Graco ProControl 1KS Operation

#53

Operation

TI16328a

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.

Important Safety Instructions

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

™

ProControl

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

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

1KS

3A1080H

II 2 G2575

Contents

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

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

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

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

Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Important Two-Component Material Information . . . . . . 8

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 8

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Keep Components A and B Separate . . . . . . . . . . . . . . 8

Moisture Sensitivity of Isocyanates . . . . . . . . . . . . . . . . 8

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Component Identification and Definition . . . . . . . . . . . 12

Wall Mount System Components . . . . . . . . . . . . . . . . 14

EasyKey Display and Keypad . . . . . . . . . . . . . . . . . . . . . 16

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

AC Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

I/S Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Graco Web Interface Port . . . . . . . . . . . . . . . . . . . . . . 18

Ethernet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Manual Override Screen . . . . . . . . . . . . . . . . . . . . . . . 22

Totals Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Reset Total Screen . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Reset Solvent Screen . . . . . . . . . . . . . . . . . . . . . . . . . 23

Alarms Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Level Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . 24

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Password Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Set Up Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . 26

System Configuration Screens . . . . . . . . . . . . . . . . . . 28

Option Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Advanced Setup Screens . . . . . . . . . . . . . . . . . . . . . . 34

Recipe Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . 40

Recipe 0 Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

ProControl Integration Specifics . . . . . . . . . . . . . . . . . . 49

System Setup for Automatic Operation . . . . . . . . . . . .49

Status Verification of Automatic Operation . . . . . . . . . 50

Discrete I/O vs Network Communications . . . . . . . . . 50

Discrete I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Automation Flow Charts . . . . . . . . . . . . . . . . . . . . . . . 55

Modbus and I/O Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Start Mix Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Stop Mix Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Color Change Process . . . . . . . . . . . . . . . . . . . . . . . . 66

Purge Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Typical PLC Interaction with ProControl 1KS . . . . . . . 69

Integrated Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . 78

Flow Control Description . . . . . . . . . . . . . . . . . . . . . . 78

Flow Control Components . . . . . . . . . . . . . . . . . . . . . 78

Fluid and Air Pressure Requirements . . . . . . . . . . . . . 79

Flow Control Operation . . . . . . . . . . . . . . . . . . . . . . . . 79

Flow Control Operating Process Example . . . . . . . . . 81

Flow Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Flow Control Startup . . . . . . . . . . . . . . . . . . . . . . . . . . 83

One-Point Learning . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Flow Control Calibration . . . . . . . . . . . . . . . . . . . . . . . 85

Pressure Flow Control Mode . . . . . . . . . . . . . . . . . . . 88

Flow Control Troubleshooting . . . . . . . . . . . . . . . . . . . 89

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Recipe (Color) Change . . . . . . . . . . . . . . . . . . . . . . . . 91

Solvent Push . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Mix Manifold Valve Settings . . . . . . . . . . . . . . . . . . . . 91

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 94

Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Solvent Push Feature . . . . . . . . . . . . . . . . . . . . . . . . 101

Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Color Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Color Change Procedures . . . . . . . . . . . . . . . . . . . . 104

Color Change Sequences . . . . . . . . . . . . . . . . . . . . 104

Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 118

System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

System Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 119

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

System Pneumatic Schematic . . . . . . . . . . . . . . . . . 130

System Electrical Schematic . . . . . . . . . . . . . . . . . . 131

EasyKey Electrical Schematic . . . . . . . . . . . . . . . . . 133

Meter Performance Data (G3000 on A and B) . . . . . . . 134

Meter Performance Data (G3000 on A, Coriolis on B) 135

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . 138

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2 3A1080H

Related Manuals

.7 7 100

MAX AIR WPR

MPa bar PSI

1.31

13.1 190

MAX FLUID WPR

MPa bar PSI

PART NO. SERIES

Read Instruction Manual

Warning: Substitution of components may impair intrinsic safety.

SERIAL

ProControl 1KS

Electronic Proportioner

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

Intrinsically safe

equipment for Class I,

Div 1, Group D, T3

Ta = -20°C to 50°C

CUS

FM08ATEX0074 II 2 G Ex ia IIA T3

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

MFG. YR.

SERIES NO. MFG. YR.

PART NO.

AMPS

VOLTS

85-250 ~

2 AMPS MAX

POWER REQUIREMENTS

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

II (2) G [Ex ia] IIA FM08ATEX0072

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

CUS

277869

50/60 Hz

ProControl 1KS

Um: 250 V

ATEX Certificate is listed here

293765b

293762b

EasyKey Label

Fluid Station Label

EasyKey and Fluid Station Control Box Label

.7 7 100

MAX AIR WPR

MPa bar PSI

FLUID PANEL

ProControl

PART NO. SERIES SERIAL

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

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

FM08ATEX0073 II 2 G Ex ia IIA T3

Related Manuals

Component Manuals in English

Manual Description

3A1163 ProControl 1KS Installation 3A1164 ProControl 1KS Repair-Parts 312782 Dispense Valve 312783 Color Change Valve Stacks 312787 Color Change Module Kit 312784 Gun Flush Box Kits 310745 Gun Air Shutoff Kit 312786 Dump Valve and Third Purge Valve Kits 312785 Network Communication Kits 308778 G3000/G3000HR/G250/G250HR Flow

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

Interface 406800 15V825 Discrete I/O Board Kit

Equipment Approvals

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

™

EasyKey

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

3A1080H 3

System Configuration and Part Numbers

.7 7 100

MAX AIR WPR

MPa bar PSI

1.31

13.1 190

MAX FLUID WPR

MPa bar PSI

PART NO. SERIES

Read Instruction Manual

Warning: Substitution of components may impair intrinsic safety.

SERIAL

ProControl 1KS

Electronic Proportioner

MAX TEMP 50°C (122°F)

Intrinsically safe

equipment for Class I,

Div 1, Group D, T3

Ta = -20°C to 50°C

CUS

FM08ATEX0074 II 2 G Ex ia IIA T3

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

MFG. YR.

Label Location on EasyKey

Label Location on Fluid Station

Maximum Fluid

Working Pressure

is listed here

TI15975a

TI15974a

Configured Part Number

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

A ProControl 1KS

None G3000 Coriolis No Yes



 

FIG. 1: Identification Label, ProControl 1KS Systems

4 3A1080H

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.

ProControl Fluid Components Maximum Working Pressure

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

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

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

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

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

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

Flow Meter Fluid Flow Rate Range

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

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

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

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

Standard Features Accessories

Feature

EasyKey with LCD

RS 485 Network Cable, 50 ft (15.25 m)

Fiber Optic and Power Cables, 50 ft (15.25 m)

Fluid Station Control Box

Discrete I/O Board

A Side Dump Valve, if color valve(s) selected

Flow Control with 15 ft (4.57 m) Cable (if selected)

Basic Web Interface

Accessory

15V536 Solvent Flow Switch Kit

15V213 Power Cable, 100 ft (30.5 m)

15G710 Fiber Optic Cable, 100 ft (30.5 m)

15G614 Flow Control Extension Cable, 40 ft (12.2 m)

15W034 Strobe Light Alarm Indicator Kit

15V331 Gateway Ethernet Communication Kit

15V963 Gateway DeviceNet Communication Kit

15V964 Gateway Profibus Communication Kit

15V337 Advanced Web Interface

NOTE: This is not a complete list of available accessories and kits. Refer to the Graco website for more information about accessories available for use with this product.

3A1080H 5

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 in your system installation man- ual.

• 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 3A1080H

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.

• Tighten all fluid connections before operating the equipment.

• 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 Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

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 forms from distributor or retailer.

• 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.

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 MSDS’s 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 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, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

3A1080H 7

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.

8 3A1080H

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.

Glossary of Terms

Advanced Web Interface (AWI) - This allows remote ProMix backup and restore, configuration, logging, and software update options.

Air Chop - the process of mixing air and solvent together during the flush cycle to help clean the lines and reduce solvent usage.

Air Chop Time- duration of each activation of the air purge valve during a chop sequence. User settable from

0.0-99.9 seconds.

Analog - relating to, or being a device in which data are represented by continuously variable, measurable, physical quantities, such as length, width, voltage, or pressure.

B Purge After Chop - Optional 2-second B solvent valve activation after the Chop sequence. This is used to separate the chop material and the Final Purge material to prevent unwanted mixing.

Basic Web Interface (BWI) - This allows remote ProMix backup and restore, logging, and software update options.

Bootloader - The utility program that handles initial system startup re-programming of the main ProMix application.

Chop Time- refers to the total length of the chop sequence during a purge. User settable from 0-999 seconds.

Coriolis Meter - a non-intrusive flow meter often used in low flow applications or with light viscosity, shear sensitive, or acid catalyzed materials. This meter uses vibration to measure flow.

Custom Language - A method to load a translation file into the ProMix to display languages other than those built into the system. Only Unicode characters through codespace 0x00FF are supported.

Digital Input and Output - a description of data which is transmitted as a sequence of discrete symbols, most commonly this means binary data represented using electronic or electromagnetic signals.

Discrete I/O - refers to data that constitutes a separate entity and has direct communication to another control.

Dose Size - the amount of resin (A) and catalyst (B) that is dispensed into an integrator.

Dose Time Alarm - the amount of time that is allowed for a dose to occur before an alarm occurs. More than 30 pulses from the flow meter of the active dose valve are needed while the Gun Trigger is on to prevent the alarm.

Dynamic Dosing - Component A dispenses constantly. Component B dispenses intermittently in the necessary volume to attain the mix ratio.

Ethernet - a method for directly connecting a computer to a network or equipment in the same physical location.

Closed Loop Flow Control - refers to the process when the flow rate is adjusted automatically to maintain a constant flow.

Color/Catalyst Purge - refers to the time required to flush the lines from the color or catalyst change module to the mix manifold during a color or catalyst change.

Color/Catalyst Fill - refers to the time required to fill the lines from the color or catalyst change module to the mix manifold.

Command Holdoff - The amount of time that flow rate learning is not allowed after the set point is changed to allow the flow rate to stabilize.

3A1080H 9

ExtSP - External Set Point selection for PLC input of the flow rate set point while operating in Flow Control Override mode.

Fiber Optic Communication - the use of light to transmit communication signals. Blue is the transmitter, and black is the receiver. This must be cross-connected between the EasyKey and the Fluid Panel for communication to work. The Fiber Optic cable has a blue band to indicate the proper connection.

Final Purge Source- source of the media used in the final purge cycle. User settable to air purge valve, solvent purge valve, or 3rd purge valve.

Final Purge Time- duration of the final purge cycle. User settable from 0-999 seconds.

Glossary of Terms

First Purge Source- source of the media used in the first purge cycle. User settable to air purge valve, solvent purge valve, or 3rd purge valve

First Purge Time- duration of the first purge cycle. User settable from 0-999 seconds.

Flow Control Resolution - a settable value that allows the flow control system to maximize its performance. The value is based on maximum desired flow rates.

Flow Rate Analog Signal - the type of communication signal that can be used on the ProControl module.

Flow Rate Tolerance - the settable percent of acceptable variance that the system will allow before a flow rate warning occurs.

Flow Set Point - a predefined flow rate target.

Flush Volume Check - system monitors flush volume.

E-11 Alarm occurs if minimum volume is not achieved. Minimum flush volume is user settable (0-999 cc).

Global - indicates that values on the screen apply to all recipes, 1 through 60.

K-factor - a value that refers to the amount of material that passes through a meter. The assigned value refers to an amount of material per pulse.

Kd - refers to the amount the fluid flow system attempts to not overshoot the target set point.

Ki - refers to the degree fluid flow over shoots its set point.

Kp - refers to the speed in which the fluid flow reaches its set point.

Learn Strength - How much and how quickly to apply the difference in the flow rate set point compared to the measured flow rate when updating the flow control data table.

Manual Mode - when the proportioning or flow control system is controlling the inputs without any input from an outside control.

Minimum Material Fill Volume - system monitors material fill volume. E-21 Alarm occurs if minimum volume is not achieved. Minimum material fill volume is user settable (0-9999 cc).

Grand Total - a non-resettable value that shows the total amount of material dispensed through the system.

GT-Off Drive Time - The amount of time to regulate the fluid pressure based on the flow rate set point after the gun trigger is closed.

GT-Off Target Rise - The additional time to regulate the fluid pressure based on the flow rate set point after the gun trigger is closed.

Gun Trigger Holdoff - The amount of time that flow rate learning is not allowed after the gun trigger is opened to allow the flow rate to stabilize.

Gun Trigger Input Signal - used to manage ratio assurance dose times and flow control processes.

Intrinsically Safe (IS) - refers to the ability to locate certain components in a hazardous location.

Idle - if the gun is not triggered for 2 minutes the system enters Idle mode. Trigger the gun to resume operation.

Job Total - a resettable value that shows the amount of material dispensed through the system for one job. A job is complete when a color change or complete system flush occurs.

Mix - when cross-linking of the resin (A) and catalyst (B) occurs.

Mix Fill Push - An option for the Autodump selection to automatically clear the Potlife alarm if the gun is in the Gun Flush Box by running new mixed material through the gun.

Mix Input Signal- refers to system mode status where system begins a dose sequence each time the mix signal is made “High”.

Mixed Material Fill Time - the amount of time that is required to load mixed material from the dose valves to the applicator/gun.

Modbus/TCP - a type of communication protocol used to communicate Digital I/O signals over an ethernet.

Network Station - a means to identify a particular individual proportioning or flow control system.

One-Point Learning - Flow Control table calibration method using learned points above a specified flow rate to interpolate the table at low flow rates with short gun trigger times.

10 3A1080H

Glossary of Terms

Overdose (A, B, C) Alarm - when either the resin (A), or catalyst (B), or reducer (C) component dispenses too much material and the system cannot compensate for the additional material.

Potlife Time - the amount of time before a material becomes unsprayable.

Potlife Volume - the amount of material that is required to move through the mix manifold, hose and applicator before the potlife timer is reset.

Purge - when all mixed material is flushed from the system.

Purge Drive - The voltage drive during the Purge sequence, maximum of 3300 mV. The response curve of the V/P regulator is not linear, so it may be necessary to test the response using Manual Override mode.

Purge Time - the amount of time required to flush all mixed material from the system.

Purge Volume Alarm - E-11 Alarm occurs if minimum flush volume is not achieved.

Third Purge Valve - refers to the use of three purge valves used to flush some waterborne materials. The valves are used to flush with water, air and solvent.

V/P - refers to the voltage to pressure device in the flow control module.

Valve Holdoff Maximum - The maximum amount of time that flow rate learning is not allowed after a dose valve cycles. The system may internally use a time less than is based on the stability of the fluid meter pulse stream.

Ratio Tolerance - the settable percent of acceptable variance that the system will allow before a ratio alarm occurs.

Sequential Color Change - the process when a color change is initiated and the system automatically flushes the old color and loads a new color.

Sequential Dosing - Components A and B dispense sequentially in the necessary volumes to attain the mix ratio.

Solvent/3rd Purge Valve Chop Time- duration of each activation of the solvent or 3rd purge valve during a chop sequence. User settable from 0.0-99.9 seconds.

Solvent Fill - the time required to fill the mixed material line with solvent.

Solvent Push - enables the user to save some mixed material by pushing it out to the gun with solvent. Requires an accessory solvent meter.

Standby - refers to the status of the system.

System Idle - This warning occurs if the ProControl is

set to Mix, and 2 minutes have elapsed since the system received a flow meter pulse.

3A1080H 11

Overview

Usage

The Graco ProControl 1KS is an electronic flow control and color change system, for use with most solvent and waterborne epoxy, polyurethane, and acid-catalyzed paints. It is not for use with “quick-setting” paints (those with a potlife of less than 15 minutes).

• Has user selectable ratio assurance and can maintain up to +/-1% accuracy, depending on materials and operating conditions.

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

Component Identification and Definition

SeeTable 1, and FIG. 2 for the wall mount system components.

Table 1: Component Descriptions

• Color change options are available for low pressure (300 psi [2.1 MPa, 21 bar]) air spray and high pressure (3000 psi [21 MPa, 210 bar]) systems with up to 30 color change valves and up to 4 catalyst change valves.

NOTE: Optional accessories are available for in field installation to achieve 30 colors.

Component Description

EasyKey (EK)

Fluid Station Control Box (ST)

Fluid Manifold (FM)

Flow Meters (MA, MS)

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

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

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

• Pneumatically Operated Dose Valve for component A

• Purge Valves for solvent and air purge

Four optional flow meters are available from Graco:

• G3000 is a general purpose gear meter typically used in flow ranges of 75-3800 cc/min. (0.02–1.0 gal/min.), pressures up to 4000 psi (28 MPa, 276 bar), and viscosities of 20–3000 centipoise. The K-factor is approximately 0.119 cc/pulse.

• G3000HR is a high resolution version of the G3000 meter. It is typically used in flow ranges of 38–1900 cc/min. (0.01–0.5 gal/min.), pressures up to 4000 psi (28 MPa, 276 bar). and viscosities of 20–3000 centipoise. The K-factor is approximately 0.061 cc/pulse.

• S3000 is a gear meter used for solvents in flow ranges of 38-1900 cc/min. (0.01–0.50 gal/min.), pressures up to 3000 psi (21 MPa, 210 bar), and viscosities of 20–50 centipoise. The K-factor is approximately 0.021 cc/pulse.

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

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

12 3A1080H

Table 1: Component Descriptions (Continued)

Component Description

Overview

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

Dual Fiber Optic Cable (FO)

Fluid Station Control Box Power Supply Cable (PS)

Flow Control Regulator Assembly (FC)

EasyKey (EK)

Fluid Station Control Box (ST)

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

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

Used to provide power to the Fluid Station Control Box.

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

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

3A1080H 13

Overview

TI15961b

FO*

FC (see F

IG. 4)

PS*

ACV

CCM

MAFM (see

IG. 3)

* See the ProControl 1KS

Repair-Parts manual for optional cable lengths.

Air Control Module

Logic Air

Regulator V/P Air

Purge

Air

Fluid

FC Cable*

Wall Mount System Components

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

14 3A1080H

Overview

TI15977a

SPV

DVA

APV

FIH

FOH

TI15976a

Regulator

V/P Air

FC Cable

Fluid In

Fluid Out

FIG. 3. Fluid Manifold

Key:

MA Component A Meter DVA Component A Dose Valve SPV Solvent Purge Valve SS Solvent Purge Valve Solvent Supply Tube

FIG. 4. Flow Control Regulator

APV Air Purge Valve AT Air Purge Valve Air Supply Tube FIH Fluid Inlet Hose FOH Fluid Outlet Hose

3A1080H 15

EasyKey Display and Keypad

TI11630A

Keypad

LCD Display

Navigation Keys Alarm Reset Key

EasyKey Display and Keypad

IG. 5. EasyKey Display and Keypad

Display

Shows graphical and text information related to setup and spray operations. Back light will turn off after 10 minutes without any key press. Press any key to turn back on.

NOTE: Pressing a key to turn on the display back light will also perform the function of that key. If you are unsure whether that key will impact your current operation, use the setup or navigation keys to turn on the display back light.

Keypad

Used to input numerical data, enter setup screens, scroll through screens, and select setup values.

In addition to the numbered keys on the EasyKey keypad, which are used to enter values in setup, there are keys to navigate within a screen and between screens, and to save entered values. See Table 2.

Table 2: EasyKey Keypad Functions (see FIG. 5)

Key Function

Setup: press to enter or exit Setup mode.

Enter: if cursor is in menu box, press Enter

key to view menu. Press Enter to save a value either keyed in from the numerical keypad or selected from a menu.

Up Arrow: move to previous field or menu item, or to previous screen within a group.

Down Arrow: move to next field or menu item, or to next screen within a group.

Left Arrow: move to previous screen group.

Right Arrow: move to next screen group.

Alarm Reset: resets alarms. If the display becomes unresponsive, pressing this key 4 times in succession will re-initialize the display.

16 3A1080H

FIG. 6. EasyKey Connections and AC Power Switch

AC Power Switch

Graco Web Interface

Audible AlarmFiber Optic Strain

Relief Port

I/S Power Discrete I/O Cable

Connector Ports

Ground Screw

Main Power Access Port

TI12638a

TI12657a

Fiber Optic Strain Relief Port

I/S Power

Ground Screw

TI15917a

TI15919a

Booth Control

(Manual Systems

only)

Muffler

Color Change Module

Logic Air Inlet

TOP VIEW

BOTTOM VIEW

OPEN

A DOSE

B DOSE

A PURGE

B PURGE

3RD PURGE

A DUMP B DUMP

Meter A

Flow Control

Gun Air

Meter B (not used)

EasyKey Display and Keypad

FIG. 7. Fluid Station Control Box Connections

3A1080H 17

EasyKey Display and Keypad

AC Power Switch

Turns system AC power on or off.

I/S Power

Power circuit to Fluid Station.

Audible Alarm

Alerts the user when an alarm occurs. Available settings for selecting which alarms will cause an audible alarm are explained in Configure Screen 1, page 29.

Clear the audible alarm by pressing the Alarm Reset

key.

Even after the Alarm Reset key is pressed, the Potlife Exceeded alarm message will remain displayed until a sufficient amount of mixed material has been dispensed to ensure that the expired material has been ejected.

Graco Web Interface Port

Used to communicate with the ProControl from a PC to:

 Upgrade software  View software version  Download

• Job and alarm logs

• Material usage report

• Setup values (can also upload)

 Clear job, alarm, and material usage

reports

 Upload a custom language to view on

screen

 Restore factory defaults  Restore setup password

See manual 313386 for more information.

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

Ethernet Connection

You can access data on an office or industrial network through the internet with the proper configuration. See manual 313386 for more information.

18 3A1080H

Run Mode Screens

NOTE: See FIG. 10 for a map of the Run screens.

Detailed screen descriptions follow.

Splash Screen

At power up, the Graco logo and software revision will display for approximately 5 seconds, followed by the

Status Screen (see page 21).

Run Mode Screens

IG. 8. Splash Screen

The Splash screen will also momentarily display “Establishing Communication.” If this display remains for more than one minute, check that the fluid station circuit board is powered up (LED is on) and that the fiber optic cable is properly connected (see Installation manual).

NOTE: If the software version of the fluid plate does not match the version of the EasyKey, the EasyKey will update the fluid plate, and the fluid plate programming

screen will appear until the update is completed.

IG. 9. Fluid Plate Programming Screen

3A1080H 19

Run Mode Screens

TI12802a

Press the Setup key to

enter Setup mode.

FIG. 10. Run Screens Map

20 3A1080H

Run Mode Screens

Status Screen

• Use the Up or Down keys to scroll through the Run screens.

• Press the Setup key to enter the Setup screens

from the Status screen.

• The other keys have no function in this Status screen.

Current Date and Time

Screen Number and Scroll Arrows: displays the

current screen number and the total number of screens in a group. The Up and Down arrows on the right edge of the screen indicate the scroll feature. The total number of screens in some groups may vary depending on system configuration selections.

Current Flow Control Data: fluid output pressure and voltage of analog signal used for driving the fluid regulator V/P.

The fluid target pressure is shown if Flow Control in Configure Screen 5 on page 30 is set to “On: Setup”.

Lock Symbol: indicates that Setup screens are password protected. See page 26.

IG. 11. Status Screen

Key to F

IG. 11:

Active Recipe: shows the active recipe.

NOTE: At power up the system defaults to Recipe

61, which is not a valid recipe number.

Status Bar: shows current alarm or operation mode (standby, mix, purge, recipe change, or the current alarm). NOTE: If the auto key board is removed from the EasyKey display board, the Status Bar will read “Auto key not found.” This indicates that the automatic mode is not operable.

Target Flow Rate and Current Flow Rate: in cc/min.

Animation: when the gun is triggered, the gun appears to spray and the component A or B hose lights up, showing which component dose valve is open.

3A1080H 21

Run Mode Screens

Manual Override Screen

IG. 12. Manual Override Screen

This screen will appear if Manual Override is set to “On” in Advanced Setup Screen 1 (page 35). It shows the active recipe, new/go to recipe, and manual override mode.

If Flow Control is set to “On” in Configure Screen 5 on page 30, this screen will also display Flow Rate Range, Flow Set Point, Flow Control Calibration (Start/Abort), and Global Flow Control Data Copy (Start/Abort).

Manual Override Menu

This field allows you to set the operating mode from the

EasyKey. Press the Enter key to view the menu, then select the desired operating mode (Standby, Mix,

Purge, or Recipe Change). See F

IG. 13.

Flow Rate Range

This screen displays the flow rate range selected on

Advanced Setup Screen 5 (see page 37).

Flow Set Point

The Flow Set Point is user settable. If Flow Control Override is set to “Off” or “Pressure” in Advanced Setup Screen 1 on page 35, the Flow Set Point will display as cc/min. Enter the desired flow set point within the range.

If Flow Control Override is set to “% Open,” the Flow Set Point will display as % Open. This percentage relates to the flow control V/P ratio which translates to a fluid flow rate. Set the initial percentage at 35% and increase as necessary to reach the desired flow rate.

Flow Control Calibration

This field allows you to calibrate flow control for each recipe. The system must be in Mix mode and receiving a

Gun Trigger signal. Press the Enter key to view the menu, then select Start or Abort. See F

The flow rate will drop to 0, then incrementally increase until it reaches the maximum flow rate. To view the progress, go to the Status Screen, page 21. The system will populate the data for the current recipe. To copy this data to all recipes, see Global Flow Control Data

Copy, page 23.

IG. 14.

FIG. 14. Flow Control Calibration

IG. 13. Manual Override Menu

22 3A1080H

Run Mode Screens

Global Flow Control Data Copy

This field allows you to copy flow control data from the

active recipe to all recipes. Press the Enter key to view the menu, then select Start or Abort. See F

FIG. 15. Global FC Data Copy

IG. 15.

Totals Screen

NOTE: Grand totals are not resettable.

Reset Total Screen

FIG. 17. Reset Total Screen

If job is reset, job number will increment by one for default.

Reset Solvent Screen

IG. 16. Totals Screen

IG. 18. Reset Solvent Total Screen

This screen shows the job totals, fill totals, grand totals, and job number. Use the tabs to reset job totals (Job Complete), reset solvent totals (Rst Solvent), or go to Level Control Screen, page 24.

The job totals generally refer to material dispensed while in Mix mode. This is likely atomized and sprayed material with the gun trigger “On”.

The fill totals generally refer to material dispensed while in Mix-fill mode after a color change or a purge operation. This is likely not sprayed or atomized, and is dispensed to a purge container.

Solvent Totals and the Rst Solvent tab only appear if “Meter” is selected under Solvent Monitor in Configure Screen 5 on page 30.

3A1080H 23

The screen will ask if you want to reset solvent total. Select Yes or No.

Run Mode Screens

Alarms Screen

IG. 19. Alarms Screen

Two screens show the last 10 alarms. Use the Up or

See F

IG. 21. If the tank volume reaches the low-level

threshold, the EasyKey screen will display the Tank Level Low alarm and prompt the user to do one of the following:

1. Refill tank volume to clear the alarm.

2. Resume mixing by selecting “Spray 25% of Remainder.” If this selection is chosen, a second alarm will occur after 25% of the remaining volume is mixed.

Refill tank volume to clear the alarm.

Down

See Table 17 on page 118 for a list of alarm codes.

keys to scroll between the two screens.

Level Control Screen

IG. 20. Level Control Screen

This screen shows the current volume for each fluid. Adjust the current volumes on this screen, or use the tab to go to Usage (Totals Screen, page 23). The Alarm Level values may be adjusted using the advanced web interface.

FIG. 21. Tank Level Low Screen (Tank A Shown)

24 3A1080H

Setup Mode

To access System Configuration Screens,

page 28.

TI12784a

Press the Setup key to

enter Setup mode.

This screen appears only if a

password is activated.

This screen appears momentarily

if a password is activated.

Press the Setup key to exit

Setup mode and return to the Status

screen.

To access Advanced Setup Screens, page

34 and Recipe Setup Screens, page 40.

Setup Mode

Press the Setup key to enter Setup mode.

NOTE: See F

IG. 22 for a map of the Setup screens.

Detailed screen descriptions follow.

FIG. 22. Setup Screens Map

3A1080H 25

Setup Mode

Password Screen

If a password has been activated (see Configure Screen 1, page 29), the Password screen will appear. You must enter the password to access the Set Up Home Screen. Entering the wrong password returns the display to the Status Screen.

NOTE: If you forget the password, you can reset the

password (to 0), using the ProControl Web Interface (see manual 313386).

IG. 23. Password Screen

NOTE: If a password is activated, Setup Locked dis-

plays momentarily after exiting Setup mode and return-

ing to the Status Screen. A lock symbol appears

Set Up Home Screen

FIG. 25. Set Up Home Screen

This screen displays when you enter Setup mode. From it you can go to Recipe and Advanced Setup Screens (pages 34-44) or System Configuration Screens

(pages 28-33). Press the Enter key to go to the selected screen set.

The screen also displays software versions and internet addresses of various components. The values shown in F

IG. 25 are only examples and may vary on your screen.

See Table 3 for further information.

on the Status Screen.

IG. 24. Setup Locked Screen

26 3A1080H

Setup Mode

Table 3: Component Software Versions

Display (may vary from

Component

examples shown) Description

EK (EasyKey) 3.01.001 EasyKey software version.

FP (Fluid Plate) 3.01.001 Fluid Plate software version.

BC (Booth Control) -.- Booth Control not installed, not detected, or not operational.

1.XX Booth Control software version 1.00 or 1.01.

2.XX Booth Control software version 2.XX.

C1/C2 (Color Change Modules 1 and 2)

-.- Color Change Module 1/2 not installed, not detected, or not operational.

1.XX Color Change Module software version 1.00 or 1.01.

2.XX Color Change Module software version 2.XX.

AK (Autokey) No Key No AutoKey installed or detected. System operates in 2K Manual

Mode only

2K-Auto 2K AutoKey detected. System can operate in 2K Manual, Semi-auto-

matic, or Automatic Mode.

3K-Auto 3K AutoKey detected. System can operate in 3K Manual, Semi-auto-

matic, or Automatic Mode.

XP (XPORT) V6.6.0.2 Example of XPORT network module software version. Other versions

are acceptable.

MC (Micro Controller) 1042.0198 Example of fluid plate micro controller version. Other versions are

acceptable.

Axx By Cz A30 B4 C4 Color Change board valve configuration. This shows the number of

valves available for each of the components. This is set by the configuration switches on the color change boards connected to the system.

Code Description

- Component not available with this machine configura-

tion.

x Component not used with this machine configuration.

1 Component available but no change stack.

4-30 Component available with change stack.

Number of valves flushed with a solvent valve.

IP (Internet Address) 192.168.178.3 Example of the address EasyKey is set to for basic and advanced

web interface reporting.

MAC (MAC address) 00204AAD1810 Example of internet MAC address. Each EasyKey will have a different

value in this format.

3A1080H 27

Setup Mode

TI12804a

System Configuration Screens

NOTE: See FIG. 26 for a map of the System Configuration Screens. Detailed screen descriptions follow.

NOTE: Each screen displays the current screen number

and the total number of screens in the group.

IG. 26. System Configuration and Option Screens Map

28 3A1080H

Setup Mode

Configure Screen 1

IG. 27. Configure Screen 1

Language

Defines the language of the screen text. Select English (default), Spanish, French, German, Italian, Dutch, Japanese (Kanji), Korean, Chinese (Simplified), and Custom.

NOTE: Refer to document 313386 for instructions on using the Custom Language feature to modify the screens to support undefined languages.

Password

The password is only used to enter Setup mode. The default is 0, which means no password is required to enter Setup. If a password is desired, enter a number from 1 to 9999.

Screen Timeout

Select the desired screen timeout in minutes (0-99). 5 is the default.

Configure Screen 2

FIG. 28. Configure Screen 2

Month

Enter current month.

Day

Enter current day.

Year

Enter current year (four digits).

Time

NOTE: Be sure to write down the password and keep it

in a secure location.

Display Units

Select the desired display units:

• cc/liter (default)

• cc/gallon

Buzzer Alarms

As the default, the alarm buzzer is set to “Potlife Only” and will sound only for the Potlife Alarm (E-2).

Set to “All Alarms” to have the buzzer sound for any alarm.

Set to “All Except Potlife” to have the buzzer sound for any alarm except a Potlife Alarm (E2). This option is not recommended unless another active method of handling the Potlife Alarm is implemented.

3A1080H 29

Enter current time in hours (24 hour clock), minutes, and seconds. Seconds are not adjustable.

Date Format

Select MM-DD-YYYY, DD-MM-YYYY, or YYYY-MM-DD.

Setup Mode

Configure Screen 3

IG. 29. Configure Screen 3

1K/2K/3K

Set this value to indicate the system performance level designation. Selecting a value other than the installed system level will result in restricted functionality.

Run Mode

NOTE: If an Autokey is installed, additional selections of

Semi-Automatic and Automatic are available.

Configure Screen 4

FIG. 30. Configure Screen 4

Dose Time Alarm

Enter the dose time (1 to 99 seconds). This is the amount of time allowed for a dose to occur before a dose time alarm occurs.

Configure Screen 5

Select the Run mode application from the pulldown menu: Automatic, Semi-Automatic (uses a manual spray gun), or Manual.

Dump Valve A

This field only appears if the color change option is detected from the cc board. Select “On” if an optional Dump Valve A is installed and desired to be used.

3rd Flush Valve

Off is default. If optional 3rd flush valve is used, set to On.

IG. 31. Configure Screen 5

Flow Control

This field only appears if Run Mode is set to “Automatic” in Configure Screen 3, page 30. Select “On”, “Off”, or “On: Setup”.

If set to “On” Advanced Setup Screen 5, page 37 and Advanced Setup Screen 6, page 38 are added.

If set to “On: Setup” Advanced Setup Screen 5, page 37 and Advanced Setup Screen 6, page 38, and Advanced Setup Screen 7, page 38 are added.

30 3A1080H

Setup Mode

Special Outputs

Select special outputs (0-4, or 3 + GFB on #4). A selection of “0” will disable use of the Special Outputs. If the “3 + GFB on #4” selection is chosen, the other 3 special outputs (1-3) can be used for user-defined functions and the special output #4 settings will duplicate those settings established for the Gun Flush Box.

Each output has two different start times and durations defined on the Recipe Setup screen (Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32), or on the Advanced Setup screen (Flush and Fill Input is set to “Global” in Option Screen 1, page 32).

NOTE: At system power up, the Special Outputs may activate for up to 1/4 second.

Solvent Monitor

Select solvent monitor (Off, Flow Switch, or Meter).

Web Browser IP

The default web browser IP address prefix is

192.168.178.__ Assign a unique number for each EasyKey in your system (1-99) and enter it here.

Configure Screen 6

IG. 32. Configure Screen 6 (Automatic mode shown)

Flow Set Source

This field only appears if Run Mode is set to “Automatic” in Configure Screen 3, page 30 and Flow Control is set to “On” in Configure Screen 5, page 30. Select “Discrete” or “Network.”

Proportioning

Select “Discrete” or “Network.”

Gun 1 Trigger

Select “Discrete”, “Network”, or “AFS 1” if Run Mode is set to “Automatic” or “Semi-automatic” in Configure

Screen 3, page 30.

Gun 2 Trigger

Displays AFS if Number of Guns is set to “2” in Configure Screen 4, page 30.

Control Network ID

Used for the Graco Gateway network system. See Graco Gateway manual 312785 for further information

3A1080H 31

Setup Mode

Option Screens

NOTE: See FIG. 26 on page 28 for a map of the Option Screens. Detailed screen descriptions follow.

NOTE: Each screen displays the current screen number

and the total number of screens in the group.

Option Screen 1

IG. 33. Option Screen 1

Minimum Material Fill Volume

Enter 0-9999 cc.

Verification Screen

FIG. 34. Verification Screen

Verification

This screen appears if Flush and Fill Input or K-factor Input are changed from “Recipe” to “Global” in Option

Screen 1.

Flush Volume Check

This field only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 30.

If set to “On”, Minimum Flush Volume will appear in Rec-

ipe Setup Screen 2, page 41.

Flush and Fill Input

If set to “Global”, Color/Catalyst Purge and Color/Catalyst Fill are added to Advanced Setup Screen 1, page

35. Advanced Setup Screen 2 and 3 are added. See pages 36-39.

If set to “Recipe”, Color/Catalyst Purge and Color/Catalyst Fill are added to Recipe Setup Screen 2, page 41. Recipe Setup Screen 3, 4, and 7 are added. See pages 42-44.

K-factor Input

Global mode is useful when the material properties, flush and fill characteristics, or K-factors are the same for all materials used by the system.

If set to “Global,” Advanced Setup Screen 4, page 37 is added.

If set to “Recipe,” Recipe Setup Screen 5, page 43, is added.

32 3A1080H

Setup Mode

Option Screen 2

IG. 35. Option Screen 2

External Color Change

If set to “Off”, Color/Catalyst Purge Time and Color/Catalyst Fill Time appear in Advanced Setup Screen 1, page 35 or Recipe Setup Screen 2, page 41 (depending on whether Flush and Fill Inputs are set to “Global” or “Recipe”).

To disable the Solvent Push feature, set to “Off.”

B Purge After Chop

NOTE: This is used to isolate the Chop cycle from the

Final Purge cycle with solvent to prevent reaction issues with some types of materials.

Optional 2-second burst (2 s B) operation of the B Purge valve on the integrator after the Chop cycle.

See Color Change Sequences, page 104 for color change charts and timing information.

If set to “On”, these fields are removed from the screens.

Auto Dump

If the auto dump feature is being used, set to “On”. Once the auto dump is enabled, the gun flush box is enabled and the potlife alarm is active for 2 minutes, the system will automatically flush out the old material.

This feature is only available in Semi-automatic mode when a Gun Flush Box is installed.

Flow Rate Monitor

This field only appears if Flow Control is set to “Off” in Configure Screen 5, page 30.

If set to “On,” Recipe Setup Screen 6 on page 43 is added, enabling setting of high and low flow limits.

If set to “Off,” flow rate monitoring is disabled and Rec-

ipe Setup Screen 6 on page 43 will not appear.

Solvent Push Enable

NOTE: See Solvent Push Feature on page 101 for

more information.

To enable the Solvent Push feature, select “Solvent” or “3rd Valve” (available if 3rd Flush Valve in Configure Screen 3, page 30, is set to “On”).

3A1080H 33

Setup Mode

TI12805b

Advanced Setup screens 2, 3, 4, and 10

appear depending on selections made in

Option screens 1 and 2. Screens 5 and 6

appear if Flow Control is set to “On” in

Configure screen 5. Screens 5, 6, and 7

appear if Flow Control is set to “On: Setup”

in Configure screen 5.

Advanced Setup Screens

NOTE: See FIG. 36 for a map of the Advanced Setup Screens. Detailed screen descriptions follow.

IG. 36. Advanced Setup Screens Map

34 3A1080H

Setup Mode

NOTE: Each screen displays the current screen number and the total number of screens in the group. The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens. The title at the top of the Advanced Setup screens will display “Global” when Flush and Fill on Option Screen 1, page 32 is set to “Global”.

Advanced Setup Screen 1

IG. 37. Advanced Setup Screen 1

Flow Control Override

This field only appears if Flow Control is set to “On” in Configure Screen 5 on page 30. The selections made will affect the display in Manual Override Screen on page 22. Choose the desired selection as defined

below:

Manual Override

This field only appears if Run Mode is set to “Automatic” or “Semi-automatic” in Configure Screen 3, page 30. Set to “On: EK” to override all outside control using the Manual Override “Flow Set Point” control to set the flow rate. Set it to “On: EXT” to use the Flow Set Source on Configure Screen 6, page 31 to determine if the flow rate is set from the Discrete or the Network input. If selected, the Manual Override Screen (page 22) will be added, and the Flow Control Override field appears (see above).

Gun 1/Gun2 Potlife Volume

Enter the potlife volume (1 to 1999 cc) for each gun. This is the amount of material required to move through the mix manifold, hose and applicator/gun before the potlife timer is reset.

Use the following information to determine approximate pot life volume (PLV) in cc:

Hose ID (inches) Volume (cc/foot)*

3/16 5.43

1/4 9.648 3/8 21.71

Integrator manifold and mixer volume = 75 cc Spray Gun Volume = 20 cc

(Hose Volume* x Feet of Hose) + 75 + 20 = PLV

Selection Description

Off Normal operation % Open Flow control regulator is opened to a

desired percentage.

Pressure Flow control regulator is opened to a

calibrated pressure.

ExtSP External Setpoint. The regulator out-

put voltage is set to a percentage of full scale. The range is 0 to 10000 which correlates to 0 to 100.00%. The register used for this is setup.RegManualPercent, at address 40120.

Color/Catalyst Purge

NOTE: ProControl 1KS uses Color only.

This field only appears if the system includes a color change module and Flush and Fill Input is set to “Global” in Option Screen 1, page 32. Enter the purge time (0 to 99 seconds). It refers to the amount of time required to flush the lines from the color or catalyst module to the dose valve or dump valve.

Color/Catalyst Fill

NOTE: ProControl 1KS uses Color only.

This field only appears if the system includes a color change module and Flush and Fill Input is set to “Global” in Option Screen 1, page 32. Enter the fill time (0 to 99 seconds). It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve.

3A1080H 35

Setup Mode

Advanced Setup Screen 2

IG. 38. Advanced Setup Screen 2

This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32.

First Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure

Screen 3 on page 30).

Chop Type

Select “Air/Solvent” or “Air/3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30). This refers to the process of mixing air and solvent (or air and 3rd flush fluid) together during the flush cycle, to help clean the lines and reduce solvent usage.

Final Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure

Screen 3 on page 30).

Air Chop Time

Advanced Setup Screen 3

FIG. 39. Advanced Setup Screen 3

This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32.

If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

First Purge Time

Enter the first purge time (0 to 999 seconds).

Total Chop Time

Enter the total chop time (0 to 999 seconds).

Final Purge Time

Enter the final purge time (0 to 999 seconds).

Mixed Material Fill Time

Enter the mixed material fill time (0 to 999 seconds). It refers to the amount of time that is required to load mixed material from the dose valves to the applicator/gun.

Enter the air chop time (0.0 to 99.9 seconds).

Solvent Chop Time/3rd Flush Valve Chop Time

Enter the solvent or 3rd flush valve chop time (0.0 to

99.9 seconds).

36 3A1080H

Setup Mode

Advanced Setup Screen 4

IG. 40. Advanced Setup Screen 4

This screen appears only if K-factor Input is set to “Global” in Option Screen 1, page 32.

K-factor A Meter

Enter the k-factor (cc/pulse) for flow meter A. This is the amount of material that passes through the flow meter per pulse (electrical pulse signal).

K-factor Solvent Meter

This field only appears if Solvent Monitor in Configure Screen 5, page 30, is set to “Meter.” Enter the k-factor

(cc/pulse) for the solvent flow meter.

Advanced Setup Screen 5

FIG. 41. Advanced Setup Screen 5 (Automatic Mode with Flow Control Only)

This screen appears only if Flow Control is set to either “On” or “On: Setup” in Configure Screen 5, page 30.

Range

Enter the flow rate range (0-300, 0-600, or 0-1200). This determines the flow control PID loop resolution.

Tolerance

Enter the flow rate tolerance (1 to 99%). This is the percentage of variance that the system will allow before a flow rate warning/alarm occurs.

Alarm Time

Enter the flow rate alarm time (1 to 99 seconds).

Enter the flow rate Ki (flow control PID loop integral value). Output drive amount based on the accumulation of error between the command and measured pressures scaled to the output transducer.

Enter the flow rate Kp (flow control PID loop proportional value). Output drive amount based on the instantaneous error between the command and measured pressures scaled to the output transducer.

Enter the flow rate Kd (flow control PID loop derivative value). Output drive amount based on the change of error between the command and measured pressures scaled to the output transducer.

3A1080H 37

Setup Mode

Advanced Setup Screen 6

IG. 42. Advanced Setup Screen 6

This screen appears only if Flow Control is set to either “On” or “On: Setup” in Configure Screen 5, page 30.

One-Point threshold

Flow Control runs in Pressure mode for flow setpoints below this value. If the setpoint is at or above this value, a linear calibration is made from (0, 0) to the point.

Learn Strength

This controls how much of the flow error signal is applied when adjusting the Pressure-Flow curve. It will always target the same flow. Because the flow control drives to pressure, the reported flow rate may jump around. However, if the material is consistent and the pressure is constant, then the actual flow is correct.

Advanced Setup Screen 7

FIG. 43. Advanced Setup Screen 7

This screen appears only if Flow Control is set to “On” in

Configure Screen 5, page 30.

Command holdoff

Learn blanking time after setpoint command change. Flow learning is turned off during this interval. May be reduced for systems that have less than around x2 from minimum to maximum pressure setpoints. May need to be increased for systems with wide pressure swings.

Gun trigger holdoff

Learn blanking time after gun trigger is opened. Flow learning is turned off during this interval. May be reduced for high-pressure systems. May need to be increased for low-pressure systems.

Pressure zero offset

Zero-pressure calibration adjustment for pressure sensor. Used primarily for accurate flow rate calculation in Pressure mode. This is added to the pressure reading, so a negative value zeroes out a positive offset.

Pressure intercept

Pressure-axis intercept of Pressure-Flow curve to match the slope with the actual response.

38 3A1080H

GT-Off drive time

Time to drive to pressure while the gun trigger is off.

GT-Off target rise

The additional pressure to control to based on flow rate setpoint when the gun is closed. This allows the system to be close to the pressure target when the gun is opened.

Purge drive

Output drive during the Purge sequence. Maximum of 3300 mV.

Valve holdoff maximum

The maximum learn blanking time after dose valve change. This is adjusted based on how much learning was needed per dose changeover up to this maximum value.

Setup Mode

Advanced Setup Screen 8

IG. 44. Advanced Setup Screen 8

This screen shows the status of digital inputs, digital outputs, and the Flow Control voltage input. If box is shaded the input is active. If not, input is off. See pages 52-54 for details on the inputs and outputs.

Advanced Setup Screen 9

Advanced Setup Screen 10

FIG. 46. Advanced Setup Screen 10

This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32 and Special Outputs is set to 1, 2, 3, 4, or 3 + GFB on #4 in Configure Screen 5, page 30. The I/O board has four programmable outputs.

NOTE: If 3 + GFB on #4 is selected, this screen will only display columns for Special 1, 2, and 3. Column Special 4 is not displayed because this output has assumed the same settings as those assigned to the Gun Flush Box #1.

IG. 45. Advanced Setup Screen 9

This screen shows the status of digital inputs and digital outputs. If box is shaded the input is active. If not, input is off. See pages 52-54 for details on the inputs and outputs.

On-Purge

Delay time at the start of the purge cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the purge cycle.

On-Fill

Delay time at the start of the fill cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the fill cycle.

3A1080H 39

Setup Mode

TI12806a

Recipe 0 Screens

Recipe screens 3, 4, 5, 6,

and 7 appear depending on

selections made in Option

screens 1 and 2

Recipe Setup Screens

NOTE: See FIG. 47 for a map of the Recipe screens. Detailed screen descriptions follow.

IG. 47: Recipe Screens Map

40 3A1080H

Setup Mode

Option Screens.

Recipe Setup Screen 1

IG. 48. Recipe Setup Screen 1

Color Valve

This field only appears if the system includes a color change module. Enter the color valve number (1 to 30).

Recipe Setup Screen 2

FIG. 49. Recipe Setup Screen 2

Minimum Flush Volume

This field only appears if Flush Volume Check is set to “On” in Option Screen 1 on page 32. Enter the minimum flush volume (0 to 9999 cc). Entering 0 disables this function.

Color/Catalyst Purge

NOTE: ProControl 1KS uses Color only.

This field only appears if the system includes a color change module and Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32. Enter the purge time (0 to 99 seconds). It refers to the amount of time required to flush the lines from the color or catalyst module to the dose valve or dump valve.

Color/Catalyst Fill

NOTE: ProControl 1KS uses Color only.

This field only appears if the system includes a color change module and Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32. Enter the fill time (0 to 99 seconds). It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve.

3A1080H 41

Setup Mode

Recipe Setup Screen 3

IG. 50. Recipe Setup Screen 3

This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32.

First Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure

Screen 3 on page 30).

Chop Type

Final Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure

Screen 3 on page 30).

Air Chop Time

Enter the air chop time (0.0 to 99.9 seconds).

Recipe Setup Screen 4

FIG. 51. Recipe Setup Screen 4

This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32.

In Automatic mode, only one gun is allowed. In Semi-automatic mode, two guns are allowed. If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

First Purge Time

Enter the first purge time (0 to 999 seconds).

Total Chop Time

Enter the total chop time (0 to 999 seconds).

Final Purge Time

Enter the final purge time (0 to 999 seconds).

Mixed Material Fill Time

Enter the mixed material fill time (0 to 999 seconds). It refers to the amount of time that is required to load mixed material from the dose valves to the applicator/gun.

Solvent Chop Time/3rd Flush Valve Chop Time

Enter the solvent or 3rd flush valve chop time (0.0 to

99.9 seconds).

42 3A1080H

Setup Mode

Recipe Setup Screen 5

IG. 52. Recipe Setup Screen 5

This screen appears only if K-factor Input is set to “Recipe” in Option Screen 1, page 32.

K-factor A Meter

Enter the k-factor (cc/pulse) for flow meter A. This is the amount of material that passes through the flow meter per pulse (electrical pulse signal).

Recipe Setup Screen 6

FIG. 53. Recipe Setup Screen 6

This screen appears only if Flow Rate Monitor is set to “On” in Option Screen 2 on page 33.

Flow Rate Monitor

Select the desired flow rate monitoring (Off, Warning, or Alarm).

Low Flow Limit

K-factor Solvent Meter

This field only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 30. Enter the k-factor (cc/pulse) for the solvent flow meter.

Enter the low flow rate limit (1 to 3999 cc/min).

High Flow Limit

Enter the high flow rate limit (1 to 3999 cc/min).

3A1080H 43

Setup Mode

Recipe Setup Screen 7

IG. 54. Recipe Screen 7

This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32 and Special Outputs is set to 1, 2, 3, or 4 in Configure Screen 5, page

30. The I/O board has four programmable outputs.

On-Purge

Delay time at the start of the purge cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the purge cycle.

On-Fill

Delay time at the start of the fill cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the fill cycle.

44 3A1080H

Recipe 0 Screens

Setup Mode

NOTE: See FIG. 47 on page 40 for a map of the Recipe 0 screens. Detailed screen descriptions follow.

Recipe 0 is typically used in multiple color systems to purge out material lines without loading a new color

Option Screens.

Recipe 0 Screen 1

Final Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure

Screen 3 on page 30).

Air Chop Time

Enter the air chop time (0.0 to 99.9 seconds).

Solvent Chop Time/3rd Flush Valve Chop Time

Enter the solvent or 3rd flush valve chop time (0.0 to

99.9 seconds).

Recipe 0 Screen 2

IG. 55. Recipe 0 Screen 1

First Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure

Screen 3 on page 30).

Chop Type

FIG. 56. Recipe 0 Screen 2

If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

Color/Catalyst Purge Time

NOTE: ProControl 1KS uses Color only.

This field only appears if the system includes a color change module. It refers to the amount of time required to flush the lines from the color or catalyst module to the dose valve or dump valve. Enter the purge time (0 to 999 seconds).

First Purge Time

Enter the first purge time (0 to 999 seconds).

Total Chop Time

Enter the total chop time (0 to 999 seconds).

Final Purge Time

Enter the final purge time (0 to 999 seconds).

3A1080H 45

Setup Mode

Recipe 0 Screen 3

IG. 57. Recipe 0 Screen 3

This screen only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 30 and Flush Vol- ume Check is set to “On” in Option Screen 1, page 32 or 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30.

Minimum Flush Volume

This field only appears if Flush Volume Check is set to “On” in Option Screen 1 on page 32. Enter the minimum flush volume (0 to 9999 cc).

Exiting Fill Source

This field only appears if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30. Select “Off,” “Air,” “Solvent,” or “3rd Valve.”

Exiting Fill Time

This field only appears if Exiting Fill Source is set to “Air,” “Solvent,” or “3rd Valve.” Enter the time in seconds.

Recipe 0 Screen 4

FIG. 58. Recipe 0 Screen 4

This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32 and Special Outputs is set to 1, 2, 3, or 4 in Configure Screen 5, page

30. The I/O board has four programmable outputs.

On-Purge

Delay time at the start of the purge cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the purge cycle.

On-Fill

Delay time at the start of the fill cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the fill cycle.

46 3A1080H

Calibration Screen

IG. 59. Calibration Screen

Use this screen to calibrate a meter. Set to “A Meter” or “Solvent Meter” (available if Solvent Monitor in Config- ure Screen 5, page 30, is set to “Meter”).

Setup Mode

• Start - start calibration

• Abort - stop calibration

• Purge - purge sampling valves after calibration

See Meter Calibration, page 102, for when and how to calibrate meter.

3A1080H 47

Setup Mode

48 3A1080H

ProControl Integration Specifics

System Setup for Automatic Operation

Configuration of the options for ProControl 1KS Automatic operation is done through a few setup screens. Several utility screens are also available for debug and verification.

First, set the ProControl 1KS to Automatic mode:

FIG. 62. Configure Screen 6

Flow Set Source

This appears only if Flow Control is turned on. Select “Discrete” or “Network”.

ProControl Integration Specifics

IG. 60. Configure Screen 3

If Flow Control is used, then turn it on. There are two activation options: “On”, and “On: Setup”. The only difference is that “On: Setup” allows the display of the

“Flow Control Tuning” screen.

IG. 61. Configure Screen 5

In Discrete mode control is driven through the analog voltage input. In Network mode control is driven through a Modbus register.

Proportioning

Select “Discrete” or “Network”.

In Discrete mode control is driven through the Discrete I/O board. In Network mode control is driven through a Modbus register.

NOTE: It is not possible to read back the active recipe number using the Discrete I/O interface.

Gun 1 Trigger

Select “Discrete”, “Network”, or “AFS 1”.

In Discrete mode the gun trigger control is read by an EasyKey digital input and sent to the Fluid Panel. In Network mode it is written to the EasyKey over the Modbus interface. In AFS 1 mode it is applied to the Fluid Panel in the Hazardous location.

NOTE: Discrete I/O is recommended. It is easy to connect in the normal location to the PLC. AFS 1 mode is used for special cases where the gun trigger timing is critical.

Several control interface options are available when using Automatic mode.

3A1080H 49

NOTE: Network gun trigger with Flow Control has a long time delay through the PLC to ProControl communications structure. This will negatively affect Flow Control operation.

ProControl Integration Specifics

Control Network ID

Select the Modbus address of the ProControl 1KS. The range is from 1 though 247.

Modbus communications for reading back information is available even when Discrete I/O control is enabled.

Status Verification of Automatic Operation

Several screens allow viewing of control interface status information.

Discrete I/O bits as used on the ProControl 1KS are available in Advanced Setup Screen 8 and Advanced Setup Screen 9 If control is through the Network interface the status data comes from those registers.

This data is updated live.

Discrete I/O vs Network Communications

The ProControl 1KS Automatic system does not use a Booth Control. Instead, it uses Discrete I/O or Network Communications to drive the system. Each method can be used exclusively, or both at the same time.

In Automatic mode, the following fields can be set to “Discrete” or “Network” (see Configure Screen 6 on page 31):

• Flow Control

• Proportioning

• Gun 1 Trigger

NOTE: In Semi-automatic mode, only the Proportioning field is available.

NOTE: The Manual Override function enables you to operate the system before the automation (PLC) is available. Manual Override still requires some communication through Discrete I/O or Network Communications. Although Manual Override is not intended to be the main mode of control, it can be used if proper Gun Trigger Input is provided.

IG. 63. Advanced Setup Screen 8

IG. 64. Advanced Setup Screen 9

50 3A1080H

ProControl Integration Specifics

Display Board Barrier Board

Discrete I/O Board (see FIG. 67)

TI12496a

Terminal Strips (see F

IG. 66)

Discrete I/O

Discrete I/O requires a 24 Vdc power supply which must be supplied on site. The ProControl does not supply power for Discrete I/O.

See Table 4 on page 54, F 9 on page 64 for inputs and outputs. Understanding these inputs and outputs is necessary to properly integrate the ProControl 1KS to the automation.

Input and output connections are made at the Discrete I/O terminal strips (F (F

IG. 67) inside the EasyKey. Also see the System

Electrical Schematic on page 131.

IG. 73 on page 63, and Table

IG. 66) and the discrete I/O board

Review the Color Change Charts (F

IG. 110-FIG. 119). A

full understanding of the color change sequence is necessary to properly drive the inputs and monitor the outputs.

See Advanced Setup Screen 9, page 39. This screen shows the actual status of all inputs and outputs. It is important to ensure that each input from local automation (PLC) is received by the EasyKey and to verify that the ProControl 1KS is sending outputs to the automation.

The following paragraphs describe each discrete I/O function in detail.

IG. 65: EasyKey Control Boards

3A1080H 51

ProControl Integration Specifics

Pin 1

TI12958a

RS485 Integration A

Flow Rate Analog Common

Alarm Reset

Remote Stop

Digital Common

Gun Trigger

Flow Control Calibrate

Flow Rate Analog In

Potlife Alarm

Digital Common

General Alarm

RS485 Integration B RS485 Integration Ground RS485 Network A (unused) RS485 Network B (unused)

RS485 Network Ground (unused)

I/O Terminal Strip Detail

INPUTS

OUTPUTS

Digital Inputs

See Automation Flow Charts, pages 55-59.

Mix Start: This is a maintained input. When High, the

ProControl 1KS will attempt to enter Mix mode. This Mix Start input should not be attempted unless the Mix_Ready output is recognized. This ensures that there are no alarms and that the Mix Start input is appropriate.

This input stays High at all times when mixing on demand is required. When Low, the intent is to stop mixing material and perform a purge or recipe change.

Do not toggle this input to set the unit to Standby mode during short work stoppages. The ProControl 1KS will automatically go into Idle mode after 2 minutes of inactivity. When a Gun Trigger input is seen, the ProControl 1KS will automatically leave Idle mode and resume mixing material where it left off.

Purge Start: This is a maintained input. When recog- nized by the ProControl 1KS, the Purge Sequence will start, using the Purge Time from the active recipe. This will also include the Solvent Fill Time. Proper monitoring of the Purge/Color Change Output is required to ensure this function has begun. Once this output is removed, the system will immediately go to Standby mode.

Gun Trigger: When High, this input signals the ProControl 1KS that the gun is actually triggered. It should be sent every time the gun is triggered. This input provides timing for alarm functions and also drives the flow control functions. Without it, no flow control functions will start.

Job Complete: This is a momentary input, 100 msec minimum. When recognized by the ProControl 1KS, the Job totals are cleared and a time/date stamp is added for retrieval.

Remote Stop: Use this input when external equipment is used to stop the system. Clear any alarms before using this input. For more information about when this input is needed, contact your Graco distributor.

Alarm Reset: This is a momentary input, 100 msec minimum. When recognized by the ProControl 1KS it clears any active alarms and allows the automation to take the next step.

Common: This is not an input, but the ProControl 1KS expects to have the COM side of the 24 Vdc supply connected as shown in Table 9. This ensures proper opera-

tion of each input and output.

Color Change Start: This is a momentary input, 100 msec minimum. When recognized by the ProControl 1KS, the Color Change sequence will begin, starting at the Color/Catalyst Dump.

NOTE: If the new recipe has the same color as the active recipe, then the Color/Catalyst Dump and Color/Catalyst Fill times are skipped and the Color Change Sequence starts with the Purge. Also, the recipe bit configuration for the Color Change must be loaded at least 100 msec before the Color Change Start input is turned on. The recipe bit configuration must remain on while the Color Change Start input is removed. Graco recommends the recipe bits stay active and do not change until a new color is required. The PLC should monitor the Purge/Color Change Output as well as the Fill Active Output to ensure the process happens as required. A complete color change without errors (resulting in a Mix Ready Output state) is a completed color change.

NOTE: This also applies if using the Modbus Registers (see the Modbus Map table in manual 312785).

52 3A1080H

IG. 66: EasyKey Terminal Strips

ProControl Integration Specifics

JLS

Purge Input

Job Complete Input

External Color Change Ready

Solvent Push Enable

Digital Input Common

Special Output #4

Mix Input

Recipe Change Input

Recipe Bit 0 Input

Flow Rate Alarm Output

Flow Control Calibrate Active

Fill Active

Mix Ready Output

Mix Active Output

Purge/Recipe Change Active Output

Digital Output Common/Power

Digital Output

Common/Power

Special Output #3

Special Output #2

Special Output #1

Digital Input Common

Recipe Bit 5 Input

Recipe Bit 4 Input

Recipe Bit 3 Input

Recipe Bit 2 Input

Recipe Bit 1 Input

Digital Output

Common/Power

FIG. 67: 255766 Discrete I/O Board

3A1080H 53

ProControl Integration Specifics

Digital Outputs

See Automation Flow Charts, pages 55-59.

Purge_CC_Active: This output will remain High during

the manual Purge or Color Change purge sequence. See the Color Change Charts (F ther information.

Fill_Active: This output will remain High while the ProControl 1KS is in the Mixed Material Fill at the end of a typical color change sequence.

Mix_Active: This output will remain High while the ProControl 1KS is in Mix mode. There may be alarm outputs while this output is High; these are typically High/Low Flow Warnings. Always monitor this output and the alarm outputs to provide feedback of the actual status of the ProControl 1KS. (See the Modbus charts in the Graco Gateway manual 312785.)

Mix_Ready: This output will remain High while there are no alarms and the ProControl 1KS is ready to go to Mix mode.

General Alarm: This output will remain High when any alarm is active. See Table 17 on page 118 for a complete list of alarms.

IG. 110-FIG. 119) for fur-

Analog Inputs

Flow Command: This is the positive side of the 0 – 10

Vdc signal. (See Common under Digital Inputs, page

52.) This input corresponds to the Flow Range setting in Advanced Setup Screen 5, page 37. For example, if the setting is 0 – 300 cc/min, the 0 Vdc analog input is 0 cc/min, therefore the 10 Vdc analog input is 300 cc/min.

Table 4: Sourcing/Sinking Inputs and Outputs

Inputs (Automation Sourcing)

1 Flow Control Calibration Black +

2 Gun Trigger White +

3 Digital In Common Red -

4 Remote Stop Green +

5 Alarm Reset Brown +

Outputs (Automation Sourcing)

6 Alarm Output Blue +

7 Digital Out Common Orange -

8 Pot Life Yellow +

Outputs (Automation Sinking)

NOTE: It is important to monitor this output along with

Mix_Active to understand the alarm’s true meaning.

Alarm_Potlife: This output will remain High along with the Alarm output when the potlife time has been reached for the active recipe. The Mix_Active output will drop Low, even if the Mix_Start input is High. This output will remain High until the potlife volume is dispensed or the ProControl 1KS completes a Purge or a Color Change. The Alarm Reset input will not stop this output but will silence the audible alarm on the EasyKey.

NOTE: The Alarm Reset

audible alarm.

To dispense the potlife volume, the ProControl 1KS Mix_Start input must be turned Off then back to High to spray material. At this point, Mix_Active, Alarm, and Alarm_Potlife outputs will be High until the potlife volume is sprayed.

Digital Out Supply: This is the supply for the digital outputs. It is the same supply for the digital inputs. (See

Common under Digital Inputs, page 52.)

key will also reset the

6 Alarm Output Blue -

7 +24 Volts Orange +

8 Pot Life Yellow -

Automation

9 Flow Rate Analog In Purple +

10 Flow Rate Analog Common Gray -

54 3A1080H

Automation Flow Charts

Start Mix Mode

Process

Is Mix Ready

bit = 1?

Must be Alarm Condi-

tion or Active Recipe

61. See Alarm Pro-

cessing on page 59,

or Startup from Recipe

61 (see NOTE below)

Set Mix bit = 1

Is Mix Active

bit = 1?

ProMix in Mix Mode

(Complete) Mix

Active = 1 while the

ProMix is in Mix

mode

YESNO

YES

NOTE: At power up the system defaults to Recipe 61, which is not a valid recipe number. Initiate a color change to Recipe 0 or a valid recipe number (1-60).

Start Mix Mode Process

See FIG. 68, Table 5, and Table 6.

ProControl Integration Specifics

IG. 68. Start Mix Mode Process Flow Chart

3A1080H 55

ProControl Integration Specifics

Mixing Mode

Process

Is Mix Active

bit = 1?

Check Alarm

Condition: is Alarm_

General bit = 1?

YESNO

YES

Mixing Mode is desired. PLC is polling to ensure

Mixing Mode is main-

tained.

Mixing Process active

Go to Start Mix Mode

Process, page 55

Go to Alarm Process-

ing, page 59

Mixing Mode Process

See FIG. 69, Table 5, and Table 6.

IG. 69. Mixing Mode Process Flow Chart

56 3A1080H

Purge Mode Process

Start

Is Mix Ready

bit = 1?

Must be Alarm

Condition or Active

Recipe 61. See

Alarm Processing

on page 59, or

Startup from Recipe

61 (see NOTE

below).

YESNO

YES

ProControl in

Purge_CC Mode

(Process Started)

Set Purge bit = 1?

Is Purge_CC_Active

bit = 1?

Is Mix Ready

bit = 1?

YES

(Wait for Mix Ready)

ProControl Purge

Process (Complete)

NOTE: At power up the system defaults to Recipe 61, which is not a valid recipe number. Initiate a color change to Recipe 0 or a valid recipe number (1-60).

See FIG. 70, Table 5, and Table 6.

ProControl Integration Specifics

IG. 70. Purge Mode Process Flow Chart

3A1080H 57

ProControl Integration Specifics

Color Change

Process

(basic)

Is Purge_CC_Ac-

tive bit = 1?

Check Alarm

Condition: is Alarm_

General bit = 1?

YES NO

YES

Is Active Recipe =

to desired recipe?

(Register 40005).

Clear ColorChange (CC)

bit (momentary input).

CC process started.

Process Alarm. See Alarm Processing,

page 59.

Load ccNewRecipe

(Register 40046) with

recipe number to Color

Change to (0 through

60 is valid).

Do nothing.

Spraying at

desired recipe.

YES

Set ColorChange (CC)

bit = 1.

ProMix Color Change

Process (Complete)

Is Mix Ready

bit = 1?

(Wait for Mix Ready)

YES

Ensure Col-

orChange bit is

seen by ProMix

Color Change Mode Process

See FIG. 71, Table 5, and Table 6.

IG. 71. Color Change Mode Process Flow Chart

58 3A1080H

Alarm Processing

Is Mix Ready

bit = 1?

Check if Potlife

Alarm: is Alarm_

Potlife bit = 1?

YESNO

NO YES

An Alarm Condition

has been found

previously. Alarm_-

General = 1.

Two options:

• Purge or Color Change to remove mixed material in the line.

• Place in Mix mode and spray the Potlife Volume set in the ProControl.

NOTE: The Reset key only silences the alarm. To clear the alarm you must use one of these two options.

Go to next process,

as desired.

Determine the exact alarm from Table 7 or Table 8 on

page 62 and solve what

caused the alarm, as

required.

Reset the alarm.

Reset_Alarm = 1.

See FIG. 72, Table 5, Table 6, and Table 7 and Table 8.

ProControl Integration Specifics

IG. 72. Alarm Processing Flow Chart

3A1080H 59

ProControl Integration Specifics

Table 5: ProControl 1KS Digital Inputs (Modbus Register 40040)

Bit Digital Input Binary Name Details

0:5 0000000000XXXXXXRecipe Binary bits for viewing discrete inputs only.

6 000000000

1000000Color Change

Set bit to “1” to initiate Color Change (momentary)

(CC)

7 00000000

8 0000000

10000000Mix Set bit initiate Mix mode (maintained)

100000000Purge Set bit to “1” to initiate Purge sequence (maintained)

9 0000001000000000Job_Complete Set bit to “1” to initiate Job Complete input (momen-

tary)

10 0000010000000000External CC

Ready

11 0000100000000000Solvent Push

Set bit to “1” to initiate External Color Change (momentary)

Set bit to “1” to initiate Solvent Push

Enable

12 0001000000000000FC _Calibrate Set bit to “1” to initiate a Flow Control Calibrate input

(momentary)

13 0010000000000000Gun_Trigger Set bit to “1” to indicate the gun is actually triggered

(maintain while gun is triggered, remove when gun is closed)

14 0

100000000000000Reset_Alarm Set bit to “1” to clear an active Alarm (momentary)

15 1000000000000000Remote Stop Set bit to remotely stop unit (momentary)

NOTE: Shaded cells relate to the flow charts on pages 55-59.

60 3A1080H

Table 6: ProControl 1KS Digital Outputs (Modbus Register 40041)

Bit Digital Output Binary Name Details

ProControl Integration Specifics

0 000000000000000

1 00000000000000

2 0000000000000

1 Purge_CC_Active “1” indicates Purge or Color Change is in progress

10Mix_Active “1” indicates Mix is in progress

100Mix_Ready “1” indicates No Alarms and OK to Mix

3 0000000000001000CC_Fill_Active “1” indicates the Fill portion of a Color Change is in

progress

4 0000000000010000FCalActive “1” indicates the Flow Control Calibrate routine is in

progress

5 0000000000100000Flow_Rate_Alarm “1” indicates the Flow Rate Alarm/Warning is

active

6 0000000001000000Special_1 “1” indicates the Special_1 output is on (monitor

only)

7 0000000010000000Special_2 “1” indicates the Special_2 output is on (monitor

only)

8 0000000100000000Special_3 “1” indicates the Special_3 output is on (monitor

only)

9 0000001000000000Special_4 “1” indicates the Special_4 output is on (monitor

only)

10 0000010000000000GFB _1_Copy “1” indicates the output for GFB 1 is on

11 0000100000000000GFB _2_Copy “1” indicates the output for GFB 2 is on

12 0 0 0

1000000000000Alarm_General “1” indicates a General Alarm is in process. (If Mix-

_Active is still High, then a Warning only.) See the Modbus charts in the Graco Gateway manual 312785 for details on type.

13 0010000000000000Alarm_Potlife “1” indicates a Potlife Alarm is in process.

14 0100000000000000AFS _1_Copy “1” indicates the AFS 1 input to the Fluid Panel is

15 1000000000000000AFS _2_Copy “1” indicates the AFS 2 input to the Fluid Panel is

NOTE: Shaded cells relate to the flow charts on pages 55-59.

3A1080H 61

ProControl Integration Specifics

Table 7: ProControl 1KS Low Word Active Alarms (Modbus Register 40010)

Code Hex Binary Code Name

None 0000 0000 0000 0000 0000 No bits set / no active low-word alarm

E-1 0001 0000 0000 0000 0001 Communication Error Alarm

E-2 0002 0000 0000 0000 0010 Potlife Alarm

E-3 0004 0000 0000 0000 0100 Ratio High Alarm

E-4 0008 0000 0000 0000 1000 Ratio Low Alarm

E-5 0010 0000 0000 0001 0000 Overdose A/B Dose Too Short Alarm

E-6 0020 0000 0000 0010 0000 Overdose B/A Dose Too Short Alarm

E-7 0040 0000 0000 0100 0000 Dose Time A Alarm

E-8 0080 0000 0000 1000 0000 Dose Time B Alarm

E-9 0100 0000 0001 0000 0000 Not used

E-10 0200 0000 0010 0000 0000 Remote Stop Alarm

E-11 0400 0000 0100 0000 0000 Purge Volume Alarm

E-12 0800 0000 1000 0000 0000 CAN Network Communication Error

E-13 1000 0001 0000 0000 0000 High Flow Alarm

E-14 2000 0010 0000 0000 0000 Low Flow Alarm

E-15 4000 0100 0000 0000 0000 System Idle Warning

E-16 8000 1000 0000 0000 0000 Setup Change Warning

Table 8: ProControl 1KS High Word Active Alarms (Modbus Register 40010)

Code Hex Binary Code Name

None 0000 0000 0000 0000 0000 No bits set / no active high-word alarm

E-17 0001 0000 0000 0000 0001 Power On Warning

E-18 0002 0000 0000 0000 0010 Defaults Loaded Warning

E-19 0004 0000 0000 0000 0100 I/O Alarm. See Alarm Troubleshooting, page 119

E-20 0008 0000 0000 0000 1000 Purge Initiate Alarm

E-21 0010 0000 0000 0001 0000 Material Fill Alarm

E-22 0020 0000 0000 0010 0000 Tank A Low Alarm

E-23 0040 0000 0000 0100 0000 Tank B Low Alarm

E-24 0080 0000 0000 1000 0000 Tank S Low Alarm

E-25 0100 0000 0001 0000 0000 Auto Dump Complete Alarm

E-26 0200 0000 0010 0000 0000 Color/Catalyst Purge Alarm

E-27 0400 0000 0100 0000 0000 Color/Catalyst Fill Alarm

E-28 0800 0000 1000 0000 0000 Material Advance Complete

E-29 1000 0001 0000 0000 0000 Tank C Low Alarm

E-30 2000 0010 0000 0000 0000 Overdose C Alarm

E-31 4000 0100 0000 0000 0000 Dose Time C Alarm

E-32 8000 1000 0000 0000 0000 Audible Buzzer Active

62 3A1080H

ProControl Integration Specifics

24 Vdc

Input

Output

Output Common

Common

Input

CommonOutput

Output Common

Output

CommonInput

Input Common

ProControl 1KS EasyKey

Digital Input

ProControl 1KS

EasyKey Digital Out-

ProControl EasyKey

Digital Output

PLC Input

(Sourcing)

PLC Input

(Sinking)

PLC Output

(Sourcing)

FIG. 73. Automation 24 Vdc Sourcing Input Diagram

3A1080H 63

ProControl Integration Specifics

Table 9: Discrete I/O Terminal Connections

Pin Port Name Details (also see pages 60 and 61)

Digital Inputs to Remote I/O Board for Proportioning

1 J2 Mix Set Bit to Initiate Mix Mode (maintain)

2 J2 Purge Set Bit to “1” to initiate Purge Sequence (maintained)

3 J2 Job_Complete Set Bit to “1” to initiate Job Complete Input (momentary)

4 J2 External CC Ready Set Bit to “1” to initiate External Color Change (maintained)

5 J2 Solvent Push Enable Set Bit to “1” to initiate Solvent Push

6* J2 Digital Input Common Set Binary Bits for Recipe to Change To (hold until changing again)

Digital Inputs to Remote I/O Board for Color Change

1* J3 Digital Input Common

2 J3 Recipe Bit 0 Set Binary Bits for Recipe to Change To (hold until changing again)

3 J3 Recipe Bit 1 Set Binary Bits for Recipe to Change To (hold until changing again)

4 J3 Recipe Bit 2 Set Binary Bits for Recipe to Change To (hold until changing again)

5 J3 Recipe Bit 3 Set Binary Bits for Recipe to Change To (hold until changing again)

6 J3 Recipe Bit 4 Set Binary Bits for Recipe to Change To (hold until changing again)

7 J3 Recipe Bit 5 Set Binary Bits for Recipe to Change To (hold until changing again)

8 J3 Color Change (CC) Set Bit to “1” to initiate Color Change (momentary)

Digital Inputs to EasyKey 10-Pin Terminal Block for Gun Trigger and Alarm Processing

1 J5 Flow Control Calibrate Set Bit to “1” to initiate Flow Control Calibrate (momentary)

2 J5 Gun Trigger Set Bit to “1” to indicate Gun is Triggered (fluid flow expected)

3† J5 Digital Input Common

4 J5 Remote Stop Set Bit to “1” to initiate a Remote Stop (momentary)

5 J5 Reset_Alarm Set Bit to “1” to Clear an Active Alarm (momentary)

* Digital inputs tied together on the I/O board (see F

IG. 67).

† Digital inputs tied together on the EasyKey Display Board.

Multiple connection points for convenience.

64 3A1080H

ProControl Integration Specifics

Table 9: Discrete I/O Terminal Connections (Continued)

Pin Port Name Details (also see pages 60 and 61)

Digital Outputs from Remote I/O Board for Proportioning

1 J4 Digital Output Common/Power

2 J4 Purge CC Active “1” Indicates Purge or Color Change is in progress

3 J4 Mix Active “1” Indicates Mix is in progress

4 J4 Mix Ready “1” Indicates No Alarms and OK to Mix

5 J4 CC Fill Active “1” Indicates the Fill Portion of a Color Change is in progress

6 J4 FC Cal Active “1” Indicates the Flow Control Calibrate routine is in progress

7 J4 Flow Rate “1” Indicates the Flow Rate Alarm/Warning is active 8 J4 Digital Output Common/Power

Digital Outputs from Remote I/O Board for Special Outputs

1 J5 Digital Output Common/Power

2 J5 Special_1 “1” Indicates the Special_1 Output is on

3 J5 Special_2 “1” Indicates the Special_2 Output is on

4 J5 Special_3 “1” Indicates the Special_3 Output is on

5 J5 Special_4 “1” Indicates the Special_4 Output is on 6 J5 Digital Output Common/Power

Digital Outputs from EasyKey 10-Pin Terminal Block for Alarm and Potlife Indication

6 J5 General Alarm Output “1” Indicates the General Alarm Output is on 7 J5 Digital Output Common/Power

8 J5 Potlife Alarm “1” Indicates the Potlife Alarm Output is on

Analog Input to EasyKey 10-Pin Terminal Block for Flow Rate Set Point

9 J5 Flow Rate Analog In (0-10

VDC)

0 - 10VDC input for Flow Setpoint relative to flow range set in 2KS Flow Range Screen

10 J5 Flow Rate Common to Pin 9 Common side of Flow Setpoint from Terminal 9

Modbus Network Communications on EasyKey 6-Pin Terminal Block

1 J10 RS485 Integration A

2 J10 RS485 Integration B

Communication to External PLC/Controller

3 J10 RS485 Integration

Shield/Ground

4 J10 RS485 Network A

Not used5 J10 RS485 Network B

6 J10 RS485 Network Shield/Ground

 Digital outputs tied together on the I/O board (see F

IG. 67).

 Digital outputs tied together on the EasyKey Display Board.

Multiple connection points for convenience.

3A1080H 65

Modbus and I/O Data

See Table 10 and Table 11 for Modbus register addresses and input/output data.

Reference the Discrete I/O listing of all the inputs and outputs (see page 67). Ensure these are fully understood. The same implementation used for Discrete I/O is used for the Network communication protocol.

For example: The Gun Trigger Input will now be a specific bit of Modbus Register 40040. Monitoring of Modbus Register 40041 for specific output status conditions will be required as explained in the Discrete I/O section of the ProControl 1KS Operation manual. The PLC will have to read the various bits, and in some cases (40040 and 40041 for example) must mask out the various bit positions to determine each of the separate input and output statuses. This requires experience and should not be done on the job site. A full understanding of the color change process as well as the required timing of various inputs and outputs is required.

NOTE: Analog input for flow control set point will now be a dedicated Modbus register. Register 40137 will require the specific flow rate (i.e. 125 cc/min). This is not a voltage reading but the actual flow target.

toggle the Mix bit; doing so restarts the Mix process from the beginning.

Color Change Process

See FIG. 71, Table 5, and Table 6.

1. Verify that Mix Ready is set. This ensures that there are no alarms and that the system is ready for the next command.

2. Load ccNewRecipe (Modbus 40046) with a recipe number to color change to.

3. Set color change (40040 bit 6).

4. Verify that Purge_CC_Active is seen (40041 bit 0).

5. Clear color change bit (momentary only).

6. Do not change the ccNewRecipe value until a new recipe change is requested.

7. The color change process will stop automatically as programmed. Monitor Purge_CC_Active bit for completion.

Start Mix Process

See FIG. 68, Table 5, and Table 6.

1. Verify that the Mix Ready bit (bit 2 of 40041) is on.

2. Turn on the Mix bit (bit 7 of 40040).

3. Verify that the Mix Active bit (bit 1 of 40041) is on, to ensure that the Mix request was received.

Stop Mix Process

See FIG. 69, Table 5, and Table 6.

1. Clear the Mix bit.

2. The Mix Active output should clear and Mix Ready should now be set.

NOTE: The ProControl 1KS will automatically go into Idle mode after 2 minutes of inactivity. A general alarm will be present and Mix Active will remain High. The Alarm bit (40010) will indicate the system Idle alarm. When a new Gun Trigger input is seen, the ProControl 1KS will resume mixing material where it left off. Do not

Purge Process

See FIG. 70, Table 5, and Table 6.

1. Verify that Mix Ready is set. This ensures that there are no alarms and that the system is ready for the next command.

2. Set purge (40040 bit 8).

3. Verify that Purge_CC_Active is seen (40041 bit 0).

4. When Purge_CC_Active bit clears, clear Purge_Start bit. Clearing this bit in the middle of a purge sequence will abort the purge sequence.

NOTE: It only requires three Modbus registers to provide full communications from the PLC to the ProControl 1KS. All other registers are on a need to view and monitor basis.

40040Robot Digital In (Send/Edit Values in ProControl 1KS) 40041Robot Digital Out (READ ONLY - Active values) 40046Go To Recipe value for next ProControl 1KS recipe

66 3A1080H

Modbus and I/O Data

Table 10: ProControl 1KS Modbus/TCP Variable Map

EasyKey

* Read/Write

Status

Modbus

Low

Limit High Limit

Read Only 40003 Current flow rate 16 Bit cc/min 0 5000 Read Only 40004 Actual ratio 16 Bit none 0 9999 Read Only 40005 Active recipe 16 Bit none 0 60

Read Only 40006 Potlife 1 remaining 16 Bit sec 0 9999 Read/Write 40007 Job complete 16 Bit none 0 0xFFFF Read/Write 40008 Reset job total 16 Bit none 0 9

Read Only 40009 Potlife 2 remaining 16 Bit sec 0 9999

Read Only 40010 Active fault 32 Bit none 0 0xFFFF FFFF

Read Only 40032 Control version 32 Bit none 0 0xFFFF FFFF Read/Write 40040 Robot digital input 16 Bit none 0x0000 0xFFFF

Read Only 40041 Robot digital output 16 Bit none 0x0000 0xFFFF Read/Write 40046 CC New recipe 16 Bit none 0 60

Read Only 40048 Current fluid pressure 16 Bit 1/100 psi 0 50000

Read Only 40049 V/P percent output 16 Bit % 0 100

Read Only **40056 Actual ratio reducer 16 Bit none 0 9999

Read Only 40114 Flow control option 16 Bit 0=proportioning only

04 1=1K flow control (future) 2=2K flow control 3=pressure override 4=manual pct. override

Read/Write 40115 Flow setpoint data source 16 Bit 0=discrete

01 1=network

Read/Write 40120 Manual override pct. drive 16 Bit % 0 100 Read/Write 40125 ***FC range 16 Bit 0=0-300 cc/min

02 1=0-600 cc/min 2=0-1200 cc/min

Read/Write 40126 FC tolerance 16 Bit % 0 99 Read/Write 40127 FC proportional gain Kp 16 Bit default=400 0 9999 Read/Write 40128 FC integral gain Ki 16 Bit default=40 0 9999 Read/Write 40129 FC alarm time 16 Bit sec 0 99 Read/Write 40137 FC setpoint 16 Bit cc/min 0 1200 Read/Write 40159 FC Learn Strength 16 Bit % 0 100 Read/Write 40171 FC Learn Threshold 16 Bit cc/min 0 1200 Read/Write 43123 FC override mode 16 Bit 0=off (normal)

02 1=% open 2=pressure mode

Read/Write 43141 FC enable 16 Bit 0=off

01 1=on

* This column represents the rule that must be implemented by automation. Writing to Read Only registers must be

avoided.

**For ProMix 3KS Systems only.

***Flow Control

3A1080H 67

Modbus and I/O Data

Table 11: ProControl 1KS Recipe Bits

Recipe Bits Number Recipe Bits Number

543210 543210

000000 0 100001 33 000001 1 100010 34 000010 2 100011 35 000011 3 100100 36 000100 4 100101 37 000101 5 100110 38 000110 6 100111 39 000111 7 101000 40 001000 8 101001 41 001001 9 101010 42 001010 10 101011 43 001011 11 101100 44 001100 12 101101 45 001101 13 101110 46 001110 14 101111 47 001111 15 110000 48 010000 16 110001 49 010001 17 110010 50 010010 18 110011 51 010011 19 110100 52 010100 20 110101 53 010101 21 110110 54 010110 22 110111 55 010111 23 111000 56 011000 24 111001 57 011001 25 111010 58 011010 26 111011 59 011011 27 111100 60 011100 28 011101 29 011110 30 011111 31 100000 32

68 3A1080H

Modbus and I/O Data

Typical PLC Interaction with ProControl 1KS

This section describes a typical interaction when a local PLC is directly connected to the Discrete I/O connections of the ProControl 1KS.

See ProControl Integration Specifics on page 49 for a detailed explanation of inputs and outputs.

NOTE: Communications fields of Configure Screen 6 must be set to DISCRETE (see page 31).

Start Mixing

To start the mix process, the PLC will monitor and ensure the Mix_Ready output is High. This provides assurance it is ready to mix. PLC will drive High the Mix_Start input, keep it High and monitor the Mix_Active output to ensure the ProControl 1KS followed through on the request.

Stop Mixing

To stop mixing (to perform a purge or color change), remove the Mix_Start input (the status bar on the EasyKey will show STANDBY). Monitor the Mix_Ready output to ensure the Mix_Active output goes Low.

Color Change

To perform a color change, ensure there are no alarms (except the Potlife Alarm). If alarms are present, the Alarm_Reset input should be sent momentarily to clear the alarm (>100 msec).

During the short On state, the recipe will be read from this binary sequence and the status bar of the EasyKey will display COLOR CHANGE XX. The Purge_CC_Active output will be High for the duration of the color change purge process. During the Mixed Material Load portion at the end of the Color Change sequence, the Fill_Active output will be on, indicating that portion of the color change. These will not be on at the same time. Once the Mix_Ready output goes High with no alarms, then the PLC has assurance that the requested color change has taken place with the requested recipe being the current active recipe. If any error occurs during the process, the requested recipe will not be loaded, and the old recipe will remain active.

NOTE: It is not possible to read the active recipe through Discrete I/O alone. Only by monitoring networked registers through the Gateway is it possible to view the active recipe. Proper management of the alarm status outputs during the color change process will ensure the active recipe is what is expected.

Purge

To start a Purge (no color change), drive the Purge_Start input High (maintained) while ensuring Mix_Ready output is High (ensuring no active alarms). An exception is Potlife alarm (see Color Change above if alarms are present.) The Purge_CC_Active output is High for the entire Purge process. Ensure there are no alarms during this process. Fill_Active is High when Mix is on. When complete, Mix _Ready output will be High, indicating a completed purge.

NOTE: No change is made to the active recipe.

NOTE: Alarm_Reset will not reset a Potlife alarm. Only

dispensing the Potlife Volume or a complete Purge/Color Change will reset a Potlife alarm.

The Alarm Reset Input will silence the audible alarm. Turn the Color_Change_Start input on momentarily (>100 msec) while the proper sequence of recipe bits are set.

NOTE: The Recipe Bits must be presented at least 100 msec before the Color Change Start input is turned on and remain until a new recipe is required.

3A1080H 69

Gun Trigger Input

This input is sent and expected every time the gun is actually triggered, and this input is turned off when the gun is not triggered. Never tie this input with any other signal. Without this input, some critical mixing alarms are eliminated.

IMPORTANT: This input must be provided through Discrete I/O for integrated flow control applications, to ensure fast coordination with the flow control process. Applications without flow control can use Gun Trigger input through Network Communications or Discrete I/O.

NOTE: The Gun Trigger input has the same effect as the air flow switch used on manual ProControl 1KS systems.

Modbus and I/O Data

Alarm Monitoring/Reset (Discrete I/O)

Anytime an alarm occurs, the Alarm Reset input will reset the alarms and allow for processing of the next step by automation, except for the following condi-

tions:

• Potlife Alarms cannot be reset by the Alarm Reset

input or through the EasyKey Alarm Reset

key. Only a Purge/Color Change or spraying the Potlife volume will reset a Potlife alarm. (See Alarm_Potlife output information on page 54.)

• When Flow Control is turned on (see Configure Screen 5 on page 30), the Flow_Rate_Alarm output will be High when the instantaneous flow rate is above or below the Flow Rate tolerance setting. (High Flow or Low Flow will be the condition, indicating in the status bar of the EasyKey.) This output will be High along with the Mix_Active output. The PLC should monitor the amount of time this condition exists and take action at a predetermined time. With Flow Control there will be times (for example during flow rate changes) where the general alarm as described here will be High (typically momentarily). The PLC must read this Alarm output (i.e. general alarm), see if Mix_Active is still High, and if so, start a timer. A typical example would be to ensure all parts are sprayed within a specific flow rate range. A maximum predetermined time would be set to allow a Low or High flow condition to exist continuously.

• Shutdown or go to Standby after the flow rate alarm time expires.

Job_Complete Input

For Applications with Dump Valves (for quick purges/color changes at or near the gun):

ProControl 1KS has four specials that can each be turned off and on twice throughout a color change sequence. See Advanced Setup Screen 8 on page 39 or Recipe Setup Screen 7 on page 44.

For example, a dump valve at a gun on a robot could be opened at the appropriate times to facilitate fast color changes. Another output could be used to automatically drive an air-operated fluid regulator High during the Purge or Color Change process.

NOTE: With integrated Flow Control, the flow control regulator automatically is driven High. See Advanced Setup Screen 5 on page 37 for specifics on setting up these values. Each of the specials can be monitored, but can only be controlled through the times entered within the setup screens of the EasyKey or by managing the proper registers on the network.

The following ProControl 1KS inputs should never be on (High) at the same time:

•Mix_Start

• Purge_Start

• Color_Change_Start

The Recipe Bits (0-6) are always on at the same time. The only time these bits are recognized is when the Color_Change_Start input is High. The Recipe Bits should be loaded and stay loaded for the current recipe. Do not change the Recipe Bits until a color change is required again. Inconsistent results are possible if this is not followed.

Every time a momentary Job_Complete input is seen by the ProControl 1KS, a job log will be recorded, logging the A and B meter volumes (cc) with a time and date stamp. The volumes will then be reset to 0. (Volume totals are accumulated since the last reset.)

NOTE: A Color Change accomplishes the same Job Complete Reset functions. The Job_Complete input is commonly used to record material usage for a specific set of parts. These volumes are sprayed material volumes.

70 3A1080H

Integration Timing Charts

Refer to FIG. 74 - FIG. 80 for integration timing charts.

3A1080H 71

FIG. 74. Integration Control Recipe Change X to Y

Modbus and I/O Data

72 3A1080H

Modbus and I/O Data

FIG. 75. Integration Control Recipe Change X to Y External Color Change

3A1080H 73

FIG. 76. Integration Control Y Purge

Modbus and I/O Data

74 3A1080H

Modbus and I/O Data

FIG. 77. Integration Control Y Fill

3A1080H 75

FIG. 78. Integration Control Y Purge and Fill

Modbus and I/O Data

76 3A1080H

Modbus and I/O Data

FIG. 79. Integration Control Mix Sequences

3A1080H 77

FIG. 80. Integration Control Alarm Processing

Modbus and I/O Data

Integrated Flow Control

TI17116a

Circuit Board

V/P (Voltage/Air Pressure) Valve

Air-operated

Fluid Regulator

Fluid Pressure Sensor

1/8 npt(f) Fluid Outlet

Fluid Pressure

Gauge Port

Power and

Signal

Cable Input

1/8 npt(f)

Fluid Inlet

Air Inlet Fitting,

1/4 in. (6 mm) OD

Tube

TI18956a

Circuit Board

(hidden) V/P (Voltage/Air Pressure) Valve

Air Pressure

Gauge

(not included)

Power and

Signal

Cable Input

Air Outlet Fitting, 1/4 in. (6 mm) OD Tube

Air Inlet Fitting, 1/4 in. (6 mm) OD Tube

Remote Fluid

Pressure

Sensor

Integrated Flow Control

Flow Control Description

Flow control is an optional feature which incorporates an intrinsically safe regulator control module with the ProControl 1KS automatic system. Flow control precisely regulates the flow of material to a manual or automatic air spray gun, to help ensure adequate coverage and avoid sags or runs in the finish coat.

NOTE: Flow control cannot be selected with dynamic dosing. It is not for use with air-assisted or airless spray guns.

Flow control uses the existing flow meters in a wall mounted fluid station or a RoboMix fluid station. There is no flow meter in the mixed material line.

Flow Control Components

249849 Flow Control Module

See FIG. 81. The 249849 Flow Control Module includes an air-operated fluid pressure regulator, fluid pressure sensor, voltage to air pressure valve, and circuit board. See manual 3A2097. The function of this unit is to receive the flow analog signal and drive (manage) the desired flow rate.

24H989 Flow Control Module

See FIG. 82. The 24H989 Flow Control Module is for use with a user-supplied, remotely mounted, air-operated fluid pressure regulator. The module includes a remote fluid pressure sensor and connecting cable, voltage to air pressure valve, and circuit board. See manual 3A2097. The function of this unit is to receive the flow analog signal and drive (manage) the desired flow rate.

NOTE: For best results, place the supplied pressure sensor as close to the remote fluid regulator as possible.

IG. 81. Cutaway of 249849 Flow Control Module

78 3A1080H

IG. 82. Cutaway of 24H989 Flow Control Module

Integrated Flow Control

Fluid and Air Pressure Requirements

The fluid input pressure to the fluid regulator must be high enough to provide a 15-20 psi (0.1-0.14 MPa,

1.0-1.4 bar) pressure differential across the regulator at the highest flow setting. For example, if the maximum flow rate set point is 280 cc/min and 35 psi outlet pressure is required to achieve that flow, the input pressure must be 50-55 psi.

Required air pressure to the flow control module is 70-100 psi (0.35-0.7 MPa, 3.5-7.0 bar).

NOTE:

• For flow control modules 249849 and 24H989 used with a 1:1 fluid regulator, the fluid outlet pressure from the regulator must be between 5-75 psi (0.034-0.52 MPa, 0.34-5.2 bar) for all flow set points. Flow rate set points with pressures outside

this range are not achievable. There must be at least 5 psi (0.034 MPa, 0.34 bar) fluid pressure at the lowest flow rate.

Flow Control Operation

See FIG. 83 for module 249849 and FIG. 84 for module 24H989. The Flow Control System includes two information loops:

•The pressure loop monitors fluid pressure with the pressure sensor in the module. This allows the system to react very quickly to set point changes.

While the gun is not triggered the system still drives to the pressure determined from the data table from the flow rate set point. This pressure drive will operate for the amount of time set in the “GT-Off drive time” value in the Advanced Screen. This screen can be accessed and the setting modified while Flow Control is set to “On: Setup” in Configure Screen 5, page 30.

The target pressure when the gun trigger is off can be adjusted using the “GT-Off target rise” value in the Advanced Setup Screen 7, page 38. This amount is added to the value from the data table. This may compensate for the immediate pressure drop at the gun when the gun trigger is opened. Adjust for gun triggers at the lowest flow rates.

• If flow control module 24H989 is used with a fluid regulator at a ratio greater than 1:1, the relationship of air pressure to fluid outlet pressure is very important. The lowest recommended air pressure from the V/P is 5 psi (0.034 MPa, 0.34 bar). Back pressure

may be required to ensure minimal fluid pressure at the lowest flow rate setpoint.

The turn down ratio of the typical fluid regulator is approximately 3:1 or 4:1, depending on material type and viscosity. For example, if the lowest flow rate required is 100 cc/min, the top flow rate achievable may be 300-400 cc/min.

NOTE: The top flow rate is not the maximum flow rate range selected.

•The flow loop monitors fluid flow through flow meter pulses, ensuring accuracy. The gun must be triggered during the flow loop.

The Flow Control System creates a data table that targets a desired flow rate based on the fluid pressure. It then monitors the flow loop to maintain the flow rate.

The data table update performance can be modified using the “Learn Strength” value in Advanced Setup Screen 6, page 38. This determines how much of the instantaneous flow error value is applied when updating the table. High values make it learn more quickly, but may lead to oscillation. Low values make it learn more slowly, but may make adjustment times unacceptable.

3A1080H 79

Integrated Flow Control

TI17118a

Air-operated Fluid Regulator

Meter B

Fluid Pressure Sensor

Mixed Material Line

Pressure Input: Feedback from Fluid Pressure Sensor

V/P (Voltage/Air Pressure) Valve

Analog Signal to V/P

Air Line

Air Signal to Regulator

Fluid Control

Board

Flow Input: Feedback from Meters A and B

Meter A

TI18958a

Air-operated Remote Fluid Regulator

Meter B

Fluid Pressure Sensor

Mixed Material Line

Pressure Input:

Feedback from

Fluid Pressure

Sensor

V/P (Voltage/Air Pressure) Valve

Analog Signal to V/P

Air Line

Air Signal to Regulator

Fluid

Control

Board

Flow Input: Feedback from

Meters A and B

Meter A

FIG. 83. ProControl 1KS Flow Control Schematic Diagram (249849 Module)

FIG. 84. ProControl 1KS Flow Control Schematic Diagram (24H989 Module)

80 3A1080H

Flow Control Operating Process Example

Integrated Flow Control

Operating Ranges

Flow Control operating ranges correlate the desired flow rate to the incoming flow set point signal (see below). The operating ranges are:

• 0-300 cc/min

• 0-600 cc/min

• 0-1200 cc/min

• 0-100% (% open in manual override mode)

In this example, the range is set to 0-300 cc/min and the target flow rate is 150 cc/min.

Step 1: Flow Set Point Input Signal

Discrete Input

A discrete signal is 0-10Vdc, which corresponds linearly to the set operating range. For example, if the set range is 0-300 cc/min and the desired flow rate is 150 cc/min, the ProControl 1KS receives a flow rate setpoint (5Vdc signal) from the PLC or robot.

Network Communication Input

Step 2: Pressure Loop

NOTE: The gun must be triggered during the pressure

loop.

See F

IG. 85 for module 249849 and FIG. 86 for module

24H989. The ProControl 1KS drives the system to the necessary pressure to meet the desired flow rate (150 cc/min). The pressure sensor in the module verifies the actual pressure and returns the reading back to the ProControl 1KS.

Step 3: Flow Loop

NOTE: The gun must be triggered during the flow loop.

The flow meters verify that the target flow rate is achieved and feeds this information back to the ProControl 1KS. The ProControl 1KS adjusts the voltage to the V/P to maintain the actual flow.

Step 2 and Step 3 repeat continuously to maintain pressure and flow.

A network communication signal is either the desired flow rate (150 cc/min in this example) or the % open.

3A1080H 81

Integrated Flow Control

TI17118a

Fluid Pressure Sensor

Step 2: Pressure Input

V/P (Voltage/Air Pressure) Valve

Analog Signal to V/P

Air Line

Step 1:

ProMix receives a

flow rate setpoint

from PLC/robot

Step 3: Flow Input

TI18958a

Fluid Pressure Sensor

Step 2: Pressure Input

V/P (Voltage/Air Pressure) Valve

Analog Signal to V/P

Air Line

Step 1:

ProControl

receives a

flow rate

setpoint from

PLC/robot

Step 3: Flow Input

Air Line to

Remote

Fluid

Regulator

FIG. 85. ProControl 1KS Flow Control Pressure Loop and Flow Loop (249849 Module)

FIG. 86. ProControl 1KS Flow Control Pressure Loop and Flow Loop (24H989 Module)

82 3A1080H

Integrated Flow Control

Flow Control Setup

1. Install the intrinsically safe flow regulator (FC) as explained in the ProControl 1KS Installation Manual.

2. Ensure that the analog signal is 0-10 Vdc, or is properly provided through network communication.

3. Calibrate the system’s flow meters; see page 102. This ensures that the K-factors are tuned to the range of materials being used.

4. Verify that the I/O inputs are working properly. If using discrete I/O, check by viewing Advanced Setup Screen 6 and Advanced Setup Screen 7, page 38. If using network communication, ensure the commands are being sent by viewing the Status Screen, page 21, and Advanced Setup Screen 6 and Advanced Setup Screen 7, page 38, for inputs.

NOTE: See the Graco Gateway manual for Flow Control Modbus addresses.

5. See Flow Control Startup.

appear. The other option, “On: Ext” is used for partial control by a PLC robot.

FIG. 88. Advanced Setup Screen 1

3. Set Flow Control Override to % Open. See F and Table 12. On the Manual Override Screen, the Flow Set Point field will display as a percentage open (see F

IG. 90).

IG. 89

Flow Control Startup

1. Set Flow Control to “On: Setup” in Configure Screen 5.

IG. 87. Configure Screen 5

2. In Advanced Setup Screen 1, turn Manual Override “On: EK”. This sets the override control source as the EasyKey. The Flow Control Override field will

IG. 89. Flow Control Override Menu

Table 12: Flow Control Override Selections

Selection Description

Off Normal operation % Open Flow control regulator is opened to a

desired percentage.

Pressure Flow control regulator is opened to a

calibrated pressure.

ExtSP External PLC in control of Set Point

NOTE: Set the Flow Control Override to “Pressure” to use the Pressure Flow Control Mode (see page 88).

3A1080H 83

Integrated Flow Control

IG. 90. Flow Set Point as a Percentage

One-Point Learning

For situations where there are fast gun triggers (less than 2 seconds) there may not be enough stable flow data to allow the flow loop to learn. This situation is also affected by low flow rates (less than 100 cc/min).

If the job sequence contains an extended gun trigger time, instead of learning at individual flow rates the system can instead learn only points above a specified flow rate, which are then linearly interpolated between that point and the (0 Pressure, 0 Flow) origin of the data table.

4. On the Manual Override Screen, drive the regula- tor to a percentage open that starts fluid flow. Fluid pressure should be above 5 psi (0.034 MPa, 0.34 bar) [see the Status Screen]. Observe the fluid flow rate at this pressure. This is the achievable low end flow rate for the system’s given restriction. If a lower flow rate is required, increase the restriction between the flow control regulator and the spray gun.

NOTE: If the lowest flow rate achieved is well below 5 psi (0.034 MPa, 0.34 bar), add restriction to achieve fluid pressure closer to 5 psi. Pressures below 5 psi can be inconsistent.

5. Drive the regulator to 100% open. This is the maximum achievable flow rate based on the low flow requirement and the flow control module’s functional range.

6. When an acceptable operating range is achieved, turn Flow Control Override Off.

One-Point Learning Example

Suppose a part has a spray sequence of:

Table 13: Example Spray Sequence

Pass Flow Rate Gun Trigger Time

The system won’t be able to learn the points at 50 and 65 cc/min. However, there is enough data to learn at the 150 cc/min set point.

If the “One-Point threshold” in the Advanced Setup Screen 6, page 38 is set to a flow rate such as 100 cc/min, then learning is disabled for flow rates below this. However, when the 150 cc/min pass is active, when the point is learned the linear interpolation is applied for the entire flow rate range.

50 1 s

65 1/2 s

50 1 s

150 4 s

IG. 91. Advanced Setup Screen 1

7. Run Flow Control Calibration, page 85.

84 3A1080H

Flow Control Calibration

Mix Calibration

Flow Control Calibration is an automatic routine that establishes a pressure vs flow profile between low and high operating points. See F unique to each recipe or may be globally copied to all recipes.

NOTE: Calibration cannot be done in recipe 0 or 61.

1. Load a color.

IG. 96. The profile may be

Integrated Flow Control

2. Go to Advanced Setup Screen 5 (see F

IG. 92).

Select the flow rate range that best covers the largest flow target for your application (for example,

0-1200).

IG. 92. Advanced Setup Screen 5 (Automatic Mode

with Flow Control Only)

3. Go to Advanced Setup Screen 1 (see F Turn Manual Override On.

IG. 93).

FIG. 94. Manual Override Screen

5. Return to the Status Screen (see F

IG. 95). The sta-

tus bar at the bottom of the screen will indicate that Mix Calibration is in progress.

IG. 95. Status Screen

6. Trigger the gun and make sure the gun trigger input is high.

IG. 93. Advanced Setup Screen 1

4. Go to the Manual Override Screen (see FIG. 94).

3A1080H 85

Set Manual Override to Mix, and set Flow Ctrl Calibration to Start.

7. On the Status Screen (see F

IG. 95), the voltage will

start at 0 and increase incrementally to 3.3 V. The flow rate will also begin to increase during calibration, but this may not show for the first few voltage increases.

8. When calibration is complete, the Status Screen will change from Mix Calibration to Mix. The unit should have built a complete table for the flow rate range selected in step 2.

NOTE: If the voltage reached 3.3 V (flow control wide open) but the unit did not reach the top of the selected flow rate range, the delivery system is not providing enough volume. Do one of the following:

• If the volume is acceptable, change the flow rate range accordingly.

Integrated Flow Control

Flow (cc/min)

Regulator Outlet Pressure, psi (MPa, bar)

0350150 200 250 30010050

(0.21, 2.1)

(0.17, 1.7)

(0.14, 1.4)

(0.10, 1.0)

(.07, 0.7)

(.035, 0.35)

• If the volume is not acceptable, increase the delivery pressure. Increasing the pressure may affect your low flow rate setting.

9. De-trigger the gun.

10. Set Manual Override to Standby.

11. To copy the data table to all recipes, see Global FC Data Copy, page 86. This loads a starting point for each recipe, and continuous learning will create a unique data table when the recipe is run.

NOTE: If you want to do a flow calibration for each recipe, do not do a Global FC Data Copy.

IG. 96. Typical Flow Calibration (0-300 cc/min range)

Global FC Data Copy

Set Global FC Data Copy to Start on the Manual Override Screen (see F

ing point for all recipes, enabling Continuous Learning (see page 87) to take over.

Global copy works very well with multiple colors when the viscosities are similar. It may only require a calibration and global copy each time a regulator is serviced or if restriction downstream of the regulator is changed.

86 3A1080H

IG. 97). Global copy provides a start-

FIG. 97. Manual Override Screen

Continuous Learning

The flow profile will automatically adjust as necessary to drive to the required flow set point, reflecting changes in material viscosity or system dynamics (such as restrictions downstream from the regulator).

When changing recipes, the profile is saved to the current active recipe. A Job Complete input will also save the profile to the active recipe.

Setting Ki and Kp

FIG. 99 shows the definition and relationship between Ki and Kp.

• The default value for Ki is 40.

• The default value for Kp is 400.

For most applications, Ki and Kp do not need to change. Do not change these vallues unless you are sure it is required.

Integrated Flow Control

Before adjusting these values, ensure that the input fluid pressure to the regulator is pulsation free, and the outlet pressure is higher than 12 psi (.08 MPa, 0.84 bar) for each flow rate set point.

Applications with viscosities less than 20 cps or greater than 300 cps may require that the Ki and Kp be adjusted. Do this by making small variable changes to

the values in Advanced Setup Screen 5. See F

IG. 98. Advanced Setup Screen 5 (Automatic Mode

IG. 98.

with Flow Control Only)

3A1080H 87

Integrated Flow Control

TI17119a

Target Flow Rate

Ki refers to the degree fluid flow over shoots its set point.

Kp refers to the speed at which fluid flow reaches its set point.

NOTE: Ki and Kp are dependent on each other. If one changes the other must change.

Pressure Flow Control Mode

When the Flow Control Override is set to “Pressure”, the system will only drive to the pressure associated with the flow rate request of the saved calibration table. It will not close the loop with the flow meters.

This mode may be used with a ProControl 1KS connected both to a robot with flow control and to a manual gun. Because there are two flow paths, the meters cannot be used to close the flow loop. Therefore the robot can run a calibration by itself. When calibration is complete, set to “Pressure.” The robot will run in open loop mode, and the manual gun can spray at the same time.

IG. 99. Kp/Ki Graph

88 3A1080H

Flow Control Troubleshooting

Problem: Flow Command does not produce fluid output.

Test the system as follows, to determine if the problem is mechanical or electrical.

1. Install a 0-100 psi (0-0.7 MPa, 0-7.0 bar), 1/8 npt(m) air pressure gauge (not supplied) as follows.

a. For module 249849: Remove the plug from the

1/8 npt(f) air gauge port and install the gauge. See F

IG. 81 on page 78.

b. For module 24H989: Install a 1/8 npt(m) x 1/8

npt (fbe) tee in the air outlet port. Install the gauge in one branch of the tee and the air outlet fitting in the other. See F

2. Set the system to Manual Override, % Open mode; see steps 2-5 under Flow Control Startup on pages 83-84.

IG. 82 on page 78.

Integrated Flow Control

3. Set the % Open value to 50. See F

IG. 100. Set % Open to 50 Percent

4. Ensure that the gun is triggered. Increase the % Open value on the EasyKey, then decrease. The gauge reading should also increase then decrease.

IG. 100.

3A1080H 89

Integrated Flow Control

Result of the Test Cause Solution

Gauge reading increases

The problem is mechanical:

1. Clear any clogs. and decreases as % Open value is changed

• restriction/plugged hose

2. Remove restrictions. and fluid flow does not

change or is not present.

• plugged gun tip

3. Clean and/or repair fluid regulator.

• fluid regulator failure

Gauge reading does not increase and decrease as % Open value is changed.

The problem is electrical:

• Fuse F2 is blown

• disconnected wires or cables

1. Measure the voltage to the regulator at one of

two places:

• At J5 on the fluid control board, measure across the white (pin 1) and black (pin 6) wire connections. The voltage should be in

• pressure control failure

the range of 0-3.3 Vdc for 0%-100% Open command (approximately 1.65 Vdc for 50%

• V/P valve failure

Open).

• flow control board failure

• At J2 on the flow control board of the module, measure across the red (pin 1) and black (pin 2) wire connections. The voltage should be in the range of 0-21 Vdc for 0%-100% Open command (approximately 12 Vdc for 50% Open).

2. If voltage is not present, check if fuse F2 on the fluid control board is blown.

3. If voltage is present, ensure the cable is properly connected to the module circuit board.

4. If cable is properly connected, replace pressure control, VP valve, and flow control board sequentially to isolate failure. See manual 3A2097.

90 3A1080H

System Operation

TI11581a

System Operation

Operation Modes

Mix

System mixes and dispenses material (apply Mix input).

Standby

Stops the system (remove Mix input).

Purge

Purges the system, using air and solvent (apply Purge

Mix Manifold Valve Settings

To open dose or purge valves, turn hex nut (E) counterclockwise. To close, turn clockwise. See Table 14 and

IG. 101.

input).

Recipe (Color) Change

The process when the system automatically flushes out the old color and loads a new color. See pages 104-116.

Solvent Push

The Solvent Push feature enables the user to save some mixed material by pushing it out to the gun with solvent. The feature requires an accessory solvent meter. See page 101 for complete information.

FIG. 101. Valve Adjustment

Table 14: Mix Manifold Valve Settings

Valve Setting Function

Dose (see F

IG. 101)

Purge (see F

IG. 101)

3A1080H 91

Hex nut (E) 1-1/4 turns out from fully closed

Limits maximum fluid flow rate into integrator and minimizes valve response time.

System Operation

I = ON

TI12656a

Start Up

1. Go through the Pre-Operation Checklist in Table 15.

Table 15: Pre-Operation Checklist

 Checklist

System grounded

Verify all grounding connections were made. See the Installation manual.

All connections tight and correct

Verify all electrical, fluid, air, and system connections are tight and installed according to the Installation manual.

Check air purge valve tubing

Check the air purge valve supply tube daily for any visible solvent accumulation. Notify your supervisor if solvent is present.

Fluid supply containers filled

Check component A and B and solvent supply containers.

Mix manifold valves set

Check that mix manifold valves are set correctly. Start with the settings recommended in Mix Mani- fold Valve Settings, page 91, then adjust as needed.

Fluid supply valves open and pressure set

2. Turn the AC Power Switch ON (I = ON, 0 = OFF).

FIG. 102. Power Switch

 Graco logo, software revision, and “Establishing

Communication” will display, followed by Status screen. See page 19.

 At power up the system defaults to Recipe 61,

which is not a valid recipe number. Initiate a color change to Recipe 0 or a valid recipe number (1-60).

 In bottom left corner, the system status displays,

which can be Standby, Mix, Purge, or an alarm notification.

Component A and B fluid supply pressures should be equal unless one component is more viscous and requires a higher pressure setting.

Solenoid pressure set

75-100 psi inlet air supply (0.5-0.7 MPa, 5.2-7 bar)

IG. 103. Status Screen

3. Verify that the EasyKey is working. The active recipe number and Standby mode should be displayed.

4. If this is the first time starting up the system, purge it as instructed in Purging Fluid Supply System, page 99. The equipment was tested with lightweight oil, which should be flushed out to avoid contaminating your material.

5. Make sure that the EasyKey is in Standby (remove Mix input).

92 3A1080H

6. Adjust component A and B fluid supplies

Manual gun shown

as needed for your application. Use lowest pressure possible.

7. Do not exceed the maximum rated working pressure shown on the system identification label or the lowest rated component in the system.

8. Open the fluid supply valves to the system.

9. Adjust the air pressure. Most applications require about 80 psi (552 kPa, 5.5 bar) air pressure to operate properly. Do not use less than 75 psi (517 kPa, 5.2 bar).

System Operation

10. Purge air from the fluid lines.

a. Shut off air to the gun by clos-

ing the air regulator or shutoff valve for the gun atomizing air.

b. Trigger the gun (man-

ual or automatic) into a grounded metal pail.

c. Go to Mix mode.

d. If the flow meters over-run because of air in the

system, an alarm will occur and operation stops.

Press the Alarm Reset

key to clear

alarm.

e. Go to Mix mode.

11. Adjust the flow rate.

The fluid flow rate shown on the EasyKey Status screen is for either component A or B, depending on which dose valve is open. The fluid supply lines on the screen highlight to show which dose valve is open.

FIG. 104. Status Screen Flow Rate Display

Watch the fluid flow rate displayed on the Status screen while the gun is fully open. Verify that the flow rate of components A and B are within 10% of each other.

If the fluid flow rate is too low: increase air pressure to component A and B fluid supplies or increase the regulated fluid pressure.

If the fluid flow rate is too high: reduce the air pressure, close the fluid manifold dose valves further, or adjust the fluid pressure regulator.

NOTE: Pressure adjustments of each component will vary with fluid viscosity. Start with the same fluid pressure for component A and B, then adjust as needed.

NOTE: Do not use the first 4-5 oz. (120-150 cc) of material as it may not be thoroughly mixed due to alarms while priming the system.

12. Turn on atomizing air to the gun. Check the spray pattern as instructed in your spray gun manual.

NOTE: Do not allow a fluid supply tank to run empty. It is possible for air flow in the supply line to turn gear meters in the same manner as fluid. This can lead to the proportioning of fluid and air that meets the ratio and tolerance settings of the equipment. This can further result in spraying uncatalyzed or poorly catalyzed material.

3A1080H 93

System Operation

0 = OFF

TI12657a

Shutdown

Overnight Shutdown

1. Leave the power on.

2. Run Recipe 0 to purge solvent through meters and gun.

Service Shutdown

1. Follow Pressure Relief Procedure on page 94.

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

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

105.

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

IG.

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 A and B 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 and B dose valve solenoids to relieve pressure. See F

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

IG. 106.

IG. 105. Power Switch

3. Do a complete system purge, following the instructions under Purging Using Recipe 0, page 99.

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 and B purge valve solenoids to relieve air and solvent pressure. See F pressure is reduced to 0.

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

IG. 108.

IG. 106. Verify that solvent

94 3A1080H

Systems with Color Change and Dump Valves

NOTE: This procedure relieves pressure through the

sampling valve.

1. Complete all steps under Single Color Systems, page 94.

2. Shut off all color supplies going to the color change valve stack(s).

3. Open the Fluid system control box. Press and hold the dump valve solenoid override, F

IG. 106.

System Operation

4. See F

IG. 107. 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 the sampling valve stops.

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

IG. 106 (see step 3).

6. Press and hold the Color stack solvent solenoid override until clean solvent comes from the dump valve, then release.

7. Shutoff the solvent supply to the color change stack solvent valve.

8. Press and hold the solvent solenoid override and dump valve override until solvent flow from the dump valve stops.

3A1080H 95

System Operation

TI15916a

Purge Valve B Solenoid

Purge Valve A Solenoid

Dose Valve A Solenoid

PowerCAN

J1J12J3J9

J14

J15

Dose Valve B Solenoid

CAN

FIG. 106. Fluid Solenoids

96 3A1080H

System Operation

TI12826a

Solvent Solenoid Overrides

Solenoid Identification Label

Solenoid

Identification

Label

Color

Color Catalyst

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

TI15977a

SPV

DVA

APV

FIH

FOH

FIG. 107: Color Change Solenoids

FIG. 108. Wall Mount Fluid Station

3A1080H 97

System Operation

Purging

Read Warnings, page 6. Follow the Grounding instructions in your system Installation manual.

To avoid splashing fluid in the eyes, wear eye protection.

There are 3 purging procedures in this manual:

• Purging Mixed Material (below)

• Purging Using Recipe 0 (page 99)

• Purging Fluid Supply System (page 99)

Use the criteria listed in each procedure to determine which procedure to use.

Purging Mixed Material

There are times when you only want to purge the fluid manifold, such as:

2. Set the solvent supply pressure regulator at a pressure high enough to completely purge the system in a reasonable amount of time but low enough to avoid splashing or an injection injury. Generally, a setting of 100 psi (0.7 MPa, 7 bar) is sufficient.

3. If using a gun flush box, place the gun into the box and close the lid. Go to Purge mode. The purge sequence automatically starts.

If the gun flush box is not used, trigger the gun (manual or automatic) into a grounded metal pail until the purge sequence is complete.

When done purging, the EasyKey automatically switches to Standby mode.

4. If the system is not completely clean, repeat step 3.

NOTE: If necessary, adjust purge sequence so only one cycle is required.

• end of potlife

• breaks in spraying that exceed the potlife

• overnight shutdown

• before servicing the fluid manifold assembly, hose or gun.

1. Go to Standby mode (remove Mix input).

Trigger the gun to relieve pressure.

If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.

If using an electrostatic gun shut off the electrostatics before flushing the gun.

Trigger the gun to relieve pressure. Engage trigger lock.

5. If spray tip was removed, reinstall it.

6. Adjust the solvent supply regulator back to its normal operating pressure.

98 3A1080H

System Operation

Purging Using Recipe 0

Recipe 0 is typically used: in multiple color systems to purge out material lines without loading a new color

To setup Recipe 0, go to Advanced Setup. Select the Recipe tab and change the Recipe to 0. The Recipe 0 Setup Screen appears. Set the chop times from 0-999 seconds in increments of 1 second.

1. Go to Standby mode (remove Mix input).

Trigger the gun to relieve pressure.

If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.

Purging Fluid Supply System

Follow this procedure before:

• the first time material is loaded into equipment*

• servicing

• shutting down equipment for an extended period of time

• putting equipment into storage

* Some steps are not necessary for initial flush-

ing, as no material has been loaded into the system yet.

1. Go to Standby mode (remove Mix input).

Trigger the gun to relieve pressure.

If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.

If using an electrostatic gun shut off the electrostatics before flushing the gun.

2. If using a gun flush box, place the gun into the box and close the lid.

3. Select Recipe 0 and press Enter .

4. If a gun flush box is not used, trigger the gun (manual or automatic) into a grounded metal pail until the purge sequence is complete.

5. The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete.

6. If the system is not completely clean, you can

repeat Recipe 0 by pressing Enter

If using an electrostatic gun, shut off the electrostatics before flushing the gun.

2. Attach solvent supply lines as follows:

• Single color systems: disconnect the fluid supply at the flow meter inlet, and connect regulated solvent supply lines.

• Multiple color systems: disconnect the fluid supply at the flow meter inlet and connect a regulated solvent supply line.

3A1080H 99

System Operation

3. Adjust the solvent fluid supply pressure. Use the lowest possible pressure to avoid splashing.

4. Remove the Fluid Station Control Box cover to access the solenoid valves. See F

IG. 106 on page

96.

5. Purge as follows:

• Single color systems: Press the manual over-

ride on the Dose Valve A solenoid valve and trigger the gun into a grounded metal pail until clean solvent flows from the gun.

• Multiple color systems: Select Recipe 0 and

press Enter . The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete.

6. Reinstall the Fluid Station Control Box cover.

7. Shut off the solvent fluid supply.

8. Disconnect the solvent supply lines and reconnect the fluid supply.

9. See page 92 for Start Up procedure.

100 3A1080H

Graco ProControl 1KS Operation

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Equipment Approvals

System Configuration and Part Numbers

Models

Standard Features Accessories

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of Isocyanates

Keep Components A and B Separate

Changing Materials

Glossary of Terms

Overview

Usage

Component Identification and Definition

Wall Mount System Components

EasyKey Display and Keypad

Keypad

Display

AC Power Switch

I/S Power

Audible Alarm

Graco Web Interface Port

Ethernet Connection

Run Mode Screens

Splash Screen

Status Screen

Manual Override Screen

Manual Override Menu

Flow Rate Range

Flow Set Point

Flow Control Calibration

Global Flow Control Data Copy

Totals Screen

Reset Total Screen

Reset Solvent Screen

Alarms Screen

Level Control Screen

Setup Mode

Password Screen

Set Up Home Screen

System Configuration Screens

Configure Screen 1

Configure Screen 2

Configure Screen 3

Configure Screen 4

Configure Screen 5

Configure Screen 6

Option Screens

Option Screen 1

Verification Screen

Option Screen 2

Advanced Setup Screens

Advanced Setup Screen 1

Advanced Setup Screen 2

Advanced Setup Screen 3

Advanced Setup Screen 4

Advanced Setup Screen 5

Advanced Setup Screen 6

Advanced Setup Screen 7

Advanced Setup Screen 8

Advanced Setup Screen 9

Advanced Setup Screen 10

Recipe Setup Screens

Recipe Setup Screen 1

Recipe Setup Screen 2

Recipe Setup Screen 3

Recipe Setup Screen 4

Recipe Setup Screen 5

Recipe Setup Screen 6

Recipe Setup Screen 7

Recipe 0 Screens

Recipe 0 Screen 1

Recipe 0 Screen 2

Recipe 0 Screen 3