Graco 3A2805K User's Manual
Contents
1. 2 2 2 2 en a e ENEE 5 06 mm cs 15 195874 SCREW mach phil pan hd 16 24P802 te per Ber sors pep 100 ohm RTD o o 120 ohm RTD 222 PLATE side Ba a mean L5 Do wm T 0 a o mme sicud E NR elbow JICO6 x SAE06 1 mm CS a O SAE06 mm c 777 NOZZLE not shown not shown a i a S un o 1 ME e eum Ra aa ai 3 3 3 S pss psa west us A pem 46 100020 WASHER lock m OOS WASHER 6 2 2 2 2 2 49 NUT 1 2 13 hex gt s emque 3 H S N HERR HJ l NO NO NO MP K 3A2805K 41 Parts t pepe FS 24U033 24U034 24U035 24U036 24U037 24U038 24V796 KIT THERMAL CUTOFF includes 528 520 PLATE with PLATE with thermal cutoff cutoff AWG heat allen x 0 16 OD See Solenoid Valve Kits page 45 Purchase Separately See O Parts included in Module Repair Kit See Nozzles Single Orifice page 45 Module Repair Kit page 44 A Replacement Warning labels signs tags and cards Parts included in Bar Clamp Kit 24U698 See are available at no cost Mounting Clamp Kits page 45 42 3A2805K Solenoid Valve Kits 24P239 24 VDC Solenoid Valve 24P240 110 VAC Solenoid Valve Za Apply thread sealant to threads Ref Part Description 101 VALVE solenoid 3w sr 24 VDC 24P239 only VALVE solenoid 3w sr 1202. Instructions Parts 7 InvisiPac GS35 Plug Free M Hot Melt Applicator PALOU 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 ti20470b PROVEN QUALITY LEADING TECHNOLOGY Contents Wanin S ec mr 3 A a AS 5 WOO T te 7 6 Component 0 61080 7 OVET OW oe E O dias 8 seated ld 8 lysis HE 9 MOURIR fece tote oO ae 9 Connect Heated 10856 9 Connect Solenoid Valve 9 Connect Triggering Device 10 Prime Before Using Equipment 10 RUS M X a aha te ee eects 11 Install year 11 SEIECHRT pe T 11 Seo 2 12 Pressure Relief Procedure 12 Maintenance i o c c a OE EL ETE 13 Replace Inlet Filter 13 Filter Maintenance Guidelines 13 TROUDIESNOOUNG cn esteso o 14 2 Check Module senem mI 16 Check Nozzle and Module 16 Check Heater esee II 17 Check TS ED
3. Ls INSULATOR clamp bar en housing T CLAMP bar aeg MEM ronan WASHER or og 2 24U698 Low Profile GS35 24U027 24U038 Dr msg ee housing did nei profile 108050 WASHER lock spring 117029 SCREW shcs M6 x 25 mE 44 1 ap po 5 _ SCREW cap sockethead 1 ep mea Lm WASHER plain 8 wastes eec fe me Numi e Nozzles Single Orifice 45 Dimensions Dimensions Single Dual and Quad GS35 0 72 in d 24P075 Shown 0 79 in ET aa L 20 0 mm E 18 16 mm SVO E E L N u T I y5 OE c NX y E lt CALA p en HL 3 lt m a LO 4 24 in 107 7 mm 1 00 in 25 4 mm 3 94 in ml En in mm in mm in mm ne ce NN a laos TORRES See Models page 6 for applicator model numbers 46 3A2805K Dimensions Slim GS35 24U021 24U026 24U021 Shown 11 68 in 296 67 mm 5 01 in 127 25 mm 4 24 in 107 70 mm 3 63 in 92 20 mm 17 02 mm 1 35 in 34 29 mm 3A2805K 47 5 66 in 143 76 mm 3A2805K CO 0 13 in 3 30 mm Y es O O o o N Dimensions Low Profile Double GS35 24U027 24U033
4. ee et 17 Check Thermal Cutoff 18 Repair 19 Before Beginning Repair 19 Replace Heater Cartridge 20 Replace RT Diss 2er 20 Replace Thermal Cutoff 20 Replace CordSet cococcccccccococonococonononononoso 22 Replace Solenoid Valve 24 Replace Module 24 Replace Applicator 24 0 5 en ee 26 Kits and Accessories esee 44 DIMENSION Sur e ditur unse 46 Technical Data hth atte nern 50 BOIS eet ee ae need 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 BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid 6 severe burns e Do not touch hot fluid or equipment ELECTRIC SHOCK HAZARD This equipment must be grounded Improp
5. heater cartridges See Replace Heater Cartridge page 20 No air to solenoid valve Check air supply Dirty or faulty triggering device Check clean or replace triggering device Solenoid valve connected Check solenoid valve air connections incorrectly Clogged manifold passage Clean or replace manifold No adhesive or incorrect Debris in nozzle Clean or replace nozzle e of e 2 t of Failed module in closed position Check for correct operation E ES Men Clean or replace See triggered Check Module page 16 Debris in module filter Replace module See Replace Module page 24 Clogged manifold passage Clean or replace manifold Adhesive out of one some Failed module in open position Clean or replace module See modules when not triggered Replace Module page 24 Adhesive pressure too high Check and reduce fluid pressure 14 3A2805K Troubleshooting Gun will not heat 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 Gun overheats Heater failure Check and replace heater
6. 24U027 Shown 0 88 in 22 35 mm E cf DE No OM Io E eE st ON o Y 48 Dimensions Low Profile Quad GS35 24Ubob 033 24U038 24U033 Shown 11 69 in E E co O e G 2 30 in 0 88 in 22 35 mm 22 35mm 22 35 mm 0 88 in 0 88 in 3 63 in 92 20 mm 5 16 in 131 06 mm 6 29 in 159 77 mm 49 3A2805K Technical Data Technical Data InvisiPac GS35 Plug Free Hot Melt Adhesive Applicator Heat up Time gt 10 minutes to 176 C at 240 VAC Maximum Working Fluid Pressure 10 3 MPa 103 bar Maximum Air Pressure 0 5 MPa 5 5 bar Minimum Air Pressure 0 3 MPa 2 7 bar Maximum Operating Temperature 204 C Ambient Storage Temperature 32 122 F 0 50 C Range Ambient Operating Temperature 32 122 F 0 50 C Range chemically resistant seals chrome 2awoss 24P240 110 VAC Sound pressure measured 6 5 ft 2m from gun at 80 psi 550kPa 75 6 dB A 5 5 bar 50 3A2805K Notes Notes 3A2805K 51 Graco Extended Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and ung 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 da
7. 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 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 A A ES B iw Mt E SS SH FIS S J N 4 gt A NA O E Figure 2 Air and Fluid Flow gt Air Fluid Grounding The equipment must be grounded to reduce the risk of static sparking Static
8. VAC 24P240 only 102 100113 CONNECTOR male 103 24P900 BUSHING 1 4 npt x 1 8 npt brass 3A2805K Qty Ref 104 105 106 Part 24P282 121140 24R942 24R943 Parts Description Qty MUFFLER 1 8 npt pp 2 FITTING straight 3 8 1 tubing OD x 1 4 npt CONNECTOR 24 VDC 1 24P239 only CONNECTOR 120 VAC 1 24P240 only 43 Kits and Accessories Kits and Accessories Module Replacement 24P241 See manual 407050 Part MODULE SCREW cap sch 10 32 2 x 1 25 in we ps iain nro 24R835 O RING 10 pack 241179 LUBRICANT anti seize Module Filter Replacement Kit Includes instructions for replacing the module filter See manual 332513 Module Rebuild Kit NOTE Requires Module Rebuild Tools Kit 24T206 Includes instructions for rebuilding the module See manual 332513 Module Rebuild Tools Kit 24T206 SEAL INSTALLATION TOOL PISTON INSTALLATION TOOL Cordsets Cordsets include the RTD Use crimp tool kit 24W086 purchase separately RTD Type 24W087 Platinum 100 Ohm 24W088 Nickel 120 Ohm 44 Heater Cartridges Heater cartridges for single dual and quad manifolds with butt splices tape and tubing See Models page 6 for model numbers Manifold Length 24V789 Single Dual 1 5 in 38 mm 24V791 2 75 in 70 mm 24V793 Slim Single 1 5 in 88 mm 24U021 24U026 m im 24U027 24U032 BEN 24U033 24U038 Single Heater Cartridges with Fer
9. 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 ee 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 do
10. 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 Gun under heats 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 Adhesive leaking from gun 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 Module seal failure Check and replace module See Check Module page 16 3A2805K 15 Troubleshooting Adhesive out of all modules Solenoid valve failure Check and replace solenoid valve WNENNOEIMISELES Adhesive pressure too high Check and reduce fluid pressure Solenoid valve connected Check solenoid valve air connections incorrectly Module failure Check and replace all modules See Check Module page 16 Check Module Check Nozzle and Module Check the module operation to verify if th
11. sparking can cause fumes to ignite or explode Grounding provides an escape wire for the electric current Pump follow manufacturer s recommendations Dispense applicator grounded through electrical connection Air compressor follow manufacturer s recommendations Fluid supply container follow local code e Solvent pails used when flushing 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 To maintain grounding continuity when flushing or relieving pressure ensure mounting manifold and electrical power connector are grounded properly 3A2805K 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 Note Provide enough room to access sides of applicator for maintenance and repair Figure 3 Mounting
12. to remove the ground screw 15 and star washer 20 from the manifold 1 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 Disconnect thermal cutoff 52 Remove the cordset 17 from the manifold 1 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 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 NOTICE Note To prevent removing wire insulation or Ensure the star washer 20 is placed disconnecting wires do not pinch any wires below the ground ring terminal when inserting wire in the manifold If wire insulation is removed the RTD or heaters 11 Insert the plug P RTD R and thermal cutoff could short out and need to be replaced 52 into the manifold ports See Fig 14 Note 13 Reinstall the manifold cover plate 52 Do not apply grease on the RTD or 14 Reconnect the cordset 17 to the heated hose thermal cutoff 15 Return to service 12 Insert the heater cartridges 3 in the manifold 1 17a E ti2048 1c Figure 14 Repair Parts NOTE See
13. 3 3 Som Nozze ot shown 16W709 PLATE cover end 24U698 ROD mtg threaded 102598 SCREW cap socket head 100020 WASHER lock WASHER plain m ums WASHER Took some mr LA 3 3 000003 eme pw 5 4 4 E NI DI N gt I Ix Ix I 3A2805K 37 Parts Guan Ao gt 5 241704 KIT THERMAL CUTOFF includes 4 4 4 4 528 520 8 PLATE with thermal cutoff 6 e ERR See resistant L SLEEVE red 2 in 50 88mm x0 160D 3 3 See Solenoid Valve Kits page 45 B Purchase Separately See O Parts included in Module Repair Kit See Nozzles Single Oritice page 45 Module Repair Kit page 44 A Replacement Warning labels signs tags and cards Parts included in Bar Clamp Kit 24U698 See are available at no cost Mounting Clamp Kits page 45 38 3A2805K Notes Parts 3A2805K 39 Parts Low Profile Quad GS35 ti22235c 3A2805K seize to first 1 2 in of threads Torque A OT QN y o a CO gt E g o amp 2 I O E oN md Q C ab So 9 gt 0 AN Apply thread sealant to threads PAS Apply a thin coating of lubricant to seals AN 40 Parts Table 9 Low Profile Quad GS35 Quantity MEC S eee la x 1 5 in mm set J ver 55 ppp pp VDC VAC gt Treten eee ee p m d da L
14. 52 3 Remove the heater cartridges 3 from the manifold 1 Note Note the placement of the heaters and lead lengths Note On guns that are not low profile if the heater cartridge does not easily pull out remove the other cover plate 18 and press out with a small screwdriver 4 Remove butt splices 52b from heater wires 3 thermal cutoff 52a and cordset wire leads 17 5 Recrimp new heater wires into new splices 52b See wiring diagram NOTICE To prevent a short to ground and blowing a MZLP fuse ensure bare wires are covered with fiberglass tape and sleeves 52c are centered over splices 52b 6 Insert the new heater cartridges 3 into the manifold 1 placing the heater with the shorter leads closer to the wiring port Note Do not apply thermal grease to the heater cartridge Reinstall the manifold cover plate 52 Reconnect the cordset 17 to the heated hose 9 Reconnect the solenoid valve power connector to the solenoid valve 9 Replace RTD The RTD is replaced by replacing the entire cordset See Replace Cordset page 22 for instructions Replace Thermal Cutoff 1 Disable gun assembly 20 Use a Phillips screws driver to remove the four screws 15 and manifold cover plate 52 Remove splices from heater wires 3 and cordset wire leads 17 Crimp wires See Wiring Diagram page 21 NOTICE To prevent a short to ground and blowing a MZLP fuse ens
15. 6 37 flare x SAE pats ts 6 mxm cst FITTING elbow 45 JIC 6 37 flare x T m A NOZZLE E 16Y799 PLUG assis 20 KIT THERMAL CUTOFF includes 528 520 PLATE with thermal cutoff 30 ET CONNECTOR splice 14 16 AWG heat az resistant Bc SLEEVE red 2 in 50 88 mm x 0 16 OD TERRE Hn H un Ni NO NO NIN NIN NIN I Tr TE See Solenoid Valve Kits page 45 B Purchase Separately See Parts included in Module Repair Kit See NOES HE ONCE page d Module Repair Kit page 44 A Replacement Warning labels signs tags and cards are available at no cost 3A2805K 27 Parts DUAL 6535 8 9 ti20421c Ax Apply thread sealant to threads IN el ES NS milina o 28 32 in lbs 3 2 3 6 Nem oN Apply a thin coating of lubricant to seals Pis See Wiring Diagram page 21 26 3A2805K Parts Table 4 Dual GS35 MAN a 1 BowswGda gt 31 1 1 11 pe momulEsc homer 2 2 2 2 2 2 HEATER 240 VAC 200W 1 2 dia x 100113 coNNECTOR male 5 1 1 S rrr iiis 195874 SCREW mach phil pan hd FILTER cartridge 80 mesh hotmelt rn 24P802 3 pack 2AWO87 CORD SET 240V applicator Pt 100 4 ohm RTD peo Je e fare cover housing homen 1 ma eon fraser safer w
16. Clamp Connect Heated Hose 1 Connect the hose fluid outlet to the manifold fluid inlet E Use two 11 16 in wrenches to tighten the hose fitting Figure 4 Connect the Heated Hose 3A2805K Installation 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 A Connect the hose cordset to melter See the heated hose manual for installation guidelines Connect Solenoid Valve 1 Connect 3 8 in diameter air supply tubing to a clean dry and non lubricated air supply and to the push to connect air inlet fitting L Figure 5 Air Inlet Fitting 2 Connect solenoid valve to 24 VDC or 110 VAC signal See Connect Triggering Device page 10 For applicators without a supplied solenoid valve Use solenoid valves with an override switch Ensure that your solenoid valve is connected to the manifold with tubing rated for 400 F 204 C e Ensure the solenoid valve is rated for high temperature applications Installation Connect Triggering Device 2 Insert a small screwdriver where the mounting screw was removed and gently press the Identify if your model uses a 24 VDC or 110 VAC electrical connector P out of the electrical solenoid valve Connect solenoid valve to 24 VDC connector housing N or 110 VAC signal 3 Thread a three conductor cable through the strain relief Connect the positive and negative wi
17. NG elbow JIC 6 37 flare x AU equ on oa a EBEN FITTING elbow 45 JIC 6 37 35 24056 laare X SAE e men eel WE NOZZLE 16Y799 leue 1 52a 52c m PLATE with thermal cutoff 52b heat resistant 0 16 OD See Solenoid Valve Kits page 43 Purchase Separately See O Parts included in Module Repair Kit See Nozzles Single Orifice page 45 Module Repair Kit page 44 A Replacement Warning labels signs tags and cards are available at no cost 32 3A2805K Notes Parts 3A2805K 33 Parts Slim GS35 ti22236c 15 15 A 52 15 20 91 A Apply thread sealant to threads Is Apply anti seize to first 1 2 in ofthreads Torque to 28 32 in lbs 3 2 3 6 Nem See Wiring Diagram page 21 Ep Apply a thin coating of lubricant to seals 34 3A2805K Parts Table 7 Slim GS35 a prop Lue iTi NE Ot Lt NM 1100113 CONNECTOR maie male aaa G 7 qnem cc D E m pezs wexonawwemsews T EL m per ferne Bone E 2 2 2 2 2 1 1 2 2 EE I I ETF TEE 2 2 1 1 NI ROP N gt gt NI ROP N gt GE Br FILTER gun 80 mesh FILTER gun 80 mesh 3 pack 24P802 pack 24P802 Seo ail CRUSE A po TOT dpi RID 24W088 CORD SET 240V hotmelt Ni 120 ohm 17b RA 7 LT pee eene O A IS A O s
18. Slim and Low Profile GS35 subsections of the Parts chapter Parts page 26 3A2605K 23 Repair Replace Solenoid Valve 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 2 Remove solenoid valve fitting 102 and solenoid damage the valve valve 9 from tube 7 1 Disable gun assembly See Before Beginning Repair page 19 3 Usea 1 2 in and 7 16 in wrench to tighten new connector 102 to tube 7 102 yO Figure 16 Remove Module From Manifold Figure 15 Replace Solenoid Valve 3 Apply high temperature lubricant to o rings in module 2 Replace Module 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 Nem 5 Connect cordset 17 to the heated hose 1 Disable gun assembly See Replace Applicator Before Beginning Repair page 19 21 Material inside the applicator can be near setpoint temperature Wear protective clothing to avoid severe burns Material inside the applicator can be near setpoint temperature Wear protective clothing to avoid severe burns 1 Disable gun assembly See 2 Use a 5 32 in 4 mm Allen wrench to remove e Before Beginning Repair page 19 the two mounting screws 22 and module 2 from manifold 1 2 Loosen the mounting bar c
19. arning PA 1 rrr ia x O a hoe jus o 52 20 KIT THERMAL CUTOFF includes 4 4 528 520 52a PLATE with thermal cutoff heat resistant 1 1 See Solenoid Valve Kits page 45 B Purchase Separately See Parts included in Module Repair Kit See PRESTIGE UMCS Jer de Module Repair Kit page 44 A Replacement Warning labels signs tags and cards are available at no cost 3A2605K 29 Parts Quad GS35 24P077 Type Shown E 8 L N vg a 16 A 36 OO NO ti20422c 2 Apply thread sealant to threads pr Apply anti seize to first 1 2 in of threads Torque to 28 32 in lbs 3 2 3 6 Nem jx Apply a thin coating of lubricant to seals AN See Wiring Diagram page 21 30 3A2805K Parts Table 5 Quad GS35 With 0 88 in Spaced Manifold Type Quantity 0 88 in 0 alu tala moue S o o 4 4 4 4 4 4 EE aaa 6 toos coNNECTOR male RRR 8 124786 SCREW set cup M4x 7x4 mm st 1 1 1 i 0 Eu VALVE solenoid 3way sr 24voc 1 t 24P240 240240 VALVE solenoid 3 way sr 110 VAC E c Fee pem 10 240276 INSULATOR clamp bar housing 1 A i 2 lese tees T x CI CI CI ee ee eee SCREW shes Mx40 2 2 2 FITTING 4 JIC 6 37 flare x SCREW mach phil
20. cument 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es 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
21. e is injury from pressurized fluid such as skin injection clogged or that pressure has not been fully and splashing fluid follow the Pressure Relief relieved after following the steps above VERY Procedure when you stop spraying and before SLOWLY loosen inlet fitting inlet filter or hose cleaning checking or servicing the equipment end coupling to relieve pressure gradually l then loosen completely Clear hose or module 1 Depressurize system obstruction 2 Close the bleed type master air valve 6 Turn off air pressure to the solenoid valve 3 Actuate the applicator repeatedly until no fluid flows 12 3A2805K Maintenance 1 0 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 2 S i MPa bar PSI Material inside the applicator can be near setpoint temperature Wear protective clothing to avoid severe burns 2 Remove dirty filter 16 from manifold 1 3A2805K Maintenance Figure 9 Inlet Filter 3 Appl
22. e module Trigger the gun without the nozzle to determine if the has failed and needs to be replaced nozzle or module is clogged 1 Insert a small Allen wrench into the top of the 1 Disable gun assembly See module Before Beginning Repair page 19 2 Press the solenoid valve override switch S to 2 Usea 1 2 in wrench to remove the nozzle manually trigger the gun Figure 11 Connect the power and solenoid cable Return the gun back into operation Figure 10 Check Module 5 Trigger the gun If the wrench moves up and down then the module a If adhesive flows clean the nozzle and is operating properly reinstall on the module b If adhesive does not flow the module is If the wrench does not move then the module needs clogged and needs to be replaced See to be replaced See Replace Module page 24 Replace Module page 24 16 3A2805K Check Heater Check the continuity of the heater to verify proper resistance If there is no continuity the heater may have failed and need to be replaced See Wiring Diagram page 21 and parts illustrations 1 Disable gun assembly See Before Beginning Repair page 19 2 Check resistance of the heater using a multimeter between the pins of the cordset connector See connectors illustrations in cordset pin tables e there is no continuity measure resistance of the heater at the butt splice terminals 52b e If the resistance is outside the range
23. er 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 Pressure Relief Procedure when you stop dispensing and before cleaning EE checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately 3A2805K Warnings FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area 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 unplu
24. g power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail Do not use pail liners unless they are antistatic or conductive Stop operation immediately if static sparking occurs or you feel a shock Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area EQUIPMENT MISUSE HAZARD 2 Misuse can cause death or serious injury MPa bar PSI Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Alterations or modificatio
25. ilable 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 RTD Type Pt 100 385 Solenoid Valve 24 VDC 24P074 B Pt 100 385 110 VAC Para ww voc mexo s ww novac mexr s W None Slim Single za 8 PrwoGes voc 240022 8 PrwoGes _ movac 240025 8 TRER Tae aoa o avoe moms N10 None Dual mews s proe mvoc mass proe rove zaar fe PwoGE None 24 VDC Ni 120 110 VAC mexe s Wm mexi p NTT Low Profile Dual 24U027 Pt 100 385 Solenoid Valve 24 VDC 24U028 B Pt 100 385 110 VAC zonje ww voc zonje N15 poe 200032 8 Nim None Quad ulmi Spacing Valve Type Pt 100 3 a 24 24 VDC roms Pr 100 885 24 Vb Pe 700 885 MO VAC Pt 100 385 5 None zza je m G0 ae N10 o ma ER ove E Bj N10 Wwe See Dimensions page 46 Low Profile Quad zaje Prwo Ges rova e PrWoGE Ne 20085 24 VDC 110 VAC aose ao 7 200087 8 Nu 240038 85720 None 3A2805K Component Identification D C ti20470b Figure 1 24P075 Shown 3A2805K C9 gt 0 1 UZ FA Component Identification Dispense module Fluid outlet nozzle 3 8 24 Fluid filter not visible
26. 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 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 24W087 Pt 100 385 RTD Cordset ti23839a 24W088 Ni 120 RTD Cordset 18 3A2805K Repair Repair Required Tools e Phillips screw driver Flat blade screw driver e 5 64 in 2 mm and 5 32 in 4 mm Allen wrenches e 1 2 in and 7 16 in wrenches Torque wrench Waste container High temperature anaerobic thread sealant 110110 High temperature lubricant 24T156 Anti sieze 241179 Crimp tool 24W086 Before Beginning Repair 4 Loosen the mounting screw and disconnect the solenoid valve power connector N from the 1 Turn off the melter system See melter manual solenoid valve J for shutdown instructions 2 Relieve pressure See Pressure Relief Procedure page 12 3 Disconnect the cordset from the heated hose lt gt O Figure 13 Disconnect Solenoid Valve Power Connector Figure 12 Disconnect Cordset 3A2605K 19 Repair Replace Heater Cartridge Disable gun assembly 2 Use a Phillips screwdriver to remove screws 15 and manifold cover plate
27. lamp and remove the applicator from the mounting bar 3 Install new applicator See Installation page 9 24 3A2805K Notes Notes 3A2805K 25 Parts Parts Single GS35 0 51 15 20 16 2 36 ti20420c AN Apply thread sealant to threads 4 a gt a us A of threads Torque O IN IDS 3 2 3 em oN Apply a thin coating of lubricant to seals Jak See Wiring Diagram page 21 u 3A2805K Parts Table 3 Single GS35 pe fa E es Fa Fc Ea pot t tro to td HOUSING HOUSING single NI M BE 6 10013 coNNECTOR male E 8 124736 scREW set cup M4x7x4mm sse 1 1 1 1 Ee VALVE solenoid 3w sr 24 VDC 24P240 240240 vate solenoid 3w sr 110 VAC po queze INSULATOR clamp bar housing 1 1 4 01 1 11 24P277 champ bar housing 2 2 2 2 2 2 CAIB CE CA BE E IA EC 43 117030 SCREW shes M x40 shcs M6 x 40 NA 24P615 FITTING adapter JIC 6 37 flare x SAE some AAA 6 mxm cst 45 195874 SCREW mach phil pan hd mach phil pan hd FILTER cartridge 80 mesh hotmelt He 2ap2rs 24P802 3 pack ED 241087 im SET 240V applicator Pt 100 ohm oo fot E DR A SCREW cap sch 10 32 x 1 25 in LABEL safety warning ABEL wamind ie amp 8 AA FITTING elbow JIC
28. listed below replace the heater cartridge See Replace Heater Cartridge page 20 Check Gun Model Pins Cordset Resis tance Values 24W087 A and C 24U021 24U0 Pt 100 26 260 280 385 RTD 24U027 24U ohms Cordset 032 All other 130 140 models ohms 24W088 1 and 2 24U021 24U0 260 280 Ni 120 26 ohms RTD 24U027 24U Cordset 032 All other 130 140 models ohms 3A2805K Troubleshooting Table 1 24W087 Pt 100 385 RTD Cordset pei Thermal Cutoff A s emm 5 kowe RTD Fed Table 2 24W088 Ni 120 RTD Cordset en TDesonpton 2 ww 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 Checkresistance 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 107 115 ohms 24W087 Pt 100 385 RTD Cordset 130 140 ohms 24W088 Ni 120 RTD Cordset 3 Replace the RTD if the resistance reading is outside the range or if there is no continuity See Replace RTD page 20 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
29. ns 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 4 3A2805K Approvals 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 e Read MSDSs to know the specific hazards of the fluids you are using e 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 6 6 3A2805K US LISTED Intertek 4002346 Conforms to ANSI UL Std 499 Certified to CAN CSA Std C22 2 No 88 Models Models All models use a 240 V heater Additional configurations are ava
30. ol ad EL A 36m F7 NOZZLE not shown e mmer PONTE rb sep 17 17 ER Pp PLUG O PLATE with thermal cutoff resistant SEE SLEEVE red 2 in 50 88 mm x 0 16 OD A See Solenoid Valve Kits page 45 B Purchase Separately See O Parts included in Module Repair Kit See ROBOS PINGE CUE Ago e Module Repair Kit page 44 A Replacement Warning labels signs tags and cards are avallable at no cost Pt J 4444 J 4444 J 4444 J 3A2805K 35 Parts Low Profile Dual GS35 Q N ti24240a 22 9 seize to first 1 2 in of threads Torque to 28 32 in lbs 3 2 3 6 Nem See Wiring Diagram page 21 Apply anti ZN 4 Apply thread sealant to threads AN BES Apply a thin coating of lubricant to seals 3A2805K 36 Parts Table 8 Low Profile Dual GS35 ROUSING Paipai BEE BEL m 3 2 2 s mm pomerne _ 1 1 1717 L Terres musta omen open T 1 p 7 1 11 s mme SCREW set TO D 0 07 A v ems VALVE scenic H 7 O 1 1 24P240 VALVE solenoid 3 way sr 120 VAC VALVE se Twy s moves 7 OA 8 U BE EA EAN m pres E 1 1 Ts 1 1 195874 SCREW mach phil pan hd 5 24W087 CORD SET 240V applicator Pt 100 ohm E RTD m fim Ne p RTD m p pues FI mE m eve 3
31. panhd mach phil pan hd FILTER gt 80 mesh hotmelt ohm RTD e e opp TT Ec eae et IE 226 M04705 SCREW cap sch 10 32x1725in 8 8 8 8 8 8 8 LABEL safety warning 1 1 1 1 FITTING elbow JIC 6 37 flare x EEEN x SAE mxm cst 16Y79 Jerus Mv E AA Eee E ii G 52c PLATE with thermal PLATE with thermal cutoff heat See Solenoid Valve Kits page 45 B Purchase Separately See O Parts included in Module Repair Kit See OE folia ORGEL qiagu sg Module Repair Kit page 44 A Replacement Warning labels signs tags and cards are available at no cost 3A2805K 31 Parts Table 6 Quad GS35 with 1 5 in Spaced Manifold Type Il Quantity pu fot booome 24P079 24P080 24P254 24P305 24P306 24P310 HousNG 1 5 in HOS EIER LM PA E RR RR MODULE NC dM A A s ow oonnecToR mde 7 peur taste O Em P ame EA ACI or lor por poo por queo ave soleno auay anzavne 1 VAC FOP ATOR E Y ITE m pes ptem pep 2108050 wasHER tock soring 2 2 2 2 2 eoo jesus a ra pa EEE a gt JIC 6 37 flare 195874 sCREW mach SCREW mach philpanhd pan hd duis SGS 80 mesh ME NIE SER ohm RTD CORD SET 240V hotmelt Ni 120 PLATE cover housing hotmelt US WASHER lock int a LH NO 104705 SCREW cap sch 10 32x 1 25in 8 16K931 LABEL safety warning aa FITTI
32. res to terminals 1 and 2 on the electrical connector P Connect the ground wire to the ground terminal Note Improper electrical connection can result in electric shock All electrical wiring must be done by a It does not matter which terminal qualified electrician and comply with all local codes the positive and negative wires are and regulations connected to 1 Loosen the mounting screw and disconnect the 1 2 electrical connector N from the solenoid valve J Set the gasket and screw aside d GND oolenoid Valve Connector Figure 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 Flush 1 Disconnect or turn off the device which triggers the solenoid valve Heat the system to working temperature Place waste container under the gun to catch the adhesive Ensure the nozzle is removed Press the manual override switch S to manually trigger the solenoid valve 6 Dispense hot melt adhesive until it is clean ti20475b Figure 8 In
33. rules Single heater cartridges are for custom manifolds only Part Length Recommended Manifold Width 24P824 4 in 5 6 in 101 6 mm 127 152 4 mm 24P825 5 in 6 7 in 127 mm 152 4 177 8 mm 24P826 Gin 7 8 in 152 4mm 177 8 203 2 mm 24P827 7 in 8 9 in 177 8mm 203 2 228 6 mm 24P828 8in 9 12 in 203 2 mm 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 Mufflers 24P282 Includes two mufflers that can be used with solenoid valve kits Blanking Plate Kit 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 Ki 24P239 24 VDC 24P240 110 VAC Inlet Filter Kit 24P ITE 24 802 Material Inlet Fittings Gear 9 Thermal Cutoff Replacement Kits For Series A and Series B Models 24V790 See Models Standard page 6 24V 792 24U021 Slim Single 24U026 24V794 24U027 Dual Low 24U032 Profile 24V796 24U033 Quad Low 24U038 Profile 3A2805K Kits and Accessories Mounting Clamp Kits oee Models page 6 for model numbers 24P277 Single Dual and Quad GS35 Descri Description Qy Ref Pat
34. stall Nozzle Use 1 2 in wrench to install nozzle See Kits and Accessories page 44 3A2805K Installation 9 O M 7 Select RTD Note For InvisiPac systems only Identify RTD type used in applicator on the system Advanced Display Module ADM The RTD type is listed on the manifold cover plate See the InvisiPac system manual for instructions to configure this setting NOTICE An incorrect RTD setting will cause the system to be incapable of maintaining the temperature setting The applicator may overheat and trip the thermal cutoff if the applicator uses a PT 100 385 and NI 120 is selected on the ADM Setup screen The applicator may under heat if the applicator uses a NI 120 and PT 100 385 is selected on the ADM Setup screen e 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 77 Operation Operation Pressure Relief Procedure MPa bar PSI 77 sitara er Follow the Pressure Relief Procedure whenever you see this symbol Material inside the module and hose may still be near setpoint temperature Wear protective clothing to avoid severe burns 73 4 f you suspect the module nozzle is clogged remove nozzle and then actuate the module to This equipment stays pressurized until pressure relieve pressure is manually relieved To help prevent serious 5 f you suspect the module or fluid hos
35. te 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
36. ure 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 Gently press wires into the manifold Install plate 52 and screws 15 526 ti20481b 3A2805K Wiring Diagram Thermal Cutoff 17 52b 52b 52b Note Slim 24U021 24U026 and Low Profile Dual 24U026 24U032 applicators use one heater 3 3A2805K Repair 21 Repair Replace Cordset See Fig 14 page 24 22 Note 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
37. y 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 Nem 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 Replace Replace filter filter every four every two months months Gun manifold filter Solenoid exhaust filters Replace filter every six months 13 Troubleshooting Troubleshooting 21 PERA No adhesive or incorrect Debris in manifold filter Replace manifold filter See amount of adhesive out of all Replace Inlet Filter page 13 modules when triggered Clogged hose Clean or replace hose Failed solenoid valve Check for correct operation Clean or replace No signal to solenoid valve Check solenoid valve for correct operation Heater failure cold gun Check and replace
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