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Graco Therm-O-Flow 20 EasyKey Instructions Manual

Hot melt pail unloaders
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Instructions - Parts
Therm-O-Flow 20
™
EasyKey
Hot Melt Pail Unloaders
20 Liter (5 Gallon) Pail Size
For applying hot melt sealant and adhesive materials. For professional use only.
Maximum Operating Temperature: 400°F (204°C)
Maximum System Air Supply Pressure: 100 psi (0.7 MPa, 7 bar)
President Powered Unloader
1800 psi (12.6 MPa, 126 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Motor Pressure
See page 2 for Contents and page 5 for Model Numbers.
Important Safety Instructions.
Read all warnings and instructions in this manual.
Save these instructions.
®
312094K
EN
TI10024A

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Summary of Contents for Graco Therm-O-Flow 20 EasyKey

  • Page 1 Instructions - Parts ® Therm-O-Flow 20 312094K ™ EasyKey Hot Melt Pail Unloaders 20 Liter (5 Gallon) Pail Size For applying hot melt sealant and adhesive materials. For professional use only. Maximum Operating Temperature: 400°F (204°C) Maximum System Air Supply Pressure: 100 psi (0.7 MPa, 7 bar) President Powered Unloader 1800 psi (12.6 MPa, 126 bar) Maximum Fluid Working Pressure 100 psi (0.7 MPa, 7 bar) Maximum Air Motor Pressure...

  • Page 2: Table Of Contents

    Pressure Relief Procedure ....27 Graco Information ......70 Trigger Lock .

  • 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: Overview

    Overview Overview How the Therm-O-Flow 20 Model Numbers Works The six digit part number stamped on your Therm-O-Flow 20 defines your machine. Each digit rep- A heated platen melts the sealant or adhesive and resents a component, as shown in the following table. directs the molten material to the pump inlet.

  • Page 6: Component Identification

    Before installing the system you should be familiar with . 1. all the Therm-O-Flow system components. See F . 1. Contact your Graco distributor for help in designing a • Platen Blow-off Valve (S) directs air to the underside system to suit your particular needs.
  • Page 7 Overview TI9752A TI10024A 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 Pump...

  • Page 8: Power Requirements

    Overview Power Requirements The heated hoses have a 16-pin connector on the inlet end cable, and an 8-pin connector on the outlet end See Table 1, and the Technical Data on page 69. cable. All heated valves, manifolds, and heaters are equipped with an 8-pin matching connector.

  • Page 9: 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 CAUTION • mechanical setup Always lift system at proper lift locations (see F .

  • Page 10: Hose Installation And Care

    Installation Hose Installation and Care 1. Do not use hose to pull equipment. 6. Do not clamp, squeeze, or zip tie hose. 7. Minimum bend radius is 8 in. (20.3 cm). 2. Use 2 wrenches to tighten. Torque to 470-550 in-lbs 8 in.

  • Page 11: Mechanical Setup

    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 Hose 1/ Throat Seal Liquid (TSL). Applicator 1 4.

  • Page 12: Grounding

    Installation Grounding For information about specific terminal locations and connections, see Electrical Schematics on Ground the supply unit as instructed here and in the page 49. individual component manuals. To connect the control panel to the electrical source: 1. Open electrical enclosure door and locate the main The power source conduit is not an adequate ground disconnect (K).

  • Page 13: Check Resistance

    Installation Check Resistance 3. Replace any parts whose resistance readings do not comply with the ranges listed in Table 2. Check the Resistance Between the Supply Check resistance at ambient room temperature Unit and the True Earth Ground (63°– 77°F [17°– 25°C] Table 2: RTD Sensors The resistance between the supply unit components and true earth ground must be less than 0.25 ohms.

  • Page 14: Overview Of The Temperature Controller Settings

    3. Select a pail of material that can eliminate the fac- tory-test oil from the system. If necessary, check Purging the System with Graco or the material supplier for a recom- mended solvent. Purging the system before the initial use can prevent material contamination, which may cause the material to 4.

  • Page 15: Operator Controls

    Operator Controls Operator Controls EasyKey Display and Keypad The EasyKey Display is a simple user interface consist- Main Power Disconnect ing of an LCD 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 16: 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 17: Easykey Display Screens

    Power Up Screens Zone Run Screen The Zone Run screen displays a summary of all 4 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 18: Setup Mode

    EasyKey Display Screens Setup Mode Zone Setup Screens Zone Setup has 2 screens. The screen number appears Entering Setup on the right side of the screen. See F . 11 and F . 12. See Table 5 on page 19 for settings. Press to enter or exit Setup.
  • Page 19 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 (1-4). Zone 1 (platen) is fixed. All other zones are select- able (hose, gun, regulator, manifold, meter).
  • Page 20 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 18 alarms, and F . 14. with the date and time. Use the Up Arrow or Down Arrow keys to see all the alarms.
  • Page 21 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 22. Press the Enter key to show drop-down lists and to enter your selection.
  • Page 22 EasyKey Display Screens Table 7: Advanced Setup Screens Screen Setting Selection Description Default Language English, Language displayed. The language is set at factory. English (See F . 16) Spanish, German, French, Japanese, Chinese, custom Number 4 / 4+4 / The number of zones in system is set at the factory. Zones 4+4S Change...

  • Page 23: Setup

    Setup Setup Purge Before Using Equipment 3. Slowly turn the ram UP regulator (N) clockwise until the ram begins to rise. See F . 19. The equipment was tested with lightweight oil, which is 4. When the ram is fully raised, install the pail. left in the fluid passages to protect parts.
  • Page 24 Setup CAUTION Lowering the ram without a pail in place can damage the pail centering guides (if equipped). 11. See F . 19. Slowly turn the ram DOWN regulator (P) clockwise to approximately 5-10 psi (34-69 kPa, 0.3-0.7 bar). The platen will begin to lower into the pail.

  • Page 25: System Heat Up

    Setup System Heat Up Prime System Never pressurize a hot melt system before turning on In a Tandem system, after a pail change has the heat. The air will be locked from the air motor until occurred on the inactive unloader, pressing the all temperature zones are within a preset window of the temperature set points.
  • Page 26 Setup 4. If a new pail was installed and: 7. With waste container in place, slowly open the air motor valve (D). • If the unit is equipped with proximity sensors, press the Pump Ready key • If the unit is not equipped with proximity sen- sors, press the Clear key if a motor error is present, then press the Pump Ready key...

  • Page 27: 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 28: 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 29: 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 Be sure to reload the empty supply unit with a full pail of material immediately. Do not raise the ram 2.
  • Page 30 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 31: System Shutdown

    Operation System Shutdown 3. 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 32: Dual Ram Cross-Over Installation

    Dual Ram Cross-Over Installation Dual Ram Cross-Over Installation Typical Installation Part No. 15H385 Cross-Over Cable was included with the Dual Ram prior to 6/19/2008. Use CAN Cable 121228 for units built after 6/19/2008 Cross-Over Cable TI10074A EasyKey Setup See EasyKey Display Screens on page 17. Pail Change Procedure See Pail Changing on page 29.

  • Page 33: Maintenance

    Maintenance Maintenance Alarm Troubleshooting The Therm-O-Flow alarms alert you to a problem and help prevent system shut downs or application errors. If an alarm occurs, operation may stop and the following Periodically (at least once a month), inspect the ram occurs.
  • Page 34 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 35: 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 36: Pump Troubleshooting

    Pump Troubleshooting Pump Troubleshooting For additional troubleshooting information about the pump, see the pump’s documentation. Problem Cause Solution Bleed air from pump. See Prime Rapid downstroke or upstroke (pump Air is trapped in pump. System, page 25. cavitation). Downstroke: Dirty or worn pump Clean or repair.

  • Page 37: 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 38: Service

    Service Service Platen Service Whenever you service the ram, follow the Ram Pres- sure Relief Procedure on page 28. Raise the platen up out of the pail before proceed- ing. See Pail Changing on page 29. Periodically (once a month), inspect the ram guide sleeves, rods and cylinders for wear or damage, replace all worn parts.
  • Page 39 Service Replacing Wiper 1. Follow Pressure Relief Procedure, page 27. 2. Separate the wiper joint, and bend back the strap- ping that covers the clamp (207). F . 21. 3. Unscrew the worm gear and remove the wiper (202). 4. Thread the strapping through the new wiper (202). 5.

  • Page 40: Air Motor/Pump Removal And Service

    Service Air Motor/Pump Removal and Service 10. Remove the screws (36) and washers (22) holding the pump adapter (107) to the platen. 11. Remove the cover from the junction box (31). This procedure must be done with the unit still Remove the screws holding the junction box to the warm.
  • Page 41 Service TI10203A . 22 312094K...

  • Page 42: Parts

    Parts Parts Therm-O-Flow 20 Part Description Part Description 100016 WASHER, lock; 1/4; units with con- 277436 CART, assembly trols 288544 PEDESTAL, enclosure 100016 WASHER, lock; 1/4; units without 288671 CONTROL, standard, 230v, 4 zone controls 288673 CONTROL, secondary, 230v, 4 112166 SCREW, cap, socket-hd;...
  • Page 43 Parts 22, 24, 39 42, 15 7, 8, 9, 10 31, 32, 33 22, 23, 24 4 (Ref) TI10025A TI10027A 312094K...

  • Page 44: Pump

    Parts Pump Part Description 207352 MOTOR, air, President; see 306982 918417 PUMP, Mini-5; see 307431 288635 PLATE, mounting 198369 ROD, tie 100340 NUT 100133 WASHER, lock 298073 ADAPTER, pump 156082 O-RING 112166 SCREW, cap, SCH 100016 WASHER, lock 207370 ROD, connecting 198412 ROD, connecting C38225 O-RING 101946 PIN, cotter, SST...

  • Page 45: 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 46: 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 47: Easykey Assembly, Part No. 255224

    Parts EasyKey Assembly, Part No. 255224 TI7918A TI7919A Back of EasyKey Assembly Part No. Description LABEL, operations DISPLAY, graphics BOARD, circuit assembly PLATE, blank SCREW, pan head cross 4-40 312094K...

  • Page 48: Spare Parts And Kits

    Parts Spare Parts and Kits Spare Parts and Kits Graco Part No. Description See manual 307431 Pump Rebuild Kit 253566 Ethernet Kit 255224 EasyKey Display Kit 253603 Pail Low and Empty Sensors 253547 Light Tower Kit 120400 Discrete I/O Cable...

  • Page 49: Electrical Schematics

    Electrical Schematics Electrical Schematics 312094K...
  • Page 50 Electrical Schematics 312094K...
  • Page 51 Electrical Schematics 1271 +24V J305 1272 24 COM SWIRL 1272 2122 LOCAL RS485 SOLENOID #1 3021 2131 EXTERNAL TO CONTROL #20 AWG TYP 1271 +24V HARNESS 311 J310 CROSS- 3121 OVER COMM 3131 BLACK 1271 GUN SWITCH +24V 1272 24 COM DH1-C2 DG1-7 DG1-6...
  • Page 52 Electrical Schematics 312094K...

  • Page 53: 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 54 Accessories KEY: Wired at Graco: back and top of wire track. High Voltage: Back and top or right of wire track. Low Voltage (+24V or less): Back and bottom of wire track. PLATEN PUMP TO DH CONNS RTDS EasyKey DISPLAY...

  • Page 55: Pail Low And Empty Sensor Kit (255233)

    Accessories Pail Low and Empty Sensor Kit (255233) The Pail Low and Empty Sensor Kit is used to indicate When ordering this kit individually to connect to an exist- that a pail is EMPTY or LOW, depending on the adjust- ing Therm-O-Flow 20 unloader assembly, use the bolts, ment of the proximity switch.

  • Page 56: Ethernet Kit (253566)

    Or enter http://java.sun.com/j2se/1.4.2/download.html and select Download J2SE JRE. The file is approxi- Use the web I/F Software to: mately 15 MB. • Install EasyKey Software If the Graco program will not start, check the  • View following.  error log Is the power on? ...
  • Page 57 Accessories Non-hazardous Area Only Local Network Patch Cable Patch Cable Local Network Connection Direct Connection Laptop PC TI8570A Control Panel Patch Cable . 27 Network Selection 312094K...
  • Page 58 Accessories Local Network Hardware and Software 2. The EasyKey software requires Sun java to operate. Configuration Open your web browser options advanced tab and select Java (Sun) and deselect the Microsoft VM selection. See F . 29. If the Sun Java option is not Hardware available follow the Software Operation procedure Patch cables are used to connect each unit to the local...
  • Page 59 Accessories Software Operation Reports Display material usage report - shows the material 1. Open Microsoft Internet Explorer. pumped from the unit. See F . 31. 2. In the address area type http://192.168.0.1 3. Click Enter. 4. Select yes when security screen appears. 5.
  • Page 60 Accessories Error Log Software/Resets Install EasyKey software - downloads the Graco Download error log - downloads the error log to the provided software to the PC (approximately 5 minutes). Once complete the control panel will be reprogrammed from the EasyKey.
  • Page 61 Accessories Ethernet Kit Installation Graco Kit 253566 is required for this connection. Do not operate Therm-O-Flow 20 with equipment enclosure doors/covers open. Disconnect power source before servicing or electrically wiring. ti8557 . 37: RJ45 Bulkhead Connector Installation 1. Power the Therm-O-Flow system off and disconnect power source.

  • Page 62: Easykey Modbus / Tcp Wiring Diagram

    Accessories EasyKey Modbus / TCP Wiring Diagram TI8761 TI8762 . 39 . 38 . 40 312094K...

  • Page 63: 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 64 Accessories 1271 +24V 1272 24 COM 3151 3152 PB 315 YELLOW BROWN ORANGE WHITE/PURPLE GREEN BLUE PURPLE Maintenance Call Button GREY Contacts are N.O. WHITE WHITE/BLACK WHITE/BROWN WHITE/RED WHITE/GREY 3321 WHITE/ORANGE 3331 WHITE/YELLOW WHITE/GREEN WHITE/BLUE ti8559 . 42: Maintenance Call Kit Wiring 312094K...

  • Page 65: 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 66 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 67: 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 68: Dimensions

    Dimensions Dimensions 2.8 in. (7.1 cm) 24.0 in. (61.0 cm) 3.2 in. (8.1 cm) 22.6 in. 32.5 in. (57.3 cm) 5.7 in. (82.6 cm) (14.5 cm) TI10028A 59.7 in. (151.6 cm) 71.0 in. Ram measures (180.3 cm) 82 in. (208.3 cm) fully extended (highest point).

  • Page 69: Technical Data

    Technical Data Technical Data Displacement pump effective area ....0.884 in. (5.7 cm Volume per cycle ....... 3.8 in. (62 cm Pump cycles per 1 gal.

  • Page 70: 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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