Graco Therm-O-Flow 200 Parts list manual

3A8005A
EN
Instructions - Parts
Therm-O-Flow®
Warm Melt
For dispensing sealants, adhesives, and other medium to high viscosity fluids. For
professional use only.
Not approved for use in explosive atmospheres or hazardous (classified) locations.
See page 4 for model information, including maximum
working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this
manual and related manuals before using
the equipment. Save these instructions.

23A8005A
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Therm-O-Flow Warm Melt . . . . . . . . . . . . . . . . . . 4
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Therm-O-Flow Warm Melt Pressure . . . . . . . . . . 5
Heat Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component Identification . . . . . . . . . . . . . . . . . . . 10
Single Therm-O-Flow Warm Melt. . . . . . . . . . . . 10
Tandem Therm-O-Flow Warm Melt . . . . . . . . . . 11
Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 12
Power Disconnect . . . . . . . . . . . . . . . . . . . . . . . 12
Integrated Air Controls . . . . . . . . . . . . . . . . . . . . 13
Platen (D) Component Identification . . . . . . . . . 14
Heat Control Box Connections. . . . . . . . . . . . . . 15
Advanced Display Module (ADM) . . . . . . . . . . . 16
ADM Display Details. . . . . . . . . . . . . . . . . . . . . . . . 17
ADM LED Status Descriptions . . . . . . . . . . . . . . 19
ADM Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ADM Soft Keys. . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Requirements . . . . . . . . . . . . . . . . . . . . . 23
Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air Line Connections . . . . . . . . . . . . . . . . . . . . . 24
Light Tower (Optional) . . . . . . . . . . . . . . . . . . . . 24
Attach Drum Stops . . . . . . . . . . . . . . . . . . . . . . . 25
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Low Level and Drum Empty Sensors. . . . . . . . . 26
Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Connect Heated Accessories. . . . . . . . . . . . . . . 27
Install Expansion Module . . . . . . . . . . . . . . . . . . 29
System Setup Screen . . . . . . . . . . . . . . . . . . . . 31
Heat Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Advanced Setup. . . . . . . . . . . . . . . . . . . . . . . . . 34
Hose Care Guidelines . . . . . . . . . . . . . . . . . . . . . . 37
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Prime Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Single Run Screen . . . . . . . . . . . . . . . . . . . . . . . 41
Tandem Run Screen . . . . . . . . . . . . . . . . . . . . . 42
Heat Run Screen . . . . . . . . . . . . . . . . . . . . . . . . 43
Events and Errors. . . . . . . . . . . . . . . . . . . . . . . . 45
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 46
Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Maintenance Screen. . . . . . . . . . . . . . . . . . . . . . 50
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
System Diagnostics Screen . . . . . . . . . . . . . . . . 51
Heat Diagnostics Screen . . . . . . . . . . . . . . . . . . 51
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
View Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Troubleshoot Errors . . . . . . . . . . . . . . . . . . . . . . 54
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Ram Assembly Troubleshooting. . . . . . . . . . . . . 66
Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . 67
Air Motor Troubleshooting . . . . . . . . . . . . . . . . . 67
Heat Control Box Troubleshooting . . . . . . . . . . . 68
Check Resistance (Heated Systems). . . . . . . . . 69
USB Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Download Procedure . . . . . . . . . . . . . . . . . . . . . 71
USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Data Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
System Configuration Settings . . . . . . . . . . . . . . 72
Custom Language File . . . . . . . . . . . . . . . . . . . . 72
Create Custom Language Strings . . . . . . . . . . . 72
Upload Procedure. . . . . . . . . . . . . . . . . . . . . . . . 73
Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Connect PLC Inputs . . . . . . . . . . . . . . . . . . . . . . 74
Connect PLC Outputs. . . . . . . . . . . . . . . . . . . . . 77
Communications Gateway Module (CGM). . . . . 79
System Error Codes . . . . . . . . . . . . . . . . . . . . . . 88
Timing Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 93
Connection Details . . . . . . . . . . . . . . . . . . . . . . . 97
Gateway Setup Screens. . . . . . . . . . . . . . . . . . 100

3A8005A 3
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Disconnect Pump from Platen . . . . . . . . . . . . . 103
Repair Platen . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Connect Platen. . . . . . . . . . . . . . . . . . . . . . . . . 106
Remove Wipers . . . . . . . . . . . . . . . . . . . . . . . . 106
Install Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Remove Displacement Pump. . . . . . . . . . . . . . 107
Install Displacement Pump. . . . . . . . . . . . . . . . 108
Remove Air Motor . . . . . . . . . . . . . . . . . . . . . . 109
Install Air Motor . . . . . . . . . . . . . . . . . . . . . . . . 110
Ram Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replace Heat Control Box Electrical Component(s)
114
Replace Fuses in Harness (25R652) . . . . . . . . 116
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . 116
End of Product Life. . . . . . . . . . . . . . . . . . . . . . 116
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
D200s 6.5 in. Rams . . . . . . . . . . . . . . . . . . . . . 117
D200 3 in. Rams. . . . . . . . . . . . . . . . . . . . . . . . 119
D60 3 in. Rams. . . . . . . . . . . . . . . . . . . . . . . . . 121
D200, D200s Pump Mounts for 55 Gallon (200 Liter)
Platen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
D60 Pump Mount for 5 Gallon (20 Liter) Platen 124
D200s Pump Mounts for 16 Gallon (60 Liter)
Platens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Heat Control Box . . . . . . . . . . . . . . . . . . . . . . . 126
Expansion Module, 26B238 . . . . . . . . . . . . . . . 127
55 Gallon Platen, 255663. . . . . . . . . . . . . . . . . 128
Cable Track Assemblies. . . . . . . . . . . . . . . . . . 129
20 Liter (5 Gallon) Platens . . . . . . . . . . . . . . . . 130
60 Liter (16 Gallon) Platens . . . . . . . . . . . . . . . 132
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . 134
System Kits and Accessories . . . . . . . . . . . . . . 134
Drum Kits and Accessories . . . . . . . . . . . . . . . 135
Platen/Pump Heat Harness . . . . . . . . . . . . . . . 135
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Tandem Cable Kit, 26B339 . . . . . . . . . . . . . . . 135
Heated Tandem Block, 26B346 . . . . . . . . . . . . 136
Check-Mate 200 CS Pump Heater Kit, 25R450 137
Platen Heater Kit, 25R451 . . . . . . . . . . . . . . . . 138
Communications Gateway Module (CGM) Kits 139
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Technical Specifications . . . . . . . . . . . . . . . . . . . 150
California Proposition 65 . . . . . . . . . . . . . . . . . . . 151
Graco Standard Warranty . . . . . . . . . . . . . . . . . . 152
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Models
43A8005A
Models
Therm-O-Flow Warm Melt
Check the identification plate (ID) on the back of the ram post near the Heat Control Box (S) for the seven-digit part
number of the Therm-O-Flow Warm Melt. Use the following matrix to define the construction of the unit, based on the
seven digits. For example, Part No. WMC11B1 represents a Warm Melt supply system (WM), a carbon steel
Check-Mate 200 Severe Duty displacement pump (C1), a D60 ram (1), a 20 L heated platen with an EPDM seal (B),
and an Advanced Display Module (ADM)/240V (1).
NOTE: The heat for the Therm-O-Flow Warm Melt is for warm melt applications with a maximum temperature of 70°
C (158° F).
The digits in the following matrix do not correspond to the reference numbers in the Parts drawings and lists.
KEY:
* When the system is configured with an ambient
pump, only an ambient platen is available.
Approvals
WM C1 1 B1
First
and
Second
Digit
Third and Fourth Digit Fifth Digit Sixth Digit
Seventh
Digit
Check-Mate Pump Options Ram Options Platen and Seal Options
Interface /
Power
Options
Size
Pump
Material
Heated/
Ambient
Name Size
Drum
Size
Platen
Size
Platen
Material
Seal
Material Wiper
Heated/
Ambient
Interface
/ Power
WM
(Warm
Melt
Supply
System)
C1 36:1 CS Ambient* 1D60 3 in. 20 L
(5 Gal) A20 L
(5 Gal) CST/AL EPDM Single
Ring Ambient* 1ADM /
240V
C2 36:1 CS Heated
≤70° C 2D200 3 in. 200 L (55 Gal) B20 L (5 Gal) CST/AL EPDM Single Ring
Heated
≤70° C 2ADM / 480V
C3 36:1 CM Ambient* 3D200s 6.5 in. 200 L
(55 Gal) C
60 L
(16
Gal)
CST/AL
PTFE
Coated
Nitrile
Single
Flat Ambient* 3No ADM / 240V
C4 36:1 CM Heated
≤70° C D
60 L
(16
Gal)
CST/AL
PTFE
Coated
Nitrile
Single
Flat
Heated
≤70° C 4No ADM / 480V
C5 68:1 CS Ambient* F
200 L
(55
Gal)
AL EPDM Double
Ring Ambient*
C6 68:1 CS Heated
≤70° C G
200 L
(55
Gal)
AL EPDM Double
Ring
Heated
≤70° C
C7 68:1 CM Ambient*
C8 68:1 CM Heated
≤70° C
CS = Carbon Steel Severe Duty
CM = Carbon Steel MaxLife
CST/AL = Carbon Steel/Aluminum
AL = Aluminum
Component Agency Approval
Heat Control Box
C
9902471

Models
3A8005A 5
Therm-O-Flow Warm Melt
Pressure
Due to factors such as the dispensing system design,
the material being pumped, and the flow rate, the
dynamic pressure will not reach the rated working (stall)
pressure of the system.
Pump Working (Stall) Pressure
Lower Size Air Motor Power Factor psi bar MPa
Check-Mate
NXT 3400 36:1 3600 248 24.8
200CS/CM
NXT 6500 68:1 5000 345 34.5

Models
63A8005A
Heat Zones
The following tables show how many heat zones are
available on Therm-O-Flow Warm Melt systems. The
tables show heat zones available for hoses or
accessories used on single or tandem systems. The
number of heat zones depends on whether the system
has an ambient or heated pump and platen, and if the
system includes a Heat Expansion Module.
Single System
Tandem System
Standard Heat Control Box with Ambient Pump
and Platen
Heated Hose Zones 4
End of Hose Zones 4
Standard Heat Control Box with Heat Expansion
Module and Ambient Pump and Platen
Heated Hose Zones 8
End of Hose Zones 8
Standard Heat Control Box with Heated Pump
and Platen
Heated Pump Zone 1
Heated Platen Zone 1
Heated Hose Zones 3
End of Hose Zones 3
Standard Heat Control Box with Heat Expansion
Module and Heated Pump and Platen
Heated Pump Zone 1
Heated Platen Zone 1
Heated Hose Zones 7
End of Hose Zones 7
Standard Heat Control Box Ambient Pump and
Platen
Heated Hose Zones 8
End of Hose Zones 8
Standard Heat Control Box Plus One Heat
Expansion Module Ambient Pump and Platen
Heated Hose Zones 12
End of Hose Zones 12
Standard Heat Control Box Plus Two Heat
Expansion Modules Ambient Pump and Platen
Heated Hose Zones 16
End of Hose Zones 16
Standard Heat Control Box Ambient Pump and
Platen
Heated Pump Zones 2
Heated Platen Zones 2
Heated Hose Zones 6
End of Hose Zones 6
Standard Heat Control Box Plus One Heat
Expansion Module and Heated Pump and
Platen
Heated Pump Zones 2
Heated Platen Zones 2
Heated Hose Zones 10
End of Hose Zones 10
Standard Heat Control Box Plus Two Heat
Expansion Modules and Heated Pump and
Platen
Heated Pump Zones 2
Heated Platen Zones 2
Heated Hose Zones 14
End of Hose Zones 14

Warnings
3A8005A 7
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.
DANGER
SEVERE ELECTRIC SHOCK HAZARD
This equipment can be powered by more than 240 V. Contact with this voltage will cause death or
serious injury.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• This equipment must be grounded. Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
WARNING
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. Get immediate surgical
treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the 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.

Warnings
83A8005A
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. 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 sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• 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.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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.
WARNING

Warnings
3A8005A 9
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. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) from distributor or
retailer.
• 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.
• Do 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.
• Do 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.
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen,
splatter may occur.
• Use minimum air pressure when removing platen from drum.
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 Safety Data Sheets (SDSs) 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.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
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. 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.
WARNING

Component Identification
10 3A8005A
Component Identification
Single Therm-O-Flow Warm Melt
D200 3 in. Dual Post, 200 Liter Platen
Key:
ARamAssembly
B Air Motor
C Displacement Pump
D Platen (see F
IG . 5)
E Advanced Display Module (ADM) (see F
IG . 7)
F Integrated Air Controls (see F
IG . 4)
G Platen Bleed Port
H Platen Lift Rod
J Pump Bleed Valve
KWetCup
L Air Line (not supplied)
M Air Line Drain Valve (not supplied)
N Air Filter (not supplied)
P Bleed Type Air Shut Off Valve (required) (not supplied)
R Level Sensors
S Heat Control Box
T Disconnect Switch (see Power Disconnect on page 12)
U*PumpHeater
V Air Motor Solenoid
W Transformer (480V only)
* Components on heated pumps only.
F IG . 1: Therm-O-Flow Warm Melt
Lift Locations
A
B
C
D
E
F
G
H
S
T
K
J
U
L
M
N
P
R
V
W

Component Identification
3A8005A 11
Tandem Therm-O-Flow Warm Melt
See Tandem Cable Kit, 26B339 on page 135.
D200 3 in. Dual Post, 200 Liter Platen
Unit A: This Therm-O-Flow Warm Melt includes an
ADM and is marked with the “A” label included in the
Tandem Cable Kit.
Unit B: This Therm-O-Flow Warm Melt does not include
an ADM and is marked with the “B” label included in the
Tandem Cable Kit.
TC: Tandem Cable Kit (26B339)
F IG . 2: Tandem Therm-O-Flow Warm Melt
B
A
Unit A Unit B
TC

Component Identification
12 3A8005A
Air Line Accessories
See F IG . 1 on page 10.
Air Line Drain Valve (M)
Air Filter (N): Removes harmful dirt and moisture from
compressed air supply.
Bleed Type Air Shut Off Valve (P): Isolates air line
accessories and Therm-O-Flow Warm Melt Supply
System for servicing. Locate upstream from all other air
line accessories.
Power Disconnect
Every Therm-O-Flow Warm Melt has a Disconnect
Switch which shuts off power to the entire system.
The Disconnect Switch (T) is located on the Heat
Control Box (S), and removes power to the entire
system. Turning OFF the Disconnect Switch (T) will also
remove power to the Air Motor Solenoid, which will stop
the Air Motor. The switch can be locked in the open
position.
F
IG . 3. Power Disconnect
S
T

Component Identification
3A8005A 13
Integrated Air Controls
AA Main Air Slider Valve
Turns air on and off to the entire system.
When
closed, the valve relieves pressure
downstream.
The valve can be locked in the closed position.
AB Ram Air Regulator
Controls the ram down pressure.
AC Ram Director Valve
Controls the ram direction.
AD Ram Air Gauge
Displays the ram down pressure.
AE Blowoff Button
Turns air on and off to push the platen out of an
empty drum.
AF Air Motor Air Regulator
Controls the air pressure to the motor.
AG Air Motor Pressure Gauge
Displays the air pressure to the motor.
AH 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 shut off air. The valve
can be locked in the closed position.
AJ Air Motor Solenoid Valve
Turns air on and off to the air motor when
system
stopped on the ADM. When closed,
the valve
relieves air trapped between it and
the motor.
AK Relief Valve
Exhausts air through relief valve to ensure air does
not exceed a certain pressure (75 psi on 68:1 sys-
tems, and 100 psi on 36:1 systems).
F
IG . 4. Integrated Air Controls
AH
AC
AK
AA
AB
AF
AD
AG
AE
AJ

Component Identification
14 3A8005A
Platen (D) Component Identification
Key:
BA Plate
BB Wiper
BC Heater Cover
BD Cap Screws
BF Bleed Stick
BG Bleed Port
BH Air Assist Body Check Valve
BJ Wiper Plate (under wiper)
BK O-ring Seal (not shown)
BL Platen Valve Port
BM Platen Valve Cap
F
IG . 5
Ambient Heated
BF
BC
BB
BJ BD
BH
BA
BA
BB
BF
BJ
BH
BG
BG BD
BL
BL
BM
BM

Component Identification
3A8005A 15
Heat Control Box Connections
Key:
CA CAN Cable Connection Ports*
CB PLC Input/Output Cord Grip
CC Heated Hose/Accessory Connector
CD Heated Pump Connection**
CE Heated Platen Connection
* On Unit A, this top port connects to the ADM. If using a
tandem system, the top connection port on Unit A is
connected to the top connection port on Unit B via the CAN
cable.
** This port can be used as a heated hose/accessory
connection when the system does not have a heated
pump/platen.
F IG . 6
Single Heat Module Expansion Heat Module
CA
CC
CB
CC
CD
CE

Component Identification
16 3A8005A
Advanced Display Module (ADM)
Front and Rear Views
Key:
DA Startup/Shutdown
Starts up or shuts down the system. Toggles
between Active and Inactive system.
DB System Status Indicator LED
DC System Soft Stop
Stops all processes and disables the Air Motor. Also
stops all heating processes and disables the heat.
This is not a safety or emergency stop.
DD Soft Keys
Defined by the icon on the screen next to the soft
key. Performs the specific operation for that icon
when pressed.
DE Cancel
Cancels a selection or number entry while in the
process of entering a number or making a selection.
Cancels the pump processes. Exits a screen with-
out saving changes.
DF Enter
Select to update a field, accept a selection or value,
acknowledge an event, enter a screen, and toggle
selected items.
DG Lock/Setup
Toggles between Run screens and the Main Menu.
DH Directional Keypad
Navigate within a screen or to a new screen.
DJ Numeric Keypad
Input numeric values.
DK Part Number Identification Label
DL USB Interface
DM CAN Cable Connection
Power and communication.
DN Module Status LEDs
Visual indicators to show the status of the ADM.
DP Token Access Cover
Access cover for blue software token.
DR Battery Access Cover
DS Light Tower Connection
NOTE: If using a tandem system, the ADM is only
included with the Therm-O-Flow Warm Melt Unit A.
F
IG . 7. ADM Component Identification
DA
DC
DD
DE
DF
DG
DH
DP
DK
DN DM
DL
DJ
DR
DS
DB

ADM Display Details
3A8005A 17
ADM Display Details
Power Up Screen
This screen appears when the ADM is powered up.
This screen remains on while the ADM runs through
initialization and establishes communication with other
modules in the system.
Menu Bar
The Menu Bar appears at the top of each screen (the
following image is only an example).
Date and Time
The date and time are always displayed in one of the
following formats. The time is always displayed as a
24-hour clock.
• DD/MM/YY HH:MM
• YY/MM/DD HH:MM
• MM/DD/YY HH:MM
Navigation Arrows
The left and right arrows are only visible when screen
navigation is allowed.
Screen Menu
The screen menu indicates the current active screen,
which is highlighted. It also indicates the associated
screens that are available by scrolling left and right.
System Modes
The current system mode is displayed in the lower left of
the Menu Bar, and toggles between Pump Status and
Heat Status. Pump Status includes: Pump Active, Pump
Inactive, Pump On, Pump Off, and Pump Priming. Heat
Status Includes: Heat Active, Heat Inactive, Heat Off,
Warming Up, Heat Soak, Heat at Temp, and Setback.
NOTE: If using a tandem system, only the active unit
system modes are displayed.
Status
The current system status is displayed in the lower right
of the Menu Bar.
Alarm/Deviation
The current system error is displayed in the middle of
the Menu Bar. There are four possibilities.
Soft Keys
Icons next to the soft keys indicate which mode or action
is associated with each soft key. Soft keys that do not
have an icon next to them are not active in the current
screen. See Advanced Display Module (ADM) on
page 16 and ADM Soft Keys on page 20.
Date and Time Navigation
Arrows
Screen Menu
Status
System Mode
Icon Function
No Icon No information or no error has occurred
Advisory
Deviation
Alarm
NOTICE
To prevent damage to the soft key buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.

ADM Display Details
18 3A8005A
Navigating the Screens
There are two types of screens:
Run screens control operations and display system
status and data.
Setup screens control system parameters and
advanced features. These screens are accessed
through the Main Menu.
Press on any Run screen to switch to the Main
Menu screens. If the system has a password lock, the
Password screen is displayed. If the system is not
locked (password is set to 0000), Menu Screen 1 is
displayed. Refer to Main Menu on page 21 for
additional information.
Press on any Setup screen to return to the Run
screen.
Press the Enter soft key to activate the editing
function on any screen.
Press the Exit soft key to exit the editing function
and save any changes.
Use the other soft keys to select the function adjacent to
them.
Use to exit a screen. Using this key while in editing
mode will exit the screen without saving changes.
Use the keys on the ADM to move through the
settings on a screen or drop down menu and to scroll
through multiple screens on the right side of the display.
Use the key to choose a field to update, to make a
selection, to save a selection or value, to enter a screen,
or to acknowledge an event.
Set Password
You can set a password to protect access to some
selections on the Main Menu screens. See Main Menu
on page 21. To set or remove the password, select
Advanced from Menu 2. See Advanced Setup Screen
1on page 34.

ADM Display Details
3A8005A 19
ADM LED Status Descriptions
ADM Icons
LED Conditions Description
System Status Green Solid Run Mode, System On
Green Flashing Setup Mode, System On
Yellow Solid Run Mode, System Off
Yellow Flashing Setup Mode, System Off
USB Status (CL) Green Flashing Data recording in progress
Yellow Solid Downloading information to USB
Green and Yellow Flashing ADM is busy, USB cannot transfer information
when in this mode
ADM Status (CN) Green Solid Power applied to module
Yellow Flashing Active Communication
Red Steady Flashing Software upload from token in progress
Red Random Flashing or Solid Module error exists
Icon Function
Alarm - See Troubleshooting, page 53
for more information.
Deviation - See Troubleshooting, page
53 for more information.
Advisory - See Troubleshooting, page
53 for more information.
No issues found with parameter or
setting value
Missing or unexpected parameter or
setting value
System is processing request
(animated)
Zone setpoint temperature showing the
temperature the zone heats too when
the heat is turned on.
Zone setback temperature showing the
setback the zone goes to when the heat
is in setback mode.
Displays the status of the lockout bit of
the PLC.

ADM Display Details
20 3A8005A
ADM Soft Keys
Icon Function
Enter or exit editing mode for a
particular screen.
Access the Schedule screens.
Access the Heat Setup screens.
Access the Diagnostics function.
Access the Events logs.
Access the Errors logs.
Access the Troubleshooting function.
Access the System Setup screen.
Access the Advanced System Setup
screens.
Access the Maintenance function.
Access the Fieldbus Gateway Setup
screens.
Access the Integration Feedback
screens.
Globalize selection. Apply a heat setting
to all of the heat zones in Heat Settings.
Confirm globalizing a setting.
Cancel globalizing a setting.
Tandem systems only. Toggle between
Pump A and Pump B.
Energizes the Air Motor to prime the
Pump.
Energizes the Pump.
Turn heat zones on and off.
Place all heat zones into setback and
out of setback.
Reset Cycle Counter.
Continue.
Previous screen.
Search.
Icon Function