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

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