUBE ASSY., 23”

(584 mm)

103 190–715 BULKHEAD FITTING,

3/8–18.6 special form straight pipe thread

106 190–720 VOLTAGE BLOCK

ENCLOSURE

110 190–735 AIR LOGIC STANDOFF

113 113–182 FLARED TUBE ASSY., 5.5”

(139.7 mm)

115 113–184 STEM ELBOW ADAPTER

125 290–300 TAG, warning; (not shown)

Qty.

1

4

1

1

2

6

1

1

1

1

1

1

1

1

1

1

4

1

1

1

1

Y Replacement Danger and W arning labels, tags and cards are available at no cost.

AIR LOGIC TUBING

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.

Tubing Part No.

Color

054–730 Natural (clear)

054–731 Blue

054–732

054–733

054–734

Red

Yellow

Black

308–581 39

Parts

Part No. 237–927


34

52

32

114

90

88

34

104 105

32

91

86

120

76

39

77

39

53

98

39

109

116

*117

*1

129

87

27

94

] 122

19

59

58

42

97

75

See parts on page 44

43

A

42

54

92

37

121

A

36

111

102

] The other cable end connects to the ground lug (25) inside the enclosure (106).

Tapered end of the check valve (1) must face up.

74

See parts on page 42

41

50

49

2

48

47

05824A

40 308–581

Parts

Part No. 237–927


Ref.

No.

Part No.

Description

1* – CHECK VALVE

2 236–281 FLUID REGULATOR,

3–100 psi (0.2–7 bar)

4* 206–995 TSL FLUID, 1 qt. (0.95 liter) bottle (not shown)

19 110–620 SCREW, nylon

27 101–816 MACHINE SCREW


34 100–527 WASHER


37 100–166 HEX NUT


40* – TSL TUBING (not shown)

41 113–135 CRUSH RING

42 113–075 WASHER

43 190–410 BLEED RESISTOR

47 113–071 90 _ ELBOW, 1/4 npt(f)

48 113–058 CONNECTOR, male, 5/32 x 1/4 npt

49 113–081 TUBE ADAPTER, male,

1/4 npt(m), for 3/8” O.D.

tube

50 113–070 REDUCER NIPPLE,

3/8–1/4 npt(m)


53 113–067 PNEUMATIC SWITCH

54 113–125 CAP SCREW, 3/8–16 x 2”

58 113–129 CAP SCREW, 1/4–20 x

1.25”

59 113–130 WASHER

74 237–929 ACCUMULATOR, see page

42 for parts

75 237–930 ISOLATOR ASSY., see page 44 for parts

76 113–123 FULL LEVEL SWITCH

77 113–124 LOW LEVEL SWITCH

86 113–172 GUN AIR FLOW SWITCH

87 113–174 TSL PUMP SWITCH

88 113–175 SWITCH BRACKET

90 l 113–143 TSL PUMP

91 113–144 TSL RESERVOIR, 1.5 qt.

(1.4 liters)

92 113–151 TUBE ADAPTER 90 _

ELBOW, 3/8 npt(f), for 3/8”

O.D. tube

Qty.

1

1

1

6

1

1

2

1

1

1

2

4

2

1

1

1

1

1

1

1

1

2

7

–

2

2

4

4

1

1

9

1

8

Ref.

No.

Part No.

Description

94 113–155 BLEED RESISTOR

CLAMP

97 113–126 CAP SCREW, 3/8–16 x 1”

98 113–165 EXHAUST VALVE

102 190–714 RESISTOR FITTING,

10–24 unc–2b x 1/4–18 npt(m)

104 191–971 SWITCH BRACKET

105 190–719 SWITCH BRACKET NUT,

10–24 unc–2b

109 190–733 ACCUMULATOR ROD

GUIDE

111 237–937 WIRE ASSY., regulator to bleed resistor

112 237–939 WIRE ASSY., component to ground (not shown–refer to Fig. 6, page 16)

114 113–212 PUSH-IN TUBE UNION

116 112–698 SWIVEL ELBOW,

1/8 npt(m)

117* – BARB FLUID

CONNECTOR

118 113–190 HOSE CLAMP (not shown)

119 113–191 CABLE CLAMP (not shown)

120 113–194 CAP SCREW

121 181–328 NUT

122 237–938 WIRE ASSY., bleed resistor to ground

123 237–569 WIRE ASSY., 25 ft. (7.6 m)

(not shown)

124 237–968 TOOL KIT, Includes items

124a & 124b (not shown),

Required to install pump seal repair kit, part no.

237–969.

124a 113–226 S PUMP ASSY. TOOL

124b 113–227 S PUMP O-RING TOOL

129 113–894 CLAMP, tube

Qty.

2

1

1

1

4

1

1

1

3

1

2

1

1

8

4

1

1

2

2

1

5

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 45.

l A pump fluid seal repair kit, part no. 237–969, is available.

308–581 41

Parts

Item 74: Part No. 237–929


225

202

213

210

203

217

226

207

209

{ 208

221

215

222

{ 214

220

218

{ 211

204

226

207

209

212

202

224

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.

42 308–581

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 N S m).


Apply dielectric lubricant to the o-ring.

214 {

201

205

206

216

211 {

219

201

223

Parts

Item 74: Part No. 237–929


Ref.

No.

Part No.

Description

201 722–834 O-RING, Viton r

202 188–555 O-RING, Viton

203 113–058 CONNECTOR, 5/32 x

1/4 npt

204 109–570 WASHER


206 113–074 TUBE ADAPTER 90 _ elbow, 3/8 npt(m), for 1/2”

O.D. tube

207 113–075 WASHER

208 { – U-CUP, urethane

209 113–164 CAP SCREW, 3/8–16 x 1.5”

210 113–066 WASHER

211 { – O-RING, Viton

212 113–140 CAP SCREW, 1/2–13 x

12.625”

213 113–141 HEX NUT, 1/2”

Qty.

4

8

8

1

4

1

1

4

2

4

4

1

4

Ref.

No.

Part No.

Description

214 { – U-CUP, hytrel & Viton

215 108–630 MACHINE SCREW, 10–24 x 0.75”

216 190–693 LOWER END BLOCK

217 190–694 UPPER END BLOCK

218 190–695 SHOULDER PIN

219 190–696 CYLINDER

220 190–697 PISTON

221 190–698 PISTON ROD

222 190–699 PISTON EXTENSION

223 190–700 HIGH VOLTAGE SHIELD

224 190–701 CAP PLUG

225 190–702 THREAD CAP

226 190–703 SUPPORT BLOCK

{ These parts are available to order as part of an

Accumulator Seal Kit, part no. 237–976.

Qty.

2

4

4

4

4

1

1

4

1

1

3

1

1

308–581 43

Parts

324

318

316

307

328

327

Item 75: Part No. 237–930


347

346

311

304

346

305

329

345

320 }

332

309 }

302 }

320 }

326

325

306 }

310*

314

315

321

330

344

322

323

310*

318

Apply anaerobic pipe sealant on the threads.

Apply lubricant.



44 308–581

Tighten securely, until bottomed out.

Lips face down.

Lips face up.

320 }

308 }

333

320 }

334

319 }

337

338

325

306 }

335

331

343

313

336

05813

Parts

Item 75: Part No. 237–930


Ref.

No.

Part No.

Description

302 } – O-RING, Viton r

304 112–325 THUMB SCREW, 1/4–20 nc x 1”

305 111–788 CAP SCREW, 1/4–20 unc–3a x 0.75”

306 } – O-RING, Viton

307 110–620 SCREW, 10–24 unc–2a x 0.5”

308 }

309 }

–

–

O-RING, Viton

O-RING, Viton

310* 113–213 BARBED HOSE FITTING

311 113–131 AIR CYLINDER

313 113–136 COMPRESSION SPRING


315 113–074 TUBE ADAPTER 90 _ elbow, 3/8 npt(m), for 1/2”

O.D. tube

316 113–134 JAM NUT, 1–1/4 uns–2b

318 113–126 CAP SCREW, 3/8–16 x 1”

319 }

320 }

–

–

O-RING, CV75

WIPING SEAL, lubrithane

& Viton r

321 190–636 GUIDE ROD

322 190–637 AIR CYLINDER ADAPTER

323 190–638 CAP PLUG

324 190–639 MOUNTING BRACKET

325 190–640 GROUND PLUG

326 190–641 HIGH VOLTAGE

ELECTRODE

Qty.

2

2

1

1

1

1

1

8

1

4

4

1

1

1

1

3

2

2

1

1

1

1

Ref.

No.

Part No.

Description

327 190–717 CYLINDER ROD COVER

328 190–718 COVER RETAINER

329 190–642 TOP SUPPORT

330 239–017 FLUID BLOCK

331 190–644 BOTTOM SUPPORT

332 190–645 TOP SEAL CARTRIDGE

333 190–646 BOTTOM SEAL

CARTRIDGE

334 190–647 ISOLATOR ROD

335 190–689 FLUID TUBE

336 238–085 SPRING RETAINER

337 190–691 GROUND ELECTRODE

338 103–310 MACHINE SCREW, 8–32 unc–2a x 1/4”

343 100–609 MACHINE SCREW, 1/4–20 unc–2a x 0.375”

344 187–959 WARNING LABEL

345 238–770 BRACKET ASSY., Isolator


347 113–184 ELBOW ADAPTER

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

} These parts are available to order as part of an Iso lator 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 .

308–581 45

Air Logic Schematic and Parts

BLUE BLUE

RED

REFILL

46 308–581

05328

CC

DD

BB

AA

Dimensions

Measurements, inches (mm)

AA

37.50

(953)

BB

27.438

(697)

CC

38.50

(978)

DD

37.250

(946)

EE

21.0

(533)

* Width at the widest point of the voltage block assembly

Width*

12.250

(311)

EE

Technical Data

Category

Maximum Working Pressure

Air Pressure Operating Range

Fluid Pressure Operating Range

Maximum Voltage

Fluid Specification

Data

100 psi (7 bar)

60–100 psi (4.2–7 bar); Typical Pressure 80 psi (5.6 bar)

0–100 psi (0–7 bar)

60 kV

For use with Graco PRO 5500wb t and PRO 3500wb t 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.

100 oz. (3 liters)

120 _ F (49 _ C)

Accumulator Capacity

Maximum Fluid Temperature

Weight

Voltage Block

Cart Kit

Air Inlet

Fluid Inlet

Air Outlet

138.0 lbs. (62.10 kg)

67.5 lbs. (30.38 kg)

1/4 npt(f) quick-disconnect

3/8–18 npsm (R3/8–19) compound thread

1/4 npsm(m)

Wetted Parts 304 SST, PTFE r , PEEK, Viton r , Epoxy, Acetal

Sound Pressure at 80 psi (5.6 bar) { 74.6 Db(A)

{ Sound pressure was measured per a time weighted average over a 4 minute complete dispense/refill cycle.

PTFE and Viton r

308–581 47

The Graco Warranty and Disclaimers

WARRANTY

Graco warrants all equipment manufactured by it 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. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for, 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 incompatibility with Graco equipment of 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 distributor for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any defective 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.

DISCLAIMERS AND LIMITATIONS

The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non–contractual liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. In no case shall Graco’s liability exceed the amount of the purchase price.

Any action for breach of warranty must be brought within two (2) years of the date of sale.

EQUIPMENT NOT COVERED BY GRACO WARRANTY

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer.

Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

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

Assembly

Changed

237–927

Part

Status

Added

Ref.

No.

Part No.

Name

237–930

Old

New

Quantity changed to 1

Old

New

Added

125 290–300 Warning Tag

81

1

100–547

104–984

–

Tee

Check Valve

104 190–716

191–971

Bracket

129 113–894 Clamp

Deleted 312 113–132 Bearing

Old

New

330 190–643

239–017

Fluid Block

Old

New

345 –

238–770

Bracket Assy.

Miscellaneous Changes: Added TSL System maintenance information.

Sales Offices: Atlanta, Detroit, Los Angeles

Foreign Offices: Belgium, Canada, England, Korea, Switzerland, France, Germany, Hong Kong, Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

PRINTED IN U.S.A. 308–581 July 1995 Revised January 1997

48 308–581

Graco 308581C H 2 O PRO Batch System Owner's Manual

H

O PRO Batch System

100 psi (7 bar) Maximum Working Air and Fluid Pressure

Part No. 237–927

Waterborne Voltage Block

Rev. C

Supersedes B

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

Warning Symbol

Caution Symbol

FIRE AND EXPLOSION HAZARD

ELECTRIC SHOCK HAZARD

PRESSURIZED EQUIPMENT HAZARD

EQUIPMENT MISUSE HAZARD

TOXIC FLUID HAZARD

MOVING PARTS HAZARD

See Fig. 2

See Fig. 1. Refer to Fig. 2 and 3.

See Fig. 3

See Fig. 3

See Fig. 4, page 15

FILL/RUN

FILL Sequence

RUN Sequence

FLUSH/RESET

FLUSH Sequence– through gun

Paint Saver

Paint Saver Sequence

IMPORTANT:

Fluid Supply Unit

Warning Signs

Ventilate the Spray Booth

Air Supply

Mounting the Voltage Block

Interlock the Gun Turbine Air Supply Remote Terminal Strip

Connect the Hoses

Ground the System

See Fig. 4

Check the System Grounding

Fluid Voltage Discharge and Grounding

Procedure

Fluid Voltage Discharge and Grounding

Procedure

(continued)

Pressure Relief Procedure

Emergency Fluid Shutoff

Operating Checklist

Voltage Block Startup Procedure

Operating the Voltage Block

Flushing and Shutdown

Problem: Voltage Loss

Cycle Counting

TSL System Maintenance

Drain and Flush the TSL System

Tubing Replacement

Isolator Service

Accumulator Service

Part No. 237–927

Waterborne Voltage Block

Part No. 237–927

Waterborne Voltage Block

Part No. 237–927

Waterborne Voltage Block

Part No. 237–927

Waterborne Voltage Block

Item 74: Part No. 237–929

Accumulator Assembly

Item 74: Part No. 237–929

Accumulator Assembly

Item 75: Part No. 237–930

Isolator Assembly

Item 75: Part No. 237–930

Isolator Assembly

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

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308504D

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