Graco 3A2824B User's Manual
Contents
1. Thermal Limit Sensor Al 7 AN T See Before Beginning Repair page 14 Relieve pressure Wait for heaters to cool Testing Check that you have continuity across the two leads If circuit is open replace thermal limit sensor 19 See FIG 9 See Fic 7 Loosen all four screws 12 from bracket 16 and shield 21 Pull bracket assembly away from heater housing 1 To remove thermal limit sensor 19 from core 2 pull upward with a steady force Disconnect thermal limit sensor from jumper wire 23 BB and heater thermostat switch 17 GG See FIG 9 Connect new thermal limit sensor to jumper wire BB and thermostat switch GG then reas semble heater in reverse order of disassembly NOTE Apply a thin film of heat sink compound 110009 to thermal limit sensor 19 TI7010a Fic 9 15 Repair Indicator Light Al 7 AN See Before Beginning Repair page 14 Relieve pressure 2 Wait for heaters to cool 3 See FIG 7 Loosen two screws 12 and remove shield 21 4 Disconnect jumper wires 23 DD EE from back of indicator light 9 then push light out through the front face of the control bracket 17 by depressing the prongs on the sides of the light See FIG 10 5 Press new light into control bracket 16 until prongs lock in place 6 Connect jumper wires DD EE and reassemble heater in reverse order of disassembly 22 TI7011a2. or 5 2 Start the pump and circulate fluid through the sys tem at a very low flow rate of about 10 12 oz min 0 30 0 35 liter min 3 After the red heater light AB turns off read the temperature on the thermometer 38 If it does not match the desired temperature adjust the setpoint ti20002a FiG 6 Setting Heater Control 12 3A2824B Troubleshooting Troubleshooting Al IN N 7 CAUSE SOLUTION No heat and heater indicator light is Heater power off or circuit breaker Turn heater power on or reset circuit off tripped breaker Bad thermostat 17 With power on check for continuity on off at clicks when turning the heater control knob To replace ther mostat see page 16 e Bad overtemperature sensor 19 With power on check for continuity at This is a high temperature limit fuse overtemperature sensor To replace and must be replaced if blown sensor see page 15 No heat but heater indicator light is Bad heater cartridge 20 With power OFF check for continuity on at heater cartridge connections which should be 29 36 ohms Heat but heater indicator light is off Bad light Check connections Replace lamp Repair Before Beginning Repair Z Repairing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly Have a qualified electrician connect power and ground to main
3. 20 Schematic Diagram 20000005 20 Dimensions 000 0c ee eee eee 21 Graco Standard Warranty 22 Graco Information Ls 22 3A2824B Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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 ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause elec tric shock e Turn off and disconnect power cord before servicing equipment Connect only to grounded electrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on power and extension cords Do not expose to rain Store indoors BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns e Do not touch hot fluid or equipment SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment e Do not spray wit
4. 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 MSDSs 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 Wear appropriate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This protective equipment includes but is not limited to e Protective eyewear and hearing protection e 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 e Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or repla
5. Fic 10 16 Heater Thermostat Switch Al 77 AN 1 See Before Beginning Repair page 14 Relieve pressure 2 Wait for heaters to cool 3 Testing See Fic 10 With thermostat probe JJ above 75 F 24 C and below 160 F 71 C the continuity across the contacts should open when turned off and close when turned up toward 8 You should hear the switch click open and closed 4 See FiG 7 Loosen two screws 12 and remove shield 20 5 See Fic 11 Detach the two push on connectors from thermostat switch 17 One is from thermal limit sensor 19 at GG and dual connector HH and FF is from heater cartridge 21 and light 8 TI7012a FiG 11 6 Pull heater control knob 9 off of heater control bracket 16 face 7 Usinga phillips head screwdriver remove screws 25 on control bracket face to release ther 3A2824B Repair mostat switch from bracket Pull thermostat Cleaning Heater Core probe JJ slowly out of heater core 2 8 Insert new thermostat probe into core with heat sink Al 7 N 2L ny MPabarP I compound 110009 Use screws 25 to install new thermostat switch behind bracket face and install Ponte kno 1 See Before Beginning Repair page 14 Relieve 9 Reattach jumper wires 22 and reassemble heater pressure in reverse order of disassembly 2 etur heaters to ool eter tien ester probe COE E dow 3 Loosen four screws 12 t
6. 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
7. 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 gun trigger 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 gun trigger lock 3A2824B To avoid skin injection do not point gun at anyone or at any part of the body To avoid fire and explosion 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 Use a compatible solvent and follow flushing instructions in your fluid supply and spray gun manual Priming System Refer to Fic 1 page 5 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 trigger lock 7 Shut off the air supply to the pump 8 Perform Pressure Relief Procedure 9 Install the gun spray tip 11 Operation Setting Heater Control Refer to FIG 6 1 Setthe heater control knob 9 to a trial setpoint of 4
8. Instructions Parts G GRACO Viscon LT Fluid Heater EN For variable heating of fluids Not approved for use in explosive atmospheres or hazardous locations Model No 16T525 1750 W 7 3 A 240VAC 50 60Hz 1 Phase 2000 psi 14 MPa 138 bar Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual Save these instructions TI19998a ce Intertek 9902471 Conforms to UL Std 499 PROVEN QUALITY LEADING TECHNOLOGY CSA Std 25 SNO 88 Contents Warnings iis ce cle llb rrr hh rs 3 Installation lessen 5 Typical Installation Drawing 5 Component Identification 6 General Information 000 0 ee 7 Selecting Tubing 0 00 esac eee 7 Mounting Heater 0 0c eee eee 8 Fluid Connections and Accessories 9 Electrical Connections 05 10 Operations 22 lr ERR IRR 11 Pressure Relief Procedure 11 Initial Flushing cee eee eee 11 Priming System 00000 eevee 11 Setting Heater Control 5 12 Troubleshooting e 13 H p iri 25 yl e eect IRE ete DIES 13 Before Beginning Repair 13 Heater Temperature Controls 14 Parts loe ERE ee 18 Accessories eae eil ca 19 Technical Data eeeeeeeese
9. anufacturing locations are registered to ISO 9001 www graco com Revised February 2013
10. ce worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture Failure to follow this warning can result in death serious injury or prop erty damage e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents e Many other fluids may contain chemicals that can react with aluminum Contact your material sup plier 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 e Open a valve to relieve the fluid expansion during heating e Replace hoses proactively at r
11. egular intervals based on your operating conditions 3A2824B Installation Typical Installation Drawing The typical installation drawing is only a guide Your Graco distributor can assist in designing your system 9 ut amp y 7 i W Key A Bleed type Master Air Valve L Fluid Filter B Air Filter M Drain Valve C Air Regulator and Gauge N Fluid Pressure Regulator D AirLine Lubricator P Fluid Supply Line E Pump Runaway Valve Q Spray Gun F Ground Wire R Fluid Return Line G Pump S Back Pressure Valve K Heater T Fluid Shutoff Valve FiG 1 Typical Installation Heated Circulating System 3A2824B No x c ti19999a Director Valve Drain Back Tube Suction Tube Pressure Relief Valve Whip End Hose Air Supply Line Installation Component Identification Component Identification Key AA Temperature control AB Heater light illuminated while heating AC Heater inlet 3 8 npt f AD Heater outlet 1 4 npt f FiG 2 Typical Installation Heated Circulating Sy
12. 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 o
13. f 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 la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com 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 For patent information see www graco com patents Original instructions This manual contains English MM 342824 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2012 Graco Inc All Graco m
14. hen pull control section up contact top of core Route wires from thermal limit switch 19 heater cartridge 20 and out of the way ground wire through center of coils 4 See Fic 12 Unscrew core 2 from housing 1 Bend tabs on thermostat away from each other Use wire brush to clean core then re install in hous after installing wire connectors so they do not ing interfere with shield 21 ti20004a FiG 12 3A2824B 17 Parts Parts Nh gt lt j 17A oo e UL A Apply a thin film of heatsink compound 26 A Stretch capillary coils KK down to contact top of core 2 Route wires from thermal limit switch 19 heater cartridge 20 and ground wire through center of coils A Apply both tape 27 and sealant 28 to all pipe threads 18 d gt ET HA gt XLI Powerfrom Brown Blue Green Control Box o Yellow 15 TA S 240 V REC es Lamp 2 1 R1 Odl mi 240 V BRE xen 1750 Watt 90 C A Bend tabs on thermostat away from each other after installing wire connectors so cover cannot contact wires A A
15. hout tip guard and trigger guard installed Engage trigger lock when not spraying Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail Do not use pail liners unless they are antistatic or conductive Stop operation immediately if static sparking occurs or you feel a shock Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area 3A2824B 3 Warnings TOXIC FLUID OR
16. ic 3 Typical Temperature Drop 3A2824B 7 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 Use included wall bracket 16 988 and insulating washers 29 part number 167002 quantity 2 See FIG 4 Use wall bracket as a template to mark bolt holes Bracket 16R988 Fic 4 1 Use 1 4 in bolts of appropriate length and lock washer CC not supplied to mount bracket 2 Use two screws 32 and washers 31 to install heater onto bracket ti20000a FiG 4 3A2824B Component Identification Fluid Connections and Accessories 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 To handle fluid expansion caused by heat e Use flexible hoses between heater and gun e Install a properly sized accumulator down stream from the heater e Install a pressure relief valve X pre set to relieve pressure when it exceeds the system maximum working pressure 3A2824B 9 Component Identification Electrical Connec
17. pound 1 oz tube Accessories 19 Technical Data Technical Data Maximum Working Pressure 2 0005 2000 psi 140 bar 14 MPa Maximum Amps slseseeee ee 7 3A Maximum Fluid Temperature 0 180 F 82 C Voltage sio pss nh aie rated ae hed EN ona 240 VAC 1750 Watts Heater Resistance 00 0 e eee eee 29 to 36 ohms Heated Core Area 0 es 68 in 438 cm Fl id Path oce ec RR ERE ee 3 parallel paths 40 in each Pressure Drop a siii 0 ee Equivalent to 40 in of 1 4 in 6 8 mm ID hose Inlet iie pee REM a EE cee deed 3 8 npt f Outlet pM PE HC 1 4 npt f Weight nue RR emm EM 9 0 Ib 4 1 kg Wetted Parts 000 cee eee Anodized aluminum zinc plated steel stainless steel PTFE Schematic Diagram Green Brown Blue Yellow Power from o Control Box ji 127 C O TEES n F 120V or 240V Lamp Oo Q i d RI 120 Volt o 850 Watt OFF Or 90 C 240 Volt 7 1000 Watt 20 3A2824B Technical Data Dimensions 38 7 cm 1 4 npsm Fluid Outlet 70 in 178 cm SJTO cable with NEMA L6 20P twist lock connector Ai 19998a 3 8 npt f Fluid Inlet 3A2824B 21 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name
18. power switch terminals Be sure to shut off all power to the equipment before repairing 1 Flush if necessary 2 Shutoff all power to equipment ANSA 3 Perform Pressure Relief Procedure page 11 3A2824B 13 Repair Heater Temperature Controls See FIG 7 Control knob 9 sets temperature of heater Indicator light 8 turns on when thermostat is heating and off when heater reaches setpoint LT tiz008b Power in FIG 7 14 3A2824B Heater Cartridge Al 74 AN 1 See Before Beginning Repair page 14 Relieve pressure Wait for heaters to cool Testing Use a multimeter to check resistance across cartridge leads per the Technical Data chart Also check that neither lead has continuity to the cartridge case See FIG 7 and Parts illustration on page 18 Loosen all four screws 12 from bracket 16 and shield 21 Pull bracket assembly away from heater housing 1 to remove heater cartridge 20 from core If necessary plug 4 can be removed from the bottom of core 2 so that cartridge can be pushed out from underneath Disconnect heater cartridge from jumper wires 22 CC and heater thermostat switch 17 HH See FiG 8 Connect new heater cartridge to jumper wire CC and thermostat heater switch H then reassemble heater in reverse order of disassembly TI7009a Fic 8 3A2824B Repair
19. pply lubricant to o ring 40 3A2824B Ref Part Description Qty 1 24K987 HOUSING heater 2 24K988 CORE heater spiral 3 24K992 INSULATOR heater 4 101754 PLUG pipe 5 24K991 BUSHING reducing 1 1 5 x 3 8 7 166863 FITTING nipple reducing 8 114286 LIGHT indicator 240V 9 24K979 KNOB control heater 10 119924 BUSHING strain relief 90 degree 11 16T187 HARNESS power heater SCREW machine hex serrated LABEL identification 154 189930 LABEL electric shock triangular 16 249521 BRACKET heater control 17 24K978 SWITCH thermostat heater 18 116343 SCREW ground 19 24K980 SENSOR thermal limit 152C QD 20 16T173 CARTRIDGE heater 1750W 240V 21 249520 SHIELD heater control 22 119858 WIRE jumper heater 23A 189285 LABEL burn hazard triangular 24 172953 LABEL designation 25 195874 SCREW machine phillips pan head 26 110009 LUBRICANT thermal 1 oz tube 29 167002 INSULATOR heat 30 16R989 BRACKET heater 31 100016 WASHER lock 32 108296 SCREW machine hex washer head 33 113914 FITTING tee 1 4 npt female 35 102124 THERMOMETER dial 39 198241 PLUG por pressure 40 111457 O RING 99 16T174 PLUG electrical locking L6 20P a a CO CR CREO CR a CE a a OO CIEE P PB aN N a a ca Not for sale A Replacement Danger and Warning labels tags and cards are available at no cost Not shown 3A2824B Accessories 110009 Heat sink com
20. stem o AG AD A A ti19998a AE Outlet thermometer AF Mounting bracket AG Heater plug AH Insulating washers 3A2824B General Information Select system components that meet temperature and pressure ratings listed in Technical Data page 20 The heater s normal output range is adjustable from 84 180 F 29 82 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 Component Identification Selecting Tubing Fluid loses some heat through the tubing or hose between the heater and spray gun Locate heater close to the spray area to minimize heat loss through plumb ing The chart in FiG 3 shows a heat loss curve for 3 com mon types of tubing Chart Notes e Higher flow rates have less heat loss Foam insulated steel tubing and high pressure air less paint hose retain heat best Insulated tubing and hose are more expensive but higher costs are commonly offset by lower operating costs 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 Typical Fluid Temperature Drop Flow Rate F
21. tions Power Cable Connections The heater power cable uses a 3 conductor cable and a NEMA L6 20P twist lock connector If another connector is used follow the table below for correct wiring his equipment must be grounded All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations Line Mains Neutral SLES Protective To help prevent heater damage avoid spilling liquids Ground Earth onto electrical components Requirements For All Installations The user must provide external over current protec tion For installations in the United States and Can ada a branch circuit breaker must be used for over current protection The maximum recom mended circuit breaker size is 15 amps Green or Green Yellow White or Blue Black or Brown ti20030a Fic 5 Connector 10 3A2824B Operation Pressure Relief Procedure Follow the Pressure Relief Procedure whenever yov see this symbol Operation Initial Flushing This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashing fluid and moving parts follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing the equipment Follow Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment 1 Engage the gun trigger lock
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