Graco Therm-O-Flow 200 Instructions-Parts List Manual Download Page 37

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Troubleshooting

Troubleshooting

Light

Light Tower

Tower

Tower (Optional)

(Optional)

Signal

Description

Red Light Off

If green light is also off, system power may be off or system operating mode is Inactive. If
green is on or flashing, there are no active errors.

Red Light On

User interaction required — alarm, system is shut down

Red Light
Flashing

User interaction required — advisory, deviation, or system is in a state that could prohibit
dispensing.

Green Light Off System is inactive

Green Light On System is ready to dispense. The heat and pump are on.

Green Light
Flashing

System will be ready to dispense in time without user interaction (heat on, pump off, and
temperature control zones have not reached set point)

334130D

Summary of Contents for Therm-O-Flow 200

Page 1: ...use use only only only Not Not Not approved approved approved for for for use use use in in in European European European explosive explosive explosive atmosphere atmosphere atmosphere locations loca...

Page 2: ...ace Wipers 45 Replace Platen RTD 45 Separate the Air Motor and Pump 46 Remove Platen 49 Replace Heater Bands and Pump RTD 49 Replace MZLP Fuse 50 Replace MZLP 51 Replace MZLP Daughter Card 52 Replace...

Page 3: ...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 Pressurized equipment can start without warnin...

Page 4: ...ef Procedure Procedure Procedure when you stop dispensing and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings dai...

Page 5: ...y 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 cre...

Page 6: ...condary 25P 8 Zones 600 V Primary 25S 8 Zones 600 V Secondary 31P 12 Zones 230 V Primary 31S 12 Zones 230 V Secondary 32P 12 Zones 400 V N Primary 32S 12 Zones 400 V N Secondary 33P 12 Zones 400 V Pri...

Page 7: ...l Manual 334127 Check Mate 800 Pump Repair Parts 334128 Check Mate 800 Throat Seal Repair Kit Repair Parts Ram Ram Ram Manual Manual Manual 334198 Therm O Flow 200 Pneumatic and Hydraulic Ram Instruct...

Page 8: ...ower Temperature Control Module MZLP C Light Tower D Cable Track E Ram F Heated Pump G Heated Platen H Integrated Air Controls 3 4 in npt inlet J Electrical Control Panel Key Key Key K Main Power Swit...

Page 9: ...Blowoff Blowoff Button Button Button Turns air on and off to push the platen out of an empty drum Key Key Key CH CH CH Blowoff Blowoff Blowoff Pressure Pressure Pressure Gauge Gauge Gauge Displays the...

Page 10: ...ey Key Key DA Multi Zone Low Power Temperature Control Module MZLP DB Ventilation Grill DC Electrical Control Panel DD Automatic Wiring Board AWB DE Power Supply 24V DF Residual Current Device GFI 63A...

Page 11: ...page 104 NOTICE NOTICE NOTICE To prevent damage to the softkey buttons do not press buttons with sharp objects such as pens plastic cards or fingernails Figure 4 Front View Key Key Key Function Functi...

Page 12: ...tion Description Green Solid Run Mode System On Green Flashing Setup Mode System On System System System Status Status Status Yellow Solid Run Mode System Off Green Flashing Data recording in progress...

Page 13: ...s off Warm Up The system is heating the material to the setpoint temperature Flashing green system status indicator LED on the ADM Heat is increasing to setpoint temperature Pump is off Heat Soak Heat...

Page 14: ...Make sure all air and fluid hoses are properly sized for the system Heat Heat Heat Control Control Control Zone Zone Zone The Therm O Flow has 4 8 or 12 heat zones Zones for the heated drum platen an...

Page 15: ...ible with room to stand directly in front of the pneumatic control panel and the electrical control panel 4 When locating the system do not install closer than 36 in 914 mm to vertical surfaces 5 Make...

Page 16: ...ne from an air source to the system air inlet H capable of delivering a minimum of 25 50 cfm at 100 psi 0 7 MPa 7 0 bar Do Do Do not not not use use use quick quick quick disconnects disconnects disco...

Page 17: ...e insulation using fiberglass tape 3 Connect large heated hose connector to MZLP 4 Repeat for any remaining channels 5 For proper operation cables must be plugged into zones 1 2 and 3 4 at all times 6...

Page 18: ...al enclosure For additional cables heated hose and fluid control devices see Accessories and Kits page 88 Connect fluid control devices to a heated hose or the electrical enclosure Use accessories if...

Page 19: ...EM 100 3 AWG EF ES 90 3 AWG 400 V N 50 60 3 EM 100 3 AWG EF ES 45 8AWG 400 V 50 60 3 EM 50 8AWG EF ES 45 8AWG 480 V 50 60 3 EM 50 8AWG 3 EF ES 50 8AWG 600 V 50 60 3 EM 50 8AWG EF Standard Finned Botto...

Page 20: ...low 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 interrupts the grounding continuity To To To maintain...

Page 21: ...econd Heat Zone C D First RTD G K Second RTD M K Earth Ground B G F E D C B A K L M J H ti24580a 3 Replace any parts whose resistance readings do not comply with the ranges listed in the RTD Sensors c...

Page 22: ...en Terminals Terminals Terminals For For For Unit Unit Unit Voltage Voltage Voltage Platen Platen Platen Model Model Model Code Code Code Resistance Resistance Resistance Values Values Values ohms ohm...

Page 23: ...system setpoint and setback temperatures for the pump platen and heat zones on the Heat A screens Note Setback temperatures must be at least 20 F 10 C lower than the setpoint temperatures Note To ens...

Page 24: ...d of grams or pounds 9 To setup the optional Schedule function see Schedule page 35 The schedule function allows the system to automatically enable and disable heating and setback at specified times 1...

Page 25: ...See Run State Chart 3 Error State Bit Low See Error State Chart 4 Error State Bit High See Error State Chart Table Table Table 7 7 7 Output Output Output Error Error Error States States States Error E...

Page 26: ...al Signal Signal Pin Pin Pin 1 1 2 2 3 4 3 5 6 4 7 8 H2 H2 H2 Customer Customer Customer Output Output Output Signal Signal Signal Pin Pin Pin 1 1 2 2 3 4 3 5 6 4 7 8 Inputs Inputs Inputs High 10 30 V...

Page 27: ...Diagrams The following block diagrams show how to connect customer inputs and outputs to the MZLP For convenience each system ships with connector kit 24P176 If a connector is lost or damaged order k...

Page 28: ...tible with the equipment wetted parts See Technical Specifications in all of the equipment manuals 1 Select the material for the initial material load 2 Verify whether the factory test oil and the ini...

Page 29: ...ram director valve CC to UP and slowly turn the ram up regulator CD clockwise until the platen G begins to rise Figure 17 Raise the Platen 3 Apply a thin coating of high temperature grease lubricant p...

Page 30: ...e dispense valve open over a waste container while the system is heating up and also when cooling down This will prevent a pressure build up caused by fluids or gases expanding from the heat Note Oper...

Page 31: ...lenoid valve CN is on The indicator light on the solenoid connector will only be on if Enable Pump Autostart is selected on the System 1 Setup screen 4 Adjust the air motor slider valve CM to the open...

Page 32: ...ver adjust the regulator by more than 5 psi 34 kPa 0 3 bar increments Make sure the pump begins to cycle and heated material flows from the bleed stem Z after several cycles of the pump 9 Prime the pu...

Page 33: ...rum was placed on the frame the pump will cycle until all air has been removed 7 Close the main air slider valve CA and release trigger lock 8 Engage trigger lock Figure 22 Trigger Lock Engaged 9 Pres...

Page 34: ...structions 1 Engage the trigger lock Figure 23 Engaged 2 Close the system master air slider valve CA 3 Set the ram director valve CC to the neutral position 4 Disengage the trigger lock Figure 24 Dise...

Page 35: ...ule Schedule Schedule Times Times Times Times are set using a 24 hour clock Several on and off times can be set each day 1 On the Schedule screen in the Setup screens set the ON times for each day of...

Page 36: ...the ram make sure the drum clamp stays clear of the platen assembly Do Do Do not not not use use use a a a drum drum drum of of of material material material that that that has has has been been been...

Page 37: ...n or flashing there are no active errors Red Light On User interaction required alarm system is shut down Red Light Flashing User interaction required advisory deviation or system is in a state that c...

Page 38: ...tive on The star character indicates the code applies to multiple system components Third Third Third or or or Last Last Last Digit Digit Digit Codes Codes Codes Relates Relates Relates To To To A Uni...

Page 39: ...erify fan is plugged in Replace if necessary AM3 High Current SSR MZLP _ Alarm Excessive current flow in the SSR Check for shorts in harness to SSR Check polarity of wiring to SSR Replace if necessary...

Page 40: ...otor Replace if necessary Adjust the drum empty level sensor to detect an empty state Ensure the ram director valve is in the down position and sufficient air is forcing the ram down Pump is trying to...

Page 41: ...ture reading has risen too high Verify setpoint upstream is not hotter than this zone s setpoint Check RTD wiring and harness connector integrity T6 _ Sensor Err Unit _ Zone _ Alarm Bad RTD Reading Re...

Page 42: ...is less than 100 VAC Verify the MZLP is plugged in at J2 and the AWB is plugged in at J5 and J6 Check incoming voltage is correct for configuration V4M AWB High Line Voltage Alarm Incoming voltage is...

Page 43: ...en wipers Worn or damaged wipers Replace wipers Closed main air valve or clogged air line Open air valve clear air line Not enough air pressure Increase air pressure Worn or damaged ram piston Replace...

Page 44: ...o air motor is off Check gauges and valves to the air motor Leak around pump wet cup Worn throat seals Replace throat seals See Servicing the Throat packings in manual 334127 or 334128 Air Air Air Mot...

Page 45: ...Electrical Schematics page 58 for wiring connections 1 If the material drum has already been removed from the supply unit go to step 2 If you need to remove the material drum see Change Drums page 36...

Page 46: ...ump Pump Pump This procedure must be done with the unit still warm The material and equipment will be hot 1 If the material drum has already been removed from the supply unit go to step 2 If you need...

Page 47: ...rom platen lift rods 15 Remove nuts F from pump air motor stand off rods at the pump end 16 Remove nuts Z and bolts holding cable tract to air motor support plate 17 Slide end of cable track outboard...

Page 48: ...Repair Figure 28 48 334130D...

Page 49: ...te is down and the ram hand valve is in the neutral position 3 Follow Pressure Relief Procedure page 34 4 Bleed off excess material and pressure in the system by opening the applicator and catching th...

Page 50: ...5 J7 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 Figure 30 Fuse Locations Fuse Fuse Fuse Kit Kit Kit Fuse Fuse Fuse Part Part Part F1 F2 250VAC 25A long white ceramic 24V289 F3 F10 250VAC 8A fast acting clear glas...

Page 51: ...mble MZLP Set MZLP rotary switch based on location See MZLP MZLP MZLP Rotary Rotary Rotary Switch Switch Switch Table Table Table 7 Use four screws 115 to install MZLP 111 or 112 to electrical enclosu...

Page 52: ...t aside 4 Unplug daughter card 112a from the MZLP 1 112 Figure 32 MZLP Daughter Card 5 Plug new daughter card 112a into the MZLP 112 6 Use screws 112b to secure daughter card to MZLP 112 7 Connect cab...

Page 53: ...and verify the connector orientation Note See Electrical Schematics page 58 if unable to determine the connector location Replace Replace Replace Power Power Power Supply Supply Supply 1 Turn the main...

Page 54: ...ar fan grill 138 and fan 136 7 Mount new fan 136 rear fan grill 138 and nuts 139 on grill 137 with the arrow pointing toward the grill 137 8 Tie down fan wires onto tie down locations on grill 137 usi...

Page 55: ...from fan into pin 4 and the black wire into pin 3 of J7 connector 12 Install transformer 235 ground wire onto ground lug of back panel 201 13 Connect transformer output power harness 234 to power ter...

Page 56: ...Repair Figure 34 Inside of Electrical Control Enclosure 56 334130D...

Page 57: ...software is updating to indicate progress To prevent corrupting the software load do not remove token until the status screen disappears Note When the screen turns on you will see the following screen...

Page 58: ...Remove token T 8 Replace token access panel 9 Press to continue to the operation screens Electrical Electrical Electrical Schematics Schematics Schematics 230V 230V 230V 3 3 3 Phase 60 Phase 60 Phase...

Page 59: ...Electrical Schematics 400V 400V 400V 3 3 3 Phase 50 Phase 50 Phase 50 Hz Hz Hz 334130D 59...

Page 60: ...Electrical Schematics 400 600VV 400 600VV 400 600VV 3 3 3 Phase 60 Phase 60 Phase 60 Hz Hz Hz 60 334130D...

Page 61: ...Electrical Schematics AWB AWB AWB and and and MZLP 1 MZLP 1 MZLP 1 334130D 61...

Page 62: ...Electrical Schematics MZLP MZLP MZLP 2 2 2 MZLP 3 MZLP 3 MZLP 3 Overtemp Overtemp Overtemp and and and Pump Pump Pump Heaters Heaters Heaters 62 334130D...

Page 63: ...Electrical Schematics MZLP MZLP MZLP Zones Zones Zones 334130D 63...

Page 64: ...Parts Parts Parts Parts Therm Therm Therm O O O Flow Flow Flow 200 200 200 Supply Supply Supply Unit Unit Unit 64 334130D...

Page 65: ...12 234966 KIT hose hanger 1 13 24V745 SENSOR level low empty 1 14 15H543 BRACKET mounting 1 Ref Ref Ref Part Part Part Description Description Description Qty Qty Qty 15 120186 BOLT mounting u bolt 2...

Page 66: ...rical Electrical Electrical Enclosure Enclosure Enclosure Ref Ref Ref Part Part Part Description Description Description Qty Qty Qty 51 24W870 KIT CONTROL air 3 regulator see manual 334201 1 52 121235...

Page 67: ...Parts Electrical Electrical Electrical Module Module Module 334130D 67...

Page 68: ...Parts 68 334130D...

Page 69: ...543 HARNESS power mzlp1 awb 1 123 17A544 HARNESS power mzlp2 awb 8 zone assemblies only 1 17A545 HARNESS power mzlp2 3 awb 12 zone assemblies only 1 Ref Ref Ref Part Part Part Description Description...

Page 70: ...CONNECTOR jumper 8 zone assemblies only Qty 1 12 zone assemblies only Qty 2 163 CONTACT socket 20 24 awg crimp tin 3 164 TUBE 1 16 shrink tube 0 13 Ref Ref Ref Part Part Part Description Description...

Page 71: ...400V N 400V N Transformer Transformer Transformer Transformer Transformer Transformer Panel Panel Panel Shown Shown Shown 1 Torque terminals to 25 27 in lbs 2 8 3 1 N m 2 Torque terminals to 13 3 16 i...

Page 72: ...30V Panel Panel Panel 400V N 400V N 400V N Panel Panel Panel 1 Torque terminals to 25 27 in lbs 2 8 3 1 N m 2 Torque terminals to 13 3 16 in lbs 1 5 1 8 N m 3 Torque terminals to 4 53 6 2 in lbs 0 5 0...

Page 73: ...227 HARNESS contactor ssr 1 228 HARNESS rcd ssr fan 1 229 See Code C Table 3 6690 24 164 FUSE fuse block buss jt60030 3 127744 CIRCUIT breaker 3p 32a ul489 230V Panel only 1 230 127745 CIRCUIT breaker...

Page 74: ...clamp 321 RTD sensor 320 must be fully contained within the sensor mount 322 5 After fastening band clamp 321 secure excess with fiberglass tape 6 Coat inside of heater 309a 309b only to within 0 75...

Page 75: ...REW cap sch 3 312 17A637 BLOCK standoff mounting 3 315 102656 MUFFLER 1 316 186925 NUT coupling 1 317 184129 COLLAR coupling 2 318 120186 BOLT mounting u bolt 2 Ref Ref Ref Part Part Part Description...

Page 76: ...band clamp 321 RTD sensor 20 must be fully contained within the sensor mount 322 5 After fastening band clamp 321 secure excess with fiberglass tape 6 Coat inside of heater 309 only to within 0 75 in...

Page 77: ...211 SCREW cap sch 3 312 17A637 BLOCK standoff mounting 3 315 102656 MUFFLER 1 316 186925 NUT coupling 1 317 184129 COLLAR coupling 2 Ref Ref Ref Part Part Part Description Description Description Qty...

Page 78: ...licone heat sink compound Do not coat sensor 4 Prior to tightening band clamp 412 RTD sensor 410 must be fully contained within the sensor mount 411 5 After fastening band clamp 412 secure excess with...

Page 79: ...SENSOR RTD 1 411 C03507 SUPPORT sensor 1 412 C31012 CLAMP 1 413 186925 NUT coupling 1 414 184129 COLLAR coupling 2 415 C38163 WASHER lock ext tooth 1 Ref Ref Ref Part Part Part Description Descriptio...

Page 80: ...OVER pump top front 1 505 24W978 COVER pump top back 506 FASTENER thread cutting screw 12 Ref Ref Ref Part Part Part Description Description Description Qty Qty Qty 507 184090 LABEL warning 2 508 1040...

Page 81: ...tion option M M M 24V634 24V634 24V634 Heated Heated Heated Drum Drum Drum Platen Platen Platen Standard Standard Standard Grid Code Grid Code Grid Code E E E option option option F F F 24V635 24V635...

Page 82: ...w off 1 611 100361 PLUG pipe 4 612 100133 WASHER lock 6 613 C19846 SCREW cap socket HD 6 614 150707 PLATE designation 1 PLATE designation 24V633 only 1 615 100508 SCREW drive 2 616 CONDUCTOR 14 2 ft 4...

Page 83: ...s Patterns Patterns 24V633 24V633 24V633 24V634 24V634 24V634 24V635 24V635 24V635 16 5 Ohms across pairs 19 25 Ohms across pairs Platen Platen Platen Coil Coil Coil Wiring Wiring Wiring 24V633 24V633...

Page 84: ...Part Part Part Description Description Description Qty Qty Qty 701 C32424 BOLT U 7 in 177 8 mm 2 702 160111 CLAMP barrel 1 703 100103 PIN cotter 2 704 100307 NUT hex 4 Ref Ref Ref Part Part Part Descr...

Page 85: ...ription Qty Qty Qty 702 100101 SCREW cap hex hd 8 703 918421 CLAMP back half assembly 1 704 918423 KIT repair 1 705 617395 PIN quick release 2 756 100133 WASHER lock 8 Ref Ref Ref Part Part Part Descr...

Page 86: ...OPTION H H H 2 2 2 Ref Ref Ref Part Part Part Description Description Description Qty Qty Qty 6 C32424 BOLT U 7 in 177 8 mm 4 801 C32271 CLAMSHELL 1 802 C19126 SCREW cap hex hd 8 803 100133 WASHER loc...

Page 87: ...cription Description Description Qty Qty Qty 851 VENT hood 1 852 112166 SCREW cap sch 4 Ref Ref Ref Part Part Part Description Description Description Qty Qty Qty 853 100016 WASHER lock 4 855 C14038 L...

Page 88: ...240V Flow Flow Flow Control Control Control and and and Manifolds Manifolds Manifolds Part Part Part No No No Description Description Description 243700 Heated Air Operated Mastic Pressure Regulator 2...

Page 89: ...ne None 115878 115882 115887 None 25 ft 7 6 m None None 115879 115883 115888 None 30 ft 9 m None None 121200 None None None Pump Pump Pump Fittings Fittings Fittings TOF 20 200 PUMP 1 11 1 2 DUAL OUTL...

Page 90: ...3135 120266 123135 123854 15D936 Compact Heated Regulator 289208 Inlet Outlet 3 8 in NPTF 16V432 100896 121311 116765 116766 116766 120267 116766 120267 120268 Mastic Regulator 243700 Inlet Outlet 3 4...

Page 91: ...Part Part Description Description Description Qty Qty Qty 1 MODULE GCA MZLP 1 2 125856 SCREW 8 32 serrated flange 4 3 16T440 CAP souriau UTS14 2 4 127511 CABLE board samtec 1 Ref Ref Ref Part Part Par...

Page 92: ...MZLP 1 will be referred to as MZLP 2 and the original MZLP that came with the system will be referred to as MZLP 1 5 Open the electrical enclosure door Note Do not force the electrical connection Mini...

Page 93: ...Part Part Description Description Description Qty Qty Qty 1 MODULE GCA MZLP 1 2 125856 SCREW 8 32 serrated flange 4 3 16T440 CAP souriau UTS14 2 4 127511 CABLE board samtec 1 Ref Ref Ref Part Part Pa...

Page 94: ...Accessories and Kits 94 334130D...

Page 95: ...ferred to as MZLP 3 and the other two that came with the system will be referred to as MZLP 1 and MZLP 2 5 Open the electrical enclosure door Note Do not force the electrical connection Minimal force...

Page 96: ...Screen Screen Screen Navigation Navigation Navigation To switch between the Setup and Operation screens press Use the keypad to navigate between screens Enable Enable Enable Disable Disable Disable He...

Page 97: ...ssure Regulator Other Advisory See Error Codes for more information Deviation See Error Codes for more information Alarm See Error Codes for more information Softkey Softkey Softkey Icons Icons Icons...

Page 98: ...e of alarm range Color Color Color A A A and and and B B B Zone Zone Zone Status Status Status Yellow Outside of advisory range Green Yellow Flashing Warmup Events Events Events The Events screens sto...

Page 99: ...wn DO DO DO System Digital Outputs 0 Pump Solenoid 1 Not Used 2 Not Used 3 Not Used ISO ISO ISO DI DI DI Customer Digital Inputs See Connect PLC page 25 ISO ISO ISO DO DO DO Customer Digital Outputs S...

Page 100: ...ens Heat Heat Heat Soak Soak Soak Time for to preheat after all zones have reached their target temperatures Pump cannot turn on until timer is complete The heat soak is a user defined time Range 0 12...

Page 101: ...or pounds Advanced Advanced Advanced 3 3 3 Disable Disable Disable USB USB USB Downloads Uploads Downloads Uploads Downloads Uploads Disables use of the USB for downloading and uploading Disable Disa...

Page 102: ...ten and zones Select which system needs to use the heated accessory Zone Zone Zone Types Types Types Hose Gun PGM Flowmeter Pressure Regulator Manifold Other Note To ensure accurate hose and gun tempe...

Page 103: ...both the number of cycles since the last reset Interval is the set number of cycles between maintenance notifications Lifetime is the number of cycles in the lifetime of the system Note The lifetime c...

Page 104: ...on the stick drive For example E GRACO 12345678 DOWNLOAD The 8 digit numeric folder name matches the 8 digit ADM serial number which is located on the back of the ADM When downloading from multiple A...

Page 105: ...ll the system will overwrite the oldest data Change Change Change Log Log Log The change log 3 CHANGE CSV tracks the changes to setpoint and setback temperatures GCA GCA GCA Log Log Log This log 4 GCA...

Page 106: ...s The custom language file is a tab delimited text file that contains two columns The first column consists of a list of strings in the language selected at the time of download The second column can...

Page 107: ...B in in in mm mm mm C C C in in in mm mm mm D D D in in in mm mm mm E E E in in in mm mm mm F F F in in in mm mm mm G G G in in in mm mm mm J J J in in in mm mm mm 59 1498 6 40 1016 37 939 21 533 25 6...

Page 108: ...on PTFE Maximum Maximum Maximum Fluid Fluid Fluid Working Working Working Pressure Pressure Pressure Merkur 6 0 in 2300 psi 15 9 MPa 159 bar Merkur 7 5 in 3000 psi 20 7 MPa 207 bar NXT 6500 3000 psi 2...

Page 109: ...ARRANTY WARRANTY WARRANTY AND AND AND DISCLAIMS DISCLAIMS DISCLAIMS ALL ALL ALL IMPLIED IMPLIED IMPLIED WARRANTIES WARRANTIES WARRANTIES OF OF OF MERCHANTABILITY MERCHANTABILITY MERCHANTABILITY AND AN...

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Summary of Contents for Therm-O-Flow 200

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Summary of Contents for Therm-O-Flow 200

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