Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Translations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 3

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Selecting Tubing . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mounting Heater . . . . . . . . . . . . . . . . . . . . . . . . . 8

Fluid Connections & Accessories . . . . . . . . . . . . 9

Electrical Connections . . . . . . . . . . . . . . . . . . . . 10

Determining Proper Fluid Temperature . . . . . . . 12

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pressure Relief Procedure . . . . . . . . . . . . . . . . 14 Initial Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Priming System . . . . . . . . . . . . . . . . . . . . . . . . . 14 Setting Heater Control . . . . . . . . . . . . . . . . . . . . 15 Adjusting for Spraying . . . . . . . . . . . . . . . . . . . . 15

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Draining Heater . . . . . . . . . . . . . . . . . . . . . . . . . 16

Unclogging Fluid Passages . . . . . . . . . . . . . . . . 16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Primary Thermostat & Probe . . . . . . . . . . . . . . . 18

Backup Thermostat . . . . . . . . . . . . . . . . . . . . . . 18

Thermal Limit Sensor . . . . . . . . . . . . . . . . . . . . 20

Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Heater Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Contents

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Hazardous Location Heaters . . . . . . . . . . . . . . . 22

Non-Hazardous Location Heaters . . . . . . . . . . . 24

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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

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

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

Translations

Manual available in following languages:

Manual Conventions

Warning

WARNING

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).

Caution

CAUTION

A caution alerts you to possible equipment damage or destruction if you do not follow instructions.

Note

A note indicates additional helpful information.

Important

An arrow indicates important information.

I

WARNING

Read warnings, pages 4-5.

??? Select system components that meet temper- ature and pressure ratings listed in Technical Data, page 28. The heater???s normal output range is adjustable from 84-220??F (29-104??C).

???Locate heater away from all flammable mate- rials and where operators will not come in contact with hot metal surfaces.

???Insulate and/or label lines and components exiting heater that may become hot.

Installation

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. 2 shows a heat loss curve for 3 com- mon types of tubing.

Chart Notes:

???The greater the flow rate, the less the heat loss.

???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.

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

Typical Fluid Temperature Drop

Heat Loss Curve - 70?? F (21?? C) ambient

(oF) oC 6

Installation

Mounting Heater

??? 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.

???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

Need wall bracket 192585 or 183982. See Acces- sories, page 26.

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.

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.

6 in.

152.4 mm

5 in.

127 mm

6

5

YY

CC

BB

FIG. 3: Bracket 192585

6 in.

152.4 mm

5 in.

127 mm

6 5

MM NN

PP

FIG. 4: Bracket 183982

05442

8631A

Cart Mounting

(FIG. 5)

You need to have 2 each of cart mounting bar 183485 and clamp 183484. See Accessories, page 26, 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. 7.

Installation

WARNING

To avoid rupturing a component, which can cause seri- ous injury, including amputation; read warnings, page 4, and follow the instructions below.

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

???Use flexible hoses between heater and gun.

???Install a properly sized accumulator down- stream from the heater.

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

DD

6

5

AA

ZZ

05543-524

FIG. 5: Cart Mounting

Fluid Connections &

Accessories

(FIG. 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.

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- sure regulator (N) near the heater???s 1/2-14 npt(f) fluid outlet. Then connect the fluid line.

X

N

L

T M

05545-524

FIG. 6: Fluid Connections & Accessories

Installation

Electrical Connections

WARNING

Read warnings, page 4. Install heater in compliance with all applicable codes and regulations.

CAUTION

To help prevent damage, avoid spilling liquids onto electrical components.

Requirements For All Installations

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 suitable for at least 221??F (105??C).

Hazardous Location Installation

Requirements

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.

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.

2.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.

The above accessories are not provided by Graco. Make sure that accessories are appropri- ate for the conditions of use.

Wall Mounted Wiring

Mount a 2-pole, explosion-proof electric switch (H) near the heater. See FIG. 7. The switch must meet the electri- cal codes for your location. Also use the correct cable and plug.

H

4

05546-524

FIG. 7: Wall Mounted Wiring

Installation

Cart Mounted Wiring

Connect a plug that meets the electrical codes for your location. See FIG. 8.

4

05547-524

FIG. 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.

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 for 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.Pour a small sample into a heat-proof container.

2.Measure and record the fluid temperature and vis- cosity using a No. 2 Zahn cup.

3.Heat water in a large container to 200??F (93??C). Place the sample in the water.

4.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).

5.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.

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.

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).

Operation

Operation

Pressure Relief Procedure

WARNING

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 at 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.

Initial Flushing

WARNING

Read warnings, page 4.

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.

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 sys- tem at very low pressure, about 10-12 oz/min (0.30-0.35 liter/min).

3.After 10 minutes, read the temperature on the ther- mometer (2). If it does not match the desired tem- perature, adjust the setpoint.

33

2

05549-524

FIG. 11: Setting Heater Control

Operation

Adjusting for Spraying

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.

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.

Maintenance

Maintenance

WARNING

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.

Unclogging Fluid Passages

(FIG. 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.

Pour in solvent

Repair

Repair

WARNING

Read warnings, pages 4-5. Make sure the main power is off and heater is cool before repairing.

Hazardous Location Heaters: See FIG. 15 & 17

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

Primary Thermostat & 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 (25).

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

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

CAUTION

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.

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).

Repair

Thermal Limit Sensor

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.Follow Pressure Relief Procedure, page 14.

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 19.

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, below.

Control Knob

1.Follow Pressure Relief Procedure, page 14.

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 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

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 (33).

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.

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).

1Torque to 89 in-lb (10 N???m)

2Electrical Housing

3Apply sealant

4Torque nuts (62) to 10-12 in-lb (1.1-1.3 N???m)

4

1 9

5

7

1 6

5

3B

3A

3

TI2336E

14, 43

19 16

4 62

15

16

62

3 10

54

55

1 6

5

4

5

1 6

8 7

1 6

5

31

29 30 33 12

51

50

1

48

58 20

9 2

32 2

56

2 2

31

3

7

8

1Torque to 89 in-lb (10 N???m)

2Apply sealant

3Apply thermal lubricant

4Torque nuts (62) to 10-12 in-lb (1.1-1.3 N???m)

ti2334E

Hazardous Location Heaters

Parts

???Replacement Danger and Warning labels, tags and cards are available at no cost.

14, 36

19

5

7

1 6

5

31

51

50 48

20

1

47

4

58

32 2

56

2 2

31

3

1Torque to 89 in-lb (10 N???m)

2Apply sealant

3Apply thermal lubricant

4Torque nuts (62) to 10-12 in-lb (1.1-1.3 N???m)

Non-Hazardous Location Heaters

Parts

???Replacement Danger and Warning labels, tags and cards are available at no cost.

Accessories

Accessories

Heater Conversion Kit

246302: Includes two fittings to make VISCON HP ports match VISCON2

Mounting Bracket

192585: European version (see below)

Measurements ??? inches (mm)

6 5

(152)(127)

H

Cart Bracket

Order 2 each of the following:

183484: Clamp

183485: Mounting bar

6

5

183484

183485

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 clamp 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.

Cable Clamp Kit 246303 Installation

1.Slide cable clamp (3) onto cable (2).

2.Place washer (F) on fitting (E).

3.Push conical-shaped packing (D) into fitting (E).

4.Place washer (C) on retaining nut (B).

5.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 inside terminal junction box.

6.Place one side of retaining clip onto retaining clip nut, and insert as shown.

3

2

Maximum Temperature Rise

100

90

80

70

60

50

40

30

20

10

0

0

Maximum Temperature Rise vs. Flow Rate

4000 watt VISCON HP heater, Test Fluid: 10w Hydraulic Oil 94.16 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

54.14

50.68

42.23 39.32

0.5 1 1.5 2 2.5 3 3.5

Flow Rate

L

1/2 npt(m) Fluid Inlet

1/2 npt(f) Fluid Outlet