Graco 256273 User manual

Instructions - Parts
Hopper or Hose
Heat Circulation Kit
For circulating heated water or oil through XM plural-component sprayer double wall
hoppers, heated hose, and Viscon®HP heater.
Approved for use in explosive atmospheres.
Model 256273
Includes parts needed to assemble heated hose system. Heated hose assembly and Viscon HP heater must be
ordered separately.
See Technical Data on page 24 for Maximum
Working Pressure and Temperature Rating infor-
mation.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
r_256273_313259_1b
313259B
ENG

Related Manuals
2313259B
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heated Hopper or Hose Circulation Kit 256273 . . 5
Heated Hose Assembly . . . . . . . . . . . . . . . . . . . . 5
Hazardous Location Heaters . . . . . . . . . . . . . . . 6
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tubing Lengths . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connecting Additional Hose Lengths . . . . . . . . 17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 26
Related Manuals
Manual Description
312359 XM Operation
313289 XM Repair
313292 XM OEM, Instructions-Parts
312747 Double Wall Hopper, Instructions-Parts
309524 Viscon®HP Heater
308981 Husky™716 Diaphragm Pump

Warnings
313259B 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNINGWARNINGWARNING
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.

Warnings
4313259B
WARNINGWARNINGWARNING
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
•FollowPressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection

Heated Hopper or Hose Circulation Kit 256273
313259B 5
Heated Hopper or Hose Circulation Kit 256273
The kit described in this manual; includes all miscellaneous parts needed to assemble the system. There are three
options for using circulation kit 256273:
• Circulate water through the heater and only the hop-
pers. See page 8.
• Circulate water through the heater, hoppers, and
heated hose. See page 10.
• Circulate water through the heater and only the
heated hose. See page 12.
Heated Hose Assembly
Order separately a heated hose assembly that meets maximum pressure and hose diameter requirements. You can
connect up to six 50 ft. (15.2 m) heated hose sections for a maximum total length of 300 ft. (91.4 m). See manual
309525.
Single Hose Assemblies
Dual Hose Assemblies
A B
C D
Dual Hose Assembly
AB
Single Hose Assembly
Part Maximum
Pressure Rating
psi (MPa, bar)
Hose Diameter
in. (mm)
Thread A
npt(m)
Thread B
npsm(f)
Approvals
245840 5000 psi (34, 345) 1/4 (6.35) 1/4 1/4
245841 7400 psi (51, 510) 1/4 (6.35) 1/4 1/4
245842 5000 psi (34, 345) 3/8 (9.53) 3/8 3/8
245843 7400 psi (51, 510) 3/8 (9.53) 3/8 3/8
245844 5000 psi (34, 345) 1/2 (12.7) 1/2 1/2
245845 7400 psi (51, 510) 1/2 (12.7) 1/2 1/2
II 2 G
Part Maximum
Pressure Rating
psi (MPa, bar)
Hose Diameter
in. (mm)
Thread A
npt(m)
Thread B
npsm(f)
Thread C
npt(m)
Thread D
npsm(f)
Approvals
248118 7400 psi (51, 510) 1/2 (12.7) 1/2 1/2 1/2 1/2
248119 7400 psi (51, 510) 3/8 (9.53) 3/8 3/8 3/8 3/8
248120 7400 psi (51, 510) A = 1/2 (12.7)
B = 3/8 (9.53)
1/21/23/83/8
248121 7400 psi (51, 510) A = 3/8 (9.53)
B = 1/4 (6.35)
3/83/81/41/4 II 2 G

Heated Hopper or Hose Circulation Kit 256273
6313259B
Hazardous Location Heaters
Part No. Series VAC (50/60 Hz single phase) / Watts / Amps Approvals
245848 A 120 / 2300 / 19.2
Approved Exd II T2 482°F (250°C)
Certificate No. ISSeP 07ATEX034X
Approved to EN 60079-0:2006 (IEC 60079-0:2004)
and EN 60079-1:2007 (IEC 60079-1:2007) for
Hazardous Locations, Temp Code T2 482°F
(250°C). See Technical Data, page 24, for
additional information.
CSA Certified and FM Approved as flame proof for
Class I, Division 1, Group D Hazardous Locations,
Temp Code T2 482°F (250°C), -20°C < T amb <
135°F (57°C). See Technical Data, page 24, for
additional information.
245863 A 240 / 4000 / 16.7
245864 A 480 / 4000 / 8.30
245862 A 200 / 4000 / 20.0
Approved Exd II T2 482°F (250°C)
Certificate No. ISSeP 07ATEX034X
Approved to EN 60079-0:2006 (IEC 60079-0:2004)
and EN 60079-1:2007 (IEC 60079-1:2007) for
Hazardous Locations, Temp Code T2 482°F
(250°C). See Technical Data, page 24, for
additional information.
CSA Certified as flame proof for Class I, Division 1,
Group D Hazardous Locations, Temp Code T2
482°F (250°C), -20°C < T amb < 135°F (57°C). See
Technical Data, page 24, for additional information.
246254 A 380 / 4000 / 10.5
II 2 G
II 2 G

Heated Hopper or Hose Circulation Kit 256273
313259B 7

Typical Installation
8313259B
Typical Installation
Key:
A Viscon HP Heater
B Husky diaphragm pump
C Hopper
DFrame
E Fluid circulation tubing
NOTE:
See FIG. 2 on page 9 for fluid schematic of heated fluid.
FIG. 1: Heat Only Hoppers Configuration
C
A
C
B
E
E
E
D
r_256273_313259_1b

Typical Installation
313259B 9
FIG. 2: Fluid schematic for only heating hoppers
Back-Mounted Hoppers (BM)
Side-Mounted Hoppers (SM)
Table 1: Tubing Lengths
Section Tubing
(BM) Hoppers
in (mm)
(SM) Hoppers
in (mm)
AA 1/2 in. 65 (1651) 50 (1270)
AB 51 (1295.4) 35 (889)
AC 7 (177.8) 4 (101.6)
BA 3/4 in. 40 (1016) 36 (914.4)
BB 29 (736.6) 17 (431.8)
BC 7 (177.8) 7 (177.8)
CA 3/8 in. 21 (533.4) 21 (533.4)
CA
AB
AA
BA BA
AC BC
AA AB
AC
BC
CA
BA
BB

Typical Installation
10 313259B
Key:
A Viscon HP Heater
B Husky diaphragm pump
C Hopper
DFrame
E Fluid circulation tubing
F Heated hose tee fittings (see heated hose connections on
page FIG. 5 and FIG. 6 on page 12 and 13.)
NOTE:
See FIG. 6 on page 13 for fluid schematic of heated fluid.
FIG. 3: Hoppers and Heated Hose Configuration
C
A
C
B
D
E
E
E
E
F
r_256273_313259_3a

Typical Installation
313259B 11
See page 9 for tubing lengths with side-mounted hoppers (SM) and back-mounted hoppers (BM).
FIG. 4: Fluid schematic for heating hoppers and heated hose
21 in. (533.4 mm)
27 in.
(685.8 mm)
23 in. (584.2 mm)
r_256273_313259_12
To Red Tubing
To Blue Tubing
(SM, BM)
(SM, BM)
(SM, BM)
(SM, BM)
(SM, BM)

Typical Installation
12 313259B
Key:
A Viscon HP heater
B Husky diaphragm pump
C Hopper (not shown)
DFrame
E Fluid circulation tubing
F Heated hose tee fitting (to red tubing)
G Return hose tee fitting (from blue tubing)
H Recirculation valve
J Heated hose assembly (purchase separately)
K Overflow tank (used for only heated hose configuration)
NOTE:
See FIG. 6 on page 13 for fluid schematic of heated fluid.
FIG. 5: Heated Hose Only Configuration
A
B
D
E
G
F
J
K
H
H
F
G
G
F
r_256273_313259_13a
Heated Water Fluid Flow

Typical Installation
313259B 13
FIG. 6: Fluid schematic for heated hose
RED
BLUE
G
F
Single Hose Shown
23 in.
(584.2 mm)
38 in.
(965.2 mm)
24 in.
(609.6 mm)

Installation
14 313259B
Installation
Grounding
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
1. Remove grounding screw on diaphragm pump (3)
and tighten ring terminal on grounding cable (15)
under ground screw.
2. Loosen grounding lug locknut (W) on back of control
box. Insert ground wire end (Y) into lug slot and
tighten locknut securely.
Tubing Lengths
The length of tubing (4, 16, 29) is determined by the
hopper mounting configuration and heating choices.
Reference the fluid schematic, from the configurations
listed below, to find the tubing lengths.
• Heating hoppers only. See FIG. 2 on page 9.
• Heating hoses only. See FIG. 6 on page 13.
• Heating hoppers and hoses. See FIG. 4 on page 11.
Cut tubing to length specified in fluid schematics.
1. Use tubing cutter to cut tubing (4) squarely to
desired lengths.
NOTE: To ensure a leak-proof seal, apply PTFE tape
on all npt threads.
2. Insert tubing through the back of the nut in each of
the plastic fittings (7) until the tube stops. Tighten
the nut hand tight, then tighten it to 1-1/2 to 2 turns
with a wrench.
Install
1. Mount bracket (1) on XM frame (D) using screws
(5).
15
Y
r_256273_313259_9
Y
W
r_256273_313259_10
3
5
1
D
r_256273_313259_5

Installation
313259B 15
2. For only heating hoppers or heating hoppers
and heated hose:
a. Remove 3/4 npt plugs from the end of the fluid
manifold and place in center.
b. Install tube fitting (31) in fluid inlet.
c. Install bushing (12) and tube fitting (17) to dia-
phragm pump fluid outlet. See FIG. 7.
3. For heating heated hose only:
a. Remove 3/4 npt plugs from the end of the fluid
manifold and place in center.
b. Install elbow (20), mounting fitting (23), o-ring
(22) and 1.5 gallon reservoir tank (21) on dia-
phragm pump fluid inlet. See FIG. 8.
c. Connect elbow fitting (7) to mounting fitting (23).
d. Install bushing (12) and elbow fitting (17) on dia-
phragm pump (3) fluid outlet.
4. Mount pump (3) on mounting bracket with four
screws (2). See FIG. 7 on page 15.
5. Connect nipple (10), air regulator/gauge (9), and fit-
ting (19) to pump (3).
6. Remove plug on XM air control supply and connect
fitting (19) in place of the plug. Connect hose (27)
between fitting (19) on 100 psi (0.7 MPa, 7 bar) XM
air supply and fitting (19) on the air regulator/gauge
(9). See FIG. 7 on page 15 or FIG. 8. Refer to Husky
716 manual 308981 if needed.
NOTE:
The air regulator (9) controls pump pressure.
FIG. 7: Pump installation for only heating hoppers or
heating hoppers and heated hose
9
12
17
31
10
19
3
2
FIG. 8: Pump installation for heating heated hose
21
20
23
7
12
17
9
10
19
22
r_256273_313259_15
3

Installation
16 313259B
7. Slide Viscon HP heater (A) into slots on XM frame.
Tighten bolts to secure to frame.
8. For heating hoppers or heating hoppers and
heated hose: install fitting (18) and elbow (17) in
the heater’s fluid inlet facing away from the XM
sprayer. Install elbow (7) in heater outlet facing the
back of the XM sprayer.
9. For heating heated hose only:connect elbow fit-
ting (17) to heater fluid inlet facing the back of the
XM sprayer. Install elbow (7) in the heater’s fluid out-
let facing upward.
10. Wire Viscon HP heater (B) to your voltage supply.
Follow wiring procedure in the Viscon HP manual
309524.
11. If heating hoppers, remove bottom plug (P) from
hopper (C). Install elbows (32) and fittings (31).
Repeat for second hopper.
12. Remove side plug (P) used for fluid inlet.
13. Replace plug with bushing (6) and elbow fitting (7).
14. Cut tubing (4, 16, 29). See Tubing Lengths on
page 14.
NOTE:
Fitting nuts may need retightening as the system
reaches normal operating temperatures.
FIG. 9
FIG. 10
A
r_256273_313259_7
r_256273_313259_16a
18
17
7
r_256273_313259_17a
17
All wiring must be done by a qualified electrician. See
warnings, page 3.
P
P
76
32
C
r_256273_313259_8
31

Installation
313259B 17
Setup
For heating hoppers only:
See fluid schematic on page 9 and parts on page 21.
NOTE: To ensure a leak-proof seal, use PTFE tape
on all pipe thread connections.
1. Connect A and B fluid hoses to shutoff check valve
outlets (H).
2. Connect bushing (12) and elbow fitting (17) in pump
outlet (3) and elbow fitting (17) on heater inlet (A)
with tubing (16).
3. Connect fitting (7) in the heater fluid outlet (A) and
tee fitting (13) with tubing (4). Connect tee fitting
(13) and fittings (7) in the hopper side ports with tub-
ing (4).
4. Connect fittings (31) to elbow in bottom outlet of
hoppers and tee fitting (30) with tubing (29). Con-
nect tee fitting (30) and the pump (3) inlet fitting (31)
with tubing (29).
For heating heated hose only:
See fluid schematic on page 13 and parts on page 22.
1. Connect A and B fluid hoses to shutoff check valve
fluid outlets (H).
2. Connect bushing (12) and elbow fitting (17) in pump
outlet (3) and elbow fitting (17) on heater inlet (A)
with tubing (16).
3. Connect fitting (7) in the heater fluid outlet (A) and
tee fitting (13) with tubing (4).
4. Connect tee fittings (13) to recirculation inlets and
recirculation outlet of heated hose. See FIG. 11.
5. Connect elbow fitting (7) to 1-1/2 gallon tank mani-
fold (23) with tubing (4).
For heating hoppers and heated hose:
See fluid schematic on page 11 and parts on page 20.
1. Connect A and B fluid hoses to shutoff check valve
outlets (H).
2. Connect bushing (12) and elbow fitting (17) in pump
outlet (3) and elbow fitting (17) on heater inlet (A)
with tubing (16).
3. Connect fitting (7) in the heater fluid outlet (A) and
tee fitting (13) to hose circulation inlet with tubing
(4).
4. Connect tee fitting (13) from hose circulation return
to tee fitting (13) with tubing (4).
5. Connect tee fitting (13) and fittings (7) in the hopper
side ports with tubing (4).
6. Connect fittings (31) to elbow in bottom outlet of
hoppers and tee fitting (30) with tubing (29). Con-
nect tee fitting (30) and the pump (3) inlet fitting (31)
with tubing (29).
Connecting Additional Hose
Lengths
Up to six 50 ft. (15.2 m) sections of heated hose can be
attached for a maximum total length of 300 ft. (91.4 m).
1. Remove plastic u-turn fittings at the end of the
heated hose assembly.
2. Connect the next length of hose, using union fittings
supplied with the hose.
3. Tubes are color coded. Connect like colors.
FIG. 11: Recirculation Inlet and Outlet Connections
NOTICE
To prevent cross-contamination, ensure you connect
“A” side fluid hose to “A” side fluid hose on additional
heated hose.
13
Hopper Inlet or
1-1/2 gallon tank
manifold
13
Heater Outlet

Operation
18 313259B
Operation
1. Select fluid to use for heating circulation.
• 50% water and 50% ethylene glycol mixture is
recommended for fastest heat-up time and pre-
vention of algae build-up regardless of ambient
temperature.
• Oil can be used but heat-up time will increase
and the hopper fill level must be decreased. See
item 2.
NOTE:
Detailed diaphragm pump operating instructions are in
the Husky 716 diaphragm pump manual 308981.
2. Fill Heating Fluid in double wall hopper (C) outer
cavity. See manual 312747 for instructions.
NOTE:
If using heated hose: each 50 ft. (15.2 m) heated
hose section holds approximately 1.25 gal. (4.7
liters) of fluid.
3. Set the flow rate of the circulation fluid by adjusting
the pump’s air regulator (7) until the pump cycles
about 50 cycles/min. Do not use a higher flow rate
as doing so will decrease system heating perfor-
mance and pump life. Never exceed the hose’s 95
psi (0.6 MPa, 6.6 bar) maximum working pressure
rating.
4. Adjust the heater thermostat to the desired circula-
tion temperature. The setting at the heater output
thermometer should be about 10° F (6° C) higher
than the desired paint temperature. Never exceed
the hose’s 140° F (60° C) maximum temperature
rating.See Viscon HP heater manual 309524 for
instructions.
NOTE:
If the hose is not being used for more than one hour,
shut off Viscon HP heater and pump to lengthen heater
life.
NOTICE
If oil is the heating fluid selected, the maximum oil
level must be 3 in. (76.2 mm) below the hopper side
port level. A higher fluid level may cause the oil to
overflow during initial pump and heater startup.

Maintenance
313259B 19
Maintenance
• Check double wall hopper heating fluid level
monthly. Add fluid as needed.
•Do not overfill when using oil. See overfilling
notice on page 18.
• Follow pump maintenance instructions in Husky 716
diaphragm pump manual 308981.
• Follow heater maintenance instructions in Viscon
HP manual 309524.
Troubleshooting
Problem Cause Solution
Fluid fittings leaking. Loose fittings. Tighten fittings after system reaches
desired temperature.
Hose not heating to desired tempera-
ture.
Diaphragm flow rate set too high. Decrease diaphragm pump flow rate
to 50 cycles/min.
Problem with Viscon HP heater. See troubleshooting in Viscon HP
heater manual 309524.
Diaphragm pump not operating cor-
rectly.
See troubleshooting in Husky 716
diaphragm pump manual 308981.
Oil overflowing out vented hopper
side fill port during startup.
Oil level higher than 3 in. (76.2 mm)
below fill port at room temperature
and at rest.
Lower oil level to 3 in. (76.2) below
hopper fill port.
Hopper not reaching set temperature
when heating fluid hose first.
Temperature loss in heated hose is
too much for the heater capacity to
compensate for.
Allow longer heating time. Insulate
heated hose bundle.
Air and heating fluid splatter is exiting
hopper vented fitting.
Diaphragm in Husky 716 diaphragm
pump is cracked.
Replace pump diaphragm. See man-
ual 308981 for parts.

Parts
20 313259B
Parts
256273, Heated Hopper or Hose Circulation Kit
For heating hoppers and heated hose
To Red Tubing
To Blue Tubing
7, 11 7, 11
13
13 13
32, 31
32, 31
30
44
16
29
29
44
Cut tubing to length. See table on page 9.
See Heater and Diaphragm Pump (3) Connections on page 22.
1
2
1
2
1
1
1
11
1
1
29 1