Graco 3A2347W - InvisiPac HM25 Tank-Free Hot Melt Delivery System Instructions

Instructions - Parts
InvisiPac™
HM25 Tank-Free™
Hot Melt Delivery System
3A2347W
EN
For delivering and dispensing hot melt adhesive pellets. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
1200 psi (8.3 MPa, 83 bar) Maximum Working Pressure
400°F (204°C) Maximum Fluid Operating Temperature
100 psi (0.7 MPa,7 bar) Maximum Air Inlet Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual and in the gun and hose manuals.
Save all instructions.
ti20440b
9902471
Certified to
CAN/CSA C22.2 No. 88
Conforms to
ANSI/UL 499
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Identification . . . . . . . . . . . . . . . . . . . 8
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Attach Components . . . . . . . . . . . . . . . . . . . . . 13
Recommended Air Setup . . . . . . . . . . . . . . . . . 17
Connect Electrical Cord . . . . . . . . . . . . . . . . . . 18
480V Electrical Circuits . . . . . . . . . . . . . . . . . . . 20
208V Electrical Circuits . . . . . . . . . . . . . . . . . . . 20
Select ADM Settings . . . . . . . . . . . . . . . . . . . . . 20
Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PLC Connection . . . . . . . . . . . . . . . . . . . . . . . . 23
Material Tracking . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Initial Startup and Prime . . . . . . . . . . . . . . . . . . 29
Manual Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Automatic Refill . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pressure Relief Procedure . . . . . . . . . . . . . . . . 33
Drain the System . . . . . . . . . . . . . . . . . . . . . . . . 33
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operation Tips to Minimize Charring . . . . . . . . . 36
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replace Outlet Filter . . . . . . . . . . . . . . . . . . . . . 37
Replace Inlet Filter . . . . . . . . . . . . . . . . . . . . . . 37
Replace Funnel Filter . . . . . . . . . . . . . . . . . . . . 38
Filter Maintenance Guidelines* . . . . . . . . . . . . . 39
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
ADM Error Code Table . . . . . . . . . . . . . . . . . . . 40
MZLP Troubleshooting . . . . . . . . . . . . . . . . . . . 53
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2
Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Multi-Zone Low Power Temperature Control Module
(MZLP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Software Update Procedure . . . . . . . . . . . . . . . 74
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 76
Incoming Power and Terminal Jumpers . . . . . . . 76
Typical Hose Applicator Wiring . . . . . . . . . . . . . 80
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Inlet Funnel Filter Kit, 24U701 . . . . . . . . . . . . . . 93
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Preventive Maintenance Kit . . . . . . . . . . . . . . . . 95
Complete Maintenance Kit . . . . . . . . . . . . . . . . 95
Non-Graco Gun Adapter Cables . . . . . . . . . . . . 96
Air Adjustment Lock, 24R084 . . . . . . . . . . . . . . 97
System Stand, 24R088 . . . . . . . . . . . . . . . . . . . 98
Caster for Stand, 120302 . . . . . . . . . . . . . . . . . 98
Adapter Plate, 24R083 . . . . . . . . . . . . . . . . . . . 98
30 Gallon Vibrating Hopper, 24R136 . . . . . . . . . 99
Light Tower Kit, 24R226 . . . . . . . . . . . . . . . . . . 101
Air Reservoir Kit, 16W366 . . . . . . . . . . . . . . . . 102
Air Metric Fitting Kit, 24W637 . . . . . . . . . . . . . 110
Material Tracking Kit, 24Y162 . . . . . . . . . . . . . 110
Appendix A - ADM . . . . . . . . . . . . . . . . . . . . . . . . 111
General Operation . . . . . . . . . . . . . . . . . . . . . . 111
Icon Identification . . . . . . . . . . . . . . . . . . . . . . . 111
Appendix B - USB Downloading, Uploading . . . 117
Download Procedure . . . . . . . . . . . . . . . . . . . . 117
Accessing Files . . . . . . . . . . . . . . . . . . . . . . . . 117
Upload Procedure . . . . . . . . . . . . . . . . . . . . . . 117
USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
System Settings File . . . . . . . . . . . . . . . . . . . . 118
System Language File . . . . . . . . . . . . . . . . . . . 119
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Graco Extended Warranty . . . . . . . . . . . . . . . . . . 126
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 126
3A2347W
Related Manuals
Related Manuals
Manuals are available at www.graco.com. Component
manuals in English:
Part
Description
3A2805
InvisiPac GS35 Hot Melt Gun Instructions Parts
InvisiPac Heated Hose Instructions - Parts
MZLP Fuse Kit, Instructions
InvisiPac Pattern Controller, Operations-Repair-Parts
Dedicated Feed Sensor Air Kit
332072
333348
334784
335010
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
3A2347W
•
•
•
•
•
•
•
•
•
1 in. socket
13 mm socket
10 mm socket
1/2 in. ratchet
Side cutter
Phillips head screwdriver
Flat head screwdriver
Multimeter
Tubing cutter
3
Models
Models
NOTICE
To prevent system damage, verify terminal jumpers
are installed correctly before applying power.
Model Channels
Voltage
˓ Type
24P260
2
200-240VAC
1˓ / PE
24P261
4
200-240VAC
1˓ / PE
24P262
2
350-415VAC Y
3˓ / Neutral / PE
24P263
4
350-415VAC Y
3˓ / Neutral / PE
Description
• 1-Phase
• 200-240VAC
50/60 Hz
32A
• 2 wire and PE
• 3-Phase with Neutral
• 350-415 VAC Line to
Line
• 200-240VAC Line to
Neutral
• 3 wire and Neutral and
50/60 Hz
40A
50/60 Hz
16A
50/60 Hz
16A
50/60 Hz
27A
50/60 Hz
27A
50/60 Hz
40A
50/60 Hz
30A
50/60 Hz
40A
24P264
2
200-240VAC ˂
3˓ / PE
24P265
4
200-240VAC ˂
3˓ / PE
PE
• 3-Phase without
Neutral
• 200-240 VAC Line to
Line
1˓ / PE
• 3 wire and PE
• 1-Phase
• 200-240VAC
24U132
24U133
24U134
6
6
6
200-240VAC
350-415VAC Y
200-240VAC ˂
3˓ / Neutral / PE
3˓ / PE
Max
Frequency Amps
• 2 wire and PE
• 3-Phase with Neutral
• 350-415 VAC Line to
Line
• 200-240VAC Line to
Neutral
• 3 wire and Neutral and
PE
• 3-Phase without
Neutral
• 200-240 VAC Line to
Line
• 3 wire and PE
4
3A2347W
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.
3A2347W
5
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.
6
3A2347W
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.
3A2347W
7
Component Identification
Component Identification
G3
G2
G4
A
G
H
G1
F
E
C
L
D
B
K
Key:
A
B
C
D
E
F
G
G1
G2
G3
G4
H
J
K
L
M
N
P
R
S
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 1-4)
Customer I/O Cable (optional)
N
R
M
P
S
ti20441b
J
FIG. 1
8
3A2347W
Component Identification
Heated Fluid Manifold
AB
Z
Y
U
R
X
AA
T
W1
W2
ti20442b
NOTE: System shown with plastic and metal shrouds removed.
FIG. 2
Key:
T
U
W1
W2
X
Y
Electrical Enclosure Front Access Door
Melter
Drain Port
Drain Tray
Inlet Filter (Low Pressure - Before Pump)
Outlet Filter (High Pressure - After Pump)
3A2347W
Z Adhesive Pellets Level Sensor
AA Power and RTD Harness Connection to Heated Hose and
Gun (harness connects from system to heated hose then
from heated hose to gun)
AB Inlet Funnel Screen
9
Component Identification
Electrical Enclosure
AC
AJ
P
ti20907b
AH
AF
AG
FIG. 3
Key:
P
Multi-Zone Low Power Temperature Control Module
(MZLP)
AC Incoming Power Connection
AF Chassis Ground
10
AG Terminal Blocks and Jumpers
AH Heater Relay
AJ Incoming Power Terminal Jumpers. See page 18.
3A2347W
Component Identification
Advanced Display Module (ADM)
B
User Interface
NOTICE
To prevent damage to soft key buttons, do not press
the buttons with sharp objects such as pens, plastic
cards, or fingernails.
NOTE: See Appendix A - ADM on page 111 for complete ADM operation details.
BB
BC
BA
Ke
y
BA
BB
BC
BD
BE
BF
Function
Heating system and pump enable/disable
System status indicator (LED)
Stop all system processes
Defined by icon next to softkey
Abort current operation
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
BD
BK
BL
BE
BF
BH
BP
TI12362a1
FIG. 4
BM
BR
BG
BN
FIG. 5
Key:
BK Part Number Identification Label
BL USB Interface
BM CAN Cable Connection (Power Supply and Communication)
BN Module Status LEDs
BP (Not used)
BR Software Token Access Panel
3A2347W
11
Component Identification
Screen Components
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
The system is increasing the material
to the set temperature.
Active
The system is ready to dispense
material.
12
•
•
•
•
•
•
•
•
•
•
•
No System Status Indicator LED on the
ADM
No heat
Pump is off
Yellow system status indicator LED on the
ADM
No heat
Pump is off (manually changed)
Flashing green system status indicator LED
on the ADM
Heat is increasing to setpoint temperature
Pump is off
Solid green system status indicator LED on
the ADM
Heat is at setpoint temperature
Pump is on
3A2347W
Setup
Setup
Grounding
Attach Components
The equipment must be grounded to reduce the risk
of electric shock. Improper grounding can cause
electric shock. Grounding provides an escape wire
for the electric current.
The InvisiPac system is equipped with a ground terminal. Have a qualified electrician ground the system
using this terminal. See Connect Electrical Cord on
page 18.
To reduce the risk of electric shock, do not connect
electrical cord until after this Attach Components
procedure is complete.
1. Place the base system in the desired operating
location and orientation. See Location on this page.
•
The bottom of the electrical enclosure has holes for
securing the InvisiPac system to a surface. The
holes are accessible through the bottom access
doors in the three rear walls of the electrical enclosure.
•
To install the InvisiPac system in place of a
non-Graco hot melt system, purchase Adapter
Plate, 24R083. See installation instructions on
page 98.
•
To raise the system to eye-level, purchase System
Stand, 24R088. See installation instructions on
page 98.
Location
Ambient temperature must be 32-120°F (0-49°C).
The supplied vacuum transfer hose length is 10 ft (3 m).
The maximum vacuum transfer hose length available is
30 ft (9.1 m). The adhesive pellets container must be
located within reach of the vacuum transfer hose and no
more than 30 ft (9.1 m).
The gun(s) must be located no more than 25 ft (7.6 m)
from the melter.
Place the base system on a surface that is eye-level for
easiest operation. Use System Stand, 24R088, to
install system at eye-level. See page 98.
If installing the system in place of a non-Graco hot melt
system, purchase Adapter Plate, 24R083. See
page 98.
NOTE: Supplied vacuum transfer hose must reach from
the system to the adhesive pellets container. Supplied
heated hose must reach from system to gun(s).
2. Install vacuum transfer inlet funnel (G3) onto system. See FIG. 7.
Optional 30 Gallon Vibrating Hopper, 24R136, available (purchase separately). See page 99.
a. Slide funnel through the bracket connected to
the air motor.
To make repairing the system easier, locate the system
so that all sides are easily accessible and have sufficient
lighting.
b.
Position the funnel so the funnel inlet faces the
desired direction.
c.
Connect 5/32 in. OD air line to funnel.
3A2347W
13
Setup
d. Install supplied hose clamp around the air motor
bracket and funnel base then tighten.
6. Apply pipe sealant to threads then attach steel
shaker tube (G) to shaker head (G1). See FIG. 8.
NOTICE
G2
G3
To prevent shaker head (G1) galling to the shaker
tube (G), do not overtighten shaker head onto shaker
tube. These should be hand-tightened.
G7
G2
G6
G4
G5
ti21130b
FIG. 7
G
3. Insert 1.3 in. (33 mm) OD clear vacuum transfer
hose (G2) into vacuum transfer funnel (G3) inlet and
secure with supplied hose clamp. See FIG. 7.
G4
G1
4. Connect the long supplied 3/8 in. OD air line (G4) to
the 3/8 in. push-to-connect fitting on the air line from
the system. See FIG. 7.
FIG. 8
NOTE: To rotate funnel, loosen set screws (qty 4, G7)
1/4 turn each. Once funnel is aligned properly, hand
tighten screws back down.
7. Attach 1.3 in. (33 mm) clear vacuum transfer hose
(G2) to steel shaker tube (G) and secure with supplied hose clamp. See FIG. 8.
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.
8. Route the 3/8 in. OD air line (G4) alongside the
1.3 in. (33 mm) clear vacuum transfer hose (G2)
and secure at multiple points with the supplied zip
ties (G5). See FIG. 8.
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.
9. If desired, secure the 1.3 in. (33 mm) clear vacuum
transfer tube and 3/8 in. OD air line with zip ties to a
supporting structure at various points in the routing.
5. Route the 1.3 in. (33 mm) OD clear vacuum transfer
hose from the system to the adhesive pellets container location.
14
ti21131a
10. Attach the other end of the long 3/8 in. OD air line
(G4) to the 3/8 in. push-to-connect fitting on the
shaker head (G1).
11. Ensure the adhesive pellets container is in the
desired operating location. The location should be
chosen to make it easy to fill the container with pellets.
3A2347W
Setup
12. 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 99.
d. Remove plug (247) from the lowest numbered
outlet on the melter. Do not use the drain
plug (W1). See FIG. 9.
NOTE: In the following step, the o-ring side of the
hydraulic fitting (68) faces the system. See FIG. 9.
NOTE: If static buildup on feed tube (G) is excessive,
install optional feed tube ground kit 24R708 to feed tube
end (G6). See FIG. 8.
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.
13. Install heated hoses, see FIG. 9:
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
247
Gun
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. 9.
h. Repeat the procedure for the remaining channels. Use the bottom melter ports first to ease
installation.
68
i.
W1
W2
AA
ti21132a
FIG. 9
a. Place a rag on the drain tray (W2) attached to
the melter. Residual oil may be in the system
from the factory. See FIG. 9.
b.
Use a 1/4 in. allen wrench to remove the drain
port plug (W1). See FIG. 9.
NOTE: A 1/4 in. allen wrench is shipped loose with the
system.
c. When fluid stops draining, re-install drain port
plug (W1) then remove rag. See FIG. 9.
3A2347W
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).
Install cap on any unused MZLP electrical connectors.
NOTE: Fluid outlet port 1 must be used and electrical
connector from that hose must be connected to MZLP
connector 1. The system will not operate unless a hose
is connected to MZLP connector 1. If a hose is not connected to connector 1, “Invalid Sensor - hose/gun” faults
will result.
14. Install gun(s), see FIG. 9:
NOTE: Use of a Graco gun is not required with this system. However, all guns attached to the system must be
rated for 1200 psi (8.3 MPa, 83 bar), 400°F (204°C),
have an RTD type sensor, and use no more than 400W.
a. Connect heated hose fluid outlet to gun fluid
inlet. Use 11/16 in. wrench to tighten. See FIG.
9.
b.
For Graco guns, attach gun electrical connector
to heated hose electrical connector. See FIG. 9.
15
Setup
c.
For non-Graco guns, attach gun electrical connector to adapter harness (16T916, 16T917, or
16Y828) then attach adapter harness connector
to heated hose connector. See Non-Graco
Gun Adapter Cables on page 96 to determine
which adapter cable to use with your valve.
17. If using the same air for the gun(s), make sure to
install the tee in the air line before the ball valve.
There should not be anything between the ball valve
and the system. See gun manual for gun air pressure requirements, and use a regulator before the
gun to decrease the air pressure, if necessary.
18. Close the ball valve.
d. Repeat for any additional guns.
15. If necessary, set up the valve controller to control
opening and close the gun. See gun manual.
NOTE: The system controls gun heating only. A separate gun controller must be set up to open and close the
guns.
WLE
16. Install the supplied air inlet bleeding ball valve and
air filter kit (Graco Part No. 24R707) at the 1/4 NPT
female system air inlet (J). See FIG. 10.
ti21147a
FIG. 11
19. Attach a 3/8 in. minimum air supply line to air filter.
See FIG. 11.
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 102.
20. To lock access to the air pressure adjustments, purchase . See installation instructions on page 96.
WLE
FIG. 10
21. To install a light tower that illuminates red when a
system error occurs, purchase Light Tower Kit,
24R226. See installation instructions on page 101.
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.
22. To upgrade a 2 channel system to a 4 channel system, purchase 4 Channel Upgrade Kit, 24R237.
See installation instructions on page 103.
ti21133a
NOTE: The system must use an air filter with a minimum flow rate of 30 scfm.
16
23. Install MZLP electrical connector caps on all unused
channels.
3A2347W
Setup
Recommended Air Setup
Main Air Line
Air In:
Less than 50 ft (15.2 m): 3/8 in.
More than 50 ft (15.2 m): 1/2 in.
80-100 psi
(5.5-6.8 bar, 0.55-6.8 MPa)
30 scfm capacity.
No dips in vacuum
transfer hose
Air In:
3/8 in.,
100 psi
(6.8 bar, 0.68 MPa),
30 scfm capacity
Regulator
Ensure funnel air
is connected
Air Filter/Ball Valve at
System Air Inlet
(Graco Kit 24R707,
included)
Vacuum
Pump
Vacuum:
40 - 80 psi (2.8-5.5 bar,
0.28-0.55 MPa);
Pump:
20-100 psi
WLF
Hopper
Shaker
InvisiPac
Vacuum
Feed Air
Regulator set to
70 psi
(4.8 bar, 0.48 MPa)
Air to applicators
Pilot
Valve
Plant Air
Supply
FIG. 12
If plant air pressure is >90 psi, add air regulator kit to the
24H420 to the air supplying the hopper shaker. Regulate the shaker air according to the vacuum feed pressure according to the table below.
NOTE: Using vacuum feed air pressure higher than
necessary may cause the melter to over fill and Interrupt
production
Vacuum Feed air Max air pressure
pressure
to hopper
40 psi (2.8 bar)
60 psi (4.1 bar)
50 psi (6.4 bar)
75 psi (5.2 bar)
60 psi (4.1 bar)
90 psi (6.2 bar)
70 psi (4.8 bar)
105 psi (7.2 bar)
80 psi (5.5 bar)
120 psi (8.3 bar)
3A2347W
17
Setup
Connect Electrical Cord
NOTE: See Grounding section on page 13.
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 13 prior to connecting electrical cord.
NOTE: The installed strain relief bushing (106) fits a
0.708-1.260 in. OD electrical cord. See FIG. 14. If
needed, use a wrench to tighten the strain relief bushing
until it is snug on the cable.
NOTE: Tubing 17F777 and 17F779 is included for
smaller diameter electrical cord. Place around the power
cord and secure in the strain relief brushing (106).
Terminal Block Jumper Installation Guide
Terminal Block Location
Jumper 2-Terminal 3-Terminal 5-Terminal
Voltage
Wire
Jumper
Jumper
Jumper
127201
126814
126815
126816
200-240VAC,
Not used Not used
3-5
6-10
1 phase
350-415VAC,
5-6,
3 phase,
Not used
2-4
Not used
8-9
WYE
200-240VAC,
4-5,
3 phase,
3-7
6-8
Not used
9-10
DELTA
NOTE: The jumpers only need to be changed if using a
different phase or voltage from what the system was
designed for at the factory.
NOTE: All necessary jumpers are supplied with the system in a bag located behind the electrical enclosure
front access panel. Keep unused jumpers in bag.
2-Terminal
126814
NOTE: The accessory strain relief bushing kit 24x190 is
available for smaller (0.512-1.024 in, 13-26 mm) OD
electrical cords. See Accessories, page 107.
3-Terminal
126815
5-Terminal
126816
ti21182a
Wire
127201
For 480V Electrical Circuits, see page 20.
1. Turn main power switch OFF.
FIG. 13: Jumpers
2. Disconnect cable from ADM, push cable through
plastic shroud, then remove plastic shroud from system.
NOTE: Use the supplied hard metal 2, 3, and 5 terminal
jumpers and jumper wire for terminals 2C-10C. Use the
red, plastic jumpers for terminals 11-14.
3. Remove electrical enclosure access door (T). See
FIG. 2 on page 9.
5. Insert electrical cord through electrical enclosure
strain relief bushing (106). See FIG. 14 on page 19.
4. Ensure the terminal block jumpers are in the correct
locations for the phase and voltage used. If necessary, change them to match FIG. 15 on page 19.
See the following table, FIG. 13, and FIG. 15.
a. Alternate electrical cord routing: using conduit,
run electrical cord from access port (X) through
hole (Y). Conduit is required when routing wires
near compressed air components.
NOTICE
To prevent system damage, verify terminal jumpers are
installed correctly before going on to the next step.
18
3A2347W
Setup
6. Attach insulated ferrules to the end of each wire.
7. Connect ground wire to chassis ground (AF). See
FIG. 14.
106
8. Connect L1, L2, L3, and N as shown in FIG. 15. Not
all models use all 4 wires.
9. Use zip ties to secure the electrical cord to the
tie-downs located on the top of the inside of the
electrical enclosure.
Y
X
10. Tighten screw-terminals to at least 10 in-lb
(1.1 N•m).
11. Install electrical enclosure door.
AF
FIG. 14
ti20907b
12. Perform Select ADM Settings on page 20 prior to
turning on heat.
FIG. 15
3A2347W
19
Setup
480V Electrical Circuits
3. On the System 2 screen:
For 480V electrical supply, a 480V to 240V step-down
transformer must be installed by a qualified electrician.
Transformer Sizing
For single-phase power, 480V to 240V transformer
24U169 (purchase separately) may be used. See Single-Phase 480V to 240V Transformer, 24U169 on
page 107.
Minimum transformer rating can be calculated by taking
output voltage times the ADM setting.
Single Phase, 20A ADM Breaker Setting Example:
240 volts x 20 amps = 4800 watts
a. Check the box in the “Installed” column for each
channel that has a heated hose and gun
installed.
b.
Three Phase, 20A ADM Breaker Setting Example:
240 volts x 20 amps x ෭ (3) = 8315 watts
Select the RTD type used on each installed
gun. See gun manual.
NOTE: An incorrect RTD setting will cause the system
to be incapable of maintaining the temperature setting.
208V Electrical Circuits
For 208V electrical supply, a qualified electrician can
install a 208V to 240V step-up transformer to improve
startup times.
Transformer Sizing
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.
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
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 111 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
a. Enter the main circuit breaker size used. This is
the circuit breaker installed external to the system for the system power supply.
between screens.
20
3A2347W
Setup
NOTE: If using a 480V to 240V transformer, the breaker
size entered will be two times the 480V rating. If using
transformer 24U169, the breaker size should be set to
30 amps and power type should be set to single phase.
NOTE: The 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.
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.
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 111, for
detailed information about each setup item.
b.
Select the incoming power type.
5. On the Advanced 1 screen, set the system date and
time.
9. Press
to switch from the Setup screens to the
Operation screens. Use
,
,
, and
to
navigate between screens.
10. On the Targets screen, use
next to
and
, shown
, to adjust system melter setting.
Also, the desired temperature setting can be typed
in using the numeric keypad.
6. On the Advanced 2 screen, set the temperature and
mass units.
7. To setup the optional Schedule function, see
Schedule on page 32.
3A2347W
21
Setup
11. On the Targets screen, adjust heated hose and gun
temperature settings:
NOTE: InvisiPac is a high powered tank-free system
that delivers heat faster than traditional tank systems.
Tanks are often run at a lower temperature than the
application temperature to avoid excessive adhesive
degradation since a large volume of adhesive sits at
temperature.
a. Press
to select the channel.
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.
NOTICE
b.
Use
and
, shown next to
, to
adjust gun temperature setting to the desired
setting for that channel.
NOTE: If a higher applicator temperature is desired,
adjust all zones to the higher temperature or adjust only
the applicator in small increments.
NOTE: Alternatively, use the physical up and down
arrow push-buttons on the ADM keypad until
is
next to the temperature setting to change then use the
numeric keypad to enter the desired temperature.
22
Set melter, hose, and gun to the same setpoint temperature for best performance. Do not set the hose
temperature higher than the melter. Running the hose
at a setpoint higher than the melter is unnecessary in
this tank-free system and could lead to adhesive degradation in the hose. Short adhesive residence time in
the melter eliminates the need to set the melter at a
lower setpoint than other zones. See Operation Tips
to Minimize Charring, page 36.
Guns
Gun heating is controlled by the InvisiPac system. A
pattern controller is required to control the opening and
closing of guns. If using an InvisiPac Pattern Controller,
refer to manual 334784 - InvisiPac Pattern Controller for
details on wiring and setup.
3A2347W
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 8.
5. Remove power from PLC.
Enable or disable hose and gun heating for that individual channel.
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.
F5
J7
Not used.
F8 F7
Disable
H2
F10 F9
Description
H1
F6
Customer Output Dropdown Options
Option
J3
Channel 1, 2, 3,
or 4 Enable/Disable
J5
Turn on or off the heating system and
pump.
J6
Heater On/Off
F1
Not used.
F2
Disable
NOTE: Each connector has four signals. The MZLP
board specifies the input range for each signal. See the
following table for pin assignments.
J1
Description
J2
Option
6. Connect the PLC to connectors H1 and H2.
F4 F3
Customer Input Dropdown Options
FIG. 16: 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.
3A2347W
23
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. 17: Customer Input
MZLP Customer Out
Customer In
250 VAC, 2A Max
To Customer Input
FIG. 18: Customer Output
24
3A2347W
Setup
Material Tracking
The material tracking function allows the user to track
product counts and material usage for long term data
collection.
Viewing the Log
In order to view the log, navigate to the Home screen
and press the material log softkey
(see below).
Different system types will have different data shown in
the material log. The chart below outlines what data is
shown for each system type.
System Type Date Cycles
InvisiPac
X
X
InvisiPac w/
ADM Unit
X
Counter
InvisiPac w/
Pattern ConX
troller
X
X
X
X
X
X*
* See Material Tracking Coverage for pattern Controller
Systems.
To exit the log, press the screen exit softkey
.
Once inside the log (see below), use the up/down arrow
keys to view previous data. The log stores up to 200
rows of data including the following:
Item
Icon
Date
N/A
Cycles
N/A
Material Used
Program
Products
Material per Product
3A2347W
25
Setup
Material Tracking Coverage for Pattern Controller Systems
Material Used
Line Configuration
Diagram
(
)
Products per Line Material per Product
(
)
(
)
Single Line
X
X
X
Multi-Unit Line
X
X
X*
Multi-Line
X
X
**
* Products on both parts of the line must be the same in order to generate accurate material per product data.
** Accurate material per product data cannot be generated for multi-line configurations (assumes different products).
26
3A2347W
Setup
Calibration
3. To calibrate using the purge method:
a. Obtain a scale and a container.
b.
Perform the following steps to calibrate the material
tracking function:
1. Navigate tj the material Tracking Screen (Screen 4
of the System chapter).
Reset the calibration weight totalizer by press-
ing and holding the reset softkey
.
c. Tare scale with empty container and purge at
least 1 lb. of material into the container.
2. To calibrate using the tape and scrape method:
a. Obtain a scale.
b.
Place tape on a procudt(s) in locations where
material is dispensed.
c.
Run normal production (un-taped products) until
a value appears in the grams per product label
(this could take several minutes of production).
d. Weigh container with material.
e. Adjust the specific gravity setting until the
weight displayed in the totalizer matches the
value measured by the scale using the following
formula:
New SG Value = Durrent SG Value x Measured Weight /
Displayed Weight
d. Run taped products(s) through line and allow
material to cool and harden on the tape.
e. Scrape all material from product and place on
scale.
f.
Adjust the specific gravity setting until the grams
per product displayed matches the value measured by the scale using the following formula:
New SG Value = Current SG Value x Measured Grams
per Product / Displayed Grams per Product
3A2347W
27
Setup
Material Alerts
Reset Material Target
This feature can be used ot monitor material usage
based on a target material per unit value. If material
alerts are enabled the system wil lrecord an event every
time the system deviates over 20% from the target. The
material alert information can be seen in the bottom left
corner of the material log (see image below).
To reset the material target value, press the reset mate-
Enable/Disable Material Alerts
NOTE: the material target will be automatically reset
whenever a Pattern Controller setting is changed (e.g.
switch from solid bead to stitched bead).
To enable/disable material alerts, select/deselect the
Enable Material Alerts setting on the Material Tracking
Screen (Screen 4 of the System chapter).
28
rial target softkey
. An hourglass will appear
indicating that the system is learning the new target
(current machine output).
3A2347W
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 111 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 117 for detailed USB information.
Overview
The system includes a vacuum transfer system that
pulls the adhesive pellets into the system as needed.
Once melted, the adhesive enters the pump where it is
pumped into the heated hoses then to the heated guns.
The gun then briefly opens to dispense the desired
quantity of adhesive.
Even though the system rises to operating temperature
quickly, there is a Schedule function in the ADM that
eliminates waiting for the system to heat up. The Schedule function automatically enables the heating system at
the user-specified times so the system is ready to dispense when a shift begins. The Schedule function also
disables the heating system at user-specified times to
ensure the heating system is disabled when not being
used.
NOTE: All setup procedures must be completed prior to
initial startup. See Setup on page 13.
NOTE: Only 1/4 in. (6 mm) round hot melt adhesive pellets can be used in the InvisiPac system. PSA-type
adhesive pellets will not work in the InvisiPac system.
1. Direct the guns into an appropriate waste container.
2. Verify the shaker inlet is at the bottom of the empty
adhesive pellets container. Optional vibrating adhesive pellets container, part 24R136, is available.
See Accessories on page 94.
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.
WLE
6. Use pump air pressure regulator (C) to adjust pump
air pressure to 0. See FIG. 1 on page 8.
7. Use vacuum transfer air pressure regulator (E) to
adjust vacuum transfer air pressure setting to
40-100 psi (280-690 kPa, 2.8-6.9 bar). Recom-
3A2347W
29
Operation
mended setting is 60 psi (414 kPa, 4.1 bar). See
FIG. 1 on page 8.
NOTE: Vacuum transfer will not begin operating until
pump reaches operating temperature.
12. With the guns open and the system up to temperature, slowly increase pump air pressure until the
pump begins to run very slowly. Approximately 20
psi (140 kPa, 1.4 bar) should be sufficient.
NOTE: Operation may be erratic below 20 psi (140 kPa,
1.4 bar).
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.
13. Continue running the pump until clean, air-free
material is dispensed from each gun.
14. When each gun is fully primed, adjust pump to
desired pressure setting:
a. Adjust pump pressure to between 20-100 psi
(140-690 kPa, 1.4-6.9 bar).
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.
b.
Use separate gun controller to repeatedly open
and close each gun while inspecting the dispense pattern.
8. On new systems only: temporarily adjust the melter
temperature to 250°F (121°C). See Select ADM
Settings on page 20 for instructions.
c.
Repeat until desired dispense pattern is
achieved.
9. Press
to enable the heaters and pump.
Manual Refill
NOTE: When system is up to temperature, the pump will
be activated automatically but will not start because
there is no air pressure supplied to the pump.
NOTE: When the melter is up to temperature, the
auto-fill function will initiate to fill the funnel with pellets.
10. On new systems only: After the melter has reached
250°F (121°C) and the funnel is filled with pellets,
set the melter temperature back to the desired operating temperature. See Select ADM Settings on
page 20 for instructions.
11. Use separate gun controller to open the guns and
keep them open.
NOTE: Use Automatic Refill whenever possible. The
system uses Automatic Refill by default and must be
manually changed to Manual Refill. Only use Manual
Refill if the Automatic Refill system is not functioning
properly and cannot be fixed in a timely manner. Perform service to automatic feed system as soon as possible to limit debris buildup on feed cap.
It is recommended to maintain a minimum flow rate of
1.5 lb/hour to prevent material from melting within the
feed cap and funnel. If production rate is below
1.5 lb/hour or system sits at temperature without dispensing for extended periods of time, use manual refilling with caution. System flow rate can be monitored by
enabling the Diagnostic screen.
NOTICE
In the following step, to prevent damage to the pump
due to pump cavitation, do not supply more than 20 psi
(140 kPa, 1.4 bar) air pressure to the pump until the
system is fully primed.
30
1. On the System 3 screen (in the Setup screens),
select “Manual” from the Refill mode dropdown.
2. Remove the phillips head screws then remove the
funnel cap from the funnel.
3A2347W
Operation
Automatic Refill
3. Fill the funnel with adhesive pellets.
The system uses automatic refill by default. If the automatic refill system is malfunctioning and cannot immediately be fixed, Manual Refill can be used.
To use automatic refill:
1. On the System 3 screen (in the Setup screens),
select “Automatic” from the Refill mode dropdown.
2. Verify shaker and tube are connected to the system.
See Attach Components on page 13.
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 8.
ti21154a
FIG. 19
4. Refill the funnel as needed to maintain the required
dispense rate.
5. When finished dispensing for the day, dispense into
a waste container until the material level is down to
the smallest diameter section of the funnel then continue purging material through the valve for an additional 75 pump strokes.
NOTE: This will lower the adhesive level within the feed
cap to the correct level to prevent any issues upon
startup the following production day.
NOTE: Pump strokes can be monitored on the Maintenance screen, or by counting pump changeovers. To
count pump changeovers, listen to the air motor exhaust
pulses; two exhaust pulses equals one pump cycle (two
strokes).
NOTE: The shaker inlet must be completely covered in
adhesive pellets in order for it to effectively pull pellets
into the tube.
4. If not already set, use vacuum transfer air pressure
regulator (E) to adjust vacuum transfer air pressure
setting to 40-100 psi (280-690 kPa, 2.8-6.9 bar).
Recommended setting is 60 psi (414 kPa, 4.1 bar).
See FIG. 1 on page 8.
NOTE: The system will automatically transfer the pellets
to the system as necessary.
Dispense
NOTE: Only hot melt adhesive pellets can be used in
the InvisiPac system.
1. If the system is empty or has air in the lines, perform
Initial Startup and Prime procedure on page 29.
2. If main power switch is OFF, turn main power switch
ON
ti21154a
.
NOTE: The main power switch should be left ON at all
times when using the Schedule function.
FIG. 20
3. Prepare for dispensing:
a. Verify air inlet ball valve (J) is open. See FIG. 1
on page 8.
3A2347W
31
Operation
b.
c.
Check pressure gauges (D, F) to verify vacuum
transfer and pump air pressures are set as
desired. See FIG. 1 on page 8.
If using Automatic Refill, see Automatic Refill
on page 31.
d. If using Manual Refill, see Manual Refill on
page 30.
e. Verify guns are closed.
4. Press
Shutdown
Press
to disable the heaters and pump. The
screen will say “Inactive”. If using the Schedule function,
the heaters and pump will be disabled automatically at
the set time. You will not need to press
if using the
Schedule function unless you wish to disable the heating system before the set time. If the heaters were manually disabled, the Schedule function will automatically
enable them at the next set time.
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.
NOTE: When system is up to temperature, the pump will
begin running automatically. It will stall at pressure
unless a gun is open. Material will be dispensed whenever a gun is open after the system is up to temperature.
5. When the system is up to temperature, use separate gun controller to open and close the guns as
desired to dispense material.
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.
NOTE: While operating the system, the actual temperatures of the hose, gun, and system melter are displayed
on the Home screen.
Set Schedule Times
NOTE: Times are set using a 24-hour clock. Several on
and off times can be set each day.
1. On the Schedule screen (in the Setup screens), set
the ON times for each day of the week.
2. Set the OFF times for each day of the week.
32
3A2347W
Operation
Drain the System
Enable Schedule Function
The Schedule function is automatically enabled when
values are entered in the Schedule screen. To disable
the Schedule function, delete all values on the Schedule
screen or turn the main power switch OFF to prevent
system from automatically enabling and disabling the
heaters.
How to Use the Schedule Function
At the end of the work day leave main power switch ON
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”.
. The Schedule function will automatically enable
and disable the heaters and pump at the specified
times.
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
2. If the heating system is disabled, press
to
enable the heaters and pump.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the Pressure
Relief Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
1. Turn main power switch OFF
.
2. Close the inlet air supply ball valve.
NOTE: Manually verify the pressure is relieved by opening the gun and ensuring no adhesive is dispensed.
3. Decrease pump air pressure to 0.
4. Close system air inlet ball valve.
5. Disconnect hose from gun inlet then place hose outlet in a waste container. Repeat for all hoses. Keep
hose to gun electrical connector connected.
6. Open gun to allow residual fluid in gun to drain.
7. When system is at operating temperature, slowly
increase pump air pressure until fluid begins flowing
into the waste container.
NOTE: It may take several minutes to empty the system. When there is no melter fluid at the pump, the
pump will begin to cycle faster.
8. When the pump begins to cycle faster, close the
system air inlet ball valve.
9. Press
to disable the heaters and pump.
10. Remove melter drain plug (W1). See FIG. 2 on page
9.
11. Disconnect hose from melter outlet.
3A2347W
33
Operation
12. Wait until system stops draining or at most 10 minutes.
5. On the System 3 screen (in the Setup screens), verify the Refill Setting is set to “Manual”.
NOTE: There will be some residual adhesive in the system.
13. When done performing the procedure that required
draining the system, set Refill Setting back to “Auto”
on the System 3 screen.
Flush
To prevent fire and explosion, use the adhesive manufacturer’s recommended cleaning fluid.
• Never exceed the cleaning fluid’s rated
temperature.
• Never flush your system or clean any aluminum
components with halogenated hydrocarbon
cleaning solutions.
To prevent severe burns, wear protective clothing.
NOTE: This procedure describes how to flush one hose
at a time for maximum effectiveness.
See the hot melt adhesive technical data sheet or
MSDS for the recommended cleaning fluid. Contact the
hot melt supplier if the technical data sheet or MSDS is
not available.
1. Perform Drain the System on page 33.
2. If the heating system is enabled, press
To prevent fire and explosion, never exceed the
cleaning fluid’s rated temperature.
6. Change the melter, heated hoses, and guns temperature settings to the high temperature hot melt
cleaning fluid manufacturer’s recommended temperature.
7. Verify the system air inlet ball valve is closed and
pump air pressure is set to 0.
8. Allow the system to heat or cool to the cleaning fluid
manufacturer’s recommended temperature.
9. Fill melter with high temperature rated hot melt
cleaning fluid. See hot melt adhesive material supplier for recommended hot melt cleaning fluids.
Fluid level should be 1/2 in. (12.7 mm) from the top
of the melter.
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 upper clamp then remove plastic melter
cap. Keep fill sensor attached to cap.
ti21053a
10. Disconnect one hose from its gun manifold.
NOTE: Keep all guns closed throughout this procedure.
34
3A2347W
Operation
11. Route the disconnected hose to a waste container.
12. If heating system is disabled, press
to enable
20. Remove and replace filter(s) in all gun manifolds.
See gun manual.
21. Replace Outlet Filter. See page 37.
the heaters and pump.
22. Turn main power switch OFF.
13. Wait for the melter temperature to reach the hot
melt cleaning fluid manufacturer’s recommended
temperature.
NOTE: The pump will not run because the system air
inlet ball valve is closed.
14. Once the required melter temperature is reached,
let the hot melt cleaning fluid “soak” in the melter at
temperature for the duration specified by the hot
melt cleaning fluid manufacturer.
NOTE: “Soaking” is important to ensure the best possible cleaning.
15. After the hot melt cleaning fluid has “soaked” for the
specified amount of time, open the system air inlet
ball valve. Slowly increase the pump air pressure
until pump begins to cycle to begin pumping the hot
melt cleaning fluid and adhesive mixture out through
the hose into the waste container.
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 9.
24. Allow the system and fluid to cool then perform any
required maintenance procedures beginning on
page 37.
25. Install fill cap onto melter rubber housing. Re-tighten
upper clamp to 25 in-lbs.
26. Slide funnel assembly through air motor bracket
then tighten clamp.
27. On the System 3 screen (in the Setup screens), set
the Refill Setting to “Auto”.
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 gun manifold.
19. Repeat steps 7 through 18 for each additional
installed hose, leaving a different hose disconnected from the gun manifold each time.
3A2347W
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 29.
35
Operation
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 32, 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.
NOTICE
Set melter, hose, and gun to the same setpoint
temperature for best performance. Do not set the
hose temperature higher than the melter. Running
the hose at a setpoint higher than the melter is
unnecessary in this tank-free system and could
lead to adhesive degradation in the hose. Short
adhesive residence time in the melter eliminates
the need to set the melter at a lower setpoint than
other zones.
36
3A2347W
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 guns. 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).
236
Replace Inlet Filter
232
237
To avoid severe burns, wear protective gloves and
clothing that will insulate your hands and body from
the hot surfaces and material.
The inlet filter is designed to prevent large items from
entering the system. The inlet filter can only be replaced
with the system empty.
1. Close the system air inlet ball valve.
28
8
ti20752a
FIG. 21
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 33 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. 21.
5. Use a 1 in. socket to unscrew outlet filter (236).
3A2347W
NOTE: Some adhesives have different melting points.
The first temperature tried should be approximately half
of the dispensing temperature. If dispensing at 400°F
(204°C), first try 200°F (93°C) then increase in 20°F
(11°C) increments. If dispensing at 250°F (121°C), first
try 125°F (52°C) then increase in 20°F (11°C) increments.
NOTE: To ensure the adhesive is a gel, not a liquid, do
not remove inlet filter cap (215) when the temperature is
above the desired temperature. If the temperature is too
low, the adhesive viscosity may be too high to remove
the inlet filter (213).
2. If the melter is below the desired temperature and
heating system is disabled, press
to enable
the heaters.
If the melter is above the desired temperature and
heating system is enabled, press
to disable
the heaters.
3. Wait until melter temperature is the desired temperature.
37
Maintenance
4. When the melter temperature is the desired temperature, turn main power switch OFF.
5. Disconnect cable from ADM, push cable through
plastic shroud, then remove plastic shroud from system.
6. Place a piece of cardboard beneath the inlet filter
cap (215) to route fluid away from system into a
waste container in the event the adhesive is a fluid.
7. Use 1 in. socket to remove inlet filter cap (215).
f.
Go to step 4.
9. Slide new screen (213) into melter base
manifold (201).
10. Install filter cap (215) then use a 1 in. socket to
tighten.
11. Feed ADM cable through plastic shroud (29) then
install shroud onto system. Connect cable to
ADM (30).
Replace Funnel Filter
701
213
705
215
707
706
201
ti20909a
FIG. 22
8. If the adhesive is a thin enough gel to remove the
inlet filter: Use an o-ring pick or small allen wrench
to remove filter screen (213) from system.
Otherwise:
a. Install inlet filter cap (215).
b.
Install shroud and ADM.
c. Turn main power switch ON.
WLF
FIG. 23
Disassembly (see FIG. 23):
1. Turn main power switch OFF.
2. Loosen and remove the two phillips head
screws (705) on the side of the funnel (706) then
remove the funnel cap (701).
3. Remove and replace foam filter (707).
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.
38
Reassembly (see FIG. 23):
1. Place funnel cap (701) onto funnel (706).
2. Install two phillips head screws (705) to secure funnel cap to funnel base.
3A2347W
Maintenance
Filter Maintenance Guidelines*
Environment Classification
Clean
Moderate
Dusty
Pump outlet filter
Gun manifold filter
System air filter
Solenoid exhaust filters
Feed funnel filter
Feed funnel inspection/clean out
Replace
filter every
six
months
Replace
filter every
four
months
Replace
filter every
two
months
* These recommendations are service level guidelines - actual service levels required in your factory will vary based
on environmental and operating conditions. High or low volume adhesive usage, as well as adhesives that contain a
powered release agent or are otherwise dusty, will have an impact on the frequency of filter maintenance. To
establish a preventative maintenance cycle tailored to your environment, Graco recommends inspecting filters every
4 weeks after installation and replacing when necessary. Document replacement intervals and use this as your
preventative maintenance schedule moving forward.
3A2347W
39
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, gun, or hose to which the error applies. The “_” (underscore)
character indicates the code applies to multiple items.
Last Digit in Code
0
1
2
3
4
5
6
7
8
9
A
B
C
Code Relates to:
Melter
Gun 1
Hose 1
Gun 2
Hose 2
Gun 3
Hose 3
Gun 4
Hose 4
Gun 5
Hose 5
Gun 6
Hose 6
An alarm will disable the heating system and pump. A deviation or advisory with not disable the heating system and
pump.
Code
A4D0
Description
High Current
Melter
Type
Alarm
Cause
Band heater or rod heater.
A4D_
High Current
Hose X
High Current
Gun X
Alarm
Hose power wires.
Alarm
Heater rods in gun manifold.
A4D_
40
Solution
Measure resistance to ground between
heater leads. Replace band heater or rod
heater. See Replace Band Heater (page 60),
or Replace Rod Heater (page 62).
Check heater resistance and resistance to
ground. Replace heated hose.
Check heater resistance and resistance to
ground. Replace gun manifold.
3A2347W
Troubleshooting
Code
A7D0
Description
Unexpected
Current
A7D_
Unexpected
Alarm
Current, Gun X
A7D_
Unexpected
Current, Hose
X
Alarm
A8D0
No Current
Melter
Alarm
A8D_
No Current
Hose X
Alarm
A8D_
No Current
Gun X
Alarm
CAC_
Comm Error
Module
Alarm
3A2347W
Type
Alarm
Cause
Unexpected current flow to melter.
Solution
Replace MZLP.
Check heater resistance and resistance to
ground. Replace heater(s).
Unexpected current flow to gun X. Replace MZLP.
Check heater resistance and resistance to
ground. Replace heater.
Unexpected current flow to hose X. Replace MZLP.
Check heater resistance and resistance to
ground. See hose manual for proper resistance range. Replace hose.
Power not getting to melter.
Check fuses F1 and F2 on MZLP with daughter board.
Check J1 is plugged into MZLP with daughter
board.
System needs a hose connected to Channel
1 or use the optional Overtemperature
Jumper, 16Y727.
Power not getting to hose.
Check fuses F5 and F6 or F9 and F10 on
MZLP that the error hose is connected to.
Check that electrical connector on the heated
hose is plugged into the MZLP.
Check continuity of pins C and D on electrical
connector at MZLP end of heated hose. See
heated hose manual for impedance measurements. Replace hose if readings are too high.
If system only uses one hose and gun, the
heated hose electrical connector must be
plugged into channel 1 of the MZLP.
Power not getting to gun.
Check fuses F3 and F4 or F7 and F8 on
MZLP that controls the error channel.
Check that electrical plug on hose is plugged
into back of MZLP.
Check continuity of hose pin A gun end to J
on MZLP connector end of hose and pin C on
gun end to pin A on the MZLP end of the
hose. Reading should be 0-1 ohm. Replace
hose if measurement is outside this range.
If system only uses one hose and gun, electrical connector of the heated hose must be
plugged into channel 1 of the MZLP.
System not responding to ADM.
System is not properly loaded with correct
software. Perform Software Update Procedure on page 74.
Dial not set correct on MZLP. Set to 1 on
board with daughter board. Set to 2 on MZLP
without the daughter board.
41
Troubleshooting
Code
CACX
Description
Missing DB
DADX
Pump Runaway
DDDX Pump Diving
DE0X
Cycle Switch
Error
L6FX
Level Sensor
Error
L8FX
Refill timeout
MMUX USB Log Full
T1D0
Low Temp
Melter
T1D_
Low Temp
Hose
42
Type
Alarm
Cause
System not acknowledging the
daughter board.
Solution
Bad connection between daughter board and
MZLP board. Loosen daughter board,
re-seat, then secure. If MZLP daughter board
does not respond to adjustment, replace
daughter board.
Alarm Pump is trying to feed adhesive, no Storage bin out of adhesive. Refill adhesive.
adhesive to feed.
Melter at incorrect temperature, to low. Check
setpoint and set to manufactures recommendation.
Plugged vacuum transfer hose or funnel.
Clear plugged hose or funnel.
Worn or damaged pump seals
Inspect pump seals. Repair if necessary.
Devia- Pump is trying to feed adhesive, no Storage bin out of adhesive pellets. Refill with
tion
adhesive to feed.
pellets.
Melter at incorrect temperature, too low.
Check melter temperature setting and set to
manufacturer’s recommendation.
Plugged vacuum transfer hose or funnel.
Clear plugged hose or funnel.
Feed rate for dispensing too high.
Worn or damaged pump seals
Inspect pump seals. Repair if necessary.
Alarm No signal from air motor sensor.
Check wiring on J16 of the daughter board.
See Electrical Schematics on page 76.
Loose cycle switch bold. Tighten cycle switch
bolt.
Replace cycle switch.
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.
Replace fill (level) sensor.
No air to fill cap.
Check for air coming from 5/32 in. air line.
Plugged orifice in fill cap below fill Remove fill cap and remove object plugging
sensor.
the orifice.
Alarm Melter did not receive enough
Storage bin out of adhesive. Refill adhesive.
adhesive pellets for flow rate.
Plugged inlet feed hose or funnel. Clear
plugged hose or funnel.
Advi- USB logs full. Data loss will occur if Download USB data. See Appendix B - USB
sory
not downloaded.
Downloading, Uploading on page 117.
Alarm Melter reached setpoint but
Check resistance of heater rods and band
dropped below setpoint and can
heater.
not recover.
Alarm Hose reached setpoint but dropped Check resistance of heated hose. Refer to
below setpoint and can not
hose manual for proper resistance range.
recover.
3A2347W
Troubleshooting
Code
T1D_
Description
Low Temp
Gun
Type
Alarm
T4C_
High MZLP
PCB Temp
Alarm
T4D0
High Temp
Melter
Alarm
T4D_
High Temp
Hose
Alarm
T4D_
High Temp
Gun
Alarm
T6D0
Sensor Error
Melter
Alarm
T6D_
Sensor Error
Hose
Alarm
T6D_
Sensor Error
Gun
Alarm
T8D_
No Temp Rise
in Gun (all
zones)
Alarm
T8D_
No Temp Rise
in Hose (all
zones)
Alarm
Cause
Gun reached setpoint but dropped
below setpoint and can not
recover.
MZLP board is overheating.
Solution
Check resistance of manifold heater rods.
Refer to gun manual for resistance value.
Ambient temperature must be under 120°F.
Replace MZLP board.
Melter continues to raise above the Verify connector J5 on MZLP board is
setpoint.
securely connected.
Replace melter RTD.
Hose continues to raise above the Hose electrical connector not plugged into
setpoint.
MZLP.
Replace hose.
Gun assembly continues to raise
Hose electrical connector not plugged into
above the setpoint.
MZLP or manifold electrical connector not
plugged into heated hose.
Replace gun RTD.
No reading from RTD.
Verify connector J5 on MZLP board is
securely connected.
Replace melter RTD.
No reading from RTD.
Hose electrical connector not plugged into
MZLP.
Replace hose RTD.
No reading from RTD.
Hose electrical connector not plugged into
MZLP or manifold electrical connector not
plugged into heated hose.
Replace gun RTD.
Temperature reading does not
Check fuses F3 and F4 or F7 and F8 on
change.
MZLP that error channel is connected to.
Check resistance of heater rods in gun manifold. Replace gun manifold.
Check resistance of hose wiring. See hose
manual for proper resistance range.
Temperature reading does not
change.
NOTE: Heater rods in the gun manifold can
also cause the no current error.
Check fuses F5 and F6 or F9 and F10 on the
MZLP that controls the error channel.
Defective heater wires in hose. Replace
heated hose.
Check resistance of hose wiring. See hose
manual for proper resistance range. Replace
heated hose.
NOTE: Heater wires in the hose can also
cause the no current error.
3A2347W
43
Troubleshooting
Code
T8D0
Description
No Temp Rise
in Melter (all
zones)
Type
Alarm
Cause
Temperature reading does not
change.
V1I_
Low Can Voltage
Alarm
Bad or overloaded power supply.
V4I_
High Can Volt- Alarm
age
No line voltage Alarm
Bad or overloaded power supply.
Pump Solenoid Error
Alarm
No voltage draw from air solenoid
for air motor.
WKFX Fill Solenoid
Error
Alarm
No voltage draw from air solenoid
for fill.
WSUX USB Invalid
Configuration
Devia- A valid configuration file can't be
tion
found for the USB.
V8M_
WJDX
Incoming line voltage is less than
100 VAC.
ADM not functioning properly.
Solution
Check fuses F1 and F2 on MZLP with daughter board.
Check J1 is properly plugged into the MZLP
with daughter board. (MZLP #1)
Check that RTD is installed in the melter.
Check resistance of heater in melter. Replace
melter heaters.
NOTE: Heater wires in the melter can also
cause the no current error.
Verify power supply voltage is 24 VDC. If voltage is low, disconnect the power lines and
re-check voltage reading. If voltage is still
low, replace power supply. If voltage is correct after disconnecting the power lines,
replace the MZLP.
Verify power supply voltage is 24 VDC. If voltage is high, replace power supply unit.
Measure incoming power with system
unplugged. If line voltage is less than
100 VAC, contact qualified electrician to correct the low voltage.
Check connector is properly connected to J14
of the daughter board.
Replace air manifold.
Check connector at J14 of the daughter
board.
Replace air solenoids. See page 69.
System is not properly loaded with correct
software. Perform Software Update Procedure on page 74. Retry USB download.
Replace ADM.
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 30.
Check funnel filter. If plugged, see Replace Funnel Filter on page 38.
44
3A2347W
Troubleshooting
Problem
Cause
Solution
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 38.
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.
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 99.
Fill Solenoid
Error
Failure of the fill solenoid or fill solenoid wiring.
Verify wiring between J13 and the refill solenoid is not damaged.
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).
Adhesive pellets in storage
bin not covering shaker
head.
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 30.
Enable Diagnostic screen on ADM then check sensor readings on the
Diagnostic screen. Sensor readings should be about 3V if melter is
completely empty (melter passage holes are visible). The normal operating range is 2.1 to 2.8V. If the sensor is reading more than 2.75V the
system should be requesting additional material.
Restart system. If the error persists after attempting another refill and
unit is needed immediately for production, place system into the manual refill mode. See Manual Refill on page 30.
The InvisiPac
system expels
adhesive pellets dust when
refilling.
3A2347W
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 38.
NOTE: Feed cap filter maintenance should be performed at regular
service intervals. It is recommended that the feed cap filter be serviced
at a minimum of every 1200 lb dispensed, however with some adhesives the frequency may need to be increased significantly to maintain
desired system cleanliness.
45
Troubleshooting
Problem
Cause
Solution
The InvisiPac
system will not
stall, pump
continues to
move even if
the guns are
all closed.
Fluid leak.
Verify that no external leakage is present.
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 52.
Feed pump not feeding adhesive.
Repair or replace air control assembly as necessary.
Control for manifold
and guns not working.
InvisiPac system does not control the timing of the manifold and
valves. This is a separate control that needs to be adjusted. Consult
control manufacturer or qualified electrician.
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 81 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 117.
Cycle Switch
Error
USB Log Full
46
Inspect and test the pressure relief valve.
Perform Flush Pressure Relief Valve, page 52.
If system is still unable to stall, the pump or pressure relief valve may
need to be repaired.
Repair or replace pump assembly as necessary.
3A2347W
Troubleshooting
Problem
Cause
Solution
The InvisiPac
system is displaying pump
runaway or
pump diving.
This error generally
This can occur if the melt rate for the system is exceeded, resulting in
occurs when the pump
air entrapment within the incoming adhesive material and lower than
cavitates due to
desired material temperature.
improper material load1. Verify that the InvisiPac system is not exceeding 33 cpm by
ing.
enabling the diagnostic screen.
2. If the cycle rate is below 33 cpm and the system is still running
away increase the InvisiPac system temperature by 10°F over the
current set point, leave hoses and guns at desired set point.
3. If the pump continues to runaway or dive continue increasing temperature by 10°F, do not exceed maximum temperature for the
material being dispensed.
NOTE: Some materials are more difficult to melt than others and it may
be impossible to process them at a rate of 25 lb/hr. The InvisiPac system was tested to achieve continuous melt rates of 25lb/hr when dispensing standard EVA packaging grade adhesives in pellet form with
an InvisiPac system temperature of 375°F and hose and valve temperatures of 350°F.
Unable to
achieve
25lb/hr 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).
1. If the cycle rate is below 33 cpm and the system is still running away
The InvisiPac system
increase the InvisiPac system temperature by 10°F over the current
monitors temperature
set point, leave hoses and guns at desired set point.
within aluminum mass
of melter (202). As melt
rates exceed 20 lb/hr a 2. If the pump continues to runaway or dive continue increasing temperature by 10°F, do not exceed maximum temperature for the
system temperature
material being dispensed.
offset may be required.
NOTE: A 50 amp breaker is required in order to maximize startup and
flow rate performance. Set the breaker size used in the Setup screens.
NOTE: Some materials are more difficult to melt than others, therefore
it may be impossible to process them at a rate of 25 lb/hr. The InvisiPac
system was tested to achieve continuous melt rates of 25lb/hr when
dispensing standard EVA packaging grade adhesives in pellet form
with an InvisiPac system temperature of 375°F and hose and valve
temperatures of 350°F.
3A2347W
47
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 MZLP
board not plugged in.
ADM cable should be plugged into J6 of the MZLP board.
Bad 24VDC power supply.
Check output on power supply should measure 24VDC, if no voltage
reading replace power supply.
ADM not functioning
properly.
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 380400 VAC for a 400 volt unit.
Melter heater rod and
gun manifold.
Measure and check heater rods in melter or manifold. Manifold resistance 130-140 ohms.
Heated hose.
Measure heater wires in hose, pins C and D. See repair section for
each hose resistance.
Insufficient power supplied to system.
Depending on hose
and gun combinations,
along with minimal supply power, startup time
will vary.
Connect system to a power supply capable of maximum power per
system specification. All changes must be performed by a qualified
electrician. See Electrical Schematics on page 76 for details about
connecting to a different power supply.
Main breaker
tripping
Slow start-up
time or system
takes longer
than 10 minutes to startup
No adhesive or
little adhesive
being dispensed
Incorrect RTD setting in 1. Verify melter, hose, and manifold temperatures are all with in the
same range of the room ambient.
system.
2. If the manifold temperature is either much higher or much lower than
the melter temperature then the RTD setting is not correct for the
RTD being used. Select correct RTD setting in the setup screen system 2 before beginning.
NOTE: Failure to have the correct RTD value will cause the manifold
and gun to either under-heat or over-heat. Setting for RTD in the ADM
screens is higher than actual RTD value. Consult manufacturer for
actual RTD value.
48
3A2347W
Troubleshooting
Problem
Cause
System indicates no errors
and correct
temperature
however manifold and gun
are over the
temperature
setpoint
Incorrect RTD setting in 1. Verify melter, hose, and manifold temperatures are all with in the
same range of the room ambient.
system.
No adhesive or
incorrect
amount of
adhesive output when all
valves are triggered
Plugged gun manifold
filter.
Replace manifold filter. Graco manifold filter in bottom of manifold or
inline filter on other manifolds.
Clogged hose.
Flush or replace hose.
Solenoid valve.
Check that correct voltage is input into valve solenoid. If voltage is correct, replace solenoid.
No signal from control
to solenoid.
If no voltage is present at solenoid, check control cable and remote
control device. Replace component.
Solenoid mufflers
plugged.
Replace solenoid mufflers.
No air to air solenoid.
Re-establish air supply to solenoid.
Plugged system outlet
filter.
Replace Outlet Filter. See page 37.
If multiple valves are
triggered simultaneously, maximum pump
rate may be exceeded.
Stagger valve opening to reduce the maximum required flow rate to
below maximum pump rate.
3A2347W
Solution
2. If the manifold temperature is either much higher or much lower than
the melter temperature then the RTD setting is not correct for the
RTD being used. Select correct RTD setting in the setup screen system 2 before beginning.
NOTE: Failure to have the correct RTD value will cause the manifold
and gun to either under-heat or over-heat. Setting for RTD in the ADM
screens is lower than actual RTD value. Consult manufacturer for
actual RTD value.
49
Troubleshooting
Problem
Cause
Solution
No adhesive or
incorrect
amount of
adhesive out of
one/some of
the valves
when triggered
Plugged tip on gun.
Replace tip on gun.
Gun in closed/partial
open position.
Replace gun.
Plugged manifold filter
(single valves manifold).
Replace manifold filter. Graco manifold filter in bottom of manifold or
inline filter on other manifolds.
Clogged hose (single
valves).
Flush or replace hose.
Solenoid valve (single
manifold).
Check that correct voltage is input into valve solenoid. If voltage is correct, replace solenoid.
No signal from control
to solenoid (single
valve manifold).
If no voltage is present at solenoid, check control cable and remote
control device. Replace component.
Plugged solenoid mufflers (single valve manifold).
Replace solenoid mufflers.
No air to solenoid (single valve manifold)
Re-establish air supply to solenoid.
Plugged system outlet
filter.
Replace Outlet Filter. See page 37.
If multiple valves are
triggered simultaneously, maximum pump
rate may be exceeded.
Stagger valve opening to reduce the maximum required flow rate to
below maximum pump rate.
Adhesive flowing out of
one/some
valves when
not triggered
Failed valve in the
open position.
Replace valve.
Adhesive pressure too
high.
Reduce air pressure to air motor.
Gun will not
heat.
Heat rod failure in manifold.
Check resistance on heater rods. Repair 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 AMD setup screen. Consult manufacture
for correct RTD value.
Thermal cutoff is
tripped.
Measure resistance of the thermal cutoff. If open, replace.
50
3A2347W
Troubleshooting
Problem
Cause
Solution
Adhesive leaking from manifold or valve.
Valve is loose on the
manifold.
Tighten screws on loose valve.
Valve o-ring failed.
Replace o-rings on the back of the leaking valve.
Failed valve, adhesive
leaking out middle of
valve.
Replace valve.
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.
No air being supplied to
air motor.
Check incoming air supply. Check that air solenoid is adjusted for air
motor.
Air solenoid not adjusting the air motor.
If air can not be adjusted at the air solenoid, check 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.
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.
Guns opening at the
wrong time.
InvisiPac system does not control the opening and closing of the guns.
The separate controller needs to be adjusted. Consult control manufacturer or qualified electrician.
No melter
heat.
Air motor will
not function.
3A2347W
Check that power plug is connected.
51
Troubleshooting
Flush Pressure Relief Valve
3. Plug air line and allow the air motor to cycle.
4. Re-connect air line to relief valve and check whether
the system will stall.
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).
5. If system still does not stall, purge ten pump cycles
of material through one gun.
6. Repeat this entire procedure until no additional air is
expelled from the gun.
Check the Pump Air Solenoid Operation
2. Remove the air line (36) from the pressure relief
valve.
Perform this procedure when directed in the Troubleshooting table.
NOTE: System must be up to operating temperature for
pump solenoid to trigger on.
1. If the heating system and pump is disabled,
press
to enable the heaters and pump.
2. Wait for system to reach the temperature setpoints.
3. Set pump air pressure to 20 psi (140 kPa, 1.4 bar).
4. Remove the 3/8 in. OD air line from the air motor.
36
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.
ti20441b1
FIG. 24
52
3A2347W
Troubleshooting
MZLP Troubleshooting
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.
Red
J3
56
FIG. 25: MZLP LED Signals
234
01
7 89
ti20441b1
Yellow
Green
MZLP
NOTE: The MZLP LED is located on the inside of the
electrical enclosure. To view, remove the electrical
enclosure front access door.
ti20348a
FIG. 26: MZLP Diagnostic LED Location
3A2347W
53
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. 27):
1. Flush the system. See page 34.
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
8. Remove air motor assembly:
Replace Throat Seal, Throat Bearing, Piston Rod,
Piston Seal, and Piston Bearing
218
240
b.
Remove dowel pin (238).
c.
Remove three screws (240).
9. Use a flat head screwdriver and a rubber mallet to
break loose the retaining nut (235).
223
239
235
233
234
225
238
27
a. Remove retaining ring (239).
226
222
10. Use channel lock pliers to remove the retaining
nut (235).
11. Insert an allen wrench through the hole in the top of
the piston rod (223) to lift the piston rod (223) up out
of the manifold. This will also pull out the throat
u-cup (234) and throat bearing (233).
12. Remove piston valve (222) from piston rod (223).
13. Remove and discard piston u-cup (225) and
bearing (226).
245
Reassembly (see FIG. 27):
1. Assemble piston rod:
3
a. Install new piston u-cup (225) onto piston
rod (223) with the lips facing the rod.
b.
ti21046a
FIG. 27
54
Install piston bearing (226) onto piston rod (223)
with grooved end towards the center of the piston rod.
3A2347W
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. 28.
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. 28
3. Push the piston rod assembly (223) into the melter
outlet manifold (203).
4. Grease the throat u-cup (234) and slide the u-cup
over the piston rod (223) with the lips facing down.
5. Place a 7/8 in. deep-well socket (3/8 in. drive) over
the piston rod (223) then use a rubber mallet to gently tap throat u-cup (234) into place. See FIG. 29.
ti21144a
FIG. 30
7. Remove seal installation tool.
8. Install retaining nut (235). See FIG. 28.
9. Install air motor assembly (see FIG. 27):
a. Install three screws (240).
b. With retaining ring around piston rod, install
dowel pin (238).
c.
Install retaining ring (239) over dowel pin.
10. Use nuts (3) to install melter shield (27).
11. Connect air lines to relief valve and air motor.
12. Install plastic shroud (27).
234
ti21047a
FIG. 29
3A2347W
55
Repair
Replace Pump Inlet Housing Checks
Reassembly (see FIG. 31):
1. Install new o-ring (229), seat (228), and ball (227)
then use a 1/2 in. drive ratchet without a socket to
install and tighten foot valve (230) onto melter.
2. Install Melter Assembly. See page 59.
Replace Pump Cylinder Seals and Piston Seals
254
218
201
239
235
233
234
227
228
229
230
233
224
226
222
257
ti20749a
FIG. 31
217
Disassembly (see FIG. 31):
216
1. Flush the system. See page 34.
217
2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
230
3. Turn main power switch OFF.
FIG. 32
4. Remove Melter Assembly. See page 58.
Disassembly (see FIG. 27):
5. Use a 1/2 in. drive ratchet without a socket to
remove foot valve (230) from bottom of melter outlet
manifold (203).
6. Remove and discard seat (228), ball (227), and
o-ring (229).
ti21048a
1. Flush the system. See page 33.
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. 27 on
page 54.
56
3A2347W
Repair
5. Remove air lines from relief valve (245) and air
motor (218) See FIG. 27 on page 54.
14. Remove and discard cylinder seals (217). See FIG.
31.
6. Remove nuts (3) securing melter shield (27) in
place then remove melter shield. See FIG. 27 on
page 54.
Reassembly:
1. Apply grease to seals (217) then install new cylinder
seals (217) onto cylinder (216). See FIG. 31.
7. Remove air motor assembly. See FIG. 27 on
page 54:
a. Remove retaining ring (239).
b.
Remove dowel pin (238).
c.
Remove three screws (240).
1303
217
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. Remove Melter Assembly. See page 58.
ti21049a
12. Use a 1/2 in. drive ratchet without a socket to
remove foot valve (230) from bottom of melter outlet
manifold (203).
FIG. 34
13. Insert cylinder tool (1301) into bottom of melter outlet manifold (203). Use a rubber mallet to gently
remove cylinder (216). See FIG. 31.
2. Place female cylinder installation tool (1302) into
melter outlet manifold (203) to protect seals from
sharp threads. See FIG. 34.
3. Use male cylinder installation tool (1303) to press
cylinder (216) into melter outlet manifold (203). If
necessary, use rubber mallet tap into place. See
FIG. 31.
1301
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).
203
5. Perform Install Melter Assembly on page 59.
6. Perform Reassembly portion of the Replace Throat
Seal, Throat Bearing, Piston Rod, Piston Seal,
and Piston Bearing procedure which starts on
page 54.
217
216
217
ti20880a
FIG. 33
3A2347W
57
Repair
Melter
4. Disconnect all heated hoses from the melter outlet
manifold (203).
Remove Melter Assembly
5. Remove cable from ADM (30) then slide forward the
shroud (29) and remove it from the system.
6. Remove screws (8) then remove electrical enclosure front access door (10).
7. Remove the air tube (36) from the relief valve (245).
Pull the air tube from the metal shroud (27).
61
8. Remove nuts (3) on the back metal shroud (27)
then remove shroud.
62
9. Loosen hose clamp on air motor bracket (528) then
remove funnel (61).
13
12
10. Remove wire connectors from the over-temperature
switch (251).
13
11. Remove insulators (52, 53) from the melter
assembly (5).
53
30
29
52
12. Disconnect the fill sensor cable from the fill
sensor (20).
27
13. Disconnect the pump cycle sensor cable from the
air motor.
14. Remove the air tube from the fill cap (62).
15. Remove the air tube from the air motor (218).
16. Loosen screw (AA) then remove sensor (125). See
FIG. 36 on page 60.
3
259
8
3
10
ti21050b
1
17. Remove electrical enclosure front access door (10).
18. Remove all heater wires from the following terminals. Pull wires up through the rubber grommet on
the top of the electrical enclosure (1). See FIG. 36
on page 60 for references.
Item
Wire
Marking 1
Wire
Marking 2
Band Heater (208)
TB1-11B
TB1-13B
Melter Heater Rod
(209)
TB1-14C
CR1-NC
Base Heater Rod (210) TB1-11C
TB1-13C
Pump Heater Rod
(250)
CR1-COM
FIG. 35
NOTE: This only needs to be done when replacing
items that require access to the bottom of the melter
assembly.
1. Perform Drain the System procedure on page 33
then wait for system to cool.
2. Close the bleed type ball valve at the system air
inlet.
3. Turn main power switch OFF.
58
TB1-12B
19. Remove four nuts (3) then remove melter assembly
from system. Save any loose insulators for reassembly.
3A2347W
Repair
20. Remove bolts (259) then remove melter assembly
from melter base (257).
6. Connect air tube to air motor (218).
7. Connect air tube to fill cap (62).
Install Melter Assembly
8. Connect fill sensor cable to the fill sensor (20).
9. Connect pump cycle sensor cable to air motor.
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).
10. Install funnel (61) into air motor bracket (528) then
tighten clamp.
11. Install temperature sensor (125) into melter then
tighten screw (AA) on band heater. See FIG. 36 on
page 60.
12. Install insulators (52, 53) onto the melter
assembly (5).
NOTICE
To prevent crushing the soft insulators (4), do not
overtighten the 4 bolts (259) in the following step.
Torque to 5-11ft-lb (7-15 N•m).
3. Use 4 bolts (259) to secure melter assembly to
melter base (257).
4. Use four nuts (3) to secure melter assembly to system.
5. Group the 4 sets of heater wires together and run
them through the grommet on the top of the electrical enclosure (1). Connect wires as noted below.
See FIG. 36 on page 60 for references.
Item
Wire
Marking 1
Wire
Marking 2
Band Heater (208)
TB1-11B
TB1-13B
Melter Heater Rod
(209)
TB1-14C
CR1-NC
Base Heater Rod (210) TB1-11C
TB1-13C
Pump Heater Rod
(250)
CR1-COM
3A2347W
TB1-12B
13. Connect wire connectors to the over-temperature
switch (251). See FIG. 38 on page 62.
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.
59
Repair
Replace Band Heater
8. While system is still near operating temperature,
loosen band clamps (CC) then slide fill cap (62) and
rubber housing off melter. When removing rubber
housing from melter, separate rubber from melter by
pressing on inside surface.
CC
9. Loosen screw (AA) then remove sensor (125).
125
53
AA
10. Locate the wires in terminal blocks TB1-11B and
TB1-13B. Loosen terminal block screws and
remove wires.
62
208
11. Pull wires up through grommet (63) on top of the
electrical enclosure (1). Clip any wire ties that hold
the wires in place.
12. Continue loosing screw (AA) then slide band
heater (208) up to remove.
Reassembly (see FIG. 36):
1. Install band heater (208) on the melter with the
opening and screw facing the front of the system in
alignment with the sensor port.
1
10
2. Install sensor (125).
3. Slide band heater up then tighten screw (AA).
NOTE: Band heater should be oriented to hold sensor in
place when tightened. It should not bend the sensor.
63
4. Route band heater wires through grommet (63) in
the top of the electrical enclosure (1).
ti20753a
FIG. 36
Disassembly (see FIG. 36):
1. Loosen clamp on air motor bracket (528) then
remove funnel assembly (61).
2. While looking through the hole in the fill cap, dispense until the fluid level in the melter is at or below
the honeycomb grid.
3. Once the fluid level is low enough, close the
bleed-type ball valve installed at the system air inlet.
4. Turn main power switch OFF.
5. Disconnect cable from ADM (30) then remove
shroud (29).
6. Remove front access door (10) from electrical
enclosure (1).
5. Connect wires to terminals as marked. Wires should
be marked as shown in the following table. Tighten
terminal block screws.
Item
Wire
Marking 1
Wire
Marking 2
Band Heater (208)
TB1-11B
TB1-13B
6. Install electrical enclosure access door (10). See
FIG. 36.
7. Install fabric melter insulator (53).
8. Install fill cap (62) rubber housing with band clamps
in place. Ensure rubber housing is fully seated on
melter or incorrect refilling may occur. Tighten band
clamps to 25 in-lbs.
9. Install funnel into fill cap (62) then tighten band
clamps (CC) on rubber housing.
7. Remove fabric melter insulator (53).
60
3A2347W
Repair
10. Slide funnel assembly (61) through air motor
bracket (528) then tighten clamp.
7. Loosen screw (AA) then remove sensor (125).
8. Remove electrical enclosure access door (10).
11. Feed ADM cable through shroud then install shroud
and connect cable to ADM.
9. Disconnect the temperature sensor cable from
MZLP connector labeled J5. See FIG. 37.
12. Open system air inlet ball valve.
NOTE: This connector also includes the over-temperature switch wires.
13. Turn main power switch ON.
Replace Band Heater Temperature Sensor
10. Disconnect wire connectors from over-temperature
switch (251). See FIG. 38 on page 62.
11. Pull cable out of the electrical enclosure then discard sensor (125) and wires.
Reassembly (see FIG. 37):
53
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. 38 on page 62.
3. Place band heater temperature sensor (125) in
melter.
4. Tighten screw (AA).
CC
AA
40
125
ti20762a
FIG. 37
Disassembly (see FIG. 37):
NOTE: Screw should lightly squeeze the temperature
sensor to hold it in place. It should not bend the sensor.
5. Connect new harness to MZLP connector labeled
J5.
6. Install electrical enclosure access door (10). See
FIG. 36 on page 60.
1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
7. Install fabric melter insulator (53).
2. Turn main power switch OFF.
8. Use nuts (3) to install metal shroud (27).
3. Disconnect cable from ADM then remove shroud.
9. Route relief valve air tube through the metal shroud
then attach to the relief valve.
4. Remove air tube (36) from relief valve. Pull the air
tube through the metal shroud (27).
10. Feed ADM cable through shroud then install shroud
and connect cable to ADM.
5. Remove nuts (3) then remove metal shroud (27).
11. Turn main power switch ON.
6. Remove fabric melter insulator (53).
12. Open system air inlet ball valve.
3A2347W
61
Repair
Replace Heater Over-Temperature Switch
6. Open system air inlet ball valve.
7. Turn main power switch ON.
Replace Heater Rod
251
255
206
250
ti21052a
FIG. 38
Disassembly (see FIG. 37):
1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
2. Turn main power switch OFF.
210
206
ti20755a
3. Disconnect cable from ADM then remove shroud.
4. Remove air tube (36) from relief valve. Pull the air
tube through the metal shroud (27).
5. Use 7/16 in. socket to remove nuts (3) then remove
metal shroud (27).
209
6. Disconnect the wire connectors from the over-temperature switch (251).
206
209
ti20754a
7. Remove the screws (255) securing the over-temperature switch (251) to the melter assembly (5),
then remove the switch.
FIG. 39
Re-assembly (see FIG. 37):
NOTE: This procedure is for replacing any of the above
heater rods.
1. Use the two screws (255) to secure the new
over-temperature switch (251) to the melter.
Disassembly (see FIG. 39):
1. Turn main power switch OFF.
2. Connect wire connectors to new over-temperature
switch.
2. If replacing the melter heater rod (209), Remove
Melter Assembly. See page 58.
3. Use 7/16 in. socket to install nuts (3) to secure
metal shroud (27).
3. Disconnect cable from ADM then remove
shroud (29).
4. Route relief valve air tube (36) through the metal
shroud then attach to the relief valve.
4. If removing the pump heater rod (250):
5. Feed ADM cable through shroud then install shroud
and connect cable to ADM.
62
a. Remove the air tube (36) from the relief
valve (245). Pull the air tube through the metal
shroud (27).
3A2347W
Repair
b.
Remove nuts (3) then remove shroud (27).
c.
5. Remove electrical enclosure front access door (10).
See FIG. 36.
6. Disconnect heater rod wires from terminal blocks
described in the following table.
Wire
Marking 1
Wire
Marking 2
TB1-14C
CR1-NC
Base Heater Rod (210) TB1-11C
TB1-13C
Pump Heater Rod
(250)
CR1-COM
Item
Melter Heater Rod
(209)
TB1-12B
Pull the air tube through the metal shroud (27)
then connect the air tube (36) to the relief
valve (245).
7. Feed ADM cable through plastic shroud then install
plastic shroud and connect cable to ADM.
Replace Fluid Pressure Relief Valve
27
3
7. Pull heater rod wires up through the grommet in the
top of the electrical enclosure (1).
8. Remove heater rod retaining ring (206) then remove
and discard heater rod (209, 210, or 250).
Reassembly (see FIG. 39):
36
244
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.
245
ti20757a
NOTICE
To prevent damaging the heater rod, do not use thermal grease in the following step.
FIG. 40
1. Drain the System. See page 33.
2. Install heater rod then install heater rod retaining
ring (206). See FIG. 39.
2. Close the system air inlet ball valve.
3. Install electrical enclosure access door (10). See
FIG. 36.
4. Remove the air tube (36) from the relief valve (245).
Pull the air tube through the metal shroud (27). See
FIG. 40.
4. If replacing the melter heater rod (209), Install
Melter Assembly. See page 58.
5. If replacing pump heater rod (210 or 250), feed
ADM cable through shroud then install shroud and
connect cable to ADM.
6. If installing the pump heater rod (250), install the
metal shroud (27):
a. Place metal shroud on system.
b.
Install and tighten nuts (3).
3A2347W
3. Turn main power switch OFF.
5. Remove nuts (3) then remove shroud (27).
6. Use crescent wrench to remove melter fluid pressure relief valve (245).See FIG. 40.
7. Use an o-ring pick to remove o-ring (244).
8. Install o-ring (244) into manifold.
NOTICE
To prevent damage to o-ring, ensure o-ring is seated
properly prior to moving to next step.
63
Repair
9. Thread new fluid pressure relief valve (245) into
manifold. See FIG. 40. Once hand-tight, use crescent wrench to tighten.
10. Use nuts (3) to install metal shroud.
11. Connect air tube to pressure relief valve.
12. Feed ADM cable through plastic shroud then install
shroud and connect cable to ADM.
64
3A2347W
Repair
Multi-Zone Low Power Temperature Control Module (MZLP)
Replace MZLP Fuse
MZLP Identification
24R234
24V510
Key
A
F1 and F2 fuses are physically the same size as F3-F10
B
C
---
F1 and F2 fuses are physically larger than F3-F10
Blue sticker on relay
Marked 24N568
Marked 24V133
Fuse
Part
24R234 MZLP Fuses
C
J1
J2
F10 F9
F8 F7
F4 F3
F2
F6
F1
A
F5
250VAC, 16A, fast acting, white
F3-F10
250VAC, 8A, fast acting
24V510 MZLP Fuses
B
J7
J6
F1, F2
F1, F2
250VAC, 25A, fast acting, white, 0.25 in x 1.2 in
F3-F10
250VAC, 8A, fast acting
Fuse Kits
J5
J3
WLD
FIG. 41: MZLP ID and Fuse Locations
NOTICE
To prevent system damage, always use fast acting
fuses. Fast acting fuses are required for short-circuit
protection.
Kit
MZLP
Description
24P859
24R234
Includes standard clear fuses.
24X479
24V289
24X480
Includes ceramic fuses used for
food industries.
24V510
Includes standard clear fuses.
Includes ceramic fuses used for
food industries.
1. Turn main power switch OFF.
2. Remove electrical enclosure front access door (10).
3A2347W
65
Repair
3. Use a proper non-conductive fuse puller tool to
remove the blown fuse.
5. Remove four screws (114) securing MZLP (112) to
electrical enclosure (1) then carefully remove MZLP
from electrical enclosure. See FIG. 42.
NOTICE
Using an improper tool, such as screw drivers or pliers may break glass on fuse.
4. Use a proper non-conductive fuse puller tool to
install the new fuse.
NOTICE
Using an improper tool, such as screw drivers or pliers may break glass on fuse.
5. Install electrical enclosure front access door (10).
6. If replacing MZLP #1, remove the daughter card and
standoffs, and re-install them on the new MZLP.
See FIG. 42 for MZLP #1 and MZLP #2 identification.
Reassembly:
1. Set MZLP rotary switch to “1” on MZLP with daughter card. Set MZLP rotary switch to “2” on MZLP
without daughter card. See FIG. 43 for rotary switch
location.
2. Use four screws (114) to install MZLP (112) to electrical enclosure (1).
3. Reconnect cables to MZLP (112).
Replace MZLP
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.
Use See MZLP Identification, page 65.
NOTE: If unable to determine connector location, see
Electrical Schematics on page 76.
Disassembly:
1. Turn main power switch OFF.
4. Install electrical enclosure front access door (10).
2. Remove electrical enclosure front access door (10).
5. Connect heated hose electrical connectors to new
MZLP.
3. Disconnect heated hose electrical connectors from
MZLP (112).
4. Note location of each cable, then unplug all cables
from the MZLP (112) that will be replaced. See FIG.
43.
NOTE: MZLP may need updated software. See Software Update Procedure on page 74.
Replace MZLP Daughter Card
Disassembly:
ti20910a
1. Turn main power switch OFF.
2. Remove electrical enclosure front access door (10).
MZLP #2
3. Note location of each cable then unplug all cables
from MZLP daughter card (112a). See FIG. 43.
1
MZLP #1
112
114
FIG. 42
66
3A2347W
Repair
4. Remove four mounting screws (112b) from daughter card (112a) and set aside. See FIG. 43.
System
Replace Fill Sensor
112b
112a
112
ti20342a
112
20
Rotary Switch
FIG. 43
5. Unplug daughter card (112a) from the MZLP (112).
Reassembly:
62
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 76.
4. Install electrical enclosure front access door (10).
ti20761a
FIG. 44
Disassembly (see FIG. 44):
1. Turn main power switch OFF.
2. Gently pull up on cable while unscrewing fill sensor
connector then remove fill sensor cable from fill
sensor (20).
3. Loosen fill sensor jam nut then remove fill
sensor (20) from fill cap (62).
Reassembly (see FIG. 44):
1. Thread new fill sensor (20) into fill cap (62). Bottom
out the sensor in the fill cap then back out 1/2 turn.
2. Tighten jam nut on fill sensor (20).
3. Connect fill sensor cable to new fill sensor (20).
3A2347W
67
Repair
Replace Fill Cap
7. Loosen upper clamp (13) on rubber housing then
remove fill cap (62).
Reassembly (see FIG. 45):
1. Place new fill cap on melter. Align funnel inlet hole
with bracket.
20
2. Install funnel through air motor bracket (528) then
tighten funnel clamp.
62
35
3. Tighten rubber housing clamp (13) to 25 in-lbs to
secure fill cap in place.
4. Connect air line (35) to fill cap (62).
5. Thread fill sensor (20) into fill cap (62). Bottom out
the sensor in the fill cap then back out 1/2 turn.
13
6. Tighten jam nut on fill sensor (20).
Replace ADM
58
30
CC
ti20760a
FIG. 45
Disassembly (see FIG. 45):
1. Turn main power switch OFF.
2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
3. Disconnect cable from ADM then remove shroud.
4. Loosen hose clamp on air motor bracket (528) then
remove funnel assembly.
ti20763a
FIG. 46
1. Turn main power switch OFF.
2. Disconnect cable (CC) from bottom of ADM (30).
See FIG. 46.
3. Remove ADM from bracket (58).
5. Loosen fill sensor jam nut then remove sensor (20)
from fill cap (62).
4. Install new ADM into bracket.
6. Remove air line (35) from fill cap (62).
5. Connect cable to bottom of new ADM.
NOTE: ADM may need updated software. See Software Update Procedure on page 74.
68
3A2347W
Repair
Air Controls
Reassembly (see FIG. 47):
1. Use two screws (405) to secure new
solenoids (402) to air control assembly (409).
Replace Air Control Solenoids
2. Feed the new solenoid cable into the electrical
enclosure and attach cable to MZLP daughter board
connector J13.
8
402
405
9
3. Insert hands through access holes (FF), see FIG.
47, in bottom of electrical enclosure then connect air
lines to air control solenoids (402).
4. Slide air control assembly (9) into place then use
two screws (8) to secure to electrical enclosure (1).
5. Install electrical enclosure front access door.
Replace Air Control Gauge
1
8
ti20764a
403
403b
403a
403c
FF
FIG. 47
9
NOTE: In order to replace the air control solenoids, the
system must be tipped back to access underneath the
electrical enclosure.
Disassembly (see FIG. 47):
1. Turn main power switch OFF.
402
2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
ti20765a
3. Remove front access panel (10) from electrical
enclosure (1).
FIG. 48
4. Use 3/8 in. socket to remove two screws (8).
Disassembly (see FIG. 48):
5. Note location of each air line connection.
6. Insert hands through access holes (FF), see FIG.
47, in bottom of electrical enclosure then disconnect
air lines from air control solenoids (402).
7. Disconnect air control solenoids cable from MZLP
daughter board connector J13. Pull wire out of the
electrical enclosure.
8. Remove two screws (405) securing solenoids (402)
to air control assembly (9) then remove air control
solenoids.
3A2347W
1. Turn main power switch OFF.
2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
3. Remove two screws (8) then slide air control
assembly (9) out from electrical enclosure (1) so the
back of the gauges are exposed.
4. Remove two nuts (403a) securing gauge (403) in
place then remove bracket (403c).
5. Place one small crescent wrench on the brass part
of the gauge then use a second small crescent
wrench to remove the air fitting (403b).
69
Repair
6. Remove air gauge from panel.
3. Use 10 mm socket to remove air motor pilot
valve (513) from air motor (218).
Reassembly (see FIG. 48):
1. Slide new air gauge into panel and slide the bracket
onto the back of the gauge. Install air fitting onto the
gauge by hand, do not tighten yet.
2. Install bracket (403c) then install two nuts (403a)
finger tight.
4. Lubricate with grease and install new air motor pilot
valve (513).
5. Torque pilot valve to 95-105 in-lb (10.7-11.9 N•m).
Replace Air Valve
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).
508
NOTICE
In the following step, do not overtighten the two
nuts (403a). Overtightening may cause the gauge to
break.
527
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.
509
Air Motor
218
Replace Pilot Valve
ti20768a
FIG. 50
218
Disassembly (see FIG. 50):
1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
513
2. Turn main power switch OFF.
3. Loosen clamp on air motor bracket (528) then
remove funnel assembly (61).
ti20767a
FIG. 49
4. Loosen upper hose clamp on rubber housing then
remove fill cap.
1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
5. Dispense until the fluid level in the melter is at or
below the honeycomb grid.
2. Turn main power switch OFF.
70
3A2347W
Repair
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.
Remove Air Motor
218
27
238
6. Once the fluid level is low enough, close the
bleed-type ball valve installed at the system air inlet.
220
7. Disconnect air hose and cable from the air motor.
8. Use 10 mm socket to remove four screws (508)
securing air valve (527) to air motor (218).
240
239
211
219
9. Remove air valve (527) and seal (509) then discard.
Reassembly (see FIG. 50):
1. Lubricate with grease then place new air valve
seal (509) onto air valve (527).
3
2. Carefully place new air valve (527) against air motor
then thread in the four screws (508). Ensure the air
valve seal (509) stays in place by applying constant
pressure against the air motor.
3. Use 10 mm socket to torque screws (508) to
95-105 in-lb (10.7-11.9 N•m).
4. Install fill cap then tighten upper hose clamp on rubber housing.
5. Connect air hose and cable to the air motor.
ti20758a
FIG. 51
See FIG. 51.
1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
2. Turn main power switch OFF.
3. Disconnect air line (36) from pressure relief
valve (245) then pull through metal shroud (27). See
FIG. 40 on page 63.
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.
3A2347W
b.
Remove dowel pin (238).
c.
Remove three screws (240).
71
Repair
7. If replacing a damaged air motor with a new fully
assembled air motor:
Replace Air Motor Piston O-Ring
511
a. Remove three screws (211) securing air motor
tie rods (220) to base plate (219).
b.
512
Remove tie rods (220) from air motor (218).
520
Install Air Motor
See FIG. 51.
1. If replacing a damaged air motor with a new fully
assembled air motor:
501
a. Install tie rods (220) onto air motor (218).
504
523
b.
Install three screws (211) securing air motor tie
rods (220) to base plate (219).
506
505
505
2. Connect air motor assembly to system:
ti20766a
510
a. Install three screws (240) to secure air motor
assembly to system.
FIG. 52
Disassembly (see FIG. 52):
b.
Install dowel pin (238).
c.
Install retaining ring (239) over dowel pin (238).
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. 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. 40 on page 63.
3. Remove Air Motor, page 71.
4. Use 10 mm socket to remove four screws (511) to
remove air manifold assembly (520). See FIG. 52.
5. Use 13 mm socket to remove two bolts (512) then
remove air motor top cap (510).
6. Remove and discard piston o-ring (504) from
piston (519).
Reassembly (see FIG. 52):
1. Lubricate all seals with grease.
2. Install new piston o-ring (504) onto piston (519).
NOTICE
Carefully reassemble air motor to prevent damage to
seals.
3. Reassemble remaining air motor parts, excluding air
manifold assembly, then install two bolts (512) finger tight.
72
3A2347W
Repair
4. Use four screws (511) to install air manifold
assembly (520) onto air motor finger tight to align
cover (506).
5. Torque two bolts (512) incrementally to 11-13 ft-lb
(15-18 N•m) to ensure top and bottom cap
seals (505) seat properly.
4. Remove four screws (511) to remove air manifold
assembly (520).
5. Remove two bolts (512) then carefully remove air
motor base cap (501) from the rest of the air motor
assembly.
6. Disconnect rod (223) from air motor piston (519)
then remove rod from air motor base cap (501).
6. Torque four air manifold screws (511) to
95-105 in-lb (10.7-11.9 N•m).
7. Remove retaining ring (517) from base cap (501)
7. Install Air Motor, page 72.
8. Remove two u-cup throat seals (507) from throat of
air motor base cap (501) and discard seals.
Replace Air Motor Throat Seals
NOTE: This procedure uses adhesive that requires a
12-hour system idle time for full cure. If possible, perform this procedure at the end of the day or week so it
can cure overnight or over the weekend while the system does not need to run. Otherwise, keep a spare air
motor on hand so it can be used while the adhesive
cures.
Reassembly (see FIG. 53):
1. Apply water-resistant grease to new u-cup
seals (507) then install seals into throat of air motor
base cap (501).
2. Install retaining ring (517) in base cap (501).
3. Carefully insert rod (223) into air motor base cap.
511
512
4. Apply high strength adhesive, supplied with kit, to
rod threads then connect rod (223) to air motor
piston (519). Torque to 35-40 ft-lb (47-54 N•m).
NOTICE
Carefully reassemble air motor to prevent damage to
seals.
520
517
507
223
507
501
502
519
ti20769a
FIG. 53
Disassembly (see FIG. 53):
5. Reassemble remaining air motor parts, excluding air
manifold assembly, then install two bolts (512) finger tight.
6. Use four screws (511) to install air manifold
assembly (520) onto air motor finger tight to align
cover (506).
7. Torque two bolts (512) incrementally to 11-13 ft-lb
(15-18 N•m) to ensure top and bottom cap
seals (505) seat properly.
1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
8. Torque four air manifold screws (511) to
95-105 in-lb (10.7-11.9 N•m).
2. Turn main power switch OFF.
9. Install Air Motor, page 72.
3. Remove Air Motor, page 71.
10. Prior to using system, wait 12 hours for adhesive
used in step 4 to fully cure.
3A2347W
73
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. 54: 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. 55: Insert Token
5. Install ADM into bracket.
7. Remove token (T).
6. Turn system main power switch ON.
8. Replace token access panel.
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.
74
9. Press
to continue to the InvisiPac operation
screens.
3A2347W
Repair
10. Navigate to System Screen. Verify the following
pages. Reference screens on page 113.
a. System Screen Page 1, Customer I/O is set correctly.
b.
System Screen Page 2, Channel and RTD
types are set correctly.
c.
System Screen Page3, System Type, Pump
Idle Time, Power Type, Circuit Breaker Size,
and Refill Settings.
3A2347W
75
Electrical Schematics
Electrical Schematics
To prevent electric shock and system damage, all
electrical work must be performed by a qualified
electrician.
Incoming Power and Terminal
Jumpers
NOTICE
To prevent severe system damage, ensure terminal
jumpers are installed correctly. See Connect Electrical Cord on page 18.
76
The incoming power and terminal jumpers are specific
to the phase and voltage used. The power type and circuit breaker size must be correctly set in the ADM. See
Select ADM Settings on page 20.
If changing power type, use the supplied hard metal 2,
3, and 5 terminal jumpers and screws and supplied
jumper wire to jumper the terminals. See Connect Electrical Cord on page 18 for detailed information about
changing terminal jumper locations.
3A2347W
3A2347W
GB1
BAND
208
1,250W
BASE
210
1,000W
250
PUMP
1,500W
MELTER
500W
209
GND
GB1
NC
NO
CR1
PS1
A1
A2
OK
-V
-V
See page 80.
Hose / Applicator Wiring
COM
G
N
L
+V
+V
122
J9
J8
J7
J1
G
L3
L2
L1
Grn/yel
BRN
16
15
14
13
12
MZTCM 1
112
BLU
J5
DH
DL
-V
+V
DRN
AUX4
AUX3
EARTH
GND
VCAN
AUX2
EARTH
GND
VCAN
AUX1
EARTH
GND
VCAN
AUX2
AUX1
VCAN
VCAN
AUX4
AUX3
VCAN
VCAN
DH
DL
-V
DRN
J6
+V
112a
125
124
126
402
123
Over temp
CYCLE SWITCH PUMP
LEVEL SENSOR
AIR SOLENOID
RTD
ADM
TEMP
OVER
DH
DL
-V
+V
DRN
Electrical Schematics
Systems with One MZLP Module
251
77
78
GB1
208
1,250W
BAND
210
1,000W
BASE
250
PUMP
1,500W
MELTER
500W
209
GND
GB1
NC
NO
CR1
PS1
A1
A2
OK
-V
-V
+V
See page 80.
Hose / Applicator Wiring
COM
G
N
L
+V
122
J9
J8
J7
J1
G
L3
L2
L1
Grn/yel
BRN
16
15
14
13
12
MZTCM 1
112
BLU
J5
DH
DL
-V
+V
DRN
AUX4
AUX3
EARTH
GND
VCAN
AUX2
EARTH
GND
VCAN
AUX1
EARTH
GND
VCAN
AUX2
AUX1
VCAN
VCAN
AUX4
AUX3
VCAN
VCAN
DH
DL
-V
DRN
J6
+V
112a
125
124
126
402
121
Over temp
CYCLE SWITCH PUMP
LEVEL SENSOR
AIR SOLENOID
RTD
TEMP
OVER
See page 80.
Hose / Applicator Wiring
129
ADM
DH
DL
-V
+V
DRN
J9
J8
G
L3
L2
L1
118
MZTCM 2
DH
DL
-V
+V
DRN
DH
DL
-V
+V
DRN
123
Electrical Schematics
Systems with Two MZLP Modules
251
3A2347W
Electrical Schematics
Systems with Three MZLP Modules
3A2347W
79
Electrical Schematics
Typical Hose Applicator Wiring
80
3A2347W
Parts
Parts
InvisiPac Systems
System Parts, Page 1 of 3
3
28
8
43
39
30
58
29
8, 75
74, 82
7
3
69
43
44
27
8, 75
8, 75
ti20732a
45
3A2347W
43
2
Apply door gaskets (11) to door (10) per layout diagram.
5
Apply pipe sealant to all non-swiveling pipe threads.
7
Orient as shown.
81
Parts
System Parts, Page 2 of 3
1
Torque to 5-11 ft-lb (7-15 N•m).
2
Apply door gaskets (11) to door (10).
3
Torque to 8-10 in-lb (0.9-1.1 N•m).
61
20
61a
48
62
43
25
13
26 3
5
12
8
13
7
53
24
1
41
52
3 1
2 11
42
10
1
40, 54
4
8
1
43
83
63
63
8
9
82
3A2347W
Parts
System Parts, Page 3 of 3
35
41 in.
(1.04 m)
33
16 in.
(0.41 m)
57
34
48 in.
(1.22 m)
35
41 in.
(1.04 m)
32
36
13 in.
(0.33 m)
34
7 in.
(0.18 m)
35
41 in.
(1.04 m)
34
87
2 in.
(0.05 m)
66 64
34
48 in.
(1.22 m)
64
66
55
65
88
34
2 in.
(0.05 m)
33
23 in.
(0.58 m)
WLF
3A2347W
83
Parts
System Parts
Ref
1
3
4
5
7
8
9
10
11
12*
13*
20
22
24
25◆
26◆
27
28
29
30❄
31
32†
33†
34†
Part
--115942
167002
24R375
--113161
----------24R041
--116658
----------24P860
117026
112739
C12509
---
35†
36†
39
40
41
42
43▲
44
45
48
49
52
53✖
54
55
57
58
61
61a
62*
63
64
65
598095
----------16U029
----110932
C38321
16T675
16T677
--------17F461
110932
--121487
198177
---
66
67
68
--101976
255021
84
Qty
Description
1
ENCLOSURE, electrical
8
NUT, hex, flange head
4
INSULATOR, heat; washer
1
MELTER AND PUMP
1
TRAY, drip
15
SCREW, flanged, hex head
1
AIR CONTROLS ASSEMBLY
1
DOOR, front
1
FOAM, border, door
1
ADAPTER, melter inlet
2
CLAMP, hose, spacer
1
SENSOR, ultrasonic
1
SHAKER AND TUBE, feed system
1
FITTING, tube, male, 1/4 npt
1
SWITCH, cycle
1
FASTENER, screw, pn hd M4 x 35 mm
1
BRACKET, back
1
COVER, filter
1
COVER, melter
1
MODULE, Advanced Display (ADM)
2
SCREW, socket head cap, M5 x 12
1
TEE, union
3.25
TUBE, nylon, round
HOSE, nylon, 3/8 in. OD, 250 psi (1.7 4.92
MPa, 17 bar)
6.75
TUBE, 5/32 in. OD, nylon
1.3
TUBE, PTFE, 1/4 in. OD
1
GROMMET, 1/4 in. ID
2
BUSHING, strain relief
1
GROMMET, wire
1
GROMMET, tube
1
LABEL, safety
1
LABEL, InvisiPac
1
LABEL, pressure gauges
1
CONNECTOR, male
10
STRAP, tie, cable
1
INSULATOR, melter manifold
1
INSULATOR, melter
2
NUT, bushing
1
LABEL, identification
1
COUPLER, 3/8 in. OD tubing
1
BRACKET, mounting
1
FUNNEL, inlet, feed
1
CONNECTOR, male
1
MANIFOLD, feed inlet
3
GROMMET, sheet metal, 3/4 in.
2
FITTING, connector, male
1
FITTING, tee, 1/8 npt x 3/8 in. tube x
3/8 in. tube
2
RESTRICTOR, air, 0.0225 in. orifice
1
TOOL, allen, wrench
FITTING, straight, hydraulic
(assemblies 24P260, 24P262, 24P264
only; Qty 2)
(assemblies 24P261, 24P263, 24P265
only; Qty 4)
(assemblies 24U132, 24U133, 24U133
only; Qty 6)
Ref
69
70
74
75
80
82
83
85
86
87
88
89
92
93
94
95◆
Qty
Part
Description
1
114606 PLUG, hole
1
24R324 SOFTWARE UPGRADE TOKEN, InvisiPac System
3
117126 SCREW, socket head cap, M5 x 16
4
16V153 WASHER, retaining
1
262907 FUNNEL SCREEN KIT (not shown)
2
117017 WASHER
1
16V540 INSULATOR, melter assembly
1
24V289 MZLP FUSES KIT (not shown)
1
24P176 I/O CONNECTOR KIT (not shown)
1
108982 CONNECTOR, tube
1
24R707 AIR INLET KIT
114271 RETAINING STRAP
(assemblies 24P260, 24P262, 24P264
only; Qty 8)
(assemblies 24P261, 24P263, 24P265
only; Qty 16)
(assemblies 24U132, 24U133, 24U133
only; Qty 24)
127208 FITTING, tee, 6 JIC x 6 JIC x 9/16-18
(assemblies 24U132, 24U133, 24U133
only; Qty 2)
FITTING, 45° elbow, hydraulic
(assemblies 24P260, 24P262, 24P264
only; Qty 2)
(assemblies 24P261, 24P263, 24P265
only; Qty 4)
(assemblies 24U132, 24U133, 24U133
only; Qty 2)
116793 FITTING, elbow, hydraulic, 9/16-18 x
9/16-18(assemblies 24P260, 24P262,
24P264 only; Qty 2)
(assemblies 24P261, 24P263, 24P265
only; Qty 4)
(assemblies 24U132, 24U133, 24U133
only; Qty 2)
--WASHER, flat
--- Not for sale.
▲ Replacement Danger and Warning labels, tags, and cards
are available at no cost.
❄ ADM does not come with software. Order software token
24R324.
Available kits (purchase separately):
Kit
24R885◆
24R028*
24R030†
Description
Cycle Switch
Inlet housing
Tubing
24R031✖
Melter
24U635
Acrylic Lens
Pressure Gauge
Includes
25, 26, 95
12, 13, 62
32, 33, 34, 35, 36, 304. See
Feed System Shaker and
Tube, 24T812 on page 90 for
identification of item 304.
53, 202, 204, 207, 211, and
253. See Melter and Pump
Parts on page 88 for identification of items 202-253.
3A2347W
Parts
Electrical Enclosure
MZLP 3
MZLP
118 4
113
114
112a
106, 107
3 118
113
114
120
110
112 2
108
113
109
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.
WLD
MZLP 2
114
101
131
132
117
111
104
102
3A2347W
WLE
105
85
Parts
Electrical Enclosure Parts
Ref
101
102
104
105
106
107
108
109
Part
--126807
123970
126839
----104641
502937
110 114421
111 117666
112* --112a 24R042
113† 16T440
✿
114
116
125856
24P175
117 115942
118† 24V510
✿✖
119
---
120 196762
121† 16T087
✿
122
123
124
125◆
126
129†
✿
16T088
16T089
16T103
16T106
16T108
16T201
130
114958
86
Description
Qty
CABINET, controls
1
MODULE, breaker
1
SWITCH, disconnect, 40 amp
1
CONTACT, n-pole
1
BUSHING, strain relief, M40 thread
1
NUT, strain relief, M40 thread
1
FITTING, bulkhead
1
FITTING, tee, 3/8 tube, 1/4 male
1
npt
BUSHING, strain relief
1
TERMINAL, ground
1
MODULE, MZLP with Daughter
1
Board
MZLP DAUGHTER BOARD
1
CAP, jam nut, sealing
(1 MZLP assemblies only; Qty 2)
(2 MZLP assemblies only; Qty 4)
(3 MZLP assemblies only; Qty 6)
SCREW, 8-32, serrated flange
12
PLATE, blank, single MZLP
(1 MZLP assemblies only; Qty 2)
(2 MZLP assemblies only; Qty 1)
NUT, hex, flange head
1
MODULE, GCA, MZLP
(2 MZLP assemblies only; Qty 1)
(3 MZLP assemblies only; Qty 2)
GASKET, foam, MZLP
(1 MZLP assemblies only; Qty 2)
(2 MZLP assemblies only; Qty 1)
PIN, straight
1
CABLE, board, male/male, 4 in.
(101 mm)
(2 MZLP assemblies only; Qty 1)
(3 MZLP assemblies only; Qty 2)
CABLE, power, male/wire
1
CABLE, CAN, male/female, 1 m
1
CABLE, pump
1
SENSOR, band heater temperature
1
CABLE, ultrasonic, M12-4p, 1 m
1
HARNESS, 2nd MZLP
(2 MZLP assemblies only; Qty 1)
(3 MZLP assemblies only; Qty 1)
STRAP, tie
4
Ref
131
Part
Description
113974 SCREW, machine, slotted hex
washer head
132 123967 KNOB, operator disconnect
133 24P176 KIT, Customer I/O connector
134✿ 16W034 HARNESS, 3rd MZLP
135✿ 16W035 CONNECTOR, jumper
Qty
2
--- Not for sale.
Available kits (purchase separately):
Kit
Description
24R237† Upgrade from 2
channel system to 4 channel system
Includes
113, 118, 121, 129, a
grounding wrist strap, and a
software upgrade token.
See 4 Channel Upgrade
Kit, 24R237 on page 103.
24U575✿ Upgrade from 4 113, 118, 121, 129,134,
channel sys135, grounding wrist strap,
tem to 6 chan- and a software upgrade
nel system
token. See 6 Channel
Upgrade Kit, 24U575 on
page 105.
24R040◆ RTD
125, 251, and 255. See
Melter and Pump Assembly, 24R375 on page 87.
24V289 MZLP fuses
Qty 8 - 8 Amp, 250V Fuses
Qty 2 - 16 Amp, 250V
Fuses
24P176 Customer I/O
2 connectors for connectConnectors
ing to H1 and H2 on MZLP
daughter board. Use for
PLC connection.
*
Purchase MZLP (118) and daughter board (112a)
separately.
✖ Use Blank Plate Kit (116) if removing MZLP (118).
3A2347W
1
1
1
1
Parts
Melter and Pump Assembly, 24R375
2 208
8 211
218
204
217
216
2 202
239
217
235
4 236
4 205
238
233
223
207
253
215 8
234 5
254
259 3
230 3
224
213
240 3
206
260
232
237
249
206
210
219
250
252 7
203
201
249
226
222 4
211 8
301
252
7
225 5
251
214
255
300
221
227
228
229
231
232
230 4
257
8
246
258
245a
209
8 247
206
242
243
1
Lubricate all seals and o-rings with
grease.
2
Orient melter (202) sensor hole in line
with band heater (208) clamp.
3
Torque to 5-11 ft-lb (7-15 N•m).
3A2347W
4
Torque to 24-30 ft-lb (33-41 N•m).
5
Orient u-cups (225, 234) with springs
in direction shown.
7
Assemble inserts (252) 0.01-0.05 in.
(0.3-1.3 mm) below surface.
244
245
8
Torque to 12-18 ft-lb (16-24 N•m).
87
Parts
Melter and Pump Parts
Ref
201❄
202✖
203•
204✖
205
206•
207✖
208
209
210
211✖
Description
MANIFOLD, melter base
MELTER
MANIFOLD, outlet
PLATE, mounting
HOUSING, heater
RING, retaining, internal
O-RING, FKM, 157
HEATER, band
HEATER, fire rod, 500 watts
HEATER, fire rod, 1000 watts
SCREW, cap, sh, 5/16-18, 0.5 in.
long
213
24R369 INLET FILTER
214•❄ 112855 PACKING, o-ring
215
24T297 PLUG, o-ring boss
216ॠ--SLEEVE, cylinder
217†‡• 108526 PACKING, o-ring, PTFE
218✓ 24R025 MOTOR, air, 2.5 in., 0.48 in.
stroke, high temperature
219
--PLATE, pump adapter
220
--ROD, tie
221• 192624 GUIDE, ball
222◆• 239932 VALVE, piston
223◆• --ROD, piston
224†◆• 105444 BALL, 0.3 in.
225†◆• --SEAL, u-cup, piston
226†◆• --BEARING, piston
227†• 105445 BALL, 0.5 in.
228†• 192642 SEAT, carbide
229†• 107079 PACKING, o-ring
230• --HOUSING, foot valve
231†• 105802 PACKING, o-ring
232†❖• 113944 PACKING, o-ring
233†• --BEARING, throat
234†‡• --SEAL, u-cup, throat
235• 193046 NUT, packing
236❖• --FILTER, assy, 100 mesh
237❖• 15K234 PACKING, o-ring
238✓ 196762 PIN, straight
239✓ 196750 SPRING, retaining
240
128190 SCREW, socket head cap,
5/16-18, 1.0 in long
242★• 117059 O-RING, fluoroelastomer
243★• 16W327 RETAINER, seat, dump valve
244★• 15Y627 PACKING, o-ring #2-116, PTFE
245★• --VALVE, relief
245a 126474 FITTING, push to connect
246• C19829 SCREW, cap, socket head,
5/16-18, 2.5 in. long
247• 15H304 FITTING, plug 9/16 in. SAE
249
167002 INSULATOR, heat
88
Part
----------111317
126475
24R039
24R034
24R036
128167
Qty
1
1
1
1
1
3
1
1
1
1
7
1
1
1
1
2
1
1
3
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
3
1
1
1
1
1
4
5
10
Ref
250•
251**•
252•❄
253✖
254
255**•
Part
24R037
126780
----558722
107388
256
257
258
259
------115506
260
297*
298*
299*
300
301
115814
24P615
126961
116793
128612
103610
*
Description
Qty
HEATER, fire rod, 1500 watts
1
SWITCH, over temperature
1
INSERT, helical
7
PLATE, melter
1
O-RING, 910
1
SCREW, machine, panhead,
2
#4-40, 3/8 in. long
LUBRICANT, grease
1
BRACKET, melter
1
GROMMET, 1/4 in. ID
1
SCREW, machine, hex washer
4
head, 1/4-20, 3.0 in. long
WASHER, flat
3
FITTING, straight, hydraulic
1
FITTING, 45 deg. elbow, hydraulic
1
FITTING, 90 deg. elbow, hydraulic
1
TUBE, cross over
1
O-RING, 014
2
Not shown or assembled. Quantity equals number of channels the unit supports.
--- Not for sale.
Available kits (purchase separately):
Kit
24P852†
Description
Pump repair
24P853‡
Cylinder
24P854◆
24P855❖
24P856★
Pump rod
100-mesh filter
Pressure relief
valve
Air motor
Melter
24R025✓
24R031✖
24R040**
24R709 •
24W594❄
24W595
---
Includes
217, 224, 225, 226, 227, 228,
229, 232, 233, 234, and seal
installation tool 15B661.
216, 217, 234, and seal installation tool 15B661.
222, 223, 224, 225, 226
232, 236, 237
242, 243, 244, 245
218, 238, 239
202, 204, 207, 211, 253, and
insulator (53). See InvisiPac
Systems parts starting on
page 81 for insulator (53)
identification.
Kit, RTD Har125, 251, and 255. See Elecness and Switch trical Enclosure on page 85.
Assembled pump 203, 206, 214, 216, 217, 221,
manifold
222, 223, 224, 225, 226, 227,
228, 229, 230, 231, 232, 233,
234, 235, 236, 237, 242, 243,
244, 245, 246, 247, 250, 251,
252, 255
Melter base kit
201, 214, 254, 252
Filter rebuild kit
See Filter Rebuild Kit,
24W595, page 110
Special tools
See Special Tools on page
94.
3A2347W
Parts
Air Motor, 24R025
4 511
528
1
Torque to 11-13 ft-lb (15-18 N•m).
2
Apply water-resistant grease.
3
Apply epoxy adhesive then torque to
35-40 ft-lb (47-54 N•m).
4
Torque to 95-105 in-lb (10.7-11.9 N•m).
513 2 4
527
518
512 1
509
4 511
520
3
507
503
522
508
501
515
507 2
517
519
504 2
502 2
505 2
502 2
523
ti20903a
506
513 2 4
510
24R025 Parts
Ref
Part
Description
501
--COVER, lower, 2.5 in.
502◆ 108993 PACKING, o-ring
503
--BEARING, 9/16 in.
504★◆ --PACKING, o-ring, FKM
505
15M289 CYLINDER, motor, 2.5 in.
506
--COVER, air motor
507◆ --SEAL, u-cup, FKM
508◆ --GASKET, cover, small
509†◆ --SEAL, air valve, manifold
510
15M291 COVER, motor, 2.5 in.
511† --SCREW, M6 x 25, thread forming
512
15M314 SCREW, cap
513
24R027 VALVE, pilot
515
15M213 MUFFLER, 3/8
516
--GREASE, water-resistant
517◆ --RING, retaining
518★ --ROD, air motor, 2.5 in.
519★ --PISTON, air motor, 2.5 in.
3A2347W
Qty
1
2
1
1
1
1
2
2
1
1
8
2
2
1
1
1
1
1
Ref
Part
520
--521★◆ --522
105444
523
--527† 24R026
528
---
Description
MANIFOLD, medium, short
ADHESIVE
BALL, 0.3 in.
LABEL, identification
VALVE, air, small
BRACKET, feed inlet assembly
Qty
1
1
4
1
1
1
--- Not for sale.
★ Included in Air Motor Piston Kit 24R705 (purchase separately.
◆ Included in Air Motor Seals Kit 24R706 (purchase separately).
†
Included in Air Motor Valve Kit 24R026 (purchase separately).
89
Parts
Feed System Shaker and Tube, 24T812
306
301
1
304
302
1
Apply pipe sealant to threads.
ti20738a
Parts
Ref
301
302
303†◆
304
305◆
306
Part
24P861
24N954
---
Description
SHAKER
TUBE, steel
TUBE, clear PVC, 1.3 in.
(33 mm) OD
--HOSE, nylon, 3/8 in. OD,
250 psi (1.7 MPa, 17 bar)
125370 CLAMP, hose, dia. 11/16 to
1-1/2 in.
125871 TIE, cable, 7.50 in. (190 mm)
Qty
1
1
10
15.5
3
4
† 30 ft (9.1 m) Feed Hose Kit 24R043 also available
(purchase separately). Kit also includes 2 hose
clamps.
★ Included in Tubing Kit 24R030. See System Parts
on page 84 for other kit contents.
◆ Not shown.
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.
90
3A2347W
Parts
Air Controls Assembly
402
405
406
1 404
401
1 404
403
ti20737a
1
Apply sealant to all non-swiveling pipe threads.
Air Controls Assembly Parts
Ref
401
402
403
404
405
406
3A2347W
Part
Description
--PANEL, air, controls
24R029 CONTROL, air, vacuum transfer and pump
15T500 GAUGE, pressure, air, panel
mount, 1/8 in. npt
15T498 FITTING, 90 degree, swivel,
5/32 in. tube x
1/8 in. female npt
100058 SCREW, cap, hex head
054753 TUBE, nylon, round, black
--- Not for sale.
Qty
1
1
2
2
2
2
91
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
Apply sealant to all non-swiveling pipe threads.
2
Apply grease.
3
Torque to 4-6 in-lb (0.5-0.7 N•m).
Ref
601
602
603
604
605
606
607
608†
92
613
1
Part
----15T413
--------108771
Description
BODY, fluid
BODY, air
PISTON, air
AIR CAP, valve
BEARING, shaft, needle
SHAFT, needle, valve
SOCKET, ball assembly
PACKING, o-ring
Qty
1
1
1
1
1
1
1
1
Ref
609†
610
611†
612†
613
614†
Part
110073
111841
----126474
---
Description
PACKING, o-ring
WASHER, plain 5/8 in.
BEARING, valve
O-RING, FKM
FITTING, push to connect
SEAL, u-cup, relief valve
i
Qty
1
2
1
1
1
1
--- Not for sale.
† Parts included in Relief Valve Repair Kit 24P857
(purchase separately).
3A2347W
Parts
Feed Inlet Funnel, 17F461
701
705
707
706
WLF
Ref
701
705
706
707
Part
262907
-------
Description
Qty
FILTER AND CAP ASSEMBLY
1
SCREW, #10-16, thread forming
2
FUNNEL, feed inlet
1
FOAM, screen, funnel
1
Inlet Funnel Filter Kit, 24U701
Ref
707
Part
---
Description
FOAM, screen, funnel
Qty
10
--- Not for sale.
3A2347W
93
Accessories
Accessories
Special Tools
These special tools are designed to make system repairs as easy as possible while ensuring that parts do not get
damaged.
Part
1301*
1302*
1303*
*
Purpose
Remove Cylinder
Install Cylinder - Female
Install Cylinder - Male
Parts included in Cylinder Tools Kit 24R227 (purchase separately).
Part
1304**
1305**
1306**
Purpose
Install Rod - Female
Install Rod - Male
Install Rod - Bullet
** Parts included in Rod Tools Kit 24R228 (purchase
separately).
ti20983a
94
3A2347W
Accessories
Preventive Maintenance Kit
This kit contains components which are commonly used
in maintenance.
Gen 1 HM25 Preventive Maintenance Kit, 24X865
Ref
1
2
3
4
5
6
7
8
Part
24U701
24W595
24X967
16T124
24P802
24X220
127110
102360
Description
Kit, Foam, Screen, Funnel
Kit, Filter Rebuild
Filter, Air, Repair
Filter, Screen, Wire
Kit, Gun Filter, 3pk
Switch, Reed
Screw, #8-32
Washer, Flat
Qty
1
2
2
1
4
1
1
1
Complete Maintenance Kit
This kit contains repair components which are not part
of regular preventive maintenance.
Gen 1 HM25 Complete Maintenance Kit, 24X869
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
Part
24P856
24P861
24R027
24R026
24R041
24P852
127520
24R042
24R885
24V510
24P859
24R039
24R037
24R036
24R034
127411
3A2347W
Description
Kit, Valve, Discharge
Kit, Shaker, Feed
Kit, Poppet
Kit, Valve, Motor
Kit, Level Sensor
Kit, Repair, Pump
Kit, Power Supply
Kit, Board, Daught.
Kit, Cycle Switch
Kit, MZLP w/ fuses
Kit, Fuses, MZLP
Kit, Band Heater
Kit, 1500W Heat Rod
Kit, 1000W Heat Rod
Kit, 500W Heat Rod
Jumper, OT
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
95
Accessories
Non-Graco Gun Adapter Cables
16T916: For connecting to non-Graco guns that use a
rectangular, 6-pin connector.
128372: For connecting to non-Graco guns that use a
rectangular 8-pin connector.
ti21128a
ti21128a
ti26719a
16T917: For connecting to non-Graco guns that use a
circular, 9-pin connector.
Non-Graco Gun Adapter Cable Installation
See Attach Components on page 13.
ti21129a
16Y828: For connecting to non-Graco guns that use a
circular 6-pin connector. IPx6 rated.
WLD
96
3A2347W
Accessories
Air Adjustment Lock, 24R084
Panel enables locking access to the air adjustment
screws.
801
802
ti20984a
NOTE: Screws are part of the base system and are
not included in the kit.
Ref
801
802
Part
-----
Description
PANEL, lock, air control
BRACKET, lock, air control
Qty
1
1
Air Adjustment Lock Installation
1. Remove screws from system air panel.
2. Use screws to install panel (801).
3. Snap bracket (802) into panel (801).
4. Insert lock through hole in panel and bracket to lock
access to the air controls. Lock not included in kit.
3A2347W
97
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
1102
A
1103
Ref
1101
1102
1103
1104
ti21918a
Part
--112395
112958
121283
Description
PLATE, adapter
SCREW flange head cap
NUT, hex, flanged
FITTING, elbow, 45 degree
Qty
1
6
9
1
ti20985a
Ref
1001
1002
1003
Part
--112395
112958
Description
STAND
SCREW flange head cap
NUT, hex, flanged
Qty
1
3
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).
98
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).
3A2347W
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*
Ref
901
902
903
904
905
907
908
909
910
Part
----126930
126929
-----
Description
Qty
HOPPER, 30 gallon
1
LID, hopper, 30 gallon
1
SHAKER, ball vibrator
1
VALVE, air pilot, 3-way, closed
1
BRACKET, shaker, container
1
HOSE, nylon, 3/8 in. OD, 250 psi
1
(1.7 MPa, 17 bar)
119798 CONNECTOR, tee, push-tube
1
113779 MUFFLER
1
111192 SCREW, cap flange head
2
3A2347W
Ref
912
914*
915
916
917
912
Part
Description
Qty
125857 SCREW, 10-24, serrated flange
4
121141 FITTING, elbow, swivel, 3/8 in.
1
tube connector, 1/4 male npt
120389 FITTING, tube
2
--CONNECTOR, tube, 90 degree
1
125539 FITTING, splitter, 3/8 in. OD tub1
ing
--- Not for sale.
*
Metric fitting included in Air Metric Fitting Kit,
24W637, page 110.
99
Accessories
30 Gallon Vibrating Hopper Installation
See FIG. 56 for illustration of installed vibrating hopper.
1. Turn main power switch OFF.
Splitter fitting
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.
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).
WLE
To shop air
supply
ti21350a
FIG. 56
NOTE: The hopper shaker will be active while the vacuum transfer system is transferring pellets.
100
3A2347W
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
J3
F5
J2
1202
F4 F3
F2
BB
F1
J1
J12
J6
J7
J5
F10 F9
F8 F7
F6
1205
ti20987b
24R226 Parts
Ref
1201
1201a
1202
1203
1204
1205
Part
16T102
----16K322
--125835
Description
LIGHT, tower, red and green
SCREW
GROMMET, single cable
BRACKET, light tower
GROMMET, multiple wires
CLIP, ferrite bead
Qty
1
3
1
1
1
1
--- Not for sale.
3A2347W
101
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.
1505
8. Route light tower cable through the other hole in the
bracket (1203), then through the grommet (1204)
into the electrical enclosure.
1503
1504
1504*
1505
9. Connect light tower cable to MZLP connector
labeled J12.
1506
1501
16W366 Parts
Ref
1501
1502
1503
1504*
1505
1506
Part
--100081
113777
114485
155665
---
Description
HOSE, nylon (6 ft)
BUSHING, pipe
TEE, branch
CONNECTOR, male, 3/8 npt
UNION, adapter
TANK, air, accumulator
Qty
1
1
1
2
1
1
--- Not for sale.
*
102
Metric fitting included in Air Metric Fitting Kit,
24W637, page 110.
3A2347W
Accessories
4 Channel Upgrade Kit, 24R237
Use this kit to upgrade a 2 channel system to a 4 channel system.
AA
1301
1306
BB
1305
1302
1304
ti20988a
◆ Not shown.
Ref
1301
1302
1303
1304
1305
1306
Part
--16T087
16T201
112190
16T440
24R324
3A2347W
Description
Qty
MODULE, GCA, MZLP
1
CABLE, jumper, male/male, 4 in.
1
HARNESS, 2nd MZLP power
1
STRAP, wrist, grounding
1
CAP, jam nut, sealing
2
SOFTWARE UPGRADE
1
TOKEN, InvisiPac System
103
Accessories
4 Channel Upgrade Kit Installation
1. Disconnect plug from power outlet or turn off circuit
breaker for incoming power.
2. Place grounding wrist strap (1304) over your wrist
and secure other end to a grounded surface.
3. Set MZLP rotary switch to “1” on MZLP with daughter card.
4. Set MZLP rotary switch to “2” on MZLP without
daughter card.
5. Remove screws (BB) then remove plate (AA) from
system.
6. Use screws (BB) to install MZLP (1301) onto system.
NOTE: The new MZLP (1301) with be referred to as
MZLP 2, and the original MZLP that came with the system will be referred to as MZLP 1 from here on. See FIG.
57.
7. Remove electrical enclosure front access door.
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop and verify the connector orientation. Verify the
connector has ‘Locked’ by gently pulling on the white
connector housing.
8. Move CAN connector from MZLP 1 connector J3 to
MZLP 2 connector J6. See FIG. 57.
9. Move power cable (CC) from MZLP 1 connector J6
to MZLP 1 connector J3. See FIG. 57.
10. Connect jumper cable (1302) to MZLP 1 connector
J6 and connect other end of jumper cable (1302) to
MZLP 2 connector J3. See FIG. 57.
11. Connect wires from power harness (1303) to connectors as labeled on the plastic connector.
12. Connect power harness (1303) to MZLP 2 connector J2.
Step 8: Move CAN Connector (DD).
MZLP 2
MZLP 1
J6
J1
J5
J9
J3
Step 9:
Move
Power
Cable
(CC).
J8
J2
J2
J8
J9
J1
J3
J5
J6
ti20989a1
Step 10: Install Jumper Cable (1302).
FIG. 57
104
3A2347W
Accessories
6 Channel Upgrade Kit, 24U575
Use this kit to upgrade a 4 channel system to a 6 channel system.
1304
CC
1308
1302
WLD
BB
1307
AA
1306
BB
1303
1305
1301
Ref
1301
1302
1303
Part
--16T087
112190
3A2347W
Description
Qty
MODULE, GCA, MZLP
1
CABLE, jumper, male/male, 4 in.
1
STRAP, wrist, grounding
1
Ref
1304
1305
1306
1307
1308
Part
24R324
16T440
16W034
16W035
127208
Description
TOKEN, software upgrade
CAP, jam nut, sealing
HARNESS, MZLP #3
CONNECTOR, jumper
FITTING, tee
Qty
1
2
1
1
2
105
Accessories
6 Channel Upgrade Kit Installation
1. Disconnect plug from power outlet or turn off circuit
breaker for incoming power.
7. Move ADM CAN connector from MZLP 2 connector
J6 to MZLP 3 connector J3. See FIG. 58.
2. Place grounding wrist strap (1303) over your wrist
and secure other end to a grounded surface.
8. Connect CAN jumper cable (1302) to MZLP 2 connector J6 and connect other end of jumper
cable (1302) to MZLP 3 connector J6. See FIG. 58.
3. Set MZLP (1301) rotary switch to “3”.
9. Install jumper connector (1307) in J5 on MZLP 3.
4. Remove screws (BB) then remove plate (AA) from
system.
5. Use screws (BB) to install MZLP (1301) onto system.
10. Connect wires from power harness (1306) to connectors as labeled on the plastic connector.
11. Connect power harness (1306) to MZLP 3 connector J2.
6. Remove electrical enclosure front access door.
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop and verify the connector orientation. Verify the
connector has ‘Locked’ by gently pulling on the white
connector housing.
12. Remove plugs (CC) from fluid manifold and replace
with tee fittings (1308).
NOTE: The new MZLP (1301) will be referred to as
MZLP 3, and the original MZLPs that came with the system will be referred to as MZLP 1 and MZLP 2 from here
on. See FIG. 58.
Step 8: Install jumper cable (1302).
0=/3
0=/3
-
7R
$'0
0=/3
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Step 7: Move ADM CAN connector.
WLD
FIG. 58
106
3A2347W
Accessories
Single-Phase 480V to 240V Transformer, 24U169
This transformer must be installed by a qualified electrician to operate 240V InvisiPac units with single-phase
480V electrical supply.
NOTE: When using transformer 24U169, the ADM amp
limit must be set to 30 amps and power type set to single phase. See step 4 of Select ADM Settings on page
20.
24U169 Electrical Specifications:
Phase:
Single
Frequency:
60 Hz
kVa:
7.5 kVa
K Rating:
1
Primary Config.:
2 winding
Secondary Config.: 2 winding
Winding material: Copper
Connection:
Wire leads
24U169 Mechanical Specifications:
Temperature Rise: 115°C (239°F)
Insulation Sys.:
180°C (356°F)
Cooling Sys.:
Air/Dry
Construction:
Enclosed-encapsulated core and coil
Enclosure:
Steel, NEMA 3R
24U169 Approvals:
Approvals:
UL listed, cUL listed, CSA approved
Sound level:
Below NEMA standards
24U169 Mounting Information:
10.6 in. (270 mm)
3A2347W
Primary Voltage
240 x 480
Secondary
Voltage
120/240
Taps
None
Primary
H1
H3
H2
H4
X4
X2
X3
X1
Secondary
Volts
480
240
240
240/120
120
Connections
H2 - H3
H1 - H3, H2 - H4
X2 - X3
X2 - X3
X1 - X3, X2 - X4
Line Leads
H1, H4
H1, H4
X1, X4
X1, X2, X4
X1, X4
8.0 in. (203 mm)
7.0 in. (178 mm)
15.0 in. (381 mm)
10.2 in. (258 mm)
24U169 Wiring:
1/4 in. (6 mm) Mounting
Hardware Required
Weight: 150 lb (68 kg)
107
Accessories
InvisiPac ADM Simulator Kit, 24R323
Use this kit to train users in ADM operation without using
the full InvisiPac system. Kit includes everything necessary
to simulate the ADM screens. Does not include an InvisiPac system.
1401
Ref
1401
1402
1403
1404
1405
Part
Description
24P860 MODULE, Advanced Display
(ADM)
124149 POWER SUPPLY, GCA
--CORD SET, US, MX, PR, CA,
TW, 115V, 10A
24R322 TOKEN, InvisiPac Simulator
24R324 SOFTWARE UPGRADE
TOKEN, InvisiPac System
Qty
1
1
1
1
1
Simulator Instructions
1. Remove ADM access panel and install InvisiPac Simulator Token (1404).
1402
1404
1403
r_24P860_3B9900_3a
FIG. 59: Remove Access Panel
ti20990a
2. Connect power supply (1402) to ADM (1401).
3. Connect cord (1403) to power supply (1402).
4. Perform Software Update Procedure on page 74.
108
3A2347W
Accessories
Overtemperature Jumper,
16Y727
Use the Overtemperature jumper plug to run the
InvisiPac melter without a hose and gun attached to the
Channel 1 electrical connection.
Installation
1. In the ADM setup screens, uninstall Channel 1. All
other Channels can be installed or uninstalled as
needed.
NOTE: Failure to uninstall Channel 1 on the ADM setup
screens will result in several Alarms regarding Channel
1 when there is no hose/gun attached to Channel 1.
2. Attach the Overtemperature jumper plug to Channel
1.
WLD
3. The ADM should have zero Active Alarms. The
melter is now ready to run without a hose and gun
attached to Channel 1.
Strain Relief Bushing Kit,
24X190
The strain relief bushing kit allows the use of a smaller
outside diameter (OD) power cord. This strain relief
bushing is intended for power cords with an OD of
0.512-1.024 in (13-26 mm).
Installation
1. Remove standard strain relief bushing (106). Retain
and reuse nut.
2. Install strain relief bushing from kit and secure with
retained nut.
3A2347W
109
Accessories
Filter Rebuild Kit, 24W595
NOTICE
Shoulder bolt (6) is left-hand threaded. To prevent
damage to the threads, turn clockwise to remove and
counterclockwise to tighten.
9
10
2
Ref.
1✖
2
3
4
5✖
6
9
10
Part
16T383
126671
126672
126673
16T382
126674
113944
15K234
Description
HOUSING, filter
SCREEN, perforated
SCREEN, 100 mesh
SCREEN, wire
CAP, filter
BOLT, shoulder
PACKING, o-ring
PACKING, o'ring
Qty.
1
1
1
1
1
1
1
1
✖ Not included. Reuse parts when replacing filter
screens.
Air Metric Fitting Kit, 24W637
For replacing air fittings with metric air fittings on InvisiPac systems. See manual 334358 for installation
instructions.
Ref.
1
2
2
1
3
4
Part
Description
Qty.
127922 FITTING, 3/8 npt(m) x M18(f)
1
127923 FITTING, 1/4 npt(m) x 10 mm
1
tube
127924 FITTING, 1/4 npt(m) x 10 mm
1
90° elbow tube
127925 FITTING, 3/8-18 npt(m) x 3/8-19
1
bspt (f)
2
Material Tracking Kit, 24Y162
1
Apply anti-seize to threads.
2
Apply lubricant surfaces shown.
3
Torque to 70+/- in-lbs. (7.9 N•m).
4
Shoulder bolt (6) is left-hand
threaded.
3
4
Ref.
1
2
3
4
5
6
7
Part
124333
128069
128070
128071
128072
128073
16U422
Description
CABLE, extension, M12, 5M
SENSOR, reflector
BRACKET, angled
BRACKET, straight
SENSOR, polarized
SENSOR, diffuse
TOKEN, software upgrade
Qty.
1
1
1
1
1
1
1
5
1
6
3
4
110
3A2347W
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.
NOTE: For information on InvisiPac Pattern Controller
screens, see manual 334784.
Enable, Disable Heating System
To enable or disable the entire heating system,
press
Description
Use the physical numeric keypad on ADM to enter temperature setting.
Select channel to view and/or
edit the gun or hose temperature setting
gun temperature setting.
Use
and
to adjust setting.
Hose temperature setting.
Use
ting.
and
to adjust set-
Use to adjust temperature settings
. To set which channels are active when the
heating system is enabled, use the System 2 screen.
See page 114.
Reset weight total
Icon Identification
Icon
Temperature settings of gun
(top) and hose (bottom)
Description
Operation Screens Only
Reset material target
Setup Screens Only
Heating disabled
Warming up, actual temperature is below setting
Enter screen to change settings
Temperature setting achieved
Exit screen
Actual temperature of hose
(left) and gun (right)
Reset Maintenance error
Schedule Screen Only
Actual temperature of system
(shown warming up)
Edit schedule value
Erase schedule value
System temperature setting.
Accept schedule change
Use
ting.
and
to adjust setCancel schedule change
3A2347W
111
Appendix A - ADM
Operation Screens
Home
Events
This screen shows the actual temperatures of the system melter and each gun 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 117.
Targets
Tracked Events
Custom Language Downloaded
Custom Language Uploaded
Fill Valve Closed
Fill Valve Open
Heat Off
Heat On
High Material Usage
Logs Downloaded
Low Material Usage
Material Target Reset
Pump Cycles Total Reset
Pump Off
Pump On
Red Stop Button Pressed
Setup Value Changed
System Power Off
System Power On
System Settings Downloaded
System Settings Uploaded
USB Disabled
USB Drive Inserted
USB Drive Removed
User Maintenance Count Reset
Setpoint Changed
This screen shows and allows editing of the temperature
settings for the system melter and each gun and hose.
See Select ADM Settings on page 20.
*
112
Code
EQU3
EQU4
EBFX
EAFX
EBDX
EADX
ECAH
EQU5
ECAL
ERM1
ERD1
EBPX
EAPX
EB0X
EC0X
EM0X
EL0X
EQU1
EQU2
EVUX
EAUX
EBUX
ERN1
ECD(*)
Zone
3A2347W
Appendix A - ADM
Errors
The Errors screens store a maximum of 200 errors. See
ADM Error Code Table on page 40. The errors list can
be downloaded in the USB logs. See Appendix B USB Downloading, Uploading on page 117.
Diagnostic
This screen shows details of various items to aid in troubleshooting the system. This screen can be hidden by
de-selecting “Enable Diagnostics Screen” on the System 3 screen. The flow rate updates every 15-20 seconds with the average flow rate over the last 15-20
seconds.
The following information is displayed.
A
B
C
0: Pump Solenoid
1: Fill Solenoid
2: Light Tower Green Light
3: Light Tower Red Light
ISO DI: Customer Digital Inputs
0: Customer Input 1
1: Customer Input 2
2: Customer Input 3
3: Customer Input 4
ISO DO: Customer Digital Outputs
0: Customer Input 1
1: Customer Input 2
2: Customer Input 3
3: Customer Input 4
Fill: Reading of Ultrasonic Fill Sensor
• Old Fill Sensor (2750-2400 mV)
• New Fill Sensor (4200-3800 mV)
Fill Sol: Current draw of fill solenoid
• (0 mA - off)
• (150-250 mA - on)
Flow/H: Melt rate of the system
Life Cycles: total number of pump cycles over life of
system.
Life Weight: Weight of material dispensed over life of
system.
Pump Sol: Current draw of pump solenoid
• (0 mA - off)
• (150-250 mA - on)
PCB Temp: PCB Temperature on MZLP1
• 32-16°F (0-71°C)
Pump CPM: Pump cycles per minute.
USB DL%: Percentage Complete, only applies when
downloading USB data.
Material Log
This screen shows a daily log of material usage. For
more details see the Setup - Material Tracking section.
Diagnostic Data
Current Draw
RTD Reading
Duty Cycle
CAN: 24 VDC power supply voltage reading (18-28
VDC)
DI: System Digital Inputs
0: Not Used
1: Not Used
2: Pump Cycle Switch Up
3: Pump Cycle Switch Down
DO: System Digital Outputs
3A2347W
113
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
System Type: Choose the model of the system. Older
versions of software may not have this option.
Enable Diagnostic Screen: Choose whether to hide
the Diagnostic screen.
Pump Idle Time to System Inactive: The heating system will be disabled after the pump has been idle for the
set amount of time
Power Type: Select the system power type.
Circuit Breaker Size: Select the circuit breaker size.
Refill Setting: To use the automatic vacuum transfer,
select Auto. To disable the automatic vacuum transfer,
select Manual. The main reason to disable automatic
refill is while flushing. However, if an issue is present
with the automatic refill system that cannot be solved in
a timely manner, manual refill can be used to return the
system to service. See Manual Refill on page 30.
See Select ADM Settings on page 20.
A PLC can be used to control or monitor the system.
See PLC Connection on page 23 for instructions.
System 4
System 2
Use this screen to enable the installed channels and
specify the type of gun RTD type used. See Select
ADM Settings on page 20.
114
Enable ADM Unit Counter: Select to enable ADM
counting of units using an external sensor.
Enable material Alerts: Select to enable record only
events indicating low/high material usage.
Specific Gravity: Required to convert the volume dispensed to mass dispensed for tracking the total weight
and flow rate.
3A2347W
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.
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.
NOTE: The lifetime cycle count will only be reset if the
Advanced Display Module (ADM) is replaced.
Schedule
Advanced 2
Use this screen to set times where the system will automatically enable and disable heating. See Select ADM
Settings on page 20.
Temperature Units: Units of measure for displayed
temperatures.
Mass Units: Units of measure for mass.
Distance Units: Units of measure for distance.
3A2347W
115
Appendix A - ADM
Advanced 3
Advanced 4
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.
This screen shows the part number and version of each
installed software module.
116
3A2347W
Appendix B - USB Downloading, Uploading
Appendix B - USB Downloading, Uploading
The system can store 150,000 entries in its logs and the
system adds a new entry to the logs every 15 seconds.
This means the system stores 655 hours of system
operation data, or 27 days of around-the-clock operation. Once full, the system will overwrite the oldest data.
NOTE: To prevent losing any data, never go more than
27 days without downloading the logs.
NOTE: Older software may store more information than
stated above.
Download Procedure
NOTE: The system can log up to 45 mb of additional
data per week, depending on system operation.
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.
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 118.
1. Insert USB flash drive into USB port. See FIG. 60.
NOTE: Flash drive must be 8 GB or smaller.
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 118.
1. If necessary, follow the Download Procedure,
page 117, to automatically generate the proper
folder structure on the USB flash drive.
FIG. 60: ADM USB Port
2. The menu bar and USB indicator lights indicate that
the USB is downloading files. Wait for USB activity
to complete. A pop-up will be present until the transfer is complete if it is not acknowledged.
NOTE: If the pop-up screen does not appear, the flash
drive is not compatible with the ADM. Try a different
flash drive.
3A2347W
2. Insert USB flash drive into USB port of computer.
3. The USB flash drive window automatically opens. If
it does not, open USB flash drive from within Windows Explorer.
4. Open Graco folder.
5. Open system folder. If working with more than one
system, there will be more than one folder within the
Graco folder. Each folder is labeled with the corre-
117
Appendix B - USB Downloading, Uploading
sponding serial number of the ADM. (The serial
number is on the back of the module.)
6. If installing the system settings file, place SETTINGS.TXT file into UPLOAD folder.
7. If installing the custom language file, place DISPTEXT.TXT file into UPLOAD folder.
NOTE: To prevent losing any data, never go more than
43 days without downloading the logs.
GCA Log
This log (3-GCA.CSV) lists the installed GCA modules
and their respective software versions.
8. Remove USB flash drive from computer.
Black Box, Diagnostics Logs
9. Install USB flash drive into InvisiPac system USB
port.
These logs (4-BLACKB.CSV, 5-DIAGN.CSV) are
designed to provide useful information to Graco when
calling for technical assistance.
10. The menu bar and USB indicator lights indicate that
the USB is uploading files. Wait for USB activity to
complete.
System Settings File
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 117, 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.
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 117, 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.
118
3A2347W
Appendix B - USB Downloading, Uploading
System Language File
Create Custom Language Strings
The system language file name is DISPTEXT.TXT and
is stored in the DOWNLOAD folder.
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.
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)
Modify the second column of the custom language file
as needed and then follow the Upload Procedure,
page 117, 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.
•
•
•
•
•
•
3A2347W
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.
119
Technical Data
Technical Data
InvisiPac Hot Melt Delivery System
US
Electrical
Electrical Service
Maximum Gun Wattage Per Channel
Input / Output Capability
General
Adhesive
Pump Flow Rate
Pump Output
Time to Temperature *
Melt Rate / Constant Throughput
Pump
Channels
System Dimensions, without vacuum tube or
shaker (Width x Height x Depth) **
Shaker Dimensions (Width x Height)
Weight
Pressure and Temperature Ranges
Main System Air Supply Pressure Range (set with
regulator on front of system)
Pump Operating Air Pressure Range
Pump Operating Fluid Pressure Range
Control Temperature Range
Ambient Temperature Range
Vacuum Transfer Specifications
Maximum Vacuum Transfer Hose Length
Maximum Vacuum Transfer Hose Maximum Vertical Rise
Vacuum Transfer Operating Pneumatic Pressure
Range (set with regulator on front of system)
Vacuum Transfer Air Consumption at 40 psi (280
kPa, 2.8 bar),
Vacuum Transfer Air Consumption at 80 psi (550
kPa, 5.5 bar)
120
Metric
24P260: 200-240VAC, 1-ph, 50/60 Hz, 32A Max
24P261: 200-240VAC, 1-ph, 50/60 Hz, 40A Max
24P262: 350-415VAC/200-240VAC, 3-ph with Neutral, 50/60 Hz, 16A
Max
24P263: 350-415VAC/200-240VAC, 3-ph with Neutral, 50/60 Hz, 16A
Max
24P264: 200-240VAC, 3-ph without Neutral, 50/60 Hz, 27A Max
24P265: 200-240VAC, 3-ph without Neutral, 50/60 Hz, 27A Max
24U132: 200-240VAC, 1-ph, 50/60 Hz, 40A Max
24U133: 350-415VAC/200-240VAC, 3-ph with Neutral, 50/60 Hz, 30A
Max
24U134: 200-240VAC, 3-ph without Neutral, 50/60 Hz, 40A Max
400 W
4 inputs (0-30VDC), 4 outputs (240VAC, 24VDC, 2A)
1/4 in. (6 mm), round, adhesive pellets
96 lb/hr
43.5 kg/hr
6.2 cc/cycle
Less than 10 minutes
25 lb/hr
11.3 kg/hr
Pneumatic Piston, 12:1
1 to 4
19.0 x 42 x 16.5 in.
483 x 1067 x 419 mm
0.4 x 4.0 ft
85 lb
0.12 x 1.22 m
39 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)
3A2347W
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 9001
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.
3A2347W
121
Technical Data
Startup Time
Single 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
Breaker
240V
11
13
15
13
16
20
15
19
26
16
22
31
18
25
36
20
28
41
30 Amp
Breaker
240V
9.9
9.9
9.9
9.9
9.9
13
9.9
12
16
9.9
14
20
11
16
23
12
18
27
Start Time in Minutes
40 Amp
50 Amp
20 Amp
30 Amp
Breaker Breaker Breaker Breaker
240V
240V
208V
208V
9.9
9.9
13
13
9.9
9.9
14
13
9.9
9.9
17
13
9.9
9.9
15
13
9.9
9.9
18
13
9.9
9.9
23
13
9.9
9.9
17
13
9.9
9.9
22
13
12
9.9
29
19
9.9
9.9
18
13
9.9
9.9
25
16
14
12
35
23
9.9
9.9
20
13
11
9.9
28
18
17
14
41
27
9.9
9.9
22
13
13
10
32
20
20
16
47
31
40 Amp
Breaker
208V
13
13
13
13
13
13
13
13
13
13
13
16
13
13
19
13
13
22
50 Amp
Breaker
208V
13
13
13
13
13
13
13
13
13
13
13
13
13
13
15
13
13
18
3A2347W
Technical Data
Three Phase
NOTE: Times are approximate and may vary with ambient conditions, voltage configuration, and machine configuration.
Start Time in Minutes
Hose
20 Amp
30 Amp
40 Amp
50 Amp
20 Amp
30 Amp
40 Amp
50 Amp
Channels Length Breaker
Breaker
Breaker
Breaker
Breaker
Breaker
Breaker
Breaker
(#)
ft (m) 240V/480V 240V/480V 240V/480V 240V/480V 208V/415V 208V/415V 208V/415V 208V/415V
4
(1.2)
1
11
9.9
9.9
9.9
13
13
13
13
12 (3.6)
1
13
9.9
9.9
9.9
14
13
13
13
25
(7.6)
1
15
9.9
9.9
9.9
16
13
13
13
4 (1.2)
2
13
9.9
9.9
9.9
14
13
13
13
12
(3.6)
2
16
11
9.9
9.9
17
13
13
13
25 (7.6)
2
20
14
10
9.9
22
14
13
13
4 (1.2)
3
14
9.9
9.9
9.9
16
13
13
13
12
(3.6)
3
18
12
9.9
9.9
20
13
13
13
25 (7.6)
3
25
17
13
9.9
26
18
13
13
4
(1.2)
4
15
10
9.9
9.9
17
13
13
13
12 (3.6)
4
21
14
11
9.9
23
15
13
13
25 (7.6)
4
30
20
15
12
34
22
17
13
4
(1.2)
5
17
11
9.9
9.9
19
13
13
13
12 (3.6)
5
23
16
12
9.9
27
18
14
13
25
(7.6)
5
34
23
17
14
40
27
20
16
4 (1.2)
6
18
12
9.9
9.9
21
14
13
13
12 (3.6)
6
26
17
13
11
30
20
15
13
6
25 (7.6)
39
26
19
16
46
31
23
19
3A2347W
123
Technical Data
Dimensions
System Dimensions
Mounting Hole Dimensions
WALL
5.3 in. (133 mm)
Minimum distance from rear mounting
hole to wall: 7.0 in. (178 mm)
2.0 in.
(51 mm)
41.6 in.
(1057 mm)
20.8 in. (529 mm)
10.1 in. (257 mm)
ti20440b1
17.3 in.
(439 mm)
7.1 in. (180 mm)
3.3 in.
(84 mm)
124
14.2 in. (361 mm)
3.3 in.
(84 mm)
3A2347W
Technical Data
System with Stand and Vacuum Feed Dimensions
Tube Bend Radius:
8.0 in. (203 mm)
12.0 in.
(305 mm)
66.5 in.
(1689 mm)
ti22341b
30.0
(762 mm)
17.0
(432 mm)
26 in.
(660 mm)
Radius:
9.1 in. (232 mm)
ti22343a
31.0
(787 mm)
3A2347W
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 3A2347
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision W, May 2016

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