Instructions and Parts
ProBell® Air Controllers
3A3954B
EN
For manual or
professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
Important
Read all warnings and instructions in this manual and in your
ProBell® Rotary Applicator manual. Save these instructions.
100 psi (0.7 MPa, 7.0 bar) Maximum Air
Inlet Pressure
electronic air control of a ProBell rotary applicator as part of a paint coating system. For
Safety Instructions
ROVEN QUALITY. LEADING TECHNOLOGY.
P
Contents
Models............................................................... 2
Related Manuals ................................................ 2
Warnings ........................................................... 3
ProBell System Information ................................. 5
System Connections and Features ...................... 6
Component I
Installation.......................................................... 9
Mount the Controller..................................... 9
Ground the Controller................................... 11
Controller Connections........................................ 12
Connect Air Lines......................................... 14
Connect Communication Cables................... 14
Connect Power ............................................ 16
Set Air Control Identity ................................. 16
Wiring the Paint Trigger Input ....................... 16
Wiring the Optional Interlock Input................. 17
Troubles
dentification..................................... 7
hooting.................................................. 18
Models
Model Description
Repair................................................................ 22
Prepare for Service ...................................... 24
Replace the Control Module.......................... 24
Replace a Trigger or Auxiliary Solenoid
Valve ............................................. 27
Replace the Voltage to Pressure (V2P)
Regulator ....................................... 28
Replace A Shaping Air Solenoid Valve........... 29
Replace the Pressure Switch........................ 30
Replace a Pressure Gauge........................... 30
Replace A Pressure Regulator...................... 31
Replace the Bearing Air Filter ....................... 31
Parts.................................................................. 32
Electronic Air Controller (Model
24Z222)......................................... 32
Manual Air Controller (Model 24Z221) ........... 35
Kits and Accessories........................................... 39
Technical Specifications...................................... 41
Graco Sta
ndard Warranty....................................42
Certification
1
24Z22
24Z222
Manual Air Controller
tronic Air Controller
Elec
Related Manuals
al No.
Manu
334452 ProBell®Rotary Applicator, Instructions/Parts
334626 ProBell®Rotary Applicator, Hollow Wrist, Instructions/Parts
657
3A3
3A3953
3A3955
A4384
3
3A4232
3A4346 ProBell®Hose Bundle
3A4738
3A4799A ProBell®Air Filters Kit
ription
Desc
ProBell
oBell
Pr
ProBell
ProBell
ProBell
ProBell
®
Electrostatic Controller
®
Speed Controller
®
System Logic Controller
®
System CGM Installation Kit
®
Cart Systems
®
Relective Speed Detection Kit
2
3A3954B
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
FIRE AND EX
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.
•Donotuse
• 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.
•Checka
• Use and clean equipment only in a well ventilated location.
• Always turn off and discharge the electrostatics when flushing, cleaning or servicing
equipment.
• Elimin
c drop cloths (potential static arc).
plasti
• 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
• 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.
PLOSION HAZARD
pail liners unless they are conductive and grounded.
pplicator resistance and electrical grounding daily.
ate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
working fire extinguisher in the work location.
CTRIC SHOCK HAZARD
ELE
s equipment must be grounded. Improper grounding, setup, or usage of the system can
Thi
se electric shock.
cau
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing or installing equipment.
nect only to grounded power source.
•Con
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
3A3954B 3
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can ca
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed
system compo
• 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.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equi
manufactu
• 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 youareusingit.
• Use equip
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep chil
• 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. This protective
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.
use death or serious injury.
the maximum working pressure or temperature rating of the lowest rated
nent. See Technical Specifications in all equipment manuals.
pment daily. Repair or replace worn or damaged parts immediately with genuine
rer’s replacement parts only.
ment only for its intended purpose. Call your distributor for information.
dren and animals away from work location.
4
3A3954B
ProBell System I
nformation
ProBell Syste
Information
The ProBell Ai
the ProBell R
Air Controll
paint, dump,
electronica
air pressur
all air in th
used to set t
This manual
Controller
troublesh
Rotary App
all system
connect th
system gro
The applic
informat
(3A3955)
the Air Co
r Controller is an optional component in
otary Applicator system. The Electronic
er sends air activation signals for the
and solvent (cup wash) valves. It also
lly controls the inner and outer shaping
es. The Manual Air Controller controls
e system. Manual air regulators are
he turbine and shaping air pressures.
covers information specific to the Air
s. It includes information on installation,
ooting, repair, and parts. See the ProBell
licator manual (334452 or 334626) for
information, including how to install and
e whole system, required interlocks,
unding, and required electrical tests.
ator manual also contains all operation
ion. See the System Logic Controller Manual
for details on how to set up parameters for
ntroller.
m
3A3954B 5
Figure 1 ProBell Electronic Air Controller, shown on
Cart (sold separately)
System Connections and Features
System Connec
Air Line Port Label
B(BearingAi
BK (Braking Air)
BR (Bearing Air Return)
DT (Dump V
PT (Paint Valve Trigger)
SI (Shaping Air Inner)
r)
alve Trigger)
tions and Features
Speed Controller
Connections
* *
* *
Electronic
Air Controller
Connections
Manual Air
Controller
Connections
SO (Sha
ST (Solvent Trigger)
TA (Turbine Air)
Aux
flex
*In
spe
ping Air Outer)
* *
iliary Triggers (for system
ibility)
systems with a speed controller, bearing air, bearing air return, and turbine air must be used from the
ed controller, not the manual air controller.
1, 2, 3,
6 3A3954B
Component Ident
ification
Component Ide
Electronic Ai
r Controller
ntification
Ref. Compo
A
BTerm
C Solenoid Valves — send air activation
D
E
Contr
of al
conn
signals for paint, dump, and solvent valves;
auxiliary signals available for system
flexibility
Air Manifold — directs incoming air to the
controller components
In
of
nent
ol Module — manages the operation
l air controller components
inal Blocks —provide electrical wire
ections
ner Shaping Air Solenoid Valve — shuts
f the flow of the inner shaping air
3A3954B
Ref. Compo
F
G
HVolt
J
Outer
off t
Volt
volt
volt
Optocoupler — isolated input to trigger
paint valve from PLC
nent
Shaping Air Solenoid Valve — shuts
he flow of the outer shaping air
age to Pressure Regulator — converts
age to pressure for the inner shaping air
age to Pressure Regulator — converts
age to pressure for the outer shaping air
7
Component Ident
ification
Manual Air Con
troller
Ref. Component
A
B Terminal Blocks —provide electrical wire
CSole
J
K
L
M
Control Module — manages the operation
of all air controller components
connections
noid Valves — send air activation
als for paint, dump, and solvent valves;
sign
liary signals available for system
auxi
bility
flexi
Pressure Switch — verifies that the bearing
air is at least 70 psi.
High-Flow Remote — piloted regulator for
turbine air
gh-Flow Remote — piloted regulator for
Hi
ner shaping air
in
High-Flow Remote — piloted regulator for
outer shaping air
Ref. Component
N
P
RTurb
S Outer Shaping Air Gauge
T
U
VAir
W
Outer Shaping Air Regulator — air pressure
signal to regulator M
Shaping Air Regulator — air pressure
Inner
l to regulator L
signa
ine Air Regulator — air pressure signal
gulator K
to re
Inner Shaping Air Gauge
Turbine Air Gauge
Filter — supplementary coalescing
filter, protects the bearing from any
air
ticles that get through the main air
par
ering system.
filt
Optocoupler — isolated input to trigger
paint valve from PLC
8 3A3954B
Installation
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.
NOTE: Install the air controller in a non-hazardous
location only.
The air controller can be mounted on the control box
stand or wall mounted. The box comes with four
mounting brackets installed in a vertical orientation.
Remove and turn the brackets if a horizontal
orientation works better for your installation.
Installation
Wall Mounting
The pre-installed mounting brackets can be used to
mount the controller on any flat wall. Mount the Air
Controller in the non-hazardous area, as close to
the applicator as possible to minimize pressure loss
in the air lines.
1. Determine the mounting location. Ensure that
the wall is strong enough to support the weight
of the mounting bracket and the controller. See
Technical Specifications, page 41.
2. See the Dimensions or use the box as a template
to mark the mounting hole locations.
3. Drill holes and use four screws to attach the
controller to the wall.
Electron
ic Air Controller
3A3954B 9
Installation
Manual Air Controller
Cart Mounting
For some ordering options, the air controller will be
mounted on the cart at the factory. If the cart was
ordered separately, follow these steps:
1. Remo
ve the 4 mounting brackets. Turn them so
are oriented horizontally. Reattach them to
they
ir controller box.
the a
2. Use four screws (provided with cart) to mount
the air controller box on the cart in the location
showninFigure1.
10 3A3954B
Installation
Ground the Con
The equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
For full system grounding instructions and
requirements, see your ProBell Rotary Applicator
manual (334452 or 334626). Use the ground wire
and clamp provided to ground the Air Controller to a
true earth ground.
troller
Figure 3 Manual Air Controller Grounding Location
Figure 2 Electronic Air Controller Grounding Location
3A3954B
11
Controller Connections
Controller Co
nnections
Overview
Air control in your ProBell system will use one of the
following common setups:
• All air control is provided by the Graco Manual Air
Controller.
• Air controls are split between the Graco Electronic
Air Controller and the Graco Speed Controller. Be
sure your system includes a power supply (sold
separately) to be mounted on either controller.
Manual Air Controller
• Your system uses some combination of Graco
controllers and your existing devices. Air
control will then require a combination of the
connections shown in the figures and use of
the Auxiliary Triggers. Be sure your system
includes a power supply (sold separately). See
ProBell System Information, page 5 for all system
connection information.
Electronic Air Control
2
1
3A3954B
Table 1 Key for Cable Connections, Electrical or Manual Air Controller
Controller Connections
Ref.
Port Label Label
Description
Color
A
AUX-A Ports 1–3 Black
AUX-E Black
B Red
BR Red
CAN
Black
DT White
Mounting Holes for Power Supply
Auxiliary Ai
r Ports — Use 4 mm (5/32 in) tubing.
Auxiliary port for optional optocoupler wiring.
Bearing Air
— Use 8 mm (5/16 in) OD tube
Bearing Air Return – Use 4 mm (5/32 in) tubing.
Graco CAN/Power (24VDC)
Dump Val
ve Trigger – Use 4 mm (5/32 in) tubing.
MA Black Main Air Port — 1/2 in. npt
PT
Green Paint V
alve Trigger – Use 4 mm (5/32 in) tubing.
SI Gray Shaping Air Inner — Use 8 mm (5/16 in.) tubing.
SO
ST
Blue
Black
TA Brow
Shaping Air Outer — Use 8 mm (5/16 in.) tubing.
ent Trigger (Cup Wash) – Use 4 mm (5/32 in) tubing.
Solv
n
Turbine Air — Use 8 mm (5/16 in.) tubing with 1 mm (0.04 in) wall to
minimize pressure drop.
3A3954B 13
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