Graco 3A2805K Invisipac Gs35 Users Manual Plug Free Hot Melt Applicator, Instructions Parts, English
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2015-04-02
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Instructions-Parts InvisiPac® GS35 Plug-Free™ Hot Melt Applicator 3A2805K 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. PROVEN QUALITY. LEADING TECHNOLOGY. EN Contents Warnings ........................................................... 3 Approvals........................................................... 5 Models............................................................... 6 Component Identification..................................... 7 Overview............................................................ 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 Operation........................................................... 12 Pressure Relief Procedure............................ 12 Maintenance ...................................................... 13 Replace Inlet Filter ....................................... 13 Filter Maintenance Guidelines....................... 13 Troubleshooting.................................................. 14 2 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 3A2805K 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. Get 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. Follow the 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. 3A2805K Pressure Relief Procedure 3 Warnings WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in can ignite or explode. To help prevent fire and explosion: • Use equipment only in well ventilated area. • Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline. • Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present. • Ground all equipment in the work area. See 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. • 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. work area Grounding Stop operation immediately . 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 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 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. Technical Data Pressure Relief Procedure 4 3A2805K 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 3A2805K 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 24P074 24P246 24P299 24P300 24P307 B B B B B B 24 VDC 110 VAC None 24 VDC 110 VAC None Pt 100 (385) Pt 100 (385) Pt 100 (385) Ni 120 Ni 120 Ni 120 Slim (Single) Part Series RTD Type Solenoid Valve 24U021 24U022 24U023 24U024 24U025 24U026 B B B B B B 24 VDC 110 VAC None 24 VDC 110 VAC None Pt 100 (385) Pt 100 (385) Pt 100 (385) Ni 120 Ni 120 Ni 120 Part Series RTD Type Solenoid Valve 24U027 24U028 24U029 24U030 24U031 24U032 B B B B B B 24 VDC 110 VAC None 24 VDC 110 VAC None Part Series RTD Type Solenoid Valve 24P075 24P076 24P247 24P301 24P302 24P308 B B B B B B 24 VDC 110 VAC None 24 VDC 110 VAC None Pt 100 (385) Pt 100 (385) Pt 100 (385) Ni 120 Ni 120 Ni 120 Pt 100 (385) Pt 100 (385) Pt 100 (385) Ni 120 Ni 120 Ni 120 Quad Part 24P077 24P078 24P079 24P080 24P250 24P254 24P303 24P304 24P305 24P306 24P309 24P310 * Dual 6 Low Profile - Dual Series Module Spacing Type* B B B B B B B B B B B B I I II II I II I I II II I II RTD Type Solenoid Valve Pt 100 (385) Pt 100 (385) Pt 100 (385) Pt 100 (385) Pt 100 (385) Pt 100 (385) Ni 120 Ni 120 Ni 120 Ni 120 Ni 120 Ni 120 24 VDC 110 VAC 24 VDC 110 VAC None None 24 VDC 110 VAC 24 VDC 110 VAC None None See Dimensions, page 46. Low Profile - Quad Part Series RTD Type Solenoid Valve 24U033 24U034 24U035 24U036 24U037 24U038 B B B B B B 24 VDC 110 VAC None 24 VDC 110 VAC None Pt 100 (385) Pt 100 (385) Pt 100 (385) Ni 120 Ni 120 Ni 120 3A2805K Component Identification Component Identification A B C D E F G H J K L M N P Dispense module Fluid outlet/nozzle (3/8–24) Fluid filter (not visible) Manifold Fluid inlet (9/16–18, —6 JIC, 37° flare) Cordset (24W087 shown) Air tube Mounting clamp (1/2 in. diameter bar) Solenoid valve (24 VDC, 110 VAC); not included with all models Muffler Air inlet (3/8 in. diameter tubing) Manual override switch Solenoid valve electrical connector Insulator Figure 1 24P075 Shown 3A2805K 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. 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. • • follow manufacturer’s recommendations. grounded through electrical connection. • follow manufacturer’s recommendations. • follow local code. • follow local code. Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity. • ensure mounting manifold and electrical power connector are grounded properly. Pump: Dispense applicator: Air compressor: Fluid supply container: Solvent pails used when flushing: To maintain grounding continuity when flushing or relieving pressure: Figure 2 Air and Fluid Flow Air Fluid 8 3A2805K 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: Use a 3/4 in. (19 mm) wrench to 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. 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). Note Provide enough room to access sides of applicator for maintenance and repair. 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: 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. • 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. Figure 4 Connect the Heated Hose 3A2805K 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. 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. 1 2 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 Before 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. Figure 6 Solenoid Valve Electrical Connector 10 3A2805K 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. 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. Figure 8 Install Nozzle Use 1/2 in. wrench to install nozzle. See Kits and Accessories, page 44. 3A2805K 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. 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. 12 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 SLOWLY 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. 3A2805K 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 Gun manifold filter Solenoid exhaust filters 3A2805K Clean Moderate Replace Replace filter filter every every months months six four Dusty Replace filter every months two 13 Troubleshooting Troubleshooting Problem No adhesive or incorrect amount of adhesive out of all modules when triggered Cause Debris in manifold filter Clogged hose Failed solenoid valve No signal to solenoid valve Incorrect solenoid valve wiring Incorrect signal to solenoid valve Solenoid muffler plugged No fluid pressure Heater failure (cold gun) No air to solenoid valve Dirty or faulty triggering device No adhesive or incorrect amount of adhesive out of one/some modules when triggered Solenoid valve connected incorrectly Clogged manifold passage Debris in nozzle Failed module in closed position Debris in module filter Adhesive out of one/some modules when not triggered 14 Clogged manifold passage Failed module in open position Adhesive pressure too high Solution Replace manifold filter. See Replace Inlet Filter, page 13. Clean or replace hose. Check for correct operation. Clean or replace. Check solenoid valve for correct operation. Check solenoid valve wiring. Check if 24 VDC or 120 VAC. Check and replace mufflers. Check adhesive delivery system. Check and replace heater cartridges. See Replace Heater Cartridge, page 20. Check air supply. Check, clean, or replace triggering device. Check solenoid valve air connections. Clean or replace manifold. Clean or replace nozzle. Check for correct operation. Clean or replace. See Check Module, page 16. Replace module. See Replace Module, page 24. Clean or replace manifold. Clean or replace module. See Replace Module, page 24. Check and reduce fluid pressure. 3A2805K Troubleshooting Problem Gun will not heat Gun overheats Gun under-heats Adhesive leaking from gun 3A2805K 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 Check delivery system RTD system requirement Thermal cutoff failure Check and replace thermal cutoff. See Replace Thermal Cutoff, page 20. 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 Check delivery system RTD system requirement. Incorrect power to heater Check and correct power. 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 Check delivery system RTD system requirement. Incorrect power to heater Check and correct power. 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. Module seal failure Check and replace module. See Check Module, page 16. 15 Troubleshooting Problem Adhesive out of all modules when not triggered Cause Solution Solenoid valve failure Adhesive pressure too high Solenoid valve connected incorrectly Module failure Check and replace solenoid valve. Check and reduce fluid pressure. Check solenoid valve air connections. Check and replace all modules. See Check Module, page 16. Check Module Check Nozzle and Module Check the module operation to verify if the module has failed and needs to be replaced. 1. Insert a small Allen wrench into the top of the module. 2. Press the solenoid valve override switch (S) to manually trigger the gun. 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. Use a 1/2 in. wrench to remove the nozzle. Figure 10 Check Module If the wrench moves up and down, then the module is operating properly 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. If the wrench does not move, then the module needs to be replaced. See Replace Module, page 24. 16 3A2805K Troubleshooting Check Heater Table 1 24W087, Pt 100 (385) RTD Cordset 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 Gun Model Pins Resistance Pin Description A B C D E Thermal Cutoff Ground Heat RTD (White) RTD (Red) Table 2 24W088, Ni 120 RTD Cordset Pin Description 1 2 3 5 G Thermal Cutoff Heat RTD (White) RTD (Red) Ground Values 24W087, A and C Pt 100 (385) RTD Cordset 24W088, Ni 120 RTD Cordset 1 and 2 24U021–24U0 26 24U027–24U032 All other models 24U021–24U0 26 24U027–24U032 All other models 260–280 ohms 130–140 ohms 260–280 ohms 130–140 ohms 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 D and E 100 (385) RTD Cordset 24W088, Ni 3 and 5 120 RTD Cordset 107-115 ohms 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. 3A2805K 17 Troubleshooting Check Thermal Cutoff 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 and needs to be replaced. 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 18 WL D 3A2805K Repair Repair Required Tools • Phillips screw driver • Flat blade screw driver • 5/64 in (2 mm) and 5/32 in. (4 mm) Allen wrenches • 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) Before Beginning 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. 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 Figure 12 Disconnect Cordset 3A2805K 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. 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). 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 F E The RTD is replaced by replacing the entire cordset. See Replace Cordset, page 22, for instructions. Replace Thermal Cutoff 1. Disable gun assembly. 20 D WLE 3A2805K Repair Wiring Diagram Thermal Cutoff 52b 17 52a 17 52b 3 52b 3 Note Slim (24U021–24U026) and Low Profile Dual (24U026–24U032) applicators use one heater (3). 3A2805K 21 Repair Replace Cordset See Fig 14, page 24. Note 1. 2. 3. 4. 22 There are two types of cordsets (17): 24W087 is for PT100 (385) RTD controlled guns and 24W088 is for NI 120 Ohm RTD controlled guns. Ensure you have the correct cordset before replacing. See Parts, page 26. Disable gun assembly. See Before Beginning Repair, page 19. Use a Phillips screwdriver to remove the four screws (15) and manifold cover plate (52). Use a 2 mm Allen wrench to remove the set screw (8) holding the cordset (17) on the manifold (1). Use a Phillips screwdriver to remove the ground screw (15) and star washer (20) from the manifold (1). 5. Remove the RTD (R) from the manifold (1). Note On guns that are not low profile, if the RTD does not easily pull out, remove the other cover plate (19) and press out with a small screwdriver. 6. Disconnect thermal cutoff (52). 7. Remove the cordset (17) from the manifold (1). 8. Install the new cordset, RTD, and ground (17 in the manifold (1). Recrimp thermal cutoff wires. See Wiring Diagram, page 21, for connections. Note Ensure the cordset bushing is fully inserted into the manifold. 9. Install set screw (8) against the cordset bushing to secure the cordset (17) to the manifold (1). 3A2805K Repair 10. Reinstall the ground lead onto the manifold (1). Note Ensure the star washer (20) is placed below the ground ring terminal. 11. Insert the plug (P), RTD (R) and thermal cutoff (52) into the manifold ports. See Fig 14. Note Do not apply grease on the RTD or thermal cutoff. 12. Insert the heater cartridges (3) in the manifold (1). Figure 14 Repair Parts 3A2805K NOTICE To prevent removing wire insulation or disconnecting wires, do not pinch any wires when inserting wire in the manifold. If wire insulation is removed, the RTD or heaters could short out and need to be replaced. 13. Reinstall the manifold cover plate (52). 14. Reconnect the cordset (17) to the heated hose. 15. Return to service. See Slim and Low Profile GS35 subsections of the Parts chapter ( Parts, page 26). NOTE: 23 Repair Replace Solenoid Valve 1. Disable gun assembly. See Before Beginning Repair, page 19. 2. Remove solenoid valve fitting (102) and solenoid valve (9) from tube (7). 3. Use a 1/2 in. and 7/16 in. wrench to tighten new connector (102) to tube (7). Figure 15 Replace Solenoid Valve Replace Module 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. Use a 5/32 in. (4 mm) Allen wrench to remove the two mounting screws (22) and module (2) from manifold (1). 24 NOTICE Do not allow adhesive to enter the air ports, to allow air to flow through valve. Adhesive in the air ports will obstruct the flow of air and damage the valve. Figure 16 Remove Module From Manifold 3. Apply high temperature lubricant to o-rings in module (2). 4. Apply anti-seize to two screw threads (22). Use a 5/32 in. (4 mm) Allen wrench to install new module (2) on manifold with two screws (22). Torque to 28–32 in.-lbs (3.2–3.6 N•m). 5. Connect cordset (17) to the heated hose. Replace Applicator Material inside the applicator can be near setpoint temperature. Wear protective clothing to avoid severe burns. 1. Disable gun assembly. See Before Beginning Repair, page 19. 2. Loosen the mounting bar clamp and remove the applicator from the mounting bar. 3. Install new applicator. See Installation, page 9 . 3A2805K Notes Notes 3A2805K 25 Parts Parts Single GS35 1 2 26 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m). See Wiring Diagram, page 21. 3A2805K Parts Table 3 Single GS35 Ref Part 1 ----- 2● Quantity 24P073 24P074 24P246 24P299 24P300 24P307 Description HOUSING, single 1 1 1 1 1 1 MODULE, sc, hotmelt HEATER, 240 VAC, 200W, 1/2 dia. x 1.5 in. 1 2 1 1 2 1 2 2 2 2 2 2 1 1 3 24V789 6 100113 CONNECTOR, male 1 1 7 24R231 TUBE, applicator, hotmelt, open 1 1 8 9* 124736 SCREW, set, cup, M4x.7x4 mm, sst 1 1 24P239 VALVE, solenoid, 3w, sr, 24 VDC 1 24P240 VALVE, solenoid, 3w, sr, 110 VAC 10 24P276 INSULATOR, clamp, bar, housing 1 1 1 1 1 1 11 24P277 CLAMP, bar, housing 2 2 2 2 2 2 12 108050 WASHER, lock, spring 2 2 2 2 2 2 13 117030 2 2 2 2 2 2 14 24P615 SCREW, shcs M6 x 40 FITTING, adapter, JIC -6 (37° flare) x SAE -6, mxm, cst 1 1 1 1 1 1 15 195874 9 9 9 9 9 9 16 24P275 1 1 1 1 1 1 17a 24W087 1 1 1 17b 24W088 SCREW, mach, phil pan hd FILTER, cartridge, 80 mesh, hotmelt (24P802 - 3 pack) CORD SET, 240V, applicator, Pt 100 ohm RTD CORD SET, 240V, hotmelt, Ni 120 ohm RTD 1 1 1 PLATE, cover, housing, hotmelt 1 1 1 1 1 1 --- 18 1 1 1 1 1 1 1 1 1 20 157021 WASHER, lock, int 1 1 1 1 1 1 22● 104705 SCREW, cap, sch; #10–32 x 1/25 in. 2 2 2 2 2 2 29▲ 16K931 1 1 1 1 1 1 34 24P547 1 1 1 1 1 1 35 24P548 LABEL, safety, warning FITTING, elbow, JIC -6 (37° flare) x SAE -6, mxm, cst FITTING, elbow, 45°, JIC -6 (37° flare) x SAE -6, mxm, cst 1 1 1 1 1 1 PLUG KIT, THERMAL CUTOFF(includes 52a-52c) 1 1 1 1 1 1 1 1 1 1 1 1 PLATE, with thermal cutoff CONNECTOR, splice, 14–16 AWG, heat resistant 1 1 1 1 1 1 3 3 3 3 3 3 SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD 3 3 3 3 3 3 --- 36■ 51 16Y799 52 24V790 52a --- 52b --- 52c --- * ● NOZZLE See Solenoid Valve Kits, page 45. Parts included in Module Repair Kit. See Module Repair Kit, page 44. 3A2805K ■ ▲ Purchase Separately. See Nozzles (Single Orifice), page 45. Replacement Warning labels, signs, tags, and cards are available at no cost. 27 Parts DUAL GS35 1 2 28 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m). See Wiring Diagram, page 21. 3A2805K Parts Table 4 Dual GS35 Ref Part 1 ----- 2● Description 24P075 24P076 24P247 24P301 24P302 24P308 HOUSING, dual 1 1 1 1 1 1 MODULE, sc, hotmelt HEATER, 240 VAC, 200W, 1/2 dia. x 1.5 in. 2 2 2 2 2 2 2 2 2 2 2 2 1 1 3 24V789 6 100113 CONNECTOR, male 1 1 7 24R231 TUBE, applicator, hotmelt, open 1 1 8 9* 124736 SCREW, set, cup, M4 x .7 x 4 mm, sst 1 1 24P239 VALVE, solenoid, 3w, sr, 24 VDC 1 24P240 VALVE, solenoid, 3w, sr, 110 VAC 10 24P276 INSULATOR, clamp, bar, housing 1 1 1 1 1 1 11 24P277 CLAMP, bar, housing 2 2 2 2 2 2 12 108050 WASHER, lock, spring 2 2 2 2 2 2 13 117030 2 2 2 2 2 2 14 24P615 SCREW, shcs M6 x 40 FITTING, adapter, JIC -6 (37° flare) x SAE -6, mxm, cst 1 1 1 1 1 1 15 195874 9 9 9 9 9 9 16 24P275 1 1 1 1 1 1 17a 24W087 1 1 1 17b 24W088 SCREW, mach, phil pan hd FILTER, cartridge, 80 mesh, hotmelt (24P802 - 3 pack) CORD SET, 240V, applicator, Pt 100 ohm RTD CORD SET, 240V, hotmelt, Ni 120 ohm RTD 1 1 1 PLATE, cover, housing, hotmelt 1 1 1 1 1 1 --- 18 1 1 1 1 1 1 1 1 1 20 157021 WASHER, lock, int 1 1 1 1 1 1 22● 104705 SCREW, cap, sch; #10–32 x 1/25 in. 4 4 4 4 4 4 29▲ 16K931 1 1 1 1 1 1 34 24P547 1 1 1 1 1 1 35 24P548 LABEL, safety, warning FITTING, elbow, JIC -6 (37° flare) x SAE -6, mxm, cst FITTING, elbow, 45°, JIC -6 (37° flare) x SAE -6, mxm, cst 1 1 1 1 1 1 PLUG KIT, THERMAL CUTOFF (includes 52a-52c) 1 1 1 1 1 1 1 1 1 1 1 1 PLATE, with thermal cutoff CONNECTOR, splice, 14–16 AWG, heat resistant SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD 1 1 1 1 1 1 3 3 3 3 3 3 3 3 3 3 3 3 --- 36■ 51 16Y799 52 24V790 52a --- 52b --- 52c --- * ● NOZZLE See Solenoid Valve Kits, page 45. Parts included in Module Repair Kit. See Module Repair Kit, page 44. 3A2805K ■ ▲ Purchase Separately. See Nozzles (Single Orifice), page 45. Replacement Warning labels, signs, tags, and cards are available at no cost. 29 Parts Quad GS35 24P077 Type I Shown 1 2 30 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21. 3A2805K Parts Table 5 Quad GS35 With 0.88 in. Spaced Manifold (Type I) Ref Part 1 2● 3 6 7 8 9* 10 11 12 13 14 15 16 ----24V791 100113 24R231 124736 24P239 24P240 24P276 24P277 108050 117030 24P615 195874 24P275 17a 24W087 17b 18 20 22● 29▲ 34 24W088 --157021 104705 16K931 24P547 35 36■ 51 52 52a 52b 24P548 --16Y799 24V790 ----- 52c --- Description HOUSING, 0.88 in. MODULE HEATER, 240 VAC, 200W, 1/2 dia x 2.75 in. CONNECTOR, male TUBE, applicator, hotmelt, open SCREW, set, cup, M4 x.7x4 mm, sst VALVE, solenoid, 3 way, sr, 24 VDC VALVE, solenoid, 3 way, sr, 110 VAC INSULATOR, clamp, bar, housing CLAMP, bar, housing WASHER, lock, spring SCREW, shcs M6 x 40 FITTING, adapter, JIC -6 (37° flare) x SAE -6, mxm, cst SCREW, mach, phil pan hd FILTER, cartridge, 80 mesh, hotmelt (24P802 - 3 pack) CORD SET, 240V, applicator, Pt 100 ohm RTD CORD SET, 240V, hotmelt, Ni 120 ohm RTD PLATE, cover, housing, hotmelt WASHER, lock, int SCREW, cap, sch; #10–32 x 1/25 in. LABEL, safety, warning FITTING, elbow, JIC -6 (37° flare) x SAE -6, mxm, cst FITTING, elbow, 45°, JIC -6 (37° flare) x SAE -6, mxm, cst NOZZLE PLUG KIT, THERMAL CUTOFF (includes 52a-52c) PLATE, with thermal cutoff CONNECTOR, splice, 14–16 AWG, heat resistant SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD * See Solenoid Valve Kits, page 45. ● Parts included in Module Repair Kit. See Module Repair Kit, page 44. 3A2805K Quantity 24P077 24P078 24P250 24P303 24P304 24P309 ■ ▲ 1 4 2 1 1 1 1 1 4 2 1 1 1 1 4 2 1 1 2 2 2 1 9 1 1 1 2 2 2 1 9 1 1 2 2 2 1 9 1 1 1 1 1 4 2 1 1 1 1 1 4 2 1 1 1 1 4 2 1 1 1 2 2 2 1 9 1 1 1 2 2 2 1 9 1 1 2 2 2 1 9 1 1 1 1 8 1 1 1 1 1 8 1 1 1 1 8 1 1 1 1 8 1 1 1 1 8 1 1 1 1 1 8 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 3 1 1 1 3 1 1 1 3 1 1 1 3 1 1 1 3 3 3 3 3 3 3 Purchase Separately. See Nozzles (Single Orifice), page 45. Replacement Warning labels, signs, tags, and cards are available at no cost. 31 Parts Table 6 Quad GS35 with 1.5 in. Spaced Manifold (Type II) Ref Part ----24V791 100113 24R231 124736 24P239 24P240 24P276 24P277 108050 117030 24P615 195874 24P275 1 2● 3 6 7 8 9* 10 11 12 13 14 15 16 17a 24W087 17b 18 20 22● 29▲ 34 24W088 --157021 104705 16K931 24P547 35 24P548 36■ 51 16Y799 52 24V790 --52a --52b 52c --- Description HOUSING, 1.5 in. MODULE HEATER, 240 VAC, 200W, 1/2 dia x 2.75 in. CONNECTOR, male TUBE, applicator, hotmelt, open SCREW, set, cup, m4 x.7x4 mm, sst VALVE, solenoid, 3 way, sr, 24 VDC VALVE, solenoid, 3 way, sr, 110 VAC INSULATOR, clamp, bar, housing CLAMP, bar, housing WASHER, lock, spring SCREW, shcs M6 x 40 FITTING, adapter, JIC -6 (37° flare) x SAE -6, mxm, cst SCREW, mach, phil pan hd FILTER, cartridge, 80 mesh, hotmelt (24P802 - 3 pack) CORD SET, 240V, applicator, Pt 100 ohm RTD CORD SET, 240V, hotmelt, Ni 120 ohm RTD PLATE, cover, housing, hotmelt WASHER, lock, int SCREW, cap, sch; #10–32 x 1/25 in. LABEL, safety, warning FITTING, elbow, JIC -6 (37° flare) x SAE -6, mxm, cst FITTING, elbow, 45°, JIC -6 (37° flare) x SAE -6, mxm, cst NOZZLE PLUG KIT, THERMAL CUTOFF (includes 52a-52c) PLATE, with thermal cutoff CONNECTOR, splice, 14–16 AWG, heat resistant SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD * See Solenoid Valve Kits, page 45. ● 32 Parts included in Module Repair Kit. See Module Repair Kit, page 44. 24P079 1 4 2 1 1 1 1 24P080 1 4 2 1 1 1 Quantity 24P254 24P305 1 4 2 1 1 2 2 2 1 9 1 1 1 2 2 2 1 9 1 1 2 2 2 1 9 1 1 1 1 1 4 2 1 1 1 1 24P306 1 4 2 1 1 1 24P310 1 4 2 1 1 2 2 2 1 9 1 1 1 2 2 2 1 9 1 1 2 2 2 1 9 1 1 1 1 8 1 1 1 1 1 8 1 1 1 1 8 1 1 1 1 8 1 1 1 1 8 1 1 1 1 1 8 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 3 1 1 1 3 1 1 1 3 1 1 1 3 1 1 1 3 3 3 3 3 3 3 ■ ▲ Purchase Separately. See Nozzles (Single Orifice), page 45. Replacement Warning labels, signs, tags, and cards are available at no cost. 3A2805K Parts Notes 3A2805K 33 Parts Slim GS35 1 2 34 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21. 3A2805K Parts Table 7 Slim GS35 Description Part 2● --- MODULE 1 1 1 1 1 1 3 24V793 HEATER, 240 VAC, 200W, 1/2 dia x 1.5 in. 1 1 1 1 1 1 6 100113 CONNECTOR, male 1 1 1 1 7 16P769 TUBE, applicator, hotmelt, open 1 1 1 1 8 124736 SCREW, set, cup, M4 x 0.7 x 4 mm, sst 1 1 1 1 9* 24P239 VALVE, solenoid, 3 way, sr, 24 VDC 1 24P240 VALVE, solenoid, 3 way, sr, 120 VAC 10 24P276 INSULATOR, clamp, bar, housing 11 24P277 CLAMP, bar, housing 2 2 2 2 2 2 12 108050 WASHER, lock, spring 2 2 2 2 2 2 13 117030 SCREW, shcs M6 x 40 2 2 2 2 2 2 14 24P615 1 1 1 1 1 1 15 195874 FITTING, adapter, JIC 06 x SAE 06, mm, cs SCREW, mach, phil pan hd 11 11 11 11 11 11 16 24P275 FILTER, gun, 80 mesh (3–pack: 24P802) 1 1 1 1 1 1 17a 24W087 1 1 1 1 1 1 1 --- HOUSING, slim 24U021 1 24U022 Quantity 24U023 24U024 Ref 1 1 1 1 1 24U026 1 1 1 1 1 24U025 1 1 1 1 1 1 18 --- CORD SET, 240V, applicator, Pt 100 ohm RTD CORD SET, 240V, hotmelt, Ni 120 ohm RTD PLATE, cover, side, slim 1 1 1 1 1 1 20 157021 WASHER, lock, int 1 1 1 1 1 1 22● 104705 SCREW, cap, sch 2 2 2 2 2 2 34 24P547 FITTING, elbow, JIC06 x SAE06, mm, cs 1 1 1 1 1 1 35 24P548 1 1 1 1 1 1 36■ --- FITTING, elbow, 45, JIC06 x SAE06, mm, c NOZZLE (not shown) 42 16W708 PLATE, cover, bottom, slim 1 1 1 1 1 1 51 16Y799 1 1 1 1 1 1 52 24V792 PLUG KIT, THERMAL CUTOFF (includes 52a-52c) 1 1 1 1 1 1 PLATE, with thermal cutoff CONNECTOR, splice, 14–16 AWG, heat resistant 1 1 1 1 1 1 3 3 3 3 3 3 3 3 3 3 3 3 17b 24W088 52a --- 52b --- 52c --- * ● SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD See Solenoid Valve Kits, page 45. Parts included in Module Repair Kit. See Module Repair Kit, page 44. 3A2805K ■ ▲ Purchase Separately. See Nozzles (Single Orifice), page 45. Replacement Warning labels, signs, tags, and cards are available at no cost. 35 Parts Low Profile Dual GS35 1 2 36 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21. 3A2805K Parts Table 8 Low Profile Dual GS35 Ref Part Description 10 ----24V793 100113 16P769 124736 24P239 24P240 24P276 HOUSING, double MODULE, sc HEATER, 240 VAC, 200W, 1/2 dia x 1.5 in. CONNECTOR, male TUBE, applicator, hotmelt, open SCREW, set, cup, M4 x 0.7 x 4 mm, sst VALVE, solenoid, 3 way, sr, 24 VDC VALVE, solenoid, 3 way, sr, 120 VAC INSULATOR, clamp, bar, housing 11 12 13 14 15 16 17a --108050 117029 24P615 195874 24P275 24W087 17b 24W088 18 20 21 22● 34 35 36■ 42 44 45 46 47 48 49 50 51 --157021 103147 104705 24P547 24P548 --16W709 24U698 102598 100020 109570 100018 --100508 16Y799 BLOCK WASHER, lock, spring SCREW, shcs, M6 x 25 FITTING, adapter, JIC06 x SAE06, mm, cs SCREW, mach, phil pan hd FILTER, gun, 80 mesh (3–pack: 24P802) CORD SET, 240V, applicator, Pt 100 ohm RTD CORD SET, 240V, hotmelt, Ni 120 ohm RTD PLATE, side WASHER, lock, int PLUG, pipe SCREW, cap, sch FITTING, elbow, JIC06 x SAE06, mm, cs FITTING, elbow, 45, JIC06 x SAE06, mm, c NOZZLE (not shown) PLATE, cover, end ROD, mtg, threaded SCREW, cap, socket head WASHER, lock WASHER, plain WASHER, lock, spring NUT, 1/2-13 hex SCREW, drive 1 2● 3 6 7 8 9* 3A2805K PLUG Quantity 24U027 24U028 24U029 24U030 24U031 24U032 1 2 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 2 2 1 5 1 1 1 2 2 1 5 1 1 1 2 2 1 5 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 2 2 1 5 1 1 2 2 1 5 1 1 2 2 1 5 1 1 1 1 1 1 3 4 1 1 1 1 3 4 1 1 1 1 3 4 1 1 1 1 3 4 1 1 1 1 3 4 1 1 1 1 3 4 1 1 1 1 1 1 2 2 2 4 1 1 1 1 1 2 2 2 4 1 1 1 1 1 2 2 2 4 1 1 1 1 1 2 2 2 4 1 1 1 1 1 2 2 2 4 1 1 1 1 1 2 2 2 4 1 37 Parts Ref 52 52a 52b 52c Part 24V794 ------- Description KIT, THERMAL CUTOFF (includes 52a-52c) PLATE, with thermal cutoff CONNECTOR, splice, 14–16 AWG, heat resistant SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD * See Solenoid Valve Kits, page 45. ● 38 Quantity 24U027 24U028 24U029 24U030 24U031 24U032 Parts included in Module Repair Kit. See Module Repair Kit, page 44. Parts included in Bar Clamp Kit 24U698. See Mounting Clamp Kits, page 45. 1 1 3 3 ■ ▲ 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 3 Purchase Separately. See Nozzles (Single Orifice), page 45. Replacement Warning labels, signs, tags, and cards are available at no cost. 3A2805K Parts Notes 3A2805K 39 Parts Low Profile Quad GS35 1 2 40 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21. 3A2805K Parts Table 9 Low Profile Quad GS35 Ref 1 2● 3 6 7 8 9* 10 11 12 13 14 15 16 17a 17b 18 20 21 22● 34 35 36■ 38▲ 39 42 44 45 46 47 48 49 50 51 3A2805K Part Description --HOUSING, quad --MODULE, sc, invisipac 24V795 HEATER, 240 VAC, 200W, 1/2 dia x 1.5 in. 100113 CONNECTOR, male 16P769 TUBE, applicator, hotmelt, open 124736 SCREW, set, cup, M4x 0.7 x 4 mm, sst 126407 VALVE, solenoid, 3 way, sr, 24 VDC 126408 VALVE, solenoid, 3 way, sr, 120 VAC 16P848 INSULATOR, clamp, bar, housing --BLOCK, mtg 108050 WASHER, lock, spring 117029 SCREW, shcs M6 x 25 126544 FITTING, adapter, JIC06 x SAE06, mm, cs 195874 SCREW, mach, phil pan hd 24P275 FILTER, gun, 80 mesh (3-pack: 24P802) 24W087 CORD SET, 240V, applicator, Pt 100 ohm RTD 24W088 CORD SET, 240V, hotmelt, Ni 120 ohm RTD --PLATE, side, quad 157021 WASHER, lock, int 103147 PLUG, pipe 104705 SCREW, cap, sch 126748 FITTING, elbow, JIC06 x SAE06, mm, cs 126749 FITTING, elbow, 45, JIC06 x SAE06, mm, c --NOZZLE (not shown) 16K931 TAG, warning, turbo 103473 STRAP, tie, wire 16V721 PLATE, cover, applicator 24U698 ROD, mtg, threaded 102598 SCREW, cap, socket head 100020 WASHER, lock 109570 WASHER, plain 100018 WASHER, lock, spring --NUT, 1/2-13 hex 100508 SCREW, drive 16Y799 PLUG 24U033 1 4 2 1 1 1 24U034 1 4 2 1 1 1 Quantity 24U035 24U036 1 4 2 1 1 1 4 2 1 1 1 24U037 1 4 2 1 1 1 24U038 1 4 2 1 1 1 1 2 2 1 6 1 1 1 1 2 2 1 6 1 1 1 2 2 1 6 1 1 1 1 1 1 2 2 1 6 1 1 1 1 2 2 1 6 1 1 1 2 2 1 6 1 1 1 1 3 8 1 1 1 1 3 8 1 1 1 3 8 1 1 1 3 8 1 1 1 3 8 1 1 1 1 3 8 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 2 2 2 2 1 41 Parts Ref 52 52a 52b 52c Part Description 24V796 KIT, THERMAL CUTOFF (includes 52a-52c) - - - PLATE, with thermal cutoff - - - CONNECTOR, splice, 14–16 AWG, heat resistant - - - SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD * See Solenoid Valve Kits, page 45. ● 42 Parts included in Module Repair Kit. See Module Repair Kit, page 44. Parts included in Bar Clamp Kit 24U698. See Mounting Clamp Kits, page 45. 24U033 24U034 Quantity 24U035 24U036 24U037 24U038 1 1 3 1 1 3 1 1 3 1 1 3 1 1 3 1 1 3 3 3 3 3 3 3 ■ ▲ Purchase Separately. See Nozzles (Single Orifice), page 45. Replacement Warning labels, signs, tags, and cards are available at no cost. 3A2805K Parts Solenoid Valve Kits 24P239, 24 VDC Solenoid Valve 24P240, 110 VAC Solenoid Valve 1 Ref 101 Apply thread sealant to threads. Part --- Description VALVE, solenoid, 3w, sr, 24 VDC; 24P239 only - - - VALVE, solenoid, 3w, sr, 120 VAC; 24P240 only 102 100113 CONNECTOR, male 103 24P900 BUSHING, 1/4 npt x 1/8 npt, brass 3A2805K Qty 1 1 1 1 Ref Part Description 104 24P282 MUFFLER, 1/8 npt, pp 105 121140 FITTING, straight, 3/8 tubing OD x 1/4 npt 106 24R942 CONNECTOR, 24 VDC; 24P239 only 24R943 CONNECTOR, 120 VAC; 24P240 only Qty 2 1 1 1 43 Kits and Accessories Kits and Accessories Module Replacement Heater Cartridges Heater cartridges for single, dual, and quad manifolds with butt splices, tape, and tubing. See Models, page 6 , for model numbers. 24P241 See manual 407050. Part Description ---MODULE 104705 SCREW, cap, sch; #10–32 x 1.25 in. 24R835 O-RING (10 pack) 24T179 LUBRICANT, anti-seize Qty 1 2 Kit 24V789 24V791 24V793 2 1 Manifold Single, Dual Quad Slim Single 24U021–24U026 Low Profile Dual 24U027–24U032 Low Profile Quad 24U033–24U038 Length 1.5 in. (38 mm) 2.75 in. (70 mm) 1.5 in. (38 mm) 1.5 in. (38 mm) Module Filter Replacement Kit 24V795 Includes instructions for replacing the module filter. See manual 332513. Single Heater Cartridges with Ferrules Kit Quantity 24P801 24T045 Single 3–pack Single heater cartridges are for custom manifolds only. Part Requires Module Rebuild Tools Kit 24T206. Includes instructions for rebuilding the module. See manual 332513. NOTE: Kit Quantity 24T046 24T047 Single 5–pack Description Qty SEAL INSTALLATION TOOL 1 PISTON INSTALLATION TOOL 1 Cordsets include the RTD. Use crimp tool kit 24W086 (purchase separately). 24W087 24W088 44 RTD Type Platinum 100 Ohm Nickel 120 Ohm 24P825 24P826 24P828 Cordsets Kit 24P824 24P827 Module Rebuild Tools Kit 24T206 ----- Length Recommended Manifold Width Module Rebuild Kit Part 1.5 in. (38 mm) 4 in. (101.6 mm) 5 in. (127 mm) 6 in. (152.4 mm) 7 in. (177.8 mm) 8 in. (203.2 mm) 5-6 in. (127-152.4 mm) 6-7 in. (152.4-177.8 mm) 7-8 in. (177.8-203.2 mm) 8-9 in. (203.2-228.6 mm) 9-12 in. (228.6-304.8 mm) High Temperature Lubricant 24T156 Packet with 3–grams of high temperature lubricant. For use on seals in InvisiPac guns. Anti-Seize 24T179 Tube with 0.5 oz of anti-seize for use on module mounting screws in InvisiPac guns. 3A2805K Kits and Accessories Mufflers Mounting Clamp Kits 24P282 See Models, page 6 , for model numbers. Includes two mufflers that can be used with solenoid valve kits. Blanking Plate Kit Ref 10 24P810 Use to run two or three modules on a quad applicator or one module on a dual applicator. See manual 407051. Solenoid Valve and Fitting Kits 3–Way (air open - spring close) Solenoid Valves Kit Description 24P239 24P240 24 VDC 110 VAC Inlet Filter Kit Qty 24P275 24P802 Single 3 Pack Material Inlet Fittings Single Kit Description 24P615 24P548 24P547 Straight 45° 90° For Series A and Series B Models. Kit Models Description 24V790 See Models, page 6 24U02124U026 24U02724U032 24U03324U038 Standard 24V794 24V796 3A2805K 11 12 13 Slim Single Dual Low Profile Quad Low Profile Part Description 24P276 INSULATOR, clamp, bar, housing - - - CLAMP, bar housing 108050 WASHER, lock, spring 117030 SCREW, shcs, M6 x 40 Qty 1 2 2 2 24U698 (Low Profile GS35, 24U027–24U038)) Ref 10 11 12 13 44 45 46 47 48 49 Part Description 24P276 INSULATOR, clamp, bar, housing - - - BLOCK, mating, low profile 108050 WASHER, lock, spring 117029 SCREW, shcs, M6 x 25 - - - ROD - - - SCREW, cap, socket head - - - WASHER, lock - - - WASHER, plain - - - WASHER, lock, spring - - - NUT, 1/2–13 Qty 1 1 2 2 1 1 1 2 2 2 Nozzles (Single Orifice) Single Thermal Cutoff Replacement Kits 24V792 24P277 (Single, Dual, and Quad GS35) 24P636 24P637 24P638 24P639 24P640 24P641 24P642 24P643 24P644 24P645 24P646 24P647 24P648 24P649 5 Pack 24P794 24P795 24P796 24P797 24P798 24P799 24P800 24P803 24P804 24P805 24P806 24P807 24P808 24P809 Description 0.008 straight 0.010 straight 0.012 straight 0.016 straight 0.018 straight 0.020 straight 0.024 straight 0.008 90° 0.010 90° 0.012 90° 0.016 90° 0.018 90° 0.020 90° 0.024 90° 45 Dimensions Dimensions Single, Dual, and Quad GS35 0.72 in. (18.16 mm) 5.01 in. (127.25 mm) 9.3 in. (236.2 mm) 0.79 in. (20.0 mm) 7.93 in. (201.42 mm) 24P075 Shown 3.63 in. (92.2 mm) 4.24 in. (107.7 mm) 1.14 in. (28.96 mm) 1.00 in. (25.4 mm) 3.07 in. (77.98 mm) 3.94 in. (100.1 mm) 24P077 Type I Shown 24P079 Type II Shown 0.5 in. (12.7 mm) 0.31 in. (7.9 mm) 0.625 in. (15.8 mm) A A C Single Dual Quad - Type I Quad - Type II 0.25 in. (6.25 mm) C B B Applicator A A A B C in. (mm) in. (mm) in. (mm) 0.88 (22.4) 0.88 (22.4) 0.88 (22.4) 2.23 (56.6) 2.23 (56.6) 3.74 (95) 4.36 (111) 0.88 (22.4) 1.5 (38) See Models, page 6 , for applicator model numbers. 46 3A2805K Dimensions Slim GS35 (24U021-24U026) 24U021 Shown 11.68 in. (296.67 mm) 0.79 in. (20.0 mm) 2.41 in. (61.21 mm) 5.01 in. (127.25 mm) 4.24 in. (107.70 mm) 3.63 in. (92.20 mm) 2.86 in. (72.64 mm) 0.67 in. (17.02 mm) 1.35 in. (34.29 mm) 3A2805K 1.0 in. (25.4 mm) 3.16 in. (80.26 mm) 4.04 in. (102.62 mm) 47 Dimensions Low Profile Double GS35 (24U027-24U033) 24U027 Shown 11.69 in. (296.93 mm) 0.79 in. (20.1 mm) 3.18 in. (80.77 mm) 1.0 in. (25.4 mm) 0.88 in. (22.35 mm) 1.94 in. (49.28 mm) 48 1.5 in. (38.1 mm) 2.30 in. (58.42 mm) 0.13 in. (3.30 mm) 6.29 in. (159.77 mm) 5.66 in. (143.76 mm) 3A2805K Dimensions Low Profile Quad GS35 (24Ubob 033-24U038) 24U033 Shown 11.69 in. (296.93 mm) 0.79 in. (20.1 mm) 3.18 in. (80.77 mm) 1.0 in. (25.4 mm) 0.88 in. 0.88 in. 0.88 in. (22.35 mm) (22.35 mm) (22.35 mm) 3.63 in. (92.20 mm) 6.29 in. (159.77 mm) 3A2805K 1.5 in. (38.1 mm) 2.30 in. (58.42 mm) 0.13 in. (3.30 mm) 5.16 in. (131.06 mm) 49 Technical Data Technical Data InvisiPac ™ GS35 Plug-Free Hot Melt Adhesive Applicator US Metric > 3,500 cycles/minute Speed Heat up Time < 10 minutes to 350°F at 240 VAC < 10 minutes to 176°C at 240 VAC 200-240V, 50–60 Hz, 400W Electrical Service Maximum Working Fluid Pressure 1500 psi 10.3 MPa, 103 bar Maximum Air Pressure 80 psi 0.5 MPa, 5.5 bar Minimum Air Pressure 40 psi 0.3 MPa, 2.7 bar Maximum Operating Temperature 400°F 204°C Ambient Storage Temperature 32-122°F 0-50°C Range Ambient Operating Temperature 32-122°F 0-50°C Range Solenoid Air Flow Rating 1.0 Cv Wetted Parts Aluminum, carbon steel, stainless steel, carbide, brass, chemically resistant seals, chrome Cordsets 24W087 24W088 Pt 100 (385) RTD Ni 120 RTD Solenoid Control Voltages 24P239 24P240 24 VDC 110 VAC Noise Sound pressure measured 6.5 ft (2m) from gun at 80 psi (550kPa, 5.5 bar) 50 75.6 dB(A) 3A2805K Notes Notes 3A2805K 51 Graco Extended Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of eighteen months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Information For more information about InvisiPac, visit www.InvisiPac.com or email InvisiPac@graco.com. To place an order, contact your Graco Distributor or call to identify the nearest distributor. For technical assistance or customer service, call toll free: 1–800–458–2133. All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. For patent information, see www.graco.com/patents. Original Instructions. This manual contains English. MM 3A2805 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2012, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revised August 2014
Source Exif Data:
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