Graco ProControl 1KS Operation
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Graco ProControl 1KS Operation

Automatic system for fluid management of single component coatings. includes flow control, flushing, and color change, for professional use only, approved for use in explosive atmospheres except the easykey
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Operation
ProControl
Automatic system for fluid management of single component coatings. Includes flow
control, flushing, and color change. For professional use only.
Approved for use in explosive atmospheres (except the EasyKey).
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
™
1KS
See pages 4-5 for model information, including maxi-
mum working pressure. Equipment approval labels are
on page 3. Some components shown are not included
with all systems.
3A1080H
2575
EN
TI16328a
II 2 G

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Summary of Contents for Graco ProControl 1KS

  • Page 1 Operation ™ ProControl 3A1080H Automatic system for fluid management of single component coatings. Includes flow control, flushing, and color change. For professional use only. Approved for use in explosive atmospheres (except the EasyKey). See pages 4-5 for model information, including maxi- Important Safety Instructions mum working pressure.

  • Page 2: Table Of Contents

    System Setup for Automatic Operation ... . 49 Graco Information ......138 Status Verification of Automatic Operation .

  • Page 3: Related Manuals

    EasyKey . See F . 1 on page 4 for label locations. Manual Description EasyKey and Fluid Station Control Box Label 3A1163 ProControl 1KS Installation 3A1164 ProControl 1KS Repair-Parts ATEX Certificate is listed here 312782 Dispense Valve 312783 Color Change Valve Stacks ProControl 1KS Intrinsically Safe (IS) System.

  • Page 4: System Configuration And Part Numbers

    PART NO. SERIES SERIAL Working Pressure Configured Part Number MAX FLUID WPR is listed here 1.31 13.1 MFG. YR. GRACO INC. P.O. Box 1441 Minneapolis, MN MAX TEMP 50°C (122°F) 55440 U.S.A. . 1: Identification Label, ProControl 1KS Systems 3A1080H...

  • Page 5: Standard Features

    15V964 Gateway Profibus Communication Kit 15V337 Advanced Web Interface NOTE: This is not a complete list of available accesso- ries and kits. Refer to the Graco website for more infor- mation about accessories available for use with this product. 3A1080H...

  • Page 6: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion 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, 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.
  • Page 7 Warnings WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • Tighten all fluid connections before operating the equipment.

  • Page 8: Important Two-Component Material Information

    Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become Spraying or dispensing materials containing isocya- suspended in the fluid.

  • Page 9: Glossary Of Terms

    Glossary of Terms Glossary of Terms Advanced Web Interface (AWI) - This allows remote Coriolis Meter - a non-intrusive flow meter often used in ProMix backup and restore, configuration, logging, and low flow applications or with light viscosity, shear sensi- software update options.
  • Page 10 Glossary of Terms First Purge Source- source of the media used in the K-factor - a value that refers to the amount of material first purge cycle. User settable to air purge valve, solvent that passes through a meter. The assigned value refers purge valve, or 3rd purge valve to an amount of material per pulse.
  • Page 11 Glossary of Terms Overdose (A, B, C) Alarm - when either the resin (A), Third Purge Valve - refers to the use of three purge or catalyst (B), or reducer (C) component dispenses too valves used to flush some waterborne materials. The much material and the system cannot compensate for valves are used to flush with water, air and solvent.

  • Page 12: Overview

    Overview Usage The Graco ProControl 1KS is an electronic flow control and color change system, for use with most solvent and waterborne epoxy, polyurethane, and acid-catalyzed paints. It is not for use with “quick-setting” paints (those with a potlife of less than 15 minutes).
  • Page 13 Overview Table 1: Component Descriptions (Continued) Component Description An optional component. It is available as a color change valve stack for either low or high Color Change pressure with up to 30 color change valves. Each stack includes one additional valve for Valves (ACV) and solvent to clean the fluid line between color changes.

  • Page 14: Wall Mount System Components

    Regulator . 4) V/P Air Fluid FC Cable* Logic Air FM (see . 3) See the ProControl 1KS Repair-Parts manual for optional cable lengths. TI15961b . 2. ProControl 1KS System, shown with G3000 Meter, Color Change, and Flow Control 3A1080H...
  • Page 15 Overview TI15977a . 3. Fluid Manifold Key: Component A Meter APV Air Purge Valve DVA Component A Dose Valve Air Purge Valve Air Supply Tube SPV Solvent Purge Valve Fluid Inlet Hose Solvent Purge Valve Solvent Supply Tube FOH Fluid Outlet Hose Regulator Fluid In V/P Air...

  • Page 16: Easykey Display And Keypad

    EasyKey Display and Keypad EasyKey Display and Keypad Keypad LCD Display TI11630A Navigation Keys Alarm Reset Key . 5. EasyKey Display and Keypad Display Table 2: EasyKey Keypad Functions (see F . 5) Shows graphical and text information related to setup Function and spray operations.
  • Page 17 AC Power Fiber Optic Strain Audible Alarm Switch Relief Port Main Power Access Port Ground Screw I/S Power Graco Web Discrete I/O Cable TI12657a Interface Connector Ports TI12638a . 6. EasyKey Connections and AC Power Switch TOP VIEW Meter A...

  • Page 18: Ac Power Switch

    Clear the audible alarm by pressing the Alarm Reset See manual 313386 for more information. key. NOTE: If using the Graco Gateway in your system, dis- Even after the Alarm Reset key is pressed, the Potlife connect its cable from the EasyKey before updating the Exceeded alarm message will remain displayed until a ProControl software.

  • Page 19: Run Mode Screens

    . 10 for a map of the Run screens. Detailed screen descriptions follow. Splash Screen At power up, the Graco logo and software revision will display for approximately 5 seconds, followed by the Status Screen (see page 21). . 8. Splash Screen The Splash screen will also momentarily display “Estab-...
  • Page 20 Run Mode Screens Press the Setup key to enter Setup mode. TI12802a . 10. Run Screens Map 3A1080H...

  • Page 21: Status Screen

    Run Mode Screens Status Screen Current Date and Time • Use the Up or Down keys to scroll through the Screen Number and Scroll Arrows: displays the Run screens. current screen number and the total number of screens in a group. The Up and Down arrows on the right edge of the screen indicate the scroll feature.

  • Page 22: Manual Override Screen

    Run Mode Screens Manual Override Screen Flow Rate Range This screen displays the flow rate range selected on Advanced Setup Screen 5 (see page 37). Flow Set Point The Flow Set Point is user settable. If Flow Control Override is set to “Off” or “Pressure” in Advanced Setup Screen 1 on page 35, the Flow Set Point will dis- play as cc/min.

  • Page 23: Totals Screen

    Run Mode Screens Global Flow Control Data Copy NOTE: Grand totals are not resettable. This field allows you to copy flow control data from the Reset Total Screen active recipe to all recipes. Press the Enter key to view the menu, then select Start or Abort. See F .

  • Page 24: Alarms Screen

    Run Mode Screens Alarms Screen See F . 21. If the tank volume reaches the low-level threshold, the EasyKey screen will display the Tank Level Low alarm and prompt the user to do one of the following: 1. Refill tank volume to clear the alarm. 2.

  • Page 25: Setup Mode

    Setup Mode Setup Mode NOTE: See F . 22 for a map of the Setup screens. Press the Setup key to enter Setup mode. Detailed screen descriptions follow. Press the Setup key to enter Setup mode. This screen appears only if a password is activated.

  • Page 26: Password Screen

    Setup Mode Password Screen Set Up Home Screen If a password has been activated (see Configure Screen 1, page 29), the Password screen will appear. You must enter the password to access the Set Up Home Screen. Entering the wrong password returns the display to the Status Screen.
  • Page 27 Setup Mode Table 3: Component Software Versions Display (may vary from Component examples shown) Description EK (EasyKey) 3.01.001 EasyKey software version. FP (Fluid Plate) 3.01.001 Fluid Plate software version. BC (Booth Control) Booth Control not installed, not detected, or not operational. 1.XX Booth Control software version 1.00 or 1.01.

  • Page 28: System Configuration Screens

    Setup Mode System Configuration Screens NOTE: See F . 26 for a map of the System Configura- NOTE: Each screen displays the current screen number tion Screens. Detailed screen descriptions follow. and the total number of screens in the group. TI12804a .
  • Page 29 Setup Mode Configure Screen 1 Screen Timeout Select the desired screen timeout in minutes (0-99). 5 is the default. Configure Screen 2 . 27. Configure Screen 1 Language Defines the language of the screen text. Select English . 28. Configure Screen 2 (default), Spanish, French, German, Italian, Dutch, Jap- anese (Kanji), Korean, Chinese (Simplified), and Cus- tom.
  • Page 30 Setup Mode Configure Screen 3 Configure Screen 4 . 30. Configure Screen 4 . 29. Configure Screen 3 Dose Time Alarm 1K/2K/3K Enter the dose time (1 to 99 seconds). This is the Set this value to indicate the system performance level amount of time allowed for a dose to occur before a designation.
  • Page 31 Screen 3, page 30. Gun 2 Trigger Displays AFS if Number of Guns is set to “2” in Config- ure Screen 4, page 30. Control Network ID Used for the Graco Gateway network system. See Graco Gateway manual 312785 for further information 3A1080H...

  • Page 32: Option Screens

    Setup Mode Option Screens Minimum Material Fill Volume Enter 0-9999 cc. NOTE: See F . 26 on page 28 for a map of the Option Screens. Detailed screen descriptions follow. Verification Screen NOTE: Each screen displays the current screen number and the total number of screens in the group.
  • Page 33 Setup Mode Option Screen 2 To disable the Solvent Push feature, set to “Off.” B Purge After Chop NOTE: This is used to isolate the Chop cycle from the Final Purge cycle with solvent to prevent reaction issues with some types of materials. Optional 2-second burst (2 s B) operation of the B Purge valve on the integrator after the Chop cycle.

  • Page 34: Advanced Setup Screens

    Setup Mode Advanced Setup Screens NOTE: See F . 36 for a map of the Advanced Setup Screens. Detailed screen descriptions follow. Advanced Setup screens 2, 3, 4, and 10 appear depending on selections made in Option screens 1 and 2. Screens 5 and 6 appear if Flow Control is set to “On”...
  • Page 35 (Hose Volume* x Feet of Hose) + 75 + 20 = PLV below: Color/Catalyst Purge Selection Description NOTE: ProControl 1KS uses Color only. Normal operation % Open Flow control regulator is opened to a This field only appears if the system includes a color desired percentage.
  • Page 36 Setup Mode Advanced Setup Screen 2 Advanced Setup Screen 3 . 38. Advanced Setup Screen 2 . 39. Advanced Setup Screen 3 This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32. This screen appears only if Flush and Fill Input is set to “Global”...
  • Page 37 Setup Mode Advanced Setup Screen 4 Advanced Setup Screen 5 . 41. Advanced Setup Screen 5 (Automatic Mode . 40. Advanced Setup Screen 4 with Flow Control Only) This screen appears only if K-factor Input is set to This screen appears only if Flow Control is set to either “Global”...
  • Page 38 Setup Mode Advanced Setup Screen 6 Advanced Setup Screen 7 . 42. Advanced Setup Screen 6 . 43. Advanced Setup Screen 7 This screen appears only if Flow Control is set to either This screen appears only if Flow Control is set to “On” in “On”...
  • Page 39 Setup Mode Advanced Setup Screen 8 Advanced Setup Screen 10 . 46. Advanced Setup Screen 10 . 44. Advanced Setup Screen 8 This screen appears only if Flush and Fill Input is set to This screen shows the status of digital inputs, digital out- “Global”...

  • Page 40: Recipe Setup Screens

    Setup Mode Recipe Setup Screens NOTE: See F . 47 for a map of the Recipe screens. Detailed screen descriptions follow. Recipe 0 Screens Recipe screens 3, 4, 5, 6, and 7 appear depending on selections made in Option screens 1 and 2 TI12806a .
  • Page 41 . 48. Recipe Setup Screen 1 Color/Catalyst Purge Color Valve NOTE: ProControl 1KS uses Color only. This field only appears if the system includes a color This field only appears if the system includes a color change module. Enter the color valve number (1 to 30).
  • Page 42 Setup Mode Recipe Setup Screen 3 Recipe Setup Screen 4 . 51. Recipe Setup Screen 4 . 50. Recipe Setup Screen 3 This screen appears only if Flush and Fill Input is set to This screen appears only if Flush and Fill Input is set to “Recipe”...
  • Page 43 Setup Mode Recipe Setup Screen 5 Recipe Setup Screen 6 . 53. Recipe Setup Screen 6 . 52. Recipe Setup Screen 5 This screen appears only if Flow Rate Monitor is set to This screen appears only if K-factor Input is set to “Rec- “On”...
  • Page 44 Setup Mode Recipe Setup Screen 7 . 54. Recipe Screen 7 This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32 and Special Out- puts is set to 1, 2, 3, or 4 in Configure Screen 5, page 30.

  • Page 45: Recipe 0 Screens

    3rd Flush Valve is set to “On” in Configure Color/Catalyst Purge Time Screen 3 on page 30). NOTE: ProControl 1KS uses Color only. Chop Type This field only appears if the system includes a color Select “Air/Solvent” or “Air/3rd Flush Valve” (available change module.
  • Page 46 Setup Mode Recipe 0 Screen 3 Recipe 0 Screen 4 . 58. Recipe 0 Screen 4 . 57. Recipe 0 Screen 3 This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32 and Special Out- This screen only appears if Solvent Monitor is set to puts is set to 1, 2, 3, or 4 in Configure Screen 5, page “Meter”...

  • Page 47: Calibration Screen

    Setup Mode Calibration Screen . 59. Calibration Screen Use this screen to calibrate a meter. Set to “A Meter” or “Solvent Meter” (available if Solvent Monitor in Config- ure Screen 5, page 30, is set to “Meter”). • Start - start calibration •...
  • Page 48 Setup Mode 3A1080H...

  • Page 49: Procontrol Integration Specifics

    ProControl Integration Specifics ProControl Integration Specifics System Setup for Automatic Operation Configuration of the options for ProControl 1KS Auto- matic operation is done through a few setup screens. Several utility screens are also available for debug and verification. First, set the ProControl 1KS to Automatic mode: .

  • Page 50: Status Verification Of Automatic Operation

    Proportioning • Gun 1 Trigger Discrete I/O bits as used on the ProControl 1KS are available in Advanced Setup Screen 8 and Advanced NOTE: In Semi-automatic mode, only the Proportioning Setup Screen 9 If control is through the Network inter- field is available.

  • Page 51: Discrete I/O

    9 on page 64 for inputs and outputs. Understanding tion (PLC) is received by the EasyKey and to verify that these inputs and outputs is necessary to properly inte- the ProControl 1KS is sending outputs to the automa- grate the ProControl 1KS to the automation. tion.
  • Page 52 Mix Start: This is a maintained input. When High, the trol functions. Without it, no flow control functions will ProControl 1KS will attempt to enter Mix mode. This Mix start. Start input should not be attempted unless the Mix- _Ready output is recognized.
  • Page 53 ProControl Integration Specifics Digital Output Common/Power Flow Rate Alarm Output Flow Control Calibrate Active Fill Active Mix Ready Output Mix Active Output Purge/Recipe Change Active Output Digital Output Common/Power Recipe Change Input Recipe Bit 5 Input Recipe Bit 4 Input Recipe Bit 3 Input Recipe Bit 2 Input Recipe Bit 1 Input...
  • Page 54 Graco Gateway manual 312785.) Alarm Reset Brown Mix_Ready: This output will remain High while there are Outputs (Automation Sourcing) no alarms and the ProControl 1KS is ready to go to Mix Alarm Output Blue mode. Digital Out Common Orange...

  • Page 55: Automation Flow Charts

    ProControl Integration Specifics Automation Flow Charts Start Mix Mode Process See F . 68, Table 5, and Table 6. Start Mix Mode Process Is Mix Ready bit = 1? Must be Alarm Condi- Set Mix bit = 1 tion or Active Recipe 61.
  • Page 56 ProControl Integration Specifics Mixing Mode Process See F . 69, Table 5, and Table 6. Mixing Mode Process Mixing Mode is desired. PLC is polling to ensure Mixing Mode is main- tained. Is Mix Active bit = 1? Mixing Process active Check Alarm Go to Start Mix Mode Condition: is Alarm_...
  • Page 57 ProControl Integration Specifics Purge Mode Process See F . 70, Table 5, and Table 6. Start Is Mix Ready bit = 1? Must be Alarm Condition or Active Recipe 61. See Alarm Processing Set Purge bit = 1? on page 59, or Startup from Recipe 61 (see NOTE below).
  • Page 58 ProControl Integration Specifics Color Change Mode Process See F . 71, Table 5, and Table 6. Color Change Process (basic) Do nothing. Is Active Recipe = Spraying at to desired recipe? desired recipe. (Register 40005). Load ccNewRecipe (Register 40046) with recipe number to Color Change to (0 through 60 is valid).
  • Page 59 ProControl Integration Specifics Alarm Processing See F . 72, Table 5, Table 6, and Table 7 and Table 8. Alarm Processing An Alarm Condition has been found previously. Alarm_- General = 1. Check if Potlife Alarm: is Alarm_ Potlife bit = 1? Two options: Determine the exact alarm from Table 7 or Table 8 on...
  • Page 60 ProControl Integration Specifics Table 5: ProControl 1KS Digital Inputs (Modbus Register 40040) Digital Input Binary Name Details 0 0 0 0 0 0 0 0 0 0 X X X X X X Recipe Binary bits for viewing discrete inputs only.
  • Page 61 ProControl Integration Specifics Table 6: ProControl 1KS Digital Outputs (Modbus Register 40041) Bit Digital Output Binary Name Details 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 Purge_CC_Active “1” indicates Purge or Color Change is in progress 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 Mix_Active “1”...
  • Page 62 ProControl Integration Specifics Table 7: ProControl 1KS Low Word Active Alarms (Modbus Register 40010) Code Binary Code Name None 0000 0000 0000 0000 0000 No bits set / no active low-word alarm 0001 0000 0000 0000 0001 Communication Error Alarm...
  • Page 63 ProControl Integration Specifics ProControl 1KS EasyKey PLC Output Digital Input (Sourcing) Input Output Common Input Common ProControl 1KS PLC Input EasyKey Digital Out- (Sinking) Output Common Input Output Common ProControl EasyKey PLC Input Digital Output (Sourcing) Output Input Common Output Common .
  • Page 64 ProControl Integration Specifics Table 9: Discrete I/O Terminal Connections Pin Port Name Details (also see pages 60 and 61) Digital Inputs to Remote I/O Board for Proportioning Set Bit to Initiate Mix Mode (maintain) Purge Set Bit to “1” to initiate Purge Sequence (maintained) Job_Complete Set Bit to “1”...
  • Page 65 ProControl Integration Specifics Table 9: Discrete I/O Terminal Connections (Continued) Pin Port Name Details (also see pages 60 and 61) Digital Outputs from Remote I/O Board for Proportioning 1 Digital Output Common/Power Purge CC Active “1” Indicates Purge or Color Change is in progress Mix Active “1”...

  • Page 66: Modbus And I/O Data

    Discrete I/O section 2. Load ccNewRecipe (Modbus 40046) with a recipe of the ProControl 1KS Operation manual. The PLC will number to color change to. have to read the various bits, and in some cases (40040 and 40041 for example) must mask out the various bit 3.
  • Page 67 Modbus and I/O Data Table 10: ProControl 1KS Modbus/TCP Variable Map EasyKey * Read/Write Modbus Status Register Description Size Units Limit High Limit Read Only 40003 Current flow rate 16 Bit cc/min 5000 Read Only 40004 Actual ratio 16 Bit none...
  • Page 68 Modbus and I/O Data Table 11: ProControl 1KS Recipe Bits Recipe Bits Number Recipe Bits Number 3A1080H...

  • Page 69: Typical Plc Interaction With Procontrol 1Ks

    Applications without flow control can use Gun Trigger and remain until a new recipe is required. input through Network Communications or Discrete I/O. NOTE: The Gun Trigger input has the same effect as the air flow switch used on manual ProControl 1KS sys- tems. 3A1080H...
  • Page 70 Every time a momentary Job_Complete input is seen by Integration Timing Charts the ProControl 1KS, a job log will be recorded, logging the A and B meter volumes (cc) with a time and date Refer to F . 74 - F .
  • Page 71 . 74. Integration Control Recipe Change X to Y...
  • Page 72 . 75. Integration Control Recipe Change X to Y External Color Change...
  • Page 73 . 76. Integration Control Y Purge...
  • Page 74 . 77. Integration Control Y Fill...
  • Page 75 . 78. Integration Control Y Purge and Fill...
  • Page 76 . 79. Integration Control Mix Sequences...
  • Page 77 . 80. Integration Control Alarm Processing...

  • Page 78: Integrated Flow Control

    Integrated Flow Control Integrated Flow Control Flow Control Description Air-operated Fluid Pressure Flow control is an optional feature which incorporates an Fluid Regulator Gauge Port intrinsically safe regulator control module with the Pro- Fluid Pressure Control 1KS automatic system. Flow control precisely Sensor regulates the flow of material to a manual or automatic 1/8 npt(f)

  • Page 79: Fluid And Air Pressure Requirements

    Integrated Flow Control Fluid and Air Pressure Flow Control Operation Requirements See F . 83 for module 249849 and F . 84 for module 24H989. The Flow Control System includes two infor- The fluid input pressure to the fluid regulator must be mation loops: high enough to provide a 15-20 psi (0.1-0.14 MPa, 1.0-1.4 bar) pressure differential across the regulator at...
  • Page 80 Regulator Air Line V/P (Voltage/Air Pressure) Valve Pressure Input: Feedback from Fluid Pressure Sensor TI17118a . 83. ProControl 1KS Flow Control Schematic Diagram (249849 Module) Air-operated Remote Fluid Regulator Mixed Material Line Flow Input: Feedback from Meters A and B...

  • Page 81: Flow Control Operating Process Example

    ProCon- A discrete signal is 0-10Vdc, which corresponds linearly trol 1KS. The ProControl 1KS adjusts the voltage to the to the set operating range. For example, if the set range V/P to maintain the actual flow.
  • Page 82 Analog Signal to V/P Air Line V/P (Voltage/Air Pressure) Valve Step 2: Pressure Input TI17118a . 85. ProControl 1KS Flow Control Pressure Loop and Flow Loop (249849 Module) Step 3: Flow Input Step 1: ProControl Fluid Pressure receives a Sensor...

  • Page 83: Flow Control Setup

    . 89 inputs. and Table 12. On the Manual Override Screen, the Flow Set Point field will display as a percentage NOTE: See the Graco Gateway manual for Flow Control open (see F . 90). Modbus addresses. 5. See Flow Control Startup.

  • Page 84: One-Point Learning

    Integrated Flow Control One-Point Learning For situations where there are fast gun triggers (less than 2 seconds) there may not be enough stable flow data to allow the flow loop to learn. This situation is also affected by low flow rates (less than 100 cc/min). If the job sequence contains an extended gun trigger time, instead of learning at individual flow rates the sys- tem can instead learn only points above a specified flow...

  • Page 85: Flow Control Calibration

    Integrated Flow Control Flow Control Calibration Flow Control Calibration is an automatic routine that establishes a pressure vs flow profile between low and high operating points. See F . 96. The profile may be unique to each recipe or may be globally copied to all recipes.
  • Page 86 Integrated Flow Control • If the volume is not acceptable, increase the delivery 11. To copy the data table to all recipes, see Global FC pressure. Increasing the pressure may affect your Data Copy, page 86. This loads a starting point for low flow rate setting.
  • Page 87 Integrated Flow Control Continuous Learning The flow profile will automatically adjust as necessary to drive to the required flow set point, reflecting changes in material viscosity or system dynamics (such as restric- tions downstream from the regulator). When changing recipes, the profile is saved to the cur- rent active recipe.

  • Page 88: Pressure Flow Control Mode

    Integrated Flow Control Pressure Flow Control Mode This mode may be used with a ProControl 1KS con- nected both to a robot with flow control and to a manual gun. Because there are two flow paths, the meters can- When the Flow Control Override is set to “Pressure”, the not be used to close the flow loop.

  • Page 89: Flow Control Troubleshooting

    Integrated Flow Control Flow Control Troubleshooting Problem: Flow Command does not produce fluid output. Test the system as follows, to determine if the problem is mechanical or electrical. 1. Install a 0-100 psi (0-0.7 MPa, 0-7.0 bar), 1/8 npt(m) air pressure gauge (not supplied) as follows. a.
  • Page 90 Integrated Flow Control Result of the Test Cause Solution Gauge reading increases The problem is mechanical: 1. Clear any clogs. and decreases as % • restriction/plugged hose 2. Remove restrictions. Open value is changed and fluid flow does not 3. Clean and/or repair fluid regulator. •...

  • Page 91: System Operation

    System Operation System Operation Operation Modes input). Recipe (Color) Change The process when the system automatically flushes out System mixes and dispenses material (apply Mix input). the old color and loads a new color. See pages 104-116. Solvent Push Standby Stops the system (remove Mix input).

  • Page 92: Start Up

    . 102. Power Switch Check air purge valve tubing Check the air purge valve supply tube daily for  Graco logo, software revision, and “Establishing any visible solvent accumulation. Notify your Communication” will display, followed by Status supervisor if solvent is present.
  • Page 93 System Operation 6. Adjust component A and B fluid supplies as needed for your application. Use low- est pressure possible. 7. Do not exceed the maximum rated work- ing pressure shown on the system identification label or the lowest rated component in the system. 8.

  • Page 94: Shutdown

    Pressure Relief Procedure NOTE: The following procedures relieve all fluid and air Overnight Shutdown pressure in the ProControl 1KS system. Use the proce- 1. Leave the power on. dure appropriate for your system configuration. 2. Run Recipe 0 to purge solvent through meters and gun.
  • Page 95 System Operation Systems with Color Change and Dump Valves NOTE: This procedure relieves pressure through the sampling valve. 1. Complete all steps under Single Color Systems, page 94. 2. Shut off all color supplies going to the color change valve stack(s). 3.
  • Page 96 System Operation Purge Valve B Dose Valve A Solenoid Purge Valve A Solenoid Solenoid Dose Valve B Solenoid Power TI15916a . 106. Fluid Solenoids 3A1080H...
  • Page 97 System Operation Solenoid Solenoid Identification Identification Label Label TI12826a Solvent Solenoid Overrides . 107: Color Change Solenoids Key: Component A Meter DVA Component A Dose Valve SPV Solvent Purge Valve Solvent Purge Valve Solvent Supply Tube APV Air Purge Valve Air Purge Valve Air Supply Tube Fluid Inlet Hose...

  • Page 98: Purging

    System Operation Purging 2. Set the solvent supply pressure regulator at a pres- sure high enough to completely purge the system in a reasonable amount of time but low enough to avoid splashing or an injection injury. Generally, a setting of 100 psi (0.7 MPa, 7 bar) is sufficient. 3.
  • Page 99 System Operation Purging Using Recipe 0 Purging Fluid Supply System Recipe 0 is typically used: in multiple color systems to Follow this procedure before: purge out material lines without loading a new color • the first time material is loaded into equipment* •...
  • Page 100 System Operation 3. Adjust the solvent fluid supply pressure. Use the lowest possible pressure to avoid splashing. 4. Remove the Fluid Station Control Box cover to access the solenoid valves. See F . 106 on page 5. Purge as follows: •...

  • Page 101: Solvent Push Feature

    (0-99%) of the 50% of the potlife volume. Solvent Push requires an accessory solvent meter (MS). NOTE: To manually interrupt Solvent Push, press the Order Graco Part No. 16D329 S3000 Solvent Meter Kit. See manual 308778. Standby key. The Solvent Purge Valve (SPV) or 1.

  • Page 102: Meter Calibration

    For a color change system, make sure the color valve is open. 2. Shut off all spray or dispense devices connected to the ProControl 1KS. 3. Place the beaker (minimum size - 250 cc) to capture fluid from the gun.
  • Page 103 Meter Calibration 7. Dispense component A into beaker. 11. After the volume for A or Solvent is entered, the K-factor is calculated and shows it on the Calibra- tion Screen. NOTE: K-factor values on the screen are viewable only. If needed, you can manually edit the K-factors in Advanced Setup Screen 4 (page 37) or Recipe a.

  • Page 104: Color Change

    Color Change Color Change Color Change Procedures Color Change Sequences . 110 through F . 119 illustrate various color change Multiple Color Systems sequences. See Table 16 to determine which figure to reference, based on the recipe change and system con- 1.
  • Page 105 Color Change Color Purge/Dump First Purge • This sequence flushes out the color with solvent, Select the First Purge Source (air, solvent, or 3rd valve) from the color valve to the Dump A valve. and First Purge Time. For most applications, air is selected.
  • Page 106 Color Change Table 16: Color Change Chart Reference Starting Ending Change Refer to Recipe Recipe Type Dump A Exiting Fill? Fig. Change . 110 Change . 111 Fill . 112 Fill . 113 Fill . 114 Fill . 115 Purge .
  • Page 107 . 110: ProControl 1KS Recipe Change Chart #1 X to Y...
  • Page 108 . 111: ProControl 1KS Recipe Change Chart #2 X to Y...
  • Page 109 . 112: ProControl 1KS Recipe Fill Chart #3 0 to Y...
  • Page 110 . 113: ProControl 1KS Recipe Fill Chart #4 0 to Y...
  • Page 111 . 114: ProControl 1KS Recipe Fill Chart #5 0 to Y...
  • Page 112 . 115: ProControl 1KS Recipe Fill Chart #6 0 to Y...
  • Page 113 . 116: ProControl 1KS Recipe Purge Chart #7 X to 0...
  • Page 114 . 117: ProControl 1KS Recipe Purge Chart #8 X to 0...
  • Page 115 . 118: ProControl 1KS Recipe Purge Chart #9 0 to 0...
  • Page 116 . 119: ProControl 1KS Recipe Purge Chart #10 0 to 0...
  • Page 117 Color Change 3A1080H...

  • Page 118: Alarms And Warnings

    They are saved in Alarm the date/time stamped log, which can be viewed on a E-13 High Flow Alarm Page 126 PC, using the ProControl 1KS Web Interface (see man- E-14 Low Flow Alarm Page 126 ual 313386). E-15 System Idle Warning...

  • Page 119: Alarm Troubleshooting

    Alarm Troubleshooting Alarm Troubleshooting Table 18. Alarm Troubleshooting E-1: COMM ERROR Cause Solution No power to the EasyKey. Connect power to EasyKey. No power to Fluid Station. The intrinsically safe power Verify that the cable is correctly connected. See Installa- cable between the EasyKey and Fluid Station is not con- tion manual.
  • Page 120 Alarm Troubleshooting Table 18. Alarm Troubleshooting (Continued) E-3: RATIO HIGH ALARM Sequential Dosing System The mix ratio is higher than the set tolerance on the previous dose cycle. Dynamic Dosing System The mix ratio is higher than the set tolerance for an A to B component volume comparison. Cause Solution There is too little restriction in the system.
  • Page 121 Alarm Troubleshooting Table 18. Alarm Troubleshooting (Continued) E-4: RATIO LOW ALARM Sequential Dosing System The mix ratio is lower than the set tolerance on the previous dose cycle. Dynamic Dosing System The mix ratio is lower than the set tolerance for an A to B component volume comparison. Cause Solution There is too much restriction in the system.
  • Page 122 2. Turn on the circulating pumps and all the booth equipment (such as fans and conveyors). 3. Check if the ProControl 1KS is reading any fluid flow. 4. If the ProControl 1KS shows there is fluid flow and there are no leaks from the gun or any other seals or fittings, the flow meters are probably being affected by pressure pulsations.
  • Page 123 Alarm Troubleshooting Table 18. Alarm Troubleshooting (Continued) E-7: DOSE TIME A ALARM and E-8: DOSE TIME B ALARM E-7: gun trigger input is active (AFS or Integration) and fewer than 31 A meter pulses were detected during the dose time selected. E-8: gun trigger input is active (AFS or Integration) and fewer than 31 B meter pulses were detected during the dose time selected.
  • Page 124 E-11: PURGE VOLUME ALARM Cause Solution ProControl 1KS solvent flow switch is not activated while Verify that the gun is not shut off and that the solvent purging. flow switch is activated while purge is taking place. Minimum flush volume is not achieved.
  • Page 125 Alarm Troubleshooting Table 18. Alarm Troubleshooting (Continued) E-12: CAN COMM ERROR ALARM Cause Solution Communication between the Color Change Module and • Verify that all cables are connected securely and that the Fluid Station is interrupted. the Color Change power LED turns on. If the power LED does not turn on, the problem is probably caused by a bad connection.
  • Page 126 Alarm Troubleshooting Table 18. Alarm Troubleshooting (Continued) E-13: HIGH FLOW ALARM or E-14: LOW FLOW ALARM (may also be set as Warnings) Cause Solution Fluid system is producing too much or too little flow. Troubleshoot fluid system for restrictions, leaks, exhausted fluid supply, incorrect settings, etc.
  • Page 127 Alarm Troubleshooting Table 18. Alarm Troubleshooting (Continued) E-19: I/O ALARM Cause Solution The Mix and Purge digital inputs are on at the same time. Ensure that only one input is on at a time. At least 1 sec delay is required when switching from Mix to Purge or vice versa.
  • Page 128 Alarm Troubleshooting Table 18. Alarm Troubleshooting (Continued) E-20: PURGE INITIATE ALARM Cause Solution System detects atomizing air to the gun when purge is Shut off gun air. selected. For systems with a gun flush box, gun is not in the box Place gun in gun flush box.
  • Page 129 Alarm Troubleshooting Table 18. Alarm Troubleshooting (Continued) E-25: AUTO DUMP COMPLETE ALARM Cause Solution A potlife alarm is active for more than 2 minutes, the gun Be sure to spray all mixed material before potlife expires. flush box is enabled and gun is in the gun flush box, and an auto dump flush sequence is complete.

  • Page 130: Schematic Diagrams

    Schematic Diagrams Schematic Diagrams System Pneumatic Schematic COLOR COLOR VALVE CHANGE STACKS CONTROL AIR EXHAUST MUFFLER MANIFOLD COLOR 1 COLOR 2 12 VDC COLOR 3 DOSE A COLOR 4 VALVE 4-WAY SOLENOID COLOR 5 COLOR 6 COLOR 7 COLOR 8 12 VDC COLOR SOLVENT DOSE B...

  • Page 131: System Electrical Schematic

    Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProControl 1KS system. Some compo- nents shown are not included with all systems. Non-Hazardous Area NON-HAZARDOUS AREA LINE OPERATOR INTERFACE FILTER DC OK 85-250 VAC...
  • Page 132 Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProControl 1KS system. Some compo- nents shown are not included with all systems. Hazardous Area HAZARDOUS AREA FLUID PANEL CONTROL BOX 3X CABLE FLUID...

  • Page 133: Easykey Electrical Schematic

    Schematic Diagrams EasyKey Electrical Schematic 3A1080H...

  • Page 134: Meter Performance Data (G3000 On A And B)

    Meter Performance Data (G3000 on A and B) Meter Performance Data (G3000 on A and B) 3A1080H...

  • Page 135: Meter Performance Data (G3000 On A, Coriolis On B)

    Meter Performance Data (G3000 on A, Coriolis on B) Meter Performance Data (G3000 on A, Coriolis on B) 3A1080H...
  • Page 136 Meter Performance Data (G3000 on A, Coriolis on B) 3A1080H...

  • Page 137: Technical Data

    Air filtration for air logic and purge air (Graco-supplied)......5 micron (minimum) filtration required; clean and dry air Air filtration for atomizing air (user-supplied) .

  • Page 138: Graco Standard Warranty

    With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.

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