Graco InvisiPac GS35 Plug-Free User manual

Type
User manual
Instructions-Parts
InvisiPac® InvisiPac®
InvisiPac®
GS35 GS35
GS35
Plug-Free™ Plug-Free™
Plug-Free™
Hot Hot
Hot
Melt Melt
Melt
Applicator Applicator
Applicator
3A2805M
EN
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
for for
for
use use
use
in in
in
waterwash waterwash
waterwash
environments. environments.
environments.
Not Not
Not
approved approved
approved
for for
for
use use
use
in in
in
explosive explosive
explosive
atmospheres atmospheres
atmospheres
or or
or
hazardous hazardous
hazardous
locations. locations.
locations.
Important Important
Important
Safety Safety
Safety
Instructions 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
BURN
HAZARD HAZARD
HAZARD
Equipmentsurfacesanduidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
Donottouchhotuidorequipment.
ELECTRIC ELECTRIC
ELECTRIC
SHOCK SHOCK
SHOCK
HAZARD HAZARD
HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore
servicingequipment.
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.
3A2805M 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.
Holdgunrmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareantistaticorconductive.
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.
Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
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.
4
3A2805M
Approvals
WARNING WARNING
WARNING
TOXIC TOXIC
TOXIC
FLUID FLUID
FLUID
OR OR
OR
FUMES FUMES
FUMES
HAZARD HAZARD
HAZARD
Toxicuidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
ReadMSDSstoknowthespecichazardsoftheuidsyouareusing.
Storehazardousuidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
PERSONAL PERSONAL
PERSONAL
PROTECTIVE PROTECTIVE
PROTECTIVE
EQUIPMENT 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
Part
Series Series
Series
RTD RTD
RTD
Type Type
Type
Solenoid Solenoid
Solenoid
Valve Valve
Valve
24P073B
Pt100(385)24VDC
24P074B
Pt100(385)110VAC
24P246B
Pt100(385)
None
24P299BNi120
24VDC
24P300BNi120
110VAC
24P307BNi120None
Slim Slim
Slim
(Single) (Single)
(Single)
Part Part
Part
Series Series
Series
RTD RTD
RTD
Type Type
Type
Solenoid Solenoid
Solenoid
Valve Valve
Valve
24U021B
Pt100(385)24VDC
24U022B
Pt100(385)110VAC
24U023B
Pt100(385)
None
24U024BNi120
24VDC
24U025BNi120
110VAC
24U026BNi120None
Dual Dual
Dual
Part Part
Part
Series Series
Series
RTD RTD
RTD
Type Type
Type
Solenoid Solenoid
Solenoid
Valve Valve
Valve
24P075B
Pt100(385)24VDC
24P076B
Pt100(385)110VAC
24P247B
Pt100(385)
None
24P301BNi120
24VDC
24P302BNi120
110VAC
24P308BNi120None
Low Low
Low
Prole Prole
Prole
- -
-
Dual Dual
Dual
Part Part
Part
Series Series
Series
RTD RTD
RTD
Type Type
Type
Solenoid Solenoid
Solenoid
Valve Valve
Valve
24U027B
Pt100(385)24VDC
24U028B
Pt100(385)110VAC
24U029B
Pt100(385)
None
24U030BNi120
24VDC
24U031BNi120
110VAC
24U032BNi120None
Quad Quad
Quad
Part Part
Part
Series Series
Series
Module Module
Module
Spacing Spacing
Spacing
Type* Type*
Type*
RTD RTD
RTD
Type Type
Type
Solenoid Solenoid
Solenoid
Valve Valve
Valve
24P077BI
Pt100(385)24VDC
24P078BI
Pt100(385)110VAC
24P079BII
Pt100(385)24VDC
24P080BII
Pt100(385)110VAC
24P250BI
Pt100(385)
None
24P254BII
Pt100(385)
None
24P303BINi120
24VDC
24P304BINi120
110VAC
24P305BIINi120
24VDC
24P306BIINi120
110VAC
24P309BINi120None
24P310BIINi120None
*
See Dimensions, page 46 .
Low Low
Low
Prole Prole
Prole
- -
-
Quad Quad
Quad
Part Part
Part
Series Series
Series
RTD RTD
RTD
Type Type
Type
Solenoid Solenoid
Solenoid
Valve Valve
Valve
24U033B
Pt100(385)24VDC
24U034B
Pt100(385)110VAC
24U035B
Pt100(385)
None
24U036BNi120
24VDC
24U037BNi120
110VAC
24U038BNi120None
6 3A2805M
ComponentIdentication
Component Component
Component
Identication Identication
Identication
A
C
B
AD
E
F
G
H
J
M
K
K
L
N
P
Figure124P075Shown
ADispensemodule
B
Fluidoutlet/nozzle(3/8–24)
CFluidlter(notvisible)
D
Manifold
E
Fluidinlet(9/16–18,—6JIC,37°are)
F
Cordset(24W087shown)
G
Airtube
H
Mountingclamp(1/2in.diameterbar)
J
Solenoidvalve(24VDC,110VAC);not
includedwithallmodels
K
Mufer
L
Airinlet(3/8in.diametertubing)
MManualoverrideswitch
N
Solenoidvalveelectricalconnector
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
Dispense
applicator: applicator:
applicator:
groundedthroughelectrical
connection.
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
onanonconductivesurface,suchaspaperor
cardboard,whichinterruptsgroundingcontinuity.
To To
To
maintain maintain
maintain
grounding grounding
grounding
continuity continuity
continuity
when when
when
ushing ushing
ushing
or or
or
relieving relieving
relieving
pressure: pressure:
pressure:
ensuremountingmanifoldand
electricalpowerconnectoraregroundedproperly.
8 3A2805M
Installation
Installation Installation
Installation
Mounting Mounting
Mounting
NOTICE NOTICE
NOTICE
Topreventheattransferringintoothercomponents
ofthepackagingline,ensurethattheinsulator(P)
isinstalled.
Low Low
Low
Prole Prole
Prole
Models: Models:
Models:
Usea3/4in.(19mm)wrenchto
adjustnutsthatcontrolpositionofgunassemblyon
threadedrod.
All All
All
Other Other
Other
Models: 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
Connect
Heated Heated
Heated
Hose 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
Connect
Solenoid Solenoid
Solenoid
Valve Valve
Valve
1.Connect3/8in.diameterairsupplytubingtoa
clean,dry,andnon-lubricatedairsupplyandto
thepush-to-connectairinlettting(L).
L
Figure5AirInletFitting
2.Connectsolenoidvalveto24VDCor110VAC
signal.SeeConnectTriggeringDevice,page10.
For For
For
applicators applicators
applicators
without without
without
a a
a
supplied supplied
supplied
solenoid solenoid
solenoid
valve: valve:
valve:
Usesolenoidvalveswithanoverrideswitch.
Ensurethatyoursolenoidvalveisconnectedtothe
manifoldwithtubingratedfor400°F(204°C).
Ensurethesolenoidvalveisratedfor
high-temperatureapplications.
3A2805M 9
Installation
Connect Connect
Connect
Triggering Triggering
Triggering
Device 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
Prime
Before Before
Before
Using Using
Using
Equipment 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
Install
Nozzle Nozzle
Nozzle
Use1/2in.wrenchtoinstallnozzle.See
KitsandAccessories,page44.
Select Select
Select
RTD 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
Pressure
Relief Relief
Relief
Procedure 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
Replace
Inlet Inlet
Inlet
Filter 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
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 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
Environment
Classication Classication
Classication
Clean Clean
Clean
Moderate Moderate
Moderate
Dusty Dusty
Dusty
Gun
manifold
lter
Solenoid
exhaust
lters
Replace
lterevery
six six
six
months
Replace
lter
everyfour four
four
months
Replace
lter
everytwo two
two
months
3A2805M 13
Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
Problem Problem
Problem
Cause Cause
Cause
Solution Solution
Solution
DebrisinmanifoldlterReplacemanifoldlter.See
ReplaceInletFilter,page13.
CloggedhoseCleanorreplacehose.
Failedsolenoidvalve
Checkforcorrectoperation.Clean
orreplace.
Nosignaltosolenoidvalve
Checksolenoidvalveforcorrect
operation.
Incorrectsolenoidvalvewiring
Checksolenoidvalvewiring.
Incorrectsignaltosolenoidvalve
Checkif24VDCor120VAC.
SolenoidmuferpluggedCheckandreplacemufers.
NouidpressureCheckadhesivedeliverysystem.
Heaterfailure(coldgun)Checkandreplace
heatercartridges.See
ReplaceHeaterCartridge,page20.
Noairtosolenoidvalve
Checkairsupply.
DirtyorfaultytriggeringdeviceCheck,clean,orreplacetriggering
device.
Solenoidvalveconnected
incorrectly
Checksolenoidvalveairconnections.
Noadhesiveorincorrect
amountofadhesiveoutofall
moduleswhentriggered
CloggedmanifoldpassageCleanorreplacemanifold.
Debrisinnozzle
Cleanorreplacenozzle.
Failedmoduleinclosedposition
Checkforcorrectoperation.
Cleanorreplace.See
CheckModule,page16.
DebrisinmodulelterReplacemodule.See
ReplaceModule,page24.
Noadhesiveorincorrect
amountofadhesiveoutof
one/somemoduleswhen
triggered
CloggedmanifoldpassageCleanorreplacemanifold.
Failedmoduleinopenposition
Cleanorreplacemodule.See
ReplaceModule,page24.
Adhesiveoutofone/some
moduleswhennottriggered
Adhesivepressuretoohigh
Checkandreduceuidpressure.
14
3A2805M
Troubleshooting
Problem Problem
Problem
Cause Cause
Cause
Solution Solution
Solution
HeaterfailureCheckandreplace
heatercartridge.See
ReplaceHeaterCartridge,page20.
Loosecordsetconnection
Checkconnection.
RTDfailureCheckandreplaceRTD.See
CheckRTD,page17.
IncorrectRTDforadhesivedelivery
system
CheckdeliverysystemRTD
requirement
ThermalcutofffailureCheckandreplace
thermalcutoff.See
ReplaceThermalCutoff,page20.
Gunwillnotheat
WrongRTDtypeselected
CheckRTDtypesettingsonthe
system.Changeifnecessary.See
SelectRTD,page11.
HeaterfailureCheckandreplace
heatercartridge.See
ReplaceHeaterCartridge,page20.
RTDfailureCheckandreplaceRTD.See
CheckRTD,page17.
IncorrectRTDforadhesivedelivery
system
CheckdeliverysystemRTD
requirement.
Incorrectpowertoheater
Checkandcorrectpower.
Gunoverheats
WrongRTDtypeselected
CheckRTDtypesettingsonthe
system.Changeifnecessary.See
SelectRTD,page11.
HeaterfailureCheckandreplace
heatercartridge.See
ReplaceHeaterCartridge,page20
RTDfailureCheckandreplaceRTD.
IncorrectRTDforadhesivedelivery
system
CheckdeliverysystemRTD
requirement.
Incorrectpowertoheater
Checkandcorrectpower.
Gununder-heats
WrongRTDtypeselected
CheckRTDtypesettingsonthe
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
Problem
Cause Cause
Cause
Solution Solution
Solution
SolenoidvalvefailureCheckandreplacesolenoidvalve.
Adhesivepressuretoohigh
Checkandreduceuidpressure.
Solenoidvalveconnected
incorrectly
Checksolenoidvalveairconnections.
Adhesiveoutofallmodules
whennottriggered
ModulefailureCheckandreplaceallmodules.See
CheckModule,page16.
Check Check
Check
Module Module
Module
Checkthemoduleoperationtoverifyifthemodule
hasfailedandneedstobereplaced.
1.InsertasmallAllenwrenchintothetopofthe
module.
2.Pressthesolenoidvalveoverrideswitch(S)to
manuallytriggerthegun.
Figure10CheckModule
Ifthewrenchmovesupanddown,thenthemodule
isoperatingproperly
Ifthewrenchdoesnotmove,thenthemoduleneeds
tobereplaced.SeeReplaceModule,page24.
Check Check
Check
Nozzle Nozzle
Nozzle
and and
and
Module 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
Check
Heater 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
Cordset
Check Check
Check
Pins Pins
Pins
Gun Gun
Gun
Model Model
Model
Resis- 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
Table
1 1
1
24W087, 24W087,
24W087,
Pt Pt
Pt
100 100
100
(385) (385)
(385)
RTD RTD
RTD
Cordset Cordset
Cordset
Pin Pin
Pin
Description Description
Description
A
ThermalCutoff
B
Ground
C
Heat-
D
RTD(White)
E
RTD(Red)
Table Table
Table
2 2
2
24W088, 24W088,
24W088,
Ni Ni
Ni
120 120
120
RTD RTD
RTD
Cordset Cordset
Cordset
Pin Pin
Pin
Description Description
Description
1
ThermalCutoff
2Heat-
3
RTD(White)
5
RTD(Red)
GGround
Check Check
Check
RTD RTD
RTD
CheckthecontinuityoftheRTDtoverifyproper
resistance.Ifthereisnocontinuity,theRTDhas
failedandneedstobereplaced.
1.Disablegunassembly.See
BeforeBeginningRepair,page19.
2.CheckresistanceoftheRTDusingamultimeter
betweenthepinsofthecordsetconnector.See
connectorsillustrationsincordsetpintables.
Cordset Cordset
Cordset
Check Check
Check
Pins Pins
Pins
Resistance Resistance
Resistance
Values Values
Values
At At
At
Room 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
Check
Thermal Thermal
Thermal
Cutoff 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
Cordset
Check Check
Check
Pins Pins
Pins
24W087,Pt100(385)
RTDCordset
A
24W088,Ni120RTD
Cordset
1
Thermal Thermal
Thermal
Cutoff Cutoff
Cutoff
W
WLL DD
18 3A2805M
Repair
Repair Repair
Repair
Required Required
Required
Tools 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
Before
Beginning Beginning
Beginning
Repair 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
Replace
Heater Heater
Heater
Cartridge 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
Replace
RTD RTD
RTD
TheRTDisreplacedbyreplacingtheentirecordset.
SeeReplaceCordset,page22,forinstructions.
Replace Replace
Replace
Thermal Thermal
Thermal
Cutoff 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
00 00
DD
EE
FF
20 3A2805M
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Graco InvisiPac GS35 Plug-Free User manual

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User manual

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