Operation ThermoLazer® 200/200TC/300TC and ThermoLazer ProMelt™ Pavement Marking Systems 3A1319F EN - For professional application of thermoplastic traffic marking compound materials (reflective beads applied simultaneously with screeding) - For outdoor use only (not to be operated in rain or damp conditions) Fuel: LP Gas (Propane Vapor) Burner capacities: See Technical Data, page 38.
System Chart System Chart SmartDie II used on ThermoLazer 300TC and ProMelt only. Smart Die II Part No. Smart Die Description 17A173 24H431 24H426 24H432 24H427 24H433 24H428 24H434 24H429 24H430 ‡17A174 24H437 24H435 24H436 24J785 ‡17A175 2 in. (5 cm) 3 in. (8 cm) 4 in. (10 cm) 5 in. (12 cm) 6 in. (15 cm) 7 in. (18 cm) 8 in. (20 cm) 9 in. (22.5 cm) 10 in. (25 cm) 12 in. (30 cm) 16 in. (41 cm) 3-3-3 in. (8-8-8 cm) 4-3-4 in. (10-8-10 cm) 4-4-4 in. (10-10-10 cm) 4-6-4 in. (10-15-10 cm) 6-4-6 in.
Contents Contents System Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component Identification - ThermoLazer 200 . . . . 6 Component Identification - ThermoLazer 200 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Component Identification - ThermoLazer 200TC .
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Warnings WARNING PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to: • Clothing and respirator as recommended by the fluid, material, and solvent manufacturer. • Gloves, shoes, overalls, face shield, hat, etc. rated for elevated temperatures of at least 500° F (260° C).
Component Identification - ThermoLazer 200 Component Identification - ThermoLazer 200 Q R N S M ZZ P X L K G U J T H V C A F E D B ti22640A W A B C D E F G H J K L M Kettle Main Burner Front Screed Box Burners Flame Indicator Screed Box (FlexDie) Rear Screed Box Burners Bead Dispenser Box Rear Swivel Wheel Rear Swivel Unlock Lever Front Screed Box Manual Shut-Off Rear Screed Box Manual Shut-Off Torch Screed Box/Bead Dispenser Box Actuator N P Q R S T U V W X ZZ ControlFlow™ Gate Valve
Component Identification - ThermoLazer 200 Component Identification - ThermoLazer 200 (continued) CC AA BB ti22642a AA Kettle Temperature Control Knob BB Kettle Temperature Indicator 3A1319F CC System Regulator 7
Component Identification - ThermoLazer 200TC Component Identification - ThermoLazer 200TC S T U Q P ZZ Z R N J W M V B C K L X H E A G F D Y A B C D E F G H J K L M N Kettle Main Burner Kettle Pilot Burner Kettle Thermopile Front Screed Box Burners Flame Indicator Screed Box (FlexDie) Rear Screed Box Burners Bead Dispenser Box Rear Swivel Wheel Rear Swivel Unlock Lever Front Screed box Manual Shut-Off Rear Screed Box Manual Shut-Off Torch P Q R S T U V W X Y Z ZZ ti22640a Screed Box/Bead
Component Identification - ThermoLazer 200TC Component Identification - ThermoLazer 200TC (Continued) DD CC AA BB ti22641a AA Kettle Temperature Control Knob BB Kettle Temperature Indicator CC Kettle Gas Safety Valve DD System Regulator 3A1319F 9
Component Identification - ThermoLazer 300TC Component Identification - ThermoLazer 300TC U P N Z X S W A AB L C J M V R ti24933a T K H A Kettle Main Burners (2) R ControlFlow Gate Valve C Kettle Pilot Burner S ControlFlow Gate Valve Actuator H Line Guide T FatTrack Swivel Tire J LP Gas Cylinder Holder U Front Swivel Unlock Lever K Screed Box Lever V Kettle Pilot Igniter Electrode L Kettle Thermopile W Access Cover with Latches M Bead Dispenser Box X Agitator Actua
Component Identification - ThermoLazer 300TC Component Identification - ThermoLazer 300TC (Continued) QQ SS AA MM NN PP LL KK UU BB GG DD HH ti14146a CC EE AA Kettle Temperature Control Knob BB Kettle Temperature Indicator CC Kettle Gas Safety Valve DD Kettle Pilot Burner Igniter EE Screed Box (SmartDie II) GG Front Screed Box Burners HH Flame Indicator KK Kettle Burners Manual Shut-Off Valve LL Kettle Burner Regulator MM Lifting Ring NN Lid/Lever Latch PP Propane Tank Co
Component Identification - ThermoLazer ProMelt Component Identification - ThermoLazer ProMelt U X P N Z W S A L C J AB M V R ti24934a T K H A Kettle Main Burners (2) R ControlFlow Gate Valve C Kettle Pilot Burner S ControlFlow Gate Valve Actuator H Line Guide T FatTrack Swivel Tire J LP Gas Cylinder Holder U Front Swivel Wheel Unlock Lever K Screed Box Lever V Kettle Pilot Igniter Electrode L Kettle Thermopile W Access Cover with Latches M Bead Dispenser Box X Agitato
Component Identification - ThermoLazer ProMelt Component Identification - ThermoLazer ProMelt (Continued) QQ AA SS RR MM NN BB LL KK UU PP GG TT VV HH DD ti15949a CC EE AA Kettle Temperature Control Knob BB Kettle Temperature Indicator CC Kettle Gas Safety Valve DD Kettle Pilot Burner Igniter EE Screed Box (SmartDie II) GG Front Screed Box Burners HH Flame Indicator KK Kettle Burners Manual Shut-Off Valve LL Kettle Burner Regulator MM Lifting Ring NN Lid/Lever Latch PP
Important Safety Information Important Safety Information If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or death. Keep gas supply hose away from hot surfaces and flames. Use equipment in accordance with state and local ordi nances with Storage, Handling and Transportation of Liquid Petroleum Gases, ANSI/NFPA58 or CSA B149.1 If equipment has been in storage, check for insects and insect nests on burners and Venturi tubes.
Important Safety Information Important Safety Information Front Screed Box Burners and Rear Screed Box Burn ers will need to be ignited to test gas lines and fitting downstream of flame adjusting valve. If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or death. BEFORE LIGHTING: Smell all around the working area for gas. Be sure to smell next to the ground because propane is heavier than air and will settle on the ground.
Important Safety Information Important Safety Information Check gas supply hose connection to LP-gas cylinder. Make sure fitting is free of debris before connecting to tank. Make sure gas connection is screwed completely on and is free of leaks.
Lighting Instructions Lighting Instructions Lighting Kettle Burners ti23097a NOTE: Read Important Safety Information, page 14-16. ThermoLazer 200 FIRE AND EXPLOSION HAZARD If pilot ignites without depressing the gas safety valve knob, replace gas safety valve. If gas safety valve knob does not pop back after releasing in pilot posi tion, STOP and replace gas safety valve. Shut off gas at propane tank before replacing valve. 1. Open kettle door to view burner. 6. Turn gas safety valve knob to “ON”.
Lighting Instructions 8. Turn temperature control to desired setting. 2. Open propane tank valve. ThermoLazer 300TC/ProMelt 1. Turn temperature control knob (AA) to “OFF”. AA ti14127a ti14124a 3. Turn gas safety valve (CC) to “PILOT” and push in. 2. Turn kettle gas safety valve (CC) to “OFF”. DD ti23102a ti14131b CC 4. Light kettle burner with torch. 3. Open kettle burner view port. (Not all models have a view port.) Kettle Burner ti23096a 5.
Lighting Instructions 8. Continue to push in gas safety valve (CC) for approximately 1 minute. If pilot goes out, repeat steps 4-6 after 10 minutes. FIRE AND EXPLOSION HAZARD If pilot ignites without depressing the gas safety valve knob, replace gas safety valve. If gas safety valve knob does not pop back after releasing in pilot posi tion, STOP and replace gas safety valve. Shut off gas at propane tank before replacing valve. 9. Turn gas safety valve knob to “ON”. 10.
Lighting Instructions ThermoLazer 300TC/ProMelt 1. Turn gas safety valve to “OFF”. 2. Close kettle manual shut-off valve (KK) when finished heating with kettle burners. Close manual shut-off valve on propane tank when finished melting and heating thermoplastic material. ti14127a 2. Remove external torch from holder.
Lighting Instructions Shutting Off Torch 5. Slowly open screed box burners flame adjusting valve. 1. Fully close torch flame adjusting valve. ThermoLazer 300TC/ProMelt ti14605a 2. Close manual shut-off valve on propane tank when finished melting and heating thermoplastic material. ThermoLazer 200/200TC ti14128a ti23072a Front Screed Box Burner Lighting Instructions Read Important Safety Information, page 14-16. 1. Make sure screed box burners flame adjusting valve is turned OFF. 2.
Lighting Instructions Rear Screed Box Burner Lighting Instructions (ThermoLazer 300TC/ProMelt) 5. Place torch at end of screed box burners to ignite and use screed box burners flame adjusting valve to adjust to desired flame. ThermoLazer 300TC shown Read Important Safety Information, page 14-16. 1. Make sure screed box burners flame adjusting valve is turned OFF. 2. Open manual shut-off valve on propane tank located at front of unit. 3. Light torch (see Torch Lighting Instructions, page 20). 4.
Screed Box ThermoLazer 200/200TC (FlexDie) Screed Box ThermoLazer 200/200TC (FlexDie) Installation a Use extreme caution when installing and removing screed box. Expect all equipment components and material to be extremely hot. See MSDS for Thermo plastic Traffic Marking Compound. ti22671a 1. Shut off screed box burners. 4. Attach spring loaded handle (Z) to the yoke (31) and turn 90 degrees to lock into place. Rear Front ti122669a 2. Remove bolt (a) and slide FlexDie into place. Z 31 ti22672a 5.
Screed Box ThermoLazer 200/200TC (FlexDie) Removal 1. Shut off screed box burners. a Rear Front ti122669a ti22677a 2. Remove the two gas hoses from quick release cou plings (10). 10 10 BURN HAZARD Make sure to use two hands when picking up screed box. Place one hand on yoke and one hand on rod. ti22675a 3. Push in and turn spring loaded handle 90 degrees and remove from yoke (31). ti17047b 31 Do NOT pick up screed box with one hand and/or at one location. ti22676a 4.
Screed Box ThermoLazer 200/200TC (FlexDie) Adjustments 3. Tighten bolts (c) on screed box mounting bracket. For optimum delivery of the thermoplastic material, make sure the screed box is aligned to center on kettle trough. 1. Loosen two bolts (c) on mounting bracket. c ti22807a c ti22805a NOTE: If plates (17, 29) are not parallel to floor, loosen screw (1) to adjust until parallel then re-tighten screw. 2.
Screed Box ThermoLazer 300TC/ProMelt (SmartDie II) Screed Box ThermoLazer 300TC/ProMelt (SmartDie II) Installation Use extreme caution when installing and removing screed box. Expect all equipment components and material to be extremely hot. See MSDS for Thermo plastic Traffic Marking Compound. 1. Shut off screed box burners. ti17300a 5. Close and lock screed shroud door. 6. Re-light screed box burners as required (see Screed Box Burner Lighting, page 21). Removal 1. Shut off screed box burners.
Screed Box ThermoLazer 300TC/ProMelt (SmartDie II) BURN HAZARD Make sure to use two hands when picking up screed box. Place one hand on yoke and one hand on rod. 2. Slide mount down until leading box edge of screed box runner is just off of the ground surface. For best performance, raise leading edge .020 in. (0.5 mm) off ground surface. Scraper blade may be used to set this depth. ti16840a Screed Box ti17047b 20 mil .020˝ 0.5 mm Do NOT pick up screed box with one hand and/or at one location.
Screed Box Line Thickness Adjustment Screed Box Line Thickness Adjustment (All ThermoLazer units) X mil # Turns mm # Turns 30 60 90 120 150 X ti17046a NOTE: 1/4 turn will change line thickness by .013 in. (0.3 mm). Turn the line adjustment screw clockwise for a thinner line, or counterclockwise for a thickaer line. Typical settings on pavement: 0.060 - 0.125 in. (0.153 - 0.318 cm). Typical settings on metal stencil: Flush - 0.0 in. (0.0 cm). 0.5 1.0 1.5 2.0 0.6 1.2 1.8 2.4 3.0 0.4 0.8 1.2 1.6 1.
Preparing ThermoLazer 200/200TC/300TC for Application Preparing ThermoLazer 200/200TC/300TC for Application BURN HAZARD Keep all access covers closed and latched when equip ment is in use. Always secure ThermoLazer by chocking wheels when adding thermoplastic. ti14122b 1. Secure the unit by chocking wheels and applying parking brake. 2. Make sure kettle burners and screed box burners are lit. 3. Allow kettle to heat up before adding material.
Preparing ThermoLazer ProMelt for Application Preparing ThermoLazer ProMelt for Application BURN HAZARD Keep all access covers closed and latched when equipment is in use. Always secure the unit by chocking wheels when adding thermoplastic. 1. Secure the unit by chocking wheels and applying parking brake. ti15951a 7. Agitate thermoplastic until material is completely melted. To get best agitation results, use the agita tor crank.
Bead Dispenser Box 13. Move ControlFlow Gate Valve Lever (S) to raised position and fill screed box with melted thermoplastic material. Bead Dispenser Box (All ThermoLazer units) The Bead Dispenser Box has multiple doors which can be opened and closed to allow beads to be dispensed at desired width patterns. S 0.5 in. ti14123a ti22649a NOTE: The material gate is adjustable. The gate is factory set at a 0.5 in. (1.3 cm) gap.
Applying Material to a Surface Double Bead Application (ThermoLazer 300TC/ProMelt) (Requires Installation of Double Bead Kit 24C528) Applying Material to a Surface 1. Fill element beads on left side (smaller chamber). 2. Fill glass beads on right side (larger chamber). Close and lock hopper door. Do not allow beads to remain in hopper, hoses or bead dispenser for an extended period of time. Beads will absorb moisture, bond to adjacent beads and harden.
Shutting Down Shutting Down 1. Turn kettle gas safety valve (CC) to “OFF” position. ti14125a 5. Fully close torch flame adjusting valve. ti14626a 2. Turn temperature control knob (AA) to “OFF”. ti14605a ti14124a 6. Turn main gas valve on propane tank OFF. 3. Fully close front and rear screed burner flow flame adjusting valve OFF. ti14128a ti16833a 4. Close kettle manual shut-off valve. Always store LP-Gas cylinder outside and in an approved/secure storage locker.
Clean-Up for ThermoLazer 200/200TC/300TC Clean-Up for ThermoLazer 200/200TC/300TC BURN HAZARD Never scoop out remaining melted thermoplastic from kettle. Remaining thermoplastic can be left to harden inside the kettle and can be remelted at a later date. 1. Secure ThermoLazer by chocking wheels. ti14603a NOTICE Be sure to thoroughly clean all material out of screed box and any open areas to prevent material from freez ing moving parts of screed box.
Clean-Up for ThermoLazer ProMelt Clean-Up for ThermoLazer ProMelt 8. Repeat step 7. 9. Rotate agitator handle to 3 o’clock and hold at this position by using the cover latch. BURN HAZARD Never scoop out remaining melted thermoplastic from kettle without proper Personal Protective Equipment. 10. Use small scraper to clean out trough, screed box, and agitators. 1. Secure unit by chocking all three wheels.
Maintenance Maintenance DAILY: Make sure LP-gas only flows to burner when safety shut-off valve knob is pressed in. DAILY: Check gas lines and fittings for gas leaks. Use soap and water mixture or LP-gas leak detector to detect gas leaks. DAILY: Check LP-gas supply hose for abrasions, cut or wear. Make sure hose fitting and tank fitting are free of debris before connecting. DAILY: Make sure kettle gas safety valve (CC) rotates freely. Make sure valve freely moves in and out at the “PILOT” position.
Maintenance FatTrack Front Swivel Wheel System FatTrack Front Swivel Tire Alignment (ThermoLazer 300TC/ProMelt) 1. Loosen cap screw (86h). Align front wheel as follows: ANNUALLY: Tighten nut on screw under dust cap until spring washer bottoms out. Then back off the nut 1/2 to 3/4 turns. ANNUALLY: Tighten nut on screw until it begins to compress spring washer. Then tighten an additional 1/4 turn. 86h MONTHLY: Grease the wheel bearing. ti14527a PERIODICALLY: Check caster locking pin for wear.
Technical Data Technical Data ThermoLazer 200/200TC (24U280) (24U281) Fuel ThermoLazer 300TC with Rear Heat (24H622) Operating Pressure (psi - bar) Maximum Heating Capacity Btu/hr (kW) Material Capacity lb (kg) 250 (17.24) Kettle burners 3 (0.21) 0.5 (0.034) 0.5 (0.034) 3 (0.21) Torch 3 (0.21) 20 (1.38) 20 (1.38) 20 (1.38) Screed box front burners 3 (0.21) 20 (1.38) 20 (1.38) 20 (1.38) Screed box rear burners 3 (0.21) 20 (1.38) N/A 20 (1.38) (1) 30,000 (8.8) (2) 30,000 (8.
Notes Notes 3A1319F 39
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.
