Graco 309376J User Manual

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Page 1

Instructions–Parts List

EnDuret Automatic

309376J

Dispense Valves

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.

TI1377A

06540A

Page 2

Table of Contents

List of Models 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Standard Warranty 36. . . . . . . . . . . . . . . . . . . . . .

Graco Information 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Basic Valve Part No.

244535 244910 Valve, ambient or water con-

244907 244908 Valve, 120 Volt E-Heat

244937 244951 Valve, 230 Volt E-Heat

Complete Valve Part No.

244961 Valve, 120 Volt E-Heat

244962 Valve, 230 Volt E-Heat

244909 Valve, 230 Volt E-Heat

297261 Complete Valve, 240 Volt E–

245184 Valve, 120 Volt E-Heat

Description (Replaces  )

ditioned. Replaces C27340 hard seat and 918512 soft seat snuff-back, if application is under 95 C (200 F).

Replaces valve 194485. Any heated PrecisionFlo before XL (July 2001) if application is under 95 C (200 F).

Replaces 243694 hard seat and 243696 soft seat snuffback valves. Any Therm-OFlow Plus (after July 2000) if application is under 95 C (200 F).

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).

Replaces 243694 hard seat and 243696 soft seat snuffback valves. Any Therm-OFlow Plus (after July 2000) if application is 95 C (200 F) to 204 C (400 F).

Heat; Swirl Equipped

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).

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).

Models

Maximum Fluid Temperature Rating C (F)

95 C (200 F) Nonpowered

95 C (200 F) 120 VAC

95 C (200 F) 230 VAC

204 C (400 F) 120 VAC

204 C (400 F) 230 VAC

204 C (400 F) 240 VAC

204 C (400 F) 230 VAC

204 C (400 F) 120 VAC

Heater Voltage

Pin Connector Wattage

ambient or water circulation for temperature conditioning

6 Pin round

8 Pin square

6 Pin round

8 Pin square

6 Pin round

150

200

150

200

150

200

Valve Outlet Connection

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.

Retainer nut with 1/8 npt(f)

5/8-18 male thread with swirl adapter

1/2 npt (m) 23

1/2 npt (m) 27

Parts Page

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Page 4

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.

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and

INSTRUCTIONS

result in serious injury.

D This equipment is for professional use only.

D Read all instruction manuals, warnings, tags, and labels before operating the equipment.

D Use the equipment only for its intended purpose. If you are uncertain, call your Graco distribu-

tor.

D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

D Check the equipment daily. Repair or replace worn or damaged parts immediately.

D Do not exceed the maximum air working pressure of 1 MPa (8.3 bar, 120 psi) to the applicator.

D Do not exceed the maximum fluid working pressure of 24 MPa (241 bar, 3500 psi) to the

applicator or manifold.

D Never exceed the recommended working pressure or the maximum air inlet pressure stated on

your pump or in the Technical Data on page 34.

D 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.

D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces.

D 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).

D Do not use the hoses to pull the equipment.

D 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.

D Always wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid

and solvent manufacturers.

D Wear hearing protection when operating this equipment.

D Comply with all applicable local, state and national fire, electrical and other safety regulations.

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WARNING

HOT SURFACE AND FLUID HAZARD

Heated fluid can cause severe burns and can cause equipment surfaces to become very hot.

D Wear protective gloves and clothing when operating this equipment in a heated system.

D Do not touch the metal heat sink when the surface is hot.

D 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.

D Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate

surgical treatment.

D Do not point the applicator at anyone or at any part of the body.

D Do not put hand or fingers over the front of the applicator.

D Do not stop or deflect fluid leaks with your hand, body, glove, or rag.

D 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.

D Tighten all the fluid connections before operating the equipment.

D 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.

D ALWAYS wear eye protection and protective clothing when installing, operating, or servicing this

dispensing equipment.

D Do not remove or modify any part of the applicator; this can cause a malfunction and result in

serious bodily injury.

D 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.

D NEVER wipe off build-up around the tip or air cap until pressure is fully relieved.

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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.

D 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.

D 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.

D Do not use this equipment with flammable liquids.

D Keep the dispense area free of debris, including solvent, rags, and gasoline.

D 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.

D Make sure all electrical work is performed by a qualified electrician only.

D Have any checks, installation, or service to electrical equipment performed by a qualified electri-

cian only.

D Make sure all electrical equipment is installed and operated in compliance with applicable

codes.

D Make sure power is disconnected when servicing and repairing equipment.

D Before operating the equipment, extinguish all open flames or pilot lights in the dispense area.

D Do not smoke in the dispensing area.

D Keep liquids away from the electrical components

D Disconnect electrical power at the main switch before servicing the equipment.

D 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.

D Provide fresh air ventilation to avoid the buildup of vapors from the fluid being dispensed.

D Know the specific hazards of the fluid you are using.

D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all

local, state and national guidelines.

D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid

and solvent manufacturer.

D Avoid exposure to heated material fumes.

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Installation

Install the automatic applicator as follows:

D mount the automatic dispense valve D attach dispense tip or nozzle D connect the air lines D connect material hose D if heated, connect the electrical cable D if temperature conditioned, connect the water

circulation

D make sure the automatic dispense valve is

grounded

Fluid Inlet

Water Circulation Ports

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. If 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.

Mountin Holes

Ambient or temperature conditioned model shown

Fig. 1

TI1377A

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Page 8

Installation

Connect Air Lines to Dispense Valve

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 fittings could melt and cause damage to the automatic 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.

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 Heated 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.

Fig. 2

Fluid Inlet

Temperature insulation spacer

240 volt heated model shown

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Page 9

Grounding

D The power source conduit is not an ad-

D A qualified electrician must complete

Installation

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

To reduce the risk of fire, explosion, or electric shock:

equate ground for the system. The unit must be grounded to either the building ground or a true earth ground.

all grounding and wiring connections and check the resistance.

Fig. 4

5412

Ground lead coming from contact 8 is fastened to the valve body

240 Volt models

TI0305

D Refer to your local code for the requirements for

a “true earth ground” in your area.

D 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.

Heater cartridge

RTD sensor

120 Volt models

Fig. 3

2. Connect the electrical cable to the electrical control panel.

3. Verify that socket contact E on six pin models (see Fig. 5) or contact eight on eight pin models (see Fig. 4) , inside control panel receptacle, is connected 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.

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Page 10

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 tape or Velcro straps. For installations where the dispense valve is moving, it is recommended that the connector be wrapped with the Graco accessory Velcro wrap (198422) and 2 Velcro straps (198442) as shown in Fig. 7.

Fig. 5

Fig. 6

Fig. 7

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Maintenance

The following tables list recommended maintenance procedures and frequencies. The maintenance is divided between mechanical and electrical tasks. A typical application is a valve mounted on a robot dispensing a moderately abrasive sealant.

Mechanical

Task

Inspect for leaks n

Check hoses for wear* n

Check/tighten fluid connections* n

Check/tighten air connections* n

Lube packings n

Rebuild dispense valve n

Replace valve n

* Assumes movement from automation.

Electrical

Task

Check cables for wear n

Verify cable connections n

Verify resistance of electric heaters n

Verify resistance of RTD sensors n

Daily

Weekly

Monthly or

30,000 cycles

3-6 months or

125,000 cycles

Monthly

6 Months

6-12 months or

250,000 cycles

18-24 months or

500,000 cycles

12 Months

36-48 months or

1,000,000 cycles

6-8 years or

2,000,000 cycles

Packing Lubrication

This valve has a primary seal, a pressurized grease area, and a secondary seal. The key to long seal life is that the secondary seal only has to seal grease.

When dispensing filled materials this grease should be refreshed once a month.

1. Remove one of the zerk grease fittings (23).

2. Using the grease gun supplied, pump a high quality grease like #115982 (high temperature moisture free) into the remaining zerk fitting until fresh grease comes out the other side.

3. Replace the grease fittings and give the valve one more shot of grease to pressurize the cavity.

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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:

D Process fluid – Abrasive or fiber filled fluids are

much harder on seals, shafts, and seats than non-abrasive fluids such as oil.

D 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.

D 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.

D 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.

D 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 can reliably operate at 60 psi of air, even with 4000 psi of downstream pressure.

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Troubleshooting

p ( ), ( ),

Some solutions require disassembling the automatic dispense valve. Always relieve system pressure before performing these procedures.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure (page 14).

See PARTS section for the parts that need to be serviced.

Problem

Air leaks from automatic dispense valve

Material leaks from front of automatic dispense valve

Material leaks from automatic dispense valve body

Automatic dispense valve does not shut off

Automatic dispense valve does not heat material

Automatic dispense valve will not open 24.1 MPa (241 bar, 3500psi)

Cause(s) Solution(s)

Loose air connections Check air connections.

Worn o-rings Replace o-rings in cylinder.

Seal, needle, or seat is worn Replace seat seals (12 & 26),

Obstruction inside dispense valve Remove nose piece (6). Check and

Worn needle Check and replace needle (7), if neces-

Worn seat (Base seal models) Check and replace or reverse seat (13)

Seal not installed correctly Check seals (15 & 16) and replace if

Seal is worn

Loose air connections Check air connections.

Worn needle-seal interface Replace rod seal (12 & 26), needle (7),

Broken retaining ring (10) or debris in air cylinder.

Spring broken or not installed correctly Disassemble dispense valve. Check

Loose heater wires Check and reconnect wire connections.

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.

Fluid pressure in outlet line greater than

Air cylinder pressure too low Increase air pressure

needle (7), and seat (13).

replace if necessary, seals (12 & 26), needle (7), and seat (13).

sary. If replacing needle, you must reverse or replace seat (13).

if necessary. Replace needle (7) with seat (13).

necessary.

and seat (13).

Disassemble dispense valve. Check and replace, if necessary, retaining ring (10) and o-rings (17, 18, 19 and 21).

spring (24) and replace, if necessary.

Reduce outlet restrictions

Reduce fluid pressure

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Page 14

Service

Pressure Relief Procedure

WARNING

HOT SURFACE AND FLUID HAZARD 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.

SKIN 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, or moving parts, follow the Pressure Relief Procedure whenever you:

D are instructed to relieve the pressure D stop spraying/dispensing D install or clean the nozzle D check or service any of the system

equipment

This procedure describes how to relieve pressure from the automatic dispense valve. See your supply unit or system documentation for instructions on relieving pressure for the entire dispensing system. Use this procedure whenever you shut off the dispense valve and before checking or adjusting any part of the system, to reduce the risk of serious injury.

1. Shut off the material supply.

2. If heated, shut off electrical power to the automatic dispense valve.

3. Close all self bleeding air supply valves for supply unit.

4. Have a container ready to catch the drainage, then bleed off material pressure by actuating the dispense valve.

5. Shut off air supply to valve.

NOTE: If you suspect that the 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. Then clear the tip/nozzle or hose.

PRESSURIZED FLUID HAZARD

High pressures can cause serious personal 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.

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Service

Prepare to Service Automatic Dispense Valve

If the unit is hot, determine whether or not you can service the unit after it has cooled down. Some materials, like polyurethanes, may cure permanently when cooled and exposed to air, preventing you from disassembling 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.

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.

4. Remove power from the automatic dispense valve.

WARNING

HOT SURFACE AND FLUID HAZARD The material and equipment will be 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 reheated, wait for the dispense valve to cool thoroughly before servicing it.

If the material in the dispense valve cures permanently 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.

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Page 16

Service

Service the Automatic Dispense Valve

The dispense valves can be serviced or replaced without disconnecting the fluid hose or temperature control cables or tubes.

Disconnect Automatic Dispense Valve from its Inlet Manifold

Remove the automatic dispense valve from its mounting bracket.

1. Perform the procedures in Prepare to Service

Automatic Dispense Valve on page 15.

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. Pull the 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/lb.

4. Reconnect air lines to dispense valve air ports.

Fig. 8

16 309376

TI1378A

Page 17

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.

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 disassembled.

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Page 18

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 #115982 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: S Do not overextend retaining ring (10) during

installation and repair.

S Make sure to assemble retaining ring

longitudinally down the shaft diameter.

S Do not stretch the ring around the diameter. S 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).

Fluid Section

10. Lubricate all seals and sliding parts with a high temperature, moisture free grease such as the #115982 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 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 reversible 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 lb-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 lb-in.

7. Insert button (33) into housing (1) and push assembly 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 lb-in.

18 309376

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).

Page 19

[14]

[18]

[1]

Service

[12]

[1]

[20]

[11]

[1]

[16]

[15]

[17]

Fig. 9

[x]

Refers to instruction steps from procedure on page 18.

[21]

[8]

TI1379A

309376 19

Page 20

Parts

Model numbers 244535, 244907, and 244937

20 309376

TI1380A

TI1379A

Page 21

Parts

ББББББББББ

Model numbers 244535, 244907, and 244937

Ref No.

1 2 3 4 5 6

7** 8 9 10** 11** 12** 13** 14** 15**

15**

Part No.

197506 197509 197508 197503 197505 198280

ÁÁ

198443

626062 15E014 111094 15E017 626064 171860 185467 626060 551191

ÁÁ

617491

ÁÁ

Description Qty.

CYLINDER, valve CYLINDER, air, top HOUSING, cylinder, air HOUSING, lubrication HOUSING, material FLANGE, nose piece

БББББББББ

(models 244535 and 244907) FLANGE, nose piece

1 1 1 1 1 1

1 (model 244937) NEEDLE, sst hardened SHAFT, valve PISTON RING, retaining, external BEARING, lube GASKET, seat SEAT, valve INSERT, snuff-back PACKING, u-cup Fluoroelastomer

БББББББББ

1/4, 1/2, 1/8

(model 244535) PACKING, u-cup urt 1/4, 1/2, 1/8

БББББББББ

(models 244907 and 244937)

Ref No.

16**

Part No.

551190

Description Qty.

SEAL, u-cup polymt 1/4, 1/2, 1/4

(model 244535)

16**

17** 18** 19**

21** 22 23** 24 26** 27* 28* 33 35 36

551193

ÁÁ

116978 106555 102895

ÁÁ

103610 111112 100846 111092 104319 115982 551189 198234 101970 110208

SEAL, u-cup PTFE 1/4, 1/2, 1/4 (models 244907 and 244937)

ББББББББ

PACKING, o-ring, fluroelastomer PACKING, o-ring, fluroelastomer PACKING, o-ring, cylinder, fluroelastomer

ББББББББ

PACKING, o-ring, fluroelastomer SCREW, cap, socket head FITTING, lubtn, st SPRING, valve PACKING, o-ring LUBRICANT, synthetic, grease GUN, grease, 3 oz. cartridge BUTTON, valve PLUG, pipe, headless PLUG, pipe, headless

2 2 1

4 8 2 1 1 1 1 1 1

1 * not shown ** Included in repair kits. Kits also include manifold o-rings

БББББББББББББББ

for all models.

NOTE: Do not overextend retaining rings (10) during

installation and repair.

Repair Kits

Part No. Description

15E012 15E011

Standard seals High temperature seals

309376 21

Page 22

Parts

Models 244962, 244909, and 244951 (240 V. Models)

9, 11, 20

Notes:

 Install sensor (3) and heater (8) with a coating of heat sink

compound (14)

 Torque screws (6) evenly to 50–60 lb-in.

 A pin crimper is used to make these connections. Soldering is

acceptable for replacements if a new pin is used.

22 309376



Ground wire

TI1382A

Page 23

Parts

ББББББББББ

Models 244962, 244909, and 244951 (240 V. Models)

Ref

Part No. Description Qty.

No.

244535

VALVE, ext, dispense, 200 deg. F (model 244962)

1 2 3 4 5** 6

7 8 9 10

244907

ÁÁ

244937 198236 C32255 C32089 109576 116412

ÁÁ

114618 116614 114185 198232

VALVE, ext, dispense, 400 deg. F (model 244909)

ББББББББ

VALVE, (model 244951) MANIFOLD, electrical SENSOR, temperature RETAINER, nozzle PACKING, o-ring, fluroelastomer SCREW, cap, button head,

ББББББББ

M6 x 60 PIN, dowel, dia. 3/16 x 1/2 lg HEATER, cartridge, 240 V SCREW, cap, button head GUARD, manifold,

Repair Kits

Part No. Description

15E012 15E011

Standard seals High temperature seals

1 1 1 1 1 4

2 1 3 1

Ref

Part No. Description Qty.

No.

11 12 13 14* 15 16

17 18 19 20

21 22

101674 105672 116675 073019 116673 116637

ÁÁ

115860 116640 115862 065345

ÁÁ

513035 197843

TERMINAL, ring, ground SCREW, set, sch. CORD, flex, LUBRICANT, thermal BUSHING, strain relief CONNECTOR, cable coupler

ББББББББ

hood INSERT, male CONTACT, connector CONNECTOR, male, crimp WIRE, copper, electrical (16 AWG)

ББББББББ

SCREW, cap, shcs Block, mounting

2 ft.

1 * not shown ** Included in repair kits. Kits also include manifold o-rings

БББББББББББББББ

for all models.

309376 23

Page 24

Model 297261 (240 V Model)

Parts

9, 11, 20

4, 26

Notes:

 Install sensor (3) and heater (8) with a coating of heat sink

compound (14)

 Torque screws (6) evenly to 50–60 lb-in.

 A pin crimper is used to make these connections. Soldering is

acceptable for replacements if a new pin is used.



Ground wire

24 309376

Page 25

Model 297261 (240 V Model)

ББББББББББ

Parts

Ref

Part No. Description Qty.

No.

1 2 4 5** 6

244907 198236 118072 109576 116412

VALVE, ext, dispense, 400 deg. F MANIFOLD, electrical HEAD, applicator, swirl PACKING, o-ring, fluroelastomer SCREW, cap, button head,

M6 x 60 7 8 9 10

114618 116614 114185 198232

PIN, dowel, dia. 3/16 x 1/2 lg

HEATER, cartridge, 240 V

SCREW, cap, button head

GUARD, manifold,

Repair Kits

Part No. Description

15E012 15E011

Standard seals High temperature seals

Ref

Part No. Description Qty.

No.

1 1 1 1 4

2 1 3 1

11 12 13 14* 15 16

17 18 19 20

21 22 23 26

101674 105672 116675 073019 116673 116637

ÁÁ

115860 116640 115862 065345

ÁÁ

513035 197843 15H098 117950

TERMINAL, ring, ground SCREW, set, sch. CORD, flex, LUBRICANT, thermal BUSHING, strain relief CONNECTOR, cable coupler

ББББББББ

hood INSERT, male CONTACT, connector CONNECTOR, male, crimp WIRE, copper, electrical (16 AWG)

ББББББББ

SCREW, cap, shcs Block, mounting ADAPTER, swirl NOZZLE, swirl, .030

1 1 1 1 1 1

1 4 1 2 ft.

4 1 1

1 * not shown ** Included in repair kits. Kits also include manifold o-rings

for all models.

БББББББББББББББ

309376 25

Page 26

Parts

Models 244961, 244908, and 245184 (120 V. Models)

9, 11, 16

TI1384A

Notes:

 Install sensor (3) and heater (8) with a coating of heat sink

compound (14)

 Torque screws (6) evenly to 50–60 in/lbs.

TI1384A

26 309376

Page 27

Parts

ББББББББББ

Models 244961, 244908, and 245184 (120 V. Models)

Ref

Part No. Description Qty.

No.

244535

VALVE, ext, dispense, 200 deg. F (model 244961)

244907

ÁÁ

244937

VALVE, ext, dispense, 400 deg. F (model 244908)

ББББББББ

VALVE, ext, dispense, 1/2 npt

(model 245184) 2 3 4 5** 6

198236 C32255 C32089 109576 116412

MANIFOLD, electrical

SENSOR, temperature

RETAINER, nozzle

PACKING, o-ring, fluroelastomer

SCREW, cap, button head,

M6 x 60 7

114618

PIN, dowel, dia. 3/16 x 1/2 lg

Repair Kits

Part No. Description

15E012 15E011

Standard seals High temperature seals

1 1 1 1 4

Ref

Part No. Description Qty.

No.

8 9 10 11 12 13 14* 15 16

116613 114185 198232 101674 105672 116675 073019 116639 065345

HEATER, cartridge, 120 V SCREW, cap, button head GUARD, manifold, TERMINAL, ring, ground SCREW, set, sch. CORD, flex, LUBRICANT, thermal CONNECTOR, receptacle, male WIRE, copper, electrical

1 3 1 1 1 1 1 1 2 ft.

(16 AWG) 17 18 19

116688 513035 197843

CLAMP, cable

SCREW, cap, shcs

Block, mounting

1 4 1

* not shown

БББББББББББББББ

** Included in repair kits. Kits also include manifold o-rings

for all models.

309376 27

Page 28

Parts

Model 244910 (ambient or temperature conditioned)

(4) 1/8 npt(f) water circulation outlet ports

(1) 1/4 npt water circulation inlet port

TI1378A

(2) 1/8 npt(f) RTD sensor ports

TI1378A

Notes:

 Apply pipe sealant to threads per G standard 4.0520

 Torque screws (7) evenly to 50–60 lb-in.

 Mounting screws (9) loose with valve

28 309376

TI1378A

Page 29

Parts

ББББББББББ

Model 244910 (ambient or temperature conditioned)

Ref

Part No. Description Qty.

No.

1 2 3* 4 5** 6**

244535 198235 070408 110208 109576 106555

VALVE, ext, dispense, 200 deg. F MANIFOLD, water SEALANT, pipe, sst PLUG, pipe, headless PACKING, o-ring, fluroelastomer PACKING, o-ring

Repair Kits

Part No. Description

15E012 15E011

Standard seals High temperature seals

Ref

Part No. Description Qty.

No.

1 1 1 5 1 2

7 8 9 10

116412 114618 513035 C32089

SCREW, cap, button head

PIN, dowel dia 3/16 x 1/2 lg

SCREW, cap, shcs

RETAINER, seat

4 2 4

1 * not shown ** Included in repair kits. Kits also include manifold o-rings

БББББББББББББББ

for all models.

309376 29

Page 30

Accessories

Use Only Genuine Graco Parts and Accessories

Description Part No.

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 fittings are rated for at least 150 psi at 140_ F.

elbow, push-in tube 1/8” male 1/4” O.D. 597151

90 90° elbow, push-in tube 1/8” male 5/32” (4mm) 198171 Straight push-in tube 1/8” male 1/4” O.D. 104172 Straight push-in tube 1/8” male 5/32” (4mm) 114263 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.

Hose and Cable Kit 8 pin square female connector and 10 ft. of cable to mate with 240 VAC valves 244021

Quick Exhaust Valve 1/8 npt(f) 104661 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 197504 45_ orbiter mount uses the following parts: 45_ Nosepiece 197842 Alternate orbiter nut 198323 Fitting nosepiece to orbiter 198324

Streaming Adapter Alternate outlet nut to retain 270xxx streaming tips or 182xxx fan tips (See Manual 308813) 617585 Steel Dispense Nozzles

1/8 npt (m)

Repair Kits

Standard seals 15E012 High temperature seals 15E011

30 309376

NPT Tube

Coil Voltage

120 Volt AC C58942 230 Volt AC 243703 24 Volt DC C59038

198457

198458

Length Orifice Size

2” .125 607665 2” .094 161505

2.12” .055 164799

1.22” .125 C17009

2.43” .09 x.37 ribbon hardened tip C01025

Page 31

Accessories

Description Part No.

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) C20700

1/2” NPT(m) x No. 10 JIC(m) (7/8 –14 with 37_ flare) C20703

1/2” NPT(m) x No. 12 JIC(m) (1-1/16 –12 with 37_ flare) C20642

198422

198442

309376 31

Page 32

2.250

Dimensions

(4) 1/8 npt(f) temperature conditioning water outlets

1/2 npt(f) process fluid inlet

1/8 npt(f) RTD sensor port

Optional RTD port

.244

.489

.375

2.531

1.135

8.310

(4) M6 x 1 mounting holes x .46” (11.6 mm) full thread depth

Electrically heated models have an insulating mounting block

1/4 npt(f) temperature conditioning water inlet

TI1377A

3.500

32 309376

Air to close

1/8 npt(f)

4.500

Air to open

TI1378A

Page 33

Model 297261 Only

2.250

Dimensions

1/2 npt(f) process fluid inlet

Optional RTD port

9.86

.244

3.500

.489

(4) M6 x 1 mounting holes x .46” (11.6 mm) full thread depth

1.135

3.215

.375

Electrically heated models have an insulating mounting block

4.500

Air to close

1/8 npt(f)

Air to open

309376 33

Page 34

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, 244961, 244962

High temperature seals in models 244907, 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

240 Volt Heater 200w @ 240 VAC, 288 ohms +30/–40

RTD Sensor (120 Volt models – pins A and B)

(240 Volt models – pins 3 and 4)

Weight (automatic dispense valve + manifold) approx. 1.8 kg (4 lbs)

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).

100 Ohm platinum RTD, 0.00385 ohm/ohm/deg C

(108.2 ohms @ 21° C (70° F))

95_C (200_)

204_C (400_)

pins C and F

pins 1 and 2

WETTED PARTS (all valves)

Aluminum, Stainless Steel, chrome, carbide, acetal plastic, PTFE, fluoroelastomer

PRIMARY SEAL MATERIALS

Model 244535 – PolymyteR (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, 244908, 244909

Polymyte is a trademark of Parker Seal.

5/8–18 with nut to accept 1/8 npt nozzles

34 309376

Page 35

120 Volt Models

Wiring Diagram

108 +/–1 W @ 70_F

18, 36

90–100 W @ 70_F

HEATER 150 W @ 120 VOLTS

Past Therm-O-Flowt accessories

240 Volt Models

248-318 W @ 70_F

200 W @ 240 VOLTS

108 +/–1 W @ 70_F

HEATER

All Therm-O-Flow Plust accessories

309376 35

Page 36

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches,

hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

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

36 309376

International Offices: Belgium, China, Japan, Korea

Graco Headquarters: Minneapolis

GRACO INC. AND SUBSIDIARIES S P.O. BOX 1441 S MINNEAPOLIS MN 55440–1441 S USA

www.graco.com

Revised 01/2012

Graco 309376J User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual