Graco 24J163 User manual

3A1651B
ENG
Installation
Heater Kits
For adding primary heaters to an HFR metering system with heated hoses. For
professional use only.
Not approved for use in European explosive atmosphere locations.
Model 24J163
See HFR Setup-Operation manual for system information,
including maximum working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this
manual and HFR Setup-Operation
manual. Save all instructions.
HFR shown with primary heaters installed

Related Manuals
23A1651B
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 12
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 12
Related Manuals
Component manuals in English. Manuals are available
at www.graco.com.
Manual No. Description
313997 HFR Setup - Operation
313998 HFR Repair - Parts
3A1652 Power Distribution Box Kits Installa
tion

Installation
3A1651B 3
Installation
These installation instructions are for adding primary
heaters to an existing HFR metering system with heated
hoses. If your system is not an HFR metering system
with heated hoses, contact Graco for the correct kit to
purchase.
Prepare Machine
1. Perform Shutdown and Pressure Relief Proce
dure described in the HFR Setup - Operation man
ual. See Related Manuals on page 2.
2. Remove incoming power to machine.
3. Verify the main power switch (A) is set to the OFF
position. See FIG. 1.
4. Open the power distribution box door (B).
5. Remove slotted enclosure cover (C).
All electrical wiring must be performed by a qualified
electrician. To prevent risk of electric shock, all
electrical wiring must be correctly installed.
To prevent risk of electric shock, verify there are no
“hot” wires connected to the machine at this point.
FIG. 1
A
C
B

Installation
43A1651B
Remove Power Modules
6. On the high volume heat panel, remove the green
plug (D) from the high power temperature control
module, HPTCM (E). See FIG. 2.
7. Remove the CAN cable (F) from the HPTCM (E).
8. Separate all two-part green plug connectors (G).
9. Disconnect the ground wire (H) for the HPTCM from
the ground screw (J).
10. Remove terminal strip screws (K) then remove the
power module assembly and set aside. See FIG. 3
on page 5 for an example of a power module
assembly.
11. Repeat for the previous steps for the low volume
heat panel.
FIG. 2: Existing Heat Panel (High Volume Side shown)
H
J
K
G
F
D
E

Installation
3A1651B 5
Install New Power Modules and HPTCMs
12. Use existing washers and screws to install new
power module 24C361 onto the high volume heat
panel.
13. Use existing washers and screws to install new
power module 24C365 onto the low volume heat
panel.
14. Use supplied washers, screws, and HPTCM mount
ing bracket to install new HPTCM onto high volume
heat panel. Repeat for low volume heat panel.
15. Set selector switch (L) on the high volume HPTCM
to position 1. Set the selector switch on the low vol
ume HPTCM to position 3.
FIG. 3: Power Module 24C361
FIG. 4: Power Module 24C365
NOTICE
To prevent faulty heating system operation, verify each
HPTCM selector switch is set to the correct position.
FIG. 5: HPTCM Selector Switch
L

Installation
63A1651B
16. Apply blue labels to high volume heat panel as
shown in FIG. 6. Verify the text on each label
matches the text shown in FIG. 6. Repeat with the
red labels for the low volume side.
NOTE: There will be unused labels on the supplied label
sheet when finished applying labels.
FIG. 6: Heat Panel Labels (High Volume side shown)
Shown without wires for clarity

Installation
3A1651B 7
Connect Power Module Wires
17. Route wire harness (M) from each heat panel inside
the machine base through the 1.5 in. access holes
to the power distribution box.
18. Connect the high volume heat panel wire harness
with blue PG116 label to circuit breaker labeled blue
CB2.
19. Connect the low volume heat panel wire harness
with red PG166 label to circuit breaker labeled red
CB9.
20. Use the short CAN cable supplied to connect the
two HPTCMs on each heat panel as shown in FIG.
7.
21. On each heat panel, connect and plug in all remain
ing wires and connectors as shown in FIG. 7.
FIG. 7
M

Installation
83A1651B
Install Primary Heaters and Wires
22. Remove plugs from access holes (N) on each side
of the machine base and install snap-in wire protec
tion bushings. See FIG. 8.
23. Use four screws (P) to mount each primary
heater (R) to the side of the machine base. Do not
install the blue primary heater plastic guards.
24. Route wire ferruled end of harnesses (S) from each
heat panel inside of machine base through the
snap-in bushings.
25. Apply oxide inhibitor to wire ferrules on each
harness (S) and connect to the corresponding pri
mary heater splice connectors (T).
26. Route high volume wire harness (S) with blue
PG508 label from high volume primary heater
through the snap-in bushing to the high volume heat
panel. Connect harness (S) to port 3 of the high vol
ume HPTCM as shown in FIG. 9.
27. Route low volume wire harness with red PG647
label from low volume primary heater through the
snap-in wire protection bushing to the low volume
heat panel. Connect harness to port 3 of the low vol
ume HPTCM.
28. Route the ground wire (X) of each harness (S)
through the snap-in bushing of the machine base
and through the snap-in bushing on the heater
mounting plate (Y). Connect to heater grounding
point (Z) using screw and lockwasher. See FIG. 8.
29. Route RTD connector (AA) from each primary
heater through snap-in bushing to corresponding
HPTCM. For the high volume heat panel, the con
nector with blue RTD480 label connects to port 2
and connector with blue OTS490 label connects to
port 1 of the high volume HPTCM. For the low vol
ume heat panel, the connector with red RTD618
label connects to port 2 and connector with red
OTS628 label connects to port 1 of the low volume
HPTCM.
FIG. 8: Base with Heaters
N
P
R
S
T
Y
Z
FIG. 9: High Volume Primary Heater Connections
S
X
AA AB

Installation
3A1651B 9
Install Primary Heater Fluid Tube
30. Remove the blue plastic guard on the front of the
machine that covers the fluid manifold.
31. Remove short U-shaped material tubes (AC) that
connect the pump outlets to the manifold inlets. See
FIG. 10.
32. Connect high volume primary heater fluid inlet
tube (AD) as shown in FIG. 11. Apply lubricant to
threads of tube fittings and torque to 21 ft-lb
(28 N•m).
33. Connect high volume primary heater fluid outlet
tube (AE) as shown in FIG. 11. Apply lubricant to
threads of tube fitting and torque to 21 ft-lb
(28 N•m).
34. Connect low volume primary heater fluid inlet
tube (AF) as shown in FIG. 11. Apply lubricant to
threads of tube fitting and torque to 21 ft-lb
(28 N•m).
35. Connect low volume primary heater fluid outlet
tube (AG) as shown in FIG. 11. Apply lubricant to
threads of tube fitting and torque to 21 ft-lb
(28 N•m).
36. Reinstall the blue plastic guard on the front of the
machine.
FIG. 10: Remove existing material tubes
FIG. 11: Install fluid lines
AC
AC
AE
AF
AD
AE
AF
AG
AG

Installation
10 3A1651B
Final Preparation
37. Verify all electrical connections including earth
grounds are complete and tight.
38. Install the blue primary heater plastic guards.
39. Close the power distribution box door.
40. Turn main power switch to the ON position.
41. Follow procedures in the system operation manual
to setup and run the heat zones. See Related Man
uals on page 2.
To prevent risk of electric shock, ground wires must
be correctly connected.