Graco 334130R, Therm-O-Flow 200 Instructions

Instructions-Parts
Therm-O-Flow® 200
334130R
EN
For applying hot melt sealant and adhesive materials from 200 Liter (55 Gallon) drums. For
professional use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this manual
and in related manuals. Save these instructions.
Maximum Operating Temperature 400°F (204°C)
See page 7 for model information.
See Technical Specifications, page 113, for maximum
working pressures.
3143485
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Identification . . . . . . . . . . . . . . . . . . . . 9
Integrated Air Controls . . . . . . . . . . . . . . . . . . . 10
Electrical Control Enclosure . . . . . . . . . . . . . . . 11
Advanced Display Module (ADM) . . . . . . . . . . . 12
Screen Components . . . . . . . . . . . . . . . . . . . . . 14
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air and Fluid Hoses . . . . . . . . . . . . . . . . . . . . . . 15
Heat Control Zone . . . . . . . . . . . . . . . . . . . . . . . 15
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unpack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Location Requirements . . . . . . . . . . . . . . . . . . . 16
Install System . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install Hydraulic Power Supply . . . . . . . . . . . . . 16
Mechanical Setup . . . . . . . . . . . . . . . . . . . . . . . 17
Install Heated Hose . . . . . . . . . . . . . . . . . . . . . . 18
Connect Multiple Devices . . . . . . . . . . . . . . . . . 19
Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . 20
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connect Secondary System . . . . . . . . . . . . . . . 21
Check Sensor Resistance . . . . . . . . . . . . . . . . . 22
Check Heater Resistance . . . . . . . . . . . . . . . . . 23
Select ADM Settings . . . . . . . . . . . . . . . . . . . . . 24
Connect PLC (Hard Wired Interface Version) . . 26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Heat Up System . . . . . . . . . . . . . . . . . . . . . . . . 31
Prime Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Prime System . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Setback Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure Relief Procedure . . . . . . . . . . . . . . . . 35
Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Change Drums . . . . . . . . . . . . . . . . . . . . . . . . . 38
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Light Tower (Optional) . . . . . . . . . . . . . . . . . . . 40
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Ram Troubleshooting . . . . . . . . . . . . . . . . . . . . 47
Heated Pump Troubleshooting . . . . . . . . . . . . . 48
Air Motor Troubleshooting . . . . . . . . . . . . . . . . . 48
2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replace Wipers . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replace Platen RTD . . . . . . . . . . . . . . . . . . . . . 49
Separate the Air Motor and Pump . . . . . . . . . . . 50
Remove Platen . . . . . . . . . . . . . . . . . . . . . . . . . 53
Replace Heater Band and Pump RTD . . . . . . . 53
Replace MZLP Fuse . . . . . . . . . . . . . . . . . . . . . 54
Replace MZLP . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Replace MZLP Daughter Card . . . . . . . . . . . . . 56
Replace AWB . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Replace Power Supply . . . . . . . . . . . . . . . . . . . 57
Replace Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Replace Transformer . . . . . . . . . . . . . . . . . . . . . 59
Update Software . . . . . . . . . . . . . . . . . . . . . . . . 61
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 62
230V, 3 Phase/60Hz . . . . . . . . . . . . . . . . . . . . . 62
400V, 3 Phase/50Hz . . . . . . . . . . . . . . . . . . . . . 63
400-600VV, 3 Phase/60Hz . . . . . . . . . . . . . . . . 64
AWB and MZLP#1 . . . . . . . . . . . . . . . . . . . . . . . 65
MZLP#2, MZLP#3, Overtemp, and Pump Heaters
66
MZLP Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Therm-O-Flow 200 Supply Unit . . . . . . . . . . . . . 68
Therm-O-Flow 200 Supply Unit . . . . . . . . . . . . . 69
Air Control Assembly . . . . . . . . . . . . . . . . . . . . . 70
Electrical Module . . . . . . . . . . . . . . . . . . . . . . . . 71
Electrical Control Module Parts . . . . . . . . . . . . . 73
Electrical Panel . . . . . . . . . . . . . . . . . . . . . . . . . 75
230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Electrical Panel Parts . . . . . . . . . . . . . . . . . . . . 77
Merkur 2200, 23:1 Pump Modules . . . . . . . . . . 78
Merkur 2200, 23:1 Pump Modules . . . . . . . . . . 79
Merkur 3400, 36:1 Pump Modules . . . . . . . . . . 80
Merkur 3400, 36:1 Pump Modules . . . . . . . . . . 81
NXT 6500, 70:1 Pump Modules . . . . . . . . . . . . 82
NXT 6500, 70:1 Pump Modules . . . . . . . . . . . . 83
24V619, Pump Shield . . . . . . . . . . . . . . . . . . . . 84
Heated Platens . . . . . . . . . . . . . . . . . . . . . . . . . 85
24V633, Heated Drum Platen, Mega-Flo (Code
E-option M) . . . . . . . . . . . . . . . . . . . . . . . . . 85
24V634, Heated Drum Platen, Standard Grid (Code
E-option F) . . . . . . . . . . . . . . . . . . . . . . . . . 85
334130R
24V635, Heated Drum Platen, Smooth Bottom (no
fin) (Code E- option S) . . . . . . . . . . . . . . . . 85
Heated Platens . . . . . . . . . . . . . . . . . . . . . . . . . 86
24V633, Heated Drum Platen, Mega-Flo (Code
E-option M) . . . . . . . . . . . . . . . . . . . . . . . . . 86
24V634, Heated Drum Platen, Standard Grid (Code
E-option F) . . . . . . . . . . . . . . . . . . . . . . . . . 86
24V635, Heated Drum Platen, Smooth Bottom (no
fin) (Code E- option S) . . . . . . . . . . . . . . . . 86
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Drum Ram Post Saddle Clamp . . . . . . . . . . . . . 88
C32463 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Option H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Drum Ram Post Saddle Clamp . . . . . . . . . . . . . 89
918395 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Option H-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Fiber Drum Reinforcement Shell Clamp . . . . . . 90
918397 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Option H-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Vent Hood Kit, 233559 . . . . . . . . . . . . . . . . . . . 91
Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . 92
Wiper Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Applicators and Dispense Valves . . . . . . . . . . . 92
CGM Installation Kit, 25C994 . . . . . . . . . . . . . . 92
Flow Control and Manifolds . . . . . . . . . . . . . . . . 92
Accessory Extension Cables . . . . . . . . . . . . . . . 93
Light Tower Kit, 24W589 . . . . . . . . . . . . . . . . . . 93
Heated Hoses and Fittings . . . . . . . . . . . . . . . . 94
8 Channel Upgrade Kit, 24V755 . . . . . . . . . . . . 96
8 Zone Upgrade Kit Installation . . . . . . . . . . . . . 97
12 Channel Upgrade Kit, 24V756 . . . . . . . . . . . 98
12 Zone Upgrade Kit Installation . . . . . . . . . . . . 99
Appendix A - ADM . . . . . . . . . . . . . . . . . . . . . . . . 100
General Operation . . . . . . . . . . . . . . . . . . . . . . 100
ADM Power . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Screen Navigation . . . . . . . . . . . . . . . . . . . . . . 100
Enable, Disable Heating System . . . . . . . . . . . 100
Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Operation Screens . . . . . . . . . . . . . . . . . . . . . 102
Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . 104
334130R
Appendix B - USB Data . . . . . . . . . . . . . . . . . . . . 109
Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Access Files . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Upload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
System Settings File . . . . . . . . . . . . . . . . . . . . 110
System Language File . . . . . . . . . . . . . . . . . . . 111
Create Custom Language Strings . . . . . . . . . . 111
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Ram Mounting and Clearance . . . . . . . . . . . . . 112
Technical Specifications . . . . . . . . . . . . . . . . . . . 113
California Proposition 65 . . . . . . . . . . . . . . . . . . . 113
Graco Standard Warranty . . . . . . . . . . . . . . . . . . 114
3
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
•
Do not touch hot fluid or equipment.
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen,
splatter may occur.
•
Use minimum air pressure when removing platen from drum.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
•
•
•
Keep clear of moving parts.
Do not operate equipment with protective guards or covers removed.
Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
•
•
•
Turn off and disconnect power at main switch before disconnecting any cables and before servicing or
installing equipment.
Connect only to grounded power source.
All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
•
•
4
Read MSDSs to know the specific hazards of the fluids you are using.
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
334130R
Warnings
WARNING
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to
the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
•
•
Open a valve to relieve the fluid expansion during heating.
Replace hoses proactively at regular intervals based on your operating conditions.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
•
•
•
•
•
•
•
Engage trigger lock when not dispensing.
Do not point dispensing device at anyone or at any part of the body.
Do not put your hand over the fluid outlet.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
Tighten all fluid connections before operating the equipment.
Check hoses and couplings daily. Replace worn or damaged parts immediately.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
•
•
•
•
•
•
•
•
•
334130R
Use equipment only in well ventilated area.
Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
Keep work area free of debris, including solvent, rags and gasoline.
Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are
present.
Ground all equipment in the work area. See Grounding instructions.
Use only grounded hoses.
Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are
antistatic or conductive.
Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until
you identify and correct the problem.
Keep a working fire extinguisher in the work area.
5
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•
•
•
•
•
•
•
•
•
•
•
•
•
Do not operate the unit when fatigued or under the influence of drugs or alcohol.
Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about
your material, request MSDS from distributor or retailer.
Do not leave the work area while equipment is energized or under pressure.
Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
Make sure all equipment is rated and approved for the environment in which you are using it.
Use equipment only for its intended purpose. Call your distributor for information.
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not kink or over bend hoses or use hoses to pull equipment.
Keep children and animals away from work area.
Comply with all applicable safety regulations.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is
not limited to:
•
•
6
Protective eyewear, and hearing protection.
Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
334130R
Models
Models
The model number stamped on your systems defines the equipment in the following categories.
See Technical Specifications, page 113, for maximum working pressure.
SER
Series
Code A
200
Code B
A
E
Code C
11P
11S
12P
12S
13P
13S
14P
14S
15P
15S
21P
21S
22P
22S
23P
23S
24P
24S
25P
25S
31P
31S
32P
32S
33P
33S
34P
34S
35P
35S
334130R
A
Frame Size
B
Air
Air/Electric
C
Zone
Config
Frame Size
55 Gallon (200 Liter)
Air/Electric
Air control only
Air and Electric
Zones, Volts, Type
4 Zones, 230 V, Primary
4 Zones, 230 V, Secondary
4 Zones, 400 V/N, Primary
4 Zones, 400 V/N, Secondary
4 Zones, 400 V, Primary
4 Zones, 400 V, Secondary
4 Zones, 480 V, Primary
4 Zones, 480 V, Secondary
4 Zones, 600 V, Primary
4 Zones, 600 V, Secondary
8 Zones, 230 V, Primary
8 Zones, 230 V, Secondary
8 Zones, 400 V/N, Primary
8 Zones, 400 V/N, Secondary
8 Zones, 400 V, Primary
8 Zones, 400 V, Secondary
8 Zones, 480 V, Primary
8 Zones, 480 V, Secondary
8 Zones, 600 V, Primary
8 Zones, 600 V, Secondary
12 Zones, 230 V, Primary
12 Zones, 230 V, Secondary
12 Zones, 400 V/N, Primary
12 Zones, 400 V/N, Secondary
12 Zones, 400 V, Primary
12 Zones, 400 V, Secondary
12 Zones, 480 V, Primary
12 Zones, 480 V, Secondary
12 Zones, 600 V, Primary
12 Zones, 600 V, Secondary
D
Pump
Ratio
E
Platen
Style
NNN
Code D
1
2
3
4
5
6
Code E
S
F
M
Code F
1
F
Platen
Seal
G
Ram
H
Drum
Clamp
None
Pump Ratio
23:1 CF (carbon filled PTFE)
36:1
70:1
23:1 (glass filled PTFE)
36:1
70:1
Platen Style
Smooth Bottom (No Fin)
Standard Finned Bottom
Mega-Flo
Platen Seal
2 Black EPDM/EPDM, SS wire braid 400°F
(204°C) hose wipers with spring retention
2
1 lower black EPDM/Chlorobutyl, SS wire
braid 400°F (204°C) hose wiper and 1
upper Green Silicone, fiberglass braid
400°F (204°C), hose wiper
3
2 White Silicone 250°F (121°C) T-Wipers
4
1 lower black EPDM/Chlorobutyl, SS wire
braid 375°F (190°C) hose wiper and 1
upper White Silicone 375°F (190°C),
T-wiper
5
2 Orange silicone o-ring 400°F (204°C)
Code G
Ram
P
Pneumatic
H
Hydraulic
Code H
Drum Clamps
N
None
1
Saddle Clamp
2
Fiber Clam Shell
3
Heavy Drum Band
7
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Manual
Description
334129
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311238
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334127
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Check-Mate® 800 Throat Seal Repair Kit,
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Accessory and Kit Manuals
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8
334130R
Component Identification
Component Identification
D
C
M
A
J
P
B
N
L
K
F
T
H
R, S
G
E
ti24544a
FIG. 1: TOF 200 Pneumatic
Key:
A
B
C
D
E
F
G
H
J
K
L
M
Lift Strap Positions
Multi-Zone Low Power Temperature Control Module
(MZLP)
Light Tower
Cable Track
Ram
Heated Pump
Heated Platen
Integrated Air Controls (3/4 in npt inlet)
Electrical Control Panel
Main Power Switch (can be locked in the open position)
ADM
Air Motor Solenoid
334130R
N
P
R
S
T
Electrical Power Input
Air Motor
Ram Plate Bleed Stick
Drum Blow Off Valve (behind ram plate bleed stick)
Drum Low and Empty Sensors
9
Component Identification
Integrated Air Controls
CN
CM
CL
CK
CJ
CF
CH
CG
CD
CE
CC
CB
CA
FIG. 2: Integrated Air Controls
Key:
CA Main Air Slider Valve
Turns air on and off to the entire system. When closed,
the valve relieves pressure downstream. Can be locked in
the closed position.
CB Ram Down Air Regulator
Controls the ram down pressure.
CC Ram Director Valve
Controls the ram direction.
CD Ram Up Air Regulator
Controls the ram up pressure.
CE Ram Down Air Gauge
Displays the ram down pressure.
CF Ram Up Air Gauge
Displays the ram up pressure.
CG Blowoff Button
Turns air on and off to push the platen out of an empty
drum.
10
CH Blowoff Pressure Gauge
Displays the blowoff pressure.
CJ Blowoff Air Regulator
Controls platen blowoff pressure.
CK Air Motor Air Regulator
Controls the air pressure to the motor.
CL Air Motor Pressure Gauge
Displays the air pressure to the motor.
CM Air Motor Slider Valve
Turns air on and off to the air motor. When closed, the
valve relieves air trapped between it and the motor. Push
the valve in to shut off air. Can be locked in the closed
position.
CN Air Motor Solenoid Valve
Turns air on and off to the air motor when system stopped
on the ADM. When closed, the valve relieves air trapped
between it and the motor.
334130R
Component Identification
Electrical Control Enclosure
DA
DB
DG
DH
DJ
DL
DK
DF
DN
DE
DD
DM
DC
Back Panel With Transformer
FIG. 3: Electrical Enclosure
Key:
DA Multi-Zone Low Power Temperature Control Module
(MZLP)
DB Ventilation Grill
DC Electrical Control Panel
DD Automatic Wiring Board (AWB)
DE Power Supply (24V)
DF Residual Current Device (GFI), 63A
334130R
DG
DH
DJ
DK
DL
DM
DN
Platen SSR (65A)
Platen Contractor
Platen Fuse
Transformer Circuit Breaker
Transformer Fuse
Transformer
System Contactor
11
Component Identification
Advanced Display Module
(ADM)
The ADM display shows graphical and text information
related to setup and spray operations. For detail on the
display and individual screens, see Appendix A - ADM,
page 100.
NOTICE
To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens, plastic
cards, or fingernails.
Use the USB port on the ADM to download or upload data. For more information about the USB data, see Appendix B - USB Data, page 109.
BB
BC
System Shutdown
BA
Enable/Disable
BD
BE
BF
BH
BG
FIG. 4: Front View
Key
BA
BB
BC
BD
BE
BF
BG
BH
12
Function
Heating system and Pump Enable/Disable
System status indicator (LED)
Stop all system processes
Defined by icon next to softkey
Abort current operation
Accept change, acknowledge error, select
item, toggle selected item
Toggle between Operation and Setup
screens
Navigate within a screen or to a new screen
334130R
Component Identification
BK
BL
BM
BR
BN
BP
FIG. 5: Back View
BK
BL
BM
BN
BP
BR
Part Number and Identification Label
USB Interface
CAN Cable Connection (Power Supply and
Communication)
Module Status LEDs
Light Tower (Optional)
Software Token Access Panel
Table 1 ADM LED Status Descriptions
LED
System Status
Conditions
Green Solid
Green Flashing
Yellow Solid
Description
Run Mode, System On
Setup Mode, System On
Run Mode, System Off
USB Status (BL)
Green Flashing
Yellow Solid
Green and Yellow Flashing
ADM Status (BN)
Green Solid
Yellow Solid
Red Steady Flashing
Data recording in progress
Downloading information to USB
ADM is busy, USB cannot transfer
information when in this mode
Power applied to module
Active Communication
Software upload from token in progress
Module error exists
Red Random Flashing or Solid
334130R
13
Component Identification
Screen Components
1. Screen Order
2. Current date and time
3. Operating Mode
4. Faults, Status
5. MZLP Plug Identifier
6. Zone Setpoint Temperature
7. Zone Actual Temperature
Operating Mode
System Off
Inactive
Warm Up
Heat Soak
Description
The system does not have power.
The heating system and pumps are disabled.
The system is heating the material to the
setpoint temperature.
Component Status
• No system status indicator LED on the
ADM
•
No heat
•
•
Pump is off
Yellow system indicator LED on the ADM
•
No heat
•
•
Pump is off
Flashing green system status indicator
LED on the ADM
•
Heat is increasing to setpoint temperature
•
Heat zones are all at temperature. Material •
is soaking for a user specified amount of
time.
•
•
Ready
Active
14
Heat is at setpoint
Material is absorbing more heat
•
Pump is off
•
Heat soak counter counts down on the
Home screen.
Flashing green system status indicator
LED on the ADM
All enabled zones are at setpoint tempera- •
ture. The Air Motor does not have power.
The system is ready to dispense.
Pump is off
Flashing green system status indicator
LED on the ADM
•
Heat is at setpoint
•
•
Pump is off
Solid green system status indicator LED
on the ADM
•
Heat is at setpoint temperature
•
Pump is on
334130R
Overview
Overview
A Heated Platen melts the sealant or adhesive and directs the molten material to the Pump inlet. The material
then travels through a Heated Pump and heated fluid
moves to the application tool.
Air and Fluid Hoses
The Therm-O-Flow requires Graco single-circuit material hoses rated at a maximum of 1250 watts. Make sure
all air and fluid hoses are properly sized for the system.
Heat Control Zone
The Therm-O-Flow has 4, 8, or 12 heat zones. Zones for
the Heated Drum Platen and the Heated Pump are not
included in the zone count. Zones 1 and 2, 3 and 4, 5
and 6, 7 and 8, 9 and 10, and 11 and 12 are each available through 12-pin connectors. The heated hoses have
a 16-pin connector at the inlet, and an 8-pin connector
at the outlet. All heated valves, manifolds, and heaters
are equipped with an 8-pin mating connector.
FIG. 6: Heat Control Zone Selection
334130R
15
Setup
Setup
1. Unpack the Ram
2. Locate and Install the Ram
3. Mechanical Setup
4. Connect hoses to Electrical Control Panel
5. Connect Electrical Control Panel to power source
5. Make sure there is easy access to an appropriate
electrical power source. The National Electrical
Code requires 3 ft (0.9 m) of open space in front of
the electrical panel. Comply with all local codes and
regulations.
6. For hydraulic rams, locate the hydraulic power supply in an area that has:
•
easy access for servicing and adjusting the
hydraulic pressure on the supply unit
7. Select ADM settings
•
sufficient clearance for the hydraulic lines that
attach to the Pump
Unpack
•
easy access to read the hydraulic fluid level
gauge
6. Ground system
1. Inspect the shipping box carefully for damage. Contact the carrier promptly if there is damage.
2. Open the box and inspect the contents carefully.
There should not be any loose or damaged parts in
the box.
3. Compare the packing slip against all items in the
box. Repost any shortages or other inspection problems immediately.
Install System
Refer to Dimensions, page 112 for mounting and clearance dimensions.
Follow all Location Requirements, page 16, when
selecting a location for the Ram.
1. Apply 50 psi download pressure to Ram.
4. Remove the unit from the skid and place it in the
desired location. See Location Requirements.
2. Wrap the bar with the lifting sling.
Location Requirements
3. Lift the system off the pallet using a crane or a forklift and place in desired location.
1. Make sure there is sufficient overhead clearance for
the Heated Pump and Ram when the Ram is in the
fully raised position (approximately 110 in. (280
cm)).
4. Level the base of the Ram, using metal shims.
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.
Install Hydraulic Power Supply
5. Bolt the Ram to the floor, using anchors that are
long enough to prevent the unit from tipping.
See the Ram manual for installation and dimensions.
3. Make sure the air regulators for the Heated Pump
and Ram are fully accessible, with room to stand
directly in front of the Pneumatic Control Panel and
the Electrical Control Panel.
4. When locating the system, do not install closer than
36 in. (914 mm) to vertical surfaces.
16
334130R
Setup
Mechanical Setup
4. Ensure Drum Low and Empty Sensors (C) are
mounted as shown.
1. Fill displacement Pump wet cup 2/3 full with Graco
Throat Seal Liquid (TSL™) for Butyl and PSA materials.
NOTE: Use IsoGuard Select® (IGS) (part no. 24F516)
for PUR or reactive Polyurethane material. IGS is
designed to dissolve and suspend the Polyurethane
materials. IGS will solidify after a period of time and
should be replaced once the solidified lube does not
return to liquid form after heating.
NOTE: The Drum Low and Empty Sensors are used to
indicate that a drum is empty. The kit contains a sensor
mounting bracket (A), activator (B), sensors (C1, C2),
and a cable for connecting the panel inside the Electrical
Enclosure.
A
C1
B
FIG. 7: Wetcup
C2
2. Turn all air regulators to their full counterclockwise
position. See Integrated Air Controls, page 10.
3. Connect a 1/2 in. (13 mm) air line from an air source
to the system air inlet (H), capable of delivering a
minimum of 25-50 cfm at 100 psi (0.7 MPa, 7.0 bar).
Do not use quick disconnects.
5. Increase the distance between the low (C1) and
empty (C2) sensors to increase the heat up time for
the tandem secondary system. Lower the drum
empty sensor (C2) to force the Heated Platen lower
into the drum. If empty sensor is set too low, the
Pump could cavitate and cause an alarm.
H
FIG. 8: Air Connection
334130R
17
Setup
Install Heated Hose
To connect a hose to a fluid control device or heated
manifold.
1. Install fitting and heated hose onto Pump outlet with
the large electrical connector side toward the system. Use 2 wrenches to tighten hose. Torque to 45
ft-lbs (61 N•m).
5. For proper operation, cables must be plugged into
zones 1–2 and 3–4 at all times.
6. Install cap on any unused MZLP electrical connectors.
7. Connect the small 8 pin connector from the heated
hose to the fluid control device or heated manifold.
NOTE: See Accessories and Kits, page 92, for available fittings and heated hoses.
FIG. 10: Heated Manifold 243697
FIG. 9
2. Wrap exposed fittings on the Pump outlet with
Nomex insulation and secure insulation using fiberglass tape.
3. Connect large heated hose connector to MZLP.
NOTE: The heated manifold (part no. 243697) shown.
See Accessories and Kits, page 92, for available manifolds and fluid control devices.
8. Use 2 wrenches to tighten hose. Torque to 45 ft-lbs
(61 N•m).
9. To connect multiple devices, see Connect Multiple
Devices, page 19.
4. Repeat for any remaining channels.
18
334130R
Setup
Connect Multiple Devices
•
Connect fluid control devices to a heated hose or
the Electrical Enclosure. Use accessories if necessary.
•
Setup all heat zones on Heat-A and Heat-B
screens.
If your application requires multiple fluid control devices:
•
Connect heated hose electrical connections to the
Electrical Enclosure. Remove from shipping box to
connect heated hoses to the Electrical Enclosure.
For additional cables, heated hose, and fluid control
devices, see Accessories and Kits, page 92.
Example: Heated zones used to connect a primary and
secondary system to a manifold and two guns. A-#
zones are on the Heat-A screen and B-# zones are on
the Heat-B screen.
FIG. 11
334130R
19
Setup
Connect Power
The Electrical Control Panel comes already attached
and wired to the Ram, however before the supply unit
becomes functional you must connect the Electrical
Control Panel to a power source.
All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
NOTE: Required voltage and amperage is noted on the
control panel label. Before running power to the unit,
make sure the plant electrical service meets the
machine’s electrical requirements. Branch circuit protection shall be provided by the end user.
Use copper conductors rated 600 volts minimum and
167°F (75°C) minimum only. Torque to 55 in-lb (6.2
N•m).
Table 2 Electrical Requirements
Electrical
Panel
Voltage
Hz
230 V
50/60
400 V/N 50/60
400 V
50/60
480 V
50/60
600 V
50/60
Phase Platen
3
EF, ES
EM
3
EF, ES
EM
3
EF, ES
EM
3
EF, ES
EM
3
EF, ES
3
EM
Full
Load
Amps
90
100
45
50
45
50
45
50
50
50
AWG
3 AWG
3 AWG
8 AWG
8 AWG
8 AWG
8 AWG
8 AWG
8 AWG
8 AWG
8 AWG
FIG. 12
To reduce the risk of fire, explosion, or electric shock,
the resistance between the supply unit components
and true earth ground must be less than 0.25 ohms.
3. Connect the ground wire to the ground lug. Have a
qualified electrician check the resistance between
each Therm-O-Flow system ground and the true
earth ground. The resistance must be less than 0.1
ohms. If the resistance is greater than 0.1 ohms, a
different ground site may be required. Do not operate the system until the problem is corrected.
NOTE: Use a meter that is capable of measuring resistance at this level.
EF Standard Finned Bottom
EM Mega-Flo
ES Smooth Bottom
1. Locate the opening in the control panel’s top housing for the conduit that will enclose the wire from the
facility’s power source. The hole will accept a cord
diameter range of 0.7–1.2 in (17–30 mm).
2. 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.
20
334130R
Setup
Grounding
Ground the unit as instructed here and in the component manuals.
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides and escape path for the electric
current.
System: ground through ground lug in Electrical Enclosure. See Connect Power, page 20.
Air and Fluid Hoses: use only electrically conductive
hoses.
Air compressor: follow manufacturer’s recommendations.
Spray gun / Dispense valve: ground through connection to a properly grounded fluid hose and Pump.
Material drums: follow local code. Use only metal
drums placed on a grounded surface. Do not place the
drum on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continuity
To maintain grounding continuity when flushing or
relieving pressure: follow instructions in your separate
gun manual for instructions on how to safely ground
your gun while flushing.
Connect Secondary System
A secondary system is a Therm-O-Flow supply system
that connects to the primary Therm-O-Flow system, with
the ADM. See Models, page 7 for secondary system
model numbers.
1. Connect adapter cable (AC) and communication
cable (SC) to the secondary Electrical Enclosure
and rout to splitter (SS) installed on the primary system.
2. To enable a secondary system, select “Enable Tandem System” on the System 1 screen. See Select
ADM Settings, page 24.
SS
AC
SC
FIG. 13
334130R
21
Setup
Check Sensor Resistance
Table 3 RTD Sensors
MZLP
To reduce risk of injury or damage to equipment, conduct these electrical checks with the Main Power
Switch OFF.
The package includes up to twelve heat sensors and
controllers for each of the heated zones. To check sensor resistance:
1
1. Turn Main Power Switch OFF.
2
2. Wait for components to cool down to ambient room
temperature 63°-77°F (17°-25°C). Check electrical
resistance for the components.
MZLP
First Heat Zone
Second Heat Zone
First RTD
Second RTD
Earth Ground
Pins
A, J
C, D
G, K
M, K
B
TOF Hose
3
MZLP Plug Component
Ram Plate
Fluid Pump
Heated
Accessory 1
1, 2
Heated
Accessory 2
Heated
Accessory 3
3, 4
Heated
Accessory 4
Heated
Accessory 5
5, 6
Heated
Accessory 6
Heated
Accessory 7
7, 8
Heated
Accessory 8
Heated
Accessory 9
9, 10
Heated
Accessory
10
Heated
Accessory
11
11, 12
Heated
Accessory
12
RTD Range
(Ohms)
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
3. Replace any parts whose resistance readings do
not comply with the ranges listed in the RTD Sensors chart below.
22
334130R
Setup
Check Heater Resistance
To reduce risk of injury or damage to equipment, conduct these electrical checks with the Main Power
Switch OFF.
1. Turn Main Power Switch OFF.
2. Make electrical resistance checks for the components.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in tables.
NOTE: Check resistance at ambient room temperature
63°-77°F (17°-25°C).
Table 4 Heaters
Component
Platen
Pump
334130R
Resistance Across
Terminals
Unit Input
Voltage
AD to BE, BE to CF, CF
220 - 240V
to AD
A to B, B to C, C to D, D
380 - 600V
to E, E to F and F to A
All voltage verAny terminal to Ground
sions
2610 to 2620
All voltage versions
T1/B1 to T3/B3
Platen or Pump
Module
Resistance Values
24V633
24V634 & 24V635
24V633
24V634 & 24V635
5.25 to 4.35 Ohms
6.36 to 4.8 Ohms
12.0 to 14.5 Ohms
13.5 to 18 Ohms
All
Greater than 100,000 Ohms
All
43.2 to 53 Ohms
23
Setup
Select ADM Settings
NOTE: See Appendix A - ADM, page 100 for detailed
ADM information, including general operation.
5. Set primary system setpoint and setback temperatures for the Pump, Platen, and heat zones on the
Heat-A-screens.
1. Turn Main Power Switch ON.
2. When the ADM is finished starting up, press
to switch from the Operation screens to the Setup
screens. Use the arrows to navigate between
screens.
3. Check system settings on the System 1 screen.
NOTE: Setback temperatures must be at least 20°F
(10°C) lower than the setpoint temperatures.
NOTE: To ensure accurate hose temperatures, be sure
all heated hoses have their “zone type” set to “Hose.”
Hoses are only present on odd zone numbers: 1, 3, 5, 7,
9, or 11.
a. Select the appropriate “Zone Type” for all
installed zones.
b. Check the “A” and “B” boxes according to which
systems needs to use the heated accessory.
6. If a secondary system is used, set temperatures on
the Heat-B-screens.
4. Set alarm levels on the System 2 screen.
24
7. Set the system date and time on the Advanced 1
screen.
334130R
Setup
8. Set the temperature and mass units on the
Advanced 2 screen. Set the specific gravity of the
material for Material Tracking functionality.
9. To setup the optional Schedule function, see
Schedule, page 37. The schedule function allows
the system to automatically enable and disable
heating and setback at specified times.
10. Optional: Set any remaining settings in the Setup
screens before using the system. These are not
required for system operation, but include useful
functions. See Appendix A - ADM, page 100 for
detailed information about each setup item.
NOTE: If the Specific Gravity is set to zero, the Home
screen will display a cycle counter instead of grams or
pounds.
334130R
25
Setup
Connect PLC (Hard Wired
Interface Version)
A PLC can control and monitor all items shown in the
Customer Digital Inputs and Outputs shown on the
Diagnostics screen. See Appendix A - ADM, page 100.
When the PLC has control of the system:
•
Functionality is restricted from the ADM
•
Automatic crossover is disabled. Rely on the PLC
and machine state indicators to know when to cross
over using the I/O.
Table 5 Customer Input
Signal No.
1
2
Unit A
Heat On Request
Setback Request
3
4
Pump On Request
PLC Control
Request (input
applies to primary
unit A only)
Description
Turn on the Heat
Put the Unit in Setback
Turn on the Pump
Control the primary
and secondary TOF
systems from the
PLC instead of the
ADM
Table 6 Customer Output
Signal No.
1
2
3
4
26
Unit A or B
Run State Bit Low
Description
See Run State
Chart
Run State Bit High See Run State
Chart
Error State Bit Low See Error State
Chart
Error State Bit High See Error State
Chart
Table 7 Output Error States
Error State
Bit High Error State Bit Low
0
0
Machine is good, no
errors are present
0
1
Active Unit Drum
Low
1
0
Active Unit Drum
Empty
1
1
Alarm Present in
System
Table 8 Output Run States
Run State
Bit High
0
0
1
1
Run State Bit Low
0
Pump Off/ Heat Off
1
Pump Off/ Heat On
0
Pump Off/ Heat At
Temp
1
Pump On/ Heat At
Temp
NOTE: All outputs are normally open when power is off.
For error (alarm) output, the contacts close when an
alarm occurs. For all others, contacts close.
NOTE: The TOF system ships with two screw terminal
connectors that plug into MZLP connectors H1 and H2.
Connectors are located in a bag on the inside of the
Electrical Enclosure. To replace the connectors, order
kit 24P176.
1. Turn Main Power Switch OFF.
2. Open the Electrical Enclosure door.
3. Route I/O cables through strain relief.
4. Remove power from the PLC.
5. Connect the PLC to connectors H1 and H2.
334130R
Setup
NOTE: Each connector has four signals. The MZLP
board specifies the input range for each signal. See the
following table for pin assignments.
FIG. 14
H1 Customer Input
Signal
1
2
3
4
Pin
1,2
3,4
5,6
7,8
H2 Customer Output
Signal
1
2
3
4
Pin
1,2
3,4
5,6
7,8
Inputs: High: 10–30 VDC, Low: 0–5 VDC. Inputs function without concern for polarity. Applying “high” voltage
will turn the heaters on and enable setback. Removing
voltage will turn the heaters off and disable setback.
Outputs: 0–250 VAC, 0–30 VDC, 2A Maximum.
334130R
27
Setup
PLC Connections Block Diagrams
The following block diagrams show how to connect customer inputs and outputs to the MZLP. For convenience, each
system ships with connector kit 24P176. If a connector is lost or damaged, order kit 24P176 for replacements.
FIG. 15: Customer Input
FIG. 16: Customer Output
28
334130R
Operation
Operation
1. Turn the Main Power Switch ON. The Graco logo
will display until communication and initialization is
complete.
NOTICE
Use fluids that are chemically compatible with the
equipment wetted parts. See Technical Specifications in all of the equipment manuals.
1. Select the material for the initial material load.
2. Verify whether the factory-test oil and the initial
material load are compatible:
a. If the two substances are compatible omit the
remaining steps in this procedure and refer to
Load Material, page 30.
b. If the two substances are incompatible perform
the remaining steps in this procedure to flush
the system.
2. Press the
button. Verify the machine is in
“Warm Up” state, and that the temperatures are
increasing. Allow the system to reach the “Ready”
state before pumping. The Pump will automatically
turn on, if autostart is enabled in setup screens,
when all the heat zones reach their setpoint temperature.
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.
Purge System
5. Turn all heat zones’ setpoint temperature to the
material manufacturer’s recommended dispense
temperature, or a minimum of 100°F (37°C) minimum.
NOTICE
Purge the system before initial use and when chemicals are changed to prevent material contamination,
which may cause the material to fail or perform poorly.
The system was factory- tested using a light soluble
oil, a soybean oil, or some other oil as tagged. Flush
the system to avoid contaminating the material that
has been designated for initial material loading.
334130R
4. Before purging be sure the entire system and waste
drum are properly grounded. See Grounding, page
21.
NOTE: Remove any dispense valve orifices before
purging. Reinstall after purging has been completed.
6. Purge the material through the system for approximately 1 to 2 minutes.
7. Remove the drum if purge material was used. See
Change Drums, page 38.
29
Operation
Load Material
4. Fill displacement pump wet cup 2/3 full with Graco
Throat Seal Liquid (TSL™) for Butyl and PSA materials.
NOTICE
To prevent damage to Platen wipers, do not use a drum
of material that has been dented or damaged. An
empty drum clamp can interfere with up and down
operation of the Ram. When raising the Ram, make
sure the drum clamp stays clear of the Platen.
NOTE: Use IsoGuard Select® (IGS) (part no. 24F516)
for PUR or reactive Polyurethane material. IGS is
designed to dissolve and suspend the Polyurethane
materials. IGS will solidify after a period of time and
should be replaced once the solidified lube does not
return to liquid form after heating.
NOTE: Before loading material, make sure there is a
minimum overhead clearance of 110 in. (280 cm) and all
air regulators are backed off to their full counterclockwise position.
1. Open the Main Air Slider Valve (CA).
CA
FIG. 18: Wetcup
5. Open drum, remove any packing material, and
inspect material for any contamination.
2. Set Ram Director Valve (CC) to UP and slowly turn
the Ram Up Regulator (CD) clockwise until the
Platen (G) begins to rise.
6. Slide the drum between the drum centering guides
and against the stops at the back of the Ram baseplate.
CD
CC
FIG. 17: Raise the Platen
FIG. 19: Drum Placement
3. Apply a thin coating of high temperature grease
lubricant (part no. 115982) to the Platen drum seals.
30
334130R
Operation
Heat Up System
7. Remove the Ram Plate Bleed Stick (R).
To reduce the risk of bursting a hose, never pressurize a hot melt system before turning on the heat. The
air will be locked from the Air Motor until all temperature zones are within a preset window of the temperature setpoints.
Keep the dispense valve open over a waste container
while the system is heating up and also when cooling
down. This will prevent a pressure build-up caused by
fluids or gases expanding from the heat.
R
NOTE: Operate at the lowest temperature and pressure
necessary for your application.
1. Turn the Main Power Switch on the Electrical Control Panel door to the ON position.
FIG. 20: Platen Bleed Handle
8. Set Ram Director Valve (CC) to down.
2. Press the
button. The zones begin to heat
CC
CB
FIG. 21: Lower the Platen
9. Slowly turn the Ram Down Air Regulator (CB) clockwise to approximately 5–10 psi (34–69 kpa, 0.3–0.7
bar). The Platen will begin to lower into the drum.
(provided they are enabled). Press
if the
zones do not begin to heat. Display status bar reads
Warm Up. When temperature reaches setpoint, the
display status bar reads Heat Soak. When heat is
on, the status will display in the status bar. See
Advanced Display Module (ADM), page 12, for
operation mode descriptions.
NOTE: The air will be locked from the Air Motor until all
temperature zones are within a preset window of the
temperature setpoints, allowing the system to heat fully
and complete the material heat soak period.
10. After the Platen seals enter the material drum,
adjust the Ram Down Air Regulator (CB) to 30–50
psi (207–345 kPa, 2.1–3.4 bar).
11. When the Ram stops, reinsert the Ram Plate Bleed
Stick (R) and hand tighten.
334130R
31
Operation
Prime Pump
3. Adjust the Air Motor Slider Valve (CM) to the open
position.
CM
1. Ensure that the system has completed the heat
soak cycle. The display status bar should read
Active.
2. Adjust the Air Motor Air Regulator (CK) to 0 psi.
4. Adjust the Air Motor Air Regulator (CK) to approximately 20 psi (138 kPa, 1.38 bar).
CK
CK
CN
5. Place a waste container under the bleed stem (Z).
Using an adjustable wrench, open the bleed stem
counterclockwise 1/3 -1/2 turn.
Z
32
334130R
Operation
6. If a new drum was installed and the unit is equipped
with proximity sensors, press the Pump Ready button
. Press the pause button
tracking.
on material
7. Adjust the Air Motor Air Regulator (CK) up by 5 psi
(34 kPa, 0.3 bar). Never adjust the regulator by
more than 5 psi (34 kPa, 0.3 bar) increments. Make
sure the Pump begins to cycle and heated material
flows from the bleed stem (Z) after several cycles of
the Pump.
8. Prime the Pump until it moves smoothly in both
directions with no air popping or erratic movement
and close the bleed stem (Z).
For Tandem Operation
Complete steps 1-5 on page 32 for the inactive unit.
Note that the heat will remain on for the inactive unit until
the system is turned off.
6. If a new drum has been installed in the inactive unit,
press the Pump Ready button
on the inactive
unit. The light on the solenoid of the inactive unit
should be on (CN).
7. Adjust the Air Motor Air Regulator (CK) up by 5 psi
(34 kPa, 0.3 bar). Never adjust the regulator by
more than 5 psi (34 kPa, 0.3 bar) increments. Make
sure the Pump begins to cycle and heated material
flows from the bleed stem (Z) after several cycles of
the Pump.
8. Prime the Pump until it moves smoothly in both
directions with no air popping or erratic movement
and close the bleed stem (Z).
CA
9. Press the Pump Ready button
unit.
for the inactive
9. Press the Play button
on the home screen to
enable material tracking and press the Pump Ready
button.
334130R
33
Operation
Prime System
7. Close the Main Air Slider Valve (CA) and release the
trigger lock.
8. Engage the trigger lock.
1. Close the Main Air Slider Valve (CA).
CA
2. If using a manual gun, lock the dispense valve trigger open by pulling and securing the trigger using
the trigger retainer (Z).
FIG. 22: Trigger Lock Engaged
9. Press
to engage material tracking.
10. Turn the Air Motor regulator to operating pressure.
NOTE: The amount of time before the Pump is automatically placed in setback is determined by the Pump Inactivity Timeout, located on System Setup Screen 1. See
Setup Screens, page 104.
Z
Setback Mode
3. Place the dispense valve over a waste container.
4. Press the pause material tracking button
home screen.
on
5. Slowly open the Main Air Slider Valve (CA).
6. Prime the system until a smooth flow of material dispenses from each dispense valve.
NOTE: On initial system startup, the Pump will cycle
until the hoses are filled. If a new drum was placed on
the frame, the Pump will cycle until all air has been
removed.
34
Set the ADM to setback mode if the system will only be
inactive for a few hours. This will reduce the time the
system needs to return to setpoint temperatures.
1. Press
to enter Setback Mode.
NOTE: The amount of time before the Pump is automatically placed in setback is determined by the Pump Inactivity Timeout, located on System Setup Screen 1. See
Setup Screens, page 104.
334130R
Operation
Pressure Relief Procedure
3. Set the Ram Director Valve (CC) to the neutral position.
Follow the Pressure Relief Procedure Whenever you see this symbol.
CC
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before cleaning, checking, or servicing equipment.
NOTE: If using a different dispense applicator, see the
applicator manual for pressure relief instructions.
4. Disengage the trigger lock.
1. Engage the trigger lock.
FIG. 24: Disengaged
5. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
FIG. 23: Engaged
2. Close the system Main Air Slider Valve (CA).
6. Engage the trigger lock.
7. Open all fluid drain valves in the system, having a
waste container ready to catch drainage. Leave
drain valve(s) open until you are ready to dispense
again.
CA
334130R
8. If you suspect the tip or hose is clogged or that pressure has not been fully relieved after following the
steps above, VERY SLOWLY loosen hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or tip obstruction.
35
Operation
NOTE: If work needs to be performed on the Ram portion, perform the following additional steps to relieve any
trapped air in the inactive portion of the Ram.
9. Validate that the Heated Pump is fully supported
and is resting on the bottom plate.
Stop Controls
Normal Stop Control
To stop all electrical and most pneumatic processes,
press the System Shutdown button
ADM.
located on the
System Shutdown
10. Toggle the Ram Director Valve up and down to
relieve any trapped air.
All electrical operations will be shut down and the air
pressure to the Air Motor will be immediately relieved,
which will stop the movement of the Heated Pump.
Electrical components located in the main control box
will remain energized, but all operations will stop until
the system Enable/Disable button
pressed.
has been
The Ram Director Valve will remain operable.
Air Motor and Heated Pump Stop
To stop only the Air Motor and Heated Pump, close the
Air Motor Slider Valve (CM). This is the preferred
method while changing drums.
36
334130R
Operation
Shutdown
CM
1. Press
to disable the heaters and Pump. The
screen will say “Inactive”. If using the Schedule
function, the heaters and Pump will be disabled
automatically at the set time. Only press
to
disable the heating system before the set time. If the
heaters were manually disabled, the Schedule function will automatically enable them at the next set
time.
Air pressure to the Air Motor will be immediately
relieved, which will stop movement of the Heated Pump
but allow the heater to remain operable.
The Ram Director Valve will also remain operable.
The Air Motor Slider Valve can be locked in the closed
position.
NOTE: Do not perform step 2 if using the Schedule
function. Leave the power on.
2. Turn the Main Power Switch OFF.
Total System Shutdown
To stop all electrical and most pneumatic processes,
turn the Main Power Switch OFF.
Schedule
The Schedule function allows the user to specify times
when the system will automatically turn on and off the
heaters and Pump.
This will remove all electrical power to the system past
the Main Power Switch.
Air pressure to the Air Motor will be relieved, which will
stop movement of the Heated Pump.
The Ram Director Valve will remain operable.
The Main Power Switch can be locked in the open position.
334130R
37
Operation
Table 9 Schedule Screen Color Identification
Use the Schedule Function
Color
Green
Yellow
Red
Gray
At the end of the work day leave the Main Power Switch
ON. The Schedule function will automatically enable
and disable the heaters and Pump at the specified
times.
Description
System on
Setback
System off
Disabled
Change Drums
Set Schedule Times
Times are set using a 24-hour clock. Several on and off
times can be set each day.
To prevent serious burns from dripping material,
never reach under the Heated Platen after the Platen
is out of the drum.
Moving parts can pinch or amputate fingers, or can
crush feet. When the Pump is running, and when raising or lowering the Ram, keep fingers and hands
away from the Pump intake, Platen, and lip of the
drum. When lowering the Platen to the baseplate,
keep feet away from the Platen.
1. On the Schedule screen (in the Setup screens), set
the ON times for each day of the week
2. Set the off times for each day of the week.
NOTICE
3. Set the setback times for each day of the week.
Enable Schedule Function
The Schedule function is automatically enabled when
values are entered in the Schedule screen. To disable a
scheduled event, navigate to the event and press
.
The event will appear gray on the screen when it is disabled. To re-enable an event, navigate to the event and
press
.
The event will appear red (system off), yellow (system
setback), or green (system on). If no events are needed,
turn the Main Power Switch OFF to prevent system from
automatically enabling and disabling the heaters.
38
Perform the following procedure to change the drum on
a fully heated system.
Be sure to reload the empty supply unit with a full
drum of material immediately. Do not raise the Ram
and remove the Platen from the empty drum until you
are ready to immediately install a new drum.
Do not raise the Ram and remove the Platen from
the empty drum unless the supply unit is at full
operating temperature. Drum changes can only be
performed when the system is heated.
An empty drum clamp can interfere with the up and
down operation of the Ram. When raising or lowering
the Ram, make sure the drum clamp stays clear of the
Platen assembly.
Do not use a drum of material that has been dented
or otherwise damaged; damage to the Platen wipers
can result.
334130R
Operation
All systems include Low/Empty Sensors:
•
•
The air will shut off to prevent the Pump from cavitation. If the Light Tower kit is installed, a solid red
light indicates that the pail is empty and ready to
change.
In a tandem system, a flashing red light means that
both drums are empty and the system has shutdown.
1. Press
to stop material tracking.
Excessive air pressure in the material drum could
cause the drum to rupture, causing serious injury. The
Platen must be free to move out of the drum. Never
use drum blowoff air with a damaged drum.
4. Release the blowoff air button and allow the Ram to
rise to its full height.
5. Remove the empty drum.
2. Push in the Air Motor Slider Valve (CM) to stop the
Pump.
CM
6. Inspect Platen and if necessary, remove any
remaining material or material build-up.
7. Follow steps in Load Material, page 30, and Prime
Pump, page 32.
3. Set Ram Director Valve (CC) to UP and raise the
Platen (G) and immediately press and hold the
Blowoff Buttons (CG) until the Platen is completely
out of the drum. Use minimum amount of air pressure necessary to push the Platen out of the drum.
CC
CG
334130R
39
Troubleshooting
Troubleshooting
Light Tower (Optional)
Signal
Red Light Off
Red Light On
Red Light Flashing
Green Light Off
Green Light On
Green Light Flashing
40
Description
If green light is also off, system power may be off or system operating mode is Inactive. If
green is on or flashing, there are no active errors
User interaction required — alarm, system is shut down
User interaction required — advisory, deviation, or system is in a state that could prohibit dispensing
System is inactive
System is ready to dispense. The heat and Pump are on.
System will be ready to dispense in time without user interaction (heat on, Pump off, and
temperature control zones have not reached set point)
334130R
Troubleshooting
Error Codes
There are three types of errors that can occur. Errors
are indicated on the display as well as by the optional
Light Tower.
Alarms are indicated by . This condition indicates a
parameter critical to the process has reached a level
requiring the system to stop. The alarm needs to be
addressed immediately.
Deviations are indicated by . This condition indicates
a parameter critical to the process has reached a level
requiring attention, but not sufficient enough to stop the
system at this time.
Advisories are indicated by . This condition indicates
a parameter that is not immediately critical to the process. The advisory needs attention to prevent more serious issues in the future.
To acknowledge the error, press
.
The third digit, or sometimes the last digit of the error
code, indicates which unit the error is active on. The “”
(star) character indicates the code applies to multiple
system components.
Third or Last Digit “”
A
B
334130R
Code Relates To:
Unit A
Unit B
The last digit of the error code indicates which system
component the error applies. The “#” (pound) character
indicates the code applies to multiple system components.
Last Digit “#”
1
2
3
5
6
7
G
H
V
W
X
Y
Code Relates To System
Component:
MZLP 1
MZLP 2
MZLP 3
MZLP 5
MZLP 6
MZLP 7
Gateway (CGM)
Gateway Heartbeat Loss
AWB Unit A
AWB Unit B
Daughter Board Unit A
Daughter Board Unit B
The last digit of the error code indicates which heat zone
the error applies. The “_” (underscore) character indicates the code applies to multiple system components.
Last Digit “_”
1
2
3
4
5
6
7
8
9
A
B
C
D
E
Code Relates To Heat
Zone:
Zone 1
Zone 2
Zone 3
Zone 4
Zone 5
Zone 6
Zone 7
Zone 8
Zone 9
Zone 10
Zone 11
Zone 12
Pump
Platen
41
Troubleshooting
Code
Description
Type
A3MF
AWB Clean Fan Filter Alarm
A4 _
High Current Unit _
Zone _
Alarm
A4C#
High Current Fan
AWB, Unit _
Deviation
A7 _
Unexp. Curr. Unit _
Zone _
Alarm
A8 _
No Current Unit _
Zone _
Alarm
Cause
Cooling inlet
screen is dirty
Defective or
shorted to
ground on
zone
Fan is drawing too much
current
Solution
Clean inlet screen.
Verify accessory is rated for 240 VAC.
Verify heater resistance and check for shorts to
ground. Replace as necessary.
Verify there is not an air obstruction at the
inlet/outlet of enclosure. Verify nothing is
preventing fan rotation. Replace fan if
necessary.
Replace MZLP.
Unexpected
current flow to Faulty accessory heater. Measure resistance to
zone
ground between heater leads.
Check for loose or disconnected wires or plugs.
No Current
Flow to the
Check for blown fuses on MZLP.
Zone
Check heater resistance for open circuit.
Check for shorts between heater and ground.
Verify cable is plugged into zones 3-4. Replace
heater if necessary.
A8C
AWB No Fan Current
Alarm
Cooling Fan
not Working
Verify fan is plugged in. Replace if necessary.
AM3#
High Current SSR
MZLP _
Alarm
Check for shorts in harness to SSR. Check
polarity of wiring to SSR. Replace if necessary.
AM4#
High Current
Contactor MZLP _
Alarm
AM8#
No Current Contactor
MZLP _
Alarm
CAC#
Comm Error MZLP _
Alarm
Excessive
current flow in
the SSR
Defective or
shorted to
ground on
MZLP
No Current
Flow to the
Contactor
System not
responding to
ADM.
Check for shorts in the harness to contactor.
Check the polarity to contactor. Replace
contactor if necessary.
Ensure harness to MZLP is connected. Ensure
wiring to contactor is secure. Replace contactor
if necessary.
System is not properly loaded with correct Software.
Dial not set correct on MZLP. Duplicate MZLP
dial
positions (i.e. 1 to 1, 2 to 2, ect).
Check all CAN connections between the ADM
and missing MZLP.
Check if hardware exists on the network.
Replace MZLP if necessary.
CACX
42
DB Not Present Unit A Alarm
Daughter
Board not
responding
Dial not set correct on MZLP 5. Set to 5 on
board with daughter board.
Ensure connections between the ADM and
hardware are secure.
Replace Daughter Board.
334130R
Troubleshooting
Code
Description
Type
Cause
Solution
CCAG
Comm. Error,
Gateway
Alarm
CACH
Gateway Heartbeat
Loss
Alarm
CACY
DB Not Present Unit B Alarm
CACV
AWB not present Unit
A
Alarm
AWB not
responding
Ensure connections between the ADM and
hardware are secure.
If a tandem system, ensure AWB 2 jumper is
installed at startup.
Replace AWB.
CACW
AWB not present Unit
B
Alarm
AWB not
responding
AWB 2 jumper was not in place at start up
Pump Runaway
Detected
Alarm
DA X
DE X
334130R
Reed Switch Failure
Detected
Alarm
CGM Module
is no longer
responding
Power removed from Gateway. Restore power.
Rotary switch on Gateway changed to positions
between 2 and 8 (must be in 0, 1, or >8
positions).
PLC went off line.
Heartbeat
signal was
Field Bus connection to CGM was broken.
removed while Restore connection between Field Bus and
PLC was
CGM.
controlling the
TOF via the
CGM
Dial not set correct on MZLP. Set to 4 on board
Daughter
with daughter board.
Board not
responding
Ensure connections between the ADM and
hardware are secure.
Replace Daughter Board.
Pump is trying
to feed
adhesive, no
adhesive to
feed.
Worn or
damaged
Pump seals
Reed switch
failed
Ensure connections between the ADM and
hardware are secure.
Replace AWB.
Adjust the drum empty level sensor to detect an
empty state.
Ensure the Ram Director Valve is in the down
position and sufficient air is forcing the Ram
down.
Melter at incorrect temperature, too low. Check
setpoint and set to manufactures
recommendation.
Inspect Pump seals and replace if necessary
Check that sensor cable is plugged into the
daughter board at J16.
Check for loose connection at reed switch.
Ensure reed switch is securely attached to the
Air Motor. Replace if necessary.
43
Troubleshooting
Code
DC X
Description
Pump Diving
Type
Alarm
L1 X
Material Level Sensor Error
Alarm
L2 X
Material Level Empty Alarm
L3 X
Material Level Low
Deviation
MMUX
USB Log Full
Advisory
MN X
Pump _ Requires
Maintenance
Advisory
Ta
Over Temperature
Switch
Alarm
Cause
Solution
Pump is trying
to feed
adhesive, no
adhesive to
feed.
Adjust the drum empty level sensor to detect an
empty state.
Ensure the Ram Director Valve is in the down
position and sufficient air is forcing the Ram
down.
Melter at incorrect temperature, too low. Check
setpoint and set to manufactures
recommendation.
Inspect Pump seals and replace if necessary
Worn or
damaged
Pump seals
Machine is
detecting an
empty state
without a low
state
Make sure the empty level sensor is not
covered in material
Verify the low level sensor is plugged into J15
of the daughter board. Verify the low level
sensor is close enough to the metal bar; adjust
if necessary.
Replace sensors.
Material drum Replace material container. If more material is
is empty
leftover, lower the empty level sensor.
Material level Replace at appropriate time.
is low
USB logs fulls.
Data loss will
occur if not
downloaded.
User defined
Pump
maintenance
counter has
run out
An over
temperature
switch has
opened.
Download USB data or disable the USB log
errors on the Advanced screen 3.
Perform Pump maintenance, then reset the
counter on the maintenance setup screen.
Check Heat Rate Option on Advanced Screen
2 to make sure it is set to Normal or Slow. If set
to Fast, the switch will open on the pump or
platen.
If “_” is 9, A, B, or C, make sure jumper
16W035 is installed in J5 on MZLP 5 and
MZLP 7 (for tandem units).
T1 _
Low Temp. Unit _
Zone _
Alarm
Zone
temperature
too low
Reduce flow rate.
Increase temperature of accessory upstream.
Faulty accessory heater measure resistance
between heater leads.
Change Low Temp Alarm Offset.
Replace accessory.
T2 _
44
Low Temp. Unit _
Zone _
Deviation
Zone temperature too
low
Reduce flow rate.
Change Low Temp Deviation Offset.
Add zone (temperature) upstream.
334130R
Troubleshooting
Code
Description
Type
High Temp. Unit _
Zone _
Deviation
AWB Temperature
Runaway
Transformer
AWB High
Transformer Temp
Alarm
T4 _
High Temp. Unit _
Zone _
Alarm
T6 _
Sensor Err. Unit _
Zone _
Alarm
T6C#
AWB Invalid
Thermistor Reading
Alarm
T8V_
No Temp. Rise Unit _
Zone _
Alarm
V1|#
Low CAN Voltage,
MZLP _
Alarm
V1M#
Low Voltage Line
AWB, Unit _
Deviation
V4|#
High CAN Voltage,
MZLP _
Alarm
V6M#
Wiring Error Line
MZLP _
Alarm
T3 _
T4C#
T4M#
Alarm
Cause
Solution
Temperature
reading has
risen too high
Change High Temp Deviation Offset.
Bad RTD
Reading
Check RTD wiring and harness/connector
integrity.
Verify setpoint upstream is not hotter than this
zone’s setpoint.
Cooling fan not Ensure inlet and outlets are not obstructed.
working or inlet Verify fan is plugged in.
is blocked/dirty
Ensure inlet and outlets are not obstructed.
Transformer
Temperature is Verify fan is plugged in.
too High
Change High Temp Alarm Offset.
Temperature
reading has
Verify setpoint upstream is not hotter than this
risen too high zone’s setpoint.
Replace RTD.
334130R
Transformer
Verify thermister is securely connected to J7 of
thermistor
the AWB. Replace transformer if necessary.
temperature is
incorrect
Check fuses on MZLP connected to that Zone.
Temperature
reading does
Check wiring to device.
not change.
Check heater resistance on device.
Verify power supply voltage is 24 VDC. If
voltage is low, disconnect the power lines and
re-check voltage reading. If voltage is still low,
replace power supply. If voltage is correct after
disconnecting the power lines.
Connect items one at a time until the voltage
drops to isolate the bad module.
The voltage to Verify transformer voltage top matches
the AWB is
incoming voltage. Verify incoming voltage is
below
correct.
threshold
Verify power supply voltage is 24 VDC. If
Bad or
voltage is high, replace power supply unit.
overloaded
power supply
Correct the Wiring.
Incoming
power is wired
incorrectly
Bad or
overloaded
power supply
45
Troubleshooting
Code
V8M#
V4M#
46
Description
No Line Voltage
MZLP _
AWB High Line
Voltage
Type
Alarm
Alarm
WJ1
Pump _ Solenoid is
disconnected
Alarm
WJ2
Pump _ Solenoid
High Current
Alarm
WSUX
Configuration Error
USB
Advisory
Cause
Solution
Verify transformer has the correct tap selected.
Incoming line
voltage is less Verify CB-1 or FU-4, FU-5, and FU-6 are not
than 100 VAC. tripped/blown.
Verify RCD-1 is not tripped.
Incoming
voltage is too
high
Measure incoming power with system
unplugged. If line voltage is less than 100 VAC,
contact qualified electrician to correct the low
voltage.
Verify the MZLP is plugged in at J2 and the
AWB is plugged in at J5 or J6.
Check incoming voltage is correct for configuration.
Verify the transformer has the correct tap (400,
480, 600) selected.
Pump is not
Verify harness is plugged into J13 of the
turning on
daughter board. Verify it is secured to the
when it should solenoid.
Replace Solenoid.
Solenoid is
drawing too
much current
USB
configuration is
not loaded
Inspect for short in harness. Inspect for a
shorted solenoid cable/short to the ground.
Replace solenoid.
Install software.
334130R
Troubleshooting
Ram Troubleshooting
Problem
Ram will not raise or lower.
Ram raises or lowers too fast.
Air leaks around cylinder rod.
Fluid squeezes past Platen wipers.
Pump will not prime properly, or
pumps air.
Air pressure will not push Platen out
of drum.
334130R
Cause
Closed main air valve or clogged air
line,
Not enough Ram air pressure.
Worn or damaged Ram piston.
Platen not fully up to temperature.
Ram air pressure too high.
Dented drum has stopped Platen.
Ram "up / down" air pressure too
high.
Worn rod seal.
Ram air pressure too high.
Worn or damaged wipers.
Closed main air valve or clogged air
line.
Not enough air pressure.
Worn or damaged Ram piston.
Ram directional valve closed or
clogged.
Ram directional valve dirty, worn, or
damaged.
Directional valve not in the down position.
Dented drum has stopped Platen.
Closed main air valve or clogged air
line.
Platen not fully up to temperature.
Not enough blow-off air pressure.
Blow-off valve passage clogged.
Dented drum has stopped Platen.
Wipers bonded to drum or drum liner.
Solution
Open air valve; clear air line.
Increase Ram air pressure.
Replace piston. See instruction manual 310523.
Wait for full temperature.
Decrease Ram air pressure.
Fix or replace drum.
Decrease Ram air pressure.
Replace o-rings in guide sleeve. See
instruction manual 310523.
Decrease Ram air pressure.
Replace wipers.
Open air valve; clear air line.
Increase air pressure.
Replace piston. See instruction manual 310523.
Open valve; clear valve or exhaust.
Clean; repair valve.
Position handle in the down position.
Fix or replace drum.
Open air valve; clear air line.
Wait for full temperature.
Increase blow-off air pressure.
Clean valve passage.
Fix or replace drum.
Lubricate wipers with high temperature grease at every drum change.
47
Troubleshooting
Heated Pump Troubleshooting
See Pump manual for additional Pump troubleshooting information.
Problem
Cause
Rapid downstroke or upstroke (Pump Material not heated to proper
cavitation).
temperature.
Air is trapped in Pump.
Solution
Check and adjust temperature to
proper setpoint. Wait for Pump/Platen
to heat up.
Bleed air from Pump. See Prime
Pump, page 32.
Clean or repair. See Pump Manual.
Material leaks around Pump outlet.
Downstroke: Dirty or worn Pump
intake valve.
Upstroke: Dirty or worn Pump piston
valve.
Machine is out of material
Loose 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.
Foreign object lodged in Pump.
Platen not fully up to temperature.
Valve to Air Motor is off.
See Air Motor Manual.
Relieve pressure. See Pump Manual.
Wait for full temperature.
Leak around Pump wet-cup.
Worn throat seals.
Clean or repair.
Adjust empty level sensor.
Tighten outlet fitting.
Check gauges and valves to the air
motor.
Replace throat seals. See Servicing
the Throat packings in manual 334127
or 334128.
Air Motor Troubleshooting
See Air Motor manual for additional Air Motor troubleshooting information. See Related Manuals, page 8.
Problem
Cause
Solution
Air motor will not run.
Air motor solenoid is off.
Air motor stalled.
Damaged main air valve spool or
poppets.
Air continuously exhausting around
Air Motor shaft.
Damaged Air Motor shaft seal.
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.
48
Wait for heat zones in use to reach
temperature setpoint values.
Inspect and clean poppets. See Air
Motor Manual.
Rebuild main air valve. See Air Motor
Manual.
Replace Air Motor shaft seal. See Air
Motor Manual.
334130R
Repair
Repair
Replace Wipers
2. Make sure the Ram Plate is down and the Ram
Director Valve is in the OFF position.
1. To replace a worn or damaged wiper (V) raise the
Ram Plate up out of the drum. Perform steps 1
through 7 of Change Drums, page 38. See wiper kit
manual for instructions about replacing the wipers.
CC
CB
V
FIG. 25: Replace Wiper
Replace Platen RTD
Reference Electrical Schematics, page 62, for wiring
connections.
To reduce the risk of injury or damage to equipment,
make sure the Main Power Switch is OFF before continuing with this procedure.
3. Turn the Main Power Switch OFF.
4. Remove the Pump cover.
1. If the material drum has already been removed from
the supply unit, go to step 2. If you need to remove
the material drum, see Change Drums, page 38.
FIG. 26: Pump Covers and Platen RTD
334130R
49
Repair
5. Remove the Platen RTD (605) from the Platen.
6. Disconnect the Platen RTD wires from pin 3 and pin
6 from the J5 connector on MZLP MZTCM-1 or
MZTCM-5.
Separate the Air Motor and
Pump
This procedure must be done with the unit still warm.
The material and equipment will be hot!
1. If the material drum has already been removed from
the supply unit, go to step 2. If you need to remove
the material drum, perform steps 1 through 6 of the
Change Drums section, page 38. Pump must be in
the full down position (Air Motor shaft fully
extended).
2. Make sure the Ram Plate is down and the Ram
Director Valve (CC) is in the neutral position.
FIG. 27: RTD Wire Connections
2760
Red
2770
White
2790
White
CC
7. Attach the leads from the new sensor to the leads of
the old sensor and pull the new sensor leads
through the cable pump shield, Cable Track, and
into the Electrical Enclosure.
8. Install the new sensor (605) into the follower/tire
plate after coating with non-silicone heat sink compound. Tighten compression nut. Ensure RTD is
fully inserted.
9. Connect the red and white wires from the new sensor to the J5 connector on MZLP MZTCM-1 or
MZTCM-5.
10. Replace the Pump covers.
ti24671a
3. Follow Pressure Relief Procedure on page 35.
4. Bleed off excess material and pressure in the system by opening the dispense gun and catching the
material in a waste container.
5. On the ADM, turn off the system heat (D).
6. Turn the Main Power Switch OFF.
7. Disconnect all material hoses.
50
334130R
Repair
8. Remove the Pump sheet metal enclosure.
22. Reverse this procedure to reinstall the new or rebuilt
Air Motor.
a. Remove the cover screws.
b. Remove the heater bands and disconnect the
ground wire.
9. If vent hood is installed, remove it.
10. Remove the Air Motor top cover.
11. Disconnect the electrical cable from the Air Motor.
12. Remove air line from Air Motor and air lines to the
follower blow-off valve.
13. Tightly strap the Air Motor to the tie bar with a cable
through the Air Motor lift ring and around the tie bar.
See FIG. 29, page 53.
14. Loosen u-bolts (X) from Platen lift rods.
15. Remove nuts (F) from Heated Pump/Air Motor
stand-off rods at the Pump end.
16. Remove nuts (Z) and bolts holding cable tract to Air
Motor support plate.
17. Slide end of Cable Track outboard of the mounting
plate.
18. Remove nuts (N) from follower lift rods.
19. Fully loosen Pump rod coupler to the Air Motor rod
(G).
20. Slowly raise elevator to achieve enough separation
of the Pump (Air Motor) tie rods to remove the
Pump.
21. Remove the Pump.
334130R
51
Repair
N
Z
X
G
F
FIG. 28
52
334130R
Repair
Remove Platen
8. Remove the screws and covers.
1. Turn the Main Power Switch OFF.
2. Disconnect the Platen power wires and the ground
wire from within the main control panel and pull out
of conduit.
3. Remove the Platen assembly from the Ram.
4. Reverse this procedure to reinstall the new or rebuilt
Platen assembly.
Replace Heater Band and Pump
RTD
9. Remove white ceramic caps and disconnect the
electrical wires from the heater band (309).
10. Remove the screw that holds the heater band in
place.
11. Remove the heater band (309a, 309b) from the
Pump.
Replace Heater Band
1. If the material drum has already been removed from
the supply unit, go to step 2. If you need to remove
the material drum, perform steps 1 through 6 of the
Change Drums, page 38. Pump must be in the full
down position (Air Motor shaft fully extended).
2. Make sure the Ram Plate is down and the Ram
Director Valve is in the neutral position.
12. Coat the inside of the heater with non silicone heat
sink compound before mounting. Maximum thickness is 0.005 in. Coat only to within 3/4 in. of vertical
ends.
13. Install a new heater band (309a, 309b) in the same
location as the old heater band:
a. Locate heater terminals so they line up with the
back of the Pump.
3. Follow the Pressure Relief Procedure, page 35.
b. Tighten the heater band.
4. Bleed off excess material and pressure in the system by opening the applicator and catching the
material in a waste container.
c.
Re-connect the heater wires and re-attach the
ceramic caps that insulate the terminal.
5. On ADM, turn off the system heat (D).
6. Turn the Main Power Switch OFF.
7.
309a
320
309b
321
ti25222a
FIG. 29
334130R
53
Repair
Replace Pump RTD
1. Turn the Main Power Switch OFF.
Fuse Kit
3. If the sensor wire is connected to the Electrical
Enclosure, disconnect it.
Part
F1, F2
24V289
2. Remove the screws that hold the front shroud in
place and remove the front shroud.
Fuse
250VAC, 25A, long, white
ceramic
F3-F10
250VAC, 8A, fast acting, clear
glass
Spare fuse kit included with system.
NOTICE
To prevent system damage, always use fast acting
fuses. Fast acting fuses are required for short-circuit protection.
1. Turn the Main Power Switch OFF.
4. Loosen the clamp (321) holding the sensor on the
Pump.
5. Tie the leads of the new sensor (320) to the old sensor and remove the old sensor. The leads of the
new sensor will be easily drawn through the conduit
for reconnecting.
6. Replace the sensor (320) in the clamp (321):
a. Place the sensor approximately 30° counter
clock-wise from the Pump outlet.
b. Tighten the clamp (321).
7. Re-connect the sensor wire to the Electrical Enclosure.
Replace MZLP Fuse
2. Open Electrical Enclosure door.
3. Use a proper non-conductive fuse puller tool to
remove the blown fuse.
NOTICE
Using an improper tool, such as screw drivers or
pliers, may break the glass on the fuse.
NOTE: F1 and F2 are white ceramic and indicate 25A
on the barrel.
NOTE: F3-F10 are clear glass and indicate 8A on the
barrel.
4. Use a proper non-conductive fuse puller tool to
install the new fuse.
Each MZLP module comes with the following fuses:
NOTICE
Using an improper tool, such as screw drivers or
pliers, may break the glass on the fuse.
5. Close the Electrical Enclosure.
FIG. 30: Fuse Locations
54
334130R
Repair
Replace MZLP
6. To reassemble the MZLP, set the MZLP rotary
switch based on location. See MZLP Rotary Switch
Table.
7. Use the four screws (115) to install MZLP (111 or
112) to Electrical Enclosure.
1. Turn the Main Power Switch OFF.
8. Reconnect the cables to the MZLP.
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop and verify the connector orientation.
2. Disconnect the heated hose electrical connectors
from the MZLP (111 or 112).
3. Note the location of each cable, then unplug all
cables from the MZLP (111 or 112) that will be
replaced.
4. Remove the four screws (115) securing the MZLP
(111 or 112) to the Electrical Enclosure, then carefully remove the MZLP from the Electrical Enclosure.
115
111
NOTE: If unable to determine the connector location,
see Electrical Schematics, page 62.
9. Connect the heated hose electrical connectors to
the new MZLP.
NOTE: The MZLP may need updated software. See
Update Software, page 61.
Table 10 MZLP Rotary Switch
MZLP
System
#1 with Daughter Primary
Card
Secondary
#2
Primary
Secondary
#3
Primary
Secondary
Rotary Switch
1
5
2
6
3
7
112
112
J5
ti25223a
FIG. 31: MZLP Identification
5. Replace MZLP.
a. To replace MZLP #1, remove the daughter card
and standoffs, and re-install them on the new
MZLP #1.
b. To replace MZLP #2 of #3, remove the jumper
(162) from MZLP #2 or #3 J5 connector and
reinstall it on the new MZLP J5 connector.
334130R
55
Repair
Replace MZLP Daughter Card
5. Plug the new daughter card (112a) into the MZLP
(112).
6. Use the screws (112b) to secure the daughter card
to the MZLP (112).
7. Connect the cables to the new daughter card
(112a).
1. Turn the Main Power Switch OFF.
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop and verify the connector orientation.
2. Note the location of each cable, then unplug all
cables from the MZLP daughter card on MZLP #1
(112).
NOTE: If unable to determine the connector location,
see Electrical Schematics, page 62.
3. Remove the four mounting screws (112b) from the
daughter card (112a) and set aside.
4. Unplug the daughter card (112a) from MZLP #1
(112).
112b
112a
112
Rotary Switch
FIG. 32: MZLP Daughter Card
56
334130R
Repair
Replace AWB
Replace Power Supply
1. Turn the Main Power Switch OFF.
2. Note the location of each cable, then unplug all
cables from the AWB (205).
NOTE: For an AWB on a secondary system, remove the
connector (182) and connect to the new AWB.
206
208
182
1. Turn the Main Power Switch OFF.
205
223
2. Open the Electrical Enclosure.
ti25224a
FIG. 33: AWB Connections
3. Remove the two screws (223) securing the AWB
(205) to the electrical panel, then carefully remove
the AWB.
4. Install the new AWB (205) and reconnect the cables.
NOTE: Do not force the electrical connection. Minimal
force is required to set the connector. If resistance is felt,
stop and verify the connector orientation.
NOTE: See Electrical Schematics, page 62, if unable
to determine the connector location.
3. Remove the power supply (208) from the din rail
(206). Disconnect the screw terminal connections
between the power supply and the power supply
harness.
Power Supply
Connection
Harness Label
V+
VGND
L
N
V+
VGND
L
N
4. Connect the power supply harness to the new
power supply.
5. Reattach the power supply to the din rail (206).
6. Torque terminals to 4.53-6.2 in-lbs (0.5-0.7 N•m).
7. Close the Electrical Enclosure door.
334130R
57
Repair
Replace Fan
6. Remove the screws (141), grill (137), four nuts
(139), rear fan grill (138), and fan (136).
141
1. Turn the Main Power Switch OFF.
2. Disconnect the plug from the power outlet or turn off
the circuit breaker for incoming power.
3. Open the Electrical Enclosure door.
4. Remove the connector from the J7 connector on the
AWB board. Remove the red (+) and black (-) fan
wires from the connector.
139
138
136
137
ti25227a
7. Mount the new fan (136), rear fan grill (138), and
nuts (139) on the grill (137) with the arrow pointing
toward the grill (137).
8. Tie down the fan wires onto the tie down locations
on the grill (137) using cable zip ties.
9. Route the fan wires into the Electrical Enclosure.
Connect the red and black fan wires to the J7 connector. Reconnect the J7 connector to the AWB.
Use cable ties to secure the fan wires to other
cables in the electrical enclosure.
J7
NOTE: To prevent fan errors on the ADM, remove the
excess slack and ensure that the cabling and zip ties do
not contact the fan blades.
ti25226a
10. Reinstall the fan grill (137) and close the Electrical
Enclosure.
5. Cut any cable ties between the end of the fan wires
to the fan (136).
58
334130R
Repair
Replace Transformer
13. Connect transformer output power harness (234) to
power terminal connections. Torque to 25–27 in-lbs
(2.8–3.1 N•m).
Table 11 Transformer Output Power Harness
Connections
See FIG. 34, page 60.
1. Turn the Main Power Switch OFF.
Power Harness Wires
CR-2 Connections
CR2-W1
CR2-W2
CR2-W3
CR2-W4
Terminal 1
Terminal 3
Terminal 5
Terminal 13
14. Install the incoming power harness (234) to the top
of the transformer in the voltage port specified on
the machine serial number label.
2. Open the Electrical Enclosure door.
3. Disconnect the incoming power harness (234) from
the top of the transformer (235).
480VAC
600VAC
4. Disconnect the transformer (235) output power harness wires (CR2-W1, -W2, -W3, -W4) from CR2.
5. Disconnect the transformer (235) ground wire from
the back panel ground lug.
6. Disconnect the red (+) and black (-) wire of the fan
from pins 4 and 3 of the J7 connector on the AWB
(205). Disconnect the J7 connector from the AWB.
400VAC
7. Cut the wire zip ties securing the fan wires.
8. Remove the flanged nuts (N) and transformer (235)
from the back panel (201).
9. Install the transformer (235) onto mounting studs on
the back panel (201) and secure with flanged nuts
(N).
10. Insert the thermal sensor connector from the transformer (235) onto the J7 connector on the AWB
(205).
ti25228a
15. Verify all electrical connections, including earth
grounds, are complete and tight. All connections
and plugs must be connected prior to applying
power.
16. Close the Electrical Control Panel door.
17. Apply power to the machine. Turn on the Main
Power Switch.
18. Restart the system.
11. Reconnect the red (+) wire from the fan into pin 4
and the black (-) wire into pin 3 of the J7 connector.
12. Install the transformer (235) ground wire onto the
ground lug of the back panel (201).
334130R
59
Repair
Z
CR-2
G
J7
234
205
235
N
201
FIG. 34: Inside of Electrical Control Enclosure
60
334130R
Repair
Update Software
When software is updated on the ADM, the software is
then automatically updated on all connected GCA components. A status screen is shown while software is
updating to indicate progress.
1. Turn the system Main Power Switch OFF.
NOTE: When the Screen turns on, you will see the following screens:
First:
Software is checking which
GCA modules will take the
available updates.
2. Remove the ADM from the bracket.
3. Remove the token access panel.
Second:
Status of the update with
approximate time until
completion.
Third:
Updates are complete.
Icon indicates update success/failure. See the following Icon table.
4. Insert and press the software upgrade token (T)
firmly into the slot.
Icon
Description
Update successful.
NOTE: There is no preferred orientation of the token.
Update unsuccessful.
Update complete, no changes necessary.
Update was successful/complete, but one
or more HCA modules did not have a CAN
boot-loader, so software was not updated
on that module.
T
5. Install the ADM into the bracket.
6. Turn the system Main Power Switch ON.
7. Remove the token (T).
8. Replace the token access panel.
NOTICE
A status is shown while software is updating to indicate progress. To prevent corrupting the software
load, do not remove the token until the status
screen disappears.
334130R
9. Press
to continue to the operation screens.
61
Electrical Schematics
Electrical Schematics
230V, 3 Phase/60Hz
62
334130R
Electrical Schematics
400V, 3 Phase/50Hz
334130R
63
Electrical Schematics
400-600VV, 3 Phase/60Hz
64
334130R
1290
18 AWG
-
J2
L
EGND
130
131
132
218
219
220
54321
G
J5
BLACK
10 AWG
2270
HARNESS 17A544 OR 17A545
AWB-1-J5 TO MZTCM-2-J2
AWB-1-J5 TO MZTCM-3-J2
315
332
240
HARNESS 17A559
AWB-1-J8 TO MZTCM-1-J6
285
239
284
238
Z104520
SEE SHEET 1
Z106725
2620
2610
J
223
222
221
220
374
372
K REVISED SHEETS 2,3, & 4
290
289
288
287
286
285
237
282
281
280
279
278
277
276
275
274
273
272
271
270
283
125
122
268
267
266
265
269
268
267
236
2320
1250
YELLOW
ENCLOSURE FAN
(FAN-2)
127421
1220
YELLOW
HARNESS 17A543
AWB-1-J6 TO MZTCM-1-J2
329
330
282
RED
10 AWG
312
313
235
18 AWG
+
-
J6
J7
1
2
3
G
1
2
266
265
284
J9
CAN
G
W4
W3
W2
3
281
J4
+
264
263
234
J3
N
L
283
10 AWG
1320
1310
1300
+
L
N
J8
AWB-1
260
259
258
257
256
233
232
231
230
229
228
227
226
225
224
223
222
221
129
217
216
215
214
213
W1
GND
L
262
J1
N
255
254
253
252
261
-
N
PS-1
251
212
HARNESS 17A552
-V
24+ GND
+V
211
210
209
208
207
206
205
204
203
202
201
250
17MAR16
06/16/16
J1
L1
A RELEASED
B SEE ECO
A257M
Z090146
Z090616
Z091443
Z093615
SEE SHEETS 1 AND 2.
E
Z092531
Z095498
SEE SHEET 1
F
D SEE SHEETS 1,2,3
Z097266
C SEE ECO
Z098180
G SEE SHEET 1
22 AWG
L1
L2
L3
G
J2
L3
3
1
4
2
J7
06/24/14
07/23/14
08/26/14
10/17/14
12/04/14
23MAR15
02JUN15
30JUN15
MZTCM-1
H REVISED SHEET3
10 AWG
HARNESS 17A543
MZTCM-1-J2 TO AWB-1-J6
12 AWG
HARNESS 17A551
MZTCM-1-J1 TO TERM BLOCKS
22 AWG
J3
J12
J13
J14
J15
334130R
J16
200
1
2
3
4
5
5
4
3
2
1
4
3
2
1
4
3
2
3
J6
J5
3
2
2
1
6
5
4
3
2
1
1
22 AWG
4
2
4
1
4
1
5
3
2790
2770
2760
2710
PLATEN-RTD
PUMP-RTD
HARNESS 17A555
2700
2680
2650
RED
RED
RED
2740
2730
1150
RED
1140
1090
RED
BLUE
1100
BLUE
114
115
109
110
238
237
236
235
234
358
355
HARNESS 17B768
MOTOR-UP
PX-LOW
PX-EMPTY
MOTOR-DN
2570
300
301
302
303
304
HARNESS 17A557
MZTCM-1-J12 TO SOL-1
SOL-1
HARNESS 17A559
MZTCM-1-J6 TO AWB-1-J8
2720
HARNESS 17A553
MZTCM-1-J7 TO SSR-1 AND CR-1
WHITE
WHITE
RED
BLUE
RED
2670
2640
HARNESS 24V745
2560
HARNESS 127511
MZTCM-1-J3 TO MZTCM-2-J6
Electrical Schematics
AWB and MZLP#1
65
66
2
3
4
5
J3
10 AWG
5
HARNESS 127511
MZTCM-2-J3 TO MZTCM-3-J6
10 AWG
215
217
218
365
364
363
362
361
360
J3
4
3
J7
2
1
215
217
218
382
381
380
379
378
377
388
389
390
340
387
386
339
J1
L3
338
337
336
L1
J2
G
L3
L2
L1
HARNESS 17A545
MZTCM-3-J2 TO AWB-1-J5
376
375
374
385
5
5
384
4
4
335
3
J5
J6
3
383
2
2
373
372
371
370
369
334
1
1
2
3
4
5
6
1
MZTCM-3
J1
333
332
331
330
329
328
327
326
325
324
323
322
321
320
L3
368
319
L1
J2
G
L3
L2
L1
HARNESS 17A544 OR 17A545
MZTCM-2-J2 TO AWB-1-J5
359
358
357
367
4
4
318
3
2
3
J7
1
366
2
J5
J6
317
1
1
2
3
4
5
356
316
315
314
313
312
311
310
309
308
307
306
6
354
250
304
1
353
251
303
MZTCM-2
352
252
302
355
351
253
305
350
254
301
HARNESS 127511
MZTCM-2-J6 TO MZTCM-1J3
300
Z104520
SEE SHEET 1
B3
T3
T1
B1
2740
2732
2732
2731
2731
2730
17MAR16
06/16/16
16 AWG
J
3
2
1
2740
2732
2731
2730
Z106725
2620
2610
2740
2730
K REVISED SHEETS 2,3, & 4
262
261
275
274
PUMP
PUMP
PLATEN
Z095498
SEE SHEET 1
SEE SHEETS 1 AND 2.
F
E
A RELEASED
Z090146
Z090616
Z091443
C SEE ECO
B SEE ECO
Z092531
D SEE SHEETS 1,2,3
A257M
Z097266
Z093615
Z098180
G REVISED PUMP WIRING
275
274
H REVISED SHEET 3
2
240V/1200W TOTAL
ALL VOLTAGES
TYPICALL ALL TOF200 AND TOFP20's
OVERTEMPS
06/24/14
07/23/14
08/26/14
10/17/14
12/04/14
23MAR15
02JUN15
30JUN15
2740
2730
2740
2732
2731
2730
2740
2730
PLATEN
AT SELECTION 7. ALL VOLTAGES
TYPICALL OF TOFP20's WITH CODE D
OVERTEMP
Electrical Schematics
MZLP#2, MZLP#3, Overtemp, and Pump Heaters
334130R
Electrical Schematics
MZLP Zones
400
401
402
403
TYPICAL ZONE PIN OUT
MZTCM-1
1 2
CONNECTOR
PIN #
FUNCTION
MZTCM-1
A
ZONE 1,L2
B
404
J9
405
MZTCM-1 J9
406
SHIELD
C
ZONE 2,L1
D
ZONE 2,L2
E
JUMPER
F
ZONE 1,START
G
ZONE 1,RTD
H
407
408
3
4
409
J8
411
RTD EXCITE
L
ZONE 2,START
M
ZONE 2,RTD
A
ZONE 3,L2
413
ZONE 4,L1
D
ZONE 4,L2
A
MZTCM-2
5 6
J
ZONE 3,START
G
ZONE 3,RTD
H
JUMPER
RTD EXCITE
L
ZONE 4,START
M
ZONE 4,RTD
ZONE 5,L2
B
SHIELD
H
MZTCM-2 J9
419
D
422
F
L
423
E
G
ZONE 5,RTD
ZONE 6,START
M
ZONE 6,RTD
A
ZONE 7,L2
B
SHIELD
D
MZTCM-2 J8
428
429
MZTCM-3
9 10
G
ZONE 7,RTD
JUMPER
ZONE 7,L1
K
RTD EXCITE
L
ZONE 8,START
M
ZONE 8,RTD
A
ZONE 9,L2
B
J9
MZTCM-3 J9
432
SHIELD
C
ZONE 10,L1
D
ZONE 10,L2
E
JUMPER
F
ZONE 9,START
G
ZONE 9,RTD
H
433
434
11 12
JUMPER
J
ZONE 9,L1
K
RTD EXCITE
L
ZONE 10,START
M
ZONE 10,RTD
A
435
ZONE 11,L2
B
436
J8
437
MZTCM-3 J8
438
SHIELD
C
ZONE 12,L1
D
ZONE 12,L2
E
JUMPER
F
ZONE 11,START
G
ZONE 11,RTD
H
439
440
334130R
H
MZTCM-3
430
431
ZONE-2-RTD
E
JUMPER
ZONE 7,START
J
427
ZONE-2-START
M
ZONE 8,L1
F
H
426
L
ZONE 8,L2
E
425
ZONE-1-START
K
JUMPER
RTD EXCITE
L
ZONE-1-RTD
F
ZONE 5,L1
K
C
J8
424
G
JUMPER
ZONE 5, START
J
D
ZONE 6,L1
F
H
G
C
8
C
ZONE 6,L2
E
J9
7
ZONE-1-HEAT
J
ZONE-2-HEAT
A
D
M
421
A
ZONE 3,L1
K
C
417
420
B
MZTCM-2
K
B
418
JUMPER
F
J
414
TYPICAL ZONE PIN OUT
SHIELD
C
E
MZTCM-1 J8
412
416
ZONE 1,L1
K
B
410
415
JUMPER
J
JUMPER
J
ZONE 11,L1
K
RTD EXCITE
L
ZONE 12,START
M
ZONE 12,RTD
H REVISED SHEET 3
Z098180
30JUN15
G SEE SHEET 1
Z097266
02JUN15
F
SEE SHEET 1
Z095498
23MAR15
E
SEE SHEETS 1 AND 2.
Z093615
12/04/14
D SEE SHEETS 1,2,3
Z092531
10/17/14
C SEE ECO
Z091443
08/26/14
Z090616
07/23/14
Z090146
06/24/14
K REVISED SHEETS 2,3, & 4
Z106725
06/16/16
B SEE ECO
J
Z104520
17MAR16
A RELEASED
SEE SHEET 1
A257M
67
Parts
Parts
Therm-O-Flow 200 Supply Unit
6
12
3
25
2
29
7
26
8
27
5
10
28
ti25003a
9
24
13
11
11
4
16
16
21
22
23
15
1
68
20
14
18
17
19
334130R
Parts
Therm-O-Flow 200 Supply Unit
Ref
Part
1
2
--Frame
24W870 KIT, air controls; see Air Control
Assembly, page 70
--CONTROL, electrical
--MODULE, pump; see Pump Modules, page 78
--PLATEN; see Heated Platens,
page 85
--RAM; see ram manual
--CLAMP, drum; see Drum Ram
Post Saddle Clamp, page 88
--SEALS, see manual 309196
24W812 ADM
24W589 KIT, light tower (optional); see
Accessories and Kits, page 92
253288 CABLE, track, IGUS
234966 KIT, hose hanger
24V745 SENSOR, level, low/empty
15H543 BRACKET, mounting
3
4
5
6
7
8
9
10
11
12
13
14
Description
Qty
Ref
Part
Description
1
1
15
16
17
18
19
20
21
22
23
24
120186
101864
111303
100575
100023
--100643
100016
110755
233559
25
26
15J076
15J074
27
15H668
28
15J075
29
184090
BOLT, mounting, u-bolt
SCREW, cap, sch
NUT, hex
SCREW, cap, hex hd
WASHER, flat
BRACKET, mounting, enclosure
SCREW, cap, sch
WASHER, lock
WASHER, plain
KIT, vent hood (optional); see
Accessories and Kits, page 92.
LABEL, warning, instructions
LABEL, warning; moving objects,
pinch
LABEL, warning; hot surface,
splatter
LABEL, warning; hot surface,
shock
LABEL, warning
1
1
1
1
1
1
1
1
1
1
1
1
Qty
2
8
4
4
4
1
4
4
4
1
2
4
2
2
1
 Replacement Warning Labels, signs, tabs, and cards
are available at no cost.
334130R
69
Parts
Air Control Assembly
56
61
53
62
66
54
57
52
66
55
59
58
66
60
51
51
Integrated Control For
TOF With Electrical Enclosure
Ref
Part
51
24W870 KIT, CONTROL, air, 3 regulator;
see manual 334201
121235 SOLENOID, air motor, ram
17A557 HARNESS, solenoid, MZLP
113445 FITTING, elbow, street
121282 FITTING, swivel, straight
120375 ADAPTER, elbow, 3/4-14 nptf x
1/2-14 npsm
--FITTING, adapter, 1/8 x 1/8 NPT(f)
--BLOCK, adapter, regulator
52
53
54
55
56
57
58
70
24X026, Integrated Control For
Hydraulic TOF With Electrical
Enclosure
Description
Qty
Ref
Part
1
59
60
-----
1
1
1
1
1
1
2
61
62
66
Integrated Control For
TOF Without Electrical Enclosure
Description
Qty
O-RING
SCREW, cap, socket hd; 1.5 in,
#8-32
--CONTROL, air, 3 regulator,
hydraulic
--LABEL, valve, shutoff, air control
255651 KIT, reg, air motor, ram
4
8
1
1
1
Parts only used with 24X026 on TOF 200 Hydraulic Systems.
334130R
Parts
Electrical Module
146 153 148 150 152 153
144
151
170
172
143
184
145 147 149
120
153
152
142
106
105
222
174
141
222
177, 119
137
118
136
103
138
139
104
111
140
141
116
115
222
158
157
160
101 113
114
159
183
115
161
112
131
334130R
112
116
71
Parts
125
126
181
165
167
222
169
134
128
127
122
168
132
165
111
131
129
133
125
162
123
130
135
156
124
72
108
109
110
334130R
Parts
Electrical Control Module Parts
Ref
Part
Description
101
103
-----
104
105
106
107
--125946
123967
---
ENCLOSURE, electrical
BUSHING, strain relief, m40
thread
NUT, strain relief, m40 thread
PLUG, hole, 1/2 in
KNOB, operator disconnect
PANEL, elec, transformer
(transformer assemblies only)
PANEL, elec, 400v/n
(400V modules only)
PANEL, elec, 230v/n
(230V modules only)
WASHER, lock, 3/8
NUT, hex
NUT, flange, serrated, 3/8-16
MODULE, gca, mzlp w/ daughter
board
MODULE, gca, mzlp
(8 zone assemblies only; Qty 1)
(12 zone assemblies only; Qty 2)
KIT, daughter, board
GASKET, foam
(8 zone assemblies only; Qty 1)
(12 zone assemblies only; Qty 2)
PLATE, blank
(4 zone assemblies only; Qty 2)
(8 zone assemblies only; Qty 1)
SCREW, 8-32, serrated flange
CAP, souriau, uts 14
(4 zone assemblies only; Qty 2)
(8 zone assemblies only; Qty 4)
(12 zone assemblies only; Qty 6)
WIRE, grounding, door
NUT, full hex
GASKET, hphm
HARNESS, power, mzlp1, awb
HARNESS, power, mzlp2, awb
(8 zone assemblies only)
HARNESS, power, mzlp2/3, awb
(12 zone assemblies only)
----108
109
110
111
100133
100307
123396
---
112
24V510
112a 24R042
113 ---
114
24P175
115
116
125856
16T440
118
119
120
122
123
--100166
--17A543
17A544
17A545
Qty
Ref
Part
Description
1
1
125
126
-----
1
2
1
1
127
128
129
17A555
17A559
127511
1
130
131
132
121226
121612
123969
123968
134
136
--17A547
24V911
1
137
138
139
140
16X884
115836
127278
24V746
12
141
142
143
144
119865
--24W812
15V551
145
121001
146
---
147
121250
148
102040
149
110755
150
121253
HARNESS, pump, mzlp1, tb, tof
1
HARNESS, output, mzlp1, ssr,
1
contact
HARNESS, pump, reed switch, tof 1
HARNESS, board, mxm, comm
1
CABLE, board, samtec
(8 zone assemblies only; Qty 1)
(12 zone assemblies only; Qty 2)
CABLE, can, male / female, 0.4m
1
CONNECTOR, thru, m12, mxf
1
SWITCH, disconnect, 100a
1
SWITCH, disconnect, ph exp 100
1
A (400V only)
HARNESS, disc, fuse, 230-600v
1
HARNESS, disc, cb, 400v/n, tof
1
FAN, 24v dc, 120m x 120m
1
(400V only)
GRILL, fan (400V only)
1
GUARD, finger (400V only)
1
NUT, keps, hex (400V only)
4
GRILL, vent
(230V and 400V assemblies only;
Qty 2) (Transformer assemblies
only; Qty1)
SCREW, mach, hex serrated
4
CONTROL, air, assy; with solenoid 1
ADM (Primary assemblies only)
1
SHIELD, membrane, ADM
0.1
(Primary assemblies only)
CABLE, can, female / female 1.0m 1
(Primary assemblies only)
BRACKET, mounting, assembly
1
(Primary assemblies only)
SCREW, shcs, 1/4uncx4.25 (Pri1
mary assemblies only)
1
NUT, lock, hex
(Primary assemblies only)
WASHER, plain (Primary assem1
blies only)
1
KNOB, display adj., ram pkgs
1
4
8
4
1
1
2
1
1
1
1
151
152
153
334130R
(Primary assemblies only)
BRACKET, pendant pivot,
(Primary assemblies only)
101550 SCREW, cap, sch
(Primary assemblies only)
100016 WASHER, lock
(Primary assemblies only)
---
Qty
1
4
5
73
Parts
Ref
Part
Description
156
157
158
159
160
24V745
------124654
SENSOR, level, low/empty
BUSHING, strain relief
NUT, bushing
GROMMET, wire
161
121228 CABLE, can, female/female,
15.0 m
(Secondary modules only)
16W035 CONNECTOR, jumper
162
163
164
165
166
---
CONNECTOR, splitter, 12(m) x
m12(f)
(Secondary modules only)
(8 zone assemblies only;
Qty 1) (12 zone assemblies only;
Qty 2)
CONTACT, socket, 20-24 awg,
crimp, tin
TUBE, 1/16 shrink tube
Qty
1
1
1
1
1
1
3
--0.13
--1
HARNESS, input, mzlp1, RTD
127771 BRIDGE, plug-in, 2pos, ut16
1
(400V and Transformer modules
only)
167 --FERRULE, wire, 10awg
(230V modules only; Qty 2) (400V
and transformer modules only; Qty
8)
168 --FERRULE, wire, 16awg
6
169 --6
FERRULE, wire, 18 awg, long
170 196548 LABEL, warning, shock
1
172 --ARTWORK, instructions, wiring, ul 1
181 --3
FERRULE, wire, 10awg, twin
182
183
184
(Secondary assemblies only)
17C669 CONNECTOR, jumper, male
(Secondary assemblies only)
123856 HARNESS, CAN, cable
(Secondary assemblies only)
17C712 TOKEN
(Secondary assemblies only)
1
1
1
 Replacement Warning labels, signs, tags, and cards
are available at no cost.
74
334130R
Parts
Electrical Panel
230V
400V
Transformer
223, 224
225
214 1
227
215 1
216, 229 1
230, 231 1
213
208
201
241
210 1
226
212
206
228
242
7
202, 203, 204, 236
223
234 6
205
4 211
Transformer Panel Shown
239
240
235
1 Torque terminals to 25-27 in-lbs (2.8-3.1 N•m).
2 Torque terminals to 13.3-16 in-lbs (1.5-1.8 N•m)
3 Torque terminals to 4.53-6.2 in-lbs (0.5-0.7 N•m)
334130R
75
Parts
230V Panel
232
400V Panel
230 1
230
207
221
2
220
2
233
218
243
219
217 3
211
1 Torque terminals to 25-27 in-lbs (2.8-3.1 N•m).
2 Torque terminals to 13.3-16 in-lbs (1.5-1.8 N•m)
3 Torque terminals to 4.53-6.2 in-lbs (0.5-0.7 N•m)
76
334130R
Parts
Electrical Panel Parts
Ref
Part
Description
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
--117666
113783
100985
24V816
--123363
126453
--128097
--126811
--120399
123359
PANEL, elec, tof, 11ga, zinc
TERMINAL, ground
SCREW, machine, pn hd
WASHER, lock ext
MODULE, gca, awb
RAIL, din, 6.5in
BLOCK, terminal, ground, 10mm
POWER SUPPLY, 24v
HARNESS, power supply, awb
CIRCUIT, breaker, 63a, 4p, rcd
HARNESS, rcd, awb
BLOCK, clamp end
RAIL, din, 19in
CONTROL, 65 amp, 120-600v
RELAY, contactor, 30a, 3p, 24vdc
co
216 6690-24 FUSE, fuse block buss jt60060
-165
217 128314 BLOCK, terminal 3-wire
218 128321 COVER, end
219 126819 BRIDGE, plug-in, 2-position
220 127717 BLOCK, terminal, 2pos, ut16
221 127718 COVER, end, ut16
222 17C137 LABEL, multi safety
223 103833 SCREW, mach, crbh
224 123452 HOLDER, anchor, wire tie, nylon
225 --HARNESS, wire, ground, 8awg
226 --HARNESS, fuse, contactor
227 --HARNESS, contactor, ssr
Qty
Ref
Part
Description
1
1
1
1
1
1
3
1
1
1
1
2
1
1
1
228
229
230
----6690-24
-164
127744
HARNESS, rcd, ssr fan
See Code C Table
231
232
233
234
235
3
237
8
2
1
3
1
1
33
12
1
1
1
238
239
240
241
242
243
Qty
FUSE, fuse block buss jt60030
CIRCUIT, breaker, 3p, 32a, ul489;
230V Panel only
127745 CIRCUIT, breaker, 20a,
4p, ul489; 400V Panel only
--See Code C Table
17L788 HARNESS, cb, rcd, 230-400V;
230V and 400V Panel only
17L789 HARNESS, cb, rcd, 400v/n; 400V
Panel only
17A541 HARNESS, fuses, transformer;
Transformer panel only
24V718 TRANSFORMER, multi-tap/230v,
6kva; Transformer panel only
128014 FILTER, voltage, transient, 600V,
3P
112380 SCREW, mach, pn hd
81/0163 WIREWAY, panduit
-B/11
81/0164 COVER, panduit
-B/11
17L790 HARNESS
129120 CONTACTOR 240V
17L787 HARNESS
If Code A is 200 and Code E is F/S and Code C is
Code C
X1X
X2X
X3X
X4X
X5X
Code C
X1X
X2X
X3X
X4X
X5X
334130R
(231)
NA
NA
24X878
24X877
24X874
1
1
3
1
1
1
1
2
4
4
1
1
1
 Replacement Warning labels, signs, tags, and cards
are available at no cost.
If Code A is 200 and Code E is M and Code C is
(229)
24X885
24X881
24X881
24X882
24X884
1
3
3
(229)
24X885
24X880
24X880
24X881
24X883
(231)
NA
NA
24X878
24X877
24X874
77
Parts
Merkur 2200, 23:1 Pump Modules
327
301 338
315
303
329
337
308 1
312
9 302
304
310
318
309a 6
305
323
318
334
317
316 2
324
325
4
320
311
322 3
335a
336
321 5
8 10 306
309b 6
335b
1 7 307
326
333
ti25145a
1 Torque to 50-60 ft-lbs (68-81 N•m).
2 Torque to 145-155 ft-lbs (196-210 N•m).
3 Coat mounting surface of sensor mounting block (322) with
non-silicone heat sink compound. Do not coat sensor.
4 Prior to tightening band clamp (321), RTD sensor (320)
must be fully contained within the sensor mount (322).
5 After fastening band clamp (321), secure excess with
fiberglass tape.
78
6 Coat inside of heater (309a, 309b) only to within 0.75 in. (19
mm) of vertical ends with non-silicone heat sink compound
before mounting.
7 Cap screws (311) must be loose while tie rods (307) are
being torqued.
8 Torque to 150 ft-lb (203 N•m).
9 Install swivel fitting (302) prior to screw (303) and reed switch
assembly (304).
10 Apply anaerobic sealant to threads.
334130R
Parts
Merkur 2200, 23:1 Pump Modules
Ref
Part
301
302
303
24W754 MOTOR, air, 6 in, 4.75 stroke, blue
155470 FITTING, swivel, union, 90°
--FASTENER, screw, slot hex, #8-32
tap
24X441 SWITCH, reed assy
--BRACKET, motor mount
15H397 ADAPTER, rod, pump
16A223 ROD, tie, vert driver
106166 NUT, mach ,hex
128322 HEATER, pump, 600 watt
24W150 PUMP, long shaft, cf; 24V003 only
24W151 PUMP, long shaft, gf; 24V006 only
109211 SCREW, cap, sch
17A637 BLOCK, standoff, mounting
102656 MUFFLER
186925 NUT, coupling
184129 COLLAR, coupling
120186 BOLT, mounting, u-bolt
304
305
306
307
308
309
310
311
312
315
316
317
318
334130R
Description
Qty
Ref
Part
Description
1
1
1
320
321
322
323
324
325
326
24Z093
C31012
C03507
C38162
C38163
-----
SENSOR, RTD
1
1
1
3
3
2
1
3
3
1
1
2
2
CLAMP
SUPPORT, sensor
SCREW, machine
WASHER, lock, ext. tooth
CONDUCTOR, ground
329
330
331
333
334
335
SHIELD, pump, tof200; see
24V619, Pump Shield, page 84
103347 VALVE, safety, 100 psi
C33049 TAPE, adhesive, fiberglass
--LUBRICANT, high temp, thermal
206994 FLUID, tsl 8 oz bottle
17B715 SUPPORT, block, overtemp
127671 SWITCH, over temp, fixed, 450°F
336
337
338
(232°C)
122338 SCREW, cap, socket bh
214656 HOSE, coupled, 10 ft (3 m)
16C009 HOOK
Qty
1
1
1
1
1
1
1
1
1.5
1
1
1
2
4
1
1
79
Parts
Merkur 3400, 36:1 Pump Modules
338
301
337
9 302
329
327
315
308 1
304
310
312
303
323
318
324
305
325
311
4
320
317
336
322 3
335a
321 5
335b
334
318
316 2
8 10 306
309a 6
336
309b 6
1 7
307
333
326
1 Torque to 50-60 ft-lbs (68-81 N•m).
2 Torque to 145-155 ft-lbs (196-210 N•m).
3 Coat mounting surface of sensor mounting block (322) with
non-silicone heat sink compound. Do not coat sensor.
4 Prior to tightening band clamp (321), RTD sensor (320)
must be fully contained within the sensor mount (322).
5 After fastening band clamp (321), secure excess with
fiberglass tape.
80
6 Coat inside of heater (309) only to within 0.75 in. (19 mm)
of vertical ends with non-silicone heat sink compound
before mounting.
7 Cap screws (311) must be loose while tie rods (307) are
being torqued.
8 Torque to 150 ft-lbs (203 N•m).
9 Install swivel fitting (302) prior to screw (303) and reed
switch assembly (304).
10 Apply anaerobic sealant to threads.
334130R
Parts
Merkur 3400, 36:1 Pump Modules
Ref
Part
301
302
303
311
312
315
316
317
318
320
321
322
323
324
325
326
24R015 MOTOR, assy, air, 7.5 in, blue
155470 FITTING, swivel, union, 90°
--FASTENER, screw, slot hex, #8-32
tap
24X441 SWITCH, reed assy
15H173 BRACKET, motor mount, tof 200
15H397 ADAPTER, rod, pump
16A223 ROD, tie, vert driver
106166 NUT, mach, hex
128322 HEATER, pump, 600 watt
24W150 PUMP, long shaft, cf; 24V004 only
24W151 PUMP, long shaft, gf; 24V007 only
109211 SCREW, cap, sch
17A637 BLOCK, standoff, mounting
102656 MUFFLER
186925 NUT, coupling
184129 COLLAR, coupling
120186 BOLT, mounting, u-bolt
24Z093 SENSOR, RTD
C31012 CLAMP
C03507 SUPPORT, sensor
C38162 SCREW, machine
C38163 WASHER, lock, ext. tooth
--CONDUCTOR, ground
--SHIELD, pump, tof200; see
329
330
331
333
334
335
103347
C33049
--206994
17B715
127671
304
305
306
307
308
309
310
336
337
338
Description
24V619, Pump Shield, page 84
VALVE, safety, 100 psi
TAPE, adhesive, fiberglass
LUBRICANT, high temp, thermal
FLUID, tsl 8 oz bottle
SUPPORT, block, overtemp
SWITCH, over temp, fixed, 450°F
(232°C)
122338 SCREW, cap, socket bh
214656 HOSE, coupled, 10 ft (3 m)
16C009 HOOK
334130R
Qty
1
1
1
1
1
1
3
3
2
1
1
3
3
1
1
2
2
1
1
1
1
1
1
1
1
1.5
1
1
1
2
4
1
1
81
Parts
NXT 6500, 70:1 Pump Modules
401
424
406 1
433
402
408
417
418
415
416
423
403
409
404 8 10
418
414
4
410
407a 6
431
411 3
430a
412 5
430b
429
407b 6
431
413 2
405 1
428
422
ti25160a
1 Torque to 50-60 ft-lbs (68-81 N•m).
2 Torque to 145-155 ft-lbs (196-210 N•m).
3 Coat mounting surface of sensor mounting block (411) with
non-silicone heat sink compound. Do not coat sensor.
4 Prior to tightening band clamp (412), RTD sensor (410)
must be fully contained within the sensor mount (411).
82
5 After fastening band clamp (412), secure excess with
fiberglass tape.
6 Coat inside of heater (407) only to within 0.75 in. (19 mm)
of vertical ends with non-silicone heat sink compound
before mounting.
8 Torque to 150 ft-lb (203 N•m).
10 Apply anaerobic sealant to threads.
334130R
Parts
NXT 6500, 70:1 Pump Modules
Ref
Part
401
402
409
410
411
412
413
414
415
416
417
418
419
422
N65LR0 MOTOR, 6500, low-noise, remote
120375 ADAPTER, elbow, 3/4 npti x 1/2
npte
15H542 BRACKET, mounting, motor,
tof200
17A406 ADAPTER, rod, pump, tof
16A223 ROD, tie, vert driver
106166 NUT, mach, hex
128322 HEATER, pump, 600 watt
24W150 PUMP, long shaft, cf; 24V005 only
24W151 PUMP, long shaft, gf; 24V008 only
C19837 SCREW, cap, socket hd
24Z093 SENSOR, RTD
C03507 SUPPORT, sensor
C31012 CLAMP
186925 NUT, coupling
184129 COLLAR, coupling
C38163 WASHER, lock, ext. tooth
--CONDUCTOR, ground
C38162 SCREW, machine
120186 BOLT, mounting, u-bolt
100307 NUT, hex
--SHIELD, pump, tof200; see
423
424
425
426
428
429
430
120588
120012
--C33049
206994
17B715
127671
403
404
405
406
407
408
431
432
433
Description
24V619, Pump Shield, page 84
PLUG, pipe, round
VALVE, safety, 50 psi
LUBRICANT, high temp, thermal
TAPE, adhesive, fiberglass
FLUID, tsl 8 oz bottle
SUPPORT, block, overtemp
SWITCH, over temp, fixed, 450°F
(232°C)
122338 SCREW, cap, socket bh
17C255 CABLE, M12, 8p, 5p, m, 0.2 m
--HOSE, coupled, 13.5 ft (4 m)
334130R
Qty
1
1
2
1
3
3
2
1
1
4
1
1
1
1
2
1
1
1
2
4
1
1
1
1
1.5
1
1
2
4
1
1
83
Parts
24V619, Pump Shield
506
510
505
509
506
511
508
507
504
509
506
ti25162a
502
506
503
Ref
Part
Description
Qty
500
501*
502*
503*
504*
505*
506*
24V619PKG
-------------
SHIELD, pump, TOF200
COVER, pump, bottom
COVER, pump, right
COVER, pump, left
COVER, pump, top, front
1
1
1
1
1
COVER, pump, top, back
FASTENER, thread-cutting
screw
12
507
Ref
507* 17J504
508* 104088
509* 15J075
510
511
--C20731
501
Description
Qty
LABEL, warning
RIVET, blind
LABEL, safety, hot surface
and shock
BUSHING, conduit, 1 in
FITTING, conduit, connector,
1 in.
2
4
2
1
1
 Replacement Warning labels, signs, tags, and cards
are available at no cost.
*
84
Part
508
Parts included in Kit 24V619PKG.
334130R
Parts
Heated Platens
24V633, Heated Drum Platen, Mega-Flo (Code E-option M)
24V634, Heated Drum Platen, Standard Grid (Code E-option F)
24V635, Heated Drum Platen, Smooth Bottom (no fin) (Code Eoption S)
605
630
629
601
628
626
625
610
609
605
601
609
611, 629
608
607
613
615
612
614
603
622
627
624
604
619
623
602
606
601
334130R
85
Parts
Heated Platens
24V633, Heated Drum Platen, Mega-Flo (Code E-option M)
24V634, Heated Drum Platen, Standard Grid (Code E-option F)
24V635, Heated Drum Platen, Smooth Bottom (no fin) (Code Eoption S)
Ref
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
Part
--C32204
15G967
C19049
24Z095
C32201
158491
158581
617227
246501
100361
100133
C19846
150707
--100508
-----
Platen Model
24V633
24V634
24V635
86
Description
PLATEN — see table 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
SCREW, cap socket, HD
PLATE, designation
PLATE, designation; 24V633 only
SCREW, drive
CONDUCTOR, 14.2 ft (4.3 m)
CONDUCTOR, 1.7 ft (0.5 m)
Description
Mega-Flo
Standard Grid
Smooth Bottom
Qty
Ref
Part
Description
Qty
1
1
1
1
1
1
1
1
1
1
4
6
6
1
1
2
6
2
618
619
620
621
622
623
----112901
111640
--127671
CONDUCTOR, 0.3 ft (0.09 m)
CONDUCTOR, ground
NUT, hex
WASHER, lock, internal
PLUG, follower, plate
4
1
12
12
1
1
Ref. No. 601
194254
617225
C57358
624
625
626
627
628
629
630
SWITCH, over temp, fixed, 450°F
(232°C)
122338 SCREW, cap, socket bh
--TUBE, ptfe, 1/4 X 5/16
--TUBE, ptfe, 3/32 X 5/32
--SLEEVE, fiberglass, hi-temp
127690 FITTING, adapter, 5/16 in. tube x
1/4 in tube
127689 FITTING, adapter, 1/4 in tube x
5/32 in tube
--TUBE, polyeth, 1/4 OD; 26 ft (7.9
m)
Qty.
1
1
1
2
3
3
3
1
1
1
Element Resistance
16.5 ohms +1/-2
19.2 ohms +2/-3
19.2 ohms +2/-3
334130R
Parts
334130R
87
Parts
Drum Ram Post Saddle Clamp
C32463
Option H-1
703
706
701
707
704
1
705
702
701
706
708
88
707
1
704
705
1 Torque to 50 in-lbs.
ti25188a
Ref
Part
Description
701
702
703
704
C32424
160111
100103
100307
Qty
BOLT, U, 7 in. (177.8 mm)
CLAMP, barrel
PIN, cotter
NUT, hex
2
1
2
4
705
706
707
708
100133
C38182
C32461
166265
WASHER, lock
WASHER, plain
CLAMP, saddle
PIN, pivot
4
2
2
1
334130R
Parts
Drum Ram Post Saddle Clamp
918395
Option H-3
705
703
751
759
708
707
706
702
1 710
1 Torque to 50 in-lbs.
704
756
761
Ref
Part
Description
702
703
704
705
756
707
708
759
710
761
100101
918421
918423
617395
100133
C19200
617433
617395
100131
C32424
SCREW, cap, hex hd
CLAMP, back half assembly
KIT, repair
PIN, quick release
334130R
WASHER, lock
WASHER, plain
SPACER, drum clamp
CLAMP, saddle
NUT, full hex
BOLT, U 7 in. (177.8 mm)
ti25189a
Qty
8
1
1
2
8
8
8
4
8
4
89
Parts
Fiber Drum Reinforcement Shell Clamp
918397
Option H-2
ti25190a
802
803
801
807
6
1 804
803
805
1 Torque to 50 in-lbs.
Ref
Part
Description
Qty
6
801
802
803
804
805
807
C32424
C32271
C19126
100133
100307
617340
617341
BOLT, U, 7 in. (177.8 mm)
CLAMSHELL
SCREW, cap, hex hd
WASHER, lock
4
1
8
12
8
4
2
90
NUT, hex
CLAMP, saddle
MOUNT, clam shell
334130R
Parts
Vent Hood Kit, 233559
855
852
853
851
Ref
Part
Description
851
852
853
855
--112166
100016
C14038
VENT hood
SCREW, cap, sch
WASHER, lock
LABEL, warning
334130R
Qty
1
4
4
1
 Replacement Warning labels, signs, tags, and cards
are available at no cost.
91
Accessories and Kits
Accessories and Kits
Wiper Kits
CGM Installation Kit, 25C994
See manual 309196 for installation and repair instructions.
This kit enables controlling logic, such as a robot controller or PLC continuously monitoring data from the
Therm-O-Flow system, as well as optionally controlling
the system accordingly. Refer to manual 3A5186 for
details on the interface. When ordering this kit, select
and order the correct communication gateway module
(CGM) that matches the field bus being used. The following CGM modules are available for the
Therm-O-Flow system.
Part No.
253291
253290
253289
253292
Description
Hose/Spring Wiper Kit
Hose and T-Wiper Kit
Twin Hose Wiper Kit
T-Wiper Kit
Applicators and Dispense
Valves
Part No.
249515
249514
249513
249512
Description
Manual Gun, Top Feed, 240V
Manual Gun, Bottom Feed, 240V
Manual Gun, Top Feed, Electric Switch,
240V
Manual Gun, Bottom Feed, Electric Switch,
240V
Air-Operated Heated Dispense
Valves
Part No.
243694
244951
244909
243701
92
Description
Automatic Dispense Valve, 240V,
Air-Operated Heated Dispense Valve
Automatic Endure Dispense Valve, 240V,
Air-Operated High Flow Heated Dispense
Valve
Automatic Endure Dispense Valve, 240V,
Air-Operated Snuff-Back Heated Dispense
Valve
45 in (114 cm) Distribution Header With
Valve, 240V
Part No.
CGMEP0
CGMDN0
CGMPB0
CGMPN0
Description
EitherNet/IP
DeviceNet
ProfiBus
ProfiNet
Flow Control and Manifolds
Part No.
243700
243656
243657
243697
289208
Description
Heated Air Operated Mastic Pressure
Regulator, 240V
23:1 Heated Pressure Compensator Valve,
240V
51:1 Heated Pressure Compensator Valve,
240V
Heated Distribution Manifold, 240V
Includes (2) 3/4 npt(f) inlet check valves, (1)
npt 4–ported manifold, (2) 1 in npt(f) outlet
gate valves, mounting bracket, 400w 230
VAC heaters, RTD sensor, and 8 pin
connector box.
Compact Heated Regulator
334130R
Accessories and Kits
Accessory Extension Cables
Light Tower Kit, 24W589
Use to connect fluid control devices and heated hoses to
the electrical control enclosure.
Tie Rod Kits
Part No. Description
Connect between controller and heated hose
129300
15 ft, 12 pin to 12 pin
129301
25 ft, 12 pin to 12 pin
Connect between controller and heated accessory
129302
15 ft, 12 pin to 8 pin
129303
25 ft, 12 pin to 8 pin
Connect between controller and heated devices
129703
25 ft, 12 pin to (2) 8 pin
129304
50 ft, 12 pin to (2) 8 pin
334130R
Use to retrofit Check-Mate 800 Displacement Pump to an
existing Therm-O-Flow system.
Part No.
24V750
24V754
Description
Bulldog® and Senator® Tie Rod Kit; see
manual 334131
NXT® Tie Rod Kit; see manual 334132
93
Accessories and Kits
Heated Hoses and Fittings
NOTE: Refer to Heated Hose, Instructions-Parts manual
3A4241 for additional information about heated hoses.
See Related Manuals on page 8.
Hose Diameter
Hose Length
3 ft (1 m)
4 ft (1.2 m)
6 ft (1.8 m)
10 ft (3 m)
15 ft (4.6 m)
20 ft (6 m)
25 ft (7.6 m)
30 ft (9 m)
Pump Fittings
-6
(9/16 in -18
JIC)
-8
(3/4 in -16
JIC)
-10
(7/8 in -14
JIC)
-12
-16
-20
(1-1/16 in -12 (1-5/16 in -12 (1-5/8 in -12
JIC)
JIC)
JIC)
None
None
None
19M423
None
None
None
None
None
19M400
19M401
19M402
19M403
None
None
None
None
None
19M404
19M405
19M406
19M407
19M408
19M409
19M410
None
19M411
19M412
19M413
19M414
19M415
None
None
None
19M416
19M417
19M418
19M419
19M420
None
None
None
None
19M421
19M422
None
None
None
16V432
100380
253267
253268
120260
120261
120262
16V432
C20678
C20679
C38006
158586
120804
120268
-6 Hose (.308 ID)
125779
123684
123683
123683
120265
-8 Hose (.401 ID)
123684
120241
120242
120244
-10 Hose (.495 ID)
123683
120242
120243
120246
-12 Hose (.617 ID)
123683
120265
123683
120265
120267
120244
120246
120247
120248
120244
120267
120246
120267
120248
120249
120249
120268
None
6308-82
126521
120246
120267
120268
123135
126521
120249
120268
120250
16V432
100380
6308-82
123135
120266
123135
123854
15D936
TOF 20/200 PUMP
1-11 1/2 DUAL
OUTLET ADD
120263
TOF MINI 5 PUMP
1/2 NPT DUAL
OUTLET ADD
120241
Hose to Hose Fittings
-16 Hose (.687 ID)
-20 Hose (1.125 ID)
Fittings
Compensator 51:1,
243657
Compensator 23:1,
243656 Inlet &
Outlet: 1-11 1/2 in
NPTF
94
123683
120265
120267
120244
120267
120246
120267
None
6308-82
126521
6308-82
126521
123135
126521
334130R
Accessories and Kits
Hose Diameter
Distribution manifold,
243697 Inlet: 3/4 in
NPTF
Distribution manifold,
243697 Outlet: 1-11
1/2 in NPTF
Compact Heated
Regulator, 289208
Inlet & Outlet: 3/8 in
NPTF
Mastic Regulator,
243700 Inlet &
Outlet: 3/4 in NPTF
Top and bottom feed
guns with and
without switch,
249512, 249513,
249514, 249515
Inlet: 7/8-14 (JIC
-10) male
Standard, High Flow
& Snuff-back
Dispense valves,
243694, 244951,
244909 Inlet: 1/2
NPTF
Distribution header,
243701 Inlet: 1/2
NPTF
Precision Gear
Meter PGM Inlet:
1-5/16-12 o-ring face
seal
Precision Gear
Meter PGM Outlet:
3/4 NPTF
PCF Metering
System Inlet &
Outlet: 3/4 NTPF
334130R
-6
(9/16 in -18
JIC)
-8
(3/4 in -16
JIC)
-10
(7/8 in -14
JIC)
-12
-16
-20
(1-1/16 in -12 (1-5/16 in -12 (1-5/8 in -12
JIC)
JIC)
JIC)
16V432
100896
124286
15Y934
C20708
125661
125661
120268
16V432
100380
6308-82
123135
120266
123135
123854
15D936
16V432
100896
121311
116765
116766
116766
120267
116766
120267
120268
16V432
100896
124286
15Y934
C20708
125661
125661
120268
117677
120264
None
120265
None
None
16V432
124287
C20768
94/1027/99
125662
125662
120268
16V432
124287
C20768
94/1027/99
125662
125662
120268
None
None
None
124238
124239
124240
16V432
100896
124286
15Y934
C20708
125661
125661
120268
16V432
100896
124286
15Y934
C20708
125661
125661
120268
95
Accessories and Kits
8 Channel Upgrade Kit, 24V755
Use this kit to upgrade a 4 Channel system to an 8 channel system.
Ref
Part
Description
Qty
1
2
3
4
--125856
16T440
127511
MODULE, GCA, MZLP
SCREW, 8–32, serrated flange
CAP, souriau, UTS14
CABLE, board, samtec
1
4
2
1
Ref
Part
Description
Qty
5
6
7
8
16W035
17A544
112190
17C712
CONNECTOR, jumper
HARNESS, power, MZLP2, AWB
STRAP, wrist, grounding
TOKEN, software upgrade
1
1
1
1
7
C
A
B
8
4
2
3
ti25236b
4
6
B
5
J3
J6
J2
5
96
6
J5
334130R
Accessories and Kits
8 Zone Upgrade Kit Installation
1. Disconnect the plug from the power outlet or turn off
the circuit breaker for incoming power.
2. Place the grounding wrist strap (7) over your wrist
and secure the other end to a grounded surface.
3. Set the kit’s MZLP (1) rotary switch to “2” on a primary system or “6” on a secondary system.
4. Remove the screws (B), the plate (A), and the gasket (C) from the system. Use the screws (2) to install
the MZLP (1) onto the system as shown.
NOTE: The new MZLP (1) will be refereed to as MZLP2,
and the original MZLP that came with the system will be
referred to as MZLP 1.
5. Open the Electrical Enclosure door.
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop, and verify the connector orientation.
6. Connect the cable (4) to the J3 connector on MZLP
1 and the J6 connector on MZLP 2.
7. Connect the power harness (6) to the MZLP 2 J2
connector and the J5 connector on the AWB. Install
the jumper (5) on the MZLP 2 J5 connector.
8. Use fittings and hoses that meet your hose routing
needs. See Accessories and Kits, page 92.
9. To ensure your system has the latest software,
insert the token (8) into the ADM. See Update Software, page 61.
334130R
97
Accessories and Kits
12 Channel Upgrade Kit, 24V756
Use this kit to upgrade an 8 channel system to a 12 channel system.
Ref
Part
Description
1
2
3
4
5
--125856
16T440
127511
16W035
MODULE, GCA, MZLP
SCREW, 8–32, serrated flange
CAP, souriau, UTS14
CABLE, board, samtec
CONNECTOR, jumper
B
1
4
2
1
1
Ref
Part
Description
Qty
6
7
8
17A545 HARNESS, power, MZLP2/3, AWB
112190 STRAP, wrist, grounding
17C712 TOKEN, software upgrade
1
1
1
7
C
A
Qty
8
6
J2
J6
4
4
ti25237b
J3
5
1
2
3
J2
98
5
6
J5
334130R
Accessories and Kits
12 Zone Upgrade Kit Installation
1. Disconnect the plug from the power outlet or turn off
the circuit breaker for incoming power.
2. Place the grounding wrist strap (7) over your wrist
and secure the other end to a grounded surface.
3. Set the kit’s MZLP (1) rotary switch to “3” on a primary system or “7” on a secondary system.
4. Remove the screws (B), plate (A), and the gasket
(C) from the system. Use the screws (2) to install
the MZLP (1) on to the system as shown.
NOTE: The new MZLP (1) will be referred to as MZLP 3,
and the other two that came with the system will be
referred to as MZLP 1 and MZLP 2.
5. Open the Electrical Enclosure door.
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop, and verify the connector orientation.
6. Connect the cable (4) to the J3 connector on MZLP
2 and the J6 connector on MZLP (1). Remove the
existing power cable from MZLP 2 J2 and AWB J5
connector.
7. Connect the power harness (6) to MZLP 2 and the
MZLP 3 J2 connector and the J5 connector on the
AWB.
8. See Install Heated Hose, page 18, to connect a
heated hose or fluid control device.
9. To ensure your system has the latest software,
insert the token (8) into the ADM. See Update Software, page 61.
334130R
99
Appendix A - ADM
Appendix A - ADM
General Operation
Enable, Disable Heating System
ADM Power
To enable or disable the entire heating system, press
The ADM automatically turns on when the Main Power
Switch is turned on.
. To set which channels are active when the heating system is enabled, use the Heat-A and Heat-B
Setup screens.
Screen Navigation
To switch between the Setup and Operation screens,
press
screens.
100
. Use the keypad to navigate between
334130R
Appendix A - ADM
Icons
Screen Icons
Softkey Icons
These are frequently used icons on the screens. The
following descriptions explain what each icon
represents.
The following icons appear in the ADM, directly to the
left or right of the soft key which activates that operation.
Icon
Description
Primary System= A
Secondary System = B
Heating Disabled
Icon
Description
Pause Material Tracking
Continue Material Tracking
Pump Ready
Setback
Warm Up, Actual temperature is outside of Target
Temperature
Reset Cycle Counter (press and hold)
Reached Target Temperature
Add or edit event
Hose
Accept schedule
Gun
Manifold
Crossover for Tandem Systems
Erase or cancel schedule
PGM
Cancel
Flow Meter
Pressure Regulator
Other
Advisory. See Error
Codes for more information.
Deviation. See Error
Codes for more information.
Alarm. See Error Codes
for more information.
334130R
Clear
Schedule Event On/Off
Heat On/Off
View Software Contents
Reprogram token with file from USB
stick
Start USB to Token Programming Process
101
Appendix A - ADM
Operation Screens
Events
Home
The Events screens store a maximum of 200 events.
The events list can be downloaded in the USB logs. See
Appendix B - USB Data, page 109.
This screen shows the temperature state of the system
and material usage.
Tracked Events
NOTE: This screen shows the target and actual temperatures for all zones on the system.
Heat A
This screen shows the target and actual temperatures
for all zones on the system.
Custom Language Downloaded
Custom Language Uploaded
Fill Valve Closed
Fill Valve Open
Heat Off
Heat On
Logs Downloaded
Pump Cycles Total Reset
Pump Off
Pump On
Red Stop Button Pressed
Setup Value Changed
System Power Off
System Power On
System Settings Downloaded
System Settings Uploaded
USB Disabled
USB Drive Inserted
USB Drive Removed
User Maintenance Count Reset
NOTE: The Heat-B screen shows information for an
optional secondary system.
Color
A and B Zone Status
White
Green
Off
On and at setpoint temperature
Outside of alarm range
Outside of advisory range
Warmup
Red
Yellow
Green/Yellow Flashing
102
334130R
Appendix A - ADM
Errors
CAN: 24 VDC power supply voltage reading (18-28
VDC)
DI: System Digital Inputs
0: Drum Empty
1: Drum Low
2: Pump Cycle Switch Up
3: Pump Cycle Switch Down
DO: System Digital Outputs
0: Pump Solenoid
1: Not Used
2: Not Used
3: Not Used
The Errors screens store a maximum of 200 errors. See
Error Codes. Download the errors list in the USB logs.
See Appendix B - USB Data, page 109.
Diagnostic - A
ISO DI: Customer Digital Inputs
See Connect PLC (Hard Wired Interface Version),
page 26.
ISO DO: Customer Digital Outputs
See Connect PLC (Hard Wired Interface Version),
page 26.
Fan: Current to fan
Heat Soak: Set time for Platen to heat after the Platen
has reached set temperature.
Life Cycles: Total number of Pump cycles over the life
of the system.
MZLP 1: Temperature on MZLP 1.
•
32-160°F (0-71°C)
Pump Sol: Current draw of Pump solenoid.
•
•
This screen shows details of various items to aid in
troubleshooting the system. This screen can be hidden
by de-selecting “Enable Diagnostics Screen” on the
System 3 screen. The flow rate updates every 15–20
seconds with average flow rate over the last 15–20
seconds.
NOTE: Diagnostic - B shows information for an optional
secondary system.
The following information is displayed.
(0 mA - off)
(150-250 mA - on)
Pump CPM: Pump cycles per minute.
USB DL%: Percentage complete, only applies when
downloading USB data. 5 downloads will occur.
Weight: Weight of material dispensed over the life of the
system.
XFMRTemp: Temperature of the transformer temperature sensor.
Diagnostic Data
A
B
C
Current Draw
RTD Reading
Duty Cycle
334130R
103
Appendix A - ADM
Setup Screens
NOTE: It is important to set all settings in the System
screens correctly to ensure optimal system performance.
Password
If the password is not “0000”, the password must be
entered to access the setup screens.
Enable Tandem System: Enable all secondary system
ADM screens.
Heat Soak: Time for to preheat after all zones have
reached their target temperatures. Pump cannot turn on
until timer is complete. The heat soak is a user-defined
time.
•
•
Range: 1-120 minutes
0 disables heat soak
Pump Inactive Timeout: If no Pump movement is
detected or either Pump for (x) amount of time, all
heated zones enter setback mode. After an additional
amount of time (x), the heat will turn off.
•
•
(x) Range: 0-120 minutes
0 disables heat soak
System 2
System 1
Enter low and high temperatures for an alarm or warning
to occur.
External Pump Control: Enable feature that automatically turns on and off the Pump when using a handheld
dispense gun with an integrated trigger switch.
Enable Diagnostic Screen: Choose whether to show
the Diagnostic screen.
Enable Temp. Adjustments: Allows temperature adjustments on the Heat-A and Heat-B Run screens.
Enable Pump Autostart: Automatically turns the Pump
on after reaching setpoint temperature and heat soak is
complete.
104
334130R
Appendix A - ADM
Advanced 1
Specific Gravity: Required to convert the volume dispensed to mass dispensed for tracking the total weight
and flow rate. When the specific gravity value is populated, the total mass dispense since the last total weight
reset is shown on the Home screen and the mass flow
rate is shown on the Diagnostic screen.
NOTE: If the Specific Gravity is set to zero, the Home
screen will display a cycle counter instead of grams or
pounds.
Language: Language displayed on the screen.
Date Format: Choose the format of the date.
Date: Set the date.
Time: Set the time.
Heat Rate Option: Control option where the user can
select the rate at which heat is applied to all zones
enabled or selected. Three options are available, Normal (default), Fast, and Slow. The Warm Up system time
would be shortest for the Fast option, then the Normal,
and longest if the Slow option is selected. If the material
set temperatures are less than 200° F (93° C), the Slow
option may be best for the application.
Advanced 3
Enter Password: If not “0000”, the Setup screens will
be password protected.
Screen Saver: The screen will go black after the set
amount of time.
Silent Mode: Disable ADM sounds.
Advanced 2
Disable USB Downloads/Uploads: Disables use of the
USB for downloading and uploading.
Disable USB Log Errors: When disabled, the system
will not warn the user when logs are full. If the logs are
full, the oldest data will be overwritten.
Temperature Units: Units of measure for displayed
temperatures.
Download Depth: Last _ Days: The USB download will
provide data as old as the number of days entered. Old
data may be in memory but will not be downloaded if
older than the number of days entered.
Mass Units: Units of measure for mass.
334130R
105
Appendix A - ADM
Advanced 4
To update the software:
Advanced 4 screen allows the user to view the software
contents within the Therm-O-Flow system, or to reprogram the system with a software update.
1. Transfer the updated TOF .gti file (with a filename
containing “17C050”) onto a USB stick. Place the
file in a "\GRACO\SOFTWARE\" subdirectory.
2. Insert a black programming token into the token slot
of the ADM.
To view the software contents, press the
soft key
icon. The screen will display the system software part
numbers and version numbers as shown below.
3. Insert the USB stick into the USB slot of the ADM. If
the USB download option is selected, a graphic of a
USB stick will appear after the download process is
completed. The graphic will appear with a pull-down
option control which allows the user to select the file
to transfer to the programming token.
4. If more than one Therm-O-Flow .gti file is present in
the “GRACO/SOFTWARE/” directory on the USB
stick, select the correct file to transfer using the
pull-down selection control.
5. Press the
soft key icon to start the USB to
token programming process.
If the software contents do not fit onto one screen, the
user can navigate down to the next page by pressing the
down arrow key.
6. During the file transfer process, a progress bar will
be displayed with a percentage completed indicator
below. This step may take a few minutes to complete.
Press the right arrow key to view the serial numbers of
the software displayed on the next screen.
7. Once the percentage indicator reached 100%, the
bottom right soft key will change to
. Press the
To reprogram the system with updated software, press
the
soft key icon on the main Advanced 4 screen.
The screen will appear as shown below.
soft key to update the system. To update the
system (or another Therm-O-Flow system) at a later
time, remove the token and reinsert it with a power
cycle.
8. To exit the screen, press the “X” key until the main
home run screen is shown.
106
334130R
Appendix A - ADM
Heat - A
Maintenance - A
The system will notify the user at the set interval that
maintenance is required. The fields in boxes can be
edited by the user. “Due” and “Current” are both the
number of cycles since the last reset. “Interval” is the set
number of cycles between maintenance notifications.
“Lifetime” is the number of cycles in the lifetime of the
system.
NOTE: The lifetime cycle count will only be reset if the
ADM is replaced.
Schedule
Use these screens to set target and setback
temperatures for the Pump, Platen, and zones. Select
which system needs to use the heated accessory.
Zone Types:
•
Hose
•
Gun
•
PGM
•
Flowmeter
•
Pressure Regulator
•
Manifold
•
Other
NOTE: To ensure accurate hose and gun temperatures,
set hose as zone 1, 3, 5, 7, 9, or 11 when connected to
MZLP and a heated hose.
334130R
Use this screen to set times that the system will
automatically enable and disable heating. See
Schedule, page 37.
107
Appendix A - ADM
Gateway 1 and 2
If the Therm-O-Flow system has a communication gateway module (CGM) installed, an additional “Gateway”
chapter containing 1 or 2 pages will be available in the
setup screens. These pages enable the user to set the
CGM IP or device address, configure the field bus protocol selections, and enable the user to view the mapping
information programmed into the CGM module. The
screens shown below illustrate the 2 pages provided if
an Ethernet I/P CGM module is installed. Refer to manual 3A5186 for information on mapping and the screens
available for the other field bus options.
108
334130R
Appendix B - USB Data
Appendix B - USB Data
Access Files
The system can store 250,000 entries in its logs and the
system adds a new entry to the logs every 15 seconds.
This means the system stores 1041 hours of system
operation data, or 43 days of around-the-clock
operation. Once full, the system will overwrite the oldest
data.
All files downloaded from the USB are put in a DOWNLOAD folder on the stick drive. For example:
“E:\GRACO\12345678\DOWNLOAD\”. The 8-digit
numeric folder name matches the 8-digit ADM serial
number, which is located on the back of the ADM. When
downloading from multiple ADMs, there will be one
sub-folder in the GRACO folder for each ADM.
NOTE: To prevent losing any data, never go more than
43 days without downloading the logs.
The log files should be opened in a spreadsheet program.
Download
NOTE: If emailing the files, zip (compress) them to minimize file size.
NOTICE
Uploading an edited system configuration file can
damage the system. Never put a modified SETTINGS.TXT file in the UPLOAD folder on the flash
drive.
NOTE: The event log, error log, system settings, and
system language files are all downloaded in this procedure.
1. Insert USB flash drive into USB port.
NOTE: Flash drive must be 8 GB or smaller.
2. The menu bar and USB indicator lights indicate that
the USB is downloading files. Wait for USB activity
to complete. A pop-up will be present until the transfer is complete if it is not acknowledged.
NOTE: If the pop-up screen does not appear, the flash
drive is not compatible with the ADM. Try a different
flash drive.
NOTE: The system can log up to 45 mb of additional
data per week, depending on system operation.
Upload
Upload a system configuration file and/or a custom language file. See System Settings File, page 110 or System Language File, page 111.
1. If necessary, follow the Download Instructions,
page 109, to automatically generate the proper
folder structure on the USB flash drive.
2. Insert USB flash drive into USB port of computer.
3. The USB flash drive window automatically opens. If
it does not, open USB flash drive from within Windows Explorer.
4. Open Graco folder.
5. Open system folder. If working with more than one
system, there will be more than one folder within the
Graco folder. Each folder is labeled with the corresponding serial number of the ADM. (The serial
number is on the back of the module.)
6. If installing the system settings file, place SETTINGS.TXT file into UPLOAD folder.
7. If installing the custom language file, place DISPTEXT.TXT file into UPLOAD folder.
8. Remove USB flash drive from computer.
9. Install USB flash drive into Therm-O-Flow system
USB port.
10. The menu bar and USB indicator lights indicate that
the USB is uploading files. Wait for USB activity to
complete.
334130R
109
Appendix B - USB Data
11. Remove USB flash drive from USB port.
GCA Log
NOTE: If a custom language file was installed, users
can now select the new language from the Language
drop-down menu.
This log (4-GCA.CSV) lists the installed GCA modules
and their respective software versions.
NOTE: If the SETTINGS.TXT or DISPTEXT.TXT files
remain in the UPLOAD folder, they will be uploaded
every time the USB drive is inserted into the corresponding ADM. To avoid unintentionally overwriting system settings, delete the files from the UPLOAD folders
on the USB drive after the upload is complete.
USB Logs
During operation, the Therm-O-Flow stores system and
performance related information to memory in the form
of log files. The Therm-O-Flow maintains the events,
data, GCA, Black Box, and Diagnostics logs. Follow the
Download Procedure, page 109, to retrieve log files.
Events Log
The event log (1-EVENT.CSV) maintains a record of the
last 175,000 events. Each event record in the log file
contains the date and time the event occurred, the event
type, event code, and event description.
Data Log
The data log (2-DATA.CSV) tracks the setpoint and
actual temperatures every 15 seconds. This log can
store up to 250,000 lines of data.
The system stores 1041 hours of system operation data,
or 43 days of around-the-clock operation. Once full, the
system will overwrite the oldest data.
Black Box, Diagnostics Log
These logs (5-BLACKB.CSV, 6-DIAGN.CSV) are
designed to provide useful information to Graco when
calling for technical assistance.
System Settings File
NOTICE
Uploading an edited system configuration file can
damage the system. Never put a modified
SETTNGS.TXT file in the UPLOAD folder on the
flash drive.
The system configuration settings file name is SETTINGS.TXT and is stored in the DOWNLOAD folder.
A system configuration settings file automatically downloads each time a USB flash drive is inserted. Use this
file to back up system settings for future recovery or to
easily replicate settings across multiple Therm-O-Flow
systems. Refer to the Upload Instructions, page 109,
for how to use this file.
It is recommended to retrieve the SETTINGS.TXT file
after all system settings are set as desired. Store the file
for future use as a backup in case the settings are
changed and need to be quickly changed back to the
desired setup.
NOTE: System settings may not be compatible between
different versions of the Therm-O-Flow software.
Change Log
The change log (3–CHANGE.CSV) tracks the changes
to setpoint and setback temperatures.
110
334130R
Appendix B - USB Data
System Language File
The system language file name is DISPTEXT.TXT and
is stored in the DOWNLOAD folder.
A system language file automatically downloads each
time a USB flash drive is inserted. If desired, use this file
to create a user-defined set of custom language strings
to be displayed within the ADM.
The system is able to display the following Unicode
characters. For characters outside of this set, the system will display the Unicode replacement character,
which appears as a white question mark inside of a
black diamond.
•
U+0020 - U+007E (Basic Latin)
•
U+00A1 - U+00FF (Latin-1 Supplement)
•
U+0100 - U+017F (Latin Extended-A)
•
U+0386 - U+03CE (Greek)
•
U+0400 - U+045F (Cyrillic)
Modify the second column of the custom language file
as needed and then follow the Upload Instructions,
page 109, to install the file.
The format of the custom language file is critical. The
following rules must be followed in order for the installation process to succeed.
1. The file name must be DISPTEXT.TXT.
2. The file format must be a tab-delimited text file using
Unicode (UTF-16) character representation.
3. The file must contain only two columns, with columns separated by a single tab character.
4. Do not add or remove rows to the file.
5. Do not change the order of the rows.
6. Define a custom string for each row in the second
column.
Create Custom Language
Strings
The custom language file is a tab-delimited text file that
contains two columns. The first column consists of a list
of strings in the language selected at the time of download. The second column can be used to enter the custom language strings. If a custom language was
previously installed, this column contains the custom
strings. Otherwise the second column is blank.
334130R
111
Dimensions
Dimensions
Ram Mounting and Clearance
A
B
D
C
E
ti24564a
F
H
ti24565a
G
J
A
in. (mm)
B
in. (mm)
C
in. (mm)
D
in. (mm)
E
in. (mm)
F
in. (mm)
G
in. (mm)
J
in. (mm)
59 (1498.6)
40 (1016)
37 (939)
21 (533)
25 (635)
58 (1473)
48 (1219)
11 (279)
Height (H)
Dimensions
Fully Raised
Fully Lowered
110 in (2794 mm)
78 in (1981 mm)
112
334130R
Technical Specifications
Technical Specifications
Therm-O-Flow 200 Hot Melt System
Displacement Pump effective area
Volume per cycle
Pump cycles per 1 gallon (3.8 liters)
Ram maximum input pressure
Maximum Pump operating temperature
Air inlet size
Air motor sound data
Pump fluid inlet size
Wetted Parts
U.S.
Metric
1.24 in.²
11.7 in.³
8 cm²
192 cm³
21
100 psi
400°F
0.7 MPA, 7 bar
204°C
3/4 npsm(f)
See Air Motor instruction manual.
1 in. npt(f)
carbon steel, brass, chrome, zinc, nickel plating, stainless steel (304, 316,
440, and 17–4 PH), alloy steel, ductile iron, PTFE
Maximum Fluid Working Pressure
23:1
36:1
70:1
2300 psi
3000 psi
3000 psi
15.9 MPa, 159 bar
20.7 MPa, 207 bar
20.7 MPa, 207 bar
100 psi
82 psi
43 psi
0.7 MPa, 7 bar
0.57 MPa, 5.7 bar
0.29 MPa, 2.9 bar
Maximum Air Input Pressure (Pumps)
23:1
36:1
70:1
Power Requirements
Compressed Air (typical)
Voltage (as selected)
25–50 scfm
220/240 V, 3-phase, 50/60 Hz
380/400 V, 3-phase, 50/60 Hz
470/490 V, 3-phase, 50/60 Hz
600 V, 3-phase, 50/60 Hz
Peak Consumption
(includes drum melt grid, pump, and a 6kVa transformer for the 230 V hoses and accessories)
with standard melt grid
with Mega-Flo melt grid
with smooth melt grid
27.1 kVa
30.2 kVa
27.1 kVa
California Proposition 65
CALIFORNIA RESIDENTS
WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.
334130R
113
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
Sealant and Adhesive Dispensing Equipment
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor, go to www.graco.com, or call to identify the nearest
distributor.
If calling from the USA: 1-800-746-1334
If calling from outside the USA: 0-1-330-966-3000
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 334130
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2016, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision R, June 2020

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