Graco 333347F User Manual

Page 1
Instructions - Parts
InvisiPac
HM25 and HM50 Tank-Free
333347F
Hot Melt Delivery System
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
EN
Important Safety Instructions
Read all warnings and instructions in this manual and in the applicator and hose manu­als. Save all instructions.
WLD
9902471
Certified to
CAN/CSA C22.2 No. 88
Conforms to ANSI/UL 499
Page 2
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
2 333347F
Page 3

Related Manuals

Manuals are available at www.graco.com. Component manuals in English:
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

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
Related Manuals
333347F 3
Page 4

Models

Models
200-240 VAC, 350-415 VAC HM50 Models
See 400 VAC Transformer models on page 6.
See 480 VAC Transformer models on page 7.
Model Channels Voltage
200-240 VAC
24T918 2
24T919 4
24T920 6
200-240 VAC
350-415 VAC Y
200-240 VAC
200-240 VAC
350-415 VAC Y
200-240 VAC
200-240 VAC
350-415 VAC Y
Δ
Δ
Δ
Φ
Type Description Frequency
1
Φ
/ PE
3Φ / PE
3
Φ
/ Neutral / PE
Φ
/ PE
1
3Φ / PE
3Φ / Neutral / PE
Φ
/ PE
1
3Φ / PE
3
Φ
/ Neutral / PE
1-Phase
200-240VAC
2 wire and PE
3-Phase without Neutral
200-240VAC
3 wire and PE
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
3 wire, Neutral, and PE
1-Phase
200-240 VAC
2 wire and PE
3-Phase without Neutral
200-240 VAC Line to Line
3 wire and PE
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
3 wire, Neutral, and PE
1-Phase
200-240 VAC
2 wire and PE
3-Phase without Neutral
200-240 VAC Line to Line
3 wire and PE
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
3 wire, Neutral, and PE
Max
Amps
50/60 Hz 32A
50/60 Hz 27A
50/60 Hz 16A
50/60 Hz 40A
50/60 Hz 27A
50/60 Hz 16A
50/60 Hz 40A
50/60 Hz 40A
50/60 Hz 30A
4 333347F
Page 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
200-240 VAC
24V423 2
24V424 4
24V425 6
200-240 VAC
350-415 VAC Y
200-240 VAC
200-240 VAC
350-415 VAC Y
200-240 VAC
200-240 VAC
350-415 VAC Y
Δ
Δ
Δ
Φ
Type Description Frequency
1
Φ
/ PE
3Φ / PE
Φ
/ Neutral / PE
3
1
Φ
/ PE
3Φ / PE
Φ
/ Neutral / PE
3
1
Φ
/ PE
3Φ / PE
Φ
/ Neutral / PE
3
1-Phase
200-240VAC
2 wire and PE
3-Phase without Neutral
200-240VAC
3 wire and PE
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
3 wire, Neutral, and PE
1-Phase
200-240VAC
2 wire and PE
3-Phase without Neutral
200-240VAC
3 wire and PE
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
3 wire, Neutral, and PE
1-Phase
200-240VAC
2 wire and PE
3-Phase without Neutral
200-240VAC
3 wire and PE
3-Phase with Neutral
350-415 VAC Line to Line
200-240 VAC Line to Neutral
3 wire, Neutral, and PE
Models
Max
Amps
50/60 Hz 32A
50/60 Hz 27A
50/60 Hz 16A
50/60 Hz 40A
50/60 Hz 27A
50/60 Hz 16A
50/60 Hz 40A
50/60 Hz 40A
50/60 Hz 30A
333347F 5
Page 6
Models
400 VAC Transformer HM25 Models
Model Channels Voltage
24V426 2 335-400 VAC
24V427 4 335-400 VAC
24V428 6 335-400 VAC
Φ
Type Description Frequency
Φ
/ PE
3
Φ
/ PE
3
Φ
/ PE
3
400 VAC Transformer HM50 Models
Φ
Model Channels Voltage
24V198 2 335-400 VAC
24V199 4 335-400 VAC
24V200 6 335-400 VAC
Type Description Frequency
Φ
/ PE
3
Φ
/ PE
3
Φ
/ PE
3
3-Phase without Neutral
335-400 VAC Line to Line
3 wire and PE
3-Phase without Neutral
335-400 VAC Line to Line
3 wire and PE
3-Phase without Neutral
335-400 VAC Line to Line
3 wire and PE
3-Phase without Neutral
335-400 VAC Line to Line
3 wire and PE
3-Phase without Neutral
335-400 VAC Line to Line
3 wire and PE
3-Phase without Neutral
335-400 VAC Line to Line
3 wire and PE
Max
Amps
50/60 Hz 17A
50/60 Hz 17A
50/60 Hz 17A
Max
Amps
50/60 Hz 17A
50/60 Hz 17A
50/60 Hz 17A
6 333347F
Page 7
480 VAC Transformer HM25 Models
Model Channels Voltage
24V429 2
24V430 4
24V431 6
400-480 VAC
400-480 VAC
400-480 VAC
Φ
Type Description Frequency
3
Φ
/ PE
3Φ / PE
3Φ / PE
480 VAC Transformer HM50 Models
Φ
Model Channels Voltage
24V201 2 400-480 VAC
24V202 4 400-480 VAC
24V203 6 400-480 VAC
Type Description Frequency
Φ
/ PE
3
Φ
/ PE
3
Φ
/ PE
3
3-Phase without Neutral
400-480 VAC Line to Line
3 wire and PE
3-Phase without Neutral
400-480 VAC Line to Line
3 wire and PE
3-Phase without Neutral
400-480 VAC Line to Line
3 wire and PE
3-Phase without Neutral
400-480 VAC Line to Line
3 wire and PE
3-Phase without Neutral
400-480 VAC Line to Line
3 wire and PE
3-Phase without Neutral
400-480 VAC Line to Line
3 wire and PE
Models
Max
Amps
50/60 Hz 14A
50/60 Hz 14A
50/60 Hz 14A
Max
Amps
50/60 Hz 14A
50/60 Hz 14A
50/60 Hz 14A
333347F 7
Page 8

Warnings

Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama­tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec­tric shock.
Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.
Connect only to grounded power source.
All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:
Do not touch hot fluid or equipment.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
+
Do not point dispensing device at anyone or at any part of the body.
Do not put your hand over the fluid outlet.
Do not stop or deflect leaks with your hand, body, glove, or rag.
•Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.
Tighten all fluid connections before operating the equipment.
Check hoses and couplings daily. Replace worn or damaged parts immediately.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
Keep clear of moving parts.
Do not operate equipment with protective guards or covers removed.
Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.
8 333347F
Page 9
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
Do not operate the unit when fatigued or under the influence of drugs or alcohol.
Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.
Do not leave the work area while equipment is energized or under pressure.
Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu­facturer’s replacement parts only.
Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.
Make sure all equipment is rated and approved for the environment in which you are using it.
Use equipment only for its intended purpose. Call your distributor for information.
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not kink or over bend hoses or use hoses to pull equipment.
Keep children and animals away from work area.
Comply with all applicable safety regulations.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:
Do not use solvent-based adhesives that can create an explosive atmosphere when processed.
Use equipment only in well ventilated area.
Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).
Keep work area free of debris, including solvent, rags and gasoline.
Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.
Ground all equipment in the work area. See Grounding instructions.
Use only grounded hoses.
Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.
Keep a working fire extinguisher in the work area.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
Read MSDSs to know the specific hazards of the fluids you are using.
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
333347F 9
Page 10
Warnings
WARNING
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:
Protective eyewear, and hearing protection.
Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or prop­erty damage.
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.
Many other fluids may contain chemicals that can react with aluminum. Contact your material sup­plier for compatibility.
10 333347F
Page 11

Component Identification

G3
G2
A
Component Identification
G4
AD
F
E
C
D
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)
FIG. 1
G
H
G1
B
WLD
K
L
G3
N
R
AC
M
P
WLD
S
J
333347F 11
Page 12
Component Identification
Heated Fluid Manifold
U
AB
Y
R
AA
T
NOTE: System shown with plastic and metal shrouds removed.
FIG. 2
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
X
W1
W2
WLD
12 333347F
Page 13
Electrical Enclosure
Component Identification
AC
FIG. 3
Key:
P Multi-Zone Low Power Temperature Control Module
(MZLP) AC Incoming Power Connection AF Chassis Ground AG Automatic Wiring Board (AWB)
P
WLD
AG
AF
333347F 13
Page 14
Component Identification
Advanced Display Module (ADM)
User Interface
NOTICE
To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.
NOTE: See Appendix A - ADM on page 114 for com­plete ADM operation details.
BB
BC
BA
BD
BE
BF
BH
BK
BL
BR
BM
BN
BP
FIG. 5
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
BG
TI12362a1
FIG. 4
B
Key Function
BA Heating system and pump enable/disable
BB System status indicator (LED)
BC Stop all system processes
BD Defined by icon next to softkey
BE Abort current operation
BF Accept change, acknowledge error, select item,
toggle selected item
BG Toggle between Operation and Setup screens
BH Navigate within a screen or to a new screen
14 333347F
Page 15
Screen Components
Component Identification
Current date and time
Operating Mode
Hose and Applicator
Heating Status
Hose Actual Temperature
FIG. 6: Main Screen Components
Operating Mode Description Component Status
System Off
Inactive
Warm Up
Active
The system doesn’t have power.
The heating system and pumps are disabled.
The system is heating the material to the set temperature.
The system is ready to dispense material.
Screens Order
Applicator Actual Temperature
No System Status Indicator LED on the ADM
No heat
Pump is off
Yellow system status indicator LED on the ADM
No heat
Pump is off
Flashing green system status indicator LED on the ADM
Heat is increasing to setpoint temperature
Pump is off
Solid green system status indicator LED on the ADM
Heat is at setpoint temperature
Pump is on
Faults, Status
Melter Heating Status
Melter Actual Temperature
333347F 15
Page 16
Component Identification
16 333347F
Page 17

Setup

Setup
Grounding
The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Ground­ing provides an escape wire for the electric current.
The InvisiPac system is equipped with a ground termi­nal. A qualified electrician must ground the system using this terminal. See Connect Electrical Cord on page 23.
NOTICE
To prevent excessive static buildup on shaker or adhe­sive bin, install optional grounding kit 24R708.
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, avail­able (purchase separately). See page 104.
To make repairing the system easier, locate the system so that all sides are easily accessible and have sufficient lighting.
Attach Components
To reduce the risk of electric shock, do not connect electrical cord until after this Attach Components procedure is complete.
WLD
FIG. 7: Grounding Kit 24R708
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.
NOTE: Only systems with transformers are supplied with a lifting strap.
NOTICE
To prevent strain on electrical or mechanical connections around the pump assembly, loop the strap around the tie rods as shown.
1. Use supplied lifting strap 127735, to transport sys­tems with transformers. Wrap strap around all three pump tie rods and loop the strap back through itself in the Choker Configuration. See strap for details. See F
IG
. 8, page 18.
333347F 17
Page 18
Setup
3. Adjust the funnel inlet:
G3
WLD
FIG. 8: Lifting Strap
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 enclo­sure.
23
81
92
WLD
a. Remove plug (23) and insert the provided 5/16
in. nut driver (92) through the access hole in the back of the system. Loosen the band clamp (81) two turns.
b. Rotate the funnel inlet (G3) and re-tighten the
band clamp (81).
G3
G4
G2
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.
FIG. 9
WLD
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).
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
18 333347F
IG
. 9.
Page 19
Setup
NOTE: In the following steps, when routing the vacuum transfer hose, ensure there are no tight coils, turns, or dips in the vacuum hose. These will inhibit optimal func­tioning of the vacuum transfer system.
NOTE: Maximum vacuum hose length is 30 ft (9.1 m). Use horizontal hose routing as much as possible. The vacuum hose must not rise more than 10 ft (3.0 m), measured from the vacuum inlet. Any vertical rise will lower the maximum flow rate of the vacuum transfer system.
6. Route the 1.3 in. (33 mm) OD clear vacuum transfer hose (G2) from the system to the adhesive pellets container location.
7. Apply pipe sealant to threads then attach steel shaker tube (G) to shaker head (G1). See F
IG
. 10.
NOTICE
To prevent shaker head (G1) galling to the shaker tube (G), do not overtighten shaker head onto shaker tube. These should be hand-tightened.
ties (G5). See 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 pel­lets.
13. Place shaker assembly in an empty adhesive pel­lets container then fill the container with adhesive pellets.
NOTE: To promote optimal system performance, pur­chase 30 Gallon Vibrating Hopper, 24R136. See installation instructions on page 104.
NOTE: If static buildup on feed tube (G) is excessive, install optional feed tube ground kit 24R708 to feed tube end (G6). See F
IG
. 7.
G2
G6
G5
G
G4
G1
ti21131a
FIG. 10
8. Attach 1.3 in. (33 mm) clear vacuum transfer hose (G2) to steel shaker tube (G) and secure with sup­plied hose clamp. See 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
333347F 19
Page 20
Setup
14. Install heated hoses, see FIG. 11:
To reduce the risk of fire and explosion, only use Graco heated hoses with the InvisiPac system. Use of non-Graco hoses will void agency approvals.
N
Applicator
247
68
W1
W2
AA
FIG. 11
ti23298a
a. Place a rag on the drain tray (W2) attached to
the melter. Residual oil may be in the system from the factory. See F
IG
. 11.
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 con­nected to connector 1, “Invalid Sensor - hose/gun” faults will result. If the melter must be run without a hose/appli­cator electrically attached to MZLP connector, use Overtemperature Jumper, 16Y727, page 113.
15. Install applicator(s), see 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
IG
plug (W1) then remove rag. See F
. 11.
d. Remove plug (247) from the lowest numbered
outlet on the melter. Do not use the drain
IG
plug (W1). See F
. 11.
NOTE: In the following step, the o-ring side of the
IG
hydraulic fitting (68) faces the system. See F
. 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.
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-
IG
tor. See F
. 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.
20 333347F
Page 21
Setup
d. Repeat for any additional applicators.
16. If necessary, set up the pattern controller (not included) to control opening and closing of the appli­cator. See pattern controller manual.
NOTE: The system controls applicator heating only. A separate pattern controller must be set up to open and close the applicator.
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.
J
19. Close the ball valve.
WLE
FIG. 13
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). Rec­ommended pressure is 100 psi (690 kPa, 6.9 bar). If air pressure is expected to drop below 80 psi (0.5 MPa, 5 bar), there is an air reservoir kit that allows the system to operate down to 60 psi (0.4 MPa, 4 bar). See Air Reservoir Kit, 16W366, on page 107.
WLE
FIG. 12
NOTE: The system must have a bleed-type ball valve
that bleeds pressure downstream when closed. Other­wise, the supplied air will need to be disconnected from the system whenever the pressure is relieved.
NOTE: The system must use an air filter with a mini­mum flow rate of 30 scfm.
18. If using the same air for the applicator(s), make sure
to install the tee in the air line before the ball valve. There should not be anything between the ball valve and the system. See applicator manual for applica- tor air pressure requirements, and use a regulator before the gun to decrease the air pressure, if nec­essary.
21. To lock access to the air pressure adjustments, pur­chase Air Adjustment Lock, 24R084. See installa­tion 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 sys­tem, 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.
333347F 21
Page 22
Setup
Recommended Air Setup
Main Air Line
Air In: Less than 50 ft (15.2 m): 3/8 in. More than 50 ft (15.2 m): 1/2 in. 80-100 psi (5.5-6.8 bar, 0.55-6.8 MPa) 30 scfm capacity.
Ensure funnel air is connected
Air Filter/Ball Valve at
System Air Inlet
(Graco Kit 24R707,
included)
Vacuum Pump
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
Air In:
3/8 in.,
100 psi
(6.8 bar, 0.68 MPa),
30 scfm capacity
Pump: 20-100 psi (1.4-6.8 bar,
0.14-0.68 MPa)
WLE
Regulator set to
Air to applicators
70 psi
(4.8 bar, 0.48 MPa)
FIG. 14
22 333347F
Page 23
Setup
Connect Electrical Cord
NOTE: See Grounding section on page 17.
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.
NOTE: The installed strain relief bushing (106) fits a
0.708-1.260 in. (18-32 mm) OD electrical cord. See F
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 avail­able for smaller (0.512-1.024 in, 13-26 mm) OD electri­cal cords. See Accessories, page 100.
IG
5. Attach insulated ferrules to the end of each wire.
106
AF
FIG. 15
.
6. Connect ground wire to chassis ground (AF). See F
IG
. 15.
7. Connect L1, L2, L3, and N as shown in F all models use all 4 wires.
WLD
IG
. 16. Not
Y
X
For 208V Electrical Circuits, see page 24.
1. Turn main power switch OFF.
2. Disconnect cable from ADM, push cable through plastic shroud, then remove plastic shroud from sys­tem.
3. Remove electrical enclosure access door (T). See 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.
FIG. 16
8. Use zip ties to secure the electrical cord to the tie-downs located on the top of the inside of the electrical enclosure.
9. Tighten screw-terminals to at least 10 in-lb (1.1 N•m).
10. Install electrical enclosure door.
11. Perform Select ADM Settings on page 24 prior to turning on heat.
333347F 23
Page 24
Setup
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 set­ting.
Single Phase, 20A ADM Breaker Setting Example:
240 volts x 20 amps = 4800 watts
Three Phase, 20A ADM Breaker Setting Example:
240 volts x 20 amps x SQRT(3) = 8315 watts
Select ADM Settings
NOTE: See Appendix A - ADM on page 114 for
detailed ADM information, including general operation.
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.
To prevent fire and explosion, a qualified electrician must determine the proper circuit breaker size to use for the power supplied to the system.
4. On the System 3 screen:
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.
a. Enter the main circuit breaker size used. This is
the circuit breaker installed external to the sys­tem for the system power supply.
NOTE: The InvisiPac system limits the amount of power it pulls based on the input circuit breaker size. This impacts the startup times because it affects the heating energy used to warm up the materials.
5. On the Advanced 1 screen, set the system date and time.
b. Select the RTD type used on each installed
applicator. See applicator manual.
24 333347F
Page 25
Setup
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.
333347F 25
Page 26
Setup
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.
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.
ring, page 36.
See Operation Tips to Minimize Char-
Applicators
Applicator heating is controlled by the system, but the system does not control opening and closing the appli­cators. Setup a separate pattern controller to open and close the applicators.
NOTE: Alternatively, use the physical up and down
arrow push-buttons on the ADM keypad until is next to the temperature setting to change then use the numeric keypad to enter the desired temperature.
c. Use and , shown next to ,
to adjust heated hose temperature setting to the desired setting for that channel.
26 333347F
Page 27
Setup
PLC Connection
A PLC can control and monitor all items shown in the dropdown menus on the System 1 screen in the Setup screens.
Customer Input Dropdown Options
Option Description
Disable Not used.
Heater On/Off Turn on or off the heating system and
pump.
Channel 1, 2, 3, 4, 5, or 6 Enable/Disable
Customer Output Dropdown Options
Enable or disable hose and applicator heating for that individual channel.
NOTE: The InvisiPac system ships with two screw-ter­minal connectors that plug into MZLP connectors H1 and H2. Connectors are located in a bag on the inside of the electrical enclosure front access door. To replace the connectors, order kit 24P176.
1. On the System 1 screen (in the Setup screens) select the function of each input on MZLP connector H1 and each output on MZLP connector H2.
2. Turn main power switch OFF.
3. Remove electrical enclosure front access door.
4. Route I/O cable through strain relief in electrical enclosure. See Customer I/O Cable (S) in 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.
F10
F8
F7
F9
F6
J2
F4
F3
F5
J1
F2
F1
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 (Devia­tion/Advisory)
Maintenance Due Indicates when the maintenance total
Indicates when there is an active devia­tion or advisory. An active deviation or advisory will NOT disable the heating system and pump.
has reached the preset notification value.
NOTE: All outputs are normally open when power is OFF. For Error (Alarm) output, the contacts open when an alarm occurs. For all others, contacts close.
J7
J6
J5
J3
WLD
FIG. 17: MZLP Board
H1 - Customer Input H2 - Customer Output
Signal Pin Signal Pin
1 1, 2 1 1, 2
2 3, 4 2 3, 4
3 5, 6 3 5, 6
4 7, 8 4 7, 8
Inputs: High: 10-30 Vdc, Low: 0-5 Vdc. Inputs function without concern for polarity. Applying “high” voltage will turn the heaters on and enable channels. Removing voltage will turn the heaters off and disable channels.
Outputs: 0-250 Vac, 0-30 Vdc, 2A Maximum.
333347F 27
Page 28
Setup
PLC Connection Block Diagrams
The following block diagrams show how to connect customer inputs and outputs to the InvisiPac MZLP. For conve­nience, each InvisiPac ships with connector kit 24P176. If a connector is lost or damaged, order kit 24P176 for replacements.
FIG. 18: Customer Input
MZLP Customer In
Customer Output
Vin (no polarity) 30 VDC Max
MZLP Customer Out
Customer In
250 VAC, 0-30 VDC, 2A Max
To Customer Input
FIG. 19: Customer Output
28 333347F
Page 29

Operation

Heating and dispensing hot melt adhesive may create potentially harmful vapors. Read material manufac­turer’s warnings and material MSDS to know specific hazards and precautions. Ventilation of the work area may be required.
Operation
Initial Startup and Prime
NOTE: All setup procedures must be completed prior to initial startup. See Setup on page 17.
NOTE: See Appendix A - ADM on page 114 for
detailed ADM information.
NOTICE
To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.
NOTE: See Appendix B - USB Downloading, Upload­ing 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 appli­cators. 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 Sched­ule function automatically enables the heating system at the user-specified times so the system is ready to dis­pense when a shift begins. The Schedule function also disables the heating system at user-specified times to ensure the heating system is disabled when not being used.
NOTE: Only 1/4 in. (6 mm) round hot melt adhesive pel­lets can be used in the InvisiPac system. PSA-type adhesive pellets will not work in the InvisiPac system.
1. Direct the applicator into an appropriate waste container.
2. Verify the shaker inlet is at the bottom of the empty adhesive pellets container. Optional vibrating adhe­sive pellets container, part 24R136, is available. See Accessories on page 100.
NOTE: The shaker inlet must be completely covered in adhesive pellets to effectively pull pellets into the tube.
3. Fill adhesive pellets container with hot melt adhe­sive pellets.
4. Turn main power switch ON .
5. Open system air inlet ball valve.
WLE
333347F 29
Page 30
Operation
6. Use pump air pressure regulator (C) to adjust pump air pressure to 0.
E
C
FIG. 20
7. Use vacuum transfer air pressure regulator (E) to adjust vacuum transfer air pressure setting to 40-100 psi (280-690 kPa, 2.8-6.9 bar). Recom­mended setting is 60 psi (414 kPa, 4.1 bar). See 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.
10. On new systems only: After the melter has reached
250°F (121°C) and the funnel is filled with pellets, set the melter temperature back to the desired oper­ating temperature. See Select ADM Settings on page 24 for instructions.
11. Use separate pattern controller to open the applica­tors and keep them open.
NOTICE
In the following step, to prevent damage to the pump due to pump cavitation, do not supply more than 20 psi (140 kPa, 1.4 bar) air pressure to the pump until the system is fully primed.
12. With the applicators open and the system up to tem­perature, slowly increase pump air pressure until the pump begins to run very slowly. Approximately 20 psi (140 kPa, 1.4 bar) should be sufficient.
NOTE: Operation may be erratic below 20 psi (140 kPa,
1.4 bar).
13. Continue running the pump until clean, air-free material is dispensed from each applicator.
14. When each applicator is fully primed, adjust pump to desired pressure setting:
To prevent fire and explosion, never exceed the clean­ing fluid’s rated temperature. If the system was just flushed, residual cleaning fluid is still in the system until the system is primed with adhesive. Do not raise temperature above cleaning fluid rated temperature until system is primed with adhesive.
NOTE: A new system may have residual oil due to test­ing at the factory prior to shipping. To prevent smoking, make sure to perform the following step.
8. On new systems only: temporarily adjust the melter
temperature to 250°F (121°C). See Select ADM Settings on page 24 for instructions.
9. Press to enable the heaters and pump.
NOTE: When system is up to temperature, the pump will be activated automatically, but will not start because there is no air pressure supplied to the pump.
NOTE: When the melter is up to temperature, the auto-fill function will initiate to fill the funnel with pellets.
a. Adjust pump pressure to between 20-100 psi
(140-690 kPa, 1.4-6.9 bar).
b. Use separate pattern controller to repeatedly
open and close each applicator while inspecting the dispense pattern.
c. Repeat until desired dispense pattern is
achieved.
Manual Refill
NOTE: Use Automatic Refill whenever possible. The
system uses Automatic Refill by default and must be manually changed to Manual Refill. Only use Manual Refill if the Automatic Refill system is not functioning properly and cannot be fixed in a timely manner. Per­form service to automatic feed system as soon as possi­ble to limit debris buildup on feed funnel.
30 333347F
Page 31
Operation
It is recommended to maintain a minimum flow rate of
1.5 lb/hour to prevent material from melting within the feed cap and funnel. If production rate is below
1.5 lb/hour or system sits at temperature without dis­pensing for extended periods of time, use manual refill­ing with caution. System flow rate can be monitored by enabling the Diagnostic screen.
1. On the System 3 screen (in the Setup screens), select “Manual” from the Refill mode dropdown.
2. Remove the two bolts from the funnel bracket, then remove the top portion of the funnel.
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 fun­nel cap to the correct level to prevent any issues upon startup the following production day.
WLD
FIG. 23
WLD
FIG. 21
3. Disconnect the sensor cable and sensor cooling air.
4. Fill the funnel with adhesive pellets.
Automatic Refill
The system uses automatic refill by default. If the auto­matic refill system is malfunctioning and cannot immedi­ately be fixed, Manual Refill can be used.
To use automatic refill:
1. On the System 3 screen (in the Setup screens), select “Automatic” from the Refill mode dropdown.
2. Verify shaker and tube are connected to the system. See Attach Components on page 17.
3. Verify shaker inlet (K) is at the bottom of the adhe­sive pellets container that is filled with hot melt adhesive pellets. See F
NOTE: The shaker inlet must be completely covered in adhesive pellets in order for it to effectively pull pellets into the tube.
IG
. 1 on page 11.
WLD
FIG. 22
333347F 31
Page 32
Operation
4. If not already set, use vacuum transfer air pressure
regulator (E) to adjust vacuum transfer air pressure setting to 40-100 psi (280-690 kPa, 2.8-6.9 bar). Recommended setting is 60 psi (414 kPa, 4.1 bar).
E
FIG. 24
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.
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 applica­tors as desired to dispense material.
NOTE: While operating the system, the actual tempera­tures of the hose, applicator, and system melter are dis­played on the Home screen.
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
on page 11.
b. Check pressure gauges (D, F) to verify vacuum
transfer and pump air pressures are set as desired. See F
c. If using Automatic Refill, see Automatic Refill
on page 31.
d. If using Manual Refill, see Manual Refill on
page 30.
IG
. 1 on page 11.
IG
. 1
32 333347F
Page 33
Operation
Shutdown
Press to disable the heaters and pump. The
screen will say “Inactive”. If using the Schedule function, the heaters and pump will be disabled automatically at
the set time. You will not need to press if using the
Schedule function unless you wish to disable the heat­ing system before the set time. If the heaters were man­ually disabled, the Schedule function will automatically enable them at the next set time.
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.
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 auto­matically enabling and disabling the heaters.
How to Use the Schedule Function
At the end of the work day leave main power switch ON
. The Schedule function will automatically enable
and disable the heaters and pump at the specified times.
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever you see this symbol.
This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Pro­cedure when you stop spraying and before cleaning, checking, or servicing the equipment.
1. Turn main power switch OFF .
2. Close the inlet air supply ball valve.
Set Schedule Times
NOTE: Times are set using a 24-hour clock. Several on
and off times can be set each day.
1. On the Schedule screen (in the Setup screens), set the ON times for each day of the week.
2. Set the OFF times for each day of the week.
333347F 33
NOTE: Manually verify the pressure is relieved by open­ing the applicator and ensuring no adhesive is dis­pensed.
Page 34
Operation
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.
12. Wait until system stops draining or at most 10 min­utes.
NOTE: There will be some residual adhesive in the sys­tem.
13. When done performing the procedure that required draining the system, set Refill Setting back to “Auto” on the System 3 screen.
Flush
To prevent fire and explosion, use the adhesive manu­facturer’s recommended cleaning fluid.
• Never exceed the cleaning fluid’s rated temperature.
• Never flush your system or clean any aluminum components with halogenated hydrocarbon cleaning solutions.
To prevent severe burns, wear protective clothing.
3. Decrease pump air pressure to 0.
4. Close system air inlet ball valve.
5. Disconnect hose from applicator inlet then place hose outlet in a waste container. Repeat for all hoses. Keep hose to applicator electrical connector connected.
6. Open applicator to allow residual fluid in applicator to drain.
7. When system is at operating temperature, slowly increase pump air pressure until fluid begins flowing into the waste container.
NOTE: It may take several minutes to empty the sys­tem. When there is no melter fluid at the pump, the pump will begin to cycle faster.
8. When the pump begins to cycle faster, close the system air inlet ball valve.
9. Press to disable the heaters and pump.
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.
10. Remove melter drain plug (W1). See F
12.
11. Disconnect hose from melter outlet.
34 333347F
IG
. 2 on page
Page 35
Operation
5. On the System 3 screen (in the Setup screens), ver­ify the Refill Setting is set to “Manual”.
To prevent fire and explosion, never exceed the clean­ing fluid’s rated temperature.
6. Change the melter, heated hoses, and applicators temperature settings to the high temperature hot melt cleaning fluid manufacturer’s recommended temperature.
7. Verify the system air inlet ball valve is closed and pump air pressure is set to 0.
8. Allow the system to heat or cool to the cleaning fluid manufacturer’s recommended temperature.
9. Fill melter with high temperature rated hot melt cleaning fluid. See hot melt adhesive material sup­plier for recommended hot melt cleaning fluids. Fluid level should be 1/2 in. (12.7 mm) from the top of the melter.
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 possi­ble cleaning.
15. After the hot melt cleaning fluid has “soaked” for the specified amount of time, open the system air inlet ball valve. Slowly increase the pump air pressure until pump begins to cycle to begin pumping the hot melt cleaning fluid and adhesive mixture out through the hose into the waste container.
16. Once the pump begins to cycle faster, close the sys­tem air inlet ball valve to stop the pump.
17. Repeat steps 7 through 16 until clean, adhe­sive-free hot melt cleaning fluid is dispensed from the detached hose.
NOTE: Now the melter and the disconnected hose are thoroughly flushed.
18. Reattach the hose to the applicator manifold.
19. Repeat steps 7 through 18 for each additional installed hose, leaving a different hose discon­nected from the applicator manifold each time.
20. Remove and replace filter(s) in all applicator mani­folds. See applicator manual.
21. Replace Outlet Filter. See page 37.
WLD
22. Turn main power switch OFF.
10. Disconnect one hose from its applicator manifold.
NOTE: Keep all applicators closed throughout this pro­cedure.
11. Route the disconnected hose to a waste container.
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.
333347F 35
Page 36
Operation
25. Install fill cap onto melter rubber housing.
26. Slide funnel assembly through air motor bracket then tighten clamp.
27. On the System 3 screen (in the Setup screens), set the Refill Setting to “Auto”.
To prevent fire and explosion, never exceed the clean­ing fluid’s rated temperature. Residual cleaning fluid is still in the system until the system is primed with adhe­sive.
28. Perform Initial Startup and Prime on page 29.
Operation Tips to Minimize Charring
Set the Pump Idle Time to System Inactive function on the System 3 screen to lowest value that will not interfere with normal operation. This feature automati­cally disables the heating system if the pump is idle for longer than the preset amount of time. Disabling the heating system minimizes adhesive degradation and limits char formation.
When possible, utilize the Schedule function, see page 33, to automatically enable and disable the heat­ing system in accordance with your production sched­ule. This will ensure adhesive spends as little time at temperature as possible. Less time at high temperature ultimately means less adhesive degradation and less
char.
NOTICE
Set melter, hose, and gun to the same setpoint temperature for best performance. Do not set the hose temperature higher than the melter. Running the hose at a setpoint higher than the melter is unnecessary in this tank-free system and could lead to adhesive degradation in the hose. Short adhesive residence time in the melter eliminates the need to set the melter at a lower setpoint than other zones.
36 333347F
Page 37

Maintenance

Maintenance
Replace Outlet Filter
The outlet filter is designed to prevent small contami­nants from entering the hoses and applicators. Inspect filter regularly. Replace the filter after flushing and when you change the adhesive used in the system.
236
232
237
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 fil­ter onto new outlet filter (236).
9. Place new outlet filter with o-rings into housing. Tighten with 1 in. socket.
10. Install small metal shroud (28) over outlet filter then tighten two screws (8).
Replace Inlet Filter
To avoid severe burns, wear protective gloves and clothing that will insulate your hands and body from the hot surfaces and material.
The inlet filter is designed to prevent large items from entering the system. The inlet filter can only be replaced with the system empty.
8
FIG. 25
1. If the system is not up to temperature, press to
enable the heaters and pump then wait for system to reach operating temperature.
To avoid severe burns, wear protective gloves and clothing that will insulate your hands and body from the hot surfaces and material.
2. Perform Pressure Relief Procedure, page 33 but
do not allow system to cool. Adhesive must be a fluid to perform this procedure.
3. Turn main power switch OFF.
4. Loosen two screws (8) then slide the small metal shroud (28) on the back of the system up to remove. See F
5. Use a 1 in. socket to unscrew outlet filter (236).
IG
28
. 25.
WLD
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) incre­ments.
NOTE: To ensure the adhesive is a gel, not a liquid, do not remove inlet filter cap (215) when the temperature is above the desired temperature. If the temperature is too low, the adhesive viscosity may be too high to remove the inlet filter (213). See F
2. If the melter is below the desired temperature and
heating system is disabled, press to enable
the heaters.
If the melter is above the desired temperature and
heating system is enabled, press to disable
the heaters.
3. Wait until melter temperature is the desired tem­perature.
IG
. 26, page 38.
333347F 37
Page 38
Maintenance
4. When the melter temperature is the desired tem­perature, turn main power switch OFF.
5. Disconnect cable from ADM, push cable through plastic shroud, then remove plastic shroud from sys­tem.
6. Place a piece of cardboard beneath the inlet filter cap (215) to route fluid away from system into a waste container in the event the adhesive is a fluid.
7. Use 1 in. socket to remove inlet filter cap (215).
213
215
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
706
705
WLD
201
FIG. 26
8. If the adhesive is a thin enough gel to remove the inlet filter: Use an o-ring pick or small allen wrench
to remove filter screen (213) from system.
Otherwise:
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.
WLD
FIG. 27
Disassembly (see FIG. 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.
38 333347F
Page 39
Maintenance
Filter Maintenance Guidelines*
Environmental Classification
Clean Moderate Dusty
Pump inlet filter Pump outlet filter Applicator manifold filter System air filter Solenoid exhaust filters Feed funnel filter Feed funnel inspection/cleanout
* These recommendations are service level guidelines - actual service levels required in your factory will vary based on environmental and operating conditions. High or low volume adhesive usage, as well as adhesives that contain a powdered release agent or are otherwise dusty, will have an impact on the frequency of filter maintenance. To estab­lish a preventative maintenance cycle tailored to your environment, Graco recommends inspecting filters every 4 weeks after installation and replacing when necessary. Document replacement intervals and use this as your preven­tative maintenance schedule moving forward.
Replace filter
every six
months
Replace filter
every four
months
Replace filter
every two
months
333347F 39
Page 40

Troubleshooting

Troubleshooting
To avoid injury due to unexpected machine operation initiated by a remote controller, disconnect the cus­tomer I/O cable from the system prior to troubleshoot­ing.
ADM Error Code Table
When an error occurs, press 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.
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
An alarm will disable the heating system and pump. A deviation or advisory will not disable the heating system and pump.
Code Description Type Cause Solution
A1D0 Low Current
Melter
A1D_ Low Current
Gun X
A1D_ Low Current
Hose X
Advi­sory
Advi­sory
Advi­sory
Melter current is less than 500mA. Faulty melter heater(s). Check heater resistance
and resistance to ground. Replace faulty heater(s).
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.
Hose current is less than 500mA. Faulty hose heater. Check heater resistance and
resistance to ground. Replace faulty hose.
40 333347F
Page 41
Troubleshooting
Code Description Type Cause Solution
A3MF High Fan Cur-
rent, Trans­former
A4D0 High Current
Melter
A4D_ High Current
Hose X
A4D_ High Current
Gun X
A7D0 Unexpected
Current
A7D_ Unexpected
Current, Gun X
A7D_ Unexpected
Current, Hose X
A8D0 No Current
Melter
A8D_ No Current
Hose X
A8D_ No Current Gun XAlarm Power not getting to applicator. Check fuses F3 and F4 (channels 1, 3, 5) or F7
A8MF No Fan Current,
Transformer
Devia­tion
Alarm Defective or shorted to ground on the
Alarm Defective or shorted to ground on the
Alarm Defective or shorted to ground on the
Alarm Unexpected current flow to melter. Faulty melter heater(s). Check heater resistance
Alarm Unexpected current flow to applicator X.Faulty applicator heater element. Check heater
Alarm Unexpected current flow to hose X. Faulty hose heat element. Check heater resis-
Alarm Power not getting to melter. Check fuses F1 and F2 on MZLP with daughter
Alarm Power not getting to hose. Check fuses F5 and F6 (channels 1, 3, 5) or F9
Devia­tion
Transformer fan is greater than 600mA.
band heater or rod heater.
hose power wires.
heater rods in applicator manifold.
Power not getting to transformer fan. Verify that fan power cable is plugged into J7 on
Replace transformer fan.
Measure resistance to ground between heater leads. Should be a high reading.
Replace heated hose.
Replace applicator manifold.
and resistance to ground. Replace faulty heater(s). See Replace Heater Rod, page 64.
Replace MZLP.
resistance and resistance to ground. Faulty MZLP. Replace MZLP.
tance and resistance to ground. Faulty MZLP. Replace MZLP.
board. Check J1 is plugged into MZLP with daughter
board and J3 on AWB.
and F10 (channels 2, 4, 6) on MZLP that the error hose is connected to.
Check that electrical connector on the heated hose is plugged into the MZLP.
Check continuity of pins C and D on electrical connector at MZLP end of heated hose. See heated hose manual for impedance measure­ments. Replace hose if readings are too high.
If system only uses one hose and applicator, the heated hose electrical connector must be plugged into channel 1 of the MZLP.
and F8 (channels 2, 4, 6) on MZLP that controls the error channel.
Check that electrical plug on hose is plugged into back of MZLP and applicator is plugged into hose.
Check continuity of hose pin A gun end to J on MZLP connector end of hose and pin C on gun end to pin A on the MZLP end of the hose. Read­ing should be 0-1 ohm. Replace hose if measure­ment is outside this range.
If system only uses one hose and applicator, electrical connector of the heated hose must be plugged into channel 1 of the MZLP.
the AWB. Verify transformer fan is free of obstructions and
can spin freely.
333347F 41
Page 42
Troubleshooting
Code Description Type Cause Solution
CAC_
1=MZLP 1 2=MZLP 2 3=MZLP 3
CACX Missing DB Alarm System not acknowledging the daugh-
DADX Pump Runaway Alarm Pump is trying to feed adhesive, no
DDDX Pump Diving Devia-
DE0X Cycle Switch
L0FX Manual Fill
L6FX Level Sensor
Comm Error Module
Error
Mode
Error
Alarm System not responding to ADM. Dial not set correct on MZLP. Set to 1 on board
with daughter board. Set to 2 on MZLP without the daughter board in center of electrical enclo­sure. Set to 3 on MZLP without daughter board on left of electrical enclosure.
System is not properly loaded with correct soft­ware. Perform Software Update Procedure on page 77.
Bad connection between daughter board and
ter board.
adhesive to feed.
Worn or damaged pump seals Inspect pump seals. Repair if necessary. Pump is trying to feed adhesive, no
tion
Alarm No signal from air motor sensor. Check wiring on J16 of the daughter board. See
Advi­sory
Alarm No signal from the level sensor. Check that sensor cable is plugged into sensor.
adhesive to feed.
Worn or damaged pump seals Inspect pump seals. Repair if necessary.
System set to manual fill mode. Change to auto fill mode. See Setup Screen Sys-
No air to fill cap. Check for air coming from 5/32 in. air line. Plugged orifice in fill cap below fill sen-
sor.
MZLP board. Loosen daughter board, re-seat, then secure.
Daughter board is not plugged into MZLP1. Plug daughter board into MZLP with dial set to 1.
Defective MZLP daughter board. Replace. Storage bin out of adhesive. Refill adhesive. Level sensor may be over heating. Verify air is
being delivered from tube (35). Melter at incorrect temperature, too low. Check
setpoint and set to manufacturer’s recommenda­tion.
Plugged vacuum transfer hose or funnel. Clear plugged hose or funnel.
Storage bin out of adhesive pellets. Refill with pellets.
Level sensor may be over heating. Verify air is being delivered from tube (35).
Melter at incorrect temperature, too low. Check melter temperature setting and set to manufac­turer’s recommendation.
Plugged vacuum transfer hose or funnel. Clear plugged hose or funnel.
Dispense rate too high. See technical ratings of system.
Electrical Schematics on page 78. Loose cycle switch bolt. Tighten cycle switch bolt. Defective cycle switch. Replace.
tem 2.
Check connector at J14 of the daughter board. Verify there is nothing blocking fill (level) sensor
line of sight. Defective fill (level) sensor. Replace.
Remove fill cap and remove object plugging the orifice.
42 333347F
Page 43
Code Description Type Cause Solution
L8FX Refill timeout Alarm Melter did not receive enough adhesive
pellets for flow rate.
M8MF High Temp Run-
away, Trans­former
MMUX USB Log Full Advi-
MNDX Pump Mainte-
nance Due
T2D0 Low Tempera-
ture, Melter
T2D_ Low Tempera-
ture, Gun X
T2D_ Low Tempera-
ture, Hose X
T4C_ High MZLP PCB
Temp
Devia­tion
sory Advi-
sory Devia-
tion
Devia­tion
Devia­tion
Alarm MZLP board is overheating. Ambient temperature must be under 120°F.
At the current rate of temp rise, the transformer will over heat in 15 minutes or less.
USB logs full. Data loss will occur if not downloaded.
Cycles are greater than user set main­tenance interval.
Melter temperature dropped to 15°F(-9°C) below setpoint.
Applicator temperature dropped to 15°F(-9°C) below setpoint.
Hose temperature dropped to 15°F(-9°C) below setpoint.
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 regula­tions.
Dirty or plugged funnel filter. Replace filter. Verify that fan power cable is plugged into J7 on
the AWB. Verify transformer fan is free of obstructions and
can spin freely. Replace transformer. Download USB data. See Appendix B - USB
Downloading, Uploading on page 120. Perform maintenance and reset “Due” counter to
0 at the Setup Maintenance screen.
Verify system is operating within meltrate specifi­cations. Consider incoming voltage and breaker setting.
Verify that the fill system (vacuum) is operating correctly. If the level of material in the melter gets too low and a large amount of cold material enters the melter, can cause the temperature to drop significantly.
With the system on and not dispensing verify that the temperature is properly controlled to the set­point. If system cannot control temperature, ver­ify the RTD is seated inside the melter.
Replace RTD if RTD was seated properly and system cannot control temperature
Faulty melter heater(s). Check heater resistance and resistance to ground. Replace faulty heater(s).
With the system on and not dispensing verify that the temperature is properly controlled to the set­point. If system cannot control temperature, replace applicator RTD. See applicator manual.
Faulty applicator heater. Check heater resistance and resistance to ground. Replace faulty heater.
Dispense rate too high for applicator to maintain setpoint. Consider applicator power and voltage.
With the system on and not dispensing verify that the temperature is properly controlled to the set­point. If system cannot control temperature, replace hose.
Faulty hose heater. Check heater resistance and resistance to ground. Replace faulty hose.
Defective MZLP board. Replace.
Troubleshooting
333347F 43
Page 44
Troubleshooting
Code Description Type Cause Solution
T4D0 High Temp
Melter
T4D_ High Temp
Hose
T4D_ High Temp Gun Alarm Applicator assembly continues to raise
T4MX High Tempera-
ture, Trans­former
T6D0 Sensor Error
Melter
T6D_ Sensor Error
Hose
T6D_ Sensor Error
Gun
T6MX Thermistor Sen-
sor Error, Trans­former
T8D_ No Temp Rise in
Gun (all zones)
Alarm Melter continues to raise above the set-
point.
Alarm Hose continues to raise above the set-
point.
above the setpoint.
Alarm Thermistor reading greater than 212°F
(100°C).
Alarm No reading from RTD. Verify connector J5 on MZLP board is securely
Alarm No reading from RTD. Hose electrical connector not plugged into MZLP.
Alarm No reading from RTD. Hose electrical connector not plugged into MZLP
Alarm No reading from transformer thermistor
sensor.
Alarm Temperature reading does not change. Check fuses F3 and F4 (channels 1, 3, 5) or F7
Check that RTD is seated in melter correctly.
Check that overtemperature switch is plugged in and check switch resistance. The switch resis­tance should be near 0 Below 400°F (204°C).
Check melter heaters’ resistance to ground. Replace heater if a heater is shorted to ground.
Turn system on without dispensing. Verify tem­perature is properly controlled to the setpoint. If setpoint is not maintained, replace RTD. If heat continues to rise past setpoint, replace MZLP.
Turn on system without dispensing. Check if hose can maintain setpoint temperature. If the hoses’ RTD readings are unstable, replace hose. If hose continually heats past setpoint, replace the MZLP.
Turn on system without dispensing. Check if applicator can maintain setpoint temperature. If the applicator’s RTD readings are unstable, replace the applicator RTD.
Check the applicator heater’s resistance to ground if the RTD readings are stable but the applicator’s temperature continues to rise. If the heater is shorted to ground, replace the applica­tor’s heater. If heater is not shorted to ground, replace MZLP.
Verify transformer fan is operating correctly and free of obstructions.
Replace transformer.
connected. Defective RTD. Replace melter RTD. See
Replace Band Heater Temperature Sensor, page 63.
Defective RTD. Replace hose.
or applicator electrical connector not plugged into heated hose.
Defective RTD. Replace applicator RTD. Verify that sensor wire is plugged into J7 on
AWB. Replace transformer.
and F8 (channels 2, 4, 6) on MZLP that error channel is connected to.
Defective heater rods in applicator manifold. Replace applicator manifold. NOTE: Defective heaters rods in the applicator manifold can also cause the no current error.
Heated hose electrical connector or wires are defective. Check resistance of hose wiring. See hose manual for proper resistance range.
44 333347F
Page 45
Code Description Type Cause Solution
T8D_ No Temp Rise in
Hose (all zones)
T8D0 No Temp Rise in
Melter (all zones)
V1I_ Low Can Volt-
age
V1MW Low Line Volt-
age
V4I_ High Can Volt-
age
V4MW High Line Volt-
age
V6MW Invalid Power
Type
V8M_ No line voltage Alarm Incoming line voltage is less than
WJDX Pump Solenoid
Error
WKFX Fill Solenoid
Error
WSUX USB Invalid
Configuration
Alarm Temperature reading does not change.
Alarm Temperature reading does not change. Check fuses F1 and F2 on MZLP with daughter
Alarm Bad or overloaded power supply. Verify power supply voltage is 24 VDC. If voltage
Devia­tion
Alarm Bad or overloaded power supply. Verify power supply voltage is 24 VDC. If voltage
Alarm Incoming line to line voltage has
Alarm During startup incoming line to line
Alarm No voltage draw from air solenoid for
Alarm No voltage draw from air solenoid for
Devia­tion
Incoming line to line voltage has dropped below 175V.
increased above 265V.
power was either below 175V or above 265 V.
100 VAC.
air motor.
fill.
A valid configuration file can't be found for the USB.
Bad ADM. Replace ADM.
Check fuses F5 and F6 (channels 1, 3, 5) or F9 and F10 (channels 2, 4, 6) on the MZLP that con­trols the error channel.
Defective heater wires in hose. Replace heated hose.
NOTE: Defective heaters wires in the hose can also cause the no current error.
Heated hose electrical connector or wires are defective. Check resistance of hose wiring. See hose manual for proper resistance range.
board. Defective heater wires in melter. Replace melter.
NOTE: Defective heaters wires in the melter can also cause the no current error.
Defective heater element(s). Check heater resis­tance and compare to reference table. See Check Heater Rod Resistance, page 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.
is low, disconnect the screw terminals +V and -V on the power supply and re-check voltage read­ing. If voltage is correct, then disconnect J8 and J9 from AWB and re-check voltage. If still low replace AWB. If correct, plug in J9 and recheck voltage. If low, replace ADM. If correct, plug in J8. If low, replace MZLP. If voltage is still low, replace power supply.
Verify incoming power is correct gauge for cur­rent draw and verify incoming power lines are securely attached to disconnect.
is high, replace power supply unit. For 3 phase with neutral have qualified electri-
cian verify neutral wire. Verify incoming power is wired to the disconnect
correctly.
Measure incoming power with system unplugged. If line voltage is less than 100 VAC, contact qualified electrician to correct the low voltage.
Check connector is properly connected to J13 of the daughter board.
Defective air manifold, replace manifold. Check connector at J13 of the daughter board. Defective air solenoids. Replace. See page 72. System is not properly loaded with correct soft-
ware. Perform Software Update Procedure on page 77. Retry USB download.
Troubleshooting
333347F 45
Page 46
Troubleshooting
Mechanical and Electrical Troubleshooting
Problem Cause Solution
Refill Timeout Error
The InvisiPac system takes a long time to refill adhesive.
Vacuum trans­fer not working
The system was unable to refill in less than 30 seconds.
Glue level in hopper is low.
Vacuum flow is restricted.
Air to vacuum assem­bly missing.
Air at system air gauge but not to air to shaker.
Air is at shaker but there is no feed.
Check hopper for adequate material and material blocking.
Verify the vacuum transfer system air pressure is 40-80 psi (60 psi rec­ommended) and that air is flowing to the feed wand while attempting to refill.
Restart system. If the error persists after attempting another refill and unit is needed immediately for production, place system into the man­ual refill mode. See Manual Refill on page 30.
Check funnel filter. If plugged, see Replace Funnel Filter on page 38.
Check hopper for adequate material and material blocking.
Verify the vacuum transfer system air pressure is 40-80 psi (60 psi rec­ommended) and that air is flowing to the feed wand while attempting to refill.
Check funnel filter. If plugged, see Replace Funnel Filter on page 38.
Verify the vacuum transfer system air pressure is 40-80 psi (60 psi rec­ommended)
Check that air line is connected or not pinched.
Plugged shaker unit, remove from system and remove plug.
Adhesive pel­lets in storage bin not cover­ing shaker head.
Fill Solenoid Error
Shaker unit not vibrat­ing.
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.
Failure of the fill sole­noid or fill solenoid wir­ing.
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.
Some materials may require agitation periodically to breakup bridging. Purchase and install 30 Gallon Vibrating Hopper, 24R136. See page 104.
Verify wiring between J13 and the refill solenoid is not damaged.
Restart system. If the error persists after attempting another refill and unit is needed immediately for production, place system into the man­ual refill mode. See Manual Refill on page 30.
46 333347F
Page 47
Problem Cause Solution
Troubleshooting
Level Sensor Error
The InvisiPac system expels adhesive pel­lets dust when refilling.
The InvisiPac system will not stall, pump continues to move even if the applicators are all closed.
Failure of the level sen­sor (20) or sensor cable 16T108 (J14 to level sensor (20)).
Check sensor cable J14 to level sensor (20).
Enable Diagnostic screen on ADM then check sensor readings on the Diagnostic screen. Sensor readings should be about 4.3V if melter is completely empty (melter passage holes are visible). The normal oper­ating range is 3.8 to 4.3V. If the sensor is reading more than 4.2V the system should be requesting additional material.
Restart system. If the error persists after attempting another refill and unit is needed immediately for production, place system into the man­ual refill mode. See Manual Refill on page 30.
Some adhesives are very dusty due to the anti-blocking agents used or because the adhesive manufactur­ing process has cre­ated small adhesive
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.
shavings. Feed inlet cap filter may have become clogged.
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 dis­pense mate­rial.
Cycle Switch Error
System is not up to temperature.
Incorrect temperature set points entered into ADM.
Air motor is not receiv­ing compressed air or air pressure too low.
Feed pump not feed­ing adhesive.
Timing control for appli­cators not working.
Cycle switch or cycle switch wiring failure.
Loose or missing fas­tener (26).
Verify that the system is active.
Verify the temperature settings are correct.
Verify that the pump air pressure is set above 20 psi. Check the Pump Air Solenoid Operation, page 54.
Repair or replace air control assembly as necessary.
Repair or replace pump assembly as necessary.
InvisiPac system does not control the timing of the applicators. This is a separate control that needs to be adjusted. Consult control manufac­turer or qualified electrician.
Check the wiring between the air motor cycle switch and J16. Repair/replace as required.
Ensure fastener (26) is tight. See InvisiPac Systems section begin­ning on page 83 for part identification.
333347F 47
Page 48
Troubleshooting
Problem Cause Solution
USB Log Full The InvisiPac system
will display this notifica­tion when the USB data logs reach 90% full.
The InvisiPac system is dis­playing pump runaway or pump diving.
This error generally occurs when the pump cavitates due to improper material load­ing.
To prevent data loss, download system data. See Appendix B - USB Downloading, Uploading on page 120.
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 tempera­ture in small increments over the current set point.
3. If the pump continues to runaway or dive continue increasing tem­perature in small increments. Do not exceed maximum temperature for the material being dispensed.
NOTE: If air has become trapped in the pump, it can be purged by fol­lowing the Pressure Relief Procedure, page 33.
NOTE: Some materials are more difficult to melt than others and it may be impossible to process them at the published melt rate. The InvisiPac system was tested to achieve continuous published melt rates when dispensing standard EVA packaging grade adhesives in pellet form with an InvisiPac system temperature of 350°F and hose and applica­tor temperatures of 350°F.
Level sensor blocked, reading level incorrect.
The system is not sup­plying enough air to the ultrasonic sensor ven­turi.
Clean feed cap by fill sensor, make sure there are no adhesive pellets blocking the sensor hole.
Ensure supplied Air Filter Kit 24R707 is installed on system air inlet.
Perform a reverse pressure flush of the sensor venture orifice:
1. Disconnect incoming air from InvisiPac system air inlet (108).
2. Disconnect air tube poush-connect union (91) from ultrasonic sen­sor air tube (35).
3. Plumb 80-100 psi (550-690 kPa, 5.5-6.9 bar) to outlet end o air tube union (91).
4. Ensure air is flowing out of the InvisiPac system air inlet (108).
5. Reconnect ultrasonic sensor air tube (35) to air tube union (91).
48 333347F
Page 49
Problem Cause Solution
Unable to achieve pub­lished melt rate at the desired adhesive tem­perature.
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 tem­perature 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.
Troubleshooting
ADM not dis­playing when system turned on
Main breaker tripping
Main power circuit
Turn main circuit breaker on or plug in power cord. breaker off or power cord unplugged.
Cable on ADM
Reconnect ADM cable. unplugged.
Connector on AWB
ADM cable should be plugged into J9 of the AWB board. board not plugged in.
Bad 24VDC power sup­ply.
Check output on power supply should measure 24VDC, if no voltage
reading replace power supply.
ADM defective. Replace ADM.
Wrong setting in ADM breaker setup.
Internal short to ground in system.
Too small of a circuit
Wrong breaker setting on ADM in the breaker setting in the setup
screen.
Unplug or disconnect power and measure between each leg of the
power to ground. There should be an open resistance reading.
Consult qualified electrician for proper size circuit breaker. breaker in main power panel.
333347F 49
Page 50
Troubleshooting
Problem Cause Solution
Slow start-up time or system takes longer than 10 min­utes to startup
No adhesive or little adhesive being dis­pensed
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-
Measure and check heater rods in melter or applicator. See applicator man­ual. See Check Heater Rod Resistance, page 54.
fold.
Heated hose defective. Measure heater wires in hose, pins C and D. See repair section for
each hose resistance.
Insufficient power sup­plied to system. Depend­ing on hose and applicator combinations, along with minimal sup­ply power, startup time will vary.
Incorrect RTD setting in system.
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.
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.
System indi­cates no errors and correct temperature however appli­cator is over the tempera­ture setpoint
Incorrect RTD setting in system.
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.
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.
50 333347F
Page 51
Problem Cause Solution
Troubleshooting
No adhesive or incorrect amount of adhesive out­put when all dispense mod­ules are trig­gered
No adhesive or incorrect amount of adhesive out of one/some of the dispense modules when triggered
Plugged applicator manifold filter.
Replace applicator manifold filter. Graco applicator manifold filter in bottom of manifold or inline filter on other applicators.
Clogged hose. Flush or replace hose.
Defective solenoid valve.
No signal from control to solenoid.
Solenoid mufflers
Check that correct voltage is input into solenoid valve. If voltage is cor­rect, replace solenoid.
If no voltage is present at solenoid, check control cable and pattern controller. Replace component.
Replace solenoid mufflers.
plugged.
No air to air solenoid. Re-establish air supply to solenoid.
Plugged system outlet
Replace Outlet Filter. See page 37.
filter.
If multiple applicators are triggered simulta-
Stagger applicator opening to reduce the maximum required flow rate
to below maximum pump rate. neously, maximum pump rate may be exceeded.
Plugged tip on dis-
Replace tip on dispense module. pense module.
Defective dispense
Replace dispense module. module in closed/par­tial open position.
Plugged applicator manifold filter (single
Replace applicator manifold filter. Graco applicator manifold filter in
bottom of manifold or inline filter on other manifolds. dispense module appli­cator).
Clogged hose Flush or replace hose.
Defective solenoid valve
No signal from control to solenoid
Plugged solenoid muf-
Check that correct voltage is input into solenoid valve. If voltage is cor-
rect, replace solenoid.
If no voltage is present at solenoid, check control cable and pattern
controller. Replace component.
Replace solenoid mufflers. flers
No air to solenoid Re-establish air supply to solenoid.
Plugged system outlet
Replace Outlet Filter. See page 37. filter.
If multiple applicators are triggered simulta-
Stagger applicator opening to reduce the maximum required flow rate
to below maximum pump rate. neously, maximum pump rate may be exceeded.
333347F 51
Page 52
Troubleshooting
Problem Cause Solution
Adhesive flow­ing out of one/some applicators when not trig­gered
Applicator will not heat.
Adhesive leak­ing from mani­fold or dispense module.
Failed valve in the open position.
Adhesive pressure too high.
Heat rod failure in appli­cator manifold.
Loose cable connection at system or manifold.
RTD failure. Check resistance on the RTD, if out of normal range replace RTD.
Incorrect RTD setting in the ADM setup.
Thermal cutoff is tripped. Measure resistance of the thermal cutoff at room temperature. If open,
Dispense module is loose on the manifold.
Dispense module o-ring failed.
Failed dispense module, adhesive leaking out middle of dispense mod­ule.
Replace dispense module.
Reduce air pressure to air motor.
Check resistance on heater rods. Repair applicator manifold if heater rods measure open.
Check cable connections on both ends of the hose.
Set correct RTD value in the ADM setup screen. Consult manufacturer for cor­rect RTD value.
replace.
Tighten screws on loose dispense module.
Replace o-rings on the back of the leaking dispense module.
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.
Air motor will not function.
System not turning on.
Cable to over-tempera­ture switch off or broken.
Over-temperature switch tripped.
No air being supplied to air motor.
Air solenoid not enabling the air motor.
Air present at air motor but it will not work.
No power to unit. Check main power breaker is turned on.
Check connection of cable to over-temperature switch both to main board and to switch. If connection good, look for break in wire.
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.
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.
Check solenoid voltage, if 24VDC present at air solenoid replace air solenoid.
Replace air motor.
Check that power plug is connected.
52 333347F
Page 53
Problem Cause Solution
Troubleshooting
Static shock when touching shaker or adhesive bin.
Adhesive not dispensing at the correct time.
Pump and vac­uum feed sys­tem cycle on and off before temperature setpoint is achieved.
Ground wire not in place on shaker assembly. Some adhe­sives, flow rates, and ambient conditions can cause excessive static buildup on the shaker tube.
Dispense modules opening at the wrong time.
Solenoid connector is installed into the light tower plug on the MZLP daughter board
Attach a ground wire from the shaft of the shaker unit to a true earth
ground. Order shaker grounding kit 24R708.
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.
Move solenoid connector from J12 (light tower) to J13 (solenoid
valves) on the daughter board on the MZLP.
333347F 53
Page 54
Troubleshooting
Flush Pressure Relief Valve
Perform this procedure when directed in the Trouble­shooting table.
1. With the system active at the required adhesive temperature, set the air motor air pressure to 20 psi (140 kPa, 1.4 bar).
2. Remove the air line (36) from the pressure relief valve.
Check the Pump Air Solenoid Operation
Perform this procedure when directed in the Trouble­shooting table.
NOTE: System must be up to operating temperature for pump solenoid to trigger on.
1. If the heating system and pump is disabled,
press to enable the heaters and pump.
2. Wait for system to reach the temperature setpoints.
3. Set pump air pressure to 20 psi (140 kPa, 1.4 bar).
4. Remove the 3/8 in. OD air line from the air motor.
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.
36
WLD
FIG. 28
3. Plug air line and allow the air motor to cycle.
4. Re-connect air line to relief valve and check whether the system will stall.
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 Heater Rod Resistance
Use the table to determine if heater elements need to be replaced.
HM25 HM50
Ref. Element
208
Band
Heater
209
Melter
Wattage Ohms Wattage Ohms
1250 43.5-48.5 2000 27-31
500 109-121 1500 36.5-40.5
Rod
Base Rod 1500 36.5-40.5 1000 54-61
210
Pump Rod 1500 36.5-40.5 1000 54-61
210
54 333347F
Page 55
MZLP Troubleshooting
Troubleshooting
MZLP
WLD
FIG. 29: MZLP LED Signals
NOTE: The MZLP LED is located on the inside of the
electrical enclosure. To view, remove the electrical enclosure front access door.
Yellow
1
0
9
8
7
6
5
Red
2
3
4
Green
J3
FIG. 30: MZLP Diagnostic LED Location
ti20348a
Signal Description
Green On MZLP is powered up and input
voltage is within operating con­ditions.
Yellow On Internal communication in pro-
cess
Red Solid MZLP failure. See troubleshoot-
ing table.
Red Flashing Software update in process or
missing software.
333347F 55
Page 56

Repair

Repair
NOTE: Some procedures require special tools. Read
through each procedure prior to beginning it to ensure you have the required tools to complete the entire pro­cedure. Order any required tools and have them on hand prior to beginning the procedure.
NOTICE
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.
Pump
Replace Throat Seal, Throat Bearing, Piston Rod, Piston Seal, and Piston Bearing
218
239 235
233
234
238
224
225
27
240
223
226
222
Disassembly (see F
1. Flush the system. See page 34.
2. Close the bleed-type ball valve installed at the sys­tem air inlet to relieve all air pressure in the system.
3. Turn main power switch OFF.
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).
IG
. 31):
13. Remove and discard piston u-cup (225) and
245
3
WLD
FIG. 31
56 333347F
bearing (226).
Reassembly (see F
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 pis­ton rod.
IG
. 31):
Page 57
Repair
c. Install piston valve (222) onto piston rod (223).
Torque to 24-30 ft-lb (33-41 N•m).
2. To protect the seals from the sharp threads, place seal installation tool 15B661 into the throat bore. See F
IG
. 32.
15B661
203
ti20877a
FIG. 32
3. Push the piston rod assembly (223) into the melter outlet manifold (203).
4. Grease the throat u-cup (234) and slide the u-cup over the piston rod (223) with the lips facing down.
6. Slide throat bearing (233) over the piston rod (223). Use socket and tap with a rubber mallet to press throat bearing (233) into place and seat the throat u-cup.
235
233
ti21144a
FIG. 34
7. Remove seal installation tool.
IG
8. Install retaining nut (235). See F
. 32.
5. Place a 7/8 in. deep-well socket (3/8 in. drive) over the piston rod (223) then use a rubber mallet to gen­tly tap throat u-cup (234) into place. See F
IG
. 33.
234
ti21047a
FIG. 33
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).
333347F 57
Page 58
Repair
Replace Pump Inlet Housing Checks
203
246
227
228
229 231
230
WLD
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
218
235
233
234
239
233
224 226
222
FIG. 35
Disassembly (see F
IG
. 35):
1. Flush the system. See page 34.
2. Close the bleed-type ball valve installed at the sys­tem air inlet to relieve all air pressure in the system.
3. Turn main power switch OFF.
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
203
217
216
217 230
WLD
FIG. 36
IG
Disassembly (see F
. 31):
1. Flush the system. See page 34.
2. Close the bleed-type ball valve installed at the sys­tem air inlet to relieve all air pressure in the system.
3. Turn main power switch OFF.
IG
4. Remove plastic shroud (27). See F
. 31 on
page 56.
58 333347F
Page 59
Repair
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
IG
place then remove melter shield. See F
. 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).
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.
1303
217
216
217
1302
203
.
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 out­let manifold (203). Use a rubber mallet to gently remove cylinder (216).
1301
203
217
216
217
ti20880a
FIG. 37
ti21049a
FIG. 38
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.
333347F 59
Page 60
Repair
Melter
Remove Melter Assembly
FF
53
218
203
75
5
245
81
251
29
3
30
6. Remove screws (8) then remove electrical enclo­sure 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
8
sensor (20). See Replace Fill Sensor, page 69.
16. Disconnect the pump cycle sensor cable from the air motor.
10
WLD
1
3
27
36
FIG. 39
NOTE: This only needs to be done when replacing
items that require access to the bottom of the melter assembly.
1. Perform Drain the System procedure on page 34
then wait for system to cool.
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.
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.
87
88
WLD
FIG. 40
20. Remove electrical enclosure front access door (10).
60 333347F
Page 61
Repair
21. Remove all heater wires from the following termi­nals. Pull wires up through the rubber grommet on the top of the electrical enclosure (1).
Wire Marking 1Wire Marking
Item
2
Band Heater (208) J4-1 J4-2
Melter Heater Rod
J4-5 J4-6
(209)
Base Heater Rod (210) J4-7 J4-8
Pump Heater Rod (210) J4-3 J4-4
22. Remove four nuts (3) then remove melter assembly from system. Save any loose insulators for reas­sembly.
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).
5. Group the 4 sets of heater wires together and run them through the grommet on the top of the electri­cal enclosure (1). Connect wires as noted below.
Wire Marking 1Wire Marking
Item
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
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).
2. With the 10 insulators (4) in place on the melter assembly, place melter assembly on melter base (257).
NOTICE
To prevent crushing the soft insulators (4), do not overtighten the 4 bolts (259) in the following step. Torque to 5-11ft-lb (7-15 N•m).
3. Use 4 bolts (259) to secure washers (268) and melter assembly to melter base (257).
4. Use four nuts (3) to secure melter assembly to sys­tem.
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.
333347F 61
Page 62
Repair
Replace Band Heater
125
AA
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
8
F
the wires in place.
10. Continue loosing screw (AA) then slide band heater (208) up to remove.
80
Reassembly (see F
IG
. 41):
1. Install band heater (208) on the melter with the
53
opening and screw facing the front of the system in alignment with the sensor port.
208
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).
1
10
WLD
FIG. 41
IG
Disassembly (see F
. 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).
63
5. Connect wires to AWB board as marked. Wires should be marked as shown in the following table.
Item
Wire Marking 1
Wire Marking 2
Band Heater (208) J4-1 J4-2
6. Install electrical enclosure access door (10). See 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.
6. Loosen clamp (80) and then remove screws (8) and funnel assembly (F).
7. Loosen screw (AA) then remove sensor (125).
62 333347F
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Repair
Replace Band Heater Temperature Sensor
53
80
40
AA
125
10
WLD
FIG. 42
IG
Disassembly (see F
. 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.
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.
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-tempera­ture 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 dis­card sensor (125) and wires.
11. Turn main power switch ON.
12. Open system air inlet ball valve.
333347F 63
Page 64
Repair
Replace Heater Over-Temperature Switch
251
255
ti21052a
FIG. 43
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.
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
206
210
210
206
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-tem­perature switch (251).
7. Remove the screws (255) securing the over-tem­perature 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.
209
206
209
WLD
FIG. 44
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).
64 333347F
Page 65
Repair
4. If removing the pump heater rod (210):
a. Remove the air tube (36) from the relief
valve (245). Pull the air tube through the metal shroud (27).
b. Remove nuts (3) then remove shroud (27).
5. Remove electrical enclosure front access door (10).
IG
See F
. 41, page 62.
6. Disconnect heater rod wires from terminal blocks described in the following table.
Item
Wire Marking 1
Wire Marking 2
Band Heater (208) J4-1 J4-2
Melter Heater Rod
J4-5 J4-6
(209)
Base Heater Rod (210) J4-7 J4-8
Pump Heater Rod
J4-3 J4-4
(210)
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
27
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.
NOTICE
To prevent damaging the heater rod, do not use thermal grease in the following step.
2. Install heater rod then install heater rod retaining ring (206). See F
IG
. 44.
3. Install electrical enclosure access door (10). See
IG
. 41, page 62.
F
4. If replacing the melter heater rod (209), Install Melter Assembly. See page 60.
3
36
244
245
ti20757a
FIG. 45
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).
333347F 65
Page 66
Repair
6. Use crescent wrench to remove melter fluid pres­sure 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.
NOTICE
To prevent damage to o-ring, ensure o-ring is seated properly prior to moving to next step.
9. Thread new fluid pressure relief valve (245) into manifold. See 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.
66 333347F
Page 67
Multi-Zone Low Power Temperature Control Module (MZLP)
Repair
Replace MZLP Fuse
MZLP Identification
24V510
Key
A F1 and F2 fuses are physically larger than F3-F10
B Blue sticker on relay
C Marked 24V133
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
Fuse Kits
Kit MZLP Description
24V289 24V510 Includes standard clear fuses.
24X480 Includes ceramic fuses used for
food industries.
1. Turn main power switch OFF.
2. Remove electrical enclosure front access door (10).
3. Use a proper non-conductive fuse puller tool to remove the blown fuse.
NOTICE
Using an improper tool, such as screw drivers or pliers may break glass on fuse.
C
J7
J6
F10
J5
F9
F8
F7
F6
F5
J2
F4
F3
F2
J1
F1
J3
WLD
FIG. 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.
A
B
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.
NOTICE
Using an improper tool, such as screw drivers or pliers may break glass on fuse.
5. Install electrical enclosure front access door (10).
333347F 67
Page 68
Repair
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.
2. Apply channel label stickers to new MZLP. See F
47.
3. Use four screws (114) to install MZLP (112) to elec­trical enclosure (1).
4. Reconnect cables to MZLP (112).
NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation.
NOTE: If unable to determine connector location, see Electrical Schematics on page 78.
.
5. Install electrical enclosure front access door (10).
6. Connect heated hose electrical connectors to new MZLP.
NOTE: MZLP may need updated software. See Soft­ware Update Procedure on page 77.
IG
.
MZLP
#1
MZLP
112
#2
114
FIG. 47
IG
6. Replace MZLP. See F
. 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.
MZLP
#3
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 daugh­ter card (112a) and set aside.
112b
112a
ti20342a
112
Rotary Switch
FIG. 48
5. Unplug daughter card (112a) from the MZLP #1 (112).
68 333347F
Page 69
Repair
Reassembly:
1. Plug new daughter card (112a) into the MZLP (112).
2. Use screws (112b) to secure daughter card to MZLP (112).
3. Connect cables to new daughter card (112a).
NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation.
NOTE: If unable to determine connector location, see Electrical Schematics on page 78.
4. Install electrical enclosure front access door (10).
System
Replace Fill Sensor
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
58
68
20
73
FIG. 49
Disassembly (see F
IG
. 49):
1. Turn main power switch OFF.
WLD
30
CC
ti20763a
FIG. 50
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 Soft­ware Update Procedure on page 77.
2. Remove filter cover (68) and filter element.
333347F 69
Page 70
Repair
Replace AWB
131
144
145
146
145
FIG. 51: AWB and Power Supply
Disassembly:
131
Reassembly:
1. Use two screws (144) to secure power supply
IG
bracket (145) to new AWB (143). See F
. 51.
2. Mount power supply (146) to power supply bracket
IG
(145). See F
. 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 electri­cal 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).
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 sup­ply bracket. See F
IG
. 51.
70 333347F
Page 71
Repair
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.
Power Supply
Connection
Harness Label
V+ V+
V- V-
GND GND
LL
NN
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.
Power Supply
Connection
Harness Label
V+ V+
V- V-
GND GND
LL NN
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 sup­ply harness (147) to J1 on AWB (143). See Electri- cal Schematics, page 78.
3. Install electrical enclosure front access door (10).
333347F 71
Page 72
Repair
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 sys­tem 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 sys­tems only (see F
IG
. 53):
a. Disconnect transformer wires from J2 connector
on AWB board and the main power switch.
FIG. 52
142
140
FF
402
405
8
9
1
WLD
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.
WLD
FIG. 53
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.
.
72 333347F
Page 73
Repair
6. Install electrical enclosure front access door.
Replace Air Control Gauge
8
403
403a
403c
403b
WLD
FIG. 54
Disassembly (see F
IG
. 54):
1. Turn main power switch OFF.
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).
NOTICE
In the following step, do not overtighten the two nuts (403a). Overtightening may cause the gauge to break.
9
4. Orient gauge as desired then tighten two nuts (403a) to secure gauge (403) in place.
5. Slide air control assembly (9) into place then use two screws (8) secure to electrical enclosure.
Air Motor
Replace Pilot Valve
C
511
218
2. Close the bleed-type ball valve installed at the sys­tem air inlet to relieve all air pressure in the system.
3. Remove two screws (8) then slide air control assembly (9) out from electrical enclosure (1) so the back of the gauges are exposed.
4. Remove two nuts (403a) securing gauge (403) in place then remove bracket (403c).
5. Place one small crescent wrench on the brass part of the gauge then use a second small crescent wrench to remove the air fitting (403b).
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.
WLD
FIG. 55: Top Pilot Valve
1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
2. Turn main power switch OFF.
3. Replace top pilot valve (511):
a. Use crescent wrench to remove the rod cover
(C).
b. Use 10 mm socket to remove air motor pilot
valve (511) from air motor (218).
c. Lubricate with grease and install new air motor
pilot valve (511).
333347F 73
Page 74
Repair
d. Torque pilot valve to 95-105 in-lb (10.7-11.9
N•m).
4. Replace bottom pilot valve (511):
29
218
6
FIG. 56: Bottom Pilot Valve
WLD
511
Replace Air Valve
218
507
FIG. 57
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).
512
509
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).
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.
74 333347F
Page 75
Repair
3. Use 10 mm socket to torque screws (509) to 95-105 in-lb (10.7-11.9 N•m).
4. Install fill cap then tighten upper hose clamp on rub­ber housing.
5. Connect air hose and cable to the air motor.
Remove Air Motor
8
74
218
82
239
27
220
238
240
219
211
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).
3
FIG. 58
WLD
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).
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.
6. Remove air motor assembly:
a. Slide retaining ring (239) down.
333347F 75
Page 76
Repair
Transformer Fan
Replace Fan
1
158
154
157
167
161(x3)
151
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).
black (-)
red (+)
161
WLE
FIG. 59
1. Turn main power switch OFF.
2. Disconnect plug from power outlet or turn off circuit breaker for incoming power.
3. Remove front access panel (10) from electrical enclosure (1).
4. Remove connector from J7 connector on AWB board. Remove red (+) and black (-) wires from con­nector.
J7
1
(+)
red
(-)
black
WLE
FIG. 61
3. Route fan wires with transformer wires into the elec­trical enclosure (1). Connect red and black fan wires to J7 connector. Reconnect J7 connector to AWB board. See F
IG
. 60.
4. Reinstall corrugated tube (167) on fan and trans-
IG
former wires. See F
. 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).
WLD
Front access panel (10) not shown.
FIG. 60
76 333347F
Page 77
Repair
Software Update Procedure
When software is updated on the ADM the software is then automatically updated on all connected GCA com­ponents. A status screen is shown while software is updating to indicate progress.
1. Turn system main power switch OFF.
2. Remove ADM from bracket.
3. Remove token access panel.
r_24P860_3B9900_3a
F
IG
. 62: Remove Access Panel
NOTE: When the screen turns on, you will see the fol-
lowing screens:
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.
4. Insert and press InvisiPac software upgrade token (T, part no. 24R324) firmly into slot.
NOTE: There is no preferred orientation of token.
T
r_24P860_3B9900_4a
IG
. 63: Insert Token
F
5. Install ADM into bracket.
6. Turn system main power switch ON.
NOTICE
A status is shown while software is updating to indicate progress. To prevent corrupting the software load, do not remove token until the status screen disappears.
Icon Description
Update successful.
Update unsuccessful.
Update complete, no changes necessary.
Update was successful/com­plete but one or more GCA modules did not have a CAN boot-loader so software was not updated on that module.
7. Remove token (T).
8. Replace token access panel.
9. Press to continue to the InvisiPac operation
screens.
333347F 77
Page 78

Electrical Schematics

Electrical Schematics
To prevent electric shock and system damage, all electrical work must be performed by a qualified elec­trician.
Incoming Power
NOTICE
To prevent severe system damage, ensure main power leads are installed correctly. See Connect Electrical
Cord on page 23.
Cable Identification
Use the table to identify cables and other system com­ponents in the electrical schematics.
Ref Part Description
9 --- Manifold, air assembly
20 24R041 Sensor, ultrasonic
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
78 333347F
Page 79
System
L1
L2
L3
GND
208 210 209 210
Band Pump Melter Base
87
Ground
Stud
Optional Light Tower
Air Solenoid
Fill Sensor
Motor Cycle Switch
Melter OT Switch and Melter RTD
5L3
3L2
1L1
6T3
4T2
2T1
NN
GB1
DC OK DC OK
-V
-V +V +V
20 86 126
251
To MZLP #2 4 and 6 Channel Option, see page 108 and 110.
140
Transformer
Option
GND
1201
9
12425
125
Electrical Schematics
30
ADM
1
1
2
2
3
3
4
4
5
5
138
TEMP
TEMP FAN -
FAN +
143
AWB
J2 J9
W1
W2
W3
W4
GND
J7
TEMP
TEMP FAN -
FAN +
GND
1
1
2
2 3 4 5
J5
L1 L2 L3
GND
123
3 4 5
L1
129
L2 L3
To MZLP #2 4 and 6 Channel Option, see page 108 and 110.
90
J4
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
147
N
J1
-
-
N
N
L
L
+
+
J8
1 2 3 4 5
J6
L1 L2 L3
GND
J3
121
GND
1
148
2 3 4 5
L1
136
L2 L3
103
2
L
146
112
121
112A
1 2 3 4
MZLP 1
1
1
J12
2
2
3
3 4
4
1
1
J13
2
2 3
3 4
4
1
J14
2 3 4
1
J15
2 3 4
1
1
J16
2
2
3
3
4
4
5
5
J5
1
1
2
2
3
3
4
4
5
5
6
6
J3
1
1
2
2
3
3
4
4
5
5
J1
121
J2
L1 L2 L3
GND
J6
1 2 3 4 5
J8
A
B C D
E
F G H
J
K
L
J9
A
B C D
E
F G H
J
K
L
GND
2
L1 L2 L3
1 2 3 4 5
Hose / Applicator Wiring
333347F 79
Page 80
Electrical Schematics
480VAC Transformer Option
N
L1
L2
L3
5L3 3L2
1L1
N
6T3
4T2
2T1
P3
P2
P1
J2
W1
W2
W3
W4
GND
143
AWB
PTC
GND
GB1
Typical Hose / Applicator Wiring
GUN
HEATER
GUN
RTD
OVER TEMP
GND
HOSE
HEATER
HOSE
RTD
J7
TEMP
TEMP
TEMP
TEMP
FAN -
FAN -
FAN +
FAN +
GB
112
MZLP1
J8
A
A
B
B
C
C
D
D
E
E
F
F
G
G
H
H
J
J
K
K
L
L
80 333347F
Page 81
2nd and 3rd MZLP Options
118 118 112
MZLP3 MZLP 2 MZLP 1
Electrical Schematics
135
J5
1
1
2
2
3
3
4
4
5
5
6
6
J3
1
1
2
2
3
3
4
4
5
5
J3
1
1
2
2
3
3
4
4
5
5
J6
1
1
2
2
3
3
4
4
5
5
121121
J3
1
1
2
2
3
3
4
4
5
5
333347F 81
Page 82

Air Schematic

Air Schematic
NOTE: Install an optional ramp up/down controller to
limit air to the air motor and slow down the system dis­pense rate.
Valve
Pressure Relief
Controller
Optional Ramp Up/Down
Air Motor Gauge
Air Motor
Air Motor Control Solenoid
Air Control Manifold
Feed Wand
Refill Gauge
Refill Control Solenoid
Safety Pop Off Valve
Restrictor
Level Sensor
Under Control Box
Line Air Inlet
82 333347F
Level Air Sensor
Page 83

Parts

InvisiPac Systems
System Parts, Page 1 of 3
1
Apply door gaskets (11) to door (10) per layout diagram.
2
Apply pipe sealant to all non-swiveling pipe threads.
3
Bottom sensor (20) out then back off 1/2 turn.
4
Lubricate all seals and o-rings with water resistant grease.
5
Torque to 5-11 ft-lb (7-15 N•m).
6
Torque to 8-10 in-lb (0.9-1.1 N•m).
53
75
22
Parts
83
24
25126
6
23
64
8
39
27
3
8
28
23
19
6
38 31
38
18
43
58
13
30
8
44
64
29
WLE
11
43
43
10
8, 14
333347F 83
Page 84
Parts
System Parts, Page 2 of 3
68
8
67
69
49
41
40
54
85
74
66
82
5
8
7
86
20
72
3
73
42
88
5
3
63
87
1
89
74
69
62
69
61
4
81
8
79
63
80
WLD
9
43
8
84 333347F
Page 85
System Parts, Page 3 of 3
35
48 in.
(1219 mm)
57
Parts
34 48 in. (1219 mm)
34 16 in. (406.4 mm)
86
91
(203 mm)
(1219 mm)
34
8 in.
32
2 in.
(50.8 mm)
78
77
76
34
24
34
48 in.
49
35
48 in.
(1219 mm)
39
WLD
36 13 in.
55
333347F 85
330.2 mm)
Page 86
Parts
System Parts
Quantities
HM50 HM25
2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel
Ref Part Description
1 --- ENCLOSURE, electrical
3 115942 NUT, hex, flange head
4 167002 INSULATOR, heat
5 24V169 SYSTEM, melter, HM25
24V542 SYSTEM, melter/pump,
HM50
6 16V540 GUARD, insulated
--- INSULATOR, wrap
7 --- TRAY, drip
8† 113161 SCREW, flange, hex hd
9 --- MANIFOLD, air, assembly
10 --- DOOR, front
11 --- FOAM, border, door
13
---
14 16V153 WASHER, retaining
15 114271 STRAP, retaining
18126961 FITTING, 45 elbow, hydraulic
19116793 FITTING
20 24R041 SENSOR, ultrasonic
21 101976 TOOL, allen, wrench
22 24N957 SHAKER, feed system
23 114606 PLUG, hole
24 120753 FITTING, push to connect
25 24A032 SWITCH, reed assy
26 --- SCREW, pan head, #8-32 x
27 --- BRACKET, back HM50
--- BRACKET, back
28 --- COVER, filter
29 --- COVER, melter HM50
--- COVER, system, HM25
30 24P860 MODULE, ADM
31 117017 WASHER
32 --- FITTING, tee, reducer
34
--- HOSE, nylon, wpr 250 psi
35 598095 TUBE, 5/32 OD, nylon
36
--- TUBE, ptfe, 1/4 in. OD
38 117126 SCREW, shcs; m5x16
FITTING, straight, hydraulic
elbow
1.5"
24T918
24V201
111111111111111111
888888888888888888
444444444444444444
111111111
111111111
111111111111111111
17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17
111111111111111111
111111111111111111
111111111111111111
222444666222444666
444444444444444444
8 8 8 16 16 16 24 24 24 8 8 8 16 16 16 24 24 24
222444666222444666
222444666222444666
111111111111111111
111111111111111111
111111111111111111
222222222222222222
222222222222222222
111111111111111111
111111111111111111
111111111
111111111111111111
111111111
111111111111111111
222222222222222222
111111111111111111
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
444444444444444444
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
333333333333333333
24V198
24T919
24V202
24V199
24T920
24V203
24V200
24V423
24V429
24V426
24V424
24V430
24V427
24V425
24V431
111111111
111111111
111111111
111111111
24V428
86 333347F
Page 87
Parts
Quantities
HM50 HM25
2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel
Ref Part Description
39 --- GROMMET, 1/4 ID
40 --- BUSHING, strain relief
41 --- GROMMET, tube
42 --- GROMMET, tube
4316Y781 LABEL, safety
44 16U007 LABEL, InvisiPac, HM25
--- LABEL, InvisiPac HM50
45 --- LABEL
47 24P859 KIT, fuses, board, temp con-
trol
48 24P176 KIT, i/o connector
49 125871 TIE, cable, 7.50 in.
50 24R324 TOKEN, software
53 16W659 INSULATOR, melter
16T677 INSULATOR, melter
54 --- NUT, bushing
57 123554 COUPLER, 3/8 in. OD tubing
58 24A326 BRACKET, mounting,
assembly
61† --- FUNNEL, large mouth
62† --- BAFFLE, pellet
63 121487 GROMMET, sheet metal, 3/4
in.
64 24R707 KIT, inlet, air
66† --- FUNNEL, insert
67† 24V506 FILTER, HM50 feed
68† --- FUNNEL, filter cover
69† --- O-RING, fluoroelastomer,
160
72 110932 CONNECTOR, male
73† --- HOUSING, sensor, HM50
74† --- SCREW, #10-16, thread
forming
75 16T675 INSULATOR, melter mani-
fold
16W671 INSULATOR, melter, mani-
fold
76 --- FITTING, tee, 1/8npt x 3/8t x
3/8t
77 --- RESTRICTOR, air, 0.0225
in. orifice
78 198177 FITTING, push, straight
79 24W001 ADAPTER, HM25
24W000 ADAPTER, melter HM50
24T918
24V201
111111111111111111
222222222222222222
111111111111111111
111111111111111111
111111111111111111
111111111
111111111111111111
111111111111111111
111111111111111111
10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
111111111111111111
111111111
222222222222222222
111111111111111111
111111111111111111
111111111111111111
111111111111111111
222222222222222222
111111111111111111
111111111111111111
111111111111111111
111111111111111111
333333333333333333
111111111111111111
111111111111111111
555555555555555555
111111111
111111111111111111
111111111111111111
111111111111111111
111111111
24T919
24V198
24V202
24T920
24V199
24V203
24V200
24V423
24V429
24V426
24V424
24V430
24V427
24V425
24V431
24V428
111111111
111111111
111111111
111111111
333347F 87
Page 88
Parts
Quantities
HM50 HM25
2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel
Ref Part Description
80 --- CLAMP, hose, spacer
81 --- CLAMP, hose, spacer
82† --- BRACKET, funnel, HM25
--- BRACKET, HM50, funnel, mounting
83 123986 FITTING, elbow, 3/8 OD tube
85 --- GROMMET
86 122030 CABLE, gca, m12-5p
87 --- WIRE, ground
88 116343 SCREW, ground
89 --- WASHER, 1/4 external tooth
lock
90 --- PLUG, phoenix, 8 pos
91 --- FITTING, 5/32 in. OD tube,
push-to-con
17A345 TOOL, 5/16 nut driver
92
127735 STRAP, lifting 3 ft
93
--- 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.
24T918
24V201
111111111
111111111222222222
111111111
111111111111111111
111111111111111111
111111111111111111
111111111111111111
111111111111111111
111111111111111111
111111111111111111
111
111111111111111111
24V198
11 11 11 11 11 11
Not shown.
24T919
24V202
24T920
24V199
24V203
24V200
24V423
24V429
24V426
24V424
24V430
24V427
24V425
24V431
24V428
111111111
111
Available kits (purchase separately):
Kit Description Includes
24R885 Cycle Switch 25, 26 24R028* Inlet housing 12, 13, 62 24V544 Tubing 32, 33, 34, 35, 36, 304. See
Feed System Shaker and Tube, 24V507 on page 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
24W000Melter Adapter 79, 80, 81
88 333347F
Page 89
Electrical Enclosure
Parts
113
MZLP
114
112
112a
2
113
3
118
MZLP 2
109
114
MZLP 3
106, 107
120 110
108
WLD
118
101
4
113
114
1
Apply sealant to all non-swiveling pipe threads.
2
Set rotary switch to “1” on MZLP with daughter card.
3
Set rotary switch to “2” on MZLP 2.
4
Set rotary switch to “3” on MZLP 3.
131
132
144
145
146
104
117
111
333347F 89
143
131
WLD
105
Page 90
Parts
142
141
137
140
Electrical Enclosure Parts
Ref Part Description
101 102 103 104 105 106 107 108 109 110 111 112* 112a 113 114 116 117 118 119 120 121 123
--- CABINET, controls
122030 CABLE, gca, m12-5p
--- HARNESS, MZLP1, AWB
123970 SWITCH, disconnect, 40a
126839 CONTACT, n-pole
120858 BUSHING, strain relief, m40 thread
120859 NUT, strain relief, m40 thread
104641 FITTING, bulkhead
121141 FITTING, elbow, swivel, 3/8t 1/4mnpt
114421 BUSHING, strain relief
117666 TERMINAL, ground
--- MODULE, MZLP with daughter board
24R042 KIT, board, daughter
16T440 CAP, souriau, uts14
125856 SCREW, 8-32, serrated flange
24P175 PLATE, blank, sgl mztcm
115942 NUT, hex, flange head
24V510 MODULE, gca, MZLP
--- GASKET, foam, mztcm
--- PIN, dowel
16T087 CABLE, board, male/male, 21 in.
127768 CABLE, can, female/female 1.5 m
WLD
Quantity
1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP
No Transformer 400/480 V Transformer
1 1 1 1 1 1
1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
2 4 6 2 4 6
12 12 12 12 12 12
2 1 2 1
1 1 1 1 1 1
1 2 1 2
2 1 2 1
1 1 1 1 1 1
1 2 1 2
1 1 1 1 1 1
90 333347F
Page 91
Ref Part Description
124 125 126
129
130 131 132 135 136 137 138 140 141 142 143 144 145 146 147 148
16T103 CABLE, pump
--- SENSOR, rtd, 1m
16T108 CABLE, ultrasonic, m12-4p, 1m
--- HARNESS, MZLP 2, awb
--- HARNESS, MZLP 2/3, awb
114958 STRAP, tie
--- SCREW, flange, serrated, 10-24 x 0.5
123967 KNOB, operator disconnect
16W035 CONNECTOR, jumper
--- HARNESS, MZLP 1, awb
--- BUSHING, cable
--- HARNESS, disc, awb
24V015 TRANSFORMER, assembly, 480v/240v
--- GROMMET, air fitting
113802 SCREW, hex hd, flanged, 3/8-16 x 5/8
24V816 MODULE, awb
114331 SCREW, mach, pnh, sems; 6-32 x 3/8
--- BRACKET, power supply
126453 POWER SUPPLY, 24v
--- HARNESS, power supply, awb
--- CABLE, board, samtec
Parts
Quantity
1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP
No Transformer 400/480 V Transformer
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1
1 1
4 4 4 4 4 4
2 2 2 2 2 2
1 1 1 1 1 1
1 1
1 1 1 1 1 1
1 1 1
1 1 1 1 1 1
1 1 1
1 1 1
3 3 3
1 1 1 1 1 1
2 2 2 2 2 2
1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
* Purchase MZLP (118) and daughter board (112a) separately.
Available kits (purchase separately):
Kit Description Includes
24V528† Upgrade from 2
channel system to 4 channel sys­tem
24V529Upgrade from 4
channel system to 6 channel sys­tem
24R040RTD 125, 251, and 255. See Melter
24V289 MZLP fuses Qty 8 - 8 Amp, 250V Fuses
24P176 Customer I/O
Connectors
113, 118, 121, 129, a ground­ing wrist strap, and a software upgrade token. See 4 Channel Upgrade Kit, 24V528 on page 108.
113, 118, 121, 129,134, 135, grounding wrist strap, and a software upgrade token. See 6 Channel Upgrade Kit, 24V529 on page 110.
and Pump Assembly on page 93.
Qty 2 - 25 Amp, 250V Fuses 2 connectors for connecting to
H1 and H2 on MZLP daughter board. Use for PLC connec­tion.
333347F 91
Page 92
Parts
Transformer Assemblies
153
4
156
157
168
161
158
152
2
160
167
161
166
2
157
3
151
WLD
1
Mount fan with arrow pointing towards grill.
2
Tie down cabling from transformer and fan using cable tie onto tie down locations. Remove excess slack and ensure cabling does not contact fan blades.
168
156
Transformer Assemblies
Ref. Part Description Qty
151 --­152 --­153 ---
ENCLOSURE, base, 480v ENCLOSURE, top, 480v TRANSFORMER, 480v/240v,
6kva; 480V systems only
---
TRANSFORMER, 400v/240v, 6kva; 400V systems only
154 ---
155
---
156 115942 157 119865
GRILL, fan FAN, 24 vdc, 120m x 120m NUT, hex, flange head SCREW, mach, hex serrated, 1/4 x 3/8 in.
158 127278 160 ---
NUT, keps, hex GROMMET, air fitting
154
155
1
170
3
Use nut to lock down the ground wire from transformer.
4
Connect black fan wire labeled (-) from transformer (153) in the pin labeled (-). Connect red fan wire labeled (+) to the connector coming from transformer (153).
2 4
166
Ref. Part Description Qty
161 125871 162 172953
1
166
1
167 ---
1
17A071
TIE, cable, 7.5 in. LABEL, designation LABEL, safety, warning TUBE, corrugated, slit; 6 in. (152.4 mm)
168
1
169 170 127754
1
GRILL, fan
1
Replacement Danger and Warning labels, tags, and cards
5 6
4
are available at no cost.
Included in Fan Replacement Kit 24V911.
--- Not for sale.
1
166
5 1 1 1
92 333347F
Page 93
Melter and Pump Assembly
HM25, 24V169 HM50, 24V542
205
4
10
211
204
202
2
254
208
236
2
239
206
Parts
218
217
238
235
233
4
234
5
216
217
223
224
220
3
225
5
226
207
10
215
213
206
210
201
249
257
258
249
268 259
1
Lubricate all seals and o-rings with grease.
2
Orient melter (202) sensor hole in line with band heater (208) clamp.
3
Torque to 5-11 ft-lb (7-15 N•m).
4
Torque to 24-30 ft-lb (33-41 N•m).
5
Orient u-cups (225, 234) with springs in direction shown.
3
209
206
253
210
WLD
252
214
240
3
219
10
211
7
252
203
251
6
255
246
10
9
242
8
247
10
243
244
245
6
Assemble inserts (252) 0.01-0.05 in. (0.3-1.3 mm) below surface.
7
Assemble inserts (252) 0.01-0.05 in. (0.3-1.3 mm) below surface.
8
Torque to 27-33 in.-lb (3-3.8 N•m).
9
Apply anaerobic thread sealant on threads.
10
Torque to 12-18 ft-lb (16-24 N•m).
222
221
227 228 229
231
232
230
4
4
333347F 93
Page 94
Parts
HM25 Melter and Pump, 24V169 HM50 Melter and Pump, 24V542
Ref. Part Description Qty.
201 ---
---
202 ---
--­203• --­204 ---
--­205 ---
--­206• 111317 207 16W615
126475
208 24V522
24R039
209• 24R037
24R034
210 24R036
24R037 211 116940 213 --­214• 112855 215 216‡• --­217†‡• 108526 218 24V558
219 --­220 --­221• 192624 222†• 239932 223 --­224†• 105444 225†• --­226†• --­227†• 105445 228†• 192642 229†• 107079 230• --­231†• 105802 232†• 113944 233†• --­234†‡• --­235• 193046
236• 238 196762 239 196750 240 101864 242 117059
---
24P855
BASE, melter, HM50 BASE, melter, HM50 TANK, melter, HM50 TANK, melter, HM25 MANIFOLD, outlet PLATE, mounting; HM50 PLATE, mounting; HM25 HOUSING, fire rod; HM50 HOUSING, fire rod; HM25 RING, retaining, int. O-RING, fluoroelastomer; (HM50 only) O-RING, fluoroelastomer;
(HM25 only) BAND, heater; HM50 only BAND, heater; HM25 only HEATER, rod,1500 watts; HM50 HEATER, rod, 500 watts; HM25 HEATER, rod,1000 watts; HM50 HEATER, rod,1500 watts; HM25 SCREW, cap,sh,5/16-18 SCREEN, wire PACKING, o-ring PLUG, o-ring boss SLEEVE, cylinder PACKING, o-ring, ptfe MOTOR, double ended, air; see page 95 PLATE, pump adapter ROD, tie, 1.5 in. stroke GUIDE, ball VALVE, piston ROD, piston BALL, (.31250) SEAL, u-cup, piston BEARING, piston BALL, (.5000) SEAT, carbide PACKING, o-ring HOUSING, foot valve O-RING PACKING, o-ring BEARING, throat SEAL, u-cup, throat NUT, packing FILTER, assy, 100 mesh, welded
PIN, straight SPRING, retaining SCREW, cap, sch; 5/16 x 1 in. O-RING, fluoroelastomer
Ref. Part Description Qty.
243 --­244 15Y627 245 ---
1
246• 121295
1 1
247• 15H304
1
249 167002
1
251
1
252• ---
1
253 ---
1 1
254 ---
3
255
1
257 ---
1
258 --­259 110298
1 1 1 1
268 115814
2 2
--- Not for sale.
7
Available kits (purchase separately):
1 1
Kit Description Includes
1
24P852† Pump repair 217, 222, 224, 225, 226, 227,
1 2 1
24P853‡ Cylinder 216, 217, 234, and seal instal-
1 3
24P854 Pump rod 222, 223, 224, 225, 226
1
24P856 Pressure relief
1 1
24V508 Melter 202, 204, 207, 211, 253, and
1 1 1 1
24R040
1 1
24R709 • Assembled pump
1 1 1 1 1 1
--- Special tools See Special Tools on page
1
1 1 3 1
24R040
---
107388
---
115506
valve
RTD 125, 251, and 255. See Elec-
manifold
RETAINER, seat, dump valve PACKING, o-ring #2-116, ptfe VALVE, relief SCREW, cap, socket head; 5/16 x
2.5 in. FITTING, plug 9/16 sae INSULATOR, heat SWITCH, overtemperature INSERT, helical PLATE, melter; HM25 only PLATE, melter; HM25 only O-RING, -910 SCREW, mach, pnh; BRACKET, shelf; HM50 only BRACKET, shelf; HM25 only GROMMET, 1/4 ID SCREW, cap, sch, HM50 only SCREW, mach, hex wash hd, 1/4 x 3 in.; HM25 only WASHER, flat, sst; HM50 only
228, 229, 231, 232, 233, 234, and seal installation tool 15B661.
lation tool 15B661.
242, 243, 244, 245
insulator (53). See InvisiPac Systems parts starting on page 83 for insulator (53) identification.
trical Enclosure on page 89. 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
100.
#4 x 3/8 in.
1/4 x 7/8 in.
1 1 1 4
9
10
1 7 1 1 1 2
1 1 1 4
;
4
4
94 333347F
Page 95
Air Motor, 24V558
2
4
505
Parts
509
512
507
509
522
513
506
511
1
Apply water-resistant grease.
2
Torque to 95-105 in-lb (10.7-11.9 N•m).
Ref. Part Description Qty
505 24A579 506 --­507† --­509† --­511 --­512† --­513 15M213
MANIFOLD, medium, short GASKET, cover, small SEAL, air valve, manifold SCREW, m6 x 25, thread forming VALVE, pilot VALVE, air, small MUFFLER, 3/8
511
1212
WLD
1 2 1 8 2 1 1
-
-- Not for sale.
Included in Air Motor Valve Kit 24R026.
333347F 95
Page 96
Parts
Feed System Shaker and Tube, 24V507
301
1
306
302
1
Apply pipe sealant to threads.
Parts
Ref Part Description Qty
301 24P861 SHAKER 1 302 24N954 TUBE, steel 1 303†--- TUBE, clear PVC, 1.3 in.
(33 mm) OD
304 --- HOSE, nylon, 3/8 in. OD,
15.5
250 psi (1.7 MPa, 17 bar)
305 125370 CLAMP, hose, dia. 11/16 to
1-1/2 in.
306 125871 TIE, cable, 7.50 in. (190 mm) 4
304
ti20738a
10
3
--- Not for sale.
† 30 ft (9.1 m) Feed Hose Kit 24R043 also available
(purchase separately). Kit also includes 2 hose clamps.
Included in Tubing Kit 24V544. See System Parts
on page 86 for other kit contents.
Not shown.
NOTE: Shaker Grounding Kit 24R708 (purchase sepa­rately) also available. Kit includes a grounding wire assembly, and a screw and washer for installing on the shaker tube (301).
96 333347F
Page 97
Air Controls Assembly
405
401
402
1
Parts
406
404
403
1
Apply sealant to all non-swiveling pipe threads.
Air Controls Assembly Parts
Ref Part Description Qty
401 --- PANEL, air, controls 1 402 24V520 CONTROL, air, vacuum trans-
fer and pump
403 15T500 GAUGE, pressure, air, panel
mount, 1/8 in. npt
404 15T498 FITTING, 90 degree, swivel,
5/32 in. tube x
1/8 in. female npt 405 100058 SCREW, cap, hex head 2 406 054753 TUBE, nylon, round, black 2 407 C38321 TIE, cable, 3.62 in. 1
--- Not for sale.
404
1
WLD
1
2
2
333347F 97
Page 98
Parts
Pressure Relief Valve, 24P856
607
3
1
606
614
1
601
2
605
611
608
1
602
609
2
603
612
2
3
610
610
604
1
Apply sealant to all non-swiveling pipe threads.
2
Apply grease.
3
Torque to 4-6 in-lb (0.5-0.7 N•m).
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
613
--- Not for sale.
† Parts included in Relief Valve Repair Kit 24P857
(purchase separately).
98 333347F
Page 99
Feed Inlet Funnel, 24V505
706
705
703
704
707
Parts
708
709
Ref. Part Description Qty
701 --­702 --­703 --­704 --­705 24V506 706 --­707 113161 708 --­709 --­710 ---
FUNNEL, large mouth BAFFLE, pellet O-RING, fluoroelastomer, 160 FUNNEL, insert FILTER, feed FUNNEL, filter cover SCREW, flange, hex hd SCREW, #10-16, thread forming BRACKET, funnel, mounting HOUSING, sensor
710
708
703
702
703
701
WLD
1 1 3 1 1 1 2 5 1 1
--- Not for sale.
333347F 99
Page 100

Accessories

Accessories
Special Tools
These special tools are designed to make system repairs as easy as possible while ensuring that parts do not get damaged.
Part Purpose
1301* Remove Cylinder
1302* Install Cylinder - Female
1303* Install Cylinder - Male
* Parts included in Cylinder Tools Kit 24R227 (pur-
chase separately).
Part Purpose
1304** Install Rod - Female
1305** Install Rod - Male
1306** Install Rod - Bullet
** Parts included in Rod Tools Kit 24R228 (purchase
separately).
    
ti20983a
100 333347F
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