Graco 3A1163A User Manual

Installation

™

ProControl

Automatic system for fluid management of single component coatings. Includes flow
control, flushing, and color change. For professional use only.

Approved for use in explosive atmospheres (except the EasyKey).

Important Safety Instructions

Read all warnings and instructions in this
manual. Save these instructions.

1KS

See pages 4-5 for model information, including maxi­mum working pressure. Equipment approval labels are
on page 3. Some components shown are not included
with all systems.

3A1163A

ENG

#53

TI16328a

II 2 G

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . 3

System Configuration and Part Numbers . . . . . . . 4

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Important Two-Component Material Information . 9

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 9

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 9

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

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

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

Component Identification and Definition . . . . . . 10

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

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

Intrinsically Safe Installation Requirements . . . 12

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2 3A1163A

Related Manuals

Related Manuals

Component Manuals in English

Manual Description

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

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

Interface
406800 15V825 Discrete I/O Board Kit

Equipment Approvals

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

™

EasyKey

EasyKey and Fluid Station Control Box Label

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

ATEX Certificate is listed here

ProControl 1KS

Electronic Proportioner

FM08ATEX0074
II 2 G
Ex ia IIA T3

CUS

Intrinsically safe

equipment for Class I,

Div 1, Group D, T3

Ta = -20°C to 50°C

MAX AIR WPR

.7 7 100

MPa bar PSI

MAX FLUID WPR

13.1 190

1.31

MPa bar PSI

MAX TEMP 50°C (122°F)

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

Read Instruction Manual

Warning: Substitution of components
may impair intrinsic safety.

PART NO. SERIES

MFG. YR.

Fluid Station Control Box Label

SERIAL

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

ProControl

PART NO. SERIES SERIAL

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

ATEX Certificate is listed here

EasyKey Label

ProControl 1KS

PART NO.

SERIES NO. MFG. YR.

277869

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

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

CUS

Ta = -20°C to 50°C
Install per 289833

Um: 250 V

ATEX Certificate is listed here

FLUID PANEL

MAX AIR WPR

.7 7 100

MPa bar PSI

FM08ATEX0073
II 2 G
Ex ia IIA T3

POWER REQUIREMENTS

VOLTS

AMPS

II (2) G
[Ex ia] IIA
FM08ATEX0072

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

85-250 ~

2 AMPS MAX

50/60 Hz

3A1163A 3

System Configuration and Part Numbers

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

A ProControl 1KS

A ProControl 1KS

A ProControl 1KS

ProControl 1KS

Electronic Proportioner

on Fluid Station
Control Box

Maximum Fluid

Working Pressure

is listed here

TI15974a

FM08ATEX0074
II 2 G
Ex ia IIA T3

MAX AIR WPR

.7 7 100

MPa bar PSI

MAX FLUID WPR

1.31

MPa bar PSI

MAX TEMP 50°C (122°F)

CUS

Intrinsically safe

equipment for Class I,

Div 1, Group D, T3

Ta = -20°C to 50°C

13.1 190

None G3000 Coriolis No Yes

✔

✔

✔ ✔

✔ ✔

✔ ✔

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

SERIAL

Label Location
on EasyKey

TI15975a

Part Number

MFG. YR.

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

FIG. 1: Identification Label, ProControl 1KS Systems

4 3A1163A

System Configuration and Part Numbers

Hazardous Location Approval

Models using a G3000, G3000HR, or intrinsically safe Coriolis meter for both A and B meters are approved for
installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3.

Maximum Working Pressure

Maximum working pressure rating is dependent on the fluid component options selected. The pressure rating is
based on the rating of the lowest rated fluid component. Refer to the component pressure ratings below.

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

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

IG. 1.

ProControl Fluid Components Maximum Working Pressure

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

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

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

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

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

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

Flow Meter Fluid Flow Rate Range

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

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

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

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

Standard Features Accessories

Feature

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

Accessory

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

3A1163A 5

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama­tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

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

• Use equipment only in well ventilated area.

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

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

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

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

• Use only grounded hoses.

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

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

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

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

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

• Connect only to grounded power source.

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

INTRINSIC SAFETY

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

• Only models with a G3000, G250, G3000HR, G250HR, or intrinsically safe Coriolis meter are
approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA
T3.

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

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

6 3A1163A

Warnings

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

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

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

servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

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

component. See Technical Data in all equipment manuals.

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

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

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

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

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

• Do not alter or modify equipment.

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

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

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

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

3A1163A 7

Warnings

WARNING

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

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

• Protective eyewear, and hearing protection.

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

8 3A1163A

Important Two-Component Material Information

Important Two-Component Material Information

Isocyanate Conditions

Spraying or dispensing materials containing isocya­nates creates potentially harmful mists, vapors, and
atomized particulates.

Read material manufacturer’s warnings and mate­rial MSDS to know specific hazards and precautions
related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventila­tion in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.

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

Material Self-ignition

Moisture Sensitivity of
Isocyanates

Isocyanates (ISO) are catalysts used in two component
coatings. ISO will react with moisture (such as humidity)
to form small, hard, abrasive crystals, which become
suspended in the fluid. Eventually a film will form on the
surface and the ISO will begin to gel, increasing in vis­cosity. If used, this partially cured ISO will reduce perfor­mance and the life of all wetted parts.

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

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant

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

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

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

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

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

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

Keep Components A and B
Separate

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

3A1163A 9

Changing Materials

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

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical
compatibility.

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

Component Identification and Definition

Component Identification and Definition

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

FO*

EK

ST

PS*

ACV

CCM

Purge

Air

Logic Air

Air Control
Module

Regulator
V/P Air

Fluid

FC Cable*

FC (see
F

IG. 8)

MAFM (see

F

IG. 6)

* See the ProControl 1KS

Repair-Parts manual for
optional cable lengths.

F

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

TI15961b

Table 1: Component Descriptions

Component Description

EasyKey (EK)

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

Fluid Station

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

Control Box (ST)

10 3A1163A

Table 1: Component Descriptions

Component Description

Component Identification and Definition

Fluid Manifold (FM)

Flow Meters (MA,
MS)

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

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

• Pneumatically Operated Dose Valve for component A

• Purge Valves for solvent and air purge
Four optional flow meters are available from Graco:

• G3000 is a general purpose gear meter typically used in flow ranges of 75-3800

cc/min. (0.02–1.0 gal/min.), pressures up to 4000 psi (28 MPa, 276 bar), and viscosi­ties of 20–3000 centipoise. The K-factor is approximately 0.119 cc/pulse.

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

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

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

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

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

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

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

An optional component. It is available as a color change valve stack for either low or high
pressure with up to 30 color change valves. Each stack includes one additional valve for
solvent to clean the fluid line between color changes.

Dual Fiber Optic
Cable (FO)

Fluid Station
Control Box Power
Supply Cable (PS)

Flow Control
Regulator
Assembly (FC)

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

Used to provide power to the Fluid Station Control Box.

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

3A1163A 11

Location

Location

Location Requirements

Do not substitute or modify system components as this
may impair intrinsic safety. For installation, mainte­nance or operation instructions, read instruction manu­als. Do not install equipment approved only for
non-hazardous location in a hazardous area. See the
identification label (F
tion for the intrinsic safety rating for your model.

• Mount EasyKey and Fluid Station within 50 ft (15.2
m) of each other, using 15U533 cable.

NOTE: An optional 15V213 100 ft (30.5 m) cable is
also available.

• EasyKey: Install in the non-hazardous area at a
convenient location for the operator to view and
operate.

• Fluid Station: Install according to requirements for
Intrinsically Safe Installation (F
nient location to connect to paint and solvent sup­plies.

NOTE: For an Intrinsically Safe Installation, the
Fluid Station may be located inside or outside the
hazardous location. Install according to appropriate
electrical codes.

IG. 1) on the EasyKey or fluid sta-

IG. 3) and at a conve-

Intrinsically Safe Installation
Requirements

See FIG. 3 on page 13.

1. The non-intrinsically safe terminals (power rail) must
not be connected to any device which uses or gen­erates more than 250 Vrms or dc unless it has been
determined that the voltage has been adequately
isolated.

2. The installation must meet the requirements of the
National Electric Code, Canadian Electrical Code
Part I, NFPA 70, Article 504 Resp., Article 505 and
ANSI/ISA 12.06.01.

3. Multiple earthing of components is allowed only if
high integrity equipotential system is realized
between the points of bonding.

4. Do not operate system with safety barrier cover
removed.

5. For ATEX, install per EN 60079-14 and applicable
local and national codes.

6. Install Coriolis flow meters as explosion proof (USA,
Canada)/flameproof Ex d (ATEX) with passive intrin­sically safe connections per the manufacturer’s
installation instructions and applicable codes.

7. Terminals 24 and 25 of optional Endress+Hauser
Coriolis flow meters installed using intrinsically safe
wiring methods. For the United States and Canada,
install all other wiring for Coriolis flow meters using
explosion proof wiring methods for Division I. For
ATEX installations, install all other wiring for Coriolis
flow meters using Flameproof, Ex d, wiring methods
for Zone 1. Observe manufacturer’s instructions for
installation and use.

8. For ATEX installations, interconnecting cabling
specified is Type A cable in accordance with EN
60079-14.

Optional Cables

Optional CAN cables and fiber optic cables are available
from Graco. See the ProControl 1KS Repair-Parts man­ual for available part numbers and lengths.

12 3A1163A

FM08ATEX0074

SYSTEM ASSEMBLY CERTIFICATE

Location

NON-HAZARDOUS
LOCATION ONLY

50’ I/S Power Cable

ProMix 2KS

EasyKey Interface

(with or without

display)

FM08ATEX0072
ASSOCIATED APPARATUS

250 VAC Maximum

Supply Voltage

Safety

Barrier

NOTE: See Intrinsically Safe Installation
Requirements on page 12.

WARNING: Substitution of components

may impair intrinsic safety. For installation,
maintenance or operation instructions, see
instruction manual.

(3’, 6’, 10’, 15’, 25’,

100’ options)

50’ Fiber Optic

Communication

Cable (100’ option)

HAZARDOUS (CLASSIFIED) LOCATION

CLASS I, DIV I, GROUP D, T3 (US AND CANADA)
CLASS I, ZONE I GROUP IIA T3 (ATEX ONLY)
TAUB = -20°C TO 50°C

ProMix 2KS Smart Fluid Plate

(Wall Panel or RoboMix Panel)

FM08ATEX0073 INTRINSIC

SAFE APPARATUS

Cable Assemblies

Flow

Meter

A

Coriolis Meter Options, DMT 00 ATEX E 074 X (No exceptions):

Flow

Meter

B

10’ I/S Power and

Communication

Cable (40’

extension option)

3’ CAN Color

Change Interface

(6’, 10’, 15’, 25’,

50’ 100’ options)

50’ CAN Booth

Control Interface

(3’, 6’, 10’, 15’,

25’, 100’ options)

Flow Control

FM08ATEX0073

Color & Catalyst

FM08ATEX0073

FM08ATEX0073

Booth Control

FM08ATEX0073

Regulator

Module

Change

Module 1

Module 2

Module

3’ CAN
Network
Cable

ADVERTISSEMENT: La substitution de
composants peut compromettre la securite
intrinseque.

NOTE: This IS control drawing also applies to the
ProControl 1KS. See also F

IG. 4 on page 15.

FIG. 3. Intrinsically Safe Installation

Size Graco P/N Endress+Hauser P/N

1/8” 15T633* 80A-04-A-SVW-9-A-N-A-B-B-A-S
3/8” 15T634* 801-08-A-999-9-A-N-A-B-B-A-S

Power

EasyKey

+24 Vdc
Common

Signal

Fluid Plate Board J3 Terminal Meter Terminal Block #

Meter Position A B
Signal 3 6 24
Common 2 5 25
* For P/N 15T633 order Coriolis Meter Kit 15V806.

For P/N 15T634 order Coriolis Meter Kit 258151.

Meter Terminal Block #

1
2

IS Control Drawing 289833

3A1163A 13

General Information

General Information

• Reference numbers and letters in parentheses in
the text refer to numbers and letters in the illustra­tions.

•F

IG. 2 on page 10 shows the basic components of a

ProControl 1KS system, and F
shows a basic system layout. Contact your Graco
distributor for an actual system design.

• Be sure all accessories are adequately sized and
pressure-rated to meet system requirements.

• There must be a shutoff valve between each fluid
supply line and the ProMix system.

• A 100 mesh minimum fluid filter must be installed on
component A fluid supply line.

• To protect the EasyKey screens from paints and sol­vents, clear-plastic protective shields are available
in packs of 10 (Part No. 197902). Clean the screens
with a dry cloth if necessary.

IG. 4 on page 15

Wall Mounting

1. See Dimensions and Mounting Hole Layouts,
page 32.

2. Ensure that the wall and mounting hardware are
strong enough to support the weight of the equip­ment, fluid, hoses, and stress caused during opera­tion.

3. Using the equipment as a template, mark the
mounting holes on the wall at a convenient height
for the operator and so equipment is easily accessi­ble for maintenance.

4. Drill mounting holes in the wall. Install anchors as
needed.

5. Bolt equipment securely.

14 3A1163A

Wall Mounting

Air In

1/4” V/P Air Supply

Regulator

Flow Control

Air Control

Module

Fluid Supply

10’ Flow Control Cable

1/4” Purge

Air Supply

1/4” Logic Air Supply

Module

Fluid

Optional

Out

Booth

Control

Meter Cable

Flow Meter

Fluid Manifold and

Optional Color Change Module

(with display)

EasyKey Interface

Control Box

Fluid System

Fluid Supply

5/32” Color Valve Air Supply

50’ I/S Power Cable

50’ Fiber Optic Cable

In

Fluid

Optional Color

Change Valves

5/32” Air On/Off

Solvent

Lines for Dose,

Supply

Solvent Purge

Air Purge, and

Val ves

TI16329a

FIG. 4. ProControl 1KS System Layout Drawing

3A1163A 15

Wall Mounting

16 3A1163A

Air Supply

Air Supply

Requirements

• Compressed air supply pressure: 75-100 psi

(517-700 kPa, 5.2-7 bar).

• Air hoses: use grounded hoses that are correctly

sized for your system.

Trapped air can cause a pump or dispense valve to
cycle unexpectedly, which could result in serious injury
from splashing or moving parts. Use bleed-type shutoff
valves.

• Air regulator and bleed-type shutoff valve:

include in each air line to fluid supply equipment.
Install an additional shutoff valve upstream of all air
line accessories to isolate them for servicing.

4. lnstall a bleed-type shutoff valve into the air purge
valve inlet line.

5. See F

IG. 6. Use the air purge valve tubing (AT, sup-

plied) to connect the air purge valve (APV) inlet to a
clean, dry air supply (install filters/dryers as

needed).

NOTICE

The ProControl potlife timer will not function properly
when used with multiple guns operating simultane­ously. To avoid having mixed material set in the equip­ment, carefully monitor potlife by some other means.

If using a Graco electrostatic PRO™ Gun, a shutoff
valve must be installed in the gun air line to shutoff the
atomizing and turbine air to the gun. Contact your
Graco distributor for information on air shutoff valves
for electrostatic applications.

• Air line filter: a 10 micron or better air filter is rec-

ommended to filter oil and water out of the air supply
and help avoid paint contamination and clogged
solenoids. See F

IG. 5.

Air Connections

See the System Pneumatic Schematic on page 29.

1. Tighten all ProControl system air and fluid line con­nections as they may have loosened during ship­ment.

2. Install a bleed-type air shutoff valve into the control
air filter inlet. See F

Use separate air supply lines for the following two
connections to avoid contaminating the purge air line
with fluid if the air purge valve and a check valve
failed.

3. Connect a clean air supply line to the shutoff valve.
This air line supplies air to operate the gun, sole­noids, and dispense valves.

IG. 5.

NOTICE

1

Install a bleed-type air
shutoff valve here.

For Air

1

Purge Valve

For Air

Flow Switch

F

IG. 5. Air Supply Control

Air Filters

Main Air Inlet

For Fluid

1

Station
Controls

TI11895a

NOTE: See Technical Data on page 35 for additional
air supply/consumption information.

3A1163A 17

Fluid Supply

Fluid Supply

Requirements

Do not exceed the pressure rating of the lowest rated
component. See the identification label (F
page 4).

To reduce the risk of injury, including fluid injection, you
must install a shutoff valve between each fluid supply
line and the fluid manifold assembly. Use the valves to
shut off fluid during maintenance and service.

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

• Fluid supply pressure tanks, feed pumps, or circulat­ing systems can be used.

• Materials can be transferred from their original con­tainers or from a central paint recirculating line.

• For an airless system, the user must supply a gun
trigger signal to the ProControl 1KS.

• See manual 313599 for Coriolis meter installation
and operation instructions.

NOTE: The fluid supply must be free of pressure spikes,
which are commonly caused by pump stroke change­over. If necessary, install pressure regulators or a surge
tank on the ProControl fluid inlets to reduce pulsation.
Contact your Graco distributor for additional information.

IG. 1 on

Fluid Connections

1. Connect the solvent supply lines.

a. Connect the solvent supply line to the 1/4 npt(f)

solvent purge valve inlet. See F

b. Multiple color system: also connect a solvent

supply line to the color change stack (Q), top
valve 4 or 5. See F

2. Connect the component supply line(s).

➜ Single color system: connect component

supply line to the component A flow meter
inlet.

➜ Multiple color system: connect supply

lines to the color change valve stack (S)
inlets. See F
marked on the valve air supply line.

NOTE: Paint Recirculating System Only

• The color change valves have two fluid
ports for each individual valve. If you are
recirculating paint, plumb the valves in one
port and out the other.

• Another option is to use a tee fitting to recir­culate.

NOTE: Verify that all unused fluid ports on the color
change valve stack are plugged before operation. An
open port will leak fluid.

NOTE: The fluid meter inlet has a fluid check valve to
prevent backflow from fluid supply pressure fluctuations.
Backflow can cause ratio inaccuracies.

3. Connect the gun fluid supply line between the fluid
regulator or fluid manifold outlets and the gun fluid
inlet.

IG. 7.

IG. 7. The color number is

IG. 6.

18 3A1163A

APV

AT

Fluid Supply

FIH

MA

DVA

SS

FIG. 6. Fluid Manifold

Connect air lines to
valves here

FOH

SPV

TI15977a

Connect solvent valve

air line here

Q

4

2

5

3

1

S

Fluid Inlets Fluid Inlets

Color Change BoardSolenoids

Fluid Outlet

Color Change Board and Solenoid Valves

IG. 7. Color Change Valves Air and Fluid Connections

F

3A1163A 19

TI12824a

Color Change Valve Stack

TI11668a

Fluid Supply

Regulator

V/P Air

FC Cable

FIG. 8. Flow Control Regulator

Fluid In

FC

Fluid Out

TI15976a

20 3A1163A

Electrical

Electrical

Requirements

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

Enclose all cables routed in the spray booth and high
traffic areas in conduit to prevent damage from paint,
solvent, and traffic.

NOTE: All options ordered on the ProControl system are
electrically tested at the factory.

The ProControl operates with 85-250 VAC, 50/60 Hz
input power, with a maximum of 2 amp current draw.
The power supply circuit must be protected with a 15
amp maximum circuit breaker.

Not included with system:

• Power supply cord compatible to your local power
configuration. Wire gauge size must be 8-14 AWG.

Connect Main Power

1. Provide power to the EasyKey. Install a bulkhead
strain relief or conduit bulkhead through the

EasyKey port . See F

2. See F

3. Ground the EasyKey to a true earth ground. See

IG. 9 and the System Electrical Schematic

on page 30 for the L1, N, and ground wiring connec­tions inside the EasyKey.

Grounding, page 27.

IG. 10.

• The input power access port
(0.88 in.) diameter. It accepts a bulkhead strain

relief fitting or conduit. See F

IG. 10.

is 22.4 mm

Input Power

Terminal Block

FIG. 9. Main Power Connection

TI13349a

3A1163A 21

Electrical

Relief Port

Audible AlarmFiber Optic Strain

Main Power
Access Port

AC Power
Switch

Ground Screw

F

IG. 10. EasyKey Connections and AC Power Switch

I/S Power Discrete I/O Cable

Graco Web
Interface

Connector Ports

Connect EasyKey to Fluid
Station Control

There are two 50 ft (15.2 m) cables to route between the
EasyKey and Fluid Station Control: the Fluid Station
Power Cable and the Fiber Optic Cable.

1. Connect the appropriate Fluid Station Power Cable

end to the EasyKey connector . See F

2. Connect the other cable end to the Fluid Station

Control connector (J10). See F

VDC

3. The Fiber Optic Cable is shipped from the factory
attached to the EasyKey connector . See

VDC

IG. 10.

IG. 11.

TI12638a TI12657a

NOTE: The fiber optic cable has a minimum bend radius
of 1.6 in. (40 mm).

5. Connect the blue and black cable connectors to the
matching connectors on the fluid station circuit
board. See F

IG. 11. Insert the cable connectors until

they bottom out (approximately ¼ in. [6 mm]), then
tighten the threaded connector.

NOTICE

To avoid cracking the circuit board, do not over-tighten
or cause excessive stress on the circuit board con­nector.

6. Tighten the strain relief connector .

F

IG. 10.

NOTE: If you need to detach the Fiber Optic Cable from
the EasyKey, note how the cable is routed inside the
enclosure. Ensure that the door can swing open and
close without catching or pulling wires.

4. Route the opposite Fiber Optic Cable end through
the Fluid Station strain relief connector . Do

not route the cable with tight bends or kinks.

22 3A1163A

J4
(Fiber Optic Output - blue)

J6
(Fiber Optic Input - black)

J10
(Power Input)

VDC

J11
(Color Change
Module)

J7
(Not Used)

Electrical

FIG. 11. Fluid Station Board Connections

3A1163A 23

Electrical

Connect Color Change Module

To install the color change module(s), see manual

312787.

Set switches S3-S6 on the color change board(s) as
shown in Table 2 and F

IG. 12, depending on the number

of color change boards and color change modules being

Connect a 5-pin electrical cable from the labeled con-

nection port
board to the color change board. See F

(J11) on the fluid station control

IG. 12.

used in your system.

For wiring between the color change board and the sole­noids, see the color change module electrical sche­matic, F

IG. 13.

If you are using two color change modules to add colors,
connect a 5-pin electrical cable from the first color
change board to the second color change board.

Table 2: Color Change Board Switch Settings

Two Color Change Boards

Color Change Board 1 Color Change Board 2

S3 S6 S5 S4 S3 S6 S5 S4

Termination

Resistor Board ID

OFF ON OFF ON ON OFF NOT USED 0 catalyst valves, 30 color

Catalyst

On/Off

Color

On/Off

Termination

Resistor Board ID

Catalyst

On/Off

Color

On/Off

Effect on System

valves

One Color Change Board

ON ON OFF ON NOT USED 0 catalyst valves, 12 color

valves

24 3A1163A

Switch S3-S6

Positions

Electrical

S6

S5

S4

ON

OFF

ON

OFF

TI13661a

J7

FIG. 12. Color Change Board Switches S3-S6

3A1163A 25

S3

J11

Electrical

WIRING DIAGRAM

COLOR 8 (21)

COLOR 7 (20)

COLOR 6 (19)

COLOR 5 (18)

COLOR 4 (17)

COLOR 3 (16)

COLOR 2 (15)

COLOR 1 (14)

COLOR FLUSH (13)

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

J8

J15

J14

J9

J16

J10

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COLOR 9 (22)

COLOR 10 (23)

COLOR 11 (24)

COLOR 12 (25)

CATALYST 4 (26)

CATALYST 3 (27)

CATALYST 2 (28)

CATALYST 1 (29)

CATALYST FLUSH (30)

N/A

FIG. 13. Color Change Module Electrical Schematic

26 3A1163A

Electrical

Grounding

Your system must be grounded. Read Warnings,
page 6. For intrinsic safety, ground wires for the
EasyKey, Fluid Station, and Gun Flush Box must all be
connected to the same true earth ground. See F
page 28.

Ground the ProControl system as instructed here and in
the individual component manuals. A ground wire and

clamp, part no. 223547, is available from Graco.

NOTE: To prevent electrical noise interference from high
voltage equipment, do not connect the robot ground to
the same ground point used by these ProControl com­ponents.

NOTE: Different ground points (unequal potential) may
cause current to flow through component cables, caus­ing incorrect signals.

EasyKey

Connect a ground wire from the EasyKey ground screw
to a true earth ground. F

IG. 14.

IG. 14,

Feed Pumps or Pressure Pots

Connect a ground wire and clamp from a true earth
ground to the pumps or pots. See pump or pressure pot
manual.

Air and Fluid Hoses

Use grounded hoses only.

Spray Gun

Follow the grounding instructions in your gun manual.

Fluid Supply Container

Follow local code.

Object Being Sprayed

Follow local code.

All Solvent Pails Used When Purging

Follow local code. Use only conductive metal pails/con­tainers placed on a grounded surface. Do not place the
pail/container on a nonconductive surface, such as
paper or cardboard, which interrupts the grounding con­tinuity.

Gun Flush Box (Manual or Semi-automatic
mode only)

Connect a ground wire from the Gun Flush Box ground
lug to a true earth ground. F

IG. 14.

Wall Mount Fluid Station

Connect a ground wire from the Wall Mount Fluid Sta­tion ground screw to a true earth ground. F

IG. 14.

Color Change Module

Connect a ground wire from the Color Change Module
ground screw to a true earth ground. A ground wire and
clamp, part no. 223547, is available from Graco. F

IG. 14.

Flow Meters

Connect the meter cables as shown in the System
Electrical Schematic Hazardous Area on page 31.

Failure to properly connect the shield may cause incor­rect signals.

Check Resistance

To ensure proper grounding, resistance between Pro­Mix components and true earth ground must be less
than 1 ohm. Read Warnings, page 6.

Have a qualified electrician check resistance between
each ProControl component and true earth ground. If
resistance is greater than 1 ohm, a different ground site
may be required. Do not operate the system until the
problem is corrected.

3A1163A 27

Electrical

Control Box

3

1

4

6

EasyKey Display

2

6

5

Robot

EasyKey ground screw

EasyKey ground wire

Control Box ground screw

Control Box ground wire

Robot ground wire. Connect to separate ground point; see NOTE on page 27.

True Earth Ground - check your local code for requirements

1

2

3

4

5

Key:

6

TI16331a

FIG. 14: Grounding

28 3A1163A

Schematic Diagrams

System Pneumatic Schematic

Schematic Diagrams

AIR INPUT

3/8 AIR FILTER
MANUAL DRAIN
5 MICRON
WALL MOUNT ONLY

PURGE AIR

05

AIR INPUT

TO MANIFOLD 1/4 TUBE

CONTROL AIR

AIR EXHAUST MUFFLER

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

AIR EXHAUST MUFFLER

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

COLOR
CHANGE
CONTROL

DOSE A

OPEN

OPEN

OPEN

VALV E

DOSE B
VALV E

PURGE A
VALV E

PURGE B
VALV E

PURGE C
VALV E
(OPTIONAL)

DUMP A
VALV E
(OPTIONAL)

DUMP B
VALV E
(OPTIONAL)

GFB 1
VALV E
(OPTIONAL)

GFB 2
VALV E
(OPTIONAL)

FLUSH AIR TO FLUID INLE T 1/4 TUBE

36 SERIES SOLENOID VALVES

MANIFOLD

A

B

A

B

A

B

A

B

A

B

A

A

A

A

CLOSE

5/32 TUBE

CLOSE

5/32 TUBE

OPEN

CLOSE

5/32 TUBE

CLOSE

5/32 TUBE

CLOSE

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

COLOR
VALV E
STACKS

COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
COLOR SOLVENT
COLOR 9
COLOR 10
COLOR 11
COLOR 12
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
CATALYST SOLVENT

COLOR 13
COLOR 14
COLOR 15
COLOR 16
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
COLOR 22
COLOR 23
COLOR 24
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30

MAC

3A1163A 29

Schematic Diagrams

System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProControl 1KS system. Some compo-

nents shown are not included with all systems.

Non-Hazardous Area

MEMBRANE
SWITCH
WITH
RIBBON
CABLE

DISPLAY

LINE

NON-HAZARDOUS AREA

DC OK
+24 VDC

COMMON
COMMON

POWER HARNESS

OPERATOR INTERFACE

+

POWER

+

SUPPLY

-

-

BARRIER
BOARD

J1

J5

J4

12L1

1

UNUSED

2

UNUSED

3

UNUSED

4

UNUSED

5

UNUSED

1
2
3

1

+24VDC

2

OPEN

3

COMMON

N

85-250 VAC

+12VDC I/S (RED)
COM (BLACK)
SHIELD

HARNESS

L1
N

ALARM

J4

DISPLAY

1

BOARD
2
3
4
5
6
7
8
9
10
11

J2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

1

+

2

-

J9

3
4

RJ45

RJ45

J6

FLOW CONTROL CAL. (BLK)

1

GUN TRIGGER (WHT )

2

DIGITAL IN COMMON (RED)

3

REMOTE STOP (GRN)

4

ALARM RESET (BRN)

5

J5

ALARM OUTPUT (BLU)

6

DIGITAL OUTPUT COMMON (ORG)

7

POT LIFE (YEL)

8

FLOW RATE ANALOG IN (PUR)

9

FLOW RATE ANALOG COMMON (GRAY)

10

POWER DIST.
TERMINAL
BLOCKS

-

-

-

-

+

+

+

+

+

-

3'

SHIELD

RJ45

RJ45

REMOTE
I/O
INTEGRATION
BOARD

1
2
3
4
5
6
7
8
9
10

I/O HARNESSES

RS485 INTEGRATION A (WHT/BLU)

1

RS485 INTEGRATION B (BLU/WHT)

2

RS485 INTEGRATION GROUND (SHIELD)

3

J10

RS485 NETWORK A (WHT/ORG)

4

RS485 NETWORK B (ORG/WHT)

5

RS485 NETWORK GROUND (SHIELD)

6

1
2
3
4
5
6

TERMINAL
BLOCKS

FILTER

OPEN

OPEN

J2

J3

J4

J5

L1
N
GND

1

GND LUG

2
3

1

POWER

2

ROCKER

1A

SWITCH

1B
2A
2B

CABLE

(50' STD.)/

(100' OPTION)

1
2
3
4
5
6

1

DIGITAL INPUT COMMON

2

RECIPE BIT 0 INPUT

3

RECIPE BIT 1 INPUT

4

RECIPE BIT 2 INPUT

5

RECIPE BIT 3 INPUT

6

RECIPE BIT 4 INPUT

7

RECIPE BIT 5 INPUT

8

RECIPE CHANGE INPUT

1

DIGITAL OUTPUT COMMON/POWER

2

PURGE/RECIPE CHG ACTIVE OUTPUT

3

MIX ACTIVE OUTPUT

4

MIX READY OUTPUT

5

FILL ACTIVE

6

FLOW CAL. ACTIVE

7

FLOW RATE ALARM OUTPUT

8

DIGITAL OUTPUT COMMON/POWER

1

DIGITAL OUTPUT COMMON/POWER

2

SPECIAL OUTPUT #1

3

SPECIAL OUTPUT #2

4

SPECIAL OUTPUT #3

5

SPECIAL OUTPUT #4

6

DIGITAL OUTPUT COMMON/POWER

L1

TERMINAL

N

BLOCK

GND

MIX INPUT
PURGE INPUT
JOB COMPLETE INPUT
EXTERNAL CLR CHG READY
RESET ALARM INPUT
DIGITAL INPUT COMMON

(+24) YEL

(COM) GRAY

ORG
BRN

RED

L1
N
GND

BEACON

GND N L1

85-250
VAC

CABLE

J7

FO IN (BLK)

J8

FO OUT (BLU)

RJ45

RJ45

P1

3'

RJ45
BULKHEAD

3'
(25'-200' OPTIONS)

RJ45

WEB SERVER

RJ45

MODULE

30 3A1163A

Schematic Diagrams

System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProControl 1KS system. Some compo-

nents shown are not included with all systems.

Hazardous Area

FO OUT
(BLU)

FO IN
(BLK)

FLUID PANEL CONTROL BOX

FLUID
PANEL
CONTROL
BOARD

J10

+12VDC I/S

2

COM

3

SHIELD

5

J4

J6

J13

J15

J14

MH2

HAZARDOUS AREA

1
2
3

J3

4
5
6

1
2
3

J12

4
5
6

UNUSED

1

UNUSED

2

UNUSED

3

UNUSED

4

UNUSED

5

UNUSED

6

1
2
3

J5

4
5
6

3
2

J11

5
4
1

3
2

J7

5
4
1

6
5
4

J8

3
2
1

6
5
4
3
2
1

6
5
4
3
2
1

6
5
4

J9

3
2
1

1
2
3
4
5
6

J1

7
8
9
10

6' STD.
(3'-100' OPTIONS)

50' STD.

GRD (BLK)
+12VDC (RED)
SHIELD (BARE)
CAN H (WHT)
CAN L (BLU)

BLACK
RED
BLACK
RED
BLACK
RED

BLACK
RED
BLACK
RED
BLACK
RED

BLACK
RED
BLACK
RED
BLACK
RED

BLACK
RED
BLACK
RED
BLACK
RED

SIG
COM
SIG
COM
SIG
COM
SIG
COM
SIG
COM

PWR (RED)
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
NOT USED
NOT USED
NOT USED
NOT USED
PWR (RED)
COM (BLACK)
SIG (WHITE)
SHIELD/GRN

GROUND
TERMINAL

MANIFOLD

MANIFOLD

3X CABLE

(10')/
(40')

GRD (BLK)
+12VDC (RED)
SHIELD (BARE)
CAN H (WHT)
CAN L (BLU)

BOOTH

3

CONTROL

2

BOARD

5
4
1

NOT USED

GFB #1

GFB #2

DUMP A

NOT USED

PURGE C

PURGE B

PURGE A

NOT USED

NOT USED

NOT USED

DOSE A

AIR FLOW SWITCH 1

AIR FLOW SWITCH 2

SOLVENT FLOW SWITCH

GFB 1 PRESSURE SWITCH

GFB 2 PRESSURE SWITCH

FLOW METER A

FLOW METER SOLVENT

12 VDC

3-WAY SOLENOID

12 VDC

4-WAY SOLENOID

V/P ANALOG OUT (WHT)
PRESS. (GRN)
+12 V (RED)
GND (BLK)
CHASSIS (BARE)

MANIFOLD

CLR 8

CLR 7

CLR 6

CLR 5

CLR 4

CLR 3

CLR 2

CLR 1

SOL CLR

MANIFOLD

CLR 21

CLR 20

CLR 19

CLR 18

CLR 17

CLR 16

CLR 15

CLR 14

CLR 13

I.S. METERS

J1

J7/J11

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

J7/J11

J7/J11

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

PRESS. SWITCH #2 + (WHT/BLK)

SOLENOID #1 COM (ORG/BLK)

SOLENOID #2 COM (RED/WHT)

J2

SIG (RED)

1
2

FLOW

1
2

CONTROL

3

BOARD

4
5

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

PRESS. SWITCH #1 + (ORG)

PRESS. SWITCH #1 - (BLU)

PRESS. SWITCH #2 - (RED/BLK)

SOLENOID #1 +12 (GRN/BLK)

COM (BLK)

J4

+ PRESSURE (GRN)

1
2

COM (RED)

3

EX+ (WHT)

4

- PRESSURE (BLK)

5

SHIELD (BARE)

1 4 5 2 3

COLOR
BOARD 1
(COLORS
1 THRU 12,
CATALYST

6

1 THRU 4)

5
4
3

J8

J9

2
1

6
5
4

J16

J15

3
2
1

6
5
4

J10

J14

3
2
1

1 4 5 2 3

6' STD.

1 4 5 2 3

COLOR
BOARD 2
(COLORS
13 THRU 30)

6
5
4

J9

J8

J15

J14

3
2
1

6
5

J16

4
3
2
1

6
5
4

J10

3
2
1

AFS #1 + (BLK)

AFS #1 - (WHT)

AFS #2 + (RED)
AFS #2 - (GRN)

SOLENOID #2 +12 (BLU/BLK)

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

1
2
3
4
5
6
7
8
9
10
11
12

MANIFOLD

MANIFOLD

ROBOMIX GFB
INTERFACE
MODULE

TECNO
V/P

FLUID
PRESS.
SENS.

CLR 9

CLR 10

CLR 11

CLR 12

CAT 4

CAT 3

CAT 2

CAT 1

SOL CAT

CLR 22

CLR 23

CLR 24

CLR 25

CLR 26

CLR 27

CLR 28

CLR 29

CLR 30

3A1163A 31

Dimensions and Mounting Hole Layouts

Dimensions and Mounting Hole Layouts

Wall Panel

(mounting bracket only)

C

E

D

B

A

TI16333a

A

Overall

Width

Module

EasyKey 14.0 (355.6) 6.6 (167.6) 13.5 (342.9) 12.0 x 12.75 (304.8 x 323.9) 0.3 (7.6) 22.2 (10.1)
Control Box 10.16

Wall Panel
(bracket only)

Air Supply
Control

Flow Control
Module

in. (mm)

(258.0)

9.5 (241.3) 0.5 (12.7) 9.0 (228.6) 8.5 x adjustable from 5.0-8.0

8.9 (226.1) 3.8 (96.5) 9.9 (251.5) 4.75 (120.7) 0.34 (8.73) 4.65 (2.12)

7.13 (181.1) 2.52 (64.0) 3.86 (98.0) 6.63 x 1.50 (168.4 x 38.1) 0.25 (6.3) 3.9 (1.78)

Overall

Depth

in. (mm)

6.0 (152.4) 11.48

B

Overall

Height

in. (mm)

(291.6)

E

Mounting Dimensions,

Width (C) x Height (D)

in. (mm)

8.0 x 10.75 (203.2 x 273.0) 0.3 (7.6) need data

(212.5 x 127.0-203.2)

Mounting
Hole Size

in. (mm)

0.5 (12.7) need data

Weight

lb (kg)

32 3A1163A

Dimensions and Mounting Hole Layouts

B

EasyKey

C

A

E

D

TI11891a

Flow Control Module

B

Control Box

C

E

D

A

TI16332a

B

A

TI13659a

E

D

C

TI14135a

Air Supply Control

C

E

TI11895a

3A1163A 33

Dimensions and Mounting Hole Layouts

34 3A1163A

Technical Data

Technical Data

Maximum fluid working pressure . . . . . . . . . . . . . . . Base system: 4000 psi (27.58 MPa, 275.8 bar)

Low pressure color change: 300 psi (2.07 MPa, 20.6 bar)
Coriolis meter: 2300 psi (15.86 MPa, 158.6 bar)
Flow control: 190 psi (1.31 MPa, 13.1 bar)

Maximum working air pressure. . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)

Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 - 100 psi (0.5 - 0.7 MPa, 5.2 - 7 bar)

Air filter inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npt(f)

Air filtration for air logic and purge air

(Graco-supplied). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 micron (minimum) filtration required; clean and dry air

Air filtration for atomizing air (user-supplied) . . . . . . 30 micron (minimum) filtration required; clean and dry air

Fluids handled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . one component:

• solvent and waterborne paints

• polyurethanes

•epoxies

• acid catalyzed varnishes

• moisture sensitive isocyanates

Viscosity range of fluid . . . . . . . . . . . . . . . . . . . . . . . 20- 5000 cps*

Fluid filtration (user-supplied) . . . . . . . . . . . . . . . . . . 100 mesh minimum

Fluid flow rate range*

G3000, G250 Meter
G3000HR, G250HR Meter
Coriolis Meter
S3000 Solvent Meter (accessory)

Fluid inlet sizes

Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dose Valve/Color Valve Adapters . . . . . . . . . . .

Fluid outlet size (static mixer) . . . . . . . . . . . . . . . . . . 1/4 npt(f)

External Power Supply Requirements . . . . . . . . . . . 85 - 250 Vac, 50/60 Hz, 2 amps maximum draw

Operating temperature range . . . . . . . . . . . . . . . . . . 41- 122° F (5-50° C)

Environmental Conditions Rating . . . . . . . . . . . . . . . indoor use, pollution degree (2), installation category II

Noise Level

Sound pressure level . . . . . . . . . . . . . . . . . . . . .

Sound power level . . . . . . . . . . . . . . . . . . . . . . .

Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303, 304 SST, Tungsten carbide (with nickel binder),

75 - 3800 cc/min. (0.02-1.00 gal./min.)
38 - 1900 cc/min. (0.01-0.50 gal./min.)
20 - 3800 cc/min. (0.005-1.00 gal./min.)
38 - 1900 cc/min. (0.01-0.50 gal./min.)

1/4 npt(f)
1/4 npt(f)

15 amp maximum circuit breaker required
8 to 14 AWG power supply wire gauge

below 70 dBA
below 85 dBA

perfluoroelastomer; PTFE

* Dependent on programmed K-factor and application. The maximum allowable flow meter pulse frequency is 425

Hz (pulses/sec). For more detailed information on viscosities, flow rates, or mixing ratios, consult your Graco dis­tributor.

See individual component manuals for additional technical data.

3A1163A 35

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: [phone] or Toll Free: 1-800-328-0211 Fax: [phone]

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 3A1163

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

Copyright 2010, Graco Inc. is registered to ISO 9001

www.graco.com