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Graco 333347F User's Manual

1. PLC Connection NOTE The InvisiPac system ships with two screw ter minal connectors that plug into MZLP connectors H1 and H2 Connectors are located in a bag on the inside of A N the electrical enclosure front access door To replace the connectors order kit 24P176 A PLC can control and monitor all items shown in the dropdown menus on the System 1 screen in the Setup 1 On the System 1 screen in the Setup screens screens select the function of each input on MZLP connector 1210712 17 12 Schedule H1 and each output on MZLP connector H2 Inactive a No Active Errors Customer Input 2 urn main power switch OFF a 1 Disable i j 3 Remove electrical enclosure front access door 4 s casera UU 4 Route I O cable through strain relief in electrical ike Tv enclosure See Customer I O Cable S in FiG 1 on 2 Disable v page 11 3 5 Remove power from PLC Customer Input Dropdown Options 6 Connect the PLC to connectors H1 and H2 Option Description NOTE Each connector has four signals The MZLP aa NOTER board specifies the input range for each signal See the pee following table for pin assignments Heater On Off Turn on or off the heating system and pump lr o o T Channel 1 2 3 Enable or disable hose and applicator e Fa 4 5 0r 6 heating for that individual channel eyeyeye J2 t5 eje Enable Disable F10 F9 F8F7 FAE3 D
2. ti23349a 1108 i 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 Adapter Plate Installation 2 Remove existing hot melt applicator system Use six screws 1102 and six nuts 1103 to secure adapter plate 1101 through the existing holes from the previous system Align the InvisiPac system with the bolts on the adapter plate 1101 then place onto the adapter plate 1101 Use the remaining three nuts 1103 to secure the InvisiPac system to the adapter plate 1101 Use elbow fitting 1104 to install system air inlet filter A not included with kit 333347F Accessories 333347F 103 Accessories 30 Gallon Vibrating Hopper 24R136 Hopper includes a shaker to ensure the adhesive pellets maintain a level surface at all times Without this the adhe sive pellets can stick together preventing them from continuously covering the vacuum transfer system s inlet This would cause the vacuum transfer system to be unable to transfer the adhesive pellets Input Air Pressure Requirement 100 psi 7 bar 0 7 MPa Air Consumption 17 1 scfm 29 1 cubic meters per hour Ref 901 902 903 904 905 907 908 909 910 104 902 901 ti20928a 126930 126929 119798 113779 111192 Description HOPPER 30 gallon LID hopper 30 gallon SHA
3. Inactive 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 11 2013 1601 Maintenance cheue SENI Set Schedule Times NOTE Times are set using a 24 hour clock Several on and off times can be set each day 1 Onthe Schedule screen in the Setup screens set the ON times for each day of the week 2 Setthe OFF times for each day of the week 333347F Operation Enable Schedule Function The Schedule function is automatically enabled when values are entered in the Schedule screen To disable a scheduled event navigate to the event and press nn The event will appear gray on the screen when it is dis abled To re enable an event navigate to the event and press m The event will appear red system off or green system on If no events are needed turn the main power switch OFF to prevent system from auto matically enabling and disabling the heaters How to Use the Schedule Function At the end of the work day leave main power switch ON The Schedule function will automatically enable and disable the heaters and pump at the specified times Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol A Vi E This equipment stays pressurized until pressure is manually relieved To help prevent s
4. 4 1 2 12 3 6 25 7 6 4 1 2 12 3 6 25 7 6 4 1 2 12 3 6 25 7 6 11 13 15 13 16 20 15 19 26 16 22 31 18 25 36 20 28 4 17 19 21 19 23 21 21 of 32 23 30 37 25 34 42 21 37 47 13 14 17 15 18 23 17 22 29 18 20 13 13 13 13 13 13 13 13 19 13 16 23 13 18 2 13 20 13 13 13 13 13 13 13 13 13 13 13 16 13 13 19 13 13 22 13 13 13 13 13 13 13 13 13 13 13 13 13 13 15 13 13 C9 12 12 12 9 6 25 7 6 A D NO O Co O O NO CO O1 CO 11 16 23 20 12 3 6 11 28 25 7 6 4 1 2 14 iN 22 32 47 20 21 24 21 26 30 24 30 36 26 34 4 28 38 48 30 42 54 18 13 20 15 15 15 15 15 15 15 15 15 15 15 18 15 16 20 15 18 23 10 25 7 15 15 15 15 15 17 15 17 21 15 19 24 16 22 15 15 15 15 15 15 15 15 15 15 15 15 15 15 12 3 NO O NO O NO O NO O NO O NO O NO O Q NO NO O N O NO NO NO O O O NO NO hoy O Of k No NO O NO O 12 3 6 25 7 6 4 1 2 12 9 6 25 7 6 4 1 2 12 9 6 25 7 6 4 1 2 12 9 6 25 7 6 4 1 2 12 9 6 25 7 6 NO O NO O NO O NO O NO O NO O NO O NO O NO O NO O NO O NO O NO Co NO O NO O NO O NO O NO O NO NO NO O NO O NO NO O NO O NO O NO O1 NO O NO O NO Co oO NO CO NO O 17 24
5. 14 SELU eC PPP 17 GYOUINGING Prem 17 LOCATION sce oem degit d main eot dete ub dict ig ima de dole Ble ars 17 Attach Components 0 0000 cece eee eens 17 Recommended Air Setup 02 cee eee 22 Connect Electrical Cord 0 0 0 0 cee eee 23 208V Electrical Circuits 0 0 0 0 eee 24 Select ADM Settings 0 00sec eee 24 ADDIICALOIS 74 53 ek xri did n oe n abii e d eee anh 26 PIC COMECON 2 4 22 4252 teta te eee dts 27 Operation es sabia d ue louem heec eee eae iE 29 9 u A 29 Initial Startup and Prime 29 Manual Refill ud a nata raptis rr IE da tec e tod a i te strc 30 Automatic Refill 2 31 DISDCNSE S zone cse SEES MESA UE deb ede tae 32 SUtI WII io ens Ser tta m p der qo dog E dp Bo eed 33 Schedule s etat aureo Gus a adeb ac Sed ut 33 Pressure Relief Procedure 33 Drain the System 00 ccc eee eee 34 FIUS ados ar s ERO sett seeks ie said 34 Operation Tips to Minimize Charring 36 Mallitenance 2a du PED UE e Ohta setae red 37 Replace Outlet Filter llle 37 Replace Inlet Filler 0 0 0 cee ee eee 37 Replace Funnel Filter 0 cc eee ee eee 38 Filter Maintenance Guidelines 39 Troubleshooting 3 0262 beeen weheae peewee bed 40 ADM Error Code Table 0 000 eee eee 40 Mechanical and Electrical Troubleshooting 46 MZLP Tro
6. 11 Attach the other end of the long 3 8 in OD air line G4 to the 3 8 in push to connect fitting on the shaker head G1 12 Ensure the adhesive pellets container is in the desired operating location The location should be chosen to make it easy to fill the container with pel lets 13 Place shaker assembly in an empty adhesive pel lets container then fill the container with adhesive pellets NOTE To promote optimal system performance pur chase 30 Gallon Vibrating Hopper 24R136 See installation instructions on page 104 NOTE If static buildup on feed tube G is excessive install optional feed tube ground kit 24 708 to feed tube end G6 See FIG 7 19 Setup 14 Install heated hoses see FIG 11 To reduce the risk of fire and explosion only use Graco heated hoses with the InvisiPac system Use of non Graco hoses will void agency approvals Applicator ti23298a a Place a rag on the drain tray W2 attached to the melter Residual oil may be in the system from the factory See FiG 11 b Usea 1 4 in allen wrench to remove the drain port plug W1 See FiG 11 NOTE A 1 4 in allen wrench is shipped loose with the system c When fluid stops draining re install drain port plug W1 then remove rag See FIG 11 d Remove plug 247 from the lowest numbered outlet on the melter Do not use the drain plug W1 See FiG 11 NOTE In the following step
7. 15 15 NO O NO O NO O NO N NO O NO O lie mos BTS EION KASOJ BTS aaa KASO BTS mos BTS mos IU KLUB 4 1 2 mos BTS EION KASOJ BTS EION mos BT EION KASOJ BT EION mos BTS oO NO N N B O N 5 Technical Data Three Phase NOTE Times are approximate and may vary with ambient conditions voltage configuration and machine configuration Start Time in Minutes Channels Length Breaker Breaker Breaker Breaker Breaker Breaker Breaker Breaker System W 8 3s 98 i8 i8 i8 a i5 99 39 98 i4 i8 i3 e araj 15 99 98 98 16 13 18 i18 i5 99 39 99 i4 i8 i3 ja e n 39 99 i7 i8 i8 e 2 uw i 39 2 sw 19 18 4 os 39 98 i6 i8 i8 ja i e 9 98 20 i8 18 a m i i 99 26 18 i8 38 is o 39 99 i7 i8 i8 ja aa H S9 2 15 i8 38 3o af 2 as v n 39 98 i 5 i8 38 m 15 i 99 zr 18 i4 38 34 p 27 20 e i2 89 99 2i i i8 ja 2B 2 3 2 i5 i8 OO NOR Co O1 N NI N OF NO N NO N NO l O O o O NO N NO N hoy O O O Of O O 29 46 23 7 zo i 2D 20 20 20 n 2 29 20 20 i 2D 29 20 20 23 a 20 20 20 26 a 29 20 20 20 2 20 20 20 26 2b 29 20 20 s M 2 2 m 22 M a 20 20 28 2 2 3s 40 2 22 2 29
8. A 167002 INSULATOR heat 24V169 SYSTEM melter HM25 RN 24V542 SYSTEM melter pump HM50 I 4 1 4 4 4 SEEGER RENKRERERERERERK RERERERENERK 17 17 17 17 17 17 17 17 17 17 17 Gn A E TEREE pE E 2 4 I I 4 1 EGESZ 111 CCGA 1 1 16V540 GUARD insulated INSULATOR wrap TRAY drip i SCREW flange hex hd 1 o_o 00 T 113161 MANIFOLD air assembly DOOR front FOAM border door FITTING straight hydraulic 16V153 WASHER retaining 15 114271 STRAP retaining 18 126961 FITTING 45 elbow hydraulic 19 116793 FITTING 20 24R041 SENSOR ultrasonic 21 101976 TOOL allen wrench 2 24N957 SHAKER feed system 114606 PLUG hole 120753 FITTING push to connect elbow SWITCH reed assy SCREW pan head 8 32 x ET d a T9 M ia 1 2 Il ev e 4 24 2 24A032 BRACKET back HM50 BRACKET back COVER filter COVER melter HM50 COVER system HM25 24P860 MODULE ADM 117017 WASHER FITTING tee reducer HOSE nylon wpr 250 psi TUBE 5 32 OD nylon TUBE ptfe 1 4 in OD 1 SCREW shcs m5x16 ev CO Wl C2 NO N Mh NI N DO NI N O gt N cO N O CO gt Ox 31 2 2 Qo O O 5 m Co O O BE H E CUN 01 nl 1 1 1 1 4 4 4 24 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 108 10 O EB
9. FIG 32 3 Push the piston rod assembly 223 into the melter outlet manifold 203 4 Grease the throat u cup 234 and slide the u cup over the piston rod 223 with the lips facing down 5 Place a 7 8 in deep well socket 3 8 in drive over the piston rod 223 then use a rubber mallet to gen tly tap throat u cup 234 into place See FIG 33 ti21047a FIG 33 333347F Hepair 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 ti21144a Fic 34 7 Remove seal installation tool 8 Install retaining nut 235 See FIG 32 9 Install air motor assembly see FIG 31 a Install three screws 240 b With retaining ring around piston rod install dowel pin 238 c Install retaining ring 239 over dowel pin 10 Use nuts 3 to install melter shield 27 11 Connect air lines to relief valve and air motor 12 Install plastic shroud 27 57 Repair Replace Pump Inlet Housing Checks A AMA ti23322a FiG 35 Disassembly see FIG 35 1 Flush the system See page 34 2 Close the bleed type ball valve installed at the sys tem air inlet to relieve all air pressure in the system 3 Turn main power switch OFF 4 Remove four bolts 246 and pump manifold 203 from melter outlet 5 Usea 1 2in drive ra
10. Fuse Kits 24V289 24V510 Includes standard clear fuses 24X480 Includes ceramic fuses used for food industries A Turn main power switch OFF 2 Remove electrical enclosure front access door 10 3 Use a proper non conductive fuse puller tool to remove the blown fuse NOTICE Using an improper tool such as screw drivers or pliers may break glass on fuse NOTE F1 and F2 are white ceramic and indicate 25A on the barrel NOTE F3 F10 are clear glass and indicate 8A on the barrel 4 Use a proper non conductive fuse puller tool to install the new fuse NOTICE Using an improper tool such as screw drivers or pliers may break glass on fuse 5 Install electrical enclosure front access door 10 67 Repair Replace MZLP mA Disassembly 1 Turn main power switch OFF 2 Remove electrical enclosure front access door 10 3 Disconnect heated hose electrical connectors from outside of MZLP 112 4 Note location of each cable then unplug all cables from the MZLP 112 that will be replaced See FIG 47 5 Remove four screws 114 securing MZLP 112 to electrical enclosure 1 then carefully remove MZLP from electrical enclosure See FIG 47 FiG 47 6 Replace MZLP See FIG 47 for MZLP 1 MZLP 2 and MZLP 8 identification a Toreplace MZLP 1 remove the daughter card and st
11. Remove Melter Assembly 7 V Mf J Ei o O 10 p ti22861a FIG 39 NOTE This only needs to be done when replacing items that require access to the bottom of the melter assembly 1 60 Perform Drain the System procedure on page 34 then wait for system to cool Close the bleed type ball valve at the system air inlet Turn main power switch OFF Disconnect all heated hoses from the melter outlet manifold Hemove cable from ADM 30 then slide forward the shroud 29 and remove it from the system 10 11 12 13 14 15 16 17 18 19 87 88 Remove screws 8 then remove electrical enclo sure front access door 10 Disconnect heater rod wires from J4 connector on AWB board Remove the air tube 36 from the relief valve 245 Pull the air tube from the metal shroud 27 Remove nuts 3 on the back metal shroud 27 then remove shroud Remove fabric melter insulator 53 Loosen screw AA then remove sensor 125 See FIG 42 page 63 Loosen hose clamp 81 then remove funnel FF Remove wire connectors from the over temperature switch 251 Remove insulators 53 75 from the melter assembly 5 Disconnect the fill sensor cable from the fill sensor 20 See Replace Fill Sensor page 69 Disconnect the pump cycle sensor cable from the air motor Remove the air tube from
12. 1 Turn main power switch OFF 2 Close the bleed type ball valve installed at the sys tem air inlet to relieve all air pressure in the system 3 Remove two screws 8 then slide air control assembly 9 out from electrical enclosure 1 so the back of the gauges are exposed 4 Remove two nuts 403a securing gauge 403 in place then remove bracket 403c ti23442a 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 FiG 55 Top Pilot Valve 1 Close the bleed type ball valve installed at the 6 Remove air gauge from panel system air inlet to relieve all air pressure in the system Heassembly see FIG 54 l l l l l l 2 Turn main power switch OFF 1 Slide new air gauge into panel and slide the bracket onto the back of the gauge Install air fitting onto the 3 Replace top pilot valve 511 gauge by hand do not tighten yet a Usecrescent wrench to remove the rod cover 2 Install bracket 403c then install two nuts 403a C finger tight b Use 10 mm socket to remove air motor pilot valve 511 from air motor 218 c Lubricate with grease and install new air motor pilot valve 511 333347F 73 Repair d Torque pilot valve to 95 105 in Ib 10 7 11 9 Nem 4 Replace bottom pilot valve 51 1 218 A deu 511 Q Se S OS Sd N aut RU C FiG 56 Bottom Pilot Valve ti23752a
13. 20 20 s s 24 20 20 ia er wi 24 20 24 z 2 2 m T CNN NE 55 5 sa 126 333347F Technical Data Dimensions System Dimensions Mounting Hole Dimensions Lt ab Minimum distance from rear mounting Es Sx hole to wall 7 0 in 178 mm 2 0 in 51 mm 5 3 in 133 mm 18 3 in 465 mm ti22RRAA 14 2 in 84 mm TERTIUM 361 mm ti23556a 41 9 in 1064 mm 22 3 in 18 3 in 566 mm 465 mm ti23555a 33334 7F 127 Technical Data System with Stand and Vacuum Feed Dimensions Tube Bend Radius 8 0 in 203 mm Jl 12 0 in CR 305 mm N A L p Q om AT NaI Tir A jim in mm im a System With Transformer 66 5 1689 mm 30 0 17 4 762 mm 442 mm 27 2 in 692 mm 4 uf V e 9 B Em ti22865a Radius 9 1 in 232 mm 31 3 795 mm 128 333347F Technical Data 333347F 129 Graco Extended Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of eighteen months from the date of sale repair or replace any part of the equipment de
14. ER 212 a 7 FUNNEL FUNNEL large mouth mouth APPLE pa PHI PERI EAE ur BEE SE n ESE e D a Ei o se N ME WEI E FER T REE ERE FEJE AES E NR EE ae Hi ia DUE E Z mene BAFFLE pellt 15 P1 LEE PH E mer OOOO re ee ee ear f rome reese ary pave ITER MER a a TTT 68t FUNNEL filter cover FUNNEL FUNNEL filter cover cover ES LENENISENENENENEN 69T O RING fluoroelastomer 160 HE IUIS eee One UE ETEREAEREREA 73t HOUSING sensor HM50 HOUSING sensor HM50 sensor HM50 EBEN Be 74t SCREW 10 16 thread SSRs EARS EM e an eee ae 75 16T675 INSULATOR melter mani ed E 16W671 INSULATOR melter mani Mi FITTING tee 1 8npt x 3 8t x Ll B n ae eee Tren 77 RESTRICTOR air 0 0225 M e DO CE bilities ee RRS RA RSE CREE RIESE SEA ESD 12 POO ADAPTER NGS et Pee woo ADAPTER meter HM5O 11 1 1 1 7 7 7 ANN 333347F 87 Parts 4 Channel 2 Channel 4 Channel 6 Channel iii AAA S CLAMP SINT HHHHH Mrs GE Eas lg fap QM ox gt CLAM ose spacer mr quarum TIT BRACKET funnel HM25 funnel HM25 Pci nen el HM50 funnel mounting CL Lu A KARAR AKARAKARA CARAKA KAEA ER ER ERRRERG ener IPIE PT SESS SF DS S EEA EE ber HUS AREE ESETDENRTEBRERESESENENESETENEI SERES MEET Lab bonu LANES ES pt PUOC PO O T coe aaa 1 4 external s lock PLUG PLUG phoenix 8pos 8 pos D a a a E 5 32 in OD tube
15. O O Co an O Co O Co O Co O Co O CO O Co O Co O Co 8 108 44 wore spspsps s O1 598095 E T E E s s T E E Ir u B Ea B XT ki z id uU Ei C2 8 117126 AEA AEA 16 16 SE EE aS GEA HES QUEM d AES SES NE EE BEES eed ARE 8 108 10 SNC 1 101 10 JE ERE O ERE O BPR O e Co 6 333347F Parts 2 Channel 4 Miis 6 Channel 2 Channel 4 Channel 6 Eu ES e e ed a ai Ed Jan Mcd i5 AAE MEERE GH KN ERA A ee IHHHBHHBHEEG NEXERENESEXCSENESENE QE RONRER e ES SI IJESEIESENEAROESES EXEEEXESESENEZES REGE AS a XIIe aa 70 70 EREREN LI ppt EIE KAKARA Teen 24V42 24T920 24V20 24V20 24V42 24V42 2 24V424 A 24V1 Description ae s GROMMET Ta ip ipis o ouse seine 2 3 a SEEN GROMMET tube EBENEN a EM ea ievr LABEL We TTT Um TABEL Pac PDS i Eoi A LGD WEN LABEL tt tf tft oath CN KIT fuses board temp con a BORER PT trol EH 48 24P176 KIT KIT i o connector connector EZ aah Ea e Dum preseron Dese ej po E TO E EE d BN E ER E sewess NSULATOR meter i v v n n npo 167677 INSULATOR melter ia ES s NUT busting 2 2 2 2 2 2 2 Ed 57 128554 COUPLER 38 in OD tubing 1 1 1 1 1 1 1 Ea ae E ty assembly n T DEI E E ES EE KO EXE
16. The following block diagrams show how to connect customer inputs and outputs to the InvisiPac MZLP For conve nience each InvisiPac ships with connector kit 24P176 If a connector is lost or damaged order kit 24P 176 for replacements MZLP Customer In Customer Output Vin no polarity 30 VDC Max FiG 18 Customer Input MZLP Customer Out Customer In 250 VAC 0 30 VDC 2A Max To Customer Input Fic 19 Customer Output 28 333347F Operation Heating and dispensing hot melt adhesive may create potentially harmful vapors Read material manufac turer s warnings and material MSDS to know specific hazards and precautions Ventilation of the work area may be required NOTE See Appendix A ADM on page 114 for detailed ADM information NOTICE To prevent damage to soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails NOTE See Appendix B USB Downloading Upload ing on page 120 for detailed USB information Overview The system includes a vacuum transfer system that pulls the adhesive pellets into the system as needed Once melted the adhesive enters the pump where it is pumped into the heated hoses then to the heated appli cators The applicator then briefly opens to dispense the desired quantity of adhesive Even though the system rises to operating temperature quickly there is a Schedule function in
17. in top of electrical enclosure then connect new heater rod wires to terminal blocks as described in the previous table NOTICE To prevent damaging the heater rod do not use thermal grease in the following step Install heater rod then install heater rod retaining ring 206 See FIG 44 Install electrical enclosure access door 10 See FIG 41 page 62 If replacing the melter heater rod 209 Install Melter Assembly See page 60 333347F Hepair If replacing pump heater rod 210 feed ADM cable through shroud then install shroud and connect cable to ADM If installing the pump heater rod 250 install the metal shroud 27 a Place metal shroud on system b Install and tighten nuts 3 c Pull the air tube through the metal shroud 27 then connect the air tube 36 to the relief valve 245 Feed ADM cable through plastic shroud then install plastic shroud and connect cable to ADM Replace Fluid Pressure Relief Valve A 7 fj 36 ti20757a Fic 45 Drain the System See page 34 Close the system air inlet ball valve Turn main power switch OFF Remove the air tube 36 from the relief valve 245 Pull the air tube through the metal shroud 27 See FIG 45 Remove nuts 3 then remove shroud 27 65 Repair Use crescent wrench to remove melter fluid pres sure
18. mended setting is 60 psi 414 kPa 4 1 bar See FIG 20 NOTE If using shaker accessory regulator should be set to at least 65 of air pressure connected to shaker NOTE Vacuum transfer will not begin operating until pump reaches operating temperature To prevent fire and explosion never exceed the clean ing fluid s rated temperature If the system was just flushed residual cleaning fluid is still in the system until the system is primed with adhesive Do not raise temperature above cleaning fluid rated temperature until system is primed with adhesive NOTE A new system may have residual oil due to test ing at the factory prior to shipping To prevent smoking make sure to perform the following step 8 On new systems only temporarily adjust the melter temperature to 250 F 121 C See Select ADM Settings on page 24 for instructions 9 Press NOM to enable the heaters and pump O 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 30 10 On new systems only After the melter has reached 250 F 121 C and the funnel is filled with pellets set the melter temperature back to the desired oper ating temperature See Select ADM Settings on page 24 for instructions 11 Use separate pattern co
19. 27 1 Turn main power switch OFF 2 Rotate funnel cap 706 and remove Lift out funnel filter 705 Reassembly see FIG 27 1 Insert filter 705 in funnel assembly Tighten funnel cap 706 on funnel 333347F Maintenance Filter Maintenance Guidelines er te Be Replace filter Replace filter Replace filter every six everyfour every two months months months These recommendations are service level guidelines actual service levels required in your factory will vary based on environmental and operating conditions High or low volume adhesive usage as well as adhesives that contain a powdered release agent or are otherwise dusty will have an impact on the frequency of filter maintenance To estab lish a preventative maintenance cycle tailored to your environment Graco recommends inspecting filters every 4 weeks after installation and replacing when necessary Document replacement intervals and use this as your preven tative maintenance schedule moving forward 333347F 39 Troubleshooting Troubleshooting z vn i ARM C To avoid injury due to unexpected machine operation initiated by a remote controller disconnect the cus tomer I O cable from the system prior to troubleshoot ing ADM Error Code Table When an error occurs i to acknowledge the error If a Maintenance error occurs navigate to the Mainte nance screen and press to clear the error amp
20. An Auto selection is available but should only be used when the specific RTD type cannot be identified Using the Auto RTD setting may result in inaccurate temperatures To prevent fire and explosion a qualified electrician must determine the proper circuit breaker size to use for the power supplied to the system 4 Onthe System 3 screen Enable Diagnostic Screen Lock Run Screens 5 P Idle Time to Syst EUR THIS itus LO minutes Power Type Single Phase EA Circuit Breaker Size Amps Refill Setting r3 a Enterthe main circuit breaker size used This is the circuit breaker installed external to the sys tem for the system power supply NOTE The InvisiPac system limits the amount of power it pulls based on the input circuit breaker size This impacts the startup times because it affects the heating energy used to warm up the materials 5 Onthe Advanced 1 screen set the system date and time 1210 12 1710 4 System Maintenance Mo Active Errors Language English Date Format Date 10 Time 17 Enter Password Screen Saver amp minute Silent Made 333347F 6 Onthe Advanced 2 screen set the temperature and mass units 12 10 12 17 11 e System TER Inactive a No Active Errors vA Temperature Units Mass Units 1 v Specific Gravity 0 980 7 To setup the optional Schedule function see Schedule on page 33 NOTE The Schedule funct
21. HARNESS MZLP 3 16W035 CONNECTOR jumper FITTING tee Qty 1 1 1 1 2 1 1 2 1304 333347F 6 Channel Upgrade Kit Installation A AN 74 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 Setthe kit s MZLP 1301 rotary switch to 3 4 Remove screws BB then remove plate AA from system 5 Use screws BB to install MZLP 1301 onto sys tem NOTE The new MZLP 1301 will be referred to as MZLP 3 and the original MZLPs that came with the sys tem will be referred to as MZLP 1 and MZLP 2 from here on See FIG 66 6 Remove electrical enclosure front access door Step 7 Install jumper cable 1302 Fic 66 333347F Accessories NOTE Do not force the electrical connection Minimal force is required to seat the connector If resistance is felt stop and verify the connector orientation 7 Connect CAN jumper cable 1302 to MZLP 2 con nector J3 and connect other end of jumper cable 1302 to MZLP 3 connector J3 See FIG 66 8 Install jumper connector 1307 in J5 on MZLP 3 9 Connect wires from power harness 1306 between AWB connector J5 and MZLP connector J2 10 Re
22. a Install three screws 240 two screws 8 screws 74 and bracket 82 to secure air motor assembly to system b Install dowel pin 238 c Install retaining ring 239 over dowel pin 238 Use four nuts 3 to install melter shield 27 Reconnect air supply line to air motor 218 Reconnect air line 86 to pressure relief valve 245 See FIG 45 on page 65 75 Repair Transformer Fan mA Replace Fan 167 161 x3 151 ti23656b FIG 59 1 Turn main power switch OFF 2 Disconnect plug from power outlet or turn off circuit breaker for incoming power 3 Remove front access panel 10 from electrical enclosure 1 4 Remove connector from J7 connector on AWB board Remove red and black wires from con nector ti23657a Fic 60 Front access panel 10 not shown 76 5 Remove screws 157 and fan grill 154 Pull two fan wires down into the transformer enclosure 6 Cut three zip ties on corrugated tube 167 and two zip ties 161 on fan grill 154 7 Remove four nuts 158 rear fan grill 170 and fan 155 Install Fan 1 Mount new fan 155 rear fan grill 170 and nuts 158 on grill 154 with the arrow pointing toward the grill 154 2 Tie down fan wires onto tie down locations on grill 154 using cable ties 161 red black ti23658b FIG 61 3 Houte
23. the o ring side of the hydraulic fitting 68 faces the system See FIG 11 e Install the supplied hydraulic fitting 68 with an o ring into the open port and tighten with an 11 16 in wrench or socket 20 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 FIG 11 h Repeat the procedure for the remaining chan nels Use the bottom melter ports first to ease installation i Install cap on any unused MZLP electrical con nectors NOTE Fluid outlet port 1 must be used and electrical connector from that hose must be connected to MZLP connector 1 The system will not operate unless a hose is connected to MZLP connector 1 If a hose is not con nected to connector 1 Invalid Sensor hose gun faults will result If the melter must be run without a hose appli cator electrically attached to MZLP connector use Overtemperature Jumper 16Y727 page 113 15 Install applicator s see FIG 11 NOTE Use of a Graco applicator is not required with this system However all applicators attached to the system must be rated for 1200 psi 8 3 MPa 83 bar 400 F 204 C have an RTD type sensor and use no more than 400W at 240 VAC a Connect heated hose fl
24. 10 11 12 Connect new harness to MZLP connector labeled J5 Install electrical enclosure access door 10 See FIG 41 on page 62 Install fabric melter insulator 53 Use nuts 3 to install metal shroud 27 See FIG 39 page 60 Route relief valve air tube through the metal shroud then attach to the relief valve Feed ADM cable through shroud then install shroud and connect cable to ADM Turn main power switch ON Open system air inlet ball valve 63 Repair Replace Heater Over Temperature Switch 74 ti21052a 4x Fic 43 Disassembly see FIG 43 1 Close the bleed type ball valve installed at the system air inlet to relieve all air pressure in the system Turn main power switch OFF Disconnect cable from ADM then remove shroud Remove air tube 36 from relief valve Pull the air tube through the metal shroud 27 See FIG 45 page 65 Use 7 16 in socket to remove nuts 3 then remove metal shroud 27 Disconnect the wire connectors from the over tem perature switch 251 Remove the screws 255 securing the over tem perature switch 251 to the melter assembly 5 then remove the switch Re assembly see FIG 43 1 2 3 4 64 Use the two screws 255 to secure the new over temperature switch 251 to the melter Connect wire connectors to new over temperature switch Use 7 16 in socket to install nuts 3
25. 11 3 kg hr Vacuum Transfer Air Consumption at 80 psi 550 29 2 scmh intermittent duty 496 at kPa 5 5 bar 25 lb hr 11 3 kg hr Required Air Tubing Size Minimum Air Tubing Inner Diameter less than 50 3 8 in 9 5 mm ft 15 2 m of tubing Minimum Air Tubing Inner Diameter 50 ft 15 2 m 1 2 in 12 7 mm or longer of tubing 77 dB A O O e o D co 2i 3 Sound Pressure Level P Code InvisiPac Base System Wetted Parts Wetted Parts C1 D PTFE chemically resistant o rings aluminum stainless steel zinc plat ing carbon steel brass carbide chrome Approvals and Standards UL499 CSA88 CE ISO 30 Gallon Vibrating Hopper Required Air Pressure Supplied To 30 Gallon 100 psi 0 7 MPa 7 bar Vibrating Hopper Air Consumption 17 1 scfm 29 1 cubic meters per hour From 70 F to 350 F 21 C to 177 C dependant upon power supply and machine configuration Excludes vacuum transfer tube shaker assembly and pellet storage bin Sound pressure level measured 3 1 ft 1 meter from equipment 124 33334 7F Technical Data Startup Time Single Phase NOTE Times are approximate and may vary with ambient conditions voltage configuration and machine configuration Start Time in Minutes 20 Amp 30 Amp 40 Amp 50 Amp 20 Amp 30 Amp 40 Amp 50 Amp Channels Length Breaker Breaker Breaker Breaker Breaker Breaker Breaker Breaker System 1 33334 7F
26. 15T500 15T498 100058 054753 C38321 Not for sale 333347F Description PANEL air controls CONTROL air vacuum trans fer and pump GAUGE pressure air panel mount 1 8 in npt FITTING 90 degree swivel 5 32 in tube x 1 8 in female npt SCREW cap hex head TUBE nylon round black TIE cable 3 62 in Qty Parts ti23308a 97 Parts Pressure Relief Valve 24P856 AN Apply sealant to all non swiveling pipe threads A Apply grease 6074 A 606 A Torque to 4 6 in lb 0 5 0 7 Nem Ref 601 602 603 604 605 606 607 6081 6091 610 6111 6121 613 614T 108771 110073 111841 Not for sale 1 Parts included in Relief Valve Repair Kit 24P857 purchase separately 98 Description BODY fluid BODY air PISTON air AIR CAP valve BEARING shaft needle SHAFT needle valve SOCKET ball assembly PACKING o ring PACKING o ring WASHER plain 5 8 in BEARING valve O RING FKM FITTING push to connect SEAL u cup relief valve Qty a N S c1 ol A 610 604 613 333347F Feed Inlet Funnel 24V505 Ref 701 702 703 704 705 706 707 708 709 710 Not for sale Part 24V506 113161 333347F 706 Description FUNNEL large mouth BAFFLE pellet O RING fluoroelastomer 160 FUNNEL insert FILTER feed FUNNEL filter cover SCREW flange hex hd SCREW 10 16 thread forming BRACKET f
27. 509 511 512T 513 15M213 Not for sale A Apply water resistant grease A Torque to 95 105 in Ib 10 7 11 9 Nem Description MANIFOLD medium short GASKET cover small SEAL air valve manifold SCREW m6 x 25 thread forming VALVE pilot VALVE air small MUFFLER 3 8 T Included in Air Motor Valve Kit 24R026 333347F Qty a N O Na a ti23558a 513 Parts 95 Parts Feed System Shaker and Tube 24V507 301 Parts Ref Part 301 24P861 302 24N954 3031 304 305 125370 306 125871 Not for sale N Apply pipe sealant to threads Description Qty SHAKER 1 TUBE steel 1 TUBE clear PVC 1 3 in 10 33 mm OD HOSE nylon 3 8 in OD 15 5 250 psi 1 7 MPa 17 bar CLAMP hose dia 11 16 to 3 1 1 2 in TIE cable 7 50 in 190 mm 4 1 SOft 9 1 m Feed Hose Kit 24R043 also available purchase separately Kit also includes 2 hose clamps Included in Tubing Kit 24V544 See System Parts on page 86 for other kit contents Not shown NOTE Shaker Grounding Kit 24R708 purchase sepa rately also available Kit includes a grounding wire assembly and a screw and washer for installing on the shaker tube 301 96 ti20738a 333347F Air Controls Assembly 405 A Apply sealant to all non swiveling pipe threads Air Controls Assembly Parts Ref 401 402 403 404 405 406 407 Part 24V520
28. Appendix B USB Downloading Uploading on page 120 Perform maintenance and reset Due counter to 0 at the Setup Maintenance screen Verify system is operating within meltrate specifi cations Consider incoming voltage and breaker setting Verify that the fill system vacuum is operating correctly If the level of material in the melter gets too low and a large amount of cold material enters the melter can cause the temperature to drop significantly With the system on and not dispensing verify that the temperature is properly controlled to the set point If system cannot control temperature ver ify the RTD is seated inside the melter Replace RTD if RTD was seated properly and system cannot control temperature Faulty melter heater s Check heater resistance and resistance to ground Replace faulty heater s With the system on and not dispensing verify that the temperature is properly controlled to the set point If system cannot control temperature replace applicator RTD See applicator manual Faulty applicator heater Check heater resistance and resistance to ground Replace faulty heater Dispense rate too high for applicator to maintain setpoint Consider applicator power and voltage With the system on and not dispensing verify that the temperature is properly controlled to the set point If system cannot control temperature replace hose Faulty hose heater Check heater resistance and resistanc
29. FIG 9 333347F NOTE In the following steps when routing the vacuum transfer hose ensure there are no tight coils turns or dips in the vacuum hose These will inhibit optimal func tioning of the vacuum transfer system NOTE Maximum vacuum hose length is 30 ft 9 1 m Use horizontal hose routing as much as possible The vacuum hose must not rise more than 10 ft 3 0 m measured from the vacuum inlet Any vertical rise will lower the maximum flow rate of the vacuum transfer system 6 Route the 1 3 in 38 mm OD clear vacuum transfer hose G2 from the system to the adhesive pellets container location 7 Apply pipe sealant to threads then attach steel shaker tube G to shaker head G1 See FIG 10 NOTICE To prevent shaker head G1 galling to the shaker tube G do not overtighten shaker head onto shaker tube These should be hand tightened N M jp 7 1 4 G1 8 Attach 1 3 in 38 mm clear vacuum transfer hose G2 to steel shaker tube G and secure with sup plied hose clamp See FIG 10 G4 q ti21131a Fic 10 9 Route the 3 8 in OD air line G4 alongside the 1 3 in 83 mm clear vacuum transfer hose G2 and secure at multiple points with the supplied zip 333347F Setup ties G5 See Fic 10 10 If desired secure the 1 3 in 83 mm clear vacuum transfer tube G2 and 3 8 in OD air line G4 with zip ties to a Supporting structure at various points in the routing
30. 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 113 107 Accessories 4 Channel Upgrade Kit 24V528 Use this kit to upgrade a 2 channel system to a 4 channel system Ref Part 1301 1302 161087 1303 1304 112190 1305 16T440 1306 24R324 1307 1308 Not shown Not for sale 108 Description MODULE GCA MZLP CABLE jumper male male 21 in HARNESS 2nd MZLP power STRAP wrist grounding CAP jam nut sealing SOFTWARE UPGRADE TOKEN InvisiPac System FITTING straight LABEL InvisiPac Channel Num bers ti23352a Qty lt N NO 1306 333347F 4 Channel Upgrade Kit Installation A AN 74 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 Setthe MZLP 1301 rotary switch to 2 4 Remove screws BB then remove plate AA from system 5 Use screws BB to install MZLP 1301 onto sys tem Apply labels from label sheet 1308 to MZLP 2 Place the 3 and 4 labels as shown in parts illustration NOTE The new MZLP 1301 with be referred to
31. J xclonmvogs P Electrical Schematics 30 ADM 123 akwNnN ahwond 129 To MZLP 2 4 and6 Channel Option see page 108 and 110 Hose Applicator Wiring 79 Electrical Schematics 480VAC Transformer Option 143 AWB J2 1 W1 L1 N sra N P3 w2 L2 5L3 1 6T3 P2 W3 L3 3L2 ata 4T2 P1 WA ILI oa Ye 2TI GNP TC GND Typical Hose Applicator Wiring 8 A B c D OVER s HOSE GUN 4 TEMP OND HEATER H RTD J K L 80 333347F Electrical Schematics 2nd and 3rd MZLP Options 118 118 n MZLP3 MZLP 2 MZLP 1 135 J5 J3 J3 J6 J3 Cc H f 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 3 3 3 3 121 3 3 3 3 121 3 3 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 333347F 81 Air Schematic Air Schematic NOTE Install an optional ramp up down controller to limit air to the air motor and slow down the system dis pense rate pueM pss JOJO 4l LAN Joijed eunsseJg Je OJ1u02 uMoq df dwey jeuondo eDnex jeu piouejos 01u02 ljeH pIojruej 104u02 JY pioueJog 0J1u02 JO1O JI oDnec 1010 N JI V JOSUSS ly 3497 40 ou1seH v ONEA HO dod jejes Jo
32. Line 350 415 VAC Y 36 Neutral PE db 200 240 VAC Line to Neutral 90 60 Hz 16A 3 wire Neutral and PE du 1 Phase 200 240 VAC 200 240 VAC 50 60 Hz 40A 2 wire and PE D 3 Phase without Neutral 200 240 VAC Line to Line 24T919 4 200 240 VAC A 50 60 Hz 27A 3 wire and PE D 3 Phase with Neutral 350 415 VAC Line to Line 350 415 VAC Y 36 Neutral PE D 200 240 VAC Line to Neutral 50 60 Hz 3 wire Neutral and PE D 1 Phase 200 240 VAC 200 240 VAC 50 60 Hz 2 wire and PE D 3 Phase without Neutral 200 240 VAC A 200 240 VAC Line to Line 50 60 Hz 24T920 3 wire and PE D 3 Phase with Neutral 350 415 VAC Line to Line 350 415 VAC Y 3 Neutral PE D 200 240 VAC Line to Neutral 50 60 Hz 3 wire Neutral and PE D 4 333347F Models 200 240 VAC 350 415 VAC HM25 Models See 400 VAC Transformer models on page 6 See 480 VAC Transformer models on page 7 1 Phase 200 240 VAC 10 PE 200 240VAC 50 60 Hz 32A 2 wire and PE eb 3 Phase without Neutral 200 240VAC JAVADI 5 200 240 VAC A 30 PE D 50 60 Hz 27A 3 wire and PE D 3 Phase with Neutral 350 415 VAC Line to Line 350 415 VAC Y 3 Neutral PE D 200 240 VAC Line to Neutral 50 60 Hz 16A 3 wire Neutral and PE D 1 Phase 200 240 VAC 200 240VAC 50 60 Hz 40A 2 wire and PE Q 3 Phase without Neutral E 200 240VAC 24V424 4 200 240 VAC A 50 60 Hz 27A 3 wire and PE en 3 Phase with Neutral 350 415 VAC Line to Line 350 415 VAC Y 36 Neutral PE D 200 240 VAC
33. Signals NOTE The MZLP LED is located on the inside of the electrical enclosure To view remove the electrical enclosure front access door Description Green On MZLP is powered up and input voltage is within operating con ditions Yellow On Internal communication in pro cess Hed Solid MZLP failure See troubleshoot ing table Red Flashing Software update in process or missing software 333347F Troubleshooting xe S QD 112 13 Fic 30 MZLP Diagnostic LED Location H1 ti20348a 55 Repair Repair NOTE Some procedures require special tools Read through each procedure prior to beginning it to ensure you have the required tools to complete the entire pro cedure 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 z A is i om ti23321a FIG 31 56 Disassembly see FIG 31 10 11 12 13 Flush the system See
34. WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings ent
35. 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 333347F 5 Onthe System 3 screen in the Setup screens ver ify the Refill Setting is set to Manual Schedule Acwanced rs C Mo Active Errors 12 10 12 17 13 Enable Diagnostic Screen Lock Run Screens Pump Idle Time to System i Inactive U minutes Power Type Single Phase B Circuit Breaker Size Amps Refill Setting Manual fY 6 Change the melter heated hoses and applicators temperature settings to the high temperature hot melt cleaning fluid manufacturer s recommended temperature 7 Verify the system air inlet ball valve is closed and pump air pressure is set to 0 8 Allow the system to heat or cool to the cleaning fluid manufacturer s recommended temperature 9 Fill melter with high temperature rated hot melt cleaning fluid See hot melt adhesive material sup plier for recommended hot melt cleaning fluids Fluid level should be 1 2 in 12 7 mm from the top of the melter d LD ti23455a 4 10 Disconnect one hose from its applicator manifold NOTE Keep all applicators closed throughout this pro cedure 11 Route the disconnected hose to a waste container 333347F Operation 12 If heating system is disabled press to enable
36. beginning NOTE Failure to have the correct RTD value will cause the applicator to either under heat or over heat Setting for RTD in the ADM screens is lower than actual RTD value Consult manufacturer for actual RTD value 50 333347F Troubleshooting Problem Cms Seo No adhesive or Plugged applicator Heplace applicator manifold filter Graco applicator manifold filter in incorrect manifold filter bottom of manifold or inline filter on other applicators amount of des veont Clogged hose Flush or replace hose put when all Defective solenoid Check that correct voltage is input into solenoid valve If voltage is cor dispense mod valve rect replace solenoid ules are trig aa No signal from control If no voltage is present at solenoid check control cable and pattern g to solenoid controller Replace component Solenoid mufflers Replace solenoid mufflers plugged No air to air solenoid Re establish air supply to solenoid Plugged system outlet Replace Outlet Filter See page 37 filter If multiple applicators Stagger applicator opening to reduce the maximum required flow rate are triggered simulta to below maximum pump rate neously maximum pump rate may be exceeded No adhesive or Plugged tip on dis Replace tip on dispense module incorrect pense module amount o Defective dispense Replace dispense module adhesive out of module in closed par tial open position one some of t
37. board is not plugged into MZLP1 Plug Defective MZLP daughter board Replace DADX Pump Runaway Alarm Pump is trying to feed adhesive no Storage bin out of adhesive Refill adhesive adhesive to feed Level sensor may be over heating Verify air is being delivered from tube 35 Melter at incorrect temperature too low Check setpoint and set to manufacturer s recommenda tion plugged hose or funnel DDDX Pump Diving Devia Pump is trying to feed adhesive no Storage bin out of adhesive pellets Refill with Level sensor may be over heating Verify air is being delivered from tube 35 Melter at incorrect temperature too low Check melter temperature setting and set to manufac turer s recommendation Plugged vacuum transfer hose or funnel Clear Dispense rate too high See technical ratings of DEOX Cycle Switch Alarm No signal from air motor sensor Check wiring on J16 of the daughter board See Error Electrical Schematics on page 78 Loose cycle switch bolt Tighten cycle switch bolt Defective cycle switch Replace LOFX Manual Fill Advi System set to manual fill mode Change to auto fill mode See Setup Screen Sys Mode sory tem 2 L6FX Level Sensor Alarm No signal from the level sensor Check that sensor cable is plugged into sensor Error Check connector at J14 of the daughter board Verify there is nothing blocking fill level sensor line of sight Defective fill level sensor Replace No air
38. cable to bottom of new ADM NOTE ADM may need updated software See Soft ware Update Procedure on page 77 69 Repair Replace AWB s e N If few B s t ga B r3 M A y i DY Lus LI ig ao CEN ga 3 EG la e e Ln p BS N gl e W rj m i AN Fic 51 AWB and Power Supply Disassembly 1 Turn main power switch OFF 2 Note location of each cable then unplug all cables from the AWB See Electrical Schematics page 78 3 Remove 2 screws 131 securing AWB 143 to electrical enclosure 1 then carefully remove AWB 4 Remove power supply 146 from power supply bracket 145 by releasing mounting tab on the side of the power supply See FIG 51 5 Remove two screws 144 securing power supply bracket 145 to AWB 143 and remove power sup ply bracket See FIG 51 70 Heassembly 1 Use two screws 144 to secure power supply bracket 145 to new AWB 143 See FiG 51 2 Mount power supply 146 to power supply bracket 145 See FIG 51 3 Connect connector labeled AWB J1 on power sup ply harness 147 to J1 on AWB 143 See Electri cal Schematics page 78 4 Usetwo screws 131 to install AWB 143 to electri cal enclosure 1 See FIG 51 5 Reconnect cables to AWB 143 NOTE Do not force the electrical connection Minimal force is required to seat the connector If resistance is felt stop and verify the connec
39. 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 e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources 333347F Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol e 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
40. fan wires with transformer wires into the elec trical enclosure 1 Connect red and black fan wires to J7 connector Reconnect J7 connector to AWB board See FIG 60 4 Reinstall corrugated tube 167 on fan and trans former wires See FIG 59 NOTE To prevent fan errors on ADM remove excess slack and ensure cabling and zip ties do not contact fan blades 5 Reinstall fan grill 154 and front access panel 10 333347F Software Update Procedure When software is updated on the ADM the software is then automatically updated on all connected GCA com ponents A status screen is shown while software is updating to indicate progress 1 Turn system main power switch OFF 2 Remove ADM from bracket 3 Remove token access panel c r 24P860 3B9900 3a Fic 62 Remove Access Panel 4 Insert and press InvisiPac software upgrade token T part no 24R324 firmly into slot NOTE There is no preferred orientation of token r 24P860 3B9900 4a FiG 63 Insert Token 5 Install ADM into bracket 6 Turn system main power switch ON NOTICE A status is shown while software is updating to indicate progress To prevent corrupting the software load do not remove token until the status screen disappears 333347F Hepair 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
41. from ADM 30 then remove shroud 29 4 Remove front access door 10 from electrical enclosure 1 5 Remove fabric melter insulators 53 6 Loosen clamp 80 and then remove screws 8 and funnel assembly F 7 Loosen screw AA then remove sensor 125 62 8 Locate the J4 1 and J4 2 wires in AWB board and remove wires 9 Pull wires up through grommet 63 on top of the electrical enclosure 1 Clip any wire ties that hold the wires in place 10 Continue loosing screw AA then slide band heater 208 up to remove Reassembly see FIG 41 1 Install band heater 208 on the melter with the opening and screw facing the front of the system in alignment with the sensor port 2 Install sensor 125 3 Slide band heater up then tighten screw AA NOTE Band heater should be oriented to hold sensor in place when tightened It should not bend the sensor 4 Route band heater wires through grommet 63 in the top of the electrical enclosure 1 5 Connect wires to AWB board as marked Wires should be marked as shown in the following table Wire Wire Marking 1 Marking 2 Band Heater 208 6 Install electrical enclosure access door 10 See FIG 41 7 Use clamp 80 and screws 8 to install funnel assembly F on melter assembly 8 Install fabric melter insulator 53 9 Feed ADM cable through shroud then install shroud and connect cable to ADM 10 Open system air inlet ball val
42. on page 24 118 Advanced 1 1210 12 17 10 e System Maintenance 9 No Active Errors language English w Date Format Date 12 10 12 Time 17 10 Enter Password Screen Saver amp minute Silent Made Language Language displayed on the screen Date Format Choose format of the date Date Set the date Time Set the time Enter Password If not 0000 the Setup screens will be password protected Screen Saver The screen will go black after the set amount of time Silent Mode Disable ADM sounds Advanced 2 12 10 12 17 11 e System Maintenance Mo Active Errors Temperature Units Mass Units fel Specific Gravity 0 980 Temperature Units Units of measure for displayed temperatures Mass Units Units of measure for mass Specific Gravity Required to convert the volume dis pensed to mass dispensed for tracking the total weight and flow rate NOTE When the specific gravity value is populated the total mass dispensed since the last total weight reset is shown on the Home screen and the mass flow rate is shown on the Diagnostic screen 333347F Advanced 3 12 10 12 17 11 e System Maintenance L Mo Active Errors Disable USB Downloads Uploads _ Disable USB Log Errors Download Depth Last Days Disable USB Downloads Uploads Disables use of the USB for downloading and uploading Disable USB Log Errors When disabled the system will not warn the user
43. page 34 Close the bleed type ball valve installed at the sys tem air inlet to relieve all air pressure in the system Turn main power switch OFF Remove plastic shroud 27 Remove vacuum transfer inlet funnel Remove air lines from relief valve 245 and air motor 218 Remove four nuts 3 securing melter shield 27 in place then remove melter shield Remove air motor assembly a Remove retaining ring 239 b Remove dowel pin 238 c Remove three screws 240 Use a flat head screwdriver and a rubber mallet to break loose the retaining nut 235 Use channel lock pliers to remove the retaining nut 235 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 Remove piston valve 222 from piston rod 223 Remove and discard piston u cup 225 and bearing 226 Reassembly see FIG 31 1 Assemble piston rod a Install new piston u cup 225 onto piston rod 223 with the lips facing the rod b Install piston bearing 226 onto piston rod 223 with grooved end towards the center of the pis ton rod 333347F c Install piston valve 222 onto piston rod 223 Torque to 24 30 ft lb 33 41 Nem 2 To protect the seals from the sharp threads place seal installation tool 15B661 into the throat bore See FIG 32 15B661 203 ti20877a
44. tem Channel Upgrade Kit 24V529 on page 110 24R040 RTD 125 251 and 255 See Melter and Pump Assembly on page 93 24V289 MZLP fuses Qty 8 8 Amp 250V Fuses P s ay 2 25 Amp 2500 Fuse _ 24P176 Customer I O 2 connectors for connecting to Connectors H1 and H2 on MZLP daughter board Use for PLC connec tion 333347F 91 Parts Transformer Assemblies 151 ti23309a 168 LN Mount fan with arrow pointing towards grill A Tie down cabling from transformer and fan using cable tie onto tie down locations Remove excess slack and ensure cabling does not contact fan blades Transformer Assemblies Ref Part Description Qty 151 ENCLOSURE base 480v 1 152 ENCLOSURE top 480v 1 153 TRANSFORMER 480v 240v 1 6kva 480V systems only TRANSFORMER 400v 240v 1 6kva 400V systems only 154 GRILL fan 1 155x FAN 24 vdc 120m x 120m 1 156 115942 NUT hex flange head 157 119865 SCREW mach hex serrated 1 4 6 x 3 8 in 158 127278 NUT keps hex 4 160 GROMMET air fitting 1 92 154 166 166 155 N AA 170 A Use nut to lock down the ground wire from transformer A Connect black fan wire labeled from transformer 153 in the pin labeled Connect red fan wire labeled to the connector coming from transformer 153 Ref Part Description Qty 161 125871 TIE cable 7 5 in 162 172953 LABEL designation 1 1664 17A071 LABEL safety warning 1 167
45. the air motor 218 Loosen screw AA then remove sensor 125 See FIG 41 on page 62 Disconnect ground screw 87 and ring terminal 88 from melter assembly Fic 40 20 Remove electrical enclosure front access door 10 333347F 21 Remove all heater wires from the following termi nals Pull wires up through the rubber grommet on the top of the electrical enclosure 1 i o Wire Marking Wire Marking 1 2 Band Heater 208 Melter Heater Rod 209 Base Heater Rod 210 22 Remove four nuts 3 then remove melter assembly from system Save any loose insulators for reas sembly 23 Remove bolts 259 insulators 249 washers 268 and melter assembly from base 257 Install Melter Assembly Er illit om 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 Ib 7 15 Nem 3 Use 4 bolts 259 to secure washers 268 and melter assembly to melter base 257 4 Use four nuts 3 to secure melter assembly to sys tem 333347F Hepair 5 Group the 4 sets of heater wires together and run them through the grommet on the top of the elec
46. the heaters and pump 13 Wait for the melter temperature to reach the hot melt cleaning fluid manufacturer s recommended temperature NOTE The pump will not run because the system air inlet ball valve is closed 14 Once the required melter temperature is reached let the hot melt cleaning fluid soak in the melter at temperature for the duration specified by the hot melt cleaning fluid manufacturer NOTE Soaking is important to ensure the best possi ble cleaning 15 After the hot melt cleaning fluid has soaked for the specified amount of time open the system air inlet ball valve Slowly increase the pump air pressure until pump begins to cycle to begin pumping the hot melt cleaning fluid and adhesive mixture out through the hose into the waste container 16 Once the pump begins to cycle faster close the sys tem air inlet ball valve to stop the pump 17 Repeat steps 7 through 16 until clean adhe sive free hot melt cleaning fluid is dispensed from the detached hose NOTE Now the melter and the disconnected hose are thoroughly flushed 18 Reattach the hose to the applicator manifold 19 Repeat steps 7 through 18 for each additional installed hose leaving a different hose discon nected from the applicator manifold each time 20 Remove and replace filter s in all applicator mani folds See applicator manual 21 Replace Outlet Filter See page 37 22 Turn main power switch OFF 23 Place was
47. to fill cap Check for air coming from 5 32 in air line Plugged orifice in fill cap below fill sen Remove fill cap and remove object plugging the sor orifice 42 33334 7F Troubleshooting Code Description Type case Solution L8FX Refill timeout Alarm Melter did not receive enough adhesive Storage bin out of adhesive Refill adhesive pellets for flow rate Plugged inlet feed hose or funnel Clear plugged hose or funnel former or less Low air pressure on feed regulator Check regu lator See Setup page 17 for air pressure regula tions Dirty or plugged funnel filter Replace filter Verify transformer fan is free of obstructions and can spin freely M8MF High Temp Run Devia At the current rate of temp rise the Verify that fan power cable is plugged into J7 on away Trans tion transformer will over heat in 15 minutes the AWB MMUX USB Log Full Advi USB logs full Data loss will occur if not nul MNDX Pump Mainte Advi Cycles are greater than user set main T2DO Low Tempera Devia Melter temperature dropped to ture Melter tion 15 F 9 C below setpoint T2D Low Tempera Devia Applicator temperature dropped to ture Gun X tion 15 F 9 C below setpoint Low Tempera Devia Hose temperature dropped to ture Hose X tion 15 F 9 C below setpoint High MZLP PCB Alarm MZLP board is overheating Temp 333347F Replace transformer Download USB data See
48. to prevent large items from entering the system The inlet filter can only be replaced with the system empty 1 Close the system air inlet ball valve ns NOTE Some adhesives have different melting points FiG 25 The first temperature tried should be approximately half of the dispensing temperature If dispensing at 400 F 1 Ifthe system is not up to temperature presse m to 204 C first try 200 F 93 C then increase in 20 F E P i 11 C increments If dispensing at 250 F 121 C first enable the heaters and pump then wait for system try 125 F 52 C then increase in 20 F 11 C incre to reach operating temperature ments NOTE To ensure the adhesive is a gel not a liquid do not remove inlet filter cap 215 when the temperature is above the desired temperature If the temperature is too low the adhesive viscosity may be too high to remove the inlet filter 213 See FiG 26 page 38 To avoid severe burns wear protective gloves and clothing that will insulate your hands and body from the hot surfaces and material 2 Perform Pressure Relief Procedure page 33 but 2 Ifthe melter is below the desired temperature and do not allow system to cool Adhesive must be a heating system is disabled press to enable fluid to perform this procedure the heaters 3 Turn main power switch OFF If the melter is above the desired temperature and heating system is enabled press to disable 4 Loosen two screw
49. when logs are full If the logs are full data will be overwritten Download Depth Last ___ Days The USB download will provide data as old as the number of days entered Old data may be in memory but will not be downloaded if older than the number of days entered Advanced 4 12 10 12 17 11 e System Maintenance Mo Active Errors Software Software Module Part Version Advanced Display 1BPUB 102 001 Temperature Control e 16T936 101004 USB Configuration 167910 1 01 0053 This screen shows the part number and version of each installed software module 333347F Appendix A ADM 119 Appendix B USB Downloading Uploading Appendix B USB Downloading Uploading The system can store 250 000 entries in its logs and the system adds a new entry to the logs every 15 seconds This means the system stores 1041 hours of system operation data or 43 days of around the clock opera tion Once full the system will overwrite the oldest data NOTE To prevent losing any data never go more than 43 days without downloading the logs Download Procedure NOTICE Uploading an edited system configuration file can damage the system Never put a modified SETTINGS TXT file in the UPLOAD folder on the flash drive NOTE The event log error log system settings and system language files are all downloaded in this proce dure See USB Logs System Settings File and Sys tem Language File starting on page 121 1 Inse
50. 0 EQUS Logs Downloaded 127101216418 EAUX USB Activity In Process 1z 10 1216 15 ELOS System Power On 12101216415 EMOX System Power Off The Events screens store a maximum of 200 events The events list can be downloaded in the USB logs See Appendix B USB Downloading Uploading on page 120 Tracked Events TrackedEvents si Fill Valve Closed Fill Valve Open Heat Off Heat On Logs Downloaded EQU5 Pump Cycles Total Reset Pump Off Pump On Red Stop Button Pressed Setup Value Changed System Power Off System Power On System Settings Downloaded EQU1 System Settings Uploaded EQU2 USB Disabled USB Drive Inserted EAUX USB Drive Removed EBUX User Maintenance Count Reset ERN1 Zone 115 Appendix A ADM Errors 120 12 17 22 e Events Eror Home Targets 9 No Active Errors late Time Code Description 1z2 10 1215 23 CACX Comm Error System PO 12 10 12 1623 CACI Comm Error MzLP 1 12 10 12 16 22 CACI Comm Error MzLP 1 1z 10 1215 22 CACX Comm Error System PO 12 10 1215 21 TEDL Sensor Err CH1 Gun 12 10 12 15 21 TBD Sensor Err Welter 12 10 12 1621 T400 High Temp Welter 12 1012 16 21 TBD Sensor Err CH1 Hose 12 10 12 1621 T402 High Temp CH1 Hose 12 10 12 1621 T401 High Temp CH1 Gun The Errors screens store a maximum of 200 errors See ADM Error Code Table on page 40 The errors list can be downloaded in the USB logs See Appendix B USB Downloading Uploading on page 120 Diagnostic J Fl
51. 1 802 BRACKET lock air control 1 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 101 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 ti23348a 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 102 Adapter Plate 24R083 Use this adapter plate to install InvisiPac in place of an existing hot melt applicator system Bolt Hole Dimensions A B C O m 9 o9 E 4 ie 9 8 in 249 mm 14 843 15 157 in 377 0 385 0 mm 17 003 17 317 in 431 9 439 9 mm e cL E 0 3 a jee d
52. 479a Electrical Enclosure Parts Quantity 1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP Description 400 480 V Transformer Hor owerncmos 3 3 3 5 5 102 wewo oAME mam a 3 3 p Wo f Harness wari awe 1 1 1 p LI 1 104 729970 SWITCH disconect da Joa 5 5 5 5 HOS eme CONTACT Me oo 1 5 5 5 106 720856 BUSHING strain reret mend 1 1 3 5 5 5 107 120869 WUT sain rereh m mend o 5 5 5 5 5 108 wen HTING ded a 5 5 5 5 109 121141 FITTING etbow swivel sectam 1 5 35 5 5 5 110 114421 BUSHING strain reief 1 3 1 1 1 111 1766 TERMINAL ground 1 1 1 J 1 1 J 112 MODULE MZLP with daughter board l a KIT board daughter 1 167440 1 e I I e l I l e I e I I e e l e 16T440 CAP souriau uts14 125856 SCREW 8 32 serrated flange 24P175 PLATE blank sgl mztcm NO NO NO 24V510 MODULE gca MZLP pa GASKET foam mztcm Ea 3 6 9 117 115942 NUT hex flange head 12 4 1 1 2 r r 7 r r r r 7 0 3 90 333347F Parts Quantity um Description HB sensona Joo 3 3 TT s ness wane ne E a O HARNESS
53. 9 105802 113944 193046 24P855 196762 196750 101864 117059 Description BASE melter HM50 BASE melter HM50 TANK melter HM50 TANK melter HM25 MANIFOLD outlet PLATE mounting HM50 PLATE mounting HM25 HOUSING fire rod HM50 HOUSING fire rod HM25 RING retaining int O RING fluoroelastomer HM50 only O RING fluoroelastomer HM25 only BAND heater HM50 only BAND heater HM25 only HEATER rod 1500 watts HM50 HEATER rod 500 watts HM25 HEATER rod 1000 watts HM50 HEATER rod 1500 watts HM25 SCREW cap sh 5 16 18 SCREEN wire PACKING o ring PLUG o ring boss SLEEVE cylinder PACKING o ring ptfe MOTOR double ended air see page 95 PLATE pump adapter ROD tie 1 5 in stroke GUIDE ball VALVE piston ROD piston BALL 31250 SEAL u cup piston BEARING piston BALL 5000 SEAT carbide PACKING o ring HOUSING foot valve O RING PACKING o ring BEARING throat SEAL u cup throat NUT packing FILTER assy 100 mesh welded PIN straight SPRING retaining SCREW cap sch 5 16 x 1 in O RING fluoroelastomer Qty D i i kesh WN e a a a NNN aea nlli D lI Il lI Il Il lI Il l l Il ls ls l cl Q Ref 2493xe 244 e 245xe 246 247 249 251 252 253 254 255 257 258 259 268 Part 15Y627 121295 15H304 167002 24R040 110298 115506 115814 No
54. Cable Board Samtec 208 24V522 Band heater HM50 Band heater HM25 209 Heater Rod 1500 W HM50 Heater Rod 500 W HM25 210 Heater Rod 1000 W HM50 24R037 Heater Rod 1500 W HM25 SWITCH OT 1201 16T102 Light Tower Ref Pat Description 333347F System 140 138 T N eh N i 1 AN L2 53 t 673 1 pa 312 i 42 E ii Qi 2D i GND GB1 Transformer 3 us Option b TEMP FAN FAN c O c N o NOOA OUN o NoN AON ahwond L1 L2 L3 GND J12 J13 Ground L 147 Stud N DC OK GND DC OK N V L V V 2 146 112A 1201 Optional Light Tower NE 9 Air Solenoid oi Fill Sensor J14 J15 anowon Ronm RwonM RoOnM Boma J16 Motor Cycle Switch 2 25 124 125 J5 Melter OT Switch i EL and Melter RTD os i cond i i To MZLP 2 4 and 6 aS Channel Option see 55 page 108 and 110 121 55 333347F xcloanmvuogs
55. GL to con IL came TTT EET ee CR ee UU M ee ee O Not for sale A Replacement Danger and Warning labels tags and cards are available at no cost ADM does not come with software Order software token 24R324 x Not shown Available kits purchase separately Description 24R885 Cycle Switch 25 26 BIRDS Inlet housing 12 13 62 LI DL EMEN 24V 544 Tubing 32 33 34 35 36 304 See Feed System Shaker and Tube 24V507 on page 96 for Mmm identification of item 304 24V5O5T Funnel 8 61 62 66 67 68 69 73 74 82 See Feed Inlet Fun nel 24V505 on page 99 24V508F Melter 53 202 204 207 211 and 253 See Melter and Pump Assembly on page 93 for s of items 202 253 24U635 Acrylic Lens ol 24WO000 x Melter Adapter 79 80 81 88 33334 7F Parts Electrical Enclosure pO a 106 107 SS 120 110 108 ti23477a A Apply sealant to all non swiveling pipe threads A Set rotary switch to 1 on MZLP with daughter card A Set rotary switch to 2 on MZLP 2 A Set rotary switch to 3 on MZLP 3 104 ti23478a 111 143 333347F 89 Parts 142 140 ti23
56. Hz 14A HM25 24V425 200 240 VAC 1 ph 50 60 Hz 40A HM50 24T920 200 240 VAC 3 ph A 50 60 Hz 40A 350 415 VAC 3 ph Y 50 60 Hz 30A HM25 24V431 HM25 24V426 HM25 24V427 HM50 24V199 335 400 VAC 3 ph Y 50 60 Hz 17A HM25 24V428 MEO 2AN 200 335 400 VAC 3 ph Y 50 60 Hz 17A VAC Maximum Applicator Wattage Per Channel Input Output Capability 43 5 kgh MBO _ 880 59 kg hr 1 3kg 2 6 kglhr IWeight 000000000000000 85 Ib 36 kg 105 Ib 48 kg NO Pneumatic Piston 127 System Dimensions without vacuum tube or 483 x 1067 x 419 mm shaker Width x Height x Depth Shaker Dimensions Width x Height 0 4x40ft 0 12 x 1 22 m Pressure and Temperature Ranges 333347F 23 Technical Data InvisiPac Hot Melt Delivery System Main System Air Supply Pressure Range set with 80 100 psi 0 55 0 69 MPa 5 5 7 bar regulator on front of system Pump Operating Air Pressure Range 14 0 69 MPa 0 7 7 bar Pump Operating Fluid Pressure Range 7 8 MPa 17 80 bar Control Temperature Range 8 204 C Ambient Temperature Range 49 C Vacuum Transfer Specifications Maximum Vacuum Transfer Hose Length 30 ft i Maximum Vacuum Transfer Hose Maximum Verti 3 0m Vacuum Transfer Operating Pneumatic Pressure 280 690 kPa 2 8 6 9 bar Range set with regulator on front of system Vacuum Transfer Air Consumption at 40 psi 280 16 1 scmh intermittent duty 496 at kPa 2 8 bar 25 lb hr
57. Instructions Parts GG g GRACO T TM InvisiPac HM25 and HM50 Tank Free a Hot Melt Delivery System a 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 e Important Safety Instructions Read all warnings and instructions in this manual and in the applicator and hose manu als Save all instructions CULA a ti22732a Intertek 9902471 Certified to PROVEN QUALITY LEADING TECHNOLOGY CAN CSA C22 2 No 88 Conforms to ANSI UL 499 CN TA Contents Related Manuals iue dete uar reri nos en ea desea 3 Required TO60ls hei EI ee teenie ke 3 Models 2 2 32 owes ta be a d Bacher aetna ted 4 200 230 VAC 350 415 VAC HM50 Models 4 200 230 VAC 350 415 VAC HM25 Models 5 400 VAC Transformer HM25 Models 6 400 VAC Transformer HM25 Models 6 480 VAC Transformer HM25 Models 7 480 VAC Transformer HM50 Models 7 Ligure TP EET 8 Component Identification 11 Heated Fluid Manifold lllssn 12 Electrical Enclosure 0 620534460 4ww edn ok RI 13 Advanced Display Module ADM
58. KER ball vibrator VALVE air pilot 3 way closed BRACKET shaker container HOSE nylon 3 8 in OD 250 psi 1 7 MPa 17 bar CONNECTOR tee push tube MUFFLER SCREW cap flange head Ref Part 912 125857 914 121141 915 120389 916 917 125539 Not for sale Description Qty SCREW 10 24 serrated flange 4 FITTING elbow swivel 3 8 in 1 tube connector 1 4 male npt FITTING tube 2 CONNECTOR tube 90 degree 1 FITTING splitter 3 8 in OD tub 1 ing Metric fitting included in Air Metric Fitting Kit 24W637 page 113 333347F 30 Gallon Vibrating Hopper Installation See FIG 64 for illustration of installed vibrating hopper 1 Turn main power switch OFF 2 With the steel shaker rod fully assembled and the 3 8 in OD air line connected to the shaker head cut the 3 8 in OD air line where the 1 3 in clear vac uum transfer hose connects to the steel shaker rod 3 Use the splitter fitting 917 to reconnect the 3 8 in OD air line that was just cut 4 Install the 48 in section of 3 8 in OD hose supplied with the kit into the remaining connection on the splitter fitting 917 5 Connect the other end of the 48 in section of 3 8 in OD air line to elbow fitting 916 on the piloted air valve 6 Connect shop air to elbow fitting 914 on the piloted air valve Shop air must be capable of 100 psi 0 7 MPa 7 bar NOTE The piloted air valve must use shop air Adding a tee at the syste
59. Line to Neutral 50 60 Hz 3 wire Neutral and PE D 1 Phase 200 240 VAC 200 240VAC 50 60 Hz 2 wire and PE D 3 Phase without Neutral E 200 240VAC 24V425 200 240 VAC A 50 60 Hz 3 wire and PE D 3 Phase with Neutral 350 415 VAC Line to Line 350 415 VAC Y 39 Neutral PE D 200 240 VAC Line to Neutral 50 60 Hz 3 wire Neutral and PE D 333347F 5 Models 400 VAC Transformer HM25 Models 400 VAC Transformer HM50 Models 3 Phase without Neutral 335 400 VAC Line to Line 3 wire and PE D 3 Phase without Neutral 335 400 VAC Line to Line 3 wire and PE aj 3 Phase without Neutral 335 400 VAC Line to Line 3 wire and PE D 50 60 Hz 24V198 m 335 400 VAC 30 PE Q5 24V 199 335 400 VAC 30 PE D 24V200 E 335 400 VAC 30 PE D 3 Phase without Neutral 335 400 VAC Line to Line 3 wire and PE D 3 Phase without Neutral 335 400 VAC Line to Line 3 wire and PE D 3 Phase without Neutral 335 400 VAC Line to Line 3 wire and PE D 50 60 Hz 333347F 480 VAC Transformer HM25 Models Models 480 VAC Transformer HM50 Models 3 Phase without Neutral 400 480 VAC Line to Line 3 wire and PE ee 3 Phase without Neutral 400 480 VAC Line to Line 3 wire and PE D 3 Phase without Neutral 400 480 VAC Line to Line 3 wire and PE db 50 60 Hz 24V201 m 400 480 VAC 30 PE d 24V202 400 480 VAC 30 PE db 24V203 E 400 480 VAC 30 PE D 333347F 3 Phase without Neutral 400 480 VAC Line to Line 3 wire an
60. TUBE corrugated slit 6 in 1 152 4 mm 168 169 170 127754 GRILL fan A Replacement Danger and Warning labels tags and cards are available at no cost Included in Fan Replacement Kit 24V91 1 Not for sale 333347F Parts Melter and Pump Assembly HM25 24V169 HM50 24V542 249 MEN LL S u cw d 245 268 oe A 259 __ 206 uu AN Lubricate all seals and o rings with grease A Assemble inserts 252 0 01 0 05 in 0 3 1 3 mm below surface A Orient melter 202 sensor hole in line with band heater 208 A Assemble inserts 252 0 01 0 05 in 0 3 1 3 mm below surface clamp AN Torque to 27 33 in lb 3 3 8 Nem Torque to 5 11 ft lb 7 15 Nem A Apply anaerobic thread sealant on threads v Torque to 24 30 ft lb 33 41 Nem Ad Torque to 12 18 ft lb 16 24 Nem A Orient u cups 225 234 with springs in direction shown 333347F 93 Parts HM25 Melter and Pump 24V169 HM50 Melter and Pump 24V542 Ref 201 202 203 204 205 206 207 208 209e 210 211 213 214 215 2161 217Tt1 218 219 220 221 22219 2239 22419 22519 22619 227 1 2281 2291 230 231 Te 2321 233 234Tt1 235 236 238 239 240 242 94 Part 111317 16W615 126475 24V 522 24R039 24R037 24R034 24R036 24R037 116940 112855 108526 24V558 192624 239932 105444 105445 192642 10707
61. W 3 1202 GROMMET single cable 1 12083 16K322 BRACKET light tower 1 1204 GROMMET multiple wires 1 1205 125835 CLIP ferrite bead 1 Not for sale 106 333347F Light Tower Kit Installation A A N 74 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 nsert grommet 1202 into hole on the light tower bracket 1203 5 Remove bolts BB from metal shroud on the sys tem then use the bolts BB to secure bracket 1203 to metal shroud 6 Route light tower cable through hole in bracket 1203 then use supplied light tower screws 12018 to install light tower 1201 7 Remove electrical enclosure front access door 8 Route light tower cable through the other hole in the bracket 1203 then through the grommet 1204 into the electrical enclosure 9 Connect light tower cable to MZLP connector labeled J12 333347F Accessories Air Reservoir Kit 16W366 This kit allows the system to operate as low as 60 psi 0 4 MPa 4 bar 3 v AS CIN van AN A ns PLANS 4 A g a La TA J is 1506 4 z z 1501 ti23351a 16W366 Parts Ref Part Description Qty 1501
62. WB If correct plug in J9 and recheck voltage If low replace ADM If correct plug in J8 If low replace MZLP If voltage is still low replace power supply V1MW Low Line Volt Devia Incoming line to line voltage has Verify incoming power is correct gauge for cur age tion dropped below 175V rent draw and verify incoming power lines are securely attached to disconnect V High Can Volt Alarm Bad or overloaded power supply Verify power supply voltage is 24 VDC If voltage Dr Jae o Pm NESS isin replace power suppyunt o n V4MW High Line Volt Alarm Incoming line to line voltage has For 3 phase with neutral have qualified electri ON ae i 7 ipeasev above asv o canvertyreurawies o V6MW Invalid Power Alarm During startup incoming line to line Verify incoming power is wired to the disconnect mE Type iui power was either below 175V or above correctly 265 V No line voltage Incoming line voltage is less than Measure incoming power with system 100 VAC unplugged If line voltage is less than 100 VAC contact qualified electrician to correct the low voltage WJDX Pump Solenoid Alarm No voltage draw from air solenoid for Error air motor the daughter board ul in WKFX Fill Solenoid Alarm No voltage draw from air solenoid for D DU IME S nn Defective air solenoids Replace See page 72 A valid configuration file can t be found System is not properly loaded with correct soft for the USB ware Perform Softwar
63. WZLP2mawo SST pop mo tess sma y 5 5 131 SCREW flange serrated 10 24x0 5 2 2 2 2 2 2 132 128967 KNOB operator isconnect i 3 3 3 35 5 135 ew CONNECTOR jumper P 5 p H86 harness mzet aw STC 1 3 5 5 5 par BUSHING abe pps I3lI3 tse harness asas Jao 3 3 3 35 140 24V615 TRANSFORMER assembly 80v24 ios 3 3 13 Ma GROMMET arfitng 3 3 3 Hag mae SCREW hexhd flanged emex 3 3 3 Ms mw WoUEmb 5 rr44_ 114361 SCREW mach pnh semsa 2 2 2 2 8 2 pas gt BRACKET powersuppy pq pae liasa POWER surety ew 3 3 3 3 35 Bar HARNESS power supply awe i 5 35 3 3 3 tas CABLE boardsamtec Purchase MZLP 118 and daughter board 112a separately Available kits purchase separately Ki Description Includes 24V528T Upgrade from 2 113 118 121 129 a ground channel system ing wrist strap and a software to 4 channel sys upgrade token See 4 Channel NI I n mi c n c5 N O tem Upgrade Kit 24V528 on page 108 24V529 Upgrade from 4 113 118 121 129 134 135 channel system grounding wrist strap anda to 6 channel sys software upgrade token See 6
64. 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 FIG 28 3 Plug air line and allow the air motor to cycle 4 Re connect air line to relief valve and check whether the system will stall 5 If system still does not stall purge ten pump cycles of material through one applicator 6 Repeat this entire procedure until no additional air is expelled from the applicator 54 Check the Pump Air Solenoid Operation A 747 Perform this procedure when directed in the Trouble shooting table NOTE System must be up to operating temperature for pump solenoid to trigger on 1 Ifthe heating system and pump is disabled press Oy to enable the heaters and pump 2 Wait for system to reach the temperature setpoints 3 Set pump air pressure to 20 psi 140 kPa 1 4 bar 4 Remove the 3 8 in OD air line from the air motor 5 Verify that air is flowing through the air line 6 fairis not flowing check the wiring between J13 and the pump solenoid Check Heater Rod Resistance Use the table to determine if heater elements need to be replaced Wes J mo Wattage Ohms Wattage Ohms 208 Band 4550 435485 2000 27 31 Heater 00 109 121 1500 36 5 40 5 1800 000 56i 209 Melter 5 Rod 333347F MZLP Troubleshooting Fic 29 MZLP LED
65. a Remove cover 29 and insulation 6 b Use 10 mm socket to remove air motor pilot valve 511 from air motor 218 c Lubricate with grease and install new air motor pilot valve 511 d Torque pilot valve to 95 105 in Ib 10 7 11 9 Nem e Replace insulation 6 and cover 29 74 Replace Air Valve FiG 5 Disassembly see FIG 57 1 Close the bleed type ball valve installed at the system air inlet to relieve all air pressure in the system 2 Turn main power switch OFF 3 Loosen clamp on air motor bracket 528 then remove funnel assembly 61 4 Loosen upper hose clamp on rubber housing then remove fill cap 5 Dispense until the fluid level in the melter is at or below the honeycomb grid NOTE If a screw or air valve seal is dropped during this procedure it could fall into the melter Melter fluid level must be below honeycomb grid before moving to next step 6 Once the fluid level is low enough close the bleed type ball valve installed at the system air inlet 7 Disconnect air hose and cable from the air motor 8 Use 10 mm socket to remove four screws 509 securing air valve 512 to air motor 218 9 Remove air valve 512 and seal 507 then discard Heassembly see FIG 57 1 Lubricate with grease then place new air valve seal 507 onto air valve 512 2 Carefully place new air valve 512 against air motor then thread in the four screws 509 Ensure the air valv
66. ailed dispense module adhesive leaking out middle of dispense mod ule No melter heat Cable to over tempera ture switch off or broken Over temperature switch tripped Air motor will not function No air being supplied to air motor Air solenoid not enabling the air motor Air present at air motor but it will not work System not turning on No power to unit 52 Thermal cutoff is tripped Replace dispense module Reduce air pressure to air motor Check resistance on heater rods Repair applicator manifold if heater rods measure open Check cable connections on both ends of the hose Check resistance on the RTD if out of normal range replace RTD Set correct RTD value in the ADM setup screen Consult manufacturer for cor rect RTD value Measure resistance of the thermal cutoff at room temperature If open replace Tighten screws on loose dispense module Replace o rings on the back of the leaking dispense module Replace dispense module Fuse blown in F1 and F2 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 Measure over temperature switch resistance It should read close to 0 ohms when at room temperature If open replace over temperature switch Make sure main system power is off when making measurement Check incom
67. ake connections between power supply harness 147 and new power supply 146 Connect connector labeled AWB J1 on power sup ply harness 147 to J1 on AWB 143 See Electri cal Schematics page 78 3 Install electrical enclosure front access door 10 71 Repair Air Controls mA Replace Air Control Solenoids NOTE In order to replace the air control solenoids the system must be tipped back to access underneath the electrical enclosure Disassembly see FIG 52 1 2 10 72 Turn main power switch OFF Disconnect plug from power outlet or turn off circuit breaker for incoming power Close the bleed type ball valve installed at the sys tem air inlet to relieve all air pressure in the system Remove front access panel 10 from electrical enclosure 1 Remove the transformer assembly for 480V sys tems only see FIG 53 a Disconnect transformer wires from J2 connector on AWB board and the main power switch b Remove three screws 142 and InvisiPac sys tem off of transformer assembly 140 Use 3 8 in socket to remove two screws 8 Note location of each air line connection Insert hands through access holes FF see FIG 52 in bottom of electrical enclosure then disconnect air lines from air control solenoids 402 Disconnect air control solenoids cable from MZLP daughter board connector J13 Pull wire out of the electrical enclosure Remove tw
68. andoffs and re install them on the new MZLP 1 b Toreplace MZLP 3 remove the jumper 135 from MZLP 3 J5 connector and reinstall it on the new MZLP 3 J5 connector Heassembly 1 Set MZLP rotary switch to 1 on MZLP with daughter card Set MZLP rotary switch to 2 or 3 on MZLP without daughter card based on location See FiG 48 for rotary switch location 68 2 Apply channel label stickers to new MZLP See FiG 4T 3 Use four screws 114 to install MZLP 112 to elec trical enclosure 1 4 Reconnect cables to MZLP 112 NOTE Do not force the electrical connection Minimal force is required to seat the connector If resistance is felt stop and verify the connector orientation NOTE If unable to determine connector location see Electrical Schematics on page 78 5 Install electrical enclosure front access door 10 6 Connect heated hose electrical connectors to new MZLP NOTE MZLP may need updated software See Soft ware Update Procedure on page 77 Replace MZLP Daughter Card mA Disassembly 1 Turn main power switch OFF 2 Remove electrical enclosure front access door 10 3 Note location of each cable then unplug all cables from MZLP daughter card 112a 4 Remove four mounting screws 112b from daugh ter card 112a and set aside Rotary Switch Fic 48 5 Unplug daughter card 112a from the MZLP 1 112 333347F Heas
69. as MZLP 2 and the original MZLP that came with the sys tem will be referred to as MZLP 1 from here on See FIG 65 6 Accessories 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 10 Connect CAN jumper cable 1302 to MZLP 1 con nector J3 and connect other end of jumper cable 1302 to MZLP 2 connector J3 See FIG 65 Connect power harness 1303 to MZLP 2 connec tor J2 Remove plugs CC from fluid manifold and replace with straight fittings 1307 or the extra fittings included with the InvisiPac system Use the fittings that meet your hose routing needs To ensure your InvisiPac system has the latest soft ware insert token 1306 into ADM Follow Soft ware Update Procedure page 77 Step 7 Install Jumper Cable 1302 MZLP 2 FIG 65 333347F MZLP 1 ti23596a 109 Accessories 6 Channel Upgrade Kit 24V529 Use this kit to upgrade a 4 channel system to a 6 channel system Ref 1301 1302 1303 1304 1305 1306 1307 1308 1309 110 1308 SM ae 1303 Part Description MODULE GCA MZLP 16T087 CABLE jumper male male 4 in 112190 STRAP wrist grounding 24R324 TOKEN software upgrade 161440 CAP jam nut sealing
70. bes p ates dte pe pid 121 System Settings File 0 0 0 121 System Language File ellus 122 Technical Data 22cm REO EEUU SE ERAS REPE 123 Stann TITIO ss hd er oL hn eoa Se RC in 125 DIMENSIONS BERE EON 127 Graco Extended Warranty 130 Graco Information 2x Se wurden a x eee owe inca 130 333347F Helated Manuals Related Manuals Manuals are available at www graco com Component manuals in English Description 3A2805 InvisiPac GS35 Hot Melt Applicator Instruc tions Parts 332072 InvisiPac Heated Hose Instructions Parts 333348 HM50 Fuse Kit Instructions Parts 333349 InvisiPac 480V Transformer Upgrade Kit Instructions Parts Required Tools Standard allen wrench set Metric allen wrench set Various sizes of crescent wrenches 11 16 in wrench 3 8 in ratchet 3 8 in socket 5 16 in driver 7 16 in socket 7 8 in deep well socket 1 in socket 13 mm socket 10 mm socket 1 2 in ratchet Side cutter Phillips head screwdriver Flat head screwdriver Multimeter Tubing cutter 333347F 3 Models Models 200 240 VAC 350 415 VAC HM50 Models See 400 VAC Transformer models on page 6 See 480 VAC Transformer models on page 7 1 Phase 200 240 VAC 10 PE 1 200 240VAC 50 60 Hz 32A 2 wire and PE D 3 Phase without Neutral E 200 240VAC TE 5 200 240 VAC A 30 PE D 50 60 Hz 27A 3 wire and PE D 3 Phase with Neutral 350 415 VAC Line to
71. com HM25 22 cpm HM50 by enabling the diagnostic screen If the cycle rate is below 11 cpm HM25 22 cpm HM50 and the system is still running away increase the InvisiPac system tempera ture in small increments over the current set point If the pump continues to runaway or dive continue increasing tem perature in small increments Do not exceed maximum temperature for the material being dispensed NOTE If air has become trapped in the pump it can be purged by fol lowing the Pressure Relief Procedure page 33 NOTE Some materials are more difficult to melt than others and it may be impossible to process them at the published melt rate The InvisiPac system was tested to achieve continuous published melt rates when dispensing standard EVA packaging grade adhesives in pellet form with an InvisiPac system temperature of 350 F and hose and applica tor temperatures of 350 F Level sensor blocked Clean feed cap by fill sensor make sure there are no adhesive pellets reading level incorrect blocking the sensor hole The system is not sup Ensure supplied Air Filter Kit 24 707 is installed on system air inlet plying enough air to the ultrasonic sensor ven turi Disconnect incoming air from InvisiPac system air inlet 108 Perform a reverse pressure flush of the sensor venture orifice Disconnect air tube poush connect union 91 from ultrasonic sen sor air tube 35 Plumb 80 100 psi 550 690 kPa 5 5 6 9 bar
72. d PE D 3 Phase without Neutral 400 480 VAC Line to Line 3 wire and PE D 3 Phase without Neutral 400 480 VAC Line to Line 3 wire and PE D 50 60 Hz Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbols refer to procedure specific risks When these symbols appear in the body of this manual or on warning labels refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause elec tric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns e 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 e Do not point
73. ding more than 4 2V the system should be requesting additional material Restart system If the error persists after attempting another refill and unit is needed immediately for production place system into the man ual refill mode See Manual Refill on page 30 The InvisiPac Some adhesives are Replace Funnel Filter see page 38 system expels very dusty due to the adhesive pel anti blocking agents lets dust when used or because the refilling adhesive manufactur ing process has cre ated small adhesive shavings Feed inlet cap filter may have become clogged NOTE Feed cap filter maintenance should be performed at regular service intervals It is recommended that the feed cap filter be inspected at a minimum of every 1200 Ib dispensed however with some adhesives the frequency may need to be increased significantly to maintain desired system cleanliness The InvisiPac Fluid leak Verify that no external leakage is present system will not stall pump continues to move even if the applicators are all closed The system System is not up to Verify that the system is active will not dis temperature Pis Dog Incorrect temperature Verify the temperature settings are correct set points entered into ADM Inspect and test the pressure relief valve Perform Flush Pressure Relief Valve page 54 If system is still unable to stall the pump or pressure relief valve may need to be repaired Air motor is not receiv V
74. e feed cap and funnel If production rate is below 1 5 Ib hour or system sits at temperature without dis pensing for extended periods of time use manual refill ing with caution System flow rate can be monitored by enabling the Diagnostic screen 1 On the System 3 screen in the Setup screens select Manual from the Refill mode dropdown 2 Remove the two bolts from the funnel bracket then remove the top portion of the funnel J 123292a FIG 21 3 Disconnect the sensor cable and sensor cooling air 4 Fill the funnel with adhesive pellets eu FiG 22 333347F Operation 5 Refill the funnel as needed to maintain the required dispense rate 6 When finished dispensing for the day dispense into a waste container until the material level is down to the melter core See FIG 23 NOTE This will lower the adhesive level within the fun nel cap to the correct level to prevent any issues upon startup the following production day ti23294a FIG 23 Automatic Refill The system uses automatic refill by default If the auto matic refill system is malfunctioning and cannot immedi ately be fixed Manual Refill can be used To use automatic refill 1 On the System 3 screen in the Setup screens select Automatic from the Refill mode dropdown 2 Verify shake
75. e Update Procedure on page 77 Retry USB download WSUX USB Invalid Devia Configuration tion Bad ADM Replace ADM 333347F 45 Troubleshooting Mechanical and Electrical Troubleshooting Pomem Cause Solon Refill Timeout Thesystem was unable Check hopper for adequate material and material blocking zu tO ren m des thal 20 Verify the vacuum transfer system air pressure is 40 80 psi 60 psi rec ommended and that air is flowing to the feed wand while attempting to refill Seconds Restart system If the error persists after attempting another refill and unit is needed immediately for production place system into the man ual refill mode See Manual Refill on page 30 Check funnel filter If plugged see Replace Funnel Filter on page 38 The InvisiPac Glue level in hopper is Check hopper for adequate material and material blocking system takes a low p Vacuum flow is Verify the vacuum transfer system air pressure is 40 80 psi 60 psi rec restricted ommended and that air is flowing to the feed wand while attempting to refill Check funnel filter If plugged see Replace Funnel Filter on page 38 Vacuum trans Air to vacuum assem Verify the vacuum transfer system air pressure is 40 80 psi 60 psi rec fer not working bly missing ommended Air at system air gauge Check that air line is connected or not pinched but not to air to shaker Air is at shaker but Plugged shake
76. e seal 507 stays in place by applying constant pressure against the air motor 333347F 5 Remove Air Motor Use 10 mm socket to torque screws 509 to 95 105 in Ib 10 7 11 9 Nem Install fill cap then tighten upper hose clamp on rub ber housing Connect air hose and cable to the air motor 2 FIG 58 1 2 ti23444a 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 Disconnect air line 36 from pressure relief valve 245 then pull through metal shroud 27 See FiG 45 on page 65 Remove three nuts 3 securing metal shroud 27 in place then remove metal shroud 27 Disconnect air supply line from air motor 218 Remove air motor assembly a Slide retaining ring 239 down 333347F 1 Hepair b Remove dowel pin 238 c Remove three screws 240 d Remove screws 8 screws 74 and bracket 82 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 Fia 58 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 Connect air motor assembly to system
77. e to ground Replace faulty hose Ambient temperature must be under 120 F Defective MZLP board Replace Troubleshooting Code Description Type Cause sowon Check that RTD is seated in melter correctly Check that overtemperature switch is plugged in and check switch resistance The switch resis T4D0 T4D_ High Temp Melter High Temp Hose Alarm Alarm T4D_ High Temp Gun High Tempera ture Trans former Sensor Error Sensor Error Alarm No reading from RTD Hose Sensor Error Thermistor Sen sor Error Trans former No Temp Rise in Gun all zones Alarm Alarm Alarm Alarm Alarm Melter continues to raise above the set point Hose continues to raise above the set point Applicator assembly continues to raise above the setpoint Thermistor reading greater than 212 F 100 C No reading from RTD No reading from RTD No reading from transformer thermistor sensor Temperature reading does not change tance should be near 0 Below 400 F 204 C Check melter heaters resistance to ground Replace heater if a heater is shorted to ground Turn system on without dispensing Verify tem perature is properly controlled to the setpoint If setpoint is not maintained replace RTD If heat continues to rise past setpoint replace MZLP Turn on system without dispensing Check if hose can maintain setpoint temperature I
78. ely 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 e Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines 333347F 9 Warnings 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 e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture Failure to follow this warning can result in death serious injury or prop erty damage e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents e Many other fluids may contain chemicals that can react with aluminum Contact your material sup plier for compatibility 10 333347F C
79. em and perfor mance related information to memory in the form of log files InvisiPac maintains the events data GCA Black Box and Diagnostics logs Follow the Download Pro cedure page 120 to retrieve log files Events Log The event log 1 EVENT CSV maintains a record of the last 175 000 events Each event record in the log file contains the date and time the event occurred the event type event code and event description Data Log The data log 2 DATA CSV tracks the setpoint and actual temperatures every 15 seconds This log can store up to 250 000 lines of data The system stores 1041 hours of system operation data or 43 days of around the clock operation Once full the system will overwrite the oldest data NOTE To prevent losing any data never go more than 43 days without downloading the logs 333347F Appendix B USB Downloading Uploading GCA Log This log 3 GCA CSV lists the installed GCA modules and their respective software versions Black Box Diagnostics Logs These logs 4 BLACKB CSV 5 DIAGN CSV are designed to provide useful information to Graco when calling for technical assistance System Settings File NOTICE Uploading an edited system configuration file can damage the system Never put a modified SETTINGS TXT file in the UPLOAD folder on the flash drive The system configuration settings file name is SETTINGS TXT and is stored in the DOWNLOAD folder A system configurati
80. ered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For more information about InvisiPac visit www InvisiPac com For technical assistance or customer service call toll free 1 800 458 2133 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice For patent information see www graco comv patents Original instructions This manual contains English MM 333347 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2014 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revsion F January 2015
81. erify that the pump air pressure is set above 20 psi Check the Pump ing compressed air or Air Solenoid Operation page 54 air pressure too low Feed pump not feed Repair or replace air control assembly as necessary ing adhesive Repair or replace pump assembly as necessary Timing control for appli InvisiPac system does not control the timing of the applicators This is cators not working a separate control that needs to be adjusted Consult control manufac turer or qualified electrician Cycle Switch Cycle switch or cycle Check the wiring between the air motor cycle switch and J16 Error switch wiring failure Hepair replace as required Loose or missing fas Ensure fastener 26 is tight See InvisiPac Systems section begin tener 26 ning on page 83 for part identification 333347F 47 Troubleshooting Probie eas Solon OOOO USB Log Full The InvisiPac system To prevent data loss download system data See Appendix B USB will display this notifica Downloading Uploading on page 120 tion when the USB data logs reach 90 full The InvisiPac system is dis playing pump runaway or pump diving This error generally This can occur if the melt rate for the system is exceeded resulting in occurs when the pump air entrapment within the incoming adhesive material and lower than cavitates due to desired material temperature improper material load ing Verify that the InvisiPac system is not exceeding 11
82. erious injury from pressurized fluid such as skin injection splashing fluid and moving parts follow the Pressure Relief Pro cedure when you stop spraying and before cleaning checking or servicing the equipment 1 Turn main power switch OFF 2 Close the inlet air supply ball valve 3 NOTE Manually verify the pressure is relieved by open ing the applicator and ensuring no adhesive is dis pensed 33 Operation Drain the System A 747 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 12 10 12 17 134 Schedule Acvanced E Ma Active Errors Enable Diagnostic Screen Lock Run Screens Purnp Idle Time to System l bs Lo minutes Power Type Single Phase B Circuit Breaker Size Amps Refill Setting Manual Y 2 Ifthe heating system is disabled press to enable the heaters and pump 3 Decrease pump air pressure to 0 4 Close system air inlet ball valve 5 Disconnect hose from applicator inlet then place hose outlet in a waste container Repeat for all hoses Keep hose to applicator electrical connector connected 6 Open applicator to allow residual fluid in applicator to drain 7 When system is at operating temperature slowly increase pump air pressure until fluid beg
83. f the hoses RTD readings are unstable replace hose If hose continually heats past setpoint replace the MZLP Turn on system without dispensing Check if applicator can maintain setpoint temperature If the applicators RTD readings are unstable replace the applicator RTD Check the applicator heater s resistance to ground if the RTD readings are stable but the applicator s temperature continues to rise If the heater is shorted to ground replace the applica tor s heater If heater is not shorted to ground replace MZLP Verify transformer fan is operating correctly and free of obstructions Replace transformer Verify connector J5 on MZLP board is securely connected Defective RTD Replace melter RTD See Replace Band Heater Temperature Sensor page 63 Hose electrical connector not plugged into MZLP Defective RTD Replace hose Hose electrical connector not plugged into MZLP or applicator electrical connector not plugged into heated hose Defective RTD Replace applicator RTD Verify that sensor wire is plugged into J7 on AWB Replace transformer Check fuses F3 and F4 channels 1 3 5 or F7 and F8 channels 2 4 6 on MZLP that error channel is connected to Defective heater rods in applicator manifold Replace applicator manifold NOTE Defective heaters rods in the applicator manifold can also cause the no current error Heated hose electrical connector or wires are defective Check re
84. follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipment only for its intended purpose Call your distributor for information Houte 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 MPa bar PSI 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 immediat
85. he dispense modules when triggered Plugged applicator Replace applicator manifold filter Graco applicator manifold filter in manifold filter single bottom of manifold or inline filter on other manifolds dispense module appli cator Clogged hose Flush or replace hose Defective solenoid Check that correct voltage is input into solenoid valve If voltage is cor valve rect replace solenoid No signal from control If no voltage is present at solenoid check control cable and pattern to solenoid controller Replace component Plugged solenoid muf Replace solenoid mufflers flers No air to solenoid Re establish air supply to solenoid Plugged system outlet Replace Outlet Filter See page 37 filter If multiple applicators are triggered simulta neously maximum Stagger applicator opening to reduce the maximum required flow rate to below maximum pump rate pump rate may be exceeded 333347F 51 Troubleshooting Promem Omes Solon O Adhesive flow ing out of one some applicators when not trig gered Failed valve in the open position Adhesive pressure too high Applicator will not heat Heat rod failure in appli cator manifold Loose cable connection at system or manifold RTD failure Incorrect RTD setting in the ADM setup Adhesive leak ing from mani fold or dispense Dispense module is loose on the manifold Dispense module o ring failed module F
86. he heaters and pump O NOTE If using the Schedule function the heaters and pump will be enabled automatically at the set time You will not need to press if using the Schedule func tion unless you wish to enable the heating system before the set time NOTE When system is up to temperature the pump will begin running automatically It will stall at pressure unless an applicator is open Material will be dispensed whenever an applicator is open after the system is up to temperature 5 When the system is up to temperature use sepa rate pattern controller to open and close the applica tors as desired to dispense material NOTE While operating the system the actual tempera tures of the hose applicator and system melter are dis played on the Home screen 12 10 12 17 23 4 Errors Targets Events gt Qd 2o Q cone 2 350 F Qoo QE 2 333347F Shutdown Press to disable the heaters and pump The screen will say Inactive If using the Schedule function the heaters and pump will be disabled automatically at the set time You will not need to press if using the Schedule function unless you wish to disable the heat ing system before the set time If the heaters were man ually disabled the Schedule function will automatically enable them at the next set time 12 10 12 17 09 Errors Targets Events m No Active Errors Qe 72 Qarma 7 D 72 F Qarma 7
87. hole in the top of the piston rod 223 to lift the piston rod 223 up out of the manifold This will also pull out the throat u cup 234 and throat bearing 233 11 Replace Pump Inlet Housing Checks See page 58 12 Use a 1 2 in drive ratchet without a socket to remove foot valve 230 from bottom of melter outlet manifold 203 See FiG 36 page 58 13 Insert cylinder tool 1301 into bottom of melter out let manifold 203 Use a rubber mallet to gently remove cylinder 216 l 1301 FIG 37 333347F Repair 14 Remove and discard cylinder seals 217 See FIG 37 Reassembly 1 Apply grease to seals 217 then install new cylinder seals 217 onto cylinder 216 See FIG 37 3y Os 9 ti21049a FIG 38 2 Place female cylinder installation tool 1302 into melter outlet manifold 203 to protect seals from sharp threads See FIG 38 Use male cylinder installation tool 1303 to press cylinder 216 into melter outlet manifold 203 If necessary use rubber mallet tap into place See FIG 38 Use a 1 2 in drive ratchet without a socket to install and tighten foot valve 230 into bottom of melter outlet manifold 203 See FIG 36 page 58 Perform Replace Pump Inlet Housing Checks on page 58 Perform Reassembly portion of the Replace Throat Seal Throat Bearing Piston Rod Piston Seal and Piston Bearing procedure which starts on page 56 59 Repair Melter
88. i N F2 F1 f ro ie H Customer Output Dropdown Options M mE Disable Not used E ac System Ready Indicates when the system is up to tem ag perature and the pump is stalled at oll E pressure O 5 Error Alarm Indicates when there is an active alarm l 1234342 M An active alarm will disable the heating FIG 1 MZLP Board gt system and pump dini H1 Customer Input H2 Customer Output OL Sir vir Ee Error Devia Indicates when there is an active devia tion Advisory tion or advisory An active deviation or advisory will NOT disable the heating system and pump 1 2 Maintenance Due Indicates when the maintenance total 8 J 56 43 5 6 has reached the preset notification 05n8 4 value Inputs High 10 30 Vdc Low 0 5 Vdc Inputs function NOTE All outputs are normally open when power is without concern for polarity Applying high voltage will OFF For Error Alarm output the contacts open when turn the heaters on and enable channels Removing an alarm occurs For all others contacts close voltage will turn the heaters off and disable channels Outputs 0 250 Vac 0 30 Vdc 2A Maximum 333347F 27 Setup PLC Connection Block Diagrams
89. in relief bush ing is intended for power cords with an OD of 0 512 1 024 in 13 26 mm Installation 1 Remove standard strain relief bushing 106 Retain and reuse nut 2 Install strain relief bushing from kit and secure with retained nut Hose Straps 4 Pack 24R0294 Use these straps to secure hoses without excessive pinching Ref Part 1 114271 Description Qty STRAP retaining 4 Pressure Gauge Replacement Kit 24R635 To replace the air gauge glass lenses and glass fuses used in the food or beverage industries Ref Description Qty 1 GAUAGE pressure acrylic 2 2 TOOL puller fuse 1 3 FUSE 250v 8a 32 113 Appendix A ADM Appendix A ADM General Operation ADM Power The ADM automatically turns on when the main power switch is turned ON Screen Navigation To switch between the Setup and Operation screens press Ey Use EM t andi to navigate between screens Enable Disable Heating System To enable or disable the entire heating system press To set which channels are active when the heating system is enabled use the System 2 screen See page 117 Icon identification Mon Description Operation Screens Only Warming up actual tempera ture is below setting 00 rue setting achieved Tarati 35D F Actual temperature of hose c left and applicator right Actual temperature of system shown warming up System temperature setting and Ll to adjust
90. ing air supply air motor is disabled until system reaches Active state When Active the pump air solenoid should supply air to the air motor Check solenoid voltage if 24VDC present at air solenoid replace air solenoid Replace air motor Check main power breaker is turned on Check that power plug is connected 33334 7F Troubleshooting Pomem Cause Solon Static shock Ground wire not in Attach a ground wire from the shaft of the shaker unit to a true earth when touching place on shaker ground Order shaker grounding kit 24R708 shaker or assembly Some adhe adhesive bin sives flow rates and ambient conditions can Cause excessive static buildup on the shaker tube Adhesive not Dispense modules InvisiPac system does not control the opening and closing of the appli dispensing at opening at the wrong cators The separate controller needs to be adjusted Consult pattern the correct time control manufacturer or qualified electrician time Pump and vac Solenoid connector is Move solenoid connector from J12 light tower to J13 solenoid uum feed sys installed into the light valves on the daughter board on the MZLP tem cycle on tower plug on the and off before MZLP daughter board temperature setpoint is achieved 333347F 53 Troubleshooting Flush Pressure Relief Valve A AMA Perform this procedure when directed in the Trouble shooting table 1
91. ins flowing into the waste container NOTE It may take several minutes to empty the sys tem When there is no melter fluid at the pump the pump will begin to cycle faster 8 When the pump begins to cycle faster close the system air inlet ball valve 9 Press to disable the heaters and pump 10 Remove melter drain plug W1 See FIG 2 on page 12 11 Disconnect hose from melter outlet 34 12 Wait until system stops draining or at most 10 min utes NOTE There will be some residual adhesive in the sys tem 13 When done performing the procedure that required draining the system set Refill Setting back to Auto on the System 3 screen Flush E A To prevent fire and explosion use the adhesive manu facturer s recommended cleaning fluid e Never exceed the cleaning fluid s rated temperature e 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 34 2 Ifthe heating system is enabled press to dis able the heaters and pump 3 Loosen hose clamp securing funnel assembly to
92. ion enables the system to automatically enable and disable heating at specified times so that the system is already up to temperature when a shift begins 8 If desired set any remaining settings in the Setup screens before going on to the next steps that use the Operation screens These are not required for system operation but include useful functions See Appendix A ADM beginning on page 114 for detailed information about each setup item 333347F 9 10 Setup Press Er to switch from the Setup screens to the Operation screens Use E Z4 t andi to navigate between screens On the Targets screen use g and n shown next to d to adjust system melter setting El 350 F Also the desired temperature setting can be typed in using the numeric keypad Targets Events 3 L n E 350 F Events Errors gt n BM d 2370 mex 25 Setup 11 On the Targets screen adjust heated hose and applicator temperature settings NOTE InvisiPac is a high powered tank free system that delivers heat faster than traditional tank systems Tanks are often run at a lower temperature than the application temperature to avoid excessive adhesive degradation since a large volume of adhesive sits at temperature a Press Fu to select the channel b Use rn and n shown next to C to aL F adjust applicator temperature setting to the desired setting for that channel NOTE If a higher applicator temperat
93. l TOONS uitis i ich bcati 1 ooh icto list t 100 Non Graco Applicator Adapter Cables 101 Air Adjustment Lock 24R084 LLL 101 System Stand 24R088 0 0 cee eee 102 Caster for Stand 120302 0c eee 102 Adapter Plate 24R083 clerus 102 30 Gallon Vibrating Hopper 24R136 104 Light Tower Kit 24R226 lelsnn 106 Air Reservoir Kit 16WS66 004 107 4 Channel Upgrade Kit 24V528 108 6 Channel Upgrade Kit 24V529 110 InvisiPac ADM Simulator Kit 24R323 112 ADM Extension Kits 0 0 00 cee eee eee 112 ADM Remote Mount Bracket 24A326 112 Overtemperature Jumper 16Y727 113 Air Metric Fitting Kit 24W637 113 Strain Relief Bushing Kit 24X190 113 Hose Straps 4 Pack 24R0294 113 Pressure Gauge Replacement Kit 24R635 113 AppendbcA ADM 2c cece en xe ERR RAD ea pce seda 114 General Operation 0 0 00 cee eee elles 114 Icon Identification 0 cee 114 Operation Screens 0 eee 115 SCID SCIECNS s i2 de E ctus eod ew e Roa odi 117 Appendix B USB Downloading Uploading 120 Download Procedure 00 cee eens 120 ACCESSING FICS 242a irs der Baba uu dei Sead 120 Upload Procedure 3c ade Reborn rs 120 USB LOGS 2 255 o0 Ge toot
94. ll ensure adhesive spends as little time at temperature as possible Less time at high temperature ultimately means less adhesive degradation and less char NOTICE Set melter hose and gun to the same setpoint temperature for best performance Do not set the hose temperature higher than the melter Running the hose at a setpoint higher than the melter is unnecessary in this tank free system and could lead to adhesive degradation in the hose Short adhesive residence time in the melter eliminates the need to set the melter at a lower setpoint than other zones 333347F Maintenance Mal ntenance 6 Insert allen wrench through the outlet filter cap to lift outlet filter 236 out of the system 7 Discard outlet filter assembly Replace Outlet Filter EM 8 Place o rings 232 237 provided with new outlet fil The outlet filter is designed to prevent small contami ter onto new outlet filter 236 nants from entering the hoses and applicators Inspect filter regularly Replace the filter after flushing and when 9 Place new outlet filter with o rings into housing you change the adhesive used in the system Tighten with 1 in socket 10 Install small metal shroud 28 over outlet filter then tighten two screws 8 Replace Inlet Filter pfit 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
95. m inlet to run the hopper shaker may impact pump and vacuum transfer performance 7 Place steel shaker rod assembly into hopper 901 with steel rod resting in the hopper groove in the rim of the hopper 8 Place lid 902 on hopper 901 NOTE The hopper shaker will be active while the vac uum transfer system is transferring pellets NOTE The air supplied to the pilot valve from the sys tem vacuum must be set to 65 of the shop air supply supplied to elbow fitting 914 or higher If the pilot valve air pressure is lower than this increase the vacuum transfer air pressure regulator E see FiG 1 on page 11 333347F Accessories Splitter fitting A S To piloted air valve Hopper shaker Piloted air valve To shop air amp supply ti21350a FIG 64 105 Accessories Light Tower Kit 24R226 The light tower enables someone away from the system to quickly see whether the system is inactive or OFF no lights warming up flashing green at temperature solid green or has an active error red S AA o 1204 D J12 CN ma and E _ o ti23350a EB 0 Ea n 1202 D o 5 ERES i L 1205 brad dem pE o P c z m E ES ago Ed 24R226 Parts Ref Part Description Qty 1201 1617102 LIGHT tower red and green 1 1201a SCRE
96. move plugs CC from fluid manifold and replace with straight fittings 1309 tee fittings 1308 or the extra fittings included with the InvisiPac system Use the fittings that meet your hose routing needs 11 To ensure your InvisiPac system has the latest soft ware insert token 1306 into ADM Follow Soft ware Update Procedure page 77 ti23597a 111 Accessories InvisiPac ADM Simulator Kit 24R323 Use this kit to train users in ADM operation without using the full InvisiPac system Kit includes everything necessary to simulate the ADM screens Does not include an InvisiPac system Ref 1401 1402 1403 1404 1405 112 Part 24P860 124149 24R322 24R324 1402 1403 ti20990a Description MODULE Advanced Display ADM POWER SUPPLY GCA CORD SET US MX PR CA TW 115V 10A TOKEN InvisiPac Simulator SOFTWARE UPGRADE TOKEN InvisiPac System 1401 Qty Simulator Instructions 1 Remove ADM access panel and install InvisiPac Simulator Token 1404 Fic 67 Remove Access Panel 2 Connect power supply 1402 to ADM 1401 3 Connect cord 1403 to power supply 1402 4 Perform Software Update Procedure on page 77 ADM Extension Kits Use the extension cables to remote mount the ADM dis play off of the InvisiPac system Kits available sepa rately Kit No Cable Length Qty 24R710 16 4 ft 5m 24R711 49 2 ft 15 m 24R712 164 ft 50 m a eS ADM Rem
97. mum vacuum transfer hose length available is 30 ft 9 1 m The adhesive pellets container must be located within reach of the vacuum transfer hose and no more than 30 ft 9 1 m away 333347F Setup The applicator s must be located no more than 25 ft 7 6 m from the melter Place the base system on a surface that is eye level for easiest operation Use System Stand 24R088 to install system at eye level See page 102 If installing the system in place of a non Graco hot melt system purchase Adapter Plate 24R083 See page 102 Optional 30 Gallon Vibrating Hopper 24R136 avail able purchase separately See page 104 To make repairing the system easier locate the system so that all sides are easily accessible and have sufficient lighting Attach Components To reduce the risk of electric shock do not connect electrical cord until after this Attach Components procedure is complete NOTE Only systems with transformers are supplied with a lifting strap NOTICE To prevent strain on electrical or mechanical connections around the pump assembly loop the strap around the tie rods as shown 1 Use supplied lifting strap 127735 to transport sys tems with transformers Wrap strap around all three pump tie rods and loop the strap back through itself in the Choker Configuration See strap for details See FIG 8 page 18 17 Setup ti23758a Fic 8 Lifting Strap 2 Place the base system in
98. n The last digit of the error code indicates the melter applicator gun or hose to which the error applies The underscore character indicates the code applies to multiple items Last Digit in Code Code Relates to Melter Applicator Gun 1 Hose 1 Applicator Gun 2 Hose 2 Applicator Gun 3 Hose 3 Applicator Gun 4 Hose 4 Hose 8 War 8 WpraorGw s An alarm will disable the heating system and pump A deviation or advisory will not disable the heating system and pump Type Cause Low Current Melter current is less than 500mA Faulty melter heater s Check heater resistance Melter and resistance to ground Replace faulty heater s Low Current Applicator current is less than 500mA Faulty applicator heater Verify applicator heater Gun X has a minimum wattage of 90 Watts at 240 VAC Check heater resistance and resistance to ground Replace faulty heater A1D Low Current Advi Hose current is less than 500mA Faulty hose heater Check heater resistance and Hose X sory resistance to ground Replace faulty hose 40 333347F Troubleshooting Lo A3MF High Fan Cur Devia Transformer fan is greater than Replace transformer fan rent Trans tion 600mA former A4D0 High Current Alarm Defective or shorted to ground on the Measure resistance to ground between heater ce ater bandmoderortodheaer Teas Shoudbeaigheadng High Current Alarm Defective or shor
99. ng when breaker off or power system turned cord unplugged d Cable on ADM Heconnect ADM cable unplugged Connector on AWB ADM cable should be plugged into J9 of the AWB board board not plugged in Bad 24VDC power sup Check output on power supply should measure 24VDC if no voltage ply reading replace power supply ADM defective Replace ADM Wrong setting in ADM Wrong breaker setting on ADM in the breaker setting in the setup breaker setup screen Internal short to ground Unplug or disconnect power and measure between each leg of the in system power to ground There should be an open resistance reading Too small of a circuit Consult qualified electrician for proper size circuit breaker breaker in main power panel Main breaker tripping 333347F 49 Troubleshooting Slow start up Wrong setting in ADM LL breaker setting on ADM in the breaker setting in the setup time or system breaker setup Screen takes longer Low incoming voltage Incoming voltage should be 200 240VAC for a 230 volt unit and 380 than 10 min 400 VAC for a 400 volt unit utes to startup Heater rod defective Measure and check heater rods in melter or applicator See applicator man Melter and gun mani ual See Check Heater Rod Resistance page 54 fold Heated hose defective Measure heater wires in hose pins C and D See repair section for each hose resistance Insufficient power sup Connect system to a power
100. ntroller to open the applica tors and keep them open NOTICE In the following step to prevent damage to the pump due to pump cavitation do not supply more than 20 psi 140 kPa 1 4 bar air pressure to the pump until the system is fully primed 12 With the applicators open and the system up to tem perature slowly increase pump air pressure until the pump begins to run very slowly Approximately 20 psi 140 kPa 1 4 bar should be sufficient NOTE Operation may be erratic below 20 psi 140 kPa 1 4 bar 13 Continue running the pump until clean air free material is dispensed from each applicator 14 When each applicator is fully primed adjust pump to desired pressure setting a Adjust pump pressure to between 20 100 psi 140 690 kPa 1 4 6 9 bar b Use separate pattern controller to repeatedly open and close each applicator while inspecting the dispense pattern c Repeat until desired dispense pattern is achieved Manual Refill NOTE Use Automatic Refill whenever possible The system uses Automatic Refill by default and must be manually changed to Manual Refill Only use Manual Refill if the Automatic Refill system is not functioning properly and cannot be fixed in a timely manner Per form service to automatic feed system as soon as possi ble to limit debris buildup on feed funnel 333347F It is recommended to maintain a minimum flow rate of 1 5 Ib hour to prevent material from melting within th
101. o screws 405 securing solenoids 402 to air control assembly 9 then remove air control solenoids ti23440a FIG 52 ti23595a FIG 53 Reassembly see FIG 52 n Use two screws 405 to secure new solenoids 402 to air control assembly 409 Feed the new solenoid cable into the electrical enclosure and attach cable to MZLP daughter board connector J13 Insert hands through access holes FF see FIG 52 in bottom of electrical enclosure then connect air lines to air control solenoids 402 Slide air control assembly 9 into place then use two screws 8 to secure to electrical enclosure 1 For 480V systems install transformer assembly 140 with screws 142 and reconnect transformer wires to J2 connector on AWB board and the main power switch 333347F Hepair 6 Install electrical enclosure front access door 3 Place one small crescent wrench on the brass part of the gauge then use a second small crescent Replace Air Control Gauge wrench to tighten the air fitting 403b NOTICE In the following step do not overtighten the two nuts 403a Overtightening may cause the gauge to break 4 Orient gauge as desired then tighten two nuts 403a to secure gauge 403 in place 5 Slide air control assembly 9 into place then use two screws 8 secure to electrical enclosure Air Motor t23441a Replace Pilot Valve Disassembly see FIG 54
102. omponent Identification AD 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 G Shaker Tube G1 Shaker Head G2 Vacuum Transfer Tube G3 Vacuum Transfer Inlet Funnel G4 Vacuum Transfer 3 8 in OD Air Supply Main Power Switch System Air Inlet Vacuum Transfer Shaker Inlet Air Motor and Pump Incoming Power Strain Relief Heated Fluid Manifold Melter oODUuUzzrAacr Customer I O Cable optional AC Drain Port AD Transformer optional FiG 1 333347F Multi Zone Low Power Temperature Control Module MZLP Fluid Outlets for connection to Heated Hoses numbered 1 6 Component Identification P ti23594a 11 Component Identification Heated Fluid Manifold ti22734a NOTE System shown with plastic and metal shrouds removed FiG 2 Key T Electrical Enclosure Front Access Door U Melter W1 Drain Port We Drain Tray X Inlet Filter Low Pressure Before Pump Y Outlet Filter High Pressure After Pump Z Adhesive Pellets Level Sensor not shown inside funnel AA Power and RTD Harness Connection to Heated Hose and Applicator harness connects from system to heated hose then from heated hose to applicator AB Inlet Funnel Screen 12 333347F Electrical Enclosure FIG 3 Key P Multi Zone Low Power Temperatu
103. on settings file automatically down loads each time a USB flash drive is inserted Use this file to back up system settings for future recovery or to easily replicate settings across multiple InvisiPac sys tems Refer to the Upload Procedure page 120 for instructions on how to use this file It is recommended to retrieve the SETTINGS TXT file after all system settings are set as desired Store the file for future use as a backup in case the settings are changed and need to be quickly changed back to the desired setup NOTE System settings may not be compatible between different versions of the InvisiPac software 121 Appendix B USB Downloading Uploading System Language File The system language file name is DISPTEXT TXT and is stored in the DOWNLOAD folder A system language file automatically downloads each time a USB flash drive is inserted If desired use this file to create a user defined set of custom language strings to be displayed within the ADM The system is able to display the following Unicode characters For characters outside of this set the sys tem will display the Unicode replacement character which appears as a white question mark inside of a black diamond U 0020 U 007E Basic Latin U 00A1 U 00FF Latin 1 Supplement U 0100 U 017F Latin Extended A U 0386 U 03CE Greek U 0400 U 045F Cyrillic Create Custom Language Strings The custom language file is a tab delimited text file
104. ote Mount Bracket 24A326 This bracket is used to remote mount the ADM display along with an ADM extension cable Ref Part Description Qty 1 BRACKET mounting assembly 1 333347F Overtemperature Jumper 16Y727 Use the Overtemperature jumper plug to run the InvisiPac melter without a hose and applicator attached to the Channel 1 electrical connection 123771a Installation 1 In the ADM setup screens uninstall Channel 1 All other Channels can be installed or uninstalled as needed Channel Installed Gun RTO Type 3 NOTE Failure to uninstall Channel 1 on the ADM setup screens will result in several Alarms regarding Channel 1 when there is no hose applicator attached to Channel 1 2 Attach the Overtemperature jumper plug to Channel 1 3 The ADM should have zero Active Alarms The melter is now ready to run without a hose and applicator attached to Channel 1 333347F Accessories Air Metric Fitting Kit 24W637 For replacing air fittings with metric air fittings on Invisi Pac systems See manual 334358 for installation instructions Ref Part Description Qty 1 127922 FITTING 3 8 npt m x M18 f 1 127923 FITTING 1 4 npt m x 10 mm 1 tube 3 127924 FITTING 1 4 npt m x 10 mm 1 90 elbow tube 4 127925 FITTING 3 8 18 npt m x 3 8 19 1 bspt f Strain Relief Bushing Kit 24X190 The strain relief bushing kit allows the use of a smaller outside diatmer OD power cord This stra
105. ow H 38 Ib Life Cycles Fill Sol 135 0 00 A Life Weight PCB Temp 1 7 Ib 115 F USB DL CAN 0 0 24 000 V m E mn G a G a G an G an G an G an G an G a G a G a G a FS SSS SS SSS SSS A B C This screen shows details of various items to aid in trou bleshooting the system This screen can be hidden by de selecting Enable Diagnostics Screen on the Sys tem 3 screen The flow rate updates every 15 20 sec onds with the average flow rate over the last 15 20 seconds The following information is displayed Diagnostic Data Current Draw B RTD Reading C Duty Cycle CAN 24 VDC power supply voltage reading 18 28 VDC 116 DI System Digital Inputs 0 Not Used 1 Not Used 2 Pump Cycle Switch Up 3 Pump Cycle Switch Down DO System Digital Outputs 0 Pump Solenoid 1 Fill Solenoid 2 Light Tower Green Light 3 Light Tower Red Light ISO DI Customer Digital Inputs 0 Customer Input 1 1 Customer Input 2 2 Customer Input 3 3 Customer Input 4 ISO DO Customer Digital Outputs 0 Customer Input 1 1 Customer Input 2 2 Customer Input 3 3 Customer Input 4 Fill Reading of Ultrasonic Fill Sensor e Old Fill Sensor 2400 2700 mV e New Fill Sensor 4200 3800 mV Fill Sol Current draw of fill solenoid e 0mA off e 150 250 mA on Flow H Melt rate of the system Life Cycles total number of pump cycles over life of system Life Weight Weight of material dispensed over life of s
106. p Recommended Air Setup Main Air Line a 1310 No dips in vacuum Air In transfer hose 3 8 in 100 psi 6 8 bar 0 68 MPa 30 scfm capacity Air In Less than 50 ft 15 2 m 3 8 in More than 50 ft 15 2 m 1 2 in 80 100 psi 5 5 6 8 bar 0 55 6 8 MPa 30 scfm capacity Ensure funnel air is connected Air Filter Ball Valve at System Air Inlet Graco Kit 24R707 included NEA Sree mom V a _ EX888 HH OLET Vacuum 40 80 psi 2 8 5 5 bar Pump 0 28 0 55 MPa 20 100 psi and at least 65 of hopper 1 4 6 8 bar gt shaker air pressure if used 0 14 0 68 MPa 2788 Air to applicators Regulator set to 70 psi 4 8 bar 0 48 MPa Fic 14 22 333347F Connect Electrical Cord NOTE See Grounding section on page 17 Improper wiring may cause electric shock or other serious injury if work is not performed properly Have a qualified electrician perform any electrical work Be sure your installation complies with all National State and Local safety and fire codes To reduce the risk of electric shock perform the entire Attach Components procedure beginning on page 17 prior to connecting electrical cord NOTE The installed strain relief bushing 106 fits a 0 708 1 260 in 18 32 mm OD electrical cord See FIG 15 If needed use a wrench to tighten the strain relief bushing until it is
107. prior to turning on heat 23 Setup 208V Electrical Circuits For 208V electrical supply a qualified electrician can install a 208V to 240V step up transformer to improve startup times Transformer Sizing Minimum transformer rating can be calculated by taking transformer output voltage times the ADM breaker set ting Single Phase 20A ADM Breaker Setting Example 240 volts x 20 amps 4800 watts Three Phase 20A ADM Breaker Setting Example 240 volts x 20 amps x SQRT 3 8315 watts Select ADM Settings NOTE See Appendix A ADM on page 114 for detailed ADM information including general operation 1 Turn main power switch ON il 2 When the ADM is finished starting up press Er to switch from the Operation screens to the Setup screens Use E gt t and B to navigate between screens 3 Onthe System 2 screen 12 10 12 17 12 Inactive il Gun RTO Type Channel Installed 7 Ft 1000 385 n 3 Pt 1000 385 ea 4 Pt 1000 385 p E 1 Pt 1000 C383 y a Check the box in the Installed column for each channel that has a heated hose and applicator installed b Select the RTD type used on each installed applicator See applicator manual 24 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
108. r Actual Temperature Operating Mode Description Component Status e No System Status Indicator LED on the ADM System Off y The system doesn t have power Nohea e Pump is off e Yellow system status indicator LED on the inactive The heating system and pumps are ADM disabled e No heat e Pump is off e Flashing green system status indicator LED Warm Up The system is heating the material to on the ADM the set temperature e Heat is increasing to setpoint temperature e Pump is off e Solid green system status indicator LED on Acie The system is ready to dispense the ADM material e Heat is at setpoint temperature e Pump is on 33334 7F 15 Component Identification 16 33334 7F Setup Grounding The equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cause fumes to ignite or explode Improper grounding can cause electric shock Ground ing provides an escape wire for the electric current The InvisiPac system is equipped with a ground termi nal A qualified electrician must ground the system using this terminal See Connect Electrical Cord on page 23 NOTICE To prevent excessive static buildup on shaker or adhe sive bin install optional grounding kit 24R708 ti23450a Fic 7 Grounding Kit 24R708 Location Ambient temperature must be 32 120 F 0 49 C The supplied vacuum transfer hose length is 10 ft 3 m The maxi
109. r and tube are connected to the system See Attach Components on page 17 3 Verify shaker inlet K is at the bottom of the adhe sive pellets container that is filled with hot melt adhesive pellets See FiG 1 on page 11 NOTE The shaker inlet must be completely covered in adhesive pellets in order for it to effectively pull pellets into the tube 31 Operation 4 If not already set use vacuum transfer air pressure regulator E to adjust vacuum transfer air pressure setting to 40 100 psi 280 690 kPa 2 8 6 9 bar Hecommended setting is 60 psi 414 kPa 4 1 bar FiG 24 NOTE The system will automatically transfer the pellets to the system as necessary Dispense NOTE Only hot melt adhesive pellets can be used in the InvisiPac system 1 Ifthe system is empty or has air in the lines perform Initial Startup and Prime procedure on page 29 2 f main power switch is OFF turn main power switch E i NOTE The main power switch should be left ON at all times when using the Schedule function 3 Prepare for dispensing a Verify air inlet ball valve J is open See FIG 1 on page 11 b Check pressure gauges D F to verify vacuum transfer and pump air pressures are set as desired See FIG 1 on page 11 c lfusing Automatic Refill see Automatic Refill on page 31 d f using Manual Refill see Manual Refill on page 30 32 e Verify applicators are closed 4 Press KO to enable t
110. r unit remove from system and remove plug there is no feed Adhesive pel Shaker unit not vibrat Verify shaker is vibrating during material loading If not the ball in the lets in storage ing shaker assembly is stuck Remove shaker housing and separate to bin not cover clean raceway and ball inside ing shaker head Materials are blocking Some materials may require agitation periodically to breakup bridging in the hopper Some Purchase and install 30 Gallon Vibrating Hopper 24R136 See adhesive materials are page 104 prone to blocking High ambient temperature and high humidity can increase the likelihood of blocking Fill Solenoid Failure of the fill sole Verify wiring between J13 and the refill solenoid is not damaged Error noid or fill solenoid wir ing Restart system If the error persists after attempting another refill and unit is needed immediately for production place system into the man ual refill mode See Manual Refill on page 30 46 333347F Troubleshooting Pomem Omes Solon Oo Level Sensor Failure of the level sen Check sensor cable J14 to level sensor 20 Error sor 20 or sensor cable 16T108 J14 to level sensor 20 Enable Diagnostic screen on ADM then check sensor readings on the Diagnostic screen Sensor readings should be about 4 3V if melter is completely empty melter passage holes are visible The normal oper ating range is 3 8 to 4 3V If the sensor is rea
111. re Control Module MZLP AC Incoming Power Connection AF Chassis Ground AG Automatic Wiring Board AWB 333347F AF Component Identification ti22859a AG 13 Component Identification Advanced Display Module ADM User Interface To prevent damage to soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails NOTE See Appendix A ADM on page 114 for com plete ADM operation details BR BC FIG 5 BA BD Key BK Part Number Identification Label BL USB Interface BM CAN Cable Connection Power Supply and Communica tion BN Module Status LEDs BF BP Not used BR Software Token Access Panel BH T112362a1 FiG 4 Ke BA Heating system and pump enable disable BB System status indicator LED y BC Stop all system processes 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 B 14 333347F Screen Components Screens Order Current date and time Operating Mode 12 10 12 17 08 e Errors Inactive Mo Active Errors qd 72 F ae Echd aN 12 F Hose and Applicator Heating Status Cy Hose Actual Temperature Fic 6 Main Screen Components Component Identification Faults Status Melter Heating Status Melter Actual Temperature Applicato
112. relief valve 245 See FIG 45 Use an o ring pick to remove o ring 244 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 10 11 12 66 Thread new fluid pressure relief valve 245 into manifold See Fic 45 Once hand tight use cres cent wrench to tighten Use nuts 3 to install metal shroud Connect air tube to pressure relief valve Feed ADM cable through plastic shroud then install shroud and connect cable to ADM 333347F Hepair Multi Zone Low Power Temperature Control Module MZLP Replace MZLP Fuse mA MZLP Identification 24V510 F1 and F2 fuses are physically larger than F3 F10 Blue sticker on relay Marked 24V133 ti23434a Fic 46 MZLP ID and Fuse Locations NOTICE To prevent system damage always use fast acting fuses Fast acting fuses are required for short circuit protection 333347F 24V510 MZLP Fuses F1 F2 250VAC 25A fast acting white 0 25 in x 1 2 in F3 F10 250VAC 8A fast acting
113. rt USB flash drive into USB port See FIG 68 NOTE Flash drive must be 8 GB or smaller Fic 68 ADM USB Port 2 The menu bar and USB indicator lights indicate that the USB is downloading files Wait for USB activity to complete A pop up will be present until the trans fer is complete if it is not acknowledged NOTE If the pop up screen does not appear the flash drive is not compatible with the ADM Try a different flash drive NOTE The system can log up to 45 mb of additional data per week depending on system operation 120 Accessing Files All files downloaded from the USB are put in a DOWN LOAD folder on the stick drive For example E GRACO 12345678 DOWNLOAD The 8 digit numeric folder name matches the 8 digit ADM serial number which is located on the back of the ADM When downloading from multiple ADMs there will be one sub folder in the GRACO folder for each ADM The log files should be opened in a spreadsheet pro gram NOTE If emailing the files zip compress them to mini mize file size Upload Procedure NOTICE Uploading an edited system configuration file can damage the system Never put a modified SETTINGS TXT file in the UPLOAD folder on the flash drive Use this procedure to install a system configuration file and or a custom language file See System Settings File or System Language File starting on page 121 1 Ifnecessary follow the Download Procedure page 120 to a
114. s make sure to install the tee in the air line before the ball valve There should not be anything between the ball valve and the system See applicator manual for applica tor air pressure requirements and use a regulator before the gun to decrease the air pressure if nec essary 333347F Setup 19 Close the ball valve ti21147b FIG 13 20 Attach a 3 8 in minimum air supply line to air filter See FIG 13 NOTE Air supply pressure must be between 80 psi 550 kPa 5 5 bar and 100 psi 690 kPa 6 9 bar Rec ommended pressure is 100 psi 690 kPa 6 9 bar If air pressure is expected to drop below 80 psi 0 5 MPa 5 bar there is an air reservoir kit that allows the system to operate down to 60 psi 0 4 MPa 4 bar See Air Reservoir Kit 16W366 on page 107 21 To lock access to the air pressure adjustments pur chase Air Adjustment Lock 24R084 See installa tion instructions on page 101 22 To install a light tower that illuminates red when a system error occurs purchase Light Tower Kit 24R226 See installation instructions on page 106 23 To upgrade a 2 channel system to a 4 channel sys tem purchase 4 Channel Upgrade Kit 24V528 See installation instructions on page 108 24 To upgrade a 4 channel system to a 6 channel sys tem purchase 6 Channel Upgrade Kit 24V529 See installation instructions on page 110 25 Install MZLP electrical connector caps on all unused channels 21 Setu
115. s 8 then slide the small metal id shroud 28 on the back of the system up to remove the heaters See FIG 25 3 Wait until melter temperature is the desired tem 5 Use a1 in socket to unscrew outlet filter 236 perature 333347F 37 Maintenance FIG 38 When the melter temperature is the desired tem perature turn main power switch OFF Disconnect cable from ADM push cable through plastic shroud then remove plastic shroud from sys tem 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 Use 1 in socket to remove inlet filter cap 215 ti23296a 26 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 oy to enable the heaters e Wait for temperature to rise 20 F 11 C beyond previous temperature f Goto step 4 10 11 Slide new screen 213 into melter base manifold 201 Install filter cap 215 then use a 1 in socket to tighten Feed ADM cable through plastic shroud 29 then install shroud onto system Connect cable to ADM 30 Replace Funnel Filter ES EY ti23297a FiG 27 Disassembly see FIG
116. sembly 1 2 3 Plug new daughter card 112a into the MZLP 112 Use screws 112b to secure daughter card to MZLP 112 Connect cables to new daughter card 112a NOTE Do not force the electrical connection Minimal force is required to seat the connector If resistance is felt stop and verify the connector orientation NOTE If unable to determine connector location see Electrical Schematics on page 78 4 Install electrical enclosure front access door 10 System Replace Fill Sensor mA 73 FIG 49 Disassembly see FIG 49 1 2 Turn main power switch OFF Remove filter cover 68 and filter element 333347F Hepair Gently pull up on cable while unscrewing fill sensor connector then remove fill sensor cable from fill sensor 20 Loosen fill sensor jam nut then remove fill sensor 20 from sensor housing 73 Reassembly see FIG 49 1 Thread new fill sensor 20 into sensor housing 73 Bottom out the sensor in the sensor housing then back out 1 2 turn 2 Tighten jam nut on fill sensor 20 3 Connect fill sensor cable to new fill sensor 20 4 Replace filter element and cover 68 Replace ADM 30 CC ti20763a Fic 50 1 Turn main power switch OFF 2 Disconnect cable CC from bottom of ADM 30 See FIG 50 3 Remove ADM from bracket 58 4 Install new ADM into bracket 5 Connect
117. set Use the physical numeric key pad on ADM to enter tempera ture setting T El 350 F 114 Select channel to view and or edit the applicator or hose temperature setting Applicator temperature setting use kA t to adjust set ting Hose temperature setting us kA Mt to adjust set ting Use to adjust temperature settings Temperature settings of applicator top and hose bottom Reset weight total etup Screens Only Enter screen to change settings Exit screen Reset Maintenance error Schedule Screen Only Edit schedule value Erase schedule value Accept schedule change Cancel schedule change 333347F Operation Screens Home Quos soo Qa so Qeni sor Qasr 350 This screen shows the actual temperatures of the sys tem melter and each applicator and hose Targets 11 27 13 16 16 Home Targets Events gt No Active Errors This screen shows and allows editing of the temperature settings for the system melter and each applicator and hose See Select ADM Settings on page 24 333347F Appendix A ADM Events 12 10 12 ERRAT P Targets Events EA Horne gt No Active Errors late Time Code Description 12101216821 ECOX Setup Valuets Changed 12101216821 ECOX Setup Valuets Changed 121012168521 ECOX Setup VYaluets Changed 12 10 12 1720 EADX Heat On 121012168520 EQUI Sys Settings Downloaded 121012168520 EQUS Custom Lang Downloaded 1z 10121 852
118. sistance of hose wiring See hose manual for proper resistance range 33334 7F Troubleshooting Code Description Type Cmse Solution T D 1 No Temp Risein Alarm Temperature reading does not change Check fuses F5 and F6 channels 1 3 5 or F9 Hose all zones and F10 channels 2 4 6 on the MZLP that con trols the error channel Defective heater wires in hose Replace heated hose NOTE Defective heaters wires in the hose can also cause the no current error Heated hose electrical connector or wires are defective Check resistance of hose wiring See hose manual for proper resistance range T8DO No Temp Risein Alarm Temperature reading does not change Check fuses F1 and F2 on MZLP with daughter Melter all board zones Defective heater wires in melter Replace melter NOTE Defective heaters wires in the melter can also cause the no current error Defective heater element s Check heater resis tance and compare to reference table See Check Heater Rod Resistance page 54 Check J1 is properly plugged into the MZLP with 8 Check that RTD is installed in the melter V 4 Low Can Volt Alarm Bad or overloaded power supply Verify power supply voltage is 24 VDC If voltage age is low disconnect the screw terminals V and V on the power supply and re check voltage read ing If voltage is correct then disconnect J8 and J9 from AWB and re check voltage If still low replace A
119. snug on the cable The accessory strain relief bushing kit 24X190 is avail able for smaller 0 512 1 024 in 13 26 mm OD electri cal cords See Accessories page 100 For 208V Electrical Circuits see page 24 1 Turn main power switch OFF 2 Disconnect cable from ADM push cable through plastic shroud then remove plastic shroud from sys tem 3 Remove electrical enclosure access door T See FIG 2 on page 12 4 Insert electrical cord through electrical enclosure strain relief bushing 106 See FIG 15 a Alternate electrical cord routing using conduit run electrical cord from access port X through hole Y Conduit is required when routing wires near compressed air components 333347F Setup 5 Attach insulated ferrules to the end of each wire SE INS 90g ro dy ID a 8 908 a F3 Y X L ti22859a AF FIG 15 6 Connect ground wire to chassis ground AF See FIG 15 7 Connect L1 L2 L3 and N as shown in Fic 16 Not all models use all 4 wires 200 240 VAC 1 FIG 16 8 Use zip ties to secure the electrical cord to the tie downs located on the top of the inside of the electrical enclosure 9 Tighten screw terminals to at least 10 in lb 1 1 Nem 10 Install electrical enclosure door 11 Perform Select ADM Settings on page 24
120. sueg 949 xog 041u02 48puf jeju ay OUT 333347F 82 Parts Parts InvisiPac Systems System Parts Page 1 of 3 11 to door 10 per layout diagram A Apply pipe sealant to all non swiveling pipe threads N Apply door gaskets out then back off 1 2 turn A Lubricate all seals and o rings with water resistant grease A Bottom sensor 20 N e uS INN lY Ov 9r 7 15 Nem A Torque to 8 10 in Ib 0 9 1 1 Nem A Torque to 5 11 ft lb s 4 On 7 Y sem D 7 Y D F c AZ i i Y Y ti23474b OCR oOo wA YU Se C 83 333347F Parts System Parts Page 2 of 3 ti23475a 333347F 84 Parts System Parts Page 3 of 3 omm 1219 mm 48 in 34 406 4 mm 1219 mm 36 13 in 330 2 mm 55 1219 mm ti23476a 85 333347F Parts o lt Oo r 3 U AY c o Channel Channel i Channel 6 Channel Channel 0 7 3 2 B cos Eug ewm c N 24V425 o 24V424 n ELE a PARU are Description ENCLOSURE electrical 115942 NUT hex flange head 8 Co O O 1 1 1 1
121. supply capable of maximum power per system plied to system Depend specification All changes must be performed by a qualified electrician See ing on hose and Models on page 4 for full power rating See Startup Time page 125 for applicator combinations startup times under varying conditions along with minimal sup ply power startup time will vary No adhesive or Incorrect RTD setting in Verify melter hose and applicator temperatures are all with in the little adhesive system same range of the room ambient being dis pensed If the applicator temperature is either much higher or much lower than the melter temperature then the RTD setting is not correct for the RTD being used Select correct RTD setting in the setup screen system 2 before beginning NOTE Failure to have the correct RTD value will cause the applicator to either under heat or over heat Setting for RTD in the ADM screens is higher than actual RTD value Consult manufacturer for actual RTD value System indi Incorrect RTD setting in 1 Verify melter hose and applicator temperatures are all within the cates no errors system same range of the room ambient and correct temperature however appli cator is over the tempera ture setpoint If the applicator temperature is either much higher or much lower than the melter temperature then the RTD setting is not correct for the RTD being used Select correct RTD setting in the setup screen system 2 before
122. t for sale Description RETAINER seat dump valve PACKING o ring 2 116 ptfe VALVE relief SCREW cap socket head 5 16 x 2 5 in FITTING plug 9 16 sae INSULATOR heat SWITCH overtemperature INSERT helical PLATE melter HM25 only PLATE melter HM25 only O RING 910 SCREW mach pnh 4 x 3 8 in BRACKET shelf HM50 only BRACKET shelf HM25 only GROMMET 1 4 ID SCREW cap sch 1 4 x 7 8 in HM50 only SCREW mach hex wash hd 1 4 x 3 in HM25 only WASHER flat sst HM50 only Available kits purchase separately Kit Description 24P8521 Pump repair 15B661 24P853 Cylinder 216 217 234 and seal instal lation tool 15B661 222 223 224 225 226 24P856 Pressure relief 242 243 244 245 valve 24P854 Pump rod 24V508 Melter identification med RTD 125 251 and 255 See Elec trical Enclosure on page 89 EE Special tools See Special Tools on page 100 Qty D S na KR N a a NG OO 217 222 224 225 226 227 228 229 231 232 233 234 and seal installation tool 202 204 207 211 253 and insulator 53 See InvisiPac Systems parts starting on page 83 for insulator 53 ual sd pump 203 206 209 214 216 217 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 242 243 244 245 246 247 251 252 manifold 255 333347F Air Motor 24V558 Ref Part 505 24A579 506 5DO7T
123. tchet without a socket to remove foot valve 230 from bottom of melter outlet manifold 203 6 Remove and discard seat 228 ball 227 o ring 229 and o ring 231 Reassembly see FIG 35 1 Install new o ring 231 o ring 229 seat 228 and ball 227 then use a 1 2 in drive ratchet 58 without a socket to install and tighten foot valve 230 onto melter 2 Apply anaerobic thread sealant on threads of four bolts 246 and connect pump to melter outlet Torque to 12 18 ft lb 16 24 Nem Replace Pump Cylinder Seals and Piston Seals A i om ti23323a FIG 36 Disassembly see FIG 31 1 Flush the system See page 34 2 Close the bleed type ball valve installed at the sys tem air inlet to relieve all air pressure in the system 3 Turn main power switch OFF 4 Remove plastic shroud 27 See FiG 31 on page 56 333347F 5 Remove air lines from relief valve 245 and air motor 218 See FiG 31 on page 56 6 Remove nuts 3 securing melter shield 27 in place then remove melter shield See Fic 31 on page 56 7 Remove air motor assembly See FIG 31 on page 56 a Remove retaining ring 239 b Remove dowel pin 238 c Remove three screws 240 8 Use a flat head screwdriver and a rubber mallet to break loose the retaining nut 235 9 Use channel lock pliers to remove the retaining nut 235 10 Insert an allen wrench through the
124. te container below drain tray W2 then remove drain plug W1 and wait for system to finish draining See FIG 2 on page 12 24 Allow the system and fluid to cool then perform any required maintenance procedures beginning on page 37 35 Operation 25 Install fill cap onto melter rubber housing 26 Slide funnel assembly through air motor bracket then tighten clamp 27 On the System 3 screen in the Setup screens set the Refill Setting to Auto Enable Diagnostic Screen Lack Run Screens Purp Idle Time to System 8 minute 1 Inactive Power Type Single Phase EA Circuit Breaker Size Amps Refill Setting t To prevent fire and explosion never exceed the clean ing fluid s rated temperature Residual cleaning fluid is still in the system until the system is primed with adhe sive 28 Perform Initial Startup and Prime on page 29 36 Operation Tips to Minimize Charring Set the Pump Idle Time to System Inactive function on the System 3 screen to lowest value that will not interfere with normal operation This feature automati cally disables the heating system if the pump is idle for longer than the preset amount of time Disabling the heating system minimizes adhesive degradation and limits char formation When possible utilize the Schedule function see page 33 to automatically enable and disable the heat ing system in accordance with your production sched ule This wi
125. ted to ground on the Replace heated hose vase peseponerwiess e High Current Alarm Defective or shorted to ground on the Replace applicator manifold A7DO Unexpected Alarm Unexpected current flow to melter Faulty melter heater s Check heater resistance Current and resistance to ground Replace faulty heater s See Replace Heater Rod page 64 A4D_ A4D_ 7D_ Unexpected Alarm Unexpected current flow to applicator Faulty applicator heater element Check heater Current Gun X X resistance and resistance to ground 7D aD aD A Faulty MZLP Replace MZLP A Unexpected Alarm Unexpected current flow to hose X Faulty hose heat element Check heater resis Current Hose X tance and resistance to ground Faulty MZLP Replace MZLP No Current Alarm Power not getting to melter Check fuses F1 and F2 on MZLP with daughter Check J1 is plugged into MZLP with daughter A No Current Alarm Power not getting to hose Check fuses F5 and F6 channels 1 3 5 or F9 Hose X and F10 channels 2 4 6 on MZLP that the error hose is connected to Check that electrical connector on the heated hose is plugged into the MZLP Check continuity of pins C and D on electrical connector at MZLP end of heated hose See heated hose manual for impedance measure ments Replace hose if readings are too high If system only uses one hose and applicator the heated hose electrical connector must be plugged into channel 1 of the MZLP A No C
126. tering the password Pump Idle Time to System Inactive The heating sys tem will be disabled after the pump has been idle for the set amount of time Power Type Select the system power type Circuit Breaker Size Select the circuit breaker size Refill Setting To use the automatic vacuum transfer select Auto To disable the automatic vacuum transfer select Manual The main reason to disable automatic refill is while flushing However if an issue is present with the automatic refill system that cannot be solved in a timely manner manual refill can be used to return the system to service See Manual Refill on page 30 See Select ADM Settings on page 24 117 Appendix A ADM Maintenance Schedule PATER Maintenance Mo Active Errors a Due Interval User 1000000 Cycles Totalizers Current Lifetirne Pump 1481 Cycles The system will notify the user at the set interval that maintenance is required The fields in boxes can be edited by the user Due and Current are both the number of cycles since the last reset Interval is the set number of cycles between maintenance notifications Lifetime is the number of cycles in the lifetime of the system NOTE The lifetime cycle count will only be reset if the Advanced Display Module ADM is replaced Schedule Pee BN TE schedule ETIN Use this screen to set times where the system will auto matically enable and disable heating See Select ADM Settings
127. termined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO
128. that contains two columns The first column consists of a list of strings in the language selected at the time of down load The second column can be used to enter the cus tom language strings If a custom language was previously installed this column contains the custom strings Otherwise the second column is blank Modify the second column of the custom language file as needed and then follow the Upload Procedure page 120 to install the file The format of the custom language file is critical The following rules must be followed in order for the installa tion process to succeed e The file name must be DISPTEXT TXT e The file format must be a tab delimited text file using Unicode UTF 16 character representa tion e The file must contain only two columns with columns separated by a single tab character e Do not add or remove rows to the file e Do not change the order of the rows e Define a custom string for each row in the sec ond column 122 33334 7F Technical Data Technical Data InvisiPac Hot Melt Delivery System Incoming Power HM25 24V423 200 240 VAC 1 ph 50 60 Hz 32A HM50 241918 200 240 VAC 3 ph A 50 60 Hz 27A 350 415 VAC 3 ph Y 50 60 Hz 16A HM25 24V429 HM50 24V201 400 480 VAC 3 ph A 50 60 Hz 14A HM25 24V424 200 240 VAC 1 ph 50 60 Hz 40A HM50 241919 200 240 VAC 3 ph A 50 60 Hz 27A 350 415 VAC 3 ph Y 50 60 Hz 16A dise Ue 400 480 VAC 3 ph A 50 60
129. the ADM that eliminates waiting for the system to heat up The Sched ule function automatically enables the heating system at the user specified times so the system is ready to dis pense when a shift begins The Schedule function also disables the heating system at user specified times to ensure the heating system is disabled when not being used 333347F Operation Initial Startup and Prime 77 NOTE All setup procedures must be completed prior to initial startup See Setup on page 17 NOTE Only 1 4 in 6 mm round hot melt adhesive pel lets can be used in the InvisiPac system PSA type adhesive pellets will not work in the InvisiPac system 1 Direct the applicator into an appropriate waste container 2 Verify the shaker inlet is at the bottom of the empty adhesive pellets container Optional vibrating adhe sive pellets container part 24R136 is available See Accessories on page 100 NOTE The shaker inlet must be completely covered in adhesive pellets to effectively pull pellets into the tube 3 Fill adhesive pellets container with hot melt adhe sive pellets 4 Turn main power switch ON d 5 Open system air inlet ball valve ti21147b 29 Operation 6 Use pump air pressure regulator C to adjust pump air pressure to O Fic 20 7 Use vacuum transfer air pressure regulator E to adjust vacuum transfer air pressure setting to 40 100 psi 280 690 kPa 2 8 6 9 bar Recom
130. the desired operating location and orientation See Location page 17 e The bottom of the electrical enclosure has holes for securing the InvisiPac system to a surface The holes are accessible through the bottom access doors in the three rear walls of the electrical enclo sure e To install the InvisiPac system in place of a non Graco hot melt system purchase Adapter Plate 24R083 See installation instructions on page 102 e To raise the system to eye level purchase System Stand 24R088 See installation instructions on page 102 NOTE Supplied vacuum transfer hose must reach from the system to the adhesive pellets container Supplied heated hose must reach from system to applicator s 18 3 Adjust the funnel inlet ti23791a a Remove plug 23 and insert the provided 5 16 in nut driver 92 through the access hole in the back of the system Loosen the band clamp 81 two turns b Rotate the funnel inlet G3 and re tighten the band clamp 81 JJ L gt ff gt f ti22735a e FiG 9 4 Insert 1 3 in 33 mm OD clear vacuum transfer hose G2 into vacuum transfer funnel G3 inlet and secure with supplied hose clamp The hose clamp should be placed over the cutouts in the funnel inlet where it can firmly hold the transfer hose See FIG 9 5 Connect the long supplied 3 8 in OD air line G4 to the 3 8 in push to connect fitting on the air line from the system See
131. the update with approximate time until completion Third Updates are complete Icon indicates update success failure See the following Icon table Update unsuccessful Update complete no changes necessary Update was successful com plete but one or more GCA modules did not have a CAN boot loader so software was not updated on that module Remove token T Replace token access panel Press fe to continue to the InvisiPac operation screens Electrical Schematics Electrical Schematics To prevent electric shock and system damage all electrical work must be performed by a qualified elec trician Incoming Power NOTICE To prevent severe system damage ensure main power leads are installed correctly See Connect Electrical Cord on page 23 78 Cable Identification Use the table to identify cables and other system com ponents in the electrical schematics o gt Meron airassembly 24P860 86 127666 Cable Extension 87 WIRE ground Plug Phoenix 8pin Harness MZLP 1 AWB 112 24V288 Module MZLP with daughter board 118 24V510 Module MZLP 16T087 Cable Board 127768 Cable CAN 16T103 Cable Pump 125 Sensor RTD 1M ize 129 d Harness MZLP 2 AWB Hamess MZLP 23 AWB 736 Hames WZLP 1 AWB 138 Harness Disc AWB Transformer 146 126453 Power Supply eS Harness Power Supply AWB ELI EN
132. to outlet end o air tube union 91 Ensure air is flowing out of the InvisiPac system air inlet 108 Heconnect ultrasonic sensor air tube 35 to air tube union 91 48 333347F Troubleshooting Unable to The InvisiPac system Ifthe cycle rate is below 11 cpm HM25 22 cpm HM50 and the achieve pub monitors temperature system is still running away increase the InvisiPac system lished meltrate within aluminum mass temperature in small increments over the current set point leave at the desired of melter 202 As melt hoses and applicators at desired set point adhesive tem rates exceed 20 Ib hr a l l l l perature system temperature Ifthe pump continues to runaway or dive continue increasing tem offset may be required perature in small increments Do not exceed maximum temperature for the material being dispensed NOTE A 50 amp breaker is required in order to maximize startup and flow rate performance Set the breaker size used in the Setup screens NOTE Some materials are more difficult to melt than others therefore it may be impossible to process them at the published melt rate The InvisiPac system was tested to achieve continuous the published melt rates when dispensing standard EVA packaging grade adhesives in pellet form with an InvisiPac system temperature of 350 F and hose and applicator temperatures of 350 F ADM not dis Main power circuit Turn main circuit breaker on or plug in power cord playi
133. to secure metal shroud 27 Route relief valve air tube 36 through the metal shroud then attach to the relief valve Feed ADM cable through shroud then install shroud and connect cable to ADM Open system air inlet ball valve Turn main power switch ON Replace Heater Rod ti23438a 74 FIG 44 Disassembly see FIG 44 NOTE This procedure is for replacing any of the above heater rods 1 2 Turn main power switch OFF If replacing the melter heater rod 209 Remove Melter Assembly See page 60 Disconnect cable from ADM then remove shroud 29 333347F If removing the pump heater rod 210 a Remove the air tube 36 from the relief valve 245 Pull the air tube through the metal shroud 27 b Remove nuts 3 then remove shroud 27 Remove electrical enclosure front access door 10 See FIG 41 page 62 Disconnect heater rod wires from terminal blocks described in the following table Wire Wire Marking 1 Marking 2 Band Heater 208 Heater 208 JA 00 1 M2 2 Heater Rod caa 5 E 6 209 Base Heater Rod 210 Heater Rod 210 MT 0 7 Heater Rod m 3 J4 4 210 Pull heater rod wires up through the grommet in the top of the electrical enclosure 1 Remove heater rod retaining ring 206 then remove and discard heater rod 209 210 Reassembly see FIG 44 1 Route new heater rod cable through grommet 63
134. tor orientation NOTE If unable to determine the connector location see Electrical Schematics page 78 6 Install electrical enclosure front access door 10 333347F Replace Power Supply mA Disassembly 1 2 3 Turn main power switch OFF Remove electrical enclosure front access door 10 Hemove power supply 146 from power supply bracket 145 by releasing mounting tab on the side of the power supply See FIG 51 Disconnect screw terminal connections between power supply 146 and power supply harness 147 according to the following table See FIG 51 Power Supply Connection Harness Label V V Heassembly 1 Make connections between power supply harness 147 and new power supply 146 according to the following table Heattach power supply 146 to power supply bracket 145 See FIG 51 Install electrical enclosure front access door 10 333347F Hepair Replace Power Supply Harness Disassembly 1 Turn main power switch OFF 2 Remove electrical enclosure front access door 10 3 Disconnect screw terminal connections between power supply 146 and power supply harness 147 according to the following table Power Supply Connection Harness Label V V v v t E 7 4 Unplug power supply harness 147 from J1 on AWB 143 See Electrical Schematics page 78 Heassembly 1 M
135. tri cal enclosure 1 Connect wires as noted below Wire Marking Wire Marking 1 2 6 Connect air tube to air motor 218 7 Connect fill sensor cable to the fill sensor 20 8 Connect pump cycle sensor cable to air motor 9 Install funnel FF then tighten clamp 81 10 Install temperature sensor 125 into melter then tighten screw AA on band heater See FIG 41 on page 62 11 Install insulators 53 75 onto the melter assembly 5 12 Connect ground wire ring terminal 87 and ground screw 88 to melter assembly 5 13 Connect wire connectors to the over temperature switch 251 See FIG 43 on page 64 14 Use nuts 3 to install metal shroud 27 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 61 Repair Replace Band Heater 74 ti22862a FIG 41 Disassembly see FIG 41 1 Once the fluid level is low enough close the bleed type ball valve installed at the system air inlet 2 Turn main power switch OFF 3 Disconnect cable
136. ubleshooting 000 eee ee eee 55 ReDall ciesa risna a eae ct r ees aa eee Sis 56 De UMM seat Gat PETERE ge ee 56 Meteran anb do i Bak pol tesa eis Gee ein oh 60 Multi Zone Low Power Temperature Control Module MZLP 67 SVSIOM wi Gb oh bores Ped Beeb ane de Pode eiue 69 Ar SOMOS Geek nent tte eae E n a aan audi eared 72 ANMO xus ace eee oe SODAS o Una ee OE neat 73 Transformer FaN cuite tra ceeds Sure oe 32 DP E E 76 Software Update Procedure 77 2 Electrical Schematics 78 INCOMING POWOL 2 25 x ac bere Ret eee See ae Ret oss 78 Cable Identification llle 78 SYVSIEM 5 4 uci a cde X adhac n tue oe E chee end 4 79 480VAC Transformer Option 00000 eee 80 Typical Hose Applicator Wiring 80 2nd and 3rd MZLP Options 0000005 81 Air Schematic 25222 vem aso X ADDE ES UE ER a Eie 82 PANS suds hot ce teat eau eta s hs Ed ede a des 83 InvisiPac Systems 0 0 cee 83 Electrical Enclosure llle 89 Transformer Assemblies llle 92 Melter and Pump Assembly 93 Air MOTO 24V 558 seu wait E e e 95 Feed System Shaker and Tube 24V507 96 Air Controls Assembly 0 0000 ee eee eee 97 Pressure Relief Valve 24P856 008 98 Feed Inlet Funnel 24V505 99 ACCOSSONGES osaan a Waa we wae eae Sens meee 100 Specia
137. uid outlet to applicator fluid inlet Use 11 16 in wrench to tighten See FiG 11 b For Graco applicators attach applicator electri cal connector to heated hose electrical connec tor See FIG 11 c Fornon Graco applicators attach applicator electrical connector to adapter harness 161916 161917 or 16Y828 then attach adapter harness connector to heated hose connector See Non Graco Applicator Adapter Cables on page 101 to determine which adapter cable to use with your applicator 333347F d Repeat for any additional applicators 16 f necessary set up the pattern controller not included to control opening and closing of the appli cator See pattern controller manual NOTE The system controls applicator heating only A separate pattern controller must be set up to open and close the applicator 17 Install the supplied air inlet bleeding ball valve and air filter kit Graco Part No 24R707 at the 1 4 NPT female system air inlet J See FIG 12 NOTE Elbows and riser tube provided with inlet air kit are optional and may be used as desired ti21133b FiG 12 NOTE The system must have a bleed type ball valve that bleeds pressure downstream when closed Other wise the supplied air will need to be disconnected from the system whenever the pressure is relieved NOTE The system must use an air filter with a mini mum flow rate of 30 scfm 18 If using the same air for the applicator
138. unnel mounting HOUSING sensor Qty a OF N QO Parts 99 Accessories Accessories Special Tools These special tools are designed to make system repairs as easy as possible while ensuring that parts do not get damaged Par Purpose Pat Pupos 1301 Remove Cylinder 1304 Install Rod Female 1302 Install Cylinder Female 1305 Install Rod Male 1303 Install Cylinder Male 1306 Install Rod Bullet Parts included in Cylinder Tools Kit 24R227 pur Parts included in Rod Tools Kit 24R228 purchase chase separately separately i O uv 1301 1302 1303 1304 1305 1306 ti20983a 100 333347F Non Graco Applicator Adapter Cables 16T916 For connecting to non Graco applicators that use a rectangular 6 pin connector ti21128a 16T917 For connecting to non Graco applicators that use a circular 9 pin connector ti21129a 16Y828 For connecting to non Graco applicators that use a circular 6 pin connector IPx6 rated ti23405a Non Graco Applicator Adapter Cable Installation See Attach Components on page 17 333347F Accessories Air Adjustment Lock 24R084 Panel enables locking access to the air adjustment screws ti23347a NOTE Screws are part of the base system and are not included in the kit Ref Part Description Qty 801 PANEL lock air control
139. ure is desired adjust all zones to the higher temperature or adjust only the applicator in small increments NOTE Alternatively use the physical up and down arrow push buttons on the ADM keypad until is next to the temperature setting to change then use the numeric keypad to enter the desired temperature c Use g and n shown next to 330 F to adjust heated hose temperature setting to the desired setting for that channel 26 NOTE Alternatively use the physical up and down arrow push buttons on the ADM keypad until 9 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 Char ring page 36 Applicators Applicator heating is controlled by the system but the system does not control opening and closing the appli cators Setup a separate pattern controller to open and close the applicators 333347F Setup
140. urrent Gun Alarm Power not getting to applicator Check fuses F3 and F4 channels 1 3 5 or F7 X and F8 channels 2 4 6 on MZLP that controls the error channel Check that electrical plug on hose is plugged into back of MZLP and applicator is plugged into hose Check continuity of hose pin A gun end to J on MZLP connector end of hose and pin C on gun end to pin A on the MZLP end of the hose Read ing should be 0 1 ohm Replace hose if measure ment is outside this range If system only uses one hose and applicator A8DO electrical connector of the heated hose must be plugged into channel 1 of the MZLP A8MF No Fan Current Devia Power not getting to transformer fan Verify that fan power cable is plugged into J7 on Verify transformer fan is free of obstructions and 333347F 41 Troubleshooting Type Cause CAC E Comm Error Alarm System not responding to ADM 1 MZLP 1 Module 2 MZLP 2 Dial not set correct on MZLP Set to 1 on board with daughter board Set to 2 on MZLP without the daughter board in center of electrical enclo sure Set to 3 on MZLP without daughter board on left of electrical enclosure 3 MZLP 3 System is not properly loaded with correct soft ware Perform Software Update Procedure on page 77 CACX Missing DB Alarm System not acknowledging the daugh Bad connection between daughter board and ter board MZLP board Loosen daughter board re seat then secure Daughter
141. utomatically generate the proper folder structure on the USB flash drive 2 nsert USB flash drive into USB port of computer 3 The USB flash drive window automatically opens If it does not open USB flash drive from within Win dows Explorer 4 Open Graco folder 5 Open system folder If working with more than one system there will be more than one folder within the Graco folder Each folder is labeled with the corre sponding serial number of the ADM The serial number is on the back of the module 6 lfinstalling the system settings file place SET TINGS TXT file into UPLOAD folder 333347F 7 lfinstalling the custom language file place DISP TEXT TXT file into UPLOAD folder 8 Remove USB flash drive from computer 9 Install USB flash drive into InvisiPac system USB port 10 The menu bar and USB indicator lights indicate that the USB is uploading files Wait for USB activity to complete 11 Remove USB flash drive from USB port NOTE If a custom language file was installed users can now select the new language from the Language drop down menu NOTE If the SETTINGS TXT or DISPTEXT TXT files remain in the UPLOAD folder they will be uploaded every time the USB drive is inserted into the corre sponding ADM To avoid unintentionally overwriting sys tem settings delete the files from the UPLOAD folders on the USB drive after the upload is complete USB Logs During operation InvisiPac stores syst
142. ve 11 Turn main power switch ON 333347F Replace Band Heater Temperature Sensor 74 ti23437a FiG 42 Disassembly see FIG 42 1 Close the bleed type ball valve installed at the system air inlet to relieve all air pressure in the system Turn main power switch OFF Disconnect cable from ADM then remove shroud Remove air tube 36 from relief valve Pull the air tube through the metal shroud 27 Remove nuts 3 then remove metal shroud 27 See FIG 39 page 60 Remove fabric melter insulator 53 Loosen screw AA then remove sensor 125 Remove electrical enclosure access door 10 Disconnect the temperature sensor cable from MZLP connector labeled J5 See FIG 42 NOTE This connector also includes the over tempera ture switch wires 10 Disconnect wire connectors from over temperature switch 251 See FIG 43 on page 64 11 Pull cable out of the electrical enclosure then dis card sensor 125 and wires 333347F Hepair Reassembly see FIG 42 1 4 Route new harness wires through grommet 63 in the top of the electrical enclosure Connect wire connectors to over temperature switch 251 See FIG 43 on page 64 Place band heater temperature sensor 125 in melter Tighten screw AA NOTE Screw should lightly squeeze the temperature sensor to hold it in place It should not bend the sensor 5
143. ystem Pump Sol Current draw of pump solenoid e 0 mA off e 150 250 mA on PCB Temp PCB Temperature on MZLP1 e 32 16 F 0 71 C Pump CPM Pump cycles per minute USB DL Percentage Complete only applies when downloading USB data 333347F Setup Screens NOTE It is important to set all settings in the System screens correctly to ensure optimal system perfor mance Password CERNE Password Mo Active Errors Password EM If the password is not 0000 the password must be entered to access the setup screens System 1 A PLC can be used to control or monitor the system See PLC Connection on page 27 for instructions System 2 12 10 12 17 12 4 Schedule Advanced Mo Active Errors Channel Installer Gun RTD Type 1 t 1000 365 t 1000 383 a Dx X1 x Bx l 2 3 4 Use this screen to enable the installed channels and specify the type of applicator RTD type used See Select ADM Settings on page 24 333347F Appendix A ADM System 3 Enable Diagnostic Screen _ Lock Run Screens Pump Idle Time to Svstem SM 0 minutes Power Type Single Phase EA Circuit Breaker Size Amps Refill Setting Enable Diagnostic Screen Choose whether to hide the Diagnostic screen Lock Run Screens Disable setpoint changes on the run operation screens If the setup screens are pass word protected the setpoints cannot be changed with out first en

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