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Graco ProControl 1KS [14/138] Wall mount system components

Overview

14 3A1080F

Wall Mount System Components

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

TI15961b

FO*

FC (see

IG. 4)

PS*

ACV

CCM

MAFM (see

IG. 3)

* See the ProControl 1KS

Repair-Parts manual for

optional cable lengths.

Air Control

Module

Logic Air

Regulator

V/P Air

Purge

Air

Fluid

FC Cable*

Содержание

A1080f 1
Operation 1
Procontro 1
Contents 2
Equipment approvals 3
Related manuals 3
Models 4
System configuration and part numbers 4
Accessories 5
Standard features 5
Standard features accessories 5
Warning 6
Warnings 6
Warning 7
Changing materials 8
Important two component material information 8
Isocyanate conditions 8
Keep components a and b separate 8
Material self ignition 8
Moisture sensitivity of isocyanates 8
Glossary of terms 9
Component identification and definition 12
Overview 12
Wall mount system components 14
Display 16
Easykey display and keypad 16
Keypad 16
Ac power switch 18
Audible alarm 18
Ethernet connection 18
Graco web interface port 18
I s power 18
Run mode screens 19
Splash screen 19
3a1080f 20
Run mode screens 20
Run screens map 20
Status screen 21
Flow control calibration 22
Flow rate range 22
Flow set point 22
Manual override menu 22
Manual override screen 22
Global flow control data copy 23
Reset solvent screen 23
Reset total screen 23
Totals screen 23
Alarms screen 24
Level control screen 24
Setup mode 25
Password screen 26
Set up home screen 26
System configuration screens 28
Configure screen 1 29
Configure screen 2 29
Configure screen 3 30
Configure screen 4 30
Configure screen 5 30
Configure screen 6 31
Option screen 1 32
Option screens 32
Verification screen 32
Option screen 2 33
Advanced setup screens 34
Advanced setup screens map 34
For a map of the advanced setup screens detailed screen descriptions follow 34
Note see 34
Advanced setup screen 1 35
Advanced setup screen 2 36
Advanced setup screen 3 36
Advanced setup screen 4 37
Advanced setup screen 5 37
Advanced setup screen 6 38
Advanced setup screen 7 38
Advanced setup screen 10 39
Advanced setup screen 8 39
Advanced setup screen 9 39
Recipe setup screens 40
Recipe setup screen 1 41
Recipe setup screen 2 41
Recipe setup screen 3 42
Recipe setup screen 4 42
Recipe setup screen 5 43
Recipe setup screen 6 43
Recipe setup screen 7 44
Recipe 0 screen 1 45
Recipe 0 screen 2 45
Recipe 0 screens 45
Recipe 0 screen 3 46
Recipe 0 screen 4 46
Calibration screen 47
Procontrol integration specifics 49
System setup for automatic operation 49
Discrete i o vs network communications 50
Status verification of automatic operation 50
Discrete i o 51
Digital inputs 52
255766 discrete i o board 53
A1080f 53 53
Procontrol integration specifics 53
Analog inputs 54
Digital outputs 54
Automation flow charts 55
Start mix mode process 55
Start mix mode process flow chart 55
Table 5 and table 6 55
Mixing mode process 56
Mixing mode process flow chart 56
Table 5 and table 6 56
Purge mode process 57
Purge mode process flow chart 57
Table 5 and table 6 57
Color change mode process 58
Color change mode process flow chart 58
Table 5 and table 6 58
Alarm processing 59
Alarm processing flow chart 59
Table 5 table 6 and table 7 and table 8 59
Table 7 procontrol 1ks low word active alarms modbus register 40010 62
Table 8 procontrol 1ks high word active alarms modbus register 40010 62
Automation 24 vdc sourcing input diagram 63
Plc input sinking 63
Plc output sourcing 63
Procontrol 1ks easykey digital input 63
Procontrol 1ks easykey digital out 63
Procontrol easykey digital output plc input sourcing 63
Color change process 66
Modbus and i o data 66
Purge process 66
Start mix process 66
Stop mix process 66
Color change 69
Gun trigger input 69
Start mixing 69
Stop mixing 69
Typical plc interaction with procontrol 1ks 69
Alarm monitoring reset discrete i o 70
Integration timing charts 70
Job_complete input 70
Integration control recipe change x to y 71
Integration control recipe change x to y external color change 72
Integration control y purge 73
Integration control y fill 74
Integration control y purge and fill 75
Integration control mix sequences 76
Integration control alarm processing 77
Cutaway of 249849 flow control module 78
Cutaway of 24h989 flow control module 78
Flow control components 78
Flow control description 78
Flow control is an optional feature which incorporates an intrinsically safe regulator control module with the pro control 1ks automatic system flow control precisely regulates the flow of material to a manual or automatic air spray gun to help ensure adequate coverage and avoid sags or runs in the finish coat 78
Flow control module 78
Flow control uses the existing flow meters in a wall mounted fluid station or a robomix fluid station there is no flow meter in the mixed material line 78
H989 flow control module 78
Integrated flow control 78
Note flow control cannot be selected with dynamic dosing it is not for use with air assisted or airless spray guns 78
Note for best results place the supplied pressure sensor as close to the remote fluid regulator as possible 78
The 249849 flow control module includes an air operated fluid pressure regulator fluid pressure sensor voltage to air pressure valve and circuit board see manual 3a2097 the function of this unit is to receive the flow analog signal and drive manage the desired flow rate 78
The 24h989 flow control module is for use with a user supplied remotely mounted air operated fluid pressure regulator the module includes a remote fluid pressure sensor and connecting cable voltage to air pressure valve and circuit board see manual 3a2097 the function of this unit is to receive the flow analog signal and drive manage the desired flow rate 78
Flow control operation 79
Fluid and air pressure requirements 79
3a1080f 80
Integrated flow control 80
Procontrol 1ks flow control schematic diagram 249849 module 80
Procontrol 1ks flow control schematic diagram 24h989 module 80
Flow control operating process example 81
Operating ranges 81
Step 1 flow set point input signal 81
Step 2 pressure loop 81
Step 3 flow loop 81
3a1080f 82
Integrated flow control 82
Procontrol 1ks flow control pressure loop and flow loop 249849 module 82
Procontrol 1ks flow control pressure loop and flow loop 24h989 module 82
Flow control setup 83
Flow control startup 83
One point learning 84
One point learning example 84
Table 13 example spray sequence 84
Flow control calibration 85
Mix calibration 85
Global fc data copy 86
Continuous learning 87
Setting ki and kp 87
Pressure flow control mode 88
Flow control troubleshooting 89
Problem flow command does not produce fluid output 89
Mix manifold valve settings 91
Operation modes 91
Recipe color change 91
Solvent push 91
Standby 91
System operation 91
Start up 92
Overnight shutdown 94
Pressure relief procedure 94
Service shutdown 94
Shutdown 94
Single color systems 94
Systems with color change and dump valves 95
Fluid solenoids 96
J1 j12 j3 j9 j14 96
Purging 98
Purging mixed material 98
Purging fluid supply system 99
Purging using recipe 0 99
Solvent push feature 101
Meter calibration 102
Color change 104
Color change procedures 104
Color change sequences 104
Multiple color systems 104
Single color systems 104
Catalyst fill 105
Catalyst purge dump 105
Chop cycle 105
Color fill 105
Color purge dump 105
Final purge 105
First purge 105
Procontrol 1ks recipe change chart 1 x to y 107
Procontrol 1ks recipe change chart 2 x to y 108
Procontrol 1ks recipe fill chart 3 0 to y 109
Procontrol 1ks recipe fill chart 4 0 to y 110
Procontrol 1ks recipe fill chart 5 0 to y 111
Procontrol 1ks recipe fill chart 6 0 to y 112
Procontrol 1ks recipe purge chart 7 x to 0 113
Procontrol 1ks recipe purge chart 8 x to 0 114
Procontrol 1ks recipe purge chart 9 0 to 0 115
Procontrol 1ks recipe purge chart 10 0 to 0 116
Alarms and warnings 118
System alarms 118
System warnings 118
To reset alarm and restart 118
Alarm troubleshooting 119
3a1080f 130
Control air 130
Purge air 130
Schematic diagrams 130
System pneumatic schematic 130
A1080f 131 131
Non hazardous area 131
Note the electrical schematic illustrates all possible wiring expansions in a procontrol 1ks system some compo nents shown are not included with all systems 131
Schematic diagrams 131
System electrical schematic 131
3a1080f 132
Booth control board 132
Flow control board 132
Fluid press sens 132
Hazardous area 132
I s meters 132
Note the electrical schematic illustrates all possible wiring expansions in a procontrol 1ks system some compo nents shown are not included with all systems 132
Schematic diagrams 132
System electrical schematic 132
Tecno v p 132
A1080f 133 133
Easykey electrical schematic 133
Schematic diagrams 133
3a1080f 134
Cc dose 134
Flow rate cc min 134
Fluid hydraulic oil viscosity 65 centipoise ratio tolerance 5 valve setting 1 5 turns open standard setting a and b feed pressure 300 psig 134
Meter performance data g3000 on a and b 134
Note maximum system flow is 3800 cc min 134
Test conditions 134
A1080f 135 135
Cc dose 135
Flow rate cc min 135
Fluid hydraulic oil viscosity 65 centipoise ratio tolerance 5 valve setting 1 5 turns open standard setting a and b feed pressure 300 psig 135
Meter performance data g3000 on a coriolis on b 135
Note maximum system flow is 3800 cc min 135
Test conditions 135
Technical data 136
For patent information see www graco com patents 138
For the latest information about graco products visit www graco com 138
Graco headquarters minneapolis international offices belgium china japan korea 138
Graco inc and subsidiaries p o box 1441 minneapolis mn 55440 1441 usa copyright 2009 graco inc all graco manufacturing locations are registered to iso 9001 www graco com revision f march 2016 138
Graco information 138
Graco standard warranty 138
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 138

Graco ProControl 1KS [14/138] Wall mount system components

Содержание

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