InvisiPac HM25 and HM50 Tank-Free Hot Melt Delivery System

InvisiPac HM25 and HM50 Tank-Free Hot Melt Delivery System

Instructions - Parts

InvisiPac

HM25 and HM50 Tank-Free

Hot Melt Delivery System

333347P

EN

For delivering and dispensing hot melt adhesive pellets. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

1200 psi (8.3 MPa, 83 bar) Maximum Working Pressure

400°F (204°C) Maximum Fluid Operating Temperature

100 psi (0.7 MPa,7 bar) Maximum Air Inlet Pressure

Important Safety Instructions

Read all warnings and instructions in this manual and in the applicator and hose manuals. Save all instructions. ti22732

9902471

Certified to

CAN/CSA C22.2 No. 88

Conforms to

ANSI/UL 499

2

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Component Identification . . . . . . . . . . . . . . . . . . . 12

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Attach Components . . . . . . . . . . . . . . . . . . . . . 17

Recommended Air Setup . . . . . . . . . . . . . . . . . 21

Connect Electrical Cord . . . . . . . . . . . . . . . . . . 22

208V Electrical Circuits . . . . . . . . . . . . . . . . . . . 23

Select ADM Settings . . . . . . . . . . . . . . . . . . . . . 23

Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

PLC Connection . . . . . . . . . . . . . . . . . . . . . . . . 26

Material Tracking . . . . . . . . . . . . . . . . . . . . . . . 28

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Initial Startup and Prime . . . . . . . . . . . . . . . . . . 32

Manual Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Automatic Refill . . . . . . . . . . . . . . . . . . . . . . . . . 35

Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pressure Relief Procedure . . . . . . . . . . . . . . . . 37

Drain the System . . . . . . . . . . . . . . . . . . . . . . . 38

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Operation Tips to Minimize Charring . . . . . . . . 40

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Replace Outlet Filter . . . . . . . . . . . . . . . . . . . . . 41

Replace Inlet Filter . . . . . . . . . . . . . . . . . . . . . . 41

Replace Funnel Filter . . . . . . . . . . . . . . . . . . . . 42

Filter Maintenance Guidelines* . . . . . . . . . . . . . 43

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 44

ADM Error Code Table . . . . . . . . . . . . . . . . . . . 44

MZLP Troubleshooting . . . . . . . . . . . . . . . . . . . 59

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Multi-Zone Low Power Temperature Control Module

(MZLP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Transformer Fan . . . . . . . . . . . . . . . . . . . . . . . . 80

Software Update Procedure . . . . . . . . . . . . . . . 81

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 82

Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . 82

Cable Identification . . . . . . . . . . . . . . . . . . . . . . 82

Air Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Preventive Maintenance Kits . . . . . . . . . . . . . . 107

Complete Maintenance Kits . . . . . . . . . . . . . . . 107

Non-Graco Applicator Adapter Cables . . . . . . 108

Air Adjustment Lock, 24R084 . . . . . . . . . . . . . 109

Feed Sensor Dedicated Air Kit, 17F699 . . . . . 109

System Stand, 24R088 . . . . . . . . . . . . . . . . . . 110

Caster for Stand, 120302 . . . . . . . . . . . . . . . . 110

Adapter Plate, 24R083 . . . . . . . . . . . . . . . . . . 110

Air Reservoir Kit, 16W366 . . . . . . . . . . . . . . . . 112

ADM Extension Kits . . . . . . . . . . . . . . . . . . . . . 117

ADM Remote Mount Bracket, 24A326 . . . . . . 117

Air Metric Fitting Kit, 24W637 . . . . . . . . . . . . . 118

Strain Relief Bushing Kit, 24X190 . . . . . . . . . . 118

Hose Straps (4 Pack), 240296 . . . . . . . . . . . . 118

Pressure Gauge Replacement Kit, 24U635 . . 118

400VAC and 480VAC Transformer Kits . . . . . 119

Adapter Cable . . . . . . . . . . . . . . . . . . . . . . . . . 119

Appendix A - ADM . . . . . . . . . . . . . . . . . . . . . . . . 120

General Operation . . . . . . . . . . . . . . . . . . . . . . 120

Icon Identification . . . . . . . . . . . . . . . . . . . . . . . 120

Appendix B - USB Downloading, Uploading . . . 126

Download Procedure . . . . . . . . . . . . . . . . . . . . 126

Accessing Files . . . . . . . . . . . . . . . . . . . . . . . . 126

Upload Procedure . . . . . . . . . . . . . . . . . . . . . . 126

USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

System Settings File . . . . . . . . . . . . . . . . . . . . 127

System Language File . . . . . . . . . . . . . . . . . . . 128

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Graco Extended Warranty . . . . . . . . . . . . . . . . . . 136

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 136

333347P

Related Manuals

Manuals are available at www.graco.com. Component manuals in English:

Part Description

334629 InvisiPac Advanced Feed System

334627 InvisiPac GM100 Plug-Free Hot Melt Applicator

3A4937 InvisiPac HM25c Feed System

3A2805 InvisiPac GS35 Hot Melt Applicator Instructions - Parts

332072 InvisiPac Heated Hose Instructions - Parts

333348 MZLP Fuse Kit, Instructions

333349 InvisiPac 480V Transformer Upgrade Kit, Instructions-Parts

334784 InvisiPac Pattern Controller, Operations-Repair-Parts

335010 Dedicated Feed Sensor Air Kit

Required Tools

• Standard allen wrench set

• Metric allen wrench set

• Various sizes of crescent wrenches

• 11/16 in. wrench

• 3/8 in. ratchet

• 3/8 in. socket

• 5/16 in. driver

• 7/16 in. socket

• 7/8 in. deep well socket

• 1 in. socket

• 13 mm socket

• 10 mm socket

• 1/2 in. ratchet

• Side cutter

• Phillips head screwdriver

• Flat head screwdriver

• Multimeter

• Tubing cutter

Related Manuals

333347P 3

4

Models

Models

Feed Systems

Part

25C193

Usage

For use in standard pellet feed applications

17D749

WLD

For use in chicklet feed applications

24N957

WLD

WLD

For use in standard pellet feed applications with separate feed bin or bulk container

333347P

200-240 VAC, 350-415 VAC HM50 Models

System Channels Voltage

Φ

Type

Description Max Amps

1-Phase

200-240

VAC

1

Φ

/ PE

2 wire and PE

50/60 Hz

3-Phase without Neutral

32A

24T918

24Y114*

2

200-240

VAC

Δ

3

Φ

/ PE

3 wire and PE

50/60 Hz

3-Phase with Neutral

350-415 VAC Line to Line

200-240 VAC Line to Neutral

27A

300-415

VAC Y

3

Φ

/ Neutral / PE

16A

3 wire, Neutral, and PE

50/60 Hz

1-Phase

200-240

VAC

1

Φ

/ PE

2 wire and PE

50/60 Hz

3-Phase without Neutral

40A

24T919

24Y115*

4

200-240

VAC

Δ

3

Φ

/ PE

3 wire and PE

50/60 Hz

3-Phase with Neutral

350-415 VAC Line to Line

200-240 VAC Line to Neutral

27A

300-415

VAC Y

3

Φ

/ Neutral / PE

16A

3 wire, Neutral, and PE

50/60 Hz

1-Phase

200-240

VAC

1

Φ

/ PE

2 wire and PE

50/60 Hz

3-Phase without Neutral

40A

24T920 6

200-240

VAC

Δ

3

Φ

/ PE

3 wire and PE

50/60 Hz

3-Phase with Neutral

350-415 VAC Line to Line

200-240 VAC Line to Neutral

40A

300-415

VAC Y

3

Φ

/ Neutral / PE

30A

3 wire, Neutral, and PE

50/60 Hz

* System comes with internal PC-8 pattern controller installed. To upgrade to PC-8e, order kit PN 17F712.

Models

333347P 5

6

Models

200-240 VAC, 350-415 VAC HM25 Models

System Channels Voltage

Φ

Type Description

1-Phase

200-240

VAC

1

Φ

/ PE

2 wire and PE

50/60 Hz

3-Phase without Neutral

24V423

24Y102*

2

200-240

VAC

Δ

300-415

VAC Y

3

Φ

/ PE

3

Φ

/ Neutral / PE

3 wire and PE

50/60 Hz

3-Phase with Neutral

350-415 VAC Line to Line

200-240 VAC Line to Neutral

3 wire, Neutral, and PE

50/60 Hz

1-Phase

200-240

VAC

1

Φ

/ PE

2 wire and PE

50/60 Hz

3-Phase without Neutral

24V424

24Y103*

4

200-240

VAC

Δ

300-415

VAC Y

3

Φ

/ PE

3

Φ

/ Neutral / PE

3 wire and PE

50/60 Hz

3-Phase with Neutral

350-415 VAC Line to Line

200-240 VAC Line to Neutral

3 wire, Neutral, and PE

50/60 Hz

1-Phase

200-240

VAC

1

Φ

/ PE

2 wire and PE

50/60 Hz

3-Phase without Neutral

24V425 6

200-240

VAC

Δ

300-415

VAC Y

3

Φ

/ PE

3

Φ

/ Neutral / PE

3 wire and PE

50/60 Hz

3-Phase with Neutral

350-415 VAC Line to Line

200-240 VAC Line to Neutral

3 wire, Neutral, and PE

50/60 Hz

Max Amps

32A

27A

16A

40A

27A

16A

40A

40A

30A

* System comes with internal PC-8 pattern controller installed. To upgrade to PC-8e, order kit PN 17F712.

333347P

400 VAC Transformer HM25 Models

System Channels Voltage

Φ

Type

24V246

24Y104*

24V427

24Y105*

24V428

2

4

6

335-400

VAC

335-400

VAC

335-400

VAC

3

Φ

/ PE

3

Φ

/ PE

3

Φ

/PE

Description

3-Phase without Neutral

3wire and PE

50/60 Hz

3-Phase without Neutral

3 wire and PE

50/60 Hz

3-Phase without Neutral

3 wire and PE

50/60 Hz

Max Amps

17A

17A

17A

400 VAC Transformer HM50 Models

System Channels Voltage

Φ

Type

24V198

24Y116*

24V199

24Y117*

24V200

2

4

6

335-400

VAC

335-400

VAC

335-400

VAC

3

Φ

/ PE

3

Φ

/ PE

3

Φ

/PE

Description

3-Phase without Neutral

3wire and PE

50/60 Hz

3-Phase without Neutral

3 wire and PE

50/60 Hz

3-Phase without Neutral

3 wire and PE

50/60 Hz

Max Amps

17A

17A

17A

* System comes with internal PC-8 pattern controller installed. To upgrade to PC-8e, order kit PN 17F712.

Models

333347P 7

8

Models

480 VAC Transformer HM25 Models

System Channels Voltage

Φ

Type

24V429

24Y106*

24V430

24Y107*

24V431

2

4

6

400-480

VAC

400-480

VAC

400-480

VAC

3

Φ

/ PE

3

Φ

/ PE

3

Φ

/PE

Description

3-Phase without Neutral

3wire and PE

50/60 Hz

3-Phase without Neutral

3 wire and PE

50/60 Hz

3-Phase without Neutral

3 wire and PE

50/60 Hz

Max Amps

14A

14A

14A

480 VAC Transformer HM50 Models

System Channels Voltage

Φ

Type

24V201

24Y118*

24V202

24Y119*

24V203

2

4

6

400-480

VAC

400-480

VAC

400-480

VAC

3

Φ

/ PE

3

Φ

/ PE

3

Φ

/PE

Description

3-Phase without Neutral

3wire and PE

50/60 Hz

3-Phase without Neutral

3 wire and PE

50/60 Hz

3-Phase without Neutral

3 wire and PE

50/60 Hz

Max Amps

14A

14A

14A

* System comes with internal PC-8 pattern controller installed. To upgrade to PC-8e, order kit PN 17F712.

333347P

Warnings

+

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or

servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,

follow the Pressure Relief Procedure and disconnect all power sources.

333347P 9

10

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Do not use solvent-based adhesives that can create an explosive atmosphere when processed.

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

333347P

333347P

Warnings

WARNING

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

11

Component Identification

Component Identification

A

F

IG

. 1

12

AD

F

E

C

D

Key:

A Advanced Display Module (ADM)

B Electrical Enclosure

C Pump Air Pressure Regulator

D Pump Air Pressure Gauge

E Vacuum Transfer Air Pressure Regulator

F Vacuum Transfer Air Pressure Gauge

H Main Power Switch

J System Air Inlet

L Air Motor and Pump

M Incoming Power Strain Relief

N Heated Fluid Manifold (Melter)

P Multi-Zone Low Power Temperature Control Module (MZLP)

R Fluid Outlets for connection to Heated Hoses (numbered 1-6)

S Customer I/O Cable (optional)

AC Drain Port

AD Transformer (optional)

R

AC

P

B

H ti23594

G3

WLD

J

S

333347P

L

N

M

Component Identification

Heated Fluid Manifold

AB

U

R

Y

X

AA

T

NOTE: System shown with plastic and metal shrouds removed.

F

IG

. 2

Key:

T Electrical Enclosure Front Access Door

U Melter

W1 Drain Port

W2 Drain Tray

X Inlet Filter (Low Pressure - Before Pump)

Y Outlet Filter (High Pressure - After Pump)

Z Adhesive Pellets Level Sensor (not shown; inside funnel)

AA Power and RTD Harness Connection to Heated Hose and

Applicator (harness connects from system to heated hose then from heated hose to applicator)

AB Inlet Funnel Screen

WLD

W1

W2

333347P 13

Component Identification

Electrical Enclosure

F

IG

. 3

Key:

P Multi-Zone Low Power Temperature Control Module

(MZLP)

AC Incoming Power Connection

AF Chassis Ground

AG Automatic Wiring Board (AWB)

WLD

AF

AG

P

AC

14 333347P

Component Identification

Advanced Display Module (ADM)

User Interface

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 400VAC and 480VAC Transformer Kits on page 119 for complete ADM operation details.

BK

BL

BB

BA

BH

BG

TI12362a1

F

IG

. 4

B

Key Function

BA Heating system and pump enable/disable

BB System status indicator (LED)

BC Stop all system processes

BD Defined by icon next to softkey

BE Abort current operation

BF Accept change, acknowledge error, select item, toggle selected item

BG Toggle between Operation and Setup screens

BH Navigate within a screen or to a new screen

BC

BD

BE

BF

BM

BR

BN

BP

F

IG

. 5

Key:

BK Part Number Identification Label

BL USB Interface

BM CAN Cable Connection (Power Supply and Communication)

BN Module Status LEDs

BP (Not used)

BR Software Token Access Panel

333347P 15

Component Identification

Screen Components

F

IG

. 6: Main Screen Components

Operating Mode

System Off

Inactive

Warm Up

Active

Description

The system doesn’t have power.

The heating system and pumps are disabled.

The system is heating the material to the set temperature.

The system is ready to dispense material.

Component Status

• No System Status Indicator LED on the

ADM

• No heat

• Pump is off

• Yellow system status indicator LED on the

ADM

• No heat

• Pump is off

• Flashing green system status indicator LED on the ADM

• Heat is increasing to setpoint temperature

• Pump is off

• Solid green system status indicator LED on the ADM

• Heat is at setpoint temperature

• Pump is on

16 333347P

Setup

Setup

Grounding Attach Components

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode.

Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

The InvisiPac system is equipped with a ground terminal. A qualified electrician must ground the system using

this terminal. See Connect Electrical Cord on page 22.

To reduce the risk of electric shock, do not connect

electrical cord until after this Attach Components

procedure is complete.

NOTE: Only systems with transformers are supplied with a lifting strap.

NOTICE

To prevent strain on electrical or mechanical connections around the pump assembly, loop the strap around the tie rods as shown.

Location

Ambient temperature must be 32-120°F (0-49°C).

The supplied vacuum transfer hose length is 10 ft (3 m).

The maximum vacuum transfer hose length available is

30 ft (9.1 m). The adhesive pellets container must be located within reach of the vacuum transfer hose and no more than 30 ft (9.1 m) away.

The applicator(s) must be located no more than 25 ft

(7.6 m) from the melter.

Place the base system on a surface that is eye-level for

easiest operation. Use System Stand, 24R088, to install system at eye-level. See page 110.

If installing the system in place of a non-Graco hot melt

system, purchase Adapter Plate, 24R083. See page 110.

To make repairing the system easier, locate the system so that all sides are easily accessible and have sufficient lighting.

1.

Use supplied lifting strap 127735, to transport systems with transformers. Wrap strap around all three pump tie rods and loop the strap back through itself in the Choker Configuration. See strap for details.

See F

IG

. 7, page 17.

F

IG

. 7: Lifting Strap

WLD

333347P 17

Setup

2.

Place the base system in the desired operating

location and orientation. See Location, page 17.

• The bottom of the electrical enclosure has holes for securing the InvisiPac system to a surface. The holes are accessible through the bottom access doors in the three rear walls of the electrical enclosure.

To install the InvisiPac system in place of a non-Graco hot melt system,

purchase Adapter

Plate, 24R083. See installation instructions on page 110.

To raise the system to eye-level,

purchase System

Stand, 24R088. See installation instructions on page 110.

NOTE: Supplied vacuum transfer hose must reach from the system to the adhesive pellets container. Supplied heated hose must reach from system to applicator(s).

3.

Adjust the funnel inlet:

G3 b.

Rotate the funnel inlet (G3) and re-tighten the band clamp (81).

G2

G3

G4

23 81

92

WLD a.

Remove plug (23) and insert the provided 5/16 in. nut driver (92) through the access hole in the back of the system. Loosen the band clamp (81) two turns.

WLD

F

IG

. 8

4.

Insert 1.3 in. (33 mm) OD clear vacuum transfer hose (G2) into vacuum transfer funnel (G3) inlet and secure with supplied hose clamp. The hose clamp should be placed over the cutouts in the funnel inlet

where it can firmly hold the transfer hose. See F

IG

.

8.

5.

Connect the long supplied 3/8 in. OD air line (G4) to the 3/8 in. push-to-connect fitting on the air line from

the system. See F

IG

. 8.

NOTE: When routing the vacuum transfer hose, ensure there are no tight coils, turns, or dips in the vacuum hose. These will inhibit optimal functioning of the vacuum transfer system.

NOTE: Maximum vacuum hose length is 30 ft (9.1 m).

Use horizontal hose routing as much as possible. The vacuum hose must not rise more than 10 ft (3.0 m), measured from the vacuum inlet. Any vertical rise will lower the maximum flow rate of the vacuum transfer system.

18 333347P

Setup

6.

Install heated hoses, see F

IG

. 9:

To reduce the risk of fire and explosion, only use

Graco heated hoses with the InvisiPac system. Use of non-Graco hoses will void agency approvals.

N

247

68

Applicator

AA

W2

W1 ti23298a

F

IG

. 9

a.

Place a rag on the drain tray (W2) attached to the melter. Residual oil may be in the system

from the factory. See F

IG

. 9.

b.

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

port plug (W1). See F

IG

. 9.

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

c.

When fluid stops draining, re-install drain port

plug (W1) then remove rag. See F

IG

. 9.

d.

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

plug (W1). See F

IG

. 9.

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

hydraulic fitting (68) faces the system. See F

IG

. 9.

e.

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

11/16 in. wrench or socket.

f.

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).

g.

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

IG

. 9.

h.

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

i.

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

Overtemperature Jumper, 16Y727, page 118.

7.

Install applicator(s), see F

IG

. 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.

a.

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

F

IG

. 9.

b.

For Graco applicators,

attach applicator electrical connector to heated hose electrical connec-

tor. See F

IG

. 9.

c.

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

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

use with your applicator.

d.

Repeat for any additional applicators.

333347P 19

Setup

8.

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.

9.

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

IG

. 10.

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

WLE

J

F

IG

. 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.

WLE

F

IG

. 11

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

See F

IG

. 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

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

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

WLD

F

IG

. 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.

5.

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

IG

.

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.

1.

Turn main power switch OFF.

2.

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

3.

Remove electrical enclosure access door (T). See

F

IG

. 2 on page 13.

4.

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

IG

. 13.

a.

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.

Y

X

AF

WLD

F

IG

. 13

6.

Connect ground wire to chassis ground (AF). See

F

IG

. 13.

7.

Connect power wires as shown in F

IG

. 14. Not all models use all 4 wires.

F

IG

. 14

8.

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

9.

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.

4.

On the System 3 screen:

Select ADM Settings

NOTE: See Appendix A - ADM on page 120 for

detailed ADM information, including general operation.

Setup

1.

Turn main power switch ON .

2.

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

, , , and to navigate

3.

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.

5.

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

a.

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

b.

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

6.

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

9.

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.

7.

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.

8.

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.

a.

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.

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.

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.

c.

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.

1.

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.

2.

Turn main power switch OFF.

3.

Remove electrical enclosure front access door.

4.

Route I/O cable through strain relief in electrical

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

IG

. 1 on page 12.

5.

Remove power from PLC.

6.

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

J2

F4 F3

F2

J1

F1

J7

J6

J5

J3

WLD

F

IG

. 15: MZLP Board

H1 - Customer Input

Signal Pin

1

2

3

4

1, 2

3, 4

5, 6

7, 8

H2 - Customer Output

Signal Pin

1

2

3

4

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

F

IG

. 16: Customer Input

MZLP Customer Out

Customer In

250 VAC, 0-30 VDC, 2A Max

To Customer Input

F

IG

. 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

X

X X

X

X

X

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

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

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

3.

To calibrate using the

purge

method: a.

Obtain a scale and a container.

b.

Reset the calibration weight totalizer by press-

Perform the following steps to calibrate the material tracking function:

1.

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

2.

To calibrate using the

tape and scrape

method: a.

Obtain a scale.

b.

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

c.

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

(this could take several minutes of production).

d.

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

e.

Scrape all material from product and place on scale.

f.

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 .

c.

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

d.

Weigh container with material.

e.

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

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.

NOTE: See Appendix A - ADM on page 120 for

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.

1.

Direct the applicator into an appropriate waste container.

2.

Fill adhesive pellets container with hot melt adhesive pellets.

3.

Turn main power switch ON .

4.

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.

WLE

32 333347P

Operation

5.

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

E

C

F

IG

. 18

6.

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

F

IG

. 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.

7.

On new systems only:

temporarily adjust the melter

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

Settings on page 23 for instructions.

9.

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).

b.

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

c.

Repeat until desired dispense pattern is achieved.

8.

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.

1.

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

2.

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

4.

Fill the funnel with adhesive pellets.

WLD

F

IG

. 20

5.

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

6.

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

the melter core. See F

IG

. 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

F

IG

. 19

3.

Disconnect the sensor cable and sensor cooling air.

F

IG

. 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:

1.

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

2.

Verify shaker and tube are connected to the system.

See Attach Components on page 17.

3.

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

adhesive pellets. See F

IG

. 1 on page 12.

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

4.

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.

1.

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

perform

Initial Startup and Prime procedure on page 32.

2.

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.

3.

Prepare for dispensing: a.

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

IG

. 1 on page 12.

b.

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

desired. See F

IG

. 1 on page 12.

c.

If using Automatic Refill,

see Automatic Refill on page 35.

d.

If using Manual Refill,

see Manual Refill on page 34.

e.

Verify applicators are closed.

E

F

IG

. 22

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

4.

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.

5.

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.

1.

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

2.

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.

1.

Turn main power switch OFF .

2.

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.

1.

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

2.

If the heating system is disabled,

press enable the heaters and pump.

to

3.

Decrease pump air pressure to 0.

4.

Close system air inlet ball valve.

5.

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

6.

Open applicator to allow residual fluid in applicator to drain.

7.

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.

8.

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.

1.

Perform Drain the System on page 38.

2.

If the heating system is enabled,

press able the heaters and pump.

to dis-

3.

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.

4.

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

9.

Press to disable the heaters and pump.

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

IG

. 2 on page

13.

38 333347P

Operation

5.

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.

6.

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

7.

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

8.

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

9.

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

IG

. 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

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.

40 333347P

Maintenance

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.

6.

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

7.

Discard outlet filter assembly.

8.

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

9.

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

8

F

IG

. 23

28

WLD

1.

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.

2.

Perform Pressure Relief Procedure, page 37 but

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

3.

Turn main power switch OFF.

4.

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

See F

IG

. 23.

5.

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.

1.

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

the inlet filter (213). See F

IG

. 24, page 42.

2.

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

3.

Wait until melter temperature is the desired temperature.

333347P 41

Maintenance

4.

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

5.

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

6.

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.

7.

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

9.

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

F

IG

. 24

WLD

201

8.

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:

a.

Install inlet filter cap (215).

b.

Install shroud and ADM.

c.

Turn main power switch ON.

d.

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

e.

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

f.

Go to step 4.

WLD

F

IG

. 25

Disassembly (see F

IG

. 25):

1.

Turn main power switch OFF.

2.

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

Reassembly (see F

IG

. 25):

1.

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 +

64

104+

NA

Replace filter every six months

Replace filter every four months

705

NA

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

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

0

1

4

5

2

3

A

B

C

8

9

6

7

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_

A1D_

A3MF

Description

Low Current

Melter

Low Current

Gun X

Low Current

Hose X

High Fan Current, Transformer

Type Cause

Advisory

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_

A4D_

A7D0

A7D_

A7D_

A8D0

A8D_

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

X.

Unexpected

Current, Hose X

No Current

Melter

No Current

Hose X

No Current Gun

X

No Fan Current,

Transformer

Type

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

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

Alarm

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_

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

Advisory

Deviation

Deviation

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_

T4D_

T4MX

T6D0

T6D_

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

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

Alarm

Alarm

Alarm

Thermistor reading greater than 212°F

(100°C).

No reading from RTD.

No reading from RTD.

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.

1.

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

22 cpm - HM50) by enabling the diagnostic screen.

2.

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.

3.

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:

1.

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

2.

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

3.

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

4.

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

5.

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.

1.

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.

2.

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.

1.

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

2.

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.

1.

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

2.

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 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.

1.

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

(140 kPa, 1.4 bar).

2.

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

36

Perform this procedure when directed in the Troubleshooting table.

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

1.

If the heating system and pump is disabled,

press to enable the heaters and pump.

2.

Wait for system to reach the temperature setpoints.

3.

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

4.

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

5.

Verify that air is flowing through the air line.

6.

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

F

IG

. 26

3.

Plug air line and allow the air motor to cycle.

4.

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

5.

If system still does not stall,

purge ten pump cycles of material through one applicator.

6.

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

1500

41-51

103-127

34-42

34-42

2000

1500

1000

1000

26-32

34-42

52-64

52-64

58 333347P

Troubleshooting

MZLP Troubleshooting

0 1

456

MZLP

WLD

F

IG

. 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.

F

IG

. 28: MZLP Diagnostic LED Location

ti20348a

333347P 59

Repair

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

27

218

240

3

245

223

226

222

239

235

233

234

238

224

225

WLD

Disassembly (see F

IG

. 29):

1.

Flush the system. See page 38.

2.

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

3.

Turn main power switch OFF.

4.

Remove plastic shroud (27).

5.

Remove vacuum transfer inlet funnel.

6.

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

7.

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

8.

Remove air motor assembly: a.

Remove retaining ring (239).

b.

Remove dowel pin (238).

c.

Remove three screws (240).

9.

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

IG

. 29):

1.

Assemble piston rod: a.

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

b.

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

F

IG

. 29

60 333347P

c.

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

Torque to 24-30 ft-lb (33-41 N•m).

2.

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

See F

IG

. 30.

15B661

203

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

235

233 ti20877a

F

IG

. 30

3.

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

4.

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

5.

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

IG

. 31.

ti21144a

F

IG

. 32

7.

Remove seal installation tool.

8.

Install retaining nut (235). See F

IG

. 30.

9.

Install air motor assembly (see F

IG

. 29):

a.

Install three screws (240).

b.

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

c.

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

F

IG

. 31

6.

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

IG

. 33):

1.

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.

2.

Replace cross over tube (269 using new o-rings

(270). Angled ring faces the melter base.

3.

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

F

IG

. 33

Disassembly (see F

IG

. 33):

1.

Flush the system. See page 38.

2.

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

3.

Turn main power switch OFF.

4.

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

5.

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

(270).

6.

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

7.

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

7.

Remove air motor assembly. See F

IG

. 29 on page 60:

a.

Remove retaining ring (239).

b.

Remove dowel pin (238).

c.

Remove three screws (240).

8.

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

9.

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

IG

. 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

F

IG

. 34

Disassembly (see F

IG

. 29):

1.

Flush the system. See page 38.

2.

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

3.

Turn main power switch OFF.

4.

Remove plastic shroud (27). See F

IG

. 29 on page 60.

5.

Remove air lines from relief valve (245) and air

motor (218) See F

IG

. 29 on page 60.

6.

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

place then remove melter shield. See F

IG

. 29 on page 60.

1301

203

217

216

217 ti20880a

F

IG

. 35

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

IG

.

35.

333347P 63

Repair

Reassembly:

1.

Apply grease to seals (217) then install new cylinder

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

IG

. 35.

1303

217

216

217

1302

203 ti21049a

F

IG

. 36

2.

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

IG

. 36.

3.

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

F

IG

. 36.

4.

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

IG

. 34, page 63.

5.

Perform Replace Pump Inlet Housing Checks on page 62.

6.

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

5

245

75

218

FF

53

81

29

251

3

30

8

10

6.

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

7.

Disconnect heater rod wires from J4 connector on

AWB board.

8.

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

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

9.

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

F

IG

. 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

F

IG

. 39 on page 67.

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

WLD

1

3

F

IG

. 37

27

36

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

1.

Perform Drain the System procedure on page 38

then wait for system to cool.

2.

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

3.

Turn main power switch OFF.

4.

Disconnect all heated hoses from the melter outlet manifold.

5.

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

87

88

F

IG

. 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

1

Wire Marking

2

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

1.

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

2.

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

3.

4.

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.

5.

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

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

6.

Connect air tube to air motor (218).

7.

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

8.

Connect pump cycle sensor cable to air motor.

9.

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

10. Install temperature sensor (125) into melter then

tighten screw (AA) on band heater. See F

IG

. 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

IG

. 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

1

10

AA

8

F

80

53

208

63

WLD

F

IG

. 39

Disassembly (see F

IG

. 39):

1.

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

2.

Turn main power switch OFF.

3.

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

4.

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

5.

Remove fabric melter insulators (53).

6.

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.

7.

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

8.

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

9.

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

IG

. 39):

1.

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

2.

Install sensor (125).

3.

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.

4.

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

5.

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

6.

Install electrical enclosure access door (10). See

F

IG

. 39.

7.

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.

8.

Install fabric melter insulator (53).

9.

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

53

40

AA

80

125

WLD

10

F

IG

. 40

Disassembly (see F

IG

. 40):

1.

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

2.

Turn main power switch OFF.

3.

Disconnect cable from ADM then remove shroud.

4.

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

5.

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

See F

IG

. 37, page 65.

6.

Remove fabric melter insulator (53).

7.

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

8.

Remove electrical enclosure access door (10).

9.

Disconnect the temperature sensor cable from

MZLP connector labeled J5. See F

IG

. 40.

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

10. Disconnect wire connectors from over-temperature

switch (251). See F

IG

. 41 on page 69.

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

Reassembly (see F

IG

. 40):

1.

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

2.

Connect wire connectors to over-temperature

switch (251). See F

IG

. 41 on page 69.

3.

Place band heater temperature sensor (125) in melter.

4.

Tighten screw (AA).

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

5.

Connect new harness to MZLP connector labeled

J5.

6.

Install electrical enclosure access door (10). See

F

IG

. 39 on page 67.

7.

Install fabric melter insulator (53).

8.

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

IG

.

37, page 65.

9.

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

5.

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

6.

Open system air inlet ball valve.

7.

Turn main power switch ON.

Replace Heater Rod

251

255 ti21052a

F

IG

. 41

Disassembly (see F

IG

. 41):

1.

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

2.

Turn main power switch OFF.

3.

Disconnect cable from ADM then remove shroud.

4.

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

tube through the metal shroud (27). See F

IG

. 43, page 70.

5.

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

6.

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

7.

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

Re-assembly (see F

IG

. 41):

1.

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

2.

Connect wire connectors to new over-temperature switch.

3.

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

4.

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

206

210

206

271

209

206

209

WLD

F

IG

. 42

Disassembly (see F

IG

. 42):

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

1.

Turn main power switch OFF.

2.

If replacing the melter heater rod (209),

Remove

Melter Assembly. See page 65.

3.

Disconnect cable from ADM then remove shroud (29).

333347P 69

Repair

4.

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).

b.

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

5.

Remove electrical enclosure front access door (10).

See F

IG

. 39, page 67.

6.

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

7.

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

Replace Fluid Pressure Relief Valve

27

3

7.

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

8.

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

Reassembly (see F

IG

. 42):

1.

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.

2.

Install heater rod then install heater rod retaining

ring (206). See F

IG

. 42.

3.

Install electrical enclosure access door (10). See

F

IG

. 39, page 67.

4.

If replacing the melter heater rod (209),

Melter Assembly. See page 65.

Install

5.

If replacing pump heater rod (271),

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

6.

If installing the pump heater rod (250),

install the metal shroud (27): a.

Place metal shroud on system.

b.

Install and tighten nuts (3).

c.

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

70

36

244

245 ti20757a

F

IG

. 43

1.

Drain the System. See page 38.

2.

Close the system air inlet ball valve.

3.

Turn main power switch OFF.

4.

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

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

F

IG

. 43.

5.

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

6.

Use crescent wrench to remove melter fluid pres-

sure relief valve (245). See F

IG

. 43.

7.

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

8.

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.

9.

Thread new fluid pressure relief valve (245) into

manifold. See F

IG

. 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

A

B

C

F1 and F2 fuses are physically larger than F3-F10

Yellow sticker on relay

Marked 24V133

1.

Turn main power switch OFF.

2.

Remove electrical enclosure front access door (10).

3.

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.

4.

Install electrical enclosure front access door (10).

C

F10 F9 F8 F7

F6

F5

J2

F4 F3

F2

J1

F1

A

B

J7

J6

J5

J3

WLD

F

IG

. 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:

1.

Turn main power switch OFF.

2.

Remove electrical enclosure front access door (10).

3.

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

4.

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

IG

.

45.

5.

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

IG

. 45.

2.

Apply channel label stickers to new MZLP. See F

IG

.

45.

3.

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

4.

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.

5.

Install electrical enclosure front access door (10).

6.

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

#1

MZLP

#3

MZLP

#2

114

112

F

IG

. 45

6.

Replace MZLP. See F

IG

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

a.

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

MZLP #1.

b.

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

Reassembly:

1.

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

IG

. 46 for rotary switch location.

Disassembly:

1.

Turn main power switch OFF.

2.

Remove electrical enclosure front access door (10).

3.

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

4.

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

112b

112a ti20342a

112

Rotary Switch

F

IG

. 46

5.

Unplug daughter card (112a) from the MZLP

#1 (112).

72 333347P

Repair

Reassembly:

1.

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

2.

Use screws (112b) to secure daughter card to

MZLP (112).

3.

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.

4.

Install electrical enclosure front access door (10).

System

Replace Fill Sensor

3.

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

4.

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

Reassembly (see F

IG

. 47):

1.

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

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

2.

Tighten jam nut on fill sensor (20).

3.

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

4.

Replace filter element and cover (68).

Replace ADM

58

68

30

CC

73

20

WLD

F

IG

. 47

Disassembly (see F

IG

. 47):

1.

Turn main power switch OFF.

2.

Remove filter cover (68) and filter element.

333347P ti20763a

F

IG

. 48

1.

Turn main power switch OFF.

2.

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

See F

IG

. 48.

3.

Remove ADM from bracket (58).

4.

Install new ADM into bracket.

5.

Connect cable to bottom of new ADM.

NOTE: ADM may need updated software. See Soft-

ware Update Procedure on page 81.

73

Repair

Replace AWB

144

145

146

131

145

131

F

IG

. 49: AWB and Power Supply

Disassembly:

1.

Turn main power switch OFF.

2.

Note location of each cable, then unplug all cables

from the AWB. See Electrical Schematics, page

82.

3.

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

4.

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

of the power supply. See F

IG

. 49.

5.

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

ply bracket. See F

IG

. 49.

Reassembly:

1.

Use two screws (144) to secure power supply

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

IG

. 49.

2.

Mount power supply (146) to power supply bracket

(145). See F

IG

. 49.

3.

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

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

cal Schematics, page 82.

4.

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

cal enclosure (1). See F

IG

. 49.

5.

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,

see Electrical Schematics, page 82.

6.

Install electrical enclosure front access door (10).

74 333347P

Repair

Replace Power Supply Replace Power Supply Harness

Disassembly:

1.

Turn main power switch OFF.

2.

Remove electrical enclosure front access door (10).

3.

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

of the power supply. See F

IG

. 49.

4.

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

according to the following table. See F

IG

. 49.

Power Supply

Connection

V+

V-

GND

L

N

Reassembly:

Harness Label

V+

V-

GND

L

N

1.

Make connections between power supply harness

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

2.

Reattach power supply (146) to power supply

bracket (145). See F

IG

. 49.

3.

Install electrical enclosure front access door (10).

Disassembly:

1.

Turn main power switch OFF.

2.

Remove electrical enclosure front access door (10).

3.

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

Power Supply

Connection

V+

V-

GND

L

N

Harness Label

V+

V-

GND

L

N

4.

Unplug power supply harness (147) from J1 on

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

Reassembly:

1.

Make connections between power supply harness

(147) and new power supply (146).

2.

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

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

cal Schematics, page 82.

3.

Install electrical enclosure front access door (10).

333347P 75

Repair

76

Air Controls

8

402

405

9

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

IG

. 50):

1.

Turn main power switch OFF.

2.

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

3.

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

4.

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

5.

Remove the transformer assembly; for 480V systems only

(see F

IG

. 51)

: a.

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

b.

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

6.

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

7.

Note location of each air line connection.

8.

Insert hands through access holes (FF), see F

IG

.

50, in bottom of electrical enclosure then disconnect

air lines from air control solenoids (402).

9.

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.

F

IG

. 50

142

140

FF

1

WLD

WLD

F

IG

. 51

Reassembly (see F

IG

. 50):

1.

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

2.

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

3.

Insert hands through access holes (FF), see F

IG

.

50, in bottom of electrical enclosure then connect air

lines to air control solenoids (402).

4.

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

5.

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.

6.

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

8

403

9 4.

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

5.

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

Air Motor

Replace Pilot Valve

403b

WLD

F

IG

. 52

Disassembly (see F

IG

. 52):

1.

Turn main power switch OFF.

2.

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

3.

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

4.

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

5.

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).

6.

Remove air gauge from panel.

Reassembly (see F

IG

. 52):

1.

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.

2.

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

3.

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).

C

511

218

WLD

F

IG

. 53: Top Pilot Valve

1.

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

2.

Turn main power switch OFF.

3.

Replace top pilot valve (511): a.

Use crescent wrench to remove rod cover (C).

b.

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

c.

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

d.

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

N•m).

4.

Replace bottom pilot valve (511):

333347P 77

Repair

218

6

29

511

WLD

F

IG

. 54: Bottom Pilot Valve

a.

Remove cover (29) and insulation (6).

b.

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

c.

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

d.

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

N•m).

e.

Replace insulation (6) and cover (29).

Replace Air Valve

218

507

512

509

2.

Turn main power switch OFF.

3.

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

4.

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

5.

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.

6.

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

7.

Disconnect air hose and cable from the air motor.

8.

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

9.

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

Reassembly (see F

IG

. 55):

1.

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

2.

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.

3.

Use 10 mm socket to torque screws (509) to

95-105 in-lb (10.7-11.9 N•m).

4.

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

5.

Connect air hose and cable to the air motor.

F

IG

. 55

Disassembly (see F

IG

. 55):

1.

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

8

218

27

239

220

240

219

3

211

74

82

238

WLD

F

IG

. 56

1.

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

2.

Turn main power switch OFF.

3.

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

F

IG

. 43 on page 70.

4.

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

5.

Disconnect air supply line from air motor (218).

6.

Remove air motor assembly: a.

Slide retaining ring (239) down.

b.

Remove dowel pin (238).

c.

Remove three screws (240).

d.

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

(82).

7.

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

a.

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

b.

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

Install Air Motor

See F

IG

. 56.

1.

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

Install tie rods (220) onto air motor (218).

b.

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

2.

Connect air motor assembly to system: a.

Install three screws (240), two screws (8), screws (74), and bracket (82) to secure air motor assembly to system.

b.

Install dowel pin (238).

c.

Install retaining ring (239) over dowel pin (238).

3.

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

4.

Reconnect air supply line to air motor (218).

5.

Reconnect air line (36) to pressure relief

valve (245). See F

IG

. 43 on page 70.

333347P 79

Repair

Transformer Fan

Replace Fan

1

158

6.

Cut three zip ties on corrugated tube (167) and two zip ties (161) on fan grill (154).

7.

Remove four nuts (158), rear fan grill (170), and fan

(155).

Install Fan

1.

Mount new fan (155), rear fan grill (170), and nuts

(158) on grill (154) with the arrow pointing toward the grill (154).

2.

Tie down fan wires onto tie down locations on grill

(154) using cable ties (161).

black (-) red (+)

154

167

161(x3)

151

157

WLE

F

IG

. 57

1.

Turn main power switch OFF.

2.

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

3.

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

4.

Remove connector from J7 connector on AWB board. Remove red (+) and black (-) wires from connector.

J7

1

161

WLE

F

IG

. 59

3.

Route fan wires with transformer wires into the electrical enclosure (1). Connect red and black fan wires to J7 connector. Reconnect J7 connector to AWB board. See F

IG

. 58.

4.

Reinstall corrugated tube (167) on fan and transformer wires. See F

IG

. 57.

NOTE: To prevent fan errors on ADM, remove excess slack and ensure cabling and zip ties do not contact fan blades.

5.

Reinstall fan grill (154) and front access panel (10).

(+)

red

(-)

black

80

WLD

F

IG

. 58

Front access panel (10) not shown.

5.

Remove screws (157) and fan grill (154). Pull two fan wires down into the transformer enclosure.

333347P

Repair

Software Update Procedure

When software is updated on the ADM the software is then automatically updated on all connected GCA components. A status screen is shown while software is updating to indicate progress.

1.

Turn system main power switch OFF.

2.

Remove ADM from bracket.

3.

Remove token access panel.

NOTE: When the screen turns on, the following screens appear:

First:

Software is checking which GCA modules will take the available updates.

Second:

Status of the update with approximate time until completion.

r_24P860_3B9900_3a

Third:

Updates are complete.

Icon indicates update success/failure. See the following Icon table.

Icon Description

Update successful.

F

IG

. 60: Remove Access Panel

5.

Install ADM into bracket.

6.

Turn system main power switch ON.

NOTICE

A status is shown while software is updating to indicate progress. To prevent corrupting the software load, do not remove token until the status screen disappears.

Update unsuccessful.

4.

Insert and press InvisiPac software upgrade token

(T, part no. 24R324) firmly into slot.

NOTE: There is no preferred orientation of token.

F

T

IG

. 61: Insert Token

r_24P860_3B9900_4a

Update complete, no changes necessary.

Update was successful/complete but one or more

GCA modules did not have a CAN boot loader so software was not updated on that module.

7.

Remove token (T).

8.

Replace token access panel.

9.

Press screens.

to continue to InvisiPac operation

10. Navigate to System screen. Verify the following pages. Reference screens on page 130.

a.

System Screen Page 1, Customer I/O is set correctly.

b.

System Screen Page 2, Channel and RTD types are set correctly.

c.

System Screen Page 3, System Type, Pump

Idle Time, Power Type, Circuit Breaker Size, and Refill Settings.

333347P 81

Electrical Schematics

Electrical Schematics

To prevent electric shock and system damage, all electrical work must be performed by a qualified electrician.

Incoming Power

NOTICE

To prevent severe system damage, ensure main power

leads are installed correctly. See Connect Electrical

Cord on page 22.

Cable Identification

Use the table to identify cables and other system components in the electrical schematics.

Ref

9

Part

---

Description

Manifold, air assembly

20 24R041 Sensor, ultrasonic

25 24R885 Switch, reed assembly

30 24P860 ADM

86 127666 Cable, Extension

87 ---

90 ---

WIRE, ground

Plug, Phoenix, 8pin

103 --Harness, MZLP #1 AWB

112 24V288 Module, MZLP with daughter board

118 24V510 Module, MZLP

121 16T087 Cable Board

123 127768 Cable, CAN,

124 16T103 Cable Pump

125 24R040 Sensor, RTD, 1M Harness

126 16T108 Cable Ultrasonic

129 --Harness, MZLP 2, AWB

--Harness, MZLP 2/3, AWB

135 16W035 Connector Jumper

136 ---

138 ---

Harness, MZLP #1 AWB

Harness, Disc AWB

140 --Transformer

143 24V816 AWB

146 126453 Power Supply

82

Ref Part

147 ---

Description

Harness Power Supply AWB

148 --Cable, Board, Samtec

181 24X521 Module, PC-8 Internal

182 128180 Power Supply, 120W

184 128183 Harness, Power, PC-8

185 128182 Cable, Communication

208 24V522 Band heater, HM50

24R039 Band heater, HM25

209 25M208 Heater Rod (1500 W), HM50,

Melt

24R034 Heater Rod (500 W), HM25,

Melt

210 25C445 Heater Rod (1000 W), HM50,

Base

25C448 Heater Rod (1500 W), HM25,

Base

271 25C446 Heater Rod (1000 W), HM50,

Pump

25C447 Heater Rod (1500 W), HM25,

Pump

251 126780 SWITCH, OT

1201 16T102 Light Tower

333347P

Systems Without Internal Pattern Controller

Review Connect Electrical

Cord section, Figure 16

L1

L2

L3

GND

GB1

W1

W2

W3

W4

140

TRANSFORMER

OPTION

138

J2

W1

W2

W3

W4

GND

143

AWB

TEMP

TEMP

FAN -

FAN +

J7

TEMP

TEMP

FAN -

FAN +

J9

1

2

3

4

5

J5

L1

L2

L3

GND

L1

L2

L3

GND

1

2

3

4

5

123

1

2

3

4

5

1

2

3

4

5

30

ADM

129

TO MZTCM #2,

4 and 6 CHANNEL OPTION

Electrical Schematics

BAND

87

208

GROUND

STUD

210 209 210

PUMP MELTER BASE

OPTIONAL LIGHT TOWER

AIR SOLENOID

FILL SENSOR

MOTOR CYCLE SWITCH

MELTER OT SWITCH

AND MELTER RTD ti 3 056 8a

251

DC OK

DC OK

-V

-V

+V

+V

20

25

86

TO MZTCM #2,

4 AND 6 CHANNEL OPTIONS

1201

9

124

125

90

1

2

3

6

7

4

5

8

J4

1

2

3

6

7

4

5

8

J8

1

2

3

4

5

1

2

3

4

5

J6

L1

L2

L3

GND

L1

L2

L3

GND

J3

1

2

1

2

148

136

103

GND

N

L

146

147

-

N

L

+

J1

-

N

L

+

126

121

112A

1

2

3

4

3

4

1

2

1

2

3

4

1

2

3

4

5

3

4

1

2

5

6

1

2

3

4

5

J3

3

4

1

2

5

J5

3

4

1

2

5

6

112

MZTCM 1

J1

1

2

1

2

3

4

3

4

1

2

3

4

5

1

2

3

4

1

2

3

4

1

2

J12

J13

J14

J15

J16

1

2

J2

L1

L2

L3

GND

L1

L2

L3

GND

J8

E

F

G

H

A

B

C

D

J

K

L

J6

1

2

3

4

5

1

2

3

4

5

J9

J

K

L

E

F

G

H

A

B

C

D

Cu s tomer Input s

(103 0VDC from PLC)

PLC Connection Wirin g

MZTCM 1

HOSE /

APPLICATOR

WIRING,

PLC 1

PLC 2

PLC 3

PLC 4

H1

7

8

5

6

3

4

1

2

Cu s tomer Output s

(dry contact to PLC)

PLC 1

PLC 2

PLC 3

PLC 4

H2

7

8

5

6

3

4

1

2

333347P 83

Electrical Schematics

Systems With Internal Pattern Controller

Review Connect Electrical

Cord section, Figure 16

L1

L2

L3

GND

GB1

W1

W2

W3

W4

140

TRANSFORMER

OPTION

138

J2

W1

W2

W3

W4

GND

143

AWB

TEMP

TEMP

FAN -

FAN +

J7

TEMP

TEMP

FAN -

FAN +

J9

1

4

5

2

3

J5

L1

L2

L3

GND

L1

L2

L3

GND

1

2

3

4

5

123

1

2

3

4

5

1

2

3

4

5

30

ADM

129

TO MZTCM #2,

4 and 6 CHANNEL OPTION

208

BAND

210 209 210

PUMP MELTER BASE

90

1

5

6

7

2

3

4

8

J4

1

5

6

7

2

3

4

8

87

GROUND

STUD

181

PC-8

P1

PE

-

+

PE

-

+

185

P4

M12

OPTIONAL

LIGHT TOWER

AIR SOLENOID

-V

-V

+V

+V

182

GND

N

L

1201

9

TO

MZLP 1-J3

OR

MZLP 2-J3

FILL SENSOR

MOTOR

CYCLE SWITCH

20

25

86

84 ti30567a

124

125

MELTER OT

SWITCH

251

MELTER RTD

To MZLP #2, 4, and 6

Channel Option, see page 117 and 11.

To MZLP #2 or Pattern

Control Board, see page 88.

126

184

-

N

L

+

J1

-

N

L

+

J8

1

2

3

4

5

1

2

3

4

5

J6

L1

L2

L3

GND

L1

L2

L3

GND

J3

1

2

1

2

148

136

103

112A

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

5

4

5

6

1

2

3

J3

3

4

1

2

5

J5

4

5

6

1

2

3

1

2

3

4

1

2

3

4

3

4

1

2

1

2

3

4

5

1

2

3

4

J12

J13

J14

J15

J16

112

MZLP 1

J1

1

2

1

2

J2

L1

L2

L3

GND

L1

L2

L3

GND

J8

H

J

K

L

E

F

G

A

B

C

D

J6

1

2

3

4

5

1

2

3

4

5

J9

J

K

L

F

G

H

A

B

C

D

E

HOSE /

Customer Inputs

(10-30VDC from PLC)

PLC Connection Wiring

MZTCM 1

H1

APPLICATOR

WIRING,

PLC 1

PLC 2

PLC 3

PLC 4

Customer Outputs

(dry contact to PLC)

7

8

5

6

3

4

1

2

PLC 1

PLC 2

PLC 3

PLC 4

H2

7

8

5

6

3

4

1

2

333347P

400 VAC Transformer Option

Electrical Schematics

480 VAC Transformer Option

333347P 85

Electrical Schematics

Typical Hose / Applicator Wiring

86 333347P

2nd and 3rd MZLP Options

118

MZLP3

135

1

2

5

6

3

4

J5

1

2

5

6

3

4

J3

1

2

3

4

5

1

2

3

4

5

121

1

2

3

4

5

J3

1

2

3

4

5

118

MZLP 2

J6

1

2

3

4

5

1

2

3

4

5

121

Internal PC-8 Options

One MZLP

Electrical Schematics

1

2

3

4

5

J3

1

2

3

4

5

112

MZLP 1

333347P 87

Air Schematic

Air Schematic

NOTE: Install an optional ramp up/down controller to limit air to the air motor and slow down the system dispense rate.

88 333347P

Parts

Parts

InvisiPac Systems

System Parts, Page 1 of 3

1

Apply door gaskets (11) to door (10) per layout diagram.

2

Apply pipe sealant to all non-swiveling pipe threads.

3

Bottom sensor (20) out then back off 1/2 turn.

4

5

Lubricate all seals and o-rings with water resistant grease.

Torque to 5-11 ft-lb (7-15 N•m).

6

Torque to 8-10 in-lb (0.9-1.1 N•m).

53

75

8

28

23

6

38

31

83

24

25

94

6

26

19 18

13

43

38

58

30

23

8

39

27

3

64

333347P

1

11

8

43

43

10

8, 14

29

44

WLG

89

Parts

System Parts, Page 2 of 3

8

49

40

41

125

5

42

88

1

54

85

9

8

43

3

5

63

87

89

4

8

74

8

7

82

86

63

81

79

80

WLE

69

62

69

20

3

72

73

74

61

68

67

69

66

90 333347P

Parts

System Parts, Page 3 of 3

57

34

48 in.

(1219 mm)

35

48 in.

(1219 mm)

34

16 in.

(406.4 mm)

333347P

WLD

86

91

34

48 in.

(1219 mm)

34

8 in.

(203 mm)

32

78

77

76

34

2 in.

(50.8 mm)

55

36

13 in.

330.2 mm)

39

24

49

35

48 in.

(1219 mm)

91

Parts

System Parts

Quantities

HM50 HM25

2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel

Ref Part

1 ---

Description

ENCLOSURE, electrical

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

3

4

5

115942 NUT, hex, flange head

167002 INSULATOR, heat

24V169 SYSTEM, melter, HM25

8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8

4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

1 1 1 1 1 1 1 1 1

24V542 SYSTEM, melter/pump,

HM50

6

--GUARD, insulated

6

--INSULATOR, wrap

7 --TRAY, drip

8† 113161 SCREW, flange, hex hd

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17

9 --MANIFOLD, air, assembly

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

10 --DOOR, front

24

25

120753 FITTING, push to connect

---

26

--elbow

SWITCH, reed assy

SCREW, pan head, #8-32 x

1.5"

27 --BRACKET, back HM50

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

11

13

---

24P615

FOAM, border, door

FITTING, straight, hydraulic

1

2

1

2

1

2

1

4

1

4

1

4

1

6

1

6

1

6

1

2

1

2

1

2

1

4

1

4

1

4

1

6

1

6

1

6

14 16V153 WASHER, retaining

4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

15

114271 STRAP, retaining

8 8 8 16 16 16 24 24 24 8 8 8 16 16 16 24 24 24

18

126961 FITTING, 45 elbow, hydraulic 2

2 2 4 4 4 6 6 6 2 2 2 4 4 4 6 6 6

19

116793 FITTING

2 2 2 4 4 4 6 6 6 2 2 2 4 4 4 6 6 6

20 24R041 SENSOR, ultrasonic

21

101976 TOOL, allen, wrench

23 114606 PLUG, hole

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

--BRACKET, back

1 1 1 1 1 1 1 1 1

28

29

---

---

COVER, filter

COVER, melter HM50

--COVER, system, HM25

30

24P860 MODULE, ADM

31 117017 WASHER

32

34

35

36

38

39

40

1 1 1 1 1 1 1 1 1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

---

---

FITTING, tee, reducer

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

--HOSE, nylon, wpr 250 psi

8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10

598095 TUBE, 5/32 OD, nylon

4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

--TUBE, ptfe, 1/4 in. OD

1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10

117126 SCREW, shcs; m5x16

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

--GROMMET, 1/4 ID

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

BUSHING, strain relief

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

41 --GROMMET, tube

42 --GROMMET, tube

43

16Y781 LABEL, safety

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

92 333347P

Parts

Quantities

HM50 HM25

2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel

Ref Part

44

Description

16U007 LABEL, InvisiPac, HM25

--LABEL, InvisiPac HM50

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

45 --LABEL

47

24P859 KIT, fuses, board, temp control

48

24P176 KIT, i/o connector

49 125871 TIE, cable, 7.50 in.

50

---

53 ‡

---

53

---

54

57

---

TOKEN, software

INSULATOR, melter

INSULATOR, melter

NUT, bushing

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

10 10 10 10 10 10

1

1

1

1

1

10

1

1

1

1

1

10

1

1

1

1

1

10

1

1

1

1

1

10

1

1

1

1

1

10

1

1

1

1

1

10

1

1

1

1

1

1

1

1

1

1

1

10 10 10

1

1

1

1

1

1

1

1

1

10

1

1

1

1

1

1

1

1

10 10

1

1

1

1

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

123554 COUPLER, 3/8 in. OD tubing 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

58

61†

24A326 BRACKET, mounting,

--assembly

FUNNEL, large mouth

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

62† --BAFFLE, pellet

63 121487 GROMMET, sheet metal, 3/4 in.

64$ 24R707 KIT, inlet, air

66† --FUNNEL, insert

1

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

67† 24V506 FILTER, HM50 feed

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

68† --FUNNEL, filter cover

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

69†

72

--O-RING, fluoroelastomer,

160

110932 CONNECTOR, male

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

73† --HOUSING, sensor, HM50

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

74†

75

75

76

77

78

---

---

---

SCREW, #10-16, thread forming

INSULATOR, melter manifold

INSULATOR, melter, manifold

--FITTING, tee, 1/8npt x 3/8t x

3/8t

RESTRICTOR, air, 0.0225 --in. orifice

198177 FITTING, push, straight

79

24W001 ADAPTER, HM25

24W000 ADAPTER, melter HM50

80

---

81

---

82† ---

CLAMP, hose, spacer

CLAMP, hose, spacer

BRACKET, funnel, HM25

83

5

1

1

1

1

1

1

1

5

1

1

1

1

1

1

1

5

1

1

1

1

1

1

1

5

1

1

1

1

1

1

1

5

1

1

1

1

1

1

1

5

1

1

1

1

1

1

1

5

1

1

1

1

1

1

1

5

1

1

1

1

1

1

1

5

1

1

1

1

1

1

1

5

1

1

1

1

1

2

5

1

1

1

1

1

2

5

1

1

1

1

1

2

5

1

1

1

1

1

2

5

1

1

1

1

1

2

5

1

1

1

1

1

2

5

1

1

1

1

1

2

5

1

1

1

1

1

2

5

1

1

1

1

1

2

1 1 1 1 1 1 1 1 1

--BRACKET, HM50, funnel, mounting

1 1 1 1 1 1 1 1 1

123986 FITTING, elbow, 3/8 OD tube 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

333347P 93

Parts

Quantities

HM50 HM25

2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel

Ref Part

85 ---

86

Description

GROMMET

127666 CABLE, gca, m12-5p

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

87

88

--WIRE, ground

116343 SCREW, ground

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

89

90

---

---

WASHER, 1/4 external tooth lock

PLUG, phoenix, 8 pos

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

91 --FITTING, 5/32 in. OD tube, push-to-con

92

17A345 TOOL, 5/16 nut driver

93

127735 STRAP, lifting 3 ft

94

--WASHER, flat

1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

--- Not for sale.

Replacement Danger and Warning labels, tags, and cards are available at no cost.

ADM does not come with software. Order software token

24R324.

$

Not shown.

Replacement filter element is 24X967.

Part of Kit 25A897 (HM25)

Part of Kit 25A898 (HM50)

Available kits (purchase separately):

Kit

25A798

Description Includes

Insulation, HM25 6, 53

25A898 Insulation, HM50 6, 53

24R885

Cycle Switch 25, 26, 94

24R028* Inlet housing 12, 13, 62

24V505† Funnel 8, 61, 62, 66, 67, 68, 69, 73,

74, 82. See Feed Inlet Fun-

nel, 24V505 on page 105.

24V508

Melter 53, 202, 204, 207, 211, and

253. See Melter and Pump

Assembly on page 100 for

identification of items 202-253.

24V504

Hydraulic Fittings 13, 18, 19

24U635 Acrylic Lens

Pressure Gauge

24W000

Melter Adapter 79, 80, 81

24X967$ Replacement air filter element

25C525

25C526

Shroud, HM25

Shroud, HM50

8, 14, 29, 44

8, 14, 29, 44

94 333347P

Electrical Enclosure, Systems without Internal Pattern Controller

Parts

MZLP

MZLP 3

118 4

113

113

114

112

2

112a

3

118

113

MZLP 2

109

114

1

Apply sealant to all non-swiveling pipe threads.

2

Set rotary switch to “1” on MZLP with daughter card.

3

Set rotary switch to “2” on MZLP 2.

4

Set rotary switch to “3” on MZLP 3.

144

145

131

146

117

111

143

106, 107

120

110

108

WLD

114

101

132

131

WLD

104

105

333347P 95

Parts

Electrical Enclosure, Systems with Internal Pattern Controller

MZLP

96

112a

113

114

112 2

3

118

113

MZLP2

1

Apply sealant to all non-swiveling pipe threads.

2

Set rotary switch to "1" on MZLP with daughter card.

3

Set rotary switch to "2" on MZLP 2.

117

131

144

183

182

114

120

110

106, 107

108

WLD

114

101

132

143

111

131

105

WLD

104

333347P

Parts

142

141

137

140

Electrical Enclosure Parts

108

109

110

111

112*

112a

113

114

Ref

101

102

103

104

105

106

107

116

117

118

119

120

121

123

Part

---

Description

CABINET, controls

127666 CABLE, gca, m12-5p

--HARNESS, MZLP1, AWB

123970 SWITCH, disconnect, 40a

126839 CONTACT, n-pole

120858 BUSHING, strain relief, m40 thread

120859 NUT, strain relief, m40 thread

104641 FITTING, bulkhead

121141 FITTING, elbow, swivel, 3/8t 1/4mnpt

114421 BUSHING, strain relief

117666 TERMINAL, ground

--MODULE, MZLP with daughter board

24R042 KIT, board, daughter

16T440 CAP, souriau, uts14

125856 SCREW, 8-32, serrated flange

24P175 PLATE, blank, sgl mztcm

115942 NUT, hex, flange head

24V510 MODULE, gca, MZLP

--GASKET, foam, mztcm

--PIN, dowel

16T087 CABLE, board, male/male, 21 in.

127768 CABLE, can, female/female 1.5 m

333347P

WLD

2

12

2

1

1

1

1

1

Quantity

1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP

No Transformer 400/480 V Transformer

1 1 1 1 1 1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

4

12

1

1

1

1

1

1

1

6

12

1

1

1

1

1

2

1

2

1

1

1

1

1

2

12

2

1

2

1

1

1

1

1

1

4

12

1

1

1

1

1

1

1

6

12

1

1

1

1

1

2

1

2

1

97

Parts

143

144

145

146

138

140

141

142

147

148

130

131

132

135

136

137

Ref Part Description

124 16T103 CABLE, pump

125

--SENSOR, rtd, 1m

126 16T108 CABLE, ultrasonic, m12-4p, 1m

129

---

---

HARNESS, MZLP 2, awb

HARNESS, MZLP 2/3, awb

114958 STRAP, tie

--SCREW, flange, serrated, 10-24 x 0.5

123967

16W035

---

---

KNOB, operator disconnect

CONNECTOR, jumper

HARNESS, MZLP 1, awb

BUSHING, cable

---

24V015

---

113802

24V816

114331

---

126453

---

---

HARNESS, disc, awb

TRANSFORMER, assembly, 480v/240v

GROMMET, air fitting

SCREW, hex hd, flanged, 3/8-16 x 5/8

MODULE, awb

SCREW, mach, pnh, sems; 6-32 x 3/8

BRACKET, power supply

POWER SUPPLY, 24v

HARNESS, power supply, awb

CABLE, board, samtec

Quantity

1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP

No Transformer 400/480 V Transformer

1 1 1 1 1 1

1

1

1

1

1

1

1

1

1

1

1

1

1 1

4

2

1

1

4

2

1

1

2

1

1

1

1

4 4

2

1

4

2

1

2

1

1

1

4

1 1 1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

2

1

1

1

1

2

1

1

1

1

1

1

1

1

3

1

2

1

3

1

2

1

1

1

1

1

1

1

1

1

3

1

2

* Purchase MZLP (118) and daughter board (112a) separately.

Available kits (purchase separately):

Internal Pattern Controller Components

Kit Description

24V528† Upgrade from 2 channel system to 4 channel system

24V529

Upgrade from 4 channel system to 6 channel system

24R040

24V289

RTD

MZLP fuses

Includes

113, 118, 121, 129, a grounding wrist strap, and a software upgrade

token. See 4 Channel Upgrade

Kit, 24V528 on page 113.

113, 118, 121, 129,134, 135, grounding wrist strap, and a soft-

ware upgrade token. See 6 Chan-

nel Upgrade Kit, 24V529 on page 115.

125, 251, and 255. See Melter and

Pump Assembly on page 100.

Qty 8 - 8 Amp, 250V Fuses

Qty 2 - 25 Amp, 250V Fuses

24P176 Customer I/O

Connectors

24X640† Add internal

PC-8 to 2-channel or 4-channel systems.

17F172 Upgrade internal

PC-8 to PC-8e.

2 connectors for connecting to H1 and H2 on MZLP daughter board.

Use for PLC connection.

181 (all items), 182, 183, 184, 185,

186, 189, 190, 192, 193. See manual 334874.

Key token to enable encoder and 4 connectors for wiring. See manual

334874.

Ref

181+

Part Description

24X521 MODULE, GCA, Internal PC-8

181b+ 128176 FRAME, cable grip, 5-position

181c+ 128177 INSERT, rubber, cable grip, 4x6mm

181d+ --PIN, .250 in

181e+ 128178 INSERT, rubber, cable grip, 4x3mm

181f+ ---

181g+ ---

182+

183+

PIN, .125 in

SCREW, #10-32 x .750

128180 POWER SUPPLY, 120 W

128443 BRACKET, power supply, PC-8 Internal

188+% --TOOL, screwdriver

187+% 128340 FUSE, automotive, 4A, 32V, mini

189+ 116772 CONNECTOR, plug, 4-position

190+

192+

193+

119162 CONNECTOR, plug, 6-position

128147 CONNECTOR, plug, 8-position

128117 CONNECTOR, plug, 12-position

% not shown

1

1

16

2

1

1

4

4

Qty

1

2

2

1

1

1

1

98 333347P

Parts

Transformer Assemblies

152

160

161

2

4

153

156

157

168

158

166

167

161

2

157

3

151

WLD

168

156

1

Mount fan with arrow pointing towards grill.

2

Tie down cabling from transformer and fan using cable tie onto tie down locations. Remove excess slack and ensure cabling does not contact fan blades.

154

170

155

1

2 4

166

166

3

Use nut to lock down the ground wire from transformer.

4

Connect black fan wire labeled (-) from transformer (153) in the pin labeled (-). Connect red fan wire labeled (+) to the connector coming from transformer (153).

Transformer Assemblies

Ref.

Part

151 ---

152 ---

153 ---

154 ---

155

---

156 115942

157 119865

158

160

---

127278

---

Description

ENCLOSURE, base, 480v

ENCLOSURE, top, 480v

TRANSFORMER, 480v/240v,

6kva; 480V systems only

TRANSFORMER, 400v/240v,

6kva; 400V systems only

GRILL, fan

FAN, 24 vdc, 120m x 120m

NUT, hex, flange head

SCREW, mach, hex serrated, 1/4 x 3/8 in.

NUT, keps, hex

GROMMET, air fitting

Qty

1

1

1

1

4

1

5

6

1

1

Ref.

Part Description

161 125871

TIE, cable, 7.5 in.

162 172953

LABEL, designation

166

17A071

LABEL, safety, warning

167 ---

TUBE, corrugated, slit; 6 in.

(152.4 mm)

168

169

170 127754

GRILL, fan

Replacement Danger and Warning labels, tags, and cards are available at no cost.

Included in Fan Replacement Kit 24V911.

--- Not for sale.

Qty

5

1

1

1

333347P 99

Parts

Melter and Pump Assembly

HM25, 24V169

HM50, 24V542

208

2

218

10

211

204

4

205

254

236

239

4

238

235

233

234

5

217

216

217

223

206

10

2

202

215

207

210

213

271

253

252

6

269

214

206

220

240

219

211

252

7

203

3

10

251

3

255

224

225

5

226

222

4

221

227

228

229

231

232

230

246

9

10

201

249

209

270

257

247

10

242

8

243

244

258

249

268

3

259

206

1

Lubricate all seals and o-rings with grease.

2

Orient melter (202) sensor hole in line with band heater (208) clamp.

3

WLE

4

Torque to 5-11 ft-lb (7-15 N•m).

Torque to 24-30 ft-lb (33-41 N•m).

245

6

Assemble inserts (252) 0.01-0.05 in. (0.3-1.3 mm) below surface.

7

Assemble inserts (252) 0.01-0.05 in. (0.3-1.3 mm) below surface.

8

Torque to 27-33 in.-lb (3-3.8 N•m).

9

Apply anaerobic thread sealant on threads.

10 Torque to 12-18 ft-lb (16-24 N•m).

5

Orient u-cups (225, 234) with springs in direction shown.

HM50 Melter and Pump, 24V542 HM25 Melter and Pump, 17F830

100 333347P

Parts

219

220

---

---

221• 192624

222†

• 239932

223

• ---

224†

• 105444

225†

• ---

226†

• ---

227†• 105445

228†• 192642

229†• 107079

230• ---

231†• 105802

232†• 113944

233†• ---

234†‡• ---

235•

236•

193046

24P855

238

239

196762

196750

240 128190

242

• 117059

243

• ---

244

• 15Y627

245

---

246• C19829

247• 15H304

249 167002

251

• 126780

252• ---

253

---

---

254 ---

255

• 107388

Ref.

201

Part

---

---

202

---

---

203• ---

204

---

---

205

---

---

206• 111317

207

16W615

208

210

213

214•

215

126475

24V522

24R039

209•

---

---

25C445

25C448

211

128167

24R369

112855

24T297

216ॠ---

217†‡• 108526

218 24V558

Description

BASE, melter, HM50

BASE, melter, HM50

TANK, melter, HM50

TANK, melter, HM25

MANIFOLD, outlet

PLATE, mounting; HM50

PLATE, mounting; HM25

HOUSING, fire rod; HM50

HOUSING, fire rod; HM25

RING, retaining, int.

O-RING, fluoroelastomer;

(HM50 only)

O-RING, fluoroelastomer;

(HM25 only)

BAND, heater; HM50 only

BAND, heater; HM25 only

HEATER, rod,1500 watts; HM50

HEATER, rod, 500 watts; HM25

HEATER, rod,1000 watts; HM50

HEATER, rod,1000 watts; HM50

SCREW, cap,sh,5/16-18

SCREEN, wire

PACKING, o-ring

PLUG, o-ring boss

SLEEVE, cylinder

PACKING, o-ring, ptfe

MOTOR, double ended, air; see page

102

PLATE, pump adapter

ROD, tie, 1.5 in. stroke

GUIDE, ball

VALVE, piston

ROD, piston

BALL, (.31250)

SEAL, u-cup, piston

BEARING, piston

BALL, (.5000)

SEAT, carbide

PACKING, o-ring

HOUSING, foot valve

O-RING

PACKING, o-ring

BEARING, throat

SEAL, u-cup, throat

NUT, packing

FILTER, assy, 100 mesh, welded

PIN, straight

SPRING, retaining

SCREW, cap, sch; 5/16 x 1 in.

O-RING, fluoroelastomer

RETAINER, seat, dump valve

PACKING, o-ring #2-116, ptfe

VALVE, relief

SCREW, cap, socket head; 5/16 x 2.5 in.

FITTING, plug 9/16 sae

INSULATOR, heat

SWITCH, overtemperature

INSERT, helical

PLATE, melter; HM25 only

PLATE, melter; HM25 only

O-RING, -910

SCREW, mach, pnh; #4 x 3/8 in.

Qty.

1

1

1

1

1

3

1

1

1

1

1

1

7

1

1

1

1

1

1

1

1

1

1

2

1

1

7

1

1

1

2

9

10

1

4

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

Ref.

257

258

259

268

269

270

271

Part

---

---

---

110298

115506

115814

128612

103610

25C446

25C447

Description

BRACKET, shelf; HM50 only

BRACKET, shelf; HM25 only

GROMMET, 1/4 ID

SCREW, cap, sch, 1/4 x 7/8 in.; HM50 only

SCREW, mach, hex wash hd, 1/4 x 3 in.;

HM25 only

WASHER, flat, sst; HM50 only

TUBE, cross over

O-RING, 014

HEATER, rod, 1000 watts; HM50

HEATER, rod, 1000 watts; HM50

Qty.

1

1

1

4

4

2

1

1

4

1

--- Not for sale.

Available kits (purchase separately):

Kit

24P852†

24P853‡

24P854

24R040

24R709 •

---

Description

Pump repair

Cylinder

Pump rod

24P856

Pressure relief valve

24V508

24R031

Melter HM50 Melter

HM25

Kit, RTD harness and switch

Assembled pump manifold

Special tools

Includes

217, 222, 224-229, 231,

232, 233, 234, and seal installation tool 15B661.

216, 217, 234, and seal installation tool 15B661.

222, 223, 224, 225, 226

242, 243, 244, 245

202, 204, 207, 211, 253, and insulator (53). See

InvisiPac Systems parts starting on page 89 for

insulator (53) identification.

125, 251, and 255. See

Electrical Enclosure,

Systems without Inter-

nal Pattern Controller on page 95.

203, 206, 209, 214, 216,

217, 221-236, 242-247,

251, 252, 255

See Special Tools on page 106.

205, 209, 254 24R034

25M208

25A893

Fire rod housing

25A894

25A8

25A896

HM25 Melter Base with heater rods

HM25 Melter Base with heater rods

HM25 Outlet Manifold with heater rods

HM25 Outlet Manifold with heater rods

201, 206, 210, 213, 215,

252

203, 206, 271, 247, 252

333347P 101

Parts

Air Motor, 24V558

2

509

512

507

4

509

505

506

522

1 2

511

1

Apply water-resistant grease.

2

Torque to 95-105 in-lb (10.7-11.9 N•m).

Ref.

Part

505 24A579

506 ---

507† ---

509† ---

511 24R027

512† ---

513 15M213

Description

MANIFOLD, medium, short

GASKET, cover, small

SEAL, air valve, manifold

SCREW, m6 x 25, thread forming

VALVE, pilot

VALVE, air, small

MUFFLER, 3/8

-

-- Not for sale.

† Included in Air Motor Valve Kit 24R026.

Qty

1

2

1

1

1

8

2

102

WLD

511

1 2

513

333347P

Air Controls Assembly

405

402

1

404

401

403

1

Apply sealant to all non-swiveling pipe threads.

Air Controls Assembly Parts

Ref

401

402

403

404

405

406

407

Part

---

Description

PANEL, air, controls

24V520 CONTROL, air, vacuum transfer and pump

128260 GAUGE, pressure, air, panel mount, 1/8 in. npt

15T498 FITTING, 90 degree, swivel,

5/32 in. tube x

1/8 in. female npt

100058 SCREW, cap, hex head

054753 TUBE, nylon, round, black

C38321 TIE, cable, 3.62 in.

Qty

1

1

2

2

2

2

1

--- Not for sale.

406

1

404

WLD

Parts

333347P 103

Parts

Pressure Relief Valve, 24P856

607 3

1

606

1

601

614

2

605

611

608

1

602

609 2

612

2

603

3

610

610

604

1

Apply sealant to all non-swiveling pipe threads.

2

Apply grease.

3

Torque to 4-6 in-lb (0.5-0.7 N•m).

613 i

Ref

601

602

603

604

Part

---

Description

BODY, fluid

--BODY, air

15T413 PISTON, air

--AIR CAP, valve

605

606

607

---

---

---

BEARING, shaft, needle

SHAFT, needle, valve

SOCKET, ball assembly

608† 108771 PACKING, o-ring

609† 110073 PACKING, o-ring

610 111841 WASHER, plain 5/8 in.

611† ---

612† ---

BEARING, valve

O-RING, FKM

613 126474 FITTING, push to connect

614† --SEAL, u-cup, relief valve

--- Not for sale.

† Parts included in Relief Valve Repair Kit 24P857

(purchase separately).

1

1

2

1

1

1

1

1

1

1

Qty

1

1

1

1

104 333347P

Feed Inlet Funnel, 24V505

706

705

8

703

704

708

82

710

708

703

702

703

Ref.

Part

702 ---

703 ---

704 ---

705 24V506

706 ---

708 126901

709 110932

710 ---

Description

BAFFLE, pellet

O-RING, fluoroelastomer, 160

FUNNEL, insert

FILTER, feed

FUNNEL, filter cover

SCREW, #10-16, thread forming

FITTING, connector, air

HOUSING, sensor

Qty

1

3

1

5

1

1

1

1

--- Not for sale.

Not included in 24V505:

Ref.

Part

61

8

82

---

113161

17A492

16Y569

Description

FUNNEL, large mouth

SCREW, flange, hex hd

BRACKET, funnel, mounting, HM25

BRACKET, funnel, mounting, HM50

Qty

1

2

1

1

61

WLD

333347P

709

Parts

105

Accessories

Accessories

Special Tools

These special tools are designed to make system repairs as easy as possible while ensuring that parts do not get damaged.

Part

1301*

1302*

1303*

Purpose

Remove Cylinder

Install Cylinder - Female

Install Cylinder - Male

Part

1304**

1305**

1306**

Purpose

Install Rod - Female

Install Rod - Male

Install Rod - Bullet

* Parts included in Cylinder Tools Kit 24R227 (purchase separately).

** Parts included in Rod Tools Kit 24R228 (purchase separately).

106 ti20983a

333347P

Accessories

Preventive Maintenance Kits

These kits contain components which are commonly used in maintenance.

HM25 Preventive Maintenance Kit, 24X867

5

6

3

4

7

8

Ref

1

2

Part Description

24V506 Kit, Foam, Screen, Funnel

24W595 Kit, Filter Rebuild

24X967 Filter, Air, Repair

16T124 Filter, Screen, Wire

24P802 Kit, Gun Filter, 3pk

24X220 Switch, Reed

127110 Screw, #8-32

102360 Washer, Flat

HM50 Preventive Maintenance Kit, 24X868

6

7

8

3

4

5

Ref

1

2

Part Description

24V506 Kit, Foam, Screen, Funnel

24W595 Kit, Filter Rebuild

24X967 Filter, Air, Repair

16T124 Filter, Screen, Wire

24P802 Kit, Gun Filter, 3pk

24X220 Switch, Reed

127110 Screw, #8-32

102360 Washer, Flat

Complete Maintenance Kits

These kits contain repair components which are not part of regular preventive maintenance.

8

9

10

11

12

13

14

15

16

17

5

6

7

2

3

Ref

1

4

HM25 Complete Maintenance Kit, 24X869

Qty

2

2

4

1

2

1

1

1

Qty

2

2

2

1

4

1

1

1

6

7

4

5

8

2

3

Ref

1

9

10

11

12

13

14

15

16

17

Part Description

24P856 Kit, Valve, Discharge

24P861 Kit, Shaker, Feed

24R027 Kit, Poppet

24R026 Kit, Valve, Motor

24R041 Kit, Level Sensor

24P852 Kit, Repair, Pump

24V816 Kit, Repair, AWB

24R042 Kit, Board, Daught.

24R885 Kit, Cycle Switch

24V510 Kit, MZLP w/ fuses

24V289 Kit, Fuses, MZLP

24R039 Kit, Band Heater

24R037 Kit, 1.5kW Heat Rod

24R034 Kit, 500W Heat Rod

126453 Power Supply, 24V

24R040 Kit, Harness, RTD

127411 Jumper, OT

HM50 Complete Maintenance Kit, 24X8670

Part Description

24P856 Kit, Valve, Discharge

24P861 Kit, Shaker, Feed

24R027 Kit, Poppet

24R026 Kit, Valve, Motor

24R041 Kit, Level Sensor

24P852 Kit, Repair, Pump

24V816 Kit, Repair, AWB

24R042 Kit, Board, Daught.

24R885 Kit, Cycle Switch

24V510 Kit, MZLP w/ fuses

24V289 Kit, Fuses, MZLP

24V522 Kit, Band Heater

24R036 Kit, 1 kW Heat Rod

24R037 Kit, 1.5W Heat Rod

126453 Power Supply, 24V

24R040 Kit, Harness, RTD

127411 Jumper, OT

1

1

1

1

1

1

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Qty

1

1

1

1

1

1

1

1

1

1

1

333347P 107

Accessories

Non-Graco Applicator Adapter

Cables

16T916: For connecting to non-Graco applicators that use a rectangular, 6-pin connector.

Adapter Cable

128621: Adapter cable allows non-Graco NI120 RTD

Hoses to be used on InvisiPac.

ti21128a

16T917: For connecting to non-Graco applicators that use a circular, 9-pin connector.

WLD

128372: For connecting to non-Graco applicators that use a rectangular 8-pin connector.

ti21129a

16Y828: For connecting to non-Graco applicators that use a circular, 6-pin connector. IPx6 rated.

Non-Graco Applicator Adapter Cable

Installation

See Attach Components on page 17.

WLD

108 333347P

Air Adjustment Lock, 24R084

Panel enables locking access to the air adjustment screws.

Accessories

Feed Sensor Dedicated Air Kit,

17F699

For connecting a dedicated air source to the feed sensor on InvisiPac

systems.

Ref

801

802

WLD

NOTE: Screws are part of the base system and are not included in the kit.

Part

---

---

801

Description

PANEL, lock, air control

BRACKET, lock, air control

802

Air Adjustment Lock Installation

1.

Remove screws from system air panel.

2.

Use screws to install panel (801).

3.

Snap bracket (802) into panel (801).

4.

Insert lock through hole in panel and bracket to lock access to the air controls. Lock not included in kit.

7

8

9

10

5

6

3

4

Ref Part

1

2

106148

110224

Description

FILTER, air, 3/8 npt

VALVE, vented 2-way

198177

128264

128277

155665

FITTING, push, straight

BRACKET

SCREW, self-tap, 10-24 x 3/8

UNION, adapter

11

12

13

14

167702 NIPPLE, pipe

16T779 RESTRICTOR, air, 0.0225 in. orifice

598095 TUBE, 5/32 in. OD, nylon; 3 ft (1 m)

127660 FITTING, 5/32 in. OD tube, push-to-connect

128292 PLUG, push-to-connect, 5/32

191892 FITTING, elbow, street, 90°

C20467 FITTING, nipple, reducing; 1/8-27 npt x

3/8-18 npt

110110 SEALANT, pipe, sst; 6 ml

Qty

1

1

8

1

1

1

1

1

1

1

1

1

1

1

Qty

1

1

Feed Sensor Dedicated Air Source

Installation

1.

Assemble parts in kit. Apply sealant (14) to all threaded joints.

2.

Mount bracket to the InvisiPac system air inlet filter.

3.

Disconnect level sensor cooling air tubes.

4.

Insert plug (11) into tube coming from under the Invisi-

Pac system shroud to prevent the system from losing air pressure.

5.

Connect connector (1) to the tube (9) coming from the kit.

6.

Rout tube (9) as needed and cut to length.

7.

Connect dedicated air supply to the auxiliary air inlet

(6).

333347P 109

Accessories

System Stand, 24R088

Use the stand to mount the system at eye level. When the system is mounted on the stand, the ADM is 45 in.

(1.14 m) above the bottom of the stand.

Adapter Plate, 24R083

Use this adapter plate to install InvisiPac in place of an existing hot melt applicator system.

C

B

Bolt Hole Dimensions

A 9.8 in. (249 mm)

B 14.843-15.157 in.

(377.0-385.0 mm)

C 17.003-17.317 in.

(431.9-439.9 mm)

A

110

1002

1001

1104

1101

1003

1102 A

WLD

WLD

1103

Ref Part Description

1101 --PLATE, adapter

1102 112395 SCREW flange head cap

1103 112958 NUT, hex, flanged

1104 121283 FITTING, elbow, 45 degree

Ref Part Description

1001 --STAND

1002 112395 SCREW flange head cap

1003 112958 NUT, hex, flanged

System Stand Installation

1.

Place stand (1001) in desired location.

2.

Use bolt holes to bolt stand in place.

3.

Place system on stand.

4.

Use screws and nuts to secure system to stand.

Caster for Stand, 120302

Qty

1

3

3

Caster with friction post mounts directly to system stand using no extra hardware. Four required. Casters raise stand an additional

4.25 in. (108 mm).

Adapter Plate Installation

1.

Remove existing hot melt applicator system.

2.

Use six screws (1102) and six nuts (1103) to secure adapter plate (1101) through the existing holes from the previous system.

3.

Align the InvisiPac system with the bolts on the adapter plate (1101) then place onto the adapter plate (1101).

4.

Use the remaining three nuts (1103) to secure the

InvisiPac system to the adapter plate (1101).

5.

Use elbow fitting (1104) to install system air inlet filter (A, not included with kit).

Qty

1

6

9

1

333347P

Accessories

Light Tower Kit, 24R226

The light tower enables someone away from the system to quickly see whether the system is inactive or OFF (no lights), warming up (flashing green), at temperature (solid green), or has an active error (red).

1201

1201a

1203

BB

1202

1205

WLD

24R226 Parts

Ref Part Description

1201 16T102 LIGHT, tower, red and green

1201a --SCREW

1202 --GROMMET, single cable

1203 16K322 BRACKET, light tower

1204 --GROMMET, multiple wires

1205 125835 CLIP, ferrite bead

--- Not for sale.

Qty

1

3

1

1

1

1

333347P

AA

1204

J12

111

Accessories

Light Tower Kit Installation

Air Reservoir Kit, 16W366

This kit allows the system to operate as low as 60 psi

(0.4 MPa, 4 bar).

1.

Turn main power switch OFF.

2.

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

3.

Remove existing grommet (AA) from electrical enclosure then install new grommet (1204) in its place.

4.

Insert grommet (1202) into hole on the light tower bracket (1203).

5.

Remove bolts (BB) from metal shroud on the system then use the bolts (BB) to secure bracket (1203) to metal shroud.

6.

Route light tower cable through hole in bracket (1203) then use supplied light tower screws (1201a) to install light tower (1201).

7.

Remove electrical enclosure front access door.

8.

Route light tower cable through the other hole in the bracket (1203), then through the grommet (1204) into the electrical enclosure.

9.

Connect light tower cable to MZLP connector labeled J12.

1505

1503

1504*

1504

1505

1506

WLD

1501

16W366 Parts

Ref Part Description

1501 --HOSE, nylon (6 ft)

1502 100081 BUSHING, pipe

1503 113777 TEE, branch

1504* 114485 CONNECTOR, male, 3/8 npt

1505 155665 UNION, adapter

1506 --TANK, air, accumulator

--- Not for sale.

*

Metric fitting included in Air Metric Fitting Kit,

24W637, page 118.

Qty

1

1

1

1

1

2

112 333347P

Accessories

4 Channel Upgrade Kit, 24V528

Use this kit to upgrade a 2 channel system to a 4 channel system.

CC

AA

1307

BB

1301

1308

1305

1308

1302

Ref Part Description

1301 --MODULE, GCA, MZLP

1302 16T087 CABLE, jumper, male/male,

21 in.

1303 --HARNESS, 2nd MZLP power

1304 112190 STRAP, wrist, grounding

1305 16T440 CAP, jam nut, sealing

1306 24R324 SOFTWARE UPGRADE TOKEN,

InvisiPac System

1307 ---

1308 ---

FITTING, straight

LABEL, InvisiPac Channel Numbers

Qty

1

1

2

1

2

1

1

1

Not shown.

--- Not for sale.

1304

333347P

1306

113

Accessories

4 Channel Upgrade Kit Installation

1.

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

2.

Place grounding wrist strap (1304) over your wrist and secure other end to a grounded surface.

3.

Set the MZLP (1301) rotary switch to “2”.

4.

Remove screws (BB) then remove plate (AA) from system.

5.

Use screws (BB) to install MZLP (1301) onto system. Apply labels from label sheet (1308) to MZLP

#2. Place the “3” and “4” labels as shown in parts illustration.

NOTE: The new MZLP (1301) with be referred to as

MZLP 2, and the original MZLP that came with the sys-

tem will be referred to as MZLP 1 from here on. See F

IG

.

1.

6.

Remove electrical enclosure front access door.

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. Verify the connector has “Locked” by gently pulling on the white connector housing.

7.

Connect CAN jumper cable (1302) to MZLP 1 connector J3 and connect other end of jumper

cable (1302) to MZLP 2 connector J6. See F

IG

. 1.

8.

Connect power harness (1303) to MZLP 2 connector J2.

9.

Remove plugs (CC) from fluid manifold and replace with straight fittings (1307) or the extra fittings included with the InvisiPac system. Use the fittings that meet your hose routing needs.

10. To ensure your InvisiPac system has the latest soft-

ware, insert token (1306) into ADM. Follow Soft-

ware Update Procedure, page 81.

J6

J5

Step 7: Install Jumper Cable (1302).

MZLP 2 MZLP 1

J9

J1

J2

J8

J3

J8

J2

J1

J9

J3

J6

J5 ti23596a

F

IG

. 1

114 333347P

Accessories

6 Channel Upgrade Kit, 24V529

Use this kit to upgrade a 4 channel system to a 6 channel system.

CC

1304

1308

1303

WLD

1306

1301

1302

1307

BB

1305

BB

AA

Ref Part

1301 ---

Description

MODULE, GCA, MZLP

1302 16T087 CABLE, jumper, male/male, 4 in.

1303 112190 STRAP, wrist, grounding

1304 24R324 TOKEN, software upgrade

1305 16T440 CAP, jam nut, sealing

1306 --HARNESS, MZLP #3

1307 16W035 CONNECTOR, jumper

1308

1309

--FITTING, tee

Qty

1

1

1

1

1

1

2

2

333347P 115

Accessories

6 Channel Upgrade Kit Installation

1.

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

2.

Place grounding wrist strap (1303) over your wrist and secure other end to a grounded surface.

3.

Set the kit’s MZLP (1301) rotary switch to “3”.

4.

Remove screws (BB) then remove plate (AA) from system.

5.

Use screws (BB) to install MZLP (1301) onto system.

NOTE: The new MZLP (1301) will be referred to as

MZLP 3, and the original MZLPs that came with the system will be referred to as MZLP 1 and MZLP 2 from here

on. See F

IG

. 2.

6.

Remove electrical enclosure front access door.

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. Verify the connector has “Locked” by gently pulling on the white connector housing.

7.

Connect CAN jumper cable (1302) to MZLP 2 connector J3 and connect other end of jumper

cable (1302) to MZLP 3 connector J3. See F

IG

. 2.

8.

Install jumper connector (1307) in J5 on MZLP 3.

9.

Connect wires from power harness (1306) between

AWB connector J5 and MZLP connector J2.

10. Remove plugs (CC) from fluid manifold and replace with straight fittings (1309), tee fittings (1308), or the extra fittings included with the InvisiPac system.

Use the fittings that meet your hose routing needs.

11. To ensure your InvisiPac system has the latest soft-

ware, insert token (1306) into ADM. Follow Soft-

ware Update Procedure, page 81.

F

IG

. 2

116

-

-

0=/3

-

-

-

-

-

Step 7: Install jumper cable (1302).

-

-

-

0=/3

-

-

-

-

-

-

-

-

0=/3

-

-

-

WLD

333347P

Accessories

InvisiPac ADM Simulator Kit, 24R323

Use this kit to train users in ADM operation without using the full InvisiPac system. Kit includes everything necessary to simulate the ADM screens. Does not include an InvisiPac system.

Simulator Instructions

1.

Remove ADM access panel and install InvisiPac

Simulator Token (1404).

1401

1402 r_24P860_3B9900_3a

F

IG

. 3: Remove Access Panel

1404

1403

2.

Connect power supply (1402) to ADM (1401).

3.

Connect cord (1403) to power supply (1402).

4.

Perform Software Update Procedure on page 81.

ti20990a

ADM Extension Kits

Use the extension cables to remote mount the ADM display off of the InvisiPac system. Kits available separately.

Ref Part Description

1401 24P860 MODULE, Advanced Display

(ADM)

1402 124149 POWER SUPPLY, GCA

1403 --CORD SET, US, MX, PR, CA,

TW, 115V, 10A

1404 24R322 TOKEN, InvisiPac Simulator

1405 24R324 SOFTWARE UPGRADE

TOKEN, InvisiPac System

Qty

1

1

1

Kit No.

Cable Length

24R710 16.4 ft (5 m)

24R711 49.2 ft (15 m)

24R712 164 ft (50 m)

1

1

Qty.

1

1

1

ADM Remote Mount Bracket,

24A326

This bracket is used to remote mount the ADM display, along with an ADM extension cable.

Ref.

1

Part Description

BRACKET, mounting assembly

Qty.

1

333347P 117

Accessories

Overtemperature Jumper,

16Y727

Use the Overtemperature jumper plug to run the

InvisiPac melter without a hose and applicator attached to the Channel 1 electrical connection.

Air Metric Fitting Kit, 24W637

For replacing air fittings with metric air fittings on Invisi-

Pac systems. See manual 334358 for installation instructions.

Ref.

1

2

3

4

Part Description

127922 FITTING, 3/8 npt(m) x M18(f)

127923 FITTING, 1/4 npt(m) x 10 mm tube

127924 FITTING, 1/4 npt(m) x 10 mm

90° elbow tube

127925 FITTING, 3/8-18 npt (m) x

3/8-19 bspt (f)

Qty.

1

1

1

1

WLD

Installation

1.

In the ADM setup screens, uninstall Channel 1. All other Channels can be installed or uninstalled as needed.

Strain Relief Bushing Kit,

24X190

The strain relief bushing kit allows the use of a smaller outside diameter (OD) power cord. This strain relief bushing is intended for power cords with an OD of

0.512-1.024 in (13-26 mm).

Installation

1.

Remove standard strain relief bushing (106). Retain and reuse nut.

2.

Install strain relief bushing from kit and secure with retained nut.

Hose Straps (4 Pack), 240296

Use these straps to secure hoses without excessive pinching.

Ref.

1

Part Description

114271 STRAP, retaining

Qty.

4

NOTE: Failure to uninstall Channel 1 on the ADM setup screens will result in several Alarms regarding Channel

1 when there is no hose/applicator attached to Channel

1.

2.

Attach the Overtemperature jumper plug to Channel

1.

3.

The ADM should have zero Active Alarms. The melter is now ready to run without a hose and applicator attached to Channel 1.

Pressure Gauge Replacement

Kit, 24U635

To replace the air gauge glass lenses and glass fuses used in the food or beverage industries.

Ref.

1

2

3

Description

GAUAGE, pressure, acrylic

TOOL, puller, fuse

FUSE, 250v, 8a

Qty.

2

1

32

118 333347P

400VAC and 480VAC Transformer Kits

Use one of these kits to transform higher voltage power (400VAC or 480VAC) to 240VAC.

Kit

127567

127568

Description

KIT, 400VAC Transformer

KIT, 480VAC Transformer

Adapter Cable

Part

128621

Description

Adapter cable allows non-Graco Ni120 RTD Hoses to be used on InvisPac

Accessories

333347P 119

Appendix A - ADM

Appendix A - ADM

General Operation

ADM Power

The ADM automatically turns on when the main power switch is turned ON.

Screen Navigation

To switch between the Setup and Operation screens, press . Use between screens.

, , , and to navigate

NOTE: For information on InvisiPac Pattern Controller screens, see manual 334784.

Enable, Disable Heating System

To enable or disable the entire heating system, press . To set which channels are active when the heating system is enabled, use the System 2 screen.

See page 123.

Icon Identification

Icon Description

Operation Screens Only

Heating disabled

Warming up, actual temperature is below setting

Temperature setting achieved

Actual temperature of hose

(left) and applicator (right)

Actual temperature of system

(shown warming up)

System temperature setting.

Use ting.

and to adjust set-

120

Icon Description

Use the physical numeric keypad on ADM to enter temperature setting.

Select channel to view and/or edit the applicator or hose temperature setting

Applicator temperature setting.

Use ting.

and to adjust set-

Hose temperature setting.

Use ting.

and to adjust set-

Use to adjust temperature settings

Temperature settings of applicator

(top) and hose (bottom)

Reset weight total

Reset material target

Setup Screens Only

Enter screen to change settings

Exit screen

Reset Maintenance error

Schedule Screen Only

Edit schedule value

Erase schedule value

Accept schedule change

Cancel schedule change

333347P

Appendix A - ADM

Operation Screens

Home Events

This screen shows the actual temperatures of the system melter and each applicator and hose.

Targets

This screen shows and allows editing of the temperature settings for the system melter and each applicator and

hose. See Select ADM Settings on page 23.

The Events screens store a maximum of 200 events.

The events list can be downloaded in the USB logs. See

Appendix B - USB Downloading, Uploading on page 126.

Tracked Events

Custom Language Downloaded

Custom Language Uploaded

Fill Valve Closed

Fill Valve Open

Heat Off

Heat On

High Material Usage

Logs Downloaded

Low Material Usage

Material Target Reset

Pump Cycles Total Reset

Pump Off

Pump On

Red Stop Button Pressed

Setup Value Changed

System Power Off

System Power On

System Settings Downloaded

System Settings Uploaded

USB Disabled

USB Drive Inserted

USB Drive Removed

User Maintenance Count Reset

EQU5

ECAL

ERM1

ERD1

EBPX

EAPX

EB0X

EC0X

Code

EQU3

EQU4

EBFX

EAFX

EBDX

EADX

ECAH

EM0X

EL0X

EQU1

EQU2

EVUX

EAUX

EBUX

ERN1

* Zone

333347P 121

Appendix A - ADM

Errors

The Errors screens store a maximum of 200 errors. See

ADM Error Code Table on page 44. The errors list can

be downloaded in the USB logs. See Appendix B -

USB Downloading, Uploading on page 126.

Diagnostic

This screen shows details of various items to aid in troubleshooting the system. This screen can be hidden by de-selecting “Enable Diagnostics Screen” on the System 3 screen. The flow rate updates every 15-20 seconds with the average flow rate over the last 15-20 seconds.

The following information is displayed.

Diagnostic Data

A

Current Draw

B

RTD Reading

C

Duty Cycle

CAN: 24 VDC power supply voltage reading (18-28

VDC)

DI: System Digital Inputs

0: Not Used

1: Not Used

2: Pump Cycle Switch Up

3: Pump Cycle Switch Down

DO: System Digital Outputs

0: Pump Solenoid

1: Fill Solenoid

2: Light Tower Green Light

3: Light Tower Red Light

ISO DI: Customer Digital Inputs

0: Customer Input 1

1: Customer Input 2

2: Customer Input 3

3: Customer Input 4

ISO DO: Customer Digital Outputs

0: Customer Input 1

1: Customer Input 2

2: Customer Input 3

3: Customer Input 4

Fill: Reading of Ultrasonic Fill Sensor

• Old Fill Sensor (2750-2400 mV)

• New Fill Sensor (4200-3800 mV)

Fill Sol: Current draw of fill solenoid

• (0 mA - off)

• (150-250 mA - on)

Flow/H: Melt rate of the system

Life Cycles: total number of pump cycles over life of system.

Life Weight: Weight of material dispensed over life of system.

Pump Sol: Current draw of pump solenoid

• (0 mA - off)

(150-250 mA - on)

PCB Temp: PCB Temperature on MZLP1

32-16°F (0-71°C)

Pump CPM: Pump cycles per minute.

USB DL%: Percentage Complete, only applies when downloading USB data.

Material Log

This screen shows a daily log of material usage. For

more details see the Material Tracking section on page

28.

122 333347P

Appendix A - ADM

Setup Screens

NOTE: It is important to set all settings in the System screens correctly to ensure optimal system performance.

Password

System 3

If the password is not “0000”, the password must be entered to access the setup screens.

System 1

System Type: Choose the model of the system.

Enable Diagnostic Screen: Choose whether to hide the Diagnostic screen.

Pump Idle Time to System Inactive: The heating system will be disabled after the pump has been idle for the set amount of time

Power Type: Select the system power type.

Circuit Breaker Size: Select the circuit breaker size.

Refill Setting: To use the automatic vacuum transfer, select Auto. To disable the automatic vacuum transfer, select Manual. The main reason to disable automatic refill is while flushing. However, if an issue is present with the automatic refill system that cannot be solved in a timely manner, manual refill can be used to return the

system to service. See Manual Refill on page 34.

See Select ADM Settings on page 23.

System 4

A PLC can be used to control or monitor the system.

See PLC Connection on page 26 for instructions.

System 2

Use this screen to enable ADM unit counter, enable material alerts and calibrate material tracking.

Use this screen to enable the installed channels and specify the type of applicator RTD type used. See

Select ADM Settings on page 23.

333347P 123

Appendix A - ADM

Enable ADM Unit Counter: Select to enable ADM counting of units using an external sensor.

Enable Material Alerts: Select to enable record only events indicating low/high material usage.

Specific Gravity: Required to convert the volume dispensed to mass dispensed for tracking the total weight and flow rate.

Maintenance

Advanced 1

The system will notify the user at the set interval that maintenance is required. The fields in boxes can be edited by the user. “Due” and “Current” are both the number of cycles since the last reset. “Interval” is the set number of cycles between maintenance notifications.

“Lifetime” is the number of cycles in the lifetime of the system.

NOTE: The lifetime cycle count will only be reset if the

Advanced Display Module (ADM) is replaced.

Schedule

Language: Language displayed on the screen.

Date Format: Choose format of the date.

Date: Set the date.

Time: Set the time.

Enter Password: If not “0000”, the Setup screens will be password protected.

Screen Saver: The screen will go black after the set amount of time.

Silent Mode: Disable ADM sounds.

Lock Run Screens: Disable setpoint changes on the run (operation) screens. If the setup screens are password protected, the setpoints cannot be changed without first entering the password.

Advanced 2

Use this screen to set times where the system will auto-

matically enable and disable heating. See Select ADM

Settings on page 23.

Temperature Units: Units of measure for displayed temperatures.

Mass Units: Units of measure for mass.

Distance Units: Units of measure for distance.

124 333347P

Advanced 3

Disable USB Downloads/Uploads: Disables use of the USB for downloading and uploading.

Disable USB Log Errors: When disabled, the system will not warn the user when logs are full. If the logs are full, data will be overwritten.

Download Depth: Last ___ Days: The USB download will provide data as old as the number of days entered.

Old data may be in memory but will not be downloaded if older than the number of days entered.

Advanced 4

This screen shows the part number and version of each installed software module.

333347P

Appendix A - ADM

125

Appendix B - USB Downloading, Uploading

Appendix B - USB Downloading, Uploading

The system can store 150,000 entries in its logs and the system adds a new entry to the logs every 15 seconds.

This means the system stores 655 hours of system operation data, or 27 days of around-the-clock operation. Once full, the system will overwrite the oldest data.

NOTE: To prevent losing any data, never go more than

27 days without downloading the logs.

Download Procedure

NOTICE

Uploading an edited system configuration file can damage the system. Never put a modified

SETTINGS.TXT file in the UPLOAD folder on the flash drive.

Accessing Files

All files downloaded from the USB are put in a DOWN-

LOAD folder on the stick drive. For example:

“E:\GRACO\12345678\DOWNLOAD\”. The 8-digit numeric folder name matches the 8-digit ADM serial number, which is located on the back of the ADM. When downloading from multiple ADMs, there will be one sub-folder in the GRACO folder for each ADM.

The log files should be opened in a spreadsheet program.

NOTE: If emailing the files, zip (compress) them to minimize file size.

NOTE: The event log, error log, system settings, and system language files are all downloaded in this proce-

dure. See USB Logs, System Settings File, and Sys-

tem Language File starting on page 127.

1.

Insert USB flash drive into USB port. See F

IG

. 4.

NOTE: Flash drive must be 8 GB or smaller.

Upload Procedure

NOTICE

Uploading an edited system configuration file can damage the system. Never put a modified

SETTINGS.TXT file in the UPLOAD folder on the flash drive.

F

IG

. 4: ADM USB Port

2.

The menu bar and USB indicator lights indicate that the USB is downloading files. Wait for USB activity to complete. A pop-up will be present until the transfer is complete if it is not acknowledged.

NOTE: If the pop-up screen does not appear, the flash drive is not compatible with the ADM. Try a different flash drive.

NOTE: The system can log up to 45 mb of additional data per week, depending on system operation.

Use this procedure to install a system configuration file

and/or a custom language file. See System Settings

File or System Language File starting on page 127.

1.

If necessary, follow the Download Procedure, page 126, to automatically generate the proper

folder structure on the USB flash drive.

2.

Insert USB flash drive into USB port of computer.

3.

The USB flash drive window automatically opens. If it does not, open USB flash drive from within Windows Explorer.

4.

Open Graco folder.

5.

Open system folder. If working with more than one system, there will be more than one folder within the

Graco folder. Each folder is labeled with the corresponding serial number of the ADM. (The serial number is on the back of the module.)

6.

If installing the system settings file,

place SET-

TINGS.TXT file into UPLOAD folder.

126 333347P

Appendix B - USB Downloading, Uploading

7.

If installing the custom language file,

place DISP-

TEXT.TXT file into UPLOAD folder.

8.

Remove USB flash drive from computer.

9.

Install USB flash drive into InvisiPac system USB port.

10. The menu bar and USB indicator lights indicate that the USB is uploading files. Wait for USB activity to complete.

11. Remove USB flash drive from USB port.

NOTE: If a custom language file was installed, users can now select the new language from the Language drop-down menu.

NOTE: If the SETTINGS.TXT or DISPTEXT.TXT files remain in the UPLOAD folder, they will be uploaded every time the USB drive is inserted into the corresponding ADM. To avoid unintentionally overwriting system settings, delete the files from the UPLOAD folders on the USB drive after the upload is complete.

USB Logs

During operation, InvisiPac stores system and performance related information to memory in the form of log files. InvisiPac maintains the events, data, GCA, Black

Box, and Diagnostics logs. Follow the Download Pro-

cedure, page 126, to retrieve log files.

Events Log

The event log (1-EVENT.CSV) maintains a record of the last 175,000 events. Each event record in the log file contains the date and time the event occurred, the event type, event code, and event description.

Data Log

The data log (2-DATA.CSV) tracks the setpoint and actual temperatures every 15 seconds. This log can store up to 250,000 lines of data.

The system stores 1041 hours of system operation data, or 43 days of around-the-clock operation. Once full, the system will overwrite the oldest data.

NOTE: To prevent losing any data, never go more than

43 days without downloading the logs.

GCA Log

This log (3-GCA.CSV) lists the installed GCA modules and their respective software versions.

Black Box, Diagnostics Logs

These logs (4-BLACKB.CSV, 5-DIAGN.CSV) are designed to provide useful information to Graco when calling for technical assistance.

System Settings File

NOTICE

Uploading an edited system configuration file can damage the system. Never put a modified

SETTINGS.TXT file in the UPLOAD folder on the flash drive.

The system configuration settings file name is

SETTINGS.TXT and is stored in the DOWNLOAD folder.

A system configuration settings file automatically downloads each time a USB flash drive is inserted. Use this file to back up system settings for future recovery or to easily replicate settings across multiple InvisiPac sys-

tems. Refer to the Upload Procedure, page 126, for

instructions on how to use this file.

It is recommended to retrieve the SETTINGS.TXT file after all system settings are set as desired. Store the file for future use as a backup in case the settings are changed and need to be quickly changed back to the desired setup.

NOTE: System settings may not be compatible between different versions of the InvisiPac software.

333347P 127

Appendix B - USB Downloading, Uploading

System Language File

The system language file name is DISPTEXT.TXT and is stored in the DOWNLOAD folder.

A system language file automatically downloads each time a USB flash drive is inserted. If desired, use this file to create a user-defined set of custom language strings to be displayed within the ADM.

The system is able to display the following Unicode characters. For characters outside of this set, the system will display the Unicode replacement character, which appears as a white question mark inside of a black diamond.

• U+0020 - U+007E (Basic Latin)

• U+00A1 - U+00FF (Latin-1 Supplement)

• U+0100 - U+017F (Latin Extended-A)

• U+0386 - U+03CE (Greek)

• U+0400 - U+045F (Cyrillic)

Create Custom Language Strings

The custom language file is a tab-delimited text file that contains two columns. The first column consists of a list of strings in the language selected at the time of download. The second column can be used to enter the custom language strings. If a custom language was previously installed, this column contains the custom strings. Otherwise the second column is blank.

Modify the second column of the custom language file

as needed and then follow the Upload Procedure, page 126, to install the file.

The format of the custom language file is critical. The following rules must be followed in order for the installation process to succeed.

• The file name must be DISPTEXT.TXT.

• The file format must be a tab-delimited text file using Unicode (UTF-16) character representation.

• The file must contain only two columns, with columns separated by a single tab character.

• Do not add or remove rows to the file.

• Do not change the order of the rows.

• Define a custom string for each row in the second column.

128 333347P

Technical Data

Technical Data

InvisiPac Hot Melt Delivery System

US Metric

Incoming Power

HM25: 24V423, 24Y102

HM50: 24T918, 24Y114

200-240 VAC, 1-ph, 50/60 Hz, 32A

200-240 VAC, 3-ph,

Δ

, 50/60 Hz, 27A

350-415 VAC, 3-ph, Y, 50/60 Hz, 16A

HM25: 24V429, 24Y106

HM50: 24V201, 24Y118

HM25: 24V424, 24Y103

HM50: 24T919, 24Y115

400-480 VAC, 3-ph,

Δ

, 50/60 Hz, 14A

200-240 VAC, 1-ph, 50/60 Hz, 40A

200-240 VAC, 3-ph,

Δ

, 50/60 Hz, 27A

350-415 VAC, 3-ph, Y, 50/60 Hz, 16A

HM25: 24V430, 24Y107

HM50: 24V202, 24Y119

HM25: 24V425

HM50: 24T920

400-480 VAC, 3-ph,

Δ

, 50/60 Hz, 14A

200-240 VAC, 1-ph, 50/60 Hz, 40A

200-240 VAC, 3-ph,

Δ

, 50/60 Hz, 40A

350-415 VAC, 3-ph, Y, 50/60 Hz, 30A

HM25: 24V431

HM50: 24V203

HM25: 24V426, 24Y104

HM50: 24V198, 24Y116

HM25: 24V427, 24Y105

HM50: 24V199, 24Y117

HM25: 24V428

HM50: 24V200

Electrical

Minimum Applicator Wattage Per Channel at 240

VAC

Maximum Applicator Wattage Per Channel

Input / Output Capability

Pump Flow Rate

HM25

HM50

Melt Rate / Constant Throughout

400-480 VAC, 3-ph,

Δ

, 50/60 Hz, 14A

335-400 VAC, 3-ph Y, 50/60 Hz, 17A

335-400 VAC, 3-ph Y, 50/60 Hz, 17A

335-400 VAC, 3-ph Y, 50/60 Hz, 17A

90 W

400 W

4 inputs (0-30V), 4 outputs (240VAC, 24VDC, 2A)

96 lb/hr

130 lb/hr

43.5 kg/hr

59 kg/hr

HM25

HM50

Weight

HM25

25 lb/hr

50 lb/hr

11.3kg/hr

22.6 kg/hr

HM50

General

Adhesive

Pump Output

Time to Temperature *

85 lb

105 lb

36 kg

48 kg

1/4 in. (6 mm), round, adhesive pellets

19.3 cc/cycle

Less than 15 minutes

Pump

Channels

Pneumatic Piston, 12:1

1 to 6

System Dimensions (Width x Height x Depth) ** 19.0 x 42 x 16.5 in.

Pressure and Temperature Ranges

Main System Air Supply Pressure Range (set with regulator on front of system)

80-100 psi

483 x 1067 x 419 mm

0.55-0.69 MPa (5.5-7 bar)

333347P 129

Technical Data

InvisiPac Hot Melt Delivery System

US

0.14-0.69 MPa (0.7-7 bar)

1.7-8 MPa (17-80 bar)

38-204°C

0-49°C

Metric

Pump Operating Air Pressure Range

Pump Operating Fluid Pressure Range

Control Temperature Range

Ambient Temperature Range

Vacuum Transfer Specifications

InvisiPac Base System

Wetted Parts

Wetted Parts

Approvals and Standards

20-100 psi

240-1200 psi

100-400°F

32-120°F

Maximum Vacuum Transfer Hose Length 30 ft

Maximum Vacuum Transfer Hose Maximum Vertical Rise

10 ft

40-100 psi Vacuum Transfer Operating Pneumatic Pressure

Range (set with regulator on front of system)

Vacuum Transfer Air Consumption at 40 psi (280 kPa, 2.8 bar),

Vacuum Transfer Air Consumption at 80 psi (550 kPa, 5.5 bar)

Required Air Tubing Size

9.5 scfm (intermittent duty; 4% at

25 lb/hr)

9.1 m

3.0 m

280-690 kPa (2.8-6.9 bar)

16.1 scmh (intermittent duty; 4% at

11.3 kg/hr)

17.2 scfm (intermittent duty; 4% at

25 lb/hr)

29.2 scmh (intermittent duty; 4% at

11.3 kg/hr)

9.5 mm Minimum Air Tubing Inner Diameter (less than 50 ft, 15.2 m of tubing)

Sound Pressure Level***

IP Code

3/8 in.

Minimum Air Tubing Inner Diameter (50 ft, 15.2 m or longer of tubing)

Sound

1/2 in.

77 dB(A)

12.7 mm

IP54

PTFE, chemically resistant o-rings, aluminum, stainless steel, zinc plating, carbon steel, brass, carbide, chrome

UL499, CSA88, CE, ISO

* From 70°F to 350°F (21°C to 177°C), dependant upon power supply and machine configuration.

** Excludes vacuum transfer tube, shaker assembly, and pellet storage bin.

*** Sound pressure level measured 3.1 ft (1 meter) from equipment.

130 333347P

Technical Data

Startup Time

Single Phase

5

5

4

4

3

4

3

3

6

6

5

6

2

2

2

1

1

1

NOTE: Times are approximate and may vary with ambient conditions, voltage configuration, and machine configuration.

Start Time in Minutes

System

5

5

4

4

3

4

3

3

Channels

(#)

1

1

2

2

1

2

6

6

5

6

Hose

Length ft (m)

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

20 Amp

Breaker

240V

11

13

15

13

16

20

15

19

26

16

22

31

18

25

36

20

28

41

30 Amp

Breaker

240V

9.9

9.9

9.9

9.9

9.9

13

9.9

12

16

9.9

14

20

11

16

23

12

18

27

40 Amp

Breaker

240V

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

12

9.9

9.9

14

9.9

11

17

9.9

13

20

50 Amp

Breaker

240V

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

12

9.9

9.9

14

9.9

10

16

20 Amp

Breaker

208V

13

14

17

15

18

23

17

22

29

18

25

35

20

28

41

22

32

47

30 Amp

Breaker

208V

13

13

13

13

13

13

13

13

19

13

16

23

13

18

27

13

20

31

13

16

13

13

13

13

13

13

40 Amp

Breaker

208V

13

13

13

13

13

13

19

13

13

22

13

13

13

13

13

13

13

13

50 Amp

Breaker

208V

13

13

13

13

13

13

15

13

13

18

30

37

25

34

21

27

32

23

42

27

37

47

19

23

27

17

19

21

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

19

24

16

22

15

17

21

15

28

17

24

31

15

15

17

15

15

15

15

18

15

16

15

15

15

15

20

15

18

23

15

15

15

15

15

15

15

15

15

15

15

15

15

15

16

15

15

18

15

15

15

15

15

15

34

42

28

38

24

30

36

26

48

30

42

54

21

26

30

20

21

24

22

27

20

25

20

20

23

20

31

20

27

36

20

20

20

20

20

20

20

20

20

20

20

20

20

20

23

20

20

26

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

21

20

20

20

20

20

20

333347P 131

Technical Data

Three Phase

NOTE: Times are approximate and may vary with ambient conditions, voltage configuration, and machine configuration.

System

Channels

(#)

1

1

Hose

Length ft (m)

4 (1.2)

12 (3.6)

1

2

2

2

25 (7.6)

4 (1.2)

12 (3.6)

3

3

3

4

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

4

4

5

5

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

5

6

6

6

1

1

1

2

2

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

3

3

2

3

4 (1.2)

12 (3.6)

25 (7.6)

4 (1.2)

4

5

4

4

12 (3.6)

25 (7.6)

4 (1.2)

12 (3.6)

6

6

5

5

6

25 (7.6)

4 (1.2)

12 (3.6)

25 (7.6)

31

40

24

34

45

22

28

35

22

26

20

26

31

19

21

19

23

21

27

16

23

30

15

19

24

16

18

15

17

21

15

15

15

15

20 Amp

Breaker

240V

30 Amp

Breaker

240V

11

13

9.9

9.9

Start Time in Minutes

40 Amp

Breaker

240V

50 Amp

Breaker

240V

20 Amp

Breaker

208V

30 Amp

Breaker

208V

9.9

9.9

9.9

9.9

13

14

13

13

40 Amp

Breaker

208V

50 Amp

Breaker

208V

13

13

13

13

23

12

17

26

15

14

20

11

16

9.9

12

17

10

9.9

9.9

11

14

34

18

26

39

17

21

30

17

23

14

18

25

15

15

13

16

20

9.9

9.9

9.9

10

9.9

9.9

13

9.9

11

15

9.9

12

17

9.9

13

19

15

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

12

9.9

9.9

14

9.9

11

16

15

16

14

17

22

16

20

26

17

23

34

19

27

40

21

30

46

20

13

13

13

14

13

13

18

13

15

22

13

18

27

14

20

31

20

13

13

13

13

13

13

13

13

13

17

13

14

20

13

15

23

20

16

13

13

19

20

13

13

13

13

13

13

13

13

13

13

13

13

16

20

15

17

23

15

15

18

15

15

15

15

16

15

15

15

15

15

16

15

15

18

15

15

15

15

15

15

15

15

15

15

15

15

36

47

28

40

53

24

32

40

26

28

22

28

34

20

22

20

24

24

31

20

27

35

20

22

27

20

20

20

20

23

20

20

20

20

20

24

20

20

27

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

20

21

20

20

20

20

20

20

20

20

20

20

20

20

132 333347P

Dimensions

240V System Dimensions System With 480V Transformer

Technical Data

A

A

B

C

WLD

HM25 HM50

A 35.5 in. (901.7 mm) 35.8 in. (409.3 mm)

B 20.8 in. (528.3 mm) 22.3 in. (566.4 mm)

C 17.6 in. (447.0mm) 18.3 in. (464.8 mm)

B

C

HM25

A 41.6 in. (1056.6 mm)

B 20.9 in. (530.9 mm)

C 17.6 in. (447.0 mm)

WLD

HM50

41.9 in. (1064.3 mm)

22.3 in. (566.4 mm)

18.3 in. (464.8 mm)

333347P 133

Technical Data

Mounting Hole Dimensions

WALL

2.0 in.

(51 mm)

Minimum distance from rear mounting hole to wall: 7.0 in. (178 mm)

1.4 in.

(35.6 mm)

HM25

HM50

C

14.2 in.

(361 mm)

7.1 in. (180 mm)

A

10.3 in.

(261.6 mm)

11.1 in.

(281.9 mm)

B

3.3 in.

(83.8 mm)

4.0 in.

(101.6 mm)

B

WLD

C

3.3 in.

(83.8 mm)

4.0 in.

(101.6 mm)

HM25

HM50

C

7.1 in.

(180 mm)

14.2 in. (361 mm)

A

11.1 in.

(281.9 mm)

11.9 in.

(302.3 mm)

B

3.4 in.

(86.4 mm)

4.0 in.

(101.6 mm)

B

C

3.4 in.

(86.4 mm)

4.0 in.

(101.6 mm)

134 333347P

System with Stand Dimensions

A

A

System

System With Transformer

17.4

(442 mm) ti22866c

in. (mm)

60.7 in. (1542 mm)

66.5 (1689 mm)

27.2 in.

(692 mm)

333347P

31.3

(795 mm) ti22865b

Technical Data

135

Graco Extended Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of eighteen months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

Sealant and Adhesive Dispensing Equipment

For the latest information about Graco products, visit

www.graco.com

.

For patent information, see

www.graco.com/patents .

TO PLACE AN ORDER, contact your Graco distributor, go to

www.graco.com

and select

“Where to Buy” in the top blue bar, or call to find the nearest distributor.

If calling from the US: 800-746-1334

If calling from outside the US: 0-1-330-966-3000

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original instructions.

This manual contains English. MM 333347

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision P, February 2017

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