Graco Therm-O-Flow 20 Parts list manual

EasyKey™Hot Melt Pail Unloaders
For applying hot melt sealant and adhesive materials.
Maximum Operating Temperature: 400°F (204°C)
NXT®2200 Powered Unloaders
2300 psi (15.9 MPa, 159 bar) Maximum Fluid Working Pressure
125 psi (.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
3000 psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure
125 psi (.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
3000 psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure
125 psi (.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 and page 6 for Model Numbers.
TI10076A
Instructions - Parts
20 Liter (5 Gallon) Pail Size
Therm-O-Flow®20
Important Safety Instructions.
Read all warnings and instructions in this manual.
Save these instructions.
311976K
EN

2311976K
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
How the Therm-O-Flow 20 Works . . . . . . . . . . . . 6
Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . 8
Power Requirements . . . . . . . . . . . . . . . . . . . . . 10
Heat Control Zone Selection . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Location Requirements . . . . . . . . . . . . . . . . . . . 11
Locate and Install the Ram . . . . . . . . . . . . . . . . 11
Hose Installation and Care . . . . . . . . . . . . . . . . 12
Mechanical Setup . . . . . . . . . . . . . . . . . . . . . . . 12
Electrically Connect Hoses . . . . . . . . . . . . . . . . 13
Connect the Electrical Control Panel to a Power
Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Check Resistance . . . . . . . . . . . . . . . . . . . . . . . 14
Overview of the Temperature Controller Settings 15
Purging the System . . . . . . . . . . . . . . . . . . . . . . 16
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . 17
Main Power Disconnect . . . . . . . . . . . . . . . . . . . 17
EasyKey Display and Keypad . . . . . . . . . . . . . . 17
LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
EasyKey Display Screens . . . . . . . . . . . . . . . . . . . 19
Power Up Screens . . . . . . . . . . . . . . . . . . . . . . 19
Run Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Purge Before Using Equipment . . . . . . . . . . . . . 25
Set Values on EasyKey . . . . . . . . . . . . . . . . . . . 25
Material Loading . . . . . . . . . . . . . . . . . . . . . . . . 25
System Heat Up . . . . . . . . . . . . . . . . . . . . . . . . 27
Prime Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Prime System . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pressure Relief Procedure . . . . . . . . . . . . . . . . 30
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Ram Pressure Relief Procedure . . . . . . . . . . . . 31
Pail Changing . . . . . . . . . . . . . . . . . . . . . . . . . . 32
System Shutdown . . . . . . . . . . . . . . . . . . . . . . . 34
Dual Ram Cross-Over Installation . . . . . . . . . . . . 35
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ground Fault Interrupt . . . . . . . . . . . . . . . . . . . . 36
Power in a Tandem System . . . . . . . . . . . . . . . . 36
Resetting the Ground Fault Interrupt . . . . . . . . . 36
Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . 36
Ram Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 38
Heated Pump Troubleshooting . . . . . . . . . . . . . . . 39
Air Motor Troubleshooting . . . . . . . . . . . . . . . . . . 39
Electrical Control Panel Troubleshooting . . . . . . 40
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Ground Fault interrupt . . . . . . . . . . . . . . . . . . . . 41
Power in a Tandem System . . . . . . . . . . . . . . . . 41
Platen Service . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Air Motor/Pump Removal and Service . . . . . . . 43
Replacing Heater Bands and Sensors in Pump
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Therm-O-Flow 20 Supply Unit . . . . . . . . . . . . . . 46
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
EasyKey Assembly, Part No. 255224 . . . . . . . . 51
Spare Parts and Kits . . . . . . . . . . . . . . . . . . . . . 52
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 54
253150 and 253156 Controls . . . . . . . . . . . . . . 54
253154 and 253160 Controls . . . . . . . . . . . . . . 58
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Light Tower Kit (253547) . . . . . . . . . . . . . . . . . . 61
Light Tower Kit Recommended Wire Routing . . 62
Pail Low and Empty Sensor Kit (255233) . . . . . 63
Ethernet Kit (253566) . . . . . . . . . . . . . . . . . . . . 64
EasyKey Modbus / TCP Wiring Diagram . . . . . . 70
Maintenance Call Kit (253548) . . . . . . . . . . . . . 71
Maintenance Call Kit (253548) Wiring . . . . . . . . 72
Discrete I/O Kit (253567) . . . . . . . . . . . . . . . . . . 73
Swirl Kit, Part No. 253263 . . . . . . . . . . . . . . . . . 75
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 78
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 78

Warnings
311976K 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
SPLATTER HAZARD
During blow off of platen splatter may occur.
• Use minimum pail removal air pressure.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regu-
lations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco
replacement parts only.
• Do not alter or modify equipment.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Do not operate when fatigued or under the influence of drugs or alcohol.
• Comply with all applicable safety regulations.

Warnings
4311976K
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
311976K 5

Overview
6311976K
Overview
How the Therm-O-Flow 20 Works
A heated platen melts the sealant or adhesive and
directs the molten material to the pump inlet. The mate-
rial then travels through a heated Check-Mate pump and
heated fluid moves to the application tool.
Model Numbers
The six digit part number stamped on your
Therm-O-Flow 20 defines your machine. Each digit rep-
resents a component, as shown in the following table.
1.
Therm-O-Flow
20 (T)
2. Number of
Heat Zones
(0, 6)
3. Heat
Controls
Supply Voltage
(0, 2, 3, 4)
4. Pump Ratio
(1, 2, 3)
5. Heated
Platen (F, S)
6. Controls
(0, B, S) Part No.
T 6 230 (2) 23:1 (1) Finned (F) Standard (B) T621FB
T 6 230 (2) 23:1 (1) Smooth (S) Standard (B) T621SB
T 6 380 (3) 23:1 (1) Finned (F) Standard (B) T631FB
T 6 380 (3) 23:1 (1) Smooth (S) Standard (B) T631SB
T 6 480 (4) 23:1 (1) Finned (F) Standard (B) T641FB
T 6 480 (4) 23:1 (1) Smooth (S) Standard (B) T641SB
T 6 230 (2) 36:1 (2) Finned (F) Standard (B) T622FB
T 6 230 (2) 36:1 (2) Smooth (S) Standard (B) T622SB
T 6 380 (3) 36:1 (2) Finned (F) Standard (B) T632FB
T 6 380 (3) 36:1 (2) Smooth (S) Standard (B) T632SB
T 6 480 (4) 36:1 (2) Finned (F) Standard (B) T642FB
T 6 480 (4) 36:1 (2) Smooth (S) Standard (B) T642SB
T 6 230 (2) 70:1 (3) Finned (F) Standard (B) T623FB
T 6 230 (2) 70:1 (3) Smooth (S) Standard (B) T623SB
T 6 380 (3) 70:1 (3) Finned (F) Standard (B) T633FB
T 6 380 (3) 70:1 (3) Smooth (S) Standard (B) T633SB
T 6 480 (4) 70:1 (3) Finned (F) Standard (B) T643FB
T 6 480 (4) 70:1 (3) Smooth (S) Standard (B) T643SB

Overview
311976K 7
T 6 230 (2) 23:1 (1) Finned (F) Secondary (S) T621FS
T 6 230 (2) 23:1 (1) Smooth (S) Secondary (S) T621SS
T 6 380 (3) 23:1 (1) Finned (F) Secondary (S) T631FS
T 6 380 (3) 23:1 (1) Smooth (S) Secondary (S) T631SS
T 6 480 (4) 23:1 (1) Finned (F) Secondary (S) T641FS
T 6 480 (4) 23:1 (1) Smooth (S) Secondary (S) T641SS
T 6 230 (2) 36:1 (2) Finned (F) Secondary (S) T622FS
T 6 230 (2) 36:1 (2) Smooth (S) Secondary (S) T622SS
T 6 380 (3) 36:1 (2) Finned (F) Secondary (S) T632FS
T 6 380 (3) 36:1 (2) Smooth (S) Secondary (S) T632SS
T 6 480 (4) 36:1 (2) Finned (F) Secondary (S) T642FS
T 6 480 (4) 36:1 (2) Smooth (S) Secondary (S) T642SS
T 6 230 (2) 70:1 (3) Finned (F) Secondary (S) T623FS
T 6 230 (2) 70:1 (3) Smooth (S) Secondary (S) T623SS
T 6 380 (3) 70:1 (3) Finned (F) Secondary (S) T633FS
T 6 380 (3) 70:1 (3) Smooth (S) Secondary (S) T633SS
T 6 480 (4) 70:1 (3) Finned (F) Secondary (S) T643FS
T 6 480 (4) 70:1 (3) Smooth (S) Secondary (S) T643SS
T 0 0 23:1 (1) Finned (F) No Controls (0) T001F0
T 0 0 23:1 (1) Smooth (S) No Controls (0) T001S0
T 0 0 36:1 (2) Finned (F) No Controls (0) T002F0
T 0 0 36:1 (2) Smooth (S) No Controls (0) T002S0
T 0 0 70:1 (3) Finned (F) No Controls (0) T003F0
T 0 0 70:1 (3) Smooth (S) No Controls (0) T003S0
1.
Therm-O-Flow
20 (T)
2. Number of
Heat Zones
(0, 6)
3. Heat
Controls
Supply Voltage
(0, 2, 3, 4)
4. Pump Ratio
(1, 2, 3)
5. Heated
Platen (F, S)
6. Controls
(0, B, S) Part No.

Overview
8311976K
Component Identification
Before installing the system you should be familiar with
all the Therm-O-Flow system components. See FIG. 1.
Contact your Graco distributor 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 253154 and 253160 Controls on page 58.
Air Line Components
The following components are included with the unit.
See FIG. 1.
• System Bleed-type Master Air Valve (A) is used to
shut off the air supply to the entire system.
• Air Line Filter (B) removes dirt and moisture from
the compressed air supply.
• Air Motor Enable Solenoid/Depressurization Valve
(V) opens to allow air to the Air Motor Air Regulator
(C) and exhausts air from the air motor at shutoff.
The built-in control delays start-up to allow material
to heat thoroughly.
• The Air Motor Remote Piloted Air Regulator (X) reg-
ulates air pressure to the air motor.
• Air Motor Bleed-type Master Air Valve (D) shuts off
the air supply to the air motor and bleeds trapped air
from the air motor.
Pneumatic Control Panel
The Pneumatic Control Panel (M) includes the following.
See FIG. 1.
• Platen Blow-off Valve (S) directs air to the underside
of the platen when depressed.
• Blow-off Air Regulator (T) controls the air pressure
to the platen blow-off valve.
• Air Motor Air Regulator (C) controls the pump outlet
pressure by adjusting the air pressure to the air
motor.
• Ram Up/Down Lever (R) changes the direction of
the ram.
• 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.
EasyKey Display and Keypad
EasyKey is a simple user interface consisting of an LCD
display and keypad (L) which controls Therm-O-Flow 20
operations.
Air and Fluid Hoses
When installing a system make sure that all air and fluid
hoses are properly sized and pressure rated for the sys-
tem.
Fluid Line Accessories (Typical)
A pressure compensator valve controls fluid pressure to
the gun/valve, and dampens pressure surges. Install a
pressure compensator valve in the fluid line, using
adapters as necessary.
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.
The Therm-O-Flow 20 requires Graco single-circuit
material hoses rated at a maximum of 1250 Watts.

Overview
311976K 9
A System Bleed-type Master Air Valve
B Air Line Filter
C Air Motor Air Regulator (bleed-type) and Gauge
D Air Motor Bleed-type Master Air Valve
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 and Gauge
P Ram Down Air Regulator and Gauge
R Ram Up/Down Lever
S Platen Blow-off Pushbutton
T Blow-Off Air Regulator and Gauge
U Electrical Power Input
V Air Motor Enable Solenoid/Depressurization Valve
W NXT Air Motor
X Air Motor Remote Piloted Air Regulator
Y Platen Bleed Stick
Z Pail Blow Off Valve
AA Maintenance Call
AB Ethernet Connection
AC Light Tower Connection
FIG. 1: Component Identification
TI10076A
TI10030A
TI10077A
V
A
B
D
H
X
P
N
R
C
T
S
J
L
W
E
G
Y
Z
M
F
K
U
AB
AA
AC

Overview
10 311976K
Power Requirements
See Table 1, and the Technical Data on page 77.
Heat Control Zone Selection
The Therm-O-Flow 20 has 6 heat zones (see FIG. 2).
• Zones 1 and 2 are always used for the heated
platen and the heated pump.
• Zones 3 and 4, 5 and 6 are each available as paired
zones through 16-pin connectors.
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.
Table 1: Electrical Requirements
AC Panel
Voltag e HZ Pha se
Full Load
Amps
240 50/60 3 36.0
380 50/60 3 17.5
480 50/60 3 18.0
FIG. 2: Heat Control Zone Selection
Platen
Valve 1
Hose 1
Valve 2
ZONE 1
Control
ZONE 2
Control
ZONE 3
Control
ZONE 4
Control
500 Watts
max
1250 Watts
max
500 Watts
max
Pump
1250 Watts
max
ZONE 5
Control
ZONE 6
Control
Hose 2
TI10092A

Installation
311976K 11
Installation
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.
Location Requirements
Refer to the Dimensions drawing on page 76 for ram
mounting and clearance dimensions.
1. Make sure there is sufficient overhead clearance for
the pump and ram when the ram is in the fully raised
position (approximately 82 in. [209 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.
Locate and Install the Ram
1. Apply 50 psi download pressure to ram.
2. Attach a lifting sling at the proper lift spots (see FIG.
3). Lift off the pallet using a crane or a forklift.
3. Position the ram in the desired location.
4. Lock the wheels, or bolt the ram to the floor. To bolt
the ram to the floor, level the base using metal
shims. Bolt the ram to the floor, using anchors that
are long enough to prevent the unit from tipping.
CAUTION
Always lift system at proper lift locations (see FIG. 3).
Do not lift in any other way.
To mount the ram directly to the floor, remove the
four wheels.
FIG. 3: Lift Locations
Lift Locations (if air is supplied to the
system and ram lever is set to down)
TI10078A

Installation
12 311976K
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.
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. Turn all air regulators to their full counterclockwise
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.
8 in.
(20.3 cm)
88

Installation
311976K 13
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.
Connect 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 Power Requirements
on page 10 and Electrical Schematics on page 54.
To connect the control panel to the electrical source:
1. Open electrical control panel door and locate the
main disconnect (K).
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.
3. 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
main disconnect (K).
The Therm-O-Flow 20 requires Graco single-circuit
material hoses rated at a maximum of 1250 Watts.
FIG. 4: Rear View of 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. Before running power to the unit,
make sure the plant electrical service meets the
machine’s electrical requirements. Check the label on
the control panel for the required voltage and amper-
age.
Hose One
Hose Two
Hose Three
(Optional)
TI8136A
For information about specific terminal locations
and connections, see Electrical Schematics on
page 54.
FIG. 5: Electrical Control Panel
Electrical
Control
Panel
TI10026A
K

Installation
14 311976K
Grounding
Ground the supply unit as instructed here and in the
individual component manuals.
•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 pails: Ground according to your local code.
Use only metal pails placed on a grounded surface.
Do not place the pail on a nonconductive surface,
such as paper or cardboard, which interrupts 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.
Check Resistance
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.
Sensor Resistance Checks
The package includes a heat sensor and controller for
each of the six heated zones. To check sensor resis-
tance:
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 Table 2.
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. To reduce the
risk of static sparking, ground the pump, the object
being dispensed to, and all other spraying/dispensing
equipment used or located in the spraying/dispensing
area. Check your local electrical code for detailed
grounding instructions for your area and type of
equipment.
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.
Conduct these electrical checks with the main discon-
nect OFF.
Check resistance at ambient room temperature
(63°– 77°F [17°– 25°C]).

Installation
311976K 15
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 54
for wiring diagram information.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in Table 3.
Overview of the Temperature
Controller Settings
Temperature controls are set in the Zone Setup screens.
See System Run Screen on page 19 for information
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 20 for a list of device types and how to
set them for each zone.
Table 2: RTD Sensor Resistance
Zone Component Terminals Range (ohms)
1 Platen 2011 & 2021 108 +/- 2%
2 Fluid Pump 2051 & 2061 108 +/- 2%
3 Dispense Hose 1 2081 & 2091 108 +/- 2%
4 Dispense Gun 1 2111 & 2121 108 +/- 2%
5 Dispense Hose 2 2261 & 2271 108 +/- 2%
6 Dispense Gun 2 2291 & 2301 108 +/- 2%
Conduct these electrical checks with the main power
disconnect OFF.
Check resistance at ambient room temperature
(63°– 77°F [17°– 25°C]).
Table 3: Resistance Chart of All Heaters
Zone Component
Between
Terminals
Unit
Voltag e
Range
(ohms)
1 Platen F/A, D/C 240 29 +3/-5
E/A 380 115 +12/-17
E/B, B/C 57.6 +6/-9
E/A 480 115 +12/-17
E/B, B/C 57.6 +6/-9
2 Pump T1/T3,
T2/T3,
B1/B3,
B2/B3
240 48 +5/-5
T1/T3,
T2/T3,
B1/B3,
B2/B3,
T3/B3
380 192 +19/-19
T1/T3,
T2/T3,
B1/B3,
B2/B3,
T3/B3
480 192 +19/-19

Installation
16 311976K
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 at ambient temperature.
3. Select a pail 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
pail are properly grounded. Refer to Grounding on
page 14.
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. Heat
soak must = 0 or you will need to wait for the preset
time to elapse (default is 45 minutes).
6. Purge the material through the system for approxi-
mately 1 to 2 minutes.
7. Remove the pail 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.

Operator Controls
311976K 17
Operator Controls
Main Power Disconnect
Turns system power on or off. Includes system circuit
breaker. See FIG. 6.
EasyKey Display and Keypad
EasyKey is a simple user interface consisting of an LCD
display (A) and keypad (B). See FIG. 7.
Use to input numerical data, enter Setup screens, scroll
through screens, and select setup values. See page 17
for additional keypad/screen navigation information. The
EasyKey includes numbered keys to enter values in
setup and the function keys listed in Table 4.
FIG. 6: Main Power Disconnect
In a Tandem System, the secondary unloader pro-
vides 24VDC power to the EasyKey display. This
allows the primary unloader to be powered down
for maintenance without interrupting production. All
accessories (light tower, swirl, etc.) and the display
board on the primary system will have power when
the secondary unloader is powered on and the pri-
mary unloader is powered off.
POWER
OFF
POWER
ON
TI8138A
TI8139A
FIG. 7: EasyKey Display and Keypad
A
B
TI8140A
Table 4: Key Descriptions
Key Function
Setup: press to enter or exit Setup mode.
Enter: if cursor is in drop-down list box, press Enter key to view drop-down list. Press Enter to save a
value either keyed in from the numerical keypad or selected from a drop-down list.
Up Arrow: move to previous field or drop-down list item.
Down Arrow: move to next field, or drop-down list item.
Continued on page 18.

Operator Controls
18 311976K
LCD Display
The two Run screens show graphical and text informa-
tion related to setup and spray operations.
A screen saver option is available in the Advanced
Setup screen 4 (see Table 7, page 24).
AAnimation: when there is flow the air motor piston
and pump displacement rod move and the gun
appears to spray.
BTotal Job Volume: recorded in units selected in
Table 7, see page 24. Press twice to reset Total
Job Volume to zero.
CCurrent Flow Rate: flow rate displayed in units
selected in Adv tab of setup. See Table 7 on page
24.
DZone Number and Icon: shows which zone data is
currently being displayed. Icon indicates component
for that zone.
ETemperature Readout: shows current temperature
of each zone, in temperature units selected in Table
7, see page 24.
FStatus Bar: shows current operation mode or
alarm.
G Current Date and Time
HSecurity Level: a padlock appears on the screen if
a password is required to enter Setup mode. If the
password was set to 0, no padlock appears and
setup can be entered without a password.
Alarm
Alerts the user to an alarm condition. Press to clear
the alarm.
Left Arrow: move to previous screen.
Right Arrow: move to next screen.
System On/Off: on starts system. Activates , , , and keys.
Heat State Toggle: starts heaters in all zones where they are enabled. Cycles through heat states
(Heat Off, Heat On/Heat Soak/Run, Setback).
Clear: clears alarms and warnings.
Pump Ready: allows pump to cycle after a DRUM EMPTY condition is removed or a MOTOR ERROR
is cleared.
Pump Crossover: transitions the active system to the inactive unloader.
Table 4: Key Descriptions
You must be in system off mode to enter Setup
.

EasyKey Display Screens
311976K 19
EasyKey Display Screens
Power Up Screens
When the EasyKey power switch is turned on the Graco
Logo screen and the phrase “Establishing Communica-
tion” displays for several seconds before the System
Run screen appears.
If the EasyKey cannot communicate with any board dur-
ing the power on phase, the phrase “Communication
Error” displays on the Graco Logo screen. Once com-
munications are established the System Run screen
appears. See FIG. 8.
Run screens and Setup screens are the two main
screen types that provide information and system con-
trol.
Run Screens
System Run Screen
The System Run screen displays and cycles through the
operating status of each enabled zone in sequence. See
FIG. 8.
From the System Run screen, press the Left Arrow
or Right Arrow key to move to the Zone Run
screens.
Zone Run Screen
The Zone Run screen displays a summary of all 6 zones
in the system. See FIG. 9.
Tandem systems contain two 6 Zone Run screens (A
and B). See FIG. 9 and FIG. 10. Expansion systems con-
tain one 6 Zone Run screen (A) and one 4 Zone Run
screen (B). See FIG. 9 and FIG. 10.
From the Zone Run screen, press the Left Arrow or
Right Arrow key to move to the System Run
screen.
FIG. 8: System Run Screen
Temperature setpoints are adjustable on this
screen if Setpoint Adjust is turned on. See
Advanced Screens, page 23. Setpoints will be
highlighted in a box. Use the Up Arrow or Down
Arrow keys to move among the setpoints.
FIG. 9: Zone A Run Screen
FIG. 10: Zone B Run Screen

EasyKey Display Screens
20 311976K
Setup Mode
Entering Setup
Press to enter or exit Setup. You must be in system
off state to enter Setup.
Password Screen
If a password was enabled you must enter the password
before entering Setup mode. See Table 7, page 24.
Entering the wrong password returns you to the Run
screens.
Setup Screen Menu
The Setup screens contain tabs across the bottom of
the screen for the Zone, Timer, Report, and Advanced
screens. The current screen is highlighted. See FIG. 11
and FIG. 12.
Zone Setup Screens
Zone Setup has 2 screens. The screen number appears
on the right side of the screen. See FIG. 11 and FIG. 12.
See Table 5 on page 21 for settings.
If a password is enabled, “Setup Locked” displays
momentarily after exiting Setup mode and returning
to the Run screens.
FIG. 11: Setup Screen 1
Press the Enter key to show drop-down lists
and to enter your selection.
FIG. 12: Setup Screen 2