Graco Therm-O-Flow Plus HM55-D Series User manual

309085
Rev. A
First choice when
quality counts.
12
3
TI0411
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
200 Liter (55 Gallon) Drum Size
Hot Melt Drum Unloaders
All Models
Therm-O-Flow Plus
Maximum Operating Temperature All Models 400F (204C)
Senator Powered Unloaders Models A–1 and A–2
Maximum Fluid Working Pressure 1900 psi
(13 MPa, 131 bar)
Maximum Air Inlet Pressure 100 psi (0.7 MPa, 7 bar)
Bulldog Powered Unloaders Models A–3 and A–4
Maximum Fluid Working Pressure 3100 psi
(21 MPa, 213 bar)
Maximum Air Inlet Pressure 100 psi (0.7 MPa, 7 bar)
King Powered Unloaders Models A–5 and A–6
Maximum Fluid Working Pressure 3900 psi
(26 MPa, 269 bar)
Maximum Air Inlet Pressure 90 psi (0.6 MPa, 6.2 bar)
Refer to page 2 for the Table of Contents.
Refer to Graco Form 309180, Installation and
Operation Guide for installation and operation
instructions.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 2000, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Parts

2 309085
Table Of Contents
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a Location for the Ram 9. . . . . . . . . . . . . .
System Accessories and Modules 9. . . . . . . . . . . . .
Installation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Ram 12. . . . . . . . . . . . . . . . . . . . . . . . . .
Electrically Connect Hoses to the
Electrical Control Panel 12. . . . . . . . . . . . . . . . . . . . .
Ground The System 13. . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Electrical Control Panel
to a Power Source 14. . . . . . . . . . . . . . . . . . . . . . .
Check the Resistance Between the
Supply Unit and the True Earth Ground 15. . . . .
Checking Resistance 15. . . . . . . . . . . . . . . . . . . . . . .
Overview of the Temperature
Controller Settings 17. . . . . . . . . . . . . . . . . . . . . . .
Graco Factory P, I, and d Settings 17. . . . . . . . . . .
Flushing the System 18. . . . . . . . . . . . . . . . . . . . . . .
Optional Low Level Kit 233096 19. . . . . . . . . . . . . . .
Optional Inactivity Timer Kit 233097 20. . . . . . . . . .
Operation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 23. . . . . . . . . . . . . . . . . .
Reading the Electrical Control Panel
Indicators 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading the Temperature Controllers 26. . . . . . . . .
Resetting the Ground Fault Interrupt 27. . . . . . . . . .
Advanced Pendant Control Screen Map 28. . . . . . . .
Advanced Pendant Control 31. . . . . . . . . . . . . . . . . . .
Operation of Pendant 32. . . . . . . . . . . . . . . . . . . . . . .
Recipe Functions 34. . . . . . . . . . . . . . . . . . . . . . . . . .
7 Day Timer Functions 36. . . . . . . . . . . . . . . . . . . . .
Date/Time Functions 38. . . . . . . . . . . . . . . . . . . . . . .
Zone Setup/PID Type Selection 39. . . . . . . . . . . . . .
Manual Send SV Temperature 40. . . . . . . . . . . . . . .
Password Change 41. . . . . . . . . . . . . . . . . . . . . . . . .
Load Graco Defaults 42. . . . . . . . . . . . . . . . . . . . . . .
Dual Ram Cross-Over Control Function 44. . . . . . .
X-Over Overview 44. . . . . . . . . . . . . . . . . . . . . . . . . .
Setup of X-Over 46. . . . . . . . . . . . . . . . . . . . . . . . . . .
Dedicate Zones 47. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting/Stopping X-Over Operations 48. . . . . . . . .
X-Over Factory Setup 50. . . . . . . . . . . . . . . . . . . . . .
Communication Errors 51. . . . . . . . . . . . . . . . . . . . . . .
Ram Troubleshooting 52. . . . . . . . . . . . . . . . . . . . . . . .
Heated Pump Troubleshooting 53. . . . . . . . . . . . . . . .
Air Motor Troubleshooting 54. . . . . . . . . . . . . . . . . . . .
Electrical Control Panel Troubleshooting 54. . . . . .
Service 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection Frequency 55. . . . . . . . . . . . . . . . . . . . . .
Removing/Replacing the CB100
Temperature Controller 55. . . . . . . . . . . . . . . . . . .
Ram Service 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing a Material Drum from the
Supply Unit 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Ram Plate 56. . . . . . . . . . . . . . . . . . . .
Pump Removal and Replacement 58. . . . . . . . . . . .
Separating the Pump andthe Air Motor 59. . . . . . .
Reattaching the Air Motor to the Pump 59. . . . . . . .
Separating the Ram Plate from the Pump 59. . . . .
For 480 VAC Supply Units –
Junction Box Schematic 60. . . . . . . . . . . . . . . . . .
For 240 VAC Supply Units –
Junction Box Schematic 33. . . . . . . . . . . . . . . . . .
Parts 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All Models Supply Unit 62. . . . . . . . . . . . . . . . . . . . . .
All Models Air MOtor and Pump Assembly 64. . . .
Model 243276 Series A Heated Pump 66. . . . . . . .
Models 243300 & 243874 Ram Plate 68. . . . . . . . .
Model 243422 Depressurization Kit 70. . . . . . . . . . .
Model 243302 6-zone and 8-zone
Control Installation Kit 71. . . . . . . . . . . . . . . . . . . .
Model 243275 Drip Shield Mount Kit 72. . . . . . . . . .
Model C32463 Saddle Assembly Clamp 73. . . . . .
All Models Control Panel Component Layout 74. .
Control Box Spare Parts List 75. . . . . . . . . . . . . . . .
Dimensions 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 82. . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 82. . . . . . . . . . . . . . . . . . . . . . .

3309085
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.
This equipment is for professional use only.
Read all instruction manuals, warnings, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your
Graco distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed 125 psi (8.8 bar) maximum inbound air pressure to the ram.
Never exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 81.
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.
Route 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).
Do not use the hoses to pull the equipment.
Use 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 manufac-
turer’s literature before using fluid or solvent in this pump.
Always wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid
and solvent manufacturers.
Wear hearing protection when operating this equipment.
Comply with all applicable local, state and national fire, electrical and other safety regulations.

4 309085
WARNING
HOT SURFACE AND FLUID HAZARD
Heated fluid can cause severe burns and can cause equipment surfaces to become very hot.
Wear eye protection, gloves and protective clothing when installing, operating, or servicing this
dispensing system.
Be sure to tighten the bleed stick after bleeding the air. Otherwise hot material will leak out of
the opening.
Do not touch the metal heat sink when the surface is hot.
Allow the equipment to cool thoroughly before servicing.
Do not wipe hot fluid that gets on your skin.
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
Fluid from the spray gun/dispense valve, 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.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
medical attention.
Do not point the gun/valve at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip/nozzle.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Always have the trigger guard on a spray gun if you are spraying.
Check the gun diffuser operation weekly (if so equipped). Refer to the gun manual.

Check the gun diffuser operation weekly (if so equipped). Refer to the gun manual.
Be sure the gun/valve trigger safety operates before dispensing.
Lock the gun/valve trigger safety when you stop dispensing.
Follow the Pressure Relief Procedure on page 23 if the spray tip/nozzle clogs, and before
cleaning, checking or servicing the equipment.
Tighten all fluid connections before operating the equipment.
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.

5309085
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 electric shock and other serious injury.
Ground the equipment, the object being dispensed to, and all other electrically conductive
objects in the dispense area. See Ground the System on page 13.
Do not use this equipment with flammable fluids.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Keep the dispense area free of debris, including solvent, rags, and gasoline.
If there is any static sparking or you feel an electric shock while using the equipment, stop dis-
pensing immediately. Do not use the equipment until you have identified and and corrected
the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or material.
Do not smoke in the dispense area.
Extinguish all open flames or pilot lights in the dispense area.
Make sure all electrical equipment is installed and operated in compliance with applicable
codes.
Make sure power is disconnected when servicing and repairing equipment.
Have any checks, installation, or service to electrical equipment performed by a qualified electri-
cian only.
Never exceed the maximum wattage of the supply unit. See the wiring diagrams in this manual
for more information.
Only use hoses that have a maximum wattage less than an equal to 1250 watts. Using hoses
with higher maximum wattage could create a runaway temperature condition.
MOVING PARTS HAZARD
Moving parts, such as the ram plate and pump inlet, can pinch or amputate your fingers.
Moving equipment parts can cause personal injury, including severing of hands or fingers.
Make sure all personnel are clear of moving parts before operating the equipment.
Keep clear of all moving parts when starting or operating the equipment.
Keep hands and fingers away from the priming piston during operation and whenever the pump
is charged with air.
Keep clear of the ram plate, pump fluid inlet, and lip of the fluid container when raising or lower-
ing the ram.
Before checking or servicing the ram or pump, follow the Pressure Relief Procedure on page
23.

6 309085
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.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all
local, state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
Avoid exposure to heated material fumes.
Provide adequate ventilation.
PRESSURIZED FLUID HAZARD
Bursts of material and air will exit the bleed port! To reduce the risk of serious injury or dam-
age to equipment, wear eye protection and protective clothing whenever working with this supply
system.

7309085
Overview
How the Therm–O–Flow Plus Works
A heated platen melts the sealant or adhesive and
directs the molten material to the pump inlet. The
material then travels through a heated Check–Mate
pump and heated fluid moves to the application tool.
Model Numbers
The model number stamped on your machine defines
the equipment in the following eight categories:
Motor
Heated Platen
Drum Ram
Heat Controls Supply Voltage
Heat Controls (number of heat zones)
Drum Unloader Options
Application Accessories
Hose Kit Layout
This manual will refer to the model number when
defining parts in your application.
Typical Model Number: HM55–D–2–2–1–1–3–1–2–N–N–N–N–CEG–DEG–NNN–NNN
Model Product Description
HM55–D 55 gal./200 liter Hot Melt Drum Unloader,
Revision D
Code A Power Ratio (Fluid Out/Air In)
119:1 Senator Standard Air Motor
219:1 Senator Quiet Air Motor
331:1 Bulldog Standard Air Motor
431:1 Bulldog Quiet Air Motor
565:1 King Standard Air Motor
665:1 King Quiet Air Motor
N None
Code B Heated Platen Style
1Standard Fin Design Heated Drum Platen
2 MegaFlo High Flow Heated Drum Platen
3Smooth Bottom No Fin Heated Drum
Platen
N None
Code C Drum Ram Style
16.5” Cylinder Dual Post Pneumatic
(100 psi) Drum Ram with Controls
26.5” Cylinder Dual Post Air–Powered
Hydraulic (200 psi) Drum Ram
N None
Code D Heat Control Supply Voltage
1220/240 VAC 50/60 Hz 3 phase
2380/400 VAC 50/60 Hz 3 phase
3470/490 VAC 50/60 Hz 3 phase
4570/590 VAC 50/60 Hz 3 phase
NNone (J–Box only for customer connection)
Code E Number of Heat Zones Available
16 Heat Zones (platen, pump, 2 hoses,
2 accessories)
28 Heat Zones (platen, pump, 3 hoses,
3 accessories)
N None
Code F Drum Unloader Options (select up to 5
or select None for each space)
1Advanced Pendant Control with 7–Day
Timer
2Low Level Kit
3Pump Inactivity Switch Kit
4Vent Hood Kit
5Drum Clam Shell*
6Heavy Duty Drum Clamp*
7Drum Ram Post Saddle Clamps*
N None
* pick only one of 5, 6, and 7
Code G Cross–Over Control
1Dual Unloader Cross–Over Control Kit
N None
Code H Application Kits
_ _ _ or NNN Hose Kit Position One
_ _ _ or NNN Hose Kit Position Two
_ _ _ or NNN Hose Kit Position Three
_ _ _ or NNN Hose Kit Position Four
Model No. HM55–D– __ – __ – __ – __ – __ – __ – __ – __ – __ – __ – __ – __ – __ – __ – __
Code A B C D E F F F F F G H H H H
Fig. 1 Model Code Layout

8 309085
Typical Installation
A Master Air Valve (bleed-type) (required)
B Pump Air Supply Hose
2 Electrical Control Panel
102 Ram Module
104 Heated Ram Plate Assembly
106 Depressurization Valve
109 Pump Assembly
115 Pump Mounting Bracket
202 Air Line Filter
203 Air Line Lubricator
204 Pump Air Regulator
211 4-way Ram Valve (Ram Up/Ram Down)
214 Pump Bleed-Type Master Air Valve (required)
226 Main Air Line Inlet
319 Ram Plate Bleed Stick
327 Lower Wiper
329 Upper Wiper
Fig. 2
115
109
226
A
202
203 204
106
102
319
211
327
104
214
329
B
2
12
3
9515B
9515B

9309085
Typical Installation
For operation and startup, refer to Graco form 309180,
Therm–O–Flow Plus Installation and Operation Guide.
The typical installation discussed below is only a guide
for selecting and installing system components and
accessories. Contact your Graco distributor and refer
to technical data sheet 325008 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 80.
NOTE: For information about converting the ram
from air to hydraulic operation, contact your Graco
distributor.
Selecting a Location for the Ram
Refer to the Ram Mounting and Clearance Dimensions
drawing on page 79 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.
Make sure there is sufficient overhead clear-
ance for the pump and ram when the ram is in
the fully raised position.
If you are installing a vent hood, make sure
there is sufficient horizontal clearance for it.
Make sure the air regulators for the pump and
ram are fully accessible.
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.
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
79 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.
System Accessories and Modules
Before you install the system you should be familiar
with the parts discussed in the subsequent para-
graphs.
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 maxi-
mum wattage could create a failure in
the electrical circuit.
The Therm–O–Flow Plus unit was designed for use
with Graco single–circuit material hoses that are rated
at a maximum of 1250 watts.
When installing a system, make sure:
all air and fluid hoses are properly sized for your
system.
to use only electrically conductive air and fluid
hoses.

10 309085
Typical Installation
Heat Control Zone Selection
The Therm–O–Flow Plus can be ordered withsix (code
E–1) or eight (code E–2) heat zones (see Fig. 3).
Zones 1 and 2 are always used for heated drum platen
and the heated pump. Zones 3 and 4, 5 and 6, and
optional zones 7 and 8 are each available as paired
zones through a 16–pin connector. The heated hoses
have a 16–pin connector on the inlet end cable, and an
8–pin connector on the outlet end cable. All heated
valves, manifolds and heaters are equipped with an
8–pin matching connector. Accessory cables are
available for other possible combinations.
TI0536
Fig. 3
NOTE: Zone seven can be used for hoses up to 15 ft. (4.5 meters) or a heated
header or any accessory device up to 750 watts with the right accessory
cable. Zone eight can be used for hand guns or automatic valves only.
ZONE
1
Control
ZONE
2
Control
ZONE
3
Control
ZONE
4
Control
ZONE
5
Control
ZONE
6
Control
ZONE
7
Control
ZONE
8
Control
Valve 1 Valve 2 Valve 3
Hose 1 Hose 2 Hose 3
Platen Pump
1250 watts
max
500 watts
max
1250 watts
max
750 watts
max
250 watts
max
500 watts
max

11309085
Typical Installation
Air Line Modules
WARNING
PRESSURIZED FLUID HAZARD AND
MOVING PARTS HAZARD
The bleed-type master air valve (C) and
auto depressurization valve (P) are re-
quired 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 (shown)
For more information, refer to Fig. 2 on page 8. The
following components are included with the module:
Bleed-type Master Air Valve (A) is used to shut off
the air supply from the entire supply unit.
Bleed-type Motor Air Valve (214) is supplied in your
system to relieve air trapped between it and the air
motor when the valve is closed (see WARNING
above). This bleed valve should be easily accessi-
ble and located downstream from the air regulator.
It can be used as a safety lockout.
Pump Air Regulator (204) 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.
Auto Depressurization Valve (106) exhausts air
from the system at shutoff. The built-in control
delays startup to allow material to heat thoroughly.
Ram Air Regulator (224) controls the air pressure
to the ram. There are separate air regulators to
control the ram pressure in the up and down direc-
tions.
Ram Air Supply Hose connects the ram air regula-
tor to the air manifold.
Ram Plate Blow-off Valve controls the air pressure
to the ram plate blow-off.
FRL (filter, regulator, lubricator) (202), (203), and
(204) 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.
Fluid Line Accessories (Typical)
A pressure compensator valve controls fluid pressure
to the gun/valve, and dampens pressure surges. Install
the pressure compensator valve in the position shown
in the Typical Installation, using adapters as neces-
sary.
Vent Hood Kit (if supplied)
The vent hood assembly is designed to efficiently 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 m3/min (300 scfm). This kit is recom-
mended for Polyurethane Reactive (PUR) applications.
Heat Control Zone Selection
The Therm–O–Flow Plus can be ordered with six
(Code E–1) or eight (Code E–2) heat zones. Zones 1
and 2 are always used for the drum heated platen and
the heat pump. Zones 3 and 4, 5 and 6, and optional
zones 7 and 8, are available as paired zones through a
16 pin connector. The heated hoses have a 16–pin
connector on the inlet end cable, and an 8–pin connec-
tor on on the outlet end cable. All heated valves,
manifolds and heaters are equipped with an 8–pin
matching connector. Accessory cables are available
for other possible connections.

12 309085
Installation
The installation procedure includes:
locating and installing the ram
electrically connecting hoses to the electrical con-
trol panel
grounding the system
connecting the electrical control panel to a power
source
checking resistance
setting controls on the electrical control panel
Graco form 309180, Therm–O–Flow Plus Installation
and Operation Guide, includes:
starting up the system
initially loading material
Installing the Ram
To install the ram, follow the procedure below. Refer to
the Ram Mounting and Clearance Dimensions drawing
on page 79 for ram mounting and clearance dimen-
sions.
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 13 mm. (1/2”) anchors. Bolt the ram to the floor
with anchors, which are long enough to prevent
the unit from tipping. Refer to the Dimensional
Drawing on page 79.
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 maxi-
mum 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. 4).
1. Connect the plug from hose 1 to the Hose 1/Gun 1
receptacle.
2. Connect the plug from hose 2 to the Hose 2/Gun 2
receptacle.
Fig. 4
Rear View of Electrical Control Box
TI0538
Hose One
Hose Two
Hose Three (optional)

13309085
Installation
Ground The System
Ground the supply unit as instructed here and in the
individual component manuals.
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock:
The 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.
A qualified electrician must complete
all grounding and wiring connections
and check the resistance as
instructed on page 15.
Refer to your local code for the requirements for
a “true earth ground” in your area.
Also read and follow the warnings on page 5.
To reduce the risk of static sparking, ground the pump,
object being dispensed to, and all other spraying/dis-
pensing equipment used or located in the spraying/dis-
pensing area. Check your local electrical code for
detailed grounding instructions for your area and type
of equipment.
Air and Fluid Hoses:
Use only electrically conductive hoses.
Dispensing/Spray Gun
Follow the dispensing/spray gun grounding instruc-
tions.
Object Material is Applied To
Ground the object according to your local code.
Material Drums
Ground the material drums according to your local
code. Use only metal drums placed on a grounded
surface. Do not place the drum on a nonconductive
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.

14 309085
Installation
Connecting the Electrical Control Panel to
a Power Source
The electrical control panel (Fig. 5) 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.
WARNING
ELECTRIC SHOCK HAZARD
Do not connect the electrical control
panel to a power source unless you are
a trained professional. Failure to follow
standard procedures or to observe the necessary
precautions could result in serious bodily injury or
equipment damage.
Fig. 5
TI0535
Have a trained electrician connect the electrical control
panel (Fig. 5) to a grounded electrical source that has
the required service ratings:
CAUTION
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty will be voided. Check the label on the con-
trol box for the proper voltage.
AC
Panel
Voltage
Hz Phase *
Platen
Selection
Full
Load
Amps
220/240 50/60 3 B–1 & B–3 70
B–2 80
380/400 50/60 3 B–1 & B–3 42
B–2 48
470/490 50/60 3 B–1 & B–3 35
B–2 40
570/590 50/60 3 B–1 & B–3 29
B–2 32
B–1 = Standard grid platen: 18 Kw
B–2 = Mega–Flow platen: 21 Kw
B–3 = Smooth bottom platen: 18 Kw
For information about specific terminal locations and
connections, see Control Panel Component Layout
on page 74 and refer to Electrical Setup in Graco form
309180, Therm–O–Flow Plus Installation and Opera-
tion Guide
To connect the control panel to the electrical source:
1. Locate the opening in the control panel‘s top
housing for the conduit that will enclose the wire
from the facility’s power source. The hole will
accept a 1” conduit fitting. It is 1.3” dia. (33mm).
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.

15309085
Installation
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.
NOTE: Use a meter that is capable of measuring re-
sistance at this level.
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.
You can check the resistance of the supply unit’s heat
sensors and heaters.
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 package includes up to eight heat sensors and
controllers for each of the heated zones. 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
components.
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 Fahrenheit).
RTD Sensors
Zone Component Terminals Value Range
1Ram Plate 2161 & 2171 97.4 – 102.8
ohms
2 Dispense
Hose 1
2231 & 2241 97.4 – 102.8
ohms
3 Dispense
Hose 1
2301 & 2310 97.4 – 102.8
ohms
4 Dispense
Gun 1
2371 & 2381 97.4 – 102.8
ohms
5 Dispense
Hose 2
2561 & 2571 97.4 – 102.8
ohms
6 Dispense
Gun 2
2631 & 2641 97.4 – 102.8
ohms
7 Dispense
Hose 3
2661 & 2671 97.4 – 102.8
ohms
8 Dispense
Gun 3
2731 & 2741 97.4 – 102.8
ohms

16 309085
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 Control Panel Component
Layout on page 74 for wiring diagram information.
3. Replace any parts whose resistance readings do
not comply with the ranges listed in Table 1.
NOTE: Check resistance at ambient room tempera-
ture (63 – 77 F).
Table 1. Heaters
Zone Component
Between
Terminals
For Unit
Voltage
Platen Model
Code
Resistance Values
(ohms)
1Ram Plate 3L1 & 3L2 240 B–1 or B–3 6.4 ohms + .65 ohms
Heaters from
J–Box or B–2 5.5 ohms + .55 ohms J–Box or
Control Box Not 240 B–1 or B–3 25.5 ohms + 2.6 ohms
B–2 22 ohms + 2.2 ohms
3L2& 3L3 240 B–1 or B–3 6.4 ohms + .65 ohms
B–2 5.5 ohms + .55 ohms
Not 240 B–1 or B–3 25.5 ohms + 2.6 ohms
B–2 22 ohms + 2.2 ohms
3L3 & 3L1 240 B–1 or B–3 6.4 ohms + .65 ohms
B–2 5.5 ohms + .55 ohms
Not 240 B–1 or B–3 25.5 ohms + 2.6 ohms
B–2 22 ohms + 2.2 ohms
Any leg to
ground
Any Any At least 70K ohms
2 Pump
Heaters from
T1 & TC 240 Any 38.4 ohms + 3.8 ohms
J–Box with
jumpers
installed
B1 & BC 240 Any 38.4 ohms + 3.8 ohms
installed
5L1 & 4L2 240 Any 38.4 ohms + 3.8 ohms
T1 & T2 Not 240 Any 153.6 ohms + 3.8 ohms
B1 & B2 Not 240 Any 153.6 ohms + 15.3 ohms
51 & 42 Not 240 Any 153.6 ohms + 15.3 ohms
3 thru 8 Check hose tag or valve manual for valve

17309085
Installation
Overview of the Temperature Controller Settings
The basic program settings for each temperature con-
troller satisfy most application needs. These settings
are preset at the factory, but can be changed. The
input type, temperature scale, and over temperature
alarm point are the critical controller settings that are
set 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 2 lists the P, I, and d settings for standard control
panels. These settings are preset at the factory. Use
the table for reference information only.
Table 2. Graco Factory P, I, and d Settings
Category P I d Unit Voltage
Ram Plate 41 118 29 ALL
Pump 50 1186 296 ALL
Hose 9.9 51 12 ALL
Gun 75 49 12 ALL
Manifold 24.1 144 36 ALL
Compensator 40.9 87 21 ALL
Header 1.7 109 16 ALL
Regulator 58.5 330 82 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.
It is not recommended that “AutoTune” be used for the
heated pump zone.

18 309085
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 fac-
tory-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 refer to
Graco form 309180, Therm–O–Flow Plus
Installation and Operation Guide, for start up
and operation instructions.
b. If the two substances are incompatible, per-
form the remaining steps in this procedure to
flush the system at ambient temperature.
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.
Provide fresh air ventilation to avoid the buildup of
flammable fumes from solvent or material.
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 13.
5. Turn all heat zones to OFF. This will allow air to
the air motor, with no alarms, in a cold state.
6. Refer to Graco form 309180, Therm–O–Flow Plus
Installation and Operation Guide, for instructions
on how to load the drum containing the solvent.
7. Flush the solvent through the system for approxi-
mately 1 to 2 minutes.
8. Remove the drum containing the solvent.

19309085
Installation
Optional Low Level Kit 233096
The Low Level Kit is used to indicate that a drum is
EMPTY or LOW, depending on the adjustment of the
limit switch. A RED beacon will illuminate when the
switch is activated. The kit contains a limit switch,
mounting bracket, a cable for connecting to the Therm-
O-Flow plus control panel, and a RED beacon assem-
bly. When a drum goes LOW or EMPTY (operator
preference), the RED beacon will illuminate. See Fig.
6.
When ordering this kit individually to connect to an
existing Therm-O-Flow Plus unloader assembly, use
the bolts, screws and washers provided to mount to
the closest ram post to the control box. Mount the limit
switch to the bracket as shown, with the limit switch
lever in the center position of the bracket. This will
ensure it makes contact with the rod actuator. Place
the rod actuator on the ram cylinder rod and adjust so
the switch actuates the RED beacon at the desired
level within the drum.
Also, when the RED beacon is illuminated indicating a
LOW or EMPTY drum, terminals 3161 and 3171 within
the main control box will be OPEN (no continuity).
These terminals 3161 & 3171 are the DRUM NOT
EMPTY/LOW connections available for the customer
for interfacing to other equipment. CLOSED (continu-
ity) at these terminals indicate the drum is NOT empty.
These are dry relay contacts rated at 10A at 28VDC
and 13A at 120VAC to 277VAC.
Fig. 6
1
3
2
TI0675
Electrical Diagram
Rod
Actuator
C58009
Switch
Bracket
Connect straight end to AP connector
on rear of TOF+ control box.
Adjust limit switch height so the switch
trips and the red beacon lights when
the ram plate is 1 in. above the full
down position.
Flat on the guide sleeve must be
parallel to the ram lift tubes.
3
2
1
12
3
TI0674
Side View Rear View
Low Level Kit Mounted on Thermo-Flo Plus
196727
Light
Assy
C58011 Roller
C07560
Switch
116157 Cable

20 309085
Installation
Optional Inactivity Timer Kit 233097
The Inactivity Timer will shut off all power to the heat
zones when the pump has not operated for 2–10
hours. This is done by a proximity switch mounted to
the pump assembly, which senses movement of a
collar mounted to the connecting rods of the air motor
and the pump assembly. Every time the collar moves
in front of the proximity switch, the timer in the main
control box resets itself and starts a new time out
cycle. Once the timer has timed out without pump
activity, the BLUE light indicating AUTO HEAT OFF will
illuminate. To reset, turn the HEAT OFF/ON switch to
OFF, then to ON.
If the Inactivity Timer Kit 233097 is ordered as a kit for
an existing system, the proximity switch will need to be
mounted to the pump assembly and wired to the pump
j–box assembly. Also the timer assembly will come
with wires pre–labeled for mounting within the Therm–
O–Flow plus control box assembly. To connect the
Inactivity Timer Kit, refer to Fig. 7.
The proximity switch contains all the hardware required
to mount to the tie rods of the pump. Ensure the
distance from the top of the mounting plate of the
proximity switch to the bottom of the air motor housing
is 2.63 in. Refer to Fig. 7. Mount the collar over the
existing connecting rod nut by breaking loose the
connection, running the air motor to allow the collar to
fit over the nut, and reconnect the nut to the air motor
shaft. Terminate the wires of the proximity switch in
the pump j–box by removing the plug of an unused
hole and terminate the wires to terminals 1251 and
1311 as shown. (Polarity of the wires is not important).
Snap the timer assembly onto the din rail of the control
panel as shown. The schematic diagram of the related
section of the control panel is shown for reference.
Ensure the top dial on the timer is set for 1 to 10
hours, and the bottom dial is set at 2. This will set the
timer for automatic shut–off of all power to the heat
zones on the control box. If the timer has not been
reset by the proximity switch by movement of the
pump, all the heat zones will not have power to oper-
ate. The BLUE light on the front of the panel will be
illuminated, indicating the timer has timed out and the
AUTO HEAT OFF has been activated by the timer. To
reset the timer, turn the HEAT ON/OFF switch to OFF
then ON again. The timer will reset and another 2
hour time out will start.
NOTE: Never set the timer for less time than it takes
your system to fully heat up from a cold start.