Graco 3A2347N - InvisiPac HM25 Tank-Free Hot Melt Delivery System Instructions

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Graco 3A2347N - InvisiPac HM25 Tank-Free Hot Melt Delivery System Instructions | Manualzz

Instructions - Parts

InvisiPac ™

HM25 Tank-Free ™

Hot Melt Delivery System

3A2347N

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 gun and hose manuals.

Save all instructions. ti20440b

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Component Identification . . . . . . . . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Attach Components . . . . . . . . . . . . . . . . . . . . . 14

Recommended Air Setup . . . . . . . . . . . . . . . . . 18

Connect Electrical Cord . . . . . . . . . . . . . . . . . . 19

480V Electrical Circuits . . . . . . . . . . . . . . . . . . . 21

208V Electrical Circuits . . . . . . . . . . . . . . . . . . . 21

Select ADM Settings . . . . . . . . . . . . . . . . . . . . . 21

Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

PLC Connection . . . . . . . . . . . . . . . . . . . . . . . . 24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Initial Startup and Prime . . . . . . . . . . . . . . . . . . 26

Manual Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Automatic Refill . . . . . . . . . . . . . . . . . . . . . . . . . 28

Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Pressure Relief Procedure . . . . . . . . . . . . . . . . 30

Drain the System . . . . . . . . . . . . . . . . . . . . . . . 30

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Operation Tips to Minimize Charring . . . . . . . . . 32

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Replace Outlet Filter . . . . . . . . . . . . . . . . . . . . . 33

Replace Inlet Filter . . . . . . . . . . . . . . . . . . . . . . 33

Replace Funnel Filter . . . . . . . . . . . . . . . . . . . . 34

Filter Maintenance Guidelines* . . . . . . . . . . . . . 35

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

ADM Error Code Table . . . . . . . . . . . . . . . . . . . 36

Graco Information 116

MZLP Troubleshooting . . . . . . . . . . . . . . . . . . . 49

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Multi-Zone Low Power Temperature Control Module

(MZLP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Software Update Procedure . . . . . . . . . . . . . . . 69

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 70

Incoming Power and Terminal Jumpers . . . . . . . 70

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Non-Graco Gun Adapter Cables . . . . . . . . . . . . 88

Air Adjustment Lock, 24R084 . . . . . . . . . . . . . . 88

System Stand, 24R088 . . . . . . . . . . . . . . . . . . . 89

Caster for Stand, 120302 . . . . . . . . . . . . . . . . . 89

Adapter Plate, 24R083 . . . . . . . . . . . . . . . . . . . 89

30 Gallon Vibrating Hopper, 24R136 . . . . . . . . . 90

Light Tower Kit, 24R226 . . . . . . . . . . . . . . . . . . 92

Air Reservoir Kit, 16W366 . . . . . . . . . . . . . . . . . 93

Appendix A - ADM . . . . . . . . . . . . . . . . . . . . . . . . 101

General Operation . . . . . . . . . . . . . . . . . . . . . . 101

Icon Identification . . . . . . . . . . . . . . . . . . . . . . . 101

Appendix B - USB Downloading, Uploading . . . 107

Download Procedure . . . . . . . . . . . . . . . . . . . . 107

Accessing Files . . . . . . . . . . . . . . . . . . . . . . . . 107

Upload Procedure . . . . . . . . . . . . . . . . . . . . . . 107

USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

System Settings File . . . . . . . . . . . . . . . . . . . . 108

System Language File . . . . . . . . . . . . . . . . . . . 109

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Graco Extended Warranty . . . . . . . . . . . . . . . . . . 116

3A2347N

Related Manuals

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

Part

3A2805

332072

Description

InvisiPac GS35 Hot Melt Gun Instructions -

Parts

InvisiPac Heated Hose Instructions - Parts

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

3A2347N 3

4

Models

Models

NOTICE

To prevent system damage, verify terminal jumpers are installed correctly before applying power.

Model Channels

24P260 2

24P261

24P262

4

2

Voltage ˓ Type

200-240VAC 1 ˓ / PE

200-240VAC 1 ˓ / PE

350-415VAC Y 3

˓

/ Neutral / PE

24P263 4 350-415VAC Y 3 ˓ / Neutral / PE

24P264

24P265

2

4

200-240VAC ˂

200-240VAC ˂

3

3

˓

˓

/ PE

/ PE

24U132 6 200-240VAC

1 ˓ / PE

24U133 6 350-415VAC Y 3 ˓ / Neutral / PE

24U134 6 200-240VAC ˂ 3 ˓ / PE

Description

• 1-Phase

• 200-240VAC

• 2 wire and PE

• 3-Phase with Neutral

• 350-415 VAC Line to

Line

• 200-240VAC Line to

Neutral

• 3 wire and Neutral and

PE

• 3-Phase without

Neutral

• 200-240 VAC Line to

Line

• 3 wire and PE

• 1-Phase

• 200-240VAC

• 2 wire and PE

• 3-Phase with Neutral

• 350-415 VAC Line to

Line

• 200-240VAC Line to

Neutral

• 3 wire and Neutral and

PE

• 3-Phase without

Neutral

• 200-240 VAC Line to

Line

• 3 wire and PE

Frequency

Max

Amps

50/60 Hz 32A

50/60 Hz 40A

50/60 Hz 16A

50/60 Hz

50/60 Hz

50/60 Hz

50/60 Hz

50/60 Hz

50/60 Hz

16A

27A

27A

40A

30A

40A

3A2347N

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.

3A2347N 5

6

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.

3A2347N

3A2347N

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.

7

Component Identification

Component Identification

G3 G2

G4

A

G

H

G1

F

E

C

D B

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

G Shaker Tube

G1 Shaker Head

G2 Vacuum Transfer Tube

G3 Vacuum Transfer Inlet Funnel

G4 Vacuum Transfer 3/8 in. OD Air Supply

H Main Power Switch

J System Air Inlet

K Vacuum Transfer (Shaker) 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 1-4)

S Customer I/O Cable (optional)

P

K

R

F IG . 1

8 ti20441b

J

S

3A2347N

N

L

M

Component Identification

Heated Fluid Manifold

AB

Z

U

X

T

AA

R

Y

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

AA Power and RTD Harness Connection to Heated Hose and

Gun (harness connects from system to heated hose then from heated hose to gun)

AB Inlet Funnel Screen ti20442b

W1

W2

3A2347N 9

Component Identification

Electrical Enclosure

AF

F IG . 3

Key:

P Multi-Zone Low Power Temperature Control Module

(MZLP)

AC Incoming Power Connection

AF Chassis Ground

AG Terminal Blocks and Jumpers

AH Heater Relay

AJ Incoming Power Terminal Jumpers. See page 19.

10

AG ti20907a

AH

AJ

AC

P

3A2347N

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 Appendix A - ADM on page 101 for com-

plete ADM operation details.

BB

BC

BA

BD

BE

BF

BK

BL

BR

BM

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

BH

BG

TI12362a1

F IG . 4

B

Ke y 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

3A2347N 11

Component Identification

Screen Components

Current date and time

Operating Mode

Screens Order

Faults, Status

Melter Heating Status

Melter Actual Temperature

Hose and Gun

Heating Status

Hose Actual Temperature

F IG . 6: Main Screen Components

Operating Mode

System Off

Inactive

Warm Up

Active

Gun Actual Temperature

Description

The system doesn’t have power.

The heating system and pumps are disabled.

The system is increasing 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 (manually changed)

• 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

12 3A2347N

Component Identification

3A2347N 13

Setup

Setup

Grounding Attach Components

The equipment must be grounded to reduce the risk of electric shock. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

The InvisiPac system is equipped with a ground terminal. Have a qualified electrician ground the system using this terminal. See

Connect Electrical Cord

on

page 19.

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).

The gun(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 89.

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

Adapter Plate, 24R083

. See

page 89.

Optional 30 Gallon Vibrating Hopper, 24R136 , available (purchase separately). See page 90.

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

To reduce the risk of electric shock, do not connect electrical cord until after this

Attach Components

procedure is complete.

1. Place the base system in the desired operating location and orientation. See

Location

on this page.

• 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 89.

• To raise the system to eye-level, purchase

System

Stand, 24R088 . See installation instructions on page 89.

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

2. Install vacuum transfer inlet funnel (G3) onto system. See F IG . 7.

a. Slide funnel through the bracket connected to the air motor.

b. Position the funnel so the funnel inlet faces the desired direction.

c. Connect 5/32 in. OD air line to funnel.

14 3A2347N

Setup d. Install supplied hose clamp around the air motor bracket and funnel base then tighten.

G3

G2

6. Apply pipe sealant to threads then attach steel

shaker tube (G) to shaker head (G1). See F IG . 8.

NOTICE

To prevent shaker head (G1) galling to the shaker tube (G), do not overtighten shaker head onto shaker tube. These should be hand-tightened.

G2

G6

G4 ti21130b

F IG . 7

3. Insert 1.3 in. (33 mm) OD clear vacuum transfer hose (G2) into vacuum transfer funnel (G3) inlet and secure with supplied hose clamp. See F IG . 7.

4. 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 . 7.

NOTE: In the following steps, 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.

5. Route the 1.3 in. (33 mm) OD clear vacuum transfer hose from the system to the adhesive pellets container location.

G5

G

G4

G1 ti21131a

F IG . 8

7. Attach 1.3 in. (33 mm) clear vacuum transfer hose

(G2) to steel shaker tube (G) and secure with sup-

plied hose clamp. See F IG . 8.

8. Route the 3/8 in. OD air line (G4) alongside the

1.3 in. (33 mm) clear vacuum transfer hose (G2) and secure at multiple points with the supplied zip

ties (G5). See F IG . 8.

9. If desired, secure the 1.3 in. (33 mm) clear vacuum transfer tube and 3/8 in. OD air line with zip ties to a supporting structure at various points in the routing.

10. Attach the other end of the long 3/8 in. OD air line

(G4) to the 3/8 in. push-to-connect fitting on the shaker head (G1).

11. Ensure the adhesive pellets container is in the desired operating location. The location should be chosen to make it easy to fill the container with pellets.

3A2347N 15

Setup

12. Place shaker assembly in an empty adhesive pellets container then fill the container with adhesive pellets.

NOTE: To promote optimal system performance, pur-

chase 30 Gallon Vibrating Hopper, 24R136

. See

installation instructions on page 90.

NOTE: If static buildup on feed tube (G) is excessive, install optional feed tube ground kit 24R708 to feed tube

end (G6). See F IG . 8.

13. 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.

AA

N

W2

247

68

W1

Gun ti21132a

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.

14. Install gun(s), see F IG . 9:

NOTE: Use of a Graco gun is not required with this system. However, all guns 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. a. Connect heated hose fluid outlet to gun fluid

inlet. Use 11/16 in. wrench to tighten. See F IG .

9.

b.

For Graco guns, attach gun electrical connector

to heated hose electrical connector. See F IG . 9.

c.

For non-Graco guns, attach gun electrical connector to adapter harness (16T916, 16T917, or

16Y828) then attach adapter harness connector

16 3A2347N

Setup to heated hose connector. See

Non-Graco

Gun Adapter Cables on page 88 to determine

which adapter cable to use with your valve.

d. Repeat for any additional guns.

15.

If necessary, set up the valve controller to control opening and close the gun. See gun manual.

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

16. 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.

18. Close the ball valve.

J ti21133a

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.

17.

If using the same air for the gun(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 gun manual for gun air pressure requirements, and use a regulator before the gun to decrease the air pressure, if necessary.

ti21147a

F IG . 11

19. 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 93.

20.

To lock access to the air pressure adjustments, purchase

Air Adjustment Lock, 24R084

. See installa-

tion instructions on page 88.

21.

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

Light Tower Kit,

24R226 . See installation instructions on page 92.

22.

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

4 Channel Upgrade Kit, 24R237

.

See installation instructions on page 94.

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

3A2347N 17

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, 0.55-6.8 MPa)

30 scfm capacity.

No dips in vacuum transfer hose

Air In:

3/8 in.,

100 psi

(6.8 bar, 0.68 MPa),

30 scfm capacity

Ensure funnel air is connected

Air Filter/Ball Valve at

System Air Inlet

(Graco Kit 24R707, included)

Vacuum:

40 - 80 psi

(2.8-5.5 bar,

0.28-0.55 MPa); and at least 65% of hopper shaker air pressure, if used

Pump:

20-100 psi

(1.4-6.8 bar,

0.14-0.68 MPa)

Air to guns

Regulator set to

70 psi

(4.8 bar, 0.48 MPa)

F IG . 12 ti21554a

18 3A2347N

Setup

Connect Electrical Cord

NOTE:

See Grounding section on page 14.

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 14 prior to connecting electrical cord.

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

0.708-1.260 in. OD electrical cord. See F IG . 14. If needed, use a wrench to tighten the strain relief bushing until it is snug on the cable.

For

480V Electrical Circuits , see page 21.

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 9.

4. Ensure the terminal block jumpers are in the correct locations for the phase and voltage used. If necessary, change them to match F IG . 15 on page 20.

See the following table, F IG . 13, and F

IG . 15.

NOTICE

To prevent system damage, verify terminal jumpers are installed correctly before going on to the next step.

Terminal Block Jumper Installation Guide

Voltage

Jumper

Wire

127201

Terminal Block Location

2-Terminal

Jumper

126814

200-240VAC,

1 phase

Not used Not used

3-Terminal

Jumper

126815

3-5

5-Terminal

Jumper

126816

6-10

350-415VAC,

3 phase,

WYE

Not used

200-240VAC,

3 phase,

DELTA

3-7

5-6,

8-9

4-5,

9-10

2-4

6-8

Not used

Not used

NOTE: The jumpers only need to be changed if using a different phase or voltage from what the system was designed for at the factory.

NOTE: All necessary jumpers are supplied with the system in a bag located behind the electrical enclosure front access panel. Keep unused jumpers in bag.

2-Terminal

126814

3-Terminal

126815 ti21182a

Wire

127201

5-Terminal

126816

F IG . 13: Jumpers

NOTE: Use the supplied hard metal 2, 3, and 5 terminal jumpers and jumper wire for terminals 2C-10C. Use the red, plastic jumpers for terminals 11-14.

5. Insert electrical cord through electrical enclosure strain relief bushing (106). See F IG . 14 on page 20.

3A2347N 19

Setup

6. Attach insulated ferrules to the end of each wire.

106

F IG

AF

. 14 ti20907a

7. Connect ground wire to chassis ground (AF). See

F IG . 14.

8. Connect L1, L2, L3, and N as shown in F IG . 15. Not all models use all 4 wires.

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

10. Tighten screw-terminals to at least 10 in-lb

(1.1 N•m).

11. Install electrical enclosure door.

12. Perform

Select ADM Settings on page 21 prior to

turning on heat.

F IG . 15

20 3A2347N

Setup

480V Electrical Circuits

For 480V electrical supply, a 480V to 240V step-down transformer must be installed by a qualified electrician.

Transformer Sizing

For single-phase power, 480V to 240V transformer

24U169 (purchase separately) may be used. See

Single-Phase 480V to 240V Transformer, 24U169 on page 98.

Minimum transformer rating can be calculated by taking 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 ෭ (3) = 8315 watts

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

Select ADM Settings

NOTE:

See Appendix A - ADM on page 101 for

detailed ADM information, including general operation.

3. On the System 2 screen: a. Check the box in the “Installed” column for each channel that has a heated hose and gun installed.

b. Select the RTD type used on each installed gun. See gun manual.

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

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:

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

3A2347N a. Enter the main circuit breaker size used. This is the circuit breaker installed external to the system for the system power supply.

21

Setup

NOTE: If using a 480V to 240V transformer, the breaker size entered will be two times the 480V rating. If using transformer 24U169, the breaker size should be set to

30 amps and power type should be set to single phase.

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. b. Select the incoming power type.

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

9. Press to switch from the Setup screens to the

Operation screens. Use navigate between screens.

, , , and to

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

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

and , shown

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

7. To setup the optional Schedule function, see

Schedule on page 29.

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 101, for

detailed information about each setup item.

22 3A2347N

Setup

11. On the Targets screen, adjust heated hose and gun temperature settings: a. Press to select the channel.

b. Use and , shown next to , to adjust gun temperature setting to the desired setting for that channel.

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.

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

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.

Guns

Gun heating is controlled by the system, but the system does not control opening and closing the valves. Setup a separate gun controller to open and close the valves.

3A2347N 23

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.

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 8.

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.

Customer Input Dropdown Options

Option

Disable

Heater On/Off

Channel 1, 2, 3, or 4 Enable/Disable

Description

Not used.

Turn on or off the heating system and pump.

Enable or disable hose and gun 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.

24

H1

H2

F IG . 16: MZLP Board

H1 - Customer Input

Signal Pin

1

2

1, 2

3, 4

3

4

5, 6

7, 8

H2 - Customer Output

Signal Pin

1

2

1, 2

3, 4

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.

3A2347N

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 . 17: Customer Input

MZLP Customer Out Customer In

250 VAC, 2A Max

To Customer Input

F IG . 18: Customer Output

3A2347N 25

Operation

Operation

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 101 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, Uploading on page 107 for detailed USB information.

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 guns.

The gun 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.

Initial Startup and Prime

NOTE: Only 1/4 in. (6 mm) round hot melt adhesive pellets can be used in the InvisiPac system. PSA-type adhesive pellets will not work in the InvisiPac system.

1. Direct the guns into an appropriate waste container.

2. Verify the shaker inlet is at the bottom of the empty adhesive pellets container. Optional vibrating adhesive pellets container, part 24R136, is available.

See Accessories on page 87.

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

3. Fill adhesive pellets container with hot melt adhesive pellets.

4. Turn main power switch ON

5. Open system air inlet ball valve.

.

ti21146a

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

air pressure to 0. See F IG . 1 on page 8.

7. 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

NOTE: All setup procedures must be completed prior to

initial startup. See Setup on page 14.

26 3A2347N

Operation

F IG . 1 on page 8.

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

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.

8.

On new systems only: temporarily adjust the melter temperature to 250°F (121°C). See

Select ADM

Settings on page 21 for instructions.

9. 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.

10.

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 21 for instructions.

11. Use separate gun controller to open the guns 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.

12. With the guns 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).

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

14. When each gun 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 gun controller to repeatedly open and close each gun while inspecting the dispense pattern.

c. Repeat until desired dispense pattern is achieved.

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 cap.

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 phillips head screws then remove the funnel cap from the funnel.

3A2347N 27

Operation

3. Fill the funnel with adhesive pellets. ti21154a

F IG . 19

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

5. When finished dispensing for the day, dispense into a waste container until the material level is down to the smallest diameter section of the funnel then continue purging material through the valve for an additional 75 pump strokes.

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

NOTE: Pump strokes can be monitored on the Maintenance screen, or by counting pump changeovers. To count pump changeovers, listen to the air motor exhaust pulses; two exhaust pulses equals one pump cycle (two strokes).

Dispense

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 14.

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 8.

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).

See F IG . 1 on page 8.

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

F IG . 20 ti21154a

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 26.

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 8.

28 3A2347N

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

desired. See F IG . 1 on page 8.

c.

If using Automatic Refill, see

Automatic Refill on page 28.

d.

If using Manual Refill,

see Manual Refill on page 27.

e. Verify guns are closed.

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.

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 a gun is open. Material will be dispensed whenever a gun is open after the system is up to temperature.

5.

When the system is up to temperature, use separate gun controller to open and close the guns as desired to dispense material.

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

Do not turn the main power switch OFF if using the

Schedule function.

Schedule

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

3A2347N

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.

29

Operation

Enable Schedule Function

The Schedule function is automatically enabled when values are entered in the Schedule screen. To disable the Schedule function, delete all values on the Schedule screen or 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.

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”.

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 gun and ensuring no adhesive is dispensed.

2.

If the heating system is disabled, press enable the heaters and pump.

3. Decrease pump air pressure to 0.

4. Close system air inlet ball valve.

to

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

6. Open gun to allow residual fluid in gun 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.

9. Press to disable the heaters and pump.

10. Remove melter drain plug (W1). See F IG . 2 on page

9.

11. Disconnect hose from melter outlet.

30 3A2347N

Operation

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

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

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 30.

2.

If the heating system is enabled, press able the heaters and pump.

to dis-

3. Loosen 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.

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

6. Change the melter, heated hoses, and guns 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.

3A2347N ti21053a

10. Disconnect one hose from its gun manifold.

NOTE: Keep all guns closed throughout this procedure.

31

Operation

11. Route the disconnected hose to a waste container.

12.

If heating system is disabled,

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

page 33.

the heaters and pump.

25. Install fill cap onto melter rubber housing.

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

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

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

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

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 gun manifold.

19. Repeat steps 7 through 18 for each additional

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

20. Remove and replace filter(s) in all gun manifolds.

See gun manual.

21.

Replace Outlet Filter . See page 33.

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 9.

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

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 29, 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.

Initial Startup and Prime on page 26.

32 3A2347N

Maintenance

Maintenance

Replace Outlet Filter

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

236

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).

Replace Inlet Filter

F

232

237

IG

8

. 21

28 ti20752a

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 30 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 . 21.

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).

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.

3A2347N 33

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

701

213

215

705

706

201 ti20909a

F IG . 22

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.

ti20927b

F IG . 23

Disassembly (see F IG . 23):

1. Turn main power switch OFF.

2. Loosen and remove the two phillips head screws (705) on the side of the funnel (706) then remove the funnel cap (701).

Reassembly (see F IG . 23):

1. Place funnel cap (701) onto funnel (706).

2. Install two phillips head screws (705) to secure funnel cap to funnel base.

34 3A2347N

Maintenance

Filter Maintenance Guidelines*

Environment Classification

Clean Moderate Dusty

Pump inlet filter

Pump outlet filter

Gun manifold filter

System air filter

Solenoid exhaust filters

Feed funnel filter

Feed funnel inspection/clean out

Replace filter every six months

Replace filter every four months

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 powered 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.

3A2347N 35

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, gun, or hose to which the error applies. The “_” (underscore) character indicates the code applies to multiple items.

Last Digit in Code

0

1

2

5

6

3

4

9

A

7

8

B

C

Code Relates to:

Melter

Gun 1

Hose 1

Gun 2

Hose 2

Gun 3

Hose 3

Gun 4

Hose 4

Gun 5

Hose 5

Gun 6

Hose 6

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

Code Description

A4D0 High Current

Melter

A4D_ High Current

Hose X

A4D_ High Current

Gun X

Type Cause

Alarm Defective or shorted to ground on the band heater or rod heater.

Alarm Defective or shorted to ground on the hose power wires.

Alarm Defective or shorted to ground on the heater rods in gun manifold.

Solution

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

Replace heated hose.

Replace gun manifold.

36 3A2347N

Troubleshooting

Code Description Type Cause

A7D0 Unexpected

Current

Solution

Alarm Unexpected current flow to melter.

Replace MZLP.

Faulty melter heater(s). Check heater resistance and resistance to ground. Replace faulty heater(s).

A7D_ Unexpected

Current, Gun X

A7D_

A8D0

Unexpected

Current, Hose

X

No Current

Melter

Alarm Unexpected current flow to gun X.

Alarm Power not getting to melter.

Faulty MZLP. Replace MZLP.

Faulty gun heater element. Check heater resistance and resistance to ground.

Alarm Unexpected current flow to hose X. Faulty MZLP. Replace MZLP.

Faulty hose heat element. Check heater resistance and resistance to ground.

Check fuses F1 and F2 on MZLP with daughter board.

A8D_

A8D_

No Current

Hose X

No Current

Gun X

Alarm Power not getting to hose.

Alarm Power not getting to gun.

Check J1 is plugged into MZLP with daughter board.

Check fuses F5 and F6 or F9 and F10 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 gun, the heated hose electrical connector must be plugged into channel 1 of the MZLP.

Check fuses F3 and F4 or F7 and F8 on

MZLP that controls the error channel.

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

CAC_ Comm Error

Module

CACX Missing DB

Alarm System not responding to ADM.

Alarm System not acknowledging the daughter board.

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 gun, electrical connector of the heated hose must be plugged into channel 1 of the MZLP.

System is not properly loaded with correct software. Perform

Software Update Procedure on page 69.

Dial not set correct on MZLP. Set to 1 on board with daughter board. Set to 2 on MZLP without the daughter board.

Defective MZLP daughter board. Replace.

Bad connection between daughter board and

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

3A2347N 37

Troubleshooting

Code Description

DADX Pump Runaway

DDDX Pump Diving

DE0X

L6FX

L8FX

Cycle Switch

Error

Level Sensor

Error

Refill timeout

Type Cause

Alarm Pump is trying to feed adhesive, no

Deviation adhesive to feed.

Worn or damaged pump seals

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

Worn or damaged pump seals

Alarm No signal from air motor sensor.

Alarm No signal from the level sensor.

No air to fill cap.

Plugged orifice in fill cap below fill sensor.

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

MMUX USB Log Full Advisory

T1D0 Low Temp

Melter

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

Alarm Melter reached setpoint but dropped below setpoint and can not recover.

T1D_ Low Temp

Hose

T1D_

T4C_

Low Temp

Gun

High MZLP

PCB Temp

Alarm Hose reached setpoint but dropped below setpoint and can not recover.

Alarm Gun reached setpoint but dropped below setpoint and can not recover.

Alarm MZLP board is overheating.

Solution

Storage bin out of adhesive. Refill adhesive.

Melter at incorrect temperature, to low. Check setpoint and set to manufactures 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.

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.

Feed rate for dispensing too high.

Inspect pump seals. Repair if necessary.

Check wiring on J16 of the daughter board.

See

Electrical Schematics on page 70.

Defective cycle switch. Replace.

Loose cycle switch bolt. Tighten cycle switch bolt.

Check that sensor cable is plugged into sensor.

Check connector at J14 of the daughter board.

Verify there is nothing blocking fill (level) sensor line of sight.

Defective fill (level) sensor. Replace.

Check for air coming from 5/32 in. air line.

Remove fill cap and remove object plugging the orifice.

Storage bin out of adhesive. Refill adhesive.

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

Download USB data. See

Downloading, Uploading

heater.

Appendix B - USB

on page 107.

Check resistance of heater rods and band

Check resistance of heated hose. Refer to hose manual for proper resistance range.

Check resistance of manifold heater rods.

Refer to gun manual for resistance value.

Ambient temperature must be under 120°F.

Defective MZLP board. Replace.

38 3A2347N

Troubleshooting

Code Description Type Cause

T4D0 High Temp

Melter

Alarm Melter continues to raise above the setpoint.

T4D_ High Temp

Hose

T4D_ High Temp

Gun

T6D0 Sensor Error

Melter

Alarm Hose continues to raise above the setpoint.

Alarm Gun assembly continues to raise above the setpoint.

Alarm No reading from RTD.

Solution

Defective RTD. Replace.

Defective RTD. Replace.

Defective RTD. Replace.

T6D_

T6D_

T8D_

T8D_

T8D0

Sensor Error

Hose

Sensor Error

Gun

No Temp Rise in Gun (all zones)

No Temp Rise in Hose (all zones)

No Temp Rise in Melter (all zones)

Alarm No reading from RTD.

Alarm No reading from RTD.

Alarm Temperature reading does not change.

Alarm Temperature reading does not change.

Alarm Temperature reading does not change.

Verify connector J5 on MZLP board is securely connected.

Defective RTD. Replace.

Hose electrical connector not plugged into

MZLP.

Defective RTD. Replace.

Hose electrical connector not plugged into

MZLP or manifold electrical connector not plugged into heated hose.

Defective RTD. Replace.

Check fuses F3 and F4 or F7 and F8 on

MZLP that error channel is connected to.

Defective heater rods in gun manifold.

Replace gun manifold.

NOTE: Defective heaters rods in the gun manifold can also cause the no current error.

Heated hose electrical connector or wires are defective. Check resistance of hose wiring.

See hose manual for proper resistance range.

Check fuses F5 and F6 or F9 and F10 on the

MZLP that controls the error channel.

Defective heater wires in hose. Replace heated hose.

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

Heated hose electrical connector or wires are defective. Check resistance of hose wiring.

See hose manual for proper resistance range.

Check fuses F1 and F2 on MZLP with daughter board.

Defective heater wires in melter. Replace melter.

NOTE: Defective heaters wires in the melter can also cause the no current error.

Check J1 is properly plugged into the MZLP with daughter board.

Check that RTD is installed in the melter.

3A2347N 39

Troubleshooting

Code Description Type Cause

V1I_ Low Can Voltage

Alarm Bad or overloaded power supply.

Solution

Verify power supply voltage is 24 VDC. If voltage is low, disconnect the power lines and re-check voltage reading. If voltage is still low, replace power supply. If voltage is correct after disconnecting the power lines, replace the MZLP.

V4I_ High Can Voltage

Alarm Bad or overloaded power supply.

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

V8M_ No line voltage Alarm Incoming line voltage is less than

100 VAC.

Measure incoming power with system unplugged. If line voltage is less than

100 VAC, contact qualified electrician to correct the low voltage.

WJDX Pump Solenoid Error

Alarm No voltage draw from air solenoid for air motor.

Check connector is properly connected to J14 of the daughter board.

Defective air manifold, replace manifold.

WKFX Fill Solenoid

Error

Alarm No voltage draw from air solenoid for fill.

WSUX USB Invalid

Configuration

Deviation

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

Bad ADM.

Check connector at J14 of the daughter board.

Defective air solenoids. Replace. See

page 63.

System is not properly loaded with correct software. Perform

Software Update Procedure on page 69. Retry USB download.

Replace ADM.

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 manual refill mode. See

Manual Refill on page 27.

Check funnel filter. If plugged, see

Replace Funnel Filter on page 34.

Check hopper for adequate material and material blocking.

The InvisiPac system takes a long time to refill adhesive.

Glue level in hopper is low.

Vacuum flow is restricted.

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 34.

40 3A2347N

Troubleshooting

Problem

Vacuum transfer not working

Adhesive pellets in storage bin not covering shaker head.

Fill Solenoid

Error

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 guns are all closed.

Cause

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.

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.

Purchase and install 30 Gallon Vibrating Hopper, 24R136 . See page 90.

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.

Solution

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.

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 manual refill mode. See

Manual Refill on page 27.

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 3V if melter is completely empty (melter passage holes are visible). The normal operating range is 2.1 to 2.8V. If the sensor is reading more than 2.75V 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 manual refill mode. See

Manual Refill on page 27.

Replace Funnel Filter , see page 34.

NOTE: Feed cap filter maintenance should be performed at regular service intervals. It is recommended that the feed cap filter be serviced 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 48.

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

3A2347N 41

Troubleshooting

Problem

The system will not dispense material.

Cycle Switch

Error

USB Log Full

The InvisiPac system is displaying pump runaway or pump diving.

Cause

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

Verify that the system is active.

Verify the temperature settings are correct.

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

Air Solenoid Operation , page 48.

Check the Pump

Control for manifold and guns not working.

Cycle switch or cycle switch wiring failure.

Loose or missing fastener (26).

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

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

Repair or replace air control assembly as necessary.

Repair or replace pump assembly as necessary.

InvisiPac system does not control the timing of the manifold and valves. 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 ning on page 74 for part identification.

To prevent data loss download system data. See

Downloading, Uploading

InvisiPac Systems

on page 107.

section begin-

Appendix B - USB

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 33 cpm by enabling the diagnostic screen.

Level sensor blocked, reading level incorrect.

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

2. If the cycle rate is below 33 cpm and the system is still running away increase the InvisiPac system temperature by 10°F over the current set point, leave hoses and guns at desired set point.

3. If the pump continues to runaway or dive continue increasing temperature by 10°F, do not exceed maximum temperature for the material being dispensed.

NOTE: Some materials are more difficult to melt than others and it may be impossible to process them at a rate of 25 lb/hr. The InvisiPac system was tested to achieve continuous melt rates of 25lb/hr when dispensing standard EVA packaging grade adhesives in pellet form with an InvisiPac system temperature of 375°F and hose and valve temperatures of 350°F.

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

Make sure the air supplied to the system is at least 80 psi (550 kPa, 5.5 bar).

42 3A2347N

Troubleshooting

Problem

Unable to achieve

25lb/hr melt rate at the desired adhesive temperature.

ADM not displaying when system turned on

Main breaker tripping

Cause

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

Solution

1. If the cycle rate is below 33 cpm and the system is still running away increase the InvisiPac system temperature by 10°F over the current set point, leave hoses and guns at desired set point.

2. If the pump continues to runaway or dive continue increasing temperature by 10°F, do not exceed maximum temperature for the material being dispensed.

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 a rate of 25 lb/hr. The InvisiPac system was tested to achieve continuous melt rates of 25lb/hr when dispensing standard EVA packaging grade adhesives in pellet form with an InvisiPac system temperature of 375°F and hose and valve temperatures of 350°F.

Turn main circuit breaker on or plug in power cord.

Main power circuit breaker off or power cord unplugged.

Cable on ADM unplugged.

Connector on MZLP board not plugged in.

Bad 24VDC power supply.

ADM defective.

Wrong setting in ADM breaker setup.

Internal short to ground in system.

Too small of a circuit breaker in main power panel.

Reconnect ADM cable.

ADM cable should be plugged into J6 of the MZLP 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.

3A2347N 43

Troubleshooting

Problem

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

No adhesive or little adhesive being dispensed

System indicates no errors and correct temperature however manifold and gun are over the temperature setpoint

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 defective.

Melter and gun manifold.

Measure and check heater rods in melter or manifold. Manifold resistance 130-140 ohms.

Heated hose defective.

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

Insufficient power supplied to system.

Depending on hose and gun combinations, along with minimal supply power, startup time will vary.

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

Electrical Schematics

connecting to a different power supply.

on page 70 for details about

Incorrect RTD setting in system.

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

2. If the manifold 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.

Incorrect RTD setting in system.

NOTE: Failure to have the correct RTD value will cause the manifold and gun 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.

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

2. If the manifold 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 manifold and gun 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.

44 3A2347N

Troubleshooting

Problem

No adhesive or incorrect amount of adhesive output when all valves are triggered

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

Cause

Plugged gun manifold filter.

Clogged hose.

Solution

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

Flush or replace hose.

Defective solenoid valve.

No signal from control to solenoid.

Solenoid mufflers plugged.

No air to air solenoid. Re-establish air supply to solenoid.

Plugged system outlet filter.

Replace Outlet Filter . See page 33.

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

Plugged tip on gun.

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

If no voltage is present at solenoid, check control cable and remote control device. Replace component.

Replace solenoid mufflers.

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

Replace tip on gun.

Replace gun.

Defective gun in closed/partial open position.

Plugged manifold filter

(single valves manifold).

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

Flush or replace hose. Clogged hose (single valves).

Defective solenoid valve (single manifold).

No signal from control to solenoid (single valve manifold).

Plugged solenoid mufflers (single valve manifold).

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

If no voltage is present at solenoid, check control cable and remote control device. Replace component.

Replace solenoid mufflers.

No air to solenoid (single valve manifold)

Plugged system outlet filter.

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

Re-establish air supply to solenoid.

Replace Outlet Filter . See page 33.

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

3A2347N 45

Troubleshooting

Problem

Adhesive flowing out of one/some valves when not triggered

Gun will not heat.

Adhesive leaking from manifold or valve.

No melter heat.

Air motor will not function.

System not turning on.

Cause

Failed valve in the open position.

Adhesive pressure too high.

Solution

Replace valve.

Reduce air pressure to air motor.

Heat rod failure in manifold.

Loose cable connection at system or manifold.

RTD failure.

Incorrect RTD setting in the ADM setup.

Thermal cutoff is tripped.

Valve is loose on the manifold.

Valve o-ring failed.

Failed valve, adhesive leaking out middle of valve.

Hose loose.

Fuse blown in F1 and

F2.

Cable to over-temperature switch off or broken.

Over-temperature switch tripped.

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

Check cable connections on both ends of the hose.

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

Set correct RTD value in the AMD setup screen. Consult manufacture for correct RTD value.

Measure resistance of the thermal cutoff. If open, replace.

Tighten screws on loose valve.

Replace o-rings on the back of the leaking valve.

Replace valve.

Tighten hose.

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

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

No air being supplied to air motor.

Air solenoid not adjusting the air motor.

Air present at air motor but it will not work.

No power to unit.

Measure over-temperature switch resistance. It should read close to 0 ohms when at room temperature. If open, replace over-temperature switch.

Check incoming air supply. Check that air solenoid is adjusted for air motor.

If air can not be adjusted at the air solenoid, check 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.

46 3A2347N

Troubleshooting

Problem

Static shock when touching shaker or adhesive bin.

Adhesive not dispensing at the correct time.

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.

Guns opening at the wrong time.

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 guns.

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

3A2347N 47

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.

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.

36 ti20441b1

F IG . 24

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 gun.

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

48 3A2347N

Troubleshooting

MZLP Troubleshooting

0 1

456

MZLP ti20441b1

F IG . 25: 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 Description

Green On

Yellow On

Red Solid

Red Flashing

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 . 26: MZLP Diagnostic LED Location ti20348a

3A2347N 49

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

F IG . 27

27

3

218

240

245

223

225

226

222

239

235

233

234

238 ti21046a

Disassembly (see F IG . 27):

1.

Flush the system. See page 31.

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 . 27):

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.

50 3A2347N

Repair 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 . 28.

15B661

203

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

Use socket and tap with a rubber mallet to press throat bearing (233) into place and seat the throat u-cup.

235

233 ti20877a

F IG . 28

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 . 29.

ti21144a

F IG . 30

7. Remove seal installation tool.

8. Install retaining nut (235). See F IG . 28.

9. Install air motor assembly (see F IG . 27):

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

F IG . 29

3A2347N ti21047a

51

Repair

Replace Pump Inlet Housing Checks

Reassembly (see F IG . 31):

1. Install new 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.

Install Melter Assembly . See page 55.

Replace Pump Cylinder Seals and Piston Seals

254

218

201

239

227

228

229

230

235

233

234

233

224

226

222

257 ti20749a

F IG . 31

Disassembly (see F IG . 31):

1.

Flush the system. See page 31.

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 Melter Assembly . See page 54.

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

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

217

216

217

230 ti21048a

F IG . 32

Disassembly (see F IG . 27):

1.

Flush

the system. See page 30.

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 . 27 on page 50.

52 3A2347N

Repair

5. Remove air lines from relief valve (245) and air

motor (218) See F IG . 27 on page 50.

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

place then remove melter shield. See F IG . 27 on page 50.

7. Remove air motor assembly. See F IG . 27 on page 50:

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.

Remove Melter Assembly . See page 54.

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

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

remove cylinder (216). See F IG . 31.

1301

203

217

216

217

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

31.

Reassembly:

1. Apply grease to seals (217) then install new cylinder

seals (217) onto cylinder (216). See F IG . 31.

216

217

1302

203 ti21049a

F IG . 34

2. Place female cylinder installation tool (1302) into melter outlet manifold (203) to protect seals from sharp threads. See F IG . 34.

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 . 31.

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).

5. Perform

Install Melter Assembly on page 55.

6. Perform Reassembly portion of the

Replace Throat

Seal, Throat Bearing, Piston Rod, Piston Seal, and Piston Bearing procedure which starts on page 50.

ti20880a

1303

217

F IG . 33

3A2347N 53

Repair

Melter

Remove Melter Assembly

30

29

62

13

12

13

53

52

61

27

3

259

8

3

10 ti21050b 1

F IG . 35

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 30

then wait for system to cool.

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

54

3. Turn main power switch OFF.

4. Disconnect all heated hoses from the melter outlet manifold (203).

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

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

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

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

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

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

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

11. Remove insulators (52, 53) from the melter assembly (5).

12. Disconnect the fill sensor cable from the fill sensor (20).

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

14. Remove the air tube from the fill cap (62).

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

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

F IG . 36 on page 56.

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

18. Remove all heater wires from the following terminals. Pull wires up through the rubber grommet on

the top of the electrical enclosure (1). See F IG . 36 on page 56 for references.

Item

Wire

Marking 1

Band Heater (208)

Melter Heater Rod

(209)

TB1-11B

TB1-14C

Base Heater Rod (210) TB1-11C

Pump Heater Rod

(250)

TB1-12B

Wire

Marking 2

TB1-13B

CR1-NC

TB1-13C

CR1-COM

3A2347N

Repair

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

20. Remove bolts (259) then remove melter assembly from melter 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).

NOTICE

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

10. Install funnel (61) into air motor bracket (528) then tighten clamp.

11. Install temperature sensor (125) into melter then

tighten screw (AA) on band heater. See F IG . 36 on page 56.

12. Install insulators (52, 53) onto the melter assembly (5).

13. Connect wire connectors to the over-temperature

switch (251). See F IG . 38 on page 58.

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.

3. Use 4 bolts (259) to secure melter assembly to melter base (257).

4. 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.

See F IG . 36 on page 56 for references.

Item

Wire

Marking 1

Band Heater (208)

Melter Heater Rod

(209)

TB1-11B

TB1-14C

Base Heater Rod (210) TB1-11C

Pump Heater Rod

(250)

TB1-12B

Wire

Marking 2

TB1-13B

CR1-NC

TB1-13C

CR1-COM

6. Connect air tube to air motor (218).

7. Connect air tube to fill cap (62).

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

9. Connect pump cycle sensor cable to air motor.

3A2347N 55

Repair

Replace Band Heater

10

1

CC

125

AA

53

62

208

63 ti20753a

F IG . 36

Disassembly (see F IG . 36):

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

2. While looking through the hole in the fill cap, dispense until the fluid level in the melter is at or below the honeycomb grid.

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

4. Turn main power switch OFF.

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

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

7. Remove fabric melter insulator (53).

8. Loosen band clamps (CC) then slide fill cap (62) and rubber housing off melter.

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

10. Locate the wires in terminal blocks TB1-11B and

TB1-13B. Loosen terminal block screws and remove wires.

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

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

Reassembly (see F IG . 36):

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 terminals as marked. Wires should be marked as shown in the following table. Tighten terminal block screws.

Item

Band Heater (208)

Wire

Marking 1

TB1-11B

Wire

Marking 2

TB1-13B

6. Install electrical enclosure access door (10). See

F IG . 36.

7. Install fabric melter insulator (53).

8. Install fill cap (62) rubber housing with band clamps in place.

9. Install funnel into fill cap (62) then tighten band clamps (CC) on rubber housing.

10. Slide funnel assembly (61) through air motor bracket (528) then tighten clamp.

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

56 3A2347N

Repair

12. Open system air inlet ball valve.

13. Turn main power switch ON.

Replace Band Heater Temperature Sensor

53

CC

AA

40

125 ti20762a

F IG . 37

Disassembly (see F IG . 37):

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).

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 . 37.

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

10. Disconnect wire connectors from over-temperature

switch (251). See F IG . 38 on page 58.

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

Reassembly (see F IG . 37):

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 . 38 on page 58.

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 . 36 on page 56.

7. Install fabric melter insulator (53).

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

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.

3A2347N 57

Repair

Replace Heater Over-Temperature Switch 6. Open system air inlet ball valve.

7. Turn main power switch ON.

Replace Heater Rod

251

255

206

250 ti21052a

F IG . 38

Disassembly (see F IG . 37):

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. 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 . 37):

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.

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

206

210

209 ti20755a

206 209 ti20754a

F IG . 39

Disassembly (see F IG . 39):

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 54.

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

4.

If removing the pump heater rod (250) : a. Remove the air tube (36) from the relief valve (245). Pull the air tube through the metal shroud (27).

58 3A2347N

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

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

See F IG . 36.

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

Item

Wire

Marking 1

Melter Heater Rod

(209)

TB1-14C

Base Heater Rod (210) TB1-11C

Pump Heater Rod

(250)

TB1-12B

Wire

Marking 2

CR1-NC

TB1-13C

CR1-COM

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, or 250).

Reassembly (see F IG . 39):

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 . 39.

3. Install electrical enclosure access door (10). See

F IG . 36.

4.

If replacing the melter heater rod (209),

Install

Melter Assembly

. See page 54.

5.

If replacing pump heater rod (210 or 250), 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).

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

Replace Fluid Pressure Relief Valve

244

27

3

245

36 ti20757a

F IG . 40

1.

Drain the System . See page 30.

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 . 40.

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

6. Use crescent wrench to remove melter fluid pres-

sure relief valve (245).See F IG . 40.

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.

3A2347N 59

Repair

9. Thread new fluid pressure relief valve (245) into

manifold. See F IG . 40. 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.

Multi-Zone Low Power

Temperature Control Module

(MZLP)

Replace MZLP Fuse

Each MZLP module comes with the following fuses:

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 16A on the barrel.

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

4. Use a proper non-conductive fuse puller tool to install the new fuse.

NOTICE

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

J1

F10 F9 F8 F7

F6 F5

J2

F4 F3

F2 F1

5. Install electrical enclosure front access door (10).

Replace MZLP

J7

J6

J5

J3 ti20349a

F IG . 41: Fuse Locations

Fuse Part

F1, F2 250VAC, 16A, fast acting, white ceramic

F3-F10 250VAC, 8A, fast acting, clear glass

Fuses available in Fuse Kit 24P859. Spare kit included.

NOTICE

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

Disassembly:

1. Turn main power switch OFF.

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

3. Disconnect heated hose electrical connectors from

MZLP (112).

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

43.

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

60 3A2347N

Repair from electrical enclosure. See F IG . 42. Replace MZLP Daughter Card ti20910a

MZLP #2

112

1

MZLP #1

114

F IG . 42

6. If replacing MZLP #1, remove the daughter card and standoffs, and re-install them on the new MZLP.

See F IG . 42 for MZLP #1 and MZLP #2 identification.

Reassembly:

1. Set MZLP rotary switch to “1” on MZLP with daughter card. Set MZLP rotary switch to “2” on MZLP without daughter card. See F IG . 43 for rotary switch location.

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

3. 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 70.

4. Install electrical enclosure front access door (10).

5. Connect heated hose electrical connectors to new

MZLP.

NOTE: MZLP may need updated software. See

Software Update Procedure on page 69.

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). See F

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

112b

IG

IG . 43.

. 43.

112a ti20342a

112

Rotary Switch

F IG . 43

5. Unplug daughter card (112a) from the MZLP (112).

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 70.

4. Install electrical enclosure front access door (10).

3A2347N 61

Repair

System

Replace Fill Sensor

20

112

Replace Fill Cap

35

62

20

62

13 ti20761a

F IG . 44

Disassembly (see F IG . 44):

1. Turn main power switch OFF.

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

3. Loosen fill sensor jam nut then remove fill sensor (20) from fill cap (62).

Reassembly (see F IG . 44):

1. Thread new fill sensor (20) into fill cap (62). Bottom out the sensor in the fill cap then back out 1/2 turn.

2. Tighten jam nut on fill sensor (20).

3. Connect fill sensor cable to new fill sensor (20). ti20760a

F IG . 45

Disassembly (see F IG . 45):

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. Disconnect cable from ADM then remove shroud.

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

5. Loosen fill sensor jam nut then remove sensor (20) from fill cap (62).

6. Remove air line (35) from fill cap (62).

7. Loosen upper clamp (13) on rubber housing then remove fill cap (62).

62 3A2347N

Repair

Reassembly (see F IG . 45):

1. Place new fill cap on melter. Align funnel inlet hole with bracket.

2. Install funnel through air motor bracket (528) then tighten funnel clamp.

3. Tighten rubber housing clamp (13) to secure fill cap in place.

4. Connect air line (35) to fill cap (62).

5. Thread fill sensor (20) into fill cap (62). Bottom out the sensor in the fill cap then back out 1/2 turn.

6. Tighten jam nut on fill sensor (20).

Replace ADM

58

30

CC ti20763a

F IG . 46

1. Turn main power switch OFF.

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

See F IG . 46.

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 Software Update Procedure on page 69.

Air Controls

Replace Air Control Solenoids

402

405

8

9

1 ti20764a

FF

F IG . 47

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 . 47):

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

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

5. Note location of each air line connection.

6. Insert hands through access holes (FF), see F IG .

47, in bottom of electrical enclosure then disconnect

air lines from air control solenoids (402).

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

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

3A2347N 63

Repair

Reassembly (see F IG . 47):

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 .

47, 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. Install electrical enclosure front access door.

Replace Air Control Gauge

6. Remove air gauge from panel.

Reassembly (see F IG . 48):

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).

NOTICE

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

403b

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

402 ti20765a

F IG . 48

Disassembly (see F IG . 48):

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).

513

218 ti20767a

F IG . 49

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

64 3A2347N

Repair

2. Turn main power switch OFF.

3. Use 10 mm socket to remove air motor pilot valve (513) from air motor (218).

4. Lubricate with grease and install new air motor pilot valve (513).

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

Replace Air Valve

509

508

527

218

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 (508) securing air valve (527) to air motor (218).

9. Remove air valve (527) and seal (509) then discard.

Reassembly (see F IG . 50):

1. Lubricate with grease then place new air valve seal (509) onto air valve (527).

2. Carefully place new air valve (527) against air motor then thread in the four screws (508). Ensure the air valve seal (509) stays in place by applying constant pressure against the air motor.

3. Use 10 mm socket to torque screws (508) 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.

ti20768a

F IG . 50

Disassembly (see F IG . 50):

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

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

3A2347N 65

Repair

Remove Air Motor

27

3

218

238

220

240

211

239

219 ti20758a

F IG . 51

See F IG . 51.

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 . 40 on page 59.

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).

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 . 51.

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) 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 . 40 on page 59.

66 3A2347N

Repair

Replace Air Motor Piston O-Ring

511

520

505

506

523

504

512

501

510

505 ti20766a

F IG . 52

Disassembly (see F IG . 52):

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.

Remove Air Motor , page 66.

4. Use 10 mm socket to remove four screws (511) to

remove air manifold assembly (520). See F IG . 52.

5. Use 13 mm socket to remove two bolts (512) then remove air motor top cap (510).

6. Remove and discard piston o-ring (504) from piston (519).

Reassembly (see F IG . 52):

1. Lubricate all seals with grease.

2. Install new piston o-ring (504) onto piston (519).

NOTICE

Carefully reassemble air motor to prevent damage to seals.

4. Use four screws (511) to install air manifold assembly (520) onto air motor finger tight to align cover (506).

5. Torque two bolts (512) incrementally to 11-13 ft-lb

(15-18 N•m) to ensure top and bottom cap seals (505) seat properly.

6. Torque four air manifold screws (511) to

95-105 in-lb (10.7-11.9 N•m).

7.

Install Air Motor , page 66.

Replace Air Motor Throat Seals

NOTE: This procedure uses adhesive that requires a

12-hour system idle time for full cure. If possible, perform this procedure at the end of the day or week so it can cure overnight or over the weekend while the system does not need to run. Otherwise, keep a spare air motor on hand so it can be used while the adhesive cures.

511

520

512

3. Reassemble remaining air motor parts, excluding air manifold assembly, then install two bolts (512) finger tight.

519

517

507

223

507

501

502 ti20769a

F IG . 53

Disassembly (see F IG . 53):

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.

Remove Air Motor , page 66.

4. Remove four screws (511) to remove air manifold assembly (520).

3A2347N 67

Repair

5. Remove two bolts (512) then carefully remove air motor base cap (501) from the rest of the air motor assembly.

6. Disconnect rod (223) from air motor piston (519) then remove rod from air motor base cap (501).

7. Remove retaining ring (517) from base cap (501)

8. Remove two u-cup throat seals (507) from throat of air motor base cap (501) and discard seals.

Reassembly (see F IG . 53):

1. Apply water-resistant grease to new u-cup seals (507) then install seals into throat of air motor base cap (501).

2. Install retaining ring (517) in base cap (501).

3. Carefully insert rod (223) into air motor base cap.

4. Apply high strength adhesive, supplied with kit, to rod threads then connect rod (223) to air motor piston (519). Torque to 35-40 ft-lb (47-54 N•m).

NOTICE

Carefully reassemble air motor to prevent damage to seals.

5. Reassemble remaining air motor parts, excluding air manifold assembly, then install two bolts (512) finger tight.

6. Use four screws (511) to install air manifold assembly (520) onto air motor finger tight to align cover (506).

7. Torque two bolts (512) incrementally to 11-13 ft-lb

(15-18 N•m) to ensure top and bottom cap seals (505) seat properly.

8. Torque four air manifold screws (511) to

95-105 in-lb (10.7-11.9 N•m).

9.

Install Air Motor , page 66.

10. Prior to using system, wait 12 hours for adhesive

used in step 4 to fully cure.

68 3A2347N

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, you will see the following screens:

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

F IG . 54: Remove Access Panel

4. Insert and press InvisiPac software upgrade token

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

NOTE: There is no preferred orientation of token.

T r_24P860_3B9900_4a

F IG . 55: Insert Token

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.

Third:

Updates are complete.

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

Icon Description

Update successful.

Update unsuccessful.

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 the InvisiPac operation

3A2347N 69

Electrical Schematics

Electrical Schematics

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

Incoming Power and Terminal

Jumpers

NOTICE

To prevent severe system damage, ensure terminal jumpers are installed correctly. See

Connect Electrical Cord on page 19.

The incoming power and terminal jumpers are specific to the phase and voltage used. The power type and circuit breaker size must be correctly set in the ADM. See

Select ADM Settings on page 21.

If changing power type, use the supplied hard metal 2,

3, and 5 terminal jumpers and screws and supplied jumper wire to jumper the terminals. See

Connect Electrical Cord on page 19 for detailed information about

changing terminal jumper locations.

70 3A2347N

Systems with One MZLP Module

Electrical Schematics

L N G

L1 L2 L3 G

H J K L M H J K L M

T° Gun RT

Gun Heater

T° Hose RT

Gun Heater

500W Melter

1500W Pump

3A2347N 71

Electrical Schematics

Systems with Two MZLP Modules

L1 L2 L3 G

T° Gun RT

Gun Heater

Hose RT

T° Gun RT

Gun Heater

Hose RT

MZLP 1 24R234

B D F H K

A C E G J

B D F H K

A C E G J

T° Gun RT

Gun Heater

Hose RT

T° Gun RT

Gun Heater

Hose RT

72 3A2347N

Systems with Three MZLP Modules

Electrical Schematics

3A2347N 73

Parts

Parts

InvisiPac Systems

System Parts, Page 1 of 3

30 58 29 8, 75 74, 82 7

3

39

3

28

8

43

69

74

44

8, 75

8, 75

45

43

2

5

7

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

Apply pipe sealant to all non-swiveling pipe threads.

Orient as shown.

27

43 ti20732a

3A2347N

System Parts, Page 2 of 3

26

25

43

83

24

52

8

10

2 11

43

48

40, 54

42

41

20

62

13

12

13

53

63

8

9

3A2347N

61

5

8

7

3

4

1

63 ti20733b

Parts

75

Parts

System Parts, Page 3 of 3

76

36

13 in.

(0.33 m) 55

35

41 in.

(1.04 m)

66

65

34

2 in.

(0.05 m)

33

23 in.

(0.58 m)

32

34

7 in.

(0.18 m)

64

35

41 in.

(1.04 m)

34

2 in.

(0.05 m)

33

16 in.

(0.41 m)

87

66 64

57

34

48 in.

(1.22 m)

35

41 in.

(1.04 m)

34

48 in.

(1.22 m) ti20734b

3A2347N

Parts

System Parts

7

8

4

5

Ref Part

1

3

---

Description

ENCLOSURE, electrical

115942 NUT, hex, flange head

167002

24R375

---

113161

INSULATOR, heat; washer

MELTER AND PUMP

TRAY, drip

SCREW, flanged, hex head

9

10

---

---

11 ---

12* ---

AIR CONTROLS ASSEMBLY

DOOR, front

FOAM, border, door

ADAPTER, melter inlet

13*

20

--CLAMP, hose, spacer

24R041 SENSOR, ultrasonic

22

24

--SHAKER AND TUBE, feed system

116658 FITTING, tube, male, 1/4 npt

25 ◆ ---

26 ◆ ---

SWITCH, cycle

FASTENER, screw, pan head, M4 x

35 mm

27

28

---

---

BRACKET, back

COVER, filter

29 --COVER, melter

30 ❄ 24P860 MODULE, Advanced Display (ADM)

31 117026 SCREW, socket head cap, M5 x 12

32† 112739 TEE, union

33† C12509 TUBE, nylon, round

34† --HOSE, nylon, 3/8 in. OD, 250 psi (1.7

MPa, 17 bar)

35† 598095 TUBE, 5/32 in. OD, nylon

36† --TUBE, PTFE, 1/4 in. OD

39

40

41

42

---

---

---

---

GROMMET, 1/4 in. ID

BUSHING, strain relief

GROMMET, wire

GROMMET, tube

43 ▲ 16U029 LABEL, safety

44 --LABEL, InvisiPac

45

48

49

52

---

110932

C38321

16T675

LABEL, pressure gauges

CONNECTOR, male

STRAP, tie, cable

INSULATOR, melter manifold

53 ✖ 16T677 INSULATOR, melter

54 --NUT, bushing

55

57

58

61

66

67

68

---

---

LABEL, identification

COUPLER, 3/8 in. OD tubing

--BRACKET, mounting

24R738 FUNNEL, inlet, feed

62*

63

--MANIFOLD, feed inlet

121487 GROMMET, sheet metal, 3/4 in.

64

65

198177

---

FITTING, connector, male

FITTING, tee, 1/8 npt x 3/8 in. tube x

3/8 in. tube

---

101976

RESTRICTOR, air, 0.0225 in. orifice

TOOL, allen, wrench

255021 FITTING, straight, hydraulic

(assemblies 24P260, 24P262,

24P264 only; Qty 2)

(assemblies 24P261, 24P263,

24P265 only; Qty 4)

(assemblies 24U132, 24U133,

24U133 only; Qty 6)

3.25

4.92

2

1

1

1

1

1

1

1

1

2

10

1

1

1

6.75

1.3

1

2

1

1

1

1

1

3

1

1

2

1

1

1

2

1

1

1

1

1

1

1

Qty

1

8

1

15

4

1

2

1

83

85

86

87

88

89

74

75

80

82

Ref Part

69

70

114606

24R324

Description

PLUG, hole

SOFTWARE UPGRADE TOKEN,

InvisiPac System

117126

16V153

262907

117017

SCREW, socket head cap, M5 x 16

WASHER, retaining

FUNNEL SCREEN KIT (not shown)

WASHER

92

93

94

16V540

24P859

24P176

108982

INSULATOR, melter assembly

MZLP FUSES KIT (not shown)

I/O CONNECTOR KIT (not shown)

CONNECTOR, tube

24R707 AIR INLET KIT (not shown)

114271 RETAINING STRAP

(assemblies 24P260, 24P262,

24P264 only; Qty 8)

(assemblies 24P261, 24P263,

24P265 only; Qty 16)

(assemblies 24U132, 24U133,

24U133 only; Qty 24)

127208 FITTING, tee, 6 JIC x 6 JIC x 9/16-18

(assemblies 24U132, 24U133,

24U133 only; Qty 2)

FITTING, 45° elbow, hydraulic

(assemblies 24P260, 24P262,

24P264 only; Qty 2)

(assemblies 24P261, 24P263,

24P265 only; Qty 4)

(assemblies 24U132, 24U133,

24U133 only; Qty 2)

116793 FITTING, elbow, hydraulic, 9/16-18 x

9/16-18 (assemblies 24P260,

24P262, 24P264 only; Qty 2)

(assemblies 24P261, 24P263,

24P265 only; Qty 4)

(assemblies 24U132, 24U133,

24U133 only; Qty 2)

Qty

1

1

1

1

1

1

1

1

2

3

4

--- 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.

Available kits (purchase separately):

Kit Description

24R885 ◆ Cycle Switch

24R028* Inlet housing

24R030† Tubing

24R031 ✖ Melter

Includes

25, 26

12, 13, 62

32, 33, 34, 35, 36, 304. See

Feed System Shaker and

Tube, 24T812 on page 83 for

identification of item 304.

53, 202, 204, 207, 211, and

253. See Melter and Pump

Parts on page 81 for identifi-

cation of items 202-253.

24U635 Acrylic Lens

Pressure Gauge

3A2347N 77

Parts

Electrical Enclosure

MZLP

MZLP 3

118 4

113

113

112a

3 118

114 112 2

113

111

MZLP 2

117

114

109

106, 107

120

110

114

108

WLD

101

3

4

1

2

Apply sealant to all non-swiveling pipe threads.

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

Set rotary switch to “2” on MZLP 2.

Set rotary switch to “3” on MZLP 3.

132

78

131

102 WLD

104

105

3A2347N

Parts

Electrical Enclosure Parts

Ref Part

101 ---

Description

CABINET, controls

102 126807 MODULE, breaker

104 123970 SWITCH, disconnect, 40 amp

105 126839 CONTACT, n-pole

106 --BUSHING, strain relief, M40 thread

107 --NUT, strain relief, M40 thread

108 104641 FITTING, bulkhead

109 502937 FITTING, tee, 3/8 tube, 1/4 male npt

110 114421 BUSHING, strain relief

111 117666 TERMINAL, ground

112* --MODULE, MZLP with Daughter

Board

112a 24R042 MZLP DAUGHTER BOARD

113† 16T440 CAP, jam nut, sealing

✿ (1 MZLP assemblies only; Qty 2)

(2 MZLP assemblies only; Qty 4)

(3 MZLP assemblies only; Qty 6)

114 125856 SCREW, 8-32, serrated flange

116 --PLATE, blank, single MZLP

(1 MZLP assemblies only; Qty 2)

(2 MZLP assemblies only; Qty 1)

117 115942 NUT, hex, flange head

118† 24R234 MODULE, GCA, MZLP

119 ---

(2 MZLP assemblies only; Qty 1)

(3 MZLP assemblies only; Qty 2)

GASKET, foam, MZLP

(1 MZLP assemblies only; Qty 2)

(2 MZLP assemblies only; Qty 1)

120 196762 PIN, straight

121† 16T087 CABLE, board, male/male, 4 in.

1

12

1

1

✿ (101 mm)

(2 MZLP assemblies only; Qty 1)

122

(3 MZLP assemblies only; Qty 2)

16T088 CABLE, power, male/wire

123 16T089 CABLE, CAN, male/female, 1 m

124 16T103 CABLE, pump 1

125 ◆ --SENSOR, band heater temperature

126 16T108 CABLE, ultrasonic, M12-4p, 1 m

1

1

129† 16T201 HARNESS, 2nd MZLP

1

1

✿ (2 MZLP assemblies only; Qty 1)

(3 MZLP assemblies only; Qty 1)

130 114958 STRAP, tie 4

Qty

1

1

1

1

1

1

1

1

1

1

1

Ref Part Description

131 113974 SCREW, machine, slotted hex washer head

132 123967 KNOB, operator disconnect

133 24P176 KIT, Customer I/O connector

134 ✿ 16W034 HARNESS, 3rd MZLP

135 ✿ 16W035 CONNECTOR, jumper

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

Qty

Available kits (purchase separately):

Kit Description

24R237† Upgrade from 2 channel system to 4 channel system

24U575 ✿ Upgrade from 4 channel system to 6 channel system

24R040

24P859

24P176

◆ RTD

MZLP fuses

Customer I/O

Connectors

Includes

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

See

4 Channel Upgrade

Kit, 24R237 on page 94.

113, 118, 121, 129,134,

135, grounding wrist strap, and a software upgrade

token. See 6 Channel

Upgrade Kit, 24U575 on page 96.

125, 251, and 255. See

Melter and Pump Assembly, 24R375 on page 80.

Qty 8 - 8 Amp, 250V Fuses

Qty 2 - 16 Amp, 250V

Fuses

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

PLC connection.

2

1

1

1

1

3A2347N 79

Parts

Melter and Pump Assembly, 24R375

2 208

211

204 218

2 202

215

206

205

207

253

213

210

254

259

236

249

232

237

238

206

250

201

252 7

214

257

249

258

209

206

1

2

3

Lubricate all seals and o-rings with grease.

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

Torque to 5-11 ft-lb (7-15 N•m).

246

4

5

7

247

242

Torque to 24-30 ft-lb (33-41 N•m).

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

Assemble inserts (252) 0.01-0.05 in.

(0.3-1.3 mm) below surface.

243

244

245

239

235

233

234 5

220 3

240

219

211

252 7

203

251

255

80 ti20739a

3A2347N

217

216

217

223

224

225 5

226

222 4

221

227

228

229

231

232

230

Parts

Melter and Pump Parts

Ref Part

201 ---

202 ✖ ---

203• ---

Description

MANIFOLD, melter base

MELTER

MANIFOLD, outlet

204 ✖ ---

205 ---

PLATE, mounting

HOUSING, heater

206• 111317 RING, retaining, internal

207 ✖ 126475 O-RING, FKM, 157

208 24R039 HEATER, band

209 24R034 HEATER, fire rod, 500 watts

210 24R036 HEATER, fire rod, 1000 watts

211 ✖ 116940 SCREW, cap, sh, 5/16-18, 0.5 in. long

213 24R369 INLET FILTER

214• 112855 PACKING, o-ring

215 24T297 PLUG, o-ring boss

216ॠ--SLEEVE, cylinder

217†‡• 108526 PACKING, o-ring, PTFE

218 ✓ 24R025 MOTOR, air, 2.5 in., 0.48 in. stroke, high temperature

219 --PLATE, pump adapter

220 --ROD, tie

221• 192624 GUIDE, ball

222 ◆ • 239932 VALVE, piston

223 ◆ • --ROD, piston

224† ◆ • 105444 BALL, 0.3 in.

225†

226†

• ---

• ---

SEAL, u-cup, piston

BEARING, piston

227†• 105445 BALL, 0.5 in.

228†• 192642 SEAT, carbide

229†• 107079 PACKING, o-ring

230• --HOUSING, foot valve

231• 105802 PACKING, o-ring

232† ❖ • 113944 PACKING, o-ring

233†• ---

234†‡• ---

BEARING, throat

SEAL, u-cup, throat

235• 193046 NUT, packing

236 ❖ • --FILTER, assy, 100 mesh

237 ❖ • 15K234 PACKING, o-ring

238 ✓ 196762 PIN, straight

239 ✓ 196750 SPRING, retaining

240 101864 SCREW, socket head cap,

5/16-18, 1.0 in long

242 ★ • 117059 O-RING, fluoroelastomer

243 ★ • 16W327 RETAINER, seat, dump valve

244 ★ • 15Y627 PACKING, o-ring #2-116, PTFE

245 ★ • --VALVE, relief

246• 121295 SCREW, cap, socket head,

5/16-18, 2.5 in. long

247• 15H304 FITTING, plug 9/16 in. SAE

249 167002 INSULATOR, heat

Qty

1

1

1

3

1

1

1

1

7

1

1

5

10

1

2

1

1

1

1

1

1

1

1

4

1

1

1

2

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

3

Ref Part Description

250• 24R037 HEATER, fire rod, 1500 watts

251**• ---

252• ---

253 ✖ ---

254 ---

SWITCH, over temperature

INSERT, helical

PLATE, melter

O-RING, 910

255**• 107388 SCREW, machine, panhead,

256 ---

257 ---

#4-40, 3/8 in. long

LUBRICANT, grease

BRACKET, melter

258 --GROMMET, 1/4 in. ID

259 115506 SCREW, machine, hex washer

297* head, 1/4-20, 3.0 in. long

120663 FITTING, straight, hydraulic 1

298* 126961 FITTING, 45 deg. elbow, hydraulic 1

299* 116793 FITTING, 90 deg. elbow, hydraulic 1

1

4

1

1

Qty

1

1

1

1

7

2

* Not shown or assembled. Quantity equals number of channels the unit supports.

--- Not for sale.

Available kits (purchase separately):

Kit Description Includes

24P852† Pump repair 217, 224, 225, 226, 227,

228, 229, 232, 233, 234, and seal installation tool

15B661.

24P853‡ Cylinder

24R025 ✓ Air motor

24R031 ✖ Melter

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

24P854 ◆ Pump rod 222, 223, 224, 225, 226

24P855 ❖ 100-mesh filter 232, 236, 237

24P856 ★ Pressure relief valve

242, 243, 244, 245

218, 238, 239

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

InvisiPac Systems parts starting on page 74 for

insulator (53) identification.

24R040** RTD

24R709 • Assembled

--pump manifold

125, 251, and 255. See

Electrical Enclosure on page 78.

203, 206, 214, 216, 217,

221, 222, 223, 224, 225,

226, 227, 228, 229, 230,

231, 232, 233, 234, 235,

236, 237, 242, 243, 244,

245, 246, 247, 250, 251,

252, 255

Special tools

See Special Tools on page 87.

3A2347N 81

Parts

Air Motor, 24R025

4 511

528

1

2

3

4

Torque to 11-13 ft-lb (15-18 N•m).

Apply water-resistant grease.

Apply epoxy adhesive then torque to

35-40 ft-lb (47-54 N•m).

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

527

509

4

511

520

522

508

513 2 4

512 1

518

507

503

515

3

517

507

2

501

523

510

506

513 2 4

24R025 Parts

Ref Part

501 ---

503 ---

Description

COVER, lower, 2.5 in.

502 ◆ 108993 PACKING, o-ring

504 ★◆ ---

BEARING, 9/16 in.

PACKING, o-ring, FKM

505 15M289 CYLINDER, motor, 2.5 in.

506 ---

507 ◆ ---

508 ◆ ---

509† ◆ ---

COVER, air motor

SEAL, u-cup, FKM

GASKET, cover, small

SEAL, air valve, manifold

510 15M291 COVER, motor, 2.5 in.

511† --SCREW, M6 x 25, thread forming

512 15M314 SCREW, cap

513 24R027 VALVE, pilot

515 15M213 MUFFLER, 3/8

516 ---

517 ◆ ---

518 ★ ---

519 ★ ---

GREASE, water-resistant

RING, retaining

ROD, air motor, 2.5 in.

PISTON, air motor, 2.5 in.

502

2

1

1

2

2

1

8

2

1

Qty

1

2

1

1

2

1

1

1

1

1

505 2

502 2

504

2

519 ti20903a

Ref Part

520 ---

521 ★◆ ---

Description

MANIFOLD, medium, short

ADHESIVE

522 105444 BALL, 0.3 in.

523 ---

527† 24R026 VALVE, air, small

528 ---

LABEL, identification

BRACKET, feed inlet assembly

-- Not for sale.

★ Included in Air Motor Piston Kit 24R705 (purchase separately.

◆ Included in Air Motor Seals Kit 24R706 (purchase separately).

† Included in Air Motor Valve Kit 24R026 (purchase separately).

Qty

1

1

1

1

4

1

82 3A2347N

Parts

Feed System Shaker and Tube, 24T812

301

1

302

1 Apply pipe sealant to threads.

Parts

Ref

301

302

Part Description

24P861 SHAKER

24N954 TUBE, steel

303† ◆ ---

304 ---

TUBE, clear PVC, 1.3 in.

(33 mm) OD

HOSE, nylon, 3/8 in. OD,

250 psi (1.7 MPa, 17 bar)

305 ◆ 125370 CLAMP, hose, dia. 11/16 to

1-1/2 in.

306 125871 TIE, cable, 7.50 in. (190 mm)

--- Not for sale.

† 30 ft (9.1 m) Feed Hose Kit 24R043 also available

(purchase separately). Kit also includes 2 hose clamps.

Included in Tubing Kit 24R030. See System Parts on page 77 for other kit contents.

◆ Not shown.

Qty

1

1

10

15.5

3

4

NOTE: Shaker Grounding Kit 24R708 (purchase separately) also available. Kit includes a grounding wire assembly, and a screw and washer for installing on the shaker tube (301).

3A2347N

306

304 ti20738a

83

Parts

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

Part

---

Description

PANEL, air, controls

24R029 CONTROL, air, vacuum transfer and pump

15T500 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

Qty

1

1

2

2

2

2

--- Not for sale.

406

1

404 ti20737a

84 3A2347N

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

2

3

Apply sealant to all non-swiveling pipe threads.

Apply grease.

Torque to 4-6 in-lb (0.5-0.7 N•m).

613 i

Ref

601

602

603

604

605

606

607

---

---

---

---

Part

---

Description

BODY, fluid

--BODY, air

15T413 PISTON, air

AIR CAP, valve

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† --BEARING, valve

612† ---

613 ---

614† ---

O-RING, FKM

FITTING, push to connect

SEAL, u-cup, relief valve

--- Not for sale.

† Parts included in Relief Valve Repair Kit 24P857

(purchase separately).

1

1

1

2

1

1

1

Qty

1

1

1

1

1

1

1

3A2347N 85

Parts

Feed Inlet Funnel, 24R738

701

705

706

Ref

701

705

706

Part

---

---

--- Not for sale.

Description

262907 FILTER AND CAP ASSEMBLY

SCREW, #10-16, thread forming

FUNNEL, feed inlet

Qty

1

2

1 ti20927b

86 3A2347N

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).

3A2347N ti20983a

87

Accessories

Non-Graco Gun Adapter Cables

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

Air Adjustment Lock, 24R084

Panel enables locking access to the air adjustment screws. ti21128a

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

801

802 ti20984a ti21129a

16Y828: For connecting to non-Graco guns that use a circular 6-pin connector.

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

WLD

Non-Graco Gun Adapter Cable Installation

See

Attach Components on page 14.

Ref

801

802

Part

---

---

Description

PANEL, lock, air control

BRACKET, lock, air control

Qty

1

1

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.

88 3A2347N

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

1002

1001

1104

1003

1101

1102 A ti20985a

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).

1103 ti21918a

Ref Part Description

1101 --PLATE, adapter

1102 112395 SCREW flange head cap

1103 112958 NUT, hex, flanged

1104 121283 FITTING, elbow, 45 degree

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

3A2347N 89

Accessories

30 Gallon Vibrating Hopper, 24R136

Hopper includes a shaker to ensure the adhesive pellets maintain a level surface at all times. Without this, the adhesive pellets can stick together, preventing them from continuously covering the vacuum transfer system’s inlet. This would cause the vacuum transfer system to be unable to transfer the adhesive pellets.

Input Air Pressure Requirement: 100 psi (7 bar, 0.7 MPa)

Air Consumption: 17.1 scfm (29.1 cubic meters per hour)

902

903

910

901

905

903

904

915

915

907

909

916 ti20928a

914

912

Ref

901

902

903

904

905

907

908

909

910

Part

---

Description

HOPPER, 30 gallon

--LID, hopper, 30 gallon

126930 SHAKER, ball vibrator

126929 VALVE, air pilot, 3-way, closed

--BRACKET, shaker, container

--HOSE, nylon, 3/8 in. OD, 250 psi

(1.7 MPa, 17 bar)

119798 CONNECTOR, tee, push-tube

113779 MUFFLER

111192 SCREW, cap flange head

Qty

1

1

1

1

1

1

1

1

2

Ref

912

914

915

916

917

Part Description

125857 SCREW, 10-24, serrated flange

121141 FITTING, elbow, swivel, 3/8 in. tube connector, 1/4 male npt

120389 FITTING, tube

--CONNECTOR, tube, 90 degree

125539 FITTING, splitter, 3/8 in. OD tubing

Qty

4

1

2

1

1

--- Not for sale.

90 3A2347N

Accessories

30 Gallon Vibrating Hopper Installation

See F IG . 56 for illustration of installed vibrating hopper.

1. Turn main power switch OFF.

2. With the steel shaker rod fully assembled and the

3/8 in. OD air line connected to the shaker head, cut the 3/8 in. OD air line where the 1.3 in. clear vacuum transfer hose connects to the steel shaker rod.

3. Use the splitter fitting (917) to reconnect the 3/8 in.

OD air line that was just cut.

4. Install the 48 in. section of 3/8 in. OD hose supplied with the kit into the remaining connection on the splitter fitting (917).

5. Connect the other end of the 48 in. section of 3/8 in.

OD air line to elbow fitting (916) on the piloted air valve.

6. Connect shop air to elbow fitting (914) on the piloted air valve. Shop air must be capable of 100 psi

(0.7 MPa, 7 bar).

NOTE: The piloted air valve must use shop air. Adding a tee at the system inlet to run the hopper shaker may impact pump and vacuum transfer performance.

7. Place steel shaker rod assembly into hopper (901) with steel rod resting in the hopper groove in the rim of the hopper.

8. Place lid (902) on hopper (901).

NOTE: The hopper shaker will be active while the vacuum transfer system is transferring pellets.

NOTE: The air supplied to the pilot valve from the system vacuum must be set to 65% of the shop air supply supplied to elbow fitting (914) or higher. If the pilot valve air pressure is lower than this, increase the vacuum

transfer air pressure regulator (E, see F IG . 1 on page 8).

To piloted air valve

F IG . 56

To shop air supply

To shaker head

Splitter fitting

Hopper shaker

Piloted air valve ti21350a

3A2347N 91

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

AA

1204

J12

BB

1202

1205

24R226 Parts

Ref Part Description

1201 16T102 LIGHT, tower, red and green

1201a ---

1202 ---

SCREW

GROMMET, single cable

1203 16K322 BRACKET, light tower

1204 --GROMMET, multiple wires

1205 125835 CLIP, ferrite bead

--- Not for sale.

92

Qty

1

3

1

1

1

1 ti20987b

3A2347N

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

1506

1505 1503 1504

1504

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.

Qty

1

1

1

1

1

2

3A2347N 93

Accessories

4 Channel Upgrade Kit, 24R237

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

AA

BB

1301

1305

1302

1304

Ref Part Description Qty

1301 --MODULE, GCA, MZLP 1

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

1

1303

1304

1305

16T201 HARNESS, 2nd MZLP power

112190 STRAP, wrist, grounding

16T440 CAP, jam nut, sealing

1306 24R324 SOFTWARE UPGRADE

TOKEN, InvisiPac System

2

1

1

1

◆ Not shown.

1306 ti20988a

94 3A2347N

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

4. Set MZLP rotary switch to “2” on MZLP without daughter card.

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

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

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 .

57.

7. 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.

8. Move CAN connector from MZLP 1 connector J3 to

MZLP 2 connector J6. See F IG . 57.

9. Move power cable (CC) from MZLP 1 connector J6

to MZLP 1 connector J3. See F IG . 57.

10. Connect jumper cable (1302) to MZLP 1 connector

J6 and connect other end of jumper cable (1302) to

MZLP 2 connector J3. See F IG . 57.

11. Connect wires from power harness (1303) to connectors as labeled on the plastic connector.

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

J6

J5

Step 8: Move CAN Connector (DD).

MZLP 2 MZLP 1

J9

J1

J2

J8

J3

Step 9:

Move

Power

Cable

(CC).

J3

J8

J2

J1

J9

J6

J5 ti20989a1

Step 10: Install Jumper Cable (1302).

F IG . 57

3A2347N 95

Accessories

6 Channel Upgrade Kit, 24U575

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

1306

CC

1308

WLD

1304

1307

1301

Ref Part Description Qty

1301 --MODULE, GCA, MZLP 1

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

1

1303 112190 STRAP, wrist, grounding

1304 16U422 TOKEN, software upgrade

1305 16T440 CAP, jam nut, sealing

1306 16W034 HARNESS, MZLP #3

1307 16W035 CONNECTOR, jumper

1308 127208 FITTING, tee

1

2

2

1

1

1

1302

BB

1305

BB

AA

96 3A2347N

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 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.

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.

7. Move ADM CAN connector from MZLP 2 connector

J6 to MZLP 3 connector J3. See F IG . 58.

8. Connect CAN jumper cable (1302) to MZLP 2 connector J6 and connect other end of jumper

cable (1302) to MZLP 3 connector J6. See F IG . 58.

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

10. Connect wires from power harness (1306) to connectors as labeled on the plastic connector.

11. Connect power harness (1306) to MZLP 3 connector J2.

12. Remove plugs (CC) from fluid manifold and replace with tee fittings (1308).

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 . 58.

Step 8: Install jumper cable (1302).

7R

$'0

-

-

0=/3

-

-

-

0=/3

-

-

-

-

0=/3

-

-

-

-

-

-

-

-

-

-

-

-

Step 7: Move ADM CAN connector.

F IG . 58

3A2347N

WLD

97

Accessories

Single-Phase 480V to 240V Transformer, 24U169

This transformer must be installed by a qualified electrician to operate 240V InvisiPac units with single-phase

480V electrical supply.

24U169 Wiring:

NOTE: When using transformer 24U169, the ADM amp limit must be set to 30 amps and power type set to sin-

gle phase. See step 4 of Select ADM Settings

on page

21.

Primary Voltage

240 x 480

Secondary

Voltage

120/240

Primary

H1 H3 H2 24U169 Electrical Specifications:

Phase:

Frequency: kVa:

K Rating:

Single

60 Hz

7.5 kVa

1

Primary Config.: 2 winding

Secondary Config.: 2 winding

Winding material: Copper

Connection: Wire leads

24U169 Mechanical Specifications:

Temperature Rise: 115°C (239°F)

Insulation Sys.:

Cooling Sys.:

Construction:

Enclosure:

180°C (356°F)

Air/Dry

Enclosed-encapsulated core and coil

Steel, NEMA 3R

24U169 Approvals:

Approvals:

Sound level:

UL listed, cUL listed, CSA approved

Below NEMA standards

24U169 Mounting Information:

X4

Volts

480

240

240

240/120

120

X2 X3

Secondary

Connections

H2 - H3

H1 - H3, H2 - H4

X2 - X3

X2 - X3

X1 - X3, X2 - X4

10.2 in. (258 mm)

8.0 in. (203 mm)

Taps

None

H4

X1

Line Leads

H1, H4

H1, H4

X1, X4

X1, X2, X4

X1, X4

1/4 in. (6 mm) Mounting

Hardware Required

Weight: 150 lb (68 kg)

98 3A2347N

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

1404

1402

1403 r_24P860_3B9900_3a

F IG . 59: Remove Access Panel

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

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

4. Perform

Software Update Procedure on page 69.

ti20990a

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

1

1

3A2347N 99

Accessories

Overtemperature Jumper, 16Y727

Use the Overtemperature jumper plug to run the

InvisiPac melter without a hose and gun attached to the

Channel 1 electrical connection.

Installation

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

WLD

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

1 when there is no hose/gun 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 gun attached to Channel 1.

100 3A2347N

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

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 104.

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 gun (right)

Actual temperature of system

(shown warming up)

System temperature setting.

Use ting.

and to adjust set-

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

3A2347N

Icon Description

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

(top) and hose (bottom)

Reset weight total

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

101

Appendix A - ADM

Operation Screens

Home Events

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

Targets

This screen shows and allows editing of the temperature settings for the system melter and each gun and hose.

See

Select ADM Settings on page 21.

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 107.

Tracked Events

Custom Language Downloaded

Custom Language Uploaded

Fill Valve Closed

Fill Valve Open

Heat Off

Heat On

Logs Downloaded

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

102 3A2347N

Errors

The Errors screens store a maximum of 200 errors. See

ADM Error Code Table on page 36. The errors list can

be downloaded in the USB logs. See

Appendix B -

USB Downloading, Uploading on page 107.

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.

Appendix A - ADM

3A2347N 103

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

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

See

PLC Connection on page 24 for instructions.

System 2

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

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.

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 27.

See Select ADM Settings on page 21.

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

Select

ADM Settings on page 21.

104 3A2347N

Appendix A - ADM

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.

Advanced 2

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

matically enable and disable heating. See Select ADM

Settings on page 21.

Temperature Units: Units of measure for displayed temperatures.

Mass Units: Units of measure for mass.

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

NOTE: When the specific gravity value is populated, the total mass dispensed since the last total weight reset is shown on the Home screen and the mass flow rate is shown on the Diagnostic screen.

3A2347N 105

Appendix A - ADM

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.

106 3A2347N

Appendix B - USB Downloading, Uploading

Appendix B - USB Downloading, Uploading

The system can store 250,000 entries in its logs and the system adds a new entry to the logs every 15 seconds.

This means 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.

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.

Download Procedure

NOTICE

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

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

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 procedure. See

USB Logs , System Settings File

, and

System Language File starting on page 108.

Upload Procedure

NOTICE

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

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

1. Insert USB flash drive into USB port. See F IG . 60.

NOTE: Flash drive must be 8 GB or smaller.

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 108.

F IG . 60: 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.

1. If necessary, follow the Download Procedure

,

page 107, 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.

3A2347N 107

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 Procedure , page 107, 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 SET-

TINGS.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 systems. Refer to the

Upload Procedure , page 107, 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.

108 3A2347N

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 107, 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.

3A2347N

Appendix B - USB Downloading, Uploading

109

Technical Data

Technical Data

InvisiPac Hot Melt Delivery System

US Metric

Electrical

Electrical Service

Maximum Gun Wattage Per Channel

Input / Output Capability

General

Adhesive

Pump Flow Rate

Pump Output

Time to Temperature *

Melt Rate / Constant Throughput

Pump

Channels

System Dimensions, without vacuum tube or shaker (Width x Height x Depth) **

Shaker Dimensions (Width x Height)

Weight

Pressure and Temperature Ranges

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

Pump Operating Air Pressure Range

Pump Operating Fluid Pressure Range

Control Temperature Range

Ambient Temperature Range

Vacuum Transfer Specifications

Maximum Vacuum Transfer Hose Length

Maximum Vacuum Transfer Hose Maximum Vertical Rise

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)

24P260: 200-240VAC, 1-ph, 50/60 Hz, 32A Max

24P261: 200-240VAC, 1-ph, 50/60 Hz, 40A Max

24P262: 350-415VAC/200-240VAC, 3-ph with Neutral, 50/60 Hz, 16A

Max

24P263: 350-415VAC/200-240VAC, 3-ph with Neutral, 50/60 Hz, 16A

Max

24P264: 200-240VAC, 3-ph without Neutral, 50/60 Hz, 27A Max

24P265: 200-240VAC, 3-ph without Neutral, 50/60 Hz, 27A Max

24U132: 200-240VAC, 1-ph, 50/60 Hz, 40A Max

24U133: 350-415VAC/200-240VAC, 3-ph with Neutral, 50/60 Hz, 30A

Max

24U134: 200-240VAC, 3-ph without Neutral, 50/60 Hz, 40A Max

400 W

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

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

96 lb/hr 43.5 kg/hr

6.2 cc/cycle

Less than 10 minutes

11.3 kg/hr 25 lb/hr

Pneumatic Piston, 12:1

1 to 4

19.0 x 42 x 16.5 in.

483 x 1067 x 419 mm

0.4 x 4.0 ft

85 lb

80-100 psi

20-100 psi

240-1200 psi

100-400°F

32-120°F

30 ft

10 ft

40-100 psi

9.5 scfm (intermittent duty; 4% at

25 lb/hr)

17.2 scfm (intermittent duty; 4% at

25 lb/hr)

0.12 x 1.22 m

39 kg

0.55-0.69 MPa (5.5-7 bar)

0.14-0.69 MPa (0.7-7 bar)

1.7-8 MPa (17-80 bar)

38-204°C

0-49°C

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)

29.2 scmh (intermittent duty; 4% at

11.3 kg/hr)

110 3A2347N

Technical Data

InvisiPac Hot Melt Delivery System

US Metric

Required Air Tubing Size

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

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

Sound

3/8 in.

1/2 in.

9.5 mm

12.7 mm

Sound Pressure Level***

IP Code

InvisiPac Base System

Wetted Parts

Wetted Parts

77 dB(A)

IP54

Approvals and Standards

30 Gallon Vibrating Hopper

Required Air Pressure Supplied To 30 Gallon

Vibrating Hopper

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

UL499, CSA88, CE, ISO 9001

100 psi 0.7 MPa (7 bar)

Air Consumption 17.1 scfm 29.1 cubic meters per hour

* 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.

3A2347N 111

Technical Data

Startup Time

Single Phase

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

5

5

4

5

3

4

3

3

4

Channels

(#)

1

1

2

2

1

2

6

6

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)

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)

31

18

25

36

15

19

26

16

22

20 Amp

Breaker

240V

11

13

15

13

16

20

20

28

41

20

11

16

23

9.9

12

16

9.9

14

30 Amp

Breaker

240V

9.9

9.9

9.9

9.9

9.9

13

12

18

27

14

9.9

11

17

9.9

9.9

12

9.9

9.9

40 Amp

Breaker

240V

9.9

9.9

9.9

9.9

9.9

9.9

9.9

13

20

Start Time in Minutes

50 Amp

Breaker

240V

9.9

9.9

20 Amp

Breaker

208V

13

14

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

17

22

29

18

25

17

15

18

23

12

9.9

9.9

14

9.9

10

16

22

32

47

35

20

28

41

23

13

18

27

13

13

19

13

16

30 Amp

Breaker

208V

13

13

13

13

13

13

13

20

31

16

13

13

19

13

13

13

13

13

40 Amp

Breaker

208V

13

13

13

13

13

13

13

13

22

13

13

13

15

13

13

13

13

13

50 Amp

Breaker

208V

13

13

13

13

13

13

13

13

18

112 3A2347N

Technical Data

Three Phase

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

Channels

(#)

1

1

1

2

2

2

3

3

3

4

4

4

5

5

5

6

6

Hose

Length ft (m)

4 (1.2)

20 Amp

Breaker

240V/480V

11

12 (3.6) 13

25 (7.6) 15

4 (1.2) 13

12 (3.6) 16

25 (7.6) 20

4 (1.2) 14

12 (3.6) 18

25 (7.6) 25

4 (1.2) 15

12 (3.6) 21

25 (7.6) 30

4 (1.2) 17

12 (3.6) 23

25 (7.6) 34

4 (1.2) 18

12 (3.6) 26

6 25 (7.6) 39

30 Amp

Breaker

240V/480V

9.9

9.9

9.9

9.9

11

14

9.9

12

17

10

14

20

11

16

23

12

17

26

40 Amp

Breaker

240V/480V

9.9

9.9

9.9

9.9

9.9

10

9.9

9.9

13

9.9

11

15

9.9

12

17

9.9

13

19

Start Time in Minutes

50 Amp

Breaker

240V/480V

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

11

16

20 Amp

Breaker

208V/415V

13

14

16

14

17

22

17

23

34

19

16

20

26

27

40

21

30

46

30 Amp

Breaker

208V/415V

13

13

13

13

13

14

13

15

22

13

13

13

18

18

27

14

20

31

40 Amp

Breaker

208V/415V

13

13

13

13

13

13

13

13

17

13

13

13

13

14

20

13

15

23

50 Amp

Breaker

208V/415V

13

13

13

13

13

13

13

13

13

13

13

13

13

13

16

13

13

19

3A2347N 113

Technical Data

Dimensions

System Dimensions

41.6 in.

(1057 mm)

20.8 in. (529 mm)

Mounting Hole Dimensions

WALL

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

2.0 in.

(51 mm) ti20440b1

17.3 in.

(439 mm)

3.3 in.

(84 mm)

7.1 in. (180 mm)

14.2 in. (361 mm)

3.3 in.

(84 mm)

114 3A2347N

System with Stand and Vacuum Feed Dimensions

Tube Bend Radius:

8.0 in. (203 mm)

12.0 in.

(305 mm)

66.5 in.

(1689 mm)

Technical Data

26 in.

(660 mm)

17.0

(432 mm)

31.0

(787 mm)

3A2347N ti22341a

30.0

(762 mm)

Radius:

9.1 in. (232 mm) ti22343a

115

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

For more information about InvisiPac, visit www.InvisiPac.com.

For technical assistance or customer service, call toll free: 1-800-458-2133.

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.

)RUSDWHQWLQIRUPDWLRQVHHZZZJUDFRFRPSDWHQWV

2ULJLQDOLQVWUXFWLRQV This manual contains English. MM 3A2347

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision N- May 2014

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