Graco Therm-O-Flow 243698 User manual

309213G
EN
Instructions-Parts List
Therm-O-Flow™
Accessory Heat Zone Controls
Maximum Operating Temperature All Models 400°F (204°C)
2-zone Accessory Control (243698)
4-zone Accessory Control (243699)
Refer to Graco form 309180, Installation and
Operation Guide for installation and operation
instructions.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
4-Zone Accessory Control - 243699
TI0561
2-Zone Accessory Control - 243698
TI0562
GRACO INC. P . O . BOX 1441 MINNEAPOLIS , MN 5544D ‐ 1441
Copyright 2000, Graco Inc . is registered to I.S . EN ISO 9001

See page 2 for Table of Contents.

Table of Contents
2309213G
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Accessories and Modules. . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrically Connect Hoses to the Electrical Control
Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ground The System . . . . . . . . . . . . . . . . . . . . . . 7
Connecting the Electrical Control Panel to a Power
Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Check the Resistance Between the Supply Unit and
the True Earth Ground . . . . . . . . . . . . . . . . . 9
Checking Resistance . . . . . . . . . . . . . . . . . . . . . 9
Overview of the Temperature Controller Settings11
Graco Factory P,I, and d Settings . . . . . . . . . . . 11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Reading the Temperature Controllers . . . . . . . . 12
Temperature Out of Range 12
Reading the Electrical Control Panel Indicators 13
Resetting the Ground Fault Interrupt . . . . . . . . 14
Electrical Control Panel Troubleshooting . . . . . . 15
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Model 243698, Control, Electrical, 230/240
VAC, 2-Zone 16
Model 243699, Control, Electrical, 230/240
VAC, 4-Zone 17
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 19
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 24

Warnings
309213G 3
Warnings
The following are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point
symbol alerts you to a general warning and the hazard symbol refers to a procedure-specific risk. Refer back to these
warnings. Additional product-specific warnings may be found throughout the body of this manual where applicable.l
WARNING
BURN HAZARD
Equipment surfaces and fluid that's heated can become very hot during operation. To avoid severe burns,
do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
SPLATTER HAZARD
During blow off of platen splatter may occur.
• Use minimum drum removal air pressure.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to a grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regula-
tions.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or
swallowed.
• Read MSDS's to know the specific hazards of the fluid you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guide- lines.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-
ponent. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer's warnings. For complete information about
your material, request MSDS from distributor or dealer.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
Graco replacement parts only.
• Do not alter or modify equipment.
• For Use equipment only for its intended purpose. Call your Graco 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.
• Do not operate when fatigued or under the influence of drugs or alcohol.
• Comply with all applicable safety regulations.

Warnings
4309213G
WARNING
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, ore when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation or toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear.
• Clothing and respirator as recommended by the fluid and solvent manufacturer.
• Gloves.
• Hearing protection.
SKIN INJECTION HAZARD
High-pressure fluid from the gun, hose leaks, or ruptured components will pierce skin. This may look like
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
•Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
•FollowPressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking or servicing the equipment.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• 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 present.
• Ground equipment and conductive objects in work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a fire extinguisher in the work area.

Overview
309213G 5
Overview
Therm-O-Flow Accessory Zone Controls
Therm-O-Flow Accessory Zone Controls are typically
used to add more heat zones to an existing Therm-O-
Flow system. As an example, a user may have a
Therm-O-Flow system with six heat zones (pump, plate,
2 hose zones, and 2 gun/access zones). There is a need
to add more hoses to the system because of a long fluid
run from the unloader to the dispense point. An acces-
sory 2- or 4-zone control can be added to the system to
heat additional zones beyond the six of the system
unloader.
Typical Installation
FIG. 1
A Master Air Valve (bleed-type) (required) G Extra Heated Hose (Zone Acc. 1)
B Pump Air Supply Hose H Extra Dispense Valve (Zone Acc. 2)
C FluidCompensator (Zone 4) I Two Zone Controller
D Heated Hose (Zones 5 and 6) J Electrical Control Panel (6 Zone)
E Hose Hanger K Heated Ram Plate Assembly
F Manual Dispense Valve L Pump Assembly (Zone 2)
C
DE
F
H
I
DG
J
B
A
L
K

Typical Installation
6309213G
Typical Installation
For operation and startup of a Therm-O-Flow unloader
system, refer to Graco form 309180,Therm-O-Flow
Installation and Operation Guide.
The Therm-O-Flow Accessory Controls are intended to
heat combinations of hot melt hoses and guns or acces-
sory devices. Accessory devices include Therm- O-Flow
guns, compensators, regulators, manifolds, and head-
ers.
System Accessories and Modules
Before you install the system you should be familiar
with the parts discussed in the subsequent
paragraphs.
Fluid Hoses
The Therm-O-Flow Accessory Zone Controls were
designed for use with Graco single-circuit material hoses
that are rated at a maximum of 1250 watts, and single
circuit devices rated at a maximum of 500 watts.
The 243698 2-zone control , can control a 25-foot
Therm-O-Flow hose (1250 watts max.), or a combination
of a hose and a gun/auxiliary zone or 2 gun/auxiliary
zones. Each gun/auxiliary zone is rated at 500 watts
maximum.
The 243699 4-zone control, can operate a maximum or
2 Therm-O-Flow hoses and 2 Therm-O-Flow gun/ auxil-
iary zones, or 4 gun/auxiliary zones when no hose zones
are used.
When installing a system, make sure:
• all air and fluid hoses are properly sized for your sys-
tem.
• to use only electrically conductive air and fluid
hoses.
WARNING
FIRE HAZARD
Only use hoses that have a maximum
wattage less than or equal to 1250 watts.
Using hoses with higher maximum wattage
could create a failure in the electrical circuit.

Installation
309213G 7
Installation
Electrically Connect Hoses to
the Electrical Control Panel
Assemble the hose and gun components as needed. For
information on connecting the hose and gun com-
ponents, follow the gun's instructions.
Electrically connect the hoses to the electrical control
panel.The connectors are located on the bottom of the
accessory zone control panel (Fig.2).
1. Connect the plug from hose 1 to the DH1 (1) hose
1250W/gun 500W receptacle.
2. Connecttheplugfromhose2totheDH2(2)hose
1250W/gun500Wreceptacle.
FIG. 2
Ground The System
Groundthesupplyunitasinstructedhereandinthe
individualcomponentmanuals.
To reduce the risk of static sparking,ground the pump,
object being dispensed to,and all other spraying/dis-
pensing equipment used or located in the spraying/dis-
pensing area.Check your local electrical code for
detailed grounding instructions for your area and type of
equipment.
Fluid Hoses
Use only Therm-O-Flow heated hoses and accessories.
Dispensing/Spray Gun
Follow the dispensing/spray gun grounding instructions.
Object Material is Applied to
Ground the object according to your local code.
Material Drums
Ground the material drums according to your local code.
Use only metal drums placed on a grounded surface.Do
not place the drum on a nonconductive surface,such as
paper or cardboard,which interrupts the grounding conti-
nuity.
Maintain Grounding Continuity When
Purging Or Relieving Pressure
Follow the instructions in your separate gun manual for
safely grounding your gun while purging.
WARNING
FIRE HAZARD
Only use hoses that have a maximum
wattage less than or equal to 1250 watts.
Using hoses with higher maximum wattage
could create a failure in the electrical circuit.
Bottom View of Electrical Control Box (4-Zone)
ENCLOSURE LAYOUT
TI0561
WARNING
FIRE, EXPLOSION, AND ELECTRIC
HAZARD
Toreducetheriskoffire,explosion,or
electricshock:
•The power source conduit is not an ade-
quate ground for the system. The unit must
be bonded to either the building ground or a
true earth ground.
•A qualified electrician must complete all
grounding and wiring connections and check
the resistance as instructed on page 9.
•Refer to your local code for the require-
ments for a "true earth ground" in your area.
•Also read and follow the warnings on pages
3and 4.

Installation
8309213G
Installation
Connecting the Electrical
Control Panel to a Power Source
FIG. 3
Haveatrainedelectricianconnecttheelectricalcontrol
panel(Fig.3)toagroundedelectricalsourcethathas
therequiredserviceratings:
Toconnectthecontrolpaneltotheelectricalsource:
1. Locate the opening in the control panel’s bottom
housing for the conduit that will enclose the wire
from the facility’s power source. The hole diameter
is .804” (20 mm) and includes a cord strain relief for
cable diameters from .236” (6 mm) to .472” (12
mm).
2. Thread the wire from the power source into the con-
trol panel housing,and then connect the power
source wires to the appropriate terminals on the
panel.See Electrical Schematics beginning on
page page 19.
WARNING
ELECTRIC SHOCK HAZARD
Do not connect the electrical control panel to
a power source unless you are a trained
professional. Failure to follow standard
procedures or to observe the necessary
precautions could result in serious bodily
injury or equipment damage.
CAUTION
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty will be voided. Check the label on the
control box for the proper voltage.
AC
Panel Voltage Hz Phase Full Load Amps
220/240 50/60 1 15.5A - 4-Zone
Control (243699)
11.0A - 2-Zone
Control (243698)

Installation
309213G 9
Installation
Check the Resistance Between
the Supply Unit and the True
Earth Ground
Have a qualified electrician check the resistance
between each supply unit component and the true
earth ground. The resistance must be less than
0.25 ohms. If the resistance is greater than 0.25
ohms, a different ground site may be required. Do
not operate the system until the problem is cor-
rected.
NOTE: Use a meter that is capable of measuring
resistance at this level.
Checking Resistance
You can check the resistance of the supply unit's heat
sensors and heaters.
NOTE: Check resistance at ambient room temperature
(63° -77°F).
Sensor Resistance Checks
To verify the RTD sensors to be used with the 2- or
4-zone heat control box, refer to the tables below.
RTD Sensors - 2-Zone Control
RTD Sensors - 4-Zone Control
An ohm meter can be used to check the resistance
between the terminals indicated. To check the sensor
resistance:
1. Make sure the power is off and that the disconnect
switch is in the OFF position.
2. Make electrical resistance checks for the compo-
nents.
3. Replace any parts whose resistance readings do not
comply with the ranges listed.
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock the resistance between the
supply unit components and true earth
ground must be less than 0.25 ohms.
WARNING
ELECTRIC SHOCK HAZARD
Do not open the electrical control panel,
unless you are a trained professional.
Before opening the control panel, make sure
that all power has been removed from the
control panel.
WARNING
ELECTROCUTION HAZARD
To reduce risk of injury or damage to
equipment, conduct these electrical checks
with the main disconnect OFF.
Zone Component Terminals Value Range
1 Dispense
Hose 1 1091 & 1101 108 + 2%
ohms
2 Dispense
Gun 1 1161 & 1171 108 + 2%
ohms
Zone Component Terminals Value Range
1 Dispense
Hose 1 1161 & 1171 108 + 2%
ohms
2 Dispense
Gun 1 1231 & 1241 108 + 2%
ohms
3 Dispense
Hose 2 1301 & 1311 108 + 2%
ohms
4 Dispense
Gun 2 1371 & 1381 108 + 2%
ohms

Installation
10 309213G
Installation
Heater Resistance Checks
To check heater resistance:
1. Make sure the power is off and that the disconnect
switch is in the OFF position.
2. Replace any parts whose resistance readings
do not comply with the ranges listed.
NOTE: Check resistance at ambient room tem-
perature (63°-77° F).
Table 1. Check Heater Resistance on 2-Zone Control (243698)
Table 2. Check Heater Resistance on 4-Zone Control (243699)
Table 3. Therm-O-Flow Gun/Aux Heater Resistance Values
Table 4. Therm-O-Flow Hose Heater Resistance Values - 50 watts/foot
WARNING
ELECTROCUTION HAZARD
To reduce risk of injury or damage to
equipment, conduct these electrical checks
with the main disconnect OFF.
Zone Component Between
Terminals Resistance Values (ohms)
1 DH Hose/Aux 1232 & 1050 Refer to Tables 3 and 4 for resistance
values for the device connected
2 DH Gun/Aux 1262 & 1050
Zone Component Between Terminals Resistance Values (ohms)
1 DH Hose/Aux 2063 &1061
Refer to Tables 3 and 4 for resistance
values for the device connected
2 DH Gun/Aux 2082 & 1061
3 DH Hose/Aux 2103 &1061
4 DH Gun/Aux 2122 & 1061
Watts Resistance Values
(ohms) at 240 VAC Therm-O-Flow Gun/Aux Device
200 288 +30/-40 Gun, Automatic and Manual
400 144 +14/-20 Compensator
400* 144 +14/-20 Manifold
500 115 +12/-16 Header
Length/ft. Resistance Values
(ohms) at 240 VAC
6 288 +30/-40
10 144 +14/-20
15 144 +14/-20
20 115 +12/-16
25 115 +12/-16