334627E, InvisiPac GM100 Plug-Free Hot Melt

334627E, InvisiPac GM100 Plug-Free Hot Melt

Repair

• Phillips screwdriver

• Flat blade screwdriver

• 3 mm, 4 mm, and 5 mm Allen wrenches

• 10 mm, 1/2 in. 11/16 in., and 3/4 in. wrenches

• Torque wrenches

• Waste container

• High-temperature anaerobic thread sealant

• High-temperature lubricant

• Anti-seize

• Crimp tool

1.

Disable the applicator.

See

Before Beginning Repair, page 21

.

2.

Use a Phillips screwdriver to remove the four screws (15) and manifold cover plate (18).

3.

Remove the heater cartridges (3) from the manifold (1).

Material inside the applicator can be near setpoint temperature. Wear protective clothing to avoid severe burns.

1.

Turn off the melter system. See melter manual for shutdown instructions.

2.

Relieve pressure.

See

Pressure Relief Procedure, page 13 .

3.

Disconnect the cordset (F) from the heated hose.

lead lengths.

4.

Remove butt splices (4) from heater wires (3), thermal cutoff (29), and cordset wire leads (17).

5.

Crimp new heater wires into new splices (4). See wiring diagram.

To prevent a short to ground and blowing a

MZLP fuse, ensure bare wires are covered and fiber glass tape and sleeves are centered over splices.

6.

Insert the new heater cartridges (3) into the manifold (1).

4.

Disconnect M8 solenoid electrical connector (N).

cartridge.

7.

Reinstall the manifold cover plate (18).

8.

Reconnect the cordset (17) to the heated hose.

9.

Reconnect the M8 solenoid electrical connector

(N).

334627E 21

Repair

The RTD is replaced by replacing the entire cordset.

See

Replace Cordset, page 24

, for instructions.

1.

Disable the applicator.

See

Before Beginning Repair, page 21 .

2.

Use a Phillips screws driver to remove the four screws (15) and manifold cover plate (18).

3.

Remove butt splices (4) from heater wires (3) and cordset wire leads (17).

4.

Crimp wires. See

Wiring Diagram

.

To prevent a short to ground and blowing a

MZLP fuse, ensure bare wires are covered with fiber glass tape (32) and sleeves (30) are centered over butt splices (4).

a.

Crimp butt splice on cordset heater wires

(17) and heater wires (3). Light pull on splice to ensure it is crimped.

b.

Slide sleeves (30) over each pair of wires before crimping.

c.

Crimp white wire to one thermal cutoff lead

(29).

d.

Crimp other thermal cutoff lead (29) to one heater wire(s) (3).

e.

Crimp other heater wire(s) to black lead (17).

f.

Wrap a short piece of fiber glass tape around each splice.

g.

Center sleeves (30) over each taped splice.

5.

Gently press wires into the manifold. Instal plate

(18) and screws (15).

22 334627E

Repair

use one heater (3).

334627E 23

Repair

10. Reinstall the ground lead onto the manifold (1).

24X039 is for slim 100 Ohm RTD controlled applicators.

24X040 is for slim 120 Ohm RTD controlled applicators.

24X760 is for dual 100 Ohm RTD controlled applicators.

24X761 is for dual 120 Ohm RTD controlled applicators.

24W087 is for Low Profile Dual, Low Profile Quad, and Quad 100 Ohm RTD controlled applicators.

24W088 is for Low Profile Dual, Low Profile Quad, and Quad 120 Ohm RTD controlled applicators.

Make sure you have the correct cordset before replacing.

1.

Disable the applicator.

See

Before Beginning Repair, page 21 .

2.

Use a Phillips screwdriver to remove the four screws (15) and manifold cover plate (18).

3.

Use a 2 mm Allen wrench to remove the set screw (6) holding the cordset (17) on the manifold

(1).

4.

Use a Phillips screwdriver to remove the ground lead and star washer (20) from the manifold (1).

next to RTD.

5.

Remove the RTD (17a) from the manifold (1).

6.

Disconnect thermal cutoff (29).

7.

Remove the cordset (17) from the manifold (1).

8.

Install the new cordset, RTD, and ground (17) in the manifold (1). Crimp thermal cutoff wires (29).

See

Wiring Diagram, page 23

for connections.

below the ground ring terminal.

11. Insert the RTD (17a) and thermal cutoff (29) into the manifold ports.

thermal cutoff.

12. Insert the heater cartridges (3) in the manifold (1).

Do not pinch any wires when inserting wire in the manifold, to prevent removing wire insulation or disconnecting wires. If wire insulation is removed, the RTD or heaters could short out and need to be replaced.

13. Reinstall the manifold cover plate (18).

14. Reconnect the cordset (17) to the heated hose.

15. Reconnect the M8 solenoid electrical connector..

inserted into the manifold.

9.

Install set screw (6) against the cordset bushing to secure the cordset (17) to the manifold (1).

24 334627E

Repair

1.

Disable the applicator.

See

Before Beginning Repair, page 21 .

2.

Turn off the air supply to the solenoid valve.

3.

Disconnect M8 solenoid electrical connector (N).

4.

Disconnect air line from air fitting (L).

Material inside the applicator can be near setpoint temperature. Wear protective clothing to avoid severe burns.

1.

Disable the applicator.

See

Before Beginning Repair, page 21 .

2.

Turn off air supply to solenoid.

3.

Use a 3 mm Allen wrench to remove the two mounting screws (22) and module (2) from manifold (1).

Do not allow adhesive to enter the air ports, to allow air to flow through valve. Adhesive in the air ports will obstruct the flow of air and damage the valve.

5.

Loosen the solenoid valve set screw with a 3 mm

Allen wrench, then remove the solenoid valve (J).

6.

Apply high temperature grease to o-rings on solenoid tubes.

7.

Install the new solenoid valve into the manifold, then use a 3 mm Allen wrench to tighten the solenoid valve set screw.

8.

Connect the M8 solenoid valve electrical connector (N).

9.

Connect the 1/4 in. air line to the solenoid. Turn air on.

4.

Verify that no glue is present in the manifold air ports.

334627E 25

Repair

5.

Hold a rag over the manifold air ports and turn the air supply ON to clean ports.

6.

Cycle solenoid by pushing the blue button on the solenoid.

7.

Turn off the air supply and remove the rag.

8.

Apply high temperature lubricant to air section o-rings (2b) and fluid section o-ring (2a) in module (2).

fluid section o-ring is black. All o-rings are fluoroelastomer. The color is only used to identify the difference in size.

9.

Apply anti-seize to two screw threads (22). Use a 3 mm Allen wrench to install new module (2) on manifold with two screws (22). Torque to 28–32 in.-lb (3.2–3.6 N•m).

10. Connect cordset (17) to the heated hose.

1.

Disable the applicator.

See

Before Beginning Repair, page 21 .

2.

Loosen the mounting bar clamp and remove the applicator from the mounting bar.

3.

Install new applicator. See

Installation, page 9

.

26 334627E

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