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

Graco 333347U - InvisiPac HM25 and HM50 Tank-Free Hot Melt Delivery System Instructions | Manualzz
Instructions - Parts
InvisiPac™
HM25 and HM50 Tank-Free™
Hot Melt Delivery System
333347U
EN
For delivering and dispensing hot melt adhesive pellets. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
1200 psi (8.3 MPa, 83 bar) Maximum Working Pressure
400°F (204°C) Maximum Fluid Operating Temperature
100 psi (0.7 MPa,7 bar) Maximum Air Inlet Pressure
Important Safety Instructions
Read all warnings and instructions in this manual and in
the applicator and hose manuals. Save all instructions.
ti22732
9902471
Certified to
CAN/CSA C22.2 No. 88
Conforms to
ANSI/UL 499
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Component Identification . . . . . . . . . . . . . . . . . . . 12
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Attach Components . . . . . . . . . . . . . . . . . . . . . 17
Recommended Air Setup . . . . . . . . . . . . . . . . . 21
Connect Electrical Cord . . . . . . . . . . . . . . . . . . 22
208V Electrical Circuits . . . . . . . . . . . . . . . . . . . 23
Select ADM Settings . . . . . . . . . . . . . . . . . . . . . 23
Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
PLC Connection . . . . . . . . . . . . . . . . . . . . . . . . 26
Material Tracking . . . . . . . . . . . . . . . . . . . . . . . 28
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Initial Startup and Prime . . . . . . . . . . . . . . . . . . 32
Manual Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Automatic Refill . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pressure Relief Procedure . . . . . . . . . . . . . . . . 37
Drain the System . . . . . . . . . . . . . . . . . . . . . . . 38
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operation Tips to Minimize Charring . . . . . . . . . 40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Replace Outlet Filter . . . . . . . . . . . . . . . . . . . . . 41
Replace Inlet Filter . . . . . . . . . . . . . . . . . . . . . . 41
Replace Funnel Filter . . . . . . . . . . . . . . . . . . . . 42
Filter Maintenance Guidelines* . . . . . . . . . . . . . 43
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ADM Error Code Table . . . . . . . . . . . . . . . . . . . 44
MZLP Troubleshooting . . . . . . . . . . . . . . . . . . . 59
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Multi-Zone Low Power Temperature Control Module
(MZLP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2
Transformer Fan . . . . . . . . . . . . . . . . . . . . . . . . 80
Software Update Procedure . . . . . . . . . . . . . . . 81
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 82
Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . 82
Cable Identification . . . . . . . . . . . . . . . . . . . . . . 82
Air Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Preventive Maintenance Kits . . . . . . . . . . . . . . 107
Complete Maintenance Kits . . . . . . . . . . . . . . . 107
Non-Graco Applicator Adapter Cables . . . . . . 108
Air Adjustment Lock, 24R084 . . . . . . . . . . . . . 109
Feed Sensor Dedicated Air Kit, 17F699 . . . . . 109
System Stand, 24R088 . . . . . . . . . . . . . . . . . . 110
Caster for Stand, 120302 . . . . . . . . . . . . . . . . 110
Adapter Plate, 24R083 . . . . . . . . . . . . . . . . . . 110
Air Reservoir Kit, 16W366 . . . . . . . . . . . . . . . . 112
ADM Extension Kits . . . . . . . . . . . . . . . . . . . . . 117
ADM Remote Mount Bracket, 24A326 . . . . . . 117
Air Metric Fitting Kit, 24W637 . . . . . . . . . . . . . 118
Strain Relief Bushing Kit, 24X190 . . . . . . . . . . 118
Hose Straps (4 Pack), 240296 . . . . . . . . . . . . 118
Pressure Gauge Replacement Kit, 24U635 . . 118
400VAC and 480VAC Transformer Kits . . . . . 119
Adapter Cable . . . . . . . . . . . . . . . . . . . . . . . . . 119
Appendix A - ADM . . . . . . . . . . . . . . . . . . . . . . . . 120
General Operation . . . . . . . . . . . . . . . . . . . . . . 120
Icon Identification . . . . . . . . . . . . . . . . . . . . . . . 120
Appendix B - USB Downloading, Uploading . . . 126
Download Procedure . . . . . . . . . . . . . . . . . . . . 126
Accessing Files . . . . . . . . . . . . . . . . . . . . . . . . 126
Upload Procedure . . . . . . . . . . . . . . . . . . . . . . 126
USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
System Settings File . . . . . . . . . . . . . . . . . . . . 127
System Language File . . . . . . . . . . . . . . . . . . . 128
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Graco Extended Warranty . . . . . . . . . . . . . . . . . . 136
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 136
333347U
Related Manuals
Related Manuals
Manuals are available at www.graco.com. Component manuals in English:
Part
Description
334629
334627
3A4937
3A2805
332072
333348
333349
334784
335010
InvisiPac Advanced Feed System
InvisiPac GM100 Plug-Free Hot Melt Applicator
InvisiPac HM25c Feed System
InvisiPac GS35 Hot Melt Applicator Instructions - Parts
InvisiPac Heated Hose Instructions - Parts
MZLP Fuse Kit, Instructions
InvisiPac 480V Transformer Upgrade Kit, Instructions-Parts
InvisiPac Pattern Controller, Operations-Repair-Parts
Dedicated Feed Sensor Air Kit
Required Tools
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Standard allen wrench set
Metric allen wrench set
Various sizes of crescent wrenches
11/16 in. wrench
3/8 in. ratchet
3/8 in. socket
5/16 in. driver
7/16 in. socket
7/8 in. deep well socket
1 in. socket
13 mm socket
10 mm socket
1/2 in. ratchet
Side cutter
Phillips head screwdriver
Flat head screwdriver
Multimeter
Tubing cutter
333347U
3
Models
Models
Feed Systems
Part
Usage
25C193
For use in standard pellet feed applications
WL
17D749
For use in chicklet feed applications
WLD
24N957
For use in standard pellet feed applications
with separate feed bin or bulk container
WLD
4
333347U
Models
200-240 VAC, 350-415 VAC HM50 Models
System
Channels
Voltage
Description
˓ Type
Max Amps
• 1-Phase
24T918
24Y114*
24T919
24Y115*
24T920
2
4
6
200-240
VAC
1˓ / PE
32A
200-240
VAC ˂
• 2 wire and PE
• 50/60 Hz
• 3-Phase without Neutral
3˓ / PE
27A
300-415
VAC Y
3˓ / Neutral / PE
•
•
•
•
•
200-240
VAC
1˓ / PE
40A
200-240
VAC ˂
• 2 wire and PE
• 50/60 Hz
• 3-Phase without Neutral
3˓ / PE
27A
300-415
VAC Y
3˓ / Neutral / PE
•
•
•
•
•
200-240
VAC
1˓ / PE
40A
200-240
VAC ˂
• 2 wire and PE
• 50/60 Hz
• 3-Phase without Neutral
3˓ / PE
40A
300-415
VAC Y
3˓ / Neutral / PE
•
•
•
•
•
3 wire and PE
50/60 Hz
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
16A
• 3 wire, Neutral, and PE
• 50/60 Hz
• 1-Phase
3 wire and PE
50/60 Hz
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
16A
• 3 wire, Neutral, and PE
• 50/60 Hz
• 1-Phase
3 wire and PE
50/60 Hz
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
30A
• 3 wire, Neutral, and PE
• 50/60 Hz
* System comes with internal PC-8 pattern controller installed. To upgrade to PC-8e, order kit PN 17F712.
333347U
5
Models
200-240 VAC, 350-415 VAC HM25 Models
System
Channels
Voltage
˓ Type
Description
Max Amps
• 1-Phase
24V423
24Y102*
24V424
24Y103*
24V425
2
4
6
200-240
VAC
1˓ / PE
32A
200-240
VAC ˂
• 2 wire and PE
• 50/60 Hz
• 3-Phase without Neutral
3˓ / PE
27A
300-415
VAC Y
3˓ / Neutral / PE
•
•
•
•
•
200-240
VAC
1˓ / PE
40A
200-240
VAC ˂
• 2 wire and PE
• 50/60 Hz
• 3-Phase without Neutral
3˓ / PE
27A
300-415
VAC Y
3˓ / Neutral / PE
•
•
•
•
•
200-240
VAC
1˓ / PE
40A
200-240
VAC ˂
• 2 wire and PE
• 50/60 Hz
• 3-Phase without Neutral
3˓ / PE
40A
300-415
VAC Y
3˓ / Neutral / PE
•
•
•
•
•
3 wire and PE
50/60 Hz
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
16A
• 3 wire, Neutral, and PE
• 50/60 Hz
• 1-Phase
3 wire and PE
50/60 Hz
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
16A
• 3 wire, Neutral, and PE
• 50/60 Hz
• 1-Phase
3 wire and PE
50/60 Hz
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
30A
• 3 wire, Neutral, and PE
• 50/60 Hz
* System comes with internal PC-8 pattern controller installed. To upgrade to PC-8e, order kit PN 17F712.
6
333347U
Models
400 VAC Transformer HM25 Models
System
Channels
Voltage
24V246
24Y104*
2
335-400
VAC
24V427
24Y105*
4
24V428
6
˓ Type
Description
• 3-Phase without Neutral
Max Amps
3˓ / PE
• 3wire and PE
• 50/60 Hz
• 3-Phase without Neutral
17A
335-400
VAC
3˓ / PE
• 3 wire and PE
• 50/60 Hz
• 3-Phase without Neutral
17A
335-400
VAC
3˓ /PE
• 3 wire and PE
• 50/60 Hz
17A
400 VAC Transformer HM50 Models
System
Channels
Voltage
˓ Type
Description
Max Amps
• 3-Phase without Neutral
24V198
24Y116*
2
335-400
VAC
3˓ / PE
17A
24V199
24Y117*
• 3wire and PE
• 50/60 Hz
• 3-Phase without Neutral
4
335-400
VAC
3˓ / PE
• 3 wire and PE
• 50/60 Hz
• 3-Phase without Neutral
17A
24V200
6
335-400
VAC
3˓ /PE
• 3 wire and PE
• 50/60 Hz
17A
* System comes with internal PC-8 pattern controller installed. To upgrade to PC-8e, order kit PN 17F712.
333347U
7
Models
480 VAC Transformer HM25 Models
System
Channels
Voltage
24V429
24Y106*
2
400-480
VAC
24V430
24Y107*
4
24V431
6
˓ Type
Description
• 3-Phase without Neutral
Max Amps
3˓ / PE
• 3wire and PE
• 50/60 Hz
• 3-Phase without Neutral
14A
400-480
VAC
3˓ / PE
• 3 wire and PE
• 50/60 Hz
• 3-Phase without Neutral
14A
400-480
VAC
3˓ /PE
• 3 wire and PE
• 50/60 Hz
14A
480 VAC Transformer HM50 Models
System
Channels
Voltage
˓ Type
Description
Max Amps
• 3-Phase without Neutral
24V201
24Y118*
2
400-480
VAC
3˓ / PE
14A
24V202
24Y119*
• 3wire and PE
• 50/60 Hz
• 3-Phase without Neutral
4
400-480
VAC
3˓ / PE
• 3 wire and PE
• 50/60 Hz
• 3-Phase without Neutral
14A
24V203
6
400-480
VAC
3˓ /PE
• 3 wire and PE
• 50/60 Hz
14A
* System comes with internal PC-8 pattern controller installed. To upgrade to PC-8e, order kit PN 17F712.
8
333347U
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.
333347U
9
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.
10
333347U
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.
333347U
11
Component Identification
Component Identification
A
AD
H
B
F
E
C
ti23594
D
Key:
A
B
C
D
E
F
H
J
L
M
N
P
R
S
AC
AD
Advanced Display Module (ADM)
Electrical Enclosure
Pump Air Pressure Regulator
Pump Air Pressure Gauge
Vacuum Transfer Air Pressure Regulator
Vacuum Transfer Air Pressure Gauge
Main Power Switch
System Air Inlet
Air Motor and Pump
Incoming Power Strain Relief
Heated Fluid Manifold (Melter)
Multi-Zone Low Power Temperature Control Module (MZLP)
Fluid Outlets for connection to Heated Hoses (numbered 1-6)
Customer I/O Cable (optional)
Drain Port
Transformer (optional)
L
G3
N
R
M
AC
P
S
WLD
J
FIG. 1
12
333347U
Component Identification
Heated Fluid Manifold
AB
Y
U
R
AA
T
X
W1
W2
WLD
NOTE: System shown with plastic and metal shrouds removed.
FIG. 2
Key:
T
U
W1
W2
X
Y
Z
AA
Electrical Enclosure Front Access Door
Melter
Drain Port
Drain Tray
Inlet Filter (Low Pressure - Before Pump)
Outlet Filter (High Pressure - After Pump)
Adhesive Pellets Level Sensor (not shown; inside funnel)
Power and RTD Harness Connection to Heated Hose and
Applicator (harness connects from system to heated hose
then from heated hose to applicator)
AB Inlet Funnel Screen
333347U
13
Component Identification
Electrical Enclosure
AC
P
WLD
AF
AG
FIG. 3
Key:
P
Multi-Zone Low Power Temperature Control Module
(MZLP)
AC Incoming Power Connection
AF Chassis Ground
AG Automatic Wiring Board (AWB)
14
333347U
Component Identification
Advanced Display Module (ADM)
User Interface
NOTICE
BK
To prevent damage to soft key buttons, do not press
the buttons with sharp objects such as pens, plastic
cards, or fingernails.
BL
NOTE: See 400VAC and 480VAC Transformer Kits
on page 119 for complete ADM operation details.
BB
BC
BM
BR
BP
BN
FIG. 5
BA
BD
BE
BF
Key:
BK Part Number Identification Label
BL USB Interface
BM CAN Cable Connection (Power Supply and Communication)
BN Module Status LEDs
BP (Not used)
BR Software Token Access Panel
BH
BG
TI12362a1
FIG. 4
B
Key
BA
BB
BC
BD
BE
BF
BG
BH
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
Toggle between Operation and Setup screens
Navigate within a screen or to a new screen
333347U
15
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 heating the material to
the set temperature.
Active
The system is ready to dispense
material.
16
•
•
•
•
•
•
•
•
•
•
•
No System Status Indicator LED on the
ADM
No heat
Pump is off
Yellow system status indicator LED on the
ADM
No heat
Pump is off
Flashing green system status indicator LED
on the ADM
Heat is increasing to setpoint temperature
Pump is off
Solid green system status indicator LED on
the ADM
Heat is at setpoint temperature
Pump is on
333347U
Setup
Setup
Grounding
The equipment must be grounded to reduce the risk of
static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.
Attach Components
To reduce the risk of electric shock, do not connect
electrical cord until after this Attach Components
procedure is complete.
NOTE: Only systems with transformers are supplied
with a lifting strap.
The InvisiPac system is equipped with a ground terminal. A qualified electrician must ground the system using
this terminal. See Connect Electrical Cord on page 22.
Location
Ambient temperature must be 32-120°F (0-49°C).
The supplied vacuum transfer hose length is 10 ft (3 m).
The maximum vacuum transfer hose length available is
30 ft (9.1 m). The adhesive pellets container must be
located within reach of the vacuum transfer hose and no
more than 30 ft (9.1 m) away.
NOTICE
To prevent strain on electrical or mechanical
connections around the pump assembly, loop the
strap around the tie rods as shown.
1. Use supplied lifting strap 127735, to transport systems with transformers. Wrap strap around all three
pump tie rods and loop the strap back through itself
in the Choker Configuration. See strap for details.
See FIG. 7, page 17.
The applicator(s) must be located no more than 25 ft
(7.6 m) from the melter.
Place the base system on a surface that is eye-level for
easiest operation. Use System Stand, 24R088, to
install system at eye-level. See page 110.
If installing the system in place of a non-Graco hot melt
system, purchase Adapter Plate, 24R083. See
page 110.
To make repairing the system easier, locate the system
so that all sides are easily accessible and have sufficient
lighting.
WLD
FIG. 7: Lifting Strap
333347U
17
Setup
2. Place the base system in the desired operating
location and orientation. See Location, page 17.
•
b. Rotate the funnel inlet (G3) and re-tighten the
band clamp (81).
The bottom of the electrical enclosure has holes for
securing the InvisiPac system to a surface. The
holes are accessible through the bottom access
doors in the three rear walls of the electrical enclosure.
•
To install the InvisiPac system in place of a
non-Graco hot melt system, purchase Adapter
Plate, 24R083. See installation instructions on
page 110.
•
G3
G4
G2
To raise the system to eye-level, purchase System
Stand, 24R088. See installation instructions on
page 110.
NOTE: Supplied vacuum transfer hose must reach from
the system to the adhesive pellets container. Supplied
heated hose must reach from system to applicator(s).
FIG. 8
4. Insert 1.3 in. (33 mm) OD clear vacuum transfer
hose (G2) into vacuum transfer funnel (G3) inlet and
secure with supplied hose clamp. The hose clamp
should be placed over the cutouts in the funnel inlet
where it can firmly hold the transfer hose. See FIG.
8.
3. Adjust the funnel inlet:
G3
23
WLD
81
5. Connect the long supplied 3/8 in. OD air line (G4) to
the 3/8 in. push-to-connect fitting on the air line from
the system. See FIG. 8.
NOTE: When routing the vacuum transfer hose, ensure
there are no tight coils, turns, or dips in the vacuum
hose. These will inhibit optimal functioning of the vacuum transfer system.
92
WLD
a. Remove plug (23) and insert the provided 5/16
in. nut driver (92) through the access hole in the
back of the system. Loosen the band clamp (81)
two turns.
18
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.
333347U
Setup
6. 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
Applicator
Install hose onto hydraulic fitting (68) with male
electrical connector side toward the system.
Use 11/16 in. wrench to tighten hose onto
hydraulic fitting (68).
g. Locate MZLP (AA) connector marked with same
number as the hose fluid outlet port. Remove
that connector cover then install connector from
heated hose. See FIG. 9.
h. Repeat the procedure for the remaining channels. Use the bottom melter ports first to ease
installation.
247
i.
68
W1
AA
W2
ti23298a
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.
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.
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.
Install cap on any unused MZLP electrical connectors.
NOTE: Fluid outlet port 1 must be used and electrical
connector from that hose must be connected to MZLP
connector 1. The system will not operate unless a hose
is connected to MZLP connector 1. If a hose is not connected to connector 1, “Invalid Sensor - hose/gun” faults
will result. If the melter must be run without a hose/applicator electrically attached to MZLP connector, use
Overtemperature Jumper, 16Y727, page 118.
7. Install applicator(s), see FIG. 9:
NOTE: Use of a Graco applicator is not required with
this system. However, all applicators attached to the
system must be rated for 1200 psi (8.3 MPa, 83 bar),
400°F (204°C), have an RTD type sensor, and use no
more than 400W at 240 VAC.
a. Connect heated hose fluid outlet to applicator
fluid inlet. Use 11/16 in. wrench to tighten. See
FIG. 9.
b. For Graco applicators, attach applicator electrical connector to heated hose electrical connector. See FIG. 9.
c.
For non-Graco applicators, attach applicator
electrical connector to adapter harness 16T916,
16T917, or 16Y828 then attach adapter harness
connector to heated hose connector. See
Non-Graco Applicator Adapter Cables on
page 108 to determine which adapter cable to
use with your applicator.
d. Repeat for any additional applicators.
333347U
19
Setup
8. If necessary, set up the pattern controller (not
included) to control opening and closing of the applicator. See pattern controller manual.
11. Close the ball valve.
NOTE: The system controls applicator heating only. A
separate pattern controller must be set up to open and
close the applicator.
9. Install the supplied air inlet bleeding ball valve and
air filter kit (Graco Part No. 24R707) at the 1/4 NPT
female system air inlet (J). See FIG. 10.
NOTE: Elbows and riser tube provided with inlet air kit
are optional and may be used as desired.
WLE
FIG. 11
12. Attach a 3/8 in. minimum air supply line to air filter.
See FIG. 11.
J
WLE
FIG. 10
NOTE: The system must have a bleed-type ball valve
that bleeds pressure downstream when closed. Otherwise, the supplied air will need to be disconnected from
the system whenever the pressure is relieved.
NOTE: The system must use an air filter with a minimum flow rate of 30 scfm.
10. If using the same air for the applicator(s), make sure
to install the tee in the air line before the ball valve.
There should not be anything between the ball valve
and the system. See applicator manual for applicator air pressure requirements, and use a regulator
before the gun to decrease the air pressure, if necessary.
20
NOTE: Air supply pressure must be between 80 psi
(550 kPa, 5.5 bar) and 100 psi (690 kPa, 6.9 bar). Recommended pressure is 100 psi (690 kPa, 6.9 bar). If air
pressure is expected to drop below 80 psi (0.5 MPa,
5 bar), there is an air reservoir kit that allows the system
to operate down to 60 psi (0.4 MPa, 4 bar). See Air
Reservoir Kit, 16W366, on page 112.
13. To lock access to the air pressure adjustments, purchase Air Adjustment Lock, 24R084. See installation instructions on page 109.
14. To install a light tower that illuminates red when a
system error occurs, purchase Light Tower Kit,
24R226. See installation instructions on page 111.
15. To upgrade a 2 channel system to a 4 channel system, purchase 4 Channel Upgrade Kit, 24V528.
See installation instructions on page 113.
16. To upgrade a 4 channel system to a 6 channel system, purchase 6 Channel Upgrade Kit, 24V529.
See installation instructions on page 115.
17. Install MZLP electrical connector caps on all unused
channels.
333347U
Setup
Recommended Air Setup
No dips in vacuum
transfer hose
Main Air Line
Air in:
Less than 50 ft (15.2 m): 3/8 in.
More than 50 ft (15.2 m): 1/2 in.
80-100 psi
(5.5-6.8 bar, 0.55-0.68 MPa)
30 scfm capacity
Ensure funneled air
is connected
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
WLD
Regulator set to 70 psi
(4.8 bar, 0.48 MPa)
Air to applicators
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)
333347U
21
Setup
Connect Electrical Cord
NOTE: See Grounding section on page 17.
5. Attach insulated ferrules to the end of each wire.
106
Improper wiring may cause electric shock or other
serious injury if work is not performed properly. Have a
qualified electrician perform any electrical work. Be
sure your installation complies with all National, State
and Local safety and fire codes.
Y
X
To reduce the risk of electric shock, perform the entire
Attach Components procedure beginning on
page 17 prior to connecting electrical cord.
WLD
AF
NOTE: The installed strain relief bushing (106) fits a
0.708-1.260 in. (18-32 mm) OD electrical cord. See FIG.
13. If needed, use a wrench to tighten the strain relief
bushing until it is snug on the cable.
FIG. 13
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).
7. Connect power wires as shown in FIG. 14. Not all
models use all 4 wires.
6. Connect ground wire to chassis ground (AF). See
FIG. 13.
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 106.
For 208V Electrical Circuits, see page 23.
1. Turn main power switch OFF.
2. Disconnect cable from ADM, push cable through
plastic shroud, then remove plastic shroud from system.
3. Remove electrical enclosure access door (T). See
FIG. 2 on page 13.
4. Insert electrical cord through electrical enclosure
strain relief bushing (106). See FIG. 13.
a. Alternate electrical cord routing: using conduit,
run electrical cord from access port (X) through
hole (Y). Conduit is required when routing wires
near compressed air components.
FIG. 14
8. Use zip ties to secure the electrical cord to the
tie-downs located on the top of the inside of the
electrical enclosure.
9. Tighten screw-terminals to at least 10 in-lb
(1.1 N•m).
10. Install electrical enclosure door.
11. Perform Select ADM Settings on page 23 prior to
turning on heat.
22
333347U
Setup
208V Electrical Circuits
For 208V electrical supply, a qualified electrician can
install a 208V to 240V step-up transformer to improve
startup times.
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.
Transformer Sizing
Minimum transformer rating can be calculated by taking
transformer output voltage times the ADM breaker setting.
Single Phase, 20A ADM Breaker Setting Example:
240 volts x 20 amps = 4800 watts
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:
Three Phase, 20A ADM Breaker Setting Example:
240 volts x 20 amps x SQRT(3) = 8315 watts
Select ADM Settings
NOTE: See Appendix A - ADM on page 120 for
detailed ADM information, including general operation.
1. Turn main power switch ON
.
2. When the ADM is finished starting up, press
to switch from the Operation screens to the Setup
screens. Use
,
,
, and
to navigate
between screens.
3. On the System 2 screen:
a. Enter the main circuit breaker size used. This is
the circuit breaker installed external to the system for the system power supply.
NOTE: The InvisiPac system limits the amount of power
it pulls based on the input circuit breaker size. This
impacts the startup times because it affects the heating
energy used to warm up the materials.
5. On the Advanced 1 screen, set the system date and
time.
a. Check the box in the “Installed” column for each
channel that has a heated hose and applicator
installed.
b. Select the RTD type used on each installed
applicator. See applicator manual.
NOTE: An incorrect RTD setting will cause the system
to be incapable of maintaining the temperature setting.
333347U
23
Setup
6. On the Advanced 2 screen, set the temperature and
mass units.
9. Press
to switch from the Setup screens to the
Operation screens. Use
,
,
, 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.
7. To setup the optional Schedule function, see
Schedule on page 36.
NOTE: The Schedule function enables the system to
automatically enable and disable heating at specified
times so that the system is already up to temperature
when a shift begins.
8. If desired, set any remaining settings in the Setup
screens before going on to the next steps that use
the Operation screens. These are not required for
system operation but include useful functions. See
Appendix A - ADM, beginning on page 120, for
detailed information about each setup item.
24
333347U
Setup
11. On the Targets screen, adjust heated hose and
applicator temperature settings:
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.
NOTE: InvisiPac is a high powered tank-free system
that delivers heat faster than traditional tank systems.
Tanks are often run at a lower temperature than the
application temperature to avoid excessive adhesive
degradation since a large volume of adhesive sits at
temperature.
a. Press
b. Use
NOTICE
Set melter, hose, and gun to the same setpoint
temperature for best performance. Do not set the
hose temperature higher than the melter. Running
the hose at a setpoint higher than the melter is
unnecessary in this tank-free system and could
lead to adhesive degradation in the hose. Short
adhesive residence time in the melter eliminates
the need to set the melter at a lower setpoint than
other zones.See Operation Tips to Minimize Char-
to select the channel.
and
, shown next to
, to
ring, page 40.
adjust applicator temperature setting to the
desired setting for that channel.
Applicators
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
Applicator heating is controlled by the InvisiPac system.
A pattern controller is required to control the opening
and closing of applicators. If using an InvisiPac Pattern
Controller, refer to manual 334784 - InvisiPac Pattern
Controller for details on wiring and setup.
arrow push-buttons on the ADM keypad until
is
next to the temperature setting to change then use the
numeric keypad to enter the desired temperature.
c.
Use
and
, shown next to
,
to adjust heated hose temperature setting to the
desired setting for that channel.
333347U
25
Setup
PLC Connection
A PLC can control and monitor all items shown in the
dropdown menus on the System 1 screen in the Setup
screens.
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 12.
5. Remove power from PLC.
Customer Input Dropdown Options
Option
Description
Disable
Not used.
Heater On/Off
Turn on or off the heating system and
pump.
Channel 1, 2, 3,
4, 5, or 6
Enable/Disable
Enable or disable hose and applicator
heating for that individual channel.
6. Connect the PLC to connectors H1 and H2.
NOTE: Each connector has four signals. The MZLP
board specifies the input range for each signal. See the
following table for pin assignments.
J1
J2
F10 F9
F8 F7
F4 F3
F2
F6
F1
F5
Customer Output Dropdown Options
Option
Description
Disable
Not used.
System Ready
Indicates when the system is up to temperature and the pump is stalled at
pressure.
Error (Alarm)
Indicates when there is an active alarm.
An active alarm will disable the heating
system and pump.
J7
J6
J5
J3
WLD
Error (Deviation/Advisory)
Maintenance Due
Indicates when there is an active deviation or advisory. An active deviation or
advisory will NOT disable the heating
system and pump.
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.
FIG. 15: MZLP Board
H1 - Customer Input
H2 - Customer Output
Signal
Pin
Signal
Pin
1
1, 2
1
1, 2
2
3, 4
2
3, 4
3
5, 6
3
5, 6
4
7, 8
4
7, 8
Inputs: High: 10-30 Vdc, Low: 0-5 Vdc. Inputs function
without concern for polarity. Applying “high” voltage will
turn the heaters on and enable channels. Removing
voltage will turn the heaters off and disable channels.
Outputs: 0-250 Vac, 0-30 Vdc, 2A Maximum.
26
333347U
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. 16: Customer Input
MZLP Customer Out
Customer In
250 VAC, 0-30 VDC, 2A Max
To Customer Input
FIG. 17: Customer Output
333347U
27
Setup
Material Tracking
The material tracking function allows the user to track
product counts and material usage for long term data
collection.
Viewing the Log
In order to view the log, navigate to the Home screen
and press the material log softkey
(see below).
Different system Types will have different data show in
the material log. The chart below outlines what data is
shown for each system type.
System Type Date Cycles
InvisiPac
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 date including the following:
Item
Date
Cycles
Material Used
Program
Products
Material per Product
28
Icon
N/A
N/A
333347U
.
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).
333347U
29
Setup
Calibration
3. To calibrate using the purge method:
a. Obtain a scale and a container.
b. Reset the calibration weight totalizer by press-
ing and holding the reset softkey
Perform the following steps to calibrate the material
tracking function:
c.
1. Navigate to the Material Tracking Screen (Screen 4
of the System chapter).
d. Weigh container with material.
2. To calibrate using the tape and scrape method:
a. Obtain a scale.
b. Place tape on a product(s) in locations where
material is dispensed.
c.
Run normal production (un-taped products) until
a value appears in the grams per product label
(this could take several minutes of production).
.
Tare scale with empty container and purge at
least 1 lb. of material into the container.
e. Adjust the specific gravity setting until the
weight displayed in the totalizer matches the
value measured by the scale using the following
formula:
New SG Value = Current SG Value x Measured Weight /
Displayed Weight
d. Run taped product(s) through line and allow
material to cool and harden on the tape.
e. Scrape all material from product and place on
scale.
f.
Adjust the specific gravity setting until the grams
per product displayed matches the value measured by the scale using the following formula:
New SG Value = Current SG Value x Measured Grams
per Product / Displayed Grams per Product
30
333347U
Setup
Material Alerts
Reset Material Target
This feature can be used to monitor material usage
based on a target material per unit value. If material
alerts are enabled the system will record an event every
time the system deviates over 20% from the target. The
material alert information can be seen in the bottom left
corner of the material log (see image below).
To reset the material target value, press the reset mate-
Enable/Disable material Alerts
To enable/disable material alerts, select/deselect the
Enable Material Alerts setting on the Material Tracking
Screen (Screen 4 of the System chapter).
333347U
rial target softkey
. An hourglass will appear
indicating that the system is learning the new target
(current machine output).
NOTE: The material target will be automatically reset
whenever a Pattern Controller setting is changed (e.g.
switch from solid bead to stitched bead).
31
Operation
Operation
Initial Startup and Prime
Heating and dispensing hot melt adhesive may create
potentially harmful vapors. Read material manufacturer’s warnings and material MSDS to know specific
hazards and precautions. Ventilation of the work area
may be required.
NOTE: See Appendix A - ADM on page 120 for
detailed ADM information.
NOTICE
To prevent damage to soft key buttons, do not press
the buttons with sharp objects such as pens, plastic
cards, or fingernails.
NOTE: See Appendix B - USB Downloading, Uploading on page 126 for detailed USB information.
Overview
NOTE: All setup procedures must be completed prior to
initial startup. See Setup on page 17.
NOTE: PSA-type adhesive pellets will not work in the
InvisiPac system.
1. Direct the applicator into an appropriate waste
container.
2. Fill adhesive pellets container with hot melt adhesive pellets.
3. Turn main power switch ON
.
4. Open system air inlet ball valve.
The system includes a vacuum transfer system that
pulls the adhesive pellets into the system as needed.
Once melted, the adhesive enters the pump where it is
pumped into the heated hoses then to the heated applicators. The applicator then briefly opens to dispense the
desired quantity of adhesive.
WLE
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.
32
333347U
Operation
5. Use pump air pressure regulator (C) to adjust pump
air pressure to 0.
9. On new systems only: After the melter has reached
250°F (121°C) and the funnel is filled with pellets,
set the melter temperature back to the desired operating temperature. See Select ADM Settings on
page 23 for instructions.
10. Use separate pattern controller to open the applicators and keep them open.
NOTICE
E
C
FIG. 18
6. Use vacuum transfer air pressure regulator (E) to
adjust vacuum transfer air pressure setting to
40-100 psi (280-690 kPa, 2.8-6.9 bar). Recommended setting is 60 psi (414 kPa, 4.1 bar). See
FIG. 18.
NOTE: Vacuum transfer will not begin operating until
pump reaches operating temperature.
In the following step, to prevent damage to the pump
due to pump cavitation, do not supply more than 20 psi
(140 kPa, 1.4 bar) air pressure to the pump until the
system is fully primed.
11. With the applicators open and the system up to temperature, slowly increase pump air pressure until
the pump begins to run very slowly. Approximately
20 psi (140 kPa, 1.4 bar) should be sufficient.
NOTE: Operation may be erratic below 20 psi (140 kPa,
1.4 bar).
12. Continue running the pump until clean, air-free
material is dispensed from each applicator.
To prevent fire and explosion, never exceed the cleaning fluid’s rated temperature. If the system was just
flushed, residual cleaning fluid is still in the system
until the system is primed with adhesive. Do not raise
temperature above cleaning fluid rated temperature
until system is primed with adhesive.
NOTE: A new system may have residual oil due to testing at the factory prior to shipping. To prevent smoking,
make sure to perform the following step.
13. When each applicator is fully primed, adjust pump to
desired pressure setting:
a. Adjust pump pressure to between 20-100 psi
(140-690 kPa, 1.4-6.9 bar).
b. Use separate pattern controller to repeatedly
open and close each applicator while inspecting
the dispense pattern.
c.
Repeat until desired dispense pattern is
achieved.
7. On new systems only: temporarily adjust the melter
temperature to 250°F (121°C). See Select ADM
Settings on page 23 for instructions.
8. Press
to enable the heaters and pump.
NOTE: When system is up to temperature, the pump will
be activated automatically, but will not start because
there is no air pressure supplied to the pump.
NOTE: When the melter is up to temperature, the
auto-fill function will initiate to fill the funnel with pellets.
333347U
33
Operation
Manual Refill
4. Fill the funnel with adhesive pellets.
NOTE: Use Automatic Refill whenever possible. The
system uses Automatic Refill by default and must be
manually changed to Manual Refill. Only use Manual
Refill if the Automatic Refill system is not functioning
properly and cannot be fixed in a timely manner. Perform service to automatic feed system as soon as possible to limit debris buildup on feed funnel.
It is recommended to maintain a minimum flow rate of
1.5 lb/hour to prevent material from melting within the
feed cap and funnel. If production rate is below
1.5 lb/hour or system sits at temperature without dispensing for extended periods of time, use manual refilling with caution. System flow rate can be monitored by
enabling the Diagnostic screen.
1. On the System 3 screen (in the Setup screens),
select “Manual” from the Refill mode dropdown.
2. Remove the two bolts from the funnel bracket, then
remove the top portion of the funnel.
WLD
FIG. 20
5. Refill the funnel as needed to maintain the required
dispense rate.
6. When finished dispensing for the day, dispense into
a waste container until the material level is down to
the melter core. See FIG. 21.
NOTE: This will lower the adhesive level within the funnel cap to the correct level to prevent any issues upon
startup the following production day.
WLD
FIG. 21
WLD
FIG. 19
3. Disconnect the sensor cable and sensor cooling air.
34
333347U
Operation
Automatic Refill
Dispense
The system uses automatic refill by default. If the automatic refill system is malfunctioning and cannot immediately be fixed, Manual Refill can be used.
To use automatic refill:
1. On the System 3 screen (in the Setup screens),
select “Automatic” from the Refill mode dropdown.
2. Verify shaker and tube are connected to the system.
See Attach Components on page 17.
3. Verify shaker inlet (K) is at the bottom of the adhesive pellets container that is filled with hot melt
adhesive pellets. See FIG. 1 on page 12.
NOTE: The shaker inlet must be completely covered in
adhesive pellets in order for it to effectively pull pellets
into the tube.
4. If not already set, use vacuum transfer air pressure
regulator (E) to adjust vacuum transfer air pressure
setting to 40-100 psi (280-690 kPa, 2.8-6.9 bar).
Recommended setting is 60 psi (414 kPa, 4.1 bar).
NOTE: Only hot melt adhesive pellets can be used in
the InvisiPac system.
1. If the system is empty or has air in the lines, perform
Initial Startup and Prime procedure on page 32.
2. If main power switch is OFF, turn main power switch
ON
.
NOTE: The main power switch should be left ON at all
times when using the Schedule function.
3. Prepare for dispensing:
a. Verify air inlet ball valve (J) is open. See FIG. 1
on page 12.
b. Check pressure gauges (D, F) to verify vacuum
transfer and pump air pressures are set as
desired. See FIG. 1 on page 12.
c.
If using Automatic Refill, see Automatic Refill
on page 35.
d. If using Manual Refill, see Manual Refill on
page 34.
E
e. Verify applicators are closed.
FIG. 22
4. Press
NOTE: The system will automatically transfer the pellets
to the system as necessary.
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 an applicator is open. Material will be dispensed
whenever an applicator is open after the system is up to
temperature.
5. When the system is up to temperature, use separate pattern controller to open and close the applicators as desired to dispense material.
333347U
35
Operation
NOTE: While operating the system, the actual temperatures of the hose, applicator, and system melter are displayed on the Home screen.
Shutdown
Press
The Schedule function allows the user to specify times
when the system will automatically turn ON and OFF the
heaters and pump.
Set Schedule Times
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
Schedule
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.
NOTE: Times are set using a 24-hour clock. Several on
and off times can be set each day.
1. On the Schedule screen (in the Setup screens), set
the ON times for each day of the week.
2. Set the OFF times for each day of the week.
Enable Schedule Function
The Schedule function is automatically enabled when
values are entered in the Schedule screen. To disable a
scheduled event, navigate to the event and press
The event will appear gray on the screen when it is disabled. To re-enable an event, navigate to the event and
press
. The event will appear red (system off) or
green (system on). If no events are needed, turn the
main power switch OFF to prevent system from automatically enabling and disabling the heaters.
Do not turn the main power switch OFF if using the
Schedule function.
How to Use the Schedule Function
At the end of the work day leave main power switch ON
. The Schedule function will automatically enable
and disable the heaters and pump at the specified
times.
36
333347U
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning,
checking, or servicing the equipment.
1. Turn main power switch OFF
.
2. Close the inlet air supply ball valve.
NOTE: Manually verify the pressure is relieved by opening the applicator and ensuring no adhesive is dispensed.
333347U
37
Operation
Drain the System
11. Disconnect hose from melter outlet.
12. Wait until system stops draining or at most 10 minutes.
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”.
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.
2. If the heating system is disabled, press
to
enable the heaters and pump.
3. Decrease pump air pressure to 0.
4. Close system air inlet ball valve.
5. Disconnect hose from applicator inlet then place
hose outlet in a waste container. Repeat for all
hoses. Keep hose to applicator electrical connector
connected.
6. Open applicator to allow residual fluid in applicator
to drain.
• Never exceed the cleaning fluid’s rated
temperature
• Never flush your system or clean any aluminum
components with halogenated hydrocarbon
cleaning solutions.
To prevent severe burns, wear protective clothing.
NOTE: This procedure describes how to flush one hose
at a time for maximum effectiveness.
See the hot melt adhesive technical data sheet or
MSDS for the recommended cleaning fluid. Contact the
hot melt supplier if the technical data sheet or MSDS is
not available.
1. Perform Drain the System on page 38.
2. If the heating system is enabled, press
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 dis-
able the heaters and pump.
3. Loosen upper hose clamp securing funnel assembly
to air motor bracket then remove funnel assembly
from system. Keep 1.3 in. (33 mm) clear tube and
funnel cap attached to funnel.
4. Loosen clamp then remove plastic melter cap. Keep
fill sensor attached to cap.
to disable the heaters and pump.
10. Remove melter drain plug (W1). See FIG. 2 on page
13.
38
333347U
Operation
5. On the System 3 screen (in the Setup screens), verify the Refill Setting is set to “Manual”.
12. If heating system is disabled, press
to enable
the heaters and pump.
13. Wait for the melter temperature to reach the hot
melt cleaning fluid manufacturer’s recommended
temperature.
NOTE: The pump will not run because the system air
inlet ball valve is closed.
14. Once the required melter temperature is reached,
let the hot melt cleaning fluid “soak” in the melter at
temperature for the duration specified by the hot
melt cleaning fluid manufacturer.
To prevent fire and explosion, never exceed the cleaning fluid’s rated temperature.
6. Change the melter, heated hoses, and applicators
temperature settings to the high temperature hot
melt cleaning fluid manufacturer’s recommended
temperature.
7. Verify the system air inlet ball valve is closed and
pump air pressure is set to 0.
8. Allow the system to heat or cool to the cleaning fluid
manufacturer’s recommended temperature.
9. Fill melter with high temperature rated hot melt
cleaning fluid. See hot melt adhesive material supplier for recommended hot melt cleaning fluids.
Fluid level should be 1/2 in. (12.7 mm) from the top
of the melter.
NOTE: “Soaking” is important to ensure the best possible cleaning.
15. After the hot melt cleaning fluid has “soaked” for the
specified amount of time, open the system air inlet
ball valve. Slowly increase the pump air pressure
until pump begins to cycle to begin pumping the hot
melt cleaning fluid and adhesive mixture out through
the hose into the waste container.
16. Once the pump begins to cycle faster, close the system air inlet ball valve to stop the pump.
17. Repeat steps 7 through 16 until clean, adhesive-free hot melt cleaning fluid is dispensed from
the detached hose.
NOTE: Now the melter and the disconnected hose are
thoroughly flushed.
18. Reattach the hose to the applicator manifold.
19. Repeat steps 7 through 18 for each additional
installed hose, leaving a different hose disconnected from the applicator manifold each time.
20. Remove and replace filter(s) in all applicator manifolds. See applicator manual.
21. Replace Outlet Filter. See page 41.
WLD
10. Disconnect one hose from its applicator manifold.
NOTE: Keep all applicators closed throughout this procedure.
11. Route the disconnected hose to a waste container.
333347U
22. Turn main power switch OFF.
23. Place waste container below drain tray (W2) then
remove drain plug (W1) and wait for system to finish
draining. See FIG. 2 on page 13.
24. Allow the system and fluid to cool then perform any
required maintenance procedures beginning on
page 41.
39
Operation
25. Install fill cap onto melter rubber housing. Re-tighten
upper clamp to 25 in-lbs.
26. Slide funnel assembly through air motor bracket
then tighten clamp.
27. On the System 3 screen (in the Setup screens), set
the Refill Setting to “Auto”.
Operation Tips to Minimize
Charring
Set the Pump Idle Time to System Inactive function
on the System 3 screen to lowest value that will not
interfere with normal operation. This feature automatically disables the heating system if the pump is idle for
longer than the preset amount of time. Disabling the
heating system minimizes adhesive degradation and
limits char formation.
When possible, utilize the Schedule function, see
page 36, to automatically enable and disable the 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
To prevent fire and explosion, never exceed the cleaning fluid’s rated temperature. Residual cleaning fluid is
still in the system until the system is primed with adhesive.
28. Perform Initial Startup and Prime on page 32.
40
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.
333347U
Maintenance
Maintenance
6. Insert allen wrench through the outlet filter cap to lift
outlet filter (236) out of the system.
7. Discard outlet filter assembly.
Replace Outlet Filter
The outlet filter is designed to prevent small contaminants from entering the hoses and applicators. Inspect
filter regularly. Replace the filter after flushing and when
you change the adhesive used in the system.
8. Place o-rings (232, 237) provided with new outlet filter onto new outlet filter (236).
9. Place new outlet filter with o-rings into housing.
Tighten with 1 in. socket.
10. Install small metal shroud (28) over outlet filter then
tighten two screws (8).
Replace Inlet Filter
236
232
To avoid severe burns, wear protective gloves and
clothing that will insulate your hands and body from
the hot surfaces and material.
237
The inlet filter is designed to prevent large items from
entering the system. The inlet filter can only be replaced
with the system empty.
1. Close the system air inlet ball valve.
8
28
WLD
FIG. 23
1. If the system is not up to temperature, press
to
enable the heaters and pump then wait for system
to reach operating temperature.
To avoid severe burns, wear protective gloves and
clothing that will insulate your hands and body from
the hot surfaces and material.
2. Perform Pressure Relief Procedure, page 37 but
do not allow system to cool. Adhesive must be a
fluid to perform this procedure.
3. Turn main power switch OFF.
4. Loosen two screws (8) then slide the small metal
shroud (28) on the back of the system up to remove.
See FIG. 23.
5. Use a 1 in. socket to unscrew outlet filter (236).
333347U
NOTE: Some adhesives have different melting points.
The first temperature tried should be approximately half
of the dispensing temperature. If dispensing at 400°F
(204°C), first try 200°F (93°C) then increase in 20°F
(11°C) increments. If dispensing at 250°F (121°C), first
try 125°F (52°C) then increase in 20°F (11°C) increments.
NOTE: To ensure the adhesive is a gel, not a liquid, do
not remove inlet filter cap (215) when the temperature is
above the desired temperature. If the temperature is too
low, the adhesive viscosity may be too high to remove
the inlet filter (213). See FIG. 24, page 42.
2. If the melter is below the desired temperature and
heating system is disabled, press
to enable
the heaters.
If the melter is above the desired temperature and
heating system is enabled, press
to disable
the heaters.
3. Wait until melter temperature is the desired temperature.
41
Maintenance
4. When the melter temperature is the desired temperature, turn main power switch OFF.
9. Slide new screen (213) into melter base
manifold (201).
5. Disconnect cable from ADM, push cable through
plastic shroud, then remove plastic shroud from system.
10. Install filter cap (215) then use a 1 in. socket to
tighten.
6. Place a piece of cardboard beneath the inlet filter
cap (215) to route fluid away from system into a
waste container in the event the adhesive is a fluid.
7. Use 1 in. socket to remove inlet filter cap (215).
11. Feed ADM cable through plastic shroud (29) then
install shroud onto system. Connect cable to
ADM (30).
Replace Funnel Filter
706
705
213
215
201
WLD
WLD
FIG. 24
FIG. 25
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:
Disassembly (see FIG. 25):
1. Turn main power switch OFF.
a. Install inlet filter cap (215).
2. Rotate funnel cap (706) and remove. Lift out funnel
filter (705).
b. Install shroud and ADM.
Reassembly (see FIG. 25):
c.
1. Insert filter (705) in funnel assembly. Tighten funnel
cap (706) on funnel.
Turn main power switch ON.
d. Once ADM software finishes starting up,
press
to enable the heaters.
e. Wait for temperature to rise 20°F (11°C) beyond
previous temperature.
f.
42
Go to step 4.
333347U
Maintenance
Filter Maintenance Guidelines*
Environmental Classification
Component
Pump Outlet Filter
Applicator Manifold Filter
System Air Inlet Filter
Applicator Solenoid Mufflers
Feed funnel filter
Feed funnel inspection/cleanout
Part Number
24W595
24P802
24X967
24P282#
24X037%
24V506
N/A
Ref
Clean
Moderate
Dusty
236
16 +
64
Replace filter Replace filter Replace filter
every four
every two
104+ every six
months
months
months
NA
705
NA
* These recommendations are service level guidelines - actual service levels required in your factory will vary based
on environmental and operating conditions. High or low volume adhesive usage, as well as adhesives that contain a
powdered release agent or are otherwise dusty, will have an impact on the frequency of filter maintenance. To establish a preventative maintenance cycle tailored to your environment, Graco recommends inspecting filters every 4
weeks after installation and replacing when necessary. Document replacement intervals and use this as your preventative maintenance schedule moving forward.
+ See appropriate applicator manual for part reference drawing.
#Standard on GS35 applicators.
%Optional upgrade to GM100 applicators.
333347U
43
Troubleshooting
Troubleshooting
To avoid injury due to unexpected machine operation
initiated by a remote controller, disconnect the customer I/O cable from the system prior to troubleshooting.
ADM Error Code Table
When an error occurs, press
nance screen and press
to acknowledge the error. If a Maintenance error occurs, navigate to the Mainteto clear the error.
The last digit of the error code indicates the melter, applicator (gun), or hose to which the error applies. The “_”
(underscore) character indicates the code applies to multiple items.
Last Digit in Code
0
1
2
3
4
5
6
7
8
9
A
B
C
Code Relates to:
Melter
Applicator (Gun) 1
Hose 1
Applicator (Gun) 2
Hose 2
Applicator (Gun) 3
Hose 3
Applicator (Gun) 4
Hose 4
Applicator (Gun) 5
Hose 5
Applicator (Gun) 6
Hose 6
An alarm will disable the heating system and pump. A deviation or advisory will not disable the heating system and
pump.
Code
A1D0
Description
Low Current
Melter
Type
Advisory
Cause
Melter current is less than 500mA.
A1D_
Low Current
Gun X
Advisory
Applicator current is less than 500mA.
A1D_
Low Current
Hose X
High Fan Current, Transformer
Advisory
Deviation
Hose current is less than 500mA.
A3MF
44
Transformer fan is greater than
600mA.
Solution
Check heater resistance and resistance to
ground. Replace heater(s). See Replace Heater
Rod, page 69.
Verify applicator heater has a minimum wattage
of 90 Watts at 240 VAC. Check heater resistance
and resistance to ground. Replace heater.
Check heater resistance and resistance to
ground. Replace hose.
Replace transformer fan.
333347U
Troubleshooting
Code
A4D0
Description
High Current
Melter
High Current
Hose X
High Current
Gun X
Unexpected
Current
Type
Alarm
Cause
Band heater or rod heater.
Alarm
Hose power wires.
Alarm
Heater rods in applicator manifold.
Alarm
Unexpected current flow to melter.
A7D_
Unexpected
Current, Gun X
Alarm
Unexpected current flow to applicator
X.
A7D_
Unexpected
Current, Hose X
Alarm
Unexpected current flow to hose X.
A8D0
No Current
Melter
Alarm
Power not getting to melter.
A8D_
No Current
Hose X
Alarm
Power not getting to hose.
A8D_
No Current Gun
X
Alarm
Power not getting to applicator.
A8MF
No Fan Current,
Transformer
Deviation
Power not getting to transformer fan.
A4D_
A4D_
A7D0
333347U
Solution
Measure resistance to ground between heater
leads. Should be a high reading. Replace heater.
Check heater resistance and resistance to
ground. Replace heated hose.
Check heater resistance and resistance to
ground. Replace applicator manifold.
Check heater resistance and resistance to
ground. Replace faulty heater(s). See Replace
Heater Rod, page 69.
Replace MZLP.
Check heater resistance and resistance to
ground. Replace applicator manifold.
Replace MZLP.
Check heater resistance and resistance to
ground. Replace hose.
Replace MZLP.
Check fuses F1 and F2 on MZLP with daughter
board.
Check J1 is plugged into MZLP with daughter
board and J3 on AWB.
System needs a hose connected to Channel 1 or
use the optional Overtemperature Jumper,
16Y727.
Check fuses F5 and F6 (channels 1, 3, 5) or F9
and F10 (channels 2, 4, 6) on MZLP that the
error hose is connected to.
Check that electrical connector on the heated
hose is plugged into the MZLP.
Check continuity of pins C and D on electrical
connector at MZLP end of heated hose. See
heated hose manual for impedance measurements. Replace hose if readings are too high.
If system only uses one hose and applicator, the
heated hose electrical connector must be
plugged into channel 1 of the MZLP.
Check fuses F3 and F4 (channels 1, 3, 5) or F7
and F8 (channels 2, 4, 6) on MZLP that controls
the error channel.
Check that electrical plug on hose is plugged into
back of MZLP and applicator is plugged into
hose.
Check continuity of hose pin A gun end to J on
MZLP connector end of hose and pin C on gun
end to pin A on the MZLP end of the hose. Reading should be 0-1 ohm. Replace hose if measurement is outside this range.
If system only uses one hose and applicator,
electrical connector of the heated hose must be
plugged into channel 1 of the MZLP.
Verify that fan power cable is plugged into J7 on
the AWB.
Verify transformer fan is free of obstructions and
can spin freely.
45
Troubleshooting
Code
CAC_
1=MZLP 1
2=MZLP 2
3=MZLP 3
Description
Comm Error
Module
Type
Alarm
Cause
System not responding to ADM.
CACX
Missing DB
Alarm
System not acknowledging the daughter board.
DADX
Pump Runaway
Alarm
Pump is trying to feed adhesive, no
adhesive to feed.
DDDX
Pump Diving
Deviation
Worn or damaged pump seals
Pump is trying to feed adhesive, no
adhesive to feed.
Worn or damaged pump seals
No signal from air motor sensor.
DE0X
Cycle Switch
Error
Alarm
L0FX
Manual Fill
Mode
Level Sensor
Error
Advisory
Alarm
L6FX
System set to manual fill mode.
No signal from the level sensor.
No air to fill cap.
Plugged orifice in fill cap below fill sensor.
46
Solution
Dial not set correct on MZLP. Set to 1 on board
with daughter board. Set to 2 on MZLP without
the daughter board in center of electrical enclosure. Set to 3 on MZLP without daughter board
on left of electrical enclosure.
System is not properly loaded with correct software. Perform Software Update Procedure on
page 81.
Bad connection between daughter board and
MZLP board. Loosen daughter board, re-seat,
then secure.
Daughter board is not plugged into MZLP1. Plug
daughter board into MZLP with dial set to 1.
Replace MZLP daughter board.
Storage bin out of adhesive. Refill adhesive.
Level sensor may be over heating. Verify air is
being delivered from tube (35).
Melter at incorrect temperature, too low. Check
setpoint and set to manufacturer’s recommendation.
Plugged vacuum transfer hose or funnel. Clear
plugged hose or funnel.
Inspect pump seals. Repair if necessary.
Storage bin out of adhesive pellets. Refill with
pellets.
Level sensor may be over heating. Verify air is
being delivered from tube (35).
Melter at incorrect temperature, too low. Check
melter temperature setting and set to manufacturer’s recommendation.
Plugged vacuum transfer hose or funnel. Clear
plugged hose or funnel.
Dispense rate too high. See technical ratings of
system.
Inspect pump seals. Repair if necessary.
Check wiring on J16 of the daughter board. See
Electrical Schematics on page 82.
Loose cycle switch bolt. Tighten cycle switch bolt.
Replace cycle switch.
Change to auto fill mode. See Setup Screen System 2.
Check for sensor LED illumination.
Check that sensor cable is plugged into sensor.
Check connector at J14 of the daughter board.
Remove fill cap and verify there is nothing blocking fill (level) sensor line of sight.
Replace fill (level) sensor.
Check system incoming air pressure is 80-100
psi.
Check for sensor cooling air coming from 5/32 in.
air line, flow should be 30-60 SCFH.
Remove fill cap and remove object plugging the
orifice.
333347U
Troubleshooting
Code
L8FX
Description
Refill timeout
Type
Alarm
Cause
Melter did not receive enough adhesive
pellets for flow rate.
M8MF
High Temp Run- Deviaaway, Transtion
former
At the current rate of temp rise, the
transformer will over heat in 15 minutes
or less.
MMUX
USB Log Full
MNDX
Pump Maintenance Due
Low Temperature, Melter
USB logs full. Data loss will occur if not
downloaded.
Cycles are greater than user set maintenance interval.
Melter temperature dropped to
15°F(-9°C) below setpoint.
T2D0
Advisory
Advisory
Deviation
Solution
Inspect storage bin for bridging and blocking.
Storage bin out of adhesive. Refill adhesive.
Plugged inlet feed hose or funnel. Clear plugged
hose or funnel.
Low air pressure on feed regulator. Check regulator. See Setup, page 17 for air pressure regulations.
Dirty or plugged funnel filter. Replace filter.
Verify that fan power cable is plugged into J7 on
the AWB.
Verify transformer fan is free of obstructions and
can spin freely.
Replace transformer.
Download USB data. See Appendix B - USB
Downloading, Uploading on page 126.
Perform maintenance and reset “Due” counter to
0 at the Setup Maintenance screen.
Verify system is operating within meltrate specifications. Consider incoming voltage and breaker
setting.
Verify that the fill system (vacuum) is operating
correctly. If the level of material in the melter gets
too low and a large amount of cold material
enters the melter, can cause the temperature to
drop significantly.
With the system on and not dispensing verify that
the temperature is properly controlled to the setpoint. If system cannot control temperature, verify the RTD is seated inside the melter.
Replace RTD if RTD was seated properly and
system cannot control temperature
T2D_
Low Temperature, Gun X
Deviation
Applicator temperature dropped to
15°F(-9°C) below setpoint.
T2D_
Low Temperature, Hose X
Deviation
Hose temperature dropped to
15°F(-9°C) below setpoint.
T4C_
High MZLP PCB
Temp
Alarm
MZLP board is overheating.
333347U
Check heater resistance and resistance to
ground. Replace heater(s).
With the system on and not dispensing verify that
the temperature is properly controlled to the setpoint. If system cannot control temperature,
replace applicator RTD. See applicator manual.
Check heater resistance and resistance to
ground. Replace heater.
Dispense rate too high for applicator to maintain
setpoint. Consider applicator power and voltage.
With the system on and not dispensing verify that
the temperature is properly controlled to the setpoint. If system cannot control temperature,
replace hose.
Check heater resistance and resistance to
ground. Replace hose.
Ambient temperature must be under 120°F.
Replace MZLP board.
47
Troubleshooting
Code
T4D0
Description
High Temp
Melter
Type
Alarm
Cause
Solution
Melter continues to raise above the set- Check that RTD is seated in melter correctly.
point.
Check that overtemperature switch is plugged in
and check switch resistance. The switch resistance should be near 0 Below 400°F (204°C).
Check melter heaters’ resistance to ground.
Replace heater if a heater is shorted to ground.
T4D_
High Temp
Hose
Alarm
Hose continues to raise above the setpoint.
T4D_
High Temp Gun
Alarm
Applicator assembly continues to raise
above the setpoint.
T4MX
High Temperature, Transformer
Alarm
T6D0
Sensor Error
Melter
Alarm
T6D_
Sensor Error
Hose
Alarm
T6D_
Sensor Error
Gun
Alarm
T6MX
Thermistor Sen- Alarm
sor Error, Transformer
T8D_
No Temp Rise in
Gun (all zones)
Alarm
Turn system on without dispensing. Verify temperature is properly controlled to the setpoint. If
setpoint is not maintained, replace RTD. If heat
continues to rise past setpoint, replace MZLP.
Turn on system without dispensing. Check if
hose can maintain setpoint temperature. If the
hoses’ RTD readings are unstable, replace hose.
If hose continually heats past setpoint, replace
the MZLP.
Turn on system without dispensing. Check if
applicator can maintain setpoint temperature. If
the applicator’s RTD readings are unstable,
replace the applicator RTD.
Check the applicator heater’s resistance to
ground if the RTD readings are stable but the
applicator’s temperature continues to rise. If the
heater is shorted to ground, replace the applicator’s heater. If heater is not shorted to ground,
replace MZLP.
Thermistor reading greater than 212°F Verify transformer fan is operating correctly and
(100°C).
free of obstructions.
Replace transformer.
No reading from RTD.
Verify connector J5 on MZLP board is securely
connected.
Replace melter RTD. See Replace Band Heater
Temperature Sensor, page 68.
No reading from RTD.
Hose electrical connector not plugged into MZLP.
Replace hose.
No reading from RTD.
Hose electrical connector not plugged into MZLP
or applicator electrical connector not plugged into
heated hose.
Replace applicator RTD.
No reading from transformer thermistor Verify that sensor wire is plugged into J7 on
sensor.
AWB.
Replace transformer.
Temperature reading does not change. Check fuses F3 and F4 (channels 1, 3, 5) or F7
and F8 (channels 2, 4, 6) on MZLP that error
channel is connected to.
Replace applicator manifold heater rods.
NOTE: Heater rods in the applicator manifold
can also cause the no current error.
Check resistance of hose wiring. See hose manual for proper resistance range.
48
333347U
Troubleshooting
Code
T8D_
T8D0
Description
No Temp Rise in
Hose (all zones)
No Temp Rise in
Melter (all
zones)
Type
Alarm
Alarm
Cause
Solution
Temperature reading does not change. Check fuses F5 and F6 (channels 1, 3, 5) or F9
and F10 (channels 2, 4, 6) on the MZLP that controls the error channel.
Check resistance of hose wiring. See hose manual for proper resistance range.
NOTE: Heater wires in the hose can also cause
the no current error.
Temperature reading does not change. Check fuses F1 and F2 on MZLP with daughter
board.
Check that RTD is installed in the melter.
Check J1 is properly plugged into the MZLP with
daughter board and in J3 on AWB.
Check heater resistance and compare to reference table. See Check Heater Rod Resistance,
page 58.
Replace melter heater.
V1I_
Low Can Voltage
Alarm
Bad or overloaded power supply.
V1MW
Low Line Voltage
Deviation
Incoming line to line voltage has
dropped below 175V.
V4I_
High Can Voltage
High Line Voltage
Invalid Power
Type
Alarm
Bad or overloaded power supply.
Alarm
V8M_
No line voltage
Alarm
Incoming line to line voltage has
increased above 265V.
During startup incoming line to line
power was either below 175V or above
265 V.
Incoming line voltage is less than
100 VAC.
WJDX
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
Deviation
A valid configuration file can't be found
for the USB.
V4MW
V6MW
Alarm
ADM: not functioning properly.
333347U
NOTE: Heater rods in the melter can also cause
the no current error.
Verify power supply voltage is 24 VDC. If voltage
is low, disconnect the screw terminals +V and -V
on the power supply and re-check voltage reading. If voltage is correct, then disconnect J8 and
J9 from AWB and re-check voltage. If still low
replace AWB. If correct, plug in J9 and recheck
voltage. If low, replace ADM. If correct, plug in
J8. If low, replace MZLP. If voltage is still low,
replace power supply.
Verify incoming power is correct gauge for current draw and verify incoming power lines are
securely attached to disconnect.
Verify power supply voltage is 24 VDC. If voltage
is high, replace power supply unit.
For 3 phase with neutral have qualified electrician verify neutral wire.
Verify incoming power is wired to the disconnect
correctly.
Measure incoming power with system
unplugged. If line voltage is less than 100 VAC,
contact qualified electrician to correct the low
voltage.
Check connector is properly connected to J13 of
the daughter board.
Replace air manifold.
Check connector at J13 of the daughter board.
Replace air solenoids. See page 76.
System is not properly loaded with correct software. Perform Software Update Procedure on
page 81. Retry USB download.
Replace ADM.
49
Troubleshooting
Mechanical and Electrical Troubleshooting
Problem
Cause
Solution
Refill Timeout
Error
The system was unable
to refill in less than 30
seconds.
Check hopper for adequate material and material blocking.
Verify the vacuum transfer system air pressure is 40-80 psi (60 psi recommended) and that air is flowing to the feed wand while attempting to
refill.
Restart system. If the error persists after attempting another refill and
unit is needed immediately for production, place system into the manual refill mode. See Manual Refill on page 34.
Check funnel filter. If plugged, see Replace Funnel Filter on page 42.
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 42.
Vacuum transfer not working
Air to vacuum assembly missing.
Verify the vacuum transfer system air pressure is 40-80 psi (60 psi recommended)
Air at system air gauge
but not to air to shaker.
Check that air line is connected or not pinched.
Air is at shaker but
there is no feed.
Plugged shaker unit, remove from system and remove plug.
Adhesive pellets in storage
bin not covering shaker
head.
Shaker unit not vibrating.
Verify shaker is vibrating during material loading. If not, the ball in the
shaker assembly is stuck. Remove shaker housing and separate to
clean raceway and ball inside.
Materials are blocking
in the hopper. Some
adhesive materials are
prone to blocking. High
ambient temperature
and high humidity can
increase the likelihood
of blocking.
Some materials may require agitation periodically to breakup bridging.
Fill Solenoid
Error
Failure of the fill solenoid or fill solenoid wiring.
Verify wiring between J13 and the refill solenoid is not damaged.
50
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 34.
333347U
Troubleshooting
Problem
Cause
Solution
Level Sensor
Error
Failure of the level sensor (20) or sensor
cable 16T108 (J14 to
level sensor (20)).
Check sensor cable J14 to level sensor (20).
Enable Diagnostic screen on ADM then check sensor readings on the
Diagnostic screen. Sensor readings should be about 4.3V if melter is
completely empty (melter passage holes are visible). The normal operating range is 3.8 to 4.3V. If the sensor is reading more than 4.2V the
system should be requesting additional material.
Restart system. If the error persists after attempting another refill and
unit is needed immediately for production, place system into the manual refill mode. See Manual Refill on page 34.
The InvisiPac
system expels
adhesive pellets dust when
refilling.
Some adhesives are
very dusty due to the
anti-blocking agents
used or because the
adhesive manufacturing process has created small adhesive
shavings. Feed inlet
cap filter may have
become clogged.
Replace Funnel Filter, see page 42.
The InvisiPac
system will not
stall, pump
continues to
move even if
the applicators
are all closed.
Fluid leak.
Verify that no external leakage is present.
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 58.
Feed pump not feeding adhesive.
Repair or replace air control assembly as necessary.
Timing control for applicators not working.
InvisiPac system does not control the timing of the applicators. This is
a separate control that needs to be adjusted. Consult control manufacturer or qualified electrician.
Cycle switch or cycle
switch wiring failure.
Check the wiring between the air motor cycle switch and J16.
Repair/replace as required.
Loose or missing fastener (26).
Ensure fastener (26) is tight. See InvisiPac Systems section beginning on page 89 for part identification.
Cycle Switch
Error
333347U
NOTE: Feed cap filter maintenance should be performed at regular
service intervals. It is recommended that the feed cap filter be
inspected at a minimum of every 1200 lb dispensed, however with
some adhesives the frequency may need to be increased significantly
to maintain desired system cleanliness.
Inspect and test the pressure relief valve.
Perform Flush Pressure Relief Valve, page 58.
If system is still unable to stall, the pump or pressure relief valve may
need to be repaired.
Repair or replace pump assembly as necessary.
51
Troubleshooting
Problem
Cause
Solution
USB Log Full
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 126.
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 (11 cpm- HM25,
ing.
22 cpm - HM50) by enabling the diagnostic screen.
2. If the cycle rate is below (11 cpm- HM25, 22 cpm - HM50)and the
system is still running away increase the InvisiPac system temperature in small increments over the current set point.
3. If the pump continues to runaway or dive continue increasing temperature in small increments. Do not exceed maximum temperature
for the material being dispensed.
NOTE: If air has become trapped in the pump, it can be purged by following the Pressure Relief Procedure, page 37.
NOTE: Some materials are more difficult to melt than others and it may
be impossible to process them at the published melt rate. The InvisiPac
system was tested to achieve continuous published melt rates when
dispensing standard EVA packaging grade adhesives in pellet form
with an InvisiPac system temperature of 350°F and hose and applicator temperatures of 350°F.
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.
Ensure supplied Air Filter Kit 24R707 is installed on system air inlet.
Perform a reverse pressure flush of the sensor venture orifice:
1. Disconnect incoming air from InvisiPac system air inlet (108).
2. Disconnect air tube poush-connect union (91) from ultrasonic sensor air tube (35).
3. Plumb 80-100 psi (550-690 kPa, 5.5-6.9 bar) to outlet end o air tube
union (91).
4. Ensure air is flowing out of the InvisiPac system air inlet (108).
5. Reconnect ultrasonic sensor air tube (35) to air tube union (91).
52
333347U
Troubleshooting
Problem
Cause
Solution
Unable to
achieve published melt rate
at the desired
adhesive temperature.
1. If the cycle rate is below (11 cpm - HM25, 22 cpm - HM50) and the
The InvisiPac system
system is still running away increase the InvisiPac system
monitors temperature
temperature in small increments over the current set point, leave
within aluminum mass
hoses and applicators at desired set point.
of melter (202). As melt
rates exceed 20 lb/hr a
2. If the pump continues to runaway or dive continue increasing temsystem temperature
perature in small increments. Do not exceed maximum temperature
offset may be required.
for the material being dispensed.
NOTE: A 50 amp breaker is required in order to maximize startup and
flow rate performance. Set the breaker size used in the Setup screens.
NOTE: Some materials are more difficult to melt than others, therefore
it may be impossible to process them at the published melt rate. The
InvisiPac system was tested to achieve continuous the published melt
rates when dispensing standard EVA packaging grade adhesives in
pellet form with an InvisiPac system temperature of 350°F and hose
and applicator temperatures of 350°F.
ADM not displaying when
system turned
on
Main breaker
tripping
333347U
Main power circuit
breaker off or power
cord unplugged.
Turn main circuit breaker on or plug in power cord.
Cable on ADM
unplugged.
Reconnect ADM cable.
Connector on AWB
board not plugged in.
ADM cable should be plugged into J9 of the AWB board.
Bad 24VDC power supply.
Check output on power supply should measure 24VDC, if no voltage
reading replace power supply.
ADM 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.
53
Troubleshooting
Problem
Cause
Solution
Slow start-up
time or system
takes longer
than 10 minutes to startup
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.
Heater rod in melter
and gun manifold.
Measure and check heater rods in melter or applicator. See applicator manual. See Check Heater Rod Resistance, page 58.
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
applicator combinations,
along with minimal supply power, startup time
will vary.
Connect system to a power supply capable of maximum power per system
specification. All changes must be performed by a qualified electrician. See
Models on page 4 for full-power rating. See Startup Time, page 131, for
startup times under varying conditions.
Incorrect RTD setting in
system.
1. Verify melter, hose, and applicator temperatures are all with in the
same range of the room ambient.
No adhesive or
little adhesive
being dispensed
2. If the applicator temperature is either much higher or much lower
than the melter temperature then the RTD setting is not correct for
the RTD being used. Select correct RTD setting in the setup screen
system 2 before beginning.
NOTE: Failure to have the correct RTD value will cause the applicator to either
under-heat or over-heat. Setting for RTD in the ADM screens is higher than
actual RTD value. Consult manufacturer for actual RTD value.
System indicates no errors
and correct
temperature
however applicator is over
the temperature setpoint
54
Incorrect RTD setting in 1. Verify melter, hose, and applicator temperatures are all within the
same range of the room ambient.
system.
2. If the applicator temperature is either much higher or much lower
than the melter temperature then the RTD setting is not correct for
the RTD being used. Select correct RTD setting in the setup screen
system 2 before beginning.
NOTE: Failure to have the correct RTD value will cause the applicator
to either under-heat or over-heat. Setting for RTD in the ADM screens
is lower than actual RTD value. Consult manufacturer for actual RTD
value.
333347U
Troubleshooting
Problem
Cause
Solution
No adhesive or
incorrect
amount of
adhesive output when all
dispense modules are triggered
Plugged applicator
manifold filter.
Replace applicator manifold filter. Graco applicator manifold filter in
bottom of manifold or inline filter on other applicators.
Clogged hose.
Flush or replace hose.
Solenoid valve.
Check that correct voltage is input into solenoid valve. If voltage is correct, replace solenoid.
No signal from control
to solenoid.
If no voltage is present at solenoid, check control cable and pattern
controller. Replace component.
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 41.
If multiple applicators
are triggered simultaneously, maximum
pump rate may be
exceeded.
Stagger applicator opening to reduce the maximum required flow rate
to below maximum pump rate.
Plugged tip on dispense module.
Replace tip on dispense module.
Dispense module in
closed/partial open
position.
Replace dispense module.
Plugged applicator
manifold filter (single
dispense module applicator).
Replace applicator manifold filter. Graco applicator manifold filter in
bottom of manifold or inline filter on other manifolds.
Clogged hose
Flush or replace hose.
Solenoid valve
Check that correct voltage is input into solenoid valve. If voltage is correct, replace solenoid.
No signal from control
to solenoid
If no voltage is present at solenoid, check control cable and pattern
controller. Replace component.
Plugged solenoid mufflers
Replace solenoid mufflers.
No air to solenoid
Re-establish air supply to solenoid.
Plugged system outlet
filter.
Replace Outlet Filter. See page 41.
If multiple applicators
are triggered simultaneously, maximum
pump rate may be
exceeded.
Stagger applicator opening to reduce the maximum required flow rate
to below maximum pump rate.
No adhesive or
incorrect
amount of
adhesive out of
one/some of
the dispense
modules when
triggered
333347U
55
Troubleshooting
Problem
Cause
Solution
Adhesive flowing out of
one/some
applicators
when not triggered
Failed valve in the open
position.
Replace dispense module.
Adhesive pressure too
high.
Reduce air pressure to air motor.
Heat rod failure in applicator manifold.
Check resistance on heater rods. Repair applicator manifold if heater rods
measure open.
Loose cable connection
at system or manifold.
Check cable connections on both ends of the hose.
RTD failure.
Check resistance on the RTD, if out of normal range replace RTD.
Incorrect RTD setting in
the ADM setup.
Set correct RTD value in the ADM setup screen. Consult manufacturer for correct RTD value.
Thermal cutoff is tripped.
Measure resistance of the thermal cutoff at room temperature. If open,
replace.
Dispense module is
loose on the manifold.
Tighten screws on loose dispense module.
Dispense module o-ring
failed.
Replace o-rings on the back of the leaking dispense module.
Failed dispense module,
adhesive leaking out
middle of dispense module.
Replace dispense module.
Hose loose.
Tighten hose.
Fuse blown in F1 and F2.
Check heater rods for a short or a short between the rod wires and ground.
Cable to over-temperature switch off or broken.
Check connection of cable to over-temperature switch both to main board and
to switch. If connection good, look for break in wire.
Over-temperature switch
tripped.
Measure over-temperature switch resistance. It should read close to 0 ohms
when at room temperature. If open, replace over-temperature switch. Make
sure main system power is off when making measurement.
No air being supplied to
air motor.
Check incoming air supply. air motor is disabled until system reaches “Active”
state. When “Active”, the pump air solenoid should supply air to the air motor.
Air solenoid not enabling
the air motor.
Check solenoid voltage, if 24VDC present at air solenoid replace air solenoid.
Air present at air motor
but it will not work.
Replace air motor.
No power to unit.
Check main power breaker is turned on.
Check that power plug is connected.
Applicator will
not heat.
Adhesive leaking from manifold or dispense
module.
No melter heat.
Air motor will
not function.
System not turning on.
56
333347U
Troubleshooting
Problem
Cause
Solution
Static shock
when touching
shaker or adhesive bin.
Ground wire not in place
on shaker assembly.
Some adhesives, flow
rates, and ambient conditions can cause excessive
static buildup on the
shaker tube.
Attach a ground wire from the shaft of the shaker unit to a true earth ground.
Order shaker grounding kit 24R708.
Adhesive not
dispensing at the
correct time.
Dispense modules opening at the wrong time.
InvisiPac system does not control the opening and closing of the applicators.
The separate controller needs to be adjusted. Consult pattern control manufacturer or qualified electrician.
Pump and vacuum feed system cycle on and
off before temperature setpoint
is achieved.
Solenoid connector is
installed into the light
tower plug on the MZLP
daughter board
Move solenoid connector from J12 (light tower) to J13 (solenoid valves) on the
daughter board on the MZLP.
333347U
57
Troubleshooting
Flush Pressure Relief Valve
Check the Pump Air Solenoid Operation
Perform this procedure when directed in the Troubleshooting table.
Perform this procedure when directed in the Troubleshooting table.
1. With the system active at the required adhesive
temperature, set the air motor air pressure to 20 psi
(140 kPa, 1.4 bar).
NOTE: System must be up to operating temperature for
pump solenoid to trigger on.
1. If the heating system and pump is disabled,
2. Remove the air line (36) from the pressure relief
valve.
press
to enable the heaters and pump.
2. Wait for system to reach the temperature setpoints.
3. Set pump air pressure to 20 psi (140 kPa, 1.4 bar).
4. Remove the 3/8 in. OD air line from the air motor.
5. Verify that air is flowing through the air line.
6. If air is not flowing, check the wiring between J13
and the pump solenoid.
Check Heater Rod Resistance
36
Use the table to determine if heater elements need to be
replaced.
HM25
WLD
FIG. 26
3. Plug air line and allow the air motor to cycle.
4. Re-connect air line to relief valve and check whether
the system will stall.
HM50
Ref. Element Wattage Ohms Wattage Ohms
Band
208
1250
41-51
2000
26-32
Heater
500
103-127 1500
34-42
209 Melter
Rod
34-42
1000
52-64
210 Base Rod 1500
34-42
1000
52-64
271 Pump Rod 1500
5. If system still does not stall, purge ten pump cycles
of material through one applicator.
6. Repeat this entire procedure until no additional air is
expelled from the applicator.
58
333347U
Troubleshooting
Re
Yello
Gre
MZLP Troubleshooting
7 89
56
J3
234
01
MZLP
ti20348a
FIG. 28: MZLP Diagnostic LED Location
WLD
FIG. 27: MZLP LED Signals
NOTE: The MZLP LED is located on the inside of the
electrical enclosure. To view, remove the electrical
enclosure front access door.
Signal
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.
333347U
59
Repair
Repair
NOTE: Some procedures require special tools. Read
through each procedure prior to beginning it to ensure
you have the required tools to complete the entire procedure. Order any required tools and have them on
hand prior to beginning the procedure.
Disassembly (see FIG. 29):
1. Flush the system. See page 38.
2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
3. Turn main power switch OFF.
NOTICE
When performing any procedure that requires
removal of seals or other soft parts, do not leave a
system that has not been flushed disassembled for
more than 30 minutes to prevent the adhesive from
hardening. Hardened adhesive will damage the seals
and other soft parts during installation.
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
a. Remove retaining ring (239).
b. Remove dowel pin (238).
c.
Remove three screws (240).
218
9. Use a flat head screwdriver and a rubber mallet to
break loose the retaining nut (235).
240
27
223
226
222
239
235
233
234
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).
238
224
225
12. Remove piston valve (222) from piston rod (223).
13. Remove and discard piston u-cup (225) and
bearing (226).
245
3
Reassembly (see FIG. 29):
1. Assemble piston rod:
a. Install new piston u-cup (225) onto piston
rod (223) with the lips facing the rod.
WLD
b. Install piston bearing (226) onto piston rod (223)
with grooved end towards the center of the piston rod.
FIG. 29
60
333347U
Repair
c.
Install piston valve (222) onto piston rod (223).
Torque to 24-30 ft-lb (33-41 N•m).
throat bearing (233) into place and seat the throat
u-cup.
2. To protect the seals from the sharp threads, place
seal installation tool 15B661 into the throat bore.
See FIG. 30.
235
15B661
233
203
ti20877a
ti21144a
FIG. 30
FIG. 32
3. Push the piston rod assembly (223) into the melter
outlet manifold (203).
4. Grease the throat u-cup (234) and slide the u-cup
over the piston rod (223) with the lips facing down.
5. Place a 7/8 in. deep-well socket (3/8 in. drive) over
the piston rod (223) then use a rubber mallet to gently tap throat u-cup (234) into place. See FIG. 31.
7. Remove seal installation tool.
8. Install retaining nut (235). See FIG. 30.
9. Install air motor assembly (see FIG. 29):
a. Install three screws (240).
b. With retaining ring around piston rod, install
dowel pin (238).
c.
Install retaining ring (239) over dowel pin.
10. Use nuts (3) to install melter shield (27).
11. Connect air lines to relief valve and air motor.
12. Install plastic shroud (27).
234
ti21047a
FIG. 31
6. Slide throat bearing (233) over the piston rod (223).
Use socket and tap with a rubber mallet to press
333347U
61
Repair
Reassembly (see FIG. 33):
Replace Pump Inlet Housing Checks
1. Install new o-ring (231), o-ring (229), seat (228),
and ball (227) then use a 1/2 in. drive ratchet
without a socket to install and tighten foot
valve (230) onto melter.
2. Replace cross over tube (269 using new o-rings
(270). Angled ring faces the melter base.
3. Apply anaerobic thread sealant on threads of four
bolts (246) and connect pump to melter outlet.
Torque to 12-18 ft-lb (16-24 N•m).
270 269
203
246
227
228
229
231
230
WLD
WLE
FIG. 33
Disassembly (see FIG. 33):
1. Flush the system. See page 38.
2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
3. Turn main power switch OFF.
4. Remove four bolts (246) and pump manifold (203)
from melter outlet.
5. Remove cross over tube (269) and discard o-rings
(270).
6. Use a 1/2 in. drive ratchet without a socket to
remove foot valve (230) from bottom of melter outlet
manifold (203).
7. Remove and discard seat (228), ball (227),
o-ring (229), and o-ring (231).
62
333347U
Repair
Replace Pump Cylinder Seals and Piston Seals
7. Remove air motor assembly. See FIG. 29 on
page 60:
a. Remove retaining ring (239).
b. Remove dowel pin (238).
c.
218
Remove three screws (240).
8. Use a flat head screwdriver and a rubber mallet to
break loose the retaining nut (235).
9. Use channel lock pliers to remove the retaining
nut (235).
235
233
234
239
233
224
226
222
10. Insert an allen wrench through the hole in the top of
the piston rod (223) to lift the piston rod (223) up out
of the manifold. This will also pull out the throat
u-cup (234) and throat bearing (233).
11. Replace Pump Inlet Housing Checks. See page
62.
12. Use a 1/2 in. drive ratchet without a socket to
remove foot valve (230) from bottom of melter outlet
manifold (203). See FIG. 34, page 63.
203
13. Insert cylinder tool (1301) into bottom of melter outlet manifold (203). Use a rubber mallet to gently
remove cylinder (216).
217
216
217
230
WLD
FIG. 34
1301
Disassembly (see FIG. 29):
1. Flush the system. See page 38.
203
2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
217
3. Turn main power switch OFF.
216
4. Remove plastic shroud (27). See FIG. 29 on
page 60.
5. Remove air lines from relief valve (245) and air
motor (218) See FIG. 29 on page 60.
6. Remove nuts (3) securing melter shield (27) in
place then remove melter shield. See FIG. 29 on
page 60.
333347U
217
ti20880a
FIG. 35
14. Remove and discard cylinder seals (217). See FIG.
35.
63
Repair
Reassembly:
1. Apply grease to seals (217) then install new cylinder
seals (217) onto cylinder (216). See FIG. 35.
1303
217
216
217
1302
203
ti21049a
FIG. 36
2. Place female cylinder installation tool (1302) into
melter outlet manifold (203) to protect seals from
sharp threads. See FIG. 36.
3. Use male cylinder installation tool (1303) to press
cylinder (216) into melter outlet manifold (203). If
necessary, use rubber mallet tap into place. See
FIG. 36.
4. Use a 1/2 in. drive ratchet without a socket to install
and tighten foot valve (230) into bottom of melter
outlet manifold (203). See FIG. 34, page 63.
5. Perform Replace Pump Inlet Housing Checks on
page 62.
6. Perform Reassembly portion of the Replace Throat
Seal, Throat Bearing, Piston Rod, Piston Seal,
and Piston Bearing procedure which starts on
page 60.
64
333347U
Repair
Melter
6. Remove screws (8) then remove electrical enclosure front access door (10).
Remove Melter Assembly
7. Disconnect heater rod wires from J4 connector on
AWB board.
8. Remove the air tube (36) from the relief valve (245).
Pull the air tube from the metal shroud (27).
FF
9. Remove nuts (3) on the back metal shroud (27)
then remove shroud.
10. Remove fabric melter insulator (53).
30
81
11. Loosen screw (AA) then remove sensor (125). See
FIG. 40, page 68.
53
29
12. Loosen hose clamp (81) then remove funnel (FF).
13. Remove wire connectors from the over-temperature
switch (251).
218
203
75
14. Remove insulators (53, 75) from the melter
assembly (5).
251
3
5
15. Disconnect the fill sensor cable from the fill
sensor (20). See Replace Fill Sensor, page 73.
8
245
16. Disconnect the pump cycle sensor cable from the
air motor.
10
WLD
17. Remove the air tube from the air motor (218).
18. Loosen screw (AA) then remove sensor (125). See
FIG. 39 on page 67.
1
3
27
36
19. Disconnect ground screw (87) and ring terminal (88)
from melter assembly.
FIG. 37
NOTE: This only needs to be done when replacing
items that require access to the bottom of the melter
assembly.
1. Perform Drain the System procedure on page 38
then wait for system to cool.
87
2. Close the bleed type ball valve at the system air
inlet.
88
3. Turn main power switch OFF.
WLD
FIG. 38
20. Remove electrical enclosure front access door (10).
4. Disconnect all heated hoses from the melter outlet
manifold.
5. Remove cable from ADM (30) then slide forward the
shroud (29) and remove it from the system.
333347U
65
Repair
21. Remove all heater wires from the following terminals. Pull wires up through the rubber grommet on
the top of the electrical enclosure (1).
5. Group the 4 sets of heater wires together and run
them through the grommet on the top of the electrical enclosure (1). Connect wires as noted below.
Item
Wire Marking Wire Marking
1
2
Item
Wire Marking Wire Marking
1
2
Band Heater (208)
J4-1
J4-2
Band Heater (208)
J4-1
J4-2
Melter Heater Rod
(209)
J4-5
J4-6
Melter Heater Rod (209) J4-5
J4-6
Base Heater Rod (210)
J4-7
J4-8
Base Heater Rod (210) J4-7
J4-8
Pump Heater Rod (271) J4-3
J4-4
Pump Heater Rod (271) J4-3
J4-4
6. Connect air tube to air motor (218).
22. Remove four nuts (3) then remove melter assembly
from system. Save any loose insulators for reassembly.
7. Connect fill sensor cable to the fill sensor (20).
23. Remove bolts (259), insulators (249), washers
(268), and melter assembly from base (257).
9. Install funnel (FF) then tighten clamp (81).
Install Melter Assembly
1. Route melter heater rod (209) wire through large
hole in the melter base (257) then through small
hole in side of melter base (257).
2. With the 10 insulators (4) in place on the melter
assembly, place melter assembly on melter
base (257).
8. Connect pump cycle sensor cable to air motor.
10. Install temperature sensor (125) into melter then
tighten screw (AA) on band heater. See FIG. 39 on
page 67.
11. Install insulators (53,75) onto the melter
assembly (5).
12. Connect ground wire ring terminal (87) and ground
screw (88) to melter assembly (5).
13. Connect wire connectors to the over-temperature
switch (251). See FIG. 41 on page 69.
14. Use nuts (3) to install metal shroud (27).
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).
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).
3. Use 4 bolts (259) to secure washers (268) and
melter assembly to melter base (257).
17. Feed ADM cable through shroud then install shroud
and connect cable to ADM.
4. Use four nuts (3) to secure melter assembly to system.
18. Reconnect all heated hoses to the melter outlet
manifold (203).
19. Turn main power switch ON.
20. Open system air inlet ball valve.
66
333347U
Repair
Replace Band Heater
7. Loosen screw (AA) then remove sensor (125).
8. Locate the J4-1 and J4-2 wires in AWB board and
remove wires.
8
9. Pull wires up through grommet (63) on top of the
electrical enclosure (1). Clip any wire ties that hold
the wires in place.
F
10. Continue loosing screw (AA) then slide band
heater (208) up to remove.
80
Reassembly (see FIG. 39):
53
208
1. Install band heater (208) on the melter with the
opening and screw facing the front of the system in
alignment with the sensor port.
2. Install sensor (125).
AA
125
3. Slide band heater up then tighten screw (AA).
NOTE: Band heater should be oriented to hold sensor in
place when tightened. It should not bend the sensor.
4. Route band heater wires through grommet (63) in
the top of the electrical enclosure (1).
1
63
10
WLD
FIG. 39
Disassembly (see FIG. 39):
1. Once the fluid level is low enough, close the
bleed-type ball valve installed at the system air inlet.
2. Turn main power switch OFF.
3. Disconnect cable from ADM (30) then remove
shroud (29).
4. Remove front access door (10) from electrical
enclosure (1).
5. Connect wires to AWB board as marked. Wires
should be marked as shown in the following table.
Item
Wire
Marking 1
Wire
Marking 2
Band Heater (208)
J4-1
J4-2
6. Install electrical enclosure access door (10). See
FIG. 39.
7. Use clamp (80) and screws (8) to install funnel
assembly (F) on melter assembly. Ensure rubber
housing is fully seated on melter or incorrect refilling
may occur. Tighten band clamps to 25 in-lbs.
8. Install fabric melter insulator (53).
9. Feed ADM cable through shroud then install shroud
and connect cable to ADM.
10. Open system air inlet ball valve.
5. Remove fabric melter insulators (53).
11. Turn main power switch ON.
6. While system is still near operating temperature,
loosen clamp (80) and then remove screws (8) and
funnel assembly (F). When removing rubber housing from melter, separate rubber from melter by
pressing on inside surface.
333347U
67
Repair
Replace Band Heater Temperature Sensor
Reassembly (see FIG. 40):
1. Route new harness wires through grommet (63) in
the top of the electrical enclosure.
2. Connect wire connectors to over-temperature
switch (251). See FIG. 41 on page 69.
53
3. Place band heater temperature sensor (125) in
melter.
4. Tighten screw (AA).
NOTE: Screw should lightly squeeze the temperature
sensor to hold it in place. It should not bend the sensor.
5. Connect new harness to MZLP connector labeled
J5.
80
40
AA
125
10
WLD
FIG. 40
Disassembly (see FIG. 40):
1. Close the bleed-type ball valve installed at the
system air inlet to relieve all air pressure in the
system.
6. Install electrical enclosure access door (10). See
FIG. 39 on page 67.
7. Install fabric melter insulator (53).
8. Use nuts (3) to install metal shroud (27). See FIG.
37, page 65.
9. Route relief valve air tube through the metal shroud
then attach to the relief valve.
2. Turn main power switch OFF.
10. Feed ADM cable through shroud then install shroud
and connect cable to ADM.
3. Disconnect cable from ADM then remove shroud.
11. Turn main power switch ON.
4. Remove air tube (36) from relief valve. Pull the air
tube through the metal shroud (27).
12. Open system air inlet ball valve.
5. Remove nuts (3) then remove metal shroud (27).
See FIG. 37, page 65.
6. Remove fabric melter insulator (53).
7. Loosen screw (AA) then remove sensor (125).
8. Remove electrical enclosure access door (10).
9. Disconnect the temperature sensor cable from
MZLP connector labeled J5. See FIG. 40.
NOTE: This connector also includes the over-temperature switch wires.
10. Disconnect wire connectors from over-temperature
switch (251). See FIG. 41 on page 69.
11. Pull cable out of the electrical enclosure then discard sensor (125) and wires.
68
333347U
Repair
Replace Heater Over-Temperature Switch
5. Feed ADM cable through shroud then install shroud
and connect cable to ADM.
6. Open system air inlet ball valve.
7. Turn main power switch ON.
251
Replace Heater Rod
255
206
ti21052a
271
FIG. 41
Disassembly (see FIG. 41):
1. Close the bleed-type ball valve installed at the
system air inlet to relieve all air pressure in the
system.
2. Turn main power switch OFF.
206
210
3. Disconnect cable from ADM then remove shroud.
4. Remove air tube (36) from relief valve. Pull the air
tube through the metal shroud (27). See FIG. 43,
page 70.
5. Use 7/16 in. socket to remove nuts (3) then remove
metal shroud (27).
209
206
6. Disconnect the wire connectors from the over-temperature switch (251).
209
WLD
7. Remove the screws (255) securing the over-temperature switch (251) to the melter assembly (5),
then remove the switch.
FIG. 42
Disassembly (see FIG. 42):
Re-assembly (see FIG. 41):
1. Use the two screws (255) to secure the new
over-temperature switch (251) to the melter.
2. Connect wire connectors to new over-temperature
switch.
3. Use 7/16 in. socket to install nuts (3) to secure
metal shroud (27).
4. Route relief valve air tube (36) through the metal
shroud then attach to the relief valve.
333347U
NOTE: This procedure is for replacing any of the above
heater rods.
1. Turn main power switch OFF.
2. If replacing the melter heater rod (209), Remove
Melter Assembly. See page 65.
3. Disconnect cable from ADM then remove
shroud (29).
69
Repair
4. If removing the pump heater rod (271):
a. Remove the air tube (36) from the relief
valve (245). Pull the air tube through the metal
shroud (27).
7. Feed ADM cable through plastic shroud then install
plastic shroud and connect cable to ADM.
Replace Fluid Pressure Relief Valve
b. Remove nuts (3) then remove shroud (27).
5. Remove electrical enclosure front access door (10).
See FIG. 39, page 67.
27
6. Disconnect heater rod wires from terminal blocks
described in the following table.
Item
Wire Marking 1 Wire Marking 2
Band Heater (208)
J4-1
J4-2
Melter Heater Rod (209) J4-5
J4-6
Base Heater Rod (210)
J4-7
J4-8
Pump Heater Rod (271) J4-3
J4-4
3
36
7. Pull heater rod wires up through the grommet in the
top of the electrical enclosure (1).
244
245
8. Remove heater rod retaining ring (206) then remove
and discard heater rod (209, 210, 271).
Reassembly (see FIG. 42):
1. Route new heater rod cable through grommet (63)
in top of electrical enclosure then connect new
heater rod wires to terminal blocks as described in
the previous table.
NOTICE
To prevent damaging the heater rod, do not use
thermal grease in the following step.
2. Install heater rod then install heater rod retaining
ring (206). See FIG. 42.
3. Install electrical enclosure access door (10). See
FIG. 39, page 67.
4. If replacing the melter heater rod (209), Install
Melter Assembly. See page 65.
5. If replacing pump heater rod (271), feed ADM cable
through shroud then install shroud and connect
cable to ADM.
6. If installing the pump heater rod (250), install the
metal shroud (27):
a. Place metal shroud on system.
b. Install and tighten nuts (3).
c.
70
Pull the air tube through the metal shroud (27)
then connect the air tube (36) to the relief
valve (245).
ti20757a
FIG. 43
1. Drain the System. See page 38.
2. Close the system air inlet ball valve.
3. Turn main power switch OFF.
4. Remove the air tube (36) from the relief valve (245).
Pull the air tube through the metal shroud (27). See
FIG. 43.
5. Remove nuts (3) then remove shroud (27).
6. Use crescent wrench to remove melter fluid pressure relief valve (245). See FIG. 43.
7. Use an o-ring pick to remove o-ring (244).
8. Install o-ring (244) into manifold.
NOTICE
To prevent damage to o-ring, ensure o-ring is seated
properly prior to moving to next step.
9. Thread new fluid pressure relief valve (245) into
manifold. See FIG. 43. 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.
333347U
Repair
Multi-Zone Low Power Temperature Control Module (MZLP)
Replace MZLP Fuse
Fuse
Part
24V510 MZLP Fuses
MZLP Identification
F1, F2
250VAC, 25A, fast acting, white, 0.25 in x 1.2 in
F3-F10
250VAC, 8A, fast acting
Fuse Kits
24V510
Kit
MZLP
Description
24V289
24V510
Includes standard clear fuses.
24X480
Includes ceramic fuses used for
food industries.
1. Turn main power switch OFF.
2. Remove electrical enclosure front access door (10).
Key
A
F1 and F2 fuses are physically larger than F3-F10
B
Yellow sticker on relay
C
Marked 24V133
NOTICE
Using an improper tool, such as screw drivers or
pliers may break glass on fuse.
C
F8 F7
NOTE: F1 and F2 are white ceramic and indicate 25A
on the barrel.
J1
J2
F10 F9
3. Use a proper non-conductive fuse puller tool to
remove the blown fuse.
F4 F3
F2
F6
F1
A
NOTE: F3-F10 are clear glass and indicate 8A on the
barrel.
B
4. Install electrical enclosure front access door (10).
F5
J7
J6
J5
J3
WLD
FIG. 44: MZLP ID and Fuse Locations
NOTICE
To prevent system damage, always use fast acting
fuses. Fast acting fuses are required for short-circuit
protection.
333347U
71
Repair
2. Apply channel label stickers to new MZLP. See FIG.
45.
Replace MZLP
3. Use four screws (114) to install MZLP (112) to electrical enclosure (1).
Disassembly:
4. Reconnect cables to MZLP (112).
1. Turn main power switch OFF.
2. Remove electrical enclosure front access door (10).
3. Disconnect heated hose electrical connectors from
outside of MZLP (112).
4. Note location of each cable, then unplug all cables
from the MZLP (112) that will be replaced. See FIG.
45.
5. Remove four screws (114) securing MZLP (112) to
electrical enclosure (1) then carefully remove MZLP
from electrical enclosure. See FIG. 45.
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop and verify the connector orientation.
NOTE: If unable to determine connector location, see
Electrical Schematics on page 82.
5. Install electrical enclosure front access door (10).
6. Connect heated hose electrical connectors to new
MZLP.
NOTE: MZLP may need updated software. See Software Update Procedure on page 81.
Replace MZLP Daughter Card
MZLP
#1
Disassembly:
MZLP
#3
112
114
MZLP
#2
FIG. 45
6. Replace MZLP. See FIG. 45 for MZLP #1, MZLP #2,
and MZLP #3 identification.
1. Turn main power switch OFF.
2. Remove electrical enclosure front access door (10).
3. Note location of each cable then unplug all cables
from MZLP daughter card (112a).
4. Remove four mounting screws (112b) from daughter card (112a) and set aside.
112b
a. To replace MZLP #1, remove the daughter card
and standoffs, and re-install them on the new
MZLP #1.
112a
b. To replace MZLP #3, remove the jumper (135)
from MZLP #3 J5 connector and reinstall it on
the new MZLP #3 J5 connector.
ti20342a
112
Rotary Switch
Reassembly:
1. Set MZLP rotary switch to “1” on MZLP with
daughter card. Set MZLP rotary switch to “2” or “3”
on MZLP without daughter card, based on location.
See FIG. 46 for rotary switch location.
72
FIG. 46
5. Unplug daughter card (112a) from the MZLP
#1 (112).
333347U
Repair
Reassembly:
1. Plug new daughter card (112a) into the MZLP (112).
2. Use screws (112b) to secure daughter card to
MZLP (112).
3. Gently pull up on cable while unscrewing fill sensor
connector then remove fill sensor cable from fill
sensor (20).
4. Loosen fill sensor jam nut then remove fill
sensor (20) from sensor housing (73).
3. Connect cables to new daughter card (112a).
Reassembly (see FIG. 47):
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.
1. Thread new fill sensor (20) into sensor housing (73).
Bottom out the sensor in the sensor housing then
back out 1/2 turn.
NOTE: If unable to determine connector location, see
Electrical Schematics on page 82.
2. Tighten jam nut on fill sensor (20).
3. Connect fill sensor cable to new fill sensor (20).
4. Install electrical enclosure front access door (10).
4. Replace filter element and cover (68).
System
Replace ADM
Replace Fill Sensor
58
68
30
CC
ti20763a
20
FIG. 48
1. Turn main power switch OFF.
73
2. Disconnect cable (CC) from bottom of ADM (30).
See FIG. 48.
3. Remove ADM from bracket (58).
4. Install new ADM into bracket.
WLD
5. Connect cable to bottom of new ADM.
FIG. 47
Disassembly (see FIG. 47):
NOTE: ADM may need updated software. See Software Update Procedure on page 81.
1. Turn main power switch OFF.
2. Remove filter cover (68) and filter element.
333347U
73
Repair
Replace AWB
Reassembly:
1. Use two screws (144) to secure power supply
bracket (145) to new AWB (143). See FIG. 49.
2. Mount power supply (146) to power supply bracket
(145). See FIG. 49.
131
3. Connect connector (labeled AWB-J1) on power supply harness (147) to J1 on AWB (143). See Electrical Schematics, page 82.
144
145
4. Use two screws (131) to install AWB (143) to electrical enclosure (1). See FIG. 49.
146
5. Reconnect cables to AWB (143).
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop and verify the connector orientation.
145
131
FIG. 49: AWB and Power Supply
NOTE: If unable to determine the connector location,
see Electrical Schematics, page 82.
Disassembly:
6. Install electrical enclosure front access door (10).
1. Turn main power switch OFF.
2. Note location of each cable, then unplug all cables
from the AWB. See Electrical Schematics, page
82.
3. Remove 2 screws (131) securing AWB (143) to
electrical enclosure (1) then carefully remove AWB.
4. Remove power supply (146) from power supply
bracket (145) by releasing mounting tab on the side
of the power supply. See FIG. 49.
5. Remove two screws (144) securing power supply
bracket (145) to AWB (143) and remove power supply bracket. See FIG. 49.
74
333347U
Repair
Replace Power Supply
Replace Power Supply Harness
Disassembly:
Disassembly:
1. Turn main power switch OFF.
1. Turn main power switch OFF.
2. Remove electrical enclosure front access door (10).
2. Remove electrical enclosure front access door (10).
3. Remove power supply (146) from power supply
bracket (145) by releasing mounting tab on the side
of the power supply. See FIG. 49.
3. Disconnect screw terminal connections between
power supply (146) and power supply harness (147)
according to the following table.
4. Disconnect screw terminal connections between
power supply (146) and power supply harness (147)
according to the following table. See FIG. 49.
Power Supply
Connection
V+
VGND
L
N
Harness Label
V+
VGND
L
N
Power Supply
Connection
V+
VGND
L
N
Harness Label
V+
VGND
L
N
4. Unplug power supply harness (147) from J1 on
AWB (143). See Electrical Schematics, page 82.
Reassembly:
Reassembly:
1. Make connections between power supply harness
(147) and new power supply (146) according to the
following table:
2. Reattach power supply (146) to power supply
bracket (145). See FIG. 49.
1. Make connections between power supply harness
(147) and new power supply (146).
2. Connect connector (labeled AWB-J1) on power supply harness (147) to J1 on AWB (143). See Electrical Schematics, page 82.
3. Install electrical enclosure front access door (10).
3. Install electrical enclosure front access door (10).
333347U
75
Repair
Air Controls
405
402
8
9
Replace Air Control Solenoids
NOTE: In order to replace the air control solenoids, the
system must be tipped back to access underneath the
electrical enclosure.
Disassembly (see FIG. 50):
1. Turn main power switch OFF.
1
2. Disconnect plug from power outlet or turn off circuit
breaker for incoming power.
WLD
3. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
FF
FIG. 50
4. Remove front access panel (10) from electrical
enclosure (1).
5. Remove the transformer assembly; for 480V systems only (see FIG. 51):
a. Disconnect transformer wires from J2 connector
on AWB board and the main power switch.
142
140
b. Remove three screws (142) and InvisiPac system off of transformer assembly (140).
6. Use 3/8 in. socket to remove two screws (8).
7. Note location of each air line connection.
WLD
FIG. 51
Reassembly (see FIG. 50):
8. Insert hands through access holes (FF), see FIG.
50, in bottom of electrical enclosure then disconnect
air lines from air control solenoids (402).
9. Disconnect air control solenoids cable from MZLP
daughter board connector J13. Pull wire out of the
electrical enclosure.
10. Remove two screws (405) securing solenoids (402)
to air control assembly (9) then remove air control
solenoids.
1. Use two screws (405) to secure new
solenoids (402) to air control assembly (409).
2. Feed the new solenoid cable into the electrical
enclosure and attach cable to MZLP daughter board
connector J13.
3. Insert hands through access holes (FF), see FIG.
50, in bottom of electrical enclosure then connect air
lines to air control solenoids (402).
4. Slide air control assembly (9) into place then use
two screws (8) to secure to electrical enclosure (1).
5. For 480V systems, install transformer assembly
(140) with screws (142) and reconnect transformer
wires to J2 connector on AWB board and the main
power switch.
6. Install electrical enclosure front access door.
76
333347U
Repair
Replace Air Control Gauge
NOTICE
8
403a
403c
In the following step, do not overtighten the two
nuts (403a). Overtightening may cause the gauge to
break.
403
9
4. Orient gauge as desired then tighten two
nuts (403a) to secure gauge (403) in place.
5. Slide air control assembly (9) into place then use
two screws (8) secure to electrical enclosure.
Air Motor
Replace Pilot Valve
403b
C
WLD
511
FIG. 52
218
Disassembly (see FIG. 52):
1. Turn main power switch OFF.
2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
3. Remove two screws (8) then slide air control
assembly (9) out from electrical enclosure (1) so the
back of the gauges are exposed.
4. Remove two nuts (403a) securing gauge (403) in
place then remove bracket (403c).
5. Place one small crescent wrench on the brass part
of the gauge then use a second small crescent
wrench to remove the air fitting (403b).
6. Remove air gauge from panel.
Reassembly (see FIG. 52):
1. Slide new air gauge into panel and slide the bracket
onto the back of the gauge. Install air fitting onto the
gauge by hand, do not tighten yet.
2. Install bracket (403c) then install two nuts (403a)
finger tight.
3. Place one small crescent wrench on the brass part
of the gauge then use a second small crescent
wrench to tighten the air fitting (403b).
WLD
FIG. 53: Top Pilot Valve
1. Close the bleed-type ball valve installed at the
system air inlet to relieve all air pressure in the
system.
2. Turn main power switch OFF.
3. Replace top pilot valve (511):
a. Use crescent wrench to remove rod cover (C).
b. Use 10 mm socket to remove air motor pilot
valve (511) from air motor (218).
c.
Lubricate with grease and install new air motor
pilot valve (511).
d. Torque pilot valve to 95-105 in-lb (10.7-11.9
N•m).
4. Replace bottom pilot valve (511):
333347U
77
Repair
2. Turn main power switch OFF.
29
218
3. Loosen clamp on air motor bracket (528) then
remove funnel assembly (61).
6
4. Loosen upper hose clamp on rubber housing then
remove fill cap.
5. Dispense until the fluid level in the melter is at or
below the honeycomb grid.
511
NOTE: If a screw or air valve seal is dropped during this
procedure it could fall into the melter. Melter fluid level
must be below honeycomb grid before moving to next
step.
6. Once the fluid level is low enough, close the
bleed-type ball valve installed at the system air inlet.
WLD
7. Disconnect air hose and cable from the air motor.
FIG. 54: Bottom Pilot Valve
8. Use 10 mm socket to remove four screws (509)
securing air valve (512) to air motor (218).
a. Remove cover (29) and insulation (6).
b. Use 10 mm socket to remove air motor pilot
valve (511) from air motor (218).
9. Remove air valve (512) and seal (507) then discard.
c.
1. Lubricate with grease then place new air valve
seal (507) onto air valve (512).
Lubricate with grease and install new air motor
pilot valve (511).
d. Torque pilot valve to 95-105 in-lb (10.7-11.9
N•m).
e. Replace insulation (6) and cover (29).
Reassembly (see FIG. 55):
2. Carefully place new air valve (512) against air motor
then thread in the four screws (509). Ensure the air
valve seal (507) stays in place by applying constant
pressure against the air motor.
3. Use 10 mm socket to torque screws (509) to
95-105 in-lb (10.7-11.9 N•m).
Replace Air Valve
218
4. Install fill cap then tighten upper hose clamp on rubber housing.
507
512
5. Connect air hose and cable to the air motor.
509
FIG. 55
Disassembly (see FIG. 55):
1. Close the bleed-type ball valve installed at the
system air inlet to relieve all air pressure in the
system.
78
333347U
Repair
Remove Air Motor
8
74
218
82
239
27
238
220
7. If replacing a damaged air motor with a new fully
assembled air motor:
a. Remove three screws (211) securing air motor
tie rods (220) to base plate (219).
b. Remove tie rods (220) from air motor (218).
Install Air Motor
240
See FIG. 56.
219
1. If replacing a damaged air motor with a new fully
assembled air motor:
a. Install tie rods (220) onto air motor (218).
211
b. Install three screws (211) securing air motor tie
rods (220) to base plate (219).
3
2. Connect air motor assembly to system:
a. Install three screws (240), two screws (8),
screws (74), and bracket (82) to secure air
motor assembly to system.
b. Install dowel pin (238).
WLD
FIG. 56
c.
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. 43 on page 70.
Install retaining ring (239) over dowel pin (238).
3. Use four nuts (3) to install melter shield (27).
4. Reconnect air supply line to air motor (218).
5. Reconnect air line (36) to pressure relief
valve (245). See FIG. 43 on page 70.
4. Remove three nuts (3) securing metal shroud (27)
in place then remove metal shroud (27).
5. Disconnect air supply line from air motor (218).
6. Remove air motor assembly:
a. Slide retaining ring (239) down.
b. Remove dowel pin (238).
c.
Remove three screws (240).
d. Remove screws (8), screws (74), and bracket
(82).
333347U
79
Repair
Transformer Fan
6. Cut three zip ties on corrugated tube (167) and two
zip ties (161) on fan grill (154).
7. Remove four nuts (158), rear fan grill (170), and fan
(155).
Replace Fan
Install Fan
1
1. Mount new fan (155), rear fan grill (170), and nuts
(158) on grill (154) with the arrow pointing toward
the grill (154).
2. Tie down fan wires onto tie down locations on grill
(154) using cable ties (161).
158
black (-)
167
154
red (+)
161
161(x3)
151
157
WLE
FIG. 57
WLE
1. Turn main power switch OFF.
FIG. 59
2. Disconnect plug from power outlet or turn off circuit
breaker for incoming power.
3. Remove front access panel (10) from electrical
enclosure (1).
4. Remove connector from J7 connector on AWB
board. Remove red (+) and black (-) wires from connector.
J7
1
3. Route fan wires with transformer wires into the electrical enclosure (1). Connect red and black fan wires
to J7 connector. Reconnect J7 connector to AWB
board. See FIG. 58.
4. Reinstall corrugated tube (167) on fan and transformer wires. See FIG. 57.
NOTE: To prevent fan errors on ADM, remove excess
slack and ensure cabling and zip ties do not contact fan
blades.
5. Reinstall fan grill (154) and front access panel (10).
(+)
red
(-)
black
WLD
Front access panel (10) not shown.
FIG. 58
5. Remove screws (157) and fan grill (154). Pull two
fan wires down into the transformer enclosure.
80
333347U
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.
NOTE: When the screen turns on, the following screens
appear:
First:
Software is checking
which GCA modules
will take the available
updates.
1. Turn system main power switch OFF.
Second:
Status of the update
with approximate time
until completion.
2. Remove ADM from bracket.
3. Remove token access panel.
Third:
Updates are complete.
Icon indicates update
success/failure. See
the following Icon
table.
Icon
Description
r_24P860_3B9900_3a
Update successful.
FIG. 60: Remove Access Panel
Update unsuccessful.
4. Insert and press InvisiPac software upgrade token
(T, part no. 24R324) firmly into slot.
Update complete, no changes necessary.
NOTE: There is no preferred orientation of token.
Update was successful/complete but one or more
GCA modules did not have a CAN boot loader so
software was not updated on that module.
7. Remove token (T).
8. Replace token access panel.
T
9. Press
r_24P860_3B9900_4a
FIG. 61: Insert Token
5. Install ADM into bracket.
6. Turn system main power switch ON.
NOTICE
A status is shown while software is updating to
indicate progress. To prevent corrupting the software
load, do not remove token until the status screen
disappears.
333347U
to continue to InvisiPac operation
screens.
10. Navigate to System screen. Verify the following
pages. Reference screens on page 130.
a. System Screen Page 1, Customer I/O is set correctly.
b. System Screen Page 2, Channel and RTD
types are set correctly.
c.
System Screen Page 3, System Type, Pump
Idle Time, Power Type, Circuit Breaker Size,
and Refill Settings.
81
Electrical Schematics
Electrical Schematics
To prevent electric shock and system damage, all
electrical work must be performed by a qualified electrician.
Incoming Power
Ref
147
148
181
182
184
185
208
NOTICE
To prevent severe system damage, ensure main power
leads are installed correctly. See Connect Electrical
Cord on page 22.
209
24R034
210
Cable Identification
Use the table to identify cables and other system components in the electrical schematics.
Part
----24X521
128180
128183
128182
24V522
24R039
25M208
25C445
25C448
271
25C446
25C447
Ref
9
Part
---
Description
Manifold, air assembly
20
24R041 Sensor, ultrasonic
25
24R885 Switch, reed assembly
30
86
87
90
103
112
24P860
127666
------24V288
118
121
123
124
125
126
129
135
136
138
140
143
146
82
251 126780
1201 16T102
Description
Harness Power Supply AWB
Cable, Board, Samtec
Module, PC-8 Internal
Power Supply, 120W
Harness, Power, PC-8
Cable, Communication
Band heater, HM50
Band heater, HM25
Heater Rod (1500 W), HM50,
Melt
Heater Rod (500 W), HM25,
Melt
Heater Rod (1000 W), HM50,
Base
Heater Rod (1500 W), HM25,
Base
Heater Rod (1000 W), HM50,
Pump
Heater Rod (1500 W), HM25,
Pump
SWITCH, OT
Light Tower
ADM
Cable, Extension
WIRE, ground
Plug, Phoenix, 8pin
Harness, MZLP #1 AWB
Module, MZLP with daughter
board
24V510 Module, MZLP
16T087 Cable Board
127768 Cable, CAN,
16T103 Cable Pump
24R040 Sensor, RTD, 1M Harness
16T108
----16W035
------24V816
126453
Cable Ultrasonic
Harness, MZLP 2, AWB
Harness, MZLP 2/3, AWB
Connector Jumper
Harness, MZLP #1 AWB
Harness, Disc AWB
Transformer
AWB
Power Supply
333347U
Electrical Schematics
Systems Without Internal Pattern Controller
Review Connect Electrical
Cord section, Figure 16
143
140
138
AWB
J2
W1
L1
L2
L3
W1
W2
W2
W3
W4
ADM
J9
1
2
3
4
5
W3
W4
GND
30
1
2
3
4
5
1
2
3
4
5
123
1
2
3
4
5
GND
J7
GB1
TRANSFORMER
OPTION
208
BAND
210
PUMP
209
MELTER
TEMP
TEMP
TEMP
FAN FAN +
TEMP
FAN FAN +
90
210
1
2
3
4
5
6
7
8
BASE
J4
J5
L1
L2
L3
GND
1
2
3
4
5
L1
L2
L3
GND
87
147
N
L
+
1
2
3
4
5
148
L1
L2
L3
GND
136
1
2
103
J3
1
2
146
112
MZTCM 1
112A
1201
OPTIONAL LIGHT TOWER
9
AIR SOLENOID
FILL SENSOR
86
20
TO MZTCM #2,
4 and 6 CHANNEL OPTION
J1
N
L
+
GND
N
L
DC OK
DC OK
-V
-V
+V
+V
129
J8
1
2
3
4
5
6
7
8
J6
GROUND
STUD
L1
L2
L3
GND
126
1
2
3
4
J12
1
2
3
4
1
2
3
4
J13
1
2
3
4
J14
1
2
3
4
J15
1
2
3
4
5
J16
1
2
3
4
1
2
3
4
5
MOTOR CYCLE SWITCH
25
1
2
3
4
124
125
J5
MELTER OT SWITCH
AND MELTER RTD
251
TO MZTCM #2,
4 AND 6 CHANNEL OPTIONS
121
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
J3
1
2
3
4
5
J1
1
2
1
2
J2
L1
L2
L3
GND
L1
L2
L3
GND
J6
1
2
3
4
5
1
2
3
4
5
J8
A
B
C
D
E
F
G
H
J
K
L
J9
A
B
C
D
E
F
G
H
J
K
L
PLC Connection Wiring
MZTCM 1
Customer Inputs
(10-30VDC from PLC)
PLC 1
PLC 2
HOSE /
APPLICATOR
WIRING,
PLC 3
PLC 4
Customer Outputs
(dry contact to PLC)
PLC 1
PLC 2
PLC 3
PLC 4
ti30568a
333347U
H1
1
2
3
4
5
6
7
8
H2
1
2
3
4
5
6
7
8
83
Electrical Schematics
Systems With Internal Pattern Controller
Review Connect Electrical
Cord section, Figure 16
140
138
J2
W1
L1
L2
L3
143
30
AWB
ADM
W1
W2
W2
W3
W4
1
2
3
4
5
W3
W4
GND
J9
208
210
BAND
PUMP
209
TEMP
TEMP
FAN FAN +
TEMP
FAN FAN +
90
210
MELTER
TEMP
1
2
3
4
5
6
7
8
BASE
J4
J5
L1
L2
L3
GND
1
2
3
4
5
L1
L2
L3
GND
87
184
GROUND
STUD
PE
+
N
L
+
1
2
112A
M12
1201
OPTIONAL
LIGHT TOWER
185
9
AIR SOLENOID
FILL SENSOR
86
126
MOTOR
CYCLE SWITCH
25
124
1
2
3
4
1
2
3
4
J12
1
2
3
4
1
2
3
4
J13
1
2
3
4
J14
1
2
3
4
J15
1
2
3
4
1
2
3
4
5
125
MELTER OT
SWITCH
251
MELTER RTD
84
1
2
3
4
5
148
L1
L2
L3
GND
136
1
2
103
J3
112
MZLP 1
P4
20
TO MZTCM #2,
4 and 6 CHANNEL OPTION
GND
N
L
-V
-V
+V
+V
TO
MZLP 1-J3
OR
MZLP 2-J3
129
J1
N
L
+
182
PE
+
L1
L2
L3
GND
J8
1
2
3
4
5
6
7
8
J6
ti30567a
1
2
3
4
5
J7
TRANSFORMER
OPTION
P1
1
2
3
4
5
123
GND
GB1
181
PC-8
1
2
3
4
5
To MZLP #2, 4, and 6
Channel Option, see
page 117 and 11.
To MZLP #2 or Pattern
Control Board, see page 88.
1
2
3
4
5
J5
1
2
3
4
5
6
1
2
3
4
5
6
J3
1
2
3
4
5
J1
1
2
1
2
J2
L1
L2
L3
GND
L1
L2
L3
GND
J6
J16
1
2
3
4
5
1
2
3
4
5
PLC Connection Wiring
J8
A
B
C
D
E
F
G
H
J
K
L
J9
A
B
C
D
E
F
G
H
J
K
L
MZTCM 1
Customer Inputs
(10-30VDC from PLC)
PLC 1
PLC 2
PLC 3
HOSE /
APPLICATOR
WIRING,
PLC 4
Customer Outputs
(dry contact to PLC)
PLC 1
PLC 2
PLC 3
PLC 4
H1
1
2
3
4
5
6
7
8
H2
1
2
3
4
5
6
7
8
333347U
Electrical Schematics
400 VAC Transformer Option
480 VAC Transformer Option
333347U
85
Electrical Schematics
Typical Hose / Applicator Wiring
86
333347U
Electrical Schematics
2nd and 3rd MZLP Options
135
1
2
3
4
5
6
J5
1
2
3
4
5
6
118
118
MZLP3
MZLP 2
J3
1
2
3
4
5
1
2
3
4
5
121
1
2
3
4
5
112
MZLP 1
J3
J6
1
2
3
4
5
1
2
3
4
5
J3
1
2
3
4
5
121
1
2
3
4
5
1
2
3
4
5
Internal PC-8 Options
One MZLP
333347U
87
Line Air Inlet
88
Level Air Sensor
Level Sensor
Restrictor
Under Control Box
Safety Pop Off Valve
Refill Gauge
Refill Control Solenoid
Air Control Manifold
Air Motor Control Solenoid
Air Motor Gauge
Feed Wand
Air Motor
Pressure Relief
Valve
Optional Ramp Up/Down
Controller
Air Schematic
Air Schematic
NOTE: Install an optional ramp up/down controller to
limit air to the air motor and slow down the system dispense rate.
333347U
Parts
Parts
InvisiPac Systems
System Parts, Page 1 of 3
1
Apply door gaskets (11) to door (10) per layout diagram.
2
Apply pipe sealant to all non-swiveling pipe threads.
3
Bottom sensor (20) out then back off 1/2 turn.
4
Lubricate all seals and o-rings with water resistant grease.
5
Torque to 5-11 ft-lb (7-15 N•m).
6
Torque to 8-10 in-lb (0.9-1.1 N•m).
83
24
53
25
94
19
18
6
26
75
8
28
23
13
43
6
38
31
38
58
23
30
8
39
27
3
8
44
29
43
64
1
11
10
8, 14
WLG
43
333347U
89
Parts
System Parts, Page 2 of 3
68
8
67
125
69
74
66
82
5
86
20
8
49
7
72
73
74
42
41
3
40
69
88
3
5
63
62
87
69
89
1
61
54
4
85
81
8
79
63
80
WLE
9
43
8
90
333347U
Parts
System Parts, Page 3 of 3
34
48 in.
(1219 mm)
57
35
48 in.
(1219 mm)
34
16 in.
(406.4 mm)
86
91
34
48 in.
(1219 mm)
49
35
48 in.
(1219 mm)
34
8 in.
(203 mm)
78
32
77
76
34
2 in.
(50.8 mm)
24
39
WLD
55
333347U
36
13 in.
330.2 mm)
91
Parts
System Parts
Quantities
24V202
24V199
24T920
24V203
24V200
24V423
24V429
24V426
24V424
24V430
24V427
24V425
24V431
24V428
6 Channel
24T919
HM25
4 Channel
24V198
2 Channel
24V201
6 Channel
24T918
2 Channel
HM50
4 Channel
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
115942
NUT, hex, flange head
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
4
167002
INSULATOR, heat
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Ref
1
5
Part
---
Description
ENCLOSURE, electrical
24V169
SYSTEM, melter, HM25
24V542
6✓
---
SYSTEM, melter/pump,
HM50
GUARD, insulated
6✠
---
INSULATOR, wrap
1
1
1
1
1
1
1
1
1
7
---
TRAY, drip
1
1
1
1
1
1
1
1
1
8†
113161
SCREW, flange, hex hd
17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17
9
---
MANIFOLD, air, assembly
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
---
DOOR, front
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
11
---
FOAM, border, door
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
13✿
24P615 FITTING, straight, hydraulic
2
2
2
4
4
4
6
6
6
2
2
2
4
4
4
6
6
6
14
16V153
WASHER, retaining
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
15✖
114271
STRAP, retaining
8
8
8
16 16 16 24 24 24
8
8
8
16 16 16 24 24 24
18✿
126961
FITTING, 45 elbow, hydraulic 2
2
2
4
4
4
6
6
6
2
2
2
4
4
4
6
6
6
19✿
116793
FITTING
2
2
2
4
4
4
6
6
6
2
2
2
4
4
4
6
6
6
20
24R041
SENSOR, ultrasonic
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
21✖
101976
TOOL, allen, wrench
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
23
114606
PLUG, hole
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
24
120753
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
25◆
---
FITTING, push to connect
elbow
SWITCH, reed assy
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
26◆
---
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
27
28
29
1
1
1
1
1
1
1
1
1
---
SCREW, pan head, #8-32 x
1.5"
BRACKET, back HM50
---
BRACKET, back
---
COVER, filter
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
---
COVER, melter HM50
---
COVER, system, HM25
30❄
24P860
MODULE, ADM
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
31
117017
WASHER
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
32
---
FITTING, tee, reducer
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
34
---
HOSE, nylon, wpr 250 psi
35
598095
TUBE, 5/32 OD, nylon
36
---
TUBE, ptfe, 1/4 in. OD
38
117126
SCREW, shcs; m5x16
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
39
---
GROMMET, 1/4 ID
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
40
---
BUSHING, strain relief
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
41
---
GROMMET, tube
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
42
---
GROMMET, tube
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
43▲
16Y781
LABEL, safety
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
92
8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10 8.10
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10 1.10
333347U
Parts
Quantities
24V426
24V424
24V430
24V427
24V425
24V431
24V428
6 Channel
24V429
2 Channel
HM25
4 Channel
24V423
24V200
24V203
6 Channel
24T920
24V199
24V202
24T919
24V198
Part
Description
16U007 LABEL, InvisiPac, HM25
24V201
Ref
44
24T918
2 Channel
HM50
4 Channel
1
1
1
1
1
1
1
1
1
---
LABEL, InvisiPac HM50
1
1
1
1
1
1
1
1
1
45
---
LABEL
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
47✖
24P859
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
48✖
24P176
KIT, fuses, board, temp control
KIT, i/o connector
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
49
125871
TIE, cable, 7.50 in.
10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
50❄
---
TOKEN, software
1
1
1
1
1
1
1
1
1
53‡✠ ---
INSULATOR, melter
1
1
1
1
1
1
1
1
1
53✓
---
INSULATOR, melter
54
---
NUT, bushing
2
2
2
2
2
2
2
2
57
123554
COUPLER, 3/8 in. OD tubing 1
1
1
1
1
1
1
58
24A326
1
1
1
1
1
1
61†
---
BRACKET, mounting,
assembly
FUNNEL, large mouth
1
1
1
1
1
62†
---
BAFFLE, pellet
1
1
1
1
1
63
121487
2
2
2
64$
24R707
GROMMET, sheet metal, 3/4 2
in.
KIT, inlet, air
1
1
1
66†
---
FUNNEL, insert
1
1
67†
24V506
FILTER, HM50 feed
1
68†
---
FUNNEL, filter cover
1
69†
---
72
110932
O-RING, fluoroelastomer,
160
CONNECTOR, male
73†
---
HOUSING, sensor, HM50
74†
---
75✓
---
75✠
---
76
---
77
---
78
198177
SCREW, #10-16, thread
forming
INSULATOR, melter manifold
INSULATOR, melter, manifold
FITTING, tee, 1/8npt x 3/8t x
3/8t
RESTRICTOR, air, 0.0225
in. orifice
FITTING, push, straight
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
24W000 ADAPTER, melter HM50
1
1
1
1
1
1
1
1
1
80★
---
CLAMP, hose, spacer
1
1
1
1
1
1
1
1
1
81★
---
CLAMP, hose, spacer
1
1
1
1
1
1
1
1
1
82†
---
BRACKET, funnel, HM25
---
BRACKET, HM50, funnel,
1
mounting
FITTING, elbow, 3/8 OD tube 1
79★
83
24W001 ADAPTER, HM25
123986
333347U
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
93
Parts
Quantities
24T919
24V202
24V199
24T920
24V203
24V200
24V423
24V429
24V426
24V424
24V430
24V427
24V425
24V431
24V428
Description
GROMMET
6 Channel
24V198
Part
---
2 Channel
24V201
Ref
85
6 Channel
HM25
4 Channel
24T918
2 Channel
HM50
4 Channel
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
86
127666
CABLE, gca, m12-5p
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
87
---
WIRE, ground
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
88
116343
SCREW, ground
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
89
---
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
90
---
WASHER, 1/4 external tooth 1
lock
PLUG, phoenix, 8 pos
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
91
---
1
1
1
1
1
1
92✖
17A345
FITTING, 5/32 in. OD tube,
push-to-con
TOOL, 5/16 nut driver
1
1
1
1
93✖
127735
STRAP, lifting 3 ft
1
1
94◆
---
WASHER, flat
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
--- Not for sale.
Available kits (purchase separately):
▲ Replacement Danger and Warning labels, tags, and cards
are available at no cost.
Kit
25A897
25A898
24R885◆
24R028*
24V505†
❄ ADM does not come with software. Order software token
24R324.
✖ Not shown.
$ Replacement filter element is 24X967.
✓ Part of Kit 25A897 (HM25)
✠
Part of Kit 25A898 (HM50)
24V508‡
24V504✿
24U635
94
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
Insulation, HM25
Insulation, HM50
Cycle Switch
Inlet housing
Funnel
Includes
6, 53
6, 53
25, 26, 94
12, 13, 62
8, 61, 62, 66, 67, 68, 69, 73,
74, 82. See Feed Inlet Funnel, 24V505 on page 105.
Melter
53, 202, 204, 207, 211, and
253. See Melter and Pump
Assembly on page 100 for
identification of items 202-253.
Hydraulic Fittings 13, 18, 19
Acrylic Lens
Pressure Gauge
24W000★
Melter Adapter
79, 80, 81
24X967$
Replacement air
filter element
25C525
Shroud, HM25
8, 14, 29, 44
25C526
Shroud, HM50
8, 14, 29, 44
333347U
Parts
Electrical Enclosure, Systems without Internal Pattern Controller
MZLP 3
MZLP
118 4
113
114
112a
3 118
113
114
106, 107
120
110
112 2
108
113
109
WLD
MZLP 2
114
101
1
Apply sealant to all non-swiveling pipe
threads.
2
Set rotary switch to “1” on MZLP with
daughter card.
3
Set rotary switch to “2” on MZLP 2.
4
Set rotary switch to “3” on MZLP 3.
131
132
144
145
146
104
117
333347U
WLD
111
143
105
131
95
Parts
Electrical Enclosure, Systems with Internal Pattern Controller
MZLP
112a
113
114
106, 107
3 118
112 2
114
120
110
108
WLD
113
MZLP2
114
101
1 Apply sealant to all non-swiveling pipe
threads.
2 Set rotary switch to "1" on MZLP with
daughter card.
131
3 Set rotary switch to "2" on MZLP 2.
132
117
144
183
143
182
104
111
131
105
WLD
96
333347U
Parts
142
141
137
140
WLD
Electrical Enclosure Parts
Ref
Part
101
---
Description
Quantity
1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP
No Transformer
400/480 V Transformer
CABINET, controls
1
1
1
1
1
1
1
1
102
127666
CABLE, gca, m12-5p
1
103
---
HARNESS, MZLP1, AWB
1
1
1
1
1
1
104
123970
SWITCH, disconnect, 40a
1
1
1
1
1
1
105
126839
CONTACT, n-pole
1
1
1
1
1
1
106
120858
BUSHING, strain relief, m40 thread
1
1
1
1
1
1
1
1
1
1
1
107
120859
NUT, strain relief, m40 thread
1
108
104641
FITTING, bulkhead
1
1
1
1
1
1
109
121141
FITTING, elbow, swivel, 3/8t 1/4mnpt
1
1
1
1
1
1
1
1
1
1
1
110
114421
BUSHING, strain relief
1
111
117666
TERMINAL, ground
1
1
1
1
1
1
112*
---
MODULE, MZLP with daughter board
1
1
1
1
1
1
112a
24R042
KIT, board, daughter
1
1
1
1
1
1
113
16T440
CAP, souriau, uts14
2
4
6
2
4
6
12
12
12
12
12
2
1
1
1
1
1
2
114
125856
SCREW, 8-32, serrated flange
12
116
24P175
PLATE, blank, sgl mztcm
2
1
117
115942
NUT, hex, flange head
1
1
1
1
2
118
24V510
MODULE, gca, MZLP
119
---
GASKET, foam, mztcm
2
1
120
---
PIN, dowel
1
1
1
121
16T087
CABLE, board, male/male, 21 in.
1
2
123
127768
CABLE, can, female/female 1.5 m
1
1
333347U
1
2
1
1
1
1
1
2
1
1
1
97
Parts
Ref
Part
124
16T103
Description
Quantity
1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP
No Transformer
400/480 V Transformer
CABLE, pump
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
125◆
---
SENSOR, rtd, 1m
1
126
16T108
CABLE, ultrasonic, m12-4p, 1m
1
---
HARNESS, MZLP 2, awb
---
HARNESS, MZLP 2/3, awb
114958
STRAP, tie
4
4
4
4
4
4
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
129
130
1
1
1
131
---
SCREW, flange, serrated, 10-24 x 0.5
2
132
123967
KNOB, operator disconnect
1
1
135
16W035 CONNECTOR, jumper
1
1
1
1
1
1
136
---
HARNESS, MZLP 1, awb
137
---
BUSHING, cable
138
---
HARNESS, disc, awb
1
1
1
140
24V015
TRANSFORMER, assembly, 480v/240v
1
1
1
141
---
GROMMET, air fitting
1
1
1
3
3
3
1
1
1
142
113802
SCREW, hex hd, flanged, 3/8-16 x 5/8
143
24V816
MODULE, awb
1
1
1
1
1
1
144
114331
SCREW, mach, pnh, sems; 6-32 x 3/8
2
2
2
2
2
2
1
1
1
145
---
BRACKET, power supply
146
126453
POWER SUPPLY, 24v
1
1
1
1
1
1
147
---
HARNESS, power supply, awb
1
1
1
1
1
1
148
---
CABLE, board, samtec
1
1
1
1
1
1
*
Purchase MZLP (118) and daughter board (112a) separately.
Available kits (purchase separately):
Internal Pattern Controller Components
Kit
24V528†
Ref
181+
181b+
181c+
181d+
181e+
181f+
181g+
182+
183+
Part
24X521
128176
128177
--128178
----128180
128443
188+%
187+%
189+
190+
192+
193+
--128340
116772
119162
128147
128117
Description
Upgrade from 2
channel system
to 4 channel system
24V529✿ Upgrade from 4
channel system
to 6 channel system
Includes
113, 118, 121, 129, a grounding
wrist strap, and a software upgrade
token. See 4 Channel Upgrade
Kit, 24V528 on page 113.
113, 118, 121, 129,134, 135,
grounding wrist strap, and a software upgrade token. See 6 Channel Upgrade Kit, 24V529 on
page 115.
24R040◆ RTD
125, 251, and 255. See Melter and
Pump Assembly on page 100.
24V289
MZLP fuses
Qty 8 - 8 Amp, 250V Fuses
Qty 2 - 25 Amp, 250V Fuses
24P176
Customer I/O
2 connectors for connecting to H1
Connectors
and H2 on MZLP daughter board.
Use for PLC connection.
24X640† Add internal
181 (all items), 182, 183, 184, 185,
PC-8 to 2-chan- 186, 189, 190, 192, 193. See mannel or 4-channel ual 334874.
systems.
17F172
Upgrade internal Key token to enable encoder and 4
PC-8 to PC-8e. connectors for wiring. See manual
334874.
98
Description
MODULE, GCA, Internal PC-8
FRAME, cable grip, 5-position
INSERT, rubber, cable grip, 4x6mm
PIN, .250 in
INSERT, rubber, cable grip, 4x3mm
PIN, .125 in
SCREW, #10-32 x .750
POWER SUPPLY, 120 W
BRACKET, power supply, PC-8 Internal
TOOL, screwdriver
FUSE, automotive, 4A, 32V, mini
CONNECTOR, plug, 4-position
CONNECTOR, plug, 6-position
CONNECTOR, plug, 8-position
CONNECTOR, plug, 12-position
Qty
1
1
1
4
4
16
2
1
1
1
1
1
2
2
1
% not shown
333347U
Parts
Transformer Assemblies
152
160
161
153
4
2
166
156
167
161 2
168
157
158
157
154
3
151
WLD
156
155
170
1
2
166
166
4
168
1
Mount fan with arrow pointing towards grill.
3
Use nut to lock down the ground wire from transformer.
2
Tie down cabling from transformer and fan using cable tie onto
tie down locations. Remove excess slack and ensure cabling
does not contact fan blades.
4
Connect black fan wire labeled (-) from transformer (153) in the
pin labeled (-). Connect red fan wire labeled (+) to the
connector coming from transformer (153).
Transformer Assemblies
Ref.
151
152
153
Part
-------
Description
Qty
1
ENCLOSURE, base, 480v
1
ENCLOSURE, top, 480v
1
TRANSFORMER, 480v/240v,
6kva; 480V systems only
--1
TRANSFORMER, 400v/240v,
6kva; 400V systems only
154 --1
GRILL, fan
155★
--1
FAN, 24 vdc, 120m x 120m
156 115942 NUT, hex, flange head
5
157 119865 SCREW, mach, hex serrated, 1/4
6
x 3/8 in.
158 127278 NUT, keps, hex
4
160 --1
GROMMET, air fitting
333347U
Ref.
161
162
166▲
167
168
169
170
Part
Description
125871 TIE, cable, 7.5 in.
172953 LABEL, designation
17A071 LABEL, safety, warning
--TUBE, corrugated, slit; 6 in.
(152.4 mm)
127754
Qty
5
1
1
1
GRILL, fan
▲ Replacement Danger and Warning labels, tags, and cards
are available at no cost.
★ Included in Fan Replacement Kit 24V911.
--- Not for sale.
99
Parts
Melter and Pump Assembly
HM25, 24V169
HM50, 24V542
208
4
218
217
238
205
239
254
10
2
216
235
211
217
233
236
204
4
234 5
223
206
2
220
202
224
3
225 5
226
240
207
222
3
4
221
10
219
215
213
211 10
271
252
253
206
7
203
252
210
227
228
229
231
232
6
251
269
214
230
255
246
9
10
201
209 270
249
242
257
247 10
258
249
268
3 259
8
243
244
245
WLE
206
1
Lubricate all seals and o-rings with grease.
6
Assemble inserts (252) 0.01-0.05 in. (0.3-1.3 mm) below surface.
2
Orient melter (202) sensor hole in line with band heater (208)
clamp.
7
Assemble inserts (252) 0.01-0.05 in. (0.3-1.3 mm) below surface.
8
3
Torque to 27-33 in.-lb (3-3.8 N•m).
Torque to 5-11 ft-lb (7-15 N•m).
9
4
Apply anaerobic thread sealant on threads.
Torque to 24-30 ft-lb (33-41 N•m).
10
5
Torque to 12-18 ft-lb (16-24 N•m).
Orient u-cups (225, 234) with springs in direction shown.
HM25 Melter and Pump, 17F830
100
HM50 Melter and Pump, 24V542
333347U
Parts
Ref.
201
Part
Description
Qty.
--1
BASE, melter, HM50
--1
BASE, melter, HM25
202✖ --1
TANK, melter, HM50
--1
TANK, melter, HM25
203•
--1
MANIFOLD, outlet
204✖ --1
PLATE, mounting; HM50
--1
PLATE, mounting; HM25
205 ❄ --1
HOUSING, fire rod; HM50
--1
HOUSING, fire rod; HM25
206•
111317
3
RING, retaining, int.
207✖ 16W615 O-RING, fluoroelastomer;
1
(HM50 only)
126475
1
O-RING, fluoroelastomer;
(HM25 only)
208
24V522
1
BAND, heater; HM50 only
24R039 BAND, heater; HM25 only
1
209• ❄ --1
HEATER, rod,1500 watts; HM50
--1
HEATER, rod, 500 watts; HM25
210
25C445 HEATER, rod,1000 watts; HM50
1
25C448 HEATER, rod,1000 watts; HM25
1
211✖ 128167
7
SCREW, cap,sh,5/16-18
213
24R369 SCREEN, wire
1
214•
112855
1
PACKING, o-ring
215
24T297
1
PLUG, o-ring boss
216ॠ--1
SLEEVE, cylinder
217†‡• 108526
2
PACKING, o-ring, ptfe
218
24V558
1
MOTOR, double ended, air; see page
102
219
--1
PLATE, pump adapter
220
--3
ROD, tie, 1.5 in. stroke
221•
192624
1
GUIDE, ball
1
222†◆• 239932
VALVE, piston
223◆• --1
ROD, piston
224†◆• 105444
1
BALL, (.31250)
225†◆• --1
SEAL, u-cup, piston
226†◆• --1
BEARING, piston
227†• 105445
1
BALL, (.5000)
228†• 192642
1
SEAT, carbide
229†• 107079
1
PACKING, o-ring
230•
--1
HOUSING, foot valve
231†• 105802
1
O-RING
232†• 113944
1
PACKING, o-ring
233†• --1
BEARING, throat
234†‡• --1
SEAL, u-cup, throat
235•
193046
1
NUT, packing
24P855
1
236•
FILTER, assy, 100 mesh, welded
238
196762
1
PIN, straight
239
196750
1
SPRING, retaining
240
128190
3
SCREW, cap, sch; 5/16 x 1 in.
242★• 117059
1
O-RING, fluoroelastomer
243★• --1
RETAINER, seat, dump valve
244★• 15Y627
1
PACKING, o-ring #2-116, ptfe
245★• ❄--1
VALVE, relief
246•
C19829 SCREW, cap, socket head; 5/16 x 2.5 in.
4
247•
15H304 FITTING, plug 9/16 sae
9
249
167002
10
INSULATOR, heat
251✿• 126780
1
SWITCH, overtemperature
252•
--7
INSERT, helical
253✖ --1
PLATE, melter; HM50 only
--1
PLATE, melter; HM25 only
254
--1
O-RING, -910
255✿• 107388
2
SCREW, mach, pnh; #4 x 3/8 in.
333347U
Ref.
257
258
259
268
269
270
271
Part
------110298
Description
Qty.
1
BRACKET, shelf; HM50 only
1
BRACKET, shelf; HM25 only
1
GROMMET, 1/4 ID
4
SCREW, cap, sch, 1/4 x 7/8 in.; HM50
only
115506
4
SCREW, mach, hex wash hd, 1/4 x 3 in.;
HM25 only
115814
4
WASHER, flat, sst; HM50 only
128612
1
TUBE, cross over
103610
2
O-RING, 014
25C446 HEATER, rod, 1000 watts; HM50
1
25C447 HEATER, rod, 1000 watts; HM25
1
--- Not for sale.
Available kits (purchase separately):
Kit
24P852†
Description
Pump repair
Includes
217, 222, 224-229, 231,
232, 233, 234, and seal
installation tool 15B661.
24P853‡
Cylinder
216, 217, 234, and seal
installation tool 15B661.
24P854◆ Pump rod
222, 223, 224, 225, 226
24P856★ Pressure relief valve
242, 243, 244, 245
24V508✖ Melter HM50
202, 204, 207, 211, 253,
24R031✖ Melter HM25
and insulator (53). See
InvisiPac Systems parts
starting on page 89 for
insulator (53) identification.
24R040✿ Kit, RTD harness and
125, 251, and 255. See
switch
Electrical Enclosure,
Systems without Internal Pattern Controller on
page 95.
24R709 • Assembled pump mani- 203, 206, 209, 214, 216,
fold
217, 221-236, 242-247,
251, 252, 255
--Special tools
See Special Tools on
page 106.
24R034 ❄ Fire rod housing HM25 205, 209, 254
25M208 ❄ Fire rod housing HM50
25A893
HM25 Melter Base with 201, 206, 210, 213, 215,
heater rods
252
HM50 Melter Base with
25A894
heater rods
25A895
HM25 Outlet Manifold
203, 206, 271, 247, 252
with heater rods
HM50 Outlet Manifold
25A896
with heater rods
101
Parts
Air Motor, 24V558
2
509
512
507
4
509
522
513
505
506
511
1
2
1
2
511
WLD
Ref.
505
506
507†
509†
511
512†
513
Part
24A579
------24R027
--15M213
1
Apply water-resistant grease.
2
Torque to 95-105 in-lb (10.7-11.9 N•m).
Description
MANIFOLD, medium, short
GASKET, cover, small
SEAL, air valve, manifold
SCREW, m6 x 25, thread forming
VALVE, pilot
VALVE, air, small
MUFFLER, 3/8
Qty
1
2
1
8
2
1
1
--- Not for sale.
†
Included in Air Motor Valve Kit 24R026.
102
333347U
Parts
Air Controls Assembly
405
402
406
1 404
401
1 404
403
1
WLD
Apply sealant to all non-swiveling pipe threads.
Air Controls Assembly Parts
Ref
401
402
403
404
405
406
407
Part
Description
--PANEL, air, controls
24V520 CONTROL, air, vacuum transfer and pump
128260 GAUGE, pressure, air, panel
mount, 1/8 in. npt
15T498 FITTING, 90 degree, swivel,
5/32 in. tube x
1/8 in. female npt
100058 SCREW, cap, hex head
054753 TUBE, nylon, round, black
C38321 TIE, cable, 3.62 in.
Qty
1
1
2
2
2
2
1
--- Not for sale.
333347U
103
Parts
Pressure Relief Valve, 24P856
607 3
1
606
1
601
614 2
605
611 608
1
602
609 2
612 2
603 3
610
610
604
613
1
Apply sealant to all non-swiveling pipe threads.
2
Apply grease.
3
Torque to 4-6 in-lb (0.5-0.7 N•m).
i
Ref
601
602
603
604
605
606
607
608†
609†
610
611†
612†
613
614†
Part
----15T413
--------108771
110073
111841
----126474
---
Description
BODY, fluid
BODY, air
PISTON, air
AIR CAP, valve
BEARING, shaft, needle
SHAFT, needle, valve
SOCKET, ball assembly
PACKING, o-ring
PACKING, o-ring
WASHER, plain 5/8 in.
BEARING, valve
O-RING, FKM
FITTING, push to connect
SEAL, u-cup, relief valve
Qty
1
1
1
1
1
1
1
1
1
2
1
1
1
1
--- Not for sale.
† Parts included in Relief Valve Repair Kit 24P857
(purchase separately).
104
333347U
Parts
Feed Inlet Funnel, 24V505
706
705
709
703
704
8
708
710
82
708
703
702
703
61
WLD
Ref.
702
703
704
705
706
708
709
710
Part
Description
Qty
--1
BAFFLE, pellet
--3
O-RING, fluoroelastomer, 160
--1
FUNNEL, insert
24V506 FILTER, feed
1
--1
FUNNEL, filter cover
126901 SCREW, #10-16, thread forming
5
110932 FITTING, connector, air
1
--1
HOUSING, sensor
--- Not for sale.
Not included in 24V505:
Ref.
61
8
82
Part
Description
Qty
--1
FUNNEL, large mouth
113161 SCREW, flange, hex hd
2
17A492 BRACKET, funnel, mounting, HM25 1
16Y569 BRACKET, funnel, mounting, HM50 1
333347U
105
Accessories
Accessories
Special Tools
These special tools are designed to make system repairs as easy as possible while ensuring that parts do not get
damaged.
Part
1301*
1302*
1303*
*
Purpose
Remove Cylinder
Install Cylinder - Female
Install Cylinder - Male
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
106
333347U
Accessories
Preventive Maintenance Kits
Complete Maintenance Kits
These kits contain components which are commonly
used in maintenance.
These kits contain repair components which are not part
of regular preventive maintenance.
HM25 Preventive Maintenance Kit, 24X867
Ref
1
2
3
4
5
6
7
8
Part
24V506
24W595
24X967
16T124
24P802
24X220
127110
102360
Description
Kit, Filter, Feed
Kit, Filter Rebuild
Filter, Air, Repair
Filter, Screen, Wire
Kit, Gun Filter, 3pk
Switch, Reed
Screw, #8-32
Washer, Flat
HM25 Complete Maintenance Kit, 24X869
Qty
2
2
2
1
4
1
1
1
HM50 Preventive Maintenance Kit, 24X868
Ref
1
2
3
4
5
6
7
8
Part
24V506
24W595
24X967
16T124
24P802
24X220
127110
102360
Description
Kit, Filter, Feed
Kit, Filter Rebuild
Filter, Air, Repair
Filter, Screen, Wire
Kit, Gun Filter, 3pk
Switch, Reed
Screw, #8-32
Washer, Flat
Qty
2
2
2
1
4
1
1
1
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Description
Kit, Valve, Discharge
Kit, Shaker, Feed
Kit, Poppet
Kit, Valve, Motor
Kit, Level Sensor
Kit, Repair, Pump
Kit, Repair, AWB
Kit, Board, Daught.
Kit, Cycle Switch
Kit, MZLP w/ fuses
Kit, Fuses, MZLP
Kit, Band Heater
Kit, 1.5kW Heat Rod
Kit, 500W Heat Rod
Power Supply, 24V
Kit, Harness, RTD
Jumper, OT
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
HM50 Complete Maintenance Kit, 24X8670
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
333347U
Part
24P856
24P861
24R027
24R026
24R041
24P852
24V816
24R042
24R885
24V510
24V289
24R039
24R037
24R034
126453
24R040
127411
Part
24P856
24P861
24R027
24R026
24R041
24P852
24V816
24R042
24R885
24V510
24V289
24V522
24R036
24R037
126453
24R040
127411
Description
Kit, Valve, Discharge
Kit, Shaker, Feed
Kit, Poppet
Kit, Valve, Motor
Kit, Level Sensor
Kit, Repair, Pump
Kit, Repair, AWB
Kit, Board, Daught.
Kit, Cycle Switch
Kit, MZLP w/ fuses
Kit, Fuses, MZLP
Kit, Band Heater
Kit, 1 kW Heat Rod
Kit, 1.5W Heat Rod
Power Supply, 24V
Kit, Harness, RTD
Jumper, OT
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
107
Accessories
Non-Graco Applicator Adapter
Cables
Adapter Cable
128621: Adapter cable allows non-Graco NI120 RTD
Hoses to be used on InvisiPac.
16T916: For connecting to non-Graco applicators that
use a rectangular, 6-pin connector.
WLD
ti21128a
16T917: For connecting to non-Graco applicators that
use a circular, 9-pin connector.
ti21129a
16Y828: For connecting to non-Graco applicators that
use a circular, 6-pin connector. IPx6 rated.
128372: For connecting to non-Graco applicators that
use a rectangular 8-pin connector.
ti26719a
ti26719a
Non-Graco Applicator Adapter Cable
Installation
See Attach Components on page 17.
WLD
108
333347U
Accessories
Air Adjustment Lock, 24R084
Feed Sensor Dedicated Air Kit,
17F699
Panel enables locking access to the air adjustment
screws.
For connecting a dedicated air source to the feed sensor
on InvisiPac™ systems.
Ref
1
2
3
4
5
6
7
8
9
10
801
802
WLD
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
11
12
13
14
Part
106148
110224
198177
128264
128277
155665
167702
16T779
598095
127660
Description
Qty
FILTER, air, 3/8 npt
1
VALVE, vented 2-way
1
FITTING, push, straight
1
BRACKET
1
SCREW, self-tap, 10-24 x 3/8
8
UNION, adapter
1
NIPPLE, pipe
1
RESTRICTOR, air, 0.0225 in. orifice
1
TUBE, 5/32 in. OD, nylon; 3 ft (1 m)
1
FITTING, 5/32 in. OD tube,
1
push-to-connect
128292 PLUG, push-to-connect, 5/32
1
191892 FITTING, elbow, street, 90°
1
C20467 FITTING, nipple, reducing; 1/8-27 npt x
1
3/8-18 npt
110110 SEALANT, pipe, sst; 6 ml
1
Feed Sensor Dedicated Air Source
Installation
1.
Assemble parts in kit. Apply sealant (14) to all
threaded joints.
1. Remove screws from system air panel.
2.
Mount bracket to the InvisiPac system air inlet filter.
2. Use screws to install panel (801).
3.
Disconnect level sensor cooling air tubes.
3. Snap bracket (802) into panel (801).
4.
4. Insert lock through hole in panel and bracket to lock
access to the air controls. Lock not included in kit.
Insert plug (11) into tube coming from under the InvisiPac system shroud to prevent the system from losing
air pressure.
5.
Connect connector (1) to the tube (9) coming from the
kit.
6.
Rout tube (9) as needed and cut to length.
7.
Connect dedicated air supply to the auxiliary air inlet
(6).
333347U
109
Accessories
System Stand, 24R088
Adapter Plate, 24R083
Use the stand to mount the system at eye level. When
the system is mounted on the stand, the ADM is 45 in.
(1.14 m) above the bottom of the stand.
Use this adapter plate to install InvisiPac in place of an
existing hot melt applicator system.
C
B
Bolt Hole Dimensions
A
B
C
9.8 in. (249 mm)
14.843-15.157 in.
(377.0-385.0 mm)
17.003-17.317 in.
(431.9-439.9 mm)
A
1002
1001
1104
1101
1003
A
1102
WLD
1103
Ref
1101
1102
1103
1104
WLD
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).
110
Part
--112395
112958
121283
Description
PLATE, adapter
SCREW flange head cap
NUT, hex, flanged
FITTING, elbow, 45 degree
Qty
1
6
9
1
Adapter Plate Installation
1. Remove existing hot melt applicator system.
2. Use six screws (1102) and six nuts (1103) to secure
adapter plate (1101) through the existing holes from
the previous system.
3. Align the InvisiPac system with the bolts on the
adapter plate (1101) then place onto the adapter
plate (1101).
4. Use the remaining three nuts (1103) to secure the
InvisiPac system to the adapter plate (1101).
5. Use elbow fitting (1104) to install system air inlet
filter (A, not included with kit).
333347U
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
F5
1202
J3
F2
J2
WLD
F4 F3
BB
F1
J1
J12
J6
J7
J5
F10 F9
F8 F7
F6
1205
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.
333347U
111
Accessories
Light Tower Kit Installation
Air Reservoir Kit, 16W366
This kit allows the system to operate as low as 60 psi
(0.4 MPa, 4 bar).
1. Turn main power switch OFF.
2. Disconnect cable from ADM, push cable through
plastic shroud, then remove shroud from system.
3. Remove existing grommet (AA) from electrical
enclosure then install new grommet (1204) in its
place.
4. Insert grommet (1202) into hole on the light tower
bracket (1203).
5. Remove bolts (BB) from metal shroud on the system then use the bolts (BB) to secure
bracket (1203) to metal shroud.
6. Route light tower cable through hole in
bracket (1203) then use supplied light tower
screws (1201a) to install light tower (1201).
7. Remove electrical enclosure front access door.
8. Route light tower cable through the other hole in the
bracket (1203), then through the grommet (1204)
into the electrical enclosure.
1505
9. Connect light tower cable to MZLP connector
labeled J12.
1503
1504
1504*
1505
1506
WLD
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.
*
112
Metric fitting included in Air Metric Fitting Kit,
24W637, page 118.
333347U
Accessories
4 Channel Upgrade Kit, 24V528
Use this kit to upgrade a 2 channel system to a 4 channel system.
CC
1307
AA
1306
1301
BB
1308
WLD
1304
1305
Ref
1301
1302
1303
1304
1305
1306
1307
1308
1308
1302
Part
Description
Qty
--MODULE, GCA, MZLP
1
16T087 CABLE, jumper, male/male,
1
21 in.
--HARNESS, 2nd MZLP power
1
112190 STRAP, wrist, grounding
1
16T440 CAP, jam nut, sealing
2
24R324 SOFTWARE UPGRADE TOKEN,
1
InvisiPac System
--FITTING, straight
2
--LABEL, InvisiPac Channel Num1
bers
◆ Not shown.
--- Not for sale.
333347U
113
Accessories
4 Channel Upgrade Kit Installation
1. Disconnect plug from power outlet or turn off circuit
breaker for incoming power.
2. Place grounding wrist strap (1304) over your wrist
and secure other end to a grounded surface.
3. Set the MZLP (1301) rotary switch to “2”.
4. Remove screws (BB) then remove plate (AA) from
system.
5. Use screws (BB) to install MZLP (1301) onto system. Apply labels from label sheet (1308) to MZLP
#2. Place the “3” and “4” labels as shown in parts
illustration.
NOTE: The new MZLP (1301) with be referred to as
MZLP 2, and the original MZLP that came with the system will be referred to as MZLP 1 from here on. See FIG.
1.
6. Remove electrical enclosure front access door.
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop and verify the connector orientation. Verify the
connector has “Locked” by gently pulling on the white
connector housing.
7. Connect CAN jumper cable (1302) to MZLP 1 connector J3 and connect other end of jumper
cable (1302) to MZLP 2 connector J6. See FIG. 1.
8. Connect power harness (1303) to MZLP 2 connector J2.
9. Remove plugs (CC) from fluid manifold and replace
with straight fittings (1307) or the extra fittings
included with the InvisiPac system. Use the fittings
that meet your hose routing needs.
10. To ensure your InvisiPac system has the latest software, insert token (1306) into ADM. Follow Software Update Procedure, page 81.
Step 7: Install Jumper Cable (1302).
MZLP 2
MZLP 1
J6
J1
J5
J9
J3
J8
J2
J2
J8
J9
J1
J3
J5
J6
ti23596a
FIG. 1
114
333347U
Accessories
6 Channel Upgrade Kit, 24V529
Use this kit to upgrade a 4 channel system to a 6 channel system.
CC
1304
1308
1302
WLD
BB
1307
AA
1306
1303
BB
1301
Ref
1301
1302
1303
1304
1305
1306
1307
1308
1309
333347U
Part
--16T087
112190
24R324
16T440
--16W035
---
1305
Description
Qty
MODULE, GCA, MZLP
1
CABLE, jumper, male/male, 4 in.
1
STRAP, wrist, grounding
1
TOKEN, software upgrade
1
CAP, jam nut, sealing
2
HARNESS, MZLP #3
1
CONNECTOR, jumper
1
FITTING, tee
2
115
Accessories
6 Channel Upgrade Kit Installation
1. Disconnect plug from power outlet or turn off circuit
breaker for incoming power.
2. Place grounding wrist strap (1303) over your wrist
and secure other end to a grounded surface.
3. Set the kit’s MZLP (1301) rotary switch to “3”.
7. Connect CAN jumper cable (1302) to MZLP 2 connector J3 and connect other end of jumper
cable (1302) to MZLP 3 connector J3. See FIG. 2.
4. Remove screws (BB) then remove plate (AA) from
system.
8. Install jumper connector (1307) in J5 on MZLP 3.
5. Use screws (BB) to install MZLP (1301) onto system.
NOTE: The new MZLP (1301) will be referred to as
MZLP 3, and the original MZLPs that came with the system will be referred to as MZLP 1 and MZLP 2 from here
on. See FIG. 2.
6. Remove electrical enclosure front access door.
NOTE: Do not force the electrical connection. Minimal
force is required to seat the connector. If resistance is
felt, stop and verify the connector orientation. Verify the
connector has “Locked” by gently pulling on the white
connector housing.
9. Connect wires from power harness (1306) between
AWB connector J5 and MZLP connector J2.
10. Remove plugs (CC) from fluid manifold and replace
with straight fittings (1309), tee fittings (1308), or the
extra fittings included with the InvisiPac system.
Use the fittings that meet your hose routing needs.
11. To ensure your InvisiPac system has the latest software, insert token (1306) into ADM. Follow Software Update Procedure, page 81.
0=/3
0=/3
-
0=/3
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Step 7: Install jumper cable (1302).
WLD
FIG. 2
116
333347U
Accessories
InvisiPac ADM Simulator Kit, 24R323
Simulator Instructions
Use this kit to train users in ADM operation without
using the full InvisiPac system. Kit includes everything
necessary to simulate the ADM screens. Does not
include an InvisiPac system.
1. Remove ADM access panel and install InvisiPac
Simulator Token (1404).
1401
1402
r_24P860_3B9900_3a
FIG. 3: Remove Access Panel
1404
2. Connect power supply (1402) to ADM (1401).
3. Connect cord (1403) to power supply (1402).
1403
4. Perform Software Update Procedure on page 81.
ADM Extension Kits
Use the extension cables to remote mount the ADM display off of the InvisiPac system. Kits available separately.
ti20990a
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
Kit No.
24R710
24R711
24R712
Qty.
1
1
1
ADM Remote Mount Bracket,
24A326
This bracket is used to remote mount the ADM display,
along with an ADM extension cable.
Ref.
1
333347U
Cable Length
16.4 ft (5 m)
49.2 ft (15 m)
164 ft (50 m)
Part
Description
Qty.
BRACKET, mounting assembly
1
117
Accessories
Overtemperature Jumper,
16Y727
Use the Overtemperature jumper plug to run the
InvisiPac melter without a hose and applicator attached
to the Channel 1 electrical connection.
Air Metric Fitting Kit, 24W637
For replacing air fittings with metric air fittings on InvisiPac systems. See manual 334358 for installation
instructions.
Ref.
1
2
3
4
Part
Description
127922 FITTING, 3/8 npt(m) x M18(f)
127923 FITTING, 1/4 npt(m) x 10 mm
tube
127924 FITTING, 1/4 npt(m) x 10 mm
90° elbow tube
127925 FITTING, 3/8-18 npt (m) x
3/8-19 bspt (f)
Qty.
1
1
1
1
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).
WLD
Installation
Installation
1. Remove standard strain relief bushing (106). Retain
and reuse nut.
1. In the ADM setup screens, uninstall Channel 1. All
other Channels can be installed or uninstalled as
needed.
2. Install strain relief bushing from kit and secure with
retained nut.
Hose Straps (4 Pack), 240296
Use these straps to secure hoses without excessive
pinching.
Ref.
1
NOTE: Failure to uninstall Channel 1 on the ADM setup
screens will result in several Alarms regarding Channel
1 when there is no hose/applicator attached to Channel
1.
2. Attach the Overtemperature jumper plug to Channel
1.
3. The ADM should have zero Active Alarms. The
melter is now ready to run without a hose and
applicator attached to Channel 1.
118
Part
Description
114271 STRAP, retaining
Qty.
4
Pressure Gauge Replacement
Kit, 24U635
To replace the air gauge glass lenses and glass fuses
used in the food or beverage industries.
Ref.
1
2
3
Description
GAUAGE, pressure, acrylic
TOOL, puller, fuse
FUSE, 250v, 8a
Qty.
2
1
32
333347U
Accessories
400VAC and 480VAC Transformer Kits
Use one of these kits to transform higher voltage
power (400VAC or 480VAC) to 240VAC.
Kit
127567
127568
Description
KIT, 400VAC Transformer
KIT, 480VAC Transformer
Adapter Cable
Part
128621
333347U
Description
Adapter cable allows non-Graco Ni120 RTD Hoses
to be used on InvisPac
119
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.
Description
Use the physical numeric keypad on ADM to enter temperature setting.
Select channel to view and/or edit
the applicator or hose temperature
setting
Applicator temperature setting.
Use
ting.
and
to adjust set-
Hose temperature setting.
NOTE: For information on InvisiPac Pattern Controller
screens, see manual 334784.
Use
ting.
and
to adjust set-
Enable, Disable Heating System
To enable or disable the entire heating system,
press
Use to adjust temperature settings
. To set which channels are active when the
heating system is enabled, use the System 2 screen.
See page 123.
Reset weight total
Icon Identification
Icon
Temperature settings of applicator
(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 applicator (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
120
333347U
Appendix A - ADM
Operation Screens
Home
Events
This screen shows the actual temperatures of the system melter and each applicator and hose.
The Events screens store a maximum of 200 events.
The events list can be downloaded in the USB logs. See
Appendix B - USB Downloading, Uploading on
page 126.
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
This screen shows and allows editing of the temperature
settings for the system melter and each applicator and
hose. See Select ADM Settings on page 23.
*
333347U
Code
EQU3
EQU4
EBFX
EAFX
EBDX
EADX
ECAH
EQU5
ECAL
ERM1
ERD1
EBPX
EAPX
EB0X
EC0X
EM0X
EL0X
EQU1
EQU2
EVUX
EAUX
EBUX
ERN1
Zone
121
Appendix A - ADM
Errors
The Errors screens store a maximum of 200 errors. See
ADM Error Code Table on page 44. The errors list can
be downloaded in the USB logs. See Appendix B USB Downloading, Uploading on page 126.
Diagnostic
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.
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
Diagnostic Data
Current Draw
RTD Reading
Duty Cycle
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
CAN: 24 VDC power supply voltage reading (18-28
VDC)
DI: System Digital Inputs
0: Not Used
1: Not Used
2: Pump Cycle Switch Up
3: Pump Cycle Switch Down
DO: System Digital Outputs
0: Pump Solenoid
1: Fill Solenoid
2: Light Tower Green Light
3: Light Tower Red Light
122
This screen shows a daily log of material usage. For
more details see the Material Tracking section on page
28.
333347U
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.
Enable Diagnostic Screen: Choose whether to hide
the Diagnostic screen.
Pump Idle Time to System Inactive: The heating system will be disabled after the pump has been idle for the
set amount of time
Power Type: Select the system power type.
Circuit Breaker Size: Select the circuit breaker size.
Refill Setting: To use the automatic vacuum transfer,
select Auto. To disable the automatic vacuum transfer,
select Manual. The main reason to disable automatic
refill is while flushing. However, if an issue is present
with the automatic refill system that cannot be solved in
a timely manner, manual refill can be used to return the
system to service. See Manual Refill on page 34.
See Select ADM Settings on page 23.
System 4
A PLC can be used to control or monitor the system.
See PLC Connection on page 26 for instructions.
System 2
Use this screen to enable ADM unit counter, enable
material alerts and calibrate material tracking.
Use this screen to enable the installed channels and
specify the type of applicator RTD type used. See
Select ADM Settings on page 23.
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123
Appendix A - ADM
Enable ADM Unit Counter: Select to enable ADM
counting of units using an external sensor.
Enable Material Alerts: Select to enable record only
events indicating low/high material usage.
Specific Gravity: Required to convert the volume dispensed to mass dispensed for tracking the total weight
and flow rate.
Advanced 1
Maintenance
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.
Advanced 2
NOTE: The lifetime cycle count will only be reset if the
Advanced Display Module (ADM) is replaced.
Schedule
Temperature Units: Units of measure for displayed
temperatures.
Mass Units: Units of measure for mass.
Distance Units: Units of measure for distance.
Use this screen to set times where the system will automatically enable and disable heating. See Select ADM
Settings on page 23.
124
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Appendix A - ADM
Advanced 3
Disable USB Downloads/Uploads: Disables use of
the USB for downloading and uploading.
Disable USB Log Errors: When disabled, the system
will not warn the user when logs are full. If the logs are
full, data will be overwritten.
Download Depth: Last ___ Days: The USB download
will provide data as old as the number of days entered.
Old data may be in memory but will not be downloaded
if older than the number of days entered.
Advanced 4
This screen shows the part number and version of
each installed software module.
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125
Appendix B - USB Downloading, Uploading
Appendix B - USB Downloading, Uploading
The system can store 150,000 entries in its logs and the
system adds a new entry to the logs every 15 seconds.
This means the system stores 655 hours of system
operation data, or 27 days of around-the-clock operation. Once full, the system will overwrite the oldest data.
NOTE: To prevent losing any data, never go more than
27 days without downloading the logs.
Download Procedure
NOTICE
Uploading an edited system configuration file can
damage the system. Never put a modified
SETTINGS.TXT file in the UPLOAD folder on the
flash drive.
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 127.
Accessing Files
All files downloaded from the USB are put in a DOWNLOAD folder on the stick drive. For example:
“E:\GRACO\12345678\DOWNLOAD\”. The 8-digit
numeric folder name matches the 8-digit ADM serial
number, which is located on the back of the ADM. When
downloading from multiple ADMs, there will be one
sub-folder in the GRACO folder for each ADM.
The log files should be opened in a spreadsheet program.
NOTE: If emailing the files, zip (compress) them to minimize file size.
Upload Procedure
NOTICE
Uploading an edited system configuration file can
damage the system. Never put a modified
SETTINGS.TXT file in the UPLOAD folder on the
flash drive.
1. Insert USB flash drive into USB port. See FIG. 4.
NOTE: Flash drive must be 8 GB or smaller.
Use this procedure to install a system configuration file
and/or a custom language file. See System Settings
File or System Language File starting on page 127.
1. If necessary, follow the Download Procedure,
page 126, to automatically generate the proper
folder structure on the USB flash drive.
2. Insert USB flash drive into USB port of computer.
FIG. 4: ADM USB Port
2. The menu bar and USB indicator lights indicate that
the USB is downloading files. Wait for USB activity
to complete. A pop-up will be present until the transfer is complete if it is not acknowledged.
3. The USB flash drive window automatically opens. If
it does not, open USB flash drive from within Windows Explorer.
4. Open Graco folder.
NOTE: If the pop-up screen does not appear, the flash
drive is not compatible with the ADM. Try a different
flash drive.
5. Open system folder. If working with more than one
system, there will be more than one folder within the
Graco folder. Each folder is labeled with the corresponding serial number of the ADM. (The serial
number is on the back of the module.)
NOTE: The system can log up to 45 mb of additional
data per week, depending on system operation.
6. If installing the system settings file, place SETTINGS.TXT file into UPLOAD folder.
126
333347U
Appendix B - USB Downloading, Uploading
7. If installing the custom language file, place DISPTEXT.TXT file into UPLOAD folder.
8. Remove USB flash drive from computer.
9. Install USB flash drive into InvisiPac system USB
port.
10. The menu bar and USB indicator lights indicate that
the USB is uploading files. Wait for USB activity to
complete.
11. Remove USB flash drive from USB port.
NOTE: If a custom language file was installed, users
can now select the new language from the Language
drop-down menu.
NOTE: If the SETTINGS.TXT or DISPTEXT.TXT files
remain in the UPLOAD folder, they will be uploaded
every time the USB drive is inserted into the corresponding ADM. To avoid unintentionally overwriting system settings, delete the files from the UPLOAD folders
on the USB drive after the upload is complete.
USB Logs
During operation, InvisiPac stores system and performance related information to memory in the form of log
files. InvisiPac maintains the events, data, GCA, Black
Box, and Diagnostics logs. Follow the Download Procedure, page 126, to retrieve log files.
Events Log
The event log (1-EVENT.CSV) maintains a record of the
last 175,000 events. Each event record in the log file
contains the date and time the event occurred, the event
type, event code, and event description.
GCA Log
This log (3-GCA.CSV) lists the installed GCA modules
and their respective software versions.
Black Box, Diagnostics Logs
These logs (4-BLACKB.CSV, 5-DIAGN.CSV) are
designed to provide useful information to Graco when
calling for technical assistance.
System Settings File
NOTICE
Uploading an edited system configuration file can
damage the system. Never put a modified
SETTINGS.TXT file in the UPLOAD folder on the
flash drive.
The system configuration settings file name is
SETTINGS.TXT and is stored in the DOWNLOAD
folder.
A system configuration settings file automatically downloads each time a USB flash drive is inserted. Use this
file to back up system settings for future recovery or to
easily replicate settings across multiple InvisiPac systems. Refer to the Upload Procedure, page 126, for
instructions on how to use this file.
It is recommended to retrieve the SETTINGS.TXT file
after all system settings are set as desired. Store the file
for future use as a backup in case the settings are
changed and need to be quickly changed back to the
desired setup.
NOTE: System settings may not be compatible between
different versions of the InvisiPac software.
Data Log
The data log (2-DATA.CSV) tracks the setpoint and
actual temperatures every 15 seconds. This log can
store up to 250,000 lines of data.
The system stores 1041 hours of system operation data,
or 43 days of around-the-clock operation. Once full, the
system will overwrite the oldest data.
NOTE: To prevent losing any data, never go more than
43 days without downloading the logs.
333347U
127
Appendix B - USB Downloading, Uploading
System Language File
The system language file name is DISPTEXT.TXT and
is stored in the DOWNLOAD folder.
A system language file automatically downloads each
time a USB flash drive is inserted. If desired, use this file
to create a user-defined set of custom language strings
to be displayed within the ADM.
The system is able to display the following Unicode
characters. For characters outside of this set, the system will display the Unicode replacement character,
which appears as a white question mark inside of a
black diamond.
•
•
•
•
•
U+0020 - U+007E (Basic Latin)
U+00A1 - U+00FF (Latin-1 Supplement)
U+0100 - U+017F (Latin Extended-A)
U+0386 - U+03CE (Greek)
U+0400 - U+045F (Cyrillic)
Create Custom Language Strings
The custom language file is a tab-delimited text file that
contains two columns. The first column consists of a list
of strings in the language selected at the time of download. The second column can be used to enter the custom language strings. If a custom language was
previously installed, this column contains the custom
strings. Otherwise the second column is blank.
Modify the second column of the custom language file
as needed and then follow the Upload Procedure,
page 126, to install the file.
The format of the custom language file is critical. The
following rules must be followed in order for the installation process to succeed.
•
•
•
•
•
•
128
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.
333347U
Technical Data
Technical Data
InvisiPac Hot Melt Delivery System
US
Incoming Power
HM25: 24V423, 24Y102
HM50: 24T918, 24Y114
HM25: 24V429, 24Y106
HM50: 24V201, 24Y118
HM25: 24V424, 24Y103
HM50: 24T919, 24Y115
HM25: 24V430, 24Y107
HM50: 24V202, 24Y119
HM25: 24V425
HM50: 24T920
HM25: 24V431
HM50: 24V203
HM25: 24V426, 24Y104
HM50: 24V198, 24Y116
HM25: 24V427, 24Y105
HM50: 24V199, 24Y117
HM25: 24V428
HM50: 24V200
Electrical
Minimum Applicator Wattage Per Channel at 240
VAC
Maximum Applicator Wattage Per Channel
Input / Output Capability
Pump Flow Rate
HM25
HM50
Melt Rate / Constant Throughout
HM25
HM50
Weight
HM25
HM50
General
Adhesive
Pump Output
Time to Temperature *
Pump
Channels
System Dimensions (Width x Height x Depth) **
Pressure and Temperature Ranges
Main System Air Supply Pressure Range (set with
regulator on front of system)
333347U
Metric
200-240 VAC, 1-ph, 50/60 Hz, 32A
200-240 VAC, 3-ph, ˂, 50/60 Hz, 27A
350-415 VAC, 3-ph, Y, 50/60 Hz, 16A
400-480 VAC, 3-ph, ˂, 50/60 Hz, 14A
200-240 VAC, 1-ph, 50/60 Hz, 40A
200-240 VAC, 3-ph, ˂, 50/60 Hz, 27A
350-415 VAC, 3-ph, Y, 50/60 Hz, 16A
400-480 VAC, 3-ph, ˂, 50/60 Hz, 14A
200-240 VAC, 1-ph, 50/60 Hz, 40A
200-240 VAC, 3-ph, ˂, 50/60 Hz, 40A
350-415 VAC, 3-ph, Y, 50/60 Hz, 30A
400-480 VAC, 3-ph, ˂, 50/60 Hz, 14A
335-400 VAC, 3-ph Y, 50/60 Hz, 17A
335-400 VAC, 3-ph Y, 50/60 Hz, 17A
335-400 VAC, 3-ph Y, 50/60 Hz, 17A
90 W
400 W
4 inputs (0-30V), 4 outputs (240VAC, 24VDC, 2A)
96 lb/hr
130 lb/hr
43.5 kg/hr
59 kg/hr
25 lb/hr
50 lb/hr
11.3kg/hr
22.6 kg/hr
85 lb
105 lb
36 kg
48 kg
1/4 in. (6 mm), round, adhesive pellets
19.3 cc/cycle
Less than 15 minutes
Pneumatic Piston, 12:1
1 to 6
19.0 x 42 x 16.5 in.
483 x 1067 x 419 mm
80-100 psi
0.55-0.69 MPa (5.5-7 bar)
129
Technical Data
InvisiPac Hot Melt Delivery System
US
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)
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
20-100 psi
240-1200 psi
100-400°F
32-120°F
Metric
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)
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
* From 70°F to 350°F (21°C to 177°C), dependant upon power supply and machine configuration.
** Excludes vacuum transfer tube, shaker assembly, and pellet storage bin.
*** Sound pressure level measured 3.1 ft (1 meter) from equipment.
130
333347U
Technical Data
Startup Time
Single Phase
HM50
HM25
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
System
(#)
ft (m)
240V
240V
240V
240V
208V
208V
208V
208V
1
4 (1.2)
11
9.9
9.9
9.9
13
13
13
13
1
12 (3.6)
13
9.9
9.9
9.9
14
13
13
13
1
25 (7.6)
15
9.9
9.9
9.9
17
13
13
13
2
4 (1.2)
13
9.9
9.9
9.9
15
13
13
13
2
12 (3.6)
16
9.9
9.9
9.9
18
13
13
13
2
25 (7.6)
20
13
9.9
9.9
23
13
13
13
3
4 (1.2)
15
9.9
9.9
9.9
17
13
13
13
3
12 (3.6)
19
12
9.9
9.9
22
13
13
13
3
25 (7.6)
26
16
12
9.9
29
19
13
13
4
4 (1.2)
16
9.9
9.9
9.9
18
13
13
13
4
12 (3.6)
22
14
9.9
9.9
25
16
13
13
4
25 (7.6)
31
20
14
12
35
23
16
13
5
4 (1.2)
18
11
9.9
9.9
20
13
13
13
5
12 (3.6)
25
16
11
9.9
28
18
13
13
5
25 (7.6)
36
23
17
14
41
27
19
15
6
4 (1.2)
20
12
9.9
9.9
22
13
13
13
6
12 (3.6)
28
18
13
10
32
20
13
13
6
25 (7.6)
41
27
20
16
47
31
22
18
333347U
1
1
1
2
2
2
3
3
3
4
4
4
5
5
5
6
6
6
4 (1.2)
12 (3.6)
25 (7.6)
4 (1.2)
12 (3.6)
25 (7.6)
4 (1.2)
12 (3.6)
25 (7.6)
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)
17
19
21
19
23
27
21
27
32
23
30
37
25
34
42
27
37
47
15
15
15
15
15
17
15
17
21
15
19
24
16
22
28
17
24
31
15
15
15
15
15
15
15
15
15
15
15
18
15
16
20
15
18
23
15
15
15
15
15
15
15
15
15
15
15
15
15
15
16
15
15
18
20
21
24
21
26
30
24
30
36
26
34
42
28
38
48
30
42
54
20
20
20
20
20
20
20
20
23
20
22
27
20
25
31
20
27
36
20
20
20
20
20
20
20
20
20
20
20
20
20
20
23
20
20
26
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
21
131
Technical Data
Three Phase
NOTE: Times are approximate and may vary with ambient conditions, voltage configuration, and machine
configuration.
HM50
HM25
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
System
(#)
ft (m)
240V
240V
240V
240V
208V
208V
208V
208V
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
1
4 (1.2)
17
15
15
15
20
20
20
20
12 (3.6)
1
19
15
15
15
20
20
20
20
25
(7.6)
1
21
15
15
15
22
20
20
20
4 (1.2)
2
19
15
15
15
20
20
20
20
12 (3.6)
2
23
15
15
15
24
20
20
20
25
(7.6)
2
26
18
15
15
28
20
20
20
4 (1.2)
20
15
15
15
22
20
20
20
3
12 (3.6)
3
26
17
15
15
28
20
20
20
25 (7.6)
3
31
21
16
15
34
23
20
20
4
(1.2)
4
22
15
15
15
24
20
20
20
12 (3.6)
4
28
19
15
15
32
22
20
20
25 (7.6)
4
35
24
18
15
40
27
20
20
4
(1.2)
5
22
16
15
15
26
20
20
20
12 (3.6)
5
31
21
16
15
36
24
20
20
25
(7.6)
5
40
27
20
16
47
31
24
20
4 (1.2)
6
24
16
15
15
28
20
20
20
12 (3.6)
6
34
23
17
15
40
27
20
20
25
(7.6)
6
45
30
23
18
53
35
27
21
132
333347U
Technical Data
Dimensions
240V System Dimensions
System With 480V Transformer
A
A
B
B
C
WLD
WLD
A
B
C
HM25
35.5 in. (901.7 mm)
20.8 in. (528.3 mm)
17.6 in. (447.0mm)
333347U
HM50
35.8 in. (409.3 mm)
22.3 in. (566.4 mm)
18.3 in. (464.8 mm)
C
A
B
C
HM25
41.6 in. (1056.6 mm)
20.9 in. (530.9 mm)
17.6 in. (447.0 mm)
HM50
41.9 in. (1064.3 mm)
22.3 in. (566.4 mm)
18.3 in. (464.8 mm)
133
Technical Data
WALL
5.3 in.
(134.6 mm)
Mounting Hole Dimensions
1.4 in.
(35.6 mm)
Minimum distance from rear mounting
hole to wall: 7.0 in. (178 mm)
A
A
5.3 in. (133 mm)
2.0 in.
(51 mm)
C
HM25
C
HM25
HM50
134
7.1 in. (180 mm)
A
10.3 in.
(261.6 mm)
11.1 in.
(281.9 mm)
B
HM50
14.2 in.
(361 mm)
WLD
B
3.3 in.
(83.8 mm)
4.0 in.
(101.6 mm)
7.1 in.
(180 mm)
14.2 in. (361 mm)
A
11.1 in.
(281.9 mm)
11.9 in.
(302.3 mm)
B
3.4 in.
(86.4 mm)
4.0 in.
(101.6 mm)
B
C
3.4 in.
(86.4 mm)
4.0 in.
(101.6 mm)
C
3.3 in.
(83.8 mm)
4.0 in.
(101.6 mm)
333347U
Technical Data
System with Stand Dimensions
A
ti22866c
A
in. (mm)
System
System With Transformer
60.7 in. (1542 mm)
66.5 (1689 mm)
17.4
(442 mm)
27.2 in.
(692 mm)
ti22865b
31.3
(795 mm)
333347U
135
Graco Extended Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of eighteen months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs
will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For more information about InvisiPac, visit www.InvisiPac.com or email [email protected].
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
For technical assistance or customer service, call toll free: 1-800-458-2133.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
)RUSDWHQWLQIRUPDWLRQVHHZZZJUDFRFRPSDWHQWV
2ULJLQDOLQVWUXFWLRQV This manual contains English. MM 333347
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision U, January 2019
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