Graco Therm-O-Flow 20 Parts list manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001
309858K
Instructions - Parts
Therm-O-Flow®20
Used to handle abrasive, high-viscosity hot melt sealants and adhesives.
Air-Powered Ram Heated Pail Unloaders
5 gallon (20 liter) pail size, 3 in. (76 mm) dual post ram
Read warnings and instructions.
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

2309858K
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Publications . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 7
Accessories and Modules . . . . . . . . . . . . . . . . . . 7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Control Panel . . . . . . . . . . . . . . . . . . . . 9
Check Resistance . . . . . . . . . . . . . . . . . . . . . . . 10
Temperature Controller Settings . . . . . . . . . . . . 11
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Loading Material . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Relief Procedure . . . . . . . . . . . . . . . . 14
Raising and Lowering Ram . . . . . . . . . . . . . . . . 14
Daily Start-up Procedure . . . . . . . . . . . . . . . . . . 15
Changing Empty Pails . . . . . . . . . . . . . . . . . . . . 16
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . 21
Ram Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Follower Service . . . . . . . . . . . . . . . . . . . . . . . . 22
Check-Mate 800 Pump/Motor Service . . . . . . . . 23
President Pump/Motor Service . . . . . . . . . . . . . 28
Inspection Frequency . . . . . . . . . . . . . . . . . . . . 29
Removing/Replacing CB100 Controller . . . . . . . 29
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 48
Part No. 617485 . . . . . . . . . . . . . . . . . . . . . . . . 52
Part No. 617349 . . . . . . . . . . . . . . . . . . . . . . . . 54
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Temperature Controller Settings . . . . . . . . . . . . . 64
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 66
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 66

Models
309858K 3
Models
Related Publications
Manual Conventions
Warning Caution
Note
Part Number Motor/Pump Ratio
Max. Fluid Working
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 page 30
918344 Bulldog®/Check-Mate™800 31:1 3100 psi (21 MPa, 214 bar) 480 VAC page 32
918437 Bulldog®/Check-Mate™800 31:1 3100 psi (21 MPa, 214 bar) 240 VAC page 32
C59398 King™65:1 5850 psi (40 MPa, 403 bar) 480 VAC page 34
234965 King™(no control) 65:1 5850 psi (40 MPa, 403 bar) 480 VAC page 34
Equipment Manual No.
President®Air Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306982
Bulldog®Air Motor (31:1) . . . . . . . . . . . . . . . . . . . . . . . . . 307049
King™Air Motor (65:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 309347
Air-powered Ram Module, 5 gal. (20 liter), 3 in. (76 mm) 310525
Check-Mate™800 Displacement Pump . . . . . . . . . . . . . . 308570
Heated Check-Mate™800 Pump Modules . . . . . . . . . . . . 310530
Hot Melt 15:1 President®Pump . . . . . . . . . . . . . . . . . . . . 307431
WARNING
A warning alerts you to the possibility of serious injury
or death if you do not follow the instructions.
Symbols, such as fire and explosion (shown), alert you
to a specific hazard and direct you to read the indi-
cated hazard warnings (pages 4-5) for detailed infor-
mation.
CAUTION
A caution alerts you to the possibility of damage to or
destruction of equipment if you do not follow instruc-
tions.
A note indicates additional helpful information.

Manual Conventions
4309858K
WARNING
SKIN 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 surgical treatment.
• Do not point the gun at anyone or at any part of the body.
• Do not put your hand or fingers over the gun fluid nozzle.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not “blow back” fluid; this is not an air spray system.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
• Use lowest possible pressure when flushing, priming, or troubleshooting.
• Engage trigger lock when not spraying.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pres-
sure hose cannot be recoupled; replace the entire hose.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area* can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes and plastic drop cloths (potential static
arc).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep work area free of debris, including solvent, rags and gasoline.
• Ground equipment and conductive objects. See Grounding.
• Hold gun firmly to side of grounded pail when triggering into pail.
• Use only grounded hoses.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regu-
lations.
• Connect only to grounded power source.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
BURN HAZARD
This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To
avoid severe burns:
• Do not touch hot fluid or equipment.
• Allow equipment to cool completely before touching it.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts. Pressurized equipment can start acci-
dentally and cause serious injury.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Before checking or servicing equipment, follow the Pressure Relief Procedure in this manual. Dis-
connect power or air supply.
• Do not move or lift pressurized equipment.

Manual Conventions
309858K 5
EQUIPMENT MISUSE HAZARD
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.
• Do not alter or modify equipment. Use only Graco parts and accessories.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Comply with all applicable safety regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear proper protective equipment when operating, servicing, or when in the operating area of
the equipment to help protect you from serious injury, including eye injury; hearing loss; and inhalation of
toxic fumes. This equipment includes but is not limited to:
• Protective eyewear
• Gloves, clothing, and respirator as recommended by the fluid and solvent manufacturer
• Hearing protection
WARNING

Installation
6309858K
Installation
Key:
A Air Line Filter
B Bleed-type Master Air Valve - required
C Pump Bleed-type Master Air Valve - required
D Pump Air Regulator
E Main Air LIne Supply
F Electrical Control Panel
GFollowerBlow-offHose
H Pump Air Supply Hose
J Pump Mounting Bracket
K Hose Hanger
L Follower Blow-off Valve Regulator
M Follower Plate Bleed Stick
N Ram Air Regulators
P Air Line Lubricator
Q Depressurization Valve
R Air Motor Pressurization Kit (King/Bulldog units only)
SPump
T Ram Control Lever
U Ram Module
V Heated Follower Plate
W Wipers
X Air Supply Bleed-type Master Air Valve
Y Air Supply Line Filter
FIG. 1
A P
B
C
D
EF
G
H
K
L
M
Q
J
N
R
T
U
V W
X
Y
S

Installation
309858K 7
Unpacking
Unpack the Therm-O-Flow 20 as follows:
1. Inspect the shipping box for damage; immediately
contact the carrier if damaged.
2. Open the box and inspect the contents for loose or
damaged parts.
3. Compare the packing slip against items in the box.
Report problems immediately.
4. Store the box and packing materials to reuse if the
equipment needs to be repackaged and shipped.
Typical Installation
The typical installation drawing, FIG. 1, is only a guide
for selecting and installing system components and
accessories. Contact your Graco distributor or Graco
Technical Assistance for help in designing a system to
suit your needs.
See Accessories section, page 57, for wiper rings and
other accessories.
Accessories and Modules
Before you install the system, familiarize yourself with
the parts discussed below. Refer to FIG. 1.
Air and Fluid Hoses
Make sure air and fluid hoses are properly sized for your
system. Use only electrically conductive air and fluid
hoses.
Air Line Modules
4-Regulator Air Control Module (246587)
This module includes the following components:
•Bleed-type Master Air Valve (B): for shutting off
and locking out the air supply from the entire supply
unit.
•Pump Bleed-type Master Air Valve (C): is installed
so the valve is easily accessible and located down-
stream from the air regulator. It can be used for a
safety lockout.
•Ram Air Regulators (N): separate air regulators to
control the ram up and down air pressures.
•Pump Air Supply Hose (H): connects pump air
regulator to the air motor.
•Follower Blow-off Valve Regulator (L): controls
air pressure to the follower blow-off valve.
•Air Filter (A) and Lubricator (P): conditions air to
the ram and pump. Pump air regulator (D) is part of
this assembly. An air line tube connects the ram air
to the ram air control module.
•Pump Air Regulator (D): adjusts air pressure to
control pump speed and outlet pressure (located on
the air control panel).
•Automatic Depressurization Valve (Q): exhausts
air from the system at shut off. The built-in timer
delays start up to allow material to heat thoroughly.
Refer to page 36-38.
WARNING
The bleed-type master air valve (C) is required to
relieve air trapped between this valve and the pump
after the pump air regulator is closed. Read warnings,
page 4.

Installation
8309858K
3-Regulator Air Control Modules
(234236, not shown)
This module includes the following components:
•Pump Bleed-type Master Air Valve (C): is installed
so the valve is easily accessible and located down-
stream from the air regulator. It can be used for a
safety lockout.
•Pump Air Regulator (D): adjusts air pressure to
control pump speed and outlet pressure (located on
the air control panel).
•Ram Air Regulator ((N): separate air regulators to
control the ram up and down air pressures.
•Pump Air Supply Hose (H): connects pump air
regulator to the air motor.
•Air Manifold (item 23, page 30): divides main air
supply into separate lines for the pump and ram.
Grounding
.
Air and fluid hoses: use only electrically conductive
hoses. Check the electrical resistance of your air and
fluid hoses. If the total resistance to ground exceeds 29
megohms, replace the hose immediately.
Dispense valve: ground through connection to a prop-
erly grounded fluid hose and pump.
Fluid supply container: follow your local code.
Solvent pails used when flushing: follow your local
code. Use only conductive, metal pails, placed on a
grounded surface. Do not place the pail on a noncon-
ductive surface, such as paper or cardboard, which
interrupts grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: follow the instructions in your sepa-
rate gun manual for safely grounding your gun while
purging.
Location
Refer to the dimensional drawings, page 60, for ram
mounting and clearance dimensions.
Make sure:
• There is sufficient space for installing and using the
equipment, including overhead clearance for the
pump and ram when the ram is fully raised.
• Air regulators for the pump and ram are fully acces-
sible.
• There is easy and safe access to an appropriate
electrical power source. The National Electrical
Code requires 3 feet (0.91 m) of open space in front
of the electrical panel.
You can install the system in a permanent location or
use a mobile platform.
Permanent Location
1. Follow the previous Location recommendations.
2. Level the base of the ram, using metal shims.
3. Using the holes in the base as a guide, drill holes for
1/2 in. (13 mm) anchors.
4. Bolt the ram to the floor anchors, which must be
long enough to prevent the unit from tipping.
Securing Ram to a Mobile Platform
Use the Mobile Platform Kit (918414) to secure the ram
to a mobile platform (included with unit). See page 30,
item 10 or page 32 or 34, item 19.
1. Follow the previous Location recommendations.
2. Locate the mobile platform on a surface where it
won't roll and brace the platform to ensure it
remains stationary while you secure the ram.
3. Place the ram on the platform and line up the holes
in its base with the holes in the platform.
4. Secure the ram to the platform with the nuts and
bolts provided.
5. Make sure the ram and platform are stable in all
operating positions so the ram won't tip.
WARNING
The system must be properly grounded. Read warn-
ings, page 4. Follow the instructions below.

Installation
309858K 9
Electrical Control Panel
Electrically Connect Hoses
Assemble hose and gun components. Follow the gun
instructions.
Electrically connect hoses to the electrical control panel.
FIG. 2. Connectors are located on the back of the electri-
cal control panel.
Connect the plug from hose 1 to the Hose 1/Gun 1
receptacle on the back of the control panel.
Connect to a Power Source
The Electrical Control Panel is shipped attached and
wired to the ram.
Have a trained electrician connect the electrical control
panel to a grounded electrical source that has the
required service ratings:
For information about specific terminal locations and
connections, see Electrical Schematic for your electri-
cal control, pages 48-55.
To connect the control panel to the electrical source:
1. Create an opening in the control panel housing for
the conduit that will enclose the wire from the power
source.
2. Thread the wire from the power source into the con-
trol panel housing.
3. Connect the power source wires to the appropriate
terminals on the DISCONNECT switch.
FIG. 2
SERIES C
HIGH TEMPERATURE
LT120
R
ALARM
ON
R
AUTO HEAT OFF
POWER ON
LT110
GROUND CONNECTED
W
OFF
HEAT
TC158
GUN
TC151
HOSE
FOLLOWER
TC129
LT114
AUTO
G
OFF ON
CONTROL ON
CONTROL
7.3
60HZ1480 o
FULL LOAD AMPS:
FREQ:PHASE:
ELECTRICAL PANEL PART No.: 617300
LINE VOLTAGE:
480 VOLTS
AT
SET
SV
OUT2
CB100
R/S
OUT1 ALM1
PV
ALM2AT
SET
SV
OUT2
CB100
R/S
OUT1 ALM1
PV
ALM2 AT
SET
SV
OUT2
CB100
R/S
OUT1 ALM1
PV
ALM2
C14044
SS166
LT164
SS116
T
T
h
h
e
e
r
r
m
m
-
-
O
O
-
-
F
F
l
l
o
o
w
w
G
G
R
R
A
A
C
C
O
O
R
R
DANGER
Control
Panel
Model: Zones: VAC: Hz: Phase:
Full
Load
Amps
617300
(Standard)
3480 60 17.3
617349 4480 60 39.8
617484 3240 60 113.8
617485 4240 60 316.0

Installation
10 309858K
Check Resistance
.
Supply Unit
Have a qualified electrician check resistance between
each supply unit component and true earth ground. The
resistance must be less than 0.25 ohms. If the resis-
tance is greater than 0.25 ohms, a different ground site
may be required. Do not operate the system until the
problem is corrected.
Sensor
.
The supply unit includes either three or four heat sen-
sors and controllers for each heated zone. To check
sensor resistance:
1. Make sure the power is off and the disconnect
switch is turned to OFF.
2. Check electrical resistance of the components at
ambient room temperature 63°-77°F (17°-25° C).
Refer to Electrical Schematic for your electrical
control, pages 48-55.
3. Replace any parts whose resistance readings do
not comply with the ranges in the chart below.
3-Zone RTD Sensors
4-Zone RTD Sensors
Heater
.
To check heater resistance:
1. Make sure the power is off and the disconnect
switch is set to OFF.
2. Check electrical resistance checks of the compo-
nents at ambient room temperature (63°-77°F).
Refer to Electrical Schematic for your electrical
control, pages 48-55.
3. Replace any parts whose resistance readings do
not comply with the ranges in the chart below.
Heaters for 3-Zone Control Panels
WARNING
The system must be properly grounded. See Ground-
ing, page 8.
WARNING
• Read warnings, page 4.
• Do not open electrical control panel unless you
are a trained professional.
• Make sure power is shut off to the control panel.
• Make sure main disconnect is OFF.
Zone Component Terminals Value Range
1 Follower 1311, 1321 108 ± 2% ohms
2 Dispense Hose 1531, 1541 108 ± 2% ohms
3 Dispense Gun 1601, 1611 108 ± 2% ohms
Zone Component Terminals Value Range
1 Follower 1311, 1321 108 ± 2% ohms
2 Dispense Hose 1531, 1541 108 ± 2% ohms
3 Dispense Gun 1601, 1611 108 ± 2% ohms
4 Pump 1381, 1391 108 ± 2% ohms
WARNING
• Read warnings, page 4.
• Make sure main disconnect is OFF.
Zone Component Terminals Value Range
1 Follower 2L1, 2L2 98-127 ohms
2L2, 2L1
2 Dispense
Hose
1532, 1551 See Technical
Data supplied
with hose
3 Dispense
Gun
1602, 1621 See Technical
Data supplied
with gun

Installation
309858K 11
Heaters for 4-Zone Control Panels
Temperature Controller Settings
The basic program settings for each temperature con-
troller meet the needs of most applications and are pre-
set at the factory.
The input type, temperature scale, and over temperature
alarm point are the critical controller settings that you
must check before doing an auto-tune or using any con-
troller in normal operation. See manual 309100 for oper-
ation of the temperature controls.
Graco Factory P, I, and d Settings
The table lists the P (proportional), I (integral), and d
(derivative) settings for standard control panels. These
settings are preset at the factory. Use the table for refer-
ence information only. See manual 309100 to assess
these values.
Graco Factory P, I, and d Settings
The P, I, and d values are usually generated by running
an auto-tune process for each heat zone. The control-
lers automatically find the proper P, I, and d values dur-
ing this auto-tune process. The values are selected to
allow the heat zones to reach their maximum tempera-
ture as fast as possible without significantly exceeding
desired temperature.
Zone Component Terminals Value Range
Follower 3L1 & 3L3 98-127 ohms
3L2 & 3L3
Dispense
Gun
1532 & 1551
See Technical
Data supplied with
gun
Dispense
Hose
1602 & 1621
See Technical
Data supplied with
hose
Pump 5L1 & 5L2 187.2 ohms + 24
ohms
Component P I d
Follower 29.5 210 52
Pump 87.3 1492 373
Hose 8.9 39 9
Gun 41.4 89 22
AL1
35
AL2
-35

Flushing
12 309858K
Flushing
.
The system was factory-tested using a light soluble oil.
Flush the system before initial use to prevent material
contamination.
To flush the system:
1. Select a solvent that is compatible with the equip-
ment wetted parts and the material being flushed.
Check with your Graco distributor or the material
supplier for a recommended solvent.
2. Before flushing, be sure the entire system and flush-
ing drums are properly grounded. Refer to Ground-
ing, page 8.
3. Perform steps 1 through 7 of the Loading Material
procedure, page 13, to load the solvent.
4. Run solvent through the system for about 1-2 min-
utes.
5. Remove the solvent drum.
6. Load material, page 13, or follow the Shutdown-
procedure, page 16.
Start Up
1. Check the tightness of material hoses and fittings to
prevent leakage.
2. Check system air and electrical lines. Make sure
that they will not interfere with moving components
within the fixture.
3. To raise the arm:
a. Close all air regulators.
b. Set the ram control lever to UP.
c. Slowly open the air regulators until the ram
starts to move up.
d. When the follower plate is above the height of
the material pail, set the ram control lever to
OFF.
4. Turn the main electrical disconnect (A) ON. FIG. 3.
5. Turn the CONTROL switch (65) to ON.
6. Open the dispense valve over a waste container
during system heatup to relieve pressure as mate-
rial expands.
7. Check the temperature controller set points and
change them if necessary. See Changing the Set
Point in manual 309100.
8. Wait until all system zones are heated to the preset
temperatures.
9. The system is ready for Loading Material.
WARNING
Read warnings, page 4.
WARNING
Read warnings, page 4.
FIG. 3
SERIES C
HIGH TEMPERATURE
LT120
R
ALARM
ON
R
AUTO HEAT OFF
POWER ON
LT110
GROUND CONNECTED
W
OFF
HEAT
TC158
GUN
TC151
HOSE
FOLLOWER
TC129
LT114
AUTO
G
OFF ON
CONTROL ON
CONTROL
7.3
60HZ1480 o
FULL LOAD AMPS:
FREQ:PHASE:
ELECTRICAL PANEL PART No.: 617300
LINE VOLTAGE:
480 VOLTS
AT
SET
SV
OUT2
CB100
R/S
OUT1 ALM1
PV
ALM2AT
SET
SV
OUT2
CB100
R/S
OUT1 ALM1
PV
ALM2 AT
SET
SV
OUT2
CB100
R/S
OUT1 ALM1
PV
ALM2
C14044
SS166
LT164
SS116
T
T
h
h
e
e
r
r
m
m
-
-
O
O
-
-
F
F
l
l
o
o
w
w
G
G
R
R
A
A
C
C
O
O
R
R
DANGER
A
65

Start Up
309858K 13
Loading Material
.
1. Make sure the follower plate is high enough to put
the material pail under it.
2. Remove the pail cover by holding it level and lifting
straight up. Place the pail under the elevated fol-
lower plate.
3. Lubricate the follower wipers with a lubricant com-
patible with the material to be pumped.
4. Make sure there is nothing between the follower
plate and pail or between the ram tie bar and top of
the ram posts. Then lower the pump into the pail.
a. Set the ram control lever to DOWN, and slowly
adjust the air regulator. FIG. 4, page 14.
b. If necessary, stop lowering the follower plate to
adjust the pail position to align with the follower
plate.
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
escape.
.
d. When air stops exhausting from the bleed stick
port, install the bleed stick to prevent hot mate-
rial from leaking out the opening.
5. Adjust the ram DOWN air regulator pressure for nor-
mal operation.
6. Purge air out of the pump and fluid lines.
a. Place a waste container under the pump bleed
port.
b. Open the bleed port and slowly adjust the
pump air regulator to start the pump and fill the
material passages.
c. Allow material to flow from the bleed port until it
is air-free, then shut off the pump and close the
bleed port.
d. Place a material waste container under the dis-
pense valve.
e. Dispense material until all air is purged.
7. Allow the system to heat for approximately 30 min-
utes.
WARNING
Material and equipment are hot. Avoid contact. Wear
protective clothing. Read warnings, pages 4-5.
CAUTION
Do not use a material pail that has been dented or
damaged; damage to the follower wipers may result.
Do not tip the pail cover when removing it as this may
spill dirt from the cover into the pail and contaminate
the material.
CAUTION
The use of a non-compatible lubricant can cause
material contamination or inadequate performance.
Check with the material supplier for a recommended
lubricant.
WARNING
When raising or lowering the ram, keep hands and
body away from ram plate and pail lip. Read warnings,
page 4.
WARNING
Read warnings, page 4.

Operation
14 309858K
Operation
Pressure Relief Procedure
1. Engage the gun trigger lock.
2. Shut off the main air supply to the pump.
3. Close all air bleed valves.
4. Disengage the gun trigger lock.
5. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun to relieve
pressure.
6. Engage the gun trigger lock.
7. Have a container ready to catch the drainage, then
open the drain valve or pump bleed valve.
8. Leave the drain valve open until you are ready to
spray/dispense again.
9. If you suspect that the spray tip/nozzle or hose is
completely clogged, or that pressure has not been
fully relieved after following the steps above, very
slowly loosen the nozzle retaining nut or hose end
coupling to relieve pressure gradually, then loosen
completely. Now clear the tip/nozzle or hose.
10. To relieve pressure in the ram, see the Ram Pres-
sure Relief Procedure, page 21.
Raising and Lowering Ram
The ram control lever on the control panel has 3 set-
tings. FIG. 4.
• Ram UP raises the ram
• Ram DOWN lowers the ram
• Ram OFF puts the ram in neutral, stopping the air
pressure from moving the ram either up or down.
WARNING
Read warnings, page 4, and follow the Pressure
Relief Procedure whenever you:
• are instructed to relieve pressure
• stop operation
• check, clean, or service any of the equipment
WARNING
When raising or lowering the ram, keep hands and
body away from ram plate and pail lip. Read warnings,
page 4.
FIG. 4
Ram UP
Ram OFF (neutral)
Ram DOWN

Operation
309858K 15
Daily Start-up Procedure
There are 2 ways to start up the system:
• Manually start the system each day
• Use the optional 7-day timer to automatically heat
up the system
Starting System Manually
1. Verify that the main disconnect is ON.
2. Turn the CONTROL switch (65) to ON. FIG. 5, page
17.
3. Turn the HEAT switch (66) to ON. Pump will not
operate until 30 minutes have elapsed, allowing
material to fully heat.
4. Open the dispense valve over a waste container to
relieve pressure when material heats and expands.
5. After each of the dispense zones is heated to oper-
ating temperature, wait an additional 30 minutes to
allow the material to heat fully.
6. Make sure that all material valves are open.
7. Turn the pump air supply ON and set the regulator
for normal operation.
8. Dispense material into a waste container. Adjust the
flow rate as needed.
Using Optional 7-Day Timer
The 7-day timer can be set to automatically turn the heat
on to the system. Using the timer requires you to:
• Create a schedule and program it into the 7-day
timer, located on the electrical control panel. Be
sure to allow at least 30 minutes for the material to
heat up before the supply unit is used. For timer pro-
gramming information, see the electronic control
panel documentation.
• Perform a nightly procedure to ready the system for
automatic operation.
Nightly Procedure:
1. Turn the CONTROL switch (65) to AUTO. FIG. 5,
page 17.
2. Turn the HEAT switch (66) to ON.
4. Open the dispense valve over a waste container to
relieve pressure when material heats and expands.
5. Make sure that all material valves are open.
6. Make sure the pump air supply has been turned off.
WARNING
• Material and equipment are hot. Avoid contact.
Wear protective clothing.
• Keep hands and fingers away from limit switches
and other moving parts.
• Read warnings, pages 4-5.
WARNING
Read warnings, page 4.
Internal timer controls pump startup. Adjust timer if
shorter startup time is desired.
WARNING
3. Follow Pressure Relief Procedure, page 14.
WARNING
Read warnings, page 4.

Operation
16 309858K
Changing Empty Pails
1. Stop the pump by closing either the bleed-type mas-
ter air valve or the fluid dispensing valve.
2. To raise the ram out of the pail, set the ram control
lever to UP. FIG. 4, page 14. At the same time, care-
fully equalize the pressure in the pail by using the
Follower Blow-off Valve Regulator to cycle the fol-
lower blow-off valve open and close.
3. When the follower plate wipers clear the rim of the
pail (i.e., when pressure under the plate is relieved),
set the ram UP air regulator to 15-20 psi (103-138
kPa, 1-1.4 bar) to allow the ram to lift the plate to its
most upright position.
4. Being careful not to damage the follower wiper or
touch hot material, scrape material from the follower
plate and wiper.
5. Follow Loading Material procedure, page 13-13,
steps 1-6, except step 3 (lubricate the wiper).
6. Turn air on to the pump, and set the pump air regu-
lator for normal operation.
Shutdown
1. Turn the CONTROL switch (65) to OFF. FIG. 5, page
17.
2. Turn OFF the main electrical disconnect.
3. Set the ram control lever to OFF. FIG. 4, page 14.
4. Shut off the air supply to the ram and pump.
6. Remove the dispense device and clean as
instructed in its manual.
Emergency Stop
1. On the electrical control panel:
a. Turn OFF the main electrical disconnect.
b. Turn the CONTROL switch (65) to OFF. FIG. 5,
page 17.
2. Close the Bleed-type Master Air Valve (C), closest
to the motor's air inlet, to stop the pump. See FIG. 1,
page 6.
3. To stop the ram:
a. Close the ram air lock-out valve.
b. Set the ram control lever to OFF. FIG. 4, page
14.
CAUTION
• To avoid damaging pumps, do not operate when
pails are empty.
• Do not raise the ram and remove the follower plate
from the pail until you are ready to immediately
install a new pail, unless you are preparing to ser-
vice the equipment.
WARNING
Due to material viscosity, you can only change pails
when the unit is at full operating temperature.
• Avoid contact with hot material and equipment
surfaces.
• Wear protective clothing.
• Read warnings, pages 4-5.
WARNING
Improperly adjusted blow-off pressure can cause seri-
ous injury or damage equipment.
• Excessive pressure - follower plate may rise too
quickly or pail may burst.
• Too little pressure - ram may lift pail off the ground.
WARNING
5. Follow Pressure Relief Procedure, page 14.

Operation
309858K 17
Reading Electrical Control Panel Indicators
Use the table and FIG. 5 below to read electrical control panel indicators. For information on setting the temperature
controllers, see Setting Temperature Controllers in Manual 309100.
Light No. Indicator
Indicator
Light is Meaning
61 Power On/Ground
Connected
ON Power is on and ground is connected.
OFF Power is off and/or ground is disconnected.
DIMLY LIT There may be a problem with system power connections.
Have a qualified electrician check connections before start-
ing the system.
62 Control On ON The CONTROL switch (65) is set to either ON or AUTO and
power is being supplied to the electrical control panel com-
ponents.
OFF The CONTROL switch (65) is set to OFF.
63 High Temperature
Alarm
ON The temperature of heated component(s) is out of range;
power to all heated components is interrupted. See High
Temperature Alarm, page 18.
OFF Temperature of heated components is in range.
64 Auto Heat Off ON The Inactivity Timer has turned off heat for the supply unit.
See Auto Heat Off, page 18.
OFF The supply unit is functioning normally.
FIG. 5
HIGH TEMPERATURE
R
ALARM
ON
R
AUTO HEAT OFF
POWER ON
GROUND CONNECTED
W
OFF
HEAT
AUTO
G
OFF ON
CONTROL ON
CONTROL
61 62 6463
6665

Operation
18 309858K
High Temperature Alarm
Should a component temperature go outside the preset
range for any of the zones, power to heated components
is interrupted, and the HIGH TEMPERATURE ALARM
light turns ON. FIG. 5, page 17. The alarm automatically
turns OFF and the system resets when the temperature
is back in range.
Auto Heat Off
Your system may have an inactivity (worklife) timer. If the
pump does not operate for a set amount of time, the
inactivity timer turns off power to the heaters, and the
the AUTO HEAT OFF (64) light turns on.
To set the inactivity timer, see the documentation pro-
vided inside the control panel.
To reheat the supply unit:
1. Turn the HEAT switch (66) OFF, then ON. FIG. 6.
2. Wait until all supply unit components return to oper-
ating temperature.
3. Resume operation.
Ground Fault Interrupt
The control panel includes a ground fault interrupt (GFI)
circuit breaker (FIG. 7). If the main electrical disconnect
is ON, but all lights on the electrical control panel are off,
have a qualified electrician check the ground fault inter-
rupt.
To reset:
.
1. Turn main electrical disconnect OFF.
2. Open electrical control box and locate the Ground
Fault Interrupt switch (71). The GFI should be in a
neutral position, between ON and OFF.
3. Turn GFI switch OFF, then ON.
4. Close the door and turn the main electrical discon-
nect ON.
For more information about the GFI switch, see the elec-
trical control panel documentation.
FIG. 6
ON
OFF
HEAT
66
WARNING
The main electrical disconnect must be OFF and qual-
ified electrician must perform service. Read warnings,
page 4.
FIG. 7
-
+
+
-
+
+
-
-
+
-
+
-
WIRE DUCT 1 X 2
WIRE DUCT 1 X 2
WIRE DUCT 1-1/2 X 2
WIRE DUCT 1 X 2
WIRE DUCT 1 X 2
WIRE DUCT 1 X 2
108
GFI
BUSS
GND
DISC
TR112
CR
166125
TR168
FU103 FU104
SSR138
FU100
SSR160
CR118 MCR125
MCR
CR118
SSR160
CR166
SSR140
SSR138
SSR153
SSR153 SSR140
FU101
FU102
SSR131
SSR133
CON127
SSR131
SSR133
OFF
ON
108
OFF
ON
OFF
ON
71

Troubleshooting
309858K 19
Troubleshooting
Ram
Electrical Control Panel
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.
Control valve closed or clogged. Open or clear valve or exhaust.
Ram raises or lowers too fast. Ram air pressure too high. Decrease ram pressure
Air leaks around cylinder rod. Worn rod seal. Replace o-rings in guide sleeve. See
manual 310523.
Fluid squeezes past follower plate
wipers.
Ram air pressure too high. Decrease ram pressure.
Worn or damaged wipers. Replace wipers, page 22.
Pump won't prime properly or
pumps air.
Main air valve closed. Open air valve.
Air line clogged. Clear air line.
Pump air pressure too low. Increase pump pressure.
Worn or damaged piston. Replace piston. See manual
310523.
Control valve closed or clogged. Open or clear valve or exhaust.
Control valve dirty, worn, or damaged. Clean or service valve.
Follower stopped by bent drum. Replace drum.
Air pressure will not hold drum
down or push plate up.
Main air valve closed. Open air valve.
Air line clogged. Clear air line.
Ram air pressure too low. Increase ram pressure.
Valve passage clogged. Clean valve passage.
Worn piston seal. Replace seal.
Problem Cause Solution
Disconnect is ON, but no indicator
lights are lit.
Ground fault interrupt has been acti-
vated.
Reset Ground Fault Interrupt, page
18.
Fuse(s) blown. Replace fuse(s).
High Temperature Alarm light on. Heated component temperature is out of
range.
See High Temperature Alarm,
page 18.
Heat turns off after inactivity timer
is triggered.
Pump inactive longer than programmed
time period.
Reset Auto Heat Off, page 18.
Temperatures are in range, but
pump will not start.
Internal timer has not reached the preset
startup time.
Adjust timer to shorten startup time.

Troubleshooting
20 309858K
Heated Pump
See the pump manual for more information.
Air Motor
See the air motor manual for more information.
Problem Cause Solution
Rapid down or up stroke (pump
cavitation).
Material not heated to proper tem-
perature.
Check and adjust temperature set point.
Air trapped in pump. Purge air from the pump - page 13, step
6.
Downstroke: Lower check in pump
is worn.
Upstroke: Upper check in pump is
worn.
Repair pump. See pump manual.
Plate is not melting material fast
enough to supply pump.
Slow pump speed to match melt capacity.
Material leaks around pump outlet. Outlet fitting is loose. Tighten outlet fitting.
Material leaks around bleed port. Bleed port fitting is loose. Tighten bleed port fitting
Pump does not operate. Air motor problem. See Air Motor troubleshooting, below.
Foreign object lodged in pump. Follow Pressure Relief Procedure, page
14. Remove pump from air motor, page
23. Remove object and reassemble
pump.
Wet-cup leaks. Worn throat seal. Tighten wet-cup and/or throat seal pack-
ings. If that does not stop leaking, replace
wet-cup and/or throat seal packings.
Problem Cause Solution
Air motor stalled Main air valve is dirty or damaged Clean/rebuild main air valve.
Air continually exhausting around
air motor shaft
Air motor shaft seal is damaged Replace air motor shaft seal.
Air continually exhausting around
the air valve/slide valve
Air valve/slide valve gasket is damaged Replace the valve gasket.
Air continually exhausting from
muffler while the motor is idle
Internal seal damage Rebuild air motor.
Oil leaking from exhaust port Too much lubricant mixed in with the air
supply
Reduce lubricant supply.
Frost build-up on muffler Air motor operating at too high a pres-
sure or cycle rate
Reduce air motor pressure, cycle
rate, or duty cycle.