Graco Therm-O-Flow 55-H Instructions-Parts List Manual

Heated supply unit with hydraulic-powered ram. 200 liter (55 gallon) drum size, 165 mm (6.5”) dual post
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INSTRUCTIONS–PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
200 Liter (55 Gallon) Drum Size
165 mm (6.5") Dual Post
Therm-O-Flow 55-H
Heated Supply Unit
with Hydraulic-Powered Ram
918–452
Silicone Follower Wipers,
31:1 Bulldog , 480 VAC,
Therm-O-Flow Pump Module,
Hydraulic Power Supply
918–453
Silicone Follower Wipers,
65:1 King , 480 VAC,
Therm-O-Flow Pump Module,
Hydraulic Power Supply
918–480
Silicone Follower Wipers,
31:1 Bulldog, 240 VAC,
Therm-O-Flow Pump Module,
Hydraulic Power Supply
GRACO INC. 47700 HALYARD DR. PLYMOUTH, MI 48170
Model 918–452
COPYRIGHT 1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
310–534
Rev. B
Supersedes Rev. A
310–534
1

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Summary of Contents for Graco Therm-O-Flow 55-H

  • Page 1 Hydraulic Power Supply 918–480 Silicone Follower Wipers, 31:1 Bulldog, 240 VAC, Therm-O-Flow Pump Module, Hydraulic Power Supply Model 918–452 GRACO INC. 47700 HALYARD DR. PLYMOUTH, MI 48170 COPYRIGHT 1996, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001 310–534...
  • Page 2: Table Of Contents

    ......Reading the Electrical Control Panel Graco Warranty and Limitation of Liability ..
  • Page 3: Symbols

    Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 82 C (180 F) or below -40 C (-40 F), except electrically heated hoses.
  • Page 4 WARNING HOT SURFACE AND FLUID HAZARD Heated fluid can cause severe burns and can cause equipment surfaces to become very hot. Wear protective gloves and clothing when operating this equipment in a heated system. Do not touch the metal heat sink when the surface is hot. Allow the equipment to cool thoroughly before servicing.
  • Page 5 WARNING FIRE, EXPLOSION AND ELECTRIC SHOCK HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in fire, explosion, or electrostatic shock and other serious injury. Ground the equipment, the object being sprayed, and all other electrically conductive objects in the dispense area.
  • Page 6 WARNING TOXIC FLUID HAZARD Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed. Know the specific hazards of the fluid you are using. Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.
  • Page 7: Typical Installation

    Typical Installation Air Line Filter Hose Hanger Lock-out Master Air Valve (bleed-type) Follower Blow-off Valve (required) Ram Air Regulators Pump Bleed-Type Master Air Valve (required) Follower Rod Pump Air Regulator Pump Assembly Main Air Line Supply Ram Hand Valve Electrical Control Panel Ram Module Follower Plate Bleed Stick Automatic Dispense Valve...
  • Page 8: Selecting A Location For The Ram And Hydraulic Power Supply

    The Therm-O-Flow 55-H unit was designed for use If you are installing a vent hood, make sure with single-circuit material hoses that are rated at a there is sufficient horizontal clearance for it.
  • Page 9 Typical Installation Air Line Modules Pump Air Regulator (D) controls pump speed and outlet pressure by adjusting the air pressure to the WARNING pump. It is located on the air control panel up- stream from the bleed-type master air valve. PRESSURIZED FLUID HAZARD AND Ram Air Regulators (O) control the air pressure to MOVING PARTS HAZARD...
  • Page 10: Installation

    Installation The installation procedure includes: Electrically Connect Hoses to the Electrical Control Panel locating and installing the ram and hydraulic power supply. See Form#310–533 for installation informa- tion. WARNING electrically connecting hoses to the electrical con- trol panel FIRE HAZARD Only use hoses that have a maximum grounding the system wattage less than or equal to 1250...
  • Page 11: Ground The System

    Installation Ground The System Object Material is Applied To Ground the object according to your local code. Ground the supply unit as instructed here and in the individual component manuals. Material Drums Ground material drums according to your local code. WARNING Make sure the drum is placed securely in the ram before operating the supply unit.
  • Page 12: Connecting The Electrical Control Panel To A Power Source

    Installation Connecting the Electrical Control Panel to Have a trained electrician connect the electrical control panel to a grounded electrical source that has the a Power Source required service ratings: The Electrical Control Panel (Fig. 4) comes already attached and wired to the ram, however before the Model: VAC: Phase:...
  • Page 13: Checking Resistance Of Electrical Components

    Installation Checking Resistance of Electrical 2. Make electrical resistance checks for the compo- nents listed below. See the appropriate wiring Components diagrams. WARNING Model: VAC: Pages: C32428 60 – 64 ELECTRIC SHOCK HAZARD C32429 66 – 70 Do not open the electrical control panel, unless you are a trained professional.
  • Page 14 Installation Heater Resistance Checks 2. Make electrical resistance checks for the compo- nents listed below. Refer to the appropriate wiring WARNING diagrams. Model: VAC: Pages: ELECTROCUTION HAZARD C32428 60 – 64 To reduce risk of injury or damage to C32429 66 –...
  • Page 15: Setting Electrical Control Panel Controls

    Installation Setting Electrical Control Panel Controls For more information about using the temperature con- trollers, refer to the temperature controller instructions included in the electrical control panel documentation. WARNING Before you begin this procedure, make sure that the HOT MATERIAL AND EQUIPMENT supply unit has been properly grounded, checked for resistance, and safely connected to a power source.
  • Page 16 Installation Setting Alarm Temperatures Configuring Temperature Controllers for Unused Zones To set the alarm temperature: If your electrical control panel has more temperature 1. If you have just set the set point, you will already controllers than are needed for your current applica- be in the set alarm mode.
  • Page 17 Installation To disconnect a temperature controller: 2. Open the electrical control panel. The temperature controller mounting holes are located in the door of the control panel. WARNING 3. For each unused temperature controller (Fig. 8): ELECTRIC SHOCK HAZARD Do not open the electrical control panel, a.
  • Page 18: Starting Up The System

    Installation Starting Up the System 5. Raise the ram, using the following procedure: a. Close all air regulators. WARNING b. Move the ram hand valve lever to the UP posi- tion. PRESSURIZED EQUIPMENT HAZARD To help reduce the risk of injury or equip- c.
  • Page 19: Initial Material Loading

    9. Slowly adjust the pump air regulator. This will start the pump and fill the material passage. For information about specific air pressure settings, refer to the Graco system documentation. 10. Dispense material from the dispense gun until air- free material is dispensed. Allow the system to heat for approximately 30 minutes.
  • Page 20: Operation

    Operation Pressure Relief Procedure 1. Lock the gun/valve trigger safety. 2. Shut off the main air supply to the material pump. This procedure describes how to relieve pressure from 3. Close all air bleed valves. the supply unit. Use this procedure whenever you shut off the dispenser/sprayer and before checking or 4.
  • Page 21: Daily Start-Up Procedure

    Operation Daily Start-up Procedure Starting the System Manually To start the system manually: WARNING 1. Verify that the main disconnect is ON. PRESSURIZED FLUID HAZARD 2. Turn the CONTROL ON switch to ON. To reduce the risk of serious bodily inju- 3.
  • Page 22 Operation Using the 7-Day Timer 1. Turn the CONTROL ON (7) switch to AUTO. The optional 7-Day Timer allows you to automatically 2. Turn the HEAT switch (8) on the electrical control heat the system without having to manually turn on the panel to ON.
  • Page 23: Changing Empty Drums

    Operation Changing Empty Drums CAUTION WARNING Do not raise the ram and remove the follower plate from the empty drum unless the supply unit is at full operating temperature. Drum MOVING PARTS HAZARD changes can only be performed when the system is To reduce risk of injury or damage to heated.
  • Page 24 Operation Changing Empty Drums 9. Bleed, from the material pump, the air that was (continued) introduced during the drum change: 6. Place the new drum in the ram: a. Place a waste container under the pump bleed a. Remove the cover from a drum of appropriate port.
  • Page 25: Shutdown

    Operation Shutdown Emergency Stop To shut down the supply unit: 1. On the electrical control panel (Fig. 11): a. Turn the CONTROL ON switch (7) to OFF. 1. On the electrical control panel (Fig. 11): a. Turn the CONTROL ON switch (7) to OFF. b.
  • Page 26: Reading The Electrical Control Panel Indicators

    Operation Reading the Electrical Control Panel Indicators Use the table and Fig. 13 below to read the indicators For information on setting the electrical controllers, see on the electrical control panel Setting Electrical Control Panel Controls on page 15. Light# Indicator: Indicator Meaning:...
  • Page 27: Resetting The Ground Fault Interrupt

    Operation Temperature Out of Range 5. Close dispense valves. Should any of the temperatures go out of the preset 6. Turn on pump air. range for any of the zones, power to the heated components is interrupted, and the HIGH 7.
  • Page 28: Flushing Safety

    Operation Flushing Safety WARNING WARNING PRESSURIZED FLUID HAZARD Always use the lowest possible fluid Use fluids and solvents that are chemically compat- pressure, and maintain firm metal-to- ible with the equipment wetted parts. See the metal contact between the gun/valve Technical Data sections of all the equipment and the drum during flushing to reduce the risk of manuals.
  • Page 29: Ram And Hydraulic Power Supply Troubleshooting

    Ram and Hydraulic Power Supply Troubleshooting For more information about the ram or hydraulic power supply, see Form# 310–533. Problem Cause(s) Solution(s) Ram won’t raise or lower or Closed main air valve or clogged air line. Open air valve, clear air line. ram moves too slowly ram moves too slowly Not enough pressure.
  • Page 30 Ram and Hydraulic Power Supply Troubleshooting (continued) Problem Cause(s) Solution(s) Pressure won’t hold drum Closed main air valve or clogged air line. Open air valve, clear air line. down or push plate up down or push plate up Not enough ram pressure. Increase ram pressure.
  • Page 31 Heated Pump Troubleshooting For more information about the Check-Mate 800 Displacement Pump, see Form# 308–570. For more information about the Therm-O-Flow Pump Module, see Form# 310–530. Problem Cause(s) Solution(s) Rapid down stroke or up stroke Material not heated to proper Check and adjust temperature set point.
  • Page 32 Air Motor Troubleshooting For more information about the air motor, see the air motor’s documentation. Problem Cause(s) Solution(s) Air motor will not shift directions, Main air valve is dirty or damaged. Clean/rebuild main air valve. stalled in DOWN position Air motor will not shift directions, stalled in UP position Air motor stalled halfway between the top and bottom...
  • Page 33 Electrical Control Panel Troubleshooting For more information about the electrical control panel, see the electrical control panel’s documentation. Problem Cause(s) Solution(s) Disconnect is ON, but no indica- The ground fault interrupt has been Reset the ground fault interrupt. tor lights are lit activated.
  • Page 34: Service

    Service Ram Service 5. Exhaust pressure from both sides of the ram: For more more information about servicing the hydrau- a. Move the ram hand valve lever to the DOWN lic ram, see Form# 310–533, 165 mm (6.5”) Hydrau- position until all hydraulic pressure is ex- lic-Powered Ram Modules.
  • Page 35: Servicing The Follower

    Position the wipers so the butt joints are 180 replacing wires that connect the follower to the pump apart (Fig. 19). and junction box, see Form# 310–530, or contact your Graco technical service representative. Servicing Wipers WARNING Butt Joint 2...
  • Page 36 Service Replacing Heat Sensors 7. Loosen the cord grip (100), located under the junc- tion box. For more information about the follower plate, refer to Figs. 33 and 34 on pages 56 and 58. 8. Remove the junction box’s cover. 9.
  • Page 37: Removing/Re-Installing The Pump From The Ram

    Service Removing/Re-installing the Pump from the 7. Bleed off pressure in the system and excess material by opening the dispense gun and catching the material in a waste container. For information about servicing the Check-Mate 8. On the electrical control panel, turn the system Displacement Pump, see Form# 308–570.
  • Page 38: Separating The Pump From The Air Motor

    (30) into the coupling nut the large flanges point upwards you re-apply RTV sealant to the pump shrouds before re-assembling them For more information, see Form# 310–530, or call your Graco technical support representative. 310–534...
  • Page 39: For 240 Vac Supply Units

    Service For 240 VAC Supply Units To Ram Junction Box 1391 1401 1321 1331 1791 1841 Fig. 21 310–534...
  • Page 40: For 480/575 Vac Supply Units

    Service For 480/575 VAC Supply Units To Ram Junction Box 1391 1401 1321 1331 1791 1841 Fig. 22 310–534...
  • Page 41: Inspection Frequency

    Service Inspection Frequency Hydraulic Power Supply Once a month, check the hydraulic fluid level. Add more fluid if necessary. See the Service section of Periodically (once a month), inspect the ram guide Form# 310–533 for instructions. sleeves, rods and cylinders for wear or damage, replace all worn parts.
  • Page 42 Notes 310–534...
  • Page 43: Parts

    Parts Model 918–452 (480 Vac), 918–480 (240 Vac) 165 mm (6.5”) Ram, 31:1 Bulldog, Therm-O-Flow Part Description Qty. Part Description Qty. 918425 Air, control C03508 Pump, HCM-800, assy. 480/575 Vac 918420 Module, Ram 165 mm (6.5”) dia. See 310–530, 308–570 and See 310–533 for parts 307–765 for parts 918461...
  • Page 44 Parts Models 918–452 (480 Vac) and 918–480 (240 Vac) 165 mm (6.5”) Ram, 31:1 Bulldog, Therm-O-Flow 50 60 70 80 1/2” npt Air Inlet Specifications Model Volts: Full Load Amps: Pump Air supply: 0.7 MPa (7 bar) (100 psi) 480/3 phase 918–452: 34.6 Pump: 60 Cycles/Min.
  • Page 45: Model 918-453, Therm-O-Flow, 480 Vac

    Parts Model 918–453, 165 mm (6.5”) Ram, 65:1 King, Therm-O-Flow, 480 Vac Part Description Qty. Part Description Qty. 918425 Air, control 140 C03508 Pump, HCM-800, assy. 480/575 Vac 918420 Module, Ram 165 mm (6.5”) dia. See 310–530, 308–570 and See 310–533 for parts 307–765 for parts 918461 Kit, hose support...
  • Page 46 Parts Model 918–453, 165 mm (6.5”) Ram, 65:1 King, Therm-O-Flow, 480 Vac 50 60 70 80 1/2” npt Air Inlet Specifications: Pump Air supply: 0.6 MPa (6 bar) (90 psi) Pump: 50 Cycles/Min. Max., 4.2 m /min (150) scfm max Max Fluid Working Pressure: 4.06 MPa (406 bar) (5850 psi) max.
  • Page 47: Model 918-510, Hydraulic Power Supply

    Elbow, male, 1/4t x 1/4p 3/8 npt 260 C12310 Hose assy. 5/8 x 54” 918508 Hose assy. 5/8 x 20”, 7/8–14(37 ) 270 171432 Emblem, Graco 521900 Element, screen, 75 micron 280 C12191 Tubing, nylon, 0.25 x 0.035 wa 100 915700 Filter assy.
  • Page 48 Parts Model 918–510, Hydraulic Power Supply opposite side Fig. 27 310–534...
  • Page 49: Model 918-425, Ram Air Control Module

    Parts Model 918–425, Ram Air Control Module Part Description Qty. Part Description Qty. C19019 Union, swivel, 1/2 npt 270 C06015 Valve, hand, 1/4 npt C36183 Muffler,, 1/4 npt 280 C38260 Tee, run male, 1/4p x 3/8t C06021 Valve, lockout, 1/2 npt 290 C38261 Tee, run male, 3/8p x 3/8 t C20485...
  • Page 50 Parts Model 918–425, Ram Air Control Module 10 20 30 60 70 80 90 AIR MOTOR 210 200 1/2” npt Air Inlet L/O VLV REG #1 VLV #1 REG #2 DOWN REG #3 PRESIDENT DOWN PUMP 320 200 VLV #3 (FOLLOWER BLOW-OFF) REG #4...
  • Page 51: Model 918-395, Heavy Duty Drum Clamp

    Parts Model 918–395, Heavy Duty Drum Clamp Part Description Qty. Part Description Qty. 918422 Clamp, cylinder 617394 Pin, quick release C19124 Screw, hex head 3/8–16 x 1 C19213 Washer, lock 3/8 918421 Clamp, back half assy. C19200 Washer, flat 3/8 918423 Kit, hinged front drum clamp 617433...
  • Page 52: Model C32434, Pump Mounting Kit

    Parts Model C32434, Pump Mounting Kit Part Description Qty. Part Description Qty. C32402 Rod, follower hot C19206 Washer, lock for 3/4 161822 Plate, motor mounting C19187 Nut, hex 3/4–10 unc 100672 Screw, set 3/8–16 unc x 1 40 50 Fig. 30 310–534...
  • Page 53: Model C03510, Pump Air Motor Mounting Kit

    Parts Model C03510, Pump Air Motor Mounting Kit Part Description Qty. Part Description Qty. 106166 Nut, hex M16 x 2 184129 Collar, coupling 190000 Rod, stand-off 186925 Nut, coupling #207647 King Air Motor ref. #C03509 Therm-O-Flow Pump Module 200 liter (55 gal.) ref. See Form# 310–530 for more information Notes...
  • Page 54: Model C32451, Vent Hood Kit

    Parts Model C32451, Vent Hood Kit Part Description Qty. Part Description Qty. 517416 Hood, vent Therm–O–Flow 55 C19092 Screw, hex hd., 1/4–20 x 7/8 lg. C32445 Bracket, vent hood middle C19198 Washer, flat 1/4 C32446 Bracket, vent hood side C19209 Washer, lock 1/4 C32444 Bolt, U, square bend...
  • Page 55: Model C32435, Heated Follower Plate Kit, Standard Finned Bottom

    Parts Model C32435, Heated Follower Plate Kit, Standard Finned Bottom (Wipers not included) Part Description Qty. Part Description Qty. 617225 Platen, heated 18 k watts 190 617227 Handle, bleed C32204 O-ring 19.5 i.d. x 0.12 200 207440 Valve, dispense See 306–715 for parts 617226 Plate, tire 210 C19254...
  • Page 56 Parts Model C32435, Heated Follower Plate Kit, Standard Finned Bottom (*Wipers not included) Wiring Heaters to the Junction Box 1321 1331 220 240 50 170 Rear Front Notes 203 mm (8”) 533 mm (21”) *See Accessories section on page 71 for ordering information. Fig.
  • Page 57: Model 918-470, Heated Follower Plate Kit, Smooth Bottom

    Parts Model 918–470, Heated Follower Plate Kit, Smooth Bottom (Wipers not included) Part Description Qty. Part Description Qty. C57358 Platen, heated 18 k watts 180 C19506 Coupling, 1/2 npt C32204 O-ring 19.5 id x 0.12 190 617227 Handle, bleed 617226 Plate, tire 200 207440 Valve, dispense...
  • Page 58 Parts Model 918–470, Heated Follower Plate Kit, Smooth Bottom (*Wipers not included) Wiring Heaters to the Junction Box 1321 1331 220 240 50 170 Notes 203 mm (8”) 610 mm (24”) *See Accessories section on page 71 for ordering information. Fig.
  • Page 59: 6-Zone Electrical Control Panel

    Solid State Relay (for SSRs 152 – 173) C78082 Terminals Terminals Timer, 7–day C78167 1092 Timer, Inactivity C78342 1092 1161 For information about other parts, contact your Graco 1162 technical support representative. 1221 GND. 1321 1331 GND. (1) Spare 1091 (8) Total 1092 Type 1492–CA1...
  • Page 60: Electrical Control Panel And Wiring For C32428 (240 Vac)

    310–534...
  • Page 61 310–534...
  • Page 62 310–534...
  • Page 63 310–534...
  • Page 64 310–534...
  • Page 65 310–534...
  • Page 66: Electrical Control Panel And Wiring For C32429 (480 Vac)

    310–534...
  • Page 67 310–534...
  • Page 68 310–534...
  • Page 69 310–534...
  • Page 70 310–534...
  • Page 71: Accessories

    Accessories Use Only Genuine Graco Parts and Accessories Description Part No. HEATED 55-GALLON FOLLOWER PLATE ASSEMBLY 560mm (22”) o.d. Order wiper rings separately Standard Finned Bottom C32435 Smooth Bottom 918–470 55-GALLON HEATED FOLLOWER WIPER RINGS KITS 560mm (22”) o.d. Kit contains upper and lower hoses and clamp...
  • Page 72: Dimensions

    Dimensions Ram Mounting and Clearance Dimensions 1168 mm (48 in.) 1151 mm (45.3 in.) 1067 mm (42 in.) 937 mm (37 in.) 737 mm 693 mm (29 in.) 635 mm 533 mm (27.3 in.) (25 in.) (21 in.) 2824 mm (111 in) 1808 mm (71 in.)
  • Page 73: Hydraulic Power Supply Mounting And Clearance Dimensions

    Dimensions Hydraulic Power Supply Mounting and Clearance Dimensions 551 mm (21.7”) 335 mm (13.2”) 292 mm (11.5”) 229 mm 279 mm (9.0”) (11.0”) 432 mm (17.0”) 785 mm (30.9”) 330 mm (13.0”) Fig. 37 310–534...
  • Page 74: Electrical Control Panel Mounting And Clearance Dimensions

    Dimensions Electrical Control Panel Mounting and Clearance Dimensions 254 mm (10”) 945 mm (37.25”) 1189 mm (46.8”) 493 mm (19.4”) 646 mm (25.4”) Fig. 38 310–534...
  • Page 75: Technical Data

    Senator Air Motor, 19:1 and Quiet Senator Air Motor, 19:1 307–592 King Air Motor, 65:1 306–968 Material Safety Data Sheet for Hydraulic Fluid 307–766 Check-Mate, King, and President are trademarks of Graco, Inc. Bulldog, Senator, and Therm-O-Flow are registered trademarks of Graco, Inc. 310–534...
  • Page 76: Graco Warranty And Limitation Of Liability

    Graco distributor to the original purchaser for use. Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defec- tive.

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