Graco 333347F Invisipac Hm25 And Hm50 Users Manual Tank Free Hot Melt Delivery System, Instructions Parts, English
2015-04-02
: Graco Graco-333347F-Invisipac-Hm25-And-Hm50-Users-Manual-686022 graco-333347f-invisipac-hm25-and-hm50-users-manual-686022 graco pdf
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Instructions - Parts InvisiPac™ HM25 and HM50 Tank-Free™ Hot Melt Delivery System 333347F EN For delivering and dispensing hot melt adhesive pellets. For professional use only. Not approved for use in explosive atmospheres or hazardous locations. 1200 psi (8.3 MPa, 83 bar) Maximum Working Pressure 400°F (204°C) Maximum Fluid Operating Temperature 100 psi (0.7 MPa,7 bar) Maximum Air Inlet Pressure Important Safety Instructions Read all warnings and instructions in this manual and in the applicator and hose manuals. Save all instructions. WLD 9902471 Certified to CAN/CSA C22.2 No. 88 Conforms to ANSI/UL 499 Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 200-230 VAC, 350-415 VAC HM50 Models . . . . . . . . . . . 4 200-230 VAC, 350-415 VAC HM25 Models . . . . . . . . . . . 5 400 VAC Transformer HM25 Models . . . . . . . . . . . . . . . . 6 400 VAC Transformer HM25 Models . . . . . . . . . . . . . . . . 6 480 VAC Transformer HM25 Models . . . . . . . . . . . . . . . . 7 480 VAC Transformer HM50 Models . . . . . . . . . . . . . . . . 7 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Heated Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Advanced Display Module (ADM) . . . . . . . . . . . . . . . . . . 14 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Attach Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Recommended Air Setup . . . . . . . . . . . . . . . . . . . . . . . . 22 Connect Electrical Cord . . . . . . . . . . . . . . . . . . . . . . . . . . 23 208V Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Select ADM Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 PLC Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Initial Startup and Prime . . . . . . . . . . . . . . . . . . . . . . . . . 29 Manual Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Automatic Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . 33 Drain the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Operation Tips to Minimize Charring . . . . . . . . . . . . . . . . 36 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Replace Outlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Replace Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Replace Funnel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Filter Maintenance Guidelines* . . . . . . . . . . . . . . . . . . . . 39 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ADM Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Mechanical and Electrical Troubleshooting . . . . . . . . . . 46 MZLP Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Multi-Zone Low Power Temperature Control Module (MZLP) 67 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Transformer Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Software Update Procedure . . . . . . . . . . . . . . . . . . . . . . 77 2 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Cable Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 480VAC Transformer Option . . . . . . . . . . . . . . . . . . . . . . 80 Typical Hose / Applicator Wiring . . . . . . . . . . . . . . . . . . . 80 2nd and 3rd MZLP Options . . . . . . . . . . . . . . . . . . . . . . . 81 Air Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 InvisiPac Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Transformer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 92 Melter and Pump Assembly . . . . . . . . . . . . . . . . . . . . . . 93 Air Motor, 24V558 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Feed System Shaker and Tube, 24V507 . . . . . . . . . . . . 96 Air Controls Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Pressure Relief Valve, 24P856 . . . . . . . . . . . . . . . . . . . . 98 Feed Inlet Funnel, 24V505 . . . . . . . . . . . . . . . . . . . . . . . 99 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Non-Graco Applicator Adapter Cables . . . . . . . . . . . . . 101 Air Adjustment Lock, 24R084 . . . . . . . . . . . . . . . . . . . . 101 System Stand, 24R088 . . . . . . . . . . . . . . . . . . . . . . . . . 102 Caster for Stand, 120302 . . . . . . . . . . . . . . . . . . . . . . . 102 Adapter Plate, 24R083 . . . . . . . . . . . . . . . . . . . . . . . . . 102 30 Gallon Vibrating Hopper, 24R136 . . . . . . . . . . . . . . 104 Light Tower Kit, 24R226 . . . . . . . . . . . . . . . . . . . . . . . . 106 Air Reservoir Kit, 16W366 . . . . . . . . . . . . . . . . . . . . . . . 107 4 Channel Upgrade Kit, 24V528 . . . . . . . . . . . . . . . . . . 108 6 Channel Upgrade Kit, 24V529 . . . . . . . . . . . . . . . . . . 110 InvisiPac ADM Simulator Kit, 24R323 . . . . . . . . . . . . . . 112 ADM Extension Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 ADM Remote Mount Bracket, 24A326 . . . . . . . . . . . . . 112 Overtemperature Jumper, 16Y727 . . . . . . . . . . . . . . . . 113 Air Metric Fitting Kit, 24W637 . . . . . . . . . . . . . . . . . . . . 113 Strain Relief Bushing Kit, 24X190 . . . . . . . . . . . . . . . . . 113 Hose Straps (4 Pack), 24R0294 . . . . . . . . . . . . . . . . . . 113 Pressure Gauge Replacement Kit, 24R635 . . . . . . . . . 113 Appendix A - ADM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Icon Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Operation Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Appendix B - USB Downloading, Uploading . . . . . . . . . . 120 Download Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Accessing Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Upload Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 System Settings File . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 System Language File . . . . . . . . . . . . . . . . . . . . . . . . . 122 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Startup Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Graco Extended Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 130 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 333347F Related Manuals Related Manuals Manuals are available at www.graco.com. Component manuals in English: Part Description 3A2805 InvisiPac GS35 Hot Melt Applicator Instructions - Parts InvisiPac Heated Hose Instructions - Parts HM50 Fuse Kit, Instructions-Parts InvisiPac 480V Transformer Upgrade Kit, Instructions-Parts MZLP Fuse Kit, Instructions 332072 333348 333349 333348 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 333347F 3 Models Models 200-240 VAC, 350-415 VAC HM50 Models See 400 VAC Transformer models on page 6. See 480 VAC Transformer models on page 7. Model Channels Voltage 200-240 VAC 24T918 2 200-240 VAC Δ 350-415 VAC Y 200-240 VAC 24T919 4 200-240 VAC Δ 350-415 VAC Y 200-240 VAC 24T920 6 200-240 VAC Δ 350-415 VAC Y Φ Type 1Φ / PE 3Φ / PE 3Φ / Neutral / PE 1Φ / PE 3Φ / PE 3Φ / Neutral / PE 1Φ / PE 3Φ / PE 3Φ / Neutral / PE Frequency Max Amps 50/60 Hz 32A • 2 wire and PE • 3-Phase without Neutral • 200-240VAC 50/60 Hz 27A • • • • 50/60 Hz 16A • 3 wire, Neutral, and PE • 1-Phase • 200-240 VAC 50/60 Hz 40A • 2 wire and PE • 3-Phase without Neutral • 200-240 VAC Line to Line 50/60 Hz 27A • • • • 50/60 Hz 16A • 3 wire, Neutral, and PE • 1-Phase • 200-240 VAC 50/60 Hz 40A • 2 wire and PE • 3-Phase without Neutral • 200-240 VAC Line to Line 50/60 Hz 40A • • • • 50/60 Hz 30A Description • 1-Phase • 200-240VAC 3 wire and PE 3-Phase with Neutral 350-415 VAC Line to Line 200-240 VAC Line to Neutral 3 wire and PE 3-Phase with Neutral 350-415 VAC Line to Line 200-240 VAC Line to Neutral 3 wire and PE 3-Phase with Neutral 350-415 VAC Line to Line 200-240 VAC Line to Neutral • 3 wire, Neutral, and PE 4 333347F Models 200-240 VAC, 350-415 VAC HM25 Models See 400 VAC Transformer models on page 6. See 480 VAC Transformer models on page 7. Model Channels Voltage 200-240 VAC 24V423 2 200-240 VAC Δ 350-415 VAC Y 200-240 VAC 24V424 4 200-240 VAC Δ 350-415 VAC Y 200-240 VAC 24V425 6 200-240 VAC Δ 350-415 VAC Y Φ Type 1Φ / PE 3Φ / PE 3Φ / Neutral / PE 1Φ / PE 3Φ / PE 3Φ / Neutral / PE 1Φ / PE 3Φ / PE 3Φ / Neutral / PE Description • 1-Phase • 200-240VAC Frequency Max Amps 50/60 Hz 32A • 2 wire and PE • 3-Phase without Neutral • 200-240VAC 50/60 Hz 27A • • • • 50/60 Hz 16A • 3 wire, Neutral, and PE • 1-Phase • 200-240VAC 50/60 Hz 40A • 2 wire and PE • 3-Phase without Neutral • 200-240VAC 50/60 Hz 27A • • • • 50/60 Hz 16A • 3 wire, Neutral, and PE • 1-Phase • 200-240VAC 50/60 Hz 40A • 2 wire and PE • 3-Phase without Neutral • 200-240VAC 50/60 Hz 40A • • • • 50/60 Hz 30A 3 wire and PE 3-Phase with Neutral 350-415 VAC Line to Line 200-240 VAC Line to Neutral 3 wire and PE 3-Phase with Neutral 350-415 VAC Line to Line 200-240 VAC Line to Neutral 3 wire and PE 3-Phase with Neutral 350-415 VAC Line to Line 200-240 VAC Line to Neutral • 3 wire, Neutral, and PE 333347F 5 Models 400 VAC Transformer HM25 Models Model Channels Voltage 24V426 2 335-400 VAC 24V427 24V428 4 6 335-400 VAC 335-400 VAC Φ Type 3Φ / PE 3Φ / PE 3Φ / PE Frequency Max Amps 50/60 Hz 17A • 3 wire and PE • 3-Phase without Neutral • 335-400 VAC Line to Line 50/60 Hz 17A • 3 wire and PE • 3-Phase without Neutral • 335-400 VAC Line to Line 50/60 Hz 17A Frequency Max Amps Description • 3-Phase without Neutral • 335-400 VAC Line to Line • 3 wire and PE 400 VAC Transformer HM50 Models Model Channels Voltage 24V198 2 335-400 VAC 24V199 24V200 6 4 6 335-400 VAC 335-400 VAC Φ Type 3Φ / PE 3Φ / PE 3Φ / PE Description • 3-Phase without Neutral • 335-400 VAC Line to Line 50/60 Hz 17A • 3 wire and PE • 3-Phase without Neutral • 335-400 VAC Line to Line 50/60 Hz 17A • 3 wire and PE • 3-Phase without Neutral • 335-400 VAC Line to Line 50/60 Hz 17A • 3 wire and PE 333347F Models 480 VAC Transformer HM25 Models Model Channels Voltage 24V429 2 400-480 VAC 24V430 24V431 4 6 400-480 VAC 400-480 VAC Φ Type 3Φ / PE 3Φ / PE 3Φ / PE Frequency Max Amps 50/60 Hz 14A • 3 wire and PE • 3-Phase without Neutral • 400-480 VAC Line to Line 50/60 Hz 14A • 3 wire and PE • 3-Phase without Neutral • 400-480 VAC Line to Line 50/60 Hz 14A Frequency Max Amps Description • 3-Phase without Neutral • 400-480 VAC Line to Line • 3 wire and PE 480 VAC Transformer HM50 Models Model Channels Voltage 24V201 2 400-480 VAC 24V202 24V203 333347F 4 6 400-480 VAC 400-480 VAC Φ Type 3Φ / PE 3Φ / PE 3Φ / PE Description • 3-Phase without Neutral • 400-480 VAC Line to Line 50/60 Hz 14A • 3 wire and PE • 3-Phase without Neutral • 400-480 VAC Line to Line 50/60 Hz 14A • 3 wire and PE • 3-Phase without Neutral • 400-480 VAC Line to Line 50/60 Hz 14A • 3 wire and PE 7 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. 8 333347F 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. 333347F 9 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. 10 333347F Component Identification Component Identification G3 G2 G4 A G AD H G1 B F E WL D C D K Key: A B C D E F G G1 G2 G3 G4 H J K L M N P R S AC AD Advanced Display Module (ADM) Electrical Enclosure Pump Air Pressure Regulator Pump Air Pressure Gauge Vacuum Transfer Air Pressure Regulator Vacuum Transfer Air Pressure Gauge Shaker Tube Shaker Head Vacuum Transfer Tube Vacuum Transfer Inlet Funnel Vacuum Transfer 3/8 in. OD Air Supply Main Power Switch System Air Inlet Vacuum Transfer (Shaker) Inlet Air Motor and Pump Incoming Power Strain Relief Heated Fluid Manifold (Melter) Multi-Zone Low Power Temperature Control Module (MZLP) Fluid Outlets for connection to Heated Hoses (numbered 1-6) Customer I/O Cable (optional) Drain Port Transformer (optional) FIG. 1 333347F L G3 N R M AC P S WLD J 11 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 12 333347F Component Identification Electrical Enclosure AC P WL D 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) 333347F 13 Component Identification Advanced Display Module (ADM) User Interface NOTICE BK To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. BL NOTE: See Appendix A - ADM on page 114 for complete ADM operation details. BB BC FIG. 5 BA BD BE BF BM BR BP BN Key: BK Part Number Identification Label BL USB Interface BM CAN Cable Connection (Power Supply and Communication) BN Module Status LEDs BP (Not used) BR Software Token Access Panel BH BG TI12362a1 FIG. 4 B Key Function BA Heating system and pump enable/disable BB System status indicator (LED) BC Stop all system processes BD Defined by icon next to softkey BE Abort current operation BF Accept change, acknowledge error, select item, toggle selected item BG Toggle between Operation and Setup screens BH Navigate within a screen or to a new screen 14 333347F Component Identification Screen Components Screens Order Current date and time Operating Mode Faults, Status Melter Heating Status Melter Actual Temperature Hose and Applicator Heating Status Hose Actual Temperature Applicator Actual Temperature FIG. 6: Main Screen Components Operating Mode Description Component Status • System Off The system doesn’t have power. Inactive The heating system and pumps are disabled. Warm Up The system is heating the material to the set temperature. Active The system is ready to dispense material. 333347F • • • • • • • • • • • 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 15 Component Identification 16 333347F Setup Setup Grounding The applicator(s) must be located no more than 25 ft (7.6 m) from the melter. The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current. The InvisiPac system is equipped with a ground terminal. A qualified electrician must ground the system using this terminal. See Connect Electrical Cord on page 23. 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 102. If installing the system in place of a non-Graco hot melt system, purchase Adapter Plate, 24R083. See page 102. Optional 30 Gallon Vibrating Hopper, 24R136, available (purchase separately). See page 104. To make repairing the system easier, locate the system so that all sides are easily accessible and have sufficient lighting. NOTICE To prevent excessive static buildup on shaker or adhesive bin, install optional grounding kit 24R708. Attach Components To reduce the risk of electric shock, do not connect electrical cord until after this Attach Components procedure is complete. NOTE: Only systems with transformers are supplied with a lifting strap. NOTICE To prevent strain on electrical or mechanical connections around the pump assembly, loop the strap around the tie rods as shown. WLD FIG. 7: Grounding Kit 24R708 Location Ambient temperature must be 32-120°F (0-49°C). 1. Use supplied lifting strap 127735, to transport systems with transformers. Wrap strap around all three pump tie rods and loop the strap back through itself in the Choker Configuration. See strap for details. See FIG. 8, page 18. 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. 333347F 17 Setup 3. Adjust the funnel inlet: G3 23 81 92 WL D a. Remove plug (23) and insert the provided 5/16 in. nut driver (92) through the access hole in the back of the system. Loosen the band clamp (81) two turns. WLD FIG. 8: Lifting Strap b. Rotate the funnel inlet (G3) and re-tighten the band clamp (81). 2. Place the base system in the desired operating location and orientation. See Location, page 17. G3 • 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 102. • To raise the system to eye-level, purchase System Stand, 24R088. See installation instructions on page 102. 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). G4 G2 WLD FIG. 9 4. Insert 1.3 in. (33 mm) OD clear vacuum transfer hose (G2) into vacuum transfer funnel (G3) inlet and secure with supplied hose clamp. The hose clamp should be placed over the cutouts in the funnel inlet where it can firmly hold the transfer hose. See FIG. 9. 5. Connect the long supplied 3/8 in. OD air line (G4) to the 3/8 in. push-to-connect fitting on the air line from the system. See FIG. 9. 18 333347F Setup NOTE: In the following steps, when routing the vacuum transfer hose, ensure there are no tight coils, turns, or dips in the vacuum hose. These will inhibit optimal functioning of the vacuum transfer system. NOTE: Maximum vacuum hose length is 30 ft (9.1 m). Use horizontal hose routing as much as possible. The vacuum hose must not rise more than 10 ft (3.0 m), measured from the vacuum inlet. Any vertical rise will lower the maximum flow rate of the vacuum transfer system. 6. Route the 1.3 in. (33 mm) OD clear vacuum transfer hose (G2) from the system to the adhesive pellets container location. 7. Apply pipe sealant to threads then attach steel shaker tube (G) to shaker head (G1). See FIG. 10. NOTICE To prevent shaker head (G1) galling to the shaker tube (G), do not overtighten shaker head onto shaker tube. These should be hand-tightened. ties (G5). See FIG. 10. 10. If desired, secure the 1.3 in. (33 mm) clear vacuum transfer tube (G2) and 3/8 in. OD air line (G4) with zip ties to a supporting structure at various points in the routing. 11. Attach the other end of the long 3/8 in. OD air line (G4) to the 3/8 in. push-to-connect fitting on the shaker head (G1). 12. Ensure the adhesive pellets container is in the desired operating location. The location should be chosen to make it easy to fill the container with pellets. 13. Place shaker assembly in an empty adhesive pellets container then fill the container with adhesive pellets. NOTE: To promote optimal system performance, purchase 30 Gallon Vibrating Hopper, 24R136. See installation instructions on page 104. NOTE: If static buildup on feed tube (G) is excessive, install optional feed tube ground kit 24R708 to feed tube end (G6). See FIG. 7. G2 G6 G5 G G4 G1 ti21131a FIG. 10 8. Attach 1.3 in. (33 mm) clear vacuum transfer hose (G2) to steel shaker tube (G) and secure with supplied hose clamp. See FIG. 10. 9. Route the 3/8 in. OD air line (G4) alongside the 1.3 in. (33 mm) clear vacuum transfer hose (G2) and secure at multiple points with the supplied zip 333347F 19 Setup f. 14. Install heated hoses, see FIG. 11: To reduce the risk of fire and explosion, only use Graco heated hoses with the InvisiPac system. Use of non-Graco hoses will void agency approvals. N Applicator 247 68 g. Locate MZLP (AA) connector marked with same number as the hose fluid outlet port. Remove that connector cover then install connector from heated hose. See FIG. 11. h. Repeat the procedure for the remaining channels. Use the bottom melter ports first to ease installation. i. W1 AA FIG. 11 W2 ti23298a a. Place a rag on the drain tray (W2) attached to the melter. Residual oil may be in the system from the factory. See FIG. 11. b. Use a 1/4 in. allen wrench to remove the drain port plug (W1). See FIG. 11. NOTE: A 1/4 in. allen wrench is shipped loose with the system. c. When fluid stops draining, re-install drain port plug (W1) then remove rag. See FIG. 11. d. Remove plug (247) from the lowest numbered outlet on the melter. Do not use the drain plug (W1). See FIG. 11. NOTE: In the following step, the o-ring side of the hydraulic fitting (68) faces the system. See FIG. 11. e. Install the supplied hydraulic fitting (68) with an o-ring into the open port and tighten with an 11/16 in. wrench or socket. 20 Install hose onto hydraulic fitting (68) with male electrical connector side toward the system. Use 11/16 in. wrench to tighten hose onto hydraulic fitting (68). Install cap on any unused MZLP electrical connectors. NOTE: Fluid outlet port 1 must be used and electrical connector from that hose must be connected to MZLP connector 1. The system will not operate unless a hose is connected to MZLP connector 1. If a hose is not connected to connector 1, “Invalid Sensor - hose/gun” faults will result. If the melter must be run without a hose/applicator electrically attached to MZLP connector, use Overtemperature Jumper, 16Y727, page 113. 15. Install applicator(s), see FIG. 11: NOTE: Use of a Graco applicator is not required with this system. However, all applicators attached to the system must be rated for 1200 psi (8.3 MPa, 83 bar), 400°F (204°C), have an RTD type sensor, and use no more than 400W at 240 VAC. a. Connect heated hose fluid outlet to applicator fluid inlet. Use 11/16 in. wrench to tighten. See FIG. 11. b. For Graco applicators, attach applicator electrical connector to heated hose electrical connector. See FIG. 11. c. For non-Graco applicators, attach applicator electrical connector to adapter harness 16T916, 16T917, or 16Y828 then attach adapter harness connector to heated hose connector. See Non-Graco Applicator Adapter Cables on page 101 to determine which adapter cable to use with your applicator. 333347F Setup 19. Close the ball valve. d. Repeat for any additional applicators. 16. If necessary, set up the pattern controller (not included) to control opening and closing of the applicator. See pattern controller manual. NOTE: The system controls applicator heating only. A separate pattern controller must be set up to open and close the applicator. WLE 17. Install the supplied air inlet bleeding ball valve and air filter kit (Graco Part No. 24R707) at the 1/4 NPT female system air inlet (J). See FIG. 12. NOTE: Elbows and riser tube provided with inlet air kit are optional and may be used as desired. FIG. 13 20. Attach a 3/8 in. minimum air supply line to air filter. See FIG. 13. J NOTE: Air supply pressure must be between 80 psi (550 kPa, 5.5 bar) and 100 psi (690 kPa, 6.9 bar). Recommended pressure is 100 psi (690 kPa, 6.9 bar). If air pressure is expected to drop below 80 psi (0.5 MPa, 5 bar), there is an air reservoir kit that allows the system to operate down to 60 psi (0.4 MPa, 4 bar). See Air Reservoir Kit, 16W366, on page 107. 21. To lock access to the air pressure adjustments, purchase Air Adjustment Lock, 24R084. See installation instructions on page 101. WLE 22. To install a light tower that illuminates red when a system error occurs, purchase Light Tower Kit, 24R226. See installation instructions on page 106. FIG. 12 NOTE: The system must have a bleed-type ball valve that bleeds pressure downstream when closed. Otherwise, the supplied air will need to be disconnected from the system whenever the pressure is relieved. NOTE: The system must use an air filter with a minimum flow rate of 30 scfm. 18. If using the same air for the applicator(s), make sure to install the tee in the air line before the ball valve. There should not be anything between the ball valve and the system. See applicator manual for applicator air pressure requirements, and use a regulator before the gun to decrease the air pressure, if necessary. 333347F 23. To upgrade a 2 channel system to a 4 channel system, purchase 4 Channel Upgrade Kit, 24V528. See installation instructions on page 108. 24. To upgrade a 4 channel system to a 6 channel system, purchase 6 Channel Upgrade Kit, 24V529. See installation instructions on page 110. 25. Install MZLP electrical connector caps on all unused channels. 21 Setup Recommended Air Setup Main Air Line No dips in vacuum transfer hose Air In: Less than 50 ft (15.2 m): 3/8 in. More than 50 ft (15.2 m): 1/2 in. 80-100 psi (5.5-6.8 bar, 0.55-6.8 MPa) 30 scfm capacity. Air In: 3/8 in., 100 psi (6.8 bar, 0.68 MPa), 30 scfm capacity Ensure funnel air is connected Air Filter/Ball Valve at System Air Inlet (Graco Kit 24R707, included) Vacuum Regulator set to 70 psi (4.8 bar, 0.48 MPa) Pump Vacuum: 40 - 80 psi (2.8-5.5 bar, 0.28-0.55 MPa); and at least 65% of hopper shaker air pressure, if used Pump: 20-100 psi (1.4-6.8 bar, 0.14-0.68 MPa) WLE Air to applicators FIG. 14 22 333347F 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. WL D AF NOTE: The installed strain relief bushing (106) fits a 0.708-1.260 in. (18-32 mm) OD electrical cord. See FIG. 15. If needed, use a wrench to tighten the strain relief bushing until it is snug on the cable. FIG. 15 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 100. 7. Connect L1, L2, L3, and N as shown in FIG. 16. Not all models use all 4 wires. 6. Connect ground wire to chassis ground (AF). See FIG. 15. For 208V Electrical Circuits, see page 24. 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 12. 4. Insert electrical cord through electrical enclosure strain relief bushing (106). See FIG. 15. a. Alternate electrical cord routing: using conduit, run electrical cord from access port (X) through hole (Y). Conduit is required when routing wires near compressed air components. FIG. 16 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 24 prior to turning on heat. 333347F 23 Setup 208V Electrical Circuits NOTE: An incorrect RTD setting will cause the system to be incapable of maintaining the temperature setting. For 208V electrical supply, a qualified electrician can install a 208V to 240V step-up transformer to improve startup times. Transformer Sizing Minimum transformer rating can be calculated by taking transformer output voltage times the ADM breaker setting. Single Phase, 20A ADM Breaker Setting Example: 240 volts x 20 amps = 4800 watts Three Phase, 20A ADM Breaker Setting Example: 240 volts x 20 amps x SQRT(3) = 8315 watts NOTE: The supported RTD types are Ni, 100 ohm; Ni, 120 ohm; NiFe, 604 ohm; Pt, 100 ohm (385), Pt, 100 ohm (392); and Pt, 1000 ohm. An “Auto” selection is available but should only be used when the specific RTD type cannot be identified. Using the “Auto” RTD setting may result in inaccurate temperatures. To prevent fire and explosion, a qualified electrician must determine the proper circuit breaker size to use for the power supplied to the system. 4. On the System 3 screen: Select ADM Settings NOTE: See Appendix A - ADM on page 114 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. a. Enter the main circuit breaker size used. This is the circuit breaker installed external to the system for the system power supply. 3. On the System 2 screen: 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. 24 333347F 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 33. 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 114, for detailed information about each setup item. 333347F 25 Setup NOTE: Alternatively, use the physical up and down 11. On the Targets screen, adjust heated hose and applicator temperature settings: 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 36. 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. Applicator heating is controlled by the system, but the system does not control opening and closing the applicators. Setup a separate pattern controller to open and close the applicators. NOTE: Alternatively, use the physical up and down arrow push-buttons on the ADM keypad until is next to the temperature setting to change then use the numeric keypad to enter the desired temperature. c. Use and , shown next to , to adjust heated hose temperature setting to the desired setting for that channel. 26 333347F 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 11. 5. Remove power from PLC. Customer Input Dropdown Options Option Description Disable Not used. Heater On/Off Turn on or off the heating system and pump. Channel 1, 2, 3, 4, 5, or 6 Enable/Disable Enable or disable hose and applicator heating for that individual channel. 6. Connect the PLC to connectors H1 and H2. NOTE: Each connector has four signals. The MZLP board specifies the input range for each signal. See the following table for pin assignments. J1 J2 F10 F9 F8 F7 F4 F3 F2 F6 Customer Output Dropdown Options Option Description Disable Not used. System Ready Indicates when the system is up to temperature and the pump is stalled at pressure. Error (Alarm) Indicates when there is an active alarm. An active alarm will disable the heating system and pump. Error (Deviation/Advisory) Indicates when there is an active deviation or advisory. An active deviation or advisory will NOT disable the heating system and pump. Maintenance Due Indicates when the maintenance total has reached the preset notification value. NOTE: All outputs are normally open when power is OFF. For Error (Alarm) output, the contacts open when an alarm occurs. For all others, contacts close. F1 F5 J7 J6 J5 J3 WLD FIG. 17: MZLP Board H1 - Customer Input H2 - Customer Output Signal Pin Signal Pin 1 1, 2 1 1, 2 2 3, 4 2 3, 4 3 5, 6 3 5, 6 4 7, 8 4 7, 8 Inputs: High: 10-30 Vdc, Low: 0-5 Vdc. Inputs function without concern for polarity. Applying “high” voltage will turn the heaters on and enable channels. Removing voltage will turn the heaters off and disable channels. Outputs: 0-250 Vac, 0-30 Vdc, 2A Maximum. 333347F 27 Setup PLC Connection Block Diagrams The following block diagrams show how to connect customer inputs and outputs to the InvisiPac MZLP. For convenience, each InvisiPac ships with connector kit 24P176. If a connector is lost or damaged, order kit 24P176 for replacements. MZLP Customer In Customer Output Vin (no polarity) 30 VDC Max FIG. 18: Customer Input MZLP Customer Out Customer In 250 VAC, 0-30 VDC, 2A Max To Customer Input FIG. 19: Customer Output 28 333347F 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 114 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: All setup procedures must be completed prior to initial startup. See Setup on page 17. NOTE: Only 1/4 in. (6 mm) round hot melt adhesive pellets can be used in the InvisiPac system. PSA-type adhesive pellets will not work in the InvisiPac system. 1. Direct the applicator into an appropriate waste container. NOTE: See Appendix B - USB Downloading, Uploading on page 120 for detailed USB information. 2. Verify the shaker inlet is at the bottom of the empty adhesive pellets container. Optional vibrating adhesive pellets container, part 24R136, is available. See Accessories on page 100. Overview NOTE: The shaker inlet must be completely covered in adhesive pellets to effectively pull pellets into the tube. 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. 3. Fill adhesive pellets container with hot melt adhesive pellets. 4. Turn main power switch ON . 5. Open system air inlet ball valve. Even though the system rises to operating temperature quickly, there is a Schedule function in the ADM that eliminates waiting for the system to heat up. The Schedule function automatically enables the heating system at the user-specified times so the system is ready to dispense when a shift begins. The Schedule function also disables the heating system at user-specified times to ensure the heating system is disabled when not being used. 333347F WLE 29 Operation 6. Use pump air pressure regulator (C) to adjust pump air pressure to 0. 10. On new systems only: After the melter has reached 250°F (121°C) and the funnel is filled with pellets, set the melter temperature back to the desired operating temperature. See Select ADM Settings on page 24 for instructions. 11. Use separate pattern controller to open the applicators and keep them open. NOTICE E C FIG. 20 7. Use vacuum transfer air pressure regulator (E) to adjust vacuum transfer air pressure setting to 40-100 psi (280-690 kPa, 2.8-6.9 bar). Recommended setting is 60 psi (414 kPa, 4.1 bar). See FIG. 20. NOTE: If using shaker accessory, regulator should be set to at least 65% of air pressure connected to shaker. 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. 12. With the applicators open and the system up to temperature, slowly increase pump air pressure until the pump begins to run very slowly. Approximately 20 psi (140 kPa, 1.4 bar) should be sufficient. NOTE: Operation may be erratic below 20 psi (140 kPa, 1.4 bar). 13. Continue running the pump until clean, air-free material is dispensed from each applicator. 14. When each applicator is fully primed, adjust pump to desired pressure setting: To prevent fire and explosion, never exceed the cleaning fluid’s rated temperature. If the system was just flushed, residual cleaning fluid is still in the system until the system is primed with adhesive. Do not raise temperature above cleaning fluid rated temperature until system is primed with adhesive. NOTE: A new system may have residual oil due to testing at the factory prior to shipping. To prevent smoking, make sure to perform the following step. 8. On new systems only: temporarily adjust the melter temperature to 250°F (121°C). See Select ADM Settings on page 24 for instructions. 9. Press to enable the heaters and pump. NOTE: When system is up to temperature, the pump will be activated automatically, but will not start because there is no air pressure supplied to the pump. a. Adjust pump pressure to between 20-100 psi (140-690 kPa, 1.4-6.9 bar). b. Use separate pattern controller to repeatedly open and close each applicator while inspecting the dispense pattern. c. Repeat until desired dispense pattern is achieved. Manual Refill NOTE: Use Automatic Refill whenever possible. The system uses Automatic Refill by default and must be manually changed to Manual Refill. Only use Manual Refill if the Automatic Refill system is not functioning properly and cannot be fixed in a timely manner. Perform service to automatic feed system as soon as possible to limit debris buildup on feed funnel. NOTE: When the melter is up to temperature, the auto-fill function will initiate to fill the funnel with pellets. 30 333347F Operation It is recommended to maintain a minimum flow rate of 1.5 lb/hour to prevent material from melting within the feed cap and funnel. If production rate is below 1.5 lb/hour or system sits at temperature without dispensing for extended periods of time, use manual refilling with caution. System flow rate can be monitored by enabling the Diagnostic screen. 1. On the System 3 screen (in the Setup screens), select “Manual” from the Refill mode dropdown. 5. Refill the funnel as needed to maintain the required dispense rate. 6. When finished dispensing for the day, dispense into a waste container until the material level is down to the melter core. See FIG. 23. NOTE: This will lower the adhesive level within the funnel cap to the correct level to prevent any issues upon startup the following production day. 2. Remove the two bolts from the funnel bracket, then remove the top portion of the funnel. WL D FIG. 23 Automatic Refill The system uses automatic refill by default. If the automatic refill system is malfunctioning and cannot immediately be fixed, Manual Refill can be used. WL D FIG. 21 To use automatic refill: 1. On the System 3 screen (in the Setup screens), select “Automatic” from the Refill mode dropdown. 3. Disconnect the sensor cable and sensor cooling air. 4. Fill the funnel with adhesive pellets. 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 11. NOTE: The shaker inlet must be completely covered in adhesive pellets in order for it to effectively pull pellets into the tube. WL D FIG. 22 333347F 31 Operation 4. If not already set, use vacuum transfer air pressure regulator (E) to adjust vacuum transfer air pressure setting to 40-100 psi (280-690 kPa, 2.8-6.9 bar). Recommended setting is 60 psi (414 kPa, 4.1 bar). e. Verify applicators are closed. 4. Press to enable the heaters and pump. NOTE: If using the Schedule function, the heaters and pump will be enabled automatically at the set time. You will not need to press if using the Schedule func- tion unless you wish to enable the heating system before the set time. E FIG. 24 NOTE: The system will automatically transfer the pellets to the system as necessary. Dispense NOTE: When system is up to temperature, the pump will begin running automatically. It will stall at pressure unless an applicator is open. Material will be dispensed whenever an applicator is open after the system is up to temperature. 5. When the system is up to temperature, use separate pattern controller to open and close the applicators as desired to dispense material. NOTE: While operating the system, the actual temperatures of the hose, applicator, and system melter are displayed on the Home screen. NOTE: Only hot melt adhesive pellets can be used in the InvisiPac system. 1. If the system is empty or has air in the lines, perform Initial Startup and Prime procedure on page 29. 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 11. b. Check pressure gauges (D, F) to verify vacuum transfer and pump air pressures are set as desired. See FIG. 1 on page 11. c. If using Automatic Refill, see Automatic Refill on page 31. d. If using Manual Refill, see Manual Refill on page 30. 32 333347F Operation Shutdown Enable Schedule Function Press The Schedule function is automatically enabled when values are entered in the Schedule screen. To disable a to disable the heaters and pump. The screen will say “Inactive”. If using the Schedule function, the heaters and pump will be disabled automatically at the set time. You will not need to press if using the Schedule function unless you wish to disable the heating system before the set time. If the heaters were manually disabled, the Schedule function will automatically enable them at the next set time. scheduled event, navigate to the event and press The event will appear gray on the screen when it is disabled. To re-enable an event, navigate to the event and press . The event will appear red (system off) or green (system on). If no events are needed, turn the main power switch OFF to prevent system from automatically enabling and disabling the heaters. How to Use the Schedule Function At the end of the work day leave main power switch ON . The Schedule function will automatically enable and disable the heaters and pump at the specified times. Do not turn the main power switch OFF if using the Schedule function. Schedule The Schedule function allows the user to specify times when the system will automatically turn ON and OFF the heaters and pump. Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. 1. Turn main power switch OFF . 2. Close the inlet air supply ball valve. Set Schedule Times NOTE: Times are set using a 24-hour clock. Several on and off times can be set each day. NOTE: Manually verify the pressure is relieved by opening the applicator and ensuring no adhesive is dispensed. 1. On the Schedule screen (in the Setup screens), set the ON times for each day of the week. 2. Set the OFF times for each day of the week. 333347F 33 Operation Drain the System 12. Wait until system stops draining or at most 10 minutes. NOTE: There will be some residual adhesive in the system. NOTE: The system must be drained prior to flushing and prior to some maintenance and repair procedures. 1. On the System 3 screen (in the Setup screens), change the Refill Setting to “Manual”. 13. When done performing the procedure that required draining the system, set Refill Setting back to “Auto” on the System 3 screen. Flush To prevent fire and explosion, use the adhesive manufacturer’s recommended cleaning fluid. • Never exceed the cleaning fluid’s rated temperature. 2. If the heating system is disabled, press to enable the heaters and pump. 3. Decrease pump air pressure to 0. • 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. 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. 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 34. 6. Open applicator to allow residual fluid in applicator to drain. 7. When system is at operating temperature, slowly increase pump air pressure until fluid begins flowing into the waste container. NOTE: It may take several minutes to empty the system. When there is no melter fluid at the pump, the pump will begin to cycle faster. 8. When the pump begins to cycle faster, close the system air inlet ball valve. 9. Press 2. If the heating system is enabled, press to dis- able the heaters and pump. 3. Loosen hose clamp securing funnel assembly to air motor bracket then remove funnel assembly from system. Keep 1.3 in. (33 mm) clear tube and funnel cap attached to funnel. 4. Loosen clamp then remove plastic melter cap. Keep fill sensor attached to cap. to disable the heaters and pump. 10. Remove melter drain plug (W1). See FIG. 2 on page 12. 11. Disconnect hose from melter outlet. 34 333347F 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 37. WLD 22. Turn main power switch OFF. 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. 333347F 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 12. 24. Allow the system and fluid to cool then perform any required maintenance procedures beginning on page 37. 35 Operation 25. Install fill cap onto melter rubber housing. 26. Slide funnel assembly through air motor bracket then tighten clamp. 27. On the System 3 screen (in the Setup screens), set the Refill Setting to “Auto”. Operation Tips to Minimize Charring Set the Pump Idle Time to System Inactive function on the System 3 screen to lowest value that will not interfere with normal operation. This feature automatically disables the heating system if the pump is idle for longer than the preset amount of time. Disabling the heating system minimizes adhesive degradation and limits char formation. When possible, utilize the Schedule function, see page 33, to automatically enable and disable the heating system in accordance with your production schedule. This will ensure adhesive spends as little time at temperature as possible. Less time at high temperature ultimately means less adhesive degradation and less char. To prevent fire and explosion, never exceed the cleaning fluid’s rated temperature. Residual cleaning fluid is still in the system until the system is primed with adhesive. 28. Perform Initial Startup and Prime on page 29. 36 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. 333347F 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 WL D FIG. 25 1. If the system is not up to temperature, press to enable the heaters and pump then wait for system to reach operating temperature. To avoid severe burns, wear protective gloves and clothing that will insulate your hands and body from the hot surfaces and material. 2. Perform Pressure Relief Procedure, page 33 but do not allow system to cool. Adhesive must be a fluid to perform this procedure. 3. Turn main power switch OFF. 4. Loosen two screws (8) then slide the small metal shroud (28) on the back of the system up to remove. See FIG. 25. 5. Use a 1 in. socket to unscrew outlet filter (236). 333347F NOTE: Some adhesives have different melting points. The first temperature tried should be approximately half of the dispensing temperature. If dispensing at 400°F (204°C), first try 200°F (93°C) then increase in 20°F (11°C) increments. If dispensing at 250°F (121°C), first try 125°F (52°C) then increase in 20°F (11°C) increments. NOTE: To ensure the adhesive is a gel, not a liquid, do not remove inlet filter cap (215) when the temperature is above the desired temperature. If the temperature is too low, the adhesive viscosity may be too high to remove the inlet filter (213). See FIG. 26, page 38. 2. If the melter is below the desired temperature and heating system is disabled, press to enable the heaters. If the melter is above the desired temperature and heating system is enabled, press to disable the heaters. 3. Wait until melter temperature is the desired temperature. 37 Maintenance 4. When the melter temperature is the desired temperature, turn main power switch OFF. 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 WL D WL D FIG. 26 8. If the adhesive is a thin enough gel to remove the inlet filter: Use an o-ring pick or small allen wrench to remove filter screen (213) from system. Otherwise: FIG. 27 Disassembly (see FIG. 27): 1. Turn main power switch OFF. a. Install inlet filter cap (215). 2. Rotate funnel cap (706) and remove. Lift out funnel filter (705). b. Install shroud and ADM. Reassembly (see FIG. 27): c. 1. Insert filter (705) in funnel assembly. Tighten funnel cap (706) on funnel. Turn main power switch ON. d. Once ADM software finishes starting up, press to enable the heaters. e. Wait for temperature to rise 20°F (11°C) beyond previous temperature. f. 38 Go to step 4. 333347F Maintenance Filter Maintenance Guidelines* Environmental Classification Clean Pump inlet filter Pump outlet filter Applicator manifold filter System air filter Solenoid exhaust filters Feed funnel filter Feed funnel inspection/cleanout Moderate Dusty Replace filter Replace filter Replace filter every six every four every two months months months * These recommendations are service level guidelines - actual service levels required in your factory will vary based on environmental and operating conditions. High or low volume adhesive usage, as well as adhesives that contain a powdered release agent or are otherwise dusty, will have an impact on the frequency of filter maintenance. To establish a preventative maintenance cycle tailored to your environment, Graco recommends inspecting filters every 4 weeks after installation and replacing when necessary. Document replacement intervals and use this as your preventative maintenance schedule moving forward. 333347F 39 Troubleshooting Troubleshooting To avoid injury due to unexpected machine operation initiated by a remote controller, disconnect the customer I/O cable from the system prior to troubleshooting. ADM Error Code Table When an error occurs, press nance screen and press to acknowledge the error. If a Maintenance error occurs, navigate to the Mainteto clear the error. The last digit of the error code indicates the melter, applicator (gun), or hose to which the error applies. The “_” (underscore) character indicates the code applies to multiple items. Last Digit in Code Code Relates to: 0 Melter 1 Applicator (Gun) 1 2 Hose 1 3 Applicator (Gun) 2 4 Hose 2 5 Applicator (Gun) 3 6 Hose 3 7 Applicator (Gun) 4 8 Hose 4 9 Applicator (Gun) 5 A Hose 5 B Applicator (Gun) 6 C Hose 6 An alarm will disable the heating system and pump. A deviation or advisory will not disable the heating system and pump. Code 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 Advisory Hose current is less than 500mA. 40 Solution Faulty melter heater(s). Check heater resistance and resistance to ground. Replace faulty heater(s). Faulty applicator heater. Verify applicator heater has a minimum wattage of 90 Watts at 240 VAC. Check heater resistance and resistance to ground. Replace faulty heater. Faulty hose heater. Check heater resistance and resistance to ground. Replace faulty hose. 333347F Troubleshooting Code A3MF A4D0 A4D_ A4D_ A7D0 Description High Fan Current, Transformer High Current Melter High Current Hose X High Current Gun X Unexpected Current Type Deviation Cause Transformer fan is greater than 600mA. Solution Replace transformer fan. Alarm Defective or shorted to ground on the band heater or rod heater. Defective or shorted to ground on the hose power wires. Defective or shorted to ground on the heater rods in applicator manifold. Unexpected current flow to melter. Measure resistance to ground between heater leads. Should be a high reading. Replace heated hose. Alarm Alarm Alarm 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. 333347F Replace applicator manifold. Faulty melter heater(s). Check heater resistance and resistance to ground. Replace faulty heater(s). See Replace Heater Rod, page 64. Replace MZLP. Faulty applicator heater element. Check heater resistance and resistance to ground. Faulty MZLP. Replace MZLP. Faulty hose heat element. Check heater resistance and resistance to ground. Faulty MZLP. 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. 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. 41 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. 42 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 77. Bad connection between daughter board and MZLP board. Loosen daughter board, re-seat, then secure. Daughter board is not plugged into MZLP1. Plug daughter board into MZLP with dial set to 1. Defective MZLP daughter board. Replace. 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 78. Loose cycle switch bolt. Tighten cycle switch bolt. Defective cycle switch. Replace. Change to auto fill mode. See Setup Screen System 2. Check that sensor cable is plugged into sensor. Check connector at J14 of the daughter board. Verify there is nothing blocking fill (level) sensor line of sight. Defective fill (level) sensor. Replace. Check for air coming from 5/32 in. air line. Remove fill cap and remove object plugging the orifice. 333347F 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 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 120. 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. 333347F Faulty melter heater(s). Check heater resistance and resistance to ground. Replace faulty heater(s). With the system on and not dispensing verify that the temperature is properly controlled to the setpoint. If system cannot control temperature, replace applicator RTD. See applicator manual. Faulty applicator heater. Check heater resistance and resistance to ground. Replace faulty heater. Dispense rate too high for applicator to maintain setpoint. Consider applicator power and voltage. With the system on and not dispensing verify that the temperature is properly controlled to the setpoint. If system cannot control temperature, replace hose. Faulty hose heater. Check heater resistance and resistance to ground. Replace faulty hose. Ambient temperature must be under 120°F. Defective MZLP board. Replace. 43 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. Defective RTD. Replace melter RTD. See Replace Band Heater Temperature Sensor, page 63. No reading from RTD. Hose electrical connector not plugged into MZLP. Defective RTD. Replace hose. No reading from RTD. Hose electrical connector not plugged into MZLP or applicator electrical connector not plugged into heated hose. Defective RTD. 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. Defective heater rods in applicator manifold. Replace applicator manifold. NOTE: Defective heaters rods in the applicator manifold can also cause the no current error. Heated hose electrical connector or wires are defective. Check resistance of hose wiring. See hose manual for proper resistance range. 44 333347F 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. Defective heater wires in hose. Replace heated hose. NOTE: Defective heaters wires in the hose can also cause the no current error. Heated hose electrical connector or wires are defective. Check resistance of hose wiring. See hose manual for proper resistance range. Temperature reading does not change. Check fuses F1 and F2 on MZLP with daughter board. Defective heater wires in melter. Replace melter. 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 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. V4MW V6MW Alarm V8M_ No line voltage Alarm 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. Bad ADM. 333347F NOTE: Defective heaters wires in the melter can also cause the no current error. Defective heater element(s). Check heater resistance and compare to reference table. See Check Heater Rod Resistance, page 54. Check J1 is properly plugged into the MZLP with daughter board and in J3 on AWB. Check that RTD is installed in the melter. Verify power supply voltage is 24 VDC. If voltage is low, disconnect the screw terminals +V and -V on the power supply and re-check voltage reading. If voltage is correct, then disconnect J8 and J9 from AWB and re-check voltage. If still low replace AWB. If correct, plug in J9 and recheck voltage. If low, replace ADM. If correct, plug in J8. If low, replace MZLP. If voltage is still low, replace power supply. 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. Defective air manifold, replace manifold. Check connector at J13 of the daughter board. Defective air solenoids. Replace. See page 72. System is not properly loaded with correct software. Perform Software Update Procedure on page 77. Retry USB download. Replace ADM. 45 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 30. Check funnel filter. If plugged, see Replace Funnel Filter on page 38. The InvisiPac system takes a long time to refill adhesive. Glue level in hopper is low. Check hopper for adequate material and material blocking. Vacuum flow is restricted. Verify the vacuum transfer system air pressure is 40-80 psi (60 psi recommended) and that air is flowing to the feed wand while attempting to refill. Check funnel filter. If plugged, see Replace Funnel Filter on page 38. Vacuum transfer not working Air to vacuum assembly missing. Verify the vacuum transfer system air pressure is 40-80 psi (60 psi recommended) Air at system air gauge but not to air to shaker. Check that air line is connected or not pinched. Air is at shaker but there is no feed. Plugged shaker unit, remove from system and remove plug. Adhesive pellets in storage bin not covering shaker head. Shaker unit not vibrating. Verify shaker is vibrating during material loading. If not, the ball in the shaker assembly is stuck. Remove shaker housing and separate to clean raceway and ball inside. Materials are blocking in the hopper. Some adhesive materials are prone to blocking. High ambient temperature and high humidity can increase the likelihood of blocking. Some materials may require agitation periodically to breakup bridging. Purchase and install 30 Gallon Vibrating Hopper, 24R136. See page 104. Fill Solenoid Error Failure of the fill solenoid or fill solenoid wiring. Verify wiring between J13 and the refill solenoid is not damaged. 46 Restart system. If the error persists after attempting another refill and unit is needed immediately for production, place system into the manual refill mode. See Manual Refill on page 30. 333347F 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 30. 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 38. 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 54. 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 83 for part identification. Cycle Switch Error 333347F 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 54. 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. 47 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 120. The InvisiPac system is displaying pump runaway or pump diving. This can occur if the melt rate for the system is exceeded, resulting in This error generally air entrapment within the incoming adhesive material and lower than occurs when the pump desired material temperature. cavitates due to 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 33. 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). 48 333347F 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 333347F Main power circuit breaker off or power cord unplugged. Turn main circuit breaker on or plug in power cord. Cable on ADM unplugged. Reconnect ADM cable. Connector on AWB board not plugged in. ADM cable should be plugged into J9 of the AWB board. Bad 24VDC power supply. Check output on power supply should measure 24VDC, if no voltage reading replace power supply. ADM defective. Replace ADM. Wrong setting in ADM breaker setup. Wrong breaker setting on ADM in the breaker setting in the setup screen. Internal short to ground in system. Unplug or disconnect power and measure between each leg of the power to ground. There should be an open resistance reading. Too small of a circuit breaker in main power panel. Consult qualified electrician for proper size circuit breaker. 49 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 defective. Melter and gun manifold. Measure and check heater rods in melter or applicator. See applicator manual. See Check Heater Rod Resistance, page 54. Heated hose defective. Measure heater wires in hose, pins C and D. See repair section for each hose resistance. Insufficient power supplied to system. Depending on hose and 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 125, 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 50 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. 333347F 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. Defective solenoid valve. Check that correct voltage is input into solenoid valve. If voltage is correct, replace solenoid. No signal from control to solenoid. If no voltage is present at solenoid, check control cable and pattern controller. Replace component. Solenoid mufflers plugged. Replace solenoid mufflers. No air to air solenoid. Re-establish air supply to solenoid. Plugged system outlet filter. Replace Outlet Filter. See page 37. If multiple 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. Defective dispense module in closed/partial open position. Replace dispense module. Plugged applicator manifold filter (single dispense module applicator). Replace applicator manifold filter. Graco applicator manifold filter in bottom of manifold or inline filter on other manifolds. Clogged hose Flush or replace hose. Defective solenoid valve Check that correct voltage is input into solenoid valve. If voltage is correct, replace solenoid. No signal from control to solenoid If no voltage is present at solenoid, check control cable and pattern controller. Replace component. Plugged solenoid mufflers Replace solenoid mufflers. No air to solenoid Re-establish air supply to solenoid. Plugged system outlet filter. Replace Outlet Filter. See page 37. 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 333347F 51 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. Applicator will not heat. 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. Adhesive leaking from manifold or dispense module. No melter heat. Air motor will not function. System not turning on. 52 Check that power plug is connected. 333347F 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. 333347F 53 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. 28 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 43.5-48.5 2000 27-31 Heater 500 109-121 1500 36.5-40.5 209 Melter Rod 54-61 210 Base Rod 1500 36.5-40.5 1000 54-61 210 Pump Rod 1500 36.5-40.5 1000 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. 54 333347F Troubleshooting Red Yellow Green MZLP Troubleshooting 7 89 56 J3 234 01 MZLP ti20348a FIG. 30: MZLP Diagnostic LED Location WLD FIG. 29: MZLP LED Signals NOTE: The MZLP LED is located on the inside of the electrical enclosure. To view, remove the electrical enclosure front access door. Signal Description Green On MZLP is powered up and input voltage is within operating conditions. Yellow On Internal communication in process Red Solid MZLP failure. See troubleshooting table. Red Flashing Software update in process or missing software. 333347F 55 Repair Repair NOTE: Some procedures require special tools. Read through each procedure prior to beginning it to ensure you have the required tools to complete the entire procedure. Order any required tools and have them on hand prior to beginning the procedure. NOTICE Disassembly (see FIG. 31): 1. Flush the system. See page 34. 2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system. 3. Turn main power switch OFF. When performing any procedure that requires removal of seals or other soft parts, do not leave a system that has not been flushed disassembled for more than 30 minutes to prevent the adhesive from hardening. Hardened adhesive will damage the seals and other soft parts during installation. 4. Remove plastic shroud (27). 5. Remove vacuum transfer inlet funnel. 6. Remove air lines from relief valve (245) and air motor (218). 7. Remove four nuts (3) securing melter shield (27) in place then remove melter shield. Pump Replace Throat Seal, Throat Bearing, Piston Rod, Piston Seal, and Piston Bearing 8. Remove air motor assembly: a. Remove retaining ring (239). b. Remove dowel pin (238). c. Remove three screws (240). 218 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. 31): 1. Assemble piston rod: a. Install new piston u-cup (225) onto piston rod (223) with the lips facing the rod. FIG. 31 56 WLD b. Install piston bearing (226) onto piston rod (223) with grooved end towards the center of the piston rod. 333347F Repair c. Install piston valve (222) onto piston rod (223). Torque to 24-30 ft-lb (33-41 N•m). 2. To protect the seals from the sharp threads, place seal installation tool 15B661 into the throat bore. See FIG. 32. 6. Slide throat bearing (233) over the piston rod (223). Use socket and tap with a rubber mallet to press throat bearing (233) into place and seat the throat u-cup. 235 15B661 203 233 ti20877a FIG. 32 3. Push the piston rod assembly (223) into the melter outlet manifold (203). 4. Grease the throat u-cup (234) and slide the u-cup over the piston rod (223) with the lips facing down. 5. Place a 7/8 in. deep-well socket (3/8 in. drive) over the piston rod (223) then use a rubber mallet to gently tap throat u-cup (234) into place. See FIG. 33. ti21144a FIG. 34 7. Remove seal installation tool. 8. Install retaining nut (235). See FIG. 32. 9. Install air motor assembly (see FIG. 31): a. Install three screws (240). b. With retaining ring around piston rod, install dowel pin (238). c. Install retaining ring (239) over dowel pin. 10. Use nuts (3) to install melter shield (27). 11. Connect air lines to relief valve and air motor. 12. Install plastic shroud (27). 234 ti21047a FIG. 33 333347F 57 Repair Replace Pump Inlet Housing Checks without a socket to install and tighten foot valve (230) onto melter. 2. Apply anaerobic thread sealant on threads of four bolts (246) and connect pump to melter outlet. Torque to 12-18 ft-lb (16-24 N•m). Replace Pump Cylinder Seals and Piston Seals 203 218 246 235 227 228 233 229 231 233 230 224 226 222 234 WLD 239 FIG. 35 Disassembly (see FIG. 35): 203 1. Flush the system. See page 34. 2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system. 217 216 3. Turn main power switch OFF. 4. Remove four bolts (246) and pump manifold (203) from melter outlet. 217 230 WLD FIG. 36 5. Use a 1/2 in. drive ratchet without a socket to remove foot valve (230) from bottom of melter outlet manifold (203). Disassembly (see FIG. 31): 6. Remove and discard seat (228), ball (227), o-ring (229), and o-ring (231). 2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system. Reassembly (see FIG. 35): 3. Turn main power switch OFF. 1. Install new o-ring (231), o-ring (229), seat (228), and ball (227) then use a 1/2 in. drive ratchet 4. Remove plastic shroud (27). See FIG. 31 on page 56. 58 1. Flush the system. See page 34. 333347F Repair 5. Remove air lines from relief valve (245) and air motor (218) See FIG. 31 on page 56. 14. Remove and discard cylinder seals (217). See FIG. 37. 6. Remove nuts (3) securing melter shield (27) in place then remove melter shield. See FIG. 31 on page 56. Reassembly: 1. Apply grease to seals (217) then install new cylinder seals (217) onto cylinder (216). See FIG. 37. 7. Remove air motor assembly. See FIG. 31 on page 56: a. Remove retaining ring (239). 1303 b. Remove dowel pin (238). c. 217 Remove three screws (240). 216 8. Use a flat head screwdriver and a rubber mallet to break loose the retaining nut (235). 217 1302 9. Use channel lock pliers to remove the retaining nut (235). 203 10. Insert an allen wrench through the hole in the top of the piston rod (223) to lift the piston rod (223) up out of the manifold. This will also pull out the throat u-cup (234) and throat bearing (233). 11. Replace Pump Inlet Housing Checks. See page 58. 12. Use a 1/2 in. drive ratchet without a socket to remove foot valve (230) from bottom of melter outlet manifold (203). See FIG. 36, page 58. 13. Insert cylinder tool (1301) into bottom of melter outlet manifold (203). Use a rubber mallet to gently remove cylinder (216). ti21049a FIG. 38 2. Place female cylinder installation tool (1302) into melter outlet manifold (203) to protect seals from sharp threads. See FIG. 38. 3. Use male cylinder installation tool (1303) to press cylinder (216) into melter outlet manifold (203). If necessary, use rubber mallet tap into place. See FIG. 38. 4. Use a 1/2 in. drive ratchet without a socket to install and tighten foot valve (230) into bottom of melter outlet manifold (203). See FIG. 36, page 58. 1301 5. Perform Replace Pump Inlet Housing Checks on page 58. 203 6. Perform Reassembly portion of the Replace Throat Seal, Throat Bearing, Piston Rod, Piston Seal, and Piston Bearing procedure which starts on page 56. 217 216 217 ti20880a FIG. 37 333347F 59 Repair Melter 6. Remove screws (8) then remove electrical enclosure front access door (10). Remove Melter Assembly 7. Disconnect heater rod wires from J4 connector on AWB board. 8. Remove the air tube (36) from the relief valve (245). Pull the air tube from the metal shroud (27). FF 9. Remove nuts (3) on the back metal shroud (27) then remove shroud. 10. Remove fabric melter insulator (53). 30 81 11. Loosen screw (AA) then remove sensor (125). See FIG. 42, page 63. 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 69. 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. 41 on page 62. 1 3 27 36 19. Disconnect ground screw (87) and ring terminal (88) from melter assembly. FIG. 39 NOTE: This only needs to be done when replacing items that require access to the bottom of the melter assembly. 1. Perform Drain the System procedure on page 34 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. 40 20. Remove electrical enclosure front access door (10). 4. Disconnect all heated hoses from the melter outlet manifold. 5. Remove cable from ADM (30) then slide forward the shroud (29) and remove it from the system. 60 333347F Repair 21. Remove all heater wires from the following terminals. Pull wires up through the rubber grommet on the top of the electrical enclosure (1). 5. Group the 4 sets of heater wires together and run them through the grommet on the top of the electrical enclosure (1). Connect wires as noted below. Item Wire Marking Wire Marking 1 2 Item Wire Marking Wire Marking 1 2 Band Heater (208) J4-1 J4-2 Band Heater (208) J4-1 J4-2 Melter Heater Rod (209) J4-5 J4-6 Melter Heater Rod (209) J4-5 J4-6 Base Heater Rod (210) J4-7 J4-8 Base Heater Rod (210) J4-7 J4-8 Pump Heater Rod (210) J4-3 J4-4 Pump Heater Rod (210) J4-3 J4-4 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. 41 on page 62. 11. Install insulators (53,75) onto the melter assembly (5). 12. Connect ground wire ring terminal (87) and ground screw (88) to melter assembly (5). 13. Connect wire connectors to the over-temperature switch (251). See FIG. 43 on page 64. 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. 333347F 61 Repair Replace Band Heater 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. 41): 53 208 1. Install band heater (208) on the melter with the opening and screw facing the front of the system in alignment with the sensor port. 2. Install sensor (125). 3. Slide band heater up then tighten screw (AA). NOTE: Band heater should be oriented to hold sensor in place when tightened. It should not bend the sensor. AA 125 4. Route band heater wires through grommet (63) in the top of the electrical enclosure (1). 5. Connect wires to AWB board as marked. Wires should be marked as shown in the following table. 1 63 10 WLD FIG. 41 Disassembly (see FIG. 41): 1. Once the fluid level is low enough, close the bleed-type ball valve installed at the system air inlet. 2. Turn main power switch OFF. 3. Disconnect cable from ADM (30) then remove shroud (29). 4. Remove front access door (10) from electrical enclosure (1). Item Wire Marking 1 Wire Marking 2 Band Heater (208) J4-1 J4-2 6. Install electrical enclosure access door (10). See FIG. 41. 7. Use clamp (80) and screws (8) to install funnel assembly (F) on melter assembly. 8. Install fabric melter insulator (53). 9. Feed ADM cable through shroud then install shroud and connect cable to ADM. 10. Open system air inlet ball valve. 11. Turn main power switch ON. 5. Remove fabric melter insulators (53). 6. Loosen clamp (80) and then remove screws (8) and funnel assembly (F). 7. Loosen screw (AA) then remove sensor (125). 62 333347F Repair Reassembly (see FIG. 42): Replace Band Heater Temperature Sensor 1. Route new harness wires through grommet (63) in the top of the electrical enclosure. 2. Connect wire connectors to over-temperature switch (251). See FIG. 43 on page 64. 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. 42 Disassembly (see FIG. 42): 1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system. 6. Install electrical enclosure access door (10). See FIG. 41 on page 62. 7. Install fabric melter insulator (53). 8. Use nuts (3) to install metal shroud (27). See FIG. 39, page 60. 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. 39, page 60. 6. Remove fabric melter insulator (53). 7. Loosen screw (AA) then remove sensor (125). 8. Remove electrical enclosure access door (10). 9. Disconnect the temperature sensor cable from MZLP connector labeled J5. See FIG. 42. NOTE: This connector also includes the over-temperature switch wires. 10. Disconnect wire connectors from over-temperature switch (251). See FIG. 43 on page 64. 11. Pull cable out of the electrical enclosure then discard sensor (125) and wires. 333347F 63 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 FIG. 43 210 Disassembly (see FIG. 43): 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. 45, page 65. 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. Re-assembly (see FIG. 43): 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. 64 FIG. 44 Disassembly (see FIG. 44): 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 60. 3. Disconnect cable from ADM then remove shroud (29). 333347F Repair 4. If removing the pump heater rod (210): a. Remove the air tube (36) from the relief valve (245). Pull the air tube through the metal shroud (27). b. Remove nuts (3) then remove shroud (27). 5. If replacing pump heater rod (210), 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. 5. Remove electrical enclosure front access door (10). See FIG. 41, page 62. b. Install and tighten nuts (3). 6. Disconnect heater rod wires from terminal blocks described in the following table. c. 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 (210) J4-4 J4-3 Pull the air tube through the metal shroud (27) then connect the air tube (36) to the relief valve (245). 7. Feed ADM cable through plastic shroud then install plastic shroud and connect cable to ADM. Replace Fluid Pressure Relief Valve 27 7. Pull heater rod wires up through the grommet in the top of the electrical enclosure (1). 3 8. Remove heater rod retaining ring (206) then remove and discard heater rod (209, 210). Reassembly (see FIG. 44): 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. 36 244 245 NOTICE To prevent damaging the heater rod, do not use thermal grease in the following step. ti20757a FIG. 45 2. Install heater rod then install heater rod retaining ring (206). See FIG. 44. 3. Install electrical enclosure access door (10). See FIG. 41, page 62. 4. If replacing the melter heater rod (209), Install Melter Assembly. See page 60. 1. Drain the System. See page 34. 2. Close the system air inlet ball valve. 3. Turn main power switch OFF. 4. Remove the air tube (36) from the relief valve (245). Pull the air tube through the metal shroud (27). See FIG. 45. 5. Remove nuts (3) then remove shroud (27). 333347F 65 Repair 6. Use crescent wrench to remove melter fluid pressure relief valve (245). See FIG. 45. 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. 45. 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. 66 333347F 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 Blue 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 F4 F3 F2 F6 F1 A F5 B J7 J6 3. Use a proper non-conductive fuse puller tool to remove the blown fuse. NOTE: F3-F10 are clear glass and indicate 8A on the barrel. 4. Use a proper non-conductive fuse puller tool to install the new fuse. NOTICE J5 Using an improper tool, such as screw drivers or pliers may break glass on fuse. J3 WLD FIG. 46: MZLP ID and Fuse Locations 5. Install electrical enclosure front access door (10). NOTICE To prevent system damage, always use fast acting fuses. Fast acting fuses are required for short-circuit protection. 333347F 67 Repair Replace MZLP 2. Apply channel label stickers to new MZLP. See FIG. 47. 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. 47. 5. Remove four screws (114) securing MZLP (112) to electrical enclosure (1) then carefully remove MZLP from electrical enclosure. 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. NOTE: If unable to determine connector location, see Electrical Schematics on page 78. 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 77. Replace MZLP Daughter Card MZLP #1 Disassembly: MZLP #3 112 114 MZLP #2 FIG. 47 6. Replace MZLP. See FIG. 47 for MZLP #1, MZLP #2, and MZLP #3 identification. a. To replace MZLP #1, remove the daughter card and standoffs, and re-install them on the new MZLP #1. b. To replace MZLP #3, remove the jumper (135) from MZLP #3 J5 connector and reinstall it on the new MZLP #3 J5 connector. Reassembly: 1. Set MZLP rotary switch to “1” on MZLP with daughter card. Set MZLP rotary switch to “2” or “3” on MZLP without daughter card, based on location. See FIG. 48 for rotary switch location. 68 1. Turn main power switch OFF. 2. Remove electrical enclosure front access door (10). 3. Note location of each cable then unplug all cables from MZLP daughter card (112a). 4. Remove four mounting screws (112b) from daughter card (112a) and set aside. 112b 112a ti20342a 112 Rotary Switch FIG. 48 5. Unplug daughter card (112a) from the MZLP #1 (112). 333347F Repair Reassembly: 1. Plug new daughter card (112a) into the MZLP (112). 2. Use screws (112b) to secure daughter card to MZLP (112). 3. Connect cables to new daughter card (112a). NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation. NOTE: If unable to determine connector location, see Electrical Schematics on page 78. 3. Gently pull up on cable while unscrewing fill sensor connector then remove fill sensor cable from fill sensor (20). 4. Loosen fill sensor jam nut then remove fill sensor (20) from sensor housing (73). Reassembly (see FIG. 49): 1. Thread new fill sensor (20) into sensor housing (73). Bottom out the sensor in the sensor housing then back out 1/2 turn. 2. Tighten jam nut on fill sensor (20). 3. Connect fill sensor cable to new fill sensor (20). 4. 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. 50 1. Turn main power switch OFF. 73 2. Disconnect cable (CC) from bottom of ADM (30). See FIG. 50. 3. Remove ADM from bracket (58). 4. Install new ADM into bracket. WLD FIG. 49 Disassembly (see FIG. 49): 5. Connect cable to bottom of new ADM. NOTE: ADM may need updated software. See Software Update Procedure on page 77. 1. Turn main power switch OFF. 2. Remove filter cover (68) and filter element. 333347F 69 Repair Reassembly: Replace AWB 1. Use two screws (144) to secure power supply bracket (145) to new AWB (143). See FIG. 51. 2. Mount power supply (146) to power supply bracket (145). See FIG. 51. 131 3. Connect connector (labeled AWB-J1) on power supply harness (147) to J1 on AWB (143). See Electrical Schematics, page 78. 144 145 4. Use two screws (131) to install AWB (143) to electrical enclosure (1). See FIG. 51. 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. 51: AWB and Power Supply NOTE: If unable to determine the connector location, see Electrical Schematics, page 78. 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 78. 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. 51. 5. Remove two screws (144) securing power supply bracket (145) to AWB (143) and remove power supply bracket. See FIG. 51. 70 333347F Repair Replace Power Supply Replace Power Supply Harness Disassembly: Disassembly: 1. Turn main power switch OFF. 1. Turn main power switch OFF. 2. Remove electrical enclosure front access door (10). 2. Remove electrical enclosure front access door (10). 3. Remove power supply (146) from power supply bracket (145) by releasing mounting tab on the side of the power supply. See FIG. 51. 3. Disconnect screw terminal connections between power supply (146) and power supply harness (147) according to the following table. 4. Disconnect screw terminal connections between power supply (146) and power supply harness (147) according to the following table. See FIG. 51. Power Supply Connection V+ VGND L N Harness Label V+ VGND L N 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 78. 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. 51. 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 78. 3. Install electrical enclosure front access door (10). 3. Install electrical enclosure front access door (10). 333347F 71 Repair Air Controls 8 405 402 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. 52): 1. Turn main power switch OFF. 1 2. Disconnect plug from power outlet or turn off circuit breaker for incoming power. WLD 3. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system. FIG. 52 FF 4. Remove front access panel (10) from electrical enclosure (1). 5. Remove the transformer assembly; for 480V systems only (see FIG. 53): 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). WL D 6. Use 3/8 in. socket to remove two screws (8). FIG. 53 7. Note location of each air line connection. Reassembly (see FIG. 52): 8. Insert hands through access holes (FF), see FIG. 52, in bottom of electrical enclosure then disconnect air lines from air control solenoids (402). 1. Use two screws (405) to secure new solenoids (402) to air control assembly (409). 9. Disconnect air control solenoids cable from MZLP daughter board connector J13. Pull wire out of the electrical enclosure. 10. Remove two screws (405) securing solenoids (402) to air control assembly (9) then remove air control solenoids. 2. Feed the new solenoid cable into the electrical enclosure and attach cable to MZLP daughter board connector J13. 3. Insert hands through access holes (FF), see FIG. 52, 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. 72 333347F Repair 3. Place one small crescent wrench on the brass part of the gauge then use a second small crescent wrench to tighten the air fitting (403b). 6. Install electrical enclosure front access door. Replace Air Control Gauge NOTICE 8 403a 403c 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 403b FIG. 54 WLD Replace Pilot Valve C Disassembly (see FIG. 54): 1. Turn main power switch OFF. 511 218 2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system. 3. Remove two screws (8) then slide air control assembly (9) out from electrical enclosure (1) so the back of the gauges are exposed. 4. Remove two nuts (403a) securing gauge (403) in place then remove bracket (403c). WLD 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. 54): 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. FIG. 55: 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 the rod cover (C). b. Use 10 mm socket to remove air motor pilot valve (511) from air motor (218). c. 333347F Lubricate with grease and install new air motor pilot valve (511). 73 Repair d. Torque pilot valve to 95-105 in-lb (10.7-11.9 N•m). Replace Air Valve 218 4. Replace bottom pilot valve (511): 507 29 218 512 6 509 FIG. 57 Disassembly (see FIG. 57): 511 1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system. 2. Turn main power switch OFF. WLD FIG. 56: Bottom Pilot Valve 3. Loosen clamp on air motor bracket (528) then remove funnel assembly (61). a. Remove cover (29) and insulation (6). 4. Loosen upper hose clamp on rubber housing then remove fill cap. b. Use 10 mm socket to remove air motor pilot valve (511) from air motor (218). 5. Dispense until the fluid level in the melter is at or below the honeycomb grid. c. 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. 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). 6. Once the fluid level is low enough, close the bleed-type ball valve installed at the system air inlet. e. Replace insulation (6) and cover (29). 7. Disconnect air hose and cable from the air motor. 8. Use 10 mm socket to remove four screws (509) securing air valve (512) to air motor (218). 9. Remove air valve (512) and seal (507) then discard. Reassembly (see FIG. 57): 1. Lubricate with grease then place new air valve seal (507) onto air valve (512). 2. Carefully place new air valve (512) against air motor then thread in the four screws (509). Ensure the air valve seal (507) stays in place by applying constant pressure against the air motor. 74 333347F Repair b. Remove dowel pin (238). 3. Use 10 mm socket to torque screws (509) to 95-105 in-lb (10.7-11.9 N•m). 4. Install fill cap then tighten upper hose clamp on rubber housing. 5. Connect air hose and cable to the air motor. Remove Air Motor 8 74 218 82 27 c. Remove three screws (240). d. Remove screws (8), screws (74), and bracket (82). 7. If replacing a damaged air motor with a new fully assembled air motor: a. Remove three screws (211) securing air motor tie rods (220) to base plate (219). 239 238 220 b. Remove tie rods (220) from air motor (218). 240 Install Air Motor 219 See FIG. 58. 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. FIG. 58 WLD b. Install dowel pin (238). 1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system. 3. Use four nuts (3) to install melter shield (27). 2. Turn main power switch OFF. 4. Reconnect air supply line to air motor (218). 3. Disconnect air line (36) from pressure relief valve (245) then pull through metal shroud (27). See FIG. 45 on page 65. 5. Reconnect air line (36) to pressure relief valve (245). See FIG. 45 on page 65. c. Install retaining ring (239) over dowel pin (238). 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. 333347F 75 Repair Transformer Fan 5. Remove screws (157) and fan grill (154). Pull two fan wires down into the transformer enclosure. 6. Cut three zip ties on corrugated tube (167) and two zip ties (161) on fan grill (154). Replace Fan 7. Remove four nuts (158), rear fan grill (170), and fan (155). 1 Install Fan 1. Mount new fan (155), rear fan grill (170), and nuts (158) on grill (154) with the arrow pointing toward the grill (154). 2. Tie down fan wires onto tie down locations on grill (154) using cable ties (161). 158 black (-) 167 154 red (+) 161(x3) 151 161 157 WLE FIG. 59 1. Turn main power switch OFF. 2. Disconnect plug from power outlet or turn off circuit breaker for incoming power. WLE FIG. 61 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. 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. 60. 4. Reinstall corrugated tube (167) on fan and transformer wires. See FIG. 59. J7 1 (+) red 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). (-) black WLD FIG. 60 76 Front access panel (10) not shown. 333347F Repair Software Update Procedure When software is updated on the ADM the software is then automatically updated on all connected GCA components. A status screen is shown while software is updating to indicate progress. 1. Turn system main power switch OFF. NOTE: When the screen turns on, you will see the following screens: First: Software is checking which GCA modules will take the available updates. 2. Remove ADM from bracket. 3. Remove token access panel. Second: Status of the update with approximate time until completion. r_24P860_3B9900_3a FIG. 62: Remove Access Panel 4. Insert and press InvisiPac software upgrade token (T, part no. 24R324) firmly into slot. Third: Updates are complete. Icon indicates update success/failure. See the following Icon table. Icon NOTE: There is no preferred orientation of token. Description Update successful. Update unsuccessful. Update complete, no changes necessary. T Update was successful/complete but one or more GCA modules did not have a CAN boot-loader so software was not updated on that module. r_24P860_3B9900_4a FIG. 63: Insert Token 5. Install ADM into bracket. 7. Remove token (T). 6. Turn system main power switch ON. 8. Replace token access panel. NOTICE A status is shown while software is updating to indicate progress. To prevent corrupting the software load, do not remove token until the status screen disappears. 333347F 9. Press to continue to the InvisiPac operation screens. 77 Electrical Schematics Electrical Schematics Cable Identification To prevent electric shock and system damage, all electrical work must be performed by a qualified electrician. Incoming Power Use the table to identify cables and other system components in the electrical schematics. Ref 9 Part --- Description Manifold, air assembly 20 24R041 Sensor, ultrasonic NOTICE 25 24A032 Switch, reed assembly To prevent severe system damage, ensure main power leads are installed correctly. See Connect Electrical Cord on page 23. 30 86 87 90 103 112 24P860 127666 ------24V288 118 121 123 124 125 126 129 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 --Sensor, RTD, 1M 16T108 ----135 16W035 136 --138 --140 --143 24V816 146 126453 147 --148 --208 24V522 24R093 209 24R037 24R034 210 24R036 24R037 251 24R040 1201 16T102 78 Cable Ultrasonic Harness, MZLP 2, AWB Harness, MZLP 2/3, AWB Connector Jumper Harness, MZLP #1 AWB Harness, Disc AWB Transformer AWB Power Supply Harness Power Supply AWB Cable, Board, Samtec Band heater, HM50 Band heater, HM25 Heater Rod (1500 W), HM50 Heater Rod (500 W), HM25 Heater Rod (1000 W), HM50 Heater Rod (1500 W), HM25 SWITCH, OT Light Tower 333347F Electrical Schematics System 30 143 140 138 AWB J2 L1 N N L2 5L3 6T3 W2 L3 3L2 4T2 W3 1L1 2T1 W1 1 2 3 4 5 W4 GND ADM J9 1 2 3 4 5 123 1 2 3 4 5 1 2 3 4 5 GND 208 Band J7 Transformer Option GB1 210 209 210 Pump Melter Base TEMP TEMP TEMP FAN - TEMP FAN - FAN + FAN + 90 J4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 J5 L1 L2 L3 GND L1 L2 L3 GND J8 1 2 3 4 5 1 2 3 4 5 148 L1 L2 L3 GND 136 J6 L1 L2 L3 GND 87 147 Ground Stud DC OK DC OK -V -V +V +V 129 To MZLP #2 4 and 6 Channel Option, see page 108 and 110. J1 N L + GND N L N L + J3 1 1 2 2 103 146 112 MZLP 1 112A 1201 Optional Light Tower 9 Air Solenoid 1 2 3 4 1 2 3 4 J12 1 2 3 4 1 2 3 4 J13 1 2 3 4 J14 1 2 3 4 J15 1 2 3 4 5 J16 1 2 3 4 Fill Sensor 20 86 126 1 2 3 4 5 Motor Cycle Switch 25 124 125 Melter OT Switch and Melter RTD 251 To MZLP #2 4 and 6 Channel Option, see page 108 and 110. 333347F J5 1 2 3 4 5 6 1 2 3 4 5 6 J3 121 1 2 3 4 5 1 2 3 4 5 J1 1 1 2 2 J2 L1 L2 L3 GND L1 L2 L3 GND J6 1 2 3 4 5 1 2 3 4 5 J8 A B C D E F G H J K L J9 A B C D E F G H J K L Hose / Applicator Wiring 79 Electrical Schematics 480VAC Transformer Option 143 AWB J2 W1 L1 N N P3 W2 L2 5L3 3L2 6T3 P2 W3 4T2 P1 W4 1L1 2T1 L3 GND J7 PTC TEMP TEMP TEMP FAN FAN + TEMP FAN FAN + GB GND GB1 Typical Hose / Applicator Wiring 112 MZLP1 J8 GUN HEATER 80 T° GUN RTD OVER TEMP GND HOSE HEATER T° HOSE RTD A A B B C C D D E E F F G G H H J J K K L L 333347F Electrical Schematics 2nd and 3rd MZLP Options 135 1 2 3 4 5 6 333347F 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 81 Line Air Inlet 82 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. 333347F 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 22 53 25 26 6 75 8 28 23 13 19 18 43 6 38 38 31 58 30 23 8 39 27 8 3 44 64 29 43 64 333347F 1 11 10 43 WLE 8, 14 83 Parts System Parts, Page 2 of 3 68 8 67 69 74 66 82 5 86 20 8 49 7 3 72 73 42 41 74 40 69 88 3 5 63 62 87 69 89 1 61 54 4 85 81 8 79 63 80 WLD 9 43 8 84 333347F 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 333347F 36 13 in. 330.2 mm) 85 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 Part --- Description ENCLOSURE, electrical 5 24V169 SYSTEM, melter, HM25 1 6 24V542 SYSTEM, melter/pump, HM50 16V540 GUARD, insulated --- 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✿ --- 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 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 22 24N957 SHAKER, feed system 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 23 114606 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 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 TOOL, allen, wrench PLUG, hole 25 FITTING, push to connect elbow 24A032 SWITCH, reed assy 26 --- 27 --- SCREW, pan head, #8-32 x 1.5" BRACKET, back HM50 --- BRACKET, back 1 1 1 1 1 1 1 1 28 --- COVER, filter 1 1 1 1 1 1 1 1 1 29 --- COVER, melter HM50 1 1 1 1 1 1 1 1 1 --- 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 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 86 WASHER 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 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 333347F Parts Quantities 24T919 24V202 24V199 24T920 24V203 24V200 24V423 24V429 24V426 24V424 24V430 24V427 24V425 24V431 24V428 6 Channel 24V198 2 Channel 24V201 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 BUSHING, strain relief 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 GROMMET, tube 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 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 39 Part --- Description GROMMET, 1/4 ID 40 --- 41 --- 42 --- GROMMET, tube 43▲ 16Y781 LABEL, safety 44 16U007 LABEL, InvisiPac, HM25 --- 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✖ 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 48✖ 24P859 KIT, fuses, board, temp control 24P176 KIT, i/o connector 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 49 125871 50❄ 24R324 TOKEN, software 1 1 1 1 1 1 1 1 1 53‡ 16W659 INSULATOR, melter 1 1 1 1 1 1 1 1 1 16T677 TIE, cable, 7.50 in. 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 INSULATOR, melter 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 54 --- NUT, bushing 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 57 123554 COUPLER, 3/8 in. OD tubing 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 58 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 61† 24A326 BRACKET, mounting, assembly --FUNNEL, large mouth 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 62† --- 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 63 121487 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 64 GROMMET, sheet metal, 3/4 2 in. 24R707 KIT, inlet, air 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 66† --- 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 67† 24V506 FILTER, HM50 feed 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 68† --- FUNNEL, filter cover 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 69† --- 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 72 110932 O-RING, fluoroelastomer, 160 CONNECTOR, male 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 73† --- HOUSING, sensor, HM50 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 74† --- 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 BAFFLE, pellet FUNNEL, insert 78 SCREW, #10-16, thread forming 16T675 INSULATOR, melter manifold 16W671 INSULATOR, melter, manifold --FITTING, tee, 1/8npt x 3/8t x 3/8t --RESTRICTOR, air, 0.0225 in. orifice 198177 FITTING, push, straight 79★ 24W001 ADAPTER, HM25 75 76 77 24W000 ADAPTER, melter HM50 333347F 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 87 Parts Quantities 1 1 1 1 1 1 1 1 1 1 1 24V428 1 24V431 1 24V425 1 24V427 1 24V430 1 24V424 1 6 Channel 24V426 24V200 1 2 Channel 24V429 24V203 --- 24T920 BRACKET, funnel, HM25 24V199 CLAMP, hose, spacer 24V202 ----- 24T919 81★ 82† 24V198 Description CLAMP, hose, spacer 24V201 Ref Part 80★ --- 6 Channel 24T918 2 Channel HM25 4 Channel 24V423 HM50 4 Channel 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 83 123986 BRACKET, HM50, funnel, 1 mounting FITTING, elbow, 3/8 OD tube 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 85 --- GROMMET 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 86 122030 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 1 90 --- WASHER, 1/4 external tooth lock PLUG, phoenix, 8 pos 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 91 --- 1 1 1 1 1 1 1 1 1 1 1 92✖ FITTING, 5/32 in. OD tube, push-to-con 17A345 TOOL, 5/16 nut driver 93✖ 127735 STRAP, lifting 3 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 --- Not for sale. ▲ Replacement Danger and Warning labels, tags, and cards are available at no cost. ❄ ADM does not come with software. Order software token 24R324. ✖ Not shown. Available kits (purchase separately): Kit 24R885◆ 24R028* 24V544 24V505† 24V508‡ 24V504✿ 24U635 24W000★ 88 Description Cycle Switch Inlet housing Tubing Includes 25, 26 12, 13, 62 32, 33, 34, 35, 36, 304. See Feed System Shaker and Tube, 24V507 on page 96 for identification of item 304. Funnel 8, 61, 62, 66, 67, 68, 69, 73, 74, 82. See Feed Inlet Funnel, 24V505 on page 99. Melter 53, 202, 204, 207, 211, and 253. See Melter and Pump Assembly on page 93 for identification of items 202-253. Hydraulic Fittings 13, 18, 19 Acrylic Lens Pressure Gauge Melter Adapter 79, 80, 81 333347F Parts Electrical Enclosure 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 333347F WLD 111 143 105 131 89 Parts 142 141 137 140 WL D Electrical Enclosure Parts Ref 101 102 103 104 105 106 107 108 109 110 111 112* 112a 113 114 116 117 118 119 120 121 123 90 Part 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 122030 CABLE, gca, m12-5p 1 1 1 --- HARNESS, MZLP1, AWB 1 1 1 1 1 1 123970 SWITCH, disconnect, 40a 1 1 1 1 1 1 126839 CONTACT, n-pole 120858 BUSHING, strain relief, m40 thread 1 1 1 1 1 1 1 1 1 1 1 1 120859 NUT, strain relief, m40 thread 1 1 1 1 1 1 104641 FITTING, bulkhead 1 1 1 1 1 1 121141 FITTING, elbow, swivel, 3/8t 1/4mnpt 1 1 1 1 1 1 114421 BUSHING, strain relief 1 1 1 1 1 1 117666 TERMINAL, ground 1 1 1 1 1 1 --- MODULE, MZLP with daughter board 1 1 1 1 1 1 24R042 KIT, board, daughter 1 1 1 1 1 1 16T440 CAP, souriau, uts14 2 4 6 2 4 6 125856 SCREW, 8-32, serrated flange 12 12 12 12 12 12 24P175 PLATE, blank, sgl mztcm 2 1 2 1 115942 1 1 1 1 1 1 1 2 1 2 NUT, hex, flange head 24V510 MODULE, gca, MZLP --- GASKET, foam, mztcm 2 --- PIN, dowel 1 16T087 CABLE, board, male/male, 21 in. 127768 CABLE, can, female/female 1.5 m 1 1 1 1 1 2 1 1 2 1 1 1 1 1 2 1 1 1 333347F Parts Ref Part 124 125◆ 126 129 130 131 132 135 136 137 138 140 141 142 143 144 145 146 147 148 * Description Quantity 1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP No Transformer 400/480 V Transformer 16T103 CABLE, pump 1 1 1 1 1 1 --- SENSOR, rtd, 1m 1 1 1 1 1 1 16T108 CABLE, ultrasonic, m12-4p, 1m 1 1 1 1 1 1 --- HARNESS, MZLP 2, awb --- HARNESS, MZLP 2/3, awb 1 1 1 1 114958 STRAP, tie 4 4 4 4 4 4 --- SCREW, flange, serrated, 10-24 x 0.5 2 2 2 2 2 2 123967 KNOB, operator disconnect 1 1 1 1 1 1 1 16W035 CONNECTOR, jumper 1 1 1 1 1 1 1 1 1 24V015 TRANSFORMER, assembly, 480v/240v 1 1 1 --- GROMMET, air fitting 1 1 1 113802 SCREW, hex hd, flanged, 3/8-16 x 5/8 3 3 3 --- HARNESS, MZLP 1, awb --- BUSHING, cable --- HARNESS, disc, awb 1 1 1 1 1 1 1 24V816 MODULE, awb 1 1 1 1 1 1 114331 SCREW, mach, pnh, sems; 6-32 x 3/8 2 2 2 2 2 2 --- BRACKET, power supply 1 1 1 1 1 1 1 1 126453 POWER SUPPLY, 24v 1 --- HARNESS, power supply, awb 1 1 1 1 1 1 --- CABLE, board, samtec 1 1 1 1 1 1 Purchase MZLP (118) and daughter board (112a) separately. Available kits (purchase separately): Kit 24V528† 24V529✿ 24R040◆ 24V289 24P176 333347F Description Upgrade from 2 channel system to 4 channel system Includes 113, 118, 121, 129, a grounding wrist strap, and a software upgrade token. See 4 Channel Upgrade Kit, 24V528 on page 108. Upgrade from 4 113, 118, 121, 129,134, 135, channel system grounding wrist strap, and a to 6 channel sys- software upgrade token. See 6 tem Channel Upgrade Kit, 24V529 on page 110. RTD 125, 251, and 255. See Melter and Pump Assembly on page 93. MZLP fuses Qty 8 - 8 Amp, 250V Fuses Qty 2 - 25 Amp, 250V Fuses Customer I/O 2 connectors for connecting to Connectors H1 and H2 on MZLP daughter board. Use for PLC connection. 91 Parts Transformer Assemblies 152 160 161 153 4 2 166 156 167 161 2 168 157 158 157 154 3 151 WL D 155 156 170 2 166 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 --------- 154 ----155★ 156 115942 157 119865 158 160 92 1 166 127278 --- Description ENCLOSURE, base, 480v ENCLOSURE, top, 480v TRANSFORMER, 480v/240v, 6kva; 480V systems only TRANSFORMER, 400v/240v, 6kva; 400V systems only GRILL, fan FAN, 24 vdc, 120m x 120m NUT, hex, flange head SCREW, mach, hex serrated, 1/4 x 3/8 in. NUT, keps, hex GROMMET, air fitting Qty 1 1 1 1 1 1 5 6 4 1 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. 333347F Parts Melter and Pump Assembly HM25, 24V169 HM50, 24V542 208 2 218 217 205 4 254 10 238 239 216 235 211 217 233 236 204 234 4 5 223 224 206 2 220 202 225 5 3 226 222 4 240 207 3 221 227 228 229 231 219 10 215 211 213 252 210 10 7 203 253 206 252 232 251 6 230 255 210 246 9 4 10 201 209 249 214 242 257 8 247 258 3 249 268 259 243 10 244 245 WLD 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 Torque to 12-18 ft-lb (16-24 N•m). 5 Orient u-cups (225, 234) with springs in direction shown. 333347F 93 Parts HM25 Melter and Pump, 24V169 HM50 Melter and Pump, 24V542 Ref. 201 202✖ 203• 204✖ 205 206• 207✖ 208 209• 210 211✖ 213 214• 215 216‡• 217†‡• 218 219 220 221• 222†◆• 223◆• 224†◆• 225†◆• 226†◆• 227†• 228†• 229†• 230• 231†• 232†• 233†• 234†‡• 235• 236• 238 239 240 242★• 94 Part Description --BASE, melter, HM50 --BASE, melter, HM50 --TANK, melter, HM50 --TANK, melter, HM25 --MANIFOLD, outlet --PLATE, mounting; HM50 --PLATE, mounting; HM25 --HOUSING, fire rod; HM50 --HOUSING, fire rod; HM25 111317 RING, retaining, int. 16W615 O-RING, fluoroelastomer; (HM50 only) 126475 O-RING, fluoroelastomer; (HM25 only) 24V522 BAND, heater; HM50 only 24R039 BAND, heater; HM25 only 24R037 HEATER, rod,1500 watts; HM50 24R034 HEATER, rod, 500 watts; HM25 24R036 HEATER, rod,1000 watts; HM50 24R037 HEATER, rod,1500 watts; HM25 116940 SCREW, cap,sh,5/16-18 --SCREEN, wire 112855 PACKING, o-ring --PLUG, o-ring boss --SLEEVE, cylinder 108526 PACKING, o-ring, ptfe 24V558 MOTOR, double ended, air; see page 95 --PLATE, pump adapter --ROD, tie, 1.5 in. stroke 192624 GUIDE, ball 239932 VALVE, piston --ROD, piston 105444 BALL, (.31250) --SEAL, u-cup, piston --BEARING, piston 105445 BALL, (.5000) 192642 SEAT, carbide 107079 PACKING, o-ring --HOUSING, foot valve 105802 O-RING 113944 PACKING, o-ring --BEARING, throat --SEAL, u-cup, throat 193046 NUT, packing 24P855 FILTER, assy, 100 mesh, welded 196762 PIN, straight 196750 SPRING, retaining 101864 SCREW, cap, sch; 5/16 x 1 in. 117059 O-RING, fluoroelastomer Qty. 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 2 2 7 1 1 1 1 2 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 Ref. 243★• 244★• 245★• 246• Part --15Y627 --121295 247• 249 251✿• 252• 253✖ 15H304 167002 24R040 --------107388 ------110298 254 255✿• 257 258 259 Description 115506 268 115814 Qty. 1 RETAINER, seat, dump valve 1 PACKING, o-ring #2-116, ptfe 1 VALVE, relief 4 SCREW, cap, socket head; 5/16 x 2.5 in. 9 FITTING, plug 9/16 sae 10 INSULATOR, heat 1 SWITCH, overtemperature 7 INSERT, helical 1 PLATE, melter; HM25 only 1 PLATE, melter; HM25 only 1 O-RING, -910 2 SCREW, mach, pnh; #4 x 3/8 in. 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 SCREW, mach, hex wash hd, 1/4 x 3 in.; HM25 only WASHER, flat, sst; HM50 only 4 4 --- Not for sale. Available kits (purchase separately): Kit 24P852† Description Pump repair 24P853‡ Cylinder 24P854◆ 24P856★ Pump rod Pressure relief valve Melter 24V508✖ 24R040✿ 24R709 • --- Includes 217, 222, 224, 225, 226, 227, 228, 229, 231, 232, 233, 234, and seal installation tool 15B661. 216, 217, 234, and seal installation tool 15B661. 222, 223, 224, 225, 226 242, 243, 244, 245 202, 204, 207, 211, 253, and insulator (53). See InvisiPac Systems parts starting on page 83 for insulator (53) identification. RTD 125, 251, and 255. See Electrical Enclosure on page 89. Assembled pump 203, 206, 209, 214, 216, 217, manifold 221, 222, 223, 224, 225, 226, 227, 228, 229, 230, 231, 232, 233, 234, 235, 236, 242, 243, 244, 245, 246, 247, 251, 252, 255 Special tools See Special Tools on page 100. 333347F 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 ----------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. 333347F 95 Parts Feed System Shaker and Tube, 24V507 306 301 1 304 302 1 Apply pipe sealant to threads. ti20738a Parts Ref 301 302 303†◆ 304 305◆ 306 Part 24P861 24N954 --- Description SHAKER TUBE, steel TUBE, clear PVC, 1.3 in. (33 mm) OD --HOSE, nylon, 3/8 in. OD, 250 psi (1.7 MPa, 17 bar) 125370 CLAMP, hose, dia. 11/16 to 1-1/2 in. 125871 TIE, cable, 7.50 in. (190 mm) Qty 1 1 10 15.5 3 4 --- Not for sale. † 30 ft (9.1 m) Feed Hose Kit 24R043 also available (purchase separately). Kit also includes 2 hose clamps. ★ Included in Tubing Kit 24V544. See System Parts on page 86 for other kit contents. ◆ Not shown. NOTE: Shaker Grounding Kit 24R708 (purchase separately) also available. Kit includes a grounding wire assembly, and a screw and washer for installing on the shaker tube (301). 96 333347F 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 15T500 GAUGE, pressure, air, panel mount, 1/8 in. npt 15T498 FITTING, 90 degree, swivel, 5/32 in. tube x 1/8 in. female npt 100058 SCREW, cap, hex head 054753 TUBE, nylon, round, black C38321 TIE, cable, 3.62 in. Qty 1 1 2 2 2 2 1 --- Not for sale. 333347F 97 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). Ref 601 602 603 604 605 606 607 608† 609† 610 611† 612† 613 614† Part ----15T413 --------108771 110073 111841 --------- 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). 98 333347F Parts Feed Inlet Funnel, 24V505 706 705 703 704 707 708 710 708 709 703 702 703 701 WLD Ref. 701 702 703 704 705 706 707 708 709 710 Part Description --FUNNEL, large mouth --BAFFLE, pellet --O-RING, fluoroelastomer, 160 --FUNNEL, insert 24V506 FILTER, feed --FUNNEL, filter cover 113161 SCREW, flange, hex hd --SCREW, #10-16, thread forming --BRACKET, funnel, mounting --HOUSING, sensor Qty 1 1 3 1 1 1 2 5 1 1 --- Not for sale. 333347F 99 Accessories Accessories Special Tools These special tools are designed to make system repairs as easy as possible while ensuring that parts do not get damaged. Part Purpose Part Purpose 1301* Remove Cylinder 1304** Install Rod - Female 1302* Install Cylinder - Female 1305** Install Rod - Male 1303* Install Cylinder - Male 1306** Install Rod - Bullet * Parts included in Cylinder Tools Kit 24R227 (purchase separately). ** Parts included in Rod Tools Kit 24R228 (purchase separately). ti20983a 100 333347F Accessories Non-Graco Applicator Adapter Cables 16T916: For connecting to non-Graco applicators that use a rectangular, 6-pin connector. Air Adjustment Lock, 24R084 Panel enables locking access to the air adjustment screws. ti21128a 16T917: For connecting to non-Graco applicators that use a circular, 9-pin connector. 801 802 WLD ti21129a 16Y828: For connecting to non-Graco applicators that use a circular, 6-pin connector. IPx6 rated. NOTE: Screws are part of the base system and are not included in the kit. Ref 801 802 Part ----- Description PANEL, lock, air control BRACKET, lock, air control Qty 1 1 Air Adjustment Lock Installation 1. Remove screws from system air panel. 2. Use screws to install panel (801). WLD Non-Graco Applicator Adapter Cable Installation 3. Snap bracket (802) into panel (801). 4. Insert lock through hole in panel and bracket to lock access to the air controls. Lock not included in kit. See Attach Components on page 17. 333347F 101 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 WL D 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). 102 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). 333347F Accessories 333347F 103 Accessories 30 Gallon Vibrating Hopper, 24R136 Hopper includes a shaker to ensure the adhesive pellets maintain a level surface at all times. Without this, the adhesive pellets can stick together, preventing them from continuously covering the vacuum transfer system’s inlet. This would cause the vacuum transfer system to be unable to transfer the adhesive pellets. Input Air Pressure Requirement: 100 psi (7 bar, 0.7 MPa) Air Consumption: 17.1 scfm (29.1 cubic meters per hour) 902 903 910 901 903 915 915 905 904 907 916 909 ti20928a 914* Ref 901 902 903 904 905 907 908 909 910 104 Part ----126930 126929 ----- Description Qty HOPPER, 30 gallon 1 LID, hopper, 30 gallon 1 SHAKER, ball vibrator 1 VALVE, air pilot, 3-way, closed 1 BRACKET, shaker, container 1 HOSE, nylon, 3/8 in. OD, 250 psi 1 (1.7 MPa, 17 bar) 119798 CONNECTOR, tee, push-tube 1 113779 MUFFLER 1 111192 SCREW, cap flange head 2 Ref 912 914* 915 916 917 912 Part Description Qty 125857 SCREW, 10-24, serrated flange 4 121141 FITTING, elbow, swivel, 3/8 in. 1 tube connector, 1/4 male npt 120389 FITTING, tube 2 --CONNECTOR, tube, 90 degree 1 125539 FITTING, splitter, 3/8 in. OD tub1 ing --- Not for sale. * Metric fitting included in Air Metric Fitting Kit, 24W637, page 113. 333347F Accessories 30 Gallon Vibrating Hopper Installation See FIG. 64 for illustration of installed vibrating hopper. 1. Turn main power switch OFF. 2. With the steel shaker rod fully assembled and the 3/8 in. OD air line connected to the shaker head, cut the 3/8 in. OD air line where the 1.3 in. clear vacuum transfer hose connects to the steel shaker rod. 3. Use the splitter fitting (917) to reconnect the 3/8 in. OD air line that was just cut. Splitter fitting To piloted air valve To shaker head 4. Install the 48 in. section of 3/8 in. OD hose supplied with the kit into the remaining connection on the splitter fitting (917). 5. Connect the other end of the 48 in. section of 3/8 in. OD air line to elbow fitting (916) on the piloted air valve. 6. Connect shop air to elbow fitting (914) on the piloted air valve. Shop air must be capable of 100 psi (0.7 MPa, 7 bar). Hopper shaker NOTE: The piloted air valve must use shop air. Adding a tee at the system inlet to run the hopper shaker may impact pump and vacuum transfer performance. Piloted air valve 7. Place steel shaker rod assembly into hopper (901) with steel rod resting in the hopper groove in the rim of the hopper. 8. Place lid (902) on hopper (901). To shop air supply ti21350a FIG. 64 NOTE: The hopper shaker will be active while the vacuum transfer system is transferring pellets. NOTE: The air supplied to the pilot valve from the system vacuum must be set to 65% of the shop air supply supplied to elbow fitting (914) or higher. If the pilot valve air pressure is lower than this, increase the vacuum transfer air pressure regulator (E, see FIG. 1 on page 11). 333347F 105 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. 106 333347F 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. * 333347F Metric fitting included in Air Metric Fitting Kit, 24W637, page 113. 107 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. 108 333347F 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. 65. 6. Remove electrical enclosure front access door. NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation. 7. Connect CAN jumper cable (1302) to MZLP 1 connector J3 and connect other end of jumper cable (1302) to MZLP 2 connector J3. See FIG. 65. 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 77. 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. 65 333347F 109 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 110 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 333347F 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. 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. 66. 3. Set the kit’s MZLP (1301) rotary switch to “3”. 4. Remove screws (BB) then remove plate (AA) from system. 8. Install jumper connector (1307) in J5 on MZLP 3. 9. Connect wires from power harness (1306) between AWB connector J5 and MZLP connector J2. 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. 66. 6. Remove electrical enclosure front access door. 0=/3 NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation. 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 77. 0=/3 - 0=/3 - - - - - - - - - - - - - - - - - - - - Step 7: Install jumper cable (1302). WL D FIG. 66 333347F 111 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. 67: 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 77. 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. 1 112 Cable Length 16.4 ft (5 m) 49.2 ft (15 m) 164 ft (50 m) Part Description Qty. BRACKET, mounting assembly 1 333347F 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 Qty. 127922 FITTING, 3/8 npt(m) x M18(f) 1 127923 FITTING, 1/4 npt(m) x 10 mm 1 tube 127924 FITTING, 1/4 npt(m) x 10 mm 1 90° elbow tube 127925 FITTING, 3/8-18 npt(m) x 3/8-19 1 bspt (f) Strain Relief Bushing Kit, 24X190 The strain relief bushing kit allows the use of a smaller outside diatmer (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), 24R0294 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. 333347F Part Description 114271 STRAP, retaining Qty. 4 Pressure Gauge Replacement Kit, 24R635 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 32 113 Appendix A - ADM Appendix A - ADM General Operation Icon Description ADM Power Select channel to view and/or edit the applicator or hose temperature setting The ADM automatically turns on when the main power switch is turned ON. Applicator temperature setting. Screen Navigation Use ting. To switch between the Setup and Operation screens, press . Use , , , and and to adjust set- Hose temperature setting. to navigate Use ting. between screens. Enable, Disable Heating System and to adjust set- Use to adjust temperature settings To enable or disable the entire heating system, press . To set which channels are active when the heating system is enabled, use the System 2 screen. See page 117. Icon Identification Icon Description Operation Screens Only Temperature settings of applicator (top) and hose (bottom) Reset weight total Setup Screens Only Enter screen to change settings Heating disabled Warming up, actual temperature is below setting Temperature setting achieved Actual temperature of hose (left) and applicator (right) Exit screen Reset Maintenance error Schedule Screen Only Edit schedule value Erase schedule value Actual temperature of system (shown warming up) Accept schedule change System temperature setting. Cancel schedule change Use and to adjust setting. Use the physical numeric keypad on ADM to enter temperature setting. 114 333347F 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 120. Targets Tracked Events Custom Language Downloaded Custom Language Uploaded Fill Valve Closed Fill Valve Open Heat Off Heat On Logs Downloaded Pump Cycles Total Reset Pump Off Pump On Red Stop Button Pressed Setup Value Changed System Power Off System Power On System Settings Downloaded System Settings Uploaded USB Disabled USB Drive Inserted USB Drive Removed User Maintenance Count Reset 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 24. * 333347F Code EQU3 EQU4 EBFX EAFX EBDX EADX EQU5 ERD1 EBPX EAPX EB0X EC0X EM0X EL0X EQU1 EQU2 EVUX EAUX EBUX ERN1 Zone 115 Appendix A - ADM DI: System Digital Inputs 0: Not Used 1: Not Used 2: Pump Cycle Switch Up 3: Pump Cycle Switch Down Errors DO: System Digital Outputs 0: Pump Solenoid 1: Fill Solenoid 2: Light Tower Green Light 3: Light Tower Red Light The Errors screens store a maximum of 200 errors. See ADM Error Code Table on page 40. The errors list can be downloaded in the USB logs. See Appendix B USB Downloading, Uploading on page 120. Diagnostic ISO DI: Customer Digital Inputs 0: Customer Input 1 1: Customer Input 2 2: Customer Input 3 3: Customer Input 4 ISO DO: Customer Digital Outputs 0: Customer Input 1 1: Customer Input 2 2: Customer Input 3 3: Customer Input 4 Fill: Reading of Ultrasonic Fill Sensor • Old Fill Sensor (2400-2700 mV) • New Fill Sensor (4200-3800 mV) A B C This screen shows details of various items to aid in troubleshooting the system. This screen can be hidden by de-selecting “Enable Diagnostics Screen” on the System 3 screen. The flow rate updates every 15-20 seconds with the average flow rate over the last 15-20 seconds. The following information is displayed. A B C Diagnostic Data Current Draw RTD Reading Duty Cycle CAN: 24 VDC power supply voltage reading (18-28 VDC) 116 Fill Sol: Current draw of fill solenoid • (0 mA - off) • (150-250 mA - on) Flow/H: Melt rate of the system Life Cycles: total number of pump cycles over life of system. Life Weight: Weight of material dispensed over life of system. Pump Sol: Current draw of pump solenoid • (0 mA - off) • (150-250 mA - on) PCB Temp: PCB Temperature on MZLP1 • 32-16°F (0-71°C) Pump CPM: Pump cycles per minute. USB DL%: Percentage Complete, only applies when downloading USB data. 333347F Appendix A - ADM Setup Screens NOTE: It is important to set all settings in the System screens correctly to ensure optimal system performance. System 3 Password If the password is not “0000”, the password must be entered to access the setup screens. System 1 A PLC can be used to control or monitor the system. See PLC Connection on page 27 for instructions. Enable Diagnostic Screen: Choose whether to hide the Diagnostic screen. Lock Run Screens: Disable setpoint changes on the run (operation) screens. If the setup screens are password protected, the setpoints cannot be changed without first entering the password. Pump Idle Time to System Inactive: The heating system will be disabled after the pump has been idle for the set amount of time Power Type: Select the system power type. Circuit Breaker Size: Select the circuit breaker size. Refill Setting: To use the automatic vacuum transfer, select Auto. To disable the automatic vacuum transfer, select Manual. The main reason to disable automatic refill is while flushing. However, if an issue is present with the automatic refill system that cannot be solved in a timely manner, manual refill can be used to return the system to service. See Manual Refill on page 30. See Select ADM Settings on page 24. System 2 Use this screen to enable the installed channels and specify the type of applicator RTD type used. See Select ADM Settings on page 24. 333347F 117 Appendix A - ADM Maintenance Advanced 1 The system will notify the user at the set interval that maintenance is required. The fields in boxes can be edited by the user. “Due” and “Current” are both the number of cycles since the last reset. “Interval” is the set number of cycles between maintenance notifications. “Lifetime” is the number of cycles in the lifetime of the system. Language: Language displayed on the screen. Date Format: Choose format of the date. Date: Set the date. Time: Set the time. Enter Password: If not “0000”, the Setup screens will be password protected. Screen Saver: The screen will go black after the set amount of time. Silent Mode: Disable ADM sounds. NOTE: The lifetime cycle count will only be reset if the Advanced Display Module (ADM) is replaced. Advanced 2 Schedule Use this screen to set times where the system will automatically enable and disable heating. See Select ADM Settings on page 24. Temperature Units: Units of measure for displayed temperatures. Mass Units: Units of measure for mass. Specific Gravity: Required to convert the volume dispensed to mass dispensed for tracking the total weight and flow rate. NOTE: When the specific gravity value is populated, the total mass dispensed since the last total weight reset is shown on the Home screen and the mass flow rate is shown on the Diagnostic screen. 118 333347F 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. 333347F 119 Appendix B - USB Downloading, Uploading Appendix B - USB Downloading, Uploading The system can store 250,000 entries in its logs and the system adds a new entry to the logs every 15 seconds. This means the system stores 1041 hours of system operation data, or 43 days of around-the-clock operation. Once full, the system will overwrite the oldest data. NOTE: To prevent losing any data, never go more than 43 days without downloading the logs. Download Procedure NOTICE Uploading an edited system configuration file can damage the system. Never put a modified SETTINGS.TXT file in the UPLOAD folder on the flash drive. NOTE: The event log, error log, system settings, and system language files are all downloaded in this procedure. See USB Logs, System Settings File, and System Language File starting on page 121. 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. 68. 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 121. 1. If necessary, follow the Download Procedure, page 120, to automatically generate the proper folder structure on the USB flash drive. 2. Insert USB flash drive into USB port of computer. FIG. 68: 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. 120 333347F 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 120, 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 120, 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. 333347F 121 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 120, 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. • • • • • • 122 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. 333347F Technical Data Technical Data InvisiPac Hot Melt Delivery System US Incoming Power HM25: 24V423 HM50: 24T918 Metric 200-240 VAC, 1-ph, 50/60 Hz, 32A 200-240 VAC, 3-ph, Δ, 50/60 Hz, 27A 350-415 VAC, 3-ph, Y, 50/60 Hz, 16A HM25: 24V429 HM50: 24V201 HM25: 24V424 HM50: 24T919 400-480 VAC, 3-ph, Δ, 50/60 Hz, 14A HM25: 24V430 HM50: 24V202 HM25: 24V425 HM50: 24T920 400-480 VAC, 3-ph, Δ, 50/60 Hz, 14A HM25: 24V431 HM50: 24V203 HM25: 24V426 HM50: 24V198 HM25: 24V427 HM50: 24V199 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, without vacuum tube or shaker (Width x Height x Depth) ** Shaker Dimensions (Width x Height) Pressure and Temperature Ranges 400-480 VAC, 3-ph, Δ, 50/60 Hz, 14A 333347F 200-240 VAC, 1-ph, 50/60 Hz, 40A 200-240 VAC, 3-ph, Δ, 50/60 Hz, 27A 350-415 VAC, 3-ph, Y, 50/60 Hz, 16A 200-240 VAC, 1-ph, 50/60 Hz, 40A 200-240 VAC, 3-ph, Δ, 50/60 Hz, 40A 350-415 VAC, 3-ph, Y, 50/60 Hz, 30A 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 0.4 x 4.0 ft 0.12 x 1.22 m 123 Technical Data InvisiPac Hot Melt Delivery System US Main System Air Supply Pressure Range (set with regulator on front of system) Pump Operating Air Pressure Range Pump Operating Fluid Pressure Range Control Temperature Range Ambient Temperature Range Vacuum Transfer Specifications Maximum Vacuum Transfer Hose Length Maximum Vacuum Transfer Hose Maximum Vertical Rise Vacuum Transfer Operating Pneumatic Pressure Range (set with regulator on front of system) Vacuum Transfer Air Consumption at 40 psi (280 kPa, 2.8 bar), Vacuum Transfer Air Consumption at 80 psi (550 kPa, 5.5 bar) Required Air Tubing Size Minimum Air Tubing Inner Diameter (less than 50 ft, 15.2 m of tubing) Minimum Air Tubing Inner Diameter (50 ft, 15.2 m or longer of tubing) Sound Sound Pressure Level*** IP Code InvisiPac Base System Wetted Parts Wetted Parts Approvals and Standards 30 Gallon Vibrating Hopper Required Air Pressure Supplied To 30 Gallon Vibrating Hopper Air Consumption 80-100 psi Metric 0.55-0.69 MPa (5.5-7 bar) 20-100 psi 240-1200 psi 100-400°F 32-120°F 0.14-0.69 MPa (0.7-7 bar) 1.7-8 MPa (17-80 bar) 38-204°C 0-49°C 30 ft 10 ft 9.1 m 3.0 m 40-100 psi 280-690 kPa (2.8-6.9 bar) 9.5 scfm (intermittent duty; 4% at 25 lb/hr) 17.2 scfm (intermittent duty; 4% at 25 lb/hr) 16.1 scmh (intermittent duty; 4% at 11.3 kg/hr) 29.2 scmh (intermittent duty; 4% at 11.3 kg/hr) 3/8 in. 9.5 mm 1/2 in. 12.7 mm 77 dB(A) IP54 PTFE, chemically resistant o-rings, aluminum, stainless steel, zinc plating, carbon steel, brass, carbide, chrome UL499, CSA88, CE, ISO 100 psi 0.7 MPa (7 bar) 17.1 scfm 29.1 cubic meters per hour * From 70°F to 350°F (21°C to 177°C), dependant upon power supply and machine configuration. ** Excludes vacuum transfer tube, shaker assembly, and pellet storage bin. *** Sound pressure level measured 3.1 ft (1 meter) from equipment. 124 333347F Technical Data Startup Time Single Phase NOTE: Times are approximate and may vary with ambient conditions, voltage configuration, and machine configuration. Start Time in Minutes HM50 HM25 Channels System (#) 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 333347F 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 Hose Length ft (m) 4 (1.2) 12 (3.6) 25 (7.6) 4 (1.2) 12 (3.6) 25 (7.6) 4 (1.2) 12 (3.6) 25 (7.6) 4 (1.2) 12 (3.6) 25 (7.6) 4 (1.2) 12 (3.6) 25 (7.6) 4 (1.2) 12 (3.6) 25 (7.6) 4 (1.2) 12 (3.6) 25 (7.6) 4 (1.2) 12 (3.6) 25 (7.6) 4 (1.2) 12 (3.6) 25 (7.6) 4 (1.2) 12 (3.6) 25 (7.6) 4 (1.2) 12 (3.6) 25 (7.6) 4 (1.2) 12 (3.6) 25 (7.6) 20 Amp 30 Amp 40 Amp 50 Amp 20 Amp 30 Amp 40 Amp 50 Amp Breaker Breaker Breaker Breaker Breaker Breaker Breaker Breaker 240V 240V 240V 240V 208V 208V 208V 208V 11 9.9 9.9 9.9 13 13 13 13 13 9.9 9.9 9.9 14 13 13 13 15 9.9 9.9 9.9 17 13 13 13 13 9.9 9.9 9.9 15 13 13 13 16 9.9 9.9 9.9 18 13 13 13 20 13 9.9 9.9 23 13 13 13 15 9.9 9.9 9.9 17 13 13 13 19 12 9.9 9.9 22 13 13 13 26 16 12 9.9 29 19 13 13 16 9.9 9.9 9.9 18 13 13 13 22 14 9.9 9.9 25 16 13 13 31 20 14 12 35 23 16 13 18 11 9.9 9.9 20 13 13 13 25 16 11 9.9 28 18 13 13 36 23 17 14 41 27 19 15 20 12 9.9 9.9 22 13 13 13 28 18 13 10 32 20 13 13 41 27 20 16 47 31 22 18 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 21 125 Technical Data Three Phase NOTE: Times are approximate and may vary with ambient conditions, voltage configuration, and machine configuration. Start Time in Minutes HM50 HM25 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 240V 240V 240V 240V 208V 208V 208V 208V System (#) ft (m) 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) 3 20 15 15 15 22 20 20 20 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 21 126 333347F Technical Data Dimensions System Dimensions Mounting Hole Dimensions WALL 2.0 in. (51 mm) 22.3 in. (566 mm) 101 in. (257 mm) 35.8in. (909 mm) 5.3 in. (133 mm) Minimum distance from rear mounting hole to wall: 7.0 in. (178 mm) 18.3 in. (465 mm) WLD System With 480V Transformer 3.3 in. (84 mm) 7.1 in. (180 mm) 3.3 in. 14.2 in. (84 mm) WLD (361 mm) 41.9 in. (1064 mm) 22.3 in. (566 mm) 18.3 in. (465 mm) WLD 333347F 127 Technical Data System with Stand and Vacuum Feed Dimensions Tube Bend Radius: 8.0 in. (203 mm) 12.0 in. (305 mm) A ti22866b A in. (mm) System System With Transformer 60.7 in. (1542 mm) 66.5 (1689 mm) 30.0 (762 mm) 17.4 (442 mm) 27.2 in. (692 mm) ti22865a Radius: 9.1 in. (232 mm) 31.3 (795 mm) 128 333347F Technical Data 333347F 129 Graco Extended Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of eighteen months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Information For more information about InvisiPac, visit www.InvisiPac.com. For technical assistance or customer service, call toll free: 1-800-458-2133. All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. For patent information, see www.graco.com/patents. Original instructions. This manual contains English. MM 333347 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revsion F, January 2015
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