Installation ProControl™ 1KS 3A1163A ENG 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 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. 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.
Component Identification and Definition Component Identification and Definition See Table 1, and FIG. 2 for the system components. EK CCM Air Control Module Purge Air PS* Regulator V/P Air Fluid FC (see FIG. 8) FO* ST FC Cable* ACV Logic Air FM (see FIG. 6) * MA See the ProControl 1KS Repair-Parts manual for optional cable lengths. TI15961b FIG. 2.
Component Identification and Definition Table 1: Component Descriptions Component Description Fluid Manifold (FM) Includes wall mounting bracket and mountings for the fluid meter and the following valves: • • Flow Meters (MA, MS) Pneumatically Operated Dose Valve for component A Purge Valves for solvent and air purge Four optional flow meters are available from Graco: • G3000 is a general purpose gear meter typically used in flow ranges of 75-3800 cc/min. (0.02–1.0 gal/min.
Location Location Location Requirements Intrinsically Safe Installation Requirements See FIG. 3 on page 13. Do not substitute or modify system components as this may impair intrinsic safety. For installation, maintenance or operation instructions, read instruction manuals. Do not install equipment approved only for non-hazardous location in a hazardous area. See the identification label (FIG. 1) on the EasyKey or fluid station for the intrinsic safety rating for your model.
Location FM08ATEX0074 SYSTEM ASSEMBLY CERTIFICATE NON-HAZARDOUS LOCATION ONLY ProMix 2KS EasyKey Interface (with or without display) Safety Barrier FM08ATEX0072 ASSOCIATED APPARATUS 250 VAC Maximum Supply Voltage HAZARDOUS (CLASSIFIED) LOCATION CLASS I, DIV I, GROUP D, T3 (US AND CANADA) CLASS I, ZONE I GROUP IIA T3 (ATEX ONLY) TAUB = -20°C TO 50°C 50’ I/S Power Cable (3’, 6’, 10’, 15’, 25’, 100’ options) 10’ I/S Power and Communication Cable (40’ extension option) ProMix 2KS Smart Fluid Plate (Wall
General Information General Information • Reference numbers and letters in parentheses in the text refer to numbers and letters in the illustrations. • FIG. 2 on page 10 shows the basic components of a ProControl 1KS system, and FIG. 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.
3A1163A Optional Color Change Valves 50’ Fiber Optic Cable 50’ I/S Power Cable EasyKey Interface (with display) 5/32” Air On/Off Lines for Dose, Air Purge, and Solvent Purge Valves Fluid In 1/4” Logic Air Supply Air Control Module Optional Booth Control Flow Control Regulator Module 10’ Flow Control Cable Fluid Supply Air In Fluid Out 1/4” V/P Air Supply Solvent Supply Fluid Manifold and Flow Meter Fluid System Control Box Fluid Supply 5/32” Color Valve Air Supply Optional Color Change
Wall Mounting 16 3A1163A
Air Supply Air Supply Requirements • Compressed air supply pressure: 75-100 psi (517-700 kPa, 5.2-7 bar). • Air hoses: use grounded hoses that are correctly sized for your system. 4. lnstall a bleed-type shutoff valve into the air purge valve inlet line. 5. See FIG. 6. Use the air purge valve tubing (AT, supplied) to connect the air purge valve (APV) inlet to a clean, dry air supply (install filters/dryers as needed).
Fluid Supply Fluid Supply Requirements Fluid Connections 1. Connect the solvent supply lines. Do not exceed the pressure rating of the lowest rated component. See the identification label (FIG. 1 on page 4). a. Connect the solvent supply line to the 1/4 npt(f) solvent purge valve inlet. See FIG. 6. b. Multiple color system: also connect a solvent supply line to the color change stack (Q), top valve 4 or 5. See FIG. 7. 2. Connect the component supply line(s).
Fluid Supply FIH MA APV AT DVA SS SPV FOH TI15977a FIG. 6. Fluid Manifold Connect solvent valve air line here Q 5 S 3 4 1 2 Fluid Inlets Connect air lines to valves here Solenoids Color Change Board Color Change Board and Solenoid Valves TI12824a Fluid Inlets Fluid Outlet Color Change Valve Stack TI11668a FIG. 7.
Fluid Supply Regulator V/P Air Fluid In FC Fluid Out FC Cable TI15976a FIG. 8.
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 FIG. 10. All electrical wiring must be completed by a qualified electrician and comply with all local codes and regulations. Enclose all cables routed in the spray booth and high traffic areas in conduit to prevent damage from paint, solvent, and traffic. 2. See FIG.
Electrical Fiber Optic Strain Relief Port Audible Alarm AC Power Switch Main Power Access Port Ground Screw I/S Power Graco Web Interface Discrete I/O Cable Connector Ports TI12638a TI12657a FIG. 10. EasyKey Connections and AC Power Switch Connect EasyKey to Fluid Station Control There are two 50 ft (15.2 m) cables to route between the EasyKey and Fluid Station Control: the Fluid Station Power Cable and the Fiber Optic Cable. 1.
Electrical J4 (Fiber Optic Output - blue) J6 (Fiber Optic Input - black) J10 (Power Input) VDC J11 (Color Change Module) J7 (Not Used) FIG. 11.
Electrical Connect Color Change Module To install the color change module(s), see manual 312787. Connect a 5-pin electrical cable from the labeled connection port (J11) on the fluid station control Set switches S3-S6 on the color change board(s) as shown in Table 2 and FIG. 12, depending on the number of color change boards and color change modules being used in your system. For wiring between the color change board and the solenoids, see the color change module electrical schematic, FIG. 13.
Electrical Switch S3-S6 Positions S4 S6 ON ON OFF OFF TI13661a S5 J7 S3 J11 FIG. 12.
Electrical WIRING DIAGRAM COLOR 8 (21) COLOR 7 (20) COLOR 6 (19) COLOR 5 (18) COLOR 4 (17) COLOR 3 (16) COLOR 2 (15) COLOR 1 (14) COLOR FLUSH (13) +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM J8 J15 J14 J9 J16 J10 COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COLOR 9 (22) COLOR 10 (23) COLOR 11 (24) COLOR 12 (25) CATALYST 4 (26) CATALYST 3 (27) N/A CATALYST 2 (28) CATALYST 1 (29) CATALYST F
Electrical Grounding Feed Pumps or Pressure Pots Connect a ground wire and clamp from a true earth ground to the pumps or pots. See pump or pressure pot manual. Your system must be grounded. Read Warnings, page 6. For intrinsic safety, ground wires for the EasyKey, Fluid Station, and Gun Flush Box must all be connected to the same true earth ground. See FIG. 14, page 28. Air and Fluid Hoses Use grounded hoses only. Spray Gun Follow the grounding instructions in your gun manual.
Control Box ground wire Robot ground wire. Connect to separate ground point; see NOTE on page 27. True Earth Ground - check your local code for requirements 4 5 6 5 Control Box ground screw 3 6 EasyKey ground wire 2 Robot EasyKey ground screw 1 Key: 2 1 EasyKey Display 4 3 6 Control Box Electrical TI16331a FIG.
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.
Dimensions and Mounting Hole Layouts Dimensions and Mounting Hole Layouts Wall Panel (mounting bracket only) C E B D A TI16333a Module A Overall Width in. (mm) Overall Depth in. (mm) B Overall Height in. (mm) Mounting Dimensions, Width (C) x Height (D) in. (mm) E Mounting Hole Size in. (mm) Weight lb (kg) EasyKey 14.0 (355.6) 6.6 (167.6) 13.5 (342.9) 12.0 x 12.75 (304.8 x 323.9) 0.3 (7.6) 22.2 (10.1) 10.16 (258.0) 6.0 (152.4) 11.48 (291.6) 8.0 x 10.75 (203.2 x 273.0) 0.3 (7.
Dimensions and Mounting Hole Layouts EasyKey C B Control Box E C D E B D TI11891a A TI16332a A Flow Control Module E B D C A TI13659a TI14135a Air Supply Control C E TI11895a 3A1163A 33
Dimensions and Mounting Hole Layouts 34 3A1163A
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.
