Therm-O-Flow Plus For all Drum Unloaders

Installation Operation Therm-O-Flow Plus For all Drum Unloaders 309180E Refer to Graco Form 309085 for further information, including parts and service Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 21 for maximum working pressures. 2 1 3 TI0411

Table Of Contents Symbols...................................... 3 Warnings..................................... 3 Unpacking and Repacking..................... 7 Ram Location Selection....................... 7 Mechanical Setup............................. 8 Electrical Setup.............................. 10 Material Loading............................. 12 System Heat Up.............................. 14 Pump Bleeding.............................. 16 System Bleeding............................. 17 Drum Changing.............................. 18 System Shut Down........................... 20 Technical Data............................... 21 Related Publications......................... 21 Dimensions.................................. 22 Graco Standard Warranty..................... 24 Graco Information............................ 24 2 309180

Symbols Warning Symbol 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. 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 (0.9 MPa, 9 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 21. Be sure that all spray/dispensing equipment and accessories are rated to withstand the maximum working pressure of the pump. Do not exceed the maximum working pressure of any component or accessory used in the system. Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 82 C (180 F) or below -40 C (-40 F). 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 manufacturer 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. 309180

HOT SURFACE AND FLUID HAZARD Heated fluid can cause severe burns and can cause equipment surfaces to become very hot. Wear protective gloves and clothing when operating this equipment in a heated system. Do not touch the metal heat sink when the surface is hot. Allow the equipment to cool thoroughly before servicing. Some heated systems are designed to dispense Polyurethane (PUR) heated materials. PUR systems are supplied with ventilation hoods, and require proper ventilation and specially designed system components. SKIN INJECTION HAZARD Spray from the spray gun, hose leaks, or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause serious injury. Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgical treatment. 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 the gun when dispensing. Check the gun diffuser operation weekly. 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 in manual 309085 if the 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 immediately. Do not repair high pressure couplings; you must replace the entire hose. Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by kinks or bends near the couplings. 4 309180

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. Ground 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. Do not use this equipment with flammable liquids. 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 dispensing immediately. Do not use the equipment until you have identified and corrected the problem. Make sure all electrical work is performed by a qualified electrician only. 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 electrician 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. 309180

MOVING PARTS HAZARD Moving parts, such as the ram follower plate/pump inlet can pinch fingers. Do not operate the equipment with the guard removed. 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 follower plate, pump fluid inlet, and lip of the fluid container when raising or lowering the ram. Before checking or servicing the ram or pump, perform the Pressure Relief Procedure in the equipment instruction manual. 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. 6 309180

Unpacking and Repacking Unpacking the Product Your Therm-O-Flow heated drum unloading system 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 included in the box. Any shortages or other inspection problems should be reported immediately. Repair and Repacking the Product When the Therm-O-Flow heated drum unloading system 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 heated drum unloading system components are customarily serviced by the purchaser or an authorized Graco distributor. When service is required, follow the Service procedures in manual 309085. 4. Remove the unit from the skid and place it in the desired location (See Selecting a Location for the Ram). 5. 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. Ram Location Selection When selecting a location for the ram, keep the following in mind: 1. There should be sufficient space for installing and using the equipment. Make sure there is sufficient overhead clearance for the pump and ram when the ram is in the fully raised position [approximately 110 inches (280 cm)]. If you are installing a vent hood, make sure there is sufficient horizontal clearance for it. 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 23 for more information. 4. If you are installing a vent hood, make sure the ram is installed near a connection to the factory ventilation system. 5. Bolt the unit in place. Make sure the air regulators for the pump and ram are fully accessible, with room to stand directly in front of the ram air control box and the electrical control box. Make sure there is easy and safe access to an appropriate electrical power source. The National Electrical Code requires 3 feet (0.9 m) of open space in front of the electrical panel. 6. Verify the exact system model number you are installing and thoroughly read the service manual. 7. If your machine is equipped with optional level controls, the warning light needs to be turned back upright, and tightened in place. 309180

Mechanical Setup Follow the procedure below for mechanical setup. 1. Check, and if necessary, tighten the heated hose connection at the pump outlet. 2. Remove nut (A Fig. 2) to fill air line lubricator with SAE 10W NON DETERGENT OIL (not included with equipment). A PH00032 Fig. 2 Fig. 1 3. Wrap exposed fittings on pump outlet with Nomex insulation and secure insulation using fiberglass tape (Fig. 3). Fig. 3 PH00012 8 309180

Mechanical Setup 4. Fill wet cup (Fig. 4), located on top of the displacement pump, 2/3 full of Graco TSL. fluid. 6. Connect a 1/2 air line from an air source, capable of delivering a minimum of 15 cfm (0.4 m 3 /m) at 80 psi (552 kpa, 5.5 bar), to the air control (Fig. 6). DO NOT USE QUICK DISCONNECTS. PH00032 PH00013 Fig. 6 Fig. 4 5. Back off all air regulators (Fig. 5 and Fig. 6) to their full counterclockwise position. NOTE: The UP/DOWN control lever is shipped inside the ram control box and should be screwed onto the face of the control now. Fig. 5 PH00014 309180

Electrical Setup NOTE: Required voltage and amperage will be noted on the machine I.D. plate. Before running power to the unit, make sure the machine electrical requirements on the I.D. plate are compatible with the plant electrical service. 2. Securely tighten 8 socket electrical connectors on short heated hose leads into 8 pin receptacle located on the dispense valves (Fig. 8). Follow the procedure below for electrical setup. 1. Securely tighten 16 pin electrical connectors on long heated hose leads into 16 socket receptacles located on the back of the electrical control panel (Fig. 7). Fig. 8 PH00017 Fig. 7 PH00016 10 309180

Electrical Setup FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD To reduce the risk of fire, explosion, or electric shock: The unit must be grounded to either the building ground or a true earth ground. The power source conduit is not an adequate ground for the system. A qualified electrician must complete all grounding and wiring connections and check the resistance. Refer to your local code for the requirements for a true earth ground in your area. 4. Have a qualified electrician connect your plant power to the control box disconnect switch according to local codes. A 1 3/8 (35 mm) diameter opening is provided on top of the box, above the connections. This opening is suitable for a 1 npt conduit or strain relief fitting (Fig. 10). 3. Open electrical enclosure door and locate main disconnect (Fig. 9). Fig. 10 PH00031 NOTE: Detailed information about checking for proper grounding and heater resistance is provided in manual 309085. Fig. 9 PH00018 309180

NOTE: Before loading material, make sure there is a minimum overhead clearance of 110 (2.8 m) and all air regulators are backed off to their full counterclockwise position. 1. Turn on the air supply (Fig. 11). Material Loading Fig. 13 PH00022 Fig. 11 2. Place the ram UP/DOWN lever (Fig. 12) in the UP position. CAUTION As the ram rises, carefully observe the heated hose cables, making sure they do not catch on any components. If a cable catches, immediately stop the ram from raising by putting the RAM UP DOWN lever into the down or neutral position and route the hose cables to prevent damage. 4. When ram is fully raised, install the drum centering guides, which were shipped separately to prevent damage. 5. Apply a thin coating of Graco TSL oil to the follower plate drum seals (Fig. 14). Fig. 12 PH00019 3. SLOWLY turn the ram UP regulator clockwise until the ram begins to rise. Fig. 14 PH00020 6. Open material container, remove any packing material, and inspect material for any contamination. 12 309180

7. Slide the material drum into position, making sure that the material drum rests evenly between the drum centering guides and the drum is fully backed into the stops located near the back of the ram baseplate. 8. Remove the follower plate bleed handle (Fig. 15). Material Loading Fig. 16 PH00022 To reduce the risk of serious injury, keep hands away from both the follower plate and material drum when lowering the ram. Fig. 15 PH00021 9. Place the ram UP/DOWN lever in the DOWN position. CAUTION Lowering the ram without a drum in place can damage the drum centering guides (if equipped). 11. After the follower plate seals enter the material drum, adjust the ram DOWN air regulator (Fig. 16) to 30 50 psi (207 345 kpa, 2.1 3.4 bar). 12. When the ram stops, reinsert the follower bleed handle (Fig. 15) and hand tighten the bleed handle. 10. SLOWLY turn the ram DOWN regulator (Fig. 16) clockwise to approximately 5 10 psi (34 69 kpa, 0.3 0.7 bar) The ram will now begin to lower the follower plate into the material drum. 309180

System Heat Up Follow the procedure below for heating up the system. To reduce the risk of bursting a hose, never pressurize a hot melt system before turning on the heat. Always allow the controllers to keep the air motor off until factory preset safe temperatures are reached. See instruction manual 309085 for complete information. 2. Place the HEAT ON/OFF switch to the ON position. CAUTION The dispense valve must be open, and kept open, over a waste container while the system is heating up. This will prevent a pressure build up caused by fluids or gasses expanding from the heat. 1. Turn the main disconnect on the control box door (Fig. 17) to the ON position. Fig. 18 PH00024 3. Each individual heat zone control with a heat device connected must be turned to RUN. Any zone without a device connected must be turned to STOP. To switch the zones between RUN and STOP push the <R/S button. 4. Determine the temperature to which material needs to be heated. Consult material supplier for recommended material application temperatures. NOTE: If an accessory pendant control is used with multiple control boxes, always turn on the power for the accessory controls before the master control box. See manual 309085 for pendant operation. Fig. 17 PH00023 14 309180

System Heat Up 5. Adjust the set points on the individual controllers to the desired temperatures by pressing the UP or DOWN arrow keys on the temperature controllers (Fig. 19). The system will begin to heat. NOTE: The air will be locked from the air motor until all temperature zones are within a preset window of the temperature set points, allowing the system to heat fully and complete the material heat soak period. Fig. 19 PH00025 309180

Pump Bleeding To reduce the risk of serious burns, always wear eye protection, gloves, and protective clothing when working around hot melt equipment and hot melt materials. 4. Locate bleed stem just below the outlet of the displacement pump (Fig. 22). Follow the procedure below for bleeding the pump. 1. Make sure the system has completed the approximately 40 minute heat soak cycle and is up to temperature. 2. Check that the air motor air isolation ball valve, located on the air control plate (Fig. 20), is closed. Fig. 22 PH00026 To reduce the risk of serious burns, always wear eye protection, gloves, and protective clothing when working around hot melt equipment and hot melt materials. 5. Place a waste container under the bleed stem. Using an adjustable wrench, open the bleed stem counterclockwise 1/3 1/2 turn. Fig. 20 PH00032 3. Adjust the pump air regulator (Fig. 21) to approximately 10 15 psi (69 103 kpa, 0.7 1 bar). 6. With waste container in place, SLOWLY open the air isolation ball valve located on the lower right of the ram control (Fig. 20). 7. Make sure the pump begins to cycle and heated material flows from the bleed stem after several cycles of the pump. 8. If the pump does not cycle, close the air isolation ball valve, adjust the air motor regulator up by 5 psi (34 kpa, 0.3 bar), and repeat step 6. Never adjust the regulator by more than 5 psi (34 kpa, 0.3 bar) increments. 9. Bleed the pump (Fig. 22) until it moves smoothly in both directions with no air popping or erratic movement and close the air motor ball valve (Fig. 20). 10. Close the bleed stem (Fig. 22). PH00029 Fig. 21 16 309180

System Bleeding To reduce the risk of serious burns, always wear eye protection, gloves, and protective clothing when working around hot melt equipment and hot melt materials. Follow the procedure below for bleeding the system. 1. Make sure the air motor isolation ball valve is closed. 3. Place the dispense valve over a waste container. 4. SLOWLY open the air isolation ball valve located on the lower right of the ram control (Fig. 20). 5. Bleed the system until a smooth flow of material dispenses from the valve. 6. Close the air motor ball valve, close the dispense valve. NOTE: The system is now ready to operate. 2. Lock the dispense valve trigger open by pulling and securing the trigger using the handle ring (Fig. 23), or open the outlet valve on an automatic system. Fig. 23 PH00027 309180

Drum Changing To reduce the risk of serious burns, always wear eye protection, gloves, and protective clothing when working around hot melt equipment and hot melt materials. 3. Adjust the ram plate/drum separation air regulator (R, Fig. 25) to 20 30 psi (138 207 kpa, 1.4 2.1 bar). R When the follower plate appears to be extended fully to the bottom of the material drum, and the pump begins to cavitate, a drum change is necessary. Follow the procedure below to change the drum on a fully heated machine. 1. Close the air motor isolation ball valve (Fig. 20). 2. Place the ram UP/DOWN lever (Fig. 24) in the UP position. PH00014 Fig. 25 Fig. 24 PH00019 Excessive air pressure in the material drum could cause the drum to rupture, causing serious injury. The ram plate must be free to move out of the drum. Never use drum separation air with cold adhesive or a damaged drum. Positive pressure is released from the drum when the ram plate seal is pulled clear. Always wear protective clothing and stand directly in front of the ram control box when removing the drum. 18 309180

Drum Changing 4. Push and hold the drum separation air push button (Fig. 26). The plate will begin to raise. 6. Continue to push the drum separation air button (Fig. 26) only enough to keep the drum from rising up with the follower plate. Excessive air pressure in the material drum could cause the drum to rupture, causing serious injury. The ram plate must be free to move out of the drum. Never use drum separation air with cold adhesive or a damaged drum. Positive pressure is released from the drum when the ram plate seal is pulled clear. Always wear protective clothing and stand directly in front of the ram control box when removing the drum. Fig. 26 PH00030 5. As the follower plate is rising, adjust the ram UP regulator (Fig. 27) to approximately 10 15 psi (69 103 kpa, 0.7 1 bar). 7. Once the follower plate leaves the drum, place the drip tray in the brackets provided. Never reach under the heated follower plate after it leaves the drum. Serious burns could result from dripping materials. 8. Follow the steps in MATERIAL LOADING (page 12) and PUMP BLEEDING (page 16). NOTE: It is only necessary to lubricate the follower plate tire seals on initial material loading. Fig. 27 PH00022 309180

System Shut Down Follow the procedure below for normal system shut down, such as at the end of the work day. 5. If the optional 7 day timer is not being used, position the main disconnect (Fig. 29) to OFF. 1. Make sure the pump rod is parked in the down position. 2. Close the air motor isolation ball valve. 3. If a 7 day timer is not being used, place the HEAT OFF/ON switch (SS125) (Fig. 28) to the OFF position. Fig. 28 PH00024 Fig. 29 PH00023 4. Lock the dispense valve trigger open by pulling and securing the trigger using the handle ring. CAUTION Many hot melt materials tend to expand when heating up and may cause a heated hose to burst. Avoid the potential of bursting a hose by opening the dispense valve during system heat up and lock the dispense valve trigger open every time you shut the system down. 20 309180

Technical Data Description Specification Voltage................................. Optional; check I.D. plate and manual 309085 Pump Area.............................. 8 cm 2 Pump Stroke Length...................... 11.8 cm 2 Maximum Air Inlet Operating Pressure Verify on I.D. Plate Senator Motor........................ Bulldog Motor........................ King Motor........................... Maximum Fluid Operating Pressure (pump only) Verify on I.D. Plate Senator Motor........................ Bulldog Motor........................ King Motor........................... Maximum Operating Temperature.......... Wetted Parts (ram plate through pump)..... Weight.................................. Main Air Inlet............................ Fluid Outlet (pump)....................... 100 psi (0.7 MPa, 7 bar) 100 psi (0.7 MPa, 7 bar) 60 psi ( 414 kpa, 4.1 bar) Check I.D. Plate 1900 psi (13 MPa, 131 bar) 3100 psi ( 21 MPa, 214 bar) 3300 psi (23 MPa, 228 bar) 400F (204C) PTFE coated aluminum, zinc or cadmium plated carbon steel, stainless steel, tungsten carbide, silicone rubber, fluoroelastomer, bronze approximately 1760 lb (800 kg) 1/2 npsm union swivel 1 npt(f) Related Publications Form Name Form# Therm-O-Flow Plus Manual................ 309085 309180

Dimensions Electrical Control Panel Mounting and Clearance Dimensions 10 (254 mm) 46.8 (1189 mm) 37.25 (945 mm) 25.4 (646 mm) Fig. 30 9513A 22 309180

Ram Mounting and Clearance Dimensions Dimensions 48 (1168 mm) 42 (1067 mm) 36.9 (937 mm) 25 (635 mm) 21 (533 mm) 108.2 (2748 mm) 68.2 (1732 mm) 64 (1626 mm) 16.7 (424 mm) Fig. 31 5.2 (132 mm) 11.1 (282 mm) 309180

Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées. Graco Information TO PLACE AN ORDER, contact your Graco distributor, or call to identify the distributor closest to you: 1 800 328 0211 Toll Free 612 623 6921 612 378 3505 Fax All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. MM 309180 24 309180 Graco Headquarters: Minneapolis International Offices: Belgium, Korea, China, Japan GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440 1441 www.graco.com PRINTED IN U.S.A. 309180 06/2000, Revised 3/2006