Graco 3A2954D User Manual

Instructions - Parts

VISCON

High Flow, High Pressure Fluid Heater

For variable heating of viscous fluids.

Not approved for use in explosive atmospheres or hazardous locations.

7250 psi (50 MPa, 500 bar) Maximum Working Pressure

Important Safety Instructions

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

3A2954D

See page 2 for model numbers, descriptions, and approvals information.

Externally Controlled, RTD

Feedback Model

Thermostat

Controlled

ti20051a

Models

Contents

Models ...................................2

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

Installation ................................ 5

TypicalInstallationDrawing ................ 5

Component Identification ....................6

General Information ...................... 7

SelectingTubing .........................7

Mounting Heater .........................8

Fluid Connections and Accessories ..........9

Electrical Connections ...................10

RTD Temperature Connection .............10

Grounding ............................. 10

Operation ................................11

Pressure Relief Procedure ................11

Initial Flushing .........................11

Priming System .........................11

Setting Heater Control ...................12

AdjustingforSpraying .................... 12

Maintenance ..............................13

Flushing ..............................13

Drain the Heater ........................ 13

Troubleshooting ...........................14

Repair ...................................16

Primary Thermostat & Probe ...............16

Overtemperature Switch ..................16

Control Knob ...........................18

Heater Core Removal and Fluid Passage

Unclogging .........................19

Heater Cartridges .......................20

RTD Sensor and Fitting Replacement ........21

Parts ....................................22

24P016 ...............................22

262853 ...............................24

Accessories ..............................26

TechnicalData ............................27

Performance Charts .....................28

Dimensions ............................29

Graco Standard Warranty ...................30

GracoInformation .........................30

Models

VAC (50/60 Hz single phase) /

Model Series Description

24P016 C Thermostat Control 240 / 5400 / 22.5

262853 C

RTD, For Use With

External Digital Control

Watts / Amps

240 / 5400 / 22.5

Approvals

9902471 Conforms to UL Std. 499 CSA Std. 22.2 No. 88

2 3A2954D

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

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 spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• 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.

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

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

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 all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

3A2954D 3

Warnings

WARNING

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

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:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• 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. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

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

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

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

THERMAL EXPANSION HAZARD

Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.

• Open a valve to relieve the fluid expansion during heating.

• Replace hoses proactively at regular intervals based on your operating conditions.

4 3A2954D

Installation

Typical Installation Drawing

The typical installation drawing is only a guide. Your Graco distributor can assist in designing your system.

Installation

EDCBA

05486-524

Key:

A Bleed-type Master Air Valve B Air Filter C Air Regulator and Gauge D Air Line Lubricator E Pump Runaway Valve F Ground Wire G Pump J Power Cable (not shown)

K Heater L Fluid Filter M Drain Valve N Fluid Pressure Regulator P Fluid Supply Line Q Spray Gun R Fluid Return Line S Back Pressure Valve

T Fluid Shutoff Valve U Director Valve V Drain Back Tube W Suction Tube X Pressure Relief Valve Y Whip End Hose Z Air Supply Line

FIG. 1: Typical Installation – Heated Circulating System

3A2954D 5

Component Identification

Thermostat

Controlled Model

A6, A8

Externally Controlled, RTD

Feedback Model

ti20051a

Key:

A1 Fluid Inlet A2 Fluid Outlet A3 Heater ON Indicator Light A4 Temperature Control Knob (24P016 Only) A5 Temperature Gauge (24P016 Only) A6 Optional External RTD Feedback Port (262853 Only) A7 Optional Inlet Ports (front and bottom) A8 Optional Outlet Ports (one on outlet manifold and one on

opposite side of heater)

6 3A2954D

General Information Selecting Tubing

Fluid loses some heat through the tubing or hose between the heater and spray gun. Locate heater close to the spray area to minimize heat loss through plumb-

• Select system components that meet temperature and pressure ratings listed in Technical Data, page 27. The heater’s normal output range is adjustable from 84-220°F (29-104°C).

• To prevent fire and explosion, locate heater away from all flammable materials and where operators will not come in contact with hot metal surfaces.

• To avoid burns, insulate and/or label lines and components exiting heater that may become hot.

Heat Loss Curve: 70°F (21°C) Ambient

(°F) °C

(9)

(8)

(7)

(6)

(5)

(20 ft.) 6.1 m steel tube Fluid: (130° F) 54° C

ing.

The chart in FIG. 2 shows a heat loss curve for 3 common types of tubing.

Chart Notes:

• Higher flow rates have less heat loss.

• Foam-insulated steel tubing and high pressure airless paint hose retain heat best. Insulated tubing and hose are more expensive, but higher costs are commonly offset by lower operating costs.

(20 ft.) 6.1 m steel tube (3/8 in.) 9 mm foam insulation Fluid: (110° F) 43° C

(20 ft.) 6.1 m airless paint hose Fluid: (110° F) 43° C

Component Identification

(4)

(3)

(2)

Typical Fluid Temperature Drop

(1)

0 0 .5 1 1.5 2 2 .5 3

(0.1) (0.2) (0.3) (0.4) (0.5) (0.6) (0.7) (0.8)

FIG. 2: Typical Temperature Drop

LPM

(GPM)

Flow Rate

3A2954D 7

Component Identification

Mounting Heater

NOTE: The Viscon HF heaters will mount anywhere a

Viscon HP heater was previously mounted. See the dimensions listed for accessory bracket 192585 on page 26 and the heater dimensions shown on page 29.

NOTE: Heater controls must be easily accessible.

NOTE: The mounting surface must be able to support

the weight of the heater and fluid and any stress caused during operation.

Wall Mounting

NOTE: Use wall bracket as a template to mark bolt

holes.

Accessory Bracket 192585

(FIG.3)

1. Use lockwashers and M8 bolts (AA) of appropriate length, not supplied, to mount bracket.

2. Install two screws (74) through spacer block and into top two heater mounting holes until they are about 1/8 in. (3 mm) from fully installed.

3. Lift heater and slide two screw heads into bracket slots.

4. Install u-bracket (78) around heater and install remaining 2 nuts (90). Tighten all nuts and bolts.

Cart Mounting

(FIG.4)

NOTE: For a 2.5 in. square tube frame cart you need to

have 2 each of cart mounting bar 183485 (CC) and clamp 183484 (BB). See Accessories, page 26, to order.

Place clamps (BB) around the cart vertical post (DD) and secure to the heater mounting bars (CC) with bolts (74) and nuts (90).

ti20055a

FIG.4

FIG. 3: Accessory Bracket 192585

8 3A2954D

ti20054a

Component Identification

Fluid Connections and Accessories

(FIG.5)

1. Install a fluid shutoff valve (T) in the heater’s 3/4 in. npt(m) fluid inlet. Do not overtighten. Connect the fluid supply line to the valve.

To prevent serious injury caused by component or equipment rupture:

• Never install a shutoff device between the heater and gun as this will trap the heated fluid and not allow for expansion.

• Never use a fluid regulator as a shutoff device if it is installed between the heater and gun

• Provide a means for adequately handling fluid expansion caused by heat.

FIG. 5: Fluid Connections and Accessories

ti20056a

To handle fluid expansion caused by heat:

• Use flexible hoses between heater and gun.

• Install a properly sized accumulator down-

stream from the heater.

• Install a pressure relief valve (X) pre-set to

relieve pressure when it exceeds the system maximum working pressure.

2. If feeding an airless spray gun, install a fluid filter (L), drain valve (M), and fluid pressure regulator (N) near the heater’s 3/4-14 npt(f) fluid outlet. Then connect the fluid outlet line.

NOTICE

The RTD sensor must always be mounted on the outlet side of housing (67). If you plumb the outlet to the left side, swap position of sensor (88) and plug (82).

3A2954D 9

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