Graco Therm-O-Flow 5 Operation manual

310528
Rev. C
First choice when
quality counts.t
Model 918337
8249A
Model 918343
Therm–O–Flow 5 Mini–5
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP IT FOR REFERENCE.
20 Liter (5 Gallon) Pail Size
76 mm (3”) Dual Post, Heated
Therm-O-Flow 5 and Mini-5
Air-Powered Ram Heated Pail Unloaders
Refer to page 2 for a list of models.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Parts
Contents

2310528
List of Models
The supply units listed below all include silicone wipers.
Part Number Motor/Pump Ratio Max. Fluid Working
Pressure
Voltage Page
918334* President15:1 126 bar (1800 psi) 480 VAC 41
918337Polyurethane
Reactive (PUR)
President 15:1 126 bar (1800 psi) 480 VAC 41
918340 (Swirl)* President 15:1 126 bar (1800 psi) 480 VAC 41
918522 President 15:1 126 bar (1800 psi) 480VAC 41
918532 President 15:1 126 bar (1800 psi) 240VAC 41
918343 Senator/Check-Mate 800 19:1 131 bar (1900 psi) 480 VAC 45
918352 (PUR)* Senator/Check-Mate 800 19:1 131 bar (1900 psi) 480 VAC 45
918344* Bulldog/Check-Mate 800 31:1 214 bar (3100 psi) 480 VAC 47
918437 Bulldog/Check-Mate 800 31:1 214 bar (3100 psi) 240 VAC 47
918593 Bulldog/Check-Mate 800 31:1 214 bar (3100 psi) 480VAC 47
C59398 King 65:1 403 bar (5850 psi) 480 VAC 49
* These models are no longer available.

310528 3
Table of Contents
List of Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unpacking and Repacking 8. . . . . . . . . . . . . . . . . . . . .
Unpacking the Product 8. . . . . . . . . . . . . . . . . . . . . .
Repair and Repacking the Product 8. . . . . . . . . . . .
Typical Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a Location for the Ram 10. . . . . . . . . . . . .
System Accessories and Modules 10. . . . . . . . . . . .
Installation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locating the Ram 13. . . . . . . . . . . . . . . . . . . . . . . . . .
Electrically Connect Hose to the Electrical
Control Panel 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground The System 14. . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Electrical Control Panel
to a Power Source 15. . . . . . . . . . . . . . . . . . . . . . . . .
Check the Resistance Between the
Supply Unit and the True Earth Ground 15. . . . . . .
Checking Resistance 16. . . . . . . . . . . . . . . . . . . . . . .
Overview of the Temperature
Controller Settings 18. . . . . . . . . . . . . . . . . . . . . . . . .
Graco Factory P, I, and D Settings 18. . . . . . . . . . .
Flushing the System 19. . . . . . . . . . . . . . . . . . . . . . .
Initial Material Loading 20. . . . . . . . . . . . . . . . . . . . . .
Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 21. . . . . . . . . . . . . . . . . .
Raising and Lowering the Ram 21. . . . . . . . . . . . . .
Daily Start-up Procedure 22. . . . . . . . . . . . . . . . . . . .
Changing Empty Pails 23. . . . . . . . . . . . . . . . . . . . . .
Shutdown 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop 24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading the Electrical Control Panel Indicators 25
Resetting the Ground Fault Interrupt 26. . . . . . . . . .
Flushing Safety 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ram Troubleshooting 28. . . . . . . . . . . . . . . . . . . . . . . .
Heated Pump Troubleshooting 29. . . . . . . . . . . . . . . .
Air Motor Troubleshooting 30. . . . . . . . . . . . . . . . . . . .
Electrical Control Panel Troubleshooting 30. . . . . .
Service 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ram Service 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing a Material Pail from the Supply Unit 31.
Servicing the Follower 32. . . . . . . . . . . . . . . . . . . . . .
Servicing the Pump/Motor Assembly
for the Check-Mate 800 34. . . . . . . . . . . . . . . . . . . . .
Servicing the Pump/Motor Assembly
for the Therm-O-Flow Mini-5 Supply Unit 38. . . . . .
Inspection Frequency 39. . . . . . . . . . . . . . . . . . . . . .
Removing/Replacing the CB100 Controller 39. . . .
Parts 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 918334, 76 mm (3”) Ram,
Therm-O-Flow 15:1 President, w/silicone
follower wipers, 480 VAC 41. . . . . . . . . . . . . . . . . . .
Model 918337, 76 mm (3”) Ram,
PUR Therm-O-Flow 15:1 President, w/silicone
follower wipers, 480 VAC 41. . . . . . . . . . . . . . . . . . .
Model 918340, 76 mm (3”) Ram,
PUR Therm-O-Flow 15:1 President, Swirl Valve,
w/silicone follower wipers, 480 VAC 41. . . . . . . . . .
Model 918522, 76 mm (3”) Ram,
Therm-O-Flow 15:1 President,
w/silicone follower wipers, 480 VAC 41. . . . . . . . . .
Model 918532, 76 mm (3”) Ram,
Therm-O-Flow 15:1 President,
w/silicone follower wipers, 240 VAC 41. . . . . . . . . .
Model 918343, 76 mm (3”) Ram, 19:1 Senator,
Therm-O-Flow Heated Check-Mate 800,
w/silicone follower wipers, 480 VAC 45. . . . . . . . . .
Model 918352, 76 mm (3”) Ram, 19:1 Senator,
PUR Therm-O-Flow Heated Check-Mate 800,
w/silicone follower wipers, 480 VAC 45. . . . . . . . . .
Model 918344, 76 mm (3”) Ram, 31:1 Bulldog,
Therm-O-Flow PUR Heated Check-Mate 800,
w/silicone follower wipers, 480 VAC 47. . . . . . . . . .
Model 918437, 76 mm (3”) Ram, 31:1 Bulldog,
Therm-O-Flow PUR Heated Check-Mate 800,
w/silicone follower wipers, 240 VAC 47. . . . . . . . . .
Model 918593, 76 mm (3”) Ram, 31:1 Bulldog,
Therm-O-Flow PUR Heated Check-Mate 800,
w/finned platen, 480 VAC 47. . . . . . . . . . . . . . . . . . .
Model C59398, 76 mm (3”) Ram, 65:1 King,
Therm-O-Flow PUR Heated Check-Mate 800,
w/silicone follower wipers, 240 VAC 49. . . . . . . . . .

4310528
Table of Contents (Continued)
Model 617318, Vent Hood Kit
for use with PUR units 55. . . . . . . . . . . . . . . . . . . . . .
Model 617334, Proximity Switch Kit (Pump
Activity) for use with Therm-O-Flow 5 units 56. . .
Model 918433, Proximity Switch Kit
(Pump Activity) for use with President Pumps 57. .
Model 617325, Heated Follower Plate Kit
for use with President pump assemblies 58. . . . . .
Model 617335, Heated Follower Plate Kit
for use with Heated Check-Mate 800
pump modules 59. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 918499, Heated Follower Plate Kit with
finned bottom for use with President pump
assemblies 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 918501, Heated Follower Plate Kit with
finned bottom for use with heated
Check–Mate 800 pump modules 61. . . . . . . . . . . . .
Model 617300 (standard), 480 VAC
3–zone electrical control panel (interior) 62. . . . . . .
Model 617330 (standard), 480 VAC
3–zone electrical control panel (interior) 63. . . . . . .
Model 617300 (standard) and 617330 (swirl),
480 VAC 3–zone and 617484 240 VAC
3–zone electrical control panel (exterior) 64. . . . . .
Model 617349 (480 VAC) and 617485 (240 VAC)
4–zone electrical control panel (exterior) 65. . . . . .
Model 617349 (480 VAC) and 617485 (240 VAC)
4–zone electrical control panel (interior) 66. . . . . . .
Schematics 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Control Panel and Wiring 67. . . . . . . . . . .
Model C03510, Pump Air Motor Mounting Kit 51. .
Model 918416, 4-Regulator Ram Air
Control Module 54. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-Zone Electrical Control Panel Mounting and
Clearance Dimensions 76. . . . . . . . . . . . . . . . . . . . . .
4-Zone Electrical Control Panel Mounting
and Clearance Dimensions 77. . . . . . . . . . . . . . . . . .
Ram Mounting and Clearance Dimensions
for Therm-O-Flow 5 78. . . . . . . . . . . . . . . . . . . . . . . .
Ram Mounting and Clearance Dimensions
w/15:1 President Air Motor 79. . . . . . . . . . . . . . . . . .
Technical Data 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications 83. . . . . . . . . . . . . . . . . . . . . . . . .
Appendix 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting List 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 86. . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 86. . . . . . . . . . . . . . . . . . . . . . . .

310528 5
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.
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 about usage, call your
Graco distributor.
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 100 psi (6.9 bar) maximum inbound air pressure to the ram.
DNever exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 82.
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 the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do
not expose non–heated hoses to temperatures above 82° C (180° F) or below -40°C (-40° F).
DDo not use the hoses to pull the equipment.
DUse fluids and solvents that are chemically compatible with the equipment wetted parts. See the
Technical Data sections of all the equipment manuals. Always read the material manufactur-
er’s literature before using fluid or solvent in this pump.
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.

6310528
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 PUR heated materials. PUR systems are supplied
with ventilation hoods, and require proper ventilation and specially designed system components.
INJECTION HAZARD
Fluid from the dispense 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.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
medical attention.
DDo not point the gun/valve at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip/nozzle.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DIf spraying, always have the trigger guard on the gun when dispensing.
DIf the unit is equipped with a gun diffuser, check the gun diffuser operation weekly. Refer to the
gun manual
gun manual.
DBe sure the gun/valve trigger safety operates before dispensing.
DLock the gun/valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 21 if the nozzle clogs, and before cleaning,
checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck 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.

310528 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.
DGround the equipment, the object being dispensed, 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 14.
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 while using the equipment, stop dispensing immediately. Identi-
fy and correct the problem.
DMake sure all electrical work is performed by a qualified electrician 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.
DHave any checks, installation, or service to electrical equipment performed by a qualified electri-
cian only.
MOVING PARTS HAZARD
Moving parts, such as the ram follower plate/pump inlet can pinch fingers.
DDo not operate the equipment with the guard removed.
DKeep clear of all moving parts when starting or operating the equipment.
DKeep hands and fingers away from the priming piston during operation and whenever the pump
is charged with air.
DKeep clear of the follower plate, pump fluid inlet, and lip of the fluid container when raising or
lowering the ram.
DBefore checking or servicing the ram or pump, follow the Pressure Relief Procedure on
page 21.
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.
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.
DProvide adequate ventilation.

8310528
Unpacking and Repacking
Unpacking the Product
Your Therm-O-Flow 5 or Mini-5 was carefully
packaged for shipment by Graco. When the package
arrives, perform the following procedure to unpack the
units:
1. Inspect the shipping box carefully for shipping
damage. Contact the carrier promptly if damage is
discovered.
2. Unseal the box and inspect the contents carefully.
There should not be any loose or damaged parts
in the box.
3. Compare the packing slip against all items in-
cluded in the box. Any shortages or other inspec-
tion problems should be reported immediately.
4. Store the box and packing materials in a safe
place for future use. Graco recommends that all
packing materials be saved in case the unit needs
to be shipped again.
Repair and Repacking the Product
When the Therm-O-Flow 5 or Mini-5 requires
service, it is the purchaser’s responsibility to have the
unit repaired. As an option, the purchaser can have the
unit repaired by an authorized Graco distributor.
On-site Service
Therm-O-Flow 5 and Mini-5 components are cus-
tomarily serviced by the purchaser or an authorized
Graco technician. When service is required, follow the
Service procedures in this manual.

310528 9
Typical Installation
A Air Line Filter
B Lock-out Master Air Valve (bleed-type)
(required)
C Pump Bleed-Type Master Air Valve (required)
D Pump Air Regulator
E Main Air Line Supply
F Electrical Control Panel
G Follower Blow-off Valve
H Pump Air Supply Hose
I Air Line Lubricator
J Heated Hose
K Hose Hanger
L Follower Blow-off Valve Regulator
M Follower Plate Bleed Stick
P Depressurization Valve
1 Pump Assembly
2 Ram Module
3 Ram Hand Valve
4 Applicator Gun or Valve
5 Heated Follower Plate Assembly
6 Wiper
AID
B
G
6
C
H
F
J
K
4
1
3
E
5
2
L
M
8247A
Fig. 1 P

10 310528
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 Technical Assistance for help in designing a
system to suit your particular needs.
This air-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 75.
Selecting a Location for the Ram
Refer to the Ram Mounting and Clearance Dimensions
drawings on page 78 for ram mounting and clearance
dimensions.
When selecting a location for the ram, keep the follow-
ing in mind:
1. There should be sufficient space for installing and
using the equipment.
DMake sure there is sufficient overhead clear-
ance for the pump and ram when the ram is in
the fully raised position.
DIf you are installing a vent hood, make sure
there is sufficient horizontal clearance for it.
DMake sure the air regulators for the pump and
ram are fully accessible.
DMake 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.
2. If you are installing a vent hood, make sure the
ram is installed or located near a connection to the
factory ventilation system.
Refer to the Ram Mounting and Clearance Dimen-
sions drawings on page 78 for ram mounting and
clearance dimensions.
3. You need to decide whether you will be bolting the
ram to the floor, or bolting it to a mobile platform.
4. If you bolt the ram to the floor, make sure:
Dyou will be able to level the base of the ram
using metal shims
Dyou have anchors long enough to prevent the
unit from tipping. Refer to the Dimensional
Drawings on page 76 for more information.
5. If you bolt the ram to a mobile platform, make
sure:
Dyou locate the platform on a surface where it
won’t roll around.
Dthe ram and platform are stable in all operating
positions, so the ram won’t tip over.
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 Typical Installation, on page 9.
Air and Fluid Hoses
When installing a system, make sure:
Dall air and fluid hoses are properly sized for your
system.
Dto use only electrically conductive air and fluid
hoses.

310528 11
Typical Installation
Air Line Modules
WARNING
PRESSURIZED FLUID HAZARD AND
MOVING PARTS 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. Trapped 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 Module (918416) (Fig. 1 on
page 9)
See the Typical Installation drawing (Fig. 1). The
following components are included with the module:
DBleed-type Lock-out Master Air Valve (B) is used to
shut off and lock out the air supply from the entire
supply unit.
DBleed-type Master Air Valve (C) is required in your
system to relieve air trapped between it and the air
motor when the valve is closed (see the Pressur-
ized Fluid Hazard And Moving Parts Hazard
WARNING above). This bleed valve should be
easily accessible and located downstream from the
air regulator. It can be used for a safety lockout.
DPump 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.
DRam Air Regulator controls the air pressure to the
ram. There are separate air regulators to control
the ram pressure in the up and down directions.
DPump Air Supply Hose (H) connects the ram air
regulator to the air manifold.
DFollower Blow-off Valve Regulator (L)(N) controls
the air pressure to the follower blow-off valve.
DPHYLA (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 PHYLA and the ram air control mod-
ule.
DAuto Depressurization Valve (P) exhausts air from
the system at shut off. The built in timer delays start
up to allow material to heat thoroughly.
2-Regulator Air Control Modules (not shown)
The following components are included with the mod-
ule:
DPump Bleed-type Master Air Valve (C) is required in
your system to relieve air trapped between it and
the air motor when the valve is closed (see the
WARNING above). Be sure the bleed valve is
easily accessible from the pump, and is located
downstream from the air regulator.
DPump Air Regulator (D) controls pump speed and
outlet pressure by adjusting the air pressure to the
pump. Locate the regulator close to the pump, but
upstream from the bleed-type master air valve.
DRam Air Regulator (not shown) controls the air
pressure to the ram.
DRam Air Supply Hose (H) connects the ram air
regulator to the air manifold.
DAir Manifold (F) divides the main air supply into
separate lines for the pump and ram.
Air Line Accessories
If you have a 2-Regulator Air Control Module, install
the following accessories, using adapters as neces-
sary:
DPump runaway valve senses when the pump is
running too fast and automatically shuts off the air
to the motor. A pump that runs too fast can be
seriously damaged.
DAir line lubricator provides automatic air motor
lubrication (standard on the 4-Regulator Air Control
Module).
DAir line filter removes harmful dirt and moisture
from the compressed air supply (standard on the
4-Regulator Air Control Module).
DAccessory 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 (617318 on page 55)
The vent hood assembly is designed to efficiently draw
fumes to the factory exhaust system during drumpail
change-out. This assembly requires connection to a
factory ventilation system that draws a minimum air
flow of 8.4 m3/min (300 scfm). This kit is required for
Polyurethane Reactive (PUR) applications.

12 310528
Notes

310528 13
Installation
The installation procedure includes:
Dlocating and installing the ram
Delectrically connecting hoses to the electrical con-
trol panel
Dgrounding the system
Dconnecting the electrical control panel to a power
source
Dchecking resistance
Dsetting controls on the electrical control panel
Dstarting up the system
Dinitially loading material
Locating the Ram
To locate the ram, follow one of the procedures below.
Refer to the Ram Mounting and Clearance Dimensions
drawings on page 78 for ram mounting and clearance
dimensions.
Bolting the Ram to the Floor
To install the ram in a permanent location:
1. Select a convenient location for the equipment.
Check that there is sufficient overhead clearance
for the pump and ram when the ram is in the fully
raised position. Make sure the air regulators for the
pump and ram are fully accessible.
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. Refer
to the Dimensional Drawings starting on page 76.
Securing the Ram to a Mobile Platform
When performing the following procedure, use the
Mobile Platform Kit (918414) to secure the ram to a
mobile platform.
To install the ram on a mobile platform:
1. Brace the platform so it remains stationary while
you attach the ram to the platform.
2. Place the ram on the platform and line up the
holes in its base with the holes in the platform.
3. Secure the ram to the platform with the provided
nuts and bolts.
Electrically Connect Hoses to the
Electrical Control Panel
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 connector is are located on the back of the
electrical control panel.
Connect the plug from hose 1 to the Hose 1/Gun 1
receptacle. Refer to page 64 for connecting the hose
to a 3-zone panel, or to page 65 for connecting the
hose to a 4-zone panel.

14 310528
Installation
Ground The System
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock:
DThe power source conduit is not an
adequate ground for the system. The
unit must be bonded to either the
building ground or a true earth
ground.
DA qualified electrician must complete
all grounding and wiring connections
and check the resistance as
instructed on page 15.
DRefer to your local code for the requirements for
a “true earth ground” in your area.
DAlso read and follow the warnings on page 7.
To reduce the risk of static sparking, ground the object
being dispensed upon and all other spraying/dispens-
ing equipment used or located in the spraying/dispens-
ing area. Check your local electrical code for detailed
grounding instructions for your area and type of equip-
ment.
Ground the supply unit as instructed here and in the
individual component manuals.
Air and Fluid Hoses
Use electrically conductive hoses only.
Dispensing/Spray Gun
Follow the dispensing/spray gun grounding instruc-
tions.
Fluid Supply Container
Ground the container according to your local code.
Object to which Material is Applied
Ground the object according to your local code.
Material Pails
Ground the material pails according to your local code.
Use only metal pails, which are conductive, placed on
a grounded surface. Do not place the pail on a noncon-
ductive surface, such as paper or cardboard, which
interrupts the grounding continuity.
Maintain Grounding Continuity When Purging Or
Relieving Pressure
Follow the instructions in your separate gun manual for
safely grounding your gun while purging.

310528 15
Installation
Connecting the Electrical Control Panel to
a Power Source
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
electrical control panel to a power source.
Fig. 2
Have a trained electrician connect the electrical control
panel to a grounded electrical source that has the
required service ratings:
Control
Panel
Model:
Zones: VAC: Hz: Phase:
Full
Load
Amps
617300
(Standard)
3 480 60 1 7.3
617330
(Swirl)
617349 4 480 60 3 9.8
For information about specific terminal locations and
connections, see Schematics on page 67 for wiring
diagram information.
To connect the control panel to the electrical source:
1. Create an opening in the control panel’s housing
for the conduit that will enclose the wire from the
facility’s power source.
2. Thread the wire from the power source into the
control panel housing, and then connect the power
source wires to the appropriate terminals on the
DISCONNECT switch.
Check the Resistance Between the Supply
Unit and the True Earth Ground
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock the resistance between
the supply unit components and true
earth ground must be less than 0.25
ohms.
Have a qualified electrician check the resistance
between each supply unit component and the true
earth ground. The resistance must be less than
0.25 ohms. If the resistance is greater than 0.25 ohms,
a different ground site may be required. Do not operate
the system until the problem is corrected.

16 310528
Installation
Checking Resistance
WARNING
ELECTRIC SHOCK HAZARD
Do not open the electrical control panel,
unless you are a trained professional.
Before opening the control panel, make sure that
all power has been removed from the control panel.
Sensor Resistance Checks
WARNING
ELECTROCUTION HAZARD
To reduce risk of injury or damage to
equipment, conduct these electrical
checks with the main disconnect OFF.
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 that the disconnect
switch is in the OFF position.
2. Make electrical resistance checks for the compo-
nents. Refer to Schematics on page 67 for wiring
diagram information.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in the chart
below.
NOTE: Check resistance at ambient room tempera-
ture (63_ – 77_ F).
3-Zone RTD Sensors
Zone Component Terminals Value Range
1 Follower 1311 &
1321
107 – 109 ohms
2 Dispense
Hose
1531 &
1541
97.4 –
102.8 ohms
3 Dispense
Gun
1601 &
1611
97.4 –
102.8 ohms
4-Zone RTD Sensors
Zone Component Terminals Value Range
1 Follower 1311 &
1321
107 – 109 ohms
2 Dispense
Hose
1531 &
1541
97.4 –
102.8 ohms
3 Dispense
Gun
1601 &
1611
97.4 –
102.8 ohms
4 Pump 1381 &
1391
97.4 –
102.8 ohms

310528 17
Installation
Heater Resistance Checks
WARNING
ELECTROCUTION HAZARD
To reduce risk of injury or damage to
equipment, conduct these electrical
checks with the main disconnect OFF.
To check heater resistance:
1. Make sure the power is off and that the disconnect
switch is in the OFF position.
2. Make electrical resistance checks for the compo-
nents. Refer to Schematics on page 67 for wiring
diagram information.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in the chart
below.
NOTE: Check resistance at ambient room tempera-
ture (63_ – 77_ F).
Heaters for 3-Zone Control Panels
Zone Component Terminals
Value
Range
1 Follower 2L1 & 2L2 98 – 127
h
2L2 & 2L1 ohms
2Dispense Hose 1532 &
1551
See
Technical
Data
supplied
w/Hose
3Dispense Gun 1602 &
1621
See
Technical
Data
supplied
w/Gun
Heaters for 4-Zone Control Panels
Zone Component Terminals
Value
Range
1 Follower 3L1 & 3L3 98 – 127
h
3L2 & 3L3 ohms
2Dispense Gun 1532 &
1551
See
Technical
Data
supplied
w/Gun
3Dispense Hose 1602 &
1621
See
Technical
Data
supplied
w/Hose
4 Pump 5L1 & 5L2 187.2 ohms
" 24 ohms

18 310528
Installation
Overview of the Temperature Controller Settings
The basic program settings for each temperature
controller satisfy most application needs. These set-
tings are preset at the factory, but can be changed.
The input type, temperature scale, and over tempera-
ture alarm point are the critical controller settings that
you must check before doing an auto-tune or using
any controller in normal operation. See form# 309100
for operation of the temperature controls.
Graco Factory P, I, and d Settings
Table 1 lists the P, I, and d settings for standard control
panels. These settings are preset at the factory. See
form# 309100 for accessing these values and use the
table for reference information only.
Table 1. Graco Factory P, I, and d Settings
Category P I d Unit Voltage
Follower 2 326 49 480
Hose .8 63 9 ALL
Pump 4.2 1081 162 480
Gun 2.1 126 19 ALL
These P, I, and d values are usually generated by
running an autotune process for each heat zone. The
controllers will automatically find the proper P (propor-
tional), I (integral), and d (derivative) values during this
autotune process. These are values that allow the heat
zones to reach their maximum temperature as fast as
possible without significantly exceeding desired tem-
perature.

310528 19
Installation
Flushing the System
Flushing the system before its initial use can prevent
material contamination, which may cause the material
to fail or perform poorly.
CAUTION
Flush the system before performing the initial
material loading procedure. The system was facto-
ry-tested using a light soluble oil, a soybean oil, or
some other oil as tagged. Flush the system to avoid
contaminating the material that has been designated
for initial material loading.
To flush the system, perform the following procedure:
1. Select the material for the initial material load.
2. Verify whether the factory-test oil and the initial
material load are compatible:
a. If the two substances are compatible, omit the
remaining steps in this procedure and perform
the Initial Material Loading procedure on
page 20.
b. If the two substances are incompatible, per-
form the remaining steps in this procedure to
flush the system.
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
and always provide adequate ventilation.
3. Select a drum containing solvent that can dissolve,
clean, and eliminate the factory-test oil from the
system. If necessary, check with Graco or the ma-
terial supplier for a recommended solvent.
4. Before flushing, be sure the entire system and
flushing drums are properly grounded. Refer to
Ground The System, on page 14.
5. Perform steps 1 through 7 of the Initial Material
Loading procedure on page 20 to load the drum
containing the solvent.
6. Flush the solvent through the system for approxi-
mately 1 to 2 minutes.
7. Remove the drum containing the solvent.
8. Perform the Initial Material Loading procedure
on page 20.
Starting Up the System
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce risk of injury or equipment
damage:
DMake sure all material hose connec-
tions are secure.
DMake sure system is ready to pres-
surize before pressurizing system.
CAUTION
To help avoid damage to equipment, be sure to open
the dispense valve during system heatup to alleviate
pressure which might occur in the system due to ma-
terial expansion.
1. Check all material hoses and fittings to insure
tightness and to prevent any material leakage.
2. Check all system air and electrical lines. Make
sure that all routing of air and electrical lines will
not interfere with any moving components within
the fixture.
3. Raise the arm, using the following procedure:
a. Close all air regulators.
b. Move the ram hand valve lever to the UP posi-
tion.
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 drum to be used, move the ram
hand valve lever to OFF.
4. Turn the electrical disconnect ON.
5. On the electrical control panel, turn the CONTROL
ON switch to ON.
6. Check the temperature controller set points and
change them if necessary. See Changing the Set
Point in form# 309100.
7. Wait until all system zones are heated to the pre-
set temperatures. Go to the next section, Initial
Material Loading.

20 310528
Installation
Initial Material Loading
WARNING
The material and equipment will be
hot! To reduce risk of injury, wear eye
protection, gloves and protective clothing
when installing, operating, or
servicing this dispensing system.
PRESSURIZED FLUID HAZARD
To reduce the risk of serious bodily inju-
ry, such as fluid injection or splashing
fluid in the eyes or on the skin, ALWAYS
wear eye protection and protective clothing when
installing, operating, or servicing this dispensing
system.
WARNING
WARNING
MOVING PARTS HAZARD
Moving equipment parts can cause per-
sonal injury, including severing of hands
or fingers. Make sure all personnel are
clear of moving parts before operating
the equipment.
WARNING
To reduce risk of injury or damage to
equipment, be sure to tighten the bleed
stick after bleeding the air. Otherwise hot
material will leak out of the opening.
CAUTION
The use of a non-compatible lubricant can cause
material contamination or inadequate performance.
Use only a lubricant compatible with the material to
be pumped. Check with the material supplier for a
recommended lubricant.
CAUTION
To help avoid damage to equipment, do not use a
drumpail of material that has been dented or other-
wise damaged; damage to the follower wipers may
result.
1. Make sure the follower plate is high enough to put
a drumpail of material under it.
2. Open a drumpail of the proper material and locate
it under the elevated follower plate.
NOTE: Whenever drumpail changes are required, re-
move the cover from the drumpail of new ma-
terial by holding it level and lifting it straight up.
Tipping the cover may allow accumulated dirt
to spill into the drumpail, which may result in
damage to the equipment.
3. Lubricate the follower wipers with a lubricant com-
patible with the material to be pumped. Check with
your material supplier for compatibility.
4. Before lowering the pump into the drumpail, make
sure that nothing is between the follower plate and
the drumpail, or between the ram tie bar and the
top of the ram posts.
5. Lower the pump into the drumpail of material.
a. To lower the pump and follower into the drum-
pail, move the ram hand valve lever to the
DOWN position and slowly adjust the air regu-
lator.
b. As the follower enters the drumpail, loosen the
bleed stick. Removing the bleed stick allows
trapped air between the follower plate and the
top of the material to escape.
c. When air stops exhausting from the bleed stick
port, replace and tighten the bleed stick.
6. Place a material waste container under the dis-
pense gun.
7. Slowly adjust the pump air regulator. This will start
the pump and fill the material passage.
8. Dispense material from the dispense gun until air-
free material is dispensed. Allow the system to
heat for approximately 30 minutes.