Graco Marine Heating System 309524N User Manual

Instructions  
High Pressure Fluid Heater  
VISCON HP  
309524N  
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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Contents  
Contents  
Translations  
Manual available in following languages:  
Manual  
Language  
309524  
309555  
309556  
309557  
309558  
309605  
309606  
309607  
English  
French  
Spanish  
German  
Swedish  
Chinese  
Korean  
Japanese  
Manual Conventions  
Warning  
Caution  
WARNING  
CAUTION  
A caution alerts you to possible equipment damage or  
destruction if you do not follow instructions.  
A warning alerts you to possible serious injury or  
death if you do not follow instructions.  
Note  
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).  
A note indicates additional helpful information.  
Important  
An arrow indicates important information.  
309524N  
3
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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.  
Follow Pressure Relief Procedure, page 14, when you stop spraying and before cleaning, check-  
ing, or servicing equipment.  
Use lowest possible pressure when flushing, priming, or troubleshooting.  
Never spray without tip guard and trigger guard installed.  
Engage trigger lock when not spraying.  
Tighten all fluid connections before operating the equipment.  
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:  
Use equipment only in well ventilated area.  
Eliminate all ignition sources, such as pilot lights, cigarettes and plastic drop cloths (potential static  
arc).  
Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.  
Keep the work area free of debris, including solvent, rags, and gasoline.  
Ground equipment and conductive objects. See Grounding, page 11.  
Hold gun firmly to side of grounded pail when triggering into pail.  
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.  
Use only grounded hoses.  
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.  
SPECIAL CONDITIONS FOR SAFE USE  
All flameproof joints are critical to the integrity of the heater as approved for hazardous locations and  
are not repairable if damaged. Damaged parts must be replaced only with genuine Graco parts with  
no substitutions.  
ELECTRIC SHOCK HAZARD  
Improper grounding, wiring, or usage of the system can cause electric shock.  
All electrical wiring must be done by a qualified electrician and comply with all local codes and regu-  
lations.  
Connect only to grounded power source.  
Turn off and disconnect power at the main switch before disconnecting any cables and before servic-  
ing equipment.  
4
309524N  
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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 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.  
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.  
Do not use hoses to pull equipment.  
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:  
Do not touch hot fluid or equipment.  
Allow equipment to cool completely before touching it.  
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.  
Read Material Safety Data Sheets (MSDS) to know the specific hazards of the fluids you are using.  
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.  
PERSONAL PROTECTIVE EQUIPMENT  
You must wear proper protective equipment when operating, servicing, or when in the operating area of  
the equipment to help protect you from serious injury, including eye injury; inhalation of toxic fumes, and  
hearing loss. This equipment includes but is not limited to:  
Protective eyewear  
Gloves, clothing, and respirator as recommended by the fluid and solvent manufacturer  
Hearing protection  
309524N  
5
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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
J
F
G
H
Y
A
B
C
D
E
K
X
P
N
V
R
L
M
T
U
W
S
05486-524  
Key:  
A
B
C
D
E
F
Bleed-type Master Air Valve  
Air Filter  
Air Regulator and Gauge  
Air Line Lubricator  
Pump Runaway Valve  
Ground Wire  
J
K
L
M
N
P
Q
R
Power Cable  
Heater  
Fluid Filter  
Drain Valve  
Fluid Pressure Regulator  
Fluid Supply Line  
Spray Gun  
S
T
Back Pressure Valve  
Fluid Shutoff Valve  
Director Valve  
Drain Back Tube  
Suction Tube  
Pressure Relief Valve  
Whip End Hose  
Air Supply Line  
U
V
W
X
Y
Z
G
H
Pump  
Explosion Proof Power Switch  
Fluid Return Line  
FIG. 1: Typical Installation – Heated Circulating System  
6
309524N  
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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-  
ing.  
Read warnings, pages 4-5.  
Select system components that meet temper-  
The chart in FIG. 2 shows a heat loss curve for 3 com-  
mon types of tubing.  
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).  
Chart Notes:  
The greater the flow rate, the less the heat  
loss.  
Locate heater away from all flammable mate-  
rials and where operators will not come in  
contact with hot metal surfaces.  
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.  
Insulate and/or label lines and components  
exiting heater that may become hot.  
Locate heater close to spray area to minimize  
heat loss through plumbing.  
Heat Loss Curve - 70° F (21° C) ambient  
(oF) o  
C
6
(20 ft.) 6.1 m steel tube  
Fluid: (130° F) 54° C  
5
4
3
2
1
0
(9)  
(8)  
(20 ft.) 6.1 m steel tube  
(3/8 in.) 9 mm foam insulation  
Fluid: (110° F) 43° C  
(7)  
(6)  
(20 ft.) 6.1 m airless paint hose  
Fluid: (110° F) 43° C  
(5)  
(4)  
(3)  
(2)  
(1)  
LPM  
(0.8) (GPM )  
0
0.5  
1
(0.3)  
1.5  
(0.4)  
2
(0.5)  
2.5  
3
(0.1)  
(0.2)  
(0.6)  
(0.7)  
Flow Rate  
FIG. 2: Typical Temperature Drop  
309524N  
7
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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,  
page 28, for more temperature code informa-  
tion.  
5 in.  
127 mm  
Heater controls must be easily accessible.  
6
The mounting surface must be able to support  
the weight of the heater and fluid, and any  
stress caused during operation.  
5
YY  
CC  
BB  
Wall Mounting  
Need wall bracket 192585 or 183982. See Acces-  
sories, page 26.  
05442  
Use wall bracket as a template to mark bolt holes.  
Bracket 192585  
6 in.  
152.4 mm  
5 in.  
127 mm  
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.  
6
5
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.  
MM  
NN  
PP  
3. Lift heater and slide two screw heads into bracket  
slots. Install remaining 2 screws and tighten all 4.  
8631A  
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.  
8
309524N  
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Installation  
Cart Mounting  
(FIG. 5)  
WARNING  
You need to have 2 each of cart mounting bar  
183485 and clamp 183484. See Accessories,  
page 26, to order.  
To avoid rupturing a component, which can cause seri-  
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)  
with M8 x 1.25 x 30 mm bolts (6) and lockwasher  
(5).  
2. Provide a means for adequately handling fluid  
expansion caused by heat. Options include:  
Use flexible hoses between heater and gun.  
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.  
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.  
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.  
DD  
6
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.  
5
AA  
ZZ  
X
N
05543-524  
L
Fluid Connections &  
Accessories  
M
T
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  
309524N  
9
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Installation  
Hazardous Location Installation  
Requirements  
Electrical Connections  
1. The heater connection must be made using one of  
the following options:  
WARNING  
a. Cable entries of a certified flameproof model.  
b. Threaded metal conduits.  
Read warnings, page 4. Install heater in compliance  
with all applicable codes and regulations.  
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.  
CAUTION  
To help prevent damage, avoid spilling liquids onto  
electrical components.  
Requirements For All Installations  
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.  
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).  
The above accessories are not provided by  
Graco. Make sure that accessories are appropri-  
ate for the conditions of use.  
10  
309524N  
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Installation  
Wall Mounted Wiring  
Cart 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.  
Connect a plug that meets the electrical codes for your  
location. See FIG. 8.  
H
4
4
1
4
2
4
9
9
1
4
2
4
9
9
3
4
8
1
2
3
4
Power terminal  
Ground terminal  
3
4
8
Neutral terminal or 2nd  
power terminal  
Tighten all terminal nuts to  
30 in-lb (3.4 N•m)  
05547-524  
1
2
3
Power terminal  
Ground terminal  
4
Neutral terminal or 2nd  
power terminal  
Tighten all terminal nuts to  
30 in-lb (3.4 N•m)  
Grounding  
05546-524  
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.  
309524N  
11  
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Installation  
To find your fluid’s Under-Boil temperature:  
Determining Proper Fluid  
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.  
CAUTION  
3. Heat water in a large container to 200°F (93°C).  
Place the sample in the water.  
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.  
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).  
Use the lowest temperature setting possible for maxi-  
mum heater life. Use the chart in FIG. 9 to determine the  
®
5. To find the temperature to use in your Under-Boil  
system:  
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).  
a. Subtract the lowest viscosity reading from the  
highest one.  
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.  
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  
90  
80  
70  
60  
50  
40  
30  
20  
10  
0
Heavy Lacquer  
Medium Lacquer  
Enamel  
oC  
20  
(70)  
30  
40  
50  
(120)  
60  
70  
(160)  
80  
(oF)  
(80)  
(90)  
(100)  
(110)  
(130)  
(140)  
(150)  
(170)  
(180)  
Temperature  
FIG. 9: Reducing Viscosity: Under-Boil Method  
12  
309524N  
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Installation  
60  
50  
40  
30  
20  
10  
Typical high-solid paint  
Typical enamel paint  
nU  
1
Typical spray  
viscosities  
nU  
2
oC  
(oF)  
15  
(60)  
25  
35  
45  
55  
65  
(80)  
(100)  
(120)  
(140)  
Temperature  
FIG. 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.  
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).  
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.  
309524N  
13  
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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  
spraying, and before cleaning, checking, or servicing  
equipment.  
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.  
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.  
Priming System  
(Refer to FIG. 1, page 6)  
4. Shut off all air and fluid supplies.  
5. Disengage the safety lock.  
1. Do not turn on the heater yet.  
2. If using an airless spray gun, do not install a spray  
tip yet.  
6. Hold a metal part of the gun firmly to a grounded  
metal pail, and trigger the gun to relieve pressure.  
3. Start the pump according to the instructions sup-  
plied with it.  
7. Engage the safety lock.  
8. Have a container ready to catch the fluid, then open  
the fluid drain valve.  
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.  
9. Install the gun spray tip.  
14  
309524N  
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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  
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  
lowest settings needed for good fluid atomization.  
3. After 10 minutes, read the temperature on the ther-  
mometer (2). If it does not match the desired tem-  
perature, adjust the setpoint.  
2. Set all system back pressure valves (S - FIG. 1) to  
maintain even fluid pressure at all gun stations.  
33  
2
05549-524  
309524N  
15  
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Maintenance  
Maintenance  
WARNING  
Unclogging Fluid Passages  
1. Drain the heater.  
Read warnings, pages 4 and 5. Make sure the main  
power is off and heater is cool before doing mainte-  
nance.  
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  
Flushing  
heater tube to soften the clog.  
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.  
4. Flush out the clog.  
5. Clean all passages thoroughly before reassembling.  
Pour in solvent  
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  
3
2. Remove heater inlet and outlet fittings. Have a con-  
tainer ready to catch the fluid.  
05551-524  
Outlet  
Inlet  
05550-524  
16  
309524N  
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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).  
Blown heat limiter (15).  
Replace block - Page 20.  
Check continuity of primary thermo-  
stat (24) and backup thermostat (10).  
Replace thermostats if necessary  
when replacing thermal limit sensor  
(15) - Pages 18-20.  
Temperature too low.  
Temperature too high.  
Fluid requires more warm-up time.  
Wrong temperature setting.  
Flow rate too high.  
Increase warm-up time.  
Adjust setting - Page 15.  
Reduce flow rate or use 2 heaters.  
Flush regularly - Page 16.  
Adjust setting - Page 15.  
Replace - Page 18.  
Clogged fluid passages.  
Wrong temperature setting.  
Failed primary thermostat (24).  
High fluctuating temperatures, about Primary thermostat (24) contacts  
220-250°F (104-120°C) at 0.1 GPM. sticking.  
Replace thermostats (24, 10) - Page  
18. Note that backup thermostat (10)  
keeps heater functioning for only a  
short time.  
Too much pressure drop or fluid will Flow rate too high.  
Reduce flow rate or use 2 heaters.  
Flush regularly - Page 16.  
not flow.  
Clogged fluid passages.  
Heater fittings leak.  
Loose or damaged fittings.  
Tighten fittings or replace heater  
block - Page 20.  
R
Mp  
SL  
230°F  
OFF  
(110°C)  
e
1
255°F  
(124°C)  
a
1
300°F  
(149°C)  
F
6-55 ohm  
R
e
2
05556-524  
FIG. 14: Electrical Schematic  
309524N  
17  
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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  
is off and heater is cool before repairing.  
To avoid shorting out the heater, do not allow capillary  
tube to contact the block terminal (3A). Follow step  
10, below.  
Hazardous Location Heaters: See FIG. 15 & 17  
Non-hazardous Location Heaters: See FIG. 16 & 18  
10. Liberally apply thermal lubricant (part no. 110009) to  
probe (EE) of new thermostat (24). Loop capillary  
tube (GG) several times and wrap the loops with tie  
strap (42-not shown). Insert probe in the heater  
block (3).  
Primary Thermostat & Probe  
11. Continue reassembling in reverse order of disas-  
sembly. See Reassembly Notes, below.  
2. Remove housing cover (18).  
3. Hazardous Location Heater only: Loosen nut (27).  
Backup Thermostat  
1. Follow Pressure Relief Procedure, page 14.  
Non-hazardous Location Heater only: Loosen  
screws (25).  
2. Remove housing cover (18).  
4. Loosen setscrew (26) in switch shaft (28).  
3. Remove screws (HH) on backup thermostat (10)  
tabs, and remove the wires one from heater block  
(3A) and one from line in (9B).  
5. Remove screw (16) and bracket (19) holding probe  
(EE).  
6. Remove wires from the primary thermostat termi-  
nals (FF).  
4. Remove the two screws (16), then remove the ther-  
mostat (10).  
7. Pull thermostat probe (EE) out of heater block (3).  
Remove thermostat (24) from housing (1).  
5. Liberally apply thermal lubricant (part no. 110009) to  
the bottom of the thermostat (10) and reinstall it in  
reverse order of disassembly.  
8. Hazardous Location Heater only: Remove screws  
(25).  
Reassembly Notes  
Non-hazardous Location Heater only: Remove  
screw standoff (35) with washer (27).  
Refer to FIG. 15 or 16 for wiring connections.  
Non-hazardous Location Heater only: Make  
sure gasket (47) is installed and aligned with  
electrical housing screw holes.  
9. Remove bracket from thermostat (24) and secure to  
new thermostat.  
Secure cover (18) with lockwashers (5) and  
screws (6 or 52); torque screws to 89 in-lb (10  
N•m).  
18  
309524N  
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Repair  
HH  
3B  
REF. 10  
REF. 19  
2
L1  
5
9A  
18  
19  
GG  
24  
27  
3A  
15  
9B  
16  
63  
FF  
3
62  
15  
25  
35  
52  
53  
L2  
GND  
63  
62  
1
26  
HH  
Wiring Diagram  
TI12339  
28  
1
10  
16  
1
3A  
54  
EE  
55  
1
2
3
Apply thermal lubricant  
51  
50  
48  
Torque to 89 in-lb (10 N•m)  
20  
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  
47  
GND  
3A  
L1  
16  
15  
FF  
GG  
19  
63  
24  
3
62  
26  
15  
28  
27  
35  
9B  
9A  
Wiring Diagram  
L2  
1
25  
16  
63  
HH  
62  
1
1
2
3
10  
Apply thermal lubricant  
1
3A  
EE  
Torque to 89 in-lb (10 N•m)  
Torque nuts (62) to 10-12 in-lb (1.1-1.3 N•m)  
TI12337B  
FIG. 16: Thermostat Repair – Non-hazardous Heaters  
309524N  
19  
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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 main power lead from the ter-  
minal of the post bushing (9A).  
2. Remove housing cover (18).  
Non-hazardous Location Heater only: Disconnect  
the main power lead from the primary thermostat  
(24).  
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.  
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.  
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.  
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).  
Control Knob  
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.  
2. Turn knob (33) to setpoint 1.  
3. Loosen setscrew (30) in the control knob (33).  
4. Remove control knob (33).  
Reassembly Notes  
Refer to FIG. 15 or 16 for wiring connections.  
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.  
Non-hazardous Location Heater only: Make  
sure gasket (47) is installed and aligned with  
electrical housing screw holes.  
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).  
Secure cover (18) with lockwashers (5) and  
screws (6 or 52); torque screws to 89 in-lb (10  
N•m).  
20  
309524N  
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Repair  
1
2
3
4
5
Torque to 89 in-lb (10 N•m)  
Electrical Housing  
1
6
5
Junction Box  
18  
Apply sealant  
5
62  
63  
63  
24  
Torque nuts (62) to 10-12 in-lb (1.1-1.3 N•m)  
10  
JJ  
29  
30  
62  
15  
33  
REF. 3A  
REF. 3  
12  
2
1A  
1
6
5
3
9A  
4
1B  
4
4
5
6
1
3A  
3B  
TI2334E  
3
FIG. 17: Control Repair – Hazardous Location Heaters  
1
1
Torque to 89 in-lb (10 N•m)  
52  
2
18  
47  
Electrical Housing  
3
Apply sealant  
24  
4
4
62  
Torque nuts (62) to 10-12 in-lb (1.1-1.3 N•m)  
63  
JJ  
29  
30  
10  
33  
12  
62  
63  
15  
REF. 3A  
REF. 3  
47  
1
2
4
7
1
9
5
3
5
6
1
3B  
3A  
TI2336E  
3
FIG. 18: Control Repair – Non-hazardous Location Heaters  
309524N  
21  
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Parts  
Parts  
Hazardous Location Heaters  
6
1
14, 43  
5
18  
16  
62  
19  
63  
24  
27  
4
25  
15  
35  
63  
16  
10  
REF. 1  
62  
52  
53  
26  
28  
3
54  
55  
30  
29  
33  
12  
1
6
5
14, 36  
47  
4
51  
50  
1
48  
58  
20  
9
2
32  
2
5
56  
2
2
6
1
31  
3
8
7
7
1
6
8
5
1
2
3
4
Torque to 89 in-lb (10 N•m)  
Apply sealant  
31  
Apply thermal lubricant  
Torque nuts (62) to 10-12 in-lb (1.1-1.3 N•m)  
ti2334E  
22  
309524N  
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Parts  
Hazardous Location Heaters  
Ref.  
Ref. No. 3  
Heater Block  
No. Part No. Description  
Qty.  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
105747 ALLEN WRENCH; 2 mm  
101369 ALLEN WRENCH; 0.0927 in.  
108676 PRIMARY THERMOSTAT  
100032 SCREW; #6-32 UNC-2A  
105672 SET SCREW; M4 x 0.7 x 6 mm  
183070 NUT; M15 x 1.5  
183068 SWITCH SHAFT  
183071 BUSHING; M15 x 1.5  
101366 SET SCREW; #10-24 x 0.312 in.  
117344 FITTING; 5/8 in. OD tube x 1/2-14  
npt(m)  
1
1
1
2
1
1
1
1
1
2
Part No. Series Part No.  
Volts / Watts  
245848  
245862  
245863  
245864  
246254  
A
A
A
A
A
246616  
246617  
246618  
246619  
246620  
120 / 2300  
200 / 4000  
240 / 4000  
480 / 4000  
380 / 4000  
Ref.  
No. Part No. Description  
Qty.  
1
2
3
183074 CONTROL HOUSING  
102124 THERMOMETER DIAL  
HEATER BLOCK; see table;  
includes ref. no. 2, 31, 32, 56  
183066 COVER  
107542 LOCKWASHER  
109114 SCREW; M8 x 1.25 mm  
104582 WASHER  
104029 GROUNDING CLAMP  
108675 BUSHING; 1000 V max.; 250 A  
max.  
1
1
1
32  
33  
35  
15A808 T-FITTING  
177968 KNOB  
183067 BRACKET  
1
1
1
1
1
2
1
1
1
1
1
1
1
3615B623 WARNING PLATE, English  
4
5
6
7
8
9
1
20  
20  
2
15B777 WARNING PLATES, multilingual  
235523 WIRE ASSEMBLY  
102478 TIE STRAP  
37  
42  
4315B625 WARNING PLATE. English  
2
2
15B819 WARNING PLATE, multilingual  
185065 ADAPTER, 3/4 npt  
15B827 LIGHT LENS  
103338 O-RING; fluoroelastomer  
117483 SOCKET JAM SCREW;  
5/8-18 x 5/16  
47  
48  
50  
51  
10  
11  
12  
108674 BACKUP THERMOSTAT  
235524 WIRE ASSEMBLY  
177969 KNOB  
1
1
1
13177922 WARNING TAG  
1
52  
53  
54  
55  
56  
58  
62  
63  
117514 SPACER  
2
1
2
1
1
1
4
4
14  
15  
16  
18  
19  
20  
21  
100055 SCREW; #6 type U  
223126 THERMAL LIMIT SENSOR, 152°  
105676 SCREW; M4 x 0.7 x 12 mm  
183073 COVER  
183072 BRACKET  
15B828 LIGHT HOUSING  
108664 ALLEN WRENCH; 6 mm  
10  
1
4
1
2
246014 LIGHT CIRCUIT BOARD  
114669 SCREW; M5 x 10 mm  
15B243 BRACKET  
15D757 HOUSING, thermometer  
100361 PLUG, pipe; 1/2 npt  
100166 NUT, full hex  
1
1
102360 WASHER, flat  
Replacement Danger and Warning labels, tags and  
cards are available at no cost.  
309524N  
23  
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Parts  
Non-Hazardous Location Heaters  
52  
18  
47  
14, 43  
16  
19  
62  
63  
24  
26  
28  
4
15  
16  
27  
35  
25  
63  
30  
29  
62  
33  
12  
3
10  
25  
53  
54  
8
51  
50  
48  
1
14, 36  
20  
47  
1
9
5
4
58  
7
2
32  
56  
2
2
31  
6
1
5
3
1
2
3
4
Torque to 89 in-lb (10 N•m)  
Apply sealant  
31  
Apply thermal lubricant  
Torque nuts (62) to 10-12 in-lb (1.1-1.3 N•m)  
TI2336E  
24  
309524N  
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Parts  
Non-Hazardous Location Heaters  
Ref.  
Ref. No. 3  
Heater Block  
Part No. Series Part No.  
No. Part No. Description  
Qty.  
23  
24  
25  
26  
27  
28  
29  
30  
31  
101369 ALLEN WRENCH; 0.0927 in.  
108676 THERMOSTAT SWITCH  
100032 SCREW; #6-32 UNC-2A  
105672 SET SCREW  
114027 WASHER, #6  
183068 SWITCH SHAFT  
112738 GROMMET  
101366 SET SCREW; #10-24 x 0.312 in.  
117344 FITTING; 5/8 in. OD tube x 1/2-14  
npt(m)  
1
1
4
1
2
1
2
1
2
Volts / Watts  
245867  
245868  
245869  
245870  
246276  
A
A
A
A
A
246616  
246617  
246618  
246619  
246620  
120 / 2300  
200 / 4000  
240 / 4000  
480 / 4000  
380 / 4000  
Ref.  
No. Part No. Description  
Qty.  
32  
33  
35  
15A808 T-FITTING  
177968 KNOB  
117526 SPACER  
1
1
2
1
1
2
1
1
1
1
1
1
1
1
2
3
15A809 ENCLOSURE  
102124 THERMOMETER DIAL  
HEATER BLOCK; see table;  
includes ref. no. 2, 31, 32, 56  
15A811 BOTTOM COVER  
107542 LOCKWASHER  
109114 SCREW  
15A990 GASKET  
104029 GROUND CLAMP  
117367 SCREW; M8 x 18 mm  
108674 THERMOSTAT  
235524 WIRE ASSEMBLY  
177969 KNOB  
1
1
1
3615B623 WARNING PLATE, English  
15B777 WARNING PLATES, multilingual  
246346 WIRE ASSEMBLY  
102478 TIE STRAP  
4
5
6
7
8
9
10  
11  
12  
1
1
6
2
2
6
1
1
1
1
10  
1
4
1
2
1
1
1
37  
42  
4315B625 WARNING PLATE, English  
15B819 WARNING PLATE, multilingual  
15A991 GASKET  
15B827 LIGHT LENS  
103338 O-RING; fluoroelastomer  
117483 SOCKET JAM SCREW;  
5/8-18 x 5/16  
111962 SCREW; 1/4-28 UNRF-3A  
246014 LIGHT CIRCUIT BOARD  
106216 NUT; 3/4-14 npsm  
100633 ALLEN WRENCH; 5/32  
15D757 HOUSING, thermometer  
100361 PLUG, pipe; 1/2 npt  
100166 NUT, full hex  
47  
48  
50  
51  
13177922 WARNING TAG  
52  
53  
54  
55  
56  
58  
62  
63  
10  
1
1
1
1
1
4
4
14  
15  
16  
18  
19  
20  
21  
22  
100055 SCREW; #6 type U  
223126 THERMAL LIMIT SENSOR, 152°  
105676 SCREW; M4 x 0.7 x 12 mm  
15A810 TOP COVER  
183072 BRACKET  
15B828 LIGHT HOUSING  
108664 ALLEN WRENCH; 6 mm  
105747 ALLEN WRENCH; 2 mm  
102360 WASHER, flat  
Replacement Danger and Warning labels, tags and  
cards are available at no cost.  
309524N  
25  
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Accessories  
Accessories  
Heater Conversion Kit  
Cart Bracket  
246302: Includes two fittings to make VISCON HP ports  
Order 2 each of the following:  
183484: Clamp  
2
match VISCON  
183485: Mounting bar  
Mounting Bracket  
192585: European version (see below)  
6
5
183484  
183485  
M8  
B
A
C
5 & 6 included with heater  
05543  
D
E
Power Cord Set*  
F
110160: 600 V, 12 Awg, Extra Hard Usage Type St, High  
Temperature (221°F, 105°C) rated  
Measurements – inches (mm)  
Thermal Lubricant  
A
B
C
D
E
F
110009: 6.5 gram tube  
5
6.76  
0.88  
3.37  
6.25  
1.44  
(127)  
(171.7)  
(22.4)  
(85.5)  
(158.8)  
(36.6)  
Cable Clamp Kit*  
246303: Contains a strain relief cable clamp and 5 m,  
221°F (105°C) cable. See page 27 for installation  
instructions.  
183982: USA version  
G
G
H
*
Hazardous location heaters are no longer rated for  
use in a hazardous area when used with these  
accessories.  
6
5
(152)  
(127)  
H
26  
309524N  
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Accessories  
Cable Clamp Kit 246303 Installation  
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.  
1. Slide cable clamp (3) onto cable (2).  
2. Place washer (F) on fitting (E).  
6. Place one side of retaining clip onto retaining clip  
nut, and insert as shown.  
3. Push conical-shaped packing (D) into fitting (E).  
4. Place washer (C) on retaining nut (B).  
Ref.  
No. Part No. Description  
Qty  
3
2
Cable, 16.4 ft. (5 m), 221° F  
(105° C)  
1
3
113162 Clamp  
1
2
05544  
FIG. 19: Cable Clamp Kit  
Key:  
A
B
C
D
E
F
Retaining clip  
Retaining nut  
Washer  
Packing  
Fitting  
Washer  
F
E
D
C
B
A
05554  
FIG. 20: Kit Assembly  
309524N  
27  
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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 II, maximum ambient temperature 135° F (57° C).  
Maximum Working Pressure . . . . . . . . . . . . . . . . . . . . . . 7250 psi (50 MPa, 500 bar)  
Voltage / Wattage / Current*. . . . . . . . . . . . . . . . . . . . . . . See Models, page 2  
2
2
Fluid Passage Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless Steel  
Temperature Operating Range. . . . . . . . . . . . . . . . . . . . . 84–219°F (-29–104°C)  
Surface Temperature Code** . . . . . . . . . . . . . . . . . . . . . . T2 (482°F, 250°C)  
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 lb. (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  
4000 watt VISCON HP heater, Test Fluid: 10w Hydraulic Oil  
100  
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.  
90  
80  
70  
60  
50  
40  
30  
20  
10  
0
68.39  
39.32  
57.70  
50.68  
54.14  
42.23  
34.96  
33.18  
30.26  
29.14  
26.64  
15.32  
24.28  
20.10  
17.40  
4000W  
2300W  
0
0.5  
1
1.5  
2
2.5  
3
3.5  
Flow Rate  
28  
309524N  
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Dimensions  
Dimensions  
Measurements – inches (mm)  
H
J
G
H
J
K
L
G
9.375  
(238)  
8.46  
(215)  
6.5  
(165)  
18  
(457)  
6.375  
(162)  
3/4 npt(f)  
Electrical  
Conduit Port  
K
L
1/2 npt(f)  
Fluid Outlet  
1/2 npt(m)  
Fluid Inlet  
309524N  
29  
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Graco Standard Warranty  
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in  
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty  
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by  
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written  
recommendations.  
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty  
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of  
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with  
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or  
maintenance of structures, accessories, equipment or materials not supplied by Graco.  
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of  
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned  
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will  
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.  
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED  
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.  
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy  
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or  
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.  
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A  
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT  
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to  
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these  
warranties.  
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or  
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the  
negligence of Graco, or otherwise.  
FOR GRACO CANADA CUSTOMERS  
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,  
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la  
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite  
de ou en rapport, directement ou indirectement, avec les procédures concernées.  
Graco Information  
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.  
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  
Revised 05/2009  
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