Graco 333347B - InvisiPac HM50 Tank-Free Hot Melt Delivery System Instructions

Instructions - Parts
InvisiPac™
HM50 Tank-Free™
Hot Melt Delivery System
333347B
EN
For delivering and dispensing hot melt adhesive pellets. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
1200 psi (8.3 MPa, 83 bar) Maximum Working Pressure
400°F (204°C) Maximum Fluid Operating Temperature
100 psi (0.7 MPa,7 bar) Maximum Air Inlet Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual and in the applicator and hose manuals. Save all instructions.
WLD
9902471
Certified to
CAN/CSA C22.2 No. 88
Conforms to
ANSI/UL 499
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HM50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . 9
Heated Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Advanced Display Module (ADM) . . . . . . . . . . . . . . . . 12
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Attach Components . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Recommended Air Setup . . . . . . . . . . . . . . . . . . . . . . 19
Connect Electrical Cord . . . . . . . . . . . . . . . . . . . . . . . 20
208V Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . 21
Select ADM Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PLC Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Initial Startup and Prime . . . . . . . . . . . . . . . . . . . . . . . 26
Manual Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Automatic Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 30
Drain the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation Tips to Minimize Charring . . . . . . . . . . . . . 33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Replace Outlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Replace Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Replace Funnel Filter . . . . . . . . . . . . . . . . . . . . . . . . . 35
Filter Maintenance Guidelines* . . . . . . . . . . . . . . . . . . 36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ADM Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . 37
Mechanical and Electrical Troubleshooting . . . . . . . . 43
MZLP Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 51
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Multi-Zone Low Power Temperature Control Module
(MZLP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Transformer Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Software Update Procedure . . . . . . . . . . . . . . . . . . . . 72
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2
Cable Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
480VAC Transformer Option . . . . . . . . . . . . . . . . . . . . 75
Typical Hose / Applicator Wiring . . . . . . . . . . . . . . . . . 75
2nd and 3rd MZLP Options . . . . . . . . . . . . . . . . . . . . . 76
Air Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
InvisiPac Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Transformer Assemblies . . . . . . . . . . . . . . . . . . . . . . . 88
Melter and Pump Assembly, 24V542 . . . . . . . . . . . . . 89
Air Motor, 24V558 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Feed System Shaker and Tube, 24V507 . . . . . . . . . . 93
Air Controls Assembly . . . . . . . . . . . . . . . . . . . . . . . . 94
Pressure Relief Valve, 24P856 . . . . . . . . . . . . . . . . . . 95
Feed Inlet Funnel, 24V505 . . . . . . . . . . . . . . . . . . . . . 96
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Non-Graco Applicator Adapter Cables . . . . . . . . . . . . 98
Air Adjustment Lock, 24R084 . . . . . . . . . . . . . . . . . . . 98
System Stand, 24R088 . . . . . . . . . . . . . . . . . . . . . . . . 99
Caster for Stand, 120302 . . . . . . . . . . . . . . . . . . . . . . 99
Adapter Plate, 24R083 . . . . . . . . . . . . . . . . . . . . . . . . 99
30 Gallon Vibrating Hopper, 24R136 . . . . . . . . . . . . 100
Light Tower Kit, 24R226 . . . . . . . . . . . . . . . . . . . . . . 102
Air Reservoir Kit, 16W366 . . . . . . . . . . . . . . . . . . . . 103
4 Channel Upgrade Kit, 24V528 . . . . . . . . . . . . . . . . 104
6 Channel Upgrade Kit, 24V529 . . . . . . . . . . . . . . . . 106
InvisiPac ADM Simulator Kit, 24R323 . . . . . . . . . . . . 108
Overtemperature Jumper, 16Y727 . . . . . . . . . . . . . . 109
Appendix A - ADM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Icon Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Operation Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Appendix B - USB Downloading, Uploading . . . . . . . . 116
Download Procedure . . . . . . . . . . . . . . . . . . . . . . . . 116
Accessing Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Upload Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
System Settings File . . . . . . . . . . . . . . . . . . . . . . . . . 117
System Language File . . . . . . . . . . . . . . . . . . . . . . . 118
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Startup Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Graco Extended Warranty . . . . . . . . . . . . . . . . . . . . . . . 126
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
333347B
Related Manuals
Related Manuals
Manuals are available at www.graco.com. Component
manuals in English:
Part
Description
3A2805
InvisiPac GS35 Hot Melt Applicator Instructions Parts
332072
InvisiPac Heated Hose Instructions - Parts
333348
HM50 Fuse Kit, Instructions-Parts
333349
InvisiPac 480V Transformer Upgrade Kit, 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
333347B
3
Models
Models
NOTICE
To prevent system damage, verify terminal jumpers
are installed correctly before applying power.
HM50
Model
Channels
Voltage
200-240 VAC
24T918
2
200-240 VAC ˂
350-415 VAC Y
200-240 VAC
24T919
4
200-240 VAC ˂
350-415 VAC Y
200-240 VAC
24T920
6
200-240 VAC ˂
350-415 VAC Y
Frequency
Max
Amps
1˓ / PE
• 1-Phase
• 200-240VAC
50/60 Hz
32A
3˓ / PE
• 2 wire and PE
• 3-Phase without Neutral
• 200-240VAC
50/60 Hz
27A
•
•
•
•
50/60 Hz
16A
1˓ / PE
• 3 wire, Neutral, and PE
• 1-Phase
• 200-240 VAC
50/60 Hz
40A
3˓ / PE
• 2 wire and PE
• 3-Phase without Neutral
• 200-240 VAC Line to Line
50/60 Hz
27A
•
•
•
•
50/60 Hz
16A
1˓ / PE
• 3 wire, Neutral, and PE
• 1-Phase
• 200-240 VAC
50/60 Hz
40A
3˓ / PE
• 2 wire and PE
• 3-Phase without Neutral
• 200-240 VAC Line to Line
50/60 Hz
40A
•
•
•
•
50/60 Hz
30A
˓ Type
3˓ / Neutral / PE
3˓ / Neutral / PE
3˓ / Neutral / PE
Description
3 wire and PE
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
3 wire and PE
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
3 wire and PE
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
• 3 wire, Neutral, and PE
4
333347B
Models
Model
Channels
Voltage
24V201
2
400-480 VAC
24V202
24V203
4
6
400-480 VAC
400-480 VAC
Frequency
Max
Amps
3˓ / PE
• 3-Phase without Neutral
• 400-480 VAC Line to Line
50/60 Hz
14A
3˓ / PE
• 3 wire and PE
• 3-Phase without Neutral
• 400-480 VAC Line to Line
50/60 Hz
14A
3˓ / PE
• 3 wire and PE
• 3-Phase without Neutral
• 400-480 VAC Line to Line
50/60 Hz
14A
˓ Type
Description
• 3 wire and PE
333347B
5
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.
6
333347B
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.
333347B
7
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.
8
333347B
Component Identification
Component Identification
G3
G2
G4
A
G
AD
H
G1
B
F
E
C
WLD
D
K
Key:
A
B
C
D
E
F
G
G1
G2
G3
G4
H
J
K
L
M
N
P
R
S
AC
AD
Advanced Display Module (ADM)
Electrical Enclosure
Pump Air Pressure Regulator
Pump Air Pressure Gauge
Vacuum Transfer Air Pressure Regulator
Vacuum Transfer Air Pressure Gauge
Shaker Tube
Shaker Head
Vacuum Transfer Tube
Vacuum Transfer Inlet Funnel
Vacuum Transfer 3/8 in. OD Air Supply
Main Power Switch
System Air Inlet
Vacuum Transfer (Shaker) Inlet
Air Motor and Pump
Incoming Power Strain Relief
Heated Fluid Manifold (Melter)
Multi-Zone Low Power Temperature Control Module (MZLP)
Fluid Outlets for connection to Heated Hoses (numbered 1-6)
Customer I/O Cable (optional)
Drain Port
Transformer (optional)
FIG. 1
333347B
L
G3
N
R
M
AC
P
S
WLD
J
9
Component Identification
Heated Fluid Manifold
AB
Y
U
AA
T
X
W1
W2
WLD
NOTE: System shown with plastic and metal shrouds removed.
FIG. 2
Key:
T
U
W1
W2
X
Y
Z
AA
Electrical Enclosure Front Access Door
Melter
Drain Port
Drain Tray
Inlet Filter (Low Pressure - Before Pump)
Outlet Filter (High Pressure - After Pump)
Adhesive Pellets Level Sensor (not shown; inside funnel)
Power and RTD Harness Connection to Heated Hose and
Applicator (harness connects from system to heated hose
then from heated hose to applicator)
AB Inlet Funnel Screen
10
333347B
Component Identification
Electrical Enclosure
AC
P
WLD
AF
AG
FIG. 3
Key:
P
Multi-Zone Low Power Temperature Control Module
(MZLP)
AC Incoming Power Connection
AF Chassis Ground
AG Automatic Wiring Board (AWB)
333347B
11
Component Identification
Advanced Display Module (ADM)
User Interface
NOTICE
BK
To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.
BL
NOTE: See Appendix A - ADM on page 110 for complete ADM operation details.
BB
BC
FIG. 5
BA
BD
BE
BF
BM
BR
BP
BN
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
FIG. 4
B
Key Function
BA
Heating system and pump enable/disable
BB
System status indicator (LED)
BC
Stop all system processes
BD
Defined by icon next to softkey
BE
Abort current operation
BF
Accept change, acknowledge error, select item, toggle
selected item
BG
Toggle between Operation and Setup screens
BH
Navigate within a screen or to a new screen
12
333347B
Component Identification
Screen Components
Screens Order
Current date and time
Operating Mode
Faults, Status
Melter Heating Status
Melter Actual Temperature
Hose and Applicator
Heating Status
Hose Actual Temperature
Applicator Actual Temperature
FIG. 6: Main Screen Components
Operating Mode
Description
Component Status
•
System Off
The system doesn’t have power.
Inactive
The heating system and pumps are disabled.
Warm Up
Active
333347B
The system is heating the material to the
set temperature.
The system is ready to dispense
material.
•
•
•
•
•
•
•
•
•
•
•
No System Status Indicator LED on the
ADM
No heat
Pump is off
Yellow system status indicator LED on the
ADM
No heat
Pump is off
Flashing green system status indicator LED
on the ADM
Heat is increasing to setpoint temperature
Pump is off
Solid green system status indicator LED on
the ADM
Heat is at setpoint temperature
Pump is on
13
Setup
Setup
Grounding
The applicator(s) must be located no more than 25 ft
(7.6 m) from the melter.
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
The InvisiPac system is equipped with a ground terminal. A qualified electrician must ground the system using
this terminal. See Connect Electrical Cord on page 20.
NOTICE
To prevent excessive static buildup on shaker or adhesive
bin, install optional grounding kit 24R708.
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 99.
If installing the system in place of a non-Graco hot melt
system, purchase Adapter Plate, 24R083. See
page 99.
Optional 30 Gallon Vibrating Hopper, 24R136, available (purchase separately). See page 100.
To make repairing the system easier, locate the system
so that all sides are easily accessible and have sufficient
lighting.
Attach Components
To reduce the risk of electric shock, do not connect
electrical cord until after this Attach Components
procedure is complete.
NOTE: Only systems with transformers are supplied
with a lifting strap.
NOTICE
To prevent strain on electrical or mechanical
connections around the pump assembly, loop the
strap around the tie rods as shown.
WLD
FIG. 7: Grounding Kit 24R708
Location
1. Use supplied lifting strap 127735, to transport systems with transformers. Wrap strap around all three
pump tie rods and loop the strap back through itself
in the Choker Configuration. See strap for details.
See FIG. 8, page 15.
Ambient temperature must be 32-120°F (0-49°C).
The supplied vacuum transfer hose length is 10 ft (3 m).
The maximum vacuum transfer hose length available is
30 ft (9.1 m). The adhesive pellets container must be
located within reach of the vacuum transfer hose and no
more than 30 ft (9.1 m) away.
14
333347B
Setup
3. Adjust the funnel inlet:
G3
23
81
92
WLD
a. Remove plug (23) and insert the provided 5/16
in. nut driver (92) through the access hole in the
back of the system. Loosen the band clamp (81)
two turns.
WLD
FIG. 8: Lifting Strap
2. Place the base system in the desired operating
location and orientation. See Location, page 14.
•
b. Rotate the funnel inlet (G3) and re-tighten the
band clamp (81).
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 99.
•
To raise the system to eye-level, purchase System
Stand, 24R088. See installation instructions on
page 99.
NOTE: Supplied vacuum transfer hose must reach from
the system to the adhesive pellets container. Supplied
heated hose must reach from system to applicator(s).
G3
G4
G2
WLD
FIG. 9
4. Insert 1.3 in. (33 mm) OD clear vacuum transfer
hose (G2) into vacuum transfer funnel (G3) inlet and
secure with supplied hose clamp. See FIG. 9.
5. Connect the long supplied 3/8 in. OD air line (G4) to
the 3/8 in. push-to-connect fitting on the air line from
the system. See FIG. 9.
333347B
15
Setup
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.
6. Route the 1.3 in. (33 mm) OD clear vacuum transfer
hose (G2) from the system to the adhesive pellets
container location.
7. Apply pipe sealant to threads then attach steel
shaker tube (G) to shaker head (G1). See FIG. 10.
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.
and secure at multiple points with the supplied zip
ties (G5). See FIG. 10.
10. If desired, secure the 1.3 in. (33 mm) clear vacuum
transfer tube (G2) and 3/8 in. OD air line (G4) with
zip ties to a supporting structure at various points in
the routing.
11. 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).
12. 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.
13. Place shaker assembly in an empty adhesive pellets container then fill the container with adhesive
pellets.
NOTE: To promote optimal system performance, purchase 30 Gallon Vibrating Hopper, 24R136. See
installation instructions on page 100.
NOTE: If static buildup on feed tube (G) is excessive,
install optional feed tube ground kit 24R708 to feed tube
end (G6). See FIG. 7.
G2
G6
G5
G
G4
G1
ti21131a
FIG. 10
8. Attach 1.3 in. (33 mm) clear vacuum transfer hose
(G2) to steel shaker tube (G) and secure with supplied hose clamp. See FIG. 10.
9. Route the 3/8 in. OD air line (G4) alongside the
1.3 in. (33 mm) clear vacuum transfer hose (G2)
16
333347B
Setup
14. Install heated hoses, see FIG. 11:
f.
To reduce the risk of fire and explosion, only use
Graco heated hoses with the InvisiPac system. Use
of non-Graco hoses will void agency approvals.
N
Applicator
247
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 FIG. 11.
h. Repeat the procedure for the remaining channels. Use the bottom melter ports first to ease
installation.
68
i.
W1
AA
W2
ti23298a
FIG. 11
a. Place a rag on the drain tray (W2) attached to
the melter. Residual oil may be in the system
from the factory. See FIG. 11.
b. Use a 1/4 in. allen wrench to remove the drain
port plug (W1). See FIG. 11.
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 FIG. 11.
d. Remove plug (247) from the lowest numbered
outlet on the melter. Do not use the drain
plug (W1). See FIG. 11.
NOTE: In the following step, the o-ring side of the
hydraulic fitting (68) faces the system. See FIG. 11.
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.
333347B
Install cap on any unused MZLP electrical connectors.
NOTE: Fluid outlet port 1 must be used and electrical
connector from that hose must be connected to MZLP
connector 1. The system will not operate unless a hose
is connected to MZLP connector 1. If a hose is not connected to connector 1, “Invalid Sensor - hose/gun” faults
will result. If the melter must be run without a hose/applicator electrically attached to MZLP connector 1, use
Overtemperature Jumper, 16Y727, page 109.
15. Install applicator(s), see FIG. 11:
NOTE: Use of a Graco applicator is not required with
this system. However, all applicators attached to the
system must be rated for 1200 psi (8.3 MPa, 83 bar),
400°F (204°C), have an RTD type sensor, and use no
more than 400W at 240 VAC.
a. Connect heated hose fluid outlet to applicator
fluid inlet. Use 11/16 in. wrench to tighten. See
FIG. 11.
b. For Graco applicators, attach applicator electrical connector to heated hose electrical connector. See FIG. 11.
c.
For non-Graco applicators, attach applicator
electrical connector to adapter harness 16T916,
16T917, or 16Y828 then attach adapter harness
connector to heated hose connector. See
Non-Graco Applicator Adapter Cables on
page 98 to determine which adapter cable to
use with your applicator.
17
Setup
d. Repeat for any additional applicators.
19. Close the ball valve.
16. If necessary, set up the pattern controller (not
included) to control opening and closing of the applicator. See pattern controller manual.
NOTE: The system controls applicator heating only. A
separate pattern controller must be set up to open and
close the applicator.
17. 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 FIG. 12.
ti21147a
FIG. 13
20. Attach a 3/8 in. minimum air supply line to air filter.
See FIG. 13.
J
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 103.
21. To lock access to the air pressure adjustments, purchase Air Adjustment Lock, 24R084. See installation instructions on page 98.
ti21133a
FIG. 12
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.
18. If using the same air for the applicator(s), make sure
to install the tee in the air line before the ball valve.
There should not be anything between the ball valve
and the system. See applicator manual for applicator air pressure requirements, and use a regulator
before the applicator to decrease the air pressure, if
necessary.
18
22. To install a light tower that illuminates red when a
system error occurs, purchase Light Tower Kit,
24R226. See installation instructions on page 102.
23. To upgrade a 2 channel system to a 4 channel system, purchase 4 Channel Upgrade Kit, 24V528.
See installation instructions on page 104.
24. To upgrade a 4 channel system to a 6 channel system, purchase 6 Channel Upgrade Kit, 24V529.
See installation instructions on page 106.
25. Install MZLP electrical connector caps on all unused
channels.
333347B
Setup
Recommended Air Setup
Main Air Line
No dips in vacuum
transfer hose
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.
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
Pump
Air to applicators
Regulator set to
70 psi
(4.8 bar, 0.48 MPa)
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
WLD
Pump:
20-100 psi
(1.4-6.8 bar,
0.14-0.68 MPa)
FIG. 14
333347B
19
Setup
Connect Electrical Cord
6. Connect ground wire to chassis ground (AF). See
FIG. 15.
NOTE: See Grounding section on page 14.
7. Connect L1, L2, L3, and N as shown in FIG. 16. Not
all models use all 4 wires.
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. (18-32 mm) OD electrical cord. See FIG.
15. If needed, use a wrench to tighten the strain relief
bushing until it is snug on the cable.
For 208V Electrical Circuits, see page 21.
FIG. 16
1. Turn main power switch OFF.
8. Use zip ties to secure the electrical cord to the
tie-downs located on the top of the inside of the
electrical enclosure.
2. Disconnect cable from ADM, push cable through
plastic shroud, then remove plastic shroud from system.
9. Tighten screw-terminals to at least 10 in-lb
(1.1 N•m).
3. Remove electrical enclosure access door (T). See
FIG. 2 on page 10.
4. Insert electrical cord through electrical enclosure
strain relief bushing (106). See FIG. 15.
10. Install electrical enclosure door.
11. Perform Select ADM Settings on page 21 prior to
turning on heat.
5. Attach insulated ferrules to the end of each wire.
106
AF
WLD
FIG. 15
20
333347B
Setup
208V Electrical Circuits
NOTE: An incorrect RTD setting will cause the system
to be incapable of maintaining the temperature setting.
For 208V electrical supply, a qualified electrician can
install a 208V to 240V step-up transformer to improve
startup times.
Transformer Sizing
Minimum transformer rating can be calculated by taking
transformer output voltage times the ADM breaker setting.
Single Phase, 20A ADM Breaker Setting Example:
240 volts x 20 amps = 4800 watts
Three Phase, 20A ADM Breaker Setting Example:
240 volts x 20 amps x SQRT(3) = 8315 watts
NOTE: The supported RTD types are Ni, 100 ohm; Ni,
120 ohm; NiFe, 604 ohm; Pt, 100 ohm (385), Pt,
100 ohm (392); and Pt, 1000 ohm. An “Auto” selection is
available but should only be used when the specific
RTD type cannot be identified. Using the “Auto” RTD
setting may result in inaccurate temperatures.
To prevent fire and explosion, a qualified electrician
must determine the proper circuit breaker size to use
for the power supplied to the system.
4. On the System 3 screen:
Select ADM Settings
NOTE: See Appendix A - ADM on page 110 for
detailed ADM information, including general operation.
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
,
,
, and
to navigate
between screens.
3. On the System 2 screen:
a. Enter the main circuit breaker size used. This is
the circuit breaker installed external to the system for the system power supply.
NOTE: The InvisiPac system limits the amount of power
it pulls based on the input circuit breaker size. This
impacts the startup times because it affects the heating
energy used to warm up the materials.
5. On the Advanced 1 screen, set the system date and
time.
a. Check the box in the “Installed” column for each
channel that has a heated hose and applicator
installed.
b. Select the RTD type used on each installed
applicator. See applicator manual.
333347B
21
Setup
6. On the Advanced 2 screen, set the temperature and
mass units.
9. Press
to switch from the Setup screens to the
Operation screens. Use
,
,
, and
to
navigate between screens.
10. On the Targets screen, use
next to
7. To setup the optional Schedule function, see
Schedule on page 30.
and
, shown
, to adjust system melter setting.
Also, the desired temperature setting can be typed
in using the numeric keypad.
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 110, for
detailed information about each setup item.
22
333347B
Setup
11. On the Targets screen, adjust heated hose and
applicator temperature settings:
a. Press
b. Use
to select the channel.
and
, shown next to
, to
adjust applicator 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.
c.
Use
and
, shown next 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.
Applicators
Applicator heating is controlled by the system, but the
system does not control opening and closing the applicators. Setup a separate pattern controller to open and
close the applicators.
333347B
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 FIG. 1 on
page 9.
5. Remove power from PLC.
Customer Input Dropdown Options
Option
Description
Disable
Not used.
Heater On/Off
Turn on or off the heating system and
pump.
Channel 1, 2, 3,
4, 5, or 6
Enable/Disable
Enable or disable hose and applicator
heating for that individual channel.
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.
J1
J2
F10 F9
F8 F7
F4 F3
F2
F6
Customer Output Dropdown Options
Option
Description
Disable
Not used.
System Ready
Indicates when the system is up to temperature and the pump is stalled at
pressure.
Error (Alarm)
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.
F1
F5
J7
J6
J5
J3
WLD
FIG. 17: MZLP Board
H1 - Customer Input
H2 - Customer Output
Signal
Pin
Signal
Pin
1
1, 2
1
1, 2
2
3, 4
2
3, 4
3
5, 6
3
5, 6
4
7, 8
4
7, 8
Inputs: High: 10-30 VDC, Low: 0-5 VDC. Inputs function without concern for polarity. Applying “high” voltage
will turn the heaters on and enable channels. Removing
voltage will turn the heaters off and disable channels.
Outputs: 0-250 VAC, 0-30 VDC, 2A Maximum.
24
333347B
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
FIG. 18: Customer Input
MZLP Customer Out
Customer In
250 VAC, 0-30 VDC, 2A Max
To Customer Input
FIG. 19: Customer Output
333347B
25
Operation
Operation
Initial Startup and Prime
Heating and dispensing hot melt adhesive may
create potentially harmful vapors. Read material
manufacturer’s warnings and material MSDS to know
specific hazards and precautions. Ventilation of the
work area may be required.
NOTE: See Appendix A - ADM on page 110 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 116 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 applicators. The applicator then briefly opens to dispense the
desired quantity of adhesive.
NOTE: All setup procedures must be completed prior to
initial startup. See Setup on page 14.
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 applicators 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 97.
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.
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.
ti21146a
26
333347B
Operation
6. Use pump air pressure regulator (C) to adjust pump
air pressure to 0.
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 operating temperature. See Select ADM Settings on
page 21 for instructions.
11. Use separate pattern controller to open the applicators and keep them open.
NOTICE
E
FIG. 20
C
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.
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
FIG. 20.
12. With the applicators open and the system up to temperature, slowly increase pump air pressure until
the pump begins to run very slowly. Approximately
20 psi (140 kPa, 1.4 bar) should be sufficient.
NOTE: If using shaker accessory, regulator should be
set to at least 65% of air pressure connected to shaker.
NOTE: Operation may be erratic below 20 psi (140 kPa,
1.4 bar).
NOTE: Vacuum transfer will not begin operating until
pump reaches operating temperature.
13. Continue running the pump until clean, air-free
material is dispensed from each applicator.
14. When each applicator is fully primed, adjust pump to
desired pressure setting:
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.
a. Adjust pump pressure to between 20-100 psi
(140-690 kPa, 1.4-6.9 bar).
b. Use separate pattern controller to repeatedly
open and close each applicator while inspecting
the dispense pattern.
c.
Repeat until desired dispense pattern is
achieved.
Manual Refill
NOTE: Use Automatic Refill whenever possible. The
system uses Automatic Refill by default and must be
manually changed to Manual Refill. Only use Manual
Refill if the Automatic Refill system is not functioning
properly and cannot be fixed in a timely manner. Perform service to automatic feed system as soon as possible to limit debris buildup on feed funnel.
NOTE: When the melter is up to temperature, the
auto-fill function will initiate to fill the funnel with pellets.
333347B
27
Operation
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.
5. Refill the funnel as needed to maintain the required
dispense rate.
6. When finished dispensing for the day, dispense into
a waste container until the material level is down to
the melter core. See FIG. 23.
NOTE: This will lower the adhesive level within the funnel cap to the correct level to prevent any issues upon
startup the following production day.
2. Remove the two bolts from the funnel bracket, then
remove the top portion of the funnel.
WLD
FIG. 23
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.
WLD
FIG. 21
3. Disconnect the sensor cable and sensor cooling air.
4. Fill the funnel with adhesive pellets.
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 FIG. 1 on page 9.
NOTE: The shaker inlet must be completely covered in
adhesive pellets in order for it to effectively pull pellets
into the tube.
WLD
FIG. 22
28
333347B
Operation
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).
e. Verify applicators are closed.
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 func-
tion unless you wish to enable the heating system
before the set time.
E
FIG. 24
NOTE: The system will automatically transfer the pellets
to the system as necessary.
Dispense
NOTE: When system is up to temperature, the pump will
begin running automatically. It will stall at pressure
unless an applicator is open. Material will be dispensed
whenever an applicator is open after the system is up to
temperature.
5. When the system is up to temperature, use separate pattern controller to open and close the applicators as desired to dispense material.
NOTE: While operating the system, the actual temperatures of the hose, applicator, and system melter are displayed on the Home screen.
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 FIG. 1
on page 9.
b. Check pressure gauges (D, F) to verify vacuum
transfer and pump air pressures are set as
desired. See FIG. 1 on page 9.
c.
If using Automatic Refill, see Automatic Refill
on page 28.
d. If using Manual Refill, see Manual Refill on
page 27.
333347B
29
Operation
Shutdown
Enable Schedule Function
Press
The Schedule function is automatically enabled when
values are entered in the Schedule screen. To disable a
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.
scheduled event, navigate to the event and press
The event will appear gray on the screen when it is disabled. To re-enable an event, navigate to the event and
press
. The event will appear red (system off) or
green (system on). If no events are needed, turn the
main power switch OFF to prevent system from automatically enabling and disabling the heaters.
How to Use the Schedule Function
At the end of the work day leave main power switch ON
. The Schedule function will automatically enable
and disable the heaters and pump at the specified
times.
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.
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
Set Schedule Times
NOTE: Times are set using a 24-hour clock. Several on
and off times can be set each day.
.
2. Close the inlet air supply ball valve.
NOTE: Manually verify the pressure is relieved by opening the applicator and ensuring no adhesive is dispensed.
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.
30
333347B
Operation
Drain the System
12. Wait until system stops draining or at most 10 minutes.
NOTE: There will be some residual adhesive in 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”.
13. When done performing the procedure that required
draining the system, set Refill Setting back to “Auto”
on the System 3 screen.
Flush
To prevent fire and explosion, use the adhesive manufacturer’s recommended cleaning fluid.
2. If the heating system is disabled, press
to
• 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.
enable the heaters and pump.
3. Decrease pump air pressure to 0.
4. Close system air inlet ball valve.
5. Disconnect hose from applicator inlet then place
hose outlet in a waste container. Repeat for all
hoses. Keep hose to applicator electrical connector
connected.
6. Open applicator to allow residual fluid in applicator
to drain.
7. When system is at operating temperature, slowly
increase pump air pressure until fluid begins flowing
into the waste container.
NOTE: It may take several minutes to empty the system. When there is no melter fluid at the pump, the
pump will begin to cycle faster.
8. When the pump begins to cycle faster, close the
system air inlet ball valve.
9. Press
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 31.
2. If the heating system is enabled, press
to dis-
able the heaters and pump.
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 disable the heaters and pump.
10. Remove melter drain plug (W1). See FIG. 2 on page
10.
11. Disconnect hose from melter outlet.
333347B
31
Operation
5. On the System 3 screen (in the Setup screens), verify the Refill Setting is set to “Manual”.
12. If heating system is disabled, press
to enable
the heaters and pump.
13. Wait for the melter temperature to reach the hot
melt cleaning fluid manufacturer’s recommended
temperature.
NOTE: The pump will not run because the system air
inlet ball valve is closed.
14. Once the required melter temperature is reached,
let the hot melt cleaning fluid “soak” in the melter at
temperature for the duration specified by the hot
melt cleaning fluid manufacturer.
To prevent fire and explosion, never exceed the
cleaning fluid’s rated temperature.
6. Change the melter, heated hoses, and applicators
temperature settings to the high temperature hot
melt cleaning fluid manufacturer’s recommended
temperature.
7. Verify the system air inlet ball valve is closed and
pump air pressure is set to 0.
8. Allow the system to heat or cool to the cleaning fluid
manufacturer’s recommended temperature.
9. Fill melter with high temperature rated hot melt
cleaning fluid. See hot melt adhesive material supplier for recommended hot melt cleaning fluids.
Fluid level should be 1/2 in. (12.7 mm) from the top
of the melter.
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, adhesive-free hot melt cleaning fluid is dispensed from
the detached hose.
NOTE: Now the melter and the disconnected hose are
thoroughly flushed.
18. Reattach the hose to the applicator manifold.
19. Repeat steps 7 through 18 for each additional
installed hose, leaving a different hose disconnected from the applicator manifold each time.
20. Remove and replace filter(s) in all applicator manifolds. See applicator manual.
21. Replace Outlet Filter. See page 34.
WLD
10. Disconnect one hose from its applicator manifold.
NOTE: Keep all applicators closed throughout this procedure.
11. Route the disconnected hose to a waste container.
32
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 FIG. 2 on page 10.
24. Allow the system and fluid to cool then perform any
required maintenance procedures beginning on
page 34.
333347B
Operation
25. Install fill cap onto melter rubber housing.
26. Slide funnel assembly through air motor bracket
then tighten clamp.
27. On the System 3 screen (in the Setup screens), set
the Refill Setting to “Auto”.
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 30, to automatically enable and disable the heating 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.
To prevent fire and explosion, never exceed the
cleaning fluid’s rated temperature. Residual cleaning
fluid is still in the system until the system is primed
with adhesive.
28. Perform Initial Startup and Prime on page 26.
333347B
33
Maintenance
Maintenance
6. Insert allen wrench through the outlet filter cap to lift
outlet filter (236) out of the system.
7. Discard outlet filter assembly.
Replace Outlet Filter
The outlet filter is designed to prevent small contaminants from entering the hoses and applicators. Inspect
filter regularly. Replace the filter after flushing and when
you change the adhesive used in the system.
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
236
232
To avoid severe burns, wear protective gloves and
clothing that will insulate your hands and body from
the hot surfaces and material.
237
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.
8
28
WLD
FIG. 25
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 FIG. 25.
5. Use a 1 in. socket to unscrew outlet filter (236).
34
NOTE: Some adhesives have different melting points.
The first temperature tried should be approximately half
of the dispensing temperature. If dispensing at 400°F
(204°C), first try 200°F (93°C) then increase in 20°F
(11°C) increments. If dispensing at 250°F (121°C), first
try 125°F (52°C) then increase in 20°F (11°C) increments.
NOTE: To ensure the adhesive is a gel, not a liquid, do
not remove inlet filter cap (215) when the temperature is
above the desired temperature. If the temperature is too
low, the adhesive viscosity may be too high to remove
the inlet filter (213). See FIG. 26, page 35.
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
to disable
the heaters.
3. Wait until melter temperature is the desired temperature.
333347B
Maintenance
4. When the melter temperature is the desired temperature, turn main power switch OFF.
9. Slide new screen (213) into melter base
manifold (201).
5. Disconnect cable from ADM, push cable through
plastic shroud, then remove plastic shroud from system.
10. Install filter cap (215) then use a 1 in. socket to
tighten.
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).
11. Feed ADM cable through plastic shroud (29) then
install shroud onto system. Connect cable to
ADM (30).
Replace Funnel Filter
706
705
213
215
201
WLD
WLD
FIG. 26
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:
FIG. 27
Disassembly (see FIG. 27):
1. Turn main power switch OFF.
a. Install inlet filter cap (215).
2. Rotate funnel cap (706) and remove. Lift out funnel
filter (705).
b. Install shroud and ADM.
Reassembly (see FIG. 27):
c.
1. Insert filter (705) in funnel assembly. Tighten funnel
cap (706) on funnel.
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.
333347B
35
Maintenance
Filter Maintenance Guidelines*
Environmental Classification
Clean
Moderate
Dusty
Pump inlet filter
Pump outlet filter
Applicator manifold filter
System air filter
Solenoid exhaust filters
Replace filter Replace filter Replace filter
every six
every four
every two
months
months
months
Feed funnel filter
Feed funnel inspection/cleanout
* These recommendations are service level guidelines - actual service levels required in your factory will vary based
on environmental and operating conditions. High or low volume adhesive usage, as well as adhesives that contain a
powdered release agent or are otherwise dusty, will have an impact on the frequency of filter maintenance. To establish a preventative maintenance cycle tailored to your environment, Graco recommends inspecting filters every 4
weeks after installation and replacing when necessary. Document replacement intervals and use this as your preventative maintenance schedule moving forward.
36
333347B
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 Mainteto clear the error.
The last digit of the error code indicates the melter, applicator (gun), or hose to which the error applies. The “_”
(underscore) character indicates the code applies to multiple items.
Last Digit in Code
Code Relates to:
0
Melter
1
Applicator (Gun) 1
2
Hose 1
3
Applicator (Gun) 2
4
Hose 2
5
Applicator (Gun) 3
6
Hose 3
7
Applicator (Gun) 4
8
Hose 4
9
Applicator (Gun) 5
A
Hose 5
B
Applicator (Gun) 6
C
Hose 6
An alarm will disable the heating system and pump. A deviation or advisory will not disable the heating system and
pump.
Code
Description
Type
Cause
Solution
A1D0
Low Current
Melter
Advisory
Melter current is less than 500mA.
Faulty melter heater(s). Check heater resistance
and resistance to ground. Replace faulty
heater(s).
A1D_
Low Current
Gun X
Advisory
Applicator current is less than 500mA.
Faulty applicator heater. Check heater resistance
and resistance to ground. Replace faulty heater.
A1D_
Low Current
Hose X
Advisory
Hose current is less than 500mA.
Faulty hose heater. Check heater resistance and
resistance to ground. Replace faulty hose.
A3MF
High Fan Current, Transformer
Deviation
Transformer fan is greater than
600mA.
Replace transformer fan.
333347B
37
Troubleshooting
Code
Description
Type
Cause
Solution
A4D0
High Current
Melter
Alarm
Defective or shorted to ground on the
band heater or rod heater.
Measure resistance to ground between heater
leads. Should be a high reading.
A4D_
High Current
Hose X
Alarm
Defective or shorted to ground on the
hose power wires.
Replace heated hose.
A4D_
High Current
Gun X
Alarm
Defective or shorted to ground on the
heater rods in applicator manifold.
Replace applicator manifold.
A7D0
Unexpected
Current
Alarm
Unexpected current flow to melter.
Faulty melter heater(s). Check heater resistance
and resistance to ground. Replace faulty
heater(s). See Replace Heater Rod, page 60.
A7D_
Unexpected
Current, Gun X
Alarm
Unexpected current flow to gun X.
Faulty applicator heater element. Check heater
resistance and resistance to ground.
A7D_
Unexpected
Current, Hose X
Alarm
Unexpected current flow to hose X.
Faulty hose heat element. Check heater resistance and resistance to ground.
Replace MZLP.
Faulty MZLP. Replace MZLP.
Faulty MZLP. Replace MZLP.
A8D0
No Current
Melter
Alarm
Power not getting to melter.
Check fuses F1 and F2 on MZLP with daughter
board.
Check J1 is plugged into MZLP with daughter
board and J3 on AWB.
A8D_
No Current
Hose X
Alarm
Power not getting to hose.
Check fuses F5 and F6 (channels 1, 3, 5) or F9
and F10 (channels 2, 4, 6) on MZLP that the error
hose is connected to.
Check that electrical connector on the heated
hose is plugged into the MZLP.
Check continuity of pins C and D on electrical connector at MZLP end of heated hose. See heated
hose manual for impedance measurements.
Replace hose if readings are too high.
If system only uses one hose and applicator, the
heated hose electrical connector must be plugged
into channel 1 of the MZLP.
A8D_
No Current Gun
X
Alarm
Power not getting to applicator.
Check fuses F3 and F4 (channels 1, 3, 5) or F7
and F8 (channels 2, 4, 6) on MZLP that controls
the error channel.
Check that electrical plug on hose is plugged into
back of MZLP and applicator is plugged into hose.
Check continuity of hose pin A gun end to J on
MZLP connector end of hose and pin C on gun
end to pin A on the MZLP end of the hose. Reading should be 0-1 ohm. Replace hose if measurement is outside this range.
If system only uses one hose and applicator, electrical connector of the heated hose must be
plugged into channel 1 of the MZLP.
A8MF
38
No Fan Current, Transformer
Deviation
Power not getting to transformer fan.
Verify that fan power cable is plugged into J7 on
the AWB.
Verify transformer fan is free of obstructions and
can spin freely.
333347B
Troubleshooting
Code
Description
Type
Cause
Solution
CAC_
1=MZLP 1
2=MZLP 2
3=MZLP 3
Comm Error
Module
Alarm
System not responding to ADM.
Dial not set correct on MZLP. Set to 1 on board
with daughter board. Set to 2 on MZLP without the
daughter board in center of electrical enclosure.
Set to 3 on MZLP without daughter board on left of
electrical enclosure.
System is not properly loaded with correct software. Perform Software Update Procedure on
page 72.
CACX
Missing DB
Alarm
System not acknowledging the daughter board.
Bad connection between daughter board and
MZLP board. Loosen daughter board, re-seat,
then secure.
Daughter board is not plugged into MZLP1. Plug
daughter board into MZLP with dial set to 1.
Defective MZLP daughter board. Replace.
DADX
Pump Runaway
Alarm
Pump is trying to feed adhesive, no
adhesive to feed.
Storage bin out of adhesive. Refill adhesive.
Melter at incorrect temperature, too low. Check
setpoint and set to manufacturer’s recommendation.
Plugged vacuum transfer hose or funnel. Clear
plugged hose or funnel.
DDDX
Pump Diving
Deviation
Worn or damaged pump seals
Inspect pump seals. Repair if necessary.
Pump is trying to feed adhesive, no
adhesive to feed.
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.
Dispense rate too high. See technical ratings of
system.
DE0X
Cycle Switch
Error
Alarm
Worn or damaged pump seals
Inspect pump seals. Repair if necessary.
No signal from air motor sensor.
Check wiring on J16 of the daughter board. See
Electrical Schematics on page 73.
Loose cycle switch bolt. Tighten cycle switch bolt.
Defective cycle switch. Replace.
L0FX
Manual Fill
Mode
Advisory
System set to manual fill mode.
Change to auto fill mode. See Setup Screen System 2.
L6FX
Level Sensor
Error
Alarm
No signal from the level sensor.
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.
333347B
No air to fill cap.
Check for air coming from 5/32 in. air line.
Plugged orifice in fill cap below fill sensor.
Remove fill cap and remove object plugging the
orifice.
39
Troubleshooting
Code
Description
Type
Cause
Solution
L8FX
Refill timeout
Alarm
Melter did not receive enough adhesive pellets for flow rate.
Storage bin out of adhesive. Refill adhesive.
Plugged inlet feed hose or funnel. Clear plugged
hose or funnel.
Low air pressure on feed regulator. Check regulator. See Setup, page 14 for air pressure recommendations.
Dirty or plugged funnel filter. Replace filter.
M8MF
High Temp Runaway, Transformer
Deviation
At the current rate of temp rise, the
transformer will over heat in 15 minutes or less.
Verify that fan power cable is plugged into J7 on
the AWB.
MMUX
USB Log Full
Advisory
USB logs full. Data loss will occur if not
downloaded.
Download USB data. See Appendix B - USB
Downloading, Uploading on page 116.
MNDX
Pump Maintenance Due
Advisory
Cycles are greater than user set maintenance interval.
Perform maintenance and reset “Due” counter to 0
at the Setup Maintenance screen.
T2D0
Low Temperature, Melter
Deviation
Melter temperature dropped to
15°F(-9°C) below setpoint.
Verify system is operating within meltrate specifications. Consider incoming voltage and breaker
setting.
Verify transformer fan is free of obstructions and
can spin freely.
Replace transformer.
Verify that the fill system (vacuum) is operating
correctly. If the level of material in the melter gets
too low and a large amount of cold material enters
the melter, can cause the temperature to drop significantly.
With the system on and not dispensing verify that
the temperature is properly controlled to the setpoint. If system cannot control temperature, verify
the RTD is seated inside the melter.
Replace RTD if RTD was seated properly and system cannot control temperature
T2D_
Low Temperature, Gun X
Deviation
Applicator temperature dropped to
15°F(-9°C) below setpoint.
T2D_
Low Temperature, Hose X
Deviation
Hose temperature dropped to
15°F(-9°C) below setpoint.
Faulty melter heater(s). Check heater resistance
and resistance to ground. Replace faulty
heater(s).
With the system on and not dispensing verify that
the temperature is properly controlled to the setpoint. If system cannot control temperature,
replace applicator RTD. See applicator manual.
Faulty applicator heater. Check heater resistance
and resistance to ground. Replace faulty heater.
Dispense rate too high for applicator to maintain
setpoint. Consider applicator power and voltage.
With the system on and not dispensing verify that
the temperature is properly controlled to the setpoint. If system cannot control temperature,
replace hose.
Faulty hose heater. Check heater resistance and
resistance to ground. Replace faulty hose.
T4C_
40
High MZLP PCB
Temp
Alarm
MZLP board is overheating.
Ambient temperature must be under 120°F.
Defective MZLP board. Replace.
333347B
Troubleshooting
Code
Description
Type
Cause
Solution
T4D0
High Temp
Melter
Alarm
Melter continues to raise above the
setpoint.
Check that RTD is seated in melter correctly.
Check that overtemperature switch is plugged in
and check switch resistance. The switch resistance should be near 0 Below 400°F (204°C).
Check melter heaters’ resistance to ground.
Replace heater if a heater is shorted to ground.
T4D_
High Temp
Hose
Alarm
Hose continues to raise above the setpoint.
T4D_
High Temp Gun
Alarm
Applicator assembly continues to raise
above the setpoint.
Turn system on without dispensing. Verify temperature is properly controlled to the setpoint. If
setpoint is not maintained, replace RTD. If heat
continues to rise past setpoint, replace MZLP.
Turn on system without dispensing. Check if hose
can maintain setpoint temperature. If the hoses’
RTD readings are unstable, replace hose. If hose
continually heats past setpoint, replace the MZLP.
Turn on system without dispensing. Check if applicator can maintain setpoint temperature. If the
applicator’s RTD readings are unstable, replace
the applicator RTD.
Check the applicator heater’s resistance to ground
if the RTD readings are stable but the applicator’s
temperature continues to rise. If the heater is
shorted to ground, replace the applicator’s heater.
If heater is not shorted to ground, replace MZLP.
T4MX
T6D0
High Temperature, Transformer
Alarm
Sensor Error
Melter
Alarm
Thermistor reading greater than 212°F
(100°C).
Verify transformer fan is operating correctly and
free of obstructions.
Replace transformer.
No reading from RTD.
Verify connector J5 on MZLP board is securely
connected.
Defective RTD. Replace melter RTD. See
Replace Band Heater Temperature Sensor,
page 59.
T6D_
Sensor Error
Hose
Alarm
No reading from RTD.
Hose electrical connector not plugged into MZLP.
Defective RTD. Replace hose.
T6D_
Sensor Error
Gun
Alarm
No reading from RTD.
Hose electrical connector not plugged into MZLP
or applicator electrical connector not plugged into
heated hose.
T6MX
Thermistor Sensor Error, Transformer
Alarm
No reading from transformer thermistor
sensor.
No Temp Rise
in Gun (all
zones)
Alarm
Defective RTD. Replace applicator RTD.
T8D_
Verify that sensor wire is plugged into J7 on AWB.
Replace transformer.
Temperature reading does not change. Check fuses F3 and F4 (channels 1, 3, 5) or F7
and F8 (channels 2, 4, 6) on MZLP that error channel is connected to.
Defective heater rods in applicator manifold.
Replace applicator manifold.
NOTE: Defective heaters rods in the applicator
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.
333347B
41
Troubleshooting
Code
Description
Type
Cause
Solution
T8D_
No Temp Rise
in Hose (all
zones)
Alarm
Temperature reading does not change.
Check fuses F5 and F6 (channels 1, 3, 5) or F9
and F10 (channels 2, 4, 6) on the MZLP that controls the error channel.
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.
T8D0
No Temp Rise
in Melter (all
zones)
Alarm
Temperature reading does not change.
Check fuses F1 and F2 on MZLP with daughter
board.
V1I_
Low Can Voltage
Alarm
Bad or overloaded power supply.
V1MW
Low Line Voltage
Deviation
Incoming line to line voltage has
dropped below 175V.
Verify incoming power is correct gauge for current
draw and verify incoming power lines are securely
attached to disconnect.
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.
V4MW
High Line Voltage
Alarm
Incoming line to line voltage has
increased above 265V.
For 3 phase with neutral have qualified electrician
verify neutral wire.
V6MW
Invalid Power
Type
Alarm
During startup incoming line to line
power was either below 175V or above
265 V.
Verify incoming power is wired to the disconnect
correctly.
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 J13 of
the daughter board.
Defective heater wires in melter. Replace melter.
NOTE: Defective heaters wires in the melter can
also cause the no current error.
Defective heater element(s). Check heater resistance and compare to reference table. See Check
Heater Rod Resistance, page 50.
Check J1 is properly plugged into the MZLP with
daughter board and in J3 on AWB.
Check that RTD is installed in the melter.
Verify power supply voltage is 24 VDC. If voltage
is low, disconnect the screw terminals +V and -V
on the power supply and re-check voltage reading.
If voltage is correct, then disconnect J8 and J9
from AWB and re-check voltage. If still low replace
AWB. If correct, plug in J9 and recheck voltage. If
low, replace ADM. If correct, plug in J8. If low,
replace MZLP. If voltage is still low, replace power
supply.
Defective air manifold, replace manifold.
WKFX
WSUX
42
Fill Solenoid
Error
Alarm
USB Invalid
Configuration
Deviation
No voltage draw from air solenoid for
fill.
Check connector at J13 of the daughter board.
A valid configuration file can't be found
for the USB.
System is not properly loaded with correct software. Perform Software Update Procedure on
page 72. Retry USB download.
Bad ADM.
Replace ADM.
Defective air solenoids. Replace. See page 67.
333347B
Troubleshooting
Mechanical and Electrical Troubleshooting
Problem
Cause
Solution
Refill Timeout
Error
The system was unable
to refill in less than 30
seconds.
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 35.
The InvisiPac
system takes a
long time to
refill adhesive.
Glue level in hopper is
low.
Check hopper for adequate material and material blocking.
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 35.
Vacuum transfer not working
Air to vacuum assembly
missing.
Verify the vacuum transfer system air pressure is 40-80 psi (60 psi recommended)
Air at system air gauge
but not to air to shaker.
Check that air line is connected or not pinched.
Air is at shaker but there
is no feed.
Plugged shaker unit, remove from system and remove plug.
Adhesive pellets in storage
bin not covering
shaker head.
Shaker unit not vibrating.
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.
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.
Some materials may require agitation periodically to breakup bridging. Purchase and install 30 Gallon Vibrating Hopper, 24R136. See page 100.
Fill Solenoid
Error
Failure of the fill solenoid
or fill solenoid wiring.
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.
Level Sensor
Error
Failure of the level sensor (20) or sensor cable
16T108 (J14 to level
sensor (20)).
Check sensor cable J14 to level sensor (20).
Enable Diagnostic screen on ADM then check sensor readings on the Diagnostic screen. Sensor readings should be about 4.3V if melter is completely
empty (melter passage holes are visible). The normal operating range is 3.8 to
4.3V. If the sensor is reading more than 4.2V the system should be requesting
additional material.
Restart system. If the error persists after attempting another refill and unit is
needed immediately for production, place system into the manual refill mode.
See Manual Refill on page 27.
333347B
43
Troubleshooting
Problem
Cause
Solution
The InvisiPac
system expels
adhesive pellets dust when
refilling.
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.
Replace Funnel Filter, see page 35.
NOTE: Feed cap filter maintenance should be performed at regular service
intervals. It is recommended that the feed cap filter be inspected at a minimum
of every 1200 lb dispensed, however with some adhesives the frequency may
need to be increased significantly to maintain desired system cleanliness.
The InvisiPac
system will not
stall, pump continues to move
even if the
applicators are
all closed.
Fluid leak.
Verify that no external leakage is present.
Inspect and test the pressure relief valve.
Perform Flush Pressure Relief Valve, page 50.
If system is still unable to stall, the pump or pressure relief valve may need to
be repaired.
The system will
not dispense
material.
System is not up to temperature.
Verify that the system is active.
Incorrect temperature set
points entered into ADM.
Verify the temperature settings are correct.
Air motor is not receiving
compressed air or air
pressure too low.
Verify that the pump air pressure is set above 20 psi. Check the Pump Air
Solenoid Operation, page 50.
Feed pump not feeding
adhesive.
Repair or replace air control assembly as necessary.
Repair or replace pump assembly as necessary.
Timing control for applicators not working.
InvisiPac system does not control the timing of the applicators. This is
a separate control that needs to be adjusted. Consult control manufacturer or qualified electrician.
Cycle switch or cycle
switch wiring failure.
Check the wiring between the air motor cycle switch and J16. Repair/replace
as required.
Loose or missing fastener (26).
Ensure fastener (26) is tight. See InvisiPac Systems section beginning on
page 78 for part identification.
The InvisiPac system will
display this notification
when the USB data logs
reach 90% full.
To prevent data loss, download system data. See Appendix B - USB Downloading, Uploading on page 116.
Cycle Switch
Error
USB Log Full
44
333347B
Troubleshooting
Problem
Cause
Solution
The InvisiPac
system is displaying pump
runaway or
pump diving.
This error generally
occurs when the pump
cavitates due to improper
material loading.
This can occur if the melt rate for the system is exceeded, resulting in air
entrapment within the incoming adhesive material and lower than desired
material temperature.
1. Verify that the InvisiPac system is not exceeding 22 cpm by
enabling the diagnostic screen.
2. If the cycle rate is below 22 cpm and the system is still running
away increase the InvisiPac system temperature by 10°F over the
current set point, leave hoses and applicators 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 the published melt rate. The InvisiPac system
was tested to achieve continuous published melt rates when dispensing standard EVA metallocene packaging grade adhesives in pellet form with an InvisiPac system temperature of 375°F and hose and applicator temperatures of
350°F.
Unable to
achieve published melt rate
at the desired
adhesive temperature.
Level sensor blocked,
reading level incorrect.
Clean feed cap by fill sensor, make sure there are no adhesive pellets blocking the sensor hole.
The system is not supplying enough air to the
ultrasonic sensor venturi.
Make sure the air supplied to the system is at least 80 psi (550 kPa, 5.5 bar).
The InvisiPac system
monitors temperature
within aluminum mass of
melter (202). As melt
rates exceed 20 lb/hr a
system temperature offset may be required.
1. If the cycle rate is below 22 cpm and the system is still running away
increase the InvisiPac system temperature by 10°F over the current
set point, leave hoses and applicators at desired set point.
2. If the pump continues to runaway or dive continue increasing temperature 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 the published melt rate. The InvisiPac system
was tested to achieve the published melt rates when dispensing standard EVA
metallocene packaging grade adhesives in pellet form with an InvisiPac system
temperature of 375°F and hose and applicator temperatures of 350°F.
333347B
45
Troubleshooting
Problem
Cause
Solution
ADM not displaying when
system turned
on
Main power circuit
breaker off or power cord
unplugged.
Turn main circuit breaker on or plug in power cord.
Cable on ADM
unplugged.
Reconnect ADM cable.
Connector on AWB
board not plugged in.
ADM cable should be plugged into J9 of the AWB board.
Bad 24VDC power supply.
Check output on power supply should measure 24VDC, if no voltage reading
replace power supply.
ADM defective.
Replace ADM.
Wrong setting in ADM
breaker setup.
Wrong breaker setting on ADM in the breaker setting in the setup screen.
Internal short to ground
in system.
Unplug or disconnect power and measure between each leg of the power to
ground. There should be an open resistance reading.
Too small of a circuit
breaker in main power
panel.
Consult qualified electrician for proper size circuit breaker.
Wrong setting in ADM
breaker setup.
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/or applicator.
Measure and check heater rods in melter or applicator. See applicator manual. See Check Heater Rod Resistance, page 50.
Heated hose defective.
Measure heater wires in hose, pins C and D. See hose manual for each hose
resistance.
Insufficient power supplied to system. Depending on hose and
applicator 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
Models on page 4 for full-power rating. See Startup Time, page 121, for
startup times under varying conditions.
Incorrect RTD setting in
system.
1. Verify melter, hose, and applicator temperatures are all with in the
same range of the room ambient.
Main breaker
tripping
Slow start-up
time or system
takes longer
than 10 minutes to startup
No adhesive or
little adhesive
being dispensed
2. If the applicator temperature is either much higher or much lower
than the melter temperature then the RTD setting is not correct for
the RTD being used. Select correct RTD setting in the setup screen
system 2 before beginning.
NOTE: Failure to have the correct RTD value will cause the applicator to either
under-heat or over-heat. Setting for RTD in the ADM screens is higher than
actual RTD value. Consult manufacturer for actual RTD value.
46
333347B
Troubleshooting
Problem
Cause
System indicates no errors
and correct
temperature
however applicator is over
the temperature setpoint
Incorrect RTD setting in 1. Verify melter, hose, and applicator temperatures are all within the
same range of the room ambient.
system.
No adhesive or
incorrect
amount of
adhesive out of
one/some of
the dispense
module when
triggered
Plugged tip on dispense module.
Replace tip on dispense module.
Defective dispense
module in closed/partial open position.
Replace dispense module.
Plugged applicator
manifold filter (single
dispense module applicator).
Replace applicator manifold filter. Graco applicator manifold filter in
bottom of manifold or inline filter on other manifolds.
Clogged hose
Flush or replace hose.
Defective solenoid
valve
Check that correct voltage is input into solenoid valve. If voltage is correct, replace solenoid.
No signal from control
to solenoid
If no voltage is present at solenoid, check control cable and pattern
controller. Replace component.
Plugged system outlet filter.
Replace Outlet Filter. See page 34.
If multiple applicators are
triggered simultaneously, maximum pump
rate may be exceeded.
Stagger applicator opening to reduce the maximum required flow rate to
below maximum pump rate.
333347B
Solution
2. If the applicator temperature is either much higher or much lower
than the melter temperature then the RTD setting is not correct for
the RTD being used. Select correct RTD setting in the setup screen
system 2 before beginning.
NOTE: Failure to have the correct RTD value will cause the applicator
to either under-heat or over-heat. Setting for RTD in the ADM screens
is lower than actual RTD value. Consult manufacturer for actual RTD
value.
47
Troubleshooting
Problem
Cause
Solution
No adhesive or
incorrect
amount of
adhesive out of
one/some of
the dispense
modules when
triggered
Plugged tip on dispense module.
Replace tip on dispense module.
Defective gun in
closed/partial open
position.
Replace dispense module.
Plugged applicator
manifold filter (single
dispense module applicator).
Replace applicator manifold filter. Graco applicator manifold filter in
bottom of manifold or inline filter on other manifolds.
Clogged hose
Flush or replace hose.
Defective solenoid
valve
Check that correct voltage is input into solenoid valve. If voltage is correct, replace solenoid.
No signal from control
to solenoid
If no voltage is present at solenoid, check control cable and pattern
controller. Replace component.
Plugged solenoid mufflers
Replace solenoid mufflers.
No air to solenoid
Re-establish air supply to solenoid.
Plugged system outlet filter.
Replace Outlet Filter. See page 34.
If multiple applicators
are triggered simultaneously, maximum
pump rate may be
exceeded.
Stagger applicator opening to reduce the maximum required flow rate
to below maximum pump rate.
Failed valve in the open
position.
Replace dispense module.
Adhesive pressure too
high.
Reduce air pressure to air motor.
Heat rod failure in applicator manifold.
Check resistance on heater rods. Repair applicator manifold if heater rods
measure open.
Loose cable connection
at system or manifold.
Check cable connections on both ends of the hose.
RTD failure.
Check resistance on the RTD, if out of normal range replace RTD.
Incorrect RTD setting in
the ADM setup.
Set correct RTD value in the ADM setup screen. Consult manufacturer for correct RTD value.
Thermal cutoff is tripped.
Measure resistance of the thermal cutoff at room temperature. If open,
replace.
Adhesive flowing out of
one/some
applicators
when not triggered
Applicator will
not heat.
48
333347B
Troubleshooting
Problem
Cause
Solution
Adhesive leaking from manifold or dispense
module.
Dispense module is
loose on the manifold.
Tighten screws on loose dispense module.
Dispense module o-ring
failed.
Replace o-rings on the back of the leaking dispense module.
Failed dispense module,
adhesive leaking out
middle of dispense module.
Replace dispense module.
Hose loose.
Tighten hose.
Fuse blown in F1 and F2.
Check heater rods for a short or a short between the rod wires and ground.
Cable to over-temperature switch off or broken.
Check connection of cable to over-temperature switch both to main board and
to switch. If connection good, look for break in wire.
Over-temperature switch
tripped.
Measure over-temperature switch resistance. It should read close to 0 ohms
when at room temperature. If open, replace over-temperature switch. Make
sure main system power is off when making measurement.
No air being supplied to
air motor.
Check incoming air supply. air motor is disabled until system reaches “Active”
state. When “Active”, the pump air solenoid should supply air to the air motor.
Air solenoid not enabling
the air motor.
Check solenoid voltage, if 24VDC present at air solenoid replace air solenoid.
Air present at air motor
but it will not work.
Replace air motor.
System not
turning on.
No power to unit.
Check main power breaker is turned on.
Check that power plug is connected.
Static shock
when touching
shaker or adhesive bin.
Ground wire not in place
on shaker assembly.
Some adhesives, flow
rates, and ambient conditions can cause excessive static buildup on the
shaker tube.
Attach a ground wire from the shaft of the shaker unit to a true earth ground.
Order shaker grounding kit 24R708.
Adhesive not
dispensing at the
correct time.
Dispense modules opening at the wrong time.
InvisiPac system does not control the opening and closing of the applicators.
The separate controller needs to be adjusted. Consult pattern control manufacturer or qualified electrician.
Pump and vacuum feed system cycle on and
off before temperature setpoint
is achieved.
Solenoid connector is
installed into the light
tower plug on the MZLP
daughter board
Move solenoid connector from J12 (light tower) to J13 (solenoid valves) on the
daughter board on the MZLP.
No melter heat.
Air motor will
not function.
333347B
49
Troubleshooting
Flush Pressure Relief Valve
Check the Pump Air Solenoid Operation
Perform this procedure when directed in the Troubleshooting table.
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).
NOTE: System must be up to operating temperature for
pump solenoid to trigger on.
2. Remove the air line (36) from the pressure relief
valve.
1. If the heating system and pump is disabled,
press
to enable the heaters and pump.
2. Wait for system to reach the temperature setpoints.
3. Set pump air pressure to 20 psi (140 kPa, 1.4 bar).
4. Remove the 3/8 in. OD air line from the air motor.
5. Verify that air is flowing through the air line.
6. If air is not flowing, check the wiring between J13
and the pump solenoid.
Check Heater Rod Resistance
36
WLD
FIG. 28
3. Plug air line and allow the air motor to cycle.
Use the table to determine if heater elements need to be
replaced.
Ref.
Element
Wattage
Ohms
208
209
Band Heater
Melter Rod
2000
1500
27-31
36.5-40.5
210
Base Rod
1000
54-61
210
Pump Rod
1000
54-61
4. Re-connect air line to relief valve and check whether
the system will stall.
5. If system still does not stall, purge ten pump cycles
of material through one applicator.
6. Repeat this entire procedure until no additional air is
expelled from the applicator.
50
333347B
Troubleshooting
Red
Yellow
Green
MZLP Troubleshooting
7 89
56
J3
234
01
MZLP
ti20348a
FIG. 30: MZLP Diagnostic LED Location
WLD
FIG. 29: 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
MZLP is powered up and input
voltage is within operating conditions.
Yellow On
Internal communication in process
Red Solid
MZLP failure. See troubleshooting
table.
Red Flashing
Software update in process or
missing software.
333347B
51
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.
Disassembly (see FIG. 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.
NOTICE
3. Turn main power switch OFF.
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.
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.
Pump
Replace Throat Seal, Throat Bearing, Piston Rod,
Piston Seal, and Piston Bearing
8. Remove air motor assembly:
a. Remove retaining ring (239).
b. Remove dowel pin (238).
c.
Remove three screws (240).
218
239
235
240
234
27
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).
233
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).
223
226
222
238
224
225
12. Remove piston valve (222) from piston rod (223).
13. Remove and discard piston u-cup (225) and
bearing (226).
245
3
Reassembly (see FIG. 31):
1. Assemble piston rod:
a. Install new piston u-cup (225) onto piston
rod (223) with the lips facing the rod.
FIG. 31
52
WLD
b. Install piston bearing (226) onto piston rod (223)
with grooved end towards the center of the piston rod.
333347B
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 FIG. 32.
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
15B661
203
233
ti20877a
FIG. 32
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 gently tap throat u-cup (234) into place. See FIG. 33.
ti21144a
FIG. 34
7. Remove seal installation tool.
8. Install retaining nut (235). See FIG. 32.
9. Install air motor assembly (see FIG. 31):
a. Install three screws (240).
b. With retaining ring around piston rod, install
dowel pin (238).
c.
Install retaining ring (239) over dowel pin.
10. Use nuts (3) to install melter shield (27).
11. Connect air lines to relief valve and air motor.
12. Install plastic shroud (27).
234
ti21047a
FIG. 33
333347B
53
Repair
2. Apply anaerobic thread sealant on threads of four
bolts (246) and connect pump to melter outlet.
Torque to 12-18 ft-lb (16-24 N•m).
Replace Pump Inlet Housing Checks
Replace Pump Cylinder Seals and Piston Seals
218
203
246
235
233
234
227
228
239
233
229
231
224
226
222
230
FIG. 35
203
Disassembly (see FIG. 35):
1. Flush the system. See page 31.
217
2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
216
217
230
3. Turn main power switch OFF.
4. Remove four bolts (246) and pump manifold (203)
from melter outlet.
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),
o-ring (229), and o-ring (231).
Reassembly (see FIG. 35):
1. Install new o-ring (231), o-ring (229), seat (228),
and ball (227) then use a 1/2 in. drive ratchet without a socket to install and tighten foot valve (230)
onto melter.
54
WLD
FIG. 36
Disassembly (see FIG. 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 plastic shroud (27). See FIG. 31 on
page 52.
5. Remove air lines from relief valve (245) and air
motor (218) See FIG. 31 on page 52.
333347B
Repair
6. Remove nuts (3) securing melter shield (27) in
place then remove melter shield. See FIG. 31 on
page 52.
Reassembly:
1. Apply grease to seals (217) then install new cylinder
seals (217) onto cylinder (216). See FIG. 37.
7. Remove air motor assembly. See FIG. 31 on
page 52:
a. Remove retaining ring (239).
1303
b. Remove dowel pin (238).
c.
217
Remove three screws (240).
216
8. Use a flat head screwdriver and a rubber mallet to
break loose the retaining nut (235).
217
1302
9. Use channel lock pliers to remove the retaining
nut (235).
203
10. Insert an allen wrench through the hole in the top of
the piston rod (223) to lift the piston rod (223) up out
of the manifold. This will also pull out the throat
u-cup (234) and throat bearing (233).
11. Replace Pump Inlet Housing Checks. See page
54.
12. Use a 1/2 in. drive ratchet without a socket to
remove foot valve (230) from bottom of melter outlet
manifold (203). See FIG. 36, page 52.
13. Insert cylinder tool (1301) into bottom of melter outlet manifold (203). Use a rubber mallet to gently
remove cylinder (216). See FIG. 35.
FIG. 38
2. Place female cylinder installation tool (1302) into
melter outlet manifold (203) to protect seals from
sharp threads. See FIG. 38.
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
FIG. 38.
4. Use a 1/2 in. drive ratchet without a socket to install
and tighten foot valve (230) into bottom of melter
outlet manifold (203). See FIG. 36, page 52.
1301
5. Perform Replace Pump Inlet Housing Checks on
page 54.
203
6. Perform Reassembly portion of the Replace Throat
Seal, Throat Bearing, Piston Rod, Piston Seal,
and Piston Bearing procedure which starts on
page 52.
217
216
217
ti21049a
ti20880a
FIG. 37
14. Remove and discard cylinder seals (217). See FIG.
37.
333347B
55
Repair
Melter
6. Remove screws (8) then remove electrical enclosure front access door (10).
Remove Melter Assembly
7. Disconnect heater rod wires from J4 connector on
AWB board.
8. Remove the air tube (36) from the relief valve (245).
Pull the air tube from the metal shroud (27).
FF
9. Remove nuts (3) on the back metal shroud (27)
then remove shroud.
10. Remove fabric melter insulator (53).
30
81
11. Loosen screw (AA) then remove sensor (125). See
FIG. 42, page 59.
53
29
12. Loosen hose clamp (81) then remove funnel (FF).
13. Remove wire connectors from the over-temperature
switch (251).
218
203
75
14. Remove insulators (53, 75) from the melter
assembly (5).
251
3
5
15. Disconnect the fill sensor cable from the fill
sensor (20). See Replace Fill Sensor, page 64.
8
245
16. Disconnect the pump cycle sensor cable from the
air motor.
10
1
3
27
WLD
36
17. Remove the air tube from the air motor (218).
18. Loosen screw (AA) then remove sensor (125). See
FIG. 41 on page 58.
19. Disconnect ground screw (87) and ring terminal (88)
from melter assembly.
FIG. 39
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 31
then wait for system to cool.
2. Close the bleed type ball valve at the system air
inlet.
3. Turn main power switch OFF.
87
88
WLD
FIG. 40
20. Remove electrical enclosure front access door (10).
4. Disconnect all heated hoses from the melter outlet
manifold.
5. Remove cable from ADM (30) then slide forward the
shroud (29) and remove it from the system.
56
333347B
Repair
21. Remove all heater wires from the following terminals. Pull wires up through the rubber grommet on
the top of the electrical enclosure (1).
5. Group the 4 sets of heater wires together and run
them through the grommet on the top of the electrical enclosure (1). Connect wires as noted below.
Item
Wire Marking Wire Marking
1
2
Item
Wire Marking Wire Marking
1
2
Band Heater (208)
J4-1
J4-2
Band Heater (208)
J4-1
J4-2
Melter Heater Rod (209)
J4-5
J4-6
Melter Heater Rod (209)
J4-5
J4-6
Base Heater Rod (210)
J4-7
J4-8
Base Heater Rod (210)
J4-7
J4-8
Pump Heater Rod (210)
J4-3
J4-4
Pump Heater Rod (210)
J4-3
J4-4
22. Remove four nuts (3) then remove melter assembly
from system. Save any loose insulators for reassembly.
6. Connect air tube to air motor (218).
23. Remove bolts (259), insulators (249), washers
(268), and melter assembly from base (257).
8. Connect pump cycle sensor cable to air motor.
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.
3. Use 4 bolts (259) to secure washers (268) and
melter assembly to melter base (257).
4. Use four nuts (3) to secure melter assembly to system.
7. Connect fill sensor cable to the fill sensor (20).
9. Install funnel (FF) then tighten clamp (81).
10. Install temperature sensor (125) into melter then
tighten screw (AA) on band heater. See FIG. 41 on
page 58.
11. Install insulators (53,75) onto the melter
assembly (5).
12. Connect ground wire ring terminal (87) and ground
screw (88) to melter assembly (5).
13. Connect wire connectors to the over-temperature
switch (251). See FIG. 43 on page 60.
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.
333347B
57
Repair
8. Locate the J4-1 and J4-2 wires in AWB board and
remove wires.
Replace Band Heater
8
9. Pull wires up through grommet (63) on top of the
electrical enclosure (1). Clip any wire ties that hold
the wires in place.
F
10. Continue loosing screw (AA) then slide band
heater (208) up to remove.
80
Reassembly (see FIG. 41):
53
208
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).
AA
125
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).
1
10
5. Connect wires to AWB board as marked. Wires
should be marked as shown in the following table.
63
WLD
FIG. 41
Disassembly (see FIG. 41):
1. Once the fluid level is low enough, close the
bleed-type ball valve installed at the system air inlet.
2. Turn main power switch OFF.
3. Disconnect cable from ADM (30) then remove
shroud (29).
4. Remove front access door (10) from electrical
enclosure (1).
Item
Wire
Marking 1
Wire
Marking 2
Band Heater (208)
J4-1
J4-2
6. Install electrical enclosure access door (10). See
FIG. 41.
7. Use clamp (80) and screws (8) to install funnel
assembly (F) on melter assembly.
8. Install fabric melter insulator (53).
9. Feed ADM cable through shroud then install shroud
and connect cable to ADM.
10. Open system air inlet ball valve.
11. Turn main power switch ON.
5. Remove fabric melter insulators (53).
6. Loosen clamp (80) and then remove screws (8) and
funnel assembly (F).
7. Loosen screw (AA) then remove sensor (125).
58
333347B
Repair
Reassembly (see FIG. 42):
Replace Band Heater Temperature Sensor
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 FIG. 43 on page 60.
53
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.
40
80
125
10
AA
WLD
FIG. 42
Disassembly (see FIG. 42):
6. Install electrical enclosure access door (10). See
FIG. 42.
7. Install fabric melter insulator (53).
8. Use nuts (3) to install metal shroud (27). See FIG.
39, page 56.
1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
9. Route relief valve air tube through the metal shroud
then attach to the relief valve.
2. Turn main power switch OFF.
10. Feed ADM cable through shroud then install shroud
and connect cable to ADM.
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).
11. Turn main power switch ON.
12. Open system air inlet ball valve.
5. Remove nuts (3) then remove metal shroud (27).
See FIG. 39, page 56.
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 FIG. 42.
NOTE: This connector also includes the over-temperature switch wires.
10. Disconnect wire connectors from over-temperature
switch (251). See FIG. 43 on page 60.
11. Pull cable out of the electrical enclosure then discard sensor (125) and wires.
333347B
59
Repair
Replace Heater Over-Temperature Switch
5. Feed ADM cable through shroud then install shroud
and connect cable to ADM.
6. Open system air inlet ball valve.
7. Turn main power switch ON.
251
Replace Heater Rod
255
206
ti21052a
210
FIG. 43
Disassembly (see FIG. 42):
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.
206
210
4. Remove air tube (36) from relief valve. Pull the air
tube through the metal shroud (27). See FIG. 45,
page 61.
5. Use 7/16 in. socket to remove nuts (3) then remove
metal shroud (27).
209
6. Disconnect the wire connectors from the over-temperature switch (251).
206
209
7. Remove the screws (255) securing the over-temperature switch (251) to the melter assembly (5),
then remove the switch.
FIG. 44
Re-assembly (see FIG. 42):
Disassembly (see FIG. 44):
1. Use the two screws (255) to secure the new
over-temperature switch (251) to the melter.
NOTE: This procedure is for replacing any of the above
heater rods.
2. Connect wire connectors to new over-temperature
switch.
1. Turn main power switch OFF.
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. See FIG. 45,
page 61.
60
WLD
2. If replacing the melter heater rod (209), Remove
Melter Assembly. See page 56.
3. Disconnect cable from ADM then remove
shroud (29).
333347B
Repair
4. If removing the pump heater rod (210):
a. Remove the air tube (36) from the relief
valve (245). Pull the air tube through the metal
shroud (27).
b. Remove nuts (3) then remove shroud (27).
6. If installing the pump heater rod (210), install the
metal shroud (27):
a. Place metal shroud on system.
b. Install and tighten nuts (3).
c.
5. Remove electrical enclosure front access door (10).
See FIG. 41.
6. Disconnect heater rod wires from terminal blocks
described in the following table.
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.
Item
Wire
Marking 1
Wire
Marking 2
Band Heater (208)
J4-1
J4-2
Melter Heater Rod (209)
J4-5
J4-6
Base Heater Rod (210)
J4-7
J4-8
27
Pump Heater Rod (210)
J4-3
J4-4
3
Replace Fluid Pressure Relief Valve
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).
Reassembly (see FIG. 44):
36
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.
244
245
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 FIG. 44.
3. Install electrical enclosure access door (10). See
FIG. 41.
4. If replacing the melter heater rod (209), Install
Melter Assembly. See page 56.
5. If replacing pump heater rod (210), feed ADM cable
through shroud then install shroud and connect
cable to ADM.
333347B
ti20757a
FIG. 45
1. Drain the System. See page 31.
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
FIG. 45.
5. Remove nuts (3) then remove shroud (27).
6. Use crescent wrench to remove melter fluid pressure relief valve (245).See FIG. 45.
61
Repair
7. Use an o-ring pick to remove o-ring (244).
Fuse Kit Fuse
Part
8. Install o-ring (244) into manifold.
24V289
F1, F2
250VAC, 25A, long, white ceramic
F3-F10
250VAC, 8A, fast acting, clear glass
NOTICE
To prevent damage to o-ring, ensure o-ring is seated
properly prior to moving to next step.
Spare fuse kit included with system.
NOTICE
9. Thread new fluid pressure relief valve (245) into
manifold. See FIG. 45. Once hand-tight, use crescent wrench to tighten.
10. Use nuts (3) to install metal shroud.
To prevent system damage, always use fast acting
fuses. Fast acting fuses are required for short-circuit
protection.
1. Turn main power switch OFF.
11. Connect air tube to pressure relief valve.
2. Remove electrical enclosure front access door (10).
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
3. Use a proper non-conductive fuse puller tool to
remove the blown fuse.
NOTICE
Using an improper tool, such as screw drivers or
pliers may break glass on fuse.
NOTE: F1 and F2 are white ceramic and indicate 25A
on the barrel.
Each MZLP module comes with the following fuses:
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.
F8 F7
F4 F3
F2
F6
NOTICE
J1
J2
F10 F9
F1
Using an improper tool, such as screw drivers or
pliers may break glass on fuse.
F5
5. Install electrical enclosure front access door (10).
J7
J6
Replace MZLP
J5
J3
WLD
FIG. 46: Fuse Locations
Disassembly:
1. Turn main power switch OFF.
2. Remove electrical enclosure front access door (10).
3. Disconnect heated hose electrical connectors from
MZLP (112).
62
333347B
Repair
4. Note location of each cable, then unplug all cables
from the MZLP (112) that will be replaced. See FIG.
48.
5. Remove four screws (114) securing MZLP (112) to
electrical enclosure (1) then carefully remove MZLP
from electrical enclosure. See FIG. 47.
5. Install electrical enclosure front access door (10).
6. Connect heated hose electrical connectors to new
MZLP.
NOTE: MZLP may need updated software. See Software Update Procedure on page 72.
Replace MZLP Daughter Card
Disassembly:
MZLP
#1
1. Turn main power switch OFF.
1
FIG. 47
114
112
MZLP
#3
MZLP
#2
6. Replace MZLP. See FIG. 47 for MZLP #1, MZLP #2,
and MZLP #3 identification.
a. To replace MZLP #1, remove the daughter card
and standoffs, and re-install them on the new
MZLP #1.
b. To replace MZLP #3, remove the jumper (135)
from MZLP #3 J5 connector and reinstall it on
the new MZLP #3 J5 connector.
Reassembly:
1. Set MZLP rotary switch to “1” on MZLP with daughter card. Set MZLP rotary switch to “2” or “3” on
MZLP without daughter card, based on location.
See FIG. 48 for rotary switch location.
2. Apply channel label stickers to new MZLP. See FIG.
47.
3. Use four screws (114) to install MZLP (112) to electrical enclosure (1).
4. Reconnect cables to MZLP (112).
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop and verify the connector orientation.
NOTE: If unable to determine connector location, see
Electrical Schematics on page 73.
333347B
2. Remove electrical enclosure front access door (10).
3. Note location of each cable then unplug all cables
from MZLP daughter card (112a).
4. Remove four mounting screws (112b) from daughter card (112a) and set aside.
112b
112a
ti20342a
112
Rotary Switch
FIG. 48
5. Unplug daughter card (112a) from the MZLP
#1 (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 73.
4. Install electrical enclosure front access door (10).
63
Repair
System
Replace ADM
58
Replace Fill Sensor
68
30
CC
ti20763a
20
FIG. 50
1. Turn main power switch OFF.
2. Disconnect cable (CC) from bottom of ADM (30).
See FIG. 50.
73
3. Remove ADM from bracket (58).
4. Install new ADM into bracket.
WLD
FIG. 49
Disassembly (see FIG. 49):
5. Connect cable to bottom of new ADM.
NOTE: ADM may need updated software. See Software Update Procedure on page 72.
1. Turn main power switch OFF.
2. Remove filter cover (68) and filter element.
3. Gently pull up on cable while unscrewing fill sensor
connector then remove fill sensor cable from fill
sensor (20).
4. Loosen fill sensor jam nut then remove fill
sensor (20) from sensor housing (73).
Reassembly (see FIG. 49):
1. Thread new fill sensor (20) into sensor housing (73).
Bottom out the sensor in the sensor housing then
back out 1/2 turn.
2. Tighten jam nut on fill sensor (20).
3. Connect fill sensor cable to new fill sensor (20).
4. Replace filter element and cover (68).
64
333347B
Repair
Disassembly:
Replace AWB
1. Turn main power switch OFF.
2. Note location of each cable, then unplug all cables
from the AWB. See FIG. 52.
3. Remove 2 screws (131) securing AWB (143) to
electrical enclosure (1) then carefully remove AWB.
131
144
4. Remove power supply (146) from power supply
bracket (145) by releasing mounting tab on the side
of the power supply. See FIG. 51.
145
146
5. Remove two screws (144) securing power supply
bracket (145) to AWB (143) and remove power supply bracket. See FIG. 51.
Reassembly:
145
1. Use two screws (144) to secure power supply
bracket (145) to new AWB (143). See FIG. 51.
131
FIG. 51: AWB and Power Supply
2. Mount power supply (146) to power supply bracket
(145). See FIG. 51.
J1
J2
F10 F9
F8 F7
F4 F3
F2
F6
F1
F5
3. Connect connector (labeled AWB-J1) on power supply harness (147) to J1 on AWB (143). See FIG. 52.
4. Use two screws (131) to install AWB (143) to electrical enclosure (1). See FIG. 51.
5. Reconnect cables to AWB (143).
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop and verify the connector orientation.
J7
J6
J5
FIG. 52: AWB Connections
333347B
NOTE: If unable to determine the connector location,
see Electrical Schematics, page 73.
J3
WLD
6. Install electrical enclosure front access door (10).
65
Repair
Replace Power Supply
Replace Power Supply Harness
Disassembly:
Disassembly:
1. Turn main power switch OFF.
1. Turn main power switch OFF.
2. Remove electrical enclosure front access door (10).
2. Remove electrical enclosure front access door (10).
3. Remove power supply (146) from power supply
bracket (145) by releasing mounting tab on the side
of the power supply. See FIG. 51.
3. Disconnect screw terminal connections between
power supply (146) and power supply harness (147)
according to the following table.
4. Disconnect screw terminal connections between
power supply (146) and power supply harness (147)
according to the following table. See FIG. 51.
Power Supply
Connection
V+
VGND
L
N
Harness Label
V+
VGND
L
N
Reassembly:
1. Make connections between power supply harness
(147) and new power supply (146) according to the
following table:
2. Reattach power supply (146) to power supply
bracket (145). See FIG. 51.
Power Supply
Connection
V+
VGND
L
N
Harness Label
V+
VGND
L
N
4. Unplug power supply harness (147) from J1 on
AWB (143). See FIG. 52.
Reassembly:
1. Make connections between power supply harness
(147) and new power supply (146).
2. Connect connector (labeled AWB-J1) on power supply harness (147) to J1 on AWB (143). See FIG. 52.
3. Install electrical enclosure front access door (10).
3. Install electrical enclosure front access door (10).
66
333347B
Repair
Air Controls
402
405
8
9
Replace Air Control Solenoids
NOTE: In order to replace the air control solenoids, the
system must be tipped back to access underneath the
electrical enclosure.
Disassembly (see FIG. 53):
1. Turn main power switch OFF.
1
2. Disconnect plug from power outlet or turn off circuit
breaker for incoming power.
WLD
3. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
FIG. 53
FF
4. Remove front access panel (10) from electrical
enclosure (1).
5. Remove the transformer assembly; for 480V systems only (see FIG. 54):
a. Disconnect transformer wires from J2 connector
on AWB board and the main power switch.
142
140
b. Remove three screws (142) and InvisiPac system off of transformer assembly (140).
6. Use 3/8 in. socket to remove two screws (8).
WLD
FIG. 54
7. Note location of each air line connection.
Reassembly (see FIG. 53):
8. Insert hands through access holes (FF), see FIG.
53, in bottom of electrical enclosure then disconnect
air lines from air control solenoids (402).
1. Use two screws (405) to secure new
solenoids (402) to air control assembly (409).
9. Disconnect air control solenoids cable from MZLP
daughter board connector J13. Pull wire out of the
electrical enclosure.
10. Remove two screws (405) securing solenoids (402)
to air control assembly (9) then remove air control
solenoids.
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 FIG.
53, in bottom of electrical enclosure then connect air
lines to air control solenoids (402).
4. Slide air control assembly (9) into place then use
two screws (8) to secure to electrical enclosure (1).
5. For 480V systems, install transformer assembly
(140) with screws (142) and reconnect transformer
wires to J2 connector on AWB board and the main
power switch.
333347B
67
Repair
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).
6. Install electrical enclosure front access door.
Replace Air Control Gauge
NOTICE
8
403a
403c
403
9
In the following step, do not overtighten the two
nuts (403a). Overtightening may cause the gauge to
break.
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
403b
FIG. 55
WLD
Replace Pilot Valve
C
Disassembly (see FIG. 55):
1. Turn main power switch OFF.
511
218
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).
WLD
FIG. 56: Top Pilot Valve
6. Remove air gauge from panel.
1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
Reassembly (see FIG. 55):
2. Turn main power switch OFF.
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.
3. Replace top pilot valve (511):
2. Install bracket (403c) then install two nuts (403a)
finger tight.
a. Use crescent wrench to remove the rod cover
(C).
b. Use 10 mm socket to remove air motor pilot
valve (511) from air motor (218).
c.
68
Lubricate with grease and install new air motor
pilot valve (511).
333347B
Repair
d. Torque pilot valve to 95-105 in-lb (10.7-11.9
N•m).
Replace Air Valve
218
4. Replace bottom pilot valve (511):
507
29
512
6
218
509
FIG. 58
Disassembly (see FIG. 58):
511
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.
WLD
FIG. 57: Bottom Pilot Valve
a. Remove cover (29) and insulation (6).
b. Use 10 mm socket to remove air motor pilot
valve (511) from air motor (218).
c.
Lubricate with grease and install new air motor
pilot valve (511).
3. Loosen clamp on air motor bracket (528) then
remove funnel assembly (61).
4. Loosen upper hose clamp on rubber housing then
remove fill cap.
5. Dispense until the fluid level in the melter is at or
below the honeycomb grid.
NOTE: If a screw or air valve seal is dropped during this
procedure it could fall into the melter. Melter fluid level
must be below honeycomb grid before moving to next
step.
d. Torque pilot valve to 95-105 in-lb (10.7-11.9
N•m).
6. Once the fluid level is low enough, close the
bleed-type ball valve installed at the system air inlet.
e. Replace insulation (6) and cover (29).
7. Disconnect air hose and cable from the air motor.
8. Use 10 mm socket to remove four screws (509)
securing air valve (512) to air motor (218).
9. Remove air valve (512) and seal (507) then discard.
Reassembly (see FIG. 58):
1. Lubricate with grease then place new air valve
seal (507) onto air valve (512).
2. Carefully place new air valve (512) against air motor
then thread in the four screws (509). Ensure the air
valve seal (507) stays in place by applying constant
pressure against the air motor.
333347B
69
Repair
3. Use 10 mm socket to torque screws (509) to
95-105 in-lb (10.7-11.9 N•m).
c.
4. Install fill cap then tighten upper hose clamp on rubber housing.
Remove Air Motor
74
a. Remove three screws (211) securing air motor
tie rods (220) to base plate (219).
82
b. Remove tie rods (220) from air motor (218).
218
27
d. Remove screws (8), screws (74), and bracket
(82).
7. If replacing a damaged air motor with a new fully
assembled air motor:
5. Connect air hose and cable to the air motor.
8
Remove three screws (240).
239
238
220
Install Air Motor
See FIG. 59.
240
1. If replacing a damaged air motor with a new fully
assembled air motor:
219
a. Install tie rods (220) onto air motor (218).
b. Install three screws (211) securing air motor tie
rods (220) to base plate (219).
211
3
2. Connect air motor assembly to system:
a. Install three screws (240), two screws (8),
screws (74), and bracket (82) to secure air
motor assembly to system.
b. Install dowel pin (238).
FIG. 59
WLD
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
FIG. 45 on page 61.
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 FIG. 45 on page 61.
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).
70
333347B
Repair
Transformer Fan
5. Remove screws (157) and fan grill (154). Pull two
fan wires down into the transformer enclosure.
6. Cut three zip ties on corrugated tube (167) and two
zip ties (161) on fan grill (154).
Replace Fan
7. Remove four nuts (158), rear fan grill (170), and fan
(151).
1
Install Fan
1. Mount new fan (151), rear fan grill (170), and nuts
(158) on grill (154) with the arrow pointing toward
the grill (154).
2. Tie down fan wires onto tie down locations on grill
(154) using cable ties (161).
158
167
154
black (-)
red (+)
161(x3)
151
161
157
WLD
FIG. 60
1. Turn main power switch OFF.
2. Disconnect plug from power outlet or turn off circuit
breaker for incoming power.
3. Remove front access panel (10) from electrical
enclosure (1).
4. Remove connector from J7 connector on AWB
board. Remove red (+) and black (-) wires from connector.
J7
WLD
FIG. 62
3. Route fan wires with transformer wires into the electrical enclosure (1). Connect red and black fan wires
to J7 connector. Reconnect J7 connector to AWB
board. See FIG. 61.
4. Reinstall corrugated tube (167) on fan and transformer wires. See FIG. 60.
NOTE: To prevent fan errors on ADM, remove excess
slack and ensure cabling and zip ties do not contact fan
blades.
(+)
red
5. Reinstall fan grill (154) and front access panel (10).
(-)
black
1
WLD
FIG. 61
333347B
Front access panel (10) not shown.
71
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.
NOTE: When the screen turns on, you will see the following screens:
First:
Software is checking
which GCA modules
will take the available
updates.
2. Remove ADM from bracket.
3. Remove token access panel.
Second:
Status of the update
with approximate time
until completion.
r_24P860_3B9900_3a
FIG. 63: Remove Access Panel
4. Insert and press InvisiPac software upgrade token
(T, part no. 24R324) firmly into slot.
Third:
Updates are complete.
Icon indicates update
success/failure. See
the following Icon
table.
Icon
NOTE: There is no preferred orientation of token.
Description
Update successful.
Update unsuccessful.
Update complete, no changes
necessary.
T
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.
r_24P860_3B9900_4a
FIG. 64: 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.
72
7. Remove token (T).
8. Replace token access panel.
9. Press
to continue to the InvisiPac operation
screens.
333347B
Electrical Schematics
Electrical Schematics
Cable Identification
To prevent electric shock and system damage, all
electrical work must be performed by a qualified
electrician.
Use the table to identify cables and other system components in the electrical schematics.
Ref
Part
Description
9
---
Manifold, air assembly
20
24R041
Sensor, ultrasonic
NOTICE
25
24A032
Switch, reed assembly
To prevent severe system damage, ensure main power
leads are installed correctly. See Connect Electrical Cord
on page 20.
30
24E451
ADM
86
127666
Cable, Extension
87
---
WIRE, ground
90
---
Plug, Phoenix, 8pin
103
---
Harness, MZLP #1 AWB
112
24V288
Module, MZLP with daughter
board
118
24V510
Module, MZLP
121
16T087
Cable Board
123
127768
Cable, CAN
124
16T103
Cable Pump
125
---
Sensor, RTD, 1M
126
16T108
Cable Ultrasonic
129
---
Harness, MZLP 2, AWB
---
Harness, MZLP 2/3, AWB
135
16W035
Connector Jumper
136
---
Harness, MZLP #1 AWB
138
---
Harness, Disc AWB
140
---
Transformer
143
24V816
AWB
146
126453
Power Supply
147
---
Harness Power Supply AWB
148
---
Cable, Board, Samtec
208
24V522
Band Heater
209
24V525
Heater Rod (1500 W)
210
24V524
Heater Rod (1000 W)
251
24R040
SWITCH, OT
120
1
16T102
Light Tower
Incoming Power
333347B
73
Electrical Schematics
System
30
143
140
138
AWB
J2
L1
N
N
L2
5L3
6T3
W2
L3
3L2
4T2
W3
1L1
2T1
W1
1
2
3
4
5
W4
GND
ADM
J9
1
2
3
4
5
1
2
3
4
5
GND
Transformer
Option
GB1
208
Band
210
209
210
Pump
Melter
Base
J7
TEMP
TEMP
TEMP
FAN -
TEMP
FAN -
FAN +
FAN +
90
J4
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
J5
L1
L2
L3
GND
L1
L2
L3
GND
J8
1
2
3
4
5
1
2
3
4
5
J6
L1
L2
L3
GND
87
147
Ground
Stud
DC OK
DC OK
-V
-V
+V
+V
GND
N
L
N
L
+
J3
148
136
1
1
2
2
103
146
112
MZLP 1
1201
Optional Light Tower
9
Air Solenoid
Fill Sensor
20
L1
L2
L3
GND
129 To MZLP #2 4 and 6
Channel Option, see
page 104 and 106.
J1
N
L
+
112A
86
126
Motor Cycle Switch
25
Melter OT Switch
and Melter RTD 251
To MZLP #2 4 and 6
Channel Option, see
page 104 and 106.
74
123
1
2
3
4
5
1
2
3
4
1
2
3
4
J12
1
2
3
4
1
2
3
4
J13
1
2
3
4
J14
1
2
3
4
J15
1
2
3
4
5
J16
1
2
3
4
1
2
3
4
5
124
125
J5
1
2
3
4
5
6
1
2
3
4
5
6
J3
121
1
2
3
4
5
1
2
3
4
5
J1
1
1
2
2
J2
L1
L2
L3
GND
L1
L2
L3
GND
J6
1
2
3
4
5
1
2
3
4
5
J8
A
B
C
D
E
F
G
H
J
K
L
J9
A
B
C
D
E
F
G
H
J
K
L
Hose / Applicator Wiring
333347B
Electrical Schematics
480VAC Transformer Option
143
AWB
J2
W1
L1
N
N
P3
W2
L2
5L3
3L2
6T3
P2
W3
4T2
P1
W4
1L1
2T1
L3
GND
J7
PTC
TEMP
TEMP
TEMP
FAN FAN +
TEMP
FAN FAN +
GB
GND
GB1
Typical Hose / Applicator Wiring
112
MZLP1
J8
GUN
HEATER
333347B
T°
GUN
RTD
OVER
TEMP
GND
HOSE
HEATER
T°
HOSE
RTD
A
A
B
B
C
C
D
D
E
E
F
F
G
G
H
H
J
J
K
K
L
L
75
Electrical Schematics
2nd and 3rd MZLP Options
135
1
2
3
4
5
6
76
J5
1
2
3
4
5
6
118
118
MZLP3
MZLP 2
J3
1
2
3
4
5
1
2
3
4
5
121
1
2
3
4
5
112
MZLP 1
J3
J6
1
2
3
4
5
1
2
3
4
5
J3
1
2
3
4
5
121
1
2
3
4
5
1
2
3
4
5
333347B
333347B
Line Air Inlet
Level Air Sensor
Level Sensor
Restrictor
Funnel Cooler
Restrictor
Funnel Cooler Air
Safety Pop Off Valve
Under Control Box
Refill Gauge
Refill Control Solenoid
Air Control Manifold
Air Motor Control Solenoid
Air Motor Gauge
Feed Wand
Air Motor
Pressure Relief
Valve
Optional Ramp Up/Down
Controller
Air Schematic
Air Schematic
NOTE: Install an optional ramp up/down controller to
limit air to the air motor and slow down the system dispense rate.
77
Parts
Parts
InvisiPac Systems
System Parts, Page 1 of 3
1
Apply door gaskets (11) to door (10) per layout diagram.
2
Apply pipe sealant to all non-swiveling pipe threads.
3
Bottom sensor (20) out then back off 1/2 turn.
4
Lubricate all seals and o-rings with water resistant grease.
83
24
22
53
25
26
75
8
28
23
13
19
18
43
6
38
38 31
50
30
23
8
39
27
8
3
44
64
29
43
1
78
11
10
43
WLD
8, 14
333347B
Parts
System Parts, Page 2 of 3
68
8
67
69
74
66
82
5
86
8
49
7
42
41
40
88
20
3
72
73
74
69
3
63
62
87
69
89
1
54
4
61
85
81
8
79
63
80
WLD
9
43
8
333347B
79
Parts
System Parts, Page 3 of 3
34
48 in.
(1219 mm)
57
35
48 in.
(1219 mm)
34
16 in.
(406.4 mm)
86
91
34
48 in.
(1219 mm)
49
35
48 in.
(1219 mm)
34
8 in.
(203 mm)
78
32
77
76
34
2 in.
(50.8 mm)
24
39
WLD
55
80
36
13 in.
330.2 mm)
333347B
Parts
System Parts
2 Channel
Ref
Part
1
---
ENCLOSURE, electrical; see page 84
3
115942
NUT, hex, flange head
4
167002
INSULATOR, heat
5
24V542
SYSTEM, melter/pump, HM50
6
---
INSULATOR, wrap
7
---
TRAY, drip
8†
113161
SCREW, flange, hex hd
9
---
MANIFOLD, air, assembly
10
---
DOOR, front
11
---
FOAM, border, door
13✿
---
FITTING, straight, hydraulic
14
16V153
WASHER, retaining
15
114271
STRAP, retaining
18✿
126961
FITTING, 45° elbow, hydraulic
19✿
116793
FITTING, 90° elbow
20
24R041
SENSOR, ultrasonic
21
101976
TOOL, allen, wrench
22
24N957
SHAKER, feed system
23
114606
PLUG, hole
24
120753
FITTING, push to connect elbow
25
24A032
SWITCH, reed assy
26
---
SCREW, pan head, #8-32 x 1.5 in.
27
---
BRACKET, back HM50
28
---
COVER, filter
29
---
COVER, melter HM50
30❄
24E451
MODULE, ADM
31
117017
WASHER
32
---
FITTING, tee, reducer
33
C12509
TUBE, nylon, rnd
34
---
HOSE, nylon, wpr 250 psi
35
598095
TUBE, 5/32 OD nylon
36
---
TUBE, ptfe, 1/4 in. OD
38
117126
SCREW, shcs; m5x16
39
---
GROMMET, 1/4 ID
40
---
BUSHING, strain relief
41
---
GROMMET, tube
42
---
GROMMET, tube
43▲
16Y781
LABEL, safety
333347B
Description
Quantity
4 Channel
6 Channel
24T918 24V201 24T919 24V202 24T920 24V203
1
8
4
1
1
1
17
1
1
1
2
4
8
2
2
1
1
1
2
2
1
1
1
1
1
1
2
1
1
8
4
1
1
1
17
1
1
1
2
4
8
2
2
1
1
1
2
2
1
1
1
1
1
1
2
1
8.10
4
1.10
3
1
2
1
1
1
8.10
4
1.10
3
1
2
1
1
1
1
8
4
1
1
1
15
1
1
1
4
4
16
4
4
1
1
1
2
2
1
1
1
1
1
1
2
1
3.25
8.10
4
1.10
3
1
2
1
1
1
1
8
4
1
1
1
17
1
1
1
4
4
16
4
4
1
1
1
2
2
1
1
1
1
1
1
2
1
8.10
4
1.10
3
1
2
1
1
1
1
8
4
1
1
1
15
1
1
1
6
4
24
6
6
1
1
1
2
2
1
1
1
1
1
1
2
1
3.25
8.10
4
1.10
3
1
2
1
1
1
1
8
4
1
1
1
17
1
1
1
6
4
24
6
6
1
1
1
2
2
1
1
1
1
1
1
2
1
8.10
4
1.10
3
1
2
1
1
1
81
Parts
2 Channel
Ref
Part
Description
6 Channel
24T918 24V201 24T919 24V202 24T920 24V203
1
1
1
1
1
1
1
1
1
1
1
1
KIT, fuses, board, temp control; see manual
407056
1
1
1
1
1
1
24P176
KIT, i/o connector
1
1
1
TIE, cable, 3.62 in.
1
10
1
C38321
1
10
10
1
1
2
1
1
1
1
3
1
1
1
1
3
1
1
5
1
1
1
1
1
1
1
1
1
1
10
1
1
2
1
1
1
1
2
1
1
1
1
3
1
1
5
1
1
1
1
1
1
1
1
1
1
44
---
LABEL, InvisiPac HM50
45
---
LABEL
47✖
24P859
48✖
49
125871
TIE, cable, 7.50 in.
50❄
24R324
TOKEN, software
53‡
---
INSULATOR, melter
54
---
NUT, bushing
57
123554
COUPLER, 3/8 in. OD tubing
58
24A326
BRACKET, mounting, assembly
61†
---
FUNNEL, large mouth
62†
---
BAFFLE, pellet
63
121487
GROMMET, sheet metal, 3/4 in.
64
24R707
KIT, inlet, air
66†
278729
FUNNEL, insert
67†
---
FILTER, HM50 feed
68†
---
FUNNEL, filter cover
69†
---
O-RING, fluoroelastomer, 160
72
110932
CONNECTOR, male
73†
---
HOUSING, sensor, HM50
74†
---
SCREW, #10-16, thread forming
75
---
INSULATOR, melter, manifold
76
---
FITTING, tee, 1/8npt x 3/8t x 3/8t
77
---
RESTRICTOR, air, 0.0225 in. orifice
78
198177
FITTING, push, straight
79
24W000
ADAPTER, melter HM50
80
---
CLAMP, hose, spacer
81
---
CLAMP, hose, spacer
82†
---
BRACKET, funnel, mounting
83
---
FITTING, 90 deg push2con 3/8
85
---
GROMMET
82
Quantity
4 Channel
1
1
2
1
1
1
1
3
1
1
1
1
3
1
1
3
1
1
1
1
1
1
1
1
1
1
10
1
1
2
1
1
1
1
2
1
1
1
1
3
1
1
5
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
3
1
1
1
1
3
1
1
3
1
1
1
1
1
1
1
1
1
1
10
1
1
2
1
1
1
1
2
1
1
1
1
3
1
1
5
1
1
1
1
1
1
1
1
1
1
333347B
Parts
2 Channel
Ref
Part
Description
FITTING, 5/32 in. OD tube, push-to-connect
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
TOOL, 5/16 nut driver
1
1
1
1
1
1
CABLE, gca, m12-5p
87
---
WIRE, ground
88
116343
SCREW, ground
89
---
WASHER, 1/4 external tooth lock
90
---
PLUG, phoenix, 8 pos
91
--127735
24T918 24V201 24T919 24V202 24T920 24V203
1
1
1
1
1
1
122030
93✖
6 Channel
1
1
1
1
1
1
86
92✖
Quantity
4 Channel
STRAP, lifting 3 ft
1
1
1
--- Not for sale.
▲ Replacement Danger and Warning labels, tags, and cards
are available at no cost.
❄ ADM does not come with software. Order software token
24R324.
✖ Not shown.
Available kits (purchase separately):
Kit
Description
Includes
24R885◆
Cycle Switch
25, 26
24R028*
Inlet housing
12, 13, 62
24V544
Tubing
32, 33, 34, 35, 36, 304. See
Feed System Shaker and
Tube, 24V507 on page 93 for
identification of item 304.
24V505†
Funnel
8, 61, 62, 66, 67, 68, 69, 73,
74, 82. See Feed Inlet Funnel, 24V505 on page 96.
24V508‡
Melter
53, 202, 204, 207, 211, and
253. See Melter and Pump
Parts on page 90 for identification of items 202-253.
24V504✿
Hydraulic Fittings 13, 18, 19
24U635
Acrylic Lens
Pressure Gauge
333347B
83
Parts
Electrical Enclosure
MZLP #3
MZLP #1
118 4
113
114
112a
3 118
113
114
106, 107
120
110
112 2
108
113
109
MZLP #2
WLD
114
101
1
Apply sealant to all non-swiveling pipe
threads.
2
Set rotary switch to “1” on MZLP with
daughter card.
3
Set rotary switch to “2” on MZLP 2.
4
Set rotary switch to “3” on MZLP 3.
131
132
144
145
146
104
117
84
WLD
111
143
105
131
333347B
Parts
142
141
137
140
WLD
Electrical Enclosure Parts
Ref
Part
Description
Quantity
1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP
No Transformer
480 V Transformer
101
---
CABINET, controls
1
1
1
1
1
1
102
122030
CABLE, gca, m12-5p
1
1
1
103
---
HARNESS, MZLP1, AWB
1
1
104
123970
SWITCH, disconnect, 40a
1
1
1
1
1
1
1
1
1
1
105
126839
CONTACT, n-pole
1
1
1
1
1
1
106
120858
BUSHING, strain relief, m40 thread
1
1
1
1
1
1
107
120859
108
104641
NUT, strain relief, m40 thread
1
1
1
1
1
1
FITTING, bulkhead
1
1
1
1
1
1
109
121141
FITTING, elbow, swivel, 3/8t 1/4mnpt
1
1
1
1
1
1
110
114421
BUSHING, strain relief
1
1
1
1
1
1
111
117666
TERMINAL, ground
1
1
1
1
1
1
112
24V28
8
MODULE, MZLP with daughter board
1
1
1
1
1
1
112a
24R04
2
KIT, board, daughter
1
1
1
1
1
1
113
16T44
0
CAP, souriau, uts14
2
4
6
2
4
6
114
125856
SCREW, 8-32, serrated flange
12
12
12
12
12
12
116
24P17
5
PLATE, blank, sgl mztcm
2
1
2
1
117
115942
NUT, hex, flange head
1
1
1
1
1
1
118
24V51
0
MODULE, gca, MZLP
1
2
1
2
333347B
85
Parts
Ref
Part
Description
Quantity
1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP
No Transformer
480 V Transformer
119
---
GASKET, foam, mztcm
2
1
120
---
PIN, dowel
1
1
1
121
16T08
7
CABLE, board, male/male, 21 in.
1
2
123
127768
CABLE, can, female/female 1.5 m
1
1
1
124
16T10
3
CABLE, pump
1
1
125◆
---
SENSOR, rtd, 1m
1
126
16T10
8
CABLE, ultrasonic, m12-4p, 1m
1
---
HARNESS, MZLP 2, awb
---
HARNESS, MZLP 2/3, awb
130
114958
STRAP, tie
4
4
4
4
4
4
131
---
SCREW, flange, serrated, 10-24 x 0.5
2
2
2
2
2
2
132
123967
KNOB, operator disconnect
1
1
1
1
1
1
135
16W03
5
CONNECTOR, jumper
136
---
HARNESS, MZLP 1, awb
137
---
BUSHING, cable
138
---
HARNESS, disc, awb
140
---
141
129
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
TRANSFORMER, assembly, 480v/240v
1
1
1
---
GROMMET, air fitting
1
1
1
142
113802
SCREW, hex hd, flanged, 3/8-16 x 5/8
3
3
3
143
24V81
6
MODULE, awb
1
1
1
1
1
1
144
114331
SCREW, mach, pnh, sems, 6-32 x 3/8
2
2
2
2
2
2
145
---
BRACKET, power supply
1
1
1
146
126453
POWER SUPPLY, 24v
1
1
1
1
1
1
147
---
HARNESS, power supply, awb
1
1
1
1
1
1
148
---
CABLE, board, samtec
1
1
1
1
1
1
86
1
1
1
1
1
1
1
333347B
Parts
Available kits (purchase separately):
Kit
Description
Includes
24V528†
Upgrade from 2
channel system
to 4 channel system
113, 118, 121, 129, a grounding wrist strap, and a software
upgrade token. See 4 Channel
Upgrade Kit, 24V528 on
page 104.
24V529✿
Upgrade from 4
channel system
to 6 channel system
113, 118, 121, 129,134, 135,
grounding wrist strap, and a
software upgrade token. See 6
Channel Upgrade Kit,
24V529 on page 106.
24R040◆
RTD
125, 251, and 255. See Melter
and Pump Assembly,
24V542 on page 89.
24V289
MZLP fuses
Qty 8 - 8 Amp, 250V Fuses
Qty 2 - 25 Amp, 250V Fuses
24P176
Customer I/O
Connectors
2 connectors for connecting to
H1 and H2 on MZLP daughter
board. Use for PLC connection.
333347B
87
Parts
Transformer Assemblies
152
160
161
153
3
2
166
156
167
161
169
157
2
158
157
154
170
151
WLD
168
155
1
2
166
166
3
156
1
Mount fan with arrow pointing towards grill.
3
Use nut to lock down the ground wire from transformer.
2
Tie down cabling from transformer and fan using cable tie onto
tie down locations. Remove excess slack and ensure cabling
does not contact fan blades.
3
Connect black fan wire labeled (-) from transformer (153) in the
pin labeled (-). Connect red fan wire labeled (+) to the
connector coming from transformer (153).
Transformer Assemblies
Ref.
Part
Ref.
Part
158
127278
NUT, keps, hex
151
---
ENCLOSURE, base, 480v
160
---
GROMMET, air fitting
1
152
---
ENCLOSURE, top, 480v
1
161★ 125871
TIE, cable, 7.5 in.
4
153
24U912
TRANSFORMER, 480v/240v, 6kva;
480V systems only
1
162
LABEL, designation
1
LABEL, safety, warning
1
TRANSFORMER, 400v/240v, 6kva;
400V systems only
1
166▲ 17A071
24U913
167
1
---
GRILL, fan
1
TUBE, corrugated, slit; 6 in. (152.4
mm)
FAN, 24 vdc, 120m x 120m
1
154
155★
---
Description
Qty
1
156
115942
NUT, hex, flange head
5
157
119865
SCREW, mach, hex serrated; 1/4 x
3/8 in.
6
88
172953
---
Description
Qty
4
▲ Replacement Danger and Warning labels, tags, and cards
are available at no cost.
★ Included in Fan Replacement Kit 24V911.
--- Not for sale.
333347B
Parts
Melter and Pump Assembly, 24V542
2
208
218
217
205
238
239
254
216
235
211
217
233
236
204
234
5
223
224
206
220
2 202
225 5
3
226
240
207
222 4
3
221
227
228
229
231
219
215
211
213
252
210
253
206
252
7
203
232
251
255
6
210
230
246
9
10
201
209
249
214
242
257
247
258
3
249
268
259
8
243
244
245
206
WLD
1
Lubricate all seals and o-rings with grease.
6
Assemble inserts (252) 0.01-0.05 in. (0.3-1.3 mm) below surface.
2
Orient melter (202) sensor hole in line with band heater (208)
clamp.
7
Assemble inserts (252) 0.01-0.05 in. (0.3-1.3 mm) below surface.
3
8
Torque to 5-11 ft-lb (7-15 N•m).
Torque to 27-33 in.-lb (3-3.8 N•m).
4
9
Torque to 24-30 ft-lb (33-41 N•m).
Apply anaerobic thread sealant on threads.
10
Torque to 12-18 ft-lb (16-24 N•m).
5
Orient u-cups (225, 234) with springs in direction shown.
333347B
89
Parts
Melter and Pump Parts
Ref.
Part
201
---
202✖
203•
204✖
-------
Part
Description
240
101864
SCREW, cap, sch; 5/16 x 1 in.
242★•
117059
O-RING, fluoroelastomer
1
---
BASE, melter HM50
Qty
.
1
TANK, melter HM50
1
243★•
RETAINER, seat, dump valve
1
MANIFOLD, outlet
1
244★•
15Y627
PACKING, o-ring #2-116, ptfe
1
PLATE, mounting
1
245★•
---
VALVE, relief
1
246•
121295
SCREW, cap, socket head; 5/16 x
2.5 in.
4
247•
15H304
FITTING, plug 9/16 sae
9
249
167002
INSULATOR, heat
251✿•
24R040
SWITCH, overtemperature
1
252•
---
INSERT, helical
7
253✖
---
PLATE, melter
1
254
---
O-RING, -910
1
255✿•
107388
SCREW, mach, pnh; #4 x 3/8 in.
2
257
---
BRACKET, shelf
1
258
---
GROMMET, 1/4 ID
1
259
110298
SCREW, cap, sch; 1/4 x 7/8 in.
4
268
115814
WASHER, flat, sst
4
Description
205
---
HOUSING, fire rod
1
206•
111317
RING, retaining, int.
3
207✖
16W615
O-RING, fluoroelastomer
1
208
24V522
BAND, heater
1
209•
24V525
HEATER, fire rod,1500 watts
1
210
24V524
HEATER, fire rod,1000 watts
2
211✖
116940
SCREW, cap, sh, 5/16-18
7
213
---
SCREEN, wire
1
214•
112855
PACKING, o-ring
1
215
---
PLUG, o-ring boss
1
216‡•
---
SLEEVE, cylinder
1
217†‡•
108526
PACKING, o-ring, ptfe
2
218
24R025
MOTOR, double ended, air; see
page 92
1
219
---
PLATE, pump adapter
1
220
---
ROD, tie, 1.5 in. stroke
3
221•
192624
GUIDE, ball
1
222†◆•
239932
VALVE, piston
1
223◆•
---
ROD, piston
1
224†◆•
105444
BALL, (.31250)
1
225†◆•
---
SEAL, u-cup, piston
1
226†◆•
---
BEARING, piston
1
227†•
105445
BALL, (.5000)
1
228†•
192642
SEAT, carbide
1
229†•
107079
PACKING, o-ring
1
230•
16T051
HOUSING, foot valve
1
231†•
105802
O-RING
1
232†•
113944
PACKING, o-ring
1
233†•
---
BEARING, throat
1
234†‡•
---
SEAL, u-cup, throat
1
235•
193046
NUT, packing
1
236•
238
24N956
FILTER, assy, 100 mesh, welded
1
196762
PIN, straight
1
239
196750
SPRING, retaining
1
90
Qty
.
3
Ref.
10
--- Not for sale.
Available kits (purchase separately):
Kit
Description
Includes
24P852†
Pump repair
217, 222, 224, 225, 226, 227,
228, 229, 231, 232, 233, 234,
and seal installation tool
15B661.
24P853‡
Cylinder
216, 217, 234, and seal installation tool 15B661.
24P854◆
Pump rod
222, 223, 224, 225, 226
333347B
Parts
Kit
Description
Includes
24P856★
Pressure relief
valve
242, 243, 244, 245
24V508✖
Melter
202, 204, 207, 211, 253, and
insulator (53). See InvisiPac
Systems parts starting on
page 78 for insulator (53)
identification.
24R040✿
RTD
125, 251, and 255. See Electrical Enclosure on page 84.
24R709 •
Assembled pump 203, 206, 209, 214, 216, 217,
manifold
221, 222, 223, 224, 225, 226,
227, 228, 229, 230, 231, 232,
233, 234, 235, 236, 242, 243,
244, 245, 246, 247, 251, 252,
255
---
Special tools
333347B
See Special Tools on page
97.
91
Parts
Air Motor, 24V558
2
509
512
507
4
509
522
513
505
506
511
1
2
1
2
511
WLD
1
Apply water-resistant grease.
2
Torque to 95-105 in-lb (10.7-11.9 N•m).
Ref.
505
Part
24A579
Description
506
---
GASKET, cover, small
2
507†
---
SEAL, air valve, manifold
1
509†
---
SCREW, m6 x 25, thread forming
8
511
---
VALVE, pilot
2
512†
---
VALVE, air, small
1
513
15M213
MUFFLER, 3/8
1
MANIFOLD, medium, short
Qty
1
†
Included in Air Motor Valve Kit 24R026.
--- Not for sale.
92
333347B
Parts
Feed System Shaker and Tube, 24V507
306
301
1
304
302
1
Apply pipe sealant to threads.
ti20738a
Parts
Ref
Part
Description
Qty
301
24P861
SHAKER
1
302
24N954
TUBE, steel
1
303†◆
---
TUBE, clear PVC, 1.3 in.
(33 mm) OD
10
304
---
HOSE, nylon, 3/8 in. OD, 250 psi
(1.7 MPa, 17 bar)
15.
5
305◆
125370
CLAMP, hose, dia. 11/16 to
1-1/2 in.
3
306
125871
TIE, cable, 7.50 in. (190 mm)
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).
--- 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 24V544. See System Parts
on page 81 for other kit contents.
◆ Not shown.
333347B
93
Parts
Air Controls Assembly
405
402
406
1 404
401
1 404
403
1
WLD
Apply sealant to all non-swiveling pipe threads.
Air Controls Assembly Parts
Ref
Part
Description
Qty
401
---
PANEL, air, controls
1
402
24V520
CONTROL, air, vacuum transfer
and pump
1
403
15T500
GAUGE, pressure, air, panel
mount, 1/8 in. npt
2
404
15T498
FITTING, 90 degree, swivel,
5/32 in. tube x 1/8 in. female npt
2
405
100058
SCREW, cap, hex head
2
406
054753
TUBE, nylon, round, black
2
407
C38321
TIE, cable, 3.62 in.
1
--- Not for sale.
94
333347B
Parts
Pressure Relief Valve, 24P856
607 3
1
606
1
601
614 2
605
611 608
1
602
609 2
612 2
603 3
610
610
604
1
Apply sealant to all non-swiveling pipe threads.
2
Apply grease.
3
Torque to 4-6 in-lb (0.5-0.7 N•m).
613
i
† Parts included in Relief Valve Repair Kit 24P857
(purchase separately).
Ref
Part
Description
Qty
601
---
BODY, fluid
1
602
---
BODY, air
1
603
15T413
PISTON, air
1
604
---
AIR CAP, valve
1
605
---
BEARING, shaft, needle
1
606
---
SHAFT, needle, valve
1
607
---
SOCKET, ball assembly
1
608†
108771
PACKING, o-ring
1
609†
110073
PACKING, o-ring
1
610
111841
WASHER, plain 5/8 in.
2
611†
---
BEARING, valve
1
612†
---
O-RING, FKM
1
613
---
FITTING, push to connect
1
614†
---
SEAL, u-cup, relief valve
1
--- Not for sale.
333347B
95
Parts
Feed Inlet Funnel, 24V505
706
705
703
704
707
708
710
708
709
703
702
703
701
WLD
Ref.
Part
Description
Qty
1
701
---
FUNNEL, large mouth
702
---
BAFFLE, pellet
1
703
---
O-RING, fluoroelastomer, 160
3
704
278729
FUNNEL, insert
1
705
24V506
FILTER, feed
1
706
---
FUNNEL, filter cover
1
707
113161
SCREW, flange, hex hd
2
708
---
SCREW, #10-16, thread forming
5
709
---
BRACKET, funnel, mounting
1
710
---
HOUSING, sensor
1
--- Not for sale.
96
333347B
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
Purpose
Part
Purpose
1301*
Remove Cylinder
1304**
Install Rod - Female
1302*
Install Cylinder - Female
1305**
Install Rod - Male
1303*
Install Cylinder - Male
1306**
Install Rod - Bullet
*
Parts included in Cylinder Tools Kit 24R227 (purchase separately).
** Parts included in Rod Tools Kit 24R228 (purchase
separately).
ti20983a
333347B
97
Accessories
Non-Graco Applicator Adapter
Cables
16T916: For connecting to non-Graco applicators 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 applicators that
use a circular, 9-pin connector.
801
802
WLD
ti21129a
16Y828: For connecting to non-Graco applicators that
use a circular, 6-pin connector.
NOTE: Screws are part of the base system and are
not included in the kit.
Ref
Part
Description
Qty
801
---
PANEL, lock, air control
1
802
---
BRACKET, lock, air control
1
Air Adjustment Lock Installation
1. Remove screws from system air panel.
2. Use screws to install panel (801).
WLD
Non-Graco Applicator Adapter Cable
Installation
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.
See Attach Components on page 14.
98
333347B
Accessories
System Stand, 24R088
Adapter Plate, 24R083
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.
Use this adapter plate to install InvisiPac in place of an
existing hot melt applicator system.
C
B
Bolt Hole Dimensions
A
B
C
9.8 in. (249 mm)
14.843-15.157 in.
(377.0-385.0 mm)
17.003-17.317 in.
(431.9-439.9 mm)
A
1002
1001
1104
1101
1003
A
1102
WLD
1103
WLD
Ref
Part
Description
Qty
1001
---
STAND
1
1002
112395
SCREW flange head cap
3
1003
112958
NUT, hex, flanged
3
System Stand Installation
1.
2.
3.
4.
Place stand (1001) in desired location.
Use bolt holes to bolt stand in place.
Place system on stand.
Use screws and nuts to secure system to stand.
Caster for Stand, 120302
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).
333347B
Ref
Part
Description
Qty
1101
---
PLATE, adapter
1
1102
112395
SCREW flange head cap
6
1103
112958
NUT, hex, flanged
9
1104
121283
FITTING, elbow, 45 degree
1
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).
99
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
903
915
915
905
904
907
916
909
ti20928a
914
912
Ref
Part
Description
Qty
909
113779
MUFFLER
1
HOPPER, 30 gallon
1
910
111192
SCREW, cap flange head
2
---
LID, hopper, 30 gallon
1
912
125857
SCREW, 10-24, serrated flange
4
903
126930
SHAKER, ball vibrator
1
914
121141
126929
VALVE, air pilot, 3-way, closed
1
FITTING, elbow, swivel, 3/8 in. tube
connector, 1/4 male npt
1
904
905
---
BRACKET, shaker, container
1
915
120389
FITTING, tube
2
907
---
HOSE, nylon, 3/8 in. OD, 250 psi
(1.7 MPa, 17 bar)
1
916
---
CONNECTOR, tube, 90 degree
1
917
125539
FITTING, splitter, 3/8 in. OD tubing
1
CONNECTOR, tee, push-tube
1
Ref
Part
Description
901
---
902
908
100
119798
Qty
--- Not for sale.
333347B
Accessories
30 Gallon Vibrating Hopper Installation
See FIG. 65 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.
Splitter fitting
To piloted
air valve
To shaker
head
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).
Hopper
shaker
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.
Piloted air
valve
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).
To shop air
supply
ti21350a
FIG. 65
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 FIG. 1 on page 9).
333347B
101
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
AA
1203
1204
J12
J2
WLD
F5
1202
F4 F3
F2
J3
F1
J1
BB
--- Not for sale.
24R226 Parts
Ref
Part
Description
1201
16T102
LIGHT, tower, red and green
1
1201a
---
SCREW
3
1202
---
GROMMET, single cable
1
1203
16K322
BRACKET, light tower
1
1204
---
GROMMET, multiple wires
1
1205
125835
CLIP, ferrite bead
1
102
J6
J7
J5
F10 F9
F8 F7
F6
1205
Qty
333347B
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.
1505
9. Connect light tower cable to MZLP connector
labeled J12.
1503
1504
1504
1505
1506
1501
WLD
16W366 Parts
Ref
Part
Description
Qty
1501
---
HOSE, nylon (6 ft)
1
1502
100081
BUSHING, pipe
1
1503
113777
TEE, branch
1
1504
114485
CONNECTOR, male, 3/8 npt
2
1505
155665
UNION, adapter
1
1506
---
TANK, air, accumulator
1
--- Not for sale.
333347B
103
Accessories
4 Channel Upgrade Kit, 24V528
Use this kit to upgrade a 2 channel system to a 4 channel system.
CC
1307
AA
1306
1301
BB
1308
WLD
1304
1305
1308
1302
Ref
Part
Description
Qty
1301
---
MODULE, GCA, MZLP
1
1302
16T087
CABLE, jumper, male/male, 21 in.
1
1303
---
HARNESS, 2nd MZLP power
1
1304
112190
STRAP, wrist, grounding
1
1305
16T440
CAP, jam nut, sealing
2
1306
24R324
SOFTWARE UPGRADE TOKEN,
InvisiPac System
1
1307
---
FITTING, straight
2
1308
---
LABEL, InvisiPac Channel Numbers
1
◆ Not shown.
--- Not for sale.
104
333347B
Accessories
4 Channel Upgrade Kit Installation
1. Disconnect plug from power outlet or turn off circuit
breaker for incoming power.
2. Place grounding wrist strap (1304) over your wrist
and secure other end to a grounded surface.
3. Set the MZLP (1301) rotary switch to “2”.
4. Remove screws (BB) then remove plate (AA) from
system.
5. Use screws (BB) to install MZLP (1301) onto system. Apply labels from label sheet (1308) to MZLP
#2. Place the “3” and “4” labels as shown in parts
illustration.
NOTE: The new MZLP (1301) with be referred to as
MZLP 2, and the original MZLP that came with the system will be referred to as MZLP 1 from here on. See FIG.
66.
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. Connect CAN jumper cable (1302) to MZLP 1 connector J3 and connect other end of jumper
cable (1302) to MZLP 2 connector J3. See FIG. 66.
8. Connect power harness (1303) to MZLP 2 connector J2.
9. Remove plugs (CC) from fluid manifold and replace
with straight fittings (1307) or the extra fittings
included with the InvisiPac system. Use the fittings
that meet your hose routing needs.
10. To ensure your InvisiPac system has the latest software, insert token (1306) into ADM. Follow Software Update Procedure, page 72.
Step 7: Install Jumper Cable (1302).
MZLP 2
MZLP 1
J6
J1
J5
J9
J3
J8
J2
J2
J8
J9
J1
J3
J5
J6
ti23596a
FIG. 66
333347B
105
Accessories
6 Channel Upgrade Kit, 24V529
Use this kit to upgrade a 4 channel system to a 6 channel system.
CC
1304
1308
1302
1309
WLD
BB
1307
1306
AA
1303
BB
1305
1301
Ref
Part
Description
1301
---
MODULE, GCA, MZLP
1
1302
16T087
CABLE, jumper, male/male, 4 in.
1
1303
112190
STRAP, wrist, grounding
1
1304
24R324
TOKEN, software upgrade
1
1305
16T440
CAP, jam nut, sealing
2
106
Qty
Ref
Part
Description
Qty
1306
---
HARNESS, MZLP #3
1307
16W035 CONNECTOR, jumper
1
1308
---
FITTING, tee
2
1309
---
FITTING, straight
2
1310
---
LABEL, InvisiPac channel numbers
1
1
333347B
Accessories
6 Channel Upgrade Kit Installation
1. Disconnect plug from power outlet or turn off circuit
breaker for incoming power.
2. Place grounding wrist strap (1303) over your wrist
and secure other end to a grounded surface.
3. Set the kit’s MZLP (1301) rotary switch to “3”.
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. Connect CAN jumper cable (1302) to MZLP 2 connector J3 and connect other end of jumper
cable (1302) to MZLP 3 connector J3. See FIG. 67.
4. Remove screws (BB) then remove plate (AA) from
system.
8. Install jumper connector (1307) in J5 on MZLP 3.
5. Use screws (BB) to install MZLP (1301) onto system.
NOTE: The new MZLP (1301) will be referred to as
MZLP 3, and the original MZLPs that came with the system will be referred to as MZLP 1 and MZLP 2 from here
on. See FIG. 67.
0=/3
6. Remove electrical enclosure front access door.
9. Connect wires from power harness (1306) between
AWB connector J5 and MZLP connector J2.
10. Remove plugs (CC) from fluid manifold and replace
with straight fittings (1309), tee fittings (1308), or the
extra fittings included with the InvisiPac system.
Use the fittings that meet your hose routing needs.
0=/3
-
0=/3
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Step 7: Install jumper cable (1302).
WLD
FIG. 67
333347B
107
Accessories
InvisiPac ADM Simulator Kit, 24R323
Simulator Instructions
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.
1. Remove ADM access panel and install InvisiPac
Simulator Token (1404).
1401
1402
r_24P860_3B9900_3a
FIG. 68: Remove Access Panel
1404
2. Connect power supply (1402) to ADM (1401).
3. Connect cord (1403) to power supply (1402).
1403
4. Perform Software Update Procedure on page 72.
ti20990a
Ref
Part
Description
1401
24P860
MODULE, Advanced Display
(ADM)
1
1402
124149
POWER SUPPLY, GCA
1
1403
---
CORD SET, US, MX, PR, CA, TW,
115V, 10A
1
1404
24R322
TOKEN, InvisiPac Simulator
1
1405
24R324
SOFTWARE UPGRADE TOKEN,
InvisiPac System
1
108
Qty
333347B
Accessories
Overtemperature Jumper, 16Y727
Use the Overtemperature jumper plug to run the InvisiPac melter without a hose and applicator attached to the
Channel 1 electrical connection.
Installation
1. In the ADM setup screens, uninstall Channel 1. All
other Channels can be installed or uninstalled as
needed.
NOTE: Failure to uninstall Channel 1 on the ADM setup
screens will result in several Alarms regarding Channel
1 when there is no hose/applicator attached to Channel
1.
WLD
2. Attach the Overtemperature jumper plug to Channel
1.
3. The ADM should have zero Active Alarms. The
melter is now ready to run without a hose and applicator attached to Channel 1.
333347B
109
Appendix A - ADM
Appendix A - ADM
General Operation
Icon
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
,
,
, and
to navigate
between screens.
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 113.
Select channel to view and/or edit
the applicator or hose temperature
setting
Applicator temperature setting.
Use
ting.
and
to adjust set-
Hose temperature setting.
Use
ting.
and
to adjust set-
Use to adjust temperature settings
Temperature settings of applicator
(top) and hose (bottom)
Reset weight total
Icon Identification
Icon
Description
Setup Screens Only
Description
Operation Screens Only
Enter screen to change settings
Heating disabled
Warming up, actual temperature is
below setting
Temperature setting achieved
Actual temperature of hose (left)
and applicator (right)
Actual temperature of system
(shown warming up)
Exit screen
Reset Maintenance error
Schedule Screen Only
Edit schedule value
Erase schedule value
Accept schedule change
System temperature setting.
Use
ting.
and
Cancel schedule change
to adjust set-
Use the physical numeric keypad
on ADM to enter temperature setting.
110
333347B
Appendix A - ADM
Operation Screens
Home
Events
This screen shows the actual temperatures of the system melter and each applicator and hose.
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 116.
Targets
Tracked Events
Custom Language Downloaded
Custom Language Uploaded
Fill Valve Closed
Fill Valve Open
Heat Off
Heat On
Logs Downloaded
This screen shows and allows editing of the temperature
settings for the system melter and each applicator and
hose. See Select ADM Settings on page 21.
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
333347B
111
Appendix A - ADM
DI: System Digital Inputs
0: Not Used
1: Not Used
2: Pump Cycle Switch Up
3: Pump Cycle Switch Down
Errors
DO: System Digital Outputs
0: Pump Solenoid
1: Fill Solenoid
2: Light Tower Green Light
3: Light Tower Red Light
The Errors screens store a maximum of 200 errors. See
ADM Error Code Table on page 37. The errors list can
be downloaded in the USB logs. See Appendix B USB Downloading, Uploading on page 116.
Diagnostic
ISO DI: Customer Digital Inputs
0: Customer Input 1
1: Customer Input 2
2: Customer Input 3
3: Customer Input 4
ISO DO: Customer Digital Outputs
0: Customer Input 1
1: Customer Input 2
2: Customer Input 3
3: Customer Input 4
Fill: Reading of Ultrasonic Fill Sensor
• Old Fill Sensor (2400-2700 mV)
• New Fill Sensor (4200-3800 mV)
A
B
C
This screen shows details of various items to aid in troubleshooting the system. This screen can be hidden by
de-selecting “Enable Diagnostics Screen” on the System 3 screen. The flow rate updates every 15-20 seconds with the average flow rate over the last 15-20
seconds.
The following information is displayed.
Diagnostic Data
A
Current Draw
B
RTD Reading
C
Duty Cycle
CAN: 24 VDC power supply voltage reading (18-28
VDC)
112
Fill Sol: Current draw of fill solenoid
• (0 mA - off)
• (150-250 mA - on)
Flow/H: Melt rate of the system
Life Cycles: total number of pump cycles over life of
system.
Life Weight: Weight of material dispensed over life of
system.
Pump Sol: Current draw of pump solenoid
• (0 mA - off)
• (150-250 mA - on)
PCB Temp: PCB Temperature on MZLP1
• 32-16°F (0-71°C)
Pump CPM: Pump cycles per minute.
USB DL%: Percentage Complete, only applies when
downloading USB data.
333347B
Appendix A - ADM
Setup Screens
NOTE: It is important to set all settings in the System
screens correctly to ensure optimal system performance.
System 3
Password
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.
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.
System 2
Use this screen to enable the installed channels and
specify the type of applicator RTD type used. See
Select ADM Settings on page 21.
333347B
113
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.
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.
NOTE: The lifetime cycle count will only be reset if the
Advanced Display Module (ADM) is replaced.
Schedule
Use this screen to set times where the system will automatically enable and disable heating. See Select ADM
Settings on page 21.
Advanced 2
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.
114
333347B
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.
333347B
115
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.
Download Procedure
NOTICE
Uploading an edited system configuration file can
damage the system. Never put a modified
SETTINGS.TXT file in the UPLOAD folder on the
flash drive.
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 117.
1. Insert USB flash drive into USB port. See FIG. 69.
NOTE: Flash drive must be 8 GB or smaller.
Accessing Files
All files downloaded from the USB are put in a DOWNLOAD folder on the stick drive. For example:
“E:\GRACO\12345678\DOWNLOAD\”. The 8-digit
numeric folder name matches the 8-digit ADM serial
number, which is located on the back of the ADM. When
downloading from multiple ADMs, there will be one
sub-folder in the GRACO folder for each ADM.
The log files should be opened in a spreadsheet program.
NOTE: If emailing the files, zip (compress) them to minimize file size.
Upload Procedure
NOTICE
Uploading an edited system configuration file can
damage the system. Never put a modified
SETTINGS.TXT file in the UPLOAD folder on the
flash drive.
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 117.
1. If necessary, follow the Download Procedure,
page 116, to automatically generate the proper
folder structure on the USB flash drive.
2. Insert USB flash drive into USB port of computer.
FIG. 69: 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.
3. The USB flash drive window automatically opens. If
it does not, open USB flash drive from within Windows Explorer.
4. Open Graco folder.
NOTE: If the pop-up screen does not appear, the flash
drive is not compatible with the ADM. Try a different
flash drive.
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.)
NOTE: The system can log up to 45 mb of additional
data per week, depending on system operation.
6. If installing the system settings file, place SETTINGS.TXT file into UPLOAD folder.
116
333347B
Appendix B - USB Downloading, Uploading
7. If installing the custom language file, place DISPTEXT.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 116, 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.
GCA Log
This log (3-GCA.CSV) lists the installed GCA modules
and their respective software versions.
Black Box, Diagnostics Logs
These logs (4-BLACKB.CSV, 5-DIAGN.CSV) are
designed to provide useful information to Graco when
calling for technical assistance.
System Settings File
NOTICE
Uploading an edited system configuration file can
damage the system. Never put a modified
SETTINGS.TXT file in the UPLOAD folder on the
flash drive.
The system configuration settings file name is
SETTINGS.TXT and is stored in the DOWNLOAD
folder.
A system configuration settings file automatically downloads each time a USB flash drive is inserted. Use this
file to back up system settings for future recovery or to
easily replicate settings across multiple InvisiPac systems. Refer to the Upload Procedure, page 116, 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.
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.
333347B
117
Appendix B - USB Downloading, Uploading
System Language File
The system language file name is DISPTEXT.TXT and
is stored in the DOWNLOAD folder.
A system language file automatically downloads each
time a USB flash drive is inserted. If desired, use this file
to create a user-defined set of custom language strings
to be displayed within the ADM.
The system is able to display the following Unicode
characters. For characters outside of this set, the system will display the Unicode replacement character,
which appears as a white question mark inside of a
black diamond.
•
•
•
•
•
U+0020 - U+007E (Basic Latin)
U+00A1 - U+00FF (Latin-1 Supplement)
U+0100 - U+017F (Latin Extended-A)
U+0386 - U+03CE (Greek)
U+0400 - U+045F (Cyrillic)
Create Custom Language Strings
The custom language file is a tab-delimited text file that
contains two columns. The first column consists of a list
of strings in the language selected at the time of download. The second column can be used to enter the custom language strings. If a custom language was
previously installed, this column contains the custom
strings. Otherwise the second column is blank.
Modify the second column of the custom language file
as needed and then follow the Upload Procedure,
page 116, 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.
•
•
•
•
•
•
118
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.
333347B
Technical Data
Technical Data
InvisiPac Hot Melt Delivery System
US
Incoming Power
24T918
Metric
200-240 VAC, 1-ph, 50/60 Hz, 32A
200-240 VAC, 3-ph, ˂, 50/60 Hz, 27A
350-415 VAC, 3-ph, Y, 50/60 Hz, 16A
24V201
400-480 VAC, 3-ph, ˂, 50/60 Hz, 14A
24T919
200-240 VAC, 1-ph, 50/60 Hz, 40A
200-240 VAC, 3-ph, ˂, 50/60 Hz, 27A
350-415 VAC, 3-ph, Y, 50/60 Hz, 16A
24V202
400-480 VAC, 3-ph, ˂, 50/60 Hz, 14A
24T920
200-240 VAC, 1-ph, 50/60 Hz, 40A
200-240 VAC, 3-ph, ˂, 50/60 Hz, 40A
350-415 VAC, 3-ph, Y, 50/60 Hz, 30A
24V203
400-480 VAC, 3-ph, ˂, 50/60 Hz, 14A
Electrical
Maximum Applicator 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)
333347B
400 W
4 inputs (0-30V), 4 outputs (240VAC, 24VDC, 2A)
1/4 in. (6 mm), round, adhesive pellets
130 lb/hr
59 kg/hr
6.2 cc/cycle
Less than 15 minutes
50 lb/hr
22.6 kg/hr
Pneumatic Piston, 12:1
1 to 6
19.0 x 42 x 16.5 in.
483 x 1067 x 419 mm
0.4 x 4.0 ft
105 lb
0.12 x 1.22 m
48 kg
80-100 psi
0.55-0.69 MPa (5.5-7 bar)
20-100 psi
240-1200 psi
100-400°F
32-120°F
0.14-0.69 MPa (0.7-7 bar)
1.7-8 MPa (17-80 bar)
38-204°C
0-49°C
30 ft
10 ft
9.1 m
3.0 m
40-100 psi
280-690 kPa (2.8-6.9 bar)
9.5 scfm (intermittent duty; 4% at
25 lb/hr)
17.2 scfm (intermittent duty; 4% at
25 lb/hr)
16.1 scmh (intermittent duty; 4% at
11.3 kg/hr)
29.2 scmh (intermittent duty; 4% at
11.3 kg/hr)
119
Technical Data
InvisiPac Hot Melt Delivery System
US
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
Sound Pressure Level***
IP Code
InvisiPac Base System
Wetted Parts
Wetted Parts
Approvals and Standards
30 Gallon Vibrating Hopper
Required Air Pressure Supplied To 30 Gallon
Vibrating Hopper
Air Consumption
Metric
3/8 in.
9.5 mm
1/2 in.
12.7 mm
77 dB(A)
IP54
PTFE, chemically resistant o-rings, aluminum, stainless steel, zinc plating, carbon steel, brass, carbide, chrome
UL499, CSA88, CE, ISO
100 psi
0.7 MPa (7 bar)
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.
120
333347B
Technical Data
Startup Time
Single Phase
NOTE: Times are approximate and may vary with ambient conditions, voltage configuration, and machine configuration.
Start Time in Minutes
20 Amp 30 Amp 40 Amp 50 Amp 20 Amp 30 Amp 40 Amp 50 Amp
Channels Hose Length Breaker Breaker Breaker Breaker Breaker Breaker Breaker Breaker
(#)
ft (m)
240V
240V
240V
240V
208V
208V
208V
208V
1
4 (1.2)
17
15
15
15
20
20
20
20
12 (3.6)
1
19
15
15
15
21
20
20
20
25 (7.6)
1
21
15
15
15
24
20
20
20
4
(1.2)
2
19
15
15
15
21
20
20
20
12 (3.6)
2
23
15
15
15
26
20
20
20
25
(7.6)
2
27
17
15
15
30
20
20
20
4 (1.2)
3
21
15
15
15
24
20
20
20
12
(3.6)
3
27
17
15
15
30
20
20
20
25 (7.6)
3
32
21
15
15
36
23
20
20
4 (1.2)
4
23
15
15
15
26
20
20
20
12
(3.6)
4
30
19
15
15
34
22
20
20
25 (7.6)
4
37
24
18
15
42
27
20
20
4
(1.2)
5
25
16
15
15
28
20
20
20
12 (3.6)
5
34
22
16
15
38
25
20
20
25 (7.6)
5
42
28
20
16
48
31
23
20
4
(1.2)
6
27
17
15
15
30
20
20
20
12 (3.6)
6
37
24
18
15
42
27
20
20
25
(7.6)
6
47
31
23
18
54
36
26
21
333347B
121
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
6
122
Hose
Length
ft (m)
4 (1.2)
12 (3.6)
25 (7.6)
4 (1.2)
12 (3.6)
25 (7.6)
4 (1.2)
12 (3.6)
25 (7.6)
4 (1.2)
12 (3.6)
25 (7.6)
4 (1.2)
12 (3.6)
25 (7.6)
4 (1.2)
12 (3.6)
25 (7.6)
20 Amp 30 Amp 40 Amp 50 Amp 20 Amp
Breaker Breaker Breaker Breaker Breaker
240V
240V
240V
240V
208V
17
15
15
15
20
19
15
15
15
20
21
15
15
15
22
19
15
15
15
20
23
15
15
15
24
26
18
15
15
28
20
15
15
15
22
26
17
15
15
28
31
21
16
15
34
22
15
15
15
24
28
19
15
15
32
35
24
18
15
40
22
16
15
15
26
31
21
16
15
36
40
27
20
16
47
24
16
15
15
28
34
23
17
15
40
45
30
23
18
53
30 Amp
Breaker
208V
20
20
20
20
20
20
20
20
23
20
22
27
20
24
31
20
27
35
40 Amp
Breaker
208V
20
20
20
20
20
20
20
20
20
20
20
20
20
20
24
20
20
27
50 Amp
Breaker
208V
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
21
333347B
Technical Data
Dimensions
System Dimensions
Mounting Hole Dimensions
WALL
2.0 in.
(51 mm)
22.3 in.
(566 mm)
101 in. (257 mm)
35.8in.
(909 mm)
5.3 in. (133 mm)
Minimum distance from rear mounting
hole to wall: 7.0 in. (178 mm)
18.3 in.
(465 mm)
WLD
System With 480V Transformer
3.3 in.
(84 mm)
7.1 in. (180 mm) 3.3 in.
14.2 in.
(84 mm)
WLD
(361 mm)
41.9 in.
(1064 mm)
22.3 in.
(566 mm)
18.3 in.
(465 mm)
WLD
333347B
123
Technical Data
System with Stand and Vacuum Feed Dimensions
Tube Bend Radius:
8.0 in. (203 mm)
12.0 in.
(305 mm)
A
ti22866a
A
in. (mm)
System
60.7 in. (1542 mm)
System With Transformer
66.5 (1689 mm)
30.0
(762 mm)
17.4
(442 mm)
27.2 in.
(692 mm)
ti22865a
Radius:
9.1 in. (232 mm)
31.3
(795 mm)
124
333347B
Technical Data
333347B
125
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 333347
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision B, May 2014

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