Graco HP 309524L User Manual

Instructions
High Pressure Fluid Heater
VISCON HP
Used for variable heating of fluids.
7250 psi (50 MPa, 500 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
See page 2 for model numbers, descriptions, and approvals information.
309524L
See page 3 for Table of Contents.
TI12338A
Hazardous Location Heater shown

Models

Models

Hazardous Location Heaters

Part No.
245848 A 120 / 2300 / 19.2
245863 A 240 / 4000 / 16.7
245864 A 480 / 4000 / 8.30
245862 A 200 / 4000 / 20.0
246254 A 380 / 4000 / 10.5
Series
VAC (50/60 Hz single phase) / Watts / Amps
Approvals
II 2 G
Approved Exd II T2 482°F (250°C) Certificate No. ISSeP 07ATEX034X Approved to EN 60079-0:2006 (IEC 60079-0:2004) and EN 60079-1:2007 (IEC 60079-1:2007) for Hazardous Locations, Temp Code T2 482°F (250°C). See Technical Data, page 28, for additional information.
CSA Certified and FM Approved as flame proof for Class I, Division 1, Group D Hazardous Locations, Temp Code T2 482°F (250°C), -20°C < T amb < 135°F (57°C). See Technical Data, page 28, for additional information.
II 2 G
Approved Exd II T2 482°F (250°C) Certificate No. ISSeP 07ATEX034X Approved to EN 60079-0:2006 (IEC 60079-0:2004) and EN 60079-1:2007 (IEC 60079-1:2007) for Hazardous Locations, Temp Code T2 482°F (250°C). See Technical Data, page 28, for additional information.

Non-hazardous Location Heaters

Model No.
245867 A 120 / 2300 / 19.2
245868 A 200 / 4000 / 20.0
245869 A 240 / 4000 / 16.7
245870 A 480 / 4000 / 8.30
246276 A 380 / 4000 / 10.5
Series
VAC (50/60 Hz single phase) / Watts / Amps
CSA Certified as flame proof for Class I, Division 1, Group D Hazardous Locations, Temp Code T2 482°F (250°C), -20°C < T amb < 135°F (57°C). See
Technical Data, page 28, for additional information.
Approvals
Conforms to UL Std. 61010-1 CSA Std. 22.2 No. 1010-1-92
2 309524L
Contents
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 3
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Selecting Tubing . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting Heater . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fluid Connections & Accessories . . . . . . . . . . . . 9
Electrical Connections . . . . . . . . . . . . . . . . . . . . 10
Determining Proper Fluid Temperature . . . . . . . 12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Relief Procedure . . . . . . . . . . . . . . . . 14
Initial Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Priming System . . . . . . . . . . . . . . . . . . . . . . . . . 14
Setting Heater Control . . . . . . . . . . . . . . . . . . . . 15
Adjusting for Spraying . . . . . . . . . . . . . . . . . . . . 15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Draining Heater . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unclogging Fluid Passages . . . . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Primary Thermostat & Probe . . . . . . . . . . . . . . . 18
Backup Thermostat . . . . . . . . . . . . . . . . . . . . . . 18
Thermal Limit Sensor . . . . . . . . . . . . . . . . . . . . 20
Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Heater Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hazardous Location Heaters . . . . . . . . . . . . . . . 22
Non-Hazardous Location Heaters . . . . . . . . . . . 24
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Translations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 30
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 30

Translations

Manual available in following languages:
Manual Language 309524 English
309555 French 309556 Spanish 309557 German 309558 Swedish 309605 Chinese 309606 Korean 309607 Japanese

Manual Conventions

Warning Caution
WARNING
A warning alerts you to possible serious injury or death if you do not follow instructions.
Symbols, such as fire and explosion (shown), alert you to a specific hazard and direct you to read the indi­cated hazard warnings (pages 4-5).
309524L 3
CAUTION
A caution alerts you to possible equipment damage or destruction if you do not follow instructions.
Note
A note indicates additional helpful information.
Important
An arrow indicates important information.

Warning

WARNING
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 the gun at anyone or at any part of the body.
Do not put your hand or fingers over the gun fluid nozzle.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Do not “blow back” fluid; this is not an air spray system.
Follow Pressure Relief Procedure, page 14, when you stop spraying and before cleaning, check-
ing, or servicing equipment.
Use lowest possible pressure when flushing, priming, or troubleshooting.
Never spray without tip guard and trigger guard installed.
Engage trigger lock when not spraying.
Tighten all fluid connections before operating the equipment.
Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pres­sure hose cannot be recoupled; replace the entire hose.
FIRE AND EXPLOSION HAZARD
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 and plastic drop cloths (potential static arc).
Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
Keep the work area free of debris, including solvent, rags, and gasoline.
Ground equipment and conductive objects. See Grounding, page 11.
Hold gun firmly to side of grounded pail when triggering into pail.
Ensure main power is off and heater is cool before flushing or servicing heater. Do not turn on heater until fluid lines are clear of solvent.
Use only grounded hoses.
If there is static sparking or you feel an electric shock, stop operation immediately. Do not use equipment until you identify and correct the problem.
ELECTRIC SHOCK HAZARD
Improper grounding, wiring, or usage of the system can cause electric shock.
All electrical wiring must be done by a qualified electrician and comply with all local codes and regu­lations.
Connect only to grounded power source.
Turn off and disconnect power at the main switch before disconnecting any cables and before servic­ing equipment.
4 309524L
Warning
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause serious injury or death.
For professional use only.
Use equipment only for its intended purpose. Call your Graco distributor for information.
Read manuals, warnings, tags, and labels before operating equipment. Follow instructions.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not alter or modify equipment. Use only Graco parts and accessories.
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.
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.
BURN HAZARD
This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To avoid severe burns:
Do not touch hot fluid or equipment.
Allow equipment to cool completely before touching it.
Wear heat protective gloves and take special care if fluid temperature exceeds 110°F (43°C).
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 Material Safety Data Sheets (MSDS) 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
You must wear proper protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury; inhalation of toxic fumes, and hearing loss. This equipment includes but is not limited to:
Protective eyewear
Gloves, clothing, and respirator as recommended by the fluid and solvent manufacturer
Hearing protection
309524L 5

Installation

Installation

Typical Installation Drawing

The typical installation drawing is only a guide. Your Graco distributor can assist in designing your system.
Z
HGF
J
Q
Y
EDCBA
XK
P
V
N
R
L
M
T
U
W
S
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 GPump H Explosion Proof Power Switch
IG. 1: Typical Installation – Heated Circulating System
F
6 309524L
JPower Cable K Heater L Fluid Filter M Drain Valve N Fluid Pressure Regulator P Fluid Supply Line QSpray Gun R Fluid Return Line
S Back Pressure Valve T Fluid Shutoff Valve U Director Valve VDrain Back Tube W Suction Tube X Pressure Relief Valve Y Whip End Hose Z Air Supply Line
Installation
I
WARNING
Read warnings, pages 4-5.
Select system components that meet temper­ature and pressure ratings listed in Technical Data, page 28. The heater’s normal output range is adjustable from 84-220°F (29-104°C).
Locate heater away from all flammable mate­rials and where operators will not come in contact with hot metal surfaces.
Insulate and/or label lines and components exiting heater that may become hot.

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 plumb­ing.
The chart in F mon types of tubing.
Chart Notes:
The greater the flow rate, the less the heat
Foam-insulated steel tubing and high pres-
Locate heater close to spray area to minimize
IG. 2 shows a heat loss curve for 3 com-
loss.
sure airless paint hose retain heat best. Insu­lated tubing and hose are more expensive, but higher costs are commonly offset by lower operating costs.
heat loss through plumbing.
oC(o
F)
6
5
(9)
(8)
4
(7)
(6)
3
(5)
(4)
2
(3)
(2)
Typical Fluid Temperature Drop
F
IG. 2: Typical Temperature Drop
1
(1)
0
00.511.522.5 3 (0.1) (0.2) (0.3) (0.4) (0.5) (0.6) (0.7) (0.8)
Heat Loss Curve - 70° F (21° C) ambient
(20 ft.) 6.1 m steel tube Fluid: (130° F) 54° C
(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
LPM
(GPM )
Flow Rate
309524L 7
Installation

Mounting Heater

The heater has a surface temperature of T2 (482°F, 250°C). Follow temperature code when locating heater. See Technical Data, page 28, for more temperature code informa­tion.
Heater controls must be easily accessible.
The mounting surface must be able to support the weight of the heater and fluid, and any stress caused during operation.
Wall Mounting
Need wall bracket 192585 or 183982. See Acces­sories, page 26.
Use wall bracket as a template to mark bolt holes.
Bracket 192585 (F
IG. 3)
Bracket depth provides required solid object clearance to comply with European flame proof standards.
6 in.
152.4 mm
5 in.
127 mm
6
5
YY
CC
F
IG. 3: Bracket 192585
6 in.
152.4 mm
5 in.
127 mm
BB
05442
1. Use M8 bolts of appropriate length and lockwasher (CC), not supplied, to mount bracket.
2. Install two screws (6) and washers (5) into top 2 heater mounting posts (BB) until they are about 1/8 in. (3 mm) from fully installed.
3. Lift heater and slide two screw heads into bracket slots. Install remaining 2 screws and tighten all 4.
Bracket 183982 (F
IG. 4)
1. Mount bracket (MM) to heater with screws (6) and lockwashers (5) supplied.
2. Use M8 bolts of the appropriate length and lock­washer (NN), not supplied, to secure the bracket to the wall.
6
5
MM
NN
IG. 4: Bracket 183982
F
PP
8631A
8 309524L
Cart Mounting
(FIG. 5)
Installation
WARNING
You need to have 2 each of cart mounting bar 183485 and clamp 183484. See Accessories, page 26, to order.
1. Place clamps (AA) around the cart vertical post (DD) and secure to the heater mounting bars (ZZ) with M8 x 1.25 x 30 mm bolts (6) and lockwasher (5).
2. Observe temperature ratings for the power cable to the terminal junction. Cable H07RN does not meet the required 221°F (105°C). An intermediate Type “e” junction may be required. Also see F
DD
6
5
AA
IG. 7.
To avoid rupturing a component, which can cause seri­ous injury, including amputation; read warnings, page 4, and follow the instructions below.
2. Provide a means for adequately handling fluid expansion caused by heat. Options include:
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.
Never install a shutoff device between the heater and gun as this will trap the heated fluid and not allow for expansion. If a fluid regulator is installed between the heater and gun, never use it as a shutoff device.
3. Install a fluid filter (L), drain valve (M), and fluid pres­sure regulator (N) near the heater’s 1/2-14 npt(f) fluid outlet. Then connect the fluid line.
ZZ
05543-524
F
IG. 5: Cart Mounting

Fluid Connections & Accessories

(FIG. 6)
1. Install a fluid shutoff valve (T) in the heater’s 1/2-14 npt(m) fluid inlet; do not overtighten. Connect the fluid line to the valve.
X
T
F
IG. 6: Fluid Connections & Accessories
N
L
M
05545-524
309524L 9
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