Graco GS35 User Manual

Instructions-Parts
InvisiPac® GS35 Plug-Free™
Hot Melt Applicator
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.
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.
3A2805K
EN
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents

Warnings ........................................................... 3
Approvals........................................................... 5
Models............................................................... 6
Component Identication..................................... 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
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
2
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 uid 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 p ower 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.
immediate surgical treatment.
Do not point dispensing device at anyone or at any part of the body.
Do not put your hand over the uid outlet.
Do not stop or deflect leaks with your hand, body, glove, or rag.
•Followthe checking, or servicing equipment.
Tighten all uid connections before operating the equipment.
Check hoses and couplings daily. Replace worn or damaged parts immediately.
Pressure Relief Procedure
when you stop dispensing and before cleaning,
Get
3A2805K 3
Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in prevent re 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 powe r or light switches on or off when ammable fumes are present.
Ground all equipment in the work area. See
Use only grounded hoses.
Hold gun rmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.
Stop operation immediately
equipment until you identify and correct the problem.
Keep a working fire extinguisher in the work area.
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
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
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 trafc 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.
if static sparking occurs or you feel a shock.Do not use
Technical Data
Pressure Relief Procedure
Grounding
in all equipment manuals.
work area
instructions.
canigniteorexplode.Tohelp
when equipment is not in use.
4
3A2805K

Approvals

WARNING
TOXIC FLUID OR FUMES HAZARD
Toxic uids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
Read MSDSs to know the specic hazards of the uids you are using.
Store hazardous uid 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 Certied to CAN/CSA
Std. C22.2 No. 88
3A2805K 5

Models

Models
All models use a 240 V heater. Additional congurations are available. Contact Graco customer service for details.
Note
Applicators with Ni 120 RTD types come with a 6pin rectangular cordset (24W088). See
Parts, page 26.

Single

Part
24P073 B 24P074 B 24P246 B 24P299 B Ni 120 24P300 B Ni 120 24P307 B Ni 120 None
Series
RTD Type
Pt 100 (385) 24 VDC Pt 100 (385) 110 VAC Pt 100 (385)
Solenoid Valve
None 24 VDC 110 VAC

Slim (Single)

Part
24U021 B 24U022 B 24U023 B 24U024 B Ni 120 24U025 B Ni 120 24U026 B Ni 120 None
Series
RTD Type
Pt 100 (385) 24 VDC Pt 100 (385) 110 VAC Pt 100 (385)
Solenoid Valve
None 24 VDC 110 VAC
Low Profile - Dual
Part
24U027 B 24U028 B 24U029 B 24U030 B Ni 120 24U031 B Ni 120 24U032 B Ni 120 None
Series
RTD Type
Pt 100 (385) 24 VDC Pt 100 (385) 110 VAC Pt 100 (385)
Solenoid Valve
None 24 VDC 110 VAC

Quad

Part
24P077 B I 24P078 B I 24P079 B II 24P080 B II 24P250 B I 24P254 B II 24P303 B I Ni 120 24P304 B I Ni 120 24P305 B II Ni 120 24P306 B II Ni 120 24P309 B I Ni 120 None 24P310 B II Ni 120 None
Series
Module Spacing Type*
RTD Type
Pt 100 (385) 24 VDC Pt 100 (385) 110 VAC Pt 100 (385) 24 VDC Pt 100 (385) 110 VAC Pt 100 (385) Pt 100 (385)
Solenoid Valve
None None 24 VDC 110 VAC 24 VDC 110 VAC
*

Dual

Part
24P075 B 24P076 B 24P247 B 24P301 B Ni 120 24P302 B Ni 120 24P308 B Ni 120 None
Series
RTD Type
Pt 100 (385) 24 VDC Pt 100 (385) 110 VAC Pt 100 (385)
Solenoid Valve
None 24 VDC 110 VAC
See Dimensions, page 46.
Low Profile - Quad
Part Series RTD Type Solenoid Valve
24U033 B Pt 100 (385) 24 VDC 24U034 B Pt 100 (385) 110 VAC 24U035 B Pt 100 (385) None 24U036 B Ni 120 24 VDC 24U037 B Ni 120 110 VAC 24U038 B Ni 120 None
6 3A2805K
Component Identication
Component Identification
Figure 1 24P075 Shown
A Dispense module B C Fluid filter (not visible)
D E F G H J
K L M Manual override switch N P Insulator
Fluid outlet/nozzle (3/8–24)
Manifold Fluid inlet (9/16–18, 6 JIC, 3 are) 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)
Solenoid valve electrical connector
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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 ltered through the manifold filter (C) before entering the dispense module fluid inlet port. Then the uid is ltered one nal time t hrough the module lter (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 uid outlet. When the air shuts off, the spring pushes the piston rod and ball into its seat and closes the uid outlet.
The gun should be rigidly mounted and remotely operated by a melter system and triggering device. The melter system provides pressurized uid to the valve. The triggering device controls the uid ow 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.
Pump:
Dispense applicator:
connection.
Air compressor:
recommendations.
Fluid supply container:
Solvent pails used when ushing:
code. Use only conductive metal pails, placed onagroundedsurface. Donotplacethepail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.
follow manufacturer’s recommendations.
grounded through electrical
follow manufacturer’s
follow local code.
follow local
Figure 2 Air and Fluid Flow
Air
Fluid
To maintain grounding continuity when ushing or relieving pressure:
electrical power connector are grounded properly.
ensure mounting manifold and
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:
adjust nuts that control position of gun assembly on threaded rod.
All Other Models:
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.
Usea3/4in.(19mm)wrenchto
See the following instructions.
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 suppl y tubing to a clean, dry, and non-lubricated air supply and to the push-to-connect air inlet fitting (L).
Figure 3 Mounting Clamp

Connect Heated Hose

1. Connect the hose uid outlet to the manifold uid inlet (E). Use two 11/16 in. wrenches to tighten the hose tting.
Figure 4 Connect the Heated Hose
Figure 5 Air Inlet Fitting
2. Connect solenoid valve to 24 VDC or 110 VAC signal. See Connect Triggering Devi ce, 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).
Ensure the solenoid valve is rated for
high-temperature applications.
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-conductorcable 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.
21
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.
Figure 6 Solenoid Valve Electrical Connector

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 pus hed out before using the equipment. See Flush, page 11.
10 3A2805K

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.
Installation

Select RTD

Note
For InvisiPac systems only.
Figure 8

Install Nozzle

Use 1/2 in. wrench to install nozzle. See
Kits and Accessories, page 44.
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.
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.
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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 uid, 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.
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 uid 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.
12
3A2805K

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

Maintenance
NOTICE
Remove the lter when the gun is hot. If the gun is cold, the adhesive will be hard and the lter 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 lter (16) from manifold (1).
Figure 9 Inlet Filter
3. Apply a thin coating of high-temperature lubricant to seals on the new lter (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 lter maintenance. To establish a preventative maintenance cycle tailored to your environment, Graco recommends inspecting lters every 4 weeks after installation and replacing when necessary. Document replacement intervals and use this as your preventative maintenance schedule moving forward.
Environment Classification
Moderate Dusty
Replace
filter
every
months
four
Replace
filter
every
months
two
Gun manifold filter
Solenoid exhaust filters
Clean
Replace
filter every
six
months
3A2805K 13

Troubleshooting

Troubleshooting
Problem Cause Solution
No adhesive or incorrect amount of adhesive out of all modules when triggered
Debris in manifold lter Replace manifold lter. See
Replace Inlet Filter, page 13.
Clogged hose Clean or replace hose. Failed solenoid valve Check for correct operation. Clean
or replace. No signal to solenoid valve
Incorrect solenoid valve wiring Incorrect signal to solenoid valve Solenoid muffler plugged Check and replace mufflers. No fluid pressure Check adhesive delivery system. Heater failure (cold gun) Check and replace
No air to solenoid valve Dirty or faulty triggering device Check, clean, or replace triggering
Solenoid valve connected incorrectly
Check solenoid valve for correct
operation.
Check solenoid valve wiring.
Check if 24 VDC or 120 VAC.
heater cartridges. See
Replace Heater Cartridge, page 20.
Check air supply.
device.
Check solenoid valve air connections.
No adhesive or incorrect amount of adhesive out of one/some modules when triggered
Adhesive out of one/some modules when not triggered
14
Clogged manifold passage Clean or replace manifold. Debris in nozzle Failed module in closed position Check for correct operation.
Debris in module filter Replace module. See
Clogged manifold passage Clean or replace manifold. Failed module in open position
Adhesive pressure too high
Clean or replace nozzle.
Clean or replace. See
Check Module, page 16.
Replace Module, page 24.
Clean or replace module. See
Replace Module, page 24.
Check and reduce fluid pressure.
3A2805K
Troubleshooting
Problem
Gun will not heat
Gun overheats
Cause Solution
Heater failure Check and replace
heater cartridge. See
Replace Heater Cartridge, page 20.
Loose cord set connection RTD failure Check and replace RTD. See
Incorrect RTD for adhesive delivery system
Thermal cutoff failure Check and replace
Wrong RTD type selected
Heater failure Check and replace
RTD failure Check and replace RTD. See
Incorrect RTD for adhesive delivery system
Check connection.
Check RTD, page 17.
Check delivery system RTD
requirement
thermal cutoff. See
Replace Thermal Cutoff, page 20.
Check RTD type settings on the
system. Change if necessary. See
Select RTD, page 11.
heater cartridge. See
Replace Heater Cartridge, page 20.
Check RTD, page 17.
Check delivery system RTD
requirement.
Gun under-heats
Adhesive leaking from gun
Incorrect power to heater Wrong RTD type selected Check RTD type settings on the
Heater failure Check and replace
RTD failure Check and replace RTD. Incorrect RTD for adhesive delivery
system Incorrect power to heater Wrong RTD type selected
Module o-ring failure Check and replace o-ring. See
Inlet tting loose Tighten tting. Manifold lter o-ring failure Check and replace o-ring. Nozzle loose Tighten nozzle. Module seal failure Check and replace module. See
Check and correct power.
system. Change if necessary. See
Select RTD, page 11.
heater cartridge. See
Replace Heater Cartridge, page 20
Check delivery system RTD
requirement.
Check and correct power.
Check RTD type settings on the
system. Change if necessary. See
Select RTD, page 11.
Replace Module, page 24.
Check Module, page 16.
3A2805K 15
Troubleshooting
Problem
Adhesive out of all modules when not triggered
Solenoid valve failure Check and replace solenoid valve. Adhesive pressure too high Solenoid valve connected
incorrectly Module failure Check and replace all modules. See
Cause Solution

Check Module

Check the module operation to verify if the m odule has failed and needs to be replaced.
1. InsertasmallAllenwrenchintothetopofthe module.
2. Press the solenoid valve override switch (S ) to manually trigger the gun.
Check and reduce fluid pressure. Check solenoid valve air connections.
Check Module, page 16.

Check Nozzle and Module

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. Usea1/2in.wrenchtoremovethenozzle.
Figure 11
3. Connect the power and solenoid cable.
4. Return the gun back into operation.
Figure 10 Check Module
If the wrench moves up and down, then the module is operating properly
If the wrench does not move, then the module needs to be replaced. See Repl ace Module, page 24.
16 3A2805K
5. Trigger the gun. a. If adhesive ows, clean the nozzle and
reinstall on the mo dule.
b. If adhesive does not ow, the module is
clogged and needs to be replaced. See
Replace Module, page 24.
Troubleshooting

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.
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
Pins
24W087, Pt 100 (385) RTD Cordset
24W088, Ni 120 RTD Cordset
A and C
1 and 2
Gun Model Resis-
tance Values
24U021–24U0 26 24U027–24U- 032
All other models
24U021–24U0 26 24U027–24U- 032
All other models
260–280 ohms
130–140 ohms
260–280 ohms
130–140 ohms

Table 1 24W087, Pt 100 (385) RTD Cordset

Pin Description
A B C D E

Table 2 24W088, Ni 120 RTD Cordset

Pin Description
1 2Heat- 3 5 G Ground
Thermal Cutoff Ground Heat - RTD (White) RTD (Red)
Thermal Cutoff
RTD (White) RTD (Red)

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 70–7F (21–22°C)
3A2805K
24W087, Pt 100 (385) RTD Cordset
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.
D and E 107-115
ohms
3 and 5 130-140
ohms
17
Troubleshooting

Check 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 andneedstobereplaced.
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
Thermal Cutoff
WLD
24W088, Ni 120 RTD Cordset
1
18 3A2805K

Repair

Required Tools

Phillips screw driver
•Flatbladescrewdriver
5/64in(2mm)and5/32in.(4mm)Allenwrenches
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)
Repair

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,
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.
if the
NOTICE
To prevent a short to ground and bl owing 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.
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).
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 berglass 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).

F
E

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 3A2805K
D
WLE

Wiring Diagram

Thermal Cutoff
Repair
17
17
52b
52b
52a
52b
33
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
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.
1. Disable gun assembly. See
Before Beginning Repair, page 19.
2. Use a Phillips screwdriver to remove the four screws (15) and manifold cover plate (52).
3. Usea2mmAllenwrenchtoremovetheset screw (8) holding the cordset (17) on the manifold (1).
4. 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,
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).
if the
22
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).
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.
Figure 14 Repair Parts
3A2805K 23
NOTE:
of the Parts chapter ( Parts, page 26).
See Slim and Low Profile GS35 subsections
Repair

Replace Solenoid Valve

1. Disable gun assembly. See
Before Beginning Repair, page 19.
2. Remove solenoid valve tting (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

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 ow 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 a5/32in. (4mm)Allenwrenchtoinstallnew module(2)onmanifoldwithtwoscrews(22). Torque to 2832 in.-lbs (3.2–3.6 N•m).
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).
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 Installat ion, page 9 .
24
3A2805K

Notes

Notes
3A2805K 25

Parts

Parts

Single GS35

ply anti-seize to rst 1/2 in. of threads. Torque
Apply thread sealant to threads.
1
Apply a thin coating of lubricant to seals.
2
Ap
3
4
28-32 in-lbs (3.2-3.6 N∙m).
to See Wiring Diagram, page 21.
26 3A2805K

Table3SingleGS35

Ref Part
1
2
3 24V789
6 100113 7 24R231 8 124736
9*
10 24P276 11 24P277 12 108050 13 117030
14 24P615
15 195874
16 24P275
17a 24W087
17b 24W088
18 20 157021 22
29
34 24P547
35 24P548
36
51 16Y799
52 24V790
52a
52b
52c
---
---
24P239 24P240
---
104705 16K931
---
---
---
---
Description
HOUSING, single MODULE, sc, hotmelt
HEATER, 240 VAC, 200W, 1/2 dia. x 1.5 in.
CONNECTOR, male TUBE, applicator, hotmelt, open SCREW, set, cup, M4x.7x4 mm, sst VALVE, solenoid, 3w, sr, 24 VDC VALVE, solenoid, 3w, sr, 110 VAC INSULATOR, clamp, bar, housing CLAMP, bar, housing WASHER, lock, spring SCREW, shcs M6 x 40
FITTING, adapter, JIC -6 (37° are) x SAE
-6, mxm, cst SCREW, mach, phil pan hd
FILTER, (24P802 CORD SET, 24 0V, 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
FITT
-6, FITTING, elbow, 45°, JIC -6 (37° flare) x SAE -6, mxm, cst
NOZZLE PLUG
KIT, THERMAL CUTOFF(includes 52a-52c)
PLATE, with thermal cutoff C resistant
SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD
cartridge, 80 mesh, hotmelt
- 3 pack)
ING, elbow, JIC -6 (37° are) x SAE
mxm, cst
ONNECTOR, splice, 14–16 AWG, heat
Parts
Quantity
24P073 24P074 24P246 24P299 24P300 24P307
111111 121121
222222
11 11 11 11 111111 11
11 111111 222222 222222 222222
111111
999999
111111
111
111
111111 111111 222222 111111
111111
111111
111111
111111
111111
333333
333333
*
See Solenoid Valve Kits, page 45.
Parts included in Module Repair Kit. See
Module Repair Kit, page 44.
3A2805K
Purchase Separately. See
Nozzles (Single Orice), page 45.
Replacement Warning labels, signs, tags, and cards are available at no cost.
27
Parts

DUAL GS35

Apply thread sealant to threads.
1
Apply a thin coating of lubricant to seals.
2
Apply anti-seize to rst 1/2 in. of threads. Torque
3
to 28-32 in-lbs (3.2-3.6 N∙m). See Wiring Diagram, page 21.
4
28 3A2805K

Table 4 Dual GS35

Parts
Ref Part
1 2
324V789
6 100113 724R231 8 124736
9*
10 24P276 11 24P277 12 108050 13 117030
14 24P615
15 195874
16 24P275
17a 24W087
17b 24W088
18 20 157021 22
29
34 24P547
35 24P548
36
51 16Y799
52 24V790
52a
52b
52c
---
---
24P239 24P240
---
104705 16K931
---
---
---
---
Description
HOUSING, dual MODULE, sc, hotmelt
HEATER, 240 VAC, 200W, 1/2 dia. x
1.5 in. CONNECTOR, male TUBE, applicator, hotmelt, open SCREW, set, cup, M4 x .7 x 4 mm, sst VALVE, solenoid, 3w, sr, 24 VDC VALVE, solenoid, 3w, sr, 110 VAC INSULATOR, clamp, bar, housing CLAMP, bar, housing WASHER, lock, spring SCREW, shcs M6 x 40
FITTING, adapter, JIC -6 (37° are) x SAE -6, mxm, cst
SCREW, mach, phil pan hd FILTER, (24P802 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
FITT SAE FITTING, elbow, 4, JIC -6 (37° flare) x SAE -6, mxm, cst
NOZZLE PLUG
KIT, THERMAL CUTOFF (includes 52a-52c)
PLATE, with thermal cutoff C heat resistant SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD
cartridge, 80 mesh, hotmelt
-3pack)
ING, elbow, JIC -6 (37° are) x
-6, mxm, cst
ONNECTOR, splice, 1416 AWG,
24P075 24P076 24P247 24P301 24P302 24P308
111111 222222
222222
11 11 11 11 111111 11
11 111111 222222 222222 222222
111111
999999
111111
111
111
111111 111111 444444 111111
111111
111111
111111
111111
111111
333333
333333
*
See Solenoid Valve Kits, page 45.
Parts included in Module Repair Kit. See
Module Repair Kit, page 44.
Purchase Separately. See
Nozzles (Single Orice), page 45.
Replacement Warning labels, signs, tags, and cards are available at no cost.
3A2805K 29
Parts

Quad GS35

24P077 Type I Shown
Apply thread sealant to threads.
1
Apply a thin coating of lubricant to seals.
2
Apply anti-seize to rst 1/2 in. of threads. Torque
3
to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21.
4
30 3A2805K

Table 5 Quad GS35 With 0.88 in. Spaced Manifold (Type I)

Ref Part
1
2
3 24V791
6 100113 7 8 124736
9*
10 24P276 11 24P277 12 108050 13 117030
14 24P615
15 195874
16 24P275
17a 24W087
17b 24W088
18 20 157021 22
29
34 24P547
35 24P548
36
51 16Y799
52 24V790
52a
52b
52c
---
---
24R231
24P239 24P240
---
104705 16K931
---
---
---
---
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° are) x SAE -6, mxm, cst
SCREW, mach, phil pan hd FILTER, cartridge, 80 mesh, hotmelt (24P802-3pack) 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 (3 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
Parts
Quantity
24P077 24P078 24P250 24P303 24P304 24P309
111111 444444
222222
11 11 11 111 111111 11
11
111111 222222 222222 222222
111111
999999
111111
111
111
111111 111111 888888 111111
111111
111111
111111
111111
111111
333333
333333
*
See Solenoid Valve Kits, page 45.
Parts included in Module Repair Kit. See
Module Repair Kit, page 44.
Purchase Separately. See
Nozzles (Single Orice), page 45.
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 II)

Ref Part
1 2
3 24V791
6 100113 7 8 124736
9*
10 24P276 11 24P277 12 108050 13 117030
14 24P615
15 195874
16 24P275
17a 24W087
17b 24W088
18 20 157021 22104705 2916K931
34 24P547
35 24P548
36 51 16Y799
52 24V790
52a
52b
52c
---
---
24R231
24P239
24P240
---
---
---
---
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° are) x SAE -6, mxm, cst
SCREW, mach, phil pan hd FILTER, cartridge, 80 mesh, hotmelt (24P802-3pack) CORD SET, 240V, applicator, Pt 100 ohm RTD CORD SET, 240V, hotmelt, Ni 120 ohm RTD
PLATE, cover, housing, hotmelt WASHER, lock, int SCREW, LABEL, safety, warning
FITTING, elbow, JIC -6 (37° flare) x SAE -6, mxm, cst FITTING, elbow, 45°, JIC -6 (37° are) 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
cap, sch; #1032 x 1/25 in.
24P079 24P080 24P254 24P305 24P306 24P310
Quantity
11 1111 44 4444
22 2222
11 11 11 11 11 1111 11
11
11 1111 22 2222 22 2222 22 2222
11 1111
99 9999
11 1111
111
11 1
11 1111 11 1111 88 8888 11 1111
11 1111
11 1111
11 1111
11 1111
11 1111
33 3333
33 3333
*
See Solenoid Valve Kits, page 45.
Parts included in Module Repair Kit. See
Module Repair Kit, page 44.
Purchase Separately. See
Nozzles (Single Orifice), page 45.
Replacement Warning labels, signs, tags, and cards are available at no cost.
32 3A2805K

Notes

Parts
3A2805K 33
Parts

Slim GS35

Apply thread sealant to threads.
1
Apply a thin coating of lubricant to seals.
2
Apply anti-seize to rst 1/2 in. of threads. Torque
3
to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21.
4
34 3A2805K
Parts

Table7SlimGS35

Quantity
Ref Part
---
1
---
2
324V793HEATER,240VAC,200W,1/2diax1.5in.111111 6 100113 CONNECTOR, male 1 1 1 1 7
16P769 TUBE, applicator, hotmelt, open 1 1 1 1
8124736SCREW,set,cup,M4x0.7x4mm,sst111111
24P239 VALVE, solenoid, 3 way, sr, 24 VDC 1 19*
24P240 VALVE, solenoid, 3 way, sr, 120 VAC 1 1 1024P276INSULATOR,clamp,bar,housing 111111 1124P277CLAMP,bar,housing 222222 12108050WASHER,lock,spring 222222
13 117030 14 24P615
15 195874 16 24P275 17a 24W087
24W088 CORD SET, 240V, hotmelt, Ni 120 ohm 17b
---
18 20157021WASHER,lock,int 111111 22104705SCREW,cap,sch 222222 3424P547FITTING,elbow,JIC06xSAE06,mm,cs111111 35 24P548 FITTING, elbow, 45, JIC06 x SAE06, mm,
---
36
42 16W708PLAT
Description
HOUSING,slim 111111 MODULE 111111
SCREW, shcs M6 x 40 FITTING, adapter, JIC 06 x SAE 06, mm,
cs SCREW, mach, phil pan hd
FILTER, gun, 80 mesh (3pack: 24P802) CORD SET, 240V, applicator, Pt 100 ohm
RTD
RTD PLATE,cover,side,slim 111111
c NOZZLE (not shown)
E, cover, bottom, slim
24U021 24U022 24U023 24U024 24U025 24U026
222222 111111
11 11 11 11 11 11
111111 111
111
111111
111111
51 16Y799
52 24V792
52a
52b
52c
*
--
---
---
e Solenoid Valve Kits, page 45.
Se
arts included in Module Repair Kit. See
P
odule Repair Kit, page 44.
M
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
111111
111111
111111
333333
333333
urchase Separately. See
P
ozzles (Single Orice), page 45.
N
Replacement Warning labels, signs, tags, and cards are available at no cost.
3A2805K 35
Parts
Low Profile Dual GS35
Apply thread sealant to threads.
1
Apply a thin coating of lubricant to seals.
2
Apply anti-seize to rst 1/2 in. of threads. Torque
3
to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21.
4
36 3A2805K
Table 8 Low Profile Dual GS35
Ref Part
1 2 3 24V793 6 100113 7 8 124736 9*
10 24P276
---
---
16P769 TUBE, applicator, hotmelt, open 1 1 1 1
24P239 24P240
Description
HOUSING, double MODULE, sc HEATER, 240 VAC, 200W, 1/2 dia x 1.5 in. CONNECTOR, male
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
Parts
Quantity
24U027 24U028 24U029 24U030 24U031 24U032
111111 222222 111111 11 11
111111 11
11
111111
11 12 108050 WASHER, lock, spring 2 2 2 2 2 2 13 117029 SCREW, shcs, M6 x 25 2 2 2 2 2 2 14 24P615 FITTING, adapter, JIC06 x SAE06, mm, cs 1 1 1 1 1 1 15 195874 SCREW, mach, phil pan hd 16 24P275 FILTER, gun, 80 mesh (3–pack: 24P802) 1 1 1 1 1 1 17a 24W087 CORD SET, 240V, applicator, Pt 100 ohm
17b 24W088 CORD SET, 240V, hotmelt, Ni 120 ohm
18 20 157021 WASHER, lock, int 1 1 1 1 1 1 21 103147 PLUG, pipe 3 3 3 3 3 3 22 34 24P547 FITTING, elbow, JIC06 x SAE06, mm, cs 1 1 1 1 1 1 35 24P548 FITTING, elbow, 45, JIC06 x SAE06, mm, c 1 1 1 1 1 1 36 42 16W70 44 24U69 45 46 47 48 49 50 1005
---
---
104705 SCREW, cap, sch 4 4 4 4 4 4
---
10259
10002 1095 1000
---
70 18
08
BLOCK 111111
555555
111
RTD
111 RTD PLATE, s
NOZZLE (not shown)
9
PLATE
8
ROD, mtg, threaded 1 1 1 1 1 1
8
SCREW, cap, socket head 1 1 1 1 1 1
0
WASHER, lock 1 1 1 1 1 1 WASHER, plain 2 2 2 2 2 2 WASHER, lock, spring 2 2 2 2 2 2 NUT, SCREW, drive 4 4 4 4 4 4
ide
, cover, end
1/2-13 hex
111111
111111
222222
51 16Y799
PLUG
111111
3A2805K 37
Parts
Ref Part
52 24V794
52a
52b
52c
---
---
---
Description
KIT, THERMAL CUTOFF (includes 52a-52c)
PLATE, with thermal cutoff CONNECTOR, sp resistant
SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD
lice, 1416 AWG, heat
Quantity
24U027 24U028 24U029 24U030 24U031 24 U032
111111
111111
333333
333333
*
See Solenoid Valve Kits, page 45.
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.
Purchase Separately. See
Nozzles (Single Orifice), page 45.
Replacement Warning labels, signs, tags, and cards are available at no cost.
38 3A2805K

Notes

Parts
3A2805K 39
Parts
Low Profile Quad GS35
Apply thread sealant to threads.
1
Apply a thin coating of lubricant to seals.
2
Apply anti-seize to rst 1/2 in. of threads. Torque
3
to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21.
4
40 3A2805K
Table 9 Low Profile Quad GS35
Ref Part
1 2
3 6 7
8 9*
10 11 12 13
14 15
16 17a 24W087
17b 24W088
18 20 21 22
34
35 36
38
39 42 44 45
46
47
48
49
50 51
---
--- 24V795
100113 16P769 TUBE, applicator, hotmelt, open 124736
126407 VALVE, solenoid, 3 way, sr, 24
126408 VALVE, solenoid, 3 way, sr, 120
16P848
--- 108050 117029 126544
195874 24P275
--- 157021 103147 104705 126748
126749
--- 16K931 103473 16V721 PLATE, cover, applicator 24U698 102598 100020 109570 100018
-
-- 100508 16Y799
Description
HOUSING, quad MODULE, sc, invisipac HEATER, 240 VAC, 200W, 1/2
dia x 1.5 in. CONNECTOR, male
SCREW, set, cup, M4x 0.7 x 4 mm, sst
VDC
VAC INSULATOR, clamp, bar, housing
BLOCK, mtg 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, quad
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)
TAG, warning, turbo STRAP, tie, wire
ROD, mtg, threaded SCREW, cap, socket head WASHER, lock WASHER, plain WASHER, lock, spring NUT, 1/2-13 hex SCREW, drive PLUG
Parts
Quantity
24U033 24U034 24U035 24U036 24U037 24U038
111111 444444
222222
11 11 11 11
111111
11
11
111111 111111 222222 222222
111111
666666
111111
111
111
111111 111111 333333 888888
111111
111111
111111 111111 111111 111111 111111 111111 222222 222222 222222 222222 111111
3A2805K
41
Parts
Ref Part
52
52a
52b
52c
24V796 KIT, THERMAL CUTOFF
---
---
---
Description
(includes 52a-52c) PLATE, with th
CONNECTOR, sp AWG, heat res SLEEVE, red, 2 in. (50.88 mm) x0.16OD
ermal cutoff
lice, 1416
istant
Quantity
24U033 24U034 24U035 24U036 24U037 24U038
111111
111111
333333
333333
*
See Solenoid
Parts includ
Module Repai
Parts included in Bar Clamp Kit 24U698. See
Mounting Clamp Kits, page 45.
Valve Kits, page 45.
ed in Module Repair Kit. See
r Kit, page 44.
Purchase Sep
Nozzles (Si
Replacement Warning labels, signs, tags, and cards are available at no cost.
arately. See
ngle Orifice), page 45.
42
3A2805K

Solenoid Valve Kits

24P239, 24 VDC Solenoid Valve 24P240, 110 VAC Solenoid Valve
Parts
Apply thread sealant to threads.
1
Part Description
Ref
101
102 100113 CONNECTOR, male 1 103 24P900 BUSHING, 1/4 npt x 1/8
---
---
VALVE, solenoid, 3w, sr, 24 VDC; 24P239 only VALVE, solenoid, 3w, sr, 120 VAC; 24P240 only
npt, brass
Qty
1
1
1
Part Description
Ref
104 24P282 MUFFLER, 1/8 npt, pp 2 105 121140
106 24R942
24R943
FITTING, straight, 3/8 tubing OD x 1/4 npt CONNECTOR, 24 VDC; 24P239 only CONNECTOR, 120 V AC; 24P240 only
Qty
1
1
1
3A2805K 43

Kits and Accessories

Kits and Accessories

Module Replacement

24P241
See manual 407050.
Part Description
---- 104705
24R835 24T179
MODULE SCREW, cap, sch; #10–32
x1.25in. O-RING (10 pack )
LUBRICANT, anti-seize
Qty
1 2
2 1

Module Filter Replacement Kit

Includes instructions for replacing the modul e lter. See manual 332513.
Kit
24P801 24T045 3–pack
Quantity
Single

Module Rebuild Kit

NOTE:
Includes instructions for rebuilding the module. See manual 332513.
Requires Module Rebuild Tools Kit 24T206.
Kit
24T046 Single 24T047 5–pack
Quantity

Heater Cartridges

Heater cartridges for single, dual, and quad manifolds with butt splices, tape, and tubing. See
Models, page 6 , for model numbers.
Kit
24V789 24V791 24V793
24V795
Manifold
Single, Dual 1.5 in. (38 mm) Quad 2.75 in. (70 mm) Slim Single
24U021–24U026 Low Profile Dual 24U027–24U032 Low Profile Quad 24U033–24U038
Length
1.5in.(38mm)
1.5in.(38mm)
1.5in.(38mm)

Single Heater Cartridges with Ferrules

Single heater cartridges are for custom manifolds only.
Part Length Recommended
Manifold Width
24P824 4 in.
(101.6 mm)
24P825 5 in.
(127 mm)
24P826 6 in.
(152.4 mm)
24P827 7 in.
(177.8 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)

Module Rebuild Tools Kit 24T206

Part Description Qty
---
---
SEAL INSTA LLA TIO N TOOL 1 PISTON INSTALLATION TOOL 1

Cordsets

Cordsets include the RTD. Use crimp tool kit 24W086 (purchase separately).
Kit RTD Type
24W087 Platinum 100 Ohm 24W088 N icke l 120 Ohm
44
24P828 8 in.
(203.2 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
Tubewith0.5ozofanti-seizeforuseonmodule mounting screws in InvisiPac guns.
3A2805K
Kits and Accessories
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
Kit Description
24P239 24P240
24 VDC 110 VAC

Inlet Filter

Kit
24P275 24P802 3 Pack
Qty
Single

Material Inlet Fittings

Mounting Clamp Kits

See Models, page 6 , for model numbe rs.
24P277 (Single, Dual, and Quad GS35)
Part Description
Ref
10 24P276
11 12 108050 13 117030
24U698 (Low Profile GS35, 24U027–24U038))
Ref
10 24P276
11
12 108050 13 117029 44 45 46 47 48 49
---
Part Description
---
---
---
---
---
---
---
INSULATOR, clamp, bar, housing CLAMP, bar housing
WASHER, lock, spring SCREW, shcs, M6 x 40
INSULATOR, clamp, bar, housing BLOCK, mating, low profile WASHER, lock, spring
SCREW, shcs, M6 x 25 ROD SCREW, cap, socket head WASHER, lock WASHER, plain WASHER, lock, spring NUT, 1/2–13 2
Qty
1
2 2 2
Qty
1
1
2 2 1 1 1 2 2
Single Kit
24P615 24P548 24P547
Thermal Cutoff Replaceme
For Series A and Series B Models.
Kit Models Description
24V790 See Models,
page 6
24V792 24U021-
24U026
24V794 24U027-
24U032
24V796 24U033-
24U038
Description
Straight 45° 90°
nt Kits
Standard
Slim Single
Dual Low Prole
Quad Low Prole
Nozzles (Single Orifice)
Single
24P636 24P794 0.008 straight 24P637 24P795 0.010 straight 24P638 24P796 0.012 straight 24P639 24P797 0.016 straight 24P640 24P798 0.018 straight 24P641 24P799 0.020 straight 24P642 24P800 0.024 straight 24P643 24P803 24P644 24P804 24P645 24P805 24P646 24P806 24P647 24P807 24P648 24P808 24P649 24P809
5 Pack Description
0.008 9
0.010 9
0.012 9
0.016 9
0.018 9
0.020 9
0.024 9
3A2805K 45

Dimensions

Dimensions

Single, Dual, and Quad GS35

24P075 Shown
0.79 in. (20.0 mm)
24P077 Type I Shown
0.72 in.
(18.16 mm)
9.3 in. (236.2 mm)
7.93 in. (201.42 mm)
5.01 in. (127.25 mm)
1.00 in.
(25.4 mm)
1.14 in.
(28.96 mm)
3.07 in.
(77.98 mm)
3.94 in.
(100.1 mm)
24P079 Type II Shown
3.63 in. (92.2 mm)
0.5 in.
(12.7 mm)
4.24 in. (107.7 mm)
0.31 in.
(7.9 mm)
0.625 in.
(15.8 mm)
A
A
A
C
B
Applicator A
in. (mm)
Single 2.23 (56.6) Dual 0.88 (22.4) 2.23 (56.6) Quad - Type I 0.88 (22.4) 3.74 (95) 0.88 (22.4) Quad - Type II 0.88 (22.4) 4.36 (111) 1.5 (38)
See Models, page 6 , for applicator model numbers.
46 3A2805K
C
B
B in. (mm)
A
0.25 in.
(6.25 mm)
C in. (mm)

Slim GS35

(24U021-24U026)
24U021 Shown
0.79 in.
(20.0 mm)
Dimensions
11.68 in.
(296.67 mm)
0.67 in. (17.02 mm)
1.35 in. (34.29 mm)
5.01 in.
(127.25 mm)
4.24 in.
(107.70 mm)
3.63 in.
(92.20 mm)
1.0 in.
(25.4 mm)
2.41 in.
(61.21 mm)
2.86 in.
(72.64 mm)
3.16 in.
(80.26 mm)
4.04 in.
(102.62 mm)
3A2805K
47
Dimensions
Low Profile Double GS35
(24U027-24U033)
24U027 Shown
0.88 in.
(22.35 mm)
1.94 in.
(49.28 mm)
0.79 in.
(20.1 mm)
1.0 in.
(25.4 mm)
6.29 in.
(159.77 mm)
11.69 in.
(296.93 mm)
1.5 in.
(38.1 mm)
0.13 in. (3.30 mm)
5.66 in.
(143.76 mm)
3.18 in.
(80.77 mm)
2.30 in.
(58.42 mm)
48 3A2805K
Low Profile Quad GS35
(24Ubob 033-24U038)
24U033 Shown
Dimensions
0.88 in.
(22.35 mm) (92.20 mm)
(22.35 mm)
3.63 in.
0.88 in.
0.79 in.
(20.1 mm)
0.88 in.
(22.35 mm)
6.29 in.
(159.77 mm)
1.0 in.
(25.4 mm)
11.69 in.
(296.93 mm)
1.5 in.
(38.1 mm)
0.13 in. (3.30 mm)
5.16 in.
(131.06 mm)
3.18 in.
(80.77 mm)
2.30 in.
(58.42 mm)
3A2805K 49

Technical D ata

Technical Data
InvisiPacGS35 Plug-Free Hot Melt Adhesive Applicator
US Metric
Speed Heat up Time 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 O p erati ng Temperature 400°F 204°C Ambient Storage Temperature
Range Ambient Operating Temperature
Range Solenoid Air Flow Rating 1.0 Cv Wetted Parts Aluminum, carbon steel, stainless steel, carbide, brass,
Cordsets
24W087 24W088 Ni 120 RTD
Solenoid Control Voltages
< 10 minutes to 350°F at 240 VAC < 10 minutes to 176°C at 240 VAC
32-122°F 0-50°C
32-122°F 0-50°C
> 3,500 cycles/minute
200-240V, 5060 Hz, 400W
chemically resistant seals, chrome
Pt 100 (385) RTD
24P239 24P240
Noise
Sound pressure measured 6.5 ft (2m) from gun at 80 psi (550kPa,
5.5 bar)
24 VDC
110 VAC
75.6 dB(A)
50 3A2805K

Notes

Notes
3A2805K 51

Graco Extended Warranty

Graco warrants all equipment referenced in this document whic h 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 Gracos 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 verication of the claimed defect. If the claimed defect is veried, 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.
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 conv enu 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.
These items sold, but not

Graco Information

For more information about InvisiPac, visit www.InvisiPac.com or email InvisiPac@graco.com.
To place an order,
For technical assistance or customer service, call toll free: 1–800–458–2133.
All written and vis ual data contained in this document reects the latest product information available at the time of publication.
GRACO INC. AND SUBSIDIARIES P.O. BOX 1441 MINNEAPOLIS MN 55440-1441 USA
contact your Graco Distributor or call to identify the nearest distributor.
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:
International Offices:
Copyright 2012, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Belgium, China, Japan, Korea
www.graco.com
Revised August 2014
Minneapolis
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