Graco VISCON HP User Manual

Instructions - Parts

VISCON

High Pressure Fluid Heater

For variable heating of fluids. For professional use only.

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

See page 2 for model information, including maximum working pressure and approvals.

Important Safety Instructions

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

309524Z

WLD

Non-Hazardous Location Heater

ti12338A

Hazardous Location Heater

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hazardous Location Heaters . . . . . . . . . . . . . . . 3

Non-Hazardous Location Heaters . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 7

Component Identification . . . . . . . . . . . . . . . . . . . . 8

General Information . . . . . . . . . . . . . . . . . . . . . . 9

Selecting Tubing . . . . . . . . . . . . . . . . . . . . . . . . . 9

Mounting Heater . . . . . . . . . . . . . . . . . . . . . . . . 10

Fluid Connections & Accessories . . . . . . . . . . . 12

Electrical Connections . . . . . . . . . . . . . . . . . . . 13

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Hazardous Area Cabling and Conduit

Requirements . . . . . . . . . . . . . . . . . . . . . . . 13

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Pressure Relief Procedure . . . . . . . . . . . . . . . . 15

Initial Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Priming System . . . . . . . . . . . . . . . . . . . . . . . . . 15

Setting Heater Control . . . . . . . . . . . . . . . . . . . 16

Adjusting for Spraying . . . . . . . . . . . . . . . . . . . . 16

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Draining Heater . . . . . . . . . . . . . . . . . . . . . . . . . 17

Unclogging Fluid Passages . . . . . . . . . . . . . . . . 17

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Primary Thermostat & Probe . . . . . . . . . . . . . . . 19

Backup Thermostat . . . . . . . . . . . . . . . . . . . . . . 19

Thermal Limit Sensor . . . . . . . . . . . . . . . . . . . . 21

Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Heater Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Hazardous Location Heaters . . . . . . . . . . . . . . . 23

Non-Hazardous Location Heaters . . . . . . . . . . . 25

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Technical Specifications . . . . . . . . . . . . . . . . . . . . 28

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

Hazardous Location Heater . . . . . . . . . . . . . . . . 29

Non-Hazardous Location Heater . . . . . . . . . . . . 29

California Proposition 65 . . . . . . . . . . . . . . . . . . . 29

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

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 30

2 309524Z

Models

Hazardous Location Heaters

See Special Conditions for Safe Use in Warnings, page 4.

Models

Part Series VAC (50/60 Hz single phase) / Watts / Amps

245848 C 120 / 2300 / 19.2

245863 C 240 / 4000 / 16.7

245864 C 480 / 4000 / 8.30

245862 C 200 / 4000 / 20.0

246254 C 380 / 4000 /10.5

Approvals

Certified to CAN/CSA C22.2 No. 88

ATEX Ratings:

ATEX Certificate No. ITS14ATEX18155X

IECEx Ratings Ex db llB T4 Gb IECEx Certificate No. IECEx ETL 14.0046X Ta = -20°C to 60°C

For US/CAN:

Class 1, Division 1, Groups C, D (T3) Ta = -20°C to 60°C

9902471

Conforms to

UL 499

18-KA4B0-0072X

II 2 G Ex db llB T4 Gb

See Technical Specifications, page 28, for additional information.

Non-Hazardous Location Heaters

Model Series VAC (50/60 Hz single phase) / Watts / Amps

26A698 A 120 / 1800 / 15

245867 C 120 / 2300 / 19.2

245868 C 200 / 4000 / 20.0

245869 C 240 / 4000 / 16.7

245870 C 480 / 4000 / 8.30

246276 C 380 / 4000 / 10.5

Certified to CAN/CSA C22.2 No. 88

24J787* C 240 / 4000 / 16.7

* Only for use with Graco NVH systems. Must be controlled by GCA.

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Approvals

9902471

Conforms to

UL 499

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

SPECIAL CONDITIONS FOR SAFE USE

• For information on the required dimensions of the flameproof joints contact the holder of this certificate (Graco Inc); Flamepath joints are not intended to be repaired.

• Special fasteners for securing equipment covers shall have a minimum yield strength of 1,100 MPa and be corrosion resistant and sized M8 x 1.25 x 30.

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 is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. 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 sparking).

• Ground all equipment in the work area. See Grounding instructions.

• Never spray or flush solvent at high pressure.

• 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.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are anti-static 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.

• Never operate with covers removed. Do not open when energized.

• Install conduit within 18 in (457 mm).

• Do not install if operating temperature exceeds ignition temperature of hazardous atmosphere.

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Warnings

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 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.

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 Safety Data Sheets (SDSs) 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. 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 Specifications in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheets (SDSs) 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.

309524Z 5

Warnings

WARNING

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.

• Do not use chlorine bleach.

• 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.

6 309524Z

Installation

Typical Installation

FIG. 1 is only a guide. Your Graco distributor can assist in designing your system.

Installation

HGF

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 H Explosion Proof Power Switch

J Power Cable 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

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Component Identification

Key:

A1 Fluid Inlet A2 Fluid Outlet A3 Heater ON Indicator Light A4 Temperature Control Knob

8 309524Z

A5 Temperature Gauge A8 Optional Outlet Ports (one on outlet manifold and one on

opposite side of heater)

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

• Select system components that meet temperature and pressure ratings listed in Technical Specifications, page 28. 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.

NOTICE

The inlet fluid temperature cannot exceed 275°F (135°C). This will cause the heater to exceed its rated temperature code.

plumbing.

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.

• Locate heater close to spray area to minimize heat loss through plumbing.

Component Identification

Typical Fluid Temperature Drop

FIG. 2: Typical Temperature Drop

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

Flow Rate

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