Graco 333347F Invisipac Hm25 And Hm50 Users Manual Tank Free Hot Melt Delivery System, Instructions Parts, English

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333347F

EN

Instructions - Parts

InvisiPac

™

HM25 and HM50 Tank-Free

™

Hot Melt Delivery System

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 manu-

als. Save all instructions.

WLD

9902471

Certified to

CAN/CSA C22.2 No. 88

Conforms to

ANSI/UL 499

2333347F

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

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

Related Manuals

333347F 3

Related Manuals

Manuals are available at www.graco.com. Component

manuals in English:

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

Part Description

3A2805 InvisiPac GS35 Hot Melt Applicator Instruc-

tions - Parts

332072 InvisiPac Heated Hose Instructions - Parts

333348 HM50 Fuse Kit, Instructions-Parts

333349 InvisiPac 480V Transformer Upgrade Kit,

Instructions-Parts

333348 MZLP Fuse Kit, Instructions

Models

4333347F

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 Type Description Frequency

Max

Amps

24T918 2

200-240 VAC 1 / PE

•

1-Phase

•

200-240VAC

•

2 wire and PE

50/60 Hz 32A

200-240 VAC 3 / PE

•

3-Phase without Neutral

•

200-240VAC

•

3 wire and PE

50/60 Hz 27A

350-415 VAC Y 3 / Neutral / PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

50/60 Hz 16A

24T919 4

200-240 VAC 1 / PE

•

1-Phase

•

200-240 VAC

•

2 wire and PE

50/60 Hz 40A

200-240 VAC 3 / PE

•

3-Phase without Neutral

•

200-240 VAC Line to Line

•

3 wire and PE

50/60 Hz 27A

350-415 VAC Y 3 / Neutral / PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

50/60 Hz 16A

24T920 6

200-240 VAC 1 / PE

•

1-Phase

•

200-240 VAC

•

2 wire and PE

50/60 Hz 40A

200-240 VAC 3 / PE

•

3-Phase without Neutral

•

200-240 VAC Line to Line

•

3 wire and PE

50/60 Hz 40A

350-415 VAC Y 3 / Neutral / PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

50/60 Hz 30A

Models

333347F 5

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 Type Description Frequency

Max

Amps

24V423 2

200-240 VAC 1 / PE

•

1-Phase

•

200-240VAC

•

2 wire and PE

50/60 Hz 32A

200-240 VAC 3 / PE

•

3-Phase without Neutral

•

200-240VAC

•

3 wire and PE

50/60 Hz 27A

350-415 VAC Y 3 / Neutral / PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

50/60 Hz 16A

24V424 4

200-240 VAC 1 / PE

•

1-Phase

•

200-240VAC

•

2 wire and PE

50/60 Hz 40A

200-240 VAC 3 / PE

•

3-Phase without Neutral

•

200-240VAC

•

3 wire and PE

50/60 Hz 27A

350-415 VAC Y 3 / Neutral / PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

50/60 Hz 16A

24V425 6

200-240 VAC 1 / PE

•

1-Phase

•

200-240VAC

•

2 wire and PE

50/60 Hz 40A

200-240 VAC 3 / PE

•

3-Phase without Neutral

•

200-240VAC

•

3 wire and PE

50/60 Hz 40A

350-415 VAC Y 3 / Neutral / PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

50/60 Hz 30A

Models

6333347F

400 VAC Transformer HM25 Models

400 VAC Transformer HM50 Models

Model Channels Voltage Type Description Frequency

Max

Amps

24V426 2 335-400 VAC 3 / PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

50/60 Hz 17A

24V427 4 335-400 VAC 3 / PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

50/60 Hz 17A

24V428 6 335-400 VAC 3 / PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

50/60 Hz 17A

Model Channels Voltage Type Description Frequency

Max

Amps

24V198 2 335-400 VAC 3 / PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

50/60 Hz 17A

24V199 4 335-400 VAC 3 / PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

50/60 Hz 17A

24V200 6 335-400 VAC 3 / PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

50/60 Hz 17A

Models

333347F 7

480 VAC Transformer HM25 Models

480 VAC Transformer HM50 Models

Model Channels Voltage Type Description Frequency

Max

Amps

24V429 2

400-480 VAC 3 / PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

50/60 Hz 14A

24V430 4

400-480 VAC 3 / PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

50/60 Hz 14A

24V431 6

400-480 VAC 3 / PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

50/60 Hz 14A

Model Channels Voltage Type Description Frequency

Max

Amps

24V201 2 400-480 VAC 3 / PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

50/60 Hz 14A

24V202 4 400-480 VAC 3 / PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

50/60 Hz 14A

24V203 6 400-480 VAC 3 / PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

50/60 Hz 14A

Warnings

8333347F

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion 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 elec-

tric 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.

Warnings

333347F 9

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 manu-

facturer’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.

WARNING

Warnings

10 333347F

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 prop-

erty 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 sup-

plier for compatibility.

WARNING

Component Identification

333347F 11

Component Identification

F

IG

. 1

WLD

WLD

A

Key:

A Advanced Display Module (ADM)

B Electrical Enclosure

C Pump Air Pressure Regulator

D Pump Air Pressure Gauge

E Vacuum Transfer Air Pressure Regulator

F Vacuum Transfer Air Pressure Gauge

GShaker Tube

G1 Shaker Head

G2 Vacuum Transfer Tube

G3 Vacuum Transfer Inlet Funnel

G4 Vacuum Transfer 3/8 in. OD Air Supply

H Main Power Switch

J System Air Inlet

K Vacuum Transfer (Shaker) Inlet

L Air Motor and Pump

M Incoming Power Strain Relief

N Heated Fluid Manifold (Melter)

P Multi-Zone Low Power Temperature Control Module (MZLP)

R Fluid Outlets for connection to Heated Hoses (numbered 1-6)

S Customer I/O Cable (optional)

AC Drain Port

AD Transformer (optional)

B

F

G1

K

L

M

N

P

H

S

R

G

G2

G3

ECD

J

G4

AC

AD

G3

Component Identification

12 333347F

Heated Fluid Manifold

Key:

T Electrical Enclosure Front Access Door

UMelter

W1 Drain Port

W2 Drain Tray

X Inlet Filter (Low Pressure - Before Pump)

Y Outlet Filter (High Pressure - After Pump)

Z Adhesive Pellets Level Sensor (not shown; inside funnel)

AA 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

F

IG

. 2

WLD

U

R

W1

Y

X

AA

AB

NOTE: System shown with plastic and metal shrouds removed.

W2

T

Component Identification

333347F 13

Electrical Enclosure

Key:

P Multi-Zone Low Power Temperature Control Module

(MZLP)

AC Incoming Power Connection

AF Chassis Ground

AG Automatic Wiring Board (AWB)

F

IG

. 3

WLD

P

AC

AF AG

Component Identification

14 333347F

Advanced Display Module (ADM)

User Interface

NOTE: See Appendix A - ADM on page 114 for com-

plete ADM operation details.

B

Key:

BK Part Number Identification Label

BL USB Interface

BM CAN Cable Connection (Power Supply and Communica-

tion)

BN Module Status LEDs

BP (Not used)

BR Software Token Access Panel

NOTICE

To prevent damage to soft key buttons, do not press

the buttons with sharp objects such as pens, plastic

cards, or fingernails.

F

IG

. 4

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

TI12362a1

BA

BB

BC

BE

BH

BG

BF

BD

F

IG

. 5

BR

BK

BL

BP BN

BM

Component Identification

333347F 15

Screen Components

F

IG

. 6: Main Screen Components

Current date and time Screens Order

Hose Actual Temperature

Operating Mode Faults, Status

Applicator Actual Temperature

Melter Actual Temperature

Hose and Applicator

Heating Status

Melter Heating Status

Operating Mode Description Component Status

System Off The system doesn’t have power.

• No System Status Indicator LED on the

ADM

• No heat

• Pump is off

Inactive The heating system and pumps are

disabled.

• Yellow system status indicator LED on the

ADM

• No heat

• Pump is off

Warm Up The system is heating the material to

the set temperature.

• Flashing green system status indicator LED

on the ADM

• Heat is increasing to setpoint temperature

• Pump is off

Active The system is ready to dispense

material.

• Solid green system status indicator LED on

the ADM

• Heat is at setpoint temperature

• Pump is on

Component Identification

16 333347F

Setup

333347F 17

Setup

Grounding

The InvisiPac system is equipped with a ground termi-

nal. A qualified electrician must ground the system using

this terminal. See Connect Electrical Cord on page 23.

Location

Ambient temperature must be 32-120°F (0-49°C).

The supplied vacuum transfer hose length is 10 ft (3 m).

The maximum vacuum transfer hose length available is

30 ft (9.1 m). The adhesive pellets container must be

located within reach of the vacuum transfer hose and no

more than 30 ft (9.1 m) away.

The applicator(s) must be located no more than 25 ft

(7.6 m) from the melter.

Place the base system on a surface that is eye-level for

easiest operation. Use System Stand, 24R088, to

install system at eye-level. See page 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, avail-

able (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.

Attach Components

NOTE: Only systems with transformers are supplied

with a lifting strap.

1. Use supplied lifting strap 127735, to transport sys-

tems 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 F

IG

. 8, page 18.

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. Ground-

ing provides an escape wire for the electric current.

NOTICE

To prevent excessive static buildup on shaker or adhe-

sive bin, install optional grounding kit 24R708.

F

IG

. 7: Grounding Kit 24R708

WLD

To reduce the risk of electric shock, do not connect

electrical cord until after this Attach Components

procedure is complete.

NOTICE

To prevent strain on electrical or mechanical

connections around the pump assembly, loop the

strap around the tie rods as shown.

Setup

18 333347F

2. Place the base system in the desired operating

location and orientation. See Location, page 17.

• 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 enclo-

sure.

•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).

3. Adjust the funnel inlet:

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.

b. Rotate the funnel inlet (G3) and re-tighten the

band clamp (81).

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 F

IG

.

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 F

IG

. 9.

F

IG

. 8: Lifting Strap

WLD

F

IG

. 9

WLD

G3

23

92

81

WLD

G3

G2

G4

Setup

333347F 19

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 func-

tioning 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 F

IG

. 10.

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

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

plied hose clamp. See F

IG

. 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

ties (G5). See F

IG

. 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 pel-

lets.

13. Place shaker assembly in an empty adhesive pel-

lets container then fill the container with adhesive

pellets.

NOTE: To promote optimal system performance, pur-

chase 30 Gallon Vibrating Hopper, 24R136. See

installation instructions on page 104.

NOTE: If static buildup on feed tube (G) is excessive,

install optional feed tube ground kit 24R708 to feed tube

end (G6). See F

IG

. 7.

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.

F

IG

. 10

ti21131a

G1

G

G2

G4

G5

G6

Setup

20 333347F

14. Install heated hoses, see F

IG

. 11:

a. Place a rag on the drain tray (W2) attached to

the melter. Residual oil may be in the system

from the factory. See F

IG

. 11.

b. Use a 1/4 in. allen wrench to remove the drain

port plug (W1). See F

IG

. 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 F

IG

. 11.

d. Remove plug (247) from the lowest numbered

outlet on the melter. Do not use the drain

plug (W1). See F

IG

. 11.

NOTE: In the following step, the o-ring side of the

hydraulic fitting (68) faces the system. See F

IG

. 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.

f. Install hose onto hydraulic fitting (68) with male

electrical connector side toward the system.

Use 11/16 in. wrench to tighten hose onto

hydraulic fitting (68).

g. Locate MZLP (AA) connector marked with same

number as the hose fluid outlet port. Remove

that connector cover then install connector from

heated hose. See F

IG

. 11.

h. Repeat the procedure for the remaining chan-

nels. Use the bottom melter ports first to ease

installation.

i. Install cap on any unused MZLP electrical con-

nectors.

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 con-

nected to connector 1, “Invalid Sensor - hose/gun” faults

will result. If the melter must be run without a hose/appli-

cator electrically attached to MZLP connector, use

Overtemperature Jumper, 16Y727, page 113.

15. Install applicator(s), see F

IG

. 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

F

IG

. 11.

b. For Graco applicators, attach applicator electri-

cal connector to heated hose electrical connec-

tor. See F

IG

. 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.

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.

F

IG

. 11

ti23298a

W2

N

247

68

AA

Applicator

W1

Setup

333347F 21

d. Repeat for any additional applicators.

16. If necessary, set up the pattern controller (not

included) to control opening and closing of the appli-

cator. See pattern controller manual.

NOTE: The system controls applicator heating only. A

separate pattern controller must be set up to open and

close the applicator.

17. Install the supplied air inlet bleeding ball valve and

air filter kit (Graco Part No. 24R707) at the 1/4 NPT

female system air inlet (J). See F

IG

. 12.

NOTE: Elbows and riser tube provided with inlet air kit

are optional and may be used as desired.

NOTE: The system must have a bleed-type ball valve

that bleeds pressure downstream when closed. Other-

wise, 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 mini-

mum 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 applica-

tor air pressure requirements, and use a regulator

before the gun to decrease the air pressure, if nec-

essary.

19. Close the ball valve.

20. Attach a 3/8 in. minimum air supply line to air filter.

See F

IG

. 13.

NOTE: Air supply pressure must be between 80 psi

(550 kPa, 5.5 bar) and 100 psi (690 kPa, 6.9 bar). Rec-

ommended 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, pur-

chase Air Adjustment Lock, 24R084. See installa-

tion instructions on page 101.

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.

23. To upgrade a 2 channel system to a 4 channel sys-

tem, purchase 4 Channel Upgrade Kit, 24V528.

See installation instructions on page 108.

24. To upgrade a 4 channel system to a 6 channel sys-

tem, purchase 6 Channel Upgrade Kit, 24V529.

See installation instructions on page 110.

25. Install MZLP electrical connector caps on all unused

channels.

F

IG

. 12

WLE

J

F

IG

. 13

WLE

Setup

22 333347F

Recommended Air Setup

F

IG

. 14

WLE

Main Air Line

Air to applicators

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 Filter/Ball Valve at

System Air Inlet

(Graco Kit 24R707,

included)

Regulator set to

70 psi

(4.8 bar, 0.48 MPa)

Air In:

3/8 in.,

100 psi

(6.8 bar, 0.68 MPa),

30 scfm capacity

No dips in vacuum

transfer hose

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)

Ensure funnel air

is connected

Vacuum Pump

Setup

333347F 23

Connect Electrical Cord

NOTE: See Grounding section on page 17.

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

0.708-1.260 in. (18-32 mm) OD electrical cord. See F

IG

.

15. If needed, use a wrench to tighten the strain relief

bushing until it is snug on the cable.

The accessory strain relief bushing kit 24X190 is avail-

able for smaller (0.512-1.024 in, 13-26 mm) OD electri-

cal cords. See Accessories, page 100.

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 sys-

tem.

3. Remove electrical enclosure access door (T). See

F

IG

. 2 on page 12.

4. Insert electrical cord through electrical enclosure

strain relief bushing (106). See F

IG

. 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.

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

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

F

IG

. 15.

7. Connect L1, L2, L3, and N as shown in F

IG

. 16. Not

all models use all 4 wires.

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.

Improper wiring may cause electric shock or other

serious injury if work is not performed properly. Have a

qualified electrician perform any electrical work. Be

sure your installation complies with all National, State

and Local safety and fire codes.

To reduce the risk of electric shock, perform the entire

Attach Components procedure beginning on

page 17 prior to connecting electrical cord.

F

IG

. 15

F

IG

. 16

WLD

106

AF

X

Y

Setup

24 333347F

208V Electrical Circuits

For 208V electrical supply, a qualified electrician can

install a 208V to 240V step-up transformer to improve

startup times.

Transformer Sizing

Minimum transformer rating can be calculated by taking

transformer output voltage times the ADM breaker set-

ting.

Single Phase, 20A ADM Breaker Setting Example:

240 volts x 20 amps = 4800 watts

Three Phase, 20A ADM Breaker Setting Example:

240 volts x 20 amps x SQRT(3) = 8315 watts

Select ADM Settings

NOTE: See Appendix A - ADM on page 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.

3. On the System 2 screen:

a. Check the box in the “Installed” column for each

channel that has a heated hose and applicator

installed.

b. Select the RTD type used on each installed

applicator. See applicator manual.

NOTE: An incorrect RTD setting will cause the system

to be incapable of maintaining the temperature setting.

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.

4. On the System 3 screen:

a. Enter the main circuit breaker size used. This is

the circuit breaker installed external to the sys-

tem for the system power supply.

NOTE: The InvisiPac system limits the amount of power

it pulls based on the input circuit breaker size. This

impacts the startup times because it affects the heating

energy used to warm up the materials.

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

time.

To prevent fire and explosion, a qualified electrician

must determine the proper circuit breaker size to use

for the power supplied to the system.

Setup

333347F 25

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

mass units.

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.

9. Press to switch from the Setup screens to the

Operation screens. Use , , , and to

navigate between screens.

10. On the Targets screen, use and , shown

next to , to adjust system melter setting.

Also, the desired temperature setting can be typed

in using the numeric keypad.

Setup

26 333347F

11. On the Targets screen, adjust heated hose and

applicator temperature settings:

NOTE: InvisiPac is a high powered tank-free system

that delivers heat faster than traditional tank systems.

Tanks are often run at a lower temperature than the

application temperature to avoid excessive adhesive

degradation since a large volume of adhesive sits at

temperature.

a. Press to select the channel.

b. Use and , shown next to , to

adjust applicator temperature setting to the

desired setting for that channel.

NOTE: If a higher applicator temperature is desired,

adjust all zones to the higher temperature or adjust only

the applicator in small increments.

NOTE: Alternatively, use the physical up and down

arrow push-buttons on the ADM keypad until is

next to the temperature setting to change then use the

numeric keypad to enter the desired temperature.

c. Use and , shown next to ,

to adjust heated hose temperature setting to the

desired setting for that channel.

NOTE: Alternatively, use the physical up and down

arrow push-buttons on the ADM keypad until is

next to the temperature setting to change then use the

numeric keypad to enter the desired temperature.

Applicators

Applicator heating is controlled by the system, but the

system does not control opening and closing the appli-

cators. Setup a separate pattern controller to open and

close the applicators.

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-

ring, page 36.

Setup

333347F 27

PLC Connection

A PLC can control and monitor all items shown in the

dropdown menus on the System 1 screen in the Setup

screens.

Customer Input Dropdown Options

Customer Output Dropdown Options

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.

NOTE: The InvisiPac system ships with two screw-ter-

minal connectors that plug into MZLP connectors H1

and H2. Connectors are located in a bag on the inside of

the electrical enclosure front access door. To replace

the connectors, order kit 24P176.

1. On the System 1 screen (in the Setup screens)

select the function of each input on MZLP connector

H1 and each output on MZLP connector H2.

2. Turn main power switch OFF.

3. Remove electrical enclosure front access door.

4. Route I/O cable through strain relief in electrical

enclosure. See Customer I/O Cable (S) in F

IG

. 1 on

page 11.

5. Remove power from PLC.

6. Connect the PLC to connectors H1 and H2.

NOTE: Each connector has four signals. The MZLP

board specifies the input range for each signal. See the

following table for pin assignments.

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.

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.

Option Description

Disable Not used.

System Ready Indicates when the system is up to tem-

perature 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 (Devia-

tion/Advisory)

Indicates when there is an active devia-

tion 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.

F

IG

. 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

J1

J2

J3

J6

J5

J7

F10 F9 F8 F7

F6 F5

F4 F3

F2 F1

WLD

Setup

28 333347F

PLC Connection Block Diagrams

The following block diagrams show how to connect customer inputs and outputs to the InvisiPac MZLP. For conve-

nience, each InvisiPac ships with connector kit 24P176. If a connector is lost or damaged, order kit 24P176 for

replacements.

F

IG

. 18: Customer Input

F

IG

. 19: Customer Output

Vin (no polarity)

30 VDC Max

Customer Output

MZLP Customer In

To Customer Input

Customer In

MZLP Customer Out

250 VAC, 0-30 VDC, 2A Max

Operation

333347F 29

Operation

NOTE: See Appendix A - ADM on page 114 for

detailed ADM information.

NOTE: See Appendix B - USB Downloading, Upload-

ing on page 120 for detailed USB information.

Overview

The system includes a vacuum transfer system that

pulls the adhesive pellets into the system as needed.

Once melted, the adhesive enters the pump where it is

pumped into the heated hoses then to the heated appli-

cators. The applicator then briefly opens to dispense the

desired quantity of adhesive.

Even though the system rises to operating temperature

quickly, there is a Schedule function in the ADM that

eliminates waiting for the system to heat up. The Sched-

ule function automatically enables the heating system at

the user-specified times so the system is ready to dis-

pense when a shift begins. The Schedule function also

disables the heating system at user-specified times to

ensure the heating system is disabled when not being

used.

Initial Startup and Prime

NOTE: 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 pel-

lets 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.

2. Verify the shaker inlet is at the bottom of the empty

adhesive pellets container. Optional vibrating adhe-

sive pellets container, part 24R136, is available.

See Accessories on page 100.

NOTE: The shaker inlet must be completely covered in

adhesive pellets to effectively pull pellets into the tube.

3. Fill adhesive pellets container with hot melt adhe-

sive pellets.

4. Turn main power switch ON .

5. Open system air inlet ball valve.

Heating and dispensing hot melt adhesive may create

potentially harmful vapors. Read material manufac-

turer’s warnings and material MSDS to know specific

hazards and precautions. Ventilation of the work area

may be required.

NOTICE

To prevent damage to soft key buttons, do not press

the buttons with sharp objects such as pens, plastic

cards, or fingernails.

WLE

Operation

30 333347F

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

air pressure to 0.

7. Use vacuum transfer air pressure regulator (E) to

adjust vacuum transfer air pressure setting to

40-100 psi (280-690 kPa, 2.8-6.9 bar). Recom-

mended setting is 60 psi (414 kPa, 4.1 bar). See

F

IG

. 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.

NOTE: A new system may have residual oil due to test-

ing 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.

NOTE: When the melter is up to temperature, the

auto-fill function will initiate to fill the funnel with pellets.

10. On new systems only: After the melter has reached

250°F (121°C) and the funnel is filled with pellets,

set the melter temperature back to the desired oper-

ating temperature. See Select ADM Settings on

page 24 for instructions.

11. Use separate pattern controller to open the applica-

tors and keep them open.

12. With the applicators open and the system up to tem-

perature, 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:

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. Per-

form service to automatic feed system as soon as possi-

ble to limit debris buildup on feed funnel.

F

IG

. 20

To prevent fire and explosion, never exceed the clean-

ing 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.

E

C

NOTICE

In the following step, to prevent damage to the pump

due to pump cavitation, do not supply more than 20 psi

(140 kPa, 1.4 bar) air pressure to the pump until the

system is fully primed.

Operation

333347F 31

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 dis-

pensing for extended periods of time, use manual refill-

ing with caution. System flow rate can be monitored by

enabling the Diagnostic screen.

1. On the System 3 screen (in the Setup screens),

select “Manual” from the Refill mode dropdown.

2. Remove the two bolts from the funnel bracket, then

remove the top portion of the funnel.

3. Disconnect the sensor cable and sensor cooling air.

4. Fill the funnel with adhesive pellets.

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 F

IG

. 23.

NOTE: This will lower the adhesive level within the fun-

nel cap to the correct level to prevent any issues upon

startup the following production day.

Automatic Refill

The system uses automatic refill by default. If the auto-

matic refill system is malfunctioning and cannot immedi-

ately be fixed, Manual Refill can be used.

To use automatic refill:

1. On the System 3 screen (in the Setup screens),

select “Automatic” from the Refill mode dropdown.

2. Verify shaker and tube are connected to the system.

See Attach Components on page 17.

3. Verify shaker inlet (K) is at the bottom of the adhe-

sive pellets container that is filled with hot melt

adhesive pellets. See F

IG

. 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.

F

IG

. 21

F

IG

. 22

WLD

WLD

F

IG

. 23

WLD

Operation

32 333347F

4. If not already set, use vacuum transfer air pressure

regulator (E) to adjust vacuum transfer air pressure

setting to 40-100 psi (280-690 kPa, 2.8-6.9 bar).

Recommended setting is 60 psi (414 kPa, 4.1 bar).

NOTE: The system will automatically transfer the pellets

to the system as necessary.

Dispense

NOTE: Only hot melt adhesive pellets can be used in

the InvisiPac system.

1. If the system is empty or has air in the lines, perform

Initial Startup and Prime procedure on page 29.

2. If main power switch is OFF, turn main power switch

ON .

NOTE: The main power switch should be left ON at all

times when using the Schedule function.

3. Prepare for dispensing:

a. Verify air inlet ball valve (J) is open. See F

IG

. 1

on page 11.

b. Check pressure gauges (D, F) to verify vacuum

transfer and pump air pressures are set as

desired. See F

IG

. 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.

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.

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 sepa-

rate pattern controller to open and close the applica-

tors as desired to dispense material.

NOTE: While operating the system, the actual tempera-

tures of the hose, applicator, and system melter are dis-

played on the Home screen.

F

IG

. 24

E

Operation

333347F 33

Shutdown

Press to disable the heaters and pump. The

screen will say “Inactive”. If using the Schedule function,

the heaters and pump will be disabled automatically at

the set time. You will not need to press if using the

Schedule function unless you wish to disable the heat-

ing system before the set time. If the heaters were man-

ually disabled, the Schedule function will automatically

enable them at the next set time.

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.

Set Schedule Times

NOTE: Times are set using a 24-hour clock. Several on

and off times can be set each day.

1. On the Schedule screen (in the Setup screens), set

the ON times for each day of the week.

2. Set the OFF times for each day of the week.

Enable Schedule Function

The Schedule function is automatically enabled when

values are entered in the Schedule screen. To disable a

scheduled event, navigate to the event and press

The event will appear gray on the screen when it is dis-

abled. 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 auto-

matically 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.

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Turn main power switch OFF .

2. Close the inlet air supply ball valve.

NOTE: Manually verify the pressure is relieved by open-

ing the applicator and ensuring no adhesive is dis-

pensed.

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 Pro-

cedure when you stop spraying and before cleaning,

checking, or servicing the equipment.

Operation

34 333347F

Drain the System

NOTE: The system must be drained prior to flushing

and prior to some maintenance and repair procedures.

1. On the System 3 screen (in the Setup screens),

change the Refill Setting to “Manual”.

2. If the heating system is disabled, press to

enable the heaters and pump.

3. Decrease pump air pressure to 0.

4. Close system air inlet ball valve.

5. Disconnect hose from applicator inlet then place

hose outlet in a waste container. Repeat for all

hoses. Keep hose to applicator electrical connector

connected.

6. Open applicator to allow residual fluid in applicator

to drain.

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 sys-

tem. When there is no melter fluid at the pump, the

pump will begin to cycle faster.

8. When the pump begins to cycle faster, close the

system air inlet ball valve.

9. Press to disable the heaters and pump.

10. Remove melter drain plug (W1). See F

IG

. 2 on page

12.

11. Disconnect hose from melter outlet.

12. Wait until system stops draining or at most 10 min-

utes.

NOTE: There will be some residual adhesive in the sys-

tem.

13. When done performing the procedure that required

draining the system, set Refill Setting back to “Auto”

on the System 3 screen.

Flush

NOTE: This procedure describes how to flush one hose

at a time for maximum effectiveness.

See the hot melt adhesive technical data sheet or

MSDS for the recommended cleaning fluid. Contact the

hot melt supplier if the technical data sheet or MSDS is

not available.

1. Perform Drain the System on page 34.

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 prevent fire and explosion, use the adhesive manu-

facturer’s recommended cleaning fluid.

• Never exceed the cleaning fluid’s rated

temperature.

• Never flush your system or clean any aluminum

components with halogenated hydrocarbon

cleaning solutions.

To prevent severe burns, wear protective clothing.

Operation

333347F 35

5. On the System 3 screen (in the Setup screens), ver-

ify the Refill Setting is set to “Manual”.

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 sup-

plier for recommended hot melt cleaning fluids.

Fluid level should be 1/2 in. (12.7 mm) from the top

of the melter.

10. Disconnect one hose from its applicator manifold.

NOTE: Keep all applicators closed throughout this pro-

cedure.

11. Route the disconnected hose to a waste container.

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.

NOTE: "Soaking” is important to ensure the best possi-

ble 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 sys-

tem air inlet ball valve to stop the pump.

17. Repeat steps 7 through 16 until clean, adhe-

sive-free hot melt cleaning fluid is dispensed from

the detached hose.

NOTE: Now the melter and the disconnected hose are

thoroughly flushed.

18. Reattach the hose to the applicator manifold.

19. Repeat steps 7 through 18 for each additional

installed hose, leaving a different hose discon-

nected from the applicator manifold each time.

20. Remove and replace filter(s) in all applicator mani-

folds. See applicator manual.

21. Replace Outlet Filter. See page 37.

22. Turn main power switch OFF.

23. Place waste container below drain tray (W2) then

remove drain plug (W1) and wait for system to finish

draining. See F

IG

. 2 on page 12.

24. Allow the system and fluid to cool then perform any

required maintenance procedures beginning on

page 37.

To prevent fire and explosion, never exceed the clean-

ing fluid’s rated temperature.

WLD

Operation

36 333347F

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”.

28. Perform Initial Startup and Prime on page 29.

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 automati-

cally 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 heat-

ing system in accordance with your production sched-

ule. 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 clean-

ing fluid’s rated temperature. Residual cleaning fluid is

still in the system until the system is primed with adhe-

sive.

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.

Maintenance

333347F 37

Maintenance

Replace Outlet Filter

The outlet filter is designed to prevent small contami-

nants from entering the hoses and applicators. Inspect

filter regularly. Replace the filter after flushing and when

you change the adhesive used in the system.

1. If the system is not up to temperature, press to

enable the heaters and pump then wait for system

to reach operating temperature.

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 F

IG

. 25.

5. Use a 1 in. socket to unscrew outlet filter (236).

6. Insert allen wrench through the outlet filter cap to lift

outlet filter (236) out of the system.

7. Discard outlet filter assembly.

8. Place o-rings (232, 237) provided with new outlet fil-

ter 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

The inlet filter is designed to prevent large items from

entering the system. The inlet filter can only be replaced

with the system empty.

1. Close the system air inlet ball valve.

NOTE: Some adhesives have different melting points.

The first temperature tried should be approximately half

of the dispensing temperature. If dispensing at 400°F

(204°C), first try 200°F (93°C) then increase in 20°F

(11°C) increments. If dispensing at 250°F (121°C), first

try 125°F (52°C) then increase in 20°F (11°C) incre-

ments.

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 F

IG

. 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 tem-

perature.

F

IG

. 25

To avoid severe burns, wear protective gloves and

clothing that will insulate your hands and body from

the hot surfaces and material.

WLD

236

232

237

28

8

To avoid severe burns, wear protective gloves and

clothing that will insulate your hands and body from

the hot surfaces and material.

Maintenance

38 333347F

4. When the melter temperature is the desired tem-

perature, turn main power switch OFF.

5. Disconnect cable from ADM, push cable through

plastic shroud, then remove plastic shroud from sys-

tem.

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).

8. If the adhesive is a thin enough gel to remove the

inlet filter: Use an o-ring pick or small allen wrench

to remove filter screen (213) from system.

Otherwise:

a. Install inlet filter cap (215).

b. Install shroud and ADM.

c. Turn main power switch ON.

d. Once ADM software finishes starting up,

press to enable the heaters.

e. Wait for temperature to rise 20°F (11°C) beyond

previous temperature.

f. Go to step 4.

9. Slide new screen (213) into melter base

manifold (201).

10. Install filter cap (215) then use a 1 in. socket to

tighten.

11. Feed ADM cable through plastic shroud (29) then

install shroud onto system. Connect cable to

ADM (30).

Replace Funnel Filter

Disassembly (see F

IG

. 27):

1. Turn main power switch OFF.

2. Rotate funnel cap (706) and remove. Lift out funnel

filter (705).

Reassembly (see F

IG

. 27):

1. Insert filter (705) in funnel assembly. Tighten funnel

cap (706) on funnel.

F

IG

. 26

WLD

215

213

201

F

IG

. 27

WLD

706

705

Maintenance

333347F 39

Filter Maintenance Guidelines*

* 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 estab-

lish 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 preven-

tative maintenance schedule moving forward.

Environmental Classification

Clean Moderate Dusty

Pump inlet filter

Replace filter

every six

months

Replace filter

every four

months

Replace filter

every two

months

Pump outlet filter

Applicator manifold filter

System air filter

Solenoid exhaust filters

Feed funnel filter

Feed funnel inspection/cleanout

Troubleshooting

40 333347F

Troubleshooting

ADM Error Code Table

When an error occurs, press to acknowledge the error. If a Maintenance error occurs, navigate to the Mainte-

nance screen and press to 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.

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

pump.

To avoid injury due to unexpected machine operation

initiated by a remote controller, disconnect the cus-

tomer I/O cable from the system prior to troubleshoot-

ing.

Last Digit in Code Code Relates to:

0Melter

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

Code Description Type Cause Solution

A1D0 Low Current

Melter

Advi-

sory

Melter current is less than 500mA. Faulty melter heater(s). Check heater resistance

and resistance to ground. Replace faulty

heater(s).

A1D_ Low Current

Gun X

Advi-

sory

Applicator current is less than 500mA. 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.

A1D_ Low Current

Hose X

Advi-

sory

Hose current is less than 500mA. Faulty hose heater. Check heater resistance and

resistance to ground. Replace faulty hose.

Troubleshooting

333347F 41

A3MF High Fan Cur-

rent, Trans-

former

Devia-

tion

Transformer fan is greater than

600mA.

Replace transformer fan.

A4D0 High Current

Melter

Alarm Defective or shorted to ground on the

band heater or rod heater.

Measure resistance to ground between heater

leads. Should be a high reading.

A4D_ High Current

Hose X

Alarm Defective or shorted to ground on the

hose power wires.

Replace heated hose.

A4D_ High Current

Gun X

Alarm Defective or shorted to ground on the

heater rods in applicator manifold.

Replace applicator manifold.

A7D0 Unexpected

Current

Alarm Unexpected current flow to melter. Faulty melter heater(s). Check heater resistance

and resistance to ground. Replace faulty

heater(s). See Replace Heater Rod, page 64.

Replace MZLP.

A7D_ Unexpected

Current, Gun X

Alarm Unexpected current flow to applicator

X.

Faulty applicator heater element. Check heater

resistance and resistance to ground.

Faulty MZLP. Replace MZLP.

A7D_ Unexpected

Current, Hose X

Alarm Unexpected current flow to hose X. Faulty hose heat element. Check heater resis-

tance and resistance to ground.

Faulty MZLP. Replace MZLP.

A8D0 No Current

Melter

Alarm Power not getting to melter. Check fuses F1 and F2 on MZLP with daughter

board.

Check J1 is plugged into MZLP with daughter

board and J3 on AWB.

A8D_ No Current

Hose X

Alarm Power not getting to hose. Check fuses F5 and F6 (channels 1, 3, 5) or F9

and F10 (channels 2, 4, 6) on MZLP that the

error hose is connected to.

Check that electrical connector on the heated

hose is plugged into the MZLP.

Check continuity of pins C and D on electrical

connector at MZLP end of heated hose. See

heated hose manual for impedance measure-

ments. Replace hose if readings are too high.

If system only uses one hose and applicator, the

heated hose electrical connector must be

plugged into channel 1 of the MZLP.

A8D_ No Current Gun

X

Alarm Power not getting to applicator. Check fuses F3 and F4 (channels 1, 3, 5) or F7

and F8 (channels 2, 4, 6) on MZLP that controls

the error channel.

Check that electrical plug on hose is plugged into

back of MZLP and applicator is plugged into

hose.

Check continuity of hose pin A gun end to J on

MZLP connector end of hose and pin C on gun

end to pin A on the MZLP end of the hose. Read-

ing should be 0-1 ohm. Replace hose if measure-

ment is outside this range.

If system only uses one hose and applicator,

electrical connector of the heated hose must be

plugged into channel 1 of the MZLP.

A8MF No Fan Current,

Transformer

Devia-

tion

Power not getting to transformer fan. Verify that fan power cable is plugged into J7 on

the AWB.

Verify transformer fan is free of obstructions and

can spin freely.

Code Description Type Cause Solution

Troubleshooting

42 333347F

CAC_

1=MZLP 1

2=MZLP 2

3=MZLP 3

Comm Error

Module

Alarm System not responding to ADM. Dial not set correct on MZLP. Set to 1 on board

with daughter board. Set to 2 on MZLP without

the daughter board in center of electrical enclo-

sure. Set to 3 on MZLP without daughter board

on left of electrical enclosure.

System is not properly loaded with correct soft-

ware. Perform Software Update Procedure on

page 77.

CACX Missing DB Alarm System not acknowledging the daugh-

ter board.

Bad connection between daughter board and

MZLP board. Loosen daughter board, re-seat,

then secure.

Daughter board is not plugged into MZLP1. Plug

daughter board into MZLP with dial set to 1.

Defective MZLP daughter board. Replace.

DADX Pump Runaway Alarm Pump is trying to feed adhesive, no

adhesive to feed.

Storage bin out of adhesive. Refill adhesive.

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 recommenda-

tion.

Plugged vacuum transfer hose or funnel. Clear

plugged hose or funnel.

Worn or damaged pump seals Inspect pump seals. Repair if necessary.

DDDX Pump Diving Devia-

tion

Pump is trying to feed adhesive, no

adhesive to feed.

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 manufac-

turer’s recommendation.

Plugged vacuum transfer hose or funnel. Clear

plugged hose or funnel.

Dispense rate too high. See technical ratings of

system.

Worn or damaged pump seals Inspect pump seals. Repair if necessary.

DE0X Cycle Switch

Error

Alarm No signal from air motor sensor. 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.

L0FX Manual Fill

Mode

Advi-

sory

System set to manual fill mode. Change to auto fill mode. See Setup Screen Sys-

tem 2.

L6FX Level Sensor

Error

Alarm No signal from the level sensor. Check that sensor cable is plugged into sensor.

Check connector at J14 of the daughter board.

Verify there is nothing blocking fill (level) sensor

line of sight.

Defective fill (level) sensor. Replace.

No air to fill cap. Check for air coming from 5/32 in. air line.

Plugged orifice in fill cap below fill sen-

sor.

Remove fill cap and remove object plugging the

orifice.

Code Description Type Cause Solution

Troubleshooting

333347F 43

L8FX Refill timeout Alarm Melter did not receive enough adhesive

pellets for flow rate.

Storage bin out of adhesive. Refill adhesive.

Plugged inlet feed hose or funnel. Clear plugged

hose or funnel.

Low air pressure on feed regulator. Check regu-

lator. See Setup, page 17 for air pressure regula-

tions.

Dirty or plugged funnel filter. Replace filter.

M8MF High Temp Run-

away, Trans-

former

Devia-

tion

At the current rate of temp rise, the

transformer will over heat in 15 minutes

or less.

Verify that fan power cable is plugged into J7 on

the AWB.

Verify transformer fan is free of obstructions and

can spin freely.

Replace transformer.

MMUX USB Log Full Advi-

sory

USB logs full. Data loss will occur if not

downloaded.

Download USB data. See Appendix B - USB

Downloading, Uploading on page 120.

MNDX Pump Mainte-

nance Due

Advi-

sory

Cycles are greater than user set main-

tenance interval.

Perform maintenance and reset “Due” counter to

0 at the Setup Maintenance screen.

T2D0 Low Tempera-

ture, Melter

Devia-

tion

Melter temperature dropped to

15°F(-9°C) below setpoint.

Verify system is operating within meltrate specifi-

cations. 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 set-

point. If system cannot control temperature, ver-

ify the RTD is seated inside the melter.

Replace RTD if RTD was seated properly and

system cannot control temperature

Faulty melter heater(s). Check heater resistance

and resistance to ground. Replace faulty

heater(s).

T2D_ Low Tempera-

ture, Gun X

Devia-

tion

Applicator temperature dropped to

15°F(-9°C) below setpoint.

With the system on and not dispensing verify that

the temperature is properly controlled to the set-

point. 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.

T2D_ Low Tempera-

ture, Hose X

Devia-

tion

Hose temperature dropped to

15°F(-9°C) below setpoint.

With the system on and not dispensing verify that

the temperature is properly controlled to the set-

point. If system cannot control temperature,

replace hose.

Faulty hose heater. Check heater resistance and

resistance to ground. Replace faulty hose.

T4C_ High MZLP PCB

Temp

Alarm MZLP board is overheating. Ambient temperature must be under 120°F.

Defective MZLP board. Replace.

Code Description Type Cause Solution

Troubleshooting

44 333347F

T4D0 High Temp

Melter

Alarm Melter continues to raise above the set-

point.

Check that RTD is seated in melter correctly.

Check that overtemperature switch is plugged in

and check switch resistance. The switch resis-

tance should be near 0 Below 400°F (204°C).

Check melter heaters’ resistance to ground.

Replace heater if a heater is shorted to ground.

Turn system on without dispensing. Verify tem-

perature is properly controlled to the setpoint. If

setpoint is not maintained, replace RTD. If heat

continues to rise past setpoint, replace MZLP.

T4D_ High Temp

Hose

Alarm Hose continues to raise above the set-

point.

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.

T4D_ High Temp Gun Alarm Applicator assembly continues to raise

above the setpoint.

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 applica-

tor’s heater. If heater is not shorted to ground,

replace MZLP.

T4MX High Tempera-

ture, Trans-

former

Alarm Thermistor reading greater than 212°F

(100°C).

Verify transformer fan is operating correctly and

free of obstructions.

Replace transformer.

T6D0 Sensor Error

Melter

Alarm 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.

T6D_ Sensor Error

Hose

Alarm No reading from RTD. Hose electrical connector not plugged into MZLP.

Defective RTD. Replace hose.

T6D_ Sensor Error

Gun

Alarm No reading from RTD. Hose electrical connector not plugged into MZLP

or applicator electrical connector not plugged into

heated hose.

Defective RTD. Replace applicator RTD.

T6MX Thermistor Sen-

sor Error, Trans-

former

Alarm No reading from transformer thermistor

sensor.

Verify that sensor wire is plugged into J7 on

AWB.

Replace transformer.

T8D_ No Temp Rise in

Gun (all zones)

Alarm 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.

Code Description Type Cause Solution

Troubleshooting

333347F 45

T8D_ No Temp Rise in

Hose (all zones)

Alarm Temperature reading does not change. Check fuses F5 and F6 (channels 1, 3, 5) or F9

and F10 (channels 2, 4, 6) on the MZLP that con-

trols the error channel.

Defective heater wires in hose. Replace heated

hose.

NOTE: Defective heaters wires in the hose can

also cause the no current error.

Heated hose electrical connector or wires are

defective. Check resistance of hose wiring. See

hose manual for proper resistance range.

T8D0 No Temp Rise in

Melter (all

zones)

Alarm Temperature reading does not change. Check fuses F1 and F2 on MZLP with daughter

board.

Defective heater wires in melter. Replace melter.

NOTE: Defective heaters wires in the melter can

also cause the no current error.

Defective heater element(s). Check heater resis-

tance 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.

V1I_ Low Can Volt-

age

Alarm Bad or overloaded power supply. 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 read-

ing. 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.

V1MW Low Line Volt-

age

Devia-

tion

Incoming line to line voltage has

dropped below 175V.

Verify incoming power is correct gauge for cur-

rent draw and verify incoming power lines are

securely attached to disconnect.

V4I_ High Can Volt-

age

Alarm Bad or overloaded power supply. Verify power supply voltage is 24 VDC. If voltage

is high, replace power supply unit.

V4MW High Line Volt-

age

Alarm Incoming line to line voltage has

increased above 265V.

For 3 phase with neutral have qualified electri-

cian verify neutral wire.

V6MW Invalid Power

Type

Alarm During startup incoming line to line

power was either below 175V or above

265 V.

Verify incoming power is wired to the disconnect

correctly.

V8M_ No line voltage Alarm Incoming line voltage is less than

100 VAC.

Measure incoming power with system

unplugged. If line voltage is less than 100 VAC,

contact qualified electrician to correct the low

voltage.

WJDX Pump Solenoid

Error

Alarm No voltage draw from air solenoid for

air motor.

Check connector is properly connected to J13 of

the daughter board.

Defective air manifold, replace manifold.

WKFX Fill Solenoid

Error

Alarm No voltage draw from air solenoid for

fill.

Check connector at J13 of the daughter board.

Defective air solenoids. Replace. See page 72.

WSUX USB Invalid

Configuration

Devia-

tion

A valid configuration file can't be found

for the USB.

System is not properly loaded with correct soft-

ware. Perform Software Update Procedure on

page 77. Retry USB download.

Bad ADM. Replace ADM.

Code Description Type Cause Solution

Troubleshooting

46 333347F

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 rec-

ommended) 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 man-

ual 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 rec-

ommended) 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 trans-

fer not working

Air to vacuum assem-

bly missing.

Verify the vacuum transfer system air pressure is 40-80 psi (60 psi rec-

ommended)

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 pel-

lets in storage

bin not cover-

ing shaker

head.

Shaker unit not vibrat-

ing.

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 sole-

noid or fill solenoid wir-

ing.

Verify wiring between J13 and the refill solenoid is not damaged.

Restart system. If the error persists after attempting another refill and

unit is needed immediately for production, place system into the man-

ual refill mode. See Manual Refill on page 30.

Troubleshooting

333347F 47

Level Sensor

Error

Failure of the level sen-

sor (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 oper-

ating 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 man-

ual refill mode. See Manual Refill on page 30.

The InvisiPac

system expels

adhesive pel-

lets dust when

refilling.

Some adhesives are

very dusty due to the

anti-blocking agents

used or because the

adhesive manufactur-

ing process has cre-

ated small adhesive

shavings. Feed inlet

cap filter may have

become clogged.

Replace Funnel Filter, see page 38.

NOTE: Feed cap filter maintenance should be performed at regular

service intervals. It is recommended that the feed cap filter be

inspected at a minimum of every 1200 lb dispensed, however with

some adhesives the frequency may need to be increased significantly

to maintain desired system cleanliness.

The InvisiPac

system will not

stall, pump

continues to

move even if

the applicators

are all closed.

Fluid leak. Verify that no external leakage is present.

Inspect and test the pressure relief valve.

Perform Flush Pressure Relief Valve, page 54.

If system is still unable to stall, the pump or pressure relief valve may

need to be repaired.

The system

will not dis-

pense mate-

rial.

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 receiv-

ing 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 feed-

ing adhesive.

Repair or replace air control assembly as necessary.

Repair or replace pump assembly as necessary.

Timing control for appli-

cators not working.

InvisiPac system does not control the timing of the applicators. This is

a separate control that needs to be adjusted. Consult control manufac-

turer or qualified electrician.

Cycle Switch

Error

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 fas-

tener (26).

Ensure fastener (26) is tight. See InvisiPac Systems section begin-

ning on page 83 for part identification.

Problem Cause Solution

Troubleshooting

48 333347F

USB Log Full The InvisiPac system

will display this notifica-

tion 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 dis-

playing pump

runaway or

pump diving.

This error generally

occurs when the pump

cavitates due to

improper material load-

ing.

This can occur if the melt rate for the system is exceeded, resulting in

air entrapment within the incoming adhesive material and lower than

desired material temperature.

1. Verify that the InvisiPac system is not exceeding (11 cpm- HM25,

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 tempera-

ture in small increments over the current set point.

3. If the pump continues to runaway or dive continue increasing tem-

perature 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 fol-

lowing 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 applica-

tor 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 sup-

plying enough air to the

ultrasonic sensor ven-

turi.

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 sen-

sor 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).

Problem Cause Solution

Troubleshooting

333347F 49

Unable to

achieve pub-

lished melt rate

at the desired

adhesive tem-

perature.

The InvisiPac system

monitors temperature

within aluminum mass

of melter (202). As melt

rates exceed 20 lb/hr a

system temperature

offset may be required.

1. If the cycle rate is below (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, leave

hoses and applicators at desired set point.

2. If the pump continues to runaway or dive continue increasing tem-

perature in small increments. Do not exceed maximum temperature

for the material being dispensed.

NOTE: A 50 amp breaker is required in order to maximize startup and

flow rate performance. Set the breaker size used in the Setup screens.

NOTE: Some materials are more difficult to melt than others, therefore

it may be impossible to process them at the published melt rate. The

InvisiPac system was tested to achieve 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 dis-

playing when

system turned

on

Main power circuit

breaker off or power

cord unplugged.

Turn main circuit breaker on or plug in power cord.

Cable on ADM

unplugged.

Reconnect ADM cable.

Connector on AWB

board not plugged in.

ADM cable should be plugged into J9 of the AWB board.

Bad 24VDC power sup-

ply.

Check output on power supply should measure 24VDC, if no voltage

reading replace power supply.

ADM defective. Replace ADM.

Main breaker

tripping

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.

Problem Cause Solution

Troubleshooting

50 333347F

Slow start-up

time or system

takes longer

than 10 min-

utes 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 380-

400 VAC for a 400 volt unit.

Heater rod defective.

Melter and gun mani-

fold.

Measure and check heater rods in melter or applicator. See applicator man-

ual. 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 sup-

plied to system. Depend-

ing on hose and

applicator combinations,

along with minimal sup-

ply 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.

No adhesive or

little adhesive

being dis-

pensed

Incorrect RTD setting in

system.

1. Verify melter, hose, and applicator temperatures are all with in the

same range of the room ambient.

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 indi-

cates no errors

and correct

temperature

however appli-

cator is over

the tempera-

ture setpoint

Incorrect RTD setting in

system.

1. Verify melter, hose, and applicator temperatures are all within the

same range of the room ambient.

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.

Problem Cause Solution

Troubleshooting

333347F 51

No adhesive or

incorrect

amount of

adhesive out-

put when all

dispense mod-

ules are trig-

gered

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 cor-

rect, 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 simulta-

neously, 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

Plugged tip on dis-

pense module.

Replace tip on dispense module.

Defective dispense

module in closed/par-

tial open position.

Replace dispense module.

Plugged applicator

manifold filter (single

dispense module appli-

cator).

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 cor-

rect, 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 muf-

flers

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 simulta-

neously, maximum

pump rate may be

exceeded.

Stagger applicator opening to reduce the maximum required flow rate

to below maximum pump rate.

Problem Cause Solution

Troubleshooting

52 333347F

Adhesive flow-

ing out of

one/some

applicators

when not trig-

gered

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 appli-

cator 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 cor-

rect RTD value.

Thermal cutoff is tripped. Measure resistance of the thermal cutoff at room temperature. If open,

replace.

Adhesive leak-

ing from mani-

fold or dispense

module.

Dispense module is

loose on the manifold.

Tighten screws on loose dispense module.

Dispense module o-ring

failed.

Replace o-rings on the back of the leaking dispense module.

Failed dispense module,

adhesive leaking out

middle of dispense mod-

ule.

Replace dispense module.

Hose loose. Tighten hose.

No melter heat. Fuse blown in F1 and F2. Check heater rods for a short or a short between the rod wires and ground.

Cable to over-tempera-

ture 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.

Air motor will

not function.

No air being supplied to

air motor.

Check incoming air supply. air motor is disabled until system reaches “Active”

state. When “Active”, the pump air solenoid should supply air to the air motor.

Air solenoid not enabling

the air motor.

Check solenoid voltage, if 24VDC present at air solenoid replace air solenoid.

Air present at air motor

but it will not work.

Replace air motor.

System not

turning on.

No power to unit. Check main power breaker is turned on.

Check that power plug is connected.

Problem Cause Solution

Troubleshooting

333347F 53

Static shock

when touching

shaker or

adhesive bin.

Ground wire not in

place on shaker

assembly. Some adhe-

sives, 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 appli-

cators. The separate controller needs to be adjusted. Consult pattern

control manufacturer or qualified electrician.

Pump and vac-

uum feed sys-

tem 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.

Problem Cause Solution

Troubleshooting

54 333347F

Flush Pressure Relief Valve

Perform this procedure when directed in the Trouble-

shooting table.

1. With the system active at the required adhesive

temperature, set the air motor air pressure to 20 psi

(140 kPa, 1.4 bar).

2. Remove the air line (36) from the pressure relief

valve.

3. Plug air line and allow the air motor to cycle.

4. Re-connect air line to relief valve and check whether

the system will stall.

5. If system still does not stall, purge ten pump cycles

of material through one applicator.

6. Repeat this entire procedure until no additional air is

expelled from the applicator.

Check the Pump Air Solenoid Operation

Perform this procedure when directed in the Trouble-

shooting table.

NOTE: System must be up to operating temperature for

pump solenoid to trigger on.

1. If the heating system and pump is disabled,

press to enable the heaters and pump.

2. Wait for system to reach the temperature setpoints.

3. Set pump air pressure to 20 psi (140 kPa, 1.4 bar).

4. Remove the 3/8 in. OD air line from the air motor.

5. Verify that air is flowing through the air line.

6. If air is not flowing, check the wiring between J13

and the pump solenoid.

Check Heater Rod Resistance

Use the table to determine if heater elements need to be

replaced.

F

IG

. 28

WLD

36

Ref. Element

HM25 HM50

Wattage Ohms Wattage Ohms

208 Band

Heater 1250 43.5-48.5 2000 27-31

209 Melter

Rod

500 109-121 1500 36.5-40.5

210 Base Rod 1500 36.5-40.5 1000 54-61

210 Pump Rod 1500 36.5-40.5 1000 54-61

Troubleshooting

333347F 55

MZLP Troubleshooting

NOTE: The MZLP LED is located on the inside of the

electrical enclosure. To view, remove the electrical

enclosure front access door.

F

IG

. 29: MZLP LED Signals

Signal Description

Green On MZLP is powered up and input

voltage is within operating con-

ditions.

Yellow On Internal communication in pro-

cess

Red Solid MZLP failure. See troubleshoot-

ing table.

Red Flashing Software update in process or

missing software.

WLD

MZLP

F

IG

. 30: MZLP Diagnostic LED Location

J3

1

4

5

6

7

8

9

2

3

0

Green

Yellow

Red

ti20348a

Repair

56 333347F

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 pro-

cedure. Order any required tools and have them on

hand prior to beginning the procedure.

Pump

Replace Throat Seal, Throat Bearing, Piston Rod,

Piston Seal, and Piston Bearing

Disassembly (see F

IG

. 31):

1. Flush the system. See page 34.

2. Close the bleed-type ball valve installed at the sys-

tem air inlet to relieve all air pressure in the system.

3. Turn main power switch OFF.

4. Remove plastic shroud (27).

5. Remove vacuum transfer inlet funnel.

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

motor (218).

7. Remove four nuts (3) securing melter shield (27) in

place then remove melter shield.

8. Remove air motor assembly:

a. Remove retaining ring (239).

b. Remove dowel pin (238).

c. Remove three screws (240).

9. Use a flat head screwdriver and a rubber mallet to

break loose the retaining nut (235).

10. Use channel lock pliers to remove the retaining

nut (235).

11. Insert an allen wrench through the hole in the top of

the piston rod (223) to lift the piston rod (223) up out

of the manifold. This will also pull out the throat

u-cup (234) and throat bearing (233).

12. Remove piston valve (222) from piston rod (223).

13. Remove and discard piston u-cup (225) and

bearing (226).

Reassembly (see F

IG

. 31):

1. Assemble piston rod:

a. Install new piston u-cup (225) onto piston

rod (223) with the lips facing the rod.

b. Install piston bearing (226) onto piston rod (223)

with grooved end towards the center of the pis-

ton rod.

NOTICE

When performing any procedure that requires

removal of seals or other soft parts, do not leave a

system that has not been flushed disassembled for

more than 30 minutes to prevent the adhesive from

hardening. Hardened adhesive will damage the seals

and other soft parts during installation.

F

IG

. 31

WLD

27

3

218

240 235

233

234

238

223

222

226

225

245

239

224

Repair

333347F 57

c. Install piston valve (222) onto piston rod (223).

Torque to 24-30 ft-lb (33-41 N•m).

2. To protect the seals from the sharp threads, place

seal installation tool 15B661 into the throat bore.

See F

IG

. 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 gen-

tly tap throat u-cup (234) into place. See F

IG

. 33.

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.

7. Remove seal installation tool.

8. Install retaining nut (235). See F

IG

. 32.

9. Install air motor assembly (see F

IG

. 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).

F

IG

. 32

F

IG

. 33

ti20877a

15B661

203

ti21047a

234

F

IG

. 34

ti21144a

233

235

Repair

58 333347F

Replace Pump Inlet Housing Checks

Disassembly (see F

IG

. 35):

1. Flush the system. See page 34.

2. Close the bleed-type ball valve installed at the sys-

tem air inlet to relieve all air pressure in the system.

3. Turn main power switch OFF.

4. Remove four bolts (246) and pump manifold (203)

from melter outlet.

5. Use a 1/2 in. drive ratchet without a socket to

remove foot valve (230) from bottom of melter outlet

manifold (203).

6. Remove and discard seat (228), ball (227),

o-ring (229), and o-ring (231).

Reassembly (see F

IG

. 35):

1. Install new o-ring (231), o-ring (229), seat (228),

and ball (227) then use a 1/2 in. drive ratchet

without a socket to install and tighten foot

valve (230) onto melter.

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

Disassembly (see F

IG

. 31):

1. Flush the system. See page 34.

2. Close the bleed-type ball valve installed at the sys-

tem air inlet to relieve all air pressure in the system.

3. Turn main power switch OFF.

4. Remove plastic shroud (27). See F

IG

. 31 on

page 56.

F

IG

. 35

WLD

230

228

227

231

203

229

246

F

IG

. 36

WLD

218

235

233

234

233

224

226

222

230

217

217

216

239

203

Repair

333347F 59

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

motor (218) See F

IG

. 31 on page 56.

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

place then remove melter shield. See F

IG

. 31 on

page 56.

7. Remove air motor assembly. See F

IG

. 31 on

page 56:

a. Remove retaining ring (239).

b. Remove dowel pin (238).

c. Remove three screws (240).

8. Use a flat head screwdriver and a rubber mallet to

break loose the retaining nut (235).

9. Use channel lock pliers to remove the retaining

nut (235).

10. Insert an allen wrench through the hole in the top of

the piston rod (223) to lift the piston rod (223) up out

of the manifold. This will also pull out the throat

u-cup (234) and throat bearing (233).

11. 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 F

IG

. 36, page 58.

13. Insert cylinder tool (1301) into bottom of melter out-

let manifold (203). Use a rubber mallet to gently

remove cylinder (216).

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

IG

.

37.

Reassembly:

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

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

IG

. 37.

2. Place female cylinder installation tool (1302) into

melter outlet manifold (203) to protect seals from

sharp threads. See F

IG

. 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

F

IG

. 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 F

IG

. 36, page 58.

5. Perform Replace Pump Inlet Housing Checks on

page 58.

6. Perform Reassembly portion of the Replace Throat

Seal, Throat Bearing, Piston Rod, Piston Seal,

and Piston Bearing procedure which starts on

page 56.

F

IG

. 37

ti20880a

217

216

217

1301

203

F

IG

. 38

ti21049a

203

217

216

217

1302

1303

Repair

60 333347F

Melter

Remove Melter Assembly

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.

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

inlet.

3. Turn main power switch OFF.

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.

6. Remove screws (8) then remove electrical enclo-

sure front access door (10).

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).

9. Remove nuts (3) on the back metal shroud (27)

then remove shroud.

10. Remove fabric melter insulator (53).

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

F

IG

. 42, page 63.

12. Loosen hose clamp (81) then remove funnel (FF).

13. Remove wire connectors from the over-temperature

switch (251).

14. Remove insulators (53, 75) from the melter

assembly (5).

15. Disconnect the fill sensor cable from the fill

sensor (20). See Replace Fill Sensor, page 69.

16. Disconnect the pump cycle sensor cable from the

air motor.

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

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

F

IG

. 41 on page 62.

19. Disconnect ground screw (87) and ring terminal (88)

from melter assembly.

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

F

IG

. 39

WLD

FF

29

30

27

10

8

203

1

3

53

3

5

218

81

75 251

245

36

F

IG

. 40

WLD

87

88

Repair

333347F 61

21. Remove all heater wires from the following termi-

nals. Pull wires up through the rubber grommet on

the top of the electrical enclosure (1).

22. Remove four nuts (3) then remove melter assembly

from system. Save any loose insulators for reas-

sembly.

23. Remove bolts (259), insulators (249), washers

(268), and melter assembly from base (257).

Install Melter Assembly

1. Route melter heater rod (209) wire through large

hole in the melter base (257) then through small

hole in side of melter base (257).

2. With the 10 insulators (4) in place on the melter

assembly, place melter assembly on melter

base (257).

3. Use 4 bolts (259) to secure washers (268) and

melter assembly to melter base (257).

4. Use four nuts (3) to secure melter assembly to sys-

tem.

5. Group the 4 sets of heater wires together and run

them through the grommet on the top of the electri-

cal enclosure (1). Connect wires as noted below.

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

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

8. Connect pump cycle sensor cable to air motor.

9. Install funnel (FF) then tighten clamp (81).

10. Install temperature sensor (125) into melter then

tighten screw (AA) on band heater. See F

IG

. 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 F

IG

. 43 on page 64.

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

15. Pull the relief valve air tube (36) through the metal

housing then attach air tube to relief valve (245).

16. Install front access door (10) onto electrical

enclosure (1).

17. Feed ADM cable through shroud then install shroud

and connect cable to ADM.

18. Reconnect all heated hoses to the melter outlet

manifold (203).

19. Turn main power switch ON.

20. Open system air inlet ball valve.

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) J4-3 J4-4

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).

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) J4-3 J4-4

Repair

62 333347F

Replace Band Heater

Disassembly (see F

IG

. 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).

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).

8. Locate the J4-1 and J4-2 wires in AWB board and

remove wires.

9. Pull wires up through grommet (63) on top of the

electrical enclosure (1). Clip any wire ties that hold

the wires in place.

10. Continue loosing screw (AA) then slide band

heater (208) up to remove.

Reassembly (see F

IG

. 41):

1. Install band heater (208) on the melter with the

opening and screw facing the front of the system in

alignment with the sensor port.

2. Install sensor (125).

3. Slide band heater up then tighten screw (AA).

NOTE: Band heater should be oriented to hold sensor in

place when tightened. It should not bend the sensor.

4. Route band heater wires through grommet (63) in

the top of the electrical enclosure (1).

5. Connect wires to AWB board as marked. Wires

should be marked as shown in the following table.

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

F

IG

. 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.

F

IG

. 41

WLD

53

AA

125

10

F

1

63

8

208

80

Item

Wire

Marking 1

Wire

Marking 2

Band Heater (208) J4-1 J4-2

Repair

333347F 63

Replace Band Heater Temperature Sensor

Disassembly (see F

IG

. 42):

1. Close the bleed-type ball valve installed at the

system air inlet to relieve all air pressure in the

system.

2. Turn main power switch OFF.

3. Disconnect cable from ADM then remove shroud.

4. Remove air tube (36) from relief valve. Pull the air

tube through the metal shroud (27).

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

See F

IG

. 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 F

IG

. 42.

NOTE: This connector also includes the over-tempera-

ture switch wires.

10. Disconnect wire connectors from over-temperature

switch (251). See F

IG

. 43 on page 64.

11. Pull cable out of the electrical enclosure then dis-

card sensor (125) and wires.

Reassembly (see F

IG

. 42):

1. Route new harness wires through grommet (63) in

the top of the electrical enclosure.

2. Connect wire connectors to over-temperature

switch (251). See F

IG

. 43 on page 64.

3. Place band heater temperature sensor (125) in

melter.

4. Tighten screw (AA).

NOTE: Screw should lightly squeeze the temperature

sensor to hold it in place. It should not bend the sensor.

5. Connect new harness to MZLP connector labeled

J5.

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

F

IG

. 41 on page 62.

7. Install fabric melter insulator (53).

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

IG

.

39, page 60.

9. Route relief valve air tube through the metal shroud

then attach to the relief valve.

10. Feed ADM cable through shroud then install shroud

and connect cable to ADM.

11. Turn main power switch ON.

12. Open system air inlet ball valve.

F

IG

. 42

WLD

AA

125

53

40

80

10

Repair

64 333347F

Replace Heater Over-Temperature Switch

Disassembly (see F

IG

. 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.

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 F

IG

. 45,

page 65.

5. Use 7/16 in. socket to remove nuts (3) then remove

metal shroud (27).

6. Disconnect the wire connectors from the over-tem-

perature switch (251).

7. Remove the screws (255) securing the over-tem-

perature switch (251) to the melter assembly (5),

then remove the switch.

Re-assembly (see F

IG

. 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.

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.

Replace Heater Rod

Disassembly (see F

IG

. 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).

F

IG

. 43

ti21052a

251

255

F

IG

. 44

WLD

210

210

209

209

206

206

206

Repair

333347F 65

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. Remove electrical enclosure front access door (10).

See F

IG

. 41, page 62.

6. Disconnect heater rod wires from terminal blocks

described in the following table.

7. Pull heater rod wires up through the grommet in the

top of the electrical enclosure (1).

8. Remove heater rod retaining ring (206) then remove

and discard heater rod (209, 210).

Reassembly (see F

IG

. 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.

2. Install heater rod then install heater rod retaining

ring (206). See F

IG

. 44.

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

F

IG

. 41, page 62.

4. If replacing the melter heater rod (209), Install

Melter Assembly. See page 60.

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.

b. Install and tighten nuts (3).

c. Pull the air tube through the metal shroud (27)

then connect the air tube (36) to the relief

valve (245).

7. Feed ADM cable through plastic shroud then install

plastic shroud and connect cable to ADM.

Replace Fluid Pressure Relief Valve

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

F

IG

. 45.

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

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)

J4-3 J4-4

NOTICE

To prevent damaging the heater rod, do not use

thermal grease in the following step.

F

IG

. 45

ti20757a

245

244

36

3

27

Repair

66 333347F

6. Use crescent wrench to remove melter fluid pres-

sure relief valve (245). See F

IG

. 45.

7. Use an o-ring pick to remove o-ring (244).

8. Install o-ring (244) into manifold.

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

manifold. See F

IG

. 45. Once hand-tight, use cres-

cent wrench to tighten.

10. Use nuts (3) to install metal shroud.

11. Connect air tube to pressure relief valve.

12. Feed ADM cable through plastic shroud then install

shroud and connect cable to ADM.

NOTICE

To prevent damage to o-ring, ensure o-ring is seated

properly prior to moving to next step.

Repair

333347F 67

Multi-Zone Low Power Temperature Control Module (MZLP)

Replace MZLP Fuse

MZLP Identification

Fuse Kits

1. Turn main power switch OFF.

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

3. Use a proper non-conductive fuse puller tool to

remove the blown fuse.

NOTE: F1 and F2 are white ceramic and indicate 25A

on the barrel.

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

barrel.

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

install the new fuse.

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

Key

24V510

AF1 and F2 fuses are physically larger than F3-F10

BBlue sticker on relay

CMarked 24V133

F

IG

. 46: MZLP ID and Fuse Locations

NOTICE

To prevent system damage, always use fast acting

fuses. Fast acting fuses are required for short-circuit

protection.

J1

J2

J3

J6

J5

J7

F10 F9 F8 F7

F6 F5

F4 F3

F2 F1

WLD

A

B

C

Fuse Part

24V510 MZLP Fuses

F1, F2 250VAC, 25A, fast acting, white, 0.25 in x 1.2 in

F3-F10 250VAC, 8A, fast acting

Kit MZLP Description

24V289 24V510 Includes standard clear fuses.

24X480 Includes ceramic fuses used for

food industries.

NOTICE

Using an improper tool, such as screw drivers or

pliers may break glass on fuse.

NOTICE

Using an improper tool, such as screw drivers or

pliers may break glass on fuse.

Repair

68 333347F

Replace MZLP

Disassembly:

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 F

IG

.

47.

5. Remove four screws (114) securing MZLP (112) to

electrical enclosure (1) then carefully remove MZLP

from electrical enclosure. See F

IG

. 47.

6. Replace MZLP. See F

IG

. 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 F

IG

. 48 for rotary switch location.

2. Apply channel label stickers to new MZLP. See F

IG

.

47.

3. Use four screws (114) to install MZLP (112) to elec-

trical enclosure (1).

4. Reconnect cables to MZLP (112).

NOTE: Do not force the electrical connection. Minimal

force is required to seat the connector. If resistance is

felt, stop and verify the connector orientation.

NOTE: If unable to determine connector location, see

Electrical Schematics on page 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 Soft-

ware Update Procedure on page 77.

Replace MZLP Daughter Card

Disassembly:

1. Turn main power switch OFF.

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

3. Note location of each cable then unplug all cables

from MZLP daughter card (112a).

4. Remove four mounting screws (112b) from daugh-

ter card (112a) and set aside.

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

#1 (112).

F

IG

. 47

114

112

MZLP

#1

MZLP

#2

MZLP

#3

F

IG

. 48

112b

112

112a

Rotary Switch

ti20342a

Repair

333347F 69

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.

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

System

Replace Fill Sensor

Disassembly (see F

IG

. 49):

1. Turn main power switch OFF.

2. Remove filter cover (68) and filter element.

3. Gently pull up on cable while unscrewing fill sensor

connector then remove fill sensor cable from fill

sensor (20).

4. Loosen fill sensor jam nut then remove fill

sensor (20) from sensor housing (73).

Reassembly (see F

IG

. 49):

1. Thread new fill sensor (20) into sensor housing (73).

Bottom out the sensor in the sensor housing then

back out 1/2 turn.

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

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

4. Replace filter element and cover (68).

Replace ADM

1. Turn main power switch OFF.

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

See F

IG

. 50.

3. Remove ADM from bracket (58).

4. Install new ADM into bracket.

5. Connect cable to bottom of new ADM.

NOTE: ADM may need updated software. See Soft-

ware Update Procedure on page 77.

F

IG

. 49

WLD

20

68

73

F

IG

. 50

ti20763a

CC

30

58

Repair

70 333347F

Replace AWB

Disassembly:

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 F

IG

. 51.

5. Remove two screws (144) securing power supply

bracket (145) to AWB (143) and remove power sup-

ply bracket. See F

IG

. 51.

Reassembly:

1. Use two screws (144) to secure power supply

bracket (145) to new AWB (143). See F

IG

. 51.

2. Mount power supply (146) to power supply bracket

(145). See F

IG

. 51.

3. Connect connector (labeled AWB-J1) on power sup-

ply harness (147) to J1 on AWB (143). See Electri-

cal Schematics, page 78.

4. Use two screws (131) to install AWB (143) to electri-

cal enclosure (1). See F

IG

. 51.

5. Reconnect cables to AWB (143).

NOTE: Do not force the electrical connection. Minimal

force is required to seat the connector. If resistance is

felt, stop and verify the connector orientation.

NOTE: If unable to determine the connector location,

see Electrical Schematics, page 78.

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

F

IG

. 51: AWB and Power Supply

145

144

146

145

131

131

Repair

333347F 71

Replace Power Supply

Disassembly:

1. Turn main power switch OFF.

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 F

IG

. 51.

4. Disconnect screw terminal connections between

power supply (146) and power supply harness (147)

according to the following table. See F

IG

. 51.

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 F

IG

. 51.

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

Replace Power Supply Harness

Disassembly:

1. Turn main power switch OFF.

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

3. Disconnect screw terminal connections between

power supply (146) and power supply harness (147)

according to the following table.

4. Unplug power supply harness (147) from J1 on

AWB (143). See Electrical Schematics, page 78.

Reassembly:

1. Make connections between power supply harness

(147) and new power supply (146).

2. Connect connector (labeled AWB-J1) on power sup-

ply harness (147) to J1 on AWB (143). See Electri-

cal Schematics, page 78.

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

Power Supply

Connection Harness Label

V+ V+

V- V-

GND GND

LL

NN

Power Supply

Connection Harness Label

V+ V+

V- V-

GND GND

LL

NN

Repair

72 333347F

Air Controls

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 F

IG

. 52):

1. Turn main power switch OFF.

2. Disconnect plug from power outlet or turn off circuit

breaker for incoming power.

3. Close the bleed-type ball valve installed at the sys-

tem air inlet to relieve all air pressure in the system.

4. Remove front access panel (10) from electrical

enclosure (1).

5. Remove the transformer assembly; for 480V sys-

tems only (see F

IG

. 53):

a. Disconnect transformer wires from J2 connector

on AWB board and the main power switch.

b. Remove three screws (142) and InvisiPac sys-

tem off of transformer assembly (140).

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

7. Note location of each air line connection.

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

IG

.

52, in bottom of electrical enclosure then disconnect

air lines from air control solenoids (402).

9. Disconnect air control solenoids cable from MZLP

daughter board connector J13. Pull wire out of the

electrical enclosure.

10. Remove two screws (405) securing solenoids (402)

to air control assembly (9) then remove air control

solenoids.

Reassembly (see F

IG

. 52):

1. Use two screws (405) to secure new

solenoids (402) to air control assembly (409).

2. Feed the new solenoid cable into the electrical

enclosure and attach cable to MZLP daughter board

connector J13.

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

IG

.

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.

F

IG

. 52

F

IG

. 53

WLD

8

9

1

405

402

FF

WLD

140

142

Repair

333347F 73

6. Install electrical enclosure front access door.

Replace Air Control Gauge

Disassembly (see F

IG

. 54):

1. Turn main power switch OFF.

2. Close the bleed-type ball valve installed at the sys-

tem air inlet to relieve all air pressure in the system.

3. Remove two screws (8) then slide air control

assembly (9) out from electrical enclosure (1) so the

back of the gauges are exposed.

4. Remove two nuts (403a) securing gauge (403) in

place then remove bracket (403c).

5. Place one small crescent wrench on the brass part

of the gauge then use a second small crescent

wrench to remove the air fitting (403b).

6. Remove air gauge from panel.

Reassembly (see F

IG

. 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.

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).

4. Orient gauge as desired then tighten two

nuts (403a) to secure gauge (403) in place.

5. Slide air control assembly (9) into place then use

two screws (8) secure to electrical enclosure.

Air Motor

Replace Pilot Valve

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. Lubricate with grease and install new air motor

pilot valve (511).

F

IG

. 54

WLD

403

8

9

403a

403b

403c

NOTICE

In the following step, do not overtighten the two

nuts (403a). Overtightening may cause the gauge to

break.

F

IG

. 55: Top Pilot Valve

WLD

511

218

C

Repair

74 333347F

d. Torque pilot valve to 95-105 in-lb (10.7-11.9

N•m).

4. Replace bottom pilot valve (511):

a. Remove cover (29) and insulation (6).

b. Use 10 mm socket to remove air motor pilot

valve (511) from air motor (218).

c. Lubricate with grease and install new air motor

pilot valve (511).

d. Torque pilot valve to 95-105 in-lb (10.7-11.9

N•m).

e. Replace insulation (6) and cover (29).

Replace Air Valve

Disassembly (see F

IG

. 57):

1. Close the bleed-type ball valve installed at the

system air inlet to relieve all air pressure in the

system.

2. Turn main power switch OFF.

3. Loosen clamp on air motor bracket (528) then

remove funnel assembly (61).

4. Loosen upper hose clamp on rubber housing then

remove fill cap.

5. Dispense until the fluid level in the melter is at or

below the honeycomb grid.

NOTE: If a screw or air valve seal is dropped during this

procedure it could fall into the melter. Melter fluid level

must be below honeycomb grid before moving to next

step.

6. Once the fluid level is low enough, close the

bleed-type ball valve installed at the system air inlet.

7. Disconnect air hose and cable from the air motor.

8. Use 10 mm socket to remove four screws (509)

securing air valve (512) to air motor (218).

9. Remove air valve (512) and seal (507) then discard.

Reassembly (see F

IG

. 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.

F

IG

. 56: Bottom Pilot Valve

WLD

218

29

6

511

F

IG

. 57

507

512

509

218

Repair

333347F 75

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 rub-

ber housing.

5. Connect air hose and cable to the air motor.

Remove Air Motor

1. Close the bleed-type ball valve installed at the

system air inlet to relieve all air pressure in the

system.

2. Turn main power switch OFF.

3. Disconnect air line (36) from pressure relief

valve (245) then pull through metal shroud (27). See

F

IG

. 45 on page 65.

4. Remove three nuts (3) securing metal shroud (27)

in place then remove metal shroud (27).

5. Disconnect air supply line from air motor (218).

6. Remove air motor assembly:

a. Slide retaining ring (239) down.

b. Remove dowel pin (238).

c. Remove three screws (240).

d. Remove screws (8), screws (74), and bracket

(82).

7. If replacing a damaged air motor with a new fully

assembled air motor:

a. Remove three screws (211) securing air motor

tie rods (220) to base plate (219).

b. Remove tie rods (220) from air motor (218).

Install Air Motor

See F

IG

. 58.

1. If replacing a damaged air motor with a new fully

assembled air motor:

a. Install tie rods (220) onto air motor (218).

b. Install three screws (211) securing air motor tie

rods (220) to base plate (219).

2. Connect air motor assembly to system:

a. Install three screws (240), two screws (8),

screws (74), and bracket (82) to secure air

motor assembly to system.

b. Install dowel pin (238).

c. Install retaining ring (239) over dowel pin (238).

3. Use four nuts (3) to install melter shield (27).

4. Reconnect air supply line to air motor (218).

5. Reconnect air line (36) to pressure relief

valve (245). See F

IG

. 45 on page 65.

F

IG

. 58

WLD

220

218

238

240

211

219

239

3

27

8

82

74

Repair

76 333347F

Transformer Fan

Replace Fan

1. Turn main power switch OFF.

2. Disconnect plug from power outlet or turn off circuit

breaker for incoming power.

3. Remove front access panel (10) from electrical

enclosure (1).

4. Remove connector from J7 connector on AWB

board. Remove red (+) and black (-) wires from con-

nector.

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).

7. Remove four nuts (158), rear fan grill (170), and fan

(155).

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).

3. Route fan wires with transformer wires into the elec-

trical enclosure (1). Connect red and black fan wires

to J7 connector. Reconnect J7 connector to AWB

board. See F

IG

. 60.

4. Reinstall corrugated tube (167) on fan and trans-

former wires. See F

IG

. 59.

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).

F

IG

. 59

F

IG

. 60

WLE

158

1

151

154

157

167

161(x3)

WLD

J7

(+)

(-)

black

red

1

Front access panel (10) not shown.

F

IG

. 61

WLE

161

red (+)

black (-)

Repair

333347F 77

Software Update Procedure

When software is updated on the ADM the software is

then automatically updated on all connected GCA com-

ponents. A status screen is shown while software is

updating to indicate progress.

1. Turn system main power switch OFF.

2. Remove ADM from bracket.

3. Remove token access panel.

4. Insert and press InvisiPac software upgrade token

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

NOTE: There is no preferred orientation of token.

5. Install ADM into bracket.

6. Turn system main power switch ON.

NOTE: When the screen turns on, you will see the fol-

lowing screens:

7. Remove token (T).

8. Replace token access panel.

9. Press to continue to the InvisiPac operation

screens.

F

IG

. 62: Remove Access Panel

F

IG

. 63: Insert Token

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.

r_24P860_3B9900_3a

T

r_24P860_3B9900_4a

Icon Description

Update successful.

Update unsuccessful.

Update complete, no changes

necessary.

Update was successful/com-

plete but one or more GCA

modules did not have a CAN

boot-loader so software was

not updated on that module.

First:

Software is checking

which GCA modules

will take the available

updates.

Second:

Status of the update

with approximate time

until completion.

Third:

Updates are complete.

Icon indicates update

success/failure. See

the following Icon

table.

Electrical Schematics

78 333347F

Electrical Schematics

Incoming Power

Cable Identification

Use the table to identify cables and other system com-

ponents in the electrical schematics.

To prevent electric shock and system damage, all

electrical work must be performed by a qualified elec-

trician.

NOTICE

To prevent severe system damage, ensure main power

leads are installed correctly. See Connect Electrical

Cord on page 23.

Ref Part Description

9 --- Manifold, air assembly

20 24R041 Sensor, ultrasonic

25 24A032 Switch, reed assembly

30 24P860 ADM

86 127666 Cable, Extension

87 --- WIRE, ground

90 --- Plug, Phoenix, 8pin

103 --- Harness, MZLP #1 AWB

112 24V288 Module, MZLP with daughter

board

118 24V510 Module, MZLP

121 16T087 Cable Board

123 127768 Cable, CAN,

124 16T103 Cable Pump

125 --- Sensor, RTD, 1M

126 16T108 Cable Ultrasonic

129 --- Harness, MZLP 2, AWB

--- Harness, MZLP 2/3, AWB

135 16W035 Connector Jumper

136 --- Harness, MZLP #1 AWB

138 --- Harness, Disc AWB

140 --- Transformer

143 24V816 AWB

146 126453 Power Supply

147 --- Harness Power Supply AWB

148 --- Cable, Board, Samtec

208 24V522 Band heater, HM50

24R093 Band heater, HM25

209 24R037 Heater Rod (1500 W), HM50

24R034 Heater Rod (500 W), HM25

210 24R036 Heater Rod (1000 W), HM50

24R037 Heater Rod (1500 W), HM25

251 24R040 SWITCH, OT

1201 16T102 Light Tower

Electrical Schematics

333347F 79

System

AWB

J2 J9

J4

J7

W1

W2

W4

GND

W3

1

2

4

3

5

1

2

4

3

5

1

2

4

3

5

ADM

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

L1

L2

GND

J3

1

2

1

2

J1

-

N

L

+

-

N

L

+

MZLP 1

J5

J12

J16

1

2

3

4

J14

J13

1

2

3

4

J15

112A J1

1

2

1

2

J6

1

2

4

3

5

1

2

4

3

5

J2

L1

L2

L3

GND

J3

1

2

4

3

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

L1

L2

L3

GND

J6

L1

L2

L3

GND

L1

L2

L3

GND

J8

1

2

4

3

5

1

2

4

3

5

6T3

4T2

2T1

5L3

3L2

1L1

NN

L3

DC OK

DC OK

-V

-V

+V

+V

GND

N

L

TEMP

TEMP

FAN +

FAN -

TEMP

TEMP

FAN +

FAN -

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

4

3

5

1

2

4

3

5

1

2

4

3

5

6

1

2

4

3

5

6

1

2

4

3

5

1

2

4

3

5

J5

L1

L2

L3

GND

L1

L2

L3

GND

1

2

3

4

140 138

143

123

30

129

90

148

136

103

112

1201

9

20 86 126

12425

125

251

121

Melter OT Switch

and Melter RTD

Motor Cycle Switch

Fill Sensor

Air Solenoid

Optional Light Tower

Hose / Applicator Wiring

Transformer

Option

87

208 210 209 210

147

146

Band Pump Melter Base

To MZLP #2 4 and 6

Channel Option, see

page 108 and 110.

To MZLP #2 4 and 6

Channel Option, see

page 108 and 110.

Ground

Stud

GB1

Electrical Schematics

80 333347F

480VAC Transformer Option

Typical Hose / Applicator Wiring

GB1

J7

6T3

4T2

2T1

N

TEMP

TEMP

FAN +

FAN -

TEMP

TEMP

FAN +

FAN -

GB

GND

J2

W1

W2

W4

GND

W3

PTC

L1

L2 5L3

3L2

1L1

N

L3

AWB

P2

P1

P3

143

OVER

TEMP

GUN

HEATER

T°

GUN

RTD

GND

J8

A

B

C

D

E

F

G

H

J

K

L

A

B

C

D

E

F

G

H

J

K

L

MZLP1

HOSE

HEATER

T°

HOSE

RTD

112

Electrical Schematics

333347F 81

2nd and 3rd MZLP Options

J3

1

2

4

3

5

1

2

4

3

5

J3

1

2

4

3

5

J6

1

2

4

3

5

1

2

4

3

5

1

2

4

3

5

1

2

4

3

5

J3

1

2

4

3

5

MZLP3 MZLP 2 MZLP 1

1

2

4

3

5

6

J5

1

2

4

3

5

6

121121

135

118 118 112

Air Schematic

82 333347F

Air Schematic

NOTE: Install an optional ramp up/down controller to

limit air to the air motor and slow down the system dis-

pense rate.

Level Sensor

Restrictor

Level Air Sensor Refill Gauge

Air Control Manifold

Refill Control Solenoid

Air Motor Control Solenoid

Air Motor Gauge

Pressure Relief

Valve

Air Motor

Feed Wand

Line Air Inlet

Under Control Box

Optional Ramp Up/Down

Controller

Safety Pop Off Valve

Parts

333347F 83

Parts

InvisiPac Systems

System Parts, Page 1 of 3

WLE

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

Apply pipe sealant to all non-swiveling pipe threads.

Bottom sensor (20) out then back off 1/2 turn.

Lubricate all seals and o-rings with water resistant grease.

Torque to 5-11 ft-lb (7-15 N•m).

Torque to 8-10 in-lb (0.9-1.1 N•m).

1

2

3

4

5

6

44

19

28

30

53

13

8, 14

3

8

83

27

25

1

26

24

18

75

6

38

58

22

10

11

8

29

8

23

23

38 31

39

64

43

43

43

6

64

Parts

84 333347F

System Parts, Page 2 of 3

WLD

54

7

5

8

8

9

1

63

20

68

67

69

66

72

74

73

69

69

62

61

81

80

79

74

82

8

8

41

49

40

4

85

63

87

89

88 3

42

3

86

43

5

Parts

333347F 85

System Parts, Page 3 of 3

WLD

76

78

32

34

16 in.

(406.4 mm)

34

8 in.

(203 mm)

34

2 in.

(50.8 mm)

36

13 in.

330.2 mm)

35

48 in.

(1219 mm)

34

48 in.

(1219 mm)

34

48 in.

(1219 mm)

49 35

48 in.

(1219 mm)

55

24

77

57

91

86

39

Parts

86 333347F

System Parts

Ref Part Description

Quantities

HM50 HM25

2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel

24T918

24V201

24V198

24T919

24V202

24V199

24T920

24V203

24V200

24V423

24V429

24V426

24V424

24V430

24V427

24V425

24V431

24V428

1 --- ENCLOSURE, electrical 111111111111111111

3 115942 NUT, hex, flange head 888888888888888888

4 167002 INSULATOR, heat 444444444444444444

5 24V169 SYSTEM, melter, HM25 111111111

24V542 SYSTEM, melter/pump,

HM50 111111111

6 16V540 GUARD, insulated 111111111

--- INSULATOR, wrap 111111111

7 --- TRAY, drip 111111111111111111

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 111111111111111111

10 --- DOOR, front 111111111111111111

11 --- FOAM, border, door 111111111111111111

13✿

---

FITTING, straight, hydraulic 222444666222444666

14 16V153 WASHER, retaining 444444444444444444

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 222444666222444666

19✿116793 FITTING 222444666222444666

20 24R041 SENSOR, ultrasonic 111111111111111111

21✖101976 TOOL, allen, wrench 111111111111111111

22 24N957 SHAKER, feed system 111111111111111111

23 114606 PLUG, hole 222222222222222222

24 120753 FITTING, push to connect

elbow 222222222222222222

25 24A032 SWITCH, reed assy 111111111111111111

26 --- SCREW, pan head, #8-32 x

1.5" 111111111111111111

27 --- BRACKET, back HM50 111111111

--- BRACKET, back 111111111

28 --- COVER, filter 111111111111111111

29 --- COVER, melter HM50 111111111

--- COVER, system, HM25 111111111

30❄24P860 MODULE, ADM 111111111111111111

31 117017 WASHER 222222222222222222

32 --- FITTING, tee, reducer 111111111111111111

34 --- HOSE, nylon, wpr 250 psi

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

35 598095 TUBE, 5/32 OD, nylon 444444444444444444

36 --- TUBE, ptfe, 1/4 in. OD

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

38 117126 SCREW, shcs; m5x16 333333333333333333

Parts

333347F 87

39 --- GROMMET, 1/4 ID 111111111111111111

40 --- BUSHING, strain relief 222222222222222222

41 --- GROMMET, tube 111111111111111111

42 --- GROMMET, tube 111111111111111111

43▲16Y781 LABEL, safety 111111111111111111

44 16U007 LABEL, InvisiPac, HM25 111111111

--- LABEL, InvisiPac HM50 111111111

45 --- LABEL 111111111111111111

47✖24P859 KIT, fuses, board, temp con-

trol 111111111111111111

48✖24P176 KIT, i/o connector 111111111111111111

49 125871 TIE, cable, 7.50 in. 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

50❄24R324 TOKEN, software 111111111111111111

53‡16W659 INSULATOR, melter 111111111

16T677 INSULATOR, melter 111111111

54 --- NUT, bushing 222222222222222222

57 123554 COUPLER, 3/8 in. OD tubing 111111111111111111

58 24A326 BRACKET, mounting,

assembly 111111111111111111

61† --- FUNNEL, large mouth 111111111111111111

62† --- BAFFLE, pellet 111111111111111111

63 121487 GROMMET, sheet metal, 3/4

in. 222222222222222222

64 24R707 KIT, inlet, air 111111111111111111

66† --- FUNNEL, insert 111111111111111111

67† 24V506 FILTER, HM50 feed 111111111111111111

68† --- FUNNEL, filter cover 111111111111111111

69† --- O-RING, fluoroelastomer,

160 333333333333333333

72 110932 CONNECTOR, male 111111111111111111

73† --- HOUSING, sensor, HM50 111111111111111111

74† --- SCREW, #10-16, thread

forming 555555555555555555

75 16T675 INSULATOR, melter mani-

fold 111111111

16W671 INSULATOR, melter, mani-

fold 111111111

76 --- FITTING, tee, 1/8npt x 3/8t x

3/8t 111111111111111111

77 --- RESTRICTOR, air, 0.0225

in. orifice 111111111111111111

78 198177 FITTING, push, straight 111111111111111111

79★24W001 ADAPTER, HM25 111111111

24W000 ADAPTER, melter HM50 111111111

Ref Part Description

Quantities

HM50 HM25

2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel

24T918

24V201

24V198

24T919

24V202

24V199

24T920

24V203

24V200

24V423

24V429

24V426

24V424

24V430

24V427

24V425

24V431

24V428

Parts

88 333347F

--- 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):

80★--- CLAMP, hose, spacer 111111111

81★--- CLAMP, hose, spacer 111111111222222222

82† --- BRACKET, funnel, HM25 111111111

--- BRACKET, HM50, funnel,

mounting 111111111

83 123986 FITTING, elbow, 3/8 OD tube 111111111111111111

85 --- GROMMET 111111111111111111

86 122030 CABLE, gca, m12-5p 111111111111111111

87 --- WIRE, ground 111111111111111111

88 116343 SCREW, ground 111111111111111111

89 --- WASHER, 1/4 external tooth

lock 111111111111111111

90 --- PLUG, phoenix, 8 pos 111111111111111111

91 --- FITTING, 5/32 in. OD tube,

push-to-con 111 111

92

✖

17A345 TOOL, 5/16 nut driver 111111111111111111

93

✖

127735 STRAP, lifting 3 ft 11 11 11 11 11 11

Ref Part Description

Quantities

HM50 HM25

2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel

24T918

24V201

24V198

24T919

24V202

24V199

24T920

24V203

24V200

24V423

24V429

24V426

24V424

24V430

24V427

24V425

24V431

24V428

Kit Description Includes

24R885◆Cycle Switch 25, 26

24R028* Inlet housing 12, 13, 62

24V544 Tubing 32, 33, 34, 35, 36, 304. See

Feed System Shaker and

Tube, 24V507 on page 96 for

identification of item 304.

24V505† Funnel 8, 61, 62, 66, 67, 68, 69, 73,

74, 82. See Feed Inlet Fun-

nel, 24V505 on page 99.

24V508‡Melter 53, 202, 204, 207, 211, and

253. See Melter and Pump

Assembly on page 93 for

identification of items 202-253.

24V504✿Hydraulic Fittings 13, 18, 19

24U635 Acrylic Lens

Pressure Gauge

24W000★Melter Adapter 79, 80, 81

Parts

333347F 89

Electrical Enclosure

WLD

WLD

Apply sealant to all non-swiveling pipe

threads.

Set rotary switch to “1” on MZLP with

daughter card.

Set rotary switch to “2” on MZLP 2.

Set rotary switch to “3” on MZLP 3.

1

2

3

4

114 112

113

118

113

114

113

118

114

106, 107

120

110

108

109

101

132

105

104

2

3

117 111 143

112a

MZLP 2

MZLP MZLP 3

4

131

146

131

145

144

Parts

90 333347F

Electrical Enclosure Parts

WLD

142

141

137

140

Ref Part Description

Quantity

1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP

No Transformer 400/480 V Transformer

101

--- CABINET, controls 111111

102

122030 CABLE, gca, m12-5p 1 1 1

103

--- HARNESS, MZLP1, AWB 111111

104

123970 SWITCH, disconnect, 40a 111111

105

126839 CONTACT, n-pole 111111

106

120858 BUSHING, strain relief, m40 thread 111111

107

120859 NUT, strain relief, m40 thread 111111

108

104641 FITTING, bulkhead 111111

109

121141 FITTING, elbow, swivel, 3/8t 1/4mnpt 111111

110

114421 BUSHING, strain relief 111111

111

117666 TERMINAL, ground 111111

112*

--- MODULE, MZLP with daughter board 111111

112a

24R042 KIT, board, daughter 111111

113

16T440 CAP, souriau, uts14 246246

114

125856 SCREW, 8-32, serrated flange 12 12 12 12 12 12

116

24P175 PLATE, blank, sgl mztcm 2 1 2 1

117

115942 NUT, hex, flange head 111111

118

24V510 MODULE, gca, MZLP 1 2 1 2

119

--- GASKET, foam, mztcm 2 1 2 1

120

--- PIN, dowel 111111

121

16T087 CABLE, board, male/male, 21 in. 1 2 1 2

123

127768 CABLE, can, female/female 1.5 m 111111

Parts

333347F 91

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

Available kits (purchase separately):

124

16T103 CABLE, pump 111111

125

◆--- SENSOR, rtd, 1m 111111

126

16T108 CABLE, ultrasonic, m12-4p, 1m 111111

129

--- HARNESS, MZLP 2, awb 1 1

--- HARNESS, MZLP 2/3, awb 1 1

130

114958 STRAP, tie 444444

131

--- SCREW, flange, serrated, 10-24 x 0.5 222222

132

123967 KNOB, operator disconnect 111111

135

16W035 CONNECTOR, jumper 1 1

136

--- HARNESS, MZLP 1, awb 111111

137

--- BUSHING, cable 111

138

--- HARNESS, disc, awb 111111

140

24V015 TRANSFORMER, assembly, 480v/240v 111

141

--- GROMMET, air fitting 111

142

113802 SCREW, hex hd, flanged, 3/8-16 x 5/8 333

143

24V816 MODULE, awb 111111

144

114331 SCREW, mach, pnh, sems; 6-32 x 3/8 222222

145

--- BRACKET, power supply 111

146

126453 POWER SUPPLY, 24v 111111

147

--- HARNESS, power supply, awb 111111

148

--- CABLE, board, samtec 111111

Ref Part Description

Quantity

1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP

No Transformer 400/480 V Transformer

Kit Description Includes

24V528† Upgrade from 2

channel system

to 4 channel sys-

tem

113, 118, 121, 129, a ground-

ing wrist strap, and a software

upgrade token. See 4 Channel

Upgrade Kit, 24V528 on

page 108.

24V529✿Upgrade from 4

channel system

to 6 channel sys-

tem

113, 118, 121, 129,134, 135,

grounding wrist strap, and a

software upgrade token. See 6

Channel Upgrade Kit, 24V529

on page 110.

24R040◆RTD 125, 251, and 255. See Melter

and Pump Assembly on

page 93.

24V289 MZLP fuses Qty 8 - 8 Amp, 250V Fuses

Qty 2 - 25 Amp, 250V Fuses

24P176 Customer I/O

Connectors

2 connectors for connecting to

H1 and H2 on MZLP daughter

board. Use for PLC connec-

tion.

Parts

92 333347F

Transformer Assemblies

Transformer Assemblies

▲Replacement Danger and Warning labels, tags, and cards

are available at no cost.

★Included in Fan Replacement Kit 24V911.

--- Not for sale.

WLD

Mount fan with arrow pointing towards grill.

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.

Use nut to lock down the ground wire from transformer.

Connect black fan wire labeled (-) from transformer (153) in the

pin labeled (-). Connect red fan wire labeled (+) to the

connector coming from transformer (153).

1

2

3

4

152

160

156

157

156

161

167

154

155

1

2

151

158

157

166 166

166

161

2

2 4

153

4

170

168

168

3

Ref. Part Description Qty

151 --- ENCLOSURE, base, 480v 1

152 --- ENCLOSURE, top, 480v 1

153 --- TRANSFORMER, 480v/240v,

6kva; 480V systems only

1

--- TRANSFORMER, 400v/240v,

6kva; 400V systems only

1

154 --- GRILL, fan 1

155

★

--- FAN, 24 vdc, 120m x 120m 1

156 115942 NUT, hex, flange head 5

157 119865 SCREW, mach, hex serrated, 1/4

x 3/8 in.

6

158 127278 NUT, keps, hex 4

160 --- GROMMET, air fitting 1

161 125871 TIE, cable, 7.5 in. 5

162 172953 LABEL, designation 1

166

▲

17A071 LABEL, safety, warning 1

167 --- TUBE, corrugated, slit; 6 in.

(152.4 mm)

1

168

169

170 127754 GRILL, fan

Ref. Part Description Qty

Parts

333347F 93

Melter and Pump Assembly

WLD

Lubricate all seals and o-rings with grease.

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

clamp.

Torque to 5-11 ft-lb (7-15 N•m).

Torque to 24-30 ft-lb (33-41 N•m).

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

Assemble inserts (252) 0.01-0.05 in. (0.3-1.3 mm) below surface.

Assemble inserts (252) 0.01-0.05 in. (0.3-1.3 mm) below surface.

Torque to 27-33 in.-lb (3-3.8 N•m).

Apply anaerobic thread sealant on threads.

Torque to 12-18 ft-lb (16-24 N•m).

1

2

3

4

5

6

7

8

9

10

217

216

217

223

224

225

226

222

221

227

228

229

231

232

230

5

4

218

239

235

233

234

220

240

219

206

211

7

246

245

244

243

242

247

255

236

208

211

204

202

207

253

213

215

206

210

201

249

257

258

209

206

252

6

214

2

2

5

3

205

254

203

268

259

249

251

252

238

210

3

3

8

9

10

HM25, 24V169

HM50, 24V542

4

10

4

4

10

10

10

Parts

94 333347F

HM25 Melter and Pump, 24V169

HM50 Melter and Pump, 24V542

--- Not for sale.

Available kits (purchase separately):

Ref. Part Description Qty.

201 --- BASE, melter, HM50 1

--- BASE, melter, HM50 1

202✖--- TANK, melter, HM50 1

--- TANK, melter, HM25 1

203• --- MANIFOLD, outlet 1

204✖--- PLATE, mounting; HM50 1

--- PLATE, mounting; HM25 1

205 --- HOUSING, fire rod; HM50 1

--- HOUSING, fire rod; HM25 1

206• 111317 RING, retaining, int. 3

207✖16W615 O-RING, fluoroelastomer;

(HM50 only)

1

126475 O-RING, fluoroelastomer;

(HM25 only)

1

208 24V522 BAND, heater; HM50 only 1

24R039 BAND, heater; HM25 only 1

209• 24R037 HEATER, rod,1500 watts; HM50 1

24R034 HEATER, rod, 500 watts; HM25 1

210 24R036 HEATER, rod,1000 watts; HM50 2

24R037 HEATER, rod,1500 watts; HM25 2

211✖116940 SCREW, cap,sh,5/16-18 7

213 --- SCREEN, wire 1

214• 112855 PACKING, o-ring 1

215

---

PLUG, o-ring boss 1

216ॠ--- SLEEVE, cylinder 1

217†‡• 108526 PACKING, o-ring, ptfe 2

218 24V558 MOTOR, double ended, air; see

page 95

1

219 --- PLATE, pump adapter 1

220 --- ROD, tie, 1.5 in. stroke 3

221• 192624 GUIDE, ball 1

222†◆• 239932 VALVE, piston 1

223◆• --- ROD, piston 1

224†◆• 105444 BALL, (.31250) 1

225†◆• --- SEAL, u-cup, piston 1

226†◆• --- BEARING, piston 1

227†• 105445 BALL, (.5000) 1

228†• 192642 SEAT, carbide 1

229†• 107079 PACKING, o-ring 1

230• --- HOUSING, foot valve 1

231†• 105802 O-RING 1

232†• 113944 PACKING, o-ring 1

233†• --- BEARING, throat 1

234†‡• --- SEAL, u-cup, throat 1

235• 193046 NUT, packing 1

236• 24P855 FILTER, assy, 100 mesh, welded 1

238 196762 PIN, straight 1

239 196750 SPRING, retaining 1

240 101864 SCREW, cap, sch; 5/16 x 1 in. 3

242★• 117059 O-RING, fluoroelastomer 1

243★• --- RETAINER, seat, dump valve 1

244★• 15Y627 PACKING, o-ring #2-116, ptfe 1

245★• --- VALVE, relief 1

246• 121295 SCREW, cap, socket head; 5/16 x

2.5 in.

4

247• 15H304 FITTING, plug 9/16 sae 9

249 167002 INSULATOR, heat 10

251

✿

•24R040 SWITCH, overtemperature 1

252• --- INSERT, helical 7

253✖--- PLATE, melter; HM25 only 1

--- PLATE, melter; HM25 only 1

254 --- O-RING, -910 1

255

✿

•107388 SCREW, mach, pnh;

#4 x 3/8 in.

2

257 --- BRACKET, shelf; HM50 only 1

--- BRACKET, shelf; HM25 only 1

258 --- GROMMET, 1/4 ID 1

259 110298 SCREW, cap, sch,

1/4 x 7/8 in.

;

HM50 only

4

115506 SCREW, mach, hex wash hd, 1/4 x

3 in.; HM25 only

4

268 115814 WASHER, flat, sst; HM50 only 4

Kit Description Includes

24P852† Pump repair 217, 222, 224, 225, 226, 227,

228, 229, 231, 232, 233, 234,

and seal installation tool

15B661.

24P853‡ Cylinder 216, 217, 234, and seal instal-

lation tool 15B661.

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

24P856★Pressure relief

valve

242, 243, 244, 245

24V508✖Melter 202, 204, 207, 211, 253, and

insulator (53). See InvisiPac

Systems parts starting on

page 83 for insulator (53)

identification.

24R040

✿

RTD 125, 251, and 255. See Elec-

trical Enclosure on page 89.

24R709 • Assembled pump

manifold

203, 206, 209, 214, 216, 217,

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.

Ref. Part Description Qty.

Parts

333347F 95

Air Motor, 24V558

-

-- Not for sale.

†Included in Air Motor Valve Kit 24R026.

WLD

509

Apply water-resistant grease.

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

1

2

505

522

507

511

511

2

513

506

512

509

4

1

21

2

Ref. Part Description Qty

505 24A579 MANIFOLD, medium, short 1

506 --- GASKET, cover, small 2

507† --- SEAL, air valve, manifold 1

509† --- SCREW, m6 x 25, thread forming 8

511 --- VALVE, pilot 2

512† --- VALVE, air, small 1

513 15M213 MUFFLER, 3/8 1

Parts

96 333347F

Feed System Shaker and Tube, 24V507

Parts

--- 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 sepa-

rately) also available. Kit includes a grounding wire

assembly, and a screw and washer for installing on the

shaker tube (301).

Apply pipe sealant to threads.

1

301

302

306

304

ti20738a

1

Ref Part Description Qty

301 24P861 SHAKER 1

302 24N954 TUBE, steel 1

303†◆--- TUBE, clear PVC, 1.3 in.

(33 mm) OD

10

304 --- HOSE, nylon, 3/8 in. OD,

250 psi (1.7 MPa, 17 bar)

15.5

305◆125370 CLAMP, hose, dia. 11/16 to

1-1/2 in.

3

306 125871 TIE, cable, 7.50 in. (190 mm) 4

Parts

333347F 97

Air Controls Assembly

Air Controls Assembly Parts

--- Not for sale.

WLD

Apply sealant to all non-swiveling pipe threads.

1

405

403

401

402

406

404

404

1

1

Ref Part Description Qty

401 --- PANEL, air, controls 1

402 24V520 CONTROL, air, vacuum trans-

fer and pump

1

403 15T500 GAUGE, pressure, air, panel

mount, 1/8 in. npt

2

404 15T498 FITTING, 90 degree, swivel,

5/32 in. tube x

1/8 in. female npt

2

405 100058 SCREW, cap, hex head 2

406 054753 TUBE, nylon, round, black 2

407 C38321 TIE, cable, 3.62 in. 1

Parts

98 333347F

Pressure Relief Valve, 24P856

--- Not for sale.

† Parts included in Relief Valve Repair Kit 24P857

(purchase separately).

606

607

601 614

605 611 608

602 609

612

610

610

613

Apply sealant to all non-swiveling pipe threads.

Apply grease.

Torque to 4-6 in-lb (0.5-0.7 N•m).

1

2

3

604

3

2

2

2

1

3

603

1

1

Ref Part Description Qty

601 --- BODY, fluid 1

602 --- BODY, air 1

603 15T413 PISTON, air 1

604 --- AIR CAP, valve 1

605 --- BEARING, shaft, needle 1

606 --- SHAFT, needle, valve 1

607 --- SOCKET, ball assembly 1

608† 108771 PACKING, o-ring 1

609† 110073 PACKING, o-ring 1

610 111841 WASHER, plain 5/8 in. 2

611† --- BEARING, valve 1

612† --- O-RING, FKM 1

613 --- FITTING, push to connect 1

614† --- SEAL, u-cup, relief valve 1

Parts

333347F 99

Feed Inlet Funnel, 24V505

--- Not for sale.

Ref. Part Description Qty

701 --- FUNNEL, large mouth 1

702 --- BAFFLE, pellet 1

703 --- O-RING, fluoroelastomer, 160 3

704 --- FUNNEL, insert 1

705 24V506 FILTER, feed 1

706 --- FUNNEL, filter cover 1

707 113161 SCREW, flange, hex hd 2

708 --- SCREW, #10-16, thread forming 5

709 --- BRACKET, funnel, mounting 1

710 --- HOUSING, sensor 1

WLD

706

704

705

703

708

707

708

709

710

703

702

703

701

Accessories

100 333347F

Accessories

Special Tools

These special tools are designed to make system repairs as easy as possible while ensuring that parts do not get

damaged.

* Parts included in Cylinder Tools Kit 24R227 (pur-

chase separately).

** Parts included in Rod Tools Kit 24R228 (purchase

separately).

Part Purpose

1301* Remove Cylinder

1302* Install Cylinder - Female

1303* Install Cylinder - Male

Part Purpose

1304** Install Rod - Female

1305** Install Rod - Male

1306** Install Rod - Bullet

    

ti20983a

Accessories

333347F 101

Non-Graco Applicator Adapter

Cables

16T916: For connecting to non-Graco applicators that

use a rectangular, 6-pin connector.

16T917: For connecting to non-Graco applicators that

use a circular, 9-pin connector.

16Y828: For connecting to non-Graco applicators that

use a circular, 6-pin connector. IPx6 rated.

Non-Graco Applicator Adapter Cable

Installation

See Attach Components on page 17.

Air Adjustment Lock, 24R084

Panel enables locking access to the air adjustment

screws.

Air Adjustment Lock Installation

1. Remove screws from system air panel.

2. Use screws to install panel (801).

3. Snap bracket (802) into panel (801).

4. Insert lock through hole in panel and bracket to lock

access to the air controls. Lock not included in kit.

ti21128a

ti21129a

WLD

Ref Part Description Qty

801 --- PANEL, lock, air control 1

802 --- BRACKET, lock, air control 1

WLD

NOTE: Screws are part of the base system and are

not included in the kit.

801

802

Accessories

102 333347F

System Stand, 24R088

Use the stand to mount the system at eye level. When

the system is mounted on the stand, the ADM is 45 in.

(1.14 m) above the bottom of the stand.

System Stand Installation

1. Place stand (1001) in desired location.

2. Use bolt holes to bolt stand in place.

3. Place system on stand.

4. Use screws and nuts to secure system to stand.

Caster for Stand, 120302

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).

Adapter Plate, 24R083

Use this adapter plate to install InvisiPac in place of an

existing hot melt applicator system.

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).

Ref Part Description Qty

1001 --- STAND 1

1002 112395 SCREW flange head cap 3

1003 112958 NUT, hex, flanged 3

WLD

1001

1003

1002

Ref Part Description Qty

1101 --- PLATE, adapter 1

1102 112395 SCREW flange head cap 6

1103 112958 NUT, hex, flanged 9

1104 121283 FITTING, elbow, 45 degree 1

WLD

A

C

B

Bolt Hole Dimensions

A 9.8 in. (249 mm)

B 14.843-15.157 in.

(377.0-385.0 mm)

C 17.003-17.317 in.

(431.9-439.9 mm)

1101

1102

1103

1104

A

Accessories

333347F 103

Accessories

104 333347F

30 Gallon Vibrating Hopper, 24R136

Hopper includes a shaker to ensure the adhesive pellets maintain a level surface at all times. Without this, the adhe-

sive 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)

--- Not for sale.

* Metric fitting included in Air Metric Fitting Kit,

24W637, page 113.

905

910

903

902

901

907

915

903

915

904

909

914*

916

912

ti20928a

Ref Part Description Qty

901 --- HOPPER, 30 gallon 1

902 --- LID, hopper, 30 gallon 1

903 126930 SHAKER, ball vibrator 1

904 126929 VALVE, air pilot, 3-way, closed 1

905 --- BRACKET, shaker, container 1

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

(1.7 MPa, 17 bar)

1

908 119798 CONNECTOR, tee, push-tube 1

909 113779 MUFFLER 1

910 111192 SCREW, cap flange head 2

912 125857 SCREW, 10-24, serrated flange 4

914* 121141 FITTING, elbow, swivel, 3/8 in.

tube connector, 1/4 male npt

1

915 120389 FITTING, tube 2

916 --- CONNECTOR, tube, 90 degree 1

917 125539 FITTING, splitter, 3/8 in. OD tub-

ing

1

Ref Part Description Qty

Accessories

333347F 105

30 Gallon Vibrating Hopper Installation

See F

IG

. 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 vac-

uum transfer hose connects to the steel shaker rod.

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

OD air line that was just cut.

4. Install the 48 in. section of 3/8 in. OD hose supplied

with the kit into the remaining connection on the

splitter fitting (917).

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

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

valve.

6. Connect shop air to elbow fitting (914) on the piloted

air valve. Shop air must be capable of 100 psi

(0.7 MPa, 7 bar).

NOTE: The piloted air valve must use shop air. Adding a

tee at the system inlet to run the hopper shaker may

impact pump and vacuum transfer performance.

7. Place steel shaker rod assembly into hopper (901)

with steel rod resting in the hopper groove in the rim

of the hopper.

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

NOTE: The hopper shaker will be active while the vac-

uum transfer system is transferring pellets.

NOTE: The air supplied to the pilot valve from the sys-

tem vacuum must be set to 65% of the shop air supply

supplied to elbow fitting (914) or higher. If the pilot valve

air pressure is lower than this, increase the vacuum

transfer air pressure regulator (E, see F

IG

. 1 on page

11).

F

IG

. 64

To shop air

supply

Splitter fitting

To piloted

air valve To shaker

head

Piloted air

valve

Hopper

shaker

ti21350a

Accessories

106 333347F

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).

24R226 Parts

--- Not for sale.

J1

J2

J3

J6

J5

J7

F10 F9 F8 F7

F6 F5

F4 F3

F2 F1

WLD

1201

1203

1202

1204

1205

J12

AA

BB

1201a

Ref Part Description Qty

1201 16T102 LIGHT, tower, red and green 1

1201a --- SCREW 3

1202 --- GROMMET, single cable 1

1203 16K322 BRACKET, light tower 1

1204 --- GROMMET, multiple wires 1

1205 125835 CLIP, ferrite bead 1

Accessories

333347F 107

Light Tower Kit Installation

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 sys-

tem then use the bolts (BB) to secure

bracket (1203) to metal shroud.

6. Route light tower cable through hole in

bracket (1203) then use supplied light tower

screws (1201a) to install light tower (1201).

7. Remove electrical enclosure front access door.

8. Route light tower cable through the other hole in the

bracket (1203), then through the grommet (1204)

into the electrical enclosure.

9. Connect light tower cable to MZLP connector

labeled J12.

Air Reservoir Kit, 16W366

This kit allows the system to operate as low as 60 psi

(0.4 MPa, 4 bar).

16W366 Parts

--- Not for sale.

* Metric fitting included in Air Metric Fitting Kit,

24W637, page 113.

Ref Part Description Qty

1501 --- HOSE, nylon (6 ft) 1

1502 100081 BUSHING, pipe 1

1503 113777 TEE, branch 1

1504* 114485 CONNECTOR, male, 3/8 npt 2

1505 155665 UNION, adapter 1

1506 --- TANK, air, accumulator 1

WLD

1501

1504

1504*

1503

1505

1505

1506

Accessories

108 333347F

4 Channel Upgrade Kit, 24V528

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

◆Not shown.

--- Not for sale.

WLD

WLD

1301

1302

1306

1304

1305

AA

BB

CC

1307

1308

1308

Ref Part Description Qty

1301 --- MODULE, GCA, MZLP 1

1302 16T087 CABLE, jumper, male/male,

21 in.

1

1303 --- HARNESS, 2nd MZLP power 1

1304 112190 STRAP, wrist, grounding 1

1305 16T440 CAP, jam nut, sealing 2

1306 24R324 SOFTWARE UPGRADE TOKEN,

InvisiPac System

1

1307 --- FITTING, straight 2

1308 --- LABEL, InvisiPac Channel Num-

bers

1

Accessories

333347F 109

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 sys-

tem. 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 sys-

tem will be referred to as MZLP 1 from here on. See F

IG

.

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 con-

nector J3 and connect other end of jumper

cable (1302) to MZLP 2 connector J3. See F

IG

. 65.

8. Connect power harness (1303) to MZLP 2 connec-

tor 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 soft-

ware, insert token (1306) into ADM. Follow Soft-

ware Update Procedure, page 77.

F

IG

. 65

J3

J6

J5

J9

J8

J2

J1

J9

J5

J6

J3

J2

J8

J1

ti23596a

MZLP 1MZLP 2

Step 7: Install Jumper Cable (1302).

Accessories

110 333347F

6 Channel Upgrade Kit, 24V529

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

WLD

1301

1302

1304

1305

BB

BB

AA

1303

1306

1308

CC

1307

Ref Part Description Qty

1301 --- MODULE, GCA, MZLP 1

1302 16T087 CABLE, jumper, male/male, 4 in. 1

1303 112190 STRAP, wrist, grounding 1

1304 24R324 TOKEN, software upgrade 1

1305 16T440 CAP, jam nut, sealing 2

1306 --- HARNESS, MZLP #3 1

1307 16W035 CONNECTOR, jumper 1

1308 --- FITTING, tee 2

1309

Accessories

333347F 111

6 Channel Upgrade Kit Installation

1. Disconnect plug from power outlet or turn off circuit

breaker for incoming power.

2. Place grounding wrist strap (1303) over your wrist

and secure other end to a grounded surface.

3. Set the kit’s MZLP (1301) rotary switch to “3”.

4. Remove screws (BB) then remove plate (AA) from

system.

5. Use screws (BB) to install MZLP (1301) onto sys-

tem.

NOTE: The new MZLP (1301) will be referred to as

MZLP 3, and the original MZLPs that came with the sys-

tem will be referred to as MZLP 1 and MZLP 2 from here

on. See F

IG

. 66.

6. Remove electrical enclosure front access door.

NOTE: Do not force the electrical connection. Minimal

force is required to seat the connector. If resistance is

felt, stop and verify the connector orientation.

7. Connect CAN jumper cable (1302) to MZLP 2 con-

nector J3 and connect other end of jumper

cable (1302) to MZLP 3 connector J3. See F

IG

. 66.

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.

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 soft-

ware, insert token (1306) into ADM. Follow Soft-

ware Update Procedure, page 77.

F

IG

. 66

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

WLD

0=/3 0=/3

0=/3

Step 7: Install jumper cable (1302).

Accessories

112 333347F

InvisiPac ADM Simulator Kit, 24R323

Use this kit to train users in ADM operation without

using the full InvisiPac system. Kit includes everything

necessary to simulate the ADM screens. Does not

include an InvisiPac system.

Simulator Instructions

1. Remove ADM access panel and install InvisiPac

Simulator Token (1404).

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

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

4. Perform Software Update Procedure on page 77.

ADM Extension Kits

Use the extension cables to remote mount the ADM dis-

play off of the InvisiPac system. Kits available sepa-

rately.

ADM Remote Mount Bracket,

24A326

This bracket is used to remote mount the ADM display,

along with an ADM extension cable.

Ref Part Description Qty

1401 24P860 MODULE, Advanced Display

(ADM)

1

1402 124149 POWER SUPPLY, GCA 1

1403 --- CORD SET, US, MX, PR, CA,

TW, 115V, 10A

1

1404 24R322 TOKEN, InvisiPac Simulator 1

1405 24R324 SOFTWARE UPGRADE

TOKEN, InvisiPac System

1

1401

1402

1403

1404

ti20990a

F

IG

. 67: Remove Access Panel

Kit No. Cable Length Qty.

24R710 16.4 ft (5 m) 1

24R711 49.2 ft (15 m) 1

24R712 164 ft (50 m) 1

Ref. Part Description Qty.

1 BRACKET, mounting assembly 1

r_24P860_3B9900_3a

Accessories

333347F 113

Overtemperature Jumper,

16Y727

Use the Overtemperature jumper plug to run the

InvisiPac melter without a hose and applicator attached

to the Channel 1 electrical connection.

Installation

1. In the ADM setup screens, uninstall Channel 1. All

other Channels can be installed or uninstalled as

needed.

NOTE: Failure to uninstall Channel 1 on the ADM setup

screens will result in several Alarms regarding Channel

1 when there is no hose/applicator attached to Channel

1.

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.

Air Metric Fitting Kit, 24W637

For replacing air fittings with metric air fittings on Invisi-

Pac systems. See manual 334358 for installation

instructions.

Strain Relief Bushing Kit,

24X190

The strain relief bushing kit allows the use of a smaller

outside diatmer (OD) power cord. This strain relief bush-

ing is intended for power cords with an OD of

0.512-1.024 in (13-26 mm).

Installation

1. Remove standard strain relief bushing (106). Retain

and reuse nut.

2. Install strain relief bushing from kit and secure with

retained nut.

Hose Straps (4 Pack), 24R0294

Use these straps to secure hoses without excessive

pinching.

Pressure Gauge Replacement

Kit, 24R635

To replace the air gauge glass lenses and glass fuses

used in the food or beverage industries.

WLD

Ref. Part Description Qty.

1 127922 FITTING, 3/8 npt(m) x M18(f) 1

2 127923 FITTING, 1/4 npt(m) x 10 mm

tube

1

3 127924 FITTING, 1/4 npt(m) x 10 mm

90° elbow tube

1

4 127925 FITTING, 3/8-18 npt(m) x 3/8-19

bspt (f)

1

Ref. Part Description Qty.

1 114271 STRAP, retaining 4

Ref. Description Qty.

1 GAUAGE, pressure, acrylic 2

2 TOOL, puller, fuse 1

3 FUSE, 250v, 8a 32

Appendix A - ADM

114 333347F

Appendix A - ADM

General Operation

ADM Power

The ADM automatically turns on when the main power

switch is turned ON.

Screen Navigation

To switch between the Setup and Operation screens,

press . Use , , , and to navigate

between screens.

Enable, Disable Heating System

To enable or disable the entire heating system,

press . To set which channels are active when the

heating system is enabled, use the System 2 screen.

See page 117.

Icon Identification

Icon Description

Operation Screens Only

Heating disabled

Warming up, actual tempera-

ture is below setting

Temperature setting achieved

Actual temperature of hose

(left) and applicator (right)

Actual temperature of system

(shown warming up)

System temperature setting.

Use and to adjust set-

ting.

Use the physical numeric key-

pad on ADM to enter tempera-

ture setting.

Select channel to view and/or edit

the applicator or hose temperature

setting

Applicator temperature setting.

Use and to adjust set-

ting.

Hose temperature setting.

Use and to adjust set-

ting.

Use to adjust temperature settings

Temperature settings of applicator

(top) and hose (bottom)

Reset weight total

Setup Screens Only

Enter screen to change settings

Exit screen

Reset Maintenance error

Schedule Screen Only

Edit schedule value

Erase schedule value

Accept schedule change

Cancel schedule change

Icon Description

Appendix A - ADM

333347F 115

Operation Screens

Home

This screen shows the actual temperatures of the sys-

tem melter and each applicator and hose.

Targets

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.

Events

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.

*Zone

Tracked Events Code

Custom Language Downloaded EQU3

Custom Language Uploaded EQU4

Fill Valve Closed EBFX

Fill Valve Open EAFX

Heat Off EBDX

Heat On EADX

Logs Downloaded EQU5

Pump Cycles Total Reset ERD1

Pump Off EBPX

Pump On EAPX

Red Stop Button Pressed EB0X

Setup Value Changed EC0X

System Power Off EM0X

System Power On EL0X

System Settings Downloaded EQU1

System Settings Uploaded EQU2

USB Disabled EVUX

USB Drive Inserted EAUX

USB Drive Removed EBUX

User Maintenance Count Reset ERN1

Appendix A - ADM

116 333347F

Errors

The Errors screens store a maximum of 200 errors. See

ADM Error Code Table on page 40. The errors list can

be downloaded in the USB logs. See Appendix B -

USB Downloading, Uploading on page 120.

Diagnostic

This screen shows details of various items to aid in trou-

bleshooting the system. This screen can be hidden by

de-selecting “Enable Diagnostics Screen” on the Sys-

tem 3 screen. The flow rate updates every 15-20 sec-

onds with the average flow rate over the last 15-20

seconds.

The following information is displayed.

CAN: 24 VDC power supply voltage reading (18-28

VDC)

DI: System Digital Inputs

0: Not Used

1: Not Used

2: Pump Cycle Switch Up

3: Pump Cycle Switch Down

DO: System Digital Outputs

0: Pump Solenoid

1: Fill Solenoid

2: Light Tower Green Light

3: Light Tower Red Light

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)

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.

Diagnostic Data

ACurrent Draw

BRTD Reading

CDuty Cycle

A B C

Appendix A - ADM

333347F 117

Setup Screens

NOTE: It is important to set all settings in the System

screens correctly to ensure optimal system perfor-

mance.

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.

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.

System 3

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 pass-

word protected, the setpoints cannot be changed with-

out first entering the password.

Pump Idle Time to System Inactive: The heating sys-

tem 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.

Appendix A - ADM

118 333347F

Maintenance

The system will notify the user at the set interval that

maintenance is required. The fields in boxes can be

edited by the user. “Due” and “Current” are both the

number of cycles since the last reset. “Interval” is the set

number of cycles between maintenance notifications.

“Lifetime” is the number of cycles in the lifetime of the

system.

NOTE: The lifetime cycle count will only be reset if the

Advanced Display Module (ADM) is replaced.

Schedule

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

matically enable and disable heating. See Select ADM

Settings on page 24.

Advanced 1

Language: Language displayed on the screen.

Date Format: Choose format of the date.

Date: Set the date.

Time: Set the time.

Enter Password: If not “0000”, the Setup screens will

be password protected.

Screen Saver: The screen will go black after the set

amount of time.

Silent Mode: Disable ADM sounds.

Advanced 2

Temperature Units: Units of measure for displayed

temperatures.

Mass Units: Units of measure for mass.

Specific Gravity: Required to convert the volume dis-

pensed 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.

Appendix A - ADM

333347F 119

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.

Appendix B - USB Downloading, Uploading

120 333347F

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 opera-

tion. 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

NOTE: The event log, error log, system settings, and

system language files are all downloaded in this proce-

dure. See USB Logs, System Settings File, and Sys-

tem Language File starting on page 121.

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

IG

. 68.

NOTE: Flash drive must be 8 GB or smaller.

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 trans-

fer is complete if it is not acknowledged.

NOTE: If the pop-up screen does not appear, the flash

drive is not compatible with the ADM. Try a different

flash drive.

NOTE: The system can log up to 45 mb of additional

data per week, depending on system operation.

Accessing Files

All files downloaded from the USB are put in a DOWN-

LOAD folder on the stick drive. For example:

“E:\GRACO\12345678\DOWNLOAD\”. The 8-digit

numeric folder name matches the 8-digit ADM serial

number, which is located on the back of the ADM. When

downloading from multiple ADMs, there will be one

sub-folder in the GRACO folder for each ADM.

The log files should be opened in a spreadsheet pro-

gram.

NOTE: If emailing the files, zip (compress) them to mini-

mize file size.

Upload Procedure

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.

3. The USB flash drive window automatically opens. If

it does not, open USB flash drive from within Win-

dows Explorer.

4. Open Graco folder.

5. Open system folder. If working with more than one

system, there will be more than one folder within the

Graco folder. Each folder is labeled with the corre-

sponding serial number of the ADM. (The serial

number is on the back of the module.)

6. If installing the system settings file, place SET-

TINGS.TXT file into UPLOAD folder.

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.

F

IG

. 68: ADM USB Port

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.

Appendix B - USB Downloading, Uploading

333347F 121

7. If installing the custom language file, place DISP-

TEXT.TXT file into UPLOAD folder.

8. Remove USB flash drive from computer.

9. Install USB flash drive into InvisiPac system USB

port.

10. The menu bar and USB indicator lights indicate that

the USB is uploading files. Wait for USB activity to

complete.

11. Remove USB flash drive from USB port.

NOTE: If a custom language file was installed, users

can now select the new language from the Language

drop-down menu.

NOTE: If the SETTINGS.TXT or DISPTEXT.TXT files

remain in the UPLOAD folder, they will be uploaded

every time the USB drive is inserted into the corre-

sponding ADM. To avoid unintentionally overwriting sys-

tem 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 perfor-

mance related information to memory in the form of log

files. InvisiPac maintains the events, data, GCA, Black

Box, and Diagnostics logs. Follow the Download Pro-

cedure, 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.

Data Log

The data log (2-DATA.CSV) tracks the setpoint and

actual temperatures every 15 seconds. This log can

store up to 250,000 lines of data.

The system stores 1041 hours of system operation data,

or 43 days of around-the-clock operation. Once full, the

system will overwrite the oldest data.

NOTE: To prevent losing any data, never go more than

43 days without downloading the logs.

GCA Log

This log (3-GCA.CSV) lists the installed GCA modules

and their respective software versions.

Black Box, Diagnostics Logs

These logs (4-BLACKB.CSV, 5-DIAGN.CSV) are

designed to provide useful information to Graco when

calling for technical assistance.

System Settings File

The system configuration settings file name is

SETTINGS.TXT and is stored in the DOWNLOAD

folder.

A system configuration settings file automatically down-

loads 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 sys-

tems. 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.

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.

Appendix B - USB Downloading, Uploading

122 333347F

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 sys-

tem 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 down-

load. The second column can be used to enter the cus-

tom 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 installa-

tion process to succeed.

• The file name must be DISPTEXT.TXT.

• The file format must be a tab-delimited text file

using Unicode (UTF-16) character representa-

tion.

• 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 sec-

ond column.

Technical Data

333347F 123

Technical Data

InvisiPac Hot Melt Delivery System

US Metric

Incoming Power

HM25: 24V423

HM50: 24T918

200-240 VAC, 1-ph, 50/60 Hz, 32A

200-240 VAC, 3-ph, , 50/60 Hz, 27A

350-415 VAC, 3-ph, Y, 50/60 Hz, 16A

HM25: 24V429

HM50: 24V201 400-480 VAC, 3-ph, , 50/60 Hz, 14A

HM25: 24V424

HM50: 24T919

200-240 VAC, 1-ph, 50/60 Hz, 40A

200-240 VAC, 3-ph, , 50/60 Hz, 27A

350-415 VAC, 3-ph, Y, 50/60 Hz, 16A

HM25: 24V430

HM50: 24V202 400-480 VAC, 3-ph, , 50/60 Hz, 14A

HM25: 24V425

HM50: 24T920

200-240 VAC, 1-ph, 50/60 Hz, 40A

200-240 VAC, 3-ph, , 50/60 Hz, 40A

350-415 VAC, 3-ph, Y, 50/60 Hz, 30A

HM25: 24V431

HM50: 24V203 400-480 VAC, 3-ph, , 50/60 Hz, 14A

HM25: 24V426

HM50: 24V198 335-400 VAC, 3-ph Y, 50/60 Hz, 17A

HM25: 24V427

HM50: 24V199 335-400 VAC, 3-ph Y, 50/60 Hz, 17A

HM25: 24V428

HM50: 24V200 335-400 VAC, 3-ph Y, 50/60 Hz, 17A

Electrical

Minimum Applicator Wattage Per Channel at 240

VAC

90 W

Maximum Applicator Wattage Per Channel 400 W

Input / Output Capability 4 inputs (0-30V), 4 outputs (240VAC, 24VDC, 2A)

Pump Flow Rate

HM25 96 lb/hr 43.5 kg/hr

HM50 130 lb/hr 59 kg/hr

Melt Rate / Constant Throughout

HM25 25 lb/hr 11.3kg/hr

HM50 50 lb/hr 22.6 kg/hr

Weight

HM25 85 lb 36 kg

HM50 105 lb 48 kg

General

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

Pump Output 19.3 cc/cycle

Time to Temperature * Less than 15 minutes

Pump Pneumatic Piston, 12:1

Channels 1 to 6

System Dimensions, without vacuum tube or

shaker (Width x Height x Depth) **

19.0 x 42 x 16.5 in. 483 x 1067 x 419 mm

Shaker Dimensions (Width x Height) 0.4 x 4.0 ft 0.12 x 1.22 m

Pressure and Temperature Ranges

Technical Data

124 333347F

Main System Air Supply Pressure Range (set with

regulator on front of system)

80-100 psi 0.55-0.69 MPa (5.5-7 bar)

Pump Operating Air Pressure Range 20-100 psi 0.14-0.69 MPa (0.7-7 bar)

Pump Operating Fluid Pressure Range 240-1200 psi 1.7-8 MPa (17-80 bar)

Control Temperature Range 100-400°F 38-204°C

Ambient Temperature Range 32-120°F 0-49°C

Vacuum Transfer Specifications

Maximum Vacuum Transfer Hose Length 30 ft 9.1 m

Maximum Vacuum Transfer Hose Maximum Verti-

cal Rise

10 ft 3.0 m

Vacuum Transfer Operating Pneumatic Pressure

Range (set with regulator on front of system)

40-100 psi 280-690 kPa (2.8-6.9 bar)

Vacuum Transfer Air Consumption at 40 psi (280

kPa, 2.8 bar),

9.5 scfm (intermittent duty; 4% at

25 lb/hr)

16.1 scmh (intermittent duty; 4% at

11.3 kg/hr)

Vacuum Transfer Air Consumption at 80 psi (550

kPa, 5.5 bar)

17.2 scfm (intermittent duty; 4% at

25 lb/hr)

29.2 scmh (intermittent duty; 4% at

11.3 kg/hr)

Required Air Tubing Size

Minimum Air Tubing Inner Diameter (less than 50

ft, 15.2 m of tubing)

3/8 in. 9.5 mm

Minimum Air Tubing Inner Diameter (50 ft, 15.2 m

or longer of tubing)

1/2 in. 12.7 mm

Sound

Sound Pressure Level*** 77 dB(A)

IP Code

InvisiPac Base System IP54

Wetted Parts

Wetted Parts PTFE, chemically resistant o-rings, aluminum, stainless steel, zinc plat-

ing, carbon steel, brass, carbide, chrome

Approvals and Standards UL499, CSA88, CE, ISO

30 Gallon Vibrating Hopper

Required Air Pressure Supplied To 30 Gallon

Vibrating Hopper

100 psi 0.7 MPa (7 bar)

Air Consumption 17.1 scfm 29.1 cubic meters per hour

* From 70°F to 350°F (21°C to 177°C), dependant upon power supply and machine configuration.

** Excludes vacuum transfer tube, shaker assembly, and pellet storage bin.

*** Sound pressure level measured 3.1 ft (1 meter) from equipment.

InvisiPac Hot Melt Delivery System

US Metric

Technical Data

333347F 125

Startup Time

Single Phase

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

configuration.

System

Channels

(#)

Hose

Length

ft (m)

Start Time in Minutes

20 Amp

Breaker

240V

30 Amp

Breaker

240V

40 Amp

Breaker

240V

50 Amp

Breaker

240V

20 Amp

Breaker

208V

30 Amp

Breaker

208V

40 Amp

Breaker

208V

50 Amp

Breaker

208V

1 4 (1.2) 11 9.9 9.9 9.9 13 13 13 13

1 12 (3.6) 13 9.9 9.9 9.9 14 13 13 13

1 25 (7.6) 15 9.9 9.9 9.9 17 13 13 13

2 4 (1.2) 13 9.9 9.9 9.9 15 13 13 13

2 12 (3.6) 16 9.9 9.9 9.9 18 13 13 13

225 (7.6)20139.99.923131313

3 4 (1.2) 15 9.9 9.9 9.9 17 13 13 13

312 (3.6)19129.99.922131313

3 25 (7.6) 26 16 12 9.9 29 19 13 13

4 4 (1.2) 16 9.9 9.9 9.9 18 13 13 13

412 (3.6)22149.99.925161313

425 (7.6)3120141235231613

54 (1.2)18119.99.920131313

5 12 (3.6) 25 16 11 9.9 28 18 13 13

525 (7.6)3623171441271915

64 (1.2)20129.99.922131313

612 (3.6)2818131032201313

625 (7.6)4127201647312218

14 (1.2)1715151520202020

112 (3.6) 19 15 15 15 21 20 20 20

125 (7.6) 21 15 15 15 24 20 20 20

24 (1.2) 19 15 15 15 21 20 20 20

212 (3.6) 23 15 15 15 26 20 20 20

225 (7.6) 27 17 15 15 30 20 20 20

34 (1.2) 21 15 15 15 24 20 20 20

312 (3.6) 27 17 15 15 30 20 20 20

325 (7.6) 32 21 15 15 36 23 20 20

44 (1.2) 23 15 15 15 26 20 20 20

412 (3.6) 30 19 15 15 34 22 20 20

425 (7.6) 37 24 18 15 42 27 20 20

54 (1.2) 25 16 15 15 28 20 20 20

512 (3.6) 34 22 16 15 38 25 20 20

525 (7.6) 42 28 20 16 48 31 23 20

64 (1.2) 27 17 15 15 30 20 20 20

612 (3.6) 37 24 18 15 42 27 20 20

625 (7.6) 47 31 23 18 54 36 26 21

HM25HM50

Technical Data

126 333347F

Three Phase

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

configuration.

System

Channels

(#)

Hose

Length

ft (m)

Start Time in Minutes

20 Amp

Breaker

240V

30 Amp

Breaker

240V

40 Amp

Breaker

240V

50 Amp

Breaker

240V

20 Amp

Breaker

208V

30 Amp

Breaker

208V

40 Amp

Breaker

208V

50 Amp

Breaker

208V

14 (1.2) 11 9.9 9.9 9.9 13 13 13 13

112 (3.6) 13 9.9 9.9 9.9 14 13 13 13

125 (7.6) 15 9.9 9.9 9.9 16 13 13 13

24 (1.2) 13 9.9 9.9 9.9 14 13 13 13

212 (3.6) 16 11 9.9 9.9 17 13 13 13

225 (7.6) 20 14 10 9.9 22 14 13 13

34 (1.2) 14 9.9 9.9 9.9 16 13 13 13

312 (3.6) 18 12 9.9 9.9 20 13 13 13

325 (7.6) 25 17 13 9.9 26 18 13 13

44 (1.2) 15 10 9.9 9.9 17 13 13 13

412 (3.6) 21 14 11 9.9 23 15 13 13

425 (7.6) 30 20 15 12 34 22 17 13

54 (1.2) 17 11 9.9 9.9 19 13 13 13

512 (3.6) 23 16 12 9.9 27 18 14 13

525 (7.6) 34 23 17 14 40 27 20 16

64 (1.2) 18 12 9.9 9.9 21 14 13 13

612 (3.6) 26 17 13 11 30 20 15 13

625 (7.6)3926191646312319

14 (1.2)1715151520202020

112 (3.6) 19 15 15 15 20 20 20 20

125 (7.6) 21 15 15 15 22 20 20 20

24 (1.2) 19 15 15 15 20 20 20 20

212 (3.6) 23 15 15 15 24 20 20 20

225 (7.6) 26 18 15 15 28 20 20 20

34 (1.2) 20 15 15 15 22 20 20 20

312 (3.6) 26 17 15 15 28 20 20 20

325 (7.6) 31 21 16 15 34 23 20 20

44 (1.2) 22 15 15 15 24 20 20 20

412 (3.6) 28 19 15 15 32 22 20 20

425 (7.6) 35 24 18 15 40 27 20 20

54 (1.2) 22 16 15 15 26 20 20 20

512 (3.6) 31 21 16 15 36 24 20 20

525 (7.6) 40 27 20 16 47 31 24 20

64 (1.2) 24 16 15 15 28 20 20 20

612 (3.6) 34 23 17 15 40 27 20 20

625 (7.6) 45 30 23 18 53 35 27 21

HM25HM50

Technical Data

333347F 127

Dimensions

System Dimensions

System With 480V Transformer

Mounting Hole Dimensions

WLD

35.8in.

(909 mm)

22.3 in.

(566 mm) 18.3 in.

(465 mm)

WLD

41.9 in.

(1064 mm)

18.3 in.

(465 mm)

22.3 in.

(566 mm)

WLD

WALL

Minimum distance from rear mounting

hole to wall: 7.0 in. (178 mm)

3.3 in.

(84 mm)

3.3 in.

(84 mm)

2.0 in.

(51 mm)

14.2 in.

(361 mm)

7.1 in. (180 mm)

101 in. (257 mm) 5.3 in. (133 mm)

Technical Data

128 333347F

System with Stand and Vacuum Feed Dimensions

ti22866b

A

ti22865a

Tube Bend Radius:

8.0 in. (203 mm)

12.0 in.

(305 mm)

30.0

(762 mm)

Radius:

9.1 in. (232 mm)

31.3

(795 mm)

17.4

(442 mm)

27.2 in.

(692 mm)

Ain. (mm)

System 60.7 in. (1542 mm)

System With Transformer 66.5 (1689 mm)

Technical Data

333347F 129

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.

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

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.