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Instructions
High Pressure Fluid Heater
VISCON HP
309524L
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.
TI12338A
Hazardous Location Heater shown
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Models Models Hazardous Location Heaters Part No. Series VAC (50/60 Hz single phase) / Watts / Amps Approvals 245848 A 120 / 2300 / 19.2 II 2 G 245863 A 240 / 4000 / 16.7 Approved Exd II T2 482°F (250°C) 245864 A 480 / 4000 / 8.30 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 fl
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Contents Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 3 Hazardous Location Heaters . . . . . . . . . . . . . . . 22 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Non-Hazardous Location Heaters . . . . . . . . . . . 24 Installation . . . . . . . . . . . . . . . . . . . .
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Warning WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. � Do not point the gun at anyone or at any part of the body. � Do not put your hand or fingers over the gun fluid nozzle. � Do not stop or deflect leaks with your hand, body, glove, or rag. � Do not “blow back” fluid; this is not an air spray system. � F
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Warning WARNING EQUIPMENT MISUSE HAZARD Misuse can cause serious injury or death. � For professional use only. � Use equipment only for its intended purpose. Call your Graco distributor for information. � Read manuals, warnings, tags, and labels before operating equipment. Follow instructions. � Check equipment daily. Repair or replace worn or damaged parts immediately. � Do not alter or modify equipment. Use only Graco parts and accessories. � Do not exceed the maximum working pressure or temp
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Installation Installation Typical Installation Drawing The typical installation drawing is only a guide. Your Graco distributor can assist in designing your system. Z Q F G H J Y A B C D E K X P N V R L M T U W S 05486-524 Key: A Bleed-type Master Air Valve JPower Cable S Back Pressure Valve B Air Filter K Heater T Fluid Shutoff Valve C Air Regulator and Gauge L Fluid Filter U Director Valve D Air Line Lubricator M Drain Valve VDrain Back Tube E Pump Runaway Valve N Fluid Pressure Regulator W S
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Installation I Selecting Tubing WARNING 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- Read warnings, pages 4-5. ing. � 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 heater’s normal output range is adjustable from 84-220°F Chart Notes: (29-104°
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Installation Mounting Heater � The heater has a surface temperature of T2 6 in. 152.4 mm (482°F, 250°C). Follow temperature code when locating heater. See Technical Data, 5 in. page 28, for more temperature code informa- 127 mm tion. � Heater controls must be easily accessible. 6 � The mounting surface must be able to support 5 the weight of the heater and fluid, and any YY stress caused during operation. CC BB Wall Mounting Need wall bracket 192585 or 183982. See Acces- 05442 sories, pag
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Installation Cart Mounting WARNING (FIG. 5) You need to have 2 each of cart mounting bar To avoid rupturing a component, which can cause seri- 183485 and clamp 183484. See Accessories, ous injury, including amputation; read warnings, page page 26, to order. 4, and follow the instructions below. 1. Place clamps (AA) around the cart vertical post 2. Provide a means for adequately handling fluid (DD) and secure to the heater mounting bars (ZZ) expansion caused by heat. Options include: with
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Installation Hazardous Location Installation Electrical Connections Requirements 1. The heater connection must be made using one of WARNING the following options: a. Cable entries of a certified flameproof model. Read warnings, page 4. Install heater in compliance b. Threaded metal conduits. with all applicable codes and regulations. If this option is used, a stopping box with CAUTION compound filling of a certified flameproof model must be placed at the entry of the To help prevent dam
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Installation Wall Mounted Wiring Cart Mounted Wiring Mount a 2-pole, explosion-proof electric switch (H) near Connect a plug that meets the electrical codes for your the heater. See FIG. 7. The switch must meet the electri- location. See FIG. 8. cal codes for your location. Also use the correct cable and plug. H 4 4 9 1 4 9 2 4 9 1 4 9 2 4 3 4 8 1 3 Power terminal Ground terminal 3 4 8 2 4 Neutral terminal or 2nd Tighten all terminal nuts to power terminal 30 in-lb (3.4 N�m) 05547-524 1 3 Pow
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Installation To find your fluid’s Under-Boil temperature: Determining Proper Fluid 1. Pour a small sample into a heat-proof container. Temperature 2. Measure and record the fluid temperature and vis- cosity using a No. 2 Zahn cup. CAUTION 3. Heat water in a large container to 200°F (93°C). Operating the heater at its highest setting, over 180°F Place the sample in the water. (82°C), for long periods of time decreases the heater life and can cause fluid to dry out; which can clog the 4. At
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Installation 60 Typical high-solid paint 50 Typical enamel paint 40 nU 1 30 Typical spray viscosities nU 2 20 10 o C 15 25 35 45 55 65 o (60) (80) (100) (120) (140) ( F) Temperature FIG. 10: Effect of Temperature on Viscosity The chart in FIG. 10 shows the effect of temperature in Once the fluid is reduced to about 34 on the chart, vis- reducing two fluids to a sprayable viscosity, between 20 cosity reduction begins to level off and temperature will and 34 seconds using a No. 2 Zahn cup. not s
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Operation Operation Pressure Relief Procedure Initial Flushing WARNING WARNING Read warnings, page 4. Read warnings, page 4. Follow Pressure Relief Procedure when you stop The heater was tested with lightweight oil, which needs spraying, and before cleaning, checking, or servicing to be flushed out before using the equipment. Ensure equipment. main power is off and heater is cool before flushing. Use a compatible solvent, and follow flushing instructions in 1. Engage the gun safety lock. yo
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Operation Setting Heater Control Adjusting for Spraying (Refer to FIG. 11) CAUTION 1. Set the heater control knob (33) to a trial setpoint of 4 or 5. Operating the heater at its highest setting, over 180°F (82°C), for long periods of time decreases the heater 2. Start the pump and circulate fluid through the sys- life and can cause fluid to dry out; which can clog the tem at very low pressure, about 10-12 oz/min heater and result in a poor finish. (0.30-0.35 liter/min). 1. Adjust pump press
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Maintenance Maintenance Unclogging Fluid Passages WARNING (FIG. 13) 1. Drain the heater. Read warnings, pages 4 and 5. Make sure the main power is off and heater is cool before doing mainte- 2. Remove the heater block (3) from the heater hous- nance. ing. See Heater Block, page 20. 3. Pour a high strength, compatible solvent into the Flushing heater tube to soften the clog. Clogged fluid passages are difficult to clean and reduce 4. Flush out the clog. heating efficiency, flow rate, and pres
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Troubleshooting Troubleshooting Problem Cause Solution Heater will not heat. 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). Check continuity of primary thermo- stat (24) and backup thermostat (10). Replace thermostats if necessary when replacing
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Repair Repair WARNING CAUTION To avoid damaging capillary tube (GG), which can cause heater malfunction, do not kink or nick the tube. Read warnings, pages 4-5. Make sure the main power To avoid shorting out the heater, do not allow capillary is off and heater is cool before repairing. tube to contact the block terminal (3A). Follow step 10, below. Hazardous Location Heaters: See FIG. 15 & 17 10. Liberally apply thermal lubricant (part no. 110009) to Non-hazardous Location Heaters: See FIG
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Repair HH 3B REF. 10 REF. 19 2 6 L1 5 9A 18 19 GG 3A 9B 16 63 FF 15 3 62 24 15 27 25 35 52 L2 GND 63 1 53 26 HH Wiring Diagram TI12339 62 28 1 10 16 1 3A EE 54 55 1 Apply thermal lubricant 51 2 50 Torque to 89 in-lb (10 N�m) 48 20 3 Torque nuts (62) to 10-12 in-lb (1.1-1.3 N�m) TI12335C FIG. 15: Thermostat Repair – Hazardous Location Heaters 3B 52 2 REF. 19 HH REF. 10 18 GND 3A 47 L1 16 15 FF GG 19 63 24 3 62 26 15 28 27 35 9B 9A L2 1 Wiring Diagram 25 16 HH 62 63 1 1 10 Apply thermal lubricant
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Repair Thermal Limit Sensor Heater Block 1. Follow Pressure Relief Procedure, page 14. CAUTION 2. Remove housing cover (18). To avoid damaging the capillary tube (GG), which can cause heater malfunction, do not kink or nick the tube. 3. Hazardous Location Heater only: Remove electrical junction box cover (4). To avoid shorting out the heater, do not allow the cap- illary tube to contact the block terminal (3A). 4. Hazardous Location Heater only: In the junction box (1B), disconnect the mai
