INSTRUCTIONS–PARTS LIST

INSTRUCTIONS

This manual contains important warnings and information.

READ AND RETAIN FOR REFERENCE

308–520

Rev. A

Model PRO 5500wb

Waterbase Isolation System

For use when electrostatically spraying conductive, waterbase fluids that have a flash point above 140 F (60 C) and a maximum organic solvent concentration of 20%, by weight.

Waterbase Voltage Control Assembly

Part No. 223–477

Isolation Stand Assemblies

Part No. 223–445; for up to a 15 gal. (57 liter) fluid container

Part No. 727–212; for a 55 gal. (209 liter) fluid container

Waterbase Fluid Hose Assemblies

See page 26 for the part numbers.

Safety Fence

Part No. 110–614

GRACO INC.

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

COPYRIGHT 1995, GRACO INC.

Table of Contents

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

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

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

6

6

Install the Safety Fence

Install the Isolation Stand

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

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

Install the Voltage Control . . . . . . . . . . . . . . . . . . . .

8

9

9

Install the Ground Terminal Plates and Fluid Hose Assembly

Ground the System

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

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

Check the System Grounding

Install the Fluid Supply Unit

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

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

10

10

12

12

Install the Air Manifold Assembly

Install the Air Line Interlock

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

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

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . .

14

14

14

Connect the Air Hoses to the Air Manifold . . . . .

Install the Gun Air Lines and Accessories

Install the Gun Fluid Line and Accessories

. . . .

. . . .

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

14

15

16

16

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

Removing the Fluid Supply from the

Isolated Area . . . . . . . . . . . . . . . . . . . . . . . . . .

Placing the Fluid Supply in the

19

19

Isolated Area . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean the Isolation Stand and the

Voltage Control . . . . . . . . . . . . . . . . . . . . . . . .

19

19

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Voltage Control Service . . . . . . . . . . . . . . . . . . . . . . . 22

Voltage Control Parts . . . . . . . . . . . . . . . . . . . . . . . . . 24

Fluid Hose Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Isolation Stand Parts . . . . . . . . . . . . . . . . . . . . . . . . . 26

Safety Fence and Pressure Tanks . . . . . . . . . . . . . 27

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

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

Voltage Discharge Procedure . . . . . . . . . . . . . . .

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

17

17

18

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

The Graco Warranty and Disclaimers . . . . . . . . . . 28

Graco Phone Numbers . . . . . . . . . . . . . . . . . . . . . . . 28

Symbols

Warning Symbol

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

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

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 10.

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Interlock the gun turbine air supply to prevent operation of the power supply unless the ventilating fans are on. See

Ventilate the Spray Booth on page 14.

Only use this equipment to spray non-flammable, waterbase fluids that have a flash point above

140 F (60 C) and a maximum organic solvent concentration of 20%, by weight.

Only flush, purge, or clean the electrostatic, waterbase spray system with non-flammable fluids that have a flash point above 140 F (60 C) and a maximum organic solvent concentration of

20%, by weight.

Do not flush the system with the gun electrostatics turned on.

If there is any static sparking while using the equipment, stop spraying immediately. Identify and correct the problem.

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.

308-520 3

ELECTRIC SHOCK HAZARD

Improper grounding or an improper setup and usage of a voltage isolation 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 10.

Components of the isolation system which are charged with high voltage must be inaccessible to personnel to avoid electric shock. These components must be contained in a safety fence that prohibits personnel from making contact with the components before the system voltage is discharged.

The areas of the waterbase fluid hose that are accessible to the personnel must be covered by the conductive hose layer. The area on the hose that is not covered by the conductive hose layer must be inside the voltage isolation system enclosure. Refer to page 16.

Install only one continuous Graco waterbase fluid hose between the isolated fluid supply and the spray gun. Do not splice hoses together.

The gun turbine air supply must be interlocked with the isolation system to shut off the turbine air supply anytime the safety fence is opened.

Follow the Voltage Discharge Procedure on page 17 when instructed to discharge the voltage, before cleaning, flushing, or servicing the system; before approaching the gun; and when opening the safety fence.

Do not use the Graco ES Display Module readings to determine if your system is discharged. The display modules will only display the system voltage while the gun power supply is operating. Follow the Voltage Discharge Procedure to ensure the system is discharged.

Do not enter a high voltage or hazardous area until all high voltage equipment has been discharged.

Do not touch the gun electrode or come within 4 inches (101.6 mm) of the nozzle during gun operation or until the voltage has been completely discharged after you stop spraying.

Follow the warnings and instructions in the PRO 5500wb spray gun manual 308–496.

EQUIPMENT MISUSE HAZARD

INSTRUCTIONS

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in a serious injury.

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 the usage, call Graco

Technical Assistance at 1–800–543–0339.

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.

4 308-520

INSTRUCTIONS

EQUIPMENT MISUSE HAZARD (continued)

Do not exceed the maximum working pressure of the lowest rated system component. The waterbase fluid hose has a 100 psi (7 bar) maximum working pressure.

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.

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.

Wear hearing protection when operating this equipment.

Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

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 17 whenever you: are instructed to relieve the pressure; stop spraying; clean, check, or servicing 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.

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.

308-520 5

A* B*

C

Non-Hazardous Area

D*

Installation

Hazardous Area

E* F

*5

*G

3*

A*

H J M*

6

311/

312*

9*

306*

1

4

*K

*2 *127 10*

7*

L*

Fig. 1

Typical Installation

NOTE: Refer also to Fig. 10, page 15.

Fig. 1 shows a typical Model PRO 5500wb system.

Accessories are available from your Graco representative.

For assistance in designing a system that is customized for your application, contact your Graco representative or Graco Technical Assistance (see the back page).

04601

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of an electric shock or other serious injury, a safety fence (L), non-conductive hoses (3 & 4), isolation stand (K), and voltage control (2) must be installed to isolate the fluid in the fluid line (306), and fluid supply unit (J) from ground and to prevent people from contacting portions of the system that are charged to high voltage.

Installation

KEY–Fig. 1

Reference

A*

B*

C

D*

E*

7*

8*

9*

10*

127*

306*

3*

4*

5*

6

L*

M*

1

2*

F

G*

H

J

K*

311/312*

Part No.

–

–

206–199

–

Description

Grounded Main Air Supply Line

Bleed-type Master Air Valve

Turbine Air Pressure Regulator

Gun Turbine Air Hose Ground Wire

235–068; 6 ft. (1.8 m)

235–069; 15 ft. (4.6 m)

235–070; 25 ft. (7.6 m)

235–071; 36 ft. (11.0 m)

235–072; 50 ft. (15.2 m)

235–073; 75 ft. (23.0 m)

235–074; 100 ft. (30. 5 m)

237–603; gun, shroud, manifold & bracket

–

–

–

223–445; for up to a 15 gal. (57 liter) fluid supply

727–212; for 55 gal.

(209 liter) fluid supply

110–614

–

223–640

223–639

208–591

223–446

223–447

186–119

210–084

110–790

223–685

223–547

223–548

190–288; 25 ft. (7.6 m)

190–289; 36 ft. (11.0 m)

190–290; 50 ft. (15.2 m)

190–291; 75 ft. (23.0 m)

185–971 & 185–972

Gun Turbine Air Supply Hose

PRO 5500wb Waterbase Electrostatic Spray Gun

Air Line Interlock Quick-disconnect Fitting

Fluid Supply Air Pressure Regulator

Fluid Supply Unit

Isolation Stand

Safety Fence

Bleed-type Air Shut-off Valve

Air Manifold Assembly

Voltage Control

Fluid Supply Unit Non-conductive Air Hose

Voltage Control Non-conductive Air Hose

Air Line Interlock Air Hose

Safety Fence Warning Sign

Grounding Rod

U-Bolts and Plate (not shown in Fig. 1)

Safety Fence Ground Cable

Main Ground Cable

Voltage Control Ground Cable

Waterbase Fluid Hose

Ground Terminal Plates

Assembly Included With

–

–

–

Gun Turbine Air Supply

Hose; refer to item E

–

See Page

–

–

–

–

–

–

223–640

–

–

–

–

–

223–477

223–477

223–477

223–477

223–477

223–477

223–477

223–477

223–477

223–477

223–639

237–548; 25 ft. (7.6 m)

237–549; 36 ft. (11.0 m)

237–550; 50 ft. (15.2 m)

237–551; 75 ft. (23.0 m)

Waterbase Fluid Hose

Assembly 237–548 to

237–551

25

25

25

25

25

26

25

25

25

25

27

–

25

25

26

–

25

–

27

26

* Equipment that must be installed for safe operation of a waterbase system

308-520 7

Installation

6.

The fence must be painted a high visibility yellow.

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.

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 , Group D Hazardous Location.

Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

7.

A means must be provided to connect the fence to a true earth ground. There must be electrical continuity between all sides of the fence and the gate.

6 ft.

(1.83 m)

Install the Safety Fence

Install the safety fence as shown in Fig. 2 or an equivalent safety fence as specified below. Anchor the fence to the floor as specified in Fig. 3.

Safety Fence Specifications

1.

The fence must provide at least a 6 x 6 x 6 foot

(1.83 x 1.83 x 1.83 m) protective area. See Fig. 2.

2.

This area must only be accessible through a single gate. The gate must be hinged and latched so it only opens outwards.

3.

The fence (L) must be bolted to the floor (R) as specified in Fig. 3. The fence must be constructed so it can withstand any forces induced by vehicles, equipment, or personnel in the area, without reducing the protection provided.

4.

The fence must be constructed so there is no more than 6 inches (152 mm) of clearance between the bottom of any portion of the fence and the building floor.

5.

The shape of the mesh pattern in the fence sides and gate is optional, but it must restrict a 2.5 inch

(64 mm) diameter spherical object from passing through it.

6 ft.

(1.83 m)

Fig. 2

KEY–Fig. 3

L Safety Fence

Q 1/2 in. (13 mm) dia. “red head” anchor bolt (or equivalent) with a maximum of 2 ft. (0.6 m) of space between the bolts on the fence flange

R Concrete Floor

Q L

Fig. 3

4 in.

(102 mm) minimum

6 ft.

(1.83 m)

R

03575

03576

Install the Isolation Stand

Installation

1.

Position the isolation stand (K) in the center of the safety fence. See Fig. 1, page 6. The isolation stand must be a minimum of 20 inches (508 mm) from any side of the fence.

2.

To help keep the stand from moving, install one

1/2 inch (13 mm) bolt in the floor in alignment with the bolt hole (S) in the bottom of the isolation stand (K). See Fig. 4.

Install the Voltage Control

The voltage control (2) contains a bleed resistor (102), which continually bleeds current to ground, and a quick-dump switch (101), which dumps the charge to ground whenever the air line interlock air hose (5) is disconnected to open the safety fence gate. See Figs.

1 and 5.

KEY–Fig. 5

2

101

102

Voltage Control

Quick-dump Switch

Bleed Resistor

3.

Place the isolation stand bolt hole (S) over the bolt in the floor.

4.

Assemble the terminal block (404) to the isolation stand grounding grate (402), and place the grate on the isolation stand as shown in Fig. 8, page 11.

2

102 101

S K

04721

Fig. 5

1.

Place the voltage control (2) 4 inches (102 mm) from the edge of the isolation stand. Refer to

Fig. 1.

2.

Secure the voltage control (2) to the floor with four

1/2 inch (13 mm) anchor bolts. See Fig. 6.

4.75 in.

(121 mm)

4.75 in.

(121 mm)

Fig. 4

Isolation Stand: Bottom View

03574

Fig. 6

Voltage Control: Bottom View

03573

308-520 9

Installation

Install the Ground Terminal Plates and

Fluid Hose Assembly

Ground the System

See Fig. 8.

The two plates (311/312) provide hose strain relief, ground the conductive layer of the fluid hose, and function as a grounding terminal for the cables, as shown in Fig. 8, page 11. Install the plates and the waterbase fluid hose (306) to the safety fence (L) as shown in

Fig. 7.

KEY–Fig. 7

L

T

U

Safety Fence

Outer Hose Jacket

Conductive Hose Layer

306

308

Fluid Hose

Ferrule Housing

311/312 Ground Terminal Plates

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.

L

312

306

Fig. 7

T

312

311

311

308

U new no.

The following grounding instructions are minimum requirements for a basic electrostatic, waterbase 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.

Connect the Cables

1.

Main ground cable: Connect the 25 foot (7.6 m) main ground cable (10) between the ground terminal plates (311/312) and a true earth ground.

2.

Voltage control ground cable: Connect the 6.5 foot

(2 m) voltage control ground cable (127) between the ground terminal plates (311/312) and the voltage control (2) base.

3.

Safety fence ground cable: Connect the 1 foot

(0.3 m) safety fence ground cable (9) between the ground terminal plates (311/312) and the safety fence.

4.

Grounding rod cable: Connect the grounding rod

(7) cable to the ground terminal plates (311/312).

Hook the grounding rod onto the safety fence, near the gate.

5.

Isolation stand cable: Connect the 1 foot (0.3 m) isolation stand cable (406) between the isolation stand terminal block (404) and the voltage control cover contact (214–refer to Fig. 13, page 23). Fasten the cable in the cable clamp (403) to provide strain relief.

Continued on page 12.

10 308-520

KEY-Fig. 8

J

K

N

P

2

7

9

Fluid Supply Unit

Isolation Stand

Connect to a true earth ground

Connect to the safety fence

Voltage Control

Grounding Rod

Safety Fence Cable

406

403

404

Installation

10 Main Ground Cable

127 Voltage Control Ground Cable

311/312 Ground Terminal Plates

402 Grounding Grate

403

404

405

406

Cable Clamp

Terminal Block

Fluid Supply Cable

Isolation Stand Cable

10

N

P 9 311/312

405

402

7 2 406

127

04784

J

405

K

Fig. 8

03572

308-520 11

Installation

Ground the System (continued)

System Components and Personnel

1.

PRO 5500wb Electrostatic Air Spray Gun: Ground the gun by connecting the red Graco Electrically

Conductive Turbine Air Hose and connecting the air hose ground wire to a true earth ground. Check the electrical grounding of the gun as instructed in the spray gun manual 308–496.

2.

Turbine air hose and the conductive layer of the waterbase fluid hose: The hoses must be properly grounded as instructed in the spray gun manual

308–496.

3.

Air compressors: Ground the equipment according to the manufacturer’s recommendations.

4.

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.

5.

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

6.

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.

7.

All electrically conductive objects or devices in the spray area: They must be properly grounded.

1.

After grounding the system, check the resistance between the ground plate (311/312) and a true earth ground. Refer to Fig. 8, page 11. The resistance must be less than 20 ohms.

2.

Measure the resistance between the isolation stand grounding grate (402) and the ground terminal plates (311/312). Refer to Fig. 8. The resistance must be less than 20 ohms.

Install the Fluid Supply Unit

1.

Place the fluid supply unit (J) on the isolation stand grounding grate (402). See Fig. 8, page 11.

2.

Connect the c-clamp of the 3 foot (0.9 m) fluid supply cable (405) from the isolation stand terminal block (404) to a metal part of the fluid supply unit

(J). See Fig. 8.

NOTE: The isolation stand and the fluid supply unit are grounded when the voltage is discharged through the voltage control.

3.

Install a bleed-type air regulator (H) and shut-off valve (M) on the fluid supply unit (J) to control and shut off air pressure to the fluid supply unit. See

Fig. 1, page 6.

Check the System Grounding

WARNING

ELECTRIC SHOCK HAZARD

If you are checking the grounding after the system is fully installed, make sure the air to the system is turned off by disconnecting the air line interlock before checking the grounding. If the gun has been operated, follow the

Voltage Discharge Procedure on page 17. This will help ensure there is no voltage to the system and help prevent electric shock.

WARNING

PRESSURIZED EQUIPMENT HAZARD

Trapped air can cause the gun to spray unexpectedly, which could result in a serious injury, including splashing in the eyes or on the skin. Install the bleed-type air regulator and shut-off valve so trapped air will be relieved after the regulators or valves are closed.

12 308-520

Installation

Installation continued on page 14

308-520 13

Installation

Install the Air Manifold Assembly

Mount the air manifold assembly (1) on the outside of the safety fence (L). See Fig. 10.

Install the Air Line Interlock

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 feet/minute

(19 linear meters/minute).

WARNING

ELECTRIC SHOCK HAZARD

The air line interlock helps to prohibit personnel from making contact with the components before the system voltage is discharged. To reduce the risk of an electric shock, the gun turbine air supply must be interlocked with the isolation system to shut off the turbine air supply anytime the enclosure or safety fence is opened. Do not tamper with or bypass the air line interlock.

Connect the 3/8 inch I.D. air line interlock air hose (5) between the grounded main air line (A) and the air manifold quick-disconnect fitting (G). See Figs. 9 and

10. Use the u-bolts and plates (8) to secure the air hose in place.

Ventilate the Spray Booth

WARNING

FLAMMABLE OR TOXIC

VAPOR HAZARD

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors.

The gun turbine air supply must be interlocked with the ventilators to prevent operation of the power supply unless the ventilating fans are on.

Connect the Air Hoses to the Air Manifold

1.

Connect the 5/16 inch I.D. non-conductive air hose

(4) between the air manifold connector (CC) and the voltage control air inlet (110). See Figs. 9 and

10.

2.

Connect a 3/8 inch O.D. air supply hose (W) between the air manifold connector (AA) and the turbine air regulator (C–see Fig. 1, page 6).

3.

Connect the 1/4 inch I.D. non-conductive air hose

(3) between the air manifold connector (BB) and the fluid supply unit air regulator (H).

KEY–Fig. 9

G

AA

BB

CC

DD

Air Line Interlock Quick-disconnect Fitting

Turbine Air Hose Connector

Pressure Pot Air Hose Connector; includes a check valve to minimize the volume of air discharged when the air line interlock is disconnected

Voltage Control Air Hose Connector

Plug

AA

BB

G

CC

DD

DD

Electrically interlock the gun turbine air supply with the ventilators to prevent operation of the electrostatic power supply unless the ventilating fans are on.

Fig. 9

Air Manifold Assembly

03579

14 308-520

KEY-Fig. 10

2

3

4

N

W

1

A

H

J

K

L

Grounded Main Air Supply Line

Fluid Supply Air Pressure Regulator

Fluid Supply Unit

Isolation Stand

Safety Fence

To True Earth Ground

Air Hose (to the turbine air regulator)

Air Manifold

Voltage Control

Fluid Supply Unit Non-conductive Air Hose

Voltage Control Non-conductive Air Hose

306 311/312

Installation

3

7

8

9

5

6

Air Line Interlock Air Hose

Safety Fence Warning Sign

Grounding Rod

U-bolts and Plate

Safety Fence Cable

10

110

127

Main Ground Cable

Voltage Control Air Inlet

Voltage Control Ground Cable

306 Waterbase Fluid Hose (to the gun fluid inlet)

311/312 Ground Terminal Plates

W H 6 A

WARNING

L

10

N

5

8

9

127

7

1

Fig. 10

Install the Gun Air Lines and Accessories

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 the turbine air hose, and you must connect the hose ground wire to a true earth ground.

4

J

110

K

2

04723

Install the air line accessories, and connect the turbine air hose and other air hoses to the PRO 5500wb spray gun as instructed in the spray gun manual 308–496.

Refer to Fig. 1, page 6.

308-520 15

Installation

Install the Gun Fluid Line and Accessories

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of an electric shock, install only one continuous Graco waterbase fluid hose between the isolated fluid supply and the spray gun. Do not splice hoses together.

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of an electric shock, the areas of the waterbase fluid hose that are accessible to personnel during normal operation must be covered by the conductive hose layer. The area on the hose that is not covered by the conductive hose layer must be inside the safety fence (L). See Fig. 11.

1.

Install a fluid regulator on the fluid line to control fluid pressure to the gun.

2.

Install a fluid filter at the fluid supply unit outlet.

3.

Connect the waterbase fluid hose (306) to the fluid supply unit (J). See Fig. 10, page 15.

4.

Connect the waterbase fluid hose (306) to the

PRO 5500wb spray gun as instructed in the spray gun manual 308–496.

Warning Signs

Mount the warning sign 186–118 (included with the gun) in the spray area where it can easily be seen and read by all operators. Mount the warning sign 186–119

(6) on the safety fence gate, as designated on the bottom of the sign. Refer to Fig. 10, page 15. Additional warning signs are available at no charge.

KEY-Fig. 11

L Safety Fence

The area on the hose that is not covered by the conductive hose layer must be inside the safety fence.

The areas of the waterbase fluid hose that are accessible to personnel during normal operation must be covered by the conductive hose layer.

L

04574

Fig. 11

16 308-520

Operation

Voltage Discharge Procedure 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, and install or clean the spray nozzles.

WARNING

ELECTRIC SHOCK HAZARD

The isolated fluid supply 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 Voltage Discharge Procedure: when instructed to discharge the voltage, before cleaning, flushing, or servicing the system equipment, before approaching the gun, and when opening the safety fence.

1.

Turn off all the air to the spray gun except the cylinder air, which triggers the gun. If an air pilot regulator is used in the system, the air pressure is needed at the regulator air inlet.

2.

Follow the Voltage Discharge Procedure, at right.

3.

Turn off the fluid supply to the gun.

4.

Trigger the gun into a grounded metal waste container to relieve fluid pressure.

5.

If an air pilot regulator is used in the system, turn off the air pressure at the regulator air inlet.

6.

Relieve fluid pressure in the fluid supply equipment as instructed in its instruction manual.

7.

Turn off the main air supply by closing the bleedtype master air valve on the main air supply line.

Leave the valve closed until you are ready to spray again.

To discharge the voltage:

1.

Turn off the turbine air to all of the spray guns connected to the isolated fluid supply unit.

2.

Disengage the interlock air hose from the quickdisconnect fitting (G). See Fig. 12, page 18. This will turn off the turbine air to the gun and trigger the voltage control quick-dump switch to discharge the electrical charge.

3.

Enter the safety fence area and remove the grounding rod (7) from the fence (L). Grasp the grounding rod by the hook end of the handle.

Touch the exposed wire of the grounding rod to a metal surface of the fluid supply unit (J) as shown in Fig. 12. If an arc is detected, correct the problem before doing anything further with the system.

See Troubleshooting on page 20.

4.

Before approaching the spray gun, verify that there is no voltage at the gun by touching a grounded rod to the gun electrode. If an arc is detected, verify that steps 1 to 3 have been completed correctly.

Before re-starting the system:

5.

After cleaning or servicing is complete, make sure that the fluid supply cable (405) and isolation stand cable (406) are properly connected. See Fig. 12.

6.

Exit the safety fence (L), close the safety fence gate (R), and reconnect the interlock air line to the quick-disconnect fitting (G).

308-520 17

KEY-Fig. 12

G

J

K

L

R

Air Line Interlock Quick-disconnect Fitting

Fluid Supply Unit

Isolation Stand

Safety Fence

Safety Fence Gate

Operation

G 7

2

7

402

405

406

Voltage Control

Grounding Rod

Grounding Grate

Fluid Supply Cable

Isolation Stand Cable

R

406

L

405

402

04784

Fig. 12

405

406

2

Operating Checklist

Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.

____ 1. Be sure all the operators are properly trained to safely operate an automatic, electrostatic, waterbase, air spray system as instructed in this manual and the gun manual 308–496.

____ 2. Be sure all the operators are trained how to properly relieve system pressure and discharge the voltage as instructed on page 17.

____ 3. Be sure the system is thoroughly grounded.

See Ground the System, page 10.

____ 4. Be sure the operator and all persons entering the spray area are properly grounded by wearing shoes with conductive soles or personal grounding straps.

J K

04724

____ 5. Be sure all the conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded.

____ 6. Be sure the workpiece hangers are clean and grounded. Contact points must be sharp points or knife edges.

____ 7. Be sure the ventilation fans are operating properly.

____ 8. Be sure all the debris, including flammable liquids and rags, is removed from the spray area.

Spraying

Follow the operating instructions in the spray gun manual 308–496.

18 308-520

Maintenance

Removing the Fluid Supply from the

Isolated Area

Clean the Isolation Stand and the

Voltage Control

WARNING

PRESSURIZED EQUIPMENT AND

ELECTRIC SHOCK HAZARD

To reduce the risk of a serious injury, follow the Pressure Relief Procedure and the Voltage Discharge Procedure on page 17 when you stop spraying and whenever you are instructed to relieve the pressure and discharge the system voltage.

WARNING

PRESSURIZED EQUIPMENT AND

ELECTRIC SHOCK HAZARD

To reduce the risk of a serious injury, follow the Pressure Relief Procedure and the Voltage Discharge Procedure on page 17 when you stop spraying and whenever you are instructed to relieve the pressure and discharge the system voltage.

1.

Relieve the pressure and discharge the system voltage.

2.

Disconnect the fluid hose and air hose from the fluid supply unit.

3.

Disconnect the cable c-clamp (405) from the fluid supply unit (J). Refer to Fig. 12.

4.

Remove the fluid supply unit (J).

Placing the Fluid Supply in the

Isolated Area

1.

Place the fluid supply unit (J) on the isolation stand

(K). See Fig. 12.

2.

Connect the c-clamp of the 3 foot (0.9 m) fluid supply cable (405) from the isolation stand terminal block to a metal part of the fluid supply unit (J).

3.

Connect the fluid hose and air hose to the fluid supply unit.

4.

Make sure that the isolation stand cable (406) is properly connected.

5.

Exit the safety fence (L), close the safety fence gate (R), and reconnect the interlock air line to the quick-disconnect fitting (G).

1.

Relieve the pressure and discharge the system voltage.

2.

Clean the isolation stand and the outer surfaces of the voltage control with a soft cloth dampened in a solvent that is suitable for use in an electrostatic waterbase system.

WARNING

FIRE AND EXPLOSION HAZARD

To reduce the risk of a fire or explosion, clean all the parts with water or a solvent that has a flash point above 140 F

(60 C) and a maximum organic solvent concentration of 20%, by weight.

3.

Make sure that the grounding grate (402) and all the surfaces of the isolation stand are clean. Refer to Fig. 12.

WARNING

ELECTRIC SHOCK HAZARD

Keep the grounding grate clean to ensure a good ground connection and reduce the risk of an electric shock.

4.

Make sure all the cables are properly connected.

See Fig. 8, page 11.

308-520 19

Troubleshooting

WARNING

ELECTRIC SHOCK HAZARD

Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.

WARNING

PRESSURIZED EQUIPMENT AND

ELECTRIC SHOCK HAZARD

To reduce the risk of a serious injury, follow the Pressure Relief Procedure and the Voltage Discharge Procedure on page 17 before doing any maintenance or service on the gun or system.

NOTE: Check the spray gun manual 308–496 for gun operation problems.

PROBLEM

The fluid is wrapping around the workpiece poorly.

The operator gets a shock.

The operator gets a shock when touching the workpiece.

CAUSE

The parts are poorly grounded.

SOLUTION

Clean the workpiece hangers; check for proper grounding on the conveyor or track.

Booth exhaust velocity is too high.

Reduce the exhaust velocity within the code limits.

There is an internal short in the fluid hose.

Replace the fluid hose.

The fluid hose conductive hose layer is too close to the isolated fluid supply.

A conductive air hose is being used from the isolated fluid supply unit to the grounded main air supply.

There is excess moisture in the air lines.

Support the fluid hose away from the ground.

A non-conductive air hose must be used.

Replace the conductive air hose.

The voltage control quick-dump switch is closed.

The bleed resistor has shorted.

The isolation stand is too close to the safety fence.

Install an air filter-moisture separator in the air supply line.

The air pressure is below 30 psi (2.1 bar).

Increase the inlet air pressure. Do not exceed 100 psi (7 bar).

–OR–

The voltage control seals are damaged.

Replace the seals. See page 22.

Replace the voltage control bleed resistor.

Position the isolation stand in the safety fence as described on page 9.

The voltage control is too close to the safety fence.

The operator is not properly grounded or is near an ungrounded object.

Position the voltage control in the safety fence as described on page 9.

Be sure the floor and the operator are properly grounded; see page 12.

The workpiece is not properly grounded.

Clean the workpiece hangers; check for proper grounding on the conveyor or track.

Troubleshooting

PROBLEM

An arc is detected with the grounding rod.

CAUSE

The voltage control is not electrically connected to the isolation stand terminal.

The fluid supply is not electrically connected to the isolation stand terminal.

The isolation stand is making poor electrical contact with the fluid supply unit.

The air line interlock has been bypassed.

The quick-dump switch is open.

SOLUTION

Connect the voltage control to the isolation stand terminal as instructed on page

10.

Connect the fluid supply to the isolation stand terminal as instructed on page 10.

Clean the isolation stand grate and/or the fluid supply unit. See page 19. Check the connection between the terminal block and the fluid supply. See page 10.

Do not bypass the air line interlock. Install it as instructed on page 14.

The voltage control seals are damaged.

Replace the seals. See page 22.

308-520 21

Voltage Control Service

Replacing the Voltage Control Rod Seal

1.

Remove the nut (106) and disconnect the two cables (117 and 406) from the quick-dump switch assembly. See Fig. 13.

2.

Remove the straps (103) from the bleed resistor

(102).

3.

Disconnect the ground connection (220).

4.

Remove the four screws (104).

5.

Disconnect the air line from the fitting (110).

6.

Remove the oil cup (208) from the quick-dump switch housing (205).

7.

Remove the five screws (215) from the top cover.

8.

Empty the oil from the oil cup (208) into a clean container. If the oil is clean, it can be reused. If there is a black carbon residue, replace the oil with electrical insulating oil, such as Diala Ax Oil (Shell

Oil Company) or an equivalent oil that meets

ANSI/ASTM D3487 and NEMA TR–P8–1975 specifications.

9.

Remove the cylinder contact (209) from the cylinder rod (Y).

10. Remove the seal flange (217) from the oil cup

(208).

11. Remove the two seals (206). Replace them with two new seals. Orientate the seals as shown in

Fig. 13.

12. Refill the oil cup (208), and reassemble the voltage control in the reverse order of disassembly. Use a semi-permanent thread sealant to fasten the cylinder contact (209) to the cylinder rod (Y).

Voltage Control Service

NOTE: The circled letters show where broken lines reconnect, such as on the cylinder rod

A

.

A

106

117

406

102

215

214

209

Fig. 13

DETAIL

B

208

206

217

Y

A

C

To strain relief/ground terminal

103

B

C

220

205

104

110

04725

308-520 23

Voltage Control Parts

NOTE: The circled letters show where broken lines reconnect, such as on the cylinder rod

A

.

105 117

106

A

213

226

215

225

211

210

212

214

209

112

111

103

B

B

102

116

108

133

C

106

206

217

216

223

127

220 221

107

222 224

A

C

204

203

218

205

104

108

133

108

109 110

03580

24 308-520

Voltage Control Parts

Use Only Genuine Graco Parts and Accessories

6*

7*

8*

9*

Part No. 223–477

Waterbase Voltage Control Assembly

Includes items 1 to 10

Ref.

No.

Part No.

Description

1*

2

3*

4*

5*

10*

223–640 AIR MANIFOLD ASSEMBLY

223–639 WATERBASE VOLTAGE CONTROL

See the separate parts list below

208–591 AIR HOSE, fluid supply unit;

6 ft. (1.83 m); 3/8 npsm(f) swivel; non-conductive

223–446 AIR HOSE, voltage control; 10 ft.

(3.05 m); 1/4-18 npsm x 1/4-18 npt; non-conductive

223–447 AIR HOSE, air line interlock; 5 ft.

(1.53 m); 3/8–18 npsm x

3/8–18 nptf

186–119 WARNING SIGN

210–084 GROUNDING ROD

110–790 U-BOLT & PLATE

223–685 CABLE ASSEMBLY, safety fence ground; 1 ft. (0.3 m)

223–547 CABLE ASSEMBLY, main ground;

25 ft. (7.6 m)

Qty.

1

1

1

1

1

1

1

2

1

1

* These parts are not shown in the Parts Drawing.

See page 15 for an illustration of these parts.

222

223

224

225

226

203

204

205

206

208

209

210

211

212

213

214

215

Ref. No. 101, Part No. 223–141

Waterbase Quick-dump Switch

Includes items 203 to 226

Ref.

No.

Part No.

Description

216

217

218

220

221

110–609 TUBING, nylon

110–610 TUBE FITTING, elbow; 1/8-27 npt

185–575 CYLINDER HOUSING

110–612 ROD SEAL

185–584 OIL CUP

185–573 CYLINDER CONTACT

103–209 O-RING, Viton

185–576 COVER PLATE

103–337 O-RING, Viton

102–025 NUT, hex; 1/4-20

185–574 COVER CONTACT

110–620 SCREW, machine, pan head;

10–24 UNC-2A x 1/2 in.

100–903 SCREW, machine, pan head;

8–32 UNC-2A x 1/2 in.

185–583 CYLINDER FLANGE

110–608 AIR PISTON CYLINDER

223–324 GROUND WIRE; 12 in. (305 mm)

103–832 SCREW, machine, pan head;

10–32 UNF-2A x 1/2 in.

100–166 NUT, hex; 10-32 UNF-2B

185–915 GROUND STRAP

100–718 WASHER, lock

110–629 CABLE CLAMP

100–985 WASHER, star

Qty.

1

1

1

1

1

2

1

1

1

1

1

5

1

1

2

1

1

1

1

1

1

1

Ref. No. 2, Part No. 223–639

Waterbase Voltage Control

Includes items 101 to 133

Ref.

No.

Part No.

Description

101

102

103

104

105

106

107

108

109

110

111

112

116

117

127

133

Qty.

223–141 WATERBASE QUICK-DUMP SWITCH

See the separate parts list at right

223–318 BLEED RESISTOR

186–081 RESISTOR STRAP

103–374 SCREW, machine, pan head;

10–32 UNF-2A x 5/8 in.

1

1

2

104–336

100–029

223–428

NUT, crown; 10–32 UNF-2B

NUT, hex cap; 1/4 x 20 UNC

BASE PLATE

103–832 SCREW, machine, pan head;

10–32 UNF-2B x 1/4 in.

186–057 BRACKET

4

2

2

1

1

4

5

1

110–737 AIR FITTING

110–745 BUSHING

110–620 SCREW, nylon;

10–24 UNC-2A x 1/2 in.

223–609 CABLE ASSEMBLY, bleed resistor to plate; 3 in. (76.2 mm)

223–528 CABLE ASSEMBLY, switch to bleed

4

1 resistor; 4 in. (102 mm);

223–548 CABLE ASSEMBLY, voltage control ground; 6.5 ft. (1.98 m)

100–718 WASHER

1

1

3

308-520 25

Fluid Hose Parts

100 psi (7 bar) Maximum Working Pressure

PTFE, 1/4 inch I.D.

Isolation Stand Parts

Part No. 223–445

Isolation Stand Assembly

For up to a 15 gallon (57 liter) fluid container

Fluid Hose

Assembly

Part No.

237–548

237–549

237–550

237–551

Bare Fluid

Hose

Part No.

190–288

190–289

190–290

190–291

Length

25 ft. (7.6 m)

36 ft. (11.0 m)

50 ft. (15.2 m)

75 ft. (23.0 m)

403,407

409

404

406 402

308

307

302

312

405

310

311

315

306

304

301

313

314

04325

310

311

312

313

314

315

301

302

304

306

307

308

Ref.

No.

Part No.

Description

190–143 BARBED INSERT

112–480 CONNECTOR, female

111–450 O-RING; fluoroelastomer

See Chart FLUID HOSE

185–549 HOSE FERRULE

185–547 FERRULE HOUSING

185–548 NUT; 5/8–24 UNEF-2B

185–971 PLATE, ground terminal

185–972 PLATE, ground terminal

100–021 SCREW, hex; 1/4-20 UNC-2A x 1”

102–025 NUT, hex; 1/4-20

154–636 WASHER

Qty.

1

5

2

1

6

1

3

1

1

1

2

2

401

03583

Ref.

No.

401

402

403

404

405

406

407

Part No.

Description

185–468 BARE STAND

185–946 GROUNDING GRATE

110–629 CABLE CLAMP

110–757 TERMINAL BLOCK

223–539 CABLE ASSEMBLY, fluid supply;

3 ft. (0.9 m)

223–529 CABLE ASSEMBLY, isolation stand; 1 ft. (0.3 m)

105–967 SCREW, thread forming, pan head;

10–16 x 0.5 in.

100–077 NUT, hex; 5/16–18

Qty.

1

1

1

1

1

1

1

2 409

Part No. 727–212

Isolation Stand Assembly

For a 55 gallon (209 liter) fluid container.

Safety Fence and Pressure Tanks

Part No. 110–614

Safety Fence

To isolate personnel from high voltage equipment.

Stainless Steel Pressure Tanks

100 psi (7 bar) Maximum Working Pressure

Models without an Agitator

Models with an Agitator Size

5 gallon

(19 liter)

10 gallon

(38 liter)

15 gallon

(57 liter)

236–149

236–150

236–151

236–152

236–153

236–154

03088A 03189A

Technical Data

Fluid Specification . . . . . . . . only use fluids that have a flash point above 140 F (60 C) and a maximum organic solvent concentration of 20%, by weight.

Maximum System Voltage . . . . . . . . . . . . . . . . . . . 60 kV

308-520 27

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.

Graco Phone Numbers

TO PLACE AN ORDER, contact your Graco distributor, or call Graco: 1–800–367–4023 Toll Free

FOR TECHNICAL ASSIST ANCE, service repair information or answers about the application of Graco equipment, call: 1–800–543–0339 Toll Free

Sales Offices: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)

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

GRACO INC.

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

PRINTED IN U.S.A.

308–520 February 1995