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Graco ProControl 1KE, Instructions - Parts Manual

The Graco ProControl 1KE is a powerful and reliable product designed for professional use. Easily operate and maintain this equipment with the help of its comprehensive Instructions - Parts Manual, available for download free of cost from our website. Access the manual at manualshive.com for hassle-free assistance.

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Parts

Table 9 Fluid and Air Control Parts, Models 24P595, 24P596, 24P597

Ref.

Part

Description

Qty.

24P595,

24R261

24P596

24P597

201

16E841

PANEL, mounting

1

✔

✔

✔

202

16P784

TRANSDUCER, I/P; includes ref. 208 1

✔

✔

✔

16P790

CABLE, fluid control

1

✔

4

16V142

CABLE, fluid control, IS

1

✔

✔

204

121141

SWIVEL, elbow

1

✔

✔

205

15T937

SWIVEL, elbow

1

✔

✔

206

104371

SCREW, #10

6

✔

✔

✔

207

104116

WASHER, #10

6

✔

✔

✔

208

– — —

BRACKET, transducer

1

✔

✔

✔

209

289813

METER, G3000

1

✔

210

501867

VALVE, check

1

✔

211

15U749

BRACKET, meter

1

✔

212

114182

SCREW, M6`

2

✔

213

114339

SWIVEL, union

1

214

— — —

NUT, hex1–12 unf

1

✔

✔

215

24C375

REGULATOR, fluid; includes refs.

214, 216, and 217

1

✔

✔

216

— — —

BRACKET, regulator

1

✔

✔

217

112310

SCREW, #8

2

✔

✔

218

100079

WASHER, lock, #8

2

✔

✔

219

109466

NUT, #8

2

✔

✔

220

— —

TUBE, air

1

✔

✔

221

24P600

TRANSDUCER, pressure, includes

fitting (ref. 222) and o-ring (ref. 225)

1

✔

✔

222

– — —

FITTING, pressure transducer

1

✔

✔

223

124843

FITTING

1

✔

✔

16K483

CABLE, meter

1

224

16V074

CABLE, meter, IS

1

✔

225

111316

O-RING

1

✔

✔

Table 10 I/P Transducer Connection Points

Pin

(Ref. 4, F/C Cable)

Wire Color

Function

Pin

(Ref. 202, Transducer)

5

Gray

Control A

1

7

Blue

Common

2

42

3A2614H

Summary of Contents for ProControl 1KE

Page 1: ...aterial use For professional use only Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See the G3000 meter manual 308778 or Coriolis meter manual 313599 for flow meter maximum working pressure See page 3 for kit information including approvals PROVEN QUALITY LEADING TECHNOLOGY ...

Page 2: ...ate the Software 19 Replace the Battery 20 Display Module 21 Display Information 21 Operation Modes 21 Screen Navigation and Editing 21 Icons 22 Run Screens 24 Password Screen 25 Setup Screens 26 Setup Screen 1 26 Setup Screen 2 27 Setup Screen 3 27 Setup Screen 4 28 Setup Screen 5 28 Setup Screen 6 29 Setup Screen 7 29 Setup Screen 8 30 Setup Screen 9 30 Deviations and Advisories 31 Troubleshooti...

Page 3: ...E Kit number Available kits are described in the tables that follow Model No Series Description 24L097 A Advanced Display Control Module ADCM with no software loaded See Manual 332013 24N672 A Advanced Display Control Module ADCM with bracket with no software loaded See Manual 332013 9902471 Class I Div 1 Group D T3 Ex ia ia Ta 0 C to 50 C Intrinsically Safe Apparatus Part of Intrinsically Safe Sy...

Page 4: ...id Regulator Manual 3A0427 Pressure Transducer Manual 407045 24L083 A 24R261 A 24R262 A 24R263 A 24L085 A 24P593 A 24P595 A 24L087 A 24P597 A 24L089 A 24L091 A See component manuals for additional approval information Must not be installed in Hazardous Location Kits for Non Hazardous Locations Configuration Kit No Series ProControl 1KE Module with bracket AC Power G3000 Meter I P Transducer Fluid R...

Page 5: ...equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail Do not use pail liners unless they are antistatic or conductive Stop operation immediately if static sparking occurs or you feel a shock Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area Static...

Page 6: ...ous locations as defined in article 500 of the National Electrical Code USA or your local electrical code Do not install equipment approved only for non hazardous location in a hazardous area See the ID label for the intrinsic safety rating for your model Ground the power supply A voltage limiting safety barrier must be properly grounded to be effective For proper grounding use a 12 gauge minimum g...

Page 7: ...ls and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it 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 C...

Page 8: ...en the maintenance total is reached for the user set target Displays a log of the last 20 alarms The ProControl 1KE is available in configurations for installation in Hazardous Locations or Non Hazardous locations The power supply for Hazardous Locations comes with one barrier to power one ProControl 1KE Up to three additional barriers can be added to the power supply to power three additional ProC...

Page 9: ... Cable Connections page 13 D Meter Cable 50 ft 15 m to terminal 4 See Cable Connections page 13 E Power Cord 10 ft 3 m see NOTE above M Ground wire and clamp PN 244524 in included with kits to ground the ProControl 1KE Module PN 238909 is sold separately to ground the meter and other components N Fluid Regulator 1 8 npt f outlet R Fluid Control Cable S Pressure Transducer T I P Transducer Current ...

Page 10: ...rned to a hazardous location Always use an intrinsically safe power supply with IS equipment Installation should be in accordance with ANSI ISA RP12 06 01 Installation of Intrinsically Safe Systems for Hazardous Classified Locations and the National Electrical Code ANSI NFPA 70 Installation in Canada should be in accordance with the Canadian Electrical Code CSA C22 1 Part 1 Appendix F For ATEX inst...

Page 11: ...s page 13 M Ground wire and clamp PN 244524 is included with kits to ground the ProControl 1KE Module PN 238909 is sold separately to ground the meter or other component N Fluid Regulator R Fluid Control Cable S Pressure Transducer T I P Transducer Current to Pressure See Air Connections page 15 U Mounting Panel See Mounting Dimensions page 44 X Pressure Transducer Fitting 1 8 npt f inlet and outl...

Page 12: ...o the ProControl 1KE coupling nuts 1 Power Supply 16M167 Connect the ground wire from the power supply to a true earth ground 2 ProControl 1KE Module Connect a ground wire and clamp to the screw on the top of the bracket Connect the other end to ground In an IS system the ProControl 1KE also is grounded by connection to the grounded power supply 3 Flow Meter Follow the instructions in manual 30877...

Page 13: ...or to Port 5 on another ProControl 1KE or Informer 3 Power From Power Supply 4 Digital Input Output To From Meter and Light Tower Accessory 5 Fiber Optic Reciever Black Lead from Port 2 on another ProControl 1KE or Informer 6 Fiber Optic Transmitter Red Lead to Port 1 on another ProControl 1KE or Informer 7 Analog Input To From Pressure Transducer Cable 8 Flow Control To From Flow Control Cable 9 ...

Page 14: ... 3 Connect IS power cable F per the following table Table 1 Power Barrier Wiring Connections Power Cable Leads Barrier Connection Brown power Connector 1 Blue common Connector 2 Glossy Black ground and Black drain connect to ground block Table 2 I P Transducer Wiring Connections Cables 16P790 non IS and 16V142 IS Wiring Table Wire Color Function DIN Connector Gray Control A Connector 1 Blue Common...

Page 15: ...r pressure higher than the top port AH air pressure Flushing air pressure must be removed from the side port AD to return to the previous flow setting Communication Options Graco Accessories are available to enable communication with a Programmable Logic Controller PLC or Personal Computer PC The Fiber Optic Converter Graco Kit 24N978 enables Modbus RTU communication with a user supplied PLC using ...

Page 16: ...Installation Typical Installation Non Hazardous Location Hazardous Location 16 3A2614H ...

Page 17: ...anced Web Interface Accessory K Ethernet Cable Accessory L Personal computer Not supplied N1 and N2 Fluid Regulator Supplied in some kits See Parts page 34 P Air Control Module Accessory Q1 and Q2 Air Lines Not supplied R1 and R2 Flow Control Cable Supplied S1 and S2 Pressure Transducer Supplied in some kits See Parts page 34 T1 and T2 I P Transducer Current to Pressure Supplied U1 and U2 Mounting...

Page 18: ...mponent or accessory in your system For information on the G3000 Graco flow meter see manual 308778 For information on the Coriolis flow meter see manual 313599 Calibrate the meter as instructed before using the meter for production NOTICE The flow meter gears and bearings can be damaged if they rotate at too high a speed To avoid high speed rotation open the fluid valve gradually Do not over speed th...

Page 19: ... the Modbus set the Modbus mode to SLAVE The address value is between 1 and 247 The modbus address corresponds to the address of the ProControl 1KE See Appendix A for further information Set the Flow Rate Percent 1 System Setup See Setup Screen 2 page 27 to set the upper and lower limit within which the operator can adjust the flow rate The settable range is 0 to 99 9 percent but the I P pressure t...

Page 20: ... appropriately 1 Disconnect power 2 Remove the module from the bracket 3 Attach the grounding strap 4 Remove 4 screws and then remove the access cover 5 Use a flathead screwdriver to pry out the old battery NOTE Dispose of battery properly in an approved container and according to applicable local guidelines 6 Replace with new battery Ensure battery fits under connector tabs before snapping other en...

Page 21: ...n Navigation and Editing Refer to this section if you have questions about screen navigation or about how to enter information and make selections All Screens 1 Use to move between screens 2 Press to enter a screen The first data field on the screen will highlight 3 Use to highlight the data you wish to change 4 Press to edit Drop Down Field 1 Use to highlight the correct choice from the dropdown me...

Page 22: ...e Enter Screen Highlight data that can be edited Also changes the function of the Up Down arrows so they move between data fields on the screen rather than between screens Error Reset Use to clear alarm after cause has been fixed Also used to cancel data entered and return to original data Exit Screen Exit data editing Up Down Arrows Use to move between screens or fields on a screen or to increment o...

Page 23: ...f Set Upper and Lower Limits for Fluid Flow Percent ProControl 1KE is Modbus Slave Screen Icons Set Pressure Units Set Maximum and Minimum Flow Rates Set Flow Rate Units Maintenance Totalizer Alarm Enable Flow Rate Alarm Enable Set Alarm Auto Clear to clear alarm on ac cessories Set Backlight Timer Volume measured by the meter Actual volume dispensed K Factor Select Pressure Transducer Set Zero Of...

Page 24: ... Flow Rate Percent Target Operator settable within the range defined on Setup Screen 2 Displays current fluid pressure if equipped and set up with a pressure transducer Otherwise this field displays just 3 dashes Displays current flow rate Move between Run Screens Run Screen 2 Use this screen to view or reset the batch totalizer and to view the grand total flow for the system The grand total cannot be ...

Page 25: ...rmation Move between Run Screens Password Screen If a password has been set the Password Screen displays when is pressed from any Run screen Enter password to enable entry to the Setup screens Set the password to 0000 to disable password protection See Setup Screen 9 to set or change the password Key Enter the screen to enter a password Press to activate a field for editing Move to the right when e...

Page 26: ...ng or to accept the highlighted selection on a dropdown menu Move to the right when editing number fields Press again to accept the entry when all digits are correct Reset Maintenance Totalizer resets the maintenance totalizer to zero Maintenance Totalizer Displays the current maintenance total in cubic centimeters Set your desired maintenance total target value in this field in cubic centimeters Se...

Page 27: ...ve between Setup Screens fields on a screen or to increment decrement the digits when editing number fields Setup Screen 3 Use this screen to set your flow rate maximum and minimum values and to select your preferred flow rate units Key Enter the screen to set or change preferences Press to activate a field for editing or to accept the highlighted selection on a dropdown menu Move to the right when edi...

Page 28: ... fields Setup Screen 5 Use this screen to calibrate your meter and to view or set your meter k factor See Calibrate the Meter page 18 for procedure Key Enter the screen to set or change preferences Press to activate a field for editing or to accept the highlighted selection on a dropdown menu Move to the right when editing number fields Press again to accept the entry when all digits are correct Star...

Page 29: ...table Exit data editing Move between Setup Screens fields on a screen or to increment decrement the digits when editing number fields Setup Screen 7 Use this screen to set your modbus preferences for ports 1 and 2 Note that ports 5 and 6 are used as modbus master devices for connecting to other ProControl 1KE or Informer modules Key Modbus mode Select off or Slave from the dropdown options Turn off ...

Page 30: ...ime Exit data editing Move between Setup Screens fields on a screen or to increment decrement the digits when editing number fields Setup Screen 9 Use this screen to enter a password that will be required to access the Setup screens This screen also displays the software version Key Enter the screen to set the password Press to activate the field for editing Move to the right when editing number field...

Page 31: ...he condition The following table explains the error type that is associated with each error code and icon Deviations and Advisories Icon and Code Description How to Correct and Clear MF Advisory alarm If enabled the maintenance totalizer alarm displays when the user set maintenance target value is reached Reset Maintenance Totalizer to zero see Setup Screen 1 page 26 Perform maintenance Press to c...

Page 32: ...sor or meter Inaccurate flow reading Meter needs calibration Calibrate meter See Calibrate the Meter page 18 Wrong transducer is selected Choose the correct trans ducer from the options in Setup Screen 6 page 29 Inaccurate pressure range Offset or slope are set incorrectly Review and correct settings for the pressure offset mV and slope mV bar See Setup Screen 6 page 29 Excessive static discharge R...

Page 33: ...ion about system function LED Signals Signal Description Green On ProControl 1KE is powered up Yellow Internal communication in progress Red solid ProControl 1KE failure See Troubleshooting Red flashing Software is updating Red flashing slowly Token error remove token and upload software token again 3A2614H 33 ...

Page 34: ...Parts Parts Kits for Hazardous Location 24L085 24P593 24P595 24L087 24P597 24L089 24L091 34 3A2614H ...

Page 35: ... 16P265 LABEL warning not shown 4 16V142 CABLE intrinsically safe fluid control 16 m 52 5 ft 1 5 See Fluid and Air Control Parts page 38 6 16K509 CABLE power intrinsically safe 50 ft 15 m 1 8 16V381 CABLE intrinsically safe pressure transducer included in Kits 24L089 24P593 and 24P597 1 9 244524 GROUND WIRE assembly with clamp 1 Intrinsically safe cables are identified by the blue tags installed on ...

Page 36: ...Parts Kits for Non Hazardous Location 24L084 24L086 24L088 24L090 24P592 24P594 24P596 36 3A2614H ...

Page 37: ...1KE with software 3b 277853 BRACKET 3c 16P265 LABEL warning not shown 4 16P790 CABLE fluid control 1 5 See Fluid and Air Control Parts page 38 7 245202 CORD set power 10 ft 3 m 13 Amp 120 V 1 8 16V380 CABLE pressure transducer included in Kits 24L088 24P592 and 24P596 1 9 244524 GROUND WIRE assembly with clamp 1 Replacement Danger and Warning labels tags and cards are available at no cost 3A2614H 3...

Page 38: ...Parts Fluid and Air Control Parts 38 3A2614H ...

Page 39: ...16 WASHER 10 2 or 6 208 BRACKET transducer 1 209 289813 METER G3000 1 210 501867 VALVE check 1 211 15U749 BRACKET meter 1 212 114182 SCREW M6 2 213 114339 SWIVEL union 1 214 NUT hex 1 12 unf 1 215 24C375 REGULATOR fluid includes refs 214 216 and 217 1 216 BRACKET regulator 1 217 112310 SCREW 8 2 218 100079 WASHER lock 8 2 219 109466 NUT 8 2 220 TUBE air 1 221 24P600 TRANSDUCER pressure includes fitt...

Page 40: ...6 208 BRACKET transducer 1 209 289813 METER G3000 1 210 501867 VALVE check 1 211 15U749 BRACKET meter 1 212 114182 SCREW M6 2 213 114339 SWIVEL union 1 214 NUT hex1 12 unf 1 215 24C375 REGULATOR fluid includes refs 214 216 and 217 1 216 BRACKET regulator 1 217 112310 SCREW 8 2 218 100079 WASHER lock 8 2 219 109466 NUT 8 2 220 TUBE air 1 221 16H282 TRANSDUCER pressure 1 222 24P600 TRANSDUCER pressur...

Page 41: ... 208 BRACKET transducer 1 209 289813 METER G3000 1 210 501867 VALVE check 1 211 15U749 BRACKET meter 1 212 114182 SCREW M6 2 213 114339 SWIVEL union 1 214 NUT hex1 12 unf 1 215 24C375 REGULATOR fluid includes refs 214 216 and 217 1 216 BRACKET regulator 1 217 112310 SCREW 8 2 218 100079 WASHER lock 8 2 219 109466 NUT 8 2 220 TUBE air 1 221 24P600 TRANSDUCER pressure includes fitting ref 222 and o ri...

Page 42: ...E check 1 211 15U749 BRACKET meter 1 212 114182 SCREW M6 2 213 114339 SWIVEL union 1 214 NUT hex1 12 unf 1 215 24C375 REGULATOR fluid includes refs 214 216 and 217 1 216 BRACKET regulator 1 217 112310 SCREW 8 2 218 100079 WASHER lock 8 2 219 109466 NUT 8 2 220 TUBE air 1 221 24P600 TRANSDUCER pressure includes fitting ref 222 and o ring ref 225 1 222 FITTING pressure transducer 1 223 124843 FITTING ...

Page 43: ... flow 24C472 Fluid Regulator 1 3 low flow 570122 Air Filter and Regulator assembly includes mounting bracket 24P600 Pressure Transducer low pressure Also purchase Hazardous Location Cable 16V381 to connect the transducer to the ProControl 1KE 24R906 Pressure Transducer high pressure includes transducer o ring and fitting Also purchase Hazardous Location Cable 16V381 to connect the transducer to the P...

Page 44: ...Overall Depth in mm Mounting Dimensions Width C x Height D in mm E Mounting Hole Size in mm Fluid and Air Controls Mounting Panel 9 5 241 3 9 0 228 6 0 5 12 7 8 5 x adjustable from 5 0 8 0 212 5 x 127 0 203 2 0 5 12 7 Power Supply 16M167 16 6 420 9 8 7 221 2 4 5 114 8 15 1 x 6 7 382 8 x 170 2 0 31 7 9 ProControl 1KE 7 2 183 6 0 152 2 8 71 2 5 x 3 0 64 x 76 0 28 7 44 3A2614H ...

Page 45: ...ng 4 Bytes Read Only 401084 Serial Number String Bytes 24 27 32 Bit String 4 Bytes Read Only 401086 Serial Number String Bytes 28 31 32 Bit String 4 Bytes Table 12 Run Registers Register Permissions Informer Modbus Register Description Size Units Low Limit High Limit Notes Read Write 402000 Date Year 16 Bit YY 1 99 Read Write 402001 Date Month 16 Bit MM 1 12 Read Write 402002 Date Day 16 Bit DD 1 ...

Page 46: ...cation Modbus StopBits 16 Bit none 1 2 Read Write 403006 Display Date Format 16 Bit 0 mm dd yy 1 dd mm yy 2 yy mm dd 0 2 Read Write 403007 Display Backlight Timer 16 Bit min 0 99 Read Write 403008 Display Maintenance Totalizer Alarm Enable 16 Bit 0 off 1 on 0 1 Read Write 403009 Display Flow Rate Alarm Enable 16 Bit 0 off 1 on 0 1 Read Write 403010 Display Alarm Auto Clear 16 Bit 0 off 1 on 0 1 Re...

Page 47: ...999000 Read Write 403025 System Meter K Factor 16 Bit cc 10 5000 0 010 to 5 000 cc Read Write 403026 System Pressure Transducer Type 16 Bit 0 Type 1 1 Type 2 0 1 Type 1 100 psi Type 2 7500 psi Read Write 403027 System Pressure Transducer Offset 32 Bit mV 0 999999 0 to 9999 99 mV Read Write 403029 System Pressure Transducer Scale 32 Bit mV Bar 0 999999 0 to 9 99999 mV Bar 3A2614H 47 ...

Page 48: ...t then return to this Appendix for information specific to the ProControl 1KE NOTE A modbus gateway Graco PN 24N977 sold separately and a Fiber Optic to Serial Converter Graco PN 24N978 sold separately are required to enable the ProControl 1KE to communicate with the AWI NOTE The AWI must be version 3 01 001 or greater Network Tab When you have finished setting up the system as directed in Manual 33...

Page 49: ...eb Interface Monitor Tab Use this tab to monitor the current device in real time The only change that can be made on this tab is to reset the batch total Click Reset to change the batch total immediately to zero 3A2614H 49 ...

Page 50: ... tab to view or change your ProControl 1KE settings For items with a field type the desired number in the field and press Enter on your keyboard The change takes place when you press Enter For drop down menus click on the desired option The change is immediate 50 3A2614H ...

Page 51: ... See Calibrate the Meter page 18 Device Name In this screen section type a name in the field to help you differentiate among ProControl1KEs if you are using more than one Events In this screen section view or adjust the alarm settings and backlight timer Use the dropdown menus to toggle between On and Off for the maintenance alarm flow alarm and auto clear For the backlight timer type a number in th...

Page 52: ...Notes Notes 52 3A2614H ...

Page 53: ... maximum Power Out Requirements Power Supply 16V680 15 VDC 1 2 A maximum Power Supply 16M167 15 VDC 160mA maximum Environmental Operating Temperature 32 122 F 0 50 C Storage Temperature 22 140 F 30 60 C Humidity 0 to 95 percent non condensing Display housing is solvent resistant Wetted Parts Meter See G3000 meter manual 308778 or Coriolis meter manual 313599 Fluid Regulator See Fluid Regulator Man...

Page 54: ...s 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 B...

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