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311510C Hose Power Controller Kit

1. d Remove large wire nut from secondary cable 0 remove AmpLok controller 2 Remove AmpLok controller See FIG 6 and FIG 7 e Disconnect cables a Remove lid from blue transformer box on bot tom front of unit b Disconnect wires from gray terminals 1 6 on AmpLok controller Terminals Fic 7 HV 20 35 Before Conversion Fic 6 AmpLok Controller HV 20 35 6 311510C Install Hose Power Controller Kit Before you can install the new hose power controller kit it must be positioned properly 1 Position hose power controller in bottom of box fac ing up Ensure it is positioned for easy wire access on top and left side of controller 2 Mark through mounting feet for drill holes 3 Drill through 29 0 136 in Tap 8 32 screw threads Install Fan Power Wires Install new wires to power fan on hose power controller 1 Tape the two new wires plain ends to a piece of flexible steel wire Route wires from the lower com partment through the middle large conduit and to the upper control box See FIG 2 2 Route tie wrap and connect the wires to their respective terminal blocks 3 Plug in the wires with push on connectors into the fan terminals terminals do not have polarity Wire Hose Power Controller 1 Connect power wire 1252 from top of control box to terminal 2 2 Connect black wire 1332 230V units or wire N 10 ga wht 380V units to terminal 3 3 Connect the two
2. black transformer primary wires to terminal 5 4 Connect the two white transformer primary wires to terminal 6 5 Route one of the large 6 gauge transformer second ary wires through the D Current Sensor which is included in the kit 6 Connect the black 6 gauge transformer secondary wires to each red 6 gauge hose power cable with wire nuts supplied Secure nuts with electrical tape 7 Connect D Sensor doughnut wires to terminals 15 and 16 Polarity does not have any affect 311510C HV 20 35 Models 8 Connect blue 5 Vdc signal wires Connect 3501 to terminal 7 and 3502 to terminal 8 9 Ensure all cable connections are secure Mount Hose Power Controller and Bracket Use screws and lockwashers provided in kit to secure hose power controller to bottom of control box Power On and Test 1 Turn power on to unit Switch the Main Disconnect to ON and switch the E Stop to ON 2 Turn on amber control power switch 3 Adjust the hose temperature set point SP1 on con trol panel above the actual temperature until the O1 output light on the display stays on constantly 4 Turn on hose zone control switch green light 5 Test newly installed hose power controller e Ensure the green signal light above terminal 4 is on e Ensure the amber current limit light above termi nal 5 is on e As the hose reaches temperature the O1 out put light will flicker less until it goes out com pletely As this occ
3. rent sensor doughnut needed Hose power controller is set too high Contact Graco Technical Assistance Parts Kit 297983 Kit 261287 For 230V and 380V H 20 35 Pro and HV 20 35 Models For 460V H 20 35 Pro Models Part No Description Qty Part No Description Qty 120387 CONTROL heater 240V 120404 CONTROL heater 480V 15H611 BRACKET mount heater control 15H611 BRACKET mount heater control 103229 SCREW cap SCH 103229 SCREW cap SCH 157021 WASHER lock int 157021 WASHER lock int 100284 NUT hex MSCR 100284 NUT hex MSCR 15H646 WIRE pair fan 15H646 WIRE pair fan 117722 NUT wire Mo AA RAA8 EE 8 311510C Connection Diagrams Hose Transformer Primary Wire Connections Check for Continuity Black to Hose Power Controller 6 Wire Nut amp Tape Black to Hose Power Controller 5 Fic 8 Hose Transfer Connection Diagram for 460V Machines From Upper Control Box Neutral on 380V Machines 1332 1252 1253 Blk 3501 Blue 3502 UE 4 5 to 12 VDC Hose Heat Transformer Sensor Wires FG 9 Watlow Din A Mite Hose Power Controller Hook Up Diagram 311510C High Voltage Units Only 460V connect two primary transformer wires together to put both coils in a series as shown Connection Diagrams 37 2161 Neutral 120 VAC 230V and 380V Machines only See detail for 460 Volt machines FIG 8 Graco Standard Warranty Graco warrants all equipment referenced in t
4. Instructions 8 GRACO Hose Power Controller Kit manic E For replacing the AmpLok Hose Controller on H 20 35 Pro Proportioners and Lag HV 20 35 Proportioners Zei Kit 297983 GE For 230V and 380V H 20 35 Pro and HV 20 35 Models equipped with an AmpLok Hose Controller Kit 261287 For 460V H 20 35 Pro Models equipped with an AmpLok Hose Controller Important Safety Instructions Read all warnings and instructions in manuals 311392 and 311393 Save these instructions wes wf Ze SN sir am a GRACO GUSMER es PROVEN QUALITY LEADING TECHNOLOGY E Graco Inc P O Box 1441 Minneapolis MN 55440 1441 Pe ey Copyright 2006 Graco Inc is registered to I S EN ISO 9001 HOO3 Contents H 20 35 Pro Models 0 ccc e eee eee 3 PANS eta eae Wate eee ole eer end gl eesti tae eet 8 Remove AmpLok Controller 3 AIUZI IOS facta Beene nang ame Ral ed ae Af 8 Install Hose Power Controller Kit 4 Kit 261287 6 eee 8 HV 20 35 Models 6 Connection Diagrams 9 Remove AmpLok Controller 6 Graco Sangara Warranty 2 dE 10 Install Hose Power Controller Kit 7 EO NO MIA ee Wi Troubleshooting e ees 8 2 311510C H 20 35 Pro Models H 20 35 Pro Models Installing this equipment requires access to parts that may cause electrical shock or other serious bodily injury if work is not performed properly This work should be performed by a qual
5. e 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 su
6. gh middle conduit Fic 2 H 20 35 Pro Upper Control Box Conduit 2 Connect the red 2161 wire to a 2161 terminal See FIG 3 3 Connect the white N wire to a neutral N terminal See FIG 3 Ty gt ie mtg l w La S ia a e Es f A e wit pa 23 ow Ree z ZE ep mee A e Fic 3 H 20 35 Pro Upper Control Box Wiring H 20 35 Pro Models 4 Use wire ties to route new wires along existing bun dles Wire Hose Power Controller Refer to FIG 8 and FIG 9 for connection diagrams 1 Place hose power controller and bracket in space next to the hose power transformer 2 Connect two black 8 gauge wires previously con nected to lower transformer wires with large wire nuts to terminals 2 and 3 on top of hose power controller These wires are 1252 and 1332 380V Units Only connect black 1252 wire to termi nal 2 and white neutral wire to terminal 3 3 Connect the two 0 transformer bottom wires pri mary to bottom of hose power controller terminal 5 4 Connect the two 220 wires 460 on 460V units to terminal 6 5 Plug in the red 2161 wire and white N wire to two terminal spades on fan of hose power controller Use either terminal terminals do not have polarity 6 Connect the blue 3501 5 Vdc wire to the top left terminal 7 on side of hose power controller 7 Connect the blue 3502 wire to terminal 8 which is below terminal 7 8 Connect t
7. he red 6 gauge hose cable that was con nected to terminal 4 on the old controller to the open terminal on the hose secondary circuit breaker 9 Install current sensor doughnut part of hose power controller kit e Disconnect 0 transformer secondary wire from circuit breaker e Install sensor on 0 large transformer cable and reconnect cable to circuit breaker e Connect sensor black wire and white wire to ter minals 15 and 16 on left side of hose power controller 10 Ensure all cable connections are secure 311510C H 20 35 Pro Models Mount Hose Power Controller and Bracket 5 Test newly installed hose power controller See FIG 5 Mount hose power controller and bracket to back wall using the following guidelines e Use the two screws saved from the AmpLok controller e Clean up wire routings and tie wrap wires in place Green signal present light e Do not run wires over sharp edges of trans former frame Amber current limit light e Do not run wires against coil of transformer Kai emm sey wi dii E e Reconnect heated hose if it was disconnected Fan Terminals behind i E Fan Power i Wires P Fic 5 H 20 35 Pro Hose Power Controller e Ensure the green signal light above terminal 4 is on e Ensure the amber current limit light above termi nal 5 is on e As the hose reaches temperature the O1 out put light will flicker less until it goes out c
8. his 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 th
9. ified electrician Refer to H 20 35 Pro Proportioner Service manual 311393 for current unit schematics d Save two of the screws Remove AmpLok Controller 1 Remove power from unit Switch the Main Discon Hose Secondary AmpLok Controller nect to OFF Circuit Breaker 2 Remove AmpLok controller see FIG 1 a Use 5 32 in hex key wrench to remove four retaining screws b Pull controller down for easier access c Remove wires from all six terminals Hose Transformer Secondary Cables Fic 1 H 20 35 Pro Before Conversion 3 Remove cables that are no longer needed a Remove the 6 red cable from top of circuit breaker that went to the AmpLok controller b Disassemble large wire nuts and tape Discard the two 16 black cables that went to the left two AmpLok terminals Discard wire nuts 311510C 3 Install Hose Power Controller Kit Mount Hose Power Controller Mount new hose power controller to bracket using the following guidelines e Use the 8 nuts and washers provided e Controller fits between bent up flanges which mount in unit facing out e Fan hangs off end of bracket away from the two larger mounting holes Install Fan Power Wires Install new wires to power fan on hose power controller 1 If necessary use a stiff wire to feed the two new wires from the lower compartment through the mid dle large conduit and to the upper control box See FIG 2 Feed wires throu
10. om pletely As this occurs the amber light will flicker Power On and Test 1 Turn power on to unit Switch the Main Disconnect off slowly and then the green light will flicker off to ON and switch the E Stop to ON slowly 2 Turn on amber control power switch If you have a true RMS AC current meter you can check one of the hose cables for 45 amps AC 2a while the O1 output light is steadily on A non true RMS AC current meter will read approx imately 30 amps 3 Adjust the hose temperature set point SP1 on con trol panel above the actual temperature until the O1 output light on the display stays on constantly 4 Turn on hose zone control switch green light e Check voltage at lower hose circuit breaker between two hose cables Keep in mind that voltage varies with hose length approximately 11 Vac per 50 ft of 3 8 in bundle plus 1 5V for whip hose If correct hose power is not detected refer to Troubleshooting page 8 311510C 5 HV 20 35 Models HV 20 35 Models Installing this equipment requires access to parts that may cause electrical shock or other serious bodily injury if work is not performed properly This work should be performed by a qualified electrician Refer to HV 20 35 Series Proportioning Unit with AmpLok manual 63942 ID for unit schematics c Remove nuts and washers from studs and then Remove AmpLok Controller 1 Remove power from unit Switch the Main Discon nect to OFF
11. pplying 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 r daction du presente document sera en Anglais ainsi que tous documents avis et procedures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 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 MM 311510C This manual contains English Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com 311510C Rev 1 2008
12. urs the amber light will flicker off slowly and then the green light will flicker off slowly If you have a true RMS AC current meter you can check one of the hose cables for 45 amps AC 2a while the O1 output light is steadily on A non true RMS AC current meter will read approx imately 30 amps e Check voltage at lower hose circuit breaker between two hose cables Keep in mind that voltage varies with hose length approximately 11 Vac per 50 ft of 3 8 in bundle plus 1 5V for whip hose If correct power is not detected refer to Troubleshooting page 8 Troubleshooting Troubleshooting Pepe Cause Per No lights on hose power controller No 4 5 to 12 VDC signal from tem Make sure connection for 01 light on perature controller temperature controller is good Polarity is reversed on 4 5 to 12 VDC No power to hose power controller Make sure green light on hose switch terminals 2 and 3 220 240 VAC or is on Make sure circuit breaker is on 460 VAC on 460V models Green light on but amber light not Opening in hose circuit Disconnect main hose plug Check on for 0 4 6 Q resistance Make sure all hose connections are secure Hose secondary circuit breaker open Check breaker Check for continuity across breaker Hose power primary circuit breaker Current sensor doughnut not con Check hose power controller connec blows nected tions 15 and 16 Hose cable not running through cur Check hose cable and reroute if

311510C Hose Power Controller Kit

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