Graco 3A1164B User Manual

Repair-Parts

™

ProControl

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

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.

3A1164B

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

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Check Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Solenoid Troubleshooting . . . . . . . . . . . . . . . . . 14

Wall Mount Fluid Manifold Troubleshooting . . . . 16

EasyKey Barrier Board Diagnostics . . . . . . . . . 17

EasyKey Display Board Diagnostics . . . . . . . . . 18

Discrete I/O Board Diagnostics . . . . . . . . . . . . . 20

Fluid Station Control Board Diagnostics . . . . . . 22

Color Change Board Diagnostics . . . . . . . . . . . 24

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . 26

System Pneumatic Schematic . . . . . . . . . . . . . . 26

EasyKey Electrical Schematic . . . . . . . . . . . . . . 27

System Electrical Schematic . . . . . . . . . . . . . . . 28

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . 30

After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Servicing EasyKey . . . . . . . . . . . . . . . . . . . . . . . 31

Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Servicing Flow Meter . . . . . . . . . . . . . . . . . . . . . 38

Servicing Color Change Module,

Color/Catalyst Valves, and Dump Valves . . 39

Servicing Flow Control . . . . . . . . . . . . . . . . . . . 40

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

ProControl 1KS System . . . . . . . . . . . . . . . . . . . 43

EasyKey Controls . . . . . . . . . . . . . . . . . . . . . . . 46

Available Cables . . . . . . . . . . . . . . . . . . . . . . . . 47

262363 Fluid Station Control Box . . . . . . . . . . . 48

262364 Valve Stack . . . . . . . . . . . . . . . . . . . . . . 50

249849 Flow Control Regulator . . . . . . . . . . . . . 51

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 54

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 54

2 3A1164B

Related Manuals

Related Manuals

Component Manuals in English

Manual Description

3A1163 ProControl 1KS Installation
3A1080 ProControl 1KS Operation
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

3A1164B 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

.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

✔

✔

✔ ✔

✔ ✔

✔ ✔

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 3A1164B

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

3A1164B 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 3A1164B

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.

3A1164B 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 3A1164B

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.

3A1164B 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.

Grounding

Grounding

Your system must be grounded. See the Grounding
instructions in your ProControl 1KS Installation man­ual.

Check Resistance

To ensure proper grounding, resistance between Pro­Control components and true earth ground must be
less than 1 ohm.

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.

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

3. Do a complete system purge, following the instruc-

tions under Purging Using Recipe 0, in the Pro-
Control 1KS Operation Manual.

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

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

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

IG. 3.

IG. 2. Verify that solvent pressure is

Systems with Color Change and Dump
Valves

NOTE: This procedure relieves pressure through the

dump valves.

1. Complete all steps under Single Color Systems,
page 10.

2. Shut off all color and catalyst supplies to the valve
stacks.

Pressure Relief Procedure

NOTE: The following procedures relieve all fluid and air

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

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

Single Color Systems

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

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

IG. 2.

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

IG. 2.

4. See F

5. Press and hold the dump valve A solenoid override,

6. Press and hold the A side (color) solvent solenoid

7. Shutoff the solvent supply to the color/catalyst

8. Press and hold the A solvent solenoid override and

IG. 2. Open the color change module. Using

the solenoid identification labels as a guide, press
and hold the override button on each color solenoid
until flow from dump valve A stops.

F

IG. 2.

override until clean solvent comes from the dump
valve, then release.

change stack solvent valves.

dump valve override until solvent flow from the
dump valve stops.

10 3A1164B

Solenoid

Identification

Label

Pressure Relief Procedure

Color Catalyst

Solenoid
Identification
Label

Color

TI12826a

FIG. 2: Color Change Solenoids

APV

AT

DVA

Solvent Solenoid
Overrides

FIH

MA

Key:

MA Component A Meter
DVA Component A Dose

Valve
SPV Solvent Purge Valve
SS Solvent Purge Valve

Solvent Supply Tube
APV Air Purge Valve
AT Air Purge Valve Air

Supply Tube
FIH Fluid Inlet Hose
FOH Fluid Outlet Hose

SS

FOH

SPV

TI15977a

FIG. 3. Fluid Manifold

3A1164B 11

Pressure Relief Procedure

12 3A1164B

Troubleshooting

Troubleshooting

Table 1: System Alarm Codes

Code Description

Follow Pressure Relief Procedure, page 10, before
cleaning, checking, or servicing equipment.

NOTE: Do not use the fluid in the line that was dis­pensed off ratio as it may not cure properly.

Alarm Codes

Table 1 lists the system alarm codes. See the system
operation manual for complete information on alarm
troubleshooting.

E-1 Communication Error Alarm
E-2 Potlife Alarm
E-3 Ratio High Alarm
E-4 Ratio Low Alarm
E-5 Overdose A/B Dose Too Short Alarm
E-6 Overdose B/A Dose Too Short Alarm
E-7 Dose Time A Alarm
E-8 Dose Time B Alarm
E-9 Mix in Setup Alarm
E-10 Remote Stop Alarm
E-11 Purge Volume Alarm
E-12 CAN Network Communication Error Alarm
E-13 High Flow Alarm
E-14 Low Flow Alarm
E-15 System Idle Warning
E-16 Setup Change Warning
E-17 Power On Warning
E-18 Defaults Loaded Warning
E-19 I/O Alarm
E-20 Purge Initiate Alarm
E-21 Material Fill Alarm
E-22 Tank A Low Alarm
E-23 Tank B Low Alarm
E-24 Tank S Low Alarm
E-25 Auto Dump Complete Alarm
E-26 Color/Catalyst Purge Alarm
E-27 Color/Catalyst Fill Alarm

3A1164B 13

Troubleshooting

Solenoid Troubleshooting

Dose Valve A
Solenoid

J14

J15

J8

Purge Valve A
Solenoid

Dose Valve B
Solenoid

Purge Valve B
Solenoid

J1J12J3J9

CAN

CAN

Power

Fiber
Optic

TI15916a

FIG. 4: Fluid Station Board and Solenoids

14 3A1164B

Troubleshooting

NOTE: Refer to the Schematic Diagrams, page 26.

If the dispense or purge valves are not turning on or off correctly, it could be caused by one of the following.

Cause Solution

1. Air regulator pressure set too
high or too low.

2. Air or electrical lines damaged or
connections loose.

Check air pressure. 80-90 psi (550-630 kPa, 5.5-6.3 bar) is commonly used.
Do not go below 70 psi (490 kPa, 4.9 bar) or above 120 psi (0.8 MPa, 8 bar).

Visually inspect air and electrical lines for kinks, damage, or loose connec­tions. Service or replace as needed.

3. Solenoid failure Manually operate the valves by removing the Fluid Station cover and press-

ing and releasing solenoid valve override buttons. F

IG. 4.

Use the control board diagnostics to check the signals. If signals do not
occur correctly, go to Cause 4.

Valves should snap open and shut quickly. If the valves actuate slowly, it
could be caused by:

• Air pressure to the valve actuators is too low. See Cause 1.

• Solenoid is clogged. Make sure air supply has 10 micron filter installed.

• Something is restricting the solenoid or tubing. Check for air output from
air line for corresponding solenoid when valve is actuated. Clear restric­tion.

• A dose valve is turned in too far. See ProControl 1KS Operation manual
for settings.

• Fluid pressure is high and air pressure is low.

4. Solenoid, cable, or fluid station
control board failure.

Check voltage level to solenoid by pulling solenoid connector and checking
voltage between pins.

If voltage is 9-15 VDC, the solenoid is damaged. Replace solenoid or correct
electrical line problem.

If there is no voltage, replace the board.

3A1164B 15

Troubleshooting

Wall Mount Fluid Manifold Troubleshooting

See FIG. 5.

APV

AT

FIH

MA

Key:

MA Component A Meter
DVA Component A Dose

Valve
SPV Solvent Purge Valve
SS Solvent Purge Valve

Solvent Supply Tube
APV Air Purge Valve
AT Air Purge Valve Air

Supply Tube
FIH Fluid Inlet Hose
FOH Fluid Outlet Hose

DVA

SS

FOH

F

IG. 5. Wall Mount Fluid Manifold

SPV

TI15977a

16 3A1164B

Troubleshooting

EasyKey Barrier Board Diagnostics

See FIG. 6 and Table 2 to troubleshoot the EasyKey barrier board. Also see the EasyKey Electrical Schematic on
page 27 and the System Electrical Schematic on pages 28 and 29.

F4

F3

D4

J4, Pin 1

J1, Pin 1

D5

F1

F2

J5, Pin 1

F

IG. 6: 255786 EasyKey Barrier Board

Table 2: EasyKey Barrier Board Diagnostics

Connector Description Diagnosis

J1 AC Power Input n/a
J4 24 Vdc Power Input to

EasyKey Display Board

J5 12 Vdc Power Output to

Fluid Station Board

3A1164B 17

D5 turns on.

D4 turns on if barrier board is functioning. If D4 does not turn on, fuses F3
or F4 (Graco Part No. 15D979) are blown or there is no input power at J4.

If there is no input power (D5 does not light), fuses F1 and F2 (Graco Part
No. 114788) may be blown.

Troubleshooting

EasyKey Display Board Diagnostics

See FIG. 7 and Table 3 to troubleshoot the EasyKey display board. Also see the EasyKey Electrical Schematic on
page 27 and the System Electrical Schematic on pages 28 and 29.

Multiple Station

GNDGNDAB

A

B

TI12923a

Integration Control

Analog In Common

Analog In Signal

Potlife Alarm

Output Common

J10

General Alarm

J6

P1

J1

J4

RT1

J9

D7

J5

Reset Alarm

Remote Stop

Gun Trigger

Input Common

TI12924a

BK885 or CR1220 Battery
(3V, 12.5 mm, lithium coin)

D11

Flow Control Calibrate

J8J7

F

IG. 7: 255767 EasyKey Display Board

18 3A1164B

R5

Table 3: EasyKey Display Board Diagnostics

Troubleshooting

Connector/
Indicator Description

J1 Graphic Display Backlight
J4 Ribbon Cable to Membrane
J5 Inputs and Outputs
J6 Remote I/O
J7 Fiber Optic Cable Input (black)
J8 Fiber Optic Cable Output (blue)

Connector/
Indicator Description

J9 24 Vdc Power Input/Alarm Output
J10 RS485 Communication Terminals
D7 (green) LED turns on when power is supplied to

board

D11 (yellow) LED blinks (heartbeat) when board is

operating
P1 Ethernet Port
R5 Display Contrast/Dimmer Switch (turn

by hand)

3A1164B 19

Troubleshooting

Discrete I/O Board Diagnostics

See FIG. 8 and FIG. 9 to troubleshoot the Discrete I/O board. Also see the System Electrical Schematic on pages
28 and 29.

I/O Terminal Strip Detail

Pin 1

Pin 1

RS485 Integration A

RS485 Integration B
RS485 Integration Ground

RS485 Network A

RS485 Network B

RS485 Network Ground

Flow Control Calibrate

Gun Trigger

Digital Common

Remote Stop

Alarm Reset

General Alarm

Digital Common

Potlife Alarm

Flow Rate Analog In

Flow Rate Analog Common

INPUTS

OUTPUTS

TI12958a

Display Board Barrier Board

Terminal Strips
(see detail above)

Discrete I/O Board
(see F

IG. 9)

TI12496b

F

IG. 8: EasyKey Control Boards and Terminal Strips

20 3A1164B

Troubleshooting

LED D1

(green)

JLS

Digital Output

Special Output #4

Special Output #3

Common/Power

Special Output #2

Digital Output

Special Output #1

Common/Power

Digital Output Common/Power

Flow Rate Alarm Output

Flow Calibrate Active

Fill Active

Mix Ready Output

Mix Active Output

Purge/Recipe Change Active Output

Digital Output Common/Power

Recipe Change Input

Recipe Bit 5 Input

Recipe Bit 4 Input

FIG. 9: 255766 Discrete I/O Board

Mix Input

Purge Input

Job Complete Input

Recipe Bit 3 Input

Recipe Bit 2 Input

Recipe Bit 1 Input

Recipe Bit 0 Input

Digital Input Common

Spare

Digital Input Common

External Color Change Ready

3A1164B 21

Troubleshooting

Fluid Station Control Board Diagnostics

See FIG. 10 and Table 4 to troubleshoot the fluid station control board. Also see the System Electrical Schematic
on pages 28 and 29.

J4

J1, Pin 1

D19

D18

(Fiber Optic Output - blue)

F1 (Fuse)

J6
(Fiber Optic Input ­black)

D15

D45

D16

D46

D17

D44

J10
(Power Input)

VDC

J11
(Color Change
Module)

D20

J7
(Not Used)

J9, Pin 1

D29

D43

D28 D30 D27 D41 D33 D31

J15, Pin 1

F

IG. 10: 255765 Fluid Station Control Board

22 3A1164B

J8, Pin 1J14, Pin 1

Troubleshooting

Table 4: Fluid Station Control Board Diagnostics

Connector

LED

and Pin Nos. Signal Description Diagnosis

D15 J1, 1 & 2 Air Flow Switch 1 Turns on when gun 1 is triggered.
D16 J1, 5 & 6 Solvent Flow Switch Turns on when solvent is flowing.
D17 J1, 9 & 10 Gun Flush Box 2 Pressure Switch Turns on when a gun is in Gun Flush Box 2.
D18 J10 Power Turns on when power is supplied to the board.
D19 n/a Communication (yellow) Turns on when board is communicating with EasyKey.
D20 n/a Board OK Blinks (heartbeat) during normal operation.
D27 J15, 1 & 2 Purge Valve C (Water Purge)
D28 J14, 3 & 4 Purge Valve A (Air Purge)
D29 J8, 5 & 6 Dump Valve B
D30 J14, 5 & 6 Purge Valve B (Solvent Purge)
D31 J8, 1 & 2 Gun Flush Box 1 Trigger

D27 through D44 turn on when ProMix sends a signal
to actuate the related solenoid valve.

D33 J8, 3 & 4 Gun Flush Box 2 Trigger
D41 J15, 5 & 6 Dump Valve A
D43 J9, 3 & 4 Dose Valve B
D44 J9, 1 & 2 Dose Valve A
D45 J1, 3 & 4 Air Flow Switch 2 Turns on when gun 2 is triggered.
D46 J1, 7 & 8 Gun Flush Box 1 Pressure Switch Turns on when a gun is in Gun Flush Box 1.
F1 n/a Replaceable Fuse Check fuse condition if there is no power to the fluid

station.

3A1164B 23

Troubleshooting

Color Change Board Diagnostics

See FIG. 11 and Table 5 to troubleshoot the color change board. Also see the System Electrical Schematic on
pages 28 and 29.

J8, Pin 1

D33

D31

D29

J15, Pin 1

D41

D35

D27

J14, Pin 1

D30

D28

D36

D34

D43

D44
J9, Pin 1

D39

D32

D38
J16, Pin 1

D37

D45

D46

J10, Pin 1

D9

D10

D8

F1 (Fuse)

J7 J11

F

IG. 11: 256172 Color Change Board

24 3A1164B

Table 5: Color Change Board Diagnostics

Troubleshooting

LED

Connector
and Pin Nos.

Board 1 Signal
Description

Board 2 Signal
Description Diagnosis

D8 n/a Board OK Board OK Blinks (heartbeat) during normal operation.
D9 n/a Communication

(yellow)

Communication
(yellow)

Turns on when board is communicating with ProMix

2KS.
D10 J7 Power Power Turns on when power is supplied to the board.
D27 J15, 5 & 6 Color 3 Color 16
D28 J14, 3 & 4 Color 1 Color 14
D29 J8, 5 & 6 Color 6 Color 19
D30 J14, 1 & 2 Color 2 Color 15
D31 J8, 3 & 4 Color 7 Color 20
D32 J16, 3 & 4 Catalyst 4 Color 26
D33 J8, 1 & 2 Color 8 Color 21
D34 J9, 5 & 6 Color 9 Color 22
D35 J15, 3 & 4 Color 4 Color 17
D36 J14, 5 & 6 Solvent (Color) Color 13

D27 through D46 turn on when ProMix 2KS sends

a signal to actuate the related solenoid valve.
D37 J10, 5 & 6 Catalyst 2 Color 28

D38 J16, 1 & 2 Catalyst 3 Color 27
D39 J16, 5 & 6 Color 12 Color 25
D41 J15, 1 & 2 Color 5 Color 18
D43 J9, 3 & 4 Color 10 Color 23
D44 J9, 1 & 2 Color 11 Color 24
D45 J10, 3 & 4 Catalyst 1 Color 29
D46 J10, 1 & 2 Solvent (Catalyst) Color 30
F1 Replaceable

Fuse

n/a n/a Check fuse condition if there is no power to the

board or if communication is interrupted between

the fluid station and the color change module.

3A1164B 25

Schematic Diagrams

Schematic Diagrams

System Pneumatic Schematic

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

26 3A1164B

EasyKey Electrical Schematic

Schematic Diagrams

GND L1 N

TERMINAL BLOCKS

ALARM

- +

L L N N

COMMON

- - + DC OK

HIGH

VOLTAGE

24 VDC+

OUTPUT

IN

24 VDC+

GRN/YEL 16 AWG

RED 16 AWG BROWN 16 AWG

GND L1 N

L1 N

RED 16 AWG BROWN 16 AWG

1 2

1A 2A

RED 16 AWG BROWN 16 AWG

LINE FILTER

POWER

ROCKER SWITCH

RJ45 BULKHEAD

RJ45

POWER SUPPLY

GND LUG

GREEN/BLACK/WHITE 22 AWG RED/BLACK/WHITE 22 AWG BLACK 18 AWG RED 18 AWG

432

DISPLAY BOARD

RED 18 AWG

BLACK 18 AWG

+

+

+

-

1

J9

+

-

-

-

IS POWER

12 VDC

UNUSED

UNUSED

UNUSED

UNUSED

BLACK 18 AWG RED 18 AWG

J4-3 J4-2 J4-1

J4

24 VDC+

IN

UNUSED

J1-5 J1-4 J1-3 J1-2 J1-1

J1

COMMON (BLACK)

+12 VDC I/S (WHITE)

J5-3 J5-2 J5-1

J5

SHIELD/GRND

RJ45

RJ45

P1

BARRIER BOARD

DISPLAY BOARD

3A1164B 27

Schematic Diagrams

System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS 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

MIX INPUT

2

PURGE INPUT

3

JOB COMPLETE INPUT

4

EXTERNAL CLR CHG READY

5

RESET ALARM INPUT

6

DIGITAL INPUT COMMON

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
N
GND

(+24) YEL

(COM) GRAY

ORG

BRN
RED

TERMINAL
BLOCK

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

28 3A1164B

Schematic Diagrams

System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS 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

+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

COM

SOLENOID #2 COM (RED/WHT)

J2

SIG (RED)

1
2

FLOW

1
2

CONTROL

3

BOARD

4
5

J7/J11

1
2
3
4
5
6

1
2
3

J15

4
5
6

1
2
3
4
5
6

J7/J11

J7/J11

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 + (WHT/BLK)

PRESS. SWITCH #2 - (RED/BLK)

SOLENOID #1 +12 (GRN/BLK)

SOLENOID #1 COM (ORG/BLK)

SOLENOID #2 +12 (BLU/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

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

3
2
1

6

J15

J14

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)

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

3A1164B 29

Service

Service

Before Servicing

• To avoid electric shock, turn off EasyKey power
before servicing.

• Servicing EasyKey display exposes you to high
voltage. Shut off power at main circuit breaker
before opening enclosure.

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

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

• Read Warnings, page 6.

NOTICE

To avoid damaging circuit board when servicing, wear
Part No. 112190 grounding strap on wrist and ground
appropriately.

1. Flush system and follow Pressure Relief Proce-
dure, page 10, if service time may exceed pot life
time and before servicing fluid components.

3. Shut off ProControl 1KS power (0 position). F

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

FIG. 12: Power Off

IG. 12.

0 = OFF

TI12657a

After Servicing

After servicing the system, be sure to follow the
Start Up checklist and procedure in the ProControl 1KS
Operation manual.

2. Close main air shutoff valve on air supply line and
on ProControl 1KS.

30 3A1164B

Service

Servicing EasyKey

Updating Software

To update software, upload new software from your PC
using the basic web interface. See manual 313386.

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

Replacing Display Board or Graphic
Display

NOTICE

To avoid damaging circuit board when servicing, wear
Part No. 112190 grounding strap on wrist and ground
appropriately.

1. Follow Before Servicing, page 30.

2. Unlock and open EasyKey door with its key.

5. Disconnect graphic display power cable (J1) from
the display board (210c).

6. Separate graphic display (210b) from display board
(210c) [connector J2 on back of board].

7. To assemble the new parts, align connector J2 on
the display board (210c) with the socket on the
graphic display (210b). Press them together. See
F

IG. 13.

8. Reconnect the graphic display power cable (J1) to
the display board (210c).

9. Mount display board assembly with screws (210e).

10. Plug all connectors into display board (210c). F

IG.

13. Confirm that the cables do not pinch when open­ing or closing the door.

11. Locate the battery on the board (see F

IG. 7 on page

18). Pull the strip to remove the protective isolator
and activate the battery.

12. Close and lock EasyKey door with key.

13. Turn EasyKey power on to test display board.

Replacing Power Supply

3. Note position of all external connections (J4, J5, J6,
J7, J8, J9, J10) to display board, then unplug the
connectors. See F

IG. 7 on page 18.

4. Remove 4 screws (210e) and the display board
assembly (210b, 210c). F

210d

IG. 13.

210a

J1

210b

TI12554a

210c

210e

F

IG. 13: Display Interface

1. Follow Before Servicing, page 30.

2. Unlock and open EasyKey door with its key.

3. Note position of power supply input and output

wires. See EasyKey Electrical Schematic, page

27. Disconnect wires from power supply (214f). See
F

IG. 14.

4. Remove power supply from din rail.

5. Install new power supply (214f). Reconnect input
and output wires in positions noted in step 3.

6. Close and lock EasyKey door with key.

7. Turn on power at main circuit breaker.

8. Turn EasyKey power on to test operation.

3A1164B 31

Service

Replacing Line Filter

1. Follow Before Servicing, page 30.

2. Unlock and open EasyKey door with its key.

3. Note position of line filter input and output wires.

See EasyKey Electrical Schematic, page 27. Dis-
connect wires and remove line filter (214l) from
bracket (214m). See F

4. Install new line filter (214l). Reconnect wires in posi­tions noted in step 3.

5. Close and lock EasyKey door with key.

6. Turn on power at main circuit breaker.

7. Turn EasyKey power on to test operation.

IG. 14.

Power Supply
Outputs (Vdc)

Replacing Power Switch

1. Follow Before Servicing, page 30.

2. Unlock and open EasyKey door with its key.

3. Note position of power switch wires. See EasyKey
Electrical Schematic, page 27. Disconnect wires
and remove switch (202, F

4. Install new power switch (202). Reconnect wires in
positions noted in step 3.

5. Close and lock EasyKey door with key.

6. Turn on power at main circuit breaker.

7. Turn EasyKey power on to test operation.

IG. 14).

FIG. 14: Power Supply

214f

202

Power Supply
Inputs (Vac)

214l,
214m

Input Power
Terminal Block

TI13349b

32 3A1164B

Service

Replacing Barrier Board

NOTICE

To avoid damaging circuit board when servicing, wear
Part No. 112190 grounding strap on wrist and ground
appropriately.

1. Follow Before Servicing, page 30.

2. Unlock and open EasyKey door with its key.

3. Disconnect the cables and connectors from J1, J4,
and J5. F

4. Using the security tool provided (Part No. 122239),
remove 2 screws (214k) and the cover (214b). See
F

IG. 15.

5. Noting their location, remove 5 screws (214g, 214h)
from the barrier board (214a). Do not remove the
screw noted in F

6. Apply thermal compound to the heatsink (Z) on the
back of the new barrier board (214a). F

7. Install the new barrier board with the 5 screws
(214g, 214h).

IG. 16.

IG. 16. Remove board.

IG. 16.

8. Install the cover (214b) with 2 screws (214k), using
the security tool.

9. Connect cables to J1, J4, and J5.

10. Close and lock EasyKey door with key.

11. Turn on power at main circuit breaker.

12. Turn EasyKey power on to test operation.

Replacing Barrier Board Fuses

Fuse Part No. Description

F1, F2 114788 Power In Fuses; 2 amp, time lag
F3, F4 15D979 Power Out Fuses; 0.4 amp, quick

acting

1. Follow Replacing Barrier Board, steps 1-4.

2. Remove the fuse (F1, F2, F3, or F4) from its fuse
holder. F

3. Snap new fuse into holder.

4. Follow Replacing Barrier Board, steps 8-12.

IG. 16.

J1J4

214c

214g

214b

J5

TI12649b

214h

214g 214a214k

FIG. 15: Replacing Barrier Board

3A1164B 33

Service

214g

214h

Do not remove
this screw

J4 (Power to Display Board)

F4

F3

J1 (Power In)

214g

F2

F1

J5
(Power to Fluid Station)

214g

1

Apply thermal compound
to surface of heatsink (Z).

214h

1

Front of Barrier Board, showing Fuses and Connectors

Z

Back of Barrier Board, showing Heatsink (Z)

FIG. 16: Barrier Board Connectors and Fuses

34 3A1164B

Service

Control Box

Replacing Control Board

NOTICE

To avoid damaging circuit board when servicing, wear
Part No. 112190 grounding strap on wrist and ground
appropriately.

1. Follow Before Servicing, page 30.

2. Disconnect fiber optic wires (J4, J6) and all cables
(J1, J3, J5, J7, J8, J9, J10, J12, J14, J15) from con­trol board (302). F

3. Remove 4 screws (303). Remove connector jam
nuts on the outside of the enclosure (301). Remove
control board (302). F

4. Install new control board (302) with 4 screws (303).

5. Connect cables to control board (302). F
Insert fiber optic cable connectors (J4, J6) into
board connectors (E), matching blue with blue, black
with black, and hand-tighten connectors. Do not
pinch or kink the fiber optic cables; the cables
require a 2 in. (51 mm) bend radius.

6. Turn EasyKey power on to test operation.

J4

(F.O. Output - blue)

IG. 17.

IG. 18.

IG. 17.

F1 (343)

J6
(F.O. Input - black)

J1

(Digital Input)

J13

(Not Used)

J12

(Solvent Meter Input)

J3

(Meter A and B Input)

J9

(Solenoid Output:

Dose Valves A and B)

J10
(Power Input)

J11
(Color Change Module)

J7
(Not Used)

J5
(Flow Control)

J8
(Solenoid Output: Dump Valve B)

J14

(Solenoid Output:

Air Purge Valve and Solvent Flush Valve)

FIG. 17: 255765 Fluid Station Control Board

3A1164B 35

J15
(Solenoid Output:
3rd Flush Valve: Dump Valve A)

Service

301

326

309

TI15974a

313

304

334

320

310

305

306

330

F1

311

303

302

343

325

332

318

314

FIG. 18: Fluid Station Control Box

312

317

TI15916a

333307

315

308

334

319

316

TI15917a

36 3A1164B

Service

Replacing Solenoids

The Fluid Station Control Box has a minimum of 4 sole­noids. If you have options installed, you have additional
(optional) solenoids for each. See Table 6 and Sche-

matic Diagrams, page 26.

To replace a single solenoid:

1. Follow Before Servicing, page 30, and shut off

power at main circuit breaker.

2. Disconnect 2 solenoid wires from control board
(302). See F
matic, page 29.

3. Unscrew 2 screws and remove solenoid (318). F

19.

4. Install new solenoid (318).

IG. 17 and System Electrical Sche-

IG.

Table 6: Control Box Solenoids

Solenoid Actuates

Standard

1 Dose Valve A
2 Dose Valve B
3 Air Purge Valve
4 Solvent Purge Valve

Optional

5 Third Flush Valve
6 Dump Valve A
7 Dump Valve B

N

5. Connect 2 wires (N) to control board (302). Solenoid
wires are polarized (red +, black –). Refer to Sys-

tem Electrical Schematic, page 29.

Replacing Control Board Fuse

Replacing the fuse with a non-Graco fuse voids the IS
system safety approval.

Fuse Part No. Description

F1 123690 Fuse; 125 mA, intrinsically safe

1. Follow Before Servicing, page 30.

2. Locate fuse F1 on the control board. See F
Remove the screw and metal strap.

3. Pull the fuse away from the board.

IG. 18.

318

F

IG. 19: Replacing Solenoids

TI15917a

4. Install the new fuse (343).

3A1164B 37

Service

Servicing Flow Meter

Coriolis Meter

1. Follow Before Servicing, page 30.

2. To remove and service the Coriolis meter, see man­ual 313599.

G3000 or G3000HR Meter

Removal

1. Follow Before Servicing, page 30.

2. Unscrew cable connector (CC) from meter (M). F

20.

3. Unscrew four 1/4-20 screws (MS) holding the meter
mounting plate (MP). F

IG. 20.

IG.

NOTE: To avoid leakage, secure the meter (M) to the
dose valve connector (H) before connecting it to the fluid
station.

2. Secure meter (M) and plate (MP) to bracket with
screws (MS).

3. Connect meter cable (CC). See F

IG. 20.

4. Connect fluid line (P).

5. Calibrate meter as instructed in ProControl 1KS
Operation manual.

P

MS

MP

M

H

4. Unscrew fluid line from meter inlet (P).

5. Unscrew meter (M) from dose valve connector (H).
F

IG. 20.

6. Service meter as instructed in the meter manual

308778.

Installation

1. Screw meter (M) securely onto the dose valve con­nector (H), using a wrench.

Cable Length

241799 5 ft (1.52 m)
241800 16 in. (406 mm)
241801 13 in. (330 mm)

FIG. 20: G3000/G3000HR Flow Meters

3X CABLE

1
2
3

J3

*

4
5
6

1
2
3

J12

*

4
5
6

*Connectors on Fluid Station Control Board

PWR (RED)
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
PWR (RED)
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
PWR (RED)
COM (BLACK)
SIG (WHITE)
SHIELD/GRN

GROUND
TERMINAL

CC

TI15977a

FLOW METER A

FLOW METER B

FLOW METER SOLVENT

IG. 21: Meter Cable Schematic

F

38 3A1164B

Servicing Color Change Module, Color/Catalyst Valves, and Dump Valves

1. Follow Before Servicing, page 30.

2. See manual 312787 for the color change module.

3. See manual 312783 for the color/catalyst valve
stacks.

4. See manual 312786 for the dump valve kits.

5. See manual 312782 to service an individual valve.

Service

3A1164B 39

Service

Servicing Flow Control

Preparation

1. Follow Before Servicing, page 30.

2. Disconnect all air and fluid lines from the flow con­trol regulator.

3. Disconnect the flow control cable from connector
(624). F

4. Remove the four screws (605) holding the air plate
(607) to the housing (611). Carefully lift the plate off
the housing and disconnect the three cables from
J1, J2, and J4 on the circuit board (618). F

Servicing the Regulator and Pressure
Sensor

Regulator Service Kit 15G843 is available. Kit parts are
marked with an asterisk, for example (602*). For best
results, use all parts in the kit.

Sensor Service Kit 15G867 is available to service the
pressure sensor only. Kit parts are marked with a sym­bol, for example (602‡). For best results, use all parts in
the kit.

1. Follow Preparation, above.

2. Remove the four screws (605) and the nut (601)
from the underside of the air plate (607). Separate
the air plate and fluid plate.

IG. 23.

IG. 22.

6. Install a new o-ring (602) on the pressure sensor
(620) and screw the sensor into the fluid plate (606).

7. Reinstall the fluid plate on the air plate. Be careful
not to pinch the pressure sensor cable. Torque the
screws (605) to 30-40 in-lb (3.4-4.5 N•m).

8. Reconnect the three cables to J1, J2, and J4 on the
circuit board (618). F

9. Reattach the air plate (607) to the housing (611).
Torque the screws (605) to 30-40 in-lb (3.4-4.5
N•m).

10. Reattach the flow control cable and all air and fluid
lines.

IG. 22.

Servicing the Flow Control Board

1. Follow Before Servicing, page 30.

2. Remove the four screws (605) holding the bracket
(614) to the housing (611). F

3. Carefully separate the bracket from the housing and
disconnect the three cables from J1, J2, and J4 on
the circuit board (618). F

4. Remove the screws (621). Replace the old board
with the new board.

5. Reconnect the three cables to J1, J2, and J4 on the
circuit board (618). F

6. Reattach the bracket (614) to the housing (611).
Torque the screws (605) to 30-40 in-lb (3.4-4.5
N•m).

IG. 22.

IG. 23.

IG. 22.

3. Unscrew the pressure sensor (620) from the fluid
plate (606).

NOTE: If you are only replacing the pressure sensor
kit 15G867, skip to step 6.

4. Remove the plug (615) and o-ring (604) from the top
of the fluid plate (606). Remove the parts of the dia­phragm assembly (613, 610, 609, 612, 617, 616).
Remove and discard the dowels (623).

5. Reassemble the diaphragm assembly using the new
parts from the kit. Be sure the AIR SIDE of the dia­phragm (617) faces down. Torque the nut (601) to
8-10 in-lb (0.9-1.1 N•m).

40 3A1164B

Servicing the V/P Valve

1. Follow Before Servicing, page 30.

2. Remove the four screws (605) holding the bracket
(614) to the housing (611). F

3. Carefully separate the bracket from the housing and
disconnect the V/P valve cable from J2 on the circuit
board (618). F

IG. 22.

4. Remove the two screws (619a) and o-rings (619b).
Install the new valve (619) with new screws and
o-rings.

5. Reconnect the V/P valve cable to J2 on the circuit
board (618). F

IG. 22.

6. Reattach the bracket (614) to the housing (611).
Torque the screws (605) to 30-40 in-lb (3.4-4.5

N•m).

IG. 23.

*623

2

605

622

*613

*610

*609

*612
*617

*616

615

604*

Flow

direction

Service

606
602*‡

620*‡

601*

607

1

603

J2 (V/P Valve)

D7 D8 D9

J4

R25

U3

R7

F

IG. 22: 249179 Flow Control Board

R27

J1

R3

J2

R4

U1

C12

C11

L1

R20

J1 (Power Input)J4 (Pressure Sensor)

R21

U5

R22

C10

624

619b

619

619a

3

1

Torque to 8-10 in-lb (0.9-1.1 N•m)

2

Torque to 30-40 in-lb (3.4-4.5 N•m)

3

Torque to 5-7 in-lb (0.6 -0.8 N•m)

611

605

621
618

614

605

TI12506a

2

2

F

IG. 23: Flow Control

3A1164B 41

Service

42 3A1164B

Parts

ProControl 1KS System

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

Parts

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.

3A1164B 43

Parts

Part No. 262380, without meter or flow control
Part No. 262381, with G3000 meter, without flow control
Part No. 262382, with G3000 meter and flow control
Part No. 262383, with Coriolis meter and flow control

335

5

2

3

24

336

2

1

2

4

17

11

9

8

10

2

Items 335 and 336 are part of the Fluid
Station Control Box. See the parts list
beginning on page 49 for descriptions.

Detail of Automatic Upgrade Kit (6)

6 6a

TI16328a

TI12496a

44 3A1164B

Part No. 262380, without meter or flow control
Part No. 262381, with G3000 meter, without flow control
Part No. 262382, with G3000 meter and flow control
Part No. 262383, with Coriolis meter and flow control

Ref.
No. Part No. Description Qty

1 262363 CONTROL BOX, fluid station; see page 48 1
2 570122 MODULE, control, air 1
3 114158 FITTING, tube, Y-adapter 1
4 15G768 PLUG, tube fitting 1
5 277869 CONTROL/DISPLAY, EasyKey; see page 46 1
6 15V256 KIT, automatic upgrade; includes item 6a 1
6a 15V825 • KIT, board, discrete I/O; part of item 6 1
8 262364 VALVE STACK, dispense/purge, high pressure; see page 50 1
9 KIT, flow meter A

none Model 262380 0
16E955 G3000 flow meter; see manual 308778; Models 262381 and

262382

15V806 KIT, Coriolis flow meter; see manual 313599; Model 262383 1

10 BRACKET, fluid station

none Models 262380 and 262383 0
16E841 Models 262381 and 262382 1

11 REGULATOR, flow control; see page 51

none Models 262380 and 262381 0
249849 Models 262382 and 262383 1

17 CABLE, flow control; connects flow control regulator to fluid

station; 10 ft (3.0 m)
none Models 262380 and 262381 0
15G611 Models 262382 and 262383 1

24 n/a TUBING, polyethylene, 5/32 in. (4 mm) ID 150 ft

Parts

1

3A1164B 45

Parts

EasyKey Controls

277869 EasyKey, with Display

Detail of Display Interface Kit (210)

210a

210d

210b

210c

210e

TI12554a

208

206

214h

214k

201

214b

214g

214a

214c

214d

221

214f

214f

201

202

214l,
214m

211

TI12417b

212

203

218

209

214l,
214m

214e,
214j

207 205, 206, 209

204

215

221 211

TI12496b

213, 223, 206

46 3A1164B

277869 EasyKey, with Display

Parts

Ref.
No. Part No. Description Qty

201 n/a CONTROL BOX, with display 1
202 116320 SWITCH, power 1
203 n/a LATCH; includes item 3a 1
203a 117818 • KEY 1
204 111987 CONNECTOR, cord strain relief 1
205 110911 NUT, hex; M5 x 0.8 4
206 111307 WASHER, lock, external tooth;

M5
207 n/a HOLDER, tie 8
208 C19293 NUT, hex 6
209 194337 WIRE, grounding, door 1
210 15X779 KIT, display, interface; includes

items 210a, 210b, 210d, and

210e; does not include 210c
210a n/a • MEMBRANE 1
210b n/a • GRAPHIC, display 1
210c 255767 • BOARD, EasyKey display 1
210d n/a • PLATE 1
210e n/a • SCREW; 4-40 x 1 in. (25

mm)
211 15D568 ALARM 1
212▲ 15W776 LABEL, warning 1
213 223547 GROUND WIRE; 25 ft (7.6 m) 1
214 n/a PLATE, application; includes

items 214a-214m

214a 255786 • BOARD, barrier, IS; (includes

fuses 15D979 and 114788,

see page 34 for fuse loca-

tion)
214b n/a • COVER 1
214c 117526 • SPACER 3
214d 119257 • BAR, ground 1
214e 114095 • BLOCK, terminal 1
214f 121314 • POWER SUPPLY; 24 Vdc;

2A
214g n/a • SCREW, machine, pan-hd;

6-32 x 3/8 in. (10 mm)
214h n/a • SCREW, machine, pan-hd;

6-32 x 1-1/2 in. (38 mm)
214j n/a • SCREW, machine, pan-hd;

8-32 x 3/4 in. (19 mm)
214k n/a • SCREW, machine, pan-hd;

10-24 x 3/8 in. (10 mm)

11

Ref.
No. Part No. Description Qty

214l 123823 • FILTER, line, single-phase;

110/250 V; 3 A
214m 123824 • BRACKET, line filter 1
215 15V280 HARNESS, connection 1
216 15G569 LABEL, EasyKey inputs 1
218 15R642 HARNESS, wire 1
220 n/a SOFTWARE, application 1

9

221 198165 CONNECTOR, RJ45, with bulk-

head fitting
223 116343 SCREW, ground; M5 x 0.8 1
224 15G869 CABLE, ethernet, CAT5; 6 ft

1

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

Parts labeled n/a are not available separately.

4

Available Cables

Part No.

1

15U531 2 (0.61) Option
15U532 3 (0.92) Standard color change

1

15V205 6 (1.83) Option
15V206 10 (3.05) Option
15V207 15 (4.57) Option
15V208 25 (7.62) Option
15U533 50 (15.25) Standard power
15V213 100 (30.50) Option

1

Part No. Length Usage

3

15D320 50 (15.25) Standard

2

15G710 100 (30.50) Option

2

(1.8 m); to make web interface

connection to a computer

CAN Cables

Length

ft (m) Usage

Fiber Optic Cables

1

1

1

3A1164B 47

Parts

262363 Fluid Station Control Box

301

326

309

TI15974a

313

304

334

320

310

305

306

311

330

303

302

343

332

318

314

325

317

312

TI15916a

333307

315

308

334

319

316

TI15917a

48 3A1164B

262363 Fluid Station Control Box

NOTE: Parts are shown on page 48, unless noted.

Ref.
No. Part No. Description Qty

301 16E380 ENCLOSURE 1
302 255765 BOARD, circuit 1
303 n/a SCREW, machine, pan hd;

4-40 x 3/16 in. (5 mm)
304 119257 CONNECTOR, bar, ground 1
305 119162 CONNECTOR, plug, 6-position 6
306 116773 CONNECTOR, plug,10-position 1
307 121818 BULKHEAD, tube; 5/32 (4 mm) 12
308 111987 CONNECTOR, cord strain relief 5
309 112173 MUFFLER 1
310 C20497 FITTING, tube, bulkhead 1
311 16E434 PLATE, mounting, box 1
312 104176 BULKHEAD; 1/4 in. (6 mm) ID

tube
313▲ 186620 LABEL, symbol, ground 2
314 108382 FITTING, seal, o-ring; 10-32 5
315 120030 PLATE, blank, solenoid 4
316 120053 FITTING, tube; 10-32 x 1/4 in.

(6 mm) OD tube
317 112253 CONNECTOR, male 12
318 121795 VALVE, solenoid, 4-way, intrin-

sically safe; 12 Vdc
319 15U725 MANIFOLD, solenoid 1
320 113783 SCREW, machine, pan hd;

10-32 x 3/8 in. (10 mm)

4

1

3

4

4

Parts

Ref.
No. Part No. Description Qty

322 112925 SCREW, cap, button hd; 1/4-20

x 3/8 in. (10 mm)
325 116343 SCREW, ground 1
326▲ 15G809 LABEL, warning 1
329 112512 FERRULE 4
330 114158 FITTING, tube, Y-adapter 1
332 n/a TUBE, nylon, red; 5/32 in.

(4 mm) OD; 4 ft (1.2 m)
333 n/a TUBE, nylon, green; 5/32 in.

(4 mm) OD; 5 ft (1.5 m)
334 n/a TUBE, nylon; 1/4 in. (6 mm)

OD; 2 ft (0.6 m)
335 15D320 CABLE, fiber-optic, twin; 50 ft

(15.25 m); see page 44 for

location
336 15U533 CABLE, CAN, intrinsically safe;

50 ft (15.25 m); see page 44 for

location
343◆ 123690 FUSE; 125 mA 1

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

◆ Replacing the fuse with a non-Graco fuse voids the
IS system safety approval.

Parts labeled n/a are not available separately.

A/R

A/R

A/R

2

1

1

3A1164B 49

Parts

262364 Valve Stack

Ref.
No. Part No. Description Qty

401 15X303 VALVE, high pressure;

includes item 413; see man­ual 312782

402 --- SCREW; 5/16-24 x 5/8 in. (16

mm)
403 15T436 ADAPTER, manifold 3
404 101970 PLUG, pipe 3
405‡ 109450 O-RING; ptfe 6
406 15T869 MANIFOLD, fluid port 1
407‡ --- SEAT, valve needle; sst 3
408 110004 O-RING; ptfe 3
409 15T872 MANIFOLD, body 2
410 --- SCREW, cap, socket-head;

1/4-20 x 5/8 in. (16 mm)
411 15T871 MANIFOLD, end cap 1

Ref.
No. Part No. Description Qty

412 15T873 PLATE, blank 1

3

413*‡ --- O-RING; ptfe 3
414 15U927 BRACKET 1

8

415 C19800 SCREW, cap, socket-hd;

1/4-20 x 1/2 in. (13 mm)

416 104371 SCREW, cap, socket-hd;

10-32 x 3/8 in. (10 mm)

417 104116 WASHER, plain; no. 10 2

‡ Parts included in Valve Seat Kit 24A351 (purchase

separately). (Optional Carbide Seat Kit 15U932 is
available separately.)

* Part included in Seal Kit 15U933 (purchase sepa-

6

rately). Kit includes additional parts; see Dispense
Valve manual 312782.

--- These parts are not available separately.

416417

2

2

401

*‡413

404

414

415

‡407

402

410

411

402

412

408

409

408

406

405‡

TI16356a

403

50 3A1164B

249849 Flow Control Regulator

Parts

Ref.
No. Part No. Description Qty

601* 102980 NUT, full, hex; 4-40 1
602‡* n/a O-RING; chemically resistant

fluoroelastomer

603 112698 ELBOW; 1/8 npt(m) x 1/4 in.

(6 mm) OD tube

604* n/a O-RING; chemically resistant

fluoroelastomer

605 n/a SCREW, cap, socket-hd;

10-32 x 1/2 in. (13 mm)
606 n/a PLATE, fluid, regulator 1
607 15F799 PLATE, air, regulator 1
609* n/a SEAT, regulator 1
610* n/a RETAINER, seat 1
611 n/a HOUSING, flow control 1
612* n/a SPACER, regulator 1
613* n/a NEEDLE, regulator 1
614 n/a BRACKET, flow control 1
615 15F806 PLUG, regulator 1
616* 168881 GASKET; acetal 1
617* 178321 DIAPHRAGM, regulator 1
618 249179 BOARD, circuit assembly 1
619 120013 VALVE, proportional, V/P;

includes items 619a and 619b
619a n/a • SCREW, cap, socket-hd;

M3 x 0.5 x 44 mm

619b 106560 • O-RING, mounting, size

007
620‡* n/a SENSOR, pressure control 1
621 107295 SCREW, machine, pan-hd;

4-40 x 3/16 in. (5 mm)
622 104765 PLUG, pipe; 1/8 ptf 1
623* 192387 PIN, dowel 2
624 15G613 WIRE HARNESS, flow control 1

* Parts included in Regulator Service Kit 15G843.

Purchase separately.

12

615

*613

1

*610

1

*609

1

*612

604*

Flow

direction

606
602*‡

620*‡

*617

601*

*616

1

*623

607

605

2

622

603

611

605

1

2

2

624

2

4

619b

619

621
618

619a

3

605

2

‡ Parts included in Sensor Service Kit 15G867.

Purchase separately.

614

TI12506a

Parts labeled n/a are not available separately.

1

Torque to 8-10 in-lbs (0.9-1.1 N•m)

2

Torque to 30-40 in-lbs (3.4-4.5 N•m)

3

Torque to 5-7 in-lbs (0.6 -0.8 N•m)

3A1164B 51

Parts

52 3A1164B

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). . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Fluids handled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . one or two component:

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),

5 micron (minimum) filtration required; clean and dry air

• solvent and waterborne paints

• polyurethanes

•epoxies

• acid catalyzed varnishes

• moisture sensitive isocyanates

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.

3A1164B 53

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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS, MN • 55440-1441

Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

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

Original instructions. This manual contains English. MM 3A1164

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised 07/2011