Graco 3A1164B User's Manual
Contents
1. 11648 FLUID PANEL CONTROL BOX HAZARDOUS AREA 3X CABLE FLUID 1 PWR RED PANEL 2 TE BLACK JFOWMETERA CONTROL 214 r SHELD GRN BOARD 5 NOT USED 6 NOT USED 15 METERS L NOT USED lt 2 coma FLOW METER SOLVENT 3 SIG WHITE J 4 SHIELD GRN S sic TECNO 9 GROUND V P ANALOG OUT WHT now COM BLK PRESS GRN CONTROL 00 0 VEMM R 12V RED 8000 2 L FUNUSED GND BLK 4 CHA2. amp Solenoid Identification Label Solvent Solenoid Overrides Fic 2 Color Change Solenoids MA Component A Meter DVA Component A Dose Key FIH Valve SPV Solvent Purge Valve SS Solvent Purge Valve Solvent Supply Tube APV Air Purge Valve AT Air Purge Valve Air Supply Tube FIH Fluid Inlet Hose FOH Fluid Outlet Hose DVA SS SPV TI15977a FOH Fic 3 Fluid Manifold 11 11648 Pressure Relief Procedure 12 11648 Troubleshooting Troubleshooting Table 1 System Alarm Codes Code Description E 1 Communication Error Alarm Follow Pressure Relief Procedure page 10 before cleaning checking or servicing equipment E 2 Potlife Alarm 3 Ratio High Alarm 4 Ratio Low Alarm NOTE Do not use the fluid in the line th
3. NON HAZARDOUS AREA OPERATOR INTERFACE 11 LINE Lu DC OK POWER 1 85 250 VAC N END 424VDC SUPPLY 20 i 1 TERMINAL L1 COMMON BLOCK COMMON H 0006 13 1 POWER A ROCKER POWER HARNESS 1 UNUSED OPEN 1g SWITCH 2 UNUSED 2 n 1 5 UNUSED HARNESS EE wee mid 1 12VDC 5 RED f COM BLACK BARRIER 3 Rat BOARD CABLE 1 1 240 50 STD J4 2 3 1 COMMON 7 100 OPTION ALARM L DISPLAY 7 1 BOARD 1 SWITCH 2 J9 2 WITH 3 3 171 N RIBBON 5 2 CABLE 6 RJ45 RJ45 y 3 JOB COMPLETE INPUT 3 DZ lt Re POWER DIST 045 045 6 1 DIGITAL INPUT COMMON 10 TERMINAL 1 1 DIGITAL INPUT COMMON 11 BLOCKS 2 RECIPE BIT 0 INPUT 3 RECIPE BIT 1 INPUT zl B 4 RECIPE BIT 2 INPUT 5 RECIPE BIT 3 INPUT 2 zu 6 RECIPE BIT 4 INPUT REMOTE 7 RECIPE BIT 5 INPUT 1 Vo 8 RECIPE CHANGE INPUT DISPLAY 2 INTEGRATION 3 2 BOARD 1 1 DIGITAL OUTPUT COMMON POWER 4 2 1 PURGE RECIPE CHG ACTIVE OUTPUT 5 3 1 MIX ACTIVE OUTPUT 6 14 4 1 MIX READY OUTPUT 7 5 FILL ACTIVE 6 1 FLOW CAL ACTIVE 8 7 1 FLOW RATE ALARM OUTPUT 39 1 FLOW CONTROL CAL BLK
4. 42 11648 Parts Parts ProControl 1KS System The part number for your equipment is printed on the equipment identification labels See FiG 1 for location of the identification labels Meter Flow Control Part No Series Description None G3000 Coriolis No Yes 262380 A ProControl 1KS v v 262381 A ProControl 1KS v v 262382 A ProControl 1KS v v 262383 A ProControl 1KS v Label Location ProControl 1KS Electronic Proportioner Intrinsically Safe IS System Install per IS Control Drawing No 289833 EasyKey Interface IS Associated Label Location on Fluid Station Apparatus for use in non hazardous KU location with IS Connection to Smart on Easy Key Control Box T115974a FMOBATEX0074 APPROVED Fluid Plate IS 1115975a Maximum Fluid 11648 Intrinsically safe Ex ia T3 equipment for Class Div 1 Group D T3 C 20 to 50 C 0359 MAX AIR WPR Working Pressure 7 is listed ig MPa bar PSI MAX TEMP 50 1225 Apparatus for use in Class Division 1 Group D C Hazardous Locations Read Instruction Manual Warning Substitution of components may impair intrinsic safety PARTNO SERIES SERIAL MFG YR Tee GRACO INC P O Box 1441 Minneapolis MN GRACO 55440 U S A Part Number Parts Part No 262380 without meter or flow contro
5. 20 5000 cps Fluid filtration 100 mesh minimum Fluid flow rate range G3000 9250 75 3800 cc min 0 02 1 00 gal min G3000HR G250HR 38 1900 cc min 0 01 0 50 gal min Coriolis 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 Flow 1 4 npt f Dose Valve Color Valve Adapters 1 4 npt f Fluid outlet size static 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 temperature 41 122 F 5 50 C Environmental Conditions Rating indoor use pollution degree 2 installation category II Noise Level Sound pressure below 70 dBA Sound power level below 85 dBA Wetted 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 rat
6. F3 e o o 214h 2 Te 5 5 b e B d Power to Fluid Station l 8 see XM e e n Sb ite 214 A Do not remove i this screw gn 214 Front of Barrier Board showing Fuses and Connectors jes E S e ai 9613 p 2 a eo O Ho o o o o Apply thermal compound o o to surface of heatsink Z M o o bg on con Back of Barrier Board showing Heatsink 2 Fic 16 Barrier Board Connectors and Fuses 34 11648 Service Control Box 2 Disconnect fiber optic wires J4 J6 and all cables J1 3 J5 J7 J8 9 J10 J12 J14 J15 from con trol board 302 FiG 17 Replacing Control Board 3 Remove 4 screws 303 Remove connector jam nuts on the outside of the enclosure 301 Remove control board 302 FIG 18 4 Install new control board 302 with 4 screws 303 5 Connect cables to control board 302 FiG 17 To avoid damaging circuit board when servicing wear Insert fib
7. 3 96 PRESS SWITCH 1 ORG 5 INTERFACE 4 E AIRFLOWSWITCH2 PRESS SWITCH 1 BLU 6 MODULE 5 6 PRESS SWITCH 2 WHT BLK 7 6 SOLVENT FLOW SWITCH i PRESS SWITCH 42 RED BLK 8 J4 3117 s EE SOLENOID 1 12 GRN BLK 19 oJ GFB 1 PRESSURE SWITCH var SOLENOID 1 COM ORG BLK 10 9 7 SG P ii SOLENOID 2 12 BLU BLK 11 16 10 77 GFB 2 PRESSURE SWITCH t SOLENOID 2 COM RED WHT 112 29 Service Service Before Servicing To avoid electric shock turn off EasyKey power before servicing Servicing EasyKey display exposes you to high voltage Shut off power at main circuit breaker before opening enclosure All electrical wiring must be done by a qualified electrician and comply with all local codes and reg ulations Do not substitute or modify system components as this may impair intrinsic safety Read Warnings page 6 To avoid damaging circuit board when servicing wear Part No 112190 grounding strap on wrist and ground appropriately 30 Flush system and follow Pressure Relief Proce dure page 10 if service time may exceed pot life time and before servicing fluid components Close main air shutoff valve on air supply line and on ProControl 1KS 3 4
8. 5 COLOR 19 COLOR 20 gt COLOR 21 H gt COLOR 22 COLOR 23 VALVE m VALVE LT OPTIONAL gt gt COLOR 24 gt COLOR 25 COLOR 26 LOR 27 gt COLOR 28 COLOR 29 COLOR 30 DUMPA VALVE OPTIONAL AE AA MAMMA E DE TE NINININININININIAINININININIAINIAIN DUMP B VALVE OPTIONAL mee MAC 36 SERIES SOLENOID VALVES GFB1 VALVE OPTIONAL 4 MANIFOLD GFB2 VALVE JT OPTIONAL 11648 Schematic Diagrams QVIHYING Sed Id avidsia 27 EasyKey Electrical Schematic Stry Stry 20021 0 9 pst F es 5 asn H gar ne zar IVNINEL WANT 00 L GSN oe L F aasnnn 4 re N i
9. ProControl 1KS Electronic Proportioner APPROVED Intrinsically safe equipment for Class Div 1 Group D T3 C 20 C to 50 C 0359 MAX AIR WPR FMO8ATEX0074 2G MPa PSI bar MAX FLUID WPR MPa bar PSI MAX TEMP 50 1227 Intrinsically Safe IS System Install IS Control Drawing No 289833 EasyKey Interface IS Associated Apparatus for use in non hazardous location with IS Connection to Smart Fluid Plate IS Apparatus for use in Class I Division 1 Group D T3 C Hazardous Locations Read Instruction Manual Warning Substitution of components may impair intrinsic safety PARTNO SERIES SERIAL MFG YR G GRACO INC Box 1441 7 Minneapolis MN GRACO 55440 U S A Part Number TF Label Location on EasyKey TI15975a 11648 System Configuration and Part Numbers Hazardous Location Approval Models using G3000 G3000HR or intrinsically safe Coriolis meter are approved for installation in a Hazardous Location Class Div Group D or Zone I Group 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
10. 7819 959 il a i g eR miS Ov 34 id C3 LNdLACAGIONS R59 R83 R86 82 810 RN TTTTT 9 FLOW CONTROL J5 Flow Control 05 ozy pe 1 e 620 68 o2vuo E agla Mg ETE 825 49 m ene s 1 y _ SOLENQM OUTPUT ENOID OU PUT Solenoid Output Dose Valves A and B J14 Solenoid Output Air Purge Valve and Solvent Flush Valve Fic 17 255765 Fluid Station Control Board 11648 _ SOLENOID 71799 4 08 Solenoid Output Dump Valve B J15 Solenoid Output 3rd Flush Valve Dump Valve A 35 Service 310 311 115974 301 313 326 303 304 6500000000 5 302 334 5 320 343 325 TI15916a 312 307 333 315 332 318 314 317 319 316 Fic 18 Fluid Station Control Box 36 11648 Replacing Solenoids The Fluid Station Control Box has a minimum of 4 sole n
11. 91 NMOYA i SWSINHOUS sir n EISE n H V T I MO NUES gt m amano OM el GH amanna E SMV 91 13062 9030 NI pan 28000 SMV EL 72007 1 NOWWOD 5MV8L 4 al fi OMY 81 VTA a i div SMV TAMADO TTR 0860807690 11648 Schematic Diagrams System Electrical Schematic NOTE The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system Some compo nents shown are not included with all systems Non Hazardous Area
12. Shut off ProControl 1KS power 0 position Fic 12 If servicing EasyKey also shut off power at main cir cuit breaker 0 OFF TI12657a After Servicing After servicing the system be sure to follow the Start Up checklist and procedure in the ProControl 1KS Operation manual 11648 Servicing EasyKey Updating Software To update software upload new software from your PC using the basic web interface See manual 313386 NOTE If using the Graco Gateway in your system dis connect its cable from the EasyKey before updating the ProControl 1KS software Replacing Display Board or Graphic Display N To avoid damaging circuit board when servicing wear Part No 112190 grounding strap on wrist and ground appropriately 1 Follow Before Servicing page 30 2 Unlock and open EasyKey door with its key 3 Note position of all external connections J4 J5 J6 J7 J8 J9 J10 to display board then unplug the connectors See 7 on page 18 4 Remove 4 screws 2106 and the display board assembly 210b 210c Fic 13 112554 Fic 13 Display Interface 11648 Service 5 Disconnect graphic display power cable J1 from the display board 210c 6 Separate graphic display 210b from display board 2106 connector J2 on back of board 7 Toassemble the new parts align connector J2 on the display board 210c with the socket on the gra
13. 317 48 115917 311 303 302 343 115916 11648 262363 Fluid Station Control Box NOTE Parts are shown on page 48 unless noted Ref No 301 302 303 304 305 306 307 308 309 310 311 312 313A 314 315 316 317 318 319 320 Part No 16E380 255765 n a 119257 119162 116773 121818 111987 112173 C20497 16E434 104176 186620 108382 120030 120053 112253 121795 15U725 113783 11648 Description Qty ENCLOSURE 1 BOARD circuit 1 SCREW machine pan hd 4 4 40 x 3 16 in 5 mm CONNECTOR bar ground CONNECTOR plug 6 position CONNECTOR plug 10 position BULKHEAD tube 5 32 4 mm 1 CONNECTOR cord strain relief MUFFLER FITTING tube bulkhead PLATE mounting box BULKHEAD 1 4 in 6 mm ID tube OF NO LABEL symbol ground 2 FITTING seal o ring 10 32 5 PLATE blank solenoid 4 FITTING tube 10 32 x 1 4 in 3 6 mm OD tube CONNECTOR male 12 VALVE solenoid 4 way intrin 4 sically safe 12 Vdc MANIFOLD solenoid 1 SCREW machine pan hd 4 10 32 x 3 8 in 10 mm Ref No 322 325 326A 329 330 332 333 334 335 336 3439 Part No 112925 116343 15G809 112512 114158 n a n a n a 15D320 15U533 123690 Parts Description Qty SCREW cap button hd 1 4 20 2 x 3 8 in 10 mm SCREW ground LABEL warning FERRULE FITTING tube Y adapter TUBE nylon
14. 4 Install new line filter 2141 Reconnect wires in posi tions noted in step 3 5 Close and lock EasyKey door with key 6 Turn on power at main circuit breaker 7 Turn EasyKey power on to test operation Replacing Power Switch AN 1 Follow Before Servicing page 30 2 Unlock and open EasyKey door with its key 3 Note position of power switch wires See EasyKey Electrical Schematic page 27 Disconnect wires and remove switch 202 FIG 14 4 Install new power switch 202 Reconnect wires in positions noted in step 3 5 Close and lock EasyKey door with key 6 Turn on power at main circuit breaker 7 Turn EasyKey power on to test operation Power Supply Outputs Vdc 214f e 202 21 Power Supply Inputs Vac E ae 2141 lae 214 D T o oh C Input Power Terminal Block Fic 14 Power Supply TI13349b 32 11648 Replacing Barrier Board A To avoid damaging circuit board when servicing wear Part No 112190 grounding strap on wrist and ground appropriately 1 Follow Before Servicing page 30
15. Your system must be grounded See the Grounding instructions in your ProControl 1KS Installation man ual Check Resistance To ensure proper grounding resistance between Pro Control components and true earth ground must be less than 1 ohm Have a qualified electrician check resistance between each ProControl component and true earth ground If resistance is greater than 1 ohm a different ground site may be required Do not operate the system until the problem is corrected Pressure Relief Procedure NOTE The following procedures relieve all fluid and air pressure in the ProControl 1KS system Use the proce 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 2 10 NOTE If a Dose Time alarm E 7 E 8 occurs clear the alarm 3 Doa complete system purge following the instruc tions under Purging Using Recipe 0 in the Pro Control 1KS Operation Manual 4 Shutoff the fluid supply to the solvent purge valve SPV and the air supply to the air purge valve APV FiG 3 5 With th
16. Parts 123823 FILTER line single phase 110 250 V 123824 BRACKET line filter 15V280 HARNESS connection 15G569 LABEL EasyKey inputs 15R642 HARNESS wire n a SOFTWARE application 198165 CONNECTOR 445 with bulk head fitting 116343 SCREW ground M5 x 0 8 15G869 CABLE ethernet CAT5 6 ft 1 8 m to make web interface connection to a computer A Replacement Danger and Warning labels tags and cards are available at no cost Parts labeled n a are not available separately Available Cables CAN Cables Length Part No ft m Usage 150531 2 0 61 Option 15U532 3 0 92 Standard color change 15V205 6 1 83 Option 15V206 10 3 05 Option 15V207 15 4 57 Option 15V208 25 7 62 Option 15U533 50 15 25 Standard power 15V213 100 30 50 Option Fiber Optic Cables Part No Length Usage 15D320 50 15 25 Standard 15G710 100 30 50 Option 47 Parts 262363 Fluid Station Control Box AI TI15974a 301 313 326 304 334 320 325 307 eeeeee _ 0000000000 315 332 314
17. tmi TER TI12924a em ui 1035 cm 79 BK885 or CR1220 Battery a NN ug V eccccccccc000002U2 E 3V 12 5 mm lithium coin J4 036 TP1 er pM 9999999999999999 zn sp GRACO T Ut e U3 51 5 R5 TP2 017 J7 28 uw OO aw m 2 o 0 000000000000 ee 59 P s 7 J8 R5 Fic 7 255767 EasyKey Display Board 18 11648 Troubleshooting Table 3 EasyKey Display Board Diagnostics Connector Connector Indicator Description Indicator Description J1 Graphic Display Backlight J9 24 Vdc Power Input Alarm Output J4 Ribbon Cable to Membrane J10 RS485 Communication Terminals J5 Inputs and Outputs 07 green LED turns on when power is supplied to J6 Remote I O board J7 Fiber Optic Cable Input black D11 yellow heartbeat when board is J8 Fiber Optic Cable Output blue P1 Ethernet Port R5 Display Contrast Dimmer Switch turn by hand 11648 19 Troubleshooting Discrete I O Board Diagnostics See FIG 8 and 9 to troubleshoot the Discrete I O board Also see the System Electrical Schematic on pages 28 and 29 Terminal Strip Detail 85485 Integration 85485 Integration B 85485 Integration Ground 85485 Network A 85485 Netw
18. If D4 does not turn on fuses Fluid Station Board or F4 Graco Part No 15D979 are blown or there is no input power at J4 If there is no input power D5 does not light fuses F1 and F2 Graco Part No 114788 may be blown 3A1164B 17 Troubleshooting EasyKey Display Board Diagnostics See 7 7 and Table to troubleshoot the EasyKey display board Also see the EasyKey Electrical Schematic on page 27 and the System Electrical Schematic on pages 28 and 29 Multiple Station a 2 k J 10 p AER 9485 JEN 8 lt 129238 5 5 g UE i s sat Integration Control gt 95 5 8 B O 0 81818 8 J9 D7 d Ss a 1 ALM WOWER 16 10 5485 16 qup 8188 B f TN as 05 NN e Pilal um 2001 5 Ene pm paga a lt 5 2 e 82 us S 5 amp 2 S8 P1 p eA 5 A 2 8 o a BAT p 8 8 j e e s 855 8 5 zB Sim 4311 411 t b pm 8 een DET ve 8
19. red 5 32 in 4 mm OD 4 ft 1 2 m TUBE nylon green 5 32 in 4 mm OD 5 ft 1 5 m TUBE nylon 1 4 in 6 mm OD 2 ft 0 6 m CABLE fiber optic twin 50 ft 1 15 25 m see page 44 for location CABLE CAN intrinsically safe 1 50 ft 15 25 m see page 44 for location FUSE 125 mA 1 A a n A R A R A R A Replacement Danger and Warning labels tags and cards are available at no cost Replacing the fuse with a non Graco fuse voids the IS system safety approval Parts labeled n a are not available separately 49 Parts 262364 Valve Stack Ref No 401 402 403 404 4053 406 407 408 409 410 411 50 Part No 15X303 15T436 101970 109450 15T869 110004 15T872 15T871 Description VALVE high pressure includes item 413 see man ual 312782 SCREW 5 16 24 x 5 8 in 16 mm ADAPTER manifold PLUG pipe O RING ptfe MANIFOLD fluid port SEAT valve needle sst O RING ptfe MANIFOLD body SCREW cap socket head 1 4 20 x 5 8 in 16 mm MANIFOLD end cap Part No 15T873 15U927 C19800 104371 104116 Description PLATE blank O RING ptfe BRACKET SCREW cap socket hd 1 4 20 x 1 2 in 13 mm SCREW cap socket hd 10 32 x 3 8 in 10 mm WASHER plain no 10 Qty N wo t Parts included in Valve Seat Kit 24A351 purchase separately Optional Carbide Seat Kit 15U932 is available separately
20. 3 Pull the fuse away from the board 4 Install the new fuse 343 11648 37 Service Servicing Flow Meter We Coriolis Meter 1 Follow Before Servicing page 30 2 remove and service the Coriolis meter see man ual 313599 G3000 G3000HR Meter Removal 1 Follow Before Servicing page 30 2 Unscrew cable connector CC from meter FIG 20 3 Unscrew four 1 4 20 screws MS holding the meter mounting plate MP Fic 20 4 Unscrew fluid line from meter inlet P 5 Unscrew meter M from dose valve connector H FiG 20 6 Service meter as instructed in the meter manual 308778 Installation 1 Screw meter M securely onto the dose valve con nector H using a wrench Cable Length 241799 5 ft 1 52 m 241800 16 in 406 mm 241801 13 in 330 mm J3 J12 NOTE To avoid leakage secure the meter M to the dose valve connector H before connecting it to the fluid station 2 Secure meter M and plate MP to bracket with screws MS 3 Connect meter cable CC See 20 4 Connect fluid line P 5 Calibrate meter as instructed in ProControl 1KS Operation manual 115977 Fic 20 G3000 G3000HR Flow Meters 3X CABLE RowwETERA 1 6 FLOW METER SOLVENT Sy PWR RED COM BLACK O d FLOW METER r SHIELD GRN
21. I 1 8 DIGITAL OUTPUT COMMON POWER 11 2 GUN TRIGGER WHT 2 1 DIGITAL OUTPUT COMMON POWER 12 DIGITAL IN COMMON RED 1 3 2 I SPECIAL OUTPUT 1 s eat 14 5 ALARM RESET BRN 3 5 SPECIAL OUTPUT 4 15 6 ALARM OUTPUT BLU 6 6 DIGITAL OUTPUT COMMON POWER 16 7 DIGITAL OUTPUT COMMON ORG 7 7 B POT LIFE YEL 8 18 9 FLOW RATE ANALOG IN PUR 9 19 10 FLOW RATE ANALOG COMMON GRAY 10 20 J 1 0 HARNESSES 24 GRAY 08 BEACON TERMINAL BRN 1 0 5485 INTEGRATION A WHT BLU 1 BLOCKS RED 2 5485 INTEGRATION B BLU WHT 2 3 5485 INTEGRATION GROUND SHIELD 3 4 5485 NETWORK A WHT ORG 4 5 5485 NETWORK B ORG WHT 5 TES 6 5485 NETWORK GROUND SHIELD 6 CABLE 7 C FOIN BLK Js FO OUT BLU r f RJ45 RJ45 3 lt 045 BULKHEAD 3 25 200 OPTIONS e P ES WEB SERVER MODULE 28 3A1164B System Electrical Schematic Schematic Diagrams NOTE The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system Some compo nents shown are not included with all systems Hazardous Area
22. PWR RED COM BLACK SIG WHITE SHIELD GRN gt GROUND TERMINAL Connectors on Fluid Station Control Board Fic 21 Meter Cable Schematic 38 11648 Servicing Color Change Module Color Catalyst Valves and Dump Valves 1 Follow Before Servicing page 30 2 Seemanual 312787 for the color change module 3 See manual 312783 for the color catalyst valve stacks 4 Seemanual 312786 for the dump valve kits 5 See manual 312782 to service an individual valve 11648 Service 39 Service Servicing Flow Control Preparation WS BA 1 Follow Before Servicing page 30 2 Disconnect all air and fluid lines from the flow con trol regulator 3 Disconnect the flow control cable from connector 624 FiG 23 4 Remove the four screws 605 holding the air plate 607 to the housing 611 Carefully lift the plate off the housing and disconnect the three cables from J1 J2 and J4 on the circuit board 618 FiG 22 Servicing the Regulator and Pressure Sensor Regulator Service Kit 156843 is available Kit parts are marked with an asterisk for example 602 For best results use all parts in the kit Sensor Service Kit 15G867 is available to service the pressure sensor only Kit parts are marked with a sym bol for example 602 F
23. eise GunFshBoriTige en 033 8 384 Gun Flush Box 2 Trigger D41 015 5 amp 6 Dump Valve A 043 9 384 Dose Valve B 044 9 182 Dose Valve 045 1 344 Air Flow Switch 2 Turns on when gun 2 is triggered 046 7 amp 8 Gun Flush 1 Pressure Switch Turns when gun is Gun Flush 1 F1 n a Replaceable Fuse Check fuse condition if there is no power to the fluid station 11648 23 Troubleshooting Color Change Board Diagnostics See Fic 11 and Table 5 to troubleshoot the color change board Also see the System Electrical Schematic on pages 28 and 29 J8 Pin 1 D33 D31 D29 J15 Pin 1 D41 D35 D27 J14 Pin 1 030 028 036 E Nx E 3 m c Mid mim EE N N 960 d o 028 E Ns Bros N72 um exi o MEE LAST BRB 022 Res m zum E NE wg 8 Noam 8 gt N U25 Nes We c 15 FUSE 125A D34 043 044 J9 Pin 1 D39 D32 D38 J16 Pin 1 D37 D45 D46 J10 Pin 1 D9 D10 F1 Fuse Kx WE eet J11 Fic 11 256172 Color Change Board 24 11648 Troublesh
24. on the EasyKey or fluid station for the system maximum working pressure See Fic 1 ProMix Fluid Components Maximum Working Pressure Base System no meter no color catalyst change option and no flow control RII 4000 psi 27 58 MPa 275 8 bar G3000 Meter Option 4000 psi 27 58 MPa 275 8 bar Coriolis Meter 2300 psi 15 86 MPa 158 6 bar Color Change Option eee 300 psi 2 07 MPa 20 6 bar Flow GControl Option e 190 psi 1 31 MPa 13 1 bar T Qa e 20 o D 20 o 5 vo 0 29000 ueber an Ue hase 75 3800 cc min 0 02 1 0 gal min G3000HHB ested aunt avente tate hea tnd bate deal eget 88445 38 1900 cc min 0 01 0 50 gal min Coriolis Meter ec Re 5 20 3800 cc min 0 005 1 00 gal min 53000 Solvent Meter accessory 38 1900 cc min 0 01 0 50 gal min Standard Features Accessories Feature Accessory EasyKey with LCD 15V536 Solvent Flow Switch Kit RS 485 Network Cable 50 ft 15 25 m 15V213 Power Cable 100 ft 30 5 m Fiber Optic and Power Cables 50 ft 15 25 m 15G710 Fiber Optic Cable 100 ft 30 5 m Fluid Station Control Box 15G614 Flow Contr
25. 06 KIT Coriolis flow meter see manual 313599 Model 262383 1 10 BRACKET fluid station none Models 262380 and 262383 0 16E841 Models 262381 and 262382 1 11 REGULATOR flow control see page 51 none Models 262380 and 262381 0 249849 Models 262382 and 262383 1 17 CABLE flow control connects flow control regulator to fluid station 10 ft 3 0 m none Models 262380 and 262381 0 15G611 Models 262382 and 262383 1 24 n a TUBING polyethylene 5 32 in 4 mm ID 150 ft 3A1164B Parts 45 Parts EasyKey Controls 277869 EasyKey with Display Detail of Display Interface Kit 210 210a 210d 112554 71124176 2140 214 o p ATI 2141 214 214 N X 214j 207 205 206 209 204 215 221 Poog 0000 203 TI12496b 213 223 206 46 11648 277869 EasyKey with Display Ref No 201 202 203 203a 204 205 206 207 208 209 210 21
26. 0a 210b 210c 210d 210e 211 212A 213 214 214a 214b 214c 214d 214e 214f 214g 214h 214j 214k Part No n a 116320 n a 117818 111987 110911 111307 n a C19293 194337 15X779 n a n a 255767 n a n a 15D568 15W776 223547 n a 255786 n a 117526 119257 114095 121314 n a n a n a n a 11648 Description CONTROL BOX with display SWITCH power LATCH includes item 3a KEY CONNECTOR cord strain relief NUT hex M5 x 0 8 WASHER lock external tooth M5 HOLDER tie NUT hex WIRE grounding door KIT display interface includes items 210a 210b 210d and 210e does not include 210c MEMBRANE GRAPHIC display BOARD EasyKey display e PLATE SCREW 4 40 x 1 in 25 mm ALARM LABEL warning GROUND WIRE 25 ft 7 6 m PLATE application includes items 214a 214m BOARD barrier IS includes fuses 15D979 and 114788 see page 34 for fuse loca tion COVER SPACER BAR ground BLOCK terminal POWER SUPPLY 24 2A SCREW machine pan hd 6 32 x 3 8 in 10 mm SCREW machine pan hd 6 32 x 1 1 2 in 38 mm SCREW machine pan hd 8 32 x 3 4 in 19 mm SCREW machine pan hd 10 24 x 3 8 in 10 mm Qty KR l 11 Ref No 2141 214m 215 216 218 220 221 223 224 Part No Description
27. 2 Unlock and open EasyKey door with its key 3 Disconnect the cables and connectors from J1 J4 and J5 FIG 16 4 Using the security tool provided Part No 122239 remove 2 screws 214k and the cover 214b See 15 5 Noting their location remove 5 screws 214g 214 from the barrier board 214a Do not remove the screw noted 16 Remove board 6 Apply thermal compound to the heatsink Z on the back of the new barrier board 214a FIG 16 7 Install the new barrier board with the 5 screws 2149 214h 214b Service Install the cover 214b with 2 screws 214k using the security tool Connect cables to J1 J4 and J5 Close and lock EasyKey door with key Turn on power at main circuit breaker Turn EasyKey power on to test operation Replacing Barrier Board Fuses A Fuse Part No Description F1 F2 114788 Power In Fuses 2 amp time lag F4 150979 Power Out Fuses 0 4 amp quick acting Follow Replacing Barrier Board steps 1 4 Remove the fuse F1 F2 or F4 from its fuse holder FiG 16 Snap new fuse into holder Follow Replacing Barrier Board steps 8 12 1126496 214 2141 214g 214a Fic 15 Replacing Barrier Board 11648 33 Service J4 Power to Display Board J1 Power In 214g 214g F2 eem em E N F4
28. 4 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2010 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised 07 2011
29. 48 Warnings SKIN INJECTION HAZARD N 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 yoY 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 drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and f
30. E uy p Nez 26 COMM Ero S s2 11 E Eee HEE Ne 36 c5 E R5 R43 z Sus N Nis e EN d tn im Tae R69 da 8 ee mno 5 i ladata Hi t 234 R32 R3 Z9R35R33 R34 R3 RAIRSO e R49 9 R48 R450 R44 R13 4 INPUT INPUT 015 045 046 017 044 043 J9 Pin 1 11648 J15 Pin 1 J8 Pin 1 J14 Pin 1 Fic 10 255765 Fluid Station Control Board 22 Troubleshooting Table 4 Fluid Station Control Board Diagnostics Connector LED Nos Signal Description Diagnosis 015 1 182 Air Flow Switch 1 Turns on when gun 1 is triggered D16 1 586 Solvent Flow Switch Turns on when solvent is flowing D17 J1 9 amp 10 Gun Flush Box 2 Pressure Switch Turns on when a gun is in Gun Flush Box 2 D18 J10 Power Turns on when power is supplied to the board D19 n a Communication yellow Turns on when board is communicating with EasyKey D20 Board OK Blinks heartbeat during normal operation 027 15 18 2 Purge Valve Water Purge 028 414 3 amp 4 Purge Valve A Air Purge 029 8 5 amp 6 Dump Valve B 030 J14 5 amp 6 Purge Valve B Solvent Purge
31. RIAL MAX FLUID WPR MFG YR GRACO INC m bar PSI iiin ace pols T MAX TEMP 50 C 122 F emAco 55440 U S A Fluid Station Control Box Label ProControl FLUID PANEL PARTNO SERIES SERIAL MAX AIR WPR 1 7 m Intrinsically safe equipment bar PSI for Class Div 1 Group D T3 Kare INC T if 289833 Box 1441 126 G MN 0359 Ex ia HAT3 eraco 55440 U ATEX Certificate is listed here EasyKey Label ProControl 1KS POWER REQUIREMENTS PART NO SERIES MFG YR VOLTS 85 250 277869 AMPS 2 AMPS MAX E 0666 50 60 Hz G Minneapolis APPROVED per 289633 5 Cog C Ex ia 5540 US Um 250 V ora 0359 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 Meter Flow Control Part No Series Description None G3000 Coriolis No Yes 262380 A ProControl 1KS v v 262381 A ProControl 1KS v v 262382 A ProControl 1KS v v 262383 A ProControl 1KS v v Control Box Label Location on Fluid Station 115974 Maximum Fluid Working Pressure is listed here 1 Identification Label ProControl 1KS Systems
32. Repair Parts gt g GRACO ProControl 1KS Automatic system for fluid management of single component coatings Includes flow control flushing and color change For professional use only 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 Read all warnings and instructions in this on page 3 Some components shown are not included manual Save these instructions with all systems TI16328a lt gt APPROVED HO03 PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Equipment Approvals 3 System Configuration and Part Numbers 4 Models 2 4 ot reser MO ES 4 WarningS 6 Important Two Component Material Information 9 Isocyanate Conditions 9 Material Self ignition 9 Keep Components A and B Separate 9 Moisture Sensitivity of Isocyanates 9 Changing Materials 9 Grounding 10 Check Resistance 10 Pressure Relief Procedure 10 Troubleshooting 13 Alarm Codes 13 Solenoid Troubleshooting 14 Wall Mount Fluid Manifold Troubl
33. SSIS BARE 5 1 PRESSURE GRN FLUID m 3 H UND 2 COM RED HH press 12VDCI S 5 UNUSED 40 WHT SENS COM 6 CI UNUSED 4 PRESSURE BLK y SHIELD gt SHIELD BARE 1 rc aa 2 J5 1 5 mn 6 213 MH2 COLOR BOARD 1 COLORS 1THRU 12 MANIFOLD i CATALYST MANIFOLD 3 100 OPTIONS mem 608 2 UM m 5 SINOC REDI 987 Hals J9 ya Is SHIELD BARE 06 5 011 4 1 CAN H WHT 6 1 CAN L BLU d 2 0012 5050 3015 116 004 3 GRD BLK 3 CARI 7 i cara p 299 12VDC RED 9 5 3 SHIELD BARE 5 4 79 WHT 0 2 E 12VDC 2 1 CAN L BLU 1 4 0 CAT1 SOLCLR SOL DR mt WEIT 14523 id MANIFOLD nm 6 BLACK rr 6 STD 5 RED NOT USED PT a 14523 JB 3 RED Gron COLOR 2 ERAK Te 2 Y BOARD 2 Lu MANIFOLD i STH 30 E DUMP A 1 21 ME a 0822 4 BLACK 4116 9 0 23 ns 31 maro NOTUSED 5 eurac 6 O BLACK PURGE B 15 16 5 RED S H 00 26 J14 1 E PURGE s E 6 0 27 2 H BiA NOT USED RE 1 3 14 0 29 6 BLACK 4 5 7 RED NOT USED i 0 30 4 BLACK RED NOTUSED BLACK DOSEA AFS 1 BLK _ 1 pe soe L AFS 1 WHT 2 1 SIG AFS 2 RED 3 2 0 7 eI AIRFLOW SWITCH T AFS 2 GRN 4
34. asonable 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 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 3A116
35. at was dis pensed off ratio as it may not cure properly E 5 Overdose A B Dose Too Short Alarm E 6 Overdose B A Dose Too Short Alarm Alarm Codes E 7 Dose Time A Alarm E 8 Dose Time B Alarm Table 1 lists the system alarm codes See the system c operation manual for complete information on alarm E Mixin Setup Alarm troubleshooting E 10 Remote Stop Alarm E 11 Purge Volume Alarm E 12 CAN Network Communication Error Alarm E 13 High Flow Alarm E 14 Low Flow Alarm E 15 System Idle Warning E 16 Setup Change Warning E 17 Power On Warning E 18 Defaults Loaded Warning 19 I O Alarm E 20 Purge Initiate Alarm E 21 Material Fill Alarm E 22 Tank A Low Alarm E 23 Tank B Low Alarm E 24 Tank S Low Alarm E 25 Auto Dump Complete Alarm E 26 Color Catalyst Purge Alarm E 27 Color Catalyst Fill Alarm 3A1164B 13 Troubleshooting Solenoid Troubleshooting Dose Valve A Solenoid Dose Valve B Solenoid Purge Valve B Purge Valve A Solenoid Solenoid 9 9 J3 J12 0000000000 J1 Fic 4 Fluid Station Board and Solenoids Fiber TI15916a 3A1164B Troubleshooting NOTE Re
36. cket from the housing and disconnect the three cables from J1 J2 and J4 on the circuit board 618 FiG 22 4 Remove the screws 621 Replace the old board with the new board 5 Reconnect the three cables to 41 J2 and J4 on the circuit board 618 FIG 22 6 Reattach the bracket 614 to the housing 611 Torque the screws 605 to 30 40 in Ib 3 4 4 5 Nem 11648 Servicing the V P Valve 1 2 Follow Before Servicing page 30 Remove the four screws 605 holding the bracket 614 to the housing 611 Fic 23 Carefully separate the bracket from the housing and disconnect the V P valve cable from J2 on the circuit board 618 Fia 22 Remove the two screws 619a and o rings 619b Install the new valve 619 with new screws and o rings Reconnect the V P valve cable to J2 on the circuit board 618 FIG 22 Reattach the bracket 614 to the housing 611 Torque the screws 605 to 30 40 in Ib 3 4 4 5 Nem J2 V P Valve D7 D8 D9 J2 vias cle mE R3 4 12 11 mm mm NBN 44 Pressure Sensor J1 Power Input Fic 22 249179 Flow Control Board 11648 Service 615 613 CO ew BR Flow 610 lt lt i TI12506a A Torque to 8 10 in Ib 0 9 1 1 Nem A Torque to 30 40 in Ib 3 4 4 5 Nem A Torque to 5 7 in Ib 0 6 0 8 Nem Fic 23 Flow Control 41 Service
37. e gun triggered push the manual override on the A purge valve solenoid to relieve air and solvent pressure See 2 Verify that solvent pressure is reduced to O NOTE If a Purge Volume alarm E 11 occurs clear the alarm Systems with Color Change and Dump Valves NOTE This procedure relieves pressure through the dump valves 1 Complete all steps under Single Color Systems page 10 2 Shut off all color and catalyst supplies to the valve stacks 3 Press and hold the dump valve A solenoid override FiG 2 4 SeeFiG 2 Open the color change module Using the solenoid identification labels as a guide press and hold the override button on each color solenoid until flow from dump valve A stops 5 Press and hold the dump valve A solenoid override FiG 2 6 Press and hold the A side color solvent solenoid override until clean solvent comes from the dump valve then release 7 Shutoff the solvent supply to the color catalyst change stack solvent valves 8 Press and hold the A solvent solenoid override and dump valve override until solvent flow from the dump valve stops 11648 Pressure Relief Procedure 5 g ae 8 2 E Se 25 _3 Catalyst 6060 OT OT 9C 0 XC 9 9 9n o o o o o o o o H
38. er optic cable connectors J4 J6 into Part No 112190 grounding strap on wrist and ground board connectors E matching blue with blue black appropriately with black and hand tighten connectors Do not pinch or kink the fiber optic cables the cables require a 2 in 51 mm bend radius 1 Follow Before Servicing page 30 6 Turn EasyKey power on to test operation 4 F1 343 F O Output blue J1 Digital Input 828 1 j 990 Zi D cutta LEY 9 gag L 13 Not Used J S o ery E 3l J6 F O Input black J10 Power Input J11 Pp Color Change Module 10060 2 III 20 N Li 2 e 60 al vv ms lS J12 Solvent Meter Input S I S 8 Smeeeoeo c as A ni S 5 ve E 20 3g 6 amp pit Not Used 222222 AndNIW313 J3 Meter A and B Input al EH R66 R61 REZ
39. eshooting 16 EasyKey Barrier Board Diagnostics 17 EasyKey Display Board Diagnostics 18 Discrete I O Board Diagnostics 20 Fluid Station Control Board Diagnostics 22 Color Change Board Diagnostics 24 2 Schematic Diagrams 26 System Pneumatic Schematic 26 EasyKey Electrical Schematic 27 System Electrical Schematic 28 Service oc eile ert ele e EIE Ar I 30 Before Servicing 30 After Servicing 30 Servicing 31 Control 35 Servicing Flow Meter 38 Servicing Color Change Module Color Catalyst Valves and Dump Valves 39 Servicing Flow Control 40 522 eee Roe ake 43 ProControl 1KS System 43 EasyKey Controls 46 Available Cables 47 262363 Fluid Station Control Box 48 262364 Valve Stack 50 249849 Flow Control Regulator 51 Technical Data 53 Graco Standard Warranty 54 Graco Information 54 11648 Related Manuals Component Manuals in English Manual Description 3A1163 ProControl 1KS Installati
40. fer to the Schematic Diagrams page 26 If the dispense or purge valves are not turning on or off correctly it could be caused by one of the following Cause Solution 1 Air regulator pressure set too high or too low Check air pressure 80 90 psi 550 630 kPa 5 5 6 3 bar is commonly used Do not go below 70 psi 490 kPa 4 9 bar or above 120 psi 0 8 MPa 8 bar 2 Airor electrical lines damaged or connections loose Visually inspect air and electrical lines for kinks damage or loose connec tions Service or replace as needed 3 Solenoid failure Manually operate the valves by removing the Fluid Station cover and press ing and releasing solenoid valve override buttons 4 Use the control board diagnostics to check the signals If signals do not occur correctly go to Cause 4 Valves should snap open and shut quickly If the valves actuate slowly it could be caused by Air pressure to the valve actuators is too low See Cause 1 Solenoid is clogged Make sure air supply has 10 micron filter installed e Something is restricting the solenoid or tubing Check for air output from air line for corresponding solenoid when valve is actuated Clear restric tion e dose valve is turned in too far See ProControl 1KS Operation manual for settings e Fluid pressure is high and air pressure is low 4 Solenoid cable or fluid station control board failure Check voltage level t
41. included in Seal Kit 150933 purchase sepa rately Kit includes additional parts see Dispense Valve manual 312782 These parts are not available separately Ref Qty No 3 412 413 t 414 8 415 3 416 3 6 417 1 3 3 2 6 1 417 416 TI16356a 11648 249849 Flow Control Regulator Ref No Part No Description 601 102980 NUT full hex 4 40 602 n a O RING chemically resistant fluoroelastomer 603 112698 ELBOW 1 8 npt m x 1 4 in 6 mm OD tube 604 n a O RING chemically resistant fluoroelastomer 605 n a SCREW cap socket hd 10 32 x 1 2 in 13 mm 606 n a PLATE fluid regulator 607 15F799 PLATE air regulator 609 n a SEAT regulator 610 n a RETAINER seat 611 n a HOUSING flow control 612 n a SPACER regulator 613 n a NEEDLE regulator 614 n a BRACKET flow control 615 15F806 PLUG regulator 616 168881 GASKET acetal 617 178321 DIAPHRAGM regulator 618 249179 BOARD circuit assembly 619 120013 VALVE proportional V P includes items 619a and 619b SCREW socket hd M3 x 0 5 x 44 mm 619b 106560 O RING mounting size 007 620 n a SENSOR pressure control 621 107295 SCREW machine pan hd 4 40 x 3 16 in 5 mm 622 104765 PLUG pipe 1 8 ptf 623 192387 PIN dowel 624 15G613 WIRE HARNESS flow control 619a n a Parts included in Regulator Service Kit 15G843 Purchase separately t Parts included in Sensor Service Kit 15G867 Purchase separa
42. ions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail e f 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 This equipment must be grounded Improper grounding setup or usage of the system can cause f ELECTRIC SHOCK HAZARD electric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations INTRINSIC SAFETY Intrinsically safe equipment that is installed improperly or connected to non intrinsically safe equipment will create a hazardous condition and can cause fire explosion or electric shock Follow local regulations and the following safety requirements e Only models with 33000 3250 G3000HR G250HR or intrinsically safe Coriolis meter are approved for installation in a Hazardous Location Class Div l Group D or Zone Group T3 Do not install equipment approved only for a non hazardous location in a hazardous area See the ID label for the intrinsic safety rating of your model Do not substitute or modify system components as this may impair intrinsic safety gt 6 116
43. ios consult your Graco dis tributor See individual component manuals for additional technical data 11648 53 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 abrasion 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 G
44. l Part No 262381 with G3000 meter without flow control Part No 262382 with G3000 meter and flow control Part No 262383 with Coriolis meter and flow control A Items 335 and 336 are part of the Fluid Station Control Box See the parts list beginning on page 49 for descriptions TI16328a Detail of Automatic Upgrade Kit 6 mms Et Lost Eu n _b i 1 E GA 9 d TD 1 4 ng 8 D 6 TI12496a 44 3A1164B Part No 262380 without meter or flow control Part No 262381 with G3000 meter without flow control Part No 262382 with G3000 meter and flow control Part No 262383 with Coriolis meter and flow control Ref No Part No Description Qty 1 262363 CONTROL BOX fluid station see page 48 1 2 570122 MODULE control air 1 3 114158 FITTING tube Y adapter 1 4 15G768 PLUG tube fitting 1 5 277869 CONTROL DISPLAY EasyKey see page 46 1 6 15V256 KIT automatic upgrade includes item 6a 1 6a 15V825 e board discrete I O part of item 6 1 8 262364 VALVE STACK dispense purge high pressure see page 50 1 9 KIT flow meter A none Model 262380 0 16E955 G3000 flow meter see manual 308778 Models 262381 and 1 262382 15V8
45. nded by the fluid and solvent manufacturer 8 11648 Important Two Component Material Information Important Two Component Material Information Isocyanate Conditions Spraying dispensing materials containing isocya nates creates potentially harmful mists vapors and atomized particulates Read material manufacturer s 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 manufacturer s warnings and material MSDS Keep Components A and B Separate Cross contamination can result in cured material in fluid lines which could cause serious injury or dam age equipment To prevent cross contamination of the equipment s wetted parts never interchange component A isocyanate and component B resin parts 11648 Moisture Sensitivity of I
46. o solenoid by pulling solenoid connector and checking voltage between pins If voltage is 9 15 VDC the solenoid is damaged Replace solenoid or correct electrical line problem If there is no voltage replace the board 11648 15 Troubleshooting Wall Mount Fluid Manifold Troubleshooting See FIG 5 FIH 1 AN RAHN i al LA E bz A ER gt 4 j DVA lt SS SPV TI15977a FOH Fic 5 Wall Mount Fluid Manifold Key MA DVA SPV SS APV AT FIH FOH Component A Meter 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 16 11648 Troubleshooting EasyKey Barrier Board Diagnostics See 6 and Table 2 to troubleshoot the EasyKey barrier board Also see the EasyKey Electrical Schematic on page 27 and the System Electrical Schematic on pages 28 and 29 J4 Pin 1 J1 Pin 1 D5 F1 2 F4 e ia D4 2 J5 Pin 1 FiG 6 255786 EasyKey Barrier Board Table 2 EasyKey Barrier Board Diagnostics Connector Description Diagnosis J1 AC Power Input n a J4 24 Vdc Power Input to D5 turns on EasyKey Display Board J5 12 Vdc Power Output to D4 turns if barrier board is functioning
47. oids If you have options installed you have additional optional solenoids for each See Table 6 and Sche matic Diagrams page 26 Service Table 6 Control Box Solenoids 5 To replace a single solenoid 1 Follow Before Servicing page 30 and shut off power at main circuit breaker 2 Disconnect 2 solenoid wires from control board 302 See 17 and System Electrical Sche matic page 29 3 Unscrew 2 screws and remove solenoid 318 FIG 19 4 Install new solenoid 318 5 Connect 2 wires to control board 302 Solenoid wires are polarized red black Refer to Sys tem Electrical Schematic page 29 Replacing Control Board Fuse Solenoid Actuates Standard 1 Dose Valve A 2 Dose Valve B 3 Air Purge Valve 4 Solvent Purge Valve Optional 5 Third Flush Valve 6 Dump Valve A AN Replacing the fuse with a non Graco fuse voids the IS system safety approval 7 Dump Valve B mE MO 115917 Fic 19 Replacing Solenoids Fuse Part No Description F1 123690 Fuse 125 mA intrinsically safe 1 Follow Before Servicing page 30 2 Locate fuse F1 on the control board See Fia 18 Remove the screw and metal strap
48. ol Extension Cable 40 ft 12 2 m Discrete I O Board 151034 Strobe Light Alarm Indicator Kit A Side Dump Valve if color valve s selected 15V331 Gateway Ethernet Communication Kit Flow Control with 15 ft 4 57 m Cable if selected 15V963 Gateway DeviceNet Communication Kit Basic Web Interface 15V964 Gateway Profibus Communication Kit 15V337 Advanced Web Interface 11648 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 this manual where applicable Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help FIRE AND EXPLOSION HAZARD prevent and explosion EUM 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 instruct
49. ollow 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 11648 7 Warnings 2 TOXIC FLUID OR FUMES HAZARD A Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDSs to know the specific hazards of the fluids you using Store hazardous fluid in approved containers and dispose of it according to applicable guidelines Always wear chemically impermeable gloves when spraying dispensing or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT 2 You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect from serious injury including eye injury hearing loss inhalation of toxic fumes and burns This equipment includes but is not limited to Protective eyewear and hearing protection Respirators protective clothing and gloves as recomme
50. on 3A1080 ProControl 1KS Operation 312782 Dispense Valve 312783 Color Change Valve Stacks 312787 Color Change Module Kit 312784 Gun Flush Box Kits 310745 Gun Air Shutoff Kit 312786 Dump Valve and Third Purge Valve Kits 312785 Network Communication Kits 308778 G3000 G3000HR G250 G250HR Flow Meter 313599 Coriolis Flow Meter 313212 Gun Flush Box Integration Kit 313290 Floor Stand Kit 313542 Beacon Kit 313386 Basic Web Interface Advanced Web Interface 406800 15V825 Discrete I O Board Kit 11648 Related Manuals Equipment Approvals Equipment approvals appear on the following labels which are attached to the Fluid Station Control Box and 7 1 on page 4 for label locations EasyKey and Fluid Station Control Box Label ATEX Certificate is listed here ProContrgl 1KS Electronic Pfoportioner Intrinsically Safe IS System Install per IS Control Drawing No 289833 EasyKey Interface IS Associated Apparatus for use in non hazardous KO location with IS Connection to Smart 074 APPROVED Fluid Plate IS 12 3 Intrinsically safe n Apparatus for use in equipment for Class Class Division 1 Group D C Ex Div 1 Group D T3 C 20 C to 50 C Hazardous Locations 0359 Read Instruction Manual MAX AIR WPR Warning Substitution of components _7 7 100 may impair intrinsic safety TER PSI PART NO SERIES SE
51. ooting Table 5 Color Change Board Diagnostics Connector Board 1 Signal _ Board 2 Signal LED Pin Nos Description Description Diagnosis D8 n a Board OK Board OK Blinks heartbeat during normal operation D9 n a Communication _ Communication Turns on when board is communicating with ProMix yellow yellow 2KS 010 7 Power Power Turns on when power is supplied to the board 027 J15 5 amp 6 Color 3 Color 16 028 14 3 amp 4 Color 1 Color 14 029 8 546 Color 6 Color 19 030 14 1 amp 2 Color 2 Color 15 031 068 3 amp 4 Color 7 20 032 16 3 amp 4 Catalyst 4 Color 26 033 J8 1 amp 2 Color 8 Color 21 034 9 546 Color 9 Color 22 035 J15 3 amp 4 Color 4 Color 17 D27 through D46 turn on when ProMix 2KS sends 036 14 546 Solvent Color Color 13 a signal to actuate the related solenoid valve D37 J10 5 amp 6 Catalyst 2 Color 28 D38 J16 1 amp 2 Catalyst 3 Color 27 039 16 546 Color 12 Color 25 D41 J15 1 amp 2 Color 5 Color 18 043 9 3 amp 4 Color 10 Color 23 044 J9 1 amp 2 Color 11 Color 24 045 J10 3 amp 4 Catalyst 1 Color 29 046 10 1842 Solvent Catalyst Color 30 F1 Replaceable n a n a Check fuse condition if there is no power to the Fuse board or if communication is interrupted between the fluid station and the color change module 11648 25 Schematic Diagrams Schematic Diagrams System Pneuma
52. or best results use all parts in the kit 1 Follow Preparation above 2 Remove the four screws 605 and the nut 601 from the underside of the air plate 607 Separate the air plate and fluid plate 3 Unscrew the pressure sensor 620 from the fluid plate 606 NOTE If you are only replacing the pressure sensor kit 15G867 skip to step 6 4 Remove the plug 615 and o ring 604 from the top of the fluid plate 606 Remove the parts of the dia phragm assembly 613 610 609 612 617 616 Remove and discard the dowels 623 5 Reassemble the diaphragm assembly using the new parts from the kit Be sure the AIR SIDE of the dia phragm 617 faces down Torque the nut 601 to 8 10 in Ib 0 9 1 1 Nem 40 6 Install a new o ring 602 on the pressure sensor 620 and screw the sensor into the fluid plate 606 7 Reinstall the fluid plate on the air plate Be careful not to pinch the pressure sensor cable Torque the Screws 605 to 30 40 in Ib 3 4 4 5 Nem 8 Reconnect three cables to 41 J2 and J4 on the circuit board 618 Fic 22 9 Reattach the air plate 607 to the housing 611 Torque the screws 605 to 30 40 in Ib 3 4 4 5 Nem 10 Reattach the flow control cable and all air and fluid lines Servicing the Flow Control Board 1 Follow Before Servicing page 30 2 Remove the four screws 605 holding the bracket 614 to the housing 611 FIG 23 3 Carefully separate the bra
53. ork B 85485 Network Ground Flow Control Calibrate Gun Trigger Digital Common INPUTS Remote Stop Alarm Reset __ General Alarm Digital Common OUTPUTS Potlife Alarm Flow Rate Analog In m B E E E B E Flow Rate Analog Common Ljoooooooooo ooooool 112958 Display Board Barrier Board Terminal Strips see detail above 55660 x e ooo e 5 yy 8 S AAA m Discrete Board o o OTE see FIG 9 Weary jol 1o 507 1124966 Fic 8 EasyKey Control Boards and Terminal Strips 20 11648 Troubleshooting N eg 5 5 5 5 oum ao gt 0 5 5 5 5 68 O S S S S Fe o 5 Do 2 8 amp amp ao o o o o AO GRACO DIGITAL OU Digital Output Common Powe
54. phic display 210b Press them together See Fic 13 8 Reconnect the graphic display power cable J1 to the display board 210c 9 Mount display board assembly with screws 2106 10 Plug all connectors into display board 210c Fic 13 Confirm that the cables do not pinch when open ing or closing the door 11 Locate the battery on the board see 7 on page 18 Pull the strip to remove the protective isolator and activate the battery 12 Close and lock EasyKey door with key 13 Turn EasyKey power on to test display board Replacing Power Supply AN 1 Follow Before Servicing page 30 2 Unlock and open EasyKey door with its key 3 Note position of power supply input and output wires See EasyKey Electrical Schematic page 27 Disconnect wires from power supply 214f See Fic 14 4 Remove power supply from din rail 5 Install new power supply 214f Reconnect input and output wires in positions noted in step 3 6 Close and lock EasyKey door with key 7 Turn on power at main circuit breaker 8 Turn EasyKey power on to test operation 31 Service Replacing Line Filter A 1 Follow Before Servicing page 30 2 Unlock and open EasyKey door with its key 3 Note position of line filter input and output wires See EasyKey Electrical Schematic page 27 Dis connect wires and remove line filter 2141 from bracket 214m See FiG 14
55. r U16 d E 9 1 Flow Rate Alarm Output U15 Flow Calibrate Active 1 5 SSE wg U12 ve Fill Active A 014 er RB wl M A 20 VRS U11 Mix Ready Output LED D1 1 green g 013 VRA Mix Active Output 5 VR7 010 Purge Recipe Change Active Output z LA zL Digital Output Common Power VRS 09 759 ii Recipe Change Input Q 07 INA U8 Recipe Bit 5 Input 2 0 Recipe Bit 4 Input RN4 FE L R5 Recipe Bit 3 Input R4 AS RN to aa Recipe Bit 2 Input 2 gt ILL Le ES Recipe Bit 1 Input N Rii Recipe Bit Input R10 2 Digital Input Common 0 Mix Input Purge Input ge inp Job Complete Input External Color Change Ready Digital Input Common Fic 9 255766 Discrete I O Board 11648 21 F1 Fuse J6 Fiber Optic Output blue J4 D18 D19 See 718 10 and Table 4 to troubleshoot the fluid station control board Also see the System Electrical Schematic J1 Pin 1 on pages 28 and 29 Fluid Station Control Board Diagnostics Troubleshooting I a 5 5 2 c Ou 6 02 gt 22 6 EX 2 ye So SOs DZ 53 e L5 Q D31 D33 D41 D27 D28 D30 he m E E 3 m 5 rss T E vi e
56. raco 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 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 re
57. socyanates 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 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 150 such as those supplied with your system 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 reassembling Changing Materials 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 Grounding Grounding
58. tely Parts labeled n a are not available separately 11648 Qty 1 1 1 1 12 Ll Parts Flow 610 direction 606 a 602 As 620 612 617 e im 616 A 112506 A Torque to 8 10 in Ibs 0 9 1 1 Nem A Torque to 30 40 in Ibs 3 4 4 5 Nem A Torque to 5 7 in Ibs 0 6 0 8 Nem 51 Parts 52 11648 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 Coriolis meter 2300 psi 15 86 MPa 158 6 bar Flow control 190 psi 1 31 MPa 13 1 bar Maximum working air 100 psi 0 7 MPa 7 bar AIPSUDDIY s seen Re RU e REDDE 75 100 psi 0 5 0 7 MPa 5 2 7 bar Air filler inlet size 3 8 npt f Air filtration for air logic and purge air 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 one or two component solvent and waterborne paints polyurethanes epoxies acid catalyzed varnishes moisture sensitive isocyanates Viscosity range
59. tic Schematic PURGE AIR AIR INPUT 26 COLOR COLO 3 8 AIR FILTER MANUAL DRAIN 5 MICRON WALL MOUNT ONLY INPUT 1 4 TUBE TO MANIFOLD CONTROL AIR AIR EXHAUST MUFFLER 12VDC 4 WAY SOLENOID MEER 12 VDC 4 WAY SOLENOID 5 12VDC MAT 4 4 WAY SOLENOID ATB T 12VDC E CP XM dee 4 WAY SOLENOID 1 Q 69 e 12 VDC E Nott Mj SK i 4 WAY SOLENOID ATE i AY _ AIR EXHAUST MUFFLER i 12VDC 7m 3 WAY SOLENOID EP i 5 12VDC mit LZ IK 3 WAY SOLENOID e 12VDC i 1 Pi NAA 1 as 3 WAY SOLENOID NE 69 La D i 12VDC Bat Z7m amp AS 3 WAY SOLENOID MZ CHANGE VALVE CONTROL STACKS OLVENT 14108 ALYST SOLVENT FLUSH AIR TO FLUID INLET PURGE A VALVE gung nna nn annann nn PURGE B COLOR 13 COLOR 14 COLOR 15 COLOR 16 COLOR 17 COLOR 18
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