Graco 3A0237L User Manual

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Instructions-Parts

Heated Hoses and

3A0237L

Applicator Kits

For use with Graco® HFR™ Metering Systems.

Not approved for use in European explosive atmospheres. For professional use only.

See page 2 for Maximum Fluid Working Pressures and approvals.

130 psi (0.9 MPa, 9 bar) Maximum Air Working Pressure

180°F (82°C) Maximum Hose Operating Temperature

Important Safety Instructions

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

Related Manuals

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Heated Hose Bundle Part Numbers . . . . . . . . . . . . 3

Fluid Temperature Sensor (FTS) . . . . . . . . . . . . . 4

Heated Whip Hose . . . . . . . . . . . . . . . . . . . . . . . 4

Individual Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Applicator Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

MD2 Valve Applicator Kits . . . . . . . . . . . . . . . . . 10

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Important Two-Component Material Information 14

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 14

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 14

Keep Components A and B Separate . . . . . . . . 14

Moisture Sensitivity of Isocyanates . . . . . . . . . . 14

Foam Resins with 245 fa Blowing Agents . . . . . 14

Changing Materials . . . . . . . . . . . . . . . . . . . . . . 15

A and B Components . . . . . . . . . . . . . . . . . . . . . . 15

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Connect Whip Hose to Gun or Gun Manifold . . 16

Connect Heated Hoses . . . . . . . . . . . . . . . . . . . 17

Connect FTS and Heated Whip Hose . . . . . . . . 20

Connect Solenoid Kit . . . . . . . . . . . . . . . . . . . . 21

Check Hoses for Leaks . . . . . . . . . . . . . . . . . . . 22

Protective Covering . . . . . . . . . . . . . . . . . . . . . . 22

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Instructions for Replacing Individual A or B Hose 24

Clean Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Bundle Individual Whip Hoses . . . . . . . . . . . . . 26

Bundle Individual Heated Hoses . . . . . . . . . . . . 28

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Whip Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Heated Hose Bundles . . . . . . . . . . . . . . . . . . . . 32

Using Fluid Temperature Sensors For Single Heat

Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Using Fluid Temperature Sensors for Dual Heat

Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

MD2 Applicator Kits . . . . . . . . . . . . . . . . . . . . . 37

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Scuff Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Solenoid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 42

Related Manuals

Component Manuals in U.S. English:

Manual Description

313997 HFR Operation 313998 HFR, Repair-Parts

313872

312185 MD2 Valve, Instructions-Parts

312666

310649

309550

309856

3A0861 Ratio Check Assembly, Instructions-Parts

™

Gun, Instructions-Parts

Fusion ment Mix Spray Gun with ClearShot

uid Technology, Instructions-Parts Fusion Automatic Plural Component,

Impingement Mix Spray Gun, Instructions-Parts

Fusion Air Purge Plural Component, Impingement Mix Spray Gun, Instructions-Parts

Fusion Mechanical Purge Plural Component, Impingement Mix Spray Gun, Instructions-Parts

™

CS Plural Component, Impinge-

™

Liq-

2 3A0237L

Heated Hose Bundle Part Numbers

Each hose contains an A component hose, a B component hose, and an air hose (1/4 npt x 1/4 npsm, m x f).

Single Hose Part No. JIC Fittings Maximum Fluid

Part No. Ratio

Stainless Steel Dual Heat Zone Hose Bundle with Air Hose

24D108 2:1 1/4 (6) A x 3/8 (10) B 5 (1.5) 24E925 24E934 5/5 6/6 3500 (24, 241) 24D109 2:1 1/4 (6) A x 3/8 (10) B 10 (3) 24E927 24E936 5/5 6/6 3500 (24, 241) 24D110 2:1 1/4 (6) A x 3/8 (10) B 25 (7.6) 24E929 24E938 5/5 6/6 3500 (24, 241) 24D111 2:1 1/4 (6) A x 3/8 (10) B 50 (15.2) 24E931 24E940 5/5 6/6 3500 (24, 241) 24D112 1:1 3/8 (10) A x 3/8 (10) B 5 (1.5) 24E933 24E934 5/5 6/6 3500 (24, 241) 24D113 1:1 3/8 (10) A x 3/8 (10) B 10 (3) 24E935 24E936 5/5 6/6 3500 (24, 241) 24D114 1:1 3/8 (10) A x 3/8 (10) B 25 (7.6) 24E937 24E938 5/5 6/6 3500 (24, 241) 24D115 1:1 3/8 (10) A x 3/8 (10) B 50 (15.2) 24E939 24E940 5/5 6/6 3500 (24, 241)

Carbon Steel Dual Heat Zone Hose Bundle with Air Hose

24D116 2:1 1/4 (6) A x 3/8 (10)B 5 (1.5) 24E901 24E910 5/5 6/6 3500 (24, 241) 24D117 2:1 1/4 (6) A x 3/8 (10)B 10 (3) 24E903 24E912 5/5 6/6 3500 (24, 241) 24D118 2:1 1/4 (6) A x 3/8 (10)B 25 (7.6) 24E905 24E914 5/5 6/6 3500 (24, 241) 24D119 2:1 1/4 (6) A x 3/8 (10)B 50 (15.2) 24E907 24E916 5/5 6/6 3500 (24, 241) 24D120 1:1 3/8 (10) A x 3/8 (10) B 5 (1.5) 24E911 24E910 5/5 6/6 3500 (24, 241) 24D121 1:1 3/8 (10) A x 3/8 (10) B 10 (3) 24E913 24E912 5/5 6/6 3500 (24, 241) 24D122 1:1 3/8 (10) A x 3/8 (10) B 25 (7.6) 24E915 24E914 5/5 6/6 3500 (24, 241) 24D123 1:1 3/8 (10) A x 3/8 (10) B 50 (15.2) 24E917 24E916 5/5 6/6 3500 (24, 241)

Carbon Steel Single Heat Zone Hose Bundle with Air Hose

24D124 2:1 1/4 (6) A x 3/8 (10) B 25 (7.6) 261520 261523 5/5 6/6 2000 (14, 138) 24D125 2:1 1/4 (6) A x 3/8 (10) B 50 (15.2) 261514 261517 5/5 6/6 2000 (14, 138) 24D126 1:1 3/8 (10) A x 3/8 (10) B 25 (7.6) 261522 261523 5/5 6/6 2000 (14, 138) 24D127 1:1 3/8 (10) A x 3/8 (10) B 50 (15.2) 261516 261517 5/5 6/6 2000 (14, 138)

Carbon Steel Single Heat Zone Hose Bundle with Air Hose

24D129 2:1 1/4 (6) A x 3/8 B 50 (15.2) 261524 261527 5/5 6/6 3500 (24, 241) 24D131 1:1 3/8 (10) A x 3/8 (10) B 50 (15.2) 261526 261527 5/5 6/6 3500 (24, 241) 24E963 1:1 1/4 (6) A x 1/4 (6) B 25 (7.6) 246065✿ 246066✿ 5/5 6/6 2000 (14, 138) 24E964 1:1 1/4 (6) A x 1/4 (6) B 50 (15.2) 246059✿ 246060✿ 5/5 6/6 2000 (14, 138) 24E965 1:1 1/2 (13) A x 1/2 (13) B 50 (15.2) 246063✿ 246064✿ 5/5 6/6 2000 (14, 138) 24E966 1:1 1/4 (6) A x 1/4 (6) B 50 (15.2) 246067✿ 246068✿ 5/5 6/6 3500 (24, 241) 24E967 1:1 1/2 (13) A x 1/2 (13) B 50 (15.2) 246071✿ 246072✿ 5/5 6/6 3500 (24, 241) 24E968 1:1 1/4 (6) A x 1/4 (6) B 10 (3) 24D190 24D191 5/5 6/6 2000 (14, 138) 24E969 1:1 3/8 (10) A x 3/8 (10) B 10 (3) 24D760 24D761 5/5 6/6 2000 (14, 138)

in. (mm)

Length ft (m)

Pressure psi (MPa, bar)A (Red) B (Blue) A (Red) B (Blue)

✿ If ordered as replacement hose for a HFR hose bun-

dles, reference manual 3A0237 not 309572.

★ All heated hose bundles are CE approved.

3A0237L 3

Heated Hose Bundle Part Numbers

Fluid Temperature Sensor (FTS)

Maximum Fluid Pressure

Part No.

258756 JIC to JIC Fluid Temperature Sensors for dual heat zones with stainless steel fittings 5000 (34.5, 345) 258758 JIC to JIC Fluid Temperature Sensors for single heat zone with stainless steel fittings 5000 (34.5, 345)

Fittings

Description

psi (MPa, bar)

Heated Whip Hose

Single Hose Part No. JIC Fittings Maximum Fluid

Part No.

Carbon Steel Single Heat Zone

24H076 1/4 (6) 10 (3) 24D190 24D191 5/5 6/6 3500 (24.1, 241) 24H077 3/8 (10) 10 (3) 24D760 24D760 5/5 6/6 3500 (24.1, 241)

Carbon Steel Dual Heat Zone

24H078 1/4 (6) 10 (3) 24H064 24H065 5/5 6/6 3500 (24.1, 241) 24H079 3/8 (10) 10 (3) 24H066 24H067 5/5 6/6 3500 (24.1, 241)

Stainless Steel Single Heat Zone

24H080 1/4 (6) 10 (3) 24H068 24H069 5/5 6/6 3500 (24.1, 241) 24H081 3/8 (10) 10 (3) 24H070 24H071 5/5 6/6 3500 (24.1, 241)

Stainless Steel Dual Heat Zone

24H082 1/4 (6) 10 (3) 24H072 24H073 5/5 6/6 3500 (24.1, 241) 24H083 3/8 (10) 10 (3) 24H074 24H075 5/5 6/6 3500 (24.1, 241)

in. (mm)

Length ft (m)

Pressure psi (MPa, bar)A (Red) B (Blue) A (Red) B (Blue)

★ All heated whip hoses are CE approved.

4 3A0237L

Individual Hoses

A Side Heated Hoses (Red)

Maximum Fluid Pressure

Length

Part No.IDin. (mm)

Carbon Steel Heated Dual Heat Zone

24E901 1/4 (6) 5 (1.5) 5/5 3500

24E903 1/4 (6) 10 (3) 5/5 3500

24E905 1/4 (6) 25 (7.6) 5/5 3500

24E907 1/4 (6) 50 (15.2) 5/5 3500

24E909 3/8 (10) 5 (1.5) 5/5 3500

24E911 3/8 (10) 10 (3) 5/5 3500

24E913 3/8 (10) 25 (7.6) 5/5 3500

24E915 3/8 (10) 50 (15.2) 5/5 3500

24E917 1/2 (13) 5 (1.5) 5/5 3500

24E919 1/2 (13) 10 (3) 5/5 3500

24E921 1/2 (13) 25 (7.6) 5/5 3500

24E923 1/2 (13) 50 (15.2) 5/5 3500

Carbon Steel Heated Single Heat Zone

246065✿ 1/4 (6) 25 (7.6) 5/5 2000

246059✿ 1/4 (6) 50 (15.2) 5/5 2000

246067✿ 1/4 (6) 50 (15.2) 5/5 3500

246094✿ 3/8 (10) 25 (7.6) 5/5 2000

246061✿ 3/8 (10) 50 (15.2) 5/5 2000

246069✿ 3/8 (10) 50 (15.2) 5/5 3500

246063✿ 1/2 (13) 50 (15.2) 8/8 2000

246071✿ 1/2 (13) 50 (15.2) 8/8 3500

24D190 1/4 (6) 10 (3) 5/5 2000

24D760 3/8 (10) 10 (3) 5/5 2000

ft (m)

JIC Fittings

psi (MPa, bar)

(24, 241)

(14, 138)

(24, 241)

(14, 138)

(24, 241)

(14, 138)

(24, 241)

(14, 138)

Individual Hoses

Maximum Fluid Pressure

Length

Part No.IDin. (mm)

Stainless Steel Heated Dual Heat Zone

24E925 1/4 (6) 5 (1.5) 5/5 3500

24E927 1/4 (6) 10 (3) 5/5 3500

24E929 1/4 (6) 25 (7.6) 5/5 3500

24E931 1/4 (6) 50 (15.2) 5/5 3500

24E933 3/8 (10) 5 (1.5) 5/5 3500

24E935 3/8 (10) 10 (3) 5/5 3500

24E937 3/8 (10) 25 (7.6) 5/5 3500

24E939 3/8 (10) 50 (15.2) 5/5 3500

24E941 1/2 (13) 5 (1.5) 5/5 3500

24E943 1/2 (13) 10 (3) 5/5 3500

24E945 1/2 (13) 25 (7.6) 5/5 3500

24E947 1/2 (13) 50 (15.2) 5/5 3500

ft (m)

JIC Fittings

psi (MPa, bar)

(24, 241)

✿ If ordered as replacement hose for a HFR hose bun-

dles, reference manual 3A0237 not 309572.

★ All heated hoses are CE approved.

3A0237L 5

Individual Hoses

A Side Unheated Hoses (Red)

Maximum Fluid

Length

Part No.IDin. (mm)

Carbon Steel Unheated

262173 1/4 (6) 5 (1.5) 5/5 3500

262175 1/4 (6) 10 (3) 5/5 3500

262177 1/4 (6) 25 (7.6) 5/5 3500

262179 1/4 (6) 50 (15.2) 5/5 3500

262181 3/8 (10) 5 (1.5) 5/5 3500

262183 3/8 (10) 10 (3) 5/5 3500

262185 3/8 (10) 25 (7.6) 5/5 3500

262187 3/8 (10) 50 (15.2) 5/5 3500

262189 1/2 (13) 5 (1.5) 8/8 3500

262191 1/2 (13) 10 (3) 8/8 3500

262193 1/2 (13) 25 (7.6) 8/8 3500

262195 1/2 (13) 50 (15.2) 8/8 3500

ft (m)

JIC Fittings

Pressure psi (MPa, bar)

(24, 241)

Maximum Fluid

Length

Part No.IDin. (mm)

Stainless Steel Unheated

262236 1/4 (6) 5 (1.5) 5/5 3500

262238 1/4 (6) 10 (3) 5/5 3500

262240 1/4 (6) 25 (7.6) 5/5 3500

262242 1/4 (6) 50 (15.2) 5/5 3500

262244 3/8 (10) 5 (1.5) 5/5 3500

262246 3/8 (10) 10 (3) 5/5 3500

262248 3/8 (10) 25 (7.6) 5/5 3500

262250 3/8 (10) 50 (15.2) 5/5 3500

262252 1/2 (13) 5 (1.5) 8/8 3500

262254 1/2 (13) 10 (3) 8/8 3500

262256 1/2 (13) 25 (7.6) 8/8 3500

262258 1/2 (13) 50 (15.2) 8/8 3500

ft (m)

JIC Fittings

Pressure psi (MPa, bar)

(24, 241)

Individual A Side Heated Whip Hose

Maximum

in.

Length

Part No.

24E949 1/4 (6) 10 (3) Single 3500

24E951 3/8 (10) 10 (3) Single 3500

24H085 1/4 (6) 10 (3) Dual 3500

24H087 3/8 (10) 10 (3) Dual 3500

24H089 1/4 (6) 10 (3) Single 3500

24H091 3/8 (10) 10 (3) Single 3500

24H093 1/4 (6) 10 (3) Dual 3500

24H095 3/8 (10) 10 (3) Dual 3500

6 3A0237L

(mm)

ft (m)

Heat Zone

Fluid Pressure psi (MPa, bar) Material

CST

(24, 241)

CST

(24, 241)

CST

(24, 241)

CST

(24, 241)

SST

(24, 241)

SST

(24, 241)

SST

(24, 241)

SST

(24, 241)

Part No.

24H224 1/4 (6) 5 (1.5) Single 3500

24H226 3/8 (10) 5 (1.5) Single 3500

24H228 1/4 (6) 5 (1.5) Dual 3500

24H230 3/8 (10) 5 (1.5) Dual 3500

24H232 1/4 (6) 5 (1.5) Single 3500

24H234 3/8 (10) 5 (1.5) Single 3500

24H236 1/4 (6) 5 (1.5) Dual 3500

24H238 3/8 (10) 5 (1.5) Dual 3500

in.

(mm)

Length ft (m)

Heat Zone

Maximum Fluid Pressure psi (MPa, bar) Material

CST

(24, 241)

CST

(24, 241)

CST

(24, 241)

CST

(24, 241)

SST

(24, 241)

SST

(24, 241)

SST

(24, 241)

SST

(24, 241)

B Side Heated Hoses (Blue)

Individual Hoses

Maximum Fluid

Length

Part No.IDin. (mm)

Carbon Steel Heated Dual Heat Zone

24E902 1/4 (6) 5 (1.5) 6/6 3500

24E904 1/4 (6) 10 (3) 6/6 3500

24E906 1/4 (6) 25 (7.6) 6/6 3500

24E908 1/4 (6) 50 (15.2) 6/6 3500

24E910 3/8 (10) 5 (1.5) 6/6 3500

24E912 3/8 (10) 10 (3) 6/6 3500

24E914 3/8 (10) 25 (7.6) 6/6 3500

24E916 3/8 (10) 50 (15.2) 6/6 3500

24E918 1/2 (13) 5 (1.5) 6/6 3500

24E920 1/2 (13) 10 (3) 6/6 3500

24E922 1/2 (13) 25 (7.6) 6/6 3500

24E924 1/2 (13) 50 (15.2) 6/6 3500

Carbon Steel Heated Single Heat Zone

246066✿ 1/4 (6) 25 (7.6) 6/6 2000

246060✿ 1/4 (6) 50 (15.2) 6/6 2000

246095✿ 3/8 (10) 25 (7.6) 6/6 2000

246070✿ 3/8 (10) 50 (15.2) 6/6 2000

246062✿ 3/8 (10) 50 (15.2) 6/6 2000

246064✿ 1/2 (13) 50 (15.2) 6/6 2000

246068✿ 1/4 (6) 50 (15.2) 6/6 3500

246072✿ 1/2 (13) 50 (15.2) 6/6 3500

24D191 1/4 (6) 10 (3) 6/6 2000

24D761 3/8 (10) 10 (3) 6/6 2000

ft (m)

JIC Fittings

Pressure psi (MPa, bar)

(24, 241)

(14, 138)

(24, 241)

(14, 138)

Maximum Fluid

Length

Part No.IDin. (mm)

Stainless Steel Heated Dual Heat Zone

24E926 1/4 (6) 5 (1.5) 6/6 3500

24E928 1/4 (6) 10 (3) 6/6 3500

24E930 1/4 (6) 25 (7.6) 6/6 3500

24E932 1/4 (6) 50 (15.2) 6/6 3500

24E934 3/8 (10) 5 (1.5) 6/6 3500

24E936 3/8 (10) 10 (3) 6/6 3500

24E938 3/8 (10) 25 (7.6) 6/6 3500

24E940 3/8 (10) 50 (15.2) 6/6 3500

24E942 1/2 (13) 5 (1.5) 6/6 3500

24E944 1/2 (13) 10 (3) 6/6 3500

24E946 1/2 (13) 25 (7.6) 6/6 3500

24E948 1/2 (13) 50 (15.2) 6/6 3500

ft (m)

JIC Fittings

Pressure psi (MPa, bar)

(24, 241)

✿ If ordered as replacement hose for a HFR hose bun-

dles, reference manual 3A0237 not 309572.

★ All heated hoses are CE approved.

3A0237L 7

Individual Hoses

B Side Unheated Hoses (Blue)

Maximum Fluid

Length

Part No.IDin. (mm)

Carbon Steel Unheated

262174 1/4 (6) 5 (1.5) 6/6 3500

262176 1/4 (6) 10 (3) 6/6 3500

262178 1/4 (6) 25 (7.6) 6/6 3500

262180 1/4 (6) 50 (15.2) 6/6 3500

262182 3/8 (10) 5 (1.5) 6/6 3500

262184 3/8 (10) 10 (3) 6/6 3500

262186 3/8 (10) 25 (7.6) 6/6 3500

262188 3/8 (10) 50 (15.2) 6/6 3500

262190 1/2 (13) 5 (1.5) 10/10 3500

262192 1/2 (13) 10 (3) 10/10 3500

262194 1/2 (13) 25 (7.6) 10/10 3500

262196 1/2 (13) 50 (15.2) 10/10 3500

ft (m)

JIC Fittings

Pressure psi (MPa, bar)

(24, 241)

Maximum Fluid

Length

Part No.IDin. (mm)

Stainless Steel Unheated

262237 1/4 (6) 5 (1.5) 6/6 3500

262239 1/4 (6) 10 (3) 6/6 3500

262241 1/4 (6) 25 (7.6) 6/6 3500

262243 1/4 (6) 50 (15.2) 6/6 3500

262245 3/8 (10) 5 (1.5) 6/6 3500

262247 3/8 (10) 10 (3) 6/6 3500

262249 3/8 (10) 25 (7.6) 6/6 3500

262251 3/8 (10) 50 (15.2) 6/6 3500

262253 1/2 (13) 5 (1.5) 10/10 3500

262255 1/2 (13) 10 (3) 10/10 3500

262257 1/2 (13) 25 (7.6) 10/10 3500

262259 1/2 (13) 50 (15.2) 10/10 3500

ft (m)

JIC Fittings

Pressure psi (MPa, bar)

(24, 241)

Individual B Side Heated Whip Hose

Maximum Fluid

Length

Part No.IDin. (mm)

24E950 1/4 (6) 10 (3) Single 3500

24E952 3/8 (10) 10 (3) Single 3500

24H086 1/4 (6) 10 (3) Dual 3500

24H088 3/8 (10) 10 (3) Dual 3500

24H090 1/4 (6) 10 (3) Single 3500

24H092 3/8 (10) 10 (3) Single 3500

24H094 1/4 (6) 10 (3) Dual 3500

24H096 3/8 (10) 10 (3) Dual 3500

8 3A0237L

ft (m)

Heat Zone

Pressure psi (MPa, bar) Material

CST

(24, 241)

CST

(24, 241)

CST

(24, 241)

CST

(24, 241)

SST

(24, 241)

SST

(24, 241)

SST

(24, 241)

SST

(24, 241)

Part No.IDin. (mm)

24H225 1/4 (6) 5 (1.5) Single 3500

24H227 3/8 (10) 5 (1.5) Single 3500

24H229 1/4 (6) 5 (1.5) Dual 3500

24H231 3/8 (10) 5 (1.5) Dual 3500

24H233 1/4 (6) 5 (1.5) Single 3500

24H235 3/8 (10) 5 (1.5) Single 3500

24H237 1/4 (6) 5 (1.5) Dual 3500

24H239 3/8 (10) 5 (1.5) Dual 3500

Length ft (m)

Heat Zone

Maximum Fluid Pressure psi (MPa, bar) Material

CST

(24, 241)

CST

(24, 241)

CST

(24, 241)

CST

(24, 241)

SST

(24, 241)

SST

(24, 241)

SST

(24, 241)

SST

(24, 241)

Applicator Kits

The table below lists applicators that can be used with the heated hoses and identifies which applicators require solenoid kits. See Related Manuals for the applicator manual numbers.

NOTE: The MD2 valves must use one of the chemical connection kits to connect to the fluid hoses. See MD2 Valve Applicator Kits on page 10.

NOTE: When selecting an applicator, if an applicator is chosen which does not have a signal communicating to the

HFR, then the sizes of the A and B pumps added together must be greater or equal to 120 cc. For example: A (red) pump size = 20 cc, B (blue) pump size = 100 cc, 20 cc + 100 cc = 120 cc. Since the pump sizes combined = 120 cc, an applicator may be selected which does not have a signal communicating to the HFR.

Applicator Handle Options Required Solenoid Kit Pressure Relief Kit

Automatic Fusion Air Purge Guns No handle

Automatic Fusion Mechanical Purge Guns No handle

Fusion Air Purge Guns

Fusion Mechanical Purge Guns

Fusion CS Guns

EP Gun

1:1 and 10:1 MD2 Valves (See MD2 Valve Applicator Kits on page 10 for models and chemical connection kits)

No handle

Electric actuated pistol

No handle

Electric actuated pistol

Pneumatic Electric actuated lever

24D161 24D161

24C067 24C067 24C067

24D160, 24C757 24D160, 24C757

24D160, 24C757

3A0237L 9

Applicator Kits

MD2 Valve Applicator Kits

Part No. (Series)

24D500 24D501 24D502 24D503 24D504 24D505 24D509 24D510 24D511 24D512 24D513 24D514 24D515 24D516 24D521 24D522 24D523 24D524 24D525 24D526 24D530 24D531 24D532 24D533 24D534 24D535 24D536 24D537

MD2 Valve

(see manual 312185)

255179

(1:1 with soft seats)

255180

(1:1 with hard seats)

255181

(10:1 with soft seats)

255182

(10:1 with hard seats)

Electric

(255208)

MD2 Handle Chemical Connection Kit

Lever

(255249)

Pneumatic

(255206)

Carbon Steel

(24D414)

Stainless Steel

(24D162)

✔

✔ ✔

✔

✔ ✔

✔

✔ ✔

✔

✔ ✔

✔

✔ ✔

✔

✔ ✔

✔

✔ ✔

✔✔

✔

✔ ✔

10 3A0237L

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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

ELECTRIC SHOCK HAZARD

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

• Turn off and disconnect power before disconnecting before installing or servicing hoses.

• Connect to grounded power source.

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

• Never cut or puncture a hose cover.

• 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.

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

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

• Replace damaged hose immediately.

• Tighten all fluid connections before operating the equipment.

• Keep clear of leaks.

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

• Never exceed hose Maximum Pressure or Temperature ratings.

• Only use chemicals that are compatible with wetted parts. See Technical Data in this manual. Read MSDSs and fluid and solvent manufacturer’s recommendations.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

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.

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

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

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.

3A0237L 11

Warnings

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.

• Read MSDSs 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 chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

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 from distributor or retailer.

• 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.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’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.

12 3A0237L

Warnings

WARNING

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:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

3A0237L 13

Important Two-Component Material Information

Isocyanate Conditions

Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Material Self-ignition

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

Keep Components A and B

Moisture Sensitivity of Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

NOTE: NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the ISO lube pump reservoir (if installed) filled

with Graco Throat Seal Liquid (TSL The lubricant creates a barrier between the ISO and the atmosphere.

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contaminated from the other side.

• Always lubricate threaded parts with ISO pump oil or grease when reassembling.

™

), Part 206995.

Separate

Foam Resins with 245 fa Blowing Agents

Some foam blowing agents will froth at temperatures

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

14 3A0237L

above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

Changing Materials

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• Most materials use ISO on the A side, but some use ISO on the B side.

• Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

A and B Components

IMPORTANT!

Material suppliers can vary in how they refer to plural component materials.

Be aware that when standing in front of the manifold on proportioner:

• Component A (Red) is on the left side.

• Component B (Blue) is on the right side.

For all machines:

• The A (Red) side is intended for ISO, hardeners, and catalysts.

• If one of the materials being used is moisture-sensitive, that material should always be in the A (Red) side.

• The B (blue) side is intended for polyols, resins, and bases.

NOTE: For ratios higher than 1:1, the higher volume is typically the B (Blue) side.

3A0237L 15

Installation

Description

The heated hose maintains proper fluid temperature while dispensing.

Fluid hoses are marked with red tape for ISO/hardener/minor volume side, blue tape for RES/resin/major volume side. Fittings have different sized threads to prevent incorrect connection, which can cause fluid crossover and permanently damage the hose.

Hoses are 5 ft (1.5 m), 10 ft (3 m), 25 ft (7.6 m), and 50 ft (15.2 m) long. The whip hose is 5 ft (1.5 m) or 10 ft (3 m) long.

Connect Whip Hose to Gun or

Tighten

IG. 1: Fusion Gun

Tighten

Gun Manifold

NOTE: For best whip hose flexibility, assemble whip hose to gun or gun manifold as instructed.

1. Assemble A and B component hoses to gun or gun manifold fittings as shown in F

2. If applicable, assemble signal cable (E1) and air hose to gun or gun manifold fittings.

3. Tighten fittings to A and B component hoses. Ensure hose remains flat after fittings are tightened. Loosen and retighten fittings as necessary to eliminate any torque on hoses. This will help achieve a flat profile on the hose.

NOTE: Use chemical connection kit (153) on all MD2 valves. See F

4. For MD2 valves with 255208 and 255249 and both EP Gun models, connect the signal cable (E1) from the applicator to the whip hose signal cable (3b).

5. See applicator manual for complete setup instructions.

IG. 2.

IG. 1 and FIG. 2.

153c

153a

IG. 2: MD2 Valve Kit 24D501

B Side Hose

A Side Hose

153b

153a

r_24d501_3a0237_1a

16 3A0237L

Installation

Connect Heated Hoses

1. Lay heated hoses end to end, matching the color coding. Red for component A (ISO), blue for component B (RES).

FIG. 3

TI14731a

4. Connect air hoses (C).

Single Heat Zone with A and B Heated Hose

TI14733a

Dual Heat Zone with A and B Heated Hose

TI15097a

Single Heat Zone with A or B Heated Hose

2. Connect fluid hoses (A, B).

3. Connect signal cables (13).

TI14732a

IG. 4

NOTE: Do not connect the main air supply to the air hose at this time.

FIG. 5

5. Connect electrical wires (D).

a. Ensure electrical wires ends are 5/8 in.

(0.625mm) long. If they are not, use a sharp scissors to strip all four wire ends to the correct length. See Strip Length Gauge for correct length.

Strip Length

TI15140a

This illustration is not to scale.

IG. 6

3A0237L 17

5/8 in.

(0.625 mm)

TI9733a

Installation

NOTE: Be careful not to cut or nick copper strands. If more than five strands are cut or nicked, trim wire and re-strip.

New hoses are pre-stripped at correct length; remove insulation to expose bare wire.

a. Ensure strip length is correct by fitting ferrule

over exposed wire. Ferrule should be flush with wire end. See F

IG. 7.

NOTE: On some older heated hoses wire insulation will not fit inside ferrule insulator. In these cases, use scissors to split and remove ferrule insulator.

b. If wire is short of ferrule end, adjust strip length

accordingly. If bare wire is protruding from ferrule, trim flush to ferrule end. See F

IG. 7.

Incorrect

Correct

a. Insert one wire from heated hose into connec-

tor. Ensure that ferrule is mating with connector insert. See F

IG. 9.

TI9770A

FIG. 9: Insert Wire and Setscrew

b. Thread in setscrew and use hex wrench to

torque setscrew to 60 in-lbs (6.78 N•m).

NOTE: To reach approximately 60 in-lbs (6.78 N•m), complete 4.5 revolutions with hex wrench after setscrew comes in contact with ferrule.

Incorrect

TI9768a

IG. 7

c. Remove ferrule and apply oxide inhibitor to bare

wire. See F

d. Reinsert wire in ferrule and apply more oxide

inhibitor to ferrule and wire end.

IG. 8

6. Pair electrical wires as follows: A-Hose to A-Hose; B-Hose to B-Hose.

NOTE: When connecting first hose section to proportioner, wire pairing does not make a difference.

IG. 8.

TI9769A

TI9779A

IG. 10: Torque Setscrew

c. Insert remaining wire from pair into connector;

ensure proper insertion depth. Thread setscrew and torque to 60 in-lbs (6.78 N•m); see sub-step B. See F

IG. 9 and FIG. 10.

d. Repeat sub-steps A through C for remaining

wire pair.

e. Re-torque all setscrews to 60 in-lbs (6.78 N•m).

NOTE: When torqued to 60 in-lbs (6.78 N•m) setscrews will be approximately flush with connector. See F

IG. 11.

18 3A0237L

f. Insert cap plugs over setscrews. See FIG. 11.

Cap plugs

Setscrews

TI9771A

IG. 11

g. Wrap connector and wire on each side of con-

nector in black electrical tape to help seal out moisture. Ensure 1 in. (25.4 mm) of wire on each side of connector is wrapped.

7. Connect cables (F). Leave slack (G) in cables as stress relief to prevent cable failure.

Installation

TI14734a

IG. 12

8. Repeat for additional hoses.

9. See Connect FTS and Heated Whip Hose, page

20.

3A0237L 19

Installation

Connect FTS and Heated Whip Hose

NOTICE

To prevent damage to probe, do not kink or excessively bend hose. Do not coil hose tighter than the minimum bend radius of 3 ft (0.9 m). Do not subject hose to excessive weight, impact, or other abuse.

1. For Single Zone Heat: Carefully extend FTS probe (H) into the hose section from the proportioner. Do not bend or kink probe. Insert in component A (red) side of main hose for foam or polyurea systems.

For Dual Zone Heat:

Carefully extend FTS probe (H) into the hose sections from the proportioner. Do not bend or kink probe. Insert in component A (red) and component B (blue) side of main hose for foam or polyurea systems.

2. Connect FTS (J) to whip hose (W).

Single Zone Heat

3. Connect whip hose ground wire (K) to ground screw on underside of FTS.

4. Connect fluid hoses to FTS (J).

NOTE: To use 1/2 in. (13 mm) ID fluid hoses, remove the adapters from the proportioner fluid manifold and install them in the FTS swivel inlets.

5. Connect electrical connectors (D).

6. Connect air hose (C) to whip air hose (L) or see Connect Solenoid Kit on page 21 for installation instructions.

7. Connect hose assembly cable (F) to FTS cable (R). Leave slack (G) in cables as stress relief, to prevent cable failure.

8. See Check Hoses for Leaks, page 22.

To Gun

To Proportioner

Dual Zone Heat

To Proportioner

FIG. 13: FTS Connections

24D160 or 24D161, page 21

ti14735a

To Gun

ti14736b

20 3A0237L

Installation

Connect Solenoid Kit

A solenoid kit is required for some applicators used with Graco Metering Systems. See Individual Hoses on page 5 to see which applicators require a solenoid kit.

NOTE: To ensure proper operation of valve, install the solenoid kit within 15 ft (4.5 m) of the applicator. The solenoid reaction time decreases if the solenoid kit is farther away from the applicator. Ensure that the scuff guard covers the solenoid if mounted between the hose and whip hose.

1. Turn off all power to the system.

2. Apply anaerobic pipe sealant to pipe threads on mufflers (205), tee fitting (202), and swivel fitting (215). Connect to valve (201).

3. Connect elbow fittings (204), and wire harness (206) to valve (201).

4. Connect air hose (C) to swivel fitting (215).

5. Connect two elbows (207) and tubing (212) to open and closed ports on the applicator. See applicator manual for port locations.

NOTE: Cut tubing (212) to desired length if necessary.

6. Install plug (203), or tube fitting (214) and ball valve (213) in the other side of the tee fitting (202).

202

IG. 15

213

212207

214

203

r_24D161_3a0237B_2b

7. For solenoid kit 24D161: Connect elbow fitting (207) and tubing (212) to the purge air port and tube fitting (214). See applicator manual for port locations.

Connect Splitter

24D160 and 24D161 use a splitter (211) to allow the Graco Metering System to dispense material from the system controls.

1. Connect the splitter (211) to the valve (201) with screw (208), washer (209), and nut (210).

2. Connect the hose communications cable (24) to the single splitter (211) connection.

202

215

IG. 14

205

206

3. Connect the wire harness (206) and signal cable (3b) from the whip hose to the splitter (211).

207

206

208

212

210

209

211

r_24D160_3a0237b_1b

205

201

204

r_24D161_3a0237b_1

IG. 16

201

3A0237L 21

Installation

4. For 24C757: Connect valve (201) to the B side pump guard (GD) with screws (208) and washers (209).

206

209

208

IG. 17

201

r_24c352_3A0237_2a

5. Remove motor cover and connect solenoid cable (206) to cable (2B).

To use 1/2 in. (13 mm) ID fluid hoses, remove the adapters from the proportioner fluid manifold and install them

in the FTS swivel inlets.

TI14737b

FIG. 18

2. For spray guns, close fluid valves on gun fluid manifold. Remove manifold from gun, see gun manual. Connect fluid whip hoses to manifold.

3. Check that all equipment is properly grounded. See system operation manual.

4. Pressure check hose. See proportioner manual for priming instructions. After all lines are free of air, check for leaks. If there are leaks, relieve pressure as instructed in proportioner manual. Tighten connections, then pressurize again to ensure leaks have stopped. Relieve pressure.

6. For 24D160 and 24D161: Connect the valve (201) between the last hose bundle and the whip hose with zip ties (not supplied.) See F

IG. 13.

Check Hoses for Leaks

1. Grease with Fusion grease and connect fluid hoses to proportioner fluid manifold (M). Red for hardener, blue for resin. See F

NOTE: The manifold hose adapters (N,P) allow use of 1/4 in. and 3/8 in. ID fluid hoses.

To check adapter tightness, torque as follows:

• A (red) side (N) to 20-25 ft-lb (27-34 N•m).

• B (blue) side (P) to 30-35 ft-lb (41-47 N•m).

IG. 18.

Protective Covering

1. Wrap all fluid hose connections with electrical tape.

TI14738a

IG. 19

2. Fold wire back on hose to ensure adequate strain relief. Wrap all electrical connections and cable connections with electrical tape to protect them from pulling apart and abrasion.

3. Install protective cover, or wrap hose bundle with duct tape to protect foam.

4. For hoses that include a protective scuff cover, unroll excess cover over hose and electrical connections. Tape securely.

22 3A0237L

Operation

Do not operate a coiled hose. A coiled hose creates uneven heat buildup which can result in hose rupture and cause serious injury, including fluid injection.

Maximum hose operating temperature is 180°F (82°C). If using hose without an FTS, measure hose temperature to ensure it does not exceed 180°F (82°C).

Hose must be properly supported to avoid excessive strain due to weight, bending, or sharp edges.

Operation

Single Heat Zone Shown

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.

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

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

1. Connect air hose (C) to main air supply if equipped.

2. Connect electrical connectors (D) to connector from fluid manifold (M) or accessory control box. See , page 16. Connect hose cable (F) to cable from proportioner fluid manifold (M) or accessory control box. Connect signal cable (24) to connector behind the proportioner fluid manifold (M).Wrap connections with electrical tape.

FIG. 20

TI14737b

(24) connector

3A0237L 23

Maintenance

1. Before disconnecting or repairing hoses, relieve all fluid pressure and shut off electrical power to proportioner. See system operation manual.

2. Be sure fluid is cool before disconnecting hoses.

Clean Orifice

Only for MD2 Valve using Orifice Block Kit 24E505 and an orifice.

NOTE: 24E505 does not come with an orifice. See on page 39 for orifice part numbers.

1. Follow Pressure Relief Procedure in MD2 valve manual.

Instructions for Replacing Individual A or B Hose

1. Before disconnecting hoses, relieve all fluid pressure and shut off electrical power to proportioner. See system operation manual.

2. Disconnect electrical wire from connectors (5). Disconnect fluid hose and remove from bundle.

3. For whip hose bundles, see Bundle Individual Whip Hoses on page 26.

4. For hose bundles, see Bundle Individual Heated Hoses on page 28.

2. Use 5/16 in. nut driver to remove orifices.

NOTICE

To prevent cross-contamination of the orifices do not interchange A component and B component parts. The A component orifice is marked with an A.

3. Remove cap from orifice.

NOTE: The cap is held in place with reverse threads.

4. Remove needle from orifice. Thoroughly inspect all o-rings and replace if necessary.

5. If necessary, use drill bit that is the same size as the orifice to drill out the orifice. Orifice size is marked on the orifice.

6. Liberally lubricate all o-rings.

7. Reassemble in reverse order. Torque orifices into fluid housing to 20-30 in-lb (2.26-3.39 N•m).

24 3A0237L

Maintenance

3A0237L 25

Maintenance

Bundle Individual Whip Hoses

Individual whip hoses must be bundled with scuff guards and air and signal cables. Follow the instructions below to bundle single and dual heat zone whip hose bundles.

See F

IG. 21 on page 27.

1. Lay out the A and B material hoses with the male fittings at the same end of the bundle.

2. Lay out the air hose (3) with the male fitting at the same end as the male fittings of the material hoses.

NOTE: The female fitting of the air hose should be 6 in. (152.4 mm) beyond the female fitting of the material hoses.

3. Lay out the signal cable (4) with the female end of the signal cable at the same end as the male ends of the material hoses.

NOTE:

• The male sign cable connector (4) should be 6 in. beyond the female ends of the material hoses.

• Use electrical tape (8) to secure position of signal cable 10 in. (254 mm) back from the end of the material hose.

4. Connect Electrical Connectors.

For Single Zone Heated Whip Hose Bundles:

a. Place one 6 AWG electrical connector (5) 24 in.

(609.6 mm) from the male material hose fittings.

5. Apply scuff guard (10) on each individual material hose up to the electrical connector (5).

6. Use red electrical tape (12) to secure the scuff guard (10) on the red material hose.

7. Use blue electrical tape (13) to secure the scuff guard (10) on the blue material hose.

8. Use electrical tape and temporarily tape the hose and cable ends together.

9. Feed the scuff guard (4) over the male material hose fittings.

10. Use black electrical tape (8) and secure at least 3 in. (76.2 mm) of scuff guard (4) next to the electrical connector (5) on side with male material hose fittings.

NOTE: Ensure no foam insulation is exposed on either material hose.

11. Fold the scuff guard (4) over itself and feed the remaining scuff guard over the entire length of the bundle.

12. Leave excess scuff guard (4) loose on the end with the female material fittings.

13. Remove electrical tape securing the hose and cable ends together.

14. Apply warning label (10) in the center of the bundle. Secure edges with black electrical tape.

b. Connect the 6 AWG wire from each material

hose to the electrical connector (5).

c. Use black electrical tape (8) to secure the con-

nector to the hose bundle.

For Dual Zone Heated Whip Hose Bundles:

a. Place two 6 AWG electrical connectors (5) 24

in. (609.6 mm) from the male material hose fittings.

b. Unlace the 6 AWG wire from each material

hose, trim back the wire, and connect to the electrical connector (5).

c. Use black electrical tape (8) to secure both con-

nectors (5) to the correct material hose.

26 3A0237L

Maintenance

Dual Heat Zone Heated Whip Hose Bundle

female fittings

6 in. (152.4 mm)

male

connector

10 in. (254 mm)

8 10

27 in. (685.8 mm)

female connector

16 in. (406.4 mm)

24 in. (609.6 mm)

male fittings

B Side

A Side

Single Heat Zone Heated Whip Hose Bundle

female fittings

male

connector

FIG. 21: Whip Hose Bundles

female connector

male fittings

B Side

A Side

3A0237L 27

Maintenance

Bundle Individual Heated Hoses

Individual hoses must be bundled with a scuff guard, FTS cable(s), and air and signal cables.Follow the instructions below to bundle individual heated hoses for dual and single zone heat.

See F

IG. 22 on page 29.

1. Lay out the A and B material hoses with the male fittings at the same end of the bundle.

2. Lay out the air hose (23) with the male fitting at the same end as the male fittings of the material hoses.

3. Lay out the signal cable (24) and FTS cable(s) (25) with the female end of the cables at the same end as the male fittings of the material hoses.

NOTE:

• All signal cable connectors (24) should be 2 in. (50.8 mm) beyond the male fittings of the material hoses.

• Use electrical tape (29) to secure position of signal cable 10 in. (254 mm) back from the end of the material hose.

4. Wrap FTS Cables.

7. Use electrical tape and temporarily tape the hose and cable ends together.

8. Feed the scuff guard (26) over the female material hose fittings.

9. Use black electrical tape (29) and tape the scuff guard (26) down 10 in. from the female fittings on the material hoses. Tape at least 3 in. (76.2 mm) of scuff guard (26).

NOTE: Ensure no foam insulation is exposed on either material hose.

10. Fold the scuff guard (26) over itself and feed the remaining scuff guard over the entire length of the bundle.

11. Leave excess scuff guard (26) loose on the end with the male material fittings.

12. Remove electrical tape securing the hose and cable ends together.

13. Apply warning label (31) in the center of the bundle. Secure edges with black electrical tape (29).

NOTICE

To heat material correctly, ensure that the red electrical tape is on the A side FTS cable and the blue electrical tape is on B side FTS cable.

a. Wrap each end of one FTS cable (25) with red

electrical tape (32). This FTS cable will correspond with the A material hose.

b. For Dual Zone Heat Only: wrap each end of the

other FTS cable (25) with blue electrical tape (33). This FTS cable will correspond with the B material hose.

5. Carefully twist the material hoses, air hose (23), and cables throughout the entire bundle with a 24 in (609.6 mm) maximum pitch.

NOTE: Do not twist 5 ft and 10 ft hose bundle lengths.

6. Tightly wrap the bundle with lace (28) with an 8 in. maximum pitch. Use black electrical tape to stop the lacing 10 in. (254 mm) from the material fittings on each end of the hoses.

28 3A0237L

Dual Heat Zone Heated Hose Bundle Shown

Maintenance

male connectors

female connectors

2 in.

50.8 mm)

A Side

male fittings

2325

28 2929

4 in.

101.6 mm)

3 in. (76.2 mm)

1 in. (25.4 mm)

10 in. (254 mm)

Machine End

female fittings

18 in.

457.2 mm)

19 in. (482.6 mm)

A Side

B Side

No exposed foam permitted.

FIG. 22: Heated Hose Bundles

B Side

3A0237L 29

Parts

Whip Hoses

NOTE: A FTS assembly must connect the heated hose and whip hose. See page 35.

Dual Heat Zone Heated Whip Hose

Single Heat Zone Heated Whip Hose

8 10

B Side

A Side

B Side

30 3A0237L

A Side

Parts

Heated Whip Hoses

Ref. No. Part No. Description Qty.

Common Parts

Ref.

12‡ TAPE, electrical; red 1 13‡ TAPE, electrical; blue 1

No. Part No. Description Qty.

4★ SCUFF GUARD; 1.75 in. dia.; see

varied parts table for length

7▲✖ 15B679 LABEL, safety; A hose, B Hose,

and whip hose, English

▲✖ 16M219 LABEL, safety; A hose, B Hose,

and whip hose, Spanish/French 8‡ TAPE, electrical; black 1 9 120542 BAG, polyethylene; not shown 2 10✿ SCUFF GUARD; 1.25 in. dia.; see

varied parts table for length

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

✖ Not shown.

‡ Purchase locally.

✿ Order 24E961for replacement scuff guard. Contains

30 ft (9 m) of braided polyester mesh.

★ Order 24E954 replacement scuff guard. Contains

200 ft (60.9 m) of braided polyester mesh.

Varied Par ts

Reference Number and Description

✖

12345

Hose Assy

Stainless Steel Dual Heat Zone

24D193 5 (1.5) See Heated

24D194 10 (3) 24D171 10 (3) 261821

24D750 25 (7.6) 24D169 33 (10) 261821

24D751 50 (15.2) 24D171 56 (17) 261821

Carbon Steel Dual Heat Zone

24D195 5 (1.5) See Heated

24D196 10 (3) 24D171 10 (3) 261821

24D752 25 (7.6) 24D169 33 (10) 261821

24D753 50 (15.2) 24D171 56 (17) 261821

Carbon Steel Single Heat Zone

24D192 10 (3) See Heated

24D822 10 (3) 24D171 10 (3) 261821 (1) 261181

24E970 10 (3) 24D171 10 (3) 261821 (1)

24E971 10 (3) 24D171 10 (3) 261821 (1)

Qty.111 2 (1)1

Length

ft (m)

Red (A) Hose Blue (B) Hose

See Heated

Whip Hose,

page 4.

Whip Hose, page 4.

See Heated Whip Hose, page 4.

Air Hose and Signal Cable

Kit

24D169 9 (2.7) 261821

24D171 10 (3) 261821 (1)

Scuff Guard

Length

ft (m)

Electrical

Connector

Splice

Air Hose and Signal Cable Kits (3)

Reference Number and Description

Kit

24D169 24E953 24E900

24D171 15B280 24E899

Qty.1 1

3A0237L 31

Air Hose 5 Pin Signal Cable

Parts

Heated Hose Bundles

NOTE: A FTS assembly must connect the heated hose and whip hose. See page 35.

Dual Heat Zone Heated Hose Bundle Shown

male connectors

female connectors

2 in.

50.8 mm)

A Side

male fittings

28 2929

Machine End

2325

female fittings

A Side

B Side

32 3A0237L

B Side

Dual Zone Heated Hose Bundles

Common Parts

Parts

Ref. No. Part No. Description Qty.

26✿ SCUFF GUARD; 1.75 in. dia.; see

varied parts table for length

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

✿ Order 24E954 for replacement scuff guard. Contains

200 ft (60.9 m) of braided polyester mesh.

27 261821 CONNECTOR, electrical 2 29‡ TAPE, electrical; black 1 30✖ 120542 BAG, polyethylene 2 31▲✖ 15B679 LABEL, safety; A hose, B Hose,

✖ Not shown.

‡ Purchase locally.

and hose bundle, English

▲✖ 16M219 LABEL, safety; A hose, B Hose,

and hose bundle, Spanish/French 32‡ TAPE, electrical; red 1 33‡ TAPE, electrical; blue 1

Varied Par ts

Reference Number and Description

21 22

Hose Assy

24D108 5 (1.5) See Heated

24D109 10 (3) 15B280 24E899 24E895 10 (3) 18 (457.2)

24D110 25 (7.6) 24F179 24E898 24E894 33 (10) 45 (1143)

24D111 50 (15.2) 15B290 24E897 24E893 56 (17) 90 (2286)

24D112 5 (1.5) 24E953 24E900 24E896 9 (2.7)

24D113 10 (3) 15B280 24E899 24E895 10 (3) 18 (457.2)

24D114 25 (7.6) 24F179 24E898 24E894 33 (10) 45 (1143)

24D115 50 (15.2) 15B290 24E897 24E893 56 (17) 90 (2286)

24D116 5 (1.5) 24E953 24E900 24E896 9 (2.7)

24D117 10 (3) 15B280 24E899 24E895 10 (3) 18 (457.2)

24D118 25 (7.6) 24F179 24E898 24E894 33 (10) 45 (1143)

24D119 50 (15.2) 15B290 24E897 24E893 56 (17) 90 (2286)

24D120 5 (1.5) 24E953 24E900 24E896 9 (2.7)

24D121 10 (3) 15B280 24E899 24E895 10 (3) 18 (457.2)

24D122 25 (7.6) 24F179 24E898 24E894 33 (10) 45 (1143)

24D123 50 (15.2) 15B290 24E897 24E893 56 (17) 90 (2286)

Qty.111121see above

Length

ft (m)

Red (A) Hose Blue (B) Hose Air Hose

See Heated Hose Bundle Part Numbers,

page 3.

Hose Bundle

Part Numbers,

page 3.

23 24 25 26 28

Scuff

5 Pin

Signal

Cable

24E953 24E900 24E896 9 (2.7)

FTS

Cable

Guard

Length

ft (m)

Tie Hose

Lacing Length

in. (mm)

3A0237L 33

Parts

Single Zone Heated Hose Bundles

Common Parts

Ref. No. Part No. Description Qty.

26✿ SCUFF GUARD; 1.75 in. dia.; see

varied parts table for length

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

✿ Order 24E954 for replacement scuff guard. Contains

200 ft (60.9 m) of braided polyester mesh.

27 261821 CONNECTOR, electrical 1 29‡ TAPE, electrical; black 1 30✖ 120542 BAG, polyethylene 2 31▲✖ 15B679 LABEL, safety; A hose, B Hose,

✖ Not shown.

‡ Purchase locally.

and hose bundle, English

▲✖ 16M219 LABEL, safety; A hose, B Hose,

and hose bundle, Spanish/French 32‡ TAPE, electrical; red 1 33‡ TAPE, electrical; blue 1

Varied Par ts

Reference Number and Description

21 22

Hose Assy

24D124 25 (7.6) See Heated

24D125 50 (15.2) 15B280 24E899 24E895 56 (17) 90 (2286)

24D126 25 (7.6) 24F179 24E898 24E894 33 (10) 45 (1143)

24D127 50 (15.2) 15B290 24E897 24E893 56 (17) 90 (2286)

24D129 50 (15.2) 15B280 24E899 24E895 56 (17) 90 (2286)

24D131 50 (15.2) 15B290 24E897 24E893 56 (17) 90 (2286)

Qty.111111see above

Length

ft (m)

Red (A) Hose Blue (B) Hose Air Hose

See Heated Hose Bundle Part Numbers,

page 3.

Hose Bundle

Part Numbers,

page 3.

23 24 25 26 28

Scuff

5 Pin

Signal

Cable

24E953 24E900 24E896 33 (10) 45 (1143)

FTS

Cable

Guard

Length

ft (m)

Tie Hose

Lacing

Length

in. (mm)

34 3A0237L

Using Fluid Temperature Sensors For Single Heat Zones

258758 Carbon Steel Fluid Temperature Sensor

Fluid Temperature Sensor

Parts

Whip Hose

Heated Fluid Hose

Using Fluid Temperature Sensors for Dual Heat Zones

258757 Stainless Steel Fluid Temperature Sensor

Fluid Temperature Sensors

TI1435a

Whip Hose

TI14736b

Heated Fluid Hose

FTS Kits

Dual Heat Zones

Description

FTS, sensor, red 24F393 1

FTS, sensor, blue 24F392 1

3A0237L 35

258756

Qty.Ref.

Description

FTS, sensor, red 24F393 1

51 52 COUPLER 16C806 1

Single Heat Zones

258758

Qty.Ref.

Parts

15F144 Hose Wire Jumper

Use the 15F144 Hose Wire Jumper to heat only the major volume hose, in a wide ratio system.

To build one complete 50 ft single side heated hose bundle, order the following parts:

Ref. Part Description Qty

100 15F144 JUMPER, hose wire; includes

two 117789 electrical connectors; 50 ft (15.2 m) long

101 chart 2,

page 36 102 15B296 CABLE, FTS 1 103 15C517 HARNESS, hose jumper 1 104 261670 FLUID TEMPERATURE

105 pur-

chase

locally 106 pur-

chase

locally

Install as follows:

HOSE, resin, heated; 50 ft (15.2 m) minimum

SENSOR HOSE, hardener, unheated; 50

ft (15.2 m) minimum; customer supplied

CONNECTORS, fluid; as required to complete assembly; not shown

req’d

1. Wrap hose wire jumper (100) around resin hose (101) in a spiral fashion.

2. Connect resin hose wire (101a) to other side of Power-Lock

™

connector (100a); see page 16.

3. Wrap FTS cable (102) around resin hose (101) in a spiral fashion.

4. Twist hoses (101 and 105) together to provide strain

relief.

5. Repeat steps 1-4 for each length of hose (101). Connect hoses, electrical connectors, and cables; see , page 16.

6. Install one -Lock connector (100a) between wires;

see page 17.

7. Connect 258758, page 20.

8. Install whip hose and gun. Ensure that gun is grounded.

9. Connect hoses to proportioner.

10. Insulate and protect hoses. See Protective Cover- ing, page 22.

Hoses (101 and 105) must be sized and pressure rated to meet the requirements of your system.

Do not operate heated hose (101) at more than 45 A. If hose is cold, turn current adjustment fully counterclockwise before reheating hose.

Spray gun must be grounded.

105

100

101a

100a

101a

102

100

101

FTS

100a

TI14739a

36 3A0237L

MD2 Applicator Kits

See MD2 Valve Applicator Kits table on page 10 for kit descriptions.

MD2 Applicator Kit 24D501 Shown

Parts

153c

153a

Apply anaerobic pipe sealant.

152

B Side Hose

151

A Side Hose

153b

153a

r_24d501_3a0237_1a

MD2 Applicator Kits

Ref. Part Description Qty.

151 VALVE; see Individual Hoses on

page 5

152★ HANDLE; see MD2 Valve Applica-

tor Kits on page 10

153★ KIT, chemical connection; see parts

lists.

★ MD2 valve kits only.

See Solenoid Kits on page 38 for parts.

24F227 Ratio Check Assembly

To check spray ratio with Fusion and Graco EP guns. See manual 3A0861 for more information.

24E505 Orifice Block Kit

To balance pressures with adjustable orifices. See manual 312185 for more information.

(153) 24D162 Stainless Steel Connection Kit

Ref. Part Description Qty.

153a 121394 FITTING, elbow; SAE 06 x 1/4

153b 122961 ADAPTER, swivel; JIC 6 x 1/4 npt 1

153c 122737 ADAPTER, swivel; 1/4 npt x JIC 5 1

npt(f)

(153) 24D414 Carbon Steel Connection Kit

Ref. Part Description Qty.

153a 122969 FITTING, elbow; 1/4 npt x SAE 06 2 153b 122721 ADAPTER, swivel; JIC 6 x 1/4 npt 1 153c 122963 ADAPTER, swivel; JIC 5 x 1/4 npt 1

3A0237L 37

Accessories

Scuff Guard

Use to keep hose clean and protect it from damage.

Part Description

24E954 200 ft (60.9 m) braided polyester

mesh. Fold back over itself for easy installation.

Part Description

24E961 30 ft (9 m) braided polyester mesh.

246456 50 ft (15.2 m) polyethylene bag.

Solenoid Kits

Not all applicator kits require a solenoid kit. See Applicator Kits, page 9.

24C757 Machine Mount Kit

Fold back over itself for easy installation.

Inflate with air for easy installation.

Apply anaerobic pipe sealant to pipe threads.

Connects to applicator.

201

203

202

213

Ref. Part Description Qty.

201 120900 VALVE, solenoid, 3 way 1 202 108638 FITTING, pipe, tee 1 203 100721 PLUG, pipe 1 204 121022 FITTING, elbow, male, 1/4 npt 2 205 121021 MUFFLER, 1/4 npt 2 206 122955 HARNESS, m12 x mini din 1

206

207

212

204

209

208

205

Ref. Part Description Qty.

207 112698 ELBOW, swivel, male; 1/8 npt 2 208 115968 SCREW, cap, socket head 2 209 GC2107 WASHER, lock, spring, #8 2 212 054130 TUBING, polyethylene; 1/4 OD;

213 114339 FITTING, union, swivel, 1/4 npt; sst 1

r_24c3521_3a0237a_1b

36 ft (11 m)

38 3A0237L

24D160 Remote Mount MD2 Kit 24D161 Remote Mount Fusion Kit

204

212

211

208

206

201

Accessories

205

215

202

203

Only 24D160

213

214

207

Apply anaerobic pipe sealant to pipe threads.

Connects to applicator.

Only 24D161

Ref. Part Description Qty.

201 120900 VALVE, solenoid, 3 way 1 202 108638 FITTING, pipe, tee 1 203 100721 PLUG, pipe; for 24D160 1 204 121022 FITTING, elbow, male; 1/4 npt 2 205 121021 MUFFLER; 1/4 npt 2 206 122955 HARNESS, m12 x mini din 1 207 112698 ELBOW, swivel, male; 1/8 npt 2,3 208 120094 SCREW, pan hd, 1 209 102360 WASHER, flat 1 210 15F988 NUT, lock, hex 1 211 120953 CONNECTOR, splitter 1 212 054130 TUBING, polyethylene; 1/4 OD;

36 ft (11 m) for 24D160;

54 ft (16.5 m) for 24D161 213 15B565 VALVE, ball 1 214 116658 FITTING, tube, male; 1/4 npt;

24D161 215 114339 FITTING, union, swivel, 1/4 npt; sst 1

212

207

r_24d161_3a0237b_3b

3A0237L 39

Technical Data

Category Data

Maximum Fluid Working Pressure

Maximum Air Working Pressure

Maximum Operating Temperature

Wetted Parts Nylon, Zinc-Plated Carbon Steel,

Total Heating Load (2 hoses)

See page 3

130 psi (0.9 MPa, 9 bar)

180°F (82°C)

303 Stainless Steel, Butyl 1/4” diameter: 11 watts/foot

(36 watts/meter)

3/8’ diameter: 13 watts/foot

(43 watts/meter)

1/2” diameter: 15 watts/foot

(49 watts/meter)

40 3A0237L

Technical Data

3A0237L 41

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

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. Toll Free: 1-800-746-1334 or Fax: 330-966-3006

All written and visual data contained in this document reflects the latest product information available at the time of publication.

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

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 3A0237

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised February 2014

Graco 3A0237L User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Heated Hose Bundle Part Numbers

Fluid Temperature Sensor (FTS)

Heated Whip Hose

Individual Hoses

Applicator Kits

MD2 Valve Applicator Kits

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of Isocyanates

Foam Resins with 245 fa Blowing Agents

Changing Materials

A and B Components

Installation

Description

Connect Heated Hoses

Connect FTS and Heated Whip Hose

Connect Solenoid Kit

Check Hoses for Leaks

Protective Covering

Operation

Maintenance

Clean Orifice

Instructions for Replacing Individual A or B Hose

Bundle Individual Whip Hoses

Bundle Individual Heated Hoses

Parts

Whip Hoses

Heated Hose Bundles

Using Fluid Temperature Sensors For Single Heat Zones

Using Fluid Temperature Sensors for Dual Heat Zones

MD2 Applicator Kits

Accessories

Scuff Guard

Solenoid Kits

Technical Data

Graco Standard Warranty

Graco Information