Graco Therm-O-Flow 200 User manual

EasyKey™Hot Melt Drum Unloaders
For applying hot melt sealant and adhesive materials.
For professional use only. Not approved to European explosive atmosphere requirements.
Maximum Operating Temperature (All Models): 400°F (204°C)
NXT 2200 Powered Unloaders, Models A-1 and A-4
2300 psi (15.9 MPa, 159 bar) Maximum Fluid Working Pressure
125 psi (0.85 MPa, 8.5 bar) Maximum System Air Pressure (Ram)
100 psi (0.7 MPa, 7 bar) Maximum Air Motor Pressure
NXT 3400 Powered Unloaders, Models A-2 and A-5
3000 psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure
125 psi (0.85 MPa, 8.5 bar) Maximum System Air Pressure (Ram)
82 psi (0.57 MPa, 5.7 bar) Maximum Air Motor Pressure
NXT 6500 Powered Unloaders, Models A-3 and A-6
3000 psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure
125 psi (0.85 MPa, 8.5 bar) Maximum System Air Pressure (Ram)
43 psi (0.29 MPa, 2.9 bar) Maximum Air Motor Pressure
See page 2 for Contents.
TI7936-lr
311208P
EN
Instructions
200 Liter (55 Gallon) Drum Size
Therm-O-Flow 200®
Important Safety Instructions.
Read all warnings and instructions in this manual.
Save these instructions.

2311208P
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . 8
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 10
Heat Control Zone Selection . . . . . . . . . . . . . . . 12
Air Line Modules . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . 13
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Location Requirements . . . . . . . . . . . . . . . . . . . 13
Hose Installation and Care . . . . . . . . . . . . . . . . 14
Mechanical Setup . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Setup . . . . . . . . . . . . . . . . . . . . . . . . . 15
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connecting the Electrical Control Panel to a Power
Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Overview of the Temperature Controller Settings 20
Purging the System . . . . . . . . . . . . . . . . . . . . . . 20
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . 21
Main Power Disconnect . . . . . . . . . . . . . . . . . . . 21
EasyKey Display and Keypad . . . . . . . . . . . . . . 21
LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
EasyKey Display Screens . . . . . . . . . . . . . . . . . . . 23
Power Up Screens . . . . . . . . . . . . . . . . . . . . . . 23
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Purge Before Using Equipment . . . . . . . . . . . . . 29
Set Values on EasyKey . . . . . . . . . . . . . . . . . . . 29
Material Loading . . . . . . . . . . . . . . . . . . . . . . . . 29
System Heat Up . . . . . . . . . . . . . . . . . . . . . . . . 31
Prime Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Prime System . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure Relief Procedure . . . . . . . . . . . . . . . . 34
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Ram Pressure Relief Procedure . . . . . . . . . . . . 35
Drum Changing . . . . . . . . . . . . . . . . . . . . . . . . . 36
System Shutdown . . . . . . . . . . . . . . . . . . . . . . . 38
Dual Ram Cross-Over Installation . . . . . . . . . . . . 39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ground Fault Interrupt . . . . . . . . . . . . . . . . . . . . 40
Power in a Tandem System . . . . . . . . . . . . . . . . 40
Resetting the Ground Fault Interrupt . . . . . . . . . 40
Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . 40
Ram Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 42
Heated Pump Troubleshooting . . . . . . . . . . . . . . . 43
Air Motor Troubleshooting . . . . . . . . . . . . . . . . . . 43
Electrical Control Panel Troubleshooting . . . . . . 44
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Ground Fault interrupt . . . . . . . . . . . . . . . . . . . . 45
Power in a Tandem System . . . . . . . . . . . . . . . . 45
Servicing Wipers . . . . . . . . . . . . . . . . . . . . . . . . 45
Pump Removal and Replacement . . . . . . . . . . . . 47
Replacing Heater Bands and Sensors in Pump
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 52
240 VAC Supply - Internal Control Box . . . . . . . 52
Electrical Control Schematics . . . . . . . . . . . . . . 53
Electrical Connections Schematic . . . . . . . . . . . 58
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
All Models Supply Unit . . . . . . . . . . . . . . . . . . . . 60
Therm-O-Flow Pump . . . . . . . . . . . . . . . . . . . . . 62
Therm-O-Flow Pump Module using NXT 3400 and
NXT 6500 Models . . . . . . . . . . . . . . . . . . . . 64
Therm-O-Flow Pump Module using NXT 2200
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Series A Heated Pump . . . . . . . . . . . . . . . . . . . 68
Heated Platens . . . . . . . . . . . . . . . . . . . . . . . . . 70
Platen Coil Checking . . . . . . . . . . . . . . . . . . . . . 72
EasyKey Assembly, Part No. 253147 . . . . . . . . 73
Swirl Kit, Part No. 253263 . . . . . . . . . . . . . . . . . 74
Drip Shield Mount Kit, Part No. 253479 . . . . . . . 75
Drum Ram Post Saddle Clamp, Part No. C32463 76
Heavy Duty Drum Band Clamp, Part No. 918395 77
Fiber Drum Reinforcement Clam Shell Clamp, Part
No. 918397 . . . . . . . . . . . . . . . . . . . . . . . . . 78
Vent Hood Accessory Kit for 6-1/2 In. Ram, Part No.
233559 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Advanced Units . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Light Tower Kit (253547) . . . . . . . . . . . . . . . . . . 80
Drum Low and Empty Sensor Kit 253559 . . . . . 82
Ethernet Kit (253566) . . . . . . . . . . . . . . . . . . . . 83
Maintenance Call Kit (253548) . . . . . . . . . . . . . 90
Discrete I/O Kit (253567) . . . . . . . . . . . . . . . . . . 92
All Models Control Panel Component Layout . . . 94
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 98
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 98

Warnings
311208P 3
Warnings
The following 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 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 drum 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
4311208P
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

Warnings
311208P 5

Overview
6311208P
Overview
How the Therm-O-Flow 200 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 heated Check–Mate pump
and heated fluid moves to the application tool.
Model Numbers
This manual refers to the typical model number listed
below when defining parts in your application. The
model number stamped on your machine defines the
equipment in the following 10 categories:
1. Motor
2. Heated Platen
3. Follower Seals
4. Drum Ram
5. Number of Heat Zones
6. Heat Controls Supply Voltage
7. Control Panel
8. Drum Unloader Options
9. Application Accessories
10. Hose Kit Layout
Typical Model Number: TOF200A–D–1–A–1–P–6–2–A–F–1–N–1–1–D–P–N-N
Model Product Description
TOF200A 55 gal./200 liter Hot Melt Drum Unloader
Code A Air Motor Selection
1 NXT 2200 HLS quiet air motor (23:1 Power Ratio)
with pump
2 NXT 3400 HLS quiet air motor (36:1 Power Ratio)
with pump
3 NXT 6500 HLS quiet air motor (70:1 Power Ratio)
with pump
N No air motor or pump
4 NXT 2200 HLS quiet air motor (23:1 Power Ratio)
with pump and heavy duty packings
5 NXT 3400 HLS quiet air motor (36:1 Power Ratio)
with pump and heavy duty packings
6 NXT 6500 HLS quiet air motor (70:1 Power Ratio)
with pump and heavy duty packings
Code B Heated Platen Style
AMega-Flo™high flow drum platen
B Standard fin design drum platen
C Smooth bottom (no fin) drum platen
Code C Tire Plate Seal Style
12 Black EPDM/EPDM, SS wire braid 400oF hose
wipers w/spring retention
2 1 lower Black EPDM/Chlorobutyl, SS wire braid
375oF hose wiper and 1 upper White Silicone
375oF T-wiper
3 1 lower Black EPDM/Chlorobutyl, SS wire braid
400oF hose wiper and 1 upper Green Silicone,
fiberglass braid 400oF, hose wiper
42 White Silicone 250oF T-Wipers
Code D Drum Ram Style
P Pneumatic Ram
H Hydraulic Ram
Code E Number of Heat Zones
6 6 Zones
8 8 Zones
N No electrical control panel (includes pneumatic
controls, independently mounted)
If Code E option N is selected, then Codes F and G must also be
option N and Code H is ignored.
Code F Customer’s Power Supply Voltage
2 220/240 Vac 50/60 Hz 3 phase
3 380/400 Vac 50/60 Hz 3 phase
4 470/490 Vac 50/60 Hz 3 phase
5 570/590 Vac 50/60 Hz 3 phase
N No electrical control panel
Code G Display and Interface Options
B Standard unit – uses EasyKey
A Advanced unit – EasyKey with discrete I/O,
Ethernet, light tower, and proximity switches.
T Tandem primary unit – Unloader A in a primary
unit.
S Tandem secondary unit – Unloader B in a tandem
unit.
N No electrical control panel
Code H Language Selection
E English
F French
GGerman
S Spanish
J Japanese
C Chinese (Simplified)
Code J Drum Clamp Options
1 Fiber drum reinforcement clam shell
2 Heavy duty drum band clamp
3 Drum ram post saddle clamps
N No drum clamp option
Code K Vent Hood Kit
NNone
Y Vent Hood Kit
Code L Swirl Solenoid Kit
NNone
1 Single Swirl Solenoid Kit
2 Dual Swirl Solenoid Kit

Overview
311208P 7
Model Code Layout
Code M Type of Hose Connection
N None
1 Single hose and end-of-hose device
2 Dual hose and end-of-hose device from tee kit
3 Hose to (compensator or regulator) with either
(second hose to dispense valve and end-of-hose
device) or to (end-of-hose device) without a second
hose.
Code N Hose 1
B -8 (.41” ID) by 10 feet, 3000 psi
C -8 (.41” ID) by 15 feet, 3000 psi
D -8 (.41” ID) by 10 feet for Air Swirl, 3000 psi
E -8 (.41” ID) by 15 feet for Air Swirl, 3000 psi
H -10 (.51” ID) by 6 feet, 3000 psi
J -10 (.51” ID) by 10 feet, 3000 psi
K -10 (.51” ID) by 15 feet, 3000 psi
L -10 (.51” ID) by 20 feet, 3000 psi
M -10 (.51” ID) by 25 feet, 3000 psi
N None
P -12 (.62” ID) by 10 feet, 3000 psi
Q -12 (.62” ID) by 15 feet, 3000 psi
R -12 (.62” ID) by 20 feet, 3000 psi
S -12 (.62” ID) by 25 feet, 3000 psi
T -16 (.87” ID) by 6 feet, 3000 psi
U -16 (.87” ID) by 10 feet, 3000 psi
V -16 (.87” ID) by 15 feet, 3000 psi
W -16 (.87” ID) by 20 feet, 3000 psi
X -16 (.87” ID) by 25 feet, 3000 psi
Y -20 (1.13” ID) by 10 feet, 3000 psi
Z -20 (1.13” ID) by 15 feet, 3000 psi
Code P End of Hose 1 Device
A 240V 23:1 heated pressure compensator valve
B 240V 51:1 heated pressure compensator valve
C Heated distribution manifold
D Heated air operated mastic pressure regulator
E Manual gun with top feed swivel
F Manual gun top feed with electric switch
G Manual gun with bottom feed swivel
H Manual gun with bottom feed with electric switch
J Air operated heated dispense valve
K Air operated high flow heated dispense valve
L Air operated snuff-back heated dispense valve
M 45” distribution header with valve
NNone
P Manual gun bottom feed with Swirl & .030 orifice
Q Manual gun top feed with Swirl & .030 orifice
R 243694 with Swirl & .030 orifice
S 244909 with Swirl & .030 orifice
Code Q Hose 2
B -8 (.41” ID) by 10 feet, 3000 psi
C -8 (.41” ID) by 15 feet, 3000 psi
D -8 (.41” ID) by 10 feet for Air Swirl, 3000 psi
E -8 (.41” ID) by 15 feet for Air Swirl, 3000 psi
H -10 (.51” ID) by 6 feet, 3000 psi
J -10 (.51” ID) by 10 feet, 3000 psi
K -10 (.51” ID) by 15 feet, 3000 psi
L -10 (.51” ID) by 20 feet, 3000 psi
M -10 (.51” ID) by 25 feet, 3000 psi
NNone
P -12 (.62” ID) by 10 feet, 3000 psi
Q -12 (.62” ID) by 15 feet, 3000 psi
R -12 (.62” ID) by 20 feet, 3000 psi
S -12 (.62” ID) by 25 feet, 3000 psi
T -16 (.87” ID) by 6 feet, 3000 psi
U -16 (.87” ID) by 10 feet, 3000 psi
V -16 (.87” ID) by 15 feet, 3000 psi
W -16 (.87” ID) by 20 feet, 3000 psi
X -16 (.87” ID) by 25 feet, 3000 psi
Y -20 (1.13” ID) by 10 feet, 3000 psi
Z -20 (1.13” ID) by 15 feet, 3000 psi
Code R End of Hose 2 Device
E Manual gun with top feed swivel
F Manual gun top feed with electric switch
G Manual gun with bottom feed swivel
H Manual gun with bottom feed with electric switch
J Air operated heated dispense valve
K Air operated high flow heated dispense valve
L Air operated snuff-back heated dispense valve
M 45” distribution header with valve
NNone
P Manual gun bottom feed with Swirl & .030 orifice
Q Manual gun top feed with Swirl & .030 orifice
R 243694 with Swirl & .030 orifice
S 244909 with Swirl & .030 orifice
TOF200A
Code
--------- ------
ABCDEFGHJ K LMN PQR

Overview
8311208P
Component Identification
Before installing the system you should be familiar with
all the system components. See FIG. 1 for
Therm-O-Flow system components.
Air and Fluid Hoses
When installing a system make sure:
• All air and fluid hoses are properly sized for the sys-
tem.
Heat Control Zone Selection
The Therm-O-Flow 200 has 6 or 8 heat zones. Zones 1
and 2 are always used for the heated drum platen and
the heated pump. Zones 3 and 4, 5 and 6, and 7 and 8
are each available as paired zones through 16-pin con-
nectors. The heated hoses have a 16-pin connector on
the inlet end cable, and an 8-pin connector on the outlet
end cable. All heated valves, manifolds, and heaters are
equipped with an 8-pin matching connector.
User Display (EasyKey)
• A simple user interface consisting of an LCD display
and keypad.
• Keypad contains the buttons which control the
Therm-O-Flow 200 operations.
Air Line Components
The following components are included with the unit.
See FIG. 1.
• System Master Air Valve (A) is used to shut off the
air supply to the system.
• Air Line Filter (B) removes dirt and moisture from
the compressed air supply.
• Air Motor Air regulator (C) and (V) control the outlet
pressure by adjusting the air pressure to the air
motor.
• Air Motor Master Air Valve (D) shuts off the air sup-
ply to the air motor and bleeds trapped air from the
air motor.
• Air motor Air Supply Hose connects the air regulator
to the air motor.
Pneumatic Control Panel
The pneumatic control panel includes the following. See
FIG. 1.
• Auto Depressurization Valve exhausts air from the
air motor at shutoff. The built-in control delays
start-up to allow material to thoroughly heat.
• Ram Air Regulators (N, P) control the air pressure
to the ram. There are separate air regulators to con-
trol the ram pressure in the up and down directions.
• Ram Up/Down Lever (R) changes the direction of
the ram.
• Blow-off air regulator (T) controls the air pressure to
the platen blow-off valve.
• Platen Blow-off Valve (S) directs air to the underside
of the platen when depressed.
Vent Hood Kit (if supplied)
The vent hood assembly is designed to efficiently draw
fumes to the factory exhaust system during drum
change-out. This assembly requires a connection to a
factory ventilation system that draws a minimum air flow
of 8.4 m3/min (300 scfm). This kit is recommended for
Polyurethane Reactive (PUR) applications.
The Therm-O-Flow 200 requires Graco single-cir-
cuit material hoses rated at a maximum of 1250
watts.

Overview
311208P 9
Component Identification
Key:
A System Master Air Valve (bleed-type)
B Air Line Filter
C Air Motor Air Regulator (bleed-type)
D Air Motor Master Air Valve (bleed-type)
ERam
FHeatedPump
GPlaten
H Air Inlet (1/2” npt)
J Electrical Control Panel
K Main Power Disconnect Switch
L EasyKey Display and Keypad
M Pneumatic Control Panel
N Ram Up Air Regulator
P Ram Down Air Regulator
R Ram Up/Down Lever
S Platen Blow-off Valve
T Blow-Off Air Regulator
U Electrical Power Input
V Air Motor Enable Solenoid/Depressurization Valve
W NXT Air Motor
X Air Motor Remote Piloted Air Regulator
Y Ram Plate Bleed Stick
Z Drum Blow Off Valve (behind ram plate bleed stick Y)
AA Maintenance Call
AB Ethernet Connection
FIG. 1: Component Identification
V
A
B
K
U
W
E
G
F
Y, Z
D
P
N
R
C
T
S
J
L
HX
AB
AA
M
TI8134A
TI7936A
TI8158A

Typical Installation
10 311208P
Typical Installation
The typical installation discussed and shown is only a
guide for selecting and installing system components
and accessories. See FIG. 2. Contact your Graco distrib-
utor for help in designing a system to suit your particular
needs.
The air-powered ram extruder forces high viscosity flu-
ids into the intake valve of the fluid pump. Wiper rings
and other accessory equipment for use with this ram are
listed in Technical Data on page 97.
Power Requirements
See Technical Data on page 97.
Selecting a Location for the Ram
Refer to the Dimensions drawing on page 96 for ram
mounting and clearance dimensions.
When selecting a location for the ram keep the following
in mind:
1. There should be sufficient space for installing and
using the equipment.
• Make sure there is sufficient overhead clear-
ance for the pump and ram when the ram is in
the fully raised position.
• If you are installing a vent hood make sure there
is sufficient horizontal clearance for it.
• Make sure the air regulators for the pump and
ram are fully accessible.
• Make sure there is easy access to an appropri-
ate electrical power source. The National Elec-
trical Code requires 3 feet of open space in front
of the electrical panel.
2. Make sure that you will be able to level the base of
the ram using metal shims.
3. When you bolt the ram to the floor the anchors
should be long enough to prevent the unit from tip-
ping. Refer to the Dimensions drawing on page 96
for more information.
4. If you are installing a vent hood, make sure the ram
is installed near a connection to the factory ventila-
tion system.
System Accessories and Modules
Before you install the system you should be familiar with
all the parts and system requirements for the
Therm-O-Flow 200.
For information about converting the ram from air to
hydraulic operation, contact your Graco distributor.

Typical Installation
311208P 11
Typical Installation (Advanced Unit Shown)
101 Electrical Control Panel
102 Ram Module
104 Heated Follower Plate
106 Depressurization Valve/Air Motor Enable Solenoid
109 Pump and Air Motor Assembly
115 Air Motor Mounting Bracket
202 Air Filter
204 Air Motor Remote-Piloted Air Regulator
211 Ram Up/Ram Down Lever
214 System Master Air Valve (required)
226 Main Air Line Inlet
319 Ram Plate Bleed Stick
327 Lower Wiper
329 Upper Wiper
330 Drum Blow Off Valve
332 Drum Low and Empty Sensors
FIG. 2: Typical Installation
101
102
104
109
115
211
319
329 327
226 202 204
Lift Locations (if air is supplied to the
system and ram lever is set to down)
214
106
CAUTION
Do not use motor lift ring
to lift entire system. See
ram lift locations, FIG. 2.
330
332
TI7937A
TI8158A

Typical Installation
12 311208P
Heat Control Zone Selection
The Therm–O–Flow 200 can be ordered with 6 (code
E–6) or 8 (code E–8) heat zones (see Fig.3). Zones 1
and 2 are always used for the heated drum platen and
the heated pump. Zones 3 and 4, 5 and 6, and optional
zones 7 and 8 are each available as paired zones
through a 16–pin connector.
The heated hoses have a 16–pin connector on the inlet
end cable, and an 8–pin connector on the outlet end
cable. All heated valves, manifolds and heaters are
equipped with an 8–pin matching connector. Accessory
cables are available for other possible combinations.
See FIG. 3.
Air Line Modules
4-Regulator Air Control Module (shown)
For more information, refer to FIG. 1 on page 9. The fol-
lowing components are included with the module:
• System Master Air Valve (bleed-type) (D) is used to
shut off the air supply to the entire supply unit.
• Air Motor Master Air Valve (bleed-type) (D) is sup-
plied in your system to relieve air trapped between it
and the air motor when the valve is energized (see
Warning above). This bleed valve should be easily
accessible and located downstream from the air
regulator.
• Air Motor Air Regulator (C) controls the pump outlet
pressure by adjusting the air pressure to the air
motor. It is located on the pneumatic control panel.
• The Air Motor Enable Solenoid, see FIG. 1 page 9,
letter (X) delays startup to allow material to heat
thoroughly.
• Ram Air Regulator (N,P) controls the air pressure to
the ram. There are separate air regulators to control
the ram pressure in the up and down directions.
• Ram Plate Blow-off Valve (S,T) controls the air to
the ram plate blow-off.
Fluid Line Accessories (Typical)
A pressure compensator valve controls fluid pressure to
the gun/valve, and dampens pressure surges. Install the
pressure compensator valve using adapters as neces-
sary.
FIG. 3: Heat Control Zone Selection
4)
:/.%

#ONTROL
:/.%

#ONTROL
:/.%

#ONTROL
:/.%

#ONTROL
:/.%

#ONTROL
:/.%

#ONTROL
:/.%

#ONTROL
:/.%

#ONTROL
6ALVE 6ALVE 6ALVE
(OSE (OSE (OSE
0LATEN 0UMP
WATTS
MAX
WATTS
MAX
WATTS
MAX
WATTS
MAX
WATTS
MAX
WATTS
MAX
The Air Motor bleed-type master air valve (D) is
required in your system to relieve motor air pressure.
Trapped air can cause the pump to cycle unexpectedly,
which can result in serious bodily injury.
Part No. 297401 is used if “None” is selected for
Configurator Code E, F, and G.

Installation Procedure
311208P 13
Installation Procedure
The installation procedure includes:
• unpacking the ram
• locating and installing the ram
• mechanical setup
• electrically connecting hoses to the electrical control
panel
• grounding the system
• connecting the electrical control panel to a power
source
• connecting to an air source
• setting controls on the electrical control panel
Unpacking
1. Inspect the shipping box carefully for damage. Con-
tact 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 prob-
lems immediately.
4. Remove the unit from the skid and place it in the
desired location (See “Location Requirements” on
page 13).
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 electri-
cal 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.
5. Apply 50 psi download pressure to ram.
6. Wrap the bar with the lifting sling. See FIG. 2 for
proper lift spots.
7. Lift off the pallet using a crane or a forklift.
8. Position the ram in the desired location.
9. Level the base of the ram, using metal shims.
10. Bolt the ram to the floor, using anchors that are long
enough to prevent the unit from tipping.
11. If your unit is equipped with optional level controls,
remove from the electrical control panel and twist
into place on top of the electrical control panel.
CAUTION
Do not use motor lift ring to lift entire system. See lift
locations, FIG. 2.
CAUTION
Do not use motor lift ring to lift entire system. See lift
locations, FIG. 2.
CAUTION
Do not use motor lift ring to lift entire system. See lift
locations, FIG. 2.

Installation Procedure
14 311208P
Hose Installation and Care
1. Do not use hose to pull equipment.
2. Use 2 wrenches to tighten. Torque to 470-550 in-lbs
(53.1-62.1 N•m).
3. Do not tape or cover hose.
4. Do not flex hose when cold.
5. Use hose support spring.
6. Do not clamp, squeeze, or zip tie hose.
7. Minimum bend radius is 8 in. (20.3 cm).
8. Do not bend or crimp hose.
9. Do not twist hose.
10. Use proper length hose.
8 in.
(20.3 cm)
88

Installation Procedure
311208P 15
Mechanical Setup
1. Check, and if necessary, tighten the heated hose
connection at the pump outlet.
2. Wrap exposed fittings on the pump outlet with
Nomex insulation and secure insulation using fiber-
glass tape.
3. Fill displacement pump wet cup 2/3 full with Graco
Throat Seal Liquid (TSL).
4. Back-off all air regulators to their full counterclock-
wise position.
5. Connect a 1/2 in. (13 mm) air line from an air source
to the system air inlet, see FIG. 1, page 9, letter (H)
capable of delivering a minimum of 15 cfm (0.4
m3/m) at 100 psi (0.7 MPa, 7.0 bar). Do not use
quick disconnects.
Electrical Setup
Electrically Connect Hoses
1. Securely tighten the 16-pin electrical connectors on
long heated hose leads into 16-socket receptacles
located on the back of the electrical control panel.
See FIG. 4.
2. Securely tighten the 8-socket electrical connectors
on short heated hose leads into 8-pin receptacle
located on the dispense valves.
The ram UP/DOWN lever is shipped inside the
pneumatic control panel and should now be
screwed onto the face of the control.
The Therm-O-Flow 200 requires Graco single-cir-
cuit material hoses rated at a maximum of 1250
watts.
FIG. 4: Rear View of Electrical Control Box
Hose One
Hose Two
Hose Three
(Optional)
TI8136A

Installation Procedure
16 311208P
Connect Power Source
The electrical control panel comes already attached and
wired to the ram, however before the supply unit
becomes functional you must connect the electrical con-
trol panel to a power source.
1. Open electrical enclosure door and locate the main
disconnect.
2. Have a qualified electrician connect your plant
power to the electrical control panel disconnect
switch according to local codes. A 1-3/8 in. (35 mm)
diameter opening is provided on top of the panel
above the connections. This opening is suitable for a
1 in. npt conduit or strain relief fitting.
BB = Standard grid platen: 18 Kw
BA = Mega-Flo™platen: 21 Kw
BC = Smooth bottom platen: 18 Kw
Grounding
Ground the supply unit as instructed here and in the
individual component manuals.
To reduce the risk of static sparking, ground the pump,
the object being dispensed to, and all other spraying/dis-
pensing equipment used or located in the spraying/dis-
pensing area. Check your local electrical code for
detailed grounding instructions for your area and type of
equipment.
•Air and fluid hoses: Use only electrically conductive
hoses.
•Dispensing/Spray Gun: Follow the dispensing/spray
gun grounding instructions.
•Object material is applied to: Ground according to
your local code.
•Material drums: Ground according to your local
code. Use only metal drums placed on a grounded
surface. Do not place the drum on a nonconductive
surface, such as paper or cardboard, which inter-
rupts the grounding continuity.
•Maintain grounding continuity when flushing or
relieving pressure: Follow the instructions in your
separate gun manual for safely grounding your gun
while flushing.
Required voltage and amperage is noted on the
control panel label. Also see Table 1. Before run-
ning power to the unit, make sure the plant elec-
trical service meets the machine’s electrical
requirements.
Table 1 Electrical Requirements
AC Panel
Voltage HZ Phase
Platen
Selection
Full Load
Amps
220 / 240 50/60 3 BB & BC 70
BA 80
380 / 400 50/60 3 BB & BC 42
BA 48
470 / 490 50/60 3 BB & BC 35
BA 40
570 / 590 50/60 3 BB & BC 29
BA 32
To reduce the risk of fire, explosion, or electric shock:
• The power source conduit is not an adequate
ground for the system. The unit must be bonded
to either the building ground or a true earth
ground.

Installation Procedure
311208P 17
Connecting the Electrical
Control Panel to a Power Source
The electrical control panel (FIG. 5) comes already
attached and wired to the ram, however before the sup-
ply unit becomes functional, you must connect the elec-
trical control panel to a power source.
Have a trained electrician connect the electrical control
panel (Fig. 5) to a grounded electrical source that has
the required service ratings, see Electrical Require-
ments on page 16.
BB = Standard grid platen: 18 Kw
BA = Mega–Flo platen: 21 Kw
BC = Smooth bottom platen: 18 Kw
For information about specific terminal locations and
connections, see Advanced Units on page 80.
To connect the control panel to the electrical source:
1. Locate the opening in the control panel’s top hous-
ing for the conduit that will enclose the wire from the
facility’s power source. The hole will accept a 1”
conduit fitting. It is 1.3” dia. (33mm).
2. Thread the wire from the power source into the con-
trol panel housing, and then connect the power
source wires to the appropriate terminals on the
DISCONNECT switch.
FIG. 5: Electrical Control Panel
CAUTION
If power and grounding connections are not done
properly, the equipment will be damaged and the war-
ranty will be voided. Check the label on the control
box for the proper voltage.
Electrical
Control
Panel
TI7935A

Installation Procedure
18 311208P
Check the Resistance Between the Supply
Unit and the True Earth Ground.
Have a qualified electrician check the resistance
between each supply unit component and the true earth
ground. The resistance must be less than 0.25 ohms. If
the resistance is greater than 0.25 ohms a different
ground site may be required. Do not operate the system
until the problem is corrected.
Checking Resistance.
Sensor Resistance Checks.
The package includes up to eight heat sensors and con-
trollers for each of the heated zones. To check sensor
resistance:
1. Make sure the power is off and that the disconnect
switch is in the OFF position.
2. Make electrical resistance checks for the compo-
nents.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in the RTD Sen-
sors chart below.
RTD Sensors
To reduce the risk of fire, explosion, or electric shock
the resistance between the supply unit components
and true earth ground must be less than 0.25 ohms.
Use a meter that is capable of measuring resis-
tance at this level.
To reduce risk of injury or damage to equipment, con-
duct these electrical checks with the main disconnect
OFF.
Check resistance at ambient room temperature
(63°– 77° Fahrenheit).
Zone Component Terminals Value Range
1 Ram Plate 2011 & 2021 108 +/- 2% ohms
2 Fluid Pump 2051 & 2061 108 +/- 2% ohms
3 Dispense Hose 1 2081 & 2091 108 +/- 2% ohms
4 Dispense Gun 1 2111 & 2121 108 +/- 2% ohms
5 Dispense Hose 2 2261 & 2271 108 +/- 2% ohms
6 Dispense Gun 2 2291 & 2301 108 +/- 2% ohms
7 Dispense Hose 3 2321 & 2331 108 +/- 2% ohms
8 Dispense Gun 3 2351 & 2361 108 +/- 2% ohms

Installation Procedure
311208P 19
Heater Resistance Checks.
To check heater resistance:
1. Make sure the power is off and that the disconnect
switch is in the OFF position.
2. Make electrical resistance checks for the compo-
nents. Refer to Electrical Schematics on page 52
for wiring diagram information.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in Table 2 or Table
3.
To reduce risk of injury or damage to equipment, con-
duct these electrical checks with the main power dis-
connect OFF.
Check resistance at ambient room temperature
(63°– 77°F) (17°– 25°C).
Table 2 Heaters
Zone Component Between
Te r m i n a l s
For Unit Voltage Platen Model Code Resistance Values (ohms)
1 Platen AB, BC, CD,
DE, EF, FA
220/240 VAC BA 16.5Ω+1 / -2
BB, BC 19.5Ω+2 / -3
AB, BC, CD,
DE, EF, FA
380/400 VAC BA 16.5Ω+1 / -2
BB, BC 19.5Ω+2 / -3
470/490 VAC BA 16.5Ω+1 / -2
BB, BC 19.5Ω+2 / -3
AB, BC, CD,
DE, EF, FA
570/590 VAC BA 16.5Ω+1 / -2
BB, BC 19.5Ω+2 / -3
Any to GND 100,000Ω Min
Table 3 Heaters
Zone Component Between Terminals For Unit Voltage Platen Model Code Resistance Values (ohms)
2 Pump T1/T3, T2/T3,
B1/B3, B2/B3
Any Any 192.0 +/- 19.2Ω
T1/T3, T2/T3,
B1/B3, B2/B3
380/400 BA
BB, BC
470/490 BA
BB, BC
Same 570/590 BA
BB, BC

Installation Procedure
20 311208P
Overview of the Temperature
Controller Settings
Temperature controls are set in the zone configuration
setup screens. See Run Screens on page 23 for infor-
mation about setting temperature controls.
P, I, and D settings are preset for device types and will
not need to be changed. Refer to the Zone Setup
Screens on page 24 for a list of device types and how to
set them for each zone.
Purging the System
Purging the system before the initial use can prevent
material contamination, which may cause the material to
fail or perform poorly.
To purge the system perform the following procedure:
1. Select the material for the initial material load.
2. Verify whether the factory-test oil and the initial
material load are compatible:
a. If the two substances are compatible omit the
remaining steps in this procedure and refer to
the start up and operation instructions.
b. If the two substances are incompatible perform
the remaining steps in this procedure to flush
the system.
3. Select a drum of material that can eliminate the fac-
tory-test oil from the system. If necessary, check
with Graco or the material supplier for a recom-
mended solvent.
4. Before purging be sure the entire system and waste
drum are properly grounded. Refer to Grounding
on page 16.
5. Turn all heat zones to 70°F (21.1°C). This allows air
to the air motor, with no alarms, in a cold state.
6. Purge the material through the system for approxi-
mately 1 to 2 minutes.
7. Remove the drum if purge material was used.
CAUTION
Purge the system before performing the initial material
loading procedure. The system was factory- tested
using a light soluble oil, a soybean oil, or some other oil
as tagged. Flush the system to avoid contaminating the
material that has been designated for initial material
loading.
Use fluids that are chemically compatible with the
equipment wetted parts. See the Technical Data sec-
tions of all the equipment manuals.
This equipment should not be used with more than one
type of fluid due to potential compatibility issues which
could result in an unpredictable reaction. Graco recom-
mends using new hoses when chemicals are changed
or care must be taken to assure that all traces of one
chemical are removed before introducing a second
chemical.
Remove any dispense valve orifices before purg-
ing. Reinstall after purging has been completed.