Graco 309160L User Manual

Instructions

Hotmelt/Warm Melt
Heated Hose

For use with Graco temperature control systems for nonflammable hotmelt
and warm melt sealants and adhesives.

WARNING

Fire, Explosion, and Electric Shock Hazard

The operating and safety features of these hoses
are designed for use only with Graco temperature
control sysems. To reduce the risk of serious injury,
never connect these hoses to any other device.

309160L

EN

Important Safety Instructions

Read all warnings and instructions in this manual.
Save these instructions.

PH00046

Table of Contents

65_F

212_F (–54_C

100_C)

3000 psi (21 MPa, 207 bar) @

3000 psi (21 MPa, 207 bar) @

List of Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operation and Maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Warranty 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Information 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Models

Part
No. Length Hose Core Size Swivel Fitting

16J875 10 ft No. 6 (0.308” ID) .31 ID (9/16–18 JIC(f))

120556 4 ft No. 8 (0.401” ID) .41 ID (3/4–16 JIC(f))

115902 6 ft No. 8 (0.401” ID) .41 ID (3/4–16 JIC(f))

115873 10 ft No. 8 (0.401” ID) .41 ID (3/4–16 JIC(f))

253281 10 ft No. 8 (0.401” ID) .41 ID (3/4–16 JIC(f))

115874 15 ft No. 8 (0.401” ID) .41 ID (3/4–16 JIC(f))

253282 15 ft No. 8 (0.401” ID) .41 ID (3/4–16 JIC(f))

115875 6 ft No. 10 (0.495” ID) .51 ID (7/8–14 JIC(f))

115876 10 ft No. 10 (0.495” ID) .51 ID (7/8–14 JIC(f))

115877 15 ft No. 10 (0.495” ID) .51 ID (7/8–14 JIC(f))

115878 20 ft No. 10 (0.495” ID) .51 ID (7/8–14 JIC(f))

115879 25 ft No. 10 (0.495” ID) .51 ID (7/8–14 JIC(f))

121200 30 ft No. 10 (0.495” ID) .51 ID (7/8–14 JIC(f))

15C586 3 ft No. 12 (0.617” ID) .62 ID (1 1/16–12 JIC(f))

115903 6 ft No. 12 (0.617” ID) .62 ID (1 1/16–12 JIC(f))

115880 10 ft No. 12 (0.617” ID) .62 ID (1 1/16–12 JIC(f))

115881 15 ft No. 12 (0.617” ID) .62 ID (1 1/16–12 JIC(f))

115882 20 ft No. 12 (0.617” ID) .62 ID (1 1/16–12 JIC(f))

115883 25 ft No. 12 (0.617” ID) .62 ID (1 1/16–12 JIC(f))

115884 6 ft No. 16 (0.867” ID) .87 ID (1 5/16–12 JIC(f))

115885 10 ft No. 16 (0.867” ID) .87 ID (1 5/16–12 JIC(f))

115886 15 ft No. 16 (0.867” ID) .87 ID (1 5/16–12 JIC(f))

115887 20 ft No. 16 (0.867” ID) .87 ID (1 5/16–12 JIC(f))

115888 25 ft No. 16 (0.867” ID) .87 ID (1 5/16–12 JIC(f))

117821 10 ft No. 20 (1.125” ID) 1.13 ID (1 5/8–12 JIC(f))

117822 15 ft No. 20 (1.125” ID) 1.13 ID (1 5/8–12 JIC(f))

Maximum Fluid Working Pressure
@ Temperature

4000 psi (28 MPa, 276 bar) @
–

_

–

_

–

_

–

–

–

3000 psi (21 MPa, 207 bar) @
213_F – 400_F (101_C – 204_C)

3000 psi (21 MPa, 207 bar) @
–65_F – 400_F (–54_C – 204_C)

–

_

2 309160

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.

WARNING

ELECTRIC SHOCK HAZARD

The hoses must be grounded. Improper grounding, set–up or usage of the hoses can cause electric
shock.

S Turn off and disconnect power before installing or servicing hoses.

S Connect to grounded power source.

S All electrical wiring must be done by a qualified electrician and comply with all local codes and

regulations.

S Never cut or puncture a hose cover.

S Do not expose to rain. Store indoors.

SKIN INJECTION HAZARD

High–pressure fluid from 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.

S Inspect hose before each use for cuts, bulges, kinks or any other damage.

S Replace damaged hose immediately.

S Replace hoses proactively at regular intervals based on your operating conditions.

S Tighten all fluid connections before operating the equipment.

S Keep clear of leaks.

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

S Never exceed hose Maximum Pressure or Temperature ratings.

S Only use chemicals that are compatible with wetted parts. See Technical Data in this manual.

Read MSDSs and fluid and solvent manufacturer

S Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning,

checking, or servicing equipment.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.

THERMAL EXPANSION HAZARD

Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to
the thermal expansion. Over–pressurization can result in equipment rupture and serious injury.

S Open a valve to relieve the fluid expansion during heating.

S Replace hoses proactively at regular intervals based on your operating conditions.

BURN HAZARD

Equipment surfaces and fluid that o avoid severe
burns:

S Do not touch hot fluid or equipment.

3309160

WARNING

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.

S Read MSDSs to know the specific hazards of the fluids you are using.

S Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

S Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:

S Use equipment only in well ventilated area.

S Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic

drop cloths (potential static arc).

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

S Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes

are present.

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

S Use only grounded hoses.

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

S If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.

S Keep a working fire extinguisher in the work area.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

S Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

S Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer
about your material, request MSDS from distributor or retailer.

S Do not leave the work area while equipment is energized or under pressure. Turn off all equipment

and follow the Pressure Relief Procedure when equipment is not in use.

S Check equipment daily. Repair or replace worn or damaged parts immediately with genuine

manufacturer .

S Do not alter or modify equipment.

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

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

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

S Keep children and animals away from work area.

S Comply with all applicable safety regulations.

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, hearing loss, inhala­tion of toxic fumes, and burns. This equipment includes but is not limited to:

S Protective eyewear, and hearing protection

S Respirators, protective clothing, and gloves as recommended by the fluid and solvent

manufacturer.

4 309160

Introduction

Each hose assembly must be controlled by a Graco
zone controller. The amount of hose used depends on
the zone controllers available for control.

The hose has two electrical connectors with cables,
each extending from the end of the hose.

The large rectangular connector is the machine end
and has 8 foot (2.42 m) of cable (see Fig. 1). The
small square connector is the gun end and has 2 foot
(0.6 m) of cable (see Fig. 2).

Fig. 1

Fig. 2

Connect the machine end connector to the Graco
temperature controller by pushing the connector on the
mating receptacle of the temperature controller or
accessory device and securing the latch.

Connect the gun end connector to any temperature
controller accessory device. These include Graco
manual and automatic hot melt dispense valves,
pressure compensators, manifolds, headers, and
pressure regulators.

PH00051

5309160

Installation

WARNING

THERMAL EXPANSION HAZARD

Fluids subjected to heat in confined
spaces, including hoses, and create a
rapid rise in pressure due to the thermal
expansion. Over–pressurization can

result in equipment rupture and serious injury.

S Open a valve to relieve the fluid expansion

during heating.

S Replace hoses proactively at regular intervals

based on your operating conditions.

WARNING

SKIN INJECTION HAZARD

To reduce the risk of serious injury,
follow the Pressure Relief Procedure
on page 7 whenever you are instructed

to relieve pressure.

4. Do not flex hose when cold.

5. Use hose support spring.

6. Do not clamp, squeeze, or zip tie hose.

NOTE: Pressure check the hose assemblies. Refer to
your system operation manual for priming and pressur­izing the fluid hoses. Check carefully for leaks at the
hose connections. If there are leaks, relieve the pres­sure as instructed on page 7.

1. Do not use hose to pull the equipment.

2. Use 2 wrenches to tighten. Torque to specification:

Torque,
Fitting in–lb ( NSm)
–4 150 (16.9)
–6 300 (33.9)
–8 500 (56.5)
–10 700 (79.1)
–12 1000 (113.0)
–16 1400 (158.2)
–20 2100 (237.3)
–24 3000 (339.0)

7. Minimum bend radius:.

Fitting Radius
–4 8 in. (203 mm)
–6 8 (203)
–8 10 (254)
–10 12 (305)
–12 14 (356)
–16 18 (457)
–20 22 (559)
–24 26 (660)

8. Do not bend or crimp hose.

9. Do not twist hose.

10. Use proper length hose.

3. Do not tape or cover hose.

6 309160

Operation and Maintenance

Pressure Relief Procedure

WARNING

SKIN INJECTION HAZARD

The system pressure must be manually
relieved to prevent the system from

starting or dispensing accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:

S are instructed to relieve the pressure,
S stop dispensing,
S check or service any of the system equipment,
S or install a new or clean the dispense gun

tip/nozzle.

1. Lock the gun trigger safety.

2. Shut off the air to the supply pumps.

3. Turn off the power (air) to the proportioning pump.

Operation

WARNING

This equipment should not be used with
more than one type of fluid due to poten­tial compatibility issues which could
result in an unpredictable reaction.
Graco recommends using new hoses

when chemicals are changed or care
must be taken to assure that all traces of one
chemical are removed before introducing a second
chemical.

CAUTION

S Do not pressurize hose until operating tempera-

ture has been reached.

S Operate at lowest possible temperature and

pressure necessary for application.

S Hose must be vented during startup and shut-

down.

S The dispense valve must be kept open over a

waste container while the system is heating up
and also when cooling down. This will prevent a
pressure build–up caused by fluids or gasses
expanding from the heat.

4. Unlock the spray gun trigger safety.

5. Hold a metal part of the gun firmly to the side of a
grounded metal pail, then trigger the gun to relieve
pressure.

6. Lock the trigger safety again.

7. If you suspect that the dispense valve or hose is

completely clogged, or that pressure has not been
fully relieved after following the steps above, very
slowly loosen the tip retaining nut or hose end

coupling to relieve pressure gradually, then loosen
completely. Wear protective gloves to avoid skin
injection or burns. Now clear the tip/nozzle or
hose.

8. Be sure the fluid is cool before disconnecting the
hoses.

Refer to your system operation manual for complete
startup and operating instructions.

Maintenance

WARNING

SKIN INJECTION HAZARD

Do not mend or repair any part of a hose
assembly. If the hose is damaged,
replace it immediately to avoid serious

injury from fluid injection and electric shock.

If the hose is not heating, be sure the connector at the
hose control box is firmly plugged in. If that does not
correct the problem, relieve the fluid pressure in the
pump and hoses, as instructed at left. If the hose is
faulty or the problem not corrected, replace the hose.
See Troubleshooting on page 8 for electrical mea­surements.

7309160

Troubleshooting

9. Check the continuity of the hose components.

a. Use an ohmmeter to check the electrical

resistance at the heating element pins be­tween pins A1 and A2 of the machine end
connector (A) that attaches to the heated hose
control. See Fig.1. The resistance of the
heating element for the various lengths of
coupled hose assemblies is given in the follow­ing coupled hose chart.

Pins A1 & A2

Length/ft

6 176 +/– 18

10 106 +/– 11

15 71 +/– 7

20 53 +/– 5

25 42 +/– 4

Any resistance reading outside the range may indicate
a faulty hose

The resistance values of the RTD will vary with tem­perature. An approximation of hose temperature must
be made to verify the resistance reading of the RTD
across pin A4 and A5 is correct.

Resistance Values (ohms) at 230 VAC

Approximate RTD resistance values at various temper­atures.

Pins A4 & A5

Temperature

C F

16 60 106

27 80 110

38 100 115

49 120 119

60 140 123

71 160 128

82 180 132

93 200 136

104 220 140

116 240 144

127 260 149

138 280 153

149 300 160

160 320 161

171 340 165

182 360 170

193 380 174

204 400 177

Approximate Resistance Values
(ohms)

b. Between pin A4 and A5 of the large machine

end connector, the RTD resistance must be
within the range of the following chart.

8 309160

10. Check all hose connections to be sure they are
securely tightened.

11. Ground the system.

Troubleshooting

Make sure there is electrical continuity (<10Ω) be­tween the following pins of the large machine end
connector and the small gun end connector

Lack of electrical continuity between any of these pins
is a failure of the hose. Replace the hose assembly.

Continuity Between Connectors

Machine End Gun End

B1 1

B2 2

B3 5

B4 3

B5 4

C1 6

C2 7

GND GND

Fig. 3

Technical Data

Maximum fluid working pressure See table on page 2. . . . . . . . . . . . . . . . . . . .

Maximum working temperature See table on page 2. . . . . . . . . . . . . . . . . . . . .

Hose fluid fittings See table on page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power required 230 VAC, 50/60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wetted parts PTFE core, SST couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power consumption 50 3 watts/linear foot of hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum Bend Radius Hose with No. 6 – No. 16 core = 8 in. (20 cm). . . . . . . . . . . . . . . . . . . . . . . . . . . .

(164 10 watts/linear meter of hose)

Hose with No. 20 core = 12 in. (30 cm)

9309160

Graco Standard Warranty

Graco warrants all equipment 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 procedures concernées.

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 distributor closest to you:
Phone: [phone] or Toll Free: 1–800–328–0211 Fax: [phone]

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.

10 309160

Original instructions. This manual contains English. MM 309160

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES S P.O. BOX 1441 S MINNEAPOLIS MN 55440–1441 S USA

Copyright 2000, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revised December 2012