Graco Therm-O-Flow 20 EasyKey User manual

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.
TI10024A
Important Safety Instructions.
Read all warnings and instructions in this manual.
Save these instructions.
312094K
EN

2312094K
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
How the Therm-O-Flow 20 Works . . . . . . . . . . . . 5
Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Identification . . . . . . . . . . . . . . . . . . 6
Power Requirements . . . . . . . . . . . . . . . . . . . . . . 8
Heat Control Zone Selection . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Location Requirements . . . . . . . . . . . . . . . . . . . . 9
Locate and Install the Ram . . . . . . . . . . . . . . . . . 9
Hose Installation and Care . . . . . . . . . . . . . . . . 10
Mechanical Setup . . . . . . . . . . . . . . . . . . . . . . . 11
Electrically Connect Hoses . . . . . . . . . . . . . . . . 11
Connect the Electrical Control Panel to a Power
Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Check Resistance . . . . . . . . . . . . . . . . . . . . . . . 13
Overview of the Temperature Controller Settings 14
Purging the System . . . . . . . . . . . . . . . . . . . . . . 14
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . 15
Main Power Disconnect . . . . . . . . . . . . . . . . . . . 15
EasyKey Display and Keypad . . . . . . . . . . . . . . 15
LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EasyKey Display Screens . . . . . . . . . . . . . . . . . . . 17
Power Up Screens . . . . . . . . . . . . . . . . . . . . . . 17
Run Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Purge Before Using Equipment . . . . . . . . . . . . . 23
Set Values on EasyKey . . . . . . . . . . . . . . . . . . . 23
Material Loading . . . . . . . . . . . . . . . . . . . . . . . . 23
System Heat Up . . . . . . . . . . . . . . . . . . . . . . . . 25
Prime System . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pressure Relief Procedure . . . . . . . . . . . . . . . . 27
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ram Pressure Relief Procedure . . . . . . . . . . . . 28
Pail Changing . . . . . . . . . . . . . . . . . . . . . . . . . . 29
System Shutdown . . . . . . . . . . . . . . . . . . . . . . . 31
Dual Ram Cross-Over Installation . . . . . . . . . . . . 32
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Ground Fault Interrupt . . . . . . . . . . . . . . . . . . . . 33
Power in a Tandem System . . . . . . . . . . . . . . . . 33
Resetting the Ground Fault Interrupt . . . . . . . . . 33
Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . 33
Ram Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 35
Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . 36
Air Motor Troubleshooting . . . . . . . . . . . . . . . . . . 36
Electrical Control Panel Troubleshooting . . . . . . 37
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ground Fault interrupt . . . . . . . . . . . . . . . . . . . . 38
Power in a Tandem System . . . . . . . . . . . . . . . . 38
Platen Service . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Air Motor/Pump Removal and Service . . . . . . . 40
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Therm-O-Flow 20 . . . . . . . . . . . . . . . . . . . . . . . 42
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
EasyKey Assembly, Part No. 255224 . . . . . . . . 47
Spare Parts and Kits . . . . . . . . . . . . . . . . . . . . . 48
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 49
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Light Tower Kit (253547) . . . . . . . . . . . . . . . . . . 53
Pail Low and Empty Sensor Kit (255233) . . . . . 55
Ethernet Kit (253566) . . . . . . . . . . . . . . . . . . . . 56
EasyKey Modbus / TCP Wiring Diagram . . . . . . 62
Maintenance Call Kit (253548) . . . . . . . . . . . . . 63
Discrete I/O Kit (253567) . . . . . . . . . . . . . . . . . . 65
Swirl Kit, Part No. 253263 . . . . . . . . . . . . . . . . . 67
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 70
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 70

Warnings
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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 symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
SPLATTER HAZARD
During blow off of platen splatter may occur.
• Use minimum pail removal air pressure.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regu-
lations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco
replacement parts only.
• Do not alter or modify equipment.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Do not operate when fatigued or under the influence of drugs or alcohol.
• Comply with all applicable safety regulations.

Warnings
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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:
• Protective eyewear.
• Clothing and respirator as recommended by the fluid and solvent manufacturer.
•Gloves.
• Hearing protection.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground equipment and conductive objects in work area. See Grounding instructions.
• Use only grounded hoses.
• Hoses are for indoor use only. Do not get hose wet.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a fire extinguisher in the work area.
WARNING

Overview
312094K 5
Overview
How the Therm-O-Flow 20
Works
A heated platen melts the sealant or adhesive and
directs the molten material to the pump inlet. The mate-
rial then travels through a Mini-5 pump and heated fluid
moves to the application tool.
Model Numbers
The six digit part number stamped on your
Therm-O-Flow 20 defines your machine. Each digit rep-
resents a component, as shown in the following table.
1.
Therm-O-Flow
20 (T)
2. Number of
Heat Zones
(0, 4)
3. Heat
Controls
Supply Voltage
(0, 2, 3, 4)
4. Pump Ratio
(0)
5. Heated
Platen (F, S)
6. Controls
(0, B, S) Part No.
T 4 230 (2) 15:1 (0) Finned (F) Standard (B) T420FB
T 4 230 (2) 15:1 (0) Smooth (S) Standard (B) T420SB
T 4 380 (3) 15:1 (0) Finned (F) Standard (B) T430FB
T 4 380 (3) 15:1 (0) Smooth (S) Standard (B) T430SB
T 4 480 (4) 15:1 (0) Finned (F) Standard (B) T440FB
T 4 480 (4) 15:1 (0) Smooth (S) Standard (B) T440SB
T 4 230 (2) 15:1 (0) Finned (F) Secondary (S) T420FS
T 4 230 (2) 15:1 (0) Smooth (S) Secondary (S) T420SS
T 4 380 (3) 15:1 (0) Finned (F) Secondary (S) T430FS
T 4 380 (3) 15:1 (0) Smooth (S) Secondary (S) T430SS
T 4 480 (4) 15:1 (0) Finned (F) Secondary (S) T440FS
T 4 480 (4) 15:1 (0) Smooth (S) Secondary (S) T440SS
T 0 0 15:1 (0) Finned (F) No Controls (0) T000F0
T 0 0 15:1 (0) Smooth (S) No Controls (0) T000S0