Graco ProBell Electrostatic Controller Parts list manual

Instructions and Parts
ProBell® Electrostatic Controller 3A3657C
EN
For controlling a ProBell rotary applicator as part of a paint coating system. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
Important Safety Instructions
Read all warnings and instructions in this manual and in your
ProBell® Rotary Applicator manual. Save these instructions.
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Models............................................................... 3
Approved System Components ........................... 3
Related Manuals ................................................ 3
Warnings ........................................................... 4
Introduction ........................................................ 7
Controller Features and Options .......................... 7
Installation.......................................................... 7
Interlocks..................................................... 7
Installation Options ...................................... 9
Pre-Installation Steps.......................................... 14
Ventilate the Spray Booth ............................. 14
Install the Rotary Applicator .......................... 14
Interlock the Isolation Enclosure
(Waterborne Only) .......................... 14
Mount the Controller ........................................... 15
Location ...................................................... 15
Mounting ..................................................... 15
Grounding ................................................... 16
Controller Connections........................................ 17
Overview..................................................... 17
Connections ................................................ 18
Discrete I/O........................................................ 20
Isolation ...................................................... 20
I/O Grounding.............................................. 20
Remote Input Operation ............................... 20
Remote Output Operation............................. 20
Discrete I/O in CAN Mode ............................ 20
Signals........................................................ 21
Analog Inputs .............................................. 25
Analog Outputs............................................ 25
Digital Inputs................................................ 26
Digital Outputs ............................................. 26
Discrete I/O Interface Connections................ 27
Operation Modes and Timing Diagrams ............... 28
Standby Mode ............................................. 29
Safe Position Mode...................................... 30
Spray Mode................................................. 32
Error Handling Mode .................................... 34
Purge Mode................................................. 36
Controller Display and Features........................... 38
Screen Areas............................................... 38
Icons...........................................................38
Input Keys and Switches .............................. 39
Additional Features ...................................... 39
Setup................................................................. 41
Setup Screen 0 (System Type) ..................... 43
Setup Screen 1 (Electrostatics Control
Mode) ............................................ 43
Setup Screen 2 (Remote Interface) ............... 44
SetupScreen3(AnalogInputType
Select) ........................................... 45
Setup Screen 4 (Analog Output Type
Select) ........................................... 45
Setup Screen 5 (Digital Output Type
Select) ........................................... 46
Setup Screen 6 (CAN Purpose ID) ................ 46
Setup Screen 7 (Log Level) .......................... 47
Setup Screen 8 (Averaging Interval).............. 47
Setup Screen 9 (Blanking Time).................... 48
Setup Screen 10 (Discharge Timer) .............. 48
Setup Screen 11 (Transition Time)................ 49
Operation........................................................... 50
System Start-up........................................... 50
Presets........................................................ 50
Run Screen 1 (Electrostatic Readings)........... 51
Run Screen 2 (Arc Limits)............................. 52
Run Screen 3 (Maintenance Counters)........... 53
Arc Detection............................................... 54
Screen Map........................................................ 57
Troubleshooting.................................................. 61
Error Codes................................................. 61
Power Cable Continuity ................................ 64
Repair................................................................65
Main Circuit Board, Power Board, LED
Panel or Keypad Membrane
Removal ........................................ 65
Power Supply Board Removal ...................... 67
CAN Board Removal.................................... 67
Software Update .......................................... 68
Parts.................................................................. 69
Dimensions ........................................................ 70
Notes ................................................................ 72
Technical Specifications...................................... 73
Graco Standard Warranty.................................... 74
23A3657C

Models
Models
Controller Description Maximum Voltage Output at Applicator
24Z098 ProBell®Electrostatic Controller, solventborne 100 kV
24Z099 ProBell®Electrostatic Controller, waterborne 60 kV
Approved System Components
Specific Electrostatic Controllers, applicator models, and power cables must be used together. Refer to
the table below for compatible models.
Model Electrostatic
Controller
Power Supply Cables Product Type System
Approvals
17J586
17J588
RxAxx0 24Z098
17J589
Solventborne
17J586
17J588
RxAxx8 24Z099
17J589
Waterborne
Related Manuals
Manual
No.
Description
334452 ProBell®Rotary Applicator,
Instructions/Parts
334626 ProBell®Rotary Applicator, Hollow
Wrist, Instructions/Parts
3A3953 ProBell®Speed Controller
3A3954 ProBell®Air Controller
3A3955 ProBell®System Logic Controller
3A4232 ProBell®Cart Systems
3A4346 ProBell®Hose Bundles Kit
3A4384 ProBell®System CGM Installation Kit
3A4738 ProBell®Reflective Speed Sensor Kit
3A4799A ProBell®Air Filters Kit
3A3657C 3

Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
For waterborne systems:
• Connect the applicator to a voltage isolation system that will discharge the system voltage
when not in use.
• All components of the voltage isolation system that are charged to high voltage must be
contained within an isolation enclosure that prevents personnel from making contact with the
high voltage components before the system voltage is discharged.
• Follow the Pressure Relief Procedure, including Voltage Discharge, in your applicator manual
when instructed to discharge the voltage; before cleaning, flushing, or servicing the system;
before approaching the front of the applicator; and before opening the isolation enclosure for
theisolatedfluidsupply.
• Do not enter a high voltage or hazardous location until all high voltage equipment has been
discharged.
• Do not touch the applicator or enter the spray area during operation. Follow the Pressure
Relief Procedure, including Voltage Discharge, in your applicator manual.
• Interlock the electrostatics controller with the voltage isolation system to shut off the
electrostatics anytime the isolation system enclosure is opened.
• Do not splice fluid hoses together. Install only one continuous Graco Waterborne Fluid Hose
between the isolated fluid supply and the applicator.
43A3657C

Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the system can cause static sparking. To help prevent fire or explosion:
• Electrostatic equipment must be used only by trained, qualified personnel who understand
the requirements of this manual.
• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to
the spray location. Resistance must not exceed 1 megohm. See Grounding instructions.
• Do not use pail liners unless they are conductive and grounded.
• Always use the required arc detection settings and maintain a safe distance of at least 6
inches (152 mm) between the applicator and the workpiece.
•Stop operation immediately if static sparking or repeated arc detection errors occur. Do not
use equipment until you identify and correct the problem.
• Check applicator resistance and electrical grounding daily.
• Use and clean equipment only in a well ventilated location.
•Alwaystu
rn off and discharge the electrostatics when flushing, cleaning or servicing
equipment.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep the spray area clean at all times. Use non-sparking tools to clean residue from the
booth and hangers.
• Keep a working fire extinguisher in the work location.
• Interlock the gun air and fluid supply to prevent operation unless ventilation air flow is above
the minimum required value.
• Interlock the Electrostatic Controller and fluid supply with the booth ventilation system to
disable operation if the air flow falls below minimum values. Follow your local codes.
For solventborne systems only:
Use only Group IIA or Group D materials.
• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment.
•Tocle
an the exterior of the equipment, cleaning solvents must have a flash point at least 15°C
(59°F) above ambient temperature. Non-ignitable fluids are preferred.
For waterborne systems only:
Use conductive waterborne fluids that meet at least one of the following conditions for
non-flammability:
•Mate
rial does not sustain burning in accordance with the Standard Test Method for Sustained
Burning of Liquid Mixtures, ASTM D4206.
•Mate
rial is classified as non-ignitable or hard to ignite as defined by EN 50176.
3A3657C 5

Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Always operate in accordance with all information given in the instruction manuals.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings.
For complete information about your material, request the Safety Data Sheet (SDS) from
distributor or retailer.
•Turnoffal
l equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Donotkin
k or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work location.
• Comply with all applicable safety regulations.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work location to help prevent serious
injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns.Thisprotective
equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
63A3657C

Introduction
Introduction
The Electrostatic Controller is designed exclusively
for controlling a ProBell rotary applicator as part of
a paint coating system.
The controller sends power to the applicator power
supply, which increases the voltage to the level set at
the controller. The fluid is charged by the applicator.
The charged fluid is attracted to the nearest grounded
object, wrapping around and evenly coating all
surfaces.
Controller Features and Options
•Thefullv
oltage setting is 100 kV for solventborne
models and 60 kV for waterborne models.
•Thecontr
oller can be mounted on the cart or wall
mounted. See Mounting, page 15.
The Electrostatic Controller provides the ability to:
• Display and set the voltage and current.
• Create and store spray presets.
• Operate the applicator electrostatics remotely via
discrete I/O or Graco CAN.
The controller has three interlocks. These interlocks
must be satisfied before the controller will operate.
Check and follow all National, State, and Local
codes regarding properly interlocking your spray
system. Other interlocks will be required. See
Interlocks, page 7 .
Installation
Interlocks
Interlocks are required to ensure that the system is
safe to operate. The controller can use internal or
external signals to receive verification that monitored
interlock conditions are in a state that is safe for the
system to operate.
•Electrostatic controller and solvent trigger:
Interlock so that solvent will not flow when the
electrostatics are on.
•Electrostatic controller and all doors or openings
in the spray area: Interlock so the electrostatics
turn off and are fully discharged before live parts
can be reached.
•Conveyor and paint trigger/electrostatics: Interlock
so the rotary applicator stops spraying and the
electrostatics turn off if the conveyor stops moving.
•Electrostatic controller and ventilation fans:
Interlock so the electrostatics turn off any time
the ventilation air flow falls below the minimum
required value. Follow local codes.
•Electrostatic Controller and Fluid Supply: Interlock
so the fluid supply shuts off in the event of a
controller fault.
•Electrostatic controller and fire control system:
Interlock so the electrostatics turn off any time the
automatic fire extinguishing system is activated.
Check interlock function every 6 months.
•Electrostatic controller and waterborne isolation
system (for waterborne systems): Interlock so
the electrostatics turn off and are fully discharged
before live parts can be reached. Check interlock
function weekly.
The following table shows how to use the Electrostatic
Controller for each interlock. The table also explains
how to bypass the interlock if the requirement is
being satisfied in another manner.
If other forms of interlock are implemented that
preclude the need to use the controller interlocks, the
controller interlocks can be disabled.
3A3657C 7

Installation
Table 1 Electrostatic Interlock Information
Interlock Pin Description
System
Interlock
Input power
cord, Pin 3
(wire 3)
Pin 3 on the Input Power Connection requires line voltage to be applied for
electrostatics to be active. See Step 2 in Connections, page 18.Thispincanbe
used to connect to safety interlock devices using line power.
If not required, bypass the interlock by connecting wire 3 to line voltage onthe
Input Power cord. The icon is displayed on the controller screen when
the System Interlock is satisfied. See Screen Areas, page 38.
24 VDC
Interlock
Discrete
I/O cable,
pin 19
Pin 19 on the Discrete I/O Cable Connection requires 24 VDC to be applied for
electrostatics to be active. This pin can be used to connect to an external device,
such as a ventilation interlock signal to the controller. Input signal values are:
0 (0 VDC or GND): Interlock not satisfied; electrostatics disabled
1 (24 VDC): interlock satisfied; electrostatics activation is not locked by
this input.
If not required, apply a constant 24 VDC to Pin 19, or see
Disable Controller Interlocks, page 9 .
Symbol A9 on the display screen (see Screen Areas, page 38) will show that
this signal is satisfied.
SAFE
POSITION
Interlock
Discrete
I/O cable,
pin 18
Pin 18 on the Discrete I/O Cable Connection requires 24 VDC to be applied
for electrostatics to be active. Apply only when the applicator is in SAFE
POSITION. See Safe Position Mode, page 30. If electrostatics are on, removing
24 VDC from this pin will not deactivate the electrostatics.
0 (0 VDC or GND): Interlock not satisfied; If electrostatics are off,
electrostatics disabled. If electrostatics are on, no change to electrostatics.
1 (24 VDC): Interlock satisfied; electrostatics activation is not locked by
this input.
If not required, apply a constant 24 VDC to Pin 18, or see
Disable Controller Interlocks, page 9 .
Symbol A10 on the display screen (see Screen Areas, page 38) will show that
this signal is satisfied.
83A3657C

Installation
Disable Controller Interlocks
If interlock requirements have been satisfied in
your system by means other than the Electrostatic
Controller, the controller interlocks can be disabled.
NOTICE
To avoid damaging the circuit boards when
servicing the control box, wear Part No.
112190 grounding strap on your wrist. Ground
appropriately each time
1. To disable the system interlock, connect wire 3
on the controller input power cord to line voltage.
The icon will be lit on the display screen.
2. Remove power from the controller.
3. Remove 4 screws and take off the access cover.
4. Locate the interlock switches on the main board.
Move the switches to the ON position, which
means the interlocks are considered satisfied.
Switch 1 is the 24 VDC Interlock (pin 19 on
theDiscreteI/Ocable). Switch2istheSAFE
POSITIONInterlock(Pin18ontheDiscreteI/O
cable).
Symbols in A9 and A10 (see
Screen Areas, page 38) on the display
screen will show that these signals are satisfied.
ON
GOHO2
Interlock switches are shown in the OFF position.
Installation Options
Installing and servicing this equipment requires
access to parts which may cause fire, explosion,
electric shock or other serious injury if work is not
performed properly.
• Do not install or service this equipment unless
you are trained and qualified.
• Be sure your installation complies with national,
state, and local codes for the installation of
electrical apparatus in a Class I, Division 1, or a
Group II, Zone 1 Hazardous Location.
• Comply with all applicable local, state, and
national fire, electrical, and other safety
regulations.
Installation details vary widely depending on the
system requirements. This section shows three
typical installations. They are not actual system
designs. For assistance in designing a system to suit
your particular needs, contact your Graco distributor.
3A3657C 9

Installation
No Integration
To reduce the risk of fire and explosion, the
controller (A) must be electrically interlocked with
the spray booth ventilation fans to prevent the
applicator from operating unless ventilation air flow
is above the minimum required value.
The defining characteristics of a No Integration
installation include:
• No integration of the rotary applicator or the
Electrostatic Controller.
• Local operation using the Electrostatic Controller
interface.
• Interlocks managed independently of the applicator
installation.
Non-Hazardous Location Hazardous Location
KEY:
AElectrostatic Controller
BElectrostatic Controller
Ground Wire
CElectrostatic Controller
Power Cord
EPower Supply Cable
FRotary Applicator
JPaint Supply Line
KDump Return Line
LSolvent Supply Line
MFluid Supply (isolation
equipment needed for
waterborne applications
only)
NFluid Supply Grounding
Wire
RAir Lines
Typical Installation With No Integration
10 3A3657C

Installation
Basic Integration
To reduce the risk of fire and explosion, the
Electrostatic Controller (A) must be electrically
interlocked with the spray booth ventilation fans
to prevent the applicator from operating unless
ventilation air flow is above the minimum required
value.
The defining characteristics of a Basic Integration
installation include:
• Integration of basic applicator and controller
functions.
• Integration of controller interlocks.
• Local operation of setup and error functions.
This example shows a basic integration that uses 6
of the 19 signals available on the Discrete I/O cable.
•Preset Select 1 (Pin 1) and Preset Select 2 (Pin 2):
Used to select Presets P000-P003. For example:
Select Preset P002 by applying 24V to Pin 2 and
Ground or no connection to Pin 1.
•Remote Enable/Disable (Pin 4): Enable remote
control through the Discrete I/O interface by
applying 24V to Pin 4.
•Electrostatic Enable (Pin 5): Use a switched
voltage source for Pin 5 to activate/trigger the
electrostatics.
•GND (Pins 8, 12, 17): Used as ground reference
for I/O signals.
•Interlocks: See Interlocks, page 7 , for information
on how to set up the required interlocks.
Non-Hazardous Location HazardousLocation KEY:
AElectrostatic Controller
BElectrostatic Controller
Ground Wire
CElectrostatic Controller
Power Cord
DDiscrete I/O Cable
EPower Supply Cable
FRotary Applicator
JPaint Supply Line
KDump Return Line
LSolvent Supply Line
MFluid Supply (isolation
equipment needed for
waterborne applications
only)
NFluid Supply Grounding
Wire
Typical Installation With Basic Integration
PDiscrete I/O Signals
RAir Lines
3A3657C 11

Installation
PLC Integration
To reduce the risk of fire and explosion, the
Electrostatic Controller (A) must be electrically
interlocked with the spray booth ventilation fans
to prevent the applicator from operating unless
ventilation air flow is above the minimum required
value.
The defining characteristics of a PLC (Programmable
Logic Controller) Integration installation include PLC
integration of all applicator and controller functions.:
See Discrete I/O, page 20, for a complete description
of the signals.
KEY:
AElectrostatic Controller
BElectrostatic Controller Ground Wire
CElectrostatic Controller Power Cord
DCAN Cable
EPower Supply Cable
FRotary Applicator
GPLC Communication Protocol Cable
HApplicator Grounding Wire
JPaint Supply Line
KDump Return Hose
LSolvent Supply Line
MFluid Supply (isolation equipment needed for waterborne applications only)
NFluid Supply Grounding Wire
PPLC (connected to Gateway inside speed controller box)
RAir Lines
TAdvanced Display Module (System Logic Controller)
UAir Controller
VAir Controller Grounding Wire
WSpeed Controller
XSpeed Controller Grounding Wire
YPower Supply
ZPower Supply Power Cord
123A3657C

Installation
Non-Hazardous Location Hazardous Location
Typical Installation With PLC Integration
3A3657C 13

Pre-Installation Steps
Pre-Installation Steps
Ventilate the Spray Booth
Provide fresh air ventilation to avoid the buildup of
flammable or toxic vapors when spraying, flushing,
or cleaning the applicator. Do not operate the
applicator unless ventilation air flow is above the
minimum required value..
Electrically interlock the Electrostatic Controller (A)
with the ventilators to prevent applicator operation
unless ventilation air flow is above the minimum
required value. Use the 24 VDC Interlock pin on
the Discrete I/O cable to connect to the ventilator
interlock. Check and follow all National, State,
and Local codes regarding air exhaust velocity
requirements.
NOTE: High velocity air exhaust will decrease the
operating efficiency of the electrostatic system. The
minimum allowable air exhaust velocity is 60 ft/minute
(19 linear meters/minute).
Install the Rotary Applicator
See the Rotary Applicator Manual (334452 or
334626) for installation instructions.
Interlock the Isolation Enclosure
(Waterborne Only)
To reduce the risk of electric shock, interlock the
Electrostatic Controller with the voltage isolation
system to shut off the electrostatics anytime the
isolation system enclosure is opened.
For information about the interlocks and their use,
see Interlocks, page 7 .
143A3657C

Mount the Controller
Mount the Controller
To reduce the risk of fire or explosion, do not install
equipment approved only for a non-hazardous
location in a hazardous location.
Location
Install the Electrostatic Controller in a non-hazardous
location only.
Mounting
The Electrostatic Controller can be mounted on the
cart or wall mounted.
Wall Mount (Flat Panel)
An optional method of mounting the controller is to
use a panel with a cutout and mounting holes.
1. See Dimensions, page 70.
2. Determine the mounting location. Ensure that
the location will support the mounting panel and
the controller.
3. Prepare the panel by cutting out the opening and
preparing the mounting holes for the controller:
a. If the two controller front panel screws are to
be used to attach the controller to the panel,
the panel holes will require tapping threads,
or providing some other sort of threaded
fastener, such as PEM nuts on the panel.
b. If an alternative fastener will be used, it may
be necessary to back out the two threaded
fasteners from the controller front cover so
that the mounting hardware can use the
existing controller front panel mounting holes.
Wall Mount (Mounting Bracket)
An optional wall mount bracket (17H288) is available
to mount the controller on any flat wall.
1. See Dimensions, page 70.
2. Determine mounting location. Ensure that the
wall is strong enough to support the weight of the
mounting bracket and the controller.
3. Position the mounting bracket on the wall and
mark mounting holes using the plate of the
bracket as a template.
4. Drill holes and attach the mounting bracket to the
wall.
5. Attach the controller to the wall mount bracket
using two 6 mm screws (provided).
3A3657C 15

Mount the Controller
Grounding
When operating the electrostatic applicator, any
ungrounded objects in the spray location (people,
containers, tools, etc.) can become electrically
charged. Improper grounding can result in static
sparking, which can cause a fire, explosion, or
electric shock. Ground all equipment, personnel,
object being sprayed, and conductive objects in or
close to the spray location. Follow the grounding
instructions below.
The following are minimum grounding requirements
for a basic electrostatic system. Your system may
include other equipment or objects which must
be grounded. Check your local electrical code for
detailed grounding instructions. Your system must be
connected to a true earth ground.
•
Rotary Applicator: Ground the applicator by
connecting the power supply cable to a properly
grounded Electrostatic Controller and connecting
thegroundwiretoatrueearthground.
•
Cart: Use the ground wire and clamp provided to
ground the frame to a true earth ground.
•
Air Controller and Speed Controller: If not mounted
on the Cart, use a ground wire and clamp to ground
to a true earth ground.
•
Electrostatic Controller: Use the ground wire
and clamp provided to ground the Electrostatic
Controller to a true earth ground.
•
Pump: ground the pump by connecting a ground
wire and clamp as described in your separate
pump instruction manual.
•
Voltage Isolation System (for waterborne
systems):
Follow the grounding procedure in the
manufacturer’s instructions.
•
FluidHose(f
or waterborne systems only):
The
hose is grounded through the conductive layer.
•
Air compressors and hydraulic power supplies:
Ground the equipment according to the
manufacturer’s recommendations.
•
All air and fluid lines
must be properly grounded.
•
All electrical cables
must be properly grounded.
•
All persons entering the spray area:
Shoes must
have conductive soles, such as leather; or personal
grounding straps must be worn. Do not wear
shoes with non-conductive soles such as rubber or
plastic. Gloves and other protective clothing must
also be conductive. Resistance must not exceed
100 megohm per EN ISO 20344, EN1149–5.
•
Object being sprayed:
Keep the workpiece hangers
clean and grounded at all times. Resistance must
not exceed 1 megohm.
•
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.
•
Flammable liquids in the spray area:
must be kept
in approved, grounded containers. Do not use
plastic containers. Do not store more than the
quantity needed for one shift.
•
All electrically conductive objects or devices in the
spray location:
including fluid containers and wash
cans, must be properly grounded.
16 3A3657C

Controller Connections
Controller Connections
Overview
AA Back panel EE Discrete I/O Cable Connection — use
in a system that requires integration
BB Enclosure FF Applicator Power Cable Connection
CC Front Plate with control and display
elements
GG Ground Connection
DD Input Power Connection HH CAN Communication Cable
Connections
3A3657C 17

Controller Connections
Connections
1. Connect the ground wire to the ground
connection (GG). Connect the other end to a true
earth ground. This connection is required for all
installations.
2. Connect the supplied controller input power cord
to the input power connection (DD) and secure
with the connector screw. This connection is
required for all installations.
The controller can operate at 100–240 VAC
(50–60 Hz). Connect the leads to a power
source according to local electrical codes. Pin
3ontheinputpower connection is the system
interlock. Pin 3 must have line voltage applied to
satisfy the system interlock. When the system
interlock pin is connected to line voltage, the
icon will appear on the controller. See
Screen Areas, page 38.
3. Connect the 7-pin end of the power cable to the
applicator power cable connection (FF) on the
controller. Connect the 4–pin end of the power
cabletoth
e rotary applicator. Follow instructions
in the rotary applicator manual. This connection
is required for all installations.
Controller Input Power Connection
Pin No. Function Wire Marking
1 Neutral conductor power supply 1
2Phase (100-240 VAC) 2
3System Interlock ON/OFF
(100-240 VAC) = ON
3
Controller Power Cord PE Grounding PE Green/Yellow
Pre-wired Power Cable Connection
Controller Applicator
Connector (F) Cable Cable Power Supply Connector
Electrical Schematic for this cable:
18 3A3657C

Controller Connections
4. Connect the Discrete I/O cable to the Discrete
I/O cable connection (EE) on the controller. The
Discrete I/O cable is required for any installation
that involves integration. Two discrete I/O
interlock connections are supplied and must
be satisfied. (See Interlocks, page 7 .) See
Discrete I/O, page 20, for a more detailed
explanation of each pin.
5. Connect the Graco CAN cables to the CAN
cable connections (HH) on the controller. CAN
communication is required for remote operation
with Graco modules to allow remote configuration
and operation of the controller.
NOTE: CAN communication is Graco proprietary
and will not work with other types of CAN.
NOTE: If CAN communication is used, connect
supplied ferrites to CAN cables near the
electrostatic controller (see below).
Discrete I/O cable Connection
Pin No. Function Wire Color
1Preset Select 1 Input White
2Preset Select 2 Input Brown
3 Error Reset Input Green
4 Remote Enable/Disable Input Yellow
5Electrostatics Enable Input Gray
6Safe-to-Move Output Pink
7Error Output Blue
Controller 8I/O Ground Red
9Current Setpoint Input Black
10 Voltage Setpoint Input Purple
11 Reserved Input Gray/Pink
12 I/O Ground Red/Blue
13 Actual Spraying Current Output White/Green
14 Actual Spraying Voltage Output Brown/Green
15 Electrostatics Discharged Output White/Yellow
16 Output External Power (24 VDC) Yellow/Brown
17 I/O Ground White/Gray
18 SAFE POSITION Interlock Input Gray/Brown
Cable19 24 VDC Interlock Input Pink/Brown
and
Pink/White
See Discrete I/O, page 20 for more information.
3A3657C 19

Discrete I/O
Discrete I/O
The controller can accept up to 19 I/O interface
signals. Systems can be designed to integrate from 1
signal up to all 19 signals.
Discrete I/O input signals are monitored
only if the Electrostatic Controller has
been placed in the Discrete I/O mode. See
Setup Screen 2 (Remote Interface), page 44.
See Signals, page 21 for available signals.
Isolation
ThediscreteI/Ointerfacesignalsareisolatedfrom
circuit ground. Isolation is required to prevent
disturbance of the measurement of the spraying
current.
NOTE: The isolation is not designed to isolate
hazardous potentials.
I/O Grounding
Pins 8, 12, and 17 are the I/O Ground pins. Connect
a ground from each connecting device to one or more
of these pins. This will match the potential of the
Electrostatic Controller and the connecting device.
Remote Input Operation
In order to accept remote input commands from the
discrete I/O interface, the following conditions must
be met:
•Thed
iscrete I/O interface must be selected by
setting Parameter P02 = 1.
See Setup Screen 2 (Remote Interface), page 44.
•TheR
EMOTE Enable input, on the Discrete I/O
cable, pin 4, must have 24 VDC (logical “1”) applied
to it to select REMOTE mode.
Connect the desired input signals. During REMOTE
input operation, error confirmation is the only local
input (using the keypad) possible.
NOTE: Values for presets P001 – P003 must be set
up prior to entering REMOTE mode. Preset P000
is the only preset which can be altered using the
Discrete I/O cable signals when the controller has
been placed in REMOTE mode. Presets P004 - P250
are not accessible in REMOTE mode.
Remote Output Operation
Connect the desired signals. Digital output signals
are generated unconditionally. Output signals require
24 VDC on Output External Power (pin 16) on the
discrete I/O Interface cable.
Discrete I/O in CAN Mode
Following is a list of inputs and outputs when
operating in CAN mode.
• Safe-to-Move Output
• Error Output
• Output External Power (24 VDC)
• Actual Spraying Current Output
• Actual Spraying Voltage Output
• Electrostatics Discharged Output
• SAFE POSITION Interlock Input
• 24 VDC Interlock Input
• System Interlock
• Electrostatic Enable Input
20 3A3657C