Graco 334129S, Therm-O-FLow 20 Instructions

Instructions-Parts
Therm-O-Flow® 20
334129S
EN
For applying hot melt sealant and adhesive materials from 20 Liter (5 Gallon) pails. 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 110, for maximum
working pressures.
3143485
Certified to
CSA STD C22.2 No. 88
Conforms to
UL STD 499
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Purge System. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Heat Up System. . . . . . . . . . . . . . . . . . . . . . . . . 30
Prime Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Prime System. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Setback Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 34
Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Change Pail . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Light Tower (Optional) . . . . . . . . . . . . . . . . . . . . 39
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ram Troubleshooting . . . . . . . . . . . . . . . . . . . . . 46
Heated Pump Troubleshooting . . . . . . . . . . . . . 47
Air Motor Troubleshooting . . . . . . . . . . . . . . . . . 47
2
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Replace Wipers . . . . . . . . . . . . . . . . . . . . . . . . . 48
Replace Platen RTD . . . . . . . . . . . . . . . . . . . . . . 49
Separate the Air Motor and Pump . . . . . . . . . . . 50
Remove Platen . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Replace Heater Band and Pump RTD . . . . . . . . 52
Replace MZLP Fuse . . . . . . . . . . . . . . . . . . . . . . 53
Replace MZLP . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Replace MZLP Daughter Card . . . . . . . . . . . . . . 55
Replace AWB . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Replace Power Supply . . . . . . . . . . . . . . . . . . . . 56
Replace Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Replace Transformer . . . . . . . . . . . . . . . . . . . . . 58
Update Software . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical Schematics. . . . . . . . . . . . . . . . . . . . . . . 61
230V, 3 Phase/60Hz . . . . . . . . . . . . . . . . . . . . . . 61
400V, 3 Phase/50Hz . . . . . . . . . . . . . . . . . . . . . . 62
400-600VV, 3 Phase/60Hz . . . . . . . . . . . . . . . . . 63
AWB and MZLP#1 . . . . . . . . . . . . . . . . . . . . . . . 64
MZLP#2, MZLP#3, Overtemp, and Pump Heaters
65
MZLP Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Therm-O-Flow 20 Supply Unit . . . . . . . . . . . . . . 67
Therm-O-Flow 20 Supply Unit . . . . . . . . . . . . . . 68
Air Control Assembly . . . . . . . . . . . . . . . . . . . . . 69
Electrical Module . . . . . . . . . . . . . . . . . . . . . . . . 70
Electrical Control Module Parts . . . . . . . . . . . . . 72
Electrical Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 74
230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical Panel Parts . . . . . . . . . . . . . . . . . . . . . 76
Merkur 2200, 23:1 Pump Modules. . . . . . . . . . . 77
Merkur 2200, 23:1 Pump Modules. . . . . . . . . . . 78
Merkur 3400, 36:1 Pump Modules. . . . . . . . . . . 79
Merkur 3400, 36:1 Pump Modules. . . . . . . . . . . 80
NXT 6500, 70:1 Pump Modules . . . . . . . . . . . . . 81
NXT 6500, 70:1 Pump Modules . . . . . . . . . . . . . 82
Pump Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
President, 15:1 Pump Module . . . . . . . . . . . . . . 84
Heated Platens . . . . . . . . . . . . . . . . . . . . . . . . . . 86
24V742, Heated Drum Platen, Standard Finned
Bottom (Code E-option F) . . . . . . . . . . . . . . 86
334129S
Related Manuals
24V743, Heated Drum Platen, Smooth Bottom
(Code E-option S) . . . . . . . . . . . . . . . . . . . . 86
Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . 88
Wiper Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Applicators and Dispense Valves. . . . . . . . . . . . 88
CGM Installation Kit, 25C994. . . . . . . . . . . . . . . 88
Flow Control and Manifolds . . . . . . . . . . . . . . . . 88
Accessory Extension Cables . . . . . . . . . . . . . . . 88
Light Tower Kit, 24W589 . . . . . . . . . . . . . . . . . . 89
Heated Hoses and Fittings. . . . . . . . . . . . . . . . . 90
8 Channel Upgrade Kit, 24V755. . . . . . . . . . . . . 92
8 Zone Upgrade Kit Installation . . . . . . . . . . . . . 93
12 Channel Upgrade Kit, 24V756. . . . . . . . . . . . 94
12 Zone Upgrade Kit Installation . . . . . . . . . . . . 95
Appendix A - ADM . . . . . . . . . . . . . . . . . . . . . . . . . 96
General Operation . . . . . . . . . . . . . . . . . . . . . . . 96
ADM Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . 96
Enable, Disable Heating System . . . . . . . . . . . . 96
Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Operation Screens . . . . . . . . . . . . . . . . . . . . . . . 98
Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . 100
Appendix B - USB Data . . . . . . . . . . . . . . . . . . . . 105
Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Access Files . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Upload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
System Settings File. . . . . . . . . . . . . . . . . . . . . 106
System Language File . . . . . . . . . . . . . . . . . . . 107
Create Custom Language Strings . . . . . . . . . . 107
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Ram Mounting and Clearance . . . . . . . . . . . . . 108
15:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Technical Specifications . . . . . . . . . . . . . . . . . . . 110
Graco Standard Warranty . . . . . . . . . . . . . . . . . . 112
334129S
Related Manuals
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334130
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Heated Hose, Instructions-Parts
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Air-Operated Dispense Valves, Instructions-Parts
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334201
3
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.
When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this
manual where applicable.
BURN HAZARD
WARNING
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
•
Do not touch hot fluid or equipment.
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen,
splatter may occur.
•
Use minimum air pressure when removing platen from drum.
MOVING PARTS HAZARD
Moving parts can pinch, cut or 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
regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
•
•
4
Read MSDSs to know the specific hazards of the fluids you are using.
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
334129S
Warnings
WARNING
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to
the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
•
•
Open a valve to relieve the fluid expansion during heating.
Replace hoses proactively at regular intervals based on your operating conditions.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
•
•
•
•
•
•
•
Engage trigger lock when not dispensing.
Do not point dispensing device at anyone or at any part of the body.
Do not put your hand over the fluid outlet.
Do not stop or 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 prevent
fire and explosion:
•
•
•
•
•
•
•
•
•
334129S
Use equipment only in well ventilated area.
Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
Keep work area free of debris, including solvent, rags and gasoline.
Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
Ground all equipment in the work area. See Grounding instructions.
Use only grounded hoses.
Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are antistatic or conductive.
Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until
you identify and correct the problem.
Keep a working fire extinguisher in the work area.
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 system
component. 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 information
about your material, request MSDS from distributor or retailer.
Do not leave the work area while equipment is energized or under pressure.
Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
Make sure all equipment is rated and approved for the environment in which you are using it.
Use equipment only for its intended purpose. Call your distributor for information.
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not kink or over bend hoses or use hoses to pull equipment.
Keep children and animals away from work area.
Comply with all applicable safety regulations.
•
•
Protective eyewear, and hearing protection.
Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
•
•
•
•
•
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is
not limited to:
6
334129S
Models
Models
The model number stamped on your system defines the equipment in the following categories.
See Technical Specifications, page 110, for maximum working pressure.
SER
A
Series
Frame Size
Code A
20P
Code B
A
E
Code C
11P
11S
12P
12S
13P
13S
14P
14S
15P
15S
21P
21S
22P
22S
23P
23S
24P
24S
25P
25S
31P
31S
32P
32S
33P
33S
34P
34S
35P
35S
NNN
334129S
Frame Size
5 Gallon (20 Liter)
Air/Electric
Air control only
Air and Electric
Zones, Volts, Type
4 Zones, 230 V, Primary
4 Zones, 230 V, Secondary
4 Zones, 400 V/N, Primary
4 Zones, 400 V/N, Secondary
4 Zones, 400 V, Primary
4 Zones, 400 V, Secondary
4 Zones, 480 V, Primary
4 Zones, 480 V, Secondary
4 Zones, 600 V, Primary
4 Zones, 600 V, Secondary
8 Zones, 230 V, Primary
8 Zones, 230 V, Secondary
8 Zones, 400 V/N, Primary
8 Zones, 400 V/N, Secondary
8 Zones, 400 V, Primary
8 Zones, 400 V, Secondary
8 Zones, 480 V, Primary
8 Zones, 480 V, Secondary
8 Zones, 600 V, Primary
8 Zones, 600 V, Secondary
12 Zones, 230 V, Primary
12 Zones, 230 V, Secondary
12 Zones, 400 V/N, Primary
12 Zones, 400 V/N, Secondary
12 Zones, 400 V, Primary
12 Zones, 400 V, Secondary
12 Zones, 480 V, Primary
12 Zones, 480 V, Secondary
12 Zones, 600 V, Primary
12 Zones, 600 V, Secondary
None
B
Air
Air/Electric
C
Zone
Config
Code D
1
2
3
4
5
6
7
Code E
S
F
D
Pump
Ratio
E
Platen
Style
Pump Ratio
23:1 CF (Carbon-Filled)
36:1 CF
70:1 CF
23:1 GF (Glass-Filled)
36:1 GF
70:1 GF
15:1 PTFE
Platen Style
Smooth Bottom (No Fin)
Standard Finned Bottom
7
Component Identification
Component Identification
C
D
M
P
J
N
B
L
A
F
K
H
T
E
G
S
R
ti24594a
FIG. 1: TOF 20
Key:
A
B
C
D
E
F
G
H
J
8
Lift Strap Positions
Multi-Zone Low Power Temperature Control Module
(MZLP)
Light Tower
Cable Track
Ram
Heated Pump
Heated Platen
Integrated Air Controls (3/4 in npt inlet)
Electrical Control Panel
K
L
M
N
P
R
S
T
Main Power Switch (can be locked in the open position)
ADM
Air Motor Solenoid
Electrical Power Input
Air Motor
Ram Plate Bleed Stick
Drum Blow Off Valve (behind ram plate bleed stick)
Drum Low and Empty Sensors
334129S
Component Identification
Integrated Air Controls
CN
CM
CL
CK
CF
CG
CE
CA
CJ
CH
CD
CC
CB
FIG. 2: Integrated Air Controls
Key:
CA Main Air Slider Valve
Turns air on and off to the entire system. When closed,
the valve relieves pressure downstream. Can be locked in
the closed position.
CB Ram Down Air Regulator
Controls the ram down pressure.
CC Ram Director Valve
Controls the ram direction.
CD Ram Up Air Regulator
Controls the ram up pressure.
CE Ram Down Air Gauge
Displays the ram down pressure.
CF Ram Up Air Gauge
Displays the ram up pressure.
CG Blowoff Button
Turns air on and off to push the platen out of an empty
drum.
334129S
CH Blowoff Pressure Gauge
Displays the blowoff pressure.
CJ Blowoff Air Regulator
Controls platen blowoff pressure.
CK Air Motor Air Regulator
Controls the air pressure to the motor.
CL Air Motor Pressure Gauge
Displays the air pressure to the motor.
CM 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.
CN 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.
9
Component Identification
Electrical Control Enclosure
DA
DB
DG
DH
DJ
DL
DK
DF
DN
DE
DD
DM
DC
Back Panel With Transformer
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
10
DG
DH
DJ
DK
DL
DM
DN
Platen SSR (65A)
Platen Contractor
Platen Fuse
Transformer Circuit Breaker
Transformer Fuse
Transformer
System Contactor
334129S
Component Identification
Advanced Display Module (ADM)
The ADM display shows graphical and text information
related to setup and spray operations. For details on the
display and individual screens, see Appendix A - ADM,
page 96.
NOTICE
To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.
Use the USB port on the ADM to download or upload
data. For more information about the USB data, see
Appendix B - USB Data, page 105.
BB
BC
System Shutdown
BA
Enable/Disable
BD
BE
BF
BH
BG
FIG. 4: Front View
Key
BA
BB
BC
BD
BE
BF
BG
BH
Function
Heating system and Pump Enable/Disable
System status indicator (LED)
Stop all system processes
Defined by icon next to softkey
Abort current operation
Accept change, acknowledge error, select
item, toggle selected item
Toggle between Operation and Setup
screens
Navigate within a screen or to a new screen
334129S
11
Component Identification
BK
BL
BR
BP
BN
BM
FIG. 5: Back View
BK
BL
BM
BN
BP
BR
Part Number and Identification Label
USB Interface
CAN Cable Connection (Power Supply and
Communication)
Module Status LEDs
Light Tower (Optional)
Software Token Access Panel
Table 1 ADM LED Status Descriptions
LED
System Status
Conditions
Green Solid
Green Flashing
Yellow Solid
Description
Run Mode, System On
Setup Mode, System On
Run Mode, System Off
USB Status (BL)
Green Flashing
Yellow Solid
Green and Yellow Flashing
ADM Status (BN)
Green Solid
Yellow Solid
Red Steady Flashing
Data recording in progress
Downloading information to USB
ADM is busy, USB cannot transfer
information when in this mode
Power applied to module
Active Communication
Software upload from token in
progress
Module error exists
Red Random Flashing or Solid
12
334129S
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
System Off
Inactive
Warm Up
Heat Soak
Ready
Active
334129S
Description
The system does not have power.
Component Status
• No system status indicator LED on the
ADM
• No heat
• Pump is off
The heating system and pumps are
• Yellow system indicator LED on the ADM
disabled.
• No heat
• Pump is off
The system is heating the material to the • Flashing green system status indicator
setpoint temperature.
LED on the ADM
• Heat is increasing to setpoint
temperature
• Pump is off
Heat zones are all at temperature. Material • Flashing green system status indicator
is soaking for a user specified amount of
LED on the ADM
time.
• Heat is at setpoint
• Material is absorbing more heat
• Pump is off
• Heat soak counter counts down on the
Home screen.
All enabled zones are at setpoint
• Flashing green system status indicator
temperature. The Air Motor does not have
LED on the ADM
power.
• Heat is at setpoint
• Pump is off
The system is ready to dispense.
• Solid green system status indicator LED
on the ADM
• Heat is at setpoint temperature
• Pump is on
13
Overview
Overview
A Heated Platen melts the sealant or adhesive and
directs the molten material to the Pump inlet. The
material then travels through a Heated Pump and
heated fluid moves to the application tool.
Air and Fluid Hoses
The Therm-O-Flow requires Graco single-circuit
material hoses rated at a maximum of 1250 watts.
Make sure all air and fluid hoses are properly sized for
the system.
Heat Control Zone
The Therm-O-Flow has 4, 8, or 12 heat zones. Zones
for the Heated Platen and the Heated Pump are not
included in the zone count. Zones 1 and 2, 3 and 4, 5
and 6, 7 and 8, 9 and 10, and 11 and 12 are each
available through 12-pin connectors. The heated hoses
have a 16-pin connector at the inlet, and an 8-pin
connector at the outlet. All heated valves, manifolds,
and heaters are equipped with an 8-pin mating
connector.
FIG. 6: Heat Control Zone Selection
14
334129S
Setup
Setup
1. Unpack the Ram
2. Locate and Install the Ram
3. Mechanical Setup
4. Connect hoses to Electrical Control Panel
5. Connect Electrical Control Panel to power source
6. Ground system
7. Select ADM settings
Unpack
1. Inspect the shipping box carefully for damage.
Contact the carrier promptly if there is damage.
2. Open the box and inspect the contents carefully.
There should not be any loose or damaged parts in
the box.
3. Compare the packing slip against all items in the
box. Repost any shortages or other inspection
problems immediately.
4. Remove the unit from the skid and place it in the
desired location. See Location Requirements.
4. Make sure there is easy access to an appropriate
electrical power source. The National Electrical
Code requires 3 ft (0.9 m) of open space in front of
the electrical panel. Comply with all local codes and
regulations.
5. When locating the system, do not install closer than
36 in. (914 mm) to vertical surfaces.
Install System
Refer to Dimensions, page 108 for mounting and
clearance dimensions.
Follow all Location Requirements, page 15, when
selecting a location for the Ram.
1. Apply 50 psi download pressure to Ram.
2. Wrap the bar with the lifting sling.
3. Lift the system off the pallet using a crane or a
forklift and place in desired location.
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.
Location Requirements
1. Make sure there is sufficient overhead clearance for
the Pump and Ram when the Ram is in the fully
raised position (approximately 75 in. (190.5 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 Integrated Air Controls for the Pump
and Ram are fully accessible, with room to stand
directly in front of the controls and the ADM.
334129S
15
Setup
Mechanical Setup
1. Fill displacement Pump wet cup 2/3 full with Graco
Throat Seal Liquid (TSL™) for Butyl and PSA
materials.
NOTE: Use IsoGuard Select® (IGS) (part no. 24F516)
for PUR or reactive Polyurethane material. IGS is
designed to dissolve and suspend the Polyurethane
materials. IGS will solidify after a period of time and
should be replaced once the solidified lube does not
return to liquid form after heating.
4. Ensure Drum Low and Empty Sensors (C) are
mounted as shown.
NOTE: The Drum Low and Empty Sensors are used to
indicate that a drum is empty. The kit contains a sensor
mounting bracket (A), activator (B), sensors (C1, C2),
and a cable for connecting the panel inside the
electrical enclosure.
B
CI
C2
FIG. 7: Wetcup
2. Turn all air regulators to their full counterclockwise
position. See Integrated Air Controls, page 9.
3. Connect a 1/2 in. (13 mm) air line from an air source
to the system air inlet (H), capable of delivering a
minimum of 25-50 cfm at 100 psi (0.7 MPa, 7.0
bar). Do not use quick disconnects.
A
FIG. 9
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.
H
FIG. 8: Air Connection
16
334129S
Install Heated Hose
4. Repeat for any remaining channels.
To connect a hose to a fluid control device or heated
manifold.
5. Install cap on any unused MZLP electrical
connectors.
1. Install fitting and heated hose onto Pump outlet
with the large electrical connector side toward the
system. Use 2 wrenches to tighten hose. Torque to
45 ft-lbs (61 N•m).
6. Connect the small 8 pin connector from the heated
Setup
hose to the fluid control device or heated manifold.
NOTE: See Accessories and Kits, page 88, for
available fittings and heated hoses.
FIG. 12: Heated Manifold 243697
FIG. 10
2. Wrap exposed fittings on the Pump outlet with
Nomex insulation and secure insulation using
fiberglass tape.
3. Connect large heated hose connector to MZLP.
NOTE: The heated manifold (part no. 243697) shown.
See Accessories and Kits, page 88, for available
manifolds and fluid control devices.
7. Use 2 wrenches to tighten hose. Torque to 45 ft-lbs
(61 N•m).
8. To connect multiple devices, see Connect Multiple
Devices, page 18.
FIG. 11
334129S
17
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
88.
•
Connect fluid control devices to a heated hose or
the electrical enclosure. Use accessories if
necessary.
•
Setup all heat zones on Heat-A and Heat-B
screens.
Example: Heated zones used to connect a primary 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. 13
NOTE: Pump settings will not be shown on Mini-5
systems with software version 1.01.042 or later.
18
334129S
Setup
Connect Power
The Electrical Control Panel comes already attached
and wired to the Ram, however before the supply unit
becomes functional you must connect the Electrical
Control Panel to a power source.
All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
FIG. 14
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
protection 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
Electric
al Panel
Voltage
230 V
400 V/N
400 V
480 V
600 V
Hz
50/60
50/60
50/60
50/60
50/60
Phase
3
3
3
3
3
Platen
EF, ES
EF, ES
EF, ES
EF, ES
EF, ES
Full
Load
Amps
50
30
30
30
25
AWG
8 AWG
8 AWG
8 AWG
8 AWG
8 AWG
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
0.25 ohms. If the resistance is greater than 0.25
ohms, a different ground site may be required. Do
not operate the system until the problem is
corrected.
NOTE: Use a meter that is capable of measuring
resistance at this level.
EF Standard Finned Bottom
EM Mega-Flo
ES Smooth Bottom
1. Locate the opening in the Control Panel’s top
housing for the conduit that will enclose the wire
from the facility’s power source. The hole will
accept a cord diameter range of 0.7–1.2 in (17–30
mm).
2. Route the wire from the power source into the
Control Panel housing, and then connect the power
source wires to the appropriate terminals on the
DISCONNECT switch.
334129S
19
Setup
Grounding
Ground the unit as instructed here and in the
component manuals.
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides and escape path for the electric
current.
System: ground through ground lug in electrical
enclosure. See Connect Power, page 19.
Air and Fluid Hoses: use only electrically conductive
hoses.
Air compressor: follow manufacturer’s
recommendations.
Spray gun / Dispense valve: ground through
connection 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
system.
2. To enable a secondary system, select “Enable
Tandem System” on the System 1 screen. See
Select ADM Settings, page 23.
SS
AC
SC
FIG. 15
20
334129S
Setup
Check Sensor Resistance
Table 3 RTD Sensors
MZLP
To reduce risk of injury or damage to equipment,
conduct these electrical checks with the Main Power
Switch OFF.
The package includes up to twelve heat sensors and
controllers for each of the heated zones. To check
sensor resistance:
MZLP Plug Component
1, 2
1
3, 4
1. Turn Main Power Switch OFF.
5, 6
2
7, 8
2. Wait for components to cool down to ambient room
temperature 63°-77°F (17°-25°C). Check electrical
resistance for the components.
MZLP
First Heat Zone
Second Heat Zone
First RTD
Second RTD
Earth Ground
Pins
A, J
C, D
G, K
M, K
B
9, 10
TOF Hose
3
11, 12
Ram Plate
Fluid Pump
Heated
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
10
Heated
Accessory
11
Heated
Accessory
12
RTD Range
(Ohms)
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
3. Replace any parts whose resistance readings do
not comply with the ranges listed in the RTD
Sensors chart below.
334129S
21
Setup
Check Heater Resistance
2. Make electrical resistance checks for the
components.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in tables.
To reduce risk of injury or damage to equipment,
conduct these electrical checks with the Main Power
Switch OFF.
NOTE: Check resistance at ambient room temperature
63°-77°F (17°-25°C).
1. Turn Main Power Switch OFF.
Table 4 Heaters
Component
Platen
Resistance Across
Terminals
SSR-1 -5 to SSR-1-6,
107 to 108
SSR-1-5 to SSR-1-6,
107 to 108
SSR-1-5/107 to
Terminal 5/6, Terminal
5/6 to SSR-1-6/108
22
220 - 240V
380 - 600V
All voltage
versions
2610 to 2620, T1/B1 to All voltage
T3/B3
versions
Any Terminal to Case
Pump
Unit Input
Voltage
Platen or Pump
Module
All configurations
All configurations
Resistance Values
12.1 to 16.6 Ohms
48.6 to 62.6 Ohms
24.3 to 31.3 Ohms
All
Greater than 70,000 Ohms
All
43.2 to 53 Ohms
334129S
Setup
Select ADM Settings
4. Set alarm levels on the System 2 screen.
NOTE: See Appendix A - ADM, page 96 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.
NOTE: Pump inactive timeout will not be shown on
Mini-5 systems with software version 1.04.042 or later.
5. Set primary system setpoint and setback
temperatures 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: Pump setpoint and setback temperature will not
be shown on Mini-5 systems with software version
1.04.042 or later.
NOTE: To ensure accurate hose temperatures, be sure
all heated hoses have their “zone type” set to “Hose.”
Hoses are only present on odd zone numbers: 1, 3, 5,
7, 9, or 11.
a. Select the appropriate “Zone Type” for all
installed zones.
b. Check the “A” and “B” boxes according to
which systems needs to use the heated
accessory.
334129S
23
Setup
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.
9. To setup the optional Schedule function, see
Schedule, page 36. 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 96 for
detailed information about each setup item.
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.
24
334129S
Setup
Connect PLC (Hard Wired
Interface Version)
Table 7 Output Error States
Error State
Bit High
0
Error State Bit
Low
0
A PLC can control and monitor all items shown in the
Customer Digital Inputs and Outputs shown on the
Diagnostics screen. See Appendix A - ADM, page 96.
0
1
1
0
When the PLC has control of the system:
1
1
•
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
1
Heat On Request
2
Setback Request
3
4
Pump On Request
PLC Control
Request (input
applies to primary
unit A only)
Description
Turn on the Heat
Put the Unit in
Setback
Turn on the Pump
Control the primary
and secondary TOF
systems from the
PLC instead of the
ADM
Table 6 Customer Output
Signal No.
Unit A or B
1
Run State Bit Low
2
3
4
334129S
Description
See Run State
Chart
Run State Bit High See Run State
Chart
Error State Bit Low See Error State
Chart
Error State Bit High See Error State
Chart
Machine is good,
no errors are
present
Active Unit Drum
Low
Active Unit Drum
Empty
Alarm Present in
System
Table 8 Output Run States
Run State
Bit High
0
0
1
1
Run State Bit Low
0
1
0
1
Pump Off/ Heat Off
Pump Off/ Heat On
Pump Off/ Heat At
Temp
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.
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.
25
Setup
NOTE: Each connector has four signals. The MZLP
board specifies the input range for each signal. See the
following table for pin assignments.
FIG. 16
Signal
1
2
3
4
H1 Customer Input
H2 Customer Output
Signal
1
2
3
4
Pin
1,2
3,4
5,6
7,8
Pin
1,2
3,4
5,6
7,8
Inputs: High: 10–30 VDC, Low: 0–5 VDC. Inputs
function without concern for polarity. Applying “high”
voltage will turn the heaters on and enable setback.
Removing voltage will turn the heaters off and disable
setback.
Outputs: 0–250 VAC, 0–30 VDC, 2A Maximum.
26
334129S
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. 17: Customer Input
FIG. 18: Customer Output
334129S
27
Operation
Operation
1. Turn the Main Power Switch ON. The Graco logo
will display until communication and initialization is
complete.
NOTICE
Use fluids that are chemically compatible with the
equipment wetted parts. See Technical
Specifications 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 29.
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
temperature.
Purge System
NOTICE
Purge the system before initial use and when
chemicals are changed to prevent material
contamination, which may cause the material to fail
or perform poorly. The system was factory- tested
using a light soluble oil, a soybean oil, or some other
oil as tagged. Flush the system to avoid
contaminating the material that has been designated
for initial material loading.
28
3. Select a pail of material that can eliminate the
factory-test oil from the system. If necessary, check
with Graco or the material supplier for a
recommended solvent.
4. Before purging, be sure the entire system and
waste pail are properly grounded. See Grounding,
page 20.
5. Turn all heat zones’ setpoint temperature to the
material manufacturer’s recommended dispense
temperature, or a minimum of 100°F (37°C)
minimum.
NOTE: Remove any dispense valve orifices before
purging. Reinstall after purging has been completed.
6. Purge the material through the system for
approximately 1 to 2 minutes.
7. Remove the pail if purge material was used. See
Change Pail, page 37.
334129S
Operation
Load Material
4. Fill displacement Pump wet cup 2/3 full with Graco
Throat Seal Liquid (TSL™) for Butyl and PSA
materials.
NOTICE
To prevent damage to Platen wipers, do not use a pail
of material that has been dented or damaged. An
empty pail clamp can interfere with up and down
operation of the Ram. When raising the Ram, make
sure the pail clamp stays clear of the Platen.
NOTE: Before loading material, make sure there is a
minimum overhead clearance of 75 in. (191 cm) and all
air regulators are backed off to their full
counterclockwise position.
NOTE: Use IsoGuard Select® (IGS) (part no. 24F516)
for PUR or reactive Polyurethane material. IGS is
designed to dissolve and suspend the Polyurethane
materials. IGS will solidify after a period of time and
should be replaced once the solidified lube does not
return to liquid form after heating.
1. Open the Main Air Slider Valve (CA).
CA
FIG. 20: Wetcup
5. Open pail, remove any packing material, and
inspect material for any contamination.
2. Set Ram Director Valve (CC) to UP and slowly turn
the Ram Up Regulator (CD) clockwise until the
Platen (G) begins to rise.
6. Slide the pail against the stops at the back of the
Ram baseplate.
CD
CC
FIG. 19: Raise the Platen
FIG. 21: Drum Placement
3. Apply a thin coating of high temperature grease
lubricant (part no. 115982) to the Platen pail seals.
334129S
29
Operation
Heat Up System
7. Remove the Ram Plate Bleed Stick (R).
R
To reduce the risk of bursting a hose, never
pressurize 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
temperature 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.
FIG. 22: Platen Bleed Handle
8. Set Ram Director Valve (CC) to down and lower the
Platen.
CC
CB
FIG. 23: Lower the Platen
9. Slowly turn the Ram Down Air Regulator (CB)
clockwise to approximately 5–10 psi (34–69 kpa,
0.3–0.7 bar). The Platen will begin to lower into the
pail.
1. Turn the Main Power Switch on the Electrical
Control 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
11, for operation mode descriptions.
NOTE: The air will be locked from the Air Motor until all
temperature zones are within a preset window of the
temperature setpoints, allowing the system to heat fully
and complete the material heat soak period.
10. After the Platen seals enter the material pail, 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.
30
334129S
Operation
Prime Pump
3. Adjust the Air Motor Slider Valve (CM) to the open
position.
CM
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.
4. Adjust the Air Motor Air Regulator (CK) to
approximately 20 psi (138 kPa, 1.38 bar).
CK
CK
CN
5. Place a waste container under the bleed stem (Z).
Using an adjustable wrench, open the bleed stem
counterclockwise 1/3 -1/2 turn.
Z
334129S
31
Operation
6. If a new pail was installed and the unit is equipped
with proximity sensors, press the Pump Ready
button
. Press the pause button
material tracking.
on
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 Main Air Slider Valve (CA).
For Tandem Operation
Complete steps 1-5 on page 31 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).
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).
CA
9. Press the Pump Ready button
unit.
for the inactive
9. Press the Play button
on the home screen to
enable material tracking and press the Pump ready
button.
32
334129S
Operation
Prime System
7. Close the Main Air Slider Valve (CA) and release the
trigger lock.
8. Engage the trigger lock.
1. Close the Main Air Slider Valve (CA).
CA
2. If using a manual gun, lock the dispense valve
trigger open by pulling and securing the trigger
using the trigger retainer (Z).
FIG. 24: Trigger Lock Engaged
9. Press
to engage material tracking.
10. Turn the Air Motor Regulator to operating pressure.
NOTE: The system is now ready to operate.
Setback Mode
Z
3. Place the dispense valve over a waste container.
4. Press the pause material tracking button
home screen.
on
5. Slowly open the Main Air Slider Valve (CA).
6. Prime the system until a smooth flow of material
dispenses from each dispense valve.
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 Inactivity Timeout, located on System Setup
Screen 1. See Setup Screens, page 100.
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.
334129S
33
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure
Whenever you see this symbol.
3. Set the Ram Director Valve (CC) to the neutral
position.
CC
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 cleaning, checking, or servicing
equipment.
NOTE: If using a different dispense applicator, see the
applicator manual for pressure relief instructions.
4. Disengage the trigger lock.
1. Engage the trigger lock.
FIG. 26: Disengaged
5. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
FIG. 25: Engaged
2. Close the system Main Air Slider Valve (CA).
CA
34
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
pressure has not been fully relieved after following
the steps above, VERY SLOWLY loosen hose end
coupling to relieve pressure gradually, then loosen
completely. Clear hose or tip obstruction.
334129S
Operation
NOTE: If work needs to be performed on the Ram
portion, perform the following additional steps to relieve
any trapped air in the inactive portion of the Ram.
Stop Controls
9. Validate that the Heated Pump is fully supported
and is resting on the bottom plate.
To stop all electrical and most pneumatic processes,
Normal Stop Control
press the System Shutdown button
the ADM.
located on
System Shutdown
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
pressed.
has been
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.
334129S
35
Operation
Shutdown
CM
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
function 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.
NOTE: Do not perform step 2 if using the Schedule
function. Leave the power on.
2. Turn the Main Power Switch OFF.
Total System Shutdown
To stop all electrical and most pneumatic processes,
turn the Main Power Switch off.
Schedule
This will remove all electrical power to the system past
the Main Power Switch.
The Schedule function allows the user to specify times
when the system will automatically turn ON and OFF
the heaters and Pump.
Air pressure to the Air Motor will be relieved, which will
stop movement of the Heated Pump.
The Ram Director Valve will remain operable.
The Main Power Switch can be locked in the open
position.
36
334129S
Operation
Use the Schedule Function
Table 9 Schedule Screen Color Identification
Color
Green
Yellow
Red
Gray
Description
System on
Setback
System off
Disabled
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 Pail
Set Schedule Times
Times are set using a 24-hour clock. Several on and off
times can be set each day.
To prevent serious burns from dripping material,
never reach under the Heated Platen after the Platen
is out of the pail.
Follow the procedure to change the pail on a fully
heated system.
NOTICE
Be sure to reload the empty supply unit with a full
pail of material immediately. Do not raise the Ram
and remove the Platen from the empty pail until you
are ready to immediately install a new pail.
Do not raise the Ram and remove the Platen from
the empty pail unless the supply unit is at full
operating temperature. Drum changes can only be
performed when the system is heated.
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.
An empty pail clamp can interfere with the up and
down operation of the Ram. When raising or
lowering the Ram, make sure the pail clamp stays
clear of the Platen assembly.
3. Set the setback times for each day of the week.
Enable Schedule Function
Do not use a pail of material that has been dented
or otherwise damaged; damage to the Platen wipers
can result.
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
disabled. 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.
All systems include Low/Empty Sensors:
•
The air will shut off to prevent the Pump from
cavitation. 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
shutdown.
1. Press
334129S
to stop material tracking.
37
Operation
2. Push in the Air Motor Slider Valve (CM) to stop the
Pump.
CM
6. Inspect Platen and if necessary, remove any
remaining material or material build-up.
7. Follow steps in Load Material, page 29, and Prime
Pump, page 31.
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 pail. Use the minimum amount of air
pressure necessary to push the Platen out of the
pail.
CC
CG
Excessive air pressure in the material pail could
cause the pail to rupture, causing serious injury. The
Platen must be free to move out of the pail. Never
use pail blowoff air with a damaged pail.
4. Release the blowoff air button and allow the Ram to
rise to its full height.
5. Remove the empty pail.
38
334129S
Troubleshooting
Troubleshooting
Light Tower (Optional)
Signal
Red Light Off
Red Light On
Red Light Flashing
Green Light Off
Green Light On
Green Light Flashing
334129S
Description
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
User interaction required — alarm, system is shut down
User interaction required — advisory, deviation, or system is in a state that could prohibit
dispensing
System is inactive
System is ready to dispense. The heat and Pump are on.
System will be ready to dispense in time without user interaction (heat on, Pump off, and
temperature control zones have not reached set point)
39
Troubleshooting
Error Codes
The last digit of the error code indicates which system
component the error applies. The “#” (pound) character
indicates the code applies to multiple system
components.
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.
Last Digit “#”
1
2
3
5
6
7
G
H
V
W
X
Y
There are three types of errors that can occur. Errors
are indicated on the display as well as by the optional
Light Tower.
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
serious issues in the future.
To acknowledge the error, press
.
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 “★”
A
B
40
Code Relates To:
Unit A
Unit B
Code Relates To System
Component:
MZLP 1
MZLP 2
MZLP 3
MZLP 5
MZLP 6
MZLP 7
Gateway (CGM)
Gateway Heartbeat Loss
AWB Unit A
AWB Unit B
Daughter Board Unit A
Daughter Board Unit B
The last digit of the error code indicates which heat
zone the error applies. The “_” (underscore) character
indicates the code applies to multiple system
components.
Last Digit “_”
1
2
3
4
5
6
7
8
9
A
B
C
D
E
Code Relates To Heat
Zone:
Zone 1
Zone 2
Zone 3
Zone 4
Zone 5
Zone 6
Zone 7
Zone 8
Zone 9
Zone 10
Zone 11
Zone 12
Pump
Platen
334129S
Troubleshooting
Code
A3MF
Description
Type
AWB Clean Fan Filter Alarm
A4 _
High Current Unit _
Zone _
Alarm
A4C#
High Current Fan
AWB, Unit _
Deviation
A7 _
Unexp. Curr. Unit _
Zone _
Alarm
A8 _
No Current Unit _
Zone _
Alarm
A8C
AWB No Fan Current Alarm
AM3#
High Current SSR
MZLP _
Alarm
AM4#
High Current
Contactor MZLP _
Alarm
AM8#
No Current Contactor Alarm
MZLP _
CAC#
Comm Error MZLP _
CACX
334129S
DB Not Present Unit
A
Alarm
Alarm
Cause
Cooling inlet
screen is dirty
Defective or
shorted to
ground on
zone
Fan is drawing
too much
current
Solution
Clean inlet screen.
Verify accessory is rated for 240 VAC.
Verify heater resistance and check for shorts to
ground. Replace as necessary.
Verify there is not an air obstruction at the
inlet/outlet of enclosure. Verify nothing is
preventing fan rotation. Replace fan if
necessary.
Unexpected
Replace MZLP.
current flow to Faulty accessory heater. Measure resistance to
zone
ground between heater leads.
No Current
Check for loose or disconnected wires or
Flow to the
plugs.
Zone
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.
Cooling Fan
Verify fan is plugged in. Replace if necessary.
not Working
Excessive
Check for shorts in harness to SSR. Check
current flow in polarity of wiring to SSR. Replace if necessary.
the SSR
Defective or
shorted to
ground on
MZLP
No Current
Flow to the
Contactor
System not
responding to
ADM
Daughter
Board not
responding
Check for shorts in the harness to contactor.
Check the polarity to contactor. Replace
contactor if necessary.
Ensure harness to MZLP is connected. Ensure
wiring to contactor is secure. Replace
contactor if necessary.
System is not properly loaded with correct
Software.
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.
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.
41
Troubleshooting
Code
CCAG
Description
Comm. Error,
Gateway
Type
Alarm
CACH
Gateway Heartbeat
Loss
Alarm
CACY
DB Not Present Unit
B
Alarm
CACV
AWB not present Unit Alarm
A
CACW
AWB not present Unit Alarm
B
DA X
Pump Runaway
Detected
Alarm
DE X
Reed Switch Failure
Detected
Alarm
42
Cause
CGM Module
is no longer
responding
Solution
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).
Heartbeat
PLC went off line.
signal was
Field Bus connection to CGM was broken.
removed while Restore connection between Field Bus and
PLC was
CGM.
controlling the
TOF via the
CGM
Daughter
Dial not set correct on MZLP. Set to 4 on board
Board not
with daughter board.
responding
Ensure connections between the ADM and
hardware are secure.
Replace Daughter Board.
AWB not
Ensure connections between the ADM and
responding
hardware are secure.
If a tandem system, ensure AWB 2 jumper is
installed at startup.
Replace AWB.
AWB not
AWB 2 jumper was not in place at start up
responding
Ensure connections between the ADM and
hardware are secure.
Replace AWB.
Pump is trying Adjust the drum empty level sensor to detect
to feed
an empty state.
adhesive, no
Ensure the Ram Director Valve is in the down
adhesive to
position and sufficient air is forcing the Ram
feed.
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
Reed switch
Check that sensor cable is plugged into the
failed
daughter board at J16.
Check for loose connection at reed switch.
Ensure reed switch is securely attached to the
Air Motor. Replace if necessary.
334129S
Troubleshooting
Code
DC X
Description
Pump Diving
Type
Alarm
Cause
Pump is trying
to feed
adhesive, no
adhesive to
feed.
Worn or
damaged
Pump seals
Machine is
detecting an
empty state
without a low
state
L1 X
Material Level Sensor Alarm
Error
L2 X
Material Level Empty Alarm
L3 X
Material Level Low
Deviation
MMUX
USB Log Full
Advisory
MN X
Pump _ Requires
Maintenance
Advisory
Ta★
Over Temperature
Switch
Alarm
T1 _
Low Temp. Unit _
Zone _
Alarm
Zone
temperature
too low
T2 _
Low Temp. Unit _
Zone _
Deviation
Zone
temperature
too low
334129S
Material drum
is empty
Material level
is low
USB logs fulls.
Data loss will
occur if not
downloaded.
User defined
Pump
maintenance
counter has
run out
An over
temperature
switch has
opened.
Solution
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.
Inspect Pump seals and replace if necessary
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.
Replace material container. If more material is
leftover, lower the empty level sensor.
Replace at appropriate time.
Download USB data or disable the USB log
errors on the Advanced screen 3.
Perform Pump maintenance, then reset the
counter on the maintenance setup screen.
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).
Reduce flow rate.
Increase temperature of accessory upstream.
Faulty accessory heater measure resistance
between heater leads.
Change Low Temp Alarm Offset.
Replace accessory.
Reduce flow rate.
Change Low Temp Deviation Offset.
Add zone (temperature) upstream.
43
Troubleshooting
Code
T3 _
Description
High Temp. Unit _
Zone _
Type
Deviation
T4C#
AWB Temperature
Runaway
Transformer
Alarm
T4M#
AWB High
Transformer Temp
Alarm
T4 _
High Temp. Unit _
Zone _
Alarm
T6 _
Sensor Err. Unit _
Zone _
Alarm
T6C#
AWB Invalid
Thermistor Reading
Alarm
T8V_
No Temp. Rise Unit _ Alarm
Zone _
V1|#
Low CAN Voltage,
MZLP _
Alarm
V1M#
Low Voltage Line
AWB, Unit _
Deviation
V4|#
High CAN Voltage,
MZLP _
Alarm
V6M#
Wiring Error Line
MZLP _
Alarm
44
Cause
Temperature
reading has
risen too high
Solution
Change High Temp Deviation Offset.
Verify setpoint upstream is not hotter than this
zone’s setpoint.
Cooling fan
Ensure inlet and outlets are not obstructed.
not working or Verify fan is plugged in.
inlet is
blocked/dirty
Transformer
Ensure inlet and outlets are not obstructed.
Temperature is Verify fan is plugged in.
too High
Temperature
Change High Temp Alarm Offset.
reading has
Verify setpoint upstream is not hotter than this
risen too high zone’s setpoint.
Bad RTD
Check RTD wiring and harness/connector
Reading
integrity.
Replace RTD.
Verify thermister is securely connected to J7 of
Transformer
the AWB. Replace transformer if necessary.
thermistor
temperature is
incorrect
Temperature
Check fuses on MZLP connected to that Zone.
reading does Check wiring to device.
not change.
Check heater resistance on device.
Bad or
Verify Power Supply voltage is 24 VDC. If
overloaded
voltage is low, disconnect the power lines and
Power Supply re-check voltage reading. If voltage is still low,
replace Power Supply. If voltage is correct
after disconnecting the power lines.
The voltage to
the AWB is
below
threshold
Bad or
overloaded
Power Supply
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.
Incoming
Correct the Wiring.
power is wired
incorrectly
334129S
Troubleshooting
Code
V8M#
Description
No Line Voltage
MZLP _
Type
Alarm
V4M#
AWB High Line
Voltage
Alarm
WJ1
Pump _ Solenoid is
disconnected
Alarm
WJ2
Pump _ Solenoid
High Current
Alarm
WSUX
Configuration Error
USB
Advisory
334129S
Cause
Solution
Incoming line Verify Transformer has the correct tap
voltage is less selected.
than 100 VAC. 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.
Incoming
Check incoming voltage is correct for
voltage is too configuration.
high
Verify the transformer has the correct tap (400,
480, 600) selected.
Pump is not
Verify harness is plugged into J13 of the
turning on
daughter board. Verify it is secured to the
when it should solenoid.
Replace Solenoid.
Solenoid is
Inspect for short in harness. Inspect for a
drawing too
shorted solenoid cable/short to the ground.
much current Replace solenoid.
USB
Install software.
configuration
is not loaded
45
Troubleshooting
Ram Troubleshooting
Problem
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.
Cause
Closed main air valve or clogged air
line,
Not enough Ram air pressure.
Worn or damaged Ram piston.
Platen not fully up to temperature.
Ram air pressure too high.
Dented drum has stopped Platen.
Ram "up / down" air pressure too
high.
Worn rod seal.
Ram air pressure too high.
Worn or damaged wipers.
Closed main air valve or clogged air
line.
Not enough air pressure.
Worn or damaged Ram piston.
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.
Air pressure will not push Platen out Closed main air valve or clogged air
of drum.
line.
Platen not fully up to temperature.
Not enough blow-off air pressure.
Blow-off valve passage clogged.
Dented drum has stopped Platen.
Wipers bonded to drum or drum
liner.
46
Solution
Open air valve; clear air line.
Increase Ram air pressure.
Replace piston. See instruction
manual 310523.
Wait for full temperature.
Decrease Ram air pressure.
Fix or replace drum.
Decrease Ram air pressure.
Replace o-rings in guide sleeve. See
instruction manual 310523.
Decrease Ram air pressure.
Replace wipers.
Open air valve; clear air line.
Increase air pressure.
Replace piston. See instruction
manual 310523.
Open valve; clear valve or exhaust.
Clean; repair valve.
Position handle in the down position.
Fix or replace drum.
Open air valve; clear air line.
Wait for full temperature.
Increase blow-off air pressure.
Clean valve passage.
Fix or replace drum.
Lubricate wipers with high
temperature grease at every drum
change.
334129S
Troubleshooting
Heated Pump Troubleshooting
See Pump manual for additional Pump troubleshooting information. See Component Identification, page 8.
Problem
Cause
Rapid downstroke or upstroke (Pump Material not heated to proper
cavitation).
temperature.
Air is trapped in Pump.
Material leaks around Pump outlet.
Material leaks around bleed port.
Pump will not move up and down.
Leak around Pump wet-cup.
Downstroke: Dirty or worn Pump
intake valve.
Upstroke: Dirty or worn Pump piston
valve.
Machine is out of material
Loose outlet fitting.
Loose bleed port fitting.
Problem with Air Motor.
Foreign object lodged in Pump.
Platen not fully up to temperature.
Valve to Air Motor is off.
Worn throat seals.
Solution
Check and adjust temperature to
proper setpoint. Wait for
Pump/Platen to heat up.
Bleed air from Pump. See Prime
Pump, page 31.
Clean or repair. See Pump Manual.
Clean or repair.
Adjust empty level sensor.
Tighten outlet fitting.
Tighten bleed port fitting.
See Air Motor Manual.
Relieve pressure. See Pump Manual.
Wait for full temperature.
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 Component Identification, page 8.
Problem
Cause
Air motor will not run.
Air motor solenoid is off.
Air motor stalled.
Damaged main air valve spool or
poppets.
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.
Damaged Air Motor shaft seal.
334129S
Air valve/slide valve gasket is
damaged.
Internal seal damage.
Air motor operating at high pressure
or high cycle rate.
Solution
Wait for heat zones in use to reach
temperature setpoint values.
Inspect and clean poppets. See Air
Motor Manual.
Rebuild main air valve. See Air Motor
Manual.
Replace Air Motor shaft seal. See Air
Motor Manual.
Replace the valve gasket. See Air
Motor Manual.
Rebuild Air Motor. See Air Motor
Manual.
Reduce pressure, cycle rate, or duty
cycle of motor.
47
Repair
Repair
Replace Wipers
1. To replace a worn or damaged wiper raise the Ram
plate up out of the drum. Perform steps 1 through 7
of Change Pail, page 37.
2. Separate the wiper joint, and bend back the
strapping that covers the clamp (207).
3. Unscrew the worm gear and remove the wiper
(202).
201
4. Thread the strapping through the new wiper (202).
5. Insert the strap end through the clamp (207) and
tighten.
6. Use a rubber mallet to pound the wiper around the
Platen (201) until the wiper ends are butted tightly
together.
7. Apply a lubricant to the wiper (202). Use a lubricant
that is compatible with the material to be pumped.
Check with the material supplier.
202
207
FIG. 27:
48
334129S
Repair
Replace Platen RTD
4. Remove the front and right side Pump cover.
Reference Electrical Schematics, page 61, for wiring
connections.
625
616
1. If the material pail has already been removed from
the supply unit, go to step 2. If you need to remove
the material pail, see Change Pail, page 37.
2. Make sure the Ram plate is down and the Ram
Director Valve is in the OFF position.
326
FIG. 28:
CC
CB
To reduce the risk of injury or damage to equipment,
make sure the Main Power Switch is off before
continuing with this procedure.
3. Turn the Main Power Switch OFF.
334129S
5. Remove the Platen RTD (616) from the Platen.
6. Disconnect the Platen RTD quick connect terminal
(625) from J5 connector on MZLP MZTCM-1 or
MZTCM-5.
7. Attach the leads from the new sensor (616) 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 (616) into the follower/tire
plate after coating with non-silicone heat sink
compound. Tighten compression nut. Ensure RTD
is fully inserted.
9. Reconnect the quick connect terminal (625).
10. Replace the Pump covers.
49
Repair
Separate the Air Motor and
Pump
8. If the system includes a Pump shield, remove the
Pump sheet metal enclosure (A). See FIG. 29.
a. Remove the cover screws (B).
b. Remove the heater bands (HB) and disconnect
the ground wire (R).
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 pail, perform steps 1 through 6 of the
Change Pail section, page 37. 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.
9. Pump must be in the full down position (Air Motor
shaft fully extended).
10. If vent hood is installed, remove it.
11. Disconnect the electrical cable from the Air Motor
(X).
12. Remove the air line from the Air Motor and air lines
to the follower blow-off valve.
13. Remove nuts (F) from Pump/Air Motor tie rods at
the Pump end.
14. Remove the nuts and bolts (T) holding the cable
tract to the Air Motor support plate. Slide the end of
the Cable Track outboard of the mounting plate.
CC
15. Remove the screws and the washers from the
Pump inlet.
16. Fully loosen the Pump rod coupler (G) to the Air
Motor rod.
17. Slowly raise the elevator to achieve enough
separation of the Pump (Air Motor) tie rods to
remove the Pump.
18. Remove the Pump (P).
3. Follow Pressure Relief Procedure on page 34.
4. Bleed off excess material and pressure in the
system by opening the dispense gun and catching
the material in a waste container.
19. Reverse this procedure to reinstall the new or
rebuilt Air Motor.
5. On the ADM, turn off the system heat (D).
6. Turn the Main Power Switch OFF.
7. Disconnect all material hoses.
50
334129S
Repair
X
G
R
T
F
HB
B
P
Z
A
FIG. 29
334129S
51
Repair
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 white ceramic caps and disconnect
the electrical wires from the heater band (309a,
309b).
9. Remove the screw that holds the heater band in
place.
10. Remove the heater band (309a, 309b) from the
Pump.
11. Coat the inside of the heater with a non silicone
heat sink compound before mounting. Maximum
thickness is 0.005 in. Coat only to within 3/4 in. of
vertical ends.
12. 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.
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 Pail, page 37. 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.
320
3. Follow the Pressure Relief Procedure, page 34.
321
4. Bleed off excess material in the system by opening
the applicator and catching the material in a waste
container.
5. On ADM, turn off the system heat (D).
FIG. 30
6. Turn the Main Power Switch OFF.
Replace Pump RTD
309a
309b
ti25342a
1. Turn the Main Power Switch OFF.
7. Remove the Pump covers.
52
334129S
Repair
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.
NOTICE
To prevent system damage, always use fast acting
fuses. Fast acting fuses are required for
short-circuit protection.
1. Turn the Main Power Switch OFF.
5. Tie the leads of the new sensor (320) to the old
sensor 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
enclosure.
Replace MZLP Fuse
Each MZLP module comes with the following fuses:
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.
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.
FIG. 31: Fuse Locations
Fuse Kit
24V289
334129S
Fuse
F1, F2
Part
250VAC, 25A, long, white
ceramic
F3-F10
250VAC, 8A, fast acting, clear
glass
Spare fuse kit included with system.
53
Repair
Replace MZLP
6. To reassemble the MZLP, set the MZLP rotary
switch based on location. See Table 10 MZLP
Rotary Switch.
7. Use the four screws (115) to install the MZLP (111
or 112) to the electrical enclosure.
1. Turn the Main Power Switch OFF.
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 61.
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
enclosure.
115
111
9. Connect the heated hose electrical connectors to
the new MZLP.
NOTE: The MZLP may need updated software. See
Update Software, page 60.
Table 10 MZLP Rotary Switch
MZLP
System
#1 with Daughter Primary
Card
Secondary
#2
Primary
Secondary
#3
Primary
Secondary
Rotary Switch
1
5
2
6
3
7
112
112
J5
FIG. 32: 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.
54
334129S
Repair
Replace MZLP Daughter Card
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).
1. Turn the Main Power Switch OFF.
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 61.
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).
112b
112a
112
FIG. 33: MZLP Daughter Card
334129S
55
Repair
Replace AWB
Replace Power Supply
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.
206
208
182
1. Turn the Main Power Switch OFF.
205
223
FIG. 34: 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 61, if unable
to determine the connector location.
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+
VGND
L
N
V+
VGND
L
N
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).
7. Close the electrical enclosure door.
56
334129S
Replace Fan
Repair
6. Remove the screws (141), grill (137), four nuts (139),
rear fan grill (138), and fan (136).
141
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.
139
138
136
137
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).
8. Tie down the fan wires onto the tie down locations
on the grill (137) using cable zip ties.
J7
9. Route the fan wires into the electrical enclosure.
Connect the red and black fan wires to the J7
connector. 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.
5. Cut any cable ties between the end of the fan wires
to the fan (136).
334129S
57
Repair
Replace Transformer
See FIG. 35, page 59.
1. Turn the Main Power Switch OFF.
2. Open the electrical enclosure door.
13. Connect the Transformer output power harness
(234) to the 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
CR2-W1
CR2-W2
CR2-W3
CR2-W4
CR-2 Connections
Terminal 1
Terminal 3
Terminal 5
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.
3. Disconnect the incoming power harness (234) from
the top of the Transformer (235).
4. Disconnect the Transformer (235) output power
harness wires (CR2-W1, -W2, -W3, -W4) from CR2.
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
Transformer (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.
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.
12. Install the Transformer (235) ground wire onto the
ground lug of the back panel (201).
58
334129S
Repair
Z
CR-2
G
J7
234
205
235
N
FIG. 35: Inside of Electrical Control Enclosure
334129S
201
59
Repair
Update Software
When software is updated on the ADM, the software is
then automatically updated on all connected GCA
components. A status screen is shown while software
is updating to indicate progress.
1. Turn the system Main Power Switch OFF.
NOTE: When the screen turns on, you will see the
following screens:
First:
Software is checking
which GCA modules will
take the available updates.
2. Remove the ADM from the bracket.
3. Remove the token access panel.
Second:
Status of the update with
approximate time until
completion.
Third:
Updates are complete.
Icon indicates update
success/failure. See the
following Icon table.
4. Insert and press the software upgrade token (T)
firmly into the slot.
Icon
NOTE: There is no preferred orientation of the token.
Description
Update successful.
Update unsuccessful.
Update complete, no changes
necessary.
T
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.
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
indicate progress. To prevent corrupting the
software load, do not remove the token until the
status screen disappears.
60
7. Remove the token (T).
8. Replace the token access panel.
9. Press
to continue to the operation screens.
334129S
Electrical Schematics
Electrical Schematics
230V, 3 Phase/60Hz
334129S
61
Electrical Schematics
400V, 3 Phase/50Hz
62
334129S
400-600VV, 3 Phase/60Hz
334129S
Electrical Schematics
63
1290
18 AWG
-
J2
L
EGND
130
131
132
218
219
220
54321
G
J5
BLACK
10 AWG
2270
HARNESS 17A544 OR 17A545
AWB-1-J5 TO MZTCM-2-J2
AWB-1-J5 TO MZTCM-3-J2
315
332
240
HARNESS 17A559
AWB-1-J8 TO MZTCM-1-J6
285
239
284
238
Z104520
SEE SHEET 1
J
2620
2610
Z106725
223
222
221
220
374
372
K REVISED SHEETS 2,3, & 4
290
289
288
287
286
285
237
282
281
280
279
278
277
276
275
283
125
122
274
273
272
271
270
236
2320
1250
ENCLOSURE FAN
(FAN-2)
127421
YELLOW
1220
268
267
266
265
269
268
267
282
RED
YELLOW
HARNESS 17A543
AWB-1-J6 TO MZTCM-1-J2
329
330
281
18 AWG
+
-
10 AWG
312
313
235
J9
CAN
J6
J7
1
2
3
G
1
2
266
284
J4
G
W4
W3
W2
3
265
264
283
J3
+
L
N
263
234
10 AWG
1320
1310
1300
+
L
N
J8
AWB-1
260
259
258
257
256
233
232
231
230
229
228
227
226
225
224
223
222
221
129
217
216
215
214
213
W1
GND
L
262
-
N
255
254
253
252
261
J1
N
PS-1
251
212
HARNESS 17A552
24+ GND
+V
-V
211
210
209
208
207
206
205
204
203
202
201
250
17MAR16
06/16/16
A RELEASED
B SEE ECO
A257M
Z090146
Z090616
Z091443
Z093615
SEE SHEETS 1 AND 2.
E
C SEE ECO
Z095498
SEE SHEET 1
F
Z092531
Z097266
D SEE SHEETS 1,2,3
Z098180
G SEE SHEET 1
22 AWG
L1
L2
L3
G
J2
L3
L1
J1
3
1
4
2
J7
06/24/14
07/23/14
08/26/14
10/17/14
12/04/14
23MAR15
02JUN15
30JUN15
MZTCM-1
H REVISED SHEET3
10 AWG
HARNESS 17A543
MZTCM-1-J2 TO AWB-1-J6
12 AWG
HARNESS 17A551
MZTCM-1-J1 TO TERM BLOCKS
22 AWG
J3
J12
J13
J14
J15
64
J16
200
2
1
2
4
3
4
5
5
4
3
2
1
4
3
2
1
4
3
2
3
J6
J5
3
2
2
1
6
5
4
3
2
1
1
22 AWG
4
1
3
1
4
5
2790
2770
2760
2710
PLATEN-RTD
PUMP-RTD
HARNESS 17A555
2700
2680
2650
RED
RED
RED
2740
2730
1150
RED
1140
1090
RED
BLUE
1100
BLUE
114
115
109
110
238
237
236
235
234
358
355
HARNESS 17B768
MOTOR-UP
PX-LOW
PX-EMPTY
MOTOR-DN
2570
300
301
302
303
304
HARNESS 17A557
MZTCM-1-J12 TO SOL-1
SOL-1
HARNESS 17A559
MZTCM-1-J6 TO AWB-1-J8
2720
HARNESS 17A553
MZTCM-1-J7 TO SSR-1 AND CR-1
WHITE
WHITE
RED
BLUE
RED
2670
2640
HARNESS 24V745
2560
HARNESS 127511
MZTCM-1-J3 TO MZTCM-2-J6
Electrical Schematics
AWB and MZLP#1
334129S
334129S
2
3
4
5
J3
10 AWG
5
HARNESS 127511
MZTCM-2-J3 TO MZTCM-3-J6
10 AWG
215
217
218
365
364
363
362
361
360
3
J3
4
3
J7
2
1
215
217
382
381
380
379
378
377
388
389
390
340
387
386
339
J1
L3
338
337
336
L1
J2
G
L3
L2
L1
218
HARNESS 17A545
MZTCM-3-J2 TO AWB-1-J5
376
375
374
385
5
5
384
4
4
335
3
J5
J6
383
2
2
373
372
371
370
369
334
1
1
2
3
4
5
6
1
MZTCM-3
J1
333
332
331
330
329
328
327
326
325
324
323
322
321
320
L3
368
319
L1
J2
G
L3
L2
L1
HARNESS 17A544 OR 17A545
MZTCM-2-J2 TO AWB-1-J5
359
358
357
367
4
4
366
3
2
3
J7
1
318
2
J5
J6
317
1
1
2
3
4
5
356
316
315
314
313
312
311
310
309
308
307
306
6
354
250
304
1
353
251
303
MZTCM-2
352
252
302
355
351
253
305
350
254
301
HARNESS 127511
MZTCM-2-J6 TO MZTCM-1J3
300
Z104520
SEE SHEET 1
B3
T3
T1
B1
2740
2732
2732
2731
2731
2730
17MAR16
06/16/16
16 AWG
J
3
2
1
2740
2732
2731
2730
Z106725
2620
2610
2740
2730
K REVISED SHEETS 2,3, & 4
262
261
275
274
PUMP
PUMP
PLATEN
A RELEASED
A257M
Z090146
Z090616
Z091443
C SEE ECO
B SEE ECO
Z092531
D SEE SHEETS 1,2,3
Z093615
Z095498
SEE SHEETS 1 AND 2.
Z097266
E
Z098180
F
SEE SHEET 1
G REVISED PUMP WIRING
275
274
H REVISED SHEET 3
2
240V/1200W TOTAL
ALL VOLTAGES
TYPICALL ALL TOF200 AND TOFP20's
OVERTEMPS
06/24/14
07/23/14
08/26/14
10/17/14
12/04/14
23MAR15
02JUN15
30JUN15
2740
2730
2740
2732
2731
2730
2740
2730
PLATEN
AT SELECTION 7. ALL VOLTAGES
TYPICALL OF TOFP20's WITH CODE D
OVERTEMP
Electrical Schematics
MZLP#2, MZLP#3, Overtemp,
and Pump Heaters
65
Electrical Schematics
MZLP Zones
400
401
402
403
TYPICAL ZONE PIN OUT
MZTCM-1
1 2
CONNECTOR
PIN #
FUNCTION
MZTCM-1
A
ZONE 1,L2
B
404
J9
405
MZTCM-1 J9
406
SHIELD
C
ZONE 2,L1
D
ZONE 2,L2
E
JUMPER
F
ZONE 1,START
G
ZONE 1,RTD
H
407
408
J
3
4
409
J8
411
ZONE 2,START
M
ZONE 2,RTD
A
ZONE 3,L2
413
414
A
MZTCM-2
5 6
J
ZONE 4,L1
D
ZONE 4,L2
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
ZONE 5,L2
B
SHIELD
H
D
M
MZTCM-2 J9
8
D
422
E
G
ZONE 5,RTD
ZONE 6,START
M
ZONE 6,RTD
A
ZONE 7,L2
B
SHIELD
MZTCM-2 J8
427
428
429
MZTCM-3
9 10
G
ZONE 7,RTD
ZONE 7,L1
K
RTD EXCITE
L
ZONE 8,START
M
ZONE 8,RTD
ZONE 9,L2
J9
MZTCM-3 J9
SHIELD
C
ZONE 10,L1
D
ZONE 10,L2
E
JUMPER
F
ZONE 9,START
G
ZONE 9,RTD
H
433
11 12
JUMPER
J
ZONE 9,L1
K
RTD EXCITE
L
ZONE 10,START
M
ZONE 10,RTD
A
435
ZONE 11,L2
B
J8
437
MZTCM-3 J8
438
SHIELD
C
ZONE 12,L1
D
ZONE 12,L2
E
JUMPER
F
ZONE 11,START
G
ZONE 11,RTD
H
439
J
440
66
H
JUMPER
J
A
432
436
ZONE-2-RTD
E
MZTCM-3
430
434
ZONE-2-START
M
JUMPER
ZONE 7,START
B
431
L
ZONE 8,L1
F
H
426
ZONE-1-START
K
ZONE 8,L2
E
425
ZONE-1-RTD
F
JUMPER
RTD EXCITE
L
D
G
ZONE 5,L1
K
C
J8
424
D
JUMPER
ZONE 5, START
J
F
L
423
C
ZONE 6,L1
F
H
G
C
7
ZONE-1-HEAT
J
ZONE 6,L2
E
J9
419
421
A
ZONE-2-HEAT
A
C
417
420
B
MZTCM-2
K
B
418
TYPICAL ZONE PIN OUT
SHIELD
C
E
MZTCM-1 J8
412
416
RTD EXCITE
L
B
410
415
JUMPER
ZONE 1,L1
K
JUMPER
ZONE 11,L1
K
RTD EXCITE
L
ZONE 12,START
M
ZONE 12,RTD
H REVISED SHEET 3
Z098180
30JUN15
G SEE SHEET 1
Z097266
02JUN15
F
SEE SHEET 1
Z095498
23MAR15
E
SEE SHEETS 1 AND 2.
Z093615
12/04/14
D SEE SHEETS 1,2,3
Z092531
10/17/14
C SEE ECO
Z091443
08/26/14
Z090616
07/23/14
Z090146
06/24/14
K REVISED SHEETS 2,3, & 4
Z106725
06/16/16
B SEE ECO
J
Z104520
17MAR16
A RELEASED
SEE SHEET 1
A257M
334129S
Parts
Parts
Therm-O-Flow 20 Supply Unit
23
25
24
8
7
3
2
9
4
14
16
18
10
17
11
27
22
26
12
13 12
1
20
11
21 12
17
18
5
6
334129S
15
ti25320a
19
13
67
Parts
Therm-O-Flow 20 Supply Unit
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
68
Part
Description
--Frame
24W870 KIT, air control; see Air Control
Assembly, page 69
--CONTROL, electrical (not used
with air control only systems)
--MODULE, pump; see Pump
Modules, page 77.
--PLATEN; see Heated Platens,
page 86
C31065 SEAL
24W812 ADM
24W589 KIT, light tower (optional); see
Accessories and Kits, page 88.
--CABLE, track
--BRACKET, cable track, enclosure
101864 SCREW, cap, sch
100020 WASHER, lock
111820 SCREW, cap, sch
Qty
1
1
1
1
1
1
1
1
1
1
4
6
6
Ref
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Part
288543
--112166
110755
100016
--106285
100179
24V745
15J076
15J074
Description
BRACKET, hose, spring
BRACKET, enclosure, ram
SCREW, cap, sch
WASHER, plain
WASHER, lock
BRACKET, cable track, NXT
BOLT, u
NUT, hex mscr
SENSOR, level, low/empty
LABEL, warning, instructions
LABEL, warning; moving objects,
pinch
15H668 LABEL, warning; hot surface,
splatter
15J075 LABEL, warning; hot surface,
shock
184090 LABEL, warning
Qty
1
1
4
8
8
1
2
4
1
2
4
334129S
2
2
1
Parts
Air Control Assembly
56
53
54
66
55
52
66
51
51
ti25005b
ti25025b
Ref
51
52
Part
Description
24W870 KIT, CONTROL, air, 3 regulator;
see manual 334201
121235 SOLENOID, air motor, ram
Qty
1
1
Ref
53
54
55
56
66
Part
Description
Qty
1
1
1
1
HARNESS, solenoid, MZLP
FITTING, elbow, street
FITTING, swivel, straight
ADAPTER, elbow, 3/4-14 nptf x
1/2-14 npsm
255651 KIT, reg, air motor, ram
17A557
113445
121282
120375
1
Replacement Warning Labels, signs, tabs, and cards
are available at no cost.
334129S
69
Parts
Electrical Module
146
144
153 148 150
152 153
170
151
172
143
184
145 147
153
142
149
120
106
105
152
222
174
141
222
137
103
136
138
104
177, 119
118
139
111
140
141
116
115
222
160
159
183
101 113
114
115
161
112
131
70
157
158
112
116
ti25023c
334129S
Parts
125
126
181
165
167
222
169
128 127
134
122
168
132
165
111
129
125
162
131
133
123
130
135
156
124
334129S
108
110
109 110
71
Parts
Electrical Control Module Parts
Ref
Part
104
105
106
107
--125946
123967
---
101
103
-----
----108
109
110
111
100133
100307
123396
---
112
24V510
112a 24R042
113 --114
24P175
115
116
125856
16T440
118
119
120
122
123
--100166
--17A543
17A544
17A545
72
Description
ENCLOSURE, electrical
BUSHING, strain relief, m40
thread
NUT, strain relief, m40 thread
PLUG, hole, 1/2 in
KNOB, operator disconnect
PANEL, elec, transformer
(transformer assemblies only)
PANEL, elec, 400v/n
(400V modules only)
PANEL, elec, 230v/n
(230V modules only)
WASHER, lock, 3/8
NUT, hex
NUT, flange, serrated, 3/8-16
MODULE, gca, mzlp w/ daughter
board
MODULE, gca, mzlp
(8 zone assemblies only; Qty 1) (12
zone assemblies only; Qty 2)
KIT, daughter, board
GASKET, foam
(8 zone assemblies only; Qty 1) (12
zone assemblies only; Qty 2)
PLATE, blank
(4 zone assemblies only; Qty 2)
(8 zone assemblies only; Qty 1)
SCREW, 8-32, serrated flange
CAP, souriau, uts 14
(4 zone assemblies only; Qty 2)
(8 zone assemblies only; Qty 4) (12
zone assemblies only; Qty 6)
WIRE, grounding, door
NUT, full hex
GASKET, hphm
HARNESS, power, mzlp1, awb
HARNESS, power, mzlp2, awb
(8 zone assemblies only)
HARNESS, power, mzlp2/3, awb
(12 zone assemblies only)
Qty
1
1
Ref
Part
Description
125
126
-----
1
2
1
1
127
128
129
17A555
17A559
127511
1
130
131
132
121226
121612
123969
123968
134
--17A547
136
24V911
137
138
139
140
16X884
115836
127278
24V746
141
142
119865
---
143
144
24W812
15V551
145
121001
146
---
147
121250
148
102040
149
(Primary assemblies only)
110755 WASHER, plain (Primary
assemblies only)
1
4
8
4
1
1
12
1
2
1
1
1
1
HARNESS, pump, mzlp1, tb, tof
HARNESS, output, mzlp1, ssr,
contact
HARNESS, pump, reed switch, tof
HARNESS, board, mxm, comm
CABLE, board, samtec
(8 zone assemblies only; Qty 1) (12
zone assemblies only; Qty 2)
CABLE, can, male / female, 0.4m
CONNECTOR, thru, m12, mxf
SWITCH, disconnect, 100a
SWITCH, disconnect, ph exp 100
A (400V only)
HARNESS, disc, fuse, 230-600v
HARNESS, disc, cb, 400v/n, tof
(400V only)
FAN, 24v dc, 120m x 120m
(400V only)
GRILL, fan (400V only)
GUARD, finger (400V only)
NUT, keps, hex (400V only)
GRILL, vent
(230V and 400V assemblies only;
Qty 2) (Transformer assemblies
only; Qty1)
SCREW, mach, hex serrated
CONTROL, air, assy; with
solenoid
ADM (Primary assemblies only)
SHIELD, membrane, ADM
(Primary assemblies only)
CABLE, can, female / female 1.0m
(Primary assemblies only)
BRACKET, mounting, assembly
(Primary assemblies only)
SCREW, shcs, 1/4uncx4.25
(Primary assemblies only)
NUT, lock, hex
1
1
Qty
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
0.1
1
1
1
1
1
334129S
Parts
Ref
150
151
152
153
156
157
158
159
160
Part
121253
--101550
100016
24V745
------124654
Description
KNOB, display adj., ram pkgs
(Primary assemblies only)
BRACKET, pendant pivot,
(Primary assemblies only)
SCREW, cap, sch
(Primary assemblies only)
WASHER, lock
(Primary assemblies only)
SENSOR, level, low/empty
BUSHING, strain relief
NUT, bushing
GROMMET, wire
CONNECTOR, splitter, 12(m) x
1
Qty
161
121228
CABLE, can, female/female,
4
16W035
1
1
1
1
1
1
164
---
334129S
166
127771
Qty 2)
CONTACT, socket, 20-24 awg,
crimp, tin
TUBE, 1/16 shrink tube
Description
HARNESS, input, mzlp1, RTD
BRIDGE, plug-in, 2pos, ut16
1
Qty
1
(400V and Transformer modules
167
---
only)
FERRULE, wire, 10awg
(230V modules only; Qty 2) (400V
and transformer modules only; Qty
8)
168
169
-----
170
172
196548 LABEL, warning, shock
1
1
--ARTWORK, instructions, wiring, ul
181
182
---
17C669
123856
CONNECTOR, jumper
184
Qty 1) (12 zone assemblies only;
---
---
183
(Secondary modules only)
(8 zone assemblies only;
163
165
5
15.0 m
162
Part
1
m12(f)
(Secondary modules only)
Ref
17C712
FERRULE, wire, 16awg
FERRULE, wire, 18 awg, long
FERRULE, wire, 10awg, twin
(Secondary assemblies only)
CONNECTOR, jumper, male
(Secondary assemblies only)
HARNESS, CAN, cable
(Secondary assemblies only)
TOKEN
6
6
3
1
1
1
(Secondary assemblies only)
3
Replacement Warning labels, signs, tags, and cards are
available at no cost.
0.13
73
Parts
Electrical Panel
230V
400V
Transformer
223, 224
225
214 1
227
215 1
216, 229 1
230, 231 1
213
208
201
241
210 1
226
212
206
228
242
7
202, 203, 204, 236
223
234 6
205
4 211
209
Transformer Panel Shown
1
2
3
74
239
240
235
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)
334129S
Parts
230V Panel
232
230
400V Panel
230 1
233
243
1
2
3
219
221
207 2
218
220 2
217 3
211
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)
334129S
75
Parts
Electrical Panel Parts
Ref
201
Part
---
Description
PANEL, elec, tof, 11ga, zinc
202
203
204
205
206
207
117666
113783
100985
24V816
--123363
208
209
126453 POWER SUPPLY, 24v
--HARNESS, power supply, awb
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
76
128097
TERMINAL, ground
SCREW, machine, pn hd
WASHER, lock ext
MODULE, gca, awb
RAIL, din, 6.5in
BLOCK, terminal, ground, 10mm
CIRCUIT, breaker, 63a, 4p, rcd
--HARNESS, rcd, awb
126811 BLOCK, clamp end
--RAIL, din, 19in
120399
CONTROL, 65 amp, 120-600v
123359
RELAY, contactor, 30a, 3p, 24vdc
co
6690-24
FUSE, fuse block buss jt60060
-165
128314 BLOCK, terminal 3-wire
128321 COVER, end
126819
BRIDGE, plug-in, 2-position
127717
BLOCK, terminal, 2pos, ut16
127718 COVER, end, ut16
17C137 LABEL, multi safety
103833 SCREW, mach, crbh
123452
HOLDER, anchor, wire tie, nylon
---
--------6690-24
-164
HARNESS, wire, ground, 8awg
HARNESS, fuse, contactor
HARNESS, contactor, ssr
HARNESS, rcd, ssr fan
See Code C Table
FUSE, fuse block buss jt60030
Qty
1
1
1
1
1
1
3
1
1
Ref
Part
127744
127745
231
232
233
234
235
17L789
17A541
24V718
1
237
128014
3
8
2
1
3
1
1
33
12
1
1
1
1
3
3
238
239
240
241
242
243
Qty
CIRCUIT, breaker, 3p, 32a, ul489;
230V Panel only
112380
81/0163
-B/11
81/0164
-B/11
17L790
129120
17L787
1
1
CIRCUIT, breaker, 20a,
4p, ul489; 400V Panel only
--See Code C Table
17L788
HARNESS, cb, rcd, 230-400V;
1
1
2
1
1
Description
3
1
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
1
1
1
SCREW, mach, pn hd
WIREWAY, panduit
2
4
COVER, panduit
4
HARNESS
CONTACTOR 240V
HARNESS
1
1
1
Replacement Warning labels, signs, tags, and cards are
available at no cost.
If Code A is 20P and Code E is F/S and Code C is
Code C
X1X
X2X
X3X
X4X
X5X
(229)
24X879
24X873
24X873
24X875
24X876
(231)
NA
NA
24X878
24X877
24X874
334129S
Parts
Merkur 2200, 23:1 Pump Modules
301
339
315
310
327
304
329
314
308 1
318
319
312
334
302
305
335
338
311 6 7 8
317
7 1 307
323
324
325
309a 5
306
320
322 3
336
336
321 4
337
309b 5
316 2
326
ti25311a
1
2
3
4
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 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).
334129S
5
6
7
8
333
Coat inside of heater (309a, 309b) only to within 3/4 in. 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).
Apply anaerobic sealant.
77
Parts
Merkur 2200, 23:1 Pump Modules
Ref
301
302
304
305
306
307
308
309
310
Part
311
312
315
316
317
318
319
320
321
322
323
324
325
326
329
330
331
333
334
24W754
C20485
24R885
--15H397
16A223
106166
--24W152
24W153
109211
17A637
102656
186925
184129
103345
100016
24Z093
C31012
C03507
C38162
C38163
----103347
C33049
--206994
127766
365
127671
335
336
17B715
127671
337
338
339
122338
214656
16C009
78
Description
MOTOR, air, 6 in, 4.75 stroke, blue
FITTING, hex, nipple
SWITCH, reed assy
BRACKET, motor mount
ADAPTER, rod, pump
ROD, tie, vert driver
NUT, mach ,hex
HEATER, pump, 600 watt
PUMP, tof200, cf; 24V572 only
PUMP, tof200, gf; 24V575 only
SCREW, cap, sch
BLOCK, standoff, mounting
MUFFLER
NUT, coupling
COLLAR, coupling
SCREW, cap, sch
WASHER, lock
SENSOR, RTD
CLAMP
SUPPORT, sensor
SCREW, machine
WASHER, lock, ext. tooth
CONDUCTOR, ground
SHIELD, pump, tof20
VALVE, safety, 100 psi
TAPE, adhesive, fiberglass
LUBRICANT, high temp, thermal
FLUID, tsl 8 oz bottle
FITTING, 45 elbow swivel, 1/2
npt(f) x 1/2 nps
SWITCH, over temp, fixed, 450°F
(232°C)
SUPPORT, block, over temp
SWITCH, over temp, fixed, 450°F
(232°C)
SCREW, cap, socket bh
HOSE, coupled
HOOK
Qty
1
1
1
1
1
3
3
2
1
1
3
3
1
1
2
2
4
1
1
1
1
1
1
1
1
1.5
1
1
1
2
1
2
4
1
1
334129S
Parts
Merkur 3400, 36:1 Pump Modules
301
339
315
327
310
304
1 308
314
329
318
319
334
312
338
323
324
302
335
336a
311 6 7 8
305
306
321 4 5
336b
316 2
309a 5
320 4
322 3
337
317
325
309b 5
326
333
7 1 307
ti25312a
1
2
3
4
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 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).
334129S
5
6
7
8
Coat inside of heater (309a, 309b) only to within 3/4 in. 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).
Apply anaerobic sealant.
79
Parts
Merkur 3400, 36:1 Pump Modules
Ref
301
302
304
305
306
307
308
309
310
Part
24R015
C20485
24R885
--15H397
16A223
106166
--24W152
24W153
311
312
315
316
317
318
319
320
321
322
323
324
325
326
327
329
330
109211
17A637
102656
186925
184129
103345
100016
24Z093
C31012
C03507
C38162
C38163
------103347
C33049
331
333
334
--206994
127766
335
336
17B715
127671
337
338
339
122338
214656
16C009
80
Description
MOTOR, assy, air, 7.5 in, blue
FITTING, nipple, hex
SWITCH, reed assy
BRACKET, motor mount, tof 200
ADAPTER, rod, pump
ROD, tie, vert driver
NUT, mach, hex
HEATER, pump, 600 watt
PUMP, tof20, long shaft, cf;
24V573 only
PUMP, tof20, long shaft, gf;
24V576 only
SCREW, cap, sch
BLOCK, standoff, mounting
MUFFLER
NUT, coupling
COLLAR, coupling
SCREW, cap, sch
WASHER, lock
SENSOR, RTD
CLAMP
SUPPORT, sensor
SCREW, machine
WASHER, lock, ext. tooth
CONDUCTOR, ground
SHIELD, pump
LABEL, identification
VALVE, safety, 100 psi
TAPE, adhesive, fiberglass; 1.5 ft
(x m)
LUBRICANT, high temp, thermal
FLUID, tsl 8 oz bottle
FITTING, 45 elbow, swivel, 1/2
npt(f) x 1/2 nps
SUPPORT, block, over temp
SWITCH, over temp, fixed, 450°F
(232°C)
SCREW, cap, socket bh
HOSE, coupled
HOOK
Qty
1
1
1
1
1
3
3
2
1
1
3
3
1
1
2
6
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
4
1
1
334129S
Parts
NXT 6500, 70:1 Pump Modules
420
408
406 1
401
418
423
419
402
432
415
416
410 4
429
409
411 3
430a
404 6 7
2
413
417
5
407a
403
403
429
412 4 5
430b
414
431
407b 5
1
405
422
333
1
2
3
4
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 with
non-silicone heat sink compound. Do not coat sensor.
5
6
7
Coat inside of heater (407a, 407b) only to within 3/4 in. of
vertical ends with non-silicone heat sink compound before
mounting.
Torque to 150 ft-lbs (203 N•m).
Apply anaerobic sealant.
Prior to tightening band clamp (412), RTD sensor (410)
must be fully contained within the sensor mount (411).
334129S
81
Parts
NXT 6500, 70:1 Pump Modules
Ref
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
422
423
424
425
426
428
429
430
431
432
82
Part
Description
N65LR0 MOTOR, 6500, low-noise, remote
120375 ADAPTER, elbow, 3/4 NPTI x 1/2
NPTE
15J288 BRACKET, mounting, motor, tof20
17A406 ADAPTER, rod, pump, tof
16A223 ROD, tie, vert driver
106166 NUT, mach, hex
128322 HEATER, pump, 600 watt
24W152 PUMP, tof20, cf; 24V574 only
24W153 PUMP, tof20, gf; 24V577 only
C19837 SCREW, cap, socket hd
24Z093 SENSOR, RTD
C03507 SUPPORT, sensor
C31012 CLAMP
186925 NUT, coupling
184129 COLLAR, coupling
C38163 WASHER, lock, ext. tooth
--CONDUCTOR, ground
C38162 SCREW, machine
103345 SCREW, cap, sch
100016 WASHER, lock
--LABEL, ID
--SHIELD, pump, tof20
120588 PLUG, pipe, round
120012 VALVE, safety, 50 psi
--LUBRICANT, high temp, thermal
C33049 TAPE, adhesive, fiberglass
206994 FLUID, tsl 8 oz bottle
17B715 SUPPORT, block, over temp
127671 SWITCH, over temp, fixed, 450
122338 SCREW, cap, socket bh
214656 HOSE, coupled
Qty
1
1
2
1
3
3
2
1
1
4
1
1
1
1
2
1
1
1
6
6
1
1
1
1
1
1.5
1
1
2
4
1
334129S
Parts
Pump Shield
507
503
506
505
504
502
501
504
Ref
501
502
503
504
505
506
507
Part
------C20474
17J504
104088
15J075
Description
COVER, pump, bottom
COVER, pump, back
COVER, pump, front
SCREW, self-tapping
LABEL, warning
RIVET, blind
LABEL, safety, hot surface and
shock
Qty
1
1
1
6
1
2
1
Replacement Warning labels, signs, tags, and cards
are available at no cost.
334129S
83
Parts
President, 15:1 Pump Module
558
551a
557
1
563
1
564
569 1
554
567
551h
568
553
556
551s
551d
551r
551r
551b
551m
551c
551p
551g
2 551f
2 551e
2 552
559 2
566 2
565 2
560 2
551k
551j
1
2
84
551n
561 2
562 2
tii000a
Torque to 20-30 ft-lbs (27-41 N•m).
Torque to 30-40 ft-lbs (41-54 N•m).
334129S
Parts
Ref
551
551a
551b
551c
551d
551e
551f
551g
551h
551j
551k
551m
551n
551p
551r
551s
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
Part
288505
24B229
918417
--198369
100340
100133
298073
156082
112166
100016
207370
198412
C38225
101946
206994
112756
--196548
100020
100179
----516587
154628
101015
C19187
--155470
100016
103345
--127732
Description
PUMP, president
MOTOR, AIR, president
PUMP, hot melt mini-5
PLATE, president mounting
ROD, standoff
NUT
WASHER, lock, 3/8
ADAPTER, pump
PACKING, o-ring, 112
SCREW, cap, sch
WASHER, lock
ROD, connecting
ROD, connecting
PACKING, o-ring
PIN, cotter, sst
FLUID, TSL, 8 oz
SCREW, cap, socket hd
BRACKET, mounting, junction box
LABEL, warning, shock
WASHER, lock
NUT, hex mscr
JUNCTION BOX, front cover
FASTENER, thread-cutting screw
BOLT, 3/4-10 x 1.5 hex head
WASHER
WASHER, lock
NUT, hex
ADAPTER
FITTING, swivel, union, 90 degree
WASHER, lock
SCREW, cap sch
JUNCTION BOX, main body
FITTING, 3/4” knockout, romex,
pushin
214656 HOSE, coupled, 61209, 10 ft
Qty
1
1
1
1
3
3
3
1
2
2
2
1
1
1
2
1
4
2
1
2
2
1
2
1
2
1
1
1
1
6
6
1
1
1
Replacement Warning labels, signs, tags, and cards are
available at no cost.
334129S
85
Parts
Heated Platens
24V742, Heated Drum Platen, Standard Finned Bottom (Code
E-option F)
24V743, Heated Drum Platen, Smooth Bottom (Code E-option S)
5
605
606
5
615
613 630 631
631
629
614
612
622
611
610
4 620
621
603 6
609 6
5 3 623
604
628
616 1
9 8 627
3 618
626
617
624
608
633
619
601
607
602
ti25315c
1
3
4
86
Coat RTD sensor (616) with non-silicone heat sink
compound. Coat from tip to 1 in from tip.
Label cables for identification. See Cable Identification.
Do not tighten heater terminal nuts down onto ceramic
insulators to prevent damage.
8
9
Coat bottom of overtemperature switch (627) with
non-silicone heat sink compound.
Label the wires on overtemperature switch (627) 2732.
2740 at the opposite end of the sensor.
334129S
Parts
Ref
Part
612
5/16 OD tube
115949 ELBOW, 1/4 npt(m),
1
613
---
1
614
---
601
602
603
604
605
606
607
608
609
610
611
615
616
--C31052
207440
24X439
--514930
C31154
--167730
100176
115948
Description
PLATEN - see table below
HOSE, seal, Mini - 5
VALVE, dispenser
HANDLE, bleed
ADAPTER, bushing
SCREW, cap, skt hd
CLAMP, worm gear
PLATE, designation
GASKET, copper
BUSHING, hex
ELBOW, 1/4 npt(m),
5/32 OD tube
TUBE, PTFE, 1/4 x 5/16;
14 ft (4.2 m)
TUBE, PTFE, 3/32 x 5/32;
14 ft (4.2 m)
--CONDUIT, hi-temp, w/ fittings
24Z094 SENSOR, RTD, 5”, 100 ohms,
with heat shrink
Platen Model
24V742
24V743
334129S
Qty
1
1
1
1
1
3
2
1
1
1
1
1
1
1
Plate (601) Description
Standard Finned
Smooth Bottom
Ref
617
618
619
620
621
623
624
626
627
628
629
Part
Qty
1
1
1
4
4
4
1
2
1
2
1
631
WASHER, lock, ext. tooth
SCREW, mach, slotted, md hd
GASKET
NUT, mach. hex
WASHER, lock, internal tooth
CONDUCTOR, heater
CONDUCTOR, ground
SCREW, drive
SWITCH, overtemp, fixed
SCREW, cap, socket, bh
FITTING, adapter, 1/4 in x 5/32 in
tube
127690 FITTING, adapter, 5/16 in tube x
1/4 in tube
054130 HOSE, tubing; 1/4 in OD;
632
---
1
630
633
C38163
C19049
15C171
102931
------100508
127671
122338
127689
Description
17 ft (5 m)
LUBRICANT, high temperature,
thermal
150286 ADAPTER
1
1
1
Parts included in Seal Kit C31065 (purchase separately).
Qty.
1
1
Element Resistance
28.8 ohms +3/-4
28.8 ohms +3/-4
87
Accessories and Kits
Accessories and Kits
Wiper Kits
Part No.
C31065
Description
Seal Kit
Applicators and Dispense
Valves
Part No.
249515
249514
249513
249512
Description
Manual Gun, Top Feed, 240V
Manual Gun, Bottom Feed, 240V
Manual Gun, Top Feed, Electric Switch,
240V
Manual Gun, Bottom Feed, Electric Switch,
240V
Air-Operated Heated Dispense
Valves
Part No.
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
This kit enables controlling logic, such as a robot
controller 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
following CGM modules are available for the
Therm-O-Flow system.
Description
EitherNet/IP
DeviceNet
ProfiBus
ProfiNet
Flow Control and Manifolds
Part No.
243700
243656
243657
243697
Description
CGM Installation Kit, 25C994
88
Part No.
CGMEP0
CGMDN0
CGMPB0
CGMPN0
289208
Description
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.
Compact Heated Regulator
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, 8pin to 8 pin
334129S
Light Tower Kit, 24W589
Accessories and Kits
Tie Rod Kits
Use to retrofit Check-Mate 800 Displacement Pump to
an existing Therm-O-Flow system.
Part No.
24V750
24V754
Description
Bulldog® and Senator® Tie Rod Kit; see
manual 334131
NXT® Tie Rod Kit; see manual 334132
334129S
89
Accessories and Kits
Heated Hoses and Fittings
Hose Diameter
-6
(9/16 in -18
JIC)
3 ft (1.5 m)
6 ft (1.8 m)
10 ft (3 m)
15 ft (4.6 m)
20 ft (6 m)
25 ft (7.6 m)
30 ft (9 m)
None
None
16J875
None
None
None
None
TOF 20/200 PUMP
1-11 1/2 DUAL
OUTLET ADD
120263
TOF MINI 5 PUMP
1/2 NPT DUAL
OUTLET ADD
120241
-10
(7/8 in -14
JIC)
Hose Length
None
None
115902
115875
115873
115876
115874
17J656
None
115878
None
115879
None
121200
Pump Fittings
-12
-16
-20
(1-1/16 in -12 (1-5/16 in -12 (1-5/8 in -12
JIC)
JIC)
JIC)
15C586
None
115880
115881
115882
115883
None
None
115884
115885
115886
115887
115888
None
None
None
117821
117822
None
None
None
16V432
100380
253267
253268
120260
120261
120262
16V432
C20678
C20679
C38006
158586
120804
120268
Hose to Hose Fittings
123683
120265
120267
120244
120267
120246
120267
-6 Hose (.308 ID)
125779
123684
123683
123683
120265
-8 Hose (.401 ID)
123684
120241
120242
120244
-10 Hose (.495 ID)
123683
120242
120243
120246
120244
120246
120247
120244
120267
120246
120267
120248
120249
120249
120268
123135
126521
120249
120268
120250
123135
123854
15D936
C20708
125661
123135
123854
-12 Hose (.617 ID)
-16 Hose (.687 ID)
-20 Hose (1.125 ID)
Compensator 51:1,
243657
Compensator 23:1,
243656
Inlet & Outlet: 1-11
1/2 in NPTF
Distribution
manifold, 243697
Inlet: 3/4 in NPTF
Distribution
manifold, 243697
Outlet: 1-11 1/2 in
NPTF
90
-8
(3/4 in -16
JIC)
123683
120265
123683
120265
120267
None
16V432
100380
16V432
100896
16V432
100380
6308-82
126521
6308-82
124286
6308-82
120246
120267
120268
Fittings
123135
120266
15Y934
123135
120266
120248
None
6308-82
126521
6308-82
126521
123135
126521
125661
120268
15D936
334129S
Accessories and Kits
Hose Diameter
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
334129S
-6
(9/16 in -18
JIC)
16V432
100896
16V432
-8
(3/4 in -16
JIC)
121311
-10
(7/8 in -14
JIC)
116765
-12
-16
-20
(1-1/16 in -12 (1-5/16 in -12 (1-5/8 in -12
JIC)
JIC)
JIC)
116766
116766
120267
124286
15Y934
C20708
125661
117677
120264
None
120265
None
16V432
124287
C20768
94/1027/99
125662
16V432
124287
C20768
94/1027/99
125662
None
None
None
124238
124239
124286
15Y934
C20708
125661
124286
15Y934
C20708
125661
100896
16V432
100896
16V432
100896
116766
120267
120268
125661
120268
None
125662
120268
125662
120268
124240
125661
120268
125661
120268
91
Accessories and Kits
8 Channel Upgrade Kit, 24V755
Use this kit to upgrade a 4 Channel system to an 8 channel system.
Ref
1
2
3
4
Part
--125856
16T440
127511
Description
Qty
MODULE, GCA, MZLP
SCREW, 8–32, serrated flange
CAP, souriau, UTS14
CABLE, board, samtec
Ref
1
4
2
1
Part
5
6
7
8
16W035
17A544
112190
17C712
Description
CONNECTOR, jumper
HARNESS, power, MZLP2, AWB
STRAP, wrist, grounding
TOKEN, software upgrade
7
C
A
B
8
2
4
3
ti25236b
B
5
4
6
J6
J3
J2
5
92
6
J5
334129S
Qty
1
1
1
1
Accessories and Kits
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
primary system or “6” on a secondary system.
4. Remove the screws (B), the plate (A), and the
gasket (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.
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 88.
9. To ensure your system has the latest software,
insert the token (8) into the ADM. See Update
Software, page 60.
334129S
93
Accessories and Kits
12 Channel Upgrade Kit, 24V756
Use this kit to upgrade an 8 channel system to a 12 channel system.
Ref
1
2
3
4
5
Part
--125856
16T440
127511
16W035
B
Description
MODULE, GCA, MZLP
SCREW, 8–32, serrated flange
CAP, souriau, UTS14
CABLE, board, samtec
CONNECTOR, jumper
A
Qty
1
4
2
1
1
Ref
Part
6
Description
17A545 HARNESS, power, MZLP2/3,
AWB
112190 STRAP, wrist, grounding
17C712 TOKEN, software upgrade
7
8
7
C
8
6
J2
J6
2
1
5
4
ti25237b
4
J3
3
J2
94
5
6
J5
334129S
Qty
1
1
1
Accessories and Kits
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
primary 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.
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 17, 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
Software, page 60.
334129S
95
Appendix A - ADM
Appendix A - ADM
General Operation
Enable, Disable Heating System
The ADM automatically turns on when the Main Power
Switch is ON.
. To set which channels are active when the
heating system is enabled, use the Heat-A and Heat-B
Setup screens.
ADM Power
Screen Navigation
To enable or disable the entire heating system, press
To switch between the Setup and Operation screens,
press
screens.
96
. Use the keypad to navigate between
334129S
Appendix A - ADM
Icons
Screen Icons
These are frequently used icons on the screens. The
following descriptions explain what each icon
represents.
Icon
Description
Primary System= A
Secondary System = B
Softkey Icons
The following icons appear in the ADM, directly to the
left or right of the soft key which activates that
operation.
Icon
Description
Pause Material Tracking
Continue Material Tracking
Heating Disabled
Warm Up, Actual
temperature is outside of
Target Temperature
Reached Target
Temperature
Hose
Gun
Manifold
Pump Ready
Setback
Reset Cycle Counter (press and hold)
Add or edit event
Accept schedule
Crossover for Tandem Systems
PGM
Erase or cancel schedule
Flow Meter
Cancel
Pressure Regulator
Clear
Other
Advisory. See Error
Codes for more
information.
Deviation. SeeError
Codes for more
information.
Alarm. See Error Codes
for more information.
Schedule Event On/Off
Heat On/Off
View Software Contents
Reprogram token with file from USB
stick
Start USB to Token Programming
Process
334129S
97
Appendix A - ADM
Operation Screens
Home
This screen shows the temperature state of the system
and material usage.
Color
White
Green
Red
Yellow
Green/Yellow Flashing
A and B Zone Status
Off
On and at setpoint
temperature
Outside of alarm range
Outside of advisory range
Warmup
Events
The Events screens store a maximum of 200 events.
The events list can be downloaded in the USB logs.
See Appendix B - USB Data, page 105.
NOTE: If present, secondary systems will be shown on
the home page.
Heat A
This screen shows the target and actual temperatures
for all zones on the system.
Tracked Events
NOTE: The Heat-B screen shows information for an
optional secondary system.
NOTE: Mini-5 systems with software version 1.04.042
or later will not display pump data.
98
Custom Language Downloaded
Custom Language Uploaded
Fill Valve Closed
Fill Valve Open
Heat Off
Heat On
Logs Downloaded
Pump Cycles Total Reset
Pump Off
Pump On
Red Stop Button Pressed
Setup Value Changed
System Power Off
System Power On
System Settings Downloaded
System Settings Uploaded
USB Disabled
USB Drive Inserted
USB Drive Removed
User Maintenance Count Reset
334129S
Appendix A - ADM
Errors
CAN: 24 VDC power supply voltage reading (18-28
VDC)
DI: System Digital Inputs
0: Drum Empty
1: Drum Low
2: Pump Cycle Switch Up
3: Pump Cycle Switch Down
DO: System Digital Outputs
0: Pump Solenoid
1: Not Used
2: Not Used
3: Not Used
The Errors screens store a maximum of 200 errors. See
Error Codes. Download the errors list in the USB logs.
See Appendix B - USB Data, page 105.
Diagnostic - A
ISO DI: Customer Digital Inputs
See Connect PLC (Hard Wired Interface Version),
page 25.
ISO DO: Customer Digital Outputs
See Connect PLC (Hard Wired Interface Version),
page 25.
Fan: Current to fan
Heat Soak: Set time for Platen to heat after the Platen
has reached set temperature.
Life Cycles: Total number of pump cycles over the life
of the system.
MZLP 1: Temperature on MZLP 1.
•
32-160°F (0-71°C)
Pump Sol: Current draw of Pump solenoid.
•
•
(0 mA - off)
(150-250 mA - on)
This screen shows details of various items to aid in
troubleshooting the system. This screen can be hidden
by de-selecting “Enable Diagnostics Screen” on the
System 3 screen. The flow rate updates every 15–20
seconds with average flow rate over the last 15–20
seconds.
USB DL%: Percentage complete, only applies when
downloading USB data. 5 downloads will occur.
NOTE: Diagnostic - B shows information for an optional
secondary system.
Weight: Weight of material dispensed over the life of
the system.
The following information is displayed.
XFMRTemp: Temperature of the Transformer
temperature sensor.
A
B
C
Diagnostic Data
Pump CPM: Pump cycles per minute.
Current Draw
RTD Reading
Duty Cycle
334129S
99
Appendix A - ADM
Setup Screens
NOTE: It is important to set all settings in the System
screens correctly to ensure optimal system
performance.
Password
If the password is not “0000”, the password must be
entered to access the setup screens.
Enable Tandem System: Enable all secondary system
ADM screens.
Heat Soak: Time for to preheat after all zones have
reached their target temperatures. Pump cannot turn on
until timer is complete. The heat soak is a user-defined
time.
•
•
Range: 1-120 minutes
0 disables heat soak
Pump Inactive Timeout: If no Pump movement is
detected or either Pump for (x) amount of time, all
heated zones enter setback mode. After an additional
amount of time (x), the heat will turn off.
•
•
(x) Range: 0-120 minutes
0 disables heat soak
NOTE: The pump inactive timeout will not be displayed
on Mini-5 systems with software versions 1.04.042 or
later.
System 2
System 1
Enter low and high temperatures for an alarm or
warning to occur.
External Pump Control: Enable feature that
automatically turns on and off the Pump when using a
handheld dispense gun with an integrated trigger
switch.
Advanced 1
Enable Diagnostic Screen: Choose whether to show
the Diagnostic screen.
Enable Temp. Adjustments: Allows temperature
adjustments on the Heat-A and Heat-B Run screens.
Enable Pump Autostart: Automatically turns the Pump
on after reaching setpoint temperature and heat soak is
complete.
100
334129S
Appendix A - ADM
Language: Language displayed on the screen.
Date Format: Choose the format of the date.
Date: Set the date.
material set temperatures are less than 200° F (93° C),
the Slow option may be best for the application.
Advanced 3
Time: Set the time.
Enter Password: If not “0000”, the Setup screens will
be password protected.
Screen Saver: The screen will go black after the set
amount of time.
Silent Mode: Disable ADM sounds.
Advanced 2
Disable USB Downloads/Uploads: Disables use of
the USB for downloading and uploading.
Disable USB Log Errors: When disabled, the system
will not warn the user when logs are full. If the logs are
full, the oldest data will be overwritten.
Download Depth: Last _ Days: The USB download will
provide data as old as the number of days entered. Old
data may be in memory but will not be downloaded if
older than the number of days entered.
Temperature Units: Units of measure for displayed
temperatures.
Mass Units: Units of measure for mass.
Specific Gravity: Required to convert the volume
dispensed to mass dispensed for tracking the total
weight and flow rate. When the specific gravity value is
populated, the total mass dispense since the last total
weight reset is shown on the Home screen and the
mass flow rate is shown on the Diagnostic screen.
NOTE: If the Specific Gravity is set to zero, the Home
screen will display a cycle counter instead of grams or
pounds.
Heat Rate Option: Control option where the user can
select the rate at which heat is applied to all zones
enabled or selected. Three options are available,
Normal (default), Fast, and Slow. The Warm Up system
time would be shortest for the Fast option, then the
Normal, and longest if the Slow option is selected. If the
334129S
101
Appendix A - ADM
Advanced 4
To update the software:
Advanced 4 screen allows the user to view the software
contents within the Therm-O-Flow system, or to
reprogram the system with a software update.
To view the software contents, press the
soft key
icon. The screen will display the system software part
numbers and version numbers as shown below.
1. Transfer the updated TOF .gti file (with a filename
containing “17C050”) onto a USB stick. Place the
file in a "\GRACO\SOFTWARE\" subdirectory.
2. Insert a black programming token into the token
slot of the ADM.
3. Insert the USB stick into the USB slot of the ADM. If
the USB download option is selected, a graphic of
a USB stick will appear after the download process
is completed. The graphic will appear with a
pull-down option control which allows the user to
select the file to transfer to the programming token.
4. If more than one Therm-O-Flow .gti file is present in
the “GRACO/SOFTWARE/” directory on the USB
stick, select the correct file to transfer using the
pull-down selection control.
5. Press the
soft key icon to start the USB to
token programming process.
If the software contents do not fit onto one screen, the
user can navigate down to the next page by pressing
the down arrow key.
6. During the file transfer process, a progress bar will
be displayed with a percentage completed
indicator below. This step may take a few minutes
to complete.
Press the right arrow key to view the serial numbers of
the software displayed on the next screen.
7. Once the percentage indicator reached 100%, the
To reprogram the system with updated software, press
the
soft key icon on the main Advanced 4 screen.
The screen will appear as shown below.
bottom right soft key will change to
. Press the
soft key to update the system. To update the
system (or another Therm-O-Flow system) at a later
time, remove the token and reinsert it with a power
cycle.
To exit the screen, press the “X” key until the main
home run screen is shown.
102
334129S
Appendix A - ADM
Heat - A
Use these screens to set target and setback
temperatures for the Pump, Platen, and zones. Select
which system needs to use the heated accessory.
Zone Types:
•
•
•
•
•
•
•
Hose
Gun
PGM
Flowmeter
Pressure Regulator
Manifold
Other
NOTE: To ensure accurate hose and gun temperatures,
set hose as zone 1, 3, 5, 7, 9, or 11 when connected to
MZLP and a heated hose.
NOTE: Pump settings will not be displayed on Mini-5
systems with software versions 1.04.042 or later.
334129S
103
Appendix A - ADM
Maintenance - A
Gateway 1 and 2
If the Therm-O-Flow system has a communication
gateway module (CGM) installed, an additional
“Gateway” chapter containing 1 or 2 pages will be
available in the setup screens. These pages enable the
user to set the CGM IP or device address, configure the
field bus protocol selections, and enable the user to
view the mapping information programmed into the
CGM module. The screens shown below illustrate the 2
pages provided if an Ethernet I/P CGM module is
installed. Refer to manual 3A5186 for information on
mapping and the screens available for the other field
bus options.
The system will notify the user at the set interval that
maintenance is required. The fields in boxes can be
edited by the user. “Due” and “Current” are both the
number of cycles since the last reset. “Interval” is the
set number of cycles between maintenance
notifications. “Lifetime” is the number of cycles in the
lifetime of the system.
NOTE: The lifetime cycle count will only be reset if the
ADM is replaced.
NOTE: Maintenance screens will not be displayed on
Mini-5 systems with software versions 1.04.042 or later.
Schedule
Use this screen to set times that the system will
automatically enable and disable heating. See
Schedule, page 36.
104
334129S
Appendix B - USB Data
Appendix B - USB Data
Access Files
The system can store 250,000 entries in its logs and the
system adds a new entry to the logs every 15 seconds.
This means the system stores 1041 hours of system
operation data, or 43 days of around-the-clock
operation. Once full, the system will overwrite the
oldest data.
All files downloaded from the USB are put in a
DOWNLOAD folder on the stick drive. For example:
“E:\GRACO\12345678\DOWNLOAD\”. The 8-digit
numeric folder name matches the 8-digit ADM serial
number, which is located on the back of the ADM.
When downloading from multiple ADMs, there will be
one sub-folder in the GRACO folder for each ADM.
NOTE: To prevent losing any data, never go more than
43 days without downloading the logs.
The log files should be opened in a spreadsheet
program.
Download
NOTE: If emailing the files, zip (compress) them to
minimize file size.
NOTICE
Uploading an edited system configuration file can
damage the system. Never put a modified
SETTINGS.TXT file in the UPLOAD folder on the
flash drive.
NOTE: The event log, error log, system settings, and
system language files are all downloaded in this
procedure.
1. Insert USB flash drive into USB port.
NOTE: Flash drive must be 8 GB or smaller.
2. The menu bar and USB indicator lights indicate that
the USB is downloading files. Wait for USB activity
to complete. A pop-up will be present until the
transfer is complete if it is not acknowledged.
Upload
Upload a system configuration file and/or a custom
language file. See System Settings File, page 106 or
System Language File, page 107.
1. If necessary, follow the Download Instructions,
page 105, to automatically generate the proper
folder structure on the USB flash drive.
2. Insert USB flash drive into USB port of computer.
3. The USB flash drive window automatically opens. If
it does not, open USB flash drive from within
Windows Explorer.
4. Open Graco folder.
NOTE: If the pop-up screen does not appear, the flash
drive is not compatible with the ADM. Try a different
flash drive.
5. Open system folder. If working with more than one
system, there will be more than one folder within
the Graco folder. Each folder is labeled with the
corresponding serial number of the ADM. (The
serial number is on the back of the module.)
NOTE: The system can log up to 45 mb of additional
data per week, depending on system operation.
6. If installing the system settings file, place
SETTINGS.TXT file into UPLOAD folder.
7. If installing the custom language file, place
DISPTEXT.TXT file into UPLOAD folder.
8. Remove USB flash drive from computer.
9. Install USB flash drive into Therm-O-Flow system
USB port.
10. The menu bar and USB indicator lights indicate that
the USB is uploading files. Wait for USB activity to
complete.
334129S
105
Appendix B - USB Data
11. Remove USB flash drive from USB port.
NOTE: If a custom language file was installed, users
can now select the new language from the Language
drop-down menu.
NOTE: If the SETTINGS.TXT or DISPTEXT.TXT files
remain in the UPLOAD folder, they will be uploaded
every time the USB drive is inserted into the
corresponding ADM. To avoid unintentionally
overwriting system settings, delete the files from the
UPLOAD folders on the USB drive after the upload is
complete.
USB Logs
During operation, the Therm-O-Flow stores system and
performance related information to memory in the form
of log files. The Therm-O-Flow maintains the events,
data, GCA, Black Box, and Diagnostics logs. Follow the
Download Procedure, page 105, to retrieve log files.
Events Log
The event log (1-EVENT.CSV) maintains a record of the
last 175,000 events. Each event record in the log file
contains the date and time the event occurred, the
event type, event code, and event description.
Data Log
The data log (2-DATA.CSV) tracks the setpoint and
actual temperatures every 15 seconds. This log can
store up to 250,000 lines of data.
The system stores 1041 hours of system operation
data, or 43 days of around-the-clock operation. Once
full, the system will overwrite the oldest data.
Change Log
GCA Log
This log (4-GCA.CSV) lists the installed GCA modules
and their respective software versions.
Black Box, Diagnostics Log
These logs (5-BLACKB.CSV, 6-DIAGN.CSV) are
designed to provide useful information to Graco when
calling for technical assistance.
System Settings File
NOTICE
Uploading an edited system configuration file can
damage the system. Never put a modified
SETTNGS.TXT file in the UPLOAD folder on the
flash drive.
The system configuration settings file name is
SETTINGS.TXT and is stored in the DOWNLOAD folder.
A system configuration settings file automatically
downloads each time a USB flash drive is inserted. Use
this file to back up system settings for future recovery
or to easily replicate settings across multiple
Therm-O-Flow systems. Refer to the Upload
Instructions, page 105, for how to use this file.
It is recommended to retrieve the SETTINGS.TXT file
after all system settings are set as desired. Store the file
for future use as a backup in case the settings are
changed and need to be quickly changed back to the
desired setup.
NOTE: System settings may not be compatible
between different versions of the Therm-O-Flow
software.
The change log (3–CHANGE.CSV) tracks the changes
to setpoint and setback temperatures.
106
334129S
Appendix B - USB Data
System Language File
The system language file name is DISPTEXT.TXT and is
stored in the DOWNLOAD folder.
A system language file automatically downloads each
time a USB flash drive is inserted. If desired, use this
file to create a user-defined set of custom language
strings to be displayed within the ADM.
The system is able to display the following Unicode
characters. For characters outside of this set, the
system will display the Unicode replacement character,
which appears as a white question mark inside of a
black diamond.
Create Custom Language
Strings
The custom language file is a tab-delimited text file that
contains two columns. The first column consists of a
list of strings in the language selected at the time of
download. The second column can be used to enter the
custom language strings. If a custom language was
previously installed, this column contains the custom
strings. Otherwise the second column is blank.
Modify the second column of the custom language file
as needed and then follow the Upload Instructions,
page 105, to install the file.
•
U+0020 - U+007E (Basic Latin)
•
U+00A1 - U+00FF (Latin-1 Supplement)
The format of the custom language file is critical. The
following rules must be followed in order for the
installation process to succeed.
•
U+0100 - U+017F (Latin Extended-A)
1. The file name must be DISPTEXT.TXT.
•
U+0386 - U+03CE (Greek)
•
U+0400 - U+045F (Cyrillic)
2. The file format must be a tab-delimited text file
using Unicode (UTF-16) character representation.
3. The file must contain only two columns, with
columns separated by a single tab character.
4. Do not add or remove rows to the file.
5. Do not change the order of the rows.
6. Define a custom string for each row in the second
column.
334129S
107
Dimensions
Dimensions
Ram Mounting and Clearance
A
B
C
D
E
F
G
J
K
L
M
P
in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm)
40
(1016)
Height (H)
28
(711)
Fully Raised
Fully Lowered
108
36
(914)
22
(558)
24
(609)
40.8
(1036)
29.7
(754)
11
(279)
6
(152)
1
(25.4)
60
(1524)
62
(1574)
Dimensions
74.3 in (1887 mm)
57.3 in (1455 mm)
334129S
Dimensions
15:1
A
B
D
E
G
K
L
M
N
P
in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm)
40
(1016)
Height (H)
28
(711)
Fully Raised
Fully Lowered
334129S
22
(558)
24
(609)
29.7
(754)
6
(152)
1
(25.4)
48
(1219)
38.5
(977)
62
(1574)
Dimensions
73.5 in (1866 mm)
56.5 in (1435 mm)
109
Technical Specifications
Technical Specifications
Therm-O-Flow 20 Hot Melt System
U.S.
Metric
1.24 in²
0.884 in²
8 cm²
5.7 cm²
Merkur and NXT
President
Pump Cycles per 1 Gallon (3.8 liters)
11.7 in³
3.8 in³
192 cm³
62.3 cm³
Merkur and NXT
President
President 4.25 in
Maximum Pump Operating Temperature
100 psi
100 psi
100 psi
0.7 MPa, 7 bar
0.7 MPa, 7 bar
0.7 MPa, 7 bar
400°F
400°F
204°C
204°C
Air inlet size
Air motor sound data
Wetted Parts
Displacement Pump Effective Area
1/2 npsm(f)
See Air Motor instruction manual.
carbon steel, brass, chrome, zinc, nickel plating, stainless steel (304, 316,
440, and 17-4 PH), alloy steel, ductile iron, PTFE
Merkur and NXT
President
Volume per Cycle
Merkur and NXT
President
Ram Maximum Input Pressure
Merkur and NXT
President
Pump Fluid Outlet Size
Merkur and NXT
President
Maximum Fluid Working Pressure
23:1
36:1
70:1
President 4.25 in
Maximum Air Input Pressure (Pumps)
23:1
36:1
70:1
President 4.25 in
Power Requirements
Compressed Air (typical)
110
21
61
1 in npt(f)
1/2 in npt(f)
2300 psi
3000 psi
3000 psi
1800 psi
15.9 MPa, 159 bar
20.7 MPa, 207 bar
20.7 MPa, 207 bar
12.6 MPa, 125 bar
100 psi
82 psi
43 psi
120 psi
0.7 MPa, 7 bar
0.57 MPa, 5.7 bar
0.29 MPa, 2.9 bar
0.8 MPa, 8.3 bar
25–50 scfm
334129S
Technical Specifications
Therm-O-Flow 20 Hot Melt System
Voltage (as selected)
220/240 V, 3-phase, 50/60 Hz
380/400 V, 3-phase, 50/60 Hz
470/490 V, 3-phase, 50/60 Hz
575 V, 3-phase, 50/60 Hz
Peak Consumption
(includes drum melt grid, pump, and a 6kVa transformer for the 230 V hoses and accessories)
Standard melt grid platen with
President pump
Standard melt grid platen with Merkur
or NXT pump
Smooth melt grid platen with
President pump
Smooth melt grid platen with Merkur
or NXT pump
334129S
6.4 kVa
8.7 kVa
6.4 kVa
8.7 kVa
111
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification
of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be
returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or
workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental
or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder,
or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered
into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu
que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés,
à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
Sealant and Adhesive Dispensing Equipment
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor, go to www.graco.com, or call to identify the nearest
distributor.
If calling from the USA: 1-800-746-1334
If calling from outside the USA: 0-1-330-966-3000
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 334129
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2016, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision S, October 2021

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