Graco Therm-O-Flow 20 Instructions - Parts Manual
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Graco Therm-O-Flow 20 Instructions - Parts Manual

Graco Therm-O-Flow 20 Instructions - Parts Manual

20 liter (5 gallon) pail size
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Instructions - Parts
20 Liter (5 Gallon) Pail Size
Therm-O-Flow
™
EasyKey
Hot Melt Pail Unloaders
For applying hot melt sealant and adhesive materials.
Maximum Operating Temperature: 400°F (204°C)
®
NXT
2200 Powered Unloaders
2300 psi (15.9 MPa, 159 bar) Maximum Fluid Working Pressure
125 psi (.85 MPa, 8.5 bar) Maximum System Air Pressure (Ram)
100 psi (0.7 MPa, 7 bar) Maximum Air Motor Pressure
®
NXT
3400 Powered Unloaders
3000 psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure
125 psi (.85 MPa, 8.5 bar) Maximum System Air Pressure (Ram)
82 psi (0.57 MPa, 5.7 bar) Maximum Air Motor Pressure
®
NXT
6500 Powered Unloaders
3000 psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure
125 psi (.85 MPa, 8.5 bar) Maximum System Air Pressure (Ram)
43 psi (0.29 MPa, 2.9 bar) Maximum Air Motor Pressure
Important Safety Instructions.
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Contents and page 6 for Model Numbers.
®
20
311976K
EN
TI10076A

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Summary of Contents for Graco Therm-O-Flow 20

  • Page 1 Instructions - Parts 20 Liter (5 Gallon) Pail Size ® Therm-O-Flow 311976K ™ EasyKey Hot Melt Pail Unloaders For applying hot melt sealant and adhesive materials. Maximum Operating Temperature: 400°F (204°C) ® 2200 Powered Unloaders 2300 psi (15.9 MPa, 159 bar) Maximum Fluid Working Pressure 125 psi (.85 MPa, 8.5 bar) Maximum System Air Pressure (Ram) 100 psi (0.7 MPa, 7 bar) Maximum Air Motor Pressure ®...

  • Page 2: Table Of Contents

    Dual Ram Cross-Over Installation ... . 35 Graco Information ......78 Typical Installation .

  • Page 3: Warnings

    Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer. • Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only. • Do not alter or modify equipment.
  • Page 4 Warnings WARNING PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to: •...
  • Page 5 Warnings 311976K...

  • Page 6: Overview

    The six digit part number stamped on your directs the molten material to the pump inlet. The mate- Therm-O-Flow 20 defines your machine. Each digit rep- rial then travels through a heated Check-Mate pump and resents a component, as shown in the following table.
  • Page 7 Overview 3. Heat 2. Number of Controls Therm-O-Flow Heat Zones Supply Voltage 4. Pump Ratio 5. Heated 6. Controls 20 (T) (0, 6) (0, 2, 3, 4) (1, 2, 3) Platen (F, S) (0, B, S) Part No. 230 (2) 23:1 (1) Finned (F) Secondary (S)

  • Page 8: Component Identification

    Therm-O-Flow system components. See F . 1. • Ram Up/Down Lever (R) changes the direction of Contact your Graco distributor for help in designing a the ram. system to suit your particular needs. • Ram Air Regulators (N, P) control the air pressure The air-powered ram extruder forces high viscosity flu- to the ram.
  • Page 9 Overview TI10077A TI10076A TI10030A . 1: Component Identification System Bleed-type Master Air Valve Ram Up Air Regulator and Gauge Air Line Filter Ram Down Air Regulator and Gauge Air Motor Air Regulator (bleed-type) and Gauge Ram Up/Down Lever Air Motor Bleed-type Master Air Valve Platen Blow-off Pushbutton Blow-Off Air Regulator and Gauge Heated Pump...

  • Page 10: Power Requirements

    Overview Power Requirements Heat Control Zone Selection See Table 1, and the Technical Data on page 77. The Therm-O-Flow 20 has 6 heat zones (see F . 2). • Zones 1 and 2 are always used for the heated Table 1: Electrical Requirements platen and the heated pump.

  • Page 11: Installation

    Installation Installation Locate and Install the Ram The installation procedure includes: • unpacking the ram 1. Apply 50 psi download pressure to ram. • locating and installing the ram • mechanical setup CAUTION Always lift system at proper lift locations (see F .

  • Page 12: Hose Installation And Care

    2. Wrap exposed fittings on the pump outlet with Nomex insulation and secure insulation using fiber- glass tape. 3. Fill displacement pump wet cup 2/3 full with Graco Throat Seal Liquid (TSL). 4. Turn all air regulators to their full counterclockwise 6.

  • Page 13: Electrically Connect Hoses

    . 5) to a grounded electrical source that has the required service ratings. See Power Requirements The Therm-O-Flow 20 requires Graco single-circuit on page 10 and Electrical Schematics on page 54. material hoses rated at a maximum of 1250 Watts.

  • Page 14: Grounding

    Installation Grounding Check Resistance Ground the supply unit as instructed here and in the Check the Resistance Between the Supply individual component manuals. Unit and the True Earth Ground The power source conduit is not an adequate ground The resistance between the supply unit components for the system.

  • Page 15: Overview Of The Temperature Controller Settings

    Installation Table 2: RTD Sensor Resistance Table 3: Resistance Chart of All Heaters Between Unit Range Zone Component Terminals Range (ohms) Zone Component Terminals Voltage (ohms) Platen 2011 & 2021 108 +/- 2% Platen F/A, D/C 29 +3/-5 Fluid Pump 2051 &...

  • Page 16: Purging The System

    Purging the System 3. Select a pail of material that can eliminate the fac- tory-test oil from the system. If necessary, check with Graco or the material supplier for a recom- Purging the system before the initial use can prevent mended solvent.

  • Page 17: Operator Controls

    Operator Controls Operator Controls EasyKey Display and Keypad EasyKey is a simple user interface consisting of an LCD Main Power Disconnect display (A) and keypad (B). See F . 7. Turns system power on or off. Includes system circuit Use to input numerical data, enter Setup screens, scroll breaker.

  • Page 18: Lcd Display

    Operator Controls Table 4: Key Descriptions Left Arrow: move to previous screen. Right Arrow: move to next screen. System On/Off: on starts system. Activates , and keys. Heat State Toggle: starts heaters in all zones where they are enabled. Cycles through heat states (Heat Off, Heat On/Heat Soak/Run, Setback).

  • Page 19: Easykey Display Screens

    Power Up Screens Zone Run Screen The Zone Run screen displays a summary of all 6 zones When the EasyKey power switch is turned on the Graco in the system. See F . 9. Logo screen and the phrase “Establishing Communica- tion”...

  • Page 20: Setup Mode

    EasyKey Display Screens Setup Mode Zone Setup Screens Zone Setup has 2 screens. The screen number appears on the right side of the screen. See F . 11 and F . 12. Entering Setup See Table 5 on page 21 for settings. Press to enter or exit Setup.
  • Page 21 EasyKey Display Screens Table 5: Zone Setup Screens Screen Setting Selection Description Unloader In single system always A. In tandem or expansion system it is selectable (See F . 11) between A and B. Zone Numeric Enter desired zone (1-6). Zone 1 (platen) and zone 2 (pump) are fixed. All other zones are selectable (hose, gun, regulator, manifold, meter).
  • Page 22 EasyKey Display Screens Timer Screen Report Screen Timer settings are explained in Table 6. See also F . 13 The Report screen shows the most recent 12 alarms, and F . 14. with the date and time. Use the Up Arrow or Down Arrow keys to see all the alarms.
  • Page 23 EasyKey Display Screens Advanced Screens Advanced Setup has 3 screens. The screen number appears on the right side of the screen. See F . 16 through F . 18, and Table 7 on page 24. The specific gravity listed in the material data sheet may be for solid form at room temperature.
  • Page 24 EasyKey Display Screens Table 7: Advanced Setup Screens Screen Setting Selection Description Default Language English, Spanish, Language displayed. English is the default. English (See F . 16) German, French, Japanese, Chinese, custom Number 6 / 6+4 / 6+6 The number of zones in system is set at the factory. Zones (8 / 8+4 / 8+8 are not used on these mod-...

  • Page 25: Setup

    Setup Setup Purge Before Using Equipment 2. Place the ram UP/DOWN lever in the UP position. The equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid con- taminating your fluid with oil, purge the equipment with a compatible material before using the equipment.
  • Page 26 Setup 9. Remove the platen bleed stick (Y). See F . 20. 10. Place the ram UP/DOWN lever in the DOWN posi- tion. TI8141A CAUTION Lowering the ram without a pail in place can damage the pail centering guides (if equipped). TI8143A .

  • Page 27: System Heat Up

    Setup System Heat Up 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. Never pressurize a hot melt system before turning on the heat.
  • Page 28 Setup 3. Adjust the air motor air regulator (C) to approxi- 7. Make sure the pump begins to cycle and heated mately 20 psi (138 kPa, 1.38 bar) on the pneumatic material flows from the bleed stem (ST) after several panel.

  • Page 29: Prime System

    Setup Prime System 3. Place the dispense valve over a waste container. 4. Slowly open the system master air valve. 5. Prime the system until a smooth flow of material dis- penses from the dispense valve. 1. Close the system bleed-type master air valve (A). 6.

  • Page 30: Operation

    Operation Operation Pressure Relief Procedure 3. Disengage trigger lock. Trigger Lock Disengaged Follow Pressure Relief Procedure when you stop spraying and before cleaning, checking, servicing, or transporting equipment. TI8050A This procedure describes how to relieve pressure for the supply unit. Use this procedure whenever you shut off 4.

  • Page 31: Ram Pressure Relief Procedure

    Operation Ram Pressure Relief Procedure 5. Exhaust air from both sides of the ram: a. Move the ram UP/DOWN lever to the DOWN position until all air is exhausted from one side of the ram. Follow Pressure Relief Procedure when you stop spraying and before cleaning, checking, servicing, or transporting equipment.

  • Page 32: Pail Changing

    Operation Pail Changing 1. Place the ram UP/DOWN lever in the UP position. Follow the procedure below to change the pail on a fully heated machine. TI8141A CAUTION 2. Dial ram up regulator pressure to 0 psi. Be sure to reload the empty supply unit with a full pail of material immediately.
  • Page 33 Operation 4. Push and hold the blow-off air pushbutton (S). The platen will begin to raise. If both unloaders in the system are empty, the pump ready and transition sequence will depend on the unloader to transition to the Run state. ✓...

  • Page 34: System Shutdown

    Operation System Shutdown 4. Lock the dispense valve trigger open by pulling and securing the trigger using the trigger retainer TR). Follow the procedure below for normal system shut down, such as at the end of the work day. 1. Make sure the pump rod (PR) is parked in the down position.

  • Page 35: Dual Ram Cross-Over Installation

    Dual Ram Cross-Over Installation Dual Ram Cross-Over Installation Typical Installation Cross-Over Cable (part number 15H385) was included with the Dual Ram prior to 6/19/2008. Use can cable, (part number 1221228) for units dated after 6/19/2008. Cross-Over Cable TI10075A EasyKey Setup See EasyKey Display and Keypad on page 17.

  • Page 36: Maintenance

    Maintenance Maintenance Periodically (at least once a month), inspect the ram guide sleeves, rods and cylinders for wear or damage. Ground Fault Interrupt Periodically (at least once a month) test the ground fault interrupt switch by pushing the TEST button. Power in a Tandem System In a Tandem System, the secondary unloader pro- vides 24VDC power to the EasyKey display.
  • Page 37 Error 246 - The EasyKey does not communicate with the Unloader PCB (246 position). • Error 300 - The EasyKey and another PCB have incompatible software. If any of the above error codes are generated, contact a Graco customer service representative. Events Cause Drum Empty - occurs when the pail empty proximity sensor is activated for the ram position.

  • Page 38: Ram Troubleshooting

    Ram Troubleshooting Ram Troubleshooting Problem Cause Solution Ram will not raise or lower. 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.

  • Page 39: Heated Pump Troubleshooting

    Heated Pump Troubleshooting Heated Pump Troubleshooting For additional troubleshooting information about the pump, see the pump’s documentation. Problem Cause Solution Rapid downstroke or upstroke (pump Material not heated to proper temper- Check and adjust temperature to cavitation). ature. proper set point. Wait for pump/platen to heat up.

  • Page 40: Electrical Control Panel Troubleshooting

    Electrical Control Panel Troubleshooting Electrical Control Panel Troubleshooting Problem Cause Solution Disconnect is ON, but EasyKey not The ground fault interrupt has been Have a qualified electrician check lit. activated. wiring. One or more fuses or circuit breakers Have a qualified electrician check tripped.

  • Page 41: Service

    Service Service Platen Service Whenever you service the ram, follow the Ram Pres- sure Relief Procedure on page 31. Raise the platen up out of the pail before proceed- ing. See Pail Changing on page 32. Periodically (once a month), inspect the ram guide sleeves, rods and cylinders for wear or damage, replace all worn parts.
  • Page 42 Service Replacing Wiper 1. Follow Pressure Relief Procedure, page 30. 2. Separate the wiper joint, and bend back the strap- ping that covers the clamp (207). F . 22. 3. Unscrew the worm gear and remove the wiper (202). 4. Thread the strapping through the new wiper (202). 5.

  • Page 43: Air Motor/Pump Removal And Service

    The pump packings do not require any other service or 6. Turn OFF the main electrical disconnect (K) located maintenance, except as described in the Daily Mainte- on the left side of the Therm-O-Flow 20. nance Procedures. See 308570 for inspection frequency of the pump.
  • Page 44 Service TI10084A . 23 311976K...

  • Page 45: Replacing Heater Bands And Sensors In Pump Module

    3. Disconnect quick connect terminal. 4. Loosen the clamp holding sensor on pump (G). See . 24. This procedure can be done when the Therm-O-Flow 20 is cool. 5. Reconnect sensor to extension wire. 6. Replace the sensor in clamp: Removing/Replacing Heater Band 1.

  • Page 46: Parts

    Parts Parts Therm-O-Flow 20 Supply Unit Part Description Part Description 100214 WASHER, lock 277436 CART, assembly 101864 SCREW, cap, socket head; 5/16-18 288544 PEDESTAL, enclosure x 1 in. (25 mm) 253150 CONTROL, standard, 230v, 6 zone 100023 WASHER, plain; 3/8 253154 CONTROL, secondary, 230v, 6 100016 WASHER, lock;...
  • Page 47 Parts 24, 26, 38 19, 24, 26 7, 8, 9, 10 4 (Ref) TI10078A TI10080A 311976K...

  • Page 48: Pump

    Parts Pump Part Description N22LH0 MOTOR, 2200; used on 288506; see 311238 N34LH0 MOTOR, 3400; used on 288507; see 311238 N65LH0 MOTOR, 6500; used on 288508; see 311238 237885 PUMP, Check-Mate; see 308570 15J213 BRACKET, air motor; used on 288506 15J288 BRACKET, air motor;...

  • Page 49: Platen

    Parts Platen Part Description PLATE, heated, finned; used on 288511 PLATE, heated, smooth; used on 288512 C31052 HOSE, seal, Mini - 5 207440 VALVE, dispenser 288855 HANDLE, bleed 15J794 ADAPTER, bushing 514930 SCREW, cap, skt hd C31154 CLAMP, worm gear 167730 GASKET, copper 100176 BUSHING, hex 115948 ELBOW, 1/4 npt(m), 5/16 OD tube...

  • Page 50: Air Control

    Parts Air Control Part Description Part Description C11033 FILTER, air 113269 VALVE, ball, bleed-type; 1/2 npt 120434 SOLENOID, motor 24V dc 113286 VALVE, safety 120435 REGULATOR, remote piloted 115952 VALVE, 4-way, 1/8 npt 15H236 VALVE, ball, female, 1/2 npt 120432 REGULATOR, panel mount C06299 MUFFLER, #10-32 unf 115957 VALVE, check 115948 ELBOW, 1/4 npt(m), 5/16 OD tube...

  • Page 51: Easykey Assembly, Part No. 255224

    Parts EasyKey Assembly, Part No. 255224 TI7918A TI7919A Back of EasyKey Assembly Part No. Description LABEL, operations 117769 DISPLAY, graphics BOARD, circuit assembly PLATE, blank SCREW, pan head cross 4-40 311976K...

  • Page 52: Spare Parts And Kits

    Parts Spare Parts and Kits Spare Parts and Kits Graco Part No. Description See manual 308570 Pump Rebuild Kit 253566 Ethernet Kit 253147 EasyKey Display Kit 117769 LCD Graphic Display 253603 Pail Low and Empty Sensors 253547 Light Tower Kit...
  • Page 53 Parts 311976K...

  • Page 54: Electrical Schematics

    Electrical Schematics Electrical Schematics 253150 and 253156 Controls FU 1062 FU 1061 311976K...
  • Page 55 Electrical Schematics 311976K...
  • Page 56 Electrical Schematics BLACK 311976K...
  • Page 57 Electrical Schematics 1.75 X 3.0 WIRE DUCT INTRF 1.75 X 3.0 WIRE DUCT DISC PARTS AIRFLOW 1.25 X 3.0 WIRE DUCT O O O O O O O O O O O O O O O O O O O O O O O INTRF O O O O O O O O O O O O O O O O O O...

  • Page 58: 253154 And 253160 Controls

    Electrical Schematics 253154 and 253160 Controls 1212 1211 FU 1062 FU 1061 311976K...
  • Page 59 Electrical Schematics 311976K...
  • Page 60 Electrical Schematics 1.75 X 3.0 WIRE DUCT INTRF 1.75 X 3.0 WIRE DUCT DISC PARTS AIRFLOW 1.25 X 3.0 WIRE DUCT INTRF O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O...

  • Page 61: Accessories

    Accessories Accessories Light Tower Kit (253547) The optional light tower kit has the following color and flashing lights to signal warnings and alarms. See F Green denotes an active system where the pump will activate when material is needed. Yellow denotes user attention is required. Flashing yellow denotes a pail is empty (when equipped with proximity sensors).

  • Page 62: Light Tower Kit Recommended Wire Routing

    Accessories Light Tower Kit Recommended Wire Routing EasyKey 1.75 X 3.0 WIRE DUCT INTRF 1271 1272 1.75 X 3.0 WIRE DUCT DISC PARTS AIRFLOW 1.25 X 3.0 WIRE DUCT O O O O O O O O O O O O O O O O O O O O O O O INTRF O O O O O O O O O O O O O O O...

  • Page 63: Pail Low And Empty Sensor Kit (255233)

    When ordering this kit individually to connect to an exist- mounting bracket (A), activator (B), sensors (C), and a ing Therm-O-Flow 20 unloader assembly, use the bolts, cable for connecting to the Therm-O-Flow 20 control screws and washers provided to mount to the closest panel.

  • Page 64: Ethernet Kit (253566)

    The Ethernet kit is designed so that the Time Environment) for the program to operate correctly. user will have network access to the Therm-O-Flow 20 Follow the screen link to Java version 1.4.2.09 or newer. unit and can clear, display, download, restore, and reset Or enter http://java.sun.com/j2se/1.4.2/download.html...
  • Page 65 Accessories Non-hazardous Area Only Local Network Patch Cable Patch Cable Local Network Connection Direct Connection Laptop PC TI8570A Control Panel Patch Cable . 29 Network Selection 311976K...
  • Page 66 Accessories Local Network Hardware and Software Configuration Browser must be closed and restarted for change to be effective. Hardware Patch cables are used to connect each unit to the local network and to the Web connection (A) on the EasyKey panel.
  • Page 67 Accessories Software Operation Reports 1. Open Microsoft Internet Explorer. Display material usage report - shows the material pumped from the unit. See F . 33. 2. In the address area type http://192.168.0.1 3. Click Enter. 4. Select yes when security screen appears. 5.
  • Page 68 Restore setup values - allows files to be uploaded and restored to the TOF. To change IP settings use the freeware configuration program available from www.lantronix.com/device-net- Software/Resets working/utilities-tools/device-installer.html. Install EasyKey software - downloads the Graco provided software to the PC (approximately 5 minutes). 311976K...
  • Page 69 Accessories Ethernet Kit Installation Graco Kit 253566 is required for this connection. Do not operate Therm-O-Flow 20 with electrical control panel doors/covers open. Disconnect power source before servicing or electrically wiring. ti8557 . 39 RJ45 Bulkhead Connector Installation 1. Power the Therm-O-Flow system off and disconnect power source.

  • Page 70: Easykey Modbus / Tcp Wiring Diagram

    Accessories EasyKey Modbus / TCP Wiring Diagram TI8761 TI8762 . 41 . 40 . 42 311976K...

  • Page 71: Maintenance Call Kit (253548)

    Accessories Maintenance Call Kit (253548) The maintenance call kit is designed for the user to indi- cate an issue has occurred and needs to be addressed, but the unit keeps operating if no serious faults have occurred. With the optional light tower kit the mainte- nance call button (E) causes the yellow light to flash making the problem more obvious.

  • Page 72: Maintenance Call Kit (253548) Wiring

    Accessories Maintenance Call Kit (253548) Wiring ti8559 . 44 311976K...

  • Page 73: Discrete I/O Kit (253567)

    Accessories Discrete I/O Kit (253567) The discrete I/O kit is designed to connect to robots or PLC that control the primary unit. This connection allows the communication of System On/Off, Heat On/Heat Soak/Ready, Setback, Pail Empty, Warnings, Alarms, Maintenance, and Gun switch. Included in this kit is the Internal Cable Harness to convert the primary unit and the 40 ft external cable, which has individual wire on the robot/PLC end for the user to install.
  • Page 74 Accessories Robot I/O Cable, Part No. 120400 No. Signal Description Signal Type Wire Color Digital Input Reference Digital Input Ref Yellow System On/Off Digital Input Brown Heat On/Off Digital Input Pump On/Off Digital Input Orange 24 Vdc from Robot/PLC Digital Input Ref System On/Off Digital Output Green...

  • Page 75: Swirl Kit, Part No. 253263

    Accessories Swirl Kit, Part No. 253263 TI7921A Air In Ref. Part Description Qty. .125 ID hose barb x 1/4 npt Male brass fitting Regulator Gauge 1/4 to 1/8 Brass Hex Nipple Solenoid Valve 120384 Cable Tube Fitting Nylon tube 3 ft. Socket head cap screw (not shown) Tube Clamp (not shown) Regulator mounting bracket...

  • Page 76: Dimensions

    Dimensions Dimensions 2.8 in. (7.1 cm) 24.0 in. (61.0 cm) 3.2 in. (8.1 cm) 32.5 in. 22.6 in. (82.6 cm) (57.3 cm) 5.7 in. (14.5 cm) TI7932A 71.0 in. Ram measures 86 in. (180.3 cm) (218 cm) fully extend- ed (highest point. 63.4 in.

  • Page 77: Technical Data

    Technical Data Technical Data Displacement pump effective area ....1.24 in. (8 cm Volume per cycle ....... 11.7 in. (192 cm Pump cycles per 1 gal.

  • Page 78: 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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