Graco 248921 310798D Instructions - Parts Manual

Instructions - Parts

248921 Hose Heat
Control Kit

310798D

For monitoring and controlling fluid temperature in low voltage heated hose.

Not for use in explosive atmospheres.

Important Safety Instructions

Read all warnings and instructions in this manual.
Save these instructions.

See page 2 for Table of Contents.

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

Copyright 2004, Graco Inc. is registered to I.S. EN ISO 9001

TI5688b

Contents

Manual Conventions

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Locate hose heat control . . . . . . . . . . . . . . . . . . . 4

Electrical requirements . . . . . . . . . . . . . . . . . . . . 4

Connect electrical cord . . . . . . . . . . . . . . . . . . . . 4

Set transformer wire taps . . . . . . . . . . . . . . . . . . . 5

Connect fluid hose . . . . . . . . . . . . . . . . . . . . . . . . 6

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Manual Conventions

WARNING

Hazard Symbol

WARNING: a potentially hazardous situation which, if

not avoided, could result in death or serious injury.
Warnings in the instructions usually include a symbol

indicating the hazard. Read the general Warnings
section for additional safety information.

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fluid Temperature Sensor (FTS) . . . . . . . . . . . . 11

Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 13

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Mounting Hole Pattern . . . . . . . . . . . . . . . . . . . . . . 15

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 16

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 16

CAUTION

CAUTION: a potentially hazardous situation which, if

not avoided, may result in property damage or
destruction of equipment.

Note

Additional helpful information.

2 310798D

Warnings

Warnings

The following warnings include general safety information for this equipment. Further product specific warnings may
be included in the text where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.

• Ground equipment and conductive objects in work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• Do not alter or modify equipment.

• For professional use only.

• Use equipment only for its intended purpose. Call your Graco distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not use hoses to pull equipment.

• Comply with all applicable safety regulations.

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

310798D 3

Setup

Setup

1. Locate hose heat control

Position hose heat control for convenient opera­tor access and maintenance, safe routing of
cables, and easy connections.

2. Electrical requirements

See TABLE 1.

WARNING

Your system must be grounded. Read warnings, page

3.

Table 1: Electrical Requirements

(kW/Full Load Amps)

Full Load

Voltage (phase)

230V (1) 15 3500

* Full load amps with all devices operating at maximum
capabilities. Fuse requirements at various flow rates and
mix chamber sizes may be less.

Peak Amps* System Watts

3. Connect electrical cord

Power cord is not supplied. Use minimum 12
AWG (3.3 mm

WARNING

Installing this equipment requires access to parts
which may cause electric shock or other serious injury
if work is not performed properly. Have a qualified
electrician connect power and ground to power switch
terminals, see F
plies with all National, State and Local safety and fire
codes.

230V, 1 phase: Using 5/32 or 4 mm hex allen
wrench and flat-head screwdriver, connect two
power leads to L1 and L2. Connect green to ground
(GND). See F

2

), 2 wire + ground.

IG. 1. Be sure your installation com-

IG. 1.

L1

L2

GND

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F

IG. 1. Connect Electrical Cord

4 310798D

4. Set transformer wire taps

Setup

WARNING

Read warnings, page 3.

Turn power switch OFF . Transformer tap wire

connections vary depending on length of heated hose.
See F

IG. 2. Verify that tap wire connections are correct.

50 ft

100 ft 150 ft

200 ft

TI3469a

.

Hose Length* ft (m) Tap Terminal

Label (ft)

50 (15.25) 50

100 (30.5) 100

150 (45.75) 150

200 (61.0) 200

* Length does not include unheated whip hose.

FIG. 2: Transformer Wire Taps

310798D 5

Setup

5. Connect fluid hose

Hoses are 50 ft (15.2 m) long. The maximum
combined hose length (including whip hose) is
210 ft (94.5 m).

When Using 261670 FTS, Unheated
Whip Hose

a. Connect desired lengths of hose.

Secure all connections as explained in
manual 309572.

b. Connect hoses to appropriate heater

fluid outlets.

c. Plug sensor cable (SC) and electrical

connector (EC) from hose heat control
into mating connectors on first length of
heated hose. See F
have slack when hose bends. Wrap
cable and electrical connections with
electrical tape.

IG. 5. Be sure cables

e. Carefully extend FTS probe (P). Do not

bend or kink probe. Insert in major vol­ume (resin) side of heated hose.

f. Connect hoses to FTS inlets. Connect

hose sensor cable (SC) to FTS cable.

g. Connect mix manifold, static mixers,

whip hose, and spray gun as explained
in separate instruction manuals.

SC

P

102

EC

RES

F

IG. 3. 261670 Fluid Temperature Sensor

FTS

TI2684c

d. See FIG. 3. Install jumper (102) in elec-

trical connector (EC) at last length of
heated hose.

6 310798D

Setup

When Using 261669 FTS, Heated
Whip Hose

a. Connect desired lengths of hose.

Secure all connections as explained in
manual 309572.

b. Connect hoses to appropriate heater

fluid outlets.

c. Plug sensor cable (SC) and electrical

connector (EC) from hose heat control
into mating connectors on first length of
heated hose. See F
have slack when hose bends. Wrap
cable and electrical connections with
electrical tape.

IG. 5. Be sure cables

e. Connect 50 ft (15.2 m) heated hose to

FTS inlets. Connect hose sensor cable
(SC) to FTS cable.

f. Connect whip hose as explained in hose

manual 309572.

FTS

EC

SC

P

d. See FIG. 4. Carefully extend FTS probe

(P). Do not bend or kink probe. Insert in
ISO side of 50 ft (15.2 m) heated hose.

RES

IG. 4. 261669 Fluid Temperature Sensor, with heated

F
whip hose

TI9582a

310798D 7

Troubleshooting

6. Startup

a.

Ensure that all harnesses, cables, and
connectors are properly connected.

Connect hose.

b. Connect power supply. Turn power ON

c. Using a screwdriver, turn current adjust-

ment screw (CA) until meter (M) reads
45 A maximum. See F
nut to secure at this setting.

IG. 5. Fasten lock-

d. Set heat control to desired hose temper-

ature.

.

M

CA

EC

SC

F

IG. 5. Heat Control Connections

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Troubleshooting

PROBLEM CAUSE SOLUTION

No temperature display. Inadequate power to temperature

control.
Loose power cable. Check cable connections.
Bad module. Replace temperature control module.

Detail of Controller Panel

#-7

Check that power supply meets
requirements.

/5434/0

TI5759a

8 310798D

Troubleshooting

PROBLEM CAUSE SOLUTION

No hose heat. Loose hose electrical connections. Check all hose connections. See

Test Hose Continuity, page 12.

Circuit breakers tripped. Check CB1 and CB2.
Hose heat not turned on. To turn on, press .

To change from Stop mode to Run
mode, press .

LED in upper right corner of display
will change.

To return to main menu, press .

Temperature setpoint too low. Check. Increase if necessary.
Maximum amp setting is too low. Check connections to current sensor.

Increase current, page 8.

Hose length tap set too low. Check and set to hose length being

used, page 5.
No voltage to transformer primary. Replace phase controller (3).
No output voltage. Replace solid state relay (2).

Low hose heat. Temperature setpoint too low. Check. Increase if necessary.

Flow too high. Decrease pressure.
Hose heat requires more time. Allow more time to preheat material.
Loose hose electrical connections. Check all hose connections. See

Test Hose Continuity, page 12.

310798D 9

Troubleshooting

10 310798D

Repair

Repair

Fluid Temperature Sensor (FTS)

Test/Removal

1. Turn power OFF . Disconnect power supply.

WARNING

Read warnings, page 3.

2. Relieve pressure, see proportioner operation man-

ual.

3. Remove tape and protective covering from FTS.

Disconnect hose cable (SC). Test with ohmmeter
between pins of cable connector.

Pins Result

1 to 2 approximately 10 ohms

1 to 3 infinity

3 to FTS groundscrew 0 ohms

1 to FTS component A

fitting (ISO)

infinity

4. If FTS fails test, replace FTS.

5. Disconnect electrical connectors (EC).

6. Disconnect FTS from mix manifold and fluid hoses.

7. Remove FTS probe (P) from hose.

Installation

See instructions on pages 6 and 7.

SC

EC

RES

FIG. 6. Fluid Temperature Sensor (Model 261670 Shown)

FTS

P

101

TI2684c

310798D 11

Transformer

Repair

Test Hose Continuity

1. Turn power OFF . Disconnect power supply.

Leave hose plugged in.

2. See Electrical Schematic, page 13. Remove wire

no. 1055 (red, 8 AWG) from solid state relay (2).

3. Remove wire no. 1102 (red, 8 AWG) from tap set-

ting on top of transformer.

4. Using an ohmmeter in continuity mode, check

between the two wires. There should be continuity.

5. If test fails, remove jumper (102) from electrical

connector of last hose section and place in electri­cal connector of first hose section. Check continuity
again. If continuity, continue testing each hose sec­tion until failure is located. Replace/remove bad
hose section.

Transformer Primary Check

4. See Electrical Schematic, page 13. Measure volt-

age at two bottom terminals of 20 A circuit breaker
(9). Measurement should be line voltage. If not,
check that lamp is illuminated red. Continue toward
disconnect switch until loose connection is found. If
all voltages are good and transformer secondary
test fails, replace transformer.

Transformer Secondary Check

1. Ensure that all harnesses, cables, and connectors

are properly connected. Connect hose.

2. Connect power supply. Turn power ON .

3. Set heat control to desired hose temperature.

WARNING

1. Ensure that all harnesses, cables, and connectors

are properly connected. Connect hose.

2. Connect power supply. Turn power ON .

3. Set heat control to desired hose temperature.

WARNING

Read warnings, page 3. Step 4 measures line voltage
and should be done by a qualified electrician. If work is
not performed properly it may cause electric shock or
other serious injury.

Read warnings, page 3. Step 4 measures line voltage
and should be done by a qualified electrician. If work is
not performed properly it may cause electric shock or
other serious injury.

4. See Electrical Schematic, page 13. Measure volt-

age across transformer hose tap (R) you are using
and top terminal on 50 A hose circuit breaker (10).
See T

ABLE 2 for readings. If reading is correct,

replace temperature control. If reading is wrong,
replace transformer.

Table 2: Transformer Voltage Readings

Transformer Tap Reading (VAC)

50’ 15-25

100’ 26-42

150’ 36-60

200’ 47-77

12 310798D

Electrical Schematic

Electrical Schematic

310798D 13

Parts

248921 Series A, Hose Heat Control Kit

Parts

20

16

17

27

19

5 (Ref)

TI5688b

5

4

16 (Ref)

123

910

TI2684b

11, 14

Ref.
No. Part No. Description Qty.

1 15F162 CONTROLLER, 240 V, dual display 1
2 15F163 RELAY, solid state, 24-240 V, 75 A 1
3 15F164 CONTROLLER, proportional,

240 V, 25 A
4 15F165 POTENTIOMETER 1
5 15F166 METER, 0-50 A 1
7 15B351 TRANSFORMER 1
9 117711 BREAKER, dual; 20 A 1
10 117503 BREAKER, single; 50 A 1
11 514556 FUSEHOLDER, 10 A 1

4 (Ref)

18

7

Ref.
No. Part No. Description Qty.

14 15F167 FUSE, 250 V, 1-8 A 1
16 15F168 DISCONNECT, electrical; 25 A 1
17 117682 STRAIN RELIEF, power cord 1

1

18 117666 TERMINAL, ground 1
19 115845 STRAIN RELIEF, cables 1
20 15F161 CONNECTOR, electrical 1
27 15F160 CABLE, hose 1
102 115834 FAN 1

102

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14 310798D

Technical Data

Input Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . 230 Vac, 1 phase, 50/60 Hz, 15 A

Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70 Vac, 50 A

Weight 75 lb (34 kg)

Mounting Hole Pattern

12 in. (305 mm)

Technical Data

1/2 in. (13 mm)
diameter holes

10.5 in. (267 mm)

3/4 in. (19 mm)

16 in. (406 mm)

14.5 in. (368 mm)

310798D 15

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 procédures concernées.

Graco Information

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: [phone] or Toll Free: 1-800-328-0211 Fax: [phone]

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 310798

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

www.graco.com

310798D

1/2008