VR COATINGS J-138 User manual

1
INSTRUCTIONS MANUAL
Keep for future use!
Serial Number:
Serial Number:Serial Number:
Serial Number:
HIGH PRESSURE HEATER
HIGH PRESSURE HEATER HIGH PRESSURE HEATER
HIGH PRESSURE HEATER 3KW
3KW3KW
3KW
VR COATINGS PVT.LTD.
J-138, MIDC PUNE – 411 026, INDIA.
TEL: [phone] FAX: [phone],
7475273 E-MAIL: vfdsouza vsnl.com

DD-01 /UI-21/0/030206
`
WARNING AND SAFETY INSTRUCTIONS
WARNING AND SAFETY INSTRUCTIONSWARNING AND SAFETY INSTRUCTIONS
WARNING AND SAFETY INSTRUCTIONS
EQUIPMENT IS FOR PROFESSIONAL USE ONLY
Do not use spray materials ontaining rea tive solvents with
equipment ontaining aluminum, galvanized or z
in oated
wetted parts. e.g. Di hloromethane and ethylene hloride an
hemi ally rea t with aluminum and galvanized or zin oated
parts and ause explosion hazard.
HIGH PRESSURE DEVICE FOR PROFESSIONAL USE
ONLY
Read and understand instru tion manual before use and
maintenan e. Observe on warnings.
Do not process flammable, explosive, toxic or otherwise
hazar ous materials without first performing an
appropriate hazar analysis.
VR Coatings annot be an expert in the hemi al and
biologi al properties of the infinite number of materials that
ould be pro essed in this ma hine. As sold by VR Coatings
,
this ma hine is not designed to safely pro ess hazardous
materials unless additional pre autions are not taken.
Before pro essing any material that are (or an rea t to
be ome) flammable, explosive, toxi or otherwise hazardous,
the user must perform a t
horough hazard analysis and risk
assessment of the entire pro ess and determine the best way to
deal with the hazard(s) identified, in luding ontingen y plans
for dealing with pro essing errors and obje t onditions.
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WARNING AND SAFETY INSTRUCT
IONS

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It is compulsory to
-know the pro uct an possible hazar s.
-store the pro uct to be use in the appropriate areas.
-keep the pro uct use uring ispensing in a suitable
container.
-Dispose the pro uct accor ing to the regulation of
hazar ous pro ucts in force in the country where the
pro uct is use .
-Were protective equipment esigne for that use.
-were glasses, gloves, shoes clothes an mask for breath.
An airless spray gun requires that flui be intro uce to
it at ver
y high pressure. Flui s un er high pressure, from
spray or leaks, can penetrate the skin an inject
substantial quantities of toxic flui into the bo y. If not
promptly an properly treate , the injury can cause
tissue eath or gangrene an may result in s
erious,
permanent isability or amputation of the woun e part.
Therefore extreme caution must be exercise when using
any airless spray equipment.
SKIN INJECTION HAZARD. Prote t han
ds and body from
high pressure fluids. Relieve pressure before dis onne ting
hydrauli or other lines and tighten all onne tions before
applying pressure. In ase of a idental skin inje tion, seek
immediate” Surgi al Treatment”. Failure to follow this
warning an result in amputation or serious injury.
IF YOU ARE INJECTED, SEE A PHYSICIAN
IMMIDIATELY. DO NOT TREAT AS A SIMPLE CUT!
NOTE TO PHYSICIAN:
Inje tion into the skin is a serious, traumati injury. It is
important to treat the injury surgi ally as soon as possible. Do
not delay treatment to resear h toxi ity. Toxi ity is on erned
with some exoti oatings inje ted dire tly in to the
bloodstream. Consultation with a plasti surgeon or a
re onstru tive hand surgeon may be advised
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WARNING AND SAFETY I
STRUCTIONS

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 All ele tri al wiring, must be done by a qualified ele tri ian
and omply with all lo al odes and regulations.
 Conne t only a grounded power sour e.
 Turn off and dis onne t power at the main swit h before
dis onne ting any ables and before servi ing equipment.
To avoid serious burns:
 Do not tou h hot fluid or equipment.
 Allow equipment to ool ompletely before tou hing it.
 Wear heat prote tive gloves and take spe ial are if fluid temperature
ex eeds 43°C.
COMPONENT RUPTURE
The system is apable of
produ ing high pressure all omponents in the system must
have a maximum working pressure apa ity, not less than the
pressure rating of the pump.
SERVICING Before servi ing, leaning or removing any part,
always shut off power sour e, arefully release pressure in fluid
portions of the system and set safety lo ks on guns and
equipment
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WARNING AND SAFETY INSTRUCTIONS
ELECTRIC SHOCK HAZARD
Improper grounding,wiring or usage of the system an
ause ele tri sho k.
BURN HAZARD
This equipment is used with heated fluid, whi h an ause
equipment surfa es to be ome very hot.

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PRESSURE RELEASE PROCEDURE
A Set trigger safely in a locke position.
B Shut off pump( Close main air supply valve an back-
off
air regulator ).
C Release flui pressure from entire system (
Open rain
valve) an trigger gun.
D Reset trigger safely in a locke position.
Due to stati ele tri ity potential generated by the high
velo ity of fluid through the pump, hose and tip, sparking
may o ur and the sy
stem may be ome hazardous. This an
result in an explosion and/or fire, if every part of the spray
equipment is not properly grounded. Be sure that both the
obje t being sprayed and the airless equipment are grounded.
This an be done by atta hing a stati
wire to water piping
or building stru tural members known to be earthen. If the
hose does not ontain a stati ele tri ity ondu tor, a stati
wire must be atta hed from the spray gun to the earth.
Before any adjustment, inspe tion, maintenan e, leaning,
removing wor
k always shut off the power sour e, arefully
release pressure in fluid of the system and set safety lo ks on
guns.
Hi
gh velo ity flow of material through equipment may reate
stati ele tri ity. All equipment being used must be properly
grounded to prevent sparking, whi h may ause fire or
explosion.
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WARNING AND SAFETY INSTRUCTIONS

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ALWAYS follow the oating or solvent manufa turer’s safety
pre autions and warnings. Never spray flammable material
near open flames, pilot lights or any other sour e of ignition.
If you experien e any stati sparking or slight sho k while
using the equipment, stop spraying immediately. Che k the
entire system for proper grounding. Do not use the system
again until the problem has been orre ted.
Follow material supplier’s
instru tions arefully and ensure
adequate ventilation of working area to prevent health hazards.
FLUSHING/CLEANING
Always flush t
he unit into a separate metal ontainer with the
spray tip removed and the gun held firmly against the side of
ontainer to ensure proper grounding and prevent stati
dis harge, whi h ould ause serious bodily injury.
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WARNING AND SAFETY INSTRUCTIONS

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IN LINE HEATER 3KW
VOLTAGE (50 Hz.-SINGLE PHASE) 230 VAC
CURRENT 14 A
MAX TEMPERATURE 100 °C
MAXIMUM WORKING PRESSURE 400 BAR
WEIGHT 28 Kg.
WETTED PARTS ALUMINUM, 304
STAINLESS STEEL, PTFE,
SILICON.
Page 15
TE
CHNICAL SPECIFICATION
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONSTECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
120
O 11
600
275
198
138
73 O
166
WALL MOUNTING
BRACKET (OPTIONAL)
20
SWIVEL JOINT
ACED TO ANY
DIRECTION
156

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Trouble shooting
Problem Cause Solution
Heater will not heat. No urrent. Che k ir uit and fuses.
Che k ontinuity of primary
thermostat, ba kup thermostat.
Che k ontinuity of thermostat
Wrong temperature setting. Adjust setting.
Fluid passage logged. Flush regularly.
Too low temperature.
Too high flow rate. Redu e flow rate or use two heaters.
Wrong temperature setting. Adjust setting. Temperature too high.
Primary thermostat failed Repla e.
Too mu h pressure drop or
fluid will not flow.
Clogged fluid passages. Flush regularly.
Heater fittings leak. Loose or damaged fittings. Tighten fittings.
TROU LE SHOOTING
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I
IN ND DE EX X
DECLARATION OF CONFIRMITY 1
SAFETY LABELS 2
WARNING AND SAFETY INSTRUCTIONS 3
OPERATING INSTRUCTIONS 8
MAINTAINANCE 13
TROUBLESHOOTING 14
TECHNICAL SPECIFICATIONS 15
DRAWINGS AND PARTLISTS
NOTES 16
WARRANTY 17
INDEX

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W
WA AR RR RA AN NT TY Y
VR Coatings warrants all equipments manufa tured by us, as long
as it is bearing original identifi ation plate, to be free from defe ts
in material and workmanship for a period of one year from ex-
works date. VR Coatings will repair or repla e any part of the
equipment proven defe tive. The warranty applies only when the
equipment is installed, operated and maintained in a ordan e with
VR Coatings written re ommendations.
Warranty laims found to be defe tive shall be verified and
onfirmed by VR Coatings.
Our warranty does not over and VR Coatings shall not be
liable for any malfun tion, damages, or fair wear and tear aused
by faulty installation, misuse, abrasion, orrosion, inadequate or
improper maintenan e, negligen e, tempering, a ident or
in orporation of non VR Coatings parts, non observan e of VR
Coatings re ommendations.
This warranty only onsists of repla ing the parts returned to
our plant prepaid transportation and proven defe tive by us. If
inspe tion of the equipment /part does not dis loses any defe t in
material or workmanship, repairs will be made at a reasonable
harge, whi h harges may in ludes the ost of parts, labor and
transportation. VR Coatings shall not be liable for any losses
resulting from a produ tion breakdown.
Material bought in equipment, whi h is sold but not
manufa tured by VR Coatings, will be subje t to the
manufa turer’s warranty. VR Coatings will provide pur haser with
reasonable assistan e in making any laim for brea h of these
warranties.
WARRANTY
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N
NO OT TE ES S
NOTES
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Safety labels
Safety labels Safety labels
Safety labels
SAFETY LA ELS AND NAMEPLATE
Page 2
FLP/WP HEATER ENCLOSURE
FLAMEPROOF AS PER IS2148-1981
WEATHER PROOF AS PER IS 13947(PART-1)-1993 FOR IP55
W.04
BURN HAZAR
W.06
WARNING
FLP/WP HEATER ENCLOSURE
FLAMEPROOF IS:2148-1981
WEATHER PROOF IS:13947(PART-I)-1993 ROTECTION IP55
O NOT OPEN WHEN ENERGISE
VR COATINGS PVT.
LTD.
W.04
WARNING
O NOT OPEN WHEN
ENERGISE
VR COATINGS PVT.
LTD.
W.07
WARNING
Read and understand instruction manual
use and maintenance observe on warning.
SKIN INJECTION HAZAR :
Protect
hands and body from high pressure
fluids.Relieve pressure before
disconnecting hydraulic or other lines and
tighten all connections before applying
pressure.In case of accidental skin
injection,see immediate “Surgical
reatment”.
SERVICING :
Before servicing, cleaning
or removing any part ,always shut off
power source.
HOT SURFACE O NOT TOUCH
ALLOW TO COOL BEFORE
SERVICING
BURN HAZAR
W.06
VR COATINGS PVT. LTD.
HIGH PRESSURE EVICE FOR PROFESSIONAL USE ONLY
Label No.W.06
Label No.W.07
Label No.W.04
N
ame Plate NP01
Safety labels free of charge on request

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INSTALLATION
• Sele t system omponents as per the temperature and pressure
ratings spe ified for the heater equipment.
• Pla e the heater assembly away from all flammable materials
and also to avoid dire t onta t with hot metal surfa e.
• Insulate and/or label lines and omponents exposed out from the
heater assembly that may be ome hot.
To avoid loss of heat between the heater assembly and spray gun,
it is important to mount the heater lose to the spray area. This
will help in maintaining of the desired temperature without undue
heat loss.
OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONSOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
OPERATING
INSTRUCTIONS
THERMOSTAT
TEMPERATURE
GAUGE
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MOUNTING
• The heater has a surfa e temperature of 250ºC Follow
temperature ode when lo ating the heater.
• Heater ontrols must be within easy rea h of the user.
The mounting surfa e must be able to support the weight of the
heater and fluid, and any stress aused during operation.
Wall Mounting:
See adjoining figure
• For mounting on the wall, a wall bra ket (2)is required.
(Part no.41 005 32 07)
• Use the wall bra ket as a template to mark bolt holes.
Bra ket (part no. 41 005 32 07) (See mounting details.)
Flui Connections & Accessories:
1. Install a fluid shut-off valve fluid inlet. Do not over-tighten.
Conne t the fluid line to the valve.
2. Provide a means for adequately handling fluid expansion
aused by heat. Options in lude :
 Use flexible hoses between heater and gun.
 Install a properly sized a umulator downstream from the
heater.
 Install a pressure relief valve, whi h is preset to relieve
pressure when it ex eeds the system maximum working
pressure.
 Continuously ir ulated drain.
OPERATING INSTRUCTIONS
Never install a shut off devi e 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 shut off devi e.
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3. Install a fluid filter, Drain valve and fluid pressure regulator
near the heater’s fluid outlet. Then onne t the fluid line.
Electrical Connections:
Hazar ous Location Installation Requirements:
1. The heater onne tion must be made using one of the
following options:
a. Cable entries of a ertified flameproof model.
b. Threaded metal onduits.
Groun ing:
Wire the heater to a properly grounded power supply through
the ele tri al onne tions and external grounding lug. In a
mobile installation, also ground the tru k or trailer to a true
earth ground.
Determining Proper Flui Temperature:
Use the lowest temperature setting possible for maximum heater
life
Requirements for all installations
:
1. The voltage supply should agree with the maximum heater
voltage and urrent rating as spe ified on the heater nameplate.
2. Condu tors used for supply onne ti
on must be suitable for
at least 105º C.
The above a essories are not provided by VRCPL.
Make sure that the a essories are appropriately rated for
the onditions of use.
OPERATING INSTRUCTIONS
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4. Flushing while installation
The unit has been fa tory tested using oil emulsion. To avoid
ontamination of the oating material to be sprayed, be sure the
emulsion is flushed from the system before spray operation
begins by using a ompatible solvent. Do as follows:
• Do not turn on heater yet.
• If using an airless spray gun, do not install a spray tip yet.
• Start the pump a ording to the instru tions supplied with it.
• Turn the system dire tor valve to ir ulate, and ir ulate
fluid for several minutes.
In this method of hot, airless spraying the fluid is heated to a
temperature just under the boiling point of its most volatile
solvent.
A. Set trigger safely in a locke position.
B. Shut off main power to the heater.
C. Circulate flui for at least 10 minutes to cool the
heate flui an heater.
D. Shut off all air an flui supplies.
E. Disengage the safety lock.
F. Hol a metal part of the gun firmly to a groun e
metal pail, an trigger the gun to relieve pressure.
G. Engage the safety lock.
H. Have a container rea y to catch the flui , then open
the flui rain valve.
PRESSURE RELEASE PROCEDURE
Follow Pressure Relief Proce ure when you stop spraying, and
before leaning, he king or servi ing equipment.
OPERATING INSTRUCTIONS
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• Open the spray gun at the last outlet to prime the line. Repeat
for all gun stations.
• Engage the gun safety lat h.
• Shut off the air supply to the pump.
• Follow the pressure relief pro edure.
• Install the gun spray tip.
Setting heater control
1. Set the heater ontrol knob to a trial set point.
2. Start the pump and ir ulate fluid through the system at very low
pressure.
3. After a few minutes, read the temperature on the thermometer if it
does not mat h the desired temperature, adjust the set point.
1. Adjust pump pressure and heater set point to the lowest settings
needed for good fluid atomization.
2. Set all system ba kpressure valves to maintain even fluid pressure
at all gun stations.
Operating the heater at its highest setting, over 100
°
C. for
long periods of time de reases the heater life and an ause
fluid to dry out; whi h an log the heater and result in poor
finish.
OPERATING INSTRUCTIONS
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Flushing
Clogged fluid passages are diffi ult to lean and redu e heating
effi ien y, flow rate, and pressure. Flush frequently, in luding
whenever system is not in use.
1. Follow Pressure Relief Pro edure.
2. Ensure main power is off and heater is ool before
flushing. Use a ompatible solvent, and follow flushing
instru tions in your fluid supply and spray gun manual. Do not
turn on the heater until flui lines are clear of solvent.
Draining Heater
1. Follow Pressure Relief Proce ure
2. Remove heater inlet and outlet fittings. Have a ontainer
ready to at h the fluid.
Unclogging Flui Passages
1. Drain the heater.
2. Pour a high strength, compatible solvent into the heater tube
to soften the log.
3. Flush out the log.
4. Clean all passages thoroughly before reassembling.
MAINTENANCE
MAINTENANCEMAINTENANCE
MAINTENANCE
Make sure the main power is off and heater is ool before
doing maintenan e.
MAINTAINANCE
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