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Electrical Control Panel Troubleshooting

311513D

11

Electrical Control Panel Troubleshooting

Problem

Cause

Solution

Disconnect is ON, but EasyKey on 
Therm-O-Flow has communication 
error.

The ground fault interrupt activated.

Reset ground fault interrupt, page 10.

One or more fuses is blown.

Replace the blown fuse(s).

Communication cable disconnected.

Connect cable.

Warnings

Cause

With optional light tower, the yellow light illuminates and green light remains on if in Run mode.

Temperature Warning - occurs when a zone temperature is above/below the se/- warning deviation speci-
fied in the Zone tab of the Setup screen.

Alarms

Cause

With optional light tower, the red light illuminates.

High Temperature - occurs when the zone temperature is above the setpoint plus alarm deviation specified in the 
Zone tab of the Setup screen.

Low Temperature - occurs when the zone temperature is below the setpoint minus alarm deviation specified in the 
Zone tab of the Setup screen while the unloader is in the Run state.

Sensor Error occurs in the following conditions:

When an enabled zone does not increase in temperature within 7 minutes while the system is in the Heat On 
state. This is the short circuit state of an RTD sensor. 

When a zone temperature exceeds 500°F (260°C). This is the open circuit state of an RTD sensor.

Heater Error - occurs if the contactor relay on a temperature board is not closed when a zone of the temperature 
board is enabled and in a heat state for the active unloader.

Communication Error - there are two possibilities:

Start up - Occurs if the EasyKey display board cannot communicate with any board in the system.

Normal Operation - occurs if any board in the system, including expansion enclosure, cannot communicate with 
the EasyKey Display board.

Events

Cause

Maintenance - occurs in advanced unit if user presses maintenance call button. See Maintenance Call Kit in 
Therm-O-Flow manual for additional information.
With optional light tower the yellow light turns on. 
See Electrical Schematics in Therm-O-Flow manual for additional information.

Summary of Contents for 311208

Page 1: ...2 Series A 400 F 204 C Maximum Control Temperature For complete system installation and operation instructions see the following manuals Important Safety Instructions Read all warnings and instruction...

Page 2: ...m 6 Connecting the Electrical Control Panel to a Power Source 7 Check the Resistance Between the Supply Unit and the True Earth Ground 8 Checking Resistance 8 Resetting the Ground Fault Interrupt 10 E...

Page 3: ...r in the work area ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power at main switch before disconnecting any cables and befor...

Page 4: ...cover The Therm O Flow Expansion Controls are intended to heat combinations of hot melt hoses and guns or acces sory devices Accessory devices include guns compen sators regulators manifolds and head...

Page 5: ...eated Hose Zones 5 and 6 E Hose Hanger F Manual Dispense Valve G Extra Heated Hose Zone Acc 1 H Extra Dispense Valve Zone Acc 2 J 4 Zone Expansion Control K Electrical Control Panel 6 Zone L Heated Ra...

Page 6: ...and accessories Dispensing Spray Gun Follow the dispensing spray gun grounding instructions Object Material is Applied To Ground the object according to your local code Material Drums Ground the mater...

Page 7: ...duit that will enclose the wire from the facility s power source The hole diameter is 0 804 20 mm and includes a cord strain relief for cable diameters from 0 236 6 mm to 0 472 12 mm 2 Thread the wire...

Page 8: ...dicated To check the sensor resistance 1 Make sure the power is off and that the disconnect switch is in the OFF position 2 Make electrical resistance checks for the compo nents 3 Replace any parts wh...

Page 9: ...etting temperature con trols P I and d settings are preset for device types and will not need to be changed Refer to the Zone Setup Screens in your Therm O Flow manual for a list of device types and h...

Page 10: ...onnect on the electrical control panel 2 Open the electrical control box and locate the Ground Fault Interrupt switch GFPE The ground fault interrupt will be in a neutral position between the ON and O...

Page 11: ...fied in the Zone tab of the Setup screen while the unloader is in the Run state Sensor Error occurs in the following conditions When an enabled zone does not increase in temperature within 7 minutes w...

Page 12: ...Electrical Control Panel Troubleshooting 12 311513D FIG 5 Electrical Schematic continued on page 13...

Page 13: ...Electrical Control Panel Troubleshooting 311513D 13 FIG 6 Electrical Schematic continued...

Page 14: ...IRE DUCT 1 25 X 3 0 WIRE DUCT SSR 113 SSR116 SSR 119 SSR 122 FU 113 FU 116 FU 119 FU 122 FU 1051 FU 1052 PCB 201 PS 123 GFPE 112 DC INT CONN 112 GND LUG N L TI8193b SSR113 SSR116 SSR119 SSR122 FU113 F...

Page 15: ...ft 4 57 m long Runs between controller and heated hose 196314 16 pin to 16 pin Extension Cable 25 ft 7 62 m long Runs between controller and heated hose 196315 16 pin to 8 pin Extension Cable 15 ft 4...

Page 16: ...Dimensions 16 311513D Dimensions Front View Side View 8 80 in 224 mm 14 50 in 368 mm 16 0 in 406 mm 14 50 in 368 mm 16 0 in 406 mm Four 0 40 in 11 mm diameter holes TI8166A TI8165A...

Page 17: ...EATER CIRCUIT HOSE RTD SENSOR 108 2 ohms 1 ohm MACHINE END DH1 DH2 CONNECTOR PINOUT GUN END DH1 DH2 CONNECTOR PINOUT GUN HEATER GUN SENSOR NOT USED GUN SWITCH GUN GROUND HOSE CORE GROUND GND 16 Pin Ou...

Page 18: ...al 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 EX...

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