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

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

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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 7 for model information.
See Technical Specifications, page 117, for maximum
working pressures.
®
200
334130W
3143485
Certified to
CSA STD C22.2 No. 88
Conforms to
UL STD 499
EN

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Summary of Contents for Graco Therm-O-Flow 200

  • Page 1 Instructions-Parts ® Therm-O-Flow 334130W 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

    Check Heater Resistance ....22 Therm-O-Flow 200 Supply Unit ... . . 70 Select ADM Settings ..... 23 Therm-O-Flow 200 Supply Unit .

  • Page 3: Related Manuals

    ........90 Graco Standard Warranty....118 Drum Ram Post Saddle Clamp 918395 Option H-3 .

  • Page 4: Warnings

    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.
  • Page 5 Warnings WARNING THERMAL EXPANSION HAZARD Fluids subjected to heat in conf i ned spaces , i nc l ud i ng hoses , can c r ea t e a r ap i d ri se i n p r essu r e due to the thermal expansion.
  • Page 6 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.

  • Page 7: Models

    Models Models The system ID label containing the model number can be found on the side of the control panel. See F . 1 page 8. The model number stamped on your system ID label defines the equipment in the following categories: B (Air/Electric) Model Series A (Frame Size)

  • Page 8: Component Identification

    Component Identification Component Identification R, S ti24544a . 1: TOF 200 Pneumatic Key: Lift Strap Positions Main Power Switch (can be locked in the open position) Multi-Zone Low Power Temperature Control Module (MZLP) Air Motor Solenoid Light Tower Electrical Power Input Cable Track Air Motor Ram Plate Bleed Stick...

  • 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. Can be locked in CJ Blowoff Air Regulator the closed position.

  • 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 DJ Platen Fuse DB Ventilation Grill 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 (ADM) The ADM display shows graphical and text information NOTICE related to setup and spray operations. For detail on the display and individual screens, see Appendix A - ADM, To prevent damage to the softkey buttons, do not page 103.
  • 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

    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.

  • Page 15: Setup

    Setup Setup 1. Unpack the Ram directly in front of the Pneumatic Control Panel and the Electrical Control Panel. 2. Locate and Install the Ram 4. When locating the system, do not install closer than 3. Mechanical Setup 36 in. (914 mm) to vertical surfaces. 4.

  • Page 16: Mechanical Setup

    Setup Mechanical Setup minimum of 25-50 cfm at 100 psi (0.7 MPa, 7.0 bar). Do not use quick disconnects. 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.

  • 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 manifold. connectors.

  • Page 18: Connect Multiple Devices

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

  • 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 Control Panel to a power source. All electrical wiring must be done by a qualified electrician and comply with all local codes and .

  • 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 cardboard, which interrupts the grounding continuity component manuals.

  • Page 21: Check Sensor Resistance

    Setup Check Sensor Resistance 3. Replace any parts whose resistance readings do not comply with the ranges listed in the RTD Sensors chart below. Table 3 RTD Sensors To reduce risk of injury or damage to equipment, RTD Range MZLP MZLP Plug Component conduct these electrical checks with the Main Power (Ohms)

  • Page 22: Check Heater Resistance

    Setup Check Heater Resistance To reduce risk of injury or damage to equipment, conduct these electrical checks with the Main Power Switch OFF. 1. Turn Main Power Switch OFF. 2. Make electrical resistance checks for the components. 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 temperatures for the Pump, Platen, and heat zones on the Heat-A-screens. NOTE: See Appendix A - ADM, page 103 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 Advanced 2 screen. Set the specific gravity of the material for Material Tracking functionality. NOTE: If the Specific Gravity is set to zero, the Home screen will display a cycle counter instead of grams or pounds.

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

    Setup Connect PLC (Hard Wired Table 7 Output Error States Interface Version) Error State Error State Bit Bit High Machine is good, no errors are present Active Unit Drum A PLC can control and monitor all items shown in the Customer Digital Inputs and Outputs shown on the Active Unit Drum Diagnostics screen.
  • Page 26 Setup NOTE: Each connector has four signals. The MZLP H1 Customer Input board specifies the input range for each signal. See the Signal following table for pin assignments. H2 Customer Output Signal Inputs: High: 10–30 VDC, Low: 0–5 VDC. Inputs function 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

    3-4 at all times. equipment wetted parts. See Technical Specifications in all of the equipment manuals. 1. Turn the Main Power Switch ON. The Graco logo will display until communication and initialization is 1. Select the material for the initial material load.

  • 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 materials. NOTICE To prevent damage to Platen wipers, do not use a ® NOTE: Use IsoGuard Select (IGS) (part no. 24F516) drum of material that has been dented or damaged.

  • Page 30: Heat Up System

    Operation 11. When the Ram stops, reinsert the Ram Plate Bleed 7. Remove the Ram Plate Bleed Stick (R). Stick (R) and hand tighten. Heat Up System To reduce the risk of bursting a hose, never pressurize a hot melt system before turning on the heat.

  • 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 Complete steps 1-5 on page 31 for the inactive unit. Note that the heat will remain on for the inactive unit Ready button .

  • Page 33: Prime System

    Operation Prime System 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. 7. Close the Main Air Slider Valve (CA) and release the trigger lock.

  • Page 34: Pressure Relief Procedure

    Operation Pressure Relief Procedure 3. Set the Ram Director Valve (CC) to the neutral position. Follow the Pressure Relief Procedure Whenever you see this symbol. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing...

  • Page 35: Stop Controls

    Operation Stop Controls NOTE: If work needs to be performed on the Ram portion, perform the following additional steps to relieve any trapped air in the inactive portion of the Ram. Normal Stop Control 9. Validate that the Heated Pump is fully supported To stop all electrical and most pneumatic processes, and is resting on the bottom plate.

  • Page 36: Shutdown

    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 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.

  • Page 37: Change Drums

    Operation Use the Schedule Function Table 9 Schedule Screen Color Identification Color Description At the end of the work day leave the Main Power Switch ON. The Schedule function will automatically enable Green System on and disable the heaters and Pump at the specified Yellow Setback times.
  • Page 38 Operation All systems include Low/Empty Sensors: pressure necessary to push the Platen out of the drum. • The air will shut off 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.

  • Page 39: 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 40: 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 There are three types of errors that can occur. Errors are indicated on the display as well as by the optional components.
  • Page 41 Troubleshooting Code Description Type Cause Solution A3MF AWB Clean Fan Filter Alarm Cooling inlet Clean inlet screen. screen is dirty A4 _ High Current Unit _ Alarm Defective or Verify accessory is rated for 240 VAC. Zone _ shorted to Verify heater resistance and check for shorts to ground on ground.
  • Page 42 Troubleshooting Code Description Type Cause Solution CACX DB Not Present Unit Alarm Daughter Dial not set correct on MZLP 5. Set to 5 on Board not board with daughter board. responding Ensure connections between the ADM and hardware are secure. Replace Daughter Board.
  • Page 43 Troubleshooting Code Description Type Cause Solution DC X Pump Diving Alarm Pump is trying Adjust the drum empty level sensor to detect to feed an 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 44 Troubleshooting Code Description Type Cause Solution T3 _ High Temp. Unit _ Deviation Temperature Change High Temp Deviation Offset. Zone _ reading has Verify setpoint upstream is not hotter than this risen too high zone’s setpoint. T4C# AWB Temperature Alarm Cooling fan Ensure inlet and outlets are not obstructed.
  • Page 45 Troubleshooting Code Description Type Cause Solution V8M# No Line Voltage Alarm Incoming line Verify transformer has the correct tap selected. MZLP _ voltage is less Verify CB-1 or FU-4, FU-5, and FU-6 are not than 100 VAC. tripped/blown. Verify RCD-1 is not tripped. Measure incoming power with system unplugged.

  • Page 46: Ram Troubleshooting

    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 47: 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 48: Repair

    Repair Repair Replace Wipers 2. Make sure the Ram Plate is down and the Ram Director 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 37.

  • Page 49: Separate The Air Motor And Pump

    Repair Separate the Air Motor and 5. Remove the Platen RTD (605) from the Platen. Pump 6. Disconnect the Platen RTD wires from pin 3 and pin 6 from the J5 connector on MZLP MZTCM-1 or MZTCM-5. This procedure must be done with the unit still warm. The material and equipment will be hot! 1.
  • Page 50 Repair 8. Remove the Pump sheet metal enclosure. 22. Reverse this procedure to reinstall the new or rebuilt Air Motor. a. Remove the cover screws. b. Remove the heater bands and disconnect the ground wire. 9. If vent hood is installed, remove it. 10.
  • Page 51 Repair . 28 334130W...

  • Page 52: 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 53: 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 place and remove the front shroud.

  • Page 54: 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 55: 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 56: 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 57: 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 58: 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). Transformer Output Power Harness Connections, Series A through E Systems Table See F . 34, page 59. Power Harness Wires CR-2 Connections 1.
  • Page 59 Repair CR-2 ** RCD-1 G, Ground . 34: Inside of Electrical Control Enclosure ** CR-2 device is included on series A through E systems. This component is not included on the series F systems. See notes on Electrical Schematics page 61. 334130W...

  • Page 60: Update Software

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

  • Page 61: Electrical Schematics

    Electrical Schematics Electrical Schematics For reference: Use schematic number 17C029S 230V, 3 Phase/60Hz ALL WIRES ARE 10 AWG ALL WIRES ARE 14 AWG SSR-1 SSR-1 FHA1 FHA2 FHB1 SSR-1 FHB2 SSR-1 SSR-1 TOF200 PLATEN HEATERS TOFP20 PLATEN HEATERS ZONE 1 ZONE 1 230v 3ph/...

  • Page 62: 400V, 3 Phase/50Hz

    Electrical Schematics 400V, 3 Phase/50Hz ALL WIRES ARE 10 AWG ALL WIRES ARE 14 AWG SSR-1 SSR-1 FHA1 FHA2 FHB1 SSR-1 FHB2 SSR-1 SSR-1 TOF200 PLATEN HEATERS TOFP20 PLATEN HEATERS ZONE 1 ZONE 1 400V/N 3PH/ 50HZ DISCONNECT HARNESS 17A550 CON-1 TO SSR-1 6 AWG 6 AWG...

  • Page 63: 400-600Vv, 3 Phase/60Hz

    Electrical Schematics 400-600VV, 3 Phase/60Hz ALL WIRES ARE 10 AWG ALL WIRES ARE 14 AWG SSR-1 SSR-1 FHA1 FHA2 FHB1 SSR-1 FHB2 SSR-1 SSR-1 TOF200 PLATEN HEATERS TOFP20 PLATEN HEATERS ZONE 1 ZONE 1 400V, 480V, 600V 3PH/ 50HZ DISCONNECT HARNESS 17A554 CON-1 TO SSR-1 6 AWG...

  • Page 64: Awb

    Electrical Schematics HARNESS 17A552 PS-1 EGND AWB-1 HARNESS 17A544 OR 17A545 AWB-1-J5 TO MZTCM-2-J2 10 AWG AWB-1-J5 TO MZTCM-3-J2 18 AWG 1290 1300 10 AWG 1310 HARNESS 17A543 AWB-1-J6 TO MZTCM-1-J2 1320 10 AWG YELLOW 1220 YELLOW BLACK 1250 2270 5 4 3 2 1 ENCLOSURE FAN 18 AWG...

  • Page 65: Mzlp#1

    Electrical Schematics MZLP#1 HARNESS 127511 MZTCM-1-J3 TO MZTCM-2-J6 22 AWG HARNESS 17A551 2560 MZTCM-1-J1 TO TERM BLOCKS SOL-1 2570 MZTCM-1 12 AWG HARNESS 17A557 2610 MZTCM-1-J12 TO SOL-1 2620 HARNESS 24V745 PX-EMPTY HARNESS 17A543 2640 MZTCM-1-J2 TO AWB-1-J6 2650 PX-LOW 2670 2680 2700...

  • Page 66: Mzlp#2, Mzlp#3 Pump Heaters

    Electrical Schematics MZLP#2, MZLP#3 Pump Heaters HARNESS 127511 MZTCM-2-J6 TO MZTCM-1J3 22 AWG HARNESS 17A544 OR 17A545 10 AWG MZTCM-2-J2 TO AWB-1-J5 MZTCM-2 HARNESS 1275115 MZTCM-2-J3 TO MZTCM-3-J6 HARNESS 17A545 10 AWG MZTCM-3-J2 TO AWB-1-J5 MZTCM-3 334130W...

  • Page 67: Mzlp#2, Mzlp#3, Overtemp

    Electrical Schematics MZLP#2, MZLP#3, Overtemp OVERTEMPS OVERTEMPS 2730 2730 PLATEN PLATEN 2730 2731 2730 2730 2730 2731 2731 2731 PUMP 2732 2732 2732 2732 PUMP 2740 2740 2740 2740 2740 2740 TYPICAL ALL TOFP20’s TYPICAL ALL TOF200 WITH CODE D AND TOFP20’S AT SECTION 7.

  • Page 68: Mzlp Zones

    Electrical Schematics MZLP Zones TYPICAL ZONE PIN OUT CONNECTOR FUNCTION PIN # MZTCM-1 ZONE 1, L2 SHIELD MZTCM-1 ZONE 2, L1 ZONE 2, L2 JUMPER ZONE 1, START MZMTCM-1 J9 ZONE 1, RTD JUMPER ZONE 1, L1 RTD EXCITE ZONE 2, START ZONE 2, RTD ZONE 3, L2 SHIELD...

  • Page 69: Parts

    See Models on page 7 for reference. The service label is located on the upper leftcorner of the control panel and ® contains a QR code that will link to the Therm-O-Flow products page of help.graco.com. This website gives you ® access to current manuals and additional support materials for the Therm-O-Flow system as well as other Graco products.

  • Page 70: Therm-O-Flow 200 Supply Unit

    Parts Therm-O-Flow 200 Supply Unit ti25003a 334130W...

  • Page 71: Therm-O-Flow 200 Supply Unit

    Parts Therm-O-Flow 200 Supply Unit are available at no cost. Part Description Frame Part Description 24W870 KIT, air controls; see Air Control 120186 BOLT, mounting, u-bolt Assembly, page 72 101864 SCREW, cap, sch CONTROL, electrical 111303 NUT, hex MODULE, pump; see Pump...

  • Page 72: Air Control Assembly

    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 Part Description 24W870 KIT, CONTROL, air, 3 regulator; O-RING see manual 334201 SCREW, cap, socket hd;...

  • Page 73: Electrical Module

    Parts Electrical Module 148 150 152 153 145 147 149 177, 119 334130W...
  • Page 74 Parts 334130W...

  • Page 75: Electrical Control Module Parts

    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 76 Parts Part Description 101550 SCREW, cap, sch (Primary assemblies only) 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...

  • Page 77: Electrical Panel

    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) 334130W...
  • Page 78 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) 334130W...

  • Page 79: Electrical Panel Parts

    Parts Electrical Panel Parts Part Description Part Description 230◆ 6690-24 FUSE, fuse block buss jt60030 PANEL, elec, tof, 11ga, zinc -164 117666 TERMINAL, ground 230✓ 134005 FUSE, block, 30A, type cc, 3P 113783 SCREW, machine, pn hd 230◆✓ 127744 CIRCUIT, breaker, 3p, 32a, 100985 WASHER, lock ext ul489;...

  • Page 80: Merkur 2200, 23:1 Pump Modules

    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 81: Merkur 2200, 23:1 Pump Modules

    Parts Merkur 2200, 23:1 Pump Modules Part Description Part Description C31012 CLAMP 24W754 MOTOR, air, 6 in, 4.75 stroke, blue C03507 SUPPORT, sensor 155470 FITTING, swivel, union, 90° C38162 SCREW, machine 24R885 SWITCH, reed assy C38163 WASHER, lock, ext. tooth BRACKET, motor mount CONDUCTOR, ground 15H397 ADAPTER, rod, pump...

  • Page 82: Merkur 3400, 36:1 Pump Modules

    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) being torqued.

  • Page 83: Merkur 3400, 36:1 Pump Modules

    Parts Merkur 3400, 36:1 Pump Modules Part Description Part Description C31012 CLAMP 24R015 MOTOR, assy, air, 7.5 in, blue C03507 SUPPORT, sensor 155470 FITTING, swivel, union, 90° C38162 SCREW, machine 24R885 SWITCH, reed assy C38163 WASHER, lock, ext. tooth 15H173 BRACKET, motor mount, tof 200 CONDUCTOR, ground 15H397 ADAPTER, rod, pump SHIELD, pump, tof200;...

  • Page 84: Nxt 6500, 70:1 Pump Modules

    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) before mounting.

  • Page 85: Nxt 6500, 70:1 Pump Modules

    Parts NXT 6500, 70:1 Pump Modules Part Description N65LR0 MOTOR, 6500, low-noise, remote 120375 ADAPTER, elbow, 3/4 npti x 1/2 npte 15H542 BRACKET, mounting, motor, tof200 17A406 ADAPTER, rod, pump, tof 16A223 ROD, tie, vert driver 106166 NUT, mach, hex 128322 HEATER, pump, 600 watt 24W150 PUMP, long shaft, cf;...

  • Page 86: 24V619, Pump Shield

    Parts 24V619, Pump Shield ti25162a Part Description Part Description 507*▲ 17J504 LABEL, warning 24V619PKG SHIELD, pump, TOF200 508* 104088 RIVET, blind 501* COVER, pump, bottom 509*▲ 15J075 LABEL, safety, hot surface 502* COVER, pump, right and shock 503* COVER, pump, left BUSHING, conduit, 1 in 504* COVER, pump, top, front...

  • Page 87: Heated Platens

    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 334130W...

  • Page 88: Heated Platens

    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 89 Parts 334130W...

  • Page 90: Drum Ram Post Saddle Clamp C32463 Option

    Parts Drum Ram Post Saddle Clamp C32463 Option H-1 Torque to 50 in-lbs. ti25188a Part Description Part Description 100133 WASHER, lock C32424 BOLT, U, 7 in. (177.8 mm) C38182 WASHER, plain 160111 CLAMP, barrel C32461 CLAMP, saddle 100103 PIN, cotter 166265 PIN, pivot 100307 NUT, hex 334130W...

  • Page 91: Drum Ram Post Saddle Clamp 918395 Option

    Parts Drum Ram Post Saddle Clamp 918395 Option H-3 Torque to 50 in-lbs. ti25189a Part Description Part Description C19200 WASHER, plain 100101 SCREW, cap, hex hd 617433 SPACER, drum clamp 918421 CLAMP, back half assembly 617395 CLAMP, saddle 918423 KIT, repair 100131 NUT, full hex 617395 PIN, quick release C32424 BOLT, U 7 in.

  • Page 92: Fiber Drum Reinforcement Shell Clamp 918397 Option H-2

    Parts Fiber Drum Reinforcement Shell Clamp 918397 Option H-2 ti25190a Torque to 50 in-lbs. Part Description Part Description C19126 SCREW, cap, hex hd C32424 BOLT, U, 7 in. (177.8 mm) 100133 WASHER, lock C32271 CLAMSHELL 100307 NUT, hex 617340 CLAMP, saddle 617341 MOUNT, clam shell 334130W...

  • Page 93: Vent Hood Kit, 233559

    Parts Vent Hood Kit, 233559 ▲ Replacement Warning labels, signs, tags, and cards Part Description are available at no cost. VENT hood 112166 SCREW, cap, sch 100016 WASHER, lock 855▲ C14038 LABEL, warning 334130W...

  • Page 94: Accessories And Kits

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

  • Page 95: Accessory Extension Cables

    Accessories and Kits Accessory Extension Cables Overtemperature Jumper 16Y727 Use to connect fluid control devices and heated hoses to Install the overtemperature jumper plug into zone 3-4 to the electrical control enclosure. run the Therm-O-Flow without a device installed in these zones.

  • Page 96: Heated Hoses And Fittings

    Accessories and Kits Heated Hoses and Fittings NOTE: Refer to Heated Hose, Instructions-Parts manual 3A4241 for additional information about heated hoses. See Related Manuals on page 3. (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)
  • Page 97 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) Distribution 16V432 124286 15Y934 C20708 125661 125661 manifold, 243697 100896 120268 Inlet: 3/4 in NPTF Distribution 16V432...

  • Page 98: 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 MODULE, GCA, MZLP 125856 SCREW, 8–32, serrated flange 16T440 CAP, souriau, UTS14 127511 CABLE, board, samtec Part Description 16W035 CONNECTOR, jumper...

  • Page 99: Zone Upgrade Kit Installation

    Accessories and Kits ti25236b 8 Zone Upgrade Kit Installation 2. Place the grounding wrist strap (7) over your wrist and secure the other end to a grounded surface. 3. Set the kit’s MZLP (1) rotary switch to “2” on a primary system or “6”...
  • Page 100 Accessories and Kits 4. Remove the screws (B), the plate (A), and the gasket (C) from the system. Use the screws (2) to install the MZLP (1) onto the system as shown. NOTE: The new MZLP (1) will be refereed to as MZLP2, and the original MZLP that came with the system will be referred to as MZLP 1.

  • Page 101: 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, AWB 125856 SCREW, 8–32, serrated flange 112190 STRAP, wrist, grounding 16T440 CAP, souriau, UTS14...

  • Page 102: 12 Zone Upgrade Kit Installation

    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 103: 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 The ADM automatically turns on when the Main Power heating system is enabled, use the Heat-A and Heat-B Switch is turned on.

  • Page 104: 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 represents.

  • Page 105: Operation Screens

    Appendix A - ADM Operation Screens Color A and B Zone Status White Home Green On and at setpoint temperature This screen shows the temperature state of the system Outside of alarm range and material usage. Yellow Outside of advisory range Green/Yellow Flashing Warmup Events...
  • Page 106 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 107: Setup Screens

    Appendix A - ADM Setup Screens Enable Temp. Adjustments: Allows temperature adjustments on the Heat-A and Heat-B Run screens. NOTE: It is important to set all settings in the System Enable Pump Autostart: Automatically turns the Pump screens correctly to ensure optimal system on after reaching setpoint temperature and heat soak is performance.
  • Page 108 Appendix A - ADM Advanced 1 Specific Gravity: Required to convert the volume dispensed to mass dispensed for tracking the total weight and flow rate. When the specific gravity value is populated, the total mass 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 109 4. If more than one Therm-O-Flow .gti file is present in the “GRACO/SOFTWARE/” directory on the USB stick, select the correct file to transfer using the pull-down selection control.
  • Page 110 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 111 Appendix A - ADM Gateway 1 and 2 If the Therm-O-Flow system has a communication gateway 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 protocol selections, and enable the user to view the mapping information programmed into the CGM module.

  • Page 112: Appendix B - Usb Data

    Once full, the system will overwrite the When downloading from multiple ADMs, there will be oldest data. one sub-folder in the GRACO folder for each ADM. NOTE: To prevent losing any data, never go more than The log files should be opened in a spreadsheet 43 days without downloading the logs.

  • Page 113: Usb Logs

    UPLOAD folders on the USB drive after the upload is These logs (5-BLACKB.CSV, 6-DIAGN.CSV) are complete. designed to provide useful information to Graco when calling for technical assistance. USB Logs System Settings File...

  • Page 114: System Language File

    Appendix B - USB Data System Language File Create Custom Language Strings The system language file name is DISPTEXT.TXT and is stored in the DOWNLOAD folder. The custom language file is a tab-delimited text file that contains two columns. The first column consists of a A system language file automatically downloads each list of strings in the language selected at the time of time a USB flash drive is inserted.

  • Page 115: 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 116 Dimensions 334130W...

  • Page 117: 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 400°F...

  • Page 118: 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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