Graco Therm-O-Flow 194485 Operation manual

Instructions–Parts List
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Therm–O–FlowR
Automatic Dispense Valves
Air–operated dispense valves. For professional use only.
Model 918483 Shown
310538L
ENG

2 310538
Table of Contents
List of Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 48. . . . . . . . . . . . . . . . . . . . . .
Graco Information 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Models
Valve
Type Part No. Type Voltage / No. of Pins Maximum Fluid Working Pressure Maximum Air Input Pressure Parts Page
TOF 194485 Snuff Back 120 V / 6 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 20
TOF 918483 Snuff Back 120 V / 6 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 22
918512 Snuff Back Ambient 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 24
TOF 918639 Snuff Back 120 V / 6 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 26
TOF+ 243694 Base Seal 240 V / 8 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 28
TOF 200 297266 Snuff Back Swirl 240 V / 8 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 30
TOF+ 243695 Base Seal H.F. 240 V / 8 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 31
TOF+ 243696 Snuff Back 240 V / 8 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 33
TOF C27340 Base Seal Ambient 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 35
TOF C34068 Base Seal 120 V / 6 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 37
TOF C34079 Base Seal 120 V / 6 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 39
TOF C50592 Base Seal 120 V / 6 241 bar, 24 MPa (3500 psi) 10 bar, 1 MPa (150 psi) 41

310538 3
Warnings
The following Warnings are for the safe setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure–specific risks.
Refer back to these Warnings. Additional product–specific warnings may be found throughout the body of this
manual where applicable.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, warnings, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain, call your Graco distribu-
tor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck the equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum air working pressure of 1 MPa (10 bar, 150 psi) to the applicator.
DDo not exceed the maximum fluid working pressure of 24 MPa (241 bar, 3500 psi) to the
applicator or manifold.
DNever exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 47.
DBe sure that all spray/dispensing equipment and accessories are rated to withstand the maxi-
mum working pressure of the pump. Do not exceed the maximum working pressure of any
component or accessory used in the system.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces.
DDo not expose Graco standard hoses to temperatures above 180_F (82_C) or below –40_F
(–40_C). Do not expose Graco electrically heated hoses to temperatures above 400°F
(222°C) or below –40_F (–40_C).
DDo not expose Graco standard hoses to temperatures above 180_F (82_C) or below –40_F
(–40_C).
DDo not use the hoses to pull the equipment.
DUse only fluids and solvents that are compatible with the equipment wetted parts. See the
Technical Data sections of all the equipment manuals. Read the fluid manufacturer’s warnings.
DAlways wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid
and solvent manufacturers.
DWear hearing protection when operating this equipment.
DComply with all applicable local, state and national fire, electrical and other safety regulations.

4 310538
WARNING
HOT SURFACE AND FLUID HAZARD
Heated fluid can cause severe burns and can cause equipment surfaces to become very hot.
DWear protective gloves and clothing when operating this equipment in a heated system.
DDo not touch the metal heat sink when the surface is hot.
DAllow the equipment to cool thoroughly before servicing.
Some heated systems are designed to dispense Polyurethane (PUR) heated materials. PUR
systems are supplied with ventilation hoods, and require proper ventilation and specially designed
system components.
SKIN INJECTION HAZARD
Spray from the applicator, hose leaks, or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on
the skin can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
surgical treatment.
DDo not point the applicator at anyone or at any part of the body.
DDo not put hand or fingers over the front of the applicator.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DFollow the Pressure Relief Procedure on page 11 whenever you are instructed to: relieve
pressure; stop dispensing; clean, check, or service the equipment; or install or clean a tip or
nozzle.
DTighten all the fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immedi-
ately. Permanently coupled hoses cannot be repaired; replace the entire hose.
DALWAYS wear eye protection and protective clothing when installing, operating, or servicing this
dispensing equipment.
DDo not remove or modify any part of the applicator; this can cause a malfunction and result in
serious bodily injury.
DUse extreme caution when cleaning or changing tips. If the tip clogs while applying material,
ALWAYS follow the Pressure Relief Procedure on page 11, then remove the tip to clean it.
DNEVER wipe off build-up around the tip or air cap until pressure is fully relieved.

310538 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 or explosion and serious injury.
DGround the equipment and the object being sprayed. The Automatic Dispense Valve is
grounded through proper connection of pin E inside the electrical control panel to truth earth
ground inside the electrical control panel. See Grounding on page 9.
DGround the equipment and the object being sprayed, and all other electrically conductive
objects in the dispense area. Proper grounding dissipates static electricity generated in the
equipment. See Grounding on page 9.
DDo not use this equipment with flammable liquids.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.
DIf there is any static sparking or you feel an electric shock while using the equipment, stop dis-
pensing immediately. Do not use the equipment until you have identified and corrected the
problem.
DMake sure all electrical work is performed by a qualified electrician only.
DHave any checks, installation, or service to electrical equipment performed by a qualified electri-
cian only.
DMake sure all electrical equipment is installed and operated in compliance with applicable
codes.
DMake sure power is disconnected when servicing and repairing equipment.
DBefore operating the equipment, extinguish all open flames or pilot lights in the dispense area.
DDo not smoke in the dispensing area.
DKeep liquids away from the electrical components
DDisconnect electrical power at the main switch before servicing the equipment.
DNever exceed maximum wattage of the supply unit.
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
DProvide fresh air ventilation to avoid the buildup of vapors from the fluid being dispensed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all
local, state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
DAvoid exposure to heated material fumes.

6 310538
Installation
Install the automatic applicator as follows:
Dmount the automatic dispense valve
Dattach dispense tip, nozzle, or swirl
Dconnect the air lines
Dconnect material hose
Dconnect the electrical cable
Dmake sure the automatic dispense valve is
grounded
Mount the Automatic Dispense Valve
Mount the automatic dispense valve to the mounting
bracket on a stationary support or robotic arm (Fig. 1),
using two socket head screws (300) and two flat
washers (50). Be sure to position the insulation
block (280) and insulation tape (290) between the
dispense valve and the mounting bracket.
Fig. 1
A
50
300
280
290
Attach Dispense Tip, Nozzle, or Swirl
Attach a dispense tip and a nozzle adapter, or a nozzle
adapter alone, to the automatic dispense valve.
Dispense Tip and Nozzle Adapter Attachment
Attach dispense tip (B) to the automatic dispense
valve.
1. Select a nozzle adapter (C) and a dispensing
tip (B).
2. Install the tip and then use the nozzle adapter (C)
to secure the tip to the seat adapter (D).
Fig. 2
B
C
D

310538 7
Installation
Nozzle Attachment
Attach a nozzle (C) to the automatic dispense valve.
1. Select a nozzle.
2. Install nozzle adapter (C) on the seat adapter (D).
3. Install nozzle in nozzle adapter (E).
Fig. 3
C
D
E
Swirl Nozzle Attachment
1. Install swirl adapter (C) on seat adapter (D).
2. Install swirl applicator head (E).
3. Install swirl nozzle (F).
Fig. 4
C
D
F
E

8 310538
Installation
Connect Air Lines to Dispense Valve
CAUTION
Only use air fittings that are rated at a temperature
equal to or higher than the operating temperature of
your fluid dispensing system. Lower rated air fit-
tings could melt and cause damage to the automat-
ic dispense valve.
These valves are air to open and air to close with a
spring to bias them closed. Use a 4–way exhausting
solenoid to operate these valves.
Making sure to connect the appropriate air lines to the
appropriate ports (see Fig. 5), securely connect air
lines to dispense valve air ports (G).
Connect Material Hose to Dispense Valve
Securely connect the material hose to the dispense
valve material inlet port (A). See Fig. 5.
Connecting Electrical Cable to Dispense
Valve
Connect electrical cable plug from your Therm–O–
Flow or Therm–O–Flow Plus hose or control.
Fig. 5
A
1/2” npt
G
360
open
close
1/8” npt
1/8” npt
Snuff–Back Valve Shown

310538 9
Installation
Grounding
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock:
DThe power source conduit is not an ad-
equate ground for the system. The unit
must be grounded to either the building
ground or a true earth ground.
DA qualified electrician must complete
all grounding and wiring connections
and check the resistance.
DRefer to your local code for the requirements for
a “true earth ground” in your area.
DAlso read and follow the warnings on page 5.
Ground the automatic dispense valve:
1. Connect the connector from a heated hose to the
receptacle on the dispense valve.
Fig. 6
Ground lead
coming from pin
E is fastened to
the bracket. A
E
B
F
C
D
Fig. 7
Ground lead
coming from con-
tact 8 to true
earth ground.
TI0305
67
5
4
12
3
2. Connect the electrical cable to the electrical control
panel.
3. Verify that socket contact E on six pin models (see
Fig. 5) or contact eight on eight pin models (see
Fig. 7) , inside control panel receptacle, is con-
nected to true earth ground.

10 310538
Troubleshooting
Some solutions require disassembling the automatic dispense valve. Always relieve system pressure before per-
forming these procedures.
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow
the Pressure Relief Procedure (page 11).
See PARTS section for the parts that need to be serviced.
Problem Cause(s) Solution(s)
Air leaks from automatic dis-
l
Loose air connections Check air connections.
pense valve Worn o-rings Replace o-rings (90) and (100) in cylin-
der base.
Worn ring Replace ring (110) in cylinder base.
Material leaks from front of
automatic dispense valve
Seal, spacer or retaining ring is worn Replace rod seal (150), spacer (160),
and retaining ring (170).
Obstruction inside dispense valve Remove seat adapter (10). Check and
replace if necessary, rod seal (150),
spacer (160), and retaining ring (170).
Worn needle Check and replace needle (140), if
necessary.If replacing needle, you must
disassemble dispense valve.
Worn seat (Base seal models) Check and replace seat (10) if neces-
sary.
Material leaks from automatic
di l b d
Seal not installed correctly Check seal (70) and replace if neces-
dispense valve body Seal is worn sary.
Automatic dispense valve
does not shut off
Loose air connections Check air connections.
does not shut off Worn needle-seal interface Check and replace, if necessary, needle
(140), rod seal (150), spacer (160), and
retaining ring (170).
retaining
ring
(170)
.
If replacing needle, you must disas-
semble dispense valve
Automatic dispense valve
does not shut off
Worn spring-piston interface Disassemble dispense valve. Check
and replace, if necessary, needle (140),
and spring (370).
Automatic dispense valve
does not shut off
Spring broken or not installed correctly Disassemble dispense valve. Check
and replace, if necessary, needle (140),
and spring (370).
Automatic dispense valve
dthttil
Loose heater wires Check and reconnect wire connections.
does not heat material Loose sensor wires Check and reconnect wire connections.
Heater unit failed Replace heater. See page 17.
Sensor failed Replace sensor. See page 17.
Temperature controller failed Replace temperature controller.
No power to heating circuitry Apply power to heating circuitry.