Graco 24C222 Operation manual

Instructions - Parts
Two-Zone and
Four-Zone Enclosure
Accessory Kits
For adding two zones or four zones of heat to a supply system. For professional use only.
Two-Zone Enclosure Accessory, Part 24C222, Series C
Four-Zone Enclosure Accessory, Part 24C526, Series B
212° F (100° C) Maximum Control Temperature of Gun or Hose
158° F (70° C) Maximum Control Temperature of Pump
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
For complete system installation, opera
tion, and repair instructions, see the appro
priate supply system operation and
repair-parts manuals or the Warm Melt
Supply System Instructions-Parts manual.
EN
3A0100H

Warnings
23A0100H
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fluid Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connect Enclosure Accessory to Power Source 6
Check Resistance . . . . . . . . . . . . . . . . . . . . . . . . 6
Connect CAN Cable . . . . . . . . . . . . . . . . . . . . . . 7
Overview of Temperature Control Settings . . . . . 7
Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . 8
Alarm Codes and Troubleshooting . . . . . . . . . . . . 9
Clear Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 13
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Two-Zone Enclosure Accessory . . . . . . . . . . . . 15
Four-Zone Enclosure Accessory . . . . . . . . . . . . 17
Appendix - User Interface Display . . . . . . . . . . . . 19
Display Overview . . . . . . . . . . . . . . . . . . . . . . . . 19
Display Details . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setup Mode Screens . . . . . . . . . . . . . . . . . . . . . 21
Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . 24
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 28
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
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 all equipment in the 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 working fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. 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 grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.

Warnings
3A0100H 3
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.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure in this manual when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu
facturer’s replacement parts only.
• Do not alter or modify equipment.
• 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.
• Comply with all applicable safety regulations.
WARNING

Installation
43A0100H
Installation
Overview
The heat zone enclosure accessory kits are typically
used to add two or four heat zones to an existing or new
supply system, including a warm melt supply system.
The enclosure accessory kits are intended to heat com
binations of warm melt hoses and dispense valves.
The enclosure accessory kits are standalone systems
with integral controls and a user interface. They are not
electrically connected to the supply system except for
ground bonding.
For operation and start-up of a supply system, refer to
the appropriate supply system or warm melt supply sys
tem manual.
Grounding
Ground the supply system as instructed here and in the
individual component manuals.
Fluid hoses: use only electrically conductive hoses.
Dispense valve: ground through connection to a prop
erly grounded fluid hose and pump.
Fluid supply container: follow local code.
Object being sprayed: follow local code.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the dispense
valve firmly to the side of a grounded metal pail, then
trigger the valve.
Setup
The heat zone enclosures can be attached to a ram or
to a wall.
Using the wall mount bracket kit 24C841, install the heat
zone enclosure accessory to a supportive wall near the
supply system. See Parts, page 15, for more informa
tion.
Fluid Hose
The heat zone enclosure accessory kits are designed
for use with Graco single-circuit material hoses rated at
a maximum of 1920 watts, and dispense valves rated at
a maximum of 1920 watts. The two-zone enclosure
accessory can operate a maximum of one hose and one
dispense valve. The four-zone enclosure accessory can
operate a maximum of two hoses and two dispense
valves.
See the appropriate supply system or warm melt supply
system manual for instructions on connecting the fluid
hose to the pump.
NOTE: When installing fluid hoses, ensure they are
properly sized for your system and are electrically
conductive.
The power source conduit is not an adequate ground
for the system. The unit must be bonded to either the
building ground or a true earth ground. To reduce the
risk of static sparking, ground the pump, the object
being dispensed to, and all other dispensing equip
ment used or located in the dispensing area. All elec
trical wiring must be done by a qualified electrician
and comply with local codes and regulations.

Installation
3A0100H 5
Electrically Connect Hoses and Dispense
Valves
Assemble the hose and dispense valve components as
needed. Refer to the dispense valve instruction manual
for instructions on connecting the hose and dispense
valve components.
Two-zone enclosure accessory:
1. Electrically connect the pigtail hose harness (65) to
zones 1 and 2.
2. Connect an extension cable (not supplied; see
Accessories, page 26, for the part number) to the
pigtail hose harness. Connect the extension cable
to the accessories as required.
Four-zone enclosure accessory:
NOTE: Two pigtail hose harnesses (65) are required
for the four-zone enclosure.
1. Electrically connect the first pigtail hose harness to
zones 1 and 2.
2. Electrically connect the second pigtail hose harness
to zones 3 and 4.
3. Connect an extension cable (not supplied; see
Accessories, page 26, for the part number) to each
pigtail hose harness. Connect the extension cables
to the accessories as required.
Connect one
end of pigtail
hose harness
(65)
Connect other
end of pigtail
hose harness
(65)
r_24C222_3A0100_a_2
Connect to
zone 1 or 2
Connect to
zone 1 or 2
Pigtail Hose Harness
r_24C222_3A0100_a_3
Connect one
end of first
pigtail hose
harness (65)
Connect other
end of first pigtail
hose harness
(65)
Connect one
endofsecond
pigtail hose
harness (65)
Connect other
end of second
pigtail hose
harness (65)
Connect to
zone 1 or 2
Connect to
zone 1 or 2
Pigtail Hose Harness

Installation
63A0100H
Connect Enclosure Accessory
to Power Source
Required voltage and amperage is noted on the electri
cal enclosure label. Also see Table 1. Before running
power to the unit, make sure the plant electrical service
meets the supply system’s electrical requirements.
Power Requirements
A 30A (minimum) - 60A (maximum) circuit breaker (not
provided) must be installed on the incoming power sup
ply. See Table 1 and the Electrical Schematics on
page 13 for more information regarding electrical
requirements.
To connect enclosure accessory to power source:
1. Open enclosure accessory door and locate power
line filter. See Parts, page 15.
2. Have a qualified electrician connect your plant
power to the electrical enclosure power line filter
according to local codes. A 1-3/8 in. (35 mm) diame
ter opening is provided in the enclosure adjacent to
the connections. This opening is suitable for a 1 in.
npt conduit or strain relief fitting (supplied).
Check Resistance
Check the Resistance Between the Supply
System and the True Earth Ground
Have a qualified electrician check the resistance
between each supply system 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 dif
ferent ground site may be required. Do not operate the
system until the problem is corrected.
NOTE: Use a meter that is capable of measuring
resistance at this level.
Have a qualified electrician connect power according
to national, state, and local safety and fire codes.
Table 1: Electrical Requirements
AC Panel
Voltage HZ Phase Full Load Amps
240 50/60 1 40.0
The resistance between the supply system compo
nents and true earth ground must be less than 0.25
ohms.

Installation
3A0100H 7
Sensor Resistance Checks
NOTE: For dispense valve and hose sensor resis
tance checks, refer to the dispense valve manual or
hose manual.
Use an ohmmeter to check the resistance between the
terminals 1 and 3. To check 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 that have resistance readings
that do not comply with the ranges listed in the dis
pense valve manual and hose manual.
NOTE: Check resistance at ambient room tempera
ture (63°– 77°F [17°– 25°C]).
Heater Resistance Checks
NOTE: For dispense valve and hose sensor resis
tance checks, refer to the dispense valve manual or
hose manual.
Use an ohmmeter to check the resistance between ter
minals L and N. To check heater 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 that have resistance readings
that do not comply with the ranges listed in the dis
pense valve manual and hose manual.
NOTE: Check resistance at ambient room tempera
ture (63°– 77°F [17°– 25°C]).
Connect CAN Cable
Connect a CAN cable (supplied) from the bottom con
nector (42) of the enclosure accessory to the display
module.
NOTE: Ensure that the display module is loaded
with the correct software version. Refer to the
appropriate supply system manual for instructions.
Overview of Temperature
Control Settings
Temperature controls are set in Setup mode. See
Appendix - User Interface Display, page 19, for infor
mation about setting temperature controls and con
trolling temperatures for each zone.
Conduct these electrical checks with the main discon
nect OFF.
Conduct these electrical checks with the main discon
nect OFF.
LN

Setup and Operation
83A0100H
Setup and Operation
See the appropriate supply system operation manual or
the Warm Melt Supply System Instructions-Parts man
ual for setup and operation instructions, including pres
sure relief and shutdown instructions.
See Appendix - User Interface Display, page 19, for
details regarding the user interface display.

Alarm Codes and Troubleshooting
3A0100H 9
Alarm Codes and Troubleshooting
Alarms alert the user to a problem and help prevent sys
tem shutdown or application errors. If an alarm occurs,
the status bar on the display shows the alarm descrip
tion, and system operation may stop.
Clear Alarms
Alarms are cleared by the solution(s) listed in the follow
ing table or from the screen in which they appear. See
the Warm Melt Supply Systems manual for detailed
information.
Alarm
Code Alarm Problem Cause Solution Clear Alarm
T4AX Deviation Above Setpoint RTD on wrong module. Verify RTD wire and heater
power cord is attached to
correct heat module.
Cleared from Heat Run
screen. See Appendix -
User Interface Display,
page 19
Shorted module. Replace module.
T1AX Deviation Below Setpoint Tripped circuit breaker. Visually check circuit
breaker for a tripped condi
tion.
Cleared from Heat Run
screen. See Appendix -
User Interface Display,
page 19.
Low power. Measure voltage across
input terminals of power
line filter. Voltage should
measure between 190 and
250 Vac.
Cable unplugged/loose wire. Check for loose or discon
nected wires and plugs.
Circuit breaker not set for L2
and L3. Visually check circuit breaker for proper setting
of L2 and L3.
Faulty heater(s). Measure resistance of
heater.
GFCI has been tripped. Visually check GFCI for a
tripped condition.
Customersuppliedmaincircuit
breaker tripped. Measurevoltageacross the disconnect switch. Voltage
should measure between
190 and 275 Vac.

Alarm Codes and Troubleshooting
10 3A0100H
Alarm
Code Alarm Problem Cause Solution Clear Alarm
T6AX No Temp Rise Tripped circuit breaker. Visually check circuit
breaker for a tripped condi
tion.
Cleared from Heat Run
screen. See Appendix -
User Interface Display,
page 19.
Low power. Measure voltage across
input terminals of power
line filter. Voltage should
measure between 190 and
250 Vac
Cable unplugged/loose wire. Check for loose or discon
nected wires and plugs.
Circuit breaker not set for L2
and L3. Visually check circuit breaker for proper setting
of L2 and L3.
Faulty heater(s). Measure resistance of
heater.
GFCI has been tripped. Visually check GFCI for a
tripped condition.
Customersuppliedmaincircuit
breaker tripped. Measurevoltageacrossthe disconnect switch. Voltage
should measure between
190 and 275 Vac.
A4AX Over current Faulty heaters. Measure resistance of
heater. Cleared from Heat Run screen. See Appendix -
User Interface Display,
page 19.
Incorrect zone type. Ensure zone is set for type
of hardware connected to
it.
High voltage. Measurevoltageacrossthe
disconnect switch. Voltage
should measure between
190 and 275 Vac.
Shorted module. If temperature for a given
zone raises when zone is
disabled, replace heat
module.