GRACO Therm-O-Flow 200 Instruction manual

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Page 1

Instructions-Parts

Therm-O-Flow

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 7 for model information.

See Technical Specifications, page 113, for maximum working pressures.

200

334130T

3143485

Page 2

Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . 8

Integrated Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Control Enclosure . . . . . . . . . . . . . . . . . . . . 10

Advanced Display Module (ADM) . . . . . . . . . . . . . . . . 11

Screen Components . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Air and Fluid Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Heat Control Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Unpack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Location Requirements . . . . . . . . . . . . . . . . . . . . . . . . 15

Install System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Install Hydraulic Power Supply . . . . . . . . . . . . . . . . . . 15

Mechanical Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Install Heated Hose . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Connect Multiple Devices . . . . . . . . . . . . . . . . . . . . . . 18

Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connect Secondary System . . . . . . . . . . . . . . . . . . . . 20

Check Sensor Resistance . . . . . . . . . . . . . . . . . . . . . . 21

Check Heater Resistance . . . . . . . . . . . . . . . . . . . . . . 22

Select ADM Settings . . . . . . . . . . . . . . . . . . . . . . . . . .23

Connect PLC (Hard Wired Interface Version) . . . . . . . 25

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Heat Up System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Prime Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Prime System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Setback Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 35

Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Change Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Light Tower (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 40

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Ram Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 47

Heated Pump Troubleshooting . . . . . . . . . . . . . . . . . . 48

Air Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 48

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Replace Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Replace Platen RTD . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Separate the Air Motor and Pump . . . . . . . . . . . . . . . 50

Remove Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Replace Heater Band and Pump RTD . . . . . . . . . . . . 53

Replace MZLP Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Replace MZLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Replace MZLP Daughter Card . . . . . . . . . . . . . . . . . . 56

Replace AWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Replace Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 57

Replace Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Replace Transformer . . . . . . . . . . . . . . . . . . . . . . . . . 59

Update Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

230V, 3 Phase/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . 62

400V, 3 Phase/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . 63

400-600VV, 3 Phase/60Hz . . . . . . . . . . . . . . . . . . . . . 64

AWB and MZLP#1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

MZLP#2, MZLP#3, Overtemp, and Pump Heaters . . . 66

MZLP Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Therm-O-Flow 200 Supply Unit . . . . . . . . . . . . . . . . . 68

Therm-O-Flow 200 Supply Unit . . . . . . . . . . . . . . . . . 69

Air Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 70

Electrical Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Electrical Control Module Parts . . . . . . . . . . . . . . . . . 73

Electrical Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Electrical Panel Parts . . . . . . . . . . . . . . . . . . . . . . . . . 77

Merkur 2200, 23:1 Pump Modules . . . . . . . . . . . . . . . 78

Merkur 2200, 23:1 Pump Modules . . . . . . . . . . . . . . . 79

Merkur 3400, 36:1 Pump Modules . . . . . . . . . . . . . . . 80

Merkur 3400, 36:1 Pump Modules . . . . . . . . . . . . . . . 81

NXT 6500, 70:1 Pump Modules . . . . . . . . . . . . . . . . . 82

NXT 6500, 70:1 Pump Modules . . . . . . . . . . . . . . . . . 83

24V619, Pump Shield . . . . . . . . . . . . . . . . . . . . . . . . . 84

Heated Platens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

24V633, Heated Drum Platen, Mega-Flo

(Code E-option M) . . . . . . . . . . . . . . . . . . . . . . . . 85

24V634, Heated Drum Platen, Standard Grid

(Code E-option F) . . . . . . . . . . . . . . . . . . . . . . . . 85

24V635, Heated Drum Platen, Smooth Bottom (no fin)

(Code E- option S) . . . . . . . . . . . . . . . . . . . . . . . . 85

Heated Platens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

24V633, Heated Drum Platen, Mega-Flo

(Code E-option M) . . . . . . . . . . . . . . . . . . . . . . . . 86

24V634, Heated Drum Platen, Standard Grid

(Code E-option F) . . . . . . . . . . . . . . . . . . . . . . . . 86

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24V635, Heated Drum Platen, Smooth Bottom (no fin)

(Code E- option S) . . . . . . . . . . . . . . . . . . . . . . . 86

Drum Ram Post Saddle Clamp . . . . . . . . . . . . . . . . . 88

C32463 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Option H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Drum Ram Post Saddle Clamp . . . . . . . . . . . . . . . . . 89

918395 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Option H-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Fiber Drum Reinforcement Shell Clamp . . . . . . . . . . 90

918397 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Option H-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Vent Hood Kit, 233559 . . . . . . . . . . . . . . . . . . . . . . . . 91

Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Wiper Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Applicators and Dispense Valves . . . . . . . . . . . . . . . . 92

CGM Installation Kit, 25C994 . . . . . . . . . . . . . . . . . . . 92

Flow Control and Manifolds . . . . . . . . . . . . . . . . . . . . 92

Accessory Extension Cables . . . . . . . . . . . . . . . . . . . 93

Light Tower Kit, 24W589 . . . . . . . . . . . . . . . . . . . . . . 93

Heated Hoses and Fittings . . . . . . . . . . . . . . . . . . . . . 94

8 Channel Upgrade Kit, 24V755 . . . . . . . . . . . . . . . . 96

8 Zone Upgrade Kit Installation . . . . . . . . . . . . . . . . . 97

12 Channel Upgrade Kit, 24V756 . . . . . . . . . . . . . . . 98

12 Zone Upgrade Kit Installation . . . . . . . . . . . . . . . . 99

Appendix A - ADM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 100

ADM Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Enable, Disable Heating System . . . . . . . . . . . . . . . 100

Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Operation Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Appendix B - USB Data . . . . . . . . . . . . . . . . . . . . . . . . . 109

Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Access Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Upload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

System Settings File . . . . . . . . . . . . . . . . . . . . . . . . 110

System Language File . . . . . . . . . . . . . . . . . . . . . . . 111

Create Custom Language Strings . . . . . . . . . . . . . . 111

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Ram Mounting and Clearance . . . . . . . . . . . . . . . . . 112

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . 113

California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . 113

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . 114

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Page 4

Warnings

WARNING

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion 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.

BURN HAZARD

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid burns:

• Do not touch hot fluid or equipment.

SPLATTER HAZARD

severe

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 amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

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 regu-

lations.

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

4 334130T

guidelines.

Page 5

THERMAL EXPANSION HAZARD

WARNING

Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure the thermal expansion. Over- pres su riz ation can resu lt in equi pm ent ru pture and se rious

• 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 may look like just a cut, but it is a serious injury that can result in amputation. Get

treatment.

injury.

skin. This

immediate surgical

Warnings

due to

• 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 deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and 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 present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

equipment until

prevent

plastic drop

fumes are

they are

334130T 5

Page 6

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 ponent. See Technical Data in all equipment manuals.

• 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 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 Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine turer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals 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 over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

system com-

information about

manufac-

and create

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent

equipment includes but is

including

manufacturer.

6 334130T

Page 7

Models

The model number stamped on your systems defines the equipment in the following categories.

See Technical Specifications, page 113, for maximum working pressure.

SER A B C D E F G H

Series Frame Size Air

Air/Electric

Zone

Config

Pump

Ratio

Platen

Style

Platen

Seal

Ram Drum

Models

Clamp

Code A Frame Size

200 55 Gallon (200 Liter)

Code B Air/Electric

A Air control only E Air and Electric

Code C Zones, Volts, Type

11P 4 Zones, 230 V, Primary 11S 4 Zones, 230 V, Secondary 12P 4 Zones, 400 V/N, Primary 12S 4 Zones, 400 V/N, Secondary 13P 4 Zones, 400 V, Primary 13S 4 Zones, 400 V, Secondary 14P 4 Zones, 480 V, Primary 14S 4 Zones, 480 V, Secondary 15P 4 Zones, 600 V, Primary 15S 4 Zones, 600 V, Secondary 21P 8 Zones, 230 V, Primary 21S 8 Zones, 230 V, Secondary 22P 8 Zones, 400 V/N, Primary 22S 8 Zones, 400 V/N, Secondary 23P 8 Zones, 400 V, Primary 23S 8 Zones, 400 V, Secondary 24P 8 Zones, 480 V, Primary 24S 8 Zones, 480 V, Secondary 25P 8 Zones, 600 V, Primary 25S 8 Zones, 600 V, Secondary 31P 12 Zones, 230 V, Primary 31S 12 Zones, 230 V, Secondary 32P 12 Zones, 400 V/N, Primary 32S 12 Zones, 400 V/N, Secondary 33P 12 Zones, 400 V, Primary 33S 12 Zones, 400 V, Secondary 34P 12 Zones, 480 V, Primary 34S 12 Zones, 480 V, Secondary 35P 12 Zones, 600 V, Primary 35S 12 Zones, 600 V, Secondary

NNN None

Code D Pump Ratio

1 23:1 CF (carbon filled PTFE) 236:1 370:1 4 23:1 (glass filled PTFE) 536:1 670:1

Code E Platen Style

S Smooth Bottom (No Fin) F Standard Finned Bottom

M Mega-Flo

Code F Platen Seal

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 black EPDM/Chlorobutyl, SS wire

braid 375°F (190°C) hose wiper and 1

upper White Silicone 375°F (190°C),

T-wiper 5 2 Orange silicone o-ring 400°F (204°C)

Code G Ram

P Pneumatic

H Hydraulic

Code H Drum Clamps

NNone

1 Saddle Clamp 2 Fiber Clam Shell 3 Heavy Drum Band

334130T 7

Page 8

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Manual Description

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3A1211

Displacement Pump Manual 334127

334128

Ram Manual 334198 Therm-O-Flow 200 Pneumatic and

Accessory and Kit Manuals 3A4241 Heated Hose, Instructions-Parts 309160 Heated Hose, Instructions-Parts 309196 Wiper Kits, Repair-Parts 310538 Air-Operated Dispense Valves,

311209 Top Feed and Bottom Feed Hot Melt

334201 Air Controls, Repair Kit

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NXT

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Check-Mate

Air Motor, Instructions-Parts

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8 334130T

Page 9

Component Identification

R, S

ti24544a

Component Identification

FIG. 1: TOF 200 Pneumatic

Key:

A Lift Strap Positions B Multi-Zone Low Power Temperature Control Module

(MZLP) C Light Tower D Cable Track ERam F Heated Pump G Heated Platen H Integrated Air Controls (3/4 in npt inlet) J Electrical Control Panel K Main Power Switch (can be locked in the open position) LADM M Air Motor Solenoid

N Electrical Power Input P Air Motor R Ram Plate Bleed Stick S Drum Blow Off Valve (behind ram plate bleed stick) T Drum Low and Empty Sensors

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Page 10

Component Identification

Integrated Air Controls

FIG. 2: Integrated Air Controls

Key:

Main Air Slider Valve

Turns air on and off to the entire system. When closed,

the valve relieves pressure downstream. Can be locked in

the closed position.

Ram Down Air Regulator

Controls the ram down pressure.

Ram Director Valve

Controls the ram direction.

Ram Up Air Regulator

Controls the ram up pressure. CE

Ram Down Air Gauge

Displays the ram down pressure.

Ram Up Air Gauge

Displays the ram up pressure.

Blowoff Button

Turns air on and off to push the platen out of an empty

drum.

Blowoff Pressure Gauge

Displays the blowoff pressure.

Blowoff Air Regulator

Controls platen blowoff pressure.

Air Motor Air Regulator

Controls the air pressure to the motor.

Air Motor Pressure Gauge

Displays the air pressure to the motor.

Air Motor Slider Valve

Turns air on and off to the air motor. When closed, the valve relieves air trapped between it and the motor. Push the valve in to shut off air. Can be locked in the closed position.

Air Motor Solenoid Valve

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.

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Page 11

Electrical Control Enclosure

Back Panel With Transformer

Component Identification

FIG. 3: Electrical Enclosure

Key:

DA Multi-Zone Low Power Temperature Control Module

(MZLP) DB Ventilation Grill DC Electrical Control Panel DD Automatic Wiring Board (AWB) DE Power Supply (24V) DF Residual Current Device (GFI), 63A

334130T 11

DG Platen SSR (65A) DH Platen Contractor DJ Platen Fuse DK Transformer Circuit Breaker DL Transformer Fuse DM Transformer DN System Contactor

Page 12

Component Identification

System Shutdown

Enable/Disable

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 100.

Use the USB port on the ADM to download or upload ta. For more information about the USB data, see

pendix B - USB Data, page 109.

Ap-

da-

NOTICE

To prevent damage to the softkey buttons, do not press buttons with sharp objects such as pens, plastic cards, or fingernails.

FIG. 4: Front View

Key Function

BA Heating system and Pump Enable/Disable BB System status indicator (LED) BC Stop all system processes BD Defined by icon next to softkey BE Abort current operation BF Accept change, acknowledge error, select

item, toggle selected item

BG Toggle between Operation and Setup

screens

BH Navigate within a screen or to a new screen

12 334130T

Page 13

FIG. 5: Back View

BK Part Number and Identification Label BL USB Interface BM CAN Cable Connection (Power Supply and

Communication) BN Module Status LEDs BP Light Tower (Optional) BR Software Token Access Panel

Component Identification

Table 1 ADM LED Status Descriptions

LED Conditions Description System Status Green Solid Run Mode, System On

Green Flashing Setup Mode, System On Yellow Solid Run Mode, System Off

USB Status (BL) Green Flashing Data recording in progress

Yellow Solid Downloading information to USB Green and Yellow Flashing ADM is busy, USB cannot transfer

information when in this mode

ADM Status (BN) Green Solid Power applied to module

Yellow Solid Active Communication

Red Steady Flashing Software upload from token in prog-

ress

Red Random Flashing or Solid Module error exists

334130T 13

Page 14

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 does not have power. • No system status indicator LED on the

ADM

• No heat

• Pump is off

Inactive The heating system and pumps are dis-

abled.

Warm Up The system is heating the material to the

setpoint temperature.

Heat Soak Heat zones are all at temperature. Material

is soaking for a user specified amount of time.

Ready All enabled zones are at setpoint tempera-

ture. The Air Motor does not have power.

Active The system is ready to dispense. • Solid green system status indicator LED

• Yellow system indicator LED on the ADM

• No heat

• Pump is off

• Flashing green system status indicator LED on the ADM

• Heat is increasing to setpoint temperature

• Pump is off

• Flashing green system status indicator LED on the ADM

• Heat is at setpoint

• Material is absorbing more heat

• Pump is off

• Heat soak counter counts down on the Home screen.

• Flashing green system status indicator LED on the ADM

• Heat is at setpoint

• Pump is off

on the ADM

• Heat is at setpoint temperature

• Pump is on

14 334130T

Page 15

Overview

A Heated Platen melts the sealant or adhesive and rects the molten material to the Pump inlet. The then travels through a Heated Pump and moves to the application tool.

heated fluid

material

di-

Air and Fluid Hoses

The Therm-O-Flow requires Graco single-circuit rial hoses rated at a maximum of 1250 watts. all air and fluid hoses are properly sized

for the system.

mate-

Make sure

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, 5 and 6, 7 and 8, 9 and 10, and 11 and available through 12-pin connectors. The heated hoses have a 16-pin connector at the nector at the outlet. All heated heaters are equipped with an

inlet, and an 8-pin con-

valves, manifolds, and

8-pin mating connector.

12 are each

3 and 4,

FIG. 6: Heat Control Zone Selection

334130T 15

Page 16

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 to power source

6. Ground system

7. Select ADM settings

Unpack

1. Inspect the shipping box carefully for damage. Con-

tact 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. Repost any shortages or other inspection prob-

lems immediately.

4. Remove the unit from the skid and place it in the desired location. See Location Requirements.

5. 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.

6. For hydraulic rams, locate the hydraulic power sup-

ply in an area that has:

• easy access for servicing and adjusting the

hydraulic pressure on the supply 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 112 for mounting and ance 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.

clear-

Location Requirements

1. Make sure there is sufficient overhead clearance for the Heated Pump and Ram when 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 Heated Pump and Ram are fully accessible, with room to stand directly in front of the Pneumatic Control Panel and the Electrical Control Panel.

4. When locating the system, do not install closer than 36 in. (914 mm) to vertical surfaces.

3. Lift the system off the pallet using a crane or a lift and place in desired location.

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.

fork-

Install Hydraulic Power Supply

See the Ram manual for installation and dimensions.

16 334130T

Page 17

Setup

Mechanical Setup

1. Fill displacement Pump wet cup 2/3 full with Graco

Throat Seal Liquid (TSL™) for Butyl and PSA mate-

rials.

NOTE: Use IsoGuard Select 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.

(IGS) (part no. 24F516)

4. Ensure Drum Low and Empty Sensors (C) are mounted as shown.

NOTE: The Drum Low and Empty Sensors are indicate that a drum is empty. mounting and a cable for connecting the panel Enclosure.

bracket (A), activator (B), sensors (C1, C2),

The kit contains a sensor

inside the Electrical

used to

FIG. 7: Wetcup

2. Turn all air regulators to their full counterclockwise position. See Integrated Air Controls, page 10.

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).

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.

FIG. 8: Air Connection

334130T 17

Page 18

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 the sys-

tem. Use 2 wrenches to tighten hose. Torque to 45 ft-lbs (61 N•m).

NOTE: See Accessories and Kits, page 92, for avail-

able fittings and heated hoses.

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 connec-

tors.

Connect the small 8 pin connector from the heated hose to the fluid control device or heated manifold.

FIG. 9

2. Wrap exposed fittings on the Pump outlet with

Nomex insulation and secure insulation using fiber-

glass tape.

3. Connect large heated hose connector to MZLP.

4. Repeat for any remaining channels.

FIG. 10: Heated Manifold 243697

NOTE: The heated manifold (part no. 243697) shown.

See Accessories and Kits, page 92, for available man-

ifolds and fluid control devices.

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 19.

18 334130T

Page 19

Setup

Connect Multiple Devices

If your application requires multiple fluid control devices:

• Connect heated hose electrical connections to the Electrical Enclosure. 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 92.

• Connect fluid control devices to a heated hose or

the Electrical Enclosure. Use accessories if neces-

sary.

• Setup all heat zones on Heat-A and Heat-B screens.

Example: Heated zones used to connect a primary and secondary system to a manifold and two guns. A-# zones are on the Heat-A screen and B-# zones are on

the Heat-B screen.

FIG. 11

334130T 19

Page 20

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 regula-

tions.

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. Branch circuit protec-

tion shall be provided by the end user.

Use copper conductors rated 600 volts minimum and 167°F (75°C) minimum only. Torque to 55 in-lb (6.2 N•m).

Table 2 Electrical Requirements

Electrical

Panel

Voltage Hz Phase Platen

230 V 50/60 3 EF, ES 90 3 AWG

EM 100 3 AWG

400 V/N 50/60 3 EF, ES 45 8 AWG

EM 50 8 AWG

400 V 50/60 3 EF, ES 45 8 AWG

EM 50 8 AWG

480 V 50/60 3 EF, ES 45 8 AWG

EM 50 8 AWG

600 V 50/60 3 EF, ES 50 8 AWG

3EM508 AWG

Full

Load

Amps AWG

FIG. 12

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 the ground wire to the ground lug. Have a qualified electrician check the resistance between each Therm-O-Flow system ground and the true earth ground. The resistance must be less than 0.1 ohms. If the resistance is greater than 0.1 ohms, a

different ground site may be required. Do not oper-

ate the system until the problem is corrected.

NOTE: Use a meter that is capable of measuring resis-

tance at this level.

EF Standard Finned Bottom EM Mega-Flo ES Smooth Bottom

1. Locate the opening in the control panel’s top hous-

ing for the conduit that will enclose the wire from the facility’s power source. The hole will accept a cord diameter range of 0.7–1.2 in (17–30 mm).

2. Thread the wire from the power source into the con-

trol panel housing, and then connect the power source wires to the appropriate terminals on the DISCONNECT switch.

20 334130T

Page 21

Setup

Grounding

Ground the unit as instructed here and in the compo-

nent 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 and escape path for the electric current.

System: ground through ground lug in Electrical Enclo-

sure. See Connect Power, page 20.

Air and Fluid Hoses: use only electrically conductive hoses.

Air compressor: follow manufacturer’s recommenda-

tions.

Spray gun / Dispense valve: ground through connec-

tion to a properly grounded fluid hose and Pump.

Material drums: follow local code. Use only metal 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: follow instructions in your separate

gun manual for instructions on how to safely ground your gun while flushing.

Connect Secondary System

A secondary system is a Therm-O-Flow supply system that connects to the primary Therm-O-Flow system, with the ADM. See Models, page 7 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 sys-

tem.

2. To enable a secondary system, select “Enable Tan-

dem System” on the System 1 screen. See Select

ADM Settings, page 24.

FIG. 13

334130T 21

Page 22

Setup

Check Sensor Resistance

To reduce risk of injury or damage to equipment, con-

duct 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 sen-

sor 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 Pins TOF Hose

First Heat Zone A, J Second Heat Zone C, D First RTD G, K Second RTD M, K Earth Ground B

Table 3 RTD Sensors

MZLP MZLP Plug Component

Ram Plate 100 +/- 2 Fluid Pump 100 +/- 2 Heated

1, 2

3, 4

5, 6

7, 8

9, 10

11, 12

Accessory 1 Heated Accessory 2 Heated Accessory 3 Heated Accessory 4 Heated Accessory 5 Heated Accessory 6 Heated Accessory 7 Heated Accessory 8 Heated Accessory 9 Heated Accessory 10100 +/- 2

Heated Accessory 11100 +/- 2

Heated Accessory 12100 +/- 2

RTD Range

(Ohms)

100 +/- 2

3. Replace any parts whose resistance readings do

not comply with the ranges listed in the RTD Sen-

sors chart below.

22 334130T

Page 23

Setup

Check Heater Resistance

To reduce risk of injury or damage to equipment, con-

duct these electrical checks with the Main Power Switch OFF.

1. Turn Main Power Switch OFF. 2. Make electrical resistance checks for the compo-

nents.

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).

Table 4 Heaters

Component

Platen

Pump

Resistance Across Terminals

AD to BE, BE to CF, CF to AD

A to B, B to C, C to D, D to E, E to F and F to A380 - 600V

Any terminal to Ground

2610 to 2620 T1/B1 to T3/B3

Unit Input Voltage

220 - 240V

All voltage ver-

sions

All voltage ver-

sions

Platen or Pump Module Resistance Values

24V633 5.25 to 4.35 Ohms

24V634 & 24V635 6.36 to 4.8 Ohms

24V633 12.0 to 14.5 Ohms

24V634 & 24V635 13.5 to 18 Ohms

All Greater than 100,000 Ohms

All 43.2 to 53 Ohms

334130T 23

Page 24

Setup

Select ADM Settings

NOTE: See Appendix A - ADM, page 100 for detailed

ADM information, including general operation.

1. Turn Main Power Switch ON.

2. When the ADM is finished starting up, press 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.

5. Set primary system setpoint and setback tempera-

tures for the Pump, Platen, and heat zones on the Heat-A-screens.

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.

4. Set alarm levels on the System 2 screen.

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.

24 334130T

Page 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 100 for detailed information about each setup item.

334130T 25

Page 26

Setup

Connect PLC (Hard Wired Interface Version)

A PLC can control and monitor all items shown in the

Customer Digital Inputs and Outputs shown on the Diag-

nostics screen. See Appendix A - ADM, page 100.

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. Unit A Description

1 Heat On Request Turn on the Heat

2 Setback Request Put the Unit in Set-

back 3 Pump On Request Turn on the Pump 4PLC Control

Request (input applies to primary unit A only)

Table 6 Customer Output

Control the primary

and secondary TOF

systems from the

PLC instead of the

ADM

Table 7 Output Error States

Error State

Bit High Error State Bit Low

0 0 Machine is good, no

errors are present

0 1 Active Unit Drum

Low

1 0 Active Unit Drum

Empty

1 1 Alarm Present in

System

Table 8 Output Run States

Run State

Bit High Run State Bit Low

0 0 Pump Off/ Heat Off 0 1 Pump Off/ Heat On 1 0 Pump Off/ Heat At

Temp

1 1 Pump On/ Heat At

Temp

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 located in a bag on the inside of the Electrical Enclosure. To replace the connectors, order kit 24P176.

Signal No. Unit A or B Description

1 Run State Bit Low See Run State

Chart 2 Run State Bit High See Run State

Chart 3 Error State Bit Low See Error State

Chart 4 Error State Bit High See Error State

Chart

26 334130T

1. Turn Main Power Switch OFF.

2. Open the Electrical Enclosure door.

3. Route I/O cables through strain relief.

4. Remove power from the PLC.

5. Connect the PLC to connectors H1 and H2.

Page 27

NOTE: Each connector has four signals. The MZLP board specifies the input range for each signal. See the

following table for pin assignments.

FIG. 14

Setup

H1 Customer Input

Signal Pin

11,2 23,4 35,6 47,8

H2 Customer Output

Signal Pin

11,2 23,4 35,6 47,8

Inputs: High: 10–30 VDC, Low: 0–5 VDC. Inputs func-

tion 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: 0–250 VAC, 0–30 VDC, 2A Maximum.

334130T 27

Page 28

Setup

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 replacements.

FIG. 15: Customer Input

FIG. 16: Customer Output

28 334130T

Page 29

Operation

1. Turn the Main Power Switch ON. The Graco logo will display until communication and initialization is complete.

Operation

NOTICE

Use fluids that are chemically compatible with the

equipment wetted parts. See Technical Specifica-

tions in all of the 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 30.

b. If the two substances are incompatible perform

the remaining steps in this procedure to flush the system.

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 tem-

perature.

Purge System

NOTICE

Purge the system before initial use and when chemi-

cals 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.

3. Select a drum of material that can eliminate the fac-

tory-test oil from the system. If necessary, check

with Graco or the material supplier for a recom-

mended solvent.

4. Before purging be sure the entire system and waste drum are properly grounded. See Grounding, page

21.

5. Turn all heat zones’ setpoint temperature to the material manufacturer’s recommended dispense

temperature, or a minimum of 100°F (37°C) mini-

mum.

NOTE: Remove any dispense valve orifices before purging. Reinstall after purging has been completed.

6. Purge the material through the system for approxi-

mately 1 to 2 minutes.

7. Remove the drum if purge material was used. See Change Drums, page 38.

334130T 29

Page 30

Operation

Load Material

NOTICE

To prevent damage to Platen wipers, do not use a drum of material that has been dented or damaged. An empty drum clamp can interfere with up and down operation of the Ram. When raising the Ram, make sure the drum clamp stays clear of the Platen.

NOTE: Before loading material, make sure there is a minimum overhead clearance of 110 in. (280 cm) and all

air regulators are backed off to their full counterclock-

wise position.

1. Open the Main Air Slider Valve (CA).

4. Fill displacement pump wet cup 2/3 full with Graco

Throat Seal Liquid (TSL™) for Butyl and PSA mate-

rials.

return to liquid form after heating.

FIG. 18: Wetcup

(IGS) (part no. 24F516)

2. Set Ram Director Valve (CC) to UP and slowly turn the Ram Up Regulator (CD) clockwise until the

Platen (G) begins to rise.

5. Open drum, remove any packing material, and inspect material for any contamination.

6. Slide the drum between the drum centering guides

and against the stops at the back of the Ram base-

plate.

FIG. 17: Raise the Platen

3. Apply a thin coating of high temperature grease lubricant (part no. 115982) to the Platen drum seals.

30 334130T

FIG. 19: Drum Placement

Page 31

Operation

7. Remove the Ram Plate Bleed Stick (R).

FIG. 20: Platen Bleed Handle

8. Set Ram Director Valve (CC) to down.

Heat Up System

To reduce the risk of bursting a hose, never pressur-

ize a hot melt system before turning on the heat. The

air will be locked from the Air Motor until all temperature zones are within a preset window of the tempera-

ture setpoints.

Keep the dispense valve open over a waste container while the system is heating up and also when cooling down. This will prevent a pressure build-up caused by fluids or gases expanding from the heat.

NOTE: Operate at the lowest temperature and pressure necessary for your application.

1. Turn the Main Power Switch on the Electrical Con-

trol Panel door to the ON position.

2. Press the button. The zones begin to heat

(provided they are enabled). Press if the zones do not begin to heat. Display status bar reads Warm Up. When temperature reaches setpoint, the display status bar reads Heat Soak. When heat is on, the status will display in the status bar. See Advanced Display Module (ADM), page 12, for operation mode descriptions.

NOTE: The air will be locked from the Air Motor until all

FIG. 21: Lower the Platen

9. Slowly turn the Ram Down Air Regulator (CB) clock-

wise to approximately 5–10 psi (34–69 kpa, 0.3–0.7 bar). The Platen will begin to lower into the drum.

10. After the Platen seals enter the material drum, adjust the Ram Down Air Regulator (CB) to 30–50 psi (207–345 kPa, 2.1–3.4 bar).

11. When the Ram stops, reinsert the Ram Plate Bleed Stick (R) and hand tighten.

temperature zones are within a preset window of the temperature setpoints, allowing the system to heat fully and complete the material heat soak period.

334130T 31

Page 32

Operation

Prime Pump

1. Ensure that the system has completed the heat soak cycle. The display status bar should read Active.

2. Adjust the Air Motor Air Regulator (CK) to 0 psi.

3. Adjust the Air Motor Slider Valve (CM) to the open position.

4. Adjust the Air Motor Air Regulator (CK) to approxi-

mately 20 psi (138 kPa, 1.38 bar).

5. Place a waste container under the bleed stem (Z). Using an adjustable wrench, open the bleed stem counterclockwise 1/3 -1/2 turn.

32 334130T

Page 33

Operation

6. If a new drum was installed and the unit is equipped

with proximity sensors, press the Pump Ready but-

ton . Press the pause button on material tracking.

7. Adjust the Air Motor Air Regulator (CK) up by 5 psi (34 kPa, 0.3 bar). Never adjust the regulator by more than 5 psi (34 kPa, 0.3 bar) increments. Make sure the Pump begins to cycle and heated material flows from the bleed stem (Z) after several cycles of the Pump.

8. Prime the Pump until it moves smoothly in both directions with no air popping or erratic movement and close the bleed stem (Z).

For Tandem Operation

Complete steps 1-5 on page 32 for the inactive unit. Note that the heat will remain on for the inactive unit until the system is turned off.

6. If a new drum has been installed in the inactive unit,

press the Pump Ready button on the inactive unit. The light on the solenoid of the inactive unit should be on (CN).

8. Prime the Pump until it moves smoothly in both directions with no air popping or erratic movement and close the bleed stem (Z).

9. Press the Pump Ready button for the inactive unit.

9. Press the Play button on the home screen to enable material tracking and press the Pump Ready button.

334130T 33

Page 34

Operation

Prime System

1. Close the Main Air Slider Valve (CA).

2. If using a manual gun, lock the dispense valve trig-

ger open by pulling and securing the trigger using the trigger retainer (Z).

7. Close the Main Air Slider Valve (CA) and release the trigger lock.

8. Engage the trigger lock.

FIG. 22: Trigger Lock Engaged

9. Press to engage material tracking.

10. Turn the Air Motor regulator to operating pressure.

3. Place the dispense valve over a waste container.

4. Press the pause material tracking button on home screen.

5. Slowly open the Main Air Slider Valve (CA).

6. Prime the system until a smooth flow of material dis-

penses from each dispense valve.

NOTE: On initial system startup, the Pump will cycle until the hoses are filled. If a new drum was placed on the frame, the Pump will cycle until all air has been removed.

NOTE: The amount of time before the Pump is automatically placed in setback is determined by the Pump Inac-

tivity Timeout, located on System Setup Screen 1. See

Setup Screens, page 104.

Setback Mode

Set the ADM to setback mode if the system will only be inactive for a few hours. This will reduce the time the system needs to return to setpoint temperatures.

1. Press to enter Setback Mode.

NOTE: The amount of time before the Pump is automatically placed in setback is determined by the Pump Inac-

tivity Timeout, located on System Setup Screen 1. See Setup Screens, page 104.

34 334130T

Page 35

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure When-

ever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief

Procedure when you stop spraying and before clean-

ing, checking, or servicing equipment.

NOTE: If using a different dispense applicator, see the applicator manual for pressure relief instructions.

1. Engage the trigger lock.

3. Set the Ram Director Valve (CC) to the neutral posi-

tion.

4. Disengage the trigger lock.

FIG. 24: Disengaged

FIG. 23: Engaged

2. Close the system Main Air Slider Valve (CA).

334130T 35

5. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure.

6. Engage the trigger lock.

7. Open all fluid drain valves in the system, having a waste container ready to catch drainage. Leave drain valve(s) open until you are ready to dispense again.

8. If you suspect the tip or hose is clogged or that pres-

sure has not been fully relieved after following the

steps above, VERY SLOWLY loosen hose end coupling to relieve pressure gradually, then loosen com-

pletely. Clear hose or tip obstruction.

Page 36

Operation

System Shutdown

NOTE: If work needs to be performed on the Ram por-

tion, perform the following additional steps to relieve any trapped air in the inactive portion of the Ram.

9. Validate that the Heated Pump is fully supported and is resting on the bottom plate.

Stop Controls

Normal Stop Control

To stop all electrical and most pneumatic processes,

press the System Shutdown button located on the ADM.

10. Toggle the Ram Director Valve up and down to relieve any trapped air.

All electrical operations will be shut down and the air pressure to the Air Motor will be immediately relieved, which will stop the movement of the Heated Pump.

Electrical components located in the main control box will remain energized, but all operations will stop until

the system Enable/Disable button has been pressed.

The Ram Director Valve will remain operable.

Air Motor and Heated Pump Stop

To stop only the Air Motor and Heated Pump, close the Air Motor Slider Valve (CM). This is the preferred method while changing drums.

36 334130T

Page 37

Operation

Shutdown

1. Press to disable the heaters and Pump. The screen will say “Inactive”. If using the Schedule function, the heaters and Pump will be disabled

automatically at the set time. Only press to disable the heating system before the set time. If the

heaters were manually disabled, the Schedule func-

tion will automatically enable them at the next set time.

Air pressure to the Air Motor will be immediately relieved, which will stop movement of the Heated Pump but allow the heater to remain operable.

The Ram Director Valve will also remain operable.

The Air Motor Slider Valve can be locked in the closed position.

Total System Shutdown

To stop all electrical and most pneumatic processes, turn the Main Power Switch OFF.

This will remove all electrical power to the system past the Main Power Switch.

Air pressure to the Air Motor will be relieved, which will stop movement of the Heated Pump.

NOTE: Do not perform step 2 if using the Schedule function. Leave the power on.

2. Turn the Main Power Switch OFF.

Schedule

The Schedule function allows the user to specify times when the system will automatically turn on and off the heaters and Pump.

The Ram Director Valve will remain operable.

The Main Power Switch can be locked in the open posi-

tion.

334130T 37

Page 38

Operation

Table 9 Schedule Screen Color Identification

Color Description

Green System on Yellow Setback Red System off Gray Disabled

Set Schedule Times

Times are set using a 24-hour clock. Several on and off times can be set each day.

Use the Schedule Function

At the end of the work day leave the Main Power Switch ON. The Schedule function will automatically enable and disable the heaters and Pump at the specified times.

Change Drums

To prevent serious burns from dripping material, never reach under the Heated Platen after the Platen is out of the drum.

Moving parts can pinch or amputate fingers, or can

crush feet. When the Pump is running, and when rais-

ing or lowering the Ram, keep fingers and hands away from the Pump intake, Platen, and lip of the drum. When lowering the Platen to the baseplate, keep feet away from the Platen.

1. On the Schedule screen (in the Setup screens), set the ON times for each day of the week

2. Set the off times for each day of the week.

3. Set the setback times for each day of the week.

Enable Schedule Function

The Schedule function is automatically enabled when values are entered in the Schedule screen. To disable a

scheduled event, navigate to the event and press .

The event will appear gray on the screen when it is dis-

abled. To re-enable an event, navigate to the event and

press .

The event will appear red (system off), yellow (system setback), or green (system on). If no events are needed, turn the Main Power Switch OFF to prevent system from automatically enabling and disabling the heaters.

Perform the following procedure to change the drum on a fully heated system.

NOTICE

Be sure to reload the empty supply unit with a full drum of material immediately. Do not raise the Ram

and remove the Platen from the empty drum until you are ready to immediately install a new drum.

Do not raise the Ram and remove the Platen from the empty drum unless the supply unit is at full operating temperature. Drum changes can only be

performed when the system is heated.

An empty drum clamp can interfere with the up and down operation of the Ram. When raising or lowering

the Ram, make sure the drum clamp stays clear of the Platen assembly.

Do not use a drum of material that has been dented or otherwise damaged; damage to the Platen wipers

can result.

38 334130T

Page 39

All systems include Low/Empty Sensors:

• The air will shut off to prevent the Pump from cavita-

tion. If the Light Tower kit is installed, a solid red light indicates that the pail is empty and ready to change.

• In a tandem system, a flashing red light means that

both drums are empty and the system has shut-

down.

Operation

Excessive air pressure in the material drum could cause the drum to rupture, causing serious injury. The Platen must be free to move out of the drum. Never use drum blowoff air with a damaged drum.

4. Release the blowoff air button and allow the Ram to rise to its full height.

1. Press to stop material tracking.

2. Push in the Air Motor Slider Valve (CM) to stop the Pump.

3. Set Ram Director Valve (CC) to UP and raise the Platen (G) and immediately press and hold the Blowoff Buttons (CG) until the Platen is completely

out of the drum. Use minimum amount of air pres-

sure necessary to push the Platen out of the drum.

5. Remove the empty drum.

6. Inspect Platen and if necessary, remove any remaining material or material build-up.

7. Follow steps in Load Material, page 30, and Prime Pump, page 32.

334130T 39

Page 40

Troubleshooting

Light Tower (Optional)

Signal Description

Red Light Off If green light is also off, system power may be off or system operating mode is Inactive. If

green is on or flashing, there are no active errors Red Light On User interaction required — alarm, system is shut down Red Light Flashing User interaction required — advisory, deviation, or system is in a state that could prohibit

dispensing Green Light Off System is inactive Green Light On System is ready to dispense. The heat and Pump are on. Green Light Flashing System will be ready to dispense in time without user interaction (heat on, Pump off, and

temperature control zones have not reached set point)

40 334130T

Page 41

Troubleshooting

Error Codes

There are three types of errors that can occur. Errors are indicated on the display as well as by the optional Light Tower.

Alarms are indicated by . This condition indicates a parameter critical to the process has reached a level requiring the system to stop. The alarm needs to be addressed immediately.

Deviations are indicated by . This condition indicates a parameter critical to the process has reached a level requiring attention, but not sufficient enough to stop the system at this time.

Advisories are indicated by . This condition indicates

a parameter that is not immediately critical to the process. The advisory needs attention to prevent more seri-

ous issues in the future.

To acknowledge the error, press .

The last digit of the error code indicates which system component the error applies. The “#” (pound) character

indicates the code applies to multiple system compo-

nents.

Code Relates To System

Last Digit “#”

1MZLP 1 2MZLP 2 3MZLP 3 5MZLP 5 6MZLP 6 7MZLP 7 G Gateway (CGM) H Gateway Heartbeat Loss VAWB Unit A WAWB Unit B X Daughter Board Unit A Y Daughter Board Unit B

The last digit of the error code indicates which heat zone

the error applies. The “_” (underscore) character indi-

cates the code applies to multiple system components.

Component:

The third digit, or sometimes the last digit of the error

code, indicates which unit the error is active on. The “★”

(star) character indicates the code applies to multiple system components.

Third or Last Digit “★” Code Relates To:

AUnit A BUnit B

Code Relates To Heat

Last Digit “_”

1 Zone 1 2 Zone 2 3 Zone 3 4 Zone 4 5 Zone 5 6 Zone 6 7 Zone 7 8 Zone 8 9 Zone 9 A Zone 10 B Zone 11 C Zone 12 DPump EPlaten

Zone:

334130T 41

Page 42

Troubleshooting

Code Description Type Cause Solution

A3MF

AWB Clean Fan Filter

Alarm

Cooling inlet

Clean inlet screen.

screen is dirty

A4 _

High Current Unit _ Zone _

Alarm

Defective or shorted to ground on

Verify accessory is rated for 240 VAC.

Verify heater resistance and check for shorts to ground. Replace as necessary.

zone

A4C#

High Current Fan AWB, Unit _

Deviation Fan is drawing

too much cur-

rent

Verify there is not an air obstruction at the inlet/outlet of enclosure. Verify nothing is preventing fan rotation. Replace fan if necessary.

A7 _

A8 _

Unexp. Curr. Unit _ Zone _

No Current Unit _ Zone _

Alarm

Unexpected current flow to zone

Alarm No Current

Flow to the Zone

Replace MZLP.

Faulty accessory heater. Measure resistance to ground between heater leads.

Check for loose or disconnected wires or plugs.

Check for blown fuses on MZLP.

Check heater resistance for open circuit.

Check for shorts between heater and ground.

Verify cable is plugged into zones 3-4. Replace heater if necessary.

A8C

AWB No Fan Current

Alarm Cooling Fan

Verify fan is plugged in. Replace if necessary.

not Working

AM3#

High Current SSR MZLP _

Alarm

Excessive current flow in

Check for shorts in harness to SSR. Check polarity of wiring to SSR. Replace if necessary.

the SSR

AM4#

High Current Contactor MZLP _

Alarm

Defective or shorted to ground on

Check for shorts in the harness to contactor. Check the polarity to contactor. Replace contactor if necessary.

MZLP

AM8#

CAC#

No Current Contactor MZLP _

Comm Error MZLP _

Alarm

No Current Flow to the Contactor

System not responding to ADM.

Ensure harness to MZLP is connected. Ensure wiring to contactor is secure. Replace contactor if necessary.

System is not properly loaded with correct Soft-

ware.

Dial not set correct on MZLP. Duplicate MZLP dial positions (i.e. 1 to 1, 2 to 2, ect).

Check all CAN connections between the ADM and missing MZLP.

Check if hardware exists on the network.

Replace MZLP if necessary.

CACX

DB Not Present Unit A

Alarm

Daughter Board not responding

Dial not set correct on MZLP 5. Set to 5 on board with daughter board.

Ensure connections between the ADM and hardware are secure.

Replace Daughter Board.

42 334130T

Page 43

Code Description Type Cause Solution

CCAG

Comm. Error, Gateway

Alarm

CGM Module is no longer responding

Power removed from Gateway. Restore power. Rotary switch on Gateway changed to positions

between 2 and 8 (must be in 0, 1, or >8 positions).

CACH

Gateway Heartbeat Loss

Alarm

Heartbeat signal was removed while PLC was

PLC went off line. Field Bus connection to CGM was broken.

Restore connection between Field Bus and CGM.

controlling the TOF via the CGM

CACY

DB Not Present Unit B

Alarm

Daughter Board not responding

Dial not set correct on MZLP. Set to 4 on board with daughter board.

Ensure connections between the ADM and hardware are secure.

Replace Daughter Board.

CACV

AWB not present Unit A

Alarm

AWB not responding

Ensure connections between the ADM and hardware are secure.

If a tandem system, ensure AWB 2 jumper is installed at startup.

Replace AWB.

CACW

AWB not present Unit

Alarm

AWB not responding

AWB 2 jumper was not in place at start up

Ensure connections between the ADM and hardware are secure.

Replace AWB.

DA X

Pump Runaway Detected

Alarm

Pump is trying to feed adhesive, no adhesive to feed.

Adjust the drum empty level sensor to detect an empty state.

Ensure the Ram Director Valve is in the down position and sufficient air is forcing the Ram down.

Melter at incorrect temperature, too low. Check setpoint and set to manufactures recommendation.

Worn or

Inspect Pump seals and replace if necessary damaged Pump seals

DE X

Reed Switch Failure Detected

Alarm Reed switch

failed

Check that sensor cable is plugged into the daughter board at J16.

Check for loose connection at reed switch. Ensure reed switch is securely attached to the Air Motor. Replace if necessary.

Troubleshooting

334130T 43

Page 44

Troubleshooting

Code Description Type Cause Solution

DC X Pump Diving Alarm

Pump is trying to feed adhesive, no adhesive to feed.

Adjust the drum empty level sensor to detect an empty state.

Ensure the Ram Director Valve is in the down position and sufficient air is forcing the Ram down.

Melter at incorrect temperature, too low. Check setpoint and set to manufactures recommendation.

Worn or

Inspect Pump seals and replace if necessary damaged Pump seals

L1 X Material Level Sen-

sor Error

Alarm

Machine is detecting an empty state without a low state

Make sure the empty level sensor is not covered in material

Verify the low level sensor is plugged into J15 of the daughter board. Verify the low level sensor is close enough to the metal bar; adjust if necessary.

Replace sensors.

L2 X Material Level Empty Alarm Material drum

is empty

L3 X Material Level Low Deviation Material level

Replace material container. If more material is leftover, lower the empty level sensor.

Replace at appropriate time.

is low

MMUX USB Log Full Advisory

USB logs fulls. Data loss will

Download USB data or disable the USB log

errors on the Advanced screen 3. occur if not downloaded.

MN X Pump _ Requires

Maintenance

Advisory

User defined Pump

Perform Pump maintenance, then reset the

counter on the maintenance setup screen. maintenance counter has run out

Ta★

Over Temperature Switch

Alarm

An over temperature switch has opened.

Check Heat Rate Option on Advanced Screen 2 to make sure it is set to Normal or Slow. If set to Fast, the switch will open on the pump or platen.

If “_” is 9, A, B, or C, make sure jumper 16W035 is installed in J5 on MZLP 5 and MZLP 7 (for tandem units).

T1 _

Low Temp. Unit _ Zone _

Alarm

Zone temperature too low

Reduce flow rate.

Increase temperature of accessory upstream.

Faulty accessory heater measure resistance

between heater leads.

Change Low Temp Alarm Offset.

Replace accessory.

T2 _

Low Temp. Unit _ Zone _

Deviation Zone tem-

perature too low

Reduce flow rate.

Change Low Temp Deviation Offset.

Add zone (temperature) upstream.

44 334130T

Page 45

Code Description Type Cause Solution

Troubleshooting

T3 _

T4C#

T4M#

T4 _

T6 _

T6C#

T8V_

V1|#

V1M#

V4|#

V6M#

High Temp. Unit _ Zone _

AWB Temperature Runaway Transformer

AWB High Transformer Temp

High Temp. Unit _ Zone _

Sensor Err. Unit _ Zone _

AWB Invalid Thermistor Reading

No Temp. Rise Unit _ Zone _

Low CAN Voltage, MZLP _

Low Voltage Line AWB, Unit _

High CAN Voltage, MZLP _

Wiring Error Line MZLP _

Deviation

Alarm

Deviation

Alarm

Temperature reading has risen too high

Cooling fan not working or inlet is blocked/dirty

Transformer Temperature is too High

Temperature reading has risen too high

Bad RTD Reading

Transformer thermistor temperature is incorrect

Temperature reading does not change.

Bad or overloaded power supply

The voltage to the AWB is below threshold

Bad or overloaded power supply

Incoming power is wired incorrectly

Change High Temp Deviation Offset.

Verify setpoint upstream is not hotter than this zone’s setpoint.

Ensure inlet and outlets are not obstructed.

Verify fan is plugged in.

Ensure inlet and outlets are not obstructed.

Verify fan is plugged in.

Change High Temp Alarm Offset.

Verify setpoint upstream is not hotter than this zone’s setpoint.

Check RTD wiring and harness/connector integrity.

Replace RTD.

Verify thermister is securely connected to J7 of the AWB. Replace transformer if necessary.

Check fuses on MZLP connected to that Zone.

Check wiring to device.

Check heater resistance on device.

Verify power supply voltage is 24 VDC. If voltage is low, disconnect the power lines and re-check voltage reading. If voltage is still low, replace power supply. If voltage is correct after disconnecting the power lines. Connect items one at a time until the voltage drops to isolate the bad module.

Verify transformer voltage top matches incoming voltage. Verify incoming voltage is correct.

Verify power supply voltage is 24 VDC. If voltage is high, replace power supply unit.

Correct the Wiring.

334130T 45

Page 46

Troubleshooting

Code Description Type Cause Solution

V8M#

V4M#

WJ1

WJ2

WSUX

No Line Voltage MZLP _

AWB High Line Voltage

Pump _ Solenoid is disconnected

Pump _ Solenoid High Current

Configuration Error USB

Alarm

Advisory

Incoming line voltage is less than 100 VAC.

Incoming voltage is too high

Pump is not turning on when it should

Solenoid is drawing too much current

USB configuration is not loaded

Verify transformer has the correct tap selected.

Verify CB-1 or FU-4, FU-5, and FU-6 are not tripped/blown.

Verify RCD-1 is not tripped.

Measure incoming power with system unplugged. If line voltage is less than 100 VAC, contact qualified electrician to correct the low voltage.

Verify the MZLP is plugged in at J2 and the AWB is plugged in at J5 or J6.

Check incoming voltage is correct for configu-

ration.

Verify the transformer has the correct tap (400, 480, 600) selected.

Verify harness is plugged into J13 of the daughter board. Verify it is secured to the solenoid.

Replace Solenoid.

Inspect for short in harness. Inspect for a shorted solenoid cable/short to the ground. Replace solenoid.

Install software.

46 334130T

Page 47

Ram Troubleshooting

Problem Cause Solution

Ram will not raise or lower.

Ram raises or lowers too fast.

Air leaks around cylinder rod.

Fluid squeezes past Platen wipers.

Pump will not prime properly, or pumps air.

Air pressure will not push Platen out of drum.

Troubleshooting

Closed main air valve or clogged air line, Not enough Ram air pressure. Increase Ram air pressure.

Worn or damaged Ram piston. Replace piston. See instruction man-

Platen not fully up to temperature. Wait for full temperature. Ram air pressure too high. Decrease Ram air pressure. Dented drum has stopped Platen. Fix or replace drum. Ram "up / down" air pressure too high. Worn rod seal. Replace o-rings in guide sleeve. See

Ram air pressure too high. Decrease Ram air pressure. Worn or damaged wipers. Replace wipers. Closed main air valve or clogged air

line. Not enough air pressure. Increase air pressure.

Worn or damaged Ram piston. Replace piston. See instruction man-

Ram directional valve closed or clogged. Ram directional valve dirty, worn, or damaged.

Directional valve not in the down position. Dented drum has stopped Platen. Fix or replace drum. Closed main air valve or clogged air line.

Platen not fully up to temperature. Wait for full temperature. Not enough blow-off air pressure. Increase blow-off air pressure. Blow-off valve passage clogged. Clean valve passage. Dented drum has stopped Platen. Fix or replace drum.

Wipers bonded to drum or drum liner. Lubricate wipers with high tempera-

Open air valve; clear air line.

ual 310523.

Decrease Ram air pressure.

instruction manual 310523.

Open air valve; clear air line.

ual 310523. Open valve; clear valve or exhaust.

Clean; repair valve.

Position handle in the down position.

Open air valve; clear air line.

ture grease at every drum change.

334130T 47

Page 48

Troubleshooting

Heated Pump Troubleshooting

See Pump manual for additional Pump troubleshooting information.

Problem Cause Solution

Rapid downstroke or upstroke (Pump cavitation).

Material leaks around Pump outlet.

Material leaks around bleed port.

Pump will not move up and down.

Leak around Pump wet-cup.

Material not heated to proper temperature.

Air is trapped in Pump.

Downstroke: Dirty or worn Pump intake valve.

Upstroke: Dirty or worn Pump piston valve.

Machine is out of material Adjust empty level sensor. Loose outlet fitting. Tighten outlet fitting.

Loose bleed port fitting. Tighten bleed port fitting.

Problem with Air Motor. See Air Motor Manual. Foreign object lodged in Pump. Relieve pressure. See Pump Manual. Platen not fully up to temperature. Wait for full temperature. Valve to Air Motor is off.

Worn throat seals.

Check and adjust temperature to proper setpoint. Wait for Pump/Platen to heat up.

Bleed air from Pump. See Prime Pump, page 32.

Clean or repair. See Pump Manual.

Clean or repair.

Check gauges and valves to the air motor.

Replace throat seals. See Servicing the Throat packings in manual 334127 or 334128.

Air Motor Troubleshooting

See Air Motor manual for additional Air Motor troubleshooting information. See Related Manuals, page 8.

Problem Cause Solution

Air motor will not run.

Air motor stalled.

Air continuously exhausting around Air Motor shaft.

Air continuously exhausting around air valve/slide valve.

Air continuously exhausting from muffler when motor is idle.

Icing on muffler.

Air motor solenoid is off. Wait for heat zones in use to reach

temperature setpoint values. Damaged main air valve spool or poppets.

Damaged Air Motor shaft seal. Replace Air Motor shaft seal. See Air

Air valve/slide valve gasket is dam-

aged.

Internal seal damage. Rebuild Air Motor. See Air Motor

Air motor operating at high pressure or high cycle rate.

Inspect and clean poppets. See Air

Motor Manual.

Rebuild main air valve. See Air Motor

Manual.

Motor Manual.

Replace the valve gasket. See Air

Motor Manual.

Manual.

Reduce pressure, cycle rate, or duty

cycle of motor.

48 334130T

Page 49

Repair

Replace Wipers

1. To replace a worn or damaged wiper (V) raise the Ram Plate up out of the drum. Perform steps 1 through 7 of Change Drums, page 38. See wiper kit

manual for instructions about replacing the wipers.

FIG. 25: Replace Wiper

2. Make sure the Ram Plate is down and the Ram Director Valve is in the OFF position.

To reduce the risk of injury or damage to equipment,

make sure the Main Power Switch is OFF before con-

tinuing with this procedure.

Replace Platen RTD

Reference Electrical Schematics, page 62, for wiring connections.

1. If the material drum has already been removed from the supply unit, go to step 2. If you need to remove the material drum, see Change Drums, page 38.

3. Turn the Main Power Switch OFF.

4. Remove the Pump cover.

FIG. 26: Pump Covers and Platen RTD

334130T 49

Page 50

Repair

ti24671a

5. Remove the Platen RTD (605) from the Platen.

6. Disconnect the Platen RTD wires from pin 3 and pin 6 from the J5 connector on MZLP MZTCM-1 or

MZTCM-5.

FIG. 27: RTD Wire Connections

2760 Red

2770 White

2790 White

Separate the Air Motor and Pump

This procedure must be done with the unit still warm. The material and equipment will be hot!

1. If the material drum has already been removed from the supply unit, go to step 2. If you need to remove the material drum, perform steps 1 through 6 of the Change Drums section, page 38. Pump must be in the full down position (Air Motor shaft fully extended).

2. Make sure the Ram Plate is down and the Ram Director Valve (CC) is in the neutral position.

7. Attach the leads from the new sensor to the leads of the old sensor and pull the new sensor leads through the cable pump shield, Cable Track, and into the Electrical Enclosure.

8. Install the new sensor (605) into the follower/tire

plate after coating with non-silicone heat sink com-

pound. Tighten compression nut. Ensure RTD is fully inserted.

9. Connect the red and white wires from the new sen-

sor to the J5 connector on MZLP MZTCM-1 or MZTCM-5.

10. Replace the Pump covers.

3. Follow Pressure Relief Procedure on page 35.

4. Bleed off excess material and pressure in the sys-

tem by opening the dispense gun and catching the material in a waste container.

5. On the ADM, turn off the system heat (D).

6. Turn the Main Power Switch OFF.

7. Disconnect all material hoses.

50 334130T

Page 51

Repair

8. Remove the Pump sheet metal enclosure.

a. Remove the cover screws.

b. Remove the heater bands and disconnect the

ground wire.

9. If vent hood is installed, remove it.

22. Reverse this procedure to reinstall the new or rebuilt Air Motor.

10. Remove the Air Motor top cover.

11. Disconnect the electrical cable from the Air Motor.

12. Remove air line from Air Motor and air lines to the follower blow-off valve.

13. Tightly strap the Air Motor to the tie bar with a cable through the Air Motor lift ring and around the tie bar. See F

. 29, page 53.

14. Loosen u-bolts (X) from Platen lift rods.

15. Remove nuts (F) from Heated Pump/Air Motor stand-off rods at the Pump end.

16. Remove nuts (Z) and bolts holding cable tract to Air Motor support plate.

17. Slide end of Cable Track outboard of the mounting plate.

18. Remove nuts (N) from follower lift rods.

19. Fully loosen Pump rod coupler to the Air Motor rod (G).

20. Slowly raise elevator to achieve enough separation of the Pump (Air Motor) tie rods to remove the Pump.

21. Remove the Pump.

334130T 51

Page 52

Repair

FIG. 28

52 334130T

Page 53

Repair

309a

309b

320

321

ti25222a

Remove Platen

1. Turn the Main Power Switch OFF.

2. Disconnect the Platen power wires and the ground wire from within the main control panel and pull out of conduit.

3. Remove the Platen assembly from the Ram.

4. Reverse this procedure to reinstall the new or rebuilt Platen assembly.

Replace Heater Band and Pump RTD

8. Remove the screws and covers.

9. Remove white ceramic caps and disconnect the electrical wires from the heater band (309).

10. Remove the screw that holds the heater band in place.

11. Remove the heater band (309a, 309b) from the Pump.

Replace Heater Band

1. If the material drum has already been removed from the supply unit, go to step 2. If you need to remove the material drum, perform steps 1 through 6 of the Change Drums, page 38. Pump must be in the full down position (Air Motor shaft fully extended).

2. Make sure the Ram Plate is down and the Ram Director Valve is in the neutral position.

3. Follow the Pressure Relief Procedure, page 35.

4. Bleed off excess material and pressure in the sys-

tem by opening the applicator and catching the material in a waste container.

5. On ADM, turn off the system heat (D).

6. Turn the Main Power Switch OFF.

12. Coat the inside of the heater with non silicone heat

sink compound before mounting. Maximum thick-

ness is 0.005 in. Coat only to within 3/4 in. of vertical ends.

13. Install a new heater band (309a, 309b) in the same location as the old heater band:

a. Locate heater terminals so they line up with the

back of the Pump.

b. Tighten the heater band.

c. Re-connect the heater wires and re-attach the

ceramic caps that insulate the terminal.

334130T 53

FIG. 29

Page 54

Repair

Replace Pump RTD

1. Turn the Main Power Switch OFF.

Fuse Kit Fuse Part

F1, F2 250VAC, 25A, long, white

24V289

F3-F10 250VAC, 8A, fast acting, clear

Spare fuse kit included with system.

ceramic

glass

2. Remove the screws that hold the front shroud in place and remove the front shroud.

3. If the sensor wire is connected to the Electrical Enclosure, disconnect it.

4. Loosen the clamp (321) holding the sensor on the Pump.

5. Tie the leads of the new sensor (320) to the old sen-

sor and remove the old sensor. The leads of the new sensor will be easily drawn through the conduit for reconnecting.

6. Replace the sensor (320) in the clamp (321):

a. Place the sensor approximately 30° counter

clock-wise from the Pump outlet.

b. Tighten the clamp (321).

7. Re-connect the sensor wire to the Electrical Enclo-

sure.

NOTICE

To prevent system damage, always use fast acting

fuses. Fast acting fuses are required for short-cir-

cuit protection.

1. Turn the Main Power Switch OFF.

2. Open Electrical Enclosure door.

3. Use a proper non-conductive fuse puller tool to remove the blown fuse.

NOTICE

Using an improper tool, such as screw drivers or pliers, may break the glass on the fuse.

NOTE: F1 and F2 are white ceramic and indicate 25A on the barrel.

Replace MZLP Fuse

Each MZLP module comes with the following fuses:

FIG. 30: Fuse Locations

54 334130T

NOTE: F3-F10 are clear glass and indicate 8A on the barrel.

4. Use a proper non-conductive fuse puller tool to install the new fuse.

NOTICE

Using an improper tool, such as screw drivers or pliers, may break the glass on the fuse.

5. Close the Electrical Enclosure.

Page 55

Repair

112

ti25223a

115

111

Replace MZLP

1. Turn the Main Power Switch OFF.

2. Disconnect the heated hose electrical connectors from the MZLP (111 or 112).

3. Note the location of each cable, then unplug all cables from the MZLP (111 or 112) that will be replaced.

4. Remove the four screws (115) securing the MZLP

(111 or 112) to the Electrical Enclosure, then carefully remove the MZLP from the Electrical Enclo-

sure.

6. To reassemble the MZLP, set the MZLP rotary switch based on location. See MZLP Rotary Switch Table.

7. Use the four screws (115) to install MZLP (111 or

112) to Electrical Enclosure.

8. Reconnect the cables to the MZLP.

NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation.

NOTE: If unable to determine the connector location, see Electrical Schematics, page 62.

9. Connect the heated hose electrical connectors to the new MZLP.

NOTE: The MZLP may need updated software. See Update Software, page 61.

Table 10 MZLP Rotary Switch

MZLP System Rotary Switch

#1 with Daughter Card

#2 Primary 2

#3 Primary 3

Primary 1 Secondary 5

Secondary 6

Secondary 7

FIG. 31: MZLP Identification

5. Replace MZLP.

a. To replace MZLP #1, remove the daughter card

and standoffs, and re-install them on the new MZLP #1.

b. To replace MZLP #2 of #3, remove the jumper

(162) from MZLP #2 or #3 J5 connector and reinstall it on the new MZLP J5 connector.

334130T 55

Page 56

Repair

112b

112a

112

Rotary Switch

Replace MZLP Daughter Card

1. Turn the Main Power Switch OFF.

2. Note the location of each cable, then unplug all cables from the MZLP daughter card on MZLP #1 (112).

3. Remove the four mounting screws (112b) from the daughter card (112a) and set aside.

4. Unplug the daughter card (112a) from MZLP #1 (112).

5. Plug the new daughter card (112a) into the MZLP (112).

6. Use the screws (112b) to secure the daughter card to the MZLP (112).

7. Connect the cables to the new daughter card (112a).

NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation.

NOTE: If unable to determine the connector location, see Electrical Schematics, page 62.

FIG. 32: MZLP Daughter Card

56 334130T

Page 57

Repair

182

205

223

ti25224a

206

208

Replace AWB

1. Turn the Main Power Switch OFF.

2. Note the location of each cable, then unplug all cables from the AWB (205).

NOTE: For an AWB on a secondary system, remove the connector (182) and connect to the new AWB.

Replace Power Supply

FIG. 33: AWB Connections

3. Remove the two screws (223) securing the AWB (205) to the electrical panel, then carefully remove the AWB.

4. Install the new AWB (205) and reconnect the cables.

NOTE: Do not force the electrical connection. Minimal force is required to set the connector. If resistance is felt, stop and verify the connector orientation.

NOTE: See Electrical Schematics, page 62, if unable to determine the connector location.

1. Turn the Main Power Switch OFF.

2. Open the Electrical Enclosure.

3. Remove the power supply (208) from the din rail (206). Disconnect the screw terminal connections between the power supply and the power supply

harness.

Power Supply

Connection Harness Label

V+ V+

V- V-

GND GND

4. Connect the power supply harness to the new power supply.

5. Reattach the power supply to the din rail (206).

6. Torque terminals to 4.53-6.2 in-lbs (0.5-0.7 N•m).

334130T 57

7. Close the Electrical Enclosure door.

Page 58

Repair

ti25226a

137

136138

139

141

ti25227a

Replace Fan

1. Turn the Main Power Switch OFF.

2. Disconnect the plug from the power outlet or turn off the circuit breaker for incoming power.

3. Open the Electrical Enclosure door.

4. Remove the connector from the J7 connector on the AWB board. Remove the red (+) and black (-) fan wires from the connector.

6. Remove the screws (141), grill (137), four nuts (139), rear fan grill (138), and fan (136).

7. Mount the new fan (136), rear fan grill (138), and nuts (139) on the grill (137) with the arrow pointing toward the grill (137).

5. Cut any cable ties between the end of the fan wires to the fan (136).

8. Tie down the fan wires onto the tie down locations on the grill (137) using cable zip ties.

9. Route the fan wires into the Electrical Enclosure.

Connect the red and black fan wires to the J7 con-

nector. Reconnect the J7 connector to the AWB. Use cable ties to secure the fan wires to other cables in the electrical enclosure.

NOTE: To prevent fan errors on the ADM, remove the excess slack and ensure that the cabling and zip ties do not contact the fan blades.

10. Reinstall the fan grill (137) and close the Electrical Enclosure.

58 334130T

Page 59

Repair

480VAC

600VAC

400VAC

ti25228a

Replace Transformer

See FIG. 34, page 60.

1. Turn the Main Power Switch OFF.

2. Open the Electrical Enclosure door.

3. Disconnect the incoming power harness (234) from the top of the transformer (235).

4. Disconnect the transformer (235) output power har-

ness wires (CR2-W1, -W2, -W3, -W4) from CR2.

13. Connect transformer output power harness (234) to power terminal connections. Torque to 25–27 in-lbs (2.8–3.1 N•m).

Table 11 Transformer Output Power Harness Connections

Power Harness Wires CR-2 Connections

CR2-W1 Terminal 1 CR2-W2 Terminal 3 CR2-W3 Terminal 5 CR2-W4 Terminal 13

14. Install the incoming power harness (234) to the top of the transformer in the voltage port specified on the machine serial number label.

5. Disconnect the transformer (235) ground wire from the back panel ground lug.

6. Disconnect the red (+) and black (-) wire of the fan from pins 4 and 3 of the J7 connector on the AWB (205). Disconnect the J7 connector from the AWB.

7. Cut the wire zip ties securing the fan wires.

8. Remove the flanged nuts (N) and transformer (235) from the back panel (201).

9. Install the transformer (235) onto mounting studs on the back panel (201) and secure with flanged nuts (N).

10. Insert the thermal sensor connector from the trans-

former (235) onto the J7 connector on the AWB (205).

11. Reconnect the red (+) wire from the fan into pin 4 and the black (-) wire into pin 3 of the J7 connector.

12. Install the transformer (235) ground wire onto the ground lug of the back panel (201).

15. Verify all electrical connections, including earth grounds, are complete and tight. All connections and plugs must be connected prior to applying power.

16. Close the Electrical Control Panel door.

17. Apply power to the machine. Turn on the Main Power Switch.

18. Restart the system.

334130T 59

Page 60

Repair

201

235

234

205

CR-2

FIG. 34: Inside of Electrical Control Enclosure

60 334130T

Page 61

Repair

Update Software

When software is updated on the ADM, the software is

then automatically updated on all connected GCA com-

ponents. A status screen is shown while software is updating to indicate progress.

1. Turn the system Main Power Switch OFF.

2. Remove the ADM from the bracket.

3. Remove the token access panel.

NOTE: When the Screen turns on, you will see the fol-

lowing screens:

First:

Software is checking which GCA modules will take the available updates.

Second:

Status of the update with approximate time until completion.

Third:

Updates are complete.

Icon indicates update success/failure. See the fol-

lowing Icon table.

4. Insert and press the software upgrade token (T) firmly into the slot.

NOTE: There is no preferred orientation of the token.

5. Install the ADM into the bracket.

6. Turn the system Main Power Switch ON.

NOTICE

A status is shown while software is updating to indi-

cate progress. To prevent corrupting the software load, do not remove the token until the status screen disappears.

Icon Description

Update successful.

Update unsuccessful.

Update complete, no changes necessary.

Update was successful/complete, but one or more HCA modules did not have a CAN boot-loader, so software was not updated on that module.

7. Remove the token (T).

8. Replace the token access panel.

9. Press to continue to the operation screens.

334130T 61

Page 62

Electrical Schematics

230V, 3 Phase/60Hz

62 334130T

Page 63

400V, 3 Phase/50Hz

Electrical Schematics

334130T 63

Page 64

Electrical Schematics

400-600VV, 3 Phase/60Hz

64 334130T

Page 65

A RELEASED A257M

Z090146

06/24/14

B SEE ECO

Z090616

07/23/14

C SEE ECO

Z091443

08/26/14

D SEE SHEETS 1,2,3

Z092531

10/17/14

E SEE SHEETS 1 AND 2.

Z093615

12/04/14

F SEE SHEET 1

Z095498

23MAR15

G SEE SHEET 1

Z097266

02JUN15

H REVISED SHEET3

Z098180

30JUN15

J SEE SHEET 1

Z104520

17MAR16

K REVISED SHEETS 2,3, & 4

Z106725

06/16/16

CAN

200

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

217

218

219

220

221

222

223

224

225

226

227

228

229

230

231

232

233

234

235

236

237

238

239

240

250

251

252

253

254

255

256

257

258

259

260

261

262

263

264

265

266

267

268

269

270

271

272

273

274

275

276

277

278

279

280

281

282

283

284

285

286

287

288

289

290

AWB-1

24+

GND

EGND

PS-1

129

130

131

265

266

267

268

332

330

329

122

125

ENCLOSURE FAN

(FAN-2)

127421

110

109

115

114

372

374

220

221

222

223

315

313

312

238

237

236

235

234

300

301

302

303

304

281

282

283

284

285

MOTOR-UP

MOTOR-DN

SOL-1

PX-LOW

PX-EMPTY

PUMP-RTD

PLATEN-RTD

54 32 1

G32

1290

1300

1310

1220

1250

2610

2620

J16 J14J15

MZTCM-1

J13 J12

L3L2L1

543214321

5 4 3 2 1

65432

432

4 3

2 1

1140

1150

1090

1100

W1W2W3W4G

2270

2320

2790

RED

2770

2720

2710

2700

2670

2680

2650

2640

2560

2570

-V

GND

132

1320

HARNESS 17A559

AWB-1-J8 TO MZTCM-1-J6

BLACK

YELLOW

RED

HARNESS 17A543

AWB-1-J6 TO MZTCM-1-J2

HARNESS 17A544 OR 17A545

AWB-1-J5 TO MZTCM-2-J2

AWB-1-J5 TO MZTCM-3-J2

HARNESS 17A543

MZTCM-1-J2 TO AWB-1-J6

HARNESS 17A551

MZTCM-1-J1 TO TERM BLOCKS

HARNESS 17A557

MZTCM-1-J12 TO SOL-1

HARNESS 127511

MZTCM-1-J3 TO MZTCM-2-J6

HARNESS 24V745

HARNESS 17A559

MZTCM-1-J6 TO AWB-1-J8

HARNESS 17A553

MZTCM-1-J7 TO SSR-1 AND CR-1

BLUE

RED

BLUE

HARNESS 17A555

2730

2740

RED

BLUE

RED

WHITE

2760

355

358

RED

HARNESS 17B768

HARNESS 17A552

18 AWG

10 AWG

18 AWG

12 AWG

10 AWG

22 AWG

AWB and MZLP#1

Electrical Schematics

334130T 65

Page 66

Electrical Schematics

A RELEASED A257M

Z090146

06/24/14

B SEE ECO

Z090616

07/23/14

C SEE ECO

Z091443

08/26/14

D SEE SHEETS 1,2,3

Z092531

10/17/14

E SEE SHEETS 1 AND 2.

Z093615

12/04/14

F SEE SHEET 1

Z095498

23MAR15

G REVISED PUMP WIRING

Z097266

02JUN15

H REVISED SHEET 3

Z098180

30JUN15

J SEE SHEET 1

Z104520

17MAR16

K REVISED SHEETS 2,3, & 4

Z106725

06/16/16

300

301

302

303

304

305

306

307

308

309

310

311

312

313

314

315

316

317

318

319

320

321

322

323

324

325

326

327

328

329

330

331

332

333

334

335

336

337

338

339

340

350

351

352

353

354

355

356

357

358

359

360

361

362

363

364

365

366

367

368

369

370

371

372

373

374

375

376

377

378

379

380

381

382

383

384

385

386

387

388

389

390

262

261

240V/1200W TOTAL

2610

2620

215

217

218

254

253

252

251

250

215

217

218

MZTCM-3

MZTCM-2

L3L2L1

54321

65432

HARNESS 127511

MZTCM-2-J3 TO MZTCM-3-J6

54321

65432

L3L2L1

54321

HARNESS 127511

MZTCM-2-J6 TO MZTCM-1J3

HARNESS 17A544 OR 17A545

MZTCM-2-J2 TO AWB-1-J5

HARNESS 17A545

MZTCM-3-J2 TO AWB-1-J5

321

2740

275

274

2730

2740

2731

2730

2731

2732

2740

2731

2732

PLATEN

PUMP

TYPICALL ALL TOF200 AND TOFP20's

OVERTEMPS

ALL VOLTAGES

2740

275

274

2730

2740

2730

2731

2732

2740

PLATEN

TYPICALL OF TOFP20's WITH CODE D

OVERTEMP

AT SELECTION 7. ALL VOLTAGES

10 AWG

16 AWG

MZLP#2, MZLP#3, Overtemp, and Pump Heaters

66 334130T

Page 67

MZLP Zones

A RELEASED A257M

Z090146

06/24/14

B SEE ECO

Z090616

07/23/14

C SEE ECO

Z091443

08/26/14

D SEE SHEETS 1,2,3

Z092531

10/17/14

E SEE SHEETS 1 AND 2.

Z093615 12/04/14

F SEE SHEET 1

Z095498

23MAR15

G SEE SHEET 1

Z097266

02JUN15

H REVISED SHEET 3

Z098180

30JUN15

J SEE SHEET 1

Z104520

17MAR16

K REVISED SHEETS 2,3, & 4

Z106725

06/16/16

400

401

402

403

404

405

406

407

408

409

410

411

412

413

414

415

416

417

418

419

420

421

422

423

424

425

426

427

428

429

430

431

432

433

434

435

436

437

438

439

440

MZTCM-1

TYPICAL ZONE PIN OUT

CONNECTOR PIN # FUNCTION

MZTCM-1

MZTCM-1 J9

A ZONE 1,L2

B SHIELD

C ZONE 2,L1

D ZONE 2,L2

E JUMPER

F ZONE 1,START

G ZONE 1,RTD

H JUMPER

J ZONE 1,L1

K RTD EXCITE

L ZONE 2,START

M ZONE 2,RTD

MZTCM-1 J8

A ZONE 3,L2

B SHIELD

C ZONE 4,L1

D ZONE 4,L2

E JUMPER

F ZONE 3,START

G ZONE 3,RTD

H JUMPER

J ZONE 3,L1

K RTD EXCITE

L ZONE 4,START

M ZONE 4,RTD

MZTCM-2

MZTCM-2 J9

A ZONE 5,L2

B SHIELD

C ZONE 6,L1

D ZONE 6,L2

E JUMPER

F ZONE 5, START

G ZONE 5,RTD

H JUMPER

J ZONE 5,L1

K RTD EXCITE

L ZONE 6,START

M ZONE 6,RTD

MZTCM-2 J8

A ZONE 7,L2

B SHIELD

C ZONE 8,L1

D ZONE 8,L2

E JUMPER

F ZONE 7,START

G ZONE 7,RTD

H JUMPER

J ZONE 7,L1

K RTD EXCITE

L ZONE 8,START

M ZONE 8,RTD

MZTCM-3

MZTCM-3 J9

A ZONE 9,L2

B SHIELD

C ZONE 10,L1

D ZONE 10,L2

E JUMPER

F ZONE 9,START

G ZONE 9,RTD

H JUMPER

J ZONE 9,L1

K RTD EXCITE

L ZONE 10,START

M ZONE 10,RTD

MZTCM-3 J8

A ZONE 11,L2

B SHIELD

C ZONE 12,L1

D ZONE 12,L2

E JUMPER

F ZONE 11,START

G ZONE 11,RTD

H JUMPER

J ZONE 11,L1

K RTD EXCITE

L ZONE 12,START

M ZONE 12,RTD

ZONE-1-RTD

ZONE-2-RTD

ZONE-1-START

ZONE-2-START

ZONE-2-HEAT

ZONE-1-HEAT

TYPICAL ZONE PIN OUT

MZTCM-2

MZTCM-3

109

1211

Electrical Schematics

334130T 67

Page 68

Parts

ti25003a

Parts

Therm-O-Flow 200 Supply Unit

68 334130T

Page 69

Therm-O-Flow 200 Supply Unit

Parts

Ref Part Description Qty

1--- Frame 1 2 24W870 KIT, air controls; see Air Control

Assembly, page 70

3 --- CONTROL, electrical 1

4 --- MODULE, pump; see Pump Mod-

ules, page 78

5 --- PLATEN; see Heated Platens,

page 85 6 --- RAM; see ram manual 1 7 --- CLAMP, drum; see Drum Ram

Post Saddle Clamp, page 88 8 --- SEALS, see manual 309196 1 9 24W812 ADM 1 10 24W589 KIT, light tower (optional); see

Accessories and Kits, page 92 11 253288 CABLE, track, IGUS 1 12 234966 KIT, hose hanger 1 13 24V745 SENSOR, level, low/empty 1 14 15H543 BRACKET, mounting 1

▲ Replacement Warning Labels, signs, tabs, and cards

are available at no cost.

Ref Part Description Qty

15 120186 BOLT, mounting, u-bolt 2 16 101864 SCREW, cap, sch 8 17 111303 NUT, hex 4 18 100575 SCREW, cap, hex hd 4 19 100023 WASHER, flat 4 20 --- BRACKET, mounting, enclosure 1 21 100643 SCREW, cap, sch 4 22 100016 WASHER, lock 4 23 110755 WASHER, plain 4 24 233559 KIT, vent hood (optional); see

Accessories and Kits, page 92.

25▲ 15J076 LABEL, warning, instructions 2 26▲ 15J074 LABEL, warning; moving objects,

pinch

27▲ 15H668 LABEL, warning; hot surface,

splatter

28▲ 15J075 LABEL, warning; hot surface,

shock

29▲ 184090 LABEL, warning 1

334130T 69

Page 70

Parts

Integrated Control For

TOF With Electrical Enclosure

24X026, Integrated Control For

Hydraulic TOF With Electrical

Enclosure

Integrated Control For

TOF Without Electrical Enclosure

Air Control Assembly

Ref Part Description Qty

52 53 54 55 56

57 --- FITTING, adapter, 1/8 x 1/8 NPT(f) 1 58 --- BLOCK, adapter, regulator 2

70 334130T

24W870

121235 17A557 113445 121282 120375

KIT, CONTROL, air, 3 regulator;

see manual 334201

SOLENOID, air motor, ram 1

HARNESS, solenoid, MZLP 1

FITTING, elbow, street 1

FITTING, swivel, straight 1

ADAPTER, elbow, 3/4-14 nptf x

1/2-14 npsm

Ref Part Description Qty

59 --- O-RING 4

60 --- SCREW, cap, socket hd; 1.5 in,

#8-32

61 --- CONTROL, air, 3 regulator,

62 --- LABEL, valve, shutoff, air control 1 66 255651 KIT, reg, air motor, ram 1

Parts only used with 24X026 on TOF 200 Hydraulic Sys-

tems.

hydraulic

Page 71

Electrical Module

184

143

144

148 150 152 153

142

106

152

153

105

145

147

149

120

174

222

141

137

136

138

139

140

141

222

160

159

157

158 101

104

103

172

170153146 151

177, 119

222

118

111

116

115

114

113

183

161

131

112

116

115

Parts

334130T 71

Page 72

Parts

110

165

167

169

125

126

181

222

128

127 122

168

125

131

165

111

129

130

156

162

124

123

108

109

135

133

132

134

72 334130T

Page 73

Electrical Control Module Parts

Parts

Ref Part Description Qty

101 --- ENCLOSURE, electrical 1 103 --- BUSHING, strain relief, m40

thread 104 --- NUT, strain relief, m40 thread 1 105 125946 PLUG, hole, 1/2 in 2 106 123967 KNOB, operator disconnect 1 107 --- PANEL, elec, transformer

(transformer assemblies only)

--- PANEL, elec, 400v/n (400V modules only)

--- PANEL, elec, 230v/n (230V modules only)

108 100133 WASHER, lock, 3/8 4 109 100307 NUT, hex 8 110 123396 NUT, flange, serrated, 3/8-16 4 111 --- MODULE, gca, mzlp w/ daughter

board

112 24V510 MODULE, gca, mzlp

(8 zone assemblies only; Qty 1) (12 zone assemblies only; Qty 2)

112a 24R042 KIT, daughter, board 1 113 --- GASKET, foam

(8 zone assemblies only; Qty 1) (12 zone assemblies only; Qty 2)

114 24P175 PLATE, blank

(4 zone assemblies only; Qty 2) (8 zone assemblies only; Qty 1)

115 125856 SCREW, 8-32, serrated flange 12 116 16T440 CAP, souriau, uts 14

(4 zone assemblies only; Qty 2) (8 zone assemblies only; Qty 4) (12 zone assemblies only; Qty 6)

118 --- WIRE, grounding, door 1 119 100166 NUT, full hex 2 120 --- GASKET, hphm 1 122 17A543 HARNESS, power, mzlp1, awb 1 123 17A544 HARNESS, power, mzlp2, awb

(8 zone assemblies only)

17A545 HARNESS, power, mzlp2/3, awb

(12 zone assemblies only)

Ref Part Description Qty

125 --- HARNESS, pump, mzlp1, tb, tof 1 126 --- HARNESS, output, mzlp1, ssr,

contact 127 17A555 HARNESS, pump, reed switch, tof 1 128 17A559 HARNESS, board, mxm, comm 1 129 127511 CABLE, board, samtec

(8 zone assemblies only; Qty 1)

(12 zone assemblies only; Qty 2) 130 121226 CABLE, can, male / female, 0.4m 1 131 121612 CONNECTOR, thru, m12, mxf 1 132 123969 SWITCH, disconnect, 100a 1

123968 SWITCH, disconnect, ph exp 100

A (400V only) 134 --- HARNESS, disc, fuse, 230-600v 1

17A547 HARNESS, disc, cb, 400v/n, tof 1

136 24V911 FAN, 24v dc, 120m x 120m

(400V only) 137 16X884 GRILL, fan (400V only) 1 138 115836 GUARD, finger (400V only) 1 139 127278 NUT, keps, hex (400V only) 4 140 24V746 GRILL, vent

(230V and 400V assemblies only;

Qty 2) (Transformer assemblies

only; Qty1) 141 119865 SCREW, mach, hex serrated 4

142 --- CONTROL, air, assy; with sole-

noid 143 24W812 ADM (Primary assemblies only) 1 144 15V551 SHIELD, membrane, ADM

(Primary assemblies only) 145 121001 CABLE, can, female / female 1.0m

(Primary assemblies only) 146 --- BRACKET, mounting, assembly

(Primary assemblies only)

147 121250 SCREW, shcs, 1/4uncx4.25 (Pri-

mary assemblies only) 148 102040

149 110755 WASHER, plain (Primary assem-

150 121253

151 ---

152 101550

NUT, lock, hex

(Primary assemblies only)

blies only)

KNOB, display adj., ram pkgs

(Primary assemblies only)

BRACKET, pendant pivot,

(Primary assemblies only)

SCREW, cap, sch

(Primary assemblies only)

0.1

334130T 73

Page 74

Parts

Ref Part Description Qty

153 100016

WASHER, lock (Primary assemblies only)

156 24V745 SENSOR, level, low/empty 1 157 --- BUSHING, strain relief 1 158 --- NUT, bushing 1 159 --- GROMMET, wire 1 160 124654

CONNECTOR, splitter, 12(m) x m12(f)

(Secondary modules only)

161 121228

CABLE, can, female/female,

15.0 m (Secondary modules only)

162 16W035

CONNECTOR, jumper (8 zone assemblies only; Qty 1) (12 zone assemblies only; Qty 2)

163 ---

CONTACT, socket, 20-24 awg, crimp, tin

164 --- TUBE, 1/16 shrink tube 0.13 165 ---

166 127771

HARNESS, input, mzlp1, RTD BRIDGE, plug-in, 2pos, ut16 (400V and Transformer modules only)

167 ---

FERRULE, wire, 10awg (230V modules only; Qty 2) (400V and transformer modules only; Qty

168 --- FERRULE, wire, 16awg 6 169 ---

FERRULE, wire, 18 awg, long

170▲ 196548 LABEL, warning, shock 1

172 --181 ---

ARTWORK, instructions, wiring, ul FERRULE, wire, 10awg, twin (Secondary assemblies only)

182 17C669

CONNECTOR, jumper, male (Secondary assemblies only)

183 123856

HARNESS, CAN, cable (Secondary assemblies only)

184 17C712

TOKEN (Secondary assemblies only)

1 1

1 3

▲ Replacement Warning labels, signs, tags, and cards

are available at no cost.

74 334130T

Page 75

Electrical Panel

Torque terminals to 25-27 in-lbs (2.8-3.1 N•m).

Torque terminals to 13.3-16 in-lbs (1.5-1.8 N•m)

Torque terminals to 4.53-6.2 in-lbs (0.5-0.7 N•m)

123

Transformer Panel Shown

239

240

235

211

205

223

228

226

201

223, 224

225

214

227

215

216, 229

230, 231

213

208

210

212

206

202, 203, 204, 236

234

241

242

230V 400V Transformer

Parts

334130T 75

Page 76

Parts

Torque terminals to 25-27 in-lbs (2.8-3.1 N•m).

Torque terminals to 13.3-16 in-lbs (1.5-1.8 N•m)

Torque terminals to 4.53-6.2 in-lbs (0.5-0.7 N•m)

123

230V Panel

400V Panel

230

232

230

233

211

219

243

220

221

207

218

217

76 334130T

Page 77

Electrical Panel Parts

Parts

Ref Part Description Qty

201 --202 117666 TERMINAL, ground 1

203 113783 SCREW, machine, pn hd 1 204 100985 WASHER, lock ext 1 205 24V816 MODULE, gca, awb 1 206 --- RAIL, din, 6.5in 1 207 123363

208 126453 POWER SUPPLY, 24v 1 209 ---

210 128097 211 --- HARNESS, rcd, awb 1

212 126811 BLOCK, clamp end 2 213 --- RAIL, din, 19in 1 214 120399

215 123359

216 6690-24

-165 217 128314 BLOCK, terminal 3-wire 8 218 128321 COVER, end 2 219 126819

220 127717 221 127718 COVER, end, ut16 1

222▲ 17C137 LABEL, multi safety 1

223 103833 SCREW, mach, crbh 33 224 123452

225 --226 --- HARNESS, fuse, contactor 1

227 --- HARNESS, contactor, ssr 1

PANEL, elec, tof, 11ga, zinc

BLOCK, terminal, ground, 10mm

HARNESS, power supply, awb CIRCUIT, breaker, 63a, 4p, rcd

CONTROL, 65 amp, 120-600v RELAY, contactor, 30a, 3p, 24vdc co FUSE, fuse block buss jt60060

BRIDGE, plug-in, 2-position BLOCK, terminal, 2pos, ut16

HOLDER, anchor, wire tie, nylon HARNESS, wire, ground, 8awg

1 1

1 3

Ref Part Description Qty

228 --- HARNESS, rcd, ssr fan 1 229 --- See Code C Table 3 230 6690-24

-164 127744

127745

231 --- See Code C Table 3 232 17L788

233 17L789

234 17A541

235 24V718

237 128014

238 112380 SCREW, mach, pn hd 2 239 81/0163

-B/11

240 81/0164

-B/11 241 17L790 HARNESS 1 242 129120 CONTACTOR 240V 1 243 17L787 HARNESS 1

▲ Replacement Warning labels, signs, tags, and cards

are available at no cost.

FUSE, fuse block buss jt60030

CIRCUIT, breaker, 3p, 32a, ul489; 230V Panel only CIRCUIT, breaker, 20a,

4p, ul489; 400V Panel only

HARNESS, cb, rcd, 230-400V; 230V and 400V Panel only HARNESS, cb, rcd, 400v/n; 400V Panel only HARNESS, fuses, transformer; Transformer panel only

TRANSFORMER, multi-tap/230v, 6kva; Transformer panel only FILTER, voltage, transient, 600V, 3P

WIREWAY, panduit 4

COVER, panduit 4

If Code A is 200 and Code E is M and Code C is If Code A is 200 and Code E is F/S and Code C is

Code C (229) (231) Code C (229) (231)

X1X 24X885 NA X1X 24X885 NA X2X 24X881 NA X2X 24X880 NA X3X 24X881 24X878 X3X 24X880 24X878 X4X 24X882 24X877 X4X 24X881 24X877 X5X 24X884 24X874 X5X 24X883 24X874

334130T 77

Page 78

Parts

Torque to 50-60 ft-lbs (68-81 N•m).

Torque to 145-155 ft-lbs (196-210 N•m).

Coat mounting surface of sensor mounting block (322) with non-silicone heat sink compound. Do not coat sensor.

Prior to tightening band clamp (321), RTD sensor (320) must be fully contained within the sensor mount (322).

After fastening band clamp (321), secure excess with fiberglass tape.

12345

Coat inside of heater (309a, 309b) only to within 0.75 in. (19 mm) of vertical ends with non-silicone heat sink compound before mounting.

Cap screws (311) must be loose while tie rods (307) are being torqued.

Torque to 150 ft-lb (203 N•m).

Install swivel fitting (302) prior to screw (303) and reed switch assembly (304).

Apply anaerobic sealant to threads.

678

ti25145a

333

326

309b

321

322

325

324

323

309a

310

308

329

315

338

301

327

337

302

304

312

318

311

317

316

307

306

318

305

335b

336

335a

334

320

Merkur 2200, 23:1 Pump Modules

78 334130T

Page 79

Merkur 2200, 23:1 Pump Modules

Parts

Ref Part Description Qty

301 24W754 302 155470 304 24R885 SWITCH, reed assy 1

305 --- BRACKET, motor mount 1 306 15H397 ADAPTER, rod, pump 1 307 16A223

308 106166 NUT, mach ,hex 3 309 128322

310 24W150

24W151

311 109211 SCREW, cap, sch 3 312 17A637 BLOCK, standoff, mounting 3 315 102656

316 186925 317 184129 318 120186 BOLT, mounting, u-bolt 2

320 24Z093 SENSOR, RTD 1

MOTOR, air, 6 in, 4.75 stroke, blue FITTING, swivel, union, 90°

ROD, tie, vert driver

HEATER, pump, 600 watt PUMP, long shaft, cf; 24V003 only PUMP, long shaft, gf; 24V006 only

MUFFLER NUT, coupling COLLAR, coupling

1 1

2 1

1 1 2

Ref Part Description Qty

321 C31012 322 C03507 323 C38162 SCREW, machine 1

324 C38163 WASHER, lock, ext. tooth 1 325 --- CONDUCTOR, ground 1 326 ---

329 103347 330 C33049 TAPE, adhesive, fiberglass 1.5

331 --333 206994 FLUID, tsl 8 oz bottle 1

334 17B715 335 127671

336 122338 337 214656 HOSE, coupled, 10 ft (3 m) 1

338 16C009 HOOK 1

CLAMP SUPPORT, sensor

SHIELD, pump, tof200; see 24V619, Pump Shield, page 84 VALVE, safety, 100 psi

LUBRICANT, high temp, thermal

SUPPORT, block, overtemp SWITCH, over temp, fixed, 450°F (232°C) SCREW, cap, socket bh

1 1

1 2

334130T 79

Page 80

Parts

Torque to 50-60 ft-lbs (68-81 N•m).

Torque to 145-155 ft-lbs (196-210 N•m).

Coat mounting surface of sensor mounting block (322) with non-silicone heat sink compound. Do not coat sensor.

Prior to tightening band clamp (321), RTD sensor (320) must be fully contained within the sensor mount (322).

After fastening band clamp (321), secure excess with fiberglass tape.

12345

Coat inside of heater (309) only to within 0.75 in. (19 mm) of vertical ends with non-silicone heat sink compound before mounting.

Cap screws (311) must be loose while tie rods (307) are being torqued.

Torque to 150 ft-lbs (203 N•m).

Install swivel fitting (302) prior to screw (303) and reed switch assembly (304).

Apply anaerobic sealant to threads.

789

338

301

337

327

304

305

318

306

307

316

317

311

318

312

315

326

333

336

335b

335a

336

320

308

310

329

323

324

325

309a

322

321

334

309b

302

Merkur 3400, 36:1 Pump Modules

80 334130T

Page 81

Merkur 3400, 36:1 Pump Modules

Ref Part Description Qty

301 24R015 302 155470 304 24R885 SWITCH, reed assy 1

305 15H173 306 15H397 ADAPTER, rod, pump 1

307 16A223 308 106166 NUT, mach, hex 3

309 128322 310 24W150

24W151

311 109211 SCREW, cap, sch 3 312 17A637 BLOCK, standoff, mounting 3 315 102656

316 186925 317 184129 318 120186 BOLT, mounting, u-bolt 2

320 24Z093 SENSOR, RTD 1 321 C31012

322 C03507 323 C38162 SCREW, machine 1

324 C38163 WASHER, lock, ext. tooth 1 325 --- CONDUCTOR, ground 1 326 ---

329 103347 330 C33049 TAPE, adhesive, fiberglass 1.5

331 --333 206994 FLUID, tsl 8 oz bottle 1

334 17B715 335 127671

336 122338 337 214656 HOSE, coupled, 10 ft (3 m) 1

338 16C009 HOOK 1

MOTOR, assy, air, 7.5 in, blue FITTING, swivel, union, 90°

BRACKET, motor mount, tof 200

ROD, tie, vert driver

HEATER, pump, 600 watt PUMP, long shaft, cf; 24V004 only PUMP, long shaft, gf; 24V007 only

MUFFLER NUT, coupling COLLAR, coupling

CLAMP SUPPORT, sensor

SHIELD, pump, tof200; see 24V619, Pump Shield, page 84 VALVE, safety, 100 psi

LUBRICANT, high temp, thermal

SUPPORT, block, overtemp SWITCH, over temp, fixed, 450°F (232°C) SCREW, cap, socket bh

1 1

2 1 1

1 1 2

1 1

1 2

Parts

334130T 81

Page 82

Parts

Torque to 50-60 ft-lbs (68-81 N•m).

Torque to 145-155 ft-lbs (196-210 N•m).

Coat mounting surface of sensor mounting block (411) with non-silicone heat sink compound. Do not coat sensor.

Prior to tightening band clamp (412), RTD sensor (410) must be fully contained within the sensor mount (411).

123

After fastening band clamp (412), secure excess with fiberglass tape.

Coat inside of heater (407) only to within 0.75 in. (19 mm) of vertical ends with non-silicone heat sink compound before mounting.

Torque to 150 ft-lb (203 N•m).

Apply anaerobic sealant to threads.

568

401

402

418

423

409

404

414

413

405

422

433

403

418

406

424

408

417

415

416

407a

411

412

429

407b

410

431

430a

430b

431

428

ti25160a

NXT 6500, 70:1 Pump Modules

82 334130T

Page 83

NXT 6500, 70:1 Pump Modules

Ref Part Description Qty

401 N65LR0 402 120375

403 15H542

404 17A406 ADAPTER, rod, pump, tof 1 405 16A223

406 106166 NUT, mach, hex 3 407 128322

408 24W150

24W151 409 C19837 410 24Z093 411 C03507 SUPPORT, sensor 1

412 C31012 CLAMP 1 413 186925

414 184129 415 C38163 416 --- CONDUCTOR, ground 1

417 C38162 SCREW, machine 1 418 120186

419 100307 422 ---

423 120588 PLUG, pipe, round 1 424 120012 VALVE, safety, 50 psi 1 425 ---

426 C33049 428 206994 FLUID, tsl 8 oz bottle 1

429 17B715 430 127671

431 122338 432 17C255 433 ---

MOTOR, 6500, low-noise, remote ADAPTER, elbow, 3/4 npti x 1/2 npte BRACKET, mounting, motor, tof200

ROD, tie, vert driver

HEATER, pump, 600 watt PUMP, long shaft, cf; 24V005 only PUMP, long shaft, gf; 24V008 only SCREW, cap, socket hd SENSOR, RTD

NUT, coupling COLLAR, coupling WASHER, lock, ext. tooth

BOLT, mounting, u-bolt NUT, hex SHIELD, pump, tof200; see 24V619, Pump Shield, page 84

LUBRICANT, high temp, thermal TAPE, adhesive, fiberglass

SUPPORT, block, overtemp SWITCH, over temp, fixed, 450°F

(232°C) SCREW, cap, socket bh CABLE, M12, 8p, 5p, m, 0.2 m HOSE, coupled, 13.5 ft (4 m)

1.5

Parts

1 1

2 1 1 4 1

1 2 1

2 4 1

1 2

4 1 1

334130T 83

Page 84

Parts

506

510 505

509

506

504

506

502

501

508

507

503

506

509

507

508

511

ti25162a

24V619, Pump Shield

Ref Part Description Qty

500 24V619PKG 501* --502* --503* --504* --- COVER, pump, top, front 1

505* --506* ---

84 334130T

SHIELD, pump, TOF200 COVER, pump, bottom COVER, pump, right COVER, pump, left

COVER, pump, top, back FASTENER, thread-cutting screw

1 1 1 1

Ref Part Description Qty

507*▲ 17J504

508* 104088

509*▲ 15J075

510 --511 C20731

▲ Replacement Warning labels, signs, tags, and cards

are available at no cost.

* Parts included in Kit 24V619PKG.

LABEL, warning RIVET, blind LABEL, safety, hot surface and shock BUSHING, conduit, 1 in FITTING, conduit, connector, 1 in.

2 4 2

1 1

Page 85

Heated Platens

601

605

601

609

608

607

615

614

603

627

624

623

606

601

622

604

619

602

612

613

605

609

625

628

610

626

629

630

611, 629

24V633, Heated Drum Platen, Mega-Flo (Code E-option M) 24V634, Heated Drum Platen, Standard Grid (Code E-option F) 24V635, Heated Drum Platen, Smooth Bottom (no fin) (Code Eoption S)

Parts

334130T 85

Page 86

Parts

Heated Platens

24V633, Heated Drum Platen, Mega-Flo (Code E-option M) 24V634, Heated Drum Platen, Standard Grid (Code E-option F) 24V635, Heated Drum Platen, Smooth Bottom (no fin) (Code Eoption S)

Ref Part Description Qty

601 --602 C32204 PACKING, o-ring 1

603 15G967 PLATE, tire 1 604 C19049

605 24Z095 SENSOR, temperature 1 606 C32201 GASKET, follower 1 607 158491

608 158581 COUPLING, hex 1 609 617227

610 246501 611 100361 PLUG, pipe 4

612 100133 WASHER, lock 6 613 C19846 SCREW, cap socket, HD 6 614 150707

--615 100508 616 --617 ---

PLATEN — see table below

SCREW, mach, slotted, RND HD

FITTING, nipple

HANDLE, follower, bleed VALVE, blow off

PLATE, designation PLATE, designation; 24V633 only SCREW, drive CONDUCTOR, 14.2 ft (4.3 m) CONDUCTOR, 1.7 ft (0.5 m)

1 1

1 1 2 6 2

Ref Part Description Qty

618 --619 --620 112901 NUT, hex 12

621 111640 WASHER, lock, internal 12 622 --- PLUG, follower, plate 1 623 127671

624 122338 625 --- TUBE, ptfe, 1/4 X 5/16 3

626 --- TUBE, ptfe, 3/32 X 5/32 3 627 ---

628 127690

629 127689

630 ---

CONDUCTOR, 0.3 ft (0.09 m) CONDUCTOR, ground

SWITCH, over temp, fixed, 450°F (232°C) SCREW, cap, socket bh

SLEEVE, fiberglass, hi-temp FITTING, adapter, 5/16 in. tube x

1/4 in tube FITTING, adapter, 1/4 in tube x

5/32 in tube TUBE, polyeth, 1/4 OD; 26 ft (7.9 m)

4 1

3 1

Platen Model Description Ref. No. 601 Qty. Element Resistance

24V633 Mega-Flo 194254 1 16.5 ohms +1/-2 24V634 Standard Grid 617225 1 19.2 ohms +2/-3 24V635 Smooth Bottom C57358 1 19.2 ohms +2/-3

86 334130T

Page 87

Parts

334130T 87

Page 88

Parts

703

706

701

707

705

704

701

707

705

704708

706

702

ti25188a

Torque to 50 in-lbs.

Drum Ram Post Saddle Clamp

C32463 Option H-1

Ref Part Description Qty

701 C32424 702 160111 703 100103 704 100307 NUT, hex 4

705 100133 706 C38182 707 C32461 708 166265

88 334130T

BOLT, U, 7 in. (177.8 mm) CLAMP, barrel PIN, cotter

WASHER, lock WASHER, plain CLAMP, saddle PIN, pivot

2 1 2

4 2 2 1

Page 89

Drum Ram Post Saddle Clamp

751

759

708

707

706

702

704

710

756

761

703

705

ti25189a

Torque to 50 in-lbs.

918395 Option H-3

Parts

Ref Part Description Qty

702 100101 703 918421 704 918423 705 617395 PIN, quick release 2

756 100133 707 C19200 708 617433 759 617395 710 100131 761 C32424

334130T 89

SCREW, cap, hex hd CLAMP, back half assembly KIT, repair

WASHER, lock WASHER, plain SPACER, drum clamp CLAMP, saddle NUT, full hex BOLT, U 7 in. (177.8 mm)

8 1 1

8 8 8 4 8 4

Page 90

Parts

ti25190a

801

804

803

805

807

803

802

Torque to 50 in-lbs.

Fiber Drum Reinforcement Shell Clamp

918397 Option H-2

Ref Part Description Qty

6 C32424 801 C32271 802 C19126 803 100133 WASHER, lock 12

804 100307 805 617340 807 617341

BOLT, U, 7 in. (177.8 mm) CLAMSHELL SCREW, cap, hex hd

NUT, hex CLAMP, saddle MOUNT, clam shell

4 1 8

8 4 2

90 334130T

Page 91

Vent Hood Kit, 233559

855

852

853

851

Parts

Ref Part Description Qty

851 --852 112166 853 100016

855▲ C14038 LABEL, warning 1

VENT hood SCREW, cap, sch WASHER, lock

1 4 4

▲ Replacement Warning labels, signs, tags, and cards

are available at no cost.

334130T 91

Page 92

Accessories and Kits

Wiper Kits

See manual 309196 for installation and repair instruc-

tions.

Part No. Description

253291 Hose/Spring Wiper Kit 253290 Hose and T-Wiper Kit 253289 Twin Hose Wiper Kit 253292 T-Wiper Kit

Applicators and Dispense Valves

Part No. Description

249515 Manual Gun, Top Feed, 240V 249514 Manual Gun, Bottom Feed, 240V 249513

249512

Manual Gun, Top Feed, Electric Switch, 240V Manual Gun, Bottom Feed, Electric Switch, 240V

Air-Operated Heated Dispense Valves

Part No. Description

243694

244951

244909

243701

Automatic Dispense Valve, 240V, Air-Operated Heated Dispense Valve Automatic Endure Dispense Valve, 240V, Air-Operated High Flow Heated Dispense Valve Automatic Endure Dispense Valve, 240V, Air-Operated Snuff-Back Heated Dispense Valve 45 in (114 cm) Distribution Header With Valve, 240V

CGM Installation Kit, 25C994

This kit enables controlling logic, such as a robot con-

troller or PLC continuously monitoring data from the Therm-O-Flow system, as well as optionally controlling the system accordingly. Refer to manual 3A5186 for details on the interface. When ordering this kit, select and order the correct communication gateway module

(CGM) that matches the field bus being used. The fol-

lowing CGM modules are available for the Therm-O-Flow system.

Part No. Description

CGMEP0 EitherNet/IP CGMDN0 DeviceNet CGMPB0 ProfiBus CGMPN0 ProfiNet

Flow Control and Manifolds

Part No. Description

243700

243656

243657

243697

289208 Compact Heated Regulator

Heated Air Operated Mastic Pressure Regulator, 240V 23:1 Heated Pressure Compensator Valve, 240V 51:1 Heated Pressure Compensator Valve, 240V Heated Distribution Manifold, 240V

Includes (2) 3/4 npt(f) inlet check valves, (1) npt 4–ported manifold, (2) 1 in npt(f) outlet gate valves, mounting bracket, 400w 230 VAC heaters, RTD sensor, and 8 pin connector box.

92 334130T

Page 93

Accessories and Kits

Accessory Extension Cables

Use to connect fluid control devices and heated hoses to the electrical control enclosure.

Part No. Description

Connect between controller and heated hose 129300 15 ft, 12 pin to 12 pin 129301 25 ft, 12 pin to 12 pin Connect between controller and heated accessory 129302 15 ft, 12 pin to 8 pin 129303 25 ft, 12 pin to 8 pin Connect between controller and heated devices 129703 25 ft, 12 pin to (2) 8 pin 129304 50 ft, 12 pin to (2) 8 pin Connect between two heated devices 15C294 30 ft, 8 pin to 8 pin

Light Tower Kit, 24W589

Tie Rod Kits

Use to retrofit Check-Mate 800 Displacement Pump to an existing Therm-O-Flow system.

Part No. Description

24V750

24V754 NXT® Tie Rod Kit; see manual 334132

Bulldog® and Senator® Tie Rod Kit; see manual 334131

334130T 93

Page 94

Accessories and Kits

Heated Hoses and Fittings

NOTE: Refer to Heated Hose, Instructions-Parts man-

ual 3A4241 for additional information about heated hoses. See Related Manuals on page 8.

-6 (9/16 in -18

Hose Diameter

Hose Length 3 ft (1 m) None None None 19M410 None None 4 ft (1.2 m) None 19M400 None None None None 6 ft (1.8 m) None 19M401 19M404 19M411 19M416 None 10 ft (3 m) 19M423 19M402 19M405 19M412 19M417 19M421 15 ft (4.6 m) None 19M403 19M406 19M413 19M418 19M422 20 ft (6 m) None None 19M407 19M414 19M419 None 25 ft (7.6 m) None None 19M408 19M415 19M420 None 30 ft (9 m) None None 19M409 None None None Pump Fittings

TOF 20/200 PUMP 1-11 1/2 DUAL OUTLET ADD 120263 TOF MINI 5 PUMP 1/2 NPT DUAL OUTLET ADD 120241

Hose to Hose Fittings

-6 Hose (.308 ID) 125779 123684 123683

-8 Hose (.401 ID) 123684 120241 120242 120244

-10 Hose (.495 ID) 123683 120242 120243 120246

-12 Hose (.617 ID)

-16 Hose (.687 ID)

-20 Hose (1.125 ID) None

Fittings Compensator 51:1, 243657 Compensator 23:1, 243656 Inlet & Outlet: 1-11 1/2 in NPTF

JIC)

16V432 100380

16V432 C20678 C20679 C38006 158586

123683 120265 123683 120265 120267

16V432 100380

-8 (3/4 in -16 JIC)

253267 253268 120260 120261 120262

120244 120246 120247 120248

120244 120267

6308-82

126521

6308-82

-10 (7/8 in -14 JIC)

120246 120267

120246 120267 120268

123135 120266

-12 (1-1/16 in -12 JIC)

123683 120265

120248 120249

123135 126521

123135 123854

-16 (1-5/16 in -12 JIC)

-20 (1-5/8 in -12 JIC)

123683 120265 120267 120244 120267 120246 120267

120249 120268

120804 120268

None

6308-82

126521

6308-82

126521 123135 126521

120249 120268

120250

15D936

94 334130T

Page 95

Accessories and Kits

Hose Diameter

Distribution manifold, 243697 Inlet: 3/4 in NPTF Distribution manifold, 243697 Outlet: 1-11 1/2 in NPTF Compact Heated Regulator, 289208 Inlet & Outlet: 3/8 in NPTF Mastic Regulator, 243700 Inlet & Outlet: 3/4 in NPTF Top and bottom feed guns with and without switch, 249512, 249513, 249514, 249515 Inlet: 7/8-14 (JIC

-10) male Standard, High Flow & Snuff-back Dispense valves, 243694, 244951, 244909 Inlet: 1/2 NPTF Distribution header, 243701 Inlet: 1/2 NPTF Precision Gear Meter PGM Inlet: 1-5/16-12 o-ring face seal Precision Gear Meter PGM Outlet: 3/4 NPTF PCF Metering System Inlet & Outlet: 3/4 NTPF

-6 (9/16 in -18 JIC)

16V432

100896

16V432

100380

16V432

100896

16V432

100896

117677

16V432

None

16V432

100896

16V432

100896

-8 (3/4 in -16 JIC)

-10 (7/8 in -14 JIC)

-12 (1-1/16 in -12 JIC)

-16 (1-5/16 in -12 JIC)

124286 15Y934 C20708 125661

6308-82

123135 120266

123135 123854

121311 116765 116766

124286 15Y934 C20708 125661

120264 None 120265 None

124287 C20768 94/1027/99 125662

None None 124238 124239

124286 15Y934 C20708 125661

116766 120267

-20 (1-5/8 in -12 JIC)

125661 120268

15D936

116766 120267 120268

125661 120268

None

125662 120268

124240

125661 120268

334130T 95

Page 96

Accessories and Kits

ti25236b

6J5

8 Channel Upgrade Kit, 24V755

Use this kit to upgrade a 4 Channel system to an 8 channel system.

Ref Part Description Qty

1 --- MODULE, GCA, MZLP 1 2 125856 SCREW, 8–32, serrated flange 4 3 16T440 CAP, souriau, UTS14 2 4 127511 CABLE, board, samtec 1

Ref Part Description Qty

5 16W035 CONNECTOR, jumper 1 6 17A544 HARNESS, power, MZLP2, AWB 1 7 112190 STRAP, wrist, grounding 1 8 17C712 TOKEN, software upgrade 1

96 334130T

Page 97

8 Zone Upgrade Kit Installation

1. Disconnect the plug from the power outlet or turn off the circuit breaker for incoming power.

2. Place the grounding wrist strap (7) over your wrist and secure the other end to a grounded surface.

3. Set the kit’s MZLP (1) rotary switch to “2” on a pri-

mary system or “6” on a secondary system.

4. Remove the screws (B), the plate (A), and the gas-

ket (C) from the system. Use the screws (2) to install the MZLP (1) onto the system as shown.

NOTE: The new MZLP (1) will be refereed to as MZLP2, and the original MZLP that came with the system will be referred to as MZLP 1.

Accessories and Kits

5. Open the Electrical Enclosure door.

NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop, and verify the connector orientation.

6. Connect the cable (4) to the J3 connector on MZLP 1 and the J6 connector on MZLP 2.

7. Connect the power harness (6) to the MZLP 2 J2 connector and the J5 connector on the AWB. Install the jumper (5) on the MZLP 2 J5 connector.

8. Use fittings and hoses that meet your hose routing needs. See Accessories and Kits, page 92.

9. To ensure your system has the latest software,

insert the token (8) into the ADM. See Update Soft-

ware, page 61.

334130T 97

Page 98

Accessories and Kits

ti25237b

12 Channel Upgrade Kit, 24V756

Use this kit to upgrade an 8 channel system to a 12 channel system.

Ref Part Description Qty

1 --- MODULE, GCA, MZLP 1 2 125856 SCREW, 8–32, serrated flange 4 3 16T440 CAP, souriau, UTS14 2 4 127511 CABLE, board, samtec 1 5 16W035 CONNECTOR, jumper 1

Ref Part Description Qty

6 17A545 HARNESS, power, MZLP2/3,

AWB 7 112190 STRAP, wrist, grounding 1 8 17C712 TOKEN, software upgrade 1

98 334130T

Page 99

12 Zone Upgrade Kit Installation

1. Disconnect the plug from the power outlet or turn off the circuit breaker for incoming power.

2. Place the grounding wrist strap (7) over your wrist and secure the other end to a grounded surface.

3. Set the kit’s MZLP (1) rotary switch to “3” on a pri-

mary system or “7” on a secondary system.

4. Remove the screws (B), plate (A), and the gasket (C) from the system. Use the screws (2) to install the MZLP (1) on to the system as shown.

NOTE: The new MZLP (1) will be referred to as MZLP 3, and the other two that came with the system will be referred to as MZLP 1 and MZLP 2.

Accessories and Kits

5. Open the Electrical Enclosure door.

NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop, and verify the connector orientation.

6. Connect the cable (4) to the J3 connector on MZLP 2 and the J6 connector on MZLP (1). Remove the existing power cable from MZLP 2 J2 and AWB J5 connector.

7. Connect the power harness (6) to MZLP 2 and the MZLP 3 J2 connector and the J5 connector on the AWB.

8. See Install Heated Hose, page 18, to connect a heated hose or fluid control device.

9. To ensure your system has the latest software,

insert the token (8) into the ADM. See Update Soft-

ware, page 61.

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Page 100

Appendix A - ADM

General Operation

ADM Power

The ADM automatically turns on when the Main Power Switch is turned on.

Screen Navigation

To switch between the Setup and Operation screens,

press . Use the keypad to navigate between screens.

Enable, Disable Heating System

To enable or disable the entire heating system, press

. To set which channels are active when the heat-

ing system is enabled, use the Heat-A and Heat-B Setup screens.

100 334130T