Graco GM100 User manual

Brand: Graco

Model: GM100

Type: User manual

This manual is also suitable for

Instructions

InvisiPac® InvisiPac®

InvisiPac®

GM100 GM100

GM100

Plug Plug

Plug

- -

Free™ Free™

Free™

Hot Hot

Hot

Melt Melt

Melt

Applicator Applicator

Applicator

334627D

For For

For

dispensing dispensing

dispensing

hot hot

hot

melt melt

melt

adhesive. adhesive.

adhesive.

For For

For

professional professional

professional

use use

use

only. only.

only.

Not Not

Not

approved approved

approved

for for

for

use use

use

in in

explosive explosive

explosive

atmospheres atmospheres

atmospheres

or or

hazardous hazardous

hazardous

locations. locations.

locations.

Important Important

Important

Safety Safety

Safety

Instructions Instructions

Instructions

Readallwarningsandinstructionsinthismanualandinrelated

manuals.Savetheseinstructions.

See page 6 for models, approval

information and working pressure

ratings.

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents

Contents

Warnings...........................................................3

Models...............................................................6

WorkingPressure........................................6

ModelApprovals..........................................6

ComponentIdentication.....................................7

Overview............................................................8

Grounding..........................................................8

Installation..........................................................9

Mounting.....................................................9

ConnectHeatedHose..................................9

RecommendedAirSetup..............................9

ConnectSolenoidValve...............................10

ConnectTriggeringDevice...........................10

BeforeUsingEquipment...............................10

Flush...........................................................11

InstallNozzle...............................................11

SelectRTD..................................................11

Operation...........................................................12

PressureReliefProcedure............................12

Maintenance......................................................13

ReplaceInletFilter.......................................13

FilterMaintenanceGuidelines.......................13

Troubleshooting..................................................14

CheckModule..............................................17

CheckNozzleandModule............................17

CheckHeater..............................................18

CheckRTD..................................................19

CheckThermalCutoff..................................19

Repair................................................................20

RequiredTools............................................20

BeforeBeginningRepair...............................20

ReplaceHeaterCartridge.............................20

ReplaceRTD...............................................21

ReplaceThermalCutoff................................21

ReplaceCordset..........................................23

ReplaceSolenoidValve...............................24

ReplaceModule...........................................24

ReplaceApplicator.......................................24

Notes................................................................25

Parts..................................................................26

SolenoidValveKits.............................................36

KitsandAccessories...........................................37

Dimensions........................................................40

TechnicalData...................................................45

GracoExtendedWarranty...................................46

334627D

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

BURN

HAZARD HAZARD

HAZARD

Equipmentsurfacesanduidthatisheatedcanbecomeveryhotduringoperation.Toavoid

severeburns:

•Donottouchhotuidorequipment.

ELECTRIC ELECTRIC

ELECTRIC

SHOCK SHOCK

SHOCK

HAZARD HAZARD

HAZARD

Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan

causeelectricshock.

•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore

servicingorinstallingequipment.

•Connectonlytogroundedpowersource.

•Allelectricalwiringmustbedonebyaqualiedelectricianandcomplywithalllocalcodes

andregulations.

SKIN SKIN

SKIN

INJECTION INJECTION

INJECTION

HAZARD HAZARD

HAZARD

High-pressureuidfromdispensingdevice,hoseleaks,orrupturedcomponentswillpierce

skin.Thismaylooklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get

Get

immediate immediate

immediate

surgical surgical

surgical

treatment. treatment.

treatment.

•Donotpointdispensingdeviceatanyoneoratanypartofthebody.

•Donotputyourhandovertheuidoutlet.

•Donotstopordeectleakswithyourhand,body,glove,orrag.

•FollowthePressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

whenyoustopdispensingandbeforecleaning,

checking,orservicingequipment.

•Tightenalluidconnectionsbeforeoperatingtheequipment.

•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.

334627D 3

Warnings

WARNING WARNING

WARNING

FIRE FIRE

FIRE

AND AND

AND

EXPLOSION EXPLOSION

EXPLOSION

HAZARD HAZARD

HAZARD

Flammablefumes,suchassolventandpaintfumes,inwork work

work

area area

area

canigniteorexplode.Tohelp

preventreandexplosion:

•Useequipmentonlyinwellventilatedarea.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and

plasticdropcloths(potentialstaticarc).

•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.

•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhenammable

fumesarepresent.

•Groundallequipmentintheworkarea.SeeGrounding Grounding

Grounding

instructions.

•Useonlygroundedhoses.

•Holdapplicatorrmlytosideofgroundedpailwhentriggeringintopail.Donotusepail

linersunlesstheyareantistaticorconductive.

•Stop Stop

Stop

operation operation

operation

immediately immediately

immediately

ifstaticsparkingoccursoryoufeelashock. .

Donotuse

equipmentuntilyouidentifyandcorrecttheproblem.

•Keepaworkingreextinguisherintheworkarea.

EQUIPMENT EQUIPMENT

EQUIPMENT

MISUSE MISUSE

MISUSE

HAZARD HAZARD

HAZARD

Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorundertheinuenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated

systemcomponent.SeeTechnical Technical

Technical

Data Data

Data

inallequipmentmanuals.

•Useuidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnicalData

inallequipmentmanuals.Readuidandsolventmanufacturer’swarnings.Forcomplete

informationaboutyourmaterial,requestMSDSfromdistributororretailer.

•TurnoffallequipmentandfollowthePressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

whenequipmentisnotinuse.

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine

manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodicationsmayvoidagencyapprovals

andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtrafcareas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

TOXIC TOXIC

TOXIC

FLUID FLUID

FLUID

OR OR

FUMES FUMES

FUMES

HAZARD HAZARD

HAZARD

Toxicuidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,

inhaled,orswallowed.

•ReadMSDSstoknowthespecichazardsoftheuidsyouareusing.

•Storehazardousuidinapprovedcontainers,anddisposeofitaccordingtoapplicable

guidelines.

334627D

Warnings

WARNING WARNING

WARNING

PERSONAL PERSONAL

PERSONAL

PROTECTIVE PROTECTIVE

PROTECTIVE

EQUIPMENT EQUIPMENT

EQUIPMENT

Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,

includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective

equipmentincludesbutisnotlimitedto:

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbytheuidandsolvent

manufacturer.

334627D 5

Models

Models Models

Models

Allmodelsusea240Vheater.

ApplicatorswithNi120RTDtypescomewitha6–pin

rectangularcordset(24X040forslim,24X761for

standardDual,and24W088forallothermodels).

Slim Slim

Slim

(Single) (Single)

(Single)

24UPart 24UPart

24UPart

RTD RTD

RTD

Type Type

Type

Solenoid Solenoid

Solenoid

Valve Valve

Valve

25B021

Pt100(385)24VDC

25B024Ni120

24VDC

Dual Dual

Dual

Part Part

Part

RTD RTD

RTD

Type Type

Type

Solenoid Solenoid

Solenoid

Valve Valve

Valve

25B075

Pt100(385)24VDC

25B301Ni120

24VDC

Quad Quad

Quad

Part Part

Part

RTD RTD

RTD

Type Type

Type

Solenoid Solenoid

Solenoid

Valve Valve

Valve

25B077

Pt100(385)24VDC

25B303Ni120

24VDC

Low Low

Low

Prole Prole

Prole

- -

Quad Quad

Quad

Part Part

Part

RTD RTD

RTD

Type Type

Type

Solenoid Solenoid

Solenoid

Valve Valve

Valve

25B033

Pt100(385)24VDC

25B036Ni120

24VDC

Low Low

Low

Prole Prole

Prole

- -

Dual Dual

Dual

Part Part

Part

RTD RTD

RTD

Type Type

Type

Solenoid Solenoid

Solenoid

Valve Valve

Valve

25B027

Pt100(385)24VDC

25B030Ni120

24VDC

Related Related

Manuals Manuals

Manuals

Manual Manual

Manual

Number Number

Number

Description Description

Description

332072InvisiPacHeatedHose

Instructions-Parts

333347InvisiPacHM25

Tank-FreeHotMelt

DeliverySystem

Working Working

Working

Pressure Pressure

Pressure

Maximum Maximum

Maximum

Working Working

Working

Fluid Fluid

Fluid

Pressure: Pressure:

Pressure:

1500psi(10.3MPa,103bar)

Maximum Maximum

Maximum

Working Working

Working

Air Air

Air

Pressure: Pressure:

Pressure:

80psi(0.5MPa,5.5bar)

Minimum Minimum

Minimum

Working Working

Working

Air Air

Air

Pressure: Pressure:

Pressure:

65psi(0.44MPa,4.4Bar)

Model Model

Model

Approvals Approvals

Approvals

6 334627D

ComponentIdentication

Component Component

Component

Identication Identication

Identication

Figure1SlimModelShownonLeft,DualLowProle

ModelShownonRight

AModule

BFluidoutlet

CFluidlter

Manifold

Fluidinlet(9/16–18,—6JIC,37°are)

Cordset

Airtubes

Mountingclamp(1/2in.diameterbar)

Solenoidvalve(24VDC)

Airinlet(1/4in.diametertubing)

MManualoverrideswitch

M8Solenoidvalveelectricalconnector

OAirCloseExhaustPort

AirOpenExhaustPort

334627D

Overview

Overview Overview

Overview

Theapplicatorusestheair-opened,airclosedmode

ofoperation.Itusesave-wayexhaustingsolenoid

tocontrolthepistoninsidethevalve.Fluidisltered

throughthemanifoldlter(C)beforeenteringthe

valveuidinletport.Thentheuidislteredonenal

timethroughthemodulelter,whichislocatedin

eachmodule,directlybeforetheballandseat.

Whenairmovesthepistonandrodfromitsseat,

itopenstheuidoutlet.Toturnofftheuid,the

solenoidredirectsairtothetopofthepiston.The

airandspringworktogethertopushthepistonand

rodintotheseat.

Theapplicatorshouldberigidlymountedand

remotelyoperatedbyameltersystemandtriggering

device.Themeltersystemprovidespressurizeduid

tothevalve.Thetriggeringdevicecontrolstheuid

owbyopeningandclosingthesolenoidvalve.

Figure2AirandFluidFlow

Air Air

Air

Fluid Fluid

Fluid

Grounding Grounding

Grounding

Theequipmentmustbegroundedtoreducethe

riskofstaticsparkingandelectricshock.Electric

orstaticsparkingcancausefumestoigniteor

explode.Impropergroundingcancauseelectric

shock.Groundingprovidesanescapewireforthe

electriccurrent.

•Pump: Pump:

Pump:

followmanufacturer’srecommendations.

•Applicator: Applicator:

Applicator:

groundedthroughelectricalconnection.

•Air Air

Air

compressor: compressor:

compressor:

followmanufacturer’s

recommendations.

•Fluid Fluid

Fluid

supply supply

supply

container: container:

container:

followlocalcode.

•Solvent Solvent

Solvent

pails pails

pails

used used

used

when when

when

ushing: ushing:

ushing:

followlocal

code.Useonlyconductivemetalpails,placed

onagroundedsurface.Donotplacethepail

onanon-conductivesurface,suchaspaperor

cardboard,whichinterruptsgroundingcontinuity.

•To To

maintain maintain

maintain

grounding grounding

grounding

continuity continuity

continuity

when when

when

ushing ushing

ushing

or or

relieving relieving

relieving

pressure: pressure:

pressure:

ensuremountingmanifoldand

electricalpowerconnectoraregroundedproperly.

8 334627D

Installation

Installation Installation

Installation

Mounting Mounting

Mounting

NOTICE NOTICE

NOTICE

Topreventheattransferringintoothercomponents

ofthepackagingline,ensurethattheinsulatoris

installed.

Low Low

Low

Prole Prole

Prole

Models: Models:

Models:

Usea3/4in.(19mm)wrench

toadjustnutsthatcontrolpositionofapplicatoron

threadedrod.

All All

All

Other Other

Other

Models: Models:

Models:

Seethefollowinginstructions.

Mountmanifoldonuptoa1/2in.(12mm)diameter

barusingmountingclamp(H)toholdtheapplicator

inplaceandensureadhesiveisappliedproperly.

Foroptimalmountingstrengthofaslimmodel,use

a7/16hexbar.

NOTE: NOTE:

NOTE:

SlimStandardDualandStandardQuad

modelsusea5mmAllenwrench.

1.Useanappropriatewrenchtoloosenthe

mountingclampandslidetheapplicatoronthe

mountingbar.

2.Tightenthemountingclamp.Torqueto144in-lb

(16.2N•m).

NOTE: NOTE:

NOTE:

Provideenoughroomtoaccesssidesof

applicatorformaintenanceandrepair.

Figure3MountingClamp

Connect Connect

Connect

Heated Heated

Heated

Hose Hose

Hose

1.Connectthehoseuidoutlettothemanifolduid

inlet(E).Usetwo11/16in.wrenchestotighten

thehosetting.

Figure4ConnecttheHeatedHose

2.Connectthecordset(F)tothehose.

3.Connectthehoseinlettothemeltersystem

outlet.Seetheheatedhosemanualfor

installationguidelines.

4.Connectthehosecordsettomelter.Seethe

heatedhosemanualforinstallationguidelines.

Recommended Recommended

Recommended

Air Air

Air

Setup Setup

Setup

1.Connecttubingfromtheairlter(Gracopart

106148)totheairregulator.

Figure5ConnecttheAirSupply

2.Settheairregulatorto80psi(5.5Bar,0.5MPa).

3.Connecttubingfromtheairregulatortothe

applicatorsolenoid.

334627D 9

Installation

Connect Connect

Connect

Solenoid Solenoid

Solenoid

Valve Valve

Valve

1.Connect1/4in.diameterairsupplytubingtoa

clean,dry,andnon-lubricatedairsupplyandto

thepush-to-connectairinlettting(L).

Figure6AirInletFitting

2.Connectsolenoidvalve(J)to24VDCsignal.

SeeConnectTriggeringDevice,page10.

NOTE: NOTE:

NOTE:

A6mmtubettingisincludedwiththe

applicator.Thettingcanbechangedusinga5

mmAllenwrench.

Connect Connect

Connect

Triggering Triggering

Triggering

Device Device

Device

AllGM100valvesusea24VDCsolenoidvalve.

Improperelectricalconnectioncanresultinelectric

shock.Allelectricalwiringmustbedonebya

qualiedelectricianandcomplywithalllocalcodes

andregulations.

Figure7SolenoidValveElectricalConnector

Standard Standard

Standard

Wiring Wiring

Wiring

Colors Colors

Colors

Terminal Terminal

Terminal

Cable Cable

Cable

Function Function

Function

M8 M8

Plus(+)24VSupply

Brown

Minus(-)

ReturnBlue/Black

Before Before

Before

Using Using

Using

Equipment Equipment

Equipment

Theequipmentwastestedwithcanolaoil,whichis

leftintheuidpassagestoprotectparts.Toavoid

contaminatingyouruidwithoil,primetheequipment

withhotmeltuntilalloftheoilispushedoutbefore

usingtheequipment.SeeFlush,page11.

10 334627D

Installation

Flush Flush

Flush

NOTE: NOTE:

NOTE:

DoNOTcyclethemoduleuntilthe

temperaturesetpointhasbeenachieved.Cycling

themodulebelowthetemperaturesetpointmay

causeprematuresealleakage.

1.Disconnectorturnoffthedevicewhichtriggers

thesolenoidvalve.

2.Ensurethenozzle(Z)isremoved.

3.Heatthesystemtoworkingtemperature.

4.Placewastecontainerundertheapplicatorto

catchtheadhesive.

5.Pressthemanualoverrideswitch(M)tomanually

triggerthesolenoidvalve.

6.Dispensehotmelt(adhesive)untilitisclean.

Figure8Flush

Install Install

Install

Nozzle Nozzle

Nozzle

Use1/2in.wrenchtoinstallnozzle.See

KitsandAccessories,page37.

Figure9InstallNozzle

Select Select

Select

RTD RTD

RTD

NOTE: NOTE:

NOTE:

ForInvisiPacsystemsonly.

IdentifyRTDtypeusedinapplicatoronthesystem

AdvancedDisplayModule(ADM).TheRTDtypeis

listedonthemanifoldcoverplate.

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.

334627D

Operation

Operation Operation

Operation

Pressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

FollowthePressureReliefProcedure

wheneveryouseethissymbol.

Thisequipmentstayspressurizeduntilpressure

ismanuallyrelieved.Tohelppreventserious

injuryfrompressurizeduid,suchasskininjection,

andsplashinguid,followthePressureRelief

Procedurewhenyoustopsprayingandbefore

cleaning,checking,orservicingtheequipment.

1.Depressurizehotmeltsystem.

2.Closethebleed-typemasterairvalve.

3.Actuatetheapplicatorrepeatedlyuntilnouid

ows.

4.Ifyoususpectthemodulenozzleisclogged,

removenozzleandthenactuatethemoduleto

relievepressure.

5.Ifyoususpectthemoduleoruidhoseis

cloggedorthatpressurehasnotbeenfully

relievedafterfollowingthestepsabove,VERY

SLOWLYlooseninlettting,inletlter,orhose

endcouplingtorelievepressuregradually,

thenloosencompletely.Clearhoseormodule

obstruction.

6.Turnoffairpressuretothesolenoidvalve.

334627D

Maintenance

Maintenance Maintenance

Maintenance

Materialinsidetheapplicatorcanbenearsetpoint

temperature.Wearprotectiveclothingtoavoid

severeburns.

Daily: Daily:

Daily:

Cleanhotmeltfromexteriorofapplicator.

Weekly: Weekly:

Weekly:

Inspecttheapplicator,uidlines,cordset,

andsolenoidcableforwearordamage.See

Repair,page20forinstructions.

Replace Replace

Replace

Inlet Inlet

Inlet

Filter Filter

Filter

NOTICE NOTICE

NOTICE

Removethelterwhentheapplicatorishot.Ifthe

applicatoriscold,theadhesivewillbehardandthe

ltermaybedifculttoremoveordamaged.

1.Disabletheapplicator.See

BeforeBeginningRepair,page20.

2.Removedirtylter(C)frommanifold(D).

Figure10InletFilter

3.Applyathincoatingofhigh-temperaturelubricant

tosealsonthenewlter(C)andinstallinthe

manifold(D).Torqueto30in.-lb(3.4N∙m),using

a5/32in.(4mm)Allenwrench.

Filter Filter

Filter

Maintenance Maintenance

Maintenance

Guidelines 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 powdered 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

Environment

Classication Classication

Classication

Clean Clean

Clean

Moderate Moderate

Moderate

Dusty Dusty

Dusty

Manifold

lter

Replace

lterevery

six six

six

months

Replace

lter

everyfour four

four

months

Replace

lter

everytwo two

two

months

334627D 13

Troubleshooting

Troubleshooting Troubleshooting

Troubleshooting

Problem Problem

Problem

Cause Cause

Cause

Solution Solution

Solution

PluggedmanifoldlterReplacemanifoldlter.See

ReplaceInletFilter,page13.

CloggedhoseCleanorreplacehose.

Failedsolenoidvalve

Checkforcorrectoperation.Clean

orreplace.

Nosignaltosolenoidvalve

Checksolenoidvalveforcorrect

operation.

Incorrectsolenoidvalvewiring

Checksolenoidvalvewiring.

Incorrectsignaltosolenoidvalve

Checkif24VDC.

SolenoidmuferpluggedCheckandreplacemufers.

NouidpressureCheckadhesivedeliverysystem.

Heaterfailure(coldapplicator)Checkandreplace

heatercartridges.See

ReplaceHeaterCartridge,page20.

Noairtosolenoidvalve

Checkairsupply.

DirtyorfaultytriggeringdeviceCheck,clean,orreplacetriggering

device.

Solenoidvalveconnected

incorrectly

Checksolenoidvalveairconnections.

Noadhesiveorincorrect

amountofadhesiveoutofall

moduleswhentriggered

CloggedmanifoldpassageCleanorreplacemanifold.

Pluggednozzle

Cleanorreplacenozzle.

Failedmoduleinclosedposition

Checkforcorrectoperation.

Cleanorreplace.See

CheckModule,page17.

PluggedmodulelterReplacemodule.See

ReplaceModule,page24.

Noadhesiveorincorrect

amountofadhesiveoutof

one/somemoduleswhen

triggered

CloggedmanifoldpassageCleanorreplacemanifold.

Failedmoduleinopenposition

Cleanorreplacemodule.See

ReplaceModule,page24.

Adhesiveoutofone/some

moduleswhennottriggered

Adhesivepressuretoohigh

Checkandreduceuidpressure.

334627D

Troubleshooting

Problem Problem

Problem

Cause Cause

Cause

Solution Solution

Solution

HeaterfailureCheckandreplace

heatercartridge.See

ReplaceHeaterCartridge,page20.

Loosecordsetconnection

Checkconnection.

RTDfailureCheckandreplaceRTD.See

CheckRTD,page19.

IncorrectRTDforadhesivedelivery

system

CheckdeliverysystemRTD

requirement

ThermalcutofffailureCheckandreplace

thermalcutoff.See

ReplaceThermalCutoff,page21.

Applicatorwillnotheat

WrongRTDtypeselected

CheckRTDtypesettingsonthe

system.Changeifnecessary.See

SelectRTD,page11.

HeaterfailureCheckandreplace

heatercartridge.See

ReplaceHeaterCartridge,page20.

RTDfailureCheckandreplaceRTD.See

CheckRTD,page19.

IncorrectRTDforadhesivedelivery

system

CheckdeliverysystemRTD

requirement.

Incorrectpowertoheater

Checkandcorrectpower.

Applicatoroverheats

WrongRTDtypeselected

CheckRTDtypesettingsonthe

system.Changeifnecessary.See

SelectRTD,page11.

HeaterfailureCheckandreplace

heatercartridge.See

ReplaceHeaterCartridge,page20

RTDfailureCheckandreplaceRTD.

IncorrectRTDforadhesivedelivery

system

CheckdeliverysystemRTD

requirement.

Incorrectpowertoheater

Checkandcorrectpower.

Applicatorunder-heats

WrongRTDtypeselected

CheckRTDtypesettingsonthe

system.Changeifnecessary.See

SelectRTD,page11.

Moduleo-ringfailureCheckandreplaceo-ring.See

ReplaceModule,page24.

InletttinglooseTightentting.

Manifoldltero-ringfailureCheckandreplaceo-ring.

Adhesiveleakingfrom

applicator

NozzlelooseTightennozzle.

334627D 15

Troubleshooting

Problem Problem

Problem

Cause Cause

Cause

Solution Solution

Solution

Lowairpressuretosolenoidvalve

Checkairsupply

LowuidpressureCheckadhesivedeliverysystem

Lowapplicatortemperature

Checkheatoperation.See

“Applicatorwillnotheat”sectionin

Troubleshooting,page14.

PluggedmanifoldlterReplacemanifoldlter(see

ReplaceInletFilter,page13).

Speedhasreducedonone

module

Modulepistonsealairleak

Checksolenoidaircloseexhaustport

(O).SeeReplaceModule,page24.

SolenoidvalvefailureCheckandreplacesolenoidvalve.

Adhesivepressuretoohigh

Checkandreduceuidpressure.

Solenoidvalveconnected

incorrectly

Checksolenoidvalveairconnections.

ModulefailureCheckandreplaceallmodules.See

CheckModule,page17.

Adhesiveoutofallmodules

whennottriggered

Noairtosolenoidvalve

Checkairsupply.

16 334627D

Troubleshooting

Check Check

Check

Module Module

Module

Checkthemoduleoperationtoverifyifthemodule

hasfailedandneedstobereplaced.

1.Visuallycheckforthepresenceofglueinthe

weephole(W).

NOTE: NOTE:

NOTE:

Ifglueispresent,themoduleneedstobe

replaced.SeeReplaceModule,page24.

2.Verifythattheairpressuretothesolenoidvalve

is65–80psi(4.4–5.5bar,0.44–0.55MPa).

Figure11CheckModule

3.Verifythatthereisairpressuretothemotor,

whichwillverifythatthereisuidpressure.

4.Makesurethesystemisatthecorrect

temperature.

5.Whilelookingintheweepholepressthesolenoid

valvemanualoverrideswitch(M)tomanually

triggertheapplicator.

NOTE: NOTE:

NOTE:

Lookthroughtheweephole.Iftherod

movesthenthemoduleisfunctioningproperly.If

theroddoesnotmove,themoduleneedstobe

replaced.SeeReplaceModule,page24.

6.Removethenozzle.

7.Pressthemanualover-rideswitchtotriggerthe

module.Ifglueowsfromtheseat,themodule

isfunctioningproperly.

Check Check

Check

Nozzle Nozzle

Nozzle

and and

and

Module Module

Module

Triggertheapplicatorwithoutthenozzletodetermine

ifthenozzleormoduleisclogged.

1.Disableapplicatorassembly.See

BeforeBeginningRepair,page20.

2.Usea1/2in.wrenchtoloosenthenozzleand

removebyhand.

Figure12

3.Connectthepowerandsolenoidcable.

4.Returntheapplicatorbackintooperation.

5.Triggertheapplicator.

a.Ifadhesiveows,cleanthenozzleand

reinstallonthemodule.

b.Ifadhesivedoesnotow,themoduleis

cloggedandneedstobereplaced.See

ReplaceModule,page24.

334627D

Troubleshooting

Check Check

Check

Heater Heater

Heater

Checkthecontinuityoftheheatertoverifyproper

resistance.Ifthereisnocontinuity,theheaterhas

failedandneedstobereplaced.

1.Disableapplicator.See

BeforeBeginningRepair,page20.

2.Checkresistanceoftheheaterusinga

multi-meterbetweenthepinsofthecordset

connector.Seeconnectorsillustrationsincordset

pintables.

3.Replacetheheatercartridgeifthe

resistancereadingisoutsidethe

rangeorifthereisnocontinuity.See

ReplaceHeaterCartridge,page20.

Cordset Cordset

Cordset

Check Check

Check

Pins Pins

Pins

Model Model

Model

Resis- Resis-

Resis-

tance tance

tance

Values Values

Values

SlimModels

365–405

Ohms

DualandDual

LowProle

Models

180–200

Ohms

24W087,

24X039,

or24X760

Pt100

(385)RTD

Cordset

AandC

Quadand

Quadlow

ProleModels

145–165

Ohms

SlimModels

365–405

Ohms

DualandDual

LowProle

Models

180–200

Ohms

24W088,

24X040,or

24X761Ni

120RTD

Cordset

1and2

Quadand

Quadlow

ProleModels

145–165

Ohms

Table Table

Table

1 1

24W087, 24W087,

24W087,

24X039, 24X039,

24X039,

or or

24X760, 24X760,

24X760,

Pt Pt

100 100

100

(385) (385)

(385)

RTD RTD

RTD

Cordset Cordset

Cordset

Pin Pin

Description Description

Description

ThermalCutoff

Ground

Heat

RTD(White)

RTD(Red)

Table Table

Table

2 2

24W088, 24W088,

24W088,

24X040, 24X040,

24X040,

or or

24X761, 24X761,

24X761,

Ni Ni

120 120

120

RTD RTD

RTD

Cordset Cordset

Cordset

Pin Pin

Description Description

Description

ThermalCutoff

2Heat-

RTD(White)

RTD(Red)

GGround

18 334627D

Troubleshooting

Check Check

Check

RTD RTD

RTD

CheckthecontinuityoftheRTDtoverifyproper

resistance.Ifthereisnocontinuity,theRTDhas

failedandneedstobereplaced.

1.Disabletheapplicator.See

BeforeBeginningRepair,page20.

2.CheckresistanceoftheRTDusingamulti-meter

betweenthepinsofthecordsetconnector.See

connectorsillustrationsincordsetpintables.

Cordset Cordset

Cordset

Check Check

Check

Pins Pins

Pins

Resistance Resistance

Resistance

Values Values

Values

At At

Room Room

Room

Temperature Temperature

Temperature

24W087,

24X039,or

24X760Pt

100(385)

RTDCordset

DandE107-115

ohms

24W088,

24X040,or

24X761Ni

120RTD

Cordset

3and5130-140

ohms

3.ReplacetheRTDiftheresistancereadingis

outsidetherange,orifthereisnocontinuity.See

ReplaceRTD,page21.

Check Check

Check

Thermal Thermal

Thermal

Cutoff Cutoff

Cutoff

Ifworkingproperly,thecutoffwilltripat500°F(260°

C)andrestat420°F(216°C).Iffailureissuspected,

allowtheapplicatortocoolandthencheckthe

continuityofthethermalcutofftoverifyithasnot

failed.Ifthereisnocontinuity,thecutoffhasfailed

andneedstobereplaced.

1.Disabletheapplicator.See

BeforeBeginningRepair,page20.

2.Removecoverplate.

3.Checkforcontinuityusingamulti-meterbetween

pinofcordsetconnectorandthewirefromthe

thermalcutoffthatconnectstotheheaterlead.

Cordset Cordset

Cordset

Check Check

Check

Pins Pins

Pins

24W087,24X039,or

24X760Pt100(385)

RTDCordset

24W088,24X040,or

24X761Ni120RTD

Cordset

334627D 19

Repair

Repair Repair

Repair

Required Required

Required

Tools Tools

Tools

•Phillipsscrewdriver

•Flatbladescrewdriver

•3mm,4mm,and5mmAllenwrenches

•10mm,1/2in.11/16in.,and3/4in.wrenches

•Torquewrenches

•Wastecontainer

•High-temperatureanaerobicthreadsealant

•High-temperaturelubricant

•Anti-seize

•Crimptool

Before Before

Before

Beginning Beginning

Beginning

Repair Repair

Repair

Materialinsidetheapplicatorcanbenearsetpoint

temperature.Wearprotectiveclothingtoavoid

severeburns.

1.Turnoffthemeltersystem.Seemeltermanual

forshutdowninstructions.

2.Relievepressure.See

PressureReliefProcedure,page12.

3.Disconnectthecordset(F)fromtheheatedhose.

Figure13DisconnectCordset

4.DisconnectM8solenoidelectricalconnector(N).

Replace Replace

Replace

Heater Heater

Heater

Cartridge Cartridge

Cartridge

1.Disabletheapplicator.

SeeBeforeBeginningRepair,page20.

2.UseaPhillipsscrewdrivertoremovethefour

screws(15)andmanifoldcoverplate(18).

3.Removetheheatercartridges(3)fromthe

manifold(1).

NOTE: NOTE:

NOTE:

Notetheplacementoftheheatersand

leadlengths.

4.Removebuttsplices(4)fromheaterwires(3),

thermalcutoff(29),andcordsetwireleads(17).

5.Crimpnewheaterwiresintonewsplices(4).See

wiringdiagram.

NOTICE NOTICE

NOTICE

Topreventashorttogroundandblowinga

MZLPfuse,ensurebarewiresarecovered

andberglasstapeandsleevesarecentered

oversplices.

6.Insertthenewheatercartridges(3)intothe

manifold(1).

NOTE: NOTE:

NOTE:

Donotapplythermalgreasetotheheater

cartridge.

7.Reinstallthemanifoldcoverplate(18).

8.Reconnectthecordset(17)totheheatedhose.

9.ReconnecttheM8solenoidelectricalconnector

(N).

20 334627D

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