Graco 3A1080C- User Manual

System Configuration and Part Numbers 3A1080C 5 Standard Features Accessories Hazardous Location Approval Models using a G3000, G3000HR, or intrinsically safe Coriolis meter are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3. Maximum Working Pr...

Warnings 6 3A1080C 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 manua...

Important Two-Component Material Information 3A1080C 9 Important Two-Component Material Information Isocyanate Conditions Material Self-ignition Keep Components A and B Separate Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component coatings. ISO will react with mo...

Glossary of Terms 10 3A1080C 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 quant...

Overview 12 3A1080C 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).• H...

Overview 14 3A1080C ProControl 1KS System Components F IG . 2. ProControl 1KS System, shown with G3000 Meter, Color Change, and Flow Control TI15961b FO* FC (see F IG . 4) PS* EK ACV CCM MA FM (see F IG . 3) * See the ProControl 1KS Repair-Parts manual for optional cable lengths. Air Control Module ...

EasyKey Display and Keyboard 16 3A1080C EasyKey Display and Keyboard 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 sc...

EasyKey Display and Keyboard 18 3A1080C AC Power Switch Turns system AC power on or off. I/S Power Power circuit to Fluid Station Control Box. Potlife Exceeded Audible Alarm Aler ts the user when a Potlife Exceeded alarm occurs. Clear by pressing the Alarm Reset key. Graco Web Interface Port Used to...

Run Mode Screens 3A1080C 19 Run Mode Screens NOTE: See F IG . 10 for a map of the Run screens. Detailed screen descriptions follow. Splash Screen At power up, the Graco logo and software revision will display for approximately 5 seconds, followed by the Status Screen (see page 21). The Splash screen...

Run Mode Screens 3A1080C 21 Status Screen • Use the Up or Down keys to scroll through the Run screens. • Press the Enter key to select a different fluid station control box. • Press the Setup key to enter the Setup screens from the Status screen. • The other keys have no function in this Status scre...

Run Mode Screens 22 3A1080C 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...

Run Mode Screens 3A1080C 23 Global Flow Control Data Copy This field allows you to copy flow control data from the active recipe to all recipes. Press the Enter key to view the menu, then select Start or Abort. See F IG . 15. Totals Screen This screen shows the job totals, grand totals, and job numb...

Run Mode Screens 24 3A1080C Alarms Screen Two screens show the last 10 alarms. Use the Up or Down keys to scroll between the two screens. See Table 13 on page 90 for a list of alarm codes. Level Control Screen This screen shows the current volume for each fluid. Adjust the actual volumes on this scr...

Setup Mode 3A1080C 25 Setup Mode Press the Setup key to enter Setup mode. NOTE: See F IG . 22 for a map of the Setup screens. Detailed screen descriptions follow. F IG . 22. Setup Screens Map To access Advanced Setup Screens, page 34 and Recipe Setup Screens, page 39. To access System Configuration ...

Setup Mode 26 3A1080C 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 passw...

Setup Mode 28 3A1080C System Configuration Screens NOTE: See F IG . 26 for a map of the System Configura- tion Screens. Detailed screen descriptions follow. NOTE: Each screen displays the current screen number and the total number of screens in the group. F IG . 26. System Configuration and Option S...

Setup Mode 3A1080C 29 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 ...

Setup Mode 30 3A1080C Configure Screen 3 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 t...

Setup Mode 3A1080C 31 Configure Screen 5 Flow Control This field only appears if Run Mode is set to “Automatic” in Configure Screen 3, page 30. Select On 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 st...

Setup Mode 32 3A1080C Option Screens NOTE: See F IG . 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 This field only appears if S...

Setup Mode 3A1080C 33 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 “Recipe”). If set to ...

Setup Mode 34 3A1080C Advanced Setup Screens NOTE: See F IG . 36 for a map of the Advanced Setup Screens. Detailed screen descriptions follow. F IG . 36. Advanced Setup Screens Map TI12805a Advanced Setup screens 2, 3, 4, and 8 appear depending on selections made in Option screens 1 and 2. Screen 5 ...

Setup Mode 3A1080C 35 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. Advanc...

Setup Mode 36 3A1080C Advanced Setup Screen 2 This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32. First Purge Source Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30). Chop Ty...

Setup Mode 3A1080C 37 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 sign...

Setup Mode 38 3A1080C Advanced Setup Screen 6 This screen shows the status of recipe analog inputs and digital outputs. If box is shaded the input recipe is active. Advanced Setup Screen 7 This screen shows the status of digital inputs and digital outputs. If box is shaded the input is active. If no...

Setup Mode 3A1080C 39 Recipe Setup Screens NOTE: See F IG . 45 for a map of the Recipe screens. Detailed screen descriptions follow. F IG . 45: Recipe Screens Map TI12806a Recipe 0 Screens Recipe screens 3, 4, 5, 6, and 7 appear depending on selections made in Option screens 1 and 2

Setup Mode 40 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. Recipe...

Setup Mode 3A1080C 41 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...

Setup Mode 42 3A1080C 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 signa...

Setup Mode 3A1080C 43 Recipe 0 Screens NOTE: See F IG . 45 on page 39 for a map of the Recipe 0 screens. Detailed screen descriptions follow. Recipe 0 is typically used in multiple color systems to purge out material lines without loading a new color NOTE: Each screen displays the current screen num...

Setup Mode 44 3A1080C Recipe 0 Screen 3 This screen only appears if Solvent Monitor is set to “Meter” 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 VolumeThis field o...

ProControl 1KS Integration Specifics 3A1080C 45 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 b...

ProControl 1KS Integration Specifics 3A1080C 47 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 en...

ProControl 1KS Integration Specifics 48 3A1080C F IG . 61: 255766 Discrete I/O Board JLS Purge I nput Job Comp lete In put Exter nal Colo r Chang e Ready Spare Dig ital Input C o mmon S p ec ia l O u tp ut # 4 Mix I nput Recipe Change Input Recipe Bit 0 Input Flow Rate Alarm Output Flow Control Cali...

ProControl 1KS Integration Specifics 3A1080C 49 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 (F IG . 78-F IG . 95) for fur- ther information. Fill_Active: Thi...

ProControl 1KS Integration Specifics 50 3A1080C Automation Flow Charts Start Mix Mode Process See F IG . 62, Table 5, and Table 6. F IG . 62. Start Mix Mode Process Flow Chart Start Mix Mode Process Is Mix Ready bit = 1? Must be Alarm Condi- tion or Active Recipe 61. See Alarm Pro- cessing on page 5...

ProControl 1KS Integration Specifics 3A1080C 51 Mixing Mode Process See F IG . 63, Table 5, and Table 6. F IG . 63. Mixing Mode Process Flow Chart Mixing Mode Process Is Mix Active bit = 1? Check Alarm Condition: is Alarm_ General bit = 1? YES NO NO YES Mixing Mode is desired. PLC is polling to ensu...

ProControl 1KS Integration Specifics 52 3A1080C Purge Mode Process See F IG . 64, Table 5, and Table 6. F IG . 64. Purge Mode Process Flow Chart Start Is Mix Ready bit = 1? Must be Alarm Condition or Active Recipe 61. See Alarm Processing on page 54, or Startup from Recipe 61 (see NOTE below). YES N...

ProControl 1KS Integration Specifics 3A1080C 53 Color Change Mode Process See F IG . 65, Table 5, and Table 6. F IG . 65. Color Change Mode Process Flow Chart Color Change Process (basic) Is Purge_CC_Active bit = 1? Check Alarm Condition: is Alarm_ General bit = 1? YES NO NO YES Is Active Recipe = t...

System Operation 62 3A1080C System Operation Operation Modes Mix System mixes and dispenses material (apply Mix input). Standby Stops the system (remove Mix input). Purge Purges the system, using air and solvent (apply Purge input). Recipe (Color) Change The process when the system automatically flu...

System Operation 3A1080C 63 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...

System Operation 3A1080C 65 General Operating Cycle 1. The system enters and loads the desired color. 2. The system enters Mix mode to begin operation. 3. The ProControl 1KS controller sends signals to acti-vate the solenoid valves. The solenoid valves acti-vate Dose Valve A. Fluid flow begins when ...

System Operation 66 3A1080C Mix Manifold Valve Settings To open dose or purge valves, turn hex nut (E) counter-clockwise. To close, turn clockwise. See Table 10 and F IG . 70. F IG . 70. Valve Adjustment E TI11581a Table 10: Mix Manifold Valve Settings Valve Setting Function Dose (see F IG . 70) Hex...

System Operation 3A1080C 67 Start Up 1. Go through the Pre-Operation Checklist in Table 11. 2. Turn the AC Power Switch ON (I = ON, 0 = OFF). ➜ Graco logo, software revision, and “Establishing Communication” will display, followed by Status screen. See page 19. ➜ At power up the system defaults to R...

System Operation 3A1080C 69 Shutdown Overnight Shutdown 1. Leave the power on. 2. Run Recipe 0 to purge solvent through meters and gun. Service Shutdown 1. Follow Pressure Relief Procedure on page 69. 2. Close main air shutoff valve on air supply line and on ProControl 1KS. 3. Shut off ProControl 1K...

System Operation 3A1080C 73 Purging There are 4 purging procedures in this manual: • Purging Mixed Material (below) • Purging Using Recipe 0 (page 74) • Purging Fluid Supply System (page 74) Use the criteria listed in each procedure to determine which procedure to use. Purging Mixed Material There a...

System Operation 74 3A1080C Purging Using Recipe 0 Recipe 0 is typically used in multiple color systems to purge out material lines without loading a new color. To setup Recipe 0, go to Advanced Setup. Select the Recipe tab and change the Recipe to 0. The Recipe 0 Setup Screen appears. Set the chop ...

Meter Calibration 76 3A1080C Meter Calibration Calibrate the meter: • The first time the system is operated. • Whenever new materials are used in the system, especially if the materials have viscosities that differ significantly. • At least once per month as part of regular mainte-nance. • Whenever ...

Color Change 78 3A1080C Color Change Color Change Procedures Multiple Color Systems 1. Shut off air to the gun. 2. Place the gun in the gun flush box if used, and close the lid. 3. Go to Standby mode (remove Mix input). 4. Select the new recipe. Begin the color change sequence. 5. If a gun flush box...

Alarms and Warnings 90 3A1080C 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: •...

Alarm Troubleshooting 3A1080C 91 Alarm Troubleshooting Table 14. Alarm Troubleshooting E-1: COMM_ERROR Cause Solution No power to the EasyKey. Connect power to EasyKey. No power to Fluid Station Control Box. The intrinsically safe power cable between the EasyKey and Fluid Station Control Box is not ...

Schematic Diagrams 3A1080C 101 Schematic Diagrams System Pneumatic Schematic 3/8 AIR FILTER MANUAL DRAIN 5 MICRON WALL MOUNT ONLY FL USH AIR TO FL UID INLE T 1/4 TUBE TO M ANIFOLD 1/4 TUBE 4-WAY SOLENOID 12 VDC PURGE A VALVE DUMP A VALVE (OPTIONAL) 4-WAY SOLENOID 12 VDC 3-WAY SOLENOID 12 VDC 3-WAY S...

Schematic Diagrams 102 3A1080C 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 BARRIER BOARD OPERATOR INTERFACE 1 2 L1 N 85-250 VAC GND N L1 ...

Schematic Diagrams 3A1080C 103 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 HAZARDOUS AREA +12VDC I/S COM SHIELD J10 2 3 5 1 2 3 4 5 6 J3 PWR ...

Schematic Diagrams 104 3A1080C EasyKey Electrical Schematic J9 4 3 2 1 GREEN/BLA CK/WHITE 22 A W G RED/BLA CK/WHITE 22 A WG BLA CK 18 A W G RED 18 A W G - + ALARM - - + DC OK POWER SUPPL Y COMMON 24 VDC+ BARRIER BO ARD J4-3 J4-2 J4-1 J1-5 J1-4 J1-3 J1-2 J1-1 TERMINAL BL OCKS POWER ROCKER SWIT CH L L...

Technical Data 3A1080C 105 Technical Data * 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...

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 Int...