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

Installation
309213G 11
Installation
Overview of the Temperature
Controller Settings
The basic program settings for each temperature con-
troller satisfy most application needs. The defaults are
for using a hose on zones 1 and 3, and a gun on zones 2
and 4. These settings are preset at the factory, but can
be changed. The input type, temperature scale, and over
temperature alarm point are the critical controller set-
tings that are set before doing an auto- tune or using any
controller in normal operation. See Form 309100 for
operation of the temperature controls.
Graco Factory P,I, and d
Settings
Table 5 lists the P, I, and d settings for standard control
panels. These settings are preset at the factory. Use the
table for reference information only.
Table 5. Graco Factory P, I, and d Settings
These P, I, and d values are usually generated by run-
ning an autotune process for each heat zone. The
controllers will automatically find the proper P (propor-
tional), I (integral), and d (derivative) values during
this autotune process. These are values that allow the
heat zones to reach their maximum temperature as
fast as possible without significantly exceeding
desired temperature.
Category P I d Unit Voltage
Hose 9.9 51 12 ALL
Gun 7.5 49 12 ALL
Manifold 1.7 109 16 ALL
Compensator 40.9 87 21 ALL

Operation
12 309213G
Operation
Reading the Temperature
Controllers
See Graco form 309100 for information on the CB100
temperature controller.
Temperature Out of Range
The temperature controllers monitor the RTD readings
from each zone and adjust the electrical power to the
zone to maintain the temperature at the set value (SV)
for each zone.
The 2-zone control (243698) has a Heat On light that
indicates the power disconnect on the panel is on and
that there is power to each connected zone. The High
Temperature Alarm light is a visual indication only. It
is lit when the zone temperature is above the SV of the
control by a Graco preset value of 40° F (22° C).
The 4-zone control (243699) has a power disconnect
switch that provides power to the temperature controls.
Power is not applied to the heat zones until the Heat On
switch is turned on. The Heat On light will illuminate,
indicating power is applied to the zones. Unlike the
2-zone control, the 4-zone control shuts down power to
the heat zones when a high temperature alarm indicates
the zone temperature is above the SB of the control by a
Graco preset value of 40° F (22° C).
The 4-zone control also has provisions for external
equipment to monitor if a high temperature alarm is
active and if all zones are within limits. “Within Limits”
means that the temperature of each zone must be in the
range of 35°F (19° C) below the SV to 40° F (22° C)
above the SV, as shown in Fig. 4.
FIG. 4
35°F (19° C)
below the SV SV 40° F (22° C)
above the SV
Within limits
(green READY light on)
HIGH TEMP
ALARM

Operation
309213G 13
Operation
Reading the Electrical Control Panel Indicators
Use the table and Fig. 5 below to read the indicators on the electrical control panel.
FIG. 5
Light Indicator: Indicator
Light is: Meaning:
AB Control On ON Power is on.
OFF Power is off.
DIMLY LIT There may be a problem with the system power connections. Have connections
checked by a qualified electrician before attempting to start the system.
AC Heat On ON The CONTROL ON switch (U) is set to either the ON or AUTO position and power is
being supplied to the electrical control panel components.
OFF The CONTROL ON switch (U) is set to the OFF position.
AD Hight
Temperature
Alarm
ON The temperature of any of the heated components is out of range, and the power to all
heated components is interrupted. For more information, see Temperature Out of
Range on page 12.
TI0562
2-Zone Accessory Control - 243698 4-Zone Accessory Control - 243699

Operation
14 309213G
Operation
Resetting the Ground Fault
Interrupt
This control panel is equipped with a ground fault inter-
rupt (GFPE) circuit breaker (Fig 6). If the disconnect
switch is ON, but all lights on the electrical control panel
are off, have a qualified electrician check the ground
fault interrupt.
To reset the ground fault interrupt, have a qualified elec-
trician:
1. Turn OFF the electrical disconnect on the electrical
control panel.
2. Open the electrical control box and locate the
Ground Fault Interrupt switch (GFPE). The ground
fault interrupt will be in a “neutral” position, between
the ON and OFF positions.
3. Move the GFPE switch to the OFF position, then
move it to the ON position.
4. Close the door and turn ON the disconnect switch.
FIG. 6
WARNING
ELECTROCUTION HAZARD
To reduce risk of injury or damage to
equipment, perform this procedure with the
main disconnect OFF.
4-Zone Accessory Control
243699
2-Zone Accessory Control
243698
TI0561
TI0562
TI0565
GFPE

Electrical Control Panel Troubleshooting
309213G 15
Electrical Control Panel Troubleshooting
For more information, see the electrical control panel documentation.
Problem Cause(s) Solution(s)
Disconnect is ON, but no indicator
lights are lit The ground fault interrupt has been
activated Reset the ground fault interrupt. See procedure on page 14.
One or more fuses has (have) been
blown Replace the blown fuse(s)
High Temperature Alarm lights The temperature of a heated component
has gone out of range. Supply unit automatically turns off
power to supply unit components and air motor.
Unit turns power back on when overheated
components reach appropriate temperatures.
High Temperature Alarm lights One or more temperature controllers
has different alarm value settings. Set the alarm values on all temperature
controllers to the same set- tings.
One or more temperature controllers
correspond to zones that are not in use. Turn off the unused temperature controller(s). See Form 309100.

Parts
16 309213G
Parts
Model 243698, Control, Electrical, 230/240 VAC, 2-Zone
TI0562
TI0562
16-pin outlet
connector
TC107
TC114
GROUND LUG
PANEL LAYOUT

Parts
309213G 17
Parts
Model 243699, Control, Electrical, 230/240 VAC, 4-Zone
(2) 16-pin
outlet connectors
TC107
TC121
TC114
TC128
CP-8
GROUND SLUG
PANEL LAYOUT
TI0561
TI0561

Parts List
18 309213G
Parts List
Device Manufacture Mfg # Graco # Qty. in
Panel
243698 2-Zone Control (230/240VAC)
SSR109, 116 Carlo Gavazzi RGC1A60D15KGU (20A) 116204 2
Lamps for LT120, 128, (Lights on Door) Siemans 3B0A -BL1 116226 2
FU100, 101 Bussmann FNQ -R -15 Class CC 116214 2
FU107 Bussmann FNQ -R -1 Class CC 116211 1
FU123, 126 Bussmann FNQ -R -6 Class CC 116208 2
TC107, 114 Temperature Controller 233150 2
243699 4-Zone Control (400VAC)
CR111, 156, 162 Deltrol 203028-85 3PDT (SEMKO)
(240VAC Coil) 116202 3
SSR116, 123, 130, 137 Carlo Gavazzi RGC1A60D15KGU (20A) 116204 4
Lamps for LT109, 158, (Lights on Door) Siemans 3B0A -BL1 116226 2
FU100, 101 Bussmann FNQ -R -20 Class CC 116215 2
FU108 Bussmann FNQ -R -2 -1/4 Class CC 116209 1
FU206, 210 Bussmann FNQ -R -6 Class CC 116208 2
FU212 Bussmann FNQ -R -1 -1/4 Class CC 116213 2
TC107, 114, 121, 128
Temperature Controller 233150 4

Electrical Schematics
309213G 19
Electrical Schematics
230/240 VAC 2 - Zone

Electrical Schematics
20 309213G
Electrical Schematics
230/240 4 - Zone