Installation. Graco 3A0237E - Heated Hoses and Applicator Kits

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Installation. Graco 3A0237E - Heated Hoses and Applicator Kits | Manualzz

Installation

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.

Tighten

Tighten

F IG . 1: Fusion Gun

Connect Whip Hose to Gun or

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 IG

. 1 and F IG . 2.

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 IG . 2.

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.

153c

153a

B Side Hose

E1

F IG . 2: MD2 Valve Kit 24D501

Tighten

3b

A Side Hose

153b

153a r_24d501_3a0237_1a

14 3A0237E

Installation

Connect Heated Hoses

4.

Connect air hoses (C).

Single Heat Zone with A and B Heated Hose

D

1.

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

B

C

TI14733a

Dual Heat Zone with A and B Heated Hose

D

A

F IG . 3

2.

Connect fluid hoses (A, B).

3.

Connect signal cables (13).

TI14731a

C

TI15097a

D

Single Heat Zone with A or B Heated Hose

D

B

C

TI15140a D

F IG . 5

A

13 TI14732a

F IG . 4

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

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

This illustration is not to scale.

5/8 in.

(0.625 mm)

TI9733a

F

IG

. 6

3A0237E 15

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

a.

Insert one wire from heated hose into connector. Ensure that ferrule is mating with connector insert. See F IG . 9.

TI9770A

F IG . 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.

Correct

Incorrect

TI9768a

F IG . 7 c.

Remove ferrule and apply oxide inhibitor to bare wire. See F IG . 8.

d.

Reinsert wire in ferrule and apply more oxide inhibitor to ferrule and wire end.

F

IG

. 8

TI9769A

TI9779A

F 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 F IG . 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.

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.

16 3A0237E

f.

Insert cap plugs over setscrews. See F

IG

. 11.

Cap plugs

Setscrews

TI9771A

F IG . 11 g.

Wrap connector and wire on each side of connector 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.

F

G

TI14734a

F IG . 12

8.

Repeat for additional hoses.

9.

See Connect FTS and Heated Whip Hose, page

18.

Installation

3A0237E 17

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.

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 19 for installation

instructions.

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.

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 20.

2.

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

D B

Single Zone Heat K

To Gun

J

R

F

To Proportioner

G

Dual Zone Heat

F

B

A H

24

C

K

3b

A

W

L

24D160 or 24D161, page 19

ti14735a

D

B

To Gun

R J

G

To Proportioner

F IG . 13: FTS Connections

18

D

B

A

D

24

H

C

W

3b

A

D

L

24D160 or 24D161, page 19

ti14736b

3A0237E

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).

213

202

207 212 214

203 r_24D161_3a0237B_2b

F IG . 15

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.

3.

Connect the wire harness (206) and signal cable

(3b) from the whip hose to the splitter (211).

206

207

206

3b

205

208

212 210

209

202

215 205

201

204 r_24D161_3a0237b_1b

F IG . 16

201

211

24 r_24D160_3a0237b_1b

F IG . 14

C

3A0237E 19

Installation

4.

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

(209).

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.

M

GD

N

206

P

TI14737b

209

208

201 r_24c352_3A0237_2a

F IG . 17

5.

Remove motor cover and connect solenoid cable

(206) to cable (2B).

2B

F IG . 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.

Protective Covering

1.

Wrap all fluid hose connections with electrical tape.

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.

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.

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 IG . 18.

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).

TI14738a

F 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.

20 3A0237E

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