Graco 333347F User Manual

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Page 1

Instructions - Parts

™

InvisiPac

™

HM25 and HM50 Tank-Free

333347F

Hot Melt Delivery System

For delivering and dispensing hot melt adhesive pellets. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

1200 psi (8.3 MPa, 83 bar) Maximum Working Pressure 400°F (204°C) Maximum Fluid Operating Temperature 100 psi (0.7 MPa,7 bar) Maximum Air Inlet Pressure

Important Safety Instructions

Read all warnings and instructions in this manual and in the applicator and hose 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

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)

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

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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

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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

350-415 VAC Y

200-240 VAC

350-415 VAC Y

Type Description Frequency

/ PE

3Φ / PE

/ Neutral / PE

/ PE

3Φ / PE

3Φ / Neutral / PE

/ PE

3Φ / PE

/ 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 30A

4 333347F

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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

350-415 VAC Y

200-240 VAC

350-415 VAC Y

Type Description Frequency

/ PE

3Φ / PE

/ Neutral / PE

/ PE

3Φ / PE

/ Neutral / PE

/ PE

3Φ / PE

/ 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

•

200-240VAC

•

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 30A

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Models

400 VAC Transformer HM25 Models

Model Channels Voltage

24V426 2 335-400 VAC

24V427 4 335-400 VAC

24V428 6 335-400 VAC

Type Description Frequency

/ PE

400 VAC Transformer HM50 Models

Model Channels Voltage

24V198 2 335-400 VAC

24V199 4 335-400 VAC

24V200 6 335-400 VAC

Type Description Frequency

/ 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

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

Max

Amps

50/60 Hz 17A

Max

Amps

50/60 Hz 17A

6 333347F

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480 VAC Transformer HM25 Models

Model Channels Voltage

24V429 2

24V430 4

24V431 6

400-480 VAC

Type Description Frequency

/ PE

3Φ / PE

480 VAC Transformer HM50 Models

Model Channels Voltage

24V201 2 400-480 VAC

24V202 4 400-480 VAC

24V203 6 400-480 VAC

Type Description Frequency

/ 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

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

Models

Max

Amps

50/60 Hz 14A

Max

Amps

50/60 Hz 14A

333347F 7

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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.

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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.

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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.

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Component Identification

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

WLD

WLD

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Component Identification

Heated Fluid Manifold

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

WLD

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Electrical Enclosure

Component Identification

FIG. 3

Key:

P Multi-Zone Low Power Temperature Control Module

(MZLP) AC Incoming Power Connection AF Chassis Ground AG Automatic Wiring Board (AWB)

WLD

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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.

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

TI12362a1

FIG. 4

Key Function

BA Heating system and pump enable/disable

BB System status indicator (LED)

BC Stop all system processes

BD Defined by icon next to softkey

BE Abort current operation

BF Accept change, acknowledge error, select item,

toggle selected item

BG Toggle between Operation and Setup screens

BH Navigate within a screen or to a new screen

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

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

. 8, page 18.

333347F 17

Page 18

Setup

3. Adjust the funnel inlet:

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.

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).

• 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

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

. 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

. 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

. 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

. 7.

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

. 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.

Applicator

247

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

. 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

. 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

. 11:

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

port plug (W1). See F

. 11.

NOTE: A 1/4 in. allen wrench is shipped loose with the system.

c. When fluid stops draining, re-install drain port

plug (W1) then remove rag. See F

. 11.

d. Remove plug (247) from the lowest numbered

outlet on the melter. Do not use the drain

plug (W1). See F

. 11.

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

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

. 11.

b. For Graco applicators, attach applicator electri-

cal connector to heated hose electrical connec-

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

. 12.

NOTE: Elbows and riser tube provided with inlet air kit are optional and may be used as desired.

19. Close the ball valve.

WLE

FIG. 13

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

. 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.

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

106

FIG. 15

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

. 15.

7. Connect L1, L2, L3, and N as shown in F all models use all 4 wires.

WLD

. 16. Not

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

. 2 on page 12.

4. Insert electrical cord through electrical enclosure strain relief bushing (106). See F

. 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

. 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

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.

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.

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

. 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

. 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.

. 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).

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.

. 1 on page 11.

. 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

. 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

. 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

36 333347F

Page 37

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.

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).

. 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.

. 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

. 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

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

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 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

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

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.

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.

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

Red

Green

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

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

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).

. 31):

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

245

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.

. 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

. 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.

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

. 33.

234

ti21047a

FIG. 33

9. Install air motor assembly (see F

. 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

. 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

. 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

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.

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

. 31 on page 56.

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

place then remove melter shield. See F

. 31 on

page 56.

7. Remove air motor assembly. See F

. 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

37.

Reassembly:

1. Apply grease to seals (217) then install new cylinder seals (217) onto cylinder (216). See F

. 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

. 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

. 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

. 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

. 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

218

203

245

251

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

. 42, page 63.

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

13. Remove wire connectors from the over-temperature switch (251).

14. Remove insulators (53, 75) from the melter assembly (5).

15. Disconnect the fill sensor cable from the fill

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

16. Disconnect the pump cycle sensor cable from the air motor.

WLD

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

. 41 on page 62.

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

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

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

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

. 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

. 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

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

9. Pull wires up through grommet (63) on top of the electrical enclosure (1). Clip any wire ties that hold

the wires in place.

10. Continue loosing screw (AA) then slide band heater (208) up to remove.

Reassembly (see F

. 41):

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

opening and screw facing the front of the system in alignment with the sensor port.

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).

WLD

FIG. 41

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).

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

. 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

125

WLD

FIG. 42

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

. 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

. 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

. 41 on page 62.

7. Install fabric melter insulator (53).

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

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

. 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

. 42.

NOTE: This connector also includes the over-temperature switch wires.

10. Disconnect wire connectors from over-temperature switch (251). See F

. 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

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Repair

Replace Heater Over-Temperature Switch

251

255

ti21052a

FIG. 43

Disassembly (see F

. 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

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

. 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

. 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

. 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

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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).

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

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

. 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

. 44.

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

. 41, page 62.

4. If replacing the melter heater rod (209), Install Melter Assembly. See page 60.

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

. 45.

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

333347F 65

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Repair

6. Use crescent wrench to remove melter fluid pressure relief valve (245). See F

. 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

. 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.

F10

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.

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

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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

47.

5. Remove four screws (114) securing MZLP (112) to electrical enclosure (1) then carefully remove MZLP from electrical enclosure. See F

. 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.

MZLP

112

114

FIG. 47

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

. 48 for rotary switch location.

MZLP

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

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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

. 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

FIG. 49

Disassembly (see F

. 49):

1. Turn main power switch OFF.

WLD

ti20763a

FIG. 50

1. Turn main power switch OFF.

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

. 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

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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

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

. 51.

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

(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

. 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

. 51.

5. Remove two screws (144) securing power supply bracket (145) to AWB (143) and remove power supply bracket. See F

. 51.

70 333347F

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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

. 51.

4. Disconnect screw terminal connections between power supply (146) and power supply harness (147) according to the following table. See F

. 51.

Power Supply

Connection

Harness Label

V+ V+

V- V-

GND GND

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

. 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

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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

. 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

. 53):

a. Disconnect transformer wires from J2 connector

on AWB board and the main power switch.

FIG. 52

142

140

402

405

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

. 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

. 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

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

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Repair

6. Install electrical enclosure front access door.

Replace Air Control Gauge

403

403a

403c

403b

WLD

FIG. 54

Disassembly (see F

. 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.

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

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

. 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):

218

FIG. 56: Bottom Pilot Valve

WLD

511

Replace Air Valve

218

507

FIG. 57

Disassembly (see F

. 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

. 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

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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

218

239

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

. 58.

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

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

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

. 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

. 45 on page 65.

6. Remove air motor assembly:

a. Slide retaining ring (239) down.

333347F 75

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Repair

Transformer Fan

Replace Fan

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.

(+)

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

. 60.

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

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

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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

. 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.

r_24P860_3B9900_4a

. 63: Insert Token

5. Install ADM into bracket.

6. Turn system main power switch ON.

NOTICE

A status is shown while software is updating to indicate progress. To prevent corrupting the software load, do not remove token until the status screen disappears.

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

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

GND

208 210 209 210

Band Pump Melter Base

Ground

Stud

Optional Light Tower

Air Solenoid

Fill Sensor

Motor Cycle Switch

Melter OT Switch and Melter RTD

5L3

3L2

1L1

6T3

4T2

2T1

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

12425

125

Electrical Schematics

ADM

138

TEMP

TEMP FAN -

FAN +

143

AWB

J2 J9

GND

TEMP

TEMP FAN -

FAN +

GND

2 3 4 5

L1 L2 L3

GND

123

3 4 5

129

L2 L3

To MZLP #2 4 and 6 Channel Option, see page 108 and 110.

147

1 2 3 4 5

L1 L2 L3

GND

121

GND

148

2 3 4 5

136

L2 L3

103

146

112

121

112A

1 2 3 4

MZLP 1

J12

3 4

J13

2 3

3 4

J14

2 3 4

J15

2 3 4

J16

121

L1 L2 L3

GND

1 2 3 4 5

B C D

F G H

B C D

F G H

GND

L1 L2 L3

1 2 3 4 5

Hose / Applicator Wiring

333347F 79

Page 80

Electrical Schematics

480VAC Transformer Option

5L3 3L2

1L1

6T3

4T2

2T1

GND

143

AWB

PTC

GND

GB1

Typical Hose / Applicator Wiring

GUN

HEATER

T°

GUN

RTD

OVER TEMP

GND

HOSE

HEATER

T°

HOSE

RTD

TEMP

FAN -

FAN +

112

MZLP1

80 333347F

Page 81

2nd and 3rd MZLP Options

118 118 112

MZLP3 MZLP 2 MZLP 1

Electrical Schematics

135

121121

333347F 81

Page 82

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

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

Apply pipe sealant to all non-swiveling pipe threads.

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

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

Torque to 5-11 ft-lb (7-15 N•m).

Torque to 8-10 in-lb (0.9-1.1 N•m).

Parts

25126

38 31

WLE

8, 14

333347F 83

Page 84

Parts

System Parts, Page 2 of 3

WLD

84 333347F

Page 85

System Parts, Page 3 of 3

48 in.

(1219 mm)

Parts

34 48 in. (1219 mm)

34 16 in. (406.4 mm)

(203 mm)

(1219 mm)

8 in.

2 in.

(50.8 mm)

48 in.

(1219 mm)

WLD

36 13 in.

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

18✿ 126961 FITTING, 45 elbow, hydraulic

19✿ 116793 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

--- HOSE, nylon, wpr 250 psi

35 598095 TUBE, 5/32 OD, nylon

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

38 117126 SCREW, shcs; m5x16

FITTING, straight, hydraulic

elbow

1.5"

24T918

24V201

111111111111111111

888888888888888888

444444444444444444

111111111

111111111111111111

17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17

111111111111111111

222444666222444666

444444444444444444

8 8 8 16 16 16 24 24 24 8 8 8 16 16 16 24 24 24

222444666222444666

111111111111111111

222222222222222222

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

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

43▲ 16Y781 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

111111111

111111111111111111

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

111111111111111111

111111111

222222222222222222

111111111111111111

222222222222222222

111111111111111111

333333333333333333

111111111111111111

555555555555555555

111111111

111111111111111111

111111111

24T919

24V198

24V202

24T920

24V199

24V203

24V200

24V423

24V429

24V426

24V424

24V430

24V427

24V425

24V431

24V428

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

✖

127735 STRAP, lifting 3 ft

✖

--- 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

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

24W000★ Melter Adapter 79, 80, 81

88 333347F

Page 89

Electrical Enclosure

Parts

113

MZLP

114

112

112a

113

118

MZLP 2

109

114

MZLP 3

106, 107

120 110

108

WLD

118

101

113

114

Apply sealant to all non-swiveling pipe threads.

Set rotary switch to “1” on MZLP with daughter card.

Set rotary switch to “2” on MZLP 2.

Set rotary switch to “3” on MZLP 3.

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

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

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

3 3 3

1 1 1 1 1 1

2 2 2 2 2 2

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

24V529✿ Upgrade from 4

channel system to 6 channel system

24R040◆ RTD 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

156

157

168

161

158

152

160

167

161

166

157

151

WLD

Mount fan with arrow pointing towards grill.

Tie down cabling from transformer and fan using cable tie onto tie down locations. Remove excess slack and ensure cabling does not contact fan blades.

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

170

Use nut to lock down the ground wire from transformer.

Connect black fan wire labeled (-) from transformer (153) in the pin labeled (-). Connect red fan wire labeled (+) to the connector coming from transformer (153).

2 4

166

Ref. Part Description Qty

161 125871 162 172953

166

167 ---

▲

17A071

TIE, cable, 7.5 in. LABEL, designation LABEL, safety, warning TUBE, corrugated, slit; 6 in. (152.4 mm)

168

169 170 127754

GRILL, fan

▲ Replacement Danger and Warning labels, tags, and cards

5 6

are available at no cost.

★ Included in Fan Replacement Kit 24V911.

--- Not for sale.

166

5 1 1 1

92 333347F

Page 93

Melter and Pump Assembly

HM25, 24V169 HM50, 24V542

205

211

204

202

254

208

236

239

206

Parts

218

217

238

235

233

234

216

217

223

224

220

225

226

207

215

213

206

210

201

249

257

258

249

268 259

Lubricate all seals and o-rings with grease.

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

Torque to 5-11 ft-lb (7-15 N•m).

Torque to 24-30 ft-lb (33-41 N•m).

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

209

206

253

210

WLD

252

214

240

219

211

252

203

251

255

246

242

247

243

244

245

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

Torque to 27-33 in.-lb (3-3.8 N•m).

Apply anaerobic thread sealant on threads.

Torque to 12-18 ft-lb (16-24 N•m).

222

221

227 228 229

231

232

230

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★• ---

246• 121295

1 1

247• 15H304

249 167002

251

252• ---

253✖ ---

1 1

254 ---

255

257 ---

258 --259 110298

1 1 1 1

268 115814

2 2

--- Not for sale.

Available kits (purchase separately):

1 1

Kit Description Includes

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

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 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

1 7 1 1 1 2

1 1 1 4

;

94 333347F

Page 95

Air Motor, 24V558

505

Parts

509

512

507

509

522

513

506

511

Apply water-resistant grease.

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

306

302

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

--- 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

Parts

406

404

403

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

WLD

333347F 97

Page 98

Parts

Pressure Relief Valve, 24P856

607

606

614

601

605

611

608

602

609

603

612

610

604

Apply sealant to all non-swiveling pipe threads.

Apply grease.

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

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