Graco 309376J User's Manual
Contents
1. TI1378A TI1378A 5 44 N 1 1 4 npt water 1 circulation inlet port i o Qi Ol Shee TI1378A 10 7 Apply pipe sealant to threads per G standard 4 0520 2 Torque screws 7 evenly to 50 60 Ib in 3 Mounting screws 9 loose with valve 28 309376 Notes Ref No 4 2 3 4 5 6 Part No 244535 198235 070408 110208 109576 106555 Repair Kits Part No 15E012 15E011 Description VALVE ext dispense 200 deg F MANIFOLD water SEALANT pipe sst PLUG pipe headless PACKING o ring fluroelastomer PACKING o ring Description Standard seals High temperature seals Parts Model 244910 ambient or temperature conditioned Qty Ref Part No No 7 116412 8 114618 9 513035 10 C32089 not shown Description SCREW cap button head PIN dowel dia 3 16 x 1 2 lg SCREW cap shcs RETAINER seat Qty ANA Included in repair kits Kits also include manifold o rings for all models 309376 29 Accessories Use Only Genuine Graco Parts and Accessories Description Tube Fittings for Air or Water Suggested air fittings for automatic dispense valve air inlet ports Do not use fittings with temperature ratings that are lower than the operating temperature of your system Contact your Graco Service Representative for more information These fitt2. ee 24 309376 Parts Model 297261 240 V Model Ref Part No Description Qty Ref Part No Description Qty No No 1 244907 VALVE ext dispense 400 deg F 1 11 101674 TERMINAL ring ground 1 2 198236 MANIFOLD electrical 1 12 105672 SCREW set sch 1 4 118072 HEAD applicator swirl 1 13 116675 CORD flex 1 5 109576 PACKING o ring fluroelastomer 1 14 073019 LUBRICANT thermal 1 6 116412 SCREW cap button head 4 15 116673 BUSHING strain relief 1 M6 x 60 16 116637 CONNECTOR cable coupler 1 7 114618 PIN dowel dia 3 16 x 1 2 lg 2 hood 8 116614 HEATER cartridge 240 V 1 17 115860 INSERT male 1 9 114185 SCREW cap button head 3 18 116640 CONTACT connector 4 10 198232 GUARD manifold 1 19 115862 CONNECTOR male crimp 1 20 065345 WIRE copper electrical 2 ft 16 AWG 21 513035 SCREW cap shcs 4 22 197843 Block mounting 1 23 15H098 ADAPTER swirl 1 26 117950 NOZZLE swirl 030 1 not shown Included in repair kits Kits also include manifold o rings for all models Repair Kits Part No Description 15E012 Standard seals 15E011 High temperature seals 309376 25 Parts Models 244961 244908 and 245184 120 V Models 9 11 16 E TI1384A C O 2 Cl e el of LL TI1384A 1 Install sensor 3 and heater 8 with a coating of
3. 2 Insert a 3 32 punch or an allen wrench through the hole in the head of the needle 7 and unscrew from shaft 8 Another punch can be used through the hole in shaft 8 to keep it from turning 3 Remove seat 13 and gasket 12 4 Pull fluid housing 5 and grease bearing housing 4 from the shaft Air Section 1 Remove 4 screws 22 from top of valve Pull top air cylinder housing 1 straight off 2 Remove the first retaining ring 10 piston 9 and second retaining ring 10 NOTE Use only the new retaining rings provided in repair kit when reassembling air section of valve 3 Pull lower air cylinder housing 2 straight away from housing 3 4 Remove shaft 8 if fluid section has been disas sembled 309376 17 Service Assembly of Automatic Dispense Valve Valve models 244535 244907 and 244937 NOTE See parts drawing on page 20 for parts refer enced in parentheses See service drawing on page 19 for references to steps in this procedure x Air Section 1 Lubricate all seals and sliding parts with a high temperature moisture free grease such as the 1115982 grease cartridge provided with the valve 2 Assemble o rings 17 19 and 21 into or onto their respective parts as shown Install o ring 18 only to housing 3 3 Insert shaft 8 small end first into housing 3 NOTE Do not overextend retaining ring 10 during installation and repair s Make sure to as
4. Shut off the material supply SKIN INJECTION HAZARD 3 The system pressure must be manually relieved to prevent the system from starting or spraying accidentally Fluid under high pressure can be injected 4 Have a container ready to catch the drainage then bleed off material pressure by actuating the dis through the skin and cause serious pense valve injury To reduce the risk of an injury 5 Shut off air supply to valve from injection splashing fluid or moving NOTE f you suspect that the nozzle or hose is parts follow the Pressure Relief completely clogged or that pressure has not Procedure whenever you 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 Then clear the tip nozzle or hose are instructed to relieve the pressure stop spraying dispensing install or clean the nozzle check or service any of the system equipment PRESSURIZED FLUID HAZARD High pressures can cause serious per sonal injury Be sure to open the dis pense valve during system heat up to alleviate pressure which might occur in the system due to material expansion 14 309376 Service 4 Remove power from the automatic dispense valve 44 WARNING HOT SURFACE AND FLUID HAZARD The material and equipment will be Prepare to Service Automatic Dispense Valve If the unit is hot determine whether or not you can s
5. Air to close m Air to open 4D Q E l 1 8 npt f T1378A 32 309376 Dimensions Model 297261 Only Cr lt lt 2 250 gt 1 2 npt f process fluid inlet Optional RTD port 4 M6 x 1 mounting holes x 46 11 6 mm full thread depth 375 Electrically heated models have an insulating mounting block 4 MTV i 3 500 4 500 Air to close f j Air to open CS 1 8 npt f 309376 33 Technical Data Maximum working fluid pressure 24 1 MPa 241 bar 3500psi Maximum static fluid pressure 34 5 MPa 345 bar 5000 psi Maximum working dry air pressure 83 MPa 8 3 bar 120 psi Maximum working temperature Standard seals in models 244535 244910 95 C 200 244961 244962 High temperature seals in models 244907 204 C 400 244908 244909 244937 244951 245184 Material Inlet on inlet manifold all models 1 2 npt f Air Inlets open and close 1 8 npt 120 Volt Heater 150w 120 Vac 96 ohms 10 pins C and F 240 Volt Heater 200w Q 240 VAC 288 ohms 30 40 pins 1 and 2 RTD Sensor 120 Volt models pins A and B 100 Ohm platinum RTD 0 00385 ohm ohm
6. 1 mu eg 2116 e 26 11 7 m D O O 9 O 9 09 IL 7 o o e TI1380A E amp Cy OD EOS S3 TEN TI1379A 20 309376 Parts Model numbers 244535 244907 and 244937 Ref Part Description Qty Ref Part Description Qty No No No No 1 197506 CYLINDER valve 1 16 551190 SEAL u cup polymt 1 4 1 2 1 4 1 2 197509 CYLINDER air top 1 model 244535 3 197508 HOUSING cylinder air 1 16 551193 SEAL u cup PTFE 1 4 1 2 1 4 1 4 197503 HOUSING lubrication 1 models 244907 and 244937 5 197505 HOUSING material 1 17 116978 PACKING o ring fluroelastomer 2 6 198280 FLANGE nose piece 1 18 106555 PACKING o ring fluroelastomer 2 models 244535 and 244907 19 102895 PACKING o ring cylinder fluroe 1 6 198443 FLANGE nose piece 1 lastomer model 244937 21 103610 PACKING o ring fluroelastomer 4 T 626062 NEEDLE sst hardened 1 22 111112 SCREW cap socket head 8 8 15E014 SHAFT valve 1 23 100846 FITTING lubtn st 2 9 111094 PISTON 2 24 111092 SPRING valve 1 107 15E017 RING retaining external 4 26 104319 PACKING o ring 1 11 626064 BEARING lube 1 27 115982 LUBRICANT synthetic grease 1 12 171860 GASKET seat 1 28 551189 GUN grease 3 oz cartridge 1 13 185467 SEAT valve 1 33 198234 BUTTON valve 1 14 626060 INSERT snuff back 1 35 101970 PLUG pipe headless 1 15 551191 PACKING u cup Fluoroelas
7. 200 F Valve 230 Volt E Heat Replaces 243694 hard seat and 243696 soft seat snuff back valves Any Therm O Flow Plus after July 2000 if application is under 95 C 200 F Valve 120 Volt E Heat Replaces C34068 hard seat 918483 soft seat snuff back any Therm O Flow before Therm O Flow Plus July 2000 if application is 95 C 200 F to 204 C 400 F Valve 230 Volt E Heat Replaces 243694 hard seat and 243696 soft seat snuff back valves Any Therm O Flow Plus after July 2000 if application is 95 C 200 F to 204 C 400 F Complete Valve 240 Volt E Heat Swirl Equipped Valve 230 Volt E Heat Replaces valve 243695 hard seat with 1 2 npt m outlet Any Therm O Flow before Therm O Flow Plus July 2000 if application is 95 C 200 F to 204 C 400 F Valve 120 Volt E Heat Replaces C34079 hard seat with 1 2 npt m outlet Any Therm O Flow Plus after July 2000 if application is 95 C 200 F to 204 C 400 F Maximum Fluid Temperature Rating C F 95 C 200 F 95 C 200 F 95 C 200 F 204 C 400 F 204 C 400 F 204 C 400 F 204 C 400 F 204 C 400 F Heater Voltage Pin Connector Wattage Nonpowered ambient or water circulation for temperature conditioning 120 VAC 6 Pin round 230 VAC 8 Pin square 120 VAC 6 Pin round 230 VAC 8 Pin square 240 VAC 8 Pin square 230 VAC 8 Pin square 120 VAC 6 Pin round Valve Outlet Connection 5 8 18 ma
8. heat sink compound 14 TH384A 2 Torque screws 6 evenly to 50 60 in Ibs Notes 26 309376 Parts Models 244961 244908 and 245184 120 V Models Ref Part No Description Qty Ref Part No Description Qty No No 1 244535 VALVE ext dispense 200 deg F 1 8 116613 HEATER cartridge 120 V 1 model 244961 9 114185 SCREW cap button head 3 1 244907 VALVE ext dispense 400 deg F 1 10 198232 GUARD manifold 1 model 244908 11 101674 TERMINAL ring ground 1 1 244937 VALVE ext dispense 1 2 npt 1 12 105672 SCREW set sch 1 model 245184 13 116675 CORD flex 1 2 198236 MANIFOLD electrical 1 14 073019 LUBRICANT thermal 1 3 C32255 SENSOR temperature 1 15 116639 CONNECTOR receptacle male 1 4 C32089 RETAINER nozzle 1 16 065345 WIRE copper electrical 2ft 5A 109576 PACKING o ring fluroelastomer 1 16 AWG 6 116412 SCREW cap button head 4 17 116688 CLAMP cable 1 M6 x 60 18 513035 SCREW cap shcs 4 7 114618 PIN dowel dia 3 16 x 1 2 lg 2 19 197843 Block mounting 1 not shown Included in repair kits Kits also include manifold o rings for all models Repair Kits Part No Description 15E012 Standard seals 15E011 High temperature seals 309376 27 Parts Model 244910 ambient or temperature conditioned 4 1 8 npt f water circulation outlet ports 8 E 2 1 8 npt f ES 77 RTD sensor ports
9. 241 bar 3500 psi to the applicator or manifold Never exceed the recommended working pressure or the maximum air inlet pressure stated on your pump or in the Technical Data on page 34 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 hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco standard hoses to temperatures above 180 F 82 C or below 40 F 40 C Do not expose Graco electrically heated hoses to temperatures above 400 F 222 C or below 40 F 40 C Do not use the hoses to pull the equipment Use only fluids and solvents that are compatible with the equipment wetted parts See the Technical Data sections of all the equipment manuals Read the fluid manufacturer s warnings 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 309376 44 WARNING HOT SURFACE AND FLUID HAZARD Heated fluid can cause severe burns and can cause equipment surfaces to become very hot e Wear protective gloves and clothing when operating this equipment in a heated system e Do not touc
10. 3 09 x 37 ribbon hardened tip Repair Kits Standard seals High temperature seals 30 309376 Part No 597151 198171 104172 114263 C58942 243703 C59038 244021 104661 198457 198458 197504 197842 198323 198324 617585 607665 161505 164799 C17009 C01025 15E012 15E011 Accessories Description Cable Wrap 10 x 10 nylon fabric pad with Velcro strip Used to secure the valve cable connector to the heated hose Protects the electrical connectors in applications where the valve is being moved Velcro Straps 1 x 12 strap used to secure ends of wrap 198422 above Fluid Inlet Adapters 1 2 NPT m x No 8 JIC m 3 4 16 with 37 flare 1 2 NPT m x No 10 JIC m 7 8 14 with 37 flare 1 2 NPT m x No 12 JIC m 1 1 16 12 with 37 flare Part No 198422 198442 C20700 C20703 C20642 309376 31 Dimensions 2 250 Ne 4 1 8 npt f temperature conditioning water outlets 1 8 npt f RTD sensor 1 2 npt f process port fluid inlet Optional Q RTD port 9 TI1377A 8 310 SI zu 4 M6 x 1 mounting holes x 46 11 6 mm eu full thread depth 1 135 K 2531 4 375 Electrically heated models have j an insulating mounting block 1 4 npt f temperature conditioning water inlet 3 500 4 500
11. Instructions Parts List GRACO EnDure Automatic 309376J Dispense Valves EN Air operated dispense valves used for sealant and adhesive materials 3500 psi 24 10 MPa 241 bar Maximum Dynamic Discharge Fluid Working Outlet Pressure 5000 psi 34 5 MPa 345 bar Maximum Static Working Pressure 120 psi 83 MPa 8 3 bar Maximum Air Pressure Important Safety Instructions Read all warnings and instructions in this manual Save these instructions Gan Ce g O Ne TI1377A 06540A PROVEN QUALITY LEADING TECHNOLOGY List of Models Warnings Installation Maintenance Troubleshooting Service 2 309376 Table of Contents M EN RN AC 3 OE re dd eee riada 4 ACCOSSOMES gt uvis ai EVE PRA IA p DR eub 7 DIMENSIONS oe scie arie race E ET RU rac ata et m 11 Technical Data eese v Ce re E 13 Wiring Diagram essere wiedive been beh eed oe iis 14 Graco Standard Warranty Graco Information esses 244535 244907 244937 Complete Valve Part No 244910 244961 244962 244908 244909 297261 244951 245184 Models Description Replaces Valve ambient or water con ditioned Replaces C27340 hard seat and 918512 soft seat snuff back if application is under 95 C 200 F Valve 120 Volt E Heat Replaces valve 194485 Any heated PrecisionFlo before XL July 2001 if application is under 95 C
12. button 33 to compress the spring 15 Place the clear plastic gasket 12 and seat 13 into their groove on housing 5 The seat is re versible and can go in either way 16 Insert needle 7 through seat 13 While holding shaft 8 screw the needle 7 into shaft 8 using Locktite blue thread locker Tighten with a 3 32 pin or punch to approximately 15 20 Ib in 17 Place snuff back ring 14 in nose piece 6 and white o ring 26 in its groove on housing 5 Align nose piece 6 and push straight into place If higher flow and less snuff back is desired do not use the snuff back ring 14 18 Insert four screws 22 with Locktite blue thread locker and tighten evenly compressing bearing 11 to 40 45 Ib in 19 Cycle valve 25 times at full air pressure to set hardened needles to carbide seat 20 Install one fitting 23 Pump grease 27 across bearing 11 and out other side Install second fitting 23 and apply another shot of grease 21 Use pipe thread sealant on plugs 36 and 35 Service 1 1 LLA 21 8 o E O E x Refers to instruction steps from COR procedure on page 18 Ll TI1379A Fig 9 309376 19 Parts Model numbers 244535 244907 and 244937 18 19 2
13. can reliably operate at 60 psi of air even with 4000 psi of downstream pressure Troubleshooting Some solutions require disassembling the automatic dispense valve Always relieve system pressure before per forming these procedures 44 WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow A the Pressure Relief Procedure page 14 See PARTS section for the parts that need to be serviced Material leaks from front of Replace seat seals 12 8 26 automatic dispense valve needle 7 and seat 13 Obstruction inside dispense valve Remove nose piece 6 Check and replace if necessary seals 12 8 26 needle 7 and seat 13 Worn needle Check and replace needle 7 if neces sary If replacing needle you must reverse or replace seat 13 Worn seat Base seal models Check and replace or reverse seat 13 if necessary Replace needle 7 with seat 13 Material leaks from automatic Seal not installed correctly Check seals 15 amp 16 and replace if E pala Automatic dispense valve Check air connections does not shut off Worn needle seal interface Replace rod seal 12 amp 26 needle 7 and seat 13 Automatic dispense valve Broken retaining ring 10 or debris in Disassemble dispense valve Check does not shut off air cylinder and replace if necessary retaining ring 10 and o rings 17 18 19 and 21 Automatic dispense valve Spring broken or not
14. d c Ss e Ne Fluid Water Inlet Circulation Ports Mounting Holes TI1377A Ambient or temperature conditioned model shown Fig 1 Mount the Automatic Dispense Valve Mount the automatic dispense valve to the mounting bracket on a stationary support or robotic arm Fig 1 using two M6x1 0 socket head screws and two flat washers lf your application is heated be sure to position the insulation block between the dispense valve and the mounting bracket Fig 2 Refer to the dimensions on page 32 309376 7 Installation Connect Air Lines to Dispense Valve 44 CAUTION Only use air fittings that are rated at a temperature equal to or higher than the operating temperature of your fluid dispensing system Lower rated air fit tings could melt and cause damage to the automat ic dispense valve These valves are air to open and air to close with a spring to bias them closed Use a 4 way exhausting solenoid to operate these valves Be sure to connect the appropriate air lines to the appropriate ports Fig 2 and securely connect air lines to dispense valve air ports See page 32 Open and Close ports are on this side Xo 240 volt heated model shown DN Fig 2 8 309376 Connect Material Hose to Dispense Valve Securely connect the material hose to the dispense valve material inlet port See Fig 2 Connect Electrical Cable to Electrically Hea
15. deg C 240 Volt models pins 3 and 4 108 2 ohms Q 21 C 70 F Weight automatic dispense valve manifold approx 1 8 kg 4 Ibs Model 244910 can be temperature conditioned with circulating water The valve manifold is equipped with 1 1 4 npt f water inlet 4 1 8 npt f water outlets 2 1 8 npt f ports that can be used for a temperature sensor see page 30 WETTED PARTS all valves Aluminum Stainless Steel chrome carbide acetal plastic PTFE fluoroelastomer PRIMARY SEAL MATERIALS Model 244535 Polymyte orange standard temperature Models 244907 and 244937 graphite fiber reinforced PTFE black high temperature Material Outlet 244951 and 245184 1 2 npt m 244910 244961 244962 5 8 18 with nut to accept 244908 244909 1 8 npt nozzles Polymyte is a trademark of Parker Seal 34 309376 Wiring Diagram 120 Volt Models 108 1 Q 70 F SENSOR RTD On A Bc 18 36 HEATER 150 W 120 VOLTS 90 100 Q O 70 F NOTE ALLOW SUFFICIENT LEAD WIRE LENGTH TO BE ABLE TO ROTATE CONNECTOR BRACKET 180 Past Therm O Flow accessories 240 Volt Models 248 318 Q O 70 F WIRING DIAGRAM SCHEMATIC DIAGRAM HEATER HEATER 200 W 240 VOLTS 7 WAI HESS ZTA SENSOR RTD A M SE SENSOR C 4 5 NOT USED 108 1 Q O 70 F 6 NOT USED 7 NOT USED ALE All T
16. e the cavity 309376 11 Maintenance Factors affecting valve life The maintenance tables should be used as a guideline for frequency of maintenance tasks Additional factors that affect valve life include the following e Process fluid Abrasive or fiber filled fluids are much harder on seals shafts and seats than non abrasive fluids such as oil e Pressure drop across the valve seat As the valve opens or closes the fluid is accelerated to a high velocity at the needle seat contact area The rate of wear at the valve will be much greater at 3000 psi than at 1000 psi Changing nozzle or tip size can have a substantial affect on wear e Number of cycles This has a much greater affect on valve wear than number of gallons If you can do the same job with fewer on off cycles the valve will last longer 12 309376 Speed of actuation Snapping the valve open and closed quickly will give longer needle and seat life Avoid long air tube runs after the solenoid or use quick exhaust valves 104661 on the dispense valve Air pressure This is what provides the force to hold the hardened SST needle against the carbide seat to seal against fluid pressure Any leakage on these hard parts at high pressure will quickly worm hole the parts and cause the valve to fail This valve has been designed with two air pistons to give it an exceptionally high 68 1 advantage of air pressure to fluid pressure This means that you
17. efect 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 mak ing any claim for breach of these warrantie
18. ervice the unit after it has cooled down Some mate rials like polyurethanes may cure permanently when cooled and exposed to air preventing you from disas sembling the dispense valve If you are working with such a material service the unit while the material is at a temperature where the material is soft enough to work with If the material can be reheated at a later time you can service the unit after it has cooled reheating the material as necessary Perform this procedure before servicing the automatic dispense valve 1 Relieve the system pressure A WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure page 14 2 Make sure material flow has been shut off 3 Make sure system air has been shut off hot To reduce risk of injury wear eye protection gloves and protective clothing when servicing this dispensing system component 5 If the material in the dispense valve can be re heated wait for the dispense valve to cool thor oughly before servicing it If the material in the dispense valve cures perma nently when cooled and or exposed to air service the unit while the material is at a temperature where the material is soft enough to work with 309376 15 Service Service the Automatic Dispense Valve The dispense valves can be serviced or replaced without disconnecting the fluid hose or temperature control cabl
19. es or tubes Disconnect Automatic Dispense Valve from its Inlet Manifold Remove the automatic dispense valve from its mount ing bracket 1 Perform the procedures in Prepare to Service Automatic Dispense Valve on page 15 44 WARNING HOT SURFACE AND FLUID HAZARD The material and equipment may be hot To reduce risk of injury wear eye protection gloves and protective clothing when servicing this dispensing system component 2 Disconnect air lines from dispense valve air ports 3 Remove 4 M 6 socket head screws that connect the valve body to the inlet manifold see Fig 8 4 Pullthe valve body straight away from the inlet manifold Reconnect Automatic Dispense Valve to Mounting Bracket 1 Install new o ring on fluid passage and water passages if used 2 Line up valve body with locating pins and heater and sensor if used 3 Push valve straight on to pins Torque retaining screws evenly to 50 60 in Ib 4 Reconnect air lines to dispense valve air ports e OU hal ui Fig 8 16 309376 TI1378A Service Valve models 244535 244907 and 244937 NOTE See parts drawing on page 20 for parts refer enced in parentheses Disassemble Automatic Dispense Valve NOTE The fluid section and the air section can be serviced independently Fluid Section 1 Remove 4 screws 22 and pull the nose piece 6 straight off
20. fy any part of the applicator this can cause a malfunction and result in serious bodily injury Use extreme caution when cleaning or changing tips If the tip clogs while applying material ALWAYS follow the Pressure Relief Procedure on page 14 then remove the tip to clean it NEVER wipe off build up around the tip or air cap until pressure is fully relieved 309376 5 44 WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD Improper grounding poor air ventilation open flames or sparks can cause a hazardous condition and result in fire or explosion and serious injury e Ground the equipment and the object being sprayed The Heated Automatic Dispense Valve is grounded to truth earth ground inside the electrical control panel See Grounding on page 9 Ground the equipment and the object being sprayed and all other electrically conductive objects in the dispense area Proper grounding dissipates static electricity generated in the equipment See Grounding 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 or you feel an electric shock while using the equipment stop dis pensing immediately Do not use the equipment until you have identified and corrected the problem Make sure all electrical work is performed by a qualified electrician only Have any checks installation or service to electrical equipment perf
21. h the metal heat sink when the surface is hot e 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 SKIN INJECTION HAZARD Spray from the applicator hose leaks or ruptured components can inject fluid into your body and cause extremely serious injury including the need for amputation Fluid splashed 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 surgical treatment Do not point the applicator at anyone or at any part of the body Do not put hand or fingers over the front of the applicator Do not stop or deflect fluid leaks with your hand body glove or rag Follow the Pressure Relief Procedure on page 14 whenever you are instructed to relieve pressure stop dispensing clean check or service the equipment or install or clean a tip or nozzle Tighten all the fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn damaged or loose parts immedi ately Permanently coupled hoses cannot be repaired replace the entire hose ALWAYS wear eye protection and protective clothing when installing operating or servicing this dispensing equipment Do not remove or modi
22. herm O Flow Plus accessories 309376 35 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or sub stitution 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 d
23. ings are rated for at least 150 psi at 140 F NPT Tube 90 elbow push in tube 1 8 male 1 4 O D 90 elbow push in tube 1 8 male 5 32 Amm Straight push in tube 1 8 male 1 4 O D Straight push in tube 1 8 male 5 32 Amm For heated hoses reference 309160 Solenoid Valve Kits for High Temperature Valves For heated double acting air actuated valves Includes solenoid 24 high temperature air tubes air fittings and muffler Coil Voltage 120 Volt AC 230 Volt AC 24 Volt DC Hose and Cable Kit 8 pin square female connector and 10 ft of cable to mate with 240 VAC valves Quick Exhaust Valve 1 8 npt f Temperature Conditioning Accessories Water Circulation RTD Sensor 1 8 npt m x 81 21mm insertion length 3 pin Picofast connector fits the cable below Sensor cable 6 ft 1 8 m 3 pin Picofast 90 connector for RTD above 198457 3 pin Omega connector on control end Fits St Clair temperature conditioning cable NOTE The following accessories are not applicable to Model 297261 Swirl Orbiter Adapters Alternate nosepiece for valve outlet 3 4 16 JIC m Fits inlet swivel on orbiter 45 orbiter mount uses the following parts 45 Nosepiece Alternate orbiter nut Fitting nosepiece to orbiter Streaming Adapter Alternate outlet nut to retain 270xxx streaming tips or 182xxx fan tips See Manual 308813 Steel Dispense Nozzles 1 8 npt m Length Orifice Size 2 125 2 094 2 12 055 1 22 125 2 4
24. installed correctly Disassemble dispense valve Check does not shut off spring 24 and replace if necessary Automatic dispense valve Loose heater wires Check and reconnect wire connections does not heat material Loose sensor wires Check and reconnect wire connections Heater unit failed Replace heater Sensor failed Replace sensor Temperature controller failed Replace temperature controller No power to heating circuitry Apply power to heating circuitry Automatic dispense valve will Fluid pressure in outlet line greater than Reduce outlet restrictions not open 24 1 MPa 241 bar 3500psi Reduce fluid pressure Air cylinder pressure too low Increase air pressure iy 309376 13 Service Pressure Relief Procedure This procedure describes how to relieve pressure from the automatic dispense valve See your supply unit or A WARNING system documentation for instructions on relieving pressure for the entire dispensing system Use this HOT SURFACE AND FLUID HAZARD procedure whenever you shut off the dispense valve The material and eguipment will be and before checking or adjusting any part of the hot To reduce risk of injury wear eye system to reduce the risk of serious injury protection gloves and protective clothing when installing operating or servicing this dispensing system 2 If heated shut off electrical power to the automatic dispense valve Close all self bleeding air supply valves for supply unit
25. ket contact E on six pin models see Fig 5 or contact eight on eight pin models see Fig 4 inside control panel receptacle is con nected to true earth ground See page 35 for schematics Snuff Back Snuff back is created when the needle is pulled back through a restrictive ring before it closes against the carbide seat For maximum snuff back leave the ring in place For maximum flow with less snuff back remove the ring For additional snuff back use a quick exhaust valve 104661 on the open air port Nozzle selection and gun movement also effect fluid cut off characteristics 309376 9 Installation Connecting the Electrical Cable from a Therm O Flow Plus Heated Hose 1 Wrap the hose cable around the hose one time Connect the electrical cable from the hose to the valve cable lock the metal clip on the top of the connector See Fig 5 2 Place the flat side of the cable connection against the hose making sure the metal clip faces away from the hose This will prevent damage to the hose from the clip rubbing against it See Fig 6 3 Secure the cable connector to the hose with heavy Fig 6 tape or Velcro straps For installations where the dispense valve is moving it is recommended that the connector be wrapped with the Graco access ory Velcro wrap 198422 and 2 Velcro straps 198442 as shown in Fig 7 Fig 7 Fig 5 10 309376 Maintenance The following tables list recommended mai
26. le thread Retainer nut with 1 8 npt f 5 8 18 male thread Retainer nut with 1 8 npt f 5 8 18 male thread Retainer nut with 1 8 npt f 5 8 18 male thread Retainer nut with 1 8 npt f 5 8 18 male thread Retainer nut with 1 8 npt f 5 8 18 male thread with swirl adapter 1 2 npt m 309376 3 Warnings The following warnings are for the safe setup use grounding maintenance and repair of this equipment The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure specific risks Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable 44 WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture malfunction or start unexpectedly and INSTRUCTIONS result in serious injury o d Mudm 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 call your Graco distribu tor 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 the maximum air working pressure of 1 MPa 8 3 bar 120 psi to the applicator Do not exceed the maximum fluid working pressure of 24 MPa
27. ntenance procedures and frequencies The maintenance is divided between mechanical and electrical tasks A typical application is a valve mounted on a robot dispensing a moder ately abrasive sealant Mechanical Monthly or 30 000 cycles 3 6 months or 125 000 cycles 6 12 months or 250 000 cycles 18 24 months or 500 000 cycles 36 48 months or 1 000 000 cycles 6 8 years or 2 000 000 cycles Task Inspect for leaks Check hoses for wear Check tighten fluid connections Check tighten air connections VIX XX Weekly Lube packings Rebuild dispense valve Replace valve Assumes movement from automation Electrical 6 Months 12 Months Task Check cables for wear NN Weekly Verify cable connections Verify resistance of electric heaters Verify resistance of RTD sensors Packing Lubrication 1 Remove one of the zerk grease fittings 23 This valve has a primary seal a pressurized grease 2 Using the grease gun supplied pump a high area and a secondary seal The key to long seal life is quality grease like 115982 high temperature that the secondary seal only has to seal grease moisture free into the remaining zerk fitting until fresh grease comes out the other side When dispensing filled materials this grease should be 3 Replace the grease fittings and give the valve one refreshed once a month more shot of grease to pressuriz
28. ormed by a qualified electri cian 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 Before operating the equipment extinguish all open flames or pilot lights in the dispense area Do not smoke in the dispensing area Keep liquids away from the electrical components Disconnect electrical power at the main switch before servicing the equipment Never exceed maximum wattage of the supply unit TOXIC FLUID HAZARD Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin swallowed or inhaled Provide fresh air ventilation to avoid the buildup of vapors from the fluid being dispensed 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 6 309376 Installation Install the automatic applicator as follows e mount the automatic dispense valve attach dispense tip or nozzle connect the air lines connect material hose if heated connect the electrical cable if temperature conditioned connect the water circulation make sure the automatic dispense valve is grounde
29. rnational Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2004 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised 01 2012 36 309376
30. s 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 reconnais sent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call one of the following numbers to identify the distributor closest to you 1 800 328 0211 Toll Free 612 623 6921 612 378 3505 Fax All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 309376 Graco Headquarters Minneapolis Inte
31. semble retaining ring longitudinally down the shaft diameter Do not stretch the ring around the diameter e Use only the new retaining rings provided in repair kit when reassembling air section of valve 4 Assemble the lowest retaining ring 10 on the shaft Add o ring 18 onto the shaft then add spring 24 a piston 9 and the next retaining ring 10 5 Slide housing 3 straight down over shaft 8 with pieces aligned as shown 6 Add next retaining ring 10 o ring 18 piston 9 and last retaining ring 10 7 Insert button 33 into housing 1 and push as sembly down over the piston and shaft 8 Align the open close air ports as shown 9 Insert four screws 22 and torque evenly to 40 50 Ib in 18 309376 Fluid Section 10 Lubricate all seals and sliding parts with a high temperature moisture free grease such as the 1115982 grease cartridge provided with the valve 11 Carefully insert U cup 15 into bearing 11 with the open end of the seal facing into the bearing Install o ring 21 on the outside groove of the bearing 12 Insert the bearing U cup end first into the grease housing 4 Push this assembly onto shaft 8 while holding bearing 11 into housing 4 13 Carefully insert U cup 16 lips first into the appropriate end of housing 5 Push this assembly onto shaft 8 up against housings 3 and 4 14 Place the valve in a vice such that it is pushing
32. strain relief 1 2 198236 MANIFOLD electrical 1 16 116637 CONNECTOR cable coupler 1 3 C32255 SENSOR temperature 1 hood 4 C32089 RETAINER nozzle 1 17 115860 INSERT male 1 Dt 109576 PACKING o ring fluroelastomer 1 18 116640 CONTACT connector 4 6 116412 SCREW cap button head 4 19 115862 CONNECTOR male crimp 1 M6 x 60 20 065345 WIRE copper electrical 2 ft 7 114618 PIN dowel dia 3 16 x 1 2 lg 2 16 AWG 8 116614 HEATER cartridge 240 V 1 21 513035 SCREW cap shcs 4 9 114185 SCREW cap button head 3 22 197843 Block mounting 1 10 198232 GUARD manifold 1 not shown Included in repair kits Kits also include manifold o rings for all models Repair Kits Part No Description 15E012 Standard seals 15E011 High temperature seals 309376 23 Parts Model 297261 240 V Model 9 11 20 E r A UN anb E na Hj Jo 0 18 ie A Ground wire Notes Install sensor 3 and heater 8 with a coating of heat sink compound 14 Torque screws 6 evenly to 50 60 Ib in A pin crimper is used to make these connections Soldering is acceptable for replacements if a new pin is used NJI
33. ted Dispense Valves Connect electrical cable plug from your Therm O Flow Therm O Flow Plus or PrecisionFlo hose or control A six pin round connector is used on 120 volt valves and an eight pin square connector is used on 240 volt valves Fluid Inlet Temperature insulation spacer Installation Grounding 44 WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD To reduce the risk of fire explosion or Ml electric shock e The power source conduit is not an ad equate ground for the system The unit must be grounded to either the building ground or a true earth ground e A qualified electrician must complete all grounding and wiring connections and check the resistance e Refer to your local code for the requirements for a true earth ground in your area e Also read and follow the warnings on page 6 Electrically Heated Models Ground the automatic dispense valve 1 Connect the connector from a heated hose to the receptacle on the dispense valve Ground lead coming from pin E is fastened to the valve body IF Heater 4 RTD cartridge sensor 120 Volt models Fig 3 Ground lead coming from contact 8 is fastened to the valve body 240 Volt models Fig 4 TIO305 2 Connect the electrical cable to the electrical control panel 3 Verify that soc
34. tomer 1 36 110208 PLUG pipe headless 1 1 4 1 2 1 8 not shown model 244535 Included in repair kits Kits also include manifold o rings 15 617491 PACKING u cup urt 1 4 1 2 1 8 1 for all models models 244907 and 244937 NOTE Do not overextend retaining rings 10 during installation and repair Repair Kits Part No Description 15E012 Standard seals 15E011 High temperature seals 309376 21 Parts Models 244962 244909 and 244951 240 V Models ur MARRU Ground wire Notes Install sensor 3 and heater 8 with a coating of heat sink compound 14 Torque screws 6 evenly to 50 60 Ib in A pin crimper is used to make these connections Soldering is E acceptable for replacements if a new pin is used EN mm NI Co 22 309376 Parts Models 244962 244909 and 244951 240 V Models Ref Part No Description Qty Ref Part No Description Qty No No 1 244535 VALVE ext dispense 200 deg F 1 11 101674 TERMINAL ring ground 1 model 244962 12 105672 SCREW set sch 1 1 244907 VALVE ext dispense 400 deg F 1 13 116675 CORD flex 1 model 244909 14 073019 LUBRICANT thermal 1 1 244937 VALVE model 244951 1 15 116673 BUSHING
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