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Graco ProControl 1KS Repair Parts
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Graco ProControl 1KS Repair Parts

Graco ProControl 1KS Repair Parts

Automatic system for fluid management of single component coatings
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Repair-Parts
ProControl
Automatic system for fluid management of single component coatings. Includes flow
control, flushing, and color change. For professional use only.
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.
3A1164E
EN
TI16328a
II 2 G

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Summary of Contents for Graco ProControl 1KS

  • Page 1 Repair-Parts ™ ProControl 3A1164E Automatic system for fluid management of single component coatings. Includes flow control, flushing, and color change. For professional use only. 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

    Fluid Station Control Board Diagnostics ..22 Graco Information ......54 Color Change Board Diagnostics .

  • 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 3A1080 ProControl 1KS Operation ATEX Certificate is listed here 312782 Dispense Valve 312783 Color Change Valve Stacks...

  • Page 4: System Configuration And Part Numbers

    Working Pressure PART NO. SERIES SERIAL Part Number is listed here MAX FLUID WPR 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 3A1164E...

  • Page 5: Standard Features

    System Configuration and Part Numbers Hazardous Location Approval Models using a G3000, G3000HR, or intrinsically safe Coriolis meter 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: Grounding

    NOTE: The following procedures relieve all fluid and air and hold the override button on each color solenoid pressure in the ProControl 1KS system. Use the proce- until flow from dump valve A stops. dure appropriate for your system configuration.
  • Page 11 Pressure Relief Procedure Solenoid Solenoid Identification Identification Label Label TI12826a Solvent Solenoid Overrides . 2: 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 12 Pressure Relief Procedure 3A1164E...

  • Page 13: Troubleshooting

    Troubleshooting Troubleshooting Table 1: System Alarm Codes Code Description Communication Error Alarm Follow Pressure Relief Procedure, page 10, before Potlife Alarm cleaning, checking, or servicing equipment. Ratio High Alarm Ratio Low Alarm NOTE: Do not use the fluid in the line that was dis- Overdose A/B Dose Too Short Alarm pensed off ratio as it may not cure properly.

  • Page 14: Solenoid Troubleshooting

    Troubleshooting Solenoid Troubleshooting Purge Valve B Dose Valve A Purge Valve A Solenoid Solenoid Solenoid Dose Valve B Solenoid Power TI15916a Fiber Optic . 4: Fluid Station Board and Solenoids 3A1164E...
  • Page 15 Something is restricting the solenoid or tubing. Check for air output from air line for corresponding solenoid when valve is actuated. Clear restric- tion. • A dose valve is turned in too far. See ProControl 1KS Operation manual for settings. • Fluid pressure is high and air pressure is low.

  • Page 16: Wall Mount Fluid Manifold Troubleshooting

    Troubleshooting Wall Mount Fluid Manifold Troubleshooting See F . 5. 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 FOH Fluid Outlet Hose TI15977a .

  • Page 17: Easykey Barrier Board Diagnostics

    D4 turns on if barrier board is functioning. If D4 does not turn on, fuses F3 Fluid Station Board or F4 (Graco Part No. 15D979) are blown or there is no input power at J4. If there is no input power (D5 does not light), fuses F1 and F2 (Graco Part No.

  • Page 18: Easykey Display Board Diagnostics

    Troubleshooting EasyKey Display Board Diagnostics See F . 7 and Table 3 to troubleshoot the EasyKey display board. Also see the EasyKey Electrical Schematic on page 27 and the System Electrical Schematic on pages 28 and 29. Multiple Station TI12923a Integration Control TI12924a BK885 or CR1220 Battery...
  • Page 19 Troubleshooting Table 3: EasyKey Display Board Diagnostics Connector/ Connector/ Indicator Description Indicator Description 24 Vdc Power Input/Alarm Output Graphic Display Backlight RS485 Communication Terminals Ribbon Cable to Membrane D7 (green) LED turns on when power is supplied to Inputs and Outputs board Remote I/O D11 (yellow) LED blinks (heartbeat) when board is...

  • Page 20: Discrete I/O Board Diagnostics

    Troubleshooting Discrete I/O Board Diagnostics See F . 8 and F . 9 to troubleshoot the Discrete I/O board. Also see the System Electrical Schematic on pages 28 and 29. I/O Terminal Strip Detail Pin 1 RS485 Integration A RS485 Integration B RS485 Integration Ground RS485 Network A RS485 Network B...
  • Page 21 Troubleshooting Digital Output Common/Power Flow Rate Alarm Output Flow Calibrate Active Fill Active Mix Ready Output LED D1 Mix Active Output (green) 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 22: Fluid Station Control Board Diagnostics

    Troubleshooting Fluid Station Control Board Diagnostics See F . 10 and Table 4 to troubleshoot the fluid station control board. Also see the System Electrical Schematic on pages 28 and 29. (Fiber Optic Output - blue) J1, Pin 1 F1 (Fuse) (Fiber Optic Input - black) (Power Input)
  • Page 23 Troubleshooting Table 4: Fluid Station Control Board Diagnostics Connector and Pin Nos. Signal Description Diagnosis J1, 1 & 2 Air Flow Switch 1 Turns on when gun 1 is triggered. J1, 5 & 6 Solvent Flow Switch Turns on when solvent is flowing. J1, 9 &...

  • Page 24: Color Change Board Diagnostics

    Troubleshooting Color Change Board Diagnostics See F . 11 and Table 5 to troubleshoot the color change board. Also see the System Electrical Schematic on pages 28 and 29. J8, Pin 1 J9, Pin 1 J15, Pin 1 J16, Pin 1 J14, Pin 1 J10, Pin 1 F1 (Fuse)
  • Page 25 Troubleshooting Table 5: Color Change Board Diagnostics Connector Board 1 Signal Board 2 Signal and Pin Nos. Description Description Diagnosis Board OK Board OK Blinks (heartbeat) during normal operation. Communication Communication Turns on when board is communicating with Pro- (yellow) (yellow) Mix 2KS.

  • Page 26: 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 27: Easykey Electrical Schematic

    Schematic Diagrams EasyKey Electrical Schematic 3A1164E...

  • Page 28: System Electrical Schematic

    Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS 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 POWER +24 VDC TERMINAL...

  • Page 29: Hazardous Area

    Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some compo- nents shown are not included with all systems. Hazardous Area HAZARDOUS AREA FLUID PANEL CONTROL BOX 3X CABLE FLUID PWR (RED) PANEL COM (BLACK)

  • Page 30: Service

    Service Service Before Servicing 3. Shut off ProControl 1KS power (0 position). F . 12. 4. If servicing EasyKey, also shut off power at main circuit breaker. • To avoid electric shock, turn off EasyKey power before servicing. • Servicing EasyKey display exposes you to high voltage.

  • Page 31: Servicing Easykey

    7. To assemble the new parts, align connector J2 on the display board (210c) with the socket on the NOTE: If using the Graco Gateway in your system, dis- graphic display (210b). Press them together. See connect its cable from the EasyKey before updating the .
  • Page 32 Service Replacing Line Filter Replacing Power Switch 1. Follow Before Servicing, page 30. 1. Follow Before Servicing, page 30. 2. Unlock and open EasyKey door with its key. 2. Unlock and open EasyKey door with its key. 3. Note position of line filter input and output wires. 3.
  • Page 33 Service Replacing Barrier Board 8. Install the cover (214b) with 2 screws (214k), using the security tool. 9. Connect cables to J1, J4, and J5. 10. Close and lock EasyKey door with key. 11. Turn on power at main circuit breaker. NOTICE To avoid damaging circuit board when servicing, wear 12.
  • Page 34 Service J1 (Power In) J4 (Power to Display Board) 214g 214g 214h (Power to Fluid Station) 214g Do not remove this screw 214h Front of Barrier Board, showing Fuses and Connectors Apply thermal compound to surface of heatsink (Z). Back of Barrier Board, showing Heatsink (Z) .

  • Page 35: Control Box

    Service Control Box 2. Disconnect fiber optic wires (J4, J6) and all cables (J1, J3, J5, J7, J8, J9, J10, J12, J14, J15) from con- trol board (302). F . 17. Replacing Control Board 3. Remove 4 screws (303). Remove connector jam nuts on the outside of the enclosure (301).
  • Page 36 Service TI15974a TI15916a TI15917a . 18: Fluid Station Control Box 3A1164E...
  • Page 37 (red +, black –). Refer to System Electrical Schematic, page 29. Replacing Control Board Fuse TI15917a . 19: Replacing Solenoids Replacing the fuse with a non-Graco fuse voids the IS system safety approval. Fuse Part No. Description 123690 Fuse;...

  • Page 38: Servicing Flow Meter

    . 20. 1. Follow Before Servicing, page 30. 4. Connect fluid line (P). 2. To remove and service the Coriolis meter, see man- 5. Calibrate meter as instructed in ProControl 1KS ual 313599. Operation manual. G3000 or G3000HR Meter Removal 1.

  • Page 39: Servicing Color Change Module, Color/Catalyst Valves, And Dump Valves

    Service Servicing Color Change Module, Color/Catalyst Valves, and Dump Valves 1. Follow Before Servicing, page 30. 2. See manual 312787 for the color change module. 3. See manual 312783 for the color/catalyst valve stacks. 4. See manual 312786 for the dump valve kits. 5.

  • Page 40: Servicing Flow Control

    Service Servicing Flow Control 6. Install a new o-ring (602) on the pressure sensor (620) and screw the sensor into the fluid plate (606). Preparation 7. Reinstall the fluid plate on the air plate. Be careful not to pinch the pressure sensor cable. Torque the screws (605) to 30-40 in-lb (3.4-4.5 N•m).
  • Page 41 Service Servicing the V/P Valve 1. Follow Before Servicing, page 30. *613 604* 2. Remove the four screws (605) holding the bracket Flow (614) to the housing (611). F . 23. *610 direction 3. Carefully separate the bracket from the housing and disconnect the V/P valve cable from J2 on the *609 602*‡...
  • Page 42 Service 3A1164E...

  • Page 43: Parts

    Parts Parts ProControl 1KS System The part number for your equipment is printed on the equipment identification labels. See F . 1 for location of the identification labels. Meter Flow Control Part No. Series Description None G3000 Coriolis ProControl 1KS 262380 ...
  • Page 44 Parts Part No. 262380, without meter or flow control Part No. 262381, with G3000 meter, without flow control Part No. 262382, with G3000 meter and flow control Part No. 262383, with Coriolis meter and flow control Items 335 and 336 are part of the Fluid Station Control Box.
  • Page 45 Parts Part No. 262380, without meter or flow control Part No. 262381, with G3000 meter, without flow control Part No. 262382, with G3000 meter and flow control Part No. 262383, with Coriolis meter and flow control Ref. Part No. Description 262363 CONTROL BOX, fluid station;...

  • Page 46: Easykey Controls

    Parts EasyKey Controls 277869 EasyKey, with Display Detail of Display Interface Kit (210) 214c 214f 210a 210d 214h 214l 210b 210c 214a 210e TI12554a 214g 214b TI12417c 214k 214d 214f 214l 214e, 214j 205, 206, 209 TI12496c 213, 223, 206 3A1164E...

  • Page 47: Available Cables

    Parts 277869 EasyKey, with Display Ref. Ref. Part No. Description Part No. Description 214l 123823 • FILTER, line, single-phase; CONTROL BOX, with display 110/250 V; 3 A 116320 SWITCH, power 15V280 HARNESS, connection LATCH; includes item 3a 15G569 LABEL, EasyKey inputs 203a 117818 •...

  • Page 48: 262363 Fluid Station Control Box

    Parts 262363 Fluid Station Control Box TI15974a TI15916a TI15917a 3A1164E...
  • Page 49  Replacement Danger and Warning labels, tags, and cards are available at no cost. (6 mm) OD tube 112253 CONNECTOR, male  Replacing the fuse with a non-Graco fuse voids the 121795 VALVE, solenoid, 4-way, intrin- IS system safety approval. sically safe; 12 Vdc Parts labeled n/a are not available separately.

  • Page 50: 262364 Valve Stack

    Parts 262364 Valve Stack Ref. Ref. Part No. Description Part No. Description 15T873 PLATE, blank 15X303 VALVE, high pressure; includes item 413; see man- 413*‡ --- O-RING; ptfe ual 312782 15U927 BRACKET SCREW; 5/16-24 x 5/8 in. (16 C19800 SCREW, cap, socket-hd; 1/4-20 x 1/2 in.

  • Page 51: 249849 Flow Control Regulator

    Parts 249849 Flow Control Regulator Ref. Part No. Description *613 604* 601* 102980 NUT, full, hex; 4-40 602‡* n/a O-RING; chemically resistant Flow fluoroelastomer *610 direction 112698 ELBOW; 1/8 npt(m) x 1/4 in. (6 mm) OD tube *609 602*‡ 604* O-RING;...
  • Page 52 Parts 3A1164E...

  • Page 53: Technical Data

    5 micron (minimum) filtration required; clean and dry air (Graco-supplied)......Air filtration for atomizing air (user-supplied) ..30 micron (minimum) filtration required; clean and dry air Fluids handled .

  • Page 54: 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.