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Instructions - Parts

For circulating heated water or oil through XM and XP plural-component sprayer double

wall hoppers, heated hose, and Viscon?? HP heater. Approved for use in explosive atmospheres.

Model 256273 (for XM)

Includes parts needed to assemble heated hose system. Heated hose assembly and Viscon HP heater must be ordered separately.

Model 24M224 (for XP)

Includes parts needed to assemble heated hose system. Heated hose assembly and Viscon HP heater must be ordered separately.

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

See Technical Data on page 26 for Maximum Working Pressure and Temperature Rating information.

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as 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, portable electric lamps, and plastic drop cloths (potential static arc).

??? Keep work area free of debris, including solvent, rags and gasoline.

???Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

???Ground all equipment in the work area. See Grounding instructions.

???Use only grounded hoses.

???Hold gun firmly to side of grounded pail when triggering into pail.

???If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

???Keep a working fire extinguisher in the work area.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

???Do not operate the unit when fatigued or under the influence of drugs or alcohol.

???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. For complete information about your material, request MSDS forms from distributor or retailer.

???Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu- facturer???s replacement parts only.

???Do not alter or modify equipment.

???Use equipment only for its intended purpose. Call your distributor for information.

???Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

???Do not kink or over bend hoses or use hoses to pull equipment.

???Keep children and animals away from work area.

???Comply with all applicable safety regulations.

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

???Turn off and disconnect power cord before servicing equipment.

???Use only grounded electrical outlets.

???Use only 3-wire extension cords.

???Ensure ground prongs are intact on sprayer and extension cords.

???Do not expose to rain. Store indoors.

Warnings

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 gun at anyone or at any part of the body.

???Do not put your hand over the spray tip.

???Do not stop or deflect leaks with your hand, body, glove, or rag.

???Do not spray without tip guard and trigger guard installed.

???Engage trigger lock when not spraying.

???Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

BURN HAZARD

Equipment surfaces and fluid that???s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

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 MSDS???s 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.

???Always wear impervious gloves when spraying or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate 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, burns, and hearing loss. This equipment includes but is not limited to:

???Protective eyewear

???Clothing and respirator as recommended by the fluid and solvent manufacturer

???Gloves

???Hearing protection

Typical Installation

NOTE: XM kit 256273 is shown in all typical installation illustrations. The general layout for XP Kit 24M224 is the same.

C C

E E

A B

r_256273_313259_1b

FIG. 1: Heat Only Hoppers Configuration

Key:

AViscon HP Heater

BHusky diaphragm pump

CHopper

DFrame

EFluid circulation tubing

NOTE:

See F IG . 2 on page 9 for fluid schematic of heated fluid.

Typical Installation

E C

ti19227a

FIG. 3: Hoppers and Heated Hose Configuration

Key:

AViscon HP Heater

BHusky diaphragm pump

CHopper

DFrame

EFluid circulation tubing

FHeated hose tee and elbow fittings (see heated hose connections on page F IG . 5 and F IG . 6 on page 12 and 13.)

NOTE:

See F IG . 6 on page 13 for fluid schematic of heated fluid.

Typical Installation

Heated Water Fluid Flow

G J

r_256273_313259_13a

FIG. 5: Heated Hose Only Configuration

Key:

AViscon HP heater

BHusky diaphragm pump

CHopper (not shown)

DFrame

EFluid circulation tubing

FHeated hose tee and elbow fitting (to red tubing)

GReturn hose tee and elbow fitting (from blue tubing)

HRecirculation valve

JHeated hose assembly (purchase separately)

KOverflow tank (used for only heated hose configuration)

NOTE:

See F IG . 6 on page 13 for fluid schematic of heated fluid.

Installation

The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit.

1.Remove grounding screw on diaphragm pump (3) and tighten ring terminal on grounding cable (15) under ground screw.

r_256273_313259_9

2.Loosen grounding lug locknut (W) on back of control box. Insert ground wire end (Y) into lug slot and tighten locknut securely.

r_256273_313259_10

The length of tubing (4, 16, 29) is determined by the hopper mounting configuration and heating choices. Reference the fluid schematic, from the configurations listed below, to find the tubing lengths.

???Heating hoppers only. See F IG . 2 on page 9.

???Heating hoses only. See F IG . 6 on page 13.

???Heating hoppers and hoses. See F IG . 4 on page 11.

Cut tubing to length specified in fluid schematics.

1.Use tubing cutter to cut tubing (4) squarely to desired lengths.

NOTE: To ensure a leak-proof seal, apply PTFE tape on all npt threads.

2.Insert tubing through the back of the nut in each of the plastic fittings (7) until the tube stops. Tighten the nut hand tight, then tighten it to 1-1/2 to 2 turns with a wrench.

Install

1.XM Kit 256273 only: Mount bracket (1) on XM frame (D) using screws (5).

r_256273_313259_5

2.XP Kit 24M224 only: Mount brackets (101, 102) on XP frame (D) using plates (105), screws (134), nuts (133).

3.XM Kit 256273 only: Remove 3/4 npt plugs from the end of the diaphragm pump fluid manifold and place in center.

4.For only heating hoppers or heating hoppers and heated hose: Install tube fitting (31) in fluid inlet. See FIG. 7.

5.For heating heated hose only (see FIG. 7):

a.Install elbow (32), mounting fitting (23), o-ring (22) and 1.5 gallon reservoir tank (21) on dia- phragm pump fluid inlet.

b.XM Kit 256273 only: Connect elbow fitting (7) to mounting fitting (23).

6.Install bushing (12) and elbow tube fitting (17) to diaphragm pump fluid outlet. See FIG. 7.

Installation

7.Mount diaphragm pump to bracket.

XM Kit 256273 only: Use four screws (2) to mount pump (3) on mounting bracket. See FIG. 7.

XP Kit 24M224 only: Use nuts (135) to mount pump (3) to threads on mounting bracket. See FIG. 7.

8.Connect air regulator assembly.

XM Kit 256273 only: Connect nipple (10), air regu- lator/gauge (9), and fitting (19) to pump (3). See FIG. 7.

XP Kit 24M224 only: Connect elbow (137), nipple (10), air regulator/gauge (9), elbow (136), and fitting (19) to pump (3).

9.Remove plug on system air control supply and con- nect fitting (19) in place of the plug. Connect hose (27) between fitting (19) on 100 psi (0.7 MPa, 7 bar) XM air supply and fitting (19) on the air regula- tor/gauge (9). See FIG. 7. Refer to Husky 716 man- ual 308981 if needed.

NOTE: The air regulator (9) controls pump pressure.

FIG. 7: Diaphragm Pump Installation

Installation

10.Slide Viscon HP heater (A) into slots on frame. Tighten bolts to secure to frame.

All wiring must be done by a qualified electrician. See warnings, page 3.

r_256273_313259_7

ti19156a

11.For heating hoppers or heating hoppers and heated hose: install fitting (18) and elbow (17) in the heater???s fluid inlet facing away from the system. Install elbow (7) in heater outlet facing the back of the system.

r_256273_313259_16a

FIG. 8

12.For heating heated hose only: connect elbow fit- ting (17) to heater fluid inlet facing the back of the system. Install elbow (7) in the heater outlet facing upward.

r_256273_313259_17a

FIG. 9

XM shown

7 11

r_256273_313259_8

15.Remove side plug (P) used for fluid inlet.

16.Replace plug with bushing (11) and elbow fitting (7).

17.Cut tubing (4, 16, 29). See Tubing Lengths on page 14.

NOTE:

Fitting nuts may need retightening as the system reaches normal operating temperatures.

Setup

For heating hoppers only:

See fluid schematic on page 9 and parts on page 21.

NOTE: To ensure a leak-proof seal, use PTFE tape on all pipe thread connections.

Installation

3.Connect fitting (7) in the heater fluid outlet (A) and tee fitting (13) to hose circulation inlet with

tubing (4).

4.Connect tee fitting (13) from hose circulation return to tee fitting (13) with tubing (4).

5.Connect tee fitting (13) and fittings (7) in the hopper side ports with tubing (4).

6.Connect fittings (31) to elbow in bottom outlet of hoppers and tee fitting (30) with tubing (29). Con- nect tee fitting (30) and the pump (3) inlet fitting (31) with tubing (29).

Hopper Inlet or 1-1/2 gallon tank manifold

Heater Outlet

Blue hose connections

ti19230a

Red hose connections

For heating heated hose only:

See fluid schematic on page 13 and parts on page 22.

1.Connect A and B fluid hoses to shutoff check valve fluid outlets (H).

2.Connect elbow fitting (17) in pump outlet (3) and elbow fitting (17) on heater inlet (A) with tubing (16).

3.Connect fitting (7) in the heater fluid outlet (A) and tee fitting (13) with tubing (4).

4.Connect tee fitting (42) and elbow fitting (41) to recirculation inlets and outlet connections of the heated hose. See F IG . 10.

5.Connect elbow fitting (7) to 1-1/2 gallon tank mani- fold (23) with tubing (4).

For heating hoppers and heated hose:

See fluid schematic on page 11 and parts on page 20.

1.Connect A and B fluid hoses to shutoff check valve outlets (H).

2.Connect elbow fitting (17) in pump outlet (3) and elbow fitting (17) on heater inlet (A) with tubing (16).

FIG. 10: Recirculation Inlet and Outlet Connections

Connecting Additional Hose

Lengths

Up to six 50 ft (15.2 m) sections of heated hose can be attached for a maximum total length of 300 ft (91.4 m).

1.Remove plastic u-turn fittings at the end of the heated hose assembly.

2.Connect the next length of hose, using union fittings supplied with the hose.

3.Tubes are color coded. Connect like colors.

NOTICE

To prevent cross-contamination, ensure you connect ???A??? side fluid hose to ???A??? side fluid hose on additional heated hose.

Operation

1.Select fluid to use for heating circulation.

???50% water and 50% ethylene glycol mixture is recommended for fastest heat-up time and pre- vention of algae build-up regardless of ambient temperature.

???Oil can be used but heat-up time will increase and the hopper fill level must be decreased. See item 2.

NOTE:

Detailed diaphragm pump operating instructions are in the Husky 716 diaphragm pump manual 308981.

2.Fill Heating Fluid in double wall hopper (C) outer cavity. See manual 312747 for instructions.

NOTICE

Do not plug top ports. Always have venting fittings installed to prevent outer cavity pressurization. Failure to do so may cause leakage into spray material.

NOTICE

If oil is the heating fluid selected, the maximum oil level must be 3 in. (76.2 mm) below the hopper side port level. A higher fluid level may cause the oil to overflow during initial pump and heater startup.

NOTE:

If using heated hose: each 50 ft. (15.2 m) heated hose section holds approximately 1.25 gal. (4.7 liters) of fluid.

3.Set the flow rate of the circulation fluid by adjusting the pump???s air regulator (9) until the pump cycles about 50 cycles/min. Do not use a higher flow rate as doing so will decrease system heating perfor- mance and pump life. Never exceed the hose???s

95 psi (0.6 MPa, 6.6 bar) maximum working pres- sure rating.

4.Adjust the heater thermostat to the desired circula- tion temperature. The setting at the heater output thermometer should be about 10?? F (6?? C) higher than the desired paint temperature. Never exceed the hose???s 140?? F (60?? C) maximum temperature rating.See Viscon HP heater manual 309524 for instructions.

NOTE:

If the hose is not being used for more than one hour, shut off Viscon HP heater and pump to lengthen heater life.

Technical Data

Maximum Working Pressure

High Pressure Fluid Hose . . . . . . . . . . . . . . . . . . . . . See Heated Hose Assembly table, page 5 Heated Fluid Circulation Components . . . . . . . . . . . . 95 psi (0.6 MPa, 6.6 bar)

Maximum Temperature Rating . . . . . . . . . . . . . . . . . . . . . 140?? F (60?? C) Wetted Parts

High Pressure Fluid Hose . . . . . . . . . . . . . . . . . . . . . Nylon, Zinc-Plated Carbon Steel Heated Fluid Circulation Tubing. . . . . . . . . . . . . . . . . Polyether-based Polyurethane, nylon

Heated Fluid Circulation Fittings . . . . . . . . . . . . . . . . Polypropylene, Aluminum, Brass, Zinc-Plated Carbon Steel

Reservoir Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Density Polyethylene Heated Hose Weight (50 ft. section) . . . . . . . . . . . . . . . . Dry: 31 lb (14.1 kg)

Wet: 41 lb (18.6 kg)

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 r??daction du pr??sente document sera en Anglais, ainsi que tous documents, avis et proc??dures judiciaires ex??cut??s, donn??s ou intent??s, ?? la suite de ou en rapport, directement ou indirectement, avec les proc??dures concern??es.

Graco Information

For the latest information about Graco products, visit www.graco.com.

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.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 313259

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES ??? P.O. BOX 1441 ??? MINNEAPOLIS MN 55440-1441 ??? USA

www.graco.com

Revised December 2012