Graco 333347P - InvisiPac HM25 and HM50 Tank-Free Hot Melt Delivery System Instructions

Use a 1/4 in. allen wrench to remove the drain

port plug (W1). See F

plug (W1) then remove rag. See F

NOTE: A 1/4 in. allen wrench is shipped loose with the system.

When fluid stops draining, re-install drain port

Remove plug (247) from the lowest numbered outlet on the melter. Do not use the drain

plug (W1). See F

hydraulic fitting (68) faces the system. See F

NOTE: In the following step, the o-ring side of the

Install the supplied hydraulic fitting (68) with an o-ring into the open port and tighten with an

11/16 in. wrench or socket.

Install hose onto hydraulic fitting (68) with male electrical connector side toward the system.

Use 11/16 in. wrench to tighten hose onto hydraulic fitting (68).

Locate MZLP (AA) connector marked with same number as the hose fluid outlet port. Remove that connector cover then install connector from

heated hose. See F

Overtemperature Jumper, 16Y727, page 118.

Repeat the procedure for the remaining channels. Use the bottom melter ports first to ease installation.

Install cap on any unused MZLP electrical connectors.

NOTE: Fluid outlet port 1 must be used and electrical connector from that hose must be connected to MZLP connector 1. The system will not operate unless a hose is connected to MZLP connector 1. If a hose is not connected to connector 1, “Invalid Sensor - hose/gun” faults will result. If the melter must be run without a hose/applicator electrically attached to MZLP connector, use

Install applicator(s), see F

. 9:

NOTE: Use of a Graco applicator is not required with this system. However, all applicators attached to the system must be rated for 1200 psi (8.3 MPa, 83 bar),

400°F (204°C), have an RTD type sensor, and use no more than 400W at 240 VAC.

Connect heated hose fluid outlet to applicator fluid inlet. Use 11/16 in. wrench to tighten. See

For Graco applicators,

attach applicator electrical connector to heated hose electrical connec-

tor. See F

Non-Graco Applicator Adapter Cables on page 108 to determine which adapter cable to

For non-Graco applicators,

attach applicator electrical connector to adapter harness 16T916,

16T917, or 16Y828 then attach adapter harness connector to heated hose connector. See

use with your applicator.

Repeat for any additional applicators.

333347P 19

Setup

If necessary,

set up the pattern controller (not included) to control opening and closing of the applicator. See pattern controller manual.

NOTE: The system controls applicator heating only. A separate pattern controller must be set up to open and close the applicator.

Install the supplied air inlet bleeding ball valve and air filter kit (Graco Part No. 24R707) at the 1/4 NPT

female system air inlet (J). See F

. 10.

NOTE: Elbows and riser tube provided with inlet air kit are optional and may be used as desired.

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. 10

NOTE: The system must have a bleed-type ball valve that bleeds pressure downstream when closed. Otherwise, the supplied air will need to be disconnected from the system whenever the pressure is relieved.

NOTE: The system must use an air filter with a minimum flow rate of 30 scfm.

10.

If using the same air for the applicator(s),

make sure to install the tee in the air line before the ball valve.

There should not be anything between the ball valve and the system. See

applicator

manual for

applicator

air pressure requirements, and use a regulator before the gun to decrease the air pressure, if necessary.

11. Close the ball valve.

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. 11

12. Attach a 3/8 in. minimum air supply line to air filter.

to operate down to 60 psi (0.4 MPa, 4 bar). See Air

. 11.

NOTE: Air supply pressure must be between 80 psi

(550 kPa, 5.5 bar) and 100 psi (690 kPa, 6.9 bar). Recommended pressure is 100 psi (690 kPa, 6.9 bar). If air pressure is expected to drop below 80 psi (0.5 MPa,

5 bar), there is an air reservoir kit that allows the system

Reservoir Kit, 16W366, on page 112.

13.

To lock access to the air pressure adjustments,

pur-

chase Air Adjustment Lock, 24R084. See installation instructions on page 109.

14.

To install a light tower that illuminates red when a system error occurs,

purchase Light Tower Kit,

24R226. See installation instructions on page 111.

15.

To upgrade a 2 channel system to a 4 channel system,

purchase 4 Channel Upgrade Kit, 24V528.

See installation instructions on page 113.

16.

To upgrade a 4 channel system to a 6 channel system,

purchase 6 Channel Upgrade Kit, 24V529.

See installation instructions on page 115.

17. Install MZLP electrical connector caps on all unused channels.

20 333347P

Setup

Recommended Air Setup

Main Air Line

Air in:

Less than 50 ft (15.2 m): 3/8 in.

More than 50 ft (15.2 m): 1/2 in.

80-100 psi

(5.5-6.8 bar, 0.55-0.68 MPa)

30 scfm capacity

Ensure funneled air is connected

No dips in vacuum transfer hose

Air Filter / Ball Valve at System Air Inlet

(Graco Kit 24R707 included)

Vacuum Pump

Vacuum:

40-80 psi

(2.8-5.5 bar,

0.28-0.55 MPa)

Pump

20-100 psi

Regulator set to 70 psi

(4.8 bar, 0.48 MPa)

Air to applicators

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. 12

If plant air pressure is >90 psi, add air regulator kit to the

24H420 to the air supplying the hopper shaker. Regulate the shaker air according to the vacuum feed pressure according to the table below.

NOTE: Using vacuum feed air pressure higher than necessary may cause the melter to over fill and interrupt production.

Vacuum Feed air pressure

Max air pressure to hopper

40 psi (2.8 bar)

50 psi (6.4 bar)

60 psi (4.1 bar)

70 psi (4.8 bar)

80 psi (5.5 bar)

60 psi (4.1 bar)

75 psi (5.2 bar)

90 psi (6.2 bar)

105 psi (7.2 bar)

120 psi (8.3 bar)

333347P 21

Setup

Connect Electrical Cord

NOTE: See Grounding section on page 17.

Attach insulated ferrules to the end of each wire.

106

Improper wiring may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician perform any electrical work. Be sure your installation complies with all National, State and Local safety and fire codes.

To reduce the risk of electric shock, perform the entire

Attach Components procedure beginning on page 17 prior to connecting electrical cord.

NOTE: The installed strain relief bushing (106) fits a

0.708-1.260 in. (18-32 mm) OD electrical cord. See F

13. If needed, use a wrench to tighten the strain relief bushing until it is snug on the cable.

NOTE: Tubing 17F777 and 17F779 is included for smaller diameter electrical cord. Place around the power cord and secure in the strain relief brushing

(106).

The accessory strain relief bushing kit 24X190 is available for smaller (0.512-1.024 in, 13-26 mm) OD electri-

cal cords. See Accessories, page 106.

For 208V Electrical Circuits, see page 23.

Turn main power switch OFF.

Disconnect cable from ADM, push cable through plastic shroud, then remove plastic shroud from system.

Remove electrical enclosure access door (T). See

. 2 on page 13.

Insert electrical cord through electrical enclosure strain relief bushing (106). See F

. 13.

Alternate electrical cord routing: using conduit, run electrical cord from access port (X) through hole (Y). Conduit is required when routing wires near compressed air components.

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. 13

Connect ground wire to chassis ground (AF). See

. 13.

Connect power wires as shown in F

. 14. Not all models use all 4 wires.

. 14

Use zip ties to secure the electrical cord to the tie-downs located on the top of the inside of the electrical enclosure.

Tighten screw-terminals to at least 10 in-lb

(1.1 N•m).

10. Install electrical enclosure door.

11. Perform Select ADM Settings on page 23 prior to

turning on heat.

22 333347P

208V Electrical Circuits

For 208V electrical supply, a qualified electrician can install a 208V to 240V step-up transformer to improve startup times.

Transformer Sizing

Minimum transformer rating can be calculated by taking transformer output voltage times the ADM breaker setting.

Single Phase, 20A ADM Breaker Setting Example:

240 volts x 20 amps = 4800 watts

Three Phase, 20A ADM Breaker Setting Example:

240 volts x 20 amps x SQRT(3) = 8315 watts

NOTE: The supported RTD types are Ni, 100 ohm; Ni,

120 ohm; NiFe, 604 ohm; Pt, 100 ohm (385), Pt,

100 ohm (392); and Pt, 1000 ohm. An “Auto” selection is available but should only be used when the specific

RTD type cannot be identified. Using the “Auto” RTD setting may result in inaccurate temperatures.

To prevent fire and explosion, a qualified electrician must determine the proper circuit breaker size to use for the power supplied to the system.

On the System 3 screen:

Select ADM Settings

NOTE: See Appendix A - ADM on page 120 for

detailed ADM information, including general operation.

Setup

Turn main power switch ON .

When the ADM is finished starting up, press to switch from the Operation screens to the Setup screens. Use between screens.

, , , and to navigate

On the System 2 screen: a.

Enter the main circuit breaker size used. This is the circuit breaker installed external to the system for the system power supply.

NOTE: The InvisiPac system limits the amount of power it pulls based on the input circuit breaker size. This impacts the startup times because it affects the heating energy used to warm up the materials.

On the Advanced 1 screen, set the system date and time.

Check the box in the “Installed” column for each channel that has a heated hose and applicator installed.

Select the RTD type used on each installed applicator. See applicator manual.

NOTE: An incorrect RTD setting will cause the system to be incapable of maintaining the temperature setting.

333347P 23

Setup

On the Advanced 2 screen, set the temperature and mass units.

Press to switch from the Setup screens to the

Operation screens. Use navigate between screens.

, , , and to

10. On the Targets screen, use and , shown next to , to adjust system melter setting.

Also, the desired temperature setting can be typed in using the numeric keypad.

To setup the optional Schedule function, see

Schedule on page 36.

NOTE: The Schedule function enables the system to automatically enable and disable heating at specified times so that the system is already up to temperature when a shift begins.

If desired,

set any remaining settings in the Setup screens before going on to the next steps that use the Operation screens. These are not required for system operation but include useful functions. See

Appendix A - ADM, beginning on page 120, for

detailed information about each setup item.

24 333347P

Setup

11. On the Targets screen, adjust heated hose and applicator temperature settings:

NOTE: InvisiPac is a high powered tank-free system that delivers heat faster than traditional tank systems.

Tanks are often run at a lower temperature than the application temperature to avoid excessive adhesive degradation since a large volume of adhesive sits at temperature.

Press b.

Use

to select the channel.

and , shown next to , to

NOTE: Alternatively, use the physical up and down arrow push-buttons on the ADM keypad until is next to the temperature setting to change then use the numeric keypad to enter the desired temperature.

NOTICE

Set melter, hose, and gun to the same setpoint temperature for best performance. Do not set the hose temperature higher than the melter. Running the hose at a setpoint higher than the melter is unnecessary in this tank-free system and could lead to adhesive degradation in the hose. Short adhesive residence time in the melter eliminates the need to set the melter at a lower setpoint than other zones.

See Operation Tips to Minimize Char-

ring, page 40.

adjust applicator temperature setting to the desired setting for that channel.

NOTE: If a higher applicator temperature is desired, adjust all zones to the higher temperature or adjust only the applicator in small increments.

Applicators

Applicator heating is controlled by the InvisiPac system.

A pattern controller is required to control the opening and closing of applicators. If using an InvisiPac Pattern

Controller, refer to manual 334784 - InvisiPac Pattern

Controller for details on wiring and setup.

Use and , shown next to , to adjust heated hose temperature setting to the desired setting for that channel.

333347P 25

Setup

PLC Connection

A PLC can control and monitor all items shown in the dropdown menus on the System 1 screen in the Setup screens.

Customer Input Dropdown Options

Option

Disable

Heater On/Off

Channel 1, 2, 3,

4, 5, or 6

Enable/Disable

Description

Not used.

Turn on or off the heating system and pump.

Enable or disable hose and applicator heating for that individual channel.

Customer Output Dropdown Options

Option

Disable

System Ready

Error (Alarm)

Description

Not used.

Indicates when the system is up to temperature and the pump is stalled at pressure.

Indicates when there is an active alarm.

An active alarm will disable the heating system and pump.

Error (Deviation/Advisory)

Indicates when there is an active deviation or advisory. An active deviation or advisory will NOT disable the heating system and pump.

Maintenance Due Indicates when the maintenance total has reached the preset notification value.

NOTE: All outputs are normally open when power is

OFF. For Error (Alarm) output, the contacts open when an alarm occurs. For all others, contacts close.

NOTE: The InvisiPac system ships with two screw-terminal connectors that plug into MZLP connectors H1 and H2. Connectors are located in a bag on the inside of the electrical enclosure front access door. To replace the connectors, order kit 24P176.

On the System 1 screen (in the Setup screens) select the function of each input on MZLP connector

H1 and each output on MZLP connector H2.

Turn main power switch OFF.

Remove electrical enclosure front access door.

Route I/O cable through strain relief in electrical

enclosure. See Customer I/O Cable (S) in F

NOTE: See Appendix A - ADM on page 120 for

Remove power from PLC.

Connect the PLC to connectors H1 and H2.

NOTE: Each connector has four signals. The MZLP board specifies the input range for each signal. See the following table for pin assignments.

F10 F9 F8 F7

F6 F5

F4 F3

WLD

. 15: MZLP Board

H1 - Customer Input

Signal Pin

1, 2

3, 4

5, 6

7, 8

H2 - Customer Output

Signal Pin

1, 2

3, 4

5, 6

7, 8

Inputs: High: 10-30 Vdc, Low: 0-5 Vdc. Inputs function without concern for polarity. Applying “high” voltage will turn the heaters on and enable channels. Removing voltage will turn the heaters off and disable channels.

Outputs: 0-250 Vac, 0-30 Vdc, 2A Maximum.

26 333347P

Setup

PLC Connection Block Diagrams

The following block diagrams show how to connect customer inputs and outputs to the InvisiPac MZLP. For convenience, each InvisiPac ships with connector kit 24P176. If a connector is lost or damaged, order kit 24P176 for replacements.

MZLP Customer In

Customer Output

Vin (no polarity)

30 VDC Max

. 16: Customer Input

MZLP Customer Out

Customer In

250 VAC, 0-30 VDC, 2A Max

To Customer Input

. 17: Customer Output

333347P 27

Setup

Material Tracking

The material tracking function allows the user to track product counts and material usage for long term data collection.

Viewing the Log

In order to view the log, navigate to the Home screen and press the material log softkey (see below).

Different system Types will have different data show in the material log. The chart below outlines what data is shown for each system type.

System Type Date Cycles

InvisiPac

InvisiPac w/

ADM Unit

Counter

InvisiPac w/

Pattern Controller

X X

*See Material Tracking Coverage for Pattern Controller

Systems.

To exit the log, press the screen exit softkey .

Once inside the log (see below), use the up/down arrow keys to view previous data. The log stores up to 200 rows of date including the following:

Item

Date

Cycles

Material Used

Program

Products

Material per Product

Icon

N/A

28 333347P

Setup

Material Tracking Coverage for Pattern

Controller Systems

Line Configuration Diagram

Material Used

( )

Products per Line

Material per Product

( ) (

)

Single Line

X X X

Multi-Unit Line

X X

Multi-Line

* Products on both parts of the line must be the same in order to generate accurate material per product data.

** Accurate material per product data cannot be generated for multi-line configurations (assumes different products).

X X

333347P 29

Setup

Calibration

To calibrate using the

purge

method: a.

Obtain a scale and a container.

Reset the calibration weight totalizer by press-

Perform the following steps to calibrate the material tracking function:

Navigate to the Material Tracking Screen (Screen 4 of the System chapter).

To calibrate using the

tape and scrape

method: a.

Obtain a scale.

Place tape on a product(s) in locations where material is dispensed.

Run normal production (un-taped products) until a value appears in the grams per product label

(this could take several minutes of production).

Run taped product(s) through line and allow material to cool and harden on the tape.

Scrape all material from product and place on scale.

Adjust the specific gravity setting until the grams per product displayed matches the value measured by the scale using the following formula:

New SG Value = Current SG Value x Measured Grams per Product / Displayed Grams per Product

ing and holding the reset softkey .

Tare scale with empty container and purge at least 1 lb. of material into the container.

Weigh container with material.

Adjust the specific gravity setting until the weight displayed in the totalizer matches the value measured by the scale using the following formula:

New SG Value = Current SG Value x Measured Weight /

Displayed Weight

30 333347P

Setup

Material Alerts

This feature can be used to monitor material usage based on a target material per unit value. If material alerts are enabled the system will record an event every time the system deviates over 20% from the target. The material alert information can be seen in the bottom left corner of the material log (see image below).

Reset Material Target

To reset the material target value, press the reset material target softkey

An hourglass will appear indicating that the system is learning the new target

(current machine output).

Enable/Disable material Alerts

To enable/disable material alerts, select/deselect the

Enable Material Alerts

setting on the Material Tracking

Screen (Screen 4 of the System chapter).

NOTE: The material target will be automatically reset whenever a Pattern Controller setting is changed (e.g. switch from solid bead to stitched bead).

333347P 31

Operation

Initial Startup and Prime

Heating and dispensing hot melt adhesive may create potentially harmful vapors. Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions. Ventilation of the work area may be required.

detailed ADM information.

NOTICE

To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

NOTE: See Appendix B - USB Downloading, Upload-

ing on page 126 for detailed USB information.

NOTE: All setup procedures must be completed prior to

initial startup. See Setup on page 17.

NOTE: PSA-type adhesive pellets will not work in the

InvisiPac system.

Direct the applicator into an appropriate waste container.

Fill adhesive pellets container with hot melt adhesive pellets.

Turn main power switch ON .

Open system air inlet ball valve.

Overview

The system includes a vacuum transfer system that pulls the adhesive pellets into the system as needed.

Once melted, the adhesive enters the pump where it is pumped into the heated hoses then to the heated applicators. The applicator then briefly opens to dispense the desired quantity of adhesive.

Even though the system rises to operating temperature quickly, there is a Schedule function in the ADM that eliminates waiting for the system to heat up. The Schedule function automatically enables the heating system at the user-specified times so the system is ready to dispense when a shift begins. The Schedule function also disables the heating system at user-specified times to ensure the heating system is disabled when not being used.

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32 333347P

Operation

Use pump air pressure regulator (C) to adjust pump air pressure to 0.

. 18

Use vacuum transfer air pressure regulator (E) to adjust vacuum transfer air pressure setting to

40-100 psi (280-690 kPa, 2.8-6.9 bar). Recommended setting is 60 psi (414 kPa, 4.1 bar). See

. 18.

NOTE: Vacuum transfer will not begin operating until pump reaches operating temperature.

To prevent fire and explosion, never exceed the cleaning fluid’s rated temperature. If the system was just flushed, residual cleaning fluid is still in the system until the system is primed with adhesive. Do not raise temperature above cleaning fluid rated temperature until system is primed with adhesive.

NOTE: A new system may have residual oil due to testing at the factory prior to shipping. To prevent smoking, make sure to perform the following step.

On new systems only:

temporarily adjust the melter

temperature to 250°F (121°C). See Select ADM

Settings on page 23 for instructions.

On new systems only:

After the melter has reached

250°F (121°C) and the funnel is filled with pellets, set the melter temperature back to the desired oper-

ating temperature. See Select ADM Settings on page 23 for instructions.

10. Use separate pattern controller to open the applicators and keep them open.

NOTICE

In the following step, to prevent damage to the pump due to pump cavitation, do not supply more than 20 psi

(140 kPa, 1.4 bar) air pressure to the pump until the system is fully primed.

11. With the applicators open and the system up to temperature, slowly increase pump air pressure until the pump begins to run very slowly. Approximately

20 psi (140 kPa, 1.4 bar) should be sufficient.

NOTE: Operation may be erratic below 20 psi (140 kPa,

1.4 bar).

12. Continue running the pump until clean, air-free material is dispensed from each applicator.

13. When each applicator is fully primed, adjust pump to desired pressure setting: a.

Adjust pump pressure to between 20-100 psi

(140-690 kPa, 1.4-6.9 bar).

Use separate pattern controller to repeatedly open and close each applicator while inspecting the dispense pattern.

Repeat until desired dispense pattern is achieved.

Press to enable the heaters and pump.

NOTE: When system is up to temperature, the pump will be activated automatically, but will not start because there is no air pressure supplied to the pump.

NOTE: When the melter is up to temperature, the auto-fill function will initiate to fill the funnel with pellets.

333347P 33

Operation

Manual Refill

NOTE: Use Automatic Refill whenever possible. The system uses Automatic Refill by default and must be manually changed to Manual Refill. Only use Manual

Refill if the Automatic Refill system is not functioning properly and cannot be fixed in a timely manner. Perform service to automatic feed system as soon as possible to limit debris buildup on feed funnel.

It is recommended to maintain a minimum flow rate of

1.5 lb/hour to prevent material from melting within the feed cap and funnel. If production rate is below

1.5 lb/hour or system sits at temperature without dispensing for extended periods of time, use manual refilling with caution. System flow rate can be monitored by enabling the Diagnostic screen.

On the System 3 screen (in the Setup screens), select “Manual” from the Refill mode dropdown.

Remove the two bolts from the funnel bracket, then remove the top portion of the funnel.

Fill the funnel with adhesive pellets.

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. 20

Refill the funnel as needed to maintain the required dispense rate.

When finished dispensing for the day, dispense into a waste container until the material level is down to

the melter core. See F

. 21.

NOTE: This will lower the adhesive level within the funnel cap to the correct level to prevent any issues upon startup the following production day.

WLD

. 19

Disconnect the sensor cable and sensor cooling air.

. 21

WLD

34 333347P

Operation

Automatic Refill

The system uses automatic refill by default. If the automatic refill system is malfunctioning and cannot immediately be fixed, Manual Refill can be used.

To use automatic refill:

On the System 3 screen (in the Setup screens), select “Automatic” from the Refill mode dropdown.

Verify shaker and tube are connected to the system.

See Attach Components on page 17.

Verify shaker inlet (K) is at the bottom of the adhesive pellets container that is filled with hot melt

adhesive pellets. See F

Initial Startup and Prime procedure on page 32.

NOTE: The shaker inlet must be completely covered in adhesive pellets in order for it to effectively pull pellets into the tube.

If not already set,

use vacuum transfer air pressure regulator (E) to adjust vacuum transfer air pressure setting to 40-100 psi (280-690 kPa, 2.8-6.9 bar).

Recommended setting is 60 psi (414 kPa, 4.1 bar).

Dispense

NOTE: Only hot melt adhesive pellets can be used in the InvisiPac system.

If the system is empty or has air in the lines,

perform

If main power switch is OFF, turn main power switch

ON .

NOTE: The main power switch should be left ON at all times when using the Schedule function.

Prepare for dispensing: a.

Verify air inlet ball valve (J) is open. See F

Check pressure gauges (D, F) to verify vacuum transfer and pump air pressures are set as

desired. See F

see Automatic Refill on page 35.

If using Automatic Refill,

If using Manual Refill,

see Manual Refill on page 34.

Verify applicators are closed.

. 22

NOTE: The system will automatically transfer the pellets to the system as necessary.

Press to enable the heaters and pump.

NOTE: If using the Schedule function, the heaters and pump will be enabled automatically at the set time. You will not need to press if using the Schedule function unless you wish to enable the heating system before the set time.

NOTE: When system is up to temperature, the pump will begin running automatically. It will stall at pressure unless an applicator is open. Material will be dispensed whenever an applicator is open after the system is up to temperature.

When the system is up to temperature,

use separate pattern controller to open and close the applicators as desired to dispense material.

333347P 35

Operation

NOTE: While operating the system, the actual temperatures of the hose, applicator, and system melter are displayed on the Home screen.

Schedule

The Schedule function allows the user to specify times when the system will automatically turn ON and OFF the heaters and pump.

Shutdown

Press to disable the heaters and pump. The screen will say “Inactive”. If using the Schedule function, the heaters and pump will be disabled automatically at the set time. You will not need to press if using the

Schedule function unless you wish to disable the heating system before the set time. If the heaters were manually disabled, the Schedule function will automatically enable them at the next set time.

Do not turn the main power switch OFF if using the

Schedule function.

Set Schedule Times

NOTE: Times are set using a 24-hour clock. Several on and off times can be set each day.

On the Schedule screen (in the Setup screens), set the ON times for each day of the week.

Set the OFF times for each day of the week.

Enable Schedule Function

The Schedule function is automatically enabled when values are entered in the Schedule screen. To disable a scheduled event, navigate to the event and press

The event will appear gray on the screen when it is disabled. To re-enable an event, navigate to the event and press . The event will appear red (system off) or green (system on). If no events are needed, turn the main power switch OFF to prevent system from automatically enabling and disabling the heaters.

How to Use the Schedule Function

At the end of the work day leave main power switch ON

. The Schedule function will automatically enable and disable the heaters and pump at the specified times.

36 333347P

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, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

Turn main power switch OFF .

Close the inlet air supply ball valve.

NOTE: Manually verify the pressure is relieved by opening the applicator and ensuring no adhesive is dispensed.

Operation

333347P 37

Operation

Drain the System

NOTE: The system must be drained prior to flushing and prior to some maintenance and repair procedures.

On the System 3 screen (in the Setup screens), change the Refill Setting to “Manual”.

11. Disconnect hose from melter outlet.

12. Wait until system stops draining or at most 10 minutes.

NOTE: There will be some residual adhesive in the system.

13. When done performing the procedure that required draining the system, set Refill Setting back to “Auto” on the System 3 screen.

Flush

If the heating system is disabled,

press enable the heaters and pump.

Decrease pump air pressure to 0.

Close system air inlet ball valve.

Disconnect hose from applicator inlet then place hose outlet in a waste container. Repeat for all hoses. Keep hose to applicator electrical connector connected.

Open applicator to allow residual fluid in applicator to drain.

When system is at operating temperature, slowly increase pump air pressure until fluid begins flowing into the waste container.

NOTE: It may take several minutes to empty the system. When there is no melter fluid at the pump, the pump will begin to cycle faster.

When the pump begins to cycle faster, close the system air inlet ball valve.

To prevent fire and explosion, use the adhesive manufacturer’s recommended cleaning fluid.

• Never exceed the cleaning fluid’s rated temperature

• Never flush your system or clean any aluminum components with halogenated hydrocarbon cleaning solutions.

To prevent severe burns, wear protective clothing.

NOTE: This procedure describes how to flush one hose at a time for maximum effectiveness.

See the hot melt adhesive technical data sheet or

MSDS for the recommended cleaning fluid. Contact the hot melt supplier if the technical data sheet or MSDS is not available.

Perform Drain the System on page 38.

If the heating system is enabled,

press able the heaters and pump.

to dis-

Loosen upper hose clamp securing funnel assembly to air motor bracket then remove funnel assembly from system. Keep 1.3 in. (33 mm) clear tube and funnel cap attached to funnel.

Loosen clamp then remove plastic melter cap. Keep fill sensor attached to cap.

Press to disable the heaters and pump.

10. Remove melter drain plug (W1). See F

. 2 on page

13.

38 333347P

Operation

On the System 3 screen (in the Setup screens), verify the Refill Setting is set to “Manual”.

To prevent fire and explosion, never exceed the cleaning fluid’s rated temperature.

Change the melter, heated hoses, and applicators temperature settings to the high temperature hot melt cleaning fluid manufacturer’s recommended temperature.

Verify the system air inlet ball valve is closed and pump air pressure is set to 0.

Allow the system to heat or cool to the cleaning fluid manufacturer’s recommended temperature.

Fill melter with high temperature rated hot melt cleaning fluid. See hot melt adhesive material supplier for recommended hot melt cleaning fluids.

Fluid level should be 1/2 in. (12.7 mm) from the top of the melter.

WLD

10. Disconnect one hose from its applicator manifold.

NOTE: Keep all applicators closed throughout this procedure.

11. Route the disconnected hose to a waste container.

12.

If heating system is disabled,

press the heaters and pump.

to enable

13. Wait for the melter temperature to reach the hot melt cleaning fluid manufacturer’s recommended temperature.

NOTE: The pump will not run because the system air inlet ball valve is closed.

14. Once the required melter temperature is reached, let the hot melt cleaning fluid “soak” in the melter at temperature for the duration specified by the hot melt cleaning fluid manufacturer.

NOTE: “Soaking” is important to ensure the best possible cleaning.

15. After the hot melt cleaning fluid has “soaked” for the specified amount of time, open the system air inlet ball valve. Slowly increase the pump air pressure until pump begins to cycle to begin pumping the hot melt cleaning fluid and adhesive mixture out through the hose into the waste container.

16. Once the pump begins to cycle faster, close the system air inlet ball valve to stop the pump.

17. Repeat steps 7 through 16 until clean, adhe-

sive-free hot melt cleaning fluid is dispensed from the detached hose.

NOTE: Now the melter and the disconnected hose are thoroughly flushed.

18. Reattach the hose to the applicator manifold.

19. Repeat steps 7 through 18 for each additional

installed hose, leaving a different hose disconnected from the applicator manifold each time.

20. Remove and replace filter(s) in all applicator manifolds. See applicator manual.

21. Replace Outlet Filter. See page 41.

22. Turn main power switch OFF.

23. Place waste container below drain tray (W2) then remove drain plug (W1) and wait for system to finish

draining. See F

. 2 on page 13.

24. Allow the system and fluid to cool then perform any required maintenance procedures beginning on

page 41.

333347P 39

Operation

25. Install fill cap onto melter rubber housing. Re-tighten upper clamp to 25 in-lbs.

26. Slide funnel assembly through air motor bracket then tighten clamp.

27. On the System 3 screen (in the Setup screens), set the Refill Setting to “Auto”.

To prevent fire and explosion, never exceed the cleaning fluid’s rated temperature. Residual cleaning fluid is still in the system until the system is primed with adhesive.

28. Perform Initial Startup and Prime on page 32.

Operation Tips to Minimize

Charring

Set the Pump Idle Time to System Inactive function on the System 3 screen to lowest value that will not interfere with normal operation. This feature automatically disables the heating system if the pump is idle for longer than the preset amount of time. Disabling the heating system minimizes adhesive degradation and limits char formation.

When possible, utilize the Schedule function, see page 36, to automatically enable and disable the heat-

ing system in accordance with your production schedule. This will ensure adhesive spends as little time at temperature as possible. Less time at high temperature ultimately means less adhesive degradation and less char.

NOTICE

40 333347P

Maintenance

Replace Outlet Filter

The outlet filter is designed to prevent small contaminants from entering the hoses and applicators. Inspect filter regularly. Replace the filter after flushing and when you change the adhesive used in the system.

Insert allen wrench through the outlet filter cap to lift outlet filter (236) out of the system.

Discard outlet filter assembly.

Place o-rings (232, 237) provided with new outlet filter onto new outlet filter (236).

Place new outlet filter with o-rings into housing.

Tighten with 1 in. socket.

10. Install small metal shroud (28) over outlet filter then tighten two screws (8).

236

Replace Inlet Filter

232

237

. 23

WLD

If the system is not up to temperature,

press to enable the heaters and pump then wait for system to reach operating temperature.

To avoid severe burns, wear protective gloves and clothing that will insulate your hands and body from the hot surfaces and material.

Perform Pressure Relief Procedure, page 37 but

do not allow system to cool. Adhesive must be a fluid to perform this procedure.

Turn main power switch OFF.

Loosen two screws (8) then slide the small metal shroud (28) on the back of the system up to remove.

the inlet filter (213). See F

. 23.

Use a 1 in. socket to unscrew outlet filter (236).

To avoid severe burns, wear protective gloves and clothing that will insulate your hands and body from the hot surfaces and material.

The inlet filter is designed to prevent large items from entering the system. The inlet filter can only be replaced with the system empty.

Close the system air inlet ball valve.

NOTE: Some adhesives have different melting points.

The first temperature tried should be approximately half of the dispensing temperature. If dispensing at 400°F

(204°C), first try 200°F (93°C) then increase in 20°F

(11°C) increments. If dispensing at 250°F (121°C), first try 125°F (52°C) then increase in 20°F (11°C) increments.

NOTE: To ensure the adhesive is a gel, not a liquid, do not remove inlet filter cap (215) when the temperature is above the desired temperature. If the temperature is too low, the adhesive viscosity may be too high to remove

. 24, page 42.

If the melter is below the desired temperature and heating system is disabled,

press to enable the heaters.

If the melter is above the desired temperature and heating system is enabled,

press the heaters.

to disable

Wait until melter temperature is the desired temperature.

333347P 41

Maintenance

When the melter temperature is the desired temperature, turn main power switch OFF.

Disconnect cable from ADM, push cable through plastic shroud, then remove plastic shroud from system.

Place a piece of cardboard beneath the inlet filter cap (215) to route fluid away from system into a waste container in the event the adhesive is a fluid.

Use 1 in. socket to remove inlet filter cap (215).

Slide new screen (213) into melter base manifold (201).

10. Install filter cap (215) then use a 1 in. socket to tighten.

11. Feed ADM cable through plastic shroud (29) then install shroud onto system. Connect cable to

ADM (30).

Replace Funnel Filter

706

705

213

215

. 24

WLD

201

If the adhesive is a thin enough gel to remove the inlet filter:

Use an o-ring pick or small allen wrench to remove filter screen (213) from system.

Otherwise:

Install inlet filter cap (215).

Install shroud and ADM.

Turn main power switch ON.

Once ADM software finishes starting up, press to enable the heaters.

Wait for temperature to rise 20°F (11°C) beyond previous temperature.

Go to step 4.

WLD

. 25

Disassembly (see F

. 25):

Turn main power switch OFF.

Rotate funnel cap (706) and remove. Lift out funnel filter (705).

Reassembly (see F

. 25):

Insert filter (705) in funnel assembly. Tighten funnel cap (706) on funnel.

42 333347P

Maintenance

Filter Maintenance Guidelines*

Component

Pump Outlet Filter

Applicator Manifold Filter

System Air Inlet Filter

Applicator Solenoid Mufflers

Feed funnel filter

Feed funnel inspection/cleanout

Part Number Ref

24W595

24P802

24X967

24P282#

24X037%

24V506

N/A

Environmental Classification

Clean Moderate

236

16 +

104+

Replace filter every six months

Replace filter every four months

705

Dusty

Replace filter every two months

* 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 powdered 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.

+ See appropriate applicator manual for part reference drawing.

#Standard on GS35 applicators.

%Optional upgrade to GM100 applicators.

333347P 43

Troubleshooting

To avoid injury due to unexpected machine operation initiated by a remote controller, disconnect the customer I/O cable from the system prior to troubleshooting.

ADM Error Code Table

When an error occurs, press nance screen and press

to acknowledge the error. If a Maintenance error occurs, navigate to the Mainte-

to clear the error.

The last digit of the error code indicates the melter, applicator (gun), or hose to which the error applies. The “_”

(underscore) character indicates the code applies to multiple items.

Last Digit in Code

Code Relates to:

Melter

Applicator (Gun) 1

Hose 1

Applicator (Gun) 2

Hose 2

Applicator (Gun) 3

Hose 3

Applicator (Gun) 4

Hose 4

Applicator (Gun) 5

Hose 5

Applicator (Gun) 6

Hose 6

An alarm will disable the heating system and pump. A deviation or advisory will not disable the heating system and pump.

Code

A1D0

A1D_

A3MF

Description

Low Current

Melter

Low Current

Gun X

Low Current

Hose X

High Fan Current, Transformer

Type Cause

Advisory

Melter current is less than 500mA.

Solution

Check heater resistance and resistance to ground. Replace heater(s). See Replace Heater

Rod, page 69.

Applicator current is less than 500mA.

Verify applicator heater has a minimum wattage of 90 Watts at 240 VAC. Check heater resistance and resistance to ground. Replace heater.

Hose current is less than 500mA.

Advisory

Deviation

Transformer fan is greater than

600mA.

Check heater resistance and resistance to ground. Replace hose.

Replace transformer fan.

44 333347P

Troubleshooting

Code

A4D0

A4D_

A7D0

A7D_

A8D0

A8D_

A8MF

Description

High Current

Melter

High Current

Hose X

High Current

Gun X

Unexpected

Current

Unexpected

Current, Gun X

Alarm Unexpected current flow to applicator

Unexpected

Current, Hose X

No Current

Melter

No Current

Hose X

No Current Gun

No Fan Current,

Transformer

Type

Alarm

Deviation

Cause

Band heater or rod heater.

Hose power wires.

Heater rods in applicator manifold.

Unexpected current flow to melter.

Unexpected current flow to hose X.

Power not getting to melter.

Power not getting to hose.

Power not getting to applicator.

Power not getting to transformer fan.

Solution

Measure resistance to ground between heater leads. Should be a high reading. Replace heater.

Check heater resistance and resistance to ground. Replace heated hose.

Check heater resistance and resistance to ground. Replace applicator manifold.

Check heater resistance and resistance to

ground. Replace faulty heater(s). See Replace

Heater Rod, page 69.

Replace MZLP.

Check heater resistance and resistance to ground. Replace applicator manifold.

Replace MZLP.

Check heater resistance and resistance to ground. Replace hose.

Replace MZLP.

Check fuses F1 and F2 on MZLP with daughter board.

Check J1 is plugged into MZLP with daughter board and J3 on AWB.

System needs a hose connected to Channel 1 or use the optional Overtemperature Jumper,

16Y727.

Check fuses F5 and F6 (channels 1, 3, 5) or F9 and F10 (channels 2, 4, 6) on MZLP that the error hose is connected to.

Check that electrical connector on the heated hose is plugged into the MZLP.

Check continuity of pins C and D on electrical connector at MZLP end of heated hose. See heated hose manual for impedance measurements. Replace hose if readings are too high.

If system only uses one hose and applicator, the heated hose electrical connector must be plugged into channel 1 of the MZLP.

Check fuses F3 and F4 (channels 1, 3, 5) or F7 and F8 (channels 2, 4, 6) on MZLP that controls the error channel.

Check that electrical plug on hose is plugged into back of MZLP and applicator is plugged into hose.

Check continuity of hose pin A gun end to J on

MZLP connector end of hose and pin C on gun end to pin A on the MZLP end of the hose. Reading should be 0-1 ohm. Replace hose if measurement is outside this range.

If system only uses one hose and applicator, electrical connector of the heated hose must be plugged into channel 1 of the MZLP.

Verify that fan power cable is plugged into J7 on the AWB.

Verify transformer fan is free of obstructions and can spin freely.

333347P 45

Troubleshooting

Code

CAC_

1=MZLP 1

2=MZLP 2

3=MZLP 3

CACX

DADX

DDDX

DE0X

L0FX

L6FX

Description

Comm Error

Module

Missing DB

Pump Runaway

Pump Diving

Cycle Switch

Error

Manual Fill

Mode

Level Sensor

Error

Type

Alarm

Deviation

Alarm

Advisory

Cause

System not responding to ADM.

System not acknowledging the daughter board.

Pump is trying to feed adhesive, no adhesive to feed.

Worn or damaged pump seals

Pump is trying to feed adhesive, no adhesive to feed.

Worn or damaged pump seals

No signal from air motor sensor.

System set to manual fill mode.

Alarm No signal from the level sensor.

No air to fill cap.

Plugged orifice in fill cap below fill sensor.

Solution

Dial not set correct on MZLP. Set to 1 on board with daughter board. Set to 2 on MZLP without the daughter board in center of electrical enclosure. Set to 3 on MZLP without daughter board on left of electrical enclosure.

System is not properly loaded with correct soft-

ware. Perform Software Update Procedure on page 81.

Bad connection between daughter board and

MZLP board. Loosen daughter board, re-seat, then secure.

Daughter board is not plugged into MZLP1. Plug daughter board into MZLP with dial set to 1.

Replace MZLP daughter board.

Storage bin out of adhesive. Refill adhesive.

Level sensor may be over heating. Verify air is being delivered from tube (35).

Melter at incorrect temperature, too low. Check setpoint and set to manufacturer’s recommendation.

Plugged vacuum transfer hose or funnel. Clear plugged hose or funnel.

Inspect pump seals. Repair if necessary.

Storage bin out of adhesive pellets. Refill with pellets.

Level sensor may be over heating. Verify air is being delivered from tube (35).

Melter at incorrect temperature, too low. Check melter temperature setting and set to manufacturer’s recommendation.

Plugged vacuum transfer hose or funnel. Clear plugged hose or funnel.

Dispense rate too high. See technical ratings of system.

Inspect pump seals. Repair if necessary.

Check wiring on J16 of the daughter board. See

Electrical Schematics on page 82.

Loose cycle switch bolt. Tighten cycle switch bolt.

Replace cycle switch.

Change to auto fill mode. See Setup Screen System 2.

Check for sensor LED illumination.

Check that sensor cable is plugged into sensor.

Check connector at J14 of the daughter board.

Remove fill cap and verify there is nothing blocking fill (level) sensor line of sight.

Replace fill (level) sensor.

Check system incoming air pressure is 80-100 psi.

Check for sensor cooling air coming from 5/32 in. air line, flow should be 30-60 SCFH.

Remove fill cap and remove object plugging the orifice.

46 333347P

Troubleshooting

Code

L8FX

M8MF

MMUX

MNDX

T2D0

T2D_

T4C_

Description

Refill timeout

High Temp Runaway, Transformer

USB Log Full

Pump Maintenance Due

Low Temperature, Melter

Low Temperature, Gun X

Low Temperature, Hose X

High MZLP PCB

Temp

Type Cause

Alarm Melter did not receive enough adhesive pellets for flow rate.

Deviation

Advisory

Deviation

Alarm

At the current rate of temp rise, the transformer will over heat in 15 minutes or less.

USB logs full. Data loss will occur if not downloaded.

Cycles are greater than user set maintenance interval.

Melter temperature dropped to

15°F(-9°C) below setpoint.

Applicator temperature dropped to

15°F(-9°C) below setpoint.

Hose temperature dropped to

15°F(-9°C) below setpoint.

MZLP board is overheating.

Solution

Inspect storage bin for bridging and blocking.

Storage bin out of adhesive. Refill adhesive.

Plugged inlet feed hose or funnel. Clear plugged hose or funnel.

Low air pressure on feed regulator. Check regu-

lator. See Setup, page 17 for air pressure regula-

tions.

Dirty or plugged funnel filter. Replace filter.

Verify that fan power cable is plugged into J7 on the AWB.

Verify transformer fan is free of obstructions and can spin freely.

Replace transformer.

Download USB data. See Appendix B - USB

Downloading, Uploading on page 126.

Perform maintenance and reset “Due” counter to

0 at the Setup Maintenance screen.

Verify system is operating within meltrate specifications. Consider incoming voltage and breaker setting.

Verify that the fill system (vacuum) is operating correctly. If the level of material in the melter gets too low and a large amount of cold material enters the melter, can cause the temperature to drop significantly.

With the system on and not dispensing verify that the temperature is properly controlled to the setpoint. If system cannot control temperature, verify the RTD is seated inside the melter.

Replace RTD if RTD was seated properly and system cannot control temperature

Check heater resistance and resistance to ground. Replace heater(s).

With the system on and not dispensing verify that the temperature is properly controlled to the setpoint. If system cannot control temperature, replace applicator RTD. See applicator manual.

Check heater resistance and resistance to ground. Replace heater.

Dispense rate too high for applicator to maintain setpoint. Consider applicator power and voltage.

With the system on and not dispensing verify that the temperature is properly controlled to the setpoint. If system cannot control temperature, replace hose.

Check heater resistance and resistance to ground. Replace hose.

Ambient temperature must be under 120°F.

Replace MZLP board.

333347P 47

Troubleshooting

Code

T4D0

T4D_

T4MX

T6D0

T6D_

T6MX

T8D_

Description

High Temp

Melter

Type Cause

Alarm Melter continues to raise above the setpoint.

Solution

Check that RTD is seated in melter correctly.

Check that overtemperature switch is plugged in and check switch resistance. The switch resistance should be near 0 Below 400°F (204°C).

High Temp

Hose

High Temp Gun

High Temperature, Transformer

Sensor Error

Melter

Sensor Error

Hose

Sensor Error

Gun

Thermistor Sensor Error, Transformer

No Temp Rise in

Gun (all zones)

Alarm

Hose continues to raise above the setpoint.

Applicator assembly continues to raise above the setpoint.

Check melter heaters’ resistance to ground.

Replace heater if a heater is shorted to ground.

Turn system on without dispensing. Verify temperature is properly controlled to the setpoint. If setpoint is not maintained, replace RTD. If heat continues to rise past setpoint, replace MZLP.

Turn on system without dispensing. Check if hose can maintain setpoint temperature. If the hoses’ RTD readings are unstable, replace hose.

If hose continually heats past setpoint, replace the MZLP.

Turn on system without dispensing. Check if applicator can maintain setpoint temperature. If the applicator’s RTD readings are unstable, replace the applicator RTD.

Alarm

Thermistor reading greater than 212°F

(100°C).

No reading from RTD.

Check the applicator heater’s resistance to ground if the RTD readings are stable but the applicator’s temperature continues to rise. If the heater is shorted to ground, replace the applicator’s heater. If heater is not shorted to ground, replace MZLP.

Verify transformer fan is operating correctly and free of obstructions.

Replace transformer.

Verify connector J5 on MZLP board is securely connected.

Replace melter RTD. See Replace Band Heater

Temperature Sensor, page 68.

Hose electrical connector not plugged into MZLP.

Replace hose.

Hose electrical connector not plugged into MZLP or applicator electrical connector not plugged into heated hose.

Alarm No reading from transformer thermistor sensor.

Replace applicator RTD.

Verify that sensor wire is plugged into J7 on

AWB.

Replace transformer.

Alarm Temperature reading does not change. Check fuses F3 and F4 (channels 1, 3, 5) or F7 and F8 (channels 2, 4, 6) on MZLP that error channel is connected to.

Replace applicator manifold heater rods.

NOTE: Heater rods in the applicator manifold can also cause the no current error.

Check resistance of hose wiring. See hose manual for proper resistance range.

48 333347P

Troubleshooting

Code

T8D_

T8D0

V1I_

V1MW

V4I_

V4MW

V6MW

V8M_

WJDX

WKFX

WSUX

Description

No Temp Rise in

Hose (all zones)

Type Cause Solution

Alarm Temperature reading does not change.

Check fuses F5 and F6 (channels 1, 3, 5) or F9 and F10 (channels 2, 4, 6) on the MZLP that controls the error channel.

Check resistance of hose wiring. See hose manual for proper resistance range.

No Temp Rise in

Melter (all zones)

Low Can Voltage

Low Line Voltage

High Can Voltage

High Line Voltage

NOTE: Heater wires in the hose can also cause the no current error.

Alarm Temperature reading does not change. Check fuses F1 and F2 on MZLP with daughter board.

Check that RTD is installed in the melter.

Check J1 is properly plugged into the MZLP with daughter board and in J3 on AWB.

Check heater resistance and compare to reference table. See Check Heater Rod Resistance, page 58.

Replace melter heater.

Alarm

Deviation

Alarm

Bad or overloaded power supply.

Incoming line to line voltage has dropped below 175V.

Bad or overloaded power supply.

Alarm Incoming line to line voltage has increased above 265V.

Invalid Power

Type

Alarm During startup incoming line to line power was either below 175V or above

265 V.

No line voltage Alarm Incoming line voltage is less than

100 VAC.

NOTE: Heater rods in the melter can also cause the no current error.

Verify power supply voltage is 24 VDC. If voltage is low, disconnect the screw terminals +V and -V on the power supply and re-check voltage reading. If voltage is correct, then disconnect J8 and

J9 from AWB and re-check voltage. If still low replace AWB. If correct, plug in J9 and recheck voltage. If low, replace ADM. If correct, plug in

J8. If low, replace MZLP. If voltage is still low, replace power supply.

Verify incoming power is correct gauge for current draw and verify incoming power lines are securely attached to disconnect.

Verify power supply voltage is 24 VDC. If voltage is high, replace power supply unit.

For 3 phase with neutral have qualified electrician verify neutral wire.

Verify incoming power is wired to the disconnect correctly.

Pump Solenoid

Error

Fill Solenoid

Error

USB Invalid

Configuration

Alarm No voltage draw from air solenoid for air motor.

Alarm No voltage draw from air solenoid for

Deviation fill.

A valid configuration file can't be found for the USB.

ADM: not functioning properly.

Measure incoming power with system unplugged. If line voltage is less than 100 VAC, contact qualified electrician to correct the low voltage.

Check connector is properly connected to J13 of the daughter board.

Replace air manifold.

Check connector at J13 of the daughter board.

Replace air solenoids. See page 76.

System is not properly loaded with correct soft-

ware. Perform Software Update Procedure on page 81. Retry USB download.

Replace ADM.

333347P 49

Troubleshooting

Mechanical and Electrical Troubleshooting

Problem

Refill Timeout

Error

Cause

The system was unable to refill in less than 30 seconds.

Solution

Check hopper for adequate material and material blocking.

Verify the vacuum transfer system air pressure is 40-80 psi (60 psi recommended) and that air is flowing to the feed wand while attempting to refill.

Restart system. If the error persists after attempting another refill and unit is needed immediately for production, place system into the man-

ual refill mode. See Manual Refill on page 34.

Check funnel filter. If plugged, see Replace Funnel Filter on page 42.

Check hopper for adequate material and material blocking.

The InvisiPac system takes a long time to refill adhesive.

Vacuum transfer not working

Adhesive pellets in storage bin not covering shaker head.

Fill Solenoid

Error

Glue level in hopper is low.

Vacuum flow is restricted.

Air to vacuum assembly missing.

Air at system air gauge but not to air to shaker.

Air is at shaker but there is no feed.

Shaker unit not vibrating.

Verify the vacuum transfer system air pressure is 40-80 psi (60 psi recommended) and that air is flowing to the feed wand while attempting to refill.

Check funnel filter. If plugged, see Replace Funnel Filter on page 42.

Verify the vacuum transfer system air pressure is 40-80 psi (60 psi recommended)

Check that air line is connected or not pinched.

Plugged shaker unit, remove from system and remove plug.

Materials are blocking in the hopper. Some adhesive materials are prone to blocking. High ambient temperature and high humidity can increase the likelihood of blocking.

Failure of the fill solenoid or fill solenoid wiring.

Verify shaker is vibrating during material loading. If not, the ball in the shaker assembly is stuck. Remove shaker housing and separate to clean raceway and ball inside.

Some materials may require agitation periodically to breakup bridging.

Verify wiring between J13 and the refill solenoid is not damaged.

Restart system. If the error persists after attempting another refill and unit is needed immediately for production, place system into the man-

ual refill mode. See Manual Refill on page 34.

50 333347P

Troubleshooting

Problem

Level Sensor

Error

The InvisiPac system expels adhesive pellets dust when refilling.

The InvisiPac system will not stall, pump continues to move even if the applicators are all closed.

The system will not dispense material.

Cause

Failure of the level sensor (20) or sensor cable 16T108 (J14 to level sensor (20)).

Some adhesives are very dusty due to the anti-blocking agents used or because the adhesive manufacturing process has created small adhesive shavings. Feed inlet cap filter may have become clogged.

Fluid leak.

System is not up to temperature.

Incorrect temperature set points entered into

ADM.

Air motor is not receiving compressed air or air pressure too low.

Feed pump not feeding adhesive.

Solution

Check sensor cable J14 to level sensor (20).

Enable Diagnostic screen on ADM then check sensor readings on the

Diagnostic screen. Sensor readings should be about 4.3V if melter is completely empty (melter passage holes are visible). The normal operating range is 3.8 to 4.3V. If the sensor is reading more than 4.2V the system should be requesting additional material.

Restart system. If the error persists after attempting another refill and unit is needed immediately for production, place system into the man-

ual refill mode. See Manual Refill on page 34.

Replace Funnel Filter, see page 42.

NOTE: Feed cap filter maintenance should be performed at regular service intervals. It is recommended that the feed cap filter be inspected at a minimum of every 1200 lb dispensed, however with some adhesives the frequency may need to be increased significantly to maintain desired system cleanliness.

Verify that no external leakage is present.

Inspect and test the pressure relief valve.

Perform Flush Pressure Relief Valve, page 58.

If system is still unable to stall, the pump or pressure relief valve may need to be repaired.

Verify that the system is active.

Verify the temperature settings are correct.

Verify that the pump air pressure is set above 20 psi. Check the Pump

Air Solenoid Operation, page 58.

Cycle Switch

Error

Timing control for applicators not working.

Cycle switch or cycle switch wiring failure.

Loose or missing fastener (26).

Repair or replace air control assembly as necessary.

Repair or replace pump assembly as necessary.

InvisiPac system does not control the timing of the applicators. This is a separate control that needs to be adjusted. Consult control manufacturer or qualified electrician.

Check the wiring between the air motor cycle switch and J16.

Repair/replace as required.

Ensure fastener (26) is tight. See InvisiPac Systems section beginning on page 89 for part identification.

333347P 51

Troubleshooting

Problem

USB Log Full

The InvisiPac system is displaying pump runaway or pump diving.

Cause

The InvisiPac system will display this notification when the USB data logs reach 90% full.

Solution

To prevent data loss, download system data. See Appendix B - USB

Downloading, Uploading on page 126.

This error generally occurs when the pump cavitates due to improper material loading.

This can occur if the melt rate for the system is exceeded, resulting in air entrapment within the incoming adhesive material and lower than desired material temperature.

Verify that the InvisiPac system is not exceeding (11 cpm- HM25,

22 cpm - HM50) by enabling the diagnostic screen.

If the cycle rate is below (11 cpm- HM25, 22 cpm - HM50)and the system is still running away increase the InvisiPac system temperature in small increments over the current set point.

If the pump continues to runaway or dive continue increasing temperature in small increments. Do not exceed maximum temperature for the material being dispensed.

NOTE: If air has become trapped in the pump, it can be purged by fol-

lowing the Pressure Relief Procedure, page 37.

NOTE: Some materials are more difficult to melt than others and it may be impossible to process them at the published melt rate. The InvisiPac system was tested to achieve continuous published melt rates when dispensing standard EVA packaging grade adhesives in pellet form with an InvisiPac system temperature of 350°F and hose and applicator temperatures of 350°F.

Clean feed cap by fill sensor, make sure there are no adhesive pellets blocking the sensor hole.

Level sensor blocked, reading level incorrect.

The system is not supplying enough air to the ultrasonic sensor venturi.

Ensure supplied Air Filter Kit 24R707 is installed on system air inlet.

Perform a reverse pressure flush of the sensor venture orifice:

Disconnect incoming air from InvisiPac system air inlet (108).

Disconnect air tube poush-connect union (91) from ultrasonic sensor air tube (35).

Plumb 80-100 psi (550-690 kPa, 5.5-6.9 bar) to outlet end o air tube union (91).

Ensure air is flowing out of the InvisiPac system air inlet (108).

Reconnect ultrasonic sensor air tube (35) to air tube union (91).

52 333347P

Troubleshooting

Problem

Unable to achieve published melt rate at the desired adhesive temperature.

Cause

The InvisiPac system monitors temperature within aluminum mass of melter (202). As melt rates exceed 20 lb/hr a system temperature offset may be required.

Solution

If the cycle rate is below (11 cpm - HM25, 22 cpm - HM50) and the system is still running away increase the InvisiPac system temperature in small increments over the current set point, leave hoses and applicators at desired set point.

If the pump continues to runaway or dive continue increasing temperature in small increments. Do not exceed maximum temperature for the material being dispensed.

ADM not displaying when system turned on

Main breaker tripping

Main power circuit breaker off or power cord unplugged.

Cable on ADM unplugged.

Connector on AWB board not plugged in.

Bad 24VDC power supply.

ADM not functioning properly.

Wrong setting in ADM breaker setup.

Internal short to ground in system.

Too small of a circuit breaker in main power panel.

NOTE: A 50 amp breaker is required in order to maximize startup and flow rate performance. Set the breaker size used in the Setup screens.

NOTE: Some materials are more difficult to melt than others, therefore it may be impossible to process them at the published melt rate. The

InvisiPac system was tested to achieve continuous the published melt rates when dispensing standard EVA packaging grade adhesives in pellet form with an InvisiPac system temperature of 350°F and hose and applicator temperatures of 350°F.

Turn main circuit breaker on or plug in power cord.

Reconnect ADM cable.

ADM cable should be plugged into J9 of the AWB board.

Check output on power supply should measure 24VDC, if no voltage reading replace power supply.

Replace ADM.

Wrong breaker setting on ADM in the breaker setting in the setup screen.

Unplug or disconnect power and measure between each leg of the power to ground. There should be an open resistance reading.

Consult qualified electrician for proper size circuit breaker.

333347P 53

Troubleshooting

Problem

Slow start-up time or system takes longer than 10 minutes to startup

Cause

Wrong setting in ADM breaker setup.

Solution

Wrong breaker setting on ADM in the breaker setting in the setup screen.

Low incoming voltage.

Incoming voltage should be 200-240VAC for a 230 volt unit and 380-

400 VAC for a 400 volt unit.

Heater rod in melter and gun manifold.

Measure and check heater rods in melter or applicator. See applicator man-

ual. See Check Heater Rod Resistance, page 58.

Heated hose.

Insufficient power supplied to system. Depending on hose and applicator combinations, along with minimal supply power, startup time will vary.

Measure heater wires in hose, pins C and D. See repair section for each hose resistance.

Connect system to a power supply capable of maximum power per system specification. All changes must be performed by a qualified electrician. See

Models on page 4 for full-power rating. See Startup Time, page 131, for

startup times under varying conditions.

Incorrect RTD setting in system.

Verify melter, hose, and applicator temperatures are all with in the same range of the room ambient.

No adhesive or little adhesive being dispensed

System indicates no errors and correct temperature however applicator is over the temperature setpoint

If the applicator temperature is either much higher or much lower than the melter temperature then the RTD setting is not correct for the RTD being used. Select correct RTD setting in the setup screen system 2 before beginning.

NOTE: Failure to have the correct RTD value will cause the applicator to either under-heat or over-heat. Setting for RTD in the ADM screens is higher than actual RTD value. Consult manufacturer for actual RTD value.

Incorrect RTD setting in system.

Verify melter, hose, and applicator temperatures are all within the same range of the room ambient.

NOTE: Failure to have the correct RTD value will cause the applicator to either under-heat or over-heat. Setting for RTD in the ADM screens is lower than actual RTD value. Consult manufacturer for actual RTD value.

54 333347P

Troubleshooting

Problem

No adhesive or incorrect amount of adhesive output when all dispense modules are triggered

Cause

Plugged applicator manifold filter.

Clogged hose.

Solenoid valve.

No adhesive or incorrect amount of adhesive out of one/some of the dispense modules when triggered

No signal from control to solenoid.

Solenoid mufflers plugged.

No air to air solenoid.

Plugged system outlet filter.

If multiple applicators are triggered simultaneously, maximum pump rate may be exceeded.

Plugged tip on dispense module.

Dispense module in closed/partial open position.

Plugged applicator manifold filter (single dispense module applicator).

Clogged hose

Solenoid valve

Solution

Replace applicator manifold filter. Graco applicator manifold filter in bottom of manifold or inline filter on other applicators.

Flush or replace hose.

Check that correct voltage is input into solenoid valve. If voltage is correct, replace solenoid.

If no voltage is present at solenoid, check control cable and pattern controller. Replace component.

Replace solenoid mufflers.

Re-establish air supply to solenoid.

Replace Outlet Filter. See page 41.

Stagger applicator opening to reduce the maximum required flow rate to below maximum pump rate.

Replace tip on dispense module.

Replace dispense module.

Replace applicator manifold filter. Graco applicator manifold filter in bottom of manifold or inline filter on other manifolds.

Flush or replace hose.

Check that correct voltage is input into solenoid valve. If voltage is correct, replace solenoid.

If no voltage is present at solenoid, check control cable and pattern controller. Replace component.

Replace solenoid mufflers.

No signal from control to solenoid

Plugged solenoid mufflers

No air to solenoid

Plugged system outlet filter.

If multiple applicators are triggered simultaneously, maximum pump rate may be exceeded.

Re-establish air supply to solenoid.

Replace Outlet Filter. See page 41.

Stagger applicator opening to reduce the maximum required flow rate to below maximum pump rate.

333347P 55

Troubleshooting

Problem

Adhesive flowing out of one/some applicators when not triggered

Applicator will not heat.

Cause

Failed valve in the open position.

Adhesive pressure too high.

Solution

Replace dispense module.

Reduce air pressure to air motor.

Heat rod failure in applicator manifold.

Loose cable connection at system or manifold.

Check resistance on heater rods. Repair applicator manifold if heater rods measure open.

Check cable connections on both ends of the hose.

Adhesive leaking from manifold or dispense module.

No melter heat.

Air motor will not function.

RTD failure.

Incorrect RTD setting in the ADM setup.

Thermal cutoff is tripped.

Dispense module is loose on the manifold.

Dispense module o-ring failed.

Check resistance on the RTD, if out of normal range replace RTD.

Set correct RTD value in the ADM setup screen. Consult manufacturer for correct RTD value.

Measure resistance of the thermal cutoff at room temperature. If open, replace.

Tighten screws on loose dispense module.

Replace o-rings on the back of the leaking dispense module.

Failed dispense module, adhesive leaking out middle of dispense module.

Replace dispense module.

Hose loose.

Tighten hose.

Fuse blown in F1 and F2.

Check heater rods for a short or a short between the rod wires and ground.

Cable to over-temperature switch off or broken.

Over-temperature switch tripped.

No air being supplied to air motor.

Air solenoid not enabling the air motor.

System not turning on.

Air present at air motor but it will not work.

No power to unit.

Check connection of cable to over-temperature switch both to main board and to switch. If connection good, look for break in wire.

Measure over-temperature switch resistance. It should read close to 0 ohms when at room temperature. If open, replace over-temperature switch. Make sure main system power is off when making measurement.

Check incoming air supply. air motor is disabled until system reaches “Active” state. When “Active”, the pump air solenoid should supply air to the air motor.

Check solenoid voltage, if 24VDC present at air solenoid replace air solenoid.

Replace air motor.

Check main power breaker is turned on.

Check that power plug is connected.

56 333347P

Troubleshooting

Problem

Static shock when touching shaker or adhesive bin.

Cause

Ground wire not in place on shaker assembly.

Some adhesives, flow rates, and ambient conditions can cause excessive static buildup on the shaker tube.

Dispense modules opening at the wrong time.

Adhesive not dispensing at the correct time.

Pump and vacuum feed system cycle on and off before temperature setpoint is achieved.

Solenoid connector is installed into the light tower plug on the MZLP daughter board

Solution

Attach a ground wire from the shaft of the shaker unit to a true earth ground.

Order shaker grounding kit 24R708.

InvisiPac system does not control the opening and closing of the applicators.

The separate controller needs to be adjusted. Consult pattern control manufacturer or qualified electrician.

Move solenoid connector from J12 (light tower) to J13 (solenoid valves) on the daughter board on the MZLP.

333347P 57

Troubleshooting

Flush Pressure Relief Valve Check the Pump Air Solenoid Operation

Perform this procedure when directed in the Troubleshooting table.

With the system active at the required adhesive temperature, set the air motor air pressure to 20 psi

(140 kPa, 1.4 bar).

Remove the air line (36) from the pressure relief valve.

Perform this procedure when directed in the Troubleshooting table.

NOTE: System must be up to operating temperature for pump solenoid to trigger on.

If the heating system and pump is disabled,

press to enable the heaters and pump.

Wait for system to reach the temperature setpoints.

Set pump air pressure to 20 psi (140 kPa, 1.4 bar).

Remove the 3/8 in. OD air line from the air motor.

Verify that air is flowing through the air line.

If air is not flowing,

check the wiring between J13 and the pump solenoid.

Check Heater Rod Resistance

Use the table to determine if heater elements need to be replaced.

WLD

. 26

Plug air line and allow the air motor to cycle.

Re-connect air line to relief valve and check whether the system will stall.

If system still does not stall,

purge ten pump cycles of material through one applicator.

Repeat this entire procedure until no additional air is expelled from the applicator.

HM25 HM50

Ref. Element

208

209

Band

Heater

Melter

Rod

210 Base Rod

271 Pump Rod

Wattage Ohms Wattage Ohms

1250

500

1500

41-51

103-127

34-42

2000

1500

1000

26-32

34-42

52-64

58 333347P

Troubleshooting

MZLP Troubleshooting

0 1

456

MZLP

WLD

. 27: MZLP LED Signals

NOTE: The MZLP LED is located on the inside of the electrical enclosure. To view, remove the electrical enclosure front access door.

Signal

Green On

Yellow On

Red Solid

Red Flashing

Description

MZLP is powered up and input voltage is within operating conditions.

Internal communication in process

MZLP failure. See troubleshooting table.

Software update in process or missing software.

. 28: MZLP Diagnostic LED Location

ti20348a

333347P 59

Repair

NOTE: Some procedures require special tools. Read through each procedure prior to beginning it to ensure you have the required tools to complete the entire procedure. Order any required tools and have them on hand prior to beginning the procedure.

NOTICE

When performing any procedure that requires removal of seals or other soft parts, do not leave a system that has not been flushed disassembled for more than 30 minutes to prevent the adhesive from hardening. Hardened adhesive will damage the seals and other soft parts during installation.

Pump

Replace Throat Seal, Throat Bearing, Piston Rod,

Piston Seal, and Piston Bearing

218

240

245

223

226

222

239

235

233

234

238

224

225

WLD

Disassembly (see F

. 29):

Flush the system. See page 38.

Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

Turn main power switch OFF.

Remove plastic shroud (27).

Remove vacuum transfer inlet funnel.

Remove air lines from relief valve (245) and air motor (218).

Remove four nuts (3) securing melter shield (27) in place then remove melter shield.

Remove air motor assembly: a.

Remove retaining ring (239).

Remove dowel pin (238).

Remove three screws (240).

Use a flat head screwdriver and a rubber mallet to break loose the retaining nut (235).

10. Use channel lock pliers to remove the retaining nut (235).

11. Insert an allen wrench through the hole in the top of the piston rod (223) to lift the piston rod (223) up out of the manifold. This will also pull out the throat u-cup (234) and throat bearing (233).

12. Remove piston valve (222) from piston rod (223).

13. Remove and discard piston u-cup (225) and bearing (226).

Reassembly (see F

. 29):

Assemble piston rod: a.

Install new piston u-cup (225) onto piston rod (223) with the lips facing the rod.

Install piston bearing (226) onto piston rod (223) with grooved end towards the center of the piston rod.

. 29

60 333347P

Install piston valve (222) onto piston rod (223).

Torque to 24-30 ft-lb (33-41 N•m).

To protect the seals from the sharp threads, place seal installation tool 15B661 into the throat bore.

See F

. 30.

15B661

203

Repair throat bearing (233) into place and seat the throat u-cup.

235

233 ti20877a

. 30

Push the piston rod assembly (223) into the melter outlet manifold (203).

Grease the throat u-cup (234) and slide the u-cup over the piston rod (223) with the lips facing down.

Place a 7/8 in. deep-well socket (3/8 in. drive) over the piston rod (223) then use a rubber mallet to gen-

tly tap throat u-cup (234) into place. See F

. 31.

ti21144a

. 32

Remove seal installation tool.

Install retaining nut (235). See F

. 30.

Install air motor assembly (see F

. 29):

Install three screws (240).

With retaining ring around piston rod, install dowel pin (238).

Install retaining ring (239) over dowel pin.

10. Use nuts (3) to install melter shield (27).

11. Connect air lines to relief valve and air motor.

12. Install plastic shroud (27).

234 ti21047a

. 31

Slide throat bearing (233) over the piston rod (223).

Use socket and tap with a rubber mallet to press

333347P 61

Repair

Replace Pump Inlet Housing Checks

270

269

203

246

Reassembly (see F

. 33):

Install new o-ring (231), o-ring (229), seat (228), and ball (227) then use a 1/2 in. drive ratchet without a socket to install and tighten foot valve (230) onto melter.

Replace cross over tube (269 using new o-rings

(270). Angled ring faces the melter base.

Apply anaerobic thread sealant on threads of four bolts (246) and connect pump to melter outlet.

Torque to 12-18 ft-lb (16-24 N•m).

227

228

229

231

230

WLE

. 33

Disassembly (see F

. 33):

Flush the system. See page 38.

Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

Turn main power switch OFF.

Remove four bolts (246) and pump manifold (203) from melter outlet.

Remove cross over tube (269) and discard o-rings

(270).

Use a 1/2 in. drive ratchet without a socket to remove foot valve (230) from bottom of melter outlet manifold (203).

Remove and discard seat (228), ball (227), o-ring (229), and o-ring (231).

WLD

62 333347P

Repair

Replace Pump Cylinder Seals and Piston Seals

218

235

233

234

233

224

226

222

203

239

Remove air motor assembly. See F

. 29 on page 60:

Remove retaining ring (239).

Remove dowel pin (238).

Remove three screws (240).

Use a flat head screwdriver and a rubber mallet to break loose the retaining nut (235).

Use channel lock pliers to remove the retaining nut (235).

10. Insert an allen wrench through the hole in the top of the piston rod (223) to lift the piston rod (223) up out of the manifold. This will also pull out the throat u-cup (234) and throat bearing (233).

11. Replace Pump Inlet Housing Checks. See page

62.

12. Use a 1/2 in. drive ratchet without a socket to remove foot valve (230) from bottom of melter outlet

manifold (203). See F

. 34, page 63.

13. Insert cylinder tool (1301) into bottom of melter outlet manifold (203). Use a rubber mallet to gently remove cylinder (216).

217

216

217

230

WLD

. 34

Disassembly (see F

. 29):

Flush the system. See page 38.

Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

Turn main power switch OFF.

Remove plastic shroud (27). See F

. 29 on page 60.

Remove air lines from relief valve (245) and air

motor (218) See F

. 29 on page 60.

Remove nuts (3) securing melter shield (27) in

place then remove melter shield. See F

. 29 on page 60.

1301

203

217

216

217 ti20880a

. 35

14. Remove and discard cylinder seals (217). See F

35.

333347P 63

Repair

Reassembly:

Apply grease to seals (217) then install new cylinder

seals (217) onto cylinder (216). See F

. 35.

1303

217

216

217

1302

203 ti21049a

. 36

Place female cylinder installation tool (1302) into melter outlet manifold (203) to protect seals from sharp threads. See F

. 36.

Use male cylinder installation tool (1303) to press cylinder (216) into melter outlet manifold (203). If necessary, use rubber mallet tap into place. See

. 36.

Use a 1/2 in. drive ratchet without a socket to install and tighten foot valve (230) into bottom of melter

outlet manifold (203). See F

. 34, page 63.

Perform Replace Pump Inlet Housing Checks on page 62.

Perform

Reassembly

portion of the Replace Throat

Seal, Throat Bearing, Piston Rod, Piston Seal,

and Piston Bearing procedure which starts on page 60.

64 333347P

Repair

Melter

Remove Melter Assembly

203

245

218

251

Remove screws (8) then remove electrical enclosure front access door (10).

Disconnect heater rod wires from J4 connector on

AWB board.

Remove the air tube (36) from the relief valve (245).

Pull the air tube from the metal shroud (27).

Remove nuts (3) on the back metal shroud (27) then remove shroud.

10. Remove fabric melter insulator (53).

11. Loosen screw (AA) then remove sensor (125). See

. 40, page 68.

12. Loosen hose clamp (81) then remove funnel (FF).

13. Remove wire connectors from the over-temperature switch (251).

14. Remove insulators (53, 75) from the melter assembly (5).

15. Disconnect the fill sensor cable from the fill

sensor (20). See Replace Fill Sensor, page 73.

16. Disconnect the pump cycle sensor cable from the air motor.

17. Remove the air tube from the air motor (218).

18. Loosen screw (AA) then remove sensor (125). See

. 39 on page 67.

19. Disconnect ground screw (87) and ring terminal (88) from melter assembly.

WLD

. 37

NOTE: This only needs to be done when replacing items that require access to the bottom of the melter assembly.

Perform Drain the System procedure on page 38

then wait for system to cool.

Close the bleed type ball valve at the system air inlet.

Turn main power switch OFF.

Disconnect all heated hoses from the melter outlet manifold.

Remove cable from ADM (30) then slide forward the shroud (29) and remove it from the system.

. 38

WLD

20. Remove electrical enclosure front access door (10).

333347P 65

Repair

21. Remove all heater wires from the following terminals. Pull wires up through the rubber grommet on the top of the electrical enclosure (1).

Item

Band Heater (208)

Melter Heater Rod

(209)

Wire Marking

J4-1

J4-5

Base Heater Rod (210) J4-7

Pump Heater Rod (271) J4-3

J4-2

J4-6

J4-8

J4-4

22. Remove four nuts (3) then remove melter assembly from system. Save any loose insulators for reassembly.

23. Remove bolts (259), insulators (249), washers

(268), and melter assembly from base (257).

Install Melter Assembly

Route melter heater rod (209) wire through large hole in the melter base (257) then through small hole in side of melter base (257).

With the 10 insulators (4) in place on the melter assembly, place melter assembly on melter base (257).

NOTICE

To prevent crushing the soft insulators (4), do not overtighten the 4 bolts (259) in the following step.

Torque to 5-11ft-lb (7-15 N•m).

Use 4 bolts (259) to secure washers (268) and melter assembly to melter base (257).

Use four nuts (3) to secure melter assembly to system.

Group the 4 sets of heater wires together and run them through the grommet on the top of the electrical enclosure (1). Connect wires as noted below.

Item

Wire Marking

Band Heater (208) J4-1

Melter Heater Rod (209) J4-5

Base Heater Rod (210) J4-7

Pump Heater Rod (271) J4-3

J4-2

J4-6

J4-8

J4-4

Connect air tube to air motor (218).

Connect fill sensor cable to the fill sensor (20).

Connect pump cycle sensor cable to air motor.

Install funnel (FF) then tighten clamp (81).

10. Install temperature sensor (125) into melter then

tighten screw (AA) on band heater. See F

. 39 on page 67.

11. Install insulators (53,75) onto the melter assembly (5).

12. Connect ground wire ring terminal (87) and ground screw (88) to melter assembly (5).

13. Connect wire connectors to the over-temperature

switch (251). See F

. 41 on page 69.

14. Use nuts (3) to install metal shroud (27).

15. Pull the relief valve air tube (36) through the metal housing then attach air tube to relief valve (245).

16. Install front access door (10) onto electrical enclosure (1).

17. Feed ADM cable through shroud then install shroud and connect cable to ADM.

18. Reconnect all heated hoses to the melter outlet manifold (203).

19. Turn main power switch ON.

20. Open system air inlet ball valve.

66 333347P

Repair

Replace Band Heater

125

208

WLD

. 39

Disassembly (see F

. 39):

Once the fluid level is low enough, close the bleed-type ball valve installed at the system air inlet.

Turn main power switch OFF.

Disconnect cable from ADM (30) then remove shroud (29).

Remove front access door (10) from electrical enclosure (1).

Remove fabric melter insulators (53).

While system is still near operating temperature, loosen clamp (80) and then remove screws (8) and funnel assembly (F). When removing rubber housing from melter, separate rubber from melter by pressing on inside surface.

Loosen screw (AA) then remove sensor (125).

Locate the J4-1 and J4-2 wires in AWB board and remove wires.

Pull wires up through grommet (63) on top of the electrical enclosure (1). Clip any wire ties that hold the wires in place.

10. Continue loosing screw (AA) then slide band heater (208) up to remove.

Reassembly (see F

. 39):

Install band heater (208) on the melter with the opening and screw facing the front of the system in alignment with the sensor port.

Install sensor (125).

Slide band heater up then tighten screw (AA).

NOTE: Band heater should be oriented to hold sensor in place when tightened. It should not bend the sensor.

Route band heater wires through grommet (63) in the top of the electrical enclosure (1).

Connect wires to AWB board as marked. Wires should be marked as shown in the following table.

Item

Band Heater (208)

Wire

Marking 1

J4-1

Wire

Marking 2

J4-2

Install electrical enclosure access door (10). See

. 39.

Use clamp (80) and screws (8) to install funnel assembly (F) on melter assembly. Ensure rubber housing is fully seated on melter or incorrect refilling may occur. Tighten band clamps to 25 in-lbs.

Install fabric melter insulator (53).

Feed ADM cable through shroud then install shroud and connect cable to ADM.

10. Open system air inlet ball valve.

11. Turn main power switch ON.

333347P 67

Repair

Replace Band Heater Temperature Sensor

125

WLD

. 40

Disassembly (see F

. 40):

Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

Turn main power switch OFF.

Disconnect cable from ADM then remove shroud.

Remove air tube (36) from relief valve. Pull the air tube through the metal shroud (27).

Remove nuts (3) then remove metal shroud (27).

Use nuts (3) to install metal shroud (27). See F

. 37, page 65.

Remove fabric melter insulator (53).

Loosen screw (AA) then remove sensor (125).

Remove electrical enclosure access door (10).

Disconnect the temperature sensor cable from

MZLP connector labeled J5. See F

. 40.

NOTE: This connector also includes the over-temperature switch wires.

10. Disconnect wire connectors from over-temperature

switch (251). See F

. 41 on page 69.

11. Pull cable out of the electrical enclosure then discard sensor (125) and wires.

Reassembly (see F

. 40):

Route new harness wires through grommet (63) in the top of the electrical enclosure.

Connect wire connectors to over-temperature

switch (251). See F

. 41 on page 69.

Place band heater temperature sensor (125) in melter.

Tighten screw (AA).

NOTE: Screw should lightly squeeze the temperature sensor to hold it in place. It should not bend the sensor.

Connect new harness to MZLP connector labeled

J5.

Install electrical enclosure access door (10). See

. 39 on page 67.

Install fabric melter insulator (53).

37, page 65.

Route relief valve air tube through the metal shroud then attach to the relief valve.

10. Feed ADM cable through shroud then install shroud and connect cable to ADM.

11. Turn main power switch ON.

12. Open system air inlet ball valve.

68 333347P

Replace Heater Over-Temperature Switch

Repair

Feed ADM cable through shroud then install shroud and connect cable to ADM.

Open system air inlet ball valve.

Turn main power switch ON.

Replace Heater Rod

251

255 ti21052a

. 41

Disassembly (see F

. 41):

Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

Turn main power switch OFF.

Disconnect cable from ADM then remove shroud.

Remove air tube (36) from relief valve. Pull the air

tube through the metal shroud (27). See F

. 43, page 70.

Use 7/16 in. socket to remove nuts (3) then remove metal shroud (27).

Disconnect the wire connectors from the over-temperature switch (251).

Remove the screws (255) securing the over-temperature switch (251) to the melter assembly (5), then remove the switch.

Re-assembly (see F

. 41):

Use the two screws (255) to secure the new over-temperature switch (251) to the melter.

Connect wire connectors to new over-temperature switch.

Use 7/16 in. socket to install nuts (3) to secure metal shroud (27).

Route relief valve air tube (36) through the metal shroud then attach to the relief valve.

206

210

206

271

209

206

209

WLD

. 42

Disassembly (see F

. 42):

NOTE: This procedure is for replacing any of the above heater rods.

Turn main power switch OFF.

If replacing the melter heater rod (209),

Remove

Melter Assembly. See page 65.

Disconnect cable from ADM then remove shroud (29).

333347P 69

Repair

If removing the pump heater rod (271)

: a.

Remove the air tube (36) from the relief valve (245). Pull the air tube through the metal shroud (27).

Remove nuts (3) then remove shroud (27).

Remove electrical enclosure front access door (10).

Melter Assembly. See page 65.

. 39, page 67.

Disconnect heater rod wires from terminal blocks described in the following table.

Item Wire Marking 1 Wire Marking 2

Band Heater (208) J4-1

Melter Heater Rod (209) J4-5

Base Heater Rod (210) J4-7

Pump Heater Rod (271) J4-3

J4-2

J4-6

J4-8

J4-4

Feed ADM cable through plastic shroud then install plastic shroud and connect cable to ADM.

Replace Fluid Pressure Relief Valve

Pull heater rod wires up through the grommet in the top of the electrical enclosure (1).

Remove heater rod retaining ring (206) then remove and discard heater rod (209, 210, 271).

Reassembly (see F

. 42):

Route new heater rod cable through grommet (63) in top of electrical enclosure then connect new heater rod wires to terminal blocks as described in the previous table.

NOTICE

To prevent damaging the heater rod, do not use thermal grease in the following step.

Install heater rod then install heater rod retaining

ring (206). See F

. 42.

Install electrical enclosure access door (10). See

. 39, page 67.

If replacing the melter heater rod (209),

Install

If replacing pump heater rod (271),

feed ADM cable through shroud then install shroud and connect cable to ADM.

If installing the pump heater rod (250),

install the metal shroud (27): a.

Place metal shroud on system.

Install and tighten nuts (3).

Pull the air tube through the metal shroud (27) then connect the air tube (36) to the relief valve (245).

244

245 ti20757a

. 43

Drain the System. See page 38.

Close the system air inlet ball valve.

Turn main power switch OFF.

Remove the air tube (36) from the relief valve (245).

Pull the air tube through the metal shroud (27). See

. 43.

Remove nuts (3) then remove shroud (27).

Use crescent wrench to remove melter fluid pres-

sure relief valve (245). See F

. 43.

Use an o-ring pick to remove o-ring (244).

Install o-ring (244) into manifold.

NOTICE

To prevent damage to o-ring, ensure o-ring is seated properly prior to moving to next step.

Thread new fluid pressure relief valve (245) into

manifold. See F

. 43. Once hand-tight, use cres-

cent wrench to tighten.

10. Use nuts (3) to install metal shroud.

11. Connect air tube to pressure relief valve.

12. Feed ADM cable through plastic shroud then install shroud and connect cable to ADM.

333347P

Repair

Multi-Zone Low Power Temperature Control Module (MZLP)

Replace MZLP Fuse

Fuse Part

24V510 MZLP Fuses

F1, F2 250VAC, 25A, fast acting, white, 0.25 in x 1.2 in

F3-F10 250VAC, 8A, fast acting

MZLP Identification

24V510

Fuse Kits

Kit

24V289

24X480

MZLP

24V510

Description

Includes standard clear fuses.

Includes ceramic fuses used for food industries.

Key

F1 and F2 fuses are physically larger than F3-F10

Yellow sticker on relay

Marked 24V133

Turn main power switch OFF.

Remove electrical enclosure front access door (10).

Use a proper non-conductive fuse puller tool to remove the blown fuse.

NOTICE

Using an improper tool, such as screw drivers or pliers may break glass on fuse.

NOTE: F1 and F2 are white ceramic and indicate 25A on the barrel.

NOTE: F3-F10 are clear glass and indicate 8A on the barrel.

Install electrical enclosure front access door (10).

C

F10 F9 F8 F7

F4 F3

A

B

WLD

. 44: MZLP ID and Fuse Locations

NOTICE

To prevent system damage, always use fast acting fuses. Fast acting fuses are required for short-circuit protection.

333347P 71

Repair

Replace MZLP

Disassembly:

Turn main power switch OFF.

Remove electrical enclosure front access door (10).

Disconnect heated hose electrical connectors from outside of MZLP (112).

Note location of each cable, then unplug all cables from the MZLP (112) that will be replaced. See F

45.

Remove four screws (114) securing MZLP (112) to electrical enclosure (1) then carefully remove MZLP from electrical enclosure. See F

. 45.

Apply channel label stickers to new MZLP. See F

45.

Use four screws (114) to install MZLP (112) to electrical enclosure (1).

Reconnect cables to MZLP (112).

NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation.

NOTE: If unable to determine connector location, see

Electrical Schematics on page 82.

Install electrical enclosure front access door (10).

Connect heated hose electrical connectors to new

MZLP.

NOTE: MZLP may need updated software. See Soft-

ware Update Procedure on page 81.

Replace MZLP Daughter Card

MZLP

114

112

. 45

Replace MZLP. See F

. 45 for MZLP #1, MZLP #2, and MZLP #3 identification.

To replace MZLP #1, remove the daughter card and standoffs, and re-install them on the new

MZLP #1.

To replace MZLP #3, remove the jumper (135) from MZLP #3 J5 connector and reinstall it on the new MZLP #3 J5 connector.

Reassembly:

Set MZLP rotary switch to “1” on MZLP with daughter card. Set MZLP rotary switch to “2” or “3” on MZLP without daughter card, based on location.

See F

. 46 for rotary switch location.

Disassembly:

Turn main power switch OFF.

Remove electrical enclosure front access door (10).

Note location of each cable then unplug all cables from MZLP daughter card (112a).

Remove four mounting screws (112b) from daughter card (112a) and set aside.

112b

112a ti20342a

112

Rotary Switch

. 46

Unplug daughter card (112a) from the MZLP

#1 (112).

72 333347P

Repair

Reassembly:

Plug new daughter card (112a) into the MZLP (112).

Use screws (112b) to secure daughter card to

MZLP (112).

Connect cables to new daughter card (112a).

NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation.

NOTE: If unable to determine connector location, see

Electrical Schematics on page 82.

Install electrical enclosure front access door (10).

System

Replace Fill Sensor

Gently pull up on cable while unscrewing fill sensor connector then remove fill sensor cable from fill sensor (20).

Loosen fill sensor jam nut then remove fill sensor (20) from sensor housing (73).

Reassembly (see F

. 47):

Thread new fill sensor (20) into sensor housing (73).

Bottom out the sensor in the sensor housing then back out 1/2 turn.

Tighten jam nut on fill sensor (20).

Connect fill sensor cable to new fill sensor (20).

Replace filter element and cover (68).

Replace ADM

WLD

. 47

Disassembly (see F

. 47):

Turn main power switch OFF.

Remove filter cover (68) and filter element.

333347P ti20763a

. 48

Turn main power switch OFF.

Disconnect cable (CC) from bottom of ADM (30).

NOTE: ADM may need updated software. See Soft-

. 48.

Remove ADM from bracket (58).

Install new ADM into bracket.

Connect cable to bottom of new ADM.

ware Update Procedure on page 81.

Repair

Replace AWB

144

145

146

131

145

131

. 49: AWB and Power Supply

Disassembly:

Turn main power switch OFF.

Note location of each cable, then unplug all cables

from the AWB. See Electrical Schematics, page

82.

Remove 2 screws (131) securing AWB (143) to electrical enclosure (1) then carefully remove AWB.

Remove power supply (146) from power supply bracket (145) by releasing mounting tab on the side

of the power supply. See F

Remove two screws (144) securing power supply bracket (145) to AWB (143) and remove power sup-

ply bracket. See F

bracket (145) to new AWB (143). See F

Reassembly:

Use two screws (144) to secure power supply

Mount power supply (146) to power supply bracket

(145). See F

ply harness (147) to J1 on AWB (143). See Electri-

Connect connector (labeled AWB-J1) on power sup-

cal Schematics, page 82.

Use two screws (131) to install AWB (143) to electri-

cal enclosure (1). See F

see Electrical Schematics, page 82.

Reconnect cables to AWB (143).

NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation.

NOTE: If unable to determine the connector location,

Install electrical enclosure front access door (10).

74 333347P

Repair

Replace Power Supply Replace Power Supply Harness

Disassembly:

Turn main power switch OFF.

Remove electrical enclosure front access door (10).

Remove power supply (146) from power supply bracket (145) by releasing mounting tab on the side

of the power supply. See F

according to the following table. See F

Disconnect screw terminal connections between power supply (146) and power supply harness (147)

Power Supply

Connection

V+

V-

GND

Reassembly:

Harness Label

V+

V-

GND

Make connections between power supply harness

(147) and new power supply (146) according to the following table:

Reattach power supply (146) to power supply

bracket (145). See F

AWB (143). See Electrical Schematics, page 82.

Install electrical enclosure front access door (10).

Disassembly:

Turn main power switch OFF.

Remove electrical enclosure front access door (10).

Disconnect screw terminal connections between power supply (146) and power supply harness (147) according to the following table.

Power Supply

Connection

V+

V-

GND

Harness Label

V+

V-

GND

Unplug power supply harness (147) from J1 on

Reassembly:

Make connections between power supply harness

(147) and new power supply (146).

Connect connector (labeled AWB-J1) on power sup-

ply harness (147) to J1 on AWB (143). See Electri-

cal Schematics, page 82.

Install electrical enclosure front access door (10).

333347P 75

Repair

Air Controls

402

405

Replace Air Control Solenoids

NOTE: In order to replace the air control solenoids, the system must be tipped back to access underneath the electrical enclosure.

Disassembly (see F

. 50):

Turn main power switch OFF.

Disconnect plug from power outlet or turn off circuit breaker for incoming power.

Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

Remove front access panel (10) from electrical enclosure (1).

Remove the transformer assembly; for 480V systems only

(see F

. 51)

: a.

Disconnect transformer wires from J2 connector on AWB board and the main power switch.

Remove three screws (142) and InvisiPac system off of transformer assembly (140).

Use 3/8 in. socket to remove two screws (8).

Note location of each air line connection.

Insert hands through access holes (FF), see F

50, in bottom of electrical enclosure then disconnect

air lines from air control solenoids (402).

Disconnect air control solenoids cable from MZLP daughter board connector J13. Pull wire out of the electrical enclosure.

10. Remove two screws (405) securing solenoids (402) to air control assembly (9) then remove air control solenoids.

. 50

142

140

WLD

. 51

Reassembly (see F

. 50):

Use two screws (405) to secure new solenoids (402) to air control assembly (409).

Feed the new solenoid cable into the electrical enclosure and attach cable to MZLP daughter board connector J13.

Insert hands through access holes (FF), see F

50, in bottom of electrical enclosure then connect air

lines to air control solenoids (402).

Slide air control assembly (9) into place then use two screws (8) to secure to electrical enclosure (1).

For 480V systems, install transformer assembly

(140) with screws (142) and reconnect transformer wires to J2 connector on AWB board and the main power switch.

Install electrical enclosure front access door.

333347P

Repair

Replace Air Control Gauge

NOTICE

In the following step, do not overtighten the two nuts (403a). Overtightening may cause the gauge to break.

403a

403c

403

9 4.

Orient gauge as desired then tighten two nuts (403a) to secure gauge (403) in place.

Slide air control assembly (9) into place then use two screws (8) secure to electrical enclosure.

Air Motor

Replace Pilot Valve

403b

WLD

. 52

Disassembly (see F

. 52):

Turn main power switch OFF.

Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

Remove two screws (8) then slide air control assembly (9) out from electrical enclosure (1) so the back of the gauges are exposed.

Remove two nuts (403a) securing gauge (403) in place then remove bracket (403c).

Place one small crescent wrench on the brass part of the gauge then use a second small crescent wrench to remove the air fitting (403b).

Remove air gauge from panel.

Reassembly (see F

. 52):

Slide new air gauge into panel and slide the bracket onto the back of the gauge. Install air fitting onto the gauge by hand, do not tighten yet.

Install bracket (403c) then install two nuts (403a) finger tight.

Place one small crescent wrench on the brass part of the gauge then use a second small crescent wrench to tighten the air fitting (403b).

511

218

WLD

. 53: Top Pilot Valve

Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

Turn main power switch OFF.

Replace top pilot valve (511): a.

Use crescent wrench to remove rod cover (C).

Use 10 mm socket to remove air motor pilot valve (511) from air motor (218).

Lubricate with grease and install new air motor pilot valve (511).

Torque pilot valve to 95-105 in-lb (10.7-11.9

N•m).

Replace bottom pilot valve (511):

333347P 77

Repair

218

511

WLD

. 54: Bottom Pilot Valve

Remove cover (29) and insulation (6).

Use 10 mm socket to remove air motor pilot valve (511) from air motor (218).

Lubricate with grease and install new air motor pilot valve (511).

Torque pilot valve to 95-105 in-lb (10.7-11.9

N•m).

Replace insulation (6) and cover (29).

Replace Air Valve

218

507

512

509

Turn main power switch OFF.

Loosen clamp on air motor bracket (528) then remove funnel assembly (61).

Loosen upper hose clamp on rubber housing then remove fill cap.

Dispense until the fluid level in the melter is at or below the honeycomb grid.

NOTE: If a screw or air valve seal is dropped during this procedure it could fall into the melter. Melter fluid level must be below honeycomb grid before moving to next step.

Once the fluid level is low enough, close the bleed-type ball valve installed at the system air inlet.

Disconnect air hose and cable from the air motor.

Use 10 mm socket to remove four screws (509) securing air valve (512) to air motor (218).

Remove air valve (512) and seal (507) then discard.

Reassembly (see F

. 55):

Lubricate with grease then place new air valve seal (507) onto air valve (512).

Carefully place new air valve (512) against air motor then thread in the four screws (509). Ensure the air valve seal (507) stays in place by applying constant pressure against the air motor.

Use 10 mm socket to torque screws (509) to

95-105 in-lb (10.7-11.9 N•m).

Install fill cap then tighten upper hose clamp on rubber housing.

Connect air hose and cable to the air motor.

. 55

Disassembly (see F

. 55):

Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

78 333347P

Repair

Remove Air Motor

218

239

220

240

219

211

238

WLD

. 56

Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

Turn main power switch OFF.

Disconnect air line (36) from pressure relief valve (245) then pull through metal shroud (27). See

. 43 on page 70.

Remove three nuts (3) securing metal shroud (27) in place then remove metal shroud (27).

Disconnect air supply line from air motor (218).

Remove air motor assembly: a.

Slide retaining ring (239) down.

Remove dowel pin (238).

Remove three screws (240).

Remove screws (8), screws (74), and bracket

(82).

7. If replacing a damaged air motor with a new fully assembled air motor:

Remove three screws (211) securing air motor tie rods (220) to base plate (219).

Remove tie rods (220) from air motor (218).

Install Air Motor