Graco Therm-O-Flow 200 Instructions - Parts Manual
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Graco Therm-O-Flow 200 Instructions - Parts Manual

Graco Therm-O-Flow 200 Instructions - Parts Manual

Bulk hot melt system
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Instructions-Parts
Therm-O-Flow
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 111, for maximum
working pressures.
®
200
334130L
EN
3143485

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Summary of Contents for Graco Therm-O-Flow 200

  • Page 1 Instructions-Parts ® Therm-O-Flow 334130L 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.

  • Page 2: Table Of Contents

    Technical Specifications ....111 Graco Standard Warranty ....112...

  • Page 3: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion 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.
  • Page 4 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. •...
  • Page 5 Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system com- ponent.

  • Page 6: Models

    Models Models The model number stamped on your systems defines the equipment in the following categories. See Technical Specifications, page 111, for maximum working pressure. Series Frame Size Zone Pump Platen Platen Drum Air/Electric Config Ratio Style Seal Clamp Code A Frame Size None 55 Gallon (200 Liter)

  • Page 7: Related Manuals

    Check-Mate 800 Pump, Repair-Parts 334128 ® 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 3A4241 Heated Hose, Instructions-Parts 309160 Heated Hose, Instructions-Parts 309196 Wiper Kits, Repair-Parts 310538...

  • Page 8: Component Identification

    Component Identification Component Identification R, S ti24544a . 1: TOF 200 Pneumatic Key: Lift Strap Positions Main Power Switch Multi-Zone Low Power Temperature Control Module (MZLP) Air Motor Solenoid Light Tower Electrical Power Input Cable Track Air Motor Ram Plate Bleed Stick Heated Pump Drum Blow Off Valve (behind ram plate bleed stick) Heated Platen...

  • Page 9: Integrated Air Controls

    Component Identification Integrated Air Controls . 2: Integrated Air Controls Key: CA Main Air Slider Valve CH Blowoff Pressure Gauge Turns air on and off to the entire system. When closed, Displays the blowoff pressure. the valve relieves pressure downstream. CJ Blowoff Air Regulator CB Ram Down Air Regulator Controls platen blowoff pressure.

  • Page 10: Electrical Control Enclosure

    Component Identification Electrical Control Enclosure Back Panel With Transformer . 3: Electrical Enclosure Key: DA Multi-Zone Low Power Temperature Control Module DG Platen SSR (65A) (MZLP) DH Platen Contractor DB Ventilation Grill DJ Platen Fuse DC Electrical Control Panel DK Transformer Circuit Breaker DD Automatic Wiring Board (AWB) DL Transformer Fuse DE Power Supply (24V)

  • Page 11: Advanced Display Module (Adm)

    Component Identification Advanced Display Module NOTICE (ADM) To prevent damage to the softkey buttons, do not The ADM display shows graphical and text information press buttons with sharp objects such as pens, plastic related to setup and spray operations. For detail on the cards, or fingernails.
  • Page 12 Component Identification . 5: Back View Part Number and Identification Label USB Interface CAN Cable Connection (Power Supply and Communication) Module Status LEDs Light Tower (Optional) Software Token Access Panel Table 1 ADM LED Status Descriptions Conditions Description System Status Green Solid Run Mode, System On Green Flashing...

  • Page 13: Screen Components

    Component Identification Screen Components 1. Screen Order 2. Current date and time 3. Operating Mode 4. Faults, Status 5. MZLP Plug Identifier 6. Zone Setpoint Temperature 7. Zone Actual Temperature Operating Mode Description Component Status System Off The system does not have power. •...

  • Page 14: Overview

    Air and Fluid Hoses The Therm-O-Flow requires Graco single-circuit mate- rial hoses rated at a maximum of 1250 watts. Make sure all air and fluid hoses are properly sized for the system.

  • Page 15: Setup

    Setup Setup 1. Unpack the ram 5. Make sure there is easy access to an appropriate electrical power source. The National Electrical 2. Locate and Install the ram Code requires 3 ft (0.9 m) of open space in front of the electrical panel.

  • Page 16: Mechanical Setup

    4. Ensure drum low and empty sensors (C) are mounted as shown. 1. Fill displacement pump wet cup 2/3 full with Graco NOTE: The Drum Low and Empty Sensors are used to Throat Seal Liquid (TSL™) for Butyl and PSA mate- indicate that a drum is empty.

  • Page 17: Install Heated Hose

    Setup Install Heated Hose 5. For proper operation, cables must be plugged into zones 1–2 and 3–4 at all times. To connect a hose to a fluid control device or heated 6. Install cap on any unused MZLP electrical connec- manifold.

  • Page 18: Connect Multiple Devices

    Setup Connect Multiple Devices • Connect fluid control devices to a heated hose or the electrical enclosure. Use accessories if neces- sary. If your application requires multiple fluid control devices: • Setup all heat zones on Heat-A and Heat-B • Connect heated hose electrical connections to the screens.

  • Page 19: Connect Power

    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 con- trol panel to a power source. All electrical wiring must be done by a qualified elec- trician and comply with all local codes and regula- tions.

  • Page 20: Grounding

    Setup Grounding Material drums: follow local code. Use only metal drums placed on a grounded surface. Do not place the drum on a nonconductive surface, such as paper or Ground the unit as instructed here and in the compo- cardboard, which interrupts the grounding continuity nent manuals.

  • Page 21: Check Sensor Resistance

    Setup Check Sensor Resistance Table 3 RTD Sensors RTD Range MZLP MZLP Plug Component (Ohms) Ram Plate 100 +/- 2 Fluid Pump 100 +/- 2 To reduce risk of injury or damage to equipment, con- Heated duct these electrical checks with the main power 100 +/- 2 Accessory 1 switch OFF.

  • Page 22: Check Heater Resistance

    Setup Check Heater Resistance To reduce risk of injury or damage to equipment, con- duct these electrical checks with the main power switch OFF. 1. Turn main power switch off. 2. Make electrical resistance checks for the compo- nents. 3. Replace any parts whose resistance readings do not comply with the ranges listed in tables.

  • Page 23: Select Adm Settings

    Setup Select ADM Settings 5. Set primary system setpoint and setback tempera- tures for the pump, platen, and heat zones on the Heat-A-screens. NOTE: See Appendix A - ADM, page 98 for detailed ADM information, including general operation. 1. Turn main power switch on. 2.
  • Page 24 Setup 8. Set the temperature and mass units on the 9. To setup the optional Schedule function, see Advanced 2 screen. Set the specific gravity of the Schedule, page 35. The schedule function allows material for Material Tracking functionality. the system to automatically enable and disable heating and setback at specified times.

  • Page 25: Connect Plc (Hard Wired Interface Version)

    Setup Connect PLC (Hard Wired Table 7 Output Error States Interface Version) Error State Bit High Error State Bit Low Machine is good, no errors are present Active Unit Drum A PLC can control and monitor all items shown in the Active Unit Drum Customer Digital Inputs and Outputs shown on the Empty...
  • Page 26 Setup NOTE: Each connector has four signals. The MZLP board specifies the input range for each signal. See the following table for pin assignments. . 14 H1 Customer Input Signal H2 Customer Output Signal Inputs: High: 10–30 VDC, Low: 0–5 VDC. Inputs func- tion without concern for polarity.
  • Page 27 Setup PLC Connections Block Diagrams The following block diagrams show how to connect customer inputs and outputs to the MZLP. For convenience, each system ships with connector kit 24P176. If a connector is lost or damaged, order kit 24P176 for replacements. .

  • Page 28: Operation

    Operation Operation 1. Turn the main power switch ON. The Graco logo will display until communication and initialization is com- NOTICE plete. Use fluids that are chemically compatible with the equipment wetted parts. See Technical Specifica- tions in all of the equipment manuals.

  • Page 29: Load Material

    Operation Load Material 4. Fill displacement pump wet cup 2/3 full with Graco Throat Seal Liquid (TSL™) for Butyl and PSA mate- rials. NOTICE To prevent damage to platen wipers, do not use a drum ® NOTE: Use IsoGuard Select (IGS) (part no.

  • Page 30: Heat Up System

    Operation Heat Up System 7. Remove the platen bleed stick (R). To reduce the risk of bursting a hose, never pressur- ize a hot melt system before turning on the heat. The air will be locked from the air motor until all tempera- ture zones are within a preset window of the tempera- ture setpoints.

  • Page 31: Prime Pump

    Operation Prime Pump 3. Adjust the air motor slider valve (CM) to the open position. 1. Ensure that the system has completed the heat soak cycle. The display status bar should read Active. 2. Adjust the air motor air regulator (CK) to 0 psi. 4.
  • Page 32 Operation For Tandem Operation 6. If a new drum was installed and the unit is equipped with proximity sensors, press the Pump Ready but- Complete steps 1-5 on page 31 for the inactive unit. Note that the heat will remain on for the inactive unit .

  • Page 33: Prime System

    Operation Prime System 7. Close the main air slider valve (CA) and release the trigger lock. 8. Engage the trigger lock. 1. Close the main air slider valve (CA). 2. If using a manual gun, lock the dispense valve trig- ger open by pulling and securing the trigger using .

  • Page 34: Pressure Relief Procedure

    Operation Pressure Relief Procedure 3. Set the ram director valve (CC) to the neutral posi- tion. Follow the Pressure Relief Procedure When- ever 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 clean-...

  • Page 35: Shutdown

    Operation Shutdown Table 9 Schedule Screen Color Identification Color Description Green System on 1. Press to disable the heaters and pump. The Yellow Setback screen will say “Inactive”. If using the Schedule func- System off tion, the heaters and pump will be disabled automat- Gray Disabled ically at the set time.

  • Page 36: Change Drums

    Operation Use the Schedule Function 2. Push in the air motor slider valve (CM) to stop the pump. 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.

  • Page 37: Troubleshooting

    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 —...

  • Page 38: Error Codes

    Troubleshooting Error Codes The last digit of the error code indicates which system component the error applies. The “#” (pound) character indicates the code applies to multiple system compo- There are three types of errors that can occur. Errors are indicated on the display as well as by the optional nents.
  • Page 39 Troubleshooting Code Description Type Cause Solution A3MF AWB Clean Fan Filter Alarm Clean inlet screen. Cooling inlet screen is dirty A4 _ Alarm Verify accessory is rated for 240 VAC. High Current Unit _ Defective or Zone _ shorted to Verify heater resistance and check for shorts to ground on ground.
  • Page 40 Troubleshooting Code Description Type Cause Solution CCAG Alarm Comm. Error, CGM Module Power removed from Gateway. Restore power. Gateway is no longer Rotary switch on Gateway changed to positions responding between 2 and 8 (must be in 0, 1, or >8 positions).
  • Page 41 Troubleshooting Code Description Type Cause Solution DC X Pump Diving Alarm Pump is trying Adjust the drum empty level sensor to detect an to feed empty state. adhesive, no Ensure the ram director valve is in the down adhesive to position and sufficient air is forcing the ram feed.
  • Page 42 Troubleshooting Code Description Type Cause Solution T4M# Alarm Ensure inlet and outlets are not obstructed. AWB High Transformer Transformer Temp Temperature is Verify fan is plugged in. too High T4 _ Alarm Change High Temp Alarm Offset. High Temp. Unit _ Temperature Zone _ reading has...
  • Page 43 Troubleshooting Code Description Type Cause Solution Alarm Pump _ Solenoid is Pump is not Verify harness is plugged into J13 of the disconnected turning on daughter board. Verify it is secured to the when it should solenoid. Replace Solenoid. Alarm Pump _ Solenoid Solenoid is Inspect for short in harness.

  • Page 44: Ram Troubleshooting

    Troubleshooting Ram Troubleshooting Problem Cause Solution Closed main air valve or clogged air Open air valve; clear air line. Ram will not raise or lower. line, Not enough ram air pressure. Increase ram air pressure. Worn or damaged ram piston. Replace piston.

  • Page 45: Heated Pump Troubleshooting

    Troubleshooting Heated Pump Troubleshooting See pump manual for additional pump troubleshooting information. Problem Cause Solution Rapid downstroke or upstroke (pump Material not heated to proper Check and adjust temperature to cavitation). temperature. proper setpoint. Wait for pump/platen to heat up. Air is trapped in pump.

  • Page 46: Repair

    Repair Repair Replace Wipers 2. Make sure the ram plate is down and the ram hand valve is in the OFF position. 1. To replace a worn or damaged wiper (V) raise the ram plate up out of the drum. Perform steps 1 through 7 of Change Drums, page 36.

  • Page 47: Separate The Air Motor And Pump

    Repair Separate the Air Motor and 6. Disconnect the platen RTD wires from pin 3 and pin 6 from the J5 connector on MZLP MZTCM-1 or Pump MZTCM-5. This procedure must be done with the unit still warm. The material and equipment will be hot! 1.
  • Page 48 Repair 8. Remove the pump sheet metal enclosure. 12. Remove air line from air motor and air lines to the follower blow-off valve. a. Remove the cover screws. 13. Tightly strap the air motor to the tie bar with a cable b.
  • Page 49 Repair . 28 334130L...

  • Page 50: Remove Platen

    Repair Remove Platen 8. Remove the screws and covers. 1. Turn the main power switch off. 2. Disconnect the platen power wires and the ground wire from within the main control panel and pull out of conduit. 3. Remove the platen assembly from the ram. 4.

  • Page 51: Replace Mzlp Fuse

    Repair Replace Pump RTD Fuse Kit Fuse Part 1. Turn the main power switch off. F1, F2 250VAC, 25A, long, white ceramic 24V289 F3-F10 250VAC, 8A, fast acting, clear glass Spare fuse kit included with system. NOTICE 2. Remove the screws that hold the front shroud in To prevent system damage, always use fast acting place and remove the front shroud.

  • Page 52: Replace Mzlp

    Repair Replace MZLP 6. To reassemble the MZLP, set the MZLP rotary switch based on location. See MZLP Rotary Switch Table. 7. Use the four screws (115) to install MZLP (111 or 112) to electrical enclosure. 1. Turn the main power switch off. 8.

  • Page 53: Replace Mzlp Daughter Card

    Repair Replace MZLP Daughter Card 5. Plug the new daughter card (112a) into the MZLP (112). 6. Use the screws (112b) to secure the daughter card to the MZLP (112). 7. Connect the cables to the new daughter card 1. Turn the main power switch off. (112a).

  • Page 54: Replace Awb

    Repair Replace AWB Replace Power Supply 1. Turn the main power switch off. 2. Note the location of each cable, then unplug all cables from the AWB (205). NOTE: For an AWB on a secondary system, remove the connector (182) and connect to the new AWB. 1.

  • Page 55: Replace Fan

    Repair Replace Fan 6. Remove the screws (141), grill (137), four nuts (139), rear fan grill (138), and fan (136). 1. Turn the main power switch off. 2. Disconnect the plug from the power outlet or turn off the circuit breaker for incoming power. 3.

  • Page 56: Replace Transformer

    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 F . 34, page 57. Power Harness Wires CR-2 Connections CR2-W1 Terminal 1 1.
  • Page 57 Repair CR-2 . 34: Inside of Electrical Control Enclosure 334130L...

  • Page 58: Update Software

    Repair Update Software NOTE: When the Screen turns on, you will see the fol- lowing screens: When software is updated on the ADM, the software is then automatically updated on all connected GCA com- First: ponents. A status screen is shown while software is Software is checking which updating to indicate progress.

  • Page 59: Electrical Schematics

    Electrical Schematics Electrical Schematics 230V, 3 Phase/60Hz 334130L...
  • Page 60 Electrical Schematics 400V, 3 Phase/50Hz 334130L...
  • Page 61 Electrical Schematics 400-600VV, 3 Phase/60Hz 334130L...
  • Page 62 Electrical Schematics AWB and MZLP#1 334130L...
  • Page 63 Electrical Schematics MZLP#2, MZLP#3, Overtemp, and Pump Heaters 334130L...
  • Page 64 Electrical Schematics MZLP Zones TYPICAL ZONE PIN OUT MZTCM-1 CONNECTOR PIN # FUNCTION MZTCM-1 ZONE 1,L2 SHIELD ZONE 2,L1 ZONE 2,L2 JUMPER ZONE 1,START MZTCM-1 J9 ZONE 1,RTD JUMPER ZONE 1,L1 RTD EXCITE ZONE 2,START ZONE 2,RTD ZONE 3,L2 TYPICAL ZONE PIN OUT SHIELD ZONE 4,L1 ZONE 4,L2...

  • Page 65: Parts

    Parts Parts Therm-O-Flow 200 Supply Unit ti25003a 334130L...
  • Page 66 Parts Therm-O-Flow 200 Supply Unit Part Description Part Description 120186 BOLT, mounting, u-bolt Frame 101864 SCREW, cap, sch 24W870 KIT, air controls; see Air Control Assembly, page 67 111303 NUT, hex CONTROL, electrical 100575 SCREW, cap, hex hd MODULE, pump; see Pump Mod-...
  • Page 67 Parts Air Control Assembly Integrated Control For Integrated Control For 24X026, Integrated Control For TOF Without Electrical Enclosure Hydraulic TOF With Electrical TOF With Electrical Enclosure Enclosure Part Description 24W870 KIT, CONTROL, air, 3 regulator; see manual 334201 121235 SOLENOID, air motor, ram 17A557 HARNESS, solenoid, MZLP 113445 FITTING, elbow, street 121282 FITTING, swivel, straight...
  • Page 68 Parts Electrical Module 148 150 152 153 145 147 149 177, 119 334130L...
  • Page 69 Parts 334130L...
  • Page 70 Parts Electrical Control Module Parts Part Description Part Description ENCLOSURE, electrical HARNESS, pump, mzlp1, tb, tof BUSHING, strain relief, m40 HARNESS, output, mzlp1, ssr, thread contact NUT, strain relief, m40 thread 17A555 HARNESS, pump, reed switch, tof 125946 PLUG, hole, 1/2 in 17A559 HARNESS, board, mxm, comm 123967 KNOB, operator disconnect 127511 CABLE, board, samtec...
  • Page 71 Parts Part Description 100016 WASHER, lock (Primary assemblies only) 24V745 SENSOR, level, low/empty BUSHING, strain relief NUT, bushing GROMMET, wire 124654 CONNECTOR, splitter, 12(m) x m12(f) (Secondary modules only) 121228 CABLE, can, female/female, 15.0 m (Secondary modules only) 16W035 CONNECTOR, jumper (8 zone assemblies only;...
  • Page 72 Parts Electrical Panel 230V 400V Transformer 230, 231 1 216, 229 1 214 1 223, 224 215 1 210 1 202, 203, 204, 236 234 6 Transformer Panel Shown 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) 334130L...
  • Page 73 Parts 230V Panel 400V 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) 334130L...
  • Page 74 Parts Electrical Panel Parts Part Description Part Description HARNESS, rcd, ssr fan PANEL, elec, tof, 11ga, zinc See Code C Table 117666 TERMINAL, ground 6690-24 FUSE, fuse block buss jt60030 113783 SCREW, machine, pn hd -164 100985 WASHER, lock ext 127744 CIRCUIT, breaker, 3p, 32a, ul489;...
  • Page 75 Parts Merkur 2200, 23:1 Pump Modules 309a 335a 309b 335b ti25145a Torque to 50-60 ft-lbs (68-81 N•m). Coat inside of heater (309a, 309b) only to within 0.75 in. (19 mm) of vertical ends with non-silicone heat sink compound Torque to 145-155 ft-lbs (196-210 N•m). before mounting.
  • Page 76 Parts Merkur 2200, 23:1 Pump Modules Part Description 24W754 MOTOR, air, 6 in, 4.75 stroke, blue 155470 FITTING, swivel, union, 90° FASTENER, screw, slot hex, #8-32 tap 24X441 SWITCH, reed assy BRACKET, motor mount 15H397 ADAPTER, rod, pump 16A223 ROD, tie, vert driver 106166 NUT, mach ,hex 128332 HEATER, pump, 600 watt 24W150 PUMP, long shaft, cf;...
  • Page 77 Parts Merkur 3400, 36:1 Pump Modules 309a 335a 335b 309b Torque to 50-60 ft-lbs (68-81 N•m). Coat inside of heater (309) only to within 0.75 in. (19 mm) of vertical ends with non-silicone heat sink compound before mounting. Torque to 145-155 ft-lbs (196-210 N•m). Cap screws (311) must be loose while tie rods (307) are Coat mounting surface of sensor mounting block (322) with being torqued.
  • Page 78 Parts Merkur 3400, 36:1 Pump Modules Part Description 24R015 MOTOR, assy, air, 7.5 in, blue 155470 FITTING, swivel, union, 90° FASTENER, screw, slot hex, #8-32 tap 24X441 SWITCH, reed assy 15H173 BRACKET, motor mount, tof 200 15H397 ADAPTER, rod, pump 16A223 ROD, tie, vert driver 106166 NUT, mach, hex 128332 HEATER, pump, 600 watt...
  • Page 79 Parts NXT 6500, 70:1 Pump Modules 407a 430a 430b 407b ti25160a Torque to 50-60 ft-lbs (68-81 N•m). After fastening band clamp (412), secure excess with fiberglass tape. Torque to 145-155 ft-lbs (196-210 N•m). Coat inside of heater (407) only to within 0.75 in. (19 mm) of vertical ends with non-silicone heat sink compound Coat mounting surface of sensor mounting block (411) with before mounting.
  • Page 80 Parts NXT 6500, 70:1 Pump Modules Part Description Part Description C38163 WASHER, lock, ext. tooth N65LR0 MOTOR, 6500, low-noise, remote CONDUCTOR, ground 120375 ADAPTER, elbow, 3/4 npti x 1/2 C38162 SCREW, machine npte 120186 BOLT, mounting, u-bolt 15H542 BRACKET, mounting, motor, 100307 NUT, hex tof200 17A406 ADAPTER, rod, pump, tof...
  • Page 81 Parts Pump Shield ti25162a Part Description Part Description 17J504 LABEL, warning 24W974 COVER, pump, bottom 104088 RIVET, blind 24W975 COVER, pump, right 15J075 LABEL, safety, hot surface and 24W976 COVER, pump, left shock 24W977 COVER, pump, top, front 24W978 COVER, pump, top, back BUSHING, conduit, 1 in C20731 FITTING, conduit, connector, 1 in.
  • Page 82 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) 611, 629 334130L...
  • Page 83 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) Part Description Part Description CONDUCTOR, 0.3 ft (0.09 m) PLATEN —...
  • Page 84 Parts 334130L...
  • Page 85 Parts Drum Ram Post Saddle Clamp C32463 Option H-1 Torque to 50 in-lbs. ti25188a Part Description C32424 BOLT, U, 7 in. (177.8 mm) 160111 CLAMP, barrel 100103 PIN, cotter 100307 NUT, hex 100133 WASHER, lock C38182 WASHER, plain C32461 CLAMP, saddle 166265 PIN, pivot 334130L...
  • Page 86 Parts Drum Ram Post Saddle Clamp 918395 Option H-3 Torque to 50 in-lbs. ti25189a Part Description 100101 SCREW, cap, hex hd 918421 CLAMP, back half assembly 918423 KIT, repair 617395 PIN, quick release 100133 WASHER, lock C19200 WASHER, plain 617433 SPACER, drum clamp 617395 CLAMP, saddle 100131 NUT, full hex C32424 BOLT, U 7 in.
  • Page 87 Parts Fiber Drum Reinforcement Shell Clamp 918397 Option H-2 ti25190a Torque to 50 in-lbs. Part Description C32424 BOLT, U, 7 in. (177.8 mm) C32271 CLAMSHELL C19126 SCREW, cap, hex hd 100133 WASHER, lock 100307 NUT, hex 617340 CLAMP, saddle 617341 MOUNT, clam shell 334130L...
  • Page 88 Parts Vent Hood Kit, 233559 Part Description VENT hood 112166 SCREW, cap, sch 100016 WASHER, lock C14038 LABEL, warning Replacement Warning labels, signs, tags, and cards are available at no cost. 334130L...

  • Page 89: Accessories And Kits

    Accessories and Kits Accessories and Kits Wiper Kits CGM Installation Kit, 25C994 See manual 309196 for installation and repair instruc- This kit enables controlling logic, such as a robot con- tions. troller or PLC continuously monitoring data from the Therm-O-Flow system, as well as optionally controlling the system accordingly.

  • Page 90: Accessory Extension Cables

    Accessories and Kits Accessory Extension Cables Use to connect fluid control devices and heated hoses to the electrical control enclosure. Part No. Description Connect between controller and heated hose 129300 15 ft, 12 pin to 12 pin 129301 25 ft, 12 pin to 12 pin Connect between controller and heated accessory 129302 15 ft, 12 pin to 8 pin...

  • Page 91: Heated Hoses And Fittings

    Accessories and Kits Heated Hoses and Fittings (9/16 in -18 (3/4 in -16 (7/8 in -14 (1-1/16 in -12 (1-5/16 in -12 (1-5/8 in -12 Hose Diameter JIC) JIC) JIC) JIC) JIC) JIC) Hose Length 3 ft (1.5 m) None None None 15C586...
  • Page 92 Accessories and Kits (9/16 in -18 (3/4 in -16 (7/8 in -14 (1-1/16 in -12 (1-5/16 in -12 (1-5/8 in -12 Hose Diameter JIC) JIC) JIC) JIC) JIC) JIC) Compact Heated 116766 Regulator, 289208 16V432 116766 121311 116765 116766 120267 Inlet &...

  • Page 93: Channel Upgrade Kit, 24V755

    Accessories and Kits 8 Channel Upgrade Kit, 24V755 Use this kit to upgrade a 4 Channel system to an 8 channel system. Part Description Part Description MODULE, GCA, MZLP 16W035 CONNECTOR, jumper 125856 SCREW, 8–32, serrated flange 17A544 HARNESS, power, MZLP2, AWB 16T440 CAP, souriau, UTS14 112190 STRAP, wrist, grounding 127511 CABLE, board, samtec...
  • Page 94 Accessories and Kits 8 Zone Upgrade Kit Installation 1. Disconnect the plug from the power outlet or turn off the circuit breaker for incoming power. 2. Place the grounding wrist strap (7) over your wrist and secure the other end to a grounded surface. 3.

  • Page 95: 12 Channel Upgrade Kit, 24V756

    Accessories and Kits 12 Channel Upgrade Kit, 24V756 Use this kit to upgrade an 8 channel system to a 12 channel system. Part Description Part Description MODULE, GCA, MZLP 17A545 HARNESS, power, MZLP2/3, 125856 SCREW, 8–32, serrated flange 112190 STRAP, wrist, grounding 16T440 CAP, souriau, UTS14 17C712 TOKEN, software upgrade 127511 CABLE, board, samtec...
  • Page 96 Accessories and Kits ti25237b 334130L...
  • Page 97 Accessories and Kits 12 Zone Upgrade Kit Installation 1. Disconnect the plug from the power outlet or turn off the circuit breaker for incoming power. 2. Place the grounding wrist strap (7) over your wrist and secure the other end to a grounded surface. 3.

  • Page 98: Appendix A - Adm

    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 heat- The ADM automatically turns on when the main power switch is turned on.

  • Page 99: Icons

    Appendix A - ADM Icons Screen Icons Softkey Icons These are frequently used icons on the screens. The The following icons appear in the ADM, directly to the following descriptions explain what each icon left or right of the soft key which activates that operation. represents.

  • Page 100: Operation Screens

    Appendix A - ADM Operation Screens Events The Events screens store a maximum of 200 events. The events list can be downloaded in the USB logs. See Home Appendix B - USB Data, page 107. This screen shows the temperature state of the system and material usage.
  • Page 101 Appendix A - ADM Errors CAN: 24 VDC power supply voltage reading (18-28 VDC) DI: System Digital Inputs 0: Drum Empty 1: Drum Low 2: Pump Cycle Switch Up 3: Pump Cycle Switch Down DO: System Digital Outputs 0: Pump Solenoid 1: Not Used 2: Not Used 3: Not Used...

  • Page 102: Setup Screens

    Appendix A - ADM Setup Screens Heat Soak: Time for to preheat after all zones have reached their target temperatures. Pump cannot turn on until timer is complete. The heat soak is a user-defined NOTE: It is important to set all settings in the System time.
  • Page 103 Appendix A - ADM Advanced 1 Specific Gravity: Required to convert the volume dis- pensed to mass dispensed for tracking the total weight and flow rate. When the specific gravity value is popu- lated, the total mass dispense since the last total weight reset is shown on the Home screen and the mass flow rate is shown on the Diagnostic screen.
  • Page 104 Appendix A - ADM Advanced 4 and 5 Advanced 4 screen shows the part number and version of each installed software module on a primary unit and Advanced 5 shows each module on a secondary unit. 334130L...
  • Page 105 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.
  • Page 106 Appendix A - ADM Gateway 1 and 2 If the Therm-O-Flow system has a communication gate- way module (CGM) installed, an additional “Gateway” chapter containing 1 or 2 pages will be available in the setup screens. These pages enable the user to set the CGM IP or device address, configure the field bus proto- col selections, and enable the user to view the mapping information programmed into the CGM module.

  • Page 107: Appendix B - Usb Data

    NOTE: If the pop-up screen does not appear, the flash system, there will be more than one folder within the drive is not compatible with the ADM. Try a different Graco folder. Each folder is labeled with the corre- flash drive. sponding serial number of the ADM. (The serial number is on the back of the module.)

  • Page 108: Usb Logs

    NOTE: If the SETTINGS.TXT or DISPTEXT.TXT files These logs (5-BLACKB.CSV, 6-DIAGN.CSV) are remain in the UPLOAD folder, they will be uploaded designed to provide useful information to Graco when every time the USB drive is inserted into the corre- calling for technical assistance.

  • Page 109: System Language File

    Appendix B - USB Data System Language File Modify the second column of the custom language file as needed and then follow the Upload Instructions, page 107, to install the file. The system language file name is DISPTEXT.TXT and is stored in the DOWNLOAD folder. The format of the custom language file is critical.

  • Page 110: Dimensions

    Dimensions Dimensions Ram Mounting and Clearance ti24564a ti24565a in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) 59 (1498.6) 40 (1016) 37 (939) 21 (533) 25 (635) 58 (1473) 48 (1219) 11 (279) Height (H) Dimensions Fully Raised...

  • Page 111: Technical Specifications

    Technical Specifications Technical Specifications Therm-O-Flow 200 Hot Melt System U.S. Metric Displacement pump effective area 1.24 in.² 8 cm² Volume per cycle 11.7 in.³ 192 cm³ Pump cycles per 1 gallon (3.8 liters) Ram maximum input pressure 100 psi 0.7 MPA, 7 bar Maximum pump operating tempera- 400°F...

  • Page 112: Graco Standard Warranty

    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.

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