![Graco ProControl 1KS [83/138] Flow control setup](/img/pdf.png)
Graco ProControl 1KS [83/138] Flow control setup
![Graco ProControl 1KS [83/138] Flow control setup](/views2/1193396/page83/bg53.png)
Integrated Flow Control
3A1080F 83
Flow Control Setup
1. Install the intrinsically safe flow regulator (FC) as
explained in the ProControl 1KS Installation Manual.
2. Ensure that the analog signal is 0-10 Vdc, or is
properly provided through network communication.
3. Calibrate the system’s flow meters; see page 102.
This ensures that the K-factors are tuned to the
range of materials being used.
4. Verify that the I/O inputs are working properly. If
using discrete I/O, check by viewing Advanced
Setup Screen 6 and Advanced Setup Screen 7,
page 38. If using network communication, ensure
the commands are being sent by viewing the Status
Screen, page 21, and Advanced Setup Screen 6
and Advanced Setup Screen 7, page 38, for
inputs.
NOTE: See the Graco Gateway manual for Flow Control
Modbus addresses.
5. See Flow Control Startup.
Flow Control Startup
1. Set Flow Control to “On: Setup” in Configure
Screen 5.
2. In Advanced Setup Screen 1, turn Manual Over-
ride “On: EK”. This sets the override control source
as the EasyKey. The Flow Control Override field will
appear. The other option, “On: Ext” is used for par-
tial control by a PLC robot.
3. Set Flow Control Override to % Open. See F
IG. 89
and Table 12. On the Manual Override Screen, the
Flow Set Point field will display as a percentage
open (see F
IG. 90).
NOTE: Set the Flow Control Override to “Pressure” to
use the Pressure Flow Control Mode (see page 88).
F
IG. 87. Configure Screen 5
FIG. 88. Advanced Setup Screen 1
F
IG. 89. Flow Control Override Menu
Table 12: Flow Control Override Selections
Selection Description
Off Normal operation
% Open Flow control regulator is opened to a
desired percentage.
Pressure Flow control regulator is opened to a
calibrated pressure.
ExtSP External PLC in control of Set Point
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
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