Graco 3A2347T User Manual

Download

Instructions - Parts

™

InvisiPac

™

HM25 Tank-Free

3A2347T

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 gun and hose manuals. Save all instructions.

ti20440b

9902471

Certified to

CAN/CSA C22.2 No. 88

Conforms to ANSI/UL 499

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Component Identification . . . . . . . . . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Attach Components . . . . . . . . . . . . . . . . . . . . . 14

Recommended Air Setup . . . . . . . . . . . . . . . . . 18

Connect Electrical Cord . . . . . . . . . . . . . . . . . . 19

480V Electrical Circuits . . . . . . . . . . . . . . . . . . . 21

208V Electrical Circuits . . . . . . . . . . . . . . . . . . . 21

Select ADM Settings . . . . . . . . . . . . . . . . . . . . . 21

Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

PLC Connection . . . . . . . . . . . . . . . . . . . . . . . . 24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Initial Startup and Prime . . . . . . . . . . . . . . . . . . 26

Manual Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Automatic Refill . . . . . . . . . . . . . . . . . . . . . . . . . 28

Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Pressure Relief Procedure . . . . . . . . . . . . . . . . 30

Drain the System . . . . . . . . . . . . . . . . . . . . . . . 30

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Operation Tips to Minimize Charring . . . . . . . . 33

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Replace Outlet Filter . . . . . . . . . . . . . . . . . . . . . 34

Replace Inlet Filter . . . . . . . . . . . . . . . . . . . . . . 34

Replace Funnel Filter . . . . . . . . . . . . . . . . . . . . 35

Filter Maintenance Guidelines* . . . . . . . . . . . . . 36

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ADM Error Code Table . . . . . . . . . . . . . . . . . . . 37

MZLP Troubleshooting . . . . . . . . . . . . . . . . . . . 50

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Multi-Zone Low Power Temperature Control Module

(MZLP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Software Update Procedure . . . . . . . . . . . . . . . 71

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 72

Incoming Power and Terminal Jumpers . . . . . . 72

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Non-Graco Gun Adapter Cables . . . . . . . . . . . . 90

Air Adjustment Lock, 24R084 . . . . . . . . . . . . . . 90

System Stand, 24R088 . . . . . . . . . . . . . . . . . . . 91

Caster for Stand, 120302 . . . . . . . . . . . . . . . . . 91

Adapter Plate, 24R083 . . . . . . . . . . . . . . . . . . . 91

30 Gallon Vibrating Hopper, 24R136 . . . . . . . . . 92

Light Tower Kit, 24R226 . . . . . . . . . . . . . . . . . . 94

Air Reservoir Kit, 16W366 . . . . . . . . . . . . . . . . . 95

Air Metric Fitting Kit, 24W637 . . . . . . . . . . . . . 103

Appendix A - ADM . . . . . . . . . . . . . . . . . . . . . . . . 104

General Operation . . . . . . . . . . . . . . . . . . . . . . 104

Icon Identification . . . . . . . . . . . . . . . . . . . . . . . 104

Appendix B - USB Downloading, Uploading . . . 110

Download Procedure . . . . . . . . . . . . . . . . . . . . 110

Accessing Files . . . . . . . . . . . . . . . . . . . . . . . . 110

Upload Procedure . . . . . . . . . . . . . . . . . . . . . . 110

USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

System Settings File . . . . . . . . . . . . . . . . . . . . 111

System Language File . . . . . . . . . . . . . . . . . . . 112

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Graco Extended Warranty . . . . . . . . . . . . . . . . . . 120

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 120

2 3A2347T

Related Manuals

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

Part Description

3A2805 InvisiPac GS35 Hot Melt Gun Instructions -

Parts

332072 InvisiPac Heated Hose Instructions - Parts

Required Tools

Related Manuals

• 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

3A2347T 3

Models

NOTICE

To prevent system damage, verify terminal jumpers are installed correctly before applying power.

Model Channels Voltage

24P260 2 200-240VAC

24P261 4 200-240VAC

24P262 2 350-415VAC Y

24P263 4 350-415VAC Y

24P264 2

24P265 4

24U132 6 200-240VAC

24U133 6 350-415VAC Y

24U134 6

200-240VAC

/ PE

/ Neutral / PE

3Φ / PE

/ PE

/ Neutral / PE

3Φ / PE

Type Description Frequency

•1-Phase

• 200-240VAC

• 2 wire and PE

• 3-Phase with Neutral

• 350-415 VAC Line to Line

• 200-240VAC Line to Neutral

• 3 wire and Neutral and

• 3-Phase without Neutral

• 200-240 VAC Line to Line

• 3 wire and PE

•1-Phase

• 200-240VAC

• 2 wire and PE

• 3-Phase with Neutral

• 350-415 VAC Line to Line

• 200-240VAC Line to Neutral

• 3 wire and Neutral and

• 3-Phase without Neutral

• 200-240 VAC Line to Line

• 3 wire and PE

50/60 Hz 32A

50/60 Hz 40A

50/60 Hz 16A

50/60 Hz 27A

50/60 Hz 40A

50/60 Hz 30A

50/60 Hz 40A

Max

Amps

4 3A2347T

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.

3A2347T 5

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.

6 3A2347T

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.

3A2347T 7

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 1-4) S Customer I/O Cable (optional)

ti20441b

FIG. 1

8 3A2347T

Heated Fluid Manifold

Component Identification

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)

ti20442b

Z Adhesive Pellets Level Sensor AA Power and RTD Harness Connection to Heated Hose and

Gun (harness connects from system to heated hose then from heated hose to gun)

AB Inlet Funnel Screen

3A2347T 9

Component Identification

Electrical Enclosure

FIG. 3

Key:

P Multi-Zone Low Power Temperature Control Module

(MZLP) AC Incoming Power Connection AF Chassis Ground

ti20907b

AG Terminal Blocks and Jumpers AH Heater Relay AJ Incoming Power Terminal Jumpers. See page 19.

10 3A2347T

Advanced Display Module (ADM)

Component Identification

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 104 for complete ADM operation details.

Ke yFunction

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

FIG. 4

TI12362a1

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

3A2347T 11

Component Identification

Screen Components

Current date and time

Operating Mode

Hose and Gun

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 increasing the material to the set temperature.

The system is ready to dispense material.

Screens Order

Gun 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 (manually changed)

• 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

12 3A2347T

Component Identification

3A2347T 13

Setup

Grounding

The equipment must be grounded to reduce the risk of electric shock. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

The InvisiPac system is equipped with a ground terminal. Have a qualified electrician ground the system using this terminal. See Connect Electrical Cord on page 19.

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).

Attach Components

To reduce the risk of electric shock, do not connect electrical cord until after this Attach Components procedure is complete.

1. Place the base system in the desired operating

location and orientation. See Location on this page.

• The bottom of the electrical enclosure has holes for securing the InvisiPac system to a surface. The holes are accessible through the bottom access doors in the three rear walls of the electrical enclosure.

• To install the InvisiPac system in place of a

non-Graco hot melt system, purchase Adapter Plate, 24R083. See installation instructions on

page 91.

The gun(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 91.

If installing the system in place of a non-Graco hot melt system, purchase Adapter Plate, 24R083. See page 91.

Optional 30 Gallon Vibrating Hopper, 24R136, available (purchase separately). See page 92.

To make repairing the system easier, locate the system so that all sides are easily accessible and have sufficient lighting.

• To raise the system to eye-level, purchase System Stand, 24R088. See installation instructions on page 91.

NOTE: Supplied vacuum transfer hose must reach from the system to the adhesive pellets container. Supplied heated hose must reach from system to gun(s).

2. Install vacuum transfer inlet funnel (G3) onto system. See F

a. Slide funnel through the bracket connected to

the air motor.

b. Position the funnel so the funnel inlet faces the

desired direction.

c. Connect 5/32 in. OD air line to funnel.

. 7.

14 3A2347T

Setup

d. Install supplied hose clamp around the air motor

bracket and funnel base then tighten.

ti21130b

FIG. 7

3. Insert 1.3 in. (33 mm) OD clear vacuum transfer hose (G2) into vacuum transfer funnel (G3) inlet and secure with supplied hose clamp. See F

. 7.

6. Apply pipe sealant to threads then attach steel shaker tube (G) to shaker head (G1). See F

. 8.

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.

4. 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

. 7.

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.

5. Route the 1.3 in. (33 mm) OD clear vacuum transfer hose from the system to the adhesive pellets container location.

ti21131a

FIG. 8

7. Attach 1.3 in. (33 mm) clear vacuum transfer hose (G2) to steel shaker tube (G) and secure with supplied hose clamp. See F

. 8.

8. Route the 3/8 in. OD air line (G4) alongside the

1.3 in. (33 mm) clear vacuum transfer hose (G2) and secure at multiple points with the supplied zip ties (G5). See F

. 8.

9. If desired, secure the 1.3 in. (33 mm) clear vacuum transfer tube and 3/8 in. OD air line with zip ties to a supporting structure at various points in the routing.

10. 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).

11. 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.

3A2347T 15

Setup

12. 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 92.

NOTE: If static buildup on feed tube (G) is excessive, install optional feed tube ground kit 24R708 to feed tube end (G6). See F

13. Install heated hoses, see F

. 8.

. 9:

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.

247

Gun

d. Remove plug (247) from the lowest numbered

outlet on the melter. Do not use the drain plug (W1). See F

. 9.

NOTE: In the following step, the o-ring side of the hydraulic fitting (68) faces the system. See F

. 9.

e. Install the supplied hydraulic fitting (68) with an

o-ring into the open port and tighten with an 11/16 in. wrench or socket.

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

. 9.

h. Repeat the procedure for the remaining chan-

nels. Use the bottom melter ports first to ease installation.

ti21132a

FIG. 9

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

the melter. Residual oil may be in the system from the factory. See F

. 9.

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

port plug (W1). See F

. 9.

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

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

plug (W1) then remove rag. See F

. 9.

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.

14. Install gun(s), see F

. 9:

NOTE: Use of a Graco gun is not required with this system. However, all guns 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.

a. Connect heated hose fluid outlet to gun fluid

inlet. Use 11/16 in. wrench to tighten. See F

b. For Graco guns, attach gun electrical connector

to heated hose electrical connector. See F

. 9.

16 3A2347T

Setup

c. For non-Graco guns, attach gun electrical con-

nector to adapter harness (16T916, 16T917, or 16Y828) then attach adapter harness connector to heated hose connector. See Non-Graco Gun Adapter Cables on page 90 to determine which adapter cable to use with your valve.

d. Repeat for any additional guns.

15. If necessary, set up the valve controller to control

opening and close the gun. See gun manual.

NOTE: The system controls gun heating only. A separate gun controller must be set up to open and close the guns.

16. 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

. 10.

17. If using the same air for the gun(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 gun manual for gun air pressure requirements, and use a regulator before the gun to decrease the air pressure, if necessary.

18. Close the ball valve.

WLE

ti21147a

FIG. 11

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

. 11.

WLE

ti21133a

FIG. 10

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

that bleeds pressure downstream when closed. Otherwise, the supplied air will need to be disconnected from the system whenever the pressure is relieved.

NOTE: The system must use an air filter with a minimum flow rate of 30 scfm.

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 95.

20. To lock access to the air pressure adjustments, purchase Air Adjustment Lock, 24R084. See installation instructions on page 90.

21. To install a light tower that illuminates red when a

system error occurs, purchase Light Tower Kit, 24R226. See installation instructions on page 94.

22. To upgrade a 2 channel system to a 4 channel system, purchase 4 Channel Upgrade Kit, 24R237.

See installation instructions on page 96.

23. Install MZLP electrical connector caps on all unused channels.

3A2347T 17

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.

Air Filter/Ball Valve at

System Air Inlet

(Graco Kit 24R707,

included)

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

No dips in vacuum transfer hose

Ensure funnel air is connected

Pump: 20-100 psi (1.4-6.8 bar,

0.14-0.68 MPa)

Air In:

3/8 in.,

100 psi

(6.8 bar, 0.68 MPa),

30 scfm capacity

WLE

Air to guns

Regulator set to

70 psi

(4.8 bar, 0.48 MPa)

FIG. 12

18 3A2347T

Setup

Connect Electrical Cord

NOTE: See Grounding section on page 14.

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 14 prior to connecting electrical cord.

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

0.708-1.260 in. OD electrical cord. See F needed, use a wrench to tighten the strain relief bushing until it is snug on the cable.

For 480V Electrical Circuits, see page 21.

. 14. If

Terminal Block Jumper Installation Guide

Terminal Block Location

Voltage

200-240VAC,

1 phase

350-415VAC,

3 phase,

WYE

200-240VAC,

3 phase,

DELTA

Jumper

Wire

127201

Not used Not used 3-5 6-10

Not used

3-7

2-Terminal

Jumper

126814

5-6,

8-9

4-5,

9-10

3-Terminal

Jumper

126815

2-4 Not used

6-8 Not used

5-Terminal

Jumper

126816

NOTE: The jumpers only need to be changed if using a

different phase or voltage from what the system was designed for at the factory.

NOTE: All necessary jumpers are supplied with the system in a bag located behind the electrical enclosure front access panel. Keep unused jumpers in bag.

2-Terminal

126814

3-Terminal

126815

5-Terminal

126816

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 9.

4. Ensure the terminal block jumpers are in the correct locations for the phase and voltage used. If neces-

sary, change them to match F See the following table, F

. 15 on page 20.

. 13, and FIG. 15.

NOTICE

To prevent system damage, verify terminal jumpers are installed correctly before going on to the next step.

ti21182a

Wire

127201

FIG. 13: Jumpers

NOTE: Use the supplied hard metal 2, 3, and 5 terminal

jumpers and jumper wire for terminals 2C-10C. Use the red, plastic jumpers for terminals 11-14.

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

. 14 on page 20.

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.

3A2347T 19

Setup

6. Attach insulated ferrules to the end of each wire. 7. Connect ground wire to chassis ground (AF). See F

. 14.

106

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

. 15. Not

all models use all 4 wires.

9. Use zip ties to secure the electrical cord to the tie-downs located on the top of the inside of the electrical enclosure.

10. Tighten screw-terminals to at least 10 in-lb (1.1 N•m).

11. Install electrical enclosure door.

FIG. 14

ti20907b

12. Perform Select ADM Settings on page 21 prior to turning on heat.

FIG. 15

20 3A2347T

Setup

480V Electrical Circuits

For 480V electrical supply, a 480V to 240V step-down transformer must be installed by a qualified electrician.

Transformer Sizing

For single-phase power, 480V to 240V transformer 24U169 (purchase separately) may be used. See Sin- gle-Phase 480V to 240V Transformer, 24U169 on page 100.

Minimum transformer rating can be calculated by taking 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

√

(3) = 8315 watts

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.

3. On the System 2 screen:

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

channel that has a heated hose and gun installed.

b. Select the RTD type used on each installed

gun. See gun manual.

NOTE: An incorrect RTD setting will cause the system to be incapable of maintaining the temperature setting.

NOTE: The supported RTD types are Ni, 100 ohm; Ni, 120 ohm; NiFe, 604 ohm; Pt, 100 ohm (385), Pt, 100 ohm (392); and Pt, 1000 ohm. An “Auto” selection is available but should only be used when the specific RTD type cannot be identified. Using the “Auto” RTD setting may result in inaccurate temperatures.

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

To prevent fire and explosion, a qualified electrician must determine the proper circuit breaker size to use for the power supplied to the system.

4. On the System 3 screen:

Select ADM Settings

NOTE: See Appendix A - ADM on page 104 for

detailed ADM information, including general operation.

1. Turn main power switch ON .

2. When the ADM is finished starting up, press to switch from the Operation screens to the Setup

screens. Use , , , and to navigate

between screens.

3A2347T 21

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

the circuit breaker installed external to the system for the system power supply.

Setup

NOTE: If using a 480V to 240V transformer, the breaker size entered will be two times the 480V rating. If using transformer 24U169, the breaker size should be set to 30 amps and power type should be set to single phase.

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.

b. Select the incoming power type.

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

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

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 104, 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.

7. To setup the optional Schedule function, see Schedule on page 29.

22 3A2347T

11. On the Targets screen, adjust heated hose and gun 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 gun 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.

Setup

c. Use and , shown next to ,

to adjust heated hose temperature setting to the desired setting for that channel.

NOTE: Alternatively, use the physical up and down

arrow push-buttons on the ADM keypad until is next to the temperature setting to change then use the

numeric keypad to enter the desired temperature.

NOTICE

Set melter, hose, and gun to the same setpoint temperature for best performance. Do not set the hose temperature higher than the melter. Running the hose at a setpoint higher than the melter is unnecessary in this tank-free system and could lead to adhesive degradation in the hose. Short adhesive residence time in the melter eliminates the need to set the melter at a lower setpoint than other zones. See Operation Tips

to Minimize Charring, page 33.

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.

Guns

Gun heating is controlled by the system, but the system does not control opening and closing the valves. Setup a separate gun controller to open and close the valves.

3A2347T 23

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, or 4 Enable/Disable

Customer Output Dropdown Options

Option Description

Disable Not used.

System Ready Indicates when the system is up to tem-

Error (Alarm) Indicates when there is an active alarm.

Error (Deviation/Advisory)

Maintenance Due Indicates when the maintenance total

Enable or disable hose and gun heating for that individual channel.

perature and the pump is stalled at pressure.

An active alarm will disable the heating system and pump.

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: 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 8.

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.

F2 F3

F10

FIG. 16: 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

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.

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.

24 3A2347T

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. 17: Customer Input

MZLP Customer In

MZLP Customer Out

Customer Output

Vin (no polarity) 30 VDC Max

Customer In

FIG. 18: Customer Output

250 VAC, 2A Max

To Customer Input

3A2347T 25

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.

NOTE: See Appendix A - ADM on page 104 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: 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 guns 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 89.

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.

NOTE: See Appendix B - USB Downloading, Uploading on page 110 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 guns. The gun 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.

4. Turn main power switch ON .

5. Open system air inlet ball valve.

WLE

6. Use pump air pressure regulator (C) to adjust pump air pressure to 0. See F

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

. 1 on page 8.

Initial Startup and Prime

NOTE: All setup procedures must be completed prior to initial startup. See Setup on page 14.

26 3A2347T

Operation

FIG. 1 on page 8.

NOTE: Vacuum transfer will not begin operating until pump reaches operating temperature.

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 21 for instructions.

9. Press to enable the heaters and pump.

12. With the guns 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 gun.

14. When each gun is fully primed, adjust pump to desired pressure setting:

a. Adjust pump pressure to between 20-100 psi

(140-690 kPa, 1.4-6.9 bar).

b. Use separate gun controller to repeatedly open

and close each gun while inspecting the dispense pattern.

c. Repeat until desired dispense pattern is

achieved.

NOTE: When system is up to temperature, the pump will be activated automatically but will not start because there is no air pressure supplied to the pump.

NOTE: When the melter is up to temperature, the auto-fill function will initiate to fill the funnel with pellets.

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

250°F (121°C) and the funnel is filled with pellets, set the melter temperature back to the desired operating temperature. See Select ADM Settings on page 21 for instructions.

11. Use separate gun controller to open the guns 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.

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 cap.

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 phillips head screws then remove the funnel cap from the funnel.

3A2347T 27

Operation

3. Fill the funnel with adhesive pellets.

ti21154a

FIG. 19

4. Refill the funnel as needed to maintain the required dispense rate.

5. When finished dispensing for the day, dispense into a waste container until the material level is down to the smallest diameter section of the funnel then continue purging material through the valve for an additional 75 pump strokes.

NOTE: This will lower the adhesive level within the feed cap to the correct level to prevent any issues upon startup the following production day.

Automatic Refill

The system uses automatic refill by default. If the 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 14.

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.

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). See F

. 1 on page 8.

NOTE: The system will automatically transfer the pellets to the system as necessary.

. 1 on page 8.

NOTE: Pump strokes can be monitored on the Maintenance screen, or by counting pump changeovers. To count pump changeovers, listen to the air motor exhaust pulses; two exhaust pulses equals one pump cycle (two strokes).

ti21154a

FIG. 20

Dispense

NOTE: Only hot melt adhesive pellets can be used in

the InvisiPac system.

1. If the system is empty or has air in the lines, perform Initial Startup and Prime procedure on page 26.

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 8.

. 1

28 3A2347T

Operation

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 28.

d. If using Manual Refill, see Manual Refill on

page 27.

e. Verify guns 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 a gun is open. Material will be dispensed whenever a gun is open after the system is up to temperature.

5. When the system is up to temperature, use sepa-

rate gun controller to open and close the guns as desired to dispense material.

. 1 on page 8.

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.

NOTE: While operating the system, the actual temperatures of the hose, gun, and system melter are displayed on the Home screen.

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.

3A2347T 29

Operation

Enable Schedule Function

The Schedule function is automatically enabled when values are entered in the Schedule screen. To disable the Schedule function, delete all values on the Schedule screen or 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.

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.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Turn main power switch OFF .

2. Close the inlet air supply ball valve.

NOTE: Manually verify the pressure is relieved by opening the gun and ensuring no adhesive is dispensed.

3. Decrease pump air pressure to 0.

4. Close system air inlet ball valve.

5. Disconnect hose from gun inlet then place hose outlet in a waste container. Repeat for all hoses. Keep hose to gun electrical connector connected.

6. Open gun to allow residual fluid in gun 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.

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

. 2 on page

11. Disconnect hose from melter outlet.

30 3A2347T

Operation

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.

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 30.

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 guns 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.

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.

ti21053a

10. Disconnect one hose from its gun manifold.

NOTE: Keep all guns closed throughout this procedure.

3A2347T 31

Operation

11. Route the disconnected hose to a waste container.

12. If heating system is disabled, press to enable

the heaters and pump.

13. Wait for the melter temperature to reach the hot melt cleaning fluid manufacturer’s recommended temperature.

NOTE: The pump will not run because the system air inlet ball valve is closed.

14. Once the required melter temperature is reached, let the hot melt cleaning fluid “soak” in the melter at temperature for the duration specified by the hot melt cleaning fluid manufacturer.

NOTE: “Soaking” is important to ensure the best 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.

20. Remove and replace filter(s) in all gun manifolds. See gun manual.

21. Replace Outlet Filter. See page 34.

22. Turn main power switch OFF.

23. Place waste container below drain tray (W2) then remove drain plug (W1) and wait for system to finish draining. See F

. 2 on page 9.

24. Allow the system and fluid to cool then perform any required maintenance procedures beginning on page 34.

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”.

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 gun manifold.

19. Repeat steps 7 through 18 for each additional installed hose, leaving a different hose disconnected from the gun manifold each time.

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 26.

32 3A2347T

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 29, 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

Operation

3A2347T 33

Maintenance

Replace Outlet Filter

The outlet filter is designed to prevent small contaminants from entering the hoses and guns. 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. 21

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

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 30 but

3. Turn main power switch OFF.

4. Loosen two screws (8) then slide the small metal

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

enable the heaters and pump then wait for system to reach operating temperature.

do not allow system to cool. Adhesive must be a fluid to perform this procedure.

shroud (28) on the back of the system up to remove. See F

. 21.

ti20752a

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).

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.

34 3A2347T

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

f. Go to step 4.

9. Slide new screen (213) into melter base manifold (201).

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

11. Feed ADM cable through plastic shroud (29) then install shroud onto system. Connect cable to ADM (30).

Replace Funnel Filter

701

705

706

201

ti20909a

FIG. 22

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.

ti20927b

FIG. 23

Disassembly (see FIG. 23):

1. Turn main power switch OFF.

2. Loosen and remove the two phillips head screws (705) on the side of the funnel (706) then remove the funnel cap (701).

Reassembly (see F

. 23):

1. Place funnel cap (701) onto funnel (706).

2. Install two phillips head screws (705) to secure funnel cap to funnel base.

3A2347T 35

Maintenance

Filter Maintenance Guidelines*

Environment Classification

Clean Moderate Dusty

Pump inlet filter

Pump outlet filter

Gun manifold filter

System air filter

Solenoid exhaust filters

Feed funnel filter

Feed funnel inspection/clean out

* 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 powered 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

36 3A2347T

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, 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

1Gun 1

2 Hose 1

3Gun 2

4 Hose 2

5Gun 3

6 Hose 3

7Gun 4

8 Hose 4

9Gun 5

A Hose 5

BGun 6

C Hose 6

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

Code Description Type Cause Solution

A4D0 High Current

Melter

A4D_ High Current

Hose X

A4D_ High Current

Gun X

Alarm Defective or shorted to ground on

the band heater or rod heater.

Alarm Defective or shorted to ground on

the hose power wires.

Alarm Defective or shorted to ground on

the heater rods in gun manifold.

Measure resistance to ground between heater leads. Should be a high reading.

Replace heated hose.

Replace gun manifold.

3A2347T 37

Troubleshooting

Code Description Type Cause Solution

A7D0 Unexpected

Current

Alarm Unexpected current flow to melter. Replace MZLP.

Faulty melter heater(s). Check heater resistance and resistance to ground. Replace faulty heater(s).

A7D_ Unexpected

Current, Gun X

Alarm Unexpected current flow to gun X. Faulty MZLP. Replace MZLP.

Faulty gun heater element. Check heater resistance and resistance to ground.

A7D_ Unexpected

Current, Hose X

A8D0 No Current

Melter

Alarm Unexpected current flow to hose X. Faulty MZLP. Replace MZLP.

Faulty hose heat element. Check heater resistance and resistance to ground.

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

ter board. Check J1 is plugged into MZLP with daughter

board.

A8D_ No Current

Hose X

Alarm Power not getting to hose. Check fuses F5 and F6 or F9 and F10 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 gun, the heated hose electrical connector must be plugged into channel 1 of the MZLP.

A8D_ No Current

Gun X

Alarm Power not getting to gun. Check fuses F3 and F4 or F7 and F8 on

MZLP that controls the error channel. Check that electrical plug on hose is plugged

into back of MZLP. 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 gun, electrical connector of the heated hose must be plugged into channel 1 of the MZLP.

CAC_ Comm Error

Module

Alarm System not responding to ADM. System is not properly loaded with correct

software. Perform Software Update Proce- dure on page 71.

Dial not set correct on MZLP. Set to 1 on board with daughter board. Set to 2 on MZLP without the daughter board.

CACX Missing DB Alarm System not acknowledging the

daughter board.

Defective MZLP daughter board. Replace. Bad connection between daughter board and

MZLP board. Loosen daughter board, re-seat, then secure.

38 3A2347T

Code Description Type Cause Solution

DADX Pump Run-

away

Alarm Pump is trying to feed adhesive, no

adhesive to feed.

Storage bin out of adhesive. Refill adhesive. Melter at incorrect temperature, to low. Check

setpoint and set to manufactures recommendation.

Plugged vacuum transfer hose or funnel. Clear plugged hose or funnel.

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

DDDX Pump Diving Devia-

tion

Pump is trying to feed adhesive, no adhesive to feed.

Storage bin out of adhesive pellets. Refill with pellets.

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.

Feed rate for dispensing too high.

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

DE0X Cycle Switch

Error

Alarm No signal from air motor sensor. Check wiring on J16 of the daughter board.

See Electrical Schematics on page 72. Defective cycle switch. Replace. Loose cycle switch bolt. Tighten cycle switch

bolt.

L6FX Level Sensor

Error

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

sor. Check connector at J14 of the daughter

board. Verify there is nothing blocking fill (level) sen-

sor line of sight.

Defective fill (level) sensor. Replace. No air to fill cap. Check for air coming from 5/32 in. air line. Plugged orifice in fill cap below fill

sensor.

L8FX Refill timeout Alarm Melter did not receive enough

adhesive pellets for flow rate.

Remove fill cap and remove object plugging

the orifice.

Storage bin out of adhesive. Refill adhesive.

Plugged inlet feed hose or funnel. Clear

plugged hose or funnel.

MMUX USB Log Full Advi-

sory

T1D0 Low Temp

Alarm Melter reached setpoint but

Melter

USB logs full. Data loss will occur if not downloaded.

dropped below setpoint and can

Download USB data. See Appendix B - USB

Downloading, Uploading on page 110.

Check resistance of heater rods and band

heater. not recover.

T1D_ Low Temp

Hose

Alarm Hose reached setpoint but dropped

below setpoint and can not

Check resistance of heated hose. Refer to

hose manual for proper resistance range. recover.

T1D_ Low Temp

Gun

Alarm Gun reached setpoint but dropped

below setpoint and can not

Check resistance of manifold heater rods.

Refer to gun manual for resistance value. recover.

T4C_ High MZLP

PCB Temp

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

Defective MZLP board. Replace.

Troubleshooting

3A2347T 39

Troubleshooting

Code Description Type Cause Solution

T4D0 High Temp

Melter

T4D_ High Temp

Hose

T4D_ High Temp

Gun

T6D0 Sensor Error

Melter

Alarm Melter continues to raise above the

Defective RTD. Replace.

setpoint.

Alarm Hose continues to raise above the

Defective RTD. Replace.

setpoint.

Alarm Gun assembly continues to raise

Defective RTD. Replace.

above the setpoint.

Alarm No reading from RTD. Verify connector J5 on MZLP board is

securely connected. Defective RTD. Replace.

T6D_ Sensor Error

Hose

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

MZLP. Defective RTD. Replace.

T6D_ Sensor Error

Gun

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

MZLP or manifold electrical connector not plugged into heated hose.

Defective RTD. Replace.

T8D_ No Temp Rise

in Gun (all zones)

Alarm Temperature reading does not

change.

Check fuses F3 and F4 or F7 and F8 on MZLP that error channel is connected to.

Defective heater rods in gun manifold. Replace gun manifold.

T8D_ No Temp Rise

in Hose (all zones)

T8D0 No Temp Rise

in Melter (all zones)

Alarm Temperature reading does not

change.

Alarm Temperature reading does not

change.

NOTE: Defective heaters rods in the gun 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.

Check fuses F5 and F6 or F9 and F10 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.

Check fuses F1 and F2 on MZLP with daughter board.

Defective heater wires in melter. Replace melter.

NOTE: Defective heaters wires in the melter can also cause the no current error.

Check J1 is properly plugged into the MZLP with daughter board.

Check that RTD is installed in the melter.

40 3A2347T

Code Description Type Cause Solution

V1I_ Low Can Volt-

age

V4I_ High Can Volt-

age

V8M_ No line voltage Alarm Incoming line voltage is less than

WJDX Pump Sole-

noid Error

WKFX Fill Solenoid

Error

WSUX USB Invalid

Configuration

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

age is low, disconnect the power lines and

re-check voltage reading. If voltage is still

low, replace power supply. If voltage is cor-

rect after disconnecting the power lines,

replace the MZLP.

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

age is high, replace power supply unit.

Measure incoming power with system 100 VAC.

Alarm No voltage draw from air solenoid

for air motor.

Alarm No voltage draw from air solenoid

for fill.

Deviation

A valid configuration file can't be found for the USB.

Bad ADM. Replace ADM.

unplugged. If line voltage is less than

100 VAC, contact qualified electrician to cor-

rect the low voltage.

Check connector is properly connected to J14

of the daughter board.

Defective air manifold, replace manifold.

Check connector at J14 of the daughter

board.

Defective air solenoids. Replace. See

page 66.

System is not properly loaded with correct

software. Perform Software Update Proce-

dure on page 71. Retry USB download.

Troubleshooting

Mechanical and Electrical Troubleshooting

Problem Cause Solution

Refill Timeout Error

The InvisiPac system takes a long time to refill adhesive.

The system was unable to refill in less than 30 seconds.

Glue level in hopper is low.

Vacuum flow is restricted.

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 27.

Check funnel filter. If plugged, see Replace Funnel Filter on page 35.

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 35.

3A2347T 41

Troubleshooting

Problem Cause Solution

Vacuum transfer not working

Adhesive pellets in storage bin not covering shaker head.

Fill Solenoid Error

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.

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 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.

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 92.

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 27.

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 guns 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 3V if melter is completely empty (melter passage holes are visible). The normal operating range is 2.1 to 2.8V. If the sensor is reading more than 2.75V 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 27.

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 35.

NOTE: Feed cap filter maintenance should be performed at regular

service intervals. It is recommended that the feed cap filter be serviced 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 49.

If system is still unable to stall, the pump or pressure relief valve may need to be repaired.

42 3A2347T

Problem Cause Solution

Troubleshooting

The system will not dispense material.

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.

Control for manifold and guns not working.

Cycle Switch Error

Cycle switch or cycle switch wiring failure.

Loose or missing fastener (26).

USB Log Full The InvisiPac system

will display this notification when the USB data logs reach 90% full.

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 49.

Repair or replace air control assembly as necessary.

Repair or replace pump assembly as necessary.

InvisiPac system does not control the timing of the manifold and valves. 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 76 for part identification.

To prevent data loss download system data. See Appendix B - USB Downloading, Uploading on page 110.

The InvisiPac system is displaying pump runaway or pump diving.

This error generally occurs when the pump cavitates due to improper material loading.

Level sensor blocked, reading level incorrect.

The system is not supplying enough air to the ultrasonic sensor venturi.

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 33 cpm by enabling the diagnostic screen.

2. If the cycle rate is below 33 cpm and the system is still running away increase the InvisiPac system temperature by 10°F over the current set point, leave hoses and guns at desired set point.

3. If the pump continues to runaway or dive continue increasing temperature by 10°F, do not exceed maximum temperature for the material being dispensed.

NOTE: Some materials are more difficult to melt than others and it may be impossible to process them at a rate of 25 lb/hr. The InvisiPac system was tested to achieve continuous melt rates of 25lb/hr when dispensing standard EVA packaging grade adhesives in pellet form with an InvisiPac system temperature of 375°F and hose and valve temperatures of 350°F.

Clean feed cap by fill sensor, make sure there are no adhesive pellets blocking the sensor hole.

Make sure the air supplied to the system is at least 80 psi (550 kPa, 5.5 bar).

3A2347T 43

Troubleshooting

Problem Cause Solution

Unable to achieve 25lb/hr 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 33 cpm and the system is still running away increase the InvisiPac system temperature by 10°F over the current set point, leave hoses and guns at desired set point.

2. If the pump continues to runaway or dive continue increasing temperature by 10°F, 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 a rate of 25 lb/hr. The InvisiPac system was tested to achieve continuous melt rates of 25lb/hr when dispensing standard EVA packaging grade adhesives in pellet form with an InvisiPac system temperature of 375°F and hose and valve temperatures of 350°F.

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 MZLP

ADM cable should be plugged into J6 of the MZLP 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.

44 3A2347T

Problem Cause Solution

Troubleshooting

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 manifold. Manifold resistance 130-140 ohms.

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 gun combinations,

Connect system to a power supply capable of maximum power per system specification. All changes must be performed by a qualified electrician. See Electrical Schematics on page 72 for details about

connecting to a different power supply. along with minimal supply power, startup time will vary.

Incorrect RTD setting in system.

1. Verify melter, hose, and manifold temperatures are all with in the same range of the room ambient.

2. If the manifold 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 manifold and gun are over the temperature setpoint

Incorrect RTD setting in system.

NOTE: Failure to have the correct RTD value will cause the manifold and gun 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 manifold temperatures are all with in the same range of the room ambient.

NOTE: Failure to have the correct RTD value will cause the manifold and gun 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.

3A2347T 45

Troubleshooting

Problem Cause Solution

No adhesive or incorrect amount of adhesive output when all valves are triggered

No adhesive or incorrect amount of adhesive out of one/some of the valves when triggered

Plugged gun manifold filter.

Replace manifold filter. Graco manifold filter in bottom of manifold or inline filter on other manifolds.

Clogged hose. Flush or replace hose.

Defective solenoid valve.

No signal from control to solenoid.

Solenoid mufflers

Check that correct voltage is input into valve solenoid. If voltage is correct, replace solenoid.

If no voltage is present at solenoid, check control cable and remote control device. 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 34.

filter.

If multiple valves are triggered simultane-

Stagger valve opening to reduce the maximum required flow rate to

below maximum pump rate. ously, maximum pump rate may be exceeded.

Plugged tip on gun. Replace tip on gun.

Defective gun in

Replace gun. closed/partial open position.

Plugged manifold filter (single valves mani-

Replace manifold filter. Graco manifold filter in bottom of manifold or

inline filter on other manifolds. fold).

Clogged hose (single valves).

Defective solenoid valve (single manifold).

No signal from control to solenoid (single valve manifold).

Plugged solenoid mufflers (single valve manifold).

No air to solenoid (single valve manifold)

Plugged system outlet filter.

If multiple valves are triggered simultaneously, maximum pump rate may be exceeded.

Flush or replace hose.

Check that correct voltage is input into valve solenoid. If voltage is cor-

rect, replace solenoid.

If no voltage is present at solenoid, check control cable and remote

control device. Replace component.

Replace solenoid mufflers.

Re-establish air supply to solenoid.

Replace Outlet Filter. See page 34.

Stagger valve opening to reduce the maximum required flow rate to

below maximum pump rate.

46 3A2347T

Problem Cause Solution

Troubleshooting

Adhesive flowing out of one/some valves when not triggered

Gun will not heat.

Adhesive leaking from manifold or valve.

Failed valve in the

Replace valve.

open position.

Adhesive pressure too

Reduce air pressure to air motor.

high.

Heat rod failure in manifold.

Loose cable connec-

Check resistance on heater rods. Repair manifold if heater rods measure open.

Check cable connections on both ends of the hose. tion 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

Set correct RTD value in the AMD setup screen. Consult manufacture

for correct RTD value.

Measure resistance of the thermal cutoff. If open, replace. tripped.

Valve is loose on the

Tighten screws on loose valve. manifold.

Valve o-ring failed. Replace o-rings on the back of the leaking valve.

Failed valve, adhesive

Replace valve. leaking out middle of valve.

No melter heat.

Air motor will not function.

System not turning on.

Hose loose. Tighten hose.

Fuse blown in F1 and F2.

Cable to over-temperature switch off or bro-

Check heater rods for a short or a short between the rod wires and

ground.

Check connection of cable to over-temperature switch both to main

board and to switch. If connection good, look for break in wire. ken.

Over-temperature switch tripped.

Measure over-temperature switch resistance. It should read close to 0

ohms when at room temperature. If open, replace over-temperature

switch.

No air being supplied to air motor.

Air solenoid not adjusting the air motor.

Air present at air motor

Check incoming air supply. Check that air solenoid is adjusted for air

motor.

If air can not be adjusted at the air solenoid, check voltage, if 24VDC

present at air solenoid replace air solenoid.

Replace air motor. but it will not work.

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

Check that power plug is connected.

3A2347T 47

Troubleshooting

Problem Cause Solution

Static shock when touching shaker or adhesive bin.

Adhesive not dispensing at the correct time.

Ground wire not in place on shaker assembly. Some adhesives, flow rates, and ambient conditions can cause excessive static buildup on the shaker tube.

Guns opening at the wrong time.

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 guns. The separate controller needs to be adjusted. Consult control manufacturer or qualified electrician.

48 3A2347T

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.

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 gun.

6. Repeat this entire procedure until no additional air is expelled from the gun.

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.

FIG. 24

ti20441b1

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.

3A2347T 49

Troubleshooting

MZLP Troubleshooting

MZLP

ti20441b1

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.

Yellow

Red

Green

FIG. 25: 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.

ti20348a

FIG. 26: MZLP Diagnostic LED Location

50 3A2347T

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

Disassembly (see F

1. Flush the system. See page 31.

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).

. 27):

FIG. 27

240

245

218

223

225

226

222

239 235

233

234

238

ti21046a

9. Use a flat head screwdriver and a rubber mallet to break loose the retaining nut (235).

10. Use channel lock pliers to remove the retaining nut (235).

11. Insert an allen wrench through the hole in the top of the piston rod (223) to lift the piston rod (223) up out of the manifold. This will also pull out the throat u-cup (234) and throat bearing (233).

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

13. Remove and discard piston u-cup (225) and bearing (226).

Reassembly (see F

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.

. 27):

3A2347T 51

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

. 28.

15B661

203

ti20877a

FIG. 28

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. 30

7. Remove seal installation tool.

8. Install retaining nut (235). See F

. 28.

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

. 29.

234

ti21047a

FIG. 29

9. Install air motor assembly (see F

. 27):

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).

52 3A2347T

Repair

Replace Pump Inlet Housing Checks

254

201

227

228

229 230

Reassembly (see F

. 31):

1. Install new o-ring (229), seat (228), and ball (227) then use a 1/2 in. drive ratchet without a socket to install and tighten foot valve (230) onto melter.

2. Install Melter Assembly. See page 56.

Replace Pump Cylinder Seals and Piston Seals

218

239

235

233 234

233

224

257

ti20749a

FIG. 31

Disassembly (see F

. 31):

1. Flush the system. See page 31.

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 Melter Assembly. See page 55.

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), and o-ring (229).

226

222

217

216

217

230

ti21048a

FIG. 32

Disassembly (see F

. 27):

1. Flush the system. See page 30.

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

. 27 on

page 51.

3A2347T 53

Repair

5. Remove air lines from relief valve (245) and air motor (218) See F

. 27 on page 51.

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

place then remove melter shield. See F

. 27 on

page 51.

7. Remove air motor assembly. See F

. 27 on

page 51:

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

31.

Reassembly:

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

. 31.

1303

217

216

217

1302

203

11. Remove Melter Assembly. See page 55.

12. Use a 1/2 in. drive ratchet without a socket to remove foot valve (230) from bottom of melter outlet manifold (203).

13. Insert cylinder tool (1301) into bottom of melter outlet manifold (203). Use a rubber mallet to gently remove cylinder (216). See F

. 31.

1301

203

217

216

217

ti20880a

FIG. 33

ti21049a

FIG. 34

2. Place female cylinder installation tool (1302) into melter outlet manifold (203) to protect seals from sharp threads. See F

. 34.

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

. 31.

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).

5. Perform Install Melter Assembly on page 56.

6. Perform Reassembly portion of the Replace Throat

Seal, Throat Bearing, Piston Rod, Piston Seal, and Piston Bearing procedure which starts on

page 51.

54 3A2347T

Repair

Melter

Remove Melter Assembly

3. Turn main power switch OFF.

4. Disconnect all heated hoses from the melter outlet manifold (203).

5. Remove cable from ADM (30) then slide forward the shroud (29) and remove it from the system.

6. Remove screws (8) then remove electrical enclosure front access door (10).

7. Remove the air tube (36) from the relief valve (245). Pull the air tube from the metal shroud (27).

8. Remove nuts (3) on the back metal shroud (27) then remove shroud.

9. Loosen hose clamp on air motor bracket (528) then remove funnel (61).

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

11. Remove insulators (52, 53) from the melter assembly (5).

12. Disconnect the fill sensor cable from the fill sensor (20).

259

ti21050b

FIG. 35

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 30

then wait for system to cool.

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

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

14. Remove the air tube from the fill cap (62).

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

16. Loosen screw (AA) then remove sensor (125). See F

. 36 on page 57.

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

18. Remove all heater wires from the following terminals. Pull wires up through the rubber grommet on the top of the electrical enclosure (1). See F

. 36

on page 57 for references.

Item

Wire Marking 1

Wire Marking 2

Band Heater (208) TB1-11B TB1-13B

Melter Heater Rod

TB1-14C CR1-NC

(209)

Base Heater Rod (210) TB1-11C TB1-13C

Pump Heater Rod

TB1-12B CR1-COM

(250)

3A2347T 55

Repair

19. Remove four nuts (3) then remove melter assembly from system. Save any loose insulators for reassembly.

20. Remove bolts (259) then remove melter assembly from melter base (257).

Install Melter Assembly

1. Route melter heater rod (209) wire through large hole in the melter base (257) then through small hole in side of melter base (257).

2. With the 10 insulators (4) in place on the melter assembly, place melter assembly on melter base (257).

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 melter assembly to melter base (257).

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

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. See F

. 36 on page 57 for references.

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

7. Connect air tube to fill cap (62).

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

9. Connect pump cycle sensor cable to air motor.

10. Install funnel (61) into air motor bracket (528) then tighten clamp.

11. Install temperature sensor (125) into melter then tighten screw (AA) on band heater. See F

. 36 on

page 57.

12. Install insulators (52, 53) onto the melter assembly (5).

13. Connect wire connectors to the over-temperature switch (251). See F

. 38 on page 59.

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

15. Pull the relief valve air tube (36) through the metal housing then attach air tube to relief valve (245).

16. Install front access door (10) onto electrical enclosure (1).

17. Feed ADM cable through shroud then install shroud and connect cable to ADM.

18. Reconnect all heated hoses to the melter outlet manifold (203).

19. Turn main power switch ON.

20. Open system air inlet ball valve.

Item

Wire Marking 1

Wire Marking 2

Band Heater (208) TB1-11B TB1-13B

Melter Heater Rod

TB1-14C CR1-NC

(209)

Base Heater Rod (210) TB1-11C TB1-13C

Pump Heater Rod

TB1-12B CR1-COM

(250)

56 3A2347T

Repair

Replace Band Heater

125

208

8. Loosen band clamps (CC) then slide fill cap (62) and rubber housing off melter.

9. Loosen screw (AA) then remove sensor (125).

10. Locate the wires in terminal blocks TB1-11B and TB1-13B. Loosen terminal block screws and remove wires.

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

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

Reassembly (see F

. 36):

1. Install band heater (208) on the melter with the opening and screw facing the front of the system in alignment with the sensor port.

2. Install sensor (125).

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

NOTE: Band heater should be oriented to hold sensor in place when tightened. It should not bend the sensor.

ti20753a

FIG. 36

Disassembly (see F

. 36):

1. Loosen clamp on air motor bracket (528) then remove funnel assembly (61).

2. While looking through the hole in the fill cap, dispense until the fluid level in the melter is at or below the honeycomb grid.

3. Once the fluid level is low enough, close the bleed-type ball valve installed at the system air inlet.

4. Turn main power switch OFF.

5. Disconnect cable from ADM (30) then remove shroud (29).

6. Remove front access door (10) from electrical enclosure (1).

7. Remove fabric melter insulator (53).

4. Route band heater wires through grommet (63) in the top of the electrical enclosure (1).

5. Connect wires to terminals as marked. Wires should be marked as shown in the following table. Tighten terminal block screws.

Item

Wire Marking 1

Wire Marking 2

Band Heater (208) TB1-11B TB1-13B

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

. 36.

7. Install fabric melter insulator (53).

8. Install fill cap (62) rubber housing with band clamps in place.

9. Install funnel into fill cap (62) then tighten band clamps (CC) on rubber housing.

10. Slide funnel assembly (61) through air motor bracket (528) then tighten clamp.

11. Feed ADM cable through shroud then install shroud and connect cable to ADM.

3A2347T 57

Repair

12. Open system air inlet ball valve.

13. Turn main power switch ON.

Replace Band Heater Temperature Sensor

125

ti20762a

FIG. 37

Disassembly (see F

. 37):

1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

9. Disconnect the temperature sensor cable from MZLP connector labeled J5. See F

. 37.

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

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

. 38 on page 59.

11. Pull cable out of the electrical enclosure then discard sensor (125) and wires.

Reassembly (see F

. 37):

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

. 38 on page 59.

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

. 36 on page 57.

2. Turn main power switch OFF.

3. Disconnect cable from ADM then remove shroud.

4. Remove air tube (36) from relief valve. Pull the air tube through the metal shroud (27).

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

6. Remove fabric melter insulator (53).

7. Loosen screw (AA) then remove sensor (125).

8. Remove electrical enclosure access door (10).

7. Install fabric melter insulator (53).

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

9. Route relief valve air tube through the metal shroud then attach to the relief valve.

10. Feed ADM cable through shroud then install shroud and connect cable to ADM.

11. Turn main power switch ON.

12. Open system air inlet ball valve.

58 3A2347T

Repair

Replace Heater Over-Temperature Switch

251

255

ti21052a

FIG. 38

Disassembly (see F

. 37):

1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

2. Turn main power switch OFF.

3. Disconnect cable from ADM then remove shroud.

6. Open system air inlet ball valve.

7. Turn main power switch ON.

Replace Heater Rod

206

250

210

206

ti20755a

4. Remove air tube (36) from relief valve. Pull the air tube through the metal shroud (27).

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

. 37):

1. Use the two screws (255) to secure the new over-temperature switch (251) to the melter.

2. Connect wire connectors to new over-temperature switch.

3. Use 7/16 in. socket to install nuts (3) to secure metal shroud (27).

4. Route relief valve air tube (36) through the metal shroud then attach to the relief valve.

5. Feed ADM cable through shroud then install shroud and connect cable to ADM.

209

206

209

ti20754a

FIG. 39

Disassembly (see F

. 39):

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 55.

3. Disconnect cable from ADM then remove shroud (29).

4. If removing the pump heater rod (250):

a. Remove the air tube (36) from the relief

valve (245). Pull the air tube through the metal shroud (27).

3A2347T 59

Repair

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

5. Remove electrical enclosure front access door (10). See F

. 36.

6. Disconnect heater rod wires from terminal blocks described in the following table.

Item

Melter Heater Rod

Wire Marking 1

TB1-14C CR1-NC

Wire Marking 2

(209)

Base Heater Rod (210) TB1-11C TB1-13C

Pump Heater Rod

TB1-12B CR1-COM

(250)

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, or 250).

Reassembly (see F

. 39):

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.

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

244

245

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

. 39.

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

. 36.

4. If replacing the melter heater rod (209), Install Melter Assembly. See page 55.

5. If replacing pump heater rod (210 or 250), 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).

ti20757a

FIG. 40

1. Drain the System. See page 30.

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

. 40.

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

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

. 40.

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.

60 3A2347T

Repair

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

. 40. 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.

3A2347T 61

Repair

Multi-Zone Low Power Temperature Control Module (MZLP)

Replace MZLP Fuse

MZLP Identification

24R234 24V510

Key

A F1 and F2 fuses are physically the same size as F3-F10 F1 and F2 fuses are physically larger than F3-F10

B --- Blue sticker on relay

C Marked 24N568 Marked 24V133

Fuse Part

F10

24R234 MZLP Fuses

F1, F2 250VAC, 16A, fast acting, white

F3-F10 250VAC, 8A, fast acting

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

WLD

FIG. 41: MZLP ID and Fuse Locations

24P859 24R234 Includes standard clear fuses.

24X479 Includes ceramic fuses used for

food industries.

NOTICE

To prevent system damage, always use fast acting fuses. Fast acting fuses are required for short-circuit

24V289 24V510 Includes standard clear fuses.

24X480 Includes ceramic fuses used for

food industries.

protection.

1. Turn main power switch OFF.

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

62 3A2347T

Repair

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.

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).

Replace MZLP

Use See MZLP Identification, page 62.

Disassembly:

1. Turn main power switch OFF.

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

. 42.

6. If replacing MZLP #1, remove the daughter card and standoffs, and re-install them on the new MZLP. See F

. 42 for MZLP #1 and MZLP #2 identifica-

tion.

Reassembly:

1. Set MZLP rotary switch to “1” on MZLP with daughter card. Set MZLP rotary switch to “2” on MZLP without daughter card. See F

. 43 for rotary switch

location.

2. Use four screws (114) to install MZLP (112) to electrical enclosure (1).

3. 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 72.

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

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

3. Disconnect heated hose electrical connectors from MZLP (112).

4. Note location of each cable, then unplug all cables from the MZLP (112) that will be replaced. See F

43.

ti20910a

MZLP #2

MZLP #1

112

114

FIG. 42

5. Connect heated hose electrical connectors to new MZLP.

NOTE: MZLP may need updated software. See Software Update Procedure on page 71.

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). See F

. 43.

3A2347T 63

Repair

4. Remove four mounting screws (112b) from daughter card (112a) and set aside. See F

. 43.

112b

112a

ti20342a

112

Rotary Switch

FIG. 43

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

Reassembly:

1. Plug new daughter card (112a) into the MZLP (112).

2. Use screws (112b) to secure daughter card to MZLP (112).

System

Replace Fill Sensor

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 72.

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

ti20761a

FIG. 44

Disassembly (see F

. 44):

1. Turn main power switch OFF.

2. Gently pull up on cable while unscrewing fill sensor connector then remove fill sensor cable from fill sensor (20).

3. Loosen fill sensor jam nut then remove fill sensor (20) from fill cap (62).

Reassembly (see F

. 44):

1. Thread new fill sensor (20) into fill cap (62). Bottom out the sensor in the fill cap then back out 1/2 turn.

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

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

64 3A2347T

Repair

Replace Fill Cap

7. Loosen upper clamp (13) on rubber housing then remove fill cap (62).

Reassembly (see F

. 45):

1. Place new fill cap on melter. Align funnel inlet hole with bracket.

2. Install funnel through air motor bracket (528) then tighten funnel clamp.

3. Tighten rubber housing clamp (13) to secure fill cap in place.

4. Connect air line (35) to fill cap (62).

5. Thread fill sensor (20) into fill cap (62). Bottom out the sensor in the fill cap then back out 1/2 turn.

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

Replace ADM

ti20760a

FIG. 45

Disassembly (see F

. 45):

1. Turn main power switch OFF.

2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

3. Disconnect cable from ADM then remove shroud.

4. Loosen hose clamp on air motor bracket (528) then remove funnel assembly.

5. Loosen fill sensor jam nut then remove sensor (20) from fill cap (62).

6. Remove air line (35) from fill cap (62).

ti20763a

FIG. 46

1. Turn main power switch OFF.

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

. 46.

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 71.

3A2347T 65

Repair

Air Controls

Replace Air Control Solenoids

402

FIG. 47

405

Reassembly (see F

. 47):

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

. 47, 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. Install electrical enclosure front access door.

Replace Air Control Gauge

ti20764a

403

403b

403a

403c

NOTE: In order to replace the air control solenoids, the system must be tipped back to access underneath the electrical enclosure.

Disassembly (see F

. 47):

1. Turn main power switch OFF.

2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

3. Remove front access panel (10) from electrical enclosure (1).

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

5. Note location of each air line connection.

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

. 47, in bottom of electrical enclosure then disconnect air lines from air control solenoids (402).

7. Disconnect air control solenoids cable from MZLP

daughter board connector J13. Pull wire out of the electrical enclosure.

8. Remove two screws (405) securing solenoids (402) to air control assembly (9) then remove air control solenoids.

402

ti20765a

FIG. 48

Disassembly (see F

. 48):

1. Turn main power switch OFF.

2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

3. Remove two screws (8) then slide air control assembly (9) out from electrical enclosure (1) so the back of the gauges are exposed.

4. Remove two nuts (403a) securing gauge (403) in place then remove bracket (403c).

5. Place one small crescent wrench on the brass part of the gauge then use a second small crescent wrench to remove the air fitting (403b).

66 3A2347T

Repair

6. Remove air gauge from panel.

Reassembly (see F

. 48):

1. Slide new air gauge into panel and slide the bracket onto the back of the gauge. Install air fitting onto the gauge by hand, do not tighten yet.

2. Install bracket (403c) then install two nuts (403a) finger tight.

3. Place one small crescent wrench on the brass part of the gauge then use a second small crescent

wrench to tighten the air fitting (403b).

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.

2. Turn main power switch OFF.

3. Use 10 mm socket to remove air motor pilot valve (513) from air motor (218).

4. Lubricate with grease and install new air motor pilot valve (513).

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

Replace Air Valve

508

527

509

Air Motor

Replace Pilot Valve

218

513

ti20767a

FIG. 49

1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

218

ti20768a

FIG. 50

Disassembly (see F

. 50):

1. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.

2. Turn main power switch OFF.

3. Loosen clamp on air motor bracket (528) then remove funnel assembly (61).

4. Loosen upper hose clamp on rubber housing then remove fill cap.

3A2347T 67

Repair

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 (508) securing air valve (527) to air motor (218).

9. Remove air valve (527) and seal (509) then discard.

Reassembly (see F

. 50):

1. Lubricate with grease then place new air valve seal (509) onto air valve (527).

2. Carefully place new air valve (527) against air motor then thread in the four screws (508). Ensure the air valve seal (509) stays in place by applying constant pressure against the air motor.

Remove Air Motor

218

238

220

240

211

239

219

3. Use 10 mm socket to torque screws (508) 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.

ti20758a

FIG. 51

See F

. 51.

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

. 40 on page 60.

4. Remove three nuts (3) securing metal shroud (27) in place then remove metal shroud (27).

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

6. Remove air motor assembly:

a. Slide retaining ring (239) down.

b. Remove dowel pin (238).

c. Remove three screws (240).

68 3A2347T

Repair

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

. 51.

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

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

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

rods (220) to base plate (219).

2. Connect air motor assembly to system:

a. Install three screws (240) 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

. 40 on page 60.

Replace Air Motor Piston O-Ring

511

512

520

501

504

523

506

505

ti20766a

510

FIG. 52

Disassembly (see F

. 52):

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. Remove Air Motor, page 68.

4. Use 10 mm socket to remove four screws (511) to remove air manifold assembly (520). See F

. 52.

5. Use 13 mm socket to remove two bolts (512) then remove air motor top cap (510).

6. Remove and discard piston o-ring (504) from piston (519).

Reassembly (see F

. 52):

1. Lubricate all seals with grease.

2. Install new piston o-ring (504) onto piston (519).

NOTICE

Carefully reassemble air motor to prevent damage to seals.

3. Reassemble remaining air motor parts, excluding air manifold assembly, then install two bolts (512) finger tight.

3A2347T 69

Repair

4. Use four screws (511) to install air manifold assembly (520) onto air motor finger tight to align cover (506).

5. Torque two bolts (512) incrementally to 11-13 ft-lb (15-18 N•m) to ensure top and bottom cap seals (505) seat properly.

6. Torque four air manifold screws (511) to 95-105 in-lb (10.7-11.9 N•m).

7. Install Air Motor, page 69.

Replace Air Motor Throat Seals

NOTE: This procedure uses adhesive that requires a

12-hour system idle time for full cure. If possible, perform this procedure at the end of the day or week so it can cure overnight or over the weekend while the system does not need to run. Otherwise, keep a spare air motor on hand so it can be used while the adhesive cures.

511

512

4. Remove four screws (511) to remove air manifold assembly (520).

5. Remove two bolts (512) then carefully remove air motor base cap (501) from the rest of the air motor assembly.

6. Disconnect rod (223) from air motor piston (519) then remove rod from air motor base cap (501).

7. Remove retaining ring (517) from base cap (501)

8. Remove two u-cup throat seals (507) from throat of air motor base cap (501) and discard seals.

Reassembly (see F

. 53):

1. Apply water-resistant grease to new u-cup seals (507) then install seals into throat of air motor base cap (501).

2. Install retaining ring (517) in base cap (501).

3. Carefully insert rod (223) into air motor base cap.

4. Apply high strength adhesive, supplied with kit, to rod threads then connect rod (223) to air motor piston (519). Torque to 35-40 ft-lb (47-54 N•m).

520

223

507

501

502

507

517

519

ti20769a

FIG. 53

Disassembly (see F

. 53):

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. Remove Air Motor, page 68.

NOTICE

Carefully reassemble air motor to prevent damage to seals.

5. Reassemble remaining air motor parts, excluding air manifold assembly, then install two bolts (512) finger tight.

6. Use four screws (511) to install air manifold assembly (520) onto air motor finger tight to align cover (506).

7. Torque two bolts (512) incrementally to 11-13 ft-lb (15-18 N•m) to ensure top and bottom cap seals (505) seat properly.

8. Torque four air manifold screws (511) to 95-105 in-lb (10.7-11.9 N•m).

9. Install Air Motor, page 69.

10. Prior to using system, wait 12 hours for adhesive used in step 4 to fully cure.

70 3A2347T

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

. 54: 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

. 55: 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.

3A2347T 71

Electrical Schematics

To prevent electric shock and system damage, all electrical work must be performed by a qualified electrician.

Incoming Power and Terminal Jumpers

NOTICE

To prevent severe system damage, ensure terminal jumpers are installed correctly. See Connect Electri- cal Cord on page 19.

The incoming power and terminal jumpers are specific to the phase and voltage used. The power type and circuit breaker size must be correctly set in the ADM. See Select ADM Settings on page 21.

If changing power type, use the supplied hard metal 2, 3, and 5 terminal jumpers and screws and supplied jumper wire to jumper the terminals. See Connect Elec- trical Cord on page 19 for detailed information about changing terminal jumper locations.

72 3A2347T

Systems with One MZLP Module

ADM

Level

Sensor

16T108

Solenoid

Optional Light Tower

RTD

16T103

Cycle Switch

Over-Temp

Switch

24R040

Electrical Schematics

16T089

Green

16T088

Red

PS1

24R042

MZLP 1

24V510

Black

16T200

CR1

COM

16T199

CHANNEL 1

Gun

Hose

Over-

Temp

Heater

GND

T°

RTD

Gun

Hose

RTD

Over-

Heater

Hose

Heater

Temp

GND

T°

RTD

Gun

Hose

CHANNEL 2

RTD

Gun

GB1

500W

Melter

24R034

GND

Pump

24R037

1500W

Band

24R039

1250W

Base

24R036

1000W

3A2347T 73

Electrical Schematics

Systems with Two MZLP Modules

Green

Red

ADM

16T201

16T089

MZLP 2

24V510

CHANNEL 3

Over

Gun

Heater

Hose

Heater

Temp

GND

T°

Gun

Hose

GND

Over

Temp

T°

Gun

Heater

Hose

Heater

Gun

T°

RTD

Hose

CHANNEL 4

RTD

Over-

Temp

Switch

16T087

Sensor

Level

16T108

Cycle Switch

16T103

24R040

BDFHK

ACEGJ

BDFHK

Solenoid

24R029

Optional Light Tower

MZLP 1

24V510

Black

24R042

16T088

PS1

16T200

CR1

16T199

COM

CHANNEL 1

Hose

Over-

Temp

Gun

Heater

GND

T°

Gun

Hose

GND

Over-

Temp

Gun

Heater

Hose

Heater

T°

RTD

T°

Gun

Hose

CHANNEL 2

RTD

GB1

Melter

500W

GND

24R034

74 3A2347T

Systems with Three MZLP Modules

Electrical Schematics

16W035

(16T089)

(16T088)

DRN

(24V510)

L1L2L3

MZTCM 1

(16T200)

MZTCM 3

(24V510)

SOLENOID J13-2,4

LEVEL SENSOR J14-1, 2, 4

(16T108)

(24P011)

-V

(24R042)

(16T199)

J12

J14

J13

CYCLE SWITCH J16-1, 4, 5

(16T103)

J16

J15

(16T106)

RTD Input

OT Input

(16T087)

(24V510)

MZTCM 2

(16T087)

(16W034)

(16T201)

-V

PS1

LNG

345

678

CR1

COM

TERMINAL BLOCK

NEU

3A2347T 75

Parts

InvisiPac Systems

System Parts, Page 1 of 3

30 58 29 8, 75 74, 82

8, 75

ti20732a

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

Apply pipe sealant to all non-swiveling pipe threads.

Orient as shown.

76 3A2347T

System Parts, Page 2 of 3

Torque to 5-11 ft-lb (7-15 N•m).

Apply door gaskets (11) to door (10).

Torque to 8-10 in-lb (0.9-1.1 N•m).

Parts

61a

40, 54

ti20733b

3A2347T 77

Parts

System Parts, Page 3 of 3

35 41 in. (1.04 m)

33 16 in. (0.41 m)

57 34 48 in. (1.22 m)

41 in.

(1.04 m)

13 in.

(0.33 m)

7 in.

(0.18 m)

2 in.

(0.05 m)

23 in.

(0.58 m)

41 in.

(1.04 m)

2 in.

(0.05 m)

48 in.

(1.22 m)

WLF

78 3A2347T

Parts

System Parts

Ref Part Description

1 --- ENCLOSURE, electrical 3 115942 NUT, hex, flange head 4 167002 INSULATOR, heat; washer 5 24R375 MELTER AND PUMP 7 --- TRAY, drip 8 113161 SCREW, flanged, hex head 9 --- AIR CONTROLS ASSEMBLY 10 --- DOOR, front 11 --- FOAM, border, door 12* --- ADAPTER, melter inlet 13* --- CLAMP, hose, spacer 20 24R041 SENSOR, ultrasonic 22 --- SHAKER AND TUBE, feed system 24 116658 FITTING, tube, male, 1/4 npt 25◆ --- SWITCH, cycle 26◆ --- FASTENER, screw, pn hd M4 x 35 mm 27 --- BRACKET, back 28 --- COVER, filter 29 --- COVER, melter 30❄ 24P860 MODULE, Advanced Display (ADM) 31 117026 SCREW, socket head cap, M5 x 12 32† 112739 TEE, union 33† C12509 TUBE, nylon, round 34† --- HOSE, nylon, 3/8 in. OD, 250 psi (1.7

MPa, 17 bar) 35† 598095 TUBE, 5/32 in. OD, nylon 36† --- TUBE, PTFE, 1/4 in. OD 39 --- GROMMET, 1/4 in. ID 40 --- BUSHING, strain relief 41 --- GROMMET, wire 42 --- GROMMET, tube 43▲ 16U029 LABEL, safety 44 --- LABEL, InvisiPac 45 --- LABEL, pressure gauges 48 110932 CONNECTOR, male 49 C38321 STRAP, tie, cable 52 16T675 INSULATOR, melter manifold 53✖ 16T677 INSULATOR, melter 54 --- NUT, bushing 55 --- LABEL, identification 57 --- COUPLER, 3/8 in. OD tubing 58 --- BRACKET, mounting 61 24R738 FUNNEL, inlet, feed 61a 110932 CONNECTOR, male 62* --- MANIFOLD, feed inlet 63 121487 GROMMET, sheet metal, 3/4 in. 64 198177 FITTING, connector, male 65 --- FITTING, tee, 1/8 npt x 3/8 in. tube x

3/8 in. tube 66 --- RESTRICTOR, air, 0.0225 in. orifice 67 101976 TOOL, allen, wrench 68 255021 FITTING, straight, hydraulic

(assemblies 24P260, 24P262, 24P264

only; Qty 2)

(assemblies 24P261, 24P263, 24P265

only; Qty 4)

(assemblies 24U132, 24U133, 24U133

only; Qty 6)

Qty

3.25

4.92

6.75

1.3

Ref Part Description

69 114606 PLUG, hole 70 24R324 SOFTWARE UPGRADE TOKEN, Invi-

1 8

74 117126 SCREW, socket head cap, M5 x 16

75 16V153 WASHER, retaining

80 262907 FUNNEL SCREEN KIT (not shown)

82 117017 WASHER 83 16V540 INSULATOR, melter assembly

85 24V289 MZLP FUSES KIT (not shown)

86 24P176 I/O CONNECTOR KIT (not shown)

87 108982 CONNECTOR, tube

88 24R707 AIR INLET KIT

89 114271 RETAINING STRAP

1 1 1 1 1 1 1

92 127208 FITTING, tee, 6 JIC x 6 JIC x 9/16-18

1 1 2

93 FITTING, 45° elbow, hydraulic

94 116793 FITTING, elbow, hydraulic, 9/16-18 x

1 2 1 1 1 1 1

--- Not for sale.

▲ Replacement Danger and Warning labels, tags, and cards

1 1 2 1 1 1 1 1 1 3 2 1

2 1

are available at no cost.

❄ ADM does not come with software. Order software token

24R324.

Available kits (purchase separately):

Kit Description Includes

24R885◆ Cycle Switch 25, 26 24R028* Inlet housing 12, 13, 62 24R030† Tubing 32, 33, 34, 35, 36, 304. See

24R031✖ Melter 53, 202, 204, 207, 211, and

24U635 Acrylic Lens

siPac System

(assemblies 24P260, 24P262, 24P264 only; Qty 8) (assemblies 24P261, 24P263, 24P265 only; Qty 16) (assemblies 24U132, 24U133, 24U133 only; Qty 24)

(assemblies 24U132, 24U133, 24U133 only; Qty 2)

(assemblies 24P260, 24P262, 24P264 only; Qty 2) (assemblies 24P261, 24P263, 24P265 only; Qty 4) (assemblies 24U132, 24U133, 24U133 only; Qty 2)

9/16-18(assemblies 24P260, 24P262, 24P264 only; Qty 2) (assemblies 24P261, 24P263, 24P265 only; Qty 4) (assemblies 24U132, 24U133, 24U133 only; Qty 2)

Feed System Shaker and Tube, 24T812 on page 85 for

identification of item 304.

253. See Melter and Pump Parts on page 83 for identification of items 202-253.

Pressure Gauge

Qty

1 1

3 4 1 2 1 1 1 1 1

3A2347T 79

Parts

Electrical Enclosure

MZLP

113

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.

114

112

112a

113

118

MZLP 2

114

109

MZLP 3

106, 107

120 110

108

118

114

WLD

101

113

131

132

117

111

104

102

80 3A2347T

WLE

105

Parts

Electrical Enclosure Parts

Ref Part Description Qty

101 --- CABINET, controls 1 102 126807 MODULE, breaker 1 104 123970 SWITCH, disconnect, 40 amp 1 105 126839 CONTACT, n-pole 1 106 --- BUSHING, strain relief, M40 thread 1 107 --- NUT, strain relief, M40 thread 1 108 104641 FITTING, bulkhead 1 109 502937 FITTING, tee, 3/8 tube, 1/4 male

npt 110 114421 BUSHING, strain relief 1 111 117666 TERMINAL, ground 1 112* --- MODULE, MZLP with Daughter

Board 112a 24R042 MZLP DAUGHTER BOARD 1 113†✿16T440 CAP, jam nut, sealing

(1 MZLP assemblies only; Qty 2)

(2 MZLP assemblies only; Qty 4)

(3 MZLP assemblies only; Qty 6)

114 125856 SCREW, 8-32, serrated flange 12 116 24P175 PLATE, blank, single MZLP

(1 MZLP assemblies only; Qty 2)

(2 MZLP assemblies only; Qty 1)

117 115942 NUT, hex, flange head 1 118†✿✖24V510 MODULE, GCA, MZLP

(2 MZLP assemblies only; Qty 1)

(3 MZLP assemblies only; Qty 2)

119 --- GASKET, foam, MZLP

(1 MZLP assemblies only; Qty 2)

(2 MZLP assemblies only; Qty 1)

120 196762 PIN, straight 1 121†✿16T087 CABLE, board, male/male, 4 in.

(101 mm)

(2 MZLP assemblies only; Qty 1)

(3 MZLP assemblies only; Qty 2)

122 16T088 CABLE, power, male/wire 1 123 16T089 CABLE, CAN, male/female, 1 m 1 124 16T103 CABLE, pump 1 125◆ 16T106 SENSOR, band heater temperature 1 126 16T108 CABLE, ultrasonic, M12-4p, 1 m 1 129†✿16T201 HARNESS, 2nd MZLP

(2 MZLP assemblies only; Qty 1)

(3 MZLP assemblies only; Qty 1)

130 114958 STRAP, tie 4

Ref Part Description Qty

131 113974 SCREW, machine, slotted hex

washer head 132 123967 KNOB, operator disconnect 1 133 24P176 KIT, Customer I/O connector 1 134✿ 16W034 HARNESS, 3rd MZLP 1 135✿ 16W035 CONNECTOR, jumper 1

--- Not for sale.

Available kits (purchase separately):

Kit Description Includes

24R237† Upgrade from 2

channel system to 4 channel system

113, 118, 121, 129, a grounding wrist strap, and a software upgrade token. See 4 Channel Upgrade Kit, 24R237 on page 96.

24U575✿ Upgrade from 4

channel system to 6 channel system

113, 118, 121, 129,134, 135, grounding wrist strap, and a software upgrade token. See 6 Channel Upgrade Kit, 24U575 on page 98.

24R040◆ RTD 125, 251, and 255. See

Melter and Pump Assembly, 24R375 on page 82.

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

Qty 2 - 16 Amp, 250V Fuses

24P176 Customer I/O

Connectors

2 connectors for connecting to H1 and H2 on MZLP daughter board. Use for PLC connection.

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

separately.

✖ Use Blank Plate Kit (116) if removing MZLP (118).

3A2347T 81

Parts

Melter and Pump Assembly, 24R375

208

211

204

202

205

207

215

253

213

206

210

201

249

257

258

209

206

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).

236

238

254

259

206

260

232

237

250

249

214

252

247

Torque to 24-30 ft-lb (33-41 N•m).

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

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

242

218

239

235

233

234

220

240

219

211

252

203

251

255

246

245a

243

244

245

Torque to 12-18 ft-lb (16-24 N•m).

ti20739b

217

216

217

223

224

225

226

222

221

227 228

229 231

232

230

82 3A2347T

Parts

Melter and Pump Parts

Ref Part Description Qty

❄

201

--- MANIFOLD, melter base 1 202✖ --- MELTER 1 203• --- MANIFOLD, outlet 1 204✖ --- PLATE, mounting 1 205 --- HOUSING, heater 1 206• 111317 RING, retaining, internal 3 207✖ 126475 O-RING, FKM, 157 1 208 24R039 HEATER, band 1 209 24R034 HEATER, fire rod, 500 watts 1 210 24R036 HEATER, fire rod, 1000 watts 1 211✖ 116940 SCREW, cap, sh, 5/16-18, 0.5 in.

long

213 24R369 INLET FILTER 1

❄

214•

112855 PACKING, o-ring 1 215 24T297 PLUG, o-ring boss 1 216‡• --- SLEEVE, cylinder 1 217†‡• 108526 PACKING, o-ring, PTFE 2 218✓ 24R025 MOTOR, air, 2.5 in., 0.48 in.

stroke, high temperature 219 --- PLATE, pump adapter 1 220 --- ROD, tie 3 221• 192624 GUIDE, ball 1 222◆• 239932 VALVE, piston 1 223◆• --- ROD, piston 1 224†◆• 105444 BALL, 0.3 in. 1 225†◆• --- SEAL, u-cup, piston 1 226†◆• --- BEARING, piston 1 227†• 105445 BALL, 0.5 in. 1 228†• 192642 SEAT, carbide 1 229†• 107079 PACKING, o-ring 1 230• --- HOUSING, foot valve 1 231• 105802 PACKING, o-ring 1 232†❖• 113944 PACKING, o-ring 2 233†• --- BEARING, throat 1 234†‡• --- SEAL, u-cup, throat 1 235• 193046 NUT, packing 1 236❖• --- FILTER, assy, 100 mesh 1 237❖• 15K234 PACKING, o-ring 1 238✓ 196762 PIN, straight 1 239✓ 196750 SPRING, retaining 1 240 101864 SCREW, socket head cap,

5/16-18, 1.0 in long 242★• 117059 O-RING, fluoroelastomer 1 243★• 16W327 RETAINER, seat, dump valve 1 244★• 15Y627 PACKING, o-ring #2-116, PTFE 1 245★• --- VALVE, relief 1 245a 126474 FITTING, push to connect 1 246• 121295 SCREW, cap, socket head,

5/16-18, 2.5 in. long 247• 15H304 FITTING, plug 9/16 in. SAE 5

Ref Part Description Qty

249 167002 INSULATOR, heat 10 250• 24R037 HEATER, fire rod, 1500 watts 1 251**• --- SWITCH, over temperature 1

❄

252•

--- INSERT, helical 7 253✖ --- PLATE, melter 1 254 558722 O-RING, 910 1 255**• 107388 SCREW, machine, panhead,

#4-40, 3/8 in. long 256 --- LUBRICANT, grease 1 257 --- BRACKET, melter 1 258 --- GROMMET, 1/4 in. ID 1 259 115506 SCREW, machine, hex washer

head, 1/4-20, 3.0 in. long 260 115814 WASHER, flat 3 297* 120663 FITTING, straight, hydraulic 1 298* 126961 FITTING, 45 deg. elbow, hydraulic 1 299* 116793 FITTING, 90 deg. elbow, hydraulic 1

* Not shown or assembled. Quantity equals number of chan-

nels the unit supports.

--- Not for sale.

Available kits (purchase separately):

Kit Description Includes

24P852† Pump repair 217, 224, 225, 226, 227, 228,

229, 232, 233, 234, and seal installation tool 15B661.

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

lation tool 15B661. 24P854◆ Pump rod 222, 223, 224, 225, 226 24P855❖ 100-mesh filter 232, 236, 237 24P856★ Pressure relief

valve 24R025✓ Air motor 218, 238, 239 24R031✖ Melter 202, 204, 207, 211, 253, and

24R040** RTD 125, 251, and 255. See Elec-

24R709 • Assembled pump

manifold

24W594❄ Melter base kit 201, 214, 254, 252 24W595 Filter rebuild kit See Filter Rebuild Kit,

--- Special tools See Special Tools on page

242, 243, 244, 245

insulator (53). See InvisiPac Systems parts starting on page 76 for insulator (53) identification.

trical Enclosure on page 80. 203, 206, 214, 216, 217, 221,

222, 223, 224, 225, 226, 227, 228, 229, 230, 231, 232, 233, 234, 235, 236, 237, 242, 243, 244, 245, 246, 247, 250, 251, 252, 255

24W595, page 103

89.

3A2347T 83

Parts

Air Motor, 24R025

Torque to 11-13 ft-lb (15-18 N•m).

Apply water-resistant grease.

Apply epoxy adhesive then torque to 35-40 ft-lb (47-54 N•m).

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

528

511

527

511

520

522

508

509

513

2 4

512

518

507

503

502

523

506

513

2 4

510

24R025 Parts

Ref Part Description Qty

501 --- COVER, lower, 2.5 in. 1 502◆ 108993 PACKING, o-ring 2 503 --- BEARING, 9/16 in. 1 504★◆ --- PACKING, o-ring, FKM 1 505 15M289 CYLINDER, motor, 2.5 in. 1 506 --- COVER, air motor 1 507◆ --- SEAL, u-cup, FKM 2 508◆ --- GASKET, cover, small 2 509†◆ --- SEAL, air valve, manifold 1 510 15M291 COVER, motor, 2.5 in. 1 511† --- SCREW, M6 x 25, thread forming 8 512 15M314 SCREW, cap 2 513 24R027 VALVE, pilot 2 515 15M213 MUFFLER, 3/8 1 516 --- GREASE, water-resistant 1 517◆ --- RING, retaining 1 518★ --- ROD, air motor, 2.5 in. 1 519★ --- PISTON, air motor, 2.5 in. 1

501

507

517

519

504

502

505

ti20903a

Ref Part Description Qty

520 --- MANIFOLD, medium, short 1 521★◆ --- ADHESIVE 1 522 105444 BALL, 0.3 in. 4 523 --- LABEL, identification 1 527† 24R026 VALVE, air, small 1 528 --- BRACKET, feed inlet assembly 1

-- Not for sale.

★ Included in Air Motor Piston Kit 24R705 (purchase sepa-

rately.

◆ Included in Air Motor Seals Kit 24R706 (purchase separately).

† Included in Air Motor Valve Kit 24R026 (purchase sepa-

rately).

515

84 3A2347T

Feed System Shaker and Tube, 24T812

301

Parts

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

--- Not for sale.

304

† 30 ft (9.1 m) Feed Hose Kit 24R043 also available

(purchase separately). Kit also includes 2 hose clamps.

★ Included in Tubing Kit 24R030. See System Parts

on page 79 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).

ti20738a

3A2347T 85

Parts

Air Controls Assembly

405

402

404

401

403

Apply sealant to all non-swiveling pipe threads.

Air Controls Assembly Parts --- Not for sale.

406

404

ti20737a

Ref Part Description Qty

401 --- PANEL, air, controls 1 402 24R029 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

86 3A2347T

Pressure Relief Valve, 24P856

607

606

614

601

605

611

608

Parts

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

613

Ref Part Description Qty

609† 110073 PACKING, o-ring 1 610 111841 WASHER, plain 5/8 in. 2 611† --- BEARING, valve 1 612† --- O-RING, FKM 1 613 126474 FITTING, push to connect 1 614† --- SEAL, u-cup, relief valve 1

--- Not for sale.

† Parts included in Relief Valve Repair Kit 24P857

(purchase separately).

3A2347T 87

Parts

Feed Inlet Funnel, 24R738

701

705

706

Ref Part Description Qty

701 262907 FILTER AND CAP ASSEMBLY 1 705 --- SCREW, #10-16, thread forming 2 706 --- FUNNEL, feed inlet 1

ti20927b

--- Not for sale.

88 3A2347T

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

3A2347T 89

Accessories

Non-Graco Gun Adapter Cables

16T916: For connecting to non-Graco guns that use a

rectangular, 6-pin connector.

ti21128a

16T917: For connecting to non-Graco guns that use a circular, 9-pin connector.

Air Adjustment Lock, 24R084

Panel enables locking access to the air adjustment screws.

801

ti21129a

16Y828: For connecting to non-Graco guns that use a circular 6-pin connector. IPx6 rated.

WLD

Non-Graco Gun Adapter Cable Installation

See Attach Components on page 14.

ti20984a

NOTE: Screws are part of the base system and are not included in the kit.

Ref Part Description Qty

801 --- PANEL, lock, air control 1 802 --- BRACKET, lock, air control 1

802

Air Adjustment Lock Installation

1. Remove screws from system air panel.

2. Use screws to install panel (801).

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

4. Insert lock through hole in panel and bracket to lock access to the air controls. Lock not included in kit.

90 3A2347T

Accessories

System Stand, 24R088

Use the stand to mount the system at eye level. When the system is mounted on the stand, the ADM is 45 in. (1.14 m) above the bottom of the stand.

1002

1001

1003

Adapter Plate, 24R083

Use this adapter plate to install InvisiPac in place of an existing hot melt applicator system.

Bolt Hole Dimensions

A 9.8 in. (249 mm) B 14.843-15.157 in.

(377.0-385.0 mm)

C 17.003-17.317 in.

(431.9-439.9 mm)

1101

1102

1104

ti20985a

Ref Part Description Qty

1001 --- STAND 1 1002 112395 SCREW flange head cap 3 1003 112958 NUT, hex, flanged 3

System Stand Installation

1. Place stand (1001) in desired location.

2. Use bolt holes to bolt stand in place.

3. Place system on stand.

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

Caster for Stand, 120302

Caster with friction post mounts directly to system stand using no extra hardware. Four required. Casters raise stand an additional

4.25 in. (108 mm).

1103

Ref Part Description Qty

1101 --- PLATE, adapter 1 1102 112395 SCREW flange head cap 6 1103 112958 NUT, hex, flanged 9 1104 121283 FITTING, elbow, 45 degree 1

ti21918a

Adapter Plate Installation

1. Remove existing hot melt applicator system.

2. Use six screws (1102) and six nuts (1103) to secure adapter plate (1101) through the existing holes from the previous system.

3. Align the InvisiPac system with the bolts on the adapter plate (1101) then place onto the adapter plate (1101).

4. Use the remaining three nuts (1103) to secure the InvisiPac system to the adapter plate (1101).

5. Use elbow fitting (1104) to install system air inlet filter (A, not included with kit).

3A2347T 91

Accessories

30 Gallon Vibrating Hopper, 24R136

Hopper includes a shaker to ensure the adhesive pellets maintain a level surface at all times. Without this, the adhesive pellets can stick together, preventing them from continuously covering the vacuum transfer system’s inlet. This would cause the vacuum transfer system to be unable to transfer the adhesive pellets.

Input Air Pressure Requirement: 100 psi (7 bar, 0.7 MPa) Air Consumption: 17.1 scfm (29.1 cubic meters per hour)

902

903

910

901

905

ti20928a

Ref Part Description Qty

901 --- HOPPER, 30 gallon 1 902 --- LID, hopper, 30 gallon 1 903 126930 SHAKER, ball vibrator 1 904 126929 VALVE, air pilot, 3-way, closed 1 905 --- BRACKET, shaker, container 1 907 --- HOSE, nylon, 3/8 in. OD, 250 psi

(1.7 MPa, 17 bar) 908 119798 CONNECTOR, tee, push-tube 1 909 113779 MUFFLER 1 910 111192 SCREW, cap flange head 2

903

907

Ref Part Description Qty

912 125857 SCREW, 10-24, serrated flange 4 914* 121141 FITTING, elbow, swivel, 3/8 in.

915 120389 FITTING, tube 2 916 --- CONNECTOR, tube, 90 degree 1 917 125539 FITTING, splitter, 3/8 in. OD tub-

--- Not for sale.

* Metric fitting included in Air Metric Fitting Kit,

24W637, page 103.

915

904

909

914*

tube connector, 1/4 male npt

ing

916

912

92 3A2347T

Accessories

30 Gallon Vibrating Hopper Installation

See FIG. 56 for illustration of installed vibrating hopper.

1. Turn main power switch OFF.

2. With the steel shaker rod fully assembled and the 3/8 in. OD air line connected to the shaker head, cut the 3/8 in. OD air line where the 1.3 in. clear vacuum transfer hose connects to the steel shaker rod.

3. Use the splitter fitting (917) to reconnect the 3/8 in. OD air line that was just cut.

4. Install the 48 in. section of 3/8 in. OD hose supplied with the kit into the remaining connection on the splitter fitting (917).

5. Connect the other end of the 48 in. section of 3/8 in. OD air line to elbow fitting (916) on the piloted air valve.

6. Connect shop air to elbow fitting (914) on the piloted air valve. Shop air must be capable of 100 psi (0.7 MPa, 7 bar).

NOTE: The air supplied to the pilot valve from the system vacuum must be set to 65% of the shop air supply supplied to elbow fitting (914) or higher. If the pilot valve air pressure is lower than this, increase the vacuum transfer air pressure regulator (E, see F

. 1 on page 8).

Splitter fitting

To piloted

air valve

To shaker

head

NOTE: The piloted air valve must use shop air. Adding a tee at the system inlet to run the hopper shaker may impact pump and vacuum transfer performance.

7. Place steel shaker rod assembly into hopper (901) with steel rod resting in the hopper groove in the rim of the hopper.

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

NOTE: The hopper shaker will be active while the vacuum transfer system is transferring pellets.

Hopper shaker

Piloted air valve

To shop air

supply

ti21350a

FIG. 56

3A2347T 93

Accessories

Light Tower Kit, 24R226

The light tower enables someone away from the system to quickly see whether the system is inactive or OFF (no lights), warming up (flashing green), at temperature (solid green), or has an active error (red).

1201

1201a

1203

1202

1205

24R226 Parts

Ref Part Description Qty

1201 16T102 LIGHT, tower, red and green 1 1201a --- SCREW 3 1202 --- GROMMET, single cable 1 1203 16K322 BRACKET, light tower 1 1204 --- GROMMET, multiple wires 1 1205 125835 CLIP, ferrite bead 1

1204

J12

F10

ti20987b

--- Not for sale.

94 3A2347T

Accessories

Light Tower Kit Installation

1. Turn main power switch OFF.

2. Disconnect cable from ADM, push cable through plastic shroud, then remove shroud from system.

3. Remove existing grommet (AA) from electrical enclosure then install new grommet (1204) in its place.

4. Insert grommet (1202) into hole on the light tower bracket (1203).

5. Remove bolts (BB) from metal shroud on the system then use the bolts (BB) to secure bracket (1203) to metal shroud.

6. Route light tower cable through hole in bracket (1203) then use supplied light tower screws (1201a) to install light tower (1201).

7. Remove electrical enclosure front access door.

Air Reservoir Kit, 16W366

This kit allows the system to operate as low as 60 psi (0.4 MPa, 4 bar).

1505

1503

1504*

1504

8. Route light tower cable through the other hole in the bracket (1203), then through the grommet (1204) into the electrical enclosure.

9. Connect light tower cable to MZLP connector labeled J12.

1505

1506

1501

16W366 Parts

Ref Part Description Qty

1501 --- HOSE, nylon (6 ft) 1 1502 100081 BUSHING, pipe 1 1503 113777 TEE, branch 1 1504* 114485 CONNECTOR, male, 3/8 npt 2 1505 155665 UNION, adapter 1 1506 --- TANK, air, accumulator 1

--- Not for sale.

* Metric fitting included in Air Metric Fitting Kit,

24W637, page 103.

3A2347T 95

Accessories

4 Channel Upgrade Kit, 24R237

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

1301

1305

Ref Part Description Qty

1301 --- MODULE, GCA, MZLP 1 1302 16T087 CABLE, jumper, male/male, 4 in. 1 1303 16T201 HARNESS, 2nd MZLP power 1 1304 112190 STRAP, wrist, grounding 1 1305 16T440 CAP, jam nut, sealing 2 1306 24R324 SOFTWARE UPGRADE

TOKEN, InvisiPac System

1302

1304

1306

ti20988a

◆ Not shown.

96 3A2347T

4 Channel Upgrade Kit Installation

Accessories

1. Disconnect plug from power outlet or turn off circuit breaker for incoming power.

2. Place grounding wrist strap (1304) over your wrist and secure other end to a grounded surface.

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

4. Set MZLP rotary switch to “2” on MZLP without daughter card.

5. Remove screws (BB) then remove plate (AA) from system.

6. Use screws (BB) to install MZLP (1301) onto system.

NOTE: The new MZLP (1301) with be referred to as MZLP 2, and the original MZLP that came with the system will be referred to as MZLP 1 from here on. See F

57.

Step 8: Move CAN Connector (DD).

7. Remove electrical enclosure front access door.

NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation.

8. Move CAN connector from MZLP 1 connector J3 to MZLP 2 connector J6. See F

. 57.

9. Move power cable (CC) from MZLP 1 connector J6 to MZLP 1 connector J3. See F

. 57.

10. Connect jumper cable (1302) to MZLP 1 connector J6 and connect other end of jumper cable (1302) to MZLP 2 connector J3. See F

. 57.

11. Connect wires from power harness (1303) to connectors as labeled on the plastic connector.

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

tor J2.

MZLP 2

MZLP 1

Step 9:

Move Power Cable (CC).

ti20989a1

Step 10: Install Jumper Cable (1302).

FIG. 57

3A2347T 97

Accessories

6 Channel Upgrade Kit, 24U575

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

1304

1308

WLD

1306

1303

1301

Ref Part Description Qty

1301 --- MODULE, GCA, MZLP 1 1302 16T087 CABLE, jumper, male/male, 4 in. 1 1303 112190 STRAP, wrist, grounding 1

1302

1307

1305

Ref Part Description Qty

1304 24R324 TOKEN, software upgrade 1 1305 16T440 CAP, jam nut, sealing 2 1306 16W034 HARNESS, MZLP #3 1 1307 16W035 CONNECTOR, jumper 1 1308 127208 FITTING, tee 2

98 3A2347T

6 Channel Upgrade Kit Installation

Accessories

1. Disconnect plug from power outlet or turn off circuit breaker for incoming power.

2. Place grounding wrist strap (1303) over your wrist and secure other end to a grounded surface.

3. Set MZLP (1301) rotary switch to “3”.

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

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

6. Remove electrical enclosure front access door.

NOTE: Do not force the electrical connection. Minimal force is required to seat the connector. If resistance is felt, stop and verify the connector orientation.

7. Move ADM CAN connector from MZLP 2 connector J6 to MZLP 3 connector J3. See F

. 58.

Step 8: Install jumper cable (1302).

8. Connect CAN jumper cable (1302) to MZLP 2 connector J6 and connect other end of jumper cable (1302) to MZLP 3 connector J6. See F

. 58.

9. Install jumper connector (1307) in J5 on MZLP 3.

10. Connect wires from power harness (1306) to connectors as labeled on the plastic connector.

11. Connect power harness (1306) to MZLP 3 connector J2.

12. Remove plugs (CC) from fluid manifold and replace with tee fittings (1308).

NOTE: The new MZLP (1301) will be referred to as MZLP 3, and the original MZLPs that came with the system will be referred to as MZLP 1 and MZLP 2 from here on. See F

. 58.

0=/3

-

-

$'0

-

Step 7: Move ADM CAN connector.

FIG. 58

-

-

-

-

-

-

-

0=/3

-

-

-

-

-

-

-

-

0=/3

-

-

-

WLD

3A2347T 99

Accessories

Single-Phase 480V to 240V Transformer, 24U169

This transformer must be installed by a qualified electrician to operate 240V InvisiPac units with single-phase 480V electrical supply.

NOTE: When using transformer 24U169, the ADM amp limit must be set to 30 amps and power type set to single phase. See step 4 of Select ADM Settings on page

21.

24U169 Electrical Specifications:

Phase: Single Frequency: 60 Hz kVa: 7.5 kVa K Rating: 1 Primary Config.: 2 winding Secondary Config.: 2 winding Winding material: Copper Connection: Wire leads

24U169 Mechanical Specifications:

Temperature Rise: 115°C (239°F) Insulation Sys.: 180°C (356°F) Cooling Sys.: Air/Dry Construction: Enclosed-encapsulated core and coil Enclosure: Steel, NEMA 3R

24U169 Approvals:

Approvals: UL listed, cUL listed, CSA approved Sound level: Below NEMA standards

24U169 Mounting Information:

24U169 Wiring:

Secondary

Primary Voltage

Voltage Taps

240 x 480 120/240 None

Primary

H1 H3 H2 H4

X4 X2 X3 X1

Secondary

Volts Connections Line Leads

480 H2 - H3 H1, H4

240 H1 - H3, H2 - H4 H1, H4

240 X2 - X3 X1, X4

240/120 X2 - X3 X1, X2, X4

120 X1 - X3, X2 - X4 X1, X4

10.2 in. (258 mm)

15.0 in. (381 mm)

1/4 in. (6 mm) Mounting Hardware Required

Weight: 150 lb (68 kg)

10.6 in. (270 mm)

100 3A2347T

8.0 in. (203 mm)

7.0 in. (178 mm)

Graco 3A2347T User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Required Tools

Models

Warnings

Component Identification

Setup

Operation

Maintenance

Troubleshooting

Repair

Electrical Schematics

Parts

Accessories