Graco VISCON HP User Manual

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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.

309524Z 3

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.

4 309524Z

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

309524Z 7

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

309524Z 9

Component Identification

Mounting Heater

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

Requires wall bracket 192585 or 183982. See Accessories, page 27. Use wall bracket as a template to mark bolt holes.

Bracket 192585

(FIG. 3)

Bracket depth provides required solid object clearance to comply with European flame proof standards.

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.

6 in.

152.4 mm

5 in.

127 mm

FIG. 3: Bracket 192585

6 in.

152.4 mm

5 in.

127 mm

05442

3. Lift heater and slide two screw heads into bracket slots. Install remaining 2 screws and tighten all 4.

Bracket 183982

(FIG. 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.

FIG. 4: Bracket 183982

8631A

10 309524Z

Component Identification

Cart Mounting

(FIG. 5)

Requires two each of cart mounting bar 183485 and clamp 183484. See Accessories, page 27, 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 FIG. 9.

XP and XP-hf Mounting

Bracket Mounted Hose Heater

See Accessories, page 27, for hazardous and non-hazardous location heaters.

WLD

FIG. 5: Cart Mounting

FIG. 6: XP and XP-hf Mounting

05543-524

WLD

FIG. 7: Mounted Hose Heater

309524Z 11

Component Identification

Fluid Connections & Accessories

(FIG. 8)

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.

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.

2. Provide a means for adequately handling fluid expansion caused by heat. Options include:

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.

FIG. 8: Fluid Connections & Accessories

05545-524

- Use flexible hoses between heater and gun.

- Install a properly sized accumulator downstream from the heater.

- Install a pressure relief valve (X) pre-set to relieve pressure when it exceeds the system maximum working pressure.

12 309524Z

Component Identification

Electrical Connections

Heater installation must be in compliance with all applicable local codes and regulations. This equipment must be grounded. Improper grounding, setup, 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.

NOTICE

To help prevent damage, avoid spilling liquids onto electrical components and never operate with the cover removed or screws missing.

Requirements For All Installations

• The power supply must not exceed heater voltage

and amperage. See Contents, page 2.

Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

Wire the heater to a properly grounded power supply through the electrical connections and grounding screw (8). In a mobile installation, also ground the truck or trailer to a true earth ground.

Hazardous Area Cabling and Conduit Requirements

• Conductors used for supply connection must be suitable for at least 221°F (105°C). An intermediate Type “e” junction may be required.

• Branch circuit breaker over-current protection must be used. See chart below for recommended branch circuit breaker by amp rating.

Rating by VAC/Watts/Amperes Circuit breaker size

120 VAC/2300 W/19.2 A 30 A

200 VAC/4000 W/20.0 A 30 A

240 VAC/4000 W/16.7 A 25 A

380 VAC/4000 W/10.5 A 25 A

480 VAC/4000 W/8.3 A 25 A

• For non-hazardous location heaters, connections are made through a strain relief cord grip. Cord grip 121603 will accept cords with an outside diameter of

0.51-0.71 in. (13-18 mm).

• Make your ground connection to the green ground lug inside the control head.

Explosion Proof

All electrical wiring in the hazardous area must be encased in Class I, Division I, Groups C1 and D approved explosion-proof conduit. Follow all National, State, and Local electric codes.

A conduit seal (D) is required within 18 in. (457 mm) of the heater for the US and Canada. All cables must be rated at 221°F (105°C).

Flame Proof (ATEX)

Use appropriate conduit, connectors, and cable glands rated for ATEX II 2 G. Follow all national, state, and local electric codes. All cable glands and cables must be rated at 221°F (105°C).

See Power Cord Set for more information on cables for hazardous locations.

• For hazardous models only: Make your power connections through the 3/4 npt port to the two post bushings in the control head. Refer to Hazardous Area Cabling and Conduit Requirements.

309524Z 13

Component Identification

Wall Mounted Wiring

Mount a 2-pole, explosion-proof electric switch (H) near the heater. See FIG. 9. The switch must meet the electrical codes for your location. Use the correct cable and plug.







Power terminal

Neutral terminal or 2nd power terminal













WLD

Ground terminal

Tighten all terminal nuts to 30 in-lb (3.4 N•m)

Cart Mounted Wiring

Connect a plug that meets the electrical codes for your location. See FIG. 10.









Power terminal

Neutral terminal or 2nd power terminal

FIG. 10: Cart Mounted Wiring

WLD











Ground terminal

Tighten all terminal nuts to 30 in-lb (3.4 N•m)

05547-524

FIG. 9: Wall Mounted Wiring

05546-524

14 309524Z

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, and splashing fluid, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Engage the gun safety lock.

2. Shut off main power to the heater.

3. Circulate fluid for at least 10 minutes to cool the heated fluid and heater.

4. Shut off all air and fluid supplies.

5. Disengage the safety lock.

Initial Flushing

To avoid fire and explosion:

• Flush equipment only in a well-ventilated area

• Ensure main power is off and heater is cool before flushing

• Do not turn on heater until fluid lines are clear of solvent

The heater was tested with lightweight oil, which needs to be flushed out before using the equipment. Ensure main power is off and heater is cool before flushing. Use a compatible solvent, and follow flushing instructions in your fluid supply and spray gun manual.

Priming System

(Refer to FIG. 1, page 7)

NOTICE

6. Hold a metal part of the gun firmly to a grounded metal pail, and trigger the gun to relieve pressure.

7. Engage the safety lock.

8. Have a container ready to catch the fluid, then open the fluid drain valve.

To prevent damage, do not turn on heater until system is fully primed.

1. Do not turn on the heater yet.

2. If using an airless spray gun, do not install a spray tip yet.

3. Start the pump according to the instructions supplied with it.

4. Turn the system director valve (U) to circulate, and circulate fluid for several minutes.

5. Open the spray gun (Q) at the last outlet to prime the line. Repeat for all gun stations.

6. Engage the gun safety latch.

7. Shut off the air supply to the pump.

8. Follow Pressure Relief Procedure.

9. Install the gun spray tip.

309524Z 15

Operation

Setting Heater Control

(Refer to FIG. 11)

1. Set the heater control knob (33) to a trial setpoint of 4 or 5.

2. Start the pump and circulate fluid through the system at very low pressure, about 10-12 oz/min (0.30-0.35 liter/min).

3. After 10 minutes, read the temperature on the thermometer (2). If it does not match the desired temperature, adjust the setpoint.

Adjusting for Spraying

NOTICE

Operating the heater at its highest setting of over 180°F (82°C) for long periods of time decreases the heater life and can cause fluid to dry out which can cause heater clogging and a poor spray pattern.

1. Adjust pump pressure and heater setpoint to the lowest settings needed for good fluid atomization

2. Set all system back pressure valves (S - FIG. 1) to maintain even fluid pressure at all gun stations.

FIG. 11: Setting Heater Control

05549-524

16 309524Z

Maintenance

Flushing

To avoid fire and explosion:

• Flush equipment only in a well-ventilated area

• Ensure main power is off and heater is cool before flushing

• Do not turn on heater until fluid lines are clear of solvent

Clogged fluid passages are difficult to clean and reduce heating efficiency, flow rate, and pressure. Flush frequently, including whenever system is not in use.

1. Follow Pressure Relief Procedure, page 15.

2. Ensure main power is off and heater is cool before flushing. Use a compatible solvent, and follow flushing instructions in your fluid supply and spray gun manual. Do not turn on heater until fluid

lines are clear of solvent.

Unclogging Fluid Passages

(FIG. 13)

1. Drain the heater.

2. Remove the heater block (3) from the heater

housing. See Heater Block, page 21.

3. Pour a high strength, compatible solvent into the

heater tube to soften the clog.

4. Flush out the clog.

5. Clean all passages thoroughly before reassembling.

Pour in solvent

Draining Heater

(FIG. 12)

1. Follow Pressure Relief Procedure, page 15.

2. Remove heater inlet and outlet fittings. Have a container ready to catch the fluid.

Outlet

Inlet

05550-524

FIG. 12: Draining Heater

05551-524

FIG. 13: Unclogging Fluid Passages

309524Z 17

Troubleshooting

Problem Cause Solution

Heater will not heat. No current. Check circuit and fuses.

Check continuity of primary thermostat (24), backup thermostat (10), and thermal limit sensor (15).

Check continuity of thermostat (10) and heater block (3) terminals - Page

19.

Burned out heater block (3). Replace block - Page 21.

Blown heat limiter (15). Check continuity of primary

thermostat (24) and backup thermostat (10). Replace thermostats if necessary when replacing thermal limit sensor (15) - Pages 19-21.

Temperature too low. Fluid requires more warm-up time. Increase warm-up time.

Wrong temperature setting. Adjust setting - Page 16.

Flow rate too high. Reduce flow rate or use 2 heaters.

Clogged fluid passages. Flush regularly - Page 17.

Temperature too high. Wrong temperature setting. Adjust setting - Page 16.

Failed primary thermostat (24). Replace - Page 19.

High fluctuating temperatures, about 220-250°F (104-120°C) at 0.1 GPM.

Too much pressure drop or fluid will not flow.

Heater fittings leak. Loose or damaged fittings. Tighten fittings or replace heater

Primary thermostat (24) contacts sticking.

Replace thermostats (24, 10) - Page

19. Note that backup thermostat (10) keeps heater functioning for only a short time.

Flow rate too high. Reduce flow rate or use 2 heaters.

Clogged fluid passages. Flush regularly - Page 17.

block - Page 21.

WHITE

BLACK

BLOCK, HEATER

WHITE

BLACK

J3 = 120 VAC

J2 = 200/240 VAC

J1 = 380/480 VAC

ti31122a

GND

BLACK

WHITE

FIG. 14: Electrical Schematic

18 309524Z

Repair

To avoid burns, electric shock, and skin injection, make sure the main power is OFF, heater is cool, and pressure is relieved before repairing.

Hazardous Location Heaters: See FIG. 15 & 17

Non-hazardous Location Heaters: See FIG. 16 & 18

Repair

NOTICE

To avoid damaging capillary tube (GG), which can cause heater malfunction, do not kink or nick the tube.

To avoid shorting out the heater, do not allow capillary tube to contact the block terminal (3a). Follow step 10, below.

10. Liberally apply thermal lubricant (part no. 110009) to probe (EE) of new thermostat (24). Loop capillary tube (GG) several times and wrap the loops with tie strap (42-not shown). Insert probe in the heater block (3).

Primary Thermostat & Probe

1. Follow Pressure Relief Procedure, page 15.

2. Remove housing cover (18).

3. Hazardous Location Heater only: Loosen nut

(27a).

Non-hazardous Location Heater only: Loosen screws (25).

4. Loosen setscrew (26) in switch shaft (28).

5. Remove screw (16) and bracket (19) holding probe (EE).

6. Remove wires from the primary thermostat terminals (FF).

7. Pull thermostat probe (EE) out of heater block (3). Remove thermostat (24) from housing (1).

8. Hazardous Location Heater only: Remove screws (25).

Non-hazardous Location Heater only: Remove screw standoff (35) with washer (27b).

11. Continue reassembling in reverse order of

disassembly. See Reassembly Notes, below.

Backup Thermostat

1. Follow Pressure Relief Procedure, page 15.

2. Remove housing cover (18).

3. Remove screws (HH) on backup thermostat (10)

tabs, and remove the wires – one from heater block (3a) and one from line in (9b).

4. Remove the two screws (16), then remove the thermostat (10).

5. Liberally apply thermal lubricant (part no. 110009) to the bottom of the thermostat (10) and reinstall it in reverse order of disassembly.

Reassembly Notes

• Refer to FIG. 15 or 16 for wiring connections.

• Non-hazardous Location Heater only: Make sure gasket (47) is installed and aligned with electrical housing screw holes.

9. Remove bracket from thermostat (24) and secure to new thermostat.

309524Z 19

• Secure cover (18) with lockwashers (5) and screws (6 or 52); torque screws to 89 in-lb (10 N•m).

Repair



E



D

/

D



/

*1'

Apply thermal lubricant

Torque to 89 in-lb (10 N•m)

E

WLE

Wiring Diagram

ti2335e

FIG. 15: Thermostat Repair – Hazardous Location Heaters

27a

GND

Wiring Diagram

ti30862a

Apply thermal lubricant

Torque to 89 in-lb (10 N•m)

FIG. 16: Thermostat Repair – Non-hazardous Heaters

ti2337e

27b

20 309524Z

Repair

Thermal Limit Sensor

NOTICE

To avoid damaging the capillary tube (GG), which can cause heater malfunction, do not kink or nick the tube.

To avoid shorting out the heater, do not allow the capillary tube to contact the block terminal (3a).

1. Follow Pressure Relief Procedure, page 15.

2. Remove housing cover (18).

3. Remove nut (FF) and nut (3b) holding the leads of the thermal limit sensor (15) and remove the sensor. See FIG. 15 or 16, page 20.

4. Apply thin film of thermal lubricant (part no. 110009) to the thermal limit sensor (15) bulb and install a new sensor in the reverse order of disassembly. See Reassembly Notes.

Control Knob

1. Follow Pressure Relief Procedure, page 15.

Heater Block

1. Follow Pressure Relief Procedure, page 15.

2. Remove housing cover (18).

3. Hazardous Location Heater only: Remove

electrical junction box cover (4).

4. Hazardous Location Heater only: In the junction

box (1b), disconnect the main power lead from the terminal of the post bushing (9a).

Non-hazardous Location Heater only: Disconnect the main power lead from the primary thermostat (24).

5. Hazardous Location Heater only: In the electrical

housing (1a), use a wrench on the flats of the post bushing (9a) to unscrew it from the housing.

6. See the appropriate sections on pages 19-21 to remove the primary thermostat and probe (24), the backup thermostat (10), the thermal limit sensor (15) and the control knob (33).

7. Remove the 6 screws (6) and lockwashers (5) holding the housing to the heater block (3).

2. Turn knob (33) to setpoint 1.

3. Loosen setscrew (30) in the control knob (33).

4. Remove control knob (33).

5. Remove adjusting knob (12) from the control knob (33), and press fit it onto the new control knob. Check the bushing (29) and replace it if worn.

6. Position new knob (33) so setpoint 1 aligns with mark (JJ) on the housing (12:00 position) and the knob is about 1/16 in. (1 mm) away from the housing. Tighten setscrew (30).

8. Reassemble heater with the new block (3) in reverse order of disassembly.

Reassembly Notes

• Refer to FIG. 15 or 16 for wiring connections.

• Non-hazardous Location Heater only: Make sure gasket (47) is installed and aligned with electrical housing screw holes.

• Secure cover (18) with lockwashers (5) and screws (6 or 52); torque screws to 89 in-lb (10 N•m).

309524Z 21

Repair

Torque to 89 in-lb (10 N•m)

Electrical Housing

Junction Box

Apply sealant

FIG. 17: Control Repair – Hazardous Location Heaters

Torque to 89 in-lb (10 N•m)

Electrical Housing

Apply sealant

ti2334g

ti2336h

FIG. 18: Control Repair – Non-hazardous Location Heaters

22 309524Z

Parts

Hazardous Location Heaters

Parts

27a

ti2334g

309524Z 23

Torque to 89 in-lb (10 N•m)

Apply sealant

Apply thermal lubricant

Torque nuts (62) to 13-14 in-lb (1.4-1.5 N•m)

Parts

Hazardous Location Heaters

Ref. No. 3 Heater Block

Part Series

245848 C 246616 120 / 2300 245862 C 246617 200 / 4000 245863 C 246618 240 / 4000 245864 C 246619 480 / 4000 246254 C 246620 380 / 4000

Ref. Part Description Qty.

1 183074 CONTROL HOUSING 1 2 102124 THERMOMETER DIAL 1 3 HEATER BLOCK; see table;

includes ref. no. 2, 31, 32, 56 4 183066 COVER 1 5 107542 LOCKWASHER 20 6 109114 SCREW; M8 x 1.25 mm 20 7 111307 WASHER; lock ext. 2 8 116343 GROUNDING CLAMP 2 9 108675 BUSHING; 1000 V max.; 250 A

max. 10 108674 BACKUP THERMOSTAT 1 11 235524 WIRE ASSEMBLY 1 12 177969 KNOB 1 14 100055 SCREW; #6 type U 10 15 223126 THERMAL LIMIT SENSOR, 152° 1 16 105676 SCREW; M4 x 0.7 x 12 mm 4 18 183073 COVER 1 19 183072 BRACKET 2 20 17D130 LIGHT HOUSING 1 21 108664 ALLEN WRENCH; 6 mm 1

Part Volts / Watts

Ref. Part Description Qty.

22 105747 ALLEN WRENCH; 2 mm 1 23 101369 ALLEN WRENCH; 0.0927 in. 1 24 108676 PRIMARY THERMOSTAT 1 25 100032 SCREW; #6-32 UNC-2A 2 26 105672 SET SCREW; M4 x 0.7 x 6 mm 1 27a 183070 NUT; M15 x 1.5 1 28 183068 SWITCH SHAFT 1 29 183071 BUSHING; M15 x 1.5 1 30 101366 SET SCREW; #10-24 x 0.312 in. 1 31 117344 FITTING; 5/8 in. OD tube x 1/2-14

npt(m)

32 15A808 T-FITTING 1

33 177968 KNOB 1 35 183067 BRACKET 1 36 15B623 WARNING PLATE, English 1

15B777 WARNING PLATES, multilingual 1 37 246346 WIRE ASSEMBLY 2 42 102478 TIE STRAP 1

43 15B625 WARNING PLATE. English 1

15B819 WARNING PLATE, multilingual 1 47 185065 ADAPTER, 3/4 npt 1 48 15B827 LIGHT LENS 1 50 103338 O-RING; fluoroelastomer 1 51 117483 SOCKET JAM SCREW;

52 117514 SPACER 2 53 246014 LIGHT CIRCUIT BOARD 1 54 114669 SCREW; M5 x 10 mm 2 55 15B243 BRACKET 1 56 15D757 HOUSING, thermometer 1 58 100361 PLUG, pipe; 1/2 npt 1 62 100166 NUT, full hex 4 63 513505 WASHER, flat 4 65 112906 WASHER, lock, spring 2

5/8-18 x 5/16

 Replacement Danger and Warning labels, tags and

cards are available at no cost.

24 309524Z

Non-Hazardous Location Heaters

Parts

27b

Torque to 89 in-lb (10 N•m)

Apply sealant

ti2336h

Apply thermal lubricant

Torque nuts (62) to 13-14 in-lb (1.4-1.5 N•m)

309524Z 25

Parts

Non-Hazardous Location Heaters

Ref. No. 3 Heater Block

Part Series

26A698 A 17X893 120 / 1800 245867 C 246616 120 / 2300 245868 C 246617 200 / 4000 245869 C 246618 240 / 4000 245870 C 246619 480 / 4000 246276 C 246620 380 / 4000 24J787 C 15A886 240 / 4000

Ref. Part Description Qty.

1 262891 ENCLOSURE 1 2* 102124 THERMOMETER DIAL 1 3 HEATER BLOCK; see table;

includes ref. no. 2, 31, 32, 56 5 107542 LOCKWASHER 1 6 109114 SCREW 6 7 15A990 GASKET 2 8* 116343 GROUND CLAMP 2 9 117367 SCREW; M8 x 18 mm 6 10 108674 THERMOSTAT 1 11 235524 WIRE ASSEMBLY 1 12* 177969 KNOB 1 14 100055 SCREW; #6 type U 10 15* 223126 THERMAL LIMIT SENSOR; 152° 1 16 105676 SCREW; M4 x 0.7 x 12 mm 4 18 15A810 TOP COVER 1 19* 183072 BRACKET 2 20 15B828 LIGHT HOUSING 1 21* 108664 ALLEN WRENCH; 6 mm 1 22* 105747 ALLEN WRENCH; 2 mm 1

Part Volts / Watts

Ref. Part Description Qty.

23* 101369 ALLEN WRENCH; 0.0927 in. 1 24* 108676 THERMOSTAT SWITCH 1 25* 100032 SCREW; #6-32 UNC-2A 4 26* 105672 SET SCREW 1 27b* 114027 WASHER; #6 2 28* 183068 SWITCH SHAFT 1 29* 112738 GROMMET 2 30* 101366 SET SCREW; #10-24 x 0.312 in. 1 31 117344 FITTING; 5/8 in. OD tube x 1/2-14

npt(m) 32* 15A808 T-FITTING 1 33* 177968 KNOB 1 35* 117526 SPACER 2 36 15B623 WARNING PLATE; English 1

15B777 WARNING PLATES; multilingual 1 37* 246346 WIRE ASSEMBLY 2 42* 102478 TIE STRAP 1 43 15B625 WARNING PLATE; English 1

15B819 WARNING PLATE; multilingual 1 47 15A991 GASKET 1 48 15B827 LIGHT LENS 1 50 103338 O-RING; fluoroelastomer 1 51 117483 SOCKET JAM SCREW;

5/8-18 x 5/16 52 111962 SCREW; 1/4-28 UNRF-3a 5 53* 246014 LIGHT CIRCUIT BOARD 1 54 106216 NUT; 3/4-14 npsm 1 55* 100633 ALLEN WRENCH; 5/32 1 56* 15D757 HOUSING; thermometer 1 58* 100361 PLUG, pipe; 1/2 npt 1 62 100166 NUT; full hex 4 63 513505 WASHER; flat 4 64 111307 WASHER; lock ext. 65 112906 WASHER; lock, spring 2

 Replacement Danger and Warning labels, tags and

cards are available at no cost.

* Parts not used in 24J787.

26 309524Z

Accessories

Heater Conversion Kit

246302: Includes two fittings to make VISCON HP ports

match VISCON

Mounting Bracket

192585: European version (see below)

Cart Bracket

Order two each of the following:

183484: Clamp

183485: Mounting bar

183484

183485

5 & 6 included with heater

Power Cord Set

For Non-Hazardous Locations:

05543

Measurements – inches (mm)

ABCDEF

(127)

6.76

(171.7)

0.88

(22.4)

3.37

(85.5)

6.25

(158.8)

1.44

(36.6)

183982: US / CAN version

(152)

(127)

110160*: 600 V, 12 Awg, Extra Hard Usage Type St, High Temperature (221°F, 105°C) rated

For Hazardous Locations (flameproof):

24W679: 600 V, 12 Awg, Extra Hard Usage Type St, High Temperature (221°F, 105°C) rated

*Hazardous location heaters are no longer rated for use in a hazardous area when used with these accessories.

Thermal Lubricant

110009: 6.5 gram tube

Hose Heater (bracket mounted)

For parts, refer to your XP and XP-hf proportioner manual.

273095: Non-hazardous locations

273094: Hazardous locations

309524Z 27

Technical Specifications

The heater can be used in the following environmental conditions: indoor use, 99% maximum relative humidity, pollution degree 2, installation category II, maximum ambient temperature 140° F (60° C).

Viscon HP High Pressure Fluid Heater

US Metric

Maximum Working Pressure 7250 psi 50 MPa, 500 bar Voltage / Wattage / Current* See Contents, page 2 Fluid Passage Area

Fluid Passage Diameter

182 in

0.435 in

117,419 mm

11.1 mm

Fluid Passage Length 133 in 3383 mm Thermometer Range 64–250°F 18–121°C Wetted Parts Stainless Steel Temperature Operating Range 84–219°F 29–104°C Weight 39 lb 17.6 kg

Notes

* Main supply fluctuation not to exceed 10%

All trademarks or registered trademarks are the property of their respective owners.

100

Maximum Temperature Rise (°F)

00.511.522.533.5

94.16

54.14

4000 watt VISCON HP heater, Test Fluid: 10w Hydraulic Oil 2300 watt VISCON HP heater, Test Fluid: 10w Hydraulic Oil

NOTE: Line shows continuous operation of 1 heater.

Use additional heaters if necessary.

68.39

57.70

50.68

39.32

33.18

29.14

42.23

34.96

24.28

20.10

Flow Rate (GPM)

30.26

.40

26.64

15.32

Maximum Temperature Rise vs. Flow Rate

4000W

2300W

28 309524Z

Dimensions

Hazardous Location Heater Non-Hazardous Location Heater

3/4 npt(f)

Electrical

Conduit Port

1/2 npt(f)

1/2 npt(m)

Fluid Outlet

Fluid Inlet

GHJKL

9.375 in. (238 mm)

8.46 in. (215 mm)

6.5 in. (165 mm)

18 in.

(457 mm)

6.375 in. (162 mm)

WLD

GHJKL

7.26 in. (184 mm)

7.04 in. (179 mm)

6.80 in. (173 mm)

17.27 in. (439 mm)

6.375 in. (162 mm)

California Proposition 65

CALIFORNIA RESIDENTS

WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.

309524Z 29

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

For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

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.

2ULJLQDOLQVWUXFWLRQV This manual contains English. MM 309524

International Offices: Belgium, China, Japan, Korea

Graco Headquarters: Minneapolis

www.graco.com

Revision

Z, September 2020

Graco VISCON HP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Models

Hazardous Location Heaters

Non-Hazardous Location Heaters

Warnings

Installation

Typical Installation

Component Identification

General Information Selecting Tubing

Mounting Heater

Fluid Connections & Accessories

Electrical Connections

Grounding

Hazardous Area Cabling and Conduit Requirements

Operation

Pressure Relief Procedure

Initial Flushing

Priming System

Setting Heater Control

Adjusting for Spraying

Maintenance

Flushing

Unclogging Fluid Passages

Draining Heater

Troubleshooting

Repair

Primary Thermostat & Probe

Backup Thermostat

Thermal Limit Sensor

Control Knob

Heater Block

Parts

Hazardous Location Heaters

Non-Hazardous Location Heaters

Accessories

Technical Specifications

Dimensions

Hazardous Location Heater Non-Hazardous Location Heater

California Proposition 65

Graco Standard Warranty

Graco Information