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Graco 3A1080C User's Manual

1. COLOR BOARD 1 COLORS 1THRU 12 LL uisu emus Gm meon N as Ca voc pn Rug H EE E GRD BLK n TADC RED l Carnan HSC 1 om SE de DCH e reo CAN L BLU m v CLR EE P eum E SEA on part c pH 4 Com E BOOTH Hume icm 3p 06 ak GRD BLK 3 CONTROL as p com Cl FH ax FEL ers 2 12VDC RED EE SE 5 SHIELD BARE 5 412v0c 6 COM CAT2 E 31 w EECH AS oe ES am ac S ER Hirt en mL mi IE SI EET n E up up bir 14523 MANIFOLD Jn 6 7 BLACK Serb eee eem ee ee ym D in TEE enn g LLL KEFE 3 L RED c COLOR 2 BLACK GT JEE r4 BOARD 2 de RED E GFB 2 2d d COLORS E 5d BLACK az E E 13THRU30 dn MANIFOLD RED ap DUMP A e RER a CLR 22 een NOTUSED TI n I E i dL ben 3 RED MANIFOLD 111 1RIS 2 QM L7 ana 2 BLACK I sati 1 O nac 7 RED Te pue IN E eae nt Ce CLR 25 6 BLACK L7 PURGEB A ETT NEE ES Dia L E S titan H ow Ja 3 RED epe AN n CN IL nac oan am I a 2 ED NOT USED ag ty CLR15 de sx pL CLR 28 br 4 COM 6 amp 8AX BE 1 D w ll ae 5 ReD A p HERE H S EL onm D Cl Jens noms 2 BLACK SE Linn TY DOSE A EE E AFS 1 BLK 1 ie ES EL Ge CR 1 SG pp Qwieumua 7
2. Solvent Solenoid Overrides FiG 76 Color Change Solenoids SANS ene BESCHE L 3 APV NC TESI P d DVA A SS SPV FOH Ba Fic 77 Fluid Manifold 72 T112826a Key MA Component A Meter DVA Component A Dose Valve Solvent Purge Valve Solvent Purge Valve Solvent Supply Tube Air Purge Valve Air Purge Valve Air Supply Tube Fluid Inlet Hose Fluid Outlet Hose FIH SPV o9 APV AT FIH FOH T115977a 3A1080C System Operation Purging 2 Setthe solvent supply pressure regulator at a pres sure 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 Head Warnings page 6 Follow the Grounding instructions in your system Installation manual To avoid splashing fluid in the eyes wear eye protec If the gun flush box is not used trig tion ger the gun manual or automatic d 3 into a grounded metal pail until the uM purge sequence is complete EI There are 4 purging procedures in this manual e Purging Mixed Material below When done purging the EasyKey automatically e Purging Using Recipe 0 page 74 switches to Standby mode e
3. CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time First Purge one of these 3rd Flush Chop Time begins Air Purge Ne Solvent Purge DN Final Purge one of these 3rd Flush Valve NNNM i OHSU GbE HT Dispense B Gun Trigger s by Operator First Purge Time M0 2M1 Chop Time air solvent or air 3rd flush M1 gt M2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 78 Color Change Chart 1 ProMix 2KS Recipe Change Chart 2 A1 to A2 B1 to B2 with Dump Valves and 3rd Flush Valve Time Sequence EE RE Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B PO Color Purge Time P0 gt P1 Color Fill Time P1 gt P2 Catalyst Purge Time P2 gt P3 Catalyst Fill Time P3 gt P4 L CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time 3rd Flush Chop Time begins Solvent Purge A 3rd Flush Valve x il Two Second Solvent Purge Gun Trigger s by Operator Ooo E MO M1 M2 M3 M4 M5 Two Second Initial Purge Time M0 gt M1 First Purge Time M1 gt M2 Chop Time air sol
4. amp ZE Lg te Leer J5 ep le Sm in y a6 T gt Te d S un eT esd HURT D5 moy del e eo e ll S A EI im 3 4 Dn Lue ae Vans aN O5 e EEEE MI e i E oa A 1 E EN EN gt 2 2 t S B 1411 111 L1 L2 Vm III es 8 SC VOR 1 Q1 MITT UT fe il U34 mm mt T ii minm vo UU HI d be U30 U35 HH 2 im HI unm n UNI IO J UI mmm un 6 gn H iii mmm VS ecccccccccccccon 7 Wim UE NN J4 Sek mt TP1 e SE g 3S 5 WI EE H GRACO 4 U5 ui i p s180 mm C 2 wm R5 TP2 an TP3 ES P Analog In Common l E GS st D o c pt Analog In Signal eg Potlife Alarm an SS SS Wes Output Common Gun Trigger General Alarm Flow Control Calibrate TI12924a 3A1080C Digital Inputs See Automation Flow Charts pages 50 54 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 mix ing 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 inac t
5. 120 psi is recom mended e Something is restricting the solenoid or tubing and e There may be dirt or moisture in the air supply Filter interrupting valve actuation air appropriately e Adose valve is turned in too far e Refer to Table 10 Mix Manifold Valve Settings page 67 for adjustment guidelines e Fluid pressure is high and air pressure is low e Adjust air and fluid pressure See recommended air pressure above 3A1080C 93 Alarm Troubleshooting Table 14 Alarm Troubleshooting E 5 OVERDOSE A B DOSE TOO SHORT ALARM and E 6 OVERDOSE B A DOSE TOO SHORT ALARM E 5 the A dose overshoots and when combined with B is too large for the mix chamber capacity E 6 the B dose overshoots and forces an A side dose that when combined with B is too large for the mix chamber capacity 0 Oe Em Valve seal or needle seat are leaking Check FIG 16 Repair the valve see valve manual 312782 Totals Screen on page 23 Sampling valve is leaking Tighten or replace valve Flow meter fluctuations caused by pressure pulsations Check for pressure pulsations Close all the manifold valves Turn on the circulating pumps and all the booth equipment such as fans and conveyors Check if the ProControl 1KS is reading any fluid flow If the ProControl 1KS shows there is fluid flow and there are no leaks from the gun or any other seals or fittings the flow meters are probably being affected by pressure pulsations Cl
6. 3A 1080C Alarm Troubleshooting Table 14 Alarm Troubleshooting E 20 PURGE INITIATE ALARM Cause System detects atomizing air to the gun when purge is Shut off gun air selected For systems with a gun flush box gun is not in the box Place gun in gun flush box Verify that gun flush box is when purge is selected operating properly For systems with auto dump on gun is not in the box Place gun in gun flush box Verify that gun flush box is when auto dump is initiated operating properly For systems with a gun flush box Fuse F2 is blown Verify condition of fuse and replace if necessary See Repair Parts manual E 21 MATERIAL FILL ALARM For systems with minimum mixed material fill volume Check for restrictions or leaks in the fluid supply system entered the system detects that fill volume is not achieved during mixed material fill time Check if the fill volume is properly configured e Adjust fill volume e Adjust fill time For systems without color change and with minimum Verify condition of fuse and replace if necessary See mixed material fill volume entered Fuse F1 is blown Repair Parts manual E 22 TANK A LOW ALARM E 23 TANK B LOW ALARM or E 24 TANK S LOW ALARM The tank volume reaches the low level threshold The EasyKey screen will display the alarm and prompt the user to do one of the following e Refill tank volume to clear the alarm e Resume mixing by selecting Spray 25 o
7. Month Enter current month Day Enter current day Year Enter current year four digits Time Enter current time in hours 24 hour clock and minutes Seconds are not adjustable Date Format Select mm dd yy or dd mm yy 29 Setup Mode Configure Screen 3 Run Moge Automatic Dump Valve A Dump Valve B Un 3rd Flush Valve Configure Run Made Dump Valve A Dump Valke B ard Flush Valve A Fic 29 Configure Screen 3 Configure Run Mode Select the Run mode application from the pulldown menu Automatic default Semi Automatic uses a manual spray gun or Manual Dump Valve A This field only appears if the system includes an optional dump valve A If dump valve A is included set to On Dump Valve B This field only appears if the catalyst change option is detected from the cc board meaning that dump valve B is present On is the only setting 3rd Flush Valve Off is default If optional 3rd flush valve is used set to On 30 Configure Screen 4 Ee t SEC Dose Size Dose ime Hlarm Fic 30 Configure Screen 4 Configure Dose Size Select the total dose size cc from the pulldown menu 100 50 25 or 10 The DD selection dynamic dosing is not used with the ProControl 1KS 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 Number of Guns Enter the number of spra
8. amp mewne Y NAE peaa ee ProControl 1KS Intrinsically Safe IS System Install Label Location P EasyKey Interface IS Associated Label Location i i Apparatus for use in non hazardous on Fluid Station x fu location with IS Connection to Smart on EasyKey Control Box TI15974a FMOBATEXO074 APPROVED Fluid Plate IS T115975a de ed i Apparatus for use in Ze Ze Class l Division 1 Group D T3 C C Ta 20 C to 50 C Hazardous Locations oe Read Instruction Manual MAX AIR WPR Warning Substitution of components Maximum Fluid may impair intrinsic safety Working Pressure PART NO SERIES SERIAL d Part Number is listed here b N GRACO INC P O Box 1441 MPa bar PSI c Mf inneapolis MN MAX TEMP 50 C 122 F GRACO 55440 U S A FiG 1 Identification Label ProControl 1KS Systems 4 3A1080C Hazardous Location Approval System Configuration and Part Numbers Models using a G3000 G3000HR or intrinsically safe Coriolis meter are approved for installation in a Hazardous Location Class I Div Group D T8 or Zone 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 o
9. 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 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 percentage of analog signal range used for driv ing the fluid regulator V P Lock Symbol indicates that Setup screens are password protected See page 26 21 Run Mode Screens Manual Override Screen Manual Override Active Recipe New Recipe Manual Override 3 t Kl Mx SG E Cc min g ec min Flow Rate Range Flow set Point Flaw Ctrl Calibration Start A Global FC Data Copy Fic 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 31 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 P
10. usually air The selected purge valve opens during the First Purge Time and closes when the time expires Chop Cycle Step M1 M2 Select the Chop Type air solvent or air Srd valve and Chop Times The air purge valve opens only during the air chop cycle and the solvent or 3rd valve opens only during the sol vent chop cycle The number of chop cycles is deter mined by dividing the Total Chop Time by the sum of the Air and Solvent Chop Times 3A 1080C Color Change Final Purge Step M2 M3 Select the Final Purge Source air solvent or 3rd valve and Final Purge Time For most applications solvent is selected The system fills the line with solvent from the dose valves to the gun using only the selected purge media usually solvent The selected purge valve opens during the Final Purge Time and closes when the time expires Fill Step M3 M4 This sequence fills the line from the dose valves to the gun and is also referred to as the mixed material fill The system begins dispensing component A until the Fill Time expires Purge Active Step M0 M3 The system turns on the Purge Recipe Change Purge Active output during steps MO M3 Fill Active Step M3 M4 The system turns on the Recipe Change Fill Active out put during step M3 M4 79 Color Change Table 12 Color Change Chart Reference Number of Starting Ending Color Catalyst Dump 3rd Purge Gun Flush Recipe Recipe Change Change Valves Valve Boxes
11. 26 System Configuration and Option Screens Map 28 y NOTE Each screen displays the current screen number and the total number of screens in the group Flush Volume Check Flush and Fill Input K Factor Input Min Material Fill Volume Dec Options Warning Switching to Global source Global source recipe for Flush and Fill Input This will overwrite recipe data Are you sure External Color Change Auto Dump Flow Rate Monitor Options oet Up Home Recipe amp Advanced Setup Sustem Configuration Ek Z DD 012 BC Lan FP 2 00 012 AK 2K Ruto AP V6 6 0 2 MC 1042 0195 IP 10 33 131 205 MAC 00204AAC1610 C1 2 01 C2 TI12804a 3A1080C Configure Screen 1 Language English Enter Password Dl Display Units L oantigure Setup Mode Configure Screen 2 Month Day Year Time Date Format L oantigure Fic 27 Configure Screen 1 Language Defines the language of the screen text Select English default Spanish French German Italian Dutch Jap anese Kanji Korean and Chinese Simplified 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 NOTE Be sure to write down the password and keep it in a secure location Display Units Select the desired display units e ccl liter default e cc gallon 3A1080C Fic 28 Configure Screen 2
12. 28 MPa 276 bar and viscosities of 20 3000 centipoise The K factor is approximately 0 061 cc pulse 3000 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 centi poise 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 gt 1 8 in fluid passages set K factor to 020 or 061 gt 3 8 in fluid passages set K factor to 061 or 0 119 12 3A1080C Component Color Change Valves ACV and Color Change Module CCM Overview Table 1 Component Descriptions Description 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 Dual Fiber Optic Cable FO Fluid Station Control Box Power Supply Cable PS Flow Control Regulator Assembly FC 3A1080C 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 fl
13. 76 Color Change i meu rw ERE xr ERR 78 Color Change Procedures 78 Color Change Sequences 78 Alarms and Warnings 90 System Alarms llle 90 System Warnings sen 90 Alarm Troubleshooting 91 Schematic Diagrams 101 System Pneumatic Schematic 101 System Electrical Schematic 102 EasyKey Electrical Schematic 104 Technical Data ege Eer EE 105 Graco Standard Warranty 106 Graco Information 106 3A1080C Related Manuals Component Manuals in English Manual Description 308778 33000 G3000HR G250 G250HR Flow Meter 313386 Basic Web Interface Advanced Web Interface 406800 15V825 Discrete UO Board Kit 3A1080C Helated Manuals 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 EasyKey and Fluid Station Control Box Label ATEX Certificate is listed here ProContrl 1KS oportioner GD FMO8ATEX0074 APPROVED 2 Intrinsically safe Ex lg WA T equipment for Class I 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 A
14. Color Purge Time P0 gt P1 Color Fill Time P1 gt P2 Catalyst Purge Time P2 gt P3 Catalyst Fill Time P3 gt P4 L CC Purge Fill Timers are independent of System Purge Timers This line defines when the System Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the System Fill Time First Purge one of these 3rd Flush Chop Time Air Purge B EM BW ISolventPurge A WW 3rd Flush Valve 4 VR KE ll Dispense B Gun Flush Box Output 1 adig dd Be en M1 M2 First Purge Time M0 gt M1 Chop Time air solvent or air 3rd flush M1 gt M2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe FIG 83 Color Change Chart 6 3A1080C 83 Color Change ProMix 2KS Recipe Change Chart 7 A1 to A2 B1 to B2 with Dump Valves 1 GFB Male SES timesSeauenes nor E DumpA eee Color Change Solvent Kc Catalyst Change Solvent Color Change A Catalyst Change B S M3 Ee TT Color Purge Time P0 gt P1 Color Fill Time P1 gt P2 Catalyst Purge Time P2 gt P3 Catalyst Fill Time P3 gt P4 4 CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time First Purge one of these 3rd Flush Chop Time be
15. Fiber Optic Strain Relief Port Logic Air Inlet wl LHN i Ground Teen A I S Power TI15919a I H Fic 7 Fluid Station Control Box Connections 3A1080C 17 EasyKey Display and Keyboard AC Power Switch Turns system AC power on or off I S Power Power circuit to Fluid Station Control Box Potlife Exceeded Audible Alarm Alerts the user when a Potlife Exceeded alarm occurs Clear by pressing the Alarm Reset Gei key Graco Web Interface Port Used to communicate with the ProMix from a PC to gt Upgrade software gt View software version Download e Job and alarm logs e Material usage report e Setup values can also upload gt Clear job alarm and material usage reports gt Upload a custom language to view on screen gt Restore factory defaults gt Restore setup password See manual 313386 for more information NOTE If using the Graco Gateway in your system dis connect its cable from the EasyKey before updating the ProMix 2KS ProControl 1KS 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 3A 1080C 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 follow
16. L POWER HARNESS BARRIER BOARD DISPLAY MEMBRANE 1 BOARD SWITCH 2 WITH 3 RIBBON CABLE z 7 POWER DIST 10 TERMINAL 11 BLOCKS DISPLAY VO Oo JOE AA FLOW CONTROL CAL BLK i e 2 GUN TRIGGER WHT D 3 DIGITAL IN COMMON RED e 4 Cl REMOTE STOP GRN e 5 CT ALARM RESET BRN i 6 ALARM OUTPUT BLU e 7 CT DIGITAL OUTPUT COMMON ORG e 3 POT LIFE YEL n 9 FLOW RATE ANALOG IN PUR e 10 TT FLOW RATE ANALOG COMMON GRAY I O HARNESSES RS485 INTEGRATION A WHT BLU RS485 INTEGRATION B BLU WHT RS485 INTEGRATION GROUND SHIELD RS485 NETWORK A WHT ORG RS485 NETWORK B ORG WHT RS485 NETWORK GROUND SHIELD CG P GOAbA J7 L FOIN BLK J8 L FO OUT BLU 3 ae 3 25 200 OPTIONS RJ45 Y WEB SERVER OPERATOR INTERFACE iH L1 85 250VAC 2L N BULKHEAD MODULE HARNESS REMOTE 1 0 INTEGRATION BOARD BCEE Ci d CO N20 TERMINAL BLOCKS AnBWN 102 LINE FILTER CONDMBWNHY DAUBRWDH DwBWNH COO Un 4 C0 NO NONHAZARDOUSAREA _ N ND TERMINAL BLOCK HVDC e RED JD NM RN COM BLACK X E 3 SHIELD CR Y CABLE 50 STD 100 OPTION MIX INPUT PURGE INPUT JOB COMPLETE INPUT EXTERNAL CLR CHG READY RESET ALARM INPUT DI
17. Purging Fluid Supply System page 74 4 Ifthe system is not completely clean repeat step 3 Use the criteria listed in each procedure to determine which procedure to use NOTE If necessary adjust purge sequence so only one cycle is required Purging Mixed Material There are times when you only want to purge the fluid manifold such as A N end of potlife breaks in spraying that exceed the potlife a the gun to relieve pressure Engage trigger overnight shutdown OCK before servicing the fluid manifold assembly hose or gun 5 If spray tip was removed reinstall it 6 Adjust the solvent supply regulator back to its nor 1 Goto Standby mode remove Mix input mal operating pressure Aw the gun to relieve pressure If you are using a high pressure gun engage the trig ger lock Remove spray tip and clean tip separately If using an electrostatic gun shut off the electrostatics before flushing the gun 3A 1080C 73 System Operation Purging Using Recipe 0 Purging Fluid Supply System Recipe 0 is typically used in multiple color systems to Follow this procedure before purge out material lines without loading a new color e the first time material is loaded into equipment e servicing To setup Recipe 0 go to Advanced Setup Select the e shutting down equipment for an extended period of Recipe tab and change the Recipe to 0 The Recipe O time Setup Screen appears Set the chop times from 0 999 e putting equipmen
18. This also applies if using the Modbus Registers see the Modbus Map table in manual 312785 3A1080C ProControl 1KS Integration Specifics Gun Trigger When High this input signals the ProCon trol 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 con trol 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 con nected as shown in Table 8 This ensures proper opera tion of each input and output UO Terminal Strip Detail RS485 Integration A RS485 Integration B RS485 Integration Ground RS485 Network A RS485 Network B RS485 Network Ground Flow Control Calibrate Gun Trigger Digital Common INPUTS Remote Stop Alarm Reset General Alarm Digital Common OU
19. 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 2100 msec 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 gt 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 3A1080C System Operation 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 Mate rial Load portion at the end of the Color Change
20. and select setup values In addition to the numbered keys on the EasyKey key pad 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 16 Keypad Q TI11630A Alarm Reset Key Table 2 EasyKey Keypad Functions see FiG 5 Mer Peg ra 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 3A1080C EasyKey Display and Keyboard AC Power Fiber Optic Strain Audible Alarm Switch Relief Port Main Power T112638a TI12657a Ground Screw LG Power Graco Web Discrete I O Cable Interface Connector Ports Fic 6 EasyKey Connections and AC Power Switch TOP VIEW Meter A Z Flow Control p Gun Air ys gu us lt AL INCL H Meter B E not used T115917a BOTTOM VIEW Booth Control Color Change Manual Systems Module Je only
21. change see page 78 3A 1080C 91 Alarm Troubleshooting Table 14 Alarm Troubleshooting E 3 RATIO HIGH ALARM The mix ratio is higher than the set tolerance on the previous dose cycle There is too little restriction in the system Check that the system is fully loaded with material Check that the supply pump s cycle rate is set prop erly Check that the spray tip nozzle is properly sized for the flow and application and that it is not worn Check that the fluid regulator is set properly If the alarm occurs during start up after purging the flow Restrict gun needle travel to slow down the initial fluid rate was probably too high delivery rate until fluid hoses are loaded with material If the alarm occurred after you were spraying for some Adjust fluid supply regulator pressure Verify that compo time the pressures from the fluid supply could be too nent A dose valve is operating properly high Slow actuation of the component A valve This can be Manually operate the Dispense A solenoid valves as caused by instructed in the ProControl 1KS Repair Parts manual to check operation e Air pressure to the valve actuator is too low e Increase air pressure Air pressure must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar 120 psi is recom mended e Something is restricting the solenoid or tubing and There may be dirt or moisture in the air supply Filter interrupting valve actuation air appropriately e A dose
22. dure appropriate for your system configuration Relieve pressure when you stop spraying before changing spray tips and before cleaning checking or servicing equipment Single Color Systems 1 While in Mix mode gun triggered shut off the fluid supply pumps pressure pots Close all fluid shutoff valves at the pump outlets 2 With the gun triggered push the manual override on the A dose valve solenoid to relieve pressure See FIG 75 NOTE If a Dose Time alarm E 7 E 8 occurs clear the alarm 3 Doacomplete system purge following the instruc tions under Purging Using Recipe 0 page 74 4 Shut off the fluid supply to the solvent purge valve SPV and the air supply to the air purge valve APV FIG 77 5 With the gun triggered push the manual override on the A purge valve solenoid to relieve air and solvent pressure See FIG 75 Verify that solvent pressure is reduced to 0 NOTE If a Purge Volume alarm E 11 occurs clear the alarm 69 System Operation Systems with Color Change and Dump Valves NOTE This procedure relieves pressure through the dump valves 1 70 Complete all steps under Single Color Systems page 69 Shut off all color and catalyst supplies to the valve stacks Press and hold the dump valve A solenoid override FIG 75 See FIG 76 Open the color change module Using the solenoid identification labels as a guide press and hold the override button on each colo
23. exiting Setup mode and return ing to the Status Screen A lock e symbol appears on the Status Screen Setup Locked FIG 24 Setup Locked Screen 26 Set Up Home Screen set Up Home ooo Recipe amp Advanced Setup System Configuration EK 200 012 BC LAr C1 2 01 FP 200 012 AK zZK Buto C AF Vb b 2z Mo 1042 0198 IP 10 55 151 405 MAL 00204AADIS10 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 42 or System Configuration Screens pages 28 33 Press the Enter i key to go to the selected screen set The screen also displays software versions and internet addresses of various components The values shown in FiG 25 are only examples and may vary on your screen See Table 3 for further information 3A1080C Setup Mode Table 3 Component Software Versions Display may vary from examples Component shown Description EK EasyKey 2 00 012 EasyKey software version FP Fluid Plate 2 00 012 Fluid Plate software version 3A1080C BC Booth Control S Booth Control not installed not detected or not oper ational Booth Control software version 1 00 or 1 01 Booth Control software version 2 XX C1 C2 Color Change Color Change Module 1 2 not installed not detected Modules 1 and 2 or not operational Color Change Module software version 1 00 or 1 01 Color Change Module software version 2 XX AK Aut
24. field only appears if the system includes a color change module Enter the catalyst valve number 1 to 4 40 Recipe Setup Screen 2 Recipe EI Minimum Flush Volume cc Potlife Time D minutes Color Catalyst Purge seconds Color Catalyst Fil seconds aESES Calibration Fic 47 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 mini mum flush volume 0 to 999 cc Entering O disables this function Potlife Time Enter the potlife time 0 to 999 minutes Entering O dis ables 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 Rec ipe in Option Screen 1 page 32 Enter the purge time O to 99 seconds It refers to the amount of time required to flush the lines from the color or catalyst mod ule 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 Rec ipe 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 3A1080C Recipe Setup Screen 3 Recipe First Purge Source Chop Tupe E AE Final Purge Sourc
25. or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou
26. 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 net worked 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 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
27. 0 gt P1 Catalyst Purge Time P1 gt P2 Color Catalyst Purge Timers are independent of Mixed Material Purge Air Chop Time Timers Solvent Chop Time First Purge one of these 3rd Flush Chop Time olvent Purge 1 rd Flush Purge Final Purge one of these Dispense A Dispense B Gun Trigger s by Operator First Purge Time M0 2M1 Chop Time air solvent or air 3rd flush M1 gt M2 Final Purge Time M2 gt M3 Notes All timing from Recipe 0 FiG 87 Color Change Chart 10 3A 1080C 85 Color Change ProMix 2KS Recipe Change Chart 11 Recipe 0 OR 61 to Recipe X with Dump Valves Time Sequence Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B B Dispense B Gun Trigger s by Operator Color Fill Time 0 gt 1 Catalyst Fill Time 1 gt 2 Mixed Fill Time 2 gt 3 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 88 Color Change Chart 11 ProMix 2KS Recipe Change Chart 12 Recipe X 0 OR 61 to Recipe 0 without Dump Valves Time Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Air Chop Time Solvent Chop Time 3rd Flush Chop Time 1 olvent Purge Final Purge one of these 3rd Flush Valve Dispense A Dispense B Gun Trigger s by Operator Color Purge Time 0 gt 1 First Purge Time 1 gt 2 Chop Time air solvent or air 3rd flush 2 gt 3 Final Purge Time 3 gt 4 Not
28. 0C ProControl 1KS Integration Specifics Mixing Mode Process See FIG 63 Table 5 and Table 6 Mixing Mode Process Mixing Mode is desired PLC is polling to ensure Mixing Mode is main tained Is Mix Active bit 1 Mixing Process active Check Alarm Condition is Alarm Go to Start Mix Mode General bit 1 Process page 50 Go to Alarm Process ing page 54 FIG 63 Mixing Mode Process Flow Chart 3A1080C 51 ProControl 1KS Integration Specifics Purge Mode Process See FIG 64 Table 5 and Table 6 NO YES Is Mix Ready bit 1 Must be Alarm Condition or Active Recipe 61 See Alarm Processing Set Purge bit 1 on page 54 or Startup from Recipe 61 see NOTE below NO YES Is Purge_CC_ Active bit 1 Wait for Mix Ready ProControl 1KS in Purge_CC Mode Is Mix Ready Process Started bit 1 NOTE At power up the system defaults to Recipe 61 which is not a valid recipe number Initiate a color change to Recipe 0 ora YES ProControl 1KS Purge valid recipe number 1 60 Process Complete Fic 64 Purge Mode Process Flow Chart 52 3A 1080C ProControl 1KS Integration Specifics Color Change Mode Process See FIG 65 Table 5 and Table 6 Color Change Process basic Is Active Recipe NO to desired recipe Register 40005 Do nothing YES Spraying at desired recipe Load ccNewRecipe Regi
29. 77777777 Tee e E EE EE EE Sa E AIRFLOW SWITCH 1 E AFS 2 GRN 4 sopounerg EE if Il PRESS SWITCH 1 15 wee M ce LLLA r PRESS SWITCH 1 BLU MODULE Ee DEER PRESS SWITCH 2 WHT BLK 7 amp COM e e_ SOLVENT FLOW SWITCH EE PRESS SWITCH 42 RED BLK 8 Ne ee D Ser CM RUNDE NOD RE OMEN com SOLENOID 1 12 GRN BLK 9 a v COM se s LH GEB 1 PRESSURE SWITCH eee ence H Ii kon SOLENOID 1 COM ORG BLK 1 10 9 sG T M dee SOLENOID 2 12 BLU BLK _ 11 i0 El COn A el GFB A PRESSURE SWITCH cenn aaaea annen SOLENOID 2 COM RED WHT L 12 103 Schematic Diagrams EasyKey Electrical Schematic 3A1080C QqvaHwingssvfd Svfu H gt _ ld Quvog Ne Spry Syry DAATL YaMOd SI 3LIHM S GA CL 35018 IVNIWH3L wanuaw YIMOd DMY 9L NMOHU8 te DN AN9 EE QuvOS u3tuuvg DMY 91 DANN nn ansima E sl NI 20A C JOVLIOA 1fd1nO 403d DAY 81 Q38 DMY 81 Q38 DAY 8L DV T8 ER i DMY 815DV T8 6r EH DMY 72 3IIHWYOV 18 038 DMV 72 ALM DV 18 N3385 ER Quvo8 AN WS Waviv 104 Technical Data Technical Data Maximum fluid working pressure Base system 4000 psi 27 58 MPa 275 8 bar Low pressure color change 300 psi 2 07 MPa 20 6 bar Cori
30. AL OPTIONAL v H D KR ve MANIFOLD COLOR COLOR CHANGE VALVE CONTROL STACKS AIR EXHAUST MUFFLER TP i 7 COLOR 1 n COLOR 2 COLOR 3 SG m Lu S 7 P COLOR 8 COLOR SOLVENT ca ME P COLOR 10 a 12VDC S COLOR 11 9 G LOR 12 9 X CATALYST 1 z EE CATALYST 4 WAY SOLENOID ATALYST 3 o CATALYST 4 m CATALYST SOLVENT e z i S V4 Sex St Xpmi sme P BE 4 WAY SOLENOID end VALVE n 3 8 AIR FILTER S e MANUAL DRAIN S gt 5 MICRON c WALL MOUNT ONLY an i y i lt 12 VDC l l L IC 2 GIS see mag 4 WAY SOLENOID um d Ge i 7 COLOR 16 g qi COLOR 17 O COLOR 18 AIR INPUT COLOR 20 HIX puec a der VALVE COLOR 23 4 WAY SOLENOID tT K ILI OPTIONAL COLOR24 C p COLOR 25 S B COLOR 26 a AIR EXHAUST MUFFLER COLOR 27 Es xi 7 COLOR 28 Ant COLOR 29 d 12VDC COLOR 30 zd 3 WAY SOLENOID sam oor a a Hi OPTIONAL SF K SE n E 12 VDC DUMP B St Z S del DE 3 WAY SOLENOID ie x cn z id Oo eg U Dy 7 Ge GFB 2 _ VALVE me OPTIONAL H 3A1080C 101 Schematic Diagrams System Electrical Schematic NOTE The electrical schematic illustrates all possible wiring expansions in a ProControl 1KS system Some compo nents shown are not included with all systems Non Hazardous Area DC OK Kuck K COMMON COMMON
31. Change CC Set Bit to 1 to initiate Color Change momentary 1 10 Pin Terminal Block Flow Control Calibrate Set Bit to 1 to initiate Flow Control Calibrate momentary 2 10 Pin Terminal Block Gun Trigger Set Bit to 1 to indicate Gun is Triggered fluid flow expected 10 Pin Terminal Block Digital Input Common 4 10 Pin Terminal Block Remote Stop Set Bit to 1 to initiate a Remote Stop momentary 5 10 Pin Terminal Block Reset Alarm Set Bit to 1 to Clear an Active Alarm momentary Digital inputs tied together on the I O board see FIG 61 1 3 5 6 T Digital inputs tied together on the EasyKey Display Board see FIG 59 Multiple connection points for convenience 3A1080C 5 ProControl 1KS Integration Specifics Table 8 Discrete I O Terminal Connections Terminal Terminal Location Details also see pages 55 and 56 Digital Outputs J4 Remote UO Board Digital Output Common Power J4 Remote I O Board Purge CC Active 1 Indicates Purge or Color Change is in progress J4 Remote UO Board Mix Active 1 Indicates Mix is in progress J4 Remote UO Board Mix Ready 1 Indicates No Alarms and OK to Mix 5 J4 Remote UO Board CC Fill Active 1 Indicates the Fill Portion of a Color Change is in progress J4 Remote I O Board FCalActive 1 Indicates the Flow Control Calibrate rou tine is in progress J4 Remote UO Board Flow Rate 1 Indicates the Flow Rat
32. Communication between the Color Change Module and Verify that the cable is correctly connected the Fluid Station Control Box is interrupted Communication between the Color Change Module and Verify condition of fuse and replace if necessary See the Fluid Station Control Box is interrupted The fluid Repair Parts manual control board fuse is blown E 13 HIGH_FLOW_ALARM or E 14 LOW_FLOW_ALARM may also be set as Warnings Cause Fluid system is producing too much or too little flow Troubleshoot fluid system for restrictions leaks exhausted fluid supply incorrect settings etc Increase or decrease flow rate as required 96 3A 1080C Alarm Troubleshooting Table 14 Alarm Troubleshooting E 15 SYSTEM IDLE WARNING Cause Mix input is high but the gun has not been triggered for 2 If not painting clear alarm and resume operation minutes If painting shut down and inspect fluid meter E 16 SETUP CHANGE WARNING O O otto The system setup parameters have been changed No action required See Event Log available through advanced web interface E 17 POWER_ON_WARNING The power to the system has been cycled No action required See Event Log available through advanced web interface E 18 DEFAULTS LOADED WARNING Cause The factory defaults have been installed on the system No action required See Event Log available through advanced web interface 3A1080C 97 Alarm Troubleshooting Table 14 Al
33. Configuration EK 2 00 012 BC Lan C1 2 01 FP 2 00 012 AK 2k Auto Ce AP Vo 6 0 2 MC 1042 0198 IP 10 33 131 2053 MAC D204BRRD1810 Meter A Meter Calibration Measured Actual Volume Volume Occ Dee K Factar 0 119 cc pulse Calioration Recipe Flow Rate Monitor Low Flow Limit DI cemin High Flow Limit cc min KH Calibration Recipe special n Purge Length On Fill Recipe screens 3 4 5 6 and 7 appear depending on selections made in Option screens 1 and 2 Setup Mode T112806a 39 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 Recipe Setup Screen 1 hecipe Ratio Ratio Tolerance Color Valve Latalyst Valve MEE Calibration Fic 46 Recipe Setup Screen 1 Ratio Enter the mix ratio of component A over component B 0 0 1 to 50 1 Set to 0 1 for ProControl 1KS Ratio Tolerance Enter the ratio tolerance 1 to 99 This refers to the percent of acceptable variance that the system will allow before a ratio alarm occurs Component A Color Valve if present This field only appears if the system includes a color change module Enter the color valve number 1 to 30 Component B Catalyst Valve if present NOTE Not used with ProControl 1KS This
34. Control 1KS to the automation Input and output connections are made at the Discrete UO terminal strips Fic 60 and the discrete I O board FiG 61 inside the EasyKey Also see the System Electrical Schematic on page 102 Review the Color Change Charts FIG 78 FIG 95 A full understanding of the color change sequence is neces sary to properly drive the inputs and monitor the out puts See Advanced Setup Screen 7 page 38 This screen shows the actual status of all inputs and outputs It is important to ensure that each input from local automa tion PLC is received by the EasyKey and to verify that the ProControl 1KS is sending outputs to the automa tion The following paragraphs describe each discrete O function in detail Barrier Board Terminal Strips see FiG 60 O ON Ven VLC EE E 00000 E b S RI Less nu I ech Ee E D ll je oj WH D C SECO teen er Discrete I O Board see FIG 61 T112496a Fic 58 EasyKey Control Boards 3A 1080C 45 ProControl 1KS Integration Specifics Multiple Station TI12923a Integration Control FiG 59 255767 EasyKey Display Board 46 a ALM POWER go amu Ty m Ce dy RS485 J6 J9 m B C 1 Q REMOTE V
35. 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 material that is required to fill from the dose valves to the applicator gun 41 Setup Mode Recipe Setup Screen 5 hecipe k F actor A Meter 0 119cc pulse D Meter 0 119cc pulse solvent Meter 0 119cc pulse MEE Calibration FiG 50 Recipe Setup Screen 5 This screen appears only if K Factor Input is set to Rec ipe 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 B Meter NOTE Not used with ProControl 1KS Enter the k factor cc pulse for flow meter B K factor Solvent Meter This field only appears if Solvent Monitor is set to Meter in Configure Screen 5 page 31 Enter the k factor cc pulse for the solvent flow meter 42 Recipe Setup Screen 6 D cc min cemin Recipe Flow Rate Monitor Low Flow Limit High Flow Limit MESE Calibration FG 51 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 Lo
36. 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 e Mix Start e Purge Start e 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 rec ipe Do not change the Recipe Bits until a color change is required again Inconsistent results are possible if this is not followed 3A1080C General Operating Cycle d 2 The system enters and loads the desired color The system enters Mix mode to begin operation The ProControl 1KS controller sends signals to acti vate the solenoid valves The solenoid valves acti vate Dose Valve A Fluid flow begins when the Gun Trigger input is seen Dose Valve A DVA opens and fluid flows to the gun Flow Meter A MA monitors the fluid volume dis pensed and sends electrical pulses to the ProCon trol 1KS controller The controller monitors these pulses and signals When the target volume dispenses Dose Valve A closes APV AT DVA SS Key MA Compone
37. GITAL INPUT COMMON DIGITAL INPUT COMMON RECIPE BIT 0 INPUT RECIPE BIT 1 INPUT RECIPE BIT 2 INPUT RECIPE BIT 3 INPUT RECIPE BIT 4 INPUT RECIPE BIT 5 INPUT RECIPE CHANGE INPUT DIGITAL OUTPUT COMMON POWER PURGE RECIPE CHG ACTIVE OUTPUT MIX ACTIVE OUTPUT MIX READY OUTPUT FILL ACTIVE FLOW CAL ACTIVE FLOW RATE ALARM OUTPUT DIGITAL OUTPUT COMMON POWER DIGITAL OUTPUT COMMON POWER SPECIAL OUTPUT 1 SPECIAL OUTPUT 2 SPECIAL OUTPUT 3 SPECIAL OUTPUT 4 DIGITAL OUTPUT COMMON POWER 24 YEL COM GRAY ORG BRN RED BEACON CABLE T 3A 1080C System Electrical Schematic NOTE The electrical schematic illustrates all possible wiring expansions in a ProControl 1KS system Some compo nents shown are not included with all systems Hazardous Area 3A1080C L FO OUT BLU FO IN BLK FLUID PANEL CONTROL BOX HAZARDOUS AREA 3X CABLE JL PWR RED COM BLACK FLOW METER A SIG WHITE r SHIELD GRN Sc NOT USED NOT USED Cs NOT USED NOT USED GROUND TERMINAL UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED PWR RED EE COM BLACK FLOW METER SOLVENT SIG WHITE SHIELD GRN fA 4 I S METERS Schematic Diagrams 1 SIG RED 2 COM BLK JA PRESSURE GRN COM RED EX WHT PRESSURE BLK SHIELD BARE UON yn LLL ET 145 2 3
38. Operation G g TM ProControl 1KS 3A10800 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 See pages 4 5 for model information including maxi Important Safety Instructions mum working pressure Equipment approval labels are Read all warnings and instructions in this on page 3 Some components shown are not included manual Save these instructions with all systems L TM6328a C d APPROVED Il 2 G PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Equipment Approvals 3 System Configuration and Part Numbers 4 leie osos ecu oe sone d EEN 4 dd e CEET 6 Important Two Component Material Information 9 Isocyanate Conditions Ls 9 Material Self ignition 9 Keep Components A and B Separate 9 Moisture Sensitivity of Isocyanates 9 Changing Materials lle 9 Glossary of Terms 10 OVOFVIGW uci vacet a TRUE eg e ue an 12 BI Le EET 12 Component Identification and Definition 12 ProControl 1KS System Components 14 EasyKey Display and Keyboard 16 DISDIAY rers den dan eid dup bb E e id 16 ICV DGG videa A Dodd ee Merits dab Were EE fait 16 AC POWer SWITCH x etd bs eat 18 WS POWER ugs rap
39. Refer to Fig Ox X Ww 9 rem OX X ow Y Ww 9 j Le we ow we o me Lx oe e Last 2 RSC Ke Ke IO o O O e Z O L 3x 5 WW leese Sus x Ya Ys We No fono Fee Sas 3X 3 Ww Ne Ne Sez Reo owe X Ne Ye Ye Ne oroe lem po 0 m Y CHE 9 9 w Ne Ye Ne oro Fin er o 9 X Ne Ne Ne oro ee Co o N X Ys N ono Fc er o o No N No No oroz Fe 8 o YesorNo YesorNo YesorNo no otor2 Feer o x Ye Ye Ye we onoz Pow Ls 3 0 w o Ys ersr Res Co X Ne Y Ys Ye tor Fic on po X No N N Ye 9hw2 Re9 NOTES FIG 87 and Fia 88 show both color and catalyst change If the color or catalyst is not changing disregard that portion of the chart O a Ha FIG 89 and FIG 90 show color change If the color is not changing disregard that portion of the chart FiG 91 page 87 shows a recipe change with Special Outputs FIG 93 page 88 shows an External Color Change 80 3A 1080C Color Change ProMix 2KS Recipe Change Chart 1 A1 to A2 B1 to B2 with Dump Valves Time Sequence SSES SE Ss Color Change Solvent EN courchageA 1 Color Change A MEM Catalyst ChangeB BB P1 P3 P4 Color Purge Time P0 gt P1 Color Fill Time P1 gt P2 Catalyst Purge Time P2 gt P3 Catalyst Fill Time P3 gt P4
40. TPUTS Potlife Alarm l Flow Rate Analog In Flow Rate Analog Common T112958a FiG 60 EasyKey Terminal Strips 47 ProControl 1KS Integration Specifics Digital Output Common Power Special Output 4 Special Output 3 Special Output 2 Special Output 1 Digital Output Common Power G EN LI O Q KE LI Digital Output Common Power Flow Rate Alarm Output Flow Control Calibrate Active CA MV Fill Active O Mix Ready Output S LO Mix Active Output C WG lt A N Purge Recipe Change Active Output RN1RN2 RN3 OU O Digital Output Common Power C Recipe Change Input Recipe Bit 5 Input C o Recipe Bit 4 Input Recipe Bit 3 Input Recipe Bit 2 Input Recipe Bit 1 Input A NO A Recipe Bit O Input ER ER cO Digital Input Common AJ OO Mix Input Purge Input Job Complete Input Spare Digital Input Common External Color Change Ready Fic 61 255766 Discrete I O Board 48 3A 1080C Digital Outputs See Automation Flow Charts pages 50 54 Purge CC Active This output will remain High during the manual Purge or Color Change purge sequence See the Color Change Charts FIG 78 FiG 95 for fur ther information Fill Active This output will remain High while the Pro Control 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 Pro Control 1KS is in Mix
41. able gloves when spraying dispensing or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury hearing loss inhalation of toxic fumes and burns This equipment includes but is not limited to e Protective eyewear and hearing protection Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 8 3A1080C Important Two Component Material Information Important Two Component Material Information Isocyanate Conditions Spraying or dispensing materials containing isocya nates creates potentially harmful mists vapors and atomized particulates Head material manufacturers warnings and mate rial MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventila tion 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 Some materials may become self igniting if applied too thickly Read material ma
42. an alarm They are saved in the date time stamped log which can be viewed on a PC using the Web Interface see manual 313386 To Reset Alarm and Restart NOTE When an alarm occurs be sure to determine the E Code before resetting it See Table 13 If you forget which E Code occurred use the Alarms Screen page 24 to view the last 10 alarms with date and time stamps To reset alarms see Table 14 Many alarms can be cleared by simply pressing the Alarm Reset Gei key 90 Table 13 System Alarm Warning Codes Code Description Details E 5 Overdose A B Dose Too Short Page 94 Alarm Overdose B A Dose Too Short Page 94 Alarm Ei Dose Time A Alarm Time A Alarm Dose Time A Alarm Page95 Page 95 EI Time B Alarm Page 95 Mix in Setup Alarm Page 96 Hemote Stop Alarm Page 96 Purge Volume Alarm Page 96 E 12 CAN Network Communication Error Page 96 Alarm High Flow Alarm Page 96 Low Flow Alarm Page 96 System Idle Warning Page 97 Setup Change Warning Page 97 Power On Warning Page 97 Defaults Loaded Warning Page 97 UO Alarm Page 98 Purge Initiate Alarm Page 99 Material Fill Alarm Page 99 Tank A Low Alarm Page 99 Tank B Low Alarm Page 99 Tank S Low Alarm Page 99 Auto Dump Complete Alarm Page 100 Color Catalyst Purge Alarm Page 100 Color Catalyst Fill Alarm Page 100 3A 1080C Alarm Troubleshooting Alarm Troubleshooting Table 14 Alarm Troubleshooting E 1 COMM ERROR OO mem GN No pow
43. arm Troubleshooting E 19 O ALARM The Mix and Purge digital inputs are on at the same time Ensure that only one input is on at a time At least 1 sec delay is required when switching from Mix to Purge or vice versa NOTE The I O alarm incorporates several sub alarms relating to internal data issues as detailed below These alarms may not apply to all software versions Fluid Plate Reboot FP Reboot Occurs if the system detects a fluid plate control board reboot or power cycle not triggered from the EasyKey The system reverts to Recipe 61 and mixed material may be in the lines Autokey Lost Occurs if the Autokey is lost or changed after having been detected A short term loss of the Autokey will not be registered Some system functions may become unavailable For example an automatic system will not respond to PLC or robot control Illegal Source Occurs if a recipe outside of the range 1 60 is detected as the source data for global recipe data copies This is possible if an invalid configuration file is sent to the EasyKey 2K 3K Error Occurs if the recipe data is incompatible with the current Autokey setting 2K or 3K This is possi ble if the Autokey is changed or an invalid configuration file is sent to the EasyKey Init Error Occurs if the recipe data codes specifying the type of machine they were made on are not what is expected For example a 3KS machine receives a con figuration file originally made
44. aterial that is required to move through the mix manifold hose and applicator before the potlife timer is reset 3A1080C Glossary of Terms Purge when all mixed material is flushed from the sys tem Purge Time the amount of time required to flush all mixed material from the system 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 Solvent Fill the time required to fill the mixed material line with solvent Standby refers to the status of the system 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 air pressure device in the flow control module 17 Overview 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 e Has user selectable ratio assurance and can main e Color change options are available for low pressure tain up to 1 accuracy depending on materials 300 psi 2 1 MPa 21 bar air spray and high pres and operating condition
45. cipe 0 by pressing Enter A 74 3A1080C 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 FIG 75 on page 71 5 Purge as follows e 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 e Multiple color systems Select Recipe 0 and press Enter amp ilil The color change LED blinks while Recipe O 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 67 for Start Up procedure 3A1080C System Operation 75 Meter Calibration Meter Calibration 4 Onthe EasyKey press the Setup o key to access setup screens 5 Press the Right Arrow mp key to select the Cali Calibrate the meter bration Screen Press the Enter lii key to select e The first time the system is operated Dose Valve A Press the Down Arrow v key and e Whenever new materials are used in the system select Start from the menu Start only one at a time especially if the materials have viscosities that differ significantly e Atleast once per month as part of regular mainte Meter A Meter nance Calibration Start e Wh
46. ctive OGun Trigger Iii Ready CO Job Complete OGeneral Alarm ORemote Stop LIPatlife Alarm OReset Rlarm OF low Rlarm Advanced Calibration t d opecial 1 2 3 On Purge B DT D Length 0 C Oo bt fo fo ol Length 0 al L 6 TI12805a 3A1080C 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 Advanced Setup Screen 1 Flow Control Override Manual Uverride Lun 1 Potlite Volume Lolor Latalyst Purge seconds Lolor Latalyst Fill seconds 4 Fic 37 Advanced Setup Screen 1 t 1 a 8 Flow Control Override This field only appears if Flow Control is set to On in Configure Screen 5 on page 31 The selections made will affect the display in Manual Override Screen on page 22 Choose the desired selection as defined below Description Off Normal operation Open LLL RN EN Flow control regulator is opened to a DU leases percentage o s Pressure Flow control regulator is opened to a Jonn o 3A1080C Setup Mode 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 to override all outside control If selected the Manual Override Screen page 22 will be added Gun 1 Gun2 Po
47. dispensed volume in cc for A or Solvent Volume field and press the Enter lt l key If the value was substantially different repeat the calibration process NOTE If the screen and actual volume is the same or if for any reason you want to cancel the calibra tion procedure scroll to Abort on the Calibration Screen menu and press the Enter li key 10 After the volume for A or Solvent is entered the Pro Control 1KS controller calculates the new flow meter K Factor and shows it on the Calibration Screen NOTE K Factor values on the screen are viewable only If needed you can manually edit the K Factors in Advanced Setup Screen 4 page 37 or Recipe Setup Screen 5 page 42 11 Before you begin production clear the system of solvent and prime it with material a Goto Mix mode b Trigger the gun into a grounded metal pail until mixed material flows from the gun nozzle C To begin operation see Start Up page 67 3A1080C 77 Color Change Color Change Color Change Procedures Multiple Color Systems 1 2 Shut off air to the gun Place the gun in the gun flush box if used and close the lid Go to Standby mode remove Mix input Select the new recipe Begin the color change sequence If a gun flush box is not used trigger the gun manual or automatic into a grounded metal pail until the color NP P change sequence is complete 2 d NOTE The color change timer does not start un
48. djust as needed d Ifthe flow meters over run because of air in the system an alarm will occur and operation stops 12 Turn on atomizing air to the gun Check the spray pattern as instructed in your spray gun manual Press the Alarm Heset x key to clear NOTE Do not allow a fluid supply tank to run empty It is alarm possible for air flow in the supply line to turn gear meters in the same manner as fluid This can lead to the mixing of fluid and air that meets the ratio and tolerance set e Goto Mix mode tings of the equipment 11 Adjust the flow rate The fluid flow rate is shown on the EasyKey Status screen The fluid supply lines on the screen high light when the dose valve is open 11 9 2009 1440 4 psi 740 ei 375cc min 4 sfocc ming Fic 73 Status Screen Flow Rate Display 68 3A 1080C Shutdown Overnight Shutdown 1 Leave the power on 2 Run Recipe O to purge solvent through meters and gun Service Shutdown 1 Follow Pressure Relief Procedure on page 69 2 Close main air shutoff valve on air supply line and on ProControl 1KS 3 Shut off ProControl 1KS power 0 position FiG 74 4 If servicing EasyKey also shut off power at main cir cuit breaker 0 OFF T112657a Fic 74 Power Switch 3A1080C System Operation Pressure Relief Procedure NOTE The following procedures relieve all fluid and air pressure in the ProControl 1KS system Use the proce
49. e Alarm Warning is active J4 Remote VO Board Digital Output GCommon Power J5 Remote UO Board Digital Output Common Power J5 Remote I O Board Special 1 1 Indicates the Special 1 Output is on 3 J5 Remote UO Board Special 2 1 Indicates the Special 2 Output is on J5 Remote UO Board Special 3 1 Indicates the Special 3 Output is on J5 Remote I O Board Special 4 1 Indicates the Special 4 Output is on J5 Remote UO Board DigtalOuputCommonPower 6 10 Pin Terminal Block General Alarm Output 1 Indicates the General Alarm Output is on 7e DEE 10 Pin Terminal Block Digital Output Common Power 8 10 Pin Terminal Block Potlife Alarm 1 Indicates the Potlife Alarm Output is on 10 Pin Terminal Block Flow Rate Analog In 0 10 0 10VDC input for Flow Setpoint relative to VDC flow range set in 2KS Flow Range Screen 10 Pin Terminal Block Flow Rate Common to Pin 9 Common side of Flow Setpoint from Terminal 9 2 1 3 4 Communications 6 Pin Terminal Block RS485 Integration A m E Communication to External PLC Controller 3 6 Pin Terminal Block RS485 Integration Shield Ground 6 Pin Terminal Block RS485 Network A 6 Pin Terminal Block RS485 Network B Communication to Multiple EasyKeys only 6 6PinTerminalBlock RS485 Network Shield Ground Digital outputs tied together on the I O board see FIG 61 Digital outputs tied together on the EasyKey Di
50. e Eoen Hi Air Chop Time seconds Solvent Chop Time seconds A MEE Calibration Fic 48 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 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 mix ing 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 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 3A1080C Setup Mode Recipe Setup Screen 4 Recipe First Purge Time Total Chop Time Final Purge Time Mixtec Fill Time MESE Calibration Fic 49 Recipe Setup Screen 4 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 32 lf 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
51. e 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 e Shutdown or go to Standby after the flow rate alarm time expires Job Complete Input Every time a momentary Job Complete input is seen by the ProControl 1KS a job log will be recorded logging the A meter volume cc with a time and date stamp The volume will then be reset to 0 Volume totals are accu mulated 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 vol umes 64 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 38 or Recipe Setup Screen 7 on page 42 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
52. e Screen 3 page 30 Gun 2 Trigger Displays AFS if Number of Guns is set to 2 in Config ure Screen 4 page 30 Control Network ID Used for the Graco Gateway network system See Graco Gateway manual 312785 for further information 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 Flush Volume Check Flush and Fill Input K Factor Input Min Material Fill Volume Dec Options FIG 33 Option Screen 1 Flush Volume Check This field only appears if Solvent Monitor is set to Meter in Configure Screen 5 page 31 If set to On Minimum Flush Volume will appear in Rec ipe Setup Screen 2 page 40 Flush and Fill Input If set to Global Color Catalyst Purge and Color Cata lyst Fill are added to Advanced Setup Screen 1 page 35 Advanced Setup Screen 2 and 3 are added See pages 36 38 If set to Recipe Color Catalyst Purge and Color Cata lyst Fill are added to Recipe Setup Screen 2 page 40 Recipe Setup Screen 3 4 and 7 are added See pages 41 42 K Factor Input If set to Global Advanced Setup Screen 4 page 37 is added If set to Recipe Recipe Setup Screen 5 page 42 is added Minimum Material Fill Volume Enter 0 9999 cc 32 Verification Screen Warning switching ta Global
53. eassembling Changing Materials e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean e Always clean the fluid inlet strainers after flushing e Check with your material manufacturer for chemical compatibility e Most materials use ISO on the A side but some use ISO on the B side Glossary of Terms Glossary of Terms Air Chop the process of mixing air and solvent together during the flush cycle to help clean the lines and reduce solvent usage 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 Closed Loop Flow Control refers to the process when the flow rate is adjusted automatically to maintain a constant flow Color Catalyst Dump 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 Coriolis Meter a non intrusive flow meter often used in low flow applications or with light viscosity shear sensi tive or acid catalyzed materials This meter uses vibra tion to measure flow Digital Input and Output a description of data which is transmitted as a sequence of discrete symbols most commonly this means binary data represented u
54. ed by the Status Screen see page 21 GRACO Control 2 00015 Easukeu ZU UI Fic 8 Splash Screen The Splash screen will also momentarily display Estab lishing Communication If this display remains for more than one minute check that the fluid station control box circuit board is powered up LED is on and that the fiber optic cable is properly connected see Installation man ual 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 Programming Fluid Plate Lade mE Fic 9 Fluid Plate Programming Screen 3A1080C Run Mode Screens 19 Run Mode Screens Job Complete Are uou sure you want to reset job totals Enter new job number or press enter to accept default Fic 10 Run Screens Map 20 11 9 2009 1440 4 D psi lll coy 9 375cc min 4 e 3i3cc min 4 Mis Eo Manual Override Active Recipe 3 t New Recipe E Manual Override 4 Flow Rate Range O 1200 ce min 4 Flow Set Point cc min Flow Ctrl Calibration Start Wi Global FC Data Copy Usage Job Total Grand Total A 0ce 0 Liters B ies 0 Liters H B l cc D Liters Cher Uc D Liters Job 0 Rusa MERI solvent Level Control Reset Solvent Are uou sure you want to reset solvent total Alarms Date Time Alarm O1 Oe 03 04 03 Pres
55. enever a flow meter is serviced or replaced Measured Actual volume volume NOTE e K Factors on the Calibration Screen are cc E updated automatically after the calibration pro K Fatctar 0 119 cc pulse cedure is completed Recipe MEZ ec e K Factor values on the screen are viewable only If needed you can manually edit the K Factors in Advanced Setup Screen 4 see page 37 or Recipe Setup Screen 5 page 42 e All values on this screen are in cc independent of the units set in Configure Screen 1 6 Dispense a minimum of 250 cc into beaker make sure enough material is dispensed to accurately read the volume with your beaker e The controller will use the active recipe K factors for meter calibration The active recipe must be recipe 1 to recipe 60 Recipes 0 and 61 do not have K factor values 7 The volume that the ProControl 1KS measured dis plays on the EasyKey 1 Before calibrating meter A prime the system with material For a color change system make sure the color valve is open 2 Shut off all spray or dispense devices connected to the ProControl 1KS 3 Place the beaker minimum size 250 cc to capture fluid from the gun 76 3A 1080C Meter Calibration 8 Compare the amounts on the EasyKey to the amount in the beaker NOTE For maximum accuracy use a gravimetric mass method to determine the actual volume dis pensed 9 Ifthe screen and actual volume are different enter the actual
56. ept default Fic 17 Reset Total Screen If job is reset job number will increment by one for default Reset Solvent Screen Reset Solvent Are uou sure uou want to reset solvent total Fic 18 Reset Solvent Total Screen The screen will ask if you want to reset solvent total Select Yes or No 23 Run Mode Screens Alarms Screen Alarms Date Time Alarm Fic 19 Alarms Screen Two screens show the last 10 alarms Use the Up A or Down Li keys to scroll between the two screens See Table 13 on page 90 for a list of alarm codes Level Control Screen Level Control Liters Hlarm Level Current Volume Color 1 10 Color z 10 Catalyst 1 10 Srel le 10 Level Control Fic 20 Level Control Screen This screen shows the current volume for each fluid Adjust the actual volumes on this screen or use the tab to go to Usage Totals Screen page 23 24 See FiG 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 Remain der If this selection is chosen a second alarm will occur after 25 of the remaining volume is mixed Hefill tank volume to clear the alarm Warning Tank Level Low Alarm Color 1 10 Liters Alarm Level 10 Liters Current Volume 1 Refil Tank Valume 2 eprau 234 of Remainde
57. er to the EasyKey Connect power to EasyKey No power to Fluid Station Control Box The intrinsically Verify that the cable is correctly connected See Installa safe power cable between the EasyKey and Fluid Station tion manual Control Box is not connected No power to Fluid Station Control Box The fluid control Verify condition of fuse and replace if necessary See board fuse is blown Repair Parts manual The fiber optic cable between the EasyKey and Fluid Verify that the cable is correctly connected See Installa Station Control Box is not connected tion manual The fiber optic cable is cut or bent Verify that the cable has not been cut or bent at a radius smaller than 1 6 in 40 mm Dirty fiber optic cable ends Disconnect fiber optic cable ends and clean with a lint free cloth A communication cable or connector failed Replace cable E 2 POTLIFE ALARM The potlife time has been exceeded for the mixed mate rial Press the Alarm Reset key to stop the audible alarm Purge the system with solvent fresh mixed mate NOTICE rial or a new color To prevent mixed material from curing in the equip ment do not shut off power Follow one of the solu Solvent Purge See Purging Mixed Material on tions at right page 73 The system purges until the preset purge time is complete New Mixed Material Purge Go to Mix mode and spray the required volume to restart the timer Color Change Perform a color
58. erator Color Purge Time 0 gt 1 Color Fill Time 1 gt 2 First Purge Time 2 gt 3 Chop Time air solvent or air 3rd flush 3 gt 4 Final Purge Time 4 gt 5 Mixed Fill Time 5 gt 6 Notes Load tables from new recipe Purge from old recipe Fill from new recipe FiG 81 Color Change Chart 4 82 3A 1080C Color Change ProMix 2KS Recipe Change Chart 5 B1 to B2 same A with Dump Valves Male S Time Sequence EE Dump B Color Change Solvent El Catalyst Change Solvent Color Change A Catalyst Change B Catalyst Purge Time P0 gt P1 Catalyst Fill Time P1 gt P2 y CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time First Purge one of these 3rd Flush Chop Time begins Air Purge NI Solvent Purge 3 3rd Flush Valve Dispense A Dispense B Gun Trigger s by Operator First Purge Time M0 gt M1 Chop Time air solvent or air 3rd flush M1 gt M2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe FIG 82 Color Change Chart 5 ProMix 2KS Recipe Change Chart 6 A1 to A2 B1 to B2 with Dump Valves 2 GFBs Vale SES me eque Geen DumpA eee i Color Change Solvent NENNEN cowchages wm Color Change A Catalyst Change BEE
59. es All timing from Recipe 0 FiG 89 Color Change Chart 12 86 3A1080C ProMix 2KS Recipe Change Chart 13 Recipe 0 OR 61 to Recipe X without Dump Valves Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Dispense A Dispense B Gun Trigger s by Operator Color Fill Time 0 gt 1 Mixed Fill Time 1 22 Notes Load tables from new recipe Purge from old recipe Fill from new recipe FiG 90 Color Change Chart 13 ProMix 2KS Recipe Change Chart 14 A1 to A2 B1 to B2 with All Time Sequence pu ESOO OOO oan i ae Color Change Solvent NEN Glace 5 5 JL eng Color Change A ew CaaystchageB ll P1 PO PRR NNNM P4 P3 Color Purge Time P0 gt P1 CC Purge Fill Timers are independent of Mixed Material Purge Timers This Color Fill Time P1 gt P2 line defines when the Mixed Fill Time defines when the Mixed Fill Time Se Air Chop Time Solvent Chop Time First Purge one of these 3rd Flush Chop Time NX Solvent Purge Nl 3rd Flush Valve Dispense A Dispense B Gun Trigger s by Operator First Purge Time M0 2M1 Chop Time air solvent or air 3rd flush M1 gt M2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe 1st On Start 1st On Length Duration 2nd On Start 2nd On Length Special Output 1 FiG 91 Color Change Chart 14 3A1080C Color Change 87 Col
60. f remain ing volume 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 3A1080C 99 Alarm Troubleshooting Table 14 Alarm Troubleshooting E 25 AUTO DUMP COMPLETE ALARM Cause A potlife alarm is active for more than 2 minutes the gun Be sure to spray all mixed material before potlife expires flush box is enabled and gun is in the gun flush box and an auto dump flush sequence is complete E 26 COLOR CATALYST PURGE ALARM System detects no meter pulses or a disruption in meter Check that meter cable is connected pulses lasting longer than 1 second throughout the Color purge time duration Clean or repair meter E 27 COLOR CATALYST FILL ALARM System detects no meter pulses or system must detect Check that meter cable is connected at least 10cc of material from each side throughout the Color fill time duration Clean or repair meter Gun dump valve or correct color catalyst valve not Open the valve open Exhausted fluid supply Check fluid level and refill if necessary Fuse F1 F2 or both are blown Verify condition of fuses and replace if necessary See Repair Parts manual 100 3A1080C Schematic Diagrams Schematic Diagrams System Pneumatic Schematic A HU OPTIONAL dr m S amp S p MAC 36 SERIES SOLENOID VALVES 12VDC B 3 WAY SOLENOID 4 GFB 1 as _ VALVE D L
61. for the digital inputs See Common under Digital Inputs page 47 3A1080C ProControl 1KS Integration Specifics Analog Inputs Flow Command This is the positive side of the O 10 Vdc signal See Common under Digital Inputs page 47 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 O Vdc analog input is O cc min therefore the 10 Vdc analog input is 300 cc min Table 4 Sourcing Sinking Inputs and Outputs Flow Control Calibration Black ES z fanmo e e enee Pm s Remote sep ee s pemr Bem e B amos Be T 7 Poos Dee s mm ew e B Wamoma Bue y oer Deel epo mec Automation 9 FowRateAnaegin use 10 Fow Rae Analog Common Gry 49 ProControl 1KS Integration Specifics Automation Flow Charts Start Mix Mode Process See FIG 62 Table 5 and Table 6 Start Mix Mode Process Is Mix Ready bit 1 Must be Alarm Condi Set Mix bit 1 tion or Active Recipe 61 See Alarm Pro cessing on page 54 or Startup from Recipe 61 see NOTE below Is Mix Active bit 1 NOTE At power up the system YES defaults to Recipe 61 which is not a valid recipe number Initiate a color change to Recipe 0 ora valid recipe number 1 60 ProControl 1KS in Mix Mode Complete Mix Active 1 while the ProControl 1KS is in Mix mode Fic 62 Start Mix Mode Process Flow Chart 50 3A 108
62. gins Air Purge wl Solvent Purge VI DM Final Purge one of these 3rd Flush Valve T RE MM E BENE Gun Flush Box Output 1 MO M1 M2 M3 M4 First Purge Time M0 2M1 Chop Time air solvent or air 3rd flush M1 gt M2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe FIG 84 Color Change Chart 7 ProMix 2KS Recipe Change Chart 8 A1 A2 same B without Dump Valves 2 GFBs Time Sequence Solvent Chop Time 3rd Flush Chop Time 3rd Flush Valve Dispense A Gun Flush Box Output 1 puc Ed ee O O A 0 1 2 3 4 5 6 Color Purge Time 0 21 Notes Load tables from new recipe Purge from old recipe Fill from new recipe FiG 85 Color Change Chart 8 84 3A1080C Color Change ProMix 2KS Recipe Change Chart 9 A1 A2 same B without Dump Valves 1 GFB Time Sequence po TimeSequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Air Chop Time B Solvent Chop Time 3rd Flush Chop Time gt Final Purge one of these 3rd Flush Valve Dispense A A A Gun Flush Box Output 1 0 1 2 3 4 5 6 Color Purge Time 0 21 Mixed Fill Time 5 256 Notes Load tables from new recipe Purge from old recipe Fill from new recipe FIG 86 Color Change Chart 9 ProMix 2KS Recipe Change Chart 10 Recipe X 0 OR 61 to Recipe 0 with Dump Valves REES Color Purge Time P
63. gs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations 3A1080C 7 Warnings 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 e Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear chemically imperme
64. i bui d dace xn S ats 18 Potlife Exceeded Audible Alarm 18 Graco Web Interface Port 18 Ethernet Connection suus 18 Run Mode Screens 19 Splash Screen 0 00 ce ee 19 Status Srcem EE 21 Manual Override Screen 22 Totals Screen 23 Reset Total Screen uu 23 Reset Solvent Screen LL 23 Alarms Screen ossia usa yes 24 Level Control Gcreen 2000 e eee 24 Setup Mode eeler debi dee He 25 Password Screen es 26 Set Up Home Screen 26 System Configuration Screens 28 Option Screens oes xac Eon 32 Advanced Setup Screens 34 Recipe Setup Screens 39 HecipeO Screens llus 43 Calibration Gcreen es 44 ProControl 1KS Integration Specifics 45 Discrete I O vs Network Communications 45 Discrete UC 45 Automation Flow Charts 50 2 System Operation 62 Operation Modes 62 Recipe Color Change 62 FOW CONTON veces bos ERI eek ied eek 62 Typical PLC Interaction with ProControl 1KS 63 General Operating Cycle 65 Mix Manifold Valve Settings 66 Slat PIC 67 vibe CET 69 Pressure Relief Procedure 69 Ee ie edere nas cdita conde oat ee cafe a n 73 Meter Calibration
65. ibration page 76 for when and how to calibrate meter 3A 1080C ProControl 1KS Integration Specifics ProControl 1KS Integration Specifics Discrete I O vs Network Communications The ProControl 1KS system does not use a Booth Con trol Instead it uses Discrete I O or Network Communi cations 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 e Flow Control e Proportioning e 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 avail able Manual Override still requires some communica tion 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 Display Board Discrete UO Discrete I O requires a 24 Vdc power supply which must be supplied on site The ProControl 1KS does not sup ply power for Discrete I O See Table 4 on page 49 FIG 67 on page 58 and Table 8 on page 59 for inputs and outputs Understanding these inputs and outputs is necessary to properly inte grate the Pro
66. iggered 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 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 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 3A1080C Manual Mode when the proportioning or flow control system is controlling the inputs without any input from an outside control Mix when cross linking of the resin A and catalyst B occurs in ProMix 2KS applications In ProControl 1KS applications indicates the system is active Mix Input Signal refers to system mode status where system begins a dose sequence each time the mix sig nal is made High Modbus TCP a type of communication protocol used to communicate Digital UO signals over an ethernet Network Station a means to identify a particular indi vidual proportioning or flow control system Overdose Alarm when either the resin A or catalyst B 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 m
67. indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 3A1080 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2010 Graco Inc is registered to ISO 9001 WWW graco com Revised June 2012
68. ion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property
69. ion and can cause fire explosion or electric shock Follow local regulations and the following safety requirements e Only models with a G3000 G250 G3000HH G250HR or intrinsically safe Coriolis meter are approved for installation in a Hazardous Location Class Div 1 Group D T3 or Zone 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 e Do not substitute or modify system components as this may impair intrinsic safety 6 3A1080C Warnings SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not operate the unit when fatigued or under the influence of dru
70. ivity When a Gun Trigger input is seen the ProControl 1KS will automatically leave Idle mode and resume mix ing 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 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 rec ipe 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 hap pens as required A complete color change without errors resulting in a Mix Ready Output state is a com pleted color change NOTE
71. l 1KS PLC Input EasyKey Digital Output Sourcing Output Common FiG 67 Automation 24 Vdc Sourcing Input Diagram 58 3A1080C ProControl 1KS Integration Specifics Table 8 Discrete I O Terminal Connections Terminal Terminal Location Details also see pages 55 and 56 Digital Inputs J2 Remote UO Board Set Bit to Initiate Mix Mode maintain J2 Remote UO Board Purge Set Bit to 1 to initiate Purge Sequence J maintained 2 Remote UO Board Job Complete Set Bit to 1 to initiate Job Complete Input momentary 4 J2 Remote I O Board External CC Ready Set Bit to 1 to initiate External Color Change maintained J2 Remote I O Board Spare J2 Remote UO Board Digital Input Common be J3 Remote I O Board Digital Input Common 2 J3 Remote UO Board Recipe Bit 0 Set Binary Bits for Recipe to Change To hold until changing again 3 J3 Remote I O Board Recipe Bit 1 Set Binary Bits for Recipe to Change To hold until changing again 4 J3 Remote I O Board Recipe Bit 2 Set Binary Bits for Recipe to Change To hold until changing again 5 J3 Remote I O Board Recipe Bit 3 Set Binary Bits for Recipe to Change To hold until changing again J3 Remote I O Board Recipe Bit 4 Set Binary Bits for Recipe to Change To hold until changing again 7 J3 Remote I O Board Recipe Bit 5 Set Binary Bits for Recipe to Change To hold until changing again J3 Remote I O Board Color
72. large dif ference between the amount of fluid dispensed and the flow meter volume displayed by the EasyKey Clean or repair meter as necessary Also see meter manual 308778 Follow Meter Calibration procedure page 76 Slow actuation of component A valve See E 3 RATIO HIGH ALARM and E 4 RATIO LOW ALARM pages 92 93 The supply pump is not turned on Turn on the supply pump System is in Mix mode with O volume entered for Min Verify condition of fuse and replace if necessary See Material Fill Volume see Option Screen 1 page 32 Hepair Parts manual and Fuse F1 is blown 3A1080C 95 Alarm Troubleshooting Table 14 Alarm Troubleshooting E 9 MIX IN SETUP ALARM Cause Attempt to operate system while in Setup mode System must be in Standby to change current recipe and cannot be operated E 10 REMOTE STOP ALARM Cause Automation has requested that the system abort all oper Abort operations Troubleshoot automation system ations E 11 PURGE VOLUME ALARM EE ProControl 1KS solvent flow switch is not activated while Verify that the gun is not shut off and that the solvent flow purging switch is activated while purge is taking place Minimum flush volume is set too high Increase solvent supply or decrease minimum volume setting No meter pulses during Color Catalyst Dump Color change solvent supply not set up or functional Check Color Change setup E 12 CAN_COMM_ERROR_ALARM Cause
73. mode There may be alarm out puts 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 13 on page 90 for a complete list of alarms 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 G i key will also reset the 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 vol ume is sprayed Digital Out Supply This is the supply for the digital out puts It is the same supply
74. nt A Meter DVA Component A Dose Valve SPV Solvent Purge Valve SS Solvent Purge Valve Solvent Supply Tube Fic 69 Fluid Manifold 3A 1080C APV AT FIH FOH System Operation NOTE The dispense volume of component A is based on the mix ratio and dose size set by the user and calculated by the ProControl 1KS controller Component A is fed to the gun as long as the Gun Trigger input is seen If the Gun Trigger input is not seen for two minutes the system switches to Idle mode which closes off the mix manifold dose valve When the Gun Trigger input is seen again the Pro Control 1KS continues the process where it left off NOTE Operation can be stopped at any time by going to Standby mode remove Mix input FIH MA T115977a Air Purge Valve Air Purge Valve Air Supply Tube Fluid Inlet Hose Fluid Outlet Hose 65 System Operation Mix Manifold Valve Settings To open dose or purge valves turn hex nut E counter clockwise To close turn clockwise See Table 10 and FIG 70 TI11581a Fic 70 Valve Adjustment Table 10 Mix Manifold Valve Settings vave sems men Dose see Hex nut E 1 1 4 turns out Limits maximum fluid flow rate into integrator FIG 70 from fully closed and minimizes valve response time Purge see Hex nut E 1 1 4 turns out Limits maximum fluid flow rate into integrator FiG 70 from fully closed and minimizes valve response time 66 3A 1080C Start Up 1 Go
75. nufacturer 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 dam age equipment To prevent cross contamination of the equipment s wetted parts never interchange component A isocyanate and component B resin parts 3A1080C 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 vis cosity If used this partially cured ISO will reduce perfor mance and the life of all wetted parts NOTE The amount of film formation and rate of crystal lization varies depending on the blend of ISO the humidity and the temperature To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use solvent on one side if it has been contam inated from the other side e Always lubricate threaded parts with ISO pump oil or grease when r
76. okey 2K Manual No AutoKey installed or detected System operates in 2K Manual Mode only 2K Auto 2K AutoKey detected System can operate in 2K Man ual Semi automatic or Automatic Mode 3K Auto 3K AutoKey detected System can operate in 3K Man ual Semi automatic 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 Internet Address 192 168 178 5 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 27 Setup Mode System Configuration Screens NOTE See FiG 26 for a map of the System Configura tion Screens Detailed screen descriptions follow Language Enter Password Display Units Configure Month Day Year Time Date Format Configure Run Mode Dump Valve A Dump Valve B 3rd Flush Valve Configure icc t Dose Size Minimum Valve B A Open aos 4 Dose Time Alarm sec Number of Guns 5 Gun Flush Dos 4 Configure Flow Control N t Special Outputs 5 Solvent Monitor A Web Browser IP 192 158 178 5 B Configure Communications Flow Contral Discrete Proportioning Gun 1 Trigger Control Network ID Configure FG
77. olis meter 2300 psi 15 86 MPa 158 6 bar Flow control 190 psi 1 31 MPa 13 1 bar Maximum working air pressure 100 psi 0 7 MPa 7 bar AIESUDDIM seii aoo ee demit emn eae PES 75 100 psi 0 5 0 7 MPa 5 2 7 bar Air filler inlet eze eee 3 8 npt f Air filtration for air logic and purge air Graco supplied llle 5 micron minimum filtration required clean and dry air Air filtration for atomizing air user supplied 30 micron minimum filtration required clean and dry air Fluids handled 0 00 cece eee eee one component e solvent and waterborne paints e polyurethanes e epoxies e acid catalyzed varnishes e moisture sensitive isocyanates Viscosity range of Hudd 20 5000 cps Fluid filtration user supplied 100 mesh minimum Fluid flow rate range 33000 G250 Meter 75 3800 cc min 0 02 1 00 gal min G3000HR G250HR Meter 38 1900 cc min 0 01 0 50 gal min Coriolis Meter 20 3800 cc min 0 005 1 00 gal min 53000 Solvent Meter accessory 38 1900 cc min 0 01 0 50 gal min Fluid inlet sizes FOW Meter 4 Git ee dace acte Rebel ie fries 1 4 npt f Dose Valve Color Valve Adapters 1 4 npt f Fluid outlet size static mixer 1 4 npt f External Power Supply Requirements 85 250 Vac 50 60 Hz 2 amps maximum draw 15 amp maximum circuit breaker required 8 to 14 AWG power supply wire gauge Operating tempera
78. on a 2KS machine Config Error Occurs if a configuration file sent to the EasyKey specifies a different hardware setup than what exists For example the configuration file specifies 2 color change boards but only 1 is present Range Error Occurs if a valve used in a recipe is not present in the current hardware setup For example a recipe calls for valve 30 but the system has only 12 valves Level Control LC Error Occurs if level control data is received by the EasyKey and the current Autokey setting 2K or 3K has changed since the level control data was originally initialized Level Control LC Range Error Occurs if level control data includes a valve range exceeding the capability of the machine Flush the system or perform a color change If possible identify the origin of the reboot or power cycle Reinstall the Autokey or verify that the Autokey is set properly Verify that the source data is from a valid recipe 1 60 Verify that the Autokey is set properly or that the configu ration file is valid Verify that the configuration file is valid Verify that the configuration file specifications and the hardware conform Verify that the recipe specifications and the hardware conform Verify that the Autokey is set properly Set level control data correctly Modbus MB Overflow Occurs if the Modbus connec Verify the Modbus protocol to the EasyKey tion to a PLC experiences data overflow 98
79. or Change Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B First Purge one of these Gun Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 22 Final Purge Time 2 53 Mixed Fill Time 3 gt 4 Notes Purge from old recipe Fill from new recipe FiG 92 Color Change Chart 15 Gun Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 22 Final Purge Time 2 53 Wait for External Color Change Ready signal before advance to step 4 3 54 Mixed Fill Time 4 55 Notes Purge from old recipe Fill from new recipe Recipe Change Purge Active Output Recipe Change Fill Active Output FiG 93 Color Change Chart 16 88 ProMix 2KS Recipe Change Chart 15 Same A Same B Time Sequence Solvent Chop Time 3rd Flush Chop Time ProMix 2KS Recipe Change Chart 16 External Color Change Option Time Sequence Air Chop Time Solvent Chop Time 3rd Flush Chop Time Load tables from new recipe Load tables from new recipe 3A1080C ProMix 2KS Recipe Change Chart 17 Recipe 0 OR 61 to Recipe X with Dump Valves and 3rd Flush Valve Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Time Sequence A Mixed Fill Time does not olvent Purge begin until the Exiting Fill 3rd Flush Purge Z Time and Color Catalyst Fill Time is complete Exiting Fill Di
80. ose the fluid shutoff valve between the fluid supply system and the flow meter The flow indication should stop If necessary install pressure regulators or a surge tank on the fluid inlets to the ProControl 1KS to reduce the fluid supply pressure Contact your Graco distributor for information Slow actuation of component A valve See E 3 RATIO HIGH ALARM and E 4 RATIO LOW ALARM pages 92 93 Running a high mix ratio and a high flow rate It may be necessary to restrict the flow rate through the component B dose valve by adjusting its hex nut E See page 66 94 3A1080C Alarm Troubleshooting Table 14 Alarm Troubleshooting E 7 DOSE TIME A ALARM and E 8 DOSE TIME B ALARM E 7 gun trigger input is active AFS or Integration and no A meter pulses are detected during the dose time selected E 8 gun trigger input is active AFS or Integration and no B meter pulses are detected during the dose time selected EE NE RN System is in Mix mode and gun is only partially triggered Fully trigger the gun allowing air but no fluid to pass through gun Fluid flow rate is too low Increase flow rate Dose time setting is too short for the current flow rate Increase the dose time setting Flow meter or cable failed or flow meter clogged To check meter sensor operation remove meter cap to expose sensor Pass a ferrous metal tool in front of the Sensor TI12792a If there is a meter or cable failure you will see a
81. out the old color and loads a new color See pages 78 89 Air Line from Fluid Inlet from FC Fluid Manifold Air Control Cable from Fluid Station Control Box FiG 68 Flow Control Regulator 62 Flow Control NOTE Flow control is not available with dynamic dos ing Flow control is an optional feature of the ProControl 1KS automatic system Flow control 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 It is not for use with air assisted or airless spray guns See FIG 68 The flow regulator FC is required to use flow control in your system Connect the fluid inlet and outlet lines air line and cable as shown Set Flow Control to On in Configure Screen 5 on page 31 Make the desired selections in Advanced Setup Screen 5 page 37 See the Graco Gateway manual 312785 for Flow Con trol Modbus addresses Fluid Outlet to Gun f s Sh D e T113656a 3A 1080C Typical PLC Interaction with ProControl 1KS This section describes a typical interaction when a local PLC is directly connected to the Discrete I O connec tions of the ProControl 1KS See ProControl 1KS Integration Specifics on page 45 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
82. played If this is the first time starting up the system purge it as instructed in Purging Fluid Supply System page 74 The equipment was tested with lightweight oil which should be flushed out to avoid contaminat ing your material Make sure that the EasyKey is in Standby remove Mix input Adjust component A fluid supply as needed for your application Use lowest pressure possible A Q Do not exceed the maximum rated work ing pressure shown on the system identification label or the lowest rated component in the system Open the fluid supply valves to the gt Cre system WK ESS Adjust the air pressure Most appli cations 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 67 System Operation 10 Purge air from the fluid lines Watch the fluid flow rate displayed on the Status screen while the gun is fully open a Shut off air to the gun by clos i ing the air regulator or shutoff Te If the fluid flow rate is too low increase air pres valve for the gun atomizing air DN sure to the fluid supply or increase the regulated fluid pressure S A jn C Dm If the fluid flow rate is too high reduce the air pressure close the fluid manifold dose valves fur a grounded metal pall C ther or adjust the fluid pressure regulator c Goto Mix mode B NOTE Pressure adjustments of each component will vary with fluid viscosity A
83. pparatus for use in Class Division 1 Group D T3 C Hazardous Locations Div 1 Group D T3 Ta 20 C to 50 C C C us Read Instruction Manual Warning Substitution of components may impair intrinsic safety PART NO SERIES MFG YR GRACO INC P O Box 1441 Minneapolis MN GRACO 55440 U S A MAX AIR WPR 7 7 100 MPa bar PSI MAX FLUID WPR SERIAL MPa bar PSI MAX TEMP 50 C 122 F Fluid Station Control Box Label FLUID PANEL MAX AIR WPR Intrinsically safe equipment MPa bar PSI for Class I Div 1 Group D T3 we GRACO INC D 5 Ta 20 C to 50 C APPROVED Install per 289833 C Ed FMO8ATEX0073 7 T dee 0359 Ex ia IIA T3 eraco 55440 U S A ProControl PART NO SERIES SERIAL ATEX Certificate is listed here EasyKey Label POWER REQUIREMENTS AMPS 2 AMPS MAX ProControl 1KS PART NO SERIES NO MFG YR GRACO INC Intrinsicall f ti for Class I Div 1 GroupD 50 60 Hz P O Box 1441 C eM US Ta 20 C to 50 C o Y Minneapolis MN APPROVED Install per 289833 9 2 G 55440 U S A Ex ia UA GRACO Um 250 V FMOBATEX0072 C C us ATEX Certificate is listed here System Configuration and Part Numbers System Configuration and Part Numbers Models The part number for your equipment is printed on the equipment identification labels See FIG 1 for location of the identification labels me Few Cone meme y p p oy D E RENE MNA NEN AN RN mm
84. ppears 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 mix ing 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 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 Advanced Setup Screen 3 First Purge Time Total Chop Time Final Purge Time Mixed Fill Time Advanced Calibration Fic 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
85. r Selection ir Fic 21 Tank Level Low Screen Tank A Shown 3A1080C Setup Mode Setup Mode P he S ZS k S d NOTE See FiG 22 for a map of the Setup screens ee enor SEHR Detailed screen descriptions follow Press the Setup a key to enter Setup mode Enter Password This screen appears only if a password is activated Set Up Home To access Advanced Setup Screens page Recipe amp Advanced setup E Keng 34 and Recipe Setup Screens page 39 EK 2 000 012 BC 1 55 C1 2 01 FF 200 012 AK 2k Auto C2 e n up UEED MC 1042 0198 To access System Configuration Screens IP 10 33 131 205 MAC 00204AAD1510 page 28 Press the Setup o key to exit Setup mode and return to the Status Screen Setup Locked This screen appears momentarily if a password is activated 11 9 2009 14 40 Opsi lll cox 1 9 375cc min 4 sfacc ming T112803a Fic 22 Setup Screens Map 3A1080C 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 ProMix Web Interface see manual 313386 Enter Password lt Fic 23 Password Screen NOTE If a password is activated Setup Locked dis plays momentarily after
86. r 40040 Digital Input Binary 0 5 jo ojo o 0 0 00 OO X X X X X X Fecipe Binary bits for viewing discrete inputs only e RO gr 1 to nitate Color Change momentary CC 7 0 0 0 00000 1 0000 00 00Mx Mx Set bit initiate Mx mode maintain bit initiate Mix mode maintain 8 0 0 0 0 0 0 0 1 0 00 0 0 0 0 O OlPuge e Ten bit to 1 to initiate Set bit to 1 to initiate Purge sequence maintained sequence maintained P PEEP Peep ep pp n SE EG Rte a a PEE momen tary External CC Set bit to 1 to initiate External Color Change Ready ee HEET E of0l0 0 0 NotUsed FC _Calibrate bit to 1 to initiate a Flow Control Calibrate input momentary 13 1 Gun Trigger Set bit to 1 to indicate the gun is actually triggered maintain while gun is triggered remove when gun is closed 54 9 o o o oo o o oo o o 9o Ress Ae Serb ta T to clear an active Alarm momenta 15 j ejo o o o o oo oo o o o D RemoteStop Set bitte remotely stop unit momentary NOTE Shaded cells relate to the flow charts on pages 50 54 3A 1080C 55 ProControl 1KS Integration Specifics Table 6 ProControl 1KS Digital Outputs Modbus Register 40041 Bit Digital Input Binary Name Details Bii as B caos Purge or Color Change Is in prog ress 0 0 0010 ANEN am Mix Mix Active ek 1 indicates Mixisinprogress Mix is in 1 indicates Mixisinprogress 0 0 0 0 0 0 0 0 0 1 0 0 Mi
87. r fluid station for the system maximum working pressure See FiG 1 ProMix Fluid Components Maximum Working Pressure Base System no meter no color catalyst change option and no flow control option 33000 Meter Option Coriolis Meter Option Color Change Option Flow Control Option Flow Meter Fluid Flow Rate Range Coriolis Meter S3000 Solvent Meter accessory Standard Features Feature Flow Control with 15 ft 4 57 m Cable if selected Basic Web Interface 3A 1080C 4000 psi 27 58 MPa 275 8 bar 4000 psi 27 58 MPa 275 8 bar 2300 psi 15 86 MPa 158 6 bar 300 psi 2 07 MPa 20 6 bar 190 psi 1 31 MPa 13 1 bar 75 3800 cc min 0 02 1 0 gal min 38 1900 cc min 0 01 0 50 gal min 20 3800 cc min 0 005 1 00 gal min 38 1900 cc min 0 01 0 50 gal min Accessories 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 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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 thi
88. r solenoid until flow from dump valve A stops Press and hold the dump valve A solenoid override FIG 75 Press and hold the A side color solvent solenoid override until clean solvent comes from the dump valve then release Shutoff the solvent supply to the color catalyst change stack solvent valves Press and hold the A solvent solenoid override and dump valve override until solvent flow from the dump valve stops 3A 1080C System Operation Purge Valve B Dose Valve A Purge Valve A e Solenoid Solenoid Solenoid Dose Valve B Solenoid S J9 J3 J12 J1 Fiber T115916a Fic 75 Fluid Solenoids 3A1080C 71 System Operation I I eessen Solenoid Identification Label 9 eeeeece eseece 966669 amp eeeeses ZT e9999 amp Oo Oo olo Ojo Oo Oo Ono o Oo Oo Oo Solenoid Identification Label JO OD ha sAjeye P
89. re Screen 3 on page 30 This refers to the process of mix ing air and solvent or air and 3rd flush fluid together during the flush cycle to help clean the lines and reduce solvent usage 3A1080C Setup Mode 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 Recipe Ii Color Catalust Purge 5 First Purge Time Total Chop Tine Final Purge Time MESE Calibration FiG 54 Recipe 0 Screen 2 lf 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 Enter the purge time 0 to 999 sec onds 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 43 Setup Mode Recipe 0 Screen 3 D cc seconds hecipe Minimum Flush Volume Exiting Fill Source Exiting Fill Dime MEE Calibration FiG 55 Recipe 0 Screen 3 This screen only appears if Solvent Monitor is set to Me
90. ress the Enter g key to view the menu then select the desired operating mode Standby Mix Purge or Recipe Change See FiG 13 Manual Override Active Recipe Mew Recipe Manual Override aLancdb Flow Rate Range Standkh lou Set Point mm Flaw Ctrl Calibration ae Global FC Data Copy LPeciPe Change Fic 13 Manual Override Menu 22 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 dis play 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 3596 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 i key to view the menu then select Start or Abort See FIG 14 The flow rate will drop to 0 then incrementally increase until it reaches the maximum flow rate To view the prog ress go to the Status Screen page 21 The system will populate the data for the current recipe To cop
91. s sure 3000 psi 21 MPa 210 bar systems with up e Models are available to operate air spray or to 30 color change valves and up to 4 catalyst air assisted systems with a capacity of up to 3800 change valves cc min NOTE Optional accessories are available for in field installation to achieve 30 colors Component Identification and Definition SeeTable 1 and FiG 2 for the system components Table 1 Component Descriptions EasyKey EK 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 Fluid Station Includes air control solenoids Its control board manages all fluid functions Control Box ST Fluid Manifold FM Includes wall mounting bracket and mountings for the fluid meter and the following valves e Pneumatically Operated Dose Valve for component A e Purge Valves for solvent and air purge Flow Meters MA Four optional flow meters are available from Graco MS e 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 viscosi ties of 20 3000 centipoise The K factor is approximately 0 119 cc pulse G3000HR is a high resolution version of the Gi3000 meter It is typically used in flow ranges of 38 1900 cc min 0 01 0 5 gal min pressures up to 4000 psi
92. s manual where applicable FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations INTRINSIC SAFETY Intrinsically safe equipment that is installed improperly or connected to non intrinsically safe equipment will create a hazardous condit
93. s the Setup a key to enter Setup mode Level Control Liters Alarm Level Current Volume Color 1 10 Color 2 10 Catalyst 1 10 o lvent 10 Level Control TI12802a 3A1080C Status Screen e Use the Up A or Down y keys to scroll through the Run screens e Press the Enter lt key to select a different fluid station control box e Press the Setup key to enter the Setup screens from the Status screen e The other keys have no function in this Status Screen 11 3 2003 psi ei 375cc min 4 sfacc ming Mis Gy Fic 11 Status Screen Key to FIG 11 1 Active Recipe shows the active recipe NOTE At power up the system defaults to Recipe 61 which is not a valid recipe number 2 Target Ratio for the active recipe The ratio can be from 0 0 1 50 0 1 in 0 1 increments For the Pro Control 1KS set the ratio at 0 1 3 Actual Ratio in hundredths calculated after each dose of A 4 Potlife Timer shows remaining potlife time in min utes Two times are shown if there are two guns manual or semi automatic mode only 3A 1080C Run Mode Screens 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 auto matic mode is not operable Target Flow Rate and Current Flow Rate in
94. seconds Mixed Material Fill Time Enter the mixed material fill time 0 to 999 seconds It refers to the amount of material that is required to fill from the dose valves to the applicator gun 3A 1080C Advanced Setup Screen 4 K Factar A Meter BEER cc pulse B Meter 0 119 cc pulse solvent Meter 0 119 cc pulse Advanced Calibration Fic 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 B Meter NOTE Not used with ProControl 1KS Enter the k factor cc pulse for flow meter B K factor Solvent Meter This field only appears if Solvent Monitor in Configure Screen 5 page 31 is set to Meter Enter the k factor cc pulse for the solvent flow meter 3A1080C Setup Mode Advanced Setup Screen 5 Flou Rate Range Tolerance d Kp Alarm Time Advanced Calibration FG 41 Advanced Setup Screen 5 Automatic Mode with Flow Control Only This screen appears only if Flow Control is set to On in Configure Screen 5 page 31 Flow Rate Range Enter the flow rate range 0 300 0 600 or 0 1200 This determines the flow control PID loop resolution Flow Rate Tolerance Enter the flow rate tolerance 1 to 99 This is the per centage of variance that
95. sing 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 in ProMix 2KS applica tions Dose Time Alarm the amount of time that is allowed for a dose to occur before an alarm occurs Ethernet a method for directly connecting a computer to a network or equipment in the same physical location Fiber Optic Communication the use of light to trans mit communication signals 10 Fill Time the amount of time that is required to load mix material to the applicator 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 accept able variance that the system will allow before a flow rate warning occurs Flow Set Point a predefined flow rate target Grand Total a non resettable value that shows the total amount of material dispensed through the system Gun Trigger Input Signal used to manage ratio assur ance dose times and flow control processes Intrinsically Safe IS refers to the ability to locate cer tain components in a hazardous location Idle if the gun is not tr
96. source Global source recipe for Flush and Fill Input This will overwrite recipe data Are you sure Fic 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 3A1080C Option Screen 2 External Color Change Auto Dump Flow Rate Monitor Dptions FiG 35 Option Screen 2 External Color Change If set to Off Color Catalyst Purge Time and Color Cat alyst Fill Time appear in Advanced Setup Screen 1 page 35 or Recipe Setup Screen 2 page 40 depend ing on whether Flush and Fill Inputs are set to Global or Hecipe 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 Flow Rate Monitor This field only appears if Flow Control is set to Off in Configure Screen 5 page 31 If set to On Recipe Setup Screen 6 on page 42 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 42 will not appear 3A1080C Setup Mode 33 Setup Mode Advanced Setup Screens NOTE See FiG 36 for a map of the Advanced Setup Screens Detailed screen descriptions follow Flow Control O
97. spense A Dispense B Gun Trigger s by Operator Exiting Fill Time 0 22 Color Fill Time 0 gt 1 Catalyst Fill Time 1 22 Mixed Fill Time 2 53 Notes Load tables from new recipe Mixed Material Purge Timers from old recipe CC Purge Fill Timers and Mixed Fill Time from new recipe Exiting Fill Source and Length are Programmable FiG 94 Color Change Chart 17 ProMix 2KS Recipe Change Chart 18 Recipe 0 OR 61 to Recipe X without Dump Valves and 3rd Flush Valve Time Sequence Color Change Solvent Catalyst Change Solvent Color Change A Exiting Fill Dispense A Dispense B Gun Trigger s by Operator Exiting Fill Time 0 gt 1 Color Fill Time 1 22 Mixed Fill Time 2 53 Notes Load tables from new recipe Mixed Material Purge Timers from old recipe CC Purge Fill Timers and Mixed Fill Time from new recipe Exiting Fill Source and Length are Programmable FiG 95 Color Change Chart 18 3A1080C Color Change 89 Alarms and Warnings Alarms and Warnings NOTE Do not use the fluid in the line that was dis pensed off ratio as it may not cure properly System Alarms System alarms alert you of a problem and help prevent off ratio spraying If an alarm occurs operation stops and the following occurs e Alarm sounds e Status bar on the EasyKey shows the alarm E Code with a description see Table 13 System Warnings Table 13 lists the System Warning Codes Warnings do not stop operation or sound
98. splay Board see FIG 59 Multiple connection points for convenience 60 3A1080C ProControl 1KS Integration Specifics Table 9 ProControl 1KS Recipe Bits Number Recipe Bits 5 4 3 2 1 1 1 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 o1 52 53 54 55 56 57 58 59 60 0 1 0 1 0 1 1 1 0 O 0 O 0 0 O 0 1 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1 1 Number 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Recipe Bits 0 1 0 1 0 1 1 0 0 1 1 1 0 O 0 O 0 0 O 0 1 1 0 0 0 0 0 O 0 O 0 O 0 1 0 0 0 0 0 5 4 3 2 0 0 0 0 0 0 0 00 0 O 0 0 0 0 0 0 0 0 0 O0 O 0 0 O 0 0 0 0 0 0 0 0 1 1 0 0 0 0 1 61 3A1080C System Operation System Operation Operation Modes rrr Mix System mixes and dispenses material apply Mix input r Standby Stops the system remove Mix input LIN a d Purges the system using air and solvent apply Purge input Purge Recipe Color Change The process when the system automatically flushes
99. ster 40046 with recipe number to Color Change to 0 through 60 is valid Ensure Color Is Change bit is seen Purge CC Active by ProControl 1KS bit 1 Set ColorChange CC bit 1 YES Clear ColorChange CC bit momentary input CC process started Wait for Mix Ready Is Mix Ready bit 1 ProControl 1KS Color Check Alarm Condition is Alarm General bit 1 NO Change Process Complete YES Process Alarm See Alarm Processing page 54 FiG 65 Color Change Mode Process Flow Chart 3A1080C 53 ProControl 1KS Integration Specifics Alarm Processing See FIG 66 Table 5 Table 6 and Table 7 NO Determine the exact alarm from Table 7 on page 57 and solve what caused the alarm as required Reset the alarm Reset Alarm 1 ER Is Mix Ready bit 1 Fic 66 Alarm Processing Flow Chart 54 Alarm Processing An Alarm Condition has been found previously Alarm_General 1 Check if Potlife Alarm is Alarm Potlife bit 1 YES Two options Purge or Color Change to remove mixed material in the line e Place in Mix mode and spray the Potlife Volume set in the ProControl 1KS NOTE The Reset key only silences the alarm To clear the alarm you must use one of these two options YES Go to next process as desired 3A1080C ProControl 1KS Integration Specifics Table 5 ProControl 1KS Digital Inputs Modbus Registe
100. t into storage seconds in increments of 1 second Some steps are not necessary for initial flush 1 Goto Standby mode remove Mix input ing as no material has been loaded into the system yet 1 Goto Standby mode remove Mix input MOA Trigger the gun to relieve pressure Aw the gun to relieve pressure If you are using a high pressure gun engage the trig ger lock Remove spray tip and clean tip separately If you are using a high pressure gun engage the trig ger lock Remove spray tip and clean tip separately If using an electrostatic gun shut off the electrostatics before flushing the gun If using an electrostatic gun shut off the electrostatics 2 If using a gun flush box place the gun into the box before flushing the gun and close the lid 2 Attach solvent supply lines as follows 3 Select Recipe 0 and press Enter i e Single color systems disconnect the fluid 4 Ifa gun flush box is not used trigger A supply at the flow meter inlet and connect regu the gun manual or automatic intoa lated solvent supply lines grounded metal pail until the purge sequence is complete SE y e Multiple color systems disconnect the fluid supply at the flow meter inlet and connect a reg 5 The color change LED blinks while Recipe O runs ulated solvent supply line and turns solid after purge sequence is complete 6 Ifthe system is not completely clean you can repeat Re
101. ter in Configure Screen 5 page 31 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 mini mum flush volume 0 to 999 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 Sol vent 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 44 Recipe 0 Screen 4 Recipe Special Un Purge Length Un Fill Fic 56 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 Out puts is set to 1 2 3 or4 in Configure Screen 5 page 31 The I O board has four programmable outputs Calibration Screen Meter Calibration H Meter Actual Volume Do 0 119 cc pulse Measured Volume re k F actor Recipe Bez ec Fic 57 Calibration Screen Use this screen to calibrate a meter Set to Meter A Meter B or Solvent Meter available if Solvent Moni tor in Configure Screen 5 page 31 is set to Meter e Start start calibration e Abort stop calibration e Purge purge sampling valves after calibration See Meter Cal
102. the system will allow before a flow rate warning alarm occurs Flow Rate Ki Enter the flow rate Ki flow control PID loop integral value This refers to the degree that fluid flow over shoots its set point Flow Rate Kp Enter the flow rate Kp flow control PID loop gain value This refers to the speed at which the fluid flow reaches its set point Flow Rate Alarm Time Enter the flow rate alarm time 1 to 99 seconds 37 Setup Mode Advanced Setup Screen 6 Advanced Setup Screen 8 Bit 0 OFC Calibrate Bit 1 OFC Lal Active 7 Bit 2 Flow Input special Bit 3 31 Volts Un Purge Bit 4 OExt CC Input Length Bit 5 On Fill Advanced Lalibration Advanced Calibration Fic 42 Advanced Setup Screen 6 P FG 44 Advanced Setup Screen 8 This screen shows the status of recipe analog inputs and digital outputs If box is shaded the input recipe is active This screen appears only if Flush and Fill Input is set to Global in Option Screen 1 page 32 and Special Out puts is set to 1 2 3 or4 in Configure Screen 5 page 31 The I O board has four programmable outputs Advanced Setup Screen 7 prog p O Mis OPurge Active O Purge LIFil Active ORecipe Change OU OMis Active t n Obun Trigger IB Ready S CT Job Complete Lllseneral Alarm ORemote Stop O Fotlife Alarm O Reset Alarm O Flow Alarm 4 Advanced Calibration Fic 43 Advanced Setup Screen 7 This screen shows the status of digital inputs and digital o
103. this input some critical mixing alarms are eliminated This input should be provided through Discrete IC only for flow control applications to ensure fast coordination with the flow control process Applica tions without integrated flow control can use Gun Trigger input through Network Communications or Discrete UC NOTE This has the same effect as the air flow switch used on manual ProControl 1KS systems 63 System Operation Alarm Monitoring Reset Discrete HO 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 e Potlife Alarms cannot be reset by the Alarm Reset input or through the EasyKey Alarm Reset x key Only a Purge Color Change or spraying the Pot life volume will reset a Potlife alarm See Alarm Potlife output information on page 49 e When Flow Control is turned on see Configure Screen 5 on page 31 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 indicat ing 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 b
104. through the Pre Operation Checklist in Table 11 Table 11 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 connec tions are tight and installed according to the Installation manual Fluid supply containers filled Check component A and solvent supply contain ers Mix manifold valves set Check that mix manifold valves are set correctly Start with the settings recommended in Mix Mani fold Valve Settings page 66 then adjust as needed a Fluid supply valves open and pressure set Solenoid pressure set 75 100 psi inlet air supply 0 5 0 7 MPa 5 2 7 bar 2 Turn the AC Power Switch ON I ON 0 OFF Z ON T112656a FIG gt Graco logo software revision and Establishing Communication will display followed by Status screen See page 19 gt At power up the system defaults to Recipe 61 which is not a valid recipe number Initiate a color change to Recipe O or a valid recipe num ber 1 60 3A1080C System Operation In bottom left corner the system status displays which can be Standby Mix Purge or an alarm notification 11 9 2009 1440 psi 740 ei 37occ min 4 sfacc ming Wl Fic 72 Status Screen Verify that the EasyKey is working The active recipe number and Standby mode should be dis
105. til a Gun Trigger input is seen and fluid flow is detected If no flow is detected within 2 minutes the color change operation aborts The system enters Standby r mode remove Mix input at the previ ous color When you are ready to spray remove the gun from the gun flush box if used and close its door manual and semi automatic systems only NOTE The gun flush box door must be closed for the atomizing air valve to open Enter Mix ES mode to start spraying Single Color Systems 1 2 3 78 Follow procedure for Purging Fluid Supply Sys tem page 74 Load the new color See Start Up page 67 Enter Mix gt mode to start spraying Color Change Sequences FIG 78 through FIG 95 illustrate various color change sequences See Table 12 to determine which figure to reference based on the recipe change and system con figuration The time sequences are detailed in the fol lowing paragraphs NOTE See Setup Mode on page 25 to select purge sources and set desired purge chop and fill times NOTES The system uses old recipe data for the purge cycle However it opens the new color valve based on the new recipe data The system uses the new recipe data for the fill cycle For the one gun flush box GFB option the spray gun must be inserted in the GFB during the entire color change cycle purge and fill The GFB trigger output will be on during the recipe change cycle For the two gun flush bo
106. tlife 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 1 4 9 648 Integrator manifold and mixer volume 75 cc Spray Gun Volume 20 cc Hose Volume x Feet of Hose 75 20 PLV 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 mod ule 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 O 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 35 Setup Mode Advanced Setup Screen 2 First Purge Source LECT Chop Tupe Air Solvent _ H 2 Solvent Hi 2 0 seconds 2 seconds A Final Purge Source Hr Chop Time solvent Chop Time Advanced Fic 38 Advanced Setup Screen 2 This screen a
107. ture range 41 122 F 5 50 C Environmental Conditions Rating indoor use pollution degree 2 installation category Il Noise Level Sound pressure level 000 e ee below 70 dBA Sound power level below 85 dBA Wetted e oc nic sp kr gaGede eee yet eae we 303 304 SST Tungsten carbide with nickel binder perfluoroelastomer PTFE Dependent on programmed K factor and application The maximum allowable flow meter pulse frequency is 425 Hz pulses sec For more detailed information on viscosities flow rates or mixing ratios consult your Graco dis tributor See individual component manuals for additional technical data 3A 1080C 105 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abras
108. uid pressure sensor voltage to air pressure transducer and circuit board The function of this unit is to receive the flow ana log signal and drive manage the desired flow rate 13 Overview ProControl 1KS System Components EK CCM Air Control Module Regulator FC see V P Air Fluid FiG 4 FO ES JA NN N j N See the ProControl 1KS Sie uen A AN Beer SSN w s Lesch Repair Parts manual for ye CNN et MAN optional cable lengths TI15961b Fic 2 ProControl 1KS System shown with G3000 Meter Color Change and Flow Control 14 3A1080C Overview FIH MA APV AT DVA a SPV FOH TI15977a Fic 3 Fluid Manifold Key MA Component A Meter APV Air Purge Valve DVA Component A Dose Valve AT Air Purge Valve Air Supply Tube SPV Solvent Purge Valve FIH Fluid Inlet Hose SS Solvent Purge Valve Solvent Supply Tube FOH Fluid Outlet Hose Regulator Fluid In FC V P Air Fluid Out FC Cable Wi TI15976a FiG 4 Flow Control Regulator 3A1080C 15 EasyKey Display and Keyboard EasyKey Display and Keyboard LCD Display men Y Em S e Ey Navigation Keys FiG 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 Keypad Used to input numerical data enter setup screens scroll through screens
109. utputs If box is shaded the input is active If not input is off 38 3A1080C Recipe Setup Screens NOTE See FIG 45 for a map of the Recipe screens Detailed screen descriptions follow Flow Control Override Manual Override Gun Lotte Volume ee Color Catalyst Purge seconds Color Catalyst Fill seconds 4 Advanced Calibration Recipe 0 Screens Recipe NJ First Purge Source fart Chop Type 1 Final Purge Source Solvent Wi Air Chop Time 2 0 seconds Solvent Chop Time seconds 4 Recipe Color Catalyst Purge 5 First Purge Time Total Chop Time Final Purge Time KEN Calibration Recipe NJ Minimum Flush Volume CC t Exiting Fill Source 3 Exiting Fill Time D seconds 4 KGR Calibration Recipe special n Purae Length On Fill ecipe FiG 45 Recipe Screens Map 3A1080C Recipe Ratia Ratio Tolerance Color Valve Catalyst Valve KH Calibration Recipe El Minimum Flush Volume CC Potlife Time minutes Color Catalyst Purge seconds Color Catalyst Fill seconds Recipe First Purge Source fart Chop Type Bir Solvent WU Final Purge Source Solvent Wi Air Chop Time 2 0 seconds Solvent Chop Time 2 O seconds A Recipe Recipe First Purge Time sec Total Chop Time sec Final Purge Time sec Mixed Fil Time sec KH Calibration Recipe K Factar A Meter Ur pulse B Meter Ur pulse solvent Meter D 118 cc pulse KEN Calibration Set Up Home o Recipe amp Advanced Setup System
110. valve is turned in too far e Refer to Table 10 Mix Manifold Valve Settings page 67 for adjustment guidelines e Fluid pressure is high and air pressure is low e Adjust air and fluid pressure See recommended air pressure above 92 3A1080C Alarm Troubleshooting Table 14 Alarm Troubleshooting E 4 RATIO LOW ALARM The mix ratio is lower than the set tolerance on the previous dose cycle There is too much restriction in the system Check that the system is fully loaded with material Check that the supply pump s cycle rate is set prop erly Check that the spray tip nozzle is properly sized for the flow and application and that it is not clogged Check that the fluid regulator is set properly If the alarm occurs during start up after purging the flow Restrict gun needle travel to slow down the initial fluid rate was probably too high delivery rate until fluid hoses are loaded with material If the alarm occurred after you were spraying for some Adjust fluid supply regulator pressure Verify that compo time the pressure from the fluid supply could be too low nent A dose valve is operating properly Slow actuation of the component A valve This can be Manually operate the Dispense A solenoid valves as caused by instructed in the ProControl 1KS Repair Parts manual to check operation e Air pressure to the valve actuator is too low e Increase air pressure Air pressure must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar
111. vent or air 3rd flush M2 gt M3 Final Purge Time M3 gt M4 Mixed Fill Time M4 gt M5 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Applies to ALL charts when 3rd Flush Valve is ON Fic 79 Color Change Chart 2 3A1080C 81 Color Change ProMix 2KS Recipe Change Chart 3 A1 to A2 same B with Dump Valves Time Sequence aa Color Change Solvent SE Color Change A CadystchagegB O o P1 PO Color Purge Time P0 gt P1 Color Fill Time P1 gt P2 CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time First Purge one of these 3rd Flush Chop Time begins Air Purge NI Solvent Purge VI 3rd Flush Valve Dispense A Dispense B Gun Trigger s by Operator First Purge Time M0 2M1 Chop Time air solvent or air 3rd flush M1 gt M2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 80 Color Change Chart 3 ProMix 2KS Recipe Change Chart 4 A1 A2 same B without Dump Valves Time Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Solvent Chop Time First Purge one of these 3rd Flush Chop Time 3rd Flush Valve Dispense A Gun Trigger s by Op
112. verride Manual Override ES Gun 1 Potlite Volume Color Catalyst Purge seconds Color Catalyst Fill seconds 4 Ed Calibration l l First Purge Source r DN Chap Tupe Bir Solvent WU Final Purge Source ES Air Chop Time 2 0 seconds Solvent Chop Time 2 0 seconds A Advanced Calibration First Purge Time Total Chop Time Final Purge Time Mixed Fill Time Advanced Calibration K Factor A Meter ERE cc pulse B Meter 0 119 cc pulse Solvent Meter 0 119 cc pulse Advanced Calibration Flow Rate Range Tolerance ki Kp Alarm Time MRecipe Bit 0 DEL Calibrate MRecipe Bit 1 OFC Cal Active ORecipe Bit 2 Flow Input ORecipe Bit 3 3 1 Volts ORecipe Bit 4 OEst CO Input O Recipe Advanced Calibration Fic 36 Advanced Setup Screens Map 34 Agvan Advanced Setup screens 2 3 4 and 8 appear depending on selections made in Option screens 1 and 2 Screen 5 appears if Flow Control is set to On in Configure screen 5 Set Up Home Recipe amp Advanced Setup System Configuration Ek 200 012 BC Lan Ci 2 01 FP 2 00 012 AK 2k Auto Ce AP V6 6 0 2 MoO 1042 0196 IP 10 33 131 205 MAC 00204AAC1610 Meter A Meter Calibration Measured Actual Volume Volume Occ j cc K Factor 0 119 cc pulse Calioration Recipe Ratio Ratio Tolerance Color Valve Catalyst Valve KI Calibration O Mix OPurge Active O Purge LIFil Active ORecipe Change O OMis A
113. w Flow Limit 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 Recipe Setup Screen 7 Recipe Special FiG 52 Recipe Screen 7 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 32 and Special Out puts is set to 1 2 3 or4 in Configure Screen 5 page 31 The I O board has four programmable outputs 3A1080C Recipe 0 Screens NOTE See FIG 45 on page 39 for a map of the Recipe 0 screens Detailed screen descriptions follow Recipe O is typically used in multiple color systems to purge out material lines without loading a new color 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 Recipe 0 Screen 1 Recipe aJ First Purge Source Ar wit Chop Tupe Air Solvent 1 Final Purge Source Solvent Hl Air Chop Time 2 0 seconds Solvent Chop Time 2 seconds A MEE Calibration FiG 53 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 Select Air Solvent or Air 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configu
114. x GFB option both spray guns must be inserted in the GFBs during the entire color change cycle purge and fill The system will turn each GFB trigger output on and off based on the preset time for each gun For Special Outputs options the system will turn each output on and off based on the preset times Each Special Output has two different start times and durations For systems without dump valves the First Purge begins after the Color Change steps are completed When going from Recipe X to Recipe 0 only the purge cycle data from Recipe 0 is used When going from Recipe 0 to Recipe X only the fill cycle data from Recipe X is used 3A1080C Color Purge Dump Step PO P1 e This sequence flushes out the color with solvent from the color valve to the Dump A valve e The color change solvent valve and the Dump A valve open during the Purge Time e The color change solvent valve closes when the Purge Time expires Color Fill Step P1 P2 e This sequence fills the line with the new color all the way to the Dump A valve e The new color valve and the Dump A valve open during the Fill Time e The new color valve and the Dump A valve close when the Fill Time expires First Purge Step MO M1 Select the First Purge Source air solvent or 3rd valve and First Purge Time For most applications air is selected The system purges the old material from the dose valves to the gun using only the selected purge media
115. x Ready Mix Ready Ready 1 indicates No Alarms and 1 indicates No Alarms and OK to Mx to Mix CC Fill Active 1 indicates the Fill portion of a Color iS T is in progress FCalActive 1 indicates the Flow Control Calibrate routine is in progress 5 1 Flow Rate Alarm 1 indicates the Flow Rate Alarm Warning is active 1 Special 1 1 indicates the Special 1 output is on monitor only Special 2 1 indicates the Special 2 output is on monitor only Special 3 1 indicates the Special 3 output is on monitor only Soho Special 4 1 indicates the Special 4 output is on monitor E 10 jojoojoo to o o ofo ojo ojojo Not Used ee eee Not Used E 12 Alarm 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 43 0 0 1 0 00 0 0000 0 0 0 O O Alarm Potlife 1 indicates a Potlife Alarm is in process NOTE Shaded cells relate to the flow charts on pages 50 54 56 3A1080C ProControl 1KS Integration Specifics Table 7 ProControl 1KS Active Alarms Modbus Register 40010 Bit Digital Input Binary Details 3A1080C 57 ProControl 1KS Integration Specifics ProControl 1KS PLC Output EasyKey Digital Input Sourcing Input Common ProControl 1KS EasyKey PLC Input Digital Output Sinking Output Common Common ProContro
116. y guns 1 or 2 NOTE Only 1 gun is used in automatic mode Gun Flush Box manual or semi automatic mode Enter the number of gun flush boxes Off 1 or 2 3A 1080C Configure Screen 5 Flow Control special Outputs solvent Monitor Web Browser IP On 5 d 192 158 178 5 Fic 31 Configure Screen 5 Configure Flow Control This field only appears if Run Mode is set to Automatic in Configure Screen 3 page 30 Select On or Off If set to On Advanced Setup Screen 5 page 37 is added Special Outputs Select special outputs 0 4 Each output has two differ ent start times and durations 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 3A1080C Setup Mode Configure Screen 6 Communications Flow Control liscrete Proportioning Gun 1 Trigger Control Network ID Fic 32 Configure Screen 6 Automatic mode shown Configure Flow Control This field only appears if Run Mode is set to Automatic in Configure Screen 3 page 30 Select Discrete or Network Proportioning Select Discrete or Network Gun 1 Trigger Displays AFS if Run Mode is set to Semi automatic in Configure Screen 3 page 30 Select Discrete or Network if Run Mode is set to Automatic in Configur
117. y this data to all recipes see Global Flow Control Data Copy page 23 Manual Override Active Recipe Mew Recipe Etang H Manual Override 1 1 TII Tm Flow Rate Range Flaw Set Point Flow Ctrl Calibration LEE END Global FC Data Copy Start lt IH FiG 14 Flow Control Calibration 3A1080C Global Flow Control Data Copy This field allows you to copy flow control data from the active recipe to all recipes Press the Enter i key to view the menu then select Start or Abort See FIG 15 Manual Override Active Recipe New Recipe Manuel Override Standb g Flow Rate Range 0 1200 cc mi 4 Flow Get Point 375 ec min Flow Ctrl Calibration SCH nn Global FC Data Copy LETT Mr Fic 15 Global FC Data Copy Totals Screen Usage Job Total rand Total cc 0 Liters cc 0 Liters cc 0 Liters cc Liters mamia saht Solvent Level Control FiG 16 Totals Screen This screen shows the job 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 Solvent Totals and the Rst Solvent tab only appear if Meter is selected under Solvent Monitor in Configure Screen 5 on page 31 NOTE Grand totals are not resettable 3A1080C Run Mode Screens Reset Total Screen Job Complete Are uou sure uou want to reset job totals Enter new job number or press enter to acc

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