Graco Inc. 262380, 262381, 262382, 262383 INSTALLATION

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 maximum working pressure. Equipment approval labels are on page 3. Some components shown are not included with all systems.

3A1163A

ENG

#53

TI16328a

II 2 G

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 . . . . . . . . . . . . . . . . . . . . . . 9

Keep Components A and B Separate . . . . . . . . . 9

Moisture Sensitivity of Isocyanates . . . . . . . . . . . 9

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9

Component Identification and Definition . . . . . . 10

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Location Requirements . . . . . . . . . . . . . . . . . . . 12

Intrinsically Safe Installation Requirements . . . 12

Optional Cables . . . . . . . . . . . . . . . . . . . . . . . . . 12

General Information . . . . . . . . . . . . . . . . . . . . . . . 14

Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fluid Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fluid Connections . . . . . . . . . . . . . . . . . . . . . . . 18

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Connect Main Power . . . . . . . . . . . . . . . . . . . . . 21

Connect EasyKey to Fluid Station Control . . . . . 22

Connect Color Change Module . . . . . . . . . . . . . 24

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Check Resistance . . . . . . . . . . . . . . . . . . . . . . . 27

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . 29

System Pneumatic Schematic . . . . . . . . . . . . . . 29

System Electrical Schematic . . . . . . . . . . . . . . . 30

Dimensions and Mounting Hole Layouts . . . . . . . 32

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 36

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 36

2 3A1163A

Related Manuals

Component Manuals in English

Manual Description

3A1080 ProControl 1KS Operation 3A1164 ProControl 1KS Repair-Parts 312782 Dispense Valve 312783 Color Change Valve Stacks 312787 Color Change Module Kit 312784 Gun Flush Box Kits 310745 Gun Air Shutoff Kit 312786 Dump Valve and Third Purge Valve Kits 312785 Network Communication Kits 308778 G3000/G3000HR/G250/G250HR Flow

Meter 313599 Coriolis Flow Meter 313212 Gun Flush Box Integration Kit 313290 Floor Stand Kit 313542 Beacon Kit 313386 Basic Web Interface/Advanced Web

Interface 406800 15V825 Discrete I/O Board Kit

Equipment Approvals

Equipment approvals appear on the following labels which are attached to the Fluid Station Control Box and

™

EasyKey

EasyKey and Fluid Station Control Box Label

. See FIG. 1 on page 4 for label locations.

ATEX Certificate is listed here

ProControl 1KS

Electronic Proportioner

FM08ATEX0074 II 2 G Ex ia IIA T3

CUS

Intrinsically safe

equipment for Class I,

Div 1, Group D, T3

Ta = -20°C to 50°C

MAX AIR WPR

.7 7 100

MPa bar PSI

MAX FLUID WPR

13.1 190

1.31

MPa bar PSI

MAX TEMP 50°C (122°F)

Intrinsically Safe (IS) System. Install per IS Control Drawing No. 289833. EasyKey Interface IS Associated Apparatus for use in non hazardous location, with IS Connection to Smart Fluid Plate IS Apparatus for use in: Class I, Division 1, Group D T3 C Hazardous Locations

Read Instruction Manual

Warning: Substitution of components may impair intrinsic safety.

PART NO. SERIES

MFG. YR.

Fluid Station Control Box Label

SERIAL

GRACO INC. P.O. Box 1441 Minneapolis, MN 55440 U.S.A.

ProControl

PART NO. SERIES SERIAL

Intrinsically safe equipment for Class I, Div 1, Group D, T3 Ta = -20°C to 50°C Install per 289833

ATEX Certificate is listed here

EasyKey Label

ProControl 1KS

PART NO.

SERIES NO. MFG. YR.

277869

GRACO INC. P.O. Box 1441 Minneapolis, MN 55440 U.S.A.

Intrinsically safe connections for Class I, Div 1, Group D

CUS

Ta = -20°C to 50°C Install per 289833

Um: 250 V

ATEX Certificate is listed here

FLUID PANEL

MAX AIR WPR

.7 7 100

MPa bar PSI

FM08ATEX0073 II 2 G Ex ia IIA T3

POWER REQUIREMENTS

VOLTS

AMPS

II (2) G [Ex ia] IIA FM08ATEX0072

GRACO INC. P.O. Box 1441 Minneapolis, MN 55440 U.S.A.

85-250 ~

2 AMPS MAX

50/60 Hz

3A1163A 3

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 Flow Control

Part No. Series Description

262380

262381

262382

262383

Label Location

A ProControl 1KS

ProControl 1KS

Electronic Proportioner

on Fluid Station Control Box

Maximum Fluid

Working Pressure

is listed here

TI15974a

FM08ATEX0074 II 2 G Ex ia IIA T3

MAX AIR WPR

.7 7 100

MPa bar PSI

MAX FLUID WPR

1.31

MPa bar PSI

MAX TEMP 50°C (122°F)

CUS

Intrinsically safe

equipment for Class I,

Div 1, Group D, T3

Ta = -20°C to 50°C

13.1 190

None G3000 Coriolis No Yes

✔

✔ ✔

Read Instruction Manual

Warning: Substitution of components may impair intrinsic safety.

PART NO. SERIES

SERIAL

Label Location on EasyKey

TI15975a

Part Number

MFG. YR.

GRACO INC. P.O. Box 1441 Minneapolis, MN 55440 U.S.A.

FIG. 1: Identification Label, ProControl 1KS Systems

4 3A1163A

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.

Example: Model 262383 has a maximum working pressure of 190 psi (1.31 MPa, 13.1 bar).

Check the identification label on the EasyKey or fluid station for the system maximum working pressure. See F

IG. 1.

ProControl Fluid Components Maximum Working Pressure

Base System (no meter, no color/catalyst change option,

and no flow control [option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)

G3000 Meter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)

Coriolis Meter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300 psi (15.86 MPa, 158.6 bar)

Color Change Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 psi (2.07 MPa, 20.6 bar)

Flow Control Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 psi (1.31 MPa 13.1 bar)

Flow Meter Fluid Flow Rate Range

G3000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-3800 cc/min. (0.02-1.0 gal./min.)

G3000HR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)

Coriolis Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3800 cc/min. (0.005-1.00 gal./min.)

S3000 Solvent Meter (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)

Standard Features Accessories

Feature

EasyKey with LCD RS 485 Network Cable, 50 ft (15.25 m) Fiber Optic and Power Cables, 50 ft (15.25 m) Fluid Station Control Box Discrete I/O Board A Side Dump Valve, if color valve(s) selected Flow Control with 15 ft (4.57 m) Cable (if selected) Basic Web Interface

Accessory

15V536 Solvent Flow Switch Kit 15V213 Power Cable, 100 ft (30.5 m) 15G710 Fiber Optic Cable, 100 ft (30.5 m) 15G614 Flow Control Extension Cable, 40 ft (12.2 m) 15W034 Strobe Light Alarm Indicator Kit 15V331 Gateway Ethernet Communication Kit 15V963 Gateway DeviceNet Communication Kit 15V964 Gateway Profibus Communication Kit 15V337 Advanced Web Interface

3A1163A 5

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.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

INTRINSIC SAFETY

Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements.

• Only models with a G3000, G250, G3000HR, G250HR, 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.

• Do not install equipment approved only for a non-hazardous location in a hazardous area. See the ID label for the intrinsic safety rating of your model.

• Do not substitute or modify system components as this may impair intrinsic safety.

6 3A1163A

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.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or

servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment

and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

3A1163A 7

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.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

8 3A1163A

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. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Material Self-ignition

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 suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant

dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contaminated from the other side.

• Always lubricate threaded parts with ISO pump oil or grease when reassembling.

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

Keep Components A and B Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

3A1163A 9

Changing Materials

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• Most materials use ISO on the A side, but some use ISO on the B side.

Component Identification and Definition

See Table 1, and FIG. 2 for the system components.

FO*

PS*

ACV

CCM

Purge

Air

Logic Air

Air Control Module

Regulator V/P Air

Fluid

FC Cable*

FC (see F

IG. 8)

MAFM (see

IG. 6)

* See the ProControl 1KS

Repair-Parts manual for optional cable lengths.

IG. 2. ProControl 1KS System, shown with G3000 Meter, Color Change, and Flow Control

TI15961b

Table 1: Component Descriptions

Component Description

EasyKey (EK)

Used to set up, display, operate, and monitor the system. The EasyKey accepts 85-250 VAC, 50/60 Hz line power and converts that power to acceptable low voltage and optical signals used by other system components.

Fluid Station

Includes air control solenoids. Its control board manages all fluid functions.

Control Box (ST)

10 3A1163A

Table 1: Component Descriptions

Component Description

Component Identification and Definition

Fluid Manifold (FM)

Flow Meters (MA, MS)

Color Change Valves (ACV) and Color Change Module (CCM)

Includes wall mounting bracket and mountings for the fluid meter and the following valves:

• 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.), pressures up to 4000 psi (28 MPa, 276 bar), and viscosities of 20–3000 centipoise. The K-factor is approximately 0.119 cc/pulse.

• G3000HR is a high resolution version of the G3000 meter. It is typically used in flow

ranges of 38–1900 cc/min. (0.01–0.5 gal/min.), pressures up to 4000 psi (28 MPa, 276 bar). and viscosities of 20–3000 centipoise. The K-factor is approximately 0.061 cc/pulse.

• S3000 is a gear meter used for solvents in flow ranges of 38-1900 cc/min. (0.01–0.50

gal/min.), pressures up to 3000 psi (21 MPa, 210 bar), and viscosities of 20–50 centipoise. The K-factor is approximately 0.021 cc/pulse.

• Coriolis is a specialty meter capable of a wide range of flow rates and viscosities.

This meter is available with 1/8 in. or 3/8 in. diameter fluid passages. For detailed information on the Coriolis meter, see manual 313599. The K-factor is user-settable; at lower flow rates use a lower K-factor.

➜ 1/8 in. fluid passages: set K-factor to .020 or .061. ➜ 3/8 in. fluid passages: set K-factor to .061 or 0.119.

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)

Fluid Station Control Box Power Supply Cable (PS)

Flow Control Regulator Assembly (FC)

Used to communicate between the EasyKey and Fluid Station Control Box.

Used to provide power to the Fluid Station Control Box.

Includes an air operated fluid pressure regulator, fluid pressure sensor, voltage to air pressure transducer and circuit board. The function of this unit is to receive the flow analog signal and drive (manage) the desired flow rate.

3A1163A 11

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