Graco 309524L User's Manual
Contents
1. 182 in 117 419 mm Fluid Passage Diameter 0 435 in 11 1 mm Fluid Passage Length 133 in 3383 mm Thermometer Range 64 250 F 18 121 C Wetted Parts 0 000 cee eee ees Stainless Steel Temperature Operating Range 84 219 F 29 104 C Surface Temperature Code T2 482 F 250 C Weight IIIA 39 Ib 17 6 Kg Main supply fluctuation not to exceed 10 The heater has a surface temperature code of T2 482 F 250 C indicating a maximum external surface temperature rating of 482 F 250 C in accordance with EN 60079 0 2006 IEC 60079 0 2004 and EN 60079 1 2007 IEC 60079 1 2007 This heater has a surface temperature code identification code of T2 indicating a maximum external surface temperature rating of 250 C 482 F in accordance with Article 500 Hazardous Locations of NFPA 70 National Electrical Code and or Section 18 Hazardous Locations of Part 1 of the Canadian Electrical Code Read and comply with the requirements of these and similar codes as to proper location of the heater Maximum Temperature Rise vs Flow Rate 100 gt 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 90 5 80 5 702. 24 309524L Non Hazardous Location Heaters Ref No 3 Heater Block Part No Series Part No Volts Watts 245867 A 246616 120 2300 245868 A 246617 200 4000 245869 A 246618 240 4000 245870 A 246619 480 4000 246276 A 246620 380 4000 Ref No Part No Description Qty 1 15A809 ENCLOSURE 1 2 102124 THERMOMETER DIAL 1 3 HEATER BLOCK see table 1 includes ref no 2 31 32 56 4 15A811 BOTTOM COVER 1 5 107542 LOCKWASHER 1 6 109114 SCREW 6 7 15A990 GASKET 2 8 104029 GROUND CLAMP 2 9 117367 SCREW M8 x 18 mm 6 10 108674 THERMOSTAT 1 11 235524 WIRE ASSEMBLY 1 12 177969 KNOB 1 134 177922 WARNING TAG 1 14 100055 SCREW 6 type U 10 15 223126 THERMAL LIMIT SENSOR 152 1 16 105676 SCREW M4 x 0 7 x 12mm 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 309524L Ref No Part No 23 101369 24 108676 25 100032 26 105672 27 114027 28 183068 29 112738 30 101366 31 117344 32 15A808 33 177968 35 117526 364 15B623 15B777 37 246346 42 102478 434 15B625 15B819 47 15A991 48 15B827 50 103338 51 117483 52 111962 53 246014 54 106216 55 100633 56 15D757 58 100361 62 100166 63 102360 Description ALLEN WRENCH 0 0927 in THERMOSTAT SWITCH SCREW 6 32 UNC 2A SET SCREW WASHER 6 SWITCH SHAFT GROMMET SET SCREW 10 24 x 0 312 in FITTING 5 8 in OD tube x 1 2 14 npt m T F
3. 05543 524 Fic 5 Cart Mounting Fluid Connections amp Accessories Fic 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 05545 524 Fic 6 Fluid Connections amp Accessories 309524L 9 Installation Electrical Connections Hazardous Location Installation Reguirements A WARNING Me re Read warnings page 4 Install heater in compliance with all applicable codes and regulations A CAUTION To help prevent damage avoid spilling liquids onto electrical components Requirements For All Installations 2 1 The voltage supply must agree with the maximum heater voltage and amperage See Models page 2 2 Conductors used for supply connection must be 1 The heater connection must be made using one of the following options a Cable entries of a certified flameproof model b Threaded metal conduits IN If this option is used a stopping box with compound filling of a certified flameproof model must be placed at the entry of the heater Unused threaded holes must be sealed by certified flameproof plugs which must be screwed in with a minimum of 5 full threads engaged and an 8 mm length of engaged threads suitable for at least 221 F 105 C IN The above accessories are not provided by 10 Graco Make sure that accessories are appropri ate for the conditions of use 3
4. Page 15 Flow rate too high Reduce flow rate or use 2 heaters Clogged fluid passages Wrong temperature setting Flush regularly Page 16 Adjust setting Page 15 Failed primary thermostat 24 Primary thermostat 24 contacts sticking Flow rate too high Replace Page 18 Replace thermostats 24 10 Page 18 Note that backup thermostat 10 keeps heater functioning for only a short time Reduce flow rate or use 2 heaters Clogged fluid passages Loose or damaged fittings Flush regularly Page 16 Tighten fittings or replace heater block Page 20 05556 524 309524L 17 Repair Repair A WARNING UU Read warnings pages 4 5 Make sure the main power is off and heater is cool before repairing A CAUTION Hazardous Location Heaters See FIG 15 amp 17 Non hazardous Location Heaters See Fic 16 amp 18 Primary Thermostat amp Probe 1 Follow Pressure Relief Procedure page 14 2 Remove housing cover 18 3 Hazardous Location Heater only Loosen nut 27 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 termi nals FF 7 Pull thermostat probe EE out of heater block 3 Remove thermostat 24 from housing 1 8 Hazardous Location Heater only Remove screws
5. ae 8631A FIG 4 Bracket 183982 309524L Installation Cart Mounting Fic 5 A WARNING IN You need to have 2 each of cart mounting bar 183485 and clamp 183484 See Accessories To avoid rupturing a component which can cause seri page 26 to order ous injury including amputation read warnings page 4 and follow the instructions below 1 Place clamps AA around the cart vertical post DD and secure to the heater mounting bars ZZ 2 Provide a means for adequately handling fluid with M8 x 1 25 x 30 mm bolts 6 and lockwasher expansion caused by heat Options include 5 2 Observe temperature ratings for the power cable to the terminal junction Cable HO7RN does not meet the required 221 F 105 C An intermediate Type e junction may be required Also see FIG 7 e Install a pressure relief valve X pre set to relieve pressure when it exceeds the system maximum working pressure e Use flexible hoses between heater and gun e Install a properly sized accumulator down stream from the heater 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 pres ji sure regulator N near the heater s 1 2 14 npt f SA fluid outlet Then connect the fluid line S a
6. 16 105676 SCREW M4 x 0 7 x 12mm 4 18 183073 COVER 1 19 183072 BRACKET 2 20 15B828 LIGHT HOUSING 1 21 108664 ALLEN WRENCH 6 mm 1 309524L Ref No Part No 22 105747 23 101369 24 108676 25 100032 26 105672 27 183070 28 183068 29 183071 30 101366 31 117344 32 15A808 33 177968 35 183067 364 15B623 15B777 37 235523 42 102478 434 15B625 15B819 47 185065 48 15B827 50 103338 51 117483 52 117514 53 246014 54 114669 55 15B243 56 15D757 58 100361 62 100166 63 102360 Description ALLEN WRENCH 2 mm ALLEN WRENCH 0 0927 in PRIMARY THERMOSTAT SCREW 6 32 UNC 2A SET SCREW M4 x 0 7 x 6mm NUT M15 x 1 5 SWITCH SHAFT BUSHING M15 x 1 5 SET SCREW 10 24 x 0 312 in FITTING 5 8 in OD tube x 1 2 14 npt m T FITTING KNOB BRACKET WARNING PLATE English WARNING PLATES multilingual WIRE ASSEMBLY TIE STRAP WARNING PLATE English WARNING PLATE multilingual ADAPTER 3 4 npt LIGHT LENS O RING fluoroelastomer SOCKET JAM SCREW 5 8 18 x 5 16 SPACER LIGHT CIRCUIT BOARD SCREW M5 x 10 mm BRACKET HOUSING thermometer PLUG pipe 1 2 npt NUT full hex WASHER flat Parts Qty AAA AA AA AA ANI ee ee Aa NAA NA ua KU A Replacement Danger and Warning labels tags and cards are available at no cost 23 Parts Non Hazardous Location Heaters lt A Torque to 89 in Ib 10 Nem A Apply sealant A Apply thermal lubricant pS A Torque nuts 62 to 10 12 in Ib 1 1 1 3 Nem D Nooo TI2336E
7. 25 Non hazardous Location Heater only Remove screw standoff 35 with washer 27 9 Remove bracket from thermostat 24 and secure to new thermostat 18 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 11 Continue reassembling in reverse order of disas sembly See Reassembly Notes below Backup Thermostat 1 Follow Pressure Relief Procedure page 14 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 ther mostat 10 5 Liberally apply thermal lubricant part no 110009 to the bottom of the thermostat 10 and reinstall it in reverse order of disassembly IN Reassembly Notes e Refer to Fic 15 or 16 for wiring connections e Non hazardous Location Heater only Make sure gasket 47 is installed and aligned with electrical housing screw holes e Secure cover 18 with lockwashers 5 and screws 6 or 52 torque screws to 89 in Ib 10 Nem 3
8. 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 as flame proof for Class 1 Division 1 Group D Hazardous Locations Temp Code T2 482 F 250 C 20 C lt T amb lt 135 F 57 C See Technical Data page 28 for additional information Non hazardous Location Heaters Model No Series VAC 50 60 Hz single phase Watis Amps Approvals 245867 A 120 2300 19 2 C 245868 A 200 4000 20 0 USNC X Conforms to 245869 A 240 4000 16 7 UL Std 61010 1 245870 A 480 4000 8 30 PSA S ea Wa 246276 A 380 4000 10 5 2 309524L Contents Models sanannnnanana 2 Manual Conventions 3 WAM ees csc dick ss Scere deers ea eterna de eae ee 4 Installation 6 Selecting Tubing 7 Mounting Heater 8 Fluid Connections amp Accessories 9 Electrical Connections 10 Determining Proper Fluid Temperature 12 Operation IA eee ed en eee ee 14 Pressure Relief Procedure 14 Initial Flushing 14 Priming System 14 Setting Heater Control 15 Adjusting for Spraying 15 Maintenance 16 FIUSH
9. 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 This manual contains English MM 309524 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2002 Graco Inc is registered to ISO 9001 www graco com Revised 12 2008
10. inlet and outlet fittings Have a con tainer ready to catch the fluid 05550 524 Fic 12 Draining Heater 16 Unclogging Fluid Passages Fic 13 1 Drain the heater 2 Remove the heater block 3 from the heater hous ing See Heater Block page 20 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 a Pour in solvent 05551 524 Fic 13 Unclogging Fluid Passages 309524L Troubleshooting Problem Troubleshooting Solution Heater will not heat Temperature too low Temperature too high 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 FIG 14 Electrical Schematic No current Check circuit and fuses Check continuity of primary thermo stat 24 backup thermostat 10 and thermal limit sensor 15 Check continuity of thermostat 10 and heater block 3 terminals Page 18 Burned out heater block 3 Replace block Page 20 Blown heat limiter 15 Fluid requires more warm up time Check continuity of primary thermo stat 24 and backup thermostat 10 Replace thermostats if necessary when replacing thermal limit sensor 15 Pages 18 20 Increase warm up time Wrong temperature setting Adjust setting
11. 0 180 F Temperature Fic 9 Reducing Viscosity Under Boil Method 12 309524L 40 30 4 20 4 Apparent viscosity with 1 Zahn cup Installation s Typical high solid paint 50 4 Si Typical enamel paint Se Typical spray viscosities 15 25 35 60 80 100 Temperature Fic 10 Effect of Temperature on Viscosity The chart in FiG 10 shows the effect of temperature in reducing two fluids to a sprayable viscosity between 20 and 34 seconds using a No 2 Zahn cup Note that temperature has more of an effect on high solid fluids than on thin enamels That is for the same 10 temperature rise the viscosity of the high solid fluid is reduced more than the enamel This means the high solid fluid is temperature sensitive and you need to take this into consideration when planning your system 309524L Once the fluid is reduced to about 34 on the chart vis cosity reduction begins to level off and temperature will not significantly improve sprayability it only uses more energy 13 Operation Operation Pressure Relief Procedure A WARNING Initial Flushing A WARNING ba Mw Read warnings page 4 Read warnings page 4 Follow Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment 1 Engage the gun safety lock 2 Shut off main power to the heater 3 Circulate fluid for a
12. 0 7 0 8 GPM Flow Rate Fic 2 Typical Temperature Drop 309524L 7 Installation Mounting Heater UA e 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 informa tion e Heater controls must be easily accessible e The mounting surface must be able to support the weight of the heater and fluid and any stress caused during operation Wall Mounting RU Need wall bracket 192585 or 183982 See Acces sories page 26 Use wall bracket as a template to mark bolt holes Bracket 192585 Fic 3 IN 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 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 lock washer NN not supplied to secure the bracket to the wall ie 6in gt a s T 5in ii AN 127 mm 05442 FIG 3 Bracket 192585 Gin 152 4 mm Sy bin A Wa 127 mm he yA oe a
13. 09524L Repair TA 9 VA A wi gt TI12339 A Apply thermal lubricant A Torque to 89 in lb 10 Nem A Torque nuts 62 to 10 12 in Ib 1 1 1 3 Nem TI12335C Fic 15 Thermostat Repair Hazardous Location Heaters Wiring Diagram A Apply thermal lubricant A Torque to 89 in lb 10 Nem ZA Torque nuts 62 to 10 12 in Ib 1 1 1 3 Nem es Fic 16 Thermostat Repair Non hazardous Heaters 309524L 19 Repair Thermal Limit Sensor A CAUTION 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 cap illary tube to contact the block terminal 3A 1 2 Follow Pressure Relief Procedure page 14 Remove housing cover 18 Remove nut FF and nut 3B holding the leads of the thermal limit sensor 15 and remove the sensor See Fic 15 or 16 page 19 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 below Control Knob 20 Follow Pressure Relief Procedure page 14 Turn knob 33 to setpoint 1 Loosen setscrew 30 in the control knob 33 Remove control knob 33 Remove adjusting knob 12 from the control knob 33 a
14. 09524L Wall Mounted Wiring Mount a 2 pole explosion proof electric switch H near the heater See Fic 7 The switch must meet the electri cal codes for your location Also use the correct cable and plug JAA 9 AA JI TIT TT ll A Power terminal A Ground terminal A Neutral terminal or 2nd A Tighten all terminal nuts to power terminal 30 in Ib 3 4 Nem 05546 524 Fic 7 Wall Mounted Wiring 309524L Installation Cart Mounted Wiring Connect a plug that meets the electrical codes for your location See FIG 8 o roe 4 a Tg JAA IAA 8 AA A Power terminal A Ground terminal A Neutral terminal or 2nd A Tighten all terminal nuts to power terminal 30 in Ib 3 4 Nem 05547 524 Fic 8 Cart Mounted Wiring Grounding Wire the heater to a properly grounded power supply through the electrical connections and external ground ing lug 8 In a mobile installation also ground the truck or trailer to a true earth ground 11 Installation Determining Proper Fluid Temperature CAUTION Operating the heater at its highest setting over 180 F 82 C for long periods of time decreases the heater life and can cause fluid to dry out which can clog the heater and result in a poor finish Use the lowest temperature setting possible f
15. 4 60 4 50 4 40 30 4 Maximum Temperature Rise 20 4 4000W 2300W 0 0 5 1 1 5 2 2 5 3 3 5 Flow Rate 28 309524L Dimensions Dimensions Measurements inches mm G H J K L 9 375 8 46 6 5 18 6 375 238 215 165 457 162 3 4 npt f yk Electrical Conduit Port 1 2 npt f Fluid Outlet 1 2 npt m Fluid Inlet 309524L 29 Graco Standard Warranty Graco warrants all eguipment 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
16. C for long periods of time decreases the heater life and can cause fluid to dry out which can clog the heater and result in a poor finish 2 Start the pump and circulate fluid through the sys tem at very low pressure about 10 12 oz min 0 30 0 35 liter min 1 Adjust pump pressure and heater setpoint to the Se Aner 1O INI S tead the Pinar atare Ow ie mer lowest settings needed for good fluid atomization mometer 2 If it does not match the desired tem perature adjust the setpoint 2 O Orr 7 CGR i P Set all system back pressure valves S FIG 1 to maintain even fluid pressure at all gun stations k 05549 524 Fic 11 Setting Heater Control 309524L 15 Maintenance Maintenance A WARNING ba Mw Read warnings pages 4 and 5 Make sure the main power is off and heater is cool before doing mainte nance Flushing Clogged fluid passages are difficult to clean and reduce heating efficiency flow rate and pressure Flush fre quently including whenever system is not in use 1 Follow Pressure Relief Procedure page 14 2 Ensure main power is off and heater is cool before flushing Use a compatible solvent and follow flush ing instructions in your fluid supply and spray gun manual Do not turn on heater until fluid lines are clear of solvent Draining Heater Fic 12 1 Follow Pressure Relief Procedure page 14 2 Remove heater
17. ESS 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information 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
18. ING IIIA Eee alee es 16 Draining Heater 16 Unclogging Fluid Passages 16 Troubleshooting 17 Rpa 2 28c2 scene eee pace kee rede 18 Primary Thermostat amp Probe 18 Backup Thermostat 18 Thermal Limit Sensor 20 Control Knob 20 Heater Block 20 Manual Conventions Warning A WARNING MW 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 indi cated hazard warnings pages 4 5 309524L Contents Pants ic fececccditeere rad didetuccacn cet aes 22 Hazardous Location Heaters 22 Non Hazardous Location Heaters 24 AGCESSOMEGS WI eee eee eee 26 Technical Data 28 DIMENSIONS s 22 03 104660 IA 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 Caution A CAUTION A caution alerts you to possible equipment damage or de
19. ITTING KNOB SPACER WARNING PLATE English WARNING PLATES multilingual WIRE ASSEMBLY TIE STRAP WARNING PLATE English WARNING PLATE multilingual GASKET LIGHT LENS O RING fluoroelastomer SOCKET JAM SCREW 5 8 18 x 5 16 SCREW 1 4 28 UNRF 3A LIGHT CIRCUIT BOARD NUT 3 4 14 npsm ALLEN WRENCH 5 32 HOUSING thermometer PLUG pipe 1 2 npt NUT full hex WASHER flat Parts Qty PO PO a Na LH SH AAA AAA AA ee ee Oe ee a eo KR KR A Eo A Replacement Danger and Warning labels tags and cards are available at no cost 25 Accessories Accessories Heater Conversion Kit 246302 Includes two fittings to make VISCON HP ports match VISCON Mounting Bracket 192585 European version see below A M8 B A Y y A D gt gt lt F a E gt Measurements inches mm A B Cc D E F 5 6 76 0 88 3 37 6 25 1 44 127 171 7 22 4 85 5 158 8 36 6 183982 USA version 6 5 amp 152 127 26 Cart Bracket Order 2 each of the following 183484 Clamp 183485 Mounting bar ow 5 YY oe 183484 183485 5 amp 6 included with heater Se A 05543 Power Cord Set 110160 600 V 12 Awg Extra Hard Usage Type St High Temperature 221 F 105 C rated Thermal Lubricant 110009 6 5 gram tube Cable Clamp Kit 246303 Contains a strain relief cable cla
20. 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 See page 3 for Table of Contents 7 GRACO 309524L a a TI12338A Hazardous Location Heater shown HO03 PROVEN QUALITY LEADING TECHNOLOGY Models Models Hazardous Location Heaters Part No Series VAC 50 60 Hz single phase Watts Amps Approvals 245848 A 120 2300 19 2 245863 A 240 4000 16 7 245864 245862 480 4000 8 30 200 4000 20 0 246254 380 4000 10 5 CE Qe LEN 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 l Division 1 Group D Hazardous Locations Temp Code T2 482 F 250 C 20 C lt T amb lt 135 F 57 C See Technical Data page 28 for additional information CE amp Approved Exd II T2 482 F 250 C Certificate No ISSeP O7ATEX034X Approved to EN 60079 0 2006 IEC 60079 0 2004 and
21. 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 FITN
22. alve Whip End Hose Air Supply Line 309524L Installation Selecting Tubing A WARNING Fluid loses some heat through the tubing or hose between the heater and spray gun Locate heater close Read warnings pages 4 5 to the spray area to minimize heat loss through plumb ing NN Select system components that meet temper The chart in FiG 2 shows a heat loss curve for 3 com ature and pressure ratings listed in Technical mon types of tubing Data page 28 The heaters normal output range is adjustable from 84 220 F 29 104 C RU Chart Notes The greater the flow rate the less the heat e Locate heater away from all flammable mate loss rials and where operators will not come in contact with hot metal surfaces e Foam insulated steel tubing and high pres sure airless paint hose retain heat best Insu lated tubing and hose are more expensive but higher costs are commonly offset by lower operating costs e Insulate and or label lines and components exiting heater that may become hot e Locate heater close to spray area to minimize heat loss through plumbing Heat Loss Curve 70 F 21 C ambient F C 6 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 Typical Fluid Temperature Drop 0 5 1 1 5 2 2 5 3 LEM 0 1 0 2 0 3 0 4 0 5 0 6
23. crews to 89 in lb 10 Nem 309524L Repair A Torque to 89 in Ib 10 Nem A Electrical Housing A Junction Box A Apply sealant A Torque nuts 62 to 10 12 in Ib 1 1 1 3 Nem T12334E Fic 17 Control Repair Hazardous Location Heaters A Torque to 89 in Ib 10 Nem A Electrical Housing A Apply sealant A Torque nuts 62 to 10 12 in Ib 1 1 1 3 Nem TI2336E Fic 18 Control Repair Non hazardous Location Heaters 309524L 21 Parts Parts Hazardous Location Heaters A Torque to 89 in Ib 10 Nem A Apply sealant 31 s A Apply thermal lubricant Ba a A Torque nuts 62 to 10 12 in Ib 1 1 1 3 Nem ti2334E 22 309524L Hazardous Location Heaters Ref No 3 Heater Block Part No Series Part No Volts Watts 245848 A 246616 120 2300 245862 A 246617 200 4000 245863 A 246618 240 4000 245864 A 246619 480 4000 246254 A 246620 380 4000 Ref No Part No Description Qty 1 183074 CONTROL HOUSING 1 2 102124 THERMOMETER DIAL 1 3 HEATER BLOCK see table 1 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 104582 WASHER 2 8 104029 GROUNDING CLAMP 2 9 108675 BUSHING 1000 V max 250 A 2 max 10 108674 BACKUP THERMOSTAT 1 11 235524 WIRE ASSEMBLY 1 12 177969 KNOB 1 134 177922 WARNING TAG 1 14 100055 SCREW 6 type U 10 15 223126 THERMAL LIMIT SENSOR 152 1
24. injury inhalation of tokic fumes and hearing loss This equipment includes but is not limited to e Protective eyewear e Gloves clothing and respirator as recommended by the fluid and solvent manufacturer e Hearing protection AN Da V v 309524L 5 Installation Installation Typical Installation Drawing The typical installation drawing is only a guide Your Graco distributor can assist in designing your system SITE ATIII Key A Bleed type Master Air Valve J Power Cable B Air Filter K Heater C Air Regulator and Gauge L Fluid Filter D Air Line Lubricator M Drain Valve E Pump Runaway Valve N Fluid Pressure Regulator F Ground Wire P Fluid Supply Line G Pump Q Spray Gun H Explosion Proof Power Switch R Fluid Return Line Fic 1 Typical Installation Heated Circulating System N lt xs lt CHo 05486 524 Back Pressure Valve Fluid Shutoff Valve Director Valve Drain Back Tube Suction Tube Pressure Relief V
25. mp and 5 m 221 F 105 C cable See page 27 for installation instructions Hazardous location heaters are no longer rated for use in a hazardous area when used with these accessories 309524L Cable Clamp Kit 246303 Installation 1 Slide cable clamp 3 onto cable 2 Accessories Screw retaining nut B into fitting E Tighten with no more than 2 in 50 mm stripped black and blue wires and 4 in 100 mm yellow green ground wire 2 Place washer F on fitting E inside terminal junction box 3 Push conical shaped packing D into fitting E 6 Place one side of retaining clip onto retaining clip nut and insert as shown 4 Place washer C on retaining nut B Ref No Part No Description Qty 2 Cable 16 4 ft 5m 221 F 1 Po 105 C S 3 113162 Clamp 1 05544 Fic 19 Cable Clamp Kit Key A Retaining clip B Retaining nut C Washer Pa N D Packing GS E Fitting ax S F Washer yy S j OD A S D B 05554 Fic 20 Kit Assembly 309524L 27 Technical Data Technical Data The heater can be used in the following environmental conditions indoor use 99 maximum relative humidity pollu tion degree 2 installation category Il maximum ambient temperature 135 F 57 C Maximum Working Pressure 7250 psi 50 MPa 500 bar Voltage Wattage Current See Models page 2 Fluid Passage Area
26. nd press fit it onto the new control knob Check the bushing 29 and replace it if worn 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 hous ing Tighten setscrew 30 Heater Block 1 Follow Pressure Relief Procedure page 14 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 ter minal 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 18 20 to remove the primary thermostat and probe 24 the backup thermostat 10 the thermal limit sensor 15 and the control knob 83 7 Remove the 6 screws 6 and lockwashers 5 hold ing the housing to the heater block 3 8 Reassemble heater with the new block 3 in reverse order of disassembly IN Reassembly Notes e Refer to Fic 15 or 16 for wiring connections e Non hazardous Location Heater only Make sure gasket 47 is installed and aligned with electrical housing screw holes e Secure cover 18 with lockwashers 5 and screws 6 or 52 torque s
27. or maxi mum heater life Use the chart in FIG 9 to determine the Under Boil temperature FIG 9 also shows the effect of temperature on reducing viscosity Note that most of the viscosity reduction occurs by 130 F 55 C Under Boil is the Graco method of hot airless spraying where the fluid is heated to a temperature just under the boiling point of its most volatile solvent To find your fluid s Under Boil temperature 1 2 Pour a small sample into a heat proof container Measure and record the fluid temperature and vis cosity using a No 2 Zahn cup Heat water in a large container to 200 F 93 C Place the sample in the water At every 10 temperature rise measure and record the viscosity and temperature Do this until solvents start boiling off and the viscosity starts to level off usually 160 170 F 71 77 C To find the temperature to use in your Under Boil system a Subtract the lowest viscosity reading from the highest one b Multiply the result by 0 90 c Subtract the result from the highest viscosity reading Find this number on your temperature and viscosity records 100 X 904 s x 80 4 h 70 60 4 40 30 20 4 Viscosity seconds with 2 Zahn cup oh Heavy Lacguer Medium Lacguer Enamel eS el E 2 30 70 80 90 100 110 40 50 120 60 70 80 C 130 140 150 160 17
28. potential static arc e Do not plug or unplug power cords or turn lights on or off when flammable fumes are present k e Keep the work area free of debris including solvent rags and gasoline e Ground equipment and conductive objects See Grounding page 11 e Hold gun firmly to side of grounded pail when triggering into pail e 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 e Use only grounded hoses e 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 uly ELECTRIC SHOCK HAZARD Improper grounding wiring or usage of the system can cause electric shock e All electrical wiring must be done by a qualified electrician and comply with all local codes and regu lations e Connect only to grounded power source e Turn off and disconnect power at the main switch before disconnecting any cables and before servic ing equipment 4 309524L Warning A WARNING ki EQUIPMENT MISUSE HAZARD NA Misuse can cause serious injury or death e For professional use only e Use equipment only for its intended purpose Call your Graco distributor for information e Read manuals warnings tags and labels before operating equipment Follow instructions e Check equipment daily Repair or replace worn or damaged parts immedia
29. struction if you do not follow instructions Note Nn A note indicates additional helpful information Important mam An arrow indicates important information Warning A WARNING SKIN INJECTION HAZARD BA High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just zt 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 e Do not put your hand or fingers over the gun fluid nozzle e Do not stop or deflect leaks with your hand body glove or rag e Do not blow back fluid this is not an air spray system e Follow Pressure Relief Procedure page 14 when you stop spraying and before cleaning check ing or servicing equipment e Use lowest possible pressure when flushing priming or troubleshooting e Never spray without tip guard and trigger guard installed e Engage trigger lock when not spraying e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately High pres sure 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 e Use equipment only in well ventilated area e Eliminate all ignition sources such as pilot lights cigarettes and plastic drop cloths
30. t least 10 minutes to cool the heated fluid and heater 4 Shut off all air and fluid supplies 5 Disengage the safety lock 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 14 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 Do not turn on heater until fluid lines are clear of solvent Priming System Refer to FIG 1 page 6 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 sup plied 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 309524L Operation Setting Heater Control Adjusting for Spraying Refer to Fig 11 1 Setthe heater control knob 33 to a trial setpoint of CAUTION 4or 5 Operating the heater at its highest setting over 180 F 82
31. tely e Do not alter or modify equipment Use only Graco parts and accessories e Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals e 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 e Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces e Do not use hoses to pull equipment e 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 e Do not touch hot fluid or equipment e Allow equipment to cool completely before touching it e 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 e Read Material Safety Data Sheets MSDS to know the specific hazards of the fluids you are using e 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 2 the eguipment to help protect you from serious injury including eye
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