Graco 334130A - Therm-O-Flow 200 Instructions

Instructions-Parts
Therm-O-Flow® 200
334130A
EN
For applying hot melt sealant and adhesive materials from 200 Liter (55 Gallon) drums. For professional
use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this manual and in related
manuals. Save these instructions.
Maximum Operating Temperature 400°F
(204 °C)
See page 6 for model information.
See Technical Specifications, page 107,
for maximum working pressures.
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Warnings ............................................................. 3
Models................................................................. 6
Related Manuals .................................................. 7
Component Identification....................................... 8
Advanced Display Module (ADM).................. 12
Overview............................................................ 15
Air and Fluid Hoses...................................... 15
Heat Control Zone........................................ 15
Setup................................................................. 16
Unpack........................................................ 16
Location Requirements................................. 16
Install System .............................................. 16
Install Hydraulic Power Supply...................... 16
Mechanical Setup ........................................ 17
Install Heated Hose...................................... 18
Connect Multiple Devices ............................. 20
Connect Power ............................................ 21
Grounding ................................................... 22
Connect Secondary System.......................... 22
Check Sensor Resistance ............................ 23
Check Heater Resistance ............................. 24
Select ADM Settings .................................... 25
Connect PLC ............................................... 27
Operation........................................................... 30
Purge System.............................................. 30
Load Material............................................... 31
Heat Up System........................................... 32
Prime Pump ................................................ 33
Prime System .............................................. 35
Setback Mode.............................................. 35
Pressure Relief Procedure............................ 36
Shutdown .................................................... 37
Schedule..................................................... 37
Change Drums ............................................ 38
Troubleshooting.................................................. 39
Repair................................................................ 46
Replace Wipers ........................................... 46
Replace Platen RTD .................................... 46
2
Separate the Air Motor and Pump ................. 47
Remove Platen ............................................ 49
Replace Heater Bands and Pump
RTD............................................... 50
Replace MZLP Fuse .................................... 51
Replace MZLP............................................. 52
Replace MZLP Daughter Card ...................... 53
Replace AWB .............................................. 54
Replace Power Supply ................................. 54
Replace Fan................................................ 55
Replace Transformer.................................... 56
Update Software .......................................... 58
Electrical Schematics.......................................... 59
Parts.................................................................. 65
Accessories and Kits........................................... 89
Wiper Kits.................................................... 89
Applicators and Dispense Valves .................. 89
Air-Operated Heated Dispense Valves........... 89
Flow Control and Manifolds .......................... 89
Accessory Extension Cables......................... 89
Light Tower Kit, 24W589 .............................. 89
Tie Rod Kits................................................. 89
8 Zone Upgrade Kit Installation ..................... 93
12 Zone Upgrade Kit Installation ................... 95
Appendix A— ADM............................................. 96
Operation Screens ....................................... 98
Setup Screens ............................................. 99
Appendix B — USB Data .................................. 103
Download .................................................. 103
Access Files .............................................. 103
Upload ...................................................... 103
USB Logs.................................................. 104
System Settings File .................................. 104
System Language File................................ 105
Create Custom Language Strings ............... 105
Dimensions ...................................................... 106
Technical Specifications.................................... 107
Graco Standard Warranty.................................. 108
334130A
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
and disconnect all power sources.
Pressure Relief Procedure
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.
334130A
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.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce
skin. This may look like just a cut, but it is a serious injury that can result in amputation.
Get
immediate surgical treatment.
•
•
•
•
•
Engage trigger lock when not dispensing.
Do not point dispensing device at anyone or at any part of the body.
Do not put your hand over the fluid outlet.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Follow the
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.
Pressure Relief Procedure
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in
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
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.
•
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.
work area
Grounding
Stop operation immediately
4
.
334130A
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
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
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.
Technical Data
Pressure Relief Procedure
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.
334130A
5
Models
Models
The model number stamped on your systems defines the equipment in the following categories.
See Technical Specifications, page 107, for maximum working pressure.
SER
Series
A
Frame Size
B
Air
Air/Electric
Zone
Config
Code A Frame Size
200 55 Gallon (200 Liter)
Code B Air/Electric
A
E
Air control only
Air and Electric
Code C Zones, Volts, Type
11P
11S
12P
12S
13P
13S
14P
14S
15P
15S
21P
21S
22P
22S
23P
23S
24P
24S
25P
25S
31P
31S
32P
32S
33P
33S
34P
34S
35P
6
C
4 Zones, 230 V, Primary
4 Zones, 230 V, Secondary
4 Zones, 400 V/N, Primary
4 Zones, 400 V/N, Secondary
4 Zones, 400 V, Primary
4 Zones, 400 V, Secondary
4 Zones, 480 V, Primary
4 Zones, 480 V, Secondary
4 Zones, 575 V, Primary
4 Zones, 575 V, Secondary
8 Zones, 230 V, Primary
8 Zones, 230 V, Secondary
8 Zones, 400 V/N, Primary
8 Zones, 400 V/N, Secondary
8 Zones, 400 V, Primary
8 Zones, 400 V, Secondary
8 Zones, 480 V, Primary
8 Zones, 480 V, Secondary
8 Zones, 575 V, Primary
8 Zones, 575 V, Secondary
12 Zones, 230 V, Primary
12 Zones, 230 V, Secondary
12 Zones, 400 V/N, Primary
12 Zones, 400 V/N, Secondary
12 Zones, 400 V, Primary
12 Zones, 400 V, Secondary
12 Zones, 480 V, Primary
12 Zones, 480 V, Secondary
12 Zones, 575 V, Primary
D
Pump
Ratio
E
F
G
Platen
Platen
Ram
Style
Seal
35S 12 Zones, 575 V, Secondary
NNN None
H
Drum
Clamp
Code D Pump Ratio
1
2
3
4
5
6
Code
E
S
F
M
Code
F
1
2
3
4
Code
G
P
H
Code
H
N
1
2
3
23:1 CF
(carbon filled PTFE)
36:1 CF
70:1 CF
23:1 GF
(glass filled PTFE)
36:1 GF
70:1 GF
Platen Style
Smooth Bottom (No Fin)
Standard Finned Bottom
Mega-Flo
Platen Seal
2 Black EPDM/EPDM, SS wire braid
400°F (204°C) hose wipers with spring
retention
1 lower Black EPDM/Chlorobutyl, SS wire
braid 400°F (204°C) hose wiper and 1
upper Green Silicone, fiberglass braid
400°F (204°C), hose wiper
2 White Silicone 250°F (121°C) T-Wipers
1 lower Black EPDM/Chlorobutyl, SS
wire braid 375°F (190°C) hose wiper and
1 upper White Silicone 375°F (190°C)
T-wiper
Ram
Pneumatic
Hydraulic
Drum Clamps
None
Saddle Clamp
Fiber Clam Shell
Heavy Drum Band
334130A
Related Manuals
Related Manuals
Manual
Description
Air Motor Manuals
311238
3A1211
NXT® Air Motor, Instructions-Parts
Saniforce® Air Motor,
Instructions-Parts
Displacement Pump Manual
334127
334128
Check-Mate® 800 Pump,
Repair-Parts
Check-Mate® 800 Throat Seal Repair
Kit, Repair-Parts
Ram Manual
334198
Therm-O-Flow 200 Pneumatic and
Hydraulic Ram, Instructions-Parts
Accessory and Kit Manuals
309160
309196
310538
311209
334201
334130A
Heated Hose, Instructions-Parts
Wiper Kits, Repair-Parts
Air-Operated Dispense Valves,
Instructions-Parts
Top Feed and Bottom Feed Hot Melt
Dispense Guns, Instructions-Parts
Air Controls, Repair Kit
7
Component Identification
Component Identification
Figure 1 TOF 200 Pneumatic
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
334130A
Component Identification
Integrated Air Controls
Figure 2 Integrated Air Controls
Key:
CA
Key:
Main Air Slider Valve
Turns air on and off to the entire system.
When closed, the valve relieves pressure
downstream.
CB
Ram Down Air Regulator
CC
Ram Director Valve
CD
Ram Up Air Regulator
CE
Ram Down Air Gauge
CF
Ram Up Air Gauge
CG
Controls the ram down pressure.
Controls the ram direction.
Controls the ram up pressure.
CH
CJ
Blowoff Air Regulator
CK
Air Motor Air Regulator
CL
Air Motor Pressure Gauge
CM
Air Motor Slider Valve
Displays the ram down pressure.
Displays the ram up pressure.
Blowoff Button
Turns air on and off to push the platen out of
an empty drum.
334130A
Blowoff Pressure Gauge
Displays the blowoff pressure.
CN
Controls platen blowoff pressure.
Controls the air pressure to the motor.
Displays the air pressure to the motor.
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
10
334130A
Component Identification
Key:
DA
DB
DC
DD
DE
DF
334130A
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
Key:
DG
DH
DJ
DK
DL
DM
Platen SSR (65A)
Platen Contactor
Platen Fuse
Transformer Circuit Breaker
Transformer Fuse
Transformer
11
Component Identification
Advanced Display Module (ADM)
The ADM display shows graphical and text
information related to setup and spray operations.
For detail on the display and individual screens, see
Appendix A— ADM, page 96.
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 103.
NOTICE
To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.
Figure 4 Front View
Key
BA
BB
BC
BD
BE
BF
BG
BH
12
Function
Heating system and pump enable/disable
System status indicator (LED)
Stop all system processes
Defined by icon next to softkey
Abort current operation
Accept change, acknowledge error, select item,
toggle selected item
Toggle between Operation and Setup screens
Navigate within a screen or to a new screen
334130A
Component Identification
Figure 5 Back View
BK
Part Number and Identification Label
BL
USB Interface
BM 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
USB Status (BL)
ADM Status (BN)
Conditions
Description
Green Flashing
Yellow Solid
Green and Yellow Flashing
Data recording in progress
Downloading information to USB
ADM is busy, USB cannot transfer
information when in this mode
Power applied to module
Active Communication
Software upload from token in
progress
Module error exists
Green Solid
Green Flashing
Yellow Solid
Green Solid
Yellow Solid
Red Steady Flashing
Red Random Flashing or Solid
334130A
Run Mode, System On
Setup Mode, System On
Run Mode, System Off
13
Component Identification
Screen Components
1.
2.
3.
4.
5.
6.
7.
Operating Mode
System Off
Inactive
Warm Up
Heat Soak
Ready
Active
14
Description
The system does not have power.
Screen Order
Current date and time
Operating Mode
Faults, Status
MZLP Plug Identifier
Zone Setpoint Temperature
Zone Actual Temperature
Component Status
• No system status indicator LED on the
ADM
• No heat
• Pump is off
The heating system and pumps are
• Yellow system indicator LED on the
disabled.
ADM
• No heat
• Pump is off
The system is heating the material to the • Flashing green system status indicator
setpoint temperature.
LED on the ADM
• Heat is increasing to setpoint
temperature
• Pump is off
• Flashing green system status indicator
Heat zones are all at temperature.
LED on the ADM
Material is soaking for a user specified
amount of time.
• Heat is at setpoint
• Material is absorbing more heat
• Pump is off
• Heat soak counter counts down on the
Home screen.
• Flashing green system status indicator
All enabled zones are at setpoint
temperature. The air motor does not have LED on the ADM
power.
• Heat is at setpoint
• Pump is off
The system is ready to dispense.
• Solid green system status indicator
LED on the ADM
• Heat is at setpoint temperature
• Pump is on
334130A
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
334130A
15
Setup
Setup
1.
2.
3.
4.
5.
6.
7.
Unpack the ram
Locate and Install the ram
Mechanical Setup
Connect hoses to electrical control panel
Connect electrical control panel to power source
Ground system
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
Location Requirements
1. Make sure there is sufficient overhead clearance
for the pump and ram when the ram is in the fully
raised position (approximately 110 in. (280 cm).)
2. If you are installing a vent hood, make sure there
is sufficient horizontal clearance for it. Locate the
ram near a connection to the factory ventilation
system.
3. Make sure the air regulators for the pump and
ram are fully accessible, with room to stand
directly in front of the pneumatic control panel
and the electrical control panel.
16
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. For hydraulic rams, locate the hydraulic power
supply in an area that has:
• easy access for servicing and adjusting the
hydraulic pressure on the supply unit.
• sufficient clearance for the hydraulic lines that
attach to the pump.
• easy access to read the hydraulic fluid level
gauge.
Install System
Refer to Dimensions, page 106 for mounting and
clearance dimensions.
Follow all Location Requirements, page 16, when
selecting a location for the ram.
1. Apply 50 psi download pressure to ram.
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.
Install Hydraulic Power Supply
See the Ram manual for installation and dimensions.
334130A
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. 24D086) 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.
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
MPa, 7.0 bar).
.
Do not use quick disconnects
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.
5. Increase the distance between the low (C1) and
empty (C2) sensors to increase the heat up time
for the tandem secondary system. Lower the
drum empty sensor (C2) to force the heated
platen lower into the drum. If empty sensor is set
too low, the pump could cavitate and cause an
alarm.
Figure 8 Air Connection
334130A
17
Setup
Install Heated Hose
To connect a hose to a fluid control device or heated
manifold.
1. Install fitting and heated hose onto pump outlet
with the large electrical connector side toward
the system. Use 2 wrenches to tighten hose.
Torque to 45 ft-lbs (61 N•m).
Note
See Accessories and Kits, page 89 for
available fittings and heated hoses.
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 cable
from track.
18
Figure 10
4. Repeat for any remaining channels.
Note
Only two accessory cables fit in cable
track. Additional cables for 8 zone and
12 zone systems are shipped loose.
5. Install cap on any unused MZLP electrical
connectors.
334130A
Setup
6. Connect the small 8 pin connector from the
heated hose to the fluid control device or heated
manifold.
Figure 11 Heated Manifold 243697
Note
The heated manifold (part no. 243697)
is included with all secondary systems.
See Accessories and Kits, page 89 for
available manifolds.
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 20.
334130A
19
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 89.
• 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.
Figure 12
20
334130A
Setup
Connect Power
The electrical control panel comes already attached
and wired to the ram, however before the supply unit
becomes functional you must connect the electrical
control panel to a power source.
All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
power source wires to the appropriate terminals
on the DISCONNECT switch.
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.
Table 2 Electrical Requirements
Electrical
Panel
Full
Hz
Phase
Platen
Load
Amps
Voltage
220 /
240
50/60
3
380 /
400
50/60
3
470 /
490
50/60
3
570 /
590
50/60
3
EF, ES
EM
EF, ES
EM
EF, ES
EM
EF, ES
EM
70
80
42
48
35
40
29
32
To reduce the risk of fire, explosion, or electric
shock, the resistance between the supply unit
components and true earth ground must be
less than 0.25 ohms.
3. Connect the ground wire to the ground lug.
Have a qualified electrician check the resistance
between each Therm-O-Flow system ground and
the true earth ground. The resistance must be
less than 0.25 ohms. If the resistance is greater
than 0.25 ohms a different ground site may be
required. Do not operate the system until the
problem is corrected.
Note
Use a meter that is capable of measuring
resistance at this level.
EF Standard Finned Bottom
EM Mega-Flo
ES Smooth Bottom
1. Locate the opening in the control panel’s top
housing for the conduit that will enclose the wire
from the facility’s power source. The hole will
accept a a cord diameter range of 0.7–1.2 in
(17–30 mm).
2. Thread the wire from the power source into the
control panel housing, and then connect the
334130A
21
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.
Material drums:
To maintain grounding continuity when flushing
follow instructions in your
separate gun manual for instructions on how to safely
ground your gun while flushing.
or relieving pressure:
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, page 21.
use only electrically conductive
hoses.
follow manufacturer’s
recommendations.
/
ground through
connection to a properly grounded fluid hose and
pump.
System:
Air and fluid hoses:
Air compressor:
Spray gun
Dispense valve:
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 rout to splitter (SS) installed on the primary
system.
2. To enable a secondary system, select “Enable
Tandem System” on the System 1 screen. See
Select ADM Settings, page 25.
Figure 14
22
334130A
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.
1,2
The package includes up to twelve heat sensors and
controllers for each of the heated zones. To check
sensor resistance:
1. Turn main power switch off.
1
3,4
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
Second Heat Zone
First RTD
Second RTD
Earth Ground
A,J
C,D
G, K
M, K
B
5,6
2
Cable 17C694
J
MZLP Plug
A
M
K
7,8
H
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.
ti24580a
9,10
3
11,12
334130A
Component
Ram Plate
Fluid Pump
Heated
Accessory
1
Heated
Accessory
2
Heated
Accessory
3
Heated
Accessory
4
Heated
Accessory
5
Heated
Accessory
6
Heated
Accessory
7
Heated
Accessory
8
Heated
Accessory
9
Heated
Accessory
10
Heated
Accessory
11
Heated
Accessory
12
RTD Range
(Ohms)
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
100 +/- 2
23
Setup
2. Make electrical resistance checks for the
components.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in tables.
Check Heater Resistance
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
For Unit Voltage
Platen Model Code
Terminals
AD, BE, FC 220/240 VAC
AD, BE, FC 380/400 VAC
470/490 VAC
AD, BE, FC 570/590 VAC
Any to GND All
Component
Pump
24
Between Terminals
T1/T3, T2/T3,
B1/B3, B2/B3
For Unit Voltage
Any
Resistance Values (ohms)
EM
EF, ES
EM
EF, ES
EM
EF, ES
EM
EF, ES
Any
Platen Model Code
Any
8.25Ω +1 / -2Ω
9.6Ω +2 / -3Ω
16.5Ω +1 / -2Ω
19.2Ω +2 / -3Ω
16.5Ω +1 / -2Ω
19.2Ω +2 / -3Ω
16.5Ω +1 / -2Ω
19.2Ω +2 / -3Ω
100,000Ω Min
Resistance Values (ohms)
192.0 +/- 19.2Ω
334130A
Setup
Select ADM Settings
Note
See Appendix A— ADM, page 96 for
detailed ADM information, including general
operation.
1. Turn main power switch on.
2. When the ADM is finished starting up, press
to switch from the Operation screens to
the Setup screens. Use the arrows to navigate
between screens.
3. Check system settings on the System 1 screen.
4. Set alarm levels on the System 2 screen.
Note
Setback temperatures must be at least
20°F (10°C) lower than the setpoint
temperatures
Note
To ensure accurate hose temperatures,
be sure all heated hoses have their
“zone type” set to “Hose.” Hoses are only
present on odd zone numbers: 1, 3, 5,
7, 9, or 11.
a. Select the appropriate “Zone Type” for all
installed zones.
b. Check the “A” and “B” boxes according to
which systems needs to use the heated
accessory.
6. If a secondary system is used, set temperatures
on the Heat-B screens.
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.
334130A
25
Setup
8. Set the temperature and mass units on the
Advanced 2 screen. Set the specific gravity of
the material for Material Tracking functionality.
9. To setup the optional Schedule function, see
Schedule, page 37.
The schedule function allows the system to
automatically enable and disable heating and
setback at specified times.
10. Optional: Set any remaining settings in the Setup
screens before using the system. These are not
required for system operation, but include useful
functions. See Appendix A— ADM, page 96 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.
26
334130A
Setup
Outputs shown on the Diagnostics screen. See
Appendix A— ADM, page 96.
When the PLC has control of the system:
• Functionality is restricted from the ADM
• Automatic crossover is disabled. Rely on the PLC
and machine state indicators to know when to
cross over using the I/O.
Connect PLC
A PLC can control and monitor all items
shown in the Customer Digital Inputs and
Table 5 Customer Input
Unit A
Signal Number
1
2
Description – Unit A
Turn on the Heat
Put the Unit in
Setback
Pump On Request Turn on the Pump
PLC Control
Unit A - Control the
Request
TOF from the PLC
instead of the ADM
Heat On Request
Setback Request
3
4
Unit B
Description – Unit B
Turn on the Heat
Put the Unit in
Setback
Pump On Request Turn on the Pump
Unit B – High make
Unit B Control
Unit B the active
Request
unit. Low Unit A is
active
Heat On Request
Setback Request
Table 6 Customer Output
Unit A
Signal Number
1
2
3
Description – Unit A
Run State Bit Low See Run State Chart
Run State Bit High See Run State Chart
Error State Bit Low See Error State
Chart
Error State Bit High See Error State
Chart
4
Table 7 Output Error States
Error State Bit
Error State Bit
High
Low
0
0
0
1
1
0
1
1
Machine is
good, no errors
are present
Active Unit
Drum Low
Active Unit
Drum Empty
Alarm Present
in System
Run State Bit
High
Low
0
1
0
334130A
0
Pump Off/ Heat
Off
Pump Off/ Heat
On
Description – Unit B
Run State Bit Low See Run State Chart
Run State Bit High See Run State Chart
Unit B IS Active Unit Unit B is the Active
Unit
Inactive Unit
The drum is empty
Drum Empty
on the inactive unit
Run State Bit
Run State Bit
High
Low
1
1
1
Table 8 Output Run States
Run State Bit
Unit B
0
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
open when an alarm occurs. For all others,
contacts close.
Note
The TOF system ships with two screw
terminal connectors that plug into MZLP
connectors H1 and H2. Connectors are
located in a bag on the inside of the electrical
enclosure. To replace the connectors, order
kit 24P176.
1. Turn main power switch off.
27
Setup
2.
3.
4.
5.
Open the electrical enclosure door.
Route I/O cables through strain relief.
Remove power from the PLC.
Connect the PLC to connectors H1 and H2.
H1 Customer Input
Signal
1
2
3
4
Note
Each connector has four signals. The
MZLP board specifies the input range for
each signal. See the following table for
pin assignments.
Pin
1,2
3,4
5,6
7,8
H2 Customer Output
Signal
1
2
3
4
Pin
1,2
3,4
5,6
7,8
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.
0–250 VAC, 0–30 VDC, 2A Maximum.
Inputs:
Outputs:
Figure 15
28
334130A
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
334130A
29
Operation
Operation
1. Turn the main power switch ON. The Graco logo
will display until communication and initialization
is complete.
2. Press the
button. Verify the machine is
in “Warm Up” state, and that the temperatures
are increasing. Allow the system to reach the
“Ready” state before pumping. The pump will
automatically turn on, if autostart is enabled in
setup screens, when all the heat zones reach
their setpoint temperature.
Purge System
NOTICE
Purge the system before initial use and when
chemicals are changed to prevent material
contamination, which may cause the material to
fail or perform poorly. The system was 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.
30
NOTICE
Use fluids that are chemically compatible with
the equipment wetted parts. See Technical
Specifications in all of the equipment manuals.
1. Select the material for the initial material load.
2. Verify whether the factory-test oil and the initial
material load are compatible:
a. If the two substances are compatible omit the
remaining steps in this procedure and refer
to Load Material, page 31.
b. If the two substances are incompatible
perform the remaining steps in this procedure
to flush the system.
3. Select a drum of material that can eliminate the
factory-test oil from the system. If necessary,
check with Graco or the material supplier for a
recommended solvent.
4. Before purging be sure the entire system
and waste drum are properly grounded. See
Grounding, page 22.
5. Turn all heat zones’ setpoint temperature to the
material manufacturer’s recommended dispense
temperature, or a minimum of 100°F (37°C)
minimum.
Note
Remove any dispense valve orifices
before purging. Reinstall after purging
has been completed.
6. Purge the material through the system for
approximately 1 to 2 minutes.
7. Remove the drum if purge material was used.
See Change Drums, page 38.
334130A
Operation
Load Material
NOTICE
To prevent damage to platen wipers, do not use a
drum of material that has been dented or damaged.
An empty drum clamp can interfere with up and
When raising the
ram, make sure the drum clamp stays clear of the
platen.
down operation of the ram.
Note
Before loading material, make sure there is a
minimum overhead clearance of 110 in. (280
cm) and all air regulators are backed off to
their full counterclockwise position.
1. Open the main air slider valve (CA).
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
3. Apply a thin coating of high temperature grease
lubricant (part no. 115982) to the platen drum
seals.
334130A
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. 24D086) 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.
Figure 19 Wetcup
5. Open drum, remove any packing material, and
inspect material for any contamination.
6. Slide the drum between the drum centering
guides and against the stops at the back of the
ram baseplate.
Figure 20 Drum Placement
31
Operation
7. Remove the platen bleed stick (R).
Figure 21 Platen Bleed Handle
8. Set ram director valve (CC) to down.
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.
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.
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 drum.
10. After the platen seals enter the material drum,
adjust the ram down air regulator (CB) to 30–50
psi (207–345 kPa, 2.1–3.4 bar).
11. When the ram stops, reinsert the platen bleed
stick (R) and hand tighten.
32
2. Press the
button. The zones begin to
heat (provided they are enabled). Press
if the zones do not begin to heat.
Display status bar reads
. When
temperature reaches setpoint, the display
status bar reads
. When heat is on,
the status will display in the status bar. See
Advanced Display Module (ADM), page 12, for
operation mode descriptions.
Warm Up
Heat Soak
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.
334130A
Operation
Prime Pump
1. Ensure that the system has completed the heat
soak cycle. The display status bar should read
.
2. Adjust the air motor air regulator (CK) to 0 psi.
Active
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.
5. Adjust the air motor air regulator (CK) to
approximately 20 psi (138 kPa, 1.38 bar).
6. Place a waste container under the bleed stem
(Z). Using an adjustable wrench, open the bleed
stem counterclockwise 1/3 -1/2 turn.
4. Adjust the air motor slider valve (CM) to the open
position.
334130A
33
Operation
7. If a new drum 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.
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
material tracking.
34
on home screen to enable
334130A
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
2. If using a manual gun, lock the dispense valve
trigger open by pulling and securing the trigger
using the trigger retainer (Z).
9. Press
to engage material tracking.
10. Turn the air motor regulator to operating
pressure.
Note
The system is now ready to operate.
Setback Mode
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.
334130A
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 99.
35
Operation
Pressure Relief Procedure
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.
3. Set the ram director valve (CC) to the neutral
position.
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.
5.
6.
7.
Figure 24 Engaged
2. Close the system master air slider valve (CA).
36
8.
Figure 25 Disengaged
Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
Engage the trigger lock.
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.
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.
334130A
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
Color
Green
Yellow
Red
Gray
Description
System on
Setback
System off
Disabled
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
Schedule
The Schedule function allows the user to specify
times when the system will automatically turn ON and
OFF the heaters and pump.
The Schedule function is automatically enabled
when values are entered in the Schedule screen. To
disable a scheduled event, navigate to the event and
press
.
The event will appear gray on the screen when it
is disabled. To re-enable an event, navigate to the
event and press
.
The event will appear red (system off), yellow (system
setback), or green (system on). If no events are
needed, turn the main power switch OFF to prevent
system from automatically enabling and disabling the
heaters.
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.
334130A
37
Operation
2. Push in the air motor slider valve (CM) to stop
the pump.
Change Drums
To prevent serious burns from dripping material,
never reach under the heated platen after the
platen is out of the drum.
Follow the procedure to change the drum on a fully
heated system.
NOTICE
Be sure to reload the empty supply unit with a full
Do not raise the ram
and remove the platen from the empty drum until
you are ready to immediately install a new drum.
drum of material immediately.
Do not raise the ram and remove the platen from
the empty drum unless the supply unit is at full
Drum changes can only be
performed when the system is heated.
operating temperature.
3. Set ram director valve (CC) to UP and raise the
platen (G) and immediately press and hold the
blowoff buttons (CG) until the platen is completely
out of the drum. Use minimum amount of air
pressure necessary to push the platen out of the
drum.
An empty drum clamp can interfere with the up
When raising or
lowering the ram, make sure the drum clamp stays
clear of the platen assembly.
and down operation of the ram.
Do not use a drum of material that has been
dented or otherwise damaged;
platen wipers can result.
damage to the
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.
Excessive air pressure in the material drum
could cause the drum to rupture, causing
serious injury. The platen must be free to move
out of the drum. Never use drum blowoff air
with a damaged drum.
4. Release the blowoff air button and allow the ram
to rise to its full height.
5. Remove the empty drum.
6. Inspect platen and if necessary, remove any
remaining material or material build-up.
7. Follow steps in Load Material, page 31, and
Prime Pump, page 33.
38
334130A
Troubleshooting
Troubleshooting
Light Tower (Optional)
Signal
Description
Red Light Off 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)
Error Codes
There are three types of errors that can occur. Errors
are indicated on the display as well as by the optional
light tower.
Alarms are indicated by . This condition indicates
a parameter critical to the process has reached a
level requiring the system to stop. The alarm needs
to be addressed immediately.
Deviations are indicated by . This condition
indicates a parameter critical to the process has
reached a level requiring attention, but not sufficient
enough to stop the system at this time.
Advisories are indicated by . This condition
indicates a parameter that is not immediately critical
to the process. The advisory needs attention to
prevent more serious issues in the future.
To acknowledge the error, press .
The third digit, or sometimes the last digit of the error
code, indicates which unit the error is active on. The
“★” (star) character indicates the code applies to
multiple system components.
Third or Last Digit
A
B
334130A
Codes Relates To:
Unit A
Unit B
The last digit of the error code indicates which
zone, pump, or platen 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
V
W
X
Y
Codes Relates To:
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
AWB Unit A
AWB Unit B
Daughter Board Unit A
Daughter Board Unit B
39
Troubleshooting
Code
A3MF
A4★_
A4C_
A7★ _
A8★_
Description
Type
AWB Clean Fan Alarm
Filter
High Current Alarm
Unit _ Zone _
Cooling inlet
screen is dirty
Defective or
shorted to
ground on
zone
High Current Deviation Fan is drawing
too much
Fan AWB, Unit
current
_
Unexp. Curr. Alarm
Unexpected
Unit _ Zone _
current flow to
zone
No Current Unit Alarm
No Current
_ Zone _
Flow to the
Zone
AWB No Fan
Current
High Current
SSR MZLP _
Alarm
AM4 _
High Current
Contactor
MZLP _
Alarm
AM8_
No Current
Contactor
MZLP _
Comm Error
MZLP _
Alarm
A8C_
AM3 _
CAC_
Cause
Alarm
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.
CACX
DB Not Present Alarm
Unit A
Daughter
Board not
responding
CACY
DB Not Present Alarm
Unit B
Daughter
Board not
responding
CACV
AWB not
present Unit
A
Alarm
AWB not
responding
40
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.
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 1. Set to 1 on board with
daughter board.
Ensure connections between the ADM and hardware
are secure.
Replace Daughter Board
Dial not set correct on MZLP 4. Set to 4 on board with
daughter board.
Ensure connections between the ADM and hardware
are secure.
Replace Daughter Board
Replace AWB
Ensure connections between the ADM and hardware
are secure.
334130A
Troubleshooting
Code
Description
DA★X
Pump Runaway
Detected
DE★X
Reed Switch
Failure
Detected
DC★X
Pump Diving
L1★X
Material Level
Sensor Error
L2★X
Material Level
Empty
Material Level
Low
USB Log Full
CACW
L3★X
MMUX
MN★X
334130A
AWB not
present Unit
B
Pump _
Requires
Maintenance
Type
Alarm
Cause
AWB not
responding
Solution
AWB 2 jumper was not in place at start up
Ensure connections between the ADM and hardware
are secure.
Replace AWB
Alarm
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
Alarm
Reed switch Check that sensor cable is plugged into the daughter
failed
board at J16.
Check for loose connection at reed switch. Ensure
reed switch is securely attached to the air motor.
Replace if necessary.
Alarm
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.
Inspect pump seals and replace if necessary
Worn or
damaged
pump seals
Alarm
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
Alarm
Material drum Replace material container. If more material is
is empty
leftover, lower the empty level sensor.
Deviation Material level Replace at appropriate time
is low
Advisory USB logs fulls. Download USB data or disable the USB log errors on
Data loss will the Advanced screen 3.
occur if not
downloaded.
Advisory User defined Perform pump maintenance, then reset the counter
on the maintenance setup screen
pump
maintenance
counter has
run out
41
Troubleshooting
Code
T1★ _
T2★_
T3★ _
T4C_
T4M_
T4★_
T6★ _
T6C_
T8V _
V1I_
V1M_
V4I_
42
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
Replace accessory
Low Temp. Unit Deviation Zone
Reduce flow rate
_ Zone _
temperature Change Low Temp Alarm
too low
Add zone (temperature) upstream
High Temp.
Deviation Temperature Change High Temp Alarm
Unit _ Zone _
reading has Verify setpoint upstream is not hotter than this zone’s
risen too high setpoint
Alarm
AWB
Cooling fan Ensure inlet and outlets are not obstructed.
Temperature
not working Verify fan is plugged in.
Runaway
or inlet is
Transformer
blocked/dirty
Alarm
AWB High
Transformer Ensure inlet and outlets are not obstructed.
Transformer
Temperature Verify fan is plugged in.
Temp
is too High
High Temp.
Alarm
Temperature Change High Temp Alarm
Unit _ Zone _
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.
Sensor Err. Unit Alarm
Reading
_ Zone _
Replace RTD
AWB Invalid Alarm
Transformer Verify thermister is securely connected to J7 of the
Thermistor
AWB. Replace transformer if necessary.
thermistor
Reading
temperature
is incorrect
No Temp. Rise Alarm
Temperature Check fuses on MZLP connected to that Zone
Unit _ Zone _
reading does Check wiring to device
not change. Check heater resistance on device
Verify power supply voltage is 24 VDC. If voltage is
Alarm
Bad or
Low CAN
overloaded low, disconnect the power lines and re-check voltage
Voltage, MZLP
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.
Low Voltage Deviation The voltage
to the AWB
Line AWB, Unit
is below
_
threshold
Alarm
Bad or
High CAN
overloaded
Voltage, MZLP
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.
334130A
Troubleshooting
Code
Description
V8M_
No Line Voltage Alarm
MZLP _
V4M_
AWB High Line Alarm
Voltage
WJ1_
Alarm
Pump _
Solenoid is
disconnected
Alarm
Pump _
Solenoid High
Current
Configuration Advisory
Error USB
V6M_
WJ2_
WSUX
334130A
Wiring Error
Line MZLP _
Type
Alarm
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
Install software
USB
configuration
is not loaded
43
Troubleshooting
Ram Troubleshooting
Problem
Ram will not raise or lower.
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.
Ram raises or lowers too fast.
high.
Air leaks around cylinder rod.
Worn rod seal.
Replace o-rings in guide sleeve. See
instruction manual 310523.
Fluid squeezes past platen wipers. Ram air pressure too high.
Decrease ram air pressure.
Worn or damaged wipers.
Replace wipers.
Pump will not prime properly, or
Closed main air valve or clogged air Open air valve; clear air line.
pumps air.
line.
Not enough air pressure.
Increase air pressure.
Worn or damaged ram piston.
Replace piston. See instruction
manual 310523.
Ram directional valve closed or
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 Closed main air valve or clogged air Open air valve; clear air line.
of drum.
line.
Platen not fully up to temperature. Wait for full temperature.
Not enough blow-off air pressure.
Increase blow-off air pressure.
Blow-off valve passage clogged.
Clean valve passage.
Dented drum has stopped platen.
Fix or replace drum.
Wipers bonded to drum or drum liner. Lubricate wipers with high
temperature grease at every
drum change.
44
334130A
Troubleshooting
Heated Pump Troubleshooting
See pump manual for additional pump troubleshooting information.
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.
Leak around pump wet-cup.
Downstroke: Dirty or worn pump
intake valve.
Upstroke: Dirty or worn pump piston
valve.
Machine is out of material
Loose outlet fitting.
Loose bleed port fitting.
Problem with air motor.
Foreign object lodged in pump.
Platen not fully up to temperature.
Valve to air motor is off.
Worn throat seals.
Solution
Check and adjust temperature to
proper set point. Wait for pump/platen
to heat up.
Bleed air from pump. See
Prime Pump, page 33.
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
Air motor will not run.
Cause
Solution
Wait for heat zones in use to reach
temperature setpoint values.
Air motor stalled.
Damaged main air valve spool or
Inspect and clean poppets. See Air
poppets.
Motor Manual.
Rebuild main air valve. See Air
Motor Manual.
Air continuously exhausting around Damaged air motor shaft seal.
Replace air motor shaft seal. See
air motor shaft.
Air Motor Manual.
Air continuously exhausting around Air valve/slide valve gasket is
Replace the valve gasket. See Air
air valve/slide valve.
damaged.
Motor Manual.
Internal seal damage.
Air continuously exhausting from
Rebuild air motor. See Air Motor
muffler when motor is idle.
Manual.
Air motor operating at high pressure Reduce pressure, cycle rate, or duty
Icing on muffler.
or high cycle rate.
cycle of motor.
334130A
Air motor solenoid is off.
45
Repair
Repair
2. Make sure the ram plate is down and the ram
hand valve is in the OFF position.
Replace Wipers
1. To replace a worn or damaged wiper (V) raise
the ram plate up out of the drum. Perform steps
1 through 7 of Change Drums, page 38 . See
wiper kit manual for instructions about replacing
the wipers.
To reduce the risk of injury or damage to
equipment, make sure the main power switch
is off before continuing with this procedure.
3. Turn the main power switch off.
Figure 26 Replace Wiper
4. Remove the pump cover.
Replace Platen RTD
Reference Electrical Schematics, page 59 for wiring
connections.
1. If the material drum has already been removed
from the supply unit, go to step 2. If you
need to remove the material drum, see
Change Drums, page 38.
Figure 27 Pump Covers and Platen RTD
5. Remove the platen RTD (605) from the platen.
46
334130A
Repair
6. Disconnect the platen RTD wires from pin 3 and
pin 6 from the J5 connector on the AWB.
Figure 28
2760
2770
2790
RTD Wire Connections
Red
White
White
7. Attach the leads from the new sensor to the leads
of the old sensor and pull the new sensor leads
through the cable pump shield, cable track, and
into the electrical enclosure.
8. Install the new sensor (605) into the follower/tire
plate after coating with non-silicone heat sink
compound. Tighten compression nut. Ensure
RTD is fully inserted.
9. Connect the red and white wires from the new
sensor to the J5 connector on the AWB.
10. Replace the pump covers.
Separate the Air Motor and Pump
2. Make sure the ram plate is down and the ram
director valve (CC) is in the neutral position.
3. Follow Pressure Relief Procedure, page 36.
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).
6. Turn the main power switch off.
7. Disconnect all material hoses.
8. Remove the pump sheet metal enclosure.
a. Remove the cover screws.
b. Remove the heater bands and disconnect
the ground wire.
This procedure must be done with the unit still
warm. The material and equipment will be hot!
1. If the material drum has already been removed
from the supply unit, go to step 2. If you need
to remove the material drum, perform steps 1
through 6 of the Change Drums, page 38. Pump
must be in the full down position (air motor shaft
fully extended).
9. If vent hood is installed, remove it.
334130A
47
Repair
10. Remove the air motor top cover.
11. Disconnect electrical cable from air motor.
12. Remove air line from air motor and air lines to the
follower blow-off valve.
13. Tightly strap the air motor to the tie bar with a
cable through the air motor lift ring and around
the tie bar. See Fig 29, page 49
14. Loosen u-bolts (X) from platen lift rods.
15. Remove nuts (F) from pump/air motor stand-off
rods at the pump end.
16. Remove nuts (Z) and bolts holding cable tract to
air motor support plate.
48
17. Slide end of cable track outboard of the mounting
plate.
18. Remove nuts (N) from follower lift rods.
19. Fully loosen pump rod coupler to the air motor
rod (G).
20. Slowly raise elevator to achieve enough
separation of the pump (air motor) tie rods to
remove the pump.
21. Remove the pump.
22. Reverse this procedure to reinstall the new or
rebuilt air motor.
334130A
Repair
Figure 29
Remove Platen
334130A
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.
49
Repair
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 Drums, page 38. Pump
must be in the full down position (air motor shaft
fully extended).
2. Make sure the ram plate is down and the ram
hand valve is in the neutral position.
8. Remove white ceramic caps and disconnect the
electrical wires from heater band (309).
9. Remove the screw that holds the heater band
in place.
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.
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.
3. Follow Pressure Relief Procedure, page 36.
4. Bleed off excess material and pressure in the
system by opening the applicator and catching
the material in a waste container.
5. On ADM, turn off the system heat (D).
6. Turn the main power switch off.
7. Remove the screws and covers.
Figure 30
50
334130A
Repair
Replace Pump RTD
Fuse Kit
Fuse
Part
24V289 F1, F2 250VAC, 25A, long, white
ceramic
F3-F10 250VAC, 8A, fast acting, clear
glass
Spare fuse kit included with system.
1. Turn the main power switch off.
2. Remove the screws that hold the front shroud in
place and remove front shroud.
3. If sensor wire is connected to electrical enclosure,
disconnect it.
4. Loosen the clamp (321) holding sensor on pump.
5. Tie the leads of the new sensor (320) to the old
sensor and remove the old sensor. The leads of
the new sensor will be easily drawn through the
conduit for reconnecting.
6. Replace the sensor (320) in 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.
Replace MZLP Fuse
NOTICE
To prevent system damage, always use fast
acting fuses. Fast acting fuses are required for
short-circuit protection.
1. Turn the main power switch off.
2. Open electrical enclosure door.
3. Use a proper non-conductive fuse puller tool to
remove the blown fuse.
NOTICE
Using an improper tool, such as screw drivers
or pliers, may break glass on fuse.
Note
F1 and F2 are white ceramic and indicate
25A on the barrel.
Note
Each MZLP module comes with the following fuses:
J1
J2
F10 F9
F4 F3
F8 F7
F2
F6
F1
F5
F3-F10 are clear glass and indicate 8A
on the barrel.
4. Use a proper non-conductive fuse puller tool to
install the new fuse
NOTICE
Using an improper tool, such as screw drivers
or pliers, may break glass on fuse.
5. Close electrical enclosure.
J7
J6
J5
J3
Figure 31 Fuse Locations
334130A
51
Repair
Replace MZLP
1. Turn the main power switch off.
2. Disconnect heated hose electrical connectors
from MZLP (111 or 112).
3. Note location of each cable, then unplug all
cables from the MZLP (111 or 112) that will be
replaced.
4. Remove four screws (115) securing MZLP (111
or 112) to electrical enclosure then carefully
remove MZLP from electrical enclosure.
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
.
7. Use four screws (115) to install MZLP (111 or
112) to electrical enclosure.
8. Reconnect cables to MZLP.
MZLP Rotary Switch
Table
Note
Do not force the electrical connection.
Minimal force is required to seat the
connector. If resistance is felt, stop and
verify the connector orientation.
Note
If unable to determine connector location,
see Electrical Schematics, page 59.
9. Connect heated hose electrical connectors to
new MZLP.
Note
MZLP may need updated software. See
Update Software, page 58.
Table 10 MZLP Rotary Switch
MZLP
Figure 32 MZLP Identification
5. Replace MZLP.
a. To replace MZLP #1, remove the daughter
card and standoffs, and re-install them on
the new MZLP #1.
52
System
Primary
#1 with
Daughter Card Secondary
Primary
#2
Secondary
Primary
#3
Secondary
Rotary Switch
0
4
1
5
2
6
334130A
Repair
Replace MZLP Daughter Card
1. Turn the main power switch off.
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.
4. Unplug daughter card (112a) from the MZLP
#1 (112).
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).
Note
Do not force the electrical connection.
Minimal force is required to seat the
connector. If resistance is felt, stop and
verify the connector orientation.
Note
If unable to determine connector location,
see Electrical Schematics, page 59.
Figure 33 MZLP Daughter Card
334130A
53
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
Figure 34 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
Do not force the electrical connection.
Minimal force is required to set the
connector. If resistance is felt, stop and
verify the connector orientation.
Note
See Electrical Schematics, page 59,
if unable to determine the connector
location.
54
Connection
V+
VGND
L
N
Harness Label
V+
VGND
L
N
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.
334130A
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
5. Cut any cable ties between the end of the fan
wires to the fan (136).
334130A
To prevent fan errors on ADM, remove
excess slack and ensure cabling and zip
ties do not contact fan blades.
10. Reinstall fan grill (137) and close the electrical
enclosure.
55
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.
1. Turn the main power switch off.
2. Open electrical enclosure door.
3. Disconnect incoming power harness (234) from
top of transformer (235).
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).
56
Power Harness Wires
RCD-1 Connections
RCD-W1
RCD-W2
RCD-W3
RCD-W4
Terminal N
Terminal 5
Terminal 3
Terminal 1
14. Install incoming power harness (234) to top of
transformer in voltage port specified on machine
serial number label.
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.
334130A
Repair
Figure 35 Inside of Electrical Control Enclosure
334130A
57
Repair
Update Software
When software is updated on the ADM the software
is then automatically updated on all connected
GCA components. A status screen is shown while
software is updating to indicate progress.
1. Turn system main power switch OFF.
2. Remove ADM from bracket.
3. Remove token access panel.
First:
Software is checking
which GCA modules
will take the available
updates.
Second:
Status of the update
with approximate time
until completion.
Third:
Updates are
complete. Icon
indicates update
success/failure. See
the following Icon
table.
Icon
4. Insert and press software upgrade token (T)
firmly into slot.
Update successful.
Note
Update unsuccessful.
There is no preferred orientation of token
Update complete, no
changes necessary.
Update was
successful/complete
but one or more HCA
modules did not have
a CAN boot-loader
so software was
not updated on that
module.
T
5. Install ADM into bracket.
6. Turn system main power switch ON.
NOTICE
A status is shown while software is updating to
indicate progress. To prevent corrupting the
software load, do not remove token until the
status screen disappears.
Description
7. Remove token (T).
8. Replace token access panel.
9. Press
to continue to the operation screens.
Note
When the screen turns on, you will see
the following screens:
58
334130A
334130A
140
139
138
137
136
135
134
133
132
131
130
129
128
127
126
125
124
123
122
121
120
119
118
117
116
115
114
113
112
111
110
109
108
107
106
105
104
103
102
101
230V
3PH/
60HZ
1L2
100
FU-1
FU-3
FU-2
1080
1070
1060
2
4
6
1
3
5
1L2
1L3
CB-1
1L1
HARNESS 17A548
DISC-1 TO FUSE
1L3
1L2
1L1
DISCONNECT
6
4
24V
A1
RCD-W3
RCD-W2
RCD-W1
A2
5
3
1081
1071
8
SSR-1 FAN
240V
-
24V 7
G
3
2
SSR-1
1
1061
CR-1
2
1
HARNESS 17A550
CON-1 TO SSR-1
6
5
4
HARNESS 17A546
CB-1 TO RCD-1
HARNESS 17A553
MZTCM-1-J7 TO CR-1
111
109
106
1150
1140
1290
1300
1100
1090
289
290
287
288
SSR-1
SSR-1
SSR-1
N
6
4
2
3
1
RCD-1
108
107
106
5
6
5
4
N
HARNESS 17A554
RCD-1 TO SSR-1 FAN
6
5
4
1320
1310
1300
1290
A
D
E
B
F
C
GND
B
A
D
F
E
TOF200 PLATEN HEATERS
ZONE 1
C
HARNESS 17A542
RCD-1 TO AWB-1
SSR-1
6
5
4
6
108
107
SSR-1
5
FHB2
FHB1
FHA2
FHA1
GND
1320
1310
1300
1290
220
219
218
217
TOFP20 PLATEN
HEATERS ZONE 1
Electrical Schematics
Electrical Schematics
230V, 3 Phase/60 Hz
59
1L3
1L1
60
400V/N
3PH/
50HZ
N
FU-3
FU-2
FU-1
1080
1070
1060
HARNESS 17A548
DISC-1 TO FUSE
1L3
1L2
1L1
DISCONNECT
CB-1
2
6
4
24V
A1
CR-1
2
A2
5
3
1
1081
1071
1061
140
139
138
137
136
135
134
133
132
131
130
129
128
127
126
125
124
123
122
121
120
119
118
117
116
115
114
113
112
1L3
1L2
1L1
7
5
3
1
HARNESS 17A547
DISC-1 TO CB-1
8
6
4
RCD-W4
RCD-W3
RCD-W2
RCD-W1
8
24V 7
G
3
2
1
SSR-1
HARNESS 17A550
CON-1 TO SSR-1
SSR-1 FAN
240V
N
111
1L1
-
1L3
110
109
108
107
106
105
104
103
102
101
1L2
100
6
5
4
HARNESS 17A546
CB-1 TO RCD-1
HARNESS 17A558
HARNESS 17A553
MZTCM-1-J7 TO CR-1
111
109
106
1150
1140
1290
1300
1100
1090
289
290
287
288
RCD-W4
RCD-W3
RCD-W2
RCD-W1
1
3
5
N
HARNESS 17A554
RCD-1 TO SSR-1 FAN
SSR-1
6
SSR-1
5
4
SSR-1
6
5
4
RCD-1
108
107
106
2
4
6
N
1320
1310
1300
1290
A
D
E
B
F
C
GND
B
A
D
F
E
TOF200 PLATEN HEATERS
ZONE 1
C
HARNESS 17A542
RCD-1 TO AWB-1
SSR-1
6
5
4
6
108
107
SSR-1
5
FHB2
FHB1
FHA2
FHA1
1320
1310
1300
220
219
218
217
TOFP20 PLATEN
HEATERS ZONE 1
1290
GND
Electrical Schematics
400V, 3 Phase/50 Hz
334130A
334130A
400-600V
3PH/
60HZ
FU-1
FU-3
FU-2
1080
1070
1060
6
4
24V
A1
CR-1
2
A2
5
3
1
H1
H4
X7
X4
1081
1071
1061
140
139
138
137
136
135
134
133
132
131
130
129
128
127
126
125
124
123
122
121
120
119
118
117
116
115
114
113
112
P3
FU-6
P2
FU-5
P1
FU-4
HARNESS 17A541
1L3
1L2
1L1
TRANS-1
X1
X2
X5
X8
H5
H2
8
24V 7
G
3
2
1
SSR-1
HARNESS 17A550
CON-1 TO SSR-1
SSR-1 FAN
240V
HARNESS 17A548
DISC-1 TO FUSE
1L3
1L2
1L1
DISCONNECT
111
1L1
-
1L3
110
109
108
107
106
105
104
103
102
101
1L2
100
X3
6
5
4
X6
X9
H6
H3
111
109
106
HARNESS 17A553
MZTCM-1-J7 TO CR-1
RCD-W3
RCD-W2
RCD-W1
1250
1220
HARNESS 127429
1150
1140
1290
1300
1100
1090
240V OUTPUT
HARNESS 17A540
226
225
289
290
287
288
6
5
4
RCD-W4
RCD-W3
RCD-W2
RCD-W1
1
3
5
N
HARNESS 17A554
RCD-1 TO SSR-1 FAN
SSR-1
6
SSR-1
5
4
SSR-1
108
107
106
RCD-1
2
4
6
N
A
D
E
B
F
C
1320
1310
1300
1290
GND
B
A
D
F
E
TOF200 PLATEN HEATERS
ZONE 1
C
HARNESS 17A542
RCD-1 TO AWB-1
SSR-1
6
5
4
6
108
107
SSR-1
5
FHB2
FHB1
FHA2
FHA1
1320
1310
1300
1290
220
219
218
217
TOFP20 PLATEN
HEATERS ZONE 1
GND
Electrical Schematics
400–600VV, 3 Phase/60 Hz
61
1290
J2
54321
AWB-1
G
J5
BLACK
RED
2270
HARNESS 17A544 OR 17A545
AWB-1-J5 TO MZTCM-2-J2
AWB-1-J5 TO MZTCM-3-J2
315
332
260
130
131
132
218
219
220
J6
J5
1
2
3
4
5
6
MOTOR-DN
240
239
HARNESS 17A559
AWB-1-J8 TO MZTCM-1-J6
290
289
288
287
1150
RED
HARNESS 17A553
MZTCM-1-J7 TO SSR-1 AND CR-1
1140
1090
BLUE
1100
RED
114
115
109
110
285
BLUE
284
286
238
232
237
234
358
238
RED
RED
RED
355
HARNESS 17B768
2740
2730
283
HARNESS 17A559
MZTCM-1-J6 TO AWB-1-J8
PLATEN-RTD
PUMP-RTD
HARNESS 17A555
236
2790
2770
2760
2720
2700
MOTOR-UP
237
WHITE
RED
BLUE
RED
WHITE
2710
2680
285
5 4 3 2 1
1
2
3
4
5
2670
282
4 3
2 1
J7
1
2
3
4
235
L1
L2
236
281
280
279
278
277
276
275
223
222
2650
235
2320
ENCLOSURE FAN
(FAN-2)
127421
125
122
274
273
272
271
270
269
268
267
PX-LOW
PX-EMPTY
284
J8
1250
YELLOW
268
267
266
265
329
330
2640
HARNESS 24V745
2570
HARNESS 17A557
MZTCM-1-J12 TO SOL-1
281
J9
CAN
1220
YELLOW
HARNESS 17A543
AWB-1-J6 TO MZTCM-1-J2
312
313
G
L3
1
2
3
4
3 1
4 2
3 1
4 2
5 4 3 2 1
SOL-1
234
J4
+
J6
J7
1
2
3
G
1
2
221
J2
J3
2560
283
J3
G
W4
W3
W2
W1
266
220
HARNESS 17A543
MZTCM-1-J2 TO AWB-1-J6
L3
L1
J1
MZTCM-1
300
301
302
303
304
282
1320
1310
1300
3
265
264
263
2620
2610
HARNESS 17A551
MZTCM-1-J1 TO TERM BLOCKS
HARNESS 127511
MZTCM-1-J3 TO MZTCM-2-J6
233
231
230
229
228
227
226
225
224
223
222
221
129
217
216
215
214
213
374
GND
259
258
257
256
372
N
L
+
L
L EGND
262
N
L
+
N
255
254
253
252
261
J1
N
PS-1
251
212
HARNESS 17A552
24+ GND
+V
250
211
210
209
208
207
206
205
204
203
202
201
-V
J12
J13
J14
J15
62
J16
200
Electrical Schematics
AWB and MZLP#1
334130A
334130A
1 2
3 4
J5
J6
388
389
390
340
387
386
339
J1
L3
338
337
336
L1
385
382
381
380
379
378
384
215
217
218
335
J2
G
L3
L2
L1
377
376
375
383
J7
1 2
3 4
374
373
372
371
370
369
334
1 2 3 4 5 J3
6
5
4
3
2
1
1 2 3 4 5
MZTCM-3
J1
L3
333
332
331
330
329
328
327
326
325
324
323
322
321
320
319
L1
368
365
364
363
362
367
HARNESS 17A545
MZTCM-3-J2 TO AWB-1-J5
215
217
218
361
360
318
J2
G
L3
L2
L1
HARNESS 17A544 OR 17A545
MZTCM-2-J2 TO AWB-1-J5
359
366
HARNESS 127511
MZTCM-2-J3 TO MZTCM-3-J6
J7
358
262
261
2620
2610
3
2
1
2740
2732
2740
2730
357
275
2730
2731
317
1 2 3 4 5 J3
J5
J6
274
356
316
315
314
313
312
311
310
309
308
307
306
6
5
4
3
2
1
354
250
304
1 2 3 4 5
353
251
303
MZTCM-2
352
252
302
355
351
253
305
350
254
301
HARNESS 127511
MZTCM-2-J6 TO MZTCM-1J3
300
B3
T3
B2
T2
B1
T1
2740
2732
2732
2731
2731
2730
PUMP
PUMP
PLATEN
PUMP HEATERS ZONE 2
240V/1200W TOTAL
ALL VOLTAGES
TYPICALL ALL TOF200 AND TOFP20's
OVERTEMPS
275
274
2740
2730
2740
2732
2731
2730
2740
2730
PLATEN
AT SELECTION 7. ALL VOLTAGES
TYPICALL OF TOFP20's WITH CODE D
OVERTEMP
Electrical Schematics
MZLP #2, MZLP#3, Overtemp, and
Pump Heaters
63
Electrical Schematics
MZLP Zones
MZTCM-1
1
2
J9
4
A
J
K
J8
H
3
B
M
5
G
C
MZTCM-2
D
6
F
L E
J9
TYPICAL ZONE PIN OUT
7
8
B
A
ZONE-1-HEAT
J8
J
C
ZONE-2-HEAT
D
G
ZONE-1-RTD
F
MZTCM-3
9 10
K
ZONE-1-START
L
M
ZONE-2-START
J9
E
ZONE-2-RTD
H
11 12
J8
64
334130A
Parts
Parts
Therm-O-Flow 200 Supply Unit
334130A
65
Parts
Therm-O-Flow 200 Supply Unit
Ref
1
2
3
4
Part
--24W870
-----
5
---
6
7
-----
8
---
9
10
24W812
24W589
11
12
13
14
15
253288
234966
24V745
15H543
120186
▲
66
Description
Frame
KIT, air controls; see
CONTROL, electrical
MODULE, pump; see
Pump Modules, page 75
PLATEN; see
Heated Platens, page 82
RAM; see ram manual
CLAMP, drum; see
Drum Ram Post Saddle
Clamp, page 85
SEALS, see manual
309196
ADM
KIT, light tower (optional);
see Accessories and Kits,
page 89
CABLE, track, IGUS
KIT, hose hanger
SENSOR, level, low/empty
BRACKET, mounting
BOLT, mounting, u-bolt
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Ref
16
17
18
19
20
Part
101864
111303
100575
100023
---
21
22
23
24
100645
100016
110755
233559
25▲
15J076
26▲
15J074
27▲ 15H668
28▲
15J075
29▲
184090
Description
SCREW, cap, sch
NUT, hex
SCREW, cap, hex hd
WASHER, flat
BRACKET, mounting,
enclosure
SCREW, cap, sch
WASHER, lock
WASHER, plain
KIT, vent hood (optional);
see Accessories and Kits,
page 89
LABEL, warning,
instructions
LABEL, warning; moving
objects, pinch
LABEL, warning; hot
surface, splatter
LABEL, warning; hot
surface, shock
LABEL, warning
Qty
8
4
4
4
1
4
4
4
1
2
4
2
2
1
Replacement Warning labels, signs, tags, and
cards are available at no cost.
334130A
Parts
Air Control Assembly
Integrated
Control
For
Integrated
TOF With Electrical Enclosure
Ref
51
52
53
Part
Description
Qty
1
24W870 KIT, CONTROL, air, 3
regulator; see manual
334201
121235 SOLENOID, air motor, ram 1
17A557 HARNESS, solenoid, MZLP 1
334130A
Control
For
TOF Without Electrical Enclosure
Ref
54
55
56
Part
Description
Qty
113445 FITTING, elbow, street
1
121282 FITTING, swivel, straight 1
120375 ADAPTER, elbow, 3/4–14 1
nptf x 1/2–14 npsm
67
Parts
Electrical Module
68
334130A
Parts
334130A
69
Parts
Electrical Control Module Parts
Ref.
101
103
Part
-----
Description
ENCLOSURE, electrical
BUSHING, strain relief, m40
thread
- - - NUT, strain relief, m40
104
thread
105 125946 PLUG, hole, 1/2 in
106 123967 KNOB, operator disconnect
- - - PANEL, elec, transformer
107
(transformer assemblies
only)
- - - PANEL, elec, 400v/n
(400V modules only)
- - - PANEL, elec, 230v
(230V modules only)
Qty
1
1
2
1
1
1
1
4
8
4
112a 24R042 KIT, daughter, board
- - - GASKET, foam
113
1
(8 zone assemblies only;
Qty 1) (12 zone assemblies
only; Qty 2)
114 24P175 PLATE, blank
(4 Zone assemblies only;
Qty 2) (8 zone assemblies
only; Qty 1)
115 125856 SCREW, 8-32, serrated
flange
116 16T440 CAP, souriau, uts14
(4 Zone only; Qty 2) (8 zone
assemblies only; Qty 4) (12
zone assemblies only; Qty
6)
117 17C694 CABLE, tof, lapp to souriau
(4 Zone only; Qty 2) (8 zone
assemblies only; Qty 4) (12
zone assemblies only; Qty
6)
- - - WIRE, grounding, door
118
119 100166 NUT, full hex
- - - GASKET, hphm
120
122 17A543 HARNESS, power, mzlp1,
awb
70
1
12
Part
Qty
1
(8 zone assemblies only )
17A545 HARNESS, power, mzlp2/3,
awb
125
---
(12 zone assemblies only)
1
1
1
(8 zone assemblies only;
Qty 1) (12 zone assemblies
only; Qty 2)
130 121226 CABLE, can, male / female,
0.4m
131 121612 CONNECTOR, thru, m12,
mxf
132 123969 SWITCH, disconnect, 100a
123968 SWITCH, disconnect, ph
exp 100 A
134
---
1
1
HARNESS, pump, mzlp1,
tb, tof
- - - HARNESS, output, mzlp1,
126
ssr, contact
127 17A555 HARNESS, pump, reed
switch, tof
128 17A559 HARNESS, board, mxm,
comm
129 127511 CABLE, board, samtec
(400V only)
1
1
1
1
HARNESS, disc, fuse,
230-600v
17A547 HARNESS, disc, cb, 400v/n,
tof
1
136 24V911 FAN, 24v dc, 120m x 120m
1
137 16X884
1
138 115836
139 127278
140 24V746
1
2
1
1
Description
123 17A544 HARNESS, power, mzlp2,
awb
1
108 100133 WASHER, lock, 3/8
109 100307 NUT, hex
110 123396 NUT, flange, serrated,
3/8-16
- - - MODULE, gca, mzlp w/
111
daughter board
112 24V510 MODULE, gca, mzlp
(8 zone assemblies only;
Qty 1) (12 zone assemblies
only; Qty 2)
Ref.
(400V only)
(400V only)
GRILL, fan
(400V only)
GUARD, finger
(400V only)
NUT, keps, hex
(400V only)
GRILL, vent
(230V and 400V assemblies
only; Qty 2) (Transformer
assemblies only; Qty 1)
141 119865 SCREW, mach, hex
serrated
- - - CONTROL, air, assy; with
142
solenoid
143 24W812 ADM
(Primary assemblies only)
144 15V551 SHIELD, membrane, ADM
(Primary assemblies only)
145 121001 CABLE, can, female /
female 1.0m
1
1
4
4
1
1
0.1
1
(Primary assemblies only)
334130A
Parts
Ref.
146
Part
---
Description
BRACKET, mounting,
assembly
Qty
1
(Primary assemblies only)
(Primary assemblies only)
148 102040 NUT, lock, hex
(Primary assemblies only)
149 110755 WASHER, plain
(Primary assemblies only)
147 121250 SCREW, shcs, 1/4uncx4.25
1
1
1
1
150 121253 KNOB, display adj., ram
pkgs
(Primary assemblies only)
- - - BRACKET, pendant pivot,
151
(Primary assemblies only)
152 101550 SCREW, cap, sch
(Primary assemblies only)
153 100016 WASHER, lock
(Primary assemblies only)
1
4
5
156 24V745 SENSOR, level, low/empty
- - - BUSHING, strain relief
157
- - - NUT, bushing
158
- - - GROMMET, wire
159
160 124654 CONNECTOR, splitter,
12(m) x m12(f)
1
1
1
1
1
161 121228 CABLE, can, female/female,
15.0 m
1
(Secondary modules only)
(Secondary modules only)
(8 zone assemblies only;
Qty 1) (12 zone assemblies
only; Qty 2)
162 16W035 CONNECTOR, jumper
163
---
164
---
▲
CONTACT, socket, 20-24
awg, crimp, tin
TUBE, 1/16 shrink tube
3
0.13
Ref.
165
Part
---
Description
HARNESS, input, mzlp1,
RTD
166 127771 BRIDGE, plug-in, 2pos,
ut16
167
168
169
(400V and Transformer
modules only)
- - - FERRULE, wire, 10awg
(230V modules only; Qty
2) (400V and transformer
modules only; Qty 8)
-----
FERRULE, wire, 16awg
FERRULE, wire, 18 awg,
long
170 196548 LABEL, warning, shock
▲
172
---
ARTWORK, instructions,
wiring, ul
180 243697 MANIFOLD, heated, 230v
181
---
(Secondary assemblies
only)
FERRULE, wire, 10awg,
twin
(Secondary assemblies
only)
182 17C669 CONNECTOR, jumper,
male
(Secondary assemblies
only)
183 123856 HARNESS, CAN, cable
(Secondary assemblies
only)
184 17C712 TOKEN
(Secondary assemblies
only)
Qty
1
1
6
6
1
1
1
3
1
1
1
Replacement Warning labels, signs, tags, and
cards are available at no cost.
334130A
71
Parts
Electrical Panel
230V
400V/N
Transformer
Transformer Panel Shown
1
2
3
72
Torque terminals to 25–27 in-lbs (2.8–3.1 N•m).
Torque terminals to 13.3–16 in-lbs (1.5–1.8
N•m).
Torque terminals to 4.53–6.2 in-lbs (0.5–0.7
N•m).
334130A
Parts
230V Panel
1
2
3
400V/N Panel
Torque terminals to 25–27 in-lbs (2.8–3.1 N•m).
Torque terminals to 13.3–16 in-lbs (1.5–1.8
N•m).
Torque terminals to 4.53–6.2 in-lbs (0.5–0.7
N•m).
334130A
73
Parts
Electrical Panel Parts
Ref.
Part
202
203
204
205
206
207
117666
113783
100985
24V816
--123363
201
---
208
209
126453
---
210
127712
211
212
213
214
--126811
--120399
215
123359
216
217
218
219
6690-24165
126818
126817
126819
220
127717
221
222▲
223
224
127718
17C137
103833
123452
225
▲
74
---
Description
PANEL, elec, tof, 11ga,
zinc
TERMINAL, ground
SCREW, machine, pn hd
WASHER, lock ext
MODULE, gca, awb
RAIL, din, 6.5in
BLOCK, terminal, ground,
10mm
POWER SUPPLY, 24v
HARNESS, power supply,
awb
CIRCUIT, breaker, 63a,
4p, rcd
HARNESS, rcd, awb
BLOCK, clamp end
RAIL, din, 19in
CONTROL, 65 amp,
120-600v
RELAY, contactor, 30a,
3p, 24vdc co
FUSE, fuse block buss
jt60060
BLOCK, terminal 3-wire
COVER, end
BRIDGE, plug-in,
2-position
BLOCK, terminal, 2pos,
ut16
COVER, end, ut16
LABEL, multi safety
SCREW, mach, crbh
HOLDER, anchor, wire tie,
nylon
HARNESS, wire, ground,
8awg
Qty.
1
1
1
1
1
1
3
Ref.
226
227
228
229
Part
------81/019640/11
Description
HARNESS, fuse, contactor
HARNESS, contactor, ssr
HARNESS, rcd, ssr fan
FUSE, class j, 40amp,
dual elmnt; 400V and
Transformer Panel only
Qty.
1
1
1
3
81/0196- FUSE, class j, 60amp,
60/11 dual elmnt; 230V Panel
3
6690-24- FUSE, fuse block buss
164
jt60030
127744 CIRCUIT, breaker, 3p,
32a, ul489; 230V Panel
3
127745 CIRCUIT, breaker, 20a,
4p, ul489; 400V Panel only
81/0196- FUSE, class j, 20amp,
20/11 dual elmnt; Transformer
1
232
17A546 HARNESS, cb, rcd,
230-400V; 230V and 400V
1
3
233
7
1
1
234
17A558 HARNESS, cb, rcd,
400v/n; 400V Panel only
17A541 HARNESS, fuses,
transformer; Transformer
1
235
24V718 TRANSFORMER,
multi-tap/230v, 6kva;
1
128014 FILTER, voltage, transient,
600V, 3P
112380 SCREW, mach, pn hd
81/0163 WIREWAY, panduit
–B/11
81/0164 COVER, panduit
–B/11
1
1
1
230
1
1
2
1
1
1
3
1
1
33
12
1
only
1
only
231
237
238
239
240
panel only
3
Panel only
panel only
Transformer panel only
2
4
4
Replacement Warning labels, signs, tags, and
cards are available at no cost.
334130A
Parts
Merkur 2200, 23:1 Pump Modules
1
2
3
4
5
Torque to 50–60 ft-lb (68–81 N•m).
Torque to 145–155 ft-lb (196–210 N•m).
Coat mounting surface of sensor mounting
block(322) with non-silicone heat sink compound.
Do not coat sensor.
Prior to tightening band clamp (321), RTD sensor
(320)must be fully contained within the sensor
mount (322).
After fastening band clamp (321), secure excess
with fiberglass tape.
334130A
6
7
8
9
10
Coat inside of heater (309a, 309b) only to within
0.75 in. (19 mm) of vertical ends with non-silicone
heat sink compound before mounting.
Cap screws (311) must be loose while tie rods
(307) are being torqued.
Torque to 150 ft-lb (203 N•m).
Install swivel fitting (302) prior to screw (303) and
reed switch assembly (304).
Apply anaerobic sealant to threads.
75
Parts
Merkur 2200, 23:1 Pump Modules
Ref.
Part
Description
301 24W754 MOTOR, air, 6 in, 4.75
stroke, blue
302 155470 FITTING, swivel, union,
90°
- - - FASTENER, screw, slot
303
hex, #8-32 tap
304 24X441 SWITCH, reed assy
305 15H173 BRACKET, motor mount
306 15H397 ADAPTER, rod, pump
307 16A223 ROD, tie, vert driver
308 106166 NUT, mach ,hex
309 120271 HEATER, pump, 600 watt
310 24W510 PUMP, long shaft, cf;
24V003 only
24W151 PUMP, long shaft, gf;
24V006 only
311 109211 SCREW, cap, sch
312 17A637 BLOCK, standoff, mounting
315 102656 MUFFLER
316 186925 NUT, coupling
317 184129 COLLAR, coupling
318 120186 BOLT, mounting, u-bolt
76
Qty
1
1
1
1
1
1
3
3
2
1
3
3
1
1
2
2
Ref.
320
321
322
323
324
325
326
Part
120275
C31012
C03507
C38162
C38163
-----
329 103347
330 C33049
--331
333 206994
334 17B715
335 127671
336 122338
337 214656
338 16C009
Description
SENSOR, RTD
CLAMP
SUPPORT, sensor
SCREW, machine
WASHER, lock, ext. tooth
CONDUCTOR, ground
SHIELD, pump, tof200;
see Pump Shield, page 81
VALVE, safety, 100 psi
TAPE, adhesive, fiberglass
LUBRICANT, high temp,
thermal
FLUID, tsl 8 oz bottle
SUPPORT, block,
overtemp
SWITCH, over temp, fixed,
450°F (232°C)
SCREW, cap, socket bh
HOSE, coupled, 10 ft (3 m)
HOOK
Qty
1
1
1
1
1
1
1
1
1.5
1
1
1
2
4
1
1
334130A
Parts
Merkur 3400, 36:1 Pump Modules
1
2
3
4
5
Torque to 50–60 ft-lb (68–81 N•m).
Torque to 145–155 ft-lb (196–210 N•m).
Coat mounting surface of sensor mounting
block(322) with non-silicone heat sink compound.
Do not coat sensor.
Prior to tightening band clamp (321), RTD sensor
(20)must be fully contained within the sensor
mount (322).
After fastening band clamp (321), secure excess
with fiberglass tape.
334130A
6
7
8
9
10
Coat inside of heater (309) only to within 0.75 in.
(19 mm) of vertical ends) with non-silicone heat
sink compound before mounting.
Cap screws (311) must be loose while tie rods
(307) are being torqued.
Torque to 150 ft-lb (203 N•m).
Install swivel fitting (302) prior to screw (303)
and reed switch assembly (304).
Apply anaerobic sealant to threads.
77
Parts
Merkur 3400, 36:1 Pump Modules
Ref.
Part
Description
301 24R015 MOTOR, assy, air, 7.5 in
,blue
302 155470 FITTING, swivel, union,
90°
- - - FASTENER, screw, slot
303
hex, #8-32 tap
304 24B568 SWITCH, reed assy
305 15H173 BRACKET, motor mount,
tof 200
306 15H397 ADAPTER, rod, pump
307 16A223 ROD, tie, vert driver
308 106166 NUT, mach ,hex
309 120271 HEATER, pump, 600 watt
310 24W510 PUMP, long shaft, cf;
24V004 only
24W151 PUMP, long shaft, gf;
24V007 only
311 109211 SCREW, cap, sch
312 17A637 BLOCK, standoff, mounting
315 102656 MUFFLER
316 186925 NUT, coupling
317 184129 COLLAR, coupling
78
Qty
1
1
1
1
1
1
3
3
2
1
1
3
3
1
1
2
Ref.
318
320
321
322
323
324
325
326
Part
120186
120275
C31012
C03507
C38162
C38163
-----
329 103347
330 C33049
--331
333 206994
334 17B715
335 127671
336 122338
337 214656
338 16C009
Description
BOLT, mounting, u-bolt
SENSOR, RTD
CLAMP
SUPPORT, sensor
SCREW, machine
WASHER, lock, ext. tooth
CONDUCTOR, ground
SHIELD, pump, tof200;
see Pump Shield, page 81
VALVE, safety, 100 psi
TAPE, adhesive, fiberglass
LUBRICANT, high temp,
thermal
FLUID, tsl 8 oz bottle
SUPPORT, block,
overtemp
SWITCH, over temp, fixed,
450°F (232°C)
SCREW, cap, socket bh
HOSE, coupled, 10 ft (3 m)
HOOK
Qty
2
1
1
1
1
1
1
1
1
1.5
1
1
1
2
4
1
1
334130A
Parts
NXT 6500, 70:1 Pump Modules
1
2
3
4
Torque to 50–60 ft-lb (68–81 N•m).
Torque to 145–155 ft-lb (196–210 N•m).
Coat mounting surface of sensor mounting block
(411) with non-silicone heat sink compound. Do
not coat sensor.
Prior to tightening band clamp (412), RTD sensor
(410) must be fully contained within the sensor
mount (411).
334130A
5
6
8
10
After fastening band clamp (412), secure excess
with fiberglass tape.
Coat inside of heater (407) only to within 0.75 in.
(19 mm) of vertical ends) with non-silicone heat
sink compound before mounting.
Torque to 150 ft-lb (203 N•m).
Apply anaerobic sealant to threads.
79
Parts
NXT 6500, 70:1 Pump Modules
Ref.
Part
Description
401 N65LR0 MOTOR, 6500, low-noise,
remote
402 120375 ADAPTER, elbow, 3/4 npti
x 1/2 npte
403 15H542 BRACKET, mounting,
motor, tof200
404 17A406 ADAPTER, rod, pump, tof
405 16A223 ROD, tie, vert driver
406 106166 NUT, mach, hex
407 120271 HEATER, pump, 600 watt
408 24W150 PUMP, long shaft, cf;
24V005 only
24W151 PUMP, long shaft, gf;
24V008 only
409 C19837 SCREW, cap, socket hd
410 120275 SENSOR, RTD
411 C03507 SUPPORT, sensor
412 C31012 CLAMP
413 186925 NUT, coupling
414 184129 COLLAR, coupling
415 C38163 WASHER, lock, ext. tooth
80
Qty
1
1
2
1
3
3
2
1
1
4
1
1
1
1
2
1
Ref.
Part
Description
- - - CONDUCTOR, ground
416
417 C38162 SCREW, machine
418 120186 BOLT, mounting, u-bolt
419 100307 NUT, hex
- - - SHIELD, pump, tof200;
422
see Pump Shield, page 81
423 120588 PLUG, pipe, round
424 120012 VALVE, safety, 50 psi
- - - LUBRICANT, high temp,
425
thermal
426 C33049 TAPE, adhesive, fiberglass
428 206994 FLUID, tsl 8 oz bottle
429 17B715 SUPPORT, block,
overtemp
430 127671 SWITCH, over temp, fixed,
450°F (232°C)
431 122338 SCREW, cap, socket bh
432 17C255 CABLE, M12, 8p, 5p, m,
0.2 m
433 255792 HOSE, coupled, 13.5 ft (4
m)
Qty
1
1
2
4
1
1
1
1
1.5
1
1
2
4
1
1
334130A
Parts
Pump Shield
Ref.
501
502
503
504
505
506
▲
Part
24W974
24W975
24W976
24W977
24W978
120792
Description
COVER, pump, bottom
COVER, pump, right
COVER, pump, left
COVER, pump, top, front
COVER, pump, top, back
FASTENER,
thread-cutting screw
Qty
1
1
1
1
12
Ref.
Part
Description
507▲ 184090 LABEL, warning
508 104088 RIVET, blind
509▲ 15J075 LABEL, safety, hot
surface and shock
- - - BUSHING, conduit, 1 in
510
511 C20731 FITTING, conduit,
connector, 1 in.
Qty
2
4
2
1
1
Replacement Warning labels, signs, tags, and
cards are available at no cost.
334130A
81
Parts
Heated Platens
24V633, Heated Drum Platen, Mega-Flo (Code E- option M)
24V634, Heated Drum Platen, Standard Grid(Code E- option F)
24V635, Heated Drum Platen, Smooth Bottom (no fin) (Code E- option S)
82
334130A
Parts
24V633, Heated Drum Platen, Mega-Flo (Code E- option M)
24V634, Heated Drum Platen, Standard Grid(Code E- option F)
24V635, Heated Drum Platen, Smooth Bottom (no fin) (Code E- option S)
Ref
Part
Description
- - - PLATEN — see table below
601
602 C32204 PACKING, o-ring
603 15G967 PLATE, tire
604 C19049 SCREW, mach, slotted,
RND HD
605 15H298 SENSOR, temperature
606 C32201 GASKET, follower
607 158491 FITTING, nipple
608 158581 COUPLING, hex
609 617227 HANDLE, follower, bleed
610 246501 VALVE, blow off
611 100361 PLUG, pipe
612 100133 WASHER, lock
613 C19846 SCREW, cap socket, HD
614 150707 PLATE, designation
615 100508 SCREW, drive
- - - CONDUCTOR, 14.2 ft (4.3
616
m)
- - - CONDUCTOR, 1.7 ft (0.5
617
m)
Platen Model
24V633
24V634
24V635
334130A
Description
Mega-Flo
Standard Grid
Smooth Bottom
Qty
1
1
1
1
1
1
1
1
1
4
6
6
1
2
6
Ref
618
Part
---
--619
620 112901
621 111640
--622
623 127671
624 122338
--625
--626
--627
628 127690
629 127689
630
---
Description
CONDUCTOR, 0.3 ft (0.09
m)
CONDUCTOR, ground
NUT, hex
WASHER, lock, internal
PLUG, follower, plate
SWITCH, over temp, fixed,
450°F (232°C)
SCREW, cap, socket bh
TUBE, ptfe, 1/4 X 5/16
TUBE, ptfe, 3/32 X 5/32
SLEEVE, fiberglass,
hi-temp
FITTING, adapter, 5/16 in.
tube x 1/4 in tube
FITTING, adapter, 1/4 in
tube x 5/32 in tube
TUBE, polyeth, 1/4 OD; 26
ft (7.9 m)
Qty
4
1
12
12
1
1
2
3
3
3
1
1
1
2
Ref. No. 601
194254
617225
C57358
Qty.
1
1
1
Element Resistance
16.5 ohms +1/-2
19.2 ohms +2/-3
19.2 ohms +2/-3
83
Parts
Heater Terminal Patterns
24V633
24V634, 24V635
16.5 Ohms across pairs
19.25 Ohms across pairs
Platen Coil Wiring
24V633
84
24V634, 24V635
334130A
Parts
Drum Ram Post Saddle Clamp
C32463
Option H-1
Ref
701
702
703
704
Part
C32424
160111
100103
100307
334130A
Description
BOLT, U, 7 in. (177.8 mm)
CLAMP, barrel
PIN, cotter
NUT, hex
Qty
2
1
2
4
Ref
705
706
707
708
Part
100133
C38182
C32461
166265
Description
WASHER, lock
WASHER, plain
CLAMP, saddle
PIN, pivot
Qty
4
2
2
1
85
Parts
Heavy Duty Drum Band Clamp
918395
Option H-3
Ref
Part
Description
702 100101 SCREW, cap, hex hd
703 918421 CLAMP, back half
assembly
704 918423 KIT, repair
705 617395 PIN, quick release
756 100133 WASHER, lock
86
Qty
8
1
1
2
8
Ref
707
708
759
710
761
Part
C19200
617433
617395
100131
C32424
Description
WASHER, plain
SPACER, drum clamp
CLAMP, saddle
NUT, full hex
BOLT, U 7 in. (177.8 mm)
Qty
8
8
4
8
4
334130A
Parts
Fiber Drum Reinforcement Clam Shell Clamp
918397
OPTION H-2
Ref
6
801
802
803
Part
C32424
C32271
C19126
100133
334130A
Description
BOLT, U, 7 in. (177.8 mm)
CLAMSHELL
SCREW, cap, hex hd
WASHER, lock
Qty
4
1
8
12
Ref
Part
Description
804 100307 NUT, hex
805 617340 CLAMP, saddle
807 617341 MOUNT, clam shell
Qty
8
4
2
87
Parts
Vent Hood Kit, 233559
Ref
851
852
▲
88
Part
Description
--VENT hood
112166 SCREW, cap, sch
Qty
1
4
Ref
Part
Description
853 100016 WASHER, lock
855▲ C14038 LABEL, warning
Qty
4
1
Replacement Warning labels, signs, tags, and
cards are available at no cost.
334130A
Accessories and Kits
Accessories and Kits
Flow Control and Manifolds
Part No.
Wiper Kits
243700
See manual 309196 for installation and repair
instructions.
243656
Part No.
253243
253244
253245
253246
Description
Hose/Spring Wiper Kit
Hose and T-Wiper Kit
Twin Hose Wiper Kit
T-Wiper Kit
Applicators and Dispense Valves
Part No.
249515
249514
249513
249512
Description
Manual Gun, Top Feed, 240V
Manual Gun, Bottom Feed, 240V
Manual Gun, Top Feed, Electric Switch,
240V
Manual Gun, Bottom Feed, Electric
Switch, 240V
Air-Operated Heated Dispense Valves
Part No.
243694
244951
244909
243701
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
Description
243697
Heated Air Operated Mastic Pressure
Regulator, 240V
23:1 Heated Pressure Compensator
Valve, 240V
51:1 Heated Pressure Compensator
Valve, 240V
Heated Distribution Manifold, 240V
289208
Compact Heated Regulator
243657
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.
Accessory Extension Cables
Use to connect fluid control devices and heated
hoses to the electrical control enclosure.
Part No.
Description
Connect between controller and heated hose
196313 15 ft, 16 pin to 16 pin
196314 25 ft, 16 to 16 pin
Connect between controller and heated accessory
196315 15 ft, 16 pin to 8 pin
196316 25 ft, 16 pin to 8 pin
Connect between controller and heated devices
196317 15 ft, 16 pin to (2) 8 pin
196318 25 ft, 16 pin to (2) 8 pin
Light Tower Kit, 24W589
Tie Rod Kits
Use to retrofit Check-Mate 800 Displacement Pump
to an existing Therm-O-Flow system.
Part No.
24V750
24V754
334130A
Description
Bulldog® and Senator® Tie Rod Kit; see
manual 334131
NXT® Tie Rod Kit; see manual 334132
89
Accessories and Kits
Heated Hoses and Fittings
Hose Diameter
Hose Length
3 ft (1.5 m)
6 ft (1.8 m)
10 ft (3 m)
15 ft (4.6 m)
20 ft (6 m)
25 ft (7.6 m)
30 ft (9 m)
- 6
- 8
- 10
- 12
- 16
- 20
(9/16 in -18
(3/4 in -16
(7/8 in -14
(1-1/16 in
(1-5/16 in
(1-5/8 in -12
JIC)
JIC)
JIC)
-12 JIC)
-12 JIC)
JICd
None
None
16J875
None
None
None
None
None
115902
115873
115874
None
None
None
None
115875
115876
115877
115878
115879
121200
15C586
None
115880
115881
115882
115883
None
None
115884
115885
115886
115887
115888
None
None
None
117821
117822
None
None
None
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
16V432
100380
253267
253268
120260
120261
120262
16V432
C20678
C20679
C38006
6301-85
6308-85
120268
-6 Hose (.308 ID)
125778
123684
123683
123683
120265
-8 Hose (.401 ID )
123684
120241
120242
120244
-10 Hose (.495 ID)
123683
123683
120265
123683
120265
120267
120242
120243
120246
120244
120246
120247
123683
120265
120267
120244
120267
120246
120267
120248
120244
120267
120246
120267
120246
120267
120268
120248
120249
6308-82
126521
6308-82
126521
123135
126521
120249
120268
123135
126521
120249
120268
120250
Hose to Hose Fittings
-12 Hose (.617 ID)
-16 Hose (.687 ID)
-20 Hose (1.125 ID)
90
None
6308-82
126521
None
334130A
Accessories and Kits
Hose Diameter
- 6
- 8
- 10
- 12
- 16
- 20
(9/16 in -18
(3/4 in -16
(7/8 in -14
(1-1/16 in
(1-5/16 in
(1-5/8 in -12
JIC)
JIC)
JIC)
-12 JIC)
-12 JIC)
JICd
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
334130A
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
16V432
100896
124286
15Y934
C20708
125661
124286
15Y934
C20708
125661
125661
120268
125661
120268
91
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
3
4
5
92
Part
125856
16T440
127511
16W035
Description
MODULE, GCA, MZLP
SCREW, 8–32, serrated
flange
CAP, souriau, UTS14
CABLE, board, samtec
CONNECTOR, jumper
Qty
1
4
2
1
1
Ref
6
7
8
9
Part
Description
17A544 HARNESS, power, MZLP2,
AWB
112190 STRAP, wrist, grounding
17C712 TOKEN, software upgrade
17C694 CABLE, TOF, LAPP to
souriau
Qty
1
1
1
2
334130A
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 “1” on a
primary system or “5” 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
6.
7.
8.
9.
Do not force the electrical connection.
Minimal force is required to seat the
connector. If resistance is felt, stop, and
verify the connector orientation.
Connect cable (4) to J3 connector on MZLP 1
and J6 connector on MZLP 2.
Connect power harness (6) to MZLP 2 connector
J2 and J5 connector on AWB.
Use fittings and hoses that meet your hose routing
needs. See Accessories and Kits, page 89.
To ensure your system has the latest
software, insert token (8) into the ADM. See
Update Software, page 58.
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.
334130A
93
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
3
4
5
94
Part
125856
16T440
127511
16W035
Description
MODULE, GCA, MZLP
SCREW, 8–32, serrated
flange
CAP, souriau, UTS14
CABLE, board, samtec
CONNECTOR, jumper
Qty
1
4
2
1
1
Ref
6
7
8
9
Part
Description
17A545 HARNESS, power,
MZLP2/3, AWB
112190 STRAP, wrist, grounding
17C712 TOKEN, software upgrade
17C694 CABLE, TOF, LAPP to
souriau
Qty
1
1
1
2
334130A
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 “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
6.
7.
8.
9.
Do not force the electrical connection.
Minimal force is required to seat the
connector. If resistance is felt, stop, and
verify the connector orientation.
Connect cable (4) to J3 connector on MZLP 2
and J6 connector on MZLP (1).
Connect power harness (6) to MZLP 2 and MZLP
3 J2 connector and J5 connector on AWB.
See Install Heated Hose, page 18, to connect a
heated hose or fluid control device.
To ensure your system has the latest
software, insert token (8) into the ADM. See
Update Software, page 58.
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.
334130A
95
Appendix A— ADM
Appendix A— ADM
General Operation
Enable, Disable Heating System
ADM Power
To enable or disable the entire heating system,
press . To set which channels are active when
the heating system is enabled, use the Heat-A and
Heat-B Setup screens.
The ADM automatically turns on when the main
power switch is turned on.
Screen Navigation
To switch between the Setup and Operation screens,
. Use the keypad to navigate between
press
screens.
96
334130A
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
Function
Primary System= A
Secondary System = B
Pause Material Tracking
Heating Disabled
Pump Ready
Warm Up, Actual temperature
is outside of Target
Temperature
Reached Target Temperature
Setback
Hose
Gun
Manifold
PGM
Flow Meter
Pressure Regulator
Other
Advisory. See Error Codes
for more information.
Deviation. See Error Codes
for more information
Alarm. See Error Codes
for more information
334130A
Icon
Continue Material Tracking
Reset Cycle Counter
(press and hold)
Add or edit event
Accept schedule
Crossover for Tandem Systems
Erase or cancel schedule
Cancel
Clear
97
Appendix A— ADM
Operation Screens
Color
Yellow
Home
This screen shows the temperature state of the
system and material usage.
Green/Yellow Flashing
A and B Zone Status
Outside of advisory
range
Warmup
Events
The Events screens store a maximum of 200 events.
The events list can be downloaded in the USB logs.
See Appendix B — USB Data, page 103.
Note
If present, secondary systems will be shown
on the home page.
Heat-A
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
98
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
334130A
Appendix A— ADM
Errors
CAN:
VDC)
24 VDC power supply voltage reading (18–28
System Digital Inputs
0: Drum Empty
1: Drum Low
2: Pump Cycle Switch Up
3: Pump Cycle Switch Down
DI:
System Digital Outputs
0: Pump Solenoid
1: Not Used
2: Not Used
3: Not Used
DO:
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 103.
Diagnostic-A
Customer Digital Inputs
See Connect PLC, page 27.
ISO DI:
Customer Digital Outputs
See Connect PLC, page 27.
ISO DO:
Fan:
current to fan
set time for platen to heat after the platen
has reached set temperature.
total number of pump cycles over life of
system
temperature on MZLP 1
• 32–160°F(0–71°C)
Heat Soak:
Life Cycles:
MZLP 1:
Current draw of pump solenoid
• (0 mA - off)
• (150-250 mA - on)
Pump Sol:
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
334130A
Pump cycles per minute.
Percentage complete, only applies when
downloading USB data. 5 downloads will occur.
Weight of material dispensed over life of
system
Temperature of transformer
temperature sensor
Pump CPM:
USB DL%:
Weight:
XFMRTemp:
Setup Screens
Note
It is important to set all settings in the System
screens correctly to ensure optimal system
performance.
99
Appendix A— ADM
Password
If the password is not “0000”, the password must be
entered to access the setup screens.
Automatically turns the
pump on after reaching setpoint temperature and
heat soak is complete.
Enable all secondary
system ADM screens.
Time for to preheat after all zones have
reached their target temperatures. Pump cannot
turn on until timer is complete. The heat soak is a
user-defined time.
• Range: 0–120 minutes
• 0 disables heat soak
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
Enable Pump Autostart:
Enable Tandem System:
Heat Soak:
Pump Inactive Timeout:
System 1
System 2
Enable feature that
automatically turns on and off the pump when using
a handheld dispense gun with an integrated trigger
switch.
Choose whether to show
the Diagnostic screen.
Allows temperature
adjustments on the Heat-A and Heat-B Run screens.
External Pump Control:
Enable Diagnostic Screen:
Enter low and high temperatures for an alarm or
warning to occur.
Enable Temp. Adjustments:
100
334130A
Appendix A— ADM
Advanced 1
Note
If the Specific Gravity is set to zero, the
Home screen will display a cycle counter
instead of grams or pounds.
Advanced 3
Language displayed on the screen.
Choose format of the date.
Set the date.
Set the time.
If not “0000”, the Setup screens will
be password protected.
The screen will go black after the set
amount of time.
Disable ADM sounds.
Language:
Date Format:
Date:
Time:
Disables use of
the USB for downloading and uploading.
When disabled, the system
will not warn the user when logs are full. If the logs
are full, the oldest data will be overwritten.
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.
Enter Password:
Disable USB Downloads/Uploads:
Screen Saver:
Disable USB Log Errors:
Silent Mode:
Download Depth: Last ___ Days:
Advanced 2
Advanced 4
Units of measure for displayed
temperatures.
Units of measure for mass.
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.
Temperature Units:
Mass Units:
Specific Gravity:
334130A
The screen shows the part number and version of
each installed software module.
101
Appendix A— ADM
Heat-A
Maintenance-A
The system will notify the user at the set interval that
maintenance is required. The fields in boxes can
be edited by the user. “Due” and “Current” are both
the number of cycles since the last reset. “Interval”
is the set number of cycles between maintenance
notifications. “Lifetime” is the number of cycles in the
lifetime of the system.
Note
The lifetime cycle count will only be reset if
the ADM is replaced.
Use these screens to set target and setback
temperatures for the pump, platen, and zones. Select
which system needs to use the heated accessory.
Schedule
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.
102
Use this screen to set times that the system
will automatically enable and disable heating.
See Schedule, page 37 .
334130A
Appendix B — USB Data
Appendix B — USB Data
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.
Note
To prevent losing any data, never go more
than 43 days without downloading the logs.
Download
NOTICE
Uploading an edited system configuration file
can damage the system. Never put a modified
SETTINGS.TXT file in the UPLOAD folder on the
flash drive.
Note
The event log, error log, system settings, and
system language files are all downloaded in
this procedure.
1. Insert USB flash drive into USB port.
Note
Flash drive must be 8 GB or smaller.
2. The menu bar and USB indicator lights indicate
that the USB is downloading files. Wait for USB
activity to complete. A pop-up will be present until
the transfer is complete if it is not acknowledged.
Note
If the pop-up screen does not appear,
the flash drive is not compatible with the
ADM. Try a different flash drive.
Note
The system can log up to 45 mb of
additional data per week, depending on
system operation.
334130A
Access Files
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.
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 104 or
System Language File, page 105.
1. If necessary, follow the
Download Instructions, page 103, to
automatically generate the proper folder structure
on the USB flash drive.
2. Insert USB flash drive into USB port of computer.
3. The USB flash drive window automatically opens.
If it does not, open USB flash drive from within
Windows Explorer.
4. Open Graco folder.
5. Open system folder. If working with more than
one system, there will be more than one folder
within the Graco folder. Each folder is labeled
with the corresponding serial number of the ADM.
(The serial number is on the back of the module.)
6. If installing the system settings file, place
SETTINGS.TXT file into UPLOAD folder.
7. If installing the custom language file, place
DISPTEXT.TXT file into UPLOAD folder.
8. Remove USB flash drive from computer.
9. Install USB flash drive into Therm-O-Flow system
USB port.
10. The menu bar and USB indicator lights indicate
that the USB is uploading files. Wait for USB
activity to complete.
11. Remove USB flash drive from USB port.
103
Appendix B — USB Data
Note
If a custom language file was installed, users
can now select the new language from the
Language drop-down menu.
Note
If the SETTINGS.TXT or DISPTEXT.TXT
files remain in the UPLOAD folder, they will
be uploaded every time the USB drive is
inserted into the corresponding ADM. To
avoid unintentionally overwriting system
settings, delete the files from the UPLOAD
folders on the USB drive after the upload is
complete.
USB Logs
During operation, the Therm-O-Flow stores system
and performance related information to memory in
the form of log files. The Therm-O-Flow maintains the
events, data, GCA, Black Box, and Diagnostics logs.
Follow the
, to retrieve log files.
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.
104
GCA Log
This log (3-GCA.CSV) lists the installed GCA
modules and their respective software versions.
Black Box, Diagnostics Log
These logs (4-BLACKB.CSV, 5-DIAGN.CSV) are
designed to provide useful information to Graco when
calling for technical assistance.
System Settings File
NOTICE
Uploading an edited system configuration file
can damage the system. Never put a modified
SETTNGS.TXT file in the UPLOAD folder on the
flash drive.
The system configuration settings file name is
SETTINGS.TXT and is stored in the DOWNLOAD
folder.
A system configuration settings file automatically
downloads each time a USB flash drive is inserted.
Use this file to back up system settings for future
recovery or to easily replicate settings across
multiple Therm-O-Flow systems. Refer to the
Upload Instructions, page 103, 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.
334130A
Appendix B — USB Data
System Language File
The system language file name is DISPTEXT.TXT
and is stored in the DOWNLOAD folder.
A system language file automatically downloads each
time a USB flash drive is inserted. If desired, use this
file to create a user-defined set of custom language
strings to be displayed within the ADM.
The system is able to display the following Unicode
characters. For characters outside of this set,
the system will display the Unicode replacement
character, which appears as a white question mark
inside of a black diamond.
• U+0020 - U+007E (Basic Latin)
• U+00A1 - U+00FF (Latin-1 Supplement)
• U+0100 - U+017F (Latin Extended-A)
• U+0386 - U+03CE (Greek)
• U+0400 - U+045F (Cyrillic)
Modify the second column of the custom
language file as needed and then follow the
Upload Instructions, page 103, to install the file.
The format of the custom language file is critical.
The following rules must be followed in order for the
installation process to succeed.
1. The file name must be DISPTEXT.TXT.
2. The file format must be a tab-delimited
text file using Unicode (UTF-16) character
representation.
3. The file must contain only two columns, with
columns separated by a single tab character.
4. Do not add or remove rows to the file.
5. Do not change the order of the rows.
6. Define a custom string for each row in the second
column.
Create Custom Language Strings
The custom language file is a tab-delimited text file
that contains two columns. The first column consists
of a list of strings in the language selected at the
time of download. The second column can be used
to enter the custom language strings. If a custom
language was previously installed, this column
contains the custom strings. Otherwise the second
column is blank.
334130A
105
Dimensions
Dimensions
Ram Mounting and Clearance
A
B
C
D
E
F
G
J
in. (mm)
in. (mm)
in. (mm)
in. (mm)
in. (mm)
in. (mm)
in. (mm)
in. (mm)
59 (1498.6) 40 (1016)
Height (H)
Fully Raised
Fully Lowered
106
37 (939)
21 (533)
25 (635)
58 (1473)
48 (1219)
11 (279)
Dimensions
110 in (2794 mm)
78 in (1981 mm)
334130A
Technical Specifications
Technical Specifications
Therm-O-Flow 200 Hot Melt System
Displacement pump effective area
Volume per cycle
Pump cycles per 1 gallon (3.8
liters)
Ram maximum input pressure
Maximum pump operating
temperature
Air inlet size
Air motor sound data
Pump fluid inlet size
Wetted Parts
Maximum Air Input Pressure (Pumps)
Compressed Air (typical)
Voltage (as selected)
8 cm2
192 cm3
0.85 MPA, 8.5 bar
204°C
3/4 npsm(f)
See air motor instruction manual.
1 in. npt(f)
carbon steel, brass, chrome, zinc, nickel plating, stainless steel (304,
316, 440, and 17–4 PH), alloy steel, ductile iron, PTFE
Merkur 6.0 in.
Merkur 7.5 in.
NXT 6500
Power Requirements
21
125 psi
400°F
Maximum Fluid Working Pressure
Merkur 6.0 in.
Merkur 7.5 in.
NXT 6500
Metric
U.S.
1.24 in.2
11.7 in.3
2300 psi
3000 psi
3000 psi
15.9 MPa, 159 bar
20.7 MPa, 207 bar
20.7 MPa, 207 bar
100 psi
82 psi
43 psi
0.7 MPa, 7 bar
0.57 MPa, 5.7 bar
0.29 MPa, 2.9 bar
25–50 scfm
220/240 V, 3-phase, 50/60 Hz
380/400 V, 3-phase, 50/60 Hz
470/490 V, 3-phase, 50/60 Hz
600 V, 3-phase, 50/60 Hz
Peak Consumption
(includes drum melt grid, pump, and a 6kVa transformer for the 230 V hoses and accessories)
with standard melt grid
with Mega-Flo melt grid
with smooth melt grid
334130A
27.1 kVa
30.2 kVa
27.1 kVa
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 334130
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 A, December 2014

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