Graco InvisiPac GS35 Plug-Free Operation manual

Instructions-Parts
InvisiPac® GS35 Plug-Free™
Hot Melt Applicator
3A2805K
EN
For dispensing hot melt adhesive. For professional use only. Not for use in waterwash
environments.
Not approved for use in explosive atmospheres or hazardous locations.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these
instructions.
1500 psi (10.3 MPa, 103 bar) Maximum
Working Fluid Pressure
80 psi (0.5 MPa, 5.5 bar) Maximum Air
Pressure
See page 6 for models and
approval information.
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Contents
Warnings ........................................................... 3
Approvals........................................................... 5
Models............................................................... 6
Component Identification..................................... 7
verview............................................................ 8
Grounding.......................................................... 8
Installation.......................................................... 9
Mounting ..................................................... 9
Connect Heated Hose.................................. 9
Connect Solenoid Valve ............................... 9
Connect Triggering Device ........................... 10
Prime Before Using Equipment..................... 10
Flush........................................................... 11
Install Nozzle............................................... 11
Select RTD.................................................. 11
peration........................................................... 12
Pressure Relief Procedure............................ 12
Maintenance ...................................................... 13
Replace Inlet Filter....................................... 13
Filter Maintenance Guidelines....................... 13
Troubleshooting.................................................. 14
Check Module.............................................. 16
Check Nozzle and Module............................ 16
Check Heater .............................................. 17
Check RTD.................................................. 17
Check Thermal Cutoff .................................. 18
Repair................................................................ 19
Before Beginning Repair............................... 19
Replace Heater Cartridge............................. 20
Replace RTD............................................... 20
Replace Thermal Cutoff................................ 20
Replace Cordset.......................................... 22
Replace Solenoid Valve ............................... 24
Replace Module........................................... 24
Replace Applicator....................................... 24
Notes ................................................................ 25
Parts.................................................................. 26
Kits and Accessories........................................... 44
Dimensions........................................................ 46
Technical Data ................................................... 50
Notes ................................................................ 51
Graco Extended Warranty................................... 52
23A2805
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Warnings
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 symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
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.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, 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. et
immediate surgical treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
•Followthe Pressure Relief Procedure when you stop dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
3A2805 3
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Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area canigniteorexplode.Tohelp
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 rounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock . 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. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• 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.
43A2805

Approvals
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.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
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.
Approvals
4002346
Conforms to ANSI/UL Std.
499 Certified to CAN/CSA
Std. C22.2 No. 88
3A2805 5

Models
Models
All models use a 240 V heater. Additional
configurations are available. Contact Graco customer
service for details.
Note
Applicators with Ni 120 RTD types come with
a 6–pin rectangular cordset (24W088). See
Parts, page 26.
Single
Part Series RTD Type Solenoid Valve
24P073 B Pt 100 (385) 24 VDC
24P074 B Pt 100 (385) 110 VAC
24P246 B Pt 100 (385) None
24P299 B Ni 120 24 VDC
24P300 B Ni 120 110 VAC
24P307 B Ni 120 None
Slim (Single)
Part Series RTD Type Solenoid Valve
24U021 B Pt 100 (385) 24 VDC
24U022 B Pt 100 (385) 110 VAC
24U023 B Pt 100 (385) None
24U024 B Ni 120 24 VDC
24U025 B Ni 120 110 VAC
24U026 B Ni 120 None
Dual
Part Series RTD Type Solenoid Valve
24P075 B Pt 100 (385) 24 VDC
24P076 B Pt 100 (385) 110 VAC
24P247 B Pt 100 (385) None
24P301 B Ni 120 24 VDC
24P302 B Ni 120 110 VAC
24P308 B Ni 120 None
Low Profile - Dual
Part Series RTD Type Solenoid Valve
24U027 B Pt 100 (385) 24 VDC
24U028 B Pt 100 (385) 110 VAC
24U029 B Pt 100 (385) None
24U030 B Ni 120 24 VDC
24U031 B Ni 120 110 VAC
24U032 B Ni 120 None
Quad
Part Series Module
Spacing
Type*
RTD Type Solenoid
Valve
24P077 B I Pt 100 (385) 24 VDC
24P078 B I Pt 100 (385) 110 VAC
24P079 B II Pt 100 (385) 24 VDC
24P080 B II Pt 100 (385) 110 VAC
24P250 B I Pt 100 (385) None
24P254 B II Pt 100 (385) None
24P303 B I Ni 120 24 VDC
24P304 B I Ni 120 110 VAC
24P305 B II Ni 120 24 VDC
24P306 B II Ni 120 110 VAC
24P309 B I Ni 120 None
24P310 B II Ni 120 None
* See Dimensions, page 46.
Low Profile - Quad
Part Series RTD Type Solenoid Valve
24U033 B Pt 100 (385) 24 VDC
24U034 B Pt 100 (385) 110 VAC
24U035 B Pt 100 (385) None
24U036 B Ni 120 24 VDC
24U037 B Ni 120 110 VAC
24U038 B Ni 120 None
63A2805

Component Identification
Component Identification
Figure 1 24P075 Shown
A Dispense module
BFluid outlet/nozzle (3/8–24)
C Fluid filter (not visible)
DManifold
EFluid inlet (9/16–18, —6 JIC, 37° flare)
FCordset (24W087 shown)
GAir tube
HMounting clamp (1/2 in. diameter bar)
JSolenoid valve (24 VDC, 110 VAC); not
included with all models
KMuffler
LAir inlet (3/8 in. diameter tubing)
M Manual override switch
NSolenoid valve electrical connector
P Insulator
3A2805 7

Overview
Overview
The valve uses the air-opened, spring closed mode
of operation. It uses a three-way exhausting solenoid
to control the piston inside the dispense module.
Fluid is filtered through the manifold filter (C) before
entering the dispense module fluid inlet port. Then
the fluid is filtered one final time through the module
filter (P), which is located in each module, directly
before the ball and seat.
When air moves the piston rod and ball from its seat,
it opens the fluid outlet. When the air shuts off, the
spring pushes the piston rod and ball into its seat and
closes the fluid outlet.
The gun should be rigidly mounted and remotely
operated by a melter system and triggering device.
The melter system provides pressurized fluid to the
valve. The triggering device controls the fluid flow by
opening and closing the solenoid valve.
Figure 2 Air and Fluid Flow
Air
Fluid
Grounding
The equipment must be grounded to reduce the
risk of static sparking. Static sparking can cause
fumes to ignite or explode. Grounding provides an
escape wire for the electric current.
• Pump: follow manufacturer’s recommendations.
• Dispense applicator: grounded through electrical
connection.
• Air compressor: follow manufacturer’s
recommendations.
• Fluid supply container: follow local code.
• Solvent pails used when flushing: follow local
code. Use only conductive metal pails, placed
onagroundedsurface. Donotplacethepail
on a nonconductive surface, such as paper or
cardboard, which interrupts grounding continuity.
• To maintain grounding continuity when flushing or
relieving pressure: ensure mounting manifold and
electrical power connector are grounded properly.
83A2805

Installation
Installation
Mounting
NOTICE
To prevent heat transferring into other components
of the packaging line, ensure that the insulator (P)
is installed.
Low Profile Models: Usea3/4in.(19mm)wrenchto
adjust nuts that control position of gun assembly on
threaded rod.
All Other Models: See the following instructions.
Mount manifold on a 1/2 in. (12 mm) diameter bar
using mounting clamp (H) to hold the gun assembly
in place and ensure adhesive is applied properly.
1. Use a 5 mm Allen wrench to loosen the mounting
clamp and slide the gun assembly on the
mounting bar.
2. Tighten the mounting clamp.
Note
Provide enough room to access sides of
applicator for maintenance and repair.
Figure 3 Mounting Clamp
Connect Heated Hose
1. Connect the hose fluid outlet to the manifold fluid
inlet (E). Use two 11/16 in. wrenches to tighten
the hose fitting.
Figure 4 Connect the Heated Hose
2. Connect the cordset (M) to the hose.
3. Connect the hose inlet to the melter system
outlet. See the heated hose manual for
installation guidelines.
4. Connect the hose cordset to melter. See the
heated hose manual for installation guidelines.
Connect Solenoid Valve
1. Connect 3/8 in. diameter air supply tubing to a
clean, dry, and non-lubricated air supply and to
the push-to-connect air inlet fitting (L).
Figure 5 Air Inlet Fitting
2. Connect solenoid valve to 24 VDC or 110 VAC
signal. See Connect Triggering Device, page 10.
For applicators without a supplied solenoid valve:
• Use solenoid valves with an override switch.
• Ensure that your solenoid valve is connected to the
manifold with tubing rated for 400°F(204°C).
• Ensure the solenoid valve is rated for
high-temperature applications.
3A2805 9

Installation
Connect Triggering Device
Identify if your model uses a 24 VDC or 110 VAC
solenoid valve. Connect solenoid valve to 24 VDC
or 110 VAC signal.
Improper electrical connection can result in electric
shock. All electrical wiring must be done by a
qualified electrician and comply with all local codes
and regulations.
1. Loosen the mounting screw and disconnect the
electrical connector (N) from the solenoid valve
(J). Set the gasket and screw aside.
Figure 6 Solenoid Valve Electrical Connector
2. Insert a small screwdriver where the mounting
screw was removed and gently press the
electrical connector (P) out of the electrical
connector housing (N).
3. Thread a three-conductor cable through the strain
relief. Connect the positive and negative wires to
terminals 1 and 2 on the electrical connector (P).
Connect the ground wire to the ground terminal.
Note
It does not matter which terminal
the positive and negative wires are
connected to.
21
GND
Solenoid Valve Connector
Figure 7
4. Reassemble the electrical connector (P) and
housing (N). Retighten strain relief.
5. Place the gasket on the housing and connect the
electrical connector into the solenoid valve (J)
with the mounting screw. See Fig. 6.
Prime efore Using Equipment
The equipment was tested with oil, which is left in the
fluid passages to protect parts. Prime the equipment
with hot melt until all of the oil is pushed out before
using the equipment. See Flush, page 11.
10 3A2805

Installation
Flush
1. Disconnect or turn off the device which triggers
the solenoid valve.
2. Heat the system to working temperature.
3. Place waste container under the gun to catch the
adhesive.
4. Ensure the nozzle is removed.
5. Press the manual override switch (S) to manually
trigger the solenoid valve.
6. Dispense hot melt (adhesive) until it is clean.
Figure 8
Install Nozzle
Use 1/2 in. wrench to install nozzle. See
Kits and Accessories, page 44.
Select RTD
Note
For InvisiPac systems only.
Identify RTD type used in applicator on the system
Advanced Display Module (ADM). The RTD type is
listed on the manifold cover plate. See the InvisiPac
system manual for instructions to configure this
setting.
NOTICE
An incorrect RTD setting will cause the system
to be incapable of maintaining the temperature
setting. The applicator may overheat and trip the
thermal cutoff, if the applicator uses a PT 100 (385)
and NI 120 is selected on the ADM Setup screen.
The applicator may under-heat if the applicator
uses a NI 120 and PT 100 (385) is selected on the
ADM Setup screen.
• If PT 100 (385) is listed, select PT 100 (385) in the
ADM Setup screens.
• If NI 120 is listed, select NI 120 in the ADM Setup
screens.
3A2805 11

Operation
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized fluid, such as skin injection,
and splashing fluid, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
1. Depressurize system.
2. Close the bleed-type master air valve.
3. Actuate the applicator repeatedly until no fluid
flows.
Material inside the module and hose may still
be near setpoint temperature. Wear protective
clothing to avoid severe burns.
4. If you suspect the module nozzle is clogged,
remove nozzle and then actuate the module to
relieve pressure.
5. If you suspect the module or fluid hose is
clogged or that pressure has not been fully
relieved after following the steps above, VERY
SL WLY loosen inlet fitting, inlet filter, or hose
end coupling to relieve pressure gradually,
then loosen completely. Clear hose or module
obstruction.
6. Turn off air pressure to the solenoid valve.
12 3A2805

Maintenance
Maintenance
Material inside the applicator can be near setpoint
temperature. Wear protective clothing to avoid
severe burns.
Daily:
Clean hot melt from exterior of gun.
Weekly:
Inspect the applicator, fluid lines, cordset,
and solenoid cable for wear or damage. See
Repair, page 19 for instructions.
Replace Inlet Filter
NOTICE
Remove the filter when the gun is hot. If the gun is
cold, the adhesive will be hard and the filter may
be difficult to remove or damaged.
1. Disable gun assembly. See
Before Beginning Repair, page 19.
Material inside the applicator can be near
setpoint temperature. Wear protective clothing
to avoid severe burns.
2. Remove dirty filter (16) from manifold (1).
Figure 9 Inlet Filter
3. Apply a thin coating of high-temperature lubricant
to seals on the new filter (16) and install in the
manifold (1). Torque to 30 in.-lbs (3.4 N∙m),
using a 5/32 in. (4 mm) Allen wrench.
Filter Maintenance Guidelines
These recommendations are service level guidelines
- actual service levels required in your factory
will vary based on environmental and operating
conditions. High or low volume adhesive usage, as
well as adhesives that contain a powered release
agent or are otherwise dusty, will have an impact
on the frequency of filter maintenance. To establish
a preventative maintenance cycle tailored to your
environment, Graco recommends inspecting filters
every 4 weeks after installation and replacing when
necessary. Document replacement intervals and
use this as your preventative maintenance schedule
moving forward.
Environment Classification
Clean Moderate Dusty
Gun
manifold
filter
Solenoid
exhaust
filters
Replace
filter every
six months
Replace
filter
every four
months
Replace
filter
every two
months
3A2805 13

Troubleshooting
Troubleshooting
Problem Cause Solution
Debris in manifold filter Replace manifold filter. See
Replace Inlet Filter, page 13.
Clogged hose Clean or replace hose.
Failed solenoid valve Check for correct operation. Clean
or replace.
No signal to solenoid valve Check solenoid valve for correct
operation.
Incorrect solenoid valve wiring Check solenoid valve wiring.
Incorrect signal to solenoid valve Check if 24 VDC or 120 VAC.
Solenoid muffler plugged Check and replace mufflers.
No fluid pressure Check adhesive delivery system.
Heater failure (cold gun) Check and replace
heater cartridges. See
Replace Heater Cartridge, page 20.
No air to solenoid valve Check air supply.
Dirty or faulty triggering device Check, clean, or replace triggering
device.
Solenoid valve connected
incorrectly Check solenoid valve air connections.
No adhesive or incorrect
amount of adhesive out of all
modules when triggered
Clogged manifold passage Clean or replace manifold.
Debris in nozzle Clean or replace nozzle.
Failed module in closed position Check for correct operation.
Clean or replace. See
Check Module, page 16.
Debris in module filter Replace module. See
Replace Module, page 24.
No adhesive or incorrect
amount of adhesive out of
one/some modules when
triggered
Clogged manifold passage Clean or replace manifold.
Failed module in open position Clean or replace module. See
Replace Module, page 24.
Adhesive out of one/some
modules when not triggered
Adhesive pressure too high Check and reduce fluid pressure.
14 3A2805

Troubleshooting
Problem Cause Solution
Heater failure Check and replace
heater cartridge. See
Replace Heater Cartridge, page 20.
Loose cord set connection Check connection.
RTD failure Check and replace RTD. See
Check RTD, page 17.
Incorrect RTD for adhesive delivery
system Check delivery system RTD requirement
Thermal cutoff failure Check and replace
thermal cutoff. See
Replace Thermal Cutoff, page 20.
Gun will not heat
Wrong RTD type selected Check RTD type settings on the
system. Change if necessary. See
Select RTD, page 11.
Heater failure Check and replace
heater cartridge. See
Replace Heater Cartridge, page 20.
RTD failure Check and replace RTD. See
Check RTD, page 17.
Incorrect RTD for adhesive delivery
system Check delivery system RTD requirement.
Incorrect power to heater Check and correct power.
Gun overheats
Wrong RTD type selected Check RTD type settings on the
system. Change if necessary. See
Select RTD, page 11.
Heater failure Check and replace
heater cartridge. See
Replace Heater Cartridge, page 20
RTD failure Check and replace RTD.
Incorrect RTD for adhesive delivery
system Check delivery system RTD requirement.
Incorrect power to heater Check and correct power.
Gun under-heats
Wrong RTD type selected Check RTD type settings on the
system. Change if necessary. See
Select RTD, page 11.
Module o-ring failure Check and replace o-ring. See
Replace Module, page 24.
Inlet fitting loose Tighten fitting.
Manifold filter o-ring failure Check and replace o-ring.
Nozzle loose Tighten nozzle.
Adhesive leaking from gun
Module seal failure Check and replace module. See
Check Module, page 16.
3A2805 15

Troubleshooting
Problem Cause Solution
Solenoid valve failure Check and replace solenoid valve.
Adhesive pressure too high Check and reduce fluid pressure.
Solenoid valve connected
incorrectly Check solenoid valve air connections.
Adhesive out of all modules
when not triggered
Module failure Check and replace all modules. See
Check Module, page 16.
Check Module
Check the module operation to verify if the module
has failed and needs to be replaced.
1. InsertasmallAllenwrenchintothetopofthe
module.
2. Press the solenoid valve override switch (S) to
manually trigger the gun.
Figure 10 Check Module
If the wrench moves up and down, then the module
is operating properly
If the wrench does not move, then the module needs
to be replaced. See Replace Module, page 24.
Check Nozzle and Module
Trigger the gun without the nozzle to determine if the
nozzle or module is clogged.
1. Disable gun assembly. See
Before Beginning Repair, page 19.
2. Usea1/2in.wrenchtoremovethenozzle.
Figure 11
3. Connect the power and solenoid cable.
4. Return the gun back into operation.
5. Trigger the gun.
a. If adhesive flows, clean the nozzle and
reinstall on the module.
b. If adhesive does not flow, the module is
clogged and needs to be replaced. See
Replace Module, page 24.
16 3A2805

Troubleshooting
Check Heater
Check the continuity of the heater to verify proper
resistance. If there is no continuity, the heater
may have failed and need to be replaced. See
Wiring Diagram, page 21, and parts illustrations.
1. Disable gun assembly. See
Before Beginning Repair, page 19.
2. Check resistance of the heater using a multimeter
between the pins of the cordset connector. See
connectors illustrations in cordset pin tables.
• If there is no continuity measure resistance of
the heater at the butt splice terminals (52b).
• If the resistance is outside the range listed
below replace the heater cartridge. See
Replace Heater Cartridge, page 20.
Cordset Check
Pins un Model Resis- tance
Values
24U021–24U0
26
24U027–24U-
032
260–280
ohms
24W087,
Pt 100
(385) RTD
Cordset
A and C
All other
models 130–140 ohms
24U021–24U0
26
24U027–24U-
032
260–280
ohms
24W088,
Ni 120
RTD
Cordset
1 and 2
All other
models 130–140 ohms
Table 1 24W087, Pt 100 (385) RTD Cordset
Pin Description
AThermal Cutoff
BGround
CHeat -
DRTD (White)
ERTD (Red)
Table 2 24W088, Ni 120 RTD Cordset
Pin Description
1Thermal Cutoff
2Heat-
3RTD (White)
5RTD (Red)
G Ground
Check RTD
Check the continuity of the RTD to verify proper
resistance. If there is no continuity, the RTD has
failed and needs to be replaced.
1. Disable gun assembly. See
Before Beginning Repair, page 19.
2. Check resistance of the RTD using a multimeter
between the pins of the cordset connector. See
connectors illustrations in cordset pin tables.
Cordset Check Pins Resistance
Values
At Room
Temperature
70–72°F
(21–22°C)
24W087, Pt
100 (385)
RTD Cordset
D and E 107-115
ohms
24W088, Ni
120 RTD
Cordset
3 and 5 130-140
ohms
3. Replace the RTD if the resistance reading is
outside the range, or if there is no continuity. See
Replace RTD, page 20.
3A2805 17

Troubleshooting
Check Thermal Cutoff
If working properly, the cutoff will trip at 450°F
(232°C) and resets at 370°F (187°C). If failure is
suspected, allow gun to cool and then check the
continuity of the thermal cutoff to verify it has not
failed. If there is no continuity, the cutoff has failed
andneedstobereplaced.
1. Disable gun assembly. See
Before Beginning Repair, page 19.
2. Remove cover plate.
3. Check for continuity using a multimeter between
pin of cordset connector and the wires from the
thermal cutoff that connects to the heater lead.
Cordset Check Pins
24W087, Pt 100 (385)
RTD Cordset A
24W088, Ni 120 RTD
Cordset 1
Thermal Cutoff
WLD
18 3A2805

Repair
Repair
Required Tools
• Phillips screw driver
•Flatbladescrewdriver
• 5/64in(2mm)and5/32in. (4mm)Allenwrenches
• 1/2 in. and 7/16 in. wrenches
• Torque wrench
• Waste container
• High-temperature anaerobic thread sealant (110110)
• High-temperature lubricant (24T156)
• Anti-sieze (24T179)
• Crimp tool (24W086)
efore eginning Repair
1. Turn off the melter system. See melter manual
for shutdown instructions.
2. Relieve pressure. See
Pressure Relief Procedure, page 12.
3. Disconnect the cordset from the heated hose.
Figure 12 Disconnect Cordset
4. Loosen the mounting screw and disconnect the
solenoid valve power connector (N) from the
solenoid valve (J).
Figure 13 Disconnect Solenoid Valve Power
Connector
3A2805 19

Repair
Replace Heater Cartridge
1. Disable gun assembly.
2. Use a Phillips screwdriver to remove screws (15)
and manifold cover plate (52).
3. Remove the heater cartridges (3) from the
manifold (1).
Note
Note the placement of the heaters and
lead lengths.
Note
On guns that are not low profile, if the
heater cartridge does not easily pull out,
remove the other cover plate (18) and
press out with a small screwdriver.
4. Remove butt splices(52b) from heater wires (3),
thermal cutoff (52a), and cordset wire leads (17).
5. Recrimp new heater wires into new splices (52b).
See wiring diagram.
NOTICE
To prevent a short to ground and blowing a
MZLP fuse, ensure bare wires are covered
with fiberglass tape and sleeves (52c) are
centered over splices (52b).
6. Insert the new heater cartridges (3) into the
manifold (1), placing the heater with the shorter
leads closer to the wiring port.
Note
Do not apply thermal grease to the
heater cartridge.
7. Reinstall the manifold cover plate (52).
8. Reconnect the cordset (17) to the heated hose.
9. Reconnect the solenoid valve power connector
to the solenoid valve (9).
Replace RTD
The RTD is replaced by replacing the entire cordset.
See Replace Cordset, page 22, for instructions.
Replace Thermal Cutoff
1. Disable gun assembly.
2. Use a Phillips screws driver to remove the four
screws (15) and manifold cover plate (52).
3. Remove splices from heater wires (3) and
cordset wire leads (17).
4. Crimp wires. See Wiring Diagram, page 21.
NOTICE
To prevent a short to ground and blowing a
MZLP fuse, ensure bare wires are covered
with fiberglass tape and sleeves (52c) are
centered over splices (52b).
a. Slide sleeves (52c) over each pair of wires
before crimping.
b. Crimp butt splice (52b) on cordset heater
wires (17) and heater wires (3). Light pull on
splice to ensure it is crimped.
c. Crimp white wire to one thermal cutoff lead
(52a).
d. Crimp other thermal cutoff lead (52a) to one
heater wire(s) (3).
e. Crimp other heater wire(s) to black lead (17).
f. Wrap a short piece of fiberglass tape around
each splice (52b).
g. Center sleeves (52c) over each taped splice
(52b).
5. Gently press wires into the manifold. Install plate
(52) and screws (15).
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20 3A2805