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Troubleshooting

Troubleshooting

Troubleshooting

Troubleshooting

Problem

Problem

Problem

Cause

Cause

Cause

Solution

Solution

Solution

Power is not on.

Turn power supply on.

ProControl 1KE Plus is completely
dark.

Loose or disconnected power
cable.

Tighten or connect cable.

ProControl 1KE Plus has power
but does not function.

Hardware failure.

Replace ProControl 1KE Plus.

Pressure or Flow Rate reads 0
when fluid is flowing.

Loose or disconnected flow
meter/pressure transducer cable.

Check the digital input/output
cable going to/from the meter.

Pressure or Flow Rate reads “—
— —” all the time.

Units in Setup are set to NONE,
indicating that the system has no
pressure transducer and/or fluid
meter.

Choose preferred units for each
device present. See

Setup Screen

6: Pressure Transducer, page 47

,

for pressure,

Setup Screen 4:

Calibration, page 45

, for flow rate.

Faulty flow meter sensor or meter.

Replace sensor or meter.

Inaccurate flow reading.

Meter needs calibration.

Calibrate meter.

See

Calibrate the Meter, page 55

.

Wrong transducer is selected.

Choose the correct transducer
from the options in

Setup Screen

6: Pressure Transducer, page 47

.

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:

Pressure Transducer, page 47

.

Excessive static discharge.

Replace ProControl 1KE Plus.

Display readout faulty.

Ambient temperature too high.

Lower ambient temperature.

Incorrect data addresses.

Check address configuration.

Incorrect communication
parameters.

Check communication
parameters.

Communication failure.

Incorrect cabling.

Check cabling and wiring. See

Installation, page 19

.

Clogs in fluid line or in meter.

Clean fluid line and/or meter.
Consult meter manual (see

Related Manuals, page 2

).

Fluid is not flowing.

Gears worn or damaged.

Service meter.

Con-

sult meter manual (see

Related Manuals, page 2

).

58

3A6948A

Содержание 24L097

Страница 1: ...permanently permanently permanently installed installed installed fluid fluid fluid supply supply supply systems systems systems For For For professional professional professional use use use only on...

Страница 2: ...n 45 Setup Screen 5 Flow Rate 46 Setup Screen 6 Pressure Transducer 47 Setup Screen 7 Pressure 48 Setup Screen 8 Operator Input Limits 49 Setup Screen 9 Additional Operator Input Limits and Timeouts 5...

Страница 3: ...ation in Manual 332013 and on this page The small label Ref 2 on the back of the module shows the ProControl 1KE Plus model number Model Model Model No No No Series Series Series Description Descripti...

Страница 4: ...id Fluid Fluid Working Working Working Pressure Pressure Pressure Part Part Part Number Number Number PSI PSI PSI MPa MPa MPa bar bar bar PSI PSI PSI MPa MPa MPa bar bar bar 25B283 25B283 25B283 N A N...

Страница 5: ...with open setpoint fluid pressure control includes fluid panel and I P to operate fluid pressure regulator N A 1 25B288 Gun Atomizing Air Control N A N A N A 1 25B289 N A 1 25B290 Closed Loop Fluid Pr...

Страница 6: ...e Note Not all meters are approved for hazardous locations See your flow meter manual for details 3 Determine fluid pressure regulator if applicable for the level of control chosen The Gun Atomizing A...

Страница 7: ...models 25B296 25B299 for fluid and atomizing air control Would you potentially want to upgrade a ProControl 1KE Plus model in the future for use with fluid and atomizing air control Do you need to pow...

Страница 8: ...or models 25B296 25B299 or models that may need to be upgraded to include atomizing air control and fluid pressure or flow control the power consumption will require a Graco IS approved G Barrier powe...

Страница 9: ...ply with with with G G G Barrier Barrier Barrier ADCM ADCM ADCM Power Power Power Input Input Input Port Port Port 3 3 3 Power Power Power Supply Supply Supply Ui 17 9 V Uo 16 4 V Ii 725 mA Io 592 2 m...

Страница 10: ...Apparatus Apparatus Class Class Class I I I Division Division Division 1 1 1 Group Group Group D D D T4 T4 T4 16P784 16P784 16P784 I P I P I P Transducer Transducer Transducer with with with ADCM ADC...

Страница 11: ...rt 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 LOCATI...

Страница 12: ...r flush solvent at high pressure 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...

Страница 13: ...Control Drawing 16M169 See Appendix A in Manual 332013 This includes safety barriers DC voltage meters ohmmeters cables and connections Remove the unit from the hazardous area when servicing Without...

Страница 14: ...ure rating of the lowest rated system component See Technical Technical Technical Specifications Specifications Specifications in all equipment manuals Use fluids and solvents that are compatible with...

Страница 15: ...luid in approved containers and dispose of it according to applicable guidelines PERSONAL PERSONAL PERSONAL PROTECTIVE PROTECTIVE PROTECTIVE EQUIPMENT EQUIPMENT EQUIPMENT Wear appropriate protective e...

Страница 16: ...ck or limit the range of fluid and atomizing air setpoint adjustments that an operator may use Alarms if the flow rate is too high or too low for the user set targets Alarms if the fluid pressure is t...

Страница 17: ...els Key Key Key E E E Fluid Fluid Fluid and and and Air Air Air Regulator Regulator Regulator I P I P I P Transducers Transducers Transducers Current to pressure I P transducers for controlling fluid...

Страница 18: ...ne Line to to to Gun Gun Gun R R R Fluid Fluid Fluid Inlet Inlet Inlet Line Line Line See Technical Specifications page 88 for pressure requirements Key Key Key AC AC AC Air Air Air Pressure Pressure...

Страница 19: ...hat are different than the options provided in the ProControl 1KE Plus Selection Guide page 6 users must provide a power supply cord with an IEC 320 C13 female converter See Technical Specifications p...

Страница 20: ...th a non IS power supply must not be returned 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 Inst...

Страница 21: ...pability below below below 50 50 50 psi psi psi 3 5 3 5 3 5 bar bar bar Key Key Key A A A Power Supply Module see ProControl 1KE Plus Selection Guide page 6 for alternate power supply module options B...

Страница 22: ...bar Key Key Key A A A Power Supply see ProControl 1KE Plus Selection Guide page 6 for alternate power supply module options B B B ProControl 1KE Plus ADCM C C C Fluid Panel L L L 2 Way Vented Valve M...

Страница 23: ...rol Control Control Panel Panel Panel Connect a ground wire to the screw on the 1KE Plus fluid panel Connect the other end to a true earth ground 5 Fluid Fluid Fluid Supply Supply Supply Ground the fl...

Страница 24: ...ption ratings and size your air supply accordingly The ProControl 1KE Plus uses an Air Flow Switch AFS to detect when the applicator gun is triggered Do not bypass the AFS See Accessories page 77 for...

Страница 25: ...g open or closed loop pressure or flow control the ProControl 1KE Plus Fluid Pressure I P Transducer must operate at an outlet air pressure of at least 10 psi 0 7 bar When using 1 1 air operated fluid...

Страница 26: ...uid I P transducer control out port to the fluid regulator air control inlet port The pilot air line should not exceed 10 ft 3 m Communication Communication Communication Options Options Options Graco...

Страница 27: ...tem Description Description Description Type Type Type A Power Supply Module 26C724 shown Supplied ordered separately B1 and B2 ProControl 1KE Plus ADCM Supplied C1 and C2 ProControl 1KE Plus Fluid Pa...

Страница 28: ...CE NOTICE NOTICE To avoid damage to the I P transducer always put the system into Standby Mode see Run Mode Selection page 34 or power the system off before reducing air pressure to the system Fluid F...

Страница 29: ...ation Navigation and and and Editing Editing Editing Refer to this section if you have questions about screen navigation or about how to enter information and make selections All All All Screens Scree...

Страница 30: ...Mode Selection page 34 Error Reset Use to clear alarm after cause has been fixed Also used to cancel data entered and return to original data Enter Screen Highlight data that can be edited Also chang...

Страница 31: ...et Upper and Lower Limits for Fluid Flow Percent ProControl 1KE is Modbus Slave Set Pressure Units Set Maximum and Minimum Flow Rates Screen Screen Screen Icons Icons Icons Set Flow Rate Units Mainten...

Страница 32: ...tion Selection Icon Icon Icon Description Description Description and and and Typical Typical Typical Application Application Application Run Run Run Screen Screen Screen Examples Examples Examples Mo...

Страница 33: ...es to the setpoint using a PID control for pressure which is targeting from the PID control for flow Current Current Current Setpoint Setpoint Setpoint to to to Pilot Pilot Pilot Air Air Air Control C...

Страница 34: ...ssure is set to 0 Flush Mode used for solvent flush Gun atomizing air pressure is set to 0 Fluid pressure is set to a percent value see Setup Screen 12 Flush Mode page 52 Icon Icon Icon Description De...

Страница 35: ...ial After a fluid Flush process the gun is shown as white to indicate that it is loaded with solvent Table Table Table 2 2 2 Standby Standby Standby Mode Mode Mode Run Run Run Screens Screens Screens...

Страница 36: ...ompared to the minimum flush volume from the setup screen If the volume was not achieved the SP alarm is activated The fluid volume is tracked as a solvent in the Job Log Table Table Table 3 3 3 Flush...

Страница 37: ...during the fill process is compared to the minimum fill volume from the setup screen If the volume was not achieved the SN alarm is activated Table Table Table 4 4 4 Fill Fill Fill Mode Mode Mode Run...

Страница 38: ...d flow while the gun trigger is activated after the amount of time selected on the screen the fluid pressure will be reduced to zero The QT alarm is activated The system is returned to Standby Mode To...

Страница 39: ...Dispense Dispense Dispense Total Total Total The paint dispense totalizer accumulates the total amount of fluid dispensed in the job logging cycle This is reset to zero when the Job Log icon is presse...

Страница 40: ...obs The most recent job which is always index 000 is initially displayed when the screen is entered the lower the index the more recent the job The Job Index can be set directly by entering the number...

Страница 41: ...reen is entered the lower the index the more recent the event The Event Index can be set directly by entering the number field and selecting a value from 000 to 500 to quickly jump to any record or th...

Страница 42: ...assword to 0000 to disable password protection See Setup Screen 16 Password page 54 to set or change the password Key Key Key Enter the screen to enter a password Press to activate a field for editing...

Страница 43: ...Target Examples Examples Examples Description Description Description Job Job Job Target Target Target Screen Screen Screen Event Event Event Log Log Log History History History Screen Screen Screen...

Страница 44: ...MF alarm is activated Clear the alarm by entering the screen selecting the Reset option and selecting the Clear Alarm button Key Key Key Enter the screen to set or change preferences Press to activat...

Страница 45: ...alibration Calibration Use this screen to calibrate your meter and to view or set your meter k factor See Calibrate the Meter page 55 for procedure Key Key Key Enter the screen to set or change prefer...

Страница 46: ...lected the maximum and minimum values shown above will automatically update based on the selected percent amount and the current active Flow Rate Target on the Run Screen Key Key Key Set the percent d...

Страница 47: ...ction on a menu Move to the right when editing number fields Press again to accept the entry when all digits are correct Select the correct pressure transducer None 100 100 100 psi psi psi 2000 2000 2...

Страница 48: ...pressure When selected the maximum and minimum values shown will automatically update based on the selected percentage and the current active target pressure on the Run screen Key Key Key Set the perc...

Страница 49: ...nitor and Accumulate Volume Only Closed Loop Pressure Control Closed Loop Flow Control Open Loop Current Setpoint Note There are no input limits for the Open Loop Current Setpoint method Key Key Key E...

Страница 50: ...ion on a menu Move to the right when editing number fields Press again to accept the entry when all digits are correct Set your desired maximum first data field and minimum second data field atomizing...

Страница 51: ...elds on a screen or to increment decrement the digits when editing number fields Setup Setup Setup Screen Screen Screen 11 11 11 Fill Fill Fill Mode Mode Mode Use this screen to set up the parameters...

Страница 52: ...igits when editing number fields Setup Setup Setup Screen Screen Screen 13 13 13 Control Control Control Method Method Method Use this screen to set the system control method See Control Method Consid...

Страница 53: ...t data editing Move between Setup Screens fields on a screen or to increment decrement the digits when editing number fields Setup Setup Setup Screen Screen Screen 15 15 15 Date Date Date and and and...

Страница 54: ...oftware version Key Key Key Enter the screen to set the password Press to activate the field for editing Move to the right when editing number fields Press again to accept the entry when all digits ar...

Страница 55: ...material into a graduated cylinder The amount the system measures will display in the measured volume field 6 Press to end the calibration 7 Press to get to the dispensed volume field then press to e...

Страница 56: ...s conditions are monitored independently of the control system The following table explains the error type that is associated with each error code and icon Press to clear alarm after the cause has bee...

Страница 57: ...t or disable alarm Setup Screen 1 Job Target page 43 Press to clear alarm F6 Runaway Flow Deviation only Active when using flow control and the flow target is not achievable Determine cause of fluid c...

Страница 58: ...rate Faulty flow meter sensor or meter Replace sensor or meter Inaccurate flow reading Meter needs calibration Calibrate meter See Calibrate the Meter page 55 Wrong transducer is selected Choose the...

Страница 59: ...ncoming system air pressure This should be at least 10 psi 0 7 bar higher than the target fluid pressure Check incoming fluid pressure from pump This should be at least 10 psi 0 7 bar higher than the...

Страница 60: ...tem function LED LED LED Signals Signals Signals Signal Signal Signal Description Description Description Green On ProControl 1KE Plus is powered up Yellow Internal communication in progress Red solid...

Страница 61: ...112190 grounding strap and ground 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 flathea...

Страница 62: ...3 25B283 25B283 and and and 25B284 25B284 25B284 Ref Ref Ref Part Part Part Description Description Description Qty Qty Qty 25B283 25B283 25B283 25B284 25B284 25B284 5 15U749 BRACKET wall mount meter...

Страница 63: ...Monitor with with with Open Open Open Loop Loop Loop Pressure Pressure Pressure Setpoint Setpoint Setpoint Models Models Models 25B285 25B285 25B285 25B286 25B286 25B286 25B287 25B287 25B287 and and...

Страница 64: ...4 npt 1 14 191929 ADAPTER 1 1 16 112906 WASHER spring lock not shown 4 4 4 4 17 GC2188 SCREW socket head cap 190 x 500 2 2 2 2 25 16P784 TRANSDUCER miniature I P 1 1 1 1 26 18A989 BRACKET pressure swi...

Страница 65: ...9 9 9 65 25B283 MODULE ADCM includes ref 68 81 and 90 1 1 1 1 68 277853 BRACKET booth control mounting included with ref 65 1 1 1 1 72 18B393 CABLE I P 2m M12 8 pin 1 1 1 1 78 551731 TUBE 5 32 OD quan...

Страница 66: ...Parts Gun Gun Gun Atomizing Atomizing Atomizing Air Air Air Control Control Control Model Model Model 25B289 25B289 25B289 66 3A6948A...

Страница 67: ...116007 NUT lock 4 37 111502 FITTING tube 1 38 18B053 CABLE I P 1 40 C38163 WASHER 10 ext tooth lock 4 41 19A899 SPACER 10 2 inches 4 42 120435 REGULATOR remote piloted 1 43 514930 SCREW socket head c...

Страница 68: ...KET booth control mounting included with ref 65 1 72 18B393 CABLE I P 2m M12 8 pin 1 78 551731 TUBE 5 32 OD quantity in ft 1 160 79 054106 TUBE 375 OD quantity in ft 0 760 81 244524 WIRE ground assemb...

Страница 69: ...Fluid Fluid Pressure Flow Pressure Flow Pressure Flow Control Control Control Models Models Models 25B290 25B290 25B290 25B291 25B291 25B291 25B292 25B292 25B292 25B293 25B293 25B293 25B294 25B294 25B...

Страница 70: ...g lock 2 2 2 2 7 GC2248 SCREW socket head cap 250 x 50 2 2 2 2 8 289813 METER G3000 assembly gear 1 1 9 114182 SCREW hex flange machine 2 2 10 19A908 CABLE meter 1 5 m 1 1 11 24C275 REGULATOR 1 1 rati...

Страница 71: ...swivel elbow 3 8 t 1 4 npt m 1 1 1 1 1 1 33 113029 NIPPLE 1 4 x 1 4 npt 1 1 1 1 1 1 34 513937 SWITCH pressure 1 1 1 1 1 1 35 103982 SCREW pan head machine 4 4 4 4 4 4 36 116007 NUT lock 4 4 4 4 4 4 3...

Страница 72: ...E ADCM includes ref 68 81 and 90 1 1 1 1 1 1 68 277853 BRACKET booth control mounting included with ref 65 1 1 1 1 1 1 69 19A906 CABLE M12 reverse key non IS 1 1 1 1 1 1 72 18B393 CABLE I P 2m M12 8 p...

Страница 73: ...Pressure Flow Pressure Flow Pressure Flow and and and Gun Gun Gun Atomizing Atomizing Atomizing Air Air Air Control Control Control Models Models Models 25B296 25B296 25B296 25B297 25B297 25B297 25B29...

Страница 74: ...t 1 14 191929 ADAPTER 1 1 15 19A782 BRACKET air fluid mounting 1 1 1 1 16 112906 WASHER spring lock 11 11 11 11 17 GC2188 SCREW socket head cap 190 x 500 5 5 5 5 18 19A788 WASHER internal tooth lock 3...

Страница 75: ...ed 2 way 1 1 1 1 52 100721 PLUG pipe 1 1 1 1 53 120389 FITTING tube 1 1 1 1 54 18A988 FITTING Y 1 4 npt m x 5 32 tube 2 2 2 2 55 18B604 BRACKET cable mounting 1 1 1 1 56 18B605 GLAND multiple entry ca...

Страница 76: ...ption 25B296 25B296 25B296 25B297 25B297 25B297 25B298 25B298 25B298 25B299 25B299 25B299 90 16P265 LABEL warning safety sheet includes labels in English French and Spanish included with ref 65 1 1 1...

Страница 77: ...y Instrinsically Instrinsically Safe Safe Safe Cables Cables Cables Part Part Part No No No Description Description Description 19Y499 IS Power Cable 50 ft 15 m for power supply 19Y502 IS Power Cable...

Страница 78: ...meter 0 02 to 1 0 gpm 75 to 3800 cc min for low to medium viscosity materials 280560 HG6000 Meter Positive displacement helical gear flow meter 0 013 to 6 0 gpm 50 to 22 712 cc min for high flow high...

Страница 79: ...DRAIN PIN 8 6 PINK NC 7 BLUE 8 DRAIN NC 513937 PRESSURE SWITCH FLUID C ONTROL COM 1 NO3 NC2 16P784 DIN C ONNECTOR FLUID C ONTROLI P 1 2 3 18B 053 I PCA BLE WHITE PIN1 BROW N PI N2 GREE N PIN3 YELLOW P...

Страница 80: ...pth Depth in mm Mounting Mounting Mounting Dimensions Dimensions Dimensions Width Width Width C C C x x x Height Height Height D D D in mm E E E Mounting Mounting Mounting Hole Hole Hole Size Size Siz...

Страница 81: ...String 4 Bytes 401044 Software Version Build Read Only 32 Bit String 4 Bytes 401072 Serial Number String Bytes 0 3 Read Only 32 Bit String 4 Bytes 401074 Serial Number String Bytes 4 7 Read Only 32 Bi...

Страница 82: ...99999 Write 0 to reset 402018 Current Maintenance Total Read Write cc 0 9999999 Write 0 to reset 402020 Current Flow Rate Read cc min 0 65535 402022 Current Pressure Read bar 0 32 bit Scaled as 1 bar...

Страница 83: ...sed bits such as 0x80000000 or 0x40000000 may be added to the bitmask to allow the write cycle Run Run Run Setpoint Setpoint Setpoint Registers Registers Registers All registers are 32 bit Address Add...

Страница 84: ...YY 2 YY MM DD 403012 Display Backlight Timer Read Write minutes 0 99 0 Always On 403014 Display Maintenance Totalizer Alarm Enable Read Write Bit 0 1 0 Off 1 On 403016 Display Flow Rate Alarm Enable...

Страница 85: ...Value 0 2 0 cc 1 l 2 gal 403052 System Pressure Maximum Read Write bar 0 0x44E584 Scaled as 1 bar 65536 Used for P3 alarm 403054 System Pressure Minimum Read Write bar 0 0x44E584 Scaled as 1 bar 65536...

Страница 86: ...ar 0 0x63E667 Scaled as 1 bar 65536 403098 Pressure minimum setpoint limit Read Write bar 0 0x63E667 Scaled as 1 bar 65536 403100 Pressure Control internal setpoint Read Write bar 0 0x63E667 Scaled as...

Страница 87: ...e cc min 0 9999 403156 Atomizing Air percentage drive maximum Read Write Percent 0 0x63E667 Scaled as 1 65536 403158 Atomizing Air percentage drive minimum Read Write Percent 0 0x63E667 Scaled as 1 65...

Страница 88: ...rdous Hazardous Hazardous Locations Locations Locations Voltage 100 240 VAC Frequency 50 60 Hz Phase 1 Amps 1 2 A maximum Power Power Power Input Input Input Requirements Requirements Requirements for...

Страница 89: ...ulator See Fluid Regulator Manual 3A0427 Fittings 17 4 17 7 303 304 316 Stainless Steel PTFE Weight Weight Weight ProControl 1KE Plus ADCM 1 5 lb 0 68 kg Mounting Bracket 1 lb 0 45 kg Power Supply 16V...

Страница 90: ...WARRANTY WARRANTY WARRANTY AND AND AND DISCLAIMS DISCLAIMS DISCLAIMS ALL ALL ALL IMPLIED IMPLIED IMPLIED WARRANTIES WARRANTIES WARRANTIES OF OF OF MERCHANTABILITY MERCHANTABILITY MERCHANTABILITY AND...

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