Graco 311208H - Therm-O-Flow 200, U.S. Owner's Manual

Graco 311208H - Therm-O-Flow 200, U.S. Owner's Manual | Manualzz
Instructions
200 Liter (55 Gallon) Drum Size
®
Therm-O-Flow 200
311208H
EasyKey™ Hot Melt Drum Unloaders
For applying hot melt sealant and adhesive materials.
Maximum Operating Temperature (All Models): 400°F (204°C)
NXT 2200 Powered Unloaders, Models A-1 and A-4
2300 psi (15.9 MPa, 159 bar) Maximum Fluid Working Pressure
125 psi (0.85 MPa, 8.5 bar) Maximum System Air Pressure (Ram)
100 psi (0.7 MPa, 7 bar) Maximum Air Motor Pressure
NXT 3400 Powered Unloaders, Models A-2 and A-5
3000 psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure
125 psi (0.85 MPa, 8.5 bar) Maximum System Air Pressure (Ram)
82 psi (0.57 MPa, 5.7 bar) Maximum Air Motor Pressure
NXT 6500 Powered Unloaders, Models A-3 and A-6
3000 psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure
125 psi (0.85 MPa, 8.5 bar) Maximum System Air Pressure (Ram)
43 psi (0.29 MPa, 2.9 bar) Maximum Air Motor Pressure
Important Safety Instructions.
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for ContentsWarnings 3
TI7936-lr
ContentsWarnings 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . 8
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 10
Heat Control Zone Selection . . . . . . . . . . . . . . . 12
Air Line Modules . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . 13
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Location Requirements . . . . . . . . . . . . . . . . . . . 13
Hose Installation and Care . . . . . . . . . . . . . . . . 14
Mechanical Setup . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Setup . . . . . . . . . . . . . . . . . . . . . . . . . 15
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connecting the Electrical Control Panel to a
Power Source . . . . . . . . . . . . . . . . . . . . . . . 17
Overview of the Temperature Controller Settings 20
Purging the System . . . . . . . . . . . . . . . . . . . . . . 20
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . 21
Main Power Disconnect . . . . . . . . . . . . . . . . . . . 21
EasyKey Display and Keypad . . . . . . . . . . . . . . 21
LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
EasyKey Display Screens . . . . . . . . . . . . . . . . . . . 23
Power Up Screens . . . . . . . . . . . . . . . . . . . . . . 23
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Purge Before Using Equipment . . . . . . . . . . . . . 29
Set Values on EasyKey . . . . . . . . . . . . . . . . . . . 29
Material Loading . . . . . . . . . . . . . . . . . . . . . . . . 29
System Heat Up . . . . . . . . . . . . . . . . . . . . . . . . 31
Prime Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Prime System . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure Relief Procedure . . . . . . . . . . . . . . . . 34
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Ram Pressure Relief Procedure . . . . . . . . . . . . 35
Drum Changing . . . . . . . . . . . . . . . . . . . . . . . . . 36
System Shutdown . . . . . . . . . . . . . . . . . . . . . . . 38
Dual Ram Cross-Over Installation . . . . . . . . . . . . 39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ground Fault Interrupt . . . . . . . . . . . . . . . . . . . . 40
Power in a Tandem System . . . . . . . . . . . . . . . . 40
Resetting the Ground Fault Interrupt . . . . . . . . . 40
Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . 40
Ram Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 42
2
Heated Pump Troubleshooting . . . . . . . . . . . . . . . 43
Air Motor Troubleshooting . . . . . . . . . . . . . . . . . . 43
Electrical Control Panel Troubleshooting . . . . . . 44
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Ground Fault interrupt . . . . . . . . . . . . . . . . . . . . 45
Power in a Tandem System . . . . . . . . . . . . . . . . 45
Servicing Wipers . . . . . . . . . . . . . . . . . . . . . . . . 45
Pump Removal and Replacement . . . . . . . . . . . . 47
Replacing Heater Bands and Sensors in Pump
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 52
240 VAC Supply - Internal Control Box . . . . . . . 52
Electrical Control Schematics . . . . . . . . . . . . . . 53
Electrical Connections Schematic . . . . . . . . . . . 58
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
All Models Supply Unit . . . . . . . . . . . . . . . . . . . . 60
Therm-O-Flow Pump . . . . . . . . . . . . . . . . . . . . . 62
Therm-O-Flow Pump Module using NXT 3400
and NXT 6500 Models . . . . . . . . . . . . . . . . 64
Therm-O-Flow Pump Module using NXT 2200
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Series A Heated Pump . . . . . . . . . . . . . . . . . . . 68
Heated Platens . . . . . . . . . . . . . . . . . . . . . . . . . 70
Platen Coil Checking . . . . . . . . . . . . . . . . . . . . . 72
EasyKey Assembly, Part No. 253147 . . . . . . . . 73
Swirl Kit, Part No. 253263 . . . . . . . . . . . . . . . . . 74
Drip Shield Mount Kit, Part No. 253479 . . . . . . . 75
Drum Ram Post Saddle Clamp, Part No. C32463 76
Heavy Duty Drum Band Clamp, Part No. 918395 77
Fiber Drum Reinforcement Clam Shell Clamp,
Part No. 918397 . . . . . . . . . . . . . . . . . . . . . 78
Vent Hood Accessory Kit for 6-1/2 In. Ram,
Part No. 233559 . . . . . . . . . . . . . . . . . . . . . 79
Advanced Units . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Light Tower Kit (253547) . . . . . . . . . . . . . . . . . . 80
Drum Low and Empty Sensor Kit 253559 . . . . . 82
Ethernet Kit (253566) . . . . . . . . . . . . . . . . . . . . 83
Maintenance Call Kit (253548) . . . . . . . . . . . . . 90
Discrete I/O Kit (253567) . . . . . . . . . . . . . . . . . . 92
All Models Control Panel Component Layout . . . 94
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 98
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 98
311208H
Warnings
Warnings
The following 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 symbol refers to procedure-specific risk. Refer back to these
warnings. Additional product-specific warnings may be found throughout the body of this manual where applicable.
WARNING
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
SPLATTER HAZARD
During blow off of platen splatter may occur.
• Use minimum drum removal air pressure.
MOVING PARTS HAZARD
Moving parts can pinch 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 in this manual. Disconnect power or air supply.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s 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.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• 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.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco
replacement parts only.
• Do not alter or modify equipment.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco 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.
• Do not operate when fatigued or under the influence of drugs or alcohol.
• Comply with all applicable safety regulations.
311208H
3
Warnings
WARNING
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear.
• Clothing and respirator as recommended by the fluid and solvent manufacturer.
• Gloves.
• Hearing protection.
SKIN INJECTION HAZARD
High-pressure fluid from gun, 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.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
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:
• 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 equipment and conductive objects in work area. See Grounding instructions.
• Use only grounded hoses.
• Hoses are for indoor use only. Do not get hose wet.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a fire extinguisher in the work area.
4
311208H
Warnings
311208H
5
Overview
Overview
How the Therm-O-Flow 200 Works
A heated platen melts the sealant or adhesive and
directs the molten material to the pump inlet. The material then travels through a heated Check–Mate pump
and heated fluid moves to the application tool.
Model Numbers
This manual refers to the typical model number listed
below when defining parts in your application. The
model number stamped on your machine defines the
equipment in the following 10 categories:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Motor
Heated Platen
Follower Seals
Drum Ram
Number of Heat Zones
Heat Controls Supply Voltage
Control Panel
Drum Unloader Options
Application Accessories
Hose Kit Layout
Typical Model Number: TOF200A–D–1–A–1–P–6–2–A–F–1–N–1–1–D–P–N-N
Model
TOF200A
Code A
1
2
55 gal./200 liter Hot Melt Drum Unloader
Code F
Air Motor Selection
NXT 2200 HLS quiet air motor (23:1 Power Ratio)
with pump
NXT 3400 HLS quiet air motor (36:1 Power Ratio)
with pump
Customer’s Power Supply Voltage
2
220/240 Vac 50/60 Hz 3 phase
3
380/400 Vac 50/60 Hz 3 phase
4
470/490 Vac 50/60 Hz 3 phase
5
570/590 Vac 50/60 Hz 3 phase
N
No electrical control panel
3
NXT 6500 HLS quiet air motor (70:1 Power Ratio)
with pump
N
No air motor or pump
B
Standard unit – uses EasyKey
4
NXT 2200 HLS quiet air motor (23:1 Power Ratio)
with pump and heavy duty packings
A
Advanced unit – EasyKey with discrete I/O,
Ethernet, light tower, and proximity switches.
5
NXT 3400 HLS quiet air motor (36:1 Power Ratio)
with pump and heavy duty packings
T
Tandem primary unit – Unloader A in a primary
unit.
6
NXT 6500 HLS quiet air motor (70:1 Power Ratio)
with pump and heavy duty packings
S
Tandem secondary unit – Unloader B in a tandem
unit.
N
No electrical control panel
Code B
Heated Platen Style
Code G
Display and Interface Options
A
Mega-Flo™ high flow drum platen
B
Standard fin design drum platen
E
English
C
Smooth bottom (no fin) drum platen
F
French
Tire Plate Seal Style
G
German
2 Black EPDM/EPDM, SS wire braid 400 F hose
wipers w/spring retention
S
Spanish
J
Japanese
1 lower Black EPDM/Chlorobutyl, SS wire braid
375oF hose wiper and 1 upper White Silicone
375oF T-wiper
C
Chinese (Simplified)
Code C
1
2
3
4
Code D
Code H
o
1 lower Black EPDM/Chlorobutyl, SS wire braid
400oF hose wiper and 1 upper Green Silicone,
fiberglass braid 400oF, hose wiper
2 White Silicone 250oF T-Wipers
Code J
Language Selection
Drum Clamp Options
1
Fiber drum reinforcement clam shell
2
Heavy duty drum band clamp
3
Drum ram post saddle clamps
N
Code K
Drum Ram Style
N
P
Pneumatic Ram
Y
H
Hydraulic Ram
Code L
Code E
6
If Code E option N is selected, then Codes F and G must also be
option N and Code H is ignored.
Product Description
No drum clamp option
Vent Hood Kit
None
Vent Hood Kit
Swirl Solenoid Kit
Number of Heat Zones
N
None
6
6 Zones
1
Single Swirl Solenoid Kit
8
8 Zones
2
Dual Swirl Solenoid Kit
N
No electrical control panel (includes pneumatic
controls, independently mounted)
311208H
Overview
N
Code M
None
Type of Hose Connection
P
Manual gun bottom feed with Swirl & .030 orifice
None
Q
Manual gun top feed with Swirl & .030 orifice
1
Single hose and end-of-hose device
R
243694 with Swirl & .030 orifice
2
Dual hose and end-of-hose device from tee kit
S
3
Hose to (compensator or regulator) with either
(second hose to dispense valve and end-of-hose
device) or to (end-of-hose device) without a second
hose.
N
244909 with Swirl & .030 orifice
Code Q
Hose 2
B
-8 (.41” ID) by 10 feet, 3000 psi
C
-8 (.41” ID) by 15 feet, 3000 psi
Hose 1
D
-8 (.41” ID) by 10 feet for Air Swirl, 3000 psi
-8 (.41” ID) by 10 feet, 3000 psi
E
-8 (.41” ID) by 15 feet for Air Swirl, 3000 psi
C
-8 (.41” ID) by 15 feet, 3000 psi
H
-10 (.51” ID) by 6 feet, 3000 psi
D
-8 (.41” ID) by 10 feet for Air Swirl, 3000 psi
J
-10 (.51” ID) by 10 feet, 3000 psi
-8 (.41” ID) by 15 feet for Air Swirl, 3000 psi
K
-10 (.51” ID) by 15 feet, 3000 psi
H
-10 (.51” ID) by 6 feet, 3000 psi
L
-10 (.51” ID) by 20 feet, 3000 psi
J
-10 (.51” ID) by 10 feet, 3000 psi
M
-10 (.51” ID) by 25 feet, 3000 psi
K
-10 (.51” ID) by 15 feet, 3000 psi
N
None
L
-10 (.51” ID) by 20 feet, 3000 psi
P
-12 (.62” ID) by 10 feet, 3000 psi
M
-10 (.51” ID) by 25 feet, 3000 psi
Q
-12 (.62” ID) by 15 feet, 3000 psi
N
None
R
-12 (.62” ID) by 20 feet, 3000 psi
-12 (.62” ID) by 10 feet, 3000 psi
S
-12 (.62” ID) by 25 feet, 3000 psi
-12 (.62” ID) by 15 feet, 3000 psi
T
-16 (.87” ID) by 6 feet, 3000 psi
-12 (.62” ID) by 20 feet, 3000 psi
U
-16 (.87” ID) by 10 feet, 3000 psi
-12 (.62” ID) by 25 feet, 3000 psi
V
-16 (.87” ID) by 15 feet, 3000 psi
T
-16 (.87” ID) by 6 feet, 3000 psi
W
-16 (.87” ID) by 20 feet, 3000 psi
U
-16 (.87” ID) by 10 feet, 3000 psi
X
-16 (.87” ID) by 25 feet, 3000 psi
V
-16 (.87” ID) by 15 feet, 3000 psi
Y
-20 (1.13” ID) by 10 feet, 3000 psi
W
-16 (.87” ID) by 20 feet, 3000 psi
Z
-20 (1.13” ID) by 15 feet, 3000 psi
-16 (.87” ID) by 25 feet, 3000 psi
Code R
-20 (1.13” ID) by 10 feet, 3000 psi
E
Manual gun with top feed swivel
-20 (1.13” ID) by 15 feet, 3000 psi
F
Manual gun top feed with electric switch
End of Hose 1 Device
G
Manual gun with bottom feed swivel
240V 23:1 heated pressure compensator valve
H
Manual gun with bottom feed with electric switch
240V 51:1 heated pressure compensator valve
J
Air operated heated dispense valve
C
Heated distribution manifold
K
Air operated high flow heated dispense valve
D
Heated air operated mastic pressure regulator
L
Air operated snuff-back heated dispense valve
Manual gun with top feed swivel
M
45” distribution header with valve
F
Manual gun top feed with electric switch
N
None
G
Manual gun with bottom feed swivel
P
Manual gun bottom feed with Swirl & .030 orifice
H
Manual gun with bottom feed with electric switch
Q
Manual gun top feed with Swirl & .030 orifice
J
Air operated heated dispense valve
R
243694 with Swirl & .030 orifice
Air operated high flow heated dispense valve
S
244909 with Swirl & .030 orifice
Code N
B
E
P
Q
R
S
X
Y
Z
Code P
A
B
E
K
L
Air operated snuff-back heated dispense valve
M
45” distribution header with valve
TOF200A
Code
-
A
-
B
-
C
-
D
-
E
-
F
-
G
-
H
End of Hose 2 Device
-
J
-
K
-
L
-
M
-
N
-
P
-
Q
R
Model Code Layout
311208H
7
Overview
Component Identification
Before installing the system you should be familiar with
all the system components. See FIG. 1 for
Therm-O-Flow system components.
Air Line Components
The following components are included with the unit.
See FIG. 1.
•
System Master Air Valve (A) is used to shut off the
air supply to the system.
•
Air Line Filter (B) removes dirt and moisture from
the compressed air supply.
•
Air Motor Air regulator (C) and (V) control the outlet
pressure by adjusting the air pressure to the air
motor.
•
Air Motor Master Air Valve (D) shuts off the air supply to the air motor and bleeds trapped air from the
air motor.
•
Air motor Air Supply Hose connects the air regulator
to the air motor.
Air and Fluid Hoses
The Therm-O-Flow 200 requires Graco single-circuit material hoses rated at a maximum of 1250
watts.
When installing a system make sure:
•
All air and fluid hoses are properly sized for the system.
Heat Control Zone Selection
The Therm-O-Flow 200 has 6 or 8 heat zones. Zones 1
and 2 are always used for the heated drum platen and
the heated pump. Zones 3 and 4, 5 and 6, and 7 and 8
are each available as paired zones through 16-pin connectors. The heated hoses have a 16-pin connector on
the inlet end cable, and an 8-pin connector on the outlet
end cable. All heated valves, manifolds, and heaters are
equipped with an 8-pin matching connector.
Pneumatic Control Panel
The pneumatic control panel includes the following. See
FIG. 1.
•
Auto Depressurization Valve exhausts air from the
air motor at shutoff. The built-in control delays
start-up to allow material to thoroughly heat.
•
Ram Air Regulators (N, P) control the air pressure
to the ram. There are separate air regulators to control the ram pressure in the up and down directions.
•
Ram Up/Down Lever (R) changes the direction of
the ram.
•
Blow-off air regulator (T) controls the air pressure to
the platen blow-off valve.
•
Platen Blow-off Valve (S) directs air to the underside
of the platen when depressed.
User Display (EasyKey)
•
A simple user interface consisting of an LCD display
and keypad.
•
Keypad contains the buttons which control the
Therm-O-Flow 200 operations.
Vent Hood Kit (if supplied)
The vent hood assembly is designed to efficiently draw
fumes to the factory exhaust system during drum
change-out. This assembly requires a connection to a
factory ventilation system that draws a minimum air flow
of 8.4 m3/min (300 scfm). This kit is recommended for
Polyurethane Reactive (PUR) applications.
8
311208H
Overview
Component Identification
M
U
AB
L
W
J
AA
S
K
T
C
R
TI8134A
A
V
N
P
E
D
Y,Z
F
G
H
B
TI8158A
TI7936A
X
FIG. 1: Component Identification
Key:
A
B
C
D
E
F
G
H
J
K
L
M
System Master Air Valve (bleed-type)
Air Line Filter
Air Motor Air Regulator (bleed-type)
Air Motor Master Air Valve (bleed-type)
Ram
Heated Pump
Platen
Air Inlet (1/2” npt)
Electrical Control Panel
Main Power Disconnect Switch
EasyKey Display and Keypad
Pneumatic Control Panel
311208H
N
P
R
S
T
U
V
W
X
Y
Z
AA
AB
Ram Up Air Regulator
Ram Down Air Regulator
Ram Up/Down Lever
Platen Blow-off Valve
Blow-Off Air Regulator
Electrical Power Input
Air Motor Enable Solenoid/Depressurization Valve
NXT Air Motor
Air Motor Remote Piloted Air Regulator
Ram Plate Bleed Stick
Drum Blow Off Valve (behind ram plate bleed stick Y)
Maintenance Call
Ethernet Connection
9
Typical Installation
Typical Installation
The typical installation discussed and shown is only a
guide for selecting and installing system components
and accessories. See FIG. 2. Contact your Graco distributor for help in designing a system to suit your particular
needs.
4. If you are installing a vent hood, make sure the ram
is installed near a connection to the factory ventilation system.
The air-powered ram extruder forces high viscosity fluids into the intake valve of the fluid pump. Wiper rings
and other accessory equipment for use with this ram are
listed in Technical Data on page 97.
Before you install the system you should be familiar with
all the parts and system requirements for the
Therm-O-Flow 200.
System Accessories and Modules
For information about converting the ram from air to
hydraulic operation, contact your Graco distributor.
Power Requirements
See Technical Data on page 97.
Selecting a Location for the Ram
Refer to the Dimensions drawing on page 96 for ram
mounting and clearance dimensions.
When selecting a location for the ram keep the following
in mind:
1. There should be sufficient space for installing and
using the equipment.
•
Make sure there is sufficient overhead clearance for the pump and ram when the ram is in
the fully raised position.
•
If you are installing a vent hood make sure there
is sufficient horizontal clearance for it.
•
Make sure the air regulators for the pump and
ram are fully accessible.
•
Make sure there is easy access to an appropriate electrical power source. The National Electrical Code requires 3 feet of open space in front
of the electrical panel.
2. Make sure that you will be able to level the base of
the ram using metal shims.
3. When you bolt the ram to the floor the anchors
should be long enough to prevent the unit from tipping. Refer to the Dimensions drawing on page 96
for more information.
10
311208H
Typical Installation
Typical Installation (Advanced Unit Shown)
101 Electrical Control Panel
102 Ram Module
104 Heated Follower Plate
106 Depressurization Valve/Air Motor Enable Solenoid
109 Pump and Air Motor Assembly
115 Air Motor Mounting Bracket
202 Air Filter
204 Air Motor Remote-Piloted Air Regulator
211 Ram Up/Ram Down Lever
214 System Master Air Valve (required)
226 Main Air Line Inlet
319 Ram Plate Bleed Stick
327 Lower Wiper
329 Upper Wiper
330 Drum Blow Off Valve
332 Drum Low and Empty Sensors
Lift Locations (if air is supplied to the
system and ram lever is set to down)
101
CAUTION
Do not use motor lift ring
to lift entire system. See
ram lift locations, FIG. 2.
109
115
332
211
102
106
TI7937A
319
329
214
226
202
204
327
330
104
TI8158A
FIG. 2: Typical Installation
311208H
11
Typical Installation
Heat Control Zone Selection
The Therm–O–Flow 200 can be ordered with 6 (code
E–6) or 8 (code E–8) heat zones (see Fig.3). Zones 1
and 2 are always used for the heated drum platen and
the heated pump. Zones 3 and 4, 5 and 6, and optional
zones 7 and 8 are each available as paired zones
through a 16–pin connector.
:/.%
#ONTROL
0LATEN
:/.%
#ONTROL
The heated hoses have a 16–pin connector on the inlet
end cable, and an 8–pin connector on the outlet end
cable. All heated valves, manifolds and heaters are
equipped with an 8–pin matching connector. Accessory
cables are available for other possible combinations.
See FIG. 3.
6ALVE 6ALVE 6ALVE (OSE (OSE (OSE :/.%
#ONTROL
:/.%
:/.%
#ONTROL #ONTROL
:/.%
#ONTROL
:/.%
#ONTROL
WATTS
MAX
WATTS
MAX
WATTS
MAX
WATTS
MAX
WATTS
MAX
:/.%
#ONTROL
WATTS
MAX
4)
0UMP
FIG. 3: Heat Control Zone Selection
Air Line Modules
The Air Motor bleed-type master air valve (D) is
required in your system to relieve motor air pressure.
Trapped air can cause the pump to cycle unexpectedly,
which can result in serious bodily injury.
4-Regulator Air Control Module (shown)
For more information, refer to FIG. 1 on page 9. The following components are included with the module:
•
System Master Air Valve (bleed-type) (D) is used to
shut off the air supply to the entire supply unit.
•
Air Motor Master Air Valve (bleed-type) (D) is supplied in your system to relieve air trapped between it
and the air motor when the valve is energized (see
Warning above). This bleed valve should be easily
accessible and located downstream from the air
regulator.
12
•
Air Motor Air Regulator (C) controls the pump outlet
pressure by adjusting the air pressure to the air
motor. It is located on the pneumatic control panel.
•
The Air Motor Enable Solenoid, see FIG. 1 page 9,
letter (X) delays startup to allow material to heat
thoroughly.
•
Ram Air Regulator (N,P) controls the air pressure to
the ram. There are separate air regulators to control
the ram pressure in the up and down directions.
•
Ram Plate Blow-off Valve (S,T) controls the air to
the ram plate blow-off.
Part No. 297401 is used if “None” is selected for
Configurator Code E, F, and G.
Fluid Line Accessories (Typical)
A pressure compensator valve controls fluid pressure to
the gun/valve, and dampens pressure surges. Install the
pressure compensator valve in the position shown in the
Typical Installation using adapters as necessary.
311208H
Installation Procedure
Installation Procedure
CAUTION
Do not use motor lift ring to lift entire system. See lift
locations, FIG. 2.
3. Make sure the air regulators for the pump and ram
are fully accessible, with room to stand directly in
front of the pneumatic control panel and the electrical control panel.
The installation procedure includes:
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.
•
unpacking the ram
5. Apply 50 psi download pressure to ram.
•
locating and installing the ram
•
mechanical setup
6. Wrap the bar with the lifting sling. See FIG. 2 for
proper lift spots.
•
electrically connecting hoses to the electrical control
panel
•
grounding the system
•
connecting the electrical control panel to a power
source
•
connecting to an air source
•
setting controls on the electrical control panel
CAUTION
Do not use motor lift ring to lift entire system. See lift
locations, FIG. 2.
7. Lift off the pallet using a crane or a forklift.
8. Position the ram in the desired location.
9. Level the base of the ram, using metal shims.
Unpacking
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.
10. Bolt the ram to the floor, using anchors that are long
enough to prevent the unit from tipping.
11. If your unit is equipped with optional level controls,
remove from the electrical control panel and twist
into place on top of the electrical control panel.
3. Compare the packing slip against all items in the
box. Report any shortages or other inspection problems immediately.
CAUTION
Do not use motor lift ring to lift entire system. See lift
locations, FIG. 2.
4. Remove the unit from the skid and place it in the
desired location (See “Location Requirements” on
page 13).
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 110 in. [280 cm]).
2. If you are installing a vent hood, make sure there is
sufficient horizontal clearance for it. Locate the ram
near a connection to the factory ventilation system.
311208H
13
Installation Procedure
Hose Installation and Care
1. Do not use hose to pull equipment.
6. Do not clamp, squeeze, or zip tie hose.
7. Minimum bend radius is 8 in. (20.3 cm).
2. Use 2 wrenches to tighten. Torque to 470-550 in-lbs
(53.1-62.1 N•m).
8 in.
(20.3 cm)
8. Do not bend or crimp hose.
3. Do not tape or cover hose.
9. Do not twist hose.
4. Do not flex hose when cold.
10. Use proper length hose.
88
5. Use hose support spring.
14
311208H
Installation Procedure
Mechanical Setup
Electrical Setup
1. Check, and if necessary, tighten the heated hose
connection at the pump outlet.
Electrically Connect Hoses
2. Wrap exposed fittings on the pump outlet with
Nomex insulation and secure insulation using fiberglass tape.
3. Fill displacement pump wet cup 2/3 full with Graco
Throat Seal Liquid (TSL).
4. Back-off all air regulators to their full counterclockwise position.
The ram UP/DOWN lever is shipped inside the
pneumatic control panel and should now be
screwed onto the face of the control.
5. Connect a 1/2 in. (13 mm) air line from an air source
to the system air inlet, see FIG. 1, page 9, letter (H)
capable of delivering a minimum of 15 cfm (0.4
m3/m) at 100 psi (0.7 MPa, 7.0 bar). Do not use
quick disconnects.
The Therm-O-Flow 200 requires Graco single-circuit material hoses rated at a maximum of 1250
watts.
1. Securely tighten the 16-pin electrical connectors on
long heated hose leads into 16-socket receptacles
located on the back of the electrical control panel.
See FIG. 4.
2. Securely tighten the 8-socket electrical connectors
on short heated hose leads into 8-pin receptacle
located on the dispense valves.
Hose One
Hose Two
Hose Three
(Optional)
TI8136A
FIG. 4: Rear View of Electrical Control Box
311208H
15
Installation Procedure
Grounding
Connect Power Source
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.
Ground the supply unit as instructed here and in the
individual component manuals.
To reduce the risk of fire, explosion, or electric shock:
•
Required voltage and amperage is noted on the
control panel label. Also see Table 1. Before running power to the unit, make sure the plant electrical service meets the machine’s electrical
requirements.
1. Open electrical enclosure door and locate the main
disconnect.
2. Have a qualified electrician connect your plant
power to the electrical control panel disconnect
switch according to local codes. A 1-3/8 in. (35 mm)
diameter opening is provided on top of the panel
above the connections. This opening is suitable for a
1 in. npt conduit or strain relief fitting.
Table 1 Electrical Requirements
AC Panel
Voltage
HZ
Phase
220 / 240
50/60
3
380 / 400
50/60
3
470 / 490
50/60
3
570 / 590
50/60
3
Platen
Selection
Full Load
Amps
BB & BC
BA
BB & BC
BA
BB & BC
BA
BB & BC
BA
70
80
42
48
35
40
29
32
The power source conduit is not an adequate
ground for the system. The unit must be bonded
to either the building ground or a true earth
ground.
To reduce the risk of static sparking, ground the pump,
the object being dispensed to, and all other spraying/dispensing equipment used or located in the spraying/dispensing area. Check your local electrical code for
detailed grounding instructions for your area and type of
equipment.
•
Air and fluid hoses: Use only electrically conductive
hoses.
•
Dispensing/Spray Gun: Follow the dispensing/spray
gun grounding instructions.
•
Object material is applied to: Ground according to
your local code.
•
Material drums: Ground according to your 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.
•
Maintain grounding continuity when flushing or
relieving pressure: Follow the instructions in your
separate gun manual for safely grounding your gun
while flushing.
BB = Standard grid platen: 18 Kw
BA = Mega-Flo™ platen: 21 Kw
BC = Smooth bottom platen: 18 Kw
16
311208H
Installation Procedure
Connecting the Electrical
Control Panel to a Power Source
The electrical control panel (FIG. 5) 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.
For information about specific terminal locations and
connections, see Advanced Units on page 80.
To connect the control panel to the electrical source:
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 1”
conduit fitting. It is 1.3” dia. (33mm).
2. Thread 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.
Electrical
Control
Panel
TI7935A
FIG. 5: Electrical Control Panel
Have a trained electrician connect the electrical control
panel (Fig. 5) to a grounded electrical source that has
the required service ratings, see Electrical Requirements on page 16.
CAUTION
If power and grounding connections are not done
properly, the equipment will be damaged and the warranty will be voided. Check the label on the control
box for the proper voltage.
BB = Standard grid platen: 18 Kw
BA = Mega–Flo platen: 21 Kw
BC = Smooth bottom platen: 18 Kw
311208H
17
Installation Procedure
Check the Resistance Between the Supply
Unit and the True Earth Ground.
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.
Have a qualified electrician check the resistance
between each supply unit component 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.
Use a meter that is capable of measuring resistance at this level.
Sensor Resistance Checks.
To reduce risk of injury or damage to equipment, conduct these electrical checks with the main disconnect
OFF.
The package includes up to eight heat sensors and controllers for each of the heated zones. To check sensor
resistance:
1. Make sure the power is off and that the disconnect
switch is in the OFF position.
2. Make electrical resistance checks for the components.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in the RTD Sensors chart below.
Checking Resistance.
Check resistance at ambient room temperature
(63°– 77° Fahrenheit).
RTD Sensors
Zone Component
1
2
3
4
5
6
7
8
18
Ram Plate
Fluid Pump
Dispense Hose 1
Dispense Gun 1
Dispense Hose 2
Dispense Gun 2
Dispense Hose 3
Dispense Gun 3
Terminals
Value Range
2011 & 2012
2051 & 2061
2081 & 2091
2111 & 2121
2261 & 2271
2291 & 2301
2321 & 2331
2351 & 2361
108 +/- 2% ohms
108 +/- 2% ohms
108 +/- 2% ohms
108 +/- 2% ohms
108 +/- 2% ohms
108 +/- 2% ohms
108 +/- 2% ohms
108 +/- 2% ohms
311208H
Installation Procedure
Heater Resistance Checks.
2. Make electrical resistance checks for the components. Refer to Advanced Units on page 80 for wiring diagram information.
To reduce risk of injury or damage to equipment, conduct these electrical checks with the main power disconnect OFF.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in Table 1 on page
16.
Check resistance at ambient room temperature
(63°– 77°F) (17°– 25°C).
To check heater resistance:
1. Make sure the power is off and that the disconnect
switch is in the OFF position.
Table 2 Heaters
Zone
Component
1
Platen
Between
For Unit Voltage Platen Model Code
Terminals
AB, BC, CD, 220/240 VAC
BA
DE, EF, FA
BB, BC
AB, BC, CD, 380/400 VAC
BA
DE, EF, FA
BB, BC
470/490 VAC
BA
BB, BC
AB, BC, CD, 570/590 VAC
BA
DE, EF, FA
BB, BC
Any to GND
Resistance Values (ohms)
16.5Ω +1 / -2
19.5Ω +2 / -3
16.5Ω +1 / -2
19.5Ω +2 / -3
16.5Ω +1 / -2
19.5Ω +2 / -3
16.5Ω +1 / -2
19.5Ω +2 / -3
100,000Ω Min
Table 3 Heaters
Zone
2
Component
Pump
Between Terminals
T1/T3, T2/T3,
B1/B3, B2/B3
T1/T3, T2/T3,
B1/B3, B2/B3
For Unit Voltage Platen Model Code
Any
Any
380/400
470/490
Same
311208H
570/590
Resistance Values (ohms)
192.0 +/- 19.2Ω
BA
BB, BC
BA
BB, BC
BA
BB, BC
19
Installation Procedure
Overview of the Temperature
Controller Settings
Temperature controls are set in the zone configuration
setup screens. See Run Screens on page 23 for information about setting temperature controls.
P, I, and D settings are preset for device types and will
not need to be changed. Refer to the Zone Setup
Screens on page 24 for a list of device types and how to
set them for each zone.
Purging the System
Purging the system before the initial use can prevent
material contamination, which may cause the material to
fail or perform poorly.
CAUTION
Purge the system before performing the initial material
loading procedure. 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.
This equipment should not be used with more than one
type of fluid due to potential compatibility issues which
could result in an unpredictable reaction. Graco recommends using new hoses when chemicals are changed
or care must be taken to assure that all traces of one
chemical are removed before introducing a second
chemical.
3. Select a drum of material that can eliminate the factory-test oil from the system. If necessary, check
with Graco or the material supplier for a recommended solvent.
4. Before purging be sure the entire system and waste
drum are properly grounded. Refer to Grounding
on page 16.
5. Turn all heat zones to 70°F (21.1°C). This allows air
to the air motor, with no alarms, in a cold state.
Remove any dispense valve orifices before purging. Reinstall after purging has been completed.
To purge the system perform the following procedure:
6. Purge the material through the system for approximately 1 to 2 minutes.
1. Select the material for the initial material load.
7. Remove the drum if purge material was used.
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
the start up and operation instructions.
b.
If the two substances are incompatible perform
the remaining steps in this procedure to flush
the system at ambient temperature.
Use fluids that are chemically compatible with the
equipment wetted parts. See the Technical Data sections of all the equipment manuals.
20
311208H
Operator Controls
Operator Controls
EasyKey Display and Keypad
Main Power Disconnect
The EasyKey Display is a simple user interface consisting of an LCD display (A) and keypad (B). See FIG. 7.
Turns system power on or off. Includes system circuit
breaker. See FIG. 6.
POWER
ON
Use to input numerical data, enter Setup screens, scroll
through screens, and select setup values. See EasyKey
Display Screens page 23 for additional keypad/screen
navigation information. The EasyKey includes numbered keys to enter values in setup and the function
keys listed in Table 4.
A
TI8138A
POWER
OFF
TI8139A
FIG. 6: Main Power Disconnect
B
In a Tandem System, the secondary unloader provides 24VDC power to the EasyKey display. This
allows the primary unloader to be powered down
for maintenance without interrupting production. All
accessories (light tower, swirl, etc.) and the display
board on the primary system will have power when
the secondary unloader is powered on and the primary unloader is powered off.
TI8140A
FIG. 7: EasyKey Display and Keypad
Table 4: Key Descriptions
Key
Function
Setup: press to enter or exit Setup mode.
Enter: if cursor is in drop-down list box, press Enter key to view drop-down list. Press Enter to save a
value either keyed in from the numerical keypad or selected from a drop-down list.
Up Arrow: move to previous field or drop-down list item.
Down Arrow: move to next field, or drop-down list item.
Left Arrow: move to previous screen.
311208H
21
Operator Controls
Table 4: Key Descriptions
Right Arrow: move to next screen.
System On/Off: on starts system. Activates
,
,
, and
keys.
Heat State Toggle: starts heaters in all zones where they are enabled. Cycles through heat states
(Heat Off, Heat On/Heat Soak/Run, Setback).
Clear: clears alarms and warnings.
Pump Ready: allows pump to cycle after a DRUM EMPTY condition is removed or a MOTOR ERROR
is cleared.
Pump Crossover: transitions the active system to the inactive unloader.
LCD Display
E
Temperature Readout: shows current temperature
of each zone, in temperature units selected in Table
7, see page 28.
F
Status Bar: shows current operation mode or
alarm.
G
Current Date and Time
H
Security Level: a padlock appears on the screen if
a password is required to enter Setup mode. If the
password was set to 0, no padlock appears and
setup can be entered without a password.
The two run screens show graphical and text information related to setup and spray operations.
A screen saver option is available in the Advanced
Setup screen 4 (see Table 7, page 28).
A
B
C
D
22
Animation: when there is flow the air motor piston
and pump displacement rod move and the gun
appears to spray.
Total Job Volume: recorded in units selected in
Table 7, see page 28. Press
twice to reset Total
Job Volume to zero.
Current Flow Rate: flow rate displayed in units
selected in Adv tab of setup. See Table 7 on page
28.
Zone Number and Icon: shows which zone data is
currently being displayed. Icon indicates component
for that zone.
You must be in system off mode to enter setup
.
Alarm
Alerts the user to an alarm condition. Press
the alarm.
to clear
311208H
EasyKey Display Screens
EasyKey Display Screens
Power Up Screens
When the EasyKey power switch is turned on the Graco
logo screen and the phrase establishing communication
displays for several seconds before the system run
screen appears.
If the EasyKey cannot communicate with any board during the power on phase, the phrase “Communication
Error” displays on the Graco Logo screen. Once communications are established the System Run Screen
appears. See FIG. 9.
Run screens and setup screens are the two main screen
types that provide information and system control.
Zone Run Screen
This screen contains all specific zone information for
each zone in the system. Tandem and expansion systems will contain two zone run screens A and B, one for
each set of 4,6, or 8 zones. The Zone Run screen steps
through the operating status of each zone in sequence.
See FIG. 9.
Temperature setpoints are adjustable on this
screen if Setpoint Adjust is turned on. See
Advanced Screens, page 27. Setpoints will be
highlighted in a box. Use the
move through the setpoints.
or
keys to
Run Mode
Run Screens
System Run Screen
From the Zone Run screen, press
or
to
access the System Run screen. This screen displays a
summary of all zones. See FIG. 8.
FIG. 9: Zone A Run Screen
FIG. 8: System Run Screen
FIG. 10: Zone B Run Screen
311208H
23
EasyKey Display Screens
Setup Mode
Entering Setup
Press
to enter or exit Setup. You must be in system
off state to enter setup.
Password Screen
If a password was enabled you must enter the password
before entering Setup mode. See Table 7, page 28.
Entering the wrong password returns you to the Run
screens.
FIG. 12: Setup Screen 2
If a password is enabled, “Setup Locked” displays
momentarily after exiting Setup mode and returning
to the Run screens.
Setup Screen Menu
The setup screens, contains all four tabs across the bottom of the screen for zone, timer, report, and advanced
screens. The Setup screen menu appears at the bottom
of all Setup screens, with the current screen highlighted.
See FIG. 11 and FIG. 12.
FIG. 11: Setup Screen 1
Zone Setup Screens
Zone Setup has 2 screens. The screen number appears
on the right side of the screen. See FIG. 11 and FIG. 12.
See Table 5 : Zone Setup Screens on page 25 for settings.
Press
to show drop-down lists and to enter your
selection.
24
311208H
EasyKey Display Screens
Table 5: Zone Setup Screens
Screen
Setting
1
Unloader
See (FIG. 11)
Zone
Selection
Numeric
Description
In single system always A. In tandem or expansion system it is selectable
between A and B.
Enter desired zone (1-8). Zone 1 (platen) and zone 2 (pump) are fixed. All
other zones are selectable (hose, gun, regulator, manifold, meter).
Select On or Off to turn zone heat on or off.
Select desired component for heat zones 3 through 8. Zone 1 (platen) and
zone 2 (pump) are fixed. Zone icons on Run screens will match selections.
Enable
On/Off
Zone Type Hose/
Gun/
Regulator/
Manifold/
Meter
Assign to
Tandem system only. Determines unloader zone is assigned to for heat control.
2
Setpoint
Numeric
Enter the temperature to which material needs to be heated. Consult material
See (FIG. 12)
supplier for recommended material application temperatures.
Setback
Numeric
Enter desired temperature to maintain during downtime, so material will not
cool completely.
Calibrate +/Select +/ -, then enter desired calibration temperature. Use if Zone Temp
Numeric
reading does not match ambient temperature of location.
Alarm
Numeric
Enter temperature range from setpoint at which an alarm condition will occur.
Range +/Warning
Numeric
Enter temperature range from setpoint at which a warning condition will occur.
Range +/-
311208H
25
EasyKey Display Screens
Timer Screen
Report Screen
Timer settings are explained in Table 6 : Timer Setup
Screen. See also FIG. 13 and FIG. 14.
The Report screen shows the most recent 12 alarms,
with the date and time. Use the
all the alarms. See FIG. 15.
or
keys to see
Grand total is displayed in liters, gallons, pounds, kilograms, or cycles, based on the units set in Advanced
screen 2. See Table 7, page 28. Grand total cannot be
reset.
There are no selectable settings on the Report screen.
FIG. 13: Timer Screen Disabled
FIG. 15: Report Screen
FIG. 14: Timer Screen, with individual day and
setback action selected
Table 6: Timer Setup Screen
Setting
Day
Selection
Individual/
M-F/
S-S/
All
Description
Select desired day(s). Selected days will be highlighted in calendar on screen.
Event Number 1-5
Select desired event number (maximum of 5 events per day).
Action
None
No timer value entered for selected event.
Off
Turns off timer for selected event.
On
Turns on timer for selected event.
Setback
Turns on setback function for selected event.
Clear All
Clears all timer events for selected day.
Numeric
Enter hours (0-23) and minutes (0-59).
Time
26
311208H
EasyKey Display Screens
Advanced Screens
Advanced setup has 3 screens. The screen number
appears on the right side of the screen. See FIG. 16
through FIG. 18, and Table 7 : Advanced Setup
Screens on page 28.
FIG. 17: Advanced Screen 2
FIG. 16: Advanced Screen 1
The specific gravity listed in the material data sheet
may be for solid form at room temperature. For
accurate weight calculations, specific gravity at the
application temperature should be used otherwise
these weight calculations may be inaccurate.
Press
to show drop-down lists and to enter your
selection.
311208H
27
EasyKey Display Screens
Table 7: Advanced Setup Screens
Screen
Setting
Selection
1
Language English,
See (FIG. 16)
Spanish,
German,
French,
Japanese,
Chinese,
custom
Number
6+8 / 6+4 /
Zones
8+4 / 6+6 /
8+8
Change
Yes/No
Setpoint
Tempera- °F/°C
ture Units
Heat Soak Numeric
2
Units
See (FIG. 17)
cycles/
gallons/
liters/
lbs/
kg
On/Off
7-Day
Timer
Pump Inac- Yes/No
tivity
External
Pump
Enable
Runaway
Rate
Specific
Gravity
3
Month
See (FIG. 18) Day
Year
Time
Password
On/Off
Numeric
Numeric
Numeric
Numeric
Numeric
Numeric
Numeric
Screen
Numeric
Saver Time
28
Description
Language displayed. The language is set at factory.
The number of zones in system is set at the factory.
Select Yes or No to allow operator to change setpoints from the Zone Run
screen.
Select desired temperature units.
Enter time (in minutes) to delay air motor start after all zones reach temperature setpoints.
Select desired units. Affects units used for Run screen job totalizers and
Report screen grand total volume.
(Enable / Disable 7 day timer).
If pump does not move for 2 hours, zones switch to setback temperatures. If
2 more hours pass without pump movement, system shuts off. Select Yes or
No.
Allows external device to control pump.
Enter speed (cycles/min) at which air motor will be shutdown, to prevent runaway.
Used to determine units when weights are selected (Lbs / Kgs).
Select current month (1-12).
Select current day (1-31).
Select current year (4 digits).
Enter hours (0-23) and minutes (0-59).
Is only used to enter Setup mode. Default is 0, which means no password is
required to enter setup. To set a password, enter a number (1–9999).
Enter minutes (1-99) for screen to be inactive before screen saver turns on
(screen dims). Press any key to restore. Default is 0 (screen saver off).
311208H
Setup
Setup
Purge Before Using Equipment
2. Place the ram UP/DOWN lever in the UP position.
The equipment was tested with lightweight oil, which is
left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, purge the equipment with a
compatible material before using the equipment. See
Purging the System, page 20.
Set Values on EasyKey
Set desired values on EasyKey setup menus. See
Setup Mode, page 24.
Material Loading
CAUTION
Do not use a drum of material that has been dented or
otherwise damaged; damage to the platen wipers can
result.
3. Slowly turn the ram UP regulator (N) clockwise until
the ram begins to rise See. FIG. 19.
4. When the ram is fully raised, install the drum centering guides.
An empty drum clamp can interfere with up and
down operation of the ram. When raising or lowering the ram, make sure the drum clamp stays clear of
the platen assembly.
Before loading material, make sure there is a minimum overhead clearance of 110" (2.8 m) and all air
regulators are backed off to their full counterclockwise position.
1. Open the system master air valve (bleed-type) (A).
N
P
A
TI8142A
FIG. 19: Pneumatic Control Panel
5. Apply a thin coating of high temp grease lubricant
(part no. 115982) to the platen drum seals (V). See
FIG. 20.
TI835A
6. Add TSL fluid to wet cup. Fill approximately 2/3 full.
7. Open drum, remove any packing material, and
inspect material for any contamination.
8. Slide the drum into position, positioning it evenly
between the drum centering guides. Be sure it is
pushed all the way against the stops at the back of
the ram baseplate.
311208H
29
Setup
9. Remove the platen bleed handle (W). See FIG. 20.
10. Place the ram UP/DOWN lever in the DOWN position.
TI8141A
CAUTION
Lowering the ram without a drum in place can damage the drum centering guides (if equipped).
W
11. See FIG. 19. Slowly turn the ram DOWN regulator
(P) clockwise to approximately 5-10 psi (34-69 kPa,
0.3-0.7 bar). The platen will begin to lower into the
drum.
V
TI8143A
FIG. 20: Platen
12. After the platen seals (V) enter the material drum,
adjust the ram DOWN air regulator (P) to 30-50 psi
(207-345 kPa, 2.1-3.4 bar). See FIG. 19 and FIG. 20.
13. When the ram stops, reinsert the platen bleed handle (W) and hand tighten. See FIG. 20.
30
311208H
Setup
System Heat Up
Prime Pump
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 set points.
CAUTION
The dispense valve must be kept 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 gasses expanding from
the heat.
Operate at the lowest temperature and pressure
necessary for your application.
In a Tandem system, after a drum change has
occurred on the inactive unloader, pressing the
Pump Ready button will allow five minutes of air to
the air motor to allow for the pump to be primed.
The inactive unloader must be within its warning
deviation setpoints and in the Ready or Heat On
state. If the five minute timer runs out before the
inactive unloader is primed, pressing the Pump
Ready button again will repeat the air to the air
motor.
1. Make sure the system has completed the approximately 40 minute heat soak cycle and is up to temperature.
2. Close the air motor valve (D).
1. Turn the main disconnect on the electrical control
panel door to the ON position.
POWER
ON
D
TI7936A
TI8138A
2. Press
. Display status bar reads Heat Off.
3. Adjust the air motor air regulator (C) to approximately 20 psi (138 kPa, 1.38 bar) on pneumatic
panel.
3. Press
. The zones begin to heat (provided they
are enabled). Display status bar reads Heat On.
When temperature reaches setpoint, display status
bar reads Run Mode.
The air will be locked from the air motor until all
temperature zones are within a preset window of
the temperature set points, allowing the system to
heat fully and complete the material heat soak
period.
C
TI8142A
311208H
31
Setup
Z
4. Place a waste container under the bleed stem (Z).
Using an adjustable wrench, open the bleed stem
counterclockwise 1/3 -1/2 turn. See FIG. 21.
5. If a new drum was installed and the unit is equipped
with proximity sensors, press the Pump Ready button
. If the unit is not equipped with proximity
sensors, press the Clear button
if a motor error
is present, then press the Pump Ready button
.
6. With waste container in place, slowly open the air
motor valve (D).
TI8143A
FIG. 21: Bleed Stem
D
TI7936A
7. Make sure the pump begins to cycle and heated
material flows from the bleed stem (Z) after several
cycles of the pump.
8. If the pump does not cycle, close the pump
bleed-type master air valve (D), adjust the air motor
air regulator (C) up by 5 psi (34 kPa, 0.3 bar). Never
adjust the regulator by more than 5 psi (34 kPa, 0.3
bar) increments.
9. Prime the pump until it moves smoothly in both
directions with no air popping or erratic movement
and close the pump bleed-type master air valve (D).
10. Close the bleed stem (Z). See FIG. 21.
32
311208H
Setup
Prime System
1. Close the system master air valve (bleed-type) (A).
2. If using a manual gun, lock the dispense valve trigger open by pulling and securing the trigger using
the trigger retainer (Z).
Z
TI8051A
3. Place the dispense valve over a waste container.
4. Slowly open the system master air valve.
5. Prime the system until a smooth flow of material dispenses from the dispense valve.
6. Close the system master air valve and release trigger lock.
7. Engage trigger lock.
Trigger Lock
Engaged
TI8049A
The system is now ready to operate.
311208H
33
Operation
Operation
Pressure Relief Procedure
3. Disengage trigger lock.
Trigger Lock
Disengaged
Follow Pressure Relief Procedure when you stop
spraying and before cleaning, checking, servicing, or
transporting equipment.
This procedure describes how to relieve pressure for the
supply unit. Use this procedure whenever you shut off
the unit and before checking or adjusting any part of the
system to reduce the risk of serious injury.
TI8050A
4. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
5. Engage trigger lock.
1. Engage trigger lock.
Trigger Lock
Engaged
Trigger Lock
Engaged
TI8049A
TI8049A
2. Close the system master air valve (bleed-type) (A).
6. 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 spray
again.
If you suspect the spray 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.
A
7. To relieve pressure in the ram, see page 35.
TI8135A
Trigger Lock
Always engage the trigger lock when you stop spraying
to prevent the gun from being triggered accidentally by
hand or if dropped or bumped.
34
311208H
Operation
Ram Pressure Relief Procedure
a. Move the ram UP/DOWN lever to the DOWN
position until all air is exhausted from one side
of the ram.
Follow Pressure Relief Procedure when you stop
spraying and before cleaning, checking, servicing, or
transporting equipment.
To relieve air pressure in the ram:
1. Relieve the supply unit pressure, see page 34.
TI8141
2. Place the ram UP/DOWN lever in the DOWN position. Move the ram to the DOWN position.
b.
Move the ram UP/DOWN lever to the UP position until all air is exhausted from the other side
of the ram.
TI8141
3. When the ram reaches the full down position, place
the ram UP/DOWN lever in the center position (off).
TI8141
4. Close the system master air valve (bleed-type) (A).
A
TI8135A
5. Exhaust air from both sides of the ram:
311208H
35
Operation
Drum Changing
Follow the procedure below to change the drum on a
fully heated machine.
CAUTION
Be sure to reload the empty supply unit with a full
drum of material immediately. Do not raise the ram
and remove the platen from the empty drum until you
are ready to immediately install a new drum.
In a Tandem system, after a drum change has
occurred on the inactive unloader, pressing the
Pump Ready button will allow five minutes of air to
the air motor to allow for the pump to be primed.
The inactive unloader must be within its warning
deviation setpoints and in the Ready or Heat On
state. If the five minute timer runs out before the
inactive unloader is primed, pressing the Pump
Ready button again will repeat the air to the air
motor.
1. Place the ram UP/DOWN lever in the UP position.
Do not raise the ram and remove the platen from
the empty drum unless the supply unit is at full
operating temperature. Drum changes can only be
performed when the system is heated.
An empty drum clamp can interfere with the up
and down operation of the ram. When raising or
lowering the ram, make sure the drum clamp stays
clear of the platen assembly.
Do not use a drum of material that has been
dented or otherwise damaged; damage to the
platen wipers can result.
TI8135A
2. Dial ram up regulator pressure to 0 psi.
No Proximity Sensors
The pump will cavitate and a motor error will appear in
the EasyKey status bar. The air motor will shut off and
the heat will continue to be applied for approximately 1
hour.
With Proximity Sensors
Drum empty will appear in the EasyKey status bar. The
air motor will shut off and the heat will continue to be
applied for approximately 1 hour. If the light tower kit is
installed a flashing yellow light indicates that the drum is
empty and ready to change. In a tandem system a flashing red light means that both drums are empty and the
system has shut down.
Excessive air pressure in the material drum could
cause the drum to rupture, causing serious injury.
The platen must be free to move out of the drum.
Attempting to change a drum when the supply unit is
cold could result in injury, damage to the equipment,
or rupture of the material drum. Never use drum
blow-off air with cold adhesive or a damaged drum.
Positive pressure is released from the drum when
the platen seal is pulled clear.
A splatter shield accessory for low viscosity material is available.
3. Adjust the platen blow-off air regulator (T) to 20-30
psi (138-207 kPa, 1.4-2.1 bar).
36
311208H
Operation
T
For tandem systems the pump ready button will
turn the air motor on for approximately 5 minutes to
prime the pump. This can be repeated as necessary.
If both unloaders in the system are empty, the
pump ready and transition sequence will depend on
the unloader to transition to the Run state.
 Active unloader cleared. Inactive unloader empty.
TI8142A
•
4. Push and hold the blow-off air push button (S). The
platen will begin to raise.
S
Pressing the pump ready button while the
active unloader is in the Heat On state will
cause the active unloader to transition to
the Run state.
 Inactive unloader cleared. Active unloader empty.
•
Pressing the pump ready button while the
inactive unloader is in the Heat On state
will cause the inactive unloader to transition to the Ready state. The active state
can then be transitioned to the loaded unit.
TI8142A
 Both unloaders cleared before pressing Pump
Ready.
5. When platen is clear of the drum, increase the ram
up pressure to 10-15 psi (69-103 kPa, 0.69-1.03
bar) to continue to raise the heated follower plate.
•
Pressing the pump ready button while the
inactive unloader is in the Heat On state
will cause the inactive unloader to transition to the Ready state. The Transition button must be pressed to transfer active
unloader status to the Ready unloader.
Pressing the Pump Ready button again
while the now inactive loader is in the Heat
On state, will cause the inactive unloader to
transition to the ready state.
•
Pressing the Pump Ready button while the
inactive unloader is in the Heat Off state
and the active unloader is in the Heat On
state will cause the active unloader to transition to the Run state.
•
This sequence is required to force the user
to only engage one unloader at a time. This
prevents accidental pumping of air into the
system.
6. Once the ram is in the full up position place the
drum cover in the brackets provided.
Never reach under the heated platen after it leaves
the drum. Serious burns could result from dripping
material.
7. Follow the steps in Material Loading (page 29) and
Prime Pump (page 31).
8. After drum change, press the Pump Ready Button
to reverse the air motor control.
9. Prime the pump.
It is only necessary to lubricate the platen seals on
initial material loading.
311208H
37
Operation
System Shutdown
4. Lock the dispense valve trigger open by pulling and
securing the trigger using the trigger retainer (Z).
Follow the procedure below for normal system shut
down, such as at the end of the work day.
1. Make sure the pump rod (Y) is parked in the down
position.
Z
A
TI8051A
CAUTION
Many hot melt materials tend to expand when heating
up and may cause a heated hose to burst. Avoid the
potential of bursting a hose by opening the dispense
valve during system heat up and lock the dispense
valve trigger open every time you shut the system
down.
TI7937A
5. If the optional 7-day timer is not being used, set the
main disconnect to OFF.
2. Close the system master air valve (bleed-type)(A).
If 7-day timer is required, system need to be in the
system on or heat off state.
A
POWER
OFF
TI8135A
TI8139A
3. If a 7-day timer is not being used, enable Pump
Inactivity (see Table 7, page 28).
38
311208H
Dual Ram Cross-Over Installation
Dual Ram Cross-Over Installation
Typical Installation
Cross-Over cable (Part No.15H385) was included with the Dual Ram prior to 6/19/2008. Use can cable, (Part No.
121228) for units dated after 6/19/2008).
Cross-Over Cable
TI7937A
TI7937A
EasyKey Setup
See EasyKey Display Screens on page 23.
Drum Change Procedure
See Drum Changing on page 36.
311208H
39
Maintenance
Maintenance
Ram
Periodically (at least once a month), inspect the ram
guide sleeves, rods and cylinders for wear or damage.
See instruction manual 310523.
Ground Fault Interrupt
Periodically (at least once a month) test the ground fault
interrupt switch by pushing the TEST button.
Power in a Tandem System
In a Tandem System, the secondary unloader provides 24VDC power to the EasyKey display. This
allows the primary unloader to be powered down
for maintenance without interrupting production. All
accessories (light tower, swirl, etc.) and the display
board on the primary system will have power when
the secondary unloader is powered on and the primary unloader is powered off.
Alarm Troubleshooting
The Therm-O-Flow alarms alert you to a problem and
help prevent system shut downs or application errors. If
an alarm occurs, operation may stop and the following
occurs.
•
Light Tower Changes (if equipped)
•
Status bar on the EasyKey Display shows the
description
•
Alarm out puts a signal sent to I/O
To Clear the alarm and restart the TOF 200 press the
Error Clear key on the EasyKey display.
See Table 8 : Therm-O-Flow Alarms.
Resetting the Ground Fault
Interrupt
This electrical control panel is equipped with a ground
fault interrupt (GFPE) circuit breaker. If the disconnect
switch is ON, but all lights on the electrical control panel
are off review troubleshooting procedures.
40
311208H
Alarm Troubleshooting
Table 8: Therm-O-Flow Alarms
Warnings
Cause
With optional light tower, the yellow light illuminates and green light remains on if in run mode.
High Temperature - occurs when a zone temperature is above the setpoint plus warning deviation specified in the
zone tab of the setup screen.
Low temperature - occurs when a zone temperature is below the setpoint minus warning deviation specified in the
zone tab of the setup screen,
Drum Low - occurs when the drum low proximity sensor is activated due to the ram position.
Alarms
Cause
With optional light tower, the red light illuminates.
High Temperature - occurs when a zone temperature is above the setpoint plus alarm deviation specified in the
zone tab of the setup screen,
Low Temperature - occurs when the zone temperature is below the setpoint minus alarm deviation specified in the
zone tab of the setup screen while the unloader is in the run state.
Sensor Error - occurs in the following conditions when an enabled zone does not increase in temperature within
two minutes while the system is in the Heat On state. This is the short circuit state o f an RTD sensor. Or when a
zone temperature exceeds 500°F (260°C). This is the open circuit state of an RTD sensor
Heat Control Error - occurs if the conductor relay on a temperature board is not closed when a zone of the temperature board is enabled and in a heat state for the active unloader,
Communication Error - there are two possibilities:
•
Start up - Occurs if the EasyKey display board cannot communicate with any board in the system.
•
Normal Operation - occurs if any board in the system, including tandem unloader, cannot communicate with the
EasyKey Display board.
Events
Cause
Drum Empty - occurs when the drum empty proximity sensor is activated for the ram position.
With optional light tower the yellow light begins flashing and the green light turns off.
Motor Shutdown - occurs when the pump exceeds the motor shutdown rate set in the advanced tab of the setup
screen.
With optional light tower the red light turns on and the green light turns off.
Maintenance Call - occurs in advanced unit if user presses maintenance call button. See “Maintenance Call Kit
(253548)” on page 90 for additional information.
With optional light tower the yellow light turns on.
See “Light Tower Kit (253547)” on page 80 for additional information.
311208H
41
Ram Troubleshooting
Ram Troubleshooting
Problem
Ram will not raise or lower.
Cause
Solution
Closed main air valve or clogged air
line,
Open air valve; clear air line.
Not enough ram air pressure.
Increase ram air pressure.
Worn or damaged ram piston.
Replace piston. See instruction manual 310523.
Platen not fully up to temperature.
Wait for full temperature.
Ram air pressure too high.
Decrease ram air pressure.
Dented drum has stopped platen.
Fix or replace drum.
Ram raises or lowers too fast.
Ram “up / down” air pressure too
high.
Decrease ram air pressure.
Air leaks around cylinder rod.
Worn rod seal.
Replace o-rings in guide sleeve. See
instruction manual 310523.
Fluid squeezes past platen wipers.
Ram air pressure too high.
Decrease ram air pressure.
Worn or damaged wipers.
Replace wipers.
Directional valve not in the down
position.
Position handle in the down position.
Closed main air valve or clogged air
line.
Open air valve; clear air line.
Not enough air pressure.
Increase air pressure.
Worn or damaged ram piston.
Replace piston. See instruction manual 310523.
Ram directional valve closed or
clogged.
Open valve; clear valve or exhaust.
Ram directional valve dirty, worn, or
damaged.
Clean; repair valve.
Dented drum has stopped platen.
Fix or replace drum.
Closed main air valve or clogged air
line.
Open air valve; clear air line.
Pump will not prime properly, or
pumps air.
Air pressure will not push platen out
of drum.
Not enough blow-off air pressure.
Increase blow-off air pressure.
Blow-off valve passage clogged.
Clean valve passage.
Dented drum has stopped platen.
Fix or replace drum.
Wipers bonded to drum or drum liner. Lubricate wipers with high temperature grease at every drum change.
42
311208H
Heated Pump Troubleshooting
Heated Pump Troubleshooting
For additional troubleshooting information about the pump, see the pump’s documentation.
Problem
Cause
Solution
Rapid downstroke or upstroke (pump Material not heated to proper temper- Check and adjust temperature to
cavitation).
ature.
proper set point. Wait for pump/platen
to heat up.
Material leaks around pump outlet.
Air is trapped in pump.
Bleed air from pump. See Prime
Pump, page 31.
Downstroke: Dirty or worn pump
intake valve.
Clean or repair. See Pump Manual.
Upstroke: Dirty or worn pump piston
valve.
Clean or repair.
Loose outlet fitting.
Tighten outlet fitting.
Material leaks around bleed port.
Loose bleed port fitting.
Tighten bleed port fitting.
Pump will not move up and down.
Problem with air motor.
See Air Motor Manual.
Foreign object lodged in pump.
Relieve pressure. See Pump Manual.
Worn throat seals.
Replace throat seals. See Servicing
the Throat packings in manual
308570 or 311536.
Leak around pump wet-cup.
Air Motor Troubleshooting
For additional air motor troubleshooting information, see the air motor manual supplied.
Problem
Cause
Solution
Air motor will not run.
Air motor solenoid is off.
Wait for heat zones in use to reach
“window” around temperature set values.
Air motor stalled.
Damaged main air valve spool or
poppets.
Rebuild main air valve. See Air Motor
Manual.
Air continuously exhausting around
air motor shaft.
Damaged air motor shaft seal.
Replace air motor shaft seal. See Air
Motor Manual.
Air continuously exhausting around
air valve/slide valve.
Air valve/slide valve gasket is damaged.
Replace the valve gasket. See Air
Motor Manual.
Air continuously exhausting from
muffler when motor is idle.
Internal seal damage.
Rebuild air motor. See Air Motor
Manual.
Icing on muffler.
Air motor operating at high pressure
or high cycle rate.
Reduce pressure, cycle rate, or duty
cycle of motor.
311208H
43
Electrical Control Panel Troubleshooting
Electrical Control Panel Troubleshooting
Problem
Disconnect is ON, but EasyKey not
lit.
Cause
The ground fault interrupt has been
activated.
Solution
Have a qualified electrician check
wiring.
One or more fuses or circuit breakers Have a qualified electrician check
tripped.
wiring.
High temperature alarm.
The temperature of a heated compo- Supply unit automatically turns off
nent has gone out of range.
power to supply unit components and
air motor. Unit turns power back on
when overheated components reach
appropriate temperatures.
Heat is turned off after a period of
pump inactivity.
Pump has not moved within the pro- See Table 7, page 28.
grammed time period and the inactivity timer has been triggered.
Pump Ready button does not clear
flashing pump ready icon.
Unloader not in Heat On state and/or Turn system to Heat On state and
wait until all zones reach warning
zones have not reached warning
deviation level.
deviation level.
44
311208H
Service
Service
Ram
Servicing Wipers
To relieve ram air pressure, follow the Ram Pressure
Relief Procedure on page 35.
Ram Pressure relief Procedure
To reduce the risk of serious injury whenever you service the ram, always follow the Ram Pressure Relief
Procedure on page 35.
1. To replace a worn or damaged wiper (V) raise the
ram plate up out of the drum. Be sure to follow all
the cautions and warnings. Perform steps 1 through
7 of the Drum Changing procedure on page 36.
See Instruction manual 309196 for instructions
about replacing tee wipers. See FIG. 22:
Periodically (once a month), inspect the ram guide
sleeves, rods and cylinders for wear or damage, replace
all worn parts. See the Service section of Form 310523
for instructions on replacing worn parts.
Pump
See the material pump instructions for its inspection frequency.
Ground Fault interrupt
Periodically (at least once a month) test the ground fault
interrupt switch by pushing the TEST button.
TI8143A
V
FIG. 22 Wipers
Power in a Tandem System
In a Tandem System, the secondary unloader provides 24VDC power to the EasyKey display. This
allows the primary unloader to be powered down
for maintenance without interrupting production. All
accessories (light tower, swirl, etc.) and the display
board on the primary system will have power when
the secondary unloader is powered on and the primary unloader is powered off.
311208H
45
Service
Replacing Heat Sensors
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, follow the procedure for Drum
Changing on page 36.
2. Make sure the ram plate is down and the ram hand
valve is in the OFF position. See page 45.
To reduce the risk of injury or damage to equipment,
make sure the main disconnect is off before continuing
with this procedure.
3. Turn OFF the main electrical disconnect switch.
4. Remove the front and right side pump cover.
5. Remove the sensor from the ram plate.
6. Disconnect the two sensor wires from the J1 or J2 of
PCB201. See Fig FIG. 23.
PCB
246
PCB
201
PCB
226
J1 J2 J3 J4 J1 J2 J3 J4
FIG. 23
7. Attach the leads from the new sensor to the leads of
the old sensor and pull the new sensor leads into
the main control panel.
8. Install the new sensor into the follower/tire plate
after coating with non-silicone heat sink compound.
Tighten compression nut.
9. Connect the two wires from the new sensor to the
J1 or J2 of PCB201.
10. Replace the pump covers.
46
311208H
Pump Removal and Replacement
Pump Removal and Replacement
For information about servicing the Check-Mate™ 800
Displacement Pump, see Instruction Manual 308570.
9. Pump must be in the full down position (air motor
shaft fully extended).
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
Drum Changing procedure on page 36. It is important that the pump rod is in the fully down (parked)
position.
Reverse the above procedure to reinstall a new or
rebuilt pump.
2. Make sure the ram plate is down and the ram hand
valve is in the neutral position.
Separating the Air Motor from the Pump
This procedure must be done with the unit still
warm. The material and equipment will be hot!
1. If vent hood is installed, remove it.
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the Pressure Relief Procedure on page 34.
2. Remove the air motor top cover.
3. Bleed off excess material and pressure in the system by opening the dispense gun and catching the
material in a waste container.
4. Remove air line from air motor and air lines to the
follower blow-off valve.
4. On the electrical control panel, turn off the system
heat (D). See FIG. 24.
5. Turn OFF the main electrical power supply to the
unit. Follow all applicable safety procedures and
lockout rules.
6. Turn OFF the main electrical disconnect (E) located
on the left side of the Them-O-Flow 200.
3. Disconnect electrical cable from air motor.
5. Tightly strap the air motor to the tie bar with a cable
through the air motor lift ring and around the tie bar.
6. Loosen U-bolts from follower lift rods.
7. Remove nuts (F) from pump/air motor stand-off rods
at the pump end. See FIG. 24.
8. Remove nuts and bolts holding cable tract to air
motor support plate.
9. Slide end of cable track outboard of the mounting
plate.
To reduce the risk of injury or damage to equipment,
make sure the main disconnect is off before continuing
with this procedure.
10. Remove nuts (2) from follower lift rods.
11. Fully loosen pump rod coupler to the air motor rod
(G).
7. Disconnect all material hoses.
12. Slowly raise elevator to achieve enough separation
of the pump (air motor) tie rods to remove the pump.
8. Remove the pump sheet metal enclosure (A). See
FIG. 24.
13. Remove the pump.
a. Remove the cover screws (B).
b.
Disconnect the pump heater wires, the ground
wire, and the sensor mounted to the pump.
c.
Remove the follower sensor (C).
311208H
14. Reverse this procedure to reinstall the new or rebuilt
air motor.
47
Pump Removal and Replacement
Removing the Follower Plate
2. Remove the follower plate assembly from the ram.
1. Disconnect the follower power wires and the follower
ground wire from within the main control panel and
pull out of conduit.
3. Reverse this procedure to reinstall the new or rebuilt
follower plate assembly.
E
D
G
F
C
A
B
TI7832
FIG. 24
48
311208H
Replacing Heater Bands and Sensors in Pump Module
Replacing Heater Bands and Sensors in Pump Module
Module heaters and sensor can be serviced without
removing the pump module from the supply unit.
Remove the front shrouds. When finished servicing the
pump module re-attach shrouds.
3
This procedure can be done when the
Therm-O-Flow 200 is cool.
Removing/Replacing Heater Band
1. Remove the screws that hold the front shroud in
place and remove the front shroud.
G
2. Disconnect the electrical wires from heater band (3).
See FIG. 25.
3
3. Remove the screw that holds the heater band in
place.
4. Remove the heater band from pump.
5. Coat the inside of the heater with non silicone heat
sink compound before mounting. Maximum thickness is 0.005”. Coat only to within 3/4” of vertical
ends.
6. Install a new heater band in the same location as
the old heater band:
a. Locate heater terminals so they line up with
back of pump.
b.
Tighten the heater band.
Re-connect heater wires and re-attach ceramic caps
that insulate terminal.
Removing/Replacing Sensor
1. Remove the screws that hold the front shroud in
place and remove front shroud.
2. If sensor wire is connected to electrical enclosure,
disconnect it.
TI8144A
FIG. 25
4. Tie the leads of the new sensor to the old sensor
and remove the old sensor. The leads of the new
sensor will be easily drawn through the conduit for
reconnecting.
5. Replace the sensor (H) in clamp:
a. Place sensor approximately 30° counter
clock-wise from pump outlet.
b.
Tighten clamp.
6. Re-connect sensor wire to electrical enclosure.
3. Loosen the clamp holding sensor on pump (G). See
FIG. 25.
311208H
49
Replacing Heater Bands and Sensors in Pump Module
Removing/Replacing RTD Sensor
1. Remove the screws that hold the front shroud in
place and remove front shroud.
2. If RTD sensor wire is connected to electrical enclosure, disconnect it.
3. Loosen the clamp holding sensor on pump.
4. Tie the leads of the new RTD sensor to the old RTD
sensor and remove the old sensor. The leads of the
new sensor will be easily drawn through the conduit
for reconnecting.
5. Remove RTD sensor.
6. Replace the sensor (H) in clamp:
a. Place RTD sensor approximately 30° counter
clock-wise from pump outlet.
b.
Tighten clamp.
7. Re-connect sensor wire to electrical enclosure.
Inspection/Maintenance Frequency
The pump packings do not require any other service or
maintenance, except as described in the Daily Maintenance Procedures. See 308570 for inspection frequency
of the pump.
Throat Packings
Refer to manual 308570 for a list of throat packing kits
and replacement instructions.
50
311208H
Replacing Heater Bands and Sensors in Pump Module
311208H
51
Electrical Schematics
Electrical Schematics
240 VAC Supply - Internal Control Box
8
8
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311208H
311208H
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Electrical Schematics
Electrical Control Schematics
TI8076A
53
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Electrical Schematics
Electrical Control Schematics
TI8077
311208H
*
#2/33
/6%2
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311208H
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Electrical Schematics
Electrical Control Schematics
TI8078A
55
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7
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56
03
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Electrical Schematics
Electrical Control Schematics
TI8079
311208H
8 7)2% $5#4
Electrical Schematics
311208H
57
Electrical Schematics
Electrical Connections Schematic
#/.
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4
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7
7
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7
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4/ #/..3
4/ 42!.3&/2-%2
Schematic continued
on next page
TI8511A
58
311208H
Electrical Schematics
Electrical Connections Schematic
Schematic continued on
previous page
1
All wires to be run through conduit and into enclosure. Conduit to be run through cable track.
2 All hoses to be run through cable track. Through 2 x 3 slot in pedestal. And through
311208H
1.75 hole in pedestal.
59
Parts
Parts
All Models Supply Unit
11
10
4
5
20*
13
12
21
19
15
8
16
1
17
6
18
3
TI8145A
2
14
TI7922A
60
311208H
Parts
All Models Supply Unit
Ref
No.
1
Part
No.
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20*
21
Description
Qty
6” motor w/glass-filled tfe seals and
1
50 psi relief valve
7.5” motor w/glass-filled tfe seals
1
and 85 psi relief valve
10.375” motor w/glass-filled tfe
1
seals and 100 psi relief valve
6” motor with cf/tfe grease pack
1
seals and 50 psi relief valve
7.5” motor with cf/tfe grease pack
1
seals and 85 psi relief valve
10.375” motor with cf/tfe grease
1
pack seals and 100 psi relief valve
Drum Platen, see Heated Platens
1
on page 70
Tire Plate Seals, see manual
1
309196 for a list of replacement
parts
RAM, see manual 310523
1
Electrical Enclosure
C32463 CLAMPS, see parts starting on
page 76
233559 Vent Hood Kit, see page 79
253137 Pneumatic controls
253547 KIT, light tower
253288 CABLE, way
253147 EasyKey, display
253559 KIT, drum low and empty sensor
(included on Adv. and TS units)
297401 Stand Alone Pneumatic Controls,
see manual 310523
15J074 LABEL, warning
15H668 LABEL, warning
15J075 LABEL, warning
184090 LABEL, warning
196548 LABEL, warning
234966 KIT, TOF Hose Hanger
15J076 LABEL, warning

Replacement Danger and Warning labels, tags,
and cards are available at no cost.
*
234966 hose hanger kit contains parts to
support one hose.
311208H
1
1
1
1
1
1
1
1
4
2
2
2
1
1
2
61
Parts
Therm-O-Flow Pump
11
17
22
4,10,14
6
11,13
18
20,21
9
3
TI7934A
TI8145A
16,19
6
9
5
5
TI8146A
62
311208H
Parts
Therm-O-Flow Pump
Ref
No.
3
4
5
6
9
10
11
13
14
15
16
17
18
19
20
21
22
Part No. Description
PEDESTAL, TOF 200
BRACKET, mounting enclosure
218093 HOSE, coupled
253137 CONTROL, air assembly
253229 HOSE coupled
100016 WASHER, lock
101864 SCREW, cap
111303 NUT, hex
110298 SCREW, cap sch
100214 WASHER, lock
100575 SCREW, cap hex head
253288 CABLE, track
15H543 BRACKET, mounting
100023 WASHER, thrust
100307 NUT, hex
120186 BOLT, mounting u-bolt
SCREW, button head
311208H
Qty.
1
1
1
1
1
8
12
4
8
4
4
1
1
4
4
2
2
63
Parts
Therm-O-Flow Pump Module using NXT 3400 and NXT 6500 Models
1
34
36
26
26
14
23
24
29
37
30
31,32,33
7
2
8
25
9
17
38
7
35
TI8132A
64
311208H
Parts
Therm-O-Flow Pump Module using NXT 3400 and NXT 6500 Models
Ref
No.
1
2
7
8
9
14
16
17
23
24
Part No.
See
Table
See
Table
120271
120275
C31012
15H396
See
Table
C03507
184129
186925
Description
MOTOR, Air
PUMP
1
HEATER
SENSOR, RTD
CLAMP
ADAPTER, rod pump
VALVE, safety (not shown)
2
1
1
1
1
SUPPORT, sensor
COLLAR, coupling
NUT, coupling
1
2
1
Description
Ratio
NXT 3400 GF/TFE
36:1
NXT 6500 GF/TFE
70:1
NXT 3400 CF/TFE
36:1
NXT 6500 CF/TFE
70:1
311208H
Qty.
1
Ref
No.
25
26
29
30
31
32
33
34
35
36
37
38
Max Air
Pressure
Max Fluid
Pressure
.57 MPA (5.7
Bar) 83 psi
.29 MPA (2.9
Bar) 43 psi
.57 MPA (5.7
Bar) 83 psi
.29 MPA (2.9
Bar) 43 psi
20.7 MPa (207
Bar) 3000 psi
20.7 MPa (207
Bar) 3000 psi
20.7 MPa (207
Bar) 3000 psi
20.7 MPa (207
Bar) 3000 psi
Part No.
106166
15H542
15H395
C19837
15H592
15H593
15H594
15H595
Description
Qty.
NUT, mach, hex
3
BRACKET, motor mount
2
ROD, tie
3
SCREW, cap, sch
4
CONDUCTOR, ground
1
SCREW, machine
1
WASHER, lock, ext tooth
1
ADAPTER, elbow, 3/4” NPTI x 1/2”
1
NPTE
COVER, pump bottom
1
COVER, pump left
1
COVER, pump right
1
COVER, pump front
1
Ref No.
1
Qty.
C38162
C38163
Ref No.
Ref No.
2
Qty.
16
Qty.
N32LH0
1
237795
1
120306
1
N65LH0
1
237795
1
120012
1
N34LH0
1
253141
1
120306
1
N65LH0
1
253141
1
120012
1
65
Parts
Therm-O-Flow Pump Module using NXT 2200 Models
1
34
15
14
26
36
30
23
29
24
31,32,33
7
25
8
9
17
38
37
2
7
35
TI8147A
66
311208H
Parts
Therm-O-Flow Pump Module using NXT 2200 Models
For NXT 2200 Models
Ref
No.
1
2
7
8
9
14
15
16
17
23
Part No.
N22LH0
See
Table
120271
120275
C31012
15H397
15H398
103347
C03507
184129
311208H
Description
NXT 2200 AIR MOTOR
PUMP
Qty.
1
1
HEATER
SENSOR, RTD
CLAMP
ADAPTER, rod pump
ADAPTER, motor mount
VALVE, safety (not shown)
SUPPORT, sensor
COLLAR, coupling
2
1
1
1
3
1
1
2
Ref
No.
24
25
26
29
30
31
32
33
34
35
36
37
38
Part No. Description
Qty.
186925 NUT, coupling
1
106166 NUT, mach, hex
3
BRACKET, motor mount
1
15H395 ROD, tie
3
109211 SCREW, cap, sch
3
CONDUCTOR, ground
1
C38162 SCREW, machine
1
C38163 WASHER, lock, ext tooth
1
ADAPTER, elbow, 3/4” NPTI x 1/2”
1
NPTE
15H592 COVER, pump bottom
1
15H593 COVER, pump left
1
15H594 COVER, pump right
1
15H595 COVER, pump front
1
Description
Ref No.
2
Max Air Pressure
Max Fluid Pressure
Qty.
NXT 2200 GF/TFE
NXT 2200 CF/TFE
237795
237141
0.7 MPA (7 Bar) 100 psi
0.7 MPA (7 Bar) 100 psi
15.9 MPa (159 Bar) 2300 psi
15.9 MPa (159 Bar) 2300 psi
1
1
67
Parts
Series A Heated Pump
Pump Top Heater
Pump Bottom Heater
Platen Heater
Platen RTD
Pump RTD
TI8148A
68
311208H
Parts
Electrical wiring shown below is located in the electrical enclosure.
380 and 480V Pump Heater
B2
Jumper, Phoenix pn 3005947
B1
T2
T1
T3
4L2
B3
5L1
575V Pump Heater
Jumper, Phoenix pn 3005947
5L1
B2
B1
T2
T1
T3
4L2
B3
230V Pump Heater
B2
Jumper, Phoenix pn 3005947
B1
T2
5L1
4L2
T1
T3
B3
311208H
69
Parts
Heated Platens
Part No, 253218 Heated Drum Platen, Mega-Flo (Code B - option A)
Part No, 253219 Heated Drum Platen, Standard Grid (Code B - Option B)
Part No. 253220 Drum Heated Platen, Smooth Bottom (no fin) (Code B - Option C)
Standard Grid Plate
Part No. 253219
Smooth Bottom No Grid
Plate Part No. 253220
28
27
10
See detail C
If one ring terminal
see detail A. If two ring
terminals see detail B
14,15
9
8
7
3
11
6
12,13
4
2
5
24
24
25
Mega-Flo Plate
Part No. 253218
25
26
26
TIHeated Platens Modified
Detail C
70
Detail A
Detail B
311208H
Parts
Part No, 253218 Heated Drum Platen, Mega-Flo (Code B-A)
Part No, 253219 Heated Drum Platen, Standard Grid (Code B-B)
Part No. 253220 Drum Heated Platen, Smooth Bottom (no fin) (Code B-C)
Ref
No.
1
Part
No.
2
3
4
5
6
7
8
9
10
11
12
C32204
15G967
C19049
15H298
C32201
158491
158581
617227
246501
100361
100133
Description
See Table 9 Drum Platen Chart
Below
PACKING, O-ring
PLATE, tire
SCREW, mach, slotted, RND HD
SENSOR, temperature
GASKET, follower
FITTING, nipple
COUPLING, hex
HANDLE, follower, bleed
VALVE, blow off
PLUG, pipe
WASHER, lock
Qty
1
1
1
1
1
1
1
1
1
1
4
6
Ref
No.
13
14
15
18
19
20
21
23
24
25
26
Part
No.
C19846
150707
100508
Description
SCREW, cap socket, HD
PLATE, designation
SCREW, drive
See Table 9 Drum Platen Chart
Below
See Table 9 Drum Plated Chart
Below
CONDUCTOR
CONDUCTOR
CONDUCTOR
SLEEVE, fiberglass, hi-temp
112901 NUT, hex
111640 WASHER, lock, internal
Qty
6
1
2
--2
4
1
3
12
12
Table 9 Drum Platen Chart
Part No.
Description
Item 1
Qty
Element
Resistance
253218
Mega-Flo Plate
194254
1
16.5Ω +1 / -2
253219
Standard Grid Plate
617225
1
19.2Ω +2 / -3
253220
Smooth Plate
C57358
1
19.2Ω +2 / -3
6
6
,
&
$
"
%
#
!
,
,
,
&
$
"
%
#
!
,
,
&)'52% (%!4%2 4%2-).!, 0!44%2.3
A
B
B
,EFT
B
A
B
A
A
A
B
B
B
,EFT
A
B
A
A
A
2IGHT
A
'ROUND SCREW
B
2IGHT
A
B
B
B
A
'ROUND SCREW
/HMS ACROSS PAIRS
311208H
/HMS ACROSS PAIRS
71
Parts
Platen Coil Checking
To check resistance across each coil to ensure that each is working properly place an ohm meter across the platen
coils as shown in the Heater Terminal Pattern illustration, or place an ohm meter across the terminals in the
Therm-O-Flow control box shown below.
8 7)2% $5#4
&5 &5 332 $
&
"
%
!
#
"
4
"
4
"
4
$#
).42&
#/.
Therm-O-Flow Control Box
6a
6b
21
19
20
19
6b
F
F
5b
6a
F
20
18
F
E
4a
5b
E
E
21
19
4b
20
21
C
18
21
A
1a
Smooth and Standard
Platen Wiring
72
2b
21
B
B
1b
18
A
C
C
2a
2b
20
3b
19
B
3a
18
3a
B
21
4a
D
D
3b
18
C
4b
19
D
D
21
18
5a
E
5a
2a
1a
19
A
21
A
1b
Mega-Flo Platen Wiring
311208H
Parts
EasyKey Assembly, Part No. 253147
5
2
3
4
1
TI7918A
TI7919A
Back of EasyKey Assembly
Ref
No.
1
2
3
4
5
Part No. Description
LABEL, operations
117769 DISPLAY, graphics
BOARD, circuit assembly
PLATE, blank
SCREW, pan head cross 4-40
311208H
Qty
1
1
1
1
4
73
Parts
Swirl Kit, Part No. 253263
6
11
8
7
5
1
4
2
TI7921A
3
Air In
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
74
Part
No.
Description
Qty.
.125 ID hose barb x 1/4 NPT Male
1
brass fitting
Regulator
1
Gauge
1
1/4 to 1/8 Brass Hex Nipple
1
Solenoid Valve
120384 Cable
1
Tube Fitting
1
Nylon tube
3 ft.
Socket head cap screw (not shown) 2
Tube Clamp (not shown)
1
Regulator mounting bracket
1
311208H
Parts
Drip Shield Mount Kit, Part No. 253479
Ref.
No.
1
2
3
Part
No.
Description
BRACKET, tray
BOLT, U 7.5 LG x 6” pipe
100131 NUT, full hex
Qty
2
2
4
Ref.
No.
4
5
Part
No.
Description
100133 WASHER, lock
115694 TRAY, drip shield, hot melt
Qty
4
2
5
1
3
4
2
3
4
TI8149A
311208H
75
Parts
Drum Ram Post Saddle Clamp, Part No. C32463
Option Code J-3
Ref
No.
1
2
3
4
Part
No.
C32424
160111
100103
100307
Description
BOLT, U, 7”
CLAMP, barrel
PIN, cotter
NUT, hex
Ref
No.
5
6
7
8
Qty
2
1
2
4
Part
No.
100133
C38182
C32461
166265
Description
WASHER, lock
WASHER, plain
CLAMP, saddle
PIN, pivot
Qty
4
2
2
1
3
8
6
5
7
4
2
1
5
5
4
4
6
5
4
7
TI8150A
3
76
311208H
Parts
Heavy Duty Drum Band Clamp, Part No. 918395
Option Code J-2
Ref
No.
2
3
4
5
6
Part
No.
100101
918421
918423
617395
100133
Description
SCREW, cap, hex HD
CLAMP, back half assembly
KIT, repair
PIN, quick release
WASHER, lock
11
8,7,6,2
Ref
No.
7
8
9
10
11
Qty
8
1
1
2
8
Part
No.
C19200
617433
617395
100131
C32424
Description
WASHER, plain
SPACER, drum clamp
CLAMP, saddle
NUT, full hex
BOLT, U 7”
6,10
3
9
Qty
8
8
4
8
4
11
4
5
TI8151A
311208H
77
Parts
Fiber Drum Reinforcement Clam Shell Clamp, Part No. 918397
Option Code J-1
Ref
No.
1
2
3
Part
No.
C32271
C19126
100133
Description
CLAMSHELL
SCREW, cap hex HD
WASHER, lock
Qty
1
8
12
Ref
No.
4
5
6
7
Part
No.
100307
617340
C32424
617341
Description
NUT, hex
CLAMP, saddle
BOLT, U, 7”
MOUNT, clam shell
Qty
8
4
4
2
1
3,4
5
6
2,3
7
TI8152A
78
311208H
Parts
Vent Hood Accessory Kit for 6-1/2 In. Ram, Part No. 233559
Ref
No.
1
2
3
5
Part
No.

Replacement Danger and Warning labels, tags,
and cards are available at no cost.
Description
VENT hood
112166 SCREW, cop sch
100016 WASHER, LOCK
C14038 LABEL, warning
1
Qty
1
4
4
1
5
2
3
TI8153A
311208H
79
Advanced Units
Advanced Units
Light Tower Kit (253547)
The optional light tower kit has the following color and
flashing lights to signal warnings and alarms. See FIG.
26.
Green denotes an active system where the pump will
activate when material is needed.
Yellow denotes user attention is required.
Flashing yellow denotes a drum is empty (when
equipped with proximity sensors).
Red denotes immediate user attention is required due to
an alarm condition or interruption of material flow. The
user should be aware that in the case of a motor error
on a Single or Tandem system, or a Tandem system
with both drums empty, heat may be applied to the
platen and pump to allow for a drum change.
TI8540A
FIG. 26
24 COM
Terminal block
PCB 300 EasyKey Board
J7
1272
1
3031
3041
2
3
4
5
3051
0 LT302
1
Light
2 Tower
3
1271
+24V
Terminal block
#18 Blue
MTW TYP
TI8523A mod
FIG. 27
80
311208H
311208H
0#"
0#"
0#"
'.$ "53
8 7)2% $5#4
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&
"
%
!
#
"
4
"
4
"
4
$#
).42&
332
./
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8 7)2% $5#4
////////
8 7)2% $5#4
////////
7
7
7
7
7
7
'.$
'.$
332 332 8 7)2% $5#4
03
////////
$#
).42&
&5 332 332 #/.
&5 ////////
#/. ///////////////
8 7)2% $5#4
///////////////
'&%0 '.$
'.$
'.$
8 7)2% $5#4
Advanced Units
Light Tower Kit Recommended Wire Routing
8 7)2% $5#4
EasyKey
'.$
,5'
1271
1272
&!.
$)3#
TI8541a
8 7)2% $5#4
FIG. 28
81
Advanced Units
Drum Low and Empty Sensor Kit
253559
This kit is standard on Code G options A,T, and S. The
kit must be purchased if Code G option B is selected.
The Drum Low and Empty Sensor Kit is used to indicate
that a drum is EMPTY or LOW, depending on the adjustment of the proximity switch. The kit contains a sensor
mounting bracket (A), activator (B), sensors (C), and a
cable for connecting to the Therm-O-Flow 200 control
panel. See FIG. 29.
The low and empty conditions will be displayed in the
status bar of the EasyKey display. An optional light tower
is also available.
With the optional light tower a yellow light indicates a
drum low condition. A flashing yellow light indicates a
drum empty condition. In a tandem system a red light
indicates both drums are empty. See “Light Tower Kit
(253547)” on page 80.
When ordering this kit individually to connect to an existing Therm-O-Flow 200 unloader assembly, use the
bolts, screws and washers provided to mount to the
closest ram post to the control box. Mount the limit
switches to the bracket as shown.
Increasing the distance between the low and empty sensors (C) increases the heat up time for the tandem secondary system. Lowering the drum empty sensor forces
the heated follower plate lower into the drum. If this is
set too low the pump could cavitate causing a system
alarm.
A
7 490
*
#/
*
0#" 5.,/!$%2 "/!2$
TI8137A
B
#/2$ '2)0
".
"+
02/8
3%.3/2 ,/7
C
7(
"5
".
"+
7(
%84%2.!, #/.42/,
02/8
3%.3/2 %-049
"5
#/2$ '2)0
mity Sensor
ections
Therm-O-Flow 200 with Proximity Switches Installed. Ram is in
full down position.
2.0”
2.0”
3.0”
TI8161A
FIG. 29: Optional Low level Kit
82
311208H
Advanced Units
Ethernet Kit (253566)
This kit is intended for use with the TOF 200 unloaders
and accessory box. The ethernet kit is designed so that
the user will have network access to the Therm-O-Flow
200 unit and can clear, display, download, restore, and
reset various values from a remote location. This kit
includes a Graco Ethernet Expansion Board (15H816),
internal Cat 5E patch cord, and the RJ45 panel mount
jack.
Web Interface
Web Interface - allows users to connect, view, and
change the setup, log, and error files. It does not display
run data.
If Java Error appears when running the program
for the first time, you must download Java RTE (Run
Time Environment) for the program to operate correctly.
Follow the screen link to Java version 1.4.2.09 or newer.
Or enter http://java.sun.com/j2se/1.4.2/download.html
and select Download J2SE JRE. The file is approximately 15 MB.

If the Graco program will not start, check the
following.
Is the power on?
Are the cables fully seated in both the PC and
Therm-O-Flow 200 ports?
•
Are the LEDs on the PC ethernet connector
illuminated?
•
Are the LEDs on the EasyKey ethernet mod
illuminated? The bottom left LED should be
constantly illuminated showing a network
connection. The bottom right LED should
illuminate when network traffic is occurring.
If there are no LEDs illuminated check for
loose connections or a loose board.
Use the web I/F Software to:
•
Install EasyKey Software
•
View
 error log
 material usage report
 setup values
•
Upload
 setup values
 a custom language to view on screen
•
Download
 setup values
 error log
 a custom language file
•
Clear
 error log
 material usage report
•
Reset
 settings to factory default
 password
•
Record
 temperature and cycle data
311208H
To isolate the problem, try communicating with a
different PC.
Check Local Network Connection. See page
85.
83
Advanced Units
Web Interface
•
Local Network Connection (most common). Patch
cable from the local network plugs into the TOF 200
Web Interface connection. See FIG. 30 and page 85.
•
Direct Connection to the TOF 200 crossover cable
from the PC plugs into the TOF 200 Web Interface
connection. See FIG. 30 and page 88.
There are two possible ways to connect a PC to the TOF
200.
Non-hazardous Area Only
Local
Network
Patch Cable
Patch Cable
Local Network Connection
or
Laptop PC
Direct Connection
TI8570A
Patch Cable
TOF 200 Enclosure
FIG. 30 Network Selection
84
311208H
Advanced Units
Local Network Connection
Hardware and Software Configuration
Hardware
Patch cables are used to connect each TOF 200 unit to
the local network and to the Web connection (A) on the
EasyKey panel. See FIG. 31
9. The TOF 200 EasyKey software requires Sun java
to operate. Open your web browser options
advanced tab and select Java (Sun) and deselect
the Microsoft VM selection. See FIG. 32. If the Sun
Java option is not available follow the Software
Operation procedure and load the Sun Java program when the appropriate screen and link appear.
Browser must be closed and restarted for change
to be effective.
A
Use smooth scrolling
HTTP 1.1 settings
ti8557
FIG. 31 EasyKey Web Connection
Microsoft Browser Configuration
8. Establish a connection/address to the local network.
a. Open the PC control panel.
b.
Select Network Connections.
c.
Double click on the local area connection.
d. Select Properties.
e. Select Internet Protocol (TCP/IP).
f.
Select Properties.
Use HTTP 1.1
Use HTTP 1.1 through proxy connections
Java (Sun)
Use Java 2 v1.4.2_09 for <applet> (requires restart)
Microsoft VM
Java console enabled (requires restart)
Java logging enabled
JIT compiler for virtual machine enabled (requires restart)
FIG. 32 Java Internet Options
It may be necessary to change the Java selection
from Sun to Microsoft for other software applications to
run correctly on your PC.
If you cannot make these changes contact your I.S.
department and request they change your computer
access rights. You must have administrative rights to
change the settings.
g. Select the appropriate Internet connection and
key in address 192.168.0.10
311208H
85
Advanced Units
Software Operation
Reports
1. Open Microsoft Internet Explorer.
Display material usage report - shows the material
pumped from the TOF 200. See FIG. 34.
2. In the address area type http://192.168.0.1
3. Click Enter.
4. Select yes when security screen appears.
5. Main software screen appears. See FIG. 33.
•
If “Cannot Read Firmware” appears check for
loose hardware connections.
•
If “Java script needs to be loaded” appears follow the screen link to install this freeware.
FIG. 34 Display Material Usage report
Clear material usage report - deletes the material
usage from the system run screen batch total. Does not
reset grand total in setup.
Record Temperature and Cycles - records temperature and cycle information once per minute. A file is
opened and data recorded. See FIG. 35.
FIG. 35
While data is recorded other web functions are unavailable. See FIG. 36.
FIG. 33 Main Software Screen
Web Navigation Screens
From the main screen (see FIG. 33) the operator can
select buttons for reports, error log, setup, software/resets, or language.
86
FIG. 36
311208H
Advanced Units
Error Log
Reset password - clears password if lost or forgotten.
Download error log - downloads the error log to the
PC.
Language
Display error log - displays the number of alarms, date,
time, recipe and what the error was. See FIG. 37.
Download custom Language - saves the current
system language to the PC. This file is opened and a
custom language added to the B column of the Excel
file. See FIG. 39.
Custom languages are limited to Ascii and Ascii
extended characters and a maximum of 32 characters.
Save the Excel file as a tab delineated file for uploading
purposes.
Restore custom language - allows the custom language file to be uploaded to the TOF.
FIG. 37 Display Error Log
Clear error log - deletes the errors from the display.
Setup
Download setup values - saves the TOF configuration
to the PC. This file can be opened and edited using
Microsoft Excel, or used to set up multiple systems.
Display setup values - indicates what values are
currently being used for the system. Allows the operator
to verify that the right values are being used. See FIG.
38.
FIG. 39 Download Custom Language
Advanced Configuration
To change IP settings use the freeware configuration
program available from www.lantronix.com/device-networking/utilities-tools/device-installer.html.
FIG. 38 Display Set up
Restore setup values - allows files to be uploaded and
restored to the TOF.
Software/Resets
Install EasyKey software - downloads the Graco
provided software to the PC (approximately 5 minutes).
Once complete the control panel will be reprogrammed
from the EasyKey.
Reset settings - places system back to factory default
mode.
311208H
87
Advanced Units
Ethernet Kit Installation
Graco Kit 253566 is required for this connection.
D
Do not operate Therm-O-Flow 200 with equipment
enclosure doors/covers open. Disconnect power
source before servicing or electrically wiring.
ti8557
Kit Installation
FIG. 40 RJ45 Bulkhead Connector Installation
1. Power the Therm-O-Flow system off and disconnect
power source.
Changing Network Configuration
2. Open the control panel door.
1. Connect PC to ethernet connection on EasyKey
with the crossover cable.
3. Remove the EasyKey Display shield.
2. Connect network to PC with DeviceInstaller.
4. Locate the 10 pin Expansion Connector J9 (A) on
the lower right of the EasyKey Display Assembly
249480 (B). See FIG. 41.
5. Plug the Ethernet Assembly 249183 (C) into J9
making sure the RJ45 connector is oriented down.
See FIG. 42 and FIG. 43.
6. Secure the Ethernet Assembly 249183 (C) to the
EasyKey Display 249480 (B) using the hardware
provided.
7. Remove plug (D) covering Ethernet opening at the
upper right corner of the Control Panel. See FIG. 40.
8. Secure Bulkhead Receptacle in the Ethernet opening at the upper right corner of the Control Panel.
3. Run DeviceInstaller program.
A freeware configuration program is available
from www.lantronix.com/device-networking/utilities-tools/device-installer.html
4. To change IP Address from Default setting
192.168.0.1
a. Run DeviceInstaller
b.
Click “Search”
c.
Select device
d. Click “Assign IP”
Select and assign specific IP address.
9. Connect one end of the Ethernet cable to Ethernet
Assembly 249183 (C).
i. Input address
10. Replace EasyKey Display shield connecting ground
terminal from Ethernet Bulkhead connector to upper
right stud.
iii. Click “Assign” (unit is programmed and will
now reboot)
11. Connect the other end of the Ethernet cable to the
Ethernet bulkhead receptacle.
v. Close/Exit DeviceInstaller
12. Close the Control Panel door.
ii. Enter subnet mask 255.255.255.0
iv. Click “Finish”
Alternate method via telnet and port 9999.
Serial Port Setup
Kit is pre-programmed with these settings.
- 57,600 baud, 8-bit, no parity, 1-stop bit.
88
311208H
Advanced Units
EasyKey Modbus / TCP Wiring Diagram
C
C
B
B
A
TI8761
FIG. 42
TI8762
FIG. 41
C
#",
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#!2$
*
*
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37)4#(
0#" B
*
See page 55 for a
complete drawing:
FIG. 43
311208H
89
Advanced Units
Maintenance Call Kit (253548)
The maintenance call kit is designed for the user to indicate an issue has occurred and needs to be addressed,
but the unit keeps operating if no serious faults have
occurred. With the optional light tower kit the maintenance call button (E) causes the yellow light to flash
making the problem more obvious. See FIG. 44. This kit
includes the push button actuator and internal harness
to connect the button. For additional light tower information see “Light Tower Kit (253547)” on page 80.
E
TI8557A
FIG. 44
90
311208H
Advanced Units
Maintenance Call Kit (253548) Wiring
0#" %!39 +%9 "/!2$
6
*
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7()4%9%,,/7
7()4%'2%%.
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7()4%0520,%
'2%%.
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7()4%'2%9
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ti8559
FIG. 45
311208H
91
Advanced Units
Discrete I/O Kit (253567)
The discrete I/O kit is designed to connect to robots or
PLC that control the primary unit. This connection allows
the communication of System On/Off, Heat On/Heat
Soak/Ready, Setback, Drum Empty, Warnings, Alarms,
Maintenance, and Gun switch. Included in this kit is the
Internal Cable Harness to convert the primary unit and
the 40 ft external cable, which has individual wire on the
robot/PLC end for the user to install.
Digital Output
See FIG. 48. Connect +Vdc to pins 5 or 14. EasyKey will
toggle outputs to +Vdc when activated.
Digital Inputs
See FIG. 48. Connect “Digital Reference” to pin 1. All
unused inputs must be tied “low” to “Digital Reference.”
To activate signal, toggle from “Digital Reference” to
+Vdc. To deactivate signal, toggle from +Vdc to “Digital
Reference”.
TI8558A
FIG. 46
Examples
System On/Off
8 7)2% $5#4
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03
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////////
“Digital Reference” is the ground reference for the
+Vdc coming from the robot or PLC.
To EasyKey
8 7)2% $5#4
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7
7
7
7
7
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///////////////
$)3#
8 7)2% $5#4
+Vdc can range from 10-30 Vdc.
8 7)2% $5#4
8 7)2% $5#4
•
Toggle from “Digital Reference” to +Vdc to turn air
motor solenoid on.
Toggle from +Vdc to “Digital Reference” to turn air
motor solenoid off.
./
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&5 &5 &5 &5 &5 &5 332 332 332 332 &!.
Pump On/Off
•
'.$
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332
8 7)2% $5#4
332 •
Toggle from “Digital Reference” to +Vdc to turn heat
on.
Toggle from +Vdc to “Digital Reference” to turn heat
off.
332 •
#/.
&5 Heat On/Off
&5 332 $
&
"
%
!
#
"
4
"
4
"
4
•
Preferred Routing
Toggle from “Digital Reference” to +Vdc to turn system on.
Toggle from +Vdc to “Digital Reference” to turn system off.
&5 •
8 7)2% $5#4
FIG. 47
92
311208H
Advanced Units
Robot I/O Cable, Part No. 120400
Pin
No. Signal Description
Digital Input Reference
Digital Input Ref
Yellow
2
System On/Off
Digital Input
Brown
3
Heat On/Off
Digital Input
Red
4
Pump On/Off
Digital Input
Orange
5
24 Vdc from Robot/PLC
Digital Input Ref
Tan
6
System On/Off
Digital Output
Green
7
System Run
Digital Output
Blue
8
Heat On/Heat Soak Ready
Digital Output
Violet
9
Setback
Digital Output
Gray
10
Drum Empty
Digital Output
White
11
Warning
Digital Output
White/Black
12
Alarm
Digital Output
Pink
13
Maintenance
Digital Output
White/Red
14
24 Vdc from Robot/PLC
Digital Input Ref
Red/Green
15
Analog Gnd Ref
17
ti8559b
Wire Color
1
16
For use with
optional Maintenance Call
Kit (253566)
Signal Type
Analog Gnd Ref
18
Analog Gnd Ref
Red/Yellow
Analog Input
White/Yellow
Analog Gnd Ref
White/Green
Analog Output
White/Blue
19
Ground
Shield Connection
27
Maintenance Call Button
Digital Output
Black
28
Maintenance Call Button
Digital Input Ref
Red/Black
FIG. 48
311208H
93
94
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8 7)2% $5#4
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3()%,$
8 7)2% $5#4
7
7
7
7
7
7
'.$
'.$
8 7)2% $5#4
&5 8 7)2% $5#4
&5 &5 &5 &5 &5 &5 332 332 332 332 332 332 #/.
03
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$#
).42&
&5 ////////
#/. ///////////////
8 7)2% $5#4
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'&%0 '.$
'.$
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8 7)2% $5#4
All Models Control Panel Component Layout
All Models Control Panel Component Layout
8 7)2% $5#4
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TI8511a
311208H
All Models Control Panel Component Layout
Spare Parts
Spare parts
Graco Part No.
Description
253566
253147
117769
253603
253547
120400
15H386
15H385
121228
120384
15H298
120275
120271
253548
253567
253559
15H592
15H593
15H594
15H595
Ethernet Kit
EasyKey Display Kit
LCD Graphic Display
Drum Low and Empty Sensors
Light Tower Kit
Discrete I/O Cable
Air Motor Sensor Cable
Crossover Comm Cable
Can Cable (for units dated after 6/19/2008)
Swirl Cable
Platen RTD Sensor
Pump RTD Sensor
Pump Heater 600W
Maintenance Call Button Kit
Discrete I/O Kit
Drum Low and Empty Sensor kit
Pump Bottom Cover
Pump Left Cover
Pump Right Cover
Pump Front Cover
Electrical Enclosure Spare Parts
311208H
Reference No.
Graco Part No.
PCB246
PCB201, 226
SR106, 113, 116, 119,
122, 125, 128
SSR130
DISC 100
DISC 100
N/A
N/A
FU1061, 1062
FU106, 108
FU113, 119, 125
FU116, 122, 128
PS122
GFPE112
N/A
249404
249405
120398
120399
120437
120438
120439
120440
116214
120426
116208
116209
120427
120428
120430
Description
6 Zone
8 Zone
Unloader Board
Temperature Board
18 amp Watlow SSR
1
2
5
1
2
7
65 amp Watlow SSR
Disconnect 60A
Disconnect 80A
Door Operating Mech - Disconnect
Shaft Disconnect
15A Fuse
7A Fuse
6A Fuse
2-1/4A Fuse
DC Pwr Supply 24V
GFPE
5KVA Transformer
1
1
1
1
1
2
2
2
2
1
1
1
1
1
1
2
2
3
3
1
1
1
95
Dimensions
Dimensions
Ram Mounting and Clearance Dimensions
61 in.
(154.9 cm)
42 in.
(106.7 cm)
25 in.
(63.5 cm)
32.5 in.
(82.6 cm)
21 in.
(53.3 cm)
TI7932A
60 in.
(152.4 cm)
Ram measures 110
in. (279.4 cm) high
when fully raised.
89 in.
(226.1 cm)
13 in.
(33 cm)
96
48 in.
(121.9 cm)
TI7937A
311208H
Technical Data
Technical Data
Displacement pump effective area . . . . . . . . . . . . . . . . . . 1.24 in.2 (8 cm2)
Volume per cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7 in.3 (192 cm3)
Pump cycles per 1 gal. (3.8 liters) . . . . . . . . . . . . . . . . . . 21
Maximum fluid working pressure
NXT 2200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300 psi (15.9 MPa, 159 bar)
NXT 3400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (20.7 MPa, 207 bar)
NXT 6500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (20.7 MPa, 207 bar)
Maximum air input pressure (Ram) . . . . . . . . . . . . . . . . . 125 psi (0.85 MPa, 8.5 bar)
Maximum air input pressure (Pumps). . . . . . . . . . . . . . . .
NXT 2200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NXT 3400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NXT 6500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum pump operating temperature . . . . . . . . . . . . . .
100 psi (0.7 MPa, 7 bar)
82 psi (0.57 MPa, 5.7 bar)
43 psi (0.29 MPa, 2.9 bar)
400°F (204°C)
Air motor piston effective area
NXT 2200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.3 in.2 (182 cm2)
NXT 3400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2 in.2 (285 cm2)
NXT 6500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.5 in.2 (545 cm2)
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npsm(f)
Pump fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 in. npt(f)
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carbon steel; brass; chrome, zinc, and nickel plating; 304,
316, 440, and 17-4 PH grades of stainless steel; alloy
steel; ductile iron; PTFE
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 lb (545 kg)
Displacement pump weight . . . . . . . . . . . . . . . . . . . . . . . 81 lb (37 kg)
Instruction Manuals
Heated Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309160
Wiper Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309196
Bare Displacement Pump Lower . . . . . . . . . . . . . . . . 308570
6.5 in. (165 mm) Global Ram Module . . . . . . . . . . . . 310523
Power requirements
Compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-50 scfm (typical)
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*
with standard melt grid. . . . . . . . . . . . . . . . . . . . . . . . 24.5 kVa
with Mega-Flo melt grid . . . . . . . . . . . . . . . . . . . . . . . 27.5 kVa
with smooth melt grid . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 kVa
* Includes drum melt grid, pump, and a 5 kVa transformer for the 230 V hoses and accessories.
311208H
97
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 procedures concernées.
Graco Information
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1-800-328-0211 Toll Free
612-623-6921
612-378-3505 Fax
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.
This manual contains English. MM 311208
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2006, Graco Inc. is registered to I.S. EN ISO 9001
www.graco.com
Revised11/2008
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