Instructions-Parts InvisiPac® GS35 Plug-Free™ Hot Melt Applicator 3A2805K For dispensing hot melt adhesive. For professional use only. Not for use in waterwash environments. Not approved for use in explosive atmospheres or hazardous locations. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. 1500 psi (10.3 MPa, 103 bar) Maximum Working Fluid Pressure 80 psi (0.5 MPa, 5.5 bar) Maximum Air Pressure See page 6 for models and approval information.
Contents Warnings ........................................................... 3 Approvals........................................................... 5 Models............................................................... 6 Component Identification..................................... 7 Overview............................................................ 8 Grounding.......................................................... 8 Installation.......................................................... 9 Mounting ...
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.
Warnings WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in can ignite or explode. To help prevent fire and explosion: • Use equipment only in well ventilated area. • Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline.
Approvals WARNING TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • Read MSDSs to know the specific hazards of the fluids you are using. • Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
Models Models All models use a 240 V heater. Additional configurations are available. Contact Graco customer service for details. Note Applicators with Ni 120 RTD types come with a 6–pin rectangular cordset (24W088). See Parts, page 26.
Component Identification Component Identification A B C D E F G H J K L M N P Dispense module Fluid outlet/nozzle (3/8–24) Fluid filter (not visible) Manifold Fluid inlet (9/16–18, —6 JIC, 37° flare) Cordset (24W087 shown) Air tube Mounting clamp (1/2 in. diameter bar) Solenoid valve (24 VDC, 110 VAC); not included with all models Muffler Air inlet (3/8 in.
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.
Installation Installation Mounting NOTICE To prevent heat transferring into other components of the packaging line, ensure that the insulator (P) is installed. Low Profile Models: Use a 3/4 in. (19 mm) wrench to adjust nuts that control position of gun assembly on threaded rod. All Other Models: See the following instructions. Mount manifold on a 1/2 in. (12 mm) diameter bar using mounting clamp (H) to hold the gun assembly in place and ensure adhesive is applied properly. 1.
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.
Installation Flush 1. Disconnect or turn off the device which triggers the solenoid valve. 2. Heat the system to working temperature. 3. Place waste container under the gun to catch the adhesive. 4. Ensure the nozzle is removed. 5. Press the manual override switch (S) to manually trigger the solenoid valve. 6. Dispense hot melt (adhesive) until it is clean. Select RTD Note For InvisiPac systems only. Identify RTD type used in applicator on the system Advanced Display Module (ADM).
Operation Operation Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, and splashing fluid, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. 1. Depressurize system. 2. Close the bleed-type master air valve. 3.
Maintenance Maintenance Material inside the applicator can be near setpoint temperature. Wear protective clothing to avoid severe burns. Daily: Clean hot melt from exterior of gun. Weekly: Inspect the applicator, fluid lines, cordset, and solenoid cable for wear or damage. See Repair, page 19 for instructions. Replace Inlet Filter NOTICE Remove the filter when the gun is hot. If the gun is cold, the adhesive will be hard and the filter may be difficult to remove or damaged. 1. Disable gun assembly.
Troubleshooting Troubleshooting Problem No adhesive or incorrect amount of adhesive out of all modules when triggered Cause Debris in manifold filter Clogged hose Failed solenoid valve No signal to solenoid valve Incorrect solenoid valve wiring Incorrect signal to solenoid valve Solenoid muffler plugged No fluid pressure Heater failure (cold gun) No air to solenoid valve Dirty or faulty triggering device No adhesive or incorrect amount of adhesive out of one/some modules when triggered Solenoid valve co
Troubleshooting Problem Gun will not heat Gun overheats Gun under-heats Adhesive leaking from gun 3A2805K Cause Solution Heater failure Check and replace heater cartridge. See Replace Heater Cartridge, page 20. Loose cord set connection Check connection. RTD failure Check and replace RTD. See Check RTD, page 17. Incorrect RTD for adhesive delivery Check delivery system RTD system requirement Thermal cutoff failure Check and replace thermal cutoff. See Replace Thermal Cutoff, page 20.
Troubleshooting Problem Adhesive out of all modules when not triggered Cause Solution Solenoid valve failure Adhesive pressure too high Solenoid valve connected incorrectly Module failure Check and replace solenoid valve. Check and reduce fluid pressure. Check solenoid valve air connections. Check and replace all modules. See Check Module, page 16. Check Module Check Nozzle and Module Check the module operation to verify if the module has failed and needs to be replaced. 1.
Troubleshooting Check Heater Table 1 24W087, Pt 100 (385) RTD Cordset Check the continuity of the heater to verify proper resistance. If there is no continuity, the heater may have failed and need to be replaced. See Wiring Diagram, page 21, and parts illustrations. 1. Disable gun assembly. See Before Beginning Repair, page 19. 2. Check resistance of the heater using a multimeter between the pins of the cordset connector. See connectors illustrations in cordset pin tables.
Troubleshooting Check Thermal Cutoff Thermal Cutoff If working properly, the cutoff will trip at 450°F (232°C) and resets at 370°F (187°C). If failure is suspected, allow gun to cool and then check the continuity of the thermal cutoff to verify it has not failed. If there is no continuity, the cutoff has failed and needs to be replaced. 1. Disable gun assembly. See Before Beginning Repair, page 19. 2. Remove cover plate. 3.
Repair Repair Required Tools • Phillips screw driver • Flat blade screw driver • 5/64 in (2 mm) and 5/32 in. (4 mm) Allen wrenches • 1/2 in. and 7/16 in. wrenches • Torque wrench • Waste container • High-temperature anaerobic thread sealant (110110) • High-temperature lubricant (24T156) • Anti-sieze (24T179) • Crimp tool (24W086) Before Beginning Repair 1. Turn off the melter system. See melter manual for shutdown instructions. 2. Relieve pressure. See Pressure Relief Procedure, page 12. 3.
Repair Replace Heater Cartridge 1. Disable gun assembly. 2. Use a Phillips screwdriver to remove screws (15) and manifold cover plate (52). 3. Remove the heater cartridges (3) from the manifold (1). Note Note the placement of the heaters and lead lengths. Note On guns that are not low profile, if the heater cartridge does not easily pull out, remove the other cover plate (18) and press out with a small screwdriver. 4.
Repair Wiring Diagram Thermal Cutoff 52b 17 52a 17 52b 3 52b 3 Note Slim (24U021–24U026) and Low Profile Dual (24U026–24U032) applicators use one heater (3).
Repair Replace Cordset See Fig 14, page 24. Note 1. 2. 3. 4. 22 There are two types of cordsets (17): 24W087 is for PT100 (385) RTD controlled guns and 24W088 is for NI 120 Ohm RTD controlled guns. Ensure you have the correct cordset before replacing. See Parts, page 26. Disable gun assembly. See Before Beginning Repair, page 19. Use a Phillips screwdriver to remove the four screws (15) and manifold cover plate (52).
Repair 10. Reinstall the ground lead onto the manifold (1). Note Ensure the star washer (20) is placed below the ground ring terminal. 11. Insert the plug (P), RTD (R) and thermal cutoff (52) into the manifold ports. See Fig 14. Note Do not apply grease on the RTD or thermal cutoff. 12. Insert the heater cartridges (3) in the manifold (1). Figure 14 Repair Parts 3A2805K NOTICE To prevent removing wire insulation or disconnecting wires, do not pinch any wires when inserting wire in the manifold.
Repair Replace Solenoid Valve 1. Disable gun assembly. See Before Beginning Repair, page 19. 2. Remove solenoid valve fitting (102) and solenoid valve (9) from tube (7). 3. Use a 1/2 in. and 7/16 in. wrench to tighten new connector (102) to tube (7). Figure 15 Replace Solenoid Valve Replace Module 1. Disable gun assembly. See Before Beginning Repair, page 19. Material inside the applicator can be near setpoint temperature. Wear protective clothing to avoid severe burns. 2. Use a 5/32 in.
Notes Notes 3A2805K 25
Parts Parts Single GS35 1 2 26 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m). See Wiring Diagram, page 21.
Parts Table 3 Single GS35 Ref Part 1 ----- 2● Quantity 24P073 24P074 24P246 24P299 24P300 24P307 Description HOUSING, single 1 1 1 1 1 1 MODULE, sc, hotmelt HEATER, 240 VAC, 200W, 1/2 dia. x 1.5 in. 1 2 1 1 2 1 2 2 2 2 2 2 1 1 3 24V789 6 100113 CONNECTOR, male 1 1 7 24R231 TUBE, applicator, hotmelt, open 1 1 8 9* 124736 SCREW, set, cup, M4x.
Parts DUAL GS35 1 2 28 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m). See Wiring Diagram, page 21.
Parts Table 4 Dual GS35 Ref Part 1 ----- 2● Description 24P075 24P076 24P247 24P301 24P302 24P308 HOUSING, dual 1 1 1 1 1 1 MODULE, sc, hotmelt HEATER, 240 VAC, 200W, 1/2 dia. x 1.5 in. 2 2 2 2 2 2 2 2 2 2 2 2 1 1 3 24V789 6 100113 CONNECTOR, male 1 1 7 24R231 TUBE, applicator, hotmelt, open 1 1 8 9* 124736 SCREW, set, cup, M4 x .
Parts Quad GS35 24P077 Type I Shown 1 2 30 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21.
Parts Table 5 Quad GS35 With 0.88 in. Spaced Manifold (Type I) Ref Part 1 2● 3 6 7 8 9* 10 11 12 13 14 15 16 ----24V791 100113 24R231 124736 24P239 24P240 24P276 24P277 108050 117030 24P615 195874 24P275 17a 24W087 17b 18 20 22● 29▲ 34 24W088 --157021 104705 16K931 24P547 35 36■ 51 52 52a 52b 24P548 --16Y799 24V790 ----- 52c --- Description HOUSING, 0.88 in. MODULE HEATER, 240 VAC, 200W, 1/2 dia x 2.75 in. CONNECTOR, male TUBE, applicator, hotmelt, open SCREW, set, cup, M4 x.
Parts Table 6 Quad GS35 with 1.5 in. Spaced Manifold (Type II) Ref Part ----24V791 100113 24R231 124736 24P239 24P240 24P276 24P277 108050 117030 24P615 195874 24P275 1 2● 3 6 7 8 9* 10 11 12 13 14 15 16 17a 24W087 17b 18 20 22● 29▲ 34 24W088 --157021 104705 16K931 24P547 35 24P548 36■ 51 16Y799 52 24V790 --52a --52b 52c --- Description HOUSING, 1.5 in. MODULE HEATER, 240 VAC, 200W, 1/2 dia x 2.75 in. CONNECTOR, male TUBE, applicator, hotmelt, open SCREW, set, cup, m4 x.
Parts Notes 3A2805K 33
Parts Slim GS35 1 2 34 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21.
Parts Table 7 Slim GS35 Description Part 2● --- MODULE 1 1 1 1 1 1 3 24V793 HEATER, 240 VAC, 200W, 1/2 dia x 1.5 in. 1 1 1 1 1 1 6 100113 CONNECTOR, male 1 1 1 1 7 16P769 TUBE, applicator, hotmelt, open 1 1 1 1 8 124736 SCREW, set, cup, M4 x 0.
Parts Low Profile Dual GS35 1 2 36 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21.
Parts Table 8 Low Profile Dual GS35 Ref Part Description 10 ----24V793 100113 16P769 124736 24P239 24P240 24P276 HOUSING, double MODULE, sc HEATER, 240 VAC, 200W, 1/2 dia x 1.5 in. CONNECTOR, male TUBE, applicator, hotmelt, open SCREW, set, cup, M4 x 0.
Parts Ref 52 52a 52b 52c Part 24V794 ------- Description KIT, THERMAL CUTOFF (includes 52a-52c) PLATE, with thermal cutoff CONNECTOR, splice, 14–16 AWG, heat resistant SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD * See Solenoid Valve Kits, page 45. ● 38 Quantity 24U027 24U028 24U029 24U030 24U031 24U032 Parts included in Module Repair Kit. See Module Repair Kit, page 44. Parts included in Bar Clamp Kit 24U698. See Mounting Clamp Kits, page 45.
Parts Notes 3A2805K 39
Parts Low Profile Quad GS35 1 2 40 Apply thread sealant to threads. Apply a thin coating of lubricant to seals. 3 4 Apply anti-seize to first 1/2 in. of threads. Torque to 28-32 in-lbs (3.2-3.6 N∙m)). See Wiring Diagram, page 21.
Parts Table 9 Low Profile Quad GS35 Ref 1 2● 3 6 7 8 9* 10 11 12 13 14 15 16 17a 17b 18 20 21 22● 34 35 36■ 38▲ 39 42 44 45 46 47 48 49 50 51 3A2805K Part Description --HOUSING, quad --MODULE, sc, invisipac 24V795 HEATER, 240 VAC, 200W, 1/2 dia x 1.5 in. 100113 CONNECTOR, male 16P769 TUBE, applicator, hotmelt, open 124736 SCREW, set, cup, M4x 0.
Parts Ref 52 52a 52b 52c Part Description 24V796 KIT, THERMAL CUTOFF (includes 52a-52c) - - - PLATE, with thermal cutoff - - - CONNECTOR, splice, 14–16 AWG, heat resistant - - - SLEEVE, red, 2 in. (50.88 mm) x 0.16 OD * See Solenoid Valve Kits, page 45. ● 42 Parts included in Module Repair Kit. See Module Repair Kit, page 44. Parts included in Bar Clamp Kit 24U698. See Mounting Clamp Kits, page 45.
Parts Solenoid Valve Kits 24P239, 24 VDC Solenoid Valve 24P240, 110 VAC Solenoid Valve 1 Ref 101 Apply thread sealant to threads.
Kits and Accessories Kits and Accessories Module Replacement Heater Cartridges Heater cartridges for single, dual, and quad manifolds with butt splices, tape, and tubing. See Models, page 6 , for model numbers. 24P241 See manual 407050. Part Description ---MODULE 104705 SCREW, cap, sch; #10–32 x 1.25 in.
Kits and Accessories Mufflers Mounting Clamp Kits 24P282 See Models, page 6 , for model numbers. Includes two mufflers that can be used with solenoid valve kits. Blanking Plate Kit Ref 10 24P810 Use to run two or three modules on a quad applicator or one module on a dual applicator. See manual 407051.
Dimensions Dimensions Single, Dual, and Quad GS35 0.72 in. (18.16 mm) 5.01 in. (127.25 mm) 9.3 in. (236.2 mm) 0.79 in. (20.0 mm) 7.93 in. (201.42 mm) 24P075 Shown 3.63 in. (92.2 mm) 4.24 in. (107.7 mm) 1.14 in. (28.96 mm) 1.00 in. (25.4 mm) 3.07 in. (77.98 mm) 3.94 in. (100.1 mm) 24P077 Type I Shown 24P079 Type II Shown 0.5 in. (12.7 mm) 0.31 in. (7.9 mm) 0.625 in. (15.8 mm) A A C Single Dual Quad - Type I Quad - Type II 0.25 in. (6.25 mm) C B B Applicator A A A B C in. (mm) in.
Dimensions Slim GS35 (24U021-24U026) 24U021 Shown 11.68 in. (296.67 mm) 0.79 in. (20.0 mm) 2.41 in. (61.21 mm) 5.01 in. (127.25 mm) 4.24 in. (107.70 mm) 3.63 in. (92.20 mm) 2.86 in. (72.64 mm) 0.67 in. (17.02 mm) 1.35 in. (34.29 mm) 3A2805K 1.0 in. (25.4 mm) 3.16 in. (80.26 mm) 4.04 in. (102.
Dimensions Low Profile Double GS35 (24U027-24U033) 24U027 Shown 11.69 in. (296.93 mm) 0.79 in. (20.1 mm) 3.18 in. (80.77 mm) 1.0 in. (25.4 mm) 0.88 in. (22.35 mm) 1.94 in. (49.28 mm) 48 1.5 in. (38.1 mm) 2.30 in. (58.42 mm) 0.13 in. (3.30 mm) 6.29 in. (159.77 mm) 5.66 in. (143.
Dimensions Low Profile Quad GS35 (24Ubob 033-24U038) 24U033 Shown 11.69 in. (296.93 mm) 0.79 in. (20.1 mm) 3.18 in. (80.77 mm) 1.0 in. (25.4 mm) 0.88 in. 0.88 in. 0.88 in. (22.35 mm) (22.35 mm) (22.35 mm) 3.63 in. (92.20 mm) 6.29 in. (159.77 mm) 3A2805K 1.5 in. (38.1 mm) 2.30 in. (58.42 mm) 0.13 in. (3.30 mm) 5.16 in. (131.
Technical Data Technical Data InvisiPac ™ GS35 Plug-Free Hot Melt Adhesive Applicator US Metric > 3,500 cycles/minute Speed Heat up Time < 10 minutes to 350°F at 240 VAC < 10 minutes to 176°C at 240 VAC 200-240V, 50–60 Hz, 400W Electrical Service Maximum Working Fluid Pressure 1500 psi 10.3 MPa, 103 bar Maximum Air Pressure 80 psi 0.5 MPa, 5.5 bar Minimum Air Pressure 40 psi 0.3 MPa, 2.
Notes Notes 3A2805K 51
Graco Extended Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of eighteen months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
