Graco 334129D, Therm-O-Flow 20 Owner's Manual

Instructions-Parts
334129D
Therm--O-Flow® 20
Therm
EN
For applying hot melt sealant and adhesive materials from 20 Liter (5 Gallon) pails. For professional use
only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this manual and in related
manuals. Save these instructions.
Maximum Operating Temperature
400°F (204 °C)
See page 6 for model information.
See Technical Specifications,
page 106, for maximum working
pressures.
3143485
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Warnings ............................................................. 3
Models................................................................. 6
Related Manuals .................................................. 7
Component Identification....................................... 8
Advanced Display Module (ADM).................. 11
Overview............................................................ 14
Air and Fluid Hoses...................................... 14
Heat Control Zone........................................ 14
Setup................................................................. 15
Unpack........................................................ 15
Location Requirements................................. 15
Install System .............................................. 15
Mechanical Setup ........................................ 16
Install Heated Hose...................................... 17
Connect Multiple Devices ............................. 18
Connect Power ............................................ 19
Grounding ................................................... 20
Connect Secondary System.......................... 20
Check Sensor Resistance ............................ 21
Check Heater Resistance ............................. 22
Select ADM Settings .................................... 23
Connect PLC ............................................... 25
Operation ........................................................... 28
Purge System .............................................. 28
Load Material............................................... 29
Heat Up System........................................... 30
Prime Pump ................................................ 31
Prime System .............................................. 32
Setback Mode.............................................. 32
Pressure Relief Procedure............................ 33
Shutdown .................................................... 34
Schedule ..................................................... 34
Change Pail................................................. 35
Troubleshooting.................................................. 36
Repair................................................................ 44
Replace Wipers ........................................... 44
Replace Platen RTD .................................... 45
Separate the Air Motor and Pump ................. 46
Remove Platen ............................................ 48
2
Replace Heater Bands and Pump
RTD............................................... 48
Replace MZLP Fuse .................................... 49
Replace MZLP............................................. 50
Replace MZLP Daughter Card ...................... 51
Replace AWB .............................................. 52
Replace Power Supply ................................. 52
Replace Fan ................................................ 53
Replace Transformer.................................... 54
Update Software .......................................... 56
Electrical Schematics.......................................... 57
Notes ............................................................... 63
Parts.................................................................. 64
Accessories and Kits........................................... 85
Wiper Kits.................................................... 85
Applicators and Dispense Valves .................. 85
Air-Operated Heated Dispense Valves ........... 85
Flow Control and Manifolds .......................... 85
Accessory Extension Cables......................... 85
Light Tower Kit, 24W589 .............................. 85
Tie Rod Kits................................................. 85
8 Zone Upgrade Kit Installation ..................... 89
12 Zone Upgrade Kit Installation ................... 91
Appendix A— ADM............................................. 92
Operation Screens ....................................... 94
Setup Screens ............................................. 95
Appendix B — USB Data .................................. 100
Download .................................................. 100
Access Files .............................................. 100
Upload ...................................................... 100
USB Logs.................................................. 101
System Settings File .................................. 101
System Language File................................ 102
Create Custom Language Strings ............... 102
Dimensions ...................................................... 103
Notes ............................................................. 105
Technical Specifications.................................... 106
Graco Standard Warranty.................................. 108
334129D
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.
• 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.
334129D
3
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.
000000
000000
SKIN INJECTION HAZARD
000000
000000
000000
000000
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:
• 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.
4
334129D
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:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
334129D
5
Models
Models
The model number stamped on your systems defines the equipment in the following categories.
See Technical Specifications, page 106, for maximum working pressure.
SER
Series
A
Frame Size
B
Air
Air/Electric
Code A Frame Size
P20
Gallon (20 Liter)
Code B Air/Electric
A
Air control only
E
Air and Electric
Code C Zones, Volts, Type
6
11P
4 Zones, 230 V, Primary
11S
12P
4 Zones, 230 V, Secondary
4 Zones, 400 V/N, Primary
12S
13P
4 Zones, 400 V/N, Secondary
4 Zones, 400 V, Primary
13S
14P
4 Zones, 400 V, Secondary
4 Zones, 480 V, Primary
14S
15P
4 Zones, 480 V, Secondary
4 Zones, 600 V, Primary
15S
21P
4 Zones, 600 V, Secondary
8 Zones, 230 V, Primary
21S
22P
8 Zones, 230 V, Secondary
8 Zones, 400 V/N, Primary
22S
23P
8 Zones, 400 V/N, Secondary
8 Zones, 400 V, Primary
23S
24P
8 Zones, 400 V, Secondary
8 Zones, 480 V, Primary
24S
25P
8 Zones, 480 V, Secondary
8 Zones, 600 V, Primary
C
Zone Config
D
Pump Ratio
E
Platen Style
25S
31P
8 Zones, 600 V, Secondary
12 Zones, 230 V, Primary
31S
32P
12 Zones, 230 V, Secondary
12 Zones, 400 V/N, Primary
32S
33P
12 Zones, 400 V/N, Secondary
12 Zones, 400 V, Primary
33S
34P
12 Zones, 400 V, Secondary
12 Zones, 480 V, Primary
34S
35P
12 Zones, 480 V, Secondary
12 Zones, 600 V, Primary
35S
12 Zones, 600 V, Secondary
NNN None
Code D Pump Ratio
1
23:1 CF (Carbon-Filled)
2
36:1 CF
3
70:1 CF
4
23:1 GF (Glass-Filled)
5
36:1 GF
6
7
70:1 GF
15:1 PTFE
Code E
Platen Style
S
Smooth Bottom (No Fin)
F
Standard Finned Bottom
334129D
Related Manuals
Related Manuals
Manual
Description
Manual
Description
306982
President® Air Motor,
Instructions-Parts
334198
Therm-O-Flow Ram, InstructionsParts
311238
NXT® Air Motor, Instructions-Parts
3A1211
Saniforce® Air Motor,
Instructions-Parts
3A4241
Heated Hose, Instructions-Parts
309196
Wiper Kits, Repair-Parts
310538
334127
Check-Mate® 800 Pump,
Repair-Parts
Air-Operated Dispense Valves,
Instructions-Parts
311209
334128
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Top Feed and Bottom Feed Hot Melt
Dispense Guns, Instructions-Parts
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Air Controls, Repair Kit
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334129D
7
Component Identification
Component Identification
Figure 1 TOF 20
Key:
A
B
C
D
E
F
G
H
J
8
Lift Strap Positions
Multi-Zone Low Power Temperature
Control Module (MZLP)
Light Tower
Cable Track
Ram
Heated Pump
Heated Platen
Integrated Air Controls (3/4 in npt inlet)
Electrical Control Panel
Key:
K
L
M
N
P
R
S
T
Main Power Switch
ADM
Air Motor Solenoid
Electrical Power Input
Air Motor
Ram Plate Bleed Stick
Drum Blow Off Valve (behind ram plate
bleed stick)
Drum Low and Empty Sensors
334129D
Component Identification
Integrated Air Controls
Figure 2 Integrated Air Controls
Key:
CA
Key:
CH
CJ
Blowoff Pressure Gauge
Displays the blowoff pressure.
Blowoff Air Regulator
CK
Controls platen blowoff pressure.
Air Motor Air Regulator
CB
Main Air Slider Valve
Turns air on and off to the entire system.
When closed, the valve relieves pressure
downstream.
Ram Down Air Regulator
CC
Controls the ram down pressure.
Ram Director Valve
CL
CD
Controls the ram direction.
Ram Up Air Regulator
CM
CE
CF
Controls the ram up pressure.
Ram Down Air Gauge
Displays the ram down pressure.
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.
334129D
CN
Controls the air pressure to the motor.
Air Motor Pressure Gauge
Displays the air pressure to the motor.
Air Motor Slider Valve
Turns air on and off to the air motor. When
closed, the valve relieves air trapped
between it and the motor. Push the valve
in to shutoff air.
Air Motor Solenoid Valve
Turns air on and off to the air motor when
system stopped on the ADM. When closed,
the valve relieves air trapped between it and
the motor.
9
Component Identification
Electrical Control Enclosure
Figure 3 Electrical Enclosure
Key:
DA
DB
DC
DD
DE
DF
10
Key:
Multi-Zone Low Power Temperature
Control Module (MZLP)
Ventilation Grill
Electrical Control Panel
Automatic Wiring Board (AWB)
Power Supply (24V)
Residual Current Device (GFI), 63A
DG
DH
DJ
DK
DL
DM
Platen SSR (65A)
Platen Contactor
Platen Fuse
Transformer Circuit Breaker
Transformer Fuse
Transformer
334129D
Component Identification
Advanced Display Module (ADM)
The ADM display shows graphical and text
information related to setup and spray operations.
NOTICE
To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.
For detail on the display and individual screens, see
Appendix A— ADM, page 92.
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 100.
Figure 4 Front View
Key
BA
BB
BC
BD
BE
BF
BG
BH
Function
Heating system and pump enable/disable
System status indicator (LED)
Stop all system processes
Defined by icon next to softkey
Abort current operation
Accept change, acknowledge error, select item,
toggle selected item
Toggle between Operation and Setup screens
Navigate within a screen or to a new screen
334129D
11
Component Identification
Figure 5 Back View
BK
BL
BM
Part Number and Identification Label
USB Interface
CAN Cable Connection (Power Supply and
Communication)
BN
BP
Module Status LEDs
Light Tower (Optional)
BR
Software Token Access Panel
Table 1 ADM LED Status Descriptions
LED
System Status
Conditions
Green Solid
Green Flashing
Yellow Solid
Description
USB Status (BL)
Green Flashing
Yellow Solid
Green and Yellow Flashing
Data recording in progress
ADM Status (BN)
Green Solid
Yellow Solid
Red Steady Flashing
Red Random Flashing or Solid
12
Run Mode, System On
Setup Mode, System On
Run Mode, System Off
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
334129D
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
Description
The system does not have power.
Component Status
• No system status indicator LED on the
ADM
• No heat
Inactive
The heating system and pumps are
disabled.
• Pump is off
• Yellow system indicator LED on the
ADM
• No heat
Warm Up
• Pump is off
The system is heating the material to the • Flashing green system status indicator
setpoint temperature.
LED on the ADM
• Heat is increasing to setpoint
temperature
Heat Soak
Heat zones are all at temperature.
Material is soaking for a user specified
amount of time.
• Pump is off
• Flashing green system status indicator
LED on the ADM
• Heat is at setpoint
• Material is absorbing more heat
• Pump is off
Ready
• Heat soak counter counts down on the
Home screen.
All enabled zones are at setpoint
• Flashing green system status indicator
temperature. The air motor does not have LED on the ADM
power.
• Heat is at setpoint
Active
The system is ready to dispense.
• Pump is off
• Solid green system status indicator
LED on the ADM
• Heat is at setpoint temperature
• Pump is on
334129D
13
Overview
Overview
A heated platen melts the sealant or adhesive and
directs the molten material to the pump inlet. The
material then travels through a heated pump and
heated fluid moves to the application tool.
Air and Fluid Hoses
The Therm-O-Flow requires Graco single-circuit
material hoses rated at a maximum of 1250 watts.
Make sure all air and fluid hoses are properly sized
for the system.
Heat Control Zone
The Therm-O-Flow has 4, 8, or 12 heat zones. Zones
for the heated 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.
Figure 6 Heat Control Zone Selection
14
334129D
Setup
Setup
1. Unpack the ram
2. Locate and Install the ram
3. Mechanical Setup
4. Connect hoses to electrical control panel
5. Connect electrical control panel to power source
6. Ground system
7. Select ADM settings
Unpack
1. Inspect the shipping box carefully for damage.
Contact the carrier promptly if there is damage.
2. Open the box and inspect the contents carefully.
There should not be any loose or damaged parts
in the box.
3. Compare the packing slip against all items in the
box. Report any shortages or other inspection
problems immediately.
4. Remove the unit from the skid and place it in the
desired location. See .
Location Requirements
1. Make sure there is sufficient overhead clearance
for the pump and ram when the ram is in the fully
raised position (approximately 75 in. (190.5 cm).
334129D
2. If you are installing a vent hood, make sure there
is sufficient horizontal clearance for it. Locate the
ram near a connection to the factory ventilation
system.
3. Make sure the integrated air controls for the
pump and ram are fully accessible, with room
to stand directly in front of the controls and the
ADM.
4. Make sure there is easy access to an appropriate
electrical power source. The National Electrical
Code requires 3 ft (0.9 m) of open space in front
of the electrical panel. Comply with all local
codes and regulations.
5. When locating the system, do not install closer
than 36 in. (914 mm) to vertical surfaces.
Install System
Refer to Dimensions, page 103, for mounting and
clearance dimensions.
Follow all Location Requirements, page 15, when
selecting a location for the ram.
1. Apply 50 psi download pressure to ram.
2. Wrap the bar with the lifting sling.
3. Lift the system off the pallet using a crane or a
forklift and place in desired location.
4. Level the base of the ram, using metal shims.
5. Bolt the ram to the floor, using anchors that are
long enough to prevent the unit from tipping.
15
Setup
Mechanical Setup
1. Fill displacement pump wet cup 2/3 full with
Graco Throat Seal Liquid (TSL™) for Butyl and
PSA materials.
Note
Use IsoGuard Select® (IGS) (part
no. 24F516) for PUR or reactive
Polyurethane material. IGS is
designed to dissolve and suspend the
Polyurethane materials. IGS will solidify
after a period of time and should be
replaced once the solidified lube does
not return to liquid form after heating.
4. Ensure drum low and empty sensors (C) are
mounted as shown.
Note
The Drum Low and Empty Sensors are
used to indicate that a drum is empty.
The kit contains a sensor mounting
bracket (A), activator (B), sensors (C1,
C2), and a cable for connecting the panel
inside the electrical enclosure.
Figure 7 Wetcup
2. Turn all air regulators to their full counterclockwise
position. See Integrated Air Controls, page 9.
3. Connect a 1/2 in. (13 mm) air line from an air
source to the system air inlet (H), capable of
delivering a minimum of 25–50 cfm at 100 psi (0.7
disconnects.
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
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.
Figure 8 Air Connection
16
334129D
Setup
Install Heated Hose
5. Install cap on any unused MZLP electrical
connectors.
To connect a hose to a fluid control device or heated
manifold.
6. Connect the small 8 pin connector from the
heated hose to the 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).
Note
See Accessories and Kits, page 85 , for
available fittings and heated hoses.
Figure 11 Heated Manifold 243697
Note
Figure 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.
The heated manifold (part
no. 243697) shown. See
Accessories and Kits, page 85 ,
for available manifolds and fluid control
devices.
7. Use 2 wrenches to tighten hose. Torque to 45
ft-lbs (61 N•m).
8. To connect multiple devices, see
Connect Multiple Devices, page 18.
Figure 10
4. Repeat for any remaining channels.
334129D
17
Setup
Connect Multiple Devices
If your application requires multiple fluid control
devices:
• Connect heated hose electrical connections to
the electrical enclosure. Use accessory cables if
necessary. Additional cables (part no. 17C694)
are provided with 8 and 12 zone systems. 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 85.
MZTCM-1
1
2
• Connect fluid control devices to a heated hose
or the electrical enclosure. Use accessories if
necessary.
• Setup all heat zones on Heat-A and Heat-B
screens.
Example: Heated zones used to connect a primary
and secondary system to a manifold and two guns.
A-# zones are on the Heat-A screen and B-# zones
are on the Heat-B screen.
MZTCM-1
1
2
J9
3
4
J9
3
4
J8
J8
MZTCM-2
MZTCM-2
5
6
5
6
J9
7
8
J9
7
8
J8
J8
MZTCM-3
MZTCM-3
9 10
9 10
J9
11 12
J9
11 12
J8
J8
Figure 12
18
334129D
Setup
Connect Power
power source wires to the appropriate terminals
on the DISCONNECT switch.
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.
Figure 13
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
230 V
400
V/N
400 V
480 V
600 V
Hz
Phase
Platen
Full
Load
Amps
AWG
3
3
EF, ES 50
EF, ES 50
8 AWG
8 AWG
50/60
50/60
50/60
3
3
3
EF, ES 30
EF, ES 30
EF, ES 25
8 AWG
8 AWG
8 AWG
Standard Finned Bottom
Mega-Flo
ES
Smooth Bottom
3. Connect the ground wire to the ground lug.
Have a qualified electrician check the resistance
between each Therm-O-Flow system ground and
the true earth ground. The resistance must be
less than 0.25 ohms. If the resistance is greater
than 0.25 ohms a different ground site may be
required. Do not operate the system until the
problem is corrected.
Note
50/60
50/60
EF
EM
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.
Use a meter that is capable of measuring
resistance at this level.
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 a cord diameter range of 0.7–1.2 in
(17–30 mm).
2. Route the wire from the power source into the
control panel housing, and then connect the
334129D
19
Setup
Grounding
Ground the unit as instructed here and in the
component manuals.
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.
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 an escape path for the
electric current.
ground through ground lug in electrical enclosure.
See Connect Power.
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.
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 6 for
secondary system model numbers.
1. Connect adapter cable (AC) and communication
cable (SC) to the secondary electrical enclosure
and route to splitter (SS) installed on the primary
system.
2. To enable a secondary system, select “Enable
Tandem System” on the System 1 screen. See
Select ADM Settings, page 23.
Figure 14
20
334129D
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. Wait for components to cool down to ambient
room temperature 63°-77°F (17°-25°C). Check
electrical resistance for the components.
MZLP Zones
Pins
First Heat Zone
A,J
Cable 17C694
J
A
M
Second Heat Zone
C,D
First RTD
G, K
Second RTD
M, K
Earth Ground
2
K
H
B
B
C
G
F
D
L E
3. Replace any parts whose resistance readings
do not comply with the ranges listed in the RTD
Sensors chart below.
334129D
ti24580a
3
MZLP Plug Component RTD Range
(Ohms)
Ram Plate 100 +/- 2
Fluid Pump 100 +/- 2
Heated
100 +/- 2
Accessory
1
1,2
Heated
100 +/- 2
Accessory
2
Heated
100 +/- 2
Accessory
3
3,4
Heated
100 +/- 2
Accessory
4
Heated
100 +/- 2
Accessory
5
5,6
Heated
100 +/- 2
Accessory
6
Heated
100 +/- 2
Accessory
7
7,8
Heated
100 +/- 2
Accessory
8
Heated
100 +/- 2
Accessory
9
9,10
Heated
100 +/- 2
Accessory
10
Heated
100 +/- 2
Accessory
11
11,12
Heated
100 +/- 2
Accessory
12
21
Setup
Check Heater Resistance
2. Make electrical resistance checks for the
components.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in tables.
Note
To reduce risk of injury or damage to equipment,
conduct these electrical checks with the main
power switch OFF.
Check resistance at ambient room
temperature 63°– 77°F (17°– 25°C).
1. Turn main power switch off.
Table 4 Heaters
Component
Platen
Between
Terminals
FHA1/FHB1
to
FHA2/FHB2
(without
jumper)
FHA1 to
FHA2 or
FHB1
(with jumper)
FHA1 to
FHB2
(with jumper)
Any to GND
For Unit Voltage Platen Model Code
Resistance Values (ohms)
220/240 VAC
EF, ES
14.4Ω +1.5/ -2
380/590 VAC
EF, ES
28.8Ω +3 / -4
380/590 VAC
EF, ES
57.6Ω +6 / -8
Component Between Terminals For Unit Voltage Platen Model Code
Pump
T1/T3
Any
Any
B1/B3
22
100,000Ω Min
Resistance Values (ohms)
192.0 +/- 19.2Ω
334129D
Setup
Select ADM Settings
Note
See Appendix A— ADM, page 92 for
detailed ADM information, including general
operation.
1. Turn main power switch on.
2. When the ADM is finished starting up, press
to switch from the Operation screens to
the Setup screens. Use the arrows to navigate
between screens.
3. Check system settings on the System 1 screen.
Note
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.
4. Set alarm levels on the System 2 screen.
6. If a secondary system is used, set temperatures
on the Heat-B screens.
7. Set the system date and time on the Advanced 1
screen.
5. Set primary system setpoint and setback
temperatures for the pump, platen, and heat
zones on the Heat-A screens.
334129D
23
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 34.
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 92 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.
24
334129D
Setup
Connect PLC
Table 7 Output Error States
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 92.
When the PLC has control of the system:
Error State Bit Error State Bit
High
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
• 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
3
4
Unit A
Description
Heat On Request
Setback Request
Turn on the Heat
Put the Unit in
Setback
Turn on the Pump
Pump On Request
PLC Control Request
(input applies to
primary to unit A
only)
Control the primary
and secondary TOF
systems from the
PLC instead of the
ADM
Table 8 Output Run States
Run State Bit
High
0
Run State Bit
Low
0
0
1
1
0
1
1
Pump Off/ Heat
Off
Pump Off/ Heat
On
Pump Off/ Heat
At Temp
Pump On/ Heat
At Temp
Note
All outputs are normally open when power is
OFF. For error (alarm) output, the contacts
close when an alarm occurs. For all others,
contacts close.
Note
Table 6 Customer Output
Signal
No.
1
2
3
4
Unit A or B
Description
Run State Bit Low
Run State Bit High
Error State Bit Low
See Run State Chart
See Run State Chart
See Error State
Chart
See Error State
Chart
Error State Bit High
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.
Note
Each connector has four signals. The
MZLP board specifies the input range for
each signal. See the following table for
pin assignments.
334129D
25
Setup
H2 Customer Output
Signal
Pin
1
1,2
2
3,4
3
5,6
4
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.
Figure 15
Outputs: 0–250 VAC, 0–30 VDC, 2A Maximum.
H1 Customer Input
Signal
Pin
1
1,2
2
3,4
3
5,6
4
7,8
26
334129D
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.
Figure 16 Customer Input
Figure 17 Customer Output
334129D
27
Operation
Operation
1. Turn the main power switch ON. The Graco logo
will display until communication and initialization
is complete.
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 the Load Material, page 29.
b. If the two substances are incompatible
perform the remaining steps in this procedure
to flush the system.
2. Press the
button. Verify the machine is
in “Warm Up” state, and that the temperatures
are increasing. Allow the system to reach the
“Ready” state before pumping. The pump will
automatically turn on, if autostart is enabled in
setup screens, when all the heat zones reach
their setpoint temperature.
Purge System
3. Select a pail of material that can eliminate the
factory-test oil from the system. If necessary,
check with Graco or the material supplier for a
recommended solvent.
4. Before purging be sure the entire system
and waste pail are properly grounded. See
Grounding, page 20.
5. Turn all heat zones’ setpoint temperature to the
material manufacturer’s recommended dispense
temperature, or a minimum of 100°F (37°C)
minimum.
Note
Remove any dispense valve orifices
before purging. Reinstall after purging
has been completed.
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 factorytested using a light soluble oil, a soybean oil, or
some other oil as tagged. Flush the system to
avoid contaminating the material that has been
designated for initial material loading.
28
6. Purge the material through the system for
approximately 1 to 2 minutes.
7. Remove the pail if purge material was used. See
Change Pail, page 35.
334129D
Operation
Load Material
NOTICE
To prevent damage to platen wipers, do not use a
pail of material that has been dented or damaged.
An empty pail clamp can interfere with up and
down operation of the ram. When raising the ram,
make sure the pail clamp stays clear of the platen.
Note
Before loading material, make sure there is a
minimum overhead clearance of 75 in. (191
cm) and all air regulators are backed off to
their full counterclockwise position.
4. 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.
1. Open the main air slider valve (CA).
Figure 19 Wetcup
2. Set ram director valve (CC) to UP and slowly
turn the ram up regulator (CD) clockwise until the
platen (G) begins to rise.
Figure 18 Raise the Platen
5. Open pail, remove any packing material, and
inspect material for any contamination.
6. Slide the pail against the stops at the back of the
ram baseplate.
Figure 20 Drum Placement
3. Apply a thin coating of high temperature grease
lubricant (part no. 115982) to the platen pail
seals.
334129D
29
Operation
7. Remove the platen bleed stick (R).
Heat Up System
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.
Figure 21 Platen Bleed Handle
8. Set ram director valve (CC) to down and lower
the platen.
Keep the dispense valve open over a waste
container while the system is heating up and also
when cooling down. This will prevent a pressure
build-up caused by fluids or gases expanding from
the heat.
Note
Operate at the lowest temperature and
pressure necessary for your application.
1. Turn the main power switch on the electrical
control panel door to the ON position.
2. Press the
button. The zones begin to
heat (provided they are enabled). Press
Figure 22 Lower the Platen
9. Slowly turn the ram down air regulator (CB)
clockwise to approximately 5–10 psi (34–69 kpa,
0.3–0.7 bar). The platen will begin to lower into
the pail.
10. After the platen seals enter the material pail,
adjust the ram down air regulator (CB) to 30–50
psi (207–345 kPa, 2.1–3.4 bar).
11. When the ram stops, reinsert the platen bleed
stick (R) and hand tighten.
30
if the zones do not begin to heat.
Up. When
Display status bar reads Warm Up
temperature reaches setpoint, the display
Soak. When heat is on,
status bar reads Heat Soak
the status will display in the status bar. See
Advanced Display Module (ADM), page 11, for
operation mode descriptions.
Note
The air will be locked from the air motor
until all temperature zones are within a
preset window of the temperature set
points, allowing the system to heat fully
and complete the material heat soak
period.
334129D
Operation
Prime Pump
5. Adjust the air motor air regulator (CK) to
approximately 20 psi (138 kPa, 1.38 bar).
1. Ensure that the system has completed the heat
soak cycle. The display status bar should read
Active.
Active
2. Adjust the air motor air regulator (CK) to 0 psi.
6. Place a waste container under the bleed stem
(Z). Using an adjustable wrench, open the bleed
stem counterclockwise 1/3 -1/2 turn.
3. Ensure air motor solenoid valve (CN) is on. The
indicator light on the solenoid connector will only
be on if “Enable Pump Autostart” is selected on
the System 1 Setup screen.
7. If a new pail was installed and the unit is equipped
with proximity sensors, press the Pump Ready
button . Press pause button on material tracking.
8. 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.
4. Adjust the air motor slider valve (CM) to the open
position.
9. Prime the pump until it moves smoothly in
both directions with no air popping or erratic
movement and close the main air slider valve
(CA).
10. Close the bleed stem (Z).
11. Press Play button on home screen to enable
material tracking.
334129D
31
Operation
Prime System
7. Close the main air slider valve (CA) and release
trigger lock.
8. Engage trigger lock.
1. Close the main air slider valve (CA).
Figure 23 Trigger Lock Engaged
9. Press
2. If using a manual gun, lock the dispense valve
trigger open by pulling and securing the trigger
using the trigger retainer (Z).
to engage material tracking.
10. Turn the air motor regulator to operating
pressure.
Note
The system is now ready to operate.
Setback Mode
3. Place the dispense valve over a waste container.
4. Press the pause material tracking button
on home screen.
5. Slowly open the main air slider valve (CA).
6. Prime the system until a smooth flow of material
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.
32
Set the ADM to setback mode if the system will only
be inactive for a few hours. This will reduce the time
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 95.
334129D
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.
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.
4. Disengage the trigger lock.
Note
If using a different dispense applicator, see
the applicator manual for pressure relief
instructions.
1. Engage the trigger lock.
Figure 25 Disengaged
5. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
6. Engage the trigger lock.
Figure 24 Engaged
2. Close the system master air slider valve (CA).
7. Open all fluid drain valves in the system, having
a waste container ready to catch drainage.
Leave drain valve(s) open until you are ready to
dispense again.
8. If you suspect the tip or hose is clogged or
that pressure has not been fully relieved after
following the steps above, VERY SLOWLY
loosen hose end coupling to relieve pressure
gradually, then loosen completely. Clear hose
or tip obstruction.
334129D
33
Operation
Shutdown
1. Press
to disable the heaters and pump.
The screen will say “Inactive”. If using the
Schedule function, the heaters and pump will be
disabled automatically at the set time. Only press
to disable the heating system before the
set time. If the heaters were manually disabled,
the Schedule function will automatically enable
them at the next set time.
Note
Do not perform step 2 if using the
Schedule function. Leave the power on.
2. Turn main power switch off.
Table 9 Schedule Screen Color Identification
Description
Color
Green
Yellow
Red
System on
Setback
System off
Disabled
Gray
Set Schedule Times
Times are set using a 24–hour clock. Several on and
off times can be set each day.
1. On the Schedule screen (in the Setup screens),
set the ON times for each day of the week.
2. Set the OFF times for each day of the week.
3. Set the setback times for each day of the week.
Enable Schedule Function
The Schedule function is automatically enabled
when values are entered in the Schedule screen. To
disable a scheduled event, navigate to the event and
Schedule
The Schedule function allows the user to specify
times when the system will automatically turn ON and
OFF the heaters and pump.
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.
Use the Schedule Function
At the end of the work day leave the main power
switch ON. The Schedule function will automatically
enable and disable the heaters and pump at the
specified times.
34
334129D
Operation
Change Pail
To prevent serious burns from dripping material,
never reach under the heated platen after the
platen is out of the pail.
Follow the procedure to change the pail on a fully
heated system.
NOTICE
Be sure to reload the empty supply unit with a full
pail of material immediately. Do not raise the ram
and remove the platen from the empty pail until
you are ready to immediately install a new pail.
3. Set ram director valve (CC) to UP and raise
the platen (G) and immediately press and hold
the blowoff buttons (CG) until the platen is
completely out of the pail. Use minimum amount
of air pressure necessary to push the platen out
of the pail.
Do not raise the ram and remove the platen from
the empty pail unless the supply unit is at full
operating temperature. Drum changes can only be
performed when the system is heated.
An empty pail clamp can interfere with the up
and down operation of the ram. When raising or
lowering the ram, make sure the pail clamp stays
clear of the platen assembly.
Do not use a pail of material that has been dented
or otherwise damaged; damage to the platen
wipers can result.
All systems include Low/Empty Sensors:
• The air will shutoff 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.
2. Push in the air motor slider valve (CM) to stop
the pump.
Excessive air pressure in the material pail
could cause the pail to rupture, causing serious
injury. The platen must be free to move out
of the pail. Never use pail blowoff air with a
damaged pail.
4. Release the blowoff air button and allow the ram
to rise to its full height.
5. Remove the empty pail.
6. Inspect platen and if necessary, remove any
remaining material or material build-up.
7. Follow steps in Load Material, page 29, and
Prime Pump, page 31.
334129D
35
Troubleshooting
Troubleshooting
Light Tower (Optional)
Signal
Red Light Off
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.
Red Light On User interaction required — alarm, system is shut down
Red Light
User interaction required — advisory, deviation, or system is in a state that could prohibit
Flashing
dispensing.
Green Light Off System is inactive
Green Light On System is ready to dispense. The heat and pump are on.
Green Light
System will be ready to dispense in time without user interaction (heat on, pump off, and
Flashing
temperature control zones have not reached set point)
36
334129D
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.
. This condition
Advisories are indicated by
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
Codes 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
V
W
X
Y
MZLP 5
MZLP 6
MZLP 7
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
334129D
Codes Relates To
System Component:
MZLP 1
MZLP 2
MZLP 3
Codes 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
37
Troubleshooting
Code
A3MF
A4 _
A4C#
A7
_
Description
Type
AWB Clean Fan Alarm
Filter
Alarm
High Current
Unit _ Zone _
Deviation
High Current
Fan AWB, Unit
_
Alarm
Unexp. Curr.
Unit _ Zone _
Cause
Cooling inlet
screen is dirty
Defective or
shorted to
ground on
zone
Fan is drawing
too much
current
Unexpected
current flow to
zone
A8 _
No Current Unit Alarm
_ Zone _
No Current
Flow to the
Zone
A8C
AWB No Fan
Current
High Current
SSR MZLP _
Alarm
AM4 #
High Current
Contactor
MZLP _
Alarm
AM8#
No Current
Contactor
MZLP _
Comm Error
MZLP _
Alarm
Cooling fan
not working
Excessive
current flow
in the SSR
Defective or
shorted to
ground on
MZLP
No Current
Flow to the
Contactor
System not
responding to
ADM.
AM3 #
CAC#
Alarm
Alarm
CACX
DB Not Present Alarm
Unit A
Daughter
Board not
responding
CACY
DB Not Present Alarm
Unit B
Daughter
Board not
responding
38
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.
Faulty accessory heater. Measure resistance to
ground between heater leads.
Check for loose or disconnected wires or plugs.
Check for blown fuses on MZLP.
Check heater resistance for open circuit.
Check for shorts between heater and ground.
Verify cable is plugged into zones 3–4. Replace
heater if necessary.
Verify fan is plugged in. Replace if necessary.
Check for shorts in harness to SSR. Check polarity of
wiring to SSR. Replace if necessary.
Check for shorts in the harness to contactor. Check
the polarity to contactor. Replace contactor if
necessary.
Ensure harness to MZLP is connected. Ensure wiring
to contactor is secure. Replace contactor if necessary.
System is not properly loaded with correct Software.
Dial not set correct on MZLP. Duplicate MZLP dial
positions (i.e. 1 to 1, 2 to 2, ect)
Check all CAN connections between the ADM and
missing MZLP.
Check if hardware exists on the network.
Replace MZLP if necessary.
Dial not set correct on MZLP 5. Set to 5 on board with
daughter board.
Ensure connections between the ADM and hardware
are secure.
Replace Daughter Board.
Dial not set correct on MZLP . Set to 4 on board with
daughter board.
Ensure connections between the ADM and hardware
are secure.
Replace Daughter Board.
334129D
Troubleshooting
Code
CACV
Description
AWB not
present Unit
A
Type
Alarm
Cause
AWB not
responding
CACW
AWB not
present Unit
B
Alarm
AWB not
responding
DA X
Pump Runaway Alarm
Detected
DE X
Reed Switch
Failure
Detected
Alarm
DC X
Pump Diving
Alarm
L1 X
Material Level
Sensor Error
Alarm
L2 X
Material Level
Empty
Material Level
Low
USB Log Full
Alarm
Pump _
Requires
Maintenance
Advisory
L3 X
MMUX
MN X
334129D
Deviation
Advisory
Pump is
trying to feed
adhesive, no
adhesive to
feed.
Worn or
damaged
pump seals
Reed switch
failed
Solution
Ensure connections between the ADM and hardware
are secure.
If a tandem system, ensure AWB 2 jumper is installed
at startup.
Replace AWB.
AWB 2 jumper was not in place at start up
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.
Pump is
Adjust the drum empty level sensor to detect an
trying to feed empty state.
adhesive, no Ensure the ram director valve is in the down position
adhesive to
and sufficient air is forcing the ram down.
feed.
Melter at incorrect temperature, too low. Check
setpoint and set to manufactures recommendation.
Worn or
Inspect pump seals and replace if necessary
damaged
pump seals
Machine is
Make sure the empty level sensor is not covered in
detecting an material
empty state
Verify the low level sensor is plugged into J15 of the
without a low daughter board. Verify the low level sensor is close
state
enough to the metal bar; adjust if necessary.
Replace sensors.
Material drum
is empty
Material level
is low
USB logs fulls.
Data loss will
occur if not
downloaded.
User defined
pump
maintenance
counter has
run out
Replace material container. If more material is
leftover, lower the empty level sensor.
Replace at appropriate time.
Download USB data or disable the USB log errors on
the Advanced screen 3.
Perform pump maintenance, then reset the counter
on the maintenance setup screen.
39
Troubleshooting
Code
T1 _
Description
Type
Low Temp. Unit Alarm
_ Zone _
Cause
Zone
temperature
too low
Solution
Reduce flow rate.
Increase temperature of accessory upstream.
Faulty accessory heater measure resistance between
heater leads.
Change Low Temp Alarm Offset.
Replace accessory.
T2 _
Low Temp. Unit Deviation
_ Zone _
Zone
temperature
too low
Reduce flow rate.
Change Low Temp Deviation Offset.
Add zone (temperature) upstream.
T3
High Temp.
Unit _ Zone _
Deviation
AWB
Temperature
Runaway
Transformer
AWB High
Transformer
Temp
High Temp.
Unit _ Zone _
Alarm
Temperature Change High Temp Deviation Offset.
reading has
Verify setpoint upstream is not hotter than this zone’s
risen too high setpoint.
Ensure inlet and outlets are not obstructed.
Cooling fan
not working
Verify fan is plugged in.
or inlet is
blocked/dirty
Transformer Ensure inlet and outlets are not obstructed.
Temperature Verify fan is plugged in.
is too High
Temperature Change High Temp Alarm Offset.
reading has
Verify setpoint upstream is not hotter than this zone’s
risen too high setpoint.
Bad RTD
Check RTD wiring and harness/connector integrity.
Reading
Replace RTD.
_
T4C#
T4M#
T4 _
T6
_
Alarm
Alarm
Sensor Err. Unit Alarm
_ Zone _
T6C#
AWB Invalid
Thermistor
Reading
Alarm
T8V _
No Temp. Rise Alarm
Unit _ Zone _
V1I#
Alarm
Low CAN
Voltage, MZLP
_
Transformer
thermistor
temperature
is incorrect
Temperature
reading does
not change.
Verify thermister is securely connected to J7 of the
AWB. Replace transformer if necessary.
Check fuses on MZLP connected to that Zone.
Check wiring to device.
Check heater resistance on device.
Bad or
Verify power supply voltage is 24 VDC. If voltage is
overloaded
low, disconnect the power lines and re-check voltage
power supply 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.
V1M#
Low Voltage
Deviation
Line AWB, Unit
_
V4I#
Alarm
High CAN
Voltage, MZLP
_
40
The voltage
to the AWB
is below
threshold
Bad or
overloaded
power supply
Verify transformer voltage top matches incoming
voltage. Verify incoming voltage is correct.
Verify power supply voltage is 24 VDC. If voltage is
high, replace power supply unit.
334129D
Troubleshooting
Code
V6M#
Description
Wiring Error
Line MZLP _
V8M#
No Line Voltage Alarm
MZLP _
V4M#
AWB High Line Alarm
Voltage
WJ1
Pump _
Solenoid is
disconnected
Alarm
WJ2
Pump _
Solenoid High
Current
Configuration
Error USB
Alarm
WSUX
334129D
Type
Alarm
Advisory
Cause
Incoming
power is wired
incorrectly
Incoming line
voltage is less
than 100 VAC.
Solution
Correct the Wiring.
Verify transformer has the correct tap selected.
Verify CB-1 or FU-4, FU-5, and FU-6 are not
tripped/blown.
Verify RCD-1 is not tripped.
Measure incoming power with system unplugged. If
line voltage is less than 100 VAC, contact qualified
electrician to correct the low voltage.
Verify the MZLP is plugged in at J2 and the AWB is
plugged in at J5 and J6.
Incoming
Check incoming voltage is correct for configuration.
voltage is too Verify the transformer has the correct tap (400, 480,
high
600) selected.
Pump is not Verify harness is plugged into J13 of the daughter
turning on
board. Verify it is secured to the solenoid.
when it should Replace Solenoid.
Solenoid is
Inspect for short in harness. Inspect for a shorted
drawing too
solenoid cable/short to the ground. Replace solenoid.
much current
USB
Install software.
configuration
is not loaded
41
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.
Cause
Solution
Closed main air valve or clogged air Open air valve; clear air line.
line,
Not enough ram air pressure.
Increase ram air pressure.
Worn or damaged ram piston.
Replace piston. See instruction
manual 310523.
Platen not fully up to temperature.
Wait for full temperature.
Ram air pressure too high.
Decrease ram air pressure.
Dented drum has stopped platen.
Fix or replace drum.
Ram "up / down" air pressure too
Decrease ram air pressure.
high.
Worn rod seal.
Replace o-rings in guide sleeve. See
instruction manual 310523.
Ram air pressure too high.
Decrease ram air pressure.
Worn or damaged wipers.
Replace wipers.
Pump will not prime properly, or
pumps air.
Closed main air valve or clogged air Open air valve; clear air line.
line.
Not enough air pressure.
Increase air pressure.
Worn or damaged ram piston.
Replace piston. See instruction
manual 310523.
Ram directional valve closed or
Open valve; clear valve or exhaust.
clogged.
Ram directional valve dirty, worn, or Clean; repair valve.
damaged.
Directional valve not in the down
Position handle in the down position.
position.
Dented drum has stopped platen.
Fix or replace drum.
Air pressure will not push platen out
of drum.
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.
42
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.
334129D
Troubleshooting
Heated Pump Troubleshooting
See pump manual for additional pump troubleshooting information. See Related Manuals, page 7.
Problem
Cause
Rapid downstroke or upstroke (pump Material not heated to proper
temperature.
cavitation).
Air is trapped in pump.
Material leaks around pump outlet.
Material leaks around bleed port.
Pump will not move up and down.
Downstroke: Dirty or worn pump
intake valve.
Upstroke: Dirty or worn pump piston
valve.
Machine is out of material
Loose outlet fitting.
Loose bleed port fitting.
Problem with air motor.
Foreign object lodged in pump.
Platen not fully up to temperature.
Valve to air motor is off.
Leak around pump wet-cup.
Worn throat seals.
Solution
Check and adjust temperature to
proper set point. Wait for pump/platen
to heat up.
Bleed air from pump. See
Prime Pump, page 31.
Clean or repair. See Pump Manual.
Clean or repair.
Adjust empty level sensor.
Tighten outlet fitting.
Tighten bleed port fitting.
See Air Motor Manual.
Relieve pressure. See Pump Manual.
Wait for full temperature.
Check gauges and valves to the air
motor.
Replace throat seals. See Servicing
the Throat packings in manual
334127 or 334128.
Air Motor Troubleshooting
See air motor manual for additional air motor troubleshooting information. See Related Manuals, page 7
Problem
Cause
Solution
Air motor will not run.
Air motor solenoid is off.
Wait for heat zones in use to reach
temperature setpoint values.
Air motor stalled.
Damaged main air valve spool or
poppets.
Inspect and clean poppets. See Air
Motor Manual.
Rebuild main air valve. See Air
Motor Manual.
Air continuously exhausting around
air motor shaft.
Damaged air motor shaft seal.
Replace air motor shaft seal. See
Air Motor Manual.
Air continuously exhausting around
air valve/slide valve.
Air valve/slide valve gasket is
damaged.
Replace the valve gasket. See Air
Motor Manual.
Air continuously exhausting from
muffler when motor is idle.
Internal seal damage.
Rebuild air motor. See Air Motor
Manual.
Icing on muffler.
Air motor operating at high pressure
or high cycle rate.
Reduce pressure, cycle rate, or duty
cycle of motor.
334129D
43
Repair
Repair
Replace Wipers
1. To replace a worn or damaged wiper raise the
ram plate up out of the drum. Perform steps 1
through 7 of Change Pail, page 35 .
2. Separate the wiper joint, and bend back the
strapping that covers the clamp (207).
3. Unscrew the worm gear and remove the wiper
(202).
4. Thread the strapping through the new wiper
(202).
5. Insert the strap end through the clamp (207) and
tighten.
6. Use a rubber mallet to pound the wiper around
the platen (201) until the wiper ends are butted
tightly together.
7. Apply a lubricant to the wiper (202). Use a
lubricant that is compatible with the material to
be pumped. Check with the material supplier.
Figure 26
44
334129D
Repair
Replace Platen RTD
4. Remove the front and right side pump cover.
Reference Electrical Schematics, page 57 for wiring
connections.
1. If the material pail has already been removed
from the supply unit, go to step 2. If you
need to remove the material pail, see
Change Pail, page 35.
2. Make sure the ram plate is down and the ram
hand valve is in the OFF position.
Figure
27
5. Remove the platen RTD (616) from the platen.
6. Disconnect the platen RTD quick connect
terminal (625) from J5 connector on the AWB.
7. Attach the leads from the new sensor (616) to the
leads of the old sensor and pull the new sensor
leads through the cable pump shield, cable track,
and into the electrical enclosure.
To reduce the risk of injury or damage to
equipment, make sure the main power switch
is off before continuing with this procedure.
8. Install the new sensor (616) into the follower/tire
plate after coating with non-silicone heat sink
compound. Tighten compression nut. Ensure
RTD is fully inserted.
9. Reconnect the quick connect terminal (625).
10. Replace the pump covers.
3. Turn main power switch off.
334129D
45
Repair
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 pail, perform steps 1 through
6 of Change Pail, page 35. 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.
6. Turn the main power switch off.
7. Disconnect all material hoses.
8. If system includes pump shield, remove the
pump sheet metal enclosure (A). See Fig 28.
a. Remove the cover screws (B).
b. Remove heater bands (HB) and disconnect
the ground wire (R).
9. Pump must be in the full down position (air motor
shaft fully extended).
10. If vent hood is installed, remove it.
11. Disconnect electrical cable from air motor (X).
12. Remove air line from air motor and air lines to the
follower blow-off valve.
13. Remove nuts (F) from pump/air motor tie rods
at the pump end.
14. Remove nuts and bolts (T) holding cable tract to
air motor support plate. Slide end of cable track
outboard of the mounting plate.
15. Remove screws and washers from pump inlet.
16. Fully loosen pump rod coupler (G) to the air
motor rod.
3. Follow Pressure Relief Procedure, page 33.
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 ADM, turn off the system heat (D).
46
17. Slowly raise elevator to achieve enough
separation of the pump (air motor) tie rods to
remove the pump.
18. Remove the pump (P).
19. Reverse this procedure to reinstall the new or
rebuilt air motor.
334129D
Repair
Figure 28
334129D
47
Repair
Remove Platen
10. Remove the heater band (309a, 309b) from
pump.
11. 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.
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.
12. Install a new heater band (309a, 309b) in the
same location as the old heater band:
a. Locate heater terminals so they line up with
back of pump.
b. Tighten the heater band.
c.
Re-connect heater wires and re-attach
ceramic caps that insulate terminal.
Replace Heater Bands and Pump
RTD
Replace Heater Band
1. If the material drum has already been removed
from the supply unit, go to step 2. If you need
to remove the material drum, perform steps 1
through 6 of the Change Pail, page 35. Pump
must be in the full down position (air motor shaft
fully extended).
Figure 29
Replace Pump RTD
1. Turn the main power switch off.
2. Make sure the ram plate is down and the ram
hand valve is in the neutral position.
3. Follow Pressure Relief Procedure, page 33.
2. Remove the screws that hold the front shroud in
place and remove front shroud.
4. Bleed off excess material in the system by
opening the applicator and catching the material
in a waste container.
3. If sensor wire is connected to electrical enclosure,
disconnect it.
5. On ADM, turn off the system heat (D).
4. Loosen the clamp (321) holding sensor on pump.
6. Turn the main power switch off.
5. Tie the leads of the new sensor (320) to the old
sensor and remove the old sensor. The leads of
the new sensor will be easily drawn through the
conduit for reconnecting.
7. Remove the pump covers.
8. Remove white ceramic caps and disconnect the
electrical wires from heater band (309a, 309b).
9. Remove the screw that holds the heater band
in place.
48
6. Replace the sensor (320) in clamp (321):
a. Place sensor approximately 30° counter
clock-wise from pump outlet.
b. Tighten clamp (321).
7. Re-connect sensor wire to electrical enclosure.
334129D
Repair
Replace MZLP Fuse
1. Turn the main power switch off.
Each MZLP module comes with the following fuses:
2. Open electrical enclosure door.
3. Use a proper non-conductive fuse puller tool to
remove the blown fuse.
J1
J2
F10 F9
F4 F3
F8 F7
F2
F6
Using an improper tool, such as screw drivers
or pliers, may break glass on fuse.
F1
F5
Note
F1 and F2 are white ceramic and indicate
25A on the barrel.
J7
Note
J6
J5
J3
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
Figure 30 Fuse Locations
Fuse Kit Fuse
24V289 F1, F2
Part
250VAC, 25A, long, white
ceramic
F3-F10 250VAC, 8A, fast acting, clear
glass
Spare fuse kit included with system.
Using an improper tool, such as screw drivers
or pliers, may break glass on fuse.
5. Close electrical enclosure.
To prevent system damage, always use fast
acting fuses. Fast acting fuses are required for
short-circuit protection.
334129D
49
Repair
Replace MZLP
b. To replace MZLP #2 or #33, remove the
jumper (162) from MZLP #2 or #3 J5
connector and reinstall it on the new MZLP
J5 connector.
6. To reassemble MZLP, Set MZLP rotary switch
based on location. See .
1. Turn the main power switch off.
7. Use four screws (115) to install MZLP (111 or
112) to electrical enclosure.
8. Reconnect cables to MZLP.
Note
2. Disconnect heated hose electrical connectors
from MZLP (111 or 112).
Do not force the electrical connection.
Minimal force is required to seat the
connector. If resistance is felt, stop and
verify the connector orientation.
3. Note location of each cable, then unplug all
cables from the MZLP (111 or 112) that will be
replaced.
Note
4. Remove four screws (115) securing MZLP (111
or 112) to electrical enclosure then carefully
remove MZLP from electrical enclosure.
If unable to determine connector location,
see Electrical Schematics, page 57.
9. Connect heated hose electrical connectors to
new MZLP.
Note
MZLP may need updated software. See
Update Software, page 56.
Table 10 MZLP Rotary Switch
MZLP
System
Rotary Switch
#1 with
Daughter Card
Primary
1
Secondary
5
#2
Primary
2
Secondary
6
Primary
3
Secondary
7
Figure 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.
50
#3
334129D
Repair
Replace MZLP Daughter Card
5. Plug new daughter card (112a) into the
MZLP (112).
6. Use screws (112b) to secure daughter card to
MZLP (112).
7. Connect cables to 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 location of each cable then unplug all cables
from MZLP daughter card on MZLP#1 (112).
3. Remove four mounting screws (112b) from
daughter card (112a) and set aside.
Note
If unable to determine connector location,
see Electrical Schematics, page 57.
4. Unplug daughter card (112a) from the MZLP
#1 (112).
Figure 32 MZLP Daughter Card
334129D
51
Repair
Replace AWB
Replace Power Supply
1. Turn the main power switch off.
2. Note location of each cable, then unplug all
cables from the AWB (205).
Note
For an AWB on a secondary system,
remove connector (182) and connect to
new AWB.
1. Turn the main power switch off.
2. Open electrical enclosure.
3. Remove power supply (208) from din rail (206).
Disconnect screw terminal connections between
the power supply and power supply harness.
Power Supply
Connection
Harness Label
V+
V+
V-
V-
GND
GND
Note
L
L
Do not force the electrical connection.
Minimal force is required to set the
connector. If resistance is felt, stop and
verify the connector orientation.
N
N
Figure 33 AWB Connections
3. Remove two screws (223) securing AWB (205)
to electrical panel then carefully remove AWB.
4. Install new AWB (205) and reconnect cables.
Note
See Electrical Schematics, page 57,
if unable to determine the connector
location.
52
4. Connect power supply harness to new power
supply.
5. Reattach power supply to din rail (206).
6. Torque terminals to 4.53–6.2 in-lbs (0.5–0.7
N•m).
7. Close electrical enclosure door.
334129D
Repair
Replace Fan
6. Remove screws (141), grill (137), four nuts (139),
rear fan grill (138), and fan (136).
1. Turn the main power switch off.
2. Disconnect plug from power outlet or turn off
circuit breaker for incoming power.
3. Open electrical enclosure door.
4. Remove connector from J7 connector on AWB
board. Remove red (+) and black (-) fan wires
from connector.
7. Mount new fan (136), rear fan grill (138), and
nuts (139) on grill (137) with the arrow pointing
toward the grill (137).
8. Tie down fan wires onto tie down locations on
grill (137) using cable zip ties.
9. Route fan wires into the electrical enclosure.
Connect red and black fan wires to J7 connector.
Reconnect J7 connector to AWB. Use cable ties
to secure fan wires to other cables in electrical
enclosure.
Note
To prevent fan errors on ADM, remove
excess slack and ensure cabling and zip
ties do not contact fan blades.
5. Cut any cable ties between the end of the fan
wires to the fan (136).
334129D
10. Reinstall fan grill (137) and close the electrical
enclosure.
53
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 35, page 57.
Power Harness Wires
RCD--1 Connections
RCD
1. Turn the main power switch off.
RCD-W1
Terminal N
RCD-W2
Terminal 5
RCD-W3
Terminal 3
RCD-W4
Terminal 1
2. Open electrical enclosure door.
3. Disconnect incoming power harness (234) from
top of transformer (235).
14. Install incoming power harness (234) to top of
transformer in voltage port specified on machine
serial number label.
4. Disconnect transformer (235) output power
harness wires (RCD-W1, -W2, -W3, -W4) from
RCD-1.
5. Disconnect transformer (235) ground wire from
the back panel ground lug.
6. Disconnect the red (+) and black (-) wire of fan
from pins 4 and 3 of J7 connector on AWB (205).
Disconnect J7 connector from AWB.
7. Cut wire zip ties securing fan wires.
8. Remove flanged nuts (N) and transformer (235)
from the back panel (201).
9. Install transformer (235) onto mounting studs on
back panel (201) and secure with flanged nuts
(N).
10. Insert thermal sensor connector from transformer
(235) onto J7 connector on AWB (205).
11. Reconnect red (+) wire from fan into pin 4 and
the black (-) wire into pin 3 of J7 connector.
12. Install transformer (235) ground wire onto ground
lug of back panel (201).
54
15. Verify all electrical connections, including earth
grounds, are compete 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.
334129D
Repair
Figure 34 Inside of Electrical Control Enclosure
334129D
55
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.
Software is checking
which GCA modules
will take the available
updates.
1. Turn system main power switch OFF.
2. Remove ADM from bracket.
3. Remove token access panel.
Status of the update
with approximate time
until completion.
Updates are
complete. Icon
indicates update
success/failure. See
the following Icon
table.
Icon
Description
Update successful.
4. Insert and press software upgrade token (T)
firmly into slot.
Update unsuccessful.
Note
There is no preferred orientation of token
Update complete, no changes
necessary.
T
Update was successful/complete
but one or more HCA modules
did not have a CAN boot-loader
so software was not updated on
that module.
7. Remove token (T).
8. Replace token access panel.
5. Install ADM into bracket.
6. Turn system main power switch ON.
9. Press
to continue to the operation screens.
A status is shown while software is updating to
indicate progress. To prevent corrupting the
software load, do not remove token until the
status screen disappears.
Note
When the screen turns on, you will see
the following screens:
56
334129D
Electrical Schematics
Electrical Schematics
230V, 3 Phase/60 Hz
334129D
57
Electrical Schematics
400V, 3 Phase/50 Hz
58
334129D
Electrical Schematics
400–600VV, 3 Phase/60 Hz
334129D
59
Electrical Schematics
AWB and MZLP#1
60
334129D
Electrical Schematics
MZLP #2, MZLP#3, Overtemp, and
Pump Heaters
334129D
61
Electrical Schematics
MZLP Zones
62
334129D
Notes
Notes
334129D
63
Parts
Parts
Therm--O-Flow 20 Supply Unit
Therm
64
334129D
Parts
Therm--O-Flow 20 Supply Unit
Therm
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
Part
- - -
Description
Frame
24W870 KIT; air control; see
Air Control Assembly
- - CONTROL, electrical (not
used with air control only
systems)
- - MODULE, pump; see
Pump Modules
- - PLATEN; see
Heated Platens
C31065 SEAL
24W812 ADM
24W589 KIT, light tower (optional);
see Accessories and Kits,
page 85
- - CABLE, track
- - BRACKET, cable track,
enclosure
101864 SCREW, cap, sch
100020 WASHER, lock
111820 SCREW, cap, sch
334129D
Qty
1
1
1
1
1
1
1
1
Ref
14
15
16
17
18
19
20
21
22
23
24
1
1
25
26
4
6
6
27
Part
Description
288543 BRACKET, hose, spring
- - BRACKET, enclosure, ram
112166 SCREW, cap, sch
110755 WASHER, plain
100016 WASHER, lock
- - BRACKET, cable track,
NXT
106285 BOLT, u
100179 NUT, hex mscr
24V745 SENSOR, level, low/empty
15J076 LABEL, warning,
instructions
15J074 LABEL, warning; moving
objects, pinch
15H668 LABEL, warning; hot
surface, splatter
15J075 LABEL, warning; hot
surface, shock
184090 LABEL, warning
Qty
1
1
4
8
8
1
2
4
1
2
4
2
2
1
65
Parts
Air Control Assembly
Ref
51
52
53
Part
Description
24W870 KIT, CONTROL, air, 3
regulator; see manual
334201
121235 SOLENOID, air motor, ram
17A557 HARNESS, solenoid,
MZLP
Qty
1
1
1
56
Part
113445
121282
120375
66
255651
Ref
54
55
Description
FITTING, elbow, street
FITTING, swivel, straight
ADAPTER, elbow, 3/4–14
nptf x 1/2–14 npsm
KIT, reg, air motor, ram
Qty
1
1
1
1
Replacement Warning labels, signs, tags, and
cards are available at no cost.
66
334129D
Parts
Electrical Module
334129D
67
Parts
68
334129D
Parts
Electrical Control Module Parts
Ref. Part
- - 101
- - 103
104
- - -
105
106
107
125946
123967
- - -
Description
ENCLOSURE, electrical
BUSHING, strain relief, m40
thread
NUT, strain relief, m40
thread
PLUG, hole, 1/2 in
KNOB, operator disconnect
PANEL, elec, transformer
Qty
1
1
1
Ref. Part
- - 125
126
- - -
127
17A555
2
1
128
17A559
1
129
127511
PANEL, elec, 400v/n
1
(400V modules only)
- - -
PANEL, elec, 230v
100133
100307
123396
111
24V509
112
24V510
WASHER, lock, 3/8
NUT, hex
NUT, flange, serrated,
3/8-16
MODULE, gca, mzlp w/
daughter board
MODULE, gca, mzlp
4
8
4
1
KIT, daughter, board
24P175
1
GASKET, foam
125856
116
16T440
- - 100166
- - -
123
17A544
17A543
WIRE, grounding, door
NUT, full hex
GASKET, hphm
HARNESS, power, mzlp1,
awb
HARNESS, power, mzlp2,
awb
121612
132
123969
123968
134
- - -
136
24V911
HARNESS, power, mzlp2/3,
awb
CABLE, can, male / female,
0.4m
CONNECTOR, thru, m12,
mxf
SWITCH, disconnect, 100a
SWITCH, disconnect, ph
exp 100 A
1
1
1
1
HARNESS, disc, fuse,
230-600v
HARNESS, disc, cb, 400v/n,
tof
1
1
FAN, 24v dc, 120m x 120m
1
(400V only)
16X884
115836
GRILL, fan
1
GUARD, finger
1
(400V only)
139
127278
NUT, keps, hex
4
(400V only)
140
24V746
12
141
142
143
1
2
1
1
GRILL, vent
(230V and 400V assemblies
only; Qty 2) (Transformer
assemblies only; Qty 1)
119865
SCREW, mach, hex
serrated
- - CONTROL, air, assy; with
solenoid
24W812 ADM
4
1
1
(Primary assemblies only)
144
15V551
SHIELD, membrane, ADM
0.1
(Primary assemblies only)
145
121001
1
146
- - -
1
147
121250
CABLE, can, female /
female 1.0m
1
(Primary assemblies only)
(8 zone assemblies only )
17A545
1
(400V only)
138
(4 Zone only; Qty 2) (8 zone
assemblies only; Qty 4) (12
zone assemblies only; Qty
6)
118
119
120
122
1
(400V only)
PLATE, blank
SCREW, 8-32, serrated
flange
CAP, souriau, uts14
131
137
(4 Zone assemblies only;
Qty 2) (8 zone assemblies
only; Qty 1)
115
1
(400V only)
(8 zone assemblies only;
Qty 1) (12 zone assemblies
only; Qty 2)
114
121226
17A547
(8 zone assemblies only;
Qty 1) (12 zone assemblies
only; Qty 2)
112a 24R042
- - 113
130
1
(230V modules only)
108
109
110
HARNESS, pump, mzlp1,
tb, tof
HARNESS, output, mzlp1,
ssr, contact
HARNESS, pump, reed
switch, tof
HARNESS, board, mxm,
comm
CABLE, board, samtec
Qty
1
(8 zone assemblies only;
Qty 1) (12 zone assemblies
only; Qty 2)
(transformer assemblies
only)
- - -
Description
BRACKET, mounting,
assembly
1
(Primary assemblies only)
SCREW, shcs, 1/4uncx4.25
1
(Primary assemblies only)
(12 zone assemblies only)
334129D
69
Parts
Ref. Part
148 102040
Description
NUT, lock, hex
Qty
1
Ref. Part
- - 165
(Primary assemblies only)
149
110755
1
WASHER, plain
166
127771
(Primary assemblies only)
150
121253
151
- - -
152
101550
1
KNOB, display adj., ram
pkgs
(Primary assemblies only)
167
- - -
4
SCREW, cap, sch
153
100016
156
157
158
159
160
24V745
- - - - - - -
5
WASHER, lock
(Primary assemblies only)
124654
1
1
1
1
SENSOR, level, low/empty
BUSHING, strain relief
NUT, bushing
GROMMET, wire
CONNECTOR, splitter,
12(m) x m12(f)
1
168
169
- - - - -
170
196548
172
- - -
181
- - -
121228
162
16W035 CONNECTOR, jumper
1
CABLE, can, female/female,
15.0 m
182
17C669
(Secondary modules only)
164
- - - - -
CONTACT, socket, 20-24
awg, crimp, tin
TUBE, 1/16 shrink tube
FERRULE, wire, 16awg
FERRULE, wire, 18 awg,
long
LABEL, warning, shock
6
6
ARTWORK, instructions,
wiring, ul
FERRULE, wire, 10awg,
twin
1
1
3
CONNECTOR, jumper,
male
1
(Secondary assemblies
only)
(8 zone assemblies only;
Qty 1) (12 zone assemblies
only; Qty 2)
163
FERRULE, wire, 10awg
(Secondary assemblies
only)
(Secondary modules only)
161
1
(230V modules only; Qty
2) (400V and transformer
modules only; Qty 8)
(Primary assemblies only)
(Primary assemblies only)
HARNESS, input, mzlp1,
RTD
BRIDGE, plug-in, 2pos,
ut16
Qty
1
(400V and Transformer
modules only)
1
BRACKET, pendant pivot,
Description
183
3
0.13
123856
HARNESS, CAN, cable
1
(Secondary assemblies
only)
184
17C712
TOKEN
1
(Secondary assemblies
only)
Replacement Warning labels, signs, tags, and
cards are available at no cost.
70
334129D
Parts
Electrical Panel
230V
400V/N
Transformer
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).
334129D
71
Parts
230V Panel
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).
72
400V/N Panel
334129D
Parts
Electrical Panel Parts
Ref.
201
Part
- - -
202
203
204
205
206
207
117666
113783
100985
24V816
- - 123363
208
209
126453
- - -
210
128097
211
212
213
214
215
216
217
218
219
220
221
222
223
224
- - 126811
- - -
Description
PANEL, elec, tof, 11ga,
zinc
TERMINAL, ground
Qty.
1
Ref.
225
1
1
1
1
1
3
226
227
228
229
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
1
1
1
1
2
1
1
120399
CONTROL, 65 amp,
120-600v
123359 RELAY, contactor, 30a,
3p, 24vdc co
6690-24- FUSE, fuse block buss
165
jt60060
128314 BLOCK, terminal 3-wire
128321 COVER, end
126819 BRIDGE, plug-in,
2-position
127717 BLOCK, terminal, 2pos,
ut16
127718 COVER, end, ut16
17C137 LABEL, multi safety
103833 SCREW, mach, crbh
123452 HOLDER, anchor, wire tie,
nylon
230
1
3
Part
- - -
HARNESS, wire, ground,
8awg
- - HARNESS, fuse, contactor
- - HARNESS, contactor, ssr
- - HARNESS, rcd, ssr fan
- - See Code C Table
6690-24- FUSE, fuse block buss
164
jt60030
127744 CIRCUIT, breaker, 3p,
32a, ul489; 230V Panel
3
1
1
33
12
Qty.
1
1
1
1
3
3
1
only
127745
231
232
- - 17A546
CIRCUIT, breaker, 20a,
4p, ul489; 400V Panel only
See Code C Table
HARNESS, cb, rcd,
230-400V; 230V and 400V
1
3
1
Panel only
233
17A558
234
17A541
235
24V718
237
128014
HARNESS, cb, rcd,
400v/n; 400V Panel only
HARNESS, fuses,
transformer; Transformer
1
panel only
7
1
1
Description
TRANSFORMER,
multi-tap/230v, 6kva;
1
Transformer panel only
238
239
240
FILTER, voltage, transient,
600V, 3P
112380 SCREW, mach, pn hd
81/0163 WIREWAY, panduit
–B/11
81/0164 COVER, panduit
–B/11
1
2
4
4
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
Code C
(229)
(231)
X1X
24X885
NA
X2X
24X885
NA
X3X
24X881
24X878
X4X
24X882
24X877
X5X
24X884
24X874
334129D
If Code A is 200 and Code E is F/S and Code C is
Code C
(229)
(231)
X1X
24X885
NA
X2X
24X885
NA
X3X
24X880
24X878
X4X
24X881
24X877
X5X
24X883
24X874
73
Parts
Merkur 2200, 23:1 Pump Modules
1
2
Torque to 50–60 ft-lb (68–81 n•m).
Torque to 145–155 ft-lbs (196–210 n•m).
7
3
Coat mounting surface of sensor mounting block 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
Coat inside of heater (309a, 309b) only to within 3/4 in
of vertical ends, with non-silicone heat sink compound
before mounting.
74
6
8
Cap screws (311) must be loose while tie rods (307) are
being torqued.
Torque to 150 ft-lbs (203 n•m).
Apply anaerobic sealant.
334129D
Parts
Merkur 2200, 23:1 Pump Modules
Description
Ref. Part
301 24W754 MOTOR, air, 6.0in, 4.75
strk, blue
302 C20485 FITTING, hex, nipple
- - 303
FASTENER, screw, slot
hex, #8-32 tap
304 24X441 SWITCH, reed assy
- - 305
BRACKET, motor mount
306 15H397 ADAPTER, rod, pump
307 16A223 ROD, tie, vert driver
308 106166 NUT, mach ,hex
309 128322 HEATER, pump, 600 watt
310 24W152 PUMP, tof200, cf; 24V572
only
24W153 PUMP, tof200, gf; 24V575
only
311 109211 SCREW, cap, sch
312 17A637 BLOCK, standoff, mounting
315 102656 MUFFLER
316 186925 NUT, coupling
317 184129 COLLAR, coupling
318 103345 SCREW, cap, sch
319 100016 WASHER, lock
320 24Z093 SENSOR, RTD
334129D
Qty
1
1
1
1
1
1
3
3
2
1
1
3
3
1
1
2
2
4
1
Part
C31012
C03507
C38162
C38163
- - - - -
Description
Qty
CLAMP
SUPPORT, sensor
SCREW, machine
WASHER, lock, ext. tooth
CONDUCTOR, ground
1
1
1
1
1
1
1
1.5
Ref.
321
322
323
324
325
326
329
330
331
C33049
- - -
333
334
206994
127766
365
127671
335
17B715
336
127671
337
338
339
122338
214656
SCREW, cap, socket bh
HOSE, coupled
16C009
HOOK
103347
SHIELD, pump, tof20
VALVE, safety, 100 psi
TAPE, adhesive, fiberglass
LUBRICANT, high temp,
thermal
FLUID, tsl 8 oz bottle
FITTING, 45 elbow swivel,
1/2 npt(f) x 1/2 nps
SWITCH, over temp, fixed,
450°F (232°C)
SUPPORT, block,
overtemperature
SWITCH, over temp, fixed,
450°F (232°C)
1
1
1
2
1
2
4
1
1
75
Parts
Merkur 3400, 36:1 Pump Modules
1
2
Torque to 50–60 ft-lb (68–81 n•m).
Coat inside of heater (309a, 309b) only to within
5 3/4 in of vertical ends, with non-silicone heat sink
compound before mounting.
Torque to 145–155 ft-lbs (196–210 n•m).
Cap screws (311) must be loose while tie rods (307)
Coat mounting surface of sensor mounting block
3 with non-silicone heat sink compound. do not coat
sensor.
6 are being torqued.
7
Prior to tightening band clamp (321) RTD sensor
4 (320) must be fully contained within the sensor
8
Torque to 150 ft-lbs (203 n•m).
Apply anaerobic sealant.
mount (322).
76
334129D
Parts
Merkur 3400, 36:1 Pump Modules
Ref. Part
301 24R015
302
303
C20485
- - -
304
305
24X441
- - -
306
307
308
309
310
15H397
16A223
106166
128322
24W152
311
312
315
316
317
318
319
Description
MOTOR, assy, air, 7.5in
,blue
FITTING, nipple, hex
FASTENER, screw, slot
hex, #8-32 tap
SWITCH, reed assy
BRACKET, motor mount,
tof 200
ADAPTER, rod, pump
Qty
1
1
1
1
1
1
3
3
2
PUMP, tof20, long shaft, cf; 1
24V573 only
24W153 PUMP, tof20, long shaft, gf;
24V576 only
109211 SCREW, cap, sch
3
17A637 BLOCK, standoff, mounting 3
102656 MUFFLER
1
186925 NUT, coupling
1
184129 COLLAR, coupling
2
103345 SCREW, cap, sch
6
100016 WASHER, lock
6
334129D
ROD, tie, vert driver
NUT, mach ,hex
HEATER, pump, 600 watt
Ref.
320
321
322
323
324
325
326
327
329
330
331
Part
24Z093
C31012
C03507
C38162
C38163
- - - - - - 103347
C33049
- - -
333
334
206994
127766
335
17B715
336
127671
337
338
339
122338
214656
16C009
Description
SENSOR, RTD
CLAMP
SUPPORT, sensor
SCREW, machine
WASHER, lock, ext. tooth
CONDUCTOR, ground
SHIELD, pump
LABEL, identification
VALVE, safety, 100 psi
TAPE, adhesive, fiberglass;
1.5 ft (x m)
LUBRICANT, high temp,
thermal
FLUID, tsl 8 oz bottle
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
FITTING, 45 elbow, swivel,
1/2 npt(f) x 1/2 nps
1
SUPPORT, block,
overtemp
SWITCH, over temp, fixed, 2
450°F (232°C)
4
SCREW, cap, socket bh
1
HOSE, coupled
1
HOOK
77
Parts
NXT 6500, 70:1 Pump Modules
1
2
Torque to 50–60 ft-lb (68–81 n•m).
Coat inside of heater (407a, 407b) only to within
5 3/4 in of vertical ends, with non-silicone heat sink
compound before mounting.
Torque to 145–155 ft-lbs (196–210 n•m).
Coat mounting surface of sensor mounting block
3 with non-silicone heat sink compound. do not coat
sensor.
6
7
Torque to 150 ft-lbs (203 n•m).
Apply anaerobic sealant.
Prior to tightening band clamp (412) rtd sensor
4 (410) must be fully contained within the sensor
mount (411).
78
334129D
Parts
NXT 6500, 70:1 Pump Modules
Description
Ref. Part
401 N65LR0 MOTOR, 6500, low-noise,
remote
402 120375 ADAPTER, elbow, 3/4 NPTI
x 1/2 NPTE
403 15J288 BRACKET, mounting,
motor, tof20
404 17A406 ADAPTER, rod, pump, tof
405 16A223 ROD, tie, vert driver
406 106166 NUT, mach, hex
407 128322 HEATER, pump, 600 watt
408 24W152 PUMP, tof 20, cf; 24V574
only
24W153 PUMP, tof 20, gf; 24V577
only
409 C19837 SCREW, cap, socket hd
410 24Z093 SENSOR, RTD
411 C03507 SUPPORT, sensor
412 C31012 CLAMP
413 186925 NUT, coupling
414 184129 COLLAR, coupling
334129D
Qty
1
1
2
1
3
3
2
Ref.
415
416
417
418
419
420
422
423
424
425
Part
C38163
- - -
Description
C38162
103345
100016
--- - -
SCREW, machine
SCREW, cap, sch
426
428
429
C33049
206994
17B715
430
127671
431
432
122338
214656
120588
120012
- - -
1
1
4
1
1
1
1
2
WASHER, lock, ext. tooth
CONDUCTOR, ground
Qty
1
1
1
6
6
1
1
1
1
WASHER, lock
LABEL, ID
SHIELD, pump, tof20
PLUG, pipe, round
VALVE, safety, 50 psi
LUBRICANT, high temp,
thermal
1
TAPE, adhesive, fiberglass 1.5
FLUID, tsl 8 oz bottle
1
SUPPORT, block,
overtemp
1
SWITCH, over temp, fixed,
450
2
SCREW, cap, socket bh
4
HOSE, coupled
1
79
Parts
Pump Shield
Ref
501
502
503
504
Part
- - - - - - C20474
Description
COVER, pump, bottom
COVER, pump, back
COVER, PUMP, front
SCREW, self-tapping
Qty
1
1
1
6
Ref
505
506
507
Part
184090
104088
15J075
Description
LABEL, warning
RIVET, blind
Qty
1
2
LABEL, safety, hot surface 1
and shock
Replacement Warning labels, signs, tags, and
cards are available at no cost.
80
334129D
Parts
President, 15:1 Pump Module
1
2
Torque to 20–30 ft-lb (27–41 N•m).
Torque to 30–40 ft-lbs (41–54 N•m).
334129D
81
Parts
Ref.
551
551a
551b
551c
Part
288505
24B229
- - - - -
551d
551e
198369
100340
551f 100133
551g 298073
551h 156082
551j
112166
551k 100016
551m 207370
551n 198412
551p C38225
551r 101946
551s 206994
552
112756
- - 553
554
196548
Description
PUMP, president
MOTOR, AIR, president
PUMP, hot melt mini-5
PLATE, president
mounting
ROD, standoff
NUT
Qty
1
1
1
1
WASHER, lock, 3/8
ADAPTER, pump
PACKING, o-ring, 112
SCREW, cap, sch
WASHER, lock
ROD, connecting
ROD, connecting
PACKING, o-ring
PIN, cotter, sst
FLUID, TSL, 8 oz
SCREW, cap, socket hd
BRACKET, mounting,
junction box,
LABEL, warning, shock
3
3
3
1
2
2
2
1
1
1
2
1
4
2
Part
Description
556
557
100020
100179
- - -
WASHER, lock
NUT, hex mscr
558
- - -
559
516587
560
561
562
563
564
154628
101015
155470
565
566
567
100016
103345
- - -
568
127732
569
214656
Ref.
555
C19187
- - -
Qty
2
2
1
JUNCTION BOX, front
cover
FASTENER,
thread-cutting screw
BOLT, 3/4-10 x 1.5 hex
head
WASHER
WASHER,lock
NUT, hex
ADAPTER
2
1
FITTING, swivel, union,
90 degree
WASHER, lock
SCREW, cap sch
JUNCTION BOX, main
body
FITTING, 3/4" knockout,
romex, pushin
HOSE, coupled, 61209,
10 ft
2
1
1
1
1
6
6
1
1
1
1
Replacement Warning labels, signs, tags, and
cards are available at no cost.
82
334129D
Parts
Heated Platens
24V742, Heated Drum Platen, Smooth Bottom (Code E- option S)
24V743, Heated Drum Platen, Standard Finned Bottom(Code E- option F)
1
Coat RTD sensor (616) with non-silicone heat sink
compound. Coat from tip to 1 in from tip.
8
Coat bottom of overtemperature switch (627) with
non-silicone heat sink compound.
3
Label cables for identification. See Cable
Identification
9
Label the wires on overtemperature switch (627)
2732. 2740 at the opposite end of the sensor.
4
Do not tighten heater terminal nuts down onto
ceramic insulators to prevent damage.
334129D
83
Parts
Ref
601
Part
602
603
604
605
606
607
608
609
610
611
C31052
207440
24X439
- - 514930
C31154
- - 167730
100176
115948
612
115949
613
---
614
---
615
616
- - 24Z094
Description
PLATEN — see table
below
HOSE, seal, Mini - 5
VALVE, dispenser
HANDLE, bleed
ADAPTER, bushing
Qty
1
SCREW, cap, skt hd
CLAMP, worm gear
PLATE, designation
GASKET, copper
BUSHING, hex
ELBOW, 1/4 npt(m), 5/16
OD tube
ELBOW, 1/4npt(m), 5/32
OD tube
TUBE, PTFE, 1/4 x 5/16;
14 ft (4.2 m)
TUBE, PTFE, 3/32 x 5/32;
14 ft (4.2 m)
CONDUIT, hi-temp, w/
fittings
SENSOR, RTD, 5”, 100
ohms, with heat shrink
1
1
1
1
3
2
1
1
1
1
Ref
617
618
619
620
621
623
624
626
627
628
629
1
630
1
631
1
632
1
633
Part
Description
C38163 WASHER, lock, ext. tooth
C19049 SCREW, mach, slotted,
rnd hd
15C171 GASKET
102931 NUT, mach. hex
- - WASHER, lock, internal
tooth
- - CONDUCTOR, heater
- - CONDUCTOR, ground
100508 SCREW, drive
127671 SWITCH, overtemp, fixed
122338 SCREW, cap, socket, bh
127689 FITTING, adapter, 1/4 in x
5/32 in tube
127690 FITTING, adapter, 5/16 in
tube x 1/4 in tube
054130 HOSE, tubing; 1/4 in OD;
17 ft (5 m)
- - LUBRICANT, high
temperature, thermal
150286 ADAPTER
Qty
1
1
1
4
4
4
1
2
1
2
1
1
1
1
1
1
Parts included in Seal Kit C31065 (purchase
separately).
Platen Model
24V742
24V743
84
Plate (601) Description
Standard Finned
Smooth Bottom
Qty.
1
1
Element Resistance
28.8 ohms +3/-4
28.8 ohms +3/-4
334129D
Accessories and Kits
Accessories and Kits
Part No.
243657
Wiper Kits
243697
Part No.
Description
C31065
Seal Kit
Applicators and Dispense Valves
Part No.
249515
249514
249513
249512
Description
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.
289208
Compact Heated Regulator
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
Accessory Extension Cables
Use to connect fluid control devices and heated
hoses to the electrical control enclosure.
Part No.
Description
Air--Operated Heated Dispense Valves
Air
Connect between controller and heated hose
129300
15 ft
129301
25 ft
Part No.
243694
Connect between controller and heated accessory
129302
15 ft
129303
25 ft
244951
244909
243701
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
Connect between controller and heated devices
129304
15 ft
129305
25 ft
Light Tower Kit, 24W589
Tie Rod Kits
Flow Control and Manifolds
Part No.
243700
243656
334129D
Description
Heated Air Operated Mastic Pressure
Regulator, 240V
23:1 Heated Pressure Compensator
Valve, 240V
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
85
Accessories and Kits
Heated Hoses and Fittings
Hose Diameter
-6
-8
(9/16 in -18 JIC) (3/4 in -16 JIC)
- 10
(7/8 in -14 JIC)
- 12
(1--1/16 in -12
(1
JIC)
- 16
(1--5/16 in -12
(1
JIC)
- 20
(1--5/8 in -12
(1
JIC)
3 ft (1.5 m)
None
None
None
15C586
None
None
6 ft (1.8 m)
None
115902
115875
None
115884
None
10 ft (3 m)
16J875
115873
115876
115880
115885
117821
15 ft (4.6 m)
None
115874
17J656
115881
115886
117822
20 ft (6 m)
None
None
115878
115882
115887
None
25 ft (7.6 m)
None
None
115879
115883
115888
None
30 ft (9 m)
None
None
121200
None
None
None
Hose Length
Pump Fittings
TOF 20/200 PUMP 1-11 1/2
DUAL OUTLET ADD 120263
TOF MINI 5 PUMP 1/2 NPT
DUAL OUTLET ADD 120241
Hose to Hose Fittings
16V432 100380
253267
253268
120260
120261
120262
16V432
C20678
C20679
C38006
158586
120804
120268
-6 Hose (.308 ID)
125779
123684
123683
123683 120265
123683 120265
120267
None
-8 Hose (.401 ID )
123684
120241
120242
120244
120244 120267
-10 Hose (.495 ID)
123683
120242
120243
120246
120246 120267
123683 120265
120244
120246
120247
120248
-12 Hose (.617 ID)
-16 Hose (.687 ID)
-20 Hose (1.125 ID)
86
6308-82
126521
6308-82
126521
123135 126521
123683 120265
120244 120267 120246 120267
120248
120249
120249 120268
120267
6308-82
120246 120267
None
123135 126521 120249 120268
120250
126521
120268
334129D
Accessories and Kits
Hose Diameter
-6
-8
(9/16 in -18 JIC) (3/4 in -16 JIC)
- 10
(7/8 in -14 JIC)
- 12
(1--1/16 in -12
(1
JIC)
- 16
(1--5/16 in -12
(1
JIC)
- 20
(1--5/8 in -12
(1
JIC)
16V432 100380
6308-82
123135 120266
123135
123854
15D936
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
Fittings
Compensator 51:1, 243657
Compensator 23:1, 243656
Inlet & Outlet: 1-11 1/2 in NPTF
Distribution manifold, 243697
Inlet: 3/4 in NPTF
Distribution manifold, 243697
Outlet: 1-11 1/2 in NPTF
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
334129D
87
Accessories and Kits
8 Channel Upgrade Kit, 24V755
Use this kit to upgrade a 4 Channel system to a 8 channel system.
Ref
1
2
Part
3
4
16T440
127511
88
125856
Description
MODULE, GCA, MZLP
SCREW, 8–32, serrated
flange
CAP, souriau, UTS14
CABLE, board, samtec
Qty
1
4
2
1
Ref
5
6
7
8
Part
Description
16W035 CONNECTOR, jumper
17A544 HARNESS, power, MZLP2,
AWB
112190 STRAP, wrist, grounding
17C712 TOKEN, software upgrade
Qty
1
1
1
1
334129D
Accessories and Kits
8 Zone Upgrade Kit Installation
5. Open the electrical enclosure door.
Note
1. Disconnect plug from power outlet or turn off
circuit breaker for incoming power.
2. Place grounding wrist strap (7) over your wrist
and secure 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 screws (B), remove plate (A), and
gasket (C) from system. Use screws (2) to install
MZLP (1) onto system as shown.
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 cable (4) to J3 connector on MZLP 1
and J6 connector on MZLP 2.
7. Connect power harness (6) to MZLP 2 connector
J2 and J5 connector on AWB. Install jumper (5)
on the MZLP 2 J5 connector
8. Use fittings and hoses that meet your hose routing
needs. See Accessories and Kits, page 85.
9. To ensure your system has the latest
software, insert token (8) into the ADM. See
Update Software, page 56.
The new MZLP (1) will be referred to
as MZLP 2, and the original MZLP that
came with the system will be referred to
as MZLP 1.
334129D
89
Accessories and Kits
12 Channel Upgrade Kit, 24V756
Use this kit to upgrade a 8 channel system to a 12 channel system.
Ref
1
2
Part
3
4
16T440
127511
90
125856
Description
MODULE, GCA, MZLP
SCREW, 8–32, serrated
flange
CAP, souriau, UTS14
CABLE, board, samtec
Qty
1
4
Ref
5
6
2
1
8
7
Part
Description
16W035 CONNECTOR, jumper
17A545 HARNESS, power,
MZLP2/3, AWB
112190 STRAP, wrist, grounding
17C712 TOKEN, software upgrade
Qty
1
1
1
1
334129D
Accessories and Kits
12 Zone Upgrade Kit Installation
5. Open the electrical enclosure door.
Note
1. Disconnect plug from power outlet or turn off
circuit breaker for incoming power.
2. Place grounding wrist strap (7) over your wrist
and secure 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 screws (B), remove plate (A), and
gasket (C) from system. Use screws (2) to install
MZLP (1) onto 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.
334129D
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 cable (4) to J3 connector on MZLP 2
and J6 connector on MZLP (1). Remove existing
power cable from MZLP 2 J2 and AWB J5
connector.
7. Connect power harness (6) to MZLP 2 and MZLP
3 J2 connector and J5 connector on AWB. Install
8. See Install Heated Hose
, to connect a heated hose or fluid control device.
9. To ensure your system has the latest
software, insert token (8) into the ADM. See
Update Software, page 56.
91
Appendix A— ADM
Appendix A— ADM
General Operation
Enable, Disable Heating System
ADM Power
To enable or disable the entire heating system,
The ADM automatically turns on when the main
power switch is turned on.
press
. 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,
. Use the keypad to navigate between
press
screens.
92
334129D
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
Icon
Function
Pause Material Tracking
Continue Material Tracking
Heating Disabled
Pump Ready
Warm Up, Actual temperature
is outside of Target
Temperature
Setback
Reached Target Temperature
Reset Cycle Counter
(press and hold)
Add or edit event
Hose
Gun
Manifold
Accept schedule
Crossover for Tandem Systems
PGM
Flow Meter
Pressure Regulator
Erase or cancel schedule
Cancel
Other
Clear
Advisory. See Error Codes
for more information.
Deviation. See Error Codes
for more information
Schedule Event On/Off
Heat On/Off
Alarm. See Error Codes
for more information
334129D
93
Appendix A— ADM
Operation Screens
Color
Yellow
Home
Green/Yellow Flashing
A and B Zone Status
Outside of advisory
range
Warmup
This screen shows the temperature state of the
system and material usage.
Events
The Events screens store a maximum of 200 events.
The events list can be downloaded in the USB logs.
See Appendix B — USB Data, page 100.
Note
If present, secondary systems will be shown
on the home page.
Heat--A
Heat
Tracked Events
This screen shows the target and actual temperatures
for all zones on the system.
Note
The Heat-B screen shows information for an
optional secondary system.
Color
White
Green
Red
94
A and B Zone Status
Off
On and at setpoint
temperature
Outside of alarm range
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
334129D
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
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 100.
Diagnostic--A
Diagnostic
DO: System Digital Outputs
0: Pump Solenoid
1: Not Used
2: Not Used
3: Not Used
ISO DI: Customer Digital Inputs
See Connect PLC, page 25.
ISO DO: Customer Digital Outputs
See Connect PLC, page 25.
Fan: current to fan
Heat Soak: set time for platen to heat after the platen
has reached set temperature.
Life Cycles: total number of pump cycles over life of
system
MZLP 1: temperature on MZLP 1
• 32–160°F(0–71°C)
Pump Sol: Current draw of pump solenoid
• (0 mA - off)
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.
Diagnostic Data
A Current Draw
B RTD Reading
C Duty Cycle
334129D
• (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 of material dispensed over life of system
XFMRTemp: Temperature of transformer
temperature sensor
Setup Screens
Note
It is important to set all settings in the System
screens correctly to ensure optimal system
performance.
95
Appendix A— ADM
Password
If the password is not “0000”, the password must be
entered to access the setup screens.
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.
Advanced 1
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.
Language: Language displayed on the screen.
Enable Tandem System: Enable all secondary
system ADM screens.
Date: Set the date.
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.
Date Format: Choose format of the date.
Time: Set the time.
Enter Password: If not “0000”, the Setup screens will
be password protected.
• Range: 0–120 minutes
Screen Saver: The screen will go black after the set
amount of time.
• 0 disables heat soak
Silent Mode: Disable ADM sounds.
96
334129D
Appendix A— ADM
Advanced 2
Disable USB Downloads/Uploads: Disables use of
the USB for downloading and uploading.
Disable USB Log Errors: When disabled, the system
will not warn the user when logs are full. If the logs
are full, the oldest data will be overwritten.
Download Depth: Last ___ Days: The USB download
will provide data as old as the number of days
entered. Old data may be in memory but will not be
downloaded if older than the number of days entered.
Advanced 4 and 5
Temperature Units: Units of measure for displayed
temperatures.
Mass Units: Units of measure for mass.
Specific Gravity: Required to convert the volume
dispensed to mass dispensed for tracking the total
weight and flow rate. When the specific gravity value
is populated, the total mass dispensed 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.
Advanced 3
Advanced 4 screen shows the part number and
version of each installed software module on a
primary unit and Advanced 5 shows each module
on a secondary unit.
334129D
97
Appendix A— ADM
Heat--A
Heat
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 cable 17C694 is connected to
MZLP and a heated hose.
98
334129D
Appendix A— ADM
Maintenance--A
Maintenance
Schedule
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.
Use this screen to set times that the system
will automatically enable and disable heating.
See Schedule, page 34 .
Note
The lifetime cycle count will only be reset if
the ADM is replaced.
334129D
99
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.
Download
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
The log files should be opened in a spreadsheet
program.
Note
If emailing the files, zip (compress) them to
minimize file size.
Upload
Upload a system configuration file and/or a custom
language file. See System Settings File, page 101 or
System Language File, page 102.
1. If necessary, follow the
Download Instructions, page 100, 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.)
If the pop-up screen does not appear,
the flash drive is not compatible with the
ADM. Try a different flash drive.
6. If installing the system settings file, place
SETTINGS.TXT file into UPLOAD folder.
Note
7. If installing the custom language file, place
DISPTEXT.TXT file into UPLOAD folder.
The system can log up to 45 mb of
additional data per week, depending on
system operation.
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.
11. Remove USB flash drive from USB port.
100
334129D
Appendix B — USB Data
Note
GCA Log
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
Black Box, Diagnostics Log
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.
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
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.
Procedure, to retrieve log files.
Follow the Download Procedure
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.
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 100, 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.
334129D
101
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.
Modify the second column of the custom
language file as needed and then follow the
Upload Instructions, page 100, 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.
• U+0020 - U+007E (Basic Latin)
4. Do not add or remove rows to the file.
• U+00A1 - U+00FF (Latin-1 Supplement)
5. Do not change the order of the rows.
• U+0100 - U+017F (Latin Extended-A)
6. Define a custom string for each row in the second
column.
• U+0386 - U+03CE (Greek)
• U+0400 - U+045F (Cyrillic)
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.
102
334129D
Dimensions
Dimensions
Ram Mounting and Clearance
A
in.
(mm)
40
(1016)
B
in.
(mm)
28
(711)
Height (H)
Fully Raised
Fully Lowered
334129D
C
in.
(mm)
36
(914)
D
in.
(mm)
22
(558)
E
in.
(mm)
24
(609)
F
in.
(mm)
40.8
(1036)
G
in.
(mm)
29.7
(754)
J
in.
(mm)
11
(279)
K
in.
(mm)
L
in.
(mm)
M
in.
(mm)
60
6 (152) 1 (25.4)
(1524)
P
in.
(mm)
62
(1574)
Dimensions
74.3 in (1887 mm)
57.3 in (1455 mm)
103
Dimensions
15:1 Pump
A
B
D
E
K
L
M
N
P
G
in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm)
29.7
38.5
40 (1016) 28 (711) 22 (558) 24 (609)
6 (152)
1 (25.4) 48 (1219)
62 (1574)
(754)
(977)
Height (H)
Fully Raised
Fully Lowered
104
Dimensions
73.5 in (1866 mm)
56.5 in (1435 mm)
334129D
Notes
Notes
334129D
105
Technical Specifications
Technical Specifications
Metric
U.S.
Air inlet size
Air motor sound data
Wetted Parts
1/2 npsm(f)
See air motor instruction manual.
carbon steel, brass, chrome, zinc, nickel plating, stainless steel (304,
316, 440, and 17–4 PH), alloy steel, ductile iron, PTFE
Merkur and NXT
President
1.24 in2
0.884 in2
8 cm2
5.7 cm2
Merkur and NXT
President
11.7 in3
3.8 in3
192 cm3
62.3 cm2
Merkur and NXT
President
21
61
Merkur and NXT
President
President 4.25 in
100 psi
100 psi
100 psi
0.7 MPa, 7 bar
0.7 MPa, 7 bar
0.7 MPa, 7 bar
Merkur and NXT
President
400°F
400°F
204°C
204°C
Merkur and NXT
President
1 in npt(f)
1/2 in npt(f)
Merkur 6.0 in
Merkur 7.5 in
NXT 6500
President 4.25 in
2300
3000
3000
1800
Merkur 6.0 in
Merkur 7.5 in
NXT 6500
President 4.25 in
100 psi
82 psi
43 psi
120 psi
Compressed Air (typical)
106
psi
psi
psi
psi
15.9
20.7
20.7
12.6
MPa,
MPa,
MPa,
MPa,
159
207
207
125
bar
bar
bar
bar
0.7 MPa, 7 bar
0.57 MPa, 5.7 bar
0.29 MPa, 2.9 bar
0.8 MPa, 8.3 bar
25–50 scfm
334129D
Technical Specifications
Voltage (as selected)
220/240 V, 3-phase, 50/60 Hz
380/400 V, 3-phase, 50/60 Hz
470/490 V, 3-phase, 50/60 Hz
575 V, 3-phase, 50/60 Hz
(includes drum melt grid, pump, and a 6kVa transformer for the 230 V hoses and accessories)
6.4 kVa
Standard melt grid platen with
President pump
8.7 kVa
Standard melt grid platen with
Merkur or NXT pump
6.4 kVa
Smooth melt grid platen with
President pump
8.7 kVa
Smooth melt grid platen with
Merkur or NXT pump
334129D
107
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
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 or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original Instructions. This manual contains English. MM 334129
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision D, October 2015

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