Graco Therm-O-Flow 200 Operation manual

Instructions-Parts
Therm-O-Flow® 200
334130A
EN
For applying hot melt sealant and adhesive materials from 200 Liter (55 Gallon) drums. For professional
use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this manual and in related
manuals. Save these instructions.
Maximum Operating Temperature 400°F
(204 °C)
See page 6 for model information.
See Technical Speci cations, page 107,
for maximum working pressures.
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Warnings .............................................................3
Models.................................................................6
Related Manuals ..................................................7
Component Identification.......................................8
Advanced isplay Module (A M).................. 12
Overview............................................................ 15
Air and Fluid Hoses...................................... 15
Heat Control Zone........................................ 15
Setup................................................................. 16
Unpack........................................................ 16
Location Requirements................................. 16
Install System.............................................. 16
Install Hydraulic Power Supply...................... 16
Mechanical Setup ........................................ 17
Install Heated Hose...................................... 18
Connect Multiple evices ............................. 20
Connect Power............................................ 21
Grounding ................................................... 22
Connect Secondary System.......................... 22
Check Sensor Resistance ............................ 23
Check Heater Resistance............................. 24
Select A M Settings .................................... 25
Connect PLC............................................... 27
Operation........................................................... 30
Purge System.............................................. 30
Load Material............................................... 31
Heat Up System........................................... 32
Prime Pump ................................................ 33
Prime System.............................................. 35
Setback Mode.............................................. 35
Pressure Relief Procedure............................ 36
Shutdown.................................................... 37
Schedule..................................................... 37
Change rums ............................................ 38
Troubleshooting.................................................. 39
Repair................................................................ 46
Replace Wipers ........................................... 46
Replace Platen RT .................................... 46
Separate the Air Motor and Pump ................. 47
Remove Platen............................................ 49
Replace Heater Bands and Pump
RT ............................................... 50
Replace MZLP Fuse .................................... 51
Replace MZLP............................................. 52
Replace MZLP aughter Card...................... 53
Replace AWB.............................................. 54
Replace Power Supply ................................. 54
Replace Fan................................................ 55
Replace Transformer.................................... 56
Update Software.......................................... 58
Electrical Schematics.......................................... 59
Parts.................................................................. 65
Accessories and Kits........................................... 89
Wiper Kits.................................................... 89
Applicators and ispense Valves .................. 89
Air-Operated Heated ispense Valves........... 89
Flow Control and Manifolds .......................... 89
Accessory Extension Cables......................... 89
Light Tower Kit, 24W589 .............................. 89
Tie Rod Kits................................................. 89
8 Zone Upgrade Kit Installation..................... 93
12 Zone Upgrade Kit Installation ................... 95
Appendix A— A M............................................. 96
Operation Screens....................................... 98
Setup Screens............................................. 99
Appendix B — USB ata .................................. 103
ownload.................................................. 103
Access Files .............................................. 103
Upload ...................................................... 103
USB Logs.................................................. 104
System Settings File .................................. 104
System Language File................................ 105
Create Custom Language Strings ............... 105
imensions...................................................... 106
Technical Specifications.................................... 107
Graco Standard Warranty.................................. 108
2334130A

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.
WARNING
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid
severe burns:
• o not touch hot fluid or equipment.
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. uring blow off of
platen, splatter may occur.
• Use minimum air pressure when removing platen from drum.
MOVIN PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• o 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 and disconnect all power sources.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. 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 or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
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 MS Ss 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.
334130A 3

Warnings
WARNING
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure
due to the thermal expansion. Over-pressurization can result in equipment rupture and serious
injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, 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. et
immediate surgical treatment.
• Engage trigger lock when not dispensing.
• o not point dispensing device at anyone or at any part of the body.
• o not put your hand over the fluid outlet.
• o not stop or deflect leaks with your hand, body, glove, or rag.
•Followthe Pressure Relief Procedure when you stop dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area canigniteorexplode.Tohelp
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.
• o not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
• Ground all equipment in the work area. See rounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. o not use pail liners unless
they are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock . onotuse
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
4334130A

Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• o not operate the unit when fatigued or under the influence of drugs or alcohol.
• o 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 ata
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MS S from distributor or retailer.
• o not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• o not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• o not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
334130A 5

Models
Models
The model number stamped on your systems defines the equipment in the following categories.
See Technical Specifications, page 107, for maximum working pressure.
SER A B C D E F H
Series Frame Size Air
Air/Electric Zone Config Pump Ratio Platen Style Platen Seal Ram rum Clamp
Code A Frame Size
200 55 Gallon (200 Liter)
Code B Air/Electric
AAir control only
E Air and Electric
Code C Zones, Volts, Type
11P 4 Zones, 230 V, Primary
11S 4 Zones, 230 V, Secondary
12P 4 Zones, 400 V/N, Primary
12S 4 Zones, 400 V/N, Secondary
13P 4 Zones, 400 V, Primary
13S 4 Zones, 400 V, Secondary
14P 4 Zones, 480 V, Primary
14S 4 Zones, 480 V, Secondary
15P 4 Zones, 575 V, Primary
15S 4 Zones, 575 V, Secondary
21P 8 Zones, 230 V, Primary
21S 8 Zones, 230 V, Secondary
22P 8 Zones, 400 V/N, Primary
22S 8 Zones, 400 V/N, Secondary
23P 8 Zones, 400 V, Primary
23S 8 Zones, 400 V, Secondary
24P 8 Zones, 480 V, Primary
24S 8 Zones, 480 V, Secondary
25P 8 Zones, 575 V, Primary
25S 8 Zones, 575 V, Secondary
31P 12 Zones, 230 V, Primary
31S 12 Zones, 230 V, Secondary
32P 12 Zones, 400 V/N, Primary
32S 12 Zones, 400 V/N, Secondary
33P 12 Zones, 400 V, Primary
33S 12 Zones, 400 V, Secondary
34P 12 Zones, 480 V, Primary
34S 12 Zones, 480 V, Secondary
35P 12 Zones, 575 V, Primary
35S 12 Zones, 575 V, Secondary
NNN None
Code D Pump Ratio
123:1 CF
(carbon filled PTFE)
236:1 CF
370:1 CF
423:1 GF
(glass filled PTFE)
536:1 GF
670:1GF
Code
EPlaten Style
S Smooth Bottom (No Fin)
FStandard Finned Bottom
MMega-Flo
Code
FPlaten Seal
12 Black EP M/EP M, SS wire braid
400°F (204°C) hose wipers with spring
retention
21 lower Black EP M/Chlorobutyl, SS wire
braid 400°F (204°C) hose wiper and 1
upper Green Silicone, fiberglass braid
400°F (204°C), hose wiper
32 White Silicone 250°F (121°C) T-Wipers
41 lower Black EP M/Chlorobutyl, SS
wire braid 375°F (190°C) hose wiper and
1 upper White Silicone 375°F (190°C)
T-wiper
Code
Ram
PPneumatic
HHydraulic
Code
HDrum Clamps
NNone
1Saddle Clamp
2Fiber Clam Shell
3HeavyrumBand
6334130A

Related Manuals
Related Manuals
Manual Description
Air Motor Manuals
311238 NXT® Air Motor, Instructions-Parts
3A1211 Saniforce® Air Motor,
Instructions-Parts
Displacement Pump Manual
334127 Check-Mate® 800 Pump,
Repair-Parts
334128 Check-Mate® 800 Throat Seal Repair
Kit, Repair-Parts
Ram Manual
334198 Therm-O-Flow 200 Pneumatic and
Hydraulic Ram, Instructions-Parts
Accessory and Kit Manuals
309160 Heated Hose, Instructions-Parts
309196 Wiper Kits, Repair-Parts
310538 Air-Operated ispense Valves,
Instructions-Parts
311209 Top Feed and Bottom Feed Hot Melt
ispense Guns, Instructions-Parts
334201 Air Controls, Repair Kit
334130A 7

Component Identification
Component Identification
Figure 1 TOF 200 Pneumatic
Key:
ALift Strap Positions
B Multi-Zone Low Power Temperature
Control Module (MZLP)
CLight Tower
Cable Track
ERam
F Heated Pump
GHeated Platen
HIntegrated Air Controls (3/4 in npt inlet)
JElectrical Control Panel
Key:
KMain Power Switch
LAM
MAir Motor Solenoid
N Electrical Power Input
PAirMotor
RRam Plate Bleed Stick
S rum Blow Off Valve (behind ram plate
bleed stick)
Trum Low and Empty Sensors
8334130A

Component Identification
Integrated Air Controls
Figure 2 Integrated Air Controls
Key:
CA Main Air Slider Valve
Turns air on and off to the entire system.
When closed, the valve relieves pressure
downstream.
CB Ram Down Air Regulator
Controls the ram down pressure.
CC Ram Director Valve
Controls the ram direction.
CD Ram Up Air Regulator
Controls the ram up pressure.
CE Ram Down Air auge
isplays the ram down pressure.
CF Ram Up Air auge
isplays the ram up pressure.
C Blowoff Button
Turns air on and off to push the platen out of
an empty drum.
Key:
CH Blowoff Pressure auge
isplays the blowoff pressure.
CJ Blowoff Air Regulator
Controls platen blowoff pressure.
CK Air Motor Air Regulator
Controls the air pressure to the motor.
CL Air Motor Pressure auge
isplays the air pressure to the motor.
CM Air Motor Slider Valve
Turns air on and off to the air motor. When
closed, the valve relieves air trapped
between it and the motor. Push the valve
in to shutoff air.
CN Air Motor Solenoid Valve
Turns air on and off to the air motor when
system stopped on the A M. When closed,
the valve relieves air trapped between it and
the motor.
334130A 9

Component Identification
Electrical Control Enclosure
Figure 3 Electrical Enclosure
10 334130A

Component Identification
Key:
A Multi-Zone Low Power Temperature
Control Module (MZLP)
B Ventilation Grill
C Electrical Control Panel
Automatic Wiring Board (AWB)
E Power Supply (24V)
F Residual Current evice (GFI), 63A
Key:
GPlatenSSR(65A)
H Platen Contactor
JPlatenFuse
K Transformer Circuit Breaker
L Transformer Fuse
M Transformer
334130A 11

Component Identification
Advanced Display Module (ADM)
The A M display shows graphical and text
information related to setup and spray operations.
For detail on the display and individual screens, see
Appendix A— A M, page 96.
Use the USB port on the A M to download or upload
data. For more information about the USB data, see
Appendix B — USB ata, page 103.
NOTICE
To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.
Figure 4 Front View
Key Function
BA
Heating system and pump enable/disable
BB
System status indicator (LE )
BC
Stop all system processes
BD
efinedbyiconnexttosoftkey
BE
Abort current operation
BF
Accept change, acknowledge error, select item,
toggle selected item
B
Toggle between Operation and Setup screens
BH
Navigatewithinascreenortoanewscreen
12 334130A

Component Identification
Figure 5 Back View
BK Part Number and Identification Label
BL USB Interface
BM CAN Cable Connection (Power Supply and
Communication)
BN Module Status LE s
BP Light Tower (Optional)
BR Software Token Access Panel
Table 1 ADM LED Status Descriptions
LED Conditions Description
Green Solid Run Mode, System On
Green Flashing Setup Mode, System On
System Status
Yellow Solid Run Mode, System Off
Green Flashing ata recording in progress
Yellow Solid ownloading information to USB
USB Status (BL)
Green and Yellow Flashing A M is busy, USB cannot transfer
informationwheninthismode
Green Solid Power applied to module
Yellow Solid Active Communication
Red Steady Flashing Software upload from token in
progress
ADM Status (BN)
Red Random Flashing or Solid Module error exists
334130A 13

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. • No system status indicator LE on the
A M
•Noheat
•Pumpisoff
Inactive The heating system and pumps are
disabled. • Yellow system indicator LE on the A M
•Noheat
•Pumpisoff
Warm Up The system is heating the material to the
setpoint temperature. • Flashing green system status indicator LE on the A M
• Heat is increasing to setpoint
temperature
•Pumpisoff
Heat Soak Heat zones are all at temperature.
Material is soaking for a user specified
amount of time.
• Flashing green system status indicator
LE on the A M
• Heatisatsetpoint
• Material is absorbing more heat
•Pumpisoff
• Heat soak counter counts down on the
Home screen.
Ready All enabled zones are at setpoint
temperature. The air motor does not have
power.
• Flashing green system status indicator
LE on the A M
• Heatisatsetpoint
•Pumpisoff
Active The system is ready to dispense. • Solid green system status indicator
LE on the A M
• Heatisatsetpointtemperature
•Pumpison
14 334130A

Overview
Overview
A heated platen melts the sealant or adhesive and
directs the molten material to the pump inlet. The
material then travels through a 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.
Heat Control Zone
The Therm-O-Flow has 4, 8, or 12 heat zones. Zones
for the heated drum platen and the heated pump
are not included in the zone count. Zones 1 and 2,
3 and 4, 5 and 6, 7 and 8, 9 and 10, and 11 and
12 are each available through 12-pin connectors.
The heated hoses have a 16-pin connector at the
inlet, and an 8-pin connector at the outlet. All heated
valves, manifolds, and heaters are equipped with an
8-pin mating connector.
Figure 6 Heat Control Zone Selection
334130A 15

Setup
Setup
1. Unpack the ram
2. Locate and Install the ram
3. Mechanical Setup
4. Connect hoses to electrical control panel
5. Connect electrical control panel to power source
6. Ground system
7. Select A M settings
Unpac
1. Inspect the shipping box carefully for damage.
Contact the carrier promptly if there is damage.
2. Open the box and inspect the contents carefully.
There should not be any loose or damaged parts
in the box.
3. Compare the packing slip against all items in the
box. Report any shortages or other inspection
problems immediately.
4. Remove the unit from the skid and place it in the
desired location. See Location Requirements .
Location Requirements
1. Make sure there is sufficient overhead clearance
for the pump and ram when the ram is in the fully
raised position (approximately 110 in. (280 cm).)
2. If you are installing a vent hood, make sure there
is sufficient horizontal clearance for it. Locate the
ram near a connection to the factory ventilation
system.
3. Make sure the air regulators for the pump and
ram are fully accessible, with room to stand
directly in front of the pneumatic control panel
and the electrical control panel.
4. Make sure there is easy access to an appropriate
electrical power source. The National Electrical
Code requires 3 ft (0.9 m) of open space in front
of the electrical panel. Comply with all local
codes and regulations.
5. For hydraulic rams, locate the hydraulic power
supply in an area that has:
• easy access for servicing and adjusting the
hydraulic pressure on the supply unit.
• sufficient clearance for the hydraulic lines that
attach to the pump.
• easy access to read the hydraulic fluid level
gauge.
Install System
Refer to imensions, page 106 for mounting and
clearance dimensions.
Follow all Location Requirements, page 16,when
selecting a location for the ram.
1. Apply 50 psi download pressure to ram.
2. Wrap the bar with the lifting sling.
3. Lift the system off the pallet using a crane or a
forklift and place in desired location.
4. Level the base of the ram, using metal shims.
5. Bolt the ram to the floor, using anchors that are
long enough to prevent the unit from tipping.
Install Hydraulic Power Supply
See the Ram manual for installation and dimensions.
16 334130A

Setup
Mechanical Setup
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. 24 086) for PUR or reactive
Polyurethane material. IGS is
designed to dissolve and suspend the
Polyurethane materials. IGS will solidify
after a period of time and should be
replaced once the solidified lube does
not return to liquid form after heating.
Figure 7 Wetcup
2. Turn all air regulators to their full counterclockwise
position. See Integrated Air Controls, page 9.
3. Connect a 1/2 in. (13 mm) air line from an air
source to the system air inlet (H), capable of
delivering a minimum of 25–50 cfm at 100 psi (0.7
MPa, 7.0 bar). Do not use quick disconnects .
Figure 8 Air Connection
4. Ensure drum low and empty sensors (C) are
mounted as shown.
Note
The rumLowandEmptySensorsare
used to indicate that a drum is empty.
The kit contains a sensor mounting
bracket (A), activator (B), sensors (C1,
C2), and a cable for connecting the panel
inside the electrical enclosure.
5. Increase the distance between the low (C1) and
empty (C2) sensors to increase the heat up time
for the tandem secondary system. Lower the
drum empty sensor (C2) to force the heated
platen lower into the drum. If empty sensor is set
too low, the pump could cavitate and cause an
alarm.
334130A 17

Setup
Install Heated Hose
To connect a hose to a fluid control device or heated
manifold.
1. Install fitting and heated hose onto pump outlet
with the large electrical connector side toward
thesystem. Use2wrenchestotightenhose.
Torque to 45 ft-lbs (61 N•m).
Note
See Accessories and Kits, page 89 for
available fittings and heated hoses.
Figure 9
2. Wrap exposed fittings on the pump outlet with
Nomex insulation and secure insulation using
fiberglass tape.
3. Connect large heated hose connector to cable
from track.
Figure 10
4. Repeat for any remaining channels.
Note
Only two accessory cables fit in cable
track. Additional cables for 8 zone and
12 zone systems are shipped loose.
5. Install cap on any unused MZLP electrical
connectors.
18 334130A

Setup
6. Connect the small 8 pin connector from the
heated hose to the fluid control device or heated
manifold.
Figure 11 Heated Manifold 243697
Note
The heated manifold (part no. 243697)
is included with all secondary systems.
See Accessories and Kits, page 89 for
available manifolds.
7. Use 2 wrenches to tighten hose. Torque to 45
ft-lbs (61 N•m).
8. To connect multiple devices, see
Connect Multiple evices, page 20.
334130A 19

Setup
Connect Multiple Devices
If your application requires multiple fluid control
devices:
• Connect heated hose electrical connections to
the electrical enclosure. Use accessory cables if
necessary. Additional cables (part no. 17C694)
areprovidedwith8and12zonesystems.Remove
from shipping box to connect heated hoses to
the electrical enclosure. For additional cables,
heated hose, and fluid control devices, see
Accessories and Kits, page 89.
• Connect fluid control devices to a heated hose
or the electrical enclosure. Use accessories if
necessary.
• Setup all heat zones on Heat-A and Heat-B
screens.
Example: Heated zones used to connect a primary
andsecondarysystemtoamanifoldandtwoguns.
A-# zones are on the Heat-A screen and B-# zones
are on the Heat-B screen.
Figure 12
20 334130A