3000 psi (207 bar, 20.7 MPa) Maximum Fluid Working Pressure

Transcription

1 INSTRUCTIONS This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. First choice when quality counts Rev. A Part No Therm-O-Flow 2 Zone Heated Dispense System 3000 psi (207 bar, 20.7 MPa) Maximum Fluid Working Pressure 140 F (60 C) Maximum Operating Temperature Part No VAC, Single Phase, 2-Zone Control Panel Refer to page 2 for Table of Contents Part No Accessory Kit: 0.62 ID x 15 Feet (4.6 m) Heated Hose Ultra-lite 6000 Dispense Gun Note This control panel will accept up to two heated hoses, or one heated hose and one heated gun. The heated hoses are 25 ft. (.87 m) in length (max). 9055A GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN COPYRIGHT 1999, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001

2 Table of Contents Symbols Warnings Typical Installation System Components Selecting a Location for the Control Panel Installation Installing the Control Panel Connecting Hoses to the Control Panel Grounding The System Connecting Power to the Control Panel Checking the Resistance Between the Supply Unit and the True Earth Ground Overview of the Temperature Controller Settings Setting the Temperature Controllers Auto Tuning the Controller Recording or Changing the Site P, I, and D Settings Graco Factory P, I, and D Settings Removing/Replacing a Controller from/to an Unused Heated Zone Operation Pressure Relief Procedure Starting the System System Shutdown Control Panel Troubleshooting Service Removing the E5CK Controller Replacing the E5CK Controller Parts Part No , 2-Zone Heated Dispense System Part No , 480 VAC 2-Zone Control Panel (interior) Part No , 480 VAC 2-Zone Control Panel (exterior) Schematics VAC 2-Zone Electrical Control Lines VAC 2-Zone Electrical Control Lines Dimensions Control Panel Mounting and Clearance Dimensions Technical Data Related Publications Appendix Setting List Graco Standard Warranty Graco Phone Number

3 Symbols Warning Symbol 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. 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 100 psi (6.9 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 31. Be sure that all spray/dispensing equipment and accessories are rated to withstand the maximum 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 manufacturer 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 HOT SURFACE AND FLUID HAZARD Heated fluid can cause severe burns and can cause equipment surfaces to become very hot. Do not set the temperature controls higher than 140 F (60 C). 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. 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 operates before dispensing. Lock the gun/valve trigger safety when you stop dispensing. Follow the Pressure Relief Procedure on page 18 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 immediately. 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

5 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 Grounding the System on page 9. Do not use this equipment with flammable liquids. Keep the dispense area free of debris, including solvent, rags, and gasoline. If there is any static sparking while using the equipment, stop dispensing immediately. Identify and correct 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 electrician only. 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 18. 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

6 Typical Installation KEY A B C 2-Zone control panel 1.0 NPT (m) fluid inlet connector 5/8 I.D. x 15 ft PTFEcore heated hose D E Flow gun (part of the asscessory kit) Straight hose swivel F G Jumper cable (part of the asscessory kit) Hose hanger (mounted by customer) A C G D E B F 9055A Fig

7 Typical Installation The typical installation discussed below is only a guide for selecting and installing system components and accessories. Contact your Graco distributor or Graco Technical Assistance for help in designing a system to suit your particular needs. Accessory equipment for use with this system is listed in the Accessories section on page NO TAG. System Components Before you install the system you should be familiar with the parts discussed below. For more information, refer to Fig. 1, A Typical Installation, on page 6. 2-Zone Control Panel (A) is the electrical control device that transmits heat and can accept up to two heated hoses, or one heated hose and one heated gun. The control panel includes the temperature controllers that are programmed by the operator. Heated Hose Accessory Kit, is supplied with the following components: 1.0 npt(m) fluid inlet connector (B) that is used to connect the fluid supply line to the heated hose. Heated hose (C) connects between the fluid supply line and a dispense device, such as a heated gun or dispense valve. Flow gun (D) connects to the heated hose and is used as the dispense device to apply the temperature conditioned fluid to the targeted object. Straight hose swivel (E) allows the operator to turn the flow gun in various directions while keeping the heated hose straight. Jumper cable (F) connects a second heated hose to the fluid supply line. In this system, the jumper cable connections can be used for two heated hoses, or one heated hose and one heated gun. Hose hanger (G) allows the operator to hang the heated hose at a fix point for support and to move the hose around freely without crimps during usage. Selecting a Location for the Control Panel When selecting a location for the control panel, keep the following in mind: Control Panel 1. There should be sufficient space for installing, servicing, and using the equipment. Make sure there is sufficient overhead clearance for the control panel. Make sure the temperature controllers for the control panel 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. When you bolt the control panel to the floor, make sure: you are able to level the base of the control panel using metal shims you have anchors long enough to prevent the unit from tipping. Heated Hoses When installing a heated hose, make sure the hose is properly sized for your system

8 Installation The installation procedure includes: Installing the control panel Connecting the heated hoses to the control panel Grounding the system Connecting power to the control panel Checking the resistance between the supply unit and the true earth ground Checking resistance Overview of the temperature controller settings Setting the temperature controllers Auto tuning controllers Recording or changing the site P, I, and D settings Graco P, I, and D settings Removing/replacing a controller from/to an unused heated zone Installing the Control Panel The control panel can be used to: heat one heated hose with an unheated gun. This hose connects to the DH1 receptacle. See Fig. 2. heat two heated hoses with unheated guns. These hoses connect to the DH1 and DH2 receptacles. See Fig. 2. Preparing to Install the Control Panel Before installing the control panel: See component manuals for specific data on component requirements. Data presented here pertains to the Therm-O-Flow control panel only. Have all system and subassembly documentation available during installation. Be sure all accessories are adequately sized and pressure-rated to meet the system s requirements. EQUIPMENT MISUSE HAZARD The Therm-O-Flow control panel and hose/sun kit weigh approximately 463 kg (210 lbs), and should never be moved or lifted by one person. Use adequate personnel and support devices when mounting, moving or handling the control assembly to prevent equipment damage or personal injury. Install the control panel in accordance with your local electrical codes. Either bolt the unit to the wall, or bolt the unit to the floor, or both. Bolting the Control Panel to a Wall To install the control panel in a permanent location: 1. Select a convenient location for the control panel. 2. Make sure there is sufficient overhead clearance for the servicing the control panel. 3. Level the base of the control panel, using metal shims. 4. Secure the control panel enclosure against a wall with two 3/8 bolts through the.44 diameter holes. Fig. 2 Bottom View of Control Panel Bolting the Control Panel to the Floor If necessary, use the holes in the base to prevent the control panel from tipping, as follows: 1. Drill holes for 1/2 in. (13 mm) anchors. (The floor anchors must be long enough to prevent the unit from tipping.) 2. Bolt the control panel to the floor. Refer to the dimensional drawing on page Using the holes in the base as a guide, drill holes for 13 mm. (1/2 ) anchors. Bolt the control panel to the floor with anchors that are long enough to prevent the unit from tipping. Refer to the dimensional drawing on page

9 Installation Connecting the Heated Hoses to the Control Panel 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 runaway temperature condition. Assemble the hose and gun components as needed. For information on connecting the hose and gun components, follow the gun s instructions. Electrically connect the hoses to the electrical control panel. The connectors are located on the bottom of the electrical control panel (Fig. 3). 1. Connect the plug from hose 1 to the Hose 1 receptacle (50). 2. Connect the plug from hose 2 to the Hose 2/Gun 1 receptacle (51) 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 10. 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 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 equipment. Fluid Hoses: Use electrically conductive hoses only. Dispensing/Spray Gun Follow the dispensing/spray gun grounding instructions. Fluid Supply Container Ground the container according to your local code. Object Material is Applied To Ground the object according to your local code. Fig. 3 Bottom View of Control Panel Grounding the System Ground the dispense equipment as instructed here and in the individual component manuals. Material Pails Ground the material pails according to your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place the pail 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

10 Installation Connecting Power to the Control Panel Have a qualified electrician connect the control panel (Fig. 4) to a grounded electrical source that has the following required service ratings: ELECTRIC SHOCK HAZARD Do not connect the control panel to a power source unless you are a trained electrician. 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 may be damaged and the warranty will be voided. Description Requirements Vac: 480 Hz: 60 Phase: 1 Full Load Amps: 6.2 For information about specific terminal locations and connections, see Schematics on page 28 for wiring diagram information. Perform the following procedure 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. Checking 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. 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. 1 3/8 DIAMETER POWER ENTRY Top View of Control Panel Fig A

11 Installation Checking Resistance ELECTRIC SHOCK HAZARD Do not open the 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. Sensor Resistance Checks ELECTROCUTION HAZARD To reduce risk of injury or damage to equipment, conduct these electrical checks with the main disconnect OFF. The control panel includes two heat sensors and a temperature controller for each heated zone. To check sensor resistance, do the following: 1. Make sure the power is off and that the disconnect switch is in the OFF position. 2. Make electrical resistance checks for the components. Refer to Schematics on page 28 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 temperature (63 77 F). Heater Resistance Checks 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 components. Refer to Schematics on page 28 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 temperature (63 77 F). Heaters for 2-Zone Control Panel Zone Component Terminals 1 Dispense Hose 1 Heater 2 Dispense Hose 2 or Gun 1 Heater 1752 & & 1773 Value Range See Technical Data supplied w/hose See Technical Data supplied w/hose RTD Sensors 2-Zone Control Panel Zone Component Terminals Value Range 1 Hose & ohms Hose 2 or Gun & ohms

12 Installation Overview of the Temperature Controller Settings The basic program settings for each temperature controller satisfy most application needs. The program settings are preset at the factory and should not be changed unless required. Figure 5 provides an illustration of the basic program settings. Refer to the table on page xx to select PID values for the specific component that controller is designated to control. For more information regarding the temperature controllers, refer to Appendix on page 32 LEVEL FUNCTION Fig

13 Installation Setting the Temperature Controllers HOT MATERIAL AND EQUIPMENT HAZARD This dispense kit is rated for operation at 60C (140F) maximum. Setting the temperature higher than 60C (140F) can result in personal injury or equipment damage. The fluid hardware is not insulated to protect the user from burns at tempertures higher than 60C (140F) The temperature controller functions for the heated zones are preset at the factory. 2-Zone Temperature Controllers Zone Temperature Controller 1 Dispense Hose 1 2 Dispense Hose 2 or Dispense Gun 1 Table 1 describes the operation indicators for the E5CK temperature controller. Table 1. Operation Indicators Indicator Display 1 Display 2 OUT1 OUT2 SUB1 MANU STOP RMT AT Description Displays the process value or parameter symbols. Displays the set point, variable, or parameter settings. Lit when control output 1 is on. Lit when control output 2 is on. Not used. Not used. Lit when control operation has been stopped. Not used. Flashes during auto-tuning. Table 2 describes the operation keys for the controller Use the keys when programming the controllers. Table 2. Operation Keys For more information about using the temperature controllers, refer to the temperature controller instructions included in the control panel documentation. Before you begin to check the controller programs, make sure that the control panel has been properly grounded, checked for resistance, and safely connected to a power source. Controller Programming Notes Fig. 6 shows an example of the E5CK temperature controller. MANU DISPLAY 1 DISPLAY 2 Key A/M key Mode key Down key Up key Description The A/M key (51) switches between auto and manual operation. Pressing the key (52) 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. The down key (53) decrements or decreases the values or settings on display 2. The up key (54) increments or increases the values or settings on display Fig

14 Installation Auto Tuning the Controllers Complete the following procedures to auto tune the temperature controllers: 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 material 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 procedure: 1. Change from the function mode to the level mode using the mode key (52). 2. Change display 1 to show the Level 0 mode, as shown in Fig Change from the level mode to the function mode using the mode key (52). 4. Using the down arrow key (53), change display 2 to show the set point function, as shown in Fig Change the set point setting by performing Perform step 5.a. or 5.b. depending on your situation in the auto tune process. See Fig. 7. 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. SET POINT FUNCTION LEVEL FUNCTION 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 minutes to 2 hours to complete. The controllers can be auto-tuned at the same time. 1. Using the down arrow key (53), change display 2, which should show the stop mode. 2. Press the down arrow key (53) again to change the status to the run mode, as shown in Fig.8. 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 executed when the controller is in the stop mode. RUN/STOP FUNCTION Fig. 8 LEVEL FUNCTION 3. Immediately after activating the run function, change from the function mode to the level mode using the mode key (52). 4. Change display 1 to show the Level 1 mode, as shown in Fig Change from the level mode to the function mode using the mode key (52). NOTE: Display 1 shows the actual temperature. Display 2 shows the set point. Fig

15 Installation Auto Tune Process (Continued) 6. Using the down arrow key (53), change display 2 to show the auto tune OFF function, as shown in Fig. 9. AUTO TUNE FUNCTION Fig. 9 LEVEL FUNCTION 7. Press the up arrow key (54) twice to display the AT-2 function (Fig. 10). NOTE: The auto tune type 2 process can take from 5 minutes to 2 hours to complete. 9. Change from the function mode to the level mode using the mode key (52). 10. Change display 1 to show the Level 0 mode, as shown in Fig Change from the level mode to the function mode using the mode key (52). 12. Using the down arrow key (53), change display 2 to show the temperature display function, as shown in Fig Return the controller to the temperature display mode. This step does not interrupt or affect the auto tune process for any controller (Fig. 11). LEVEL LEVEL TEMPERATURE DISPLAY FUNCTION FUNCTION AUTO TUNE TYPE-2 SETTING Fig. 10 FUNCTION 8. Wait 2 to 3 seconds for the AT light (Fig. 10) to start flashing. This indicates the start of the auto tune process. When the AT light stops flashing, the auto tune process is complete. Fig Repeat steps 1 through 13 to auto tune the other five controllers. 15. Go to the next procedure: recording the site P, I, and D settings

16 Installation Recording or Changing the Site P, I, and D Settings Programmed controllers sometimes fail. To avoid doing a lengthy auto tune after replacing a controller, record the P, I, and D settings for your site by performing the following procedure: NOTE: P denotes proportional band. I denotes integral time, and D denotes derivative time. 1. Change from the function mode to the level mode using the mode key (52). 2. Change display 1 to show the Level 1 mode, as shown in Fig Change from the level mode to the function mode using the mode key (52). 4. Using the down arrow key (53), change display 2 to show the proportional band (P) setting, as shown in Fig Using the down arrow key (53), change display 2 to show the integral time (I) setting, as shown in Fig. 13. INTEGRAL TIME SETTING Fig. 13 LEVEL FUNCTION 7. Record the I setting for the controller in Table Using the down arrow key (53), change display 2 to show the derivative time (D) setting, as shown in Fig. 14. LEVEL LEVEL PROPORTIONAL BAND SETTING FUNCTION DERIVATIVE TIME SETTING FUNCTION Fig Record the P setting for the controller in Table 3. Table 3. Site P, I, and D Settings Category P I D Hose 1 Hose 2/Gun 1 Fig Record the D setting for the controller in Table Repeat the procedure to record the P, I, and D settings for each heated zone and E5CK controller used at your site. 11. Keep the recorded settings in a safe place for later reference, in case a programmed controller fails. The auto-tune process is complete. As an option, go to the next procedure: Graco Factory P, I, and D settings

17 Installation Graco Factory P, I, and D Settings Table 4 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 4. Graco Factory P, I, and D Settings Category P I D Unit Voltage Hose ALL Gun ALL Compare the P, I, and D settings that you recorded for your site with the Graco factory P, I, and D settings for standard control panels. Removing/Replacing a Controller from/to an Unused Heated Zone If one of the two temperature controllers is not being used for your current application, you must remove the unused controller. If any heat zone is not being used and its temperature controller is not removed, the supply unit will experience a high temperature fault when power is applied to the supply unit. To remove the unused controller, do the following: 1. Refer to the Service section. 2. Complete the Removing the E5CK Controller procedure on page 23. To replace the controller, do the following: 1. Refer to the Service section. 2. Complete the Replacing the E5CK Controller procedure on page 24. NOTE: System is shipped with the Hose 1 controller installed. The Hose 2/Gun 1 controller is shipped loose with the control panel hole plugged. The Hose 2/Gun 1 controller is shipped with preset factory PID settings

18 Operation The operation procedures include: Pressure relief procedure Starting the system System shutdown Reading the control panel indicators Pressure Relief Procedure This procedure describes how to relieve pressure from the dispense hose/gun. Use this procedure whenever you shut off the dispenser/sprayer and before checking or adjusting any part of the system, to reduce the risk of serious injury. MOVING PARTS HAZARD Follow the Pressure Relief Procedure below before checking or repairing the ram or any other part of the system and when shutting down the system. Keep hands and fingers away from the follower plate, fluid pump inlet, and lip of the fluid container when raising or lowering the ram to reduce the risk of pinching or amputating hands or fingers. During operation, also keep hands and fingers away from limit switches to reduce the risk of pinching or amputating hands or fingers. The material and equipment will be hot! To reduce risk of injury, wear eye protection, gloves and protective clothing when installing, operating, or servicing this dispensing system. INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, moving parts, follow the Pressure Relief Procedure whenever you: are instructed to relieve the pressure stop spraying/dispensing check or service any of the system equipment install or clean the spray tip/nozzle To relieve pressure in the dispense hose/gun, perform the following procedure: 1. Lock the gun/valve trigger safety. 2. Shut off the main air supply to the pump. 3. Unlock the gun/valve trigger safety. 4. Hold a metal part of the gun/valve firmly to the side of a grounded metal drum/pail, and trigger the gun/valve to relieve pressure. 5. Lock the gun/valve trigger safety. If you suspect that the tip/nozzle or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, very slowly loosen the tip retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear the tip/nozzle or hose. HIGH PRESSURES CAN CAUSE SE- RIOUS PERSONAL INJURY. Be sure to OPEN THE DISPENSE VALVE DURING SYSTEM HEATUP to alleviate pressure which might occur in the system due to material expansion

19 Operation Starting the System To start the system: 1. Verify that the main disconnect is ON. 2. Turn the CONTROL ON switch to ON. 3. Open the dispense valve over a waste container to allow the material to expand. This will prevent damage to the equipment. 4. After each of the dispense zones is heated to operating temperature. 5. Make sure that the material supply line is open. 6. Dispense some material into a waste container. 7. Verify the flow rate is correct; adjust if required. With the material heated, and the flow rate corrected as necessary, the system is ready for operation. System Shutdown To shut down the control panel, do the following: 1. On the control panel: a. Turn the CONTROL ON switch to OFF. b. Turn OFF the main electrical disconnect. To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure (page 18). 2. Relieve the pressure. 3. Close the material supply line. HOT SURFACE AND FLUID HAZARD To reduce risk of injury, wear eye protection, gloves and protective clothing when installing, operating, or servicing this system. PRESSURIZED FLUID HAZARD To reduce the risk of serious bodily injury, such as fluid injection or splashing fluid in the eyes or on the skin, ALWAYS wear eye protection and protective clothing when installing, operating, or servicing this system. Do not over pressurize the system, as this could result in serious injury or damage to the equipment. NOTE: It is normal for the pump to stop moving if the dispense gun or other fluid valve is closed

20 Operation Reading the Control Panel Indicators Use the table and Fig. 16 to read the indicators on the control panel. For information on setting the temperature controllers, see Setting the Temperature Controllers on page 13. Temperature Out of Range Should any of the temperatures go out of the preset range for any of the zones, power to the heated components is interrupted, and the HIGH TEMPERATURE ALARM light goes ON. The alarm automatically goes OFF and the system resets when the temperature is back in range. Light# Indicator: Indicator Meaning: Light is: 61 Ground Detected ON Power is on and ground is detected. 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. OFF Power is off or ground is not detected. 62 Control On ON The CONTROL ON switch (64) is set to either the ON or AUTO position and power is being supplied to the control panel components. OFF The CONTROL ON switch (64) is set to the OFF position. 63 High Temperature Alarm ON OFF The temperature of any of the heated components is out of range, and the power to all heated components is interrupted. None of the heated components have temperatures that are out of range. GROUND DETECTED GROUND DETECTED OVERTEMPERATURE FAULT Fig

21 Operation Control On Power On Ground Detected 61 Power On Ground Detected 64 Off Auto On 63 Overtemperature Fault Fig

22 Control Panel Troubleshooting Note: The control panel lights are the Push to Test type. Problem Cause(s) Solution(s) Disconnect is ON, but no indicator One or more fuses has (have) been Replace the blown fuse(s) lights are lit blown High Temperature Alarm lights High Temperature Alarm indicator is lit before the unit has heated up One of the Ground Detected indicators comes on Unused temperature control zone flashes Error indication and the High Temperature Alarm lights. After adding a second hose or a heated gun, the second temperature zone does not function. The temperature of a heated component has gone out of range. One or more temperature controllers has different alarm value settings. One or more temperature controllers correspond to zones that are not in use. The control panel has detected that one of the power leads is connected to ground. A problem may exist with the system power connections. Unused temperature controller is waiting for a sensor and detecting an alarm condition. A problem may exist with the system power connections. Control panel automatically turns off power to components. Panel turns power back on when overheated components reach appropriate temperatures. Set the alarm values on all temperature controllers to the same settings. Turn off the unused temperature controller(s). See procedure on page 17. To reduce the risk of serious injury, have the power connections checked by a qualifed electrician. With power off, disconnect wire 1142 from terminal 4 on the unused controller. Insulate the bare end of the wire. Unused zone was disconnected. With power off, reconnect wire 1142 to terminal 4 on the second temperature controller

23 Service Removing the E5CK Controller To remove the E5CK controller, do the following: a. If applicable, remove the snap pin that secures the terminal cover on the E5CK controller. Remove the terminal cover (Fig. 18). ELECTRIC SHOCK HAZARD Do not open the 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. TERMINAL COVER 1. Check to ensure that main electrical power is turned OFF. 2. Check to ensure that the system CONTROL ON switch on the control panel is turned to OFF. 3. If required, perform the following steps to remove the defective the E5CK controller housing from the control panel (Fig. 17). ADAPTER CONTROL PANEL Fig. 18 SNAP PIN 7986A b. Remove the mounting screws from the adapter on the E5CK controller. c. Disconnect the wires from the E5CK controller terminals. Label each wire to match the controller terminal numbers. Fig. 19 shows the rear view of the E5CK controller. LOCKING TABS RELEASE TABS GASKET 7986A Fig A Fig. 17 d. At the front of the control panel, squeeze the locking tabs and the release tabs on both sides of the controller. Pull the controller straight out of the control panel

24 Service Replacing the E5CK Controller To replace the E5CK controller, do the following: NOTE: The E5CK controller is part of the Temperature Controller Kit, P/N ELECTRIC SHOCK HAZARD Do not open the control panel, unless you are a trained professional. 5. At the back of the control panel, install the adapter on the E5CK controller (Fig. 20). 6. Tighten the two mounting screws on adapter. To avoid damaging the E5CK controller, tighten the screws alternately. Do not over tighten the screws. 7. Connect the wires to the E5CK controller terminals (Fig. 21). Do not over tighten the screws. Before opening the control panel, make sure that all power has been removed from the control panel. 1. Check to ensure that main electrical power is turned OFF. 2. Check to ensure that the system CONTROL ON switch on the control panel is turned to OFF. NOTE: Before inserting the replacement E5CK controller into the panel, make sure the gasket is in place. Fig A 3. Insert the E5CK controller into the mounting hole in the control panel (Fig. 20). 4. Push the controller straight into the control panel until the locking tabs on each side snap into place. ADAPTER CONTROL PANEL 8. If applicable, use the snap pin to install terminal cover on the E5CK controller (Fig. 22). TERMINAL COVER SNAP PIN LOCKING TABS Fig A RELEASE TABS Fig. 20 GASKET 7986A 9. After replacing the E5CK controller, you must complete the series of procedures that are listed under Setting Temperature Controllers on page 13 to program the controller settings

25 Parts Part No , 2-Zone Heated Dispense System Ref. Part No. Description Qty. No CONTROLLER, 480 VAC, 1 electrical 2-zone KIT, accessory; Includes items 1 2a 2h 2a VALVE, needle (pistol grip, 1 Ultra-lite flo-gun) 2b C08088 NOZZLE, 4 mm x 1/4 npt(m) 1 2c C20635 ADAPTER, 1 npt(m) x 1 1/16- JIC(m) x 45 1 Ref. Part No. Description Qty. No. 2d C34104 HOSE, heated, 3000 psi, 1 heated.62 id x 15 2e C20642 ADAPTER, 1 1/16-12 JIC x 1 1/2 npt (m) 2f C34130 HOSE, hanger 1 2g HOSE, swivel 1/2 npt (mxf) 1 2h C07738 CABLE, 25 extension, 14 pin m x f 1 1 2b 2f 2a 2d 2e 2g 2h 2 2c 9055A Fig

26 Parts Part No , 480 VAC 2-zone Control Panel (interior) Heat Sinks (Typical) TERMINALS V Fuses FU FNA 5 FU FNA 5 FU FNA 15 FU FNA 15 FU FNA 15 FU FNA 15 TOTAL (6) TYPE CE 6 Disconnect 120V Terminals GND GND (4) Spares TOTAL (27) Type CA1 Fuse (Typical) 7-day Timer Relay (Typical) Spare Parts Part Number Temperature Controller For information about other parts, contact your Graco distributor. Fig

27 Parts Part No , 480 VAC 2-zone Control Panel (exterior) Fig A

28 Schematics 480 VAC 2-Zone, Electrical Control, Lines A

29 Schematics 480 VAC 2-Zone, Electrical Control, Lines Notes: This panel was design to heat 2 (two) components only. The configurations are listed below: 1. One dispense hose (use DH1). 2. One dispense hose and one dispense gun (use DH1 and DG1). 3. Two dispense hoses (use DH1 and DH2). In configuration #2, the gun is electrically connected through hose #1. DH2 connector is not used. 9056A

30 Dimensions 2-Zone Electrical Control Panel Mounting and Clearance Dimensions 254 mm (10 ) 914 mm (36 ) 533 mm (21 ) Footprint of Control Panel Fig

31 Technical Data Unit Description Specification Control Panel Input power requirement 480 VAC, 60Hz, 1 phase Amps Temperature controllers (2) Dimensions Weight 6.2 Floating Amps 140 F (60 C) maximum temperature Type: PID* Tuning: Manual or Auto tune Sensor type: RTD 100 ohm 42 inches (1067 mm) high by 21 inches (533 mm) wide by 10 inches (254 mm) deep 210 lbs. (463 kg) with hose and gun kit Dispense Gun Maximum fluid working pressure 3500 psi (241 bar, 24 MPa) Temperature rating 60 C (140 F) maximum temperature Fluid inlet port 1/2 npt(f) Fluid outlet port 1/4 npt(f) Wetted components Fluid section: 17 4 PH Stainless steel Fluid tube: 300 series stainless steel Valve needle: Carbide and 17 4 stainless steel Other: Stainless steel, Viton, and polyurethane Dimensions 5.90 inches ( mm) height, 1.20 inches (30.48 mm) width, 8.05 inches ( mm) length Weight oz. (636 g) Heated Hose Maximum fluid working pressure 3000 psi (207 bar, 20.7 MPa) Length.62 id (1.57 cm) x 15 feet (4.6 m) Straight Swivel Maximum fluid working pressure 6000 psi (415 bar, 41.5 MPa) Fluid inlet/outlet ports 1/2 npt(m) x 1/2 npt(f) Wetted components Polyurethane seal Related Publications Form Name Form# Ultra-lite 6000 Dispense Valve High Pressure Hose Swivels Ultra-lite and Therm-O-Flow are trademarks of Graco, Inc. Viton is a registered trademark of the DuPont Company. *PID denotes proportional band (P), integrated time (I), and derivative time (D)

32 Appendix Temperature Controller Settings List Level 0, Function Mode Parameter Names Set point Run/Stop Level 1, Function Mode Parameter Names Auto-tuning Execute/Cancel Alarm value 1 Alarm value 2 Proportional band Integral time Derivative time Control period (heat) Level 2, Function Mode Parameter Names SP ramp time unit SP ramp set value MV at stop MV at PV error MV upper limit MV lower limit MV change rate limit Input digital filter Alarm 1 hysteresis Setup, Function Mode Parameter Names Input type C/F selection Parameter initialize Control output 1 assignment Control output 2 assignment Auxiliary control 1 assignment Alarm 1 type Alarm 1 open in alarm Alarm 2 type Alarm 2 open in alarm Direct/Reverse operation Expansion, Function Mode Parameter Names Set point upper limit Set point lower limit PID/ON/OFF ST alpha range: 0.01 to 1.00 AT calculated gain Standby sequence reset setting method Automatic return of display mode AT hysteresis Alarm 2 hysteresis Input shift upper limit Input shift lower limit

33 Notes

34 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 by an authorized Graco distributor 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 procedures concernées. Graco Phone Number TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you: Toll Free. 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 Sales Offices: Minneapolis, Detroit Foreign Offices: Belgium, England, Korea, France, Germany, Hong Kong, Japan GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN PRINTED IN U.S.A March 1999