Page 1
Air-Powered Ram Heated Pail Unloaders Refer to page 2 for a list of models. Model 918337 Model 918343 8249A Mini–5 Therm–O–Flow 5 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441 ECOPYRIGHT 1999, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...
List of Models The supply units listed below all include silicone wipers. Part Number Motor/Pump Ratio Max. Fluid Working Voltage Page Pressure 918334* President 15:1 126 bar (1800 psi) 480 VAC 918337 President 15:1 126 bar (1800 psi) 480 VAC Polyurethane (PUR) Reactive...
......Model 918522, 76 mm (3”) Ram, Graco Factory P, I, and D Settings ...
Page 4
... Model 617334, Proximity Switch Kit (Pump Model C03510, Pump Air Motor Mounting Kit Activity) for use with Therm-O-Flow 5 units . . . Model 918416, 4-Regulator Ram Air Model 918433, Proximity Switch Kit Control Module .
D Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco distributor. D Do not alter or modify this equipment. Use only genuine Graco parts and accessories. D Check the equipment daily. Repair or replace worn or damaged parts immediately.
Page 6
WARNING HOT SURFACE AND FLUID HAZARD Heated fluid can cause severe burns and can cause equipment surfaces to become very hot. D Wear protective gloves and clothing when operating this equipment in a heated system. D Do not touch the metal heat sink when the surface is hot. D Allow the equipment to cool thoroughly before servicing.
Page 7
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. D Ground the equipment, the object being dispensed, and all other electrically conductive objects in the dispense area.
When the Therm-O-Flow 5 or Mini-5 requires packaged for shipment by Graco. When the package service, it is the purchaser’s responsibility to have the arrives, perform the following procedure to unpack the unit repaired. As an option, the purchaser can have the units: unit repaired by an authorized Graco distributor.
Typical Installation Air Line Filter Hose Hanger Lock-out Master Air Valve (bleed-type) Follower Blow-off Valve Regulator (required) Follower Plate Bleed Stick Pump Bleed-Type Master Air Valve (required) Depressurization Valve Pump Air Regulator Pump Assembly Main Air Line Supply Ram Module Electrical Control Panel Ram Hand Valve Follower Blow-off Valve...
Contact your Graco representative or 4. If you bolt the ram to the floor, make sure: Graco Technical Assistance for help in designing a system to suit your particular needs. you will be able to level the base of the ram...
Page 11
Typical Installation Air Line Modules 2-Regulator Air Control Modules (not shown) The following components are included with the mod- WARNING ule: PRESSURIZED FLUID HAZARD AND D Pump Bleed-type Master Air Valve (C) is required in MOVING PARTS HAZARD your system to relieve air trapped between it and The bleed-type master air valve (C) is the air motor when the valve is closed (see the required in your system to relieve air...
Installation Securing the Ram to a Mobile Platform The installation procedure includes: D locating and installing the ram When performing the following procedure, use the D electrically connecting hoses to the electrical con- Mobile Platform Kit (918414) to secure the ram to a trol panel mobile platform.
Installation Ground The System Ground the supply unit as instructed here and in the individual component manuals. WARNING Air and Fluid Hoses Use electrically conductive hoses only. FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD To reduce the risk of fire, explosion, or Dispensing/Spray Gun electric shock: Follow the dispensing/spray gun grounding instruc-...
Installation Connecting the Electrical Control Panel to For information about specific terminal locations and connections, see Schematics on page 67 for wiring a Power Source diagram information. The Electrical Control Panel (Fig. 2) comes already attached and wired to the ram, however before the supply unit becomes functional, you must connect the To connect the control panel to the electrical source: electrical control panel to a power source.
Installation Checking Resistance 3. Replace any parts whose resistance readings do not comply with the ranges listed in the chart below. WARNING NOTE: Check resistance at ambient room tempera- ELECTRIC SHOCK HAZARD ture (63_ – 77_ Do not open the electrical control panel, unless you are a trained professional.
Page 17
Installation Heater Resistance Checks Heaters for 3-Zone Control Panels Value WARNING Zone Component Terminals Range ELECTROCUTION HAZARD Follower 2L1 & 2L2 98 – 127 ohms 2L2 & 2L1 To reduce risk of injury or damage to equipment, conduct these electrical checks with the main disconnect OFF.
Installation Overview of the Temperature Controller Settings The basic program settings for each temperature Table 1. Graco Factory P, I, and d Settings controller satisfy most application needs. These set- Category Unit Voltage tings are preset at the factory, but can be changed.
3. Select a drum containing solvent that can dissolve, starts to move up. clean, and eliminate the factory-test oil from the system. If necessary, check with Graco or the ma- d. When the follower plate is above the height of terial supplier for a recommended solvent.
Installation Initial Material Loading CAUTION WARNING To help avoid damage to equipment, do not use a drumpail of material that has been dented or other- The material and equipment will be wise damaged; damage to the follower wipers may hot! To reduce risk of injury, wear eye result.
Operation Pressure Relief Procedure This procedure describes how to relieve pressure for the supply unit. Use this procedure whenever you shut off the dispenser/sprayer and before checking or WARNING adjusting any part of the system, to reduce the risk of serious injury.
Operation Daily Start-up Procedure 7. Dispense some material into a waste container. 8. Verify the flow rate is correct; adjust if required. WARNING With the material heated, and the flow rate corrected as necessary, the system is ready for operation. PRESSURIZED FLUID HAZARD To reduce the risk of serious bodily inju- WARNING...
Operation Changing Empty Pails WARNING CAUTION Bursts of material and air will exit the bleed port! To reduce risk of injury or To help avoid damage to equipment, be sure to damage to equipment, wear eye reload the empty supply unit with a full drumpail of protection, gloves and protective clothing material immediately.
Operation Changing Empty Pails Shutdown (continued) 6. Lower the follower into the drumpail: 1. Turn the CONTROL ON switch to OFF. a. Move the ram hand valve lever to the DOWN 2. Turn OFF the main electrical disconnect. position. 3. Move the ram hand valve lever (Fig. 3 on page 21) b.
Operation Reading the Electrical Control Panel Indicators Use the table and Fig. 4 below to read the indicators on the electrical control panel. For information on setting the temperature controllers, see Setting Temperature Controllers in Form# 309100. Light# Indicator: Indicator Meaning: Light is: Power On/...
Operation Resetting the Ground Fault Interrupt Temperature Out of Range Should any of the temperatures go out of the preset This control panel is equipped with a ground fault range for any of the zones, power to the heated interrupt (GFI) circuit breaker (Fig. 6). If the disconnect components is interrupted, and the HIGH switch is ON, but all lights on the electrical control TEMPERATURE ALARM light goes ON.
Operation Flushing Safety WARNING Use fluids and solvents that are chemically compat- ible with the equipment wetted parts. See the Technical Data sections of all the equipment manuals. Always read the material manufacturer’s literature before using fluid or solvent in this pump. 1.
Ram Troubleshooting Problem Cause(s) Solution(s) Ram won’t raise or lower Closed main air valve or clogged air line Open air valve, clear air line Not enough air pressure Increase ram pressure Worn or damaged piston Replace piston. See procedure in Form #310523.
2. Remove the pump from the air motor. Wet-cup leaks Worn throat seal For Therm-O-Flow Mini-5: 1. Tighten wet-cup and/or throat seal packings. 2. Replace wet-cup and/or throat seal packings if tightening does not stop leaking. For Therm-O-Flow 5, replace wet-cup and throat seal packings. 310528...
Air Motor Troubleshooting For additional 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...
Service Ram Service To relieve ram air pressure, follow the procedure below. For more more information about servicing the ram, see Form# 310525, 76 mm (3”) 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.
For information about replacing wires connecting the strapping that covers the clamp. Loosen the clamp follower to the pump, see Form# 310530 or contact by unscrewing the worm gear, then remove the your Graco technical service representative. wiper. Servicing Wipers WARNING 4.
Page 33
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 pages 58 and 59. To replace a sensor: 8. Remove the junction box’s cover. 9. Disconnect the 2 sensor wires from the junction WARNING box.
Service Servicing the Pump/Motor Assembly for 5. Turn off the electrical power to the supply unit. Fol- low all applicable safety procedures and lockout the Check-Mate 800 rules. 6. Turn OFF the main electrical disconnect. For specific information about servicing the Check-Mate 800 pump, see either Form# 308570 or WARNING 310530.
Page 35
6. Remove the 6 screws (170) and washers (160) from the follower adapter. D you re-apply RTV sealant to the pump shrouds before re-assembling them For more information, see Form# 310530, or call your Graco technical support representative. 7. Slide off the follower. 310528...
Page 36
Service 240 Volt Ram Plate Assembly Wiring 9599A Fig. 10 310528...
Page 37
Service 480/575 Volt Ram Plate Assembly Wiring To Ram Junction Box Fig. 11 310528...
Service Servicing the Pump/Motor Assembly for 7. Turn OFF the main electrical disconnect. the Therm-O-Flow Mini-5 Supply Unit WARNING The sections below describe how to: ELECTROCUTION HAZARD D remove the pump lower assembly from the air motor To reduce risk of injury or damage to D re-attach the pump lower assembly to the air motor equipment, make sure the main discon- D remove the follower from the pump lower assembly...
Service Inspection Frequency Removing/Replacing the CB100 Controller See Form# 309100 for instructions on removing and/or Periodically (once a month), inspect the ram guide replacing the temperature controllers on the system. sleeves, rods and cylinders for wear or damage, replace all worn parts. See the Service section of Form# 310523, 310525, 310533 for instructions on replacing worn parts.
Parts Therm-O-Flow Mini-5 Models 918334 (standard), 918337 (PUR), 918340 (Swirl), 918522, and 918532 76 mm (3”) Ram, 15:1 President, w/silicone follower wipers Vent hood exhaust outlet typ. both sides View in direction of arrow A 1/2” npt Material Outlet Ref. Specifications: 918334, 918337, 918340 Pump Air supply: 8.2 bar (120 psi) Pump: 70 Cycles/Min.
Page 42
Parts Model 918334, 76 mm (3”) Ram, Therm-O-Flow 15:1 President, w/silicone follower wipers, 480 VAC Part Description Qty. Part Description Qty. 617321 Assembly, junction box C31203 Kit, blow-off/bleed 918505 Control, air 617325 Follower, TFE coated, heated 20 li- ter (5 gal.) C31197 Kit, hose support 100 918414...
Page 43
Model 918522, 76 mm (3”) Ram, Therm-O-Flow, 15:1 President, w/silicone follower wipers 480 VAC Part Description Qty. Part Description Qty. 617321 Assembly, junction box 918499 Inductor, heated, PTFE 20 liter (5 gal.) 918505 Control, air 100 918414 Base, portable ram 20 liter (5 gal.) C31197 Kit, hose support 130 617330...
Parts Therm-O-Flow 5 Model C59398 76 mm (3”) Ram, 65:1 King, Heated Check-Mate 800, w/silicone follower wipers 1” npt Material Outlet Ref. 8250A Specifications 918344 Pump Air supply: 4.2 bar (60 psi) Pump: 50 Cycles/Min. Max., 4.4 m /min (150 scfm) Max Fluid Working Pressure: 214 bar (3100 psi) max.
Page 50
Parts Model C59398, 76 mm (3”) Ram, 65:1 King, Therm-O-Flow PUR Heated Check-Mate 800, w/silicone follower wipers 480 VAC Part Description Qty. Part Description Qty. 241200 Motor, King 8cm SST 120 617347 Kit, follower blow-off/bleed C31197 Kit, hose support 130 617335 Follower, heated, tfe coated, 20 liter (5 gal.) C19127...
Parts Model C03510, Pump Air Motor Mounting Kit #207647 King Air Motor ref. #C03509 HCM 800- 200 liter (55 gal.) Notes Torque to 81 – 89 N.m (60 – 66 ft-lb) Torque to 196 – 210 N.m (145 – 155 ft-lb) 7990A Part Description...
Parts Model 617318, Vent Hood Kit for use with PUR units 76 mm (3”) outlet typ. Both sides Part Description Qty. Part Description Qty. C56022 Hood, vent 20 liter (5 gal.) C19802 Screw, shc 1/4”–20 x 3/4” C14038 Label C19198 Washer, flat 1/4”...
Parts Model 617334, Proximity Switch Kit (Pump Activity) for use with Therm-O-Flow 5 units 40 50 To pump junction box ref 4 mm (.157”) max. set-up dimension Part Description Qty. Part Description Qty. 617337 Collar, clamp C20874 Seal, conduit 1/2”...
Parts Model 918433, Proximity Switch Kit (Pump Activity) for use with President Pumps 4 mm (.157”) max. set-up dimension main control C31202 ref. s ref 6.35 mm (.25”) 6.1 mm (2.4”) air motor full down stroke ref 5.79 mm (2.28”) set-up dimension 617415 Connecting rod ref (part of...
Parts Model 617325, Heated Follower Plate Kit with smooth bottom for use with President pump assemblies Apply sealer 70 80 item 240 80 70 60 100 90 Apply sealer item 240 Part Description Qty. Part Description Qty. 617396 Adapter, pump/follower C19213 Washer, lock 3/8”...
Parts Model 918499, Heated Follower Plate Kit with finned bottom for use with President pump assemblies 150 160 70, 80 Apply sealer item 240 60, 70, 80 100 90 9527A Apply sealer item 240 Part Description Qty. Part Description Qty. 617396 Adapter, pump/follower C19815 Screw, shc 1/4”–20 x 2”...
Temperature Controller 195764 1711 Solid State Relay (for SSRs 153 & 160) C78082 1752 Timer, 7–day C78167 1772 Timer, Inactivity C78342 1792 For information about other parts, contact your Graco technical support representative. (5) Spares TOTAL (34) Type CA1 310528...
Temperature Controller 195764 1691 Solid State Relay (for SSRs 153 & 160) C78082 1752 Timer, 7–day C78167 1772 1812 Timer, Inactivity C78342 For information about other parts, contact your Graco (3) Spares technical support representative. TOTAL (32) Type CA1 310528...
1641 Solid State Relay (for SSRs 153 & 160) C78082 1661 1662 Timer, 7–day C78167 1711 Timer, Inactivity C78342 1752 1772 For information about other parts, contact your Graco 1972 technical support representative. (3) Spares (36) Total Type CA1 310528...
Accessories Use Only Genuine Graco Parts and Accessories Description Part No. HEATED 5-GALLON FOLLOWER PLA TE ASSEMBLY Used for 240, 480, 575 VAC. 305 mm (12”) O.D. Silicone Wiper hose CM800 Heated Module finned bottom 918501 15:1 President finned bottom...
Dimensions Ram Mounting and Clearance Dimensions for Therm-O-Flow 5 610 mm (24.0”) 559 mm (22.0”) 406 mm 457 mm (16.0”) (18.0”) (4 X) Φ13.46 mm (0.53”) 1470 mm 1842 mm (57.9”) (72.5”) 310528...
Dimensions Ram Mounting and Clearance Dimensions w/15:1 President Air Motor 610 mm (24.0”) 559 mm (22.0”) 406 mm 457 mm (16.0”) (18.0”) (4 X) Φ13.46 mm (0.53”) 1203 mm 1666 mm (47.4”) (65.6”) 310528...
Page 80
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”) 310528...
Page 81
Ram Mounting and Clearance Dimensions 937 mm 736 mm (36.9 ”) (29.0 ”) 635 mm 533 mm (25 .0”) (21.0 ”) 1067 mm. (42.0 ”) 1168 mm. (46.0 ”) 2748 mm. (108.2 ”) 1732 mm (68.2 ”) 310528...
Wetted parts (ram) Carbon steel, aluminum, nitrile, nylon, nickel plating Wetted parts (pump) See Form# 308570 for Therm-O-Flow 5 units Call Technical Service for Therm-O-Flow Mini-5 units Floor space dimensions (w/vent hood) 914 mm wide x 610 mm deep (36” x 24”)
308570 Heated Check-Mate 800 Pump Modules 310530 Mini–5 Hot Melt 15:1 Ratio President Pump 307431 Hydraulic Power Supply 307550 Check-Mate, King, Mini-5, and President are trademarks of Graco, Inc. Bulldog, Senator, and Therm-O-Flow are registered trademarks of Graco, Inc. 310528...
Appendix Older Style (E5KC) Temperature Controller Setup, Function Mode Parameter Names Settings List Input type Level 0, Function Mode Parameter Names _C/_F selection Set point Parameter initialize Run/Stop Control output 1 assignment Level 1, Function Mode Parameter Names Control output 2 assignment Auto-tuning Execute/Cancel Auxiliary control 1 assignment Alarm value 1...
Graco distributor to the original purchaser for use. 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.