Graco InvisiPac GS35 Plug-Free User manual

Instructions-Parts
InvisiPac® InvisiPac®
InvisiPac®GS35 GS35 GS35Plug-Free™ Plug-Free™ Plug-Free™
Hot Hot
HotMelt Melt MeltApplicator Applicator Applicator3A2805M
EN
For For
Fordispensing dispensing dispensinghot hot hotmelt melt meltadhesive. adhesive. adhesive.For For Forprofessional professional professionaluse use useonly. only. only.Not Not Notfor for foruse use usein in inwaterwash waterwash waterwash
environments. environments.
environments.
Not Not
Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or orhazardous hazardous hazardouslocations. locations. locations.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanual.Savethese
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.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Warnings...........................................................3
Approvals...........................................................5
Models...............................................................6
ComponentIdenti󰘰cation.....................................7
Overview............................................................8
Grounding..........................................................8
Installation..........................................................9
Mounting.....................................................9
ConnectHeatedHose..................................9
ConnectSolenoidValve...............................9
ConnectTriggeringDevice...........................10
PrimeBeforeUsingEquipment.....................10
Flush...........................................................11
InstallNozzle...............................................11
SelectRTD..................................................11
Operation...........................................................12
PressureReliefProcedure............................12
Maintenance......................................................13
ReplaceInletFilter.......................................13
FilterMaintenanceGuidelines.......................13
Troubleshooting..................................................14
CheckModule..............................................16
CheckNozzleandModule............................16
CheckHeater..............................................17
CheckRTD..................................................17
CheckThermalCutoff..................................18
Repair................................................................19
BeforeBeginningRepair...............................19
ReplaceHeaterCartridge.............................20
ReplaceRTD...............................................20
ReplaceThermalCutoff................................20
ReplaceCordset..........................................22
ReplaceSolenoidValve...............................24
ReplaceModule...........................................24
ReplaceApplicator.......................................24
Notes................................................................25
Parts..................................................................26
KitsandAccessories...........................................44
Dimensions........................................................46
TechnicalData...................................................50
Notes................................................................51
GracoExtendedWarranty...................................52
2
3A2805M

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore
servicingequipment.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromdispensingdevice,hoseleaks,orrupturedcomponentswillpierce
skin.Thismaylooklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Get
immediate immediate
immediatesurgical surgical surgicaltreatment. treatment. treatment.
•Donotpointdispensingdeviceatanyoneoratanypartofthebody.
•Donotputyourhandoverthe󰘱uidoutlet.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopdispensingandbeforecleaning,
checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
3A2805M 3

Warnings
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Tohelp
prevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareantistaticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnicalData
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
4
3A2805M

Approvals
WARNING WARNING
WARNING
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadMSDSstoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
Approvals Approvals
Approvals
4002346 4002346
4002346
ConformstoANSI/ULStd.
499Certi󰘰edtoCAN/CSA
Std.C22.2No.88
3A2805M 5

Models
Models Models
Models
Allmodelsusea240Vheater.Additional
con󰘰gurationsareavailable.ContactGracocustomer
servicefordetails.
Note
ApplicatorswithNi120RTDtypescomewith
a6–pinrectangularcordset(24W088).See
Parts,page26.
Single Single
Single
Part Part
PartSeries Series
SeriesRTD RTD
RTDType Type TypeSolenoid Solenoid
SolenoidValve Valve Valve
24P073BPt100(385)24VDC
24P074BPt100(385)110VAC
24P246BPt100(385)None
24P299BNi12024VDC
24P300BNi120110VAC
24P307BNi120None
Slim Slim
Slim(Single) (Single) (Single)
Part Part
PartSeries Series
SeriesRTD RTD
RTDType Type TypeSolenoid Solenoid
SolenoidValve Valve Valve
24U021BPt100(385)24VDC
24U022BPt100(385)110VAC
24U023BPt100(385)None
24U024BNi12024VDC
24U025BNi120110VAC
24U026BNi120None
Dual Dual
Dual
Part Part
PartSeries Series
SeriesRTD RTD
RTDType Type TypeSolenoid Solenoid
SolenoidValve Valve Valve
24P075BPt100(385)24VDC
24P076BPt100(385)110VAC
24P247BPt100(385)None
24P301BNi12024VDC
24P302BNi120110VAC
24P308BNi120None
Low Low
LowPro󰘰le Pro󰘰le Pro󰘰le- - -Dual Dual Dual
Part Part
PartSeries Series
SeriesRTD RTD
RTDType Type TypeSolenoid Solenoid
SolenoidValve Valve Valve
24U027BPt100(385)24VDC
24U028BPt100(385)110VAC
24U029BPt100(385)None
24U030BNi12024VDC
24U031BNi120110VAC
24U032BNi120None
Quad Quad
Quad
Part Part
PartSeries Series
SeriesModule Module
Module
Spacing Spacing
Spacing
Type* Type*
Type*
RTD RTD
RTDType Type TypeSolenoid Solenoid
Solenoid
Valve Valve
Valve
24P077BIPt100(385)24VDC
24P078BIPt100(385)110VAC
24P079BIIPt100(385)24VDC
24P080BIIPt100(385)110VAC
24P250BIPt100(385)None
24P254BIIPt100(385)None
24P303BINi12024VDC
24P304BINi120110VAC
24P305BIINi12024VDC
24P306BIINi120110VAC
24P309BINi120None
24P310BIINi120None
* See Dimensions, page 46 .
Low Low
LowPro󰘰le Pro󰘰le Pro󰘰le- - -Quad Quad Quad
Part Part
PartSeries Series
SeriesRTD RTD
RTDType Type TypeSolenoid Solenoid
SolenoidValve Valve Valve
24U033BPt100(385)24VDC
24U034BPt100(385)110VAC
24U035BPt100(385)None
24U036BNi12024VDC
24U037BNi120110VAC
24U038BNi120None
6 3A2805M

ComponentIdentication
Component Component
ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
A
CB
AD
E
F
G
H
J
M
K
K
L
N
P
Figure124P075Shown
ADispensemodule
BFluidoutlet/nozzle(3/8–24)
CFluid󰘰lter(notvisible)
DManifold
EFluidinlet(9/16–18,—6JIC,37°󰘱are)
FCordset(24W087shown)
GAirtube
HMountingclamp(1/2in.diameterbar)
JSolenoidvalve(24VDC,110VAC);not
includedwithallmodels
KMuf󰘱er
LAirinlet(3/8in.diametertubing)
MManualoverrideswitch
NSolenoidvalveelectricalconnector
PInsulator
3A2805M
7

Overview
Overview Overview
Overview
Thevalveusestheair-opened,springclosedmode
ofoperation.Itusesathree-wayexhaustingsolenoid
tocontrolthepistoninsidethedispensemodule.
Fluidis󰘰lteredthroughthemanifold󰘰lter(C)before
enteringthedispensemodule󰘱uidinletport.Then
the󰘱uidis󰘰lteredone󰘰naltimethroughthemodule
󰘰lter(P),whichislocatedineachmodule,directly
beforetheballandseat.
Whenairmovesthepistonrodandballfromitsseat,
itopensthe󰘱uidoutlet.Whentheairshutsoff,the
springpushesthepistonrodandballintoitsseatand
closesthe󰘱uidoutlet.
Thegunshouldberigidlymountedandremotely
operatedbyameltersystemandtriggeringdevice.
Themeltersystemprovidespressurized󰘱uidtothe
valve.Thetriggeringdevicecontrolsthe󰘱uid󰘱owby
openingandclosingthesolenoidvalve.
C
P
Figure2AirandFluidFlow
Air Air
Air
Fluid Fluid
Fluid
Grounding Grounding
Grounding
Theequipmentmustbegroundedtoreducethe
riskofstaticsparking.Staticsparkingcancause
fumestoigniteorexplode.Groundingprovidesan
escapewirefortheelectriccurrent.
•Pump: Pump:
Pump:followmanufacturer’srecommendations.
•Dispense Dispense
Dispenseapplicator: applicator: applicator:groundedthroughelectrical
connection.
•Air Air
Aircompressor: compressor: compressor:followmanufacturer’s
recommendations.
•Fluid Fluid
Fluidsupply supply supplycontainer: container: container:followlocalcode.
•Solvent Solvent
Solventpails pails pailsused used usedwhen when when󰘱ushing: 󰘱ushing: 󰘱ushing:followlocal
code.Useonlyconductivemetalpails,placed
onagroundedsurface.Donotplacethepail
onanonconductivesurface,suchaspaperor
cardboard,whichinterruptsgroundingcontinuity.
•To To
Tomaintain maintain maintaingrounding grounding groundingcontinuity continuity continuitywhen when when󰘱ushing 󰘱ushing 󰘱ushingor or or
relieving relieving
relievingpressure: pressure: pressure:ensuremountingmanifoldand
electricalpowerconnectoraregroundedproperly.
8 3A2805M

Installation
Installation Installation
Installation
Mounting Mounting
Mounting
NOTICE NOTICE
NOTICE
Topreventheattransferringintoothercomponents
ofthepackagingline,ensurethattheinsulator(P)
isinstalled.
Low Low
LowPro󰘰le Pro󰘰le Pro󰘰leModels: Models: Models:Usea3/4in.(19mm)wrenchto
adjustnutsthatcontrolpositionofgunassemblyon
threadedrod.
All All
AllOther Other OtherModels: Models: Models:Seethefollowinginstructions.
Mountmanifoldona1/2in.(12mm)diameterbar
usingmountingclamp(H)toholdthegunassembly
inplaceandensureadhesiveisappliedproperly.
1.Usea5mmAllenwrenchtoloosenthemounting
clampandslidethegunassemblyonthe
mountingbar.
2.Tightenthemountingclamp.
Note
Provideenoughroomtoaccesssidesof
applicatorformaintenanceandrepair.
H
P
Figure3MountingClamp
Connect Connect
ConnectHeated Heated HeatedHose Hose Hose
1.Connectthehose󰘱uidoutlettothemanifold󰘱uid
inlet(E).Usetwo11/16in.wrenchestotighten
thehose󰘰tting.
M
E
Figure4ConnecttheHeatedHose
2.Connectthecordset(M)tothehose.
3.Connectthehoseinlettothemeltersystem
outlet.Seetheheatedhosemanualfor
installationguidelines.
4.Connectthehosecordsettomelter.Seethe
heatedhosemanualforinstallationguidelines.
Connect Connect
ConnectSolenoid Solenoid SolenoidValve Valve Valve
1.Connect3/8in.diameterairsupplytubingtoa
clean,dry,andnon-lubricatedairsupplyandto
thepush-to-connectairinlet󰘰tting(L).
L
Figure5AirInletFitting
2.Connectsolenoidvalveto24VDCor110VAC
signal.SeeConnectTriggeringDevice,page10.
For For
Forapplicators applicators applicatorswithout without withouta a asupplied supplied suppliedsolenoid solenoid solenoidvalve: valve: valve:
•Usesolenoidvalveswithanoverrideswitch.
•Ensurethatyoursolenoidvalveisconnectedtothe
manifoldwithtubingratedfor400°F(204°C).
•Ensurethesolenoidvalveisratedfor
high-temperatureapplications.
3A2805M 9

Installation
Connect Connect
ConnectTriggering Triggering TriggeringDevice Device Device
Identifyifyourmodelusesa24VDCor110VAC
solenoidvalve.Connectsolenoidvalveto24VDC
or110VACsignal.
Improperelectricalconnectioncanresultinelectric
shock.Allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
1.Loosenthemountingscrewanddisconnectthe
electricalconnector(N)fromthesolenoidvalve
(J).Setthegasketandscrewaside.
J
N
P
Figure6SolenoidValveElectricalConnector
2.Insertasmallscrewdriverwherethemounting
screwwasremovedandgentlypressthe
electricalconnector(P)outoftheelectrical
connectorhousing(N).
3.Threadathree-conductorcablethroughthestrain
relief.Connectthepositiveandnegativewiresto
terminals1and2ontheelectricalconnector(P).
Connectthegroundwiretothegroundterminal.
Note
Itdoesnotmatterwhichterminal
thepositiveandnegativewiresare
connectedto.
21
GND
SolenoidValveConnector
Figure7
4.Reassembletheelectricalconnector(P)and
housing(N).Retightenstrainrelief.
5.Placethegasketonthehousingandconnectthe
electricalconnectorintothesolenoidvalve(J)
withthemountingscrew.SeeFig.6.
Prime Prime
PrimeBefore Before BeforeUsing Using UsingEquipment Equipment Equipment
Theequipmentwastestedwithoil,whichisleftinthe
󰘱uidpassagestoprotectparts.Primetheequipment
withhotmeltuntilalloftheoilispushedoutbefore
usingtheequipment.SeeFlush,page11.
10 3A2805M

Installation
Flush Flush
Flush
1.Disconnectorturnoffthedevicewhichtriggers
thesolenoidvalve.
2.Heatthesystemtoworkingtemperature.
3.Placewastecontainerundertheguntocatchthe
adhesive.
4.Ensurethenozzleisremoved.
5.Pressthemanualoverrideswitch(S)tomanually
triggerthesolenoidvalve.
6.Dispensehotmelt(adhesive)untilitisclean.
Figure8
Install Install
InstallNozzle Nozzle Nozzle
Use1/2in.wrenchtoinstallnozzle.See
KitsandAccessories,page44.
Select Select
SelectRTD RTD RTD
Note
ForInvisiPacsystemsonly.
IdentifyRTDtypeusedinapplicatoronthesystem
AdvancedDisplayModule(ADM).TheRTDtypeis
listedonthemanifoldcoverplate.SeetheInvisiPac
systemmanualforinstructionstocon󰘰gurethis
setting.
NOTICE NOTICE
NOTICE
AnincorrectRTDsettingwillcausethesystem
tobeincapableofmaintainingthetemperature
setting.Theapplicatormayoverheatandtripthe
thermalcutoff,iftheapplicatorusesaPT100(385)
andNI120isselectedontheADMSetupscreen.
Theapplicatormayunder-heatiftheapplicator
usesaNI120andPT100(385)isselectedonthe
ADMSetupscreen.
•IfPT100(385)islisted,selectPT100(385)inthe
ADMSetupscreens.
•IfNI120islisted,selectNI120intheADMSetup
screens.
3A2805M
11

Operation
Operation Operation
Operation
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressure
ismanuallyrelieved.Tohelppreventserious
injuryfrompressurized󰘱uid,suchasskininjection,
andsplashing󰘱uid,followthePressureRelief
Procedurewhenyoustopsprayingandbefore
cleaning,checking,orservicingtheequipment.
1.Depressurizesystem.
2.Closethebleed-typemasterairvalve.
3.Actuatetheapplicatorrepeatedlyuntilno󰘱uid
󰘱ows.
Materialinsidethemoduleandhosemaystill
benearsetpointtemperature.Wearprotective
clothingtoavoidsevereburns.
4.Ifyoususpectthemodulenozzleisclogged,
removenozzleandthenactuatethemoduleto
relievepressure.
5.Ifyoususpectthemoduleor󰘱uidhoseis
cloggedorthatpressurehasnotbeenfully
relievedafterfollowingthestepsabove,VERY
SLOWLYlooseninlet󰘰tting,inlet󰘰lter,orhose
endcouplingtorelievepressuregradually,
thenloosencompletely.Clearhoseormodule
obstruction.
6.Turnoffairpressuretothesolenoidvalve.
12
3A2805M

Maintenance
Maintenance Maintenance
Maintenance
Materialinsidetheapplicatorcanbenearsetpoint
temperature.Wearprotectiveclothingtoavoid
severeburns.
Daily: Daily:
Daily:
Cleanhotmeltfromexteriorofgun.
Weekly: Weekly:
Weekly:
Inspecttheapplicator,󰘱uidlines,cordset,
andsolenoidcableforwearordamage.See
Repair,page19forinstructions.
Replace Replace
ReplaceInlet Inlet InletFilter Filter Filter
NOTICE NOTICE
NOTICE
Removethe󰘰lterwhenthegunishot.Ifthegunis
cold,theadhesivewillbehardandthe󰘰ltermay
bedif󰘰culttoremoveordamaged.
1.Disablegunassembly.See
BeforeBeginningRepair,page19.
Materialinsidetheapplicatorcanbenear
setpointtemperature.Wearprotectiveclothing
toavoidsevereburns.
2.Removedirty󰘰lter(16)frommanifold(1).
16
1
Figure9InletFilter
3.Applyathincoatingofhigh-temperaturelubricant
tosealsonthenew󰘰lter(16)andinstallinthe
manifold(1).Torqueto30in.-lbs(3.4N∙m),
usinga5/32in.(4mm)Allenwrench.
Filter Filter
FilterMaintenance Maintenance MaintenanceGuidelines Guidelines 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 󰘰lter maintenance. To establish
a preventative maintenance cycle tailored to your
environment, Graco recommends inspecting 󰘰lters
every 4 weeks after installation and replacing when
necessary. Document replacement intervals and
use this as your preventative maintenance schedule
moving forward.
Environment Environment
EnvironmentClassi󰘰cation Classi󰘰cation Classi󰘰cation
Clean Clean
CleanModerate Moderate
ModerateDusty Dusty Dusty
Gun
manifold
󰘰lter
Solenoid
exhaust
󰘰lters
Replace
󰘰lterevery
six six
sixmonths
Replace
󰘰lter
everyfour four
four
months
Replace
󰘰lter
everytwo two
two
months
3A2805M 13

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
Problem Problem
ProblemCause Cause
CauseSolution Solution Solution
Debrisinmanifold󰘰lterReplacemanifold󰘰lter.See
ReplaceInletFilter,page13.
CloggedhoseCleanorreplacehose.
FailedsolenoidvalveCheckforcorrectoperation.Clean
orreplace.
NosignaltosolenoidvalveChecksolenoidvalveforcorrect
operation.
IncorrectsolenoidvalvewiringChecksolenoidvalvewiring.
IncorrectsignaltosolenoidvalveCheckif24VDCor120VAC.
Solenoidmuf󰘱erpluggedCheckandreplacemuf󰘱ers.
No󰘱uidpressureCheckadhesivedeliverysystem.
Heaterfailure(coldgun)Checkandreplace
heatercartridges.See
ReplaceHeaterCartridge,page20.
NoairtosolenoidvalveCheckairsupply.
DirtyorfaultytriggeringdeviceCheck,clean,orreplacetriggering
device.
Solenoidvalveconnected
incorrectly
Checksolenoidvalveairconnections.
Noadhesiveorincorrect
amountofadhesiveoutofall
moduleswhentriggered
CloggedmanifoldpassageCleanorreplacemanifold.
DebrisinnozzleCleanorreplacenozzle.
FailedmoduleinclosedpositionCheckforcorrectoperation.
Cleanorreplace.See
CheckModule,page16.
Debrisinmodule󰘰lterReplacemodule.See
ReplaceModule,page24.
Noadhesiveorincorrect
amountofadhesiveoutof
one/somemoduleswhen
triggered
CloggedmanifoldpassageCleanorreplacemanifold.
FailedmoduleinopenpositionCleanorreplacemodule.See
ReplaceModule,page24.
Adhesiveoutofone/some
moduleswhennottriggered
AdhesivepressuretoohighCheckandreduce󰘱uidpressure.
14
3A2805M

Troubleshooting
Problem Problem
ProblemCause Cause
CauseSolution Solution Solution
HeaterfailureCheckandreplace
heatercartridge.See
ReplaceHeaterCartridge,page20.
LoosecordsetconnectionCheckconnection.
RTDfailureCheckandreplaceRTD.See
CheckRTD,page17.
IncorrectRTDforadhesivedelivery
system
CheckdeliverysystemRTD
requirement
ThermalcutofffailureCheckandreplace
thermalcutoff.See
ReplaceThermalCutoff,page20.
Gunwillnotheat
WrongRTDtypeselectedCheckRTDtypesettingsonthe
system.Changeifnecessary.See
SelectRTD,page11.
HeaterfailureCheckandreplace
heatercartridge.See
ReplaceHeaterCartridge,page20.
RTDfailureCheckandreplaceRTD.See
CheckRTD,page17.
IncorrectRTDforadhesivedelivery
system
CheckdeliverysystemRTD
requirement.
IncorrectpowertoheaterCheckandcorrectpower.
Gunoverheats
WrongRTDtypeselectedCheckRTDtypesettingsonthe
system.Changeifnecessary.See
SelectRTD,page11.
HeaterfailureCheckandreplace
heatercartridge.See
ReplaceHeaterCartridge,page20
RTDfailureCheckandreplaceRTD.
IncorrectRTDforadhesivedelivery
system
CheckdeliverysystemRTD
requirement.
IncorrectpowertoheaterCheckandcorrectpower.
Gununder-heats
WrongRTDtypeselectedCheckRTDtypesettingsonthe
system.Changeifnecessary.See
SelectRTD,page11.
Moduleo-ringfailureCheckandreplaceo-ring.See
ReplaceModule,page24.
Inlet󰘰ttinglooseTighten󰘰tting.
Manifold󰘰ltero-ringfailureCheckandreplaceo-ring.
NozzlelooseTightennozzle.
Adhesiveleakingfromgun
ModulesealfailureCheckandreplacemodule.See
CheckModule,page16.
3A2805M 15

Troubleshooting
Problem Problem
ProblemCause Cause
CauseSolution Solution Solution
SolenoidvalvefailureCheckandreplacesolenoidvalve.
AdhesivepressuretoohighCheckandreduce󰘱uidpressure.
Solenoidvalveconnected
incorrectly
Checksolenoidvalveairconnections.
Adhesiveoutofallmodules
whennottriggered
ModulefailureCheckandreplaceallmodules.See
CheckModule,page16.
Check Check
CheckModule Module Module
Checkthemoduleoperationtoverifyifthemodule
hasfailedandneedstobereplaced.
1.InsertasmallAllenwrenchintothetopofthe
module.
2.Pressthesolenoidvalveoverrideswitch(S)to
manuallytriggerthegun.
2
Figure10CheckModule
Ifthewrenchmovesupanddown,thenthemodule
isoperatingproperly
Ifthewrenchdoesnotmove,thenthemoduleneeds
tobereplaced.SeeReplaceModule,page24.
Check Check
CheckNozzle Nozzle Nozzleand and andModule Module Module
Triggerthegunwithoutthenozzletodetermineifthe
nozzleormoduleisclogged.
1.Disablegunassembly.See
BeforeBeginningRepair,page19.
2.Usea1/2in.wrenchtoremovethenozzle.
Figure11
3.Connectthepowerandsolenoidcable.
4.Returnthegunbackintooperation.
5.Triggerthegun.
a.Ifadhesive󰘱ows,cleanthenozzleand
reinstallonthemodule.
b.Ifadhesivedoesnot󰘱ow,themoduleis
cloggedandneedstobereplaced.See
ReplaceModule,page24.
16 3A2805M

Troubleshooting
Check Check
CheckHeater Heater Heater
Checkthecontinuityoftheheatertoverifyproper
resistance.Ifthereisnocontinuity,theheater
mayhavefailedandneedtobereplaced.See
WiringDiagram,page21,andpartsillustrations.
1.Disablegunassembly.See
BeforeBeginningRepair,page19.
2.Checkresistanceoftheheaterusingamultimeter
betweenthepinsofthecordsetconnector.See
connectorsillustrationsincordsetpintables.
•Ifthereisnocontinuitymeasureresistanceof
theheateratthebuttspliceterminals(52b).
•Iftheresistanceisoutsidetherangelisted
belowreplacetheheatercartridge.See
ReplaceHeaterCartridge,page20.
Cordset Cordset
CordsetCheck Check Check
Pins Pins
Pins
Gun Gun
GunModel Model ModelResis- Resis-
Resis-
tance tance
tance
Values Values
Values
24U021–24U0
26
24U027–24U-
032
260–280
ohms
24W087,
Pt100
(385)RTD
Cordset
AandC
Allother
models
130–140
ohms
24U021–24U0
26
24U027–24U-
032
260–280
ohms
24W088,
Ni120
RTD
Cordset
1and2
Allother
models
130–140
ohms
Table Table
Table1 1 124W087, 24W087, 24W087,Pt Pt Pt100 100 100(385) (385) (385)RTD RTD RTDCordset Cordset Cordset
Pin Pin
PinDescription Description Description
AThermalCutoff
BGround
CHeat-
DRTD(White)
ERTD(Red)
Table Table
Table2 2 224W088, 24W088, 24W088,Ni Ni Ni120 120 120RTD RTD RTDCordset Cordset Cordset
Pin Pin
PinDescription Description Description
1ThermalCutoff
2Heat-
3RTD(White)
5RTD(Red)
GGround
Check Check
CheckRTD RTD RTD
CheckthecontinuityoftheRTDtoverifyproper
resistance.Ifthereisnocontinuity,theRTDhas
failedandneedstobereplaced.
1.Disablegunassembly.See
BeforeBeginningRepair,page19.
2.CheckresistanceoftheRTDusingamultimeter
betweenthepinsofthecordsetconnector.See
connectorsillustrationsincordsetpintables.
Cordset Cordset
CordsetCheck Check CheckPins Pins PinsResistance Resistance
Resistance
Values Values
Values
At At
AtRoom Room Room
Temperature Temperature
Temperature
70–72 70–72
70–72° ° °F F F
(21–22 (21–22
(21–22° ° °C) C) C)
24W087,Pt
100(385)
RTDCordset
DandE107-115
ohms
24W088,Ni
120RTD
Cordset
3and5130-140
ohms
3.ReplacetheRTDiftheresistancereadingis
outsidetherange,orifthereisnocontinuity.See
ReplaceRTD,page20.
3A2805M
17

Troubleshooting
Check Check
CheckThermal Thermal ThermalCutoff Cutoff Cutoff
Ifworkingproperly,thecutoffwilltripat450°F
(232°C)andresetsat370°F(187°C).Iffailureis
suspected,allowguntocoolandthencheckthe
continuityofthethermalcutofftoverifyithasnot
failed.Ifthereisnocontinuity,thecutoffhasfailed
andneedstobereplaced.
1.Disablegunassembly.See
BeforeBeginningRepair,page19.
2.Removecoverplate.
3.Checkforcontinuityusingamultimeterbetween
pinofcordsetconnectorandthewiresfromthe
thermalcutoffthatconnectstotheheaterlead.
Cordset Cordset
CordsetCheck Check CheckPins Pins Pins
24W087,Pt100(385)
RTDCordset
A
24W088,Ni120RTD
Cordset
1
Thermal Thermal
ThermalCutoff Cutoff Cutoff
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18 3A2805M

Repair
Repair Repair
Repair
Required Required
RequiredTools Tools Tools
•Phillipsscrewdriver
•Flatbladescrewdriver
•5/64in(2mm)and5/32in.(4mm)Allenwrenches
•1/2in.and7/16in.wrenches
•Torquewrench
•Wastecontainer
•High-temperatureanaerobicthreadsealant(110110)
•High-temperaturelubricant(24T156)
•Anti-sieze(24T179)
•Crimptool(24W086)
Before Before
BeforeBeginning Beginning BeginningRepair Repair Repair
1.Turnoffthemeltersystem.Seemeltermanual
forshutdowninstructions.
2.Relievepressure.See
PressureReliefProcedure,page12.
3.Disconnectthecordsetfromtheheatedhose.
Figure12DisconnectCordset
4.Loosenthemountingscrewanddisconnectthe
solenoidvalvepowerconnector(N)fromthe
solenoidvalve(J).
J
N
Figure13DisconnectSolenoidValvePower
Connector
3A2805M 19

Repair
Replace Replace
ReplaceHeater Heater HeaterCartridge Cartridge Cartridge
1.Disablegunassembly.
2.UseaPhillipsscrewdrivertoremovescrews(15)
andmanifoldcoverplate(52).
3.Removetheheatercartridges(3)fromthe
manifold(1).
Note
Notetheplacementoftheheatersand
leadlengths.
Note
On guns that are not low pro󰘰le, ifthe
heatercartridgedoesnoteasilypullout,
removetheothercoverplate(18)and
pressoutwithasmallscrewdriver.
4.Removebuttsplices(52b)fromheaterwires(3),
thermalcutoff(52a),andcordsetwireleads(17).
5.Recrimpnewheaterwiresintonewsplices(52b).
Seewiringdiagram.
NOTICE NOTICE
NOTICE
Topreventashorttogroundandblowinga
MZLPfuse,ensurebarewiresarecovered
with󰘰berglasstapeandsleeves(52c)are
centeredoversplices(52b).
6.Insertthenewheatercartridges(3)intothe
manifold(1),placingtheheaterwiththeshorter
leadsclosertothewiringport.
Note
Donotapplythermalgreasetothe
heatercartridge.
7.Reinstallthemanifoldcoverplate(52).
8.Reconnectthecordset(17)totheheatedhose.
9.Reconnectthesolenoidvalvepowerconnector
tothesolenoidvalve(9).
Replace Replace
ReplaceRTD RTD RTD
TheRTDisreplacedbyreplacingtheentirecordset.
SeeReplaceCordset,page22,forinstructions.
Replace Replace
ReplaceThermal Thermal ThermalCutoff Cutoff Cutoff
1.Disablegunassembly.
2.UseaPhillipsscrewsdrivertoremovethefour
screws(15)andmanifoldcoverplate(52).
3.Removesplicesfromheaterwires(3)and
cordsetwireleads(17).
4.Crimpwires.SeeWiringDiagram,page21.
NOTICE NOTICE
NOTICE
Topreventashorttogroundandblowinga
MZLPfuse,ensurebarewiresarecovered
with󰘰berglasstapeandsleeves(52c)are
centeredoversplices(52b).
a.Slidesleeves(52c)overeachpairofwires
beforecrimping.
b.Crimpbuttsplice(52b)oncordsetheater
wires(17)andheaterwires(3).Lightpullon
splicetoensureitiscrimped.
c.Crimpwhitewiretoonethermalcutofflead
(52a).
d.Crimpotherthermalcutofflead(52a)toone
heaterwire(s)(3).
e.Crimpotherheaterwire(s)toblacklead(17).
f.Wrapashortpieceof󰘰berglasstapearound
eachsplice(52b).
g.Centersleeves(52c)overeachtapedsplice
(52b).
5.Gentlypresswiresintothemanifold.Installplate
(52)andscrews(15).
W
WLL     EE
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20 3A2805M