Graco Therm-O-Flow Series Operation manual

310538N
EN
Instructions-Parts List
Therm-O-Flow®
Automatic Dispense Valves
Air-operated dispense valves. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Model 918483 Shown

Table of Contents
2310538N
Table of Contents
List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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

Warnings
310538N 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
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in serious injury.
• This equipment is for professional use only.
• Read all instruction manuals, warnings, tags, and labels before operating the equipment.
• Use the equipment only for its intended purpose. If you are uncertain, call your Graco distributor.
• Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
• Check the equipment daily. Repair or replace worn or damaged parts immediately.
• Do not exceed the maximum air working pressure of 1 MPa (10 bar, 150 psi) to the applicator.
• Do not exceed the maximum fluid working pressure of 24 MPa (241 bar, 3500 psi) to the applicator or
manifold.
• Never exceed the recommended working pressure or the maximum air inlet pressure stated on your
pump or in the Technical Data on page 47.
• Be sure that all spray/dispensing equipment and accessories are rated to withstand the maximum
working pressure of the pump. Do not exceed the maximum working pressure of any component or
accessory used in the system.
• Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not expose Graco standard hoses to temperatures above 180F (82C) or below –40F (–40C). Do
not expose Graco electrically heated hoses to temperatures above 400F (222C) or below –40F
(–40C).
• Do not expose Graco standard hoses to temperatures above 180F (82C) or below –40F (–40C).
• Do not use the hoses to pull the equipment.
• Use 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.
• Always wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid and
solvent manufacturers.
• Wear hearing protection when operating this equipment.
• Comply with all applicable local, state and national fire, electrical and other safety regulations.
INSTRUCTIONS

Warnings
4310538N
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.
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.
• Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-
cal treatment.
• Do not point the applicator at anyone or at any part of the body.
• Do not put hand or fingers over the front of the applicator.
• Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
• Follow 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.
• Tighten all the fluid connections before operating the equipment.
• Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
• ALWAYS wear eye protection and protective clothing when installing, operating, or servicing this dis-
pensing equipment.
• Do not remove or modify any part of the applicator; this can cause a malfunction and result in serious
bodily injury.
• Use 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.
• NEVER wipe off build-up around the tip or air cap until pressure is fully relieved.

Warnings
310538N 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.
• Ground 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.
• Ground 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.
• Do not use this equipment with flammable liquids.
• Keep the dispense area free of debris, including solvent, rags, and gasoline.
• If there is any static sparking or you feel an electric shock while using the equipment, stop dispens-
ing immediately. Do not use the equipment until you have identified and corrected the problem.
• Make sure all electrical work is performed by a qualified electrician only.
• Have any checks, installation, or service to electrical equipment performed by a qualified electrician
only.
• Make sure all electrical equipment is installed and operated in compliance with applicable codes.
• Make sure power is disconnected when servicing and repairing equipment.
• Before operating the equipment, extinguish all open flames or pilot lights in the dispense area.
• Do not smoke in the dispensing area.
• Keep liquids away from the electrical components.
• Disconnect electrical power at the main switch before servicing the equipment.
• Never 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.
• Provide fresh air ventilation to avoid the buildup of vapors from the fluid being dispensed.
• 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.
• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
• Avoid exposure to heated material fumes.

Installation
6310538N
Installation
Install the automatic applicator as follows:
• mount the automatic dispense valve
• attach dispense tip, nozzle, or swirl
• connect the air lines
• connect material hose
• connect the electrical cable
• make 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
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

Installation
310538N 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
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

Installation
8310538N
Installation
Connect Air Lines to 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).
FIG. 5
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.
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 fittings
could melt and cause damage to the automatic
dispense valve.
Snuff-Back Valve Shown

Installation
310538N 9
Installation
Grounding Ground the automatic dispense valve:
1. Connect the connector from a heated hose to the
receptacle on the dispense valve.
FIG. 6
FIG. 7
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 connected to
true earth ground.
WARNING
FIRE, EXPLOSION, AND ELECTRIC
HAZARD
To reduce the risk of fire, explosion, or
electric shock:
• The power source conduit is not an ade-
quate ground for the system. The unit must
be grounded to either the building ground or
a true earth ground.
• A qualified electrician must complete all
grounding and wiring connections and check
the resistance.
• Refer to your local code for the require-
ments for a “true earth ground” in your area.
• Also read and follow the warnings on page
5.
Ground lead
coming from pin
E is fastened to
the bracket.
Ground lead
coming from con-
tact 8 to true
earth ground.

Troubleshooting
10 310538N
Troubleshooting
Some solutions require disassembling the automatic dispense valve. Always relieve system pressure before
performing these procedures.
See PARTS section for the parts that need to be serviced.
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow
the Pressure Relief Procedure (page 11).
Problem Cause(s) Solution(s)
Air leaks from automatic dispense
valve
Loose air connections Check air connections.
Worn o-rings Replace o-rings (90) and (100) in cylinder
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 necessary.
Material leaks from automatic dispense
valve body
Seal not installed correctly Check seal (70) and replace if necessary.
Seal is worn
Automatic dispense valve
does not shut off
Loose air connections Check air connections.
Worn needle-seal interface Check and replace, if necessary, needle
(140), rod seal (150), spacer (160), and
retaining ring (170).
If replacing needle, you must disassemble
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 does not
heat material
Loose heater wires Check and reconnect wire connections.
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.