Graco ProControl 1KE Plus User Manual

ProControl 1KE Plus

In-Line Fluid Monitoring and Control Packages

The Affordable Way to Control Fluids,
Reduce Waste &

Improve Quality

The ProControl 1KE Plus is an easy-to-use

fluid monitoring and control package that

accurately measures and regulates single

component fluid and gun atomizing air,

improving your finishing process.

Reliable Information and Control

Choose the ProControl 1KE Plus to manage your fluids and atomizing air. Built to save you time and money, ProControl 1KE Plus
packages are backed by Graco's proven reliability standards.

Easy-to-Read Display

Navigate easily using icons and

number based screen

PIN Protected Versatility

Lock system settings or limit

adjustable ranges

Key Applications

• Manual spray finishing

• Automatic spray finishing

• Solvent metering

• Single fluid dispensing

Key Industries

• Auto feeder

• Truck and bus

• Automotive

• Farm and construction

• Aerospace

• Wood

Maintenance Alert

Alerts you when equipment
needs service

Comprehensive Information

Tracks and monitors fluid pressure,
flow rates, atomizing air, material usage

Includes job logs and event logs with date
and time stamps

Optimize operation, material savings and
reporting with unique modes for filling,
flushing and dispensing

2

ProControl 1KE Plus

Manage Fluids for Better Spray Performance

Actively manage fluid pressure or flow rate and air pressure to lock in precise spray parameters. The
ProControl 1KE Plus not only monitors fluids, its closed loop controls manage fluids and improve spray
performance for manual and automatic applications.

Precise
Control

Liquid Material

Prevent overspray and material waste
by managing pressure or flow rate

Atomizing Air

Maintain a high quality finish by
managing fan or atomizing air

Easy
Adjustment

Pressure & Flow Rate

Manage the spray pressure or flow
rate with true close-loop control for
manual or automatic applications

Preset upper and lower limits,
allowing operator to adjust the
output within those limits or lock
the setting entirely

Precision Current to
Pressure Controller (I/P)

To modulate fluid regulator
or to control atomizing air pressure

Accurate
Reporting

Material Use

Easily collect material use data to:

• Track material usage for
individual jobs, times and operators

• Improve operational efficiency and quality

• Report solvent and paint usage for
environmental compliance

Gun Air Regulator

For improved control of
atomizing air pressure

Fluid Regulator

To suit your spray
requirements with a
standard regulator or
choosen alternative

Pressure Transducer

For accurate feedback on
outbound fluid pressure

Fluid Flow Meter

To suit material
requirements with
standard G3000 or
alternative selection

3

System Installation and Integration

Integration and remote communication with Programmable
Logic Controller (PLC)

Power Barrier

Manual Dispense

(G-Barrier power module shown with cover removed)

Fluid Panel 1

Fluid Panel 2

Automatic Dispense

ADCM 1

Communications

ADCM 2

PLC

Hazardous Area

✔ Flexible installation options for the operator interface or fluid panel. Can to be directly mount-

ed in the spray booth hazardous locations or outside the hazardous area

✔ Communications with ProControl 1KE Plus display are achieved through fiber optical cable

and converters connected to the PLC

✔ Multiple ProControl 1KE Plus systems can be linked to the PLC

✔ Many PLC communication protocols are available. Refer to Accessories for details

4

Non-hazardous Area

Ordering Information

STEP

1

Application Requirement

Advanced Display Control Module (ADCM)
with software and bracket only

Flow Monitor (ADCM w/G3000 and short
cable, no fluid panel)

Flow Monitor with open loop fluid
pressure control (includes fluid panel &
I/P to operate fluid pressure regulator)

Gun Atomizing Air Control

Closed Loop Fluid Pressure Control

Closed Loop Fluid Pressure or
Fluid Flow Control

Closed Loop Fluid Pressure and Flow
+ Gun Atomizing Air Control

STEP

2

G3000
Meter

NA NA NA NA NA

ü

ü ü

ü

—

— —

NA NA NA

NA

NA

ü ü ü

ü

—

— —

ü ü ü

ü

—

— —

STEP

3

Standard
1:1 Fluid
Regulator

NA NA NA NA

—

ü

ü ü

—

—

ü ü

—

ü ü

Pressure
Transducer

NA

NA

NA

NA

ü

ü

ü

ü

ü

Qty I/P current
to pressure
transducers for
managing fluid and
atomizing air control

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

Air
Regulator
and Gauge

NA

NA

NA

NA

ü

NA

NA

NA

NA

NA

NA

ü

ü

ü

ü

STEP

4

ProControl
1KE Plus
Package
Part Number

25B283

25B284

25B285

25B286

25B287

25B288

25B289

25B290

25B291

25B292

25B293

25B294

25B295

25B296

25B297

25B298

25B299

STEP

1

STEP

2

STEP

3

STEP

4

Determine level of control needed.

Determine flow meter (if applicable for level of control chosen)

Gun Atomizing Air Control and Closed Loop Fluid Pressure Control units do not use a flow meter

ü G3000 meter is the standard recommended meter.

— Refer to replacement parts and accessories section for alternate Graco offerings.

NOTE: Not all meters are allowed in hazardous locations see meter brochure 336165 and instruction manuals for details.

Determine fluid pressure regulator (if applicable for level of control chosen)

Gun Atomizing Air Control units do not use a fluid pressure regulator

ü24C375 1:1 Low Flow Regulator is standard (see manual 3A0427)

— Refer to replacement parts and accessories section for alternate Graco offerings.

Select base model package part number from table above

5

Ordering Information

STEP

Determine power supply and order separately

5

NON-HAZARDOUS LOCATIONS

For non-hazardous locations order power supply 16V680 AC/DC Converter and select a power
cord below.

Cord Options

245202 120 in (3 m) North American 120 VAC power cord

116281 72 in (1.8 m) extension (Male x Female) IEC-320 cord

242001 Short, 8 in (0.2 m), IEC-320 Europe style power cord

242005 Short, 8 in (0.2 m), IEC-320 x ANZ style power cord

Power Cord

HAZARDOUS LOCATIONS

To determine the correct Power Module for your application, answer these questions:

Yes No

Will you be using 1KE Plus models 25B296-24B299 for fluid and atomizing air control?
Would you potentially want to upgrade a 1KE Plus model in the future for use with fluid and atomizing air
control?

Do you need to power more than one 1KE Plus unit or want the ability to power up to three units from
one power module in the future?
Will the application ever require greater than 50 psi (3.4 bar) of fluid pressure at the outlet of the 1KE Plus
for units with the standard 1:1 24C375 fluid regulator OR for units using an alternate air operated fluid
regulator, will the application ever require greater than 50 psi (3.4 bar) of air pilot pressure to the fluid
regulator?

If you answered YES to ANY of these questions order the 26C724 I.S. G-Barrier Power Module
If you answered NO to ALL of these questions you may consider ordering the 16M167 Single I.S. Barrier Power Module*

* Note: The 16M167 Single I.S. Barrier Power Module has power limitations. It cannot be used on 1KE Plus units that require greater than 50 psi of fluid pressure
(50 psi of pilot air pressue for alternate air-operated fluid regulator use) or on units that control fluid and atomizing air.

16V680 has an IEC-320-C13 female

input power connection and 68 in.

(1.7 m) output cord to connect to
Port 3 of the ProControl 1KE Plus

ADCM user interface.

26C724 I.S. G-Barrier Power
Module (shown with cover
removed)

Flow Meters

Highly accurate gear and mass flow meters are ideal for
finishing applications using most solventborne and waterborne
paints and resins.

G250, G3000 and S3000

• Positive displacement, spur gear flow meter

• Designed for low to medium viscosity materials

• Stainless steel compatible

HG6000/HG6000 HR

• Positive displacement, helical gear flow meter

• Designed for higher flow rates and higher viscosity materials

• Stainless steel, water-base compatible

Coriolis Mass Flow

• Non-intrusive mass flow meter

• Designed for all abrasive and filled materials

• Stainless steel, waterborne and acid compatible

6

G3000

HG6000

S3000

Coriolis Mass Flow

Ordering Information

Replacement Parts - Accessories

Power (See page 6 for important information on proper power selection)

16V680 Non-Intrinsically Safe (Non-I.S.) Power Supply, 100-240 VAC input,

50/60 Hz, 15 VDC output

16M167 Intrinsically Safe (I.S.) Power Supply Module, 100–240 VAC input.

Includes 50 ft (15 m) I.S. power cable

26C724 G-Barrier Intrinsically Safe (I.S.) Power Module, provides up to three

I.S. power output circuits. 100-240 VAC, 50/60 Hz, input. Includes
one I.S. 50 ft (15 m) I.S. Power Cable

Cables

Non-Intrinsically Safe Cables

18A987 Meter Cable Extension, 50 ft (15 m), for meter cable, port #4
16V069 Non-I.S. Power Cable, 50 ft (15 m)
16V070 Non-I.S. Power Cable, 100 ft (30 m)
16V380 Non-I.S. Sensor Cable, 50’ (15 m),

port #7 (pressure transducer) and
#10 (air flow switch or gun trigger)

16P791 Non-I.S. Control Cable, 50’ (15 m),
port #8 (fluid pressure/flow control) and
#9 (atomizing air pressure control)

18A986 Indicator Light Cable, 50’ (15 m), fluid panel to light

Intrinsically Safe Cables

19Y499 I.S. Power Cable, 50 ft (15 m), for power supply
19Y502 I.S. Power Cable, 100 ft (30 m), for power supply
18B244 I.S. Meter Cable Extension, 50 ft (15 m), meter cable, port #4
16V381 I.S. Sensor Cable, 50’ (15 m), port #7 (pressure transducer)

and #10 (air flow switch or gun trigger)
16V071 I.S. Control Cable, 50’ (15 m), port #8 (fluid pressure/flow control)

and #9 (atomizing air pressure control)

Fiber Optic Communication Cable

17T898 10 ft (3 m) Fiber Optic Cable
16M172 50 ft (15 m) Fiber Optic Cable
16M173 100 ft (30 m) Fiber Optic Cable
17B160 330 ft (100.5 meter) Fiber Optic Cable

Indicators

25P594 I.S. Indicator Light Tower, 2 color light with bracket and cables

Supply Air

570122 Dual Unit Air Filter and Regulator Assembly with 5 µm filter, manual

Interfaces

24R086 Fiber Optic to Serial Converter Module with 24V, 2 amp power

24N978 Fiber Optic to Serial Converter, communicates from the

Meters & Transducers

289813 G3000 Meter

280560 HG6000 Meter

258718 S3000 Solvent Meter

25P592 Pressure Transducer Kit, 100 psi (7 bar, 0.7 MPa)
Used to measure fluid pressure

25P593 High Pressure Sensor Kit, 4500 psi (310 bar, 31.0 MPa)
Used to convert to higher pressure operation
See manual 3A6948 component pressure ratings

25B359 Medium Pressure Sensor Kit, 2000 psi (138 bar, 13.8 MPa)
Used to convert to higher pressure operation
See manual 3A6948 component pressure ratings

Coriolis Meter Kit

Non-intrusive Mass Flow Meter, for abrasive and filled materials
and a range of flow rates

24N525 1/4 in Coriolis Flow Meter Kit

drain, and mounting bracket

supply and enclosure, commicates from ProControl 1KE Plus to a PLC
See manual 332356 for details.

ProControl 1KE Plus to a PLC. See manual 332356 for details

Positive displacement, gear flow meter, 0.02 to 1.0 gpm
(75 to 3800 cc/min), for low to medium viscosity materials

Positive displacement, helical gear flow meter, 0.013 to 6.0 gpm
(50 to 22,712 cc/min), for high flow, high viscosity materials

Positive displacement, gear flow meter, 0.01 to 0.5 gpm
(38 to 1900 cc/min), for light viscosity materials

Hardware Upgrades

25B322 Basic Upgrade Kit for converting a previous generation ProControl 1KE

to the new 1KE Plus platform. Kit includes software token, fluid plate
with basic hardware. User must provide ADCM display, fluid meter,
I/P transducer, fluid regulator, pressure transducer, and power supply
from original ProControl 1KE or purchase separately. Gun air control
is not included, if needed order 25B323 separately for air control
hardware. See manual 3A6948 for details

25B323 Air Control Upgrade Kit adds air control to a ProControl 1KE Plus

fluid plate

25B325 Pressure Switch Conversion Kit converts ProControl 1KE Plus fluid

plate gun air flow switch to a pressure switch for detection of gun
trigger status

Communication Gateway

25B471 Ethernet Communication Gateway Assembly
25B472 DeviceNet Communication Gateway Assembly
25B473 Profibus Communication Gateway Assembly
25B486 Ethernet Communication Gateway Assembly

with Fiber Conversion Module, no cable
18C235 Bare Ethernet Gateway Module
18C236 Expansion Module, DeviceNet for 18C235
18C237 Expansion Module, Profibus for 18C235

Fluid Regulators

24C375 1:1 Low Flow Regulator (5-90 psi, 0.3-6.3 bar, 35-620 KPa)
24E471 1:2 Low Flow Regulator (5-50 psi, 0.3-3.5 bar, 35-350 KPa)
24E472 1:3 Low Flow Regulator (5-30 psi, 0.3-2.1 bar, 35-201 KPa)
234272 Low Pressure Fluid Regulator

(6-145 psi, 0.4-10.0 bar, 40-1000 KPa), 7 gpm

234266 High Pressure Fluid Regulator

(70-900 psi, 5.0-60.0 bar, 0.5-6 MPa), 11.3 gpm

7

ABOUT GRACO

Founded in 1926, Graco is a world leader in fluid handling systems and components. Graco products
move, measure, control, dispense and apply a wide range of fluids and viscous materials used
in vehicle lubrication, commercial and industrial settings.

The company’s success is based on its unwavering commitment to technical excellence, world-class
manufacturing and unparalleled customer service. Working closely with qualified distributors, Graco
offers systems, products and technology that set the quality standard in a wide range of fluid handling
solutions. Graco provides equipment for spray finishing, protective coating, paint circulation, lubrication,
and dispensing sealants and adhesives, along with power application equipment for the contractor
industry. Graco’s ongoing investment in fluid management and control will continue to provide
innovative solutions to a diverse global market.

GRACO LOCATIONS

MAILING ADDRESS

P.O. Box 1441
Minneapolis, MN 55440-1441
Tel: [phone]
Fax: [phone]

AMERICAS

MINNESOTA

Worldwide Headquarters
Graco Inc.
88 -11th Avenue N.E.
Minneapolis, MN 55413

EUROPE

BELGIUM

European Headquarters
Graco N.V.
Industrieterrein-Oude Bunders
Slakweidestraat 31
3630 Maasmechelen,
Belgium
Tel: [phone]
Fax: [phone]

ASIA PACIFIC

AUSTRALIA

Graco Australia Pty Ltd.
Suite 17, 2 Enterprise Drive
Bundoora, Victoria 3083
Australia
Tel: [phone]
Fax: [phone]

CHINA

Graco Hong Kong Ltd.
Shanghai Representative Office
Building 7, No.1-2,
Wenshui Road 299,
Jing’an District,
Shanghai 200436,
The People’s Republic of China
Tel: [phone]
Fax: [phone]

INDIA

Graco India Pvt Ltd
Plot No 295, Udyog Vihar Phase-IV
Gurugram - 122015 (Haryana)
India
Tel: [phone]
Fax: [phone]

JAPAN

Graco K.K.
1-27-12 Hayabuchi
Tsuzuki-ku
Yokohama City, Japan 2240025
Tel: [phone]
Fax: [phone]

KOREA

Graco Korea Inc.
38, Samsung 1-ro 1-gil
Hwaseong-si, Gyeonggi-do,
18449
Republic of Korea
Tel: [phone]
Fax: [phone]

SALES/

DISTRIBUTION/

SERVICE

North America

Customer Service

800-328-0211

Fax [phone]

Call today for product information or to request a demonstration.
877-84GRACO (1-877-844-7226) or visit us at www.graco.com/procontrol1keplus

Graco Inc. is registered to I.S. EN ISO 9001

©2021 Graco Inc. 345008 Rev. J 2/21 All written and visual data contained in this document are based on the latest product information available at the time
of publication. Graco reserves the right to make changes at any time without notice. All other brand names or marks are used for identification purposes and
are trademarks of their respective owners. For patent information, see www.graco.com/patents.