Graco Therm-O-Flow Plus Instructions Manual Download Page 45

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309085

Dual Ram Cross-Over Control Function

Fig. 13

TI0676

Only one Pendant

mounted to either

Unloader

243254 Auto Cross-Over Assembly (2)

includes J–Box, light assy, and

machine cables

Mount to Ram Piston Rod

C58011 Roller (2)

C58009

Bracket

(1)

241402 Switches (2)

To low switch

116157

To empty switch

To air motor solenoid (C07458)

To control box AP (116155)

To control box LS (116156)

To other unit (116159)

To control box communication port PN (195756)

Summary of Contents for Therm-O-Flow Plus

Page 1: ...Maximum Air Inlet Pressure 100 psi 0 7 MPa 7 bar Bulldog Powered Unloaders Models A 3 and A 4 Maximum Fluid Working Pressure 3100 psi 21 MPa 213 bar Maximum Air Inlet Pressure 100 psi 0 7 MPa 7 bar K...

Page 2: ...42 Dual Ram Cross Over Control Function 44 X Over Overview 44 Setup of X Over 46 Dedicate Zones 47 Starting Stopping X Over Operations 48 X Over Factory Setup 50 Communication Errors 51 Ram Troublesho...

Page 3: ...imum inbound air pressure to the ram Never exceed the recommended working pressure or the maximum air inlet pressure stated on your pump or in the Technical Data on page 81 Be sure that all spray disp...

Page 4: ...r amputation Splashing fluid in the eyes or on the skin can also cause serious injury Fluid injected into the skin might look like just a cut but it is a serious injury Get immediate medical attention...

Page 5: ...quipment is installed and operated in compliance with applicable codes Make sure power is disconnected when servicing and repairing equipment Have any checks installation or service to electrical equi...

Page 6: ...zardous fluid according to all local state and national guidelines Always wear protective eyewear gloves clothing and respirator as recommended by the fluid and solvent manufacturer Avoid exposure to...

Page 7: ...Platen 2 MegaFlo High Flow Heated Drum Platen 3 Smooth Bottom No Fin Heated Drum Platen N None Code C Drum Ram Style 1 6 5 Cylinder Dual Post Pneumatic 100 psi Drum Ram with Controls 2 6 5 Cylinder D...

Page 8: ...ssurization Valve 109Pump Assembly 115 Pump Mounting Bracket 202Air Line Filter 203Air Line Lubricator 204Pump Air Regulator 211 4 way Ram Valve Ram Up Ram Down 214Pump Bleed Type Master Air Valve req...

Page 9: ...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 and safe access to an ap...

Page 10: ...able All heated valves manifolds and heaters are equipped with an 8 pin matching connector Accessory cables are available for other possible combinations TI0536 Fig 3 NOTE Zone seven can be used for h...

Page 11: ...regulators to control the ram pressure in the up and down direc tions Ram Air Supply Hose connects the ram air regula tor to the air manifold Ram Plate Blow off Valve controls the air pressure to the...

Page 12: ...and ram are fully accessible 2 Level the base of the ram using metal shims 3 Using the holes in the base as a guide drill holes for 13 mm 1 2 anchors Bolt the ram to the floor with anchors which are l...

Page 13: ...ing ground the pump 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 inst...

Page 14: ...e warranty will be voided Check the label on the con trol box for the proper voltage AC Panel Voltage Hz Phase Platen Selection Full Load Amps 220 240 50 60 3 B 1 B 3 70 B 2 80 380 400 50 60 3 B 1 B 3...

Page 15: ...the control panel You can check the resistance of the supply unit s heat sensors and heaters Sensor Resistance Checks WARNING ELECTROCUTION HAZARD To reduce risk of injury or damage to equipment condu...

Page 16: ...Unit Voltage Platen Model Code Resistance Values ohms 1 Ram Plate 3L1 3L2 240 B 1 or B 3 6 4 ohms 65 ohms Heaters from J Box or B 2 5 5 ohms 55 ohms J Box or Control Box Not 240 B 1 or B 3 25 5 ohms...

Page 17: ...tings are preset at the factory Use the table for reference information only Table 2 Graco Factory P I and d Settings Category P I d Unit Voltage Ram Plate 41 118 29 ALL Pump 50 1186 296 ALL Hose 9 9...

Page 18: ...orm the remaining steps in this procedure to flush the system at ambient temperature WARNING Use fluids and solvents that are chemically compat ible with the equipment wetted parts See the Technical D...

Page 19: ...the rod actuator on the ram cylinder rod and adjust so the switch actuates the RED beacon at the desired level within the drum Also when the RED beacon is illuminated indicating a LOW or EMPTY drum te...

Page 20: ...of the proximity switch to the bottom of the air motor housing is 2 63 in Refer to Fig 7 Mount the collar over the existing connecting rod nut by breaking loose the connection running the air motor to...

Page 21: ...R184 Selection E3 Control Box Wiring of Timer Relay 1 Remove the terminal jumper between 1251 and 1252 2 Snap the timer assembly to the din rail in the control box as shown 3 Connect the wires supplie...

Page 22: ...22 309085 Notes...

Page 23: ...cur in the system due to material expansion To relieve pressure in the supply unit perform the following procedure 1 Lock the gun valve trigger safety 2 Shut off the main air supply to the pump 3 Clos...

Page 24: ...sure always follow the Pressure Relief Procedure page 23 4 Relieve the supply unit pressure NOTE The auto depressurization circuit relieves air pressure from the supply unit when power is turned off 5...

Page 25: ...he temperature of any of the heated components is out of range and the power to all heated components is interrupted For more information see Temperature Out of Range on page 26 OFF None of the heated...

Page 26: ...ADY light also indicates that the air solenoid is allowed to operate Resetting the Supply Unit After the Inactivity T imer Worklife Timer Has Been Triggered Your system may have an inactivity timer If...

Page 27: ...pment perform this procedure with the main disconnect OFF To reset the ground fault interrupt have a qualified electrician 1 Turn OFF the electrical disconnect on the electrical control panel 2 Open t...

Page 28: ...28 309085 Advanced Pendant Control Screen Map TI0683 See Next Page...

Page 29: ...29 309085 Advanced Pendant Control Screen Map TI0683 F5 F4 OP 1 OP 3 OP 4 See Previous Page LOADS DEFAULT SETTINGS FOR F LOADS DEFAULT SETTINGS FOR C...

Page 30: ...30 309085 Notes...

Page 31: ...rating efficiency Easy to use functions are provided to quickly change the SV tem perature settings of each controller without the need to manually access each temperature control Three recipes are av...

Page 32: ...ccesses the TIMER screens In these screens the 7 Day Timer can be turned on and off The F3 MAN selection accesses the MANUAL opera tion screen Here any SV can be can be sent to any zone controller as...

Page 33: ...tory If for some reason communication errors exist with the pendant to the temperature con troller zones reference manual 309100 section Check Communication Parameters Zone 1 is address 1 zone 2 is ad...

Page 34: ...he recipe functions while in the MAIN menu screen press F1 VIEW to proceed to the view screens as shown Pressing 1 on the key pad will access the VIEW SEND RECIPE screen shown 1 V I E W S E N D R E C...

Page 35: ...I P E S T E M P S 3 Z O N E S E T U P P I D 4 P A S S W O R D C H A N G E E X I T N E X T F1 F2 F3 F4 F5 Press 1 on the keypad to access the Edit RECIPES TEMPS screen S E T B A C K 0 1 Z O N E 0 1 S...

Page 36: ...operly the HEAT OFF ON switch on the Therm O Flow Plus control box must be left in the ON position This allows power to all heat zones and allows the tempera ture controllers to manage the heat to the...

Page 37: ...enu and turning the Timer ON will run that ACTIVE work week The defaults are Start time of 0700 and Stop time of 1700 for all days of all work weeks NOTE To keep the timer from starting zones on a par...

Page 38: ...M E C H A N G E 9 L O A D D E F A U L T S 0 B A C K F1 F2 F3 F4 F5 Select 8 and the follow EDIT TIME DATE screen will show Pressing the F2 NXT button will toggle the cursor from the different location...

Page 39: ...status to ACTIVE if a heat device is connected to the zone Turn to UNUSED if nothing is connected to the zone Pressing F4 CHG will change the F Key selections to allow editing of the zone NAME or togg...

Page 40: ...will send the SV shown on the display to the zone shown Note that incrementing through the zones will keep the same SV temperature setting This makes it easy to set all zones to 250 F for example Pres...

Page 41: ...E C I P E S T E M P S 3 Z O N E S E T U P P I D 4 P A S S W O R D C H A N G E E X I T N E X T F1 F2 F3 F4 F5 Press 4 on the numeric keypad to access the PASS WORD CHANGE screen E D I T P A S S W O R...

Page 42: ...U I T C F 1 F 3 F 5 F1 F2 F3 F4 F5 If this screen is accessed by accident press F3 QUIT to return to the previous screen Pressing F1 F will send all the settings to all the ACTIVE zones with the prope...

Page 43: ...43 309085 Notes...

Page 44: ...goes LOW and the other drum has not been changed since being empty the AMBER light of the drum to be changed will begin to flash off on alerting the operator to change the drum NOTE The air solenoid i...

Page 45: ...s Over Assembly 2 includes J Box light assy and machine cables Mount to Ram Piston Rod C58011 Roller 2 C58009 Bracket 1 241402 Switches 2 To low switch 116157 To empty switch To air motor solenoid C07...

Page 46: ...ed header assembly requires 500W for operation Therefore the heated header assem blies should always be connected on zones 3 4 5 or 6 of any Therm O Flow Plus control assembly The 8 Zone control panel...

Page 47: ...nloader or FACTORY SETUP FACTORY SET UP will be discussed later Press A on the keypad to access the DEDICATE ZONES screen as shown below A L W A Y S O N Z O N E 0 1 N A M E G U N 1 A C T I V E Z N C H...

Page 48: ...will change to the other unloader indicated by the GREEN light on the beacon assembly and the pendant will keep the heat zones of the empty drum on for 59 min This allows time for the operator to chan...

Page 49: ...X OVER when no cross over modules exist on the system there will be communication errors and the X OVER will be disabled Starting the X OVER automatically ENABLES it expecting to com municate with cr...

Page 50: ...is ordered When F1 or F5 is pressed the operator will be prompted to ensure the communication cables to UNLOADER A or UNLOADER B cross over control box is the ONLY one connected When ready the operato...

Page 51: ...ss over control box will blink indicating that it had timed out and is ignoring all commmands from the pendant The pendant is constantly sending commands to the cross over module to ensure it is opera...

Page 52: ...ed wipers Replace wipers See procedure on page 56 Pump won t prime properly or Closed main air valve or clogged air line Open air valve clear air line pumps air Not enough pump air pressure Increase p...

Page 53: ...or normal opera tion Downstroke Lower check in pump is worn or fouled Upstroke Upper check in pump is worn or fouled Clean rebuild or replace pump as nec essary Material leaks around pump outlet Outle...

Page 54: ...cle rate Reduce pressure cycle rate or duty cycle of the air motor Electrical Control Panel Troubleshooting For more information see the electrical control panel documentation Problem Cause s Solution...

Page 55: ...165 mm 6 5 Global Ram Module Ram Pressure Relief Procedure WARNING To reduce the risk of serious injury whenever you service the ram always follow the procedure below To relieve air pressure in the ra...

Page 56: ...an perform without removing the ram plate from the supply unit servicing wipers replacing heat sensors To remove the ram plate from the supply unit see the procedure on page 59 For information about r...

Page 57: ...e risk of injury or damage to equipment make sure the main discon nect is OFF before continuing with this procedure 3 Turn OFF the main electrical disconnect 4 Turn the system HEAT ON switch to OFF 5...

Page 58: ...e main electrical disconnect WARNING ELECTROCUTION HAZARD To reduce risk of injury or damage to equipment make sure the main discon nect is OFF before continuing with this procedure 7 Bleed off excess...

Page 59: ...the Air Motor to the Pump Perform the above procedure in reverse order to reattach the pump to the air motor Be sure that when you reinsert the collar couplings into the coupling nut the large flanges...

Page 60: ...60 309085 Service For 400 480 and 575 VAC Supply Units Junction Box Schematic Fig 18 TI0673...

Page 61: ...61 309085 Service For 240 VAC Supply Units Junction Box Schematic Fig 19 TI0673...

Page 62: ...62 309085 Parts All Models Supply Unit 15 16 11 12 18 8 9 17 1 6 10 7 4 3 113 114 1 2 3 22 2 5 21 14 13 20 Hydraulic Powered Ram Models C 2 only See Instruction form 310523 TI0411...

Page 63: ...se support 6 5 rams 1 7 C32402 ROD follower heated 2 8 243422 KIT depressurize see page 71 for details 1 9 C14043 LABEL pinch point 4 10 C14005 LABEL heated equipment 2 11 101015 WASHER 2 12 C19187 NU...

Page 64: ...ee 307592 220571 used on code A 2 see 307592 208356 used on code A 3 see 307049 215255 used on code A 4 see 307304 207647 used on code A 5 see 306968 220106 used on code A 6 see 307741 502 243276 PUMP...

Page 65: ...65 309085 Notes...

Page 66: ...d Pump Ram Plate Sensor Ram Plate 2nd Sensor Optional 604 632 620 To Ram Plate To Main Panel Prox switch Optional To Ram Plate 627 603 605 602 613 614 615 616 617 618 621 622 606 611 609 607 608 601 6...

Page 67: ...COVER pump left side assy 1 612 C14009 LABEL high voltage 2 613 100016 WASHER lock 1 4 in 4 614 C19080 SCREW hex head 1 4 20 x 0 5 in 13 mm 4 615 C20867 BUSHING conduit 3 4 npt 2 616 C20716 LOCKNUT c...

Page 68: ...e B 2 Part No 243875 Ram Plate Smooth Bottom Code B 3 9517A 337 307 308 341 340 308 305 314 303 329 342 327 302 301 304 305 338 335 312 311 310 309 315 316 305 317 325 318 326 319 320 345 330 332 322...

Page 69: ...service part 321 100721 PLUG pipe 1 322 100361 PLUG pipe 6 323 100133 WASHER lock 6 324 C19846 SCREW cap socket hd 6 325 517414 BUSHING pipe brass 1 326 115667 KIT band heater 1 327 115655 SEAL wiper...

Page 70: ...07430 CONNECTOR sealed 1 402 C20715 FITTING conduit 1 403 C07458 CONNECTOR sealed 1 404 C20485 FITTING 1 2 npt 1 405 115712 VALVE solenoid 240V 1 406 C07403 NUT wire gray 2 407 617550 TERMINAL ring 16...

Page 71: ...8 703 C19213 WASHER lock 8 704 C19200 WASHER plain 4 705 C19124 SCREW cap hex hd 4 706 C14004 LABEL warning 1 707 C14003 LABEL warning 1 708 C32424 U BOLT 7 in 2 709 617727 STOP control panel 1 710 C1...

Page 72: ...o Description Qty Ref Part No No Description Qty 901 195863 BRACKET 2 902 617395 CLAMP saddle 2 903 C32424 U BOLT 7 in 2 904 100131 NUT hex 4 905 100133 WASHER lock 8 906 100101 SCREW cap hex head 4 9...

Page 73: ...o No Description Qty Ref Part No No Description Qty 801 C32424 U BOLT 7 in 2 802 160111 CLAMP 1 803 100103 PIN cotter 2 804 100307 NUT hex 4 805 100133 WASHER lock 4 806 C38182 WASHER plain 2 807 C324...

Page 74: ...Hose Guns Platen Pump Power Connections Power Disconnect Ground Fault Protector Power Leg Fuses Optional Inactivity Timer Relay Hose and Gun Zone Fuses Blow Off Valve Heater Fuse Relay Logic and Solen...

Page 75: ...LPJ 17 1 2SP Class J 116216 2 FU103 104 Bussmann LPJ 7SP Class J 116217 2 FU100 101 102 Bussmann LPJ 80SP Class J 116218 3 FU284 Bussmann GDC 1A 5 x 20mm 116225 1 TC220 227 234 241 250 257 Syscon RKC...

Page 76: ...ussmann LPJ 45SP Class J 116224 3 FU284 Bussmann GDC 1A 5 x 20mm 116225 1 TC220 227 234 241 250 257 Syscon RKC CB100FDA9 VN AC 51 A Y 233150 6 115972 6 Zone Control 575VAC CR303 Potter Brumfield KUIP...

Page 77: ...n LPJ 80SP Class J 116218 3 FU284 Bussmann GDC 1A 5 x 20mm 116225 1 TC220 227 234 241 250 257 264 271 Syscon RKC CB100FDA9 VN AC 51 A Y 233150 8 115975 8 Zone Control 400VAC CR303 Potter Brumfield KUI...

Page 78: ...LPJ 45SP Class J 116224 3 FU284 Bussmann GDC 1A 5 x 20mm 116225 1 TC220 227 234 241 250 257 264 271 Syscon RKC CB100FDA9 VN AC 51 A Y 233150 8 115977 8 Zone Control 575VAC CR303 Potter Brumfield KUIP...

Page 79: ...nsions Ram Mounting and Clearance Dimensions Fig 20 21 0 in 42 0 in 48 in 25 in 1067 mm 1168 mm 533 mm 635 mm 29 0 36 9 937 mm 737 mm 1732 mm 68 2 108 2 132 mm 282 mm 64 0 16 7 2748 mm 5 2 11 1 1626 m...

Page 80: ...Used with 243275 to retain any material drips from heated plates 233098 Pendant Control with 7 day Timer Plugs into any Therm O Flow Plus 6 8 zone control box Part No Accessory Controllers and Cables...

Page 81: ...fluid outlet size 1 npt f Wetted parts Carbon steel brass chrome zinc and nickel plating 304 316 440 and 17 4 PH grades of SST alloy steel ductile inron glass filled Weight 1200 lbs 545 kg Displacemen...

Page 82: ...or any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to perso...

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