Graco 3A1163A manual

Installation Pr oContr ol ™ 1KS 3A1163A ENG A utomatic system for fluid mana gement of single component coati ngs. Includes flo w contr ol, flushing, and color chan ge . For prof essional use only . Appro ved f or use in explosive atmospheres (e xcept the EasyKe y). See pages 4- 5 f or model in f orm ation, including maxi- mum w orking pressure. [...]

2 3A1163A Contents Related M anuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Equipment Appro vals . . . . . . . . . . . . . . . . . . . . . . . 3 System Configuration and Part Numbers . . . . . . . 4 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Related Manuals 3A1163A 3 Related Manuals Component Manuals in English Equipment Appr o v als Equipment appro v als appear on the f ollowing labels which are attached to the Fluid Station Control Bo x and EasyK ey ™ . See F IG . 1 on page 4 f or label locations . Manual De scription 3A1080 ProControl 1KS Oper ation 3A1164 ProControl 1KS Repair- P[...]

System Configuration and Part Numbers 4 3A1163A System Configuration and P ar t Numbers Models The part number f or your equipment is printed on the equipment identification labels. See F IG . 1 f or location of the identifica tion labels. P ar t No. Series Description Meter Flow Con trol None G3000 Coriolis No Y es 262380 A ProControl 1KS ✔ ✔ [...]

System Configuration and Part Numbers 3A1163A 5 Standard Features Accessories Hazardou s Location Appro va l Models using a G3000 , G3000HR, or intrinsically saf e Coriolis meter f or both A and B meters are approv ed f or installation in a Hazar dous Location - Class I, Div I, Group D , T3 or Zone I Group IIA T3. Maximum W orking Pressure Maximum [...]

Warnings 6 3A1163A Wa r n i n g s The f ollowing w ar nings are f or the setup , use, groundin g, maintenance, and rep air of this equipment. The e xclama- tion point symbol ale r ts you to a gener al warning and the hazard symbols ref er to procedure-specific risks. When these symbols appear in the body of this manual , ref er ba ck to these W arn[...]

Warnings 3A1163A 7 SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierc e skin. This ma y look like just a cut, but it is a serious inju r y that can result in amputatio n. Get immed iate surgical treatment. • Do not spr ay wit hout tip guard and trigger guard installed. • Engage trigger loc k when n[...]

Warnings 8 3A1163A T O XIC FLUID OR FUMES HAZARD T o xic fluids or fumes can cause serious injury or death if splashed in the e yes or on skin, in haled, or s wallowed. • Read MSDSs to know the specific ha zards of the fluids y ou are using. • Store hazardou s fluid in approv ed container s, and dispose of it according to applicab le guidelines[...]

Important Two-Component Materi al Information 3A1163A 9 Impor tant T w o-Component Material Inf ormation Isocy anate Conditions Material Self-ignition K eep Components A and B Separate Moisture Sensitivity of Isocy anates Isocy anates (ISO) are catalyst s used in two component coatings. ISO will react with mo isture (such as humidity) to f or m sma[...]

Component Identification and Definiti on 10 3A1163A Component Identification and Definition See T able 1, and F IG . 2 f or the system comp onents. F IG . 2. ProCon trol 1KS System, sho wn with G3000 Meter , Color Change, and Flow Control TI15961b * See the ProControl 1KS Repair-P ar ts manual f or optional cab le lengths . FO* FC (see F IG . 8) PS[...]

Component Identification and Definiti on 3A1163A 11 Fluid Manif old (FM) Includes wall mo unting brac ket an d mountings f or the fluid met er and the f ollowing v alv es: • Pneumatically Ope rated Dose V alve for component A • Purge V alves f or solv ent and air purge Flow Me ters (MA, MS) F our optional flow meters are av ailab le from Gr aco[...]

Location 12 3A1163A Location Location Requirements • Mount EasyKe y and F luid Station within 50 ft (15.2 m) of each other , using 15U533 cab le. NO TE: An optional 15V213 10 0 ft (30.5 m) cab le is also av ailabl e. • EasyKey: Install in the non -hazardous area at a conv enient location f or the operato r to view and operat e. • Fluid Statio[...]

Location 3A1163A 13 F IG . 3. Intrinsicall y Safe Installation NON-HAZARDOUS LOCA TION ONL Y HAZARDOUS (CLASSI FIED) LOCA TION CLASS I, DIV I, GROUP D , T3 (US AND CANAD A) CLASS I, ZONE I GR OUP IIA T3 (A TEX ONL Y) T A UB = -20°C T O 50°C ProMix 2KS EasyK ey Interf ace (with or without displa y) Saf ety Barrier ProMix 2KS Smar t Fluid Plate (W [...]

General Information 14 3A1163A General Inf ormation • Ref erence n umbers and letters in parentheses in the text ref e r to numbers and letters in the illustra- tions. •F IG . 2 on page 10 sho ws the basic components of a ProControl 1KS system, and F IG . 4 on page 15 shows a basic system la yout. Contact y our Graco distributor f or an actual [...]

Wall Mounting 3A1163A 15 F IG . 4. ProCon trol 1KS System La yout Dra wing TI16329a EasyK ey Interf ace (with display) Fluid System Control Box Optional Color Change Module 50’ I/S P ower Cable Flow Control Regulator Module Optional Color Change V alves Air Control Module 5/32” Color V alve Air Supply 50’ Fiber Optic Cable Air In Fluid Out Fl[...]

Wall Mounting 16 3A1163A[...]

Air Sup ply 3A1163A 17 Air Suppl y Requirements • Compressed air suppl y pressure: 75-100 psi (517-700 kPa, 5.2-7 bar). • Air hoses: use g rounded hoses tha t are correctly sized f or y our system. • Air regulator and b leed-type shutoff v alve: include in each air line to flui d supply equipment. Install an additional shut off valv e upstrea[...]

Fluid Supply 18 3A1163A Fluid Suppl y Requirements ProControl models are a v ailable to operate air spr ay or air-assisted syste ms with a capacity of up to 3800 cc/min. • Fluid supply pr essure tanks, f eed pu mps, or circulat- ing systems can be used. • Materials can be transf erred from t heir original con- tainers or from a cen tral paint r[...]

Fluid Suppl y 3A1163A 19 F IG . 6. Fluid Manifold TI15977a MA SPV DV A APV AT SS FIH FOH F IG . 7. Color Change V alves Air and Fluid Connections Q S 1 2 4 5 3 Connect solv ent v alv e air line here Color Change Board and Solenoid V alves Color Change Board Solenoids Color Change V alve Stac k Connect air lines to val ve s h e re Fluid Inlets Fluid[...]

Fluid Supply 20 3A1163A F IG . 8. Flow Contr ol Regulator TI15976a Regulator V/P Air FC Cable FC Fluid In Fluid Ou t[...]

Electrical 3A1163A 21 Electrical Requirements NO TE: All options ord ered on the ProControl system are electr ically tested at the factor y . The ProContr ol operates with 85-250 V AC , 50/60 Hz input po wer , with a maximum of 2 amp current dr aw . The pow er supply circuit must be prot ected with a 15 amp maximum circuit br eaker . Not included w[...]

Electrical 22 3A1163A Connect EasyKe y to Fluid Station Contr ol There are two 50 ft (15.2 m) cab les to rou te between t he EasyK ey and Fluid Station Control: the Flui d Station P ow er Cable and the Fiber Optic Ca b le. 1. Connect the appro priate Fluid Station P o wer Cabl e end to the Ea syK e y conn ector . See F IG . 10. 2. Connect the othe [...]

Electrical 3A1163A 23 F IG . 11. Fluid Station Boar d Connections J11 (Color Chan ge Module) J7 (Not Used) J10 (P ower Input) J4 (Fiber Optic Outp ut - b lue) J6 (Fiber Optic Input - blac k) VDC[...]

Electrical 24 3A1163A Connect Color Change Module T o install the color change module(s), see manual 312787. Connect a 5-pin electrical cab le from the labeled con- nection por t (J11) on the flui d station control board to the color change board. See F IG . 12. If y ou are using two color chan ge modules to add colors, connect a 5-pin electrical c[...]

Electrical 3A1163A 25 F IG . 12. Color Change Boar d Switches S3-S6 S3 S4 S5 S6 OFF ON OFF ON Switch S3-S6 P ositions J7 J11 TI13661a[...]

Electrical 26 3A1163A F IG . 13. Color Change Module Electr ical Schematic WIRING DIA GRAM COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC J8 J15 J14 J9 J16 J10 COL OR 8 (21) COL OR 7 (20) COL OR 6 (19) COL OR 5 (18) COL OR 4 (17) COL OR 3 (16) COL OR 2 (15) COL OR 1 (14) COL OR FLUSH (13) COL OR 9[...]

Electrical 3A1163A 27 Gr ounding Ground the ProCont rol system as instructed here and in the individual compone nt manuals . A ground wire and clamp , par t no . 223547, is availab le from Graco. NO TE: T o prev ent electrical noise interf erence from high v oltage equipment, do no t connect the robot g round to the same grou nd point used by these[...]

Electrical 28 3A1163A F IG . 14: Gr ounding EasyKey Display 1 2 3 4 5 6 TI16331a Key: EasyK ey ground scre w EasyK ey ground wire Control Box gr ound screw Control Box gr ound wire Robot ground wire. Connect to separate ground point; see NO TE on page 27. T ru e Earth Ground - check your local code f or requirements 1 2 3 4 5 6 Control Bo x Robot 6[...]

Schematic Diagrams 3A1163A 29 Schematic Dia grams System Pneumatic Schematic 3/8 AIR FIL TER MANU AL DRAIN 5 MICRON W ALL MOUNT ONL Y FLUSH AIR TO FL UID INLET 1/4 TUBE TO MANIFOLD 1/4 TUBE 4-W A Y SOLENOID 12 VDC PURGE A VA LV E DUMP A VA LV E (OPTIONAL) 4-W A Y SOLENOID 12 VDC 3-W A Y SOLENOID 12 VDC 3-W A Y SOLENOID 12 VDC AIR EXHAUST MUFFLER OP[...]

Schematic Diagrams 30 3A1163A System Electrical Schematic NO TE: The electrical schematic illustrates all possible wiring ex pansions in a ProControl 1KS system. Some compo- nents shown are not includ ed with all systems. Non-Hazar dous Area BARRIER BOARD OPERA TOR INTERF ACE 1 2 L1 N 85-250 VAC GND N L1 85-250 V AC 1 2 3 J5 +12VDC I/S (RED) COM (B[...]

Schematic Diagrams 3A1163A 31 System Electrical Schematic NO TE: The electrical schematic illustrates all possible wiring e xpansions in a ProControl 1KS system. Some compo- nents shown are not includ ed with all systems. Hazardous Area HAZARDOUS AREA +12VDC I/S COM SHIELD J10 2 3 5 1 2 3 4 5 6 J3 PWR (RED) COM (BLACK) SIG (WHITE) SHIELD/GRN NOT US[...]

Dimensions and Mounting Hole Layou ts 32 3A1163A Dimensions and Mounting Hole La y outs W all Pa nel (mounting brac ket only) TI16333a A D C B E Module A Overall Width in. (mm) Overall Depth in. (mm) B Overall Height in. (mm) Mounting Dimensi ons, Width (C) x Height (D) in. (mm) E Mountin g Hole Size in. (mm) We i gh t lb (kg) EasyK ey 14.0 (35 5.6[...]

Dimensions and Mounting Hole Layou ts 3A1163A 33 Control Bo x TI16332a E A B C D EasyKe y TI11891a TI11895a Air Supply Co ntrol TI13659a Flow Contr ol Module TI14135a D C E A B E C E A B C D[...]

Dimensions and Mounting Hole Layou ts 34 3A1163A[...]

Technical Data 3A1163A 35 Te c h n i c a l D a t a * Dependent on progra mmed K-f actor and applicat ion. The maximum allo wab le flo w meter pulse freq uency is 425 Hz (pulses/sec). F or more detailed inf or mation on viscositie s, flow rates, or mixing ratios, consult your Graco dis- tributor . See individual component man uals f or additional te[...]

All written and visual data contained in this document reflects the latest product information available at the time of publica tion. Graco reserves the right to make changes a t any time without notice. Original instructions. This m anual con tains English. MM 3A1163 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Kor[...]