Graco Therm-O-Flow 200 Operation manual

Instructions - Parts List
4-Zone Heat Control
4-Zone Heat Control for Therm-O-Flow®Hot Melt Drum Unloaders.
For professional use only.
Part No. 255372, Series A
400°F (204°C) Maximum Control Temperature
For complete system installation and operation instructions,
see the following manuals:
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Therm-O-Flow 200 311208
Therm-O-Flow 20 (6-Zone) 311976
Therm-O-Flow 20 (4-Zone) 312094
TI8191a
311513D
ENG

2311513D
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fluid Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrically Connect Hoses to the Electrical Control
Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ground the System . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting the Electrical Control Panel to a Power
Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Check the Resistance Between the Supply Unit and
the True Earth Ground . . . . . . . . . . . . . . . . . 8
Checking Resistance . . . . . . . . . . . . . . . . . . . . . 8
Resetting the Ground Fault Interrupt . . . . . . . . . 10
Electrical Control Panel Troubleshooting . . . . . . 11
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 18
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 18

Warnings
311513D 3
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 symbols refer to procedure-specific risks. 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
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.
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.
• 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 forms from distributor or retailer.
• 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.

Installation
4311513D
Installation
Overview
Therm-O-Flow Expansion 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, two hose zones, and two 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 dis-
pense point. An expansion 4-zone control can be added
to the system to heat additional zones beyond the six of
the system unloader. When properly connected with
appropriate communication cables, the Therm-O-Flow
system can recognize the main system unloader as well
as the expansion zones.
For operation and startup of a Therm-O-Flow unloader
system, refer to your Therm-O-Flow manual (see front
cover).
The Therm-O-Flow Expansion Controls are intended to
heat combinations of hot melt hoses and guns or acces-
sory devices. Accessory devices include guns, compen-
sators, regulators, manifolds, and headers. See FIG. 1
for a typical installation.
Fluid Hoses
The Therm-O-Flow Expansion 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 255372 4-zone control can operate a maximum of
two hoses and two gun/auxiliary zones, or four gun/aux-
iliary zones when no hose zones are used.
See Accessories, page 15, for zone connection instruc-
tions.
When installing a system, make sure:
• all air and fluid hoses are properly sized for your
system.
• to use only electrically conductive air and fluid
hoses.
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
311513D 5
Key:FIG. 1
A Bleed Type Master Air Valve (required)
B Pump Air Supply Hose
C Fluid Compensator (Zone 4)
D Heated Hose (Zones 5 and 6)
E Hose Hanger
F Manual Dispense Valve
G Extra Heated Hose (Zone Acc. 1)
H Extra Dispense Valve (Zone Acc. 2)
J 4-Zone Expansion Control
K Electrical Control Panel (6 Zone)
L Heated Ram Plate Assembly
M Pump Assembly (Zone 2)
FIG. 1. Typical Installation (Therm-O-Flow 200 Shown)
TI10278a
A
B
C
D
E
F
G
H
J
K
L
M
D

Installation
6311513D
Electrically Connect Hoses to
the Electrical Control Panel
Assemble the hose and gun components as needed.
For information on connecting the hose and gun compo-
nents, follow the gun's instructions.
Electrically connect the hoses to the electrical control
panel. The connectors are located on the bottom of the
expansion 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.
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 con-
tinuity.
Maintain Grounding Continuity When
Purging Or Relieving Pressure
Follow the instructions in your separate gun manual for
safely grounding your gun while purging.
Only use hoses that have a maximum wattage less
than or equal to 1250 watts. Using hoses with
higher maximum wattage could create a runaway
temperature condition.
FIG. 2. Bottom View of Electrical Control Box
TI8164b
DH1 DH2
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.
A qualified electrician must complete all grounding
and wiring connections and check the resistance as
instructed on page 8.
Refer to your local code for the requirements for a
true earth ground in your area.

Installation
311513D 7
Connecting the Electrical
Control Panel to a Power Source
Have a trained electrician connect the electrical control
panel (FIG. 3) to a grounded electrical source that has
the required service ratings. See Table 1.
For information about specific terminal locations and
connections, see the schematic drawing on page 17.
To connect the control panel to the electrical source:
1. Locate the opening in the control panel`s top hous-
ing for the conduit that will enclose the wire from the
facility's power source. The hole diameter is 0.804"
(20 mm) and includes a cord strain relief for cable
diameters from 0.236" (6 mm) to 0.472" (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.
FIG. 3. Electrical Control Panel
CAUTION
If power and grounding connections are not done
properly, the equipment will be damaged and the war-
ranty will be voided. Check the label on the control
box for the proper voltage.
Table 1: Electrical Specifications
Panel
Voltage,
Vac Hz Phase
Full Load
Amps
220/240 50/60 1 15.5
TI8193b

Installation
8311513D
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 corrected.
Checking Resistance
You can check the resistance of the supply unit's heat
sensors and heaters.
Sensor Resistance Checks
To verify the RTD sensors to be used with the 4-zone
heat control, refer to the table below.
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 in the chart below.
The resistance between the supply unit compo-
nents and true earth ground must be less than 0.25
ohms.
Use a meter that is capable of measuring resis-
tance at this level.
Do not open the electrical control panel unless you
are a trained professional. Before opening the con-
trol panel, make sure that all power has been
removed from the control panel.
Table 2: RTD Sensors, 4-Zone Control
Zone Component Terminals
Value
Range,
ohms
1 Dispense
Hose 1
2011 &
2021
108 +/- 2%
2 Dispense Gun
1
2041 &
2051
108 +/- 2%
3 Dispense
Hose 2
2081 &
2091
108 +/- 2%
4 Dispense Gun
2
2110 &
2111
108 +/- 2%
Check resistance at 63-77°F (17-25°C).

Installation
311513D 9
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. Make electrical resistance checks for the compo-
nents. Refer to your Therm-O-Flow manual for wir-
ing diagram information.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in Tables 3 and 4.
Use the following tables for the appropriate zone control.
Resistance values of the heating elements for the vari-
ous devices vary by length and/or type. If the resistance
values are not within the indicated range, reference the
appropriate device manual for further information.
Overview of Temperature Controller
Settings
Temperature controls are set in the zone configuration
setup screens. See Run Screens in your Therm-O-Flow
manual for information about setting temperature con-
trols.
P, I, and d settings are preset for device types and will
not need to be changed. Refer to the Zone Setup
Screens in your Therm-O-Flow manual for a list of
device types and how to set them for each zone.
Check resistance at 63-77°F (17-25°C).
Table 3: Check Heater Resistance, 4-Zone Control
Zone Component
Between
Terminals
Resistance
Values,
ohms
1 DH Hose/
Auxiliary
1134 &
1142
See Table 4
and Table 5
for
resistance
values for
the device
connected.
2 DH Gun/
Auxiliary
1162 &
1142
3 DH Hose/
Auxiliary
1192 &
1142
4 DH Gun/
Auxiliary
1222 &
1142
Table 4: Gun/Auxiliary Heater Resistance Values
Device Watts
Resistance
Values, ohms at
240 Vac
Gun, automatic or
manual
200 288, +30/- 40
Compensator 400 144, +14/- 20
Manifold 400 144, +14/- 20
Heater 500 115, +12/- 16
Table 5: Hose Heater Resistance Values (50 Watts/ft)
Length, ft (m)
Resistance Values,
ohms at 240 Vac
6 (1.83) 288, +30/- 40
10 (3.05) 144, +14/- 20
15 (4.57) 144, +14/- 20
20 (6.10) 115, +12/- 16
25 (7.62) 115, +12/- 16
Table 4: Gun/Auxiliary Heater Resistance Values
Device Watts
Resistance
Values, ohms at
240 Vac

Installation
10 311513D
Resetting the Ground Fault
Interrupt
This control panel is equipped with a ground fault inter-
rupt (GFPE) circuit breaker (FIG. 4). 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. 4. Reset Ground Fault Interrupt
1.25 X 3.0 WIRE DUCT
1.25 X 3.0 WIRE DUCT
1.25 X 3.0 WIRE DUCT
1.25 X 3.0 WIRE DUCT
SSR 113
SSR116
SSR 119
SSR 122
FU 113 FU 116
FU 119 FU 122
FU 1051
FU 1052
PCB
201
PS
123
GFPE
112
DC INT
CONN
112
GND
LUG
NL
+
-
TI0565b
GFPE

Electrical Control Panel Troubleshooting
311513D 11
Electrical Control Panel Troubleshooting
Problem Cause Solution
Disconnect is ON, but EasyKey on
Therm-O-Flow has communication
error.
The ground fault interrupt activated. Reset ground fault interrupt, page 10.
One or more fuses is blown. Replace the blown fuse(s).
Communication cable disconnected. Connect cable.
Warnings
Cause
With optional light tower, the yellow light illuminates and green light remains on if in Run mode.
Temperature Warning - occurs when a zone temperature is above/below the setpoint +/- warning deviation speci-
fied in the Zone tab of the Setup screen.
Alarms
Cause
With optional light tower, the red light illuminates.
High Temperature - occurs when the zone temperature is above the setpoint plus alarm deviation specified in the
Zone tab of the Setup screen.
Low Temperature - occurs when the zone temperature is below the setpoint minus alarm deviation specified in the
Zone tab of the Setup screen while the unloader is in the Run state.
Sensor Error occurs in the following conditions:
• When an enabled zone does not increase in temperature within 7 minutes while the system is in the Heat On
state. This is the short circuit state of an RTD sensor.
• When a zone temperature exceeds 500°F (260°C). This is the open circuit state of an RTD sensor.
Heater Error - occurs if the contactor relay on a temperature board is not closed when a zone of the temperature
board is enabled and in a heat state for the active unloader.
Communication Error - there are two possibilities:
• Start up - Occurs if the EasyKey display board cannot communicate with any board in the system.
• Normal Operation - occurs if any board in the system, including expansion enclosure, cannot communicate with
the EasyKey Display board.
Events
Cause
Maintenance - occurs in advanced unit if user presses maintenance call button. See Maintenance Call Kit in
Therm-O-Flow manual for additional information.
With optional light tower the yellow light turns on.
See Electrical Schematics in Therm-O-Flow manual for additional information.

Electrical Control Panel Troubleshooting
12 311513D
FIG. 5. Electrical Schematic (continued on page 13)

Electrical Control Panel Troubleshooting
311513D 13
FIG. 6. Electrical Schematic (continued)

Parts
14 311513D
Parts
Part No. 255372, 4-Zone Electrical Control, 230/240 Vac
1.25 X 3.0 WIRE DUCT
1.25 X 3.0 WIRE DUCT
1.25 X 3.0 WIRE DUCT
1.25 X 3.0 WIRE DUCT
SSR 113
SSR116
SSR 119
SSR 122
FU 113 FU 116
FU 119 FU 122
FU 1051
FU 1052
PCB
201
PS
123
GFPE
112
DC INT
CONN
112
GND
LUG
NL
+
-
TI8193b
SSR113
SSR116 SSR119 SSR122 FU113
FU119 FU122
FU1051
FU1052
FU116
CONN112
Temperature
Board
Crossover
(Communication)
Cable Connection
Two 16-Pin Outlet
Connectors

Accessories
311513D 15
Part No. 255372, 4-Zone Electrical Control, 230/240 Vac
Accessories
Always use genuine Graco parts and accessories. For a full selection of Graco heated hoses and accessories, see
your Graco distributor.
Device Manufacturer Manufacturer’s Part No. Graco Part No.
Qty. in
Panel
SSR113, 116, 119, 122 Watlow CZ18-A60V-DC10 120398 4
FU1061, 1062 Bussmann FNQ-R-20 Class CC 116215 2
FU116, 122 Bussmann FNQ-R-2-1/4 Class CC 116209 2
FU113, 119 Bussmann FNQ-R-6 Class CC 116208 2
Temperature Board Graco 249405 249405 1
CONN112 Allen Bradley 100-C23VA10
Part No. Description
196313 16 pin to 16 pin Extension Cable, 15 ft (4.57 m) long. Runs between controller and heated hose.
196314 16 pin to 16 pin Extension Cable, 25 ft (7.62 m) long. Runs between controller and heated hose.
196315 16 pin to 8 pin Extension Cable, 15 ft (4.57 m) long. Runs between controller and heated accessory.
196316 16 pin to 8 pin Extension Cable, 25 ft (7.62 m) long. Runs between controller and heated accessory.
196317 16 pin to (2) 8 pin Extension Cable, 15 ft (4.57 m) long. Runs between controller and heated devices.
196318 16 pin to (2) 8 pin Extension Cable, 25 ft (7.62 m) long. Runs between controller and heated devices.
15H385 Cable, 25 ft (7.62 m) long, for communication to Therm-O-Flow System Unloader. Connects PN con-
nector of 4-zone control to PN connector of system control. For units built before 6/19/2008.
121228 CAN cable, 49 ft (15 m) long. Use for units built after 6/19/2008.

Dimensions
16 311513D
Dimensions
Front View Side View
8.80 in.
(224 mm)
14.50 in.
(368 mm)
16.0 in.
(406 mm)
14.50 in.
(368 mm)
16.0 in.
(406 mm)
Four 0.40 in. (11 mm)
diameter holes
TI8166A TI8165A

Technical Data
311513D 17
Technical Data
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220/240 Vac
Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50/60 Hz
Full Load Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 A
HOSE HEATER CIRCUIT
HOSE RTD SENSOR
108.2 ohms +/- 1 ohm
MACHINE END DH1/DH2
CONNECTOR PINOUT
GUN END DH1/DH2
CONNECTOR PINOUT
GUN HEATER
GUN SENSOR
NOT USED
GUN SWITCH
GUN GROUND
HOSE
CORE
GROUND
GND
16-Pin Output Connector Pinout Designations
A1
A2
A3
A4
A5
B1
B2
B3
B4
B5
C1
C2
C3
C4
C5
TI0314c
SHOWN FOR
REFERENCE

All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 311513
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2006, Graco Inc. is registered to ISO 9001
www.graco.com
Revised 03/2010
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages 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 BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: [phone] or Toll Free: 1-800-328-0211 Fax: [phone]