Graco 309077 Operation manual

309077
Rev. –
First choice when
quality counts. 
9403A
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
200 Liter (55 Gallon) Drum Size,
165 mm (6.5”) Dual Post Air-Powered Ram
Warm Melt Supply Units
480V Heated Supply Unit, 19:1 Ratio Senator Pump with
Stainless Steel Check-Mate 800 Displacement Pump
1900 psi (13 MPa, 131 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
160  F (71  C) Maximum Operating Temperature
Part No. 241973
Module Supply Unit with Smooth Bottom Plate
Part No. 243164
Module Supply Unit with Finned Bottom Plate
Refer to page 2 for the Table of Contents.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

2 309077
Table Of Contents
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a Location for the Ram 8. . . . . . . . . . . . . .
System Accessories and Modules 8. . . . . . . . . . . . .
Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Ram 11. . . . . . . . . . . . . . . . . . . . . . . . . .
Electrically Connect Hoses to the
Electrical Control Panel 11. . . . . . . . . . . . . . . . . . . . .
Ground The System 12. . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Electrical Control Panel
to a Power Source 13. . . . . . . . . . . . . . . . . . . . . . . . .
Check the Resistance Between the
Supply Unit and the True Earth Ground 14. . . . . . .
Checking Resistance 14. . . . . . . . . . . . . . . . . . . . . . .
Overview of the Temperature
Controller Settings 16. . . . . . . . . . . . . . . . . . . . . . . . .
Setting Temperature Controllers 17. . . . . . . . . . . . .
Set Temperature Controllers to Auto Mode 17. . . .
First Steps – Programming Tip 18. . . . . . . . . . . . .
Checking Critical Controller Settings 18. . . . . . . . .
Auto Tuning the Controllers 20. . . . . . . . . . . . . . . . .
Recording the Site P, I, and D Settings 22. . . . . . . .
Graco Factory P, I, and D Settings 23. . . . . . . . . . .
Configuring Temperature Controllers for
Unused Heated Zones 23. . . . . . . . . . . . . . . . . . . . . .
Flushing the System 24. . . . . . . . . . . . . . . . . . . . . . .
Starting Up the System 24. . . . . . . . . . . . . . . . . . . . .
Initial Material Loading 25. . . . . . . . . . . . . . . . . . . . . .
Operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 26. . . . . . . . . . . . . . . . . .
Raising and Lowering the Ram 27. . . . . . . . . . . . . .
Daily Start-up Procedure 27. . . . . . . . . . . . . . . . . . . .
Changing Empty Drum 29. . . . . . . . . . . . . . . . . . . . .
Shutdown 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop 31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading the Electrical Control Panel
Indicators 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading the Temperature Controllers 33. . . . . . . . .
Resetting the Ground Fault Interrupt 34. . . . . . . . . .
Flushing Safety 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ram Troubleshooting 36. . . . . . . . . . . . . . . . . . . . . . . .
Heated Pump Troubleshooting 37. . . . . . . . . . . . . . . .
Air Motor Troubleshooting 38. . . . . . . . . . . . . . . . . . . .
Electrical Control Panel Troubleshooting 38. . . . . .
Service 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection Frequency 39. . . . . . . . . . . . . . . . . . . . . .
Ram Service 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing a Material Drum from the
Supply Unit 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Follower 40. . . . . . . . . . . . . . . . . . . . . .
Pump Removal and Replacement 42. . . . . . . . . . . .
Separating the Pump from the Air Motor 43. . . . . .
Re-attaching the Air Motor to the Pump 43. . . . . . .
Removing the Follower from the Pump 43. . . . . . .
Removing the E5CK Temperature Controller 44. . .
Installing the E5CK Temperature Controller 45. . . .
For 480 VAC Supply Units – Schematic 46. . . . . . .
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 241973, 165 mm Ram,
19:1 Senator, Heated Check-Mate 800,
with smooth bottom plate 48. . . . . . . . . . . . . . . . . . .
Model 243164, 165 mm Ram,
19:1 Senator, Heated Check-Mate 800,
with finned bottom plate 50. . . . . . . . . . . . . . . . . . . .
Model 241974 Pump Module 52. . . . . . . . . . . . . . . .
Model 241987 Therm-O-Flow Pump Module 53. . .
Model 241986 Displacement Pump 54. . . . . . . . . . .
Model C32437, Ram Air Control Module 56. . . . . .
Model C32434, Pump Mounting Kit 58. . . . . . . . . . .
Model C32451, Vent Hood Kit 59. . . . . . . . . . . . . . .
Model C32429 6-zone
Electrical Control Panel 60. . . . . . . . . . . . . . . . . . . . .
Model 918470 and 243165
Heated Follower Plate Kit 62. . . . . . . . . . . . . . . . . . .
Schematics 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Control Panel Mounting
and Clearance Dimensions 72. . . . . . . . . . . . . . . . . .
Ram Mounting and Clearance Dimensions 73. . . .
Technical Data 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications 74. . . . . . . . . . . . . . . . . . . . . . . . .
Appendix 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting List 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 76. . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 76. . . . . . . . . . . . . . . . . . . . . . .

3309077
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the corresponding
instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, warnings, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your
Graco distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed 125 psi (8.8 bar) maximum inbound air pressure to the ram.
Never exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 74.
Be sure that all spray/dispensing equipment and accessories are rated to withstand the maxi-
mum working pressure of the pump. Do not exceed the maximum working pressure of any
component or accessory used in the system.
Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do
not expose Graco hoses to temperatures above 82° C (180° F) or below -40°C (-40° F).
Do not use the hoses to pull the equipment.
Use fluids and solvents that are chemically compatible with the equipment wetted parts. See
the Technical Data sections of all the equipment manuals. Always read the material manufac-
turer’s literature before using fluid or solvent in this pump.
Always wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid
and solvent manufacturers.
Wear hearing protection when operating this equipment.
Comply with all applicable local, state and national fire, electrical and other safety regulations.

4 309077
WARNING
HOT SURFACE AND FLUID HAZARD
Heated fluid can cause severe burns and can cause equipment surfaces to become very hot.
Wear protective gloves and clothing when operating this equipment in a heated system.
Do not touch the metal heat sink when the surface is hot.
Allow the equipment to cool thoroughly before servicing.
Some heated systems are designed to dispense Polyurethane (PUR) heated materials. PUR
systems are supplied with ventilation hoods, and require proper ventilation and specially designed
system components.
INJECTION HAZARD
Spray from the spray gun, hose leaks, or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on
the skin can also cause serious injury.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
medical attention.
Do not point the gun/valve at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip/nozzle.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Always have the trigger guard on the gun when dispensing.
Check the gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun/valve trigger safety o
p
erates before dis
p
ensing
B
e sure
th
e gun
/
va
l
ve
t
r
i
gger sa
f
e
t
y opera
t
es
b
e
f
ore
di
spens
i
ng.
Lock the gun/valve trigger safety when you stop dispensing.
Follow the Pressure Relief Procedure on page 26 if the nozzle clogs, and before cleaning,
checking or servicing the equipment.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immedi-
ately. Do not repair high pressure couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.

5309077
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames or sparks can cause a hazardous condition
and result in fire or explosion and serious injury.
Ground the equipment and the object being sprayed, and all other electrically conductive ob-
jects in dispense area. Proper grounding dissipates static electricity generated in the equipment.
See Ground the System on page 12.
Do not use this equipment with flammable liquids.
Keep the dispense area free Do not smoke in the dispense area.
If there is any static sparking while using the equipment, stop dispensing immediately. Identi-
fy and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or material.
Do not smoke in the dispense area.
Extinguish all open flames or pilot lights in the dispense area.
Do not turn on or off any light switch in the dispense area.
Keep the dispense area free of debris, including solvent, rags, and gasoline.
FIRE, EXPLOSION AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition
and result in fire, explosion, or electrostatic shock and other serious injury.
Ground the equipment, the object being dispensed, and all other electrically conductive objects
in the dispense area. Proper grounding dissipates static electricity generated in the equipment.
See Ground the System on page 12.
Do not use this equipment with flammable liquids.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Keep the dispense area free of debris, including solvent, rags, and gasoline.
If there is any static sparking or you feel an electric shock while using the equipment, stop dis-
pensing immediately. Do not use the equipment until you have identified and and corrected
the problem.
Make sure all electrical work is performed by a qualified electrician only.
Make sure all electrical equipment is installed and operated in compliance with applicable
codes.
Make sure power is disconnected when servicing and repairing equipment.
Have any checks, installation, or service to electrical equipment performed by a qualified electri-
cian only.
Never exceed the maximum wattage of the supply unit. See the wiring diagrams in this manual
for more information.
Only use hoses that have a maximum wattage less than an equal to 1250 watts. Using hoses
with higher maximum wattage could create a runaway temperature condition.

6 309077
WARNING
MOVING PARTS HAZARD
Moving parts, such as the ram follower plate/pump inlet can pinch fingers.
Do not operate the equipment with the guard removed.
Keep clear of all moving parts when starting or operating the equipment.
Keep hands and fingers away from the priming piston during operation and whenever the pump
is charged with air.
Keep clear of the follower plate, pump fluid inlet, and lip of the fluid container when raising or
lowering the ram.
Before checking or servicing the ram or pump, follow the Pressure Relief Procedure on page
26.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all
local, state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
Avoid exposure to heated material fumes.
Provide adequate ventilation.

7309077
Typical Installation
A Air Line Filter
B Lock-out Master Air Valve (bleed-type) (required)
C Pump Bleed-Type Master Air Valve (required)
D Pump Air Regulator
E Main Air Line Supply
F Electrical Control Panel
G Follower Plate Bleed Stick
H Pump Air Supply Hose
I Air Line Lubricator
J Pump Mounting Bracket
K Fluid Regulator (compensator)
L Heated Hose
M Hose Hanger
P Depressurization Valve
R Automatic Dispense Valve
10 Follower Rod
100 Ram Module
106 Pump Assembly
107 Wipers
109 Heated Follower Plate Assembly
110 Ram Hand Valve
9402A
9403A
Fig. 1
L
F
M
H
K
C
L
J
106
E
B
A
ID
10
R
P
100
G
110
107
109

8 309077
Typical Installation
The typical installation discussed below is only a guide
for selecting and installing system components and
accessories. Contact your Graco distributor for help in
designing a system to suit your particular needs.
This air-powered ram extruder forces high viscosity
fluids into the intake valve of the fluid pump. Wiper
rings and other accessory equipment for use with this
ram are listed in the Accessories section on page 70.
NOTE: For more information about converting the ram
from air to hydraulic operation, contact your Graco dis-
tributor.
Selecting a Location for the Ram
Refer to the Ram Mounting and Clearance Dimensions
drawing (Fig. 43 on page 73) for ram mounting and
clearance dimensions.
When selecting a location for the ram, keep the follow-
ing in mind:
1. There should be sufficient space for installing and
using the equipment.
Make sure there is sufficient overhead clear-
ance for the pump and ram when the ram is in
the fully raised position.
If you are installing a vent hood, make sure
there is sufficient horizontal clearance for it.
Make sure the air regulators for the pump and
ram are fully accessible.
Make sure there is easy and safe access to an
appropriate electrical power source. The
National Electrical Code requires 3 feet of
open space in front of the electrical panel.
2. Make sure that you will be able to level the base of
the ram using metal shims.
3. When you bolt the ram to the floor the anchors
should be long enough to prevent the unit from
tipping. Refer to the Dimensional Drawing on page
73 for more information.
4. If you are installing a vent hood, make sure the
ram is installed near a connection to the factory
ventilation system.
System Accessories and Modules
Before you install the system you should be familiar
with the parts discussed in the subsequent para-
graphs.
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 maxi-
mum wattage could create a failure in
the electrical circuit.
The Therm–O–Flow 55 unit was designed for use with
single–circuit material hoses that are rated at a maxi-
mum of 1250 watts. For information about using
material hoses with higher wattages, contact your
Graco distributor.
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.

9309077
Typical Installation
4-Regulator Air Control Module
Fig. 2
O
C
D
I
A
E
B
9402A

10 309077
Typical Installation
Air Line Modules
WARNING
PRESSURIZED FLUID HAZARD AND
MOVING PARTS HAZARD
The bleed-type master air valve (C) and
auto depressurization valve (P) are re-
quired in your system to relieve air
trapped between this valve and the
pump after the pump air regulator is
closed. Trapped air can cause the pump
to cycle unexpectedly, which could result in serious
bodily injury, including splashing in the eyes or on
the skin and injury from moving parts.
4-Regulator Air Control Module (shown)
For more information, refer to Fig. 1 page 7 and Fig.
2 page 9. The following components are included
with the module:
Bleed-type Lock-out Master Air Valve (B) is used to
shut off and lock out the air supply from the entire
supply unit.
Bleed-type Master Air Valve (C) is required in your
system to relieve air trapped between it and the air
motor when the valve is closed (see preceding
Pressurized Fluid Hazard And Moving Parts
Hazard WARNING). This bleed valve should be
easily accessible and located downstream from the
air regulator. It can be used for a safety lockout.
Pump Air Regulator (D) controls pump speed and
outlet pressure by adjusting the air pressure to the
pump. It is located on the air control panel up-
stream from the bleed-type master air valve.
Auto Depressurization Valve (P) exhausts air from
the system at shut off. The built in timer delays
start up to allow material to heat thoroughly.
Ram Air Regulator controls the air pressure to the
ram. There are separate air regulators to control
the ram pressure in the up and down directions.
Ram Air Supply Hose (H) connects the ram air
regulator to the air manifold.
Follower Blow-off Valve (N) controls the air pres-
sure to the follower blow-off.
FRL (filter, regulator, lubricator) (A), (D), and (I)
conditions the air to the ram and the pump. The
pump air regulator is located in this assembly. The
ram air is taken from this assembly; an air line tube
connects the FRL and the ram air control module.
Fluid Line Accessories
A fluid regulator (K) controls fluid pressure to the
gun/valve, and dampens pressure surges. Install the
fluid regulator in the position shown in the Typical
Installation, using adapters as necessary.
Vent Hood Kit
The vent hood assembly is designed to efficiently draw
fumes to the factory exhaust system during drum
change-out. This assembly requires connection to a
factory ventilation system that draws a minimum air
flow of 8.4 m3/min (300 scfm). This kit is required for
Polyurethane Reactive (PUR) applications.

11309077
Installation
The installation procedure includes:
locating and installing the ram
electrically connecting hoses to the electrical con-
trol panel
grounding the system
connecting the electrical control panel to a power
source
checking resistance
setting controls on the electrical control panel
starting up the system
initially loading material
Installing the Ram
To install the ram, follow the procedure below. Refer to
the Ram Mounting and Clearance Dimensions drawing
(Fig. 43 on page 73) for ram mounting and clearance
dimensions.
1. Select a convenient location for the equipment.
Check that there is sufficient overhead clearance
for the pump and ram when the ram is in the fully
raised position. Make sure the air regulators for the
pump and ram are fully accessible.
2. Level the base of the ram, using metal shims.
3. Using the holes in the base as a guide, drill holes
for 13 mm. (1/2”) anchors. Bolt the ram to the floor
anchors, which are long enough to prevent the unit
from tipping. Refer to the Dimensional Drawing on
page 73.
Electrically Connect Hoses to the
Electrical Control Panel
WARNING
FIRE HAZARD
Only use hoses that have a maximum
wattage less than or equal to 1250
watts. Using hoses with higher maxi-
mum wattage could create a runaway
temperature condition.
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 back of the
electrical control panel (Fig. 3).
1. Connect the plug from hose 1 to the Hose 1/Gun 1
receptacle (S).
2. Connect the plug from hose 2 to the Hose 2/Gun 2
receptacle (T).
Fig. 3
Rear View of Electrical Control Box
S
T

12 309077
Installation
Ground The System
Ground the supply unit as instructed here and in the
individual component manuals.
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock:
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 14.
Refer to your local code for the requirements for
a “true earth ground” in your area.
Also read and follow the warnings on page 5.
To reduce the risk of static sparking, ground the pump,
object being sprayed, and all other spraying/dispensing
equipment used or located in the spraying/dispensing
area. Check your local electrical code for detailed
grounding instructions for your area and type of equip-
ment.
Air and Fluid Hoses:
Use only electrically conductive hoses.
Dispensing/Spray Gun
Follow the dispensing/spray gun grounding instruc-
tions.
Fluid Supply Container
Ground the container according to your local code.
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 continuity.
Maintain Grounding Continuity When Purging Or
Relieving Pressure
Follow the instructions in your separate gun manual for
safely grounding your gun while purging.

13309077
Installation
Connecting the Electrical Control Panel to
a Power Source
The electrical control panel (Fig. 4) comes already
attached and wired to the ram, however before the
supply unit becomes functional, you must connect the
electrical control panel to a power source.
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.
Fig. 4
480 VOLTS
Have a trained electrician connect the electrical control
panel (Fig. 4) to a grounded electrical source that has
the required service ratings:
CAUTION
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty will be voided.
Control
Panel
Part No.
VAC Hz Phase Full
Load
Amps
C32429 480 60 3 34.6
For information about specific terminal locations and
connections, see Schematics on page 64 for wiring
diagram information.
To connect the control panel to the electrical source:
1. Create an opening in the control panel‘s housing
for the conduit that will enclose the wire from the
facility’s power source.
2. Thread the wire from the power source into the
control panel housing, and then connect the power
source wires to the appropriate terminals on the
DISCONNECT switch.

14 309077
Installation
Check the Resistance Between the Supply
Unit and the True Earth Ground
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.
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.
NOTE: Use a meter that is capable of measuring
resistance at this level.
Checking Resistance
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.
You can check the resistance of the supply unit’s heat
sensors and heaters.
Sensor Resistance Checks
WARNING
ELECTROCUTION HAZARD
To reduce risk of injury or damage to
equipment, conduct these electrical
checks with the main disconnect OFF.
The supply unit includes six heat sensors and control-
lers for each of the six heated zones. 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. Refer to Schematics on page 64 for wiring
diagram information.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in the chart
below.
NOTE: Check resistance at ambient room tempera-
ture (63 – 77 Fahrenheit).
RTD Sensors
Zone Component Terminals Value Range
1 Follower 1321 &
1331
97.4 – 102.8 ohms
2 Dispense
Hose 1
1521 &
1531
97.4 – 102.8 ohms
2 Dispense
Hose 2
1661 &
1671
97.4 – 102.8 ohms
4 Pump 1391 &
1401
97.4 – 102.8 ohms
5 Dispense
Gun 1
1591 &
1601
97.4 – 102.8 ohms
6 Dispense
Gun 2
1731 &
1741
97.4 – 102.8 ohms

15309077
Installation
Heater Resistance Checks
WARNING
ELECTROCUTION HAZARD
To reduce risk of injury or damage to
equipment, conduct these electrical
checks with the main disconnect OFF.
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 Schematics on page 64 for wiring
diagram information.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in the chart
below.
NOTE: Check resistance at ambient room tempera-
ture (63 – 77 F).
Heaters
Value Range
Zone Component Terminals 480 VAC
1 Follower 3L1 & 3L2 25.5 ohms + 2.6 ohms
3L2 & 3L3
3L3 & 3L1
2 Dispense Hose 1 2002 & 1092 See Technical Data supplied w/Hose
3 Dispense Hose 2 2042 & 1092 See Technical Data supplied w/Hose
4 Pump 5L1 & 5L2 187.2 ohms + 24 ohms
5Dispense Gun 2 2062 & 1092 See Technical Data supplied w/Hose
6Dispense Gun 2 2062 & 1092 See Technical Data supplied w/Hose

16 309077
Installation
Overview of the Temperature Controller Settings
The basic program settings for each temperature controller satisfy most application needs. These settings are pre-
set at the factory, but can be changed. The input type, temperature scale, and over temperature alarm point are
the critical controller settings that you must check before doing an auto-tune or using any controller in normal op-
eration. Figure 5 provides an illustration of the basic program settings. Refer to the Appendix on page 75 for
more information.
FUNCTION
MODE
LEVEL
MODE
Fig. 5

17309077
Installation
Setting Temperature Controllers
WARNING
HOT MATERIAL AND EQUIPMENT
HAZARD
This supply unit is rated for operation at
206C (400F) maximum. Setting the
temperature higher than 206C (400F)
can result in personal injury or equip-
ment damage.
The temperature controller functions for each of the six
heated zones are preset at the factory.
Follower Supply Pump
Dispense Hose 1 Dispense Gun 1
Dispense Hose 2 Dispense Gun 2
However, the critical controller settings must be
checked before using the controllers for the first time
and after replacing a defective controller. For removal
and replacement procedures, see Service on page 44.
Read the information on this page which describes
how to use the controllers. For the Setting List, which
defines each function mode parameter name, see the
Appendix on page 75.
Before you begin to check the controller programs,
make sure that the supply unit has been properly
grounded, checked for resistance, and safely con-
nected to a power source.
Controller Programming Notes
Fig. 6 shows an example of the E5CK temperature
controller.
Fig. 6
XY
Z
DISPLAY 1
DISPLAY 2
W
MANU
Table 1 describes the operation indicators for the
E5CK temperature controller.
Table 1. Operation Indicators
Indicator Description
Display 1 Displays the process value or pa-
rameter symbols.
Display 2 Displays the set point, variable, or
parameter settings.
OUT1 Lit when control output 1 is on.
OUT2 Lit when control output 2 is on.
SUB1 Lit when the output function as-
signed to auxiliary output 1 is on.
MANU Lit when the manual operation mode
is being used.
STOP Lit when control operation has been
stopped.
RMT Lit during remote operation.
AT Flashes during auto-tuning.
Table 2 describes the operation keys for the controller
Use the keys when programming the controllers.
Table 2. Operation Keys
Key Description
A/M key The A/M key (W) switches between
auto and manual operation.
Mode key Pressing the key (X) for more than
one second changes the display
from the level mode (Display 1) to
the function mode (Display 2), or
vice versa.
Pressing the key for less than one
second displays the menu options in
each level.
Adjust the settings using the arrow
keys when the values are displayed
in the function mode.
Down key The down key (Y) decrements or de-
creases the values or settings on
display 2.
Up key The up key (Z) increments or in-
creases the values or settings on
display 2.
Set Temperature Controllers to Auto Mode
The procedures in this manual are documented to
program the temperature controllers with the heat
zones switched to the auto mode. Before starting the
programming process, make sure the MANU light
indicator is turned off. Press the A/M key (W) on each
temperature controller to switch the heated zone to the
auto mode of operation. See Fig. 6.

18 309077
Installation
First Steps – Programming Tip
Perform the following procedures to program each
controller without the heating zone turned on.
NOTE: Refer to Figure 6, Table 1, and Table 2 for
user information about the E5CK controller.
Setting the Controller to the Stop Mode
To set the controller to the stop mode, perform the
following procedure:
1. Immediately after applying power to the unit, press
the mode key (X) twice to display the Run/Stop
option, which is displayed in Level 0 (Fig. 7).
2. If the Run mode is displayed, press the up arrow
key (Z) to change the setting to the Stop mode
(See Fig. 7). Verify that the stop light turns on.
NOTE: In the Stop mode, configuration changes can
be made to the controller without heating the
zone powered-on.
Fig. 7
RUN/STOP
FUNCTION
FUNCTION
MODE
LEVEL
MODE
Disabling the Alarm 2 Setting
To avoid actuating the alarm, perform the following
procedure to disable the alarm 2 setting while in the
stop mode:
1. Change display 0 to show the Setup mode, as
shown in Fig. 8.
2. Using the down arrow key (Y), change display 2 to
show the alarm 2 type, as shown in Fig. 8.
Fig. 8
ALARM 2 TYPE
SETTING
LEVEL
MODE
FUNCTION
MODE
3. Go to the next procedure to check the three critical
controller settings.
Checking Critical Controller Settings
The critical controller settings must be checked before
auto tuning a controller or using any of the controllers
in normal operation.
To check the critical controller settings, complete the
following procedures in the given order for each E5CK
controller:
Checking the input type setting
Checking the temperature scale setting
Checking the over temperature alarm point setting
Checking the Input Type Setting
To check the input type setting, perform the following
procedure:
1. Change from the function mode to the level mode
using the mode key (X).
2. Change display 1 to show the Setup mode, as
shown in Fig. 9.
3. Change from the level mode to the function mode
using the mode key (X).
4. Using the down arrow key (Y), change display 2 to
show the input type function, as shown in Fig. 9.
5. Change the input type code setting to show the
numeral 1, as shown in Fig. 9.
Fig. 9
INPUT TYPE
SETTING
LEVEL
MODE
FUNCTION
MODE
6. Go to the next procedure to check the temperature
scale setting.

19309077
Installation
Checking the Temperature Scale Setting
To check the temperature scale setting, perform the
following procedure:
1. Using the down arrow key (Y), change display 2 to
show the temperature scale function, as shown in
Fig. 10.
2. Change the temperature scale setting to show the
letter F, as shown in Fig. 10.
Fig. 10
TEMPERATURE
SCALE SETTING
LEVEL
MODE
FUNCTION
MODE
Checking the Over Temperature Alarm Point
Settings
There are three over temperature alarm point settings.
To check each setting, perform the following proce-
dure:
1. To check the alarm 2 type function, perform the
following steps:
a. Using the down arrow key (Y), change display
2 to show the alarm 2 type function, as shown
in Fig.11 .
b. Change the setting to show the value: 2, as
shown in Fig. 11.
Fig. 11
OVER TEMPERATURE
ALARM 2 TYPE
LEVEL
MODE
FUNCTION
MODE
2. To check the alarm value 1 function, perform the
following steps:
a. Change from the function mode to the level
mode using the mode key (X).
b. Change display 1 to show the Level 1 mode,
as shown in Fig. 12.
c. Change from the level mode to the function
mode using the mode key (X).
d. Using the down arrow key (Y), change display
2 to show the alarm value 1 function, as
shown in Fig. 12.
e. Change the alarm value 1 code setting to
show the value: 00, as shown in Fig. 12.
Fig. 12
ALARM VALUE 1
SETTING
LEVEL
MODE
FUNCTION
MODE
3. To check the alarm value 2 function, perform the
following steps:
a. Using the down arrow key (Y), change display
2 to show the alarm value 2 function, as
shown in Fig. 13.
b. Change the alarm value 2 code setting to
show the value: 35, as shown in Fig. 13.
Fig. 13
LEVEL
MODE
FUNCTION
MODE
ALARM VALUE 2
FUNCTION
4. Go to the next procedure to auto tune all the zones
at once.

20 309077
Installation
Auto Tuning the Controllers
After the critical controller settings have been checked,
complete the following procedures:
Changing the Set Point
Auto Tune Process
Changing the Set Point
During the auto tune process, the temperature can rise
as much as 40 higher than the set point. If the mate-
rial reacts adversely to higher temperatures, the set
point should be lowered approximately 40 to avoid the
adverse reaction. After the auto tune process is
completed, the set point can be raised back to the
desired temperature.
To change the set point, perform the following proce-
dure:
1. Change from the function mode to the level mode
using the mode key (X).
2. Change display 1 to show the Level 0 mode, as
shown in Fig. 14.
3. Change from the level mode to the function mode
using the mode key (X).
4. Using the down arrow key (53), change display 2
to show the set point function, as shown in Fig. 14.
5. Change the set point setting by performing Per-
form step 5.a or 5.b depending on your situation in
the auto tune process. See Fig. 14.
a. If starting the auto tune process, lower the set
point setting approximately 40 to avoid an
adverse material reaction.
b. If finishing the auto tune process, reset the set
point, raising the setting to the desired material
temperature.
Fig. 14
SET POINT
FUNCTION FUNCTION
MODE
LEVEL
MODE
NOTE: Display 1 shows the actual temperature.
Display 2 shows the set point.
6. Repeat steps 1 through 5 to change the set point
for the other five controllers.
7. Go to the next procedure to perform the auto tune
process.
Auto Tune Process
The auto tune process adjusts the P, I, and D settings
to the optimal level at each controller.
With the unit at ambient temperature, auto tune each
temperature controller by performing the following
procedure:
NOTE: The auto-tuning process can take from 5 min-
utes to 2 hours to complete. The controllers
can be auto-tuned at the same time.
1. Using the down arrow key (Y), change display 2,
which should show the stop mode.
2. Press the down arrow key (Y) again to change the
status to the run mode, as shown in Fig.15. Verify
that the stop light is off (see Fig. 6.).
NOTE: In the run mode, the zones are heated while
the configuration changes are programmed
into the controller. Auto tuning cannot be exe-
cuted when the controller is in the stop mode.
Fig. 15
RUN/STOP
FUNCTION FUNCTION
MODE
LEVEL
MODE
3. Immediately after activating the run function,
change from the function mode to the level mode
using the mode key (X).
4. Change display 1 to show the Level 1 mode, as
shown in Fig. 16.
5. Change from the level mode to the function mode
using the mode key (X).