Graco Therm-O-Flow 55-H Operation manual

310–534
Rev. B
Supersedes Rev. A
Model 918–452
1
310–534
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
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 V AC,
Therm-O-Flow Pump Module,
Hydraulic Power Supply
918–453
Silicone Follower Wipers,
65:1 King  , 480 V AC,
Therm-O-Flow Pump Module,
Hydraulic Power Supply
918–480
Silicone Follower Wipers,
31:1 Bulldog, 240 V AC,
Therm-O-Flow Pump Module,
Hydraulic Power Supply
GRACO INC. 47700 HALY ARD DR. PL YMOUTH, MI 48170
COPYRIGHT 1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

2310–534
Table Of Contents
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a Location for the Ram and
Hydraulic Power Supply 8. . . . . . . . . . . . . . . . . . . . .
System Accessories and Modules 8. . . . . . . . . . . .
Installation 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Ram and Hydraulic
Power Supply 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrically Connect Hose to the
Electrical Control Panel 10. . . . . . . . . . . . . . . . . . . . .
Ground The System 11. . . . . . . . . . . . . . . . . . . . . . .
Connecting the Electrical Control Panel
to a Power Source 12. . . . . . . . . . . . . . . . . . . . . . . . .
Check the Resistance Between the
Supply Unit and the T rue Earth Ground 12. . . . . . .
Checking Resistance of Electrical
Components 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Electrical Control Panel Controls 15. . . . . .
Starting Up the System 18. . . . . . . . . . . . . . . . . . . . .
Initial Material Loading 19. . . . . . . . . . . . . . . . . . . . .
Operation 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 20. . . . . . . . . . . . . . . . . .
Raising and Lowering the Ram 20. . . . . . . . . . . . . .
Daily Start-up Procedure 21. . . . . . . . . . . . . . . . . . .
Changing Empty Drums 23. . . . . . . . . . . . . . . . . . . .
Shutdown 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading the Electrical Control Panel
Indicators 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting the Ground Fault Interrupt 27. . . . . . . . .
Flushing Safety 28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ram and Hydraulic Power Supply
Troubleshooting 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ram Service 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing a Material Drum from
the Supply Unit 34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Follower 35. . . . . . . . . . . . . . . . . . . . . .
Removing/Re-installing the Pump
from the Ram 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separating the Pump from the Air Motor 38. . . . . .
Re-attaching the Air Motor to the Pump 38. . . . . . .
Removing the Follower from the Pump 38. . . . . . .
For 240 V AC Supply Units 39. . . . . . . . . . . . . . . . . .
For 480/575 V AC Supply Units 40. . . . . . . . . . . . . .
Inspection Frequency 41. . . . . . . . . . . . . . . . . . . . . .
Parts 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 918–452 (480 V ac),
918–480 (240 V ac) 43. . . . . . . . . . . . . . . . . . . . . . . .
Model 918–453, Therm-O-Flow , 480 V ac 45. . . . .
Model 918–510, Hydraulic Power Supply 47. . . . .
Model 918–425, Ram Air Control Module 49. . . . .
Model 918–395, Heavy Duty Drum Clamp 51. . . .
Model C32434, Pump Mounting Kit 52. . . . . . . . . .
Model C03510, Pump Air Motor Mounting Kit 53. .
Model C32451, Vent Hood Kit 54. . . . . . . . . . . . . . .
Model C32435, Heated Follower Plate Kit,
Standard Finned Bottom 55. . . . . . . . . . . . . . . . . . . .
Model 918–470, Heated Follower Plate Kit,
Smooth Bottom 57. . . . . . . . . . . . . . . . . . . . . . . . . . .
6-zone Electrical Control Panel 59. . . . . . . . . . . . . .
Electrical Control Panel and Wiring for
C32428 (240 V AC) 60. . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Control Panel and Wiring for
C32429 (480 V AC) 66. . . . . . . . . . . . . . . . . . . . . . . .
Accessories 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ram Mounting and Clearance Dimensions 72. . . .
Hydraulic Power Supply Mounting and
Clearance Dimensions 73. . . . . . . . . . . . . . . . . . . . .
Electrical Control Panel Mounting and
Clearance Dimensions 74. . . . . . . . . . . . . . . . . . . . .
Technical Data 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications 75. . . . . . . . . . . . . . . . . . . . . . . . .
Graco W arranty and Limitation of Liability 76. . . . .
Graco Phone Numbers 76. . . . . . . . . . . . . . . . . . . . . . .

3
310–534
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the corresponding
instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in serious injury .
D
This equipment is for professional use only .
D
Read all instruction manuals, warnings, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are uncertain about usage, call Graco
T echnical Assistance at 313–416–3425.
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 .
D
Do not exceed 0.7 MPa (7 bar) (100 psi) maximum inbound air pressure to the hydraulic power
supply’ s air motor .
D
Do not exceed 0.7 MPa (7 bar) (100 psi) maximum inbound air pressure to the hydraulic power
supply’ s air valve.
D Do not exceed 1.6 MPa (16 bar) (225 psi) maximum inbound hydraulic pressure to the ram.
D Do not exceed 0.7 MPa (7 bar) (100 psi) maximum inbound air pressure to the material pump.
D Never exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the T echnical Data on page 75.
D Be 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.
D 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.
D Use fluids and solvents that are chemically compatible with the equipment wetted parts. See
the T echnical Data sections of all the equipment manuals. Always read the material manufac -
turer’
s literature before using fluid or solvent in this pump.
D Always wear protective eyewear , gloves, clothing, and respirator as recommended by the fluid
and solvent manufacturers.
DW ear hearing protection when operating this equipment.
D Comply with all applicable local, state and national fire, electrical and other safety regulations.
D Read the Material Safety Data Sheet for Hydraulic Fluid, Form# 307–766, and follow all applica -
ble safety warnings for handling, use, and disposal of hydraulic fluid.

4310–534
WARNING
HOT SURFACE AND FLUID HAZARD
Heated fluid can cause severe burns and can cause equipment surfaces to become very hot.
DW ear 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.
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.
INJECTION HAZARD
Spray from the spray gun, hose leaks, or ruptured components can inject fluid into your body and
cause extremely serious injury , including the need for amputation. Splashing fluid in the eyes or on
the skin can also cause serious injury .
D Fluid injected into the skin might look like just a cut, but it is a serious injury . Get immediate
medical attention.
D
Do not point the gun/valve at anyone or at any part of the body .
D
Do not put your hand or fingers over the spray tip/nozzle.
D Do not stop or deflect fluid leaks with your hand, body , glove, or rag.
D Always have the trigger guard on the gun when dispensing.
D Check the gun dif fuser operation weekly . Refer to the gun manual.
D Check
the
gun
dif fuser
operation
weekly
.
Refer
to
the
gun
manual
.
D Be sure the gun/valve trigger safety operates before dispensing.
D Lock the gun/valve trigger safety when you stop dispensing.
D Follow the Pressure Relief Procedure on page 20 if the nozzle clogs, and before cleaning,
checking or servicing the equipment.
DT ighten all fluid connections before operating the equipment.
D Check the hoses, tubes, and couplings daily . Replace worn, damaged, or loose parts immedi -
ately
. Do not repair high pressure couplings; you must replace the entire hose.

5
310–534
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 sprayed, and all other electrically conductive objects in
the dispense area. Proper grounding dissipates static electricity generated in the equipment.
See Ground the System on page 1 1.
D
Do not use this equipment with flammable liquids.
D Keep the dispense area free of debris, including solvent, rags, and gasoline.
D If 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.
D
Make sure all electrical work is performed by a qualified electrician only .
D
Make sure all electrical equipment is installed and operated in compliance with applicable
codes.
D
Make sure power is disconnected when servicing and repairing equipment.
D Have any checks, installation, or service to electrical equipment performed by a qualified electri -
cian only .
D
Never exceed the maximum wattage of the supply unit. See the wiring diagrams in this manual
for more information.
D Only use hoses that have a maximum wattage less than or equal to 1250 watts. Using hoses
with higher maximum wattage could create a runaway temperature condition.
MOVING P ARTS HAZARD
Moving parts, such as the ram follower plate/pump inlet can pinch or amputate fingers.
D Do not operate the equipment with the guard removed.
D Keep clear of all moving parts when starting or operating the equipment.
D Keep hands and fingers away from the priming piston during operation and whenever the pump
is charged with air .
D
Keep clear of the follower plate, pump fluid inlet, and lip of the fluid container when raising or
lowering the ram.
D Before checking or servicing the ram or pump, follow the Pressure Relief Procedure on
page 20.

6310–534
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.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all
local, state and national guidelines.
D Always wear protective eyewear , gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer .
DA
void exposure to heated material fumes.
D Provide adequate ventilation.

7
310–534
Typical Installation
A Air Line Filter
B Lock-out Master Air V alve (bleed-type)
(required)
C
Pump Bleed-T ype Master Air V alve (required)
D
Pump Air Regulator
E Main Air Line Supply
F Electrical Control Panel
G Follower Plate Bleed Stick
H Pump Air Supply Hose
I Air Line Lubricator
J Pump Mounting Bracket
K Fluid Regulator (compensator)
L Heated Hose
M Hose Hanger
N Follower Blow-of f V alve
O
Ram Air Regulators
P Follower Rod
Q Pump Assembly
R Ram Hand V alve
S
Ram Module
T Automatic Dispense V alve
U
Heated Follower Plate Assembly
V Wipers
W
Drum Clamp
X Hydraulic Power Supply
Fig. 1
Therm-O-Flow Supply Unit Model 918–452 shown with Hydraulic Powered Ram Module
(918–420), Hoses, Fluid Regulator, and Dispense Valve
A
B
C
D
E
F
G
H
I
J
K
L
L
M
N
O
P
Q
R
S
T
U
VW
X

8310–534
Typical Installation
The typical installation discussed below is only a guide
for selecting and installing system components and
accessories. Contact your Graco representative or
Graco T echnical Assistance for help in designing a
system to suit your particular needs.
This hydraulic-powered ram extruder forces high
viscosity fluids into the intake valve of the fluid pump.
Wiper rings and other accessory equipment for use
with this ram are listed in the Accessories section on
page 71.
Selecting a Location for the Ram and
Hydraulic Power Supply
For information about the dimensions of the ram and
hydraulic power supply , refer to the mounting and
clearance dimension drawings, Figs. 36 and 37 on
pages 72 and 73.
When selecting a location for the ram, keep the follow -
ing in mind:
1. There should be suf ficient space for installing and
using the equipment.
D Make sure there is suf ficient overhead clear -
ance for the pump and ram when the ram is in
the fully raised position.
D If you are installing a vent hood, make sure
there is suf ficient horizontal clearance for it.
D Make sure the air regulators for the pump and
ram are fully accessible.
D Make sure there is easy and safe access to an
appropriate electrical power source. The
National Electrical Code requires 3 feet of
open space in front of the electrical panel.
D Locate the hydraulic power supply in an area
that:
–
has easy access for servicing and adjust -
ing the hydraulic pressure on the supply
unit
–
has suf ficient clearance for the hydraulic
lines that you will attach to the pump
– will allow you to easily read the hydraulic
fluid level gauge
2. Make sure that you will be able to level the base of
the ram using metal shims.
3. When you bolt the ram to the floor, the anchors
should be long enough to prevent the unit from
tipping. Refer to the Dimensional Drawing on
page 72 for more information.
4. If you are installing a vent hood, make sure the
ram is installed near a connection to the factory
ventilation system.
5. Place the hydraulic power supply so there is easy
access for servicing the unit.
System Accessories and Modules
Before you install the system you should be familiar
with the parts discussed below . For more information,
refer to Fig. 1, A T ypical Installation, on page 7.
Air and Fluid Hoses
WARNING
FIRE HAZARD
Only use hoses that have a maximum
wattage less than or equal to 1250
watts. Using hoses with higher maximum wattage
could create a runaway temperature condition.
The Therm-O-Flow 55-H unit was designed for use
with single-circuit material hoses that are rated at a
maximum of 1250 watts. For information about using
material hoses with higher wattages, contact your
Graco technical support representative.
When installing a system, make sure:
D all air and fluid hoses are properly sized for your
system.
D
to use only electrically conductive air and fluid
hoses.

9
310–534
Typical Installation
Air Line Modules
WARNING
PRESSURIZED FLUID HAZARD AND
MOVING P ARTS HAZARD
The bleed-type master air valve (C) is
required in your system to relieve air
trapped between this valve and the
pump after the pump air regulator is
closed. T rapped air can cause the pump
to cycle unexpectedly , which could result
in serious bodily injury , including splashing in the
eyes or on the skin and injury from moving parts.
4-Regulator Air Control Modules (918–425) (shown)
See the T ypical Installation drawing (Fig. 1) and Fig. 2.
The following components are included with the mod -
ule:
D
Bleed-type Lock-out Master Air Valve (B) is used to
shut of f and lock out the air supply from the entire
supply unit.
D Pump Bleed-type Master Air V alve (C) is required in
your system to relieve air trapped between it and
the air motor when the valve is closed (see the
Pressurized Fluid Hazard And Moving Parts
Hazard W ARNING above). This bleed valve
should be easily accessible and located down -
stream from the air regulator . It can be used for a
safety lockout.
O
BC
AID
Fig. 2
N
D Pump Air Regulator (D) controls pump speed and
outlet pressure by adjusting the air pressure to the
pump. It is located on the air control panel up -
stream from the bleed-type master air valve.
D Ram Air Regulators (O) control the air pressure to
the hydraulic power supply that controls ram move -
ment. There are separate air regulators to control
the ram pressure in the up and down directions.
D Hydraulic Power Supply (X) controls the ram’ s
movement.
D
Follower Blow-of f V alve (N) controls the air pres -
sure to the follower blow-of f.
D
FRL (filter , regulator , lubricator) (A), (D), and (I)
conditions the air to the ram and the pump. The
pump air regulator is located in this assembly . The
ram air is taken from this assembly; an air line tube
connects the FRL and the ram air control module.
Air Line Accessories
D Pump runaway valve senses when the pump is
running too fast and automatically shuts of f the air
to the motor . A pump that runs too fast can be
seriously damaged.
D Accessory bleed-type air valve isolates the air line
accessories for servicing. Locate upstream from all
other air line accessories. This isolates the acces -
sories for servicing.
Vent Hood Kit
The vent hood assembly is designed to ef ficiently draw
fumes to the factory exhaust system during drum
change-out. This assembly requires connection to a
factory ventilation system that draws a minimum air
flow of 8.4 m
3
/min (300 scfm). This kit is required for
Polyurethane Reactive (PUR) applications.
Hydraulic Power Supply Module
The hydraulic power supply module delivers up to
39 liters per minute (10 gpm) at 66 cycles per minute
for moving the ram cylinder rods.

10 310–534
Installation
The installation procedure includes:
D locating and installing the ram and hydraulic power
supply . See Form#310–533 for installation informa -
tion.
D
electrically connecting hoses to the electrical con -
trol panel
D grounding the system
D connecting the electrical control panel to a power
source
D checking resistance
D setting controls on the electrical control panel
D starting up the system
D initially loading material
Installing the Ram and Hydraulic Power
Supply
To install the ram and hydraulic power supply , follow
the installation procedure in Form# 310–533, Hydraulic
Powered Ram Modules. See the ram mounting and
clearance dimensions drawing (Fig. 36 on page 72) for
ram mounting and clearance dimensions. See the
hydraulic power supply dimensions drawing (Fig. 37 on
page 73) for hydraulic power supply clearance dimen -
sions.
Electrically Connect Hoses to the
Electrical Control Panel
WARNING
FIRE HAZARD
Only use hoses that have a maximum
wattage less than or equal to 1250
watts. Using hoses with higher maximum wattage
could create a runaway temperature condition.
Assemble the hose and gun components as needed.
For information on connecting the hose and gun com -
ponents, follow the gun’s instructions.
Electrically connect the hoses to the electrical control
panel. The connectors are located on the back of the
electrical control panel (Fig. 3).
1. Connect the plug from hose 1 to the Hose 1/Gun 1
receptacle (1).
2. Connect the plug from hose 2 to the Hose 2/Gun 2
receptacle (2).
Fig. 3
Rear V iew of Electrical Control Box
1
2