Graco Therm-O-Flow 200 Bulk Hot User Manual

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

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

2 334130T

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

334130T 3

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.

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

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

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

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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,

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Instruc-

Dis-

8 334130T

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

334130T 9

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.

10 334130T

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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.

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

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

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

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

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