Graco 3A1080C User Manual

Operation

™

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.

3A1080C

#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

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . 10

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Component Identification and Definition . . . . . . 12

ProControl 1KS System Components . . . . . . . . 14

EasyKey Display and Keyboard . . . . . . . . . . . . . . 16

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

AC Power Switch . . . . . . . . . . . . . . . . . . . . . . . . 18

I/S Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Potlife Exceeded Audible Alarm . . . . . . . . . . . . 18

Graco Web Interface Port . . . . . . . . . . . . . . . . . 18

Ethernet Connection . . . . . . . . . . . . . . . . . . . . . 18

Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . 19

Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Manual Override Screen . . . . . . . . . . . . . . . . . . 22

Totals Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Reset Total Screen . . . . . . . . . . . . . . . . . . . . . . 23

Reset Solvent Screen . . . . . . . . . . . . . . . . . . . . 23

Alarms Screen . . . . . . . . . . . . . . . . . . . . . . . . . 24

Level Control Screen . . . . . . . . . . . . . . . . . . . . . 24

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Password Screen . . . . . . . . . . . . . . . . . . . . . . . 26

Set Up Home Screen . . . . . . . . . . . . . . . . . . . . 26

System Configuration Screens . . . . . . . . . . . . . 28

Option Screens . . . . . . . . . . . . . . . . . . . . . . . . . 32

Advanced Setup Screens . . . . . . . . . . . . . . . . . 34

Recipe Setup Screens . . . . . . . . . . . . . . . . . . . 39

Recipe 0 Screens . . . . . . . . . . . . . . . . . . . . . . . 43

Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . 44

ProControl 1KS Integration Specifics . . . . . . . . . 45

Discrete I/O vs Network Communications . . . . . 45

Discrete I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Automation Flow Charts . . . . . . . . . . . . . . . . . . 50

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 62

Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . 62

Recipe (Color) Change . . . . . . . . . . . . . . . . . . . 62

Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Typical PLC Interaction with ProControl 1KS . . 63

General Operating Cycle . . . . . . . . . . . . . . . . . . 65

Mix Manifold Valve Settings . . . . . . . . . . . . . . . . 66

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Pressure Relief Procedure . . . . . . . . . . . . . . . . 69

Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Color Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Color Change Procedures . . . . . . . . . . . . . . . . . 78

Color Change Sequences . . . . . . . . . . . . . . . . . 78

Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . 90

System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 90

System Warnings . . . . . . . . . . . . . . . . . . . . . . . 90

Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . 91

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . 101

System Pneumatic Schematic . . . . . . . . . . . . . 101

System Electrical Schematic . . . . . . . . . . . . . . 102

EasyKey Electrical Schematic . . . . . . . . . . . . . 104

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Graco Standard Warranty . . . . . . . . . . . . . . . . . . 106

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 106

2 3A1080C

Related Manuals

Component Manuals in English

Manual Description

3A1163 ProControl 1KS Installation 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

3A1080C 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

.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

MAX AIR WPR

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 3A1080C

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.

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.

ProMix 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

3A1080C 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 3A1080C

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.

3A1080C 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 3A1080C

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.

3A1080C 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.

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.

Color/Catalyst Dump - refers to the time required to flush the lines from the color or catalyst change module to the mix manifold during a color or catalyst change.

Color/Catalyst Fill - refers to the time required to fill the lines from the color or catalyst change module to the mix manifold.

Coriolis Meter - a non-intrusive flow meter often used in low flow applications or with light viscosity, shear sensitive, or acid catalyzed materials. This meter uses vibration to measure flow.

Digital Input and Output - a description of data which is transmitted as a sequence of discrete symbols, most commonly this means binary data represented using electronic or electromagnetic signals.

Discrete I/O - refers to data that constitutes a separate entity and has direct communication to another control.

Dose Size - the amount of resin (A) and catalyst (B) that is dispensed into an integrator (in ProMix 2KS applications).

Dose Time Alarm - the amount of time that is allowed for a dose to occur before an alarm occurs.

Ethernet - a method for directly connecting a computer to a network or equipment in the same physical location.

Fill Time - the amount of time that is required to load mix material to the applicator.

Flow Control Resolution - a settable value that allows the flow control system to maximize its performance. The value is based on maximum desired flow rates.

Flow Rate Analog Signal - the type of communication signal that can be used on the ProControl module.

Flow Rate Tolerance - the settable percent of acceptable variance that the system will allow before a flow rate warning occurs.

Flow Set Point - a predefined flow rate target.

Grand Total - a non-resettable value that shows the

total amount of material dispensed through the system.

Gun Trigger Input Signal - used to manage ratio assurance dose times and flow control processes.

Intrinsically Safe (IS) - refers to the ability to locate certain components in a hazardous location.

Idle - if the gun is not triggered for 2 minutes the system enters Idle mode. Trigger the gun to resume operation.

Job Total - a resettable value that shows the amount of material dispensed through the system for one job. A job is complete when a color change or complete system flush occurs.

K-factor - a value that refers to the amount of material that passes through a meter. The assigned value refers to an amount of material per pulse.

Ki - refers to the degree fluid flow over shoots its set point.

Kp - refers to the speed in which the fluid flow reaches its set point.

Fiber Optic Communication - the use of light to transmit communication signals.

10 3A1080C

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”.

Modbus/TCP - a type of communication protocol used to communicate Digital I/O signals over an ethernet.

Network Station - a means to identify a particular individual proportioning or flow control system.

Overdose Alarm - when either the resin (A) or catalyst (B) component dispenses too much material and the system cannot compensate for the additional material.

Potlife Time - the amount of time before a material becomes unsprayable.

Potlife Volume - the amount of material that is required to move through the mix manifold, hose and applicator before the potlife timer is reset.

Purge - when all mixed material is flushed from the system.

Purge Time - the amount of time required to flush all mixed material from the system.

Ratio Tolerance - the settable percent of acceptable variance that the system will allow before a ratio alarm occurs.

Sequential Color Change - the process when a color change is initiated and the system automatically flushes the old color and loads a new color.

Solvent Fill - the time required to fill the mixed material line with solvent.

Standby - refers to the status of the system.

Third Purge Valve - refers to the use of three purge

valves used to flush some waterborne materials. The valves are used to flush with water, air and solvent.

V/P - refers to the voltage to air pressure device in the flow control module.

3A1080C 11

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).

• Has user selectable ratio assurance and can maintain up to +/-1% accuracy, depending on materials and operating conditions.

• Models are available to operate air spray or air-assisted systems with a capacity of up to 3800 cc/min.

Component Identification and Definition

SeeTable 1 and FIG. 2 for the system components.

• Color change options are available for low pressure (300 psi [2.1 MPa, 21 bar]) air spray and high pressure (3000 psi [21 MPa, 210 bar]) systems with up to 30 color change valves and up to 4 catalyst change valves.

NOTE: Optional accessories are available for in field installation to achieve 30 colors.

Table 1: Component Descriptions

Component Description

EasyKey (EK)

Fluid Station Control Box (ST)

Fluid Manifold (FM)

Flow Meters (MA, MS)

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.

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

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.

12 3A1080C

Table 1: Component Descriptions

Component Description

Overview

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

Dual Fiber Optic Cable (FO)

Fluid Station Control Box Power Supply Cable (PS)

Flow Control Regulator Assembly (FC)

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.

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.

3A1080C 13

Overview

ProControl 1KS System Components

FO*

PS*

ACV

CCM

Purge

Air

Logic Air

Air Control Module

Regulator V/P Air

Fluid

FC Cable*

FC (see F

IG. 4)

MAFM (see

IG. 3)

* See the ProControl 1KS

Repair-Parts manual for optional cable lengths.

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

TI15961b

14 3A1080C

APV

Overview

FIH

DVA

FOH

FIG. 3. Fluid Manifold

Key:

MA Component A Meter DVA Component A Dose Valve SPV Solvent Purge Valve SS Solvent Purge Valve Solvent Supply Tube

Regulator

Fluid In

V/P Air

FC Cable

SPV

APV Air Purge Valve AT Air Purge Valve Air Supply Tube FIH Fluid Inlet Hose FOH Fluid Outlet Hose

TI15977a

Fluid Out

TI15976a

IG. 4. Flow Control Regulator

3A1080C 15

EasyKey Display and Keyboard

LCD Display

IG. 5. EasyKey Display and Keypad

Keypad

TI11630A

Navigation Keys Alarm Reset Key

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.

In addition to the numbered keys on the EasyKey keypad, which are used to enter values in setup, there are keys to navigate within a screen and between screens, and to save entered values. See Table 2.

Table 2: EasyKey Keypad Functions (see FIG. 5)

Key Function

Setup: press to enter or exit Setup mode.

Enter: if cursor is in menu box, press Enter

key to view menu. Press Enter to save a value either keyed in from the numerical keypad or selected from a menu.

Up Arrow: move to previous field or menu item, or to previous screen within a group.

Down Arrow: move to next field or menu item, or to next screen within a group.

Left Arrow: move to previous screen group.

Right Arrow: move to next screen group.

Alarm Reset: resets alarms.

16 3A1080C

Relief Port

TOP VIEW

Ground Screw

I/S Power Discrete I/O Cable

Graco Web Interface

Connector Ports

FIG. 6. EasyKey Connections and AC Power Switch

Audible AlarmFiber Optic Strain

Main Power Access Port

TI12638a

EasyKey Display and Keyboard

AC Powe r Switch

TI12657a

Logic Air Inlet

OPEN

A PURGE

B DOSE

A DOSE

BOTTOM VIEW

Booth Control

(Manual Systems

B PURGE

3RD PURGE

only)

Meter A

Flow Control

Gun Air

Muffler

A DUMP B DUMP

Meter B (not used)

TI15917a

Color Change Module

Fiber Optic Strain Relief Port

Ground Screw

IG. 7. Fluid Station Control Box Connections

3A1080C 17

I/S Power

TI15919a

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.

Graco Web Interface Port

Used to communicate with the ProMix from a PC to:

➜ Upgrade software ➜ View software version ➜ Download

• Job and alarm logs

• Material usage report

• Setup values (can also upload)

➜ Clear job, alarm, and material usage

reports

➜ Upload a custom language to view on

screen

➜ Restore factory defaults ➜ Restore setup password

See manual 313386 for more information.

NOTE: If using the Graco Gateway in your system, disconnect its cable from the EasyKey before updating the ProMix 2KS/ProControl 1KS software.

Ethernet Connection

You can access data on an office or industrial network through the internet with the proper configuration. See manual 313386 for more information.

18 3A1080C

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).

IG. 8. Splash Screen

The Splash screen will also momentarily display “Establishing Communication.” If this display remains for more than one minute, check that the fluid station control box circuit board is powered up (LED is on) and that the fiber optic cable is properly connected (see Installation manual).

NOTE: If the software version of the fluid plate does not match the version of the EasyKey, the EasyKey will update the fluid plate, and the fluid plate programming

screen will appear until the update is completed.

IG. 9. Fluid Plate Programming Screen

3A1080C 19

Run Mode Screens

Press the Setup key to

enter Setup mode.

TI12802a

FIG. 10. Run Screens Map

20 3A1080C

Run Mode Screens

Status Screen

• Use the Up or Down keys to scroll through the Run screens.

• Press the Enter key to select a different fluid station control box.

• Press the Setup key to enter the Setup screens from the Status screen.

• The other keys have no function in this Status screen.

Status Bar: shows current alarm or operation mode

(standby, mix, purge, recipe change, or the current alarm).

NOTE: If the auto key board is removed from the EasyKey display board, the Status Bar will read “Auto key not found.” This indicates that the automatic mode is not operable.

Target Flow Rate and Current Flow Rate: in

cc/min.

Animation: when the gun is triggered, the gun

appears to spray and the component A or B hose lights up, showing which component dose valve is open.

Current Date and Time

Screen Number and Scroll Arrows: displays the

current screen number and the total number of screens in a group. The Up and Down arrows on the right edge of the screen indicate the scroll feature. The total number of screens in some groups may vary depending on system configuration selections.

IG. 11. Status Screen

Key to F

IG. 11:

Active Recipe: shows the active recipe.

NOTE: At power up the system defaults to Recipe

61, which is not a valid recipe number.

Target R atio: for the active recipe. The ratio can be from 0.0:1–50.0:1, in 0.1 increments. For the ProControl 1KS, set the ratio at 0:1.

Actual Ratio: in hundredths, calculated after each dose of A.

Potlife Timer: shows remaining potlife time in minutes. Two times are shown if there are two guns (manual or semi-automatic mode only).

Current Flow Control Data: fluid output pressure

and percentage of analog signal range used for driving the fluid regulator V/P.

Lock Symbol: indicates that Setup screens are

password protected. See page 26.

3A1080C 21

Run Mode Screens

Manual Override Screen

IG. 12. Manual Override Screen

This screen will appear if Manual Override is set to “On” in Advanced Setup Screen 1 (page 35). It shows the active recipe, new/go to recipe, and manual override mode.

If Flow Control is set to “On” in Configure Screen 5 on page 31, this screen will also display Flow Rate Range, Flow Set Point, Flow Control Calibration (Start/Abort), and Global Flow Control Data Copy (Start/Abort).

Manual Override Menu

This field allows you to set the operating mode from the EasyKey. Press the Enter key to view the menu,

then select the desired operating mode (Standby, Mix, Purge, or Recipe Change). See F

IG. 13.

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.

If Flow Control Override is set to “% Open,” the Flow Set Point will display as % Open. This percentage relates to the flow control V/P ratio which translates to a fluid flow rate. Set the initial percentage at 35% and increase as necessary to reach the desired flow rate.

Flow Control Calibration

This field allows you to calibrate flow control for each recipe. The system must be in Mix mode and receiving a

Gun Trigger signal. Press the Enter key to view the menu, then select Start or Abort. See F

The flow rate will drop to 0, then incrementally increase until it reaches the maximum flow rate. To view the progress, go to the Status Screen, page 21. The system will populate the data for the current recipe. To copy this data to all recipes, see Global Flow Control Data

Copy, page 23.

IG. 14.

FIG. 14. Flow Control Calibration

IG. 13. Manual Override Menu

22 3A1080C

Run Mode Screens

Global Flow Control Data Copy

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 F

IG. 15. Global FC Data Copy

IG. 15.

Totals Screen

Reset Total Screen

FIG. 17. Reset Total Screen

If job is reset, job number will increment by one for default.

Reset Solvent Screen

IG. 16. Totals Screen

This screen shows the job totals, grand totals, and job number. Use the tabs to reset job totals (Job Complete), reset solvent totals (Rst Solvent), or go to Level Control Screen, page 24.

Solvent Totals and the Rst Solvent tab only appear if “Meter” is selected under Solvent Monitor in Configure

Screen 5 on page 31.

NOTE: Grand totals are not resettable.

3A1080C 23

IG. 18. Reset Solvent Total Screen

The screen will ask if you want to reset solvent total. Select Yes or No.

Run Mode Screens

Alarms Screen

IG. 19. Alarms Screen

Two screens show the last 10 alarms. Use the Up or

See F

IG. 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.

Down

See Table 13 on page 90 for a list of alarm codes.

keys to scroll between the two screens.

Level Control Screen

IG. 20. Level Control Screen

This screen shows the current volume for each fluid. Adjust the actual volumes on this screen, or use the tab to go to Usage (Totals Screen, page 23).

FIG. 21. Tank Level Low Screen (Tank A Shown)

24 3A1080C

Setup Mode

Press the Setup key to enter Setup mode.

Press the Setup key to

enter Setup mode.

NOTE: See F

IG. 22 for a map of the Setup screens.

Detailed screen descriptions follow.

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

FIG. 22. Setup Screens Map

screen.

This screen appears momentarily

if a password is activated.

TI12803a

3A1080C 25

Setup Mode

Password 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).

IG. 23. Password Screen

NOTE: If a password is activated, Setup Locked dis-

plays momentarily after exiting Setup mode and returning to the Status Screen. A lock symbol appears

Set Up Home Screen

FIG. 25. Set Up Home Screen

This screen displays when you enter Setup mode. From it you can go to Recipe and Advanced Setup Screens (pages 34-42) or System Configuration Screens

(pages 28-33). Press the Enter key to go to the selected screen set.

The screen also displays software versions and internet addresses of various components. The values shown in F

IG. 25 are only examples and may vary on your screen.

See Table 3 for further information.

on the Status Screen.

IG. 24. Setup Locked Screen

26 3A1080C

Setup Mode

Table 3: Component Software Versions

Display (may vary from examples

Component

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 oper-

ational.

1.XX Booth Control software version 1.00 or 1.01.

2.XX Booth Control software version 2.XX.

C1/C2 (Color Change Modules 1 and 2)

-.- Color Change Module 1/2 not installed, not detected, or not operational.

1.XX Color Change Module software version 1.00 or 1.01.

2.XX Color Change Module software version 2.XX.

AK (Autokey) 2K-Manual No AutoKey installed or detected. System operates in

2K Manual Mode only

2K-Auto 2K AutoKey detected. System can operate in 2K Man-

ual, Semi-automatic, or Automatic Mode.

3K-Auto 3K AutoKey detected. System can operate in 3K Man-

ual, Semi-automatic, or Automatic Mode.

XP (XPORT) V6.6.0.2 Example of XPORT network module software version.

Other versions are acceptable.

MC (Micro Controller) 1042.0198 Example of fluid plate micro controller version. Other

versions are acceptable.

IP (Internet Address) 192.168.178.5 Example of the address EasyKey is set to for basic

and advanced web interface reporting.

MAC (MAC address) 00204AAD1810 Example of internet MAC address. Each EasyKey will

have a different value in this format.

3A1080C 27

Setup Mode

System Configuration Screens

NOTE: See FIG. 26 for a map of the System Configura- tion Screens. Detailed screen descriptions follow.

NOTE: Each screen displays the current screen number

and the total number of screens in the group.

TI12804a

IG. 26. System Configuration and Option Screens Map

28 3A1080C

Setup Mode

Configure Screen 1

IG. 27. Configure Screen 1

Language

Defines the language of the screen text. Select English (default), Spanish, French, German, Italian, Dutch, Japanese (Kanji), Korean, and Chinese (Simplified).

Password

The password is only used to enter Setup mode. The default is 0, which means no password is required to enter Setup. If a password is desired, enter a number from 1 to 9999.

Configure Screen 2

FIG. 28. Configure Screen 2

Month

Enter current month.

Day

Enter current day.

Year

Enter current year (four digits).

Time

NOTE: Be sure to write down the password and keep it

in a secure location.

Display Units

Select the desired display units:

• cc/liter (default)

• cc/gallon

Enter current time in hours (24 hour clock) and minutes. Seconds are not adjustable.

Date Format

Select mm/dd/yy or dd/mm/yy.

3A1080C 29

Setup Mode

Configure Screen 3

IG. 29. Configure Screen 3

Configure Screen 4

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.

Number of Guns

Run Mode

Select the Run mode application from the pulldown menu: Automatic (default), Semi-Automatic (uses a manual spray gun), or Manual.

Dump Valve A

This field only appears if the system includes an optional dump valve A. If dump valve A is included, set to On.

Dump Valve B

This field only appears if the catalyst change option is detected from the cc board, meaning that dump valve B is present. On is the only setting.

3rd Flush Valve

Off is default. If optional 3rd flush valve is used, set to On.

Enter the number of spray guns (1 or 2).

NOTE: Only 1 gun is used in automatic mode.

Gun Flush Box (manual or semi-automatic mode)

Enter the number of gun flush boxes (Off, 1, or 2).

30 3A1080C

Setup Mode

Configure Screen 5

IG. 31. Configure Screen 5 FIG. 32. Configure Screen 6 (Automatic mode shown)

Flow Control

This field only appears if Run Mode is set to “Automatic” in Configure Screen 3, page 30. Select On or Off.

If set to “On,” Advanced Setup Screen 5, page 37 is added.

Special Outputs

Configure Screen 6

Flow Control

This field only appears if Run Mode is set to “Automatic” in Configure Screen 3, page 30. Select “Discrete” or “Network.”

Proportioning

Select “Discrete” or “Network.”

Select special outputs (0-4). Each output has two different start times and durations.

Solvent Monitor

Select solvent monitor (Off, Flow Switch, or Meter).

Web Browser IP

The default web browser IP address prefix is

192.168.178.__ Assign a unique number for each EasyKey in your system (1-99) and enter it here.

Gun 1 Trigger

Displays AFS if Run Mode is set to “Semi-automatic” in Configure Screen 3, page 30.

Select “Discrete” or “Network” if Run Mode is set to “Automatic” in Configure Screen 3, page 30.

Gun 2 Trigger Displays AFS if Number of Guns is set to “2” in Config-

ure Screen 4, page 30.

Control Network ID

Used for the Graco Gateway network system. See Graco Gateway manual 312785 for further information

3A1080C 31

Setup Mode

Option Screens

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

IG. 33. Option Screen 1

Verification Screen

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.

Flush Volume Check

This field only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 31.

If set to “On”, Minimum Flush Volume will appear in Rec-

ipe Setup Screen 2, page 40.

Flush and Fill Input

If set to “Global”, Color/Catalyst Purge and Color/Catalyst Fill are added to Advanced Setup Screen 1, page

35. Advanced Setup Screen 2 and 3 are added. See pages 36-38.

If set to “Recipe”, Color/Catalyst Purge and Color/Catalyst Fill are added to Recipe Setup Screen 2, page 40. Recipe Setup Screen 3, 4, and 7 are added. See pages 41-42.

K-Factor Input

If set to “Global,” Advanced Setup Screen 4, page 37 is added.

If set to “Recipe,” Recipe Setup Screen 5, page 42, is added.

Minimum Material Fill Volume

Enter 0-9999 cc.

32 3A1080C

Option Screen 2

IG. 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”).

Setup Mode

If set to “On”, these fields are removed from the screens.

Auto Dump

If the auto dump feature is being used, set to “On”. Once the auto dump is enabled, the gun flush box is enabled and the potlife alarm is active for 2 minutes, the system will automatically flush out the old material.

Flow Rate Monitor

This field only appears if Flow Control is set to “Off” in Configure Screen 5, page 31.

If set to “On,” Recipe Setup Screen 6 on page 42 is added, enabling setting of high and low flow limits.

If set to “Off,” flow rate monitoring is disabled and Rec- ipe Setup Screen 6 on page 42 will not appear.

3A1080C 33

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

IG. 36. Advanced Setup Screens Map

34 3A1080C

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

IG. 37. Advanced Setup Screen 1

Flow Control Override

This field only appears if Flow Control is set to “On” in Configure Screen 5 on page 31. The selections made will affect the display in Manual Override Screen on page 22. Choose the desired selection as defined

below:

Selection Description

Off Normal operation % Open Flow control regulator is opened to a

desired percentage.

Pressure Flow control regulator is opened to a

calibrated pressure.

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. If selected, the

Manual Override Screen (page 22) will be added.

Gun 1/Gun2 Potlife Volume

Enter the potlife volume (1 to 1999 cc) for each gun. This is the amount of material required to move through the mix manifold, hose and applicator/gun before the potlife timer is reset.

Use the following information to determine approximate pot life volume (PLV) in cc:

Hose ID (inches) Volume (cc/foot)*

3/16 5.43

1/4 9.648 3/8 21.71

Integrator manifold and mixer volume = 75 cc Spray Gun Volume = 20 cc

(Hose Volume* x Feet of Hose) + 75 + 20 = PLV

Color/Catalyst Purge NOTE: ProControl 1KS uses Color only.

This field only appears if the system includes a color change module and Flush and Fill Input is set to “Global” in Option Screen 1, page 32. Enter the purge time (0 to 99 seconds). It refers to the amount of time required to flush the lines from the color or catalyst module to the dose valve or dump valve.

Color/Catalyst Fill NOTE: ProControl 1KS uses Color only.

This field only appears if the system includes a color change module and Flush and Fill Input is set to “Global” in Option Screen 1, page 32. Enter the fill time (0 to 99 seconds). It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve.

3A1080C 35

Setup Mode

Advanced Setup Screen 2

IG. 38. Advanced Setup Screen 2

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).

Chop Type

Select “Air/Solvent” or “Air/3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30). This refers to the process of mixing air and solvent (or air and 3rd flush fluid) together during the flush cycle, to help clean the lines and reduce solvent usage.

Final 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).

Air Chop Time

Advanced Setup Screen 3

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.

If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

First Purge Time

Enter the first purge time (0 to 999 seconds).

Total Chop Time

Enter the total chop time (0 to 999 seconds).

Final Purge Time

Enter the final purge time (0 to 999 seconds).

Mixed Material Fill Time

Enter the mixed material fill time (0 to 999 seconds). It refers to the amount of material that is required to fill from the dose valves to the applicator/gun.

Enter the air chop time (0.0 to 99.9 seconds).

Solvent Chop Time/3rd Flush Valve Chop Time

Enter the solvent or 3rd flush valve chop time (0.0 to

99.9 seconds).

36 3A1080C

Setup Mode

Advanced Setup Screen 4

IG. 40. Advanced Setup Screen 4

This screen appears only if K-Factor Input is set to “Global” 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.

Enter the k-factor (cc/pulse) for flow meter B.

K-factor Solvent Meter This field only appears if Solvent Monitor in Configure

Screen 5, page 31, is set to “Meter.” Enter the k-factor

(cc/pulse) for the solvent flow meter.

Advanced Setup Screen 5

FIG. 41. Advanced Setup Screen 5 (Automatic Mode with Flow Control Only)

This screen appears only if Flow Control is set to “On” in

Configure Screen 5, page 31.

Flow Rate Range

Enter the flow rate range (0-300, 0-600, or 0-1200). This determines the flow control PID loop resolution.

Flow Rate Tolerance

Enter the flow rate tolerance (1 to 99%). This is the percentage of variance that the system will allow before a flow rate warning/alarm occurs.

Flow Rate Ki

Enter the flow rate Ki (flow control PID loop integral value). This refers to the degree that fluid flow overshoots its set point.

Flow Rate Kp

Enter the flow rate Kp (flow control PID loop gain value). This refers to the speed at which the fluid flow reaches its set point.

Flow Rate Alarm Time

Enter the flow rate alarm time (1 to 99 seconds).

3A1080C 37

Setup Mode

Advanced Setup Screen 6

IG. 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.

IG. 43. Advanced Setup Screen 7

This screen shows the status of digital inputs and digital outputs. If box is shaded the input is active. If not, input is off.

38 3A1080C

Recipe Setup Screens

NOTE: See FIG. 45 for a map of the Recipe screens. Detailed screen descriptions follow.

Recipe 0 Screens

Setup Mode

Recipe screens 3, 4, 5, 6,

and 7 appear depending on

selections made in Option

screens 1 and 2

TI12806a

IG. 45: Recipe Screens Map

3A1080C 39

Setup Mode

Option Screens.

Recipe Setup Screen 1

IG. 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.

Recipe Setup Screen 2

FIG. 47. Recipe Setup Screen 2

Minimum Flush Volume

This field only appears if Flush Volume Check is set to “On” in Option Screen 1 on page 32. Enter the minimum flush volume (0 to 999 cc). Entering 0 disables this function.

Potlife Time

Enter the potlife time (0 to 999 minutes). Entering 0 disables this function.

Color/Catalyst Purge

Ratio Tolerance

Enter the ratio tolerance (1 to 99%). This refers to the percent of acceptable variance that the system will allow before a ratio alarm occurs.

Component A (Color) Valve (if present)

This field only appears if the system includes a color change module. Enter the color valve number (1 to 30).

Component B (Catalyst) Valve (if present) NOTE: Not used with ProControl 1KS.

This field only appears if the system includes a color change module. Enter the catalyst valve number (1 to

4).

NOTE: ProControl 1KS uses Color only.

This field only appears if the system includes a color change module and Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32. Enter the purge time (0 to 99 seconds). It refers to the amount of time required to flush the lines from the color or catalyst module to the dose valve or dump valve.

Color/Catalyst Fill NOTE: ProControl 1KS uses Color only.

This field only appears if the system includes a color change module and Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32. Enter the fill time (0 to 99 seconds). It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve.

40 3A1080C

Setup Mode

Recipe Setup Screen 3

IG. 48. Recipe Setup Screen 3

This screen appears only if Flush and Fill Input is set to “Recipe” 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).

Chop Type

Final 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).

Recipe Setup Screen 4

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.

If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

First Purge Time

Enter the first purge time (0 to 999 seconds).

Total Chop Time

Enter the total chop time (0 to 999 seconds).

Final Purge Time

Enter the final purge time (0 to 999 seconds).

Mixed Material Fill Time

Enter the mixed material fill time (0 to 999 seconds). It refers to the amount of material that is required to fill from the dose valves to the applicator/gun.

Air Chop Time

Enter the air chop time (0.0 to 99.9 seconds).

Solvent Chop Time/3rd Flush Valve Chop Time

Enter the solvent or 3rd flush valve chop time (0.0 to

99.9 seconds).

3A1080C 41

Setup Mode

Recipe Setup Screen 5

IG. 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).

Recipe Setup Screen 6

FIG. 51. Recipe Setup Screen 6

This screen appears only if Flow Rate Monitor is set to “On” in Option Screen 2 on page 33.

Flow Rate Monitor

Select the desired flow rate monitoring (Off, Warning, or Alarm).

Low Flow Limit

K-factor B Meter NOTE: Not used with ProControl 1KS.

Enter the k-factor (cc/pulse) for flow meter B.

K-factor Solvent Meter

This field only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 31. Enter the k-factor (cc/pulse) for the solvent flow meter.

Enter the low flow rate limit (1 to 3999 cc/min).

High Flow Limit

Enter the high flow rate limit (1 to 3999 cc/min).

Recipe Setup Screen 7

IG. 52. Recipe Screen 7

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. The I/O board has four programmable outputs.

42 3A1080C

Recipe 0 Screens

Setup Mode

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

Option Screens.

Recipe 0 Screen 1

Final 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).

Air Chop Time

Enter the air chop time (0.0 to 99.9 seconds).

Solvent Chop Time/3rd Flush Valve Chop Time

Enter the solvent or 3rd flush valve chop time (0.0 to

99.9 seconds).

Recipe 0 Screen 2

IG. 53. Recipe 0 Screen 1

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).

Chop Type

FIG. 54. Recipe 0 Screen 2

If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

Color/Catalyst Purge Time NOTE: ProControl 1KS uses Color only.

This field only appears if the system includes a color change module. Enter the purge time (0 to 999 seconds).

First Purge Time

Enter the first purge time (0 to 999 seconds).

Total Chop Time

Enter the total chop time (0 to 999 seconds).

Final Purge Time

Enter the final purge time (0 to 999 seconds).

3A1080C 43

Setup Mode

Recipe 0 Screen 3

IG. 55. Recipe 0 Screen 3

This screen only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 31 and Flush Vol- ume 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.

Recipe 0 Screen 4

FIG. 56. Recipe 0 Screen 4

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. The I/O board has four programmable outputs.

Calibration Screen

Minimum Flush Volume

This field only appears if Flush Volume Check is set to “On” in Option Screen 1 on page 32. Enter the minimum flush volume (0 to 999 cc).

Exiting Fill Source

This field only appears if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30. Select “Off,” “Air,” “Solvent,” or “3rd Valve.”

Exiting Fill Time

This field only appears if Exiting Fill Source is set to “Air,” “Solvent,” or “3rd Valve.” Enter the time in seconds.

IG. 57. Calibration Screen

Use this screen to calibrate a meter. Set to “Meter A,” “Meter B,” or “Solvent Meter” (available if Solvent Monitor in Configure Screen 5, page 31, is set to “Meter”).

• Start - start calibration

• Abort - stop calibration

• Purge - purge sampling valves after calibration

See Meter Calibration, page 76, for when and how to calibrate meter.

44 3A1080C

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.

In Automatic mode, the following fields can be set to “Discrete” or “Network” (see Configure Screen 6 on page 31):

• Flow Control

• Proportioning

• Gun 1 Trigger

NOTE: In Semi-automatic mode, only the Proportioning field is available,

NOTE: The Manual Override function enables you to operate the system before the automation (PLC) is available. Manual Override still requires some communication through Discrete I/O or Network Communications. Although Manual Override is not intended to be the main mode of control, it can be used if proper Gun Trigger Input is provided.

Discrete I/O

Discrete I/O requires a 24 Vdc power supply which must be supplied on site. The ProControl 1KS does not supply power for Discrete I/O.

See Table 4 on page 49, F 8 on page 59 for inputs and outputs. Understanding these inputs and outputs is necessary to properly integrate the ProControl 1KS to the automation.

Input and output connections are made at the Discrete I/O terminal strips (F (F

IG. 61) inside the EasyKey. Also see the System

Electrical Schematic on page 102.

Review the Color Change Charts (F understanding of the color change sequence is necessary to properly drive the inputs and monitor the outputs.

See Advanced Setup Screen 7, page 38. This screen shows the actual status of all inputs and outputs. It is important to ensure that each input from local automation (PLC) is received by the EasyKey and to verify that the ProControl 1KS is sending outputs to the automation.

IG. 67 on page 58, and Table

IG. 60) and the discrete I/O board

IG. 78-FIG. 95). A full

Display Board Barrier Board

IG. 58: EasyKey Control Boards

The following paragraphs describe each discrete I/O function in detail.

Terminal Strips (see F

IG. 60)

Discrete I/O Board (see FIG. 61)

TI12496a

3A1080C 45

ProControl 1KS Integration Specifics

Multiple Station

GND

TI12923a

Integration Control

RT1

FIG. 59: 255767 EasyKey Display Board

Analog In Common

Analog In Signal

Reset Alarm

Remote Stop

Potlife Alarm

Output Common

General Alarm

Gun Trigger

Input Common

Flow Control Calibrate

TI12924a

46 3A1080C

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. When Low, the intent is to stop mixing material and perform a purge or recipe change.

Do not toggle this input to set the unit to Standby mode during short work stoppages. The ProControl 1KS will automatically go into Idle mode after 2 minutes of inactivity. When a Gun Trigger input is seen, the ProControl 1KS will automatically leave Idle mode and resume mixing material where it left off.

Purge Start: This is a maintained input. When recog- nized by the ProControl 1KS, the Purge Sequence will start, using the Purge Time from the active recipe. This will also include the Solvent Fill Time. Proper monitoring of the Purge/Color Change Output is required to ensure this function has begun. Once this output is removed, the system will immediately go to Standby mode.

Gun Trigger: When High, this input signals the ProControl 1KS that the gun is actually triggered. It should be sent every time the gun is triggered. This input provides timing for alarm functions and also drives the flow control functions. Without it, no flow control functions will start.

Job Complete: This is a momentary input, 100 msec minimum. When recognized by the ProControl 1KS, the Job totals are cleared and a time/date stamp is added for retrieval.

Remote Stop: Use this input when external equipment is used to stop the system. Clear any alarms before using this input. For more information about when this input is needed, contact your Graco distributor.

Alarm Reset: This is a momentary input, 100 msec minimum. When recognized by the ProControl 1KS it clears any active alarms and allows the automation to take the next step.

Common: This is not an input, but the ProControl 1KS expects to have the COM side of the 24 Vdc supply connected as shown in Table 8. This ensures proper opera-

tion of each input and output.

I/O Terminal Strip Detail

Color Change Start: This is a momentary input, 100

msec minimum. When recognized by the ProControl 1KS, the Color Change sequence will begin, starting at the Color/Catalyst Dump.

NOTE: If the new recipe has the same color as the active recipe, then the Color/Catalyst Dump and Color/Catalyst Fill times are skipped and the Color Change Sequence starts with the Purge. Also, the recipe bit configuration for the Color Change must be loaded at least 100 msec before the Color Change Start input is turned on. The recipe bit configuration must remain on while the Color Change Start input is removed. Graco recommends the recipe bits stay active and do not change until a new color is required. The PLC should monitor the Purge/Color Change Output as well as the Fill Active Output to ensure the process happens as required. A complete color change without errors (resulting in a Mix Ready Output state) is a completed color change.

NOTE: This also applies if using the Modbus Registers (see the Modbus Map table in manual 312785).

Pin 1

IG. 60: EasyKey Terminal Strips

RS485 Integration A RS485 Integration B

RS485 Integration Ground RS485 Network A RS485 Network B RS485 Network Ground

Flow Control Calibrate Gun Trigger Digital Common Remote Stop Alarm Reset General Alarm Digital Common Potlife Alarm Flow Rate Analog In Flow Rate Analog Common

INPUTS

OUTPUTS

TI12958a

3A1080C 47

ProControl 1KS Integration Specifics

JLS

Digital Output

Special Output #4

Special Output #3

Common/Power

Special Output #2

Digital Output

Special Output #1

Common/Power

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

FIG. 61: 255766 Discrete I/O Board

Mix Input

Purge Input

Job Complete Input

Recipe Bit 3 Input

Recipe Bit 2 Input

Recipe Bit 1 Input

Recipe Bit 0 Input

Digital Input Common

Spare

Digital Input Common

External Color Change Ready

48 3A1080C

ProControl 1KS Integration Specifics

Digital Outputs

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 (F ther information.

Fill_Active: This output will remain High while the ProControl 1KS is in the Mixed Material Fill at the end of a typical color change sequence.

Mix_Active: This output will remain High while the ProControl 1KS is in Mix mode. There may be alarm outputs while this output is High; these are typically High/Low Flow Warnings. Always monitor this output and the alarm outputs to provide feedback of the actual status of the ProControl 1KS. (See the Modbus charts in the Graco Gateway manual 312785.)

Mix_Ready: This output will remain High while there are no alarms and the ProControl 1KS is ready to go to Mix mode.

General Alarm: This output will remain High when any alarm is active. See Table 13 on page 90 for a complete list of alarms.

IG. 78-FIG. 95) for fur-

Analog Inputs

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. For example, if the setting is 0 – 300 cc/min, the 0 Vdc analog input is 0 cc/min, therefore the 10 Vdc analog input is 300 cc/min.

Table 4: Sourcing/Sinking Inputs and Outputs

Inputs (Automation Sourcing) 1 Flow Control Calibration Black + 2 Gun Trigger White + 3 Digital In Common Red - 4 Remote Stop Green + 5 Alarm Reset Brown +

Outputs (Automation Sourcing) 6 Alarm Output Blue + 7 Digital Out Common Orange - 8 Pot Life Yellow +

Outputs (Automation Sinking)

NOTE: It is important to monitor this output along with

Mix_Active to understand the alarm’s true meaning.

Alarm_Potlife: This output will remain High along with the Alarm output when the potlife time has been reached for the active recipe. The Mix_Active output will drop Low, even if the Mix_Start input is High. This output will remain High until the potlife volume is dispensed or the ProControl 1KS completes a Purge or a Color Change. The Alarm Reset input will not stop this output but will silence the audible alarm on the EasyKey.

NOTE: The Alarm Reset audible alarm.

To dispense the potlife volume, the ProControl 1KS Mix_Start input must be turned Off then back to High to spray material. At this point, Mix_Active, Alarm, and Alarm_Potlife outputs will be High until the potlife volume is sprayed.

Digital Out Supply: This is the supply for the digital outputs. It is the same supply for the digital inputs. (See

Common under Digital Inputs, page 47.)

key will also reset the

6 Alarm Output Blue - 7 +24 Volts Orange + 8 Pot Life Yellow -

Automation 9 Flow Rate Analog In Purple + 10 Flow Rate Analog Common Gray -

3A1080C 49

ProControl 1KS Integration Specifics

Automation Flow Charts

Start Mix Mode Process

See FIG. 62, Table 5, and Table 6.

Start Mix

Mode Process

Must be Alarm Condi-

tion or Active Recipe

61. See Alarm Pro-

cessing on page 54,

or Startup from Recipe

61 (see NOTE below)

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).

Is Mix Ready

bit = 1?

YESNO

Set Mix bit = 1

Is Mix Active

bit = 1?

YES

ProControl 1KS in Mix

Mode (Complete).

Mix Active = 1 while

the ProControl 1KS is

in Mix mode

IG. 62. Start Mix Mode Process Flow Chart

50 3A1080C

Mixing Mode Process

See FIG. 63, Table 5, and Table 6.

ProControl 1KS Integration Specifics

Mixing Mode

Process

Mixing Mode is desired. PLC is polling to ensure

Mixing Mode is main-

tained.

Check Alarm

Condition: is Alarm_

General bit = 1?

YES

Is Mix Active

bit = 1?

YESNO

Mixing Process active

Go to Start Mix Mode

Process, page 50

Go to Alarm Process-

ing, page 54

IG. 63. Mixing Mode Process Flow Chart

3A1080C 51

ProControl 1KS Integration Specifics

Purge Mode Process

See FIG. 64, Table 5, and Table 6.

Start

Must be Alarm

Condition or Active

Recipe 61. See

Alarm Processing

on page 54, or

Startup from Recipe

61 (see NOTE below).

Is Mix Ready

bit = 1?

YESNO

Set Purge bit = 1?

YES

Is Purge_CC_Active

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).

IG. 64. Purge Mode Process Flow Chart

52 3A1080C

(Wait for Mix Ready)

Is Mix Ready

bit = 1?

YES

ProControl 1KS in

Purge_CC Mode

(Process Started)

ProControl 1KS Purge

Process (Complete)

Color Change Mode Process

See FIG. 65, Table 5, and Table 6.

ProControl 1KS Integration Specifics

Color Change

Process

(basic)

Do nothing. Spraying at

desired recipe.

Ensure ColorChange bit is seen by ProControl 1KS

YES NO

Is Active Recipe = to desired recipe?

(Register 40005).

Purge_CC_Active

bit = 1?

YES

Load ccNewRecipe

(Register 40046) with

recipe number to Color

Change to (0 through

60 is valid).

Set ColorChange (CC)

bit = 1.

Clear ColorChange (CC)

bit (momentary input).

CC process started.

IG. 65. Color Change Mode Process Flow Chart

3A1080C 53

Check Alarm

Condition: is Alarm_

General bit = 1?

YES

(Wait for Mix Ready)

Is Mix Ready

bit = 1?

YES

Process Alarm. See Alarm Processing,

ProControl 1KS Color

Change Process

(Complete)

page 54.

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.

Determine the exact alarm

from Table 7 on page 57

and solve what caused the

alarm, as required.

Reset the alarm.

Reset_Alarm = 1.

NO YES

Is Mix Ready

bit = 1?

Check if Potlife

Alarm: is Alarm_

Potlife bit = 1?

YESNO

Two options:

• 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.

NOTE: The Reset key only silences the alarm. To clear the alarm you must use one of these two options.

Go to next process,

as desired.

IG. 66. Alarm Processing Flow Chart

54 3A1080C

ProControl 1KS Integration Specifics

Table 5: ProControl 1KS Digital Inputs (Modbus Register 40040)

Bit Digital Input Binary Name Details

0:5 0000000000XXXXXXRecipe Binary bits for viewing discrete inputs only. 6 000000000

1000000Color Change

Set bit to “1” to initiate Color Change (momentary)

(CC) 7 00000000 8 0000000

10000000Mix Set bit initiate Mix mode (maintain)

100000000Purge Set bit to “1” to initiate Purge sequence (maintained)

9 0000001000000000Job_Complete Set bit to “1” to initiate Job Complete input (momen-

tary)

10 0000010000000000External CC

Ready

Set bit to “1” to initiate External Color Change

(momentary) 11 0000100000000000Not Used 12 0001000000000000FC _Calibrate Set bit to “1” to initiate a Flow Control Calibrate input

(momentary) 13 0010000000000000Gun_Trigger Set bit to “1” to indicate the gun is actually triggered

(maintain while gun is triggered, remove when gun is

closed) 14 0

100000000000000Reset_Alarm Set bit to “1” to clear an active Alarm (momentary)

15 1000000000000000Remote Stop Set bit to remotely stop unit (momentary)

NOTE: Shaded cells relate to the flow charts on pages 50-54.

3A1080C 55

ProControl 1KS Integration Specifics

Table 6: ProControl 1KS Digital Outputs (Modbus Register 40041)

Bit Digital Input Binary Name Details

0 000000000000000

1 Purge_CC_Active “1” indicates Purge or Color Change is in prog-

ress 1 00000000000000 2 0000000000000

10Mix_Active “1” indicates Mix is in progress

100Mix_Ready “1” indicates No Alarms and OK to Mix

3 0000000000001000CC_Fill_Active “1” indicates the Fill portion of a Color Change is

in progress 4 0000000000010000FCalActive “1” indicates the Flow Control Calibrate routine is

in progress 5 0000000000100000Flow_Rate_Alarm “1” indicates the Flow Rate Alarm/Warning is

active 6 0000000001000000Special_1 “1” indicates the Special_1 output is on (monitor

only) 7 0000000010000000Special_2 “1” indicates the Special_2 output is on (monitor

only) 8 0000000100000000Special_3 “1” indicates the Special_3 output is on (monitor

only) 9 0000001000000000Special_4 “1” indicates the Special_4 output is on (monitor

only) 10 0000010000000000Not Used 11 0000100000000000Not Used 12 0 0 0

1000000000000Alarm_General “1” indicates a General Alarm is in process. (If

Mix_Active is still High, then a Warning only.) See

the Modbus charts in the Graco Gateway manual

312785 for details on type. 13 0010000000000000Alarm_Potlife “1” indicates a Potlife Alarm is in process.

NOTE: Shaded cells relate to the flow charts on pages 50-54.

56 3A1080C

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 Byte: 0 0000 0000 0100 0000 Dose_Time_A_Alarm Low Byte: 0 0000 0000 1000 0000 Dose_Time_B_Alarm Low Byte: 0 0000 0001 0000 0000 Mix_In_Setup_Alarm Low Byte: 0 0000 0010 0000 0000 Remote_Stop_Alarm Low Byte: 0 0000 0100 0000 0000 Purge_Volume_Alarm Low Byte: 0 0000 1000 0000 0000 CAN_Comm_Error_Alarm Low Byte: 0 0001 0000 0000 0000 High_Flow_Alarm Low Byte: 0 0010 0000 0000 0000 Low_Flow_Alarm Low Byte: 0 0100 0000 0000 0000 System_Idle_Alarm Low Byte: 0 1000 0000 0000 0000 Setup_Change_Alarm High Byte: 0 0000 0000 0000 0001 Power_On_Alarm High Byte: 0 0000 0000 0000 0010 Defaults_Loaded_Alarm High Byte: 0 0000 0000 0000 0100 IO_Alarm High Byte: 0 0000 0000 0000 1000 Purge_Initiate_Error High Byte: 0 0000 0000 0001 0000 Material_Fill_Alarm High Byte: 0 0000 0000 0010 0000 Tank_A_Low_Alarm High Byte: 0 0000 0000 0100 0000 Tank_B_Low_Alarm High Byte: 0 0000 0000 1000 0000 Tank_S_Low_Alarm High Byte: 0 0000 0001 0000 0000 Auto_Dump_Complete High Byte: 0 0000 0010 0000 0000 Color/Catalyst_Purge_Alarm High Byte: 0 0000 0100 0000 0000 Color/Catalyst_Fill_Alarm High Byte: 0 0000 1000 0000 0000 Num_Alarm_Desc High Byte: 0 0001 0000 0000 0000 Spare3_Alarm High Byte: 0 0010 0000 0000 0000 Spare2_Alarm High Byte: 0 0100 0000 0000 0000 Spare1_Alarm High Byte: 0 1000 0000 0000 0000 Potlife_Buzzer

3A1080C 57

ProControl 1KS Integration Specifics

ProControl 1KS

PLC Output

EasyKey Digital Input

(Sourcing)

Input Common

ProControl 1KS EasyKey

Digital Output

Output Common

24 Vdc

Output

CommonInput

24 Vdc

PLC Input

Input

(Sinking)

ProControl 1KS

EasyKey Digital Output

Output Common

Output

FIG. 67. Automation 24 Vdc Sourcing Input Diagram

24 Vdc

CommonOutput

PLC Input

(Sourcing)

Input

Common

58 3A1080C

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

Change (maintained) 5 J2, Remote I/O Board Spare 6* J2, Remote I/O Board Digital Input Common

1* J3, Remote I/O Board Digital Input Common 2 J3, Remote I/O Board Recipe Bit 0 Set Binary Bits for Recipe to Change To (hold

until changing again) 3 J3, Remote I/O Board Recipe Bit 1 Set Binary Bits for Recipe to Change To (hold

until changing again) 4 J3, Remote I/O Board Recipe Bit 2 Set Binary Bits for Recipe to Change To (hold

until changing again) 5 J3, Remote I/O Board Recipe Bit 3 Set Binary Bits for Recipe to Change To (hold

until changing again) 6 J3, Remote I/O Board Recipe Bit 4 Set Binary Bits for Recipe to Change To (hold

until changing again) 7 J3, Remote I/O Board Recipe Bit 5 Set Binary Bits for Recipe to Change To (hold

until changing again) 8 J3, Remote I/O Board Color Change (CC) Set Bit to “1” to initiate Color Change

(momentary)

1 10 Pin Terminal Block Flow Control Calibrate Set Bit to “1” to initiate Flow Control Calibrate

(momentary) 2 10 Pin Terminal Block Gun Trigger Set Bit to “1” to indicate Gun is Triggered

(fluid flow expected) 3† 10 Pin Terminal Block Digital Input Common 4 10 Pin Terminal Block Remote Stop Set Bit to “1” to initiate a Remote Stop

(momentary) 5 10 Pin Terminal Block Reset_Alarm Set Bit to “1” to Clear an Active Alarm

(momentary) * Digital inputs tied together on the I/O board (see F † Digital inputs tied together on the EasyKey Display Board (see F

IG. 61).

IG. 59).

Multiple connection points for convenience.

3A1080C 59

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” Indicates the Fill Portion of a Color

Change is in progress 6 J4, Remote I/O Board FCalActive “1” Indicates the Flow Control Calibrate rou-

tine is in progress 7 J4, Remote I/O Board Flow_Rate “1” Indicates the Flow Rate Alarm/Warning is

active 8★ J4, Remote I/O Board Digital Output Common/Power

1★ J5, Remote I/O Board Digital Output Common/Power 2 J5, Remote I/O Board Special_1 “1” Indicates the Special_1 Output is on 3 J5, Remote I/O Board Special_2 “1” Indicates the Special_2 Output is on 4 J5, Remote I/O Board Special_3 “1” Indicates the Special_3 Output is on 5 J5, Remote I/O Board Special_4 “1” Indicates the Special_4 Output is on 6★ J5, Remote I/O Board Digital Output Common/Power

6 10 Pin Terminal Block General Alarm Output “1” Indicates the General Alarm Output is on 7◆ 10 Pin Terminal Block Digital Output Common/Power 8 10 Pin Terminal Block Potlife Alarm “1” Indicates the Potlife Alarm Output is on 9 10 Pin Terminal Block Flow Rate Analog In (0-10

VDC)

0 - 10VDC input for Flow Setpoint relative to

flow range set in 2KS Flow Range Screen 10 10 Pin Terminal Block Flow Rate Common to Pin 9 Common side of Flow Setpoint from Terminal

Communications

1 6 Pin Terminal Block RS485 Integration A 2 6 Pin Terminal Block RS485 Integration B

Communication to External PLC/Controller 3 6 Pin Terminal Block RS485 Integration

Shield/Ground

4 6 Pin Terminal Block RS485 Network A

Communication to Multiple EasyKeys only5 6 Pin Terminal Block RS485 Network B 6 6 Pin Terminal Block RS485 Network Shield/Ground

★ Digital outputs tied together on the I/O board (see F

◆ Digital outputs tied together on the EasyKey Display Board (see F

IG. 61).

IG. 59).

Multiple connection points for convenience.

60 3A1080C

Table 9: ProControl 1KS Recipe Bits

Recipe Bits Number Recipe Bits Number

543210 543210

000000 0 100001 33 000001 1 100010 34 000010 2 100011 35 000011 3 100100 36 000100 4 100101 37 000101 5 100110 38 000110 6 100111 39 000111 7 101000 40 001000 8 101001 41 001001 9 101010 42 001010 10 101011 43 001011 11 101100 44 001100 12 101101 45 001101 13 101110 46 001110 14 101111 47 001111 15 110000 48 010000 16 110001 49 010001 17 110010 50 010010 18 110011 51 010011 19 110100 52 010100 20 110101 53 010101 21 110110 54 010110 22 110111 55 010111 23 111000 56 011000 24 111001 57 011001 25 111010 58 011010 26 111011 59 011011 27 111100 60 011100 28 011101 29 011110 30 011111 31 100000 32

ProControl 1KS Integration Specifics

3A1080C 61

System Operation

Operation Modes

Mix

System mixes and dispenses material (apply Mix input).

Standby

Stops the system (remove Mix input).

Purge

Purges the system, using air and solvent (apply Purge input).

Recipe (Color) Change

The process when the system automatically flushes out the old color and loads a new color. See pages 78-89.

Flow Control

NOTE: Flow control is not available with dynamic dos-

ing.

Flow control is an optional feature of the ProControl 1KS automatic system. Flow control regulates the flow of material to a manual or automatic air spray gun, to help ensure adequate coverage and avoid sags or runs in the finish coat. It is not for use with air-assisted or airless spray guns.

See F

IG. 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.

Set Flow Control to “On” in Configure Screen 5 on page 31. Make the desired selections in Advanced Setup Screen 5, page 37.

See the Graco Gateway manual 312785 for Flow Control Modbus addresses.

Fluid Inlet from

Fluid Manifold

Cable from

Fluid Station

Control Box

FIG. 68. Flow Control Regulator

Air Line from Air Control

Fluid Outlet to Gun

TI13656a

62 3A1080C

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).

Start Mixing

To start the mix process, the PLC will monitor and ensure the Mix_Ready output is High. This provides assurance it is ready to mix. PLC will drive High the Mix_Start input, keep it High and monitor the Mix_Active output to ensure the ProControl 1KS followed through on the request.

Stop Mixing

To stop mixing (to perform a purge or color change), remove the Mix_Start input (the status bar on the EasyKey will show STANDBY). Monitor the Mix_Ready output to ensure the Mix_Active output goes Low.

Color Change

To perform a color change, ensure there are no alarms (except the Potlife Alarm). If alarms are present, the Alarm_Reset input should be sent momentarily to clear the alarm (>100 msec).

During the short On state, the recipe will be read from this binary sequence and the status bar of the EasyKey will display COLOR CHANGE XX. The Purge_CC_Active output will be High for the duration of the color change purge process. During the Mixed Material Load portion at the end of the Color Change sequence, the Fill_Active output will be on, indicating that portion of the color change. These will not be on at the same time. Once the Mix_Ready output goes High with no alarms, then the PLC has assurance that the requested color change has taken place with the requested recipe being the current active recipe. If any error occurs during the process, the requested recipe will not be loaded, and the old recipe will remain active.

NOTE: It is not possible to read the active recipe through Discrete I/O alone. Only by monitoring networked registers through the Gateway is it possible to view the active recipe. Proper management of the alarm status outputs during the color change process will ensure the active recipe is what is expected.

Purge

To start a Purge (no color change), drive the Purge_Start input High (maintained) while ensuring Mix_Ready output is High (ensuring no active alarms). An exception is Potlife alarm (see Color Change above if alarms are present.) The Purge_CC_Active output is High for the entire Purge process. Ensure there are no alarms during this process. Fill_Active is High when Mix is on. When complete, Mix _Ready output will be High, indicating a completed purge.

NOTE: No change is made to the active recipe.

NOTE: Alarm_Reset will not reset a Potlife alarm. Only

dispensing the Potlife Volume or a complete Purge/Color Change will reset a Potlife alarm.

The Alarm Reset Input will silence the audible alarm. Turn the Color_Change_Start input on momentarily (>100 msec) while the proper sequence of recipe bits are set.

NOTE: The Recipe Bits must be presented at least 100 msec before the Color Change Start input is turned on and remain until a new recipe is required.

3A1080C 63

Gun Trigger Input

This input is sent and expected every time the gun is actually triggered, and this input is turned off when the gun is not triggered. Never tie this input with any other signal. Without this input, some critical mixing alarms are eliminated. This input should be provided through Discrete I/O only for flow control applications to ensure fast coordination with the flow control process. Applications without integrated flow control can use Gun Trigger input through Network Communications or Discrete I/O.

NOTE: This has the same effect as the air flow switch used on manual ProControl 1KS systems.

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 condi-

tions:

• Potlife Alarms cannot be reset by the Alarm Reset

input or through the EasyKey Alarm Reset key. Only a Purge/Color Change or spraying the Pot-

life volume will reset a Potlife alarm. (See Alarm_Potlife output information on page 49.)

• When Flow Control is turned on (see Configure Screen 5 on page 31), the Flow_Rate_Alarm output will be High when the instantaneous flow rate is above or below the Flow Rate tolerance setting. (High Flow or Low Flow will be the condition, indicating in the status bar of the EasyKey.) This output will be High along with the Mix_Active output. The PLC should monitor the amount of time this condition exists and take action at a predetermined time. With Flow Control there will be times (for example during flow rate changes) where the general alarm as described here will be High (typically momentarily). The PLC must read this Alarm output (i.e. general alarm), see if Mix_Active is still High, and if so, start a timer. A typical example would be to ensure all parts are sprayed within a specific flow rate range. A maximum predetermined time would be set to allow a Low or High flow condition to exist continuously.

• Shutdown or go to Standby after the flow rate alarm time expires.

Job_Complete Input

For Applications with Dump Valves (for quick purges/color changes at or near the gun):

ProControl 1KS has four specials that can each be turned off and on twice throughout a color change sequence. See Advanced Setup Screen 8 on page 38 or Recipe Setup Screen 7 on page 42.

For example, a dump valve at a gun on a robot could be opened at the appropriate times to facilitate fast color changes. Another output could be used to automatically drive an air-operated fluid regulator High during the Purge or Color Change process.

NOTE: With integrated Flow Control, the flow control regulator automatically is driven High. See Advanced Setup Screen 5 on page 37 for specifics on setting up these values. Each of the specials can be monitored, but can only be controlled through the times entered within the setup screens of the EasyKey or by managing the proper registers on the network.

The following ProControl 1KS inputs should never be on (High) at the same time:

•Mix_Start

• Purge_Start

• Color_Change_Start

The Recipe Bits (0-6) are always on at the same time. The only time these bits are recognized is when the Color_Change_Start input is High. The Recipe Bits should be loaded and stay loaded for the current recipe. Do not change the Recipe Bits until a color change is required again. Inconsistent results are possible if this is not followed.

Every time a momentary Job_Complete input is seen by the ProControl 1KS, a job log will be recorded, logging the A meter volume (cc) with a time and date stamp. The volume will then be reset to 0. (Volume totals are accumulated since the last reset.)

NOTE: A Color Change accomplishes the same Job Complete Reset functions. The Job_Complete input is commonly used to record material usage for a specific set of parts. These volumes are sprayed material volumes.

64 3A1080C

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. The controller monitors these pulses and signals.

6. When the target volume dispenses, Dose Valve A closes.

NOTE: The dispense volume of component A is based on the mix ratio and dose size set by the user and calculated by the ProControl 1KS controller.

7. Component A is fed to the gun as long as the Gun Trigger input is seen.

8. If the Gun Trigger input is not seen for two minutes, the system switches to Idle mode, which closes off the mix manifold dose valve.

9. When the Gun Trigger input is seen again, the ProControl 1KS continues the process where it left off.

NOTE: Operation can be stopped at any time by going to Standby mode (remove Mix input).

FIH

APV

DVA

FOH

Key:

MA Component A Meter DVA Component A Dose Valve SPV Solvent Purge Valve SS Solvent Purge Valve Solvent Supply Tube

SPV

APV Air Purge Valve AT Air Purge Valve Air Supply Tube FIH Fluid Inlet Hose FOH Fluid Outlet Hose

TI15977a

IG. 69. Fluid Manifold

3A1080C 65

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

IG. 70.

Table 10: Mix Manifold Valve Settings

IG. 70. Valve Adjustment

TI11581a

Valve Setting Function

Dose (see F

IG. 70)

Purge (see F

IG. 70)

Hex nut (E) 1-1/4 turns out from fully closed

Limits maximum fluid flow rate into integrator and minimizes valve response time.

66 3A1080C

System Operation

Start Up

1. Go through the Pre-Operation Checklist in Table 11.

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.

Fluid supply containers filled

Check component A and solvent supply containers.

Mix manifold valves set

Check that mix manifold valves are set correctly. Start with the settings recommended in Mix Mani- fold Valve Settings, page 66, then adjust as needed.

Fluid supply valves open and pressure set Solenoid pressure set

➜ In bottom left corner, the system status displays,

which can be Standby, Mix, Purge, or an alarm notification.

FIG. 72. Status Screen

3. Verify that the EasyKey is working. The active recipe number and Standby mode should be displayed.

4. If this is the first time starting up the system, purge it as instructed in Purging Fluid Supply System, page 74. The equipment was tested with lightweight oil, which should be flushed out to avoid contaminating your material.

75-100 psi inlet air supply (0.5-0.7 MPa, 5.2-7 bar)

2. Turn the AC Power Switch ON (I = ON, 0 = OFF).

I = ON

TI12656a

IG. 71. Power Switch

➜ Graco logo, software revision, and “Establishing

Communication” will display, followed by Status screen. See page 19.

➜ 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).

5. Make sure that the EasyKey is in Standby (remove Mix input).

6. Adjust component A fluid supply as needed for your application. Use lowest pressure possible.

7. Do not exceed the maximum rated working pressure shown on the system identification label or the lowest rated component in the system.

8. Open the fluid supply valves to the system.

9. Adjust the air pressure. Most applications require about 80 psi (552 kPa, 5.5 bar) air pressure to operate properly. Do not use less than 75 psi (517 kPa, 5.2 bar).

3A1080C 67

System Operation

10. Purge air from the fluid lines.

a. Shut off air to the gun by clos-

ing the air regulator or shutoff valve for the gun atomizing air.

b. Trigger the gun (man-

ual or automatic) into

Manual gun shown

a grounded metal pail.

c. Go to Mix mode.

d. If the flow meters over-run because of air in the

system, an alarm will occur and operation stops.

Press the Alarm Reset

key to clear

alarm.

e. Go to Mix mode.

11. Adjust the flow rate.

Watch the fluid flow rate displayed on the Status screen while the gun is fully open.

If the fluid flow rate is too low: increase air pressure to the fluid supply or increase the regulated fluid pressure.

If the fluid flow rate is too high: reduce the air pressure, close the fluid manifold dose valves further, or adjust the fluid pressure regulator.

NOTE: Pressure adjustments of each component will vary with fluid viscosity. Adjust as needed.

12. Turn on atomizing air to the gun. Check the spray pattern as instructed in your spray gun manual.

NOTE: Do not allow a fluid supply tank to run empty. It is possible for air flow in the supply line to turn gear meters in the same manner as fluid. This can lead to the mixing of fluid and air that meets the ratio and tolerance settings of the equipment.

The fluid flow rate is shown on the EasyKey Status screen. The fluid supply lines on the screen highlight when the dose valve is open.

IG. 73. Status Screen Flow Rate Display

68 3A1080C

System Operation

Shutdown

Overnight Shutdown

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). F

4. If servicing EasyKey, also shut off power at main circuit breaker.

IG. 74.

0 = OFF

Pressure Relief Procedure

NOTE: The following procedures relieve all fluid and air

pressure in the ProControl 1KS system. Use the procedure appropriate for your system configuration.

Relieve pressure when you stop spraying, before changing spray tips, and before cleaning, checking, or servicing equipment.

Single Color Systems

1. While in Mix mode (gun triggered), shut off the fluid supply pumps/pressure pots. Close all fluid shutoff valves at the pump outlets.

2. With the gun triggered, push the manual override on the A dose valve solenoid to relieve pressure. See F

IG. 75.

NOTE: If a Dose Time alarm (E-7, E-8) occurs, clear the alarm.

IG. 74. Power Switch

TI12657a

3. Do a complete system purge, following the instructions under Purging Using Recipe 0, page 74.

4. Shut off the fluid supply to the solvent purge valve (SPV) and the air supply to the air purge valve (APV), F

5. With the gun triggered, push the manual override on the A purge valve solenoid to relieve air and solvent pressure. See F is reduced to 0.

NOTE: If a Purge Volume alarm (E-11) occurs, clear the alarm.

IG. 77.

IG. 75. Verify that solvent pressure

3A1080C 69

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, F

IG. 75.

4. See F

IG. 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. Press and hold the dump valve A solenoid override, F

IG. 75.

6. Press and hold the A side (color) solvent solenoid override until clean solvent comes from the dump valve, then release.

7. Shutoff the solvent supply to the color/catalyst change stack solvent valves.

8. Press and hold the A solvent solenoid override and dump valve override until solvent flow from the dump valve stops.

70 3A1080C

Dose Valve A Solenoid

Purge Valve A Solenoid

System Operation

Purge Valve B Solenoid

Dose Valve B Solenoid

J14

J15

CAN

J1J12J3J9

Power

Fiber Optic

TI15916a

FIG. 75. Fluid Solenoids

3A1080C 71

System Operation

Solenoid

Identification

Label

Color Catalyst

Solenoid Identification Label

Color

TI12826a

FIG. 76: Color Change Solenoids

APV

DVA

Solvent Solenoid Overrides

FIH

Key:

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

FOH

SPV

TI15977a

FIG. 77. Fluid Manifold

72 3A1080C

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)

Use the criteria listed in each procedure to determine which procedure to use.

Purging Mixed Material

There are times when you only want to purge the fluid manifold, such as:

2. Set the solvent supply pressure regulator at a pressure high enough to completely purge the system in a reasonable amount of time but low enough to avoid splashing or an injection injury. Generally, a setting of 100 psi (0.7 MPa, 7 bar) is sufficient.

3. If using a gun flush box, place the gun into the box and close the lid. Go to Purge mode. The purge sequence automatically starts.

If the gun flush box is not used, trigger the gun (manual or automatic) into a grounded metal pail until the purge sequence is complete.

When done purging, the EasyKey automatically switches to Standby mode.

4. If the system is not completely clean, repeat step 3.

NOTE: If necessary, adjust purge sequence so only one cycle is required.

• end of potlife

• breaks in spraying that exceed the potlife

• overnight shutdown

• before servicing the fluid manifold assembly, hose or gun.

1. Go to Standby mode (remove Mix input).

Trigger the gun to relieve pressure.

If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.

If using an electrostatic gun shut off the electrostatics before flushing the gun.

Trigger the gun to relieve pressure. Engage trigger lock.

5. If spray tip was removed, reinstall it.

6. Adjust the solvent supply regulator back to its normal operating pressure.

3A1080C 73

System Operation

Purging Using Recipe 0

Recipe 0 is typically used in multiple color systems to purge out material lines without loading a new color.

To setup Recipe 0, go to Advanced Setup. Select the Recipe tab and change the Recipe to 0. The Recipe 0 Setup Screen appears. Set the chop times from 0-999 seconds in increments of 1 second.

1. Go to Standby mode (remove Mix input).

Trigger the gun to relieve pressure.

If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.

Purging Fluid Supply System

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

* Some steps are not necessary for initial flush-

ing, as no material has been loaded into the system yet.

1. Go to Standby mode (remove Mix input).

Trigger the gun to relieve pressure.

If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.

If using an electrostatic gun shut off the electrostatics before flushing the gun.

2. If using a gun flush box, place the gun into the box and close the lid.

3. Select Recipe 0 and press Enter .

4. If a gun flush box is not used, trigger the gun (manual or automatic) into a grounded metal pail until the purge sequence is complete.

5. The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete.

6. If the system is not completely clean, you can repeat Recipe 0 by pressing Enter

If using an electrostatic gun, shut off the electrostatics before flushing the gun.

2. Attach solvent supply lines as follows:

• Single color systems: disconnect the fluid

supply at the flow meter inlet, and connect regulated solvent supply lines.

• Multiple color systems: disconnect the fluid

supply at the flow meter inlet and connect a regulated solvent supply line.

74 3A1080C

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 F

IG. 75 on page 71.

5. Purge as follows:

• Single color systems: Press the manual over-

ride 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 . The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete.

6. Reinstall the Fluid Station Control Box cover.

7. Shut off the solvent fluid supply.

System Operation

8. Disconnect the solvent supply lines and reconnect the fluid supply.

9. See page 67 for Start Up procedure.

3A1080C 75

Meter Calibration

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.

NOTE:

• K-Factors on the Calibration Screen are

updated automatically after the calibration procedure is completed.

4. On the EasyKey, press the Setup key to access setup screens.

5. Press the Right Arrow key to select the Cali- bration Screen. Press

Dose Valve A. Press the Down Arrow select Start from the menu. Start only one at a time.

the Enter key to select

key and

• K-Factor values on the screen are viewable only. If needed, you can manually edit the K-Factors in Advanced Setup Screen 4 (see page 37) or Recipe Setup Screen 5 (page 42).

• All values on this screen are in cc, independent of the units set in Configure Screen 1.

• The controller will use the active recipe K-factors for meter calibration. The active recipe must be recipe 1 to recipe 60. Recipes 0 and 61 do not have K-factor values.

1. Before calibrating meter A, prime the system with material. For a color change system, make sure the color valve is open.

2. Shut off all spray or dispense devices connected to the ProControl 1KS.

3. Place the beaker (minimum size - 250 cc) to capture fluid from the gun.

6. Dispense a minimum of 250 cc into beaker; make sure enough material is dispensed to accurately read the volume with your beaker.

7. The volume that the ProControl 1KS measured displays on the EasyKey.

76 3A1080C

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.

NOTE: If the screen and actual volume is the same or if for any reason you want to cancel the calibration procedure, scroll to Abort on the Calibration

Screen menu and press the Enter key

10. After the volume for A or Solvent is entered, the ProControl 1KS controller calculates the new flow meter K-Factor and shows it on the Calibration Screen.

Meter Calibration

NOTE: K-Factor values on the screen are viewable only. If needed, you can manually edit the K-Factors in Advanced Setup Screen 4 (page 37) or Recipe Setup Screen 5 (page 42).

11. Before you begin production, clear the system of solvent and prime it with material.

a. Go to Mix mode.

b. Trigger the gun into a grounded metal pail until

mixed material flows from the gun nozzle.

c. To begin operation, see Start Up, page 67.

3A1080C 77

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

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.

NOTE: The color change timer does not start until a Gun Trigger input is seen and fluid flow is detected. If no flow is detected within 2 minutes, the color change operation aborts. The system enters

Standby mode (remove Mix input) at the previ-

ous color.

6. When you are ready to spray, remove the gun from the gun flush box if used, and close its door (manual and semi-automatic systems only).

NOTE: The gun flush box door must be closed for the atomizing air valve to open.

mode (remove Mix input).

Color Change Sequences

FIG. 78 through FIG. 95 illustrate various color change sequences. See Table 12 to determine which figure to reference, based on the recipe change and system configuration. The time sequences are detailed in the following paragraphs.

NOTE: See Setup Mode on page 25 to select purge sources and set desired purge, chop, and fill times.

NOTES:

• The system uses old recipe data for the purge cycle. However, it opens the new color valve based on the new recipe data.

• The system uses the new recipe data for the fill cycle.

• For the one gun flush box (GFB) option, the spray gun must be inserted in the GFB during the entire color change cycle (purge and fill). The GFB trigger output will be on during the recipe change cycle.

• For the two gun flush box (GFB) option, both spray guns must be inserted in the GFBs during the entire color change cycle (purge and fill). The system will turn each GFB trigger output on and off based on the preset time for each gun.

• For Special Outputs options, the system will turn each output on and off based on the preset times. Each Special Output has two different start times and durations.

7. Enter Mix mode to start spraying.

• For systems without dump valves, the First Purge begins after the Color Change steps are completed.

Single Color Systems

1. Follow procedure for Purging Fluid Supply System, page 74.

2. Load the new color. See Start Up, page 67.

3. Enter Mix mode to start spraying.

78 3A1080C

• When going from Recipe X to Recipe 0, only the purge cycle data from Recipe 0 is used.

• When going from Recipe 0 to Recipe X, only the fill cycle data from Recipe X is used.

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.

• The new color valve and the Dump A valve close when the Fill Time expires.

First Purge

Step M0-M1

Select the First Purge Source (air, solvent, or 3rd valve) and First Purge Time. For most applications, air is selected.

Final Purge

Step M2-M3

Select the Final Purge Source (air, solvent, or 3rd valve) and Final Purge Time. For most applications, solvent is selected.

The system fills the line with solvent from the dose valves to the gun, using only the selected purge media (usually solvent). The selected purge valve opens during the Final Purge Time and closes when the time expires.

Fill

Step M3-M4

This sequence fills the line from the dose valves to the gun, and is also referred to as the mixed material fill. The system begins dispensing component A until the Fill Time expires.

Purge Active

Step M0-M3

The system turns on the Purge/Recipe Change Purge Active output during steps M0-M3.

Fill Active

Step M3-M4

The system turns on the Recipe Change Fill Active output during step M3-M4.

The system purges the old material from the dose valves to the gun, using only the selected purge media (usually air). The selected purge valve opens during the First Purge Time and closes when the time expires.

Chop Cycle

Step M1-M2

Select the Chop Type (air/solvent or air/3rd valve) and Chop Times.

The air purge valve opens only during the air chop cycle, and the solvent (or 3rd valve) opens only during the solvent chop cycle. The number of chop cycles is determined by dividing the Total Chop Time by the sum of the Air and Solvent Chop Times.

3A1080C 79

Color Change

Table 12: Color Change Chart Reference

Number of

Starting

Recipe

Ending Recipe

Color

Change

Catalyst

Change

Dump

Valves

3rd Purge

Valve

Gun Flush

Boxes Refer to Fig.

X X Ye s Ye s Ye s Ye s 0 FIG. 79 X X Ye s Ye s Ye s No 0 FIG. 78 X X Ye s No No No 0 FIG. 81 X X Ye s No Ye s No 0, 1, or 2 FIG. 80 X X No Ye s Ye s No 0, 1, or 2 FIG. 82 X X No No No No 0, 1, or 2 FIG. 92 X X Ye s Ye s Ye s N o 1 F X X YesNoNoNo 1F X X Ye s Ye s Ye s No 2 FIG. 83 X X Ye s No No No 2 FIG. 85 X 0 Yes Ye s Ye s N o 0 , 1 , o r 2 F X 0 Yes No Yes No 0, 1, or 2 F X 0 YesNoNoNo0, 1, or 2F X 0 No Yes Yes No 0, 1, or 2 F

X 0 No No No No 0, 1, or 2 F 0 or 61 X Ye s Ye s Ye s No 0, 1, or 2 FIG. 88* 0 or 61 X Ye s No Ye s No 0, 1, or 2 FIG. 88* 0 or 61 X Ye s No No No 0, 1, or 2 FIG. 90** 0 or 61 X No Ye s Ye s No 0, 1, or 2 FIG. 88* 0 or 61 X No No No No 0, 1, or 2 FIG. 90**

0 0 Ye s Ye s Ye s N o 0 , 1 , o r 2 F

0 0 Yes No Yes No 0, 1, or 2 F

0 0 YesNoNoNo0, 1, or 2F

0 0 No Yes Yes No 0, 1, or 2 FIG. 87*

0 0 No No No No 0, 1, or 2 F

61 0 Ye s o r No Yes o r No Yes o r No No 0, 1, or 2 FIG. 87*

0 X Yes Yes Yes Yes 0, 1, or 2 FIG. 94

0 X Ye s N o Ye s Ye s 0, 1, o r 2 F

0 X Yes No No Yes 0, 1, or 2 F

0 X No Yes Yes Ye s 0, 1, o r 2 F IG. 94

0 X No No No Yes 0, 1, or 2 F

IG. 84 IG. 86

IG. 87* IG. 87* IG. 89** IG. 87* IG. 89**

IG. 87* IG. 87* IG. 89**

IG. 89**

IG. 94 IG. 95

IG. 95

NOTES:

* F

IG. 87 and FIG. 88 show both color and catalyst change. If the color or catalyst is not changing, disregard that

portion of the chart.

** F

IG. 89 and FIG. 90 show color change. If the color is not changing, disregard that portion of the chart.

IG. 91 (page 87) shows a recipe change with Special Outputs.

IG. 93 (page 88) shows an External Color Change.

80 3A1080C

Dump A

Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Valve

Dispense A AA Dispense B BB

Gun Trigger(s) by Operator

Chop Time (air/solvent or air/3rd flush) M1->M2

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

alve Time-Sequence

Color Purge Time P0->P1

Color Fill Time P1->P2

Catalyst Purge Time P2->P3

Catalyst Fill Time P3->P4

First Purge (one of these) 3rd Flush Chop Time

First Purge Time M0->M1

Final Purge Time M2->M3

Mixed Fill Time M3->M4

FIG. 78: Color Change Chart 1

ProMix 2KS Recipe Change

Chart 1: A1 to A2, B1 to B2 with Dump Valves

P0 P1 P2 P3 P4

M0 M1 M2 M3 M4

Air Chop Time

Solvent Chop Time

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

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Valve

Dispense A AA Dispense B BB

Gun Trigger(s) by Operator

*Two Second Initial Purge Time M0->M1

Chop Time (air/solvent or air/3rd flush) M2->M3

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe *Applies to ALL charts when 3rd Flush Valve is ON

alve Time-Sequence

Color Purge Time P0->P1

Color Fill Time P1->P2

Catalyst Purge Time P2->P3

Catalyst Fill Time P3->P4

First Purge (one of these) 3rd Flush Chop Time

*Two Second Solvent Purge

First Purge Time M1->M2

Final Purge Time M3->M4

Mixed Fill Time M4->M5

FIG. 79: Color Change Chart 2

Chart 2: A1 to A2, B1 to B2 with Dump Valves and 3rd Flush Valve

P0 P1 P2 P3 P4

M0 M1 M2 M3 M4 M5

ProMix 2KS Recipe Change

Air Chop Time

Solvent Chop Time

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.

3A1080C 81

Color Change

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Valve

Dispense A AA Dispense B BB

Gun Trigger(s) by Operator

Chop Time (air/solvent or air/3rd flush) M1->M2

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

alve Time-Sequence

Color Purge Time P0->P1

Color Fill Time P1->P2

First Purge (one of these) 3rd Flush Chop Time

First Purge Time M0->M1

Final Purge Time M2->M3

Mixed Fill Time M3->M4

FIG. 80: Color Change Chart 3

ProMix 2KS Recipe Change

Chart 3: A1 to A2, same B with Dump Valves

P0 P1 P2 P3 P4

CC Purge/Fill Timers are independent of Mixed Material Purge Timers. This

Air Chop Time

Solvent Chop Time

M0 M1 M2 M3 M4

line defines when the Mixed Fill Time begins. The longer of the two timers defines when the Mixed Fill Time begins.

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A A Catalyst Change B Air Chop Time B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Valve

Dispense A A AA Dispense B BB

Gun Trigger(s) by Operator

Chop Time (air/solvent or air/3rd flush) 3->4

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

alve Time-Sequence

First Purge (one of these) 3rd Flush Chop Time

Color Purge Time 0->1

Color Fill Time 1->2

First Purge Time 2->3

Final Purge Time 4->5

Mixed Fill Time 5->6

FIG. 81: Color Change Chart 4

ProMix 2KS Recipe Change

Chart 4: A1-A2, same B without Dump Valves

Solvent Chop Time

012 3 4 5 6

82 3A1080C

Dump A

Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Valve

Dispense A AA Dispense B BB

Gun Trigger(s) by Operator

Chop Time (air/solvent or air/3rd flush) M1->M2

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

alve Time-Sequence

Catalyst Purge Time P0->P1

Catalyst Fill Time P1->P2

First Purge (one of these) 3rd Flush Chop Time

First Purge Time M0->M1

Final Purge Time M2->M3

Mixed Fill Time M3->M4

FIG. 82: Color Change Chart 5

ProMix 2KS Recipe Change

Chart 5: B1 to B2, same A with Dump Valves

P0 P1 P2 P3 P4

M0 M1 M2 M3 M4

CC Purge/Fill Timers are independent of Mixed Material Purge Timers. This

Air Chop Time

Solvent Chop Time

line defines when the Mixed Fill Time begins. The longer of the two timers defines when the Mixed Fill Time begins.

Color Change

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Valve

Dispense A AA Dispense B BB

Gun Flush Box Output #1 Gun Flush Box Output #2

Chop Time (air/solvent or air/3rd flush) M1->M2

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

alve Time-Sequence

Color Purge Time P0->P1

Color Fill Time P1->P2

Catalyst Purge Time P2->P3

Catalyst Fill Time P3->P4

First Purge (one of these) 3rd Flush Chop Time

First Purge Time M0->M1

Final Purge Time M2->M3

Mixed Fill Time M3->M4

FIG. 83: Color Change Chart 6

Chart 6: A1 to A2, B1 to B2 with Dump Valves, 2 GFBs

P0 P1 P2 P3 P4

M0 M1 M2 M3 M4

ProMix 2KS Recipe Change

Air Chop Time

Solvent Chop Time

CC Purge/Fill Timers are independent of System Purge Timers. This line defines when the System Fill Time begins. The longer of the two timers defines when the System Fill Time begins.

3A1080C 83

Color Change

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Valve

Dispense A AA Dispense B BB

Gun Flush Box Output #1 Gun Flush Box Output #2

Chop Time (air/solvent or air/3rd flush) M1->M2

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

alve Time-Sequence

Color Purge Time P0->P1

Color Fill Time P1->P2

Catalyst Purge Time P2->P3

Catalyst Fill Time P3->P4

First Purge (one of these) 3rd Flush Chop Time

First Purge Time M0->M1

Final Purge Time M2->M3

Mixed Fill Time M3->M4

FIG. 84: Color Change Chart 7

ProMix 2KS Recipe Change

Chart 7: A1 to A2, B1 to B2 with Dump Valves, 1 GFB

P0 P1 P2 P3 P4

M0 M1 M2 M3 M4

Air Chop Time

Solvent Chop Time

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.

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A A Catalyst Change B Air Chop Time B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Valve

Dispense A A AA Dispense B BB

Gun Flush Box Output #1 Gun Flush Box Output #2

Chop Time (air/solvent or air/3rd flush) 3->4

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

alve Time-Sequence

First Purge (one of these) 3rd Flush Chop Time

Color Purge Time 0->1

Color Fill Time 1->2

First Purge Time 2->3

Final Purge Time 4->5

Mixed Fill Time 5->6

FIG. 85: Color Change Chart 8

ProMix 2KS Recipe Change

Chart 8: A1-A2, same B without Dump Valves, 2 GFBs

Solvent Chop Time

012 3 4 5 6

84 3A1080C

Color Change

ProMix 2KS Recipe Change

Chart 9: A1-A2, same B without Dump Valves, 1 GFB

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A A Catalyst Change B Air Chop Time B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Valve

Dispense A A AA Dispense B BB

Gun Flush Box Output #1 Gun Flush Box Output #2

Chop Time (air/solvent or air/3rd flush) 3->4

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

alve Time-Sequence

First Purge (one of these) 3rd Flush Chop Time

012 3 4 5 6

Color Purge Time 0->1

Color Fill Time 1->2

First Purge Time 2->3

Final Purge Time 4->5

Mixed Fill Time 5->6

Solvent Chop Time

FIG. 86: Color Change Chart 9

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Purge

Dispense A Dispense B

Gun Trigger(s) by Operator

Chop Time (air/solvent or air/3rd flush) M1->M2

Notes: All timing from Recipe 0

alve Time-Sequence

Color Purge Time P0->P1

Catalyst Purge Time P1->P2

First Purge (one of these) 3rd Flush Chop Time

First Purge Time M0->M1

Final Purge Time M2->M3

Chart 10: Recipe X, 0, OR 61 to Recipe 0 with Dump Valves

P0 P1 P2

M0 M1 M2 M3

ProMix 2KS Recipe Change

Air Chop Time

Solvent Chop Time

Color/Catalyst Purge Timers are independent of Mixed Material Purge Timers.

FIG. 87: Color Change Chart 10

3A1080C 85

Color Change

Dump A A Dump B B

Color Change Solvent Catalyst Change Solvent Color Change A A A Catalyst Change B B B

Air Purge Solvent Purge 3rd Flush Purge

Dispense A A A Dispense B BB

Gun Trigger(s) by Operator

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

FIG. 88: Color Change Chart 11

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Air Chop Time

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Valve

alve Time-Sequence

First Purge (one of these) 3rd Flush Chop Time

Chart 11: Recipe 0 OR 61 to Recipe X with Dump Valves

alve Time-Sequence

Color Fill Time 0->1

Catalyst Fill Time 1->2

Mixed Fill Time 2->3

Chart 12: Recipe X, 0, OR 61 to Recipe 0 without Dump Valves

ProMix 2KS Recipe Change

012 3

ProMix 2KS Recipe Change

Solvent Chop Time

Dispense A A Dispense B

Gun Trigger(s) by Operator

Color Purge Time 0->1

First Purge Time 1->2

Chop Time (air/solvent or air/3rd flush) 2->3

Notes: All timing from Recipe 0

Final Purge Time 3->4

FIG. 89: Color Change Chart 12

01 2 3 4

86 3A1080C

Color Change

FIG. 90: Color Change Chart 13

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Valve

alve Time-Sequence

Color Purge Time P0->P1

Color Fill Time P1->P2

Catalyst Purge Time P2->P3

Catalyst Fill Time P3->P4

First Purge (one of these) 3rd Flush Chop Time

Chart 13: Recipe 0 OR 61 to Recipe X without Dump Valves

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A A Catalyst Change B

Air Purge Solvent Purge 3rd Flush Purge

Dispense A A A A Dispense B B B

Gun Trigger(s) by Operator

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

alve Time-Sequence

P0 P1 P2 P3 P4

ProMix 2KS Recipe Change

01 2

Color Fill Time 0->1

Mixed Fill Time 1->2

ProMix 2KS Recipe Change

Chart 14: A1 to A2, B1 to B2 with All

Air Chop Time

Solvent Chop Time

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.

Dispense A AA Dispense B BB

Gun Trigger(s) by Operator

M0 M1 M2 M3 M4

First Purge Time M0->M1

Chop Time (air/solvent or air/3rd flush) M1->M2

Final Purge Time M2->M3

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

Special Output #1

Special Output #2

Special Output #3

Special Output #4

Recipe Change Purge Active Output

Recipe Change Fill Active Output

Mixed Fill Time M3->M4

1st On/Start 1st On Length/Duration 2nd On/Start 2nd On Length

FIG. 91: Color Change Chart 14

3A1080C 87

Color Change

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B Air Chop Time B

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Purge

Dispense A AA Dispense B BB

Gun Trigger(s) by Operator

Chop Time (air/solvent or air/3rd flush) 1->2

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

alve Time-Sequence

First Purge (one of these) 3rd Flush Chop Time

First Purge Time 0->1

Final Purge Time 2->3

Mixed Fill Time 3->4

FIG. 92: Color Change Chart 15

ProMix 2KS Recipe Change Chart 15: Same A, Same B

Solvent Chop Time

01 23 4

Dump A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Air Chop Time

Air Purge Solvent Purge Final Purge (one of these) 3rd Flush Purge

Dispense A AA Dispense B BB

Gun Trigger(s) by Operator

Chop Time (air/solvent or air/3rd flush) 1->2

Wait for External Color Change Ready signal

Notes: Load tables from new recipe Purge from old recipe Fill from new recipe

Recipe Change Purge Active Output

Recipe Change Fill Active Output

alve Time-Sequence

First Purge (one of these) 3rd Flush Chop Time

First Purge Time 0->1

Final Purge Time 2->3

(before advance to step 4) 3->4

Mixed Fill Time 4->5

FIG. 93: Color Change Chart 16

ProMix 2KS Recipe Change

Chart 16: External Color Change Option

Solvent Chop Time

01 234 5

88 3A1080C

Color Change

Dump A A Dump B B

Color Change Solvent Catalyst Change Solvent Color Change A A A Catalyst Change B B B

Air Purge Solvent Purge 3rd Flush Purge

Dispense A A A Dispense B BB

Gun Trigger(s) by Operator

Notes: Load tables from new recipe Mixed Material Purge Timers from old recipe CC Purge/Fill Timers and Mixed Fill Time f rom new recipe *Exiting Fill Source and Length are Programmable

FIG. 94: Color Change Chart 17

Dump A A Dump B

Color Change Solvent Catalyst Change Solvent Color Change A A A Catalyst Change B

Chart 17: Recipe 0 OR 61 to Recipe X with Dump Valves and 3rd Flush Valve

alve Time-Sequence

*Exiting Fill Time 0->2

Color Fill Time 0->1

Catalyst Fill Time 1->2

Mixed Fill Time 2->3

Chart 18: Recipe 0 OR 61 to Recipe X without Dump Valves and 3rd Flush Valve

alve Time-Sequence

ProMix 2KS Recipe Change

*Exiting Fill

012 3

ProMix 2KS Recipe Change

Mixed Fill Time does not begin until the Exiting Fill Time and Color/Catalyst Fill Time is complete.

Air Purge Solvent Purge 3rd Flush Purge

Dispense A A A A Dispense B BB

Gun Trigger(s) by Operator

Notes: Load tables from new recipe Mixed Material Purge Timers from old recipe CC Purge/Fill Timers and Mixed Fill Time f rom new recipe *Exiting Fill Source and Length are Programmable

FIG. 95: Color Change Chart 18

*Exiting Fill

012 3

*Exiting Fill Time 0->1

Color Fill Time 1->2

Mixed Fill Time 2->3

3A1080C 89

Alarms and Warnings

NOTE: Do not use the fluid in the line that was dis-

pensed off ratio as it may not cure properly.

System Alarms

System alarms alert you of a problem and help prevent off-ratio spraying. If an alarm occurs, operation stops and the following occurs:

• Alarm sounds.

• Status bar on the EasyKey shows the alarm E-Code with a description (see Table 13).

System Warnings

Table 13 lists the System Warning Codes. Warnings do not stop operation or sound an alarm. They are saved in the date/time stamped log, which can be viewed on a PC, using the Web Interface (see manual 313386).

To Reset Alarm and Restart

NOTE: When an alarm occurs be sure to determine the

E-Code before resetting it. See Table 13. If you forget which E-Code occurred, use the Alarms Screen (page

24) to view the last 10 alarms, with date and time

stamps.

To reset alarms, see Table 14. Many alarms can be

cleared by simply pressing the Alarm Reset

key.

Table 13: System Alarm/Warning Codes

Code Description Details

E-1 Communication Error Alarm Page 91 E-2 Potlife Alarm Page 91 E-3 Ratio High Alarm Page 92 E-4 Ratio Low Alarm Page 93 E-5 Overdose A/B Dose Too Short

Alarm

E-6 Overdose B/A Dose Too Short

Alarm E-7 Dose Time A Alarm Page 95 E-8 Dose Time B Alarm Page 95 E-9 Mix in Setup Alarm Page 96 E-10 Remote Stop Alarm Page 96 E-11 Purge Volume Alarm Page 96 E-12 CAN Network Communication Error

Alarm E-13 High Flow Alarm Page 96 E-14 Low Flow Alarm Page 96 E-15 System Idle Warning Page 97 E-16 Setup Change Warning Page 97 E-17 Power On Warning Page 97 E-18 Defaults Loaded Warning Page 97 E-19 I/O Alarm Page 98 E-20 Purge Initiate Alarm Page 99 E-21 Material Fill Alarm Page 99 E-22 Tank A Low Alarm Page 99 E-23 Tank B Low Alarm Page 99 E-24 Tank S Low Alarm Page 99 E-25 Auto Dump Complete Alarm Page 100 E-26 Color/Catalyst Purge Alarm Page 100 E-27 Color/Catalyst Fill Alarm Page 100

Page 94

Page 96

90 3A1080C

Alarm Troubleshooting

Table 14. Alarm Troubleshooting

E-1: COMM_ERROR

Cause Solution

No power to the EasyKey. Connect power to EasyKey.

Alarm Troubleshooting

No power to Fluid Station Control Box. The intrinsically safe power cable between the EasyKey and Fluid Station Control Box is not connected.

No power to Fluid Station Control Box. The fluid control board fuse is blown.

The fiber optic cable between the EasyKey and Fluid Station Control Box is not connected.

The fiber optic cable is cut or bent. Verify that the cable has not been cut or bent at a radius

Dirty fiber optic cable ends. Disconnect fiber optic cable ends and clean with a

A communication cable or connector failed. Replace cable.

E-2: POTLIFE_ALARM

Cause Solution

The potlife time has been exceeded for the mixed material.

NOTICE

To prevent mixed material from curing in the equipment, do not shut off power. Follow one of the solutions at right.

Verify that the cable is correctly connected. See Installation manual.

Verify condition of fuse and replace if necessary. See Repair-Parts manual.

Verify that the cable is correctly connected. See Installation manual.

smaller than 1.6 in. (40 mm).

lint-free cloth.

Press the Alarm Reset alarm. Purge the system with solvent, fresh mixed mate-

rial, or a new color:

• Solvent Purge - See Purging Mixed Material on

page 73. The system purges until the preset purge time is complete.

key to stop the audible

• New Mixed Material Purge - Go to Mix mode and

spray the required volume to restart the timer.

• Color Change - Perform a color change, see page

78.

3A1080C 91

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 Solution

There is too little restriction in the system. • 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.

If the alarm occurs during start up, after purging, the flow rate was probably too high.

If the alarm occurred after you were spraying for some time, the pressures from the fluid supply could be too

Restrict gun needle travel to slow down the initial fluid delivery rate until fluid hoses are loaded with material.

Adjust fluid supply regulator pressure. Verify that component A dose valve is operating properly.

high. Slow actuation of the component A valve. This can be

caused by:

Manually operate the Dispense A solenoid valves as instructed in the ProControl 1KS Repair-Parts manual to check operation.

• Air pressure to the valve actuator is too low. • Increase air pressure. Air pressure must be 75-120 psi (0.52-0.84 MPa, 5.2-8.4 bar); 120 psi is recommended.

• Something is restricting the solenoid or tubing and

interrupting valve actuation air.

• There may be dirt or moisture in the air supply. Filter appropriately.

• A dose valve is turned in too far. • Refer to Table 10: Mix Manifold Valve Settings,

page 67, for adjustment guidelines.

• Fluid pressure is high and air pressure is low. • Adjust air and fluid pressure. See recommended air pressure above.

92 3A1080C

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 Solution

There is too much restriction in the system. • 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.

If the alarm occurs during start up, after purging, the flow rate was probably too high.

If the alarm occurred after you were spraying for some time, the pressure from the fluid supply could be too low.

Slow actuation of the component A valve. This can be caused by:

Restrict gun needle travel to slow down the initial fluid delivery rate until fluid hoses are loaded with material.

Adjust fluid supply regulator pressure. Verify that component A dose valve is operating properly.

Manually operate the Dispense A solenoid valves as instructed in the ProControl 1KS Repair-Parts manual to check operation.

• Air pressure to the valve actuator is too low. • Increase air pressure. Air pressure must be 75-120 psi (0.52-0.84 MPa, 5.2-8.4 bar); 120 psi is recommended.

• Something is restricting the solenoid or tubing and

interrupting valve actuation air.

• There may be dirt or moisture in the air supply. Filter appropriately.

• A dose valve is turned in too far. • Refer to Table 10: Mix Manifold Valve Settings,

page 67, for adjustment guidelines.

• Fluid pressure is high and air pressure is low. • Adjust air and fluid pressure. See recommended air pressure above.

3A1080C 93

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 F

IG. 16

Repair the valve (see valve manual 312782).

Totals Screen on page 23. I Sampling valve is leaking. Tighten or replace valve. Flow meter fluctuations caused by pressure pulsations. Check for pressure pulsations:

1. Close all the manifold valves.

2. Turn on the circulating pumps and all the booth equipment (such as fans and conveyors).

3. Check if the ProControl 1KS is reading any fluid flow.

4. If the ProControl 1KS shows there is fluid flow and there are no leaks from the gun or any other seals or fittings, the flow meters are probably being affected by pressure pulsations.

5. Close the fluid shutoff valve between the fluid supply system and the flow meter. The flow indication should stop.

6. If necessary, install pressure regulators or a surge tank on the fluid inlets to the ProControl 1KS to reduce the fluid supply pressure. Contact your Graco distributor for information.

Slow actuation of component A valve. See E-3: RATIO_HIGH_ALARM and E-4:

RATIO_LOW_ALARM, pages 92-93.

Running a high mix ratio and a high flow rate. It may be necessary to restrict the flow rate through the

component B dose valve by adjusting its hex nut (E). See page 66.

94 3A1080C

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. Fluid flow rate is too low. Increase flow rate. Dose time setting is too short for the current flow rate. Increase the dose time setting. Flow meter or cable failed or flow meter clogged. To check meter sensor operation, remove meter cap to

expose sensor. Pass a ferrous metal tool in front of the sensor.

TI12792a

If there is a meter or cable failure, you will see a large difference between the amount of fluid dispensed and the flow meter volume displayed by the EasyKey. Clean or repair meter as necessary. Also see meter manual

308778.

Follow Meter Calibration procedure, page 76.

Slow actuation of component A valve. See E-3: RATIO_HIGH_ALARM and E-4:

RATIO_LOW_ALARM, pages 92-93.

The supply pump is not turned on. Turn on the supply pump. System is in Mix mode with 0 volume entered for Min

Material Fill Volume (see Option Screen 1, page 32),

Verify condition of fuse and replace if necessary. See Repair-Parts manual.

and Fuse F1 is blown.

3A1080C 95

Alarm Troubleshooting

Table 14. Alarm Troubleshooting

E-9: MIX_IN_SETUP_ALARM

Cause Solution

Attempt to operate system while in Setup mode. 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.

E-11: PURGE_VOLUME_ALARM

Cause Solution

ProControl 1KS solvent flow switch is not activated while purging.

Verify that the gun is not shut off and that the solvent flow switch is activated while purge is taking place.

Minimum flush volume is set too high. Increase solvent supply or decrease minimum volume

setting.

No meter pulses during Color/Catalyst Dump. Color change solvent supply not set up or functional.

Check Color Change setup.

E-12: CAN_COMM_ERROR_ALARM

Cause Solution

Communication between the Color Change Module and

Verify that the cable is correctly connected.

the Fluid Station Control Box is interrupted. Communication between the Color Change Module and

the Fluid Station Control Box is interrupted. The fluid

Verify condition of fuse and replace if necessary. See Repair-Parts manual.

control board fuse is blown.

E-13: HIGH_FLOW_ALARM or E-14: LOW_FLOW_ALARM (may also be set as Warnings)

Cause Solution

Fluid system is producing too much or too little flow. Troubleshoot fluid system for restrictions, leaks,

exhausted fluid supply, incorrect settings, etc. Increase or decrease flow rate, as required.

96 3A1080C

E-15: SYSTEM_IDLE_WARNING

Cause Solution

Alarm Troubleshooting

Table 14. Alarm Troubleshooting

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 Solution

The system setup parameters have been changed. No action required. See Event Log available through

advanced web interface.

E-17: POWER_ON_WARNING

Cause Solution

The power to the system has been cycled. No action required. See Event Log available through

advanced web interface.

E-18: DEFAULTS_LOADED_WARNING

Cause Solution

The factory defaults have been installed on the system. No action required. See Event Log available through

advanced web interface.

3A1080C 97

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.

Fluid Plate Reboot (FP Reboot): Occurs if the system detects a fluid plate control board reboot or power cycle not triggered from the EasyKey. The system reverts to Recipe 61, and mixed material may be in the lines.

Autokey Lost: Occurs if the Autokey is lost or changed after having been detected. (A short term loss of the Autokey will not be registered.) Some system functions may become unavailable. For example, an automatic system will not respond to PLC or robot control.

Illegal Source: Occurs if a recipe outside of the range 1-60 is detected as the source data for global recipe data copies. This is possible if an invalid configuration file is sent to the EasyKey.

2K/3K Error: Occurs if the recipe data is incompatible with the current Autokey setting (2K or 3K). This is possible if the Autokey is changed or an invalid configuration file is sent to the EasyKey.

Init Error: Occurs if the recipe data codes specifying the type of machine they were made on are not what is expected. For example, a 3KS machine receives a configuration file originally made on a 2KS machine.

Config Error: Occurs if a configuration file sent to the EasyKey specifies a different hardware setup than what exists. For example, the configuration file specifies 2 color change boards but only 1 is present.

Flush the system or perform a color change. If possible, identify the origin of the reboot or power cycle.

Reinstall the Autokey, or verify that the Autokey is set properly.

Verify that the source data is from a valid recipe (1-60).

Verify that the Autokey is set properly or that the configuration file is valid.

Verify that the configuration file is valid.

Verify that the configuration file specifications and the hardware conform.

Range Error: Occurs if a valve used in a recipe is not present in the current hardware setup. For example, a

Verify that the recipe specifications and the hardware

conform. recipe calls for valve 30 but the system has only 12 valves.

Level Control (LC) Error: Occurs if level control data is

Verify that the Autokey is set properly. received by the EasyKey, and the current Autokey setting (2K or 3K) has changed since the level control data was originally initialized.

Level Control (LC) Range Error: Occurs if level control

Set level control data correctly. data includes a valve range exceeding the capability of the machine.

Modbus (MB) Overflow: Occurs if the Modbus connec-

Verify the Modbus protocol to the EasyKey. tion to a PLC experiences data overflow.

98 3A1080C

E-20: PURGE_INITIATE_ALARM

Cause Solution

Alarm Troubleshooting

Table 14. Alarm Troubleshooting

System detects atomizing air to the gun when purge is

Shut off gun air.

selected. For systems with a gun flush box, gun is not in the box

when purge is selected. 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.

For systems with a gun flush box, Fuse F2 is blown. Verify condition of fuse and replace if necessary. See

Repair-Parts manual.

E-21: MATERIAL_FILL_ALARM

Cause Solution

For systems with minimum mixed material fill volume

Check for restrictions or leaks in the fluid supply system. entered, the system detects that fill volume is not achieved during mixed material fill time.

Check if the fill volume is properly configured:

• Adjust fill volume.

• Adjust fill time.

For systems without color change and with minimum mixed material fill volume entered, Fuse F1 is blown.

Verify condition of fuse and replace if necessary. See

Repair-Parts manual.

E-22: TANK_A_LOW_ALARM, E-23: TANK_B_LOW_ALARM, or E-24: TANK_S_LOW_ALARM

Cause Solution

The tank volume reaches the low-level threshold. The EasyKey screen will display the alarm and prompt

the user to do one of the following:

• Refill tank volume to clear the alarm.

• Resume mixing by selecting “Spray 25% of remaining volume.” 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.

3A1080C 99

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. pulses lasting longer than 1 second throughout the Color purge time duration.

Clean or repair meter.

E-27: COLOR/CATALYST_FILL_ALARM

Cause Solution

System detects no meter pulses, or system must detect

Check that meter cable is connected. at least 10cc of material from each side throughout the Color fill time duration.

Gun, dump valve, or correct color/catalyst valve not

Clean or repair meter.

Open the valve. open.

Exhausted fluid supply. Check fluid level and refill if necessary. Fuse F1, F2, or both are blown. Verify condition of fuses and replace if necessary. See

Repair-Parts manual.

100 3A1080C

Graco 3A1080C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Equipment Approvals

System Configuration and Part Numbers

Models

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of Isocyanates

Keep Components A and B Separate

Changing Materials

Glossary of Terms

Overview

Usage

Component Identification and Definition

ProControl 1KS System Components

EasyKey Display and Keyboard

Keypad

Display

AC Power Switch

I/S Power

Potlife Exceeded Audible Alarm

Graco Web Interface Port

Ethernet Connection

Run Mode Screens

Splash Screen

Status Screen

Manual Override Screen

Totals Screen

Reset Total Screen

Reset Solvent Screen

Alarms Screen

Level Control Screen

Setup Mode

Password Screen

Set Up Home Screen

System Configuration Screens

Option Screens

Advanced Setup Screens

Recipe Setup Screens

Recipe 0 Screens

Calibration Screen

ProControl 1KS Integration Specifics

Discrete I/O vs Network Communications

Discrete I/O

Automation Flow Charts

System Operation

Operation Modes

Recipe (Color) Change

Flow Control

Typical PLC Interaction with ProControl 1KS

General Operating Cycle

Mix Manifold Valve Settings

Start Up

Shutdown

Pressure Relief Procedure

Purging

Meter Calibration

Color Change

Color Change Procedures

Color Change Sequences

Alarms and Warnings

System Alarms

System Warnings

Alarm Troubleshooting