Graco ProControl 1KE Plus Operation manual

Instructions-Parts
ProControl™ ProControl™
ProControl™1KE 1KE 1KEPlus Plus PlusModels Models Modelsfor for for
Management Management
Managementof of ofFluid Fluid Fluidand and andAir Air Air3A6948A
EN
Use Use
Useto to tomonitor monitor monitorand and andactively actively activelymanage manage manage1K 1K 1K󰘱uid 󰘱uid 󰘱uidpressure pressure pressureor or or󰘱ow 󰘱ow 󰘱owrate, rate, rate,as as aswell well wellas as astrack track trackmaterial material materialuse use usein in in
permanently permanently
permanentlyinstalled installed installed󰘱uid 󰘱uid 󰘱uidsupply supply supplysystems. systems. systems.For For Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinthemeter,
regulator,andpowersupplymanualsbeforeusingtheequipment.
Save Save
Savethese these theseinstructions. instructions. instructions.
SeetheG3000,S3000,G250meter
manual(308778)orCoriolismeter
manual(313599)for󰘱owmeter
maximumworkingpressure.
Seepage3formodelinformation,
includingapprovals.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
ProControl1KEPlusModels...............................3
ProControl1KEPlusADCM..........................3
ProControl1KEPlusPressureRatings...........4
ProControl1KEPlusModelSelection
Matrix............................................5
ProControl1KEPlusSelectionGuide............6
PowerSupplySelectionGuide......................7
ComponentEntityParameters......................9
ComponentCircuitConnector
Drawing.........................................11
Warnings...........................................................12
Overview............................................................16
Components................................................17
Installation..........................................................19
Non-HazardousLocations............................19
HazardousLocations....................................20
Grounding...................................................23
CableConnectionstotheAdvancedDisplay
ControlModule(ADCM)..................23
AirConnections...........................................24
FluidConnections........................................25
CommunicationOptions...............................26
Operation...........................................................28
PressureReliefProcedure............................28
FluidRegulatorOperation.............................28
FlowMeterOperation...................................28
ADCMModule....................................................29
DisplayInformation......................................29
OperationModes.........................................29
ScreenNavigationandEditing......................29
Icons...........................................................30
ControlMethodConsiderations............................32
RunScreens......................................................34
Screen1:RunOperations............................34
Screen2:JobLogTotalizer..........................39
Screen3:JobLogHistory............................40
Screen4:EventLogHistory.........................41
PasswordScreen...............................................42
SetupScreens....................................................43
SetupScreen1:JobTarget..........................43
SetupScreen2:Maintenance
Totalizer.........................................44
SetupScreen3:GrandTotals......................45
SetupScreen4:Calibration..........................45
SetupScreen5:FlowRate...........................46
SetupScreen6:PressureTransducer...........47
SetupScreen7:Pressure............................48
SetupScreen8:OperatorInputLimits...........49
SetupScreen9:AdditionalOperatorInput
LimitsandTimeouts........................50
SetupScreen10:PIDData..........................51
SetupScreen11:FillMode..........................51
SetupScreen12:FlushMode......................52
SetupScreen13:ControlMethod.................52
SetupScreen14:Modbus............................53
SetupScreen15:DateandTime..................53
SetupScreen16:Password.........................54
CalibratetheMeter.............................................55
SettheModbusAddresses.................................55
UpdatetheSoftware...........................................55
DeviationsandAdvisories...................................56
Troubleshooting..................................................58
BatteryReplacementProcedure...................61
Parts..................................................................62
Accessories........................................................77
ElectricalSchematic...........................................79
MountingDimensions.........................................80
AppendixA-ModbusVariableMap.....................81
DeviceIdenti󰘰cationRegisters......................81
RunRegisters..............................................82
RunSetpointRegisters.................................83
SetupRegisters...........................................84
TechnicalSpeci󰘰cations......................................88
GracoStandardWarranty....................................90
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNo. No. No.Description Description Description
308778VolumetricFluidFlowMeter,Instructions-PartsManual
313599CoriorlisMeterKits,Instructions-PartsManual
3A0427LowFlowFluidRegulator,Instructions-PartsManual
3A1244GracoControlArchitectureModuleProgramming,InstructionsManual
332013DCMandADCM,InstructionsManual
332196ISPowerSupplyModules,Instructions-PartsManual
23A6948A

ProControl1KEPlusModels
ProControl ProControl
ProControl1KE 1KE 1KEPlus Plus PlusModels Models Models
ProControl ProControl
ProControl1KE 1KE 1KEPlus Plus PlusADCM ADCM ADCM
AllAdvancedDisplayControlModules(ADCM)arebasehardwaremodelnumber24L097(Ref.1)without
applicationsoftware.Model24L097isnotavailableforseparatesale.*SeeapprovalinformationinManual
332013andonthispage.Thesmalllabel(Ref.2)onthebackofthemoduleshowstheProControl1KE
Plusmodelnumber.
Model Model
ModelNo. No. No.Series Series
SeriesDescription Description
Description
24L097* 24L097*
24L097*BAdvancedDisplayControlModule(ADCM),withnosoftwareloaded.SeeManual
332013.
9902471
ClassI,Div.1,
GroupDT3
Exia[ia]
Ta=0°Cto50°C
IntrinsicallySafeApparatus
PartofIntrinsicallySafeSystem.
ForuseinClassI,Division1,GroupDT3HazardousLocations
* *
*SeetheParts,page62,forreplacementADCMwithsoftware.
3A6948A3

ProControl1KEPlusModels
ProControl ProControl
ProControl1KE 1KE 1KEPlus Plus PlusPressure Pressure Pressure
Ratings Ratings
Ratings
Air Air
Airand and andFluid Fluid FluidMaximum Maximum MaximumWorking Working WorkingPressure Pressure Pressureby by byPart Part PartNumber Number Number
Maximum Maximum
MaximumAir Air AirWorking Working WorkingPressure Pressure PressureMaximum Maximum MaximumFluid Fluid FluidWorking Working WorkingPressure Pressure Pressure
Part Part
PartNumber Number Number
PSI PSI
PSIMPa MPa
MPabar bar barPSI PSI
PSIMPa MPa
MPabar bar bar
25B283 25B283
25B283N/AN/AN/AN/AN/AN/A
25B284 25B284
25B284N/AN/AN/A400027.58275.8
25B285 25B285
25B2851000.6896.893002.0720.7
25B286 25B286
25B2861000.6896.89400027.58275.8
25B287 25B287
25B2871000.6896.893002.0720.7
25B288 25B288
25B2881000.6896.89N/AN/AN/A
25B289 25B289
25B2891000.6896.89N/AN/AN/A
25B290 25B290
25B290
Thru Thru
Thru
25B299 25B299
25B299
1000.6896.891000.6896.89
43A6948A

ProControl1KEPlusModels
ProControl ProControl
ProControl1KE 1KE 1KEPlus Plus PlusModel Model ModelSelection Selection SelectionMatrix Matrix Matrix
Thenumberedcolumnsinthefollowing
tablecorrespondtothenumberedstepsin
ProControl1KEPlusSelectionGuide,page6.
Powersupplymodulesarediscussedin
PowerSupplySelectionGuide,page7.
Component Component
ComponentSelection Selection SelectionMatrix Matrix Matrix
1 1
12 2 23 3 3(included) (included) (included)(included) (included) (included)4 4
4
ProControl ProControl
ProControlApplication Application Application
Control Control
ControlRequirement Requirement Requirement
Fluid Fluid
FluidFlow Flow Flow
Meter* Meter*
Meter*
Fluid Fluid
Fluid
Regulator** Regulator**
Regulator**
Pressure Pressure
Pressure
Transducer*** Transducer***
Transducer***
Current Current
Current- - -to to to- - -
Pressure Pressure
PressureI/P I/P I/P
Transducer**** Transducer****
Transducer****
ProControl ProControl
ProControl1KE 1KE 1KE
Plus Plus
PlusSystem System System
Models Models
Models
ADCMw/softwareand
bracketonlyN/AN/AN/AN/A25B283
FlowMonitor(ADCM
w/G3000and5ft
(1.5m)cable,no
󰘱uidpanel)
✔N/AN/AN/A25B284
✔✔N/A125B285
✔—N/A125B286
—✔N/A125B287
FlowMonitorwith
opensetpoint󰘱uid
pressurecontrol
(includes󰘱uidpanel
andI/Ptooperate󰘱uid
pressureregulator)——N/A125B288
GunAtomizingAir
ControlN/AN/AN/A125B289
N/A✔✔125B290
ClosedLoopFluid
PressureControlN/A—✔125B291
✔✔✔125B292
✔—✔125B293
—✔✔125B294
ClosedLoopFluid
PressureorFluid
FlowControl
——✔125B295
✔✔✔225B296
✔—✔225B297
—✔✔225B298
ClosedLoopFluid
Pressure/Flow+Gun
AtomizingAirControl
——✔225B299
✔=Included
—=Notincluded.However,thesystemwill
accommodateauser-suppliedcomponent.
* *
*AGracoG3000high-pressuremeter(289813)is
usedinmodelssoldwitha󰘱uid󰘱owmeter.Ifyou
intendtosupplyyourown󰘱uid󰘱owmeter,ordera
modelwithoutacheckmarkbelow.Makesurethe
󰘱uid󰘱owmeterisappropriatefor󰘱uidcompatibility,
viscosity,󰘱owraterange,etc.
** **
**AGraco1:1low-󰘱owair-operatedregulator
(24C375)isusedinmodelssoldwitha󰘱uidregulator.
Ifyouintendtosupplyyourownair-operated󰘱uid
regulator,orderamodelwithoutacheckmarkbelow.
Makesurethe󰘱uidregulatorisappropriatefor󰘱uid
pressurerange,materialcompatibility,viscosity,󰘱ow
raterange,etc.(Note: Note:
Note:Backpressureatthe󰘱uid
regulatoroutletmustbeaminimumof10psi(0.7
bar).)
*** ***
***Allmodelsintendedforusewithapressure
transducercomewithalow-pressure100psi(6.9
bar)transducer.
**** ****
****Formanaging󰘱uidandatomizingaircontrol.The
numberbelowindicatesthequantityincluded.
3A6948A5

ProControl1KEPlusModels
ProControl ProControl
ProControl1KE 1KE 1KEPlus Plus PlusSelection Selection SelectionGuide Guide Guide
(Numberedsteps1–4correspondtothenumbered
columnsintheProControl1KEPlusModelSelection
Matrix,page5.)
1.Chooselevelofapplicationcontrolneeded.
2.Determine󰘱owmeter,ifapplicableforlevelof
controlchosen.(GunAtomizingAirControland
ClosedLoopFluidPressureControlunitsdonot
usea󰘱owmeter.)
TheG3000meteristhestandardrecommended
meter.
Note: Note:
Note:Notallmetersareapprovedforhazardous
locations.Seeyour󰘱owmetermanualfordetails.
3.Determine󰘱uidpressureregulator,ifapplicable
forthelevelofcontrolchosen.(TheGun
AtomizingAirControlunit,25B289,doesnotuse
a󰘱uidpressureregulator.)
TheGraco24C3751:1LowFlowRegulatoris
standard.
4.SelectbaseProControl1KEPlusmodelpart
numberfromtheProControl1KEPlusModel
SelectionMatrix,page5.
Note
ProControl1KEPlusunitscomewith5ft.
(1.5m)cablelengthstoallowmounting
theusercontrolinterface(ADCM)nearthe
󰘱uidpanel.Ifamoreremotemountingis
required,purchasetheappropriateextension
cables,availablein50ft.(16m)lengths.
SeeAccessories,page77.
63A6948A

ProControl1KEPlusModels
Power Power
PowerSupply Supply SupplySelection Selection SelectionGuide Guide Guide
TopreventFireandExplosion,whenusingaPro
Control1KEPlussysteminahazardouslocation,
useapowersupplywithanISbarrier.
Powersupplymodulesareorderedseparatelyand
dependonwhetheryourProControl1KEPlussystem
isbeingusedinanon-hazardousorhazardous
location.Additionalconsiderationsforeachlocation
arediscussedbelow.
Note
Powersupplymodulescomewithpower
cablestoconnecttoport3oftheProControl
1KEPlusADCMuserinterface.
Non Non
Non- - -Hazardous Hazardous HazardousLocations Locations Locations
Orderpowersupply16V680(AC/DCConverter)and
chooseapowercordbelow.
Note
The16V680AC/DCConverterhasan
IEC-320-C13femaleinputpowerconnection
anda68in.(1.7m)outputcordtoconnect
toport3oftheProControl1KEPlusADCM
userinterface.
•245202–120in.(3m)NorthAmerican120VAC
powercord.
•116281–72in.(1.8m)extension(MalexFemale)
IEC-320cord.
•242001–8in.(0.2m)IEC-320European-style
powercord.
•242005–8in.(0.2m)IEC-320ANZ-stylepower
cord.
Hazardous Hazardous
HazardousLocations Locations Locations
Todeterminethecorrectpowersupplymodule,
answerthesequestions:
Yes Yes
YesNo No No
WillyoubeusingProControl1KE
Plusmodels25B296–25B299for
󰘱uidandatomizingaircontrol?
Wouldyoupotentiallywantto
upgradeaProControl1KEPlus
modelinthefutureforusewith󰘱uid
andatomizingaircontrol?
Doyouneedtopowermorethan
oneProControl1KEPlusunit,or
wanttheabilitytopowerupto
threeunitsfromonepowersupply
moduleinthefuture?
Willyourapplicationeverrequire
greaterthan50psi(3.4bar)of
󰘱uidpressureattheoutletofthe
ProControl1KEPlusforunitswith
thestandardGraco24C3751:1
LowFlowRegulator;
or,
forunitsusinganalternate
air-operated󰘱uidregulator,willyour
applicationeverrequiregreater
than50psi(3.4bar)ofairpilot
pressuretothe󰘱uidregulator?
Ifyouanswered“Yes”toanyofthesequestions,
orderthe26C724ISG-BarrierPowerSupplyModule.
Note
UptothreetotalProControl1KEPlusmodels
ofanycon󰘰gurationcanbepoweredby
asingleG-Barrier.Ifyouareaddinga
ProControl1KEPlusmodeltoanexisting
26C724G-BarrierPowerSupplyModule,
orderapowercablekit19Y499(50ft(16m))
or19Y502(100ft(32m)).
Ifyouanswered“No”toallofthesequestions,you
mayconsiderorderingthe16M167SingleISBarrier
PowerSupplyModule.
Note
The16M167SingleISBarrierPowerSupply
Modulehaspowerlimitations.Itcannotbe
usedonProControl1KEPlusmodelsthat
requiregreaterthan50psi(3.4bar)of󰘱uid
pressure(50psi(4.4bar)ofpilotairpressure
foralternateair-operated󰘱uidregulatoruse),
oronunitsthatcontrol󰘱uidandatomizingair.
3A6948A7

ProControl1KEPlusModels
Power Power
Powersupply supply supplynotes notes notesbased based basedupon upon uponProControl ProControl ProControl1KE 1KE 1KE
Plus Plus
Plusmodel model modelnumber number number(seecolumn4inProControl1KE
PlusModelSelectionMatrix,page5).
•Formodels25B296–25B299,ormodelsthatmay
needtobeupgradedtoincludeatomizingair
controland󰘱uidpressureor󰘱owcontrol,thepower
consumptionwillrequireaGracoISapproved
G-Barrierpowermodule(26C724).Systemsthat
mayoperateabove50psi(3.5bar)requirethe
G-Barrierpowermodule(26C724)toguarantee
optimalperformance.
•Formodels25B284–25B295,thesecanbe
poweredbyaGracoG-Barrierpowermodule
(26C724)orasingleISbarrieroutputpower
module(16M167).
83A6948A

ProControl1KEPlusModels
Component Component
ComponentEntity Entity EntityParameters Parameters Parameters
ThefollowingentityparametervaluesaretakenfromtheADCMcontroldrawingforbasemodel24L097
(16M169)andfromtheISPowerSupplyModulemanual.
ADCM ADCM
ADCM(24L097) (24L097) (24L097)with with with16M167 16M167 16M167Power Power PowerSupply Supply Supply
(with (with
(witha a aPepperl+Fuchs Pepperl+Fuchs Pepperl+FuchsZ713 Z713 Z713barrier) barrier) barrier)
ADCM ADCM
ADCM
Power Power
PowerInput Input Input
(Port (Port
(Port3) 3) 3)
Power Power
PowerSupply Supply Supply
Ui=17.9V≥ ≥
≥Uo=15.75V
Ii=725mA≥ ≥
≥Io=723mA
Pi=2.9W≥ ≥
≥Po=2.84W
Ci=2.3μF≤ ≤
≤Co=5.38μF
Li=50μH≤ ≤
≤Lo=570μH
ADCM ADCM
ADCM(24L097) (24L097) (24L097)with with with26C724 26C724 26C724Power Power PowerSupply Supply Supply
(with (with
(withG G G- - -Barrier) Barrier) Barrier)
ADCM ADCM
ADCM
Power Power
PowerInput Input Input
(Port (Port
(Port3) 3) 3)
Power Power
PowerSupply Supply Supply
Ui=17.9V≥ ≥
≥Uo=16.4V
Ii=725mA≥ ≥
≥Io=592.2mA
Pi=2.9W≥ ≥
≥Po=2.82W
Ci=2.3μF≤ ≤
≤Co=2.4μF
Li=50μH≤ ≤
≤Lo=64μH
Meter Meter
MeterSensor Sensor Sensor(24W651) (24W651) (24W651)with with withADCM ADCM ADCM(24L097) (24L097) (24L097)
Meter Meter
MeterSensor Sensor SensorADCM ADCM ADCMDigital Digital Digital
Output Output
Output
(Port (Port
(Port4) 4) 4)
Ui=30V≥ ≥
≥Uo=17.9V
Ii=110mA≥ ≥
≥Io=100mA
Pi=800mW≥ ≥
≥Po=441mW
Ci=0.4μF≤ ≤
≤Co=4.8μF
Li=10μH≤ ≤
≤Lo=20,000μH
25P594 25P594
25P594Light Light LightKit Kit Kitwith with withADCM ADCM ADCM(24L097) (24L097) (24L097)
Light Light
LightKit Kit KitADCM ADCM
ADCMDigital Digital Digital
Output Output
Output
(Port (Port
(Port4) 4) 4)
Ui=30V≥ ≥
≥Uo=17.9V
Ii=1000mA≥ ≥
≥Io=217mA
Pi=3400mW≥ ≥
≥Po=937mW
Ci=0μF≤ ≤
≤Co=4.8μF
Li=0μH≤ ≤
≤Lo=5000μH
Class Class
ClassI, I, I,Division Division Division1, 1, 1,Group Group GroupD, D, D,T3 T3 T3
3A6948A9

ProControl1KEPlusModels
16H282 16H282
16H282Pressure Pressure PressureTransducer Transducer Transducerwith with withADCM ADCM ADCM(24L097) (24L097) (24L097)
*Pressure *Pressure
*Pressure
Transducer Transducer
Transducer
ADCM ADCM
ADCMAnalog Analog Analog
Output Output
Output
(Port (Port
(Port7) 7) 7)
Ui=6V≥ ≥
≥Uo=5.88V
Ii=61mA≥ ≥
≥Io=61mA
Pi=90mW≥ ≥
≥Po=90mW
Ci=5310ρF≤ ≤
≤Co=700μF
Li=8.52μH≤ ≤
≤Lo=50,000μH
Simple Simple
SimpleApparatus Apparatus Apparatus
Class Class
ClassI, I, I,Division Division Division1, 1, 1,Group Group GroupD, D, D,T4 T4 T4
513937 513937
513937Pressure Pressure PressureSwitch Switch Switchwith with withADCM ADCM ADCM(24L097) (24L097) (24L097)
*Pressure *Pressure
*Pressure
Switch Switch
Switch
ADCM ADCM
ADCMAnalog Analog Analog
Output Output
Output
(Port (Port
(Port8) 8) 8)
Ui=17.9V≥ ≥
≥Uo=17.9V
Ii=73mA≥ ≥
≥Io=124mA
Pi=1.25W≥ ≥
≥Po=540mW
Ci=10,800ρF≤ ≤
≤Co=2μF
Li=9.119μH≤ ≤
≤Lo=15,000μH
Simple Simple
SimpleApparatus Apparatus Apparatus
Class Class
ClassI, I, I,Division Division Division1, 1, 1,Group Group GroupD, D, D,T4 T4 T4
16P784 16P784
16P784I/P I/P I/PTransducer Transducer Transducerwith with withADCM ADCM ADCM(24L097) (24L097) (24L097)
I/P I/P
I/PTransducer Transducer TransducerADCM ADCM
ADCMAnalog Analog Analog
Output Output
Output
(Port (Port
(Port8) 8) 8)
Ui=30V≥ ≥
≥Uo=17.9V
Ii=125mA≥ ≥
≥Io=124mA
Pi=700mW≥ ≥
≥Po=540mW
Ci=10,800ρF≤ ≤
≤Co=2μF
Li=9.119μH≤ ≤
≤Lo=15,000μH
Class Class
ClassI, I, I,Division Division Division1, 1, 1,Group Group GroupD, D, D,T3 T3 T3
119159 119159
119159Air Air AirFlow Flow FlowSwitch Switch Switchwith with withADCM ADCM ADCM(24L097) (24L097) (24L097)
*Air *Air
*AirFlow Flow FlowSwitch Switch SwitchADCM ADCM ADCMAnalog Analog Analog
Output Output
Output
(Port (Port
(Port10) 10) 10)
Ui=17.9V≥ ≥
≥Uo=5.88V
Ii=73mA≥ ≥
≥Io=61mA
Pi=1.25W≥ ≥
≥Po=90mW
Ci=1995.3ρF≤ ≤
≤Co=700μF
Li=8.133μH≤ ≤
≤Lo=50,000μH
Simple Simple
SimpleApparatus Apparatus Apparatus
Class Class
ClassI, I, I,Division Division Division1, 1, 1,Group Group GroupD, D, D,T4 T4 T4
* *
*SimpleApparatusinaccordancewithUL/EN/IEC60079–11,clause5.7.
103A6948A

ProControl1KEPlusModels
Component Component
ComponentCircuit Circuit CircuitConnector Connector Connector
Drawing Drawing
Drawing
Module Pow er supply
G-Barrier
Part num ber 26C724
Module power supply
Part number 16M167
ADCM
Part number 25B2 83
I/P Transducer
Part number 16P784
Pressure switch
Simple Appartus
Part number 513937
Fluid pressure
transducer
Simple Appartus
Part number 16H282
OR
Graco Fluid Meter
W/24W650 or
24W651 sensor
Air Flow Switch
Simple Appartus
Part number 119159
Port 8
Port 9
Port 10
Port 4
Port 3
Indicator light
Part number 19A993
I/P Transducer
Part number 16P784
Pressure switch
Simple Appartus
Part number 513937
Port 7
NON-HAZARDOUS
LOCATION HAZARDOUS LOCATION
Fluid panel assem bly
Class I, Div. 1, Group D, T3
Class I, Zone 1, IIA,T3
Splitter for optional light kit
II 2 G
Ex ia IIA T3 Ga
Figure1ComponentCircuitConnectorDrawing
Optional Optional
OptionalCables Cables Cablesby by byPort Port Port
Port Port
Port# # #Part Part Part# # #Length Length
Length
16K50950ft(15.2m)
316K615100ft(30.5m)
418B24450ft(15.2m)
716V38150ft(15.2m)
816V07150ft(15.2m)
916V07150ft(15.2m)
1016V38150ft(15.2m)
3A6948A11

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenanceandrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolreferstoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Neversprayor󰘱ushsolventathighpressure.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareanti-staticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinawellventilatedarea.
•Donotcleanwithadrycloth.
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore
servicingorinstallingequipment.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
123A6948A

Warnings
WARNING WARNING
WARNING
INTRINSIC INTRINSIC
INTRINSICSAFETY SAFETY SAFETY
Intrinsicallysafeequipmentthatisinstalledimproperlyorconnectedtonon-intrinsicallysafe
equipmentwillcreateahazardousconditionandcancause󰘰re,explosion,orelectricshock.
Followlocalregulationsandthefollowingsafetyrequirements.
•InstallationshouldbeinaccordancewithANSI/ISARP12.06.01“InstallationofIntrinsically
SafeSystemsforHazardous(Classi󰘰ed)Locations”andtheNationalElectricalCode®
(ANSI/NFPA70).
•InstallationinCanadashouldbeinaccordancewiththeCanadianElectricalCode,CSA
C22.1,Part1,AppendixF.
•ForATEX,installperEN60079–14andapplicablelocalandnationalcodes.
•Equipmentthatcomesincontactwithintrinsicallysafeterminalsmustmeettheentity
parameterrequirementsspeci󰘰edinControlDrawing16M169.SeeAppendixAinManual
332013.Thisincludessafetybarriers,DCvoltagemeters,ohmmeters,cables,and
connections.Removetheunitfromthehazardousareawhenservicing.
•Withoutthesafetybarrier,theequipmentisnolongerintrinsicallysafeandmustnotbe
operatedinhazardouslocations,asde󰘰nedinarticle500oftheNationalElectricalCode
(USA)oryourlocalelectricalcode.
•Donotinstallequipmentapprovedonlyfornon-hazardouslocationinahazardousarea.See
theIDlabelfortheintrinsicsafetyratingforyourmodel.
•Donotuseintrinsicallysafeequipmentwithapowersupplythathasnobarrier.Intrinsic
safetymaybecompromised.
•Groundthepowersupply.Avoltagelimitingsafetybarriermustbeproperlygroundedtobe
effective.Forpropergrounding,usea12gaugeminimumgroundwire.Thebarrier’sground
mustbewithin1ohmoftrueearthground.
•Donotremoveanycoveruntilpowerhasbeenremoved.
•Donotsubstitutesystemcomponentsasthismayimpairintrinsicsafety.
3A6948A13

Warnings
WARNING WARNING
WARNING
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay
looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Getimmediate immediate immediatesurgical surgical surgical
treatment. treatment.
treatment.
•Donotspraywithouttipguardandtriggerguardinstalled.
•Engagetriggerlockwhennotspraying.
•Donotpointgunatanyoneoratanypartofthebody.
•Donotputyourhandoverthespraytip.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopsprayingandbeforecleaning,checking,
orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.
Forcompleteinformationaboutyourmaterial,requestSafetyDataSheet(SDS)from
distributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
143A6948A

Warnings
WARNING WARNING
WARNING
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheets(SDSs)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Protectiveequipment
includesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
3A6948A15

Overview
Overview Overview
Overview
TheProControl1KEPlusisanelectronic󰘱owcontrol
and󰘱uidmonitoringsystem.Dependingonthe
model,theProControl1KEPluscanperformthe
followingfunctions:
•Manages󰘱uidpressureor󰘱owratebyeither
open-looporclosed-loopcontrolformanualor
automaticsystems.
•Showsreal-time󰘱uid󰘱owrateorpressure.
•Monitorsandreportsoverall󰘱uiduse.
•Providespasswordprotectedsettingstolockor
limittherangeof󰘱uidandatomizingairsetpoint
adjustmentsthatanoperatormayuse.
•Alarmsifthe󰘱owrateistoohighortoolowforthe
user-settargets.
•Alarmsifthe󰘱uidpressureistoohighortoolow
fortheuser-settargets.
•Managesatomizinggunairpressurebyopen-loop
control.
•Alarmswhenthemaintenancetotalisreachedfor
theuser-settarget.
•Displaysalogofthelast100alarms.
•Trackssprayedmaterialand󰘱ushmaterialusage
byjob.
•Displayslogsofthelast500jobs.
•AllowsforintegrationtoplantPLC/SystemControl
andremotemonitoringthroughavailableoptions
listedinAccessories,page77.
163A6948A

Overview
Components Components
Components
Figure2ViewofFluidPanelwithcoverremoved
Key: Key:
Key:
A A
APower Power
PowerSupply Supply Supply—Suppliespowertothe
system.
B B
BProControl ProControl
ProControl1KE 1KE 1KEPlus Plus PlusAdvanced Advanced AdvancedDisplay Display Display
Control Control
ControlModule Module Module(ADCM) (ADCM) (ADCM)—Userinterfacefor
con󰘰guringsystemsetup,selectingoperating
modes,setting󰘱ow/pressuretargets,logging
jobs,monitoringstatus,andviewingmaterial
usage,job,andalarmlogs.Fiberopticports
areavailableforcommunicatingwithan
externalPLC.
C C
CFluid Fluid FluidPanel Panel Panel—Containstheairand󰘱uid
hardwarecomponents.
Note
Alternative󰘱owmetersand󰘱uid
regulatorscanbeinstalledadjacent
tothe󰘱uidpanelandplumbedinas
neededforapplicationandmaterial
compatibility.
D D
DAir Air
AirManifold Manifold Manifold—Distributesairtothecontrol
devicesandatomizingairforequipped
models.
Key: Key:
Key:
E E
EFluid Fluid Fluidand and andAir Air AirRegulator Regulator RegulatorI/P I/P I/PTransducers Transducers Transducers—
Currenttopressure(I/P)transducersfor
controlling󰘱uidandairregulatorpressure
settingsbytheADCM.
F F
FAir Air AirRegulator Regulator Regulator—Air-operatedair-pressure
regulatorforcontrollingatomizingair
pressuretotheapplicatorgun.
G G
GAir Air AirFlow Flow FlowSwitch Switch Switch(AFS) (AFS) (AFS)—Air󰘱owswitch
usedtodeterminewhenapplicatorgunis
triggered.TheAFSisrequiredonsystems
foractiveclosed-looppressureor󰘱ow
control.
H H
HFluid Fluid
FluidFlow Flow FlowMeter Meter Meter—Measures󰘱owrateand
materialusage.
J J
JFluid Fluid
FluidRegulator Regulator Regulator—Air-operated󰘱uid-pressure
regulatorforcontrolling󰘱uidpressuretothe
applicatorgun.
K K
KFluid Fluid FluidPressure Pressure PressureTransducer Transducer Transducer—Deviceused
formeasuring󰘱uidpressure.Thepressure
transducerisrequiredonsystemsforactive
closed-loop󰘱uidpressureor󰘱owcontrol.
L L
L2–Way 2–Way
2–WayVented Vented VentedValve Valve Valve—Supplyairshut-off
valve.
3A6948A17

Overview
Key: Key:
Key:
M* M*
M*Air Air AirSupply Supply SupplyLine Line Line—See
TechnicalSpeci󰘰cations,page88,for
pressureandair-cleanlinessrequirements.
N* N*
N*Air Air AirOutlet Outlet OutletLine Line Lineto to toGun Gun Gun
P* P*
P*Fluid Fluid FluidOutlet Outlet OutletLine Line Lineto to toGun Gun Gun
R* R*
R*Fluid Fluid FluidInlet Inlet InletLine Line Line—See
TechnicalSpeci󰘰cations,page88,for
pressurerequirements.
Key: Key:
Key:
AC AC
ACAir Air AirPressure Pressure PressureCut Cut Cut- - -Out Out OutSwitches Switches Switches—Usedto
protecttheI/Ptransducerswhenairpressure
isremovedandtheI/Ptransducersarebeing
electricallypoweredbytheADCM.
AD AD
ADCheck Check
CheckValve Valve Valve
* *
*Requiredcomponentsprovidedbyuser.
183A6948A

Installation
Installation Installation
Installation
Non Non
Non- - -Hazardous Hazardous HazardousLocations Locations Locations
NOTE: NOTE:
NOTE:Non-hazardouspowersupplymodules(seeProControl1KEPlusSelectionGuide,page6)
aresuppliedwithanAC/DCConverter.Usersmustselectandorderanappropriatepowercordfor
thelocalregion.Inareaswithpowerconnectionsthataredifferentthantheoptionsprovidedinthe
ProControl1KEPlusSelectionGuide,page6,usersmustprovideapowersupplycordwithanIEC320–C13
femaleconverter.SeeTechnicalSpeci󰘰cations,page88,forpowerrequirements.
Key: Key:
Key:
A A
APowerSupplyModule
B B
BProControl1KEPlusADCM
C C
CFluidPanel
L L
L2–WayVentedValve
M* M*
M*AirSupplyLine
N* N*
N*AirOutletLinetoGun
P* P*
P*FluidOutletLine
Key: Key:
Key:
R* R*
R*FluidInletLine
S* S*
S*FluidInletShut-offValve
T T
TAccessoryLightTower
U U
UGroundWire
V* V*
V*Gun
* *
*User-provided
3A6948A19

Installation
Hazardous Hazardous
HazardousLocations Locations Locations
Donotsubstituteormodifysystemcomponents
asthismayimpairintrinsicsafety.Forinstallation,
maintenance,oroperationinstructions,read
instructionmanuals.Donotinstallequipment
approvedonlyfornon-hazardouslocationsina
hazardouslocation.Seetheidenti󰘰cationlabelfor
theintrinsicsafetyratingforyourequipment.
Intrinsicallysafe(IS)equipmentshouldnotbeused
withapowersupplythathasnobarrier.Donot
moveunitsfromanon-ISsetuptoanISsetup.IS
equipmentthathasbeenusedwithanon-ISpower
supplymustnotbereturnedtoahazardouslocation.
Alwaysuseanintrinsicallysafepowersupplywith
ISequipment.
•InstallationshouldbeinaccordancewithANSI/ISA
RP12.06.01,“InstallationofIntrinsicallySafe
SystemsforHazardous(Classi󰘰ed)Locations,”
andtheNationalElectricalCode®(ANSI/NFPA
70).
•InstallationinCanadashouldbeinaccordance
withtheCanadianElectricalCode,CSAC22.1,
Part1,AppendixF.
•ForATEX,installperEN60079-14andapplicable
localandnationalcodes.
•Multipleearthingofcomponentsisallowedonly
ifahighintegrityequipotentialsystemisrealized
betweenthepointsofbonding.
•Donotremoveanycoveruntilpowerhasbeen
removed.
•InstallADCMaccordingtoControlDrawingNumber
16M169.SeeAppendixAinManual332013.
203A6948A