Operation ProControl™ 1KS 3A1080C EN 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. See pages 4-5 for model information, including maximum working pressure. Equipment approval labels are on page 3.
Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . 3 System Configuration and Part Numbers . . . . . . . 4 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Important Two-Component Material Information . 9 Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 9 Material Self-ignition . . . . . . . . . . .
Related Manuals Related Manuals Equipment Approvals Component Manuals in English Equipment approvals appear on the following labels which are attached to the Fluid Station Control Box and EasyKey™. See FIG. 1 on page 4 for label locations.
System Configuration and Part Numbers System Configuration and Part Numbers Models The part number for your equipment is printed on the equipment identification labels. See FIG. 1 for location of the identification labels. Meter Part No.
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. The pressure rating is based on the rating of the lowest rated fluid component. Refer to the component pressure ratings below.
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, 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.
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. • Engage trigger lock when not spraying. • Do not point gun at anyone or at any part of the body. • Do not put your hand over the spray tip.
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. • Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. • Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates. Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates. Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area.
Glossary of Terms Glossary of Terms Air Chop - the process of mixing air and solvent together during the flush cycle to help clean the lines and reduce solvent usage. Analog - relating to, or being a device in which data are represented by continuously variable, measurable, physical quantities, such as length, width, voltage, or pressure. Closed Loop Flow Control - refers to the process when the flow rate is adjusted automatically to maintain a constant flow.
Glossary of Terms Manual Mode - when the proportioning or flow control system is controlling the inputs without any input from an outside control. Mix - when cross-linking of the resin (A) and catalyst (B) occurs (in ProMix 2KS applications). In ProControl 1KS applications, indicates the system is active. Mix Input Signal- refers to system mode status where system begins a dose sequence each time the mix signal is made “High”.
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). • Color change options are available for low pressure • Has user selectable ratio assurance and can main(300 psi [2.
Overview Table 1: Component Descriptions Component Description Color Change Valves (ACV) and Color Change Module (CCM) An optional component. It is available as a color change valve stack for either low or high pressure with up to 30 color change valves. Each stack includes one additional valve for solvent to clean the fluid line between color changes. Dual Fiber Optic Cable (FO) Used to communicate between the EasyKey and Fluid Station Control Box.
Overview ProControl 1KS System Components EK CCM Air Control Module Purge Air PS* Regulator V/P Air Fluid FC (see FIG. 4) FO* ST FC Cable* ACV Logic Air FM (see FIG. 3) * MA See the ProControl 1KS Repair-Parts manual for optional cable lengths. TI15961b FIG. 2.
Overview FIH MA APV AT DVA SS SPV FOH TI15977a FIG. 3. Fluid Manifold Key: MA DVA SPV SS Component A Meter Component A Dose Valve Solvent Purge Valve Solvent Purge Valve Solvent Supply Tube Regulator V/P Air Fluid In APV AT FIH FOH Air Purge Valve Air Purge Valve Air Supply Tube Fluid Inlet Hose Fluid Outlet Hose FC Fluid Out FC Cable TI15976a FIG. 4.
EasyKey Display and Keyboard EasyKey Display and Keyboard Keypad LCD Display TI11630A Navigation Keys Alarm Reset Key FIG. 5. EasyKey Display and Keypad Display Shows graphical and text information related to setup and spray operations. Back light will turn off after 10 minutes without any key press. Press any key to turn back on. Keypad Used to input numerical data, enter setup screens, scroll through screens, and select setup values.
EasyKey Display and Keyboard Fiber Optic Strain Relief Port AC Power Switch Audible Alarm Main Power Access Port TI12638a TI12657a Ground Screw I/S Power Graco Web Interface Discrete I/O Cable Connector Ports FIG. 6.
EasyKey Display and Keyboard AC Power Switch Turns system AC power on or off. I/S Power Power circuit to Fluid Station Control Box. Potlife Exceeded Audible Alarm Alerts the user when a Potlife Exceeded alarm occurs. Clear by pressing the Alarm Reset key.
Run Mode Screens Run Mode Screens NOTE: See FIG. 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). FIG. 8. Splash Screen The Splash screen will also momentarily display “Establishing Communication.
Run Mode Screens Press the Setup key to enter Setup mode. TI12802a FIG. 10.
Run Mode Screens Status Screen • 5 Status Bar: shows current alarm or operation mode Use the Up or Down Run screens. keys to scroll through the • Press the Enter station control box. key to select a different fluid • Press the Setup key to enter the Setup screens appears to spray and the component A or B hose lights up, showing which component dose valve is open.
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 display as cc/min. Enter the desired flow set point within the range. FIG. 12. Manual Override Screen If Flow Control Override is set to “% Open,” the Flow Set Point will display as % Open.
Run Mode Screens Global Flow Control Data Copy Reset Total Screen This field allows you to copy flow control data from the active recipe to all recipes. Press the Enter key to view the menu, then select Start or Abort. See FIG. 15. FIG. 17. Reset Total Screen FIG. 15. Global FC Data Copy Totals Screen If job is reset, job number will increment by one for default. Reset Solvent Screen FIG. 16. Totals Screen FIG. 18.
Run Mode Screens Alarms Screen See FIG. 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. Resume mixing by selecting “Spray 25% of Remainder.” If this selection is chosen, a second alarm will occur after 25% of the remaining volume is mixed. Refill tank volume to clear the alarm. FIG. 19. Alarms Screen Two screens show the last 10 alarms.
Setup Mode Setup Mode Press the Setup key to enter Setup mode. NOTE: See FIG. 22 for a map of the Setup screens. Detailed screen descriptions follow. Press the Setup key to enter Setup mode. This screen appears only if a password is activated. To access Advanced Setup Screens, page 34 and Recipe Setup Screens, page 39. To access System Configuration Screens, page 28. Press the Setup key to exit Setup mode and return to the Status screen. This screen appears momentarily if a password is activated.
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. NOTE: If you forget the password, you can reset the password (to 0), using the ProMix Web Interface (see manual 313386). FIG. 25. Set Up Home Screen This screen displays when you enter Setup mode.
Setup Mode Table 3: Component Software Versions Component Display (may vary from examples shown) Description EK (EasyKey) 2.00.012 EasyKey software version. FP (Fluid Plate) 2.00.012 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. 2.XX Booth Control software version 2.XX. -.- Color Change Module 1/2 not installed, not detected, or not operational. 1.
Setup Mode System Configuration Screens NOTE: See FIG. 26 for a map of the System Configuration Screens. Detailed screen descriptions follow. NOTE: Each screen displays the current screen number and the total number of screens in the group. TI12804a FIG. 26.
Setup Mode Configure Screen 1 Configure Screen 2 FIG. 27. Configure Screen 1 FIG. 28. Configure Screen 2 Language Month Defines the language of the screen text. Select English (default), Spanish, French, German, Italian, Dutch, Japanese (Kanji), Korean, and Chinese (Simplified). Enter current month. Password Day Enter current day. The password is only used to enter Setup mode. The default is 0, which means no password is required to enter Setup.
Setup Mode Configure Screen 3 Configure Screen 4 OR FIG. 30. Configure Screen 4 Dose Size Select the total dose size (cc) from the pulldown menu: 100, 50, 25, or 10. The DD selection (dynamic dosing) is not used with the ProControl 1KS. Dose Time Alarm Enter the dose time (1 to 99 seconds). This is the amount of time allowed for a dose to occur before a dose time alarm occurs. FIG. 29.
Setup Mode Configure Screen 5 Configure Screen 6 FIG. 31. Configure Screen 5 FIG. 32. Configure Screen 6 (Automatic mode shown) Flow Control Flow Control This field only appears if Run Mode is set to “Automatic” in Configure Screen 3, page 30. Select On or Off. This field only appears if Run Mode is set to “Automatic” in Configure Screen 3, page 30. Select “Discrete” or “Network.” If set to “On,” Advanced Setup Screen 5, page 37 is added. Special Outputs Select special outputs (0-4).
Setup Mode Option Screens Verification Screen NOTE: See FIG. 26 on page 28 for a map of the Option Screens. Detailed screen descriptions follow. NOTE: Each screen displays the current screen number and the total number of screens in the group. Option Screen 1 FIG. 34. Verification Screen Verification This screen appears if Flush and Fill Input or K-Factor Input are changed from “Recipe” to “Global” in Option Screen 1. FIG. 33.
Setup Mode Option Screen 2 FIG. 35. Option Screen 2 External Color Change If set to “Off”, Color/Catalyst Purge Time and Color/Catalyst Fill Time appear in Advanced Setup Screen 1, page 35 or Recipe Setup Screen 2, page 40 (depending on whether Flush and Fill Inputs are set to “Global” or “Recipe”). If set to “On”, these fields are removed from the screens. Auto Dump If the auto dump feature is being used, set to “On”.
Setup Mode Advanced Setup Screens NOTE: See FIG. 36 for a map of the Advanced Setup Screens. Detailed screen descriptions follow. Advanced Setup screens 2, 3, 4, and 8 appear depending on selections made in Option screens 1 and 2. Screen 5 appears if Flow Control is set to “On” in Configure screen 5. TI12805a FIG. 36.
Setup Mode NOTE: Each screen displays the current screen number and the total number of screens in the group. The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens. Advanced Setup Screen 1 Manual Override This field only appears if Run Mode is set to “Automatic” or “Semi-automatic” in Configure Screen 3, page 30. Set to “On” to override all outside control.
Setup Mode Advanced Setup Screen 2 Advanced Setup Screen 3 FIG. 38. Advanced Setup Screen 2 FIG. 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” in Option Screen 1, page 32. First Purge Source Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30).
Setup Mode Advanced Setup Screen 4 Advanced Setup Screen 5 FIG. 40. Advanced Setup Screen 4 FIG. 41. Advanced Setup Screen 5 (Automatic Mode with Flow Control Only) This screen appears only if K-Factor Input is set to “Global” in Option Screen 1, page 32. This screen appears only if Flow Control is set to “On” in Configure Screen 5, page 31. K-factor A Meter Flow Rate Range Enter the k-factor (cc/pulse) for flow meter A.
Setup Mode Advanced Setup Screen 6 FIG. 42. Advanced Setup Screen 6 This screen shows the status of recipe analog inputs and digital outputs. If box is shaded the input recipe is active. Advanced Setup Screen 7 Advanced Setup Screen 8 FIG. 44. Advanced Setup Screen 8 This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32 and Special Outputs is set to 1, 2, 3, or 4 in Configure Screen 5, page 31. The I/O board has four programmable outputs. FIG. 43.
Setup Mode Recipe Setup Screens NOTE: See FIG. 45 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 FIG.
Setup Mode NOTE: Each screen displays the current screen number and the total number of screens in the group. The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens. Recipe Setup Screen 2 Recipe Setup Screen 1 FIG. 47. Recipe Setup Screen 2 FIG. 46. Recipe Setup Screen 1 Ratio Enter the mix ratio of component A over component B (0.0:1 to 50:1). Set to 0:1 for ProControl 1KS.
Setup Mode Recipe Setup Screen 3 Recipe Setup Screen 4 FIG. 48. Recipe Setup Screen 3 FIG. 49. Recipe Setup Screen 4 This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32. This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32. First Purge Source If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.
Setup Mode Recipe Setup Screen 5 FIG. 50. Recipe Setup Screen 5 This screen appears only if K-Factor Input is set to “Recipe” in Option Screen 1, page 32. K-factor A Meter Enter the k-factor (cc/pulse) for flow meter A. This is the amount of material that passes through the flow meter per pulse (electrical pulse signal). K-factor B Meter NOTE: Not used with ProControl 1KS. Recipe Setup Screen 6 FIG. 51.
Setup Mode Recipe 0 Screens NOTE: See FIG. 45 on page 39 for a map of the Recipe 0 screens. Detailed screen descriptions follow. Recipe 0 is typically used in multiple color systems to purge out material lines without loading a new color NOTE: Each screen displays the current screen number and the total number of screens in the group. The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens.
Setup Mode Recipe 0 Screen 3 Recipe 0 Screen 4 FIG. 56. Recipe 0 Screen 4 FIG. 55. Recipe 0 Screen 3 This screen only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 31 and Flush Volume Check is set to “On” in Option Screen 1, page 32 or 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30. This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32 and Special Outputs is set to 1, 2, 3, or 4 in Configure Screen 5, page 31.
ProControl 1KS Integration Specifics ProControl 1KS Integration Specifics Discrete I/O vs Network Communications The ProControl 1KS system does not use a Booth Control. Instead, it uses Discrete I/O or Network Communications to drive the system. Each method can be used exclusively, or both at the same time.
Flow Control Calibrate Gun Trigger Input Common Remote Stop Reset Alarm General Alarm Output Common Potlife Alarm Analog In Signal Analog In Common RT1 B A GND GND B A ProControl 1KS Integration Specifics Multiple Station TI12923a Integration Control TI12924a FIG.
ProControl 1KS Integration Specifics Digital Inputs See Automation Flow Charts, pages 50-54. Mix Start: This is a maintained input. When High, the ProControl 1KS will attempt to enter Mix mode. This Mix Start input should not be attempted unless the Mix_Ready output is recognized. This ensures that there are no alarms and that the Mix Start input is appropriate. This input stays High at all times when mixing on demand is required.
Digital Output Common/Power Special Output #1 Special Output #2 Special Output #3 Digital Output Common/Power Special Output #4 ProControl 1KS Integration Specifics JLS 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 Recipe Bit 0 Input Digital I
ProControl 1KS Integration Specifics Digital Outputs Analog Inputs See Automation Flow Charts, pages 50-54. Purge_CC_Active: This output will remain High during the manual Purge or Color Change purge sequence. See the Color Change Charts (FIG. 78-FIG. 95) for further information. Flow Command: This is the positive side of the 0 – 10 Vdc signal. (See Common under Digital Inputs, page 47.) This input corresponds to the Flow Range setting in Advanced Setup Screen 5, page 37.
ProControl 1KS Integration Specifics Automation Flow Charts Start Mix Mode Process See FIG. 62, Table 5, and Table 6. Start Mix Mode Process NO YES Is Mix Ready bit = 1? Must be Alarm Condition or Active Recipe 61. See Alarm Processing on page 54, or Startup from Recipe 61 (see NOTE below) Set Mix bit = 1 NO NOTE: At power up the system defaults to Recipe 61, which is not a valid recipe number. Initiate a color change to Recipe 0 or a valid recipe number (1-60).
ProControl 1KS Integration Specifics Mixing Mode Process See FIG. 63, Table 5, and Table 6. Mixing Mode Process Mixing Mode is desired. PLC is polling to ensure Mixing Mode is maintained. NO Is Mix Active bit = 1? YES Mixing Process active Check Alarm Condition: is Alarm_ General bit = 1? NO Go to Start Mix Mode Process, page 50 YES Go to Alarm Processing, page 54 FIG. 63.
ProControl 1KS Integration Specifics Purge Mode Process See FIG. 64, Table 5, and Table 6. Start NO Is Mix Ready bit = 1? Must be Alarm Condition or Active Recipe 61. See Alarm Processing on page 54, or Startup from Recipe 61 (see NOTE below). Set Purge bit = 1? NO NO (Wait for Mix Ready) Is Mix Ready bit = 1? NOTE: At power up the system defaults to Recipe 61, which is not a valid recipe number. Initiate a color change to Recipe 0 or a valid recipe number (1-60).
ProControl 1KS Integration Specifics Color Change Mode Process See FIG. 65, Table 5, and Table 6. Color Change Process (basic) Do nothing. Spraying at desired recipe. YES Is Active Recipe = to desired recipe? (Register 40005). NO Load ccNewRecipe (Register 40046) with recipe number to Color Change to (0 through 60 is valid). Ensure ColorChange bit is seen by ProControl 1KS NO Is Purge_CC_Active bit = 1? YES NO Set ColorChange (CC) bit = 1. Clear ColorChange (CC) bit (momentary input).
ProControl 1KS Integration Specifics Alarm Processing See FIG. 66, Table 5, Table 6, and Table 7. Alarm Processing An Alarm Condition has been found previously. Alarm_General = 1. NO Check if Potlife Alarm: is Alarm_ Potlife bit = 1? Two options: Determine the exact alarm from Table 7 on page 57 and solve what caused the alarm, as required. • Purge or Color Change to remove mixed material in the line. • Place in Mix mode and spray the Potlife Volume set in the ProControl 1KS.
ProControl 1KS Integration Specifics Table 5: ProControl 1KS Digital Inputs (Modbus Register 40040) Bit Digital Input Binary Name Details 0:5 0 0 0 0 0 0 0 0 0 0 X X X X X X Recipe Binary bits for viewing discrete inputs only.
ProControl 1KS Integration Specifics Table 6: ProControl 1KS Digital Outputs (Modbus Register 40041) Bit Digital Input Binary Name Details 0 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 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 Mix_Active “1” indicates Mix is in progress 2 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 Mix_Ready “1” indicates No Alarms and OK to Mix 3 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 CC_Fill_Active “1” indicates the Fill portion of a Color Chang
ProControl 1KS Integration Specifics Table 7: ProControl 1KS Active Alarms (Modbus Register 40010) Bit Digital Input Binary Name Details Low Byte: 0 0000 0000 0000 0000 No Bits Set No Active Alarms Low Byte: 0 0000 0000 0000 0001 Comm_Error Low Byte: 0 0000 0000 0000 0010 Potlife_Alarm Low Byte: 0 0000 0000 0000 0100 Ratio_High_Alarm Low Byte: 0 0000 0000 0000 1000 Ratio_Low_Alarm Low Byte: 0 0000 0000 0001 0000 Overdose_A_Alarm Low Byte: 0 0000 0000 0010 0000 Overdose_B_Alarm Low
ProControl 1KS Integration Specifics ProControl 1KS EasyKey Digital Input PLC Output (Sourcing) Input Common Output Input 24 Vdc Common PLC Input (Sinking) ProControl 1KS EasyKey Digital Output 24 Vdc Output Common Input Output Common ProControl 1KS EasyKey Digital Output PLC Input (Sourcing) Output Common Output Input 24 Vdc Common FIG. 67.
ProControl 1KS Integration Specifics Table 8: Discrete I/O Terminal Connections Terminal Terminal Location Name Details (also see pages 55 and 56) Digital Inputs 1 J2, Remote I/O Board Mix Set Bit to Initiate Mix Mode (maintain) 2 J2, Remote I/O Board Purge Set Bit to “1” to initiate Purge Sequence (maintained) 3 J2, Remote I/O Board Job_Complete Set Bit to “1” to initiate Job Complete Input (momentary) 4 J2, Remote I/O Board External CC Ready Set Bit to “1” to initiate External Color Ch
ProControl 1KS Integration Specifics Table 8: Discrete I/O Terminal Connections Terminal Terminal Location Name Details (also see pages 55 and 56) Digital Outputs 1★ J4, Remote I/O Board Digital Output Common/Power 2 J4, Remote I/O Board Purge_CC Active “1” Indicates Purge or Color Change is in progress 3 J4, Remote I/O Board Mix_Active “1” Indicates Mix is in progress 4 J4, Remote I/O Board Mix_Ready “1” Indicates No Alarms and OK to Mix 5 J4, Remote I/O Board CC_Fill_Active “1” Indi
ProControl 1KS Integration Specifics Table 9: ProControl 1KS Recipe Bits Recipe Bits 5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 3A1080C 3 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 2 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 Number 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
System Operation System Operation Operation Modes Flow Control NOTE: Flow control is not available with dynamic dosing. Mix System mixes and dispenses material (apply Mix input). Standby Stops the system (remove Mix input). See FIG. 68. The flow regulator (FC) is required to use flow control in your system. Connect the fluid inlet and outlet lines, air line, and cable as shown. Purge Purges the system, using air and solvent (apply Purge input).
System Operation Typical PLC Interaction with ProControl 1KS This section describes a typical interaction when a local PLC is directly connected to the Discrete I/O connections of the ProControl 1KS. See ProControl 1KS Integration Specifics on page 45 for a detailed explanation of inputs and outputs. NOTE: Communications fields of Configure Screen 6 must be set to DISCRETE (see page 31).
System Operation Alarm Monitoring/Reset (Discrete I/O) Anytime an alarm occurs, the Alarm Reset input will reset the alarms and allow for processing of the next step by automation, except for the following conditions: • key. Only a Purge/Color Change or spraying the Potlife volume will reset a Potlife alarm. (See Alarm_Potlife output information on page 49.) • ProControl 1KS has four specials that can each be turned off and on twice throughout a color change sequence.
System Operation General Operating Cycle 1. The system enters and loads the desired color. 2. The system enters Mix mode to begin operation. 3. The ProControl 1KS controller sends signals to activate the solenoid valves. The solenoid valves activate Dose Valve A. Fluid flow begins when the Gun Trigger input is seen. 4. Dose Valve A (DVA) opens, and fluid flows to the gun. 5. Flow Meter A (MA) monitors the fluid volume dispensed and sends electrical pulses to the ProControl 1KS controller.
System Operation Mix Manifold Valve Settings To open dose or purge valves, turn hex nut (E) counterclockwise. To close, turn clockwise. See Table 10 and FIG. 70. E TI11581a FIG. 70. Valve Adjustment Table 10: Mix Manifold Valve Settings 66 Valve Setting Function Dose (see FIG. 70) Hex nut (E) 1-1/4 turns out from fully closed Limits maximum fluid flow rate into integrator and minimizes valve response time. Purge (see FIG.
System Operation Start Up 1. Go through the Pre-Operation Checklist in Table 11. ➜ In bottom left corner, the system status displays, which can be Standby, Mix, Purge, or an alarm notification. Table 11: Pre-Operation Checklist ✓ Checklist System grounded Verify all grounding connections were made. See the Installation manual. All connections tight and correct Verify all electrical, fluid, air, and system connections are tight and installed according to the Installation manual.
System Operation Watch the fluid flow rate displayed on the Status screen while the gun is fully open. 10. Purge air from the fluid lines. a. Shut off air to the gun by closing the air regulator or shutoff valve for the gun atomizing air. b. Trigger the gun (manual or automatic) into a grounded metal pail. c. Go to Mix mode. If the fluid flow rate is too low: increase air pressure to the fluid supply or increase the regulated fluid pressure.
System Operation Shutdown Pressure Relief Procedure Overnight Shutdown NOTE: The following procedures relieve all fluid and air pressure in the ProControl 1KS system. Use the procedure appropriate for your system configuration. 1. Leave the power on. 2. Run Recipe 0 to purge solvent through meters and gun. Service Shutdown 1. Follow Pressure Relief Procedure on page 69. 2. Close main air shutoff valve on air supply line and on ProControl 1KS. 3. Shut off ProControl 1KS power (0 position). FIG. 74. 4.
System Operation Systems with Color Change and Dump Valves NOTE: This procedure relieves pressure through the dump valves. 1. Complete all steps under Single Color Systems, page 69. 2. Shut off all color and catalyst supplies to the valve stacks. 3. Press and hold the dump valve A solenoid override, FIG. 75. 4. See FIG. 76. Open the color change module. Using the solenoid identification labels as a guide, press and hold the override button on each color solenoid until flow from dump valve A stops. 5.
System Operation Dose Valve A Solenoid Purge Valve B Solenoid Purge Valve A Solenoid Dose Valve B Solenoid J9 J3 J12 J1 J14 J15 J8 CAN CAN Power Fiber Optic TI15916a FIG. 75.
System Operation Color Solenoid Identification Label Catalyst Color Solenoid Identification Label TI12826a Solvent Solenoid Overrides FIG. 76: Color Change Solenoids Key: FIH MA MA Component A Meter DVA Component A Dose Valve SPV Solvent Purge Valve SS Solvent Purge Valve Solvent Supply Tube APV Air Purge Valve AT Air Purge Valve Air Supply Tube FIH Fluid Inlet Hose FOH Fluid Outlet Hose APV AT DVA SS FOH SPV TI15977a FIG. 77.
System Operation Purging Read Warnings, page 6. Follow the Grounding instructions in your system Installation manual. To avoid splashing fluid in the eyes, wear eye protection. There are 4 purging procedures in this manual: • • • Purging Mixed Material (below) Purging Using Recipe 0 (page 74) Purging Fluid Supply System (page 74) 2.
System Operation Purging Using Recipe 0 Purging Fluid Supply System Recipe 0 is typically used in multiple color systems to purge out material lines without loading a new color. Follow this procedure before: • the first time material is loaded into equipment* • servicing • shutting down equipment for an extended period of time • putting equipment into storage To setup Recipe 0, go to Advanced Setup. Select the Recipe tab and change the Recipe to 0. The Recipe 0 Setup Screen appears.
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 FIG. 75 on page 71. 5. Purge as follows: • Single color systems: Press the manual override on the Dose Valve A solenoid valve and trigger the gun into a grounded metal pail until clean solvent flows from the gun. • Multiple color systems: Select Recipe 0 and press Enter .
Meter Calibration Meter Calibration 4. On the EasyKey, press the Setup key to access setup screens. 5. Press the Right Arrow Calibrate the meter: • The first time the system is operated. • Whenever new materials are used in the system, especially if the materials have viscosities that differ significantly. • At least once per month as part of regular maintenance. • Whenever a flow meter is serviced or replaced. key to select the Cali- bration Screen. Press the Enter key to select Dose Valve A.
Meter Calibration 8. Compare the amounts on the EasyKey to the amount in the beaker. NOTE: For maximum accuracy, use a gravimetric (mass) method to determine the actual volume dispensed. 9. If the screen and actual volume are different, enter the actual dispensed volume in cc for A or Solvent Volume field, and press the Enter key. If the value was substantially different, repeat the calibration process.
Color Change Color Change Color Change Procedures Multiple Color Systems 1. Shut off air to the gun. 2. Place the gun in the gun flush box if used, and close the lid. 3. Go to Standby mode (remove Mix input). 4. Select the new recipe. Begin the color change sequence. 5. If a gun flush box is not used, trigger the gun (manual or automatic) into a grounded metal pail until the color change sequence is complete.
Color Change Color Purge/Dump Step P0-P1 • This sequence flushes out the color with solvent, from the color valve to the Dump A valve. • The color change solvent valve and the Dump A valve open during the Purge Time. • The color change solvent valve closes when the Purge Time expires. Color Fill Step P1-P2 • This sequence fills the line with the new color all the way to the Dump A valve. • The new color valve and the Dump A valve open during the Fill Time.
Color Change Table 12: Color Change Chart Reference Number of Gun Flush Boxes Refer to Fig. Starting Recipe Ending Recipe Color Change Catalyst Change Dump Valves 3rd Purge Valve X X Yes Yes Yes Yes 0 FIG. 79 X X Yes Yes Yes No 0 FIG. 78 X X Yes No No No 0 FIG. 81 X X Yes No Yes No 0, 1, or 2 FIG. 80 X X No Yes Yes No 0, 1, or 2 FIG. 82 X X No No No No 0, 1, or 2 FIG. 92 X X Yes Yes Yes No 1 FIG. 84 X X Yes No No No 1 FIG.
Color Change ProMix 2KS Recipe Change Chart 1: A1 to A2, B1 to B2 with Dump Valves Valve Time-Sequence Dump A Dump B A B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A B A B P0 P1 P2 P3 P4 Color Purge Time P0->P1 Color Fill Time P1->P2 Catalyst Purge Time P2->P3 Catalyst Fill Time P3->P4 CC Purge/Fill Timers are independent of Mixed Material Purge Timers. This line defines when the Mixed Fill Time begins.
Color Change ProMix 2KS Recipe Change Chart 3: A1 to A2, same B with Dump Valves Valve Time-Sequence Dump A Dump B A Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A B A P0 P1 P2 P3 P4 Color Purge Time P0->P1 Color Fill Time P1->P2 CC Purge/Fill Timers are independent of Mixed Material Purge Timers. This line defines when the Mixed Fill Time begins. The longer of the two timers defines when the Mixed Fill Time begins.
Color Change ProMix 2KS Recipe Change Chart 5: B1 to B2, same A with Dump Valves Valve Time-Sequence Dump A Dump B B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A B B P0 P1 P2 P3 P4 Catalyst Purge Time P0->P1 Catalyst Fill Time P1->P2 CC Purge/Fill Timers are independent of Mixed Material Purge Timers. This line defines when the Mixed Fill Time begins. The longer of the two timers defines when the Mixed Fill Time begins.
Color Change ProMix 2KS Recipe Change Chart 7: A1 to A2, B1 to B2 with Dump Valves, 1 GFB Valve Time-Sequence A Dump A Dump B B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A A B B P0 P1 P2 P3 P4 Color Purge Time P0->P1 Color Fill Time P1->P2 Catalyst Purge Time P2->P3 Catalyst Fill Time P3->P4 CC Purge/Fill Timers are independent of Mixed Material Purge Timers. This line defines when the Mixed Fill Time begins.
Color Change ProMix 2KS Recipe Change Chart 9: A1-A2, same B without Dump Valves, 1 GFB Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A A B Air Chop Time Solvent Chop Time 3rd Flush Chop Time First Purge (one of these) Air Purge Solvent Purge 3rd Flush Valve Final Purge (one of these) Dispense A Dispense B A A A B B Gun Flush Box Output #1 Gun Flush Box Output #2 0 1 2 3 4 5 6 Color Purge Time 0->1 Color Fill Time 1->2 Fi
Color Change ProMix 2KS Recipe Change Chart 11: Recipe 0 OR 61 to Recipe X with Dump Valves Valve Time-Sequence Dump A Dump B A B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A A B B Air Purge Solvent Purge 3rd Flush Purge Dispense A Dispense B A A B B Gun Trigger(s) by Operator 0 1 2 3 Color Fill Time 0->1 Catalyst Fill Time 1->2 Mixed Fill Time 2->3 Notes: Purge from old recipe Fill from new recipe Load tables from new recipe FIG.
Color Change ProMix 2KS Recipe Change Chart 13: Recipe 0 OR 61 to Recipe X without Dump Valves Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A A Air Purge Solvent Purge 3rd Flush Purge Dispense A Dispense B A A A B B Gun Trigger(s) by Operator 0 1 2 Color Fill Time 0->1 Mixed Fill Time 1->2 Notes: Purge from old recipe Fill from new recipe Load tables from new recipe FIG.
Color Change ProMix 2KS Recipe Change Chart 15: Same A, Same B Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A B Air Chop Time Solvent Chop Time 3rd Flush Chop Time First Purge (one of these) Air Purge Solvent Purge 3rd Flush Purge Final Purge (one of these) Dispense A Dispense B A A B B Gun Trigger(s) by Operator 0 1 2 3 4 First Purge Time 0->1 Chop Time (air/solvent or air/3rd flush) 1->2 Final Purge Time 2->3 Mixed Fill Ti
Color Change ProMix 2KS Recipe Change Chart 17: Recipe 0 OR 61 to Recipe X with Dump Valves and 3rd Flush Valve Valve Time-Sequence Dump A Dump B A B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A A B B Air Purge Solvent Purge 3rd Flush Purge Mixed Fill Time does not begin until the Exiting Fill Time and Color/Catalyst Fill Time is complete.
Alarms and Warnings Alarms and Warnings Table 13: System Alarm/Warning Codes Code Description Details E-1 Communication Error Alarm Page 91 E-2 Potlife Alarm Page 91 System Alarms E-3 Ratio High Alarm Page 92 E-4 Ratio Low Alarm Page 93 System alarms alert you of a problem and help prevent off-ratio spraying.
Alarm Troubleshooting Alarm Troubleshooting Table 14. Alarm Troubleshooting E-1: COMM_ERROR Cause No power to the EasyKey. Solution Connect power to EasyKey. No power to Fluid Station Control Box. The intrinsically Verify that the cable is correctly connected. See Installasafe power cable between the EasyKey and Fluid Station tion manual. Control Box is not connected. No power to Fluid Station Control Box. The fluid control board fuse is blown. Verify condition of fuse and replace if necessary.
Alarm Troubleshooting Table 14. Alarm Troubleshooting E-3: RATIO_HIGH_ALARM The mix ratio is higher than the set tolerance on the previous dose cycle. Cause There is too little restriction in the system. Solution • Check that the system is fully loaded with material. • Check that the supply pump’s cycle rate is set properly. • Check that the spray tip/nozzle is properly sized for the flow and application, and that it is not worn. • Check that the fluid regulator is set properly.
Alarm Troubleshooting Table 14. Alarm Troubleshooting E-4: RATIO_LOW_ALARM The mix ratio is lower than the set tolerance on the previous dose cycle. Cause There is too much restriction in the system. Solution • Check that the system is fully loaded with material. • Check that the supply pump’s cycle rate is set properly. • Check that the spray tip/nozzle is properly sized for the flow and application, and that it is not clogged. • Check that the fluid regulator is set properly.
Alarm Troubleshooting Table 14. Alarm Troubleshooting E-5: OVERDOSE_A/B_DOSE_TOO_SHORT_ALARM and E-6: OVERDOSE_B/A_DOSE_TOO_SHORT_ALARM E-5: the A dose overshoots and, when combined with B, is too large for the mix chamber capacity. E-6: the B dose overshoots and forces an A side dose that, when combined with B, is too large for the mix chamber capacity. Cause Solution Valve seal or needle/seat are leaking. Check FIG. 16 Totals Screen on page 23. I Repair the valve (see valve manual 312782).
Alarm Troubleshooting Table 14. Alarm Troubleshooting E-7: DOSE_TIME_A_ALARM and E-8: DOSE_TIME_B_ALARM E-7: gun trigger input is active (AFS or Integration) and no A meter pulses are detected during the dose time selected. E-8: gun trigger input is active (AFS or Integration) and no B meter pulses are detected during the dose time selected. Cause Solution System is in Mix mode and gun is only partially triggered, Fully trigger the gun. allowing air but no fluid to pass through gun.
Alarm Troubleshooting Table 14. Alarm Troubleshooting E-9: MIX_IN_SETUP_ALARM Cause Attempt to operate system while in Setup mode. Solution System must be in Standby to change current recipe, and cannot be operated. E-10: REMOTE_STOP_ALARM Cause Solution Automation has requested that the system abort all oper- Abort operations. Troubleshoot automation system. ations.
Alarm Troubleshooting Table 14. Alarm Troubleshooting E-15: SYSTEM_IDLE_WARNING Cause Solution Mix input is high, but the gun has not been triggered for 2 If not painting, clear alarm and resume operation. minutes. If painting, shut down and inspect fluid meter. E-16: SETUP_CHANGE_WARNING Cause The system setup parameters have been changed. Solution No action required. See Event Log available through advanced web interface. E-17: POWER_ON_WARNING Cause The power to the system has been cycled.
Alarm Troubleshooting Table 14. Alarm Troubleshooting 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. NOTE: The I/O alarm incorporates several sub-alarms relating to internal data issues, as detailed below. These alarms may not apply to all software versions.
Alarm Troubleshooting Table 14. Alarm Troubleshooting E-20: PURGE_INITIATE_ALARM Cause Solution System detects atomizing air to the gun when purge is selected. Shut off gun air. For systems with a gun flush box, gun is not in the box when purge is selected. Place gun in gun flush box. Verify that gun flush box is operating properly. For systems with auto dump on, gun is not in the box when auto dump is initiated. Place gun in gun flush box. Verify that gun flush box is operating properly.
Alarm Troubleshooting Table 14. Alarm Troubleshooting 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. E-26: COLOR/CATALYST_PURGE_ALARM Cause Solution System detects no meter pulses, or a disruption in meter Check that meter cable is connected.
Schematic Diagrams Schematic Diagrams System Pneumatic Schematic COLOR CHANGE CONTROL AIR EXHAUST MUFFLER COLOR 1 COLOR 2 COLOR 3 COLOR 4 COLOR 5 COLOR 6 COLOR 7 COLOR 8 COLOR SOLVENT COLOR 9 COLOR 10 COLOR 11 COLOR 12 CATALYST 1 CATALYST 2 CATALYST 3 CATALYST 4 CATALYST SOLVENT 4-WAY SOLENOID A B E E OS CL UB 2T 5/3 N E OP E E OS CL UB 2T / 53 N E OP DOSE A VALVE 1/4 TUBE 12 VDC A B DOSE B VALVE 12 VDC 05 CONTROL AIR 3/8 AIR FILTER MANUAL DRAIN 5 MICRON WALL MOUNT ONLY 4-WAY SOLENOID AIR INP
Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProControl 1KS system. Some components shown are not included with all systems.
Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProControl 1KS system. Some components shown are not included with all systems.
DISPLAY BOARD P1 BARRIER BOARD J9 1 2 3 4 RJ45 DISPLAY BOARD RJ45 J5 J1 J4 24 VDC+ IN RED 18 AWG BLACK 18 AWG RED/BLACK/WHITE 22 AWG J5-1 J5-2 J5-3 SHIELD/GRND COMMON (BLACK) +12 VDC I/S (WHITE) UNUSED UNUSED J1-2 J1-1 UNUSED UNUSED J1-4 J1-3 UNUSED RED 18 AWG BLACK 18 AWG J1-5 J4-1 J4-2 J4-3 GREEN/BLACK/WHITE 22 AWG IS POWER 12 VDC + + + + - RED 18 AWG BLACK 18 AWG DC OK + - - 24 VDC+ HIGH VOLTAGE IN POWER SUPPLY 24 VDC+ OUTPUT GND LUG COMMON RJ45
Technical Data Technical Data Maximum fluid working pressure . . . . . . . . . . . . . . . Base system: 4000 psi (27.58 MPa, 275.8 bar) Low pressure color change: 300 psi (2.07 MPa, 20.6 bar) Coriolis meter: 2300 psi (15.86 MPa, 158.6 bar) Flow control: 190 psi (1.31 MPa, 13.1 bar) Maximum working air pressure. . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar) Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 - 100 psi (0.5 - 0.7 MPa, 5.
Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. 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.
