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See page 3 for maximum working pressure and other model information. ® ™ ™ Therm-O-Flow 20 with Bulldog /King pump Therm-O-Flow 20 with President pump Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001...
Models Models Max. Fluid Working Part Number Motor/Pump Ratio Pressure Voltage Page 918522 President 15:1 1800 psi (12 MPa, 124 bar) 480 VAC page 30 918532 President 15:1 1800 psi (12 MPa, 124 bar) 240 VAC page 30 246653 President (no control) 15:1 1800 psi (12 MPa, 124 bar) 240 VAC...
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Manual Conventions WARNING 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 medical attention. • Do not point the gun at anyone or at any part of the body.
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Misuse can cause serious injury or death. • For professional use only. • Use equipment only for its intended purpose. Call your Graco distributor for information. • Read manuals, warnings, tags, and labels before operating equipment. Follow instructions. • Check equipment daily. Repair or replace worn or damaged parts immediately.
Installation Installation Key: Air Line Filter Ram Air Regulators Bleed-type Master Air Valve - required Air Line Lubricator Pump Bleed-type Master Air Valve - required Depressurization Valve Pump Air Regulator Air Motor Pressurization Kit (King/Bulldog units only) Main Air LIne Supply Pump Electrical Control Panel Ram Control Lever...
Installation Unpacking Air Line Modules Unpack the Therm-O-Flow 20 as follows: 4-Regulator Air Control Module (246587) 1. Inspect the shipping box for damage; immediately Refer to page 36-38. contact the carrier if damaged. This module includes the following components: 2. Open the box and inspect the contents for loose or damaged parts.
Installation Location 3-Regulator Air Control Modules (234236, not shown) Refer to the dimensional drawings, page 60, for ram This module includes the following components: mounting and clearance dimensions. • Pump Bleed-type Master Air Valve (C): is installed Make sure: so the valve is easily accessible and located down- stream from the air regulator.
Installation Electrical Control Panel Have a trained electrician connect the electrical control panel to a grounded electrical source that has the required service ratings: Electrically Connect Hoses Assemble hose and gun components. Follow the gun Control Full instructions. Panel Load Model: Zones: VAC: Hz: Phase:...
Installation Heaters for 4-Zone Control Panels Graco Factory P, I, and d Settings The table lists the P (proportional), I (integral), and d Zone Component Terminals Value Range (derivative) settings for standard control panels. These Follower 3L1 & 3L3 98-127 ohms settings are preset at the factory.
1. Select a solvent that is compatible with the equip- ment wetted parts and the material being flushed. 6. Open the dispense valve over a waste container Check with your Graco distributor or the material during system heatup to relieve pressure as mate- supplier for a recommended solvent.
Start Up Loading Material b. If necessary, stop lowering the follower plate to adjust the pail position to align with the follower plate. WARNING c. As the follower plate enters the pail, remove the bleed stick to allow trapped air between the fol- lower plate and the top of the material to Material and equipment are hot.
Operation Operation Pressure Relief Procedure 10. To relieve pressure in the ram, see the Ram Pres- sure Relief Procedure, page 21. WARNING Raising and Lowering Ram WARNING Read warnings, page 4, and follow the Pressure Relief Procedure whenever you: • are instructed to relieve pressure •...
Operation Daily Start-up Procedure 7. Turn the pump air supply ON and set the regulator for normal operation. 8. Dispense material into a waste container. Adjust the WARNING flow rate as needed. Using Optional 7-Day Timer • Material and equipment are hot. Avoid contact. The 7-day timer can be set to automatically turn the heat Wear protective clothing.
Operation Changing Empty Pails 4. Being careful not to damage the follower wiper or touch hot material, scrape material from the follower plate and wiper. CAUTION 5. Follow Loading Material procedure, page 13-13, • To avoid damaging pumps, do not operate when steps 1-6, except step 3 (lubricate the wiper).
Operation Reading Electrical Control Panel Indicators Use the table and F . 5 below to read electrical control panel indicators. For information on setting the temperature controllers, see Setting Temperature Controllers in Manual 309100. Indicator Light No. Indicator Light is Meaning Power On/Ground Power is on and ground is connected.
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Operation High Temperature Alarm Ground Fault Interrupt Should a component temperature go outside the preset The control panel includes a ground fault interrupt (GFI) range for any of the zones, power to heated components circuit breaker (F . 7). If the main electrical disconnect is interrupted, and the HIGH TEMPERATURE ALARM is ON, but all lights on the electrical control panel are off, light turns ON.
Troubleshooting Troubleshooting Problem Cause Solution Ram does not raise or lower. Main air valve closed. Open air valve. Air line clogged. Clear air line. Ram air pressure too low. Increase ram pressure. Worn or damaged piston. Replace piston. See manual 310523.
Troubleshooting Heated Pump See the pump manual for more information. Problem Cause Solution Rapid down or up stroke (pump Material not heated to proper tem- Check and adjust temperature set point. cavitation). perature. Air trapped in pump. Purge air from the pump - page 13, step Downstroke: Lower check in pump Repair pump.
Service Service Before Servicing 1. Remove material pail. Follow Changing Empty Pails procedure, page 16, step 1-4. Follow the procedure’s warnings and cau- tions. WARNING Read warnings, page 4. 2. Follow the Pressure Relief Procedure, page 14. 3. Follow the Ram Pressure Relief Procedure, below. Ram Service For more information on servicing the ram, see manual 310525.
Replacing Heat Sensors For more information about the follower plate, refer To replace wires connecting the follower to the to pages 26-27. pump, see Manual 310530 or contact your Graco distributor. 1. Follow Before Servicing procedure, page 21. Replacing Wipers 2.
Service Check-Mate 800 Pump/Motor or a razor, to carefully scrape the sealant off the shroud seams. Service 9. Pumps C03509 and C03512 only: disconnect the junction box from the pump. For specific information about servicing the a. Remove the junction box cover. Check-Mate 800 pump, see manual 308570 or 310530.
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• Apply RTV sealant to the pump shrouds before assembling them For more information, see manual 310530, or call your Graco distributor. Removing Follower Plate Refer to page 41. 1. Remove the pump by following steps 1-12 of the Removing the Pump Assembly procedure.
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Service 240/480 Volt Ram Plate Assembly Wiring (3 Zone Control) 240V FOLLOWER HEATERS FHA1 FHB1 FHA2 FHB2 480V FOLLOWER HEATERS FHA1 FHB1 FHA2 FHB2 . 12 309858D...
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Service 240 Volt Ram Plate Assembly Wiring (4 Zone Control) To Control Box FHA1 FHB1 PUMP SENSOR FHA2 FHB2 FOLLOWER SENSOR PHT1 PHB1 PROX SWITCH PHT2 PHB2 PUMP GROUNDING SCREW FOLLOWER GROUNDING SCREW PUMP HEATERS 600/860W 600/860W FOLLOWER HEATERS . 13 309858D...
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Service 480/575 Volt Ram Plate Assembly Wiring (4 Zone Control) TO CONTROL BOX FHA1 FHB1 PUMP SENSOR FHA2 FHB2 FOLLOWER SENSOR PHT1 PHB1 PROX SWITCH PHT2 PHB2 PUMP GROUNDING SCREW FOLLOWER GROUNDING SCREW PUMP HEATERS 600/860W 600/860W FOLLOWER HEATERS . 14 309858D...
Service President Pump/Motor Service 4. Remove the air lines (116, 117) from the blow-off valve (103). 5. Remove the 6 screws (109) and washers (108). For more information on servicing the pump lower assembly, refer to manual 307431. 6. Slide off the follower plate (9). Removing Pump from Air Motor 1.
Service Inspection Frequency Ground Fault Interrupt Periodically (once a month) test the ground fault inter- rupt switch by pushing the TEST button. See the litera- ture that came with the electrical control panel. Periodically (once a month), inspect the ram guide sleeves, rods and cylinders for wear or damage, replace Removing/Replacing CB100 all worn parts.
Parts Parts Therm-O-Flo 20 Models 918522, 918532, and 246653 3” (76 mm) Ram, 15:1 President, with silicone follower wiper, 918522 - 480 VAC, 918532 - 240 VAC 33,34 Torque to 20-30 ft-lbs (27-41 N•m) Torque to 30-40 ft-lbs (41-54 N•m) Fill packing nut 1/2 full of TSL (43) Tie-wrap armored portion of sensor onto conduit leading up to junction box;...
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Parts Model 918522 Model 918532 With Electrical Control, Includes 1-45 With Electrical Control, Includes 1-45 Model 246653 Part No. Description Qty. Without Electrical Control, Includes 1-12, 15, 22-45 918506 KIT, depressurizing (see page 37) 234236 CONTROL BOX C31197 KIT, hose support Part No.
Parts Part No. 246587 4-Regulator Ram Air Control Module Ref. Part No. Description Qty. 234236 CONTROL BOX 101682 SCREW; 1-1/4-20 x 5/8” C11034 LUBRICATOR, oil C11029 REGULATOR, air C36260 GAUGE, air pressure 113269 VALVE, ball, vented C19024 ELBOW, swivel; 1/2-14 npsm x 1/2-14 nptf C19197 WASHER;...
Parts Part No. C03510 Pump Air Motor Mounting Kit Ref. Part No. Description Qty. 106166 NUT, M16 x 2 190000 ROD, tie 184129 COLLAR, coupling 186925 NUT, coupling; 1-1/4-12 UNF 309858D...
Parts Part No. 244757 Heated Follower Plate Kit with smooth bottom for use with Heated Check-Mate 800 pump modules 123, 124 Ref. Ref. Part No. Description Qty. Part No. Description Qty. 100176 BUSHING; 3/8-18 x 1/4-18 npt 244710 PLATE, heated; smooth bottom 115948 ELBOW, 90°;...
Parts Part No. 244754 Heated Follower Plate Kit with finned bottom for use with President pump assemblies 109 108 105 106 113, 123, 124 Ref. Ref. Part No. Description Qty. Part No. Description Qty. 100176 BUSHING; 3/8-18 x 1/4-18 npt 244707 PLATE, heated;...
FU100/101, 600 V (for Part No. 617300) 15C347 1792 FU100/101, 600 V (for Part No. 617485) 15C348 (2) SPARE FU103/104, 250 V (for Part No. 617485) 15C496 To order other parts, contact your Graco distributor. TOTAL (31), TYPE CA1 309858D...
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Parts Part No 617300 and 617484 Standard, 3-zone Electrical Control Panel (exterior) 617300 - 480 VAC (shown), 617484 - 240 VAC TC129 TC151 TC158 DH/DG HOSE FOLLOWER LINE VOLTAGE: PHASE: FREQ: 60HZ FULL LOAD AMPS: ELECTRICAL PANEL PART No.: 617300 OUT1 OUT2 ALM1...
1662 FU179, 125 V 15C343 FU100/101/102, 600 V (for Part No. 617349) 15C346 1711 1752 FU100/101/102, 250 V (for Part No. 617484) 15C349 1772 To order other parts, contact your Graco distributor. 1792 (1) SPARE TOTAL (34), TYPE CA1 309858D...
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ALM1 ALM2 CB100 CB100 CB100 CB100 POWER ON CONTROL ON HIGH TEMPERATURE AUTO HEAT OFF GROUND CONNECTED ALARM LT110 LT120 LT164 LT114 CONTROL ON AUTO HEAT DANGER AUTO 480 VOLTS SS116 SS166 DH/DG Therm-O-Flow Auto Pressurization Solenoid GRACO C14044 309858D...
Electrical Schematic Pin Chart Hose Sensor 18 AWG Blue (routed as a twisted pair) Hose Sensor 18 AWG Blue Gun Sensor 18 AWG Blue (routed as a twisted pair) (routed as a twisted pair) Gun Sensor 18 AWG Blue (routed as a twisted pair) Hose Heater 18 AWG Black Gun Heater 18 AWG Black Hose Heater 18 GA White...
See manual 308570 for CheckMate 800 See manual 307431 for 15:1 President pump Ceramic Washer 15C176 Electric terminal washer for heated Therm-O-Flow 20 plate Heater/Sensor Repair Kit C32202 Includes heaters, sensors, and wires for replacing heaters and sensors 7 Day Timer Kit...
CB100 CB100 CB100 CB100 POWER ON CONTROL ON HIGH TEMPERATURE AUTO HEAT OFF GROUND CONNECTED ALARM LT164 LT110 LT114 LT120 CONTROL ON AUTO HEAT DANGER AUTO 480 VOLTS SS116 SS166 42” (1067 mm) Therm-O-Flow GRACO C14044 21” (533 mm) 309858D...
Temperature Controller Settings Temperature Controller Settings New Style Symbol Name First alarm (ALM1) Second alarm (ALM2) Auto-tuning (AT) Self-tuning (ST) Proportional band Intergral time Derivative time Anti-reset windup (ARW) Heat-side proportion- ing cycle Cool-side proportion- ing band (Pc) Deadband (db) Cool-side proportion- ing cycle (Pc)
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Temperature Controller Settings Level 1, Function Mode Parameter Names Setup, Function Mode Parameter Names Symbol Name Symbol Name Auto-tuning Execute/Cancel Input type Alarm value 1 SP ramp set value Alarm value 2 MV at stop Proportional band MV at PV error Integral time MV upper limit Derivative time...
With the exception of any special, extended, or limited warranty published by Graco, 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 defective.
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