Graco 334130B User Manual
Instructions-Parts
334130B
Therm-O-Flow® 200
For applying hot melt sealant and adhesive materials from 200 Liter (55 Gallon) drums. For professional
use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this manual and in related
manuals. Save these instructions.
Maximum Operating Temperature 400°F
(204 °C)
See page 6 for model information.
EN
See Technical Specifications, page 107,
for maximum working pressures.
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Warnings .............................................................3
Models................................................................. 6
Related Manuals .................................................. 7
Component Identification.......................................8
Advanced Display Module (ADM).................. 12
Overview............................................................15
Air and Fluid Hoses...................................... 15
Heat Control Zone........................................ 15
Setup ................................................................. 16
Unpack........................................................16
Location Requirements................................. 16
Install System .............................................. 16
Install Hydraulic Power Supply...................... 16
Mechanical Setup ........................................ 17
Install Heated Hose...................................... 18
Connect Multiple Devices ............................. 20
Connect Power ............................................ 21
Grounding ................................................... 22
Connect Secondary System..........................22
Check Sensor Resistance ............................23
Check Heater Resistance............................. 24
Select ADM Settings .................................... 25
Connect PLC............................................... 27
Operation........................................................... 30
Purge System.............................................. 30
Load Material............................................... 31
Heat Up System...........................................32
Prime Pump ................................................33
Prime System.............................................. 35
Setback Mode..............................................35
Pressure Relief Procedure............................ 36
Shutdown .................................................... 37
Schedule..................................................... 37
Change Drums ............................................ 38
Troubleshooting..................................................39
Repair................................................................ 47
Replace Wipers ........................................... 47
Replace Platen RTD ....................................47
Separate the Air Motor and Pump................. 48
Remove Platen ............................................ 50
Replace Heater Bands and Pump
RTD...............................................51
Replace MZLP Fuse .................................... 52
Replace MZLP............................................. 53
Replace MZLP Daughter Card...................... 54
Replace AWB.............................................. 55
Replace Power Supply................................. 55
Replace Fan ................................................ 56
Replace Transformer....................................57
Update Software.......................................... 59
Electrical Schematics.......................................... 60
Parts.................................................................. 66
Accessories and Kits........................................... 90
Wiper Kits.................................................... 90
Applicators and Dispense Valves.................. 90
Air-OperatedHeatedDispense Valves........... 90
Flow Control and Manifolds .......................... 90
Accessory Extension Cables.........................90
Light Tower Kit, 24W589 .............................. 90
Tie Rod Kits................................................. 90
8 Zone Upgrade Kit Installation..................... 94
12 Zone Upgrade Kit Installation ................... 96
Appendix A— ADM............................................. 97
Operation Screens ....................................... 99
Setup Screens........................................... 100
Appendix B — USB Data .................................. 105
Download.................................................. 105
Access Files.............................................. 105
Upload ...................................................... 105
USB Logs.................................................. 106
System Settings File .................................. 106
System Language File................................ 107
Create Custom Language Strings ............... 107
Dimensions...................................................... 108
Technical Specifications.................................... 109
Graco Standard Warranty.................................. 110
2
334130B
Warnings
Warnings
The following warnings are for the 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. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during ope ration. To avoid
severe burns:
• Do not touch hot fluid or equipment.
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of
platen, splatter may occur.
• Use minimum air pressure when removing platen from drum.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amp utate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with pro tec tiv e guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the
ELECTRIC SHOCK HAZARD
This equipment must be grounded. 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 before
servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
Pressure Relief Procedure
and disconnect all power sources.
334130B 3
Warnings
WARNING
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure
due to the thermal expansion. Over-pressurization can result in equipment rupture and serious
injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce
skin. This may look like just a cut, but it is a serious injury that can result in amputation.
immediate surgical treatment.
• Engage trigger lock when not dispensing.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or defle ct leaks with your hand, body, glove, or rag.
•Followthe
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
Pressure Relief Procedure
when you stop dispensing and before cleaning,
Get
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
• Ground all equipment in the work area. See
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
•
Stop operation immediately
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
if static sparking occurs or you feel a shock.Donotuse
Grounding
work area
instructions.
canigniteorexplode.Tohelp
4
334130B
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modif y equipmen t. Al terati on s or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or o ver bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
Technical Data
Pressure Relief Procedure
in all equipment manuals.
when equipment is not in use.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
334130B 5
Models
Models
The model number stamped on your systems defines the equipment in the following categories.
See Technical Specifications, page 109, for maximum working pressure.
SER A B C D E F G H
Series FrameSize Air
Air/Electric
Zone
Config
Pump
Ratio
Platen
Style
Platen
Seal
Ram Drum
Clamp
Code A Frame Size
200
Code B
Code C
11P
11S
12P
12S
13P
13S
14P
14S
15P
15S
21P
21S
22P
22S
23P
23S
24P
24S
25P
25S
31P
31S
32P
32S
33P
33S
34P
34S
35P
55 Gallon (200 Liter)
Air/Electric
Air control only
A
E Air and Electric
Zones, Volts, Type
4 Zones, 230 V, Primary
4 Zones, 230 V, Secondary
4 Zones, 400 V/N, Primary
4 Zones, 400 V/N, Secondary
4 Zones, 400 V, Primary
4 Zones, 400 V, Secondary
4 Zones, 480 V, Primary
4 Zones, 480 V, Secondary
4 Zones, 575 V, Primary
4 Zones, 575 V, Secondary
8 Zones, 230 V, Primary
8 Zones, 230 V, Secondary
8 Zones, 400 V/N, Primary
8 Zones, 400 V/N, Secondary
8 Zones, 400 V, Primary
8 Zones, 400 V, Secondary
8 Zones, 480 V, Primary
8 Zones, 480 V, Secondary
8 Zones, 575 V, Primary
8 Zones, 575 V, Secondary
12 Zones, 230 V, Primary
12 Zones, 230 V, Secondary
12 Zones, 400 V/N, Primary
12 Zones, 400 V/N, Secondary
12 Zones, 400 V, Primary
12 Zones, 400 V, Secondary
12 Zones, 480 V, Primary
12 Zones, 480 V, Secondary
12 Zones, 575 V, Primary
35S
NNN None
Code D
CodeEPlaten
CodeFPlaten Seal
Co
CodeHDrum Clamps
12 Zones, 575 V, Secondary
Pump Ratio
23:1 CF
1
(carbon filled PTFE)
2
36:1 CF
3
70:1 CF
23:1 GF
4
(glass filled PTFE)
5
36:1 GF
670:1GF
Style
S Smooth Bottom (No Fin)
F
Standard Finned Bottom
MMega-Flo
1
2 Black EPDM/EPDM, SS wire braid
400°F (204°C) hose wipers with spring
retention
2
1 lower Black EPDM/Chlorobutyl, SS wire
braid 400°F (204°C) hose wiper and 1
upper Green Silicone, fiberglass braid
400°F (204°C), hose wiper
3
2 White Silicone 250°F (121°C) T-Wipers
4
1 lower Blac k EPDM/Chlorobutyl, S S
wire braid 375°F (190°C) hose wiper and
1 upper White Silicone 375°F (190°C)
T-wiper
deGRam
PPneumatic
HHydraulic
NNone
1
Saddle Clamp
2
Fiber Clam Shell
3HeavyDrumBand
6 334130B
Related Manuals
Manual Description
Air Motor Manuals
Related Manuals
311238
3A1211
Displacement Pump Manual
334127
334128
Ram Manual
334198
Accessory and Kit Manuals
309160 Heated Hose, Instructions-Parts
309196 Wiper Kits, Repair-Parts
310538 Air-Operated Dispense Valves,
311209 Top Feed and Bottom Feed Hot Melt
334201
NXT® Air Motor, Instructions-Parts
Saniforce® Air Motor,
Instructions-Parts
Check-Mate® 800 Pump,
Repair-Parts
Check-Mate® 800 Throat Seal Repair
Kit, Repair-Parts
Therm-O-Flow 200 Pneumatic and
Hydraulic Ram, Instructions-Parts
Instructions-Parts
Dispense Guns, Instructions-Parts
Air Controls, Repair Kit
334130B
7
Component Identification
Component Identification
Figure 1 TOF 200 Pneumatic
Key:
A
B Multi-Zone Low Power Temperature
C
D
ERam
F Heated Pump
G
H
J
8 334130B
Lift Strap Positions
Control Module (MZLP)
Light Tower
Cable Track
Heated Platen
Integrated Air Controls (3/4 in npt inlet)
Electrical Control Panel
Key:
K
LADM
M
N Electrical Power Input
PAirMotor
R
S Drum Blow Off Valve (behind ram plate
T
Main Power Switch
Air Motor Solenoid
Ram Plate Bleed Stick
bleed stick)
Drum Low and Empty Sensors
Integrated Air Controls
Component Identificatio n
Figure 2 Integrated Air Controls
Key:
CA Main Air Slider Valve
Turns air on and off to the entire system.
When closed, the valve relieves pressure
downstream.
CB
CC Ram Director Valve
CD
CE
CF
CG Blowoff Button
Ram Down Air Regulator
Controls the ram down pressure.
Controls the ram direction.
Ram Up Air Regulator
Controls the ram up pressure.
Ram Down Air Gauge
Displays the ram down pressure.
Ram Up Air Gauge
Displays the ram up pressure.
Turns air on and off to push the platen out of
an empty drum.
Key:
CH Blowoff Pressure G auge
Displays the blowoff pressure.
CJ
CK
CL
CM Air Motor Slider Valve
CN Air Motor Solenoid Valve
Blowoff Air Regulator
Controls platen blowoff pressure.
Air Motor Air Regulator
Controls the air pres sure to the motor.
Air Motor Pressure Gauge
Displays the air pressure to the motor.
Turns air on and off to the air mo tor. When
closed, the valve relieves air trapped
between it and the motor. Push the valve
in to shutoff air.
Turns air on and off to the air motor when
system stopped on the ADM. When closed,
the valve relieves air trapped between it and
the motor.
334130B 9
Component Identification
Electrical Control Enclosure
Figure 3 Electrical Enclosure
10 334130B
Component Identificatio n
Key:
DA Multi-Zone Low Power Temperature
Control Module (MZLP)
DB
DC Electrical Control Panel
DD
DE
DF
Ventilation Grill
Automatic Wiring Board (AWB)
Power Supply (24V)
Residual Current Device (GFI), 63A
Key:
DGPlatenSSR(65A)
DH
DJPlatenFuse
DK
DL
DM
Platen Contactor
Transformer Circuit Breaker
Transformer Fuse
Transformer
334130B
11
Component Identification
Advanced Display Module (ADM)
The ADM display shows graphical and text
information related to setup and spray operations.
For detail on the display and individual screens, see
Appendix A— ADM, page 97.
Use the USB port on the ADM to download or upload
data. For more information about the USB data, see
Appendix B — USB Data, page 105.
NOTICE
To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.
Figure 4 Front View
Key
BA
BB
BC
BD
BE
BF
BG
BH
Function
Heating system and pump enable/disable
m status indicator (LED)
Syste
ll system processes
Stop a
dbyiconnexttosoftkey
Define
current operation
Abort
Accept change, acknowledge error, select item,
toggle selected item
Toggle between Operation and Setup screens
Navigatewithinascreenortoanewscreen
12
334130B
Figure 5 Back View
BK
BL
BM
Table 1 ADM LED Status Descriptions
Part Number and Identi fication Label
USB Interface
CAN Cable Connection (Power Supply and
Communication)
BN
BP
BR
Component Identificatio n
Module Status LEDs
Light Tower (Optional)
Software Token Access Panel
LED
System Status
USB Status (BL)
ADM Status (BN)
Conditions
Green Solid Run Mode, System On
Green Flashing Setup Mode, System On
Yellow Solid Run Mode, System Off
Green Flashing
Yellow Solid Downloading information to U SB
Green and Yellow Flashing ADM is busy, USB cannot transfer
Green Solid
Yellow Solid Active Communication
Red Steady Flashing Software upload from token in
Red Random Flashing or Solid
Description
Data recording in progress
informationwheninthismode
Power applied to module
progress
Module error exists
334130B 13
Component Identification
Screen Components
1. Screen Order
2. Current date and time
3. Operating Mode
4. Faults, Status
5. MZLP Plug Identifier
6. Zone Setpoint Temperature
7. Zone Actual Temperature
Operating Mode Description Component Status
System Off The system do
es not have powe r.
• No system sta
ADM
tus indicator LED on the
Inactive The heating system and pumps are
disabled.
Warm Up The system is heating the material to the
setpoint temperature.
Heat Soak
Ready All enabled zones are at setpoint
Heat zones are all at temperature.
Material is soaking for a user specified
amount of time.
temperature. The air motor does not have
power.
•Noheat
•Pumpisoff
• Yellow system indicator LED on the
ADM
•Noheat
•Pumpisoff
• Flashing green system status indicator
LED on the ADM
• Heat is increasing to setpoint
temperature
•Pumpisoff
• Flashing green system status indicator
LED on the ADM
• Heatisatsetpoint
• Material is absorbing more heat
•Pumpisoff
• Heat soak counter counts down on the
Home screen.
• Flashing green system status indicator
LED on the ADM
• Heatisatsetpoint
Act
14
ive
system is ready to dispense.
The
•Pumpisoff
• Solid green system status indicator
LED on the ADM
• Heatisatsetpointtemperature
•Pumpison
334130B
Overview
A heated platen melts the sealant or adhesive and
directs the molten material to the pump inlet. The
material then travels through a heated pump and
heated fluid moves to the application tool.
Air and Fluid Hoses
The Therm-O-Flow requires Graco single-circuit
material hoses rated at a maximum of 1250 watts.
Make sure all air and fluid hoses are properly sized
for the system.
Heat Control Zone
The Therm-O-Flow has 4, 8, or 12 heat zones. Zones
for the heated drum platen and the heated pump
are not included in the zone count. Zones 1 and 2,
3 and 4, 5 and 6, 7 and 8, 9 and 10, and 11 and
12 are each available through 12-pin connectors.
The heated hoses have a 16-pin connector at the
inlet, and an 8-pin connector at the o u tlet. All heated
valves, manifolds, and heaters are equipped with an
8-pin mating connector.
Overview
Figure 6 Heat Control Zone Selection
334130B 15
Setup
Setup
1. Unpack the ram
2. Locate and Install the ram
3. Mechanical Setup
4. Connect hoses to electrical control panel
5. Connect electrical control panel t o power source
6. Ground system
7. Select ADM settings
Unpack
1. Inspect the shipping box carefully for damage.
Contact the carrier promptly if there is damage.
2. Open the box and inspect the contents carefully.
There should not be any loose or damaged parts
in the box.
3. Compare the packing slip against all items in the
box. Re port any shortages or other inspection
problems immediately.
4. Remove the unit from the skid and place it in the
desired location. See
Location Requirements
.
4. Make sure there is easy access to an appropriate
electrical power source. The National Electrical
Code requires 3 ft (0.9 m) of open space in front
of the electrical panel. Comply with all local
codes and regulations.
5. For hydraulic rams, locate the hydraulic power
supply in an area that has:
• easy access for servicing and adjusting the
hydraulic pressure on the su pply unit.
• sufficient clearance for the hydraulic lines that
attach to the pump.
• easy access to read the hydraulic fluid level
gauge.
Install System
Refer to Dimensions, page 108 for mounting and
clearance dimensions.
Follow all Location Requirements, page 16,when
selecting a location for the ram.
1. Apply 50 psi download pressure to ram.
2. Wrap the bar with the lifting sling.
3. Lift the system off the pallet using a crane or a
forklift and place in desired location.
Location Requirements
1. Make sure there is sufficient overhead clearance
for the pump and ram w hen the ram is in the fully
raised position (approximately 110 in. (280 cm).)
2. If you are installing a vent hood, make sure there
is sufficient horizontal clearance for it. Locate the
ram near a connection to the factory ventilation
system.
3. Make sure the air regulators for the pump and
ram are fully accessible, with room to stand
directly in front of the pneumatic control panel
and the electrical control panel.
4. Level the base of the ram, using metal shims.
5. Bolt the ram to the floor, using anchors that are
long enough to prevent the unit from tipping.
Install Hydraulic Power Supply
See the Ram manual for installation and dimensions.
16 334130B
Setup
Mechanical Setup
1. Fill displacement pump wet cup 2/3 full with
Graco Throat Seal Liquid (TSL™) for Butyl and
PSA materials.
Note
Use IsoGuard Select® (IGS) (part
no. 24F516) for PUR or reactive
Polyurethane material. IGS is
designed to dissolve and suspend the
Polyurethane materials. IGS will solidify
after a period of time and should be
replaced once the solidified lube does
not return to liquid form after heating.
Figure 7 Wetcup
4. Ensure drum low and empty sensors (C) are
mounted as shown.
Note
TheDrumLowandEmptySensorsare
used to indicate that a drum is empty.
The kit contains a sensor mounting
bracket (A), activator (B), sensors (C1,
C2), and a cable for connecting the panel
inside the electrical enclosure.
2. Turn all air regulators to their full counterclockwise
position. See Integrated Air Controls, page 9.
3. Connect a 1/2 in. (13 mm) air line from an air
source to the system air inlet (H), capable of
delivering a minimum of 25–50 cfm at 100 psi (0.7
MPa, 7.0 bar).
Figure 8 Air Connection
Do not use quick disconnects
.
5. Increase the distance between the low (C1) and
empty (C2) sensors to increase the heat up time
for the tandem secondary system. Lower the
drum empty sensor (C2) to force the heated
platen lower into the drum. If empty sensor is set
too low, the pump could cavitate and cause an
alarm.
334130B
17
Setup
Install Heated Hose
To connect a hose to a fluid control device or heated
manifold.
1. Install fitting and heated hose onto pump outlet
with the large electrical connector side toward
thesystem.Use2wrenchestotightenhose.
Torque to 45 ft-lbs (61 N•m).
Note
See Accessories and Kits, page 90 for
available fittings and heated hoses.
Figure 9
2. Wrap exposed fittings on the pump outlet with
Nomex insulation and secure insulation using
fiberglass tape.
3. Connect large heated hose connector to cable
from track.
Figure 10
4. Repeat for any remaining channels.
Note
Only two accessory cables fit in cable
track. Addi tional cables for 8 zone and
12 zone systems are shipped loose.
5. For proper operation, cables must be plugged
into zones 1–2 and 3–4 at all times.
6. Install cap on any unused MZLP electrical
connectors.
18 334130B
7. Connect the small 8 pin connector from the
heated hose to the fluid control device or heated
manifold.
Figure 11 Heated Manifold 243697
Note
Theheatedmanifold(part
no. 243697) shown. See
Accessories and Kits, page 90,for
available manifolds and fluid control
devices.
Setup
8. Use 2 wrenches to tighten hose. Torque to 45
ft-lbs (61 N•m).
9. To connect multiple devices, see
Connect Multiple Devices, page 20.
334130B 19
Setup
Connect Multiple Devices
If your application requires multiple fluid control
devices:
• Connect heated hose electrical connections to
the electrical enclosure. Use accessory cables if
necessary. Additional cables (part no. 17C694)
areprovidedwith8and12zonesystems.Remove
from shipping box to connect heated hoses to
the electrical enclosure. For additional cables,
heated hose, and fluid control devices, see
Accessories and Kits, page 90.
• Connect fluid control devices to a heated hose
or the electrical enclosure. Use accessories if
necessary.
• Setup all heat zones on Heat-A and Heat-B
screens.
Example: Heated zones used to connect a primary
andsecondarysystemtoamanifoldandtwoguns.
A-# zones are on the Heat-A screen and B-# zones
are on the Heat-B screen.
Figure 12
20 334130B
Setup
Connect Power
The electrical control panel comes already attached
and wired to the ram, however before the supply unit
becomes functional you must connect the electrical
control panel to a power source.
All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
Note
Required voltage and amperage is noted on
the control panel label. Before running power
to the unit, make sure the plant electrical
service meets the machine’s electrical
requirements.
Table 2 Electrical Requirements
Elec-
trical
Panel
Voltage
220 /
240
Hz Phase Platen
50/60 3
EF, ES
EM 80
Full
Load
Amps
70
power source wires to the appropriate terminals
on the DISCONNECT switch.
Figure 13
To reduce the risk of fire, explosion, or electric
shock, the resistance between the supply unit
components and true earth ground must be
less than 0.25 ohms.
3. Connect
Haveaqu
between
the true
less tha
than 0.2
requir
proble
the ground wire to the ground lug.
alified electrician check the resistance
each Therm-O-Flow system ground and
earthground. Theresistancemustbe
n 0.25 ohms. If the resistance is greater
5 ohms a different ground site may be
ed. Do not operate the system until the
m is corrected.
380 /
400
470 /
490
570 /
590
EF
EM Mega-Flo
ES Smooth Bottom
1. Locate the opening in the control panel’s top
housing for the conduit that will enclose the wire
from the facility’s power source. The hole will
accept a a cord diameter range of 0.7–1.2 in
(17–30 mm).
2. Thread the wire from the power source into the
control panel housing, and then connect the
50/60 3
50/60 3
50/60 3
Standard Finned Bottom
EF, ES
EM 48
EF, ES
EM 40
EF, ES
EM 32
42
35
29
Note
Use a meter that is capable of measuring
resistance at this level.
334130B
21
Setup
Grounding
Ground the unit as instructed here and in the
component manuals.
The equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape path for the
electric current.
System:
enclosure. See Connect Power, page 21.
Air and fluid hoses:
hoses.
Air compressor:
recommendations.
Spray gun/Dispense valve:
connection to a properly grounded fluid hose and
pump.
ground through ground lug in electrical
use only electrically conductive
follow manufacturer’s
ground through
Material drums:
drums placed on a grounded surface. Do not place
the drum on a nonconductive surface, such as
paper or cardboard, which interrupts the grounding
continuity.
To maintain grounding continuity when flushing
or relieving pressure:
separate gun manual for instructions on how to safely
ground your gun while flushing.
follow local code. Use only metal
follow instructions in your
Connect Secondary System
A secondary system is a Th erm-O-Flow supply
system that connects to the primary Therm-O-Flow
system, with the ADM. See Models, page 6 for
secondary system model numbers.
1. Connect adapter cable (AC) and communication
cable (SC) to the secondary electrical enclosure
and rout to splitter (SS) installed on the primary
system.
2. To enable a secondary system, select “Enable
Tandem System” on the System 1 screen. See
Select ADM Settings, page 25.
Figure 14
22
334130B
Setup
Check Sensor Resistance
To reduce risk of injury or damage to equipment,
conduct these electrical checks with the main
power switch OFF.
The package includes up to twelve heat sensors and
controllers for each of the heated zones. To check
sensor resistance:
1. Turn main power switch off.
2. Wait for components to cool down to ambient
room temperature 63°-77°F (17°-25°C). Check
electrical resistance for the components.
MZLP Zones Pins
First Heat Zone A,J
Second Heat Zone C,D
First RTD
Second RTD
Earth Ground
G, K
M, K
B
3. Replace any parts whose resistance readings
do not comply with t he ranges listed in the RTD
Sensors chart below.
Cable 17C694
A
J
M
H
G
F
E
L
K
C
D
Table 3 RTD Sensors
MZLP MZLP Plug
1
2
B
ti24580a
3
1,2
3,4
5,6
7,8
9,10
11,12
Component
RTD Range
(Ohms)
Ram Plate 100 +/- 2
Fluid Pump 100 +/- 2
Heated
100 +/- 2
Accessory
1
Heated
100 +/- 2
Accessory
2
Heated
100 +/- 2
Accessory
3
Heated
100 +/- 2
Accessory
4
Heated
100 +/- 2
Accessory
5
Heated
100 +/- 2
Accessory
6
Heated
100 +/- 2
Accessory
7
Heated
100 +/- 2
Accessory
8
Heated
100 +/- 2
Accessory
9
Heated
100 +/- 2
Accessory
10
Heated
100 +/- 2
Accessory
11
Heated
100 +/- 2
Accessory
12
334130B 23
Setup
Check Heater Resistance
To reduce risk of injury or damage to equipment,
conduct these electrical checks with the main
power switch OFF.
1. Turn main power switch off.
Table 4 Heaters
Component
Platen
Between
Terminals
AD, BE, FC 220/240 VAC
AD, BE, FC
AD, BE, FC 570/590 VAC
Any to GND
For Unit Voltage
380/400 VAC
470/490 VAC
All Any
2. Make electrical resistance checks for the
components.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in tables.
Note
Check resistance at ambient room
temperature 63°– 77°F (17°– 25°C).
Platen Model Code Resistance Values (ohms)
EM
EF, ES 9.6Ω +2 / -3Ω
EM
EF, ES 19.2Ω +2 / -3Ω
EM
EF, ES 19.2Ω +2 / -3Ω
EM
EF, ES 19.2Ω +2 / -3Ω
8.25Ω +1 / -2Ω
16.5Ω +1 / -2Ω
16.5Ω +1 / -2Ω
16.5Ω +1 / -2Ω
100,000Ω Min
Component
Pump T1/T3, T2/T3,
Between Terminals For Unit Voltage
B1/B3, B2/B3
Platen Model Code Resistance Values (ohms)
Any Any
192.0 +/- 19.2Ω
24
334130B
Select ADM Settings
Note
See Appendix A— ADM, page 97 for
detailed ADM information, including general
operation.
1. Turn main power switch on.
Setup
2. When the ADM is finished starting up, p res s
to switch from the Operation screens to
the Setup screens. Use the arrows to navigate
between screens.
3. Check system settings on the System 1 screen.
4. Set alarm levels on the System 2 screen.
Note
Setback temperatures must be at least
20°F (10°C) lower than the setpoint
temperatures
Note
To ensure accurate hose temperatures,
be sure all heated hoses have their
“zone type” set to “Hose.” Hoses are only
present on odd zone numbers: 1, 3, 5,
7, 9, or 11.
a. Select the appropriate “Zone Type” for all
installed zones.
b. Check the “A” and “B” boxes according to
which systems needs to use the heated
accessory.
6. If a secondary system is used, set temperatures
on the Heat-B screens.
7. Set the system date and time on the Advanced 1
screen.
5. Set primary system setpoint and setback
temperatures for the pump, platen, and heat
zones on the Heat-A screens.
334130B 25
Setup
8. Set the temperature and mass units on the
Advanced 2 screen. Set the specific gravity of
the material for Material Tracking functionality.
Note
If the Specific Gravity is set to zero, the
Home screen will display a cycle counter
instead of grams or pounds.
9. To setup the optional Schedule function, see
Schedule, page 37.
The schedule function allows the system to
automatically enable and disable heating and
setback at specified times.
10. Optional: Set any remaining settings in the Setup
screens before using the system. These are not
required for system operation, but include useful
functions. See Appendix A— ADM, page 97 for
detailed information about each setup item.
26 334130B
Setup
Connect PLC
A PLC can control and monitor all items
shown in the Customer Digital Inputs and
Outputs shown on the Diagnostics screen. See
Appendix A— ADM, page 97.
When the PLC has control of the system:
• Functionality is restricted from the ADM
• Automatic crossover is disabled. Rely on the PLC
and machine state indicators to know when to
cross over using the I/O.
Table 5 Customer Input
Signal
No.
1
2
3
4
Table 6 Customer Output
Signal
No.
1
2
3
4
Unit A Description
Heat On Request
Setback Request
Pump On Request
PLC Control Request
(input applies to
primary to unit A
only)
Unit A or B Description
Run State Bit Low See Run State Chart
Run State Bit High See Run State Chart
Error State Bit Low See Error State
Error State Bit High See Error State
Turn on the Heat
Put the Unit in
Setback
Turn on the Pump
Control the primary
and secondary TOF
systems from the
PLC instead of the
ADM
Chart
Chart
Table 7 Output Error States
Error State Bit
High
0 0 Machine is
01ActiveUnit
10ActiveUnit
1 1 Alarm Present
Table 8 Output Run States
Run State Bit
High
00
01
10
11
Note
All outputs are normally open when power is
OFF. For error (alarm) output, the contacts
close when an alarm occurs. For all others,
contacts close.
Note
The TOF system ships with two screw
terminal connectors that plug into MZLP
connectors H1 and H2. Connectors are
locatedinabagontheinsideoftheelectrical
enclosure. To replace the connectors, order
kit 24P176.
1. Turn main power switch off.
2. Open the electrical enclosure door.
3. Route I/O cables through strain relief.
Error State Bit
Low
good, no errors
are present
Drum Low
Drum Empty
in System
Run State Bit
Low
Pump Off/ Heat
Off
Pump Off/ Heat
On
Pump Off/ Heat
At Temp
Pump On/ Heat
At Temp
334130B
4. Remove power from the PLC.
5. Connect the PLC to connectors H1 and H2.
Note
Each connector has four signals. The
MZLP board specifies the input range for
each signal. See the following table for
pin assignments.
27
Setup
H2 Customer Output
Signal
11,2
23,4
35,6
47,8
Pin
Figure 15
Inputs:
function without concern for polarity. Applying “high”
voltage will turn the heaters on and enable setback.
Removing voltage will turn the heaters off and disable
setback.
Outputs:
H1 Customer Input
Signal
11,2
23,4
35,6
47,8
Pin
High: 10–30 VDC, Low: 0–5 VDC. Inputs
0–250VAC,0–30VDC,2AMaximum.
28 334130B
PLC Connections Block Diagrams
The following block diagrams show how to connect customer inputs and outputs to the MZLP. For
convenience, each system ships with connector kit 24P176. If a connector is lost or damaged, order kit
24P176 for replaceme nts.
Setup
Figure 1
Figure 17 Customer Output
6 Customer Input
334130B 29
Operation
Operation
1. Turn the main power switch ON. The Graco logo
will display until communication and initialization
is complete.
2. Press the button. Verify the machine is
in “Warm Up” state, and that the temperatures
are increasing. Allow the system to reach the
“Ready” state before pumping. The pump will
automatically turn on, if autostart is enabled in
setup screens, when all the heat zones reach
their setpoint temperature.
Purge System
NOTICE
Use fluids that are chemically compa tible with
the equipment wetted parts. See Technical
Specifications in all of th e equipment manuals.
1. Select the material for the initial material load.
2. Verify whether the factory-test oil and the initial
material load are compatible:
a. If the two substances are compatible omit the
remaining steps in this procedure and refer
to Load Material, page 31.
b. If the two substances are incompatible
perform the remaining steps in this procedure
to flush the system.
3. Select a drum of material that can eliminate the
factory-test oil from the system. If necessary,
check with Graco or the material supplier for a
recommended solvent.
4. Beforepurgingbesuretheentiresystem
and waste drum are properly grounded. See
Grounding, page 22.
5. Turn all heat zones’ setpoint temperature to the
material manufacturer’s recommended dispense
temperature, or a minimum of 100°F (37°C)
minimum.
Note
NOTIC
Purge the system before initial use and when
chemicals are changed to prevent material
contamination, which may cause the material to
fail or perform poorly. The system was factory-
tested using a light soluble oil, a soybean oil, or
some other oil as tagged. Flush the system to
avoid contaminating the material that has been
designated for initial material loading.
E
Remove any dispense valve orifices
before purging. Reinstall after purging
has been completed.
6. Purge the material through the system for
approximately 1 to 2 minutes.
7. Remove the drum if purge material was used.
See Change Drums, page 38.
30 334130B
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