Page 1 Instructions ® InvisiPac HM10 Hot Melt Delivery System 3A7259C For delivering and dispensing hot melt adhesive pellets. For professional use only. Not approved for use in explosive atmospheres or hazardous (classified) locations. 1200 psi (8.3 MPa, 83 bar) Maximum Fluid Working Pressure 400°F (204°C) Maximum Fluid Operating Temperature 100 psi (0.7 MPa,7 bar) Maximum Air Inlet Pressure.
Page 2: Table Of Contents
Contents Models ........3 Communications Gateway Module (CGM) ..48 Warnings .
Page 3: Models
Technical Specifications ....138 Feed Systems, page 3. Graco Standard Warranty ....140 Related Manuals...
Page 4 Models 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.
Page 5: Warnings
Warnings Warnings The following are general warnings related to the setup, use, grounding, maintenance, and repair of this equipment. Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols that appear in the body of the manual refer to these general warnings. When these symbols appear throughout the manual, refer back to these pages for a description of the specific hazard.
Page 6 Warnings WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion: • Do not use solvent-based adhesives that can create an explosive atmosphere when processed. •...
Page 7 Warnings WARNING TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • Read Safety Data Sheets (SDSs) to know the specific hazards of the fluids you are using. •...
Page 8: Component Identification
Component Identification Component Identification Ref. Description Ref. Description Funnel Inlet Advanced Display Module (ADM) Pump Air Pressure Gauge Main Power Switch Pump Air Pressure Regulator Hopper Lid USB Port Cover Air Venturi Restrictor Electrical Port Covers for Heated Hose System Air Filter with System Air Inlet Connection Ports AMZ Circuit Board Assembly Melter Fluid Outlets Plugs for Heated Hose...
Page 9: Typical Installation
Typical Installation Typical Installation The installation shown is only a guide for selecting an installing system components. The components in the typical installation illustrations are not included with the system. On-Board Hopper Models Typical Installation Ref. Description 256‡ Electrical Port Covers for Heated Hose Connection Ports 628‡...
Page 10 Typical Installation Remote Vacuum Feed Models Typical Installation Ref. Description 256‡ Electrical Port Covers for Heated Hose Connection Ports 628‡ Melter Fluid Outlets Plugs for Heated Hose Connection 62‡ Bleed-Type Air Valve Applicator Heated Hose Main Air Line Power Cord Applicator Air Line Applicator Electrical Line Feed Tube...
Page 11: Installation
Installation Installation Grounding System Installation Kits • System Stand Kit 17S264. See details on page 129. • Adapter Plate Kit 25M528. See details on page 129. The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static Drain Before Using sparking can cause fumes to ignite or explode.
Page 12: System Requirements
1200 psi (8.3 MPa, 83 bar), 400°F (204°C), have an RTD type sensor, and use no more than 1250W at 240 30 scfm capacity. VAC. Non-Graco heated hoses require an electrical adapter cable. • Applicator air regulator: Set to 70 psi (4.8 bar, 0.48 MPa).
Page 13: Setup Adhesive Supply
Installation Setup Adhesive Supply Remote Vacuum Feed Models: Connect Feed System 1. Refer to the feed system manual to install the feed system. See Compatible Drum Vacuum Feed Systems, page 3. 2. Adjust the funnel inlet if desired. a. Loosen the funnel fasteners (231) to adjust the funnel inlet.
Page 14: Heated Hose And Applicator Connections
Installation Heated Hose and Applicator c. Connect the heated hose (BB) to the melter Connections fluid outlet starting with the bottom port. Use two wrenches to torque hose to 300 in-lb (33 N•m). NOTICE Over-tightening the hose port connector will damage The equipment surfaces and components can the connector seal and cause fluid leaks.
Page 15 Installation Port Connector Options Hose Torque Instructions Torque to 180 in-lb (20 N•m). Hose-to System: Torque to 300 in-lb (33 N•m). Always use two wrenches. . 4: Heated Hose and Applicator Typical Installation 3A7259C...
Page 16: Air Supply Installation
Installation Air Supply Installation NOTICE Oiling the air supply can damage the air controls components. Do not install an oiler on the air supply to the system. • System inlet air filter (60): The system must use an air filter with a minimum flow rate of 30 scfm. •...
Page 17: Connect Material Tracking Input
A trigger sensor or dry contact input can be used to 4. Refer to the table and image below to connect add material tracking to InvisiPac HM10 systems. See flying leads to the System I/O Board on AMZ #1 Repair Kits (starting on page 119) for additional details.
Page 18: Connect Electrical Cord
Installation Perform the following steps to connect a dry contact to NOTE: The strain relief bushing (205) fits a 0.71–0.98 in. the InvisiPac system: (18–25 mm) OD electrical cord. 1. Route cable through one of the cable grommets 5. Attach insulated ferrules to the end of each wire. (CG) in back of the InvisiPac electrical enclosure.
Page 19: Set Baseline Adm Settings
Installation Set Baseline ADM Settings Setup Applicators on the Gun Setup Screen 1. Select the Menu Symbol > Setup > Gun Menu Symbol > Setup Screens Setup. 1. Turn main power switch (204) ON. 2. Check the Installed box for each channel that has a heated hose and an applicator installed.
Page 20 Installation NOTE: The system limits current draw on incoming NOTICE power lines based on the circuit breaker size entered. The minimum value for the setting is 15 A, and a larger To prevent adhesive degradation, regularly disable the circuit breaker will allow the system to draw more heating system and do not set the hose temperature power and reduce startup time.
Page 21: Setup
Setup Setup 3. Wire the desired PLC inputs to the System I/O Board on AMZ. Digital Inputs Wiring (0–30 VDC), page 22. DANGER See F . 13 for reference. SEVERE ELECTRIC SHOCK HAZARD Dry Contact Inputs Wiring (Open/Closed This equipment can be powered by more than 240V. Circuit), page 23.
Page 22 Setup Digital Inputs Wiring (0–30 VDC) 3. Connect an input signal wire to the desired input terminal on J9. Terminals are labeled by input Item Specifications number. Connect all remaining inputs. Digital Input 0-30 VDC NOTICE Signal Low: 0-2.5 V Signal High: 10-30 V The system I/O board and the PLC could become damaged if connections are made to J8.
Page 23 Setup Dry Contact Inputs Wiring (Open/Closed 1. Access the Electrical Enclosure. Follow the steps Circuit) on page 83. 2. Connect a jumper wire (16-28 AWG) between “-” Item Specifications terminal on J8 and “ISO GND” terminal on J9. Dry Contact Open/Closed Circuit Signal Low: Open Circuit 3.
Page 24: Wire Plc Outputs
Setup Wire PLC Outputs PLC Output Specifications Configure up to two PLC outputs to indicate the Item Specification following states: Output Type Dry Contact (Open/Close Circuit) Max Voltage 24 VDC / 240 VAC • InvisiPac System Ready Max Current • Error Present 1.
Page 25 Setup Set PLC Settings on the ADM Output Options Output Action Unused Output disabled System Ready Close contact when the system is ready Error (Alarm) Open contact when the alarm is present. NOTE: alarms disable the system heat and pump. Error Close contact when a deviation (Deviation/Advisory)
Page 26: Operation
Operation Operation Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol. Heating and dispensing hot melt adhesive may create potentially harmful vapors. Read material manufacturer’s warnings and material SDSs to know specific hazards and precautions. Ventilation of the work area may be required.
Page 27 Operation 4. Open the bleed-type air valve (62). 6. Navigate to the Home screen and set the melter, hose, and applicator temperatures. See Set Temperatures on the Home Screen, page 20. On new systems only: A new system may have residual oil in the melter from factory testing prior to shipping.
Page 28: Dispense Adhesive
Operation Dispense Adhesive 6. When the system is up to temperature, the pump will start automatically. If the system is empty or has air in the lines, perform the Initial Startup and Prime Procedure, page 26 before dispensing. 1. Turn main power switch ON. 2.
Page 29: Shutdown
Operation Shutdown Manual Refill Dispensing Only use Manual Refill during maintenance or if the or 1. Dispense adhesive into a waste container until the automatic refill setting is not functioning properly and material level is down into the melter core. This will cannot be fixed in a timely manner.
Page 30: Maintenance
Maintenance Maintenance Drain the System 4. Disconnect hose from applicator inlet then place hose outlet in a waste container. Repeat for all hoses. Keep hose to applicator electrical connector connected. 5. Open applicator to allow residual fluid in applicator to drain. 6.
Page 31: Flushing Procedure
Maintenance Flushing Procedure To help prevent fire and explosion, use the adhesive manufacturer’s recommended cleaning fluid. • Never exceed the cleaning fluid’s rated temperature. • Never flush your system or clean any aluminum components with halogenated hydrocarbon cleaning solution. See the hot melt adhesive technical data sheet or SDS for the recommended cleaning fluid and cleaning fluid temperature requirements.
Page 32: Inspection Schedule
Maintenance Funnel Maintenance Inspect the Funnel Cover and Funnel Filter Inspect and clean the funnel and funnel filter to ensure clear melter air and pellet flow. The funnel cover and filter and can be inspected without interrupting production. • Remove, inspect, and clean the funnel cover. •...
Page 33: Pump Filter Maintenance
Maintenance Pump Filter Maintenance Clean Funnel Base The equipment surfaces and components can The equipment surfaces and components can become very hot. To avoid severe burns, wear become very hot. To avoid severe burns, wear protective gloves and clothing that will insulate your protective gloves and clothing that will insulate your hands and body from the hot surfaces and adhesive hands and body from the hot surfaces and adhesive...
Page 34 Maintenance Replace the Pump Inlet Filter The pump inlet filter prevents large items from entering 1 in. socket the system. 1. Warm the system to operating temperature. The adhesive must be fluid to perform this procedure. Replace the component before the system cools. 2.
Page 35: Software Update Procedure
The latest software version for the system can be found at help.graco.com. Drag and drop the software files from help.graco.com onto the root directory of the flash drive. 1. Remove the USB port Cover (515). 2. Plug the USB with software updates into the USB Port.
Page 36: Adm Guide
ADM Guide ADM Guide Screen Navigation Symbol Description The associated melter, hose, or applicator Select the Menu Symbol on the home screen to is on and warming up to temperature. open the screen menu. The associated melter, hose, or applicator is ready for operation.
Page 37: Data Management
ADM Settings, page 19 for basic configurations and Download Log Files to a USB instructions. See page 43 for additional screen details. The InvisiPac HM10 has the ability to download runtime Gun Setup information to a USB drive. The information is stored as...
Page 38 ADM Guide Download System Settings Upload System Settings The InvisiPac HM10 is able to download configured 1. Download the system settings to a USB drive. settings and temperatures to a USB drive. Once 2. Insert the USB drive into the USB slot.
Page 39: Adm Screens
ADM Screens ADM Screens Diagnostics Screens C - The amount of time it took for the previous fill event Read-only view of the important system diagnostic to complete. When using Hopper Auto or Bin Auto a information. refill time of 4000ms is ideal, please refer to section E for optimization of these devices.
Page 40 ADM Screens H - The number of pump cycles that occur per minute. between the hub and the ADM to insure a proper connection is made. L - This indicates how much material the HM10 is dispensing per hour. This value is calculated using the E - The indicator is green when the 4 channel upgrade cycle rate above, the known volume of the pump, and is enabled.
Page 41 Check to make sure the correct RTD has been selected as well. Graco guns will always use a Pt100/1000 setting on the Gun Setup Screen.
Page 42: Logs Screens
ADM Screens Logs Screens Events Screen Read-only view of errors, events and usage. Select the Menu Symbol > Logs > Events. Select the Menu Symbol > Logs. Press the up and down arrows to read the log entries. Usage Screen Errors Screen Select the Menu Symbol >...
Page 43: Setup Screens
ADM Screens Setup Screens Material Tracking Set system and component settings. See Set Baseline ADM Settings, page 19 for basic configurations and instructions. . 43: Material Tracking Screen Capture Name Description Enable AUX unit Check to enable the AUX unit counter counter on the System I/O Board.
Page 44 ADM Screens Maintenance . 44: Maintenance Screen Name Description Current Resettable counter for the variable in the row. NOTE: to reset to zero and clear an existing advisory, select the counter and press the reset softkey. Interval Maintenance interval period for variable in the row.
Page 45: Advanced Screens
ADM Screens Advanced Screens Display Configure and view system settings and preferences. General display settings including language, time and password protection. Name Description Language Select the display language. Number Format Select number format Date Format Select the display date format. Date Enter the date and time.
Page 46 ADM Screens Units Software Select the system units to be used on the display. Read only display of system software. Select the Advanced > Software. Name Description Name Description System Part number of the software on the most Temperature Select the system temperature units. Software Part recently loaded system software token.
Page 47 ADM Screens EtherNet/IP This screen displays the hardware revision, system serial number, and data map identification information. It also enables the user to set the IP address, DHCP settings, subnet mask, gateway, and DNS information. Select the Advanced > EtherNet/IP. PROFINET This screen displays the hardware revision, system serial number, and data map identification information.
Page 48: Communications Gateway Module (Cgm)
NOTE: Automation Outputs can be monitored by the corresponding Automation Inputs to verify that the NOTE: The following system network configuration files InvisiPac received the data. are available at help.graco.com. NOTE: See Automation Outputs, page 49, and the • Add On Instructions: Allen Bradley Automation Inputs, page 60 for a full list of CGM inputs and outputs.
Page 49: Automation Outputs
Communications Gateway Module (CGM) Automation Outputs The map is organized into three categories: Command/Feedback Bitmasks, DINT variables, and a command interface. Command Bitmasks The first 64 Tag IDs are reserved for command bits, their usage is covered below. Heartbeat – The InvisiPac unit will supply a heartbeat that toggles on a 3 second timer. The PLC must mirror the bit state back through the command bitmask.
Page 50 Communications Gateway Module (CGM) Quick Start: The system needs a minimum of 3 bits controlled by the PLC to become operational (Heartbeat, Enable PLC Control, and Activate System). As seen below, the Heartbeat from the PLC mirrors the heartbeat from the InvisiPac.
Page 51 Communications Gateway Module (CGM) Acknowledge Current Alarm – This is equivalent to pressing the check mark on the ADM Screen to clear the alarm pop-up screen. It acknowledges the alarm present, but the alarm will only clear once the alarm conditions on the system are resolved.
Page 52 Communications Gateway Module (CGM) NOTE: On an HM10 without the 4 channel unlock token present, the system will enable the first two channel requests, and will ignore the remaining. For example, if a request was presented for channels 1, 3, and 4, only channels 1 and 3 would be enabled.
Page 53 Communications Gateway Module (CGM) Refill Mode Selection: Refill modes are selected using an enumeration and a strobe bit, as shown below. . 53 NOTE: HM25c and HM10 have different enumeration values. Hopper Auto uses a shorter pulse duration than “Bin Auto”...
Page 54 Communications Gateway Module (CGM) Material Tracking: The InvisiPac will provide material tracking information through the gateway as well as through the HMI. Units Produced and Weight Dispensed are items that may be ideal for daily production tracking. Weight dispensed is reported in thousandths of kilograms or pounds, depending on the weight unit selection. They can be reset by toggling “Reset Material Tracker –...
Page 55 Communications Gateway Module (CGM) Maintenance Counters: Maintenance counters count up from zero and can be reset on an individual bases by toggling their corresponding bit high. When the maintenance counter is greater than or equal to the maintenance interval, a corresponding advisory will be generated by the system to indicate maintenance is due. Once the appropriate maintenance actions have been performed, a reset can be performed by toggling the corresponding reset bit.
Page 56 Communications Gateway Module (CGM) Flow Rate: Indicates the mass of material being dispensed per hour. It is represented in thousandths of a kilogram or pound, depending on the units selected. . 62 Refill Optimization: The HM10 has an adjustable air restrictor installed to help regulate the flow of glue pellets. This variable helps find the optimal resistance for the type of pellets being fed into the melter.
Page 57 Communications Gateway Module (CGM) InvisiPac Map2, 2000409 Automation Outputs (signals from PLC to InvisiPac) Data Description Units Min Value Format Byte Type Value Strobe New Boolean Maintenance Interval - Weight Dispensed Reserved Bit Boolean Reserved Bit Boolean Reserved Bit Boolean Reserved Bit Boolean Reserved Bit...
Page 58 Communications Gateway Module (CGM) InvisiPac Map2, 2000409 Automation Outputs (signals from PLC to InvisiPac) Data Description Units Min Value Format Byte Type Value Units - Temperature Boolean 0: °C 1: °F Units - Mass Boolean 0: kg 1: lbs Units - Distance Boolean 0: mm 1: in.
Page 59 Communications Gateway Module (CGM) InvisiPac Map2, 2000409 Automation Outputs (signals from PLC to InvisiPac) Data Description Units Min Value Format Byte Type Value New Maintenance Heat On: Intervals - Elapsed Heat On Hours(16-31) 65535 Heat On: 0 16-31 Times (Bitpacked) Integer Pump Idle Hours Pump...
Page 60: Automation Inputs
Communications Gateway Module (CGM) Automation Inputs InvisiPac Map2, 2000409 Automation Inputs (signals from InvisiPac to PLC) Data Description Units Format Byte Type Value Value 1 Heartbeat Boolean 2 PLC Control Enabled Boolean 3 System - Active (Power Boolean 4 System - Heat Active Boolean 5 System - Pump Active Boolean...
Page 61 Communications Gateway Module (CGM) InvisiPac Map2, 2000409 Automation Inputs (signals from InvisiPac to PLC) Data Description Units Format Byte Type Value Value 33 Units - Temperature Boolean 0: °C 1: °F 34 Units - Mass Boolean 0: kg 1: lbs 35 Units - Distance Boolean 0: mm...
Page 62 Communications Gateway Module (CGM) InvisiPac Map2, 2000409 Automation Inputs (signals from InvisiPac to PLC) Data Description Units Format Byte Type Value Value 68 Zone Setpoint Integer Whole Degrees (C or F) °C: 38 °C: 204 XXXXXX Gun: Temperature: Channel 3 Gun (Bits 31-16) °F: 100 °F: 400...
Page 63 Communications Gateway Module (CGM) InvisiPac Map2, 2000409 Automation Inputs (signals from InvisiPac to PLC) Data Description Units Format Byte Type Value Value 81 Zone Actual Integer Whole Degrees (C or F) °C: 38 °C: 204 XXXXXX Gun: Temperature: Channel 7 Gun (Bits 31-16) °F: 100 °F: 400...
Page 64 Communications Gateway Module (CGM) InvisiPac Map2, 2000409 Automation Inputs (signals from InvisiPac to PLC) Data Description Units Format Byte Type Value Value 101 Refill Mode Enum Integer Enumeration: 0-31 0: Manual 1: Hopper Automatic 152-155 2: Bin Automatic 3: Bin Auto-Adaptive 102 Refill Optimization For Integer Whole Percent: 0-31...
Page 65: Command Interface
Communications Gateway Module (CGM) Command Interface This section provides details about the CGM Command Interface. The command interface portion of the map, allows the user to request further information or control more parameters of the InvisiPak system, which are not part of the other assigned memory locations. The command interface variables are assigned instance locations 40, 41, 61, 62 and 63 outlined in the Automation Inputs, page 60 and Automation Outputs, page 49.
Page 66: Command Interface Table
Communications Gateway Module (CGM) 4. Wait for the Command Interface - Status Bits Success (bit 1) to become set. NOTE: if the Command Interface - Success has been set , valid data will be present within the Command Interface Value (Read/Write Return) Bytes (automation input). 5.
Page 67 Communications Gateway Module (CGM) Command Interface - Description Variable Definition Read/Write Command ID Specific Gravity in thousands (a value of 1000 0x0306 Specific Graviyt Read/Write corresponds to 1.000 grams/cc) Value - Setting 0 - Unused 1 - Heaters On/Off 2 – Pump Enable/Disable 3 - Channel 1 Enable/Disable 4 - Channel 2 Enable/Disable 0x0307...
Page 68 Communications Gateway Module (CGM) Command Interface - Description Variable Definition Read/Write Command ID 0x0319 CH2 Gun RTD type See CH1 Gun RTD Type Read/Write 0x031A CH3 Gun RTD type See CH1 Gun RTD Type Read/Write 0x031B CH4 Gun RTD type See CH1 Gun RTD Type Read/Write 0x031C...
Page 69 Communications Gateway Module (CGM) Command Interface - Description Variable Definition Read/Write Command ID Used to set the offset of a bead within the active pattern (see Bead Offset Lookup Table to determine 0x0731 - the appropriate command for each bead/gun Pattern Bead Offset Read/Write 0x07F0...
Page 70 Communications Gateway Module (CGM) Command Interface - Description Variable Definition Read/Write Command ID 0x8132 Line 2 Encoder Scaling See Line 1 Encoder Scaling Read/Write Line 1 fixed line speed. Values are in hundredths of 0x8133 Line 1 Fixed Line Speed ft/min.
Page 71: Troubleshooting
Troubleshooting Troubleshooting Melter Pump and Fluid Hose 4. Install the port connector onto the melter pump. Torque the fluid port connector to 180 in-lb (20 Leak Troubleshooting N•m). 1. Drain the System. Follow the steps on page 30. 5. Use two wrenches to install the heated fluid hose onto the port connector.
Page 72: Fill Rate Troubleshooting And Venturi Air Adjustment
Troubleshooting Fill Rate Troubleshooting and Venturi Air Adjustment The Fill/Pump Diagnostics Screen displays the fill rate between the hopper and the melter. 1. Navigate to the Fill/Pump Diagnostics Screen: Home > Diagnostics > Select the Fill/Pump tab. 2. Adjust the air venturi if the fill rate is slow or fast. a.
Page 73: Fill System Verification Checklist
Troubleshooting Fill System Verification Power Input Verification Checklist Checklist Follow this checklist to troubleshoot common refill or dispensing-related errors. ✓ Check air filter by removing quick turn cap on top of This equipment can be powered by more than 240V. funnel.
Page 74: Error Codes
Error Codes Error Codes DANGER ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240V. Contact with this voltage will cause death or serious injury. • Turn off and disconnect power at main switch before disconnecting any cables and before troubleshooting and servicing equipment.
Page 75: Alarms
Error Codes Alarms Shuts system down Code Description Cause Solution ✓One or more of the fuses in the fuse harness A2D0* Low Current: Melter Current through the melter assembly is blown. heating rods is less than expected ✓Remove short with corresponding melter heating rod and replace the fuse.
Page 76 Error Codes Code Description Cause Solution ✓Check for damaged wiring. A7D0 Unexpected Unexpected current to the Current: Melter melter ✓Check heater resistance to ground See Check Melter and Pump Heater Resistance, page 98. ✓Replace all faulty heaters. See Replace a Heater Rod, page 99.
Page 77 Error Codes Code Description Cause Solution Melter ran out of adhesive ✓Add pellets to the feed system. DADX* Pump Runaway ✓Reduce the adhesive flow rate. ✓Verify the adhesive temperature setting. ✓See Fill System Verification Checklist, page 73. ✓Inspect the pump seals. Worn or damaged pump seals ✓Replace if necessary.
Page 78 Error Codes Code Description Cause Solution ✓Install a properly functioning applicator or hose. T4D(C) High Temperature: An applicator or hose Applicator Zone or temperature deviated ✓Turn on the system without dispensing. Verify Hose Zone above setpoint the hose maintains a stable setpoint temperature. ✓Verify the melter temperature setting is not set above the hose.
Page 79: Advisories And Deviations
Error Codes Code Description Cause Solution V4M1 High Line Voltage: Refer to the Power Input Verification Checklist, page 73. V6M1 Invalid Power Type: Refer to the Power Input Verification Checklist, page 73. (C): Channel and component-specific error. See Zone (C) Lookup Table, page 74 for component error zone. * Does not shut down system or melter zone Advisories and Deviations Does not shut the system down...
Page 80 Error Codes Code Description Cause Solution ✓Check if pump pressure as been increased from B3AX High Glue per Unit Pump pressure too high. desired level. ✓Navigate to material tracking page from home Glue per unit target needs screen and reset target setting. to be reset.
Page 81 ✓Use a compatible license key. WNU0 Invalid USB License The USB license key is not for an InvisiPac HM10. ✓Ensure that the USB license key is correctly inserted to the USB hub behind the ADM. The Graco License Image on the USB license key ✓Remove and reinsert the USB license key.
Page 82: Repair
Repair Repair Prepare Equipment for Service Remove Equipment Covers 1. Prepare Equipment for Service. Follow the steps on page 82. 2. Loosen the fasteners on the front melter cover (10) DANGER to remove the front cover. SEVERE ELECTRIC SHOCK HAZARD 3.
Page 83: Install Equipment Covers
Repair Install Equipment Covers Refer to F . 68. 1. Tighten the fasteners to install the rear melter cover (224). 2. Connect the air lines to the triple union fitting (236). 3. Install the air filter (60). 4. Tighten the fasteners to install the front melter cover (10).
Page 84: Sensor And Switch Repairs
Repair Sensor and Switch Repairs Install the Level Sensor 1. Thread the level sensor (240) into the sensor housing until it bottoms out, then back it out 1/4 turn. Hand tighten the jam nut. DANGER 2. Feed the level sensor cable through the top of the SEVERE ELECTRIC SHOCK HAZARD sensor housing.
Page 85: Melter Sensor Repairs
Repair Melter Sensor Repairs Temperature Sensor (RTD) Over-Temperature Switch . 72: Temperature Sensor and Over-Temperature Switch Locations Replace the Temperature Sensor (RTD) See F . 72 for details. . 73: Melter Control Connections (J1) 5. Install the ADM Screen. Follow the steps on page 1.
Page 86: Air Control Repairs
Repair Replace Over-Temperature Switch Access Air Controls See F . 72 for details. 1. Prepare Equipment for Service. Follow the steps on page 82. 1. Prepare Equipment for Service. Follow the steps 2. Remove the melter cover (10). See Remove on page 82.
Page 87: Hopper Repair
Repair Hopper Repair Replace an Air Control Solenoid The air control assembly has two solenoids. Replace Refer to Hopper Assembly (On-Board Hopper the pump or fill solenoid as needed. Models only), page 112. 1. Access Air Controls. Follow the steps on page 86. 1.
Page 88: Melter Pump Assembly Repairs
Repair Prepare for Melter Pump Repairs 15. While installing the bowl assembly, reconnect the air line from the bottom rear of the hopper to the fitting (50) in the shaker (42). 16. Apply medium strength thread locker to the four studs sticking up and tighten the nuts (14) to secure the bowl.
Page 89 Repair Disconnect the Melter Pump Assembly from the System 1. Prepare for Melter Pump Repairs. Follow the steps on page 88. 2. Access the Electrical Enclosure. Follow the steps on page 83. 3. Disconnect the heater rod (623) wires from the fuse harness on the AMZ.
Page 90 Repair . 77: Melter Pump Connections 3A7259C...
Page 91 Repair Install the Melter to the System Remove the Melter Plate Remove the melter plate (635) as needed to access the bottom of the melter. Reinstall the melter plate before installing the melter to the system. DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240V.
Page 92: Melter Pump Component Repairs
Repair Melter Pump Component Assemble the Air Motor Repairs 1. Install the motor retaining o-ring (607) onto the motor. Air Motor Repairs 2. Install cycle switch (234) and the funnel motor support bracket (639) on the air motor. See F .
Page 93: Remove Pump Components From The Melter
Repair Apply threadlocker to threads Torque to 90-110 in-lbs . 79: Funnel and Air Motor Removal Remove Pump Components 3. Remove Pump Inlet Housing. Follow the steps on page 95. from the Melter 4. Remove the Pump Cylinder. Follow the steps on 1.
Page 94 Repair Remove the Piston Rod, Throat Seal, and Piston Foot Service Procedure Throat Bearing Note the u-cup orientation . 81: Piston Foot Assembly 1. Remove the Piston Rod, Throat Seal, and Throat Bearing. Follow the steps on page 94. . 80 Piston Rod Assembly Installation 2.
Page 95 Repair Remove Pump Inlet Housing Remove the Pump Cylinder Use Cylinder Repair Tools Kit 24R227, page 120 to remove the cylinder from the melter. 1301 Socket Wrench . 83: Cylinder Assembly Removal 1. Prepare for Melter Pump Repairs. Follow the steps on page 88.
Page 96: Assemble Pump Components
Repair Assemble Pump Components Install Pump Inlet Housing See F . 82 for reference. 1. Install o-rings (645) and (655) onto the inlet housing. The equipment surfaces and components can 2. Install the o-ring (643), seat (619), and ball (644) into become very hot.
Page 97 Repair Install the Piston Rod, Throat Seal, and Replace the Fluid Pressure Relief Valve Throat Bearing Torque to 24-30 ft-lb Use seal installation tool to protect the seals from the threads. See Seal Installation Tool 15B661, page 120. Seal Installation Tool 15B661 Air Tube 7/8 in.
Page 98: Heater Repairs
Repair Heater Repairs Install the Fluid Pressure Relief Valve 1. Install the pressure relief valve (630). Torque to 24-30 ft-lb. 2. Clean drained fluid from the side of the melter. DANGER 3. Roll the melter jacket (632) back around the melter SEVERE ELECTRIC SHOCK HAZARD and secure with fasteners (633).
Page 99 Repair Disconnect the Heater Rods 4. Connect the heater wires to fuse holder harness holder (221) on the AMZ circuit board. 1. Prepare for Melter Pump Repairs, page 88. 2. Access the Electrical Enclosure. Follow the steps on page 83. 3.
Page 100: Electrical Component Repairs
Repair Electrical Component Repairs 2. Use a non-conductive fuse puller tool to remove the blown fuse. NOTICE Using an improper tool, such as a screwdriver or DANGER pliers may break fuse or cause damage to board. Use SEVERE ELECTRIC SHOCK HAZARD a fuse puller.
Page 101 Repair 5. Set the AMZ dial position to 1. 10. Place the new ADM in front of the unit and connect the M12 cable. Connect the right angle USB to the ADM and USB bulkhead cable. For 4 channel units, the USB hub should not be connected to anything at this point as it cannot be used during programming.
Page 102 Repair a. Remove the ADM and panel as described above. b. Disconnect the front panel USB bulkhead from the right angle cable. c. Plug the front panel USB bulkhead into the USB hub. d. Plug the USB hub into the right angle cable. e.
Page 103: Amz Wiring Connections
AMZ Wiring Connections AMZ Wiring Connections 3A7259C...
Page 104 AMZ Wiring Connections AMZ Ref. Component Connection Instructional Information Wiring Details✺ Melter Sensors: Melter Sensor Repairs, page 85 Fig. 73 on page 85 Over-Temperature Switch (233) and Temperature Sensor RTD (252) Transformer Fan Transformer Installation, page Fig. 99 on page 106 Level Sensor (240) Install the Level Sensor, page 84 --- Cycle Switch (234)
Page 105: Electrical Schematics
Electrical Schematics Electrical Schematics Common Schematic Applicable to All Systems 3A7259C...
Page 106 Electrical Schematics Incoming Power Typical Hose and Applicator Wiring Incoming Power: 240V Models APPLICATOR HEATER & OVERTEMP θ HOSE HEATER HOSE OVERTEMP θ APPLICATOR RTD . 98: 240V Incoming Power (J22) Incoming Power: 480V Models HOSE RTD ti31245a Connects to Ch 1-4. See Common Schematic, page 105.
Page 107: Light Tower Wiring
Electrical Schematics Light Tower Wiring . 101: Light Tower Kit 20B729 Wiring 3A7259C...
Page 108: Pneumatic Schematic
Electrical Schematics Pneumatic Schematic 3A7259C...
Page 109: Parts
Parts Parts System Structure 3A7259C...
Page 110 Parts System Structure Ref. Part Description Qty. Ref. Part Description Qty. 20✚ 112395 Flange Head Cap Screw - - - - - System Base 21✚ 127278 Keps Nut 2✚ 128014 Transient Voltage Filter 22✚ 129337 Terminal Block 3‡ ★ 102360 Washer ‡...
Page 111 Parts Shipped Loose Parts Ref. Part Description Qty. 129189 Fuse Puller Tool (not shown) 33★ 127129 45° Swivel Elbow Fitting, MxF ‡ JIC-6 2 Channel Systems 4 Channel Systems 34★ 122719 90° Swivel Elbow Fitting, JIC 06, ‡ FM, MS 2 Channel Systems 4 Channel Systems 157350...
Page 112 Parts Hopper Assembly (On-Board Hopper Models only) Ref. Part Description Qty. 20B923 Hopper 38★ - - - - - Threaded Hex Stud 39★ - - - - - Threaded Damper Stud 20B913 Skirt Bowl Assembly (Includes 14 qty 4) - - - - - Grommet, 1.313 ID 25V441 Pneumatic Turbine Vibrator...
Page 113 Parts Safety Labels 3A7259C...
Page 114 Parts Common System Parts 3A7259C...
Page 115 Parts Common System Parts Ref. Part Description Qty. 126780 Over-Temperature Switch Ref. Part Description Qty. 234★ 24R885 Reed Switch Assembly (cycle - - - - - Electrical Enclosure switch kit) 25M525 AMZ Circuit Board Assembly 104641 Bulkhead Fitting 125856 Serrated Flange Screw, 8-32 - - - - - Triple Union Fitting, 1/4 tube 123967 Operator Disconnect Knob...
Page 116: Melter Pump Assembly: 20B911
Parts Melter Pump Assembly: 20B911 3A7259C...
Page 117 Parts Melter Pump Assembly: 20B911 Ref. Part Description Qty. Ref. Part Description Qty. - - - - - Drip Tray 601★ - - - - - Melter Manifold 641★- - - - - - Piston U-Cup Seal 24P855 Outlet Filter Assembly, 100 mesh, welded 642★...
Page 118: Air Regulator Assembly
Parts Air Regulator Assembly 504a 504b Ref. Part Description Qty. Ref. Part Description Qty. 113498 Safety Valve, 110 psi — Regulator Bracket — Muffler Vent — Air Control Label 15R324 USB Plug Harness, 129477 Solenoid Valve, 3 way Bulkhead, 32 in. 128260 Pressure Gauge 109466...
Page 119: Repair Kits
Repair Kits Repair Kits Melter Manifold Pump Repair Kits Melter Pump Repair Kit 20B919 See page 92 for repair instructions. Description Qty. PTFE O-ring Packing Throat Seal Throat Bearing Piston Rod Piston Ball, .31250) Piston Valve Seat, Carbide Piston U-Cup Seal Piston Bearing O-Ring Packing Ball .5000...
Page 120 Repair Kits Air and Fluid Connection Kits Heater Rod Replacement Kit 17P347 See Heater Repairs, page 98 for repair instructions. Fluid Port Connectors Kit 24V504 Ref. Description Qty. Pump Heaters, fire rod, 1000 watts, 240V Melter Manifold Repair Tools See Melter Pump Component Repairs, page 92 for instructions.
Page 121: Hopper Kits
Repair Kits Hopper Kits ADM Kits See Hopper Repair, page 87 for repair instructions. ADM Screen Protector Kit 18D314PKG Hopper Standoff Kit 20B927 Tear-off screen protector for ADM screen. 10-pack. Ref. Description Qty. Remote Mount for ADM 20B690 Threaded Hex Stud 1.
Page 122: Electrical Kits
Repair Kits Funnel Assembly Kit 20B912 ADM with Software USB 20B929 See Replace Advanced Display Module (ADM), page 101 for instructions. Ref. Description Qty. 1410 ADM GCA Module, 9 in. 1411 Flash Drive, HM10 Programmed Electrical Kits Cycle Switch Kit 24R885 Ref.
Page 123: Light Tower Kit 20B729
Repair Kits Light Tower Kit 20B729 1. Follow the procedure to Access the Electrical Enclosure, page 83. 2. Remove the two screws on the back of the unit and remove the vertical enclosure plate. 3. Remove the screws (203) and remove the electrical enclosure plate (261) from the back corner of the 1501 unit.
Page 124 Repair Kits 6. Mount the light tower (1501) to the bracket (1502) using the supplied hardware. 7. Run the light tower communication cable through the cord grip frame (1506) and into the electrical enclosure. 8. Connect the light tower cable to the mating cable labeled LIGHT_TWR that is attached to the terminal blocks.
Page 125: Amz Circuit Board Replacement Kit 25M525
Repair Kits AMZ Circuit Board Replacement Kit 25M525 See Replace Auto Multi-Zone (AMZ) Circuit Board, page 100 for instructions. 1602 1603 Ref. Description Qty. 1602 GCA Module, MZLP4 1603 Identification Label 3A7259C...
Page 126: Kits
Repair Kits Communications Gateway Module and Fieldbus Kits See Communications Gateway Module (CGM) and Ref. Description Qty. Fieldbus Setup, page 127 for requirements and CGM Map Token installation instructions. Bracket HM10 CGM Installation Kit 20B839 Socket Head Cap Screw, #10-32 X .75 4 Lock Washer See Communications Gateway Module (CGM) and Serrated Flange Screw, 8-32...
Page 127: Communications Gateway Module (Cgm) And Fieldbus Setup
Repair Kits Communications Gateway Assemble the CGM to the Mounting Plate. Module (CGM) and Fieldbus 1. Follow the CGM Grounding Instructions, page X. Setup 2. Install the CGM Base to the mounting plate (301) with the mounting screws (302). Fieldbus Installation Requirements 3.
Page 128 Repair Kits Install the CGM in the Electrical Enclosure DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240V. Contact with this voltage will cause death or serious injury. • Turn off and disconnect all power before servicing electrical components.
Page 129: Installation Kits
Repair Kits Installation Kits System Stand Kit 17S264 Adapter Plate Kit 25M528 1102 1101 1203 1103 1201 1202 Ref. Description Qty. Ref. Description Qty. 1101 Adapter Plate 1201 Stand 1102 Flanged Head Cap Screw 1202 Flange Hex Nut 1103 Flanged Hex Nut 1203 Flange Head Cap Screw 3A7259C...
Page 130 Repair Kits Air Reservoir Kit 16W366 Allows the system to operate on lower pressure or restricted air supply lines. 1504 1504 1501 1503 1505 1502 1506 Ref. Description Qty. 1501 Nylon Hose (6 ft) 1502 Pipe Bushing 1503 Pipe Tee 1504 Male Connector, 3/8 npt 1505...
Page 131: Upgrade Kits
Repair Kits Upgrade Kits Material Tracking Kit Used to track material consumption per product without a pattern controller. Installation 1. See Connect Material Tracking Input, page 17, for details on hardware installation. 2. Navigate to the Material Tracking Setup screen (see Material Tracking, page 43) and check “Enable AUX Counter”...
Page 132 Repair Kits 480V Transformer Upgrade Kit 17S265 Transformer Installation Used to upgrade to a 240 VAC system for 480 VAC incoming power. DANGER Ref. Description Qty. SEVERE ELECTRIC SHOCK HAZARD Transformer Base This equipment can be powered by more than 240V. 480V Transformer Contact with this voltage will cause death or serious Hex Flange Head Nut...
Page 133 Repair Kits 5. Disconnect wire harness from disconnect switch 7. Route wires from the transformer base through the (239). grommet (18). . 114 . 116 6. Connect wire harness to the back side of terminal 8. Make electrical connections. See Electrical block (22).
Page 134 Repair Kits 4 Channel Upgrade Kit 20B918 Ref. Description Qty. Upgrade HM10 2-channel systems to a 4-channel Hub, USB, 4 Port system. Flash Drive, 4 Channel Upgrade 1601 Double-Sided Tape Channel Upgrade Instructions DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240V. Contact with this voltage will cause death or serious injury.
Page 135: Adapter Kits
Dimensions Dimensions Adapter Kits Hose Adapters Use to connect non-Graco hoses to an InvisiPac system. Part Description 128621 For connecting to non-Graco hoses that use a NI 120 RTD. Applicator Adapters Use to connect non-Graco applicators to Graco heated hoses.
Page 136: Mounting Hole Dimensions
Mounting Hole Dimensions Mounting Hole Dimensions 480V Models 240V Models 3A7259C...
Page 137 Mounting Hole Dimensions 3A7259C...
Page 138: Technical Specifications
Technical Specifications Technical Specifications InvisiPac HM10 Hot Melt Delivery System Electrical Specifications Incoming Power Nominal Voltage Type Description Frequency Model Range Amps • 1-phase 20B715, 200–240 VAC 1(Ø) 50/60 Hz 32 A • 2 wire 20B716, 20B725, • 3-Phase without neutral 200–240 VAC...
Page 139 Technical Specifications HM10 Metric Temperature Specifications Time to Temperature* Less than 10 minutes Control Temperature Range 100°–400°F 38°–204°C Ambient Temperature Range 32°–122°F 0°–50°C Pressure Specifications System Air Supply Inlet 80–100 psi 0.55–0.69 MPa (5.5–7 bar) Pump Operating Air Pressure Range 20–100 psi 0.14–0.69 MPa (0.7–7 bar) (set with regulator on front of system)
Page 140: Graco Standard Warranty
With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.