Graco ProControl 1KS Installation Manual
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Graco ProControl 1KS Installation Manual

Automatic system for fluid management of single component coatings. includes flow control, flushing, and color change
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Installation
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.
3A1163A
ENG
TI16328a
II 2 G

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Summary of Contents for Graco ProControl 1KS

  • Page 1 Installation ™ 3A1163A 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). See pages 4-5 for model information, including maxi- Important Safety Instructions mum working pressure.

  • Page 2: Table Of Contents

    General Information ..... . . 14 Graco Information ......36 Wall Mounting .

  • Page 3: Related Manuals

    EasyKey . See F . 1 on page 4 for label locations. Manual Description EasyKey and Fluid Station Control Box Label 3A1080 ProControl 1KS Operation 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

    Maximum Fluid PART NO. SERIES SERIAL Working Pressure MAX FLUID WPR Part Number 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 3A1163A...
  • Page 5 System Configuration and Part Numbers Hazardous Location Approval Models using a G3000, G3000HR, or intrinsically safe Coriolis meter for both A and B meters are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3. Maximum Working Pressure Maximum working pressure rating is dependent on the fluid component options selected.

  • 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. • Do not spray without tip guard and trigger guard installed. •...
  • Page 8 Warnings WARNING TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • Read MSDSs to know the specific hazards of the fluids you are using. •...

  • Page 9: 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 10: Component Identification And Definition

    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 Table 1: Component Descriptions Component Description Used to set up, display, operate, and monitor the system. The EasyKey accepts 85-250...
  • Page 11 Pneumatically Operated Dose Valve for component A • Purge Valves for solvent and air purge Four optional flow meters are available from Graco: Flow Meters (MA, • G3000 is a general purpose gear meter typically used in flow ranges of 75-3800 cc/min.

  • Page 12: Location

    8. For ATEX installations, interconnecting cabling specified is Type A cable in accordance with EN 60079-14. Optional Cables Optional CAN cables and fiber optic cables are available from Graco. See the ProControl 1KS Repair-Parts man- ual for available part numbers and lengths. 3A1163A...
  • Page 13 801-08-A-999-9-A-N-A-B-B-A-S Power EasyKey Meter Terminal Block # NOTE: This IS control drawing also applies to the +24 Vdc ProControl 1KS. See also F . 4 on page 15. Common Signal Fluid Plate Board J3 Terminal Meter Terminal Block # Meter Position...

  • Page 14: General Information

    . 2 on page 10 shows the basic components of a ProControl 1KS system, and F . 4 on page 15 shows a basic system layout. Contact your Graco distributor for an actual system design. • Be sure all accessories are adequately sized and pressure-rated to meet system requirements.
  • Page 15 Wall Mounting 1/4” V/P Air Supply 1/4” Purge Air Supply Meter Cable TI16329a . 4. ProControl 1KS System Layout Drawing 3A1163A...
  • Page 16 Wall Mounting 3A1163A...

  • Page 17: Air Supply

    Contact your Install an additional shutoff valve upstream of all air Graco distributor for information on air shutoff valves line accessories to isolate them for servicing. for electrostatic applications.

  • Page 18: Fluid Supply

    Another option is to use a tee fitting to recir- culate. • For an airless system, the user must supply a gun trigger signal to the ProControl 1KS. NOTE: Verify that all unused fluid ports on the color change valve stack are plugged before operation. An •...
  • Page 19 Fluid Supply TI15977a . 6. Fluid Manifold Connect solvent valve air line here Fluid Inlets Fluid Inlets Connect air lines to Solenoids Color Change Board Fluid Outlet valves here TI12824a Color Change Board and Solenoid Valves Color Change Valve Stack TI11668a .
  • Page 20 Fluid Supply Regulator Fluid In V/P Air Fluid Out FC Cable TI15976a . 8. Flow Control Regulator 3A1163A...

  • Page 21: Electrical

    Electrical Electrical Requirements Connect Main Power 1. Provide power to the EasyKey. Install a bulkhead strain relief or conduit bulkhead through the EasyKey port . See F . 10. All electrical wiring must be completed by a qualified 2. See F .

  • Page 22: Connect Easykey To Fluid Station Control

    Fiber Optic Strain Audible Alarm Switch Relief Port Main Power Access Port Ground Screw I/S Power Graco Web Discrete I/O Cable Interface Connector Ports TI12638a TI12657a . 10. EasyKey Connections and AC Power Switch Connect EasyKey to Fluid NOTE: The fiber optic cable has a minimum bend radius of 1.6 in.
  • Page 23 Electrical (Fiber Optic Output - blue) (Fiber Optic Input - black) (Power Input) (Color Change Module) (Not Used) . 11. Fluid Station Board Connections 3A1163A...

  • Page 24: Connect Color Change Module

    Electrical Connect Color Change Module To install the color change module(s), see manual Set switches S3-S6 on the color change board(s) as 312787. shown in Table 2 and F . 12, depending on the number of color change boards and color change modules being Connect a 5-pin electrical cable from the labeled con- used in your system.
  • Page 25 Electrical Switch S3-S6 Positions TI13661a . 12. Color Change Board Switches S3-S6 3A1163A...
  • Page 26 Electrical WIRING DIAGRAM +12VDC COLOR 8 (21) COLOR 9 (22) +12VDC +12VDC COLOR 10 (23) COLOR 7 (20) +12VDC +12VDC COLOR 11 (24) COLOR 6 (19) +12VDC +12VDC COLOR 12 (25) COLOR 5 (18) +12VDC +12VDC CATALYST 4 (26) COLOR 4 (17) +12VDC +12VDC COLOR 3 (16)

  • Page 27: Grounding

    Connect a ground wire from the Color Change Module problem is corrected. ground screw to a true earth ground. A ground wire and clamp, part no. 223547, is available from Graco. F . 14. Flow Meters Connect the meter cables as shown in the System Electrical Schematic Hazardous Area on page 31.
  • Page 28 Electrical TI16331a . 14: Grounding 3A1163A...

  • Page 29: Schematic Diagrams

    Schematic Diagrams Schematic Diagrams System Pneumatic Schematic COLOR COLOR VALVE CHANGE STACKS CONTROL AIR EXHAUST MUFFLER COLOR 1 COLOR 2 COLOR 3 12 VDC COLOR 4 COLOR 5 DOSE A COLOR 6 VALVE COLOR 7 4-WAY SOLENOID COLOR 8 COLOR SOLVENT COLOR 9 COLOR 10 COLOR 11...

  • Page 30: 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 31 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 32: Dimensions And Mounting Hole Layouts

    Dimensions and Mounting Hole Layouts Dimensions and Mounting Hole Layouts Wall Panel (mounting bracket only) TI16333a Overall Overall Overall Mounting Dimensions, Mounting Width Depth Height Width (C) x Height (D) Hole Size Weight Module in. (mm) in. (mm) in. (mm) in.
  • Page 33 Dimensions and Mounting Hole Layouts EasyKey Control Box TI11891a TI16332a Flow Control Module TI13659a TI14135a Air Supply Control TI11895a 3A1163A...
  • Page 34 Dimensions and Mounting Hole Layouts 3A1163A...

  • Page 35: 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 36: 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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