Graco ProControl 1KE Instructions - Parts Manual
Instructions-Parts
ProControl 1K
Management of
Usetomonito
Important
Read all warnings and instructions in this manual. Save these
instructions.
See the G3000 meter manual (308778)
or Coriolis meter manual (313599) for
flow meter maximum working pressure.
See page 3 for kit information, including
approvals.
r and control flow rate and track material use. For professional use only.
Safety Instructions
E® Kits for
Fluid and Air
3A2614H
EN
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
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
Run Screens ......................................................24
odule................................................... 21
Display I
Operati
Screen N
Icons...........................................................22
nformation ...................................... 21
on Modes ......................................... 21
avigation and Editing...................... 21
Password Screen ............................................... 25
Setup Screens....................................................26
Setup Screen 1............................................ 26
Setup Screen 2............................................ 27
Setup Screen 3............................................ 27
Setup Screen 4............................................ 28
Setup Screen 5............................................ 28
Setup Screen 6............................................ 29
Setup Screen 7............................................ 29
Setup Screen 8............................................ 30
Setup Screen 9............................................ 30
Deviation
Troubleshooting.................................................. 32
Parts.................................................................. 34
Accessori
Mounting Dimensions ......................................... 44
Appendix A - Modbus Variable Map ..................... 45
Appendix
Notes................................................................. 52
Technical Data ...................................................53
Graco St
s and Advisories ................................... 31
es........................................................ 43
B - Advanced Web Interface................. 48
andard Warranty.................................... 54
2
3A2614H
ProControl 1KE Models 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.
7
24L09
2
24N67
trinsically Safe Apparatus
In
art of Intrinsically Safe System.
P
or use in Class I, Division 1, Group D T3 Hazardous Locations
F
See Manual 332013, Appendix A, Control Drawing 16M169 for entity parameters.
Series
A
A
ss I,Div. 1,
Cla
Gro
Ex
=0°C to 50°C
Ta
Description
Advan
33201
Advan
See M
2471
990
up D T3
ia [ia]
ced Display Control Module (ADCM), with no software loaded. See Manual
3.
ced Display Control Module (ADCM) with bracket, with no software loaded.
anual 332013.
3A2614H 3
ProControl 1KE Models and Kits
ProControl 1KE systems are not approved for use in hazardous locations unless all accessories and all
wiring meet local, state, and national codes.
Kits for Hazardous Locations
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
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.
84
24L0
24P592
24P594
24L086
24P596
24L088
L090
24
9902471
Conforms to/Certified to UL/CSA Standard 61010–1
Serie
A
A
A
A
A
A
A
s
ntrol 1KE
ProCo
ewithbracket
Modul
✔✔✔✔
✔✔✔ ✔
✔✔✔✔
✔✔✔✔✔
✔✔✔✔✔
✔✔✔✔✔✔
✔✔✔
AC
Power
Config
G3000
Meter
uration
I/P
Transducer
Fluid
Regulator
Pressure
Transducer
4
3A2614H
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 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.
3A2614H 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 3A2614H
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.
3A2614H
7
Overview
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 f
•Showsreal-
•Displaysar
• Monitors an
•Alarmsift
the user-s
•Alarmswhe
the user-s
•Displays
pressure or flow rate.
an air.
time fluid flow rate.
esettable batch totalizer.
d reports overall fluid use.
he flow rate is too fast or too slow for
et targets.
n the maintenance total is reached for
et 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 3A2614H
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:
A
Flow Meter Fluid Inlet, 1/4 npt female
inlet/outlet.
B
C Power Supply and Cable (6 ft., 2 m), to
D
E
M
N
Control 1KE Module with Bracket
Pro
terminal 3. See Cable Connections, page 13.
Meter Cable (50 ft., 15 m), to terminal 4. See
Cable Connections, page 13.
ower Cord (10 ft., 3 m), see NOTE above.
P
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
R
S
T
U
X
A
AE
AF
A
d Control Cable
Flui
Pressure Transducer
I/P Transducer (Current to Pressure). See
Air Connections, page 15.
unting Panel. See
Mo
unting Dimensions, page 44.
Mo
Pressure Transducer Fitting, 1/8 npt (f) inlet
and outlet
Light Tower with Splitter (accessory)
Flow Meter Fluid Outlet, 1/4 npt (f)
Pressure Transducer Cable
3A2614H 9
Installation
Hazardous Locations
Do not substit
as this may imp
maintenance,
instruction m
approved onl
hazardous lo
the intrinsi
Intrinsica
power suppl
from a non-I
that has bee
not be retur
an intrinsi
ute or modify system components
air intrinsic safety. For installation,
or operation instructions, read
anuals. Do not install equipment
y for non-hazardous location in a
cation. See the identification label for
c safety rating for your model.
lly safe equipment should not be used with a
y that has no barrier. Do not move units
S setup to an IS setup. IS equipment
n used with a non-IS power supply must
ned to a hazardous location. Always use
cally 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.
Nonhazar
dous Location
Hazardou
s Location
10 3A2614H
Installation
Key:
A
Flow Meter, 1/4 npt female inlet/outlet
B
ProControl 1KE Module with Bracket
C Power Supply
D
Meter Cable (50 ft., 15 m), to terminal 4. See
Cable Connections, page 13.
E
Power Cord (not supplied)
F
Power Cabl
Cable Conn
M
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
R
Fluid Control Cable
Pressure Tran
S
T
I/P Transduc
Air Connecti
U
Mounting Panel. See
Mounting Dimensions, page 44.
X
Pressure Transducer Fitting, 1/8 npt (f) inlet
and outlet
AE
Flow Mete
AF
Pressure Transducer Cable
r
sducer
er (Current to Pressure). See
ons, page 15.
r Fluid Outlet, 1/4 npt (f)
3A2614H
11
Installation
Grounding
The equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
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.
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.
2
1
3A2614H
Installation
Cable Connect
Port Descripti
1
2
3 Power
4
Fiber Opt
Fiber Optic Transmitter Black Lead to RX on Fiber Optic Converter (PN 16K465) or to Port
Digita
ions
on
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)
5
6
7
8
9
10
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
Di
rom Pressure Transducer Cable
To/F
used.
Not
Not used.
3A2614H 13
Installation
Electrical Co
Install per Graco Control Drawing 16M169, in Manual
332013. See also Figure 1.
1. Connect main power supply cord (E, not
supplied) through strain relief to terminals L and
N on the power supply unit.
Note: Use either strain relief (5) or (6), depending
onthesizeofthecord.
2. Connect power cord ground wire (W) to ground
terminal block (Y).
3. Connect IS power cable (F) per the following
table.
nnections
Table 1 Power Barrier Wiring Connections
Power Cable Leads Barrier Connection
Brown (power) Connector 1
Blue (common) Connector 2
Glossy Black (ground) and Black (drain) connect to
ground block.
Table 2 I/P Transducer Wiring Connections; Cables 16P790 (non-IS) and 16V142 (IS)
Wiring Table
Wire Color
Gray Control A Connector 1
Blue
Function
Common Connector 2
DIN Connector
Figure 1
KEY
E
F
W
XBarrier
Y
5
6
4
1
Inbound AC Power Cord
Power Cable
Ground Wires
Ground Block
Strain Relief Fitting
Strain Relief Fitting
3A2614H
Installation
Air Connectio
ns
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 incoming air line (Q) to 1/4 in. npt (f)
inlet (AB) on I/P transducer (T). Kits with a fluid
regulator (See Parts, page 34), include a 3/8
tube fitting.
2. Kits with fluid regulator: Check that the air tube
isconnectedfrom5/32tubefitting(AC)onI/P
transducer to 5/32 tube fitting (AH) on fluid
regulator (N).
Other Kits: The air outlet is 1/4 in npt (f).
The I/P trans
whenever air
is operatin
NOTE:
• The side port (AD) on the fluid regulator can be
used for high-speed flushing with an independent
air source. Set the air pressure higher than the top
port (AH) air pressure.
• Flushing air pressure must be removed from the
side port (AD) to return to the previous flow setting.
ducer exhausts a small amount of air
is connected, whether or not the system
g.
Communication Options
Graco Accessories are available to enable
communication with a Programmable Logic
Controller (PLC) or Personal Computer (PC).
•TheFi
•AModb
ber Optic Converter (Graco Kit 24N978)
es Modbus RTU communication with a
enabl
supplied PLC using a serial cable.
user-
us Gateway (Graco Kit 24N977) used
Fiber Optic Converter (Graco Kit 24N978)
with a
les Modbus TCP communication with a
enab
-suppled PLC.
user
• 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.
3A2614H 15
Installation
Typical Installation
Non-Hazardous
Location
Hazardous Location
16 3A2614H
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
2
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.
d
ed in some kits. See
page 34.
sory
zardous Location
3A2614H
17
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