Graco ProBell 24Z221 Parts list manual

InstructionsandParts
ProBell® ProBell®
ProBell®Air Air AirControllers Controllers Controllers3A3954D
EN
For For
Formanual manual manualor or orelectronic electronic electronicair air aircontrol control controlof of ofa a aProBell ProBell ProBellrotary rotary rotaryapplicator applicator applicatoras as aspart part partof of ofa a apaint paint paintcoating coating coatingsystem. system. system.For For For
professional professional
professionaluse use useonly. only. only.Not Not Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or orhazardous hazardous hazardouslocations. locations. locations.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinyour
ProBell®RotaryApplicatormanual.Save Save
Savethese these theseinstructions. instructions. instructions.
100psi(0.7MPa,7.0bar)MaximumAir
InletPressure
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Models...............................................................2
RelatedManuals................................................2
Warnings...........................................................3
ProBellSystemInformation.................................5
SystemConnectionsandFeatures......................6
ComponentIdenti󰘰cation.....................................7
Installation..........................................................9
MounttheController.....................................9
GroundtheController...................................11
ControllerConnections........................................12
ConnectAirLines.........................................14
ConnectCommunicationCables...................14
ConnectPower............................................16
SetAirControlIdentity.................................16
WiringthePaintTriggerInput.......................16
WiringtheOptionalInterlockInput.................17
Troubleshooting..................................................18
Repair................................................................22
PrepareforService......................................24
ReplacetheControlModule..........................24
ReplacetheTriggerorAuxiliarySolenoid
Valve.............................................27
ReplacetheVoltagetoPressure(V2P)
Regulator.......................................28
ReplaceaShapingAirSolenoidValve...........29
ReplacethePressureSwitch........................30
ReplaceaPressureGauge...........................30
ReplaceaPressureRegulator......................31
ReplacetheBearingAirFilter.......................31
Parts..................................................................32
ElectronicAirController(Model
24Z222).........................................32
ManualAirController(Model24Z221)...........35
KitsandAccessories...........................................39
TechnicalSpeci󰘰cations......................................41
CaliforniaProposition65.....................................41
Models Models
Models
Model Model
ModelDescription Description DescriptionCerti󰘰cation Certi󰘰cation
Certi󰘰cation
24Z221ManualAirController
24Z222ElectronicAirController
Related Related
RelatedManuals Manuals Manuals
Manual Manual
Manualin in in
English English
English
Description Description
Description
334452ProBell®RotaryApplicator,Instructions/Parts
334626ProBell®RotaryApplicator,HollowWrist,Instructions/Parts
3A3657ProBell®ElectrostaticController
3A3953ProBell®SpeedController
3A3955ProBell®SystemLogicController
3A4384ProBell®SystemCGMInstallationKit
3A4232ProBell®CartSystems
3A4346ProBell®HoseBundle
3A4738ProBell®RelectiveSpeedDetectionKit
3A4799AProBell®AirFiltersKit
23A3954D

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanual,referbacktotheseWarnings.Product-speci󰘰c
hazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughoutthebodyofthismanual
whereapplicable.
WARNING WARNING
WARNINGFIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,intheworkareacanigniteorexplode.
Paintorsolvent󰘱owingthroughthesystemcancausestaticsparking.Tohelpprevent󰘰reor
explosion:
•Electrostaticequipmentmustbeusedonlybytrained,quali󰘰edpersonnelwhounderstand
therequirementsofthismanual.
•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorcloseto
thespraylocation.Resistancemustnotexceed1megohm.SeeGrounding Grounding
Groundinginstructions.
•Donotusepaillinersunlesstheyareconductiveandgrounded.
•Alwaysusetherequiredarcdetectionsettingsandmaintainasafedistanceofatleast6
inches(152mm)betweentheapplicatorandtheworkpiece.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingorrepeatedarcdetectionerrorsoccur.Donot
useequipmentuntilyouidentifyandcorrecttheproblem.
•Checkapplicatorresistanceandelectricalgroundingdaily.
•Useandcleanequipmentonlyinawellventilatedlocation.
•Alwaysturnoffanddischargetheelectrostaticswhen󰘱ushing,cleaningorservicing
equipment.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.
•Keepthesprayareacleanatalltimes.Usenon-sparkingtoolstocleanresiduefromthe
boothandhangers.
•Keepaworking󰘰reextinguisherintheworklocation.
•Interlockthegunairand󰘱uidsupplytopreventoperationunlessventilationair󰘱owisabove
theminimumrequiredvalue.
•InterlocktheElectrostaticControllerand󰘱uidsupplywiththeboothventilationsystemto
disableoperationiftheair󰘱owfallsbelowminimumvalues.Followyourlocalcodes.
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore
servicingorinstallingequipment.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
3A3954D3

Warnings
WARNING WARNING
WARNINGEQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.
Forcompleteinformationaboutyourmaterial,requesttheSafetyDataSheet(SDS)from
distributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworklocation.
•Complywithallapplicablesafetyregulations.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworklocationtohelppreventserious
injury,includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
43A3954D

ProBellSystemInformation
ProBell ProBell
ProBellSystem System SystemInformation Information Information
TheProBellAirControllerisanoptionalcomponentin
theProBellRotaryApplicatorsystem.TheElectronic
AirControllersendsairactivationsignalsforthe
paint,dump,andsolvent(cupwash)valves.Italso
electronicallycontrolstheinnerandoutershapingair
pressures.TheManualAirControllercontrolsallair
inthesystem.Manualairregulatorsareusedtoset
theturbineandshapingairpressures.
•Thismanualcoversinformationspeci󰘰ctotheAir
Controllers.Itincludesinformationoninstallation,
troubleshooting,repair,andparts.
•SeetheProBellRotaryApplicatormanual(334452
or334626)forallsysteminformation,including
installationandconnectionofthewholesystem,
requiredinterlocks,systemgrounding,required
electricaltests,andoperationprocedures.
•SeetheSystemLogicControllerManual(3A3955)
fordetailsonhowtosetupparametersfortheAir
Controller.
Figure1ProBellElectronicAirController,shownon
Cart(soldseparately)
3A3954D5

SystemConnectionsandFeatures
System System
SystemConnections Connections Connectionsand and andFeatures Features Features
Air Air
AirLine Line LinePort Port PortLabel Label LabelSpeed Speed
SpeedController Controller Controller
Connections Connections
Connections
Electronic Electronic
Electronic
Air Air
AirController Controller Controller
Connections Connections
Connections
Manual Manual
ManualAir Air Air
Controller Controller
Controller
Connections Connections
Connections
B(BearingAir)
√*√*
BK(BrakingAir)
√
BR(BearingAirReturn)
√*√*
DT(DumpValveTrigger)
√√
PT(PaintValveTrigger)
√√
SI(ShapingAirInner)
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√√
SO(ShapingAirOuter)
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√√
ST(SolventTrigger)
√√
TA(TurbineAir)
√*√*
AuxiliaryTriggers(forsystem
󰘱exibility)1,2,3,√√
*Insystemswithaspeedcontroller,bearingair,bearingairreturn,andturbineairmustbeusedfromthe
speedcontroller,notthemanualaircontroller.
63A3954D

ComponentIdentication
Component Component
ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
Electronic Electronic
ElectronicAir Air AirController Controller Controller
Ref. Ref.
Ref.Component Component ComponentDescription Description
Description
AControlModuleManagestheoperation
ofallaircontroller
components
BTerminalBlocksProvideselectricalwire
connections
CSolenoidValvesSendsairactivationsignals
forpaint,dump,and
solventvalves;auxiliary
signalsavailableforsystem
󰘱exibility
DAirManifoldDirectsincomingairtothe
controllercomponents
EInnerShaping
AirSolenoid
Valve
Shutsoffthe󰘱owofthe
innershapingair
Ref. Ref.
Ref.Component Component ComponentDescription Description
Description
FOuterShaping
AirSolenoid
Valve
Shutsoffthe󰘱owofthe
outershapingair
GVoltageto
Pressure
Regulator
Convertsvoltageto
pressurefortheinner
shapingair
HVoltageto
Pressure
Regulator
Convertsvoltageto
pressurefortheouter
shapingair
JOptocouplerIsolatesinputtothetrigger
paintvalvefromthePLC
3A3954D7

ComponentIdentication
Manual Manual
ManualAir Air AirController Controller Controller
Ref. Ref.
Ref.Component Component ComponentDescription Description
Description
AControlModuleManagestheoperation
ofallaircontroller
components
BTerminalBlocksProvideselectricalwire
connections
CSolenoidValvesSendsairactivation
signalsforpaint,
dump,andsolvent
valves;auxiliarysignals
availableforsystem
󰘱exibility
JPressureSwitchVeri󰘰esthatthebearing
airisatleast70psi
KHigh-FlowRemotePilotedregulatorfor
turbineair
LHigh-FlowRemotePilotedregulatorfor
innershapingair
MHigh-FlowRemotePilotedregulatorfor
outershapingair
Ref. Ref.
Ref.Component Component ComponentDescription Description
Description
NOuterShapingAir
Regulator
Airpressuresignalto
regulatorM
PInnerShapingAir
Regulator
Airpressuresignalto
regulatorL
RTurbineAir
Regulator
Airpressuresignalto
regulatorK
SOuterShapingAir
Gauge
TInnerShapingAir
Gauge
UTurbineAirGauge
VAirFilterSupplementary
coalescingair󰘰lter
thatprotectsthebearing
fromanyparticlesthat
getthroughthemainair
󰘰lteringsystem
WOptocouplerIsolatesinputtothe
triggerpaintvalvefrom
thePLC
83A3954D

Installation
Installation Installation
Installation
Mount Mount
Mountthe the theController Controller Controller
Toreducetheriskof󰘰reorexplosion,donotinstall
equipmentapprovedonlyforanon-hazardous
locationinahazardouslocation.
Note
Theaircontrollercanbemountedonthe
controlboxstandoronawall.Thebox
comeswithfourmountingbracketsinstalled
inaverticalorientation.Removeandturn
thebracketsifahorizontalorientationworks
betterforyourinstallation.
Wall Wall
WallMounting Mounting Mounting
Thepre-installedmountingbracketscanbeusedto
mountthecontrolleronany󰘱atwall.Mounttheair
controllerinthenon-hazardousarea,asclosetothe
applicatoraspossible,tominimizepressurelossin
theairlines.
1.Determinethemountinglocation.Ensurethat
thewallisstrongenoughtosupporttheweight
ofthemountingbracketandthecontroller.See
TechnicalSpeci󰘰cations,page41.
2.Seethedimensionsorusetheboxasatemplate
tomarkthemountingholelocations.
3.Drillholesandusefourscrewstoattachthe
controllertothewall.
Electronic Electronic
ElectronicAir Air AirController Controller Controller
3A3954D9

Installation
Manual Manual
ManualAir Air AirController Controller Controller
Cart Cart
CartMounting Mounting Mounting
Forsomeorderingoptions,theaircontrolleris
mountedonthecartatthefactory.Ifthecartwas
orderedseparately,followthesesteps:
1.Removethefourmountingbrackets.Turnthem
sotheyareorientedhorizontally.Reattachthem
totheaircontrollerbox.
2.Usefourscrews(providedwiththecart)
tomounttheaircontrollerboxonthecart
inthelocationshowninFigure1.See
ProBellSystemInformation,page5.
103A3954D

Installation
Ground Ground
Groundthe the theController Controller Controller
Theequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.
Forfullsystemgroundinginstructionsand
requirements,seetheProBellRotaryApplicator
manual(334452or334626).Usetheprovided
groundwireandclamptogroundtheaircontrollerto
atrueearthground.
Figure2ElectronicAirControllerGroundingLocation
Figure3ManualAirControllerGroundingLocation
3A3954D11

ControllerConnections
Controller Controller
ControllerConnections Connections Connections
Overview Overview
Overview
AircontrolinyourProBellsystemwilluseoneofthe
followingsetups:
•AllaircontrolisprovidedbytheGracoManualAir
Controller.
•AircontrolsaresplitbetweentheGracoElectronic
AirControllerandtheGracoSpeedController.Be
surethatyoursystemincludesapowersupply(sold
separately)tobemountedoneithercontroller.
•YoursystemusesacombinationofGraco
controllersandyourexistingdevices.Air
controlwillthenrequireacombinationofthe
connectionsshowninthe󰘰guresanduseof
theauxiliarytriggers.Besurethatyoursystem
includesapowersupply(soldseparately).See
ProBellSystemInformation,page5forallsystem
connectioninformation.
Manual Manual
ManualAir Air AirController Controller Controller
Electronic Electronic
ElectronicAir Air AirControl Control Control
123A3954D

ControllerConnections
Table Table
Table1 1 1Key Key Keyfor for forCable Cable CableConnections, Connections, Connections,Electrical Electrical Electricalor or orManual Manual ManualAir Air AirController Controller Controller
Ref. Ref.
Ref.Port Port
PortLabel Label LabelLabel Label Label
Color Color
Color
Description Description
Description
AMountingholesforpowersupply.
AUX-APorts1–3BlackAuxiliaryAirPorts—Use4mm(5/32in)tubing.
AUX-E BlackAuxiliaryportforoptionaloptocouplerwiring.
B RedBearingAir—Use8mm(5/16in)ODtube.
BR RedBearingAirReturn—Use4mm(5/32in)tubing.
CAN
BlackGracoCAN/Power(24VDC)
DT WhiteDumpValveTrigger—Use4mm(5/32in)tubing.
MA BlackMainAirPort—1/2in.npt
PT
GreenPaintValveTrigger—Use4mm(5/32in)tubing.
SI
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GrayShapingAirInner—Use8mm(5/16in.)tubing.
SO
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BlueShapingAirOuter—Use8mm(5/16in.)tubing.
ST
BlackSolventTrigger(CupWash)—Use4mm(5/32in)tubing.
TA BrownTurbineAir—Use8mm(5/16in.)tubingwith1mm(0.04in)wallto
minimizepressuredrop.
3A3954D13

ControllerConnections
Connect Connect
ConnectAir Air AirLines Lines Lines
GracoAirControllersarelabeledwiththesame
referencelettersastheapplicator,foreasier
matching.
NOTICE NOTICE
NOTICE
Use󰘰lteredairtopreventcontaminationofthe
paint󰘰nishandtopreventdamagetotheair
bearing.Airthatisnotadequately󰘰lteredcanclog
bearingairpassagesandcausebearingfailure.
TheProBellRotaryApplicatorManualcontains
detailed󰘰lteringspeci󰘰cations.
Note
Fortheturbineair(TA),bearingair(B),
shapingairinner(SI)andshapingairouter
(SO)lines,use8mm(5/16in)ODtubewith
1mm(0.04in)wall.Forthebearingairreturn
(BR)andthethreetriggers(DT,PT,andST),
use4mm(5/32in)tube.
NOTICE NOTICE
NOTICE
Takegreatcaretoconnecttheairlinestothe
correctports.Incorrectairlineconnectionswill
damagetheapplicator.
1.Connectallninerequiredairlinestothe
applicator󰘰rst.Seeyourapplicatormanualfor
instructions.
2.Air Air
AirActivation Activation ActivationSignal Signal SignalLines Lines Lines(DT, (DT, (DT,PT, PT, PT,ST): ST): ST):Connect
thelinesthatprovideairactivationsignalsforthe
dumpvalve(DT),thepaintvalve(PT)andthe
solventvalve(ST).
3.Shaping Shaping
ShapingAir Air AirLines Lines Lines(SI, (SI, (SI,SO): SO): SO):Connectthelines
thatprovidetheshapingairinner(SI)andthe
shapingairouter(SO).
4.Turbine Turbine
TurbineAir Air Air(TA), (TA), (TA),Bearing Bearing BearingAir Air Air(B), (B), (B),and and andBearing Bearing BearingAir Air Air
Return Return
Return(BR): (BR): (BR):
•Electronic Electronic
ElectronicAir Air AirController: Controller: Controller:Connecttheseairline
totheGracospeedcontroller(ifpresent)orto
anotheraircontroldeviceinyoursystem.
•Manual Manual
ManualAir Air AirController: Controller: Controller:Connecttheseairlines
totheportswiththematchinglabels.
5.Connectthemainairsupplylineintothemainair
󰘰tting(MA,Ref.7)onthesideofthebox.
Note
Oncetheairisapplied,itwill󰘱owfreely
outPortB.Thecontrollerhasnooption
toturnthisairoff.(ManualController
only)
Connect Connect
ConnectCommunication Communication CommunicationCables Cables Cables
Theaircontrollers(ManualorElectronic)
communicatetotherestofthesystemoverGraco
CANcables.Eachcomponentandthepowersupply
mustbeontheGracoCANnetwork.Thebest
connectionpatterndependsonwhethertheAir
Controlleriselectronicormanual.
1.ConnectaGracoCANcablefromthesystem
logiccontroller(DD)totheelectrostaticcontroller
(EE)ordirectlytotheelectronicaircontrol(BB)
fornon-electrostaticsystems.
2.IfthepowersupplyisattachedtotheAir
Controller,installtheterminationresistor(201)
onthesplitterinsidethebox.
Note
IftheAirControllerwaspurchasedas
partofasystem,theterminationresistor
willbeinstalledatthefactory.Ifnot,the
resistorcomeswiththepowersupply.
3.ManualAirController:
a.ConnectaGracoCANcablefromthepower
supply(AA)totheright(inside)portonthe
AirController(BB).
b.ConnectaGracoCANcablefromthe
otherportontheAirController(BB)tothe
ElectrostaticController(CC).
4.ElectronicAirController(withSpeedController):
a.ConnectaGracoCANcablefromthepower
supply(AA)tothelower/rearportonthe
SpeedController(EE).
b.ConnectaGracoCANcablefromtheSpeed
Controller(EE)totheAirController(BB).
c.ConnectaGracoCANcablefromtheAir
Controller(BB)totheElectrostaticController
(CC).
143A3954D

ControllerConnections
One One
OneGun Gun GunWiring Wiring Wiring
Note
Forsystemswithoutanelectrostaticcontroller(CC),connectthesystemlogiccontrollerdirectlytoan
openCANportoneitherthespeedcontroller(EE)orelectronicaircontroller(BB).
Two Two
TwoGun Gun GunWiring Wiring Wiring
Othercon󰘰gurations(notshown)arepossible.FollowtheseruleswhenbuildingtheCANnetwork.
•Connectcontrollersinseries.
•Aterminationresistormustbeinstalledonthe
powersupplyport.
•Removeanyotherterminationresistorsfromthe
system.
•SetIDsonallboxes.
3A3954D15

ControllerConnections
Connect Connect
ConnectPower Power Power
OnepowersupplyisrequiredintheGracoCAN
network,typicallymountedonthebottomofthe
SpeedController,ortheManualAirController.
1.Connectapowercordtothepowersupply
connector.AcordsuitableforuseinNorth
Americaisprovidedwiththepowersupply.See
TechnicalSpeci󰘰cations,page41.Thepower
supplyissoldseparatelyfromtheaircontrollers,
butincludedinsystempurchases.
2.ConnecttheotherendofthecordtoACpower.
SeeTechnicalSpeci󰘰cations,page41,formore
information.
Set Set
SetAir Air AirControl Control ControlIdentity Identity Identity
Theaircontrollercomespresetfromthefactoryto
controloneapplicator.Intwo-applicatorsystems,the
identityofthecontrolmodulemustbesetinorderto
communicatewiththesystemproperly.
1.Removeplug(24)toaccesscontrolmodule
rotaryswitchbypushingfromtheinsideofthe
boxwithascrewdriver.
2.Usingascrewdriver,setthecontrolmodule
rotaryswitchto“1”fortheaircontrollerthat
controlsthesecondapplicator.
3.Replacetheplug.
4.Restartthesystembyremovingandreapplying
power.
Wiring Wiring
Wiringthe the thePaint Paint PaintTrigger Trigger TriggerInput Input Input
ThePaintTriggerInputprovidesameanstosignal
theSystemLogicControllertoactivatethepaint
triggersolenoid.Thisnormallyopen(maintained)
contactprovidesasignaltothesystemtoindicate
whetherornottotriggerspraydeviceorspraydevice
istriggered(InputOnly).IftheinputisOPENthe
systemdeactivatespainttriggersolenoid.Theinput
mustbemaintainedCLOSEDtoactivatepainttrigger
solenoid.
Note
ThePaintTriggerdiscreteinputmustbe
enabledontheSystemLogicController.Ifit
issetto’Local’or‘Network’,thediscreteinput
isignoredandthespraydevicetriggersignal
ishandledviathenetworkcommunications,
ormanually.SeeSystemLogicController
manual3A3955.
ThePaintTriggerInputusesanoptocouplerto
protecttheGracoProBellaircontrolboxfromoutside
voltages.
•Optocouplerports13+and14arewiredtothe
controlmodule.
•OptocouplerportsA1+andA2-arewiredtothe
externaldeviceorPLC.
Applythe24VDCsignaltoA1+andGNDtoA2–.
OnlyoneA2–portneedstobeconnectedtoGND,as
thetwoportslabeledA2–areconnectedinternally.
A1+ A1+
A1+(relative (relative (relativeto to toA2–) A2–) A2–)Function Function
Function
24VDCPaintTriggerActive
Lessthan13.5VDCPaintTrigger
Inactive
163A3954D

ControllerConnections
Wiring Wiring
Wiringthe the theOptional Optional OptionalInterlock Interlock InterlockInput Input Input
TheOptionalInterlockInputprovidesameans
tosignaltheSystemLogicControllertostopthe
ProBellsystem.Thisnormallyopencontactturns
theapplicatoroffwhenactivated.IftheProBellair
controllerreadstheinputasCLOSEDitinterrupts
systemoperationandputsthegunintoGunOff
mode.IftheinputisreadasOPEN,thesystem
operatesnormally.
Theoptionalinterlockoptocouplerdoesnotcome
pre-installedandmustbepurchasedandinstalled
separately.Installkit24Z226tousetheOptional
InterlockInput.
ForeachProBellAirController,theInterlockInputis
ondifferentterminalblocks.Removethewiresinthe
existingterminalblocksandinstallintheOptocoupler
portsasshownbelow.
Terminal Terminal
TerminalBlock Block Block
Manual Manual
ManualAir Air Air
Controller Controller
Controller
Electronic Electronic
ElectronicAir Air Air
Controller Controller
Controller
Optocoupler Optocoupler
Optocoupler
Port Port
Port14 14 14
98
Optocoupler Optocoupler
Optocoupler
Port Port
Port13+ 13+ 13+
109
NOTICE NOTICE
NOTICE
Topreventdamagetoequipment,donotusethese
terminalblockswithoutanoptocouplerpresent.
TheOptionalInterlockInputusesanoptocouplerto
protecttheGracoProBellaircontrolboxfromoutside
voltages.
•Optocouplerports13+and14arewiredtothe
controlmodule.
•OptocouplerportsA1+andA2-arewiredtothe
externaldeviceorPLC.
Applythe24VDCsignaltoA1+andGNDtoA2–.
OnlyoneA2–portneedstobeconnectedtoGND,as
thetwoportslabeledA2–areconnectedinternally.
A1+ A1+
A1+(relative (relative (relativeto to toA2–) A2–) A2–)Function Function
Function
24VDCInterlockActivated
(systemstop)
Lessthan13.5VDCInterlockInactive
(systemrun)
3A3954D17

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
Table Table
Table2 2 2Control Control ControlModule Module ModuleLED LED LEDDiagnostics Diagnostics Diagnostics
Module Module
ModuleStatus Status StatusLED LED LEDSignal Signal SignalDiagnosis Diagnosis
DiagnosisSolution Solution
Solution
GreenonThesystemispoweredup.———
YellowInternalcommunicationisinprogress.———
RedsolidHardwarefailureReplacethemodule.
Red󰘱ashingfastThesystemisuploadingsoftware.———
Red󰘱ashingslowTokenerrorRemovethetokenand
uploadthesoftwaretoken
again.
Table Table
Table3 3 3Communication Communication CommunicationErrors Errors Errors
Code Code
CodeEvent Event
Event
Type Type
Type
Name Name
NameDescription Description DescriptionSolution Solution
Solution
CAP1
or
CAP2
AlarmCommu-
nication
ErrorAir
Control
TheSystemLogic
Controllerhaslost
communication
withtheair
controller.
•VerifyGracoCANconnectiononbottomoftheAir
Controller.
•CheckstatusLEDsonthecontrolmodule.
•Cyclepower.
CA00AlarmCom-
munica-
tionEr-
rorLogic
Con-
troller
SystemLogic
Controller
communication
hasbeenlost.
VerifyGracoCANconnectionontheSystemLogic
Controller
CDP1
or
CDD2
AlarmDuplicate
AirCon-
troller
TheSystem
LogicController
identi󰘰estwo
ormoreair
controllersset
tothesamegun.
•TheaircontrollerhasthesameCANIDasanother
module.
•AdjusttheselectorswitchontheControlModule.See
SetAirControlIdentity,page16forinstructions.
WSC1
or
WSC2
AlarmIncorrect
AirCon-
trolCon-
󰘰guration
Theaircontrol
identi󰘰esaV2P
feedbacksignal
onaManualAir
Controller.
•Verifythattheaircontroltypeiscorrect.Seethe
GunScreen2sectionoftheProBellSystemLogic
Controllermanual3A3955.
•Replacethecontrolmoduleifneeded.
183A3954D

Troubleshooting
Table Table
Table4 4 4Electronic Electronic ElectronicShaping Shaping ShapingAir Air AirErrors Errors Errors
Code Code
CodeEvent Event
Event
Type Type
Type
Name Name
NameDescription Description DescriptionSolution Solution
Solution
P111or
P112
AlarmPressureLow,
Air1(Inner)
Actualairpressure1
islowerthanthealarm
limitforlongerthanthe
alarmtime(assetonGun
Screen2).
Verifyshapingair1(inner)hoseisnot
cutorsplit.
P121or
P122
AlarmPressureLow,
Air2(Outer)
Actualairpressure2
islowerthanthealarm
limitforlongerthanthe
alarmtime(assetonGun
Screen2).
Verifyshapingair2(outer)hoseisnot
cutorsplit.
P211or
P212
Devia-
tion
PressureLow,
Air1(Inner)
Actualairpressure1is
lowerthanthedeviation
limitforlongerthanthe
deviationtime(asseton
GunScreen2).
Verifyshapingair1(inner)hoseisnot
cutorsplit.
P221or
P222
Devia-
tion
PressureLow,
Air2(Outer)
Actualairpressure2is
lowerthanthedeviation
limitforlongerthanthe
deviationtime(asseton
GunScreen2).
Verifyshapingair2(outer)hoseisnot
cutorsplit.
P311or
P312
Devia-
tion
Pressure
High,Air1
(Inner)
Actualairpressure1is
higherthanthedeviation
limitforlongerthanthe
deviationtime(asseton
GunScreen2).
P321or
P322
Devia-
tion
Pressure
High,Air2
(Outer)
Actualairpressure2is
higherthanthedeviation
limitforlongerthatthe
deviationtime(asseton
GunScreen2).
P411or
P412
AlarmPressure
High,Air1
(Inner)
Actualairpressure1is
higherthanthealarm
limitforlongerthanthe
alarmtime(assetonGun
Screen2).
P421or
P422
AlarmPressure
High,Air2
(Outer)
Actualairpressure2is
higherthanthealarm
limitforlongerthanthe
alarmtime(assetonGun
Screen2).
•Calibratethevoltagetopressure
regulator.SeetheSystemLogic
Controllermanual.
•Verifyairtubingisconnectedproperly.
•Verifycableconnectionbetween
voltagetopressure(V2P)regulator
andconnector6onthecontrol
module.Retrycalibration.
•ReplacetheV2Pregulator.
P511or
P512
AlarmCalibration
Error,Inner
ShapingAir
Thereturnedvalueof
theinnershapingair
calibrationisoutofrange.
P521or
P522
AlarmCalibration
Error,Outer
ShapingAir
Thereturnedvalueof
theoutershapingair
calibrationisoutofrange.
•Relieveinletairpressure.Retry
calibration.SeeSystemLogic
Controllermanual.
•Verifycableconnectionbetween
voltagetopressure(V2P)regulator
andconnector6onthecontrol
module.Retrycalibration.
•Replacecable17K902.
•Replacevolltagetopressureregulator
3A3954D19

Troubleshooting
Code Code
CodeEvent Event
Event
Type Type
Type
Name Name
NameDescription Description DescriptionSolution Solution
Solution
P611or
P612
AlarmSensor
Disconnected,
InnerShaping
Air
Thereturnedvalueofthe
pressuresensorforinner
shapingairiszero
P6Y1or
P6Y2
AlarmSensor
Disconnected,
OuterShaping
Air.
Thereturnedvalueofthe
pressuresensorforouter
shapingairiszero.
•Replacecable17K902.
•Replacevolltagetopressureregulator
Table Table
Table5 5 5Solenoid Solenoid SolenoidErrors Errors Errors
Code Code
CodeEvent Event
Event
Type Type
Type
Name Name
NameDescription Description DescriptionRemedy Remedy Remedy
WJ31
or
WJ32
AlarmPaintSolenoid
Removed
Systemdoesnotdetectthe
PaintTriggersolenoid.
Electronic: Electronic:
Electronic:Verifywiringonterminals1
and3.Manual: Manual:
Manual:Verifywiringonterminals
1and2.
WJ41
or
WJ42
AlarmDump
Solenoid
Removed
Systemdoesnotdetectthe
DumpTriggersolenoid.
Electronic: Electronic:
Electronic:Verifywiringonterminals4
and5.Manual: Manual:
Manual:Verifywiringonterminals
5and6.
WJ51
or
WJ52
AlarmCupWash
Solenoid
Removed
Systemdoesnotdetectthe
CupWashsolenoid.
Electronic: Electronic:
Electronic:Verifywiringonterminals6
and7.Manual: Manual:
Manual:Verifywiringonterminals
7and8.
WJ61
or
WJ62
AlarmInnerShaping
AirSolenoid
Removed
Systemdoesnotdetect
theShapingAir1(inner)
solenoid.
Electronic: Electronic:
Electronic:Verifywiringonterminals
13and14.Manual: Manual:
Manual:Verifywiringon
terminals17and18.
WJ71
or
WJ72
AlarmOuterShaping
AirSolenoid
Removed
Systemdoesnotdetect
theShapingAir2(outer)
solenoid.
Electronic: Electronic:
Electronic:Verifywiringonterminals
20and21.Manual: Manual:
Manual:Verifywiringon
terminals20and21.
WJ81
or
WJ82
AlarmTurbineAir
Solenoid
Removed
Systemdoesnotdetect
theTurbineAirsolenoid,
ManualAirController.
Manual: Manual:
Manual:Verifywiringonterminals3and
4intheManualAirController.
WJ91
or
WJ92
AlarmAuxiliary1
Solenoid
Removed
Systemdoesnotdetectthe
Auxiliary1solenoid.
Electronic: Electronic:
Electronic:Verifywiringonterminals
27and28.Manual: Manual:
Manual:Verifywiringon
terminals23and24.
WJA1
or
WJa2
AlarmAuxiliary2
Solenoid
Removed
Systemdoesnotdetectthe
Auxiliary2solenoid.
Electronic: Electronic:
Electronic:Verifywiringonterminals
29and30.Manual: Manual:
Manual:Verifywiringon
terminals25and26.
WJB1
or
WJB2
AlarmAuxiliary3
Solenoid
Removed
Systemdoesnotdetectthe
Auxiliary3solenoid.
Electronic: Electronic:
Electronic:Verifywiringonterminals
31and32.Manual: Manual:
Manual:Verifywiringon
terminals27and28.
Table Table
Table6 6 6Bearing Bearing BearingAir Air AirPressure Pressure PressureErrors Errors Errors(Manual (Manual (ManualAir Air AirController Controller ControllerOnly) Only) Only)
Code Code
CodeEvent Event
Event
Type Type
Type
Name Name
NameDescription Description DescriptionSolution Solution
Solution
P9P1
or
P9P2
AlarmAirControl
PressureLow
AirControllernolonger
detectsbearingair.
(Manualaircontroller
only.)
Verifythatinletairpressureand󰘱oware
suf󰘰cient.
203A3954D