PowerCure System Troubleshooting

Solution:
Do not use the system if you cannot mount the red ring (1-11) properly. If the mixer is not secured by the red ring adhesive may flow into the grey cover (1-12) during application and can soil the dispenser completely. Always ensure the caps are closed properly before starting the application.

• Check if the mixer is mounted properly; if not, mount it properly and try again.
  
• Check if the grey cap is soiled; if it is, use the spare one and clean after the adhesive is fully cured.

Solution
Adhesive may leak into the grey cover (1-12) if the mixer, red ring (1-11) or grey cover (1-12) are not mounted properly.
• Always ensure the parts are mounted correctly and locked before starting the application.
• Cleaning: remove and disassemble all the soiled parts. Remove wet adhesive with a spatula as thoroughly as possible. Let the adhesive cure. Remove cured adhesive manually. It can be pulled off the plastic parts quite easily as it won't stick to the dispenser.

It seems the mixer (1-10) is not tight enough and leaked.

Solution
The mixer (1-10) is designed for use with PowerCure but has a limited lifetime.
• In applications that require a lot of adhesive, make sure you replace your mixer from time to time. If the drive shaft gets dirty, replace the mixer more often.
• The mixer drive shaft must be straight and should not wobble when the shaft is rotating. If the drive shaft wobbles, send the dispenser for repair.

Solution:
In most cases this happens when the grey cover is not aligned correctly and the user has tried to force it. Finding the right position can require a little practice..

Alternatively:
The system is designed to work at all times as long as the control switch (1-5) is not pushed while the grey cover (1-12) is not in place. If the control switch is pushed, the hex key of the drive shaft will be in a different position than the hex on the mixer. In this case, please remove the mixer (1-11) from the grey cover (1-12) and mount the empty grey cover first, then the mixer (possibly use a new mixer) and then the red ring (1-11).

It seems the mixer (1-10) is not tight enough and leaked.

After storing the system for some days I tried to remove the mixer to start work again. I wasn't able to remove the mixer as it seems the adhesive has cured into the PowerCure pack. How can I resolve this issue?

Solution

If the PowerCure system is going to be stored for longer periods without being used, it should be completely emptied before storing. Typically the mixer will still be removable from the system for up to about 1 week without use. If the mixer cannot be removed, proceed as follows:

DO NOT TRY TO REMOVE THE MIXER BY USING ANY TOOL WHEN THE MIXER IS MOUNTED TO THE POWERCURE DISPENSER. THIS MAY RESULT IN DAMAGE TO THE GREY CAP AS WELL AS TO THE DISPENSER AS A WHOLE.
Remove the red ring (1-11) and the grey cover (1-12). Remove the PowerCure pack together with the grey cap and the mounted mixer.
Pull the mixer (1-10) as far as you can and turn it in one direction (may require some force)
The mixer will come loose and can then be pulled out.
If the mixer was blocked, dispose of both the mixer and the PowerCure pack and start again with new components.

Solution:

This is normal. The PowerCure Dispenser does not work like a normal adhesive caulking gun; instead, it is based on one motor which drives three functions. After the control switch is pushed, first of all the gear is aligned, then force is applied to the adhesive sausage and then the extrusion of the accelerator is started. This process takes about 15 seconds. It can only be accelerated a little by pushing the rack (1-14) into the adhesive prior to pushing the control switch (1-5).

Solution

There are several possibilities here:

• Check if the battery is still charged; if not, replace and recharge the battery.
  
• When you "pump" the control switch (1-5) (i.e. push and release the button multiple times within a short period), the electronics of the PowerCure Dispenser may become confused and stop working. Wait a few seconds and restart the application.
  
• Using the system in very cold conditions is more demanding and consumes more power; under these conditions, the system will stop working when it reaches the maximum load.
  
• The mixer may be blocked with e.g. cured material; if this is the case you should hear a noise and feel a vibration when pushing the control switch.

Answer
Yes, this is normal; the system reverses for 5 seconds after application stops in order to release the pressure from the adhesive and stop it from flowing. When the system is in reverse, the process can be stopped immediately by pushing the control switch (1-5).

Solution

The aluminum barrel can be secured again by hand.

Solution

Movable parts of the Dispenser, such as the drive shaft for the mixer, the rack (1-14), the speed limiter (1-1), the control switch (1-5), and the bayonet sleeve (1-8) need to be kept clean of adhesive to ensure they can function as intended. Typically, cured adhesive can be pulled off easily as it won't stick to the material of the dispenser.

Solution

The PowerCure Dispenser may run more slowly if the maximum speed on the speed limiter (1-1) is accidentally reduced.
• Move the speed limiter (1-1) to the front. In addition, the system may run more slowly at low temperatures, as the battery capacity is lower and material viscosity may be higher.
• If you are using the system at normal temperature, and moving the speed limiter (1-1) to the front does not increase extrusion speed, the system may be broken.

Solution

The filling level indicator (1-15) has probably come off the rack (1-14) and is blocking it. It may be possible to fix this issue as follows:
• CAUTION: REMOVE THE BATTERY FIRST
• Try to see the red filling level indicator (1-15) inside the back of the dispenser.
• You can use a wooden spatula to get the red part out.
If you can't get it out, send the dispenser for servicing.

Solution

Foil wrapping is an indication of wear and tear and requires the plunger to be replaced. In a worst case scenario, foil wrapping can result in broken foil, soiling the PowerCure Dispenser from the inside and possibly damaging it irreversibly. It is best to stop using the equipment until the plunger has been replaced.
Currently plunger replacement has to be done by an authorized service center. Request service (PDF)

Solution:

If the foil of the PowerCure pack is broken the following procedure must be followed:
Remove the battery, push the release button (1-17)
Ensure that the grey cover (1-12) is removed
Pull back the rack (1-14) until the rack termination (1-15) comes out of the dispenser. Pull at the rack termination (1-15) to remove it from the rack (1-14)
DO NOT PULL BACK THE RACK (1-14) COMPLETELY. THIS MAY CAUSE ADHESIVE TO GET INTO THE GEARING, WHICH WOULD DESTROY THE SYSTEM COMPLETELY
Push the control switch (1-5) until the plunger and rack (1-14) can be taken out of the dispenser from the front
Send the disassembled system for servicing.

As a user of the Sika PowerCure dispenser you may have experienced breaking of the grey cap. The grey cap is designed to close the PowerCure dispenser and also to act as an overload protection to prevent more severe damage. With increasing age the bayonet closure (the other side of the grey cap) gets worn out, which can lead to unexpected end cap breakage. Both, bayonet and grey cap, are wear and tear parts that need to be replaced from time to time.

It is recommended to replace the bayonet closure

• If the grey cap breaks regularly without excess load e.g. by the use of a too small nozzle.
  
• If the grey cap breaks on a dispenser that has been regularly used for more than 2 years; this period may be shorter if the dispenser is used for more than 10 unipacks a day.
  
• To facilitate the replacement of the bayonet of the PowerCure dispenser, Sika introduces a new maintenance kit for the closure system of the dispenser.

The kit contains:

• End cap
  
• Bayonet closure
  
• PowerCure service tool
  
• Maintenance instructions