Graco 3A2614F User Manual

Instructions-Parts

ProControl 1KE®

Management of F

Kits for

luid and

Air

Use to monitor and control ﬂow rate and track material use. For professional use only.

Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.

See the G3 (308778) manual (3 maximum

000 meter manual

or Coriolis meter

13599) for ﬂow meter working pressure.

3A2614F

See page includi

ng approvals.

3 for kit information,

PROVEN QUALITY. LEADING TECHNOLOGY.

ProControl 1KE Models and Kits.......................... 3

Warnings ........................................................... 5

Overview............................................................ 8

Installation.......................................................... 9

Non-Hazardous Locations ............................ 9

Hazardous Locations.................................... 10

Grounding ................................................... 12

Cable Connections....................................... 13

Electrical Connections.................................. 14

Air Connections ........................................... 15

Operation........................................................... 18

Pressure Relief Procedure............................ 18

Fluid Regulator Operation............................. 18

Flow Meter Operation................................... 18

Calibrate the Meter ...................................... 18

Set the Modbus Addresses........................... 19

Set the Flow Rate Percent............................ 19

Update the Software .................................... 19

Replace the Battery...................................... 20

Display M

odule................................................... 21

Display Operati Screen N

Icons...........................................................22

Information ...................................... 21

on Modes ......................................... 21

avigation and Editing ...................... 21

Run Screens ......................................................24

Password Screen ............................................... 25

Setup Screen

Setup Screen Setup Screen Setup Screen Setup Scree Setup Scree Setup Scree Setup Scree Setup Scre Setup Scre

Deviations and Advisories ................................... 31

Troubleshooting.................................................. 32

Parts.................................................................. 34

Accessories........................................................ 43

Mounting Dimensions ......................................... 44

Appendi

Appendix B - Advanced Web Interface................. 48

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

Graco S

s.................................................... 26

1............................................ 26

2............................................ 27

3............................................ 27

n 4 ............................................ 28

n 5 ............................................ 28

n 6 ............................................ 29

n 7 ............................................ 29

en 8 ............................................ 30

en 9 ............................................ 30

x A - Modbus Variable Map ..................... 45

tandard Warranty.................................... 54

3A2614F

ProControl 1KE M

odels and Kits

ProControl 1K

All Advanced Display Control Modules (ADCM) are base model number 24L097 (Ref. 1). Models 24L097 and 24N672 (ADCM with bracket) are not available for separate sale. See approval information in Manual 332013 and on this page. The small label (Ref. 2) on the back of the module shows the ProControl 1KE Kit number. Available kits are described in the tables that follow.

E Models and Kits

Model No.

24L097

24N672

Intrinsically Safe Apparatus

Part of Intrinsically Safe System.

For use in Class I, Division 1, Group D T3 Hazardous Locations

See Manual 332013, Appendix A, Control Drawing 16M169 for entity parameters.

Series

Class I,Div. 1,

Group D T3

Ex ia [ia]

Ta=0°C to 50°C

Description

Advanced Display Control Module (ADCM), with no software loaded. See Manual

332013.

Advanced Display Control Module (ADCM) with bracket, with no software loaded. See Manual 332013.

9902471

3A2614F 3

ProControl 1KE M

ProControl 1KE systems are not approved for use in hazardous locations unless all accessories and all wiring meet local, state, and national codes.

Kit No.

24L083 24R261 24R262 24R263 24L085 24P593 24P595 24L087 24P597 24L089 24L091

Series

A A A A A A A A A A A

odels and Kits

Kits for Hazardous Locations

Conﬁguration

ProControl 1KE Module with bracket (Manual

332013)*

✔✔ ✔✔ ✔✔ ✔✔ ✔✔✔ ✔✔ ✔✔ ✔✔✔✔ ✔✔✔ ✔ ✔✔✔✔ ✔✔✔✔✔ ✔✔✔✔✔ ✔✔✔✔✔✔ ✔✔✔

No Power

* See component manuals for additional approval information. ** Must not be installed in Hazardous Location.

AC Power with barrier**

G3000 Meter (Manual

308778)*

I/P Transducer

Fluid Regulator (Manual 3A0427)*

Pressure Transducer (Manual

407045)*

r Non-Hazardous Locations

Kits fo

Kit No.

24L0 24P592 24P594 24L086 24P596 24L088

L090

9902471 Conforms to/Certiﬁed to UL/CSA Standard 61010–1

Serie

A A A A A A A

ntrol 1KE

ProCo

ewithbracket

Modul

✔✔✔✔ ✔✔✔ ✔ ✔✔✔✔ ✔✔✔✔✔ ✔✔✔✔ ✔✔✔✔✔✔ ✔✔✔

AC Power

Conﬁg

G3000 Meter

uration

I/P Transducer

Fluid Regulator

Pressure Transducer

3A2614F

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 symbol refers to procedure-speciﬁc risks. When these symbols appear in the body of this manual or on warning labels, 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. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working ﬁre extinguisher in the work area.

Static charge may build up on plastic parts during cleaning and could discharge and ignite ﬂammable vapors. To help prevent ﬁre and explosion:

• Clean plastic parts only in a well ventilated area.

• Do not clean with a dry cloth.

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 or installing equipment.

• Connect only to grounded power source or grounded electrical outlets.

• Use only 3–wire extension cords.

• Ensure ground prongs are intact on power and extension cords.

• Do not expose to rain. Store indoors.

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

3A2614F 5

Warnings

WARNING

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.

• Be sure your installation complies with national, state, and local codes for the installation of electrical apparatus in a Class I, Group D, Division 1 Hazardous Location, including all of the local safety ﬁre codes, NFPA 33, NEC 500 and 516, and OSHA 1910.107.

• Equipment that comes in contact with intrinsically safe terminals must meet the entity parameter requirements speciﬁed in Control Drawing 16M169. See Appendix A in Manual

332013. This includes safety barriers, DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the hazardous area when servicing.

• If a printer, computer, or other electrical component is connected, it must be used in conjunction with a safety barrier.

• Without the safety barrier, the equipment is no longer intrinsically safe and must not be operated in hazardous locations, as deﬁned in article 500 of the National Electrical Code (USA) or your local electrical code.

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

• Ground the power supply. A voltage limiting safety barrier must be properly grounded to be effective. For proper grounding, use a 12 gauge minimum ground wire. The barrier’s ground must be within 1 ohm of true earth ground.

• Do not operate the power supply module with the cover removed.

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

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.

• 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.

6 3A2614F

Warnings

WARNING

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. Alterations or modiﬁcations may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which youareusingit.

• 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.

TOXIC FLUID OR FUMES Toxic ﬂuids or fumes can cause serious injury or death if splashed in the eyesoronskin, 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.

PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective 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.

3A2614F

Overview

The ProControl 1KE Advanced Display Control Module is an electronic ﬂow control and ﬂuid monitoring system. The ProControl 1KE performs the following functions:

• Manages ﬂuid

• Manages the

•Showsreal-

•Displaysar

• Monitors a

•Alarmsift the user-s

•Alarmswhe the user-

•Displays

pressure or ﬂow rate.

fan air.

time ﬂuid ﬂow rate.

esettable batch totalizer.

nd reports overall ﬂuid use.

he ﬂow rate is too fast or too slow for et targets.

n the maintenance total is reached for

set target.

alogofthelast20alarms.

The ProControl 1KE is available in conﬁgurations for installation in Hazardous Locations or Non-Hazardous locations. The power supply for Hazardous Locations comes with one barrier, to power one ProControl 1KE. Up to three additional barriers can be added to the power supply to power three additional ProControl 1KEs. See Accessories, page 43 ,to order additional barriers. Order ProControl 1KE Kit 24R261, 24R262, or 24R263,, based on your choice of the ﬂuid management compononets. These kits do not include a power supply.

8 3A2614F

Installation

Non-Hazardous Locations

Installation

NOTE: Kits su Users in area converter. S

pplied with an AC/DC Converter are shipped with a North American 120 VAC power cord (E).

s with another standard voltage must provide a power supply cord with an IEC 320–C13 female

ee Technical Data, page 53 for power requirements.

Key:

C Power Supply and Cable (6 ft., 2 m), to

Meter Fluid Inlet, 1/4 npt female

Flow

t/outlet.

inle

ProControl 1KE Module with Bracket

terminal 3. See Cable Connections, page 13.

ter Cable (50 ft., 15 m), to terminal 4. See

ble Connections, page 13.

Power Cord (10 ft., 3 m), see NOTE above.

Ground wire and clamp. PN 244524 in included with kits to ground the ProControl 1KE Module. PN 238909 is sold separately to ground the meter and other components.

Fluid Regulator, 1/8 npt (f) outlet

Fluid Control Cable

Pressure Transducer

I/P Transducer (Current to Pressure). See

Air Connections, page 15.

Mounting Panel. See

Mounting Dimensions, page 44.

ressure Transducer Fitting, 1/8 npt (f) inlet

nd outlet

Light Tower with Splitter (accessory)

Flow Meter Fluid Outlet, 1/4 npt (f)

Pressure Transducer Cable

3A2614F 9

Installation

Hazardous Locations

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 location. See the identiﬁcation label for the intrinsic safety rating for your model.

Intrinsically safe equipment should not be used with a power supply that has no barrier. Do not move units from a non-IS setup to an IS setup. IS equipment that has been used with a non-IS power supply must not be returned to a hazardous location. Always use an intrinsically safe power supply with IS equipment.

• Installation should be in accordance with ANSI/ISA RP12.06.01, “Installation of Intrinsically Safe Systems for Hazardous (Classiﬁed) Locations,” and the National Electrical Code® (ANSI/NFPA

70).

• Installation in Canada should be in accordance with the Canadian Electrical Code, CSA C22.1, Part 1, Appendix F.

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

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

• Do not remove any cover until power has been removed.

• Install according to Control Drawing Number 16M169. See Appendix A in Manual 332013.

Nonhaza

rdous Location

Hazardo

us Location

10 3A2614F

Installation

Key:

Flow Meter, 1/4 npt female inlet/outlet

ProControl 1KE Module with Bracket

C Power Supply

Meter Cable (50 ft., 15 m), to terminal 4. See

Cable Connections, page 13.

Power Cord (not supplied)

Power Cabl

Cable Conn

Ground wire and clamp. PN 244524 is included with kits to ground the ProControl 1KE Module. PN 238909 is sold separately to ground the meter or other component.

with Barrier

e(50ft.,15m)toterminal3. See

ections, page 13.

N Fluid Regulato

Fluid Control Cable

Pressure Tran

I/P Transduc

Air Connecti

Mounting Panel. See

Mounting Dimensions, page 44.

Pressure Transducer Fitting, 1/8 npt (f) inlet and outlet

Flow Mete

Pressure Transducer Cable

sducer

er (Current to Pressure). See

ons, page 15.

r Fluid Outlet, 1/4 npt (f)

3A2614F

Installation

Grounding

The equipment risk of static or static spar explode. Imp shock. Groun electric cur

NOTE: The ProControl 1KE does not provide 500 VAC isolation through the coupling nuts on the enclosure. The associated apparatus and the ﬁeld apparatus cable shields must not be connected to the ProControl 1KE coupling nuts.

must be grounded to reduce the

sparking and electric shock. Electric

king can cause fumes to ignite or

roper grounding can cause electric

ding provides an escape wire for the

rent.

1. Power Supply 16M167: Connect the ground wire

from the power supply to a true earth ground.

2. ProControl 1KE Module: Connect a ground

wireandclamptothescrewonthetopofthe bracket. Connect the other end to ground. In an IS system, the ProControl 1KE also is grounded by connection to the grounded power supply.

3. Flow Meter: Follow the instructions in manual

308778 (G3000) or manual 313599 (Coriolis) to ground the ﬂow meter and check its electrical grounding continuity.

4. Fluid and Air Control: Ground through connection

to the mounting panel that also holds the grounded ﬂow meter.

5. Fluid Supply: Ground the ﬂuid supply unit.

3A2614F

Installation

Cable Connect

Port Descripti

3 Power

Fiber Opt

Fiber Optic Transmitter Black Lead to RX on Fiber Optic Converter (PN 16K465) or to Port

Digita

ions

ic Receiver

l Input/Output

Connection

RedLeadf Port6ona

5 on another ProControl 1KE (or Informer)

From Power Supply

To/Fro

rom TX on Fiber Optic Converter (PN 16K465) or from nother ProControl 1KE (or Informer)

m Meter and Light Tower (Accessory)

Fiber Optic Reciever Black Lead from Port 2 on another ProControl 1KE (or Informer)

Fiber Optic Transmitter Red Lead to Port 1 on another ProControl 1KE (or Informer)

Analog Input

Flow Control To/From Flow Control Cable

Motor Control

gital Input/Output

rom Pressure Transducer Cable

To/F

used.

Not

Not used.

3A2614F 13

Installation

Electrical Co

Install per Graco Control Drawing 16M169, in Manual

332013. See also Figure 1.

1. Connect main supplied) th N on the power Note: Use ei onthesizeo

2. Connect pow terminal bl

3. Connect IS table.

nnections

power supply cord (E, not

rough strain relief to terminals L and

supply unit.

ther strain relief (5) or (6), depending

fthecord.

er cord ground wire (W) to ground

ock (Y).

power cable (F) per the following

Table 1 Power Barrier Wiring Connections

Power Cable Le

Brown (power) Connector 1

Blue (common) Connector 2

Glossy Blac ground blo

Table 2 I/ Cables 16P790 (non-IS) and 16V142 (IS)

Wiring Table Wire Color

Gray Control A Connector 1

Blue

P Transducer Wiring Connections;

ads

k (ground) and Black (drain) connect to

ck.

Function

Common Connect

Barrier Conne

DIN Conne

ction

ctor

or 2

Figure 1

KEY

XBarrier

Inbound AC Power Cord

ower Cable

Ground Wires

Ground Block

Strain Relief Fitting

3A2614F

Installation

Air Connectio

NOTICE

To avoid damage to the I/P transducer, use clean, dry, oil-free air, ﬁltered through at least a 40 micron ﬁlter.

1. Connect incom inlet (AB) on regulator (S tube ﬁtting.

2. Kits with ﬂu is connecte transducer regulator ( Other Kits:

The I/P transducer exhausts a small amount of air whenever air is connected, whether or not the system is operating.

NOTE:

•Thetoppo

used for h air sourc side por

• Flushin

top port

igh-speed ﬂushing with an independent

e. Set the air pressure higher than the

t (AD) air pressure.

g air pressure must be removed from the

(AH) to return to the previous ﬂow setting.

ing air line (Q) to 1/4 in. npt (f)

I/P transducer (T). Kits with a ﬂuid

ee Parts, page 34), include a 3/8

id regulator: Check that the air tube dfrom5/32tubeﬁtting(AC)onI/P to 5/32 tube ﬁtting (AD) on ﬂuid

N).

The air outlet is 1/4 in npt (f).

rt (AH) on the ﬂuid regulator can be

Commun

Graco Accessories are available to enable communication with a Programmable Logic Controller (PLC) or Personal Computer (PC).

• The Fiber Optic Converter (Graco Kit 24N978) enables Modbus RTU communication with a user-supplied PLC using a serial cable.

• A Modbus Gateway (Graco Kit 24N977) used with a Fiber Optic Converter (Graco Kit 24N978) enables Modbus TCP communication with a user-suppled PLC.

ication Options

• A Modbus Gateway (Graco Kit 24N977) canbeconnectedto(orinstalledin) an Advanced Web Interface (Graco Kit 15V377) to enable communication with a PC using an ethernet cable. See

Appendix B - Advanced Web Interface, page 48,

for instructions.

These communication kits come with installation and setup directions necessary for their use with the ProControl 1KE.

3A2614F 15

Installation

Typical Installation

Non-Hazardous Location

Hazardous Location

16 3A2614F

Installation

Key

A1 and A2

B1 and B2 ProControl 1K C Power Supply a

D1 and D2 Meter Cable (50 ft., 15 m) Supplied in kits with meter E

F G Fiber Optic Cable (100 ft., 30 m) H J K L Personal computer Not supplied. N1 and N2

P Q1 and Q2 R1 and R2 Flow Con S1 and S

T1 and T2 I/P Transducer (Current to Pressure) Supplied U1 and U2 V1 and V2 Splitter to meter and light tower

W1 and W2 Pressure Transducer Cable. Supplied in some kits. See

Flow Meter

EModulewithBracket

nd Barrier

Power Cord (10 ft., 3 m), not shown Supplied in Non-Hazardous

Power Cable (50 ft., 15 m) Supplied

Serial Cable Advanced Web Interface Ethernet Cable

Fluid Regulator

Air Cont Air Lines Not supplied

Pressure Transducer

Mounti

(non-hazardous installations) or IS cable kit for hazardous location installations.

rol Module

trol Cable

ng Panel

Supplied in some kits. See

Parts, page 34.

Supplied SuppliedinHa

Kits

Location Kits

Accessory Accessory Accessory Accessory

Supplied in some kits. See

Parts, page 34.

Accessory

Supplie Suppli

Parts,

Supplied Acces

Parts, page 34.

ed in some kits. See

page 34.

sory

zardous Location

3A2614F

+ 37 hidden pages

Graco 3A2614F User Manual

Contents

Warnings

Overview

Installation

Non-Hazardous Locations

Hazardous Locations

Grounding

Table 1 Power Barrier Wiring Connections

Typical Installation